Cylinder head (5S-FE)¶

Components¶

Removal of cylinder head¶

(See Cylinder head (5S-FE))

Disconnect cable from negative terminal of battery.

Caution

Work must be started after approx. 20 seconds or longer from the time the ignition switch is turned to the LOCK position and the negative (–) terminal cable is disconnected from the battery.
Drain engine coolant. (See page CO-6)
Remove engine under covers.
Remove engine hood side panels.
Remove suspension upper brace.
(A/T) Disconnect throttle cable from throttle body.
Disconnect accelerator cable from throttle body.
Remove cruise control actuator (w/ cruise control system) and accelerator linkage. (See Cylinder block (5S-FE) › Removal of engine, step 11)
Remove air cleaner cap. (See Cylinder block (5S-FE) › Removal of engine, step 9)
Disconnect ground strap connector.
Disconnect vacuum hoses.
1. Brake booster vacuum hose from intake manifold
2. Vacuum sensor hose from intake manifold
3. A/C VSV vacuum hose from intake manifold
4. A/C VSV air hose from ISC valve
Remove distributor. (See Distributor (5S-FE))
Remove front exhaust pipe. (See Cylinder block (5S-FE) › Removal of engine, step 29)
Remove exhaust manifold and catalytic converter assembly.
1. Disconnect the oxygen sensor (main) connector.
2. (CALIF. only) Disconnect the sub-oxygen sensor connector.
3. Remove the six bolts and manifold upper heat insulator.
4. Remove the two bolts, two nuts and catalytic converter stay.
5. Remove the six nuts, the exhaust manifold and catalytic converter assembly.
Separate exhaust manifold and catalytic converter.

Remove the following parts:
1. Five bolts
2. Manifold lower heat insulator
3. Eight bolts
4. Two catalytic converter heat insulators
5. Three bolts and two nuts
6. Exhaust manifold
7. Gasket
8. Retainer
9. Cushion
10. Catalytic converter
Remove water outlet and housing.
1. Disconnect the following connectors:
  - Water temperature sender gauge connector
  - Water temperature sensor connector
  - Cold start injector time switch connector
2. Remove the two bolts, and disconnect the fuel inlet hose (with the fuel return tube) from the water outlet and cylinder head.
3. Disconnect the following hoses:
  1. Water filler hose
  2. Radiator hose
  3. Heater water hose
  4. ISC water by-pass hose
  5. Water by-pass pipe hose
  6. Two EVAP BVSV vacuum hoses
4. Remove the two bolts, the water outlet, housing assembly and gasket.
Remove water by-pass pipe.
1. Remove the bolt, two nuts and oil cooler heat protector.
2. Disconnect the following hoses:
  1. ISC water by-pass hose
  2. Heater water hose
  3. Two oil cooler water by-pass hoses
3. Remove the two bolts, two nuts, water by-pass pipe and gasket.
4. Remove the O-ring from the water by-pass hose.
Remove throttle body. (See steps 7 to 10 on page FI-143)
Remove cold start injector pipe. (See step 3 on page FI-102)
Remove cold start injector. (See steps 2 and 4 on pages FI-102 and 103)
Remove EGR valve and vacuum modulator.
1. (CALIF. only) Disconnect EGR gas temperature sensor connector.
2. Remove the following hoses:
  1. Two vacuum hoses from EGR VSV
  2. Vacuum hose from charcoal canister
3. Loosen the union nut of the EGR pipe, and remove two bolts, the EGR valve, vacuum modulator, vacuum hoses assembly and gasket.
Remove fuel pressure VSV.
1. Disconnect the VSV connector.
2. Disconnect the following hoses:
  1. Vacuum hose from fuel pressure regulator
  2. Vacuum hose from intake manifold
3. Remove the two bolts and VSV. Disconnect the ground strap.
Remove EGR VSV.
1. Disconnect the VSV connector.
2. Remove the bolt and VSV.
Remove intake manifold.
1. Disconnect the alternator connector and wire.
2. Disconnect the two wire clamps from the wire brackets.
3. Disconnect the clip of the engine wire from the LH accelerator bracket.
4. Remove the two bolts and manifold stay.
5. Remove the six bolts, two nuts, intake manifold and gasket.
Remove delivery pipe and injectors. (See steps 7 to 10 and 12 on pages FI-122 and 123)
Remove camshaft timing pulley. (See Timing belt (5S-FE) › Removal of timing belt, steps 9–17)
Remove No.1 idler pulley and tension spring. (See Timing belt (5S-FE) › Removal of timing belt, step 22)
Remove No.3 timing belt cover.

