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                                                                                                                                                                          GI
                                                                                                   ENGINE MECHANICAL
                                                                                                                                                                          MA



                                                                                              SECTION                       EM                                            LC

                                                                                                                                                                          EC

                                                                                                                                                                          FE

                                                               CONTENTS                                                                                                   CL

PRECAUTIONS ...............................................................3                 CAMSHAFT SPROCKET RUNOUT ...........................44
                                                                                             VALVE GUIDE CLEARANCE ....................................44
                                                                                                                                                                          MT
  Parts Requiring Angular Tightening.............................3
  Liquid Gasket Application Procedure ..........................3                            VALVE GUIDE REPLACEMENT ................................45
                                                                                             VALVE SEATS .........................................................46
PREPARATION ...............................................................4
                                                                                             REPLACING VALVE SEAT FOR SERVICE PARTS ....46
                                                                                                                                                                          AT
  Special Service Tools ..................................................4
                                                                                             VALVE DIMENSIONS ...............................................47
  Commercial Service Tools ...........................................6
                                                                                             VALVE SPRING .......................................................47
NOISE, VIBRATION AND HARSHNESS (NVH)                                                                                                                                      TF
                                                                                             VALVE LIFTER ........................................................47
TROUBLESHOOTING .....................................................8                 Assembly ...................................................................48
  NVH Troubleshooting - Engine Noise .........................9
OUTER COMPONENT PARTS .....................................10
                                                                                       Installation..................................................................48   PD
                                                                                       Valve Clearance.........................................................53
  Removal and Installation ...........................................10                  CHECKING .............................................................53
     TIGHTENING PROCEDURES ...................................12                          ADJUSTING ............................................................55        AX
MEASUREMENT OF COMPRESSION PRESSURE ....14                                           ENGINE ASSEMBLY.....................................................58
OIL PAN.........................................................................15     Removal and Installation ...........................................58
  Components...............................................................15             REMOVAL ...............................................................59       SU
  Removal.....................................................................15          INSTALLATION........................................................61
  Installation..................................................................18   CYLINDER BLOCK .......................................................62
TIMING CHAIN ..............................................................20          Components...............................................................62        BR
  Components...............................................................20             CYLINDER BLOCK HEATER ....................................63
     POSITION FOR APPLYING LIQUID GASKET ............21                                Removal and Installation ...........................................63
  Removal.....................................................................23
                                                                                                                                                                          ST
                                                                                       Disassembly...............................................................63
  Inspection...................................................................29         PISTON, CRANKSHAFT AND OIL JET ......................63
  Installation..................................................................29     Inspection...................................................................64    RS
OIL SEAL.......................................................................36         PISTON AND PISTON PIN CLEARANCE ..................64
  Replacement..............................................................36             PISTON RING SIDE CLEARANCE ............................65
     VALVE OIL SEAL .....................................................36               PISTON RING END GAP..........................................65                 BT
     OIL SEAL INSTALLATION DIRECTION .....................37                              CONNECTING ROD BEND AND TORSION ...............66
     FRONT OIL SEAL ....................................................37                CYLINDER BLOCK DISTORTION AND WEAR ...........66
     REAR OIL SEAL ......................................................37               PISTON-TO-BORE CLEARANCE ..............................67                       HA
CYLINDER HEAD..........................................................39                 CRANKSHAFT.........................................................68
  Components...............................................................39             BEARING CLEARANCE ...........................................68
  Removal.....................................................................40             CONNECTING ROD BUSHING CLEARANCE                                             SC
                                                                                             (SMALL END) ..........................................................71
  Disassembly...............................................................42
                                                                                             FLYWHEEL/DRIVE PLATE RUNOUT ........................71
  Inspection...................................................................43                                                                                         EL
                                                                                         Assembly ...................................................................72
     CYLINDER HEAD DISTORTION ...............................43
                                                                                           PISTON ..................................................................72
     CAMSHAFT VISUAL CHECK ....................................43
                                                                                           OIL JET ..................................................................72
     CAMSHAFT RUNOUT ..............................................43                                                                                                     IDX
                                                                                           CRANKSHAFT.........................................................72
     CAMSHAFT CAM HEIGHT .......................................43
                                                                                             REPLACEMENT OF PILOT BUSHING (M/T) OR
     CAMSHAFT JOURNAL CLEARANCE ........................43
                                                                                             PILOT CONVERTER (A/T)........................................75
     CAMSHAFT END PLAY............................................44
                                                      CONTENTS                                 (Cont'd)
     FLYWHEEL/DRIVE PLATE .......................................75                      Cylinder Block............................................................82
SERVICE DATA AND SPECIFICATIONS (SDS) .........76                                        Piston, Piston Ring and Piston Pin ...........................83
  General Specifications...............................................76                   AVAILABLE PISTON ................................................83
  Compression Pressure ..............................................76                     PISTON RING .........................................................84
  Cylinder Head ............................................................76              PISTON PIN ............................................................84
  Valve ..........................................................................77     Connecting Rod .........................................................84
     VALVE ....................................................................77        Crankshaft..................................................................85
     VALVE CLEARANCE................................................77                   Available Main Bearing..............................................86
     AVAILABLE SHIMS ..................................................77                   UNDERSIZE ............................................................86
     VALVE SPRING .......................................................79              Available Connecting Rod Bearing............................87
     VALVE LIFTER ........................................................79                CONNECTING ROD BEARING .................................87
     VALVE GUIDE .........................................................80                UNDERSIZE ............................................................87
  Valve Seat..................................................................80         Miscellaneous Components.......................................87
  Camshaft and Camshaft Bearing ..............................81                            BEARING CLEARANCE ...........................................87




                                                                                  EM-2
           PRECAUTIONS
                                              Parts Requiring Angular Tightening

          Parts Requiring Angular Tightening                             NAEM0001
                                                                                    GI
          



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