4A–FE engine is an in–line, 4–cylinder, 1.6 liter DOHC 16–valve engine. Instruction - page 33
INSTALLATION OF ENGINE
1. ASSEMBLE ENGINE AND TRANSAXLE
(See MT section)
2. INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN
VEHICLE
(a) Attach the engine chain hoist to the engine hangers.
(b) Lower the engine into the engine compartment. Tilt
the transaxle downward, lower the engine and clear
the LH mounting.
NOTICE: Be careful not to hit the PS gear housing.
(c) Keep the engine level, and align RH and LH mount-
ings with the body bracket.
(f) Attach the LH mounting insulator to the mounting
bracket and body with the through bolt and four
bolts. Tighten the bolts.
Torque:
Bolt 63 N–m (650 kgf–cm, 47 ft–lbf)
Through bolt 87 N–m (890 kgf–cm, 64 ft–lbf)
(g) Tighten the through bolt and two nuts of the RH
mounting insulator.
Torque:
Nut 52 N–m (530 kgf–cm, 38 ft–lbf)
Through bolt 87 N–m (890 kgf–cm, 64 ft–lbf)
(h) Remove the engine chain hoist from the engine.
(e) Install the LH mounting bracket to the transaxle
case with the three bolts.
Torque: 52 N–m (530 kgf–cm, 38 ft–lbf)
(d) Attach the RH mounting insulator to the mount-
ing bracket and body, and temporarily install
the through bolt and two nuts.
–
ENGINE MECHANICAL
Cylinder Block (3S–GTE)
EM–258
6. INSTALL CATALYTIC CONVERTER
(a) Place new cushion, retainer and gasket on the catalyt-
ic converter.
(b) Install the catalytic converter with the three bolts
and two nuts.
Torque: 29 N–m (300 kgf–cm, 22 ft–lbf)
4. INSTALL LH ENGINE MOUNTING STAY
Install the mounting stay with the bolt and nut.
Torque: 21 N–m (210 kgf–cm, 15 ft–lbf)
5. CONNECT GROUND STRAP
Connect the ground strap to the transaxle with the bolt.
3. INSTALL RH ENGINE MOUNTING STAY
Install the mounting stay with the bolt and nut.
Torque: 73 N–m (740 kgf–cm, 54 ft–lbf)
(d) Install the LH converter stay with the three bolts.
Torque: 59 N–m (600 kgf–cm, 43 ft–lbf)
(c) Install the RH converter stay with the four bolts.
Torque: 59 N–m (600 kgf–cm, 43 ft–lbf)
–
ENGINE MECHANICAL
Cylinder Block (3S–GTE)
EM–259
9. INSTALL ENGINE MOUNTING CENTER MEMBER
(a) Install the engine mounting center member with the
four bolts.
Torque: 52 N–m (530 kgf–cm, 38 ft–lbf)
(b) Install and torque the four bolts holding the insulators
to the center member.
Torque: 73 N–m (740 kgf–cm, 54 ft–lbf)
8. INSTALL REAR ENGINE MOUNTING BRACKET AND
INSULATOR
(a) Install the mounting bracket with the three bolts.
Torque: 77 N–m (790 kgf–cm, 57 ft–lbf)
(b) Temporarily install the mounting insulator with the
through bolt.
7. INSTALL FRONT ENGINE MOUNTING BRACKET AND
INSULATOR
(a) Install the mounting bracket with the two bolts.
Torque: 77 N–m (790 kgf–cm, 57 ft–lbf)
(b) Temporarily install the mounting insulator with the
through bolt and nut.
10. TIGHTEN FRONT AND REAR ENGINE MOUNTING
THROUGH BOLTS
(a) Tighten the rear through bolt.
Torque: 87 N–m (890 kgf–cm, 64 ft–lbf)
(b) Tighten the front through bolt.
Torque: 87 N–m (890 kgf–cm, 64 ft–lbf)
–
ENGINE MECHANICAL
Cylinder Block (3S–GTE)
EM–260
18. INSTALL FRONT EXHAUST PIPE
(a) Install the support hook on the front exhaust pipe to
the support bracket.
(b) Place two new gaskets on the front and rear of the
front exhaust pipe.
(c) Temporarily install the two bolts and new nuts holding
the exhaust pipe to the center exhaust pipe.
(d) Using a 14 mm deep socket wrench, install the three
new nuts holding the exhaust pipe to the catalytic
converter.
Torque: 62 N–m (630 kgf–cm, 46 ft–lbf)
(e) Tighten the two bolts and nuts holding the exhaust
pipe to the center exhaust pipe.
Torque: 43 N–m (440 kgf–cm, 32 ft–lbf)
(f) Install the clamp with the bolt.
12. INSTALL A/C COMPRESSOR AND IDLER PULLEY
BRACKET
(a) Install the compressor and idler pulley bracket with
the four bolts.
Torque: 27 N–m (280 kgf–cm, 20 ft–lbf)
(b) Connect the two connectors.
