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                                                                                                    ENGINE MECHANICAL                                                      GI




                                                                                               SECTION                       EM                                            MA




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                                                                CONTENTS                                                                                                   FE


PRECAUTIONS ...............................................................4            Components...............................................................29
                                                                                                                                                                           CL
  Supplemental Restraint System (SRS) AIR                                               Removal.....................................................................30
  BAG ............................................................................4     Installation..................................................................31   MT
  Parts Requiring Angular Tightening.............................4                      Disassembly...............................................................31
  Liquid Gasket Application Procedure ..........................4                       Inspection...................................................................31
PREPARATION ...............................................................5               CYLINDER HEAD DISTORTION ...............................31                      AT
  Special Service Tools ..................................................5                CAMSHAFT VISUAL CHECK ....................................32
  Commercial Service Tools ...........................................8                    CAMSHAFT RUNOUT ..............................................32
                                                                                           CAMSHAFT CAM HEIGHT .......................................32                   TF
                                                                                           CAMSHAFT JOURNAL CLEARANCE ........................32
                                   KA24DE
                                                                                           CAMSHAFT END PLAY............................................33
NOISE, VIBRATION AND HARSHNESS (NVH)                                                       CAMSHAFT SPROCKET RUNOUT ...........................33                          PD
TROUBLESHOOTING ...................................................10                      VALVE GUIDE CLEARANCE ....................................33
  NVH Troubleshooting Chart - Engine Noise .............11                                 VALVE GUIDE REPLACEMENT ................................34
                                                                                           VALVE SEATS .........................................................35         AX
OUTER COMPONENT PARTS .....................................12
                                                                                           REPLACING VALVE SEAT FOR SERVICE PARTS ....35
  Removal and Installation ...........................................12
                                                                                           VALVE DIMENSIONS ...............................................36
MEASUREMENT OF COMPRESSION PRESSURE ....15                                                 VALVE SPRING .......................................................37          SU
OIL PAN.........................................................................16         VALVE LIFTER AND VALVE SHIM ............................37
  Components...............................................................16           Assembly ...................................................................38
  Removal.....................................................................16        Valve Clearance.........................................................38
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  Installation..................................................................17         CHECKING .............................................................38
TIMING CHAIN ..............................................................18              ADJUSTING ............................................................39
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  Components...............................................................18         ENGINE ASSEMBLY.....................................................41
     LIQUID GASKET APPLICATION PLACES..................19                               Removal and Installation ...........................................41
  Removal.....................................................................20           REMOVAL ...............................................................42       RS
     UPPER TIMING CHAIN ............................................20                     INSTALLATION........................................................43
     IDLER SPROCKET ..................................................21              CYLINDER BLOCK .......................................................44
     LOWER TIMING CHAIN ...........................................21                   Components...............................................................44        BT
  Inspection...................................................................22       Removal and Installation ...........................................45
  Installation..................................................................23      Disassembly...............................................................45
     LOWER TIMING CHAIN ...........................................23                      PISTON AND CRANKSHAFT ....................................45                    HA
     IDLER SPROCKET ..................................................24                Inspection...................................................................45
     UPPER TIMING CHAIN ............................................24                     PISTON AND PISTON PIN CLEARANCE ..................45
OIL SEAL.......................................................................26          PISTON RING SIDE CLEARANCE ............................46
                                                                                                                                                                           SC
  Replacement..............................................................26              PISTON RING END GAP..........................................46
     VALVE OIL SEAL .....................................................26                CONNECTING ROD BEND AND TORSION ...............46
     OIL SEAL INSTALLING DIRECTION .........................26                             CYLINDER BLOCK DISTORTION AND WEAR ...........47
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     FRONT OIL SEAL ....................................................26                 PISTON-TO-BORE CLEARANCE ..............................47
     REAR OIL SEAL ......................................................27                CRANKSHAFT.........................................................48
CYLINDER HEAD..........................................................29
                                                                                                                                                                           IDX
                                                                                           BEARING CLEARANCE ...........................................49
                                                      CONTENTS                                   (Cont'd)
        CONNECTING ROD BUSHING CLEARANCE                                                   Tension Adjustment....................................................79
        (SMALL END) ..........................................................51             AFTER BELT REPLACEMENT..................................79
        REPLACEMENT OF CONNECTING ROD                                                          AFTER ENGINE OVERHAUL OR ENGINE
        BUSHING (SMALL END) ..........................................51                       REASSEMBLY (WITH ROCKER COVERS
        FLYWHEEL/DRIVE PLATE RUNOUT ........................52                                 REMOVED) .............................................................80
  Assembly ...................................................................52       OIL SEAL.......................................................................82
     PISTON ..................................................................52         Replacement..............................................................82
     CRANKSHAFT.........................................................53                  VALVE OIL SEAL .....................................................82
     REPLACING PILOT BUSHING ..................................54                           OIL SEAL INSTALLING DIRECTION .........................82
SERVICE DATA AND SPECIFICATIONS (SDS) .........55                                           CAMSHAFT OIL SEAL .............................................83
  General Specifications...............................................55                   FRONT OIL SEAL ....................................................83
     COMPRESSION PRESSURE ...................................55                             REAR OIL SEAL ......................................................83
  Cylinder Head ............................................................55         CYLINDER HEAD..........................................................84
  Valve ..........................................................................56     Components...............................................................84
     VALVE ....................................................................56        Removal.....................................................................85
     VALVE SPRING .......................................................56              Disassembly...............................................................87
     VALVE GUIDE .........................................................57             Inspection...................................................................88
     VALVE LIFTER ........................................................57                CYLINDER HEAD DISTORTION ...............................88
     VALVE CLEARANCE ADJUSTMENT .........................57                                 CAMSHAFT VISUAL CHECK ....................................88
     AVAILABLE SHIMS ..................................................58                   CAMSHAFT RUNOUT ..............................................88
     VALVE SEAT ...........................................................59               CAMSHAFT CAM HEIGHT .......................................89
  Cylinder Block............................................................60              CAMSHAFT JOURNAL CLEARANCE ........................89
  Camshaft and Camshaft Bearing ..............................61                            CAMSHAFT END PLAY............................................89
  Piston, Piston Ring and Piston pin............................62                          CAMSHAFT SPROCKET RUNOUT ...........................90
     PISTON ..................................................................62            VALVE GUIDE CLEARANCE ....................................90
     PISTON PIN ............................................................62              VALVE GUIDE REPLACEMENT ................................91
     PISTON RING .........................................................62                VALVE SEATS .........................................................91
  Connecting Rod .........................................................63                REPLACING VALVE SEAT FOR SERVICE PARTS ....92
  Crankshaft..................................................................63            VALVE DIMENSIONS ...............................................92
  Bearing Clearance .....................................................64                 VALVE SPRING .......................................................93
  Available Main Bearing..............................................64                    ROCKER SHAFT AND ROCKER ARM ......................93
     STANDARD .............................................................64               HYDRAULIC VALVE LIFTER ....................................94
     UNDERSIZE (SERVICE) ..........................................64                    Assembly ...................................................................94
  Available Connecting Rod Bearing............................64                         Installation..................................................................95
     STANDARD .............................................................64          ENGINE ASSEMBLY.....................................................99
     UNDERSIZE (SERVICE) ..........................................64                    Removal and Installation ...........................................99
  Miscellaneous Components.......................................65                         REMOVAL .............................................................100
                                                                                       CYLINDER BLOCK .....................................................102
                                    VG33E                                                Components.............................................................102
                                                                                         Removal and Installation .........................................103
NOISE, VIBRATION AND HARSHNESS (NVH)                                                     Disassembly.............................................................103
TROUBLESHOOTING ...................................................66                       PISTON AND CRANKSHAFT ..................................103
  NVH Troubleshooting Chart - Engine Noise .............67                               Inspection.................................................................104
OUTER COMPONENT PARTS .....................................68                               PISTON AND PISTON PIN CLEARANCE ................104
  Removal and Installation ...........................................68                    PISTON RING SIDE CLEARANCE ..........................104
MEASUREMENT OF COMPRESSION PRESSURE ....70                                                  PISTON RING END GAP........................................104
OIL PAN.........................................................................72          CONNECTING ROD BEND AND TORSION .............105
  Removal.....................................................................72            CYLINDER BLOCK DISTORTION AND WEAR .........105
  Installation..................................................................73          PISTON-TO-BORE CLEARANCE ............................106
                                                                                            CRANKSHAFT.......................................................107
TIMING BELT ................................................................75
                                                                                            BEARING CLEARANCE .........................................108
  Components...............................................................75
                                                                                               CONNECTING ROD BUSHING CLEARANCE
  Removal.....................................................................76               (SMALL END) ........................................................110
  Inspection...................................................................77              REPLACEMENT OF CONNECTING ROD
     BELT TENSIONER AND TENSIONER SPRING ..........78                                          BUSHING (SMALL END) ........................................110
  Installation..................................................................78



