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MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE

Fuel System Pressure Relief

Procedure

    Caution : The fuel system is under pressure. To avoid fuel spillage and the risk of personal injury or fire, it is necessary to relieve the fuel system pressure before disconnecting the fuel lines.

  1. Remove the fuel cap.
  2. Remove the fuel pump fuse Ef18 from the engine fuse block.
  3. Start the engine and allow the engine to stall.
  4. Crank the engine for an additional 10 seconds.

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Fuel Tank

Removal Procedure

    Caution : The fuel system is under pressure. To avoid fuel spillage and the risk of personal injury or fire, it is necessary to relieve the fuel system pressure before disconnecting the fuel lines.

  1. Relieve the fuel pressure. Refer to "Fuel System Pressure Relief" in this section.
  2. Disconnect the negative battery cable.
  3. Drain the fuel tank.
  4. Remove the front muffler. Refer to Section 1G, Exhaust System

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  5. Remove the fuel tank filler tube clamp at the fuel tank.
  6. Disconnect the fuel tank filler tube.
  7. Disconnect the fuel vapor line near the fuel tank filler tube.
  8. Disconnect the fuel pump harness connector.

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  9. Disconnect the fuel inlet line and the fuel return line near the right front of the fuel tank.
  10. Remove the Fuel pump. Refer to "Fuel Pump" in this section.

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  11. Remove the parking brake cables support brackets.
  12. Support the fuel tank.
  13. Remove the fuel tank strap retaining nuts.
  14. Remove the fuel tank strap.
  15. Carefully lower the fuel tank.
  16. Remove the fuel tank.
  17. Transfer any parts as needed.

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Installation Procedure

  1. Raise the fuel tank into position.
  2. Install the fuel tank straps.
  3. Install the fuel tank strap retaining nuts.

    4. Tighten
    Tighten the fuel tank strap retaining nuts to 20 N•m (15 lb-ft).

  4. Install the parking brake cables support bracket.

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  5. Install the fuel pump. Refer to "Fuel Pump" in this section.
  6. Connect the fuel outlet line and the fuel return line.

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  7. Connect the fuel pump harness connector.
  8. Connect the fuel vapor line.
  9. Connect the fuel tank filler tube.
  10. Connect the fuel tank vent tube.
  11. Install the fuel tank filler tube clamp at the fuel tank.

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  12. Install the front muffler. Refer to Section 1G, Exhaust System
  13. Connect the negative battery cable.
  14. Fill the fuel tank.
  15. Perform a leak check of the fuel tank and the fuel line connections.

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Fuel Pump

Removal Procedure

    Caution : The fuel system is under pressure. To avoid fuel spillage and the risk of personal injury or fire, it is necessary to relieve the fuel system pressure before disconnecting the fuel lines.

  1. Relieve the fuel system pressure.
    1. Remove the fuel cap.
    2. Remove fuel pump fuse Ef18 from the engine fuse block.
    3. Start the engine and allow the engine to stall.
    4. Crank the engine for an additional 10 seconds.
  2. Disconnect the negative battery cable.
  3. Remove the rear seat. Refer to Section 9H, Seats.
  4. Remove the fuel pump access cover.
  5. Disconnect the electrical connector at the fuel pump assembly.
  6. Disconnect the fuel outlet line.
  7. Disconnect the fuel tank return line.

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  8. Turn the lock ring counterclockwise to clear the tank tabs.
  9. Remove the fuel pump assembly from the tank.

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Installation Procedure

  1. Clean the gasket mating surface on the fuel tank.
  2. Position the new gasket in place.
  3. Install the fuel pump into the fuel tank in the same location as removed for ease of line and connector installation.
  4. Position the lock ring in place and turn it clockwise until it contacts the tank stop.
  5. Connect the fuel pump assembly connector.
  6. Install the fuel pump outlet line.
  7. Install the fuel tank return line.
  8. Install the fuel pump access cover.
  9. Connect the negative battery cable.
  10. Perform an operational check of the fuel pump.
  11. Install the rear seat. Refer to Section 9H, Seats.

