Caravan 2.5TD

RG ENGINE 9a - 1
ENGINE
TABLE OF CONTENTS
page page
ENGINE 2.5L TURBO DIESEL ENGINE BLOCK

DESCRIPTION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
DESCRIPTION - 2.5L COMMON RAIL CRANKSHAFT
DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . 2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
DESCRIPTION - ENGINE COVER . . . . . . . . . . 3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
REMOVAL STANDARD PROCEDURE - CHECKING
REMOVAL - 2.5L DIESEL ENGINE . . . . . . . . . . 3 CRANKSHAFT END PLAY . . . . . . . . . . . . . . . 31
REMOVAL - ENGINE COVER . . . . . . . . . . . . . 6 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION - 2.5L TURBO DIESEL CYLINDER LINERS
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION - ENGINE COVER . . . . . . . . . . 7 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SPECIFICATIONS INSPECTION ..................... . . . . . 34
SPECIFICATIONS - 2.5L COMMON RAIL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . 8 INTERNAL VACUUM PUMP
SPECIFICATIONS - TORQUE . . . . . . . . . . . . 10 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 35
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 12 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
STANDARD PROCEDURE PISTON & CONNECTING ROD
STANDARD PROCEDURE - VALVE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 STANDARD PROCEDURE - PISTON RING
STANDARD PROCEDURE - MEASURING FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
PISTON PROTRUSION . . . . . . . . . . . . . . . . . 18 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 INSPECTION ..................... . . . . . 38
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 21 CRANKSHAFT OIL SEAL - FRONT
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
CAMSHAFT(S) INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22 VIBRATION DAMPER
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23 ENGINE COVER - FRONT
CYLINDER HEAD COVER(S) DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 43
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25 CRANKSHAFT MAIN BEARINGS
CAMSHAFT OIL SEAL(S) REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27 CRANKSHAFT OIL SEAL - REAR
ROCKER ARMS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 OIL PAN
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46
HYDRAULIC LIFTERS OIL PUMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29 REMOVAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 30 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30
9a - 2 ENGINE RG
INSTALLATION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 52
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 47 VALVE TIMING
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 48 STANDARD PROCEDURE - LOCKING ENGINE
OIL PRESSURE SENSOR/SWITCH 90° AFTER TDC . . . . . . . . . . . . . . . . . . . . . . . 53
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 48 BALANCE SHAFT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 54
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 48 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
OIL TEMPERATURE SENSOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 TIMING BELT / CHAIN COVER(S)
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 48 REMOVAL
OIL PRESSURE RELIEF VALVE REMOVAL - TIMING BELT OUTER COVER . . 56
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 49 REMOVAL - TIMING BELT INNER COVER . . . 56
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 INSTALLATION
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 49 INSTALLATION - TIMING BELT OUTER
OIL COOLER & LINES COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 INSTALLATION - TIMING BELT INNER
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 50 COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
OIL FILTER TIMING BELT IDLER PULLEY
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 51 TMNG BELT/CHAIN TENSIONER
OIL JET REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 ADJUSTMENTS
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 52 ADJUSTMENT - TIMING BELT TENSIONER . 60
INTAKE MANIFOLD TIMING BELT/CHAIN AND SPROCKETS
ENGINE 2.5L TURBO DIESEL DESCRIPTION SPECIFICATION

Thermostat Opening 80°C ± 2°C
DESCRIPTION Generator Rating Denso 12V-95A
Cooling System Capacity 13.8 Liters W/O Auxiliary
DESCRIPTION - 2.5L COMMON RAIL DIESEL Heater
ENGINE 16.6 Liters With Auxiliary
This 2.5 Liter (2500cc) four-cylinder “common rail” Heater
direct injection engine is an in-line overhead valve Engine Oil Capacity 6.0L W/Filter Change
diesel engine. This engine utilizes a cast iron cylin- Timing System Belt Driven Camshafts In
der block and an aluminum cylinder head. The Cylinder Head Cover
engine is turbocharged and intercooled. The engine
Air Intake Dry Filter
also has four valves per cylinder and dual overhead
camshafts (Fig. 1). Fuel Feed Vane Pump Incorporated
In Injection Pump
DESCRIPTION SPECIFICATION Fuel System Direct Fuel Injection
Displacement 2.5L (2499 cc) Combustion Cycle 4 Stroke
Bore 92.00 Cooling System Water Cooling
Stroke 94.00 Injection Pump Rotary Pump and
Electronically Managed
Compression Ratio 17.5:1
Lubrication Pressure Lubricated By
Vacuum at Idle 685.8 mm/Hg (27.0
Rotary Pump
In/Hg)
Engine Rotation Clockwise Viewed From
Belt Tension Automatic Belt Tensioner
Front Cover
RG ENGINE 9a - 3
ENGINE 2.5L TURBO DIESEL (Continued)
DESCRIPTION - ENGINE COVER
Fig. 2 ENGINE COVER

1 - ENGINE COVER MOUNTING BOLTS
2 - ENGINE COVER
Fig. 1 2.5L COMMON RAIL DIESEL ENGINE

The engine cover is a black plastic cover used to
cover the top of the engine (Fig. 10). It is used to iso-
late engine noises.
REMOVAL
REMOVAL - 2.5L DIESEL ENGINE
(1) Disconnect negative battery cable.
(2) Remove engine cover (Fig. 2). (Refer to 9 -
ENGINE - REMOVAL)
(3) Remove air cleaner housing, MAF sensor, and
air intake tube assembly (Fig. 3). Fig. 3 MASS AIR FLOW (MAF) SENSOR LOCATION
(4) Remove coolant pressure tank pressure cap. 1 - MAF SENSOR ELECTRICAL CONNECTOR
(5) Raise vehicle on hoist. 2 - RETAINING CLAMPS
(6) Drain cooling system (Refer to 7 - COOLING/ 3 - MASS AIR FLOW (MAF) SENSOR
4 - AIR CLEANER HOUSING
ENGINE/COOLANT - STANDARD PROCEDURE).
(7) Remove lower splash shield.
(8) Remove splash shield side panels.
9a - 4 ENGINE RG
(9) Remove power steering reservoir hose from (15) Drain coolant system (Refer to 7 - COOLING/
power steering pump and drain power steering fluid ENGINE/COOLANT - STANDARD PROCEDURE).
(Fig. 4). (16) Remove coolant pressure tank (Fig. 5).
Fig. 4 RESERVOIR AND HOSES - 2.5L DIESEL Fig. 5 COOLANT RECOVERY PRESSURE
1 - POWER STEERING FLUID RESERVOIR CONTAINER LOCATION
2 - RESERVOIR BRACKET 1 - PRESSURE/VENT CAP
3 - SUPPLY HOSE BRACKET 2 - BRAKE MASTER CYLINDER
4 - RETURN HOSE FROM GEAR 3 - BATTERY
5 - ROUTING CLIP 4 - BATTERY SHIELD
6 - PRESSURE HOSE TO GEAR 5 - COOLANT RECOVERY PRESSURE CONTAINER RETAING
7 - SUPPLY HOSE (PUMP END) CLIP
8 - PRESSURE HOSE (PUMP END) 6 - ENGINE COVER
9 - SUPPLY HOSE 7 - COOLANT RECOVERY PRESSURE CONTAINER
10 - RETURN HOSE
(10) Disconnect high pressure line at pump (Fig.

4).
(11) Disconnect power steering pump return hose
clamp (Fig. 4).
(12) Remove power steering return line retaining
clamp (Fig. 4).
(13) Remove power steering line clamps from oil
pan (Fig. 4).
(14) Remove power steering pump reservoir and
bracket (Fig. 4).
RG ENGINE 9a - 5
(17) Remove battery shield.
(18) Remove charge air cooler outlet hose.
(19) Remove charge air cooler inlet hose (Fig. 6).
Fig. 7 UPPER AND LOWER RADIATOR HOSES

1 - COOLANT BYPASS HOSE
2 - RADIATOR ASSEMBLY
3 - UPPER RADIATOR HOSE
Fig. 6 CHARGE AIR COOLER HOSES
4 - COOLING FAN
1 - COOLING MODULE 5 - LOWER RADIATOR HOSE
2 - BYPASS HOSE 6 - CHARGE AIR COOLER
3 - UPPER RADIATOR HOSE 7 - RADIATOR BRACKET
4 - CHARGE AIR COOLER OULET HOSE
5 - CHARGE AIR COOLER INLET HOSE
6 - LOWER RADIATOR HOSE (33) Remove front wheels.
7 - CHARGE AIR COOLER (34) Remove the suspension cradle assembly (Refer
to 13 - FRAME & BUMPERS/FRAME/ENGINE
(20) Disconnect upper radiator hose at engine (Fig. CRADLE CROSSMEMBER - REMOVAL).
7). (35) Remove both axle shaft assemblies (Refer to 3
(21) Disconnect lower radiator hose at engine (Fig. - DIFFERENTIAL & DRIVELINE/HALF SHAFT -
7). REMOVAL).
(22) Disconnet brake booster vacuum supply hose. (36) Disconnect the clutch slave cylinder quick dis-
(23) Disconnect heater core return hose at engine. connect line (RHD only)(Refer to 6 - CLUTCH/SLAVE
(24) Disconnect egr solenoid vacuum line at brake CYLINDER - REMOVAL).
booster check valve. (37) Disconnect reverse lamp connector.
(25) Disconnect fuel injector, cam sensor, boost (38) Disconnect shifter cables at the tranmission
pressure/intake air temp sensor, fuel rail high pres- (Refer to 21 - TRANSMISSION/TRANSAXLE/MAN-
sure, and egr solenoid connectors (Fig. 8). UAL/GEAR SHIFT CABLE - REMOVAL).
(26) Disconnect generator electrical connectors. (39) Disconnect exhaust pipe from the turbo-
(27) Disconnect coolant temp sensor and glow plug charger downpipe and reposition to right side of vehi-
electrical connectors. cle.
(28) Disconnect injection pump and A/C compres- (40) Disconnect cabin heater coolant line (Refer to
sor electrical connectors. 24 - HEATING & AIR CONDITIONING/CABIN
(29) Disconnect starter electrical connectors. HEATER/HEATER UNIT - REMOVAL).
(30) Disconnect ground wires at engine block. (41) Remove front engine mount bracket retaining
(31) Raise vehicle on hoist. bolts from lower radiator support
(32) Disconnect oil temp sensor, oil pressure sen- (42) Lower vehicle. Evacuate the A/C system
sor, engine speed sensor, and vehicle speed sensor (Refer to 24 - HEATING & AIR CONDITIONING/
electrical connector (Fig. 9).
9a - 6 ENGINE RG
Fig. 8 ENGINE COMPONENT LOCATIONS Fig. 9 REAR ENGINE VIEW

1 - FUEL INJECTOR RETURN LINE 1 - SUSPENSION CRADLE
2 - FUEL INJECTOR SUPPLY LINE 2 - ENGINE BLOCK
3 - OIL SEPARATOR 3 - OIL PRESSURE SWITCH
4 - FUEL INJECTOR 4 - OIL TEMPERATURE SENSOR
5 - CAMSHAFT POSITION SENSOR 5 - VEHICLE SPEED SENSOR
6 - BOOST PRESSURE/INTAKE AIR TEMPERATURE SENSOR 6 - TRANSMISSION
7 - EGR SOLENOID
8 - FUEL PRESSURE SENSOR
9 - CYLINDER HEAD COVER/INTAKE MANIFOL
10 - FUEL RAIL
11 - WIRING HARNESS RETAINING CLIPS
PLUMBING/REFRIGERANT - STANDARD PROCE-

DURE).
(43) Disconnect the A/C lines at the A/C compres-
sor.
(44) Disconnect the fuel supply and return lines.
(45) Position engine cradle under engine and lower
vehicle over cradle.
(46) Remove right engine mount bolts.
(47) Remove left engine mount through bolt.
(48) Raise vehicle, leaving engine and transmis-
sion on engine cradle.
(49) Lift engine from engine cradle and diassemble
as necessary.
REMOVAL - ENGINE COVER

(1) Remove engine cover retaining bolts.
(2) Remove engine cover from engine (Fig. 10).
Fig. 10 ENGINE COVER
1 - ENGINE COVER MOUNTING BOLTS
2 - ENGINE COVER
RG ENGINE 9a - 7
INSTALLATION (24) Connect brake booster vacuum supply line.

