4A–FE engine is an in–line, 4–cylinder, 1.6 liter DOHC 16–valve engine. Manual — part 23
9. INSTALL OIL PRESSURE SWITCH
Apply adhesive to two or three threads.
Adhesive: Part No. 08833–00080, THREE BOND
1324 or equivalent
10. INSTALL ALTERNATOR BRACKET
Install the alternator bracket with the three bolts.
Torque: 42 N–m (425 kgf–cm, 31 ft–lbf )
11. INSTALL ENGINE HANGERS
Install the engine hanger with the bolt. Install the two
engine hangers. Install the ground strap.
Torque: 25 N–m (250 kgf–cm, 18 ft–lbf)
(c) Install the gasket to the head cover.
(d) Install the head cover with the four grommets and
nuts. Uniformly tighten the nuts in several
passes.
Torque: 23 N–m (230 kgf–cm, 17 ft–lbf)
HINT: Install the grommets so that its markings are
as shown in the illustration. Then install the grom-
met to its original position.
8. INSTALL CYLINDER HEAD COVER
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder head as shown in
the illustration.
Seal packing: Part No. 08826–00080 or equivalent
7. INSTALL HIGH–TENSION CORD CLAMP AND PCV
VALVE
–
ENGINE MECHANICAL
Cylinder Head (5S–FE)
EM–178
13. INSTALL NO.1 IDLER PULLEY AND TENSION SPRING
(See step 4 on page
EM–75
)
14. INSTALL CAMSHAFT TIMING PULLEY
(See steps 9 to 21 and 24 on pages
EM–76
to 80)
15. INSTALL INJECTOR AND DELIVERY PIPE
(See steps 1 and 2 on pages
FI–175
and 176)
(b) Install the two manifold stays with the four bolts.
Alternately tighten the bolts. Install the connector
bracket (CALIF. only).
Torque:
12 mm. head bolt 22 N–m (220 kgf–cm, 16 ft–lbf)
14 mm head bolt 42 N–m (425 kgf–cm, 31 ft–lbf)
(c) Install the engine wire protector with the bolt.
16. INSTALL INTAKE MANIFOLD
(a) Install a new gasket and the intake manifold with
the six bolts and two nuts. Uniformly tighten the
bolts and nuts in several passes.
Torque: 19 N–m (195 kgf–cm, 14 ft–lbf)
12. INSTALL No.3 TIMING BELT COVER
Install the timing belt cover with the four bolts.
Torque: 7.8 N–m (80 kgf–cm, 69 in–lbf)
(d) Connect the two wire clamps to the wire brackets.
(e) Connect the PCV hose to the PVC valve.
17. INSTALL ACCELERATOR BRACKET
–
ENGINE MECHANICAL
Cylinder Head (5S–FE)
EM–179
(c) Connect the following hoses:
(1) PS air hose to intake manifold
(2) Two air hoses to air tube
(3) (w/ A/C)
Air hose to intake manifold
(4) Vacuum hose to gas filter
(5) Vacuum hose to fuel pressure regulator
(d) (w/ A/C)
Connect the ASV connector.
21. CONNECT VACUUM HOSES
(a) Vacuum sensor hose to gas filter
(b) Brake booster vacuum hose to intake manifold
(c) (w/ Cruise Control System (w/o ABS))
Actuator vacuum hose to intake manifold
22. INSTALL EGR VALVE AND VACUUM MODULATOR
(a) Install a new gasket and the EGR valve with the
union nut and two nuts.
Torque:
Union nut 59 N–m (600 kgf–cm, 43 ft–lbf)
Bolt 13 N–m (130 kgf–cm, 9 ft–lbf)
(b) Install the EGR modulator– to the clamp.
18. INSTALL VSV FOR EGR
19. CONNECT ENGINE WIRE GROUND STRAPS AND
CONNECTORS
(a) Two engine ground straps to intake manifold
(b) Knock sensor connector
(c) VSV connector for EGR
20. INSTALL AIR TUBE, ASV (FOR A/C) AND VACUUM
PIPE
(a) Install the air tube, ASV assembly and the vacuum
hose bracket with the four bolts.
(b) Install the vacuum pipe with the bolt.
–
ENGINE MECHANICAL
Cylinder Head (5S–FE)
EM–180
(c) Connect the following hoses:
(1) Vacuum hose (from port Q of EGR vacuum
modulator) to port G of VSV for EGR
(2) Vacuum hose (from EGR valve) to port E of
VSV for EGR
(3) Vacuum hose to charcoal canister
(d) Install the vacuum hose clamp to the bracket.
(e) (CALIF. only)
Install the connector to the bracket. Connect the
EGR gas temperature sensor connector.
23. INSTALL THROTTLE BODY
(See steps 2 to 5 on pages
FI–204
and 205)
24. INSTALL WATER BY–PASS PIPE
(a) Install a new O–ring to the by–pass pipe.
(b) Apply soapy water on the O–ring.
(c) Install a new gasket and the by–pass pipe with the
two nuts and two bolts.
