4A–FE engine is an in–line, 4–cylinder, 1.6 liter DOHC 16–valve engine. Instruction - page 2
EFI system problems
Vacuum leaks:
•
PCV line
•
EGR line
•
Intake manifold
•
T–VIS valve (3S–GTE)
•
Throttle body
•
ISC valve (3S–GTE and 5S–FE)
•
Brake booster line
Air suction between air flow meter
and throttle body (3S–GTE)
Insufficient fuel flow
Incorrect ignition timing
Incorrect valve clearance
Carbon deposits in combustion chambers
Repair as necessary
Check PCV system
Check rings
Troubleshoot fuel system
Reset timing
Adjust valve clearance
Inspect cylinder head
Oil leak
PCV line clogged
Piston ring worn or damaged
Air cleaner clogged
EFI system problems
Incorrect ignition timing
EFI system problems
Incorrect ignition timing
EGR system faulty
Repair as necessary
Check hoses and repair as
necessary
FI–13
IG–25
, 29, 37
EM–13
,17,22
EM–92
, 127,
161
EXCESSIVE OIL CONSUMPTION
Check air cleaner
Repair as necessary
Reset timing
Repair as necessary
Reset timing
Check EGR system
Engine diesels
(runs after ignition
switch is turned off)
EM–94
,129,
163
AFTER FIRE, BACKFIRE
Muffler explosion
(after fire) on
deceleration only
Muffler explosion
(after fire) all the
time
Deceleration fuel cut system always off
Valve stem and guide bushing worn
ENGINE DIESELING
Check EFI (fuel cut) system
IG–25
, 29, 37
EC–9
, 22, 38
Valve stem oil seal worn
Excessive oil
consumption
Repair as necessary
Engine backfires
Possible cause
Possible cause
Possible cause
IG–25
, 29, 37
Check seals
Problem
Remedy
Remedy
Problem
Remedy
Problem
Page
Page
Page
MA–5
Check valves and guide bushing
EM–204
, 244,
289
–
ENGINE MECHANICAL
Troubleshooting
EM–10
Incorrect ignition timing
Vacuum leaks:
•
PCV line
•
EGR line
•
Intake manifold
•
T–VIS valve (3S–GTE)
•
Throttle body
•
ISC valve (3S–GTE and 5S–FE)
•
Brake booster line
EFI system problems
Fuel leak
Air cleaner clogged
Incorrect ignition timing
ER system problems:
•
Injector faulty
•
Deceleration fuel cut system
faulty
Idle speed too high
Check ISC system
(3S–GTE and 5S–FE)
Adjust idle speed (4A–FE)
Inspect plugs
Check EGR system
Check compression
Inflate tires to proper pressure
Troubleshoot clutch
Troubleshoot brakes
Spark plug faulty
EG R system always on
Low compression
Tires improperly inflated
Clutch slips
Brakes drag
Check ISC system
(3S–GTE and 5S–FE)
Adjust idle Speed (4A–FE)
Reset timing
Repair as necessary
Repair as necessary
Check air cleaner
Reset timing
Repair as necessary
EXCESSIVE FUEL CONSUMPTION
MA–8
IG–7
, 11, 16
EC–9
, 22, 38
EM–31
UNPLEASANT ODOR
MA–8
IG–25
, 29, 37
MA–5
IG–25
, 29, 37
Poor gasoline
mileage
Incorrect idle speed
Repair as necessary
Unpleasant odor
Possible cause
Possible cause
FI–208
, 211
FI–208
, 211
Problem
Problem
Remedy
Remedy
Page
Page
–
ENGINE MECHANICAL
Troubleshooting
EM–11
ENGINE TUNE–UP
INSPECTION OF ENGINE COOLANT
(See steps 1 and 2 on page
CO–5
)
INSPECTION OF ENGINE OIL
(See steps 1 and 2 on page
LU–5
)
INSPECTION OF BATTERY
(See steps 1 and 2 on page
CH–2
)
Standard specific gravity:
1.25 – 1.27 when fully charged at 20
°
C (68
°
F)
INSPECTION OF AIR FILTER
(See step 3 on page
MA–5
)
INSPECTION OF HIGH–TENSION
CORDS
(See page
IG–7
, 11 or 16)
Maximum resistance: 25 k
per cord
INSPECTION OF SPARK PLUGS
(Conventional Type only (4A–FE))
(See page
IG–7
)
Correct electrode gap: 0.8 mm (0.031 in.)
