Page 3427 of 4770

A07363
A07365
S05981
SST
S05990
(a)
(b)(c)
A07360
(e)(d)
± ENGINE MECHANICAL (5S±FE)CYLINDER HEAD
EM±35
1207 Author: Date:
(d) Loosen the union nut of the EGR pipe, and remove the
bolt, 2 nuts, the EGR valve, vacuum modulator, vacuum
hoses assembly and gasket.
12. DISCONNECT ENGINE WIRE FROM INTAKE MAN-
IFOLD
(a) Disconnect the engine wire clamp from the bracket on the
LH side of the intake manifold.
(b) Disconnect the 2 engine wire clamps from the 2 brackets
on the front side of the intake manifold.
13. DISCONNECT FUEL INLET HOSE FROM DELIVERY
PIPE
(a) Using SST, loosen the fuel pulsation damper.
SST 09612±24014 (09617±24011)
(b) Remove the fuel pulsation damper and 2 gaskets, and
disconnect the fuel inlet hose from the delivery pipe.
14. REMOVE INTAKE MANIFOLD
(a) Disconnect the MAP sensor vacuum hose from the gas
filter.
(b) Disconnect the brake booster vacuum hose from the in-
take manifold.
(c) Disconnect the PCV hose from the intake manifold.
(d) Remove the 2 bolts, and disconnect the 2 ground wires
from the intake manifold.
(e) Disconnect the knock sensor 1 connector.
Page 3452 of 4770
A07362
Gray
Brown
No.1
No.2
No.3
No.4
A07361
California
A07359
S05990
(b)
(c)(d)
A07360
(e)
(f)
EM±60
± ENGINE MECHANICAL (5S±FE)CYLINDER HEAD
1232 Author: Date:
(m) Connect the 4 injector connectors.
HINT:
The No.1 and No.3 injector connectors are brown, and the No.2
and No.4 injector connectors are gray.
16. California:
INSTALL AIR HOSE FOR AIR ASSIST SYSTEM
Connect the air hose to the cylinder head port.
17. INSTALL INTAKE MANIFOLD
(a) Install a new gasket and the intake manifold with the 6
bolts and 2 nuts. Uniformly tighten the bolts and nuts in
several passes.
Torque: 19 N´m (195 kgf´cm, 14 ft´lbf)
(b) Connect the MAP sensor vacuum hose to the gas filter.
(c) Connect the brake booster vacuum hose to the intake
manifold.
(d) Connect the PCV hose to the intake manifold.
(e) Connect the 2 ground wires to the intake manifold with the
2 bolts.
(f) Connect the knock sensor 1 connector.
Page 3453 of 4770

