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ENGINE MECHANICAL

1. 150 PISTON TO BORE CLEARANCE 135 AVAILABLE PISTON eene 150 CRANKSHAFT 2 titer es retos 136 PISTON RING eret nire dicken 150 BEARING CLEARANCE seen 137 PISTON PIN EE 151 CONNECTING ROD BUSHING CLEARANCE Connecting Rod iate 151 SMALL END na 140 Crankshaft ssssssssseseeseseeeeeenene 152 REPLACEMENT OF CONNECTING ROD Available Main Bearing eeen 153 BUSHING SMALL END seese 140 NO 1 MAIN BEARING eene 153 FLYWHEEL DRIVE PLATE RUNOUT 140 NO 2 AND 3 MAIN BEARING 153 Assembly 3 Ene tee eee 141 NO 4 MAIN BEARING eene 153 PISTON WEE 141 UNDERSIZE inet tede 153 CRANKSHAFT AA 141 Available Connecting Rod Bearing 154 REPLACING PILOT BUSHING M T OR PILOT CONNECTING ROD BEARING UNDERSIZE 154 CONVERTER AST eeeseeeee 143 Miscellaneous Components 154 BEARING CLEARANCE eee 154 EM 3 PRECAUTIONS KA24DE PRECAUTIONS PFP 00001 Precautions for Supplemental Restraint System SRS AIR BAG and SEAT BELT PRE TENSIONER 850000 The Supplemental Restraint System such as AIR BAG and SEAT BELT PRE TENSIONER used along with a front seat belt helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision This system may include se
2. 2 Install the upper timing chain and sprockets aligning the paint marks made during removal as shown SEM549G EM 26 TIMING CHAIN KA24DE 3 Install the chain tensioner Remove the pin holding the tensioner Mati k piston in the bore of the tensioner ating mar eh AA LI QC D Mating mark the timing chain is correctly installed e Check that the timing chain mating marks are aligned so that FOC CZ d Upper timing chain tensioner Mating mark JEM547G 4 Install the camshaft sprocket cover CAUTION Do not to tear or damage the cylinder head gasket Do not let the upper timing chain slip or jump on the sprockets when installing the camshaft sprocket cover e Use a scraper to remove all traces of liquid gasket from mating surfaces of the engine block and cam shaft sprocket cover e Apply liquid gasket on the head gasket surface e Apply a continuous bead of liquid gasket to the cylinder head camshaft sprocket cover Refer to EM 5 Precautions for Liquid Gasket Use Genuine Silicone RTV Sealant or equivalent Refer to MA 12 Recommended Fluids and Lubricants 5 Install the rocker cover gasket on the rocker cover e Apply a continuous bead of liquid gasket to the cylinder head camshaft sprocket cover Refer to EM 5 Precautions for Liquid Gasket Use Genuine Silicone RTV Sealant or equivalent Refer to GI 42 RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS 6 Install the rocker cover Tig
3. e Donotallow any magnetic materials to contact the ring gear teeth on drive plate and rear plate Disassembly EBsocaTY PISTON AND CRANKSHAFT 1 Place the engine on a work stand KV10106500 2 Drain the engine of coolant Refer to MA 26 DRAINING ENGINE COOLANT 3 Drain the engine oil Refer to MA 30 Changing Engine Oil 4 Remove the timing belt Refer to EM 91 Removal 5 Remove the engine oil pan and oil pump Refer to LU 16 Removal and Installation 6 Remove the water pump Refer to CO 25 Removal 7 Remove the cylinder head Refer to EM 105 Removal SEM326FA 8 Remove the pistons with connecting rod assemblies e When disassembling the pistons and connecting rods remove the snap ring first then heat the piston to 60 70 C 140 158 F or use a piston pin press stand at room tem perature CAUTION e When the piston rings are not replaced make sure that piston rings are installed in their original position and direction e When replacing the piston rings install them with the punchmark facing up If there is no punchmark install SEMBITB with either side up EM 132 CYLINDER BLOCK VG33E and VG33ER 9 Remove the bearing caps and crankshaft e Before removing the bearing caps measure the crankshaft end play CAUTION The bearing cap bolts must be loosened in two or three steps in the numerical order as shown Inspection PISTON AND P
4. Limit After installing in connecting rod EM 151 0 40 0 0157 Crankshaft SEM394 SERVICE DATA AND SPECIFICATIONS SDS VG33E and VG33ER EBSOOGU9 Unit mm in Out of round Ka Ka Taper A Ki EM715 Grade No 3 62 696 62 975 2 4683 2 4793 Grade No 4 62 963 62 969 2 4789 2 4791 No 1 main journal Grade No 5 62 957 62 963 2 4786 2 4789 Main journal dia Dm Grade No 6 62 951 62 957 2 4784 2 4786 Grade No 0 62 967 62 975 2 4790 2 4793 Except No 1 main journal Grade No 1 62 959 62 967 2 4787 2 4790 Grade No 2 62 951 62 959 2 4784 2 4787 Pin journal dia Dp 49 955 49 974 1 9667 1 9675 Center distance r 41 5 1 634 Out of round X Y Standard Less than 0 005 0 0002 Taper A B Standard Less than 0 005 0 0002 Standard Less than 0 025 0 0010 Runout total indicator reading Limit Less than 0 10 0 0039 Standard 0 050 0 170 0 0020 0 0067 End free play Limit 0 30 0 0118 EM 152 SERVICE DATA AND SPECIFICATIONS SDS Available Main Bearing NO 1 MAIN BEARING Grade number Upper main bearing With oil groove No 1 No 4 SUE With oil groove SC d v S No 4 Thickness T mm in Lower main bearing Without oil il groove Width W mm in VG33E and VG33ER EBSOOGUA Identification color
5. 3 eoi redes 118 SUPERCHARGER eese 124 Components ecco keen etes 124 eu Le UE EE 125 Inspection ie sot ese eR Le uet s 126 SUPERCHARGER FLANGE sese 126 ROTOR SYSTEM thee 126 SUPERCHARGER BYPASS VALVE ACTUA Ho c LE 126 Installatioln Teronen Pics ee PEE 127 ENGINE ASSEMBLY eee 128 SERVICE DATA AND SPECIFICATIONS SDS 144 Removal and Installation 128 General Specifications sesssssss DEMOLS 129 Cylinder Head 22 esses Accel teet Ree INSTALLATION eeeeeeeeeenneennnennn 130 VI CYLINDER BLOCK senes 131 VTT E Components esses 131 VALVE SPRING A Removal and Installation 132 HYDRAULIC VALVE LIFTER Disassembly rerna a a ii 132 VALVE GUIDE dio ede PISTON AND CRANKSHAFT 132 ROCKER SHAFT AND ROCKER ARM 146 Inspectloh it re er entree et 133 Valve Seat nete de e e e aed 147 PISTON AND PISTON PIN CLEARANCE 133 INTAKE VALVE SEAT occ 147 PISTON RING SIDE CLEARANCE 133 EXHAUST VALVE SEAT 148 PISTON RING END GAP esee 134 Camshaft and Camshaft Bearing 148 CONNECTING ROD BEND AND TORSION 134 Cylinder Block AAA 149 CYLINDER BLOCK DISTORTION AND WEAR 134 Piston Piston Ring and Piston Pin
6. WEM098 EM 135 CYLINDER BLOCK VG33E and VG33ER 3 Measure the piston skirt diameter Piston diameter A refer to EM 150 AVAILABLE PISTON Measuring point a 49 0 mm 1 929 in distance from the top 4 Check that the piston to bore clearance B is within specification Calculate the clearance from the differ ence between the cylinder bore inner diameter step 1and 2 and the piston skirt diameter step 3 Piston to cylinder bore clearance B No 1 2 and 6 cylinders 0 025 0 045 mm 0 0010 0 0018 in No 3 and 4 cylinders 0 015 0 025 mm 0 0006 0 0010 in No 5 cylinder VG33E only 0 030 0 040 mm 0 0012 0 0016 in No 5 cylinder VG33ER only 0 025 0 045 mm 0 0010 0 0018 in 5 Determine the required oversized piston according to the amount of cylinder bore wear Oversize pistons are available for service Refer to EM 150 AVAILABLE PISTON 6 The cylinder bore honing size is determined by adding the piston skirt diameter to the piston to bore clear ance then subtracting the specified honing allowance Honing diameter size calculation D A B C where D see step 1 and 2 cylinder bore diameter after honing A see step 3 piston skirt diameter B see step 4 piston to bore clearance C honing allowance of 0 02 mm 0 0008 in 7 Install the main bearing caps and tighten them to the specified torque to prevent distortion of the cylin
7. Disconnect the fuel hose Remove the negative battery cable Remove the hood Refer to El 12 Removal and Installation Remove the air cleaner Remove the power steering drive belt generator drive belt and A C compressor drive belt Remove the radiator Refer to CO 14 Removal and Installation Remove the exhaust manifold heat shield Disconnect the exhaust system at rear of TWC manifold Remove the A C compressor from bracket Refer to MTC 67 Removal and Installation for Compressor Disconnect the accelerator wire vacuum hoses electrical connectors heater hoses and vacuum booster hose Remove the four power steering pump bolts Remove the transmission Refer to MT 10 Removal and Installation F85W71C MT 48 Removal and Installation FS5R30A AT 62 REMOVAL AND INSTALLATION RL4RO1A AT 407 REMOVAL AND INSTALLATION RE4RO01A Install the engine slingers and attach engine lift hooks as shown Remove the LH and RH engine mounts Lift and remove the engine WBIAO111E INSTALLATION Installation is in the reverse order of removal EM 47 CYLINDER BLOCK KA24DE CYLINDER BLOCK PFP 11010 Components 8s00GS0 SEC 110 120 135 150 210 For Canada model only U 34 44 3 5 4 5 25 33 0 30 40 3 1 4 1 22 30 7 O 16 19 1 6 1 9 12 14 4 9 5 9 0 5 0 6 43 4 52 1 14 5 15
8. VG33E and VG33ER PRECAUTIONS PFP 00001 Precautions for Supplemental Restraint System SRS AIR BAG and SEAT BELT PRE TENSIONER zemmer The Supplemental Restraint System such as AIR BAG and SEAT BELT PRE TENSIONER used along with a front seat belt helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision This system may include seat belt switch inputs and dual stage front air bag modules If equipped with dual stage front air bag modules the SRS system uses the seat belt switches to determine the front air bag deployment and may only deploy one front air bag depending on the severity of a collision and whether the front occupants are belted or unbelted Information necessary to service the system safely is included in the SRS and SB section of this Service Manual The vehicle may be equipped with a passenger 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 for certain types of collision When the switch is turned to the OFF position the pas senger air bag is disabled and will not inflate A passenger air bag OFF i
9. 0 2 mm 0 008 in or less VALVE DIMENSIONS 1 Check the dimensions of each valve Refer to EM 145 Valve 2 When the valve head has been worn to less then 0 5 mm 0 020 1 margin thickness in in margin thickness T replace the valve e VALVE SPRING Squareness 1 Measure the S dimension of the valve spring against a right angle tool for out of square as shown Out of square less than 2 0 mm 0 079 in SEM207E 2 Ifthe valve spring out of square exceeds the limit replace the valve spring Pressure 1 Check the valve spring pressure at the specified valve open height as shown Standard pressure 523 7 N 53 4 kg 117 7 Ib with valve open at 30 0 mm 1 181 in Limit pressure with 733 N 74 8 kg 164 8 Ib valve open at 30 mm 1 181 in 2 If not within specification replace the valve spring EM 115 CYLINDER HEAD VG33E and VG33ER ROCKER SHAFT AND ROCKER ARM 1 Check the rocker shafts for scratches damage and wear 2 Check the outer diameter of the rocker shaft Rocker shaft outer diameter 17 979 18 000 mm 0 7078 0 7087 in SEM761A 3 Check the inner diameter of the rocker arm Rocker arm inner diameter 18 007 18 028 mm 0 7089 0 7098 in Rocker arm to shaft clearance 0 007 0 049 mm 0 0003 0 0019 in CAUTION Keep the rocker arm with the hydraulic valve lifter standing upright to prevent air from entering the hydraulic valve lifter when c
10. 227 60 227 70 mm 8 9606 8 9645 in EM If necessary replace the cylinder block PISTON TO BORE CLEARANCE 1 Using a bore gauge measure the cylinder bore for out of round taper standard inner diameter and wear Out of round difference 0 015 mm 0 0006 in between X and Y standard Taper difference between A 0 015 mm 0 0006 in and C standard Unit mm in SEM321AA If the measurements exceed specifications hone all of the cylin der bores Replace the cylinder block if necessary Refer to EM 149 Cylinder Block SEM320A 2 Check for scratches and seizure If scratches and seizure is Cylinder bore grad number found hone the cylinder bores and replace the pistons e f both the cylinder block and pistons are replaced with new ones select the piston of the same grade number according to the following table These numbers are punched on cylin der block and piston in either Arabic or Roman numerals Refer to EM 150 AVAILABLE PISTON S a pe 20902 _ 9o0j 00 LJ o o o SEM557AA Combination Grade Number For Cylinder Bore and Piston Piston Sub grade Except for No 1 2 grade No number For No 3 4 and 5 cylinders and 6 cylinders P ans if necessary Cylinder bore ZN N A Identification grade No 1 2 3 u 3 2 3 symbol Piston grade No 2 1 3 2 3 3 4 4 4 5 5 6 1 2 3 Piston pin outer diameter grade number Engine front
11. 27 935 27 955 mm 1 0998 1 1006 in SEM012A 4 If clearance exceeds the limit replace camshaft and or cylinder head Camshaft journal clearance Standard 0 045 0 090 mm 0 0018 0 0035 in Limit 0 12 mm 0 0047 in CAMSHAFT END PLAY 1 Install camshaft in cylinder head 2 Measure camshaft end play bes Camshaft end play Standard 0 070 0 148 mm 0 0028 0 0058 in Limit 0 2 mm 0 008 in 3 If end play exceeds the limit replace camshaft and remeasure camshaft end play 4 f end play still exceeds the limit after replacing camshaft replace the cylinder head SEM296D CAMSHAFT SPROCKET RUNOUT 1 Install sprocket on camshaft 2 Measure camshaft sprocket runout Runout total indicator reading Limit 0 15 mm 0 0059 in 3 If it exceeds the limit replace camshaft sprocket AEM328 EM 36 CYLINDER HEAD KA24DE VALVE GUIDE CLEARANCE 1 Measure valve deflection as shown Valve and valve guide mostly wear in this direction Valve deflection limit dial gauge reading Intake amp Exhaust 0 2 mm 0 008 in Dial gauge 2 Ifthe valve exceeds the deflection limit check the valve to valve guide clearance a Measure valve stem diameter and valve guide inner diameter b Check that clearance is within specification Valve to valve guide clearance valve guide inner diameter valve stem diameter Unit mm in Valve Standard Limit Intake 0 020 0 053 0 0008 0 00
12. Limit 0 023 mm 0 0009 in If the clearance exceeds the limit replace the connecting rod or connecting rod bushing or the piston and rod set with pin SEM673E REPLACEMENT OF CONNECTING ROD BUSHING SMALL END 1 Drive the small end bushing into the rod until it is flush with end surface of the rod CAUTION The oil hole in the bushing and the connecting rod must be aligned when installed for proper lubrication SEM062A 2 After driving in the small end bushing ream the bushing so the clearance between the connecting rod bushing and the piston pin is at specification Clearance between connecting rod bushing and piston pin 0 005 0 017 mm 0 0002 0 0007 in FLYWHEEL DRIVE PLATE RUNOUT Measure the runout using a dial gauge as shown The runout is mea sured with a dial gauge reading from a full rotation of the flywheel M T only or driveplate A T only Runout total indicator reading Flywheel M T only less than 0 15 mm 0 0059 in Drive plate A T only less than 0 15 mm 0 0059 in CAUTION e Do not damage the ring gear teeth e Check the drive plate for deformation or cracks e Do not allow any magnetic materials to contact the ring gear teeth EM 140 CYLINDER BLOCK VG33E and VG33ER e Do not resurface the flywheel M T Replace as necessary Assembly zesoen PISTON 1 Install a new snap ring on one side of piston pin hole 2 Heat the piston to 60 70 C 140 158 F and assemble
13. Mark on shaft Mark on housing protruding Not mark on housing indented SEM837BA b After installation of the distributor confirm that the distributor rotor head is aligned as shown A Sg 3 No 1 cylinder at TDC SEM337F 15 Install the fuel injector tube assembly Refer to EM 80 Removal and Installation 16 Connect all of the fuel injector harness connectors 17 Install the fuel feed and fuel return hoses to the fuel injector tube assembly 18 Install the intake manifold collector VG33E only Refer to EM 80 OUTER COMPONENT PARTS EM 122 19 a poop ame O ae 20 21 22 CYLINDER HEAD VG33E and VG33ER Connect the following parts Harness connectors for IACV AAC valve Throttle position sensor Throttle position switch Distributor ignition coil S US Distributor f N VG33E Y EGRC solenoid valve VG33E only EGR temperature sensor VG33E only Water hoses from collector VG33ER only Heater hoses PCV hose from RH LH rocker cover Vacuum hoses for e Brake master cylinder e Pressure regulator Purge hose from purge control valve Spark plug wires Three left right bank injector connectors Ground harness WBIA0191E EGR tube VG33E only Install the ASCD and accelerator control wires on to the intake manifold collector VG33E only Check the hydraulic valve lifter Push the plunger forcefully with your finger e Be sure to check the hydraulic lifte
14. PISTON 6 Oylinder rebore diameter D is determined by adding piston to cylinder bore clearance B to the piston diameter A and subtracting the honing allowance C Rebore size calculation D A B C Where D rebore diameter A piston diameter as measured B piston to cylinder bore clearance C honing allowance of 0 02 mm 0 0008 in 7 Install the main bearing caps and tighten the cap bolts to specification This will prevent distortion of the cylinder bores during the honing process Main bearing cap bolts 46 56 N m 4 7 5 7 kg m 34 41 ft Ib 8 Hone the cylinder bores to obtain the specified piston to cylinder bore clearance CAUTION e When any cylinder needs boring all other cylinders must also be bored e Do not cut too much out of the cylinder bore at a time Cut only 0 05 mm 0 0020 in or so at a time 9 Measure finished cylinder bore for out of round and taper CAUTION e Measurement should be done after cylinder bore cools down CRANKSHAFT 1 Checkthe crankshaft main and pin journals for scratches wear or cracks EM 53 CYLINDER BLOCK KA24DE 2 With a micrometer measure the journals for taper and out of round Out of round X Y Main journal less than 0 01 mm 0 0004 in Crankshaft pin less than 0 005 mm 0 0002 in Taper A B Main journal less than 0 01 mm 0 0004 in Crankshaft pin less than 0 005 mm 0 0002 in Tapere A e B Out of round X Y SEM316A
15. Unit mm in Standard Limit Main bearing clearance 0 020 0 047 0 0008 0 0019 0 1 0 004 Connecting rod bearing clearance 0 010 0 035 0 0004 0 0014 0 09 0 0035 Available Main Bearing zeen STANDARD Unit mm in Grade number Thickness Identification color 0 1 821 1 825 0 0717 0 0719 Black 1 1 825 1 829 0 0719 0 0720 Brown 2 1 829 1 833 0 0720 0 0722 Green 3 1 833 1 837 0 0722 0 0723 Yellow 4 1 837 1 841 0 0723 0 0725 Blue UNDERSIZE SERVICE Unit mm in Thickness Main journal diameter Dm 0 25 0 0098 1 952 1 960 0 0769 0 0772 Grind so that bearing clearance is the specified value Available Connecting Rod Bearing Seen STANDARD Unit mm in Grade number Thickness Identification color 0 1 505 1 508 0 0593 0 0594 1 1 508 1 511 0 0594 0 0595 Brown 2 1 511 1 514 0 0595 0 0596 Green UNDERSIZE SERVICE Unit mm in Thickness Crank pin journal diameter Dp 0 08 0 0031 1 540 1 548 0 0606 0 0609 0 12 0 0047 1 560 1 568 0 0614 0 0617 EE bearingclearance isthe specified value 0 25 0 0098 1 625 1 633 0 0640 0 0643 Miscellaneous Components zemmer Unit mm in Camshaft sprocket runout TIR Less than 0 15 0 0059 Flywheel runout TIR Less than 0 15 0 006 Drive plate runout TIR Less than 0 15 0 006 Total indicator reading EM 71 PRECAUTIONS
16. block distortion limit A B 0 2 mm 0 008 in 4 If necessary replace cylinder block PISTON TO CYLINDER BORE CLEARANCE 1 Using a bore gauge measure cylinder bore for wear out of round and taper If it exceeds the limit rebore all cylinders Replace cylinder block if necessary Standard inner diameter Refer to EM 67 Cylinder Block Out of round X Y standard 0 015 mm 0 0006 in Taper A B standard 0 010 mm 0 0004 in Wear limit 0 2 mm 0 008 in 2 Unit mm in SEM040 10 0 39 60 2 36 120 4 72 Ke EM 52 CYLINDER BLOCK KA24DE 2 Check for scratches and seizure If seizure is found hone it CAUTION Piston grade number If the cylinder block and pistons are replaced match the piston grade with the grade number on the cylinder block upper surface as shown Refer to EM 69 PISTON 3 Measure piston skirt diameter Piston diameter A refer to EM 69 PISTON Measuring point A at approximately 48 mm height a from the top 1 89 in 4 Check that piston to cylinder bore clearance is within specification Piston to cylinder bore clearance B 0 020 0 040 mm 0 0008 0 0016 in 5 Determine the piston oversize according to the amount of cylinder bore wear for the specified piston to bore clearance NOTE Determine piston oversize according to amount of cylinder wear Oversize pistons are available for ser vice Refer to EM 69
17. e Do not remove the engine until the exhaust system has completely cooled off Otherwise you may burn yourself and or fire may break out in the fuel line EM For safety the tension of wires should be loosened against the engine Before disconnecting a fuel hose release the fuel pressure from the fuel line Refer to EC 616 FUEL PRESSURE RELEASE VG33E EC 1218 FUEL PRESSURE RELEASE VG33ER e Before removing the front axle from the transmission place safety stands under the designated front supporting points Refer to GI 37 Lifting Points Raise the engine and transmission in a safe manner For engines not equipped with engine slingers attach the appropriate slingers and bolts as described in the PARTS CATALOG CAUTION e When lifting engine be careful not to strike adjacent parts especially accelerator wire casing brake lines and brake master cylinder In hoisting the engine always use engine slingers in a safe manner Before separating engine and transmission remove crankshaft position sensor OBD from the assembly e Always take extra care not to damage edge of crankshaft position sensor OBD or ring gear teeth e Do not loosen front engine mounting insulator cover mounting nuts When cover is removed damper oil flows Mounting nut Mounting nut out and mounting insulator will not function e Tighten all bolts and nuts to specification Front engine mounting insulator REMOVAL e
18. manifold LH exhaust manifold Tighten in numerical order EBSO0GTQ SEM861CA WBIA0193E CYLINDER HEAD VG33E and VG33ER VG33ER RH exhaust manifold Doa D 6 A e Front amea Yay LH exhaust manifold a RA Front wi 3 797 es eres ee Ot 8 Tighten in numerical order WBIA0194E Install the cylinder head with a new head gasket e Install the washers between the bolts and cylinder head with the beveled side up as shown e Do not rotate the crankshaft and camshaft separately or the valves will hit the pistons l 3 Cylinder head side Oylinder head bolt washer SEM877A Tighten the cylinder head bolts in the numerical order as shown Use the specified angle wrench as necessary Angle wrench ST10120000 J24239 01 e Apply new engine oil to the threads and seating surfaces of the cylinder head bolts before installation e Cylinder head bolts No 4 7 9 and 12 L1 are longer than the other bolts L2 Cylinder head bolts L1 127 mm 5 00 in Cylinder head bolts L2 106 mm 4 17 in e Install the intake manifold and cylinder head at the same time using the 14 steps Le SE mmm 1 9 A SES bolt CH A Li SI em 78 AEM496 EM 119 CYLINDER HEAD VG33E and VG33ER Tighten bolts in numerical order SEM825C Cylinder head and intake manifold nuts and bolts tight TIGHTENING METHOD m ening Step 1
19. of pressure or a hammer and suitable tool 3 Ream out the cylinder head valve guide hole to specification for the service valve guide part as shown Valve guide hole diameter for service parts Intake 11 175 11 196 mm 0 4400 0 4408 in Exhaust 12 175 12 196 mm 0 4793 0 4802 in 4 Heat the cylinder head to 150 160 C 302 320 F in heated oil and press the service valve guide into the cylinder head to the specified height as shown Height L 13 2 13 4 mm 0 520 0 528 in 5 Ream out the new service valve guide in the cylinder head to the specified diameter Valve guide finished inner diameter Intake 7 000 7 018 mm 0 2756 0 2763 in Exhaust 8 000 8 011 mm 0 3150 0 3154 in EM 113 VG33E and VG33ER SEMO008A SEM264A Intake side Exhaust side SEMO89C SEMOB88C CYLINDER HEAD VG33E and VG33ER VALVE SEATS Check the valve seats for any pitting at the valve contact surface and re surface or replace the valve seat if it has worn out e Before repairing the valve seats check the valve and valve guide for wear Refer to EM 145 Valve e Use both hands to cut the valve seat uniformly REPLACING VALVE SEAT FOR SERVICE PARTS 1 Bore out the old seat until it collapses The machine depth stop should be set so that the boring cannot continue beyond the bottom of the face of the valve seat recess in the cylinder head 2 Ream outthe cylinder head recess
20. pace 7 6 8 9 55 64 Torsion bar E N m kg m ft Ib WEM064 1 Remove the engine undercover and hood Refer to El 12 Removal and Installation 2 Drain the coolant from the cylinder block and radiator Refer to MA 26 DRAINING ENGINE COOLANT EM 129 ENGINE ASSEMBLY VG33E and VG33ER 3 Before disconnecting fuel hose release the fuel pressure from the fuel line Refer to EC 616 FUEL PRESSURE RELEASE VG33E EC 1218 FUEL PRESSURE RELEASE VG33ER 4 Disconnect the vacuum hoses fuel tubes wires harnesses and connectors 5 Remove the radiator with shroud and cooling fan Refer to CO 30 Removal and Installation 6 Remove the drive belts Refer to MA 24 Checking Drive Belts 7 Discharge the A C system refrigerant Refer to MTC 64 HFC 134a R 134a Service Procedure 8 Remove the A C compressor manifold Refer to MTC 66 Components 9 Remove the power steering oil pump from the engine Refer to PS 17 Components 10 Remove the front exhaust tubes Refer to EX 3 Removal and Installation 11 Remove the transmission from the vehicle Refer to AT 62 REMOVAL AND INSTALLATION RL4RO1A AT 407 REMOVAL AND INSTALLATION RE4RO1A MT 10 Removal and Installation FS5W71C MT 48 Removal and Installation FS5R30A 12 Install the engine slingers Slinger bolts 20 26 N m 2 1 2 7 kg m 15 20 ft lb A Engine slinger S
21. ssesessseseeeenneene nennen 91 Removal eet eit Pt tue e er E 91 INSPOCUION s otio rn TOR Rd 93 BELT TENSIONER AND TENSIONER SPRING 94 Installation iiit eate marec 94 Tension Adjustment A 95 AFTER BELT REPLACEMENT onn 95 AFTER ENGINE OVERHAUL OR ENGINE REASSEMBLY WITH ROCKER COVERS REMOVED 5e too tiet E anes 96 OIL SEAL retenti tree eee De Paten 99 Replacement inanir ie i a E eE a 99 VALVE OIL SEAL raer ainei ai aaia 99 CAMSHAFT OIL SEAL een 99 FRONT OIL SEAL essen 100 REAR OIL SEAL 5 heme dne 101 CYLINDER HEAD eene 102 Measurement of Compression 102 ell ee 104 el RTE 105 Disassembly n oho 108 n SDOCLIOFi 2 cocci tee ttd n 110 CYLINDER HEAD DISTORTION 110 CAMSHAFT VISUAL CHECK 110 CAMSHAFT RUNOUT eee 110 CAMSHAFT CAM HEIGHT oieee 110 CAMSHAFT JOURNAL CLEARANCE 111 CAMSHAFT END PLAY essen 111 CAMSHAFT SPROCKET RUNOUT 111 VALVE GUIDE CLEARANCE 112 VALVE GUIDE REPLACEMENT 113 VALVE SEATS eege eege 114 REPLACING VALVE SEAT FOR SERVICE e RE et eei senes 114 VALVE DIMENSIONS sees 115 VALVE SPRING deeg EES 115 ROCKER SHAFT AND ROCKER ARM 116 HYDRAULIC VALVE LIFTER 116 Assembly si iint DE Ds 117 InstallatiOn
22. tighten cylinder head bolts 29 N m 3 0 kg m 2 II 22 ft Ib SE 283 Step2 tighten cylinder head bolts 59 N m 6 0 kg m ZS S 43 ft Ib 62s Step 3 loosen cylinder head bolts completely Step 4 tighten cylinder head bolts 10 N m 1 0 kg m 7 ft lb Step 5 tighten intake manifold bolts and nuts 4 N m 0 4 kg m 2 9 ft lb Step 6 tighten intake manifold bolts and nuts 18 N m 1 8 kg m 13 ft lb Step 7 tighten intake manifold bolts and nuts 16 20 N m 1 6 2 0 kg m 12 14 ft Ib i T Step8 loosen intake manifold bolts and nuts com SR pletely SS Step 9 tighten cylinder head bolts 29 N m 3 0kg m 222 22 ft lb Step 10 turn cylinder head bolts 60 to 65 degrees clockwise if an angle wrench is not avail able tighten cylinder head bolts 54 64 N m 5 5 6 5 kg m 40 47 ft Ib Step 11 tighten cylinder head sub bolts 9 0 11 8 N m 0 92 1 20 kg m 6 7 8 7 ft Ib Step 12 tighten intake manifold bolts and nuts 4 N m 0 4 kg m 2 9 ft Ib Step 13 tighten intake manifold bolts and nuts 9 N m 0 9 kg m 6 5 ft Ib Step 14 tighten intake manifold bolts and nuts 8 10 N m 0 8 1 0 kg m 5 8 7 ft Ib EM 120 CYLINDER HEAD e f only the intake manifold is removed and is to be used again install it in a three step procedure Tighten the nuts and bolts in the numerical order as shown Intake manifold nuts and bolts tightening steps Step 1 4 N m 0 4 kg m 2
23. 22 Apply liquid gasket Use Genuine Silicone RTV or equivalent Refer to GI Section Recommended Chemical Products and Sealants Refer to step 14 in Installation of CYLINDER HEAD ei N m kg m in Ib P N m kg m ft Ib WEM139 EM 84 OUTER COMPONENT PARTS VG33E and VG33ER VG33E SEC 140 208 Stud bolt Short 30 44 78 60 59 e Cylinder head sae S OO 41 61 G oF E CTI Wl o 9 22 10 8 0 94 1 1 6 8 8 0 12 25 17 15 1 3 1 7 9 12 OJ 28 5 33 3 2 9 3 4 21 0 24 5 m Keen EK 12 7 16 7 1 3 1 7 9 4 12 3 Mu 1 3 1 7 9 4 12 3 0 28 5 33 3 2 9 3 4 21 0 24 5 12 7 16 7 1 8 1 7 9 4 12 3 ei N m kg m in Ib D Nm kg m ft Ib Apply Genuine Silicone RTV or equivalent Refer to GI Section e Always replace after every disassembly WBIA0374E 1 Thermostat housing 2 Oil pressure switch 3 LH exhaust manifold cover 4 LH exhaust manifold and catalyst 5 RH exhaust manifold and catalyst 6 RH exhaust manifold cover EM 85 OUTER COMPONENT PARTS VG33E and VG33ER 7 Heated oxygen sensor 1 bank 1 8 Heated oxygen sensor 1 bank 2 9 Exhaust manifold stud bolt 10 Oil filter bracket VG33ER SEC 140 208 4 1 6 1 30 44 07s 8 0 58 Dien 58 9 9 22 10 8 e 40 60 0 94 1 1 8 2 4 1 6 1 e 30 44 f N 127 167 1 3 1 7
24. 3 Measure the crankshaft runout Runout total indicator reading less than 0 10 mm 0 0039 in 4 fthe crankshaft is out of specification replace the crankshaft BEARING CLEARANCE Method A using a bore gauge and micrometer Use Method A or Method B Method A is preferred because it is more accurate NOTE Use the following procedures to inspect the bearing clearance using Method A bore gauge and micrometer Main bearing 1 Set main bearings in their proper positions on the cylinder block and main bearing caps Follow the position numbering as shown SEM448C 2 Install the main bearing caps on the cylinder block e Tighten the main bearing cap bolts in two or three steps to specification Main bearing cap bolts 46 56 N m 4 7 5 7 kg m 34 41 ft Ib EM 54 CYLINDER BLOCK KA24DE 3 Measure the inner diameter A of each main bearing as shown 4 Measure the outer diameter Dm of each crankshaft main jour nal as shown 5 Calculate the main bearing clearance Main bearing clearance A Dm Standard 0 020 0 047 mm 0 0008 0 0019 in Limit 0 1 mm 0 004 in If the main bearing clearance exceeds the limit replace the bearing 6 If the clearance cannot be adjusted within the standard of any bearing grind the crankshaft journals and use an undersized replacement bearing as follows a When grinding the crankshaft journals confirm that the L dimension in fillet roll is more tha
25. 39 v mH 2nd 18 22 1 8 2 2 13 16 4 0 5 0 29 36 62A 0 37 3 48 0 3 8 4 9 28 35 O 45 1 es 0 52 0 66 45 1 57 3 Q8 U 1225 17 15 D 1 3 1 7 9 12 Wies az 0 64 0 85 55 6 73 8 O 16 21 1 6 2 1 12 15 X SN On di e Deg NKE 27 CU 40 5o dd s 4 1 5 1 30 37 O 29 4 34 3 3 0 3 5 W 6 10 0 6 1 0 52 87 De d i SH 3 SS d S j lt 45 60 4 6 6 1 33 44 D U 6 21 1 6 2 1 12 15 O 16 19 1 6 1 9 BO 142 152 N m kg m in Ib W ta 14 5 15 5 105 112 O N m kg m ft Ib Apply Genuine Silicone RTV or equivalent Refer to GI Section Lubricate with new engine oil e Always replace after every disassembly WBIAO232E EM 13 OUTER COMPONENT PARTS KA24DE 1 Throttle body 2 EGR temperature sensor 3 EGR valve 4 EGR tube 5 Oil dipstick 6 Exhaust manifold 7 Heated oxygen sensor 1 8 Exhaust manifold cover 9 TWC manifold 10 TWC manifold gaskets 11 Exhaust manifold gaskets 12 Crankshaft pulley 13 Generator bracket 14 Generator 15 Water pump 16 Adjusting bar 17 Water pump pulley 18 Oil pressure switch 19 Oil filter 20 Oil filter bracket 21 Knock sensor 22 Water inlet 23 Thermostat 24 Intake manifold bracket Ignition System Outer Components SEC 140 147 220 221 226 O 20 29 2 0 3 0 14 22 g o s 10 8
26. 9 4 12 3 46 c 4 33 8 l 2 9 3 4 21 0 24 5 0 12 7 16 7 1 3 1 7 9 4 12 3 46 O 28 5 33 3 2 9 3 4 eee 21 0 24 5 e Always replace after every disassembly Apply Genuine Silicone RTV Sealant or equivalent Refer to GI Section ei N m kg m in Ib Wh 1285 33 3 2 9 3 4 21 0 24 6 T N m kg m ft b ei 9 22 10 8 0 94 1 1 6 8 8 0 WBIA0378E EM 86 OUTER COMPONENT PARTS VG33E and VG33ER Thermostat housing 2 Oil pressure switch 3 LH exhaust manifold cover LH catalyst 5 Exhaust manifold left bank 6 RH catalyst Exhaust manifold right bank 8 RH exhaust manifold cover 9 Gasket Heated oxygen sensor 1 bank 1 11 Heated oxygen sensor 1 bank 2 12 Exhaust manifold stud bolt Oil filter bracket EM EM 87 OIL PAN VG33E and VG33ER OIL PAN PFP 11110 Removal reen WARNING Place the vehicle on a flat and solid surface e Place chocks in front of and behind the rear wheels e You should not remove the oil pan until the exhaust system and cooling system have completely cooled off Otherwise you may burn yourself and a fire could break out in the fuel line e When removing the front and rear engine mounting bolts and nuts lift the engine slightly to ensure safety CAUTION e In lifting the engine be careful not to hit against any adjacent parts
27. 9 ft lb Step2 9 N m 0 9 kg m 6 5 ft Ib Step3 8to 10 N m 0 8 1 0 kg m 5 8 7 ft Ib CAUTION If replacing the intake manifold with a new one the cylin der head gasket must also be replaced 6 Install both rocker covers Rocker cover bolts 1 3 N m 0 1 0 3 kg m 9 26 in Ib 7 Install the A C compressor generator and power steering pump brackets 8 Install the power steering pump Refer to PS 17 Components 9 Install the A C compressor Refer to MTC 67 Removal and Installation for Compressor 10 Install the generator Refer to SC 37 Installation 11 Install the exhaust front tube to the exhaust manifold Refer to EX 3 Removal and Installation 12 Install the rear belt cover and camshaft sprocket Refer to EM 80 Removal and Installation CAUTION RH camshaft sprocket and LH camshaft sprocket are differ ent parts Be sure to install them in the correct location VG33E and VG33ER Tighten bolts in numerical order SEM825C SEM403C Description Identification mark 0 RH camshaft sprocket R3 0 53 LH camshaft sprocket L3 9 27 SEM303A 13 Install the timing belt and adjust the timing belt tension Refer to EM 94 Installation EM 121 CYLINDER HEAD VG33E and VG33ER 14 Install the distributor a Align the mark on the distributor shaft with the protruding mark on the distributor housing Distributor drive gear
28. EM 68 SERVICE DATA AND SPECIFICATIONS SDS KA24DE Piston Piston Ring and Piston pin zement PISTON Unit mm in i a A SEM804E Grade No 1 88 970 88 980 3 5027 3 5031 Standard Grade No 2 88 980 88 990 3 5031 3 5035 Piston skirt diameter A Grade No 3 88 990 89 000 3 5035 3 5039 0 5 0 020 89 470 89 500 3 5224 3 5236 Service Oversize 1 0 0 039 89 970 90 000 3 5421 3 5433 Height a Approximately 48 1 89 Piston pin hole diameter d 20 993 21 005 0 8265 0 8270 Piston to cylinder bore clearance 0 020 0 040 0 0008 0 0016 PISTON PIN Unit mm in Standard Limit Piston pin outer diameter 20 989 21 001 0 8263 0 8268 Interference fit of piston pin to piston pin hole 0 002 to 0 01 0 0001 to 0 0004 Connecting rod bushing clearance 0 005 0 017 0 0002 0 0007 0 023 0 0009 PISTON RING Unit mm in Standard Limit Top 0 040 0 080 0 0016 0 0031 0 1 0 004 Side clearance 2nd 0 030 0 070 0 0012 0 0028 0 1 0 004 Oil 0 065 0 135 0 0026 0 0053 Top 0 28 0 52 0 0110 0 0205 1 0 0 039 Ring gap 2nd 0 45 0 69 0 0177 0 0272 1 0 0 039 Oil rail ring 0 20 0 69 0 0079 0 0272 1 0 0 039 EM 69 SERVICE DATA AND SPECIFICATIONS SDS Connecting Rod Gi EN Z WBIA0178E KA24DE EBSO0GSZ Unit mm in Standard Limit Center
29. Harness connectors for SS E e IACV AAC valve J THD SS e Throttle position sensor SEN E Ly A S5 e Throttle position switch SOK e e Distributor ignition coil SEES R e Distributor XO FS NL T VESE Y e EGRC solenoid valve VG33E only Sx i e EGR temperature sensor VG33E only b Water hoses from collector c Heater hoses d PCV hose from RH LH rocker cover 7 1 EGR valve e Vacuum hoses for Lx NG Ge e Brake master cylinder e Pressure regulator f Purge hose from purge control valve g Spark plug wires h Distributor assembly i Three left right bank injector connectors WBIA0191E j Ground harness 7 Remove the fuel feed and fuel return hoses from the injector fuel Oe dd assembly e Pe EE BR isconnect the right injector harness connectors S eas ee 1999 Injector harness ee ty OS E uel return hose Fuel feed hose LY Hed 9 Remove the injector fuel tube assembly 10 Remove the intake manifold from the engine loosen the bolts in numerical order as shown The following parts should be discon nected to remove intake manifold e Engine coolant temperature switch harness connector e Thermal transmitter harness connector Jj e Water hose from the thermostat housing X S r ron Loosen in numerical order SEMO34E EM 106 11 12 13 14 15 16 17 18 19 20 Remove the cylinder head with exhaust manifold loosen the CYLINDER HEAD VG33E and VG33ER Remove both of the camshaft sp
30. Intake camshaft R yer C e Mark the part with their original position and direction for cor E e X ON eS rect placement for installation CR 7 ES A pO oo He Ss Qk 5 Lag Unico LI STE c lt 5 Engine front Tighten in numerical order Loosen in reverse order Exhaust camshaft AEM352 3 Remove the cylinder head bolts in numerical order as shown e Loosen the cylinder head bolts in two or three steps CAUTION Remove the bolts in the correct numerical order to avoid warping or cracking the cylinder head Loosen in numerical order SEM274D 4 Remove the cylinder head and cylinder head gasket Disassembly zement 1 Remove the intake manifold and exhaust manifold Refer to EM 13 Removal and Installation 2 Remove the valve components using Tool as shown Valve spring compressor KV101092S0 J26336 B 3 Remove the valve oil seals using a suitable tool Inspection eBsooass CYLINDER HEAD DISTORTION 1 Clean the sealing surface of the cylinder head EM 34 CYLINDER HEAD KA24DE 2 Use a reliable straightedge and feeler gauge to check the flat ness of cylinder head surface Check the cylinder head sealing e OLO surface flatness along the six positions as shown Gy Cylinder head surface flatness Limit 0 1 mm 0 004 in If it exceeds the limit replace or resurface the cylinder head SEM294D 3 Resurface the cylinder head as necessa
31. OUTER COMPONENT PARTS 2 Intake manifold collector 3 5 Water outlet 6 8 Engine coolant temperature sensor 9 11 O ring 12 14 Insulator 15 17 Fueltube 18 20 Fuel return hose 21 23 EGR guide tube 24 26 EGR tube 27 29 Throttle opener 30 EM 81 VG33E and VG33ER Gasket Thermal transmitter Intake manifold Water pump Fuel injector Fuel pressure regulator Throttle body EGR temperature sensor EGR control valve Ground OUTER COMPONENT PARTS VG33E and VG33ER VG33ER SEC 140 147 148 163 164 173 210 221 Wy 8 4 10 8 0 86 1 1 74 6 95 5 Ky 8 4 10 8 0 86 1 1 74 6 95 5 g 0 18 22 1 8 2 2 13 pe S i ep D e Wi 8 0 7 0 8 61 69 Ky 8 4 10 8 0 86 1 1 74 6 9 tightening order jist 9 11 0 9 1 1 6 5 8 0 2nd 18 22 1 8 22 o o A 13 16 Wei 8 0 7 0 8 61 69 wae Refer to CYLINDER HEAD 3 914 17 1 4 1 7 10 12 Refer to CYLINDER HEAD 2 00 3 00 14 46 21 69 SEC 164 gt 2 9 3 8 0 30 0 39 26 0 33 9 Apply Genuine Silicone RTV Sealant or equivalent Refer to GI Section Nem kg m in Ib Nem kg m ft lb 1 6 2 1 12 15 Always replace after every disassembly WBIA0186E 1 PCV valve 2 Intake manifold collector 3 Gasket 4 Copper washer 5 Water outlet 6 Thermal transmitter EM 82 Fresh air inlet Distributor Fuel inject
32. PFP 00003 Noise Vibration and Harshness NVH casooass Camshaft bearing noise 6 E Tappet noise 5 ac 3 G 2 Op W is gt Ge ISS D 5 Timing chain X V a I ds chain XC AM H 2 M SS ensioner ps LS i V j LNC P Ee j Q es Valve Cie o o TIMING CHAIN Water pump noise Piston pin noise Z ROTATION Sc MECHANISM DRIVE BELT Power steering oil pump Idler pulley Connecting rod Piston bearing noise Water pump slap noise Air conditioner compressor Idler pulley Main bearing noise EM 11 NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING KA24DE NVH TROUBLESHOOTING CHART ENGINE NOISE Use the chart below to help you find the cause of the symptom 1 Locate the area where noise occurs 2 Confirm the type of noise 3 Specify the operating condition of the engine 4 Check the specified noise source If necessary repair or replace these parts Operating condition of engine Location of Type of Before After When M Whe While Source of Check item Reference noise noise warm warm start tee nrev driv noise page up up ing g ving ing Topot Ne kin gor C A A B lappet Valve clearance EM 37 engine clicking noise Rocker C nat amsha cover Camshaft journal clearance Cylinder Rattle C A A B C bearing Camshaft runo t EM 36 head noise Pisto
33. PIN CLEARANCE 50 Replacement sssssssssnnnseseesessseerernnrnrnrenserrrttrnrnnnnnene 28 PISTON RING SIDE CLEARANCE 51 VALVE OIL SEAL eene 28 PISTON RING END GAR 51 FRONT OIL SEAL eee 28 CONNECTING ROD BEND AND TORSION 51 REAR OIL SEAL eene nnn 30 CYLINDER BLOCK DISTORTION AND WEAR 52 PISTON TO CYLINDER BORE CLEARANCE 52 CRANKSHAFT 53th ntt ta metae 53 BEARING CLEARANCE eee 54 CONNECTING ROD BUSHING CLEARANCE SMALL END dei irairim aen aaiae naia aE 57 REPLACEMENT OF CONNECTING ROD BUSHING SMALL END neee 58 FLYWHEEL DRIVE PLATE RUNOUT 58 Assembly 3 2 ccr be hid Dp 58 PISTON iude eee e haesit edet eit 58 CRANKSHAFT aa e eraat pi apaia onas nnns 60 REPLACING PILOT BUSHING 61 SERVICE DATA AND SPECIFICATIONS SDS 63 General Specifications ssssssssss 63 COMPRESSION PRESSURE seee 63 Cylind r Head 2 nte teen oet 63 VIE 63 NALV e sericea ebe Sege 63 VALVE SPRING sseeeeeenm 64 VALVE GUIDE i oett tete pee teg eg 64 VALVE LIFTER iiit s 64 VALVE CLEARANCE ADJUSTMENT 65 AVAILABLE SHIMS eee 65 VALVE SEAT int Lr net Re ties 66 Cylinder Block AA 67 Camshaft and Camshaft Bearing 68 Piston Piston Ring and Piston pin 69 PISTON WEE 69 PISTON PIN WE 6
34. SPECIFICATIONS SDS VG33E and VG33ER Available Connecting Rod Bearing eBsoocus CONNECTING ROD BEARING UNDERSIZE Unit mm in Thickness Crank pin journal diameter Dp Standard 1 502 1 506 0 0591 0 0593 49 955 49 974 1 9667 1 9675 0 08 0 0031 1 542 1 546 0 0607 0 0609 Undersize 0 12 0 0047 1 562 1 566 0 0615 0 0617 SS EE SE 0 25 0 0098 1 627 1 631 0 0641 0 0642 Miscellaneous Components EBSO0GUC Unit mm in Flywheel drive plate runout total indicator reading Less than 0 15 0 0059 BEARING CLEARANCE Unit mm in Standard 0 030 0 048 0 0012 0 0019 No 1 Main bearing clearance Limit 0 060 0 0024 Standard 0 038 0 065 0 0015 0 0026 No 2 3 4 Main bearing clearance Limit 0 080 0 0031 Standard 0 024 0 064 0 0009 0 0025 Connecting rod bearing clearance Limit 0 090 0 0035 EM 154
35. Sealant on the head gasket surface Refer to GI 42 RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS e Install the front engine cover 6 Install oil strainer and oil pan Refer to EM 17 Installation 7 Install the oil pump and distributor drive shaft e Make sure the flat side of the distributor drive shaft is facing the engine Failure to do so will result in the distributor being out of time 8 Install the crankshaft pulley and crankshaft pulley bolt Refer to EM 13 Removal and Installation Flat side AEM391 EM 25 TIMING CHAIN KA24DE 9 If installed remove Tool Tool number J 45499 10 Install the rear plate Rear plate bolts 10 mm hex 3 4N m 0 3 0 4 kg m 32 35 in Ib 14 mmhex 16 22 N m 1 6 2 2 kg m 12 16 ft Ib Engine 7 Oil Pan Rear plate LBIAO363E 11 Install the A C compressor and idler pulley bracket Refer to MTC 67 Removal and Installation for Com pressor 12 Install the radiator shroud and cooling fan with coupling Refer to CO 14 Removal and Installation 13 Install the A C compressor generator and power steering pump drive belts Refer to MA 15 Checking Drive Belts 14 Install the intake air duct IDLER SPROCKET Install the lower timing chain Refer to EM 24 LOWER TIMING CHAIN UPPER TIMING CHAIN 1 Install the lower timing chain and idler sprocket Refer to EM 24 LOWER TIMING CHAIN and EM 26 IDLER SPROCKET
36. as necessary NOTE The resurfacing limit of the cylinder head is determined by the amount of cylinder block resurfacing necessary Se Head surface flatness less than 0 1 mm 0 004 in y pael gauge i Resurfacing limit D Ce Zei H z H DI 39 8 Amount of cylinder head resurfacing is A pw e Ee Amount of cylinder block resurfacing is B SEM868A Maximum resurfacing limit A B 0 2 mm 0 008 in 2 After resurfacing cylinder head check the nominal cylinder head height is within specification Check that the camshaft rotates freely by hand If resistance is felt the cylinder head must be replaced Nominal cylinder head height 106 8 107 2 mm 4 205 4 220 in CAMSHAFT VISUAL CHECK Check camshaft for scratches seizure and wear Replace as necessary CAMSHAFT RUNOUT 1 Support the camshaft at the No 2 and No 4 camshaft journals 2 Measure camshaft runout at the No 3 journal as shown 3 If the measured runout exceeds the limit replace the camshaft Runout limit total indicator 0 1 mm 0 004 in reading WBIA0235E CAMSHAFT CAM HEIGHT 1 Measure the camshaft cam height as shown Standard cam height 38 943 39 133 mm for intake and exhaust 1 5332 1 5407 in Cam wear limit 0 15 mm 0 0059 in 2 Ifthe measured wear is beyond the limit replace the camshaft SEM549A EM 110 CYLINDER HEAD VG33E and VG33ER CAMSHAFT JOURNAL CLEARANCE 1 Measure the outer diameter of the cams
37. block surface for scratches or seizure If scratches or seizure are found hone or replace the cylinder block Piston Ring End Gap Top ring 0 28 0 52 mm 0 0110 0 0205 in 2nd ring 0 45 0 69 mm 0 0177 0 0272 in Oil ring rail ring 0 20 0 69 mm 0 0079 0 0272 in Limit 1 0 mm 0 039 in CONNECTING ROD BEND AND TORSION Measure the connecting rod bend and torsion as shown If either of the measurements exceed the limits replace the connect ing rod assembly SEMO38F EM 51 CYLINDER BLOCK KA24DE Bend limit 0 15 mm 0 0059 in per 100 mm Torsion Eeler gauge 3 94 in length Torsion limit 0 30 mm 0 0118 in per 100 mm 3 94 in length SEMOOS3F CYLINDER BLOCK DISTORTION AND WEAR 1 Clean upper face of cylinder block 2 Use a reliable straightedge and feeler gauge to check the flat Measuring points ness of the cylinder block upper face surface Check along the six positions as shown Cylinder block distortion Standard Limit 0 1 mm 0 004 in SEM255CB 3 If the block distortion exceeds specification resurface the block Replace the block if necessary The limit for cylinder block resurfacing is determined by cylinder head resurfacing Amount of cylinder head resurfacing is A Amount of cylinder block resurfacing is B The maximum limit is as follows A B 0 2 mm 0 008 in Nominal block height at crankshaft center 246 95 247 05 mm 9 7224 9 7264 in Max
38. in Ib SOS 77S Radiator 7 Remove the air inlet tube upper and lower supports ANC Air inlet Sy upper support Ge at Le IN NS Air inlet tube upper sup EM 125 SUPERCHARGER VG33E and VG33ER 8 Remove the air inlet tube bolts nuts and studs Position the air inlet tube aside e Disconnect the evaporative emission vacuum hose e Disconnect the brake booster vacuum hose e Disconnect the TPS sensor electrical connector e Disconnect the TPS switch electrical connector 9 Remove the supercharger bolts and the supercharger assembly EE e Disconnect the boost control valve vacuum hose p ZIlT TB e Disconnect the PCV hose Heated oxygen sensor electrical connectors D N m kg m ft ib J Inspection zeen SUPERCHARGER FLANGE 1 Clean the mating surface of the supercharger flange 2 Check the flange surface for any deformation and flatness Use a reliable straightedge and feeler gauge or attach the super charger flange to the intake collector mating flange and check that the flatness is within specification Flange flatness limit 0 12 mm 0 005 in LEM117 ROTOR SYSTEM 1 Check that the supercharger pulley rotates smoothly when turning it by hand in a clockwise direction Rotating torque must not exceed specification Rotating torque 0 5 N m 0 05 kg m 4 in Ib 2 Check that both the left and right rotors are free from any cracks or contamination SUPERCHARGER BYPAS
39. mark 1 822 1 825 0 0717 0 0719 1 825 1 828 0 0719 0 0720 1 828 1 831 0 0720 0 0721 22 4 22 6 0 882 0 890 1 834 1 837 0 0722 0 0723 1 837 1 840 0 0723 0 0724 Oo oO BRB OJN 1 831 1 834 0 0721 0 0722 1 840 1 843 0 0724 0 0726 NO 2 AND 3 MAIN BEARING Grade number Thickness T mm in Width W mm in Black A Brown B Green C Yellow D Blue E Pink F Purple G Identification color 18 9 19 1 0 744 0 752 0 1 817 1 821 0 0715 0 0717 1 1 821 1 825 0 0717 0 0719 2 1 825 1 829 0 0719 0 0720 3 1 829 1 833 0 0720 0 0722 4 1 838 1 837 0 0722 0 0723 NO 4 MAIN BEARING Grade number Thickness T mm in Black Brown Green Yellow Blue Identification color 0 1 817 1 821 0 0715 0 0717 Black 1 1 821 1 825 0 0717 0 0719 Brown 2 1 825 1 829 0 0719 0 0720 Green 3 1 829 1 833 0 0720 0 0722 Yellow 4 1 833 1 837 0 0722 0 0723 Blue UNDER SIZE Thickness T mm in Unit mm in Main journal diameter Dm 0 25 0 0098 No 1 main bearing 1 956 1 962 0 0770 0 0772 No 2 3 and No 4 main bearing EM 153 1 948 1956 0 0767 0 0770 Grind so that bearing clearance is the specified value SERVICE DATA AND
40. number of each cylinder block main journal is punched on the respective cylinder bore The grade numbers are punched in either Arabic or Roman numerals AEM501 b The grade number of each crankshaft main journal is punched on the respective crankshaft as shown These numbers are punched in either Arabic or Roman numerals qu ntl X No 4 journal No 3 grade number No 2 SEM167B c Select the main bearing with a suitable thickness according to the following tables EM 138 CYLINDER BLOCK VG33E and VG33ER No 1 Main Bearing Grade Number Identification Color Crankshaft journal grade Main journal grade number number 3 or III 4 or IV 5orV 6 or VI 3 or Ill 0 Black 1 Brown 2 Green 3 Yellow 4or IV 1 Brown 2 Green 3 Yellow 4 Blue 5orV 2 Green 3 Yellow 4 Blue 5 Pink 6 or VI 3 Yellow 4 Blue 5 Pink 6 Purple All Except No 1 Main Bearing Grade Number Identification Color Crankshaft journal grade num Main journal grade number ber 0 1 or 2 or Il 0 0 Black 1 Brown 2 Green 10r 1 Brown 2 Green 3 Yellow 2 or II 2 Green 3 Yellow 4 Blue Connecting Rod Bearing Big End 1 Install the connecting rod bearing on the connecting rod big end and cap 2 Install the connecting rod cap to the connecting rod Tighten the connecting rod cap bolts to specification Refer to EM 131 Compon
41. sprocket crankshaft sprocket and belt tensioner are clean and free from oil and water e Installation should be carried out when engine is cold Removal eesooaTF 1 Remove the engine under cover 2 Drain the engine coolant from the radiator Refer to MA 26 DRAINING ENGINE COOLANT EM 91 p SS 2 oN rk 14 Remove the crankshaft pulley bolt 13 TIMING BELT VG33E and VG33ER CAUTION Do not spill coolant on the engine drive belts Remove the radiator Refer to CO 30 Removal and Installation Remove the engine cooling fan and water pump pulley Remove the following drive belts e Power steering pump drive belt e Compressor drive belt e Alternator drive belt e Supercharger drive belt if equipped Remove all of the spark plugs Remove the distributor protector Remove the compressor drive belt idler bracket Disconnect the fresh air intake tube from the rocker cover Disconnect the water hose from the thermostat housing Set the No 1 piston at TDC on the compression stroke by rotat ing the crankshaft Remove the crankshaft pulley using a suitable puller BTDC WBIA0188E Crankshaft pulley Remove the front upper and lower timing belt covers Timing belt front upper cover Water inlet hose Radiator upper hose Water pump pulley Timi ming peit Idler bracket front lower cover AEM223 EM 92 TIMING BELT VG33E and VG33ER 15 Align the timing belt sprockets to
42. the piston piston pin connecting rod and the new snap ring on the other side e Align the direction of the piston and connecting rod with the marks as shown e Numbers stamped on the connecting rod and cap correspond to each cylinder and should be aligned when assembled as qu Front mark gt Engine front Oil hole shown e After assembly check that the connecting rod swings smoothly on the piston Cylinder number SEM400F 3 Install and align the piston rings at 90 degree angles as shown Top ding e Oil ring upper rail On a Oil ring and deg LK WK lower rail SEM160B CRANKSHAFT 1 Set the main bearings in their proper positions on the cylinder Upper main bearing No 4 With oil groove block and main bearing caps No 2 e Confirm that the correct main bearings are used Refer to EM S 3 A ont 137 BEARING CLEARANCE No 4 e Apply new engine oil to the bearing friction surfaces een 2 Install the crankshaft and main bearing caps and tighten the bolts to the specified torque in numerical order as shown engine e Prior to tightening the bearing cap bolts place the bearing cap in the proper position by shifting the crankshaft in the axial direction e Tighten the bearing cap bolts gradually in two or three steps Tighten the bearing cap bolts in numerical order as shown e After securing the bearing cap bolts check that the crankshaft turns smoothly by hand e Lubricate the threads and
43. the punchmarks on the camshaft sprockets and crankshaft sprocket LH compression Crankshaft timing ei stroke sprocket Aligning markS SEM511EA Number of timing belt teeth for installation reference Total number of timing belt teeth 133 Between LH and RH camshaft sprockets 40 Number of teeth between timing marks Between LH camshaft sprocket and crankshaft timing sprocket 43 5 Install the remaining parts in the reverse order of removal Tension Adjustment zement AFTER BELT REPLACEMENT NOTE If the timing belt was replaced or to adjust tension on a used belt follow this procedure 1 Loosen the tensioner lock nut then turn the tensioner clockwise and counterclockwise with a hexagon wrench at least two times 2 Tighten the tensioner lock nut 3 Turn the crankshaft clockwise a full rotation at least two times then slowly set the No 1 piston at TDC on the compression stroke AEM440 EM 95 TIMING BELT VG33E and VG33ER 4 Measure the deflection of the timing belt midway between the 98 N camshaft sprockets while pushing with the specified force as AM 10 kg 22 w shown Belt deflection when 13 15 mm 0 51 0 59 in engine is cold reference at 98 N 10 kg 22 Ib force Gainshaft value Camehaft sprocket sprocket LH 5 Ifthe belt deflection is not within specification return to step 1 PP and repeat the procedure Tensioner pulley raid Bete Crankshaft sprocket S
44. the timing marks on the engine e Align the punchmark on the LH camshaft sprocket with the punchmark on the timing belt rear cover e Align the punchmark on the crankshaft sprocket with the alignment mark on the oil pump housing e Temporarily install the crankshaft pulley bolt on the crank Timing belt LAA shaft to rotate the crankshaft r upper cover Punchmark Crankshaft sprocket 16 Loosen the timing belt tensioner nut rotate the tensioner then remove the timing belt SEM240A Inspection EBsooGTe Visually check the condition of the timing belt Replace the timing belt as necessary Item to check Visual inspection Cause Tooth is broken tooth root is cracked e Camshaft jamming e Distributor jamming e Damaged camshaft crankshaft oil seal SEM394A Back surface is cracked e Tensioner jamming wom e Overheated engine e Interference with belt cover SEM395A EM 93 Item to check TIMING BELT Visual inspection VG33E and VG33ER Cause e Side surface is worn e Belt corners are worn and round e Wicks are frayed and coming out SEM396A e Improper installation of belt e Malfunctioning crankshaft pulley plate timing belt plate e Teeth are worn e Canvas on tooth face is worn down e Canvas on tooth is fluffy rubber layer is worn down and faded white or weft is worn down and invisible Rotating direction SEM397A e Poor belt co
45. to the valve lifters so they are installed in their original positions If hydraulic valve lifter is kept on its side there is a risk of air entering it After removal always set hydraulic valve lifter straight up or when laying it on its side have it soak in new engine oil SEM870BA Remove exhaust manifolds from cylinder head loosen the bolts in the numerical order as shown RH exhaust manifold LH exhaust manifold Loosen in numerical order LBIAO323E EM 108 CYLINDER HEAD VG33E and VG33ER VG33ER RH exhaust manifold A 6 3 Front air 0 G6 LH exhaust manifold Loosen in numerical order WBIA0192E 2 Remove the rocker shafts with the rocker arms e Loosen the bolts in two or three steps 3 Remove the hydraulic valve lifters and lifter guide e Hold the hydraulic valve lifters with wire so that they will not drop out of the lifter guide SEM304A 4 Remove the oil seal and camshaft e Before removing the camshaft measure the camshaft end play Refer to EM 111 CAMSHAFT END PLAY 5 Remove the valve components using Tool as shown EM 109 CYLINDER HEAD VG33E and VG33ER 6 Remove the valve oil seals using Tool or suitable tool Inspection essooero CYLINDER HEAD DISTORTION 1 Measure the cylinder head sealing surface using a straight edge e aignteage and a feeler gauge as shown If the surface flatness is beyond the specified limit resurface it or replace it
46. traces of liquid gasket from mating surface using a scraper as shown Also remove all traces of the old liquid gasket from the mating sur face of the cylinder block Apply a continuous bead of liquid gasket to mating surface of rear oil seal retainer Use Genuine Silicone RTV Sealant or equivalent Refer to Gl 42 RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS e Apply the liquid gasket around the inner side of the bolt holes EM 31 KA24DE e Install the new oil seal in the direction shown Engine Engine inside m outside Oil seal lip Dust seal lip SEM715A Diameter of liquid gasket 2 0 3 0 mm AEM404 CYLINDER HEAD KA24DE CYLINDER HEAD PFP 11041 On Vehicle Service EBSOOGSF CHECKING COMPRESSION PRESSURE 1 2 3 ONO 10 12 13 Warm up the engine Turn the ignition switch OFF Release the fuel pressure Refer to EC 46 FUEL PRESSURE RELEASE Remove all of the spark plugs e Clean area around plug with compressed air before removing the spark plug Disconnect the camshaft position sensor harness connector at the distributor Remove the fuel injector fuse No 3 on FUSE BLOCK J B behind the driver side instrument lower panel Attach a compression tester to the No 1 cylinder as shown Depress the accelerator pedal fully to keep the throttle valve wide open Crank the engine and record the highest gauge indication Repeat the measurement on each cylinder e Always use
47. 0 45915 45945 45915 45 45 86 1 36 3 30 6 30 8 502 1 421 1 429 1 205 1 213 d d Contacting width W 1 48 1 63 Contacting width W 1 8 2 0 0 0583 0 0642 0 071 0 079 Machining data AEM456 SEM621F Standard Service Cylinder head seat recess diameter Intake 37 500 37 516 1 4764 1 4770 38 000 38 016 1 4961 1 4967 D Exhaust 32 200 32 216 1 2677 1 2683 32 700 32 716 1 2874 1 2880 Intake 0 064 0 096 0 0025 0 0038 Valve seat interference fit Exhaust 0 064 0 096 0 0025 0 0038 Intake 37 580 37 596 1 4795 1 4802 38 080 38 096 1 4992 1 4998 Valve seat outer diameter d Exhaust 32 280 32 296 1 2709 1 2715 32 780 32 796 1 2905 1 2912 Intake 6 1 6 3 0 240 0 248 Depth H Exhaust 6 1 6 3 0 240 0 248 Intake 5 8 6 0 0 228 0 236 i Height ht 5 9 6 0 0 232 0 236 e Exhaust 5 9 6 0 0 232 0 236 5 32 5 42 0 209 0 213 EM 66 SERVICE DATA AND SPECIFICATIONS SDS KA24DE Intake 0 24 0 64 0 0094 0 0252 Height h2 0 34 0 64 0 0134 0 0252 Exhaust 0 43 0 73 0 0169 0 0287 T Intake 42 02 42 52 1 6543 1 6740 o Valve seat resurface limit L EM Exhaust 42 03 42 53 1 6547 1 6744 Cylinder Block eesooasw Unit mm in WBIAO177E Standard Limit Distortion 0 1 0 004 Grade 1 89 000 89 010 3 5039 3 5043 Inn
48. 0 95 1 1 82 5 95 5 Engine front U 7 3 48 0 4 Ds 4 9 28 35 f a 0 39 49 4 0 5 0 29 36 5851 65 0 52 0 66 45 1 57 3 Wi N m kg m in Ib N m kg m ft lb e Always replace after every disassembly WBIA0180E 1 Spark plug 2 Ignition wires 3 Camshaft position sensor built into distributor 4 EGR tube 5 Exhaust manifold 6 Heated oxygen sensor 1 7 Exhaust manifold cover 8 TWC manifold 9 TWC manifold gaskets EM 14 Exhaust manifold Tighten in numerical order Loosen in reverse order U 37 3 48 0 3 8 4 9 27 5 35 4 N m kg m ft lb OUTER COMPONENT PARTS KA24DE Intake manifold Engine front gt Rocker cover ZINEA Ze e eA oco Tighten in numerical order Loosen in reverse order 0 15 7 18 6 1 6 1 9 11 6 13 7 Throttle position sensor Tighten in numerical order 1st 9 11 0 9 1 1 6 5 8 0 Loosen in reverse order 2nd O 18 22 1 8 2 2 13 16 WBIAOO99E EM 15 OIL PAN KA24DE OIL PAN PFP 11110 Components easooas7 SEC 110 5 washer e ei N m kg m in Ib Io E Drain plug wel Nem kg m ft Ib 0 65 0 76 56 66 el 294 392 E Apply Genuine Anaerobic Liquid Gasket 3 00 4 00 21 69 28 91 or equivalent Refer to GI Section E Always replace after every disassembly WBIAO174E Removal EBSt0GSS 1 Remove the engine under c
49. 015 0 0006 EM 149 SERVICE DATA AND SPECIFICATIONS SDS VG33E and VG33ER Grade No 3 66 645 66 651 2 6238 2 6240 No 1 main Grade No 4 66 651 66 657 2 6240 2 6243 journal Grade No 5 66 657 62 663 2 6243 2 6245 Main journal inner diameter Grade No 6 66 663 66 669 2 6245 2 6248 Grade No 0 66 645 66 654 2 6238 2 6242 Except No t Grade No 1 66 654 66 663 2 6242 2 6245 main journal Grade No 2 66 663 66 672 2 6245 2 6249 Difference innner diameter Standard Less than 0 05 0 0020 between cylinders Piston Piston Ring and Piston Pin EBStoGU7 AVAILABLE PISTON Unit mm in d A SE Grade No 2 1 91 480 91 485 3 6016 3 6018 Grade No 3 2 91 485 91 490 3 6018 3 6020 Standard for No 3 Grade No 3 3 91 490 91 495 3 6020 3 6022 4 and 5 cylinders Grade No 4 4 91 495 91 500 3 6022 3 6024 Grade No 4 5 91 500 91 505 3 6024 3 6026 d Skirt diamig Grade No 5 6 91 505 91 510 3 6026 3 6027 Standard for No 1 Grade No 1 91 465 91 475 3 6010 3 6014 2 and 6 cylinders Grade No 2 91 475 91 485 3 6014 3 6018 Grade No 3 91 485 91 495 3 6018 3 6022 0 25 0 0098 oversize Service 91 715 91 745 3 6108 3 6120 0 50 0 0197 oversize Service 91 965 91 995 3 6207 3 6218 Height a 49 0 1 929 deer Grade No 0 20 969 20 975 0 8255 0
50. 159B EM 60 CYLINDER BLOCK KA24DE 5 Install the piston assemblies into the corresponding cylinder bores using Tool as shown EM03470000 e Position the piston assembly so that the front mark on the pis ton head faces toward the front of the engine e Make sure the connecting rod does not scratch the cylinder wall e Make sure the connecting rod bolts do not scratch the crank shaft journals e Apply new engine oil to the piston rings and sliding surface of piston 6 Install the connecting rod bearing caps If reusing the connecting rod bearing caps they must be installed in their original position and direction Tighten the connecting rod bearing cap nuts in two steps to specification For step 2 use a suitable angle wrench or tighten to specification if an angle wrench is not available Connecting rod bearing nuts tighten in two steps Step1 14 16 N m 1 4 1 6 kg m 10 12 ft Ib Step2 60 to 65 degrees clockwise 38 44 N m 3 9 4 5 kg m 28 33 ft Ib 7 Measure the connecting rod side clearance Connecting rod side clearance Standard 0 2 0 4 mm 0 008 0 016 in Limit 0 6 mm 0 024 in If the clearance is beyond the limit replace either the connecting rod or crankshaft or both as necessary REPLACING PILOT BUSHING 1 Remove the pilot bushing using Tool as shown ST16610001 J23907 or suitable tool SEM916AA EM 61 CYLINDER BLOCK KA24DE 2 Install the pilot b
51. 21 0 08 0 0031 Exhaust 0 040 0 073 0 0016 0 0029 0 1 0 004 c Ifthe clearance exceeds the limit replace the valve and remea sure the clearance d If the clearance still exceeds the limit after replacing the valve replace the valve guide SEM298D VALVE GUIDE REPLACEMENT 1 To remove the valve guide heat the cylinder head to 120 140 C 248 284 F by soaking in heated oil SEMO008A EM 37 CYLINDER HEAD KA24DE To remove the valve guide use a press less than 20 KN 2 met ric ton 2 2 US ton 2 0 Imp ton pressure or hammer and suit able tool to slide the valve guide out of the cylinder head Ream the cylinder head valve guide hole Valve guide hole diameter for service parts Intake amp Exhaust 11 175 11 196 mm 0 4400 0 4408 in SEM300D Heat cylinder head to 120 140 C 248 284 F in heated oil and press the replacement valve guide into the valve guide hole in the cylinder head Press the valve guide in to the specified height L as shown Projection L 13 3 13 9 mm 0 524 0 547 in Ream the new replacement valve guide Finished size Intake amp Exhaust 7 000 7 018 mm 0 2756 0 2763 in SEM300D EM 38 CYLINDER HEAD KA24DE VALVE SEATS Check valve seats for pitting at contact surface Resurface or replace if excessively worn e Before repairing the valve seats check the valves and valve guides for wear as shown If th
52. 24 EM 148 SERVICE DATA AND SPECIFICATIONS SDS VG33E and VG33ER 2o EM671 Intake 38 943 39 133 1 5332 1 5407 Cam height A Exhaust 38 943 39 133 1 5332 1 5407 Wear limit of cam height 0 15 0 0059 Total indicator reading Cylinder Block exsooaus Unit mm in X Y e d e Unit mm in SEM321AA Standard Less than 0 03 0 0012 Distortion Limit 0 10 0 004 Grade No 1 91 500 91 505 3 6024 3 6026 Grade No 2 91 505 91 510 3 6026 3 6027 Standard for No 3 and 4 cylin Grade No 3 91 510 91 515 3 6027 3 6029 ders Grade No 4 91 515 91 520 3 6029 3 6031 Grade No 5 91 520 91 525 3 6031 3 6033 Grade No 6 91 525 91 530 3 6033 3 6035 Grade No 1 91 500 91 510 3 6024 3 6027 Standard for No 1 2 and 6 cylin Grade No 2 91 510 91 520 3 6027 3 6031 Cylinder bore Inner diameter ders Grade No 3 91 520 91 530 3 6031 3 6035 Grade No 1 91 515 91 520 3 6029 3 6031 Grade No 2 91 520 91 525 3 6031 3 6033 Grade No 3 91 525 91 530 3 6033 3 6035 Standard for No 5 cylinder Grade No 4 91 530 91 535 3 6035 3 6037 Grade No 5 91 535 91 540 3 6037 3 6039 Grade No 6 91 540 91 545 3 6039 3 6041 Wear limit 0 20 0 0079 Out of round difference between X and Y Less than 0 015 0 0006 Taper difference between A and C Less than 0
53. 386 1 3394 Clearance between lifter and filter guide EM 64 0 025 0 061 0 0010 0 0024 SERVICE DATA AND SPECIFICATIONS SDS KA24DE VALVE CLEARANCE ADJUSTMENT Unit mm in NEUES Intake 0 31 0 39 0 012 0 015 Exhaust 0 39 0 47 0 015 0 019 AVAILABLE SHIMS Thicknessmm in Identification mark Thickness mm in Identification mark 1 90 0 0748 190 1 92 0 0756 192 1 94 0 0764 194 1 96 0 0772 196 1 98 0 0780 198 2 00 0 0787 200 2 02 0 0795 202 2 04 0 0803 204 2 06 0 0811 206 2 08 0 819 208 2 10 0 0827 210 2 12 0 0835 212 2 14 0 0843 214 2 16 0 0850 216 2 18 0 0858 218 2 20 0 0866 220 2 22 0 0874 222 2 24 0 0882 224 2 26 0 0890 226 2 28 0 0898 228 2 30 0 0906 230 2 32 0 0913 232 2 34 0 0921 234 2 36 0 0929 236 2 38 0 0937 238 2 40 0 0945 240 2 42 0 0953 242 2 44 0 0961 244 2 46 0 0969 246 2 48 0 0976 248 2 50 0 0984 250 2 52 0 0992 252 2 54 0 1000 254 2 56 0 1008 256 2 58 0 1016 258 2 60 0 1024 260 2 62 0 1031 262 2 64 0 1039 264 2 66 0 1047 266 2 68 0 1055 268 2 24 mm 224 0 0882 in Thickness is stamped SEM308D EM 65 SERVICE DATA AND SPECIFICATIONS SDS KA24DE VALVE SEAT Unit mm in Cylinder head INTAKE EXHAUST I 7 YY H H D L 34 1 34 28 1 1
54. 46 SERVICE DATA AND SPECIFICATIONS SDS VG33E and VG33ER Valve Seat INTAKE VALVE SEAT EBS00GU4 Standard d 41 6 41 8 1 638 1 646 dia Oversize 0 5 0 020 RO 3 0 5 0 012 0 020 44 500 44 516 1 7520 1 7526 dia Cylinder head 41 6 41 8 1 638 1 646 dia L 44 8x0 1 1 764 0 004 Unit mm in SEM639F Intake L 44 7 44 9 mm 1 760 1 768 in EM 147 SERVICE DATA AND SPECIFICATIONS SDS VG33E and VG33ER EXHAUST VALVE SEAT Standard 34 3 34 5 Oversize 0 5 0 020 1 350 1 358 dia R0 3 0 5 0 012 0 020 37 500 37 516 1 4764 1 4770 dia Cylinder head 34 4 34 6 L 45 4 0 1 1 79 0 004 1 354 1 362 dia Unit mm in AEM455 Exhaust L 45 4 45 6 mm 1 787 1 795 in Camshaft and Camshaft Bearing Easoogus Unit mm in RH camshaft Front SEM893BA Standard Max tolerance Camshaft journal to bearing clearance 0 060 0 105 0 0024 0 0041 0 15 0 0059 A 47 000 47 025 1 8504 1 8514 Inner diameter of camshaft bearing B 42 500 42 525 1 6732 1 6742 C 48 000 48 025 1 8898 1 8907 A 46 920 46 940 1 8472 1 8480 Outer diameter of camshaft journal B 42 420 42 440 1 6701 1 6709 C 47 920 47 940 1 8866 1 8874 RES Camshaft runout TIR Less than 0 04 0 0016 0 1 0 004 Camshaft end play 0 03 0 06 0 0012 0 00
55. 5 EM 8 Holding camshaft pulley while tightening or loosening camshaft bolt Tool name Kent Moore No PREPARATION KA24DE Description Valve seat cutter set NT048 Finishing valve seat dimensions Piston ring expander NTO30 Removing and installing piston ring Valve guide drift Removing and installing valve guide Intake amp Exhaust a 10 5 mm 0 413 in dia b 6 6 mm 0 260 in dia Valve guide reamer NTO16 Reaming valve guide 1 or hole for oversize valve guide 2 Intake di 7 0 mm 0 276 in dia d2 211 2 mm 0 441 in dia Exhaust di 8 0 mm 0 315 in dia d2 12 2 mm 0 480 in dia Front oil seal drift Installing front oil seal a 52 mm 2 05 in dia b 44 mm 1 73 in dia Rear oil seal drift WEM152 Installing rear oil seal a 46 mm 1 81 in b 110 mm 4 33 in c 84 mm 3 31 in d 96 mm 3 78 in Thread repair tool for oxygen sensor a J 43897 18 b J 43897 12 Flutes AEM488 EM 9 a 18 mm 0 71 in b 12 mm 0 47 in PREPARATION KA24DE Tool name Kent Moore No Description Anti seize thread compound For preventing corrosion seizing and galling on high temperature applications Crankshaft pulley puller Removing crankshaft pulley PBICO887E EM 10 NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING KA24DE NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING
56. 5 105 112 rn W i Tighten in two stages pa 1st 14 16 1 4 1 6 10 12 2nd 60 65 degrees Apply coolant 4 7 5 7 34 41 Lubricate with new engine oil Apply Genuine Silicone RTV Sealant or equivalent Refer to GI section i N m kg m in O N m kg m ft Ib e Always replace after every disassembly WBIA0181E EM 48 CYLINDER BLOCK KA24DE 1 Block heater 2 Drain plug 3 Cylinder block 4 Rear oil seal retainer 5 Rear oil seal 6 Drive plate reinforcement A T 7 Drive plate A T 8 Rear plate A T 9 Pilot converter A T 10 Dust cover A T 11 Flywheel M T 12 Rear plate M T 13 Pilot bushing M T 14 Main bearing cap 15 Main bearing 16 Connecting rod bearing 17 Connecting rod 18 Snap ring 19 Piston pin 20 Piston 21 Piston rings 22 Crankshaft 23 Oil strainer 24 Oil jet 25 Oil seal Removal and Installation Se Ts 2 To remove the cylinder block for disassembly remove the engine Refer to EM 46 Removal and Installa tion CAUTION e When installing sliding parts lubricate the contacting surfaces with new engine oil e Place removed parts such as bearings and bearing caps in their proper order and direction e When installing connecting rod nuts and main bearing cap bolts apply new engine oil to the threads and seating surfaces e Do not allow any magnetic materials to contact the ring gear teeth of the flywheel or drive plate I
57. 622D Apply the sealant without breaks to the specified location with Inner the specified dimensions side e If there is a groove for the sealant application apply the seal ant to the groove e As for the bolt holes normally apply the sealant inside the holes If specified it should be applied outside the holes Make sure to read the text of this manual e Within five minutes of the sealant application install the mat ing component e If the sealant protrudes wipe it off immediately e Do not retighten after the installation e After 30 minutes or more have passed from the installation fill the engine with the specified oil and coolant Refer to MA 30 Changing Engine Oil and MA 26 REFILLING ENGINE COOLANT Inner side SEM159F EM 73 PREPARATION VG33E and VG33ER PREPARATION PFP 00002 Special Service Tools Semer The actual shapes of kent Moore tools may differ from those of special service tools illustrated here Tool number Kent Moore No Tool name ST0501S000 Disassembling and assembling E Engine stand assembly 1 ST05011000 ES Engine stand 2 ST05012000 Base KV10106500 Engine stand shaft Description KV10110001 Engine sub attachment NTO32 ST10120000 Loosening and tightening cylinder head bolt a 13 mm 0 51 in dia J24239 01 b Cylinder head bolt wrench Q b 12 mm 0 47 in lt a c 10 mm 0 39 in KV10112100 T
58. 8258 Grade No 1 20 975 20 981 0 8258 0 8260 For No 3 and 4 cylinders 0 015 0 025 0 0006 0 0010 dere t0 Standard ades Nee Mors 0 025 0 045 0 0010 0 0018 For No 5 cylinder VG33E only 0 030 0 040 0 0012 0 0016 PISTON RING Standard Unit mm in Limit Top 0 040 0 080 0 0016 0 0031 0 11 0 0043 Side clearance 2nd 0 030 0 070 0 0012 0 0028 0 10 0 0039 Oil 0 015 0 185 0 0006 0 0073 EM 150 SERVICE DATA AND SPECIFICATIONS SDS VG33E and VG33ER Standard Limit Top 0 21 0 31 0 0083 0 0122 0 43 0 0169 Ring gap 2nd 0 50 0 60 0 0197 0 0236 0 69 0 0272 Oil rail ring 0 20 0 60 0 0079 0 0236 0 84 0 0331 PISTON PIN Unit mm in Piston pin outer diameter 20 971 20 983 0 8256 0 8261 Interference fit of piston pin to piston 0 to 0 004 0 to 0 0002 Piston pin to connecting rod bushing clearance 0 005 0 017 0 0002 0 0007 Values measured at ambient temperature of 20 C 68 F Connecting Rod cBsooavs Unit mm in Center distance 154 1 154 2 6 067 6 071 Bend torsion per 100 3 94 Limit Bend 0 15 0 0059 Torsion 0 30 0 0118 Piston pin bushing inner diameter 20 982 20 994 0 8261 0 8265 Connecting rod big end inner diameter 53 000 53 013 2 0866 2 0871 Standard Side clearance 0 20 0 35 0 0079 0 0138
59. 9 PISTON RING aan 69 Connecting Rod sssssssseenene 70 Crankshaft ette deme ke tere cte degit 70 Bearing Clearance ssseeeseesireerreerresrreerrreerees 71 Available Main Bearing eseeeeeess 71 STANDARD an 71 UNDERSIZE SERVICE sss 71 Available Connecting Rod Bearing 71 STANDARD itunes 71 UNDERSIZE SERVICE sess 71 Miscellaneous Components ssss 71 VG33E and VG33ER PRECAUTIONS reete 72 Precautions for Supplemental Restraint System SRS AIR BAG and SEAT BELT PRE TEN SIONE RG Ue Re ei E 72 Parts Requiring Angular Tightening 72 Precautions for Liquid Gasket 73 REMOVAL OF LIQUID GASKET SEALING 73 LIQUID GASKET APPLICATION PROCEDURE 73 PREPARATION reete rre 74 Special Service Tools a se 74 Commercial Service Tools sssssssss 76 NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING eene 78 Noise Vibration and Harshness NVH 78 NVH TROUBLESHOOTING CHART ENGINE NOISE neta iot or ette Seet ahaa ential 79 OUTER COMPONENT PARTS 80 Removal and Installation 80 OIL PAN E T EE ERE 88 SE le TR 88 instalation EE 89 TIMING BELT enhn rara ege ed ee 91 Components
60. Apply engine oil to new oil seal and install it using a suitable tool i 2 Suitable tool A SEM292D e Install the new oil seal in the direction shown Engine Engine inside e outside Oil seal lip Dust seal lip SEM715A 6 Install the crankshaft pulley Refer to EM 13 Removal and Installation EM 29 OIL SEAL KA24DE 7 If installed remove Tool Tool number J 45499 D mm hex bolt Bell housing 8 Install the rear plate Rear plate bolts 10 mm hex 3 4N m 0 3 0 4 kg m 32 35 in Ib 14mm hex 16 22 N m 1 6 2 2 kg m 12 16 ft lb Engine Oil Pan Rear plate LBIA0363E 9 Install radiator shroud Refer to CO 14 Components REAR OIL SEAL 1 Remove the flywheel M T or drive plate A T Refer to MT 10 Removal and Installation FS5W71C MT 48 Removal and Installation FS5R30A AT 62 REMOVAL AND INSTALLATION RL4R01A AT 407 REMOVAL AND INSTALLATION RE4RO14A 2 Remove the rear oil seal retainer 3 Remove the rear oil seal from the retainer CAUTION Be careful not to scratch the rear oil seal retainer 4 Apply engine oil to new oil seal and install it using suitable tool KA M i iS SS SE X R zi d x Suitable tool RRX NNN EM 20 OIL SEAL Install rear oil seal retainer Rear oil seal 6 4 7 5 N m 0 65 0 76 kg m retainer bolts 56 66 in Ib Before installing rear oil seal retainer remove all
61. B ENGINE SECTION E M ENGINE MECHANICAL KA24DE CYLINDER HEAD euer cnc EEN Parana aa RR 32 AMA TAL On Vehicle Service ccccceecccecececcecesccccececeeaeeens 32 PRECAUTION S ue ee ee ege 4 CHECKING COMPRESSION PRESSURE 32 Precautions for Supplemental Restraint System COMponentS asco dese Gala uade Stool uence sn 33 SRS AIR BAG and SEAT BELT PRE TEN PRG TOMA e eee EEN 33 SIONER e ncn UE See NEEN a dd d mm Ro ed dE a alid id a nu an d alee m can ge d 4 Disassembly CETERO PAREN OHIO E PRORA 34 Parts Requiring Angular Tightening 4 INSpECt ON ates E RE 34 Precautions for Liquid Gasket 5 CYLINDER HEAD DISTORTION s 34 REMOVAL OF LIQUID GASKET SEALING 5 CAMSHAFT VISUAL CHECK ce 35 LIQUID GASKET APPLICATION PROCEDURE 5 CAMSHAFT RUNOUT eee 35 PREPARATION E euer EEN EENS 6 CAMSHAFT CAM HEIGHT 35 Special Service Tools cccccsccecessstseeesesteeeesees 6 CAMSHAFT JOURNAL CLEARANCE 36 Commercial Service Tools 8 CAMSHAFT END PLAY ess 36 NOISE VIBRATION AND HARSHNESS NVH CAMSHAFT SPROCKET RUNOUT seisein 36 TROUBLESHOOTING eeeeeer eere 11 VALVE GUIDE CLEARANCE sss 37 Noise Vibration and Harshness NVH 11 VALVE GUIDE REPLACEMENT oa 37 NVH TROUBLESHOOTING CHART ENGINE VAPUE SEATS costa uet cuti eG 39 NOISE
62. BLOCK KA24DE CRANKSHAFT 1 Set the main bearings in their proper positions on the cylinder block and main bearing caps as shown e Confirm that correct main bearings are used Refer to EM 54 BEARING CLEARANCE e Apply new engine oil to bearing surfaces SEM448C Install the crankshaft and main bearing caps and tighten the bolts in numerical order as shown to specification e Apply new engine oil to the bolt threads and seat surface e Prior to tightening the bearing cap bolts place bearing cap in its proper position by shifting crankshaft in the axial direction e Tighten the bearing cap bolts gradually in two or three stages to specification Tighten the bearing cap bolts in the numerical order as shown Main bearing cap bolts 46 56 N m 4 7 5 7 kg m 34 41 ft Ib e After securing bearing cap bolts make sure crankshaft turns smoothly by hand Measure the crankshaft end play as shown Crankshaft end play Standard 0 05 0 18 mm 0 0020 0 0071 in Limit 0 3 mm 0 012 in If beyond the limit replace No 3 bearing with a new one EEM122 Install connecting rod bearings in connecting rods and connect ing rod caps e Confirm that correct bearings are used Refer to EM 56 Connecting Rod Bearing Big End e Install bearings so that oil hole in connecting rod aligns with oil hole of bearing e Apply new engine oil to bearing surfaces bolt threads and seating surfaces SEM
63. CAUTION Reaming should be done in circles concentric to the valve guide center so that valve seat will have the correct fit Reaming bore for service valve seat Oversize 0 5 mm 0 020 in Recess diameter Intake 44 500 44 516 mm 1 7520 1 7526 in Exhaust 97 500 37 516 mm 1 4764 1 4770 in SEM795A 3 Heat the cylinder head to 150 160 C 302 320 F by soak ing it in heated oil SEMO008A 4 Press fit the valve seat into the cylinder head until it seats on the bottom of the valve seat bore 5 Cutor grind the valve seat using a suitable tool to specification Valve Intake Exhaust Seat face angle a degrees 45 45 Contacting width W mm in 1 75 0 0689 1 7 0 067 6 After cutting lap the valve seat with an abrasive compound 7 Check the valve seating dimensions SEM892B EM 114 CYLINDER HEAD VG33E and VG33ER 8 Use a depth gauge to measure the distance L between the mounting surface of the cylinder head spring seat and the valve stem end as shown Intake 44 7 44 9 mm 1 760 1 768 in Exhaust 45 4 45 6 mm 1 787 1 795 in e f the distance L as shown is shorter than specified repeat step 5 above to adjust it e f the distance L as shown is longer and the valve stem tip cannot be ground within the specified limit to obtain the speci fied distance L then replace the valve seat with a new one SEM621F Valve stem tip grinding allowance
64. EM323F 13 Raise the engine slightly with the engine slingers and then remove the engine mounting nuts from both sides 14 Lift and remove the engine from the vehicle INSTALLATION Installation is in the reverse order of removal EM 130 CYLINDER BLOCK VG33E and VG33ER CYLINDER BLOCK PFP 11010 Components zeen SEC 110 120 150 313 Seal rubber 23 s 5 fg 6 8 EM p peus 0 6 0 8 52 69 Oil pump cover Outer gear EI Front oil seal Es M Ae o Oil strainer a Gasket CO di i i RS A W 6 4 7 5 SE Oil pump housing Sel EE 39 69 8 lt Regulator valve 4 7 amp Spring Dis 17 29 51 Shim CO 1 6 1 7 Rear plate Regulator plug 11 6 12 3 Bes 93 8 5 9 5 61 69 6 3 8 3 0 64 0 85 55 6 73 8 9 22 29 2 2 3 0 16 22 Ky 6 3 8 3 0 64 0 85 55 6 73 8 Eiywheei or drive oat o 21 26 Rear oil seal retainer y 2 1 2 7 15 20 D T Y Knock sensor S i m ru Gasket s Reinforcement 1 6 2 1 e ES Gasket 23 2 plate WE OC i ES A T model p 2 M Sa Drain plug is 34 44 3 5 4 5 25 33 AO Rear oil seal CH F Piston rings Oil level gauge guide J Fa TOO Ka p ad Cover plate Pg C2 Zz A Piston Ek exh E pd P Drain plug i S 9 a4 44 PN A Snap ring 2 3 3 5 4 5 S 25 33 SY Snap ring gt lt S aa ue We X 47 7 63 4 c Piston pin Connecting rod FFY
65. EM744DA AFTER ENGINE OVERHAUL OR ENGINE REASSEMBLY WITH ROCKER COVERS REMOVED NOTE If the engine was overhauled or previously disassembled i e intake manifold or cylinder head were removed follow this timing belt tension adjustment procedure 1 Loosen the rocker shaft bolts to relieve the belt tension caused by the camshafts 2 Loosen the tensioner lock nut keeping the tensioner steady with a hexagon wrench 3 Turn the tensioner 70 to 80 degrees clockwise with a hexagon wrench to release the belt tension and temporarily tighten the lock nut 4 Turn the crankshaft clockwise at least twice then slowly set the No 1 piston at TDC on the compression stroke 5 Push the middle of the timing belt between the RH camshaft sprocket and tensioner pulley with the specified force 98 N 10 kg 22 Ib to apply tension on part A and part B of the timing belt as shown Camshaft 6 Loosen the tensioner lock nut keeping the tensioner steady with rocket Dee a hexagon wrench RH LH Timing belt Crankshaft sprocket AEM446 7 Position a feeler gauge size 0 5 mm 0 0206 in thick and 12 7 mm 0 500 in wide under the tensioner pulley as shown Crankshaft sprocket Tensioner pulley Feeler gauge SEM240E EM 96 10 11 12 13 TIMING BELT tioned between the tensioner pulley and the timing belt as shown e The timing belt will move about 2 5 teeth Tighten the tensioner lock nut k
66. ER HEAD PFP 11041 Measurement of Compression Semer Warm up the engine Turn the ignition switch OFF Release the fuel pressure Refer to EC 46 FUEL PRESSURE RELEASE VG33E EC 46 FUEL PRESSURE RELEASE VG33ER Remove all of the spark plugs e Clean the area around the spark plug with compressed air before removing the spark plugs Disconnect the camshaft position sensor harness connector at the distributor Remove the fuel injector fuse 3 on FUSE BLOCK J B behind the instrument panel lower panel Refer to PG 63 FUSE BLOCK JUNCTION BOX J B Attach the compression tester to the spark plug hole for the No 1 cylinder 20 mm 0 79 in dia Use compressor tester whose end rubber portion is less than 20 mm 0 79 in dia Otherwise it may be caught by cylinder head during removal SEM387C Depress the accelerator pedal fully to keep the throttle valve wide open Crank the engine and record the highest compression tester gauge reading Repeat the measurement on each cylinder NOTE Always use a fully charged battery to obtain the specified engine speed Compression kPa kg cm psi 300 rpm Standard 1 196 12 2 173 Minimum 883 9 0 128 Difference limit between cylinders 98 1 0 14 If the cylinder compression in one or more cylinders is low pour a small amount of engine oil into the cyl inders through the spark plug holes and retest the compression e f adding oil improves the cy
67. ISTON PIN CLEARANCE 1 Measure the inner diameter of piston pin hole dp as shown Standard diameter dp 20 969 20 981 mm 0 8255 0 8260 in SEM684E 2 Measure the outer diameter of piston pin Dp as shown Standard diameter Dp 20 971 20 983 mm 0 8256 0 8261 in Micrometer 3 Calculate piston pin clearance If the clearance is out of specification replace the piston and pin Piston pin clearance dp Dp 0 0 004 mm 0 0 0002 in PISTON RING SIDE CLEARANCE Measure the piston ring to piston side clearance as shown Side clearance Top ring 0 040 0 080 mm 0 0016 0 0031 in 2nd ring 0 030 0 070 mm 0 0012 0 0028 in Cil ring 0 015 0 185 mm 0 0006 0 0073 in Side clearance maximum limit Top ring 0 11 mm 0 0043 in 2nd ring 0 1 mm 0 004 in Cil ring D Feeler gauge SEMO024AA If out of specification replace piston and or piston ring assembly EM 133 CYLINDER BLOCK VG33E and VG33ER PISTON RING END GAP With the piston ring on top of the piston insert the piston and ring Piston into the cylinder bore as shown Measure the piston ring gap Press fit End gap Top ring 0 21 0 31 mm 0 0083 0 0122 in 2ndring 0 50 0 60 mm 0 0197 0 0236 in Cil ring 0 20 0 60 mm 0 0079 0 0236 in Ring gap maximum limit Top ring 0 43 mm 0 0169 in 2ndring 0 69 mm 0 0272 in SEM822B Oil ring 0 84 mm 0 0331 in If o
68. N Pilot converter A T model Pilot bushing M T model Main bearing EI Select proper thickness a Dei 5 4 7 2 0 55 0 73 47 7 63 4 Crankshaft EI Engine rear rubber M T model A EI 9 20 100 9 2 10 2 67 74 Oil pan PA d Tighten or loosen in two or three stages A Gasket e e 2 Chamfer i N Engine rear rubber ge M T model E gt Piston pin qe Gasket CO Fa S SCH p 6 3 8 3 SR EN 29 39 X Ri 0 64 0 85 Connecting rod bearing EI Main bearing cap Connecting rod cap a 3 Refer to Assembly Oil pan side Apply liquid gasket Use Genuine 3 0 4 0 22 29 Brain plug Eech Silicone RTV or equivalent Refer to yl Nem kg m in Ib amp Apply sealant GI Section Recommended Chemical Products and Sealants 9 Nem kg m ft lb EI Lubricate with new engine oil WEM142 EM 131 CYLINDER BLOCK VG33E and VG33ER Canada Models Block Heater d e Cylinder block Engine Front 16 22 0 16 2 2 14 19 Coolant W i N m kg m in tb Block heater LEM112 Removal and Installation Speer CAUTION When installing sliding parts such as bearings and pistons be sure to apply engine oil on the slid ing surfaces Place removed parts such as bearings and bearing caps in their proper order and direction When installing connecting rod bolts and main bearing cap bolts apply new engine oil to threads and seating surfaces
