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                                                                                                                                                                          GI
                                                                                                   ENGINE MECHANICAL
                                                                                                                                                                          MA



                                                                                              SECTION                       EM                                            LC

                                                                                                                                                                          EC

                                                                                                                                                                          FE

                                                               CONTENTS                                                                                                   CL

PRECAUTIONS ...............................................................3                 CAMSHAFT RUNOUT ..............................................48
                                                                                             CAMSHAFT CAM HEIGHT .......................................48
                                                                                                                                                                          MT
  Parts Requiring Angular Tightening.............................3
  Liquid Gasket Application Procedure ..........................3                            CAMSHAFT JOURNAL CLEARANCE ........................49
                                                                                             CAMSHAFT END PLAY............................................49
PREPARATION ...............................................................4
                                                                                             CAMSHAFT SPROCKET RUNOUT ...........................50
                                                                                                                                                                          AT
  Special Service Tools ..................................................4
                                                                                             VALVE GUIDE CLEARANCE ....................................50
  Commercial Service Tools ...........................................6
                                                                                             VALVE GUIDE REPLACEMENT ................................50
NOISE, VIBRATION AND HARSHNESS (NVH)                                                                                                                                      TF
                                                                                             VALVE SEATS .........................................................51
TROUBLESHOOTING .....................................................8                       REPLACING VALVE SEAT FOR SERVICE PARTS ....51
  NVH Troubleshooting - Engine Noise .........................9                              VALVE DIMENSIONS ...............................................52
OUTER COMPONENT PARTS .....................................10
                                                                                                                                                                          PD
                                                                                             VALVE SPRING .......................................................52
  Removal and Installation ...........................................10                     VALVE LIFTER ........................................................53
     TIGHTENING PROCEDURES ...................................12                       Assembly ...................................................................53     AX
  Disassembly and Assembly of Power Valve (A/T) ....14                                 Installation..................................................................54
     DISASSEMBLY ........................................................14            Valve Clearance.........................................................58
     ASSEMBLY .............................................................15             CHECKING .............................................................58        SU
     INSPECTION AFTER ASSEMBLY .............................16                            ADJUSTING ............................................................60
MEASUREMENT OF COMPRESSION PRESSURE ....17                                           ENGINE ASSEMBLY.....................................................62
OIL PAN.........................................................................19     Removal and Installation ...........................................62             BR
  Components...............................................................19             REMOVAL ...............................................................63
  Removal.....................................................................19          INSTALLATION........................................................65
  Installation..................................................................22   CYLINDER BLOCK .......................................................66             ST
TIMING CHAIN ..............................................................24          Components...............................................................66
  Components...............................................................24             CYLINDER BLOCK HEATER ....................................67
                                                                                                                                                                          RS
     POSITION FOR APPLYING LIQUID GASKET ............25                                Removal and Installation ...........................................67
  Removal.....................................................................27       Disassembly...............................................................67
  Inspection...................................................................34         PISTON, CRANKSHAFT AND OIL JET ......................67                         BT
  Installation..................................................................34     Inspection...................................................................69
OIL SEAL.......................................................................42         PISTON AND PISTON PIN CLEARANCE ..................69
  Replacement..............................................................42             PISTON RING SIDE CLEARANCE ............................69                       HA
     VALVE OIL SEAL .....................................................42               PISTON RING END GAP..........................................69
     OIL SEAL INSTALLATION DIRECTION .....................43                              CONNECTING ROD BEND AND TORSION ...............70
     FRONT OIL SEAL ....................................................43                CYLINDER BLOCK DISTORTION AND WEAR ...........70                                SC
     REAR OIL SEAL ......................................................43               PISTON-TO-BORE CLEARANCE ..............................71
CYLINDER HEAD..........................................................44                 CRANKSHAFT.........................................................72
  Components...............................................................44             BEARING CLEARANCE ...........................................72                 EL
                                                                                             CONNECTING ROD BUSHING CLEARANCE
  Removal.....................................................................45
                                                                                             (SMALL END) ..........................................................75
  Disassembly...............................................................47                                                                                            IDX
                                                                                             FLYWHEEL/DRIVE PLATE RUNOUT ........................76
  Inspection...................................................................48
                                                                                         Assembly ...................................................................76
     CYLINDER HEAD DISTORTION ...............................48
                                                                                           PISTON ..................................................................76
     CAMSHAFT VISUAL CHECK ....................................48
                                                      CONTENTS                                  (Cont'd)
        PLUG ......................................................................77     Valve Seat..................................................................85
        OIL JET ..................................................................77      Camshaft and Camshaft Bearing ..............................86
        CRANKSHAFT.........................................................78             Cylinder Block............................................................87
        KNOCK SENSOR ....................................................80               Piston, Piston Ring and Piston Pin ...........................88
        REPLACEMENT OF PILOT BUSHING (M/T) OR                                                AVAILABLE PISTON ................................................88
        PILOT CONVERTER (A/T)........................................80                      PISTON RING .........................................................89
        FLYWHEEL/DRIVE PLATE .......................................81                       PISTON PIN ............................................................89
SERVICE DATA AND SPECIFICATIONS (SDS) .........82                                         Connecting Rod .........................................................89
  General Specifications...............................................82                 Crankshaft..................................................................90
  Compression Pressure ..............................................82                   Available Main Bearing..............................................91
  Cylinder Head ............................................................82               UNDERSIZE ............................................................91
  Valve ..........................................................................83      Available Connecting Rod Bearing............................92
     VALVE ....................................................................83            CONNECTING ROD BEARING .................................92
     VALVE CLEARANCE................................................83                       UNDERSIZE ............................................................92
     VALVE SPRING .......................................................83               Miscellaneous Components.......................................92
     VALVE LIFTER ........................................................83                 BEARING CLEARANCE ...........................................92
     AVAILABLE LIFTERS (SHIMLESS TYPE) ..................84
     VALVE GUIDE .........................................................85




                                                                                   EM-2
           PRECAUTIONS
                                              Parts Requiring Angular Tightening

          Parts Requiring Angular Tightening                             NAEM0001
                                                                                    GI
          



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