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4A–FE engine is an in–line, 4–cylinder, 1.6 liter DOHC 16–valve engine. Manual - part 14

(f) Apply a light coat of engine oil on the threads and

under the heads of the bearing cap bolts.

(g) Install and uniformly tighten the ten bearing cap

bolts in several passes in the sequence shown.

Torque: 13 N–m (130 kgf–cm, 9 ft–lbf)

B. Install intake camshaft

(a) Set the intake camshaft so the knock pin is slightly

above the top of the cylinder head.

(i) Using SST, tap in the oil seal.
SST 09223–46011

(e) Install the five bearing caps in their proper loca-

tions.

(h) Apply MP grease to a new oil seal lip.

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ENGINE MECHANICAL

Cylinder Head (4A–FE)

EM–106

(b) Apply MP grease to the thrust portion of the

camshaft.

camshaft gear by matching the assembly
installation
marks on each gear.

NOTICE: There are also timing marks (for TDC)

on each gear as shown in the illustration. Do not

use these marks.

(d) Roll down the intake camshaft onto the bearing

journals while engaging gears with each other.

HINT: The above angle allows the No.1 and No.3
cylinder cam lobes of the intake camshaft to push
their valve lifters evenly.
(e) Install the four bearing caps in their proper loca-

tions.

(i) Install the No.1 bearing cap with the arrow mark

facing forward.

NOTICE: If the No.1 bearing cap does not fit properly,

push the camshaft gear backwards by prying apart the

cylinder head and camshaft gear with a screwdriver.

(j) Apply a light coat of engine oil on the threads and

under the heads of the bearing cap bolts.

(k) Install and alternately tighten the two bolts in several

passes.

Torque: 13 N–m (130 kgf–cm, 9 ft–lbf)

(f) Apply a light coat of engine oil on the threads and

under the heads of the bearing cap bolts.

(g) Install and uniformly tighten the eight bearing

cap
bolts in several passes in the sequence shown.

Torque: 13 N–m (130 kgf–cm, 9 ft–lbf)

(h) Remove the service bolt (C).

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ENGINE MECHANICAL

Cylinder Head (4A–FE)

EM–107

5. INSTALL PS DRIVE BELT ADJUSTING STRUT

Install the adjusting strut with the two bolts.
Torque: 39 N–m (400 kgf–cm, 29 ft–lbf)

6. INSTALL ENGINE HANGERS

Install the engine hanger with the bolt. Install the two
engine hangers.
Torque: 27 N–m (280 kgf–cm, 20 ft–lbf)

7. INSTALL FAN BELT ADJUSTING BAR

Install the adjusting bar with the two bolts.
Torque: 20 N–m (200 kgf–cm, 14 ft–lbf)

8. INSTALL CAMSHAFT TIMING PULLEY

(See step 7 on page

EM–41

)

9. INSTALL TIMING BELT

(See steps 8 to 13,15 to 17,19 to 22 on pages

EM–41

to 45)

4. CHECK AND ADJUST VALVE CLEARANCE

(See page

EM–13

)

Turn the camshaft and position the cam lobe upward,
and check and adjust the valve clearance.
Valve clearance (Cold):

Intake 0.15 – 0.25 mm (0.006 – 0.010 in.)
Exhaust 0.20 – 0.30 mm (0.008 – 0.012 in.)

(m) Check that the timing marks of the camshaft

gears are aligned.

HINT: The assembly installation marks are on up-
side.

(l) Turn the exhaust camshaft clockwise, and set it

with knock pin facing upward.

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ENGINE MECHANICAL

Cylinder Head (4A–FE)

EM–108

11. INSTALL CYLINDER HEAD COVER

(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder head as shown in

the illustration.

Seal packing: Part No. 08826–00080 or equivalent

12. INSTALL INTAKE MANIFOLD

(a) Install a new gasket and the intake manifold with

the seven bolts and two nuts. Uniformly tighten the
bolts and nuts in several passes.

Torque: 19 N–m (195 kgf–cm, 14 ft–lbf)

(b) Connect the PCV hose to PCV valve on the cylinder

head.

and cap nuts. Uniformly tighten the nuts in sev-
eral passes.

Torque: 7.8 N–m (80 kgf–cm, 69 in.–lbf)

10. INSTALL SEMI–CIRCULAR PLUG

(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the circular plug.
Seal packing: Part No. 08826–00080 or equivalent

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ENGINE MECHANICAL

Cylinder Head (4A–FE)

EM–109

tighten the bolts.

Torque:

12 mm bolt head 19 N–m (195 kgf–cm, 14 ft–lbf)
14 mm bolt head 39 N–m (400 kgf–cm, 29 ft–lbf)

15. INSTALL VACUUM PIPE, EGR VACUUM

MODULATOR AND EGR VSV
(a) Install the vacuum pipe, vacuum modulator and

VSV assembly with the two nuts.

