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(c) Install the vacuum hose bracket and engine wire har±
ness with the bolt.
(d) Install the No.1 air intake chamber and manifold stays,
wire bracket with the 4 bolts.
14 mm head bolt
Torque: 42 N±m (425 kgf±cm, 31 ft±lbf)
12 mm head bolt
Torque: 22 N±m (220 kgf±cm, 16 ft±lbf)
17. INSTALL VSV OR VSV ASSEMBLY
18. CALIFORNIA ONLY:
CONNECT VSV (FOR FUEL PRESSURE CONTROL)
CONNECTOR
19. CONNECT KNOCK SENSOR AND VSV (FOR EGR)
CONNECTORS
20. INSTALL 2 ENGINE WIRE GROUND STRAPS TO
INTAKE MANIFOLD(b) 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)
16. INSTALL INTAKE MANIFOLD
(a) Connect the 2 wire clamps to the wire brackets on the
intake manifold.
21. CALIFORNIA:
INSTALL AIR TUBE
(a) Install the air tube and wire clamp with the 3 bolts.
± 5S±FE ENGINEENGINE MECHANICALEG1±76
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25. INSTALL EGR VALVE AND VACUUM MODULATOR
(a) Install a new gasket and the EGR valve with the union
nut and 2 nuts.
Union nut:
Torque: 59 N±m (600 kgf±cm, 43 ft±lbf)
Nut:
Torque: 13 N±m (130 kgf±cm, 9 ft±lbf)
(b) Install the EGR modulator to the clamp. 23. CONNECT VACUUM HOSES
Connect the following hoses:
(1) MAP sensor hose to air intake chamber
(2) Brake booster vacuum hose to air intake chamber
(3) PS vacuum hose to air intake chamber
(4) Vacuum sensing hose to fuel pressure regulator.
24. w/ A/C:
CONNECT A/C IDLE±UP VALVE CONNECTOR(b) Connect the following hoses:
(1) w/ A/C:
A/C hose (from ASV) to air tube
(2) 2 air hoses (from PS pump) to air tube
(3) 2 vacuum hoses to VSV (for fuel pressure con±
trol)
(4) Vacuum hose to air intake chamber
22. EXCEPT CALIFORNIA:
INSTALL AIR TUBE
(a) Install the air tube and wire clamp with the 3 bolts.
(b) Connect the following hoses to the air tube:
(1) w/ A/C:
Air hose from ASV
(2) 2 air hose from PS pump
± 5S±FE ENGINEENGINE MECHANICALEG1±77
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(c) Type A:
Install the throttle body with the 4 bolts.
Torque: 19 N±m (195 kgf±cm, 14 ft±lbf)
HINT: Each bolt is indicated in the illustration.
Bolt length:
A 45 mm (1.77 in.)
B 55 mm (2.17 in.)
(d) Type e:
Install the throttle body with the 2 bolts and 2 nuts.
Torque: 19 N±m (195 kgf±cm, 14 ft±lbf)
(e) Connect the following hoses to the throttle body:
(1) PCV hose
(2) 2 vacuum hoses from EGR vacuum modulator
(3) Vacuum hose from TVV (for EVAP) (c) Connect the vacuum hose clamp.
(d) Connect the following hoses:
(1) Vacuum hose to charcoal canister
(2) Vacuum hose (from EGR valve) to E port of VSV
(for EGR)
(3) Vacuum hose (from Q port of EGR vacuum mod±
ulator) to G port of VSV (for EGR)
(e) Connect the EGR gas temperature sensor connector.
26. INSTALL THROTTLE BODY
(a) Connect the following hoses to the throttle body:
(1) Water bypass hose from water outlet
(2) Water bypass hose from water bypass pipe
(3) California:
Air hose from cylinder head
Except California:
Air hose from air tube
(b) Place a new gasket on the intake chamber, facing the
protrusion downward.
