Page 92 of 4770

5. REMOVE AIR CLEANER CAP, RESONATOR AND
AIR CLEANER HOSE
(a) Disconnect the intake air temperature sensor connec±
tor.
(b) California only:
Disconnect the air hose from the air cleaner hose.
(c) Loosen the air cleaner hose clamp bolt.
(d) Disconnect the 4 air cleaner cap clips.
(e) Disconnect the air cleaner hose from the throttle
body, and remove the air cleaner cap together with
the resonator and air cleaner hose.
6. REMOVE GENERATOR (See page CH±10)
7. REMOVE DISTRIBUTOR
(See page IG±13 end 32)
CYLINDER HEAD REMOVAL
(See Components for Removal and Installation)
1. DISCONNECT NEGATIVE (±) TERMINAL CABLE
FROM BATTERY
CAUTION: Work must be started after 90 seconds from
the time the ignition switch is turned to the ªLOCKº
position and the negative (±) terminal cable is discon±
nected from the battery.
2. DRAIN ENGINE COOLANT
3. A/T:
DISCONNECT THROTTLE CABLE FROM
THROTTLE BODY
4. DISCONNECT ACCELERATOR CABLE FROM
THROTTLE BODY
8. DISCONNECT FRONT EXHAUST PIPE
(a) Loosen the 2 bolts, and disconnect the bracket.
(b) Using a 14 mm deep socket wrench, remove the 3
nuts holding the front exhaust pipe to the WU±TWC.
(c) Disconnect the front exhaust pipe and gaskets.
± 5S±FE ENGINEENGINE MECHANICALEG1±42
Page 93 of 4770
10. SEPARATE EXHAUST MANIFOLD AND WARM UP
THREE±WAY CATALYTIC CONVERTER
Remove the following parts:
(1) 3 bolts
(2) Manifold lower heat insulator
(3) 8 bolts
(4) 2 WU±TWC heat insulators 9. REMOVE EXHAUST MANIFOLD AND WARM UP
THREE±WAY CATALYTIC CONVERTER ASSEMBLY
(a) Disconnect the main oxygen and sub oxygen sensor
connectors.
(b) Remove the 4 bolts and upper heat insulator.
(e) Remove the 6 nuts, the exhaust manifold and WU ±
TWC assembly. (c) Remove the bolt, nut and No. 1 manifold stay.
(d) Remove the bolt, nut and manifold stay.
± 5S±FE ENGINEENGINE MECHANICALEG1±43
Page 94 of 4770
11. DISCONNECT OIL PRESSURE SWITCH
CONNECTOR
12. DISCONNECT ENGINE WIRE (FOR OXYGEN
SENSORS) FROM ENGINE HANGER
13. REMOVE WATER OUTLET
(a) Disconnect the following connectors:
(1) Engine coolant temperature sender gauge con±
nector
(2) Engine coolant temperature sensor connector
(b) Disconnect the following hoses:
(1) Upper radiator hose
(2) Water bypass pipe hose
(3) Heater water hose
(4) IAC water bypass hose
(5) 2 TVV (for EVAP) vacuum hoses
14. REMOVE WATER BYPASS PIPE
(a) Disconnect the following hoses:
(1) IAC water bypass hose
(2) Heater water hose
(3) w/ Oil Cooler:
2 oil cooler water bypass hoses (5) 3 bolts and 2 nuts
(6) Exhaust manifold
(7) Gasket
(8) Retainer
(9) Cushion
(10) WU±TWC
(c) Remove the 2 bolts, water outlet and gasket.
± 5S±FE ENGINEENGINE MECHANICALEG1±44
Page 95 of 4770
(f) Disconnect the following hoses from the throttle
body, and remove 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 (c) Disconnect the following hoses from the throttle
body.
(1) PCV hose
(2) 2 vacuum hoses from EGR vacuum modulator
(3) Vacuum hose from TVV (for EVAP) (b) Remove the 2 bolts, 2 nuts, water bypass pipe and
gasket.
(c) Remove the O±ring from the water bypass hose.
15. REMOVE THROTTLE BODY
(a) Disconnect the throttle position sensor connector.
(b) Disconnect the IAC valve connector.
(d) Type A:
Remove the 4 bolts.
(e) Type B:
Remove the 2 bolts and 2 nuts.
± 5S±FE ENGINEENGINE MECHANICALEG1±45
Page 96 of 4770
17. DISCONNECT VACUUM HOSES
Disconnect the following hoses:
(1) MAP sensor hose from air intake chamber
(2) Brake booster vacuum hose from air intake cha±
mber
(3) PS vacuum hose from air intake chamber
(4) Vacuum sensing hose from fuel pressure regula±
tor 1
S. W/ A/C:
DISCONNECT A/C IDLE±UP VALVE CONNECTOR
19. EXCEPT CALIFORNIA:
REMOVE AIR TUBE
(a) Disconnect the following hoses from the air tube:
(1) w/ A/C:
Air hose from ASV
(2) 2 air hoses from PS pump I6. REMOVE EGR VALVE AND VACUUM MODULATOR
(a) Disconnect the EGR gas temperature sensor connec±
tor.
(b) Disconnect the following hoses:
(1) 2 vacuum hoses from VSV (for EGR)
(2) Vacuum hose from charcoal canister
(c) Disconnect the vacuum hose clamp.
(d) Loosen the union nut of the EGR pipe, and remove the
2 nuts, EGR valve, vacuum modulator, vacuum hoses
assembly and gasket.
(b) Remove the 3 bolts, wire clamp and air tube.
± 5S±FE ENGINEENGINE MECHANICALEG1±46
Page 97 of 4770
20. CALIFORNIA:
REMOVE AIR TUBE
(a) Disconnect the following hoses:
(1) w/ A/C:
A/C hose (from ASV) from air tube
(2) 2 air hoses (from PS pump) from air tube
(3) California only:
2 vacuum hoses from VSV (for fuel pressure
control)
(4) Vacuum hose from air intake chamber
(b) Remove the 3 bolts, wire clamp and air tube.
21. DISCONNECT 2 ENGINE WIRE GROUND STRAPS
FROM INTAKE MANIFOLD
22. DISCONNECT KNOCK SENSOR AND VSV (FOR
EGR) CONNECTORS
23. CALIFORNIA ONLY:
DISCONNECT VSV (FOR FUEL PRESSURE CON±
TROL) CONNECTOR
24. REMOVE VSV OR VSV ASSEMBLY
25. REMOVE INTAKE MANIFOLD
(a) Remove the 4 bolts, wire bracket, No.1 air intake
chamber and manifold stays.
(b) Remove the bolt, vacuum hose bracket, and discon±
nect the engine wire.
(c) Remove the6 bolts, 2 nuts, intake manifold and
gasket.
± 5S±FE ENGINEENGINE MECHANICALEG1±47
Page 126 of 4770
(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
Page 127 of 4770

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