69. S VALVE ACTUATOR 1 Apply air pressure of less than 12 kPa 90 mmHg 3 54 inHg to the supercharger bypass valve actuator s lower side hose port and check for any leakage LEM116 EM 126 SUPERCHARGER VG33E and VG33ER 2 Check the supercharger bypass valve actuator rod for smooth movement while maintaining the pressure at the specified levels below Rod starts to extend at approximately 12 kPa 90 mmHg 3 54 inHg Rod is fully extended at approximately 33 3 kPa 250 mmHg 9 84 inHg EM Rod full extended length 20 83 22 71 mm 0 82 0 89 in Installation EBS oGTU Installation is in the reverse order of removal e Replace all gaskets make sure that all gasket surfaces are clean and undamaged e Follow all torque sequences for tightening nuts and bolts e Refill the cooling system Refer to MA 26 REFILLING ENGINE COOLANT EM 127 ENGINE ASSEMBLY VG33E and VG33ER ENGINE ASSEMBLY PFP 10001 Removal and Installation Se Engine Mounting SEC 112 SE P OJ 59 78 6 8 Cii poe 43 58 x 7A Jas 55 4 4 5 6 32 41 L A Z AA N D se 78 6 8 43 58 U 43 55 4 4 5 6 As 55 4 4 4 32 41 32 41 Dias 55 4 4 5 6 32 41 O Nem kg m ft Ib AEM471 EM 128 ENGINE ASSEMBLY VG33E and VG33ER WARNING e Place the vehicle on a flat and solid surface e Place wheel chocks at the front and back of the rear wheels
70. a fully charged battery to obtain specified engine speed Compression kPa kg cm psi 300 rpm Standard 1 226 12 5 178 Minimum 1 030 10 5 149 Difference limit between cylinders 98 1 0 14 If the compression in one or more cylinders is low Pour a small amount of engine oil into the cylinders through the spark plug hole Retest the compression e If adding oil improves cylinder compression piston rings may be worn or damaged If so replace piston rings after checking piston e If pressure stays low a valve may be sticking or seating improperly Inspect and repair valve and valve seat Refer to EM 40 VALVE DIMENSIONS EM 39 VALVE SEATS If valve or valve seat is dam aged excessively replace it e f compression in any two cylinders adjacent cylinders is low and if adding oil does not improve com pression there is leakage past the gasket surface If so replace cylinder head gasket Reinstall the spark plugs fuel injector fuse fuel pump fuse and reconnect camshaft position sensor har ness connector at the distributor Erase the DTC stored in the ECM Refer to EC 61 HOW TO ERASE EMISSION RELATED DIAGNOSTIC INFORMATION CAUTION Always erase the DTC after checking compression EM 32 CYLINDER HEAD KA24DE EBSO0GSG Components 1 4 7 10 13 16 19 SEC 111 130 Refer to Installation in CYLINDER HEAD yx Selecting parts Apply Genui
71. able pin EM 19 TIMING CHAIN KA24DE SEC 135 Camshaft sprocket cover Front cover 64 75 0 65 0 76 56 4 66 0 Mg Nm kg m in Ib 0 65 0 76 D N m kg m ft ib 56 4 66 0 a 1 6 1 9 12 14 Apply liquid gasket Use Genuine Silicone RTV or equivalent Refer to GI Section Recommended Chemical Products and Sealants EEN LIQUID GASKET APPLICATION PLACES po Front cover 2 3 mm 0 08 0 12 in dia Camshaft sprocket cover Half moon area lt le Rocker cover rubber gasket 2 to 3 mm 0 08 to 0 12 in diameter liquid gasket Cylinder head and camshaft sprocket cover AEM479 Removal eesooase CAUTION e After removing timing chain do not turn crankshaft and camshaft separately or valves will strike piston heads e When installing chain tensioners or other sliding parts lubricate contacting surfaces with new engine oil e Apply new engine oil to bolt threads and seat surfaces when installing camshaft sprockets and crankshaft pulley e Do not spill engine coolant on drive belts EM 20 TIMING CHAIN KA24DE UPPER TIMING CHAIN 1 Remove the air cleaner assembly 2 Remove the spark plug wires 3 Set No 1 piston at TDC on its compression stroke WEM067 Remove the vacuum hoses electrical harness connectors and harness clamps Remove the power steering belt Remove the power steering pump and position it to one side Remove the idler
72. ap to connecting rod e Tighten the connecting rod cap bolts in two stages to specification Connecting rod cap bolts Stage 1 14 16 N m 1 4 1 6 kg m 10 12 ft Ib Stage2 60 65 degrees 3 Measure inner diameter C of each bearing Inside micrometer AEM027 4 Measure outer diameter Dp of each crankshaft pin journal AEM028 EM 56 CYLINDER BLOCK KA24DE 5 Calculate connecting rod bearing clearance Connecting rod bearing clearance C Dp Standard 0 010 0 035 mm 0 0004 0 0014 in Limit 0 09 mm 0 0035 in If the clearance exceeds the limit replace the bearing 6 If the clearance cannot be adjusted within the standard of any bearing grind crankshaft journal and use undersized bearing Refer to EM 71 UNDERSIZE SERVICE 7 Ifthe crankshaft is replaced select the connecting rod bearing Crank pin according to the following table grade number NOTE The grade number of each crankshaft pin are punched on the crankshaft as shown These grade numbers are in either Arabic or Roman numerals Crankshaft pin grade number Connecting rod bearing grade number 0 0 1 orl 1 2 IH 2 SEM567B or Method B using a plastigage Measure the bearing clearances using the plastigage CAUTION e Do not turn crankshaft or connecting rod while plastigage is being inserted e When bearing clearance exceeds the specified limit ensure that the proper bearing has been installed Then i
73. ard 770 837 N 78 5 85 4 kg 173 1 188 2 Ib at 30 0 mm 1 181 in Pressure at valve open height Limit 733 N 74 8 kg 164 8 Ib at 30 0 mm 1 181 in Out of square 2 0 mm 0 079 in HYDRAULIC VALVE LIFTER Unit mm in Lifter outside diameter 15 947 15 957 0 6278 0 6282 Lifter guide inside diameter 16 000 16 013 0 6299 0 6304 Clearance between lifter and lifter guide 0 043 0 066 0 0017 0 0026 VALVE GUIDE Unit mm in Standard Service Intake 11 023 11 034 0 4340 0 4344 11 223 11 234 0 4418 0 4423 Outer diameter Exhaust 12 023 12 034 0 4733 0 4738 12 223 12 234 0 4812 0 4817 Valve guide Inner diameter Finished Intake 7 000 7 018 0 2756 0 2763 size Exhaust 8 000 8 011 0 3150 0 3154 Intake 10 975 10 996 0 4321 0 4329 11 175 11 196 0 4400 0 4408 Cylinder head valve guide hole diameter Exhaust 11 975 11 996 0 4715 0 4723 12 175 12 196 0 4793 0 4802 Intake Interference fit of valve guide 0 027 0 059 0 0011 0 0023 Exhaust Standard Max tolerance Intake 0 020 0 053 0 0008 0 0021 Valve to valve guide clearance 0 10 0 0039 Exhaust 0 030 0 049 0 0012 0 0019 Valve deflection limit 0 20 0 0079 ROCKER SHAFT AND ROCKER ARM Unit mm in Rocker shaft Outer diameter 17 979 18 000 0 7078 0 7087 Rocker arm Inner diameter 18 007 18 028 0 7089 0 7098 Clearance between rocker arm and rocker shaft 0 007 0 049 0 0003 0 0019 EM 1
74. ark WEMO81 CAMSHAFT SPROCKET RUNOUT 1 Support the camshaft at the No 2 and No 4 camshaft journals 2 Install the sprocket on the camshaft EM 111 CYLINDER HEAD VG33E and VG33ER 3 Measure the camshaft sprocket runout Runout limit total indicator 0 1 mm 0 004 in reading SEM872B 4 If the runout exceeds the limit replace the camshaft sprocket VALVE GUIDE CLEARANCE 1 Measure the valve deflection at a right angled direction to the camshaft The valve and valve guide mostly wear in that direc tion Valve deflection limit 0 20 mm 0 0079 in dial gauge reading 2 If the valve guide deflection exceeds the limit check the valve to valve guide clearance a Measure valve stem diameter and valve guide inner diameter as shown b Check that the valve to valve guide clearance is within specifica tion Valve to valve guide clearance Intake 0 020 0 053 mm 0 0008 0 0021 in Exhaust 0 030 0 049 mm 0 0012 0 0019 in SEMBOOA Limit 0 10 mm 0 0039 in c If the valve to valve guide clearance exceeds the limit replace the valve or valve guide as necessary Center Bottom Valve guide SEM751A EM 112 CYLINDER HEAD VALVE GUIDE REPLACEMENT 1 To remove the valve guide heat cylinder head to 150 160 C 302 320 F by soaking it in heated oil 2 Drive out the valve guide using a press with a pressure limited to under 20 kN 2 ton 2 2 US ton 2 0 Imp ton
75. asket e sensor 20 29 Throttle body 2 0 3 0 tightening order 14 22 T 20 27 2 1 2 7 15 19 Die 21 1 6 2 1 12 15 Apply liquid gasket Use Genuine Silicone RTV or equivalent Refer to Gl Section Recommended Refer to step 14 Chemical Products and Sealants in Installation of CYLINDER HEAD ei N m kg m in Ib OJ Nm kg m ap WEM141 EM 124 SUPERCHARGER VG33E and VG33ER Removal CAUTION Do not disassemble or adjust the supercharger 1 Disconnect the negative battery cable 2 Disconnect the accelerator cable from the throttle body and the iri Accelerat bl air inlet tube bracket ccelerator cable NC Nec EBSO0GTS t tube L Air inle TaN Nt Pa l E ASOD cable d Throttle body QS g e A SCH Ten hi 4 SZ LAS A s LEM105 3 Disconnect the ASCD cable from the throttle body and the air inlet tube bracket if equipped 4 Remove the air inlet duct Fea U e Disconnect the PCV hoses AN Bd FAN AAA g kA Z S lee V dv NN WA e Disconnect the resonator hose NA Rv Resonator hose li 2 NS LAE YONG mer ee vA e PVC hoses WM y LEM110 5 Partially drain the cooling system Refer to MA 26 DRAINING ENGINE COOLANT 6 Remove the supercharger pulley cover and supercharger A C compressor drive belt Refer to MA 24 Checking Drive Belts Supercharger pulley cover y Mg 5 4 7 3 0 55 0 74 48 64 ei N m kg m
76. at belt switch inputs and dual stage front air bag modules If equipped with dual stage front air bag modules the SRS system uses the seat belt switches to determine the front air bag deployment and may only deploy one front air bag depending on the severity of a collision and whether the front occupants are belted or unbelted Information necessary to service the system safely is included in the SRS and SB section of this Service Manual The vehicle may be equipped with a passenger 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 for certain types of collision When the switch is turned to the OFF position the pas senger air bag is disabled and will not inflate A passenger air bag OFF indicator 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 WARNING e To avoid rendering the SRS inoperative which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation all maintenance must be per form
77. between cylinders 98 1 0 14 Unit degree Valve timing a b C d e f 240 244 4 60 9 51 EM 144 SERVICE DATA AND SPECIFICATIONS SDS Cylinder Head WBIA0236E VG33E and VG33ER EBS00GU2 Unit mm in Standard Limit Nominal cylinder head height H 106 8 107 2 4 205 4 220 Head surface distortion Less than 0 03 0 0012 0 1 0 004 Valve VALVE T Margin thickness RR TQ EBS00GUS Unit mm in L SEM188 Intake 42 0 42 2 1 654 1 661 Valve head diameter D Exhaust 34 95 35 25 1 376 1 388 Intake 125 3 125 9 4 933 4 957 Valve length L Exhaust 124 2 124 8 4 890 4 913 Intake 6 965 6 980 0 2742 0 2748 Valve stem diameter d Exhaust 7 962 7 970 0 3135 0 3138 Intake Valve seat angle o 45 15 45 45 degrees Exhaust Intake 1 15 1 45 0 0453 0 0571 Valve margin T Exhaust 1 35 1 65 0 0531 0 0650 Valve margin T limit More than 0 5 0 020 Valve stem end surface grinding limit Less than 0 2 0 008 Intake 0 0 Valve clearance Exhaust 0 0 VALVE SPRING Free height 50 47 mm 1 987 in Valve closed installation height 40 0 mm 1 575 in Valve open height EM 145 30 0 mm 1 181 in SERVICE DATA AND SPECIFICATIONS SDS VG33E and VG33ER Stand
78. der bores when honing 8 Hone the cylinder bores e When any cylinder needs honing all other cylinders must also be honed e Do not hone too much out of the cylinder bore at a time Hone only 0 05 mm 0 0020 in in diameter at each pass Hone the cylinders to obtain specified piston to bore clearance and a smooth bore surface 10 Measure the finished cylinder bore for out of round and taper refer to step 1 e All measurements must be done after the cylinder bore cools down CRANKSHAFT 1 Checkthe crankshaft main and pin journals for any scoring wear or cracks 2 With a micrometer measure the journals for taper and out of round Out of round X Y less than 0 005 mm 0 0002 in Taper A B less than 0 005 mm 0 0002 in Taper A B Out of round X Y SEM316A EM 136 CYLINDER BLOCK VG33E and VG33ER 3 Measure the crankshaft runout as shown Runout total indicator reading less than 0 10 mm 0 0039 in BEARING CLEARANCE Method A Using Bore Gauge and Micrometer NOTE Either of the following two methods may be used to check bearing clearance However method A gives a more reliable result and is the preferable method Main Bearing 1 Set the main bearings in their proper positions on the cylinder Upper main bearing we 4 With oil groove block and main bearing caps as shown No 2 2 Install the main bearing caps on the cylinder block Tighten the V ou main bearing cap bolts
79. distance S 164 95 165 05 6 4941 6 4980 Bend per 100 mm 3 94 in 0 15 0 0059 Torsion per 100 mm 3 94 in 0 30 0 0118 Connecting rod small end inner diameter d 23 970 24 000 0 9437 0 9449 Piston pin bushing inner diameter 21 000 21 012 0 8268 0 8272 Connecting rod big end inner diameter D 53 000 53 013 2 0866 2 0871 Side clearance Without bearing Crankshaft SEM394 0 2 0 4 0 008 0 016 0 6 0 024 EBSO0GTO Unit mm in Out of round Ka Qq Taper A uU Q9 EM715 Grade No 0 59 967 59 975 2 3609 2 3612 Main journal diameter Dm Grade No 1 59 959 59 967 2 3606 2 3609 Grade No 2 59 951 59 959 2 3603 2 3606 Grade No 0 49 968 49 974 1 9672 1 9675 Pin journal diameter Dp Grade No 1 49 962 49 968 1 9670 1 9672 Grade No 2 49 956 49 962 1 9668 1 9670 Center distance r 47 95 48 05 1 8878 1 8917 Standard Limit Journal 0 01 0 0004 Taper of journal and pin A B Pin 0 005 0 0002 Journal 0 01 0 0004 Out of round of journal and pin X Y Pin 0 005 0 0002 Runout TIR EM 70 0 10 0 0039 SERVICE DATA AND SPECIFICATIONS SDS KA24DE Free end play 0 05 0 18 0 0020 0 0071 0 3 0 012 Fillet roil More than 0 1 0 004 Total indicator reading Bearing Clearance Semer
80. e side supporting it with wire 6 Remove the idler pulley and bracket Set the No 1 piston to TDC on its compression stroke 8 Remove the distributor e N Distributor WEM067 EM 22 TIMING CHAIN KA24DE 9 Remove the crankshaft bolt e f necessary remove the rear plact and install Tool to prevent crankshaft rotation Tool number J 45499 l 14mm hex bolt Bell housing 10 Remove the crankshaft pulley with a suitable puller LEM115 11 Remove the oil pan Refer to EM 16 Removal 12 Remove the oil pump distributor drive shaft and the oil pickup strainer 13 Remove the front cover CAUTION Be careful not to tear or damage the cylinder head gasket 14 Remove the following parts Lower timing e Release the timing chain tensioner by pushing the piston in S chain auide and inserting a suitable pin into the pin hole e Chain tension arm e Lower timing chain guide e Air duct SEM796E 15 Remove the upper timing chain Refer to EM 21 UPPER TIMING CHAIN EM 23 TIMING CHAIN KA24DE 16 Wipe off the links of the timing chain next to the timing marks on the sprockets Put paint marks on the timing chain matching uae them with the timing marks on the crankshaft sprocket and idler sprocket i E jj y EI St A ef H zi SE CY TED M oie E Vo I Paint mark Z AEM482 17 Remove the lower timing chain crankshaft sprocket and id
81. ect exhaust tube 16 Remove the relay rod Refer to PS 20 Components It is not necessary to disconnect pitman arm 17 Remove the oil pan bolts in numerical order as shown 18 Remove the oil pan a Insert Tool between the cylinder block and the oil pan and tap 1 NT SO 9 using a plastic hammer to separate the pan from the engine KV101 11100 block as shown 93228 i o CAUTION Ow xu e Do not drive seal cutter into oil pump or rear oil seal retainer portion or aluminum mating face will be dam gt O slide fe aged e Do not insert screwdriver or oil pan flange will be deformed PBICOO02E EM 88 OIL PAN VG33E and VG33ER b Slide Tool by tapping on the side 2 with a hammer to remove the oil pan from the engine block Installation Ease 1 Before installing the oil pan remove all traces of the liquid gas ket from the mating surface using a scraper as shown e Also remove all traces of liquid gasket from the mating sur Scraper face of the cylinder block SEM350B 2 Apply the liquid gasket to the oil pump gasket and rear oil seal retainer gasket SEM894B 3 Apply a continuous bead of liquid gasket to mating surface of oil pan e Use Genuine Silicone RTV Sealant or equivalent Refer to Gl 42 RECOMMENDED CHEMICAL PRODUCTS AND SEAL ANTS SEM351B e Be sure the liquid gasket bead is 3 5 4 5 mm 0 138 0 177 in wide Apply the liquid gasket to the oil pan going ar
82. ed by an authorized NISSAN INFINITI dealer e Improper maintenance including incorrect removal and installation of the SRS can lead to per sonal injury caused by unintentional activation of the system For removal of Spiral Cable and Air Bag Module see the SRS section e Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual SRS wiring harnesses can be identified by yellow and or orange harnesses or harness connectors e The vehicle may be equipped with a passenger air bag deactivation switch which can be operated by the customer When the passenger air bag is switched OFF the passenger air bag is disabled and will not inflate When the passenger air bag is switched ON the passenger air bag is enabled and could inflate for certain types of collision After SRS maintenance or repair make sure the passenger air bag deactivation switch is in the same position ON or OFF as when the vehicle arrived for service Parts Requiring Angular Tightening zones e Use an angle wrench for the final tightening of the following engine parts Cylinder head bolts Connecting rod cap nuts Do not use a torque value for final tightening The torque value for these parts are for a preliminary step Ensure thread and seat surfaces are clean and coated with engine oil EM 4 PRECAUTIONS Precautions for Liquid Gasket REMOVAL OF LIQUID GASKET SEALING e After removing the mounting bolts and nu
83. eeping the tensioner steady with a hexagon wrench Turn the crankshaft clockwise or counterclockwise to remove the feeler gauge Turn the crankshaft clockwise at least two full rotations then slowly set the No 1 piston at TDC on the compression stroke Measure the deflection of the timing belt midway between the camshaft sprockets while pushing with a force of 98 N 10 kg 22 Ib as shown Belt deflection when engine is cold reference value 13 15 mm 0 51 0 59 in at 98 N 10 kg 22 Ib force If the belt deflection is not within specification return to step 1 and repeat procedure EM 97 VG33E and VG33ER Turn the crankshaft clockwise until the feeler gauge is posi Feeler gauge Tensioner pulley Timing belt Crankshaft sprocket SEM889BA Camshaft sprocket RH sprocket LH Tensioner pulley Timing belt Crankshaft sprocket SEM744DA TIMING BELT VG33E and VG33ER 14 Install the lower and upper belt covers Front upper belt cover Water inlet Rear belt cover Compressor bracket L Bolt s Rubber washer 5 by Rubber washer Front upper belt cover Front lower belt cover Welded nut Hexagon bolt with washer Bolt pac eee washer Rear elt poer 4 Front lower belt cover a Rubber washer 4 Bolt il Front lower belt cover Front lower belt cover Lock spring washer SEM313F 15 Install the remaining components in the rev
84. ents 3 Measure the inner diameter C of each connecting rod bearing installed in the connecting rod big end Inside micrometer AEMO27 4 Measure the outer diameter Dp of each crankshaft connecting rod journal AEM034 5 Calculate the connecting rod bearing clearance Connecting rod bearing clearance C Dp Standard 0 024 0 064 mm 0 0009 0 0025 in Limit 0 090 mm 0 0035 in 6 If the connecting rod bearing clearance exceeds the limit replace the connecting rod bearing 7 fthe clearance cannot be adjusted within the standard of any bearing grind the crankshaft journals and use undersized bearings Refer to EM 154 Available Connecting Rod Bearing EM 139 CYLINDER BLOCK VG33E and VG33ER Method B Using Plastigage CAUTION e Do not turn the crankshaft or the connecting rod while the plastigage is being inserted e When the bearing clearance exceeds the specified limit ensure that the proper bearing has been installed Then if an excessive bearing clearance exists use a thicker main bearing or undersized bearing so that the specified bearing clearance is obtained CONNECTING ROD BUSHING CLEARANCE SMALL END 1 Measure the inner diameter C of the connecting rod small end 2 Measure the outer diameter Dp of the piston pin bushing 3 Calculate the connecting rod bushing clearance Connecting rod bushing clearance C Dp Standard 0 005 0 017 mm 0 0002 0 0007 in
85. er diameter Grade 2 89 010 89 020 3 5043 3 5047 0 2 0 008 Cylinder bore Grade 3 89 020 89 030 3 5047 3 5051 Out of round X Y Less than 0 015 0 0006 Taper A B Less than 0 010 0 0004 Difference in inner diameter between cylinders Less than 0 03 0 0012 0 2 0 008 Piston to cylinder bore clearance 0 020 0 040 0 0008 0 0016 Cylinder block height From crankshaft center 246 95 247 05 9 7224 9 7264 0 2 0 008 Wear limit Total amount of cylinder head resurfacing and cylinder block resurfacing EM 67 SERVICE DATA AND SPECIFICATIONS SDS KA24DE Camshaft and Camshaft Bearing casooasx Unit mm in Zi Gi NH MS s EM120 A D WBIA0176E Standard Limit Gain height Intake 41 755 41 945 1 644 1 651 am height Exhaust 41 815 42 005 1 646 1 654 Wear limit of cam height 0 2 0 008 Camshaft journal to bearing clearance 0 045 0 090 0 0018 0 0035 0 12 0 0047 Inner diameter of camshaft bearing H Io 5 28 000 28 025 1 1024 1 1033 journals Outer diameter of camshaft journal 1 to 5 D journals 27 935 27 955 1 0998 1 1006 Camshaft runout Less than 0 02 0 0008 0 04 0 0016 Camshaft end play 0 070 0 148 0 0028 0 0058 0 2 0 008 a 224 b 224 c 1 Valve timing Degree on crankshaft d 45 e 7 f 37 Total indicator reading
