Page 2763 of 4770
± DIAGNOSTICSENGINE (1MZ±FE)
DI±343
578 Author: Date:
3 Check for open and short in harness and connector between ECM and A/F sen-
sors (bank 1, 2 sensor 1) (See page IN±31).
NG Repair or replace harness or connector.
OK
4 Check resistance of A/F sensor heater (See page SF±68).
NG Replace A/F sensor.
OK
5 Check air induction system (See page SF±1).
NG Repair or replace.
OK
6 Check EGR system (See page EC±11).
NG Replace EGR system.
OK
7 Check fuel pressure (See page SF±21).
NG Check and repair fuel pump, fuel pipe line and
filter (See page SF±1).
OK
Page 2767 of 4770
± DIAGNOSTICSENGINE (1MZ±FE)
DI±347
582 Author: Date:
3 Check for open and short in harness and connector between ECM and A/F sen-
sors (bank 1, 2 sensor 1) (See page IN±31).
NG Repair or replace harness or connector.
OK
4 Check resistance of A/F sensor heater (See page SF±68).
NG Replace A/F sensor.
OK
5 Check air induction system (See page SF±1).
NG Repair or replace.
OK
6 Check EGR system (See page EC±11).
NG Replace EGR system.
OK
7 Check fuel pressure (See page SF±21).
NG Check and repair fuel pump, fuel pipe line and
filter (See page SF±1).
OK
Page 3427 of 4770

A07363
A07365
S05981
SST
S05990
(a)
(b)(c)
A07360
(e)(d)
± ENGINE MECHANICAL (5S±FE)CYLINDER HEAD
EM±35
1207 Author: Date:
(d) Loosen the union nut of the EGR pipe, and remove the
bolt, 2 nuts, the EGR valve, vacuum modulator, vacuum
hoses assembly and gasket.
12. DISCONNECT ENGINE WIRE FROM INTAKE MAN-
IFOLD
(a) Disconnect the engine wire clamp from the bracket on the
LH side of the intake manifold.
(b) Disconnect the 2 engine wire clamps from the 2 brackets
on the front side of the intake manifold.
13. DISCONNECT FUEL INLET HOSE FROM DELIVERY
PIPE
(a) Using SST, loosen the fuel pulsation damper.
SST 09612±24014 (09617±24011)
(b) Remove the fuel pulsation damper and 2 gaskets, and
disconnect the fuel inlet hose from the delivery pipe.
14. REMOVE INTAKE MANIFOLD
(a) Disconnect the MAP sensor vacuum hose from the gas
filter.
(b) Disconnect the brake booster vacuum hose from the in-
take manifold.
(c) Disconnect the PCV hose from the intake manifold.
(d) Remove the 2 bolts, and disconnect the 2 ground wires
from the intake manifold.
(e) Disconnect 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 3462 of 4770

S05253
EM±70
± ENGINE MECHANICAL (5S±FE)ENGINE UNIT
1242 Author: Date:
(g) Disconnect the engine wire clamp from the bracket on the
RH fender apron.
(h) Disconnect the MAP sensor connector.
(i) Disconnect the wire clamp from the bracket for the MAP
sensor.
(j) Disconnect the 2 ground strap connectors from the RH
fender apron.
(k) Disconnect the 2 ground strap connectors from the LH
fender apron.
(l) Disconnect the engine wire protector clamp from the bat-
tery bracket.
(m) Disconnect the engine wire from the clamp on the fuel fil-
ter.
(n) Disconnect the ground cable from the transaxle.
(o) Disconnect the brake booster vacuum hose from the in-
take manifold.
(p) Disconnect the heater hose from the water outlet.
(q) Disconnect the heater hose from the water bypass pipe.
(r) Disconnect the fuel inlet hose from the fuel filter.
(s) Disconnect the MAP sensor vacuum hose from the gas
filter on the intake manifold.
13. DISCONNECT ENGINE WIRE FROM CABIN
(a) Remove the under cover.
(b) Disconnect the 3 ECM connectors.
(c) Disconnect the 3 cowl wire connectors from the connec-
tors on the bracket.
(d) Disconnect the grommet from the cowl panel, and pull out
the engine wire.
14. REMOVE DRIVE SHAFTS (See page SA±17)
15. DISCONNECT TRANSAXLE CONTROL CABLE(S)
FROM TRANSAXLE
16. M/T:
REMOVE STARTER (See page ST±5)
17. M/T:
DISCONNECT CLUTCH RELEASE CYLINDER AND
TUBE FROM TRANSAXLE
Page 3472 of 4770

