4A–FE engine is an in–line, 4–cylinder, 1.6 liter DOHC 16–valve engine. Manual - part 25

2. CHECK CONNECTING ROD THRUST CLEARANCE

Using a dial indicator, measure the thrust clearance
while moving the connecting rod back and forth.
Standard thrust clearance: 0.150 – 0.250 mm

(0 .0059 – 0.0098 in.)

Maximum thrust clearance: 0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, re-
place the connecting rod assembly. If necessary, re-
place the crankshaft.

DISASSEMBLY OF CYLINDER BLOCK

(See page

EM–184

)

1. REMOVE REAR OIL SEAL RETAINER

Remove the six bolts, retainer and gasket.

3. REMOVE CONNECTING ROD CAPS AND CHECK OIL

CLEARANCE
(a) Check the matchmarks on the connecting rod and

cap to ensure correct reassembly.

ing rod bolts and lift off the connecting rod cap.

HINT: Keep the lower bearing inserted with the connect-
ing cap.

(b) Remove the connecting rod cap nuts.

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EM–194

(e) Clean the crank pin and bearing.
(f) Check the crank pin and bearing for pitting and

scratches.

If the crank pin or bearing is damaged, replace the
bearings. If necessary, grind or replace the crank–
shaft.

(h) Install the connecting rod cap.

(See step 6 on page

EM–212

)

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

NOTICE: Do not turn the crankshaft.

(d) Cover the connecting rod bolts with a short piece

of hose to protect the crankshaft from damage.

(i) Remove the connecting rod cap.

(See procedure (b) and (c) above)

(g) Lay a strip of Plastigage across the crank pin.

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EM–195

HINT: If using a standard bearing, replace it with one
having the same number marked on the connecting rod
cap. There are three sizes of standard bearings, marked
“1” ”2” and ”3” accordingly.
(Reference)
Standard sized bearing center wall thickness:

Mark ”’1”

1.486 –1.490 mm
(0.0585 – 0.0587 in.)

Mark ”2”

1.490 – 1.494 mm

(0–0587 – 0.0588 in.)

Mark ”3”

1.494 –1.498 mm

(0.0588 – 0.0590 in.)

(k) Completely remove the Plastigage.

4. REMOVE PISTON AND CONNECTING ROD

ASSEMBLIES
(a) Using a ridge reamer, remove all the carbon from the

top of the cylinder.

(b) Cover the connecting rod bolts.

(See page

EM–195

)

bearing through the top of the cylinder block.

HINT:

•

Keep the bearings, connecting rod and cap together.

•

Arrange the piston and connecting rod assemblies in
correct order.

5. CHECK CRANKSHAFT THRUST CLEARANCE

Using a dial indicator, measure the thrust clearance
while prying the crankshaft back and forth with a
screwdriver.
Standard thrust clearance: 0.020 – 0.220 mm

(0.0008 – 0.0087 in.)

Maximum thrust clearance: 0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, re-
place the thrust washers as a set.
Thrust washer thickness: 2.440 – 2.490 mm

(0.0961 – 0.0980)

(j) Measure the Plastigage at its widest point.
Standard oil clearance:

STD

0.020 – 0.051 mm
(0.0008 – 0.0020 in.)

U/S

0.25 0.019 – 0.065 mm
(0.0007 – 0.0026 in.)

Maximum oil clearance: 0.08 mm (0.0031 in.)
If the oil clearance is greater than maximum, replace
the bearings. If necessary, grind or replace the
crankshaft.

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(b) Using the removed main bearing cap bolts, pry

the main bearing cap back and forth, and re-
move the main bearing caps, lower bearings
and lower thrust washers (No.3 main bearing
cap only).

HINT:

•

Keep the lower bearing and main bearing cap
together.

•

Arrange the main bearing caps and lower thrust
washers in correct order.

(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for pitting

and scratches. If the journal or bearing is dam-
aged, replace the bearings. If necessary, grind
or replace the crankshaft.

6. REMOVE MAIN BEARING CAPS AND CHECK OIL

CLEARANCE
(a) Remove the main bearing cap bolts.

(f) Place the crankshaft on the cylinder block.
(g) Lay a strip of Plastigage across each journal.

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(j) Measure the Plastigage at its widest point.
Standard clearance:

STD

0.015 – 0.033 mm
(0 .0006 – 0.0013 in . )

U/S 0.25 0.018 – 0.056 mm

(0.0007 – 0.0022 in.)

Maximum clearance: 0.10 mm (0.0039 in.)
HINT: If replacing the cylinder block subassembly, the
bearing standard clearance will be: 0.015–0.045 mm
(0.0006 – 0.0018 in.) If the oil clearance is greater than
maximum, replace the bearings. If necessary, grind or
replace the crankshaft.
HINT: If using a standard bearing, replace it with one
having the same number. If the number of the bearing
cannot be determined, select the correct bearing by add-
ing together the numbers imprinted on the cylinder block
and crankshaft, then selecting the bearing with the same
number as the total. There are five sizes of standard
bearings, marked ”1 ”, ”2”, ”3”, ”4” and ”5” accordingly.

(h) Install the main bearing caps.

(See step 4 on page

EM–211

)

Torque: 60 N–m (610 kgf–cm, 44 ft–lbf)

NOTICE: Do not turn the crankshaft.

EXAMPLE: Cylinder block ”2” + Crankshaft ”1”
= Bearing ”3”

(i) Remove the main bearing caps.

(See procedure (a) and (b) above)

Cylinder block

Number marked

Crankshaft

Bearing

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(Reference)
Cylinder block main journal bore diameter:

Mark ”1” 52.025 – 52.031 mm

(2.0482 – 2.0485 in.)

Mark ”2” 52–031 – 52.037 mm

(2.0485 – 2.0487 in.)

Mark ”3” 52.037 – 52.043 mm

(2.0487 – 2.0489 in.)

Crankshaft journal diameter:

Mark ”0” 47 . 994 – 48.000 mm

(1.8895 –1.8898 in.)

Mark ”1” 47.988 – 47.994 mm

(1.8893 – 1.8895 in.)

Mark ”2” 47 .982 – 47.988 mm

(1.8891 –1. 8893 in.)

Standard sized bearing center wall thickness:

Mark ”’1” 2.002 – 2.005 mm

(0.0788 – 0.0789 in.)

Mark ”2” 2.005 – 2.008 mm

(0.0789 – 0.0791 in.)

Mark ”3” 2.008 – 2.011 mm

(0.0791 – 0.0792 in.)

Mark ”4” 2.011 – 2.014 mm

(0.0792 – 0.0793 in.)

Mark ”5” 2.014 – 2.017 mm

(0.0793 – 0.0794 in.)

(k) Completely remove the Plastigage.

7. REMOVE CRANKSHAFT

(a) Lift out the crankshaft.
(b) Remove the upper bearings and upper thrust washers

from cylinder block.

HINT: Arrange the main bearing caps, bearings and
thrust washers in correct order.

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INSPECTION OF CYLINDER BLOCK

1. CLEAN CYLINDER BLOCK
A. Remove gasket material

Using a gasket scraper, remove all the gasket material
from the surface contacting the cylinder head.

B. Clean cylinder block

Using a soft brush and solvent, thoroughly clean the
cylinder block.

2. INSPECT TOP SURFACE OF CYLINDER BLOCK FOR

FLATNESS
Using a precision straight edge and feeler gauge, mea-
sure the surface contacting the cylinder head for
warpage.
Maximum warpage: 0.05 mm (0.0020 in.)
If warpage is greater than maximum, replace the cylin-
der block.

3. INSPECT CYLINDER FOR VERTICAL SCRATCHES

Visually check the cylinder for vertical scratches.
If deep scratches are present, rebore all the four cylinders.
If necessary, replace the cylinder block.

4. INSPECT CYLINDER BORE DIAMETER

HINT: There are three sizes of the standard cylinder
bore diameter, marked ”1 ”, ”2” and ”3” accordingly.
The mark is stamped on the top of the cylinder block.

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ENGINE MECHANICAL

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EM–200

Using a cylinder gauge, measure the cylinder bore
diameter at positions A, B and C in the thrust and
axial directions.
Standard diameter:

STD Mark ”1” 81.000 – 81.010 mm

(3.1890 – 3.1894 in.)

Mark ”2” 81.010 – 81.020 mm

(3.1894 – 3.1898 in.)

Mark ”3” 81.020 – 81.030 mm

(3.1898 – 3.1902 in.)

Maximum diameter:

STD

81.23 mm (3.1980 in.)

O/S

0.50 81.73 mm (3.2177 in.)

If the diameter is greater than maximum, rebore all
the four cylinders. If necessary, replace the cylin-
der block.

DISASSEMBLY OF PISTON AND
CONNECTING ROD ASSEMBLIES

1. CHECK FIT BETWEEN PISTON AND PISTON PIN

Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as a
set.

5. REMOVE CYLINDER RIDGE

If the wear is less than 0.2 mm (0.008 in.), using a ridge
reamer, grind the top of the cylinder.

2. REMOVE PISTON RINGS

(a) Using a piston ring expander, remove the two compres-

sion rings.

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EM–201

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