4A–FE engine is an in–line, 4–cylinder, 1.6 liter DOHC 16–valve engine. Manual — part 27

ASSEMBLY OF CYLINDER BLOCK

(See page

EM–184

)

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, O–rings and oil seals with new
parts.

3. INSTALL BEARINGS

(a) Align the bearing claw with the groove of the connect-

ing rod or connecting cap.

(b) Install the bearings in the connecting rod and connect-

ing rod cap.

2. INSTALL UPPER THRUST WASHERS

Install the thrust washers under the No.3 main bearing
cap position of the block with the oil grooves facing
outward.

(a) Align the bearing claw with the claw groove of the

main bearing cap or cylinder block.

(b) Install the bearings in the cylinder block and main

bearing caps.

1. INSTALL MAIN BEARINGS

HINT: Upper bearings have an oil groove and oil holes;
lower bearings do not.

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ENGINE MECHANICAL

Cylinder Block (4A–FE)

EM–210

(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: 60 N–m (610 kgf–cm, 44 ft–lbf)

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

(See step 5 on page

EM–196

)

4. INSTALL MAIN BEARING CAPS AND LOWER THRUST

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

with the grooves facing outward.

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.

(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 (4A–FE)

EM–211

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

under the cap nuts.

(d) Install and alternately tighten the connecting rod

cap nuts in several passes.

Torque: 49 N–m (500 kgf–cm, 36 ft–lbf)

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

(See step 2 on page

EM–194

)

6. INSTALL CONNECTING ROD CAPS

(a) Match the numbered connecting rod cap with the

connecting rod.

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

facing forward.

(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.

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)

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ENGINE MECHANICAL

Cylinder. Block (4A–FE)

EM–212

POST ASSEMBLY

1. INSTALL PS PUMP BRACKET

Install the PS pump bracket with the three bolts.
Torque: 19 N–m (195 kgf–cm, 14 ft–lbf)

2. INSTALL RH ENGINE MOUNTING BRACKET

Install the mounting bracket with the three bolts.
Torque: 51 N–m (525 kgf–cm, 38 ft–lbf)

3. INSTALL ALTERNATOR BRACKET

Install the alternator bracket with the three bolts.
Torque: 39 N–m (400 kgf–cm, 29 ft–lbf)

4. INSTALL OIL FILTER (See page

LU–7

)

5. INSTALL OIL PUMP AND OIL PAN

(See pages

LU–14

and 15)

6. INSTALL WATER PUMP (See pages

CO–9

and 10)

7. INSTALL CYLINDER HEAD (See pages

EM–104

to 114)

8. INSTALL PULLEYS AND TIMING BELT

(See pages

EM–40

to 43)

9. INSTALL ALTERNATOR (See page

CH–23

)

10. INSTALL DISTRIBUTOR (See page

IG–24

)

11. REMOVE ENGINE STAND

13. (M /T)

INSTALL FLYWHEEL
(a) Install the flywheel on the crankshaft.
(b) Install and uniformly tighten the six mounting bolts

in several passes in the sequence shown.

Torque: 78 N–m (800 kgf–cm, 58 ft–lbf)

14. (A/T)

INSTALL DRIVE PLATE (See procedure in step 13)
Torque: 64 N–m (650 kgf–cm, 47 ft–lbf)

15. (M/T)

INSTALL CLUTCH DISC AND COVER
(See CL section)

12. INSTALL REAR END PLATE

Install the end plate with the two bolts.
Torque: 9.3 N–m (95 kgf–cm, 82 in–lbf)

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ENGINE MECHANICAL

Cylinder Block (4A–FE)

EM–213

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. INSTALL STARTER (See page

ST–22

)

(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.

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ENGINE MECHANICAL

Cylinder Block (4A–FE)

EM–214

(f) Attach the LH mounting insulator to the mounting

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

Torque:

Bolt 48 N–m (490 kgf–cm, 35 ft–lbf)

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

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

RH mounting insulator.

Torque:

Nut 52 N–m (530 kgf–cm, 38 ft–lbf)

Bolt 64 N–m (650 kgf–cm, 47 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 three bolts.
Torque: 42 N–m (430 kgf–cm, 31 ft–lbf)

5. INSTALL CONNECTOR TO GROUND WIRE ON RH

FENDER APRON

8. 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.

6. INSTALL LH ENGINE MOUNTING STAY

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

7. CONNECT GROUND WIRE TO TRANSAXLE

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ENGINE MECHANICAL

Cylinder Block (4A–FE)

EM–215

10. 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: 64 N–m (650 kgf–cm, 47 ft–lbf)

12. INSTALL PS PUMP

(a) Install the PS pump with the two bolts.
Torque: 39 N–m (400 kgf–cm, 29 ft–lbf)

(b) Install the drive belt.
(c) Connect the air hose to the air pipe.
(d) Connect the air hose to the air intake chamber.

9. 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.

11. TIGHTEN FRONT AND REAR ENGINE MOUNTING

THROUGH BOLTS
Torque: 87 N–m 1890 kgf–cm, 64 ft–lbf)

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ENGINE MECHANICAL

Cylinder Block (4A–FE)

EM–216

17. INSTALL FRONT EXHAUST PIPE

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

the support bracket.

(b) Place two (CALIF.) or three (others) new gaskets

on the front and rear of the front exhaust pipe.

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

the front exhaust pipe to the catalytic converter.

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

(CALIF.) or three (others) new nuts holding the
front exhaust pipe to the exhaust manifold.

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

exhaust pipe to the catalytic converter.

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

(f) Install the clamp with the bolt.
(g) Connect the oxygen sensor connector.

13. (w/ A/C)

INSTALL A/C COMPRESSOR
(a) Install the compressor with the four bolts.
Torque: 25 N–m (250 kgf–cm, 18 ft–lbf)

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

16. (A/T)
INSTALL TRANSAXLE CONTROL CABLE TO ENGINE
MOUNTING CENTER MEMBER
Install the control cable with the two clamps and bolts.

14. CONNECT HEATER HOSE TO WATER INLET PIPE
15. INSTALL DRIVE SHAFTS (See SA section)

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ENGINE MECHANICAL

Cylinder Block (4A–FE)

EM–217