Engine (G4KC-GSL 24) 5 GENERAL ENGINE BLOCK - ‘Conenession M7 Disasceneue EM-s6 weonioas BCT COOuNG sysTEM ‘Tmin system Skene coatings CourONENTS eure Ble¥one eu. Inova eh enaron Bon CYLINDER HEAD ASSEMBLY LUBRICATION SYSTEM ‘Sourentns eu.29 — YBouenent eu. INSPECTION | ‘EM 36 INSTALLATION. 8} ences ene Salus BIC INTAKE AND EXHAUST SYSTEM ENGINE AND TRANSAXLE ASSEMBLY REMOVAL... EM=85 INSTALLATION ensEM2 GENERAL SPECIFICATIONS swces Cc Desevption Specifications ‘nie Genera ype Inne, Doutle Overhoad Conshat Numero einer ‘ Bow sonm (3.4840) Stoke stim (S819) “oa lplecomant zoggce (143. 90eu.n) Compression ratio Nos Fring over eae ‘Valve timing Inako vhe Opens arog 11° ~ B1D0 3 Cleses ‘aD 22" ~ ABDC &” Eenvst pens (8800) on ees (ATO) i Vaive ae length Intake 113.180 (4.45598) 112.930 (44608) Bihaust 105.8mm (416890, | 105 7am (16288) Stem OD, nae 5485 ~5.asoren (02181 - 021857) Exhaust 53458 ~ 5.470nen (02140 - 021690) Faco argo 525" = 4575" Marge irate 102mm (0.040%) Exhaust ‘oemm (0.0228), Valve stom to valve guide clearance 0.020 - 0.047mm (0.00078 - ov018sin) (030 = assem (0.00818 - 0.00212) 2.7mm (o0027Sin) 8.9mm (0.00358) Eshaust 498 - 44anm (17044-17101) 38 eam (17208 - Hot) ‘Valve seat ‘Wits ot seat const, 4.48 - 148m (0.0657 ~ 0.05751) 1135-168 (0.0531 — 06cm) aero 45.10" 47.44 (198770) 180.2 0935 rm (4188 2 1 Seb/1 S770) 598. 1.24g26.0nm 67-742 26eb/1. 0236) 15" MAXGENERAL Description ‘Specicsions i coi arse Fi) rake (0.17 ~0.28mm (0.0067 - 2.0080.) 0.10 - 030mm (o0age Sarva) aust 027 ~ 0.590 (0.0108 - 2.01281) 10.20 040mm _ (o007e-oorern) | (liner nena Fanos of gost eutaco Fsioas of anfold murtng surtace ‘Oreste rework mensions of Max. 008mm (0.00%8m ) Max. 016mm (0.0090, ‘yincer block hiner bore (Gutreund and ape of enc bore Clarence wih iton {To setts fo new pars) 188.00 ~89.03mm (9.4645 - 9.4667) ‘Less than DSnm (0.001) (0.08 Comm (0.0008 ~ L006) Piston (OD (osetia to naw pts) Ring grove with Not OF ring Serica versie 8797 ~88.00mm (3.4694 ~94645in) 1.22 124mm (00480 ~ 108881) 4122 "1am (0.0480 — D488) 201 = 20amm (09791 - 00788) 025, 050mm (0010, 020i) oversize 125mm (0.04960) 120mm (00896) 205mm (0.0807) Piston ing Sie cesance Nos Nee Ot rng End oa No Nez Ot rng side cal Senea vee 0.08 - 007mm (o.0012 ~ coozrn (0.8 ~ .07mm (0.0012 -c.ooz7m) (0.08 ~0.15mm (0.0028 - C0058} 0.15 - 030mm (0.0050 C0116) 8.30 - B.45mm (0.0118 -CO177n) 020 - 0 7omm (0.0078 Ca2rsin) 025, os0ram(a.010, 0.020) eerie 0.1mm (004m) (4m (0.004) 2m (0.08in} .6rm (0.0296) ‘7mm (0.02751), .Bnm (00st) ‘Connecting ro Bena CCennacing fo bg edo erankaatt 2.5mm (0.00208) orees ‘O.1mm (0.008n,) oF bas 0400" asd (00008 8.010) 0.3mm (0.0188) Oi earane (ose nts new pars) 0.028 - 0.046nm (0.0011 -0.09t8n) 2.05 (0.0018)ema ENGINE (G4KC - GSL2. Description ‘Spectcations| mie omens Em nah ink 49.90mm (1.7244in} Einaust {5.000 (1.7718in} soumal OD, Intake Noa : 30mm (11811) 0234.5: 2ame (094494) Susi No 40mm (15748) No2i48: 2am (09449%) Searing ol ceararce ‘nthe Not: 0.020 0.057 (0.00078 c.00228e)} 0.09m (0.0085in) Ne235: 0045 ~0.08anm 8:t2mm (0.00471) (0.00177 ~ 0.00923 exaust No12:345 0085 - 02mm 0.12mm (0.00479) ‘O00i77 = ooszan End play 0.1 -0.2amm (0.0039 -Cone6n.) | 0.24rm (0.0084) 47.954 - 47 972mm (18979 - 8986) ‘Jounal 0, 51.942 - s1.9s0mm (20840 20458In} nd ay (207 = 0.25mm (0.0027 = 0@Ds8in} _| Crankehat bearing Sireaarance 0026 - .04mm (0.0010 - 00018) Cooling method Wotorsoatd, pressurized. “orced ‘fouaten th secret an Tne Pressured congated tn ype Radiator cap Main vale opening prossiro Vacuum va opening pressure 69 ~110kpa (12 ~ 1696, 0.89 ~1Ahgiore) “Tap 100pe, 0 07glome) os Te ‘ale opening temperature Fuloponng terest ‘Wax polar ype win Joe ave 32'0 (177 F) 850 Or) ‘Coolent pune Cenirtugal ype rpoter we ered bet [Engine coolant emperatre sensor Tyo Hest-enstive themistor ype eletarce 231 250KD at 20 (8) we ry ype Element Lnwoven oot 98 ‘Exhaust pipe Mater Expansion resonance type Suspension sytem ubbor hangarsGENERAL EMS ‘SERVICE STANDRDS Sand vel [ Antireozo “Maxture ratio of atreaze in coolant ETHVLENE GLYCOL BASE FOR ALUN =e ‘noiTENNa TonOUE item i rr Tete in ae 6 0) “| tame aia za 28 | as - m0 Fre ot 8 108) a | mase=araa 24-28 | rra5- 024 Balarc sa edt TT inter oF is ar oo Tan oor ing din ove bok 0 | eo-m2e0 19-23 | 97-1000 | Tein can combo 6) 7 [tates eat | are -7 i gan ct 6 x10) we as-is | tata | taser i pn bok 8 109) 2 | Beason | e731 | om maat Engine soppon tesatbonaToxa | 1 | tea-aan | a0-as | nse ~m050 rahe spor bras bor ioxas) | 2 | ~sea-aar | anes | nee 0059 [Engine support brackst bolt (M8 x 30) 1 186 ~ 245, 20-25 1446 - 18.07 Camshaft bearing cap bot (MB) 16 “ioe 12.74 11-13 7.95 ~ 9.99 ha Cringe bot 6) a] aaa sias | 20-32 | foas—an10 jin oad to 0 [ata vaors a0" | a +00" woo" | ass 00 oF Engine hanger bolt : 2 19.6 ~ 26.46 20-27, 14.46 ~ 19.52 ‘Gyfinder head cover bolt 18 784-88 08-10 ‘578-728 rena uly Eo Ce yee! ot 7 [ore=tera | 1a 18 | en6 ons Die at bok 7 [uire=tara | te 10 | e875 30 Trg cen eer Do 2 | s8-1176 | yo-12 | _1a8-80r ‘Timing chain tensioner arm bot 1 98 -11.76 10-12, 7.23 ~ 867 Focv tor 1 peessize | i012 | 738 nar ONT a ena lO 1 [ose-e7 | esas | or aro ‘Balance shaft chain tensioner arm bolt 1 88-1176 10-12 7.23 - 867 Bala Sacha gio bat 2 [ee-i% | 19-12 | 723-807 alr a can isonet 2 [eesti | 10-12 | 709-807 lr pun bat 5 [98-2840 | 20-27 | vaas-988 TC baciet bot 4 | tea 208) 20-28 | taa8 ie Sta bot 2 [caitsssa [48-68] ess 0070 Torsone or aco 7 [es2-4a1 | a= as] ead son itr ons conte Bt a [yar eise | ee | oar 1580 Vir oro_cona rat 1 [ise =anas | a0~27 | 0a8 082Ems ENGINE (G4KC - GSL 2.4) fem ‘ueniiy [| __m atm ieee ‘Water inet pipe bot 2 188 - 2646 20-27 1446 - 19.52 ‘Of level gauge assembly bol 7 784-176 08-12 ‘578-887 Ianon cot bot «| see-se3_| 04-06 | 289-938 rake mandols bot 3 | tesa-a7aa | 19-28 | 1979-2028 Toke mani aut 2) tee -a7ae | 19-28 | 1979-2028 ‘take manifold stay bot 4 yaee-2744 | 19-28 | 1879-2024 “Extiaust manifold hest protector bot 4 yaee-ara4 | 19-28 18.73 ~ 20.24 ‘Exhaust mano at 7 | soa-aa1 [40-05 | paso-a2sa Estaust maniold stay bot QB) 2 yee a | 19-88 1874 20.28 is! mano stay bot (10) 1 | sist-s7me | sa-59 | sea -a26 Frnt rte bot 2 | so2-see | 40-e0 | 2aa~a397 Engine cover rat 2 | se2-se5 | 04-08 | 2a0-ase [ Engine cover mouning bracket bt 2 [7-176 | 08-12 | _s7e-as7 | Cranes poston sensor bot 1 | see-ses | os-o8 | 200-48 Oyen sensor 1 pasnaat | 5-45 | 2500-s269 Kook seer + [666-2588 [17-26 | 1229-1879 Ol teroorature sons 1 w8-902 | 20-40 | 1446-2582 [Camshaft postion sensor 1 382 - 588, 04-08 280 - 434 (i pressure ston 1 [rein ti7e | 08-12 | 578-087 Main bearng cap bok Wo | 26a8ea5" | 27 eas | toate ase (OF her + [176-1608 | 12-18 | eer 187 ‘Connecting vod bearing cap bot 3 ves+o0" | 20400 | 1406+00"GENERAL, COMPRESSION. err Ghore 1 oe tari ac of power. casio consumo toner poor eonary Bets he compression 1. Warm up ea stop engin. gine te warm upto nena eperting em 2. Remove jon cols (8 EE group - ton) 8. Remove soar pugs Using fmm og ranch, remove the perk pgs. 4 Chock onder compression pressure arse a conpaeson gage moe apa 1b. Futy open ne veto, © Who cranking te engi pression pressure Wore ‘Anays us a fly charged battery oabtan engine S000 of 200 rpm or ve. 14 Ropest steps (a) through (6) for each ence, Grore ‘This massuroment must be done ae shorta time as posse ‘ompraston prossure 1 288Pa (180glen, 1859s) Hiren pressure 338ePa (11 gon, 4p) Ditreneebotoen each oyindee 00k? (ong, Ips) ors EM @. tnaeylndar compression noe ore cinder elon, coura smal amount of ang on he {ye ough fe spark log hoe and repeat ‘Sapa (6) tough) evindor wh fw com: pressen, * Taeg ol helps te compression i aly {hale paton ngs ancl cynger bore re ton or damaged +f ossur stay low, a vale maybe sk Ingo seating is impropr,o tere may bo Tosca past the gosta, Relat sour pgs Insta igniter co. (0 EE group - gion)Ema ENGINE (G4KC - GSL2.4) VALVE CLEARANCE INSPECTION AND buUstaeNt Gnore Inspect and aust the vale clearance when the on: ‘eis ol (Engine oot emperature: 20°C} and andr head setae onthe inde boc 1. emo the engine cover). 