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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.............................5                        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.......................................................................89
     VALVE SPRING .......................................................56
                                                                                         Replacement..............................................................89
     VALVE GUIDE .........................................................57
                                                                                            VALVE OIL SEAL .....................................................89
     VALVE LIFTER ........................................................57
                                                                                            OIL SEAL INSTALLING DIRECTION .........................89
     VALVE CLEARANCE ADJUSTMENT .........................57
                                                                                            CAMSHAFT OIL SEAL .............................................90
     AVAILABLE SHIMS ..................................................58
                                                                                            FRONT OIL SEAL ....................................................90
     VALVE SEAT ...........................................................59
                                                                                            REAR OIL SEAL ......................................................90
  Cylinder Block............................................................60
                                                                                       CYLINDER HEAD..........................................................91
  Camshaft and Camshaft Bearing ..............................61
                                                                                         Components...............................................................91
  Piston, Piston Ring and Piston pin............................62
                                                                                         Removal.....................................................................92
     PISTON ..................................................................62
                                                                                         Disassembly...............................................................94
     PISTON PIN ............................................................62
     PISTON RING .........................................................62             Inspection...................................................................95
  Connecting Rod .........................................................63                CYLINDER HEAD DISTORTION ...............................95
                                                                                            CAMSHAFT VISUAL CHECK ....................................95
  Crankshaft..................................................................63
                                                                                            CAMSHAFT RUNOUT ..............................................95
  Bearing Clearance .....................................................64
                                                                                            CAMSHAFT CAM HEIGHT .......................................95
  Available Main Bearing..............................................64                    CAMSHAFT JOURNAL CLEARANCE ........................95
     STANDARD .............................................................64               CAMSHAFT END PLAY............................................96
     UNDERSIZE (SERVICE) ..........................................64                       CAMSHAFT SPROCKET RUNOUT ...........................96
  Available Connecting Rod Bearing............................64                            VALVE GUIDE CLEARANCE ....................................96
     STANDARD .............................................................64               VALVE GUIDE REPLACEMENT ................................97
     UNDERSIZE (SERVICE) ..........................................64                       VALVE SEATS .........................................................98
  Miscellaneous Components.......................................65                         REPLACING VALVE SEAT FOR SERVICE PARTS ....99
                                                                                            VALVE DIMENSIONS ...............................................99
                         VG33E AND VG33ER                                                   VALVE SPRING .....................................................100
                                                                                            ROCKER SHAFT AND ROCKER ARM ....................101
PRECAUTIONS .............................................................66                 HYDRAULIC VALVE LIFTER ..................................101
  Supplemental Restraint System (SRS) AIR                                                Assembly .................................................................101
  BAG and SEAT BELT PRE-TENSIONER.............66                                         Installation................................................................102
  Parts Requiring Angular Tightening...........................67                      SUPERCHARGER .......................................................107
  Liquid Gasket Application Procedure ........................67                         Components.............................................................107
PREPARATION .............................................................68              Removal...................................................................108
  Special Service Tools ................................................68               Inspection.................................................................109
  Commercial Service Tools .........................................70                      SUPERCHARGER FLANGE ...................................109
NOISE, VIBRATION AND HARSHNESS (NVH)                                                        ROTOR SYSTEM ..................................................109
TROUBLESHOOTING ...................................................72                       SUPERCHARGER BYPASS VALVE ACTUATOR .....110
  NVH Troubleshooting Chart - Engine Noise .............73                               Installation................................................................110
OUTER COMPONENT PARTS .....................................74                          ENGINE ASSEMBLY................................................... 111
  Removal and Installation ...........................................74                 Removal and Installation ......................................... 111
MEASUREMENT OF COMPRESSION PRESSURE ....77                                                  REMOVAL .............................................................112