Recommended spark plugs: ND Q16R–U
NGK BCPRSEY
INSPECTION OF ALTERNATOR DRIVE
BELT
(See step 3 on page
CH–3
)
Drive belt tension:
4A–FE
New belt 160
±
20 lbf
Used belt 130 t 20 lbf
3S–GTE
w/ A/C
New belt 165
±
10 lbf
Used belt 84
±
15 lbf
w/o
A/C New belt 150
±
25 lbf
Used belt 130
±
25 lbf
5S–FE
w/ A/C
New belt 165
±
10 lbf
Used belt 110
±
10 lbf
w/o A/C
New belt 125 + 25 lbf
Used belt 95
±
20 lbf
–
ENGINE MECHANICAL
Engine Tune–Up
EM–12
4. INSPECT VALVE CLEARANCE
(a) Check only the valves indicated.
•
Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.
•
Record the out–of–specification valve clearance
measurements . They will be used later to determine
the required replacement adjusting shim.
Valve clearance (Cold):
Intake 0.15 – 0.25 mm (0.006 – 0.010 in.)
Exhaust 0.20 – 0.30 mm (0.008 – 0.012 in.)
(b) Turn the crankshaft one revolution (360
°
) and align
the mark as above. (See procedure in step 3)
(c) Check only the valves indicated as shown. Measure
the valve clearance. (See procedure in step (a))
INSPECTION AND ADJUSTMENT OF
VALVE CLEARANCE (4A–FE)
HINT: Inspect and adjust the valve clearance when the
engine is cold.
1. DISCONNECT HIGH–TENSION CORDS FROM SPARK
PLUGS
2. REMOVE CYLINDER HEAD COVER
(See steps 18 and 24 on pages
EM–85
and 87)
3. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley and align its groove with
timing mark ”0” of the No.1 timing belt cover.
(b) Check that the valve lifters on the No.1 cylinder are
loose and valve lifters on the No.4 are tight.
If not, turn the crankshaft one revolution (360
°
) and align
the mark as above.
5. ADJUST VALVE CLEARANCE
(a) Remove the adjusting shim.
•
Turn the crankshaft to position the cam lobe of
the camshaft on the adjusting valve upward.
•
Position the notch of the valve lifter facing the
spark plug side.
–
ENGINE MECHANICAL
Engine Tune–Up
EM–13
(b) Determine the replacement adjusting shim size by
following the Formula or Charts:
•
Using a micrometer, measure the thickness of the
removed shim.
•
Calculate the thickness of a new shim so that the
valve clearance comes within specified value.
T ............... Thickness of used shim
A ............... Measured valve clearance
N .............. Thickness of new shim
Intake N = T + (A – 0.20 mm (0.008 in.))
Exhaust N = T + (A – 0.25 mm (0.010 in.))
•
Select a new shim with a thickness as close as
possible to the calculated value.
HINT: Shims are available in seventeen sizes in increments of
0.05 mm (0.0020 in.), from 2.50 mm (0.0984
in.) to 3.30 mm (0.1299 in.).
(c) Install a new adjusting shim.
•
Place a new adjusting shim on the valve lifter.
•
Using SST (A), press down the valve lifter and
remove SST (B).
SST 09248–55020 (09248–05011 (A), 09248–05021 (B))
(d) Recheck the valve clearance.
6. REINSTALL CYLINDER HEAD COVER
(See steps 11 and 17 on pages
EM–109
and 111)
7. RECONNECT HIGH–TENSION CORDS TO SPARK
PLUGS
•
Using SST (A), press down the valve lifter and
place SST (B) between the camshaft and valve
lifter. Remove SST (A).