Remove the four bolts and timing belt cover.
Notice
- Support the timing belt, so 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 belt to come into contact with oil, water or dust.
Remove RH front engine hanger.

Remove the two bolts and engine hanger.
Remove LH front engine hanger.

Remove the bolt and engine hanger.
Remove oil pressure switch.
Remove cylinder head cover.

Remove the four nuts, grommets, head cover and gasket.

Hint

Arrange the grommets in correct order so that they can be reinstalled into their original positions. This minimizes any possibility of oil leakage from reuse grommets.
Remove camshafts.

Notice

Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.

A. Remove exhaust camshaft
1. Set the knock pin of the intake camshaft at 10 – 45° BTDC of camshaft angle.
  
  Hint
  
  The above angle allows No.2 and No.4 cylinder cam lobes of the exhaust camshaft to push their valve lifters evenly.
2. Secure the exhaust camshaft sub-gear to drive gear with a service bolt.
  
  Recommended service bolt:
  - Thread diameter – 6 mm
  - Thread pitch – 1.0 mm
  - Bolt length – 16 – 20 mm (0.63 – 0.79 in.)
  Hint
  
  When removing the camshaft, make certain that the torsional spring force of the sub-gear has been eliminated by the above operation.
3. Remove the two bolts and rear bearing cap.
4. Uniformly loosen and remove the six bolts on the No.1, No.2 and No.4 bearing cap in several passes in the sequence shown.
  
  Notice
  
  Do not remove the No.3 bearing cap bolts at this stage.
5. Remove the No.1, No.2 and No.4 bearing caps.
6. Alternately loosen and remove the two bolts on the No.3 bearing cap.
  Hint
  - As two No.3 bearing cap bolts are loosened, check that the camshaft is being lifted out straight and level.
  - If the camshaft is not being lifted out straight and level, retighten the two No.3 bearing cap bolts. Then reverse the order of above steps from (f) to (a) and reset the knock pin of the intake camshaft at 10 – 45° BTDC, and repeat steps from (b) to (f) once again.
  Notice
  
  Do not pry on or attempt to force the camshaft with a tool or other objects.
7. Remove the No.3 bearing cap and exhaust camshaft.
B. Remove intake camshaft
1. Set the knock pin of the intake camshaft at 80 – 115° BTDC of camshaft angle.
  
  Hint
  
  The above angle allows the No.1 and No.3 cylinder cam lobes of intake camshaft to push their valve lifters evenly.
2. Remove the two bolts, front bearing cap and oil seal.
3. Uniformly loosen and remove the bolts on the No.1, No.3 and No.4 bearing cap in several passes in the sequence shown.
  
  Notice
  
  Do not remove the No.2 bearing cap bolts at this stage.
4. Remove the No.1, No.3 and No.4 bearing caps.
5. Alternately loosen and remove the two bolts on the No.2 bearing cap.
  Hint
  - As two No.2 bearing cap bolts are loosened, check that the camshaft is being lifted out straight and level, after breaking the adhesion on the front bearing cap.
  - If the camshaft is not being lifted out straight and level, retighten the two No.2 bearing cap bolts. Reverse the order of above steps from (e) to (a) and reset the knock pin of the intake camshaft at 80 – 115° BTDC, and repeat steps from (b) to (e) once again.
  Notice
  
  Do not pry on or attempt to force the camshaft with a tool or other objects.
6. Remove the No.2 bearing cap and camshaft.
Disassemble exhaust camshaft.
1. Mount the hexagonal wrench head portion of the camshaft in a vise.
  