                                                                                       CYLINDER BLOCK .....................................................114



                                                                                  EM-2
                                                     CONTENTS                                 (Cont'd)
    Components.............................................................114             VALVE ..................................................................127   GI
    Removal and Installation .........................................115                  VALVE SPRING .....................................................128
    Disassembly.............................................................115            HYDRAULIC VALVE LIFTER ..................................128
       PISTON AND CRANKSHAFT ..................................115                         VALVE GUIDE .......................................................128        MA
    Inspection.................................................................116         ROCKER SHAFT AND ROCKER ARM ....................128
       PISTON AND PISTON PIN CLEARANCE ................116                              Valve Seat................................................................129
       PISTON RING SIDE CLEARANCE ..........................116                            INTAKE VALVE SEAT ............................................129
       PISTON RING END GAP........................................117                      EXHAUST VALVE SEAT.........................................130
       CONNECTING ROD BEND AND TORSION .............117                                 Camshaft and Camshaft Bearing ............................131
       CYLINDER BLOCK DISTORTION AND WEAR .........117                                  Cylinder Block..........................................................132      LC
       PISTON-TO-BORE CLEARANCE ............................118                         Piston, Piston Ring and Piston Pin .........................133
       CRANKSHAFT.......................................................119                AVAILABLE PISTON ..............................................133
       BEARING CLEARANCE .........................................120                      PISTON RING .......................................................133
                                                                                                                                                                         EC
        CONNECTING ROD BUSHING CLEARANCE                                                   PISTON PIN ..........................................................134
        (SMALL END) ........................................................122         Connecting Rod .......................................................134
        REPLACEMENT OF CONNECTING ROD
                                                                                                                                                                         FE
                                                                                        Crankshaft................................................................134
        BUSHING (SMALL END) ........................................123                 Available Main Bearing............................................135
        FLYWHEEL/DRIVE PLATE RUNOUT ......................123                              NO. 1 MAIN BEARING ...........................................135             CL
    Assembly .................................................................123          NO. 2 AND 3 MAIN BEARING ................................135
      PISTON ................................................................123           NO. 4 MAIN BEARING ...........................................135
      CRANKSHAFT.......................................................124                 UNDER SIZE .........................................................135       MT
        REPLACING PILOT BUSHING (M/T) OR PILOT                                          Available Connecting Rod Bearing..........................136
        CONVERTER (A/T) ................................................125                CONNECTING ROD BEARING UNDERSIZE ...........136
SERVICE DATA AND SPECIFICATIONS (SDS) .......126                                        Miscellaneous Components.....................................136                 AT
  General Specifications.............................................126                   BEARING CLEARANCE .........................................136
  Cylinder Head ..........................................................127
  Valve ........................................................................127                                                                                      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"                               NEEM0125
                                          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 in a frontal collision. The Supplemental Restraint System con-
                                          sists of a driver air bag module (located in the center of the steer-
                                          ing wheel), a front passenger air bag module (located on the instru-
                                          ment panel on the passenger side), seat belt pre-tensioners, a
                                          diagnosis sensor unit, warning lamp, wiring harness, and spiral
                                          cable.
                                          The vehicle (except Crew Cab model) is equipped with a passen-
                                          ger air bag deactivation switch. Because no rear seat exists where
                                          a rear-facing child restraint can be placed, the switch is designed
                                          to turn off the passenger air bag so that a rear-facing child restraint
                                          can be used in the front passenger seat. The switch is located in
                                          the center of the instrument panel, near the ashtray. When the
                                          switch is turned to the ON position, the passenger air bag is
                                          enabled and could inflate in a frontal collision. When the switch is
                                          turned to the OFF position, the passenger air bag is disabled and
                                          will not inflate in a frontal collision. A passenger air bag OFF indi-
                                          cator on the instrument panel lights up when the passenger air bag
                                          is switched OFF. The driver air bag always remains enabled and is
                                          not affected by the passenger air bag deactivation switch.
                                          Information necessary to service the system safely is included in
                                          the RS section of this Service Manual.
                                          WARNING:
                                          



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