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Fuel Sender

Removal Procedure

  1. Disconnect the insulator connector.

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  2. Push the terminal wedge(1) in the insulator connector.

    3. Notice : The wedge may be disconnected with severe load but can be reconnected.


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  3. Push the wedge(1) outside and then pull the wires tp disconnect from insulator.

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  4. Remove the fuel-level sensor(1) from the sender-housing(2).
  5. Remove the sender-housing(2).

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  6. Remove fuel sender assembly(3).

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Installation Procedure

  1. Wind the wires(1) the sender assembly(2).

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  2. Install the sender assembly onto the fuel pump assembly(1).

    3. Notice : Unless correctly install the sender assmembly, fuel gauge indicate inexactly.

  3. Install the fuel-level sensor onto the sender-housing.

    4. Notice : Unless correctly install the fuel-level sensor, fuel-level warning lamp indicate inexactly.


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  4. Connect the wire into the insulator connector.

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  5. Connect the insulator connector.

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Fuel Filter

Removal Procedure

    Caution : The fuel system is under pressure. To avoid fuel spillage and the risk of personal injury or fire, it is necessary to relieve the fuel system pressure before disconnecting the fuel lines.

  1. Relieve the fuel system pressure. Refer to " Fuel System Pressure Relief " in this section.
  2. Disconnect the negative battery cable.
  3. Remove the fuel filter mounting bracket assembly bolt.

  4. Remove the fuel filter cover.
  5. Disconnect the inlet/outlet fuel lines by moving the line connector lock forward and pulling the hose off of the fuel filter tube.

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Installation Procedure

  1. Install the new fuel filter into the retaining clamp. Note the flow direction.
  2. Install the fuel filter.
  3. Connect the inlet/outlet lines. Secure the lines with the connector lock.

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  4. Install the fuel filter cover.
  5. Install the fuel filter mounting bracket assembly bolt with the fuel filter ground.

    6. Tighten
    Tighten the fuel filter mounting bracket assembly bolts to 4 N•m (35 lb-ft).

  6. Connect the negative battery cable.
  7. Perform a leak test of the fuel filter.

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Fuel Rail and Injectors (1.4L/1.6L DOHC)

Removal Procedure

    Caution : The fuel system is under pressure. To avoid fuel spillage and the risk of personal injury or fire, it is necessary to relieve the fuel system pressure before disconnecting the fuel lines.

  1. Relieve the fuel system pressure. Refer to "Fuel Pump"in this section.
  2. Disconnect the negative battery cable.
  3. Remove the intake manifold bracket bolts.

  4. Remove the intake manifold bracket.
  5. Disconnect the fuel injector harness connectors.

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  6. Remove the fuel feed line.
  7. Remove the fuel rail mounting bolts.

    8. Notice : Before removal, the fuel rail assembly may be cleaned with a spray-type cleaner, following package instructions. Do not immerse the fuel rails in liquid cleaning solvent. Use care in removing the fuel rail assembly to prevent damage to the electrical connectors and the injector spray tips. Prevent dirt and other contaminants from entering open lines and passages. Fittings should be capped and holes plugged during service.

    Important : If an injector becomes separated from the rail and remains in the cylinder head, replace the injector O-ring seals and the retaining clip.

  8. Remove the fuel rail with the fuel injectors attached.

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  9. Remove the fuel injector retainer clips.
  10. Remove the fuel injectors by pulling down and out.
  11. Discard the fuel injector O-rings.

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Installation Procedure

    Important : Different injectors are calibrated for different flow rates. When ordering new fuel injectors, be certain to order the identical part number that is inscribed on the old injector.

  1. Lubricate the new fuel injector O-rings with engine oil. Install the new O-rings on the fuel injectors.
  2. Install the fuel injectors into the fuel rail sockets with the fuel injector terminals facing outward.

