4A–FE engine is an in–line, 4–cylinder, 1.6 liter DOHC 16–valve engine. Manual — part 10

3. INSPECT TENSION SPRING

(a) Measure the free length of tension spring.
Free length: 46.0 mm (1.811 in.)

If the free length is not as specified, replace the tension
spring.
(b) Measure the tension of the tension spring at the

specified installed length.

Installed tension:

32 – 37 N (3.25 – 3.75 kgf, 7.2 – 8.3 lbf)

at 50.5 mm (1.988 in.)

If the installed tension is not as specified, replace the
tension spring.

(e) If there is noticeable wear on the belt teeth, check

the timing cover for damage, correct gasket installa-
tion, and the foreign material on the pulley teeth.
If necessary, replace the timing belt.

(d) If there is wear or damage on only one side of the

belt, check the belt guide and the alignment of each
pulley.

(c) If there is noticeable wear or cracks on the belt face,

check to see if there are nicks on the side of the idler
pulley lock.

2. INSPECT IDLER PULLEYS

Check that the idler pulley turns smoothly.

–

ENGINE MECHANICAL

Timing Belt (5S–FE)

EM–74

4. TEMPORARILY INSTALL NO.1 IDLER PULLEY AND

TENSION SPRING
(a) Install the pulley with the bolt. Do not tighten the

bolt yet.

HINT: Use bolt 42 mm (1.65 in.) in length.
(b) Install the tension spring.
(c) Pry the pulley toward the left as far as it will go and

tighten the bolt.

(d) Check that the idler pulley moves smoothly.

INSTALLATION OF TIMING BELT

(See page

EM–67

)

1. INSTALL OIL PUMP PULLEY

(a) Align the cutouts of the pulley and shaft, and slide

on the pulley.

(b) Using SST, install the nut.

SST 09616–30011

Torque:. 28 N–m (290 kgf–cm, 21 ft–lbf)

5. TEMPORARILY INSTALL TIMING BELT

NOTICE: The engine should be cold.
(a) Using the crankshaft pulley bolt, turn the crankshaft

and align the timing marks of the crankshaft
timing pulley and oil pump body.

3. INSTALL NO.2 IDLER PULLEY

(a) Install the pulley with the bolt.
Torque: 42 N–m (425 kgf–cm, 31 ft–lbf)

HINT: Use bolt 35 mm (1.38 in.) in length.
(b) Check that the idler pulley moves smoothly.

2. INSTALL CRANKSHAFT TIMING PULLEY

(a) Align the timing pulley set key with the key groove

of the pulley.

(b) Slide on the timing pulley, facing the flange side

inward.

–

ENGINE MECHANICAL

Timing Belt (5S–FE)

EM–75

9. INSTALL CAMSHAFT TIMING PULLEY

(a) Align the camshaft knock pin with the knock pin

groove of the pulley, and slide on the timing pulley.

(b) Using SST, install the plate washer and bolt.
SST 09249–63010 and 09278–54012
Torque: 54 N–m (550 kgf–cm, 40 ft–lbf)

37 N–m (380 kgf–cm, 27 ft–lbf) for SST

HINT: Use a torque wrench with a fulcrum length of
340 mm (13.39 in.)

(b) Remove any oil or water on the crankshaft pulley, oil

pump pulley, water pump pulley, No.1 idler pulley,
No.2 idler pulley, and keep them clean.

(c) Install the timing belt on the crankshaft timing pulley,

oil pump pulley, No.1 idler pulley, water pump
pulley and No.2 idler pulley.

HINT (When re–using timing belt): Align the points
marked during removal, and install the belt with the ar-
row pointing in the direction of engine revolution.

8. INSTALL CRANKSHAFT PULLEY

(a) Align the pulley set key with the key groove of the

pulley, and slide on the pulley.

(b) Using SST, install the pulley bolt.

SST 09213–54015 (09214–00030) and
09330–00021

Torque: 108 N–m (1,100 kgf–cm, 80 ft–lbf)

7. INSTALL NO.1 TIMING BELT COVER

(a) Install the gasket to the timing belt cover.
(b) Install the timing belt cover with the four bolts.

6. INSTALL TIMING BELT GUIDE

Install the guide, facing the cup side outward.

