4A–FE engine is an in–line, 4–cylinder, 1.6 liter DOHC 16–valve engine. Manual — part 35
29. REMOVE FRONT EXHAUST PIPE
(a) Loosen the bolt, and disconnect the clamp from the
bracket.
(b) Remove the two bolts and nuts holding the front
exhaust pipe to the center exhaust pipe.
(c) Using a 14 mm deep socket wrench, remove the
three nuts holding the front exhaust pipe to the cata-
lytic converter.
(d) Disconnect the support hook on the front exhaust
pipe from the support bracket, and remove the front
exhaust pipe and two gaskets.
30. (A/T)
DISCONNECT TRANSAXLE CONTROL CABLE FROM
ENGINE MOUNTING CENTER MEMBER
31. REMOVE DRIVE SHAFTS (See SA section)
32. (w/ A/C)
REMOVE A/C COMPRESSOR WITHOUT
DISCONNECTING HOSES
(a) Disconnect the A/C compressor connector.
(b) Remove the drive belt.
(c) Remove the three bolts, and disconnect the A/C
compressor.
HINT: Put aside the compressor, and suspend it to the
radiator support with a string.
33. REMOVE PS PUMP WITHOUT DISCONNECTING
HOSES
(a) Disconnect the two air hoses from the air pipe.
(b) Remove the PS drive belt.
(c) Remove the four bolts, and disconnect the PS pump
from the engine.
HINT: Put aside the pump and suspend it to the cowl
with a string.
28. REMOVE SUSPENSION LOWER CROSSM EM BER
Remove the four bolts, two nuts and lower crossmem-
ber.
–
ENGINE MECHANICAL
Cylinder Block (5S–FE)
EM–274
35. REMOVE FRONT ENGINE MOUNTING INSULATOR
AND BRACKET
(a) Remove the through bolt, nut and mounting insulator.
(b) Remove the two bolts and mounting bracket.
37. REMOVE CONNECTOR FROM GROUND WIRE ON RH
FENDER APRON
38. REMOVE RH ENGINE MOUNTING STAY
Remove the bolt, nut and mounting stay.
39. REMOVE LH ENGINE MOUNTING STAY
(M/T)
(a) Remove the two nuts and mounting stay.
(b) Remove the bolt, and disconnect the ground strap.
36. REMOVE REAR ENGINE MOUNTING INSULATOR
AND BRACKET
(a) Remove the through bolt and mounting insulator.
(b) Remove the three bolts and mounting bracket.
34. REMOVE ENGINE MOUNTING CENTER MEMBER
Remove the eight bolts and center member.
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ENGINE MECHANICAL
Cylinder Block (5S–FE)
EM–275
40. REMOVE ENGINE AND TRANSAXLE ASSEMBLY
FROM VEHICLE
(a) Attach the engine chain hoist to the engine hangers.
(A/T)
(a) Remove the bolt, nut and mounting stay.
(b) Remove the bolt, and disconnect the ground
strap.
(c) Remove the three (M/T) or two (A/T) bolts and LH
mounting bracket.
(b) Remove the through bolt, four bolts and LH
mounting insulator.
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ENGINE MECHANICAL
Cylinder Block (5S–FE)
EM–276
(e) Lift the engine out of the vehicle slowly and care-
fully.
NOTICE: Be careful not to hit the PS gear hous-
ing or neutral start switch (A/T).
(f) Make sure the engine is clear of all wiring, hoses
and cables.
(g) Place the engine and transaxle assembly onto
the stand.
41. (A/T) REMOVE STARTER (See page
ST–5
)
42. SEPARATE ENGINE AND TRANSAXLE
M/T (See MT section)
A/T (See AT section)
(d) Remove the through bolt, two nuts and RH
mounting insulator.
–
ENGINE MECHANICAL
Cylinder Block (5S–FE)
EM–277
8. REMOVE RH ENGINE MOUNTING BRACKET
Remove the three bolts and mounting bracket.
9. REMOVE PS PUMP BRACKET
Remove the three bolts and PS pump bracket.
10. REMOVE TIMING BELT AND PULLEYS
(See pages
EM–69
to 73)
11. REMOVE CYLINDER HEAD
(See pages
EM–151
to 159)
12. REMOVE WATER PUMP AND ALTERNATOR
ADJUSTING BAR (See pages
CO–12
and 13)
13. REMOVE OIL PAN AND OIL PUMP
(See pages
LU–17
and 18)
14. REMOVE OIL FILTER (See page
LU–7
)
15. (w/ OIL COOLER)
REMOVE OIL COOLER (See page
LU–29
)
PREPARATION FOR DISASSEMBLY
1. (M /T)
REMOVE CLUTCH COVER AND DISC
2. (M/T)
REMOVE FLYWHEEL
3. (A/T)
REMOVE DRIVE PLATE
4. REMOVE REAR END PLATE
Remove the bolt and end plate.