S05251
EM±80
± ENGINE MECHANICAL (5S±FE)ENGINE UNIT
1252 Author: Date:
(b) Connect the generator connector.
(c) Install the wire clamp to the generator.
(d) Connect the starter cable.
(e) Connect the starter connector.
(f) Install the DLC1 to the bracket.
(g) Install the engine wire clamp to the bracket on the RH
fender apron.
(h) Connect the MAP sensor connector.
(i) Install the wire clamp to the bracket for the MAP sensor.
(j) Connect the VSV connector for the vapor pressure sen-
sor.
(k) Connect the 2 ground strap connectors to the RH fender
apron.
(l) Connect the 2 ground strap connectors to the LH fender
apron.
(m) Install the engine wire protector clamp to the battery
bracket.
(n) Install the engine wire to the clamp on the fuel filter.
(o) Connect the ground cable to the transaxle.
(p) Connect the brake booster vacuum hose to the intake
manifold.
(q) Connect the heater hose to the water outlet.
(r) Connect the heater hose to the water bypass pipe.
(s) Connect the fuel inlet hose to the fuel filter with 2 new gas-
kets and the union bolt.
Torque: 29 N´m (300 kgf´cm, 21 ft´lbf)
(t) Connect the MAP sensor vacuum hose to the gas filter on
the intake manifold.
33. INSTALL FRONT EXHAUST PIPE
(a) Install the support bracket with the nut.
Torque: 33 N´m (330 kgf´cm, 24 ft´lbf)
(b) Temporarily install 2 new gaskets and the front exhaust
pipe with the 2 bolts and 5 nuts.
(c) Tighten the 3 nuts holding the exhaust manifold to the
front exhaust pipe.
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
(d) Tighten the 2 bolts and 2 nuts holding the front exhaust
pipe to the center exhaust pipe.
Torque: 56 N´m (570 kgf´cm, 41 ft´lbf)
(e) Install the bracket with the 2 bolts.
Torque: 33 N´m (330 kgf´cm, 24 ft´lbf)
(f) Install the support stay with the 2 bolts.
Torque: 33 N´m (330 kgf´cm, 24 ft´lbf)
34. INSTALL RADIATOR (See page CO±23)
35. INSTALL CRUISE CONTROL ACTUATOR
36. INSTALL BATTERY TRAY AND BATTERY
37. INSTALL AIR CLEANER CASE
Install the air cleaner case with the 3 bolts.
Page 3539 of 4770

S04790
Chamber Stay
Engine
HangerEGR
Pipe
S04791
8 mm Hexagon
Wrench
A01807
(b)
(c)
A01808
± ENGINE MECHANICAL (1MZ±FE)CYLINDER HEAD
EM±33
1319 Author: Date:
(t) Disconnect the engine wire clamp from the emission con-
trol valve set.
(u) Remove the 2 bolts and No.1 engine hanger.
(v) Remove the 2 bolts and air intake chamber stay.
(w) Remove the 4 nuts, No.2 EGR pipe and 2 gaskets.
(x) Using an 8 mm hexagon wrench, remove the 2 bolts, 2
nuts, the air intake chamber assembly and gasket.
9. REMOVE INTAKE MANIFOLD ASSEMBLY
(a) Disconnect the 6 injector connectors.
(b) Disconnect the fuel inlet hose from the fuel filter.
CAUTION:
Perform connecting operations of the fuel tube connector
(quick type) after observing the precautions.
(See page SF±1)
(c) Disconnect the heater hose from the intake manifold.
(d) Remove the 9 bolts, 2 nuts, 2 plate washers, the intake
manifold, delivery pipes and injectors assembly.
NOTICE:
Be careful not to drop the injectors when removing
the delivery pipes.
Pay attention to put any hung load on the injector to
and from the side direction.
Page 3573 of 4770

S04791
8 mm Hexagon
Wrench
S04790
Chamber Stay
Engine
Hanger EGR
Pipe
± ENGINE MECHANICAL (1MZ±FE)CYLINDER HEAD
EM±67
1353 Author: Date:
(b) Connect the fuel inlet hose to the fuel filter.
CAUTION:
Perform connecting operations of the fuel tube connector
(quick type) after observing the precaution.
(See page SF±1)
(c) Connect the heater hose to the intake manifold.
29. RETIGHTEN WATER OUTLET MOUNTING BOLTS
AND NUTS
Tighten the 2 bolts and 2 nuts.
Torque: 15 N´m (150 kgf´cm, 11 ft´lbf)
30. INSTALL AIR INTAKE CHAMBER ASSEMBLY
(a) Using an 8 mm hexagon wrench, install a new gasket and
the air intake chamber assembly with the 2 bolts and 2
nuts. Uniformly tighten the bolts and nuts in several
passes.
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)
(b) Install 2 new gaskets and No.2 EGR pipe with the 4 nuts.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
(c) Install the No.1 engine hanger with the 2 bolts.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
(d) Install the air intake chamber stay with the 2 bolts.
Torque: 19.5 N´m (200 kgf´cm, 14 ft´lbf)
(e) Connect the PCV hose to the PCV valve on the RH cylin-
der head.
(f) Connect the ground strap and cable to the intake air con-
trol valve for the ACIS.
(g) Connect the ground cable and strap with the nut.
Torque: 14.5 N´m (145 kgf´cm, 10 ft´lbf)
(h) Connect the ground cable to the air intake chamber.
(i) Connect the brake booster vacuum hose to the air intake
chamber.
(j) Connect the 2 water bypass hoses to the throttle body.
(k) Connect the air assist hose to the throttle body.
(l) Connect the purge hose to the emission control valve set.
(m) Connect the 2 vacuum hoses to the vacuum tank for the
ACIS.
(n) Connect the engine wire clamp to the emission control
valve set.
(o) Install the PS pressure tube with the 2 nuts.
(p) Connect the throttle position sensor connector.
(q) Connect the IAC valve connector.
(r) Connect the EGR gas temperature sensor connector.
(s) Connect the EGR valve position sensor connector.
(t) Connect the VSV connector for the ACIS.
(u) Connect the VSV connecter for the EVAP.
(v) Connect the VSV connector for the EGR.