Page 3461 of 4770

EM08F±04
S05251
± ENGINE MECHANICAL (5S±FE)ENGINE UNIT
EM±69
1241 Author: Date:
REMOVAL
1. REMOVE HOOD
2. REMOVE FRONT FENDER APRON SEALS
3. DRAIN ENGINE COOLANT
4. DRAIN ENGINE OIL
5. DISCONNECT ACCELERATOR CABLE
6. REMOVE AIR CLEANER CAP
(a) Disconnect the IAT sensor connector.
(b) Disconnect the VSV connector for the EVAP
(c) Disconnect the PCV hose from the cylinder head cover.
(d) Disconnect the EVAP hose from the throttle body.
(e) Disconnect the EVAP hose from the VSV.
(f) Disconnect the 2 clamps, and disconnect the air cleaner
cap from the air cleaner case.
(g) Loosen hose clamp, and disconnect the air cleaner hose
from the throttle body.
(h) Remove the air cleaner cap and hose assembly.
7. REMOVE AIR CLEANER CASE
(a) Remove the air filter.
(b) Remove the 3 bolts and air cleaner case.
8. REMOVE BATTERY AND TRAY
9. REMOVE CRUISE CONTROL ACTUATOR
10. REMOVE RADIATOR (See page CO±18)
11. REMOVE FRONT EXHAUST PIPE
(a) Remove the 2 bolts holding the support stay to the sup-
port bracket.
(b) Remove the 2 bolts holding the support bracket to the
front frame.
(c) Remove the 2 bolts and 2 nuts holding the front exhaust
pipe to the center exhaust pipe.
(d) Remove the 3 nuts holding the front exhaust pipe to the
exhaust manifold.
(e) Remove the front exhaust pipe and 2 gaskets.
(f) Remove the nut and support bracket.
12. DISCONNECT CONNECTORS, WIRES, CABLES,
CLAMPS AND HOSES
(a) Disconnect the generator wire.
(b) Disconnect the generator connector.
(c) Disconnect the wire clamp from the generator.
(d) Disconnect the starter cable.
(e) Disconnect the starter connector.
(f) Disconnect the DLC1 from the bracket.
Page 3463 of 4770
S05250
Connector
S05246
S05254
M/T
S04616
A/T
S05247
± ENGINE MECHANICAL (5S±FE)ENGINE UNIT
EM±71
1243 Author: Date:
18. DISCONNECT A/C COMPRESSOR FROM ENGINE
(a) Disconnect the A/C compressor connector.
(b) Remove the drive belt.
(c) Remove the 3 bolts, and disconnect the A/C compressor
from the engine.
(d) Remove the cylinder block insulator.
19. DISCONNECT PS PUMP FROM ENGINE
(a) Disconnect the PS oil pressure switch connector.
(b) Loosen the 2 bolts, and remove the drive belt.
(c) Remove the 2 bolts, and disconnect the PS pump from
the engine.
20. REMOVE BOLTS HOLDING TRANSAXLE TO LH EN-
GINE MOUNTING INSULATOR
M/T:
Remove the 3 bolts.
A/T:
Remove the 4 bolts.
21. REMOVE NUTS HOLDING REAR ENGINE MOUNTING
BRACKET TO FRONT FRAME
(a) Remove the 2 hole plugs.
(b) Remove the 3 nuts.
Page 3465 of 4770

S05526
TMMK
Made
TMC
Made
A02198
S05530
S05529
Turn
± ENGINE MECHANICAL (5S±FE)ENGINE UNIT
EM±73
1245 Author: Date:
30. A/T:
REMOVE STARTER (See page ST±5)
31. DISCONNECT CONNECTORS
(a) Disconnect the VSS connector.
(b) M/T:
Disconnect the back±up light switch connector.
(c) A/T:
Disconnect the PNP switch connector.
(d) A/T:
Disconnect the 2 solenoid connectors.
32. REMOVE NO.1 EXHAUST MANIFOLD STAY
Remove the 2 bolts and manifold stay.
33. REMOVE NO.2 EXHAUST MANIFOLD STAY AND LH
STIFFENER PLATE
(a) TMC Made:
Remove the 2 nuts and manifold stay.
(b) TMMK Made:
Remove the bolt, nut and manifold stay.
(c) Remove the 2 bolts and stiffener plate.
34. REMOVE INTAKE MANIFOLD STAY
Remove the 2 bolts and intake manifold stay.
35. REMOVE RH STIFFENER PLATE
Remove the 4 bolts and stiffener plate.
36. REMOVE EXHAUST PIPE BRACKET, OIL PAN INSU-
LATOR AND NO.2 REAR END PLATE
(a) Remove the 2 bolts and exhaust pipe bracket.
(b) Remove the 2 bolts, oil pan insulator and rear end plate.
37. A/T:
REMOVE TORQUE CONVERTER CLUTCH BOLTS
(a) Turn the crankshaft pulley bolt to gain access to each bolt.
(b) Hold the crankshaft pulley bolt with a wrench, and remove
the 6 bolts.
Page 3468 of 4770