  Notice
  
  Be careful not to damage the camshaft.
2. Insert a service bolt (A) into the service hole of the camshaft sub-gear.
3. Using a screwdriver, turn the sub-gear clockwise, and remove the service bolt (B).
  
  Notice
  
  Be careful not to damage the camshaft.
4. Using snap ring pliers, remove the snap ring.
5. Remove the following parts:
  1. Wave washer
  2. Camshaft sub-gear
  3. Camshaft gear spring
Remove cylinder head.
1. Using SST, uniformly loosen and remove the ten cylinder head bolts in several passes in the sequence shown.
  
  SST 09011-38121
  
  Notice
  
  Head warpage or cracking could result from removing bolts in the incorrect order.
2. 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 cylinder head and cylinder block surfaces of the cylinder head.

Disassembly of cylinder head¶

(See Cylinder head (5S-FE))

Remove valve lifters and shims.

Hint

Arrange the valve lifters and shims in correct order.
Remove valves.
1. Using SST, compress the valve spring and remove the two keepers.
  
  SST 09202-70010
2. Remove the spring retainer, valve spring, valve and spring seat.
  
  Hint
  
  Arrange the valves, valve springs, spring seats and spring retainers in correct order.
3. Using needle-nose pliers, remove the oil seal.

Inspection, cleaning and repair of cylinder head components¶

Clean top surfaces of pistons and cylinder block.
1. 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. Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
3. Using compressed air, blow carbon and oil from the bolt holes.
  
  Caution
  
  Protect your eyes when using high-compressed air.
Clean cylinder head.
1. Remove gasket material
  
  Using a gasket scraper, remove all the gasket material from the cylinder block surface.
  
  Notice
  
  Be careful not to scratch the cylinder block contact surface.
2. Clean combustion chambers
  
  Using a wire brush, remove all the carbon from the combustion chambers.
  
  Notice
  
  Be careful not to scratch the cylinder block contact surface.
3. Clean valve guide bushings
  
  Using a valve guide bushing brush and solvent, clean all the guide bushings.
4. Clean cylinder head
  
  Using a soft brush and solvent, thoroughly clean the cylinder head.
Inspect cylinder head.
1. Inspect for flatness
  
  Using precision straight edge and feeler gauge, measure the surfaces contacting the cylinder block manifolds for warpage.
  
  Surface Maximum warpage
  
  Cylinder block side 0.05 mm (0.0020 in.)
  
  Manifold side 0.08 mm (0.0031 in.)
  
  If warpage is greater than maximum, replace the cylinder head.
2. Inspect for cracks
  
  Using a dye penetrant, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks.
  
  If cracked, replace the cylinder head.
Clean valves.
1. Using a gasket scraper, chip off any carbon from the valve head.
2. Using a wire brush, thoroughly clean the valve.
Inspect valve stems and guide bushings.
1. Using a caliper gauge, measure the inside diameter of the guide bushing.
  
  Bushing inside diameter: 6.010 – 6.030 mm (0.2366 – 0.2374 in.)
2. Using a micrometer, measure the diameter of the valve stem.
  
  Valve stem diameter:
  - Intake – 5.970 – 5.985 mm (0.2350 – 0.2356 in.)
  - Exhaust – 5.965 – 5.980 mm (0.2348 – 0.2354 in.)
3. Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement.
  
  Standard oil clearance:
  - Intake – 0.025 – 0.060 mm (0.0010 – 0.0024 in.)
  - Exhaust – 0.030 – 0.065 mm (0.0012 – 0.0026 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.
If necessary, replace valve guide bushings.
1. (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. 8 mm (0.31 in.) from the valve stem end.
  
  Notice
  
  Be careful not damage to the valve lifter hole.
2. Gradually heat the cylinder head to 80 – 100°C (176 – 212°F).
3. Using SST and a hammer, tap out the guide bushing.
  
  SST 09201-70010
4. Using a caliper gauge, measure the bushing bore diameter of the cylinder head.
5. Select a new guide bushing (STD size or O/S 0.05).
  
