4A–FE engine is an in–line, 4–cylinder, 1.6 liter DOHC 16–valve engine. Manual - part 23

9. INSTALL OIL PRESSURE SWITCH

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

1324 or equivalent

10. INSTALL ALTERNATOR BRACKET

Install the alternator bracket with the three bolts.
Torque: 42 N–m (425 kgf–cm, 31 ft–lbf )

11. INSTALL ENGINE HANGERS

Install the engine hanger with the bolt. Install the two
engine hangers. Install the ground strap.
Torque: 25 N–m (250 kgf–cm, 18 ft–lbf)

nuts. Uniformly tighten the nuts in several
passes.

Torque: 23 N–m (230 kgf–cm, 17 ft–lbf)

HINT: Install the grommets so that its markings are
as shown in the illustration. Then install the grom-
met to its original position.

8. 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

7. INSTALL HIGH–TENSION CORD CLAMP AND PCV

VALVE

–

ENGINE MECHANICAL

Cylinder Head (5S–FE)

EM–178

13. INSTALL NO.1 IDLER PULLEY AND TENSION SPRING

(See step 4 on page

EM–75

)

14. INSTALL CAMSHAFT TIMING PULLEY

(See steps 9 to 21 and 24 on pages

EM–76

to 80)

15. INSTALL INJECTOR AND DELIVERY PIPE

(See steps 1 and 2 on pages

FI–175

and 176)

(b) Install the two manifold stays with the four bolts.

Alternately tighten the bolts. Install the connector
bracket (CALIF. only).

Torque:

12 mm. head bolt 22 N–m (220 kgf–cm, 16 ft–lbf)

14 mm head bolt 42 N–m (425 kgf–cm, 31 ft–lbf)

16. INSTALL INTAKE MANIFOLD

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

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

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

12. INSTALL No.3 TIMING BELT COVER

Install the timing belt cover with the four bolts.
Torque: 7.8 N–m (80 kgf–cm, 69 in–lbf)

(d) Connect the two wire clamps to the wire brackets.
(e) Connect the PCV hose to the PVC valve.

17. INSTALL ACCELERATOR BRACKET

–

ENGINE MECHANICAL

Cylinder Head (5S–FE)

EM–179

(1) PS air hose to intake manifold
(2) Two air hoses to air tube
(3) (w/ A/C)

Air hose to intake manifold

(4) Vacuum hose to gas filter
(5) Vacuum hose to fuel pressure regulator

(d) (w/ A/C)
Connect the ASV connector.

21. CONNECT VACUUM HOSES

(a) Vacuum sensor hose to gas filter
(b) Brake booster vacuum hose to intake manifold
(c) (w/ Cruise Control System (w/o ABS))
Actuator vacuum hose to intake manifold

22. INSTALL EGR VALVE AND VACUUM MODULATOR

(a) Install a new gasket and the EGR valve with the

union nut and two nuts.

Torque:

Union nut 59 N–m (600 kgf–cm, 43 ft–lbf)

Bolt 13 N–m (130 kgf–cm, 9 ft–lbf)

(b) Install the EGR modulator– to the clamp.

18. INSTALL VSV FOR EGR
19. CONNECT ENGINE WIRE GROUND STRAPS AND

CONNECTORS
(a) Two engine ground straps to intake manifold
(b) Knock sensor connector
(c) VSV connector for EGR

20. INSTALL AIR TUBE, ASV (FOR A/C) AND VACUUM

PIPE
(a) Install the air tube, ASV assembly and the vacuum

hose bracket with the four bolts.

(b) Install the vacuum pipe with the bolt.

–

ENGINE MECHANICAL

Cylinder Head (5S–FE)

EM–180

(1) Vacuum hose (from port Q of EGR vacuum
modulator) to port G of VSV for EGR
(2) Vacuum hose (from EGR valve) to port E of
VSV for EGR
(3) Vacuum hose to charcoal canister

(d) Install the vacuum hose clamp to the bracket.
(e) (CALIF. only)

Install the connector to the bracket. Connect the
EGR gas temperature sensor connector.

23. INSTALL THROTTLE BODY

(See steps 2 to 5 on pages

FI–204

and 205)

24. INSTALL WATER BY–PASS PIPE

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

two nuts and two bolts.

Torque(Nut): 9.3 N–m (95 kgf–cm, 82 in–lbf)

(b) Connect the following hoses:

(1) Upper radiator hose
(2) Water by–pass pipe hose
(3) Heater water hose
(4) ISC water by–pass hose
(5) EVAP BVSV vacuum hose (from port P of
throttle body)
(6) EVAP BVSV vacuum hose (from charcoal can-
ister)

(d) Connect the following hoses:

(1) ISC water by–pass hose
(2) Heater water hose
(3) (w/ Oil Cooler)
Two oil cooler water by–pass hoses

(e) (w / Oil Cooler)

Install the water by–pass hose heat protector.
(See step 3 on page

LU–30

)

25. INSTALL WATER OUTLET

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

two bolts.

