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Cylinder head
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General
Specifications
Degrees of difficulty
Section number Section number
Contents
| Crankshaft | - | inspection........................................................ | Engine overhaul - reassembly | sequence................................... | |||
| Crankshaft | - | refitting........................................................... | Engine rebuilding | alternatives................................................ | |||
| Crankshaft | - | removal.......................................................... | 12 Engine removal - methods and | precautions............................... | |||
| Cylinder head - cleaning and | inspection.................................. | ||||
| Cylinder head - | disassembly................................................ | ||||
| Cylinder | head | - | reassembly.................................................. | ||
| Engine - removal and | refitting............................................... | ||||
| Engine | block | - | cleaning....................................................... | ||
| Engine block - | inspection.................................................... | ||||
| Engine overhaul - disassembly | sequence................................. | ||||
| Engine overhaul - general | information...................................... | ||||
General information................................................. 1
Initial start-up after overhaul........................................ 22
Main and connecting rod bearings - inspection.................. 17
Piston rings - refitting............................................... 19
Pistons/connecting rods - inspection............................. 15
Pistons/connecting rods - refitting.................................. 21
Pistons/connecting rods - removal................................ 11
Valves - servicing.................................................... 9
| Engine codes: | |||
| 1.3 litre (1332 cc) | Non-VVT-i | engine....................................... | 4E-FE |
| 1.4 litre (1398 cc) | VVT-i | engine............................................. | 4Z2-FE |
| 1.6 litre (1587 cc) | Non-VVT-i | engine...................................... | 4A-FE |
| 1.6 litre (1598 cc) | VVT-i | engine............................................. | 3ZZ-FE |
| Warpage limits: | |||
| Block | surface.................................................................... | 0.05 mm | |
| Manifold | surfaces............................................................... | 0.10 mm | |
| Engine block | |||
| Block warpage | limit............................................................... | 0.05 mm | |
| Cylinder bore diameter (nominal): | |||
| 1.3 litre 4E-FE | engine......................................................... | 74.00 to 74.03 mm | |
| 1.4 litre 4ZZ-FE | engine....................................................... | 79.00 to 79.013 mm | |
| 1.6 litre 4A-FE | engine......................................................... | 81.00 to 81.03 mm | |
| 1.6 litre 3ZZ-FE | engine....................................................... | 79.00 to 79.013 mm | |
| Valves and related components | |||
| Valve stem diameter: | |||
| Non-VVT-i engines: | |||
| Intake.......................................................................... | 5.970 to 5.985 mm | ||
| Exhaust........................................................................ | 5.965 to 5.980 mm | ||
| VVT-i engines: | |||
| Intake.......................................................................... | 5.470 to 5.485 mm | ||
| Exhaust........................................................................ | 5.465 to 5.480 mm | ||
| Valve spring: | |||
| Free length: | |||
| 1.3 litre 4E-FE | engine....................................................... | 39.80 mm | |
| 1.4 litre 4ZZ-FE | engine...................................................... | 43.40 mm | |
| 1.6 litre 4A-FE | engine....................................................... | 38.57 mm | |
| 1.6 litre 3ZZ-FE | engine...................................................... | 43.40 mm |
2B•2 Engine removal and overhaul procedures
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