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                                                                                                   ENGINE MECHANICAL                                                      GI




                                                                                              SECTION                       EM                                            MA




                                                                                                                                                                          LC

                                                                                                                                                                          EC

                                                               CONTENTS                                                                                                   FE


PRECAUTIONS ...............................................................3           Installation..................................................................37
                                                                                                                                                                          CL
  Parts Requiring Angular Tightening.............................3                   CYLINDER HEAD..........................................................38
  Liquid Gasket Application Procedure ..........................3                      Components...............................................................38        MT
  Special Cautions to Ensure the Safe Disposal of                                      Removal.....................................................................39
  Sodium-filled Exhaust Valves ......................................3                 Disassembly...............................................................41
     DEALER DISPOSAL INSTRUCTIONS .........................4                           Inspection...................................................................43    AT
PREPARATION ...............................................................6              CYLINDER HEAD DISTORTION ...............................43
  Special Service Tools ..................................................6               CAMSHAFT VISUAL CHECK ....................................43
  Commercial Service Tools ...........................................8                   CAMSHAFT RUNOUT ..............................................43                PD
NOISE, VIBRATION AND HARSHNESS (NVH)                                                      CAMSHAFT CAM HEIGHT .......................................43
TROUBLESHOOTING ...................................................10                     CAMSHAFT JOURNAL CLEARANCE ........................44
                                                                                          CAMSHAFT END PLAY............................................44                 AX
  NVH Troubleshooting - Engine Noise .......................11
                                                                                          CAMSHAFT SPROCKET RUNOUT ...........................45
OUTER COMPONENT PARTS .....................................12
                                                                                          VALVE GUIDE CLEARANCE ....................................45
  Removal and Installation ...........................................12
                                                                                          VALVE GUIDE REPLACEMENT ................................45                      SU
MEASUREMENT OF COMPRESSION PRESSURE ....15                                                VALVE SEATS .........................................................46
DRIVE BELTS................................................................16             REPLACING VALVE SEAT FOR SERVICE PARTS ....47
  Checking ....................................................................16         VALVE DIMENSIONS ...............................................48
                                                                                                                                                                          BR
AIR CLEANER...............................................................17              VALVE SPRING .......................................................48
  Changing....................................................................17          HYDRAULIC LASH ADJUSTER ................................48
     VISCOUS PAPER TYPE ...........................................17                     ROCKER ARM, SHIM AND ROCKER ARM GUIDE.....49
                                                                                                                                                                          ST
SPARK PLUG................................................................18           Assembly ...................................................................49
  Changing....................................................................18       Installation..................................................................52   RS
     PLATINUM-TIPPED TYPE ........................................18                 TURBOCHARGER.........................................................58
OIL PAN.........................................................................20     Removal.....................................................................58
  Components...............................................................20          Disassembly...............................................................59       BT
  Removal.....................................................................20       Inspection...................................................................60
  Installation..................................................................23        OIL AND WATER TUBES .........................................60
TIMING CHAIN ..............................................................25             ROTOR SHAFT .......................................................60           HA
  Components...............................................................25             TURBINE WHEEL ....................................................61
  Removal.....................................................................26          COMPRESSOR WHEEL ...........................................61
  Inspection...................................................................28         WASTEGATE VALVE ...............................................61               SC
                                                                                          WASTEGATE VALVE ACTUATOR ............................62
  Installation..................................................................29
                                                                                       Assembly ...................................................................62
OIL SEAL.......................................................................34
                                                                                       Installation..................................................................62   EL
  Replacement..............................................................34
                                                                                          OIL TUBES..............................................................63
     VALVE OIL SEAL .....................................................34
                                                                                          WATER TUBES .......................................................63
     FRONT OIL SEAL ....................................................34
                                                                                     CHARGE AIR COOLER ................................................64
                                                                                                                                                                          IDX
     REAR OIL SEAL ......................................................35
INTAKE MANIFOLD ......................................................36               Removal and Installation ...........................................64
  Removal.....................................................................36       Inspection...................................................................64
                                                                                     ENGINE ASSEMBLY.....................................................65
                                                    CONTENTS                                (Cont'd)
  Removal and Installation ...........................................65              Compression Pressure ..............................................82
     REMOVAL ...............................................................66        Drive Belt Deflection and Tension .............................83
     INSTALLATION........................................................67           Spark Plug .................................................................83
CYLINDER BLOCK .......................................................68              Cylinder Head ............................................................83
  Components...............................................................68         Valve ..........................................................................84
  Removal and Installation ...........................................69                 VALVE ....................................................................84
  Disassembly...............................................................69           VALVE SPRING .......................................................84
     PISTON AND CRANKSHAFT ....................................69                        HYDRAULIC LASH ADJUSTER (HLA) .......................84
  Inspection...................................................................70        VALVE GUIDE .........................................................85
     PISTON AND PISTON PIN CLEARANCE ..................70                                VALVE SHIM CLEARANCE ADJUSTMENT ................85
     PISTON RING SIDE CLEARANCE ............................70                           AVAILABLE SHIM ....................................................86
     PISTON RING END GAP..........................................71                     VALVE SEAT ...........................................................87
     CONNECTING ROD BEND AND TORSION ...............71                                   VALVE SEAT RESURFACE LIMIT.............................88
     CYLINDER BLOCK DISTORTION AND WEAR ...........71                                 Camshaft and Camshaft Bearing ..............................88
     PISTON-TO-BORE CLEARANCE ..............................72                        Cylinder Block............................................................89
     CRANKSHAFT.........................................................73            Piston, Piston Ring and Piston pin............................90
     BEARING CLEARANCE ...........................................73                     PISTON ..................................................................90
       CONNECTING ROD BUSHING CLEARANCE                                                  PISTON RING .........................................................90
       (SMALL END) ..........................................................76          PISTON PIN ............................................................90
       REPLACEMENT OF CONNECTING ROD                                                  Connecting Rod .........................................................91
       BUSHING (SMALL END) ..........................................76               Crankshaft..................................................................92
       REPLACEMENT OF PILOT BUSHING (M/T) OR
                                                                                      Main Bearing..............................................................93
       PILOT CONVERTER (A/T)........................................76
                                                                                         STANDARD .............................................................93
       FLYWHEEL/DRIVE PLATE RUNOUT ........................77
                                                                                         UNDERSIZE ............................................................93
       OIL JET (FOR PISTON) ...........................................77
                                                                                      Connecting Rod Bearing ...........................................93
  Assembly ...................................................................78
                                                                                         STANDARD SIZE ....................................................93
    PISTON ..................................................................78
                                                                                         UNDERSIZE ............................................................93
    CRANKSHAFT.........................................................79
                                                                                      Bearing Clearance .....................................................94
SERVICE DATA AND SPECIFICATIONS (SDS) .........82
                                                                                      Miscellaneous Components.......................................94
  General Specifications...............................................82




                                                                               EM-2
           PRECAUTIONS
                                               Parts Requiring Angular Tightening

          Parts Requiring Angular Tightening                              NMEM0001
          



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