4A–FE engine is an in–line, 4–cylinder, 1.6 liter DOHC 16–valve engine. Manual - part 15

(c) Install the manifold stay with the three (CALIF.) or

two (Ex. CALIF.) bolts. Alternately tighten the
bolts.

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

(b) Install a new gasket and the exhaust manifold

with the two bolts and three new nuts. Uniformly
tighten the bolts and nuts in several passes.

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

25. INSTALL EXHAUST MANIFOLD

(a) Install the lower heat insulator to the exhaust manifold

with the three bolts.

–

ENGINE MECHANICAL

Cylinder Head (4A–FE)

EM–114

26. INSTALL DISTRIBUTOR (See page 

IG–24

)

27. INSTALL FRONT EXHAUST PIPE

(See step 17 on page 

EM–217

)

28. INSTALL SUSPENSION LOWER CROSSM EM BER

(See page 18 on page 

EM–218

)

29. INSTALL ENGINE UNDER COVERS
30. INSTALL AIR CLEANER
31. INSTALL ACCELERATOR CABLE, AND ADJUST IT
32. ( A/T )

CONNECT THROTTLE CABLE, AND ADJUST IT

33. FILL WITH ENGINE COOLANT (See page 

CO–6

)

Capacity (w/ Heater):

M/T 5.2 liters (5.5 US qts, 4.6 Imp. qts)
A/T 5.6 liters (5.9 US qts, 4.9 Imp. qts)

34. CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY
35. START ENGINE AND CHECK FOR LEAKS
36. PERFORM ENGINE ADJUSTMENT

(a) Adjust the ignition timing. (See page 

IG–25

)

Ignition timing:

10

°

 BTDC idle

(w/ Terminals TE1 and E1 connected)

(b) Adjust the idle speed. (See page 

MA–8

)

Idle speed: 800 rpm (w/ Cooling fan OFF)

37. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift
points and smooth operation.
38. RECHECK ENGINE COOLANT LEVEL AND OIL LEVEL

(d) Install the upper heat insulator with the five

(CALIF.) or four (Ex. CALIF.) bolts.

–

ENGINE MECHANICAL

Cylinder Head (4A–FE)

EM–115

CYLINDER HEAD (3S–GTE)

COMPONENTS

–

ENGINE MECHANICAL

Cylinder Head (3S–GTE)

EM–116

COMPONENTS (Cont’d)

–

ENGINE MECHANICAL

Cylinder Head (3S–GTE)

EM–117

REMOVAL OF CYLINDER HEAD

(See pages 

EM–116

 and 117)

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. DRAIN ENGINE COOLANT (See page 

CO–6

)

3. DISCONNECT ACCELERATOR CABLE FROM

THROTTLE BODY

4. REMOVE AIR CLEANER CAP

(See step 7 on page 

EM–224

)

5. REMOVE INTERCOOLER

(See steps 13 to 15 on pages 

TC–9

 and 20)

6. REMOVE ALTERNATOR (See page 

CH–7

)

7. REMOVE ENGINE UNDER COVER
8. REMOVE SUSPENSION LOWER CROSSMEMBER

(See step 33 on page 

EM–228

)

9. REMOVE FRONT EXHAUST PIPE

(See step 34 on page 

EM–229

)

10. REMOVE RH FRONT ENGINE HANGER AND NO.1

ALTERNATOR BRACKET
Remove the three bolts, engine hanger and alternator
bracket.

11. REMOVE CATALYTIC CONVERTER

(a) Remove the four bolts and RH converter stay.

–

ENGINE MECHANICAL

Cylinder Head (3S–GTE)

EM–118

12. REMOVE TURBOCHARGER

(See steps 16 to 21 on pages 

TC–10

 and 11)

13. REMOVE THROTTLE BODY

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

FI–194

 and 195)

14. REMOVE COLD START INJECTOR

(See steps 2 to 4 on pages 

FI–146

 and 147)

15. REMOVE EXHAUST MANIFOLD

(a) Remove the nine nuts, exhaust manifold and gas.

ket.

(c) Remove the three bolts, two nuts and catalytic con-

verter. Remove the gasket, retainer and cushion.

(d) Remove the five bolts and front heat insulator.
(e) Remove the four bolts and rear heat insulator.

(b) Remove the three bolts and LH converter stay.

–

ENGINE MECHANICAL

Cylinder Head (3S–GTE)

EM–119

17. DISCONNECT HOSES

(a) Brake booster vacuum hose from intake manifold
(b) Turbocharging pressure sensor hose from intake

manifold

18. REMOVE NO.2 AIR TUBE

(a) Disconnect the air hose from the No.1 air tube.
(b) Remove the bolt and No.1 air tube.

(b) Remove the bolt, nut and heat insulator.

16. REMOVE DISTRIBUTOR (See page 

IG–26

)

19. REMOVE LH ENGINE HANGER

Remove the two bolts and engine hanger.

(c) A/C ASV air hose from No.1 air tube

–

ENGINE MECHANICAL

Cylinder Head (3S–GTE)

EM–120

20. REMOVE EGR VACUUM MODULATOR AND VSV

(a) Disconnect the EGR VSV connector.
(b) Disconnect the following hoses:

(1) Vacuum hose from EGR valve
(2) Vacuum hose from EGR vacuum modulator

23. REMOVE WATER OUTLET

(a) Disconnect the following connectors:

•

Water temperature sender gauge connector

•

Water temperature sensor connector

•

Cold start injector time switch connector

21. REMOVE EGR VALVE AND PIPE

(a) Disconnect the vacuum hose from the EGR valve.
(b) Remove the four bolts, the EGR valve, pipe assembly

and two gaskets.

22. REMOVE VACUUM PIPE

(a) Disconnect the vacuum hose from the vacuum pipe.
(b) Remove the bolt and vacuum pipe.

(c) Remove the bolt, vacuum modulator and VSV as-

sembly.

–

ENGINE MECHANICAL

Cylinder Head (3S–GTE)

EM–121