(25) Connect heater core return hose to coolant
INSTALLATION - 2.5L TURBO DIESEL ENGINE pipe.
(1) Reassembly engine and transmission assembly (26) Connect lower radiator hose to engine (Fig. 7).
and install on engine cradle. (27) Install charger air cooler inlet hose (Fig. 6).
(2) Position engine and cradle assembly under (28) Install charge air cooler outlet hose (Fig. 6).
vehicle. (29) Connect upper radiator hose to engine (Fig.
(3) Slowly lower the vehicle down over the engine 7).
and cradle assembly. (30) Install battery shield.
(4) Install right engine mount bolts. Torque to (31) Install coolant reserve pressure container
54N·m (40 ft. lbs.) (Refer to 7 - COOLING/ENGINE/COOLANT RECOV-
(5) Install left engine mount through bolt. Torque ERY PRESS CONTAINER - INSTALLATION).
to 75N·m (55 ft. lbs.) (32) Install power steering reservoir and bracket
(6) Raise vehicle and engine from engine cradle. (Fig. 4).
(7) Attach front engine mount bracket to lower (33) Raise vehicle
radiator support. Torque to 54N·m (40 ft. lbs.) (34) Connect oil pressure sensor, oil temperature
(8) Connect cabin heater coolant hose. sensor, engine speed sensor, and vehicle speed sensor
(9) Connect exhaust pipe to the turbocharger electrical connector (Fig. 9).
downpipe flange. Torque to 28 N·m (250 in. lbs.) (35) Install suspension cradle in vehicle (Refer to
(10) Connect reverse lamp electrical connector at 13 - FRAME & BUMPERS/FRAME/ENGINE CRA-
transmission. DLE CROSSMEMBER - INSTALLATION).
(11) Connect both shifter cables (Refer to 21 - (36) Install both axle shaft assemblies (Refer to 3 -
TRANSMISSION/TRANSAXLE/MANUAL/GEAR DIFFERENTIAL & DRIVELINE/HALF SHAFT -
SHIFT CABLE - INSTALLATION). INSTALLATION).
(12) Connect the clutch slave cylinder quick dis- (37) Connect the power steering supply, pressure,
connect connector (RHD only)(Refer to 6 - CLUTCH/ and return lines to power steering pump (Fig. 4).
SLAVE CYLINDER - INSTALLATION). (38) Install the power steering line brackets on oil
(13) Install engine harness into bracket on trans- pan (Fig. 4).
mission. (39) Install lower splash shield and side panels.
(14) Lower vehicle. (40) Install both front wheel and tire assemblies.
(15) Connect fuel supply and return lines. (41) Lower vehicle.
(16) Connect A/C lines to A/C compressor. Torque (42) Install air cleaner housing, MAF sensor, and
to 23N·m (17 ft. lbs.) air intake tube assembly (Fig. 3).
(17) Route engine wiring harnes to proper location. (43) Refill transmission to proper level (Refer to 21
(18) Connect engine harness ground cables to - TRANSMISSION/TRANSAXLE/MANUAL/FLUID -
engine block STANDARD PROCEDURE).
(19) Connect starter solenoid electrical connector (44) Refill engine coolant (Refer to 7 - COOLING/
and battery feed wire to starter. Torque to 10N·m (90 ENGINE/COOLANT - STANDARD PROCEDURE).
in. lbs.) (45) Recharge A/C system (Refer to 24 - HEATING
(20) Connect A/C compressor, injection pump, glow & AIR CONDITIONING/PLUMBING/REFRIGER-
plugs, and coolant temperature sensor electrical con- ANT - STANDARD PROCEDURE) .
nectors. (46) Install engine cover (Refer to 9 - ENGINE -
(21) Connect generator electrical connector. Torque INSTALLATION) (Fig. 2).
to 9N·m (75 in. lbs.) (47) Connect negative battery cable.
(22) Connect the fuel injector, fuel pressure sensor,
boost pressure/intake air temp sensor, cam sensor, INSTALLATION - ENGINE COVER
and egr solenoid electrical connectors (Fig. 8). (1) Install engine cover on engine.
(23) Connect egr solenoid vacuum supply line to (2) Install the engine cover mounting bolts (Fig.
brake boost vacuum supply line. 10).
9a - 8 ENGINE RG
SPECIFICATIONS DESCRIPTION SPECIFICATION

-0.25 53.690-53.705 mm
SPECIFICATIONS - 2.5L COMMON RAIL
Connecting Rod Bearing
DIESEL ENGINE
ENGINE SPECIFICATIONS Nominal 53.977-54.016 mm
-0.25 53.727-53.766 mm
DESCRIPTION SPECIFICATION Clearance Between 0.022-0.076 mm
Journal and Bearing
Type R2516C
Crankshaft End Play
Number of Cylinders 4
End Play 0.080-0.280 mm
Bore 92 mm
Adjustment Thrust Washers
Stroke 94 mm
Thrust Washers Available 2.31-2.36 mm
Displacement 2499.5cc
2.41-2.46 mm
Injection Order 1-3-4-2
2.51-2.56 mm
Compression Ratio 17.5:1 (± 0.5)
Carrier with thrust 27.670-27.820 mm
Maximum Power 103kW (140 HP) @ 4000
washers installed
RPM
MAIN BEARING CARRIERS
Peak Torque 320Nm (32.6 kgm) @
2000 RPM Internal Diameter
CRANKSHAFT Front 67.025-67.050 mm
Front Journal Diameter Center 66.670-66.690 mm
Nominal 62.985-63.005 mm Rear 85.985-86.005 mm
-0.25 62.735-62.755 mm LINERS
Front Bearing Diameter Internal Diameter 91.997-92.015 mm
Nominal 63.045-63.074 mm Protrusion 0.01-0.06 mm
-0.25 62.795-62.824 mm Adjustment Shims
Clearance Between 0.040-0.089 mm Available Shims 0.15 mm
Journal and Bearing 0.17 mm
Center Journal Diameter 0.20 mm
Nominal 63.005-63.020 mm 0.23 mm
-0.25 62.755-62.770 mm 0.25 mm
Center Bearing Diameter CYLINDER HEAD
Nominal 63.005-63.020 mm Minimum Thickness 89.95-90.05 mm
-0.25 62.755-62.770 mm Gasket Thickness 1.32 mm ± 0.08, 0
Clearance Between 0.008-0.051 mm notches
Journal and Bearing 1.42 mm ± 0.08, 1 notch
Rear Journal Diameter 1.52 mm ± 0.08, 2
Nominal 89.980-90.000 mm notches
-0.25 89.730-99.750 mm CONNECTING RODS
Rear Bearing Diameter Weight (without the 1129-1195 grams
crankbearing)
Nominal 90.045-90.065 mm
Small End Bearing 30.035-30.050 mm
-0.25 89.795-89.815 mm
Internal Diameter
Clearance Between 0.045-0.080 mm
Large End Internal 53.977-54.016 mm
Journal and Bearing
Diameter
Connecting Rod Journal
Nominal 53.940-53.955 mm
RG ENGINE 9a - 9
DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION

PISTONS Opens 65° B.B.D.C.
Skirt Diameter (measured 91.912-91.928 mm Closes 29° A.T.D.C.
at approximately 10 mm Face Angle
above the bottom of the
Intake 45° 25’-55° 35’
skirt)
Exhaust 45° 25’-45° 35’
Piston Clearance 0.065-0.083 mm
Head Diameter
Top of Piston to Cylinder 0.69-0.83 mm
Head Intake 32.30-32.50 mm
Piston Potrusion 0.49-0.60 Fit Gasket Exhaust 30.80-31.00 mm
Number (1.32), 0 notches Head Stand Down
or holes Intake 1.08-1.34 mm
0.61-0.70 Fit Gasket Exhaust 0.99-1.25 mm
Number (1.42), 1 notch Stem Diameter
or hole Intake 5.952-5.970 mm
0.71-0.83 Fit Gasket Exhaust 5.942-5.960 mm
Number (1.52), 2 notches Clearance in Guide
or holes
Intake 0.030-0.060 mm
PISTON PINS
Exhaust 0.040-0.070 mm
Type Full Floating
VALVE GUIDE
Pin Diameter 29.992-29.996 mm
Inside Diameter 6.00-6.012 mm
Clearance 0.004-0.012 mm
Fitted Height
PISTON RINGS
Intake 14.5-15.0 mm
Clearance in Groove
Exhaust 16.5-17.0 mm
Top 0.078-0.137 mm
VALVE SPRINGS
Second 0.070-0.110 mm
Free Length 45.26 mm
Oil Control 0.040-0.080 mm
Fitted Length 38.00 mm
Fitted Gap
Load at Fitted Length 182 ± 5-10% Kg
Top 0.30-0.45 mm
Load at Top of Lift 395 ± 5% Kg
Second 0.30-0.45 mm
Number of Coils 8
Oil Control 0.25-0.50 mm
LUBRICATION
CAMSHAFT
System Pressure at 4000 4.5-5.0 bar (oil at
Journal Diameter–Front 29.960-29.980 mm RPM 90-100°C)
Bearing Clearance 0.03-0.08 mm Pressure Relief Valve 6.50 bar
Journal Diameter–Center 39.250-39.270 mm Opens
Bearing Clearance 0.03-0.08 mm Pressure Relief Valve 51.5 mm
Journal Diameter–Rear 39.250-39.270 mm Spring-Free Length
Bearing Clearance 0.03-0.08 mm OIL PUMP
HYDRAULIC LIFTER Outer Rotor End Float 0.060-0.160 mm
Outside Diameter 11.994 ± 0.006 mm Inner Rotor End Float 0.060-0.160 mm
VALVES Outer Rotor to Body 0.130-0.240 mm

Diameter Clearance
Intake Valve
Rotor Body to Drive Gear 0.90-1.50 mm
Opens 16° B.T.D.C. Clearance (pump not
Closes 58° A.B.D.C. fitted)
Exhaust Valve
9a - 10 ENGINE RG
SPECIFICATIONS - TORQUE
2.5L DIESEL TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.

Oil Pump Bolts 10.8 8 96
Vacuum Pump Bolts 10.8 8 96
Crankshaft Gear Bolts 10.8 8 96
Crankshaft Position 10.8 8 96
Sensor Bolts
Flywheel Bolts - Refer to
the Service Procedure
Cylinder Head Bolts -
Refer to the Service
Procedure
Reluctor Wheel Bolts 14.6 11 130
Rear Main Bearing 27.5 21 240
Support Bolts
Oil Cooler to Engine Block 47.1 35 —
Bolt
Oil Cooler Mounting Stud 50 37 —
Water Pump Housing Nuts 24.4 18 212
Connecting Rod Bolts -
Refer to the Service
Procedure
Balance Shaft Bolts 32.4 24 —
Oil Jet Bolts 10.8 8 96
Oil Pan Bolts 11.8 8 96
Crankshaft Hub Bolt 304 225 —
Front Engine Cover Bolts 11.8 8 96
Transmission to Engine 83.4 62 —
Bolts
Cylinder Head Cover / 27.5 20 —
Intake Manifold Bolts
Camshaft Access Plugs 80 59 —
Oil Separator Bolts 10.8 8 96
Camshaft Position Sensor 10.8 8 96
Bolt
Boost Pressure / Intake 5.4 — 48
Air Temp. Sensor Bolts
Accessory Drive Bracket 47.1 35 —
Bolts
Vacuum Line Fitting Bolt 56.9 42 —
Fuel Pump Nuts 27.5 21 —
Fuel Line Fittings at Pump 27.5 21 —
Inner Timing Belt Cover
Bolts
RG ENGINE 9a - 11
DESCRIPTION N·m Ft. Lbs. In. Lbs.

8mm 10.8 8 96
10mm 47.1 35 —
Outer Timing Belt Cover
Bolts
3mm 6 — 54
8mm 10.8 8 96
Engine Mount Bracket to 47.1 35 —
Cylinder Head Bolts
Intake Inlet Tube Bolts 10.1 8 89
Camshaft Sprocket Bolts 108 80 —
Timing Belt Idler Pulley 47.1 35 —
Bolt
Timing Belt Tensioner Bolt 34.7 26 —
Fuel Pump Nut 88.3 65 —
Engine Lift Hook Bolts 32.4 24 —
Thermostat Housing Bolts 27.5 21 —
Turbocharger Oil Feed 24.5 18 217
Line Fitting
Exhaust Manifold Nuts 32.4 24 —
Exhaust Manifold 27.5 21 —
Heatshield Bolts
EGR Valve Nuts 32.4 24 —
EGR Cooler to EGR Bolts 32.4 24 —
Turbocharger Downpipe 32.4 24 —
Nuts
Turbocharger Bracket 47.1 35 —
Bolts
Vibration Damper to 27.5 21 —
Crankshaft Hub Bolts
Crankshaft Support Bolts 44.1 33 —
Turbocharger to Exhaust 32.4 24 —
Manifold Nuts
9a - 12 ENGINE RG
SPECIAL TOOLS
VM.1013 DIAL INDICATOR

VM.1001 CYLINDER LINER PULLER
VM.1005 TORQUE ANGLE GAUGE
VM.1016 CYLINDER RETAINER
VM.1010 CYLINDER LINER PROTRUSION TOOL

RG ENGINE 9a - 13
VM.1050 CRANKSHAFT REAR SEAL INSTALLER VM.1053 EXHAUST CAMSHAFT ALIGNMENT PIN
VM.1054 RELIEF VALVE REMOVER/CENTRAL

CARRIER PIN REMOVER/INSTALLER
VM.1051 TDC ALIGNMENT PIN
VM.1055 CAMSHAFT/INJECTION PUMP GEAR

VM.1052 INTAKE CAMSHAFT ALIGNMENT PIN HOLDER
9a - 14 ENGINE RG
VM.1056 BALANCE SHAFT LOCKING PIN
VM.1061 FRONT OIL SEAL INSTALLER
VM.1062 POWER STEERING PUMP INSTALLER
VM.1059 OIL PRESSURE RELIEF VALVE INSTALLER
VM.1060 OIL JET REMOVER /INSTALLER

