4A–FE engine is an in–line, 4–cylinder, 1.6 liter DOHC 16–valve engine. Manual - part 8

13. INSTALL TIMING BELT TENSIONER

(a) Turn the No.1 idler pulley bolt counterclockwise to

obtain the specified torque toward the left as far as
the No.1 idler pulley will go, and temporarily install
the tensioner with the two bolts.

Torque: 18 N–m (180 kgf–cm, 13 ft–lbf)

NOTICE: To apply the correct torque, apply the
torque wrench along the axis through the bolts of the

No.1 idler pulley and exhaust camshaft timing pulley.

12. SET TIMING BELT TENSIONER

(a) Using a press, slowly press in the push rod using

100 –1,000 kg (220 – 2,205 Ib, 981 – 9,807 N) of
pressure.

(b) Align the holes of the push rod and housing, pass a

1.27 mm hexagon wrench through the holes to keep
the setting position of the push rod.

(c) Release the press.

(a) Remove any oil or water on the camshaft timing

pulley, and keep it clean.

(b) Install the timing belt, checking the tension between

the crankshaft timing pulley and intake camshaft
timing pulley.

(b) Slowly turn the crankshaft pulley 5/6 revolution,

and align its groove with the ATDC 60

°

 mark of the

No.1 timing belt cover.

NOTICE: Always turn the crankshaft clockwise.

•

Align the matchmarks of the timing belt and camshaft
timing pulleys.

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ENGINE MECHANICAL

Timing Belt (3S–GTE)

EM–58

(c) Insert a 1.90 mm (0.075 in.) feeler gauge between

the tensioner body and No.1 idler pulley stopper.

(d) Turn the No.1 idler pulley bolt counterclockwise to

obtain the specified torque.

Torque: 18 N–m (180 kgf–cm, 13 ft–lbf)

NOTICE: To apply the correct torque, apply the torque

wrench along the axis through the bolts of the No.1

idler pulley and exhaust camshaft timing pulley.

(e) While pushing the tensioner, alternately tighten the

two bolts.

Torque: 21 N–m (210 kgf–cm, 15 ft–lbf)

(f) Remove the 1.90 mm (0.075 in.) feeler gauge.
(g) Remove the 1.27 mm hexagon wrench from the

tensioner.

(i) Using a feeler gauge, check the specified clearance

between the tensioner body and No.1 idler pulley
stopper.

Clearance: 1.80 – 2.20 mm (0.071 – 0.087 in.)

If the clearance is not as specified, remove the tensioner
and reinstall it.

14. CHECK VALVE TIMING

(a) Slowly turn the crankshaft pulley two revolutions

from TDC to TDC.

NOTICE: Always turn the crankshaft clockwise.

(h) Slowly turn the crankshaft pulley one revolution,

and align its groove with the ATDC 60

°

 mark of

the
No.1 timing belt cover.

NOTICE: Always turn the crankshaft clockwise.

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ENGINE MECHANICAL

Timing Belt (3S–GTE)

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15. INSTALL NO.2 TIMING BELT COVER

(a) Install the gasket to the timing belt cover.
(b) Install the belt cover with the five bolts.

16. INSTALL SPARK PLUGS (See page 

IG–13

)

Torque: 18 N–m (180 kgf–cm, 13 ft–lbf)

17. INSTALL CYLINDER HEAD COVER

(a) Install the cylinder head cover.

(See step 7 on pages 

EM–143

 and 144)

(b) Install the engine wire protector between the

cylinder head cover and No.3 timing belt cover.

19. INSTALL RH ENGINE MOUNTING INSULATOR

Install the mounting insulator with the through bolt and
two nuts.
Torque:

Nut 

52 N–m (530 kgf–cm, 38 ft–lbf)

Through bolt 

87 N–m (890 kgf–cm, 64 ft–lbf)

(b) Check that each pulley aligns with the timing marks

as shown in the illustration.
If the marks do not align, remove the timing belt and
reinstall it.

18. INSTALL RH ENGINE MOUNTING BRACKET

Install the mounting bracket with the three bolts.
Torque: 52 N–m (530 kgf–cm, 38 ft–lbf )

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ENGINE MECHANICAL

Timing Belt (3S–GTE)

EM–60

22. INSTALL THROTTLE BODY

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

FI–197

 and

198)

23. INSTALL EGR VALVE AND PIPE

(See step 19 on page 

EM–145

)

24. INSTALL EGR VACUUM MODULATOR AND VSV

(See step 20 on page 

EM–146

)

25. INSTALL INTERCOOLER

(See steps 11 to 13 on page 

TC–17

)

26. INSTALL ALTERNATOR (See page 

CH–23

)

27. INSTALL RH ENGINE UNDER COVER
28. CONNECT CABLE TO NEGATIVE TERMINAL OF

BATTERY

29. CHECK AND ADJUST DRIVE BELTS

(a) Adjust the alternator drive belt.
Drive belt tension:

w/ A/C 

New belt 

165

 

10 lbf

Used belt 

84

 

15 lbf

w/o A/C 

New belt 

150

 

25 lbf

Used belt 

130

 

20 lbf

(b) Adjust the PS drive belt.
Drive belt tension: New belt 

125 

±

 25 lbf

Used belt  80 

±

 20 lbf

30. INSTALL RH FRONT WHEEL

20. INSTALL RH ENGINE MOUNTING STAY

Install the mounting stay with the bolt and nut.
Torque: 73 N–m (740 kgf–cm, 54 ft–lbf)

21. INSTALL PS DRIVE BELT

Install the drive belt with the pivot bolt and adjusting
bolt.

