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ENGINE MECHANICAL (C24SE) 6A-75
RTW 46JSH000101
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.
130RW 002
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.
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Page 2090 of 6020
6A-76 ENGINE MECHANICAL (C24SE)
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.
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Page 2091 of 6020

ENGINE MECHANICAL (C24SE) 6A-77
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 API-SF/CC, SF/CD, SG/CD
CCMC-G5/PD2
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.
Observe the relevant national regulations when disposing of
used oil.
Engine Oil Filling Quantities
Engine Model Initial filling
(litres) Filling quantity
with filter change* (litres) MIN to MAX
(litres)
2.4L 4.80 4.25 1.00
*Up to mark "MAX" on oil dipstick
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 temperature (>70°C oil and
approx. 80 °C coolant)
450 - 500 kpa
Oil drain plug M14 × 1.5
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6A-78 ENGINE MECHANICAL (C24SE)
Cooling System
Radiator
Type: Cross-flow
Radiator core surface in cm
2: 2000
Cooling system capacity (in litres): 8
Anti-freeze Mixture
Anti-freeze Mixture
Required
Quantity Up to-10
°
°°
°
C
Quantity in litres Up to-20
°
°°
°
C
Quantity in litres Up to-30
°
°°
°
C
Quantity in litres Up to-40
°
°°
°
C
Quantity of litres
(in litres) Water (80%) An ti -
Freeze (20%) Water
(66%) An ti -
Freeze (34%) Water
(56%) An ti -
Freeze (44%) Water
(48%) An ti -
Freeze (52%)
7.2 5.7 1.5 4.7 2.5 4.0 3.2 3.4 3.8
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 CO content
in vol. % Ignition timing in CA BTDC (adjustment
ensues at able speed,
ignition marks must align) with TDC sensor measuring instrument:
Closed Loop System 825 *<0.4 *** 8 to 12
Open Loop System 825
**1.0+0.2
-0.5 *** 8 to 12
Note) * CO content adjustment not applicable.
** CO content adjustment refer to Section 6E1 (W /O catalytic converter system)
*** Ignition timing adjustment not possible.
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ENGINE MECHANICAL (C24SE) 6A-79
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
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Page 2094 of 6020

6A-80 ENGINE MECHANICAL (C24SE)
Cylinder Head (continued)
Valve System
Valve lifter valve play compensator
(hydraulic)
Valve rotators
(inlet or outlet) outlet
Valve play
(warm or cold) inlet mm 0
outlet mm 0
Cylinder head bottom, face parallelism mm 0.05
Valve Dimensions
C24SE
A in mm B in
mm C(diameter in mm) and identification mark D
1) 2) Normal K Oversize K1
0.075 Oversize K2
0.150 Oversize A
0.250
Inlet valve
104.2 103.8 41.8 7.012
6.998 7.087
7.073 7.162
7.148 7.262
7.248 44
°
Outlet valve 104.0 103.6 36.5 6.992
6.978 7.087
7.053 7.142
7.128 7.242
7.228 44
°
Valve stem
bore - 7.050
7.030 7.125
7.105 7.200
7.180 7.300
7.280 -
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
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
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ENGINE MECHANICAL (C24SE) 6A-81
Grinding Dimension for Camshaft Bearing Position Bearing Bearing journal
diameter in mm Diameter
in housing
normal -0.1mm normal -0.1mm
1 42.470 42.455 42.370
42.355 42.525
42.425 42.500
42.400
2 42.720 42.705 42.620
42.605 42.775
42.750 42.675
42.650
3 42.970 42.955 42.870
42.855 43.025
43.000 42.925
42.900
4 43.220 43.205 43.120
43.105 43.275
43.250 43.175
43.150
5 43.470 43.455 43.370
43.355 43.525
43.500 43.425
43.400
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Page 2096 of 6020

6A-82 ENGINE MECHANICAL (C24SE)
Crankshaft, Cylinder Block
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) 1 87.48
87.49 87.49
87.50 99
00 87.46
87.47 87.47
87.48 99
00
Customer service (2.4L) - 87.99 88.00 0+0.5 87.97 87.98 7+0.5
Piston diameter must be measured at the position "D".
*inclusive
Cylinder Bore
Rebore cylinder Permissible oversize to 0.5mm (see parts
microfiche)
After reboring, invalidate original crankcase
housing coefficient and drive in new oversize
coefficient
Permissible out-of-round: 0.013mm
Permissible taper: 0.013mm
Measure out-of-round in bore at 4 different
heights
Piston projection above upper edge of cylinder block 0.40mm
Piston
Type Recessed pistons
Clearance For short-blocks and cylinder blocks with complete pistons, the clearance is 0.02 to
0.04mm
For replacement (oversize), depending on
available pistons, a clearance of 0.02 to
0.04mm is permissible
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