  Both intake and exhaust
  
  Bushing bore diameter mm (in.) Bushing size
  
  11.000 – 11.027 (0.4331 – 0.4342) Use STD
  
  11.050 – 11.077 (0.4350 – 0.4361) Use O/S 0.05
  
  If the bushing bore diameter of the cylinder head is greater than 11.027 mm (0.4341 in.), machine the bushing bore to the following dimension:
  
  11.050 – 11.077 mm (0.4350 – 0.4361 in.)
  
  If the bushing bore diameter of the cylinder head is greater than 11.077 mm (0.4361 in.), replace the cylinder head.
6. Gradually heat the cylinder head to 80 – 100°C (176 – 212°F).
7. Using SST and a hammer, tap in a new guide bushing until the snap ring makes contact with the cylinder head.
  
  SST 09201-70010
8. Using a sharp 6 mm reamer, ream the guide bushing to obtain the standard specified clearance (See Inspection, cleaning and repair of cylinder head components) between the guide bushing and valve stem.
Inspect and grind valves.
1. Grind the valve enough to remove pits and carbon.
2. Check that the valve is ground to the correct valve face angle.
  
  Valve face angle: 44.5°
3. Check the valve head margin thickness.
  
  Standard margin thickness: 0.8 – 1.2 mm (0.031 – 0.047 in.)
  
  Minimum margin thickness: 0.5 mm (0.020 in.)
  
  If the margin thickness is less than minimum, replace the valve.
4. Check the valve overall length.
  
  Standard overall length:
  - Intake – 100.60 mm (3.9606 in.)
  - Exhaust – 100.45 mm (3.9547 in.)
  Minimum overall length:
  - Intake – 100.1 mm (3.941 in.)
  - Exhaust – 100.0 mm (3.937 in.)
  If the overall length is less than minimum, replace the valve.
5. Check the surface of the valve stem tip for wear.
  
  If the valve stem tip is worn, resurface the tip with a grinder or replace the valve.
  
  Notice
  
  Do not grind off more than the minimum.
Inspect and clean valve seats.
1. Using a 45° carbide cutter, resurface the valve seats. Remove only enough metal to clean the seats.
2. Check the valve seating position.
  
  Apply a thin coat of prussian blue (or white lead) to the valve face. Lightly press to the valve against the seat. Do not rotate the valve.
3. Check the valve face and seat for the following:
  - If blue appears 360° around the face, the valve is concentric. If not, replace the valve.
  - If blue appears 360° around the valve seat, the guide and face are concentric. If not, resurface the seat.
  - Check that the seat contact is in the middle of the valve face with the following width:
    
    1.0 – 1.4 mm (0.039 – 0.055 in.)
  If not, correct the valve seats as follows:
  1. If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat.
  2. If the seating is too low on the valve face, use 75° and 45° cutters to correct the seat.
4. Hand-lap the valve and valve seat with an abrasive compound.
5. After hand-lapping, clean the valve and valve seat.
Inspect valve springs.
1. Using a steel square, measure the squareness of the valve spring.
  
  Maximum squareness: 2.0 mm (0.075 in.)
  
  If squareness is greater than maximum, replace the valve spring.
2. Using vernier calipers, measure the free length of the valve spring.
  
  Free length: 45.0 mm (1.772 in.)
  
  If the free length is not as specified, replace the valve spring.
3. Using a spring tester, measure the tension of the valve spring at the specified installed length.
  
  Installed tension: 16.7 – 19.3 kg (36.8 – 42.5 lb, 164 – 189 N) at 34.7 mm (0.000 in.)
  
  If the installed tension is not as specified, replace the valve spring.
Inspect camshafts and bearings.
1. Inspect camshaft for runout
  1. Place the camshaft on V-blocks.
  2. Using a dial indicator, measure the circle runout at the center journal.
  Maximum circle runout: 0.04 mm (0.0016 in.)
  
  If the circle runout is greater than maximum, replace the camshaft.
2. Inspect cam lobes
  
  Using a micrometer, measure the cam lobe height.
  
