Part 1

CYLINDER HEAD (5S-FE) COMPONENTS
REMOVAL OF CYLINDER HEAD
1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY

CAUTION: Work must be started after approx. 20 seconds or longer from the time the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery.

2. DRAIN ENGINE COOLANT
3. (A/T)
DISCONNECT THROTTLE CABLE FROM THROTTLE BODY
4. DISCONNECT ACCELERATOR CABLE FROM THROTTLE BODY
5. (w/ CRUISE CONTROL SYSTEM) REMOVE CRUISE CONTROL ACTUATOR
6. REMOVE AIR CLEANER CAP
7. REMOVE ALTERNATOR
8. REMOVE DISTRIBUTOR
9. REMOVE ENGINE UNDER COVERS
10. REMOVE SUSPENSION LOWER CROSSMEMBER
11. REMOVE FRONT EXHAUST PIPE
12. REMOVE OXYGEN SENSOR (MAIN)
13. (CALIF. ONLY) REMOVE SUB-OXYGEN SENSOR






14. REMOVE EXHAUST MANIFOLD AND CATALYTIC CONVERTER ASSEMBLY
(a) Remove the six bolts and manifold upper heat insulator.






(b) Remove the two bolts, two nuts and catalytic converter stay.






(c) Remove the six nuts, the exhaust manifold and catalytic converter assembly.






15. SEPARATE EXHAUST MANIFOLD AND CATALYTIC CONVERTER
(a) Remove the five bolts and lower manifold heat insulator.
(b) Remove the eight bolts and two catalytic converter heat insulator.






(c) Remove the three bolts, two nuts, catalytic converter, gasket, retainer and cushion.






16. REMOVE WATER OUTLET
(a) Disconnect the following connectors:
- Water temperature sender gauge connector
- Water temperature sensor connector
(b) Disconnect the following hoses:
(1) Upper radiator hose
(2) Water by-pass pipe hose
(3) Heater water hose
(4) ISC water by-pass hose
(5) Two EVAP BVSV vacuum hoses






(c) Remove the two bolts, water outlet and gasket.






17. REMOVE WATER BY-PASS PIPE
(a) (w/ Oil Cooler)
Remove the water by-pass hose heat protector
(b) Disconnect the following hoses:
(1) ISC water by-pass hose
(2) Heater water hose
(3) (w/ Oil Cooler)
Two oil cooler water by-pass hoses






(c) Remove the two bolts, two nuts, water by-pass pipe and gasket.
(d) Remove the 0-ring from the water by-pass hose.
18. REMOVE THROTTLE BODY






19. REMOVE EGR VALVE AND VACUUM MODULATOR
(a) (CALIF. only)
Disconnect EGR gas temperature sensor connector, and disconnect the connector from the bracket.
(b) Remove the following hoses:
(1) Two vacuum hoses from EGR VSV
(2) Vacuum hose from charcoal canister
(c) Disconnect the vacuum hose clamp from the bracket.






(d) Loosen the union nut of the EGR pipe, and remove two nuts the EGR valve, vacuum modulator, vacuum hoses assembly and gasket.






20. DISCONNECT VACUUM HOSES
(a) Vacuum sensor hose from gas filter
(b) Brake booster vacuum hose from intake manifold
(c) (W/ Cruise Control System (w/o ABS) Actuator vacuum hose from intake manifold






21. REMOVE AIR TUBE, ASV (FOR A/C) AND VACUUM PIPE

(a) (w/AC)
Disconnect the ASV connector.
(b) Disconnect the following hoses:
(1) PS air hose from intake manifold
(2) Two air hoses from air tube (3) (w/AC)
Air hose from intake manifold
(4) Vacuum hose from gas filter
(5) Vacuum hose from fuel pressure regulator






(c) Remove the four bolts, vacuum hose bracket, the air tube and ASV assembly.
(d) Remove the bolt and vacuum pipe.






22. DISCONNECT ENGINE WIRE GROUND STRAPS AND CONNECTORS
(a) Two engine ground straps from intake manifold
(b) Knock sensor connector
(c) VSV connector for EGR
23. REMOVE VSV FOR EGR






24. REMOVE ACCELERATOR BRACKET
25. REMOVE INTAKE MANIFOLD
(a) Disconnect the PCV hose from the PCV valve.
(b) Disconnect the two wire clamps from the wire brackets.






(c) Remove the bolt, and disconnect the engine wire protector from the intake manifold.
(d) Remove the four bolts, connector bracket (CALIF. only) and two manifold stays.






(e) Remove the six bolts, two nuts, intake manifold and gasket.
26. REMOVE DELIVERY PIPE AND INJECTORS
27. REMOVE CAMSHAFT TIMING PULLEY
28. REMOVE NO.1 IDLER PULLEY AND TENSION SPRING