Z19014Turn
Black
Colored
Bolt A/T
S05530
A02198
S05526
TMC
Made
TMMK
Made
EM±76
± ENGINE MECHANICAL (5S±FE)ENGINE UNIT
1248 Author: Date:
7. A/T:
INSTALL TORQUE CONVERTER CLUTCH BOLTS
(a) Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive:
Part No. 08833±00070, THREE BOND 1324 or equiva-
lent
(b) Hold the crankshaft pulley bolt with a wrench, and install
the 6 bolts evenly.
Torque: 27 N´m (280 kgf´cm, 20 ft´lbf)
HINT:
First tighten the black colored bolt, install the other bolts.
8. INSTALL NO.2 REAR END PLATE, OIL PAN INSULA-
TOR AND EXHAUST PIPE BRACKET
(a) Install the oil pan insulator to the rear end plate.
(b) Install the rear end plate and exhaust pipe bracket with
the 4 bolts.
Torque:
9.3 N´m (95 kgf´cm, 82 in.´lbf) for 10 mm head
19 N´m (195 kgf´cm, 14 ft´lbf) for 12 mm head
9. INSTALL RH STIFFENER PLATE
Install the stiffener plate with the 4 bolts.
Torque: 39 N´m (398 kgf´cm, 29 ft´lbf)
10. INSTALL INTAKE MANIFOLD STAY
Install the manifold stay with the 2 bolts.
Torque: 39 N´m (398 kgf´cm, 29 ft´lbf)
11. INSTALL LH STIFFENER PLATE AND NO.2 EXHAUST
MANIFOLD STAY
(a) TMC Made:
Temporarily install the stiffener plate and manifold stay
with the 2 bolts and 2 nuts.
(b) TMMK Made:
Temporarily install the stiffener plate and manifold stay
with the 3 bolts and nut.
(c) Tighten the 2 bolts holding the stiffener plate to the trans-
axle.
Page 3471 of 4770

S04616
A/T
S05246
S05250
Connector
S05253
± ENGINE MECHANICAL (5S±FE)ENGINE UNIT
EM±79
1251 Author: Date:
A/T:
Install the 4 bolts.
Torque: 64 N´m (650 kgf´cm, 47 ft´lbf)
24. REMOVE ENGINE SLING DEVICE
25. CONNECT TRANSAXLE CONTROL CABLE(S) TO
TRANSAXLE
26. INSTALL PS PUMP
(a) Install the PS pump with the 2 bolts.
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)
(b) Install the drive belt.
(c) Connect the PS oil pressure switch connector.
27. INSTALL A/C COMPRESSOR
(a) Install the cylinder block insulator and A/C compressor
with the 3 bolts.
Torque: 25.5 N´m (260 kgf´cm, 19 ft´lbf)
(b) Install the drive belt.
(c) Connect the A/C compressor connector.
28. M/T:
INSTALL CLUTCH RELEASE CYLINDER AND TUBE
TO TRANSAXLE
29. M/T:
INSTALL STARTER (See page ST±19)
30. INSTALL DRIVE SHAFTS (See page SA±24)
31. CONNECT ENGINE WIRE TO CABIN
(a) Push in the engine wire through the cowl panel. Install the
grommet.
(b) Connect the 3 engine ECM connectors.
(c) Connect the 3 cowl wire connectors to the connectors on
the bracket.
(d) Install the under cover.
32. CONNECT CONNECTORS, WIRES, CABLES,
CLAMPS AND HOSES
(a) Connect the generator wire.
Page 3473 of 4770
± ENGINE MECHANICAL (5S±FE)ENGINE UNIT
EM±81
1253 Author: Date:
38. INSTALL AIR CLEANER CAP
(a) Connect the air cleaner hose to the throttle body.
(b) Attach the air cleaner cap to the air cleaner case, and
install the 2 clamps.
(c) Tighten the air cleaner hose clamp.
(d) Connect the PCV hose to the cylinder head cover.
(e) Connect the EVAP hose to the throttle body.
(f) Connect the EVAP hose to the VSV.
(g) Connect the IAT sensor connector.
(h) Connect the VSV connector for the EVAP.
39. CONNECT ACCELERATOR CABLE
40. INSTALL ENGINE FENDER APRON SEALS
41. INSTALL HOOD
42. FILL ENGINE WITH OIL
43. FILL WITH ENGINE COOLANT
44. START ENGINE AND CHECK FOR LEAKS
45. RECHECK ENGINE COOLANT AND OIL LEVELS
Page 3475 of 4770
A07354
Grommet
Cylinder Head
Cover
Gasket
Camshaft Oil Seal
Cylinder Head Assembly
No.3 Timing Belt Cover
Crankshaft Position Sensor
ConnectorWire Clamp Water Bypass Hose Exhaust Camshaft Intake Camshaft
Camshaft Bearing Cap PCV Hose
Cylinder Head Gasket
IAC Valve Water Bypass Hose
Knock Sensor 1 Connector
N´m (kgf´cm, ft´lbf)
Non±reusable part
44 (450, 33)
19 (190, 14)
VSV for EGR
: Specified torquex 10
1st 49 (500, 36)
2nd Turn 90° See page EM±53
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
EM±83
1255 Author: Date:
Page 3476 of 4770
A07367
Water Pump, Water Bypass Pipe
and Oil Cooler Assembly
Water Pump and Water
Bypass Pipe Assembly
(w/o Oil Cooler)
Union Bolt
Generator Drive Belt Adjusting Bar
Knock Sensor 1Oil Filter
Oil Dipstick
PS Pump
Bracket
Crankshaft Position Sensor Connector
Oil Pump
Gasket x 10
Oil Strainer
Oil Pan
Drain Plug
N´m (kgf´cm, ft´lbf)
Non±reusable partx 17 Gasket
Gasket O±Ring
8.8 (90, 78 in.´lbf)5.4 (55, 48 in.´lbf)
5.4 (55, 48 in.´lbf)
O±Ring
78.5 (800, 58)
w/ Oil Cooler
: Specified torque
Crankshaft
Front Oil
Seal
EM±84
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
1256 Author: Date: