4A–FE engine is an in–line, 4–cylinder, 1.6 liter DOHC 16–valve engine. Manual — part 21
3. INSPECT CYLINDER HEAD
A. Inspect for flatness
Using precision straight edge and feeler gauge, measu-
re the surfaces contacting the cylinder block and man-
ifold for warpage.
Maximum warpage:
Cylinder block side 0.05 mm (0.0020 in.)
Manifold side
0.08 mm (0.0031 in.)
If warpage is greater than maximum, replace the cylin-
der head.
B. Inspect for cracks
Using a dye penetrant, check the combustion chamber,
intake ports, exhaust ports and cylinder block surface
for cracks.
If cracked, replace the cylinder head.
4. CLEAN VALVES
(a) Using a gasket scraper, chip off any carbon from the
valve head.
(b) Using a wire brush, thoroughly clean the valve.
D. Clean cylinder head
Using a soft brush and solvent, thoroughly clean the
cylinder head.
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ENGINE MECHANICAL
Cylinder Head (5S–FE)
EM–162
(b) Using a micrometer, measure the diameter of the
valve stem.
Valve stem diameter:
Intake
5.970 – 5.985 mm
(0.2350 – 0.2356 in.)
Exhaust
5.965 – 5.980 mm
(0.2348 – 0.2354 in.)
(c) Subtract the valve stem diameter measurement
from the guide bushing inside diameter measure-
ment.
Standard oil clearance:
Intake
0.025 – 0.060 mm
(0–0010 – 0.0024 in.)
Exhaust
0.030 – 0.065 mm
(0.0012 – 0.0026 in.)
Maximum oil clearance:
Intake
0.08 mm (0.0031 in.)
Exhaust
0.10 mm (0.0039 in.)
If the clearance is greater than maximum, replace the
valve and guide bushing.
6. IF NECESSARY, REPLACE VALVE GUIDE BUSHINGS
(a) (Exhaust (w/ Snap Ring))
Insert an old valve wrapped with tape into the valve
guide bushing, and break off the valve guide bushing
by hitting it with a hammer. Remove the snap
ring.
HINT: Wrap the tape approx. 8 mm (0.31 in.) from the
valve stem end.
NOTICE: Be careful not to damage the valve lifter
hole.
(b) Gradually heat the cylinder head to 80 –100
В°
C (176
– 212
В°
F).
5. INSPECT VALVE STEMS AND GUIDE BUSHINGS
(a) Using a caliper gauge, measure the inside diameter
of the guide bushing.
Bushing inside diameter:
6.010 – 6.030 mm (0.2366 – 0.2374 in.)
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ENGINE MECHANICAL
Cylinder Head (5S–FE)
EM–163
(e) Select a new guide bushing (STD or 0/S 0.05).
If the bushing bore diameter of the cylinder
head is greater than 11.012 mm (0.04335 in.),
machine the bushing bore to the following di-
mension:
11.035 – 11.062 mm (0.4344 – 0.4355 in.)
If the bushing bore diameter of the cylinder head is
greater than 11.062 mm (0.4355 in.), replace the
cylinder head.
(c) Using SST and a hammer, tap out the guide
bushing.
SST 09201–70010
(d) Using a caliper gauge, measure the bushing bore
diameter of the cylinder head.
(f) Gradually heat the cylinder head to 80–100
В°
C
(176– 212
В°
F).
HINT: Different the bushings are used for the in-
take and exhaust.
Bushing bore diameter mm (in.)
Both intake and exhaust
Bushing size
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ENGINE MECHANICAL
Cylinder Head (5S–FE)
EM–164
(g) (Intake)
Using SST and a hammer, tap in a new guide
bushing until there is 8.0 – 8.8 mm (0.315 –
0.346 in.) protruding from the cylinder head.
SST 09201–70010
(h) (Exhaust)
Using SST and a hammer, tap in a new guide
bushing until the snap ring makes contact with
the cylinder head.
SST 09201–70010
(h) Using a sharp 6 mm reamer, ream the guide
bushing to obtain the standard specified clear-
ance (See page
EM–163
) between the guide
bushing and valve stem.
(d) Check the valve overall length.
Standard overall length:
Intake
97.60 mm (3.8425 in.)
Exhaust 98.45 mm (3.8760 in.)
Minimum overall length:
Intake
97.1 mm (3.823 in.)
Exhaust 98.0 mm (3.858 in.)
If the overall length is less than minimum, replace the
valve.
(c) Check the valve head margin thickness.
Standard margin thickness: 0.8 –1.2 mm
(0.031 – 0.047 in.)
Minimum margin thickness: 0.5 mm (0.020 in.)
If the margin thickness is less than minimum, replace
the valve.
7. INSPECT AND GRIND VALVES
(a) Grind the valve enough to remove pits and carbon.
(b) Check that the valve is ground to the correct valve
face angle.
Valve face angle: 44.5
В°
. _
–
, . r
•
, I , �’
8.0 – 8 8 mm
;
1
Snap
Ring
_,
.