2. Remove th eynder had ove 22" Dacanneat the gion eal connect) and re ‘move te gto cal Disconnect he PCY nose) and the broather oso rom Ba eyinder had cove ©. Leosen te cylinder head over Bots and then remove he cover) ee gasket 3. Set No: eyinder to TOClemprssin. 2 Tun he erarnsrat pulby an ai ts row vi neuming mark “Te halonertining eranGENERAL emo Check tat the mark) ofthe camshat ting _—_b._Turn the crarkshat pu ane revlon (60") sprocket are natal no on the indo head fn lig bo grave ih ring mark"Te te life ae shown th luton. Tower tng eran cover. Io ten ranahat one reveatin (9607) ©, Chock oly ves indeated a¢ shown. (NO. & yaar” TOCkeompreeion), Measure tho vale Saran. anon Net 3nd Token 4 Inspect the vate learance om 2 Chock only te ve mest a shown, INO. cyender: TOCIComeression measure Me vane oarnce 5. Agus th ako and exhaust va clara, 1° Set the Nat cyl fo the TOCIeomeresslon, (See page EM 6) 1b Maia on te ming chan end camshet ting sprit, Ramo the aor hols bot) ofthe ting chan ower, Using tetness gauge, measure the car anco between tho lappa ad tho base oxch of ‘camshal “Recordthe out sociation valve dearance rmaaguroments. Thay wl ba vee ate to dtr. rine th equted relanment using lappt. ‘Varo clearance ‘Specticaton ‘The bolt mest not be reused once It has boon as- persue: 20°C [68°F] combed. Fite: 010 «090mm (00050-00118) mse etna de sere nl! ti Esha: 020-0407 (00078-00187) SSthcmer and ooatete ntEM-10 ‘Remove the ont eamshal earn capt) @ 1. Remove he exhaust camshat sprocket {5 Remove the exhaust came besng ap and swhaustcarshat. (S00 pago EM » 35) 1h. Remove th naa bemenaf tearing op ann take carshat (Se0pago EM = 28) QS cauion When csconnect the timing chain trom the camara tnng sprocket, ong te tng Lot irng chain wit a sing &\ caurion {Be careful not to drop anything Inside timing ‘hain cover |. Moaaure te tickness oe amovedappet us OF PAK wa yy Xt Caleta ne these of ne appt so tat thea clarance comes wna te apeciiod ‘Valve clearance (Engine coolant ter perature" 20°) JF Ticknoss & romovad tappat 2: Mosoured vale olarancs IN Thosness ef new appet $1 0.20mm0.00730)1 Esau: N= T+ (A0.30mm (0118) | Seoct arom appa wha sicknass a cos poseblots the caculiod va, Gnore Shine are sate in 47s comnts of 015mm {@avoan)"tom can fo1Tan) to 2880mm (aan) 1m. Place anew tappet onthe cya he. AY Hold he trang cheba, and pace te Inske ‘camsha ang ng srocot assent. ‘flight matchmarie an th timing chain and famshat trang pret. plata te ate and ehaust camshett (Se page EM - 4) «4. ‘ata ha ont bearing ap, 1 Intl he sei le bo page EM- 44) Tighoing og 12 tstkm( Sigh, 88 ~ 1.08) Tum the orankgalt two tun in the operat Ing crowen(cleckwse) and realgn crankset ‘proaatandesmanal sprocket ining mars 1. Recheck he vahe olaranee, ‘Valve clearance (Engine coolant tem- porature = 20°0) [Bpecticaion) Intake : 0.17 ~ 23m (00067 -0.0090in) Exhaust 027 -0:33mm (9.0106 - 0.01280.)GENERAL M11 TROUBLESHOOTING ewes Sympiion ‘Suspect area Remedy (See pane) Eng mst wih | Wm aaniaha baarngs ops he ean and bara ‘strermal ror | Lose or meepe ere vel 1 rogue fener eng nes. Aap oF rpc the yas rou ‘Wor aston mes Inset cinder for a fos of compression. {Gtteanmpton may ocmay not causo | Ropar or opt a ogre te engi mse) Wom canksha rst boarngs Fepac ho canara and bearings a vcured Zia nisi win | Stuck vats opal o rpc a ected stromal va _| (Gabon bucko on he ve sem) ‘ _| cae cease wor or misaligned tring chan | Replace ring cha ard sprocket Wom canshat bes epi the carat and vale i. Engi mise win |» Faulty cynder eed gastt andor |» irpac he cynder head ana nghe Coasrtconspton | "erring oer aap thw eyndar | teak ag to Be cof pareages | _ Resa end engin oc cooing system. | sor fauy heed gest + Cool consompton may ermay net | + Rapa orp a aque |_* eats engine ores Engh mise | Wom vahes. gues ander vo | Popa or pace a oud | onsareen wom piston as. pect the enor ora ss oF {Gteonurpton may ormay not case comprossen {ho engin fo mite) + Raptor rpc a aque. Engh nase on | Ieonet ol vsonty + Da te ol srt, bl oly + ta he const vscotyot teste tow scons. | Wo canncha rw beara + poate baring an rari. {Rar or rpc os outed Upper engine ras, [Low of esse ep or ote a5 requred seaargets 2902 | een vate epg opiate vo seo ‘Wor o ity vee i. ep the vale iio. amped epoca eth, ‘Wor timing han onsen appzabie. | Reise he ting Gan enema ss recurs Wor cashat bes. + lepet he caahal bes. + Rape he trang camehat and he ter a regu ‘Wor whe gus ova seme inspec tho vals and vate gues ‘an repair a6veaued “Suck valves, (Carbon onthe vaio stom or | Inspect the wales and valve gues, ‘ae seat may cause th velo stay ope. | the eps as vege Worn civ bt, ir, tensioner ane bearing. | Replce as roquredEM 12 ENGINE (G4KC - GSL: Sympton | _ ‘Suspect arom Remedy (868 page) Tomer engin nasa, | Low ol pressure ‘Repat or vague. {oper 3 0 Toss or daaged Tyne [Ri orepace ta weak ‘Damaged oil pan, contacting the oil * Inspect the oll pa. puro szreon, 1 Insect he of pum seraen, {Repair rplace a5 requ ‘i pump screen ook, damaged or resleod, | + Insacl te ol pump seeen. 1 Repair orepoce as equed vance, |» Iepac he piso, piston ph 858 cjnaer bore | + epi rogues ‘Bcesine piston pinioison earance | + Inpedt be piston, pson pi and the sonncting ros 1 Fear or epace as requ ‘icesaieconneding red bearing Gearence_| Inspec the fellowing compenens end toate 8 rosa re comactng ee bearings. 1 Ts connecting rods. {rs cranehat pn journals ‘Excessive ankahal bearng Gearance | lepoct he telowing components, and repair as requires Ths crankshat bearings ‘hs crankenat man outs, 2 m oyinder book Eroessve psano-eindor bore ‘incorrect piston, piston pin and connecting | + Vey the piston pins and connecting rod isalaton roast etalod cot + Fapal as vequred ‘Eigine poke wnder_| Low pi prowsure pair or epee as enue. ea Excessive cornoding rod bearing Gearanes | epoca following components and ropa evaqured ‘Tho conectng rod bearngs. {he cannectng vd, 1 Ths canna ‘cessive cranishal beatng Ssaranca | Iapectine folowing eompenenis, and repair 5 vores ha crenahalboarings. {The crankshaft main ural {ne eyinger lesGENERAL M13 Symetion —_Buspect roa Remedy (See pa50) | ge wal not | Hyezaulealy oskod eynaer "Remove epark plugs and check or ud tonkeankshat |» Cootnantreszeneyndet. 2. Irapeat to broken head gaol val nt rie + Ott ner 1 Inaeet or eecaed engine beck 1 Fostin oyinder ar eyindor hos 4 Irapeat fora slong us njecto ance lasing te ropuato. ‘Broken tning chain anal ting oan | nde trang chlo gear. 2 _ ator incr 1 spect ends for damaged Broken vane ‘conponenis andor foreign materials. {Piston mater 2 ‘Repaoreplace as requled {Foreign mater ‘Seized canahat or canneaing rod bearnos, | 1, Ingpect eankahak and eonnacing tos besrng 2p Yoqued, - ent or bokan contig od 1. Iipestcomecng ras. 2._Repa 29 routed, 5. spect cana 2_Repar as rogueSPECIAL TOOLS. evo Tool (Number and name) Tustation Use ‘rankahat tent ol sel nstlor Tesla of th Wont ol seal (oaare-sKoo0) 8 | as osciesoo0 (o2aat-He0) 8 Bona H0 ‘yee poor Fema and netalaion of he whoa! (ovest-sKo00) fd erent ploy “orgs ang adaptor (asa -4a000, Traalten of bole & nats needing an angular ratios (oez2-4000) insalaton othe vaio som aGENERAL “eal (Number and name) Use ‘ae sping compressr & elder 2222000), osz22K0) oral and inaalton of he maka or exaust vane 1 ogae.scooo B 09220-34100 (hots) ‘Granta var of eal metal (o2a1esKtoo) (o22atHi09) Tesaaion of tho Sankaha rear al sal Re oser4aKi0o 8: oneari00eM. ENGINE (G4KC - GSL 2.4) TIMING SYSTEM COMPONENT cur 784-9808 -10,5:78-723) 5. Oylndornaad cover 7, Grankshale spacket 2. Exaustcamshat sprocket, 3 on 8. CwvTasseny 5 Timing chat tensioner 4 Timng chan 10. Tnng chan cover 5 Timing chan tensioner atm 11, oF pan 6. Timng chan guise‘TmnG system, M17 98- 1176(1.0~12,723- 867) TOROUE : Nm (gta 1, Balance sha meaue 4 Balance shat chsn sprocet 2. Ginger boc | 5 shat chan guise 8. Balance sha chan ©, Balance shel chin onsen armM18 ENGINE (G4KC - GSL 2.4) REMOVAL corse 5, Romave theangine mount tack Engin removals net raquired or this proceduro 1) Sot te acko ho engine ol pan- “TMG CHAIN 1. Remove the engine covert). 2, Remove Ri font wheel 21. Pamve RH sd ov Letad Flac wooden Bsc between he akan engne 4. SetNa eyner'oTOCteompresson pon Remove the 2bos, 2nats and engine ment rack‘TING sysTEM, EM 19 6 Terorayeson the water pump pully bots. 10. Romove the water pur pully). 7. Remove dive bot. ‘er 45, Remove he cenkahat pully). 12, Remove the engine support back) 18, Dlsconnac the gnton cot connector) 9. Remove the sve bot tansoner pully and tan ‘one. Gore Torsone pully bat is lt -handed sow.EM 20 ENGINE (G4KC - GSL 2.4) 18, Remove thePCY hes{A)endereaterhosatemtho 18 ora tho sompresor track. 18. Loosentn ynder hes over bots andthen remove ‘ho nce headcover) and gaat. 20, Remove hoof pan.‘TIMING SYSTEM. 21. Ramee ning ca cov by ng he fona between the cylinder head ae tnd Bock ta erowdrr ‘Be careful not to damage the contact storia bok nds beet an tng eran 2% Tapa sro at ath a ace of malnbesrng cap. As 8 reeut of hi, he Baton a tot eynder paced a bo daca foran compreseon stoke. 25, Ital a eat i alr compressing te tng en 24, Remove ho tning chal tensioned em.21 25. Remove he ting chan tnsaner a). 28, Remove the fring chan. 27. Reve ho fing chan guid). 29, Remove the eankshatt chain sprocket)EM22 BALANCE SHAFT CHAIN 1. emove the mig chan 2. Intl eat in aflor compressing th balanos shat {Remove the balance shat chan tnsionerA) 4 Remove the lanes shat chan tansinar ar). 5. Remove the balance shat chain gue{C). 8. move the balance shat modulo(A) and balanos shat cha) INSPECTION ccom SPOCKETS, CHAN TENSIONER, CHAIN GUIDE, GARIN TENSIONER AFAT (Chockthocanshalt sprocket endorankshat sproskat for ebnormal wer, rake, or damage. Replace 25 noveseary. 2. Inspec tha tesloner arm and chain gue for abnor ra wear, rake damp FRepace as necessary 3. Check hat theonslonepstonmovessmeoshywhon ‘he ratchet pats roleasod wih thin ro. BELT, IDLER, BELT TENSIONER, PULLEY 1. Check he tot ro or dt depots Replace, # necessary. Smal doposts shouldbe wiped away with a dry cot ‘paper. Dot cean wih sok. 2. When the eng Ie overhauled or bel tsslon ac Just, chook ho bot carta. Hany of th fotowng flaws are ein, replace he bat. Grore * Do no band, twist or tum the timing bet inside + Do ot alow te tning bt o come into contact ato ator and tea, 3. Inapoct ho dot for easy and erent relation and ‘ck fr pay nose,TiMING SYSTEM INSTALLATION. een 4 rsa tho balance shat chala guide) BALANCE SHAFT CHAIN 1. Tho ky of rane shoul be aligned ity he mat Ing fo of man bearng cap. As 2 raul fh, ha sion of Not cyinder spaced al he top dad com fer on compressa stoke 2 Conf the balance sat mada tning math. Timing marks 10 be visual aignod wih cortors of acon ae ming nen, 5. Instalthe balan sha tensioner arm). Tahtening tore 98 11TEN (10 -1.24ghm. 7.28 - B67bA) 1 nse ne bance sha tensioner) and remove he 3, ntal balance shaft module hat he timing marc ot _SSt Bunce shat modu sprockat shoud be Mlehed — “Tananng au ‘ththe Ging mark(clerink)obalanesshatchain. gi Tt FONIM(IO = 12kghm, 7.28 ~ BS7BLA) “Tightening tore 7. Cont the ning mari.EM 24 ENGINE (G4KC - GSL 2.4) “rmine CHA 5. tttal ting cba. “otetal a rng chain wth slack tween each 1 stallerankahat chain aprocka) alt (cam, can alow the below procedure Crankshat soot) > Timing chan guet®) > Intl carssat sprocket) -> Exhaust camshaft timing oban. 2. Insta ing cain jo), Tighening wrens 7B SANMOS - 10hgim, 5.78 ~ 7.28012) 8, Sot cranhsat thatthe Kay of cranks should be llgned wah the mating uae of ran bear cap. Pulte iho, exhaust cash esomot at the ‘TOC mark of ako sprookat and exhas spockat Should be aignod wi he top autace of ender oad, Asa osu of tis, place the pon on Nos Stndor at te top dead ‘centr on compression stove. 4 sal tring chain guido, Tightening race 93- TENmt‘TMING SYSTEM, M25 {6 Intl timing chalntnsonar am), 8, stating chain con —ee ee ___ gine setlat lccatons on chain cover and on Tiguan toque AG pulley > aerator pulley > ier uty > PIG puro pubey > pulley > water Foul au oo ah courte - loc ‘moving auto fensioner ply bo wth wench ‘or puting eten alo oteaner ply, asthe ‘0 tensioner ploy soy. 22, Install engine mounting rack Tiong a, Gar ean, igi, 7‘TING svSTEM, 25, Intl FH side cover 28, ntl FE ret whoo, 25, Install engine covert Tigo toque 382" 580N, M29EM -30 CYLINDER HEAD ASSEMBLY COMPONENTS caseue ENGINE (G4KC - GL 2.4 “TOROUE : Nam (afin) [-—_ 26405, 28.) + 90°60" 1. Gpinaar nasa 2 Cynder head gasket ‘3 Gjanaer BookCYLINDER HEAD ASSEMBLY 539-637 (65-65,907-a70) TORQUE : Nan (gm, LA) 5. Casha baring cap 2. Gamanat ont bering cap 1 Eahaust camshan 4 take cama 5. Exhaust camshat sprocket, 8. Rataner 10. Vake speng " 8 8 EM.31 (17 13,795 - 939) Vaiv stem selEM-32 ENGINE (G4KC - GSL 2.4) REMOVAL cxice Engin removals ot required for his procedure QS cauTion * Use fender covers o avo damaging painted surtacee. + Toavold damaging the cylinder head, walt un + Whon handing « mela! gaoket, take care not {old the gackat or damage the contact sur face ofthe gasket + To.avold damage, unplug the wiing connec tore carefully white holding the connector portion. Ghore * hark a wing and hess 0 wo misconnes- + Tur the cranksaf pu sothatthe No.1 pion ‘S atap deed conta (Se page ENS) 1. Disconnect ne negate emina om te bay. 2. Remove engine over). 8, Remove alr uct » 2 3 4 “Rema ta nah er howe end a cleaner assay Disconnect the AFS connector Disconnect th breathorhso(6) rom aircleaner Disconnect the EOM connector. (S80 FL group) Feros he intake ar hose anda closer as: ser).CYLINDER HEAD ASSEMBLY 7. ln tho engin cola Forove te radar cap speed dating. 18, Romove the uppor and lower raatr hosEM-34 14, Dicsenoct GMP comecor(A), and knook sensor connector). rearan 19, Rarmove nab mani (See page EM 85) 18. Disconnect PCSY connector(A), WTS connector}, 20, Remove exaust mani. (S86 page EM - 87) ‘condenser comecter(, and GKP sansor conn’ to) 21, Remove ti cain (Seecage EM -8) 22, Remove CWVT assombly and carat sprska(). 17, Remove dehery pipe) brake vacuum hoss(8), and SV hose(¢).CYLINDER HEAD ASSEMBLY 28, Remove camshaft 1) Remove rot camshaft bearing exp) ‘quonce shown. M35 Remove the cynder heed bots, then remove the ‘finder head 1) Using tro square wrench, uniferny foson ‘andreme he 10 cylinder headbots, hsverl passas, nthe soquonca shown. Romove the 10 hinge Nad bats ana pat washes caution ‘ead warpace or eracking could result trom re- ‘moving bots in an Incorrect order 2) Lite ofinder head tom the domes onthe cyiecer Heck and place the eylndorhoad on ‘wood Hoek on bench, B) caurion ‘Be careful net to damage the contact surfaces of the eyinder heed and eyinder bosEM-36 ENGINE (GaKc DISASSEMBLY ernie INSPECTION. sac Gore (CYLINDER HEAD ‘ently MLAMechanics! Lash Agusta, vates, 1. nepect for tanoss. Valve Springs as thoy are removed sora sach tom Using pression sagt edge and feeer gauge, ‘an be etalon te egal poston ‘messure nesta the conoctng te inde ode And te mantles for warpage. 1. move MLAS(N) Flaine ofeyinder head gasket surface Stenderd .0snm(0.002n) 2. Remove vaties 1), Using S87(00222-sK000, 09222:3K100), om ese te ave spring and remove retainer iock, vewisa 2 Inopect or each (Chee he combustion chamber, nike ports, exh 2) Remove he spring retainer, pris ancy: bok surace racks erehod, Feplce the cinder heas 15) Using needle-nose prs, romovo the va stm elCYLINDER HEAD ASSEMBLY EM-s7 \VALVE AND VALVE SPRING 3), Subtract the valve stom dlamator massurernt Irom te vale guide mde darmstor measure 1. Inspect vate ets and vv guides ment 1) Using acaliper gauge, messure tne side lam: "Yaiv simto-gude dowrance ‘tort te ve gas. oe Ink: 0.020 -0.0¢7mm (0.0008 - 0.0018) Exmaust 0.080 Osan (0.002 = 0.002%n) [urna Inka = 07m (0027.9) shaust: 009mm (0.0035) tho clexanceisgroator han maxirum, the ah anavave guide, 2 napoct aes 1) Check he vave is ground to te caret vane face ang, 2) Chock tat he surface of he val for wos Iie va tae is wor, repace the ve 2) Chock te vate head margin hiesness ine margn thoes os then marr ace the ae. Margin [Standary com inlako = 1.Com0 0401) Exhaust! 08erN0.0820n) 2) Using amicrmatar, measure the amatartthg oni — va sar Valve stem 00, Irak #5465 ~ 5.480 (02153 ~ 02357) rm _Bahaust: 5486 - 547Omm (02149 - 0.21580)EM 28 4) Chaokthe surface of the val stamp wos Ine va stam tps wom. replace the vale. Inspect valve seats {Check ne valve ae fr evidence of overoaing and improper conac wit te vale face, Faplae he aes nossa. Bolre reconatening tho soa, check the vane guide for wear. bw vahe gue won place fen ‘ooction he ees econaton ta valves uh ‘vale coat gnder er et. Tho valve set contact, wih shouldbe witin spectitins and ented on {he vane too, 1) Usinga tel square, measure the out square ofthe valve spring. 2) Using a varnior calpor, measure the te length ofthe vee epg Valve sping {Stara Free height 474mm (1.867719) Outtequare 15" Ite te long is not as specie, role tho vane spring ENGINE (G4KC - GSL2.4) mua 1. Inspect MLA Us « meteneter, measure he MLA outslde dan ote “WA 00. Intakaleerauet 7258000) 231.964 ~ 918802584 2 Using calor gauge, maasure MLA tppet bre nor damtorot ender hoa Tappet bore 10. (ike/Emnaust 22.000 ~ $2.25} 2568 o2608in) 8, Subtract MLA outside carmater measuraent om ‘aopet bore ste sameter measure. NLA to tappet2ore lerance [standael Inake/Esnaust 0.020 ~0.06%mn(@.0008 0.0024) {urea Intakavexmauet: o.7mm.0027in)CYLINDER HEAD ASSEMBLY ‘CAMSHAFT 1. Inspect cam bas Using a miomior, measure the cam obehegh. Ink: 9.70 - 43:90 (1.7204~ 1.7286) sat 4.90 ~ 45. 10mm (1.7677 1.77560.) EM af Inspec camsatjouralclesrance, 1) Oban te 2) Paco te cama onthe cylinder hoa 1g cape and cemehat unas 9) Lay @ ip of plastigage soroes each ofthe sasha oura. Ie cam lobe height is ess than stand replace 44) rata to bearing caps. (S00 ago EM 44) A caution Do not tum the camsEM -40. ENGINE (Gak. 15) Remove the besing ope 3 Inspect cash ond play. (6) Measure plasigag ats widest pot 1) Instat the camshat. (Seepage EM 4) ‘Bearing all learance 2) Using nscator measure the orplay while (Standard value ‘moving he camera back stor, ‘nike — Nt Journal: 0.02 -0.0s7mm (0.0008 - 0.0022) ‘Gamehatt end play Nez, journal : 0048 = 082mm {Standard valu}: 010 -02nm(0.008~ 0.00871) (0.0018 ~ 0.90920) [Rima 0.24 (0.0094) Esau 0.015 0 082n (0.0018 ~ 0.0082) [Lent leak Not ural: cen (0.0085) No.5. journal: 2mm (0.0047) Exh * 12mm (0.0047) Ite od py e gostor than maximum, opiace the carmia W nacossary replace cyt hae 2) Remove he carahats te ol larance ie geator han meimum, = Place ta carat. I necessary, roplce ey Sor bone 17) Comply orev tho plastigage 8), Remove the carshatsCYLINDER HEAD ASSEMBLY cowvr assemsLy Inspect OWT assert 1) Chock that the CVT assombly witnat t, 2) Apply vey!tape he retard le excoptthe one ietng ty tho arom nthe ataon EM 41 4) Under the condton of) tum the CWVT assem iy toe advance angle side (he arow marod rectonin te ustraton) wit your nana ‘Depenang onthe al presturo, the CVT assar- Dy um fo the echanoe aie wehout ping fof by hand, Also, under th concn at ho pressure can be hardly soped because of the Sr lakapo rom te por ere may be ho ass that npn could be hardy released 3) Windtpe sound the ip ofthe algun and ply air of apron. 1S0kp(1 Skee, Pipe) othe port ha coment {Pecorm hs oder release the look pn fo the maximum dlgy angle tocking) (Gaore When theo slashes, wipe it of wha shop rag and the thes 5) Excopt to poston where the lock pin meets at ‘he maximum delay ang lhe CVV aster Dy tum bac and forth and chock he movable ‘ange an thal hore no detbance, ‘Sanda: Morale snoihyinherange about 225 19). Tumtne CVT assemety with yourhendandtock iCal ho asin dlay ang poston (cour ‘eloEM -42 REASSEMBLY coun Gnore ‘Thorough evan apa fo be assombiod Before instaling the pars apply rsh engine oa! ‘sng and oaing surtaces Feplace al seas with now ones. 1. st vaio, 1) Using 857(08222-4000), push na news Do re reuse at vahe som seas Incarctinetalaton of he so could regu i olen ge paste ale gules. 2) Intl ho va, va spring ant sping tanr. valve springs 50 that the site coated wih fanamol faces toward the vale sping retainer ad 8) Using te S$T(00222-2K000, 09222.2K'00), compress tho sprog and sil ho rlanor lock. Ato rstaing the vais, ensure that ‘he retina locks are corosly place below rolasing the vate sprig comprescor 4) ght tap tho end of each vale som wo oF {o.nsus proper seating othe valve andreainer ox esa LAs, ‘Chock tat he MLA rites smth by hand MLA can be inte ints ogi positon,(CYLINDER HEAD ASSEMBLY EM 43 INSTALLATION. sxron ‘3, Pave the oynder head carey in odor otto dar ‘age he gaskt wah he battom par oe end 4 rata ender naas bots 1) Apply ight coat itegine ol one threads and Uundor te heads ofthe ender head bot 2) Using tle square paxagon wrench install and lghtntte 10ayinder beable and pal wath (27, in sovoral passos, nthe saquance shown, 1. sal OV ster, Tiahining tore S4:3Nm (5igin, 25.3) + OO" + 90° Gnore ‘Atways use nw cyinder has bot beck wae Tereaetess Gore Be carat of he instalation arectonEM 04 5. Install OCMIA) end OTS (8). Tighining tora GEV RB= FEN. 0- 1 2kgkm, 7.29 8.67bAm) (OTS: 196 ~ zasanmigo ~ ZaKgim, "7 o) + Do not reuse the OCV when dropped. 1 Keep clean the OC. + Downot hold the OCV sieeve during servicing. + When the OCV Ie inated onthe engine, do ‘not move the engine wit holding the OCV yoke, 1. Intat he CVVT and camshat apeocet Tightening tora eStart, 997 470848) Gnore Holt the reapers howd wrench goton of the msnan ih ws, and ns the Bt ena CWT second 7. intl camete ‘Appa Sightcat of engine of on camshaft ours. 4. Insalcamshat bearing caps inher proper lations Toning oer, (Group A eu 8 — Group. “Tightening tore Mg: 10.78- 12ratin(.t~1.Sighm, 7.95 ~ 93804) Ia are =o one = aim bose aaa any Buta) cine) Aime) Crms) i caatinecin, POREO CIOs EO) j J 8. Install ming hal. (See page EM 23) 10, Check and asa vae clearance. (Soe page EM-8) 171 Install he exhaust manos (Soe apge EM 87) 12, Insta he ake raniteld. (See pape EM - 87)CYLINDER HEAD ASSEMBLY EM 45 13, Install water mp contol assombly (8) 15, Connect PCSV connor (A), WTS connector (8), ‘condenser omecter (0), ahd CAP sensor connector Tightening wre, o Bots TA? 21 S6Nm(15 ~ 224ghm, ‘oes - is0bim) Nuts 18.6 ~ 2640Nm(20 ~ 274m, {aus * 180m Grore + Assomble war tap contol assemtiy and a ‘erinotpipeto water pump assomblDefore ets lerassombing of atari pipe tobe tighianed. + Insert ater wetng Ong arlnersurice fhe ‘moet housing. Aaya anew Orig. "4 sal doivery pipe (A, brake hose(8), and PCS hos (CEM 06 ENGINE (G4KC - GSL 2.4) 1B, Connect CNP connacior (A), and kneck sensor con- 21. Connett AC witch (A, lonatorconnoe (8), and ore) s colipressue sen (0).CYLINDER HEAD ASSEMBLY EM 47 24, Intl h ina st hse a a eleaner assembly. 25, instal ha engine cover 28, Connect ne negative amino the bate 27. lw angine cool. 28, Sarthe engin and chock or loke. 28, Rochock agin cola lvl ano oeEM 08 ENGINE (G4KC - GSL 2.4) ENGINE AND TRANSAXLE ASSEMBLY REMOVAL cose Marka wing and hoses to avid miscanec- ten + Inspection the timing bat boere removing he ‘yer hoa «Terme crankshaft ploy stat ho No.1 piston [Sattop deed canter (Seepage EM" 8) Disconseet he naagatve terminal rm th battery Ferreve tho ongin cover 1 2 Remove ne air uct. Femove he ish ar hose anda cleaner assomb ” 2 Disonneet he AFS canna, Disconnect the bresthor Noes tom a leaner Dleccanact he ECM connecter. (G38 FL gue) ‘Remove the ike a hose anda leaner 5. Remove tnt wheel. 7. Drain the opine cota Femove te aor capo sped rin,ENGINE AND TRANSAXLE ASSEMBLY 9, Ramove the hestar hose, 10. Disconnect AIC ewichiA), aerator connects) ‘apd prossure owen)ENGINE (G4KC - GSL. 18, Disconnect PIS pump ol pressure swich connec ‘oH 18, Disconnect POSV connector), WTS connector), conaenter connector). an CKP sensor connec: ‘ono q SSA VRS 20, Remeve ho batty body backs,ENGINE AND TRANSAXLE ASSE! 22 2 2, 28 a. Disconnect the ground cable rom he tarsal Disconnect the tensa wite hamess connecter, ‘am, Disconet he itor sen connector. Disconnect he rani range connector. Disconect ne input shat sped connecter. Disconect he ouput shat speed connector. Disconnect he vile speed sensor somectr Femove control abi vanes ange sith Serle Drain rane ol Dissonect EPS camectr (See ST group) Remove lower sm blink. (Se0DS gr) Ferove tile end bali. (S60 DS group) Femove sailor ink. (S00 8S rou) 2. 29, . 34 eu st Fomeve power sisting rum hose(A) end dain ‘ower stenng ero front rol stopper mounting bt, Remove rea rol stopper mouring bl, Reto stewing wont mounting (S00 ST group) Disconect agen sonsor connor.M82 ENGINE (G4KC- GSL 2.4) 28, Remove Hon exaust pipe. 38, Remove the kanesle mounting brackots). 24, lata jack and ormove sub raat) 125, Ramo dive shat om rasa 159, Jack up the veil 95. lnctal Jack fr supporting engine and vansaslo as sary 7. Remove th engine mouning back)ENGINE AND TRANSAXLE ASSEMBLY INSTALLATION. sce Instataton sn he rvere eter of ero Pad the folowing Adjust he Sh eae ‘Agus he rte cable Rel ne eng with engine ol Fell he wansado with i, Ball he race wth engine coolant ‘led ai trom the cooing sytem wih the heater ‘al open + Gian the batry poste and cable taminals wih sandpaper assemble them, then apply gresee 10 prevent coroson Inspec for uel leakage. ‘er assomtsing the Tul ine, tum on the gniton foe (0 ot eperte the stare) 20 tna he fel pup rae or approxima wo seconds and tal fn pressurize Fopeat this operation two or hres times, hen check ‘orl leakage at any port inthe ua ine M53EM 54 ENGINE (@4KC - GSL 2.4) ENGINE BLOCK COMPONENTS cases 2352-27.4424-28, 1735-2028) TORQUE : Nam (ktm os) 1. Paton | 5: Piston pe 2 Paton &. Gonnostng rodiower bearing 4 Connecting ro 5. Gonnesing rdtesring cae 1 Ganecting od upper bearing 1 Ladaor ameENGINE BLOCK EM 55 TORQUE : Nm (gt, ttt) 1. Grankshat upper bearing “. Grankahat over baring 2. Thus bearing 5 Man bearing op 3. GrananatM56 DISASSEMBLY «om UT remove Rye. LNT :remoe drive pat. ‘naa engine to engl stand for dsasemby Ferrow ing chan. (Seepage EM - 18) Ferove eynder head. (Seepage EM - 32) pee ewe Rerave NC compressorA) tom engine. (See HA ) ENGINE (G4KC-GSL2.4)ENGINE BLOCK EM-57 78) 11 Remove hock sensor. 14, Romove water pump, (S00 page E 15, Romove balance shat mode. (See pape EM 81) 18, Remove lator roi). 17. Chock the ennecting rod end play. (S60 page EM - 33) 18. Remove he conocting od caps and check ar ance, (Seo page EM 58) 18, Romove pistn ad connecting rod assembles. 1) Using aridge ame, remow alin carbon rom ‘help othe ytnaor 2) Puen to piston, connecting tod aesemby ane Upper beang tough the op ofthe eylncor ‘oo Nove Rept bows, cnet re dep gamer + Arrange the piston ana connecting rod assem ble he comet order, 20, Remove cranksat boating cap and chock ol oar anco. (S09 pago EM =), 21. Check he cankshat ond ply (See page EM 63)ENGINE (G4KC - GSL2.4) £22, Lhe orakshatA) cut o he engine, being cart oto damage jours, Guore “rage te man boas ands Deus ho Cec ctr 23, Cheek ft between pion ana ston pi. “Ty tw move tne piston bark and orth onthe piston Din. any ovement fel, ope the pston and ph as eset 24, Remove piston rings. 1) Using apston ring exponer, remove the 2 com pression tgs 2) Remove 2 ido alls arte spacer by hand nore ‘Arange ho piston rags inthe coect order ony. 25, Disconnact connecting rod tom piston INSPECTION. excuse ‘CONNECTING ROD ANO CRANKSHAFT (Chachi canning red end play Ling for gauge, measure the end play while roving the caocing ea back and ot "“Bendard end py 0-0 25nm(0008 -OGTOR) asian ond ‘O.35rmm(a03380) + toutatcerance instal a nw connecting od 4 et ourobotrece,repace ne cranks (Check tre comectng road bearing otc +) Check the matenmarks on the connecting tod land cap ore ligne o ue coo easton by. 2) remove 2 vray a 9) Remowthe connecting rodeapand beedng hal, 4) Clan th crank pn and bear. 15) Pace paeigage across the crank pn 68) Reinstalthebearnighaandcapandtorquethe bot Tghionng wee wm ong eaebie) som Gore Do not tun me crankshaft 7) Remow? bot, connecting ode anbestngENGINE BLOCK 18) Mossuro te plasigag at is wisest pont ‘Standard olf desrance (0.026 ~ 0.0¢8mm0.0011 - 0018) 9) ho plesigage messures to wide ooo nar- ‘om, fomov the upper al of boating, = ‘tal anew, compote bearing withthe aa color ‘mark soc tho color as shown in the next Ge), and ache ne cloorance AS caution Do not fl, shim, or serape the bearings or the caps to adjust clewrance, 10) ho plastigag shows th clearance i il in- Comedy, ty the not lrg or rater Dering (he {alo ised above or below that on), and check ‘earance again, Nove {the proper clearance cant be ebained by using ‘he operprte ager or anata eaitys, scene ‘Sankhat and ear cree, Ay eavron "a mark ar ndacphrabe because of 9- ‘unuinion oft and ust do ot se ters tha we brash or sre: Cea hem on wih vento eoteget CONNECTING ROD MARK LOCATION DISCRIMINATION OF CONNECTING ROD CLASS MARK | INSIDE DIAMETER : a) S800 51.0080 20078 20081m) > Be | S008 = 51.0%2nm (2008-20089), ‘51.012 51.016 . © | ones 2008s) (CRANKSHAFT PIN MARK LOCATION. BIscRIMNaTiON OF