14. INSTALL EGR VALVE

Install the EGR valve with the two nuts.
Torque: 13 N–m (130 kgf–cm, 9 ft–lbf)

(b) Connect the following hoses:

(1) Water inlet pipe water by–pass hose
(2) Fuel return hose (from fuel filter)

13. INSTALL AIR PIPE

(a) Install the air pipe with the two nuts.

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ENGINE MECHANICAL

Cylinder Head (4A–FE)

EM–110

16. INSTALL ENGINE WIRE TO INTAKE MANIFOLD

(a) Install the engine wire with the three bolts.
(b) Install the engine wire on the engine to vacuum pipe

with the wire clamp.

•

EGR VSV connector

•

(CALIF. only)
EGR gas temperature sensor connector

•

Vacuum sensor connector

17. INSTALL ENGINE WIRE TO No.3 TIMING BELT COVER

(a) Install the wire clamp on the engine wire to the wire

bracket.

(b) Install the engine wire with the bolt.
(c) Connect the following connectors and wire:

•

Alternator connector.

•

Alternator wire

•

Oil pressure switch connector

•

A/C compressor connector

18. INSTALL ACV

(a) Install a new O–ring to the ACV.
(b) Apply soapy water to the O–ring.
(c) Install the ACV with the bolt and nut.
(d) Connect the air hose to the air pipe.
Torque: 13 N–m (130 kgf–cm, 9 ft–lbf)

19. INSTALL INJECTORS AND DELIVERY PIPE

(See steps 1 to 5 on pages

FI–158

and 159)

20. INSTALL THROTTLE BODY

(See steps 2 to 5 on page

FI–191

)

(b) Connect the following hoses:

(1) Two vacuum hoses (from EGR vacuum modula-
tor) to EGR valve
(2) Vacuum hose (from EGR VSV) to EGR valve

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ENGINE MECHANICAL

Cylinder Head (4A–FE)

EM–111

23. INSTALL WATER INLET AND INLET HOUSING

(a) Remove any old packing (FIPG) material and be

careful not to drop any oil on the contact surfaces of
the inlet housing and cylinder head.

•

Using a razor blade and gasket scraper, remove
all the oil packing (FIPG) material from the gas-
ket surfaces and sealing groove.

•

Thoroughly clean all components to remove all
the loose material.

•

Using a non–residue, clean both sealing sur-
faces.

(b) Apply seal packing to the inlet housing groove.
Seal packing: Part No. 08826–00100 or equivalent

•

Install a nozzle that has been cut to a 2 – 3 mm
(0.08 – 0.12 in.) opening.

HINT: Avoid applying an excessive amount to the sur-
face.

•

Parts must be assembled within 15 minutes of
application. Otherwise the material must be re-
moved and reapplied.

•

Immediately remove nozzle from the tube and
reinstall cap.

22. CONNECT VACUUM HOSES

(a) Vacuum sensor hose togas filter on intake manifold
(b) Brake booster vacuum hose to intake manifold
(c) Three A/C vacuum hoses to ASV on intake manifold
(d) A/C vacuum hose to air pipe

21. INSTALL PS PUMP

(a) Install the PS pump and drive belt with the two

bolts.

Torque: 39 N–m (400 kgf–cm, 29 ft–lbf)

(b) Connect the following hoses:

(1) Air hose to air pipe
(2) Air hose to intake manifold

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ENGINE MECHANICAL

Cylinder Head (4A–FE)

EM–112

(d) Connect the following hoses: ,

(1) Lower radiator hose
(2) Water inlet pipe hose
(3) Auxiliary air valve water by–pass hose
(4) Heater water hose
(5) EVAP BVSV vacuum hose (from port P of
throttle body)
(6) EVAP BVSV vacuum hose (from charcoal canister)

(e) Connect the following connectors:

•

Water temperature sender gauge connector

•

Water temperature sensor connector

24. INSTALL WATER OUTLET

(a) Remove any old packing (FIPG) material and be

careful not to drop any oil on the contact surfaces of
the water outlet and cylinder head.

•

Using a razor blade and gasket scraper, remove all
the oil packing (FIPG) material from the gasket
surfaces and sealing groove.

•

Thoroughly clean all components to remove all
the loose material.

•

Using a non–residue, clean both sealing surfaces.

(b) Apply seal packing to the water outlet groove.
Seal packing: Part No. 08826–00100 or equivalent

•

Install a nozzle that has been cut to a 2 – 3 mm
(0.08 – 0.12 in.) opening.

HINT: Avoid applying an excessive amount to the surface.

•

Parts must be assembled within 15 minutes of
application. Otherwise the material must be removed
and reapplied.

•

Immediately remove nozzle from the tube and rein-
stall cap.

(d) Connect the upper radiator hose to the water outlet.

with the bolt and two nuts.

Torque: 20 N–m (200 kgf–cm, 14 ft–lbf)

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ENGINE MECHANICAL

Cylinder Head (4A–FE)

EM–113

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