± 5S±FE ENGINEENGINE MECHANICALEG1±78
Page 129 of 4770
(b) Connect the following hoses:
(1) Upper radiator hose
(2) Water bypass pipe hose
(3) Heater water hose
(4) IAC water bypass hose
(5) TVV (for EVAP) vacuum hose (from P port of
throttle body)
(6) TVV (for EVAP) vacuum hose (from charcoal canister) 27. INSTALL WATER BYPASS PIPE
(a) Install a new 0±ring to the bypass pipe.
(b) Apply soapy water on the 0± ring.
(c) Install a new gasket and the bypass pipe with the 2
nuts and 2 bolts.
Torque (Nut): 8.8 N±m (90 kgf±cm. 78 in.±lbf)
28. INSTALL WATER OUTLET
(a) Install a new gasket and the water outlet with the 2
bolts.
Torque: 15 N±m (150 kgf±cm, 11 ft±lbf)
(d) Connect the following hoses:
(1) IAC water bypass hose
(2) Heater water hose
(3) w/ Oil Cooler:
2 oil cooler water bypass hoses (f) Connect the IAC valve connector.
(g) Connect the throttle position sensor connector.
± 5S±FE ENGINEENGINE MECHANICALEG1±79
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17. M/T:
REMOVE CLUTCH RELEASE CYLINDER WITHOUT
DISCONNECTING TUBE
Remove the 4 bolts, release cylinder and tube from
the transaxle.15. DISCONNECT FUEL INLET HOSE
CAUTION: Catch leaking fuel in a container.
16. M/T:
REMOVE STARTER
19. DISCONNECT VACUUM HOSES
(a) MAP sensor hose from air intake chamber
(b) Brake booster vacuum hose from air intake chamber 18. DISCONNECT TRANSAXLE CONTROL CABLE (S)
FROM TRANSAXLE
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20. DISCONNECT ENGINE WIRE FROM CABIN
(a) Remove the under cover.
(b) Remove the lower instrument panel.
(c) Remove the glove compartment door.
(d) Remove the glove compartment.
(e) Disconnect the following connectors:
(1) 2 ECM connectors
(2) 2 cowl wire connector
(f) Remove the 2 nuts, and pull out the engine wire from
the cowl panel.(c) Charcoal canister vacuum hose
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19. M/T:
INSTALL CLUTCH RELEASE CYLINDER
Install the release cylinder and tube with the 4 bolts.
20. M/T:
INSTALL STARTER17. CONNECT VACUUM HOSES
(a) MAP sensor hose to air intake chamber
(b) Brake booster vacuum hose to air intake chamber
18. CONNECT TRANSAXLE CONTROL CABLE
(S) TO TRANSAXLE (c) Charcoal canister vacuum hose
± 5S±FE ENGINEENGINE MECHANICALEG1±131
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4. REINSTALL TVV
(a) Apply adhesive to 2 or 3 threads of the TVV, and
install it.
Adhesive:
Part No. 08833±00070, THREE BOND 1324
or equivalent
Torque: 29 N±m (300 kgf±cm, 22 ft±lbf)
(b) Reconnect 2 vacuum hoses.
5. REFILL WITH ENGINE COOLANT
CHECK VALVE INSPECTION
INSPECT CHECK VALVE
(a) Check that air flows from the yellow port to the black
port.
(b) Check that air does not flow from the black port to the
yellow port.
If operation is not as specified, replace the check
valve.
TVV INSPECTION
1. DRAIN ENGINE COOLANT
2. REMOVE TVV FROM WATER INLET HOUSING
(a) Disconnect the following hoses:
(1) Vacuum hose (from throttle body)
(2) Vacuum hose (from charcoal canister)
(b) Remove the TVV.
3. INSPECT TVV OPERATION
(a) Cool the TVV to below 35C (95F) with cool water.
(b) Check that air does not flow from the upper port to
lower port.
(c) Heat the TVV to above 54C (129F) with hot water.
(d) Check that air flows from the upper port to lower port.
If operation is not as specified, replace the TVV.
± 5S±FE ENGINEEMISSION CONTROL SYSTEMSEG1±151