Page 2465 of 4264

ENGINE MECHANICAL (C24SE) 6A-45
Valve Seating, Mill
Place cylinder head on block of wood.
Inlet and exhaust, Guide Drift and Valve Seat Cutter 5-8840-
2593-0.
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 2466 of 4264
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 2467 of 4264
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 2468 of 4264

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 5-8840-
2597-0.
4. Install flywheel, clutch and transmission.
Page 2469 of 4264
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.
RTW46ASH002801
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.
5. Remove oil intake pipe, oil intake pipe bracket, and oil baffle plate.
6. Remove the bearing bridge.
Page 2470 of 4264

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 2471 of 4264
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 2472 of 4264

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-35Nm (3.5 kgfm) +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.