VM.1063 FUEL INJECTOR REMOVER
RG ENGINE 9a - 15
VM.1068 90 DEGREES AFTER TDC ALIGNMENT PIN

VM.1064 POWER STEERING PUMP GEAR
REMOVER
VM.1069 CRANKSHAFT REM/INSTALL SLEEVE
VM.1065 PISTON RING COMPRESSOR
VM.1066 CYLINDER HEAD COVER ALIGNMENT

PINS VM.1070 FLYWHEEL LOCKING TOOL
9a - 16 ENGINE RG
VM.1072 COMPRESSION TESTER ADAPTER
VM.1075 FLYWHEEL ALIGNMENT PINS
VM.1073 CRANKSHAFT FRONT BEARING VM.1077 POWER STEERING BELT REMOVER

REMOVER/INSTALLER
VM.1078 POWER STEERING BELT INSTALLER

VM.1074 TIMING BELT RETAINER
RG ENGINE 9a - 17
CYLINDER HEAD
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVE SERVICE
This procedure is done with the engine cylinder
head removed from the block.
DISASSEMBLY
(1) Remove the engine cylinder head from the cyl-
inder block. Refer to cylinder head removal and
installation in this section.
(2) Use Valve Spring Compressor Tool and com-
press each valve spring.
(3) Remove the valve locks, retainers, and springs.
(4) Use an Arkansas smooth stone or a jewelers
file to remove any burrs on the top of the valve stem,
especially around the groove for the locks.
(5) Remove the valves, and place them in a rack in
the same order as removed.
VALVE CLEANING Fig. 11 VALVE SPRING CHART

(1) Clean all carbon deposits from the combustion
LOAD Kg HEIGHT mm STATE
chambers, valve ports, valve stems, valve stem
P1 0.00 H1 45.26 FREE LENGTH
guides and head. P2 182-5 H2 38.00 VALVE CLOSED
(2) Clean all grime and gasket material from the +10%
engine cylinder head machined gasket surface. P3 395±5% H3 28.20 VALVE OPEN
INSPECTION VALVE STAND DOWN

(1) Inspect for cracks in the combustion chambers
Valve stand down is to maintain the adequate com-
and valve ports.
pression ratio.
(2) Inspect for cracks on the exhaust seat.
(1) Invert cylinder head.
(3) Inspect for cracks in the gasket surface at each
(2) Fit each valve to its respective valve guide.
coolant passage.
(3) Using a straight edge and feeler gauge, check
(4) Inspect valves for burned, cracked or warped
valve head stand down: Inlet valve head stand down
heads.
1.08 to 1.34 mm (.042 to .052 ins.) and exhaust valve
(5) Inspect for scuffed or bent valve stems.
stand down .99 to 1.25 mm (.035 to .049 ins.).
(6) Replace valves displaying any damage.
(4) If valve head stand down is not in accordance
(7) Check valve spring height (Fig. 11).
with above, discard original valves, check stand down
with new valves and recut valve seat inserts to
VALVE REFACING obtain correct stand down.
(1) Use a valve refacing machine to reface the
intake and exhaust valves to the specified angle. VALVE GUIDES
(2) After refacing, a margin of at least 4.52-4.49
(1) Valve Guides height requirement.
mm (.178-.177 inch) must remain (Fig. 12). If the
(2) Measurement A (Fig. 13): 16.50 - 17.00 mm.
margin is less than 4.49 mm (.177 inch), the valve
Measurment B : 14.50 - 15.00 mm.
must be replaced.
VALVE STEM-TO-GUIDE CLEARANCE
VALVE SEAT REFACING
(1) Install a pilot of the correct size in the valve
MEASUREMENT
guide bore. Reface the valve seat to the specified (1) Measure and record internal diameter of valve
angle with a good dressing stone. Remove only guides. Valve guide internal diameter is 8.0 to 8.015
enough metal to provide a smooth finish. mm (.3149 to .3155 ins.).
(2) Use tapered stones to obtain the specified seat (2) Measure valve stems and record diameters.
width when required. Intake valve stem diameter 7.94 to 7.96 mm (.3125 to
9a - 18 ENGINE RG
CYLINDER HEAD (Continued)
Fig. 13 VALVE GUIDE HEIGHT

.3133 in). Exhaust valve stem diameter 7.92 to 7.94
mm (.3118 to .31215 in).
(3) Subtract diameter of valve stem from internal
diameter of its respective valve guide to obtain valve
stem clearance in valve guide. Clearance of inlet
valve stem in valve guide is .040 to .075 mm (.0015
to .0029 in). Clearance of exhaust valve stem in valve
guide is .060 to .093 mm (.0023 to .0036 in).
(4) If valve stem clearance in valve guide exceeds
tolerances, new valve guides must be installed.
STANDARD PROCEDURE - MEASURING

PISTON PROTRUSION
Fig. 12 VALVE SPECS. (1) Use special tool VM.1010 with dial indicator
special tool VM.1013 (Fig. 14).
MEASUREMENT INTAKE EXHAUST (2) Bring the piston of cylinder no. 1 exactly to top
A 7.940-7.960 7.922-7.940
dead center.
B 8.00-8.015 8.000-8.015
(3) Zero the dial indicator on the cylinder block
C 1.08-1.34 0.990-1.250
+0.07
mating surface.
(4) Setup the dial indicator on the piston crown
D 2.2 ± 0.08 2.09
(above the center of the piston pin) 5mm (1/8 in.)
20.09 from the edge of the piston and note the measure-
E 1.80-2.20 1.65-2.05 ment.
F 2.73-3.44 2.45-3.02
(5) Repeat the procedure with the rest of the cyl-
G 41.962-41.985 35.964-35.987
inders.
H 42.070-42.086 36.050-36.066
I 7.14-7.19 7.00-7.05
(6) Establish the thickness of the steel gasket by
L 3.11-3.26 3.10-3.25 averaging the four piston potrusion readings.
RG ENGINE 9a - 19
(8) Support engine and remove right engine mount
(Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT
MOUNT - REMOVAL).
CAUTION: Before removing the cylinder head cover/

intake manifold or timing belt the engine must put
at 90° after TDC. Failure to do so could result in
valve and/or piston damage during reassembly.
(Refer to 9 - ENGINE/VALVE TIMING - STANDARD
PROCEDURE)
(9) Remove timing belt outer cover (Refer to 9 -

ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(10) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
Fig. 14 MEASURING PISTON PROTRUSION SPROCKETS - REMOVAL).
(11) Remove timing belt inner cover (Refer to 9 -
Measure Dimension 0.49-0.60 ENGINE/VALVE TIMING/TIMING BELT / CHAIN
(mm) COVER(S) - REMOVAL).
Cylinder Head Gasket 1.32 (12) Remove cylinder head cover/intake manifold
Thickness (mm) No Holes or Notches (Fig. 15)(Refer to 9 - ENGINE/CYLINDER HEAD/
Piston Clearance (mm) 0.72-0.83 CYLINDER HEAD COVER(S) - REMOVAL).
Measure Dimension 0.61-0.70

(mm)
Cylinder Head Gasket 1.42
Thickness (mm) 1 Hole or Notch
Piston Clearance (mm) 0.72-0.84
Measure Dimension 0.71-0.83

(mm)
Cylinder Head Gasket 1.52
Thickness (mm) 2 Holes or Notches
Piston Clearance (mm) 0.68-0.81
REMOVAL
(2) Remove front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
REMOVAL).
(3) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
Fig. 15 CYLINDER HEAD COVER/INTAKE
(4) Drain cooling system (Refer to 7 - COOLING/
MANIFOLD ASSEMBLY
(5) Remove power steering belt (Refer to 7 - 1 - CYLINDER HEAD COVER/INTAKE MANIFOLD BOLTS(LONG)
2 - CYLINDER HEAD COVER/INTAKE MANIFOLD
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
3 - CYLINDER HEAD
REMOVAL).
4 - CYLINDER HEAD COVER/INTAKE MANIFOLD GASKET
(6) Remove accessory drive belt (Refer to 7 - 5 - CYLINDER HEAD COVER/INTAKE MANIFOLD
COOLING/ACCESSORY DRIVE/DRIVE BELTS - BOLTS(SHORT)
REMOVAL).
(7) Remove generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - REMOVAL).
9a - 20 ENGINE RG
(13) Remove rocker arm and lifter assemblies from (19) Remove exhaust manifold heat shield (Fig.
cylinder head. 17).
(14) Remove cylinder head cover/intake manifold
gasket from cylinder head.
(15) Disconnect glow plug and engine coolant tem-
perture electrical connectors.
(16) Remove coolant recovery pressure container
(Refer to 7 - COOLING/ENGINE/COOLANT RECOV-
ERY PRESS CONTAINER - REMOVAL).
(17) Remove thermostat housing to upper radiator
hose pipe (Fig. 16).
(18) Remove turbocharger outlet to charge air
cooler pipe (Fig. 16).
Fig. 17 EXHAUST MANIFOLD AND

TURBOCHARGER
1 - TURBOCHARGER OIL SUPPLY BANJO BOLT
2 - COPPER WASHER
3 - EXHAUST MANIFOLD GASKET
4 - COPPER WASHER
5 - EXHAUST MANIFOLD HEAT SHIELD RETAINING BOLT
Fig. 16 TURBOCHARGER AND COOLANT PIPES 6 - TURBOCHARGER
1 - TURBOCHARGER OUTLET PIPE RETAINING BOLT 7 - ENGINE LIFT HOOK
2 - TURBOCHARGER OUTLET PIPE 8 - ENGINE LIFT HOOK RETAINING BOLT
3 - ADAPTER HOSE 9 - SPACER
4 - HEAT SHIELD 10 - EXHAUST MANIFOLD RETAINING NUT
5 - HOSE CLAMPS 11 - TURBOCHARGER OIL RETURN HOSE
6 - TURBOCHARGER INLET PIPE RETAINING BOLT 12 - HOSE CLAMPS
7 - TURBOCHARGER INLET PIPE 13 - EXHAUST MANIFOLD STUDS
8 - ADAPTER HOSE
9 - HOSE CLAMPS (20) Remove exhaust manifold retaining nuts (Fig.
10 - CLAMP
17).
11 - EGR VALVE TO INTAKE AIR INLET PIPE
(21) Slide exhaust manifold and turbocharger off of
12 - CLAMP
13 - THERMOSTAT HOUSING TO UPPER RADIATOR HOSE
exhaust manifold studs (Fig. 17).
PIPE (22) Remove cylinder head bolts.
RG ENGINE 9a - 21
(23) Remove cylinder head assembly from engine INSTALLATION
block (Fig. 18).
CAUTION: Piston protrusion must be measured to
determine cylinder head gasket thickness if one or
more cylinder liners have been replaced (Refer to 9
- ENGINE/CYLINDER HEAD - STANDARD PROCE-
DURE).
NOTE: If cylinder liner(s) have not been removed,

the same thickness head gasket that was removed
can be used.
(1) Clean and inspect gasket mating surfaces.

(2) Position correct head gasket on engine block.
(3) Place cylinder head on engine block (Fig. 18).
CAUTION: New cylinder head bolts must be used.
(4) Tighten cylinder head bolts following procedure