86. ere aoe 12 REPLACING VALVE SEAT sss 39 OUTER COMPONENT PARTS Een 13 VALVE DIMENSIONS ees 40 Removal and Installation 13 VALVE SPRING cocccccccccccccccccecccccccccccccccececcsecescees 40 OIL PAWN EE ES 16 VALVE LIFTER AND ADJUSTING SHIM 41 Components eene 16 EE 42 Removal NEE 16 IristallatiOn 3 5 eere ctt tbe te e cereos 42 Installation EE EIS RED e betta tege EN I CO DE 17 Valve Clearance ENEE 43 TIMING CHAIN eese enne nnn nnn nnns 19 CHECKING esee 43 ele lee EE 19 ADJUSTING coccccccccccccccceccceccccccecccsccecccscceseccesesees 44 LIQUID GASKET APPLICATION PLACES 20 ENGINE ASSEMBLY trntntttetnntnn 46 Removal apis vi venu E EET Ee E 20 Removal and Installation nets Nee tok EE ERR 46 UPPER TIMING CHAIN EE 21 HEMOVAT iu bet cessione rcd oct tea 47 IDLER SPROCKET eene 21 INSTALLATION tegen 47 LOWER TIMING CHAIN een 22 CYLINDER BLOCK EE 48 Inspection OPTAT ENN NNN Na EE d NNN EN VW Cer eg EN NEEN NN TIAE 24 Components iio a a FOR aOR TOES KEEN BO IEDI 48 Installation AE AE mye e SSES KEE AE EE EE EE NEE os 24 Removal and Installation EE te ae Maen ehe E 49 LOWER TIMING CHAIN en 24 Disassembly 2 ttes devas er etie tenes 49 IDLER SPROCKET eee 26 PISTON AND CRANKSHAFT sss 49 UPPER TIMING CHAIN een 26 In SpeCtlOD eios eerte entera TE 50 OK EA er DEN 28 PISTON AND PISTON
87. erse order of removal EM 98 OIL SEAL VG33E and VG33ER OIL SEAL PFP 00100 Replacement zesoen VALVE OIL SEAL 1 Remove the rocker cover 2 Remove the rocker shaft assembly and valve lifters with the valve lifter guide 3 Remove the valve spring using Tool as shown way 7 e The piston concerned should be set at TDC to prevent the pa SEE valve from falling into the cylinder bore TT 4 Remove the valve oil seals e When removing the intake side valve oil seal use Tool or a suitable tool e When removing the exhaust side valve oil seal pull it out with a suitable tool SEM285A 5 Apply new engine oil to the new valve oil seal and install it to specification as shown e When installing intake side valve oil seal use Tool as shown e When installing exhaust side valve oil seal set it by hand KV10107501 E e 3 For intake valve side 15 5 mm 0 587 0 610 in 14 9 WBIA0189E CAMSHAFT OIL SEAL 1 Remove the timing belt Refer to EM 91 Removal 2 Remove the camshaft sprocket Refer to EM 104 Components 3 Remove the camshaft Refer to EM 108 Disassembly 4 Remove the camshaft oil seal EM 99 OIL SEAL VG33E and VG33ER CAUTION Be careful not to scratch camshaft 5 Apply new engine oil to the new camshaft oil seal 6 Position the oil seal in the specified direction as shown Engine Engine inside a outside Oil seal lip Dust seal lip SEM715A 7 Install the oil sea
88. especially the accelerator wire casing end brake tube and brake master cylinder 1 Remove the undercover 2 Drain the engine oil Refer to MA 30 Changing Engine Oil 3 Remove the stabilizer bracket bolts RH amp LH Refer to FSU 20 Removal 4 Remove the front propeller shaft from front differential carrier Refer to PR 8 Removal and Installation 5 Remove the front drive shaft fixing bolts Refer to FAX 20 Removal and Installation 6 Remove the front differential carrier bleeder hoseFFD 11 Components 7 Remove the front suspension cross member Refer to FSU 5 Components 8 Remove the differential front mounting bolts and rear mounting bolts Refer to FFD 11 Components 9 Remove the front differential carrier Refer to FFD 9 Removal and Installation 10 Remove the front differential carrier mounting bracket Refer to FFD 11 Components 11 Remove the starter motor Refer to SC 25 VG33E AND VG33ER MODELS 12 Remove the transmission to rear engine mounting bracket nuts Refer to MT 10 Removal and Installa tion F85W71C MT 48 Removal and Installation FS5R30A AT 62 REMOVAL AND INSTALLA TION RLARO1A AT 407 REMOVAL AND INSTALLATION RE4RO14A 13 Remove the engine mounting bolts or nuts Refer to EM 128 Removal and Installation 14 Remove the power steering gear mounting brackets Refer to PS 15 Hemoval and Installation 15 Lift up the engine If necessary disconn
89. ey are worn replace them Then resurface the valve seat as necessary e Use both hands to resurface the valve seat uniformly using a suitable tool as shown SEM302D REPLACING VALVE SEAT 1 Bore out the old seat until it collapses Boring should not con tinue beyond the bottom face of the seat recess in the cylinder head Set the machine depth stop to prevent damage diameter SEM795A 2 Ream the cylinder head valve seat recess Reaming bore for service valve seat Oversize 0 5 mm 0 020 in Intake 38 000 38 016 mm 1 4961 1 4967 in Exhaust 32 700 32 716 mm 1 2874 1 2880 in CAUTION Use the valve guide center for a reference point for reaming so the valve and valve seat will have the correct fit 3 Heat the cylinder head to 120 140 C 248 284 F in heated oil SEMO008A EM 39 CYLINDER HEAD KA24DE 4 Press fit valve seat until it seats on the bottom of the recess 5 Cut or grind valve seat using suitable tool to the specified dimen sions Seat face a 45 15 45 45 degrees Contacting width W Intake 1 48 1 63 mm 0 0583 0 0642 in Exhaust 1 8 2 0 mm 0 071 0 079 in SEM892B 6 After cutting lap valve seat with abrasive compound Check the valve seat dimensions Refer to EM 66 VALVE SEAT 8 Use a depth gauge to measure the distance between the mount ing surface of the cylinder head spring seat and the valve stem end I
90. f exces sive bearing clearance exists use a thicker main bearing or undersized bearing so that the specified bearing clearance is obtained CONNECTING ROD BUSHING CLEARANCE SMALL END 1 Measure inner diameter C of bushing 2 Measure outer diameter Dp of piston pin 3 Calculate connecting rod bushing clearance Connecting rod bushing clearance C Dp Standard 0 005 0 017 mm 0 0002 0 0007 in Limit 0 023 mm 0 0009 in If the calculated clearance is out of specification replace the connecting rod assembly or the piston set with pin or both as necessary EM 57 CYLINDER BLOCK KA24DE REPLACEMENT OF CONNECTING ROD BUSHING SMALL END 1 Drive in the small end bushing until it is flush with the rod end surface CAUTION Align the oil holes before installing for lubrication 2 Ream the bushing until clearance with piston pin is within specification Connecting rod bushing clearance 0 005 0 017 mm 0 0002 0 0007 in FLYWHEEL DRIVE PLATE RUNOUT Using a dial gauge rotate the flywheel driveplate and measure the runout by the total dial gauge indicator reading as shown Runout total indicator less than 0 15 mm 0 006 in reading CAUTION e Becareful not to damage the ring gear teeth e Do not allow any magnetic materials to contact the ring gear teeth e Do not resurface the flywheel M T Replace as necessary Assembly casooass PISTON 1 Completely remove any foreign material
91. f the distance is shorter than specified repeat step 5 through 7 above to adjust it If it is longer replace the valve seat with a new one N Valve seat resurface limit height L Intake 42 02 42 52 mm 1 6543 1 6740 in Exhaust 42 03 42 53 mm 1 6547 1 6744 in SEM621F VALVE DIMENSIONS Check dimensions of each valve Refer to EM 63 VALVE When F margin thickness valve head has been worn down to less than the margin thickness T replace the valve Do not grind the valve stem more than the grinding limit specification Margin thickness T 0 5 mm 0 020 in Valve stem tip grinding limit 0 2 mm 0 008 in SEM188A VALVE SPRING Squareness 1 Measure the spring out of square dimension S as shown po S Out of square Out of square S less than 2 2 mm 0 087 in 2 Ifthe out of square measurement exceeds the limit replace the spring SEM288A EM 40 CYLINDER HEAD KA24DE Pressure 1 Check the valve spring pressure at the specified spring height Pressure N kg Ib at height mm in Standard 418 0 42 6 93 9 at 29 17 1 1484 Limit 393 0 40 1 88 4 at 29 17 1 1484 2 If not within specification replace the spring VALVE LIFTER AND ADJUSTING SHIM 1 Visually check the valve lifter and adjusting shim contact and sliding surfaces for wear and scratches AEM499 2 Check the diameter of the valve li
92. fer to EM 43 Valve Clearance EM 45 ENGINE ASSEMBLY KA24DE ENGINE ASSEMBLY PFP 10001 Removal and Installation SS SEC 112 Dia 52 4 2 5 3 30 38 nox Dan 42 3 2 4 3 23 31 T N m kg m ft Ib WEMO055 WARNING Position vehicle on a flat and solid surface Place chocks at front and back of rear wheels Do not remove engine until exhaust system has completely cooled off Otherwise you may burn yourself and or fire may break out in fuel line Before disconnecting fuel hose release fuel pressure Refer to EC 46 FUEL PRESSURE RELEASE Be sure to hoist engine and transmission in a safe manner For engines not equipped with engine slingers attach proper slingers and bolts described in PARTS CATALOG EM 46 ENGINE ASSEMBLY KA24DE CAUTION When lifting engine be sure to clear surrounding parts Take special care near accelerator wire casing brake lines and brake master cylinder In hoisting the engine always use engine slingers in a safe manner Before separating engine and transmission remove the crankshaft position sensor OBD from the assembly Always take extra care not to damage edge of crankshaft position sensor OBD or ring gear teeth REMOVAL 1 DD D d OO P Co bh A Co N 14 15 16 Drain the coolant from engine block and radiator Refer to MA 16 Changing Engine Coolant Release the fuel pressure Refer to EC 46 FUEL PRESSURE RELEASE
93. from the cylinder block inside the crankshaft case and cylinder bores by blowing compressed air in the passages and oil passages 2 Install the oil jets e Oil jets for the No 1 and No 3 cylinders are a different shape from those for the No 2 and No 4 cylinders as shown For No 2 and 4 For No 1 and 3 cylinders cylinders WBIA0219E e Insert the oil jet knock pin into the cylinder block knock pin hole and tighten the knock pin bolt to specification Oil jet bolt 30 40 N m 3 1 4 1 kg m 22 30 ft Ib Knock pin hole PBICO478bE EM 58 CYLINDER BLOCK KA24DE 3 Heat piston to 60 to 70 C 140 to 158 F and assemble piston piston pin and connecting rod e Align the direction of piston and connecting rod KV10110300 SEM215E e Numbers stamped on connecting rod and cap correspond to each cylinder e After assembly make sure connecting rod swings smoothly Frontmark Piston grade number Cylinder number SEM262C 4 Set piston rings as shown Punchmark side CAUTION up if present e When piston rings are not replaced make sure that pis ton rings are mounted in their original positions e When piston rings are being replaced and no punchmark is present piston rings can be mounted with either side up LEMO69 5 Align piston rings so that end gaps are positioned as shown e Top ring e Oil ring upper rail Oil ring lower rail 2nd ring SEM160B EM 59 CYLINDER
94. fter as shown 3 Check the diameter of the valve lifter guide bore as shown SEM303D 4 If the measurements exceed the standard diameter or clearance replace valve lifter or cylinder head as necessary Valve lifter outer diameter 33 960 33 975 mm 1 3370 1 3376 in Lifter guide bore diameter 34 000 34 021 mm 1 3386 1 3394 in Valve lifter to valve lifter guide clearance 0 025 0 061 mm 0 0010 0 0024 in EM 41 CYLINDER HEAD KA24DE Assembly casooask 1 Install valve component parts e Always use new valve oil seal Refer to EM 28 VALVE OIL SEAL e Before installing valve oil seal install valve spring seat e Install outer valve spring uneven pitch type with its narrow pitch side toward cylinder head side After installing the valve component parts tap valve stem tip with a plastic hammer to assure a proper fit Wide pitch Narrow pitch Se Cylinder head side SEM638B Installation SE 1 Tighten the cylinder head bolts in the numerical order as shown using the five step procedure Cylinder head bolt tightening steps Step a 29 N m 3 0 kg m 22 ft lb Step b 79 N m 8 1 kg m 59 ft lb Step c Loosen all bolts completely Step d 25 34 N m 2 5 3 5 kg m 18 25 ft lb Step e 86 91 degrees clockwise NOTE If an angle wrench is not available mark all of the cylinder head bolts on the side facing engine fr
95. haft journal Standard outer camshaft journal diameter A 46 920 46 940 mm 1 8472 1 8480 in B 42 420 42 440 mm 1 6701 1 6709 in C 47 920 47 940 mm 1 8866 1 8874 in ie SEM893BA 2 Measure the inner diameter of the camshaft bearing for the cor responding camshaft journal positions measured in step 1 Standard inner camshaft bearing diameter A 47 000 47 025 mm 1 8504 1 8514 in B 42 500 42 525 mm 1 6732 1 6742 in C 48 000 48 025 mm 1 8898 1 8907 in Bore gauge SEM879A 3 The camshaft journal is the difference between the outer diameter of the camshaft journal and the inner diameter of the camshaft bearing If the clearance exceeds the limit replace camshaft and or cylinder head Camshaft journal clearance limit 0 15 mm 0 0059 in CAMSHAFT END PLAY 1 Install the camshaft and the locate plate in the cylinder head 2 Measure the camshaft end play Standard camshaft end play 0 03 0 06 mm 0 0012 0 0024 in Locate plate Dial gauge SEM392E 3 If it is out of the specified range select thickness of camshaft mm in 0 018 0 029 0 040 locate plate to obtain standard specified end play 0 0007 0 0011 0 0016 Example When camshaft end play is 0 08 mm 0 0031 in with camshaft locate plate 1 replace camshaft locate plate 1 with camshaft locate plate 4 to set the end play at 0 04 mm 0 0016 in No A identification Punched identification mark m
96. hecking HYDRAULIC VALVE LIFTER 1 Check the contact and sliding surfaces for wear or scratches 2 Check the outer diameter of the valve lifter Valve lifter outer diameter 15 947 15 957 mm 0 6278 0 6282 in SEM243E 3 Check the valve lifter guide inner diameter Valve lifter guide inner diameter 16 000 16 013 mm 0 6299 0 6304 in Standard clearance between 0 043 0 066 mm valve lifter and lifter guide 0 0017 0 0026 in SEM760A EM 116 CYLINDER HEAD Assembly 1 Install the valve component parts e Always use a new valve oil seal Refer to EM 99 VALVE OIL SEAL e Install the valve spring uneven pitch type with the narrow pitch side toward cylinder head side e After installing valve component parts use plastic hammer to lightly tap valve stem tip to assure a proper fit Install the camshafts locate plates and cylinder head rear cov ers e Position the knock pin of the camshaft at the top as shown Install the valve lifters and the valve guide e Assemble the valve lifters in their original position and hold all of the valve lifters with wire to prevent the lifters from falling out of the guide e Remove the wire after installing the lifters and guide Install the rocker shafts with the rocker arms e Tighten the bolts gradually in two or three stages to specifica tion in the following camshaft positions e Before tightening the bolts the camshaft must be p
97. hten the bolts in the numerical order as shown Rocker cover bolts 8 11 N m 0 8 1 1 kg m 69 95 in Ib Tighten in numerical order AEM357 7 Install the distributor align the distributor to the mark as shown WEM067 8 Install the vacuum hoses electrical harnesses connectors and harness clamps EM 27 FRONT OIL SEAL 1 2 OIL SEAL KA24DE OIL SEAL PFP 00100 Replacement EBScoGSE VALVE OIL SEAL 1 Remove the rocker cover 2 Remove the camshaft Refer to EM 19 TIMING CHAIN 3 Remove valve spring and valve oil seal with Tool or a suitable tool NOTE The piston must be at TDC on the compression stroke to prevent the valve from falling into the combus tion chamber 4 Apply engine oil to new valve oil seal and install it with Tool SEM289D e The valve oil seal must be installed to specification over the valve stem opening as shown Unit mm in SEM290D Remove radiator shroud Refer to CO 14 Components Remove the crankshaft bolt e f necessary remove the rear plact and install Tool to prevent crankshaft rotation Tool Se Ye N Tool number J 45499 Ze 7A P Vy D d 4 hex BUS KA bolt ol Bell housing Flex plate LBIAO364E EM 28 OIL SEAL KA24DE 3 Remove the crankshaft pulley with a suitable puller 4 Remove front oil seal using suitable tool CAUTION Be careful not to scratch the front cover AEM385 5
98. ightening bearing cap cylinder head bolts BT8653 A etc Angle wrench NTO14 KV10110600 Disassembling and assembling valve compo 433986 EN nents Valve spring compressor EA NT033 EM 74 PREPARATION VG33E and VG33ER Tool number Kent Moore No Le Tool name Description KV10107501 Installing valve oil seal Valve oil seal drift NT025 KV10110300 Piston pin press stand assembly 1 KV10110310 Cap 2 KV10110330 Spacer 3 ST13030020 Press stand 4 ST13030030 Spring 5 KV10110340 Drift 6 KV10110320 Center shaft a vist Q C WEM150 Disassembling and assembling piston with connecting rod EM03470000 J8037 Piston ring compressor Installing piston assembly into cylinder bore ST16610001 J23907 Pilot bushing puller NT045 Removing crankshaft pilot bushing KV10111100 Removing oil pan J37228 Seal cutter NT046 WS39930000 Pressing the tube of liquid gasket Tube presser NT052 PREPARATION VG33E and VG33ER Tool number Kent Moore No Description Tool name KV10117100 Loosening or tightening heated oxygen sen J36471 A sor Front heated oxygen sensor wrench For 22 mm 0 87 in hexagon nut KV10114400 J38365 Heated oxygen sensor wrench as a NT636 Commercial Service Tools Kent Moore No Tool name Loosening or tightening rear heated oxygen se
99. ion and direction for installation into their original position 10 Remove the oil jets Inspection EbscoGSR PISTON AND PISTON PIN CLEARANCE 1 2 3 Measure the inner diameter of piston pin hole dp Standard diameter dp 20 993 21 005 mm 0 8265 0 8270 in AEM023 Measure the outer diameter of piston pin Dp Standard diameter Dp 20 989 21 001 mm 0 8263 0 8268 in Micrometer AEMO24 Calculate the piston pin clearance Piston pin clearance dp Dp 0 002 0 01 mm 0 0001 0 0004 in If it exceeds the above value replace piston and pin assembly EM 50 CYLINDER BLOCK KA24DE PISTON RING SIDE CLEARANCE Measure the piston ring side clearance as shown If the clearance exceeds the specification replace piston ring If the clearance exceeds the maximum side clearance limit with the new piston ring replace piston Side Clearance Top ring 0 04 0 08 mm 0 0016 0 0031 in 2nd ring 0 03 0 07 mm 0 0012 0 0028 in Oil ring 0 065 0 135 mm 0 0026 0 0053 in Limit Top 2nd 0 1 mm 0 004 in Feeler gauge Ring SEM249CA PISTON RING END GAP 1 Measure the piston ring end gap as shown If out of specifica tion replace piston ring If gap exceeds maximum limit with a new ring rebore cylinder and use oversized piston and piston Piston rings Refer to EM 69 Piston Piston Ring and Piston pin 2 When replacing the piston check cylinder
100. l using Tool as shown SEM284A 8 Install the remaining components in the reverse order of removal FRONT OIL SEAL 1 Remove the timing belt and crankshaft sprocket Refer to EM 91 Removal 2 Remove the oil pump assembly Refer to LU 16 Removal and Installation 3 Remove the front oil seal from the oil pump body 4 Apply new engine oil to the new oil seal 5 Position the oil seal with the correct orientation as shown Engine Engine inside a outside Oil seal lip Dust seal lip SEM715A EM 100 6 7 OIL SEAL VG33E and VG33ER Install the new oil seal using a suitable tool as shown Install the remaining components in the reverse order of removal REAR OIL SEAL 1 2 3 6 Remove the flywheel or drive plate Refer to CL 12 Components Remove the rear oil seal retainer Remove the rear oil seal from the retainer CAUTION Be careful not to scratch the rear oil seal retainer Apply new engine oil to the new oil seal Position the new oil seal as shown Engine inside a Oil seal lip Install the new oil seal using a suitable tool Install the rear oil seal retainer with a new gasket on the cylinder block CAUTION Always use a new oil seal retainer gasket Install the remaining components in the reverse order of removal EM 101 Engine outside Dust seal lip SEM715A SEM242E 1 2 3 11 CYLINDER HEAD VG33E and VG33ER CYLIND
101. ler sprocket Inspection eBsooasc Check for cracks and excessive wear at the roller links Replace the chain if necessary AEM403 Installation raso0as0 LOWER TIMING CHAIN 1 Install crankshaft sprocket Crankshaft e Make sure that the mating marks of crankshaft sprocket face Crankshaft sprocket the front of the engine Oil pump drive gear Oil thrower N SEM205C 2 Install the idler sprocket and lower timing chain using the mating marks and the paint marks made during the removal process CAUTION Be careful not to tear or damage the cylinder head gasket EM 24 TIMING CHAIN KA24DE 3 Install the chain guide and the chain tension arm Pin hole Lower timing chain tensioner Tension arm SEM796E 4 Install the lower chain tensioner and remove the pin securing the piston in the tensioner body 5 Install the front cover and oil seal e Using a scraper or other suitable tool remove all traces of liq uid gasket from the cylinder block and front cover mating sur faces e Install a new crankshaft seal in ie iront gover Engine a Enge e Apply a continuous bead of Genuine Silicone RTV Sealant or inside outside equivalent to the front cover Refer to MA 12 Recom mended Fluids and Lubricants Oil seal lip Dust seal lip SEM715A e Install a new front oil seal using a suitable tool Refer to EM 28 FRONT OIL SEAL d ae Ji Suitable tool A SEM292D e Apply Genuine Silicone RTV
102. linder compression the piston rings may be worn or damaged If so replace the piston rings after checking the piston e f the pressure stays low a valve may be sticking or seating improperly Inspect and repair the valve and valve seat If the valve or valve seat is damaged replace them as necessary Refer to EM 110 Inspection e If the compression in any two adjacent cylinders is low and if adding oil does not improve the compres sion there is possible leakage past the head gasket If so replace the cylinder head gasket EM 102 CYLINDER HEAD VG33E and VG33ER 12 Reinstall all the spark plugs fuel injector fuse fuel pump fuse and reconnect the camshaft position sen sor harness connector at the distributor 13 Erase the DTC stored in the ECM CAUTION Always erase the DTC after checking compression Refer to EC 61 HOW TO ERASE EMISSION RELATED DIAGNOSTIC INFORMATION VG33E EC 61 HOW TO ERASE EMISSION RELATED DIAGNOSTIC INFORMATION VG33ER EM 103 CYLINDER HEAD VG33E and VG33ER Components zeen SEC 10291119130 Exhaust oF oy Tot fel To IS 4 RH cylinder LH cylinder Ok 8 0 1 0 3 9 26 head front Si head front Intake 9 Jo Y Tol don Lo lo Align cut portion to cylinder head bolt BI 18 22 S 1 8 2 2 J 9 81 12 8 1 00 1 30 87 112 8 43 10 8 Qo 20 0 86 1 10 75 95 1 3 0 1 0 3 9 26 FIC Refe
