4A–FE engine is an in–line, 4–cylinder, 1.6 liter DOHC 16–valve engine. Manual - part 3

 

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4A–FE engine is an in–line, 4–cylinder, 1.6 liter DOHC 16–valve engine. Manual - part 3

 

 

(b) Determine the replacement adjusting shim size by

following the Formula or Charts:

•

Using a micrometer, measure the thickness of the
removed shim.

•

Calculate the thickness of a new shim so that the
valve clearance comes within the specified value.
T .......... Thickness of used shim
A .......... Measured valve clearance
N .......... Thickness of new shim

Intake N = T + (A – 0.20 mm (0.008 in.))

Exhaust N = T + (A – 0.33 mm (0.013 in.))

•

Select a new shim with a thickness as close as
possible to the calculated value.

HINT: Shims are available in seventeen sizes in increments
of 0.05 mm (0.0020 in.), from 2.50 mm (0.0984 in.)
to 3.30 mm (0.1299 in.)

9. ADJUST VALVE CLEARANCE

(a) Remove the adjusting shim.

•

Turn the crankshaft to position the cam lobe of
the camshaft on the adjusting valve upward.

•

Position the notch of the valve lifter facing the
spark plug side.

•

Using SST (A), press down the valve lifter and
place SST (B) between the camshaft and valve
lifter. Remove SST (A).

SST 09248–55020 (09248–05011 (A), 09248–05021 (B))
HINT: Apply SST (B) at a slight angle on the side
marked with ”7”, at the position shown in the illustration.

•

Remove the adjusting  shim with
small screwdriver and magnetic fin-
ger.

–

ENGINE MECHANICAL

Engine Tune–Up

EM–18

10. REINSTALL CYLINDER HEAD COVER

(See step 7 on pages 

EM–143

 and 144)

11. REINSTALL THROTTLE BODY

(See steps 2, 3, 5 to 8, 10 and 11 on pages 

FI–197

 and

198)

12. REINSTALL EGR VALVE AND PIPE

(See step 19 on page 

EM–145

)

13. REINSTALL EGR VACUUM MODULATOR AND VSV

(See step 20 on page 

EM–146

)

14. RECONNECT HIGH–TENSION CORDS TO SPARK

PLUGS

15. REINSTALL INTERCOOLER

(See steps 11 to 13 on page 

TC–17

)

(c) Install a new adjusting shim.

•

Place a new adjusting shim on the valve lifter.

•

Using SST (A), press down the valve lifter and
remove SST (B).
SST 09248–55020 (09248–05011 (A), 09248–05021 (B))

(d) Recheck the valve clearance.

–

ENGINE MECHANICAL

Engine Tune–Up

EM–19

Intake valve clearance (Cold): 0.15 – 0.25 mm (0.006 – 0.010 in.)
EXAMPLE: The 2.800 mm (0.1 102 in.) shim is installed, and the
measured clearance is 0.450 mm (0.0177 in.). Replace the 2.800 mm
(0.1 102 in.) shim with a new No. 12 shim.

Adjusting Shim Selection Chart (Intake)

New shim thickness

2.900 (0.1142)

3.150 (0.1240)

3.000 (0–1181)

2.500 (0.0984)

3.200 (0.1260)

3.300 (0.1299)

2.800 (0.1102)

2.750 (0.1083)

3.250 (0.1280)

2.700 (0.1063)

2.550 (0.1004)

3.100 (0.1220)

3.050 (0.1201)

2.950 (0.1161)

2.600 (0.1024)

2.850 (0.1122)

2.650 (0.1043)

Thickness

Thickness

Shim

No.

Shim

No.

mm (in.)

HINT: New shims have the thickness in
millimeters imprinted on the face.

–

ENGINE MECHANICAL

Engine Tune–Up

EM–20

Exhaust valve clearance (Cold): 0.28 – 0.38 mm (0.011 – 0.015 in.)
EXAMPLE: The 2.800 mm (0.1 102 in.) shim is installed, and the mea-
sured clearance is 0.450 mm (0.0177 in.). Replace the 2.800 mm
(0.1102 in.) shim with a new No.9 shim.

Adjusting Shim Selection Chart (Exhaust)

New shim thickness

3.300 (0.1299)

3.150 (0.1240)

2.850 (0. 1122)

3.050 (0.1201)

2.500 (0.0984)

2.950 (0.1161)

2.900 (0.1142)

3.100 (0.1220)

2.800 (0.1102)

2.700 (0.1063)

2.550 (0.1004)

2.650 (0.1043)

3.000 (0–1181)

3.250 (0.1280)

3.200 (0.1260)

2.600 (0.1024)

2.750 (0.1083)

Thickness

Thickness

Shim

No.

