4A–FE engine is an in–line, 4–cylinder, 1.6 liter DOHC 16–valve engine. Manual — part 13
B. Inspect cam lobes
Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake
35.210 – 35.310 mm
(1.3862 –1. 3902 in.)
Exhaust
34.910 – 35.010 mm
(1.3744 – 1.3783 in.)
Minimum cam lobe height:
Intake
34.81 mm (1.3705 in.)
Exhaust
34.51 mm (1.3587 in.)
If the cam lobe height is less than minimum, replace the
camshaft.
C. Inspect camshaft journals
Using a micrometer, measure the journal diameter.
Journal diameter:
Exhaust No.1
24.949 – 24.965 mm
(0.9822 – 0.9829 in.)
Others
22.949 – 22.965 mm
(0.9035 – 0.9041 in.)
If the journal diameter is not as specified, check the oil
clearance.
10. INSPECT CAMSHAFTS AND BEARINGS
A. Inspect camshaft for runout
(a) Place the camshaft on V–blocks.
(b) Using a dial indicator, measure the circle runout at
the center journal.
Maximum circle runout: 0.04 mm (0.0016 in.)
If the circle runout is greater than maximum, replace the
camshaft.
(c) Using a spring tester, measure the tension of the
valve spring at the specified installed length.
Installed tension:
143 – 155 N (14.6 – 15.8 kgf, 32.2 – 34.8 lbf )
at 34.7 mm (1.366 in.)
If the installed tension is not as specified, replace the
valve spring.
(b) Using a vernier caliper, measure the free length of
the valve spring.
Free length: 43.8 mm (1.724 in.)
If the free length is not as specified, replace the valve
spring.
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ENGINE MECHANICAL
Cylinder Head (4A–FE)
EM–98
E. Inspect camshaft gear spring
Using a vernier caliper, measure the free distance be-
tween the spring ends.
Free distance: 17.0 –17.6 mm (0.669 – 0.693 in.)
If the free distance is not as specified, replace the gear
spring.
F. Inspect camshaft journal oil clearance
(a) Clean the bearing caps and camshaft journals.
(b) Place the camshafts on the cylinder head.
(c) Lay a strip of Plastigage across each of the camshaft
journals.
D. Inspect camshaft bearings
Check the bearings for flaking and scoring.
If the bearings are damaged, replace the bearing caps
and
cylinder head as a set.
(d) Install the bearing caps.
(See step 3 on pages
EM–105
to 107)
Torque: 13 N–m (130 kgf–cm, 9 ft–lbf)
NOTICE: Do not turn the camshaft.
(e) Remove the bearing caps.
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ENGINE MECHANICAL
Cylinder Head (4A–FE)
EM–99
H. Inspect camshaft gear backlash
(a) Install the camshafts without installing the exhaust
camshaft sub–gear.
(See step 3 on pages
EM–105
to 107)
(b) Using a dial indicator, measure the backlash.
Standard backlash: 0.020 – 0.200 mm
(0.0008 – 0.0079 in.)
Maximum backlash: 0.30 mm (0.0188 in.)
If the backlash is greater than maximum, replace the
camshafts.
11. INSPECT VALVE LIFTERS AND LIFTER BORES
(a) Using a caliper gauge, measure the lifter bore diame-
ter of the cylinder head.
Lifter bore diameter:
28.005 – 28.026 mm
(1.1026 –1.1034 in.)
G. Inspect camshaft thrust clearance
(a) Install the camshafts.
(See step 3 on pages
EM–105
to 107)
(b) Using a dial indicator, measure the thrust clearance
while moving the camshaft back and forth.
Standard thrust clearance:
Intake
0.030 – 0.085 mm
(0.0012 – 0.0033 in.)
Exhaust
0.035 – 0.090 mm
(0.0014 – 0.0035 in.)
Maximum thrust clearance:
0.11 mm (0.0043 in.)
If the thrust clearance is greater than maximum, replace
the camshaft. If necessary, replace the bearing caps and
cylinder head as a set.
(f) Measure the Plastigage at its widest point.
Standard oil clearance: 0.035 – 0.072 mm
(0.0014 – 0.0028 in.)
Maximum oil clearance: 0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, replace the
camshaft. If necessary, replace the bearing caps and
cylinder head as a set.
(g) Completely remove the Plastigage.
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ENGINE MECHANICAL
Cylinder Head (4A–FE)
EM–100
12. INSPECT INTAKE AND EXHAUST MANIFOLDS
Using precision straight edge and feeler gauge, mea-
sure the surface contacting the cylinder head for warp-
age.
Maximum warpage:
Intake 0.20 mm (0.0079 in.)
Exhaust 0.30 mm (0.0118 in.)
If warpage is greater than maximum, replace the man-
ifold.
(c) Subtract the lifter diameter measurement from
the lifter bore diameter measurement.
Standard oil clearance: 0.020 – 0.051 mm
(0.0008 – 0.0020 in.)
Maximum oil clearance: 0.07 mm (0.0028 in.)
If the oil clearance is greater than maximum, re-
place the
lifter. If necessary, replace the cylinder head.
