ENGINE MECHANICAL
SECTION
EM
MODIFICATION NOTICE:
Gasoline engine:
lKA24DE engine information has been added.
CONTENTS
KA24DE
PRECAUTIONS AND PREPARATION............... 2002
Parts Requiring Angular Tightening................. 2002
Liquid Gasket Application Procedure .............. 2002
Special Service Tools ...................................... 2003
Commercial Service Tools ............................... 2006
OUTER COMPONENT PARTS........................... 2007
COMPRESSION PRESSURE.............................. 2010
Measurement of Compression Pressure ......... 2010
OIL PAN............................................................... 2011
Removal ........................................................... 2011
Installation ........................................................ 2012
TIMING CHAIN.................................................... 2013
Removal ........................................................... 2015
Inspection ......................................................... 2017
Installation ........................................................ 2018
OIL SEAL REPLACEMENT................................ 2021
CYLINDER HEAD................................................ 2024Removal ........................................................... 2025
Installation ........................................................ 2025
Disassembly ..................................................... 2026
Inspection ......................................................... 2026
Assembly.......................................................... 2032
Valve Clearance............................................... 2032
ENGINE REMOVAL............................................. 2035
Removal ........................................................... 2036
Installation ........................................................ 2037
CYLINDER BLOCK............................................. 2038
Disassembly ..................................................... 2039
Inspection ......................................................... 2039
Assembly.......................................................... 2045
SERVICE DATA AND SPECIFICATIONS
(SDS).................................................................... 2049
General Specifications ..................................... 2049
Inspection and Adjustment .............................. 2049
EM
General Specifications
Cylinder arrangement In-line 4
Displacement cm
3(cu in) 2,389 (145.78)
Bore and stroke mm (in) 89 x 96 (3.50 x 3.78)
Valve arrangement DOHC
Firing order 1-3-4-2
Number of piston rings
Compression 2
Oil 1
Number of main bearings 5
Compression ratio 9.2
COMPRESSION PRESSURE
Unit: kPa (bar, kg/cm2, psi)/300 rpm
Compression pressure
Standard 1,226 (12.26, 12.5, 178)
Minimum 1,030 (10.30, 10.5, 149)
Differential limit between
cylinders98 (0.98, 1.0, 14)
Inspection and Adjustment
CYLINDER HEADUnit: mm (in)
Standard Limit
Head surface distortionLess than
0.03 (0.0012)0.1 (0.004)
SEM519E
VALVEUnit: mm (in)
SEM188
Valve head diameter ªDº
Intake 36.5 - 36.7 (1.437 - 1.445)
Exhaust 31.2 - 31.4 (1.228 - 1.236)
Valve length ªLº
Intake101.02 - 102.65
(3.9772 - 4.0413)
Exhaust98.52 - 99.12
(3.8787 - 3.9024)
Valve stem diameter ªdº
Intake 6.965 - 6.980 (0.2742 - 0.2748)
Exhaust 6.945 - 6.960 (0.2734 - 0.2740)
Valve seat angle ªaº
Intake & Exhaust 45É15¢- 45É45¢
Valve margin ªTº
Intake 1.15 - 1.45 (0.0453 - 0.0571)
Exhaust 1.44 - 1.75 (0.0567 - 0.0689)
Valve margin ªTº limit More than 0.5 (0.020)
Valve stem end surface
grinding limitLess than 0.2 (0.008)
SERVICE DATA AND SPECIFICATIONS (SDS)KA24DE
EM-2049
