4A–FE engine is an in–line, 4–cylinder, 1.6 liter DOHC 16–valve engine. Manual — part 36

(b) Using the removed main bearing cap bolts, pry the main

bearing cap back and forth, and remove the main bear-
ing caps, lower bearings and lower thrust washers
(No.3 main bearing cap only).

HINT:

•

Keep the lower bearing and main bearing cap together.

•

Arrange the main bearing caps and lower thrust wash-
ers– in correct order.

(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for pitting

and scratches.

If the journal or bearing is damaged, replace the
bearings.
If necessary, grind or replace the crankshaft.

(c) Lift out the crankshaft.
HINT: Keep the upper bearing and upper thrust
washers together with the cylinder block.

6. REMOVE MAIN BEARING CAPS AND CHECK OIL

CLEARANCE
(a) Remove the main bearing cap bolts.

(f) Place the crankshaft on the cylinder block.
(g) Lay a strip of Plastigage across each journal.

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ENGINE MECHANICAL

Cylinder Block (5S–FE)

EM–282

(j) Measure the Plastigage at its widest point.
Standard clearance:

No.3

STD

0.025 – 0.044 mm
(0–0010 – 0.0017 in.)

U /S 0.25 0.027 – 0.067 mm

(0.0011 – 0.0026 in.)

Others STD

0.015 – 0.034 mm
(0.0006 – 0.0013 in.)

U /S

0.25 0.019 – 0.059 mm
(0.0007 – 0.0023 in.)

Maximum clearance: 0.08 mm (0.0031 in.)
HINT: If replacing the cylinder block subassembly, the bear-
ing standard clearance will be:
No.3

0.027 – 0.054 mm

(0 .0011 – 0.0021 in.)

Others

0.017 – 0.044 mm

(0.0007 – 0.0017 in.)

If the oil clearance is greater than maximum, replace the
bearings. If necessary, grind or replace the crankshaft.
HINT: If using a standard bearing, replace it with one having
the same number. If the number of the bearing cannot be
determined, select the correct bearing by adding together
the numbers imprinted on the cylinder block and crankshaft,
then selecting the bearing with the same number as the to-
tal. There are five sizes of standard bearings, marked ”1 ”,
”2”, ”3”, ”4” and ”5” accordingly.

(h) Install the main bearing caps.

(See step 4 on page

EM–298

)

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

NOTICE: Do not turn the crankshaft.

EXAMPLE: Cylinder block ”2” + Crankshaft ”1 ”

= Bearing ”3”

(i) Remove the main bearing caps.

(See procedure (a) and (b) above)

Cylinder block

Number marked

Crankshaft

Bearing

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ENGINE MECHANICAL

Cylinder Block (5S–FE)

EM–283

(Reference)

Cylinder block main journal bore diameter:

Mark ”1 ”

59.020 – 59.026 mm

(2.3236 – 2.3239 in.)

Mark ”2”

59.026 – 59.032 mm

(2.3239 – 2.3241 in.)

Mark ”3”

59.032 – 59.038 mm

(2.3241 – 2.3243 in.)

Crankshaft journal diameter:

Mark ”0”

54. 998 – 55.003 mm

(2.1653 – 2.1655 in.)

Mark ”’1”

54.993 – 54.998 mm

(2.1651 – 2.1653 in.)

Mark ”2”

54.988 – 54.993 mm

(2.1649 – 2.1651 in.)

Standard sized bearing center wall thickness:

No.3

Mark ”’1”

1. 992 – 1. 995 mm

(0 .0784 – 0.0785 in.)

Mark ”2”

1.995 – 1.998 mm

(0.0785 – 0.0787 in.)

Mark ”3”

1. 998 – 2.001 mm

(0.0787 – 0.0788 in.)

Mark ”4”

2.001 – 2.004 mm

(0.0788 – 0.0789 in.)

Mark ”5”

2.004 – 2.007 mm

(0.0789 – 0.0790 in.)

Others

Mark ”1 ”

1.997 – 2.000 mm

(0.0786 – 0.0787 in.)

Mark ”2”

2.000 – 2.003 mm

(0.0787 – 0.0789 in.)

Mark ”3”

2.003 – 2.006 mm
(0–0789 – 0.0790 in.)

Mark ”4”

2.006 – 2.009 mm

(0.0790 – 0.0791 in.)

Mark ”5”

2.009 – 2.012 mm

(0.0791 – 0.0792 in.)

(k) Completely remove the Plastigage.

7. REMOVE CRANKSHAFT

(a) Lift out the crankshaft.
(b) Remove the upper bearings and upper thrust washers

from cylinder block.

HINT: Arrange the main bearing caps, bearings
and thrust washers in correct order.

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ENGINE MECHANICAL

Cylinder Block (5S–FE)

EM–284

INSPECTION OF CYLINDER BLOCK

1. CLEAN CYLINDER BLOCK
A. Remove gasket material

Using a gasket scraper, remove all the gasket material
from the surface contacting cylinder head.

B. Clean cylinder block

Using a soft brush and solvent, thoroughly clean the
cylinder block.

