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

26. REMOVE WATER BY–PASS PIPE

(a) Disconnect the following hoses:

(1) Water by–pass hose from cylinder block
(2) Water by–pass hoses from No.1 air tube
(3) Vacuum hose from turbocharging pressure
VSV
(4) Heater water hose

(b) Disconnect the following hoses:

(1) Upper radiator hose
(2) Water by–pass hose from water by–pass pipe
(3) Water by–pass pipe hose from ISC valve
(4) Heater water hose
(5) Two EVAP VSV vacuum hoses

(c) Remove the two bolts, water outlet and gasket.

24. REMOVE OIL PRESSURE SWITCH
25. REMOVE OIL COOLER

(See steps 4 to 6 on pages

LU–24

and 25)

27. REMOVE INTAKE MANIFOLD STAYS

Remove the two bolts and manifold stay. Remove the
two manifold stays.

(b) Remove the two bolts, two nuts, water by–pass

pipe, gasket and O–ring.

ENGINE MECHANICAL

Cylinder Head (3S–GTE)

EM–122

(b) Disconnect the following hoses:

(1) Vacuum hose (from T–VIS VSV) from T–VIS
actuator
(2) Vacuum hose (from T–VIS vacuum tank)
from intake manifold

(c) Remove the two bolts, the T–VIS vacuum tank,

T–VIS VSV, turbocharging pressure VSV and
bracket assembly.

28. REMOVE NO.1 AIR TUBE

(a) Disconnect the following hoses:

(1) Vacuum hose from intake manifold
(2) Two PS vacuum hoses
(3) Vacuum hose from turbocharging pressure
VSV

29. REMOVE T–VIS VACUUM TANK, T–VIS VSV,

TURBOCHARGING PRESSURE VSV AND BRACKET
(a) Disconnect the following connectors:

T–VIS VSV connector

Turbocharging pressure VSV connector

30. REMOVE INTAKE MANIFOLD AND T–VIS VALVE

(a) Remove the bolt, and disconnect the ground strap.
(b) Disconnect the knock sensor connector.

(b) Remove the three bolts and air tube.

ENGINE MECHANICAL

Cylinder Head (3S–GTE)

EM–123

31. REMOVE CHARCOAL CANISTER

(See step 20 on page

EM–226

)

32. REMOVE DELIVERY PIPE AND INJECTORS

(See steps 8 to 14 on pages

FI–161

and 162)

34. REMOVE CAMSHAFT TIMING PULLEYS

(See steps 15 to 19 on pages

EM–48

and 49)

35. REMOVE NO.1 IDLER PULLEY

(See step 24 on page

EM–51

)

33. REMOVE CYLINDER HEAD COVER

Remove the ten screws, seal washers, head cover and
two gaskets.

(c) Remove the four bolts, three nuts, intake man-

ifold, T–VIS VSV and two gaskets.

36. REMOVE NO.3 TIMING BELT COVER

Remove the five bolts and timing belt cover.

ENGINE MECHANICAL

Cylinder Head (3S–GTE)

EM–124

38. REMOVE CYLINDER HEAD

(a) Using SST, uniformly loosen and remove the ten

cylinder head bolts in several passes in the se-
quence shown.

SST 09043–38100
NOTICE: Cylinder head warpage or cracking could

result from removing in incorrect order.
(b) Remove the ten plate washers.

(c) Lift the cylinder head from the dowels on the

cylinder block, and place the cylinder head on
wooden blocks on a bench.

|HINT: If the cylinder head is difficult to lift off, pry
between the cylinder head and cylinder block with
a screwdriver.
NOTICE: Be careful not to damage the contact

surfaces of the cylinder head and cylinder block.

NOTICE:

Support the timing belt, so that the meshing
of the crankshaft timing pulley and timing
belt does not shift.

Be careful not to drop anything inside the
timing belt cover.

Do not allow the timing belt to come into
contact with oil, water or dust.

37. REMOVE CAMSHAFTS

Uniformly loosen ad remove the ten bearing cap bolts
in several passes in the sequence shown, and remove
the five bearing caps, oil seal and camshaft. Remove
the intake and exhaust camshafts.

ENGINE MECHANICAL

Cylinder Head (3S–GTE)

EM–125

2. REMOVE VALVES

(a) Using SST, compress the valve spring and remove

the two keepers.