(b) Using SST, tap in a new gasket until its surface is
flush with the upper edge of the cylinder head
cover.
SST 09550–10012 (09552–10010, 09560–10010)
(c) Apply a light coat of IMP grease to the gasket lip.
(b) Using a micrometer, measure the lifter diameter.
Lifter diameter: 27.975 – 27.985 mm
(1.1014 –1.1018 in.)
13. IF NECESSARY, REPLACE SPARK PLUG TUBE
GASKET
(a) Using a screwdriver, pry out the gasket.
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ENGINE MECHANICAL
Cylinder Head (4A–FE)
EM–101
ASSEMBLY OF CYLINDER HEAD
(See page
EM–81
)
HINT:
•
Thoroughly clean all parts to be assembled.
•
Before installing the parts, apply new engine oil
to all
sliding and rotating surfaces.
•
Replace all gaskets and oil seals with new
ones.
1. INSTALL SPARK PLUG TUBES
HINT: When using a new cylinder head, spark plug
tubes must be installed.
(a) Apply adhesive to the spark plug tube hole of the
cylinder head.
Adhesive: Part No. 08833–00070, THREE BOND 1324
or equivalent
(b) Using a press, press in a new spark plug tube un-
til there is 46.8 – 47.6 mm (1.843 –1.874 in.)
protruding from the cylinder head.
NOTICE: Avoid tapping a new spark plug tube in
too far by measuring the amount of protrusion
while pressing.
2. INSTALL VALVES
(a) Using SST, push in a new oil seal.
SST 09201–41020
HINT: The intake valve oil seal is brown and the
exhaust valve oil seal is black.
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ENGINE MECHANICAL
Cylinder Head (4A–FE)
EM–102
(c) Using SST, compress the valve spring and place the
two keepers around the valve stem.
SST 09202–70010
3. INSTALL VALVE LIFTERS AND SHIMS
(a) Install the valve lifter and shim.
(b) Check that the valve lifter rotates smoothly by hand.
(b) Install the following parts:
(1) Valve
(2) Spring seat
(3) Valve spring
(4) Spring retainer
(d) Using a plastic–faced hammer, lightly tap the
valve stem tip to assure proper fit.
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ENGINE MECHANICAL
Cylinder Head (4A–FE)
EM–103
(c) Apply a light coat of engine oil on the threads and
under the heads of the cylinder head bolts.
(d) Install the plate washer to each cylinder head
bolt.
(e) Using SST, install and uniformly tighten the ten
cylinder head bolts in several passes in the se-
quence shown.
SST 09205–16010
Torque: 60 N–m (610 kgf–cm, 44 ft–lbf)
HINT: Cylinder head bolts are in length of 90 mm
(3.54 in.) and 108 mm (4.25 in.). Install the 90 mm
(3.54 in.) bolts (A) in intake manifold side posi-
tions. Install the 108 mm (4.25 in.) bolts (B) in ex-
haust manifold side positions.
INSTALLATION OF CYLINDER HEAD
(See page
EM–81
)
1. INSTALL CYLINDER HEAD
(a) Place a new cylinder head gasket in position on the
cylinder block.
NOTICE: Be careful of the installation direction.
(b) Place the cylinder head in position on the cylinder
head gasket.
(b) Install the following parts:
(1) Camshaft gear spring
(2) Camshaft sub–gear
(3) Wave washer
HINT: Align the pins on the gears with the gear
spring ends.
2. ASSEMBLE EXHAUST CAMSHAFT
(a) Mount the hexagon wrench head portion of the
camshaft in a vise.
NOTICE: Be careful not to damage the camshaft.
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ENGINE MECHANICAL
Cylinder Head (4A–FE)
EM–104
A. Install exhaust camshaft
(a) Apply MP grease to the thrust portion of the
camshaft.
(b) Place the intake camshaft so the knock pin is located
slightly counterclockwise from the vertical
axis of the camshaft.
HINT: The above angle allows the No.1 and No.3 cylin-
der cam lobes of the exhaust camshaft to push their
valve lifters evenly.
3. INSTALL CAMSHAFTS
NOTICE: Since the thrust clearance of the camshaft
is small, the camshaft must be kept level while it is
being installed. If the camshaft is not kept level, the
portion of the cylinder head receiving the shaft
thrust may crack or be damaged, causing the cam-
shaft to seize or break. To avoid this, the following
steps should be carried out.
(d) Insert service bolts (A) and (13) into the service
hole of the camshaft sub–gear.
(e) Using a screwdriver, align the holes of the cam-
shaft drive gear and sub–gear by turning cam-
shaft sub–gear clockwise, and install a service
bolt (C).
NOTICE: Be careful not to damage the camshaft.
(c) Remove any old packing (FIPG) material.
(d) Apply seal packing to the cylinder head as shown
in the illustration.
Seal packing: Part No. 08826–00080 or
equivalent
(c) Using snap ring pliers, install the snap ring.
–
ENGINE MECHANICAL
Cylinder Head (4A–FE)
EM–105
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