Isuzu Engine TF C24SE Workshop Manual

Download

Page 1

WORKSHOP MANUAL

TF SERIES

ENGINE

C24SE

SECTION 6

Page 2

Page 3

ENGINE DIAGNOSIS (C24SE) 6-1

SECTION 6

ENGINE DIAGNOSIS

CONTENTS

PAGE

Engine Diagnosis............................................................................................................... 6- 2

Hard Starting ................................................................................................................. 6- 2

Engine Compression Test Procedure ......................................................................... 6- 3

Rough Engine Idling or Engine Stalling...................................................................... 6- 4

Rough Engine Running ................................................................................................ 6- 5

Hesitation....................................................................................................................... 6- 6

Engine Lacks Power ..................................................................................................... 6- 7

Engine Noisy ................................................................................................................. 6- 8

Abnormal Noise Due to Hydraulic Lash Adjustor ...................................................... 6- 9

Troubleshooting Procedure ......................................................................................... 6- 9

Abnormal Combustion.................................................................................................. 6-11

Engine Oil Consumption Excessive ............................................................................ 6-12

Fuel Consumption Excessive ...................................................................................... 6-13

Oil Problems.................................................................................................................. 6-13

Engine Oil Pressure Check .......................................................................................... 6-13

Malfunction Indicator Lamp ......................................................................................... 6-14

Page 4

6-2 ENGINE DIAGNOSIS (C24SE)

Engine Diagnosis

Hard Starting

1.Starting Motor Does Not Turn Over

Trouble Shooting Procedure

Turn on headlights and starter switch.

Condition Possible cause Correction

Headlights go out or dim considerably

Terminals poorly connected Clean battery posts and terminals

Starting motor coil circuit shorted Overhaul or replace

Starting motor defective Overhaul or replace

2.Ignition Trouble - Starting Motor Turns Over But Engine Does Not Start

Spark Test

Disconnect a high tension cable from any spark plug. Connect the spark plug tester (use commercially available tool), crank the engine, and check if a spark is generated in the spark plug tester. Before cranking the engine, make sure that the spark plug tester is properly grounded. To avoid electrical shock, do not touch the high tension cable while the engine is running.

Condition Possible cause Correction

Spark jumps across gap Spark plug defective Clean, adjust spark gap or replace

Spark plug wire in correct Connect properly or replace

Ignition timing incorrect Refer to Ignition System

Fuel not reaching fuel injector(s)

Valve timing incorrect Adjust

Engine lacks compression Refer to item 4 (Engine lacks

No sparking takes place Ignition coil disconnected or

Electronic Ignition System with

Poor connections in engine

Engine Control Module cable

Battery run down or under charged

or engine

broken

module

harness

disconnected or defective

Recharge or replace battery

and connect properly

Refer to item 3 (Trouble in fuel system)

compression)

Connect properly or replace

Replace

Correct

Correct or replace

Page 5

3.Trouble in Fuel System

Condition Possible cause Correction

Starting motor turns over and spark occurs but engine does not start.

Water in fuel system Clean

Fuel filter clogged Replace filter

Fuel pipe clogged Clean or replace

Fuel pump defective Replace

Fuel pump circuit open Correct or replace

Evaporative Emission Control

Multiport Fuel Injection System

4.Engine Lacks Compression

Condition Possible cause Correction

Engine lacks compression Spark plug loosely fitted or spark

Spark plug wire incorrect Connect properly or replace

Valve timing incorrect Adjust

Cylinder head gasket defective Replace gasket

Valve incorrectly seated Lap valve

Valve stem seized Replace valve and valve guide

Valve spring weakened Replace

Cylinder or piston rings worn Overhaul engine

Piston ring seized Overhaul engine.

Engine Compression Test Procedure

1. Start and run the engine until the engine reaches normal operating temperature.

2. Turn the engine off.

3. Remove all the spark plugs.

4. Remove ignition coil fuse (15A) and disable the ignition system.

5. Remove the fuel pump relay from the relay and fuse box.

Fuel tank empty Fill

system circuit clogged

faulty

plug gasket defective

ENGINE DIAGNOSIS (C24SE) 6-3

Correct or replace

Refer to "Electronic Fuel Injection" section

Tighten to specified torque or replace gasket

6. Engage the starter and check that the cranking speed is approximately 300 rpm.

7. Install cylinder compression gauge into spark plug hole.

8. With the throttle valve opened fully, keep the starter engaged until the compression gauge needle reaches the maximum level. Note the reading.

9. Repeat the test with each cylinder. The pressure difference between the individual cylinders should not exceed 100kPa (14.5 psi).

Page 6

6-4 ENGINE DIAGNOSIS (C24SE)

Rough Engine Idling or Engine Stalling

Condition Possible cause Correction

Trouble in fuel injection system Idle air control valve defective Replace

Throttle shutting off incomplete Correct or replace

Throttle position sensor circuit

Fuel injector circuits open or

Fuel injectors damaged Replace

Fuel pump relay defective Replace

Manifold Absolute Pressure

Engine Coolant Temperature

Intake Air Temperature sensor

Knock Sensor (KS) circuits open

KS defective Replace

KS Module circuits open or

KS Module defective Replace

Vehicle Speed Sensor circuit open

Vehicle Speed Sensor defective Replace

Trouble in emission control system

Canister purge solenoid circuit

Canister purge solenoid defective Replace

Evaporative Emission Canister

Trouble in ignition system Refer to Hard Start

Others Engine lacks compression Refer to Hard Start

Valve incorrectly seated Lap valve

Air Cleaner Filter clogged Replace filter element

Valve timing incorrect Readjust

Idle air control valve broken Replace

Correct or replace

open or shorted

Correct or replace

shorted

Correct or replace Sensor cable disconnected or broken

Replace Sensor defective

Correct or replace Sensor cable disconnected or broken

Replace Sensor defective

Correct or replace cable disconnected or broken

Replace defective

Correct or replace or shorted

Correct or replace ground

Correct or replace or shorted

Engine Control Module defective Replace

Correct open

Replace Purge control valve defective

Troubleshooting Guide

Page 7

Rough Engine Running

Condition Possible cause Correction

Engine misfires regularly Ignition coil layer shorted Replace

Spark plugs fouling Clean or install hotter type plug

Spark plug(s) insulator nose

Spark plug wire incorrect Connect properly or replace

Fuel injector(s) defective Replace

Engine control module faulty Replace

Engine knocks regularly Spark plugs running too hot Install colder type spark plugs

Powertrain control module faulty Replace

Engine lacks power Spark plugs fouled Clean

Spark plug wire incorrect Connect properly or replace

Fuel injectors defective Replace

Manifold Absolute Pressure

Engine Coolant Temperature

Engine Control Module faulty Replace

Intake Air Temperature Sensor or

Throttle Position Sensor or

Knock Sensor or Knock Sensor

Knock Sensor Module or Knock

ENGINE DIAGNOSIS (C24SE) 6-5

Replace leaking

Correct or replace (MAP) Sensor or Manifold Absolute Pressure Sensor circuit defective

Correct or replace Sensor or Engine Coolant Temperature Sensor circuit defective

Correct or replace Intake Air Temperature Sensor circuit defective

Correct or replace Throttle Position Sensor circuit defective

Correct or replace circuits defective

Correct or replace Sensor Module circuits defective

Page 8

6-6 ENGINE DIAGNOSIS (C24SE)

Hesitation

Condition Possible cause Correction

Hesitation on acceleration Throttle Position Sensor

Throttle Position Sensor circuit

Excessive play in accelerator

Manifold Absolute Pressure

MAP Sensor defective Replace Intake Air Temperature (IAT)

Knock Sensor (KS) Circuit open or

KS defective Replace KS Module circuits open or

KS Module defective Replace IAT Sensor defective Replace Hesitation at high speeds

(Fuel pressure too low) Fuel pipe clogged Clean or replace Fuel filter clogged Replace Defective fuel pump system Check and replace Fuel Pressure Control Valve

Hesitation at high speeds

(Fuel injector not working normally)

Cable of Multiport Fuel Injection

Hesitation at high speeds Engine Control Module defective Replace Throttle Position Sensor circuit

Throttle Position Sensor defective Replace Engine Coolant Temperature

Engine Coolant Temperature

MAP Sensor cable open or

MAP Sensor defective Replace IAT Sensor circuit open or shorted Correct or replace IAT Sensor defective Replace KS Circuit open or shorted Correct or replace KS defective Replace KS Module circuit open or shorted Correct or replace KS Module defective Replace Throttle valve not wide opened Check and correct or replace Air Cleaner Filter clogged Replace filter element Power supply voltage too low Check and correct or replace

Replace throttle valve assembly adjustment incorrect

Correct or replace open or shorted

Adjust or replace linkage

Correct or replace (MAP) Sensor circuit open or shorted

Correct or replace Sensor circuit open or shorted

Correct or replace shorted

Fuel tank strainer clogged Clean or replace

Replace leaking

Power supply or ground circuit for Multiport Fuel Injection System shorted or open

System disconnected or defective

open or shorted

Sensor circuit open or shorted

Sensor defective

shorted

Check and correct or replace

Correct or replace

Replace

Correct or replace

Page 9

Engine Lacks Power

Condition Possible cause Correction

Trouble in fuel system Fuel Pressure Control Valve not

Fuel injector clogged Clean or replace

Fuel pipe clogged Clean

Fuel filter clogged or fouled Replace

Fuel pump drive circuit not

Fuel tank not sufficiently breathing

Water in fuel system Clean

Inferior quality fuel in fuel system Use fuel of specified octane rating

Engine Control Module supplied

Throttle Position Sensor cable

Throttle Position Sensor defective Replace

Manifold Absolute Pressure

Intake Air Temperature sensor not

Engine Coolant Temperature

Engine Control Module defective Replace

Trouble in intake or exhaust system

Air duct kicked or flattened Correct or replace

Ignition failure

Heat range of spark plug

Electronic Ignition System with

ENGINE DIAGNOSIS (C24SE) 6-7

Replace working normally

Correct or replace working normally

Clean or replace due to clogged Evaporative Emission Control System circuit

Correct circuit poor voltage

Correct or replace disconnected or broken

Replace Sensor not working normally

Replace working normally

Correct or replace Sensor circuit open or shorted

Replace Sensor defective

Air Cleaner Filter clogged Replace filter element

inadequate

module

Refer to Hard Start

Troubleshooting Guide

Install spark plugs of adequate

heat range

Replace

Page 10

6-8 ENGINE DIAGNOSIS (C24SE)

Condition Possible cause Correction

Engine overheating Level of Engine Coolant too low Replenish

Thermo switch or fan motor

defective

Thermostat defective Replace

Engine Coolant pump defective Correct or replace

Radiator clogged Clean or replace

Radiator filter cap defective Replace

Level of oil in engine crankcase

too low or wrong oil in engine

Resistance in exhaust system

increased

Throttle Position Sensor

adjustment incorrect

Throttle Position Sensor circuit

open or shorted

Cylinder head gasket damaged Replace

Cooling Fan clutch defective Replace

Fan belt slipping Adjust tension of V-belt or replace

Engine overcooling Thermostat defective Replace (Use a thermostat set to

Engine lacks compression - Refer to Hard Start

Others Tire inflation pressure abnormal Adjust to recommend pressures

Brake drag Adjust

Clutch slipping Adjust or replace

Level of oil in engine crankcase

too high

Engine Noisy

Abnormal engine noise often consists of various noises originating in rotating parts, sliding parts and other moving parts of the engine. It is, therefore, advisable to locate the source of noise systematically.

Condition Possible cause Correction

Noise from crank journals or from crank bearings (Faulty crank journals and crank bearings usually make dull noise that becomes more evident when accelerating)

Crankshaft out of round Replace crank bearings and

Crank bearing seized Replace crank bearings and

Oil clearance increased due to worn crank journals or crank bearings

Replace

Change or replenish

Clean exhaust system or replace

defective parts

Adjust Wide Open Throttle switch

setting

Correct or replace

V-belt

open at 92°C (197.6°F))

Correct level of engine oil

Replace crank bearings and

crankshaft or regrind crankshaft

and install the over size bearing

crankshaft or regrind crankshaft

and install the over size bearing

crankshaft or regrind crankshaft

and install the over size bearing

Page 11

Abnormal Noise Due to Hydraulic Lash Adjuster

Should abnormal noise due to the hydraulic lash adjuster trouble be heard immediately after the engine is started, inspect as follows:

Condition Possible cause Correction

Abnormal noise is heard Air contaminated Bleed

HLA is spongy Check ball valve broken Repair

Safety valve in cylinder head

broken

Valve clearance is not zero HLA inside stick Replace HLA assembly

Troubleshooting Procedure

Short out each spark plug in sequence using insulated spark plug wire removers. Locate cylinder with defective bearing by listening for abnormal noise that stops when spark plug is shorted out.

Condition Possible cause Correction

Noise from connecting rods or from connecting rod bearings (Faulty connecting rods or connecting rod bearings usually make an abnormal noise slightly higher than the crank bearing noise, which becomes more evident when engine is accelerated)

Crankpin out of round Replace connecting rod bearings

Bearing or crankshaft pin worn Replace connecting rod bearings

Connecting rod bent Correct or replace

Connecting rod bearing seized Replace connecting rod bearings

Troubleshooting Procedure

Abnormal noise stops when the spark plug on the cylinder with defective parts is shorted out.

Condition Possible cause Correction

Piston and cylinder (Faulty piston or cylinder usually makes a combined mechanical thumping noise which increases when engine is suddenly accelerated but diminishes gradually as the engine warms up)

Piston seized Replace piston and cylinder body

Piston ring broken Replace piston and cylinder body

Piston defective Replace pistons and others

Piston clearance increased due to cylinder wear

ENGINE DIAGNOSIS (C24SE) 6-9

Replace

and crankshaft or regrind

crankshaft and install the under

size bearing

and crankshaft or regrind

crankshaft and install the under

size bearing

and crankshaft or regrind

crankshaft and install the under

size bearing

Replace piston and cylinder body

Page 12

6-10 ENGINE DIAGNOSIS (C24SE)

Troubleshooting Procedure

Condition Possible cause Correction

Piston pin noise (Piston makes noise each time it goes up and down)

Troubleshooting Procedure

The slapping sound stops when spark plug on bad cylinder is shorted out.

Condition Possible cause Correction

Timing belt noise Timing belt tension is incorrect Replace pusher or adjust the

Tensioner bearing defective Replace

Timing belt defective Replace

Timing wheels defective Replace

Timing belt comes in contact with

Valve noise Valve and valve guide seized Replace valve and valve guide

Valve spring broken Replace

Valve seat off-positioned Correct

Crankshaft noise Crankshaft end play excessive

Engine knocking Preignition due to use of spark

Fuel too low in octane rating Replace fuel

Wide Open Throttle enrichment

Selection of transmission gear

Engine overheating Refer to "Engine Lacks Power"

Others Water pump defective Replace

V-belt slipping Adjust tension of V-belt or replace

Piston pin or piston pin hole worn Replace piston, piston pin and

connecting rod assy

tension pulley or replace timing

belt

Replace timing belt and timing timing cover

(noise occurs when clutch is engaged)

plugs of inadequate heat range

system failure

incorrect

cover

Replace thrust bearing

Install Spark Plugs of adequate

heat range

Refer to Section 6E

Caution operator or incorrect gear

selection

V-belt

Page 13

Abnormal Combustion

Condition Possible cause Correction

Trouble in fuel injection system Fuel pressure control valve

Fuel filter clogged Replace

Fuel pump clogged Clean or replace

Fuel tank or fuel pipe clogged Clean or replace

Fuel injector clogged Clean or replace

Fuel pump relay defective Replace

Power supply cable for fuel pump

Manifold Absolute Pressure

Engine Coolant Temperature

ECT Sensor defective Replace

Throttle Position Sensor

Throttle Position Sensor defective Replace

Throttle Position Sensor

Vehicle Speed Sensor cable

Vehicle Speed Sensor loosely

Vehicle Speed Sensor in wrong

Engine Control Module cable

Trouble in emission control system

Heated Oxygen Sensor defective

Signal vacuum hose loosely fitted

ECT Sensor circuit open or

ECT Sensor defective Replace

Evaporative Emission Control

Trouble in ignition system - Refer to "Engine Lacks Power"

Trouble in cylinder head parts Carbon deposits in combustion

Carbon deposit on valve, valve

defective

loosely connected or defective

Sensor circuit open or shorted

Sensor defective

(ECT) Sensor circuit open or shorted

adjustment incorrect

connector loosely connected

loosely connected or defective

fixed

contact or defective

loosely connected or defective

Heated Oxygen Sensor circuit open (If applicable)

(If applicable)

or defective

shorted

system (If applicable)

chamber

seat and valve guide

ENGINE DIAGNOSIS (C24SE) 6-11

Replace

Reconnect, correct or replace

Correct or replace

Replace

Correct or replace

Reconnect

Correct or replace

Fix tightly

Replace

Correct or replace

Replace

Correct or replace

Refer to Section 6E

Remove carbon

Page 14

6-12 ENGINE DIAGNOSIS (C24SE)

Engine Oil Consumption Excessive

Condition Possible cause Correction

Oil leaking Oil pan drain plug loose Retighten or replace gasket

Oil pan setting bolds loosened Retighten

Oil pan gasket broken Replace gasket

Front cover retaining bolts loose

Head cover retaining bolts loose

Oil filter adapter cracked Replace

Oil filter attaching bolt loose or

Crankshaft front or rear oil seal

Oil pressure unit loose or broken Retighten or replace

Blow-by gas hose broken Replace hose

Engine/Transmission coupling

Oil leaking into combustion chambers due to poor seal in valve system

Valve stem or valve guide worn Replace valve and valve guide

Oil leaking into combustion chambers due to poor seal in cylinder parts

Piston ring gaps incorrectly

Piston rings set with wrong side

Piston rings sticking Rebore cylinder and replace

Piston ring and ring groove worn Replace pistons and others

Return ports in oil rings clogged Clean piston and replace rings

Crank case ventilation, Positive Crankcase Ventilation System malfunctioning

Others Improper oil viscosity Use oil of recommended S.A.E.

Continuous high speed driving

Retighten or replace gasket or gasket broken

Retighten or replace oil filter rubber gasket broken

Replace oil seal defective

Replace oil seal area

Valve stem oil seal defective Replace

Cylinders and pistons worn excessively

positioned

Positive Crankcase Ventilation Hose clogged

and or severe usage such as trailer towing

Rebore cylinder and replace

pistons and others

Correct

pistons and others

Clean

viscosity

Continuous high speed operation

and or severe usage will normally

cause increased oil consumption

Page 15

Fuel Consumption Excessive

Condition Possible cause Correction

Trouble in fuel system Mixture too rich or too lean due to

Fuel cut function does not act Refer to "Abnormal Combustion"

Trouble in ignition system Misfiring or abnormal combustion

Others Engine idle speed too high Reset Idle Air Control Valve

Returning of accelerator control

Fuel system leakage Correct or replace

Clutch slipping Correct

Brake drag Correct

Selection of transmission gear

Oil Problems

Condition Possible cause Correction

Oil pressure too low Wrong oil in use Replace with correct engine oil

Relief valve sticking Replace

Oil pump not operating properly Correct or replace

Oil pump strainer clogged Clean or replace strainer

Oil pump worn Replace

Oil pressure gauge defective Correct or replace

Crankshaft bearing or connecting

Oil contamination Wrong oil in use Replace with new engine oil

Oil filter clogged Replace oil filter

Cylinder head gasket damage Replace gasket

Burned gases leaking Replace piston and piston rings or

Oil not reaching valve system Oil passage in cylinder head or

Engine Oil Pressure Check

1. Check for dirt, gasoline or water in the engine oil.

a. Check the viscosity of the oil. b. Change the oil if the viscosity is outside the

specified standard.

c. Refer to the "Maintenance and Lubrication"

section of this manual.

2. Check the engine oil level. The level should fall somewhere between the "ADD" and the "FULL" marks on the oil level dipstick. If the oil level does not reach the "ADD" mark on the oil level dipstick, engine oil must be added.

trouble in fuel injection system

due to trouble in ignition system

sluggish

incorrect

rod bearing worn

cylinder body clogged

3. Remove the oil pressure unit.

4. Install an oil pressure gauge.

5. Start the engine and allow the engine to reach normal operating temperature (About 80°C).

6. Measure the oil pressure.

Oil pressure should be: 150 kPa(21.8 psi) at idle speed.

7. Stop the engine.

8. Remove the oil pressure gauge

9. Install the oil pressure unit.

10. Start the engine and check for leaks.

ENGINE DIAGNOSIS (C24SE) 6-13

Refer to "Abnormal Combustion"

Refer to Hard Start or Abnormal Combustion Troubleshooting Guide

Correct

Caution operator of incorrect gear selection

Replace

rebore cylinders

Clean or correct

Page 16

6-14 ENGINE DIAGNOSIS (C24SE)

Malfunction Indicator Lamp

The instrument panel "CHECK ENGINE" Malfunction Indicator lamp (MIL) illuminates by self diagnostic system when the system checks the starting of engine, or senses malfunctions.

Condition Possible cause Correction

"CHECK ENGINE" MIL does not illuminate at the starting of engine

MIL circuit open Correct or replace

Command signal circuit to operate

Engine Control Module (ECM)

ECM defective Replace

“CHECK ENGINE” MIL illuminates, and stays on

Heated oxygen sensor connector

Heated oxygen sensor lead wire

Heated oxygen sensor circuit

Deterioration engine coolant

Engine coolant temperature

Throttle position sensor open or

Deterioration of crankshaft

Crankshaft position sensor circuit

Vehicle speed sensor circuit open Correct or replace

Manifold absolute pressure sensor

Intake air temperature sensor

Fuel injector circuit open or shorted Correct or replace

ECM driver transistor defective Replace EPROM or ECM

Malfunctioning of ECM RAM

Bulb defective Replace

self diagnostic system shorted

cable loosely connected, disconnected or defective

Deterioration heated oxygen sensor of internal element

terminal improper contact (If applicable)

shorted (If applicable)

open (If applicable)

temperature sensor of internal element

sensor connector terminal improper contact

sensor lead wire shorted

sensor circuit open

shorted circuits

position sensor

open or shorted

circuit open or shorted

(Random Access Memory) or Malfunctioning of ECM PROM (Programmed Read Only Memory)

Correct or replace

Replace

Reconnect properly

Correct

Correct or replace

Replace

Reconnect properly

Correct

Correct or replace

Replace

Correct or replace

Replace EPROM or ECM

Page 17

ENGINE MECHANICAL (C24SE) 6A-1

SECTION 6A

ENGINE MECHANICAL

CONTENTS

PAGE

General Description......................................................................................................... 6A- 4

ENGINE PICTORIAL .................................................................................................... 6A- 6

Main Data and Specification ........................................................................................... 6A-11

CRANKCASE VENTILATION SYSTEM ....................................................................... 6A-16

ENGINE ASSEMBLY & LOOSE PARTS ..................................................................... 6A-17

OPERATIONS ON ENGINE AGGREGATES.................................................................... 6A-18

Engine Damping Blocks(Engine without Transmission)......................................... 6A-18

Toothed Belt and Timing Check ............................................................................... 6A-21

Toothed Belt Tension, Adjust .................................................................................... 6A-23

Toothed Belt, Replace ................................................................................................ 6A-24

OPERATIONS ON INSTALLED ENGINE ......................................................................... 6A-26

Gasket, Exhaust Manifold, Cylinder Head ................................................................ 6A-26

Gasket, Intake Manifold, Cylinder Head .................................................................... 6A-26

Seal Ring, Camshaft Housing, Timing Side.............................................................. 6A-27

Seal Ring, Thermostat Housing, Cylinder Head ....................................................... 6A-27

Seal Ring - Front Camshaft Housing, Replace ......................................................... 6A-28

Toother Belt Rear Cover............................................................................................. 6A-30

Toother Belt Tension Roller ....................................................................................... 6A-31

COMPONENT PARTS ...................................................................................................... 6A-32

Cylinder Head .............................................................................................................. 6A-32

Hydraulic Valve Lifter.................................................................................................. 6A-33

OPERATIONS ON CYLINDER HEAD AND CAMSHAFT HOUSING ............................... 6A-34

Camshaft...................................................................................................................... 6A-34

Camshaft Housing Removal and Installation ........................................................... 6A-35

Cylinder Head .............................................................................................................. 6A-35

Hydraulic Valve Lifers, Replace ................................................................................. 6A-37

Camshaft Housing, Replace....................................................................................... 6A-37

Page 18

6A-2 ENGINE MECHANICAL (C24SE)

PAGE

Camshaft Housing, Check for Plance Surface ......................................................... 6A-39

Cylinder Head, Removal and Installation.................................................................. 6A-39

Cylinder Head, Disassemble and Assemble............................................................. 6A-42

Valve, Grind ................................................................................................................. 6A-44

Valve Guide, Ream ..................................................................................................... 6A-44

Valve Seating, Mill....................................................................................................... 6A-45

Cylinder Head, Overhaul............................................................................................. 6A-45

Flywheel....................................................................................................................... 6A-46

Starter Ring Gear(Manual Transmission) ................................................................. 6A-47

Seal Ring, Crankshaft ................................................................................................. 6A-48

Seal Ring, Crankshaft Rear ........................................................................................ 6A-48

Oil Pan and Bearing Bridge........................................................................................ 6A-49

OPERATIONS ON CRANK DRIVE ................................................................................... 6A-51

Con-Rod Bearing......................................................................................................... 6A-51

