4A–FE engine is an in–line, 4–cylinder, 1.6 liter DOHC 16–valve engine. Manual — part 19
21. INSTALL LH ENGINE HANGER
Install the LH engine hanger and reservoir tank with the
two bolts. Alternately tighten the bolts.
Torque:
12 mm head bolt 19 N–m (195 kgf–cm, 14 ft–lbf)
14 mm head bolt 39 N–m (400 kgf–cm, 29 ft–lbf)
23. CONNECT HOSES
(a) Brake booster vacuum hose to intake manifold
(b) Turbocharging pressure sensor hose to intake man-
ifold
(b) Connect the following hoses:
(1) Vacuum hose to EGR valve
(2) Vacuum hose to EGR vacuum modulator
(c) Connect the EGR VSV connector.
20. INSTALL EGR VACUUM MODULATOR AND VSV
(a) Install the EGR vacuum modulator and VSV assembly
with the bolt.
22. INSTALL NO.2 AIR TUBE
(a) Install the air tube with the bolt.
(b) Connect the air hose to the No.1 air tube.
–
ENGINE MECHANICAL
Cylinder Head (3S–GTE)
EM–146
26. INSTALL COLD START INJECTOR
(See steps 1 to 3 on page
FI–148
)
27. INSTALL THROTTLE BODY
(See steps 2, 3 and 5 to 8 on pages
FI–197
and 198)
28. INSTALL TURBOCHARGER
(See steps 5 to 10 on pages
TC–15
to 17)
i
(b) Install a new gasket and the exhaust manifold
with the nine nuts. Uniformly tighten the nuts in
several passes.
Torque: 52 N–m (530 kgf–cm, 38 ft–lbf)
29. INSTALL CATALYTIC CONVERTER
(a) Install the front heat insulator with the five bolts.
(b) Install the rear heat insulator with the four bolts.
25. INSTALL EXHAUST MANIFOLD
(a) Install the heat insulator with the bolt and nut.
(c) A/C ASV air hose to No.1 air tube
24. INSTALL DISTRIBUTOR (See page
IG–28
)
–
ENGINE MECHANICAL
Cylinder Head (3S–GTE)
EM–147
30. INSTALL NO.1 ALTERNATOR BRACKET AND RH
FRONT ENGINE HANGER
Install the alternator bracket and engine hanger with the
three bolts.
Torque: 39 N–m (400 kgf–cm, 29 ft–lbf)
(e) Install the RH converter stay with the four bolts.
Alternately tighten the bolts.
Torque: 59 N–m (600 kgf–cm, 43 ft–lbf)
(f) Install the LH converter stay with the three bolts.
Alternately tighten the bolts.
Torque: 59 N–m (600 kgf–cm, 43 ft–lbf)
(d) Install the catalytic converter with the three bolts
and two nuts.
Torque: 29 N–m (300 kgf–cm, 22 ft–lbf)
(c) Place a new gasket, the cushion and retainer on
the catalytic converter.
–
ENGINE MECHANICAL
Cylinder Head (3S–GTE)
EM–148
31. INSTALL FRONT EXHAUST PIPE
(See step 18 on page
EM–261
)
32. INSTALL SUSPENSION LOWER CROSSMEMBER
(See step 19 on page
EM–262
)
33. INSTALL ALTERNATOR (See page
CH–23
)
34. INSTALL INTERCOOLER
(See steps 11 to 13 on page
TC–17
)
35. INSTALL AIR CLEANER CAP
(See step 44 on page
EM–117
)
36. INSTALL ACCELERATOR CABLE, AND ADJUST IT
37. FILL WITH ENGINE COOLANT (See page
CO–6
)
Capacity (w/ Heater):
6.5 liters (6.9 US qts, 5.7 Imp. qts)
38. START ENGINE AND CHECK FOR LEAKS
39. ADJUST IGNITION TIMING (See page
IG–29
)
Ignition timing:
10
В°
BTDC @ idle
(w/ Terminals TO and E1 connected)
40. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift
points and smooth operation.
41. RECHECK ENGINE COOLANT AND OIL LEVELS
–
ENGINE MECHANICAL
Cylinder Head (3S–GTE)
EM–149
CYLINDER HEAD (5S–FE)
COMPONENTS
–
ENGINE MECHANICAL
Cylinder Head (5S–FE)
EM–150
REMOVAL OF CYLINDER HEAD
(See page
EM–150
)
1. DISCONNECT CABLE FROM NEGATIVE TERMINAL
OF BATTERY
CAUTION: Work must be started after approx. 20
seconds or longer from the time the ignition switch is
turned to the ”LOCK” position and the negative (–)
terminal cable is disconnected from the battery.
2. DRAIN ENGINE COOLANT (See page
CO–6
)
3. (A/T)
.DISCONNECT THROTTLE CABLE FROM THROTTLE
BODY
4. DISCONNECT ACCELERATOR CABLE FROM
THROTTLE BODY
5. (w/ CRUISE CONTROL SYSTEM)
REMOVE CRUISE CONTROL ACTUATOR
(See step 11 on page
EM–270
)
6. REMOVE AIR CLEANER CAP
(See step 6 on page
EM–269
)
7. REMOVE ALTERNATOR (See page
CH–9
)
8. REMOVE DISTRIBUTOR (See page
IG–30
)
9. REMOVE ENGINE UNDER COVERS
10. REMOVE SUSPENSION LOWER CROSSMEMBER
(See step 28 on page
EM–274
)
11. REMOVE FRONT EXHAUST PIPE
(See step 29 on page
EM–274
)
12. REMOVE OXYGEN SENSOR (MAIN)
13. (CALIF. ONLY)
REMOVE SUB–OXYGEN SENSOR
14. REMOVE EXHAUST MANIFOLD AND CATALYTIC
CONVERTER ASSEMBLY
(a) Remove the six bolts and manifold upper heat
insulator.
–
ENGINE MECHANICAL
Cylinder Head (5S–FE)
EM–151
16. REMOVE WATER OUTLET
(a) Disconnect the following connectors:
•
Water temperature sender gauge connector
•
Water temperature sensor connector
(b) Disconnect the following hoses:
(1) Upper radiator hose
(2) Water by–pass pipe hose
(3) Heater water hose
(4) ISC water by–pass hose
(5) Two EVAP BVSV vacuum hoses
15. SEPARATE EXHAUST MANIFOLD AND CATALYTIC
CONVERTER
(a) Remove the five bolts and lower manifold heat insula-
tor.
(b) Remove the eight bolts and two catalytic converter
heat insulator.
(c) Remove the three bolts, two nuts, catalytic con-
verter, gasket, retainer and cushion.
(b) Remove the two bolts, two nuts and catalytic
converter stay.
(c) Remove the six nuts, the exhaust manifold
and catalytic converter assembly.
–
ENGINE MECHANICAL
Cylinder Head (5S–FE)
EM–152
19. REMOVE EGR VALVE AND VACUUM MODULATOR
(a) (CALIF. only)
Disconnect EGR gas temperature sensor connector,
and disconnect the connector from the bracket.
(b) Remove the following hoses:
(1) Two vacuum hoses from EGR VSV
(2) Vacuum hose from charcoal canister
(c) Disconnect the vacuum hose clamp from the
bracket.
17. REMOVE WATER BY–PASS PIPE
(a) (w/ Oil Cooler)
Remove the water by–pass hose heat protector.
(See step 8 on page
LU–29
)
(b) Disconnect the following hoses:
(1) ISC water by–pass hose
(2) Heater water hose
(3) (w/ Oil Cooler)
Two oil cooler water by–pass hoses
(c) Remove the two bolts, two nuts, water by–pass pipe
and gasket.
(d) Remove the O–ring from the water by–pass hose.
18. REMOVE THROTTLE BODY
(See steps 6 to 9 on pages
FI–201
and 202)
(d) Loosen the union nut of the EGR pipe, and re-
move two nuts the EGR valve, vacuum modula-
tor, vacuum hoses assembly and gasket.
(c) Remove the two bolts, water outlet and gasket.
–
ENGINE MECHANICAL
Cylinder Head (5S–FE)
EM–153
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