SST 09248–55020 (09248–05011 (A), 09248–05021 (B))
HINT: Apply SST (B) on the side marked with ”7”, at
the position shown in the illustration.
•
Remove the adjusting shim with small
screwdriver and magnetic finger.
–
ENGINE MECHANICAL
Engine Tune–Up
EM–14
Intake valve clearance (Cold):
0.15 – 0.25 mm (0.006 – 0.010 in.)
EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed, and
the measured clearance is 0.450 mm (0.0177 in.). Replace the
2.800 mm (0.1102 in.) shim with a new No.24 shim.
Adjusting Shim Selection Chart (Intake)
New shim thickness
2.550 (0.1004)
2–500 (0.0984)
2.600 (0.1024)
3.050 (0.1201)
2.950 (0.1161)
3.250 (0. 1280)
2.700 (0. 1063)
2.850 (0.1122)
2.650 (0.1043)
2.800 (0.1102)
3.300 (0.1299)
3.150 (0.1240)
3.000 (0.1181)
2.900 (0.1142)
3.200(0.1260)
3.100 (0.1220)
2.750 (0.1083)
Thickness
Thickness
Shim
No.
Shim
No.
mm (in.)
–
ENGINE MECHANICAL
Engine Tune–Up
EM–15
Exhaust valve clearance (Cold):
0.20 – 0.30 mm (0.008 – 0.012 in.)
EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed, and
the measured clearance is 0.450 mm (0.0177 in.). Replace the
2.800 mm (0.1102 in.) shim with a new No.22 shim.
Adjusting Shim Selection Chart (Exhaust)
New shim thickness
3.000(0.1181)
2.650 (4.1043)
3.100 (0.1220)
2.800 (0.1102)
2.900 (0.1142)
3.150 (0.1240)
2.600 (0.1024)
3.050 (0.1201)
2.550 (0.1004)
2.750 (0.1083)
2.700 (0.1063)
2.850 (0.1122)
3.200 (0.1260)
2.500 (0.0984)
3.300 (0.1299)
2.950 (0.1161)
3.250 (0.1280)
Thickness
Thickness
Shim
No.
Shim
No.
mm (in.)
–
ENGINE MECHANICAL
Engine Tune–Up
EM–16
INSPECTION AND ADJUSTMENT OF
VALVE CLEARANCE (3S–GTE)
HINT: Inspect and adjust the valve clearance when the
engine is cold.
1. REMOVE INTERCOOLER
(See steps 13 to 15 on pages
TC–9
and 10)
2. DISCONNECT HIGH–TENSION CORDS FROM SPARK
PLUGS
3. REMOVE EGR VACUUM MODULATOR AND VSV
(See step 20 on page
EM–121
)
4. REMOVE EGR VALVE AND PIPE
(See step 21 on page
EM–121
)
5. REMOVE THROTTLE BODY
(See steps 2, 3, 5 to 8, 10 and 11 on pages
FI–194
and
195)
6. REMOVE CYLINDER HEAD COVER
(See step 33 on page
EM–124
)
8. INSPECT VALVE CLEARANCE
(a) Check only the valves indicated.
•
Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.
•
Record the out–of–specification valve clearance
measurements. They will be used later to determine
the required replacement adjusting shim.
Valve clearance (Cold):
Intake 0.15 – 0.25 mm (0.006 – 0.010 in.)
Exhaust 0.28 – 0.38 mm (0.071 – 0.015 in.)
(b) Turn the crankshaft one revolution (360
°
) and align
the mark as above. (See procedure in step 7)
(c) Check only the valves indicated as shown.
Measure the valve clearance.
(See procedure in step (a))
7. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley and align its groove with
timing mark ”0” of the No.1 timing belt cover.
(b) Check that the valve lifters on the No.1 cylinder are
loose and valve lifters on No.4 are tight.
If not, turn the crankshaft one revolution (360
°
) and align
the mark as above.
–
ENGINE MECHANICAL
Engine Tune–Up
EM–17