Piston with Con-Rod................................................................................................... 6A-51

Con-Rod ....................................................................................................................... 6A-52

Pistion Rings ............................................................................................................... 6A-53

OPERATIONS ON REMOVED ENGINE ........................................................................... 6A-55

Crankshaft ................................................................................................................... 6A-55

Bearing Free Play Measurement................................................................................ 6A-57

Plastigage Method ...................................................................................................... 6A-57

Micrometer and gauge method.................................................................................. 6A-58

Bypass Valve ............................................................................................................... 6A-59

Oil Filter ....................................................................................................................... 6A-59

Oil Pump ...................................................................................................................... 6A-59

Oil Pump Safety Valve ................................................................................................ 6A-60

Oil Pump(Overhaul) .................................................................................................... 6A-60

OPERATIONS ON OIL CIRCULATION ............................................................................ 6A-61

Cylinder Head Safety Valve ........................................................................................ 6A-61

OPERATIONS ON COOLING SYSYTEM ......................................................................... 6A-63

Cooling System, Check for Leakes ........................................................................... 6A-63

Cooling System, Fill Up and Bleed ............................................................................ 6A-63

Refill Coolant ............................................................................................................... 6A-64

Ignition Timing, Check................................................................................................ 6A-64

Page 19

ENGINE MECHANICAL (C24SE) 6A-3

PAGE

ENGINE EXTERNAL PARTS............................................................................................ 6A-65

Radiator ....................................................................................................................... 6A-65

Thermostat................................................................................................................... 6A-66

Water Pump ................................................................................................................. 6A-66

Coating sealing surfaces with Silicone Grease ....................................................... 6A-67

Alternator ..................................................................................................................... 6A-67

Starter .......................................................................................................................... 6A-67

V-belt Tension of Alternator ....................................................................................... 6A-68

FUEL INJECTION SYSTEM.............................................................................................. 6A-69

Map Sensor.................................................................................................................. 6A-69

Pressure Regulator ..................................................................................................... 6A-69

ECM (Engine Control Module).................................................................................... 6A-69

ECT............................................................................................................................... 6A-70

Idle Air Control(IAC) Valve.......................................................................................... 6A-70

Ignition Coil ................................................................................................................. 6A-70

Crank Position Sensor................................................................................................ 6A-71

FUEL INJECTOR .............................................................................................................. 6A-72

Knock Sensor.............................................................................................................. 6A-72

Oxygen Sensor............................................................................................................ 6A-73

Throttle Valve Position Sensor .................................................................................. 6A-73

Acclelerator Pedal and Cable..................................................................................... 6A-73

Air Cleaner Filter ......................................................................................................... 6A-74

Spark Plug Thread ...................................................................................................... 6A-75

TECHNICAL DATA ........................................................................................................... 6A-76

Recommended Troque Values................................................................................... 6A-87

SPECIAL SERVICE TOOL................................................................................................ 6A-88

Page 20

6A-4 ENGINE MECHANICAL (C24SE)

GENERAL DESCRIPTION

Engine Cleanliness And Care

An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the thousandths of a millimeter (ten thousandths of an inch). Accordingly, when any internal engine parts are serviced, care and cleanliness are important. Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically stated. l A liberal coating of engine oil should be applied to all friction areas during assembly to protect and lubricate

the surfaces on initial operation.

l Whenever valve train components, pistons, piston rings, connecting rods, rod bearings, and crankshaft journal

bearings are removed for service, they should be retained in order.

l Battery cables should be disconnected before any major work is performed on the engine. Failure to

l The four cylinders of this engine are identified by numbers; cylinders 1, 2, 3 and 4, as counted from crankshaft

General Information on Engine Service

The following information on engine service should be noted carefully, as it is important in preventing damage and

t the time of installation, they should be installed in the same locations and with the same mating surfaced as

when removed.

disconnect cables may result in damage to wire harness or other electrical parts.

pulley.

Page 21

ENGINE MECHANICAL (C24SE) 6A-5

contributing to reliable engine performance: l When raising or supporting the engine for any reason, do not use a jack under the oil pan. Due to the small

clearance between the oil pan and the oil pump strainer, jacking against the oil pan may cause damage to the oil pick up unit.

l The 12-volt electrical system is capable of damaging circuits. When performing any work where electrical

terminals could possible be grounded, the ground cable of the battery should be disconnected at the battery.

l Any time the intake air duct or air cleaner is removed, the intake opening should be covered. This will protect

against accidental entrance of foreign material into the cylinder which could cause extensive damage when the engine is started.

Cylinder Block

The cylinder block is made of cast iron. The crankshaft is supported by five bearings. The bearing cap is made of nodular cast iron.

Cylinder Head

The cylinder head is made of aluminum alloy casting with a spark plug in the center.

Valve Train

Valve system is a single over head camshaft. The valves clearance adjustment are hydraulic. Hydraulic valve lifter adjustment, no adjustment necessary.

Intake Manifold

The intake manifold is made of aluminum alloy.

Exhaust Manifold

The exhaust manifold is made of high Si-Mo nodular iron.

Pistons and Connecting Rods

Aluminum pistons are used after selecting the grade that meets the cylinder bore diameter. Each piston has two

compression rings and one oil ring. The piston pin is made of cast hardened steel. The connecting rod bearings are made of modular cast iron. The connecting rod bearings are made of steel backed with tri-metal babbitt metal.

Crankshaft and Bearings

The crank shaft is made of modular cast iron. Pins and journal are graded for correct size selection for their bearing.

Page 22

6A-6 ENGINE MECHANICAL (C24SE)

ENGINE PICTORIAL

Front View

“4WD OIL PAN”

Page 23

Inlet Side View

ENGINE MECHANICAL (C24SE) 6A-7

“4WD OIL PAN”

Page 24

6A-8 ENGINE MECHANICAL (C24SE)

Rear View

“4WD OIL PAN”

Page 25

Exhaust Side View

ENGINE MECHANICAL (C24SE) 6A-9

“4WD OIL PAN”

Page 26

6A-10 ENGINE MECHANICAL (C24SE)

Top View

Page 27

Main Data and Specifications

Engine - General C24SE

Engine type Four-cycle, water cooled cross-flow with single over head

Combustion chamber type (Volume) Hemispherical (43.3cm3)

Timing train system Belt drive

No. of cylinders-bore ´ stroke mm (in) 4-87.5´100.0 (3.44´3.93)

Bore Spacing(C/L to C/L) 93.0 mm (3.66 in)

Firing Order 1-3-4-2

Bore´Stroke mm (in) 87.5´100.0 (3.44´3.93)

Total piston displacement cm3 (in3) 2,405(146.80)

Combustion Chamber Volume 43.3cm3

No. of piston ring Compression ring: 2, Oil ring: 1

Compression pressure kg/cm2 (psi/pa) 12.2-16.3 (174-232/1200-1600)

Ignition timing (BTDC) No adjustment

Idling speed: rpm(WO/AC,W/AC) A/C off 825

Valve clearances (At cold)

Intake mm (in) 0 (0) (Hydraulic valve lash adjustment)

Exhaust mm (in) 0 (0) ( " )

Open at (BTDC) deg 17°30’

Close at (ABDC) deg 76°30’

Exhaust valves

Open at (BBDC) deg 58°30’

Close at (ATDC) deg 35°30’

Ignition system Fully transistorized battery ignition

Distributor type Not applicable, Electronic Spark Timing control

Distributor advance type Not applicable, Electronic Spark Timing control

Spark plug type RN9YC4

Spark plug gap mm (in) 1.0--1.1 (0.039--0.043)

Lubrication system

Lubricating method Fully flow pressure circulation

Special engine oil (API grade) SE, SF, SG or SH grade

Oil pressure kg/cm2 (psi/Pa) rpm 4-4.6 (56.9-65.4/400-450)

Oil pump type Gear

Oil filter type Cartridge full flow

Oil capacity lit. (US/UK gal.) 4.25

Cooling system

Radiator type Corrugated fin with reserve tank

Coolant capacity lit. (US/UK gal.)

Water pump type Centrifugal

Thermostat Wax pellet with jiggle hole

ENGINE MECHANICAL (C24SE) 6A-11

camshaft

Micro-computer control, fuel injection

2.3 (0.66/0.55)

Page 28

6A-12 ENGINE MECHANICAL (C24SE)

Engine - General C24SE

Fuel system Electronically controlled Multi Port Fuel Injection System

Fuel pump type Electric

Fuel pressure kg/cm2 (psi/Pa) 3.4 (48.4/334)

Fuel filter type Cartridge paper element

Air cleaner type Dry paper element

Battery Type/V-Ax No. of units 34B19L/50D20L

Alternator

Capacity V-A(W) 12-90 (1080), 12-100 (1200)

Starter

Output V-kW 1.4

Exhaust system CO Adjustment (1) Applicable to Open Loop System (Not equipped H2OS)

(2) Not applicable to Closed Loop System (Equipped H2OS)

Compression Ratio (with Tolerance) 9.6:1±0.25

Cylinder Head Material Aluminum Alloy (gravity cast)

Cylinder Block Material Cast Iron

No. of Mounting Points (including trans.) 3

Engine Installation Angles

Overall Dimensions (L ´´´´ W ´´´´H):

Engine Weight

Camshaft Type SOHC

No. of Valves per Cylinder

Spark Plug Location Side

Port Arrangement Cross Flow

Working Principle Spark Ignition 4-stroke

4° 60'

-Longitudinal

-Lateral 7° 50' (towards exhaust side)

- TF (2.4Litre/2WD) 610´564´708mm

- TF (2.4Litre/4WD) 610´564´746mm

140kg

- TF (2.4Liter/Man)

- Inlet

- Exhaust 1

Page 29

Valve System C24SE

Actuation Type Direct-acting Inverted Bucked Tappet

Valve Clearance Adjustment Hydraulic

Valve Rotor Type None

Inlet-Valve Material Chromium Alloyed Steel

Exhaust-Valve Material Head: Cr-Mn-Ni Alloyed Shaft: Cr-Si Alloyed &Cr plated

Valve Spring Material GME 06 100-C1

Valve Guide Material QS 13 MR 00

Valve Seal Type Lip

Water Pump C24SE

Type Centrifugal

Drive-Material &Type HNBR Toothed-belt

Bearing Type Double Row Ball

Shaft Seal Type Mechanical Ceramic

Thermostat-Coolant C24SE

Type Bypass

Oil Pump & Filter C24SE

Type Gear Pump

Location Front of Engine

Drive Direct Crankshaft Driven

Filter Type Full Flow with Bypass for blocked filter

Reservoir-Description & Location 1-piece below Engine

Reservoir Material Aluminum Alloy (pressure cast)

Recommended Oil-Run-in 10W/30SG

Oil Classification API&CCMC

Spark Plugs Conventional

Type Electronic Spark Control

No. of Coils &Type 2 Solid State

Coil Location Engine-mounted

Ignition Lead Type Inductive (hi-resistance)

Oil & Oil Reservoir C24SE

Replacement Oil Fill Volume

Ignition Components C24SE

ENGINE MECHANICAL (C24SE) 6A-13

-Seat Insert Material Sintered Iron

-With Filter change 4.25liters

-Without Filter change 4.00liters

-Service (above-18°C) 10W/40SG

-Service (below-18°C) 5W/30SG

Page 30

6A-14 ENGINE MECHANICAL (C24SE)

Crankshaft C24SE

Material Nodular Cast Iron

Bearing subjected to End Thrust Guide Bearing NO.3

Main Bearing-Material &Type Steel Backed Tri-metal Babbitt

Front Seal-Diameter &Type 35.0mm Lip Seal

Rear seal-Diameter &Type 90.0mm Micro-lip Seal

Crankshaft Balancing Individually Balanced

No. of Counterweights 8

Camshaft C24SE

Location Overhead (Cylinder Head)

Material Grey Cast Iron

Bearing Material Aluminum

No. of Bearings Camshaft Drive-Material &Type

Pistons C24SE

Material Aluminum Alloy

Finish & Type Tin-coated Strutless

Piston Rings

Function (top to bottom)

-Ring 1

-Ring 2 Compression Ring

-Ring 3 Oil Ring

Description -Ring 1 Rectangular

-Ring 2 Taper Face

-Ring 3 3-piece (2 Scrapers&1 Expander)

Material -Ring 1 Molybdenum Inlay Nodular Cast Iron

-Ring 2 Cast Iron (individually cast)

-Ring 3 Steel

Material Case Hardened Steel

Retention Locked in Rod

Bearing Machined in Piston Pin Boss

Connecting Rod C24SE

Material Nodular Cast Iron

Bearing-Material &Type Steel Backed Tri-metal Babbitt

Inlet Manifold C24SE

Material Aluminum Alloy

Exhaust Manifold C24SE

Description Dual Take-down

Material High Si-Mo Nodular Iron

200-250 HB5/750

(Camshaft drive type: toothed belt

Camshaft drive material: rubber composite GD380)

Compression Ring

Page 31

ENGINE MECHANICAL (C24SE) 6A-15

Engine Specification Matrix for destination

04 HEO FOR TF MODEL:

VEHICLE MODEL TFR/S

Major Description AUSTRALIA, CHILE,

GULF, NEW

ZEALAND, SAUDI

ARABIA, SOUTH

AFRICA

VEHICLE TYPE 4´2 4x4 4´2 4´4 4´2

VEHICLE IDENT. CODE TX TY TX TY TX

ENGINE TYPE C24SE ¬ ¬

FUEL CONTROL SYSYTEM CLOSE LOOP CLOSED LOOP OPEN LOOP

COMPRESSION RATIO 9.6:1 ¬ ¬

FUEL OCTANE(ROD) 91RON 85RON 80RON

FUEL TYPE UN-LEADED UN-LEADED LEADED

HO2 YES YES YES NO

EVAP CANISTER YES YES YES YES

PURGE CONTROL SOLENOID

CHECK & RELIEF VALVE YES YES YES YES

ECM YES YES YES YES

EXHAUST SYSTEM

FRONT PIPE

SILENCER

TWC YES YES YES NO

CO ADJUSTMENT NO NO NO YES

Refer to 6A-77 Refer to 6A-77 Refer to 6A-77

YES

COLOMBIA, COSTA

RICA, EQUADOR,

YES YES YES

2.4L

GUATEMALA

BOLIVIA, GENERAL

EXPORT, PERU,

VENEZUELA

Page 32

6A-16 ENGINE MECHANICAL (C24SE)

CRANKCASE VENTILATION SYSTEM

The Engine Ventilation System passes crankcase vapours, via the Engine Vent Pipe, to the Cam Support Cover, where separation of oil and exhaust gases occur. The oil drains into the Cylinder Head, via the Camshaft Support. The gases pass through the Primary and Secondary Vent Hoses to the intake system, and are consumed during the combustion process.

Page 33

ENGINE MECHANICAL (C24SE) 6A-17

ENGINE ASSEMBLY & LOOSE PARTS

Loose Parts

1 Alternator 2 P/S Pivot Spacer 3 P/S Adjusting Screw 4 P/S Adjusting Plate 5 P/S Adjusting Nut 6 Alternator & Fan Drive Belt 7 A/C Compressor Drive Belt 8 P/S Pump Drive Belt 9 Tensioner Bolt

10 Tensioner Pulley 11 Pulley Dust Shield Cover 12 Pulley Spacer 13 A/C Compressor Bracket 14 Pulley Bolt 15 Fan Pulley 16 Cooling Fan

Engine Assembly

20 C24SE

Page 34

6A-18 ENGINE MECHANICAL (C24SE)

OPERATIONS ON ENGINE AGGREGATES

Engine Damping Blocks (Engine Without Transmission)

Removal

1. Remove bonnet.

2. Remove radiator.

3. Remove air inlet hose.

4. Remove power steering pump drive belt and power steering pump from engine.

5. Remove all cable connections, hoses and lines from engine.

6. Remove accelerator cable from inlet pipe.

7. Remove exhaust pipe from manifold.

8. Remove lower nine bolts and transmission from engine block.

9. Remove clutch slave cylinder and allow to hang free.

10. Remove starter from engine block.

11. Remove upper bolts of left and right engine mounting from damping blocks.

12. Raise engine slightly.

13. Remove lower bolts of left and right damping blocks.

14. Remove damping blocks.

Page 35

ENGINE MECHANICAL (C24SE) 6A-19

Attach engine to cable, support transmission with car jack and remove upper transmission fastening bolt.

Press off engine from transmission and lift out of engine compartment.

Installation

Lower engine into engine compartment and insert guide bushings on cylinder block into transmission.

Tighten (Torque)

Transmission to cylinder block (M10) -45 N×m (4.6 kgf×m) Transmission to cylinder block (M12) -60 N×m (6.1 kgf×m)

Installation

1. Install engine to vehicle and transmission.

2. Install clutch slave cylinder.

Tighten (Torque)

Transmission to engine block bolts - 76 N×m (7.6 kgf×m)

RTW46AS H000401

3. Install left engine damping block to sidemember.

4. Install left and right engine damping blocks to engine brackets.

Tighten (Torque)

Engine damper block to sidememebr - 50 N×m (5.1 kgf×m) Engine damper block to engine bracket - 85 N×m (8.6 kgf×m)

5. Install exhaust pipe to manifold.

Page 36

6A-20 ENGINE MECHANICAL (C24SE)

6. Install power steering pump and V-belt.

Adjust

Adjust power steering pump V-belt tension according to the corresponding operation.

Installation

7. Install radiator according to the corresponding operation.

8. Install air inlet hose.

9. Install all electrical cable connections, hoses and lines to engine.

10. Install accelerator cable from inlet pipe.

11. Install bonnet.

Inspection

1. Check engine oil level.

2. Fill up cooling system and bleed according to the corresponding operation.

Page 37

ENGINE MECHANICAL (C24SE) 6A-21

Toothed Belt and Timing Check

Removal

1. Remove the belts on the bracket for alternator.

2. Remove the fan.

3. Remove the V-belt for power steering.

4. Remove the V-belt for A/C.

5. Remove the fan belt.

6. Remove the fan shroud.

7. Remove the crankshaft pulley while counterholding on the fastening bolt of toothed belt drive gear.

8. Remove the toothed belt from cover.

Inspection

1. Turn the crankshaft in the engine rotational direction mark(2) so that the notch (1) on the camshaft gear aligns with the mark on toothed belt rear cover.

2. Check the timing belt for worn, cracks or oil adhesion.

3. Check that the cast on the water pump aligns with the counterpart on cylinder block (arrowed).

4. The tension of a toothed belt is correctly adjusted when the pointer and the center of the notch are aligned(I). The tension of a run-in toothed belt (regardless of mileage covered) is correctly adjusted when the pointer is positioned approx. 4mm (0.16 in.) to the left of the center of the notch(II). Check the condition of the run-in toothed belt for suitability for reuse. Only toothed belts of the toothed belt tension rollers must be replaced and the source of oil contamination must be eliminated.

Page 38

6A-22 ENGINE MECHANICAL (C24SE)

Installation

1. Install the toothed belt to the cover.

2. Install the crankshaft pulley while counterholding on the fastening bolt of toothed belt drive gear.

3. Install the fan shroud.

Tighten(Torque)

Crankshaft pulley bolts - 20 N×m (2.1 kgf×m)

4. Install the fan belt

5. Install the V-belt for A/C.

6. Install the V-belt for power steering.

7. Install the fan.

8. Install the belts on the bracket for alternator.

Page 39

ENGINE MECHANICAL (C24SE) 6A-23

Toothed Belt Tension, Adjust (Engines with toothed belt tension roller)

Removal

Refer to 6A-21. Toothed Belt and Timing check and removal steps.

Adjust

1. Loosen the fastening bolt of the toothed belt tension roller.

2. Turn the toothed belt tension roller at adjustment eccentric (1) in the direction of arrow (counterclockwise), until pointer (2) comes to the right stop.

3. If necessary tighten the fastening bolt of toothed belt tension roller.

4. Rotate the crankshaft twice (720°) in the engine rotational direction until marks (2) and (1) align again.

5. Turn the eccentric in the direction of arrow (clockwise) until pointer (1) and notch (2) are positioned to suit age of toothed belt.

6. Rotate the crankshaft twice (720°) in the engine rotational direction again and correct adjustment if necessary.

Installation

Refer to 6A-21. Toothed Belt and Timing check and installation steps.

Page 40

6A-24 ENGINE MECHANICAL (C24SE)

Toothed Belt, Replace (Engine with toothed belt tension roller)

Removal

1. Remove the belts on the bracket for alternator.

2. Remove the fan.

3. Remove the V-belt for power steering.

4. Remove the V-belt for A/C.

5. Remove the fan belt.

6. Remove the fan shroud.

7. Remove the crankshaft pulley while counterholding on the fastening bolt of toothed belt drive gear.

8. Remove the toothed belt from cover.

Adjust

Turn the crankshaft in the engine rotational direction to mark(2). Align markings on toothed belt and on toothed belt rear cover. Simultaneously, notch (1) on camshaft gear must align with the mark on toothed belt rear cover. Turn the crankshaft slowly and smoothly.

Page 41

ENGINE MECHANICAL (C24SE) 6A-25

Adjust

Loosen the fastening bolt of the toothed belt tension roller and turn the adjustment eccentric in the direction of arrow (clockwise) until pointer (1) comes to the left stop. Remove the toothed belt.

Installation

1. Install a new toothed belt while keeping tension side taut.

Adjust

Toothed belt tension - see operation " Toothed Belt Tension".

2. Install the toothed belt to the cover.

3. Install the crankshaft pulley while counterholding on the fastening bolt of toothed belt drive gear.

4. Install the fan shroud.

5. Install the fan belt.

6. Install the V-belt for A/C.

7. Install the V-belt for power steering.

8. Install the fan.

9. Install the belts to the bracket for alternator.

Page 42

6A-26 ENGINE MECHANICAL (C24SE)

OPERATIONS ON INSTALLED ENGINE

SEALING OPERATIONS

Gasket, Exhaust Manifold, Cylinder Head

Removal

1. Remove front exhaust pipe from exhaust manifold.

2. Remove exhaust manifold heat shield.

3. Remove exhaust manifold retaining nut.

4. Remove exhaust manifold from cylinder head.

Clean

Sealing surfaces.

Tighten (Torque)

Exhaust manifold to cylinder head - 22 N×m (2.2 kgf×m) Front exhaust pipe to exhaust manifold - 25 N×m (2.6 kgf×m)

Gasket, Intake Manifold, Cylinder Head

Removal

1. Remove air intake hose.

2. Remove drive belt for alternator.

3. Remove bolt clamping bracket for alternator from intake manifold.

4. Remove intake manifold from cylinder head.

Clean

Sealing surfaces

Tighten (Torque)

Intake manifold to cylinder head - 22 N×m (2.2 kgf×m) Clamping bracket for alternator to intake manifold - 25 N×m (2.5 kgf×m)

Installation

1. Install V-belt according to the corresponding operation.

2. Install air intake hose.

Page 43

ENGINE MECHANICAL (C24SE) 6A-27

Seal Ring, Camshaft Housing, Timing Side

Removal

1. Remove front toothed belt cover toothed belt from camshaft timing gear according to the corresponding operation.

2. Remove camshaft housing cover and camshaft timing gear.

3. Remove sealing ring by making hole in middle of ring, turning in self-tapping screw and edging out.

Installation

1. Install sealing ring by using 5-8840-0451-0 with camshaft sprocket bolt and washer.

2. Install coat seal lips of shaft seal ring slightly.

Seal Ring, Thermostat Housing, Cylinder Head

Removal

1. Open radiator drain tap and collect coolant.

2. Remove toothed belt rear cover and toothed belt according to the corresponding operation.

3. Remove camshaft housing cover.

4. Remove camshaft timing gear by counterholding camshaft with a flat spanner.

5. Remove cable from temperature sensor.

6. Remove upper inner hex bolts of rear toothed belt cover.

7. Turn rear toothed belt cover to one side.

8. Remove thermostat housing.

9. Remove sealing ring from cylinder head.

Clean

Sealing surfaces in cylinder head and thermostat housing.

Installation

1. Install sealing ring in recess of cylinder head.

Page 44

6A-28 ENGINE MECHANICAL (C24SE)

2. Install cable to temperature sensor.

3. Install upper bolts of rear toothed belt rear cover.

4. Install camshaft timing gear then check timing according to the corresponding operation.

5. Install camshaft housing cover.

6. Install toothed belt and front cover.

7. Fill up and bleed cooling system according to the corresponding operation.

Tighten (Torque)

Thermostat housing to cylinder head - 15 N×m/1.5 kgf×m.

Seal Ring - Front Camshaft Housing, Replace

Removal

Mark running direction of toothed belt. Remove toothed belt-see operation “Toothed Belt, Replace”.

Camshaft housing cover, camshaft pulley-counterhold on hex of camshaft.

Removal

Screw self-tapping screw into seal ring.

Edge out seal ring.

Installation

Lightly coat sealing lip of seal ring with protective grease.

Install seal ring with 5-8840-0451-0 into camshaft housing-use screw and washer of camshaft pulley.

Page 45

ENGINE MECHANICAL (C24SE) 6A-29

Installation

Camshaft pulley-counterhold at hex head of camshaft, camshaft housing cover.

Toothed belt-see operation “Toothed Belt, Replace”. Note operating erection of toothed belt.