(c) Connect the A/C compressor connector.
13. INSTALL ALTERNATOR (See page
CH–23
)
14. INSTALL DEFLECTOR TO TRANSFER EXTENSION
HOUSING
15. INSTALL DYNAMIC DAMPER TO TRANSFER
EXTENSION HOUSING
16. INSTALL FRONT PROPELLER SHAFT
(See PR section)
17. INSTALL DRIVE SHAFTS
(See SA section)
11. INSTALL PS PUMP
(a) Install the PS pump with the four bolts.
Torque:
Adjusting bolt 39 N–m (400 kgf–cm, 29 ft–lbf)
Others 43 N–m (440 kgf–cm, 32 ft–lbf)
(b) Install the drive belt.
(c) Connect the two air hoses to the air pipe.
–
ENGINE MECHANICAL
Cylinder Block (3S–GTE)
EM–261
19. INSTALL SUSPENSION LOWER CROSSMEMBER
Install the lower crossmember with the four bolts and
two nuts.
Torque: 152 N–m (1,550 kgf–cm, 112 ft–lbf)
20. CONNECT ENGINE WIRE TO CABIN
(a) Push in the engine wire through the cowl panel.
Install the two nuts.
(b) Connect the following connectors.
(1) Two engine ECU connectors
(2) Two cowl wire connectors
(3) A/C amplifier connector
–
ENGINE MECHANICAL
Cylinder Block (3S–GTE)
EM–262
23. INSTALL TURBOCHARGING PRESSURE SENSOR
AND A/C ASV
(a) Install the turbocharging pressure sensor and A/C
ASV with the bolt.
(b) Connect the following hoses:
(1) Two vacuum hoses to ASV (from A/C ASV)
(2) Vacuum hose to ASV (from turbocharging
pressure sensor)
(c) Connect turbocharging pressure sensor connector.
24. CONNECT TRANSAXLE OIL COOLER TUBE
(a) Align the matchmarks on the oil cooler hoses and
tubes.
(b) Connect the two oil cooler hoses.
Torque: 34 N–m (350 kgf–cm, 25 ft–lbf)
21. CONNECT ENGINE WIRE
(a) Engine wire clamp to wire bracket on RH fender
apron
(b) Two cowl wire connectors
22. CONNECT HOSES
(a) Brake booster vacuum hose from intake manifold
(b) Turbocharging pressure sensor hose from gas filter
25. CONNECT TRANSAXLE CONTROL CABLES TO
TRANSAXLE
–
ENGINE MECHANICAL
Cylinder Block (3S–GTE)
EM–263
33. INSTALL ENGINE WIRE BRACKET
(a) Install the wire bracket with the two bolts. Install the
noise filter.
(b) Install the wire clamp to the wire bracket.
34. CONNECT WIRES AND CONNECTORS
(a) Check connector
(b) Igniter connector
(c) Ground strap from LH fender apron
26. INSTALL CLUTCH RELEASE CYLINDER
Install the release cylinder and tube with the four bolts.
27. INSTALL STARTER (See page
ST–22
)
28. CONNECT CONNECTORS
(1) Engine room wire connector
(2) Noise filter connector
32. INSTALL CHARCOAL CANISTER
(a) Install the charcoal canister with the two bolts.
(b) Connect the three hoses.
29. CONNECT FUEL HOSES
Torque (Union bolt): 29 N–m (300 kgf–cm, 22 ft–lbf)
30. CONNECT SPEEDOMETER CABLE
31. CONNECT HEATER HOSES
–
ENGINE MECHANICAL
Cylinder Block (3S–GTE)
EM–264
36. INSTALL SUSPENSION UPPER BRACE
(a) Install the suspension upper brace with the two
bolts and four bolts.
Torque: Bolt 21 N–m (210 kgf–cm, 15 ft–lbf)
Nut 64 N–m (650 kgf–cm, 47 ft–lbf)
(b) Install the outside lower windshield moulding.
(c) Install the two wiper arms.
40. INSTALL INJECTOR SOLENOID RESISTOR AND FUEL
PUMP RESISTOR
(a) Install the solenoid resistor and fuel pump resistor
with the bolt.
(b) Connect the two connectors.
41. INSTALL BATTERY
37. (w/ CRUISE CONTROL SYSTEM)
INSTALL CRUISE CONTROL ACTUATOR
(a) Connect the cable to the actuator.
(b) Connect the actuator connector
(c) install the actuator with the three bolts.
(d) Install the actuator cover with the two nuts.
35. INSTALL IGNITION COIL
(a) Install the ignition coil with the two bolts.
(b) Connect the high–tension cord.
(c) Connect the ignition coil connector.
38. INSTALL RADIATOR RESERVOIR TANK
Install the reservoir tank with the two nuts.
39. INSTALL RADIATOR (See pages
CO–24
and 25)
–
ENGINE MECHANICAL
Cylinder Block (3S–GTE)
EM–265