–

ENGINE MECHANICAL

Timing Belt (5S–FE)

EM–76

11. INSTALL TIMING BELT

HINT (When re–using timing belt):

•

Check that the matchmark on the timing belt matches
the end of the No.1 timing belt cover.

If the matchmark does not align, shift the meshing of the
timing belt and crankshaft timing pulley until they align.
(See page

EM–71

)

(a) Remove any oil or water on the camshaft timing

pulley, and keep it clean.

(b) Install the timing belt, and checking the tension

between the crankshaft timing pulley and camshaft
timing pulley.

(b) Using SST, turn the camshaft, and align the hole of

the camshaft timing pulley with the timing mark of
the bearing cap.
SST 09278–54012

10. SET NO.1 CYLINDER–TO TDC/COMPRESSION

(a) Turn the crankshaft pulley, and align its groove with

timing mark ”0” of the No.1 timing belt cover.

•

Align the matchmarks of the timing belt and camshaft
timing pulley.

–

ENGINE MECHANICAL

Timing Belt (5S–FE)

EM–77

(d) Slowly turn the crankshaft pulley 1 7/8 revolutions,

and align its groove with the mark at BTDC 45

В°

(for

No.1 cylinder) of the No.1 timing belt cover.

NOTICE: Always turn the crankshaft clockwise.

(c) Check that each pulley aligns with the timing marks

as shown in the illustration.
If the timing marks do not align, remove the timing belt
and reinstall it.

(e) Torque the mounting bolt of the No.1 idler pulley.
Torque: 42 N–m (425 kgf–cm, 31 ft–lbf)
(f) Recheck the valve timing.

(b) Slowly turn the crankshaft pulley two revolutions

from TDC to TDC.

NOTICE: Always turn the crankshaft clockwise.

12. CHECK VALVE TIMING

(a) Loosen the No.1 idler pulley bolt 1 /2 turn.

–

ENGINE MECHANICAL

Timing Belt (5S–FE)

EM–78

17. INSTALL RH ENGINE MOUNTING INSULATOR

Install the mounting insulator with the through bolt and
two nuts.
Torque:

Nut

52 N–m (530 kgf–cm, 38 ft–lbf)

Through bolt

87 N–m (890 kgf–cm, 64 ft–lbf)

18. INSTALL PS RESERVOIR TANK TO BRACKET

13. INSTALL NO.2 TIMING BELT COVER

(a) Disconnect the engine Wire protector between the

No.3 timing belt cover and cylinder head cover.

(b) Install the two gaskets to the No.1 and No.2 belt

covers.

(c) Install the belt cover with the five bolts.

14. INSTALL ENGINE WIRE TO ALTERNATOR BRACKET

AND ADJUSTING BAR
Install the engine wire with the two bolts.

15. INSTALL SPARK PLUGS

Torque: 18 N–m (180 kgf–cm, 13 ft–lbf)

16. INSTALL RH ENGINE MOUNTING BRACKET

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

(d) Install the two clamps of the engine wire protector

to each bolt.

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ENGINE MECHANICAL

Timing Belt (5S–FE)

EM–79

22. INSTALL ALTERNATOR (See page

CH–25

)

23. (w/ CRUISE CONTROL SYSTEM (w/o ABS)

INSTALL CRUISE CONTROL ACTUATOR
(See step 33 on page

EM–309

)

24. INSTALL RH FRONT WHEEL
25. CONNECT CABLE TO NEGATIVE TERMINAL OF

BATTERY

26. CHECK AND ADJUST DRIVE BELTS

Adjust the drive belts.
Drive belt tension:

Alternator

w/ A/C

New belt 165

В±

10 lbf

Used belt 110

В±

10 lbf

w/o A/C

New belt 125

В±

25 lbf

Used belt 95

В±

20 lbf

PS pump

New belt 125

В±

10 lbf

Used belt 80

В±

20 lbf

27. INSTALL RH ENGINE UNDER COVER

19. INSTALL RH ENGINE MOUNTING STAY

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

20. CONNECT GROUND CONNECTOR TO GROUND WIRE

ON RH FENDER APRON

21. INSTALL PS DRIVE BELT

Install the drive belt with the pivot bolt and adjusting
bolt.

–

ENGINE MECHANICAL

Timing Belt (5S–FE)

EM–80

CYLINDER HEAD (4A–FE)

COMPONENTS

–

ENGINE MECHANICAL

Cylinder Head (4A–FE)

EM–81