Tighten (Torque)

Camshaft pulley to cammshaft-45 N×m (3.7 kgf×m)

Tighten (Torque)

Camshaft housing cover to cover to housing-8 N×m (0.8 kgf×m)

Page 46

6A-30 ENGINE MECHANICAL (C24SE)

Toothed Belt Rear Cover (Engine with toothed belt tension roller)

Removal

1. Mark operating direction of toothed belt.

2. Remove toothed belt according to the operation "Toothed Belt".

3. Remove toothed belt tension roller according to the operation "Toothed Belt Tension Roller ".

4. Remove fastening bolt while counterholding with 5-88402598-0 (Holding wrench).

5. Remove toothed belt drive gear while counterholding with 5-8840-2598-0 (Holding wrench).

6. Remove camshaft housing cover.

7. Remove camshaft pulley while counterholding at hex head of camshaft.

8. Remove toothed belt rear cover (arrows) from oil pump and camshaft housing.

Page 47

ENGINE MECHANICAL (C24SE) 6A-31

Installation

1. Install toothed belt rear cover.

2. Install camshaft pulley while counterholding at camshaft hex head.

3. Install camshaft housing cover.

Tighten (Torque)

Toothed belt rear cover to oil pump and camshaft housing - 6 N×m/4 lbf ft. Camshaft housing cover to housing - 6 N×m (0.6 kgf×m). Camshaft pulley to camshaft - 45 N×m (4.6 kgf×m).

4. Install toothed belt drive gear to crankshaft - 130 N×m (13.3 kgf×m).

5. Install toothed belt according to the operation "Toothed Belt".

Toothed Belt Tension Roller

Removal

1. Mark operating direction of toothed belt.

2. Remove toothed belt according to the operation "Toothed Belt”.

3. Remove toothed belt tension roller (1) from oil pump.

Installation

1. Install toothed belt tension roller and make sure that the locking lever (1) engages in the guide lugs (arrowed) on the oil pump housing.

2. Install toothed belt according to the operation "Toothed Belt" with paying attention to the operating direction of toothed belt.

Tighten (Torque)

Toothed belt tension roller to oil pump - 25 N×m (2.5 kgf×m)

Page 48

6A-32 ENGINE MECHANICAL (C24SE)

COMPONENT PARTS

CYLINDER HEAD

1. Camshaft Housing Cover

2. Camshaft Housing

3. Camshaft

4. Cylinder Head

(A) Valve Drive

(A)

Page 49

ENGINE MECHANICAL (C24SE) 6A-33

HYDRAULIC VALVE LIFTER

1. Hydraulic Valve Lifter

1. Oil reservoir

2. Piston with ball head (moving)

3. Pressure cylinder (fixed)

4. Check ball

5. Pressure chamber

6. Oil feed

Page 50

6A-34 ENGINE MECHANICAL (C24SE)

OPERATIONS ON CYLINDER HEAD AND CAMSHAFT HOUSING

Camshaft

Removal

1. Remove cylinder head according to the corresponding operation.

2. Remove camshaft housing from cylinder head and lay housing on base provided

3. Remove rear sealing gasket and plate camshaft housing with taking care not to damage housing.

4. Remove thrust plate.

5. Remove camshaft.

6. Remove front sealing gasket and plate from camshaft housing with taking care not to damage housing.

Inspection

All parts.

Installation

1. Install camshaft.

2. Coat sliding surfaces with molybdenum disulphate paste.

Tighten (Torque)

Thrust plate for camshaft housing - 8 N×m (0.8 kgf×m)

Page 51

ENGINE MECHANICAL (C24SE) 6A-35

Camshaft Housing, Removal and Installation

Cylinder Head

Important!

Remove cylinder head only from cold engine (room temperature).

Removal

1. Remove ground cable from battery.

2. Open radiator drain tap and collect coolant.

3. Remove air intake hose.

4. Remove all cable connections, hoses and lines to the cylinder head.

5. Remove accelerator cable on the throttle valve.

6. Remove V-belt for alternator.

7. Remove front toothed belt cover according to the corresponding operation.

8. Bring piston of 1st cylinder to TDC and mark the position.

9. Remove camshaft housing cover.

10. Remove camshaft timing gear after releasing tension on toothed belt.

11. Remove upper bolts of rear toothed belt cover.

12. Remove exhaust pipe from exhaust manifold.

13. Remove cylinder head after loosening bolts from outside inwards (at first quarter turn then half turn) in a spiral pattern.

14. Remove camshaft housing from cylinder head.

15. Remove rocker arm, pressure parts and hydraulic valve lifter adjuster.

Page 52

6A-36 ENGINE MECHANICAL (C24SE)

Clean

All sealing surfaces, drill holes in cylinder head bolts.

Check cylinder block and cylinder head for plane surface according to the corresponding operations.

Installation

1. Install cylinder head sealing with marking "OBEN/TOP" facing upwards and to right side of engine.

2. Install cylinder head on cylinder block.

3. Install hydraulic valve lash adjuster, pressure parts and rocker arm - molybdenum disulphate paste.

4. Install camshaft housing-Sealing Compound TB-1207C or equivalent.

Important!

Use new cylinder head bolts. Screw in bolts until they rest on cover.

Torque - Angle Method

Cylinder head to cylinder block - 25 N×m (2.5 kgf×m) Further turn angle 90°+90°+ 90°. Tighten cylinder head bolts from inside outwards. In four stages in a spiral pattern.

5. Install rear toothed belt cover onto camshaft housing.

6. Install toothed belt and apply tension according to the corresponding operation.

Tighten (Torque)

Camshaft timing gear to camshaft - 45 N×m (4.6 kgf×m)

7. Install camshaft housing cover and front toothed belt cover.

8. Install cable connections, all hoses and lines onto cylinder head.

9. Adjust accelerator cable for free of play.

10. Install V-belt according to the corresponding operation.

11. Install air intake hose.

12. Install front exhaust pipe.

13. Install ground cable onto battery.

14. Fill up cooling system and bleed according to the corresponding operation.

Page 53

ENGINE MECHANICAL (C24SE) 6A-37

Hydraulic Valve Lifters, Replace

Removal

1. Remove the spark plug connectors and spark plugs.

2. Remove the camshaft housing cover.

Removal

3. Turn the crankshaft at fastening bolt of toothed belt drive gear in the direction of the engine rotation until the cam of hydraulic valve lifter being replaced stands vertically.

Removal

4. Apply 5-8840-0457-0 to the camshaft housing, valve spring cap and tension valve spring.

Removal

5. Remove the cam follower from camshaft housing.

Note thrust pieces.

6. Remove hydraulic valve lifter from camshaft housing.

Camshaft Housing, Replace

Removal

Cylinder head-see operation “Cylinder Head. Remove and Install”.

Page 54

6A-38 ENGINE MECHANICAL (C24SE)

Inspection

All parts, if necessary replace.

When replacing camshaft, always replace all cam followers.

Installation

Insert hydraulic valve lifter (1) in camshaft housing.

Coat sliding surfaces of rocker arm with Mcs, Paste and insert in camshaft housing.

Adjust

Adjustment of the hydraulic valve liters is not required. Pretension is provided by the design.

Installation

1. Remove 5-8840-0457-0 and install the camshaft housing cover.

2. Insert the spark plug connectors.

Tighten (Torque)

Guide plate to camshaft housing. Insert camshaft with MoS

paste.

Installation

1. Install the front seal ring in camshaft housing with 5-8840-0451-0.

2. Install the camshaft housing rear cover.

3. Install the cylinder head.

Page 55

ENGINE MECHANICAL (C24SE) 6A-39

Camshaft Housing, Check for Plane Surface

Clean

Sealing surfaces.

Inspection

Check length and width of sealing surface for deformation and diagnosis for warpage and use straight edge feeler gauge.

Measure

Height of camshaft housing (sealing surface to sealing surface). Dimension I: (74.0 mm)

Cylinder Head, Removal and Installation

Important

Only remove cylinder head with engine cold (room temperature).

Removal

1. Remove the alternator, power steering and V-belts.

Removal

2. Loosen the fastening bolts from alternator.

3. Loosen the lower alternator fastening bolt by swinging the alternator to the rear.

Removal

4. Remove the front toothed belt cover.

5. Remove the toothed belt from camshaft pulley.

See operation "Timing Check and Adjust".

Page 56

6A-40 ENGINE MECHANICAL (C24SE)

Removal

6. Remove the camshaft housing cover and camshaft pulley by counter-holding at the hex head of camshaft.

Removal

7. Remove the fastening bolts from camshaft housing.

Removal

8. Remove the exhaust pipe from exhaust manifold.

9. Loosen the cylinder head bolts spirally from the outside inwards (first 1/4, then 1/2 revolution).

Removal

1. Remove the camshaft housing from cylinder head.

2. Remove the cam followers, thrust pieces and hydraulic valve lifters.

Note the allocation.

3. Remove the cylinder head.

Clean

Sealing surfaces, bores and threads of cylinder head bolts.

Inspection

Check cylinder head and cylinder block for plane surfface-see operations “Cylinder Head, Check for Plane Surface” and “Cylinder Block, Check for Plane Surface.”

Page 57

ENGINE MECHANICAL (C24SE) 6A-41

Installation

1. Install the cylinder head gasket.

Mark "OBEN/TOP" on top and turn it towards timing side

of engine.

2. Place cylinder head on cylinder block.

1 2 3

Installation

1. Insert the hydraulic valve lifters (3), thrust pieces (2) and cam followers (1) with MoS2 paste.

Note allocation.

2. Apply a bead of Sealing Compound TB1207C to sealing surface of cylinder head.

3. Install the camshaft housing on cylinder head.

Torque-Angle Method

Cylinder head and camshaft housing with new cylinder head bolts to cylinder block.

Cylinder head bolts in sequence shown.

Installation

1. Install the rear toothed belt cover to camshaft housing.

2. Install the camshaft pulley to camshaft.

3. Install the camshaft housing cover to housing.

Installation

1. Install the toothed belt on camshaft pulley.

See operation "Timing Adjust".

2. Install the front toothed belt cover.

Page 58

6A-42 ENGINE MECHANICAL (C24SE)

Installation

1. Install the fastening bolts.

2. Loosen the lower alternator fastening bolt.

3. Install the alternator, power steering and V-belts.

Cylinder Head, Disassemble and Assemble

Removal

1. Remove the hydraulic valve lifters.

Lay aside in installation positions.

2. Remove the spark plugs, exhaust manifold and intake manifold from cylinder head.

Removal

1. Mark valves.

2. Remove the tension valve springs with 5-8840-2594-0 (1).

3. Remove valve keepers, valve spring cap and valve spring.

Removal

1. Remove the valve and valve stem seal.

2. Remove the valve spacer ring (1-exhaust) and valve spring seat (2-intake).

3. Remove valve from cylinder head.

Clean

Sealing surfaces.

Page 59

ENGINE MECHANICAL (C24SE) 6A-43

Inspection

Sealing surfaces for plane surface, guides, sliding and bearing points for wear-see operation “Cylinder Head. Overhaul”.

Installation

1. Coat the valves with engine oil and insert in cylinder head.

2. Install the valve spacer ring or valve rotator(exhaust) and valve spring seal(intake).

3. Push the accompanying assembly sleeve onto valve stem and coat with engine oil.

4. Insert a new valve stem seal with 5-8840-2601-0 (1).

5. Drive the valve stem seal carefully in to stop with light hammer blow.

Installation

1. Install the valve springs and valve spring caps.

2. Install the tension valve springs with 5-8840-2594-0 (1), valve keeper.

Important!

Note markings made on valves.

Tighten (Torque)

Exhaust manifold and intake manifold with new gaskets to cylinder head.

Thermostat housing with new seal ring to cylinder head:

Tighten (Torque)

Spark plugs with spark plug wrench to cylinder head.

Installation

1. Coat hydraulic valves lifters (1) with oil.

2. Insert them in cylinder head.

Note installation position.

Page 60

6A-44 ENGINE MECHANICAL (C24SE)

Valve, Grind

Valves can be reused once or twice after regrinding-only if there are no crater-like burns on the valve cone. Excessive grinding can cause the upper valve head edge to become too thin.

Important!

Valve stem protection must not exceed dimension “A”-use 58840-2596-0. Do not regrind valve stem ends.

For all valve reworking note that angle of valve head is 44°and the valve seat 45°-see also “Technical Data”.

Valve, Grind In

Grind-In the valve to improve valve seating. Grind-In by rhythmically lifting valves and turning uniformly. Use commercially available grinding tool.

Important!

Use only fine-grained pastes for grinding. Lubricate valve stem before grinding in.

Clean

After grinding, carefully clean valve and valve soat.

Valve Guide, Ream

Measure

Diameter of valve guide-dial gauge and internal measuring instrument.

Important!

Valve oversizes are available ex-works. Oversize identification, on the valve guide and on the valve stem end with the following specified identificaton flgures/letters-see also “Technical Data”.

Identification Mark

Size Production Customer Service Reamer

Normal none K

0.075 mm 1 K1

0.150mm 2 K2

Ream valve guide from the upper side of the cylinder head to the next oversize (use 5-8840-2599-0). After reaming, cross out identification mark and stamp in new identification mark.

