4A–FE engine is an in–line, 4–cylinder, 1.6 liter DOHC 16–valve engine. Manual - part 35

29. REMOVE FRONT EXHAUST PIPE

(a) Loosen the bolt, and disconnect the clamp from the

bracket.

(b) Remove the two bolts and nuts holding the front

exhaust pipe to the center exhaust pipe.

(c) Using a 14 mm deep socket wrench, remove the

three nuts holding the front exhaust pipe to the cata-
lytic converter.

(d) Disconnect the support hook on the front exhaust

pipe from the support bracket, and remove the front
exhaust pipe and two gaskets.

30. (A/T)

DISCONNECT TRANSAXLE CONTROL CABLE FROM
ENGINE MOUNTING CENTER MEMBER

31. REMOVE DRIVE SHAFTS (See SA section)

32. (w/ A/C)

REMOVE A/C COMPRESSOR WITHOUT
DISCONNECTING HOSES
(a) Disconnect the A/C compressor connector.
(b) Remove the drive belt.
(c) Remove the three bolts, and disconnect the A/C
compressor.
HINT: Put aside the compressor, and suspend it to the
radiator support with a string.

33. REMOVE PS PUMP WITHOUT DISCONNECTING

HOSES
(a) Disconnect the two air hoses from the air pipe.
(b) Remove the PS drive belt.
(c) Remove the four bolts, and disconnect the PS pump

from the engine.

HINT: Put aside the pump and suspend it to the cowl
with a string.

28. REMOVE SUSPENSION LOWER CROSSM EM BER

Remove the four bolts, two nuts and lower crossmem-
ber.

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ENGINE MECHANICAL

Cylinder Block (5S–FE)

EM–274

35. REMOVE FRONT ENGINE MOUNTING INSULATOR

AND BRACKET
(a) Remove the through bolt, nut and mounting insulator.
(b) Remove the two bolts and mounting bracket.

37. REMOVE CONNECTOR FROM GROUND WIRE ON RH

FENDER APRON

38. REMOVE RH ENGINE MOUNTING STAY

Remove the bolt, nut and mounting stay.

39. REMOVE LH ENGINE MOUNTING STAY

(M/T)
(a) Remove the two nuts and mounting stay.
(b) Remove the bolt, and disconnect the ground strap.

36. REMOVE REAR ENGINE MOUNTING INSULATOR

AND BRACKET
(a) Remove the through bolt and mounting insulator.
(b) Remove the three bolts and mounting bracket.

34. REMOVE ENGINE MOUNTING CENTER MEMBER

Remove the eight bolts and center member.

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ENGINE MECHANICAL

Cylinder Block (5S–FE)

EM–275

40. REMOVE ENGINE AND TRANSAXLE ASSEMBLY

FROM VEHICLE
(a) Attach the engine chain hoist to the engine hangers.

(A/T)

(a) Remove the bolt, nut and mounting stay.
(b) Remove the bolt, and disconnect the ground

strap.

(c) Remove the three (M/T) or two (A/T) bolts and LH

mounting bracket.

(b) Remove the through bolt, four bolts and LH

mounting insulator.

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ENGINE MECHANICAL

Cylinder Block (5S–FE)

EM–276

(e) Lift the engine out of the vehicle slowly and care-

fully.

NOTICE: Be careful not to hit the PS gear hous-

ing or neutral start switch (A/T).

(f) Make sure the engine is clear of all wiring, hoses

and cables.

(g) Place the engine and transaxle assembly onto

the stand.

41. (A/T) REMOVE STARTER (See page 

ST–5

)

42. SEPARATE ENGINE AND TRANSAXLE

M/T (See MT section)
A/T (See AT section)

(d) Remove the through bolt, two nuts and RH

mounting insulator.

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ENGINE MECHANICAL

Cylinder Block (5S–FE)

EM–277

8. REMOVE RH ENGINE MOUNTING BRACKET

Remove the three bolts and mounting bracket.

9. REMOVE PS PUMP BRACKET

Remove the three bolts and PS pump bracket.

10. REMOVE TIMING BELT AND PULLEYS

(See pages 

EM–69

 to 73)

11. REMOVE CYLINDER HEAD

(See pages 

EM–151

 to 159)

12. REMOVE WATER PUMP AND ALTERNATOR

ADJUSTING BAR (See pages 

CO–12

 and 13)

13. REMOVE OIL PAN AND OIL PUMP

(See pages 

LU–17

 and 18)

14. REMOVE OIL FILTER (See page 

LU–7

)

15. (w/ OIL COOLER)

REMOVE OIL COOLER (See page 

LU–29

)

PREPARATION FOR DISASSEMBLY

1. (M /T)

REMOVE CLUTCH COVER AND DISC

2. (M/T)

REMOVE FLYWHEEL

3. (A/T)

REMOVE DRIVE PLATE

4. REMOVE REAR END PLATE

Remove the bolt and end plate.