below.
Cylinder Head Bolt Torquing Procedure

(1) Lubricate cylinder head bolts with engine oil.
(2) Torque bolts to 30N·m in numerical starting
with bolt #1 (Fig. 19).
(3) Tighten all bolts an additional 75°, starting
with bolt #4 then 5-6-7-8-9-10-1-2-3 (Fig. 19).
Fig. 18 CYLINDER HEAD ASSEMBLY (4) Tighten all bolts an additional 50° in numerical
1 - VALVE SPRING order starting with bolt #11 then 12-13-14-15-16-
2 - CYLINDER HEAD BOLT 17-18 (Fig. 19).
3 - GLOW PLUG (5) Without loosening any bolts tighten all bolts an
4 - COOLANT TEMPERATURE SENSOR additional 75° in the following seguence: 4-5-6-7-8-9-
5 - CYLINDER HEAD ALIGNMENT DOWEL 10-1-2-3-11-12-13-14-15-16-17-18.
6 - CYLINDER BLOCK
7 - CYLINDER LINER
8 - ENGINE BLOCK DECK
9 - CYLINDER HEAD GASKET
10 - CYLINDER HEAD
11 - ROCKER ARM AND LIFTER ASSEMBLY
CLEANING
Thoroughly clean the engine cylinder head and cyl-
inder block mating surfaces. Clean the intake and
exhaust manifold and engine cylinder head mating
surfaces. Remove all gasket material and carbon.
Check to ensure that no coolant or foreign material
has fallen into the tappet bore area.
Remove the carbon deposits from the combustion
chambers and top of the pistons.
INSPECTION
Use a straightedge and feeler gauge to check the
flatness of the engine cylinder head and block mating
surfaces.
The minimum cylinder head thickness is 89.95mm
(3.541 in.).
Fig. 19 CYLINDER HEAD TORQUE SEQUENCE
9a - 22 ENGINE RG
(5) Slide exhaust manifold and turbocharger on CAMSHAFT(S)
exhaust manifold studs (Fig. 17).
(6) Install exhaust manifold retaining nuts. Torque
DESCRIPTION
nuts to 32.4N·m.
The camshafts are made of gray cast iron with
(7) Install exhaust manifold heat shield (Fig. 17).
eight machined lobes and four bearing journals (Fig.
Torque bolts to 27.5N·m.
20).
(8) Install turbocharger outlet to charge air cooler
pipe (Fig. 16).
(9) Install thermostat housing to upper radiator
hose pipe (Fig. 16). Install retaining bolt and torque
to 47.1N·m.
(10) Install coolant recovery pressure container
(Refer to 7 - COOLING/ENGINE/COOLANT RECOV-
ERY PRESS CONTAINER - INSTALLATION).
(11) Connect glow plug and coolant temperature
sensor electrical connectors.
(12) Install new cylinder head cover/intake mani-
fold gasket.
(13) Install rocker arm and lifter assemblies.Be
sure to put rocker arm and lifter assemblies in
same location as removed. Fig. 20 CAMSHAFTS
(14) Install cylinder head cover/intake manifold 1 - INTAKE CAMSHAFT
(Fig. 15)(Refer to 9 - ENGINE/CYLINDER HEAD/ 2 - EXHAUST CAMSHAFT
CYLINDER HEAD COVER(S) - INSTALLATION).
(15) Install timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN OPERATION
COVER(S) - INSTALLATION). When the camshaft rotates the lobes actuate the
(16) Install timing belt (Refer to 9 - ENGINE/ hydraulic lifters and rocker arms, forcing downward
VALVE TIMING/TIMING BELT/CHAIN AND on the rocker arms which opens the valves.
SPROCKETS - INSTALLATION) .
(17) Install timing belt outer cover (Refer to 9 - REMOVAL
ENGINE/VALVE TIMING/TIMING BELT / CHAIN (1) Disconnect negative battery cable.
COVER(S) - INSTALLATION). (2) Remove front wiper unit (Refer to 8 - ELEC-
(18) Remove crankshaft and both camshaft TRICAL/WIPERS/WASHERS/WIPER MODULE -
locking pins at this time (Refer to 9 - ENGINE/ REMOVAL).
VALVE TIMING - STANDARD PROCEDURE). (3) Remove engine cover (Refer to 9 - ENGINE -
(19) Install generator (Refer to 8 - ELECTRICAL/ REMOVAL).
CHARGING/GENERATOR - INSTALLATION). (4) Drain cooling system (Refer to 7 - COOLING/
(20) Install accessory drive belt (Refer to 7 - ENGINE/COOLANT - STANDARD PROCEDURE).
COOLING/ACCESSORY DRIVE/DRIVE BELTS - (5) Remove air cleaner housing.
INSTALLATION). (6) Remove power steering belt (Refer to 7 -
(21) Install power steering belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS -
COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
INSTALLATION). (7) Remove accessory drive belt (Refer to 7 -
(22) Install right engine mount (Refer to 9 - COOLING/ACCESSORY DRIVE/DRIVE BELTS -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT - REMOVAL).
INSTALLATION). (8) Remove generator (Refer to 8 - ELECTRICAL/
(23) Install air cleaner housing assembly. CHARGING/GENERATOR - REMOVAL).
(24) Refill cooling system (Refer to 7 - COOLING/ (9) Support engine and remove right engine mount
ENGINE/COOLANT - STANDARD PROCEDURE). (Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT
(25) Install engine cover (Refer to 9 - ENGINE - MOUNT - REMOVAL).
INSTALLATION).
(26) Install front wiper unit (Refer to 8 - ELEC-
INSTALLATION).
(27) Connect negative battery cable.
RG ENGINE 9a - 23
CAMSHAFT(S) (Continued)
intake manifold or timing belt the engine must put
PROCEDURE)

SPROCKETS - REMOVAL).
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - REMOVAL).
(14) With cylinder head cover/intake manifold on
work bench, remove plugs at rear of cylinder head
cover/intake manifold.
(15) Remove camshaft oil seals (Fig. 21). Fig. 21 CAMSHAFT ASSEMBLY
(16) Remove snapring and thrust washer from
1 - INTAKE CAMSHAFT
camshaft (Fig. 21).
2 - SNAPRING
(17) Slide camshaft through access hole at rear of 3 - CAMSHAFT OIL SEAL
cylinder head cover/intake manifold. 4 - THRUST WASHER
INSTALLATION 6 - EXHAUST CAMSHAFT
(1) Lubricate the camshafts with Mopart Engine
Oil Supplement, or equivalent. (7) Install timing belt (Refer to 9 - ENGINE/
(2) Carefully install camshafts into access holes in VALVE TIMING/TIMING BELT/CHAIN AND
rear of cylinder head cover/intake manifold. SPROCKETS - INSTALLATION) .
(3) Install thrust washer, snapring, and camshaft (8) Install timing belt outer cover (Refer to 9 -
oil seal (Fig. 21). ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
CHECKING CAMSHAFT ENDPLAY (9) Install right engine mount (Refer to 9 -
(1) After camshafts are properly installed in cylin- ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
der head cover check end play of camshafts with a INSTALLATION).
dial indicator. The end play should be between .10 (10) Install generator (Refer to 8 - ELECTRICAL/
mm – .30 mm. CHARGING/GENERATOR - INSTALLATION).
(11) Install accessory drive belt (Refer to 7 -
NOTE: If the camshaft endplay is not within speci-
fication, measure thickness of the camshaft spacer.
INSTALLATION).
Camshaft spacer thickness should be 2.8 ± .02mm.
(12) Install power steering belt (Refer to 7 -
(4) Install access hole plugs and gaskets at rear of COOLING/ACCESSORY DRIVE/DRIVE BELTS -
cylinder head cover/intake manifold. Torque plugs to INSTALLATION).
80N·m. (13) Install air cleaner housing.
(5) Install cylinder head cover/intake manifold on (14) Refill cooling system (Refer to 7 - COOLING/
engine block (Refer to 9 - ENGINE/CYLINDER ENGINE/COOLANT - STANDARD PROCEDURE).
HEAD/CYLINDER HEAD COVER(S) - INSTALLA- (15) Install front wiper unit (Refer to 8 - ELEC-
TION). TRICAL/WIPERS/WASHERS/WIPER MODULE -
(6) Install timing belt inner cover (Refer to 9 - INSTALLATION).
ENGINE/VALVE TIMING/TIMING BELT / CHAIN (16) Connect negative battery cable.
9a - 24 ENGINE RG
CYLINDER HEAD COVER(S) (8) Remove accessory drive belt (Refer to 7 -

REMOVAL).
DESCRIPTION
The cylinder head cover is made of cast aluminum
CHARGING/GENERATOR - REMOVAL).
and is also the intake manifold on this engine (Fig.
(10) Support engine and remove right engine
22).
mount (Refer to 9 - ENGINE/ENGINE MOUNTING/
RIGHT MOUNT - REMOVAL).
(11) Remove outer timing belt cover (Refer to 9 -
(13) Remove inner timing belt cover (Refer to 9 -
(14) Disconnect camshaft position sensor, boost
pressure/intake air temperature sensor, EGR sole-
noid, and fuel pressure sensor electrical connectors
(Fig. 23).

MANIFOLD
REMOVAL
intake manifold the engine must put at 90° after
TDC. Failure to do so could result in valve and/or
piston damage during reassembly. (Refer to 9 -
ENGINE/VALVE TIMING - STANDARD PROCEDURE)

REMOVAL).
(3) Remove engine cover (Refer to 9 - ENGINE - Fig. 23 ENGINE COMPONENT LOCATIONS
REMOVAL). 1 - FUEL INJECTOR RETURN LINE
(4) Drain cooling system (Refer to 7 - COOLING/ 2 - FUEL INJECTOR SUPPLY LINE
ENGINE/COOLANT - STANDARD PROCEDURE). 3 - OIL SEPARATOR
(5) Rotate engine until 90° after TDC is reached. 4 - FUEL INJECTOR
Install both camshaft locking pins and the crankshaft 5 - CAMSHAFT POSITION SENSOR
locking pin. (Refer to 9 - ENGINE/VALVE TIMING - 6 - BOOST PRESSURE/INTAKE AIR TEMPERATURE SENSOR
STANDARD PROCEDURE) 7 - EGR SOLENOID
(6) Remove air cleaner housing assembly. 8 - FUEL PRESSURE SENSOR
(7) Remove power steering belt (Refer to 7 - 9 - CYLINDER HEAD COVER/INTAKE MANIFOL
10 - FUEL RAIL
11 - WIRING HARNESS RETAINING CLIPS
REMOVAL).
RG ENGINE 9a - 25
CYLINDER HEAD COVER(S) (Continued)
(15) Disconnect vacuum lines at EGR solenoid. in an upright position when removed from cylinder
(16) Position electrical harness out of way. head.
(17) Remove fuel injectors (Refer to 14 - FUEL (26) Remove rocker arm and lifter assemblies from
SYSTEM/FUEL INJECTION/FUEL INJECTOR - cylinder head (Fig. 25).
REMOVAL).
(18) Remove fuel rail (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL RAIL - REMOVAL).
(19) Remove power steering pump reservoir from
bracket.
(20) Remove oil dipstick tube retaining bolt at
intake manifold inlet.
(21) Disconnect oil separator outlet hose at separa-
tor.
(22) Remove turbo inlet tube retaining bolt at
intake manifold.
(23) Disconnect EGR tube at intake manifold inlet
tube.
retaining bolts (Fig. 24).
(25) Lift cylinder head cover/intake manifold from
cylinder head (Fig. 24).

MANIFOLD GASKET LOCATION
1 - THERMOSTAT HOUSING
4 - CYLINDER HEAD

gasket from cylinder head.
INSTALLATION
(1) Clean and inspect sealing surfaces.
(2) Install new gasket on cylinder head.
NOTE: Apply a small amount of grease on each

valve stem. This will help hold the rocker arm in
position during the cylinder head cover installation.
MANIFOLD ASSEMBLY (3) Install rocker arm and lifter assemblies in cyl-
1 - CYLINDER HEAD COVER/INTAKE MANIFOLD BOLTS(LONG) inder head (Fig. 25).Be sure to put rocker arm
2 - CYLINDER HEAD COVER/INTAKE MANIFOLD and lifter assemblies in same location as
3 - CYLINDER HEAD removed.
4 - CYLINDER HEAD COVER/INTAKE MANIFOLD GASKET (4) Install cylinder head cover/intake manifold
5 - CYLINDER HEAD COVER/INTAKE MANIFOLD alignment studs in cylinder head (Fig. 26).
BOLTS(SHORT)
(5) Install cylinder head cover/intake manifold
over alignment stud.
NOTE: When removing rocker arm and lifter assem-
blies, be sure to keep them in order as they were
removed from the cylinder head. Always keep lifters
9a - 26 ENGINE RG
Fig. 26 CYLINDER HEAD COVER/INTAKE Fig. 27 CYLINDER HEAD COVER/INTAKE