Page 61

ENGINE MECHANICAL (C24SE) 6A-45

Valve Seating, Mill

Place cylinder head on block of wood. Inlet and exhaust, Guide Drift and Valve Seat Cutter 5-88402593-0. Valve seat-45°, side face, upper correction-30°, side face (arrows on cutter). Valve seat width:

Inlet-1.0 to 1.5 mm/0.04 to 0.06 in. Exhaust-1.7 to 2.2 mm/0.072 to 0.088 in.

Inspection

Valve stem projection-use 5-8840-2596-0.

Important!

If dimension “A” is exceeded, use new valves. Check valve stem projection again. If dimension “A” is exceeded, replace cylinder head.

Cylinder Head, Overhaul

Cylinder head disassembled.

Valve, Grind

Important!

Ensure that there are no crater-like burns on the valve cone.

Regrinding possible once or twice. Grinding of valve stem end is not permitted.

Angle at valve head-44°

Inspection

Check valve stem projection as shown 5-8840-2596-0.

Valve, Grind in

Lubricate valve stem, use fine-graining grinding paste.

Lift up valve from seat rythmically using valve grinding tool (1) for distribution of grinding paste.

Page 62

6A-46 ENGINE MECHANICAL (C24SE)

Inspection

Check contact pattern (I) on valve seat and in cylinder head.

Clean

Valves, valve guides, cylinder head.

Flywheel

Removal

1. Remove transmission and clutch.

2. Remove flywheel while locking with 5-88400-446-0.

Torque - Angle Method

Flywheel to crankshaft - 65 Nm/6.5 kgf×m.+30° to 45°

Important!

Use new bolts. Do not apply grease to the thread.

Installation

1. Install clutch and transmission.

Component Parts

Flywheel and Ring gear. (Manual Transmission)

Page 63

ENGINE MECHANICAL (C24SE) 6A-47

Starter Ring Gear (Manual Transmission)

Removal

1. Remove flywheel according to the corresponding operation.

2. Drill starter ring gear underneath tooth gap approx. 8mm/0.30in. deep with 8mm/0.25in. diameter drill.

3. Separate starter ring gear with chisel on the drilling point.

Installation

1. Install starter ring gear with inner chamfered edge to flywheel.

2. Heat starter ring gear evenly to 180°C /356°F to 230°C /446°F (yellow paint mark)

3. Install flywheel according to the corresponding operation.

Inspection

Lateral run-out of starter ring gear - max. 0.5mm/0.02in.

Page 64

6A-48 ENGINE MECHANICAL (C24SE)

Seal Ring, Crankshaft (Oil Pump Housing)

Removal

1. Remove toothed belt rear cover according to the corresponding operation.

2. Remove sealing ring by making hole in middle of ring, turning in self-tapping screw and edging out.

Installation

1 Install the protective sleeve to the crankshaft.

2. Coat the sealing lip with protective grease.

3. Install the sealing ring.

4. Install the sealing ring using 5-8840-0455-0.

5. Install the rear toothed belt cover and toothed belt according to the corresponding operations.

6. Replace the sealing ring with a new one.

7. Tighten the belt to the crankshaft.

Seal Ring, Crankshaft Rear

Removal

1. Remove transmission and clutch.

2. Remove flywheel or flex plate according to the corresponding operations.

3. Make hole in middle of sealing ring, turn in self-tapping screw and edge out.

Installation

1. Install protective sleeve.

2. Coat sealing lip with Protective Grease.

3. Install sealing ring using 5-8840-0459-0 and 5-88402597-0.

4. Install flywheel, clutch and transmission.

Page 65

ENGINE MECHANICAL (C24SE) 6A-49

Reassembly

Reassemble clutch assembly.

Disassembly

Disassemble clutch assembly to flywheel using 5-8840-2634-0

Torque Angle-Method

Clutch assembly to flywheel-17.6Nm/1.8 kgfm.

Oil Pan and Bearing Bridge

Removal

1. Remove the crossmember.

2. Shift downward the power steering unit (and front axle [4´4 model only]).

3. Loosen fixing bolts.

4. Remove oil pan from oil pump and cylinder block.

RTW46AS H002801

5. Remove oil intake pipe, oil intake pipe bracket, and oil baffle plate.

6. Remove the bearing bridge.

Page 66

6A-50 ENGINE MECHANICAL (C24SE)

Clean

Sealing surfaces.

013RW004

Installation

1. Apply a bead of Sealing Compound, TB120TC or eguivalent to joint of oil pump.

2. Apply the recommended light gasket to the oil pan fitting surface as shown in the illustration.

3. Install the bearing bridge.

4. Install baffle plate, or reuse baffle plate.

Caution

Baffle plates can be retrofitted without difficulty - replace baffle plate.

5. Install oil intake pipe to oil pump and oil intake pipe bracket to cylinder block.

6. Install oil pan and new gasket to cylinder block and insert bolts with Locking Compound 15 10 177 (90 167 347). Maximum assembly time including torque check is 10 min.

7. Return the power steering unit (and front axle [4´4 model only]).

8. Install the crossmember.

Tighten (Torque)

Oil intake pipe to oil pump -8N×m (0.8 kgf×m) Oil intake pipe bracket to cylinder block - 6 N×m (0.6 kgf×m) Oil pan to cylinder block - 8 N×m (0.8 kgf×m) Bearing bridge to cylinder block – 8 N×m (0.8 kgf×m)

Page 67

ENGINE MECHANICAL (C24SE) 6A-51

OPERATIONS ON CRANK DRIVE

Con-Rod Bearing

Removal

1. Remove oil pan and bearing bridge according to the corresponding operation.

2. Remove con-rod bearing cap and con-rod bearing after marking both sides.

Clean

Con-rod journal, con-rod bearing cap

Installation

1. Install new bearing shafts lightly coated with engine oil.

2. Install con-rod bearing cap.

Torque-Angle Method

Con-rod bearing cap to con-rod - 35N×m (3.5 kgf×m) +45° to 60°

Important!

Use new bolts.

3. Install oil pan and bearing bridge according to the corresponding operation.

Piston with Con-Rod

Removal

1. Remove cylinder head and oil pan according to the corresponding operations.

2. Remove piston with con-rod after marking con-rod bearing cap.

Inspection

Remove and install all parts, if applicable.

Important!

Ring gap offset: Piston rings - 180°. Oil scraper rings - 25 to 50 mm/1 to 2 in. from gap of intermediate ring to the left and to the right.

Page 68

6A-52 ENGINE MECHANICAL (C24SE)

Installation

1. Install piston with con-rod by inserting with engine oil.

2. Coat piston rings with engine oil and compress with piston ring compressor.

Important!

Installation position: Arrow / notch on piston head on timing side of engine Beads on con-rod on clutch side

Torque-Angle Method

Piston to cylinder block. Con-rod bearing cap to con-rod-35N×m (3.5 kgf×m) +45° to 60°

Important!

Use new bolts.

Installation

1. Install oil pan and cylinder head according to the corresponding operations.

2. Install sealing Gasket or replace if damaged.

3. Install camshaft housing to cylinder head.

4. Install cylinder head according to the corresponding operation.

Con-Rod

Removal

1. Remove piston with con-rod according to the corresponding operation.

2. Disassemble con-rod piston assembly by pressing out piston pin, using 5-8840-0468-0.

Installation

1. Slide guide drift (5-8840-0468-0) in horizontal position through piston and con-rod as far as side plate stops.

2. Tighten bolts evenly so that the piston rests flush on the rear plate.

3. Remove centre piece from guide drift and insert piston bolts (lubricated) into guide drift.

Page 69

ENGINE MECHANICAL (C24SE) 6A-53

4. Heat a new con-rod to 280°C in the oil bath.

5. Install the con-rod to the piston and insert the piston pin.

Important!

Since the con-rods have no weight balancing studs, re-working is not possible. Exchange con-rods in sets only. Installation position, beads on con-rod point to the flattening on the piston pin eye. Firmly seated piston pin cannot be pushed in. Carry out installation quickly.

Piston Rings

Removal

1. Remove piston with con-rod according to the corresponding operation.

2. Remove piston rings using commercially available ring installer or piston ring clamp pliers.

Clean

Piston ring grooves - ground piece of old piston ring

Inspection

Piston ring gap For piston ring sizes, permissible piston ring gaps - see "Technical Data"

Page 70

6A-54 ENGINE MECHANICAL (C24SE)

RTW46AS H002401

Installation

1. Install oil scraper ring.

2. Offset ring gaps of steel band rings each 25 to 50 mm/1 to 2in. to the left or right of the intermediate ring gap.

3. Install piston rings.

4. Offset ring gaps by approx. 180°.

5. Install second piston ring with identification mark "TOP" facing upwards.

6. Install piston with con-rod according to the corresponding operation.

Page 71

ENGINE MECHANICAL (C24SE) 6A-55

OPERATIONS ON REMOVED ENGINE

Crankshaft

Removal

1. Mount the engine on an engine overhaul stand with appropriate adapters.

2. Remove the aggregates, flywheel/drive disc, oil pan, bearing bridge and oil pump according to the corresponding operation.

3. Mark the con-rod bearing cover.

4. Remove the crankshaft bearing cover.

5. Remove the crankshaft from cylinder block.

Inspection

Remove and install all parts if necessary.

Crankshaft pulse pickup sensor rotor inspection and repair. Inspect the crankshaft pulse pickup sensor rotor for excessive wear and damage. Replace the crankshaft pulse pickup rotor if the inspection results exceed wear and damage limits.

Installation

1. Install the crankshaft pulse pickup sensor. Torque: 13Nm (1.3 kgfm)

2. Install new bearing shells into the cylinder block and bearing cover.

3. Coat the bearing shafts with engine oil. For oversizes-see “Technical Data”

4. Install a new crankshaft into the cylinder block.

Note

The sealing of the crankshaft can be corrected with light blows with a rubber hammer on the crank arm (arrowed).

Page 72

6A-56 ENGINE MECHANICAL (C24SE)

5. Apply a bead of sealant (TB-1207C or equivalent) in the grooves of both bearing shells.

Important!

After installation of bearing cover, press in sealing compound again from above, until compound emerges at the joints.

Torque - Angle Method

Bearing cover to cylinder block - 50 N×m (5.1 kgf×m) +40° to 50° Con-rod bearing cover to con-rod - 35 N×m (3.5 kgf×m) +45° to 60°. Use new bolts.

6. Install oil pump, oil pan, bearing bridge rear crankshaft sealing, flywheel/drive plate, and aggregates according to the corresponding operations.

Inspection

Bearing play - bearing cover removed

Measure

With "Plastigage" (ductile plastic threads) Cut threads to length of bearing width and lay axiaity between crankshaft journal and bearing shell (arrowed). Install bearing cover with correct torque.

Important!

Grease crankshaft journal and lubricate bearing shell slightly so that the thread does not tear when the bearing cover is moved.

Crankshaft

Inspection

End play when bearing shells are installed. Front end contact surfaces of flywheel/flexible plate. Permissible end play - see "Technical Data "

Page 73

ENGINE MECHANICAL (C24SE) 6A-57

Inspection

Out-of-round (run-out)-middle bearing shell removed when mounting on front and rear bearing. Permissible out-of-round - see "Technical Data"

Bearing Free Play Measurement

Two methods for measuring bearing free play are described -

1. Plastigage method and 2. micrometer and gauge method.

The two procedures are suitable for measuring both con-rod and main bearing free play. For both methods ensure con-rod and main bearing caps are identified (1) prior to removal as they are machine matched.

1.Plastigage Method

Removal

1. Remove bearing cap and shell.

2. Lightly coat journals and bearings with engine oil to prevent Plastigage from tearing when cap is removed.

Installation

1. Lay a length of Plastigage across width of crank pin and fit bearing cap and shell using old bolts at this stage.

Important!

Do not allow crankshaft to rotate.

Torque - Angle Method

Main bearing cap bolt - 60 N×m (6.1 kgf×m) +40° + to 50°. Con-rod bearing cap bolts - 35 N×m (3.6 kgf×m) +45°.

Removal

1. Remove bearing cap and shell.

Measure

Width of Plastigage -use scale supplied with Plastigage.

If con-rod bearing clearance exceeds 0.031mm/0.001in or main journal bearing clearance exceeds 0.04mm/0.02in. check crankshaft journal diameters - see corresponding operation. Replace bearing if crankshaft is within specification - see "Technical Data"

Page 74

6A-58 ENGINE MECHANICAL (C24SE)

Clean

Plastigage from journals.

Lightly coat journals and bearings with engine oil.

Installation

Install bearing cap and shell using new bolts.

Torque - Angle Method

Main bearing cap bolt - 60 N×m (6.1 kgf×m) +40° to 50°. Con-rod bearing cap bolts - 35 N×m (3.9 kgf×m) +45°.

