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

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