103. mbly 1 KV10110310 Cap 2 KV10110330 Spacer 3 ST13030020 Press stand 4 ST13030030 Spring 5 KV10110340 Drift 6 KV10110320 gem Center shaft connecting rod EM03470000 J 8037 Piston ring compressor Installing piston assembly into cylinder bore J 36467 Valve oil seal remover NT034 Removing valve oil seal ST16610001 J 23907 Pilot bushing puller NT045 Removing crankshaft pilot bushing KV10111100 Removing oil pan J 37228 Seal cutter NT046 WS39930000 Pressing the tube of liquid gasket Tube presser NT052 PREPARATION KA24DE Tool number Kent Moore No Description Tool name KV101151S0 Changing valve lifter shims J 38972 Lifter stopper set 1 KV10115110 J 38972 1 Camshaft pliers 2 KV10115120 J 38972 2 SECH Lifter stopper KV10117100 Loosening or tightening heated oxygen sen J 36471 A sor Front heated oxygen sensor wrench oF NT379 For 22 mm 0 87 in hexagon nut KV10114700 J 38139 Main bearing cap remover ZZA0023D Removing crankshaft main bearing cap For No 3 and No 5 bearings J 45499 Ring gear stopper Commercial Service Tools Tool name Kent Moore No e LBIAO362E Preventing crankshaft rotation EBS00GS4 Description Spark plug wrench O E zb eo Removing and installing spark plug Pulley holder NTO3
104. n and piston pin clear Slap or E A u B B u Piston pin ance EM 50 or knock noise Connecting rod bushing EM 57 clearance Crank Sea ring SCH clearance EM 51 shaft pulley iston ring end gap 7 Cylinder Se d A B B A eie slap Connecting rod bend and net ep block torsion EM 52 upper side Piston to bore clearance E engine Connect Connecting rod bearing il pan ing rod clearance Big end EM 56 or Knock A B B B B bearing Connecting rod bushing EM 57 noise clearance Small end Main bear Crankshaft runout EM 53 or SES A B A p S ing noise Main bearing oil clearance EM 54 Front of Timing engine chain and i Timing Tappingor A A B B B chainten Ming chain cracksand Seen ticking wear chain sioner cover noise Squeak Drive belts MA 16 ing or fizz A B B C Sticking or Drive belt deflection DRIVE ing slipping BELT DEFLEC Front of Creaking A B A B A B Drive belts Idler pulley bearing opera TION AND engine Slipping tion TENSION Squall Water CO 11 hia A B B A B pump Water pump operation Inspec noise tion A Closely related B Related C Sometimes related Not related EM 12 OUTER COMPONENT PARTS KA24DE OUTER COMPONENT PARTS PFP 00100 Removal and Installation EBSo0GS6 Engine Outer Components SEC 120 140 147 150 163 164 210 220 221 230 231 Diva 19 1 1 2 1 9 9 1 14 1 CHEN O 1st 9 11 0 9 1 1 6 5 8 0 0 30 0
105. n the specified limit L 0 1 mm 0 004 in b Grind the crankshaft to use it with replacement parts Refer to EM 70 Crankshaft and EM 71 Available Main Bearing 7 Ifthe crankshaft is reused measure the main bearing clearance and select the thickness of the main bearing If the crankshaft or cylinder block is replaced select the thick ness of the main bearings as follows a The grade number of each cylinder block main journal is punched on the respective cylinder block These numbers are punched in either Arabic or Roman numerals Journal grade number EEM120 EM 55 CYLINDER BLOCK KA24DE b The grade number of each crankshaft main journal is punched D z Crank main on crankshaft These numbers are punched in either Arabic or journal grade Roman numerals number o9 No 1 WIL 9 SEM272C c Select the main bearing with a suitable thickness according to the following example and table Example Main journal grade number is 1or Crankshaft journal grade number is 2 or Il Main bearing grade number 1 2 3 Yellow Main Bearing Grade Number and Identification Color Main journal grade number 0 1orl 2 or Il 0 0 Black 1 Brown 2 Green Grankshaftj rnal gr de 1orl 1 Brown 2 Green 3 Yellow number 2 or II 2 Green 3 Yellow 4 Blue Connecting Rod Bearing Big End 1 Install connecting rod bearing to connecting rod and cap 2 Install connecting rod c
106. nal tightening of the following engine parts Cylinder head bolts Connecting rod cap nuts Do not use a torque value for final tightening The torque value for these parts are for a preliminary step Ensure thread and seat surfaces are clean and coated with engine oil EM 72 PRECAUTIONS VG33E and VG33ER Precautions for Liquid Gasket zemmer REMOVAL OF LIQUID GASKET SEALING e After removing the mounting bolts and nuts separate the mating Jj R surface using a seal cutter and remove the liquid gasket sealing Ka _ 5 ll CAUTION KV101 11100 Be careful not to damage the mating surfaces 337228 0 e Usea plastic hammer to lightly tap 1 the areas where the liquid SEN 7 gasket is applied To advance the cutter use a plastic hammer 2 to slide the cutter along the joint CAUTION If for some unavoidable reason a tool such as a flat bladed screwdriver is used be careful not to damage the mating sur faces PBICO002E LIQUID GASKET APPLICATION PROCEDURE de Using a scraper remove the old liquid gasket adhering to the gasket application surface and the mating surface e Remove the sealant completely from the groove of the gasket application surface mounting bolts and bolt holes PBICOO03E Thoroughly clean the gasket application surface and the mating surface and remove adhering moisture grease and foreign materials Attach the sealant tube to the tube presser EMA0
107. ndicator 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 WARNING e To avoid rendering the SRS inoperative which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation all maintenance must be per formed by an authorized NISSAN INFINITI dealer e Improper maintenance including incorrect removal and installation of the SRS can lead to per sonal injury caused by unintentional activation of the system For removal of Spiral Cable and Air Bag Module see the SRS section e Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual SRS wiring harnesses can be identified by yellow and or orange harnesses or harness connectors e The vehicle may be equipped with a passenger air bag deactivation switch which can be operated by the customer When the passenger air bag is switched OFF the passenger air bag is disabled and will not inflate When the passenger air bag is switched ON the passenger air bag is enabled and could inflate for certain types of collision After SRS maintenance or repair make sure the passenger air bag deactivation switch is in the same position ON or OFF as when the vehicle arrived for service Parts Requiring Angular Tightening Seenen e Use an angle wrench for the fi
108. ne Silicone RTV or equivalent Refer to GI Section Lubricate with new engine oil Wi N m kg m in Ib Di N m kg m ft lb e Always replace after every disassembly Oil filler cap Intake camshaft Valve lifter Valve spring Intake valve Cylinder head bolt Rocker cover gaskets Removal CAUTION e When installing camshafts chain tensioners oil seals or other sliding parts lubricate contacting surfaces with new engine oil 11 14 17 20 Wie 11 0 8 1 1 69 95 WBIA0233E Rocker cover 3 Camshaft bracket Exhaust camshaft 6 Adjusting shim Valve cotter 9 Spring retainer Spring seat 12 Valve oil seal Exhaust valve 15 Cylinder head Valve guide 18 Valve seat Cylinder head gasket EBSOOGSH EM 33 CYLINDER HEAD KA24DE e Apply new engine oil to threads and seat surfaces when installing cylinder head camshaft sprocket crankshaft pulley and camshaft bracket e Attach tags to valve lifters so as not to mix them up Before removing camshaft and idler sprockets apply paint marks to them for re timing 1 Remove upper timing chain and idler sprocket Refer to EM 21 UPPER TIMING CHAIN and EM 21 IDLER SPROCKET e For re timing during cylinder head removal and installation apply paint marks to the camshaft sprock ets upper timing chain lower timing chain and idler sprocket 2 Remove camshaft brackets and camshafts Remove the bolts in the reverse order as shown
109. nsor For right bank a 22 mm 0 87 in EBSO0GT9 Description Spark plug wrench NTO47 Removing and installing spark plug Pulley holder WEM153 Holding camshaft pulley while tightening or loosening camshaft bolt Valve seat cutter set NTO48 Finishing valve seat dimensions Piston ring expander NTO30 Removing and installing piston ring Valve guide drift NTO15 EM 76 Removing and installing valve guide Intake amp Exhaust a 10 5 mm 0 413 in dia b 6 6 mm 0 260 in dia Kent Moore No Tool name PREPARATION VG33E and VG33ER Description Valve guide reamer Reaming valve guide 1 or hole for oversize valve guide 2 Intake di 7 0 mm 0 276 in dia d2 11 2 mm 0 441 in dia Exhaust di 8 0 mm 0 315 in dia d2 12 2 mm 0 480 in dia Camshaft oil seal drift Installing camshaft oil seal a 60 mm 2 36 in dia b 44 5 mm 1 752 in dia c 75 mm 2 95 in Front oil seal drift Installing front oil seal a 52 mm 2 05 in dia b 44 mm 1 73 in dia Rear oil seal drift WEM152 Installing rear oil seal a 46 mm 1 81 in b 110 mm 4 33 in c 84 mm 3 31 in d 96 mm 3 78 in a J 43897 18 b J 43897 12 Thread repair tool for oxygen sensor Flutes AEM488 18 mm 0 71 in 12 mm 0 47 in o D Anti seize thread compound AEM489 EM 77 For pre
110. nstallation is in the reverse order of removal Disassembly EBsocasa PISTON AND CRANKSHAFT 1 DPN Place the engine on a work stand Remove the oil pan Refer to EM 16 Removal Remove the timing chain Refer to EM 20 Removal Remove the water pump Refer to CO 10 Removal Remove the cylinder head Refer to EM 33 Removal Remove the pistons with connecting rods CAUTION Use care not to scratch the engine block cylinder bore when removing the piston and connecting rod assemblies Sech YS KV10105001 SEM744 Remove bearing caps in the numerical order as shown and remove the crankshaft Loosen the main bearing cap bolts in several steps in the numerical order as shown e Before removing the main bearing caps mark the location and direction on each cap and bolt for correct placement for installation e Before removing the main bearing cap bolts measure crank shaft end play Refer to EM 53 CRANKSHAFT 0 2 Loosen in numerical order cemiis EM 49 CYLINDER BLOCK KA24DE b Using the main bearing cap bolts remove the main bearing cap while shaking it right and left as shown e Remove the No 3 and No 5 main bearing caps using Tool Main Bearing Cap Remover KV10114700 J 38139 8 Remove the crankshaft 9 Remove the main bearings from the cylinder block journals and the main bearing caps CAUTION Before removal mark the main bearings with their locat
111. off immediately e Do not retighten after the installation EMA0622D D Inner 7 Groove Bolt hole Inner side SEM159F e After 30 minutes or more have passed from the installation fill the engine with the specified oil and coolant Refer to MA 20 Changing Engine Oil and MA 17 REFILLING ENGINE COOLANT EM 5 PREPARATION KA24DE PREPARATION PFP 00002 Special Service Tools zones The actual shapes of Kent Moore tools may differ from those of the special service tools illustrated here Tool number Kent Moore No Description Tool name ST0501S000 Disassembling and assembling E Engine stand assembly 1 ST05011000 ES Engine stand 2 ST05012000 Base KV10105001 Engine attachment NTOS31 KV101092S0 Disassembling and assembling valve compo J26336 B nents Valve spring compressor 1 KV10109210 Compressor 2 KV100109220 WEM044 Adapter KV10112100 Tightening bearing cap cylinder head bolts BT8653 A etc Angle wrench NTO14 KV10116300 J 38955 Valve oil seal drift Installing valve oil seal a 25 0 98 dia b 14 4 0 567 dia c 11 8 0 465 dia d 10 0 39 dia e 11 0 43 f 9 0 35 WEM151 EM 6 PREPARATION KA24DE Tool number Kent Moore No Description Tool name KV10110300 Disassembling and assembling piston with Piston pin press stand asse
112. ont Then turn each cylinder head bolt to the specified angle Tightening torque Nem kg m ft lb SEM276D Set camshafts and camshaft brackets e Set the dowel pins of both the intake and exhaust camshafts at 12 o clock position when installing the camshafts Tighten the camshaft bracket bolts in the order shown using two Intake camshaft steps e e Apply new engine oil to bolt threads and seat surfaces GU ONE TOR O 2 A e Sr Dec r S Cl M Camshaft bracket bolt HEEN steps x OD on Qa 9 Step 2N m 0 2 kg m 17 in Ib Like ke Lia Laco Step2 9 11 8 N m 0 92 1 2 kg m 79 9 104 2 in Ib m CAL Exhaust camshaft Tighten in numerical order Loosen in reverse order AEM352 Install upper timing chain and idler sprocket Refer to EM 26 UPPER TIMING CHAIN EM 26 IDLER SPROCKET EM 42 CYLINDER HEAD KA24DE Valve Clearance Some CHECKING Check valve clearance while engine is warm but not running 1 Remove the following parts e Rocker cover e All spark plugs 2 Set No 1 cylinder at TDC on its compression stroke e Align pointer with TDC mark on crankshaft pulley e Check that valve lifters on No 1 cylinder are loose and valve lifters on No 4 are tight If not turn crankshaft one revolution 360 and align as above 3 Check only those valves as shown Tare ORG EP Ee ai on IS EEC OEK Srel INT SAS Meurs Ld im EXH CZ AEM382 4 Using a feeler ga
113. or cap Engine cooling fan Fuel feed hose Air relief plug OUTER COMPONENT PARTS 11 14 17 20 23 O ring Insulator Fuel tube Fuel return hose Ground EM 83 9 12 15 18 21 24 VG33E and VG33ER Engine coolant temperature sensor 10 13 16 19 22 Intake manifold Water pump Fuel injector Fuel pressure regulator Throttle body IACV AAC valve assembly OUTER COMPONENT PARTS VG33E and VG33ER VG33ER SEC 140 147 148 163 164 173 210 221 Supercharger do not disassemble 24 5 31 3 2 5 3 2 18 23 Supercharger bypass valve actuator 0 21 29 2 2 2 9 16 21 det 19 6 23 5 20 24 15 17 Supercharger tightening order loosen in reverse order BC f 9 8 11 8 1 0 1 2 87 104 Gasket e Air inlet tube Intake manifold collector tightening order loosen in reverse order SH Lc IACV AAC manifold collector d i valve assembly Throttle body 0 11 8 13 7 Dist 9 11 1 2 1 4 9 10 0 9 1 1 6 5 8 0 2nd 18 22 7 8 0 7 0 8 61 69 1 822 Copper washer S 13 16 Water outlet Refer to step 14 in Installation of CYLINDER HEAD Thermal transmitter Intake manifold Engine coolant temperature Gasket e sensor T 20 27 2 1 2 7 15 19 ie 21 1 6 2 1 12 15 20 29 Throttle body 2 0 3 0 tightening order 14
114. ositioned where the lobe is not contacting the lifter Set No 1 piston at TDC on the compression stroke and tighten the rocker shaft bolts for No 2 No 4 and No 6 cylinders Set No 4 piston at TDC on the compression stroke and tighten the rocker shaft bolts for No 1 No 3 and No 5 cylinders EM 117 VG33E and VG33ER EBSOOGTP Wide pitch Narrow pitch V Cylinder head side SEM638B Knock pin SEM834B SEM280A Rocker shaft direction Exhaust Fl Te oF Tol igi O RH cylinder LH cylinder C head front head front g LioF ol Lig Lei Lio Intake SEM835BA CYLINDER HEAD Installation 1 Set the No 1 piston at TDC on the compression stroke as fol lows Align the crankshaft sprocket aligning mark with the mark on the oil pump body Make sure that the knock pin on camshaft is still positioned at the top Install both cylinder block drain plugs and tighten to specifica tion e Use Genuine High Performance Thread Sealant or equiva lent Refer to GI 42 RECOMMENDED CHEMICAL PROD UCTS AND SEALANTS Drain plug 34 44 N m 3 5 4 5 kg m 25 33 ft lb Install the exhaust manifolds on to the cylinder head tighten the bolts in the numerical order as shown CAUTION Tighten the exhaust manifold bolts to specification in the numerical order as shown Refer to EM 80 OUTER COM PONENT PARTS EM 118 VG33E and VG33ER RH exhaust
115. ound the bolt holes as shown Groove Bolt hole SEMO15E EM 89 OIL PAN VG33E and VG33ER Install the oil pan and tighten the oil pan bolts to specification and in the numerical order as shown e Installation of the oil pan must be done within 5 minutes of the liquid gasket application e Wait at least 30 minutes before filling the engine with oil Oil pan bolts 6 3 8 3 N m 0 64 0 85 kom 55 6 73 8 in Ib WBIA0187E Install the remaining components in the reverse order of removal EM 90 TIMING BELT VG33E and VG33ER TIMING BELT PFP 13028 Components EBSo0GTE SEC 120 130 135 Rear belt cover Cylinder block RH camshaft sprocket EJ 0 78 88 8 0 9 0 58 65 Washer Conical washer Belt tensioner nut 9 43 58 4 4 5 9 32 43 Front upper belt cover 3 5 0 3 0 5 Apply locking sealant to 26 43 L5 ates threads on cylinder sprocket block side BIO 78 88 8 0 9 0 58 65 Tensioner spring Belt tensioner Timing belt plate Front lower belt cover Crankshaft sprocket Crank pulley plate Crankshaft pulley 141 156 Wel Nem kg m in Ib DI Nem kg m ft lb E Lubricate with new engine oil WBIA0101E CAUTION e Do not bend or twist timing belt e After removing timing belt do not turn crankshaft and camshaft separately because valves will strike piston heads e Make sure that timing belt camshaft
116. over 2 Drain the engine oil Refer to MA 20 Changing Engine Oil 3 Remove the front suspension member Refer to FSU 10 Front Suspension Parts 4 Remove the oil pan bolts in the numerical order as shown lt Loosen bolts in numerical order Front AEM497 5 Remove the oil pan using Tool as shown 3 Insert Tool between the cylinder block and oil pan and separate Psy Lo ll the oil pan from the engine block by tapping 1 with a plastic KV101 11100 hammer as shown 37228 0 e Be careful not to damage the aluminum mating surface Ow uml e Do not insert a screwdriver which may damage the oil pan flange BaO Slide b Slide the Tool by tapping on the side 2 of the Tool with a plastic hammer as shown PBICOO02E 6 Pullthe oil pan out from the front side EM 16 OIL PAN KA24DE Installation Seeeen 1 Use a scraper to remove the old liquid gasket from the mating surface of the oil pan e Remove all traces of the liquid gasket from the mating surface of the cylinder block Apply a continuous bead of liquid gasket to the mating surface of the oil pan e Use Genuine Anaerobic Liquid Gasket or equivalent Refer to MA 12 RECOMMENDED FLUIDS AND LUBRICANTS e Apply the liquid gasket to the groove on the oil pan mating surface AEM300 e Allow a 7 mm 0 28 in clearance around the bolt holes 7 mm 0 28 in Liquid gasket Groove Bolt hole SEMO15E e Be
117. pulley and bracket Remove the rocker cover loosen and remove the rocker cover bolts in the numerical order as shown YO OU NISSAN O6 O Loosen in numerical order AEM356 8 Remove the camshaft sprocket cover AEM374 9 Wipe off the links of the timing chain next to the timing marks on the sprockets Put paint marks on the timing chain matching them with the timing marks on the cam sprockets and idler sprocket Upper timing chain tensioner Mating mark JEM547G 10 Remove cam sprocket bolts cam sprockets and upper timing chain IDLER SPROCKET 1 Remove upper timing chain EM 21 TIMING CHAIN KA24DE Refer to EM 21 UPPER TIMING CHAIN 2 If not removing the lower cover support lower timing chain using a suitable tool to prevent the chain tensioner spring from coming out NOTE This step is only to be applied when the lower cover is not being removed 3 Remove the idler sprocket AEM480 LOWER TIMING CHAIN 1 Drain the coolant by removing the cylinder block drain plug and opening the radiator drain cock Refer to MA 16 Changing Engine Coolant 2 Drain the engine oil Refer to MA 20 Changing Engine Oil Remove the intake air duct 4 Remove the following parts e Generator drive belt e A C compressor drive belt e Cooling fan with coupling e Radiator shroud 5 Remove the A C compressor without disconnecting the A C hoses and position it to th
118. r Squall Creak A B B A B pump Water pump operation CO 26 noise A Closely related B Related C Sometimes related Not related EM 79 OUTER COMPONENT PARTS VG33E and VG33ER PFP 00100 OUTER COMPONENT PARTS Removal and Installation EBSO0GTB VG33E SEC 140 147 148 163 164 173 210 221 e Wi 8 0 7 0 8 61 69 Kg 8 43 10 8 I 8 4 10 8 0 86 1 1 74 6 95 5 0 86 1 1 74 6 95 6 Ky 8 4 10 8 0 86 1 1 74 6 95 5 Dis 22 1 8 22 13 16 amp E d 8 4 10 8 0 86 1 1 74 6 95 5 EDAN A e Gr P tightening order D v Lgs N Dier 9 11 21 27 2 1 2 8 15 0 9 1 1 m 6 5 8 0 9 15 25 1 5 2 5 11 2nd 18 22 1 8 2 2 13 16 OAE 15 20 1 5 2 0 11 Dau 17 9 16 21 1 6 2 1 12 15 1 4 1 7 10 12 te OU Refer to 8 l EE z SFr SF CYLINDER HEAD 2 00 3 00 SE gt 14 46 21 69 EC 164 el 2 9 3 8 0 30 0 39 26 0 33 9 9 11 15 1 1 1 5 8 Apply Genuine Silicone RTV Sealant or equivalent Refer to GI Section Nem kom in Ib Nem kg m ft lb Always replace after every disassembly WBIA0185E EM 80 10 13 16 19 22 25 28 31 PCV valve Copper washer Fresh air inlet Distributor Fuel injector cap Engine cooling fan Fuel feed hose Air relief plug EGRC solenoid valve EGRC BPT valve IACV AAC valve assembly