CRANKSHAFTEM-60 ENGINE (G4KC - GSL2.4) CCAMINATION OF CRANKSHAFT 11) Secon cxsass | ark | oyauerener em | | opanwsnarr | Connect: | ASSeNEnG sGenenTON , + arses a7 ran anc" | wenmrica | caTion oF ate sooo) 7 7 [#7860 = #7 3880 aw DELON vans‘) 10 [ee Teranten A 5 ata ee eI) won LL (1.8878 ~ 1.8881in.) aA C (GREEN) LACE OF IDEITIFICATION many (ConwEcTING we [ees mone RS RSARS BREMNER be) __p coun =) hone we [ee ]ae@uen eA eL0e) DISCRIMINATION OF CONNECTING ROD BEARING cuass | an | THGKNESE OF a [swe [etsy A [wm | cM, Ce a a a Check the cankahalt bearing ol clasrance 1) Te check main berngojoural ot wsrnoe, remove he main caps andbearg hates 2) Clean each main ural ar bearing hall wins loan step tower 13) Plaoo oe sip of pasigage across ech man pura 4) eit he earings and eps, hen forge the ote “Tightening tor 254i 2 Tei 1BSRDIM) + 45" 1 not tm to crankshatENGINE BLOCK 5). Removethecapandbesing again, andmessure ‘te wos part the plasigegs ® plasigage measures 100 wide or too nae row, remove the upper ha of he bearing. Sal anew, complet bearing wit the same color ‘ar aces the cobra shown ithe nan 0 Ur, andrecneck te clearance Q) cauon Do not Mle, shim, or serape te bearings or the cape to adjust clearance. 17) We pasigage shows the clearance is sti n= ‘corse ret ager sale bearing the olor std above or alow tat one), and chock ‘oarance aga Grore {tho propor laranas cannot bo eblaind by wxing {mo apprennte larger or smal Bearings repo ‘anlahat and start over, Gy caumion tthe marks are indecipherable because of an 3e- ‘cumulation of ert and dust, do not scrub thor (nth a wire brush or seraper. Clean them onty with {Solvent or dotergent EM 61 CONNECTING RODS 1. Whon rinsing, mako sure that cyngor numbers ‘ul on the connecting rod and cap at daaesorbly ‘atch Wher anaw csonacing fedsinstaled mak {Sur tha th notches for hldbg the bearing nace ‘scm a sume ase 2 Replace the connatng rd tt s damaged on the Att faces st sther end Also # lop woar ot ‘Soverlreughsurace of the nldedlamatar othe Small ends apparnt, the rod rust bo roped 25 3. Using a concingrod airing ool check te rod for bond and te: Ithe messed val close fo the ‘repaint correct the rodbyaposs. Any connecting ‘odtnathas boon sveolybontordsiorted sould be replaces. “Rowabl bordelsomoctng roa (.osmm Toor (0020 in/.06 i) orloss ‘Alowabe wit of comectng rod (rm 100m (00099 8.94) or oss Ccrankshat bore mar location Ltrs hav en stampad onthe lok as mark tho 20 of echo tho 5 mah ural boos. Uso nom, an the numbers ota stamped onthe crank (markstr main joule), o choose a reat DoarngeEM 62 DISCRIMINATION OF CYLINDER BLOCK [[eatss [ware [sive orawereR . a | 58:00 = 58.06 | (@20e7 2.20680) 5 3 /58:008 = 58 012Rm (220922080) ° D382 SB0r8m (@20s222084n) | (CRANKSHACT JOURNAL MARK LOCATION. [SISCIIMRNATION OF CRANKSHAFT DISCRIMINATION OF CRANKSHAFT cass: MARK ‘OUTSIDE DIAMETER OF JOURNAL 5igs4~ 51.9500 (eosse 20456) 51.48 —61.954nm (20482 - 20454). 51.942 51 940mm (ous 200520) BEARING ENGINE (G&KC -GSL2.4) PLAGE OF IDENTIFICATION MARK (CRANKSHAFT ING) DISCAIMINATION OF CRD HSH DISCRIMINATION OF CRANKSHAFT BEARING onl THICKNESS OF cuss | mark nee 226 = 2.029r" a BLWE | o7er-co7ean) 2.029 ~ 2.060" 2 BLACK | coves o7e7In) 2020 - 2.0880 e NONE | co0798 - 00786in) 2017 - 2020nm s GREEN | (oo7s4 075i) 2014-20170 2 YELLOW | (oc70s~ ocroain) SELECTION CRANKGHArY |, RANK: | _ ASSEM IDENTIFICATION | peNTIFICA: | SIFICATION. MARK | TION MARK | OF BEARING am DivEUoM) to [be ‘C(GREEN) | 210) (NONE) i a0) ‘C(GREEN) ve pe (NONE) L ec) TRIBLAGKY a) (NONE) | we be 7 (BLACK) l 20 A TBLUE)ENGINE BLOCK EM 63 4 Check eankahat and pay 5. Inspect mah journals and rank pins Using a cal indicator, measure ho rust larance "Using a miromata, maak the darmter ofeach While pring the eraanant back endfor wih 8 malnjournd and ork pin tinal carats snd 518800 “Standard end play (ous - 20«8n) (0.07 = 0.25mm (0.0027 - 0.0098) Crank pn dlanote : 47.958 - 47.972mm Uma 6 6mm (0.01 8n) (1678 - 1.886) rte ond pay ie gostor han maximo, replace the thst Bearings a 2 set. ‘Thrust bearing thickness 4.825 - 1 985r4n00758 - 0.0736in) —EM 64 ccrLnper BLOCK 1. Remove gasket material Using gaskat sage, romove lhe gasket matoral from ths top aura he eying oc 2 Clean eynderbock Using aso brush and sven, Poroughly leanne extn Bock. 3. Inspect top auras of yindor lek for abo Using procson suaight edge and folor gauge, rmeaoute the suraco contacing tho oyinder heed ‘ast for warpage “Fsiness of cylinder block gaskateurace ‘Stander Less an .05me(0.020 4 nspoc cinder bore ametor “ica St yao reel eta I doop scratches are presen, rplace te onder ‘ose 5 nspoc oyinder bore same Messure podtiontton the Botom of the cylinder ‘oat "10.7mo 3562 y16ommI6 2000210082677, check the exinder bore azo code onthe cylinder Dock Using ender bore gauge, measur the onder ene bore ameter at poston Ine trast sd al - = rections. + | Cytacer bore ner mater | Se “Standard dlamator y {8800 - B80imm a £88.00 ~ BCom (0.4845 ~ 34857) aay 188.03 ~ 88.02r0m 5 (S4sie. 9.4688) B 18.08 - B8.00r0m cc 4850. 9.4657in) uENGINE BLOCK EM 65 7. Cheek te piston se code on he piston tp tee Boring liner 1. Oversize pidons shoud be selected acorng to he largest bore cnr [entire [Si [os 72m (06T9R) 2 oso (2629) Guore ‘The sz o son stamped on op ote piston 2. Measure the ouside Bamstr of te piston to be tee 3. Recording tthe measured 0, east the new toe site Tew bore saa = Paton O10 + 008 10 0 4mm (0.0008 to 0:0'6in fewarance between piston and eflecer)-0.0tmm (20008) (heing Marg) Drore ‘Stamp the grade mark of basic ameter wih rtber samp. Sie cass | Piston ourer diameter | Sie a Brat ~ 788mm e (9.4888 5469719) 2 46a7 — 24641) Nene {8799 - 88.00 [esas saetsiy |. Solct the piston related onder bore class. ‘lose 062 - Coa (200078 ~ GGOI6TIN) 4 Borw each ole eyinders tthe cleiated sz, QS caution Toprevent istotion that may result rom temper- ature rise during honing, Bore the eylinder holes Inthe tring order: 5. Hone the cyndors, ishing them to the props: d- rmensin piston eufelde mle gep wit vind) 6, Chock the oxrance between the piston andoyinder ‘Standard: 008 Damm (0008 -0.0%6in) When born he ayindes ish al of he cynders ‘ene sane once. a Dw anyone rrEM -66 PISTON AND RINGS 1. san piston 1) Using a east separ, emave ne carbon tem tho pion op, 2) Usinga groove cleanin olor brokancng, clean the ston ing roves 2) Using cohent and brash horougny clean te pon. Gnore De not uss 2 wits Brash 12. The standard measurement ofthe piston ousie meri akon 47 rm (1-85 in) fom tho top ans of ‘Standard diameter {7.87 ~ 88. 00mm (8.4695~ 8.4685) 2. Caled tha dterenes between he clade bere moter andthe piston darrtor Pistondo-elindor cleerance (0.62 o.04mm0.08 0.0016) ENGINE (G&KC-GSL 2.4) Inspect the pston tng side clearance Using a fool gauge, measuretheearance between row piston reg arin wal of rg groove. Piaton rng sds erence Standara Nott? 003 - 007mm (0.0012 - 0.0027!) No2: 003 - arm (00012 -o00z7!) Olin 0.06 0.1m 0.0024 - 060591) nt Nat : 0.1mm (0004in} No2: 0.1mm (0004in) (Ot ng: 02mm (00a) 1 loarecosgroator han maximum replace the pistonENGINE BLOCK 5. Inspeet lon ng end gap. ‘To moasuro tno pon eng end gap, inser piston ‘ng it te cynaer bore. Postion te ig a ight angles fo the eynder wal by gent pasang down wha piston, Measure the gap witha eter gauge. the ot ewosece he sre lint, replace the pton ng he gp too larg, recheck tho yan bore ‘tamotorepanst the wear tts on page EM 64 tho ore i over the serie li. the eye Bock rust bo rebrod. (S08 page EM 65) Pieton ring end gap Standard. Nos! 015 - od (0.0089 - 0.01180) Nea: 090 osm fa0r%8 ~ 00177m) Ot eng 020 - 070mm (0.0079 - 00275) Umi Nt: 0.6mm (0.0256) Nog : 07mm (0.0275) Ob tng! Om (0418) EM 67 PISTON PINS 1. Measure the lamatr of pln i Piston pin diamater 21.001 2.006nm (0.8268 ~ 0.8270) 2. Moasur the aon pinse-piston clesranes. Piston plniopton clesrance ‘0.0% Gem 0.0004 C0008) ‘3. Check he tren been he piston pn amar and the connecting red mal nd amt. Piston pi-to-cenneeting rd interfeence (.0%6 = O.oszmn (0.00068 = 0.00126). 01 BRERSURE SUCH 1. Chock the cetinuty between he terminal and the boay th an armmete I the is-no conn, repiace the cll pressureM6 ENGINE (G4KC - GSL 2.4 REASSEMBLY cams: Dnore + Through clean al parts to assemble. 1 Botore stating ne pars, apy rash engine of {pal seg and rtaig suraces + Foplace ad gaat, Oring and of seal with new prs. 1. Astoria pion and canacting od. 1) Uso 2 meraute press for nsttaion. 2) The pion front mark and tho connecting ros ‘ron marc muat face th ting bet side of he engine 2. che no conn btoon He nla he Soay no te rae span re Shay an ten he ie fost rope he < och 21a no contly whan #5458 7s) vcs 1 pd oegn ne Ml ess sopra i feakage. a aks, the phragm i 2. Insta ison ngs. 1) Instat ollng spacer and sis ail by hand 2) Using aplston cing expand, instal ho 2 com preesior ngs win the code massing upwara {3 Postonth piston rages hat he ing end aeENGINE BLOCK ntl eonnctg od Bearings. 1) Aign bw bearing caw with tn groove fhe con- esing red or cennectng Yo cp. 2) Insta tho boarngs( inthe connecting rod and connecting od e800). 4 Install min boarng. Nore Upper bearings have an of groove of. hoes; Lower baring 09 not. 1)Algn ne bearing claw wth tho cam groove fhe Cylinder beck. push he 5 upper Deeings) 2). ‘gn tho bearing claw wth the caw groove of the main bearng cap, and pushin the 5 lower bowing EM 69 5. Intl rustbearings. Instat he2 tut boarngs(A) under the No journal oston of fe einder eck win te groove a+ fg outers, 6. Plaoecrankahat an he eying block, 7. Place main baring caps on ond bok 8. Install min tearing ca bos, Tighining torque Man baarng ep bot 25.45 2 Tim, 1OS2B) +48" Nove + The man besrng cep bots are dghsned in 2 progastve stops, + If any othe bearing cap ots n broken or de Tome) rpiae 1) Apply aight coat engine oon the threads ans Under the bearing cap batsEM 70 ENGINE (G4KC - GSL 2.4) 2) Insta and unr tghin he 10 bearing cap) Aap engine ol tothe bot rads. sal be otaia) mn soveral pastes, In tho saquorce ‘od cape wth bean, ana trque he bal shown, - Tigo tor, “Tightening torque: 2 Whim (2 Fgh, 0 SOBA RD {osm (ong, 14.4600) + 90° Maintain éomwrars force 0 te ring compressor 0 proven te ings tom expanding bates entrng the ‘finder bore 8) tighten he bearing cap bois by 45° th ‘oral sear shown 4) Check tat he crankshaft tus smooth Soon 8. Chack rankshat end pay. (S60 page EM - 62) o-oo an amano Tetenks en einen sane BETTErAs 42g 17282020) Gnore Before ntaling the pistons apply a coat of gino ot {© he ng grooves and cinder Bare 1) Remove the connarting rod cap, ane ip short ectons otter nose over he treade ene OF te comeing rod bts. 1%, Insta aasorrame(A) with 10 bots 2) Intl ho ring compressor, chack hat the bot Ingi sncirelyn plac, on peson he piston ‘te cynaer, and ap in usng he wooden han: {a a names {3}. Stop ator the ring compressor pops tse, anc chock tha comecting rodlohack ural eos ment before pushing te piston no pace,ENGINE BLOCK Ew7 Gore + Be assombing lder ame, tho lau slant Lotte 5800 shout be apd aca fame. + The part must be assomtied iin 5 minutes ar soaan was apple. + Aaply sealant fo the ener treads of the bot 1. Instat ol peesure sersr. 1) Apply ates to 2 03 treads. ‘este’: MS 721-800) or savalont 2) Intal ho ot pressure sensor (A) Tightening torte T4~ 176A (08 ~ 1 2kgim, 8.78 B7BI) 1, Iota aro ees, 1) Apply engine otto new ol seal ip. 2) Uaing $S7(00091-+1109, 08214-0K100 and a har api th ol seal unlit utes Mash Win he rar eel retainer eoge. 18, Insta lane shaft module, (S28 page EM 8) "4, Insta water pump. (See page EM - 78) 15, Ins CAP senso) and sensor cover Tightening torque 382- 38ENm Ot 289 -494b1n) seme SigcE ENGINE (G4KC -GSL2.4) 17, ata knock sarsot). 19, Install onsionr assembly intograts bracket) “Tiohioning oraue SSC hig Yoru —— Yes 25d8Nim (1.7 ~28igim, 1220-187abrt) 98 92 «32590%) 18, Insta ol lve gauge assembly 20, Install power stoerng pomp backs ns power stor- oq pump. (Se ST group) 21, natal aero. (S00 EE group) 1) Install new Oving on theo tv gauge 2) Aoply engine aon the Oving Instat AVG cxmpressor. (See HA gr 2) Intl the ai evel gags assemiy(A) wi the apap bor 2 23, Insta cylin: hese. (See pape EM - 43) “Tiohiening torque ——~SSCSCSCSCS*S*~*«S, Ca tings, (So page EM 25) Tt TBA (08 1.2kgim, 878 ~ 67) 25, natal ol pan 1) Using arazor bade and gasket scape, remove ‘lth ot pacing mel am tne gost Su ‘acoe Nore ‘Ghack na th mating surtacs are clean an cry be- fore anoying gud gate,ENGINE BLOCK 2) Apply tquld gasket as an even baad, covered between the edges a he rating sure. Use igus’ gasket LOCTITESG00” or equiv: Tontgs721-408). EM-73 28, Remove once stand 27, AT neal ve plate Tightening tora 117.8 127-4Nn (12 ~ 13g, 86.75 - 92.6861.) 28, MIT: tal yon, Tighiening torgue 117.8 127 ANN 12 19kgkm, 85.75 ~ 89.81.) *+ To prevent leakage of ol, apy quit gasket toler tessa the bl hoes. +o ot ist he parts five mutes o° moro ‘nave elapsed since applying the qu gasket insted, reap ud gasket afr removing the resis, + Aer assomby, wait a lest 30 minutes before ‘yg ho engin with of, 3) sta to ol pani noni ghen the bots in sevrl pass. Tightening torque MSG): 26.48 = 3098Nm (27 ~ .thgm, ‘ose ~ 221.8) M6(C)-0-18.76Nm(1.0~ 12k, 7.25~ 8.6704) Gyore + Aaya na aap) Dts + Ina and nominee! passaEM.74 ENGINE (G4KC -GSL2.4) COOLING SYSTEM COMPONENT cre 147-2188 (15-22, 1084. 18.90) 196 - 25.40(20~27, 14.46 ~ 19.52) “TORQUE : Nom (tins) 1 Wate pump 5. Watortemp con assent 2. Water pump gasketCOOLING SYSTEM, ENGINE COOLANT REFILLING AND BLEEDING sous @ warn [Never remove the reat cap when the engine ls hot. Serous scaling could be causodby hot Mul unde high pressure escaping fom the radar. & cauion When pouring engine cotent,be sure to shut the ‘rlny Box band no to let coolant spill on the letra parts or the pan. any cootant spl, ‘neo I of immediatly. 1. Mako cure the engine snd racitr are col tothe 2 Ramo redatr cop, Loosen the dae plug, and dan the coolant 4 Tighten th asator dain plug secur 5 Ramove, tan andrensta the reservoir. Filth tank hata to me MAX mark wth water, ten Up 1 the MAX mere wth antioezo 6. il ld mature wn coolant and waters: 6) alan ‘trough tho radiator cap, Pus he uppeoworhosos ‘ofthe radatorso es Dsed ai een + Use only genuine atroesetootant 1 Far boat sorsionprtacton, he colat con. cantar mustbe maintained yar found at 50% ‘minum. Coatsnconcantons ae en 50% ‘nay not ronde suiien pretacton agains! co traln eeu + Golan coreoramtons ret tan 0% itn Farseeing ony oa scorers By eavron * Do not mix. dtrent brands of a Ieatwoslnt, + Dovnot use adetional rust Inhibitors or ant- rust products; they may not be compatible ‘wth the eootet. M75 7. Sarthe ongino and un coolant roves. ‘Wien te cooing fan opartes and coolant crea laos, ot eslant rough he radiator cap. 8. Repeat unl th cooIng fan 3 ~ Simos anblood ac utente of he cosng eaten, 8. Instn radiator cap andthe reser tarktothe “a3 ne wih colar, 10, Pun the vehele under i vil the cooing fan opr sles 2-9 bes. 11, Stop he entine an wat coolant ges coo 12, Repeat 6011 unto coolant eel does al any ‘nore, aed outa he cooing oyetem, Nove ‘As ts 0 lad a oto he cooing 5)s0m and rt ‘oolan wher coolant gos cool completa, reco iho coolant wveln ta reserva tak er 2~ 32s ‘ter rplacig coolant cap TesTING 1. Romovo te radar cap wot #6 eal with engine coolant er ntl ino possi ete 2. Aoplyaprossue of 93 12843 (0.95 ~ 1.254 1219p 3. Cheek tora top in posse 4. me pressure crops, piace to cap.en yesnNe 1 Walt until engine is coo, hen cary reno te radar cap and lhe restr with engin coals, then ital ion the pressure tote. 2. Apply a pressure teste 16 the radtr nd app Procure of 93 120KPa (O95 ~ 1.25Kgler 14 = ‘open. 3. Inspector engine coolant aks anda drop in pos 4. Remove the tester and renal te redlator cap. cfr ange ol in the coolant ado cotati the engin ot ENGINE (G4KC - GSL.2.4) REMOVAL soso WATER PUN 1. Drain he angne coo. ‘oat 2. Remove ore bat 8, Remove exhaust manos. (Se0 apge EM - 87) 44. Remove te water pure. 1) Remove he 4 bole an pump pute. 2) Remove the water pumo(®) and gasket. 5. Ramove water inet pipe nitCOOLING SYSTEM, ‘THERMOSTAT emo! ofthe theemosat would have an adver ‘ec causing 2 erng of calng afeney. Do ‘at romove the thamosta. ever tha engine lands fo ommost 1. rain engine coolant ots eal is below theme. 2 Remove water nai) ane hermosa). INSPECTION. con \waTeR PUMP 1. Check eaehpertforeec,camage or waar, ane piace th eosin pp ascemby #necsssany 2 Chack te basing or damage, abnarmal nase and sluggish rotation, and race ine coolant pump as Serly# nesoseary 8. Chock or cosa lekage. colat leaks trom hole, tha seals eect, Replace te colt pump 95- sonbly Gore ‘A sma sein of weeping" tom he ed hes ‘oat ‘THERMOSTAT 1. Inmeree the thermostat in water and pracy hast Ito valve cpening temperature isnot as spect, replace he hermosi Chock the va it ‘Va it: Bm (0.3n) of more at 950 OS) iho vane snot espace, replace the harmo" ENGINE (G4KC - GSL 2.4) INSTALLATION ess ‘THERMOSTAT WaTER PUMP 1. Pace thermestt in harmosttneusng. 4. Insta he water pur. 1) Insta te tarmostat with tho jggle abe up vrs 1) Insta ne water pump(a) ands new gash wih the S bots 2) ntl anon thermostat) Tanning trans 1815 2646Nm (2.0 - 27hgtm, 14.6 ~ 18.5264) 2. intal water nit) sox “Tightening toreue eee 1477 = 20 seN (15 ~ 2.2kghm, 10.84 - 15.900) 2. natal ator nat pipe a 3. Falwih orgie coolant. “Tiahtening torque 4 Start engin and check or tak. $916 2640Nen (20 ~ 274ghm, 14.46 ~ 10:5b¢) Install exhaust mani. (S90 page EM -87) Instat ave bot. Star engin an check fo lak. 5. Falwa engine coolant @ 7. Recheck engine coolant veLUBRICATION SYSTEM EM-79 LUBRICATION SYSTEM COMPONENT me 98-1176 (0-12,723- 867) frm scence ‘TORQUE : Nam (afm OL) “Balance shat module “4 Balanco shar can sprocket 2, Ojindr beck 55 Balance shat un gud 5. Balance shattchaln 6, Balance shat en fonsioner armM20 ENGINE (G4KC - GSL 2.4 OIL AND FILTER ccnase QS caurion * Prolonged and repeated contact with mineral ‘i ll reeut nthe romoval of nara fats {rom the kin, leading to dryness, Iittion ‘and derma. In addon, used engine oll ‘ontine potently harmful contaminants ‘inion may eause skin cancer. + Exereige caution In order to minimize the lngth and trequeney of contact of your skin 1 used ofl Wear protective clothing and ‘stoves. Wash your skin thoroughly with soap land water, or use wateriess hand cleaner, {remove any used engine oll _DO not use _gasolo, thinner, or solvents Iorderto preserve the environment, used oll and used ol iter must be disposed of ony at designated aloposa tes. 1 ran engae ot 4. Remove th a er exp 1 Remove te ot eain plug, and dante lino 2 Replace ol itr, Chock and clean te ol er intaatin surac. ©. Cheek te part numer ofthe new ol ers as ima oon, 6 Rep Caan ene ote usaf anew ©. Lgnty serow he ol ar lace, and ten nal te gaskat contacts ho soa Tightening torque N76" 1568Nn (1.2 1.0hgtm, 8.67 ~ 11.578) 3. Rett wth engine ol te Clean ane instal th oF dain plug with @ new asta Tiohtening torque 38.2 4 Thm (4.0 ~4.Sigim, 269 - sain) ili Hash engine i ‘Capacity Drain an ro WO ter crange: 4.0 (4.290.252 as) {WO Otter change 3.71 (90U.S.e8, 326i a) 4. Start engine and check rol aks '5. Recheck ene o vs. INSPECTION 1. Cheek oni ol quality {Gheck tool or dtarraton, entry of water, eal forng or timing. Ie quay Waly poor, repice the ot 2 Check eng al oe ‘Aor warming up he angle andthen S minutes ater the eng sop olla sreula be between" L tnd” Fark on tho ope Io, ehactr leakage and aa ll up tthe" F* mace Grore Donot A wih engin of above the” F mark ‘SELECTION OF ENGINE OIL Recommend AP clsstteaton: 8) OR ABOVE Fecormonde SAE viscosity radu: SW-20 Grore Forbes portance and maximum potscton a ‘ypesc pation sole only fase unicants Wheh + Satis ne requirement ofthe AP lassitcaton. 1 Fave paper SAE grase number or expectedam- bent fenperture range Lubricants nt donot have bath an SAE grade um ber and API service dasscaton onthe cantainar Should nt busesLUBRICATION SYSTEM. REMOVAL crv 1. Drain engin ot 2, Remove he eve bat 8. Tarn thecrankshat and align the whe groove onthe ‘ankahat ploy wi te pl onthe lower cove: (S00 page EM 8) 4. Remove theo pan. (S08 page EM - 20) ‘5. Remove he tinng chan. (See page EM - 18) 8. Remove balance shat chains) and balance shat roa EM 81 INSTALLATION. wcice 1. Intl balan shat chan 2, Conf the tatanoe shaft moc timing mark. Tn lng mars Toe visual alignd win comtrs of a conteasttinng notches. (Seepage EM=25) Intl balance shat modu tht the ting mar of Balance shat moc sprocist shou be matched ‘wth ho meg mar (or nk ofbalanos shaken. Tighinig torque Tesh (17am, 12.5010) « 0" 60" Insta ning chain, (Se page EM 24) Insta ol pa. (See apge EM - 28) Filwith onghe ‘Stat engine and check oaksEM 02 ENGINE (G4KC -GSL2.4) INTAKE AND EXHAUST SYSTEM COMPONENT curce INTAKE MANIFOLD 1 intake manld geskat 2 nate manfold assombiy 43. Toto bodyINTAKE AND EXHAUST SYSTEM. [EXHAUST MANIFOLD EM 83 02-443 (60-45, 2092-3259) se62-2748 (19=28, 1373-2020) “TORQUE: Kam (atm, OLA) 1. Heat peotector 2 Gena mantis 3. Exhaust manfol gasketEM 84 MUFFLER 98 - 147(1.0-15,728 - 1088) esas 8 (10 15,723 - 10.88) 992-508 (40-60,2892~ 4337) 392 58.8(4.0- 60,2892 ~ 43.7) TORAUE : Nam (atin, I.) Calais conver er ber 2. Contormutor 5 Gasket 5. Mein mutlorINTAKE AND EXHAUST SYSTEM EM-85 REMOVAL ewes INTAKE MANIFOLD 1 Remove the engne cover. (Soo page EM 18) 2. Disconnect ETS connector)M26 ENGINE (G4KC - GSL2.4 7. Remove oll pressure svtch comneciorA) from 10, Remove ol lel gauge. bracket 11, Remove tae mano tay). ‘Sy SeINTAKE AND EXHAUST SYSTEM. [EXHAUST MANIFOLD 1. Ramove the oxygen sensor connector. 2. Ramo the trot mur, 3, Remove the heat protector. 5. Remove exhaust mani) and gasket). EM-87 INSTALLATION sxx [EXHAUST MANIFOLD 1. sta galt and exhaust manos Tigieingforus 292 eINIM.0~ 5kgim, 28.92 ~ SOS) 2. nstal exhaist mentld stay bt, “Tieiorng tore 51 94 S7S2NMSA~ Sokal, 383 - 42.601) 3, Insta heat proteter Tieng ove feos aris, 4 rata rot mut ‘Tahiering tore 392~ 58.8Nim.0~ 6oxgim, 28 ret) 5. Consct eygen sensor connec INTAKE MANIFOLD 1 Intl gasket and intako ano “Fatening Torus 1882-27-44. = 284glm, 18.7 ~ 20.2b60) 2 natal inate mano stay Tiohonng ove 185-2744 at 2o.2eun) <4 nt ot a ga 4. natal Povo 5. Intl arclsaner aston. 6 Insta engine cover.