S05982
SST
Fulcrum
Length
A07365
A07363
A07364
Clamp
Connector
A01564(b)(c)(d)
± ENGINE MECHANICAL (5S±FE)CYLINDER HEAD
EM±61
1233 Author: Date:
18. CONNECT FUEL INLET HOSE TO DELIVERY PIPE
(a) Temporarily connect the fuel inlet hose with 2 new gas-
kets and fuel pulsation damper.
(b) Using SST, tighten the fuel pulsation damper.
SST 09612±24014 (09617±24011)
Torque:
34 N´m (350 kgf´cm, 25 ft´lbf)
29 N´m (300 kgf´cm, 21 ft´lbf) for use with SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm (1.181 in.).
19. INSTALL ENGINE WIRE
(a) Install the 2 engine wire clamps to the 2 brackets on the
front side of the intake manifold.
(b) Install the engine wire clamp to the bracket on the LH side
of the intake manifold.
20. INSTALL EGR VALVE AND VACUUM MODULATOR
(a) Install a new gasket, the EGR valve, EGR pipe and vacu-
um modulator assembly with the union nut, 2 nuts and
bolt.
Torque:
13.3 N´m (136 kgf´cm, 10 ft´lbf) for nut
61.2 N´m (624 kgf´cm, 45 ft´lbf) for union nut
(b) Install the hose clamp to the bracket on the intake man-
ifold.
(c) Install the VSV for the EGR with the bolt.
(d) Connect the VSV connector for the EGR.
21. INSTALL INTAKE MANIFOLD STAY
Install the intake manifold stay with the bolt and nut.
Torque: 39 N´m (398 kgf´cm, 29 ft´lbf)
22. INSTALL WATER OUTLET
(a) Install a new gasket and the water outlet with the 2 nuts.
Torque: 15 N´m (150 kgf´cm, 11 ft´lbf)
(b) Connect the radiator hose to the water outlet.
(c) Connect the water bypass pipe hose to the water outlet.
(d) Connect the heater water hose to the water outlet.
(e) Connect the ECT sensor connector.
(f) Connect the ECT sender gauge connector.
23. CONNECT OIL PRESSURE SWITCH CONNECTOR
24. CONNECT NOISE FILTER CONNECTOR
Page 3457 of 4770
A01565
Engine Wire Clamp
Brake Booster
Vacuum Hose
DLC1
Ground Strap
Connector
Generator
Wire
Wire
Clamp
Generator
ConnectorMAP Sensor
Vacuum HoseMAP Sensor
Connector
Fuel Inlet Hose
Engine
Wire
Starter
Connector
Starter
CableEngine
Wire
ProtectorGround
Cable (M/T)
Ground Strap Connector Wire
Clamp
Ground
Cable (A/T)
Heater
Hose
A01658
No.2 Instrument Panel
Under Cover
Cowl Side Trim Front Door Inside Scuff Plate
Engine Wire
± ENGINE MECHANICAL (5S±FE)ENGINE UNIT
EM±65
1237 Author: Date:
Page 3462 of 4770

S05253
EM±70
± ENGINE MECHANICAL (5S±FE)ENGINE UNIT
1242 Author: Date:
(g) Disconnect the engine wire clamp from the bracket on the
RH fender apron.
(h) Disconnect the MAP sensor connector.
(i) Disconnect the wire clamp from the bracket for the MAP
sensor.
(j) Disconnect the 2 ground strap connectors from the RH
fender apron.
(k) Disconnect the 2 ground strap connectors from the LH
fender apron.
(l) Disconnect the engine wire protector clamp from the bat-
tery bracket.
(m) Disconnect the engine wire from the clamp on the fuel fil-
ter.
(n) Disconnect the ground cable from the transaxle.
(o) Disconnect the brake booster vacuum hose from the in-
take manifold.
(p) Disconnect the heater hose from the water outlet.
(q) Disconnect the heater hose from the water bypass pipe.
(r) Disconnect the fuel inlet hose from the fuel filter.
(s) Disconnect the MAP sensor vacuum hose from the gas
filter on the intake manifold.
13. DISCONNECT ENGINE WIRE FROM CABIN
(a) Remove the under cover.
(b) Disconnect the 3 ECM connectors.
(c) Disconnect the 3 cowl wire connectors from the connec-
tors on the bracket.
(d) Disconnect the grommet from the cowl panel, and pull out
the engine wire.
14. REMOVE DRIVE SHAFTS (See page SA±17)
15. DISCONNECT TRANSAXLE CONTROL CABLE(S)
FROM TRANSAXLE
16. M/T:
REMOVE STARTER (See page ST±5)
17. M/T:
DISCONNECT CLUTCH RELEASE CYLINDER AND
TUBE FROM TRANSAXLE
Page 3472 of 4770