2. INSPECT TOP SURFACE OF CYLINDER BLOCK FOR

FLATNESS
Using a precision straight edge and feeler gauge, mea-
sure the surface contacting the cylinder head for
warpage.
Maximum warpage: 0.05 mm (0.0020 in.)
If warpage is greater than maximum, replace the cylin-
der block.

3. INSPECT CYLINDER FOR VERTICAL SCRATCHES

Visually check the cylinder for vertical scratches.
If deep scratches are present, rebore all the four cylin-
ders.
If necessary, replace the cylinder block.

4. INSPECT CYLINDER BORE DIAMETER

HINT: There are three sizes of the standard cylinder
bore diameter, marked ”1 ”, ”2” and ”3” accordingly. The
mark is stamped on the top of the cylinder block.

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ENGINE MECHANICAL

Cylinder Block (5S–FE)

EM–285

Using a cylinder gauge, measure the cylinder bore
diameter at positions A, B and C in the thrust and ax-
ial directions.
Standard diameter:

STD

Mark ”1 ”

87.000 – 87. 010 mm

(3.4252 – 3.4256 in.)

Mark ”2”

87.010 – 87.020 mm

(3.4256 – 3.4260 in.)

Mark ”3”

87.020 – 87.030 mm

(3.4260 – 3.4264 in.)

Maximum diameter:

STD 87.23mm(3.4342

in.)

O/S 0.50

87.73 mm (3.4350 in.)

If the diameter is greater than maximum, rebore all
the four cylinders. If necessary, replace the cylinder
block.

DISASSEMBLY OF PISTON AND
CONNECTING ROD ASSEMBLIES

1. CHECK FIT BETWEEN PISTON AND PISTON PIN

Try to move the piston back and forth on the piston
pin.
If any movement is felt, replace the piston and pin as a
set.

5. REMOVE CYLINDER RIDGE

^

If the wear is less than 0.2 mm (0.008 in.), using a
ridge reamer, grind the top of the cylinder.

2. REMOVE PISTON RINGS

(a) Using a piston ring expander, remove the two com-

pression rings.

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ENGINE MECHANICAL

Cylinder Block (5S–FE)

EM–286

HINT:

•

The piston and pin are a matched set.

•

Arrange the pistons, pins, rings, connecting
rods and bearings in correct order.

(b) Remove the two side rails and oil ring expander

by hand.

HINT: Arrange the rings in correct order only.

3. DISCONNECT CONNECTING ROD FROM PISTON

(a) Using a small screwdriver, pry out the two snap

rings.

(c) Using plastic–faced hammer and brass bar, lightly

tap out the piston pin and remove the connect-
ing rod .

(b) Gradually heat the piston to 80 – 90

В°

C (176 –

194

В°

F).

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ENGINE MECHANICAL

Cylinder Block (5S–FE)

EM–287

2. INSPECT PISTON
A. Inspect piston oil clearance

HINT: There are three sizes of the standard piston di-
ameter, marked ”1 ”, ”2” and ”3” accordingly. The mark
is stamped on the piston top.
(a) Using a micrometer, measure the piston diameter at

right angles to the piston pin center line, 23.5 mm
(0.925 in.) from the piston head.

Piston diameter:

STD

Mark ”1”

86.850 – 86.860 mm
(3.4193 – 3.4197 in.)

Mark ”2”

86.860 – 86.87 0 mm
(3.4197 – 3.4201 in.)

Mark ”3”

86.870 – 86.880 mm
(3.4201 – 3.4205 in.)

O/S 0.50

87.350 – 87.380 mm
(3.4390 – 3.4402 in.)

INSPECTION OF PISTON AND
CONNECTING ROD ASSEMBLIES

1. CLEAN PISTON

(a) Using a gasket scraper, remove the carbon from the

piston top.

(c) Using solvent and a brush, thoroughly clean the

piston.

NOTICE: Do not use a wire brush.

(b) Using a groove cleaning tool or broken ring,

clean the piston ring grooves.

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ENGINE MECHANICAL

Cylinder Block (5S–FE)

EM–288

(b) Measure the cylinder bore diameter in the thrust

directions.
(See step 4 on page

EM–286

)

(c) Subtract the piston diameter measurement from

the cylinder bore diameter measurement.
Standard oil clearance: 0.140 – 0.160 mm

(0.0055 – 0.0063 in.)

Maximum oil clearance: 0.18 mm (0.0071 in.)

If the oil clearance is greater than maximum, re-
place all the four pistons and rebore all the four
cylinders. If necessary, replace the cylinder block.
HINT (Use new cylinder block): Use a piston with
the same number mark as the cylinder bore diam-
eter marked on the cylinder block.

B. Inspect piston ring groove clearance

Using a feeler gauge, measure the clearance between
new piston ring and the wall of the piston ring groove.
Ring groove clearance:

No.10.040 – 0.080 mm. (0.0016 – 0.0031 in.)
No.20.030 – 0.070 mm (0.0012 – 0.0028 in.)

If the clearance is greater than maximum, replace the
piston.

C. Inspect piston ring end gap

(a) Insert the piston ring into the cylinder bore.
(b) Using a piston, push the piston ring a little beyond

the bottom of the ring travel, 115 mm (4.53 in.) from
the top of the cylinder block.

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ENGINE MECHANICAL

Cylinder Block (5S–FE)

EM–289