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4A–FE engine is an in–line, 4–cylinder, 1.6 liter DOHC 16–valve engine. Manual - part 19

21. INSTALL LH ENGINE HANGER

Install the LH engine hanger and reservoir tank with the
two bolts. Alternately tighten the bolts.
Torque:

12 mm head bolt 19 N–m (195 kgf–cm, 14 ft–lbf)

14 mm head bolt 39 N–m (400 kgf–cm, 29 ft–lbf)

23. CONNECT HOSES

(a) Brake booster vacuum hose to intake manifold
(b) Turbocharging pressure sensor hose to intake man-

ifold

(b) Connect the following hoses:

(1) Vacuum hose to EGR valve
(2) Vacuum hose to EGR vacuum modulator

20. INSTALL EGR VACUUM MODULATOR AND VSV

(a) Install the EGR vacuum modulator and VSV assembly

with the bolt.

22. INSTALL NO.2 AIR TUBE

(a) Install the air tube with the bolt.
(b) Connect the air hose to the No.1 air tube.

–

ENGINE MECHANICAL

Cylinder Head (3S–GTE)

EM–146

26. INSTALL COLD START INJECTOR

(See steps 1 to 3 on page

FI–148

)

27. INSTALL THROTTLE BODY

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

FI–197

and 198)

28. INSTALL TURBOCHARGER

(See steps 5 to 10 on pages

TC–15

to 17)

(b) Install a new gasket and the exhaust manifold

with the nine nuts. Uniformly tighten the nuts in
several passes.

Torque: 52 N–m (530 kgf–cm, 38 ft–lbf)

29. INSTALL CATALYTIC CONVERTER

(a) Install the front heat insulator with the five bolts.
(b) Install the rear heat insulator with the four bolts.

25. INSTALL EXHAUST MANIFOLD

(a) Install the heat insulator with the bolt and nut.

24. INSTALL DISTRIBUTOR (See page

IG–28

)

–

ENGINE MECHANICAL

Cylinder Head (3S–GTE)

EM–147

30. INSTALL NO.1 ALTERNATOR BRACKET AND RH

FRONT ENGINE HANGER

Install the alternator bracket and engine hanger with the
three bolts.
Torque: 39 N–m (400 kgf–cm, 29 ft–lbf)

(e) Install the RH converter stay with the four bolts.

Alternately tighten the bolts.

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

(f) Install the LH converter stay with the three bolts.

Alternately tighten the bolts.

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

(d) Install the catalytic converter with the three bolts

and two nuts.

Torque: 29 N–m (300 kgf–cm, 22 ft–lbf)

the catalytic converter.

–

ENGINE MECHANICAL

Cylinder Head (3S–GTE)

EM–148

31. INSTALL FRONT EXHAUST PIPE

(See step 18 on page

EM–261

)

32. INSTALL SUSPENSION LOWER CROSSMEMBER

(See step 19 on page

EM–262

)

33. INSTALL ALTERNATOR (See page

CH–23

)

34. INSTALL INTERCOOLER

(See steps 11 to 13 on page

TC–17

)

35. INSTALL AIR CLEANER CAP

(See step 44 on page

EM–117

)

36. INSTALL ACCELERATOR CABLE, AND ADJUST IT
37. FILL WITH ENGINE COOLANT (See page

CO–6

)

Capacity (w/ Heater):

6.5 liters (6.9 US qts, 5.7 Imp. qts)

38. START ENGINE AND CHECK FOR LEAKS
39. ADJUST IGNITION TIMING (See page

IG–29

)

Ignition timing:

BTDC @ idle

(w/ Terminals TO and E1 connected)

40. PERFORM ROAD TEST

Check for abnormal noise, shock, slippage, correct shift
points and smooth operation.

41. RECHECK ENGINE COOLANT AND OIL LEVELS

–

ENGINE MECHANICAL

Cylinder Head (3S–GTE)

EM–149

CYLINDER HEAD (5S–FE)

COMPONENTS

–

ENGINE MECHANICAL

Cylinder Head (5S–FE)

EM–150

REMOVAL OF CYLINDER HEAD

(See page

EM–150

)

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. DRAIN ENGINE COOLANT (See page

CO–6

)

3. (A/T)

.DISCONNECT THROTTLE CABLE FROM THROTTLE
BODY

4. DISCONNECT ACCELERATOR CABLE FROM

THROTTLE BODY

5. (w/ CRUISE CONTROL SYSTEM)

REMOVE CRUISE CONTROL ACTUATOR
(See step 11 on page

EM–270

)

6. REMOVE AIR CLEANER CAP

(See step 6 on page

EM–269

)

7. REMOVE ALTERNATOR (See page

CH–9

)

8. REMOVE DISTRIBUTOR (See page

IG–30

)

9. REMOVE ENGINE UNDER COVERS
10. REMOVE SUSPENSION LOWER CROSSMEMBER

(See step 28 on page

EM–274

)

11. REMOVE FRONT EXHAUST PIPE

(See step 29 on page

EM–274

)

12. REMOVE OXYGEN SENSOR (MAIN)
13. (CALIF. ONLY)

REMOVE SUB–OXYGEN SENSOR

14. REMOVE EXHAUST MANIFOLD AND CATALYTIC

CONVERTER ASSEMBLY
(a) Remove the six bolts and manifold upper heat

insulator.

–

ENGINE MECHANICAL

Cylinder Head (5S–FE)

EM–151

16. REMOVE WATER OUTLET

(a) Disconnect the following connectors:

•

Water temperature sender gauge connector

•

Water temperature sensor connector

(b) Disconnect the following hoses:

(1) Upper radiator hose
(2) Water by–pass pipe hose
(3) Heater water hose
(4) ISC water by–pass hose
(5) Two EVAP BVSV vacuum hoses

15. SEPARATE EXHAUST MANIFOLD AND CATALYTIC

CONVERTER
(a) Remove the five bolts and lower manifold heat insula-

tor.

(b) Remove the eight bolts and two catalytic converter

heat insulator.

verter, gasket, retainer and cushion.

(b) Remove the two bolts, two nuts and catalytic

converter stay.

–

ENGINE MECHANICAL

Cylinder Head (5S–FE)

EM–152

19. REMOVE EGR VALVE AND VACUUM MODULATOR

(a) (CALIF. only)

Disconnect EGR gas temperature sensor connector,
and disconnect the connector from the bracket.

(b) Remove the following hoses:

(1) Two vacuum hoses from EGR VSV
(2) Vacuum hose from charcoal canister

bracket.

17. REMOVE WATER BY–PASS PIPE

(a) (w/ Oil Cooler)

Remove the water by–pass hose heat protector.
(See step 8 on page

LU–29

)

(b) Disconnect the following hoses:

(1) ISC water by–pass hose
(2) Heater water hose
(3) (w/ Oil Cooler)

Two oil cooler water by–pass hoses

and gasket.

(d) Remove the O–ring from the water by–pass hose.

18. REMOVE THROTTLE BODY

(See steps 6 to 9 on pages

FI–201

and 202)

(d) Loosen the union nut of the EGR pipe, and re-

move two nuts the EGR valve, vacuum modula-
tor, vacuum hoses assembly and gasket.

–

ENGINE MECHANICAL

Cylinder Head (5S–FE)

EM–153

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