Torque(Nut): 9.3 N–m (95 kgf–cm, 82 in–lbf)
(b) Connect the following hoses:
(1) Upper radiator hose
(2) Water by–pass pipe hose
(3) Heater water hose
(4) ISC water by–pass hose
(5) EVAP BVSV vacuum hose (from port P of
throttle body)
(6) EVAP BVSV vacuum hose (from charcoal can-
ister)
(d) Connect the following hoses:
(1) ISC water by–pass hose
(2) Heater water hose
(3) (w/ Oil Cooler)
Two oil cooler water by–pass hoses
(e) (w / Oil Cooler)
Install the water by–pass hose heat protector.
(See step 3 on page
LU–30
)
25. INSTALL WATER OUTLET
(a) Install a new gasket and the water outlet with the
two bolts.
Torque: 15 N–m (150 kgf–cm, 11 ft–lbf)
–
ENGINE MECHANICAL
Cylinder Head (5S–FE)
EM–181
26. ASSEMBLE EXHAUST MANIFOLD AND CATALYTIC
CONVERTER
(a) Place the cushion, retainer and a new gasket on
the catalytic converter.
(b) Install the catalytic converter to the exhaust manifold
with the three bolts and two nuts.
Torque: 29 N–m (300 kgf–cm, 22 ft–lbf)
27. INSTALL EXHAUST MANIFOLD AND CATALYTIC
CONVERTER ASSEMBLY
(a) Install a new gasket, the exhaust manifold and catalyt-
ic converter assembly with the six new nuts. Uni-
formly tighten the nuts in several passes.
Torque: 49 N–m (500 kgf–cm, 36 ft–lbf)
(c) Install the lower manifold head insulator with the
five bolts.
(d) Install the two catalytic converter heat insulators
with the eight bolts.
(b) Install the catalytic converter stay with the two
bolts and two new nuts. Alternately tighten the
bolts and nut.
Torque: 42 N–m (425 kgf–cm, 31 ft–lbf)
(c) Connect the following connectors:
•
Water temperature sender gauge connector
•
Water temperature sensor connector
–
ENGINE MECHANICAL
Cylinder Head (5S–FE)
EM–182
28. (CALIF. ONLY)
INSTALL SUB–OXYGEN SENSOR
29. INSTALL OXYGEN SENSOR (MAIN)
10. INSTALL FRONT EXHAUST PIPE
(See step 15 on page
EM–305
)
31. INSTALL SUSPENSION LOWER CROSSMEMBER
(See page 16 on page
EM–306
)
32. INSTALL ENGINE UNDER COVERS
33. INSTALL DISTRIBUTOR (See page
IG–35
)
34. INSTALL ALTERNATOR (See page
CH–24
)
35. INSTALL AIR CLEANER CAP AND HOSE
(See step 38 on page
EM–310
)
36. (w/ CRUISE CONTROL SYSTEM)
INSTALL CRUISE CONTROL ACTUATOR
(See step 33 on page
EM–309
)
37. INSTALL ACCELERATOR CABLE, AND ADJUST IT
38. (A/T)
CONNECT THROTTLE CABLE, AND ADJUST IT
39. CONNECT CABLE TO NEGATIVE TERMINAL OF
BATTERY
40. FILL WITH ENGINE COOLANT (See page
CO–6
)
Capacity (w/ Heater):
M/T 6.2 liters (6.6 US qts, 5.5 Imp. qts)
A/T 6.1 liters (6.4 US qts, 5.4 Imp. qts)
41. START ENGINE AND CHECK FOR LEAKS
42. ADJUST IGNITION TIMING (See page
IG–37
)
Ignition timing:
10
В°
BTDC), idle
(w/ Terminals TE1 and E1 connected)
43. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct
shift points and smooth operation.
44. RECHECK ENGINE COOLANT LEVEL AND OIL LEVEL
(c) Install the manifold upper heat insulator with the six
bolts.
–
ENGINE MECHANICAL
Cylinder Head (5S–FE)
EM–183
CYLINDER BLOCK (4A–FE)
COMPONENTS
–
ENGINE MECHANICAL
Cylinder Block (4A–FE)
EM–184
6. REMOVE AIR CLEANER
(a) Disconnect the intake air temperature sensor connec-
tor.
(b) Disconnect the accelerator cable from the bracket
on the air cleaner cap.
(c) Disconnect the four air cleaner cap clips.
(d) Disconnect the air hose from the air pipe.
(e) Disconnect the air cleaner hose from the throttle
body, and remove the air cleaner cap and element.
(f) Remove the three bolts and air cleaner case.
7. DISCONNECT ACCELERATOR CABLE FROM
THROTTLE BODY
8. REMOVE ENGINE RELAY BOX, AND DISCONNECT
ENGINE WIRE CONNECTORS
(a) Remove the two nuts, and disconnect the relay box
from the battery.
REMOVAL OF ENGINE
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. REMOVE HOOD
3. REMOVE ENGINE UNDER COVER
4. DRAIN ENGINE COOLANT (See page
CO–6
)
5. DRAIN ENGINE OIL (See page
LU–7
)
(b) Remove the lower cover from the relay box.
(c) Disconnect the fusible link cassette and two con–
nectors of the engine wire from the relay box.
–
ENGINE MECHANICAL
Cylinder Block (4A–FE)
EM–185
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