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  3. Install the fuel injector retainer clips onto the fuel injectors and the fuel rail ledge.
  4. Make sure that the clip is parallel to the fuel injector harness connector.
  5. Install the fuel rail assembly into the cylinder head.
  6. Install the fuel rail mounting bolts.

    7. Tighten
    Tighten the fuel rail mounting bolts to 25 N•m (18 lb-ft).


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  7. Connect the fuel feed hose.

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  8. Connect the fuel injector harness connectors. Rotate each fuel injector as required to avoid stretching the wireing harness.
  9. Install the intake manifold bracket with the bolts.
  10. Connect the negative battery cable.
  11. Perform a leak check of the fuel rail and fuel injectors.

Fuel Rail and Injectors (1.8L DOHC)

Removal Procedure

    Caution : The fuel system is under pressure. To avoid fuel spillage and the risk of personal injury or fire, it is necessary to relieve the fuel system pressure before disconnecting the fuel lines.

  1. Relieve the fuel system pressure. Refer to " Fuel System Pressure Relief " in this section.
  2. Disconnect the negative battery cable.

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  3. Remove the engine cover. Refer to "1.8L-FAM I DOHC Engine Mechanical".
  4. Remove the air cleaner assembly. Refer to "1.8L-FAM I DOHC Engine Mechanical".

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  5. Disconnect the fuel feed line at the fuel rail.
  6. Remove the fuel rail retaining bolts.

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    Notice : Before removal, the fuel rail assembly may be cleaned with a spray-type cleaner, following package instructions. Do not immerse the fuel rails in liquid cleaning solvent. Use care in removing the fuel rail assembly to prevent damage to the electrical connectors and the injector spray tips. Prevent dirt and other contaminants from entering open lines and passages. Fittings should be capped and holes plugged during service.

    Important : If an injector becomes separated from the rail and remains in the cylinder head, replace the injector O-ring seals and the retaining clip.

  7. Remove the fuel rail with the injectors attached.

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  8. Remove the fuel injector retainer clips.
  9. Remove the fuel injectors by pulling them down and out.
  10. Discard the fuel injector O-rings.

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Installation Procedure

    Important : Different injectors are calibrated for different flow rates. When ordering new fuel injectors, be certain to order the identical part number that is inscribed on the old injector.

  1. Lubricate the new fuel injector O-rings with engine oil. Install the new O-rings on the fuel injectors.
  2. Install the fuel injectors into the fuel rail sockets with the fuel injector terminals facing outward.
  3. Install the fuel injector retaining clips onto the fuel injector and the fuel rail ledge.
  4. Make sure that the clips are parallel to the fuel injector harness connector.

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  5. Install the fuel rail assembly into the cylinder head.
  6. Install the fuel rail retaining bolts.

    7. Tighten
    Tighten the fuel rail retaining bolts to 12 N•m (10 lb-in).

  7. Connect the fuel feed line to the fuel rail.
  8. Connect the fuel injector connectors. Rotate each fuel injector as required.

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Engine Coolant Temperature Sensor (1.4L/1.6L DOHC)

Removal Procedure

  1. Relieve the coolant system pressure.
  2. Disconnect the negative battery cable.
  3. Disconnect the engine coolant temperature (ECT) sensor connector.

    4. Notice : Take care when handling the engine coolant temperature sensor. Damage to the sensor will affect the proper operation of the fuel injection system.

  4. Remove the ECT sensor

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Installation Procedure

  1. Install the engine coolant temperature (ECT) sensor.

    2. Tighten
    Tighten the engine coolant temperature (ECT) sensor to 17.5 N•m (13 lb-ft).

  2. Connect the ECT sensor connector.
  3. Connect the negative battery cable.

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Engine Coolant Temperature Sensor (1.8L DOHC)

Removal Procedure

  1. Relieve the coolant system pressure.
  2. Disconnect the negative battery cable.
  3. Disconnect the engine coolant temperature (ECT) sensor connector.