5. INSTALL ENGINE TO ENGINE STAND FOR

DISASSEMBLY

6. REMOVE ALTERNATOR (See page 

CH–9

)

7. REMOVE DISTRIBUTOR (See page 

IG–31

)

16. REMOVE KNOCK SENSOR

Using SST, remove the knock sensor.
SST 09816–30010

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ENGINE MECHANICAL

Cylinder Block (5S–FE)

EM–278

2. CHECK CONNECTING ROD THRUST CLEARANCE

Using a dial indicator, measure the thrust clearance
while moving the connecting rod back and forth.
Standard thrust clearance: 0.160 – 0.312 mm

(0.0063 – 0.0123 in.)

Maximum thrust clearance: 0.35 mm (0.0138 in.)
If the thrust clearance is greater than maximum, re-
place the connecting rod assembly. If necessary, re-
place the crankshaft.

3. REMOVE CONNECTING ROD CAPS AND CHECK OIL

CLEARANCE
(a) Check the matchmarks on the connecting rod and

cap to ensure correct reassembly.

DISASSEMBLY OF CYLINDER BLOCK

(See page 

EM–268

)

1. REMOVE REAR OIL SEAL RETAINER

Remove the six bolts, retainer and gasket.

(c) Using a plastic–faced hammer, lightly tap the con-

necting rod bolts and lift off the connecting rod
cap.

HINT: Keep the lower bearing inserted with the
connecting cap.

(b) Using SST, remove the connecting rod cap nuts.
SST 09011–38121

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ENGINE MECHANICAL

Cylinder Block–(5S–FE)

EM–279

(e) Clean the crank pin and bearing.
(f) Check the crank pin and bearing for pitting and

scratches.

If the crank pin or bearing is damaged, replace the
bearings. If necessary, grind or replace the crank–
shaft.

(h) Install the connecting rod cap.

(See step 6 on pages 

EM–299

 and 300)

Torque: 1st 25 N–m (250 kgf–cm, 18 ft–lbf)

2nd Turn 90

°

NOTICE: Do not turn the crankshaft.

(d) Cover the connecting rod bolts with a short piece

of hose to protect the crankshaft from damage.

(i) Remove the connecting rod cap.

(See procedure (b) and (c) above)

(g) Lay a strip of Plastigage across the crank pin.

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ENGINE MECHANICAL

Cylinder Block (5S–FE)

EM–280

HINT: If using a standard bearing, replace it with one
having the same number marked on the connecting rod
cap. There are three sizes of standard bearings, marked
”1 ”, ”2” and ”3” accordingly.
(Reference)
Standard sized bearing center wall thickness:

Mark ”1” 

1.484 – 1.488 mm
(0–0584 – 0.0586 in.)

Mark ”2” 

1.488 – 1.492 mm

(0.0586 – 0.0587 in.)

Mark ”3” 

1.492 – 1.496 mm

(0.0587 – 0.0589 in.)

(k) Completely remove the Plastigage.

4. REMOVE PISTON AND CONNECTING ROD

ASSEMBLIES
(a) Using a ridge reamer, remove ail the carbon from the

top of the cylinder.

(b) Cover the connecting rod bolts.

(See page 

EM–280

)

(c) Push the piston, connecting rod assembly and upper bear-

ing through the top of the cylinder block.

(j) Measure the Plastigage at its widest point.

Standard oil clearance:

STD 

0.024 – 0.055 mm,

(0.0009 – 0.0022 in . )

U /S 0.25 

0.023 – 0.069 mm

(0.0009 – 0.0027 in.)

Maximum oil clearance: 0.08 mm (0.0031 in.)

If the oil clearance is greater than maximum, re-
place the bearings. If necessary, grind or replace
the crankshaft.

5. CHECK CRANKSHAFT THRUST CLEARANCE

Using a dial indicator, measure the thrust clearance
while
prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance: 0.020 – 0.220 mm

(0.0008 – 0.0087 in.)

Maximum thrust clearance: 0.30 mm (0.0118 in.
If the thrust clearance is greater than maximum, replace
the thrust washers as a set.
Thrust washer thickness: 2.440 – 2.490 mm

(0.0961 – 0.0980 in.)

HINT:

•

Keep the bearings, connecting rod and cap together.

•

Arrange the piston and connecting rod assemblies in cor-
rect order.

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ENGINE MECHANICAL

Cylinder Block (5S–FE)

EM–281