MANIFOLD ALIGNMENT STUDS VM.1066 MANIFOLD TIGHTENING SEQUENCE
1 - CYLINDER HEAD COVER/INTAKE MANIFOLD ALIGNMENT
STUDS VM.1066 (9) Connect EGR tube at intake manifold inlet
2 - CYLINDER HEAD tube. Torque clamp to 10.8 N·m.
(10) Install turbo inlet tube retaining bolt at
intake manifold. Torque bolt to 27.5 N·m.
NOTE: Be sure to lubricate cylinder head cover/in-
(11) Connect oil separator outlet hose at separator.
take manifold retaining bolts with engine oil before
(12) Install oil dipstick tube retaining bolt at
assembly. If new bolts are being installed, DO NOT
intake manifold inlet. Torque bolt to 10 N·m.
lubricate before assembly.
(13) Install power steering pump reservoir in
(6) Install two cylinder head cover/intake manifold bracket.
retaining bolts and tighten finger tight. (14) Install fuel rail (Refer to 14 - FUEL SYSTEM/
(7) Remove alignment studs and install remaining FUEL DELIVERY/FUEL RAIL - INSTALLATION).
retaining bolts (Fig. 24). Tighten retaining bolts fin- (15) Install fuel injectors and fuel injector supply
ger tight. lines (Refer to 14 - FUEL SYSTEM/FUEL INJEC-
(8) Torque cylinder head cover/intake manifold TION/FUEL INJECTOR - INSTALLATION).
retaining bolts following procedure below. (16) Connect vacuum lines at EGR solenoid.
(17) Clip wiring harness retainers on studs on fuel
CYLINDER HEAD COVER/INTAKE MANIFOLD rail (Fig. 23).
(18) Connect camshaft position sensor, boost pres-
TIGHTENING PROCEDURE sure/intake air temperature sensor, EGR solenoid,
(1) Coat all bolts being reused with clean engine
and fuel pressure sensor electrical connectors (Fig.
oil.
23).
(2) Install the M8x35 bolts into holes 1,2,3,4,5, and
(19) Install inner timing belt cover (Refer to 9 -
12. Install the M8x85 bolts into holes
6,7,8,9,10,11,13,14,15, and 16. Tighten all bolt hand
tight.
(20) Install timing belt (Refer to 9 - ENGINE/
(3) Alternate between bolts #11 and #16 to seat
cylinder head cover/intake manifold on cylinder head
(Fig. 27). Torque bolts to 7 N·m.
(21) Install outer timing belt cover (Refer to 9 -
(4) Torque all cylinder head cover/intake manifold
retaining bolts to 25 N·m in numerical order starting
with #1 and ending with #16 (Fig. 27).
RG ENGINE 9a - 27
(22) Install right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION).
(23) Install generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - INSTALLATION).
INSTALLATION).
INSTALLATION).
(26) Install air cleaner housing assembly.
(27) Remove crankshaft and both camshaft locking
pins (Refer to 9 - ENGINE/VALVE TIMING - STAN-
DARD PROCEDURE).
(28) Refill cooling system (Refer to 7 - COOLING/
(29) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(30) Install front wiper unit (Refer to 8 - ELEC-
INSTALLATION).
(31) Connect negative battery cable. Fig. 28 CAMSHAFT GEAR REMOVAL/INSTALLATION
1 - TIMING BELT INNER COVER
2 - CAMSHAFT SPROCKET
CAMSHAFT OIL SEAL(S) 3 - IDLER PULLEYS
REMOVAL 5 - VM.1055
(2) Remove air cleaner housing assembly. (4) Torque camshaft sprockets to 108 N·m using
(3) Support engine and remove right engine mount VM.1055 (Fig. 28).
(Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT (5) Install outer timing belt cover (Refer to 9 -
MOUNT - REMOVAL). ENGINE/VALVE TIMING/TIMING BELT / CHAIN
(4) Remove outer timing belt cover (Refer to 9 - COVER(S) - INSTALLATION).
ENGINE/VALVE TIMING/TIMING BELT / CHAIN (6) Install right engine mount (Refer to 9 -
COVER(S) - REMOVAL). ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION).
WARNING: Before removing the timing belt the (7) Install air cleaner housing assembly.
engine must put at 90° after TDC. Failure to do so (8) Connect negative battery cable.
could result in valve and/or piston damage during
reassembly. (Refer to 9 - ENGINE/VALVE TIMING -
STANDARD PROCEDURE) ROCKER ARMS
DESCRIPTION
The rocker arms are made of stamped steel (Fig.
29).
(6) Using VM.1055, remove both camshaft gears
(Fig. 28).
(7) Remove both camshaft oil seals.
OPERATION
The rocker arms are used as a link between the
camshaft and valves. As the camshaft rotates the
INSTALLATION
lobes of the camshafts apply downward pressure on
(1) Install new camshaft oil seal using VM.1057.
the rocker arms. This pressure is then transmitted to
(2) Install camshaft sprockets and tighten retain-
the valves which causes the valves to open.
ing bolts finger tight.
REMOVAL
9a - 28 ENGINE RG
ROCKER ARMS (Continued)
(9) Remove rocker arm from lifter (Fig. 30).
Fig. 30 ROCKER ARM ASSEMBLY

1 - ROCKER ARM ASSEMBLY
Fig. 29 CYLINDER HEAD ASSEMBLY
1 - VALVE SPRING 3 - HYDRAULIC LIFTER
2 - CYLINDER HEAD BOLT 4 - CYLINDER HEAD
3 - GLOW PLUG 5 - VALVE
4 - COOLANT TEMPERATURE SENSOR
5 - CYLINDER HEAD ALIGNMENT DOWEL
6 - CYLINDER BLOCK INSTALLATION
7 - CYLINDER LINER (1) Clean and inspect gasket sealing surfaces.
8 - ENGINE BLOCK DECK (2) Install new gasket on cylinder head.
9 - CYLINDER HEAD GASKET (3) Lubricate lifter ball end of lifter(s), valve(s),
10 - CYLINDER HEAD
and rocker arm roller(s) with Mopart Engine Oil
Supplement or equivlalent.
(4) Connect rocker arm(s) to lifter and reposition
(2) Remove front wiper unit (Refer to 8 - ELEC- on valve(s) (Fig. 30).
TRICAL/WIPERS/WASHERS/WIPER MODULE - (5) Install cylinder head cover/intake manifold
REMOVAL). (Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
(3) Remove air cleaner housing assembly. DER HEAD COVER(S) - INSTALLATION).
(4) Support engine and remove right engine mount (6) Install inner timing belt cover (Refer to 9 -
(Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT ENGINE/VALVE TIMING/TIMING BELT / CHAIN
MOUNT - REMOVAL). COVER(S) - INSTALLATION).
(5) Remove outer timing belt cover (Refer to 9 - (7) Install timing belt (Refer to 9 - ENGINE/
ENGINE/VALVE TIMING/TIMING BELT / CHAIN VALVE TIMING/TIMING BELT/CHAIN AND
COVER(S) - REMOVAL). SPROCKETS - INSTALLATION) .
(6) Remove timing belt (Refer to 9 - ENGINE/ (8) Install outer timing belt cover (Refer to 9 -
VALVE TIMING/TIMING BELT/CHAIN AND ENGINE/VALVE TIMING/TIMING BELT / CHAIN
SPROCKETS - REMOVAL). COVER(S) - INSTALLATION).
(7) Remove inner timing belt cover (Refer to 9 - (9) Install right engine mount (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
COVER(S) - REMOVAL). INSTALLATION).
(8) Remove cylinder head cover/intake manifold (10) Install air cleaner housing assembly.
RG ENGINE 9a - 29
ROCKER ARMS (Continued)
(11) Install front wiper unit (Refer to 8 - ELEC- (3) Remove engine cover (Refer to 9 - ENGINE -
TRICAL/WIPERS/WASHERS/WIPER MODULE - REMOVAL).
INSTALLATION). (4) Support engine and remove right engine mount
(12) Connect negative battery cable. (Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT
MOUNT - REMOVAL).
HYDRAULIC LIFTERS ENGINE/VALVE TIMING/TIMING BELT / CHAIN
DESCRIPTION
Valve lash is controlled by hydraulic tappets CAUTION: Before removing the cylinder head cover/
located inside the cylinder head, in tappet bores intake manifold or the timing belt the engine must
below the camshafts (Fig. 31). put at 90° after TDC. Failure to do so could result in
PROCEDURE)

(7) Remove inner timing belt cover (Refer to 9 -
(Fig. 32)(Refer to 9 - ENGINE/CYLINDER HEAD/
CYLINDER HEAD COVER(S) - REMOVAL).
Fig. 31 CYLINDER HEAD ASSEMBLY

1 - VALVE SPRING
2 - CYLINDER HEAD BOLT
3 - GLOW PLUG
4 - COOLANT TEMPERATURE SENSOR
5 - CYLINDER HEAD ALIGNMENT DOWEL
6 - CYLINDER BLOCK
7 - CYLINDER LINER
8 - ENGINE BLOCK DECK
9 - CYLINDER HEAD GASKET
10 - CYLINDER HEAD Fig. 32 CYLINDER HEAD COVER/INTAKE
MANIFOLD
1 - CYLINDER HEAD COVER/INTAKE MANIFOLD BOLTS(LONG)
REMOVAL 2 - CYLINDER HEAD COVER/INTAKE MANIFOLD
(1) Disconnect negative battery cable. 3 - CYLINDER HEAD
(2) Remove front wiper unit (Refer to 8 - ELEC- 4 - CYLINDER HEAD COVER/INTAKE MANIFOLD GASKET
TRICAL/WIPERS/WASHERS/WIPER MODULE - BOLTS(SHORT)
REMOVAL).
9a - 30 ENGINE RG
HYDRAULIC LIFTERS (Continued)
(9) Remove rocker arm and lifter assemblies from CRANKSHAFT
lifter bores.
DESCRIPTION
INSPECTION The crankshaft is a forged steel type design with
Clean each lifter assembly in cleaning solvent to
five main bearing journals. The crankshaft is located
remove all varnish and sludge deposits. Inspect for
at the bottom of the engine block and is held in place
indications of scuffing on the side and base of each
with three main bearing supports (Fig. 34).
lifter body.
INSTALLATION
(1) Install rocker arm and lifter assemblies in
lifter bores.
(Fig. 32) (Refer to 9 - ENGINE/CYLINDER HEAD/
CYLINDER HEAD COVER(S) - INSTALLATION).
(5) Install timing belt outer cover (Refer to 9 -
INSTALLATION).
INSTALLATION).
(8) Install front wiper unit (Refer to 8 - ELECTRI-
CAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).
ENGINE BLOCK
DESCRIPTION
The 2.5L CRD Diesel engine uses a cast iron
engine block with wet cast iron cylinder liners (Fig. Fig. 34 CRANKSHAFT ASSEMBLY
33). 1 - CRANKSHAFT SUPPORT HALVE
2 - MAIN BEARING HALVE
3 - CRANKSHAFT
5 - CRANKSHAFT SUPPORT HALVE
6 - MAIN BEARING SUPPORT BOLTS
7 - WASHERS
OPERATION
The crankshaft transfers force generated by com-
bustion within the cylinder bores to the flywheel or
flexplate.
Fig. 33 ENGINE BLOCK

RG ENGINE 9a - 31
CRANKSHAFT (Continued)
STANDARD PROCEDURE - CHECKING REMOVAL

CRANKSHAFT END PLAY (1) Remove engine from vehicle (Refer to 9 -
(1) Mount a dial indicator to a stationary point at ENGINE - REMOVAL).
rear of engine. Locate the probe perpendicular (2) Mount engine on an engine stand.
against the flywheel (Fig. 35). (3) Drain engine oil and remove oil filter.
(2) Move the crankshaft all the way to the front of (4) Remove timing belt outer cover (Refer to 9 -
its travel. ENGINE/VALVE TIMING/TIMING BELT / CHAIN
(3) Zero the dial indicator. COVER(S) - REMOVAL).
(4) Move the crankshaft all the way to the rear and (5) Remove timing belt (Refer to 9 - ENGINE/
read dial indicator. For crankshaft end play clearances VALVE TIMING/TIMING BELT/CHAIN AND
(Refer to 9 - ENGINE - SPECIFICATIONS). SPROCKETS - REMOVAL).
(8) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(9) Remove flywheel.
(10) Remove rear main bearing support/adapter
plate retaining bolts and remove adapter plate (Fig.
36).
Fig. 35 CHECKING CRANKSHAFT END PLAY

1 - DIAL INDICATOR
2 - ADAPTER PLATE Fig. 36 REAR MAIN BEARING SUPPORT
3 - REAR MAIN BEARING SUPPORT 1 - ADAPTER PLATE
4 - SEALING RING 2 - REAR MAIN BEARING SUPPORT
5 - SEALING RING 3 - CRANKSHAFT
6 - ALIGNMENT PIN 4 - REAR MAIN BEARING SUPPORT RETAINING BOLTS
7 - CRANKSHAFT
8 - RELUCTOR WHEEL
9 - RELUCTOR WHEEL RETAINING BOLT
10 - REAR MAIN BEARING SUPPORT RETAINING BOLTS
11 - FLYWHEEL
12 - FLYWHEEL BOLTS
9a - 32 ENGINE RG
(11) Remove rear main bearing support by thread-
ing two retaining bolts in holes provided. Tighten
bolts equally to push main bearing support out of
block (Fig. 37).
Fig. 38 CRANKSHAFT SLEEVE VM.1069

1 - CRANKSHAFT SLEEVE VM.1069
2 - ENGINE BLOCK
Fig. 37 REAR MAIN BEARING SUPPORT REMOVAL

1 - BOLTS
2 - REAR MAIN BEARING SUPPORT
3 - CRANKSHAFT
(12) Remove front engine cover (Refer to 9 -