    4. Notice : Take care when handling the engine coolant temperature sensor. Damage to the sensor will affect the proper operation of the fuel injection system.

  4. Remove the ECT sensor from the electronic ignition (EI) system ignition coil adapter.

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Installation Procedure

  1. Coat the threads of the ECT sensor with sealer.
  2. Install the ECT sensor into the EI system ignition coil adapter.

    3. Tighten
    Tighten the engine coolant temperature sensor to 20 N•m (15 lb-ft).

  3. Connect the ECT sensor connector.
  4. Fill the coolant system.
  5. Connect the negative battery cable.

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Throttle Position Sensor (1.8L DOHC)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the air intake tube and resonator.
  3. Disconnect the throttle position (TP) sensor connector.
  4. Remove the TP sensor retaining bolts and the TP sensor.

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Installation Procedure

  1. With the throttle valve closed, position the TP sensor on the throttle shaft. Align the TP sensor with the bolt holes.
  2. Install the TP sensor retaining bolts.

    3. Tighten
    Tighten the throttle position sensor retaining bolts to 2 N•m (18 lb-in).

  3. Connect the TP sensor connector.
  4. Install the air intake tube and resonator.
  5. Connect the negative battery cable.

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Throttle Body (1.4L/1.6L DOHC)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the intake air tube.
  3. Disconnect the breather hose.

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  4. Disconnect the coolant hose from the throttle body.
  5. Disconnect the throttle cables by opening the release slot.
  6. Disconnect the main throttle idle actuator (MTIA) electrical connector.
  7. Remove the throttle body bolt and the nuts.
  8. Remove the throttle body.

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Installation Procedure

  1. Install the throttle body assembly to the intake manifold.
  2. Install the throttle body retaining nuts and the bolt.

    3. Tighten
    Tighten the throttle body retaining nuts and the bolt to 15 N•m (11 lb-ft).

  3. Connect the throttle cable.
  4. Connect the coolant hoses.

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  5. Connect the breather hose.
  6. Install the intake air tube.
  7. Connect the negative battery cable.

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Throttle Body (1.8L DOHC)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the intake air temperature (IAT) sensor connector.
  3. Disconnect the breather hose from the valve cover.
  4. Remove the air intake tube.

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  5. Disconnect the throttle cables by opening the throttle and moving the cable through the release slot.
  6. Disconnect the vacuum hoses from the throttle body.
  7. Disconnect the throttle position (TP) sensor and the idle air control valve connectors.
  8. Disconnect the coolant hoses from the throttle body.
  9. Remove the throttle body retaining nuts.

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    Notice : Cover the opening of the intake manifold after removing the throttle body assembly. This will prevent any objects or debris from entering the engine which may cause damage.

  10. Remove the throttle body and discard the gasket.
  11. Remove the TP sensor. Refer to "Throttle Position Sensor "in this section.
  12. Remove the idle air control (IAC) valve. Refer to "Idle Air Control Valve "in this section.

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Installation Procedure

    Notice : Use care in cleaning old gasket material from machined aluminum surfaces. Sharp tools may damage sealing surfaces.

  1. Clean the gasket mating surface on the intake manifold.

    2. Notice : The throttle body may be cleaned in a cold immersion-type cleaner following disassembly. The TP sensor and the idle air control valve should not come in contact with any solvent or cleaner, as they may be damaged.

  2. Clean the throttle body.

  3. Install the TP sensor. Refer to " Throttle Position Sensor "in this section.
  4. Install the IAC valve. Refer to "Idle Air Control Valve " in this section.
  5. Install the throttle body assembly with a new gasket to the intake manifold.
  6. Install the throttle body retaining nuts.

    7. Tighten
    Tighten the throttle body retaining nuts to 10 N•m (89 lb-in).


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  7. Connect the TP sensor connector and the IAC valve connector.
  8. Connect the coolant hoses to the throttle body.
  9. Connect the vacuum hoses to the throttle body.

