Page 3449 of 4770

P03445
Drive Gear
Sub±Gear Service
Bolt
EM7797
Seal Packing
P03282
P03283
: Seal Packing
S05932
Marking
15° 15°
± ENGINE MECHANICAL (5S±FE)CYLINDER HEAD
EM±57
1229 Author: Date:
(9) Remove the service bolt.
6. CHECK AND ADJUST VALVE CLEARANCE
(See page EM±4)
Turn the camshaft and position the cam lobe upward, and in-
spect and adjust the valve clearance.
7. INSTALL SEMI±CIRCULAR PLUGS
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the semi±circular plug grooves.
Seal packing: Part No. 08826±00080 or equivalent
(c) Install the 2 semi±circular plugs to the cylinder head.
8. INSTALL CYLINDER HEAD COVER
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder head as shown in the
illustration.
Seal packing: Part No. 08826±00080 or equivalent
(c) Install the gasket to the head cover.
(d) Install the head cover with the 4 grommets and nuts. Uni-
formly tighten the nuts in several passes.
Torque: 44 N´m (450 kgf´cm, 33 ft´lbf)
HINT:
Install the grommets so that their markings are as shown in the
illustration.
Page 3450 of 4770

P13638
Adhesive
S05962
Z09141
California
Except California New O±RingNew Insulator
New GrommetNew O±Ring
New GrommetNew
O±Ring EM±58
± ENGINE MECHANICAL (5S±FE)CYLINDER HEAD
1230 Author: Date:
9. INSTALL OIL PRESSURE SWITCH
(a) Apply adhesive to 2 or 3 threads.
Adhesive:
Part No. 08833±00080, THREE BOND 1324 or equiva-
lent
(b) Install the oil pressure switch.
10. INSTALL ENGINE HANGERS AND GENERATOR
BRACKET
(a) Install the generator bracket and RH engine hanger as-
sembly with the 3 bolts.
Torque: 42 N´m (425 kgf´cm, 31 ft´lbf)
(b) Install the LH engine hanger with the bolt.
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
11. INSTALL NO.3 TIMING BELT COVER
Install the timing belt cover with the 3 bolts.
Torque: 7.8 N´m (80 kgf´cm, 69 in.´lbf)
12. TEMPORARILY INSTALL NO.1 IDLER PULLEY AND
TENSION SPRING (See page EM±23)
13. INSTALL CAMSHAFT TIMING PULLEY
(See page EM±23)
14. CONNECT TIMING BELT TO CAMSHAFT TIMING
PULLEY (See page EM±23)
15. INSTALL INJECTORS AND DELIVERY PIPE
(a) California:
Install a new insulator and grommet to each injector.
(b) Except California:
Install a new grommet to each injector.
(c) California:
Apply a light coat of gasoline onto 2 new O±rings, and
install them to each injector.
(d) Except California:
Apply a light coat of gasoline onto a new O±ring, and
install it to each injector.
Page 3451 of 4770
S06009
Upward
ConnectorTurn
Push
S05935New Insulator
Spacer
S06002
S06003
Upward
ConnectorTurn
S06001
± ENGINE MECHANICAL (5S±FE)CYLINDER HEAD
EM±59
1231 Author: Date:
(e) While turning the injector clockwise and counterclock-
wise, push it to the delivery pipe. Install the 6 injectors.
(f) Position the injector connector upward.
(g) Install the 2 spacers and 4 new insulators (Except Califor-
nia) to the cylinder head.
(h) Attach the 4 injectors together with the delivery pipe to the
cylinder head.
(i) Temporarily install the 2 bolts holding the delivery pipe to
the cylinder head.
(j) Check that the injectors rotate smoothly.
HINT:
If injectors do not rotate smoothly, the probable cause is incor-
rect installation of O±rings. Replace the O±rings.
(k) Position the injector connector upward.
(l) Tighten the 2 bolts holding the delivery pipe to the cylinder
head.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
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 3454 of 4770