                                                                                  EM-2
                                                     CONTENTS                                 (Cont'd)
      FLYWHEEL/DRIVE PLATE RUNOUT ......................110                             Piston, Piston Ring and Piston Pin .........................122                 GI
    Assembly ................................................................. 111         AVAILABLE PISTON ..............................................122
      PISTON ................................................................ 111          PISTON RING .......................................................122
      CRANKSHAFT....................................................... 111                AVAILABLE PISTON ..............................................123           MA
        REPLACING PILOT BUSHING (M/T) OR PILOT                                             PISTON RING .......................................................123
        CONVERTER (A/T) ................................................113                PISTON PIN ..........................................................124
SERVICE DATA AND SPECIFICATIONS (SDS) .......114                                        Connecting Rod .......................................................124
  General Specifications.............................................114                Crankshaft................................................................124
  Cylinder Head ..........................................................115           Available Main Bearing............................................125
  Valve ........................................................................115        NO. 1 MAIN BEARING ...........................................125            LC
     VALVE ..................................................................115           NO. 2 AND 3 MAIN BEARING ................................125
     VALVE SPRING .....................................................116                 NO. 4 MAIN BEARING ...........................................125
     HYDRAULIC VALVE LIFTER ..................................116                          UNDER SIZE .........................................................126
                                                                                                                                                                        EC
     VALVE GUIDE .......................................................116             Available Connecting Rod Bearing..........................126
     ROCKER SHAFT AND ROCKER ARM ....................116                                   CONNECTING ROD BEARING UNDERSIZE ...........126
                                                                                                                                                                        FE
  Valve Seat................................................................117         Miscellaneous Components.....................................126
     INTAKE VALVE SEAT ............................................117                     BEARING CLEARANCE .........................................126
     EXHAUST VALVE SEAT.........................................118                                                                                                     CL
  Camshaft and Camshaft Bearing ............................119
  Cylinder Block..........................................................120
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                                                                                 EM-3
                                                PRECAUTIONS
Supplemental Restraint System (SRS) "AIR BAG"

                                            Supplemental Restraint System (SRS) "AIR
                                            BAG"                                                           NGEM0081
The Supplemental Restraint System "AIR BAG" and "SEAT BELT PRE-TENSIONER", used along with a seat
belt, helps to reduce the risk or severity of injury to the driver and front passenger in certain types of colli-
sions. The Supplemental Restraint System consists of air bag module (located in the center of the steering
wheel), a front passenger air bag model (located on the instrument panel on the passenger side), seat belt
pre-tensioners, a diagnosis sensor unit, a crash zone sensor (4WD models), a warning lamp, wiring harness,
and spiral cable.
Information necessary to service the system safely is included in the RS section of this Service Manual.
WARNING:



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