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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 ................................44
                                                                                             VALVE SEATS .........................................................45
PREPARATION ...............................................................4
                                                                                             REPLACING VALVE SEAT FOR SERVICE PARTS ....45
                                                                                                                                                                          AT
  Special Service Tools ..................................................4
                                                                                             VALVE DIMENSIONS ...............................................46
  Commercial Service Tools ...........................................6
                                                                                             VALVE SPRING .......................................................46
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.....................................................59
OIL PAN.........................................................................15     Removal and Installation ...........................................59
  Components...............................................................15             REMOVAL ...............................................................60       SU
  Removal.....................................................................15          INSTALLATION........................................................62
  Installation..................................................................18   CYLINDER BLOCK .......................................................63
TIMING CHAIN ..............................................................20          Components...............................................................63        BR
  Components...............................................................20             CYLINDER BLOCK HEATER ....................................64
     POSITION FOR APPLYING LIQUID GASKET ............21                                Removal and Installation ...........................................64
  Removal.....................................................................23
                                                                                                                                                                          ST
                                                                                       Disassembly...............................................................64
  Inspection...................................................................29         PISTON, CRANKSHAFT AND OIL JET ......................64
  Installation..................................................................29     Inspection...................................................................65    RS
OIL SEAL.......................................................................36         PISTON AND PISTON PIN CLEARANCE ..................65
  Replacement..............................................................36             PISTON RING SIDE CLEARANCE ............................66
     VALVE OIL SEAL .....................................................36               PISTON RING END GAP..........................................66                 BT
     OIL SEAL INSTALLATION DIRECTION .....................37                              CONNECTING ROD BEND AND TORSION ...............67
     FRONT OIL SEAL ....................................................37                CYLINDER BLOCK DISTORTION AND WEAR ...........67
     REAR OIL SEAL ......................................................37               PISTON-TO-BORE CLEARANCE ..............................68                       HA
CYLINDER HEAD..........................................................38                 CRANKSHAFT.........................................................69
  Components...............................................................38             BEARING CLEARANCE ...........................................69
  Removal.....................................................................39             CONNECTING ROD BUSHING CLEARANCE                                             SC
                                                                                             (SMALL END) ..........................................................72
  Disassembly...............................................................42
                                                                                             FLYWHEEL/DRIVE PLATE RUNOUT ........................72
  Inspection...................................................................42                                                                                         EL
                                                                                         Assembly ...................................................................73
     CYLINDER HEAD DISTORTION ...............................42
                                                                                           PISTON ..................................................................73
     CAMSHAFT VISUAL CHECK ....................................42
                                                                                           OIL JET ..................................................................73
     CAMSHAFT RUNOUT ..............................................42                                                                                                     IDX
                                                                                           CRANKSHAFT.........................................................73
     CAMSHAFT CAM HEIGHT .......................................43
                                                                                             REPLACEMENT OF PILOT BUSHING (M/T) OR
     CAMSHAFT JOURNAL CLEARANCE ........................43
                                                                                             PILOT CONVERTER (A/T)........................................76
     CAMSHAFT END PLAY............................................43
                                                      CONTENTS                                 (Cont'd)
     FLYWHEEL/DRIVE PLATE .......................................76                      Cylinder Block............................................................84
SERVICE DATA AND SPECIFICATIONS (SDS) .........77                                        Piston, Piston Ring and Piston Pin ...........................85
  General Specifications...............................................77                   AVAILABLE PISTON ................................................85
  Compression Pressure ..............................................77                     PISTON RING .........................................................86
  Cylinder Head ............................................................77              PISTON PIN ............................................................86
  Valve ..........................................................................78     Connecting Rod .........................................................86
     VALVE ....................................................................78        Crankshaft..................................................................87
     VALVE CLEARANCE................................................78                   Available Main Bearing..............................................88
     AVAILABLE SHIMS ..................................................78                   UNDERSIZE ............................................................88
     VALVE SPRING .......................................................80              Available Connecting Rod Bearing............................89
     VALVE LIFTER ........................................................80                CONNECTING ROD BEARING .................................89
     AVAILABLE LIFTERS (SHIMLESS TYPE) ..................81                                 UNDERSIZE ............................................................89
     VALVE GUIDE .........................................................82             Miscellaneous Components.......................................89
  Valve Seat..................................................................82            BEARING CLEARANCE ...........................................89
  Camshaft and Camshaft Bearing ..............................83




                                                                                  EM-2
           PRECAUTIONS
                                              Parts Requiring Angular Tightening

          Parts Requiring Angular Tightening                             NAEM0001
                                                                                    GI
          



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