Exhaust
Length
Intake
EM2534
P03366
SST
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ENGINE MECHANICAL
Cylinder Head (5S–FE)
EM–165
(b) Check the valve seating position. Apply a light
coat of prussian blue (or white lead) to the valve
face. Lightly press the valve against the seat.
Do not rotate valve.
(c) Check the valve face and seat for the following:
•
If blue appears 360
В°
around the face, the
valve is concentric. If not, replace the
valve.
•
If blue appears 360
В°
around the valve
seat, the guide and face are concentric. If
not, resurface the seat.
•
Check that the seat contact is in the middle
of the valve face with the following width:
1.0 –1. 4 mm (0.039 – 0.055 in.)
If not, correct the valve seats as follows:
(1) If the seating is too high on the valve face,
use 30
В°
and 45
В°
cutters to correct the seat.
(e) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, resurface the tip
with a grinder or replace the valve.
NOTICE: Do not grind off more than minimum.
8. INSPECT AND CLEAN VALVE SEATS
(a) Using a 45
В°
carbide cutter, resurface the valve seats.
Remove only enough metal to clean the seats.
(2) If the seating is too low on the valve face,
use 75
В°
and 45
В°
cutters to correct the seat.
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ENGINE MECHANICAL
Cylinder Head (5S–FE)
EM–166
10. INSPECT CAMSHAFTS AND BEARINGS
A. Inspect camshaft for runout
(a) Place the camshaft on V–blocks.
(b) Using a dial indicator, measure the circle runout at
the center journal.
Maximum circle runout: 0.04 mm (0.0016 in.)
If the circle runout is greater than maximum, replace the
camshaft.
(c) Using a spring tester, measure the tension of the
valve spring at the specified installed length.
Installed tension:
164 – 189 N (16.7 – 19.3 kgf, 36.8 – 42.5 lbf )
at 34.7 mm 0.366 in.)
If the installed tension is not as specified, replace the
valve spring.
9. INSPECT VALVE SPRINGS
(a) Using a steel square, measure the squareness of the
valve spring.
Maximum squareness: 2.0 mm (0.079 in.)
If the squareness is greater than maximum, replace the
valve spring.
(b) Using a vernier caliper, measure the free length of
the valve spring.
Free length: 41.96 – 41.99 mm (1.6520 – 1.6531 in.)
If the free length is not as specified, replace the valve
spring.
(d) Hand–lap the valve and valve seat with an abra-
sive compound.
(e) After hand–lapping, clean the valve and valve
seat.
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ENGINE MECHANICAL
Cylinder Head (5S–FE)
EM–167
B. Inspect cam lobes
Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake
42.010 – 42.110 mm
(1–6539 – 1.6579 in.)
Exhaust 40.060 – 40.160 mm
(1.5772 – 1.5811 in.)
Minimum cam lobe height:
Intake
41.90 mm (1.6496 in.)
Exhaust 39.95 mm (1.5728 in.)
If the cam lobe height is less than minimum, replace
the camshaft.
C. Inspect camshaft journals
Using a micrometer, measure the journal diameter.
Journal diameter: 26.959 – 26.975 mm
(1.0614 –1.0620 in.)
If the journal diameter is not as specified, check the oil
clearance.
E. Inspect camshaft gear spring
Using a vernier caliper, measure the free distance be-
tween the spring ends.
Free distance: 22.5 – 22.9 mm (0.886 – 0.902 in.)
If the free distance is not as specified, replace the gear
spring.
F. Inspect camshaft journal oil clearance
(a) Clean the bearing caps and camshaft journals.
(b) Place the camshafts on the cylinder head.
(c) Lay a strip of Plastigage across each of the camshaft
journals.
D. Inspect camshaft bearings
Check the bearings for flaking and scoring.
If the bearings are damaged, replace the bearing caps
and cylinder head as a set.
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ENGINE MECHANICAL
Cylinder Head (5S–FE)
EM–168
G. Inspect camshaft thrust clearance
(a) Install the camshafts.
(See step 4 on pages
EM–175
to 177)
(b) Using a dial indicator, measure the thrust clearance
while moving the camshaft back and forth.
Standard thrust clearance:
Intake
0.045 – 0.100 mm
(0.0018 – 0.0039 in.)
Exhaust 0.030 – 0.085 mm
(0.0012 – 0.0033 in.)
Maximum thrust clearance:
Intake
0.12 mm (0.0047 in.)
Exhaust 0.10 mm (0.0039 in.)
If the thrust clearance is greater than maximum, replace
the camshaft. If necessary, replace the bearing caps
and cylinder head as a set.
(f) Measure the Plastigage at its widest point.
Standard oil clearance: 0.025 – 0.062 mm
(0.0010 – 0.0024 in.)
Maximum oil clearance: 0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, re-
place the camshaft. If necessary, replace the bear-
ing caps and cylinder head as a set.
(g) Completely remove the Plastigage.
(d) Install the bearing caps.
(See step 4 on pages
EM–175
to 177)
Torque: 19 N–m (190 kgf–cm, 94 ft–lbf)
NOTICE: Do not turn the camshaft.
(e) Remove the bearing caps.
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ENGINE MECHANICAL
Cylinder Head (5S–FE)
EM–169
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