119. r to e CYLINDER HEAD 8 43 10 8 0 86 1 10 75 95 3 78 88 8 0 9 0 58 65 Cylinder head side Ky Nem kg m in Ib Cylinder h eT ylinder head gasket identification for VG33E O Nem kg m ft lb D Lubricate with new engine oil Oj wi Always replace after every disassembly WBIA0190E EM 104 CYLINDER HEAD VG33E and VG33ER 1 LH rocker cover 2 Intake rocker shaft 3 Gasket 4 Rocker arm 5 Hydraulic valve lifter 6 Valve lifter guide 7 Valve collet 8 Valve spring 9 Valve spring 10 Valve oil seal 11 Valve guide 12 Valve seat 13 Valve spring seat 14 Exhaust valve 15 Exhaust rocker shaft EM 16 Cylinder head rear cover 17 Rear cover gasket 18 Camshaft locate plate 19 LH cylinder head 20 RH rocker cover 21 Oil filler cap 22 Cylinder block 23 LH camshaft 24 Camshaft front oil seal 25 RH cylinder head Removal EBSCOGTM 1 Release the fuel pressure Refer to EC 46 FUEL PRESSURE RELEASE VG33E EC 46 FUEL PRESSURE RELEASE VG33ER 2 Remove the timing belt Refer to EM 91 Removal 3 Drain the engine coolant by removing the drain plugs from both sides of the cylinder block se plug o SMA208CA 4 Separate the ASCD and accelerator control wires from the intake manifold collector VG33E only 5 Remove the intake manifold collector VG33E only EM 105 CYLINDER HEAD VG33E and VG33ER 6 The following parts must be disconnected a
120. r with the rocker arm is in the free position not on the lobe If the valve lifter moves more than 1 mm 0 04 in air may be inside it Bleed the air out by running the engine at 1 000 rom under no load for about 10 minutes If the hydraulic valve lifters are still noisy replace them Bleed off the air by running the engine at 1 000 rpm under no SEM531A load for about 10 minutes Repeat as necessary to bleed the air out of the new lifters Install the remaining components in the reverse order of removal EM 123 SUPERCHARGER VG33E and VG33ER SUPERCHARGER PFP 14110 Components EBSO0GTR SEC 140 147 148 163 164 173 210 221 Supercharger do not disassemble Supercharger tightening order loosen in reverse order dab aC Supercharger bypass valve actuator 0 21 29 2 2 2 9 16 21 C 19 6 23 5 20 24 15 17 el 9 8 11 8 1 0 1 2 87 104 Gasket e Air inlet tube Intake manifold collector tightening order loosen in reverse order 19 6 23 5 Gasket N 2 0 2 4 15 17 SH TT IACV AAC d valve assembly manifold collector Throttle body 118 137 Dier 9 11 1 2 1 4 9 10 0 9 1 1 6 5 8 0 Ze 2nd 18 22 7 8 07 08 61 69 18 22 Copper washer g tab Water outlet Thermal transmitter Intake manifold Refer to step 14 in Installation of Engine coolant CYLINDER HEAD temperature G
121. ring cap nut Step 1 14 16 N m 1 4 1 6 kg m 10 12 ft lb Step 2 60 65 degrees clockwise or 38 44 N m 3 9 4 5 kg m 28 33 ft Ib EM 142 CYLINDER BLOCK VG33E and VG33ER 6 Measure the connecting rod side clearance Connecting rod side clearance Standard 0 20 0 35 mm 0 0079 0 0138 in Limit 0 40 mm 0 0157 in If beyond the limit replace the connecting rod and or crankshaft 7 Install the rear oil seal and retainer REPLACING PILOT BUSHING M T OR PILOT CONVERTER A T 1 Remove the pilot bushing M T or pilot converter A T using Tool as shown ST16610001 J23907 or suitable tool 2 Install the pilot bushing M T or pilot converter A T as shown Crankshaft Pilot bushing M T Pilot converter AEM500 EM 143 SERVICE DATA AND SPECIFICATIONS SDS SERVICE DATA AND SPECIFICATIONS SDS General Specifications Cylinder arrangement VG33E and VG33ER PFP 00030 V 6 Displacement 3 275 cm 199 84 cu in Bore and stroke 91 5 x 88 mm 3 602 x 3 27 in Valve arrangement OHC Firing order 1 2 3 4 5 6 Compression 2 Number of piston rings Oil 1 Number of main bearings 4 Ess 8 9 1 Compression ratio VG33ER 8 3 1 Cylinder numbers e FRONT SEM713A Unit kPa kg cm psi 300 rpm Standard 1 196 12 2 173 Compression pressure Minimum 883 9 0 128 Differential limit
122. rockets SEM819C Remove the rear timing belt cover Remove the distributor and ignition wires CAUTION After removing the distributor from the cylinder head do not rotate the distributor rotor Remove the harness clamp from RH rocker cover Remove the front exhaust tube from the exhaust manifold Refer to EX 3 Removal and Installation Remove the A C compressor and generator Refer to MTC 67 Removal and Installation for Compressor A C compressor SC 37 Removal generator Remove the power steering pump Refer to PS 17 Components Remove the A C compressor generator and power steering pump brackets Loosen and remove the bolts from both rocker covers in the order shown Remove both rocker covers For RH cylinder head bolts in the numerical order as shown For LH cylinder head e A warped or cracked cylinder head could result from not removing the cylinder head bolts in the specified numerical order e Loosen the cylinder head bolts in two or three steps Loosen in numerical order Ne EM 107 CYLINDER HEAD VG33E and VG33ER Disassembly Semer CAUTION When installing sliding parts such as rocker arms camshafts and oil seals be sure to apply new engine oil on the sliding surfaces When tightening cylinder head bolts and rocker shaft bolts apply new engine oil to thread por tions and seat surfaces of bolts Do not disassemble hydraulic valve lifter Attach tags
123. ry to specification The limit of cylinder head resurfacing is determined by the cylinder block resurfacing Amount of cylinder head resurfacing is A Amount of cylinder block resurfacing is B Maximum limit A B 0 2 mm 0 008 in 4 After resurfacing the cylinder head e Check that the camshaft rotates freely by hand If resistance is felt the cylinder head must be replaced Nominal cylinder head height 126 3 126 5 mm 4 972 4 980 in CAMSHAFT VISUAL CHECK Check the camshaft for scratches seizure and wear CAMSHAFT RUNOUT 1 Measure the camshaft runout at the center of the journal Runout total indicator reading Standard less than 0 02 mm 0 0008 in Limit 0 04 mm 0 0016 in 2 Ifthe camshaft runout exceeds the limit replace the camshaft SEM926C CAMSHAFT CAM HEIGHT 1 Measure camshaft cam height Standard cam height Intake 41 755 41 945 mm 1 644 1 651 in Exhaust 41 815 42 005 mm 1 646 1 654 in Cam height wear limit Intake amp Exhaust 0 2 mm 0 008 in 2 If wear is beyond the limit replace camshaft EM 35 CYLINDER HEAD KA24DE CAMSHAFT JOURNAL CLEARANCE 1 Install camshaft bracket and tighten bolts to the specified torque 2 Measure inner diameter of camshaft bearing Standard inner diameter No 1 to No 5 journals 28 000 28 025 mm 1 1024 1 1033 in 3 Measure outer diameter of camshaft journal Standard outer diameter No 1 to No 5 journals
124. se parts Operating condition of engine w o gt Locationof Type of S Ei gt z Source of Reference P 3 2 D o Check item noise noise z z S 5 o noise page 2zi egal S 3 3 3 9 lt Z 5lajla S o o Q bonn Tekingor a a B PPet Hydraulic valve lifter EM 116 engine clicking noise Rocker cover Rattle c alla B C Meli Camshaft journal clearance EM 111 Cylinder d Camshaft runout EM 110 head noise Slap or A B B Piston pin Piston and piston pin clearance EM 133 knock noise Connecting rod bushing clearance EM 140 Crank Piston to bore clearance EM 135 shaft pul Si 2 Pistonslap Piston ring side clearance EM 133 ley Sap Orta R B n noise Piston ring end gap EM 134 Cylinder Connecting rod bend and torsion EM 134 block Connect f Side of in itod Connecting rod bushing clearance EM 140 engine Knock A B C B B B de Small end Connecting rod bearing EM 139 Oil pan noise clearance Big end Main bear Main bearing oil clearance EM 137 Knock A S A 2 S ing noise Crankshaft runout EM 136 Timing belt Aning d C A A A noise too hissing Timing belt tight Loose timing belt EM 9a cover Timing belt Belt contacting case Clatter A B C A noise too loose Squeak o ing or fizz A B mE B C bt Drive belts deflection ing Sticking or slipping MA 24 Front of Other engine Creaking A B A B A B drive belts Idler pulley bearing operation Slipping Wate
125. seat surfaces of the bolts with new Tighten in numerical order engine oil Ws Lower main bearing SEM208E SEM550EA EM 141 CYLINDER BLOCK VG33E and VG33ER Measure the crankshaft end play as shown Crankshaft end play Standard 0 050 0 170 mm 0 0020 0 0067 in Limit 0 30 mm 0 0118 in If beyond the limit replace the bearing with a new one Install the connecting rod bearings in the connecting rods and connecting rod caps e Confirm that the correct sized bearings are installed Refer to EM 139 Connecting Rod Bearing Big End e Install the bearings so that the oil hole in the connecting rod aligns with the oil hole in the bearing as shown SEM159B Install the pistons with connecting rods using Tool as shown EM03470000 Install the piston assemblies into their corresponding cylinder e bores using Tool as shown or suitable tool e Do not scratch the cylinder wall with the connecting rod e Position the piston so the front mark on the piston head faces toward the front of the engine Install the connecting rod bearing caps and nuts e Lubricate the connecting rod bearing cap stud threads and nut seats with new engine oil e Tighten the connecting rod bearing cap nuts to specification in two steps Only if an angle wrench is not available tighten the connecting rod bearing cap nuts to the torque specification in step 2 Connecting rod bea
126. sure the bead of liquid gasket has a diameter of 3 5 4 5 mm 0 138 0 177 in e Installation must be done within 5 minutes after applying the liquid gasket AEM301 EM 17 OIL PAN KA24DE Install the oil pan e Wait at least 30 minutes before refilling the engine oil e Tighten the oil pan bolts to specification in numerical order as shown Oil pan bolts 6 4 7 5 N m 0 65 0 76 kg m 56 66 in Ib Tighten bolts in numerical order Front AEM498 Install the remaining parts in the reverse order of removal EM 18 TIMING CHAIN KA24DE PFP 13028 TIMING CHAIN Components EBSOOGSA I9 1st 2 0 2 17 2nd 9 0 11 8 0 92 1 2 79 9 104 2 9 6 4 7 5 0 65 0 76 56 4 66 0 AC TN s 8 0 65 0 76 56 4 66 0 Apply Genuine Silicone RTV Sealant or equivalent Refer to GI section QI N m kg m in Ib U N m kg m ft lb 0 142 152 14 5 15 5 105 112 EI Lubricate with new engine oil X Always replace after every disassembly WBIA0214E 1 Timing chain tensioner upper 2 Cam sprocket 3 Timing chain upper 4 Water pump 5 Water pump pulley 6 Crankshaft pulley 7 Front oil seal 8 Front cover 9 Camshaft sprocket cover 10 Oil slinger 11 Oil pump drive gear 12 Timing chain lower 18 Crankshaft sprocket 14 Chain guide 15 Idler sprocket 16 Chain tension arm 17 Timing chain tensioner lower 18 Suit
127. surface with Tool B Remove Tool A KV10115110 J38972 1 Yo Rotate the adjusting shim until a hole is visible Blow air into the hole to separate the adjusting shim from the valve lifter Remove the adjusting shim using a small screwdriver and a magnetic finger or suitable tool EM 44 CYLINDER HEAD KA24DE 8 Calculate the replacement adjusting shim size a Using a micrometer to determine the thickness of the removed adjusting shim SEM145D b Calculate the thickness of the new adjusting shim so that the valve clearance comes within the specified values N Thickness of new shim R Thickness of removed shim M Measured valve clearance Intake and exhaust shim calculation N R M 0 37 mm 0 0146 mi c Select a new adjusting shim with the thickness as close as pos sible to the calculated value N Refer to EM 65 AVAILABLE SHIMS NOTE Shims are available in thicknesses from 1 96 2 68 mm 0 0772 0 1055 in in increments of 0 02 mm 0 0008 in The adjusting shim thickness is stamped on the bottom of the adjusting shim as shown 2 24 mm 2 24 0 0882 in Thickness is stamped SEM308D 9 Install the new adjusting shim using a suitable tool CAUTION Install the adjusting shim with the surface on which the thickness is stamped facing down 10 Place Tool A as described in steps 2 through 4 11 Remove Tool B 12 Remove Tool A 13 Recheck the valve clearance Re
128. t 1 15 1 45 0 0453 0 0571 Valve margin T limit More than 0 5 0 020 Valve stem end surface grinding limit VALVE SPRING Free height mm in Less than 0 2 0 008 50 3 1 9831 Pressure Standard 418 0 42 6 93 9 at 29 17 1 1484 N kg Ib at height mm in Limit 393 0 40 1 88 4 at 29 17 1 1484 Out of square mm in Less than 2 2 0 087 VALVE GUIDE Unit mm in L SEM301D Standard Service Valve guide Intake 11 023 11 034 0 4340 0 4344 11 223 11 234 0 4418 0 4423 Outer diameter Exhaust 11 023 11 034 0 4340 0 4344 11 223 11 234 0 4418 0 4423 Valve guide Intake 7 000 7 018 0 2756 0 2763 Inner diameter Finished size Exhaust 7 000 7 018 0 2756 0 2763 Cylinder head valve guide hole Intake 10 975 10 996 0 4321 0 4329 11 175 11 196 0 4400 0 4408 diameter Exhaust 10 975 10 996 0 4321 0 4329 11 175 11 196 0 4400 0 4408 Interference fit of valve guide 0 027 0 059 0 0011 0 0023 Standard Limit Intake 0 020 0 053 0 0008 0 0021 0 08 0 0031 Stem to guide clearance Exhaust 0 040 0 073 0 0016 0 0029 0 1 0 004 Valve deflection limit 0 2 0 008 Projection length L 13 3 13 9 0 524 0 547 VALVE LIFTER Unit mm in Valve lifter outer diameter 33 960 33 975 1 3370 1 3376 Lifter guide inner diameter 34 000 34 021 1 3
129. to the specified torque in two or three No A steps Refer to EM 131 Components i j Moi No 2 No 3 Lower main bearing SEM208E 3 Measure the inner diameter A of each main bearing as shown SEM505A 4 Measure the outer diameter Dm of each crankshaft main jour nal as shown 5 Calculate the main bearing clearance as A Dm for each crankshaft journal No 1 main bearing clearance A Dm Standard 0 030 0 048 mm 0 0012 0 001 9in EM 137 CYLINDER BLOCK VG33E and VG33ER Limit 0 060 mm 0 0024 in No 2 3 and No 4 main bearing clearance A Dm Standard 0 038 0 065 mm 0 0015 0 0026 in Limit 0 080 mm 0 0031 in 6 Ifthe clearance exceeds the specified limits replace the bearing 7 If clearance cannot be adjusted within the standard of any bear ing grind crankshaft journal and use undersized bearing a When grinding crankshaft journal confirm that L dimension in fillet roll is more than the specified limit L 0 1 mm 0 004 in b As necessary grind the crankshaft journals to specification or replace with an available service part Refer to EM 152 Crank shaft 8 If the crankshaft is reused measure the main bearing clear ances and select the required thickness of the main bearings If the crankshaft is replaced with a new one it is necessary to select the required thickness of the main bearings as follows a The grade
130. ts disconnect the com ponent using a seal cutter CAUTION Be careful not to damage the mating surfaces e Usea plastic hammer to lightly tap 1 the areas where the liquid gasket is applied To advance the cutter use a plastic hammer 2 to slide the cutter along the joint CAUTION If for some unavoidable reason a tool such as a flat bladed screwdriver is used be careful not to damage the mating sur faces LIQUID GASKET APPLICATION PROCEDURE 1 Using a scraper remove the old liquid gasket adhering to the gasket application surface and the mating surface e Remove the sealant completely from the groove of the gasket application surface mounting bolts and bolt holes KA24DE EBSO00GS2 Se Ston r oe 79 Se siae aS PBICO275E PBICOO03E 2 Thoroughly clean the gasket application surface and the mating surface and remove adhering moisture grease and foreign materials 3 Attach the sealant tube to the tube presser 4 Apply the sealant without breaks to the specified location with the specified dimensions e If there is a groove for the sealant application apply the seal ant to the groove e As for the bolt holes normally apply the sealant inside the holes If specified it should be applied outside the holes Make sure to read the text of this manual e Within five minutes of the sealant application install the mat ing component e If the sealant protrudes wipe it
131. uge measure clearance between valve lifter and camshaft e Record any valve clearance measurements which are out of specification They will be used later to determine the required replacement adjusting shim Valve clearance hot Intake 0 31 0 39 mm 0 012 0 015 in Exhaust 0 39 0 47 mm 0 015 0 019 in SEM304D 5 Turn crankshaft one revolution 360 degrees and align mark on crankshaft e with pointer 6 Check only those valves as shown e Use the same procedure as described in step 4 er paru LAE HEB miis oui INT SOS Seen eO AXIS us TEB ix Sa bj len AEM383 7 Ifall of the valve clearances are within specification install the following parts e Rocker cover e All spark plugs EM 43 CYLINDER HEAD KA24DE ADJUSTING CAUTION Adjust the valve clearance while engine is cold 1 2 7 Turn the crankshaft to position the camshaft lobe on the valve that must be adjusted upward Place Tool A around camshaft as shown CAUTION Toal DENS Before placing Tool A rotate notch toward the center of KV101151 NS the cylinder head as shown to simplify the shim removal Rotate Tool A so that lifter is pushed down CAUTION Be careful not to damage the cam surface with Tool A Place Tool B between camshaft and the edge of the valve lifter to retain valve lifter CAUTION e Tool B must be placed as close to camshaft bracket as possible e Be careful not to damage cam
132. ushing as shown Pilot bushing converter AEM500 EM 62 SERVICE DATA AND SPECIFICATIONS SDS SERVICE DATA AND SPECIFICATIONS SDS General Specifications Cylinder arrangement KA24DE PFP 00030 In line 4 Displacement 2 389 cm 145 78 cu in Bore and stroke 89 x 96 mm 3 50 x 3 78 in Valve arrangement DOHC Firing order 1 3 4 2 Compression 2 Number of piston rings Oil 1 Number of main bearings 5 9 2 Compression ratio COMPRESSION PRESSURE Unit kPa kg cm psi 300 rpm Standard 1 226 12 5 178 Minimum 1 030 10 5 149 Differential limit between cylinders Cylinder Head 98 1 0 14 EBSOOGSU T Margin thickness D a SEM188 Unit mm in Nominal cylinder head height H 126 3 126 5 4 972 4 980 SEM519E Limit Cylinder head surface distortion 0 1 0 004 Va l ve EBSO0GSV VALVE Unit mm in Intake 36 5 36 7 1 437 1 445 Valve head diameter D Exhaust 31 2 31 4 1 228 1 236 Intake 101 17 101 47 3 9831 3 9949 Valve length L Exhaust 98 67 98 97 3 8846 3 8964 EM 63 SERVICE DATA AND SPECIFICATIONS SDS KA24DE Intake 6 965 6 980 0 2742 0 2748 Valve stem diameter d Exhaust 6 945 6 960 0 2734 0 2740 Valve seat angle o Intake amp Exhaust 45 15 45 45 Intake 0 95 1 25 0 0374 0 0492 Valve margin T Exhaus
133. ut of specification replace the piston ring If the gap still exceeds the limit even with a new ring rebore the cylinder and use an oversized piston and piston rings Refer to EM 150 Piston Piston Ring and Piston Pin CAUTION When replacing the piston check the cylinder block surface for scratches or seizure If scratches or seizure are found hone or replace the cylinder block CONNECTING ROD BEND AND TORSION Using a suitable tool and a feeler gauge measure the connecting Bend rod bend and torsion as shown Bend limit 0 15 mm 0 0059 in per 100 mm 3 94 in length Torsion limit 0 30 mm 0 0118 in per 100 mm 3 94 in length SEM038F If it exceeds the limit replace connecting rod assembly Torsion SEMO03F CYLINDER BLOCK DISTORTION AND WEAR 1 Clean the upper face of the cylinder block and measure the dis tortion using a straight edge and feeler gauge as shown Cylinder block distortion Standard less than 0 03 mm 0 0012 in Limit 0 10 mm 0 004 in SEM394E 2 If the distortion exceeds the specified limit resurface the cylinder block sealing surface The resurfacing limit is determined by the amount of cylinder head resurfacing required EM 134 CYLINDER BLOCK VG33E and VG33ER Amount of cylinder head resurfacing is A Amount of cylinder block resurfacing is B Maximum resurfacing limit A B 0 2 mm 0 008 in Nominal cylinder block height from crankshaft center
134. venting corrosion seizing and galling on high temperature applications NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING VG33E and VG33ER NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING PFP 00003 Noise Vibration and Harshness NVH EBSOOGTA Tappet noise Timing belt Camshaft bearing noise Timing chain s and chain tensioner noise A NU ZR Yr ex wry VG33ER h Drive belt noise Supercharger slipping Water pump pulley Idler pulley Idler pulley Air conditioner A compressor pulley Power Drive belt Steering LN pump pulley Generator pulley Crankshaft pulley Drive belt noise Stick slippage Drive belt noise VG33E slipping Idler pulley K Water pump pulley Air conditioner compressor pulley 7 Connecting rod bearing noise Piston slap noise Power steering pump pulley Alternator pulley Crankshaft pulley Drive belt noise Stick slippage Main bearing noise WBIA0100E EM 78 NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING VG33E and VG33ER NVH TROUBLESHOOTING CHART ENGINE NOISE Use the chart below to help you find the cause of the symptom 1 Locate the area where noise occurs 2 Confirm the type of noise 3 Specify the operating condition of engine 4 Check specified noise source If necessary repair or replace the
135. ver sealing e Coolant leakage at water pump e Camshaft not functioning properly e Distributor not functioning properly e Excessive belt tension Oil coolant or water con taminated the belt BELT TENSIONER AND TENSIONER SPRING 1 Check the belt tensioner for smooth turning 2 Check the condition of the tensioner spring 3 Replace the tensioner as necessary 1 nstallation stroke Confirm that the No 1 piston is set at TDC on the compression EM 94 e Poor oil sealing of each oil seal e Coolant leakage at water pump e Poor belt cover sealing SEM558 EBSO0GTH Aligning 4 Rear 4 Aligning marks belt cover 97 marks O Camshaft O G sprocket sprocket LH at TDC in compression gning stroke Oil pump ark SEM510EA Crankshaft timing sprocket TIMING BELT VG33E and VG33ER 2 Install the tensioner and tensioner spring e Once the stud is removed apply a locking sealant to the threads of the stud on the cylinder block side before installing Hook tensioner spring E Tensioner spring an DANI S A Arrow A SEM243A 3 Turn the tensioner fully outward with a hexagon wrench and temporarily tighten the lock nut SEM829A E ON RS VO OC Q Camshaft yi vA z sprocket S 7 4 Setthe timing belt when the engine is cold 1 Point the arrow on timing belt toward the front of the belt cover 2 Align the white lines on the timing belt with

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