Torque: 15 N–m (150 kgf–cm, 11 ft–lbf)

–

ENGINE MECHANICAL

Cylinder Head (5S–FE)

EM–181

26. ASSEMBLE EXHAUST MANIFOLD AND CATALYTIC

CONVERTER
(a) Place the cushion, retainer and a new gasket on

the catalytic converter.

(b) Install the catalytic converter to the exhaust manifold

with the three bolts and two nuts.

Torque: 29 N–m (300 kgf–cm, 22 ft–lbf)

27. INSTALL EXHAUST MANIFOLD AND CATALYTIC

CONVERTER ASSEMBLY
(a) Install a new gasket, the exhaust manifold and catalyt-

ic converter assembly with the six new nuts. Uni-
formly tighten the nuts in several passes.

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

five bolts.

(d) Install the two catalytic converter heat insulators

with the eight bolts.

(b) Install the catalytic converter stay with the two

bolts and two new nuts. Alternately tighten the
bolts and nut.

Torque: 42 N–m (425 kgf–cm, 31 ft–lbf)

•

Water temperature sender gauge connector

•

Water temperature sensor connector

–

ENGINE MECHANICAL

Cylinder Head (5S–FE)

EM–182

28. (CALIF. ONLY)

INSTALL SUB–OXYGEN SENSOR

29. INSTALL OXYGEN SENSOR (MAIN)
10. INSTALL FRONT EXHAUST PIPE

(See step 15 on page

EM–305

)

31. INSTALL SUSPENSION LOWER CROSSMEMBER

(See page 16 on page

EM–306

)

32. INSTALL ENGINE UNDER COVERS
33. INSTALL DISTRIBUTOR (See page

IG–35

)

34. INSTALL ALTERNATOR (See page

CH–24

)

35. INSTALL AIR CLEANER CAP AND HOSE

(See step 38 on page

EM–310

)

36. (w/ CRUISE CONTROL SYSTEM)

INSTALL CRUISE CONTROL ACTUATOR
(See step 33 on page

EM–309

)

37. INSTALL ACCELERATOR CABLE, AND ADJUST IT
38. (A/T)

CONNECT THROTTLE CABLE, AND ADJUST IT

39. CONNECT CABLE TO NEGATIVE TERMINAL OF

BATTERY

40. FILL WITH ENGINE COOLANT (See page

CO–6

)

Capacity (w/ Heater):

M/T 6.2 liters (6.6 US qts, 5.5 Imp. qts)
A/T 6.1 liters (6.4 US qts, 5.4 Imp. qts)

41. START ENGINE AND CHECK FOR LEAKS
42. ADJUST IGNITION TIMING (See page

IG–37

)

Ignition timing:

BTDC), idle

(w/ Terminals TE1 and E1 connected)

43. PERFORM ROAD TEST

Check for abnormal noise, shock, slippage, correct
shift points and smooth operation.

44. RECHECK ENGINE COOLANT LEVEL AND OIL LEVEL

bolts.

–

ENGINE MECHANICAL

Cylinder Head (5S–FE)

EM–183

CYLINDER BLOCK (4A–FE)

COMPONENTS

–

ENGINE MECHANICAL

Cylinder Block (4A–FE)

EM–184

6. REMOVE AIR CLEANER

(a) Disconnect the intake air temperature sensor connec-

tor.

(b) Disconnect the accelerator cable from the bracket

on the air cleaner cap.

(c) Disconnect the four air cleaner cap clips.
(d) Disconnect the air hose from the air pipe.
(e) Disconnect the air cleaner hose from the throttle

body, and remove the air cleaner cap and element.

(f) Remove the three bolts and air cleaner case.

7. DISCONNECT ACCELERATOR CABLE FROM

THROTTLE BODY

8. REMOVE ENGINE RELAY BOX, AND DISCONNECT

ENGINE WIRE CONNECTORS
(a) Remove the two nuts, and disconnect the relay box

from the battery.

REMOVAL OF ENGINE

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 HOOD
3. REMOVE ENGINE UNDER COVER
4. DRAIN ENGINE COOLANT (See page

CO–6

)

5. DRAIN ENGINE OIL (See page

LU–7

)

(b) Remove the lower cover from the relay box.
(c) Disconnect the fusible link cassette and two con–

nectors of the engine wire from the relay box.

–

ENGINE MECHANICAL

Cylinder Block (4A–FE)

EM–185

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