S05548
Wire
Clamp
S05297
Clamp
Sensor
Connector
S05281
EM±62
± ENGINE MECHANICAL (5S±FE)CYLINDER HEAD
1234 Author: Date:
25. INSTALL IGNITION COILS AND NO.2 INTAKE MAN-
IFOLD STAY ASSEMBLY
(a) TMC Made:
Install the 2 ignition coils and manifold stay assembly with
the 2 nuts and 2 bolts.
Torque:
21 N´m (214 kgf´cm, 15 ft´lbf) for 12 mm head
42 N´m (428 kgf´cm, 31 ft´lbf) for 14 mm head
(b) TMMK Made:
Install the 2 ignition coils and manifold stay assembly with
the nut and 3 bolts.
Torque:
21 N´m (214 kgf´cm, 15 ft´lbf) for 12 mm head
42 N´m (428 kgf´cm, 31 ft´lbf) for 14 mm head
(c) Install the wire clamp to the manifold stay.
(d) Connect the 4 high±tension cords to the spark plugs.
(e) Install the 4 high±tension cords to the 2 clamps on the cyl-
inder head cover.
(f) Connect the 2 ignition coil connectors.
26. INSTALL THROTTLE BODY (See page SF±34)
27. INSTALL EXHAUST MANIFOLD
(a) California:
Install the A/F sensor connector for the wiring side to the
bracket to the LH engine hanger.
(b) Except California:
Install the heated oxygen sensor for the wiring side to the
bracket to the LH engine hanger.
(c) Attach the exhaust manifold to the front exhaust pipe.
(d) Install a new gasket, the exhaust manifold, No.2 and No.3
exhaust manifold heat insulators assembly with the 6
nuts. Uniformly tighten the nuts in several passes.
Torque: 49 N´m (500 kgf´cm, 36 ft´lbf)
(e) Install the wire clamp.
(f) California:
Connect the A/F sensor connector.
(g) Except California:
Connect the heated oxygen sensor (bank 1 sensor 1)
connector.
(h) Install the No.1 exhaust manifold stay with the 2 bolts.
Torque: 42 N´m (425 kgf´cm, 31 ft´lbf)
Page 3455 of 4770
S05300
TMC
Made
TMMK
Made
S05282
± ENGINE MECHANICAL (5S±FE)CYLINDER HEAD
EM±63
1235 Author: Date:
(i) TMC Made:
Install the No.2 exhaust manifold stay with the 2 nuts.
Torque:
42 N´m (425 kgf´cm, 31 ft´lbf) for manifold side
58 N´m (591 kgf´cm, 43 ft´lbf) for block side
(j) TMMK Made:
Install the No.2 exhaust manifold stay with the bolt and
nut.
Torque:
42 N´m (425 kgf´cm, 31 ft´lbf) for manifold side
41.5 N´m (423 kgf´cm, 31 ft´lbf) for block side
(k) Install the No.1 exhaust manifold heat insulator with the
3 (California) or 5 (Except California) bolts.
(l) Install 3 new nuts holding the front exhaust pipe to the ex-
haust manifold.
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
28. INSTALL GENERATOR (See page CH±16)
29. INSTALL AIR CLEANER CASE (See page EM±75)
30. FILL WITH ENGINE COOLANT
31. START ENGINE AND CHECK FOR LEAKS
32. RECHECK ENGINE COOLANT LEVEL AND OIL LEV-
EL
Page 3456 of 4770

EM0YV±01
A02195
Radiator Reservoir Hose
Generator Drive BeltUpper Radiator
Hose
Support BracketFront Exhaust Pipe PS Oil Pressure Switch
ConnectorBattery TrayBattery
PS Pump Drive Belt
PS Pump
Support Stay Upper Radiator Support
Lower Radiator Hose
A/C Compressor
Cylinder Block Insulator
LH Front Fender Apron Seal
Oil Cooler Hose (A/T)
Cruise Control ActuatorEVAP Hose
Air Filter Upper Radiator
Support
EVAP Hose Hood
PCV Hose
Support
Bracket Gasket
Non±reusable part Gasket
Clamp
N´m (kgf´cm, ft´lbf)
62 (630, 46)
56 (570, 41)
: Specified torque
Washer Hose
for Windshield
No.1 Electric
Cooling Fan
Connector
ECT Switch
Connector No.2 Electric
Cooling Fan
ConnectorRadiator
Assembly
A/C Compressor
ConnectorLower Radiator
Support
RH Front Fender
Aplon Seal
Cruise
Control
Actuator
Connector
Battery
Hold±Down
ClampAir Cleaner
Case
VSV
Connector
for EVAP
EVAP
Hose
IAT Sensor
Connector
Air
Cleaner
Cap
EM±64
± ENGINE MECHANICAL (5S±FE)ENGINE UNIT
1236 Author: Date:
ENGINE UNIT
COMPONENTS