4A–FE engine is an in–line, 4–cylinder, 1.6 liter DOHC 16–valve engine. Manual - part 18

ASSEMBLY OF CYLINDER HEAD

(See page 

EM–117

)

HINT:

•

Thoroughly clean all parts to be assembled.

•

Before installing the parts, apply new engine oil
to all sliding and rotating surfaces.

•

Replace all gaskets and oil seals with new
ones.

(b) Install the following parts:

(1) Valve
(2) Spring seat
(3) Valve spring
(4) Spring retainer

1. INSTALL VALVES

(a) Using SST, push in a new oil seal.
SST 09201–41020

HINT: Install the valve spring, facing the white
painted mark upward.

HINT: The intake valve oil seal is brown and the
exhaust valve oil seal is black.

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ENGINE MECHANICAL

Cylinder Head (3S–GTE)

EM–138

2. INSTALL VALVE LIFTERS AND SHIMS

(a) Install the valve lifter and shim.
(b) Check that the valve lifter rotates smoothly by hand.

(c) Using SST, compress the valve spring and place

the two keepers around the valve stem.

SST 09202–70010

(d) Using a plastic–faced hammer, lightly tap the

valve stem tip to assure proper fit.

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ENGINE MECHANICAL

Cylinder Head (3S–GTE)

EM–139

INSTALLATION OF CYLINDER HEAD

(See pages 

EM–116

 and 117)

1. INSTALL CYLINDER HEAD
A. Place cylinder head on cylinder block

(a) Place a new cylinder head gasket in position on the

cylinder block.

NOTICE: Be careful of the installation direction.

(b) Place the cylinder head in position on the cylinder

head gasket.

B. Install cylinder head bolts

HINT:

•

The cylinder head bolts are tightened in two
progressive steps (steps (b) and (d)).

•

If any cylinder head bolt is broken or deformed,
replace it.

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

under the heads of the cylinder head bolts.

(b) Install the plate washer to each cylinder head bolt.
(c) Using SST, install and uniformly tighten the ten

cylinder head bolts in several passes in the se-
quence shown.

SST 09043–38100
Torque: 49 N–m (500 kgf–cm, 36 ft–lbf)

If any one of the cylinder head bolts does not meet the
torque specification, replace the cylinder head bolt.

(e) Retighten the cylinder head bolts 90

°

 in the

numerical order shown.
(f) Check that the painted mark is now at a 90

°

 angle

to front.

(d) Mark the front of the cylinder head bolt head with

paint.

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ENGINE MECHANICAL

Cylinder Head (3S–GTE)

EM–140

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

under the heads of the bearing cap bolts.

(e) Install and uniformly tighten the ten bearing cap

bolts on one side in several passes in the se-
quence shown.

Torque: 19 N–m (190 kgf–cm, 14 ft–lbf)

2. INSTALL CAMSHAFTS

(a) Place the camshaft on the cylinder head with the

No.1 cam lobe facing outward as shown.

(b) Apply seal packing to the No.1 bearing cap as

shown.

Seal packing: Part No. 08826–00080 or equivalent

(c) Install the bearing caps in their proper locations.
HINT: Each bearing cap has a number and front
mark.

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

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ENGINE MECHANICAL

Cylinder Head (3S–GTE)

EM–141

3. ADJUST VALVE CLEARANCE (See page 

EM–17

)

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

Intake 0.15 – 0.25 mm (0.006 – 0.010 in.)
Exhaust 0.28 – 0.38 mm (0.011 – 0.015 in.)

7. INSTALL CYLINDER HEAD COVER

(a) Apply seal packing to the cylinder head as shown in

the illustration.

