4A–FE engine is an in–line, 4–cylinder, 1.6 liter DOHC 16–valve engine. Manual — part 9

16. REINSTALL NO.2 TIMING BELT COVER

(See step 15 on page

EM–60

)

17. REINSTALL SPARK PLUGS (See page

IG–13

)

Torque: 180 kg–cm (13 ft–Ib, 18 N–m)

18. REINSTALL CYLINDER HEAD COVER

(See step 7 on pages

EM–143

and 144)

19. REINSTALL THROTTLE BODY

(See steps 2, 3, 5 to 8, 10 and 11 on pages

FI–197

and

198)

20. REINSTALL EGR VALVE AND PIPE

(See step 19 on page

EM–145

)

21. REINSTALL EGR VACUUM MODULATOR AND VSV

(See step 20 on page

EM–146

)

22. REINSTALL INTERCOOLER

(See steps 11 to 13 on page

TC–17

)

23. REINSTALL ALTERNATOR (See page

CH–23

)

24. REINSTALL RH ENGINE UNDER COVER
25. REINSTALL RH FRONT WHEEL
26. RECONNECT CABLE TO NEGATIVE TERMINAL OF

BATTERY

(f) Hold the hexagon wrench head portion of the

camshaft with a wrench, and install the pulley bolt.

Torque: 59 N–m (600 kgf–cm, 43 ft–lbf)

41 N–m (420 kgf–cm, 30 ft–lbf) for SST

HINT (Intake camshaft timing pulley):

•

Use SST.
SST 09249–63010

•

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

NOTICE: Do not make use of the timing belt tension

when tightening the bolt.

(g) Turn the crankshaft clockwise two revolutions from

TDC to TDC.

(h) Recheck the valve timing.

(See step 14 on page

EM–64

)

–

ENGINE MECHANICAL

Timing Belt (3S–GTE)

EM–66

REMOVAL OF TIMING BELT

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 (–) ter-

minal cable is disconnected from the battery.

2. REMOVE RH FRONT WHEEL
3. REMOVE RH ENGINE UNDER COVER
4. (w/ CRUISE CONTROL SYSTEM (w/o ABS))

REMOVE CRUISE CONTROL ACTUATOR
(See page 11 on page

EM–270

)

5. REMOVE ALTERNATOR (See page

CH–9

)

TIMING BELT (5S–FE)

COMPONENTS

–

ENGINE MECHANICAL

Timing Belt (5S–FE)

EM–67

8. DISCONNECT CONNECTOR FROM GROUND WIRE

ON RH FENDER APRON

9. REMOVE RH ENGINE MOUNTING STAY

Remove the bolt, nut and mounting stay.

10. DISCONNECT PS RESERVOIR TANK FROM BRACKET

12. REMOVE RH ENGINE MOUNTING BRACKET

Remove the three bolts and mounting bracket.
HINT: Lower the jack and perform the operation with
the engine fully down.

13. REMOVE SPARK PLUGS

7. SLIGHTLY JACK UP ENGINE

Raise the engine enough to remove the weight from the
engine mounting on the right side.

11. REMOVE RH ENGINE MOUNTING INSULATOR

Remove the through bolt, two nuts and mounting insu-
lator.

6. REMOVE PS DRIVE BELT

Loosen the two bolts, and remove the drive belt.

–

ENGINE MECHANICAL

Timing Belt (5S–FE)

EM–68

17. REMOVE TIMING BELT FROM CAMSHAFT TIMING

PULLEY
HINT (When re–using timing belt): Place the matchmarks
on the timing belt and camshaft timing pulley, and
place matchmark on timing belt to match the end of the
No.1 timing belt cover.

14. DISCONNECT ENGINE WIRE FROM ALTERNATOR

BRACKET AND ADJUSTING BAR
Remove the two bolts, and disconnect the engine wire
from the alternator bracket and adjusting bar.