  Standard cam lobe height:
  - Intake – 35.310 – 35.410 mm (1.3902 – 1.3941 in.)
  - Exhaust – 35.560 – 35.660 mm (1.4000 – 1.4039 in.)
  Minimum cam lobe height:
  - Intake – 35.20 mm (1.3858 in.)
  - Exhaust – 35.45 mm (1.3957 in.)
  If the cam lobe height is greater than minimum, replace the camshaft.
3. Inspect camshaft journals
  
  Using a micrometer, measure the journal diameter.
  
  Journal diameter: 26.959 – 26.975 mm (1.0614 – 1.0620 in.)
  
  If the journal diameter is not as specified, check the oil clearance.
4. Inspect camshaft bearings
  
  Check the bearings for flaking and scoring.
  
  If the bearings are damaged, replace the bearing caps and cylinder head as a set.
5. Inspect camshaft gear spring
  
  Using vernier calipers, measure the free distance between the spring end.
  
  Free distance: 22.5 – 22.9 mm (0.886 – 0.902 in.)
  
  If the free distance is not as specified, replace the gear spring.
6. Inspect camshaft journal oil clearance
  1. Clean the bearing caps and camshaft journals.
  2. Place the camshafts on the cylinder head.
  3. Lay a strip of Plastigage across each of the camshaft journals.
  4. Install the bearing caps. (See Installation of cylinder head, step 4)
    
    Torque: 190 kg-cm (14 ft-lb, 19 N·m)
    
    Notice
    
    Do not turn the camshaft.
  5. Remove the bearing caps.
  6. Measure the Plastigage at its widest point.
    
    Standard oil clearance: 0.025 – 0.062 mm (0.0010 – 0.0024 in.)
    
    Maximum oil clearance: 0.10 mm (0.0039 in.)
    
    If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.
  7. Completely remove the Plastigage.
7. Inspect camshaft thrust clearance
  1. Install the camshafts. (See Installation of cylinder head, step 4)
  2. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
  Standard thrust clearance:
  - Intake – 0.045 – 0.100 mm (0.0018 – 0.0039 in.)
  - Exhaust – 0.030 – 0.085 mm (0.0012 – 0.0033 in.)
  Maximum thrust clearance:
  - Intake – 0.12 mm (0.0047 in.)
  - Exhaust – 0.10 mm (0.0039 in.)
  If the thrust clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.
8. Inspect camshaft gear backlash
  1. Install the camshafts without installing the exhaust cam sub-gear. (See Installation of cylinder head, step 4)
  2. Using a dial indicator, measure the backlash.
  Standard backlash: 0.020 – 0.200 mm (0.0008 – 0.0079 in.)
  
  Maximum backlash: 0.30 mm (0.0188 in.)
  
  If the backlash is greater than maximum, replace the camshafts.
Inspect valve lifters and lifter bores.
1. Using a caliper gauge, measure the lifter bore diameter of the cylinder head.
  
  Lifter bore diameter: 28.000 – 28.021 mm (1.1024 – 1.1032 in.)
2. Using a micrometer, measure the lifter diameter.
  
  Lifter diameter: 27.975 – 27.985 mm (1.1014 – 1.1018 in.)
3. Subtract the lifter diameter measurement from the lifter bore diameter measurement.
  
  Standard oil clearance: 0.015 – 0.046 mm (0.0005 – 0.0018 in.)
  
  Maximum oil clearance: 0.07 mm (0.0028 in.)
  
  If the oil clearance is greater than maximum, replace the lifter. If necessary, replace the cylinder head.
Inspect intake and exhaust manifolds.

Using precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage.

Maximum warpage: 0.30 mm (0.0118 in.)

If warpage is greater than maximum, replace the manifold.

Assembly of cylinder head¶

(See Cylinder head (5S-FE))

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 and oil seals with new ones.

Install valves.
1. Using SST, push in a new oil seal.
  
  SST 09201-41020
  
  Hint
  
  The intake valve oil seal is brown and the exhaust valve oil seal is black.
2. Install the following parts:
  1. Valve
  2. Spring seat
  3. Valve spring
  4. Spring retainer
3. Using SST, compress the valve spring and place the two keepers around the valve stem.
  
