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.)

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

C (176

– 212

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.

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

(176– 212

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

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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.

(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

. _
–
, . r

•

, I , ‘’

8.0 – 8 8 mm
;
1
Snap
Ring

Exhaust

Length

Intake

EM2534

P03366

SST

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ENGINE MECHANICAL

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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.

•

If blue appears 360

around the face, the

valve is concentric. If not, replace the
valve.

•

If blue appears 360

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

and 45

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

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

and 45

cutters to correct the seat.

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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.

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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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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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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