2.Micrometer and gauge method.

Crankshaft removed.

Installation

1. Install caps and bearing shells to con-rods and cylinder block.

Measure

Con-rod and main bearing diameters at three points I, II, III (arrowed). Divide the sum of the three measurements by three to obtain a mean diameter.

The top illustration shows con-rod measuring points. The second illustration shows main bearing measuring points.

Measure

Crankshaft main and con-rod bearing journals at points I and II. Divide the sum of both measurements to obtain a mean diameter.

Crankshaft must be replaced if mean diameter of main or conrod journals is below specified limit - see "Technical Data".

If crankshaft is serviceable subtract crankshaft mean journal diameters from corresponding shell bearing mean diameters to determine bearing clearance.

Permissible main bearing clearance - 0.015 to 0.04mm/0.0006 to 0.002in. Permissible con-rod bearing clearance - 0.006 to

0.031mm/0.002 to 0.001in.

Page 75

ENGINE MECHANICAL (C24SE) 6A-59

Bypass Valve

Removal

1. Remove oil filter.

2. Remove bypass valve by cutting thread in locking disc with M 10 tap (3rd stage), turning in M 10 bolt and taking out bypass valve from seating.

Installation

1. Install bypass valve using drift (diameter approx. 15mm/0.6in.).

Oil Filter

Removal

1. Remove oil filter using commercially available tool.

Installation

1. Install oil filter by hand and oil seal ring.

2. Fill up engine oil while preventing overflow.

Oil Pump

Removal

1. Remove rear toothed belt cover, and oil pan according to the corresponding operations.

2. Remove oil filter, wiring plug from oil pressure switch, oil pump from cylinder block, and oil pressure switch from oil pump.

Clean

Sealing surfaces

Installation

1. Install oil pressure switch to oil pump, oil pump to cylinde block, oil pan, bearing bridge wiring plug, oil filter and toothed belt cover.

Tighten (Torque)

Oil pressure switch to oil pump - 30 N×m (3.2 kgf×m) Oil pump to cylinder block - 6 N×m (0.6 kgf×m) Oil intake pipe to oil pump - 8 N×m (0.8 kgf×m) Intake pipe bracket to cylinder block - 8 N×m (0.8 kgf×m) *Insert bolts with Locktite (Refer to General Description Recommended Liguid Gasket)

Page 76

6A-60 ENGINE MECHANICAL (C24SE)

Oil Pump Safety Valve

Removal

1. Remove closure plug.

2. Remove seal ring.

3. Remove spring.

4. Remove piston.

Installation

1. Install piston (observe installation position).

2. Install spring.

3. Install seal ring.

4. Install closure plug.

Tighten (Torque)

Closure plug - 30 N×m (3.0 kgf×m)

Oil Pump (Overhaul)

Removal

1. Remove oil pump according to the corresponding operation.

2. Remove oil cover and pressure control valve.

Inspect

Clearance between gear pair and housing upper edge - see “Technical Data”. Check housing, cover and pressure control valve.

Installation

1. Install pump cover with Sealing Compound 15 03 166 (90 094 714).

2. Install oil pump safety valve according to the corresponding operation.

3. Install oil pump according to the corresponding operation.

Page 77

ENGINE MECHANICAL (C24SE) 6A-61

OPERATIONS ON OIL CIRCULATION

Cylinder Head Safety Valve

Removal

1. Remove cylinder head according to the corresponding operation.

2. Make hole in core plugs with pointed drift, turn in self tapping screw and edge out.

Important!

Cover oil duct in cylinder head with piece of cloth.

3. Pull out valve retainer, using commercially available tool.

4. Remove ball and spring.

5. Cut three threads in the ball seating with M 10 tap (3rd stage).

6. Coat tap with grease.

7. Remove ball seating from cylinder head with commercially available tool.

Do not damage cylinder head.

Page 78

6A-62 ENGINE MECHANICAL (C24SE)

Installation

1. Install new pressure valve into cylinder head - with suitable pipe until stop.

2. Install core hole plugs into cylinder head - with suitable pipe to end of chamfer.

Page 79

ENGINE MECHANICAL (C24SE) 6A-63

OPERATIONS ON COOLING SYSTEM

Caution!

Before working with the cooling system, be sure to confirm that the temperature of the engine is cooled down. Failure to observe this may cause burn.

Cooling System, Check for Leaks

Installation

1. Install commercially available coolant checking instrument onto compensation tank (Refer to section 6B; Engine cooling).

2. Check coolant level.

Inspection

Use 5-8840-0277-0 tester & 5-8840-2603-0 adaptor.

Cooling System, Fill Up and Bleed

Important!

Radiator and heater core are made from alminium. To avoid corrosion, use only anti-freeze with corrosion protection.

Replace Coolant

1. Confirm the engine is cold enough.

2. Open the radiator cap, pour coolant to the filler neck level and close the cap.

3. Pour coolant into the reservoir until MAX line is reached.

4. Start the engine, run 2 ~ 3 minutes at idling speed and switch off the engine.

5. Refill coolant if the coolant level is lowered.

Page 80

6A-64 ENGINE MECHANICAL (C24SE)

Important!

Do not loosen or open the radiator cap when coolant is hot. Doing so may cause hot water or steam to splash out, resulting in burn. When opening the radiator cap, be sure to confirm the coolant is cold. Cover a thick cloth over the cap and loosen it slowly to reduce pressure, then open the cap.

6. Close the radiator cap firmly and run the engine at approx. 2000 rpm. In addition, set the heater temperature adjuster to the max position to circulate coolant in the heater conduit system.

7. Confirm that the temperature gauge reads half or more of full scale and that the thermostat is activated. Then continue idling 5 minutes more and switch off the engine, and allow it to cool.

8. After the engine cools down, check the coolant level and refill it if necessary. When the level is lowered extremely, check the coolant conduit system and reservoir hose for leak.

9. Pour coolant into the reservoir to MAX level.

Refill Coolant

Important!

After closing the cooling system, let engine run warm until thermostat opens (coolant approx. 92°C/197.6F)

Inspection

Coolant level Allow engine to cool. If necessary, refill coolant.

Check that cooling system self-bleeds during engine warmingup phase.

Ignition Timing, Check

No Adjustment

Page 81

ENGINE MECHANICAL (C24SE) 6A-65

ENGINE EXTERNAL PARTS

Radiator

Removal

1. Disconnect battery ground cable.

2. Loosen a drain plug to drain EC.

3. Disconnect radiator inlet hose and outlet hose from the engine.

4. Remove fan guide(1), clips(2) on both sides and the bottom lock, then remove lower fan guide(3) with fan shroud(4).

5. Disconnect the reserve tank hose(6) from radiator.

RTW46BS H000101

6. Remove bracket(5).

RTW36BM H000101

7. Lift up and remove the radiator assembly with hose, taking care not to damage the radiator core with a fan blade.

Page 82

6A-66 ENGINE MECHANICAL (C24SE)

Installation

Follow the removal procedure in the reverse order to install the radiator.

Thermostat

Removal

1. Remove water outlet nozzles with thermostat from thermostat housing.

2. Remove coolant hose and collect coolant.

Important!

Remove and Install thermostat only together with water outlet nozzles.

Tighten (Torque)

Water outlet nozzles to thermostat housing - 8 N×m (0.8 kgf×m)

Installation

1. Install coolant hose.

2. Fill cooling system and bleed according to the corresponding operation.

Water Pump

Removal

1. Remove lower hose band from pipe band and collect coolant.

2. Remove front toothed belt cover according to the corresponding operation.

3. Remove water pump from cylinder block after releasing tension on toothed belt.

Clean

Sealing surfaces

Page 83

ENGINE MECHANICAL (C24SE) 6A-67

Coating sealing surfaces with Silicone Grease

Installation

1. Install water pump to cylinder block with new rubber Oring.

2. Apply tension to toothed belt according to the corresponding operation.

3. Install coolant hoses.

4. Fill cooling system and bleed according to the corresponding operation.

Alternator

Removal

1. Remove ground cable from battery.

2. Remove cable connection from alternator and V-belt.

3. Remove alternator from retaining strap and lower fastening.

Installation

1. Install alternator by tightening firmly by hand.

2. Install V-belt and apply tension according to the corresponding operation.

3. Install cable connections to alternator.

4. Install ground cable to battery.

Starter

Removeal

1. Remove cable connections from starter.

2. Remove upper bolt of transmission side.

3. Remove lower bolt of engine side.

Tighten (Torque)

Starter to cylinder block: Engine side - 51 N×m (5.2 kgf×m) Transmission side - 75 N×m (7.6 kgf×m)

Starter support to cylinder block - 25 N×m (2.5 kgf×m)

Re-connect cables.

Page 84

6A-68 ENGINE MECHANICAL (C24SE)

V-belt Tension of Alternator

Measure

Measure V-belt tension of alternator. Permitted values for new V-belt are approx. 311-489N (31-50 kgf). Note: V-belt to deflection as loaded with 10kg : 8-12mm.

Adjust

Adjust V-belt tension by loosening clamping bracket and lower alternator bracket and moving alternator.

Tighten (Torque)

Clamping bracket to alternator - 35 N×m (3.6 kgf×m) Lower alternator bracket - 25 N×m (2.6 kgf×m)

V-Belt Tension of Power Steering Pump

Measure

Measure V-belt tension of power steering pump. Permitted values for new belt are approx. 578-712N (59-73 kgf) and 534667N (54-68 kgf) for used belt. Note: V-belt to deflection as loaded with 10kg : 8-12mm.

Adjust

Adjust V-belt tension by loosening clamping bolt, lower pump bracket, and adjusting nuts and moving steering pump.

Tighten (Torque)

Adjusting nuts - 18 N×m (1.8 kgf×m) Clamping bolt - 25 N×m (2.6 kgf×m) Lower pump bracket - 26 N×m (2.6 kgf×m)

Page 85

ENGINE MECHANICAL (C24SE) 6A-69

FUEL INJECTION SYSTEM

MAP SENSOR

Removal

1. Disconnect the battery cable.

2. Disconnect the electrical connector from the sensor.

3. Remove the mounting bolts securing the sensor to the manifold.

4. Remove the sensor from the intake manifold.

Installation

1. Push MAP sensor into the manifold.

2. Install the mounting bolts and tighten them.

3. Connect electrical connector.

4. Connect the battery cable.

Pressure Regulator

Removal

1. Remove vacuum hose.

2. Remove fuel hoses.

3. Remove pressure regulator.

Installation

1. Install pressure regulator.

2. Install fuel hoses.

3. Install vacuum hoses.

ECM (Engine Control Module)

Removal

(2.4L)

1. Disconnect the ECM connector.

2. Remove the four hex bolts and nuts.

3. Remove the ECM from the ECM bracket on engine.

Page 86

6A-70 ENGINE MECHANICAL (C24SE)

(2.4L)

1. Install the ECM to the ECM bracket on engine.

2. Tighten the four screws to the bracket.

3. Connect the connector.

ECT

Removal

Installation

1. Remove wiring harness plug and coolant temperature sensor.

Tighten (Torque)

Temperature sensor to intake pipe - 10 N×m (1.0 kgf×m) Wiring harness plug to temperature sensor

Inspection

Coolant level

Idle Air Control (IAC) Valve

Removal

1. Remove wiring harness plug, hose clamps and idle speed adjuster.

Installation

1. Install idle speed adjuster, hose clamps and wiring harness plug.

Ignition Coil

Removal

1. Remove 2 bolts, plug and ignition coil.

Installation

1. Install ignition coil, plug and bolts.

Page 87

ENGINE MECHANICAL (C24SE) 6A-71

Crank Position Sensor

Removal

1. Remove crank position sensor.

Installation

1. Install crank position sensor.

Page 88

6A-72 ENGINE MECHANICAL (C24SE)

FUEL INJECTOR

Removal

Caution: To reduce the risk of fire and personal injury, it is necessary to relieve the fuel system pressure before servicing the fuel system components.

Caution: After relieving the fuel system pressure, a small amount of fuel may be released when servicing fuel lines or connections. Reduce the chance of personal injury by covering the fuel line fitting with a shop towel before disconnecting the fittings. The towel will absorb any fuel that may leak out. When the disconnect is completed, place the towel in an approved container.

1. Depressurize the fuel system.

2. Disconnect the fuel inlet.

3. Disconnect the fuel return line.

4. Remove the fuel rail from the intake manifold.

5. Remove the fuel injector from the fuel rail by disengaging claws.

Installation

1. Install the fuel injector to the fuel rail by engaging claws.

2. Install the fuel rail to the intake manifold.

3. Connect the fuel return line firmly.

4. Connect the fuel supply line firmly.

Knock sensor

Removal

1. Remove fixing bolts.

2. Disconnect the connector at the other side.

Tighten (Torque)

Oxygen sensor in exhaust pipe - 30N×m (3.2 kgf×m) When re-using, insert oxygen sensor.

Page 89

ENGINE MECHANICAL (C24SE) 6A-73

Oxygen Sensor (If applicable)

Removal

1. Remove wiring harness plug.

2. Remove oxygen sensor from the front exhaust pipe.

Tighten (Torque)

Oxygen sensor in exhaust pipe - 30 N×m (3.1 kgf×m)

Throttle Valve Position Sensor

Removal

1. Remove wiring harness connector.

2. Remove throttle valve position sensor.

Installation

1. Install throttle valve position sensor.

2. Install wiring harness connector.

Accelerator Pedal and Cable

Removal

1. Remove pad stopper from pedal stop bolt.

Installation

1. Install pad stopper.

Inspection

Ensure that accelerator pedal is fully in idle position and accelerator level at engine is in closed position.

Pull outer sleeve of accelerator cable towards pedal and check that clip on sleeve is in slot nearest to grommet.

Reposition clip if necessary, and check that full throttle and idle positions are obtained at engine lever.

Page 90

6A-74 ENGINE MECHANICAL (C24SE)

RTW46JSH00 0101

Air Cleaner Filter

NOTE: The air cleaner filter is not damaged with the edge of the air cleaner housing.

Removal

(2.4L)

1. Remove air cleaner cover and air cleaner element.

2. Remove air intake nose.

3. Remove lower air cleaner.

4. Remove mud guard.

5. Remove front fender cover.

6. Remove outside air intake duct.

Inspection

Check the air cleaner filter for damage or dust clogging. Replace if it is damaged, or clean if it is clogged.

130RW002

Cleaning Method

Tap the air cleaner filter gently so as not to damage the paper filter, or clean the element by blowing with compressed air of about 490 kPa (71 psi) from the clean side if it is extremely dirty.

Installation

(2.4L)

1. Install outside air intake duct.

2. Install front fender cover.

3. Install mud guard.

4. Install lower air cleaner.

5. Install air intake hose.

6. Install air cleaner element and air cleaner cover.

Page 91

ENGINE MECHANICAL (C24SE) 6A-75

Spark Plug Thread

Recondition

Ream thread and recut using commercially available spark plug thread drill (observe manufacturer's instructions).

Removal

Remove thread bush on spark plug. (dimensions (A) = 17mm/0.67in.)

Tighten (Torque)

Spark plug with thread bush into cylinder head - 25N×m (2.5 kgf×m) - use.

Page 92

6A-76 ENGINE MECHANICAL (C24SE)

TECHNICAL DATA

SOHC Gasoline Engine C24SE

Engine Oil Viscosity

The following engine oils can be used: A = single-grade oils B = multigrade oils C = easy run oils depending on the outside temperature.

Engine Oil Quality

It is important that the following API and CCMC classes are used:

Engines Single and multigrade oils Easy run oils

Petrol API-SF/CC, SF/CD, SG/CC,

SG/CD, CCMC/G4

Important!

CD engine oils designed by manufacturers specially for diesel engines are not suitable for petrol engines, unless a sufficient performance class for petrol engines (e.g. API-SF/CCMC-G4) is also indicated.

Disposal.

API-SF/CC, SF/CD, SG/CD

CCMC-G5/PD2

Observe the relevant national regulations when disposing of

*Up to mark "MAX" on oil dipstick

used oil.

Engine Oil Filling Quantities

Engine Model Initial filling

(litres)

2.4L 4.80 4.25 1.00

Oil Pump

Backlash 0.1 to 0.2mm Gaps in gears opposite housing 0.03 to 0.1mm Oil pressure at idle speed Engine at operating

450 - 500 kpa Oil drain plug M14 ´ 1.5

Filling quantity

with filter change*

(litres)

temperature (>70°C oil and approx. 80°C coolant)

MIN to MAX

(litres)

Page 93

ENGINE MECHANICAL (C24SE) 6A-77

Cooling System

Radiator

Type: Cross-flow

Radiator core surface in cm

: 2000

Cooling system capacity (in litres): 7.2

Anti-freeze Mixture

Required

Quantity

(in litres) Water

7.2 5.7 1.5 4.7 2.5 4.0 3.2 3.4 3.8

Up to-10°°°°C

Quantity in litres

(80%)

Anti-

Freeze

(20%)

Up to-20°°°°C

Quantity in litres

Water

(66%)

Anti-

Freeze

(34%)

Up to-30°°°°C

Quantity in litres

Water

(56%)

Anti-

Freeze

(44%)

Up to-40°°°°C

Quantity of litres

Water

(48%)

Anti-

Freeze

(52%)

Cooling System (continued)

Fan

Type Visco Clutch Fan Number of blades 5 Distribution of blades asymmetric Diameter mm

Radiator cap

Boiling point 123°C Opening pressure kPa (bar) 120 to 135 (1.20 to 1.35)

Thermostat

Start of opening 92°C Fully opened 107°C Type Bypassed

Idle Speeds, CO Content, Ignition Adjustment

Applicable System Idle speed in min-1 (rpm)

Manual

Closed Loop System 825 *<0.4 *** 8 to 12

Open Loop System 825

Note) * CO content adjustment not applicable. ** CO content adjustment refer to Section 6E1 (W/O catalytic converter system) *** Ignition timing adjustment not possible.

CO content

in vol. %

+0.2

**1.0

-0.5

Ignition timing in CA BTDC (adjustment

ensues at able speed,

ignition marks must align) with TDC

sensor measuring instrument:

*** 8 to 12

Page 94

6A-78 ENGINE MECHANICAL (C24SE)

Adjustment Values/Checking Values

Valve clearance

Inlet Hydraulic valve lash adjustment Outlet No adjustment necessary

Spark plugs - electrode gap 1.0 ~ 1.1mm

Compression The difference in compression

between the individual cylinders in the engine must not exceed 100 kPa (1 bar).

Pressure loss The pressure loss of an engine

in perfect condition per cylinder is not more than max. 25%

Cylinder Head

Cylinder Head Gasket Thickness - installed mm 1.2

Valve seat width at cylinder head inlet mm 1.0 to 1.5 outlet mm 1.7 to 2.2

Valve stem play inlet mm 0.018 to 0.052 outlet mm 0.038 to 0.072

Permissible valve stem to cone runout inlet mm 0.03 outlet mm 0.33

Overall height of cylinder head (Sealing surface to sealing surface) mm 95.5 ± 0.25

Installation height inlet and outlet valves mm 17.85 to 18.25 dimension "A" Distance Gauge

5-8840-2596-0

Installation height valve guide mm 83.50 to 83.80

Sealing surface peak-to-valley height mm max. 0.025

Page 95

ENGINE MECHANICAL (C24SE) 6A-79

Valve Dimensions

C24SE A in mm B in

1) 2) Normal K Oversize K1

Inlet valve 104.2 103.8 41.8 7.012

Outlet valve 104.0 103.6 36.5 6.992

Valve stem bore

1) Production

2) Customer service The P and A department only supplies valves with a length of 103.8mm (inlet valve) and 103.6mm (outlet valve)

only

- 7.050

Cylinder Head (continued)

Valve System

Valve lifter valve play compensator

Valve rotators (inlet or outlet) outlet

Valve play (warm or cold) inlet mm 0 outlet mm 0

Cylinder head height mm 280.3±0.075 Cylinder head bottom, face parallelism mm 0.05

C(diameter in mm) and identification mark D

Oversize K2

0.075

7.087

6.998

6.978

7.030

Camshaft

2.4L Identification letter K

Colour code Normal size -

0.1mm undersize violet

Radial runout mm 0.03

End play mm 0.09 to 0.21

Cam lift Inlet and outlet valve mm 6.67

7.073

7.087

7.053

7.125

7.105

(hydraulic)

0.150

7.162

7.148

7.142

7.128

7.200

7.180

Oversize A

0.250

7.262

7.248

7.242

7.228

7.300

7.280

44°

Page 96

6A-80 ENGINE MECHANICAL (C24SE)

Grinding Dimension for Camshaft Bearing Position

Bearing Bearing journal

diameter in mm

normal -0.1mm normal -0.1mm

1 42.470

42.455

2 42.720

42.705

3 42.970

42.955

4 43.220

43.205

5 43.470

43.455

42.370

42.355

42.620

42.605

42.870

42.855

43.120

43.105

43.370

43.355

42.525

42.425

42.775

42.750

43.025

43.000

43.275

43.250

43.525

43.500

Diameter

in housing

42.500

42.400

42.675

42.650

42.925

42.900

43.175

43.150

43.425

43.400

Page 97

ENGINE MECHANICAL (C24SE) 6A-81

Cylinder Grinding and Piston Dimensions

Size Cylinder bore dia. in mm Cylinder to Related piston dia. in mm Piston head Crankshaft co- efficient housing co-efficient over to over to

Production

(2.4L)

Customer

service

(2.4L)

Piston diameter must be measured at the position "D". *inclusive

1 87.48

87.49

- 87.99 88.00 0+0.5 87.97 87.98 7+0.5

87.49

87.50

Crankshaft, Cylinder Block

99 00

Cylinder Bore

Rebore cylinder Permissible oversize to 0.5mm (see parts

After reboring, invalidate original crankcase

Permissible out-of-round: 0.013mm Permissible taper: 0.013mm Measure out-of-round in bore at 4 different

Piston projection above upper edge of cylinder block

Piston

Type Recessed pistons

Clearance For short-blocks and cylinder blocks with

For replacement (oversize), depending on

87.46

87.47

microfiche)

housing coefficient and drive in new oversize coefficient

heights

0.40mm

complete pistons, the clearance is 0.02 to

0.04mm

available pistons, a clearance of 0.02 to

0.04mm is permissible

87.47

87.48

99 00

Page 98

6A-82 ENGINE MECHANICAL (C24SE)

Crankshaft, Cylinder Block (continued)

Piston Rings

2.4L Square ring Height mm 1.2

Tapered ring Height mm 1.5

Oil scraper Height mm 2.5

Ring gap offset 180°

Note that the upper steel band ring gap is offset 25 to 50mm to the left and the lower 25 to 50mm to the right opposite the intermediate ring gap.

Piston Pin

Length mm 61.5 Diameter mm 21 Type Shrunk into con-rod Play mm 2.4L in piston 0.010-0.015 in con-rod none Installation When installing piston pins,

Crankshaft, Cylinder Block (continued)

The permissible weight variation of con-rods without piston and bearing shell inside an engine is 8 g. As the con-rods do not have balancing studs, reworking is not possible. Con-rods can only be replaced in sets.

heat con-rods to approx. 280°C in oil bath. This temperature should under no circumstances be exceeded.

Page 99

ENGINE MECHANICAL (C24SE) 6A-83

Crankshaft, Cylinder Block (continued)

Crankshaft

jounal

I, II, IV, V

Diameter

Bearing journal and colour code from 57.9820 green

Bearing shell identification mark

Colour code and embossed

Identification mark brown-662N

Normal size

to 57.9885

> 57.9885 brown

to 57.9950

Crankshaft bearing

I, II, IV, V

green-663N

Guide

bearing

III

Widtht

25.900

25.850

Guide bearing

III

brown-655N

green-658N

Con-rod journal

Diameter

48.988

48.970

Con-rod bearing

Crankshaft

Diameter

Bearing journal and colour code from 57.7320 green/

Bearing shell identification mark

Colour code and embossed

Identification mark brown/blue-664 A

Crankshaft

Diameter

Bearing journal and colour code from 57.4820 green/

Bearing shell identification mark

Colour code and embossed

Identification mark brown/white-666 B

Guide

jounal

I, II, IV, V

0.25mm Undersize for Production and Customer Service

to 57.7385 blue

> 57.7385 brown/

to 57.7450 blue

0.50mm Undersize Customer Service

to 57.4885 blue

> 57.4885 brown/

to 57.4950 blue

Crankshaft bearing

I, II, IV, V

green/blue-655 A

jounal

I, II, IV, V

Crankshaft bearing

I, II, IV, V

green/white-667 B

bearing

III

Widtht

26.100

26.050

Guide bearing

III

brown/blue-657 A

green/blue-658 A

Guide

bearing

III

Widtht

26.300

26.250

Guide bearing

III

brown/blue-659 B

green/blue-660 B

Con-rod journal

Diameter

Con-rod bearing

Con-rod journal

Diameter

Con-rod bearing

Con-rod width

1 to 4

Width

1 to 4

48.738

48.720

1 to 4

48.488

48.470

1 to 4

26.580

26.460

Width

26.390

26.338

Con-rod width

26.580

26.460

Con-rod width

26.580

26.460

Page 100

6A-84 ENGINE MECHANICAL (C24SE)

Piston Pins

Dimensions

Length mm Diameter mm

Type Shank-fit in con-rod

Clearance

In piston mm In con-rod mm

Installation See operation “Con-rod, Replace”

61.5 21

2.4L

0.010 to 0.015 0