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4. CONNECT ENGINE WIRE HARNESS WITH WIRE
CLAMP AND BOLT
5. CALIFORNIA ONLY:
CONNECT VSV (FOR FUEL PRESSURE CONTROL)
CONNECTOR AND VACUUM HOSES
6. CONNECT KNOCK SENSOR AND VSV (FOR EGR)
CONNECTORS
7. CONNECT 2 ENGINE WIRE GROUND STRAPS TO
INTAKE MANIFOLD
10. 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 vacuum modulator to the clamp. 8. 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) Vacuum sensing hose to fuel pressure regulator.
9. w/ A/C:
CONNECT A/C IDLE±UP VALVE CONNECTOR (c) 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)
(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)
± 5S±FE ENGINEMFI/SFI SYSTEMEG1±199
Page 250 of 4770
(c) Connect the vacuum hose clamp.
(d) Connect the following hoses:
(1) Vacuum hose to charcoal canister
(2) Vacuum hose (from EGR valves) to E port of VSV
(for EGR)
(3) Vacuum hose (from Q port EGR vacuum modula±
tor) to G port of VSV (for EGR)
(e) Connect the EGR gas temperature sensor connector.
13. 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 to air tube11. CONNECT VACUUM HOSES TO VSV (FOR EVAP)
(a) From P port of throttle body
(b) From charcoal canister
(b) Place a new gasket on the intake chamber, facing the
protrusion downward. 12. CONNECT PS VACUUM HOSES
± 5S±FE ENGINEMFI/SFI SYSTEMEG1±200
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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)
Bolt length:
A 45 mm (1.77 in.)
B 55 mm (2.17 in.)
(d) Type B:
Install the throttle body with the 2 bolts and 2 nuts.
Torque: 19 N±m (195 kgf±cm, 14 ft±lbf)
14. INSTALL AIR CLEANER CAP, RESONATOR AND
AIR CLEANER HOSE
(a) Connect the air cleaner hose to the throttle body.
(b) Install the air cleaner cap together with the resonator
and air cleaner hose.
(c) California only:
Connect the air hose to the air cleaner hose.
(d) Connect the intake air temperature sensor connector.
15. A/T:
CONNECT AND ADJUST THROTTLE CABLE
16. CONNECT AND ADJUST ACCELERATOR CABLE
17. FILL WITH ENGINE COOLANT
Capacity:
6.3 liters (6.7 US qts. 5.5 Imp. qts)
18. CONNECT NEGATIVE (±) TERMINAL CABLE TO
BATTERY (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)
(f) Connect the IAC valve connector.
(g) Connect the throttle position sensor connector.
± 5S±FE ENGINEMFI/SFI SYSTEMEG1±201
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FUEL TANK AND LINE
COMPONENTS
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FUEL LINES AND CONNECTIONS
INSPECTION
(a) Check the fuel lines for cracks, leakage and all con±
nections for deformation.
(b) Check the fuel tank vapor vent system hoses and
connections for looseness, sharp bends or damage.
(c) Check the fuel tank for deformation, cracks, fuel leak±
age and tank band looseness.
(d) Check the filler neck for damage or fuel leakage.
(e) Hose and tube connections are as shown in the illus±
tration.
If a problem is found, repair or replace the part as
necessary.
PRECAUTIONS
1. Always use new gaskets when replacing the fuel
tank or component parts.
2. Apply the proper torque to all parts tightened.
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2. INSPECT THROTTLE POSITION SENSOR
(a) Apply vacuum to the throttle opener.
(b) Disconnect the sensor connector.
(c) Insert a thickness gauge between the throttle stop
screw and stop lever.
ON±VEHICLE INPSECTION
1. INSPECT THROTTLE BODY
(a) Check that the throttle linkage moves smoothly.
(b) Check the vacuum at each port.
wStart the engine.
wCheck the vacuum with your finger.
THROTTLE BODY
Other than idle
No vacuum
No vacuum No vacuum
No vacuum Port name
Vacuum Vacuum At idle
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3. INSPECT AND ADJUST THROTTLE OPENER
A. Warm up engine
Allow the engine to warm up to normal operating
temperature.
B. Check idle speed
Idle speed:
750 +50 rpm
C. Check and adjust throttle opener setting speed
(a) Disconnect the vacuum hose from the throttle opener,
and plug the hose end.
(b) Maintain the engine at 2,500 rpm.
(c) Release the throttle valve.
(d) Check that the throttle opener is set.
Throttle opener setting speed:
1,300 ± 1,500 rpm (w/ Cooling fan OFF) (d) Using an ohmmeter, measure the resistance between
each terminal.
(e) Reconnect the sensor connector.
Clearance between
lever and stop screw
Throttle valve fully
open0.50 mm (0.020 in.)
0.70 mm (0.028 in.)Between
terminals
2.0 ± 10.2 k 2.3 k or less 0.2 ± 5.7 k
0 mm (0 in.)
2.5 ± 5.9 k Resistance
VTA ± E2
IDL ± E2
VTA ± E2IDL ± E2
VC ± E2Infinity
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(e) Adjust the throttle opener setting speed by turning
the throttle opener adjusting screw.
COMPONENTS FOR REMOVAL AND
INSTALLATION
(f) Reconnect the vacuum hose to the throttle opener.
± 5S±FE ENGINEMFI/SFI SYSTEMEG1±206