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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.
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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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31. ASSEMBLE EXHAUST MANIFOLD AND WARM UP
THREE±WAY CATALYTIC CONVERTER
Assemble the following parts:
(1) WU±TWC
(2) Cushion
(3) Retainer
(4) Gasket
(5) Exhaust manifold
(6) 3 bolts and 2 nuts
Torque: 29 N±m (300 kgf±cm, 22 ft±lbf)
(c) Connect the following connectors:
(1) Engine coolant temperature sender gauge con±
nector
(2) Engine coolant temperature sensor connector
29. CONNECT ENGINE WIRE (FOR OXYGEN SENSORS)
TO ENGINE HANGER
30. CONNECT OIL PRESSURE SWITCH CONNECTOR
32. INSTALL EXHAUST MANIFOLD AND WARM UP
THREE±WAY CATALYTIC CONVERTER
ASSEMBLY
(a) Install a new gasket, the exhaust manifold and WU ±
TWC assembly with the 6 nuts. Uniformly tighten the
nuts in several passes.
Torque: 49 N±m (540 kgf±cm, 36 ft±lbf)
(7) 2 converter heat insulators
(8) 8 bolts
(9) Manifold lower heat insulator
(10) 3 bolts
± 5S±FE ENGINEENGINE MECHANICALEG1±80
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33. CONNECT FRONT EXHAUST PIPE
(a) Place a new gasket on the front exhaust pipe.
(b) Using a 14 mm deep socket wrench, install the 3 new
nuts holding the front exhaust pipe to the WU ±TWC.
Torque: 62 N±m (630 kgf±cm, 46 ft±lbf)
(c) Install the bracket with the 2 bolts.
34. INSTALL DISTRIBUTOR
(See page IG±17 and 37)
35. INSTALL GENERATOR (See page CH±24)
36. 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. (d) Install the manifold upper heat insulator with the 4
bolts.
(e) Connect the main oxygen and sub oxygen sensor
connectors. (c) Install the No. 1 manifold stay with the bolt and nut.
Torque: 42 N±m (425 kgf±cm, 31 ft±lbf)
(b) Install the manifold stay with the bolt and nut.
Torque: 42 N±m (425 kgf±cm, 31 ft±lbf)
± 5S±FE ENGINEENGINE MECHANICALEG1±81
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ENGINE REMOVAL
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 'LOCK'
position and the negative (±) terminal cable Is discon±
nected from the battery.
2. REMOVE BATTERY AND TRAY
3. REMOVE HOOD
4. REMOVE ENGINE UNDER COVER
5. DRAIN ENGINE COOLANT
6. DRAIN ENGINE OIL
7. DISCONNECT ACCELERATOR CABLE FROM
THROTTLE BODY
8. A/T:
DISCONNECT THROTTLE CABLE FROM
THROTTLE BODY
9. REMOVE AIR CLEANER ASSEMBLY, 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.
(f) Remove the element.
(g) Remove the 3 bolts and air cleaner case.
10. w/ CRUISE CONTROL SYSTEM:
REMOVE CRUISE CONTROL ACTUATOR
(a) Remove the actuator cover.
(b) Disconnect the actuator connector.
(c) Remove the 3 bolts, and disconnect the actuator with
the bracket.
11. REMOVE RADIATOR
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Page 136 of 4770
(c) Disconnect the following connectors:
(1) Igniter connector
(2) California only:
Ignition coil connector
(3) Noise filter connector
(4) 2 ground straps from LH fender apron
(5) Connector from LH fender apron 12. DISCONNECT WIRES AND CONNECTORS
(a) Remove the engine relay box, and disconnect the 5
connectors.
(b) Connector from LH fender apron
(6) Data link connector 1
(7) 2 ground straps from RH fender apron
(d) Disconnect the MAP sensor connector.
13. DISCONNECT HEATER HOSES
14. DISCONNECT FUEL RETURN HOSE
CAUTION: Catch leaking fuel in a container.
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Page 137 of 4770
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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Page 143 of 4770
9. REMOVE TIMING BELT AND PULLEYS
10. REMOVE CYLINDER HEAD
11. REMOVE WATER PUMP AND GENERATOR
ADJUSTING BAR
12. REMOVE OIL PAN AND OIL PUMP
13. REMOVE OIL FILTER
14. w/ OIL COOLER:
REMOVE OIL COOLER 4. REMOVE REAR END PLATE
Remove the bolt and end plate.
5. INSTALL ENGINE TO ENGINE STAND FOR
DISASSEMBLY
6. REMOVE GENERATOR
7. REMOVE DISTRIBUTOR1. M/T:
REMOVE CLUTCH COVER AND DISC
2. M/T:
REMOVE FLYWHEEL
3. A/T:
REMOVE DRIVE PLATE
15. REMOVE KNOCK SENSOR
Using SST, remove the knock sensor.
SST 09816 ± 300108. REMOVE PS PUMP BRACKET
Remove the 3 bolts and PS pump bracket.
PREPARATION FOR DISASSEMBLY
± 5S±FE ENGINEENGINE MECHANICALEG1±93