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ENGINE MECHANICAL

Timing Belt (3S–GTE)

EM–61

ADJUSTMENT OF VALVE TIMING

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. REMOVE RH FRONT WHEEL
3. REMOVE RH ENGINE UNDER COVER
4. REMOVE ALTERNATOR (See page 

CH–7

)

5. REMOVE INTERCOOLER

(See steps 13 to 15 on pages 

TC–9

 and 10)

6. REMOVE SPARK PLUGS
7. REMOVE NO.2 TIMING BELT COVER

(See step 16 on page 

EM–48

)

•

If there is more than one timing pulley tooth be-
tween the timing marks, realign the timing marks
in accordance with step 13.

•

If the timing marks are aligned or the difference is
less than one timing pulley tooth, proceed to step
14.

8. CHECK CAMSHAFT TIMING PULLEY MARKS

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

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

NOTICE: Always turn the crankshaft clockwise.

(b) Check that the timing marks of the camshaft timing

pulleys are aligned with the timing mark of the No.3
timing belt cover.

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Timing Belt (3S–GTE)

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9. REMOVE EGR VACUUM MODULATOR AND VSV

(See step 20 on page 

EM–121

)

10. REMOVE EGR VALVE AND PIPE

(See step 21 on page 

EM–121

)

11. REMOVE THROTTLE BODY

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

FI–194

 and

195)

12. REMOVE CYLINDER HEAD COVER

(See step 33 on page. 

EM–124

)

(d) Reinstall the timing belt, checking the tension be-

tween the crankshaft timing pulley and intake
camshaft timing pulley.

NOTICE: Install the timing belt when the engine is

cold.

13. ADJUST CAMSHAFT TIMING PULLEY TIMING

MARKS
(a) Remove the two bolts and timing belt tensioner.

(c) Rotate the camshaft with a wrench and align the

alignment marks of the camshaft timing pulley and
No.3 timing belt cover.

(b) Remove the timing belt from the camshaft timing

pulleys.

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ENGINE MECHANICAL

Timing Belt (3S–GTE)

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(b) Next make a note of the crankshaft pulley angle on

the No.1 timing belt cover.

HINT: Perform this check separately for the intake and
exhaust sides.
If the crankshaft pulley movement is within 

 

 2.4 mm

(0.094 in.) of TDC, it is correct.
If it is greater than 2.4 mm (0:094 in.), go back to step 11.

14. CHECK VALVE TIMING

(a) Using a wrench, turn and align the groove of the

camshaft with the drilled mark of the No.1 camshaft
bearing cap.

NOTICE: Always turn the crankshaft clockwise.

(e) Install the timing belt tensioner with the two bolts.

(See steps 12 and 13 on page 

EM–58

)

Torque: 21 N–m (210 kgf–cm, 15 ft–lbf)

(f) Turn the crankshaft pulley two revolutions from

TDC to TDC.

NOTICE: Always turn the crankshaft clockwise.

(g) Check that each pulley aligns with the timing marks

as shown in the illustration.

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ENGINE MECHANICAL

Timing Belt (3S–GTE)

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(e) Select one overlapped hole of the camshaft and timing

pulley, and insert the match pin into it.

HINT:

•

If there is not an overlapped hole, rotate the crankshaft
a little and insert the pin into the nearly overlapped
hole.

•

By changing the pin hole to the next one, the
crankshaft pulley angle can be adjusted by approx. 2

°

.

•

By changing the pin hole to the next two, the
crankshaft pulley angle can be adjusted by approx. 5

°

.

15. ADJUST VALVE TIMING

(a) Hold the hexagon wrench head portion of the

camshaft with a wrench, and remove the two
camshaft timing pulley bolts.

HINT (Intake camshaft timing pulley): Use SST.
SST 09249–63010
NOTICE: Do not make use of the timing belt tension

when loosening the pulley bolts.

(d) Turn the crankshaft pulley, and align its groove with

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

NOTICE: Always turn the crankshaft clockwise.

(b) Check that the camshaft grooves are aligned with

the drilled mark of the No.1 camshaft bearing cap.

(c) Using a magnetic finger, remove the knock pin from

the pin hole of the camshaft timing pulley.

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ENGINE MECHANICAL

Timing Belt (3S–GTE)

EM–65