Shim

No.

mm (in.)

DI Z7

HINT: New shims have the thickness in
millimeters imprinted on the face.

–

ENGINE MECHANICAL

Engine Tune–Up

EM–21

INSPECTION AND ADJUSTMENT OF
VALVE
CLEARANCE (5S–FE)

HINT: Inspect and adjust the valve clearance when the
engine is cold.

1. REMOVE ACCELERATOR BRACKET
2. DISCONNECT HIGH–TENSION CORDS FROM SPARK

PLUGS

3. DISCONNECT ENGINE WIRE PROTECTOR BETWEEN

CYLINDER HEAD COVER AND NO.3 TIMING BELT
COVER

4. REMOVE CYLINDER HEAD COVER

(See step 33 on page 

EM–156

)

5. SET NO.1 CYLINDER TO TDC/COMPRESSION

(a) Turn the crankshaft pulley and align its groove with

timing mark ”0” of the No.1 timing belt cover.

(b) Check that the valve lifters on the No.1 cylinder are

loose and valve lifters on the No.4 are tight.

If not, turn the crankshaft one revolution (360

°

) and

align
the mark as above.

6. INSPECT VALVE CLEARANCE

(a) Check only the valves indicated.

•

Using a feeler gauge, measure the clearance
between the valve lifter and camshaft.

•

Record the out–of–specification valve clear-
ance
measurements. They will be used later to deter-
mine the required replacement adjusting shim.

Valve clearance (Cold):

Intake 0.19 – 0.29 mm (0.007 – 0.011 in.)

Exhaust 0.28 – 0.38 mm (0.011 – 0.015 in.)

(b) Turn the crankshaft one revolution (360

°

) and align

the mark as above. (See procedure in step 3)

(c) Check only the valves indicated as shown. Measure

the valve clearance. (See procedure in step (a))

7. ADJUST VALVE CLEARANCE

(a) Remove the adjusting shim.

•

Turn the crankshaft to position the cam lobe of
the camshaft on the adjusting valve upward.
Position the notch of the valve lifter facing the
spark plug side.

–

ENGINE MECHANICAL

Engine Tune–Up

EM–22

(b) Determine the replacement adjusting shim size by

following the Formula or Charts:

•

Using a micrometer, measure the thickness of the
removed shim.

•

Calculate the thickness of a new shim so that the
valve clearance comes within specified value.
T ............... Thickness of used shim
A ............... Measured valve clearance
N ............... Thickness of new shim

Intake N = T + (A – 0.24 mm (0.009 in.))

Exhaust N = T + (A – 0.33 mm (0.013 in.))

•

Select a new shim with a thickness as close as
possible to the calculated value.

HINT: Shims are available in seventeen sizes in incre-
ments of 0.05 mm (0.0020 in.), from 2.50 mm (0.0984
in.) to 3.30 mm (0.1299 in.).
(c) Install a new adjusting shim.

•

Place a new adjusting shim on the valve lifter.

•

Using SST (A), press down the valve lifter and
remove SST (13).

SST 09248–55020 (09248–05011 (A), 09248–05021 (B))
(d) Recheck the valve clearance.

8. REINSTALL CYLINDER HEAD COVER

(See step 8 on page 

EM–178

)

9. INSTALL ENGINE WIRE PROTECTOR BETWEEN

CYLINDER HEAD COVER AND NO.3 TIMING BELT
COVER

10. RECONNECT HIGH–TENSION CORDS TO SPARK

PLUGS

11. INSTALL ACCELERATOR BRACKET

•

Using SST (A), press down the valve lifter and
place SST (B) between the camshaft and valve
lifter. Remove SST (A).

SST 09248–55020 (09248–05011 (A), 09248–05021 (B))
HINT: Apply SST (B) at a slight angle on the side
marked with ”9”, at the position shown in the illustration.

•

Remove the adjusting shim with small
screwdriver and magnetic finger.

–

ENGINE MECHANICAL

Engine Tune–Up

EM–23

Intake valve clearance (Cold):
0.19 – 0.29 mm (0.007 – 0.011 in.)
EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed,
and the measured clearance is 0.450 mm (0.0177 in.).
Replace the 2.800 mm
(0.1102 in.) shim with a new No. 11 shim.

–

ENGINE

 MECHANICAL

E

n

g

in

e

 T

une–Up

EM–24

Intake valve clearance (Cold):
0.28 – 0.38 mm (0.011 – 0.015 in.)
EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed,
and the measured clearance is 0.450 mm (0.0177 in.).
Replace the 2.800 mm
(0.1102 in.) shim with a new No.9 shim.

–

ENGINE

 MECHANICAL

E

n

g

in

e

 T

une–Up

EM–25

 

 

 

 

 

 

 

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