S05251
EM±80
± ENGINE MECHANICAL (5S±FE)ENGINE UNIT
1252 Author: Date:
(b) Connect the generator connector.
(c) Install the wire clamp to the generator.
(d) Connect the starter cable.
(e) Connect the starter connector.
(f) Install the DLC1 to the bracket.
(g) Install the engine wire clamp to the bracket on the RH
fender apron.
(h) Connect the MAP sensor connector.
(i) Install the wire clamp to the bracket for the MAP sensor.
(j) Connect the VSV connector for the vapor pressure sen-
sor.
(k) Connect the 2 ground strap connectors to the RH fender
apron.
(l) Connect the 2 ground strap connectors to the LH fender
apron.
(m) Install the engine wire protector clamp to the battery
bracket.
(n) Install the engine wire to the clamp on the fuel filter.
(o) Connect the ground cable to the transaxle.
(p) Connect the brake booster vacuum hose to the intake
manifold.
(q) Connect the heater hose to the water outlet.
(r) Connect the heater hose to the water bypass pipe.
(s) Connect the fuel inlet hose to the fuel filter with 2 new gas-
kets and the union bolt.
Torque: 29 N´m (300 kgf´cm, 21 ft´lbf)
(t) Connect the MAP sensor vacuum hose to the gas filter on
the intake manifold.
33. INSTALL FRONT EXHAUST PIPE
(a) Install the support bracket with the nut.
Torque: 33 N´m (330 kgf´cm, 24 ft´lbf)
(b) Temporarily install 2 new gaskets and the front exhaust
pipe with the 2 bolts and 5 nuts.
(c) Tighten the 3 nuts holding the exhaust manifold to the
front exhaust pipe.
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
(d) Tighten the 2 bolts and 2 nuts holding the front exhaust
pipe to the center exhaust pipe.
Torque: 56 N´m (570 kgf´cm, 41 ft´lbf)
(e) Install the bracket with the 2 bolts.
Torque: 33 N´m (330 kgf´cm, 24 ft´lbf)
(f) Install the support stay with the 2 bolts.
Torque: 33 N´m (330 kgf´cm, 24 ft´lbf)
34. INSTALL RADIATOR (See page CO±23)
35. INSTALL CRUISE CONTROL ACTUATOR
36. INSTALL BATTERY TRAY AND BATTERY
37. INSTALL AIR CLEANER CASE
Install the air cleaner case with the 3 bolts.
Page 3507 of 4770

EM04I±04
S04994
CO/HC Meter
± ENGINE MECHANICAL (1MZ±FE)CO/HC
EM±1
1287 Author: Date:
CO/HC
INSPECTION
HINT:
This check is used only to determine whether or not the idle CO/
HC complies with regulations.
1. INITIAL CONDITIONS
(a) Engine at normal operating temperature
(b) Air cleaner installed
(c) All pipes and hoses of air induction system connected
(d) All accessories switched OFF
(e) All vacuum lines properly connected
HINT:
All vacuum hoses for EGR systems, etc. should be properly
connected.
(f) SFI system wiring connectors fully plugged
(g) Ignition timing check correctly
(h) Transmission in neutral position
(i) Tachometer and CO/HC meter calibrated by hand
2. START ENGINE
3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180
SECONDS
4. INSERT CO/HC METER TESTING PROBE AT LEAST
40 cm (1.3 ft) INTO TAILPIPE DURING IDLING
5. IMMEDIATELY CHECK CO/HC CONCENTRATION
AT IDLE AND/OR 2,500 RPM
HINT:
When doing the 2 mode (idle and 2,500 rpm) test, these mea-
surement order prescribed by the applicable local regulations.
Page 3508 of 4770

EM±2
± ENGINE MECHANICAL (1MZ±FE)CO/HC
1288 Author: Date:
If the CO/HC concentration dose not comply with regulations,
troubleshoot in the order given below.
See the table below for possible causes, then inspect and cor-
rect the applicable causes if necessary.
COHCProblemsCauses
NormalHighRough idle1. Faulty ignitions:
Incorrect timin
gIncorrect timing
Fouled, shorted or improperly gapped plugs
Open or crossed hi
gh±tension cordsOen or crossed high±tension cords
2. Incorrect valve clearance
3 Leaky EGR valve
3 Leaky EGR valve
4.Leaky intake and exhaust valves
5.Leaky cylinder
LowHighRough idle1. Vacuum leaks:LowHighRough idle
(
Filtrating HC reading)
1. Vacuum leaks:
PCV hose(Filtrating HC reading)PCV hose
EGR valveEGR valve
Intake manifoldIntake manifold
Air intake chamberAir intake chamber
Throttle bodyThrottle body
IAC valveIAC valve
Brake booster lineBrake booster line
2. Lean mixture causing misfire
HighHighRough idle
(Black smoke from exhaust)1. Restricted air filter
2. Faulty SFI system
Faulty pressure regulator
Defective ECT sensor
Faulty ECM
Faulty injectors
Faulty throttle position sensor
Faulty MAF meter