5. INSTALL ENGINE TO ENGINE STAND FOR
DISASSEMBLY
6. REMOVE ALTERNATOR (See page
CH–9
)
7. REMOVE DISTRIBUTOR (See page
IG–31
)
16. REMOVE KNOCK SENSOR
Using SST, remove the knock sensor.
SST 09816–30010
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ENGINE MECHANICAL
Cylinder Block (5S–FE)
EM–278
2. CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance
while moving the connecting rod back and forth.
Standard thrust clearance: 0.160 – 0.312 mm
(0.0063 – 0.0123 in.)
Maximum thrust clearance: 0.35 mm (0.0138 in.)
If the thrust clearance is greater than maximum, re-
place the connecting rod assembly. If necessary, re-
place the crankshaft.
3. REMOVE CONNECTING ROD CAPS AND CHECK OIL
CLEARANCE
(a) Check the matchmarks on the connecting rod and
cap to ensure correct reassembly.
DISASSEMBLY OF CYLINDER BLOCK
(See page
EM–268
)
1. REMOVE REAR OIL SEAL RETAINER
Remove the six bolts, retainer and gasket.
(c) Using a plastic–faced hammer, lightly tap the con-
necting rod bolts and lift off the connecting rod
cap.
HINT: Keep the lower bearing inserted with the
connecting cap.
(b) Using SST, remove the connecting rod cap nuts.
SST 09011–38121
–
ENGINE MECHANICAL
Cylinder Block–(5S–FE)
EM–279
(e) Clean the crank pin and bearing.
(f) Check the crank pin and bearing for pitting and
scratches.
If the crank pin or bearing is damaged, replace the
bearings. If necessary, grind or replace the crank–
shaft.
(h) Install the connecting rod cap.
(See step 6 on pages
EM–299
and 300)
Torque: 1st 25 N–m (250 kgf–cm, 18 ft–lbf)
2nd Turn 90
В°
NOTICE: Do not turn the crankshaft.
(d) Cover the connecting rod bolts with a short piece
of hose to protect the crankshaft from damage.
(i) Remove the connecting rod cap.
(See procedure (b) and (c) above)
(g) Lay a strip of Plastigage across the crank pin.
–
ENGINE MECHANICAL
Cylinder Block (5S–FE)
EM–280
HINT: If using a standard bearing, replace it with one
having the same number marked on the connecting rod
cap. There are three sizes of standard bearings, marked
”1 ”, ”2” and ”3” accordingly.
(Reference)
Standard sized bearing center wall thickness:
Mark ”1”
1.484 – 1.488 mm
(0–0584 – 0.0586 in.)
Mark ”2”
1.488 – 1.492 mm
(0.0586 – 0.0587 in.)
Mark ”3”
1.492 – 1.496 mm
(0.0587 – 0.0589 in.)
(k) Completely remove the Plastigage.
4. REMOVE PISTON AND CONNECTING ROD
ASSEMBLIES
(a) Using a ridge reamer, remove ail the carbon from the
top of the cylinder.
(b) Cover the connecting rod bolts.
(See page
EM–280
)
(c) Push the piston, connecting rod assembly and upper bear-
ing through the top of the cylinder block.
(j) Measure the Plastigage at its widest point.
Standard oil clearance:
STD
0.024 – 0.055 mm,
(0.0009 – 0.0022 in . )
U /S 0.25
0.023 – 0.069 mm
(0.0009 – 0.0027 in.)
Maximum oil clearance: 0.08 mm (0.0031 in.)
If the oil clearance is greater than maximum, re-
place the bearings. If necessary, grind or replace
the crankshaft.
5. CHECK CRANKSHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance
while
prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance: 0.020 – 0.220 mm
(0.0008 – 0.0087 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.
If the thrust clearance is greater than maximum, replace
the thrust washers as a set.
Thrust washer thickness: 2.440 – 2.490 mm
(0.0961 – 0.0980 in.)
HINT:
•
Keep the bearings, connecting rod and cap together.
•
Arrange the piston and connecting rod assemblies in cor-
rect order.
–
ENGINE MECHANICAL
Cylinder Block (5S–FE)
EM–281
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