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                                                                                                   ENGINE MECHANICAL                                                      GI




                                                                                              SECTION                       EM                                            MA




                                                                                                                                                                          LC

                                                                                                                                                                          EC

                                                               CONTENTS                                                                                                   FE


                                  KA24DE                                               Removal.....................................................................30
                                                                                                                                                                          CL
                                                                                       Installation..................................................................31
PRECAUTIONS ...............................................................4
                                                                                       Disassembly...............................................................31       MT
  Supplemental Restraint System (SRS) AIR
                                                                                       Inspection...................................................................31
  BAG and SEAT BELT PRE-TENSIONER...............4
                                                                                          CYLINDER HEAD DISTORTION ...............................31
  Parts Requiring Angular Tightening.............................4                        CAMSHAFT VISUAL CHECK ....................................32                    AT
  Liquid Gasket Application Procedure ..........................5                         CAMSHAFT RUNOUT ..............................................32
PREPARATION ...............................................................6              CAMSHAFT CAM HEIGHT .......................................32
  Special Service Tools ..................................................6               CAMSHAFT JOURNAL CLEARANCE ........................32                           TF
  Commercial Service Tools ...........................................8                   CAMSHAFT END PLAY............................................33
NOISE, VIBRATION AND HARSHNESS (NVH)                                                      CAMSHAFT SPROCKET RUNOUT ...........................33
TROUBLESHOOTING ...................................................10                     VALVE GUIDE CLEARANCE ....................................33                    PD
  NVH Troubleshooting Chart - Engine Noise .............11                                VALVE GUIDE REPLACEMENT ................................34
OUTER COMPONENT PARTS .....................................12                             VALVE SEATS .........................................................35
  Removal and Installation ...........................................12                  REPLACING VALVE SEAT FOR SERVICE PARTS ....35                                   AX
                                                                                          VALVE DIMENSIONS ...............................................36
MEASUREMENT OF COMPRESSION PRESSURE ....15
                                                                                          VALVE SPRING .......................................................37
OIL PAN.........................................................................16                                                                                        SU
                                                                                          VALVE LIFTER AND VALVE SHIM ............................37
  Components...............................................................16          Assembly ...................................................................38
  Removal.....................................................................16       Valve Clearance.........................................................38
  Installation..................................................................17        CHECKING .............................................................38
                                                                                                                                                                          BR
TIMING CHAIN ..............................................................18             ADJUSTING ............................................................39
  Components...............................................................18        ENGINE ASSEMBLY.....................................................41
     LIQUID GASKET APPLICATION PLACES..................19
                                                                                                                                                                          ST
                                                                                       Removal and Installation ...........................................41
  Removal.....................................................................20          REMOVAL ...............................................................42
     UPPER TIMING CHAIN ............................................20                    INSTALLATION........................................................43
     IDLER SPROCKET ..................................................21
                                                                                                                                                                          RS
                                                                                     CYLINDER BLOCK .......................................................44
     LOWER TIMING CHAIN ...........................................21                  Components...............................................................44
  Inspection...................................................................22      Removal and Installation ...........................................45             BT
  Installation..................................................................23     Disassembly...............................................................45
     LOWER TIMING CHAIN ...........................................23
                                                                                          PISTON AND CRANKSHAFT ....................................45
     IDLER SPROCKET ..................................................24                                                                                                  HA
                                                                                       Inspection...................................................................45
     UPPER TIMING CHAIN ............................................24
                                                                                          PISTON AND PISTON PIN CLEARANCE ..................45
OIL SEAL.......................................................................26
                                                                                          PISTON RING SIDE CLEARANCE ............................46
  Replacement..............................................................26             PISTON RING END GAP..........................................46                 SC
     VALVE OIL SEAL .....................................................26               CONNECTING ROD BEND AND TORSION ...............46
     OIL SEAL INSTALLING DIRECTION .........................26                            CYLINDER BLOCK DISTORTION AND WEAR ...........47
     FRONT OIL SEAL ....................................................26                PISTON-TO-BORE CLEARANCE ..............................47
                                                                                                                                                                          EL
     REAR OIL SEAL ......................................................27               CRANKSHAFT.........................................................48
CYLINDER HEAD..........................................................29                 BEARING CLEARANCE ...........................................49
  Components...............................................................29                                                                                             IDX
                                                      CONTENTS                                   (Cont'd)
        CONNECTING ROD BUSHING CLEARANCE                                               OIL PAN.........................................................................79
        (SMALL END) ..........................................................51         Removal.....................................................................79
        REPLACEMENT OF CONNECTING ROD                                                    Installation..................................................................80