Seal packing: Part No. 08826–00080 or equivalent

5. INSTALL NO.1 IDLER PULLEY
(See step 4 on page 

EM–55

)

6. INSTALL CAMSHAFT TIMING PULLEYS
(See steps 9 to 15 on pages 

EM–56

 to 60)

4. INSTALL NO.3 TIMING BELT COVER

Install the No.3 belt cover with the five bolts.
Torque: 8.8 N–m (90 kgf–cm, 78 in–lbf)

(g) Using SST, tap in the two camshaft oil seals.
SST 09223–50010

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ENGINE MECHANICAL

Cylinder Head (3S–GTE)

EM–142

(b) Install the two gaskets to the head cover.
(c) Install the head cover with the twelve seal wa-

shers and screws. Uniformly tighten the screws
in several passes.

Torque: 2.5 N–m (25 kgf–cm, 21 in–lbf)

(b) Install the intake manifold with the four bolts and

three nuts. Uniformly tighten the bolts and nuts
in several passes.

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

8. INSTALL DELIVERY PIPE AND INJECTORS

(See steps 2 to 8 on pages 

FI–166

 to 168)

9. INSTALL CHARCOAL CANISTER

(See step 32 on page 

EM–264

)

10. INSTALL T–VIS VALVE AND INTAKE MANIFOLD

(a) Place a new gasket, the T–VIS valve and the other

new gasket on the cylinder head.

(c) Connect the knock sensor connector.
(d) Connect the ground strap with the bolt.

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ENGINE MECHANICAL

Cylinder Head (3S–GTE)

EM–143

11. INSTALL T–VIS VACUUM TANK, T–VIS VSV,

TURBOCHARGING PRESSURE VSV AND BRACKET
(a) Install the T–VIS vacuum tank, T–VIS VSV, tur–

bocharging pressure VSV and bracket assembly
with the two bolts.

(b) Connect the following hoses:

(1) Vacuum hose (from T–VIS VSV) to T–VIS actua-
tor
(2) Vacuum hose (from T–VIS vacuum tank) to
intake manifold

12. INSTALL NO.1 AIR TUBE

(a) Install the air tube with the three bolts.

14. INSTALL WATER BY–PASS PIPE

(a) Install a new O–ring to the pipe.
(b) Apply soapy water on the O–ring.
(c) Install a new gasket to the water pump.
(d) Install the water by–pass pipe with the two nuts and

two bolts.

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

13. INSTALL INTAKE MANIFOLD STAYS

Install the manifold stay with the two bolts. Alternately
tighten the bolts. Install the two manifold stays.
Torque: 25 N–m (260 kgf–cm, 19 ft–lbf)

(b) Connect the following hoses:

(1) Vacuum hose to intake manifold
(2) Two PS vacuum hoses
(3) Vacuum hose to turbocharging pressure VSV

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ENGINE MECHANICAL

Cylinder Head (3S–GTE)

EM–144

16. INSTALL OIL PRESSURE SWITCH

Apply adhesive to two or three threads.
Adhesive: Part No. 08833–00080, THREE BOND

1324 or equivalent

17. INSTALL WATER OUTLET

(a) Install a new gasket and the water outlet with the

two bolts.

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

19. INSTALL EGR VALVE AND PIPE

(a) Install two new gaskets, the EGR valve and pipe

assembly with the four bolts. Alternately tighten the
bolts.

Torque:

To cylinder head 25 N–m (260 kgf–cm, 19 ft–lbf)

To intake manifold 19 N–m (195 kgf–cm, 14 ft–lbf)

(b) Connect the vacuum hose to the EGR valve.

(e) Connect the following hoses:

(1) Water by–pass hose to cylinder block
(2) Water by–pass hoses to No.1 air tube
(3) Vacuum hose to turbocharging pressure VSV
(4) Heater water hose

15. INSTALL OIL COOLER

(See steps 2 to 4 on pages 

LU–26

 and 27)

(b) Connect the following hoses:

(1) Upper radiator hose
(2) Water by–pass hose to water by–pass pipe
(3) Water by–pass pipe hose to ISC valve
(4) Heater water hose
(5) Two EVAP VSV vacuum hoses

18. INSTALL VACUUM PIPE

(a) Install the vacuum pipe with the bolt.
(b) Connect the vacuum hose to the vacuum pipe.

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ENGINE MECHANICAL

Cylinder Head (3S–GTE)

EM–145