  SST 09202-70010
4. Using a plastic-faced hammer, lightly tap the valve stem tip to assure proper fit.
Install valve lifters and shims.
1. Install the valve lifter and shim.
2. Check that the valve lifter rotates smoothly by hand.

Installation of cylinder head¶

(See Cylinder head (5S-FE))

Install cylinder head.
1. Place cylinder head on cylinder block
  1. Place a new cylinder head gasket in position on the cylinder block.
    
    Notice
    
    Be careful of the installation direction.
  2. Place the cylinder head in position on the cylinder head gasket.
2. Install cylinder head bolts
  Hint
  - The cylinder head bolts are tightened in two progressive steps (steps (b) and (d)).
  - If any cylinder head bolt is broken or deformed, replace it.
  1. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
  2. Using SST, install and uniformly tighten the ten cylinder head bolts in several passes in the sequence shown.
    
    SST 09011-38121
    
    Torque: 500 kg-cm (36 ft-lb, 47 N·m)
    
    If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.
  3. Mark the front of the cylinder head bolt head with paint.
  4. Retighten the cylinder head bolts 90° in the numerical order shown.
  5. Check that the painted mark is now at a 90° angle to front.
Install spark plug tubes.
1. Clean the cylinder head tube holes of any residual adhesive, oil or foreign particles. Remove any oil with kerosene or gasoline.
2. Screw the threads of the spark plug tube coated with adhesive into the cylinder head.
3. Using the spark plug tube nut and a 30 mm socket wrench, tighten the spark plug tubes.
  
  Torque: 400 kg-cm (29 ft-lb, 39 N·m)
Assemble exhaust camshaft.
1. Mount the hexagonal wrench head portion of the camshaft in a vise.
  
  Notice
  
  Be careful not to damage the camshaft.
2. Install the following parts:
  1. Camshaft gear spring
  2. Camshaft sub-gear
  3. Wave washer
  Hint
  
  Align the pins on the gears with the spring ends.
3. Using snap ring pliers, install the snap ring.
4. Insert a service bolt (A) into the service hole of the camshaft sub-gear.
5. Using a screwdriver, align the holes of the camshaft main gear and sub-gear by turning the camshaft sub-gear clockwise, and install a service bolt (B).
  
  Notice
  
  Be careful not to damage the camshaft.
Install camshafts.

Notice

Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.

A. Install intake camshaft
1. Apply MP grease to the thrust portion of the camshaft.
2. Place the intake camshaft at 80 – 115° BTDC of camshaft angle on the cylinder head.
  
  Hint
  
  The above angle allows the No.1 and No.3 cylinder cam lobes of the intake camshaft to push their valve lifters evenly.
3. Apply seal packing to the No.1 bearing cap as shown.
  
  Seal packing: Part No. 08826-00080 or equivalent
4. Install the bearing caps in their proper locations.
5. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
6. Install and uniformly tighten the ten bearing cap bolts in several passes in the sequence shown.
  
  Torque: 190 kg-cm (14 ft-lb, 19 N·m)
7. Apply MP grease to a new oil seal lip.
8. Using SST, tap in the oil seal.
  
  SST 09223-46011
B. Install exhaust camshaft
1. Set the knock pin of the intake camshaft at 10 – 45° BTDC of camshaft angle.
  
  Hint
  
  The above angle allows the No.2 and No.4 cylinder cam lobes of the exhaust camshaft to push their valve lifters evenly.
2. Apply MP grease to the thrust portion of the camshaft.
3. Engage the exhaust camshaft gear to the intake camshaft gear by matching the timing marks on each gear.
4. Roll down the exhaust camshaft onto the bearing journals while engaging gears with each other.
  
  Notice
  
  There are also assembly reference marks on each gear as shown in the illustration. Do not use these marks.
5. Turn the intake camshaft clockwise or counterclockwise little by little until the exhaust camshaft sits in the bearing journals evenly without rocking the camshaft on the bearing journals.
  
