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 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.
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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)
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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.
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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).
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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 Nm (5.1 kgfm) +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 2478 of 4264
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 con-
rod 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 2479 of 4264
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 cylinder
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)