ENGINE/ENGINE BLOCK/ENGINE COVER -
REMOVAL).
(13) Remove crankshaft sprocket.
(14) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(15) Remove oil pump pickup tube (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP - REMOVAL).
(16) Remove balance shaft assembly (Refer to 9 -
ENGINE/VALVE TIMING/BALANCE SHAFT -
REMOVAL).
(17) Remove oil jets (Refer to 9 - ENGINE/LUBRI-
CATION/OIL JET - REMOVAL).
(18) Remove piston and connecting rod assemblies Fig. 39 CRANKSHAFT SUPPORT RETAINERS/
(Refer to 9 - ENGINE/ENGINE BLOCK/PISTON & BALANCE SHAFT OIL FEED
CONNECTING ROD - REMOVAL). 1 - CRANKSHAFT SUPPORT RETAINERS/BALANCE SHAFT OIL
FEED
(19) Slide special tool VM.1069 on crankshaft (Fig.
2 - ENGINE BLOCK
38).
(20) Using special tool VM.1054, remove crank-
shaft support retainers (Fig. 39). (1) Install crankshaft in engine block. Be sure to
(21) Slide crankshaft out rear of engine block. align oil holes in crankshaft supports and
engine block.
INSTALLATION (2) Install crankshaft support retainers (Fig. 39).
(3) Remove special tool VM.1069 from crankshaft
NOTE: Before installing crankshaft in engine block, (Fig. 38).
be sure the notches in the crankshaft supports are (4) Install crankshaft sprocket.
facing towards the front of the engine.
RG ENGINE 9a - 33
(5) Install front engine cover (Refer to 9 -
INSTALLATION).
(6) Install rear main bearing support in engine
block. Be sure to align oil hole in rear main
bearing support with hole in block.
(7) Install adapter plate and retaining bolts (Fig.
36). Torque bolts to 27.5N·m.
(8) Install flywheel.
(9) Install piston and connecting rod assemblies
(Refer to 9 - ENGINE/ENGINE BLOCK/PISTON &
CONNECTING ROD - INSTALLATION).
(10) Install oil jets (Refer to 9 - ENGINE/LUBRI-
CATION/OIL JET - INSTALLATION).
(11) Install balance shaft assembly (Refer to 9 -
INSTALLATION).
(12) Install oil pump pickup tube (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP - INSTALLATION).
(13) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(14) Install cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
DER HEAD COVER(S) - INSTALLATION).
COVER(S) - INSTALLATION). Fig. 40 CYLINDER LINER REMOVER
(19) Install engine in vehicle.
(20) Fill engine oil with proper oil to correct level.
CYLINDER LINERS
DESCRIPTION
The cylinder wall liner used on this engine is of
the wet design. O-rings are used to seal the liner to
the engine block.
REMOVAL
(1) Remove engine from vehicle.
(2) With engine completely disassembled, use spe-
cial tool VM.1001 to remove liner assembly (Fig. 40).
(3) Tighten bolt on VM.1001 to remove liner from
block (Fig. 41). Fig. 41 CYLINDER LINER REMOVAL
(4) Remove shims from cylinder liner or cylinder 1 - SPECIAL TOOL VM.1001
block recess. Keep shims with each cylinder liner. 2 - CYLINDER LINER
3 - ENGINE BLOCK
9a - 34 ENGINE RG
CYLINDER LINERS (Continued)
INSPECTION
The cylinder walls should be checked for out-of-
round and taper with a dial bore gauge. The cylinder
bore out-of-round is 0.100 mm (.0039 in.) maximum
and cylinder bore taper is 0.100 mm (.0039 in.) max-
imum. If the cylinder walls are badly scuffed or
scored, new liners should be installed and honed, and
new pistons and rings fitted.
Measure the cylinder bore at three levels in direc-
tions A and B (Fig. 42). Top measurement should be
10 mm (3/8 in.) down and bottom measurement
should be 10 mm (3/8 in.) up from the bottom bore.
Fig. 43 LINER INSTALLATION

1 - CYLINDER LINER
2 - SHIMS
3 - O-RINGS
Fig. 42 LINER INSPECTION 4 - BLOCK LEDGE
5 - ENGINE BLOCK
INSTALLATION
(1) Carefully clean liner and engine block, and
degrease the engine block where it comes into contact
with the liners. Install the liners in the engine block
as shown, rotating them back and forth by 45° in
order to guarantee correct positioning (Fig. 43).
(2) Measure the liner recess relative to block deck
with a dial indicator mounted on a special tool
VM-1010 A. All the measurements must be taken
on high pressure pump side of engine block..
Zero dial gauge on block deck.
(3) Move dial gauge to cylinder liner record read-
ing on dial gauge.
(4) Remove liner and special tool.
(5) Then select the correct shim thickness to give
proper protrusion (0.01 - 0.06 mm).
(6) Fit the shim and the O-rings onto the liner.
(7) Lubricate the lower liner location in the block.
(8) Fit the liners in the crankcase making sure
that the shim is positioned correctly in the seat. Lock
the liners in position using special tool (VM.1076)
and bolts (Fig. 44). Clean the residual LOCTITE on
the upper surface of the block deck. Fig. 44 LINER CLAMP LOCATION
(9) Recheck the liner protrusion. It should be 0.01
1 - ENGINE BLOCK
- 0.06 mm.
2 - LINER RETAINER VM.1076
(10) Reassemble engine. 3 - CYLINDER LINER
(11) Install engine in vehicle.
RG ENGINE 9a - 35
INTERNAL VACUUM PUMP

DESCRIPTION
The diesel engine uses a internal vacuum pump.
This vacuum pump is mounted in the front of the
engine block under the engine front cover (Fig. 45).
The vacuum pump is driven by a sprocket on the
crankshaft.
Fig. 45 VACUUM PUMP

REMOVAL
Fig. 46 OIL PUMP AND VACUUM PUMP
(2) Remove air cleaner housing.
(3) Remove power steering belt (Refer to 7 - 1 - VACUUM PUMP
2 - CRANKSHAFT SPROCKET
3 - OIL PUMP
REMOVAL).
4 - ENGINE BLOCK
(4) Remove accessory drive belt (Refer to 7 - 5 - CRANKSHAFT
REMOVAL).
(5) Support engine and remove right engine mount INSTALLATION
(Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT (1) Lubricate vacuum pump blades and install in
MOUNT - REMOVAL). vacuum pump body as shown (Fig. 47).
(6) Remove vibration damper/crankshaft pulley (2) Install vacuum pump in engine block (Fig. 46).
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION Torque bolts to 10.8N·m.
DAMPER - REMOVAL). (3) Install crankshaft sprocket (Fig. 46). Torque
(7) Remove outer timing belt cover (Refer to 9 - bolts to 10.8N·m.
ENGINE/VALVE TIMING/TIMING BELT / CHAIN (4) Install front engine cover (Refer to 9 -
COVER(S) - REMOVAL). ENGINE/ENGINE BLOCK/ENGINE COVER -
(8) Remove timing belt (Refer to 9 - ENGINE/ INSTALLATION).
VALVE TIMING/TIMING BELT/CHAIN AND (5) Install front crankshaft hub. Torque bolt to
SPROCKETS - REMOVAL). 304N·m.
(9) Remove timing belt inner cover (Refer to 9 - (6) Install timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL). COVER(S) - INSTALLATION).
NOTE: Crankshaft hub has LHD thread. VALVE TIMING/TIMING BELT/CHAIN AND
(10) Remove crankshaft hub. (8) Install timing belt outer cover (Refer to 9 -
(11) Remove front engine cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN
ENGINE/ENGINE BLOCK/ENGINE COVER - COVER(S) - INSTALLATION).
REMOVAL). (9) Install vibration damper/crankshaft pulley.
(12) Remove crankshaft sprocket (Fig. 46).
(13) Remove vacuum pump (Fig. 46).
9a - 36 ENGINE RG
INTERNAL VACUUM PUMP (Continued)
Fig. 47 VACUUM PUMP COMPONENTS

1 - VACUUM PUMP BODY
2 - VACUUM PUMP BLADE TAPERED EDGE
3 - VACUUM PUMP BLADE

INSTALLATION).
INSTALLATION).
COOLING/ACCESSORY DRIVE/DRIVE BELTS - Fig. 48 PISTON AND CONNECTING ROD ASSEMBLY
INSTALLATION). 1 - PISTON PIN
(13) Install air cleaner housing. 2 - PISTON
(14) Connect negative battery cable. 3 - SNAP RING
4 - CONNECTING ROD ALIGNMENT NUMBERS
5 - CONNECTING ROD BOLT
PISTON & CONNECTING ROD 6
7
-
-
CONNECTING
CONNECTING
ROD BEARING
ROD
8 - SNAP RING
DESCRIPTION
The pistons are of a free floating design. Oil jets in
the engine block lubricate and cool the piston and pin (.0118 to .0177 in.). Oil control ring gap .25 to .50mm
assembly. The connecting rods have a pressed in (.0098 to .0196 in.).
place wrist pin bushing which is lubricated by the oil (2) If ring gaps exceed dimension given, new rings
jets (Fig. 48). or cylinder liners must be fitted. Keep piston rings in
piston sets.
STANDARD PROCEDURE - PISTON RING (3) Check piston ring to groove clearance (Fig. 50).
Top compression ring gap .080 to .130mm (.0031 to
FITTING .0051 in.). Second compression ring gap .070 to
(1) Wipe cylinder bore clean. Insert ring and push .110mm (.0027 to .0043 in.). Oil control ring gap .040
down with piston to ensure it is square in bore. The to .080mm (.0015 to .0031 in.).
ring gap measurement must be made with the ring
positioning at least 12 mm (0.50 in.) from bottom of REMOVAL
cylinder bore (Fig. 49). Check gap with feeler gauge. (1) Disconnect negative battery cable.
Top compression ring gap .30 to .45mm (.0118 to (2) Remove cylinder head (Refer to 9 - ENGINE/
.0177 in.). Second compression ring gap .30 to .45mm CYLINDER HEAD - REMOVAL).
RG ENGINE 9a - 37
PISTON & CONNECTING ROD (Continued)
NOTE: Be careful not to nick or scratch crankshaft
journals
(9) After removal, install bearing cap on the mat-

ing rod and mark pistons with matching cylinder
number when removed from engine block.
PISTON PIN - REMOVAL

(1) Secure connecting rods in a soft jawed vice.
(2) Remove 2 snap rings securing piston pin (Fig.
51).
(3) Push piston pin out of piston and connecting
rod (Fig. 51).
Fig. 49 RING END GAP MEASUREMENT

1 - FEELER GAUGE
Fig. 50 PISTON RING TO GROOVE CLEARANCE

(3) Raise vehicle on hoist.
Fig. 51 PISTON AND CONNECTING ROD ASSEMBLY
(5) Remove oil pump pickup tube.(Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP - REMOVAL) 1 - PISTON PIN
2 - PISTON
(6) Remove balance shaft assembly (Refer to 9 -
3 - SNAP RING
4 - CONNECTING ROD ALIGNMENT NUMBERS
REMOVAL). 5 - CONNECTING ROD BOLT
(7) Remove top ridge of cylinder bores with a ridge 6 - CONNECTING ROD BEARING
reamer before removing pistons from cylinder block. 7 - CONNECTING ROD
Be sure to keep top of pistons covered during 8 - SNAP RING
this operation.
(8) Piston and connecting rods must be removed
from top of cylinder block. Rotate crankshaft so that
each connecting rod is centered in cylinder bore.
9a - 38 ENGINE RG
PISTON RING - REMOVAL (4) Check and record internal diameter of crank
(1) ID mark on face of top and second piston rings end of connecting rod.
must point toward piston crown.
(2) Using a suitable ring expander, remove top and NOTE: When changing connecting rods, all four
second piston rings (Fig. 52). must have the same weight and be stamped with
the same number. Replacement connecting rods
will only be supplied in sets of four.
Connecting rods are supplied in sets of four since

they all must be of the same weight category. Max
allowable weight difference is 5 gr.
NOTE: On one side of the big end of the con-rod

there is a two-digit number which refers to the
weight category. On the other side of the big end
there is a four digit number on both the rod and the
cap. These numbers must both face the injection
pump side of the block (Fig. 53). Lightly heat the
piston in oven. Insert piston pin in position and
secure it with provided snap rings.
Fig. 52 PISTON RINGS - REMOVAL/INSTALLATION

(3) Remove upper oil ring side rail, lower oil ring
side rail and then the oil expander from piston.
(4) Carefully clean carbon from piston crowns,
skirts and ring grooves ensuring the 4 oil holes in
the oil control ring groove are clear.
INSPECTION
PISTONS
(1) Piston Diameter: Size: 91.912-91.928mm
(3.6185-3.6192 in.) Maximum wear limit .05mm
(.0019 in.).
(2) Check piston pin bores in piston for roundness.
Make 3 checks at 120° intervals. Maximum out of Fig. 53 CONNECTING ROD IDENTIFICATION
roundness .05mm (.0019in.). 1 - SMALL END OF CONNECTING ROD
(3) The piston diameter should be measured 2 - 2 DIGIT NUMBER LOCATION
approximately 15 mm (.590 in.) up from the base. 3 - 4 DIGIT NUMBER LOCATION
(4) Skirt wear should not exceed 0.1 mm (.00039
in.). The Four digit numbers marked on con rod
(5) The clearance between the cylinder liner and big end and rod cap must be on the same side
piston should not exceed 0.065-0.083 mm as the injection pump (Fig. 53). After having
(.0025-.0032 in.). coated threads with Molyguard, tighten con rod bolts
(6) Make sure the weight of the pistons does not to 29 N·m (21 ft. lbs.) plus 60°.
differ by more than 5 g.
PISTON PINS
CONNECTING RODS (1) Measure the diameter of piston pin in the cen-
(1) Assemble bearing shells and bearing caps to ter and both ends.
their respective connecting rods ensuring that the (2) Piston pin diameter is 29.992 to 29.996mm
serrations on the cap and reference marks are (1.1807 to 1.1809 in.).
aligned.
(2) Tighten connecting cap bolts to 29 N·m (21 ft.
lbs.) plus 60°.
(3) Without loosening connecting rod bolts, tighten
all bolts to 88N·m.
RG ENGINE 9a - 39
INSTALLATION (6) Remove connecting rod from vice.
PISTON PIN INSTALLATION PISTON RINGS - INSTALLATION

(1) Secure connecting rod in soft jawed vice. (1) Install rings on the pistons using a suitable
(2) Lubricate piston pin and piston with clean ring expander (Fig. 55).
engine oil.
(3) Position piston on connecting rod (Fig. 54).
CAUTION: Ensure arrow on piston crown and the

bearing cap numbers on the connecting rod are on
the opposite side.
(4) Install piston pin (Fig. 54).