  Notice
  
  It is very important to replace the camshaft in the bearing journals evenly while tightening bearing caps in the subsequent steps.
6. Install the bearing caps in their proper location.
7. Apply a light coat of engine oil on the threads and under the heads of bearing cap bolts.
8. Install and uniformly tighten the ten bearing cap bolts in several passes, in the sequence shown.
  
  Torque: 190 kg-cm (14 ft-lb, 19 N·m)
9. Remove the service bolt (B).
Check and adjust valve clearance. (See Engine tune-up › Inspection and adjustment of valve clearance (5S-FE))

Turn the camshaft and position the cam lobe upward, and check and adjust the valve clearance.

Valve clearance (cold):
- Intake – 0.19 – 0.29 mm (0.007 – 0.011 in.)
- Exhaust – 0.28 – 0.38 mm (0.011 – 0.015 in.)
Install semi-circular plugs.
1. Remove any old packing (FIPG) material.
2. Apply seal packing to the semi-circular plug grooves.
  
  Seal packing: Part No. 08826-00080 or equivalent
3. Install the two semi-circular plugs to the cylinder head.
Install cylinder head cover.
1. Remove any old packing (FIPG) material.
2. Apply seal packing to the cylinder head as shown in the figure.
  
  Seal packing: Part No. 08826-00080 or equivalent
3. Install the gasket to the head cover.
4. Install the head cover with the four grommets and nuts.
  
  Torque: 180 kg-cm (13 ft-lb, 18 N·m)
  
  Hint
  
  Install the grommets so that its markings are as shown in the illustration. Then install the grommet to its original position.
Install oil pressure switch.

Apply adhesive to two or three threads.

Adhesive: Part No. 08833-00080, THREE BOND 1324 or equivalent
Install RH front engine hanger.

Install the engine hanger with the two bolts.

Torque: 250 kg-cm (18 ft-lb, 25 N·m)
Install LH front engine hanger.

Install the engine hanger with the bolt.

Torque: 250 kg-cm (18 ft-lb, 25 N·m)
Install No.3 timing belt cover.

Install the timing belt cover with the four bolts.

Torque: 80 kg-cm (69 in.-lb, 7.8 N·m)
Install No.1 idler pulley and tension spring. (See Timing belt (5S-FE) › Installation of timing belt, step 4)
Install camshaft timing pulley. (See Timing belt (5S-FE) › Installation of timing belt, steps 9–17)
Install injector and delivery pipe. (See steps 1 and 3 to 6 on pages FI-125 to 127)
Install intake manifold.
1. Install a new gasket and the intake manifold with the six bolts and two nuts.
  
  Torque: 195 kg-cm (14 ft-lb, 19 N·m)
2. Install the manifold stay with the two bolts.
  
  Torque:
  - 12 mm head bolt – 195 kg-cm (14 ft-lb, 19 N·m)
  - 14 mm head bolt – 425 kg-cm (31 ft-lb, 42 N·m)
3. Connect the two wire clamps to the wire bracket.
4. Connect the wire clamp to the accelerator bracket.
5. Connect the alternator connector and wire.
Install EGR VSV.
1. Install the VSV with the bolt.
2. Connect the VSV connector.
Install fuel pressure VSV.
1. Install the VSV with the two bolts. Connect the ground strap.
2. Connect the following hoses:
  1. Vacuum hose from fuel pressure regulator
  2. Vacuum hose from intake manifold
3. Connect the VSV connector.
Install EGR valve and vacuum modulator.
1. Install a new gasket and the EGR valve with the union nut and two bolts.
  
  Torque:
  - Union nut – 600 kg-cm (43 ft-lb, 59 N·m)
  - Bolt – 130 kg-cm (9 ft-lb, 13 N·m)
2. Install the EGR modulator to the clamp.
3. Connect the following hoses:
  1. Vacuum hose (from Q port of EGR vacuum modulator) to G port of EGR VSV
  2. Vacuum hose (from EGR valve) to E port of EGR VSV
  3. Vacuum hose to charcoal canister
4. (CALIF. only) Connect the EGR gas temperature sensor connector.
Install cold start injector. (See steps 1 and 3 on page FI-104)
Install cold start injector pipe. (See step 2 on page FI-104)
Install throttle body. (See steps 2 to 5 on pages FI-146 and 147)
Install water by-pass pipe.
1. Install a new O-ring to the by-pass pipe.
2. Apply soapy water on the O-ring.
3. Install a new gasket and the by-pass pipe with the two nuts and two bolts.
  