15. REMOVE NO.2 TIMING BELT COVER

Remove the five bolts, timing belt cover and two gas-
kets.

16. 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.

(b) Check that the hole of the camshaft timing pulley is

aligned with the timing mark of the bearing cap.
If not, turn the crankshaft one revolution (360

В°

).

–

ENGINE MECHANICAL

Timing Belt (5S–FE)

EM–69

HINT (When re–using timing belt): After loosening the
crankshaft pulley bolt, check that the timing belt match-
mark aligns with the end of the No.1 timing belt cover
when the crankshaft pulley groove is aligned with the
timing mark ”0” of the No.1 timing belt cover. If the
matchmark does not align, align as follows:

18. REMOVE CAMSHAFT TIMING PULLEY

Using SST, remove the bolt, plate washer and timing
pulley.
SST 09249–63010 and 09278–54012

19. REMOVE CRANKSHAFT PULLEY

(a) Using SST, remove the pulley bolt.

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

(a) Loosen the mounting bolt of the No.1 idler pulley

and shift the pulley toward the left as far as it will go,
and temporarily tighten it.

(b) Remove the timing belt from the camshaft timing

pulley.

–

ENGINE MECHANICAL

Timing Belt (5S–FE)

EM–70

(b) Using SST, remove the pulley.

SST 09213–60017 (09213–00020, 09213–00030,
09213–00050)
HINT (When re–using timing belt): Remove the pulley
without turning it.

(When matchmark is out of alignment on counter-
clockwise)

•

Align the matchmark by pulling the timing belt up
on the No.1 idler pulley side while turning the
crankshaft pulley clockwise.

(When matchmark is out of alignment on clockwise)

•

Align the matchmark by pulling the timing belt up
on the water pump pulley side while turning the
crankshaft pulley counterclockwise.

•

After aligning the matchmark, hold the timing
belt. And turn the crankshaft pulley clockwise,
and align its groove with timing mark ”0” of the
No.1 timing belt cover.

•

After aligning the matchmark, hold the timing
belt. And turn the crankshaft pulley counterclock-
wise, and align its groove with timing mark ”0” of
the No.1 timing belt cover.

–

ENGINE MECHANICAL

Timing Belt (5S–FE)

EM–71

22. REMOVE TIMING BELT

HINT (When re–using timing belt): Draw a direction
arrow on the timing belt (in the direction of engine revo-
lution), and place matchmarks on the timing belt and
crankshaft timing pulley.

23. REMOVE NO.1 IDLER PULLEY AND TENSION SPRING

Remove the bolt, pulley and tension spring.

20. REMOVE NO.1 TIMING BELT COVER

Remove the four bolts, timing belt cover and gasket.

24. REMOVE NO.2 IDLER PULLEY

Remove the bolt and pulley.

21. REMOVE TIMING BELT GUIDE

–

ENGINE MECHANICAL

Timing Belt (5S–FE)

EM–72

INSPECTION OF TIMING BELT
COMPONENTS

1. INSPECT TIMING BELT

NOTICE:

•

Do not bend, twist or turn the timing belt inside out.

•

Do not allow the timing belt to come into contact
with oil, water or steam.

•

Do not utilize timing belt tension when installing or
removing the mounting bolt of the camshaft timing
pulley.

If there are any defects as shown in the illustrations,
check the following points:
(a) Premature parting

•

Check the proper installation.

•

Check the timing cover gasket for damage and
proper installation.

25. REMOVE CRANKSHAFT TIMING PULLEY

If the pulley cannot be removed by hand, use two
screwdrivers.
HINT: Position shop rags as shown to prevent damage.

26. REMOVE Oil PUMP PULLEY

Using SST, remove the nut and pulley.
SST 09616–30011

(b) If the belt teeth are cracked or damaged, check to

see if either camshaft or water pump is locked.

–

ENGINE MECHANICAL

Timing Belt (5S–FE)

EM–73