SST 09202–70010
(b) Remove the spring retainer, valve spring, valve and

spring seat.

DISASSEMBLY OF CYLINDER HEAD

(See page

EM–117

)

1. REMOVE VALVE LIFTERS AND SHIMS

HINT: Arrange the valves, valve springs, spring
seats and spring retainers in correct order.

HINT: Arrange the valve lifters and shims in cor-
rect order.

(c) Using needle–nose pliers, remove the oil seal.

ENGINE MECHANICAL

Cylinder Head (3S–GTE)

EM–126

INSPECTION, CLEANING AND REPAIR
OF CYLINDER HEAD COMPONENTS

1. CLEAN TOP SURFACES OF PISTONS AND CYLINDER

BLOCK
(a) Turn the crankshaft, and bring each piston to top

dead center (TDC). Using a gasket scraper, remove
all the carbon from the piston top surface.

2. CLEAN CYLINDER HEAD
A. Remove gasket material

Using a gasket scraper, remove all the gasket material
from the surface contacting the cylinder block.
NOTICE: Be careful not to scratch the cylinder block

contact surface.

(b) Using a gasket scraper, remove all the gasket

material from the surface contacting the cylin-
der head.

(c) Using compressed air, blow carbon and oil from

the bolt holes.

CAUTION: Protect your eyes when using high–

compressed air.

6. Clean combustion chambers

Using a wire brush, remove all the carbon from the com-
bustion chambers.
NOTICE: Be careful not to scratch the cylinder block

contact surface.

C. Clean valve guide bushings .

Using a valve guide bushing brush and solvent, clean all
the guide bushings.

ENGINE MECHANICAL

Cylinder Head (3S–GTE)

EM–127

3. INSPECT CYLINDER HEAD
A. Inspect for flatness

Using precision straight edge and feeler gauge, mea-
sure the surfaces contacting the cylinder block, T–VIS
valve and exhaust manifold for warpage.
Maximum warpage:

Cylinder block side 0.20 mm (0.0079 in.)
T–VIS valve side 0.20 mm (0.0079 in.)
Exhaust manifold side 0.30 mm (0.0118 in.)

If warpage is greater than maximum, replace the cylin-
der head.

B. Inspect for cracks

Using a dye penetrant, check the combustion chambers,
intake ports, exhaust ports and cylinder block surface for
cracks.
If cracked, replace the cylinder head.

4. CLEAN VALVES

(a) Using a gasket scraper, chip off any carbon from the

valve head.

(b) Using a wire brush, thoroughly clean the valve.

D. Clean cylinder head

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

ENGINE MECHANICAL

Cylinder Head (3S–GTE)

EM–128

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

valve stem.

Valve stem diameter:

Intake

5.960 – 5.975 mm
(0.2346 – 0.2352 in.)

Exhaust

5.955 – 5.970 mm
(0.2344 – 0.2350 in.)

(c) Subtract the valve stem diameter measurement

from the guide bushing inside diameter mea-
surement.

Standard oil clearance:

Intake

0.025 – 0.058 mm
(0.0010 – 0.0023 in.)

Exhaust 0.030 – 0.063 mm

(0.0012 – 0.0025 in.)

Maximum oil clearance:

Intake

0.08 mm (0.0031 in:)

Exhaust

0.10 mm (0.0039 in.)

If the clearance is greater than maximum, replace
the valve and guide bushing.

6. IF NECESSARY, REPLACE VALVE GUIDE BUSHINGS

(a) (w/ Snap Ring)

Insert an old valve wrapped with tape into the valve
guide bushing, and break off the valve guide bushing
by hitting it with a hammer. Remove the snap
ring.

HINT: Wrap the tape approx. 13 mm (0.51 in.) from the
valve stem end.
NOTICE: Be careful not to damage the valve lifter

hole.

(b) Gradually heat the cylinder head to 80– 100

°

C (176

– 21 2

°

F) .

5. INSPECT VALVE STEMS AND GUIDE BUSHINGS

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

of the guide bushing.

Bushing inside diameter:

6.000 – 6.018 mm (0.2362 – 0.2369 in.)

ENGINE MECHANICAL

Cylinder Head (3S–GTE)

EM–129

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