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PRODUKT NIEDOSTĘPNY
Indeks towaru: SILNIK 2,4
Realizacja zamówienia: 24

WYMIANA USZCZELKI GŁOWICY

 Labor Operations: Click to display a list of Labor Operations associated with this procedure



NOTE: The Cylinder head bolts should be examined BEFORE reuse. If the threads are necked down, the bolts should be replaced .

Necking (1) can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale (2) , the bolt should be replaced.

NOTE: Cylinder head should be cleaned and inspected prior to replacment.

1. Position the new cylinder head gasket on engine block with the part number (1) facing up. Ensure gasket is seated over the locating dowels in block.

2. Position cylinder head onto engine block.

3. Before installing the bolts, the threads should be lightly coated with engine oil.



4. Tighten the cylinder head bolts in the sequence shown. Using the 4 step torque-turn method, tighten according to the following values:

  1. First: All to 34 N·m (25 ft. lbs.)
  2. Second: All to 82 N·m (60 ft. lbs.)
  3. Third: All to 82 N·m (60 ft. lbs.)CAUTION:Do not use a torque wrench for the Fourth step.
  4. Fourth: Turn all bolts an additional 1/4 Turn

5. Install rocker arms

6. Install camshafts (3)- INSTALLATION).



7. Install cylinder head cover 



8. Install rear timing belt cover and tighten fasteners (1,2)- INSTALLATION).

9. Install timing belt tensioner.

10. Install camshaft sprockets and timing belt



11. Connect cam sensor wiring connector (3).

12. Install ignition coil and plug wires. Connectignition coil wiring connector.



13. Non-Turbo equipped vehicles: Install power steering pump bracket (3) and reservoir ( 1) to cylinder head.



14. Turbocharger equipped vehicles:

  1. Install coolant return line (2).
  2. Install coolant supply line (3).
  3. Install oil supply line (1).
  4. Install oil return tube (4).

15. Turbocharger equipped vehicles:

  1. Install elbow (3)
  2. Install turbocharger support bracket (2).
  3. Install elbow support bracket (4).
  4. Install turbocharger heat shields (1).

16. Install exhaust pipe to manifold. Tighten fasteners to 28 N·m (20 ft. lbs.).

17. Install accessory drive belts



18. Connect engine coolant temperature sensor connector.

19. Connect upper radiator hose to coolant outlet (2). Connect heater hoses to thermostat housing.

20. Install heater tube support bracket to cylinder head.



21. Turbocharger equipped vehicles: Install lower intake manifold support bracket (3).



22. Install fastener (3) attaching dipstick tube (1) to lower intake manifold.



23. Connect fuel supply line (1) quick-connect at the fuel rail assembly

24. Install upper intake manifold

25. Remove radiator pressure cap (3) and fill the cooling system (refer to section 7).

26. Connect negative cable to battery.



27. Install clean air hose (1) and air cleaner housing (2).

  

 

 

 

 

 

 

 

 

TABELA WARTOŚCI MOMENTÓW DOKRĘCANIA

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.
Balance Shaft Carrier to Block—Bolts 54 40 -
Balance Shaft Gear Cover—Double Ended Fastener 12 - 105
Balance Shaft Sprocket—Bolt 28 - 250
Balance Shaft Chain Tensioner—Bolts 12 - 105
Balance Shaft Carrier Cover—Bolts 12 - 105
Camshaft Bearing Caps 12 - 105
Camshaft Sprocket—Bolt 115 85 -
Connecting Rod Cap—Bolts 27 +¼ turn 20 +¼ turn -
Crankshaft Main Bearing Cap/Bedplate    
-M8 Bolts 28 - 250
-M11 Bolts 75 55 -
Crankshaft Damper—Bolt 136 100 -
Cylinder Head—Bolts Refer to Procedure
Cylinder Head Cover-Bolts 12 - 105
Flex Plate to Crankshaft-Bolts 95 70 -
Engine Mount Through bolt-Right 118 87 -
Engine Support Bracket-Bolts 61 45 -
Exhaust Manifold-Bolts 23 - 200
Exhaust Manifold Heat Shield-Bolts 12 - 105
Exhaust Pipe to Manifold-Bolts 28 20 248
Intake Manifold Upper-Bolts 12 - 105
Intake Manifold Lower-Bolts 12 - 105
Intake Manifold Upper-Bolts (Turbo) Refer to 9-ENGINE/MANIFOLDS/INTAKE UPPER-INSTALLATION
Intake Manifold Lower-Bolts (Turbo) Refer to 9-ENGINE/MANIFOLDS/INTAKE UPPER-INSTALLATION
Oil Cooler Connector Bolt (Turbo) 55 41 -
Oil Filter Refer to Procedure Refer to Procedure -
Oil Filter Adapter-Bolts 12 - 105
Oil Jet Fastener (Turbo) 12 - 105
Oil Pan-Bolts 12 - 105
Oil Pan Drain—Plug 28 20 -
Oil Pump to Block—Bolts 28 20 -
Oil Pump Cover Plate-Screws 13 - 118
Oil Pump Pick-up Tube-Bolt 23 - 200
PCV Valve 8 - 70
Spark Plugs 18 13 -
Timing Belt Cover-Front Upper and Lower-Bolts 6 - 50
Timing Belt Cover-Rear      
—M6 Bolts 12 - 105
—M8 Bolts 28 - 250
Timing Belt Idler Pulley 61 45 -
Timing Belt Tensioner Lock Bolt 25 - 220
Timing Belt Tensioner Assembly-Bolts 61 45 -

2,4 / 2,4 Turbo GENERAL SPECIFICATIONS

DESCRIPTION

SPECIFICATION

Metric

Standard
Type In-Line OHV, DOHC
Number of Cylinders 4
Firing Order 1-3-4-2
Compression Ratio  
Non-Turbo 9.5:1
Turbo 8.1:1
Max. Variation Between Cylinders 25%
Displacement 2.4 Liters 148 cu. in.
Bore 87.5 mm 3.445 in.
Stroke 101.0 mm 3.976 in.
Compression Pressure 1172-1551 kPa 170-225 psi

CYLINDER BLOCK

DESCRIPTION

SPECIFICATION

Metric

Standard
Cylinder Bore Diameter 87.4924-87.5076 mm 3.4446-3.4452 in.
Out-of-Round (Max.) 0.051 mm 0.002 in.
Taper (Max.) 0.051 mm 0.002 in.

PISTONS

DESCRIPTION

SPECIFICATION

Metric

Standard
Piston Diameter
Non-Turbo 87.456-87.474 mm 3.4431-3.4439 in.
Turbo 87.436-87.454 mm 3.4424-3.4431 in.
Clearance @ 24.6 mm (0.551 in.) from bottom of skirt (Non-Turbo) 0.018-0.0516 mm 0.0007-0.0020 in.
Clearance @ 22 mm (0.866 in.) from bottom of skirt (Turbo) 0.046-0.064 mm 0.0018-0.0025 in.
Weight
Non-Turbo 345-355 grams 12.17-12.52 oz.
Turbo 331-339 grams 11.67-11.95 oz.
Land Clearance (Diametrical)    
Non-Turbo 0.563-0.621 mm 0.022-0.024 in.
Turbo 0.556-0.674 mm 0.021-0.027 in.
Piston Length    
Non-Turbo 66.25 mm 2.608 in.
Turbo 61.43 mm 2.419 in.
Piston Ring Groove Depth No. 1    
Non-Turbo 3.946-4.045 mm 0.155-0.159 in.
Turbo 3.713-3.882 mm 0.146-0.153 in.
Piston Ring Groove Depth No. 2    
Non-Turbo 4.555-4.680 mm 0.179-0.184 in.
Turbo 4.118-4.297 mm 0.162-0.169 in.
Piston Ring Groove Depth No. 3    
Non-Turbo 4.108-4.220 mm 0.162-0.166 in.
Turbo 2.818-2.967 mm 0.110-0.116 in.

PISTON RINGS

DESCRIPTION

SPECIFICATION

Metric

Standard
Ring Gap-Top Compression Ring    
Non-Turbo 0.25-0.51 mm 0.0098-0.020 in.
Turbo 0.20-0.40 mm 0.0078-0.0157 in.
Wear Limit 0.8 mm 0.031 in.
Ring Gap-2nd Compression Ring    
Non-Turbo 0.23-0.48 mm 0.009-0.018 in.
Turbo 0.20-0.40 mm 0.007-0.015 in.
Wear Limit 0.8 mm 0.031 in.
Ring Gap-Oil Control Steel Rails    
Non-Turbo 0.25-0.64 mm 0.009-0.025 in.
Turbo 0.15-0.66 mm 0.005-0.025 in.
Wear Limit 1.0 mm 0.039 in.
Ring Side Clearance-Compression Rings    
Non-Turbo 0.030-0.080 mm 0.0011-0.0031 in.
Turbo 0.035-0.085 mm 0.001-0.003 in.
Wear Limit 0.10 mm 0.004 in.
Ring Side Clearance-Oil Ring Pack    
Non-Turbo 0.012-0.178 mm 0.0004-0.0070 in.
Turbo 0.027-0.176 mm 0.001-0.006 in.
Ring Width-Compression Rings
Non-Turbo 1.47-1.50 mm 0.057-0.059 in.
Turbo Top Ring 1.17-1.19 mm 0.0460-0.0468 in.
Turbo 2nd Ring 1.472-1.49 mm 0.057-0.058 in.
Ring Width-Oil Ring Pack    
Non-Turbo 2.72–2.88 mm 0.107–0.1133 in.
Turbo 2.64-2.89 mm 0.103-0.113 in.

CONNECTING ROD

DESCRIPTION

SPECIFICATION

Metric

Standard
Bearing Clearance 0.025–0.071 mm 0.0009–0.0027 in.
Wear Limit 0.075 mm 0.003 in.
Bore Diameter-Piston Pin    
   
Non-Turbo 20.96–20.98 mm 0.8252–0.8260 in.
Turbo 22.007-22.015 mm 0.8664-0.8667 in.
Bore Diameter-Crankshaft End    
Non-Turbo 52.993-53.007 mm 2.0863-2.0868 in.
Turbo 52.992-53.008 mm 2.0862-2.0869 in.
Side Clearance 0.13–0.38 mm 0.005–0.015 in.
Wear Limit 0.40 mm 0.016 in.
Weight-Total (Less Bearing)    
   
Non-Turbo 565.8 grams 19.96 oz.
Turbo 663.5 grams 23.4 oz.

CRANKSHAFT

DESCRIPTION

SPECIFICATION

Metric

Standard
Connecting Rod Journal Diameter 49.984 - 50.000 mm 1.968 - 1.9685 in.
Main Bearing Journal Diameter 59.992 - 60.008 mm 2.362 - 2.3625 in.
Journal Out-of-Round (Max.) 0.0035 mm 0.0003 in.
Journal Taper (Max.) 0.007 mm 0.0001 in.
End Play 0.09 - 0.24 mm 0.0035 - 0.0094 in.
Wear Limit 0.38 mm 0.015 in.
Main Bearing Diametrical Clearance 0.018 - 0.062 mm 0.0007 - 0.0024 in.

HYDRAULIC LASH ADJUSTER

DESCRIPTION

SPECIFICATION

Metric

Standard
Body Diameter 15.901 - 15.913 mm 0.626 - 0.6264 in.
Plunger Travel Minimum (Dry) 3.0 mm 0.118 in.

CYLINDER HEAD CAMSHAFT BEARING BORE DIAMETER

DSECRIPTION

SPECIFICATION

Metric

Standard
Journals No.1 - 6 26.020 - 26.041 mm 1.024 - 1.025 in.

CAMSHAFT

DESCRIPTION

SPECIFICATION

Metric

Standard
Journal Diameter No. 1–6 25.976 - 25.995 mm 1.022 - 1.023 in.
Bearing Clearance - Diametrical 0.025 - 0.065 mm 0.0009 - 0.0025 in.
End Play 0.05 - 0.17 mm 0.0019 - 0.0066 in.
Lift (Zero Lash)  
Intake 8.25 mm (0.324 in.)
Exhaust 6.60 mm (0.259 mm)
Intake Valve Timing*  
Closes (ABDC) 44.3°
Opens (ATDC) 6.2°
Duration 218°
Exhaust Valve Timing*  
Closes (ATDC) 0.8°
Opens (BBDC) 39.9°
Duration 220.7°
Valve Overlap 5.4°
*
All reading in crankshaft degrees at 0.5 mm (0.019 in.) valve lift.

CYLINDER HEAD

DESCRIPTION

SPECIFICATION

Metric

Standard
Material Cast Aluminum
Gasket Thickness (Compressed) 0.71 mm 0.028 in.

VALVE SEAT

DESCRIPTION

SPECIFICATION

Metric

Standard
Angle 44.5 - 45°
Seat Diameter - Intake 34.37 - 34.63 mm 1.353 - 1.363 in.
Seat Diameter - Exhaust 27.06 - 27.32 mm 1.065 - 1.075 in.
Runout (Max.) 0.05 mm 0.002 in.
Valve Seat Width - Intake and Exhaust 0.9 - 1.3 mm 0.035 - 0.051 in.
Service Limit - Intake 2.0 mm 0.079 in.
Service Limit - Exhaust 2.5 mm 0.098 in.

VALVE GUIDE

DESCRIPTION

SPECIFICATION

Metric

Standard
Diameter I.D. 5.975 - 6.000 mm 0.235 - 0.236 in.
Guide Bore Diameter 11.0 - 11.02 mm 0.4330 - 0.4338 in.
Guide Height (spring seat to guide tip) 13.25 - 13.75 mm 0.521 - 0.541 in.

VALVES

DESCRIPTION

SPECIFICATION

Metric

Standard
Face Angle - Intake and Exhaust 44.5 - 45°
Head Diameter - Intake 34.67 - 34.93 mm 1.364 - 1.375 in.)
Head Diameter - Exhaust 28.32 - 28.52 mm 1.114 - 1.122 in.
Valve Length (Overall)    
Intake 112.76 - 113.32 mm 4.439 - 4.461 in.
Exhaust 110.89 - 111.69 mm 4.365 - 4.397 in.
Valve Stem Diameter    
Intake 5.934 - 5.952 mm 0.2337 - 0.2344 in.
Exhaust 5.906 - 5.924 mm 0.2326 - 0.2333 in.

VALVE MARGIN

DESCRIPTION

SPECIFICATION

Metric

Standard
Intake 1.2 - 1.7 mm 0.047 - 0.066 in.
Service Limit 0.95 mm (.0037 in.)
Exhaust 0.985 - 1.315 mm 0.038 - 0.051 in.
Service Limit 1.05 mm .039 in.

VALVE STEM TIP

DESCRIPTION

SPECIFICATION

Metric

Standard
Intake 48.04 mm 1.891 in.
Exhaust 47.99 mm 1.889 in.

VALVE STEM TO GUIDE CLEARANCE

DESCRIPTION

SPECIFICATION

Metric

Standard
Intake 0.048 - 0.066 mm 0.0018 - 0.0025 in.
Max. Allowable 0.076 mm 0.003 in.
Service Limit 0.25 mm 0.010 in.
Exhaust 0.0736 - 0.094 mm 0.0029 - 0.0037 in.
Max. Allowable 0.101 mm 0.004 in.
Service Limit 0.25 mm 0.010 in.

VALVE SPRINGS

DESCRIPTION

SPECIFICATION
  Metric Standard
Free Length (Approx.) 49.34 mm 1.943 in.
Nominal Force (Valve Closed) 311 N ±16.6 @ 38.0 mm 70 lbs. @ 1.496 in.
Nominal Force (Valve Open) 596 N ± 30.7 N@ 29.25 mm 134 lbs. @ 1.152 in.
Installed Height 38.00 mm 1.496 in.
Number of Coils 7.8
Wire Diameter 3.61 mm 0.142 in

OIL PUMP

DESCRIPTION

SPECIFICATION

Metric

Standard
Clearance Over Rotors (Max.) 0.10 mm 0.004 in.
Cover Out-of-Flat (Max.) 0.025 mm 0.001 in.
Inner Rotor Thickness (Min.) 10.699 mm 0.421 in.
Outer Rotor Thickness (Min.) 10.699 mm 0.421 in.
Outer Rotor Clearance (Max.) 0.039 mm 0.015 in.
Outer Rotor Diameter (Min.) 85.924 mm 3.383 in.
Tip Clearance Between Rotors (Max.) 0.20 mm 0.008 in.

OIL PRESSURE

DESCRIPTION

SPECIFICATION

Metric

Standard
At Curb Idle Speed* 25 kPa 4 psi
At 3000 rpm 170 - 550 kPa 25 - 80 psi

CAUTION: *If pressure is ZERO at curb idle, DO NOT run engine at 3000 rpm.