        BUSHING (SMALL END) ..........................................51               TIMING BELT ................................................................82
        FLYWHEEL RUNOUT ..............................................52
                                                                                         Components...............................................................82
  Assembly ...................................................................52
                                                                                         Removal.....................................................................83
     PISTON ..................................................................52
                                                                                         Inspection...................................................................84
     CRANKSHAFT.........................................................53
                                                                                            BELT TENSIONER AND TENSIONER SPRING ..........85
     REPLACING PILOT BUSHING ..................................54
                                                                                         Installation..................................................................85
SERVICE DATA AND SPECIFICATIONS (SDS) .........55
                                                                                         Tension Adjustment....................................................86
  General Specifications...............................................55
                                                                                            AFTER BELT REPLACEMENT..................................86
     COMPRESSION PRESSURE ...................................55
                                                                                               AFTER ENGINE OVERHAUL OR ENGINE
  Cylinder Head ............................................................55
                                                                                               REASSEMBLY (WITH ROCKER COVERS
  Valve ..........................................................................56           REMOVED) .............................................................87
     VALVE ....................................................................56
                                                                                       OIL SEAL.......................................................................90
     VALVE SPRING .......................................................56
                                                                                         Replacement..............................................................90
     VALVE GUIDE .........................................................57
                                                                                            VALVE OIL SEAL .....................................................90
     VALVE LIFTER ........................................................57
                                                                                            OIL SEAL INSTALLING DIRECTION .........................90
     VALVE CLEARANCE ADJUSTMENT .........................57
                                                                                            CAMSHAFT OIL SEAL .............................................91
     AVAILABLE SHIMS ..................................................58
                                                                                            FRONT OIL SEAL ....................................................91
     VALVE SEAT ...........................................................59
                                                                                            REAR OIL SEAL ......................................................91
  Cylinder Block............................................................60
                                                                                       CYLINDER HEAD..........................................................92
  Camshaft and Camshaft Bearing ..............................61
                                                                                         Components...............................................................92
  Piston, Piston Ring and Piston Pin ...........................62
                                                                                         Removal.....................................................................93
     PISTON ..................................................................62
                                                                                         Disassembly...............................................................95
     PISTON PIN ............................................................62
     PISTON RING .........................................................62             Inspection...................................................................96
  Connecting Rod .........................................................63                CYLINDER HEAD DISTORTION ...............................96
                                                                                            CAMSHAFT VISUAL CHECK ....................................96
  Crankshaft..................................................................63
                                                                                            CAMSHAFT RUNOUT ..............................................96
  Bearing Clearance .....................................................64
                                                                                            CAMSHAFT CAM HEIGHT .......................................96
  Available Main Bearing..............................................64                    CAMSHAFT JOURNAL CLEARANCE ........................96
     STANDARD .............................................................64               CAMSHAFT END PLAY............................................97
     UNDERSIZE (SERVICE) ..........................................64                       CAMSHAFT SPROCKET RUNOUT ...........................97
  Available Connecting Rod Bearing............................64                            VALVE GUIDE CLEARANCE ....................................97
     STANDARD .............................................................64               VALVE GUIDE REPLACEMENT ................................98
     UNDERSIZE (SERVICE) ..........................................64                       VALVE SEATS .........................................................99
  Miscellaneous Components.......................................65                         REPLACING VALVE SEAT FOR SERVICE PARTS ..100
                                                                                            VALVE DIMENSIONS .............................................100
                         VG33E AND VG33ER                                                   VALVE SPRING .....................................................101
                                                                                            ROCKER SHAFT AND ROCKER ARM ....................102
PRECAUTIONS .............................................................66                 HYDRAULIC VALVE LIFTER ..................................102
  Supplemental Restraint System (SRS) AIR                                                Assembly .................................................................102
  BAG and SEAT BELT PRE-TENSIONER.............66                                         Installation................................................................103
  Parts Requiring Angular Tightening...........................66                      SUPERCHARGER .......................................................108
  Liquid Gasket Application Procedure ........................67                         Components.............................................................108
PREPARATION .............................................................68              Removal...................................................................109
  Special Service Tools ................................................68               Inspection.................................................................110
  Commercial Service Tools .........................................70                      SUPERCHARGER FLANGE ...................................110
NOISE, VIBRATION AND HARSHNESS (NVH)                                                        ROTOR SYSTEM ..................................................110
TROUBLESHOOTING ...................................................72                       SUPERCHARGER BYPASS VALVE ACTUATOR ..... 111
  NVH Troubleshooting Chart - Engine Noise .............73                               Installation................................................................ 111
OUTER COMPONENT PARTS .....................................74                          ENGINE ASSEMBLY...................................................112
  Removal and Installation ...........................................74                 Removal and Installation .........................................112
MEASUREMENT OF COMPRESSION PRESSURE ....77                                                  REMOVAL .............................................................113
                                                                                       CYLINDER BLOCK .....................................................115



