4A–FE engine is an in–line, 4–cylinder, 1.6 liter DOHC 16–valve engine. Manual — part 38

(c) Apply a light coat of engine oil on the threads and

under the heads of the main bearing caps.

(d) Install and uniformly tighten the ten bolts of the

main bearing caps in several passes in the se-
quence
shown.

Torque: 59 N–m (600 kgf–cm, 43 ft–lbf)

(e) Check that the crankshaft turns smoothly.
(f) Check the crankshaft thrust clearance.

(See step 5 on page

EM–281

)

5. INSTALL PISTON AND CONNECTING ROD

ASSEMBLIES
(a) Cover the connecting rod bolts with a short piece of

hose to protect the crankshaft from damage.

4. INSTALL MAIN BEARING CAPS AND LOWER THRUST

WASHERS
(a) Install the two thrust washers on the No.3 bearing

cap with the grooves facing outward.

(b) Install the five main bearing caps in their proper

locations.

HINT: Each bearing cap has a number and front
mark.

3. PLACE CRANKSHAFT ON CYLINDER BLOCK

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ENGINE MECHANICAL

Cylinder Block (5S–FE)

EM–298

(a) Apply a light coat of engine oil on the threads and

under the cap nuts.

(b) Using SST, install and alternately tighten the cap

nuts in several passes.

SST 09011–38121
Torque: 25 N–m (250 kgf–cm, 18 ft–lbf)

If any one of the cap nuts does not meet the tor-
que specification, replace the connecting rod bolt
and cap nut as a set.

6. INSTALL CONNECTING ROD CAPS
A. Place connecting rod cap on connecting rod

(a) Match the numbered connecting rod cap with the

connecting rod.

(b) Install the connecting rod cap with the front mark

facing forward.

B. Install connecting rod cap nuts

HINT:

•

The cap nuts are tightened in two progressive steps
(steps (b) and (d)).

•

If any one of the connecting rod bolts is broken or
deformed, replace it.

(b) Using a piston ring compressor, push the correctly

numbered piston and connecting rod assemblies
into each cylinder with the front mark of the piston
facing forward.

(c) Mark the front of the cap nut with the paint.

–

ENGINE MECHANICAL

Cylinder Block (5S–FE)

EM–299

POST ASSEMBLY

1. INSTALL KNOCK SENSOR

Using SST, install the knock sensor.
SST 09816–30010
Torque: 37 N–m (380 kgf–cm, 27 ft–lbf)

2. (w/ OIL COOLER)

INSTALL OIL COOLER (See page

LU–30

)

3. INSTALL OIL FILTER (See page

LU–7

)

4. INSTALL OIL PUMP AND OIL PAN

(See pages

LU–21

and 22)

5. INSTALL WATER PUMP AND ALTERNATOR

ADJUSTING BAR (See pages

CO–14

and 15)

6. INSTALL CYLINDER HEAD

(See pages

EM–173

to 182)

7. INSTALL PULLEYS AND TIMING BELT

(See pages

EM–75

to 79)

(d) Retighten the cap nuts 90

В°

in the numerical order

shown.

(e) Check that the painted mark is now at a 90

В°

angle to the front.

(f) Check that the crankshaft turns smoothly.
(g) Check the connecting rod thrust clearance. (See

step 2 on page

EM–279

)

8. INSTALL RH ENGINE MOUNTING BRACKET

Install the mounting bracket with the three bolts.
Torque: 52 N–m (530 kgf–cm, 38 ft–lbf)

9. INSTALL PS PUMP BRACKET

Install the PS pump bracket with the three bolts.
Torque: 43 N–m (440 kgf–cm, 32 ft–lbf)

7. INSTALL REAR OIL SEAL RETAINER

Install a new gasket and the retainer with the six bolts.
Torque: 9.3 N–m (95 kgf–cm, 82 in.–lbf)

–

ENGINE MECHANICAL

Cylinder Block (5S–FE)

EM–300

14. (M /T)

INSTALL FLYWHEEL
(a) Apply adhesive to two or three threads of the

mounting bolt end.

Adhesive: Part No. 08833–00070, THREE BOND 1324

or equivalent

15. (A/T)

INSTALL DRIVE PLATE (See procedure in step 14)
Torque: 83 N–m (850 kgf–cm, 61 ft–lbf)

16. (M /T)

INSTALL CLUTCH DISC AND COVER
(See CL section)

(b) Install the flywheel on the crankshaft.
(c) Install and uniformly tighten the mounting bolts in

several passes in the sequence shown.

Torque: 88 N–m (900 kgf–cm, 65 ft–lbf)

10. INSTALL ALTERNATOR (See page

CH–25

)

11. INSTALL DISTRIBUTOR (See page

IG–35

)

12. REMOVE ENGINE STAND

13. INSTALL REAR END PLATE

Torque: 9.3 N–m (95 kgf–cm, 82. in.–lbf)

–

ENGINE MECHANICAL

Cylinder Block (5S–FE)

EM–301

3. INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN

VEHICLE
(a) Attach the engine chain hoist to the engine hangers,
(b) Lower the engine into the engine compartment.

Tilt the transaxle downward, lower the engine and
clear the LH mounting.