  Torque (nut): 95 kg-cm (82 in.-lb, 9.3 N·m)
4. Connect the following hoses:
  1. ISC water by-pass hose
  2. Heater water hose
  3. Two oil cooler water by-pass hoses
5. Install the oil cooler heat protector with the bolt and two nuts.
Install water outlet and housing.
1. Install a new gasket, the water outlet and housing assembly with the two bolts.
  
  Torque: 150 kg-cm (11 ft-lb, 15 N·m)
2. Connect the following hoses:
  1. Water by-pass pipe hose
  2. EVAP BVSV vacuum hose (from P port of throttle body)
  3. EVAP BVSV vacuum hose (from charcoal canister)
  4. Water filler hose
  5. Radiator hose
  6. Heater water hose
  7. ISC water by-pass hose
3. Install the fuel inlet hose (with the return tube) from the water outlet and cylinder head.
4. Connect the following connectors:
  - Water temperature sender gauge connector
  - Water temperature sensor connector
  - Cold start injector time switch connector
Assemble exhaust manifold and catalytic converter.

Assemble the following parts:
1. Catalytic converter
2. Cushion
3. Retainer
4. Gasket
5. Exhaust manifold
6. Three bolts and two nuts
  
  Torque: 300 kg-cm (22 ft-lb, 29 N·m)
7. Two converter heat insulators
8. Eight bolts
9. Manifold lower heat insulator
10. Five bolts
Install exhaust manifold and catalytic converter assembly.
1. Install a new gasket, the exhaust manifold and catalytic converter assembly with the new six nuts.
  
  Torque: 500 kg-cm (36 ft-lb, 49 N·m)
2. Install the catalytic converter stay with the two bolts and two new nuts.
  
  Torque: 425 kg-cm (31 ft-lb, 42 N·m)
3. Install the manifold upper heat insulator with the six bolts.
4. Connect the oxygen sensor (main) connector.
5. (CALIF. only) Connect the sub-oxygen sensor connector.
Install front exhaust pipe. (See Cylinder block (5S-FE) › Disassembly of cylinder block, step 15)
Install distributor. (See Distributor (5S-FE) › Installation of distributor, steps 1–4)
Connect vacuum hoses.
1. A/C VSV vacuum hose from intake manifold
2. A/C VSV air hose from ISC valve
3. Vacuum sensor hose from intake manifold
4. Brake booster vacuum hose from intake manifold
Connect ground strap connector.
Install air cleaner cap. (See Cylinder block (5S-FE) › Installation of engine, step 35)
Install cruise control actuator (w/ cruise control system) and accelerator linkage. (See Cylinder block (5S-FE) › Installation of engine, step 33)
Install accelerator cable, and adjust it.
(A/T) Connect throttle cable, and adjust it.
Install suspension upper brace. (See Cylinder block (5S-FE) › Installation of engine, step 36)
Connect cable to negative terminal of battery.
Fill with engine coolant. (See page CO-7)

Capacity (w/ heater): 13.0 liters (13.7 US qts, 11.4 Imp. qts)
Start engine and check for leaks.
Adjust ignition timing. (See Distributor (5S-FE) › Installation of distributor, steps 9–13)

Ignition timing: 10° BTDC @ idle (w/ terminals TE1 and E1 connected)
Install engine hood side panels.
Install engine under cover.
Perform road test.

Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
Recheck engine coolant level and oil level.

Surface	Maximum warpage
Cylinder block side	0.05 mm (0.0020 in.)
Manifold side	0.08 mm (0.0031 in.)

Bushing bore diameter mm (in.)	Bushing size
11.000 – 11.027 (0.4331 – 0.4342)	Use STD
11.050 – 11.077 (0.4350 – 0.4361)	Use O/S 0.05