4A–FE engine is an in–line, 4–cylinder, 1.6 liter DOHC 16–valve engine. Manual - part 31

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

hand.

HINT: Arrange the rings in correct order only.

HINT:

•

The piston and pin are a matched set.

•

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

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, light-

ly tap out the piston pin and remove the con-
necting rod.

(b) Gradually heat the piston to 80 – 90

°

C (176 –

194

°

F).

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ENGINE MECHANICAL

Cylinder Block (3S–GTE)

EM–242

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, 30.1 mm
(1.185 in.) from the piston head.

Piston diameter:

Mark ”’1” 85–920 – 85.930 mm

(3–3827 – 3.3831 in.)

Mark ”2” 85–930 – 85 . 940 mm

(3–3831 – 3.3835 in.)

Mark ”3” 85.940 – 85.950 mm

(3.3835 – 3.3839 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 cleaner tool or broken ring, clean

the piston ring grooves.

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ENGINE MECHANICAL

Cylinder Block (3S–GTE)

EM–243

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.1 0.040 – 0.080 mm

(0.0016 – 0.0031 in.)

No.2  0.030 – 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, 100 mm (3.94 in.) from
the top of the cylinder block.

(b) Measure the cylinder bore diameter in the thrust

directions. (See step 4 on page 

EM–241

)

(c) Subtract the piston diameter measurement from

the cylinder bore diameter measurement.

Standard oil clearance: 0.070 – 0.090 mm 

(0.0028 – 0.0035 in.)

 Maximum oil clearance: 0.110 mm (0.0043 in.)
If the oil clearance is greater than maximum, re-
place all the four pistons. If necessary, replace the
cylinder block.
HINT (Use new cylinder block): Use a piston with
the same number mark as the cylinder bore diame-
ter marked on the cylinder block.

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ENGINE MECHANICAL

Cylinder Block (3S–GTE)

EM–244

A. Inspect connecting rod alignment

Using rod aligner and feeler gauge, check the connect-
ing rod alignment.

•

Check for bending.

Maximum bending:

0.05 mm (0.0020 in.) per 100 mm (3.94 in.)

If bend is greater than maximum, replace the connecting
rod assembly.

•

Check for twist.

Maximum twist:

0.15 mm (0.0059 in.) per 100 mm (3.94 in.)

If twist is greater than maximum, replace the connecting
rod assembly.

(c) Using a feeler gauge, measure the end gap.
Standard end gap:

No.1 

0.330 – 0.550 mm
(0.0130 – 0.0217 in.)

No.2 

0.450 – 0.670 mm
(0.0177 – 0.0264 in.)

Oil (Side rail) 0.200 – 0.600 mm

(0.0079 – 0.0236 in.)

Maximum end gap:
No.1 

0.85 mm (0.0335 in.)

No. 2 

0.97 mm (0.0382 in.)

Oil (Side rail) 0.90 mm (0.0354 in.)

If the end gap is greater than maximum, replace
the piston ring. If the end gap is greater than maxi-
mum, even with a new piston ring, replace the cyl-
inder block.

D. Inspect piston pin fit

At 60

°

C (140

°

F), you should be able to push the piston

pin into the piston pin hole with your thumb.

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ENGINE MECHANICAL

Cylinder Block (3S–GTE)

EM–245

(c) Subtract the piston pin diameter measurement from

the bushing inside diameter measurement.

Standard oil clearance: 0.005 – 0.011 mm

(0.0002 – 0.0004 in.)

Maximum oil clearance: 0.05 mm (0.0020 in.)
If the oil clearance is greater than maximum, replace
the bushing. If necessary, replace the piston and piston
pin as a set.

B. Inspect piston pin oil clearance

(a) Using a caliper gauge, measure the inside diameter

of the connecting rod bushing.

Bushing inside diameter: 22.005 – 22.017 mm

(0.8663 – 0.8668 in.)

(b) Align the oil holes of a new bushing and the con-

necting rod.

(c) Using SST and a press, press in the bushing.
SST 09222–30010

(b) Using a micrometer, measure the piston pin di-

ameter.
Piston pin diameter: 21.997 – 22.009 mm

(0.8660 – 0.8665 in.)

C. If necessary, replace connecting rod bushing

(a) Using SST and a press, press out the bushing.
SST 09222–30010

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ENGINE MECHANICAL

Cylinder Block (3S–GTE)

EM–246

(d) Using a pin hole grinder, hone the bushing to ob-

tain the standard specified clearance (see step
B above) between the bushing and piston pin.

(e) Check the piston pin fit at normal room tempera-

ture. Coat the piston pin with engine oil, and
push it into the connecting rod with your thumb.

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ENGINE MECHANICAL

Cylinder Block (3S–GTE)

EM–247

2. INSPECT MAIN JOURNALS AND CRANK PINS

(a) Using a micrometer, measure the diameter of each

main journal and crank pin.

Main journal diameter:

STD 

54.988 – 55.003 mm
(2.1653 – 2.1655 in.)

U/S 0.25  54.745 – 54.755 mm

(2.1553 – 2.1557 in.)

Crank pin diameter:

STD 

47.985 – 48.000 mm
(1.8892 –1.8898 in.)

U /S 0.25  47.745 – 47.755 mm

(1.8797 – 1.8801 in.)
If the diameter is not as specified, check the oil clearance
(See pages 

EM–234

 to 238). If necessary, grind or replace

the crankshaft.
(b) Check each main journal and crank pin for taper and out–

of–round as shown.

Maximum taper and out–of–round: 0.02 mm (0.0008 in.)
If the taper and out–of–round is greater than maximum, r
place the crankshaft.

3. IF NECESSARY, GRIND AND HONE MAIN JOURNALS AND/

OR CRANK PINS
Grind and hone the main journals and/or crank pins to the
finished undersized diameter (See procedure step 2).
Install new main journal and/or crank pin undersized bear-
ings.

INSPECTION AND REPAIR OF CRANKSHAFT

1. INSPECT CRANKSHAFT FOR RUNOUT

(a) Place the crankshaft on V–blocks.
(b) Using a dial indicator, measure the circle runout at

the center journal.

Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the crank-
shaft.

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ENGINE MECHANICAL

Cylinder Block (3S–GTE)

EM–248

B. If oil pump is installed to the cylinder block:

(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver, pry out the oil seal.
NOTICE: Be careful not to damage the crankshaft.

Tape the screwdriver tip.

(c) Apply MP grease to a new oil seal lip.
(d) Using SST and a hammer, tap in the oil seal until

its surface is flush with the oil pump case edge.

SST 09226–10010

(b) Using SST and a hammer, tap in a new oil seal until

its surface is flush with the oil pump case edge.

SST 09226–10010
(c) Apply MP grease to the oil seal lip.

1. REPLACE CRANKSHAFT FRONT OIL SEAL
A. If oil pump is removed from cylinder block:

(a) Using screwdriver and hammer, tap out the oil seal.

REPLACEMENT OF CRANKSHAFT
OIL SEALS

HINT: There are two methods (A and B) to replace
the oil seal which are as follows:

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ENGINE MECHANICAL

Cylinder Block (3S–GTE)

EM–249