                                                                                  EM-2
                                                     CONTENTS                                 (Cont'd)
    Components.............................................................115             VALVE ..................................................................128   GI
    Removal and Installation .........................................116                  VALVE SPRING .....................................................129
    Disassembly.............................................................116            HYDRAULIC VALVE LIFTER ..................................129
       PISTON AND CRANKSHAFT ..................................116                         VALVE GUIDE .......................................................129        MA
    Inspection.................................................................117         ROCKER SHAFT AND ROCKER ARM ....................129
       PISTON AND PISTON PIN CLEARANCE ................117                              Valve Seat................................................................130
       PISTON RING SIDE CLEARANCE ..........................117                            INTAKE VALVE SEAT ............................................130
       PISTON RING END GAP........................................118                      EXHAUST VALVE SEAT.........................................131
       CONNECTING ROD BEND AND TORSION .............118                                 Camshaft and Camshaft Bearing ............................132
       CYLINDER BLOCK DISTORTION AND WEAR .........118                                  Cylinder Block..........................................................133      LC
       PISTON-TO-BORE CLEARANCE ............................119                         Piston, Piston Ring and Piston Pin .........................134
       CRANKSHAFT.......................................................120                AVAILABLE PISTON ..............................................134
       BEARING CLEARANCE .........................................121                      PISTON RING .......................................................134
                                                                                                                                                                         EC
        CONNECTING ROD BUSHING CLEARANCE                                                   PISTON PIN ..........................................................135
        (SMALL END) ........................................................123         Connecting Rod .......................................................135
        REPLACEMENT OF CONNECTING ROD
                                                                                                                                                                         FE
                                                                                        Crankshaft................................................................135
        BUSHING (SMALL END) ........................................124                 Available Main Bearing............................................136
        FLYWHEEL/DRIVE PLATE RUNOUT ......................124                              NO. 1 MAIN BEARING ...........................................136             CL
    Assembly .................................................................124          NO. 2 AND 3 MAIN BEARING.................................136
      PISTON ................................................................124           NO. 4 MAIN BEARING ...........................................136
      CRANKSHAFT.......................................................125                 UNDER SIZE .........................................................136       MT
        REPLACING PILOT BUSHING (M/T) OR PILOT                                          Available Connecting Rod Bearing..........................137
        CONVERTER (A/T) ................................................126                CONNECTING ROD BEARING UNDERSIZE ...........137
SERVICE DATA AND SPECIFICATIONS (SDS) .......127                                        Miscellaneous Components.....................................137                 AT
  General Specifications.............................................127                   BEARING CLEARANCE .........................................137
  Cylinder Head ..........................................................128
  Valve ........................................................................128                                                                                      TF

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                                                                                                                                                                         IDX
                                                                                 EM-3
                                           PRECAUTIONS                                              KA24DE
Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"

                                          Supplemental Restraint System (SRS) "AIR
                                          BAG" and "SEAT BELT PRE-TENSIONER"                             NGEM0085
                                          The Supplemental Restraint System such as "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 passen-
                                          ger for certain types of collision. The Supplemental Restraint Sys-
                                          tem consists of driver air bag module (located in the center of the
                                          steering wheel), front passenger air bag module (located on the
                                          instrument panel on passenger side), seat belt pre-tensioners, a
                                          diagnosis sensor unit, crash zone sensor, seat belt buckle
                                          switches, 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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