    10. Important : Make sure the throttle/cruise control cables do not hold the throttle open. With the engine off, check to see that the accelerator pedal is free.

  10. Connect the throttle cable.
  11. Install the air intake tube.
  12. Connect the breather hose to the valve cover.
  13. Connect the IAT sensor connector.
  14. Connect the negative battery cable.
  15. Fill the cooling system.

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Front Heated Oxygen Sensor (HO2S1) (1.4L/1.6L DOHC)

Removal Procedure

  1. Disconnect the negative battery cable.

    2. Notice : The oxygen sensor uses a permanently attached pigtail and connector. This pigtail should not be removed from the oxygen sensor. Damage or removal of the pigtail or the connector could affect proper operation of the oxygen sensor. Take care when handling the oxygen sensor. Do not drop the oxygen sensor.

  2. Disconnect the front heated oxygen sensor (HO2S1) connector.

    3. Notice : The oxygen sensor may be difficult to remove when engine temperature is below 48°C (120°F). Excessive force may damage threads in the exhaust manifold.

  3. Carefully remove the HO2S1 from the exhaust manifold.

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Installation Procedure

    Important : A special anti-seize compound is used on the oxygen sensor threads. This compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads. If a sensor is removed from any engine and if for any reason it is to be reinstalled, the threads must have anti-seize compound applied before reinstallation.

  1. Coat the threads of the HO2S1 with an anti-seize compound, if needed.
  2. Install the HO2S1 into the exhaust manifold.

    3. Tighten
    Tighten the oxygen sensor to 40 N•m (30 lb-ft).

  3. Connect the HO2S1 connector.
  4. Connect the negative battery cable.

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Front Heated Oxygen Sensor (HO2S1) (1.8L DOHC)

Removal Procedure

  1. Disconnect the negative battery cable.

    2. Notice : The oxygen sensor (O2S) uses a permanently attached pigtail and connector. This pigtail should not be removed from the O2S. Damage or removal of the pigtail or the connector could affect proper operation of the O2S. Take care when handling the O2S. Do not drop the O2S.

  2. Disconnect the HO2S1 connector.

    3. Notice : The oxygen sensor may be difficult to remove when engine temperature is below 118°F (48°C). Excessive force may damage threads in the exhaust manifold.

  3. Carefully remove the HO2S1 from the exhaust manifold.

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Installation Procedure

    Important : A special anti-seize compound is used on the oxygen sensor threads. This compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or serviced sensors will already have the compound applied to the threads. If a sensor is removed from any engine and is to be reinstalled, the threads must have an anti-seize compound applied before reinstallation.

  1. Coat the threads of the HO2S1 with an anti-seize compound, if needed.
  2. Install the HO2S1 into the exhaust manifold.

    3. Tighten
    Tighten the oxygen sensor to 40 N•m (30 lb-ft).

  3. Connect the HO2S1 connector.
  4. Connect the negative battery cable.

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Rear Heated Oxygen Sensor (HO2S2)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the electrical connector.

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  3. Remove the heated oxygen sensor.

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Installation Procedure

  1. Install the rear heated oxygen sensor.

    2. Tighten
    Tighten the heated oxygen sensor to 42 N•m (31 lb-ft).


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  2. Connect the electrical connector.
  3. Connect the negative battery cable.

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Intake Air Temperature Sensor (1.4L/1.6L DOHC)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the intake air temperature (IAT) sensor connector.
  3. Remove the IAT sensor.

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Installation Procedure

  1. Install the IAT sensor.

    2. Tighten
    Tighten the IAT sensor to 22 N•m (16 lb-ft).

  2. Connect the IAT sensor connector.
  3. Connect the negative battery cable.

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Intake Air Temperature Sensor (1.8L DOHC)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the intake air temperature (IAT) sensor connector.
  3. Remove the IAT sensor by pulling it out of the air intake tube.

Installation Procedure

  1. Install the IAT sensor into the air intake tube.
  2. Connect the IAT connector.
  3. Connect the negative battery cable.

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Idle Air Control Valve (1.8L DOHC)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the air intake resonator.
  3. Disconnect the idle air control (IAC) valve connector.
  4. Remove the IAC valve retaining bolts.

    5. Notice : On IAC valves that have been in service, do not push on the valve pintle. The force required to move the pintle may damage the threads on the worm drive.

  5. Remove the IAC valve.

    6. Notice : Do not use methyl ethyl ketone because it can damage the parts.

  6. Clean the IAC valve O-ring seal area, the pintle valve seat, and the air passage with a suitable fuel system cleaner.

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Installation Procedure

    Important : If installing a new IAC valve, be sure to replace it with an identical part. The IAC valve pintle shape and diameter are designed for the specific application. Measure the distance between the tip of the IAC valve pintle and the mounting flange. If the distance is greater than 1.1 inches (28 mm), use finger pressure to slowly retract the pintle. The force required to retract the pintle will not damage the IAC valve. The purpose of the 1.1-inch (28-mm) setting is to prevent the IAC pintle from bottoming out on the pintle seat. This 1.1-inch (28-mm) setting is also an adequate setting for controlled idle on a restart.

  1. Lubricate a new O-ring with engine oil. Install the new O-ring onto the valve.
  2. Install the IAC valve into the throttle body.
  3. Install the IAC valve retaining bolts.

    4. Tighten
    Tighten the idle air control valve retaining bolts to 3 N•m (27 lb-in).

  4. Connect the IAC valve connector.
  5. Install the air intake resonator.
  6. Connect the negative battery cable.
  7. Start the engine and check for the proper idle speed.

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Manifold Absolute Pressure Sensor (1.4L/1.6L DOHC)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the manifold Absolute pressure (MAP) sensor electrical connector.
  3. Disconnect the MAP sensor vacuum hose.
  4. Remove the MAP sensor bolt.
  5. Remove the MAP sensor.

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Installation Procedure

  1. Install the manifold absolute pressure (MAP) sensor with the bolt.

    2. Tighten
    Tighten the MAP sensor bolt to 8 N•m (71 lb-in).

  2. Connect the MAP sensor vacuum hose.
  3. Connect the MAP sensor electrical connector.
  4. Connect the negative battery cable.

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Manifold Absolute Pressure Sensor (1.8L DOHC)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the fuel rail. Refer to "Fuel Rail and Injectors" in this section.
  3. Disconnect the manifold absolute pressure (MAP) sensor connector from the MAP sensor.
  4. Remove the MAP sensor retaining bolt.
  5. Remove the MAP sensor from the intake manifold.

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Installation Procedure

  1. Connect the MAP sensor connector to the MAP sensor.
  2. Install the MAP sensor into the intake manifold.
  3. Install the MAP sensor retaining bolt.

    4. Tighten
    Tighten the MAP sensor retaining bolt to 8 N•m (71 lb-in).

  4. Connect the fuel rail. Refer to "Fuel Rail and Injectors" in this section.
  5. Connect the negative battery cable.

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Exhaust Gas Recirculation Valve (1.4L/1.6L DOHC)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the electrical exhaust gas recirculation valve electrical connector.
  3. Remove the EEGR valve retaining bolts.
  4. Remove the EEGR valve.

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Installation Procedure

  1. Install the EEGR valve with the bolts.

    2. Tighten
    Tighten the electrical exhaust gas recirculation valve retaining bolts to 30 N•m (22 lb-ft).

  2. Connect the EEGR valve electrical connector.
  3. Connect the negative battery cable.

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Exhaust Gas Recirculation Valve (1.8L DOHC)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the vacuum hose from the exhaust gas recirculation (EGR) valve.
  3. Remove the EGR valve retaining bolts.
  4. Remove the EGR valve from the electronic ignition (EI) system ignition coil adapter.

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Installation Procedure

  1. Clean the EI system ignition coil adapter mating surface.
  2. Install a new EGR valve gasket.
  3. Install the EGR valve with the bolts.

    4. Tighten
    Tighten the exhaust gas recirculation valve retaining bolts to 20 N•m (15 lb-ft).

  4. Connect the vacuum hose to the EGR valve.
  5. Connect the negative battery cable.

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Knock Sensor (1.4L/1.6L DOHC)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the intake manifold support bracket bolts.
  3. Remove the intake manifold support bracket.

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  4. Disconnect the knock sensor electrical connector.
  5. Remove the knock sensor bolt.
  6. Remove the knock sensor.

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Installation Procedure

  1. Install the knock sensor with the bolt.

    2. Tighten
    Tighten the knock sensor bolt to 20 N•m (15 lb-ft).

  2. Connect the knock sensor electrical connector.

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  3. Install the intake manifold support bracket with the bolts.

    4. Tighten
    Tighten the intake manifold support bracket upper bolts to 25 N•m (18 lb-ft).
    Tighten the intake manifold support bracket lower bolts to 45 N•m (33 lb-ft).

  4. Connect the negative battery cable.

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Knock Sensor (1.8L DOHC)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Raise and suitably support the vehicle.
  3. Disconnect electrical connector at the knock sensor.

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  4. Remove the bolt and the knock sensor.

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Installation Procedure

  1. Install the knock sensor with the bolt.

    2. Tighten
    Tighten the knock sensor bolt to 20 N•m (15 lb-ft).


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  2. Connect the electrical connector at the knock sensor.
  3. Lower the vehicle.
  4. Connect the negative battery cable.

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Evaporative Emission Canister

Removal Procedure

    Caution : Canister and vacuum hoses contain fuel vapors. Do not smoke in the area or permit an open flame.

  1. Remove the bolt that secures the canister flange to the vehicle.
  2. Slide the canister out of the track holder.
  3. Disconnect the canister fuel vapor hoses.
  4. Remove the canister cover.
  5. Remove the canister.

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Installation Procedure

  1. Insert the canister into the track and slide it into position.
  2. Connect the canister fuel vapor hoses.

    3. Tighten
    Tighten the evaporative emission canister flange bolt to 4 N•m (35 lb-in).

  3. Install the canister flange bolt.

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Evaporative Emission Canister Purge Solenoid Valve (1.4L/1.6L DOHC)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the evaporative (EVAP) emission canister purge solenoid connector.
  3. Disconnect the vacuum hoses from the EVAP canister purge solenoid.
  4. Remove the EVAP canister purge solenoid from the intake manifold.

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Installation Procedure

  1. Install the EVAP canister purge solenoid.
  2. Connect the vaccum hoses.
  3. Connect the solenoid connector.

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Evaporative Emission Canister Purge Solenoid Valve (1.8L DOHC)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the evaporative (EVAP) emission canister purge solenoid connector.
  3. Disconnect the vacuum hoses from the EVAP canister purge solenoid.
  4. Remove the EVAP canister purge solenoid bracket bolt from the intake manifold.
  5. Unclip the EVAP canister purge solenoid from the mounting bracket.

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Installation Procedure

  1. Attach the EVAP canister purge solenoid to the mounting bracket.
  2. Install the EVAP canister purge solenoid and the mounting bracket to the intake manifold with the bracket bolt.

    3. Tighten
    Tighten the evaporative emission canister purge solenoid bracket upper bolt to 25 N•m (18 lb-in).

  3. Connect the vacuum hoses to the EVAP canister purge solenoid.
  4. Connect the EVAP canister purge solenoid connector.
  5. Connect the negative battery cable.

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Crankshaft Position (CKP) Sensor

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the crankshaft position sensor (CKP) electrical connector.

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  3. Remove the crankshaft position sensor (CKP) bolt.
  4. Remove the CKP sensor.

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Installation Procedure

  1. Install the CKP sensor with the bolt.

    2. Tighten
    Tighten the crankshaft position sensor (CKP) bolt to 6.5 N•m (57 lb-in).


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  2. Connect the CKP sensor electrical connector.
  3. Connect the negative battery cable.

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Camshaft Position Sensor (1.4L/1.6L DOHC)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the engine cover bolts and the nuts.
  3. Remove the engine cover.

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  4. Disconnect the CMP sensor electrical connector.
  5. Remove the timing belt front cover. Refer to Section 1C, DOHC Engine Mechanical.
  6. Remvoe the CMP sensor bolts.
  7. Remvoe the CMP sensor from the top.

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Installation Procedure

  1. Install the camshaft position sensor and bolt.

    2. Tighten
    Tighten the camshaft position sensor bolts to 7 N•m (62 lb-in).


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  2. Install the timing bolt front cover. Refer to Section 1C, DOHC Engine Mechanical.
  3. Connect the CMP sensor electrical connector.
  4. Install the engine cover.
  5. Connect the negative battery cable.

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Camshaft Position Sensor (1.8L DOHC)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the engine cover.
  3. Disconnect the sensor electrical connector. Refer to Section 1C2, 1.8L-FAM I DOHC Engine Mechanical.
  4. Disconnect the air cleaner assembly. Refer to Section 1C2, 1.8L-FAM I DOHC Engine Mechanical.
  5. Remove the timing belt front cover. Refer to Section 1C2, 1.8L-FAM I DOHC Engine Mechanical.

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  6. Remove the camshaft position sensor bolts.
  7. Remove the camshaft position sensor from the top.

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Installation Procedure

  1. Install the camshaft position sensor and bolts.

    2. Tighten
    Tighten the camshaft position bolts to 6.5 N•m (58 lb-in).


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  2. Install the timing belt front cover, the crankshaft pulley, the accessory drive belt, and the air filter. Refer to Section 1C, DOHC Engine Mechanical.
  3. Connect the sensor electrical connector.
  4. Install the engine cover.
  5. Connect the negative battery cable.

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Engine Control Module (1.4L/1.6L DOHC)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the engine control module (ECM) wiring harness connector.
  3. Remove the nuts from the engine control module (ECM) mounting bracket.

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  4. Remove the engine control module (ECM) mounting bracket with the bolt and the nut.

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Installation Procedure

  1. Install the engine control module (ECM) mounting bracket with the bolt and the nut.

    2. Tighten
    Tighten the ECM mounting bracket bolt and the nut to 12 N•m (9 lb-ft).


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  2. Install the engine control module (ECM) with the nuts.

    3. Tighten
    Tighten the engine control module (ECM) nut to 12 N•m (9 lb-ft).


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Engine Control Module (1.8L DOHC)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the air intake tube and resonator.
  3. Disconnect the ECM connectors from the ECM.
  4. Remove the engine Control module.

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Installation Procedure

  1. Install the ECM to the intake manifold.

    2. Tighten
    Tighten the ECM to 8 N•m (71 lb-in).


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Direct Ignition System (1.4L/1.6L DOHC)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the DIS connector.
  3. Note the ignition wire location and remove the ignition wire.
  4. Remvoe the DIS retaining nuts.
  5. Remove the DIS.

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Installation Procedure

  1. Install the DIS into the mounting location and install the retaining nuts.

    2. Tighten
    Tighten the DIS retaining nuts to 10 N•m (89 lb-in).

  2. Connect the DIS connector.
  3. Connect the negative battery cable.

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Direct Ignition System (1.8L DOHC)

Removal Procedure

  1. Remove the engine cover. Refer to "1.8L-FAM I DOHC Engine Mechanical".
  2. Disconnect the DIS connector.
  3. Remove the DIS bolts.
  4. Remove the DIS.

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Installation Procedure

  1. Install the DIS.

    2. Tighten
    Tighten the DIS to 10 N•m (89 lb-in).

  2. Connect the DIS connector.
  3. Connect the negative battery cable.


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