NOTICE: Be careful not to hit the PS gear housing or

neutral start switch (A/T).

INSTALLATION OF ENGINE

1. ASSEMBLE ENGINE AND TRANSAXLE

M/T (See MT section)
A/T (See AT section)

2. (A/T)

INSTALL STARTER (See page

ST–23

)

(e) Install the LH mounting bracket to the transaxle

case with the three bolts.

Torque: 52 N–m (530 kgf–cm, 38 ft–lbf)

(d) Attach the RH mounting insulator to the mount-

ing bracket and body, and temporarily install
the through bolt and two nuts.

(c) Keep the engine level, and align RH and LH

mountings with the body bracket.

–

ENGINE MECHANICAL

Cylinder Block (5S–FE)

EM–302

(f) Attach the LH mounting insulator to the mounting

bracket and body with the through bolt and four
bolts. Torque the bolts.

Torque:

Bolt 63 N–m (650 kgf–cm, 47 ft–lbf)

Through bolt 87 N–m (890 kgf–cm, 64 ft–lbf)

(g) Torque the through bolt and two nuts of the RH

mounting insulator.

Torque:

Nut 52 N–m (530 kgf–cm, 38 ft–lbf)

Through bolt 87 N–m (890 kgf–cm, 64 ft–lbf)

(h) Remove the engine chain hoist from the engine.

4. INSTALL RH ENGINE MOUNTING STAY

Install the mounting stay with the bolt and nut.
Torque: 73 N–m (740 kgf–cm, 54 ft–lbf)

5. CONNECT GROUND CONNECTOR TO GROUND WIRE

ON RH FENDER APRON

6. INSTALL LN ENGINE MOUNTING STAY

(M/T)
(a) Install the mounting stay with the two nuts.
(b) Connect the ground strap.
Torque: 21 N–m (210 kgf–cm, 15 ft–lbf)

(A/T)

(a) Install the mounting stay with the bolt and nut.
Torque: 21 N–m (210 kgf–cm, 15 ft–lbf)

(b) Connect the ground strap to the transaxle with the

bolt.

–

ENGINE MECHANICAL

Cylinder Block (5S–FE)

EM–303

9. INSTALL ENGINE MOUNTING CENTER MEMBER

(a) Install the engine mounting center member with the

four bolts.

Torque: 52 N–m (530 kgf–cm, 38 ft–lbf)

(b) Install and torque the four bolts holding the insulators

to the center member.

Torque: 73 N–m (740 kgf–cm, 54 ft–lbf)

7. INSTALL FRONT ENGINE MOUNTING BRACKET AND

INSULATOR
(a) Install the mounting bracket with the two bolts.
Torque: 77 N–m (790 kgf–cm, 57 ft–lbf)

(b) Temporarily install the mounting insulator with the

through bolt and nut.

8. INSTALL REAR ENGINE MOUNTING BRACKET AND

INSULATOR
(a) Install the mounting bracket with the three bolts.
Torque: 77 N–m (790 kgf–cm, 57 ft–lbf)

(b) Temporarily install the mounting insulator with the

through bolt.

10. TIGHTEN FRONT AND REAR ENGINE MOUNTING

THROUGH BOLTS
(a) Tighten the rear through bolt.
Torque: 87 N–m (890 kgf–cm, 64 ft–lbf)

(b) Tighten the front through bolt.
Torque: 87 N–m (890 kgf–cm, 64 ft–lbf)

–

ENGINE MECHANICAL

Cylinder Block (5S–FE)

EM–304

15. INSTALL FRONT EXHAUST PIPE

(a) Install the support hook on the front exhaust pipe to

the support bracket.

(b) Place two new gaskets on the front and rear of the

front exhaust pipe.

(c) Temporarily install the two bolts and new nuts holding

the exhaust pipe to the center exhaust pipe.

(d) Using a 14 mm deep socket wrench, install the three

new nuts holding the exhaust pipe to the catalytic
converter.

Torque: 62 N–m (630 kgf–cm, 46 ft–lbf)
(e) Tighten the two bolts and nuts holding the exhaust

pipe to the center exhaust pipe.

Torque: 43 N–m (440 kgf–cm, 32 ft–lbf)

(f) Install the clamp with the bolt.

11. INSTALL PS PUMP

(a) Install the PS pump with the four bolts.
Torque:

Adjusting bolt 39 N–m (400 kgf–cm, 29 ft–lbf)

Others 43 N–m (440 kgf–cm, 32 ft–lbf)

(b) Install the drive belt.
(c) Connect the two air hoses to the air pipe.

12. (w/ A/C)

INSTALL A/C COMPRESSOR
(a) Install the compressor with the three bolts.
Torque: 27 N–m (280 kgfc 20 ft–lbf)

(b) Connect the two connectors.
(c) Connect the A/C compressor connector.

13. INSTALL DRIVE SHAFTS (See SA section)

14. (A/T)

INSTALL TRANSAXLE CONTROL CABLE TO ENGINE
MOUNTING CENTER MEMBER
Install the control cable with the two clamps and bolts.

–

ENGINE MECHANICAL

Cylinder Block (5S–FE)

EM–305