(5) Install clips in piston to retain piston pin (Fig.
54).
Fig. 55 PISTON RINGS-INSTALLATION

(2) Top compression ring is tapered and chromium
plated. The second ring is of the scraper type and
must be installed with scraping edge facing bottom of
the piston. The third is an oil control ring. Ring gaps
must be positioned, before inserting piston into the
liners, as follows.
(3) Top ring gap must be positioned at the #3 posi-
tion (looking at the piston crown from above) (Fig.
56).
(4) Second piston ring gap should be positioned at
the #1 position (Fig. 56).
(5) Oil control ring gap should be positioned at the
#2 position (Fig. 56).
Fig. 54 PISTON AND CONNECTING ROD ASSEMBLY

1 - PISTON PIN
2 - PISTON
3 - SNAP RING
Fig. 56 PISTON RING GAP LOCATION
4 - CONNECTING ROD ALIGNMENT NUMBERS 3 - TOP COMPRESSION RING GAP POSITION
5 - CONNECTING ROD BOLT 1 - SECOND COMPRESSION RING GAP POSITION
6 - CONNECTING ROD BEARING 2 - OIL CONTROL RING GAP POSITION
7 - CONNECTING ROD
8 - SNAP RING
(6) When assembling pistons check that compo-
nents are installed in the same position as before dis-
9a - 40 ENGINE RG
assembly, determined by the numbers stamped on (5) Tap the piston down in cylinder bore, using a
the crown of individual pistons. Engine cylinders are hammer handle. At the same time, guide connecting
numbered starting from gear train end of the engine. rod into position on connecting rod journal.
Face arrow on top of piston toward front of (6) Install connecting rod caps (Fig. 58). Install rod
engine. Therefore, the numbers stamped on connect- bolts and tighten to 30N·m (22 ft.lb.) plus 60°. Then
ing rod big end should face toward the injection torque to 88N·m (65 ft.lb).
pump side of engine. To insert piston into cylinder
use a ring compressor (VM.1065) as shown in (Fig.
57).
INSTALLATION
(1) Before installing pistons, and connecting rod
assemblies into the bore, be sure that compression
ring gaps are staggered so that neither is in line with
oil ring rail gap (Fig. 56).
(2) Before installing the ring compressor, make
sure the oil ring expander ends are butted together.
(3) Immerse the piston head and rings in clean
engine oil, slide the ring compressor, over the piston
and tighten (Fig. 57). Ensure position of rings
does not change during this operation.
NOTE: Be sure arrow on top of piston faces

towards front of engine.
NOTE: Be careful not to nick crankshaft journals.
(4) Rotate crankshaft so that the connecting rod

journal is on the center of the cylinder bore. Insert
rod and piston into cylinder bore and guide rod over
the crankshaft journal.
Fig. 58 PISTON AND CONNECTING ROD
INSTALLATION
1 - PISTON AND CONNECTING ROD ASSEMBLY
2 - FOUR DIGIT NUMBER
3 - CONNECTING ROD BOLT
4 - FOUR DIGIT NUMBER
(7) Install cylinder head (Refer to 9 - ENGINE/

CYLINDER HEAD - INSTALLATION).
(8) Install balance shaft assembly (Refer to 9 -
INSTALLATION).
(9) Install oil pump pickup tube (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP - INSTALLA-
TION).
Fig. 57 PISTON INSTALLATION USING VM.1065

RG ENGINE 9a - 41
CRANKSHAFT OIL SEAL -

FRONT
REMOVAL
MOUNT - REMOVAL).
(4) Remove power steering belt (Refer to 7 -
REMOVAL).
(5) Remove accessory drive belt (Refer to 7 -
REMOVAL).
(6) Remove vibration damper/crankshaft pulley
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
SPROCKETS - REMOVAL). Fig. 59 ENGINE COVER - FRONT
(9) Remove timing belt inner cover (Refer to 9 - 1 - CRANKSHAFT HUB RETAINING BOLT
ENGINE/VALVE TIMING/TIMING BELT / CHAIN 2 - FRONT ENGINE COVER RETAINING BOLTS
3 - ENGINE BLOCK
4 - FRONT ENGINE COVER ALIGNMENT DOWELS
5 - FRONT ENGINE COVER
NOTE: Crankshaft hub retaining bolt has LHD
6 - CRANKSHAFT HUB
thread.
(10) Remove crankshaft hub.

(11) Remove front engine cover (Fig. 59) (Refer to
9 - ENGINE/ENGINE BLOCK/ENGINE COVER -
REMOVAL).
(12) With cover on work bench, pry out old seal.
INSTALLATION
(1) Clean engine block and front engine cover seal-
ing surfaces.
(2) Install crankshaft oil seal on VM.1061 (Fig.
60).
(3) Place sleeve for VM.1061 on workbench as
shown (Fig. 60).
Fig. 60 VM.1061 PLACEMENT

1 - VM.1061
3 - WORK BENCH
4 - SLEEVE FROM VM.1061
9a - 42 ENGINE RG
CRANKSHAFT OIL SEAL - FRONT (Continued)
(4) Using hammer, install new seal into front VIBRATION DAMPER
engine cover (Fig. 61).
REMOVAL
REMOVAL).
REMOVAL).
(3) Remove vibration damper retaining bolts and
damper (Fig. 62).
Fig. 61 CRANKSHAFT OIL SEAL INSTALLATION

WITH VM.1061
1 - VM.1061
3 - WORK BENCH

INSTALLATION).
(6) Install crankshaft hub and retaining bolt.
Torque bolt to 304N·m.
ENGINE/VALVE TIMING/TIMING BELT / CHAIN Fig. 62 VIBRATION DAMPER
COVER(S) - INSTALLATION). 1 - BELT TENSIONER RETAINING BOLT
(8) Install timing belt (Refer to 9 - ENGINE/ 2 - BELT TENSIONER
VALVE TIMING/TIMING BELT/CHAIN AND 3 - IDLER PULLEY
SPROCKETS - INSTALLATION) . 4 - VIBRATION DAMPER/CRANKSHAFT PULLEY
(9) Install timing belt outer cover (Refer to 9 - 5 - VIBRATION DAMPER/CRANKSHAFT PULLEY RETAINING
BOLTS
(10) Install vibration damper/crankshaft pulley INSTALLATION
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION (1) Install vibration damper and retaining bolts
DAMPER - INSTALLATION). (Fig. 62). Torque bolts to 27.5N·m.
(11) Install accessory drive belt (Refer to 7 - (2) Install accessory drive belt (Refer to 7 - COOL-
COOLING/ACCESSORY DRIVE/DRIVE BELTS - ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
INSTALLATION). LATION).
(12) Install power steering belt (Refer to 7 - (3) Install power steering belt (Refer to 7 - COOL-
COOLING/ACCESSORY DRIVE/DRIVE BELTS - ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
INSTALLATION). LATION).
INSTALLATION).
(14) Install air cleaner housing.
RG ENGINE 9a - 43
ENGINE COVER - FRONT

DESCRIPTION
The front engine cover on this engine is a stamped
steel cover which covers the oil pump and vacuum
pump.
REMOVAL
MOUNT - REMOVAL).
REMOVAL).
REMOVAL).
(6) Remove vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
Fig. 63 ENGINE COVER - FRONT
CAUTION: Before removing the cylinder head cover/ 1 - CRANKSHAFT HUB RETAINING BOLT
intake manifold or timing belt the engine must put 2 - FRONT ENGINE COVER RETAINING BOLTS
3 - ENGINE BLOCK
4 - FRONT ENGINE COVER ALIGNMENT DOWELS
(Refer to 9 - ENGINE/VALVE TIMING - STANDARD 6 - CRANKSHAFT HUB
PROCEDURE)
(8) Remove timing belt (Refer to 9 - ENGINE/ (5) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL). SPROCKETS - INSTALLATION) .
(9) Remove timing belt inner cover (Refer to 9 - (6) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL). COVER(S) - INSTALLATION).
(7) Install vibration damper (Refer to 9 - ENGINE/
NOTE: Crankshaft hub has LHD thread. ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
(10) Remove crankshaft hub. (8) Install right engine mount (Refer to 9 -
(11) Remove front engine cover (Fig. 63). ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION).
INSTALLATION (9) Install accessory drive belt (Refer to 7 - COOL-
(1) Clean engine block and front engine cover seal- ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
ing surfaces. LATION).
(2) Apply a continous 3mm bead of Silicone Sealer (10) Install power steering belt (Refer to 7 -
to cover, install within 10 minutes (Fig. 63). Torque COOLING/ACCESSORY DRIVE/DRIVE BELTS -
bolts to 11.8N·m. INSTALLATION).
(3) Install crankshaft hub (Fig. 63). Torque bolt to (11) Install air cleaner housing.
304N·m. (12) Connect negative battery cable.
9a - 44 ENGINE RG
CRANKSHAFT MAIN CRANKSHAFT FRONT MAIN BEARING

(1) Using special tool VM.1073 push front main
BEARINGS bearing out of front of engine block (Fig. 65).
REMOVAL
The engine must be removed from vehicle and com-
pletely disassembled to replace the front main bear-
ing.
CRANKSHAFT MAIN BEARINGS

(1) With crankshaft assembly removed from
engine.
(2) Remove crankshaft supports from crankshaft
and remove bearing halves from supports (Fig. 64).
Fig. 65 FRONT MAIN BEARING REMOVAL

1 - VM.1073
2 - FRONT CRANKSHAFT MAIN BEARING
3 - ENGINE BLOCK
Fig. 64 CRANKSHAFT ASSEMBLY

3 - CRANKSHAFT
7 - WASHERS
RG ENGINE 9a - 45
CRANKSHAFT MAIN BEARINGS (Continued)
INSTALLATION
CRANKSHAFT MAIN BEARINGS
(1) Install bearing halves in crankshaft supports.
(2) Lubricate crankshaft and main bearings with
clean engine oil.
(3) Install crankshaft supports on crankshaft (Fig.
66). Torque bolts to 44.1N·m.
Fig. 67 FRONT MAIN BEARING INSTALLATION

2 - ENGINE BLOCK
3 - SPECIAL TOOL VM.1073
Fig. 66 CRANKSHAFT ASSEMBLY

3 - CRANKSHAFT
7 - WASHERS Fig. 68 FRONT MAIN BEARING ALIGNMENT
1 - ENGINE BLOCK
FRONT CRANKSHAFT MAIN BEARING 2 - OIL HOLE IN BEARING
(1) Using special tool VM.1073, push front crank-
shaft main bearing in engine block (Fig. 67).
(2) Be sure oil hole in bearing lines up with oil gal-
lery in engine block (Fig. 68).
(3) Reassemble engine and install in vehicle.
9a - 46 ENGINE RG
CRANKSHAFT OIL SEAL -

REAR
REMOVAL
This must be done with either the engine or trans-
mission removed from vehicle.
(1) Remove flywheel assembly.
(2) Pry out old crankshaft oil seal.
INSTALLATION
(1) Using special tool VM.1050, install rear crank-
shaft oil seal in rear main bearing support (Fig. 69).
Fig. 70 OIL PAN AND PRESSURE RELIEF VALVE

1 - OIL PAN RETAINING BOLTS
2 - POWER STEERING LINE BRACKETS
3 - OIL PAN GASKET
4 - OIL PRESSURE SENSOR
5 - ENGINE BLOCK
6 - OIL PRESSURE RELIEF VALVE
7 - OIL PAN RETAINING BOLTS
Fig. 69 REAR CRANKSHAFT OIL SEAL 8 - OIL PAN
INSTALLATION USING VM.1050
1 - SPECIAL TOOL VM.1050
2 - REAR MAIN BEARING SUPPORT
INSTALLATION
3 - OIL PAN (1) Clean oil pan and sealing surfaces. Inspect oil
4 - ENGINE TO TRANSMISSION ADAPTER PLATE pan and engine block.
(2) Install oil pan, gasket, and retaining bolts (Fig.
70).
(2) Install engine or tranmission in vehicle.
(3) Be sure power steering line brackets are in
proper location (Fig. 70).
OIL PAN (4) Torque oil pan bolts to 11.8N·m.
(5) Lower vehicle.
REMOVAL (6) Refill engine oil to proper level.
(3) Drain engine oil from engine.
(4) Remove all oil pan retaining bolts and oil pan
(Fig. 70).
RG ENGINE 9a - 47
OIL PUMP REMOVAL

REMOVAL (3) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
REMOVAL (4) Remove oil pump pickup tube retaining bolt
(1) Disconnect negative battery cable. and pull pickup tube from engine block (Fig. 72).
REMOVAL).
REMOVAL).
(7) Remove front engine cover (Refer to 9 -
REMOVAL).
(8) Remove crankshaft sprocket (Fig. 71).
(9) Remove oil pump retaining bolts and remove
pump from engine block (Fig. 71).
Fig. 72 OIL PUMP PICKUP TUBE ASSEMBLY

1 - BALANCE SHAFT
2 - OIL JET RETAINING BOLT
3 - OIL JET
4 - ENGINE BLOCK
5 - CRANKSHAFT
6 - BALANCE SHAFT RETAINING BOLTS
7 - OIL DIPSTICK TUBE RETAINER
8 - RUBBER BUSHING
9 - RETAINING BOLT
Fig. 71 OIL PUMP AND VACUUM PUMP INSTALLATION

1 - VACUUM PUMP
2 - CRANKSHAFT SPROCKET INSTALLATION
3 - OIL PUMP (1) Lubricate oil pump rotor with engine oil.
4 - ENGINE BLOCK (2) Install oil pump in bore in engine block (Fig.
5 - CRANKSHAFT
71).
9a - 48 ENGINE RG
OIL PUMP (Continued)
(3) Install oil pump retaining bolts (Fig. 71).
Torque bolts to 10.8N·m.
(4) Install crankshaft sprocket (Fig. 71). Torque
bolts to 10.8N·m.
INSTALLATION).
(9) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
INSTALLATION).
(11) Connect negative battery cable. Fig. 73 REAR ENGINE VIEW
1 - SUSPENSION CRADLE
INSTALLATION 2 - ENGINE BLOCK
(1) Lubricate o-ring on oil pump pickup tube with 3 - OIL PRESSURE SWITCH
engine oil. 4 - OIL TEMPERATURE SENSOR
(2) Install pickup tube in engine block and install 5 - VEHICLE SPEED SENSOR
6 - TRANSMISSION
retaining bolt (Fig. 72). Torque bolt to 32.4N·m.
CATION/OIL PAN - INSTALLATION). (4) Lower vehicle.
(4) Refill engine oil to proper level. (5) Start engine and check for leaks.
(5) Connect negative battery cable. (6) Check and adjust oil level as necessary.
OIL PRESSURE SENSOR/ OIL TEMPERATURE SENSOR

SWITCH
DESCRIPTION
DESCRIPTION The oil temperature sensor is located on the right
side of the engine block. The sensor screws into the
The oil pressure switch is located on the right side
engines main oil gallery (Fig. 74).
of the engine block. The switch screws into the
engines main oil gallery (Fig. 73).
REMOVAL
REMOVAL (1) Disconnect negative battery cable.
(3) Disconnect oil temperature sensor electrical
connector (Fig. 74).
(3) Disconnect oil pressure switch electrical con-
(4) Remove oil temperature sensor from engine
nector (Fig. 73).
block.
(4) Remove oil pressure switch from engine block.
INSTALLATION INSTALLATION
(1) Apply Mopart Thread Sealant to the sensor
(1) Apply Mopart Thread Sealant to the switch
threads.
threads.
(2) Install oil temperature sensor in engine block.
(2) Install oil pressure switch in engine block.
(3) Connect oil temperature sensor electrical con-
(3) Connect oil pressure switch electrical connector
nector (Fig. 74)
(Fig. 73).
RG ENGINE 9a - 49
OIL TEMPERATURE SENSOR (Continued)
Fig. 75 OIL PRESSURE RELIEF VALVE

1 - O-RING
2 - OIL PRESSURE RELIEF VALVE CAP
3 - OIL PRESSURE RELIEF VALVE SPRING
4 - OIL PRESSURE RELIEF VALVE PLUNGER
Fig. 74 REAR ENGINE VIEW

1 - SUSPENSION CRADLE
2 - ENGINE BLOCK
3 - OIL PRESSURE SWITCH
4 - OIL TEMPERATURE SENSOR
5 - VEHICLE SPEED SENSOR
6 - TRANSMISSION
(4) Lower vehicle.

(5) Start engine and check for leaks.
(6) Check and adjust oil level as necessary.
OIL PRESSURE RELIEF VALVE

DESCRIPTION
The oil pressure relief valve mounts in the front of
the engine block and is used to control oil flow
through the engines lubrication system (Fig. 75).
REMOVAL
(1) Remove engine oil pan (Refer to 9 - ENGINE/
LUBRICATION/OIL PAN - REMOVAL).
(2) Using special tool VM.1054, remove oil pres-
sure relief valve from engine block (Fig. 76).
INSTALLATION
(1) Thoroughly clean all components and relief
valve pocket in cylinder block. Fig. 76 OIL PRESSURE RELIEF VALVE REMOVAL
(2) Lubricate all oil pressure relief valve compo- 1 - VM.1054
nents with engine oil. 2 - OIL PRESSURE RELIEF VALVE
(3) Install oil pressure relief valve plunger, spring, 3 - ENGINE BLOCK
and cap. 4 - OIL PUMP
9a - 50 ENGINE RG
OIL PRESSURE RELIEF VALVE (Continued)
(4) Using special tool VM.1059, push oil pressure
relief valve cap in untill flush with engine block (Fig.
77).
Fig. 78 OIL FILTER HOUSING RETAINING NUT

1 - OIL FILTER HOUSING
2 - OIL FILTER HOUSING RETAINING NUT
Fig. 77 OIL PRESSURE RELIEF VALVE 3 - OIL COOLER
INSTALLATION
1 - VM.1059
2 - OIL PRESSURE RELIEF VALVE
3 - ENGINE BLOCK
4 - OIL PUMP

OIL COOLER & LINES

REMOVAL
(1) Drain cooling system (Refer to 7 - COOLING/
(3) Remove oil filter cap and filter (Refer to 9 -
ENGINE/LUBRICATION/OIL FILTER - REMOVAL).
(4) Remove oil filter housing retaining nut and
housing (Fig. 78).
(5) Disconnect coolant hoses at cooler (Fig. 79). Fig. 79 WATER PUMP AND OIL COOLER
(6) Remove oil cooler retaining bolt at engine block ASSEMBLIES
(Fig. 79). 1 - WATER PUMP HOUSING STUDS
(7) Remove oil cooler retaining stud and remove oil 2 - WATER PUMP
cooler from engine block (Fig. 79). 3 - RETAINING NUTS
4 - OIL COOLER RETAINING STUD
INSTALLATION 5 - OIL COOLER TO ENGINE BLOCK RETAINING BOLT
6 - OIL COOLER COOLANT HOSE
(1) Clean oil cooler and engine block sealing sur-
7 - ENGINE BLOCK
faces.
RG ENGINE 9a - 51
OIL COOLER & LINES (Continued)
(2) Install oil cooler, retaining bolt, and stud (Fig. REMOVAL
79). Torque retaining bolt to 47.1N·m and stud to (1) Raise vehicle on hoist.
50N·m. (2) Remove oil filter cap drain plug and drain oil
(3) Connect coolant hoses at cooler (Fig. 79). from oil filter housing (Fig. 81).
(4) Install oil filter housing and retaining nut (Fig. (3) Remove oil filter cap with suitable oil filter
78). Torque retaining nut to 3.5 Kg. wrench (Fig. 81).
(5) Install oil filter cartridge and oil filter cap
(Refer to 9 - ENGINE/LUBRICATION/OIL FILTER -
INSTALLATION).
(6) Lower vehicle.
(7) Refill cooling system (Refer to 7 - COOLING/
OIL FILTER
DESCRIPTION
The oil filter used on this engine is a cartridge
style filter (Fig. 80).
Fig. 81 OIL COOLER AND FILTER ASSEMBLY

1 - WATER PUMP HOUSING
2 - OIL FILTER HOUSING
3 - OIL FILTER CAP
4 - OIL FILTER CAP DRAIN PLUG
5 - OIL COOLER
(4) Remove oil filter cartridge from housing.
INSTALLATION
(1) Clean oil filter cap and drain plug with suit-
able solvent.
Fig. 80 OIL FILTER ASSEMBLY
(2) Install new oil filter cartridge in oil filter hous-
1 - OIL FILTER CAP ing.
2 - DRAIN PLUG
(3) Install oil filter cap and drain plug
3 - OIL FILTER CARTRIDGE
(4) Lower vehicle from hoist.
9a - 52 ENGINE RG
OIL JET
DESCRIPTION
There are four oil jets installed in the engine block.
These oil jets are used to cool and lubricate the pis-
ton assemblies (Fig. 82).
Fig. 82 OIL JET ASSEMBLY

1 - RETAINING BOLT
2 - OIL JET
3 - O-RING
REMOVAL
CAUTION: Use caution when removing and install-
ing oil jets. Damage to oil jet nozzle could cause
severe engine damage.
(1) Disconnect negative battery cable. Fig. 83 OIL JET REMOVAL/INSTALLATION

(2) Raise vehicle on hoist. 1 - SPECIAL TOOL VM.1060
(3) Remove oil pan (Refer to 9 - ENGINE/LUBRI- 2 - OIL JET
CATION/OIL PAN - REMOVAL). 3 - CONNECTING ROD
(4) Using special tool VM.1060 to hold oil jet. 4 - CRANKSHAFT
Remove oil jet retaining bolt and remove oil jet from
engine block (Fig. 83).
INTAKE MANIFOLD
INSTALLATION
DESCRIPTION
CAUTION: Use caution when removing and installa- (Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
ing oil jets. Damage to oil jet nozzle could cause DER HEAD COVER(S) - DESCRIPTION)
severe engine damage.
REMOVAL
(1) Lubricate o-ring on oil jet. (1) (Refer to 9 - ENGINE/CYLINDER HEAD/CYL-
(2) Using special tool VM.1060, install oil jet in INDER HEAD COVER(S) - REMOVAL)
engine block (Fig. 83).
(3) Install oil jet retaining bolt. Torque bolt to INSTALLATION
10.8N·m. (1) (Refer to 9 - ENGINE/CYLINDER HEAD/CYL-
(4) Install oil pan (Refer to 9 - ENGINE/LUBRI- INDER HEAD COVER(S) - INSTALLATION)
(5) Refill engine oil to proper level.
RG ENGINE 9a - 53
VALVE TIMING
STANDARD PROCEDURE - LOCKING ENGINE
90° AFTER TDC
(2) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL).
(3) Rotate engine untill notch in hub is in the fol-
lowing position (Fig. 84).
Fig. 85 TDC AND 90 DEGREES AFTER TDC

ALIGNMENT PIN LOCATION
1 - ENGINE BLOCK
2 - VM.1051 TDC PIN OR VM.1068 90 DEGREES ATDC PIN
3 - FLYWHEEL
Fig. 84 CRANKSHAFT HUB ALIGNMENT

1 - VIBRATION DAMPER/CRANKSHAFT PULLEY
2 - CRANKSHAFT HUB NOTCH
3 - VIBRATION DAMPER/CRANKSHAFT PULLEY TO
CRANKSHAFT HUB BOLTS
(4) Special tool VM.1068 can be install in engine

block as shown at this time (Fig. 85). This will lock
the engine at 90° after TDC.
REMOVAL).
REMOVAL).
(7) Remove plug in cylinder head cover/intake
manifold and insert VM.1053 to lock exhaust cam- Fig. 86 EXHAUST CAMSHAFT LOCKING PIN
shaft in position (Fig. 86). VM.1053
1 - EXHAUST MANIFOLD HEAT SHIELD
CHARGING/GENERATOR - REMOVAL). 2 - EXHAUST CAMSHAFT LOCKING PIN VM.1053
3 - COOLANT TUBE FROM THERMOSTAT HOUSING TO UPPER
RADIATOR HOSE
9a - 54 ENGINE RG
VALVE TIMING (Continued)
(9) Remove plug in cylinder head cover/intake BALANCE SHAFT
manifold and insert VM.1052 to lock intake camshaft
in position (Fig. 87).
DESCRIPTION
The 2.5L Common Rail Diesel engine is equipped
with two nodular cast iron balance shafts in a cast
aluminum carrier. The balance shaft assembly is
mounted to the engine block (Fig. 88).
Fig. 87 INTAKE CAMSHAFT LOCKING PIN VM.1052

2 - GLOW PLUG ELECTRICAL CONNECTOR
4 - FUEL RAIL
5 - INTAKE CAMSHAFT LOCKING PIN VM.1052
(10) At this point the timing belt can be removed

for service.
(11) After engine service is completed and timing
belt reinstalled, remove both camshaft locking pins Fig. 88 BALANCE SHAFT ASSEMBLY
from cylinder head cover/intake manifold.
1 - BALANCE SHAFT
(12) Install both camshaft access plugs.
(13) Remove 90° after TDC engine locking pin. 3 - OIL JET
(14) Install starter motor (Refer to 8 - ELECTRI- 4 - ENGINE BLOCK
CAL/STARTING/STARTER MOTOR - INSTALLA- 5 - CRANKSHAFT
TION). 6 - BALANCE SHAFT RETAINING BOLTS
(15) Install generator (Refer to 8 - ELECTRICAL/ 7 - OIL DIPSTICK TUBE RETAINER
CHARGING/GENERATOR - INSTALLATION). 8 - RUBBER BUSHING
(16) Install engine cover (Refer to 9 - ENGINE - 9 - RETAINING BOLT
INSTALLATION).
(17) Install front wiper unit (Refer to 8 - ELEC- OPERATION
The balance shaft is driven by the crankshaft. The
INSTALLATION).
balance shafts are connected by heelical gears. The
dual-counter rotating shafts decrease second order
vertical shaking forces caused by component move-
ment.
RG ENGINE 9a - 55
BALANCE SHAFT (Continued)
REMOVAL
(4) Remove balance shaft assembly (Fig. 89).
Fig. 90 TDC AND 90 DEGREES AFTER TDC

ALIGNMENT PIN LOCATION
1 - ENGINE BLOCK
2 - VM.1051 TDC PIN OR VM.1068 90 DEGREES ATDC PIN
3 - FLYWHEEL
bly (Fig. 91). This will ensure proper balance shaft

and crankshaