4A–FE engine is an in–line, 4–cylinder, 1.6 liter DOHC 16–valve engine. Instruction - page 37

3. INSPECT CONNECTING ROD
A. Inspect connecting rod alignment

Using rod aligner and feeler gauge, check the connect-
ing rod alignment.

•

Check for bending.

Maximum bending:

0.05 mm (0.0020 in.) per 100 mm (3.94 in.)

If bend is greater than maximum, replace the connect-
ing rod assembly.

•

Check for twist.

Maximum twist:

0.15 mm (0.0059 in.) per 100 mm (3.94 in.)

If twist is greater than maximum, replace the connecting
rod assembly.

(c) Using a feeler gauge, measure the end gap.
Standard end gap:

No.1

0.270 – 0.500 mm
(0.0106 – 0.0197 in.)

No.2

0.350 – 0.600 mm
(0.0138 – 0.0234 in . )

Oil (Side rail) 0.200 – 0.550 mm

(0.0079 – 0.0217 in.)

Maximum end gap:

No.1

1.10 mm (0.0433 in.)

No.2

1.20 mm (0.0472 in.)

Oil (Side rail) 1.15 mm (0.0453 in.)

If the end gap is greater than maximum, replace
the piston ring. If the end gap is greater than max-
imum, even with a new piston ring, rebore all the
four cylinders or replace the cylinder block.

D. Inspect piston pin fit

At 60

°

C (140

°

F), you should be able to push the pis-

ton pin into the piston pin hole with your thumb.

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ENGINE MECHANICAL

Cylinder Block (5S–FE)

EM–290

(c) Subtract the piston pin diameter measurement from

the bushing inside diameter measurement.
Standard oil clearance: 0.005 – 0.011 mm

(0.0002 – 0.0004 in.)

Maximum oil clearance: 0.05 mm (0.0020 in.)
If the oil clearance is greater than maximum, re-
place the bushing: If necessary, replace the piston
and piston pin as a set.

B. Inspect piston pin oil clearance

(a) Using a caliper gauge, measure the inside diameter

of the connecting rod bushing.

Bushing inside diameter: 22.005 – 22.017 mm

(0.8663 – 0.8668 in.)

(b) Align the oil holes of a new bushing and the con-

necting rod.

(c) Using SST and a press, press in the bushing.
SST 09222–30010

(b) Using a micrometer, measure the piston pin di-

ameter.
Piston pin diameter: 21.997 – 22.009 mm

(0.8660–0. 8665 in.)

C. If necessary, replace connecting rod bushing

(a) Using SST and a press, press out the bushing.
SST 09222–30010

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ENGINE MECHANICAL

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(b) If the cap nut cannot be turned easily, measure

the outside diameter of the connecting rod bolt
with a vernier caliper.
Standard diameter: 7.860 – 8.000 mm

(0.3094 – 0.3150 in.)

Minimum diameter: 7.60 mm (0.2992 in.)

HINT: If the location of this area cannot be judged
by visual inspection, measure the outer diameter
at the location shown in the illustration. If the out-
side diameter is less than minimum, replace the
connecting rod bolt and cap nut as a set.

D. Inspect connecting rod bolts

(a) Install the cap nut to the connecting rod bolt. Check

that the cap nut can be turned easily by hand to the
end of the thread.

(e) Check the piston pin fit at normal room temperature.

Coat the piston pin with engine oil, and push it into
the connecting rod with your thumb.

(d) Using a pinhole grinder, hone the bushing to obtain

the standard specified clearance (see step B
above) between the bushing and piston pin.

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ENGINE MECHANICAL

Cylinder Block (5S–FE)

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BORING OF CYLINDERS

HINT:

•

Bore all the four cylinders for the oversized piston
outside diameter.

•

Replace all the piston rings with ones to match the
oversized pistons.

1. KEEP OVERSIZED PISTONS
Oversized piston diameter:

O/S 0.50

87.350 – 87.380 mm
(3.4390 – 3.4402 in.)

2. CALCULATE AMOUNT TO BORE CYLINDERS

(a) Using a micrometer, measure the piston diameter at

right angles to the piston pin center line, 23.5 mm
(0.925 in.) from the piston head.

(b) Calculate the amount each cylinder is to be rebored

as follows:
Size to be rebored = P + C – H
P = Piston diameter
C = Piston clearance

0.140 – 0.160 mm (0.0055 – 0.0063 in.)

H = Allowance for honing

0.02 mm (0.0008 in.) or less

3. BORE AND HONE CYLINDERS TO CALCULATED

DIMENSIONS
Maximum honing: 0.02 mm (0.0008 in.)
NOTICE: Excess honing will destroy the finished
roundness.

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ENGINE MECHANICAL

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2. INSPECT MAIN JOURNALS AND CRANK PINS

(a) Using a micrometer, measure the diameter of each

main journal and crank pin.

Main journal diameter:

STD

54.998 – 55.003 mm
(2.1653 – 2.1655 in.)

U/S 0.25

54.745 – 54.755 mm
(2.1553 – 2.1557 in.)

Crank pin diameter:

STD

51.985 – 52.000 mm
(2.0466 – 2.0472 in.)

U/S 0.25

51.745 – 51.755 mm
(2.0372 – 2.0376 in.)

If the diameter is not as specified, check the oil clearance
(See pages

EM–279

to 283). If necessary, grind or replace

the crankshaft.
(b) Check each main journal and crank pin for taper and

out–of–round as shown.

Maximum taper and out–of–round: 0.02 mm (0.0008 in.)
If the taper and out–of–round is greater than maximum,
replace the crankshaft.

3. IF NECESSARY, GRIND AND HONE MAIN JOURNALS

AND/OR CRANK PINS
Grind and hone the main journals and/or crank pins to
the finished undersized diameter (See procedure in step
2).
Install new main journal and/or crank pin undersized
bearings.

REPLACEMENT OF CRANKSHAFT OIL
SEALS

(See pages

EM–249

and 250)

INSPECTION AND REPAIR OF
CRANKSHAFT

1. INSPECT CRANKSHAFT FOR RUNOUT

(a) Place the crankshaft on V–blocks.
(b) Using a dial indicator, measure the circle runout at

the center journal.

Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace
the crankshaft.

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ENGINE MECHANICAL

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ASSEMBLY OF PISTON AND
CONNECTING ROD ASSEMBLIES

1. ASSEMBLE PISTON AND CONNECTING ROD

(a) Using a small screwdriver, install a new snap ring

on one side of the piston pin hole.

2. INSTALL PISTON RINGS

(a) Install the oil ring expander and two side rails by

hand.

(c) Coat the piston pin with engine oil.
(d) Align the front marks of the piston and connecting

rod, and push in the piston pin with your thumb.

(b) Gradually heat the piston to 80 – 90

°

C (176 – 194

°

F).

(e) Using a small screwdriver, install a new snap ring

on the other side of the piston pin hole.

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3. INSTALL BEARINGS

(a) Align the bearing claw with the groove of the connect-

ing rod or connecting cap.

(b) Install the bearings in the connecting rod and connect-

ing rod cap.

(b) Using a piston ring expander, install the two com-

pression rings with the code mark facing up-
ward.

Code mark: No.1 1N or T

No.2 2N or 2T

(c) Position the piston rings so that the ring ends are

as shown.

NOTICE: Do not align the ring ends.

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ENGINE MECHANICAL

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1. INSTALL MAIN BEARINGS

HINT:

•

Main bearings come in widths of 19.2 mm (0.756 in.)
and 22.9 mm (0.902 in.). Install the 22.9 mm (0.902
in.) bearings in the No.3 cylinder block journal posi-
tion with the main bearing cap. Install the 19.2 mm
(0.756 in.) bearings in the other positions.

•

Upper bearings have an oil groove and oil holes; low-
er bearings do not.

ASSEMBLY OF CYLINDER BLOCK

(See page

EM–268

)

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, O–rings and oil seals with new
parts.

(b) Align the bearing claw with the claw groove of the

main bearing cap, and push in the five lower bear-
ings.

HINT: A number is marked on each main bearing cap
to indicate the installation position.

2. INSTALL UPPER THRUST WASHERS

Install the two thrust washers under the No.3 journal
position of the cylinder block with the oil grooves facing
outward.

(a) Align the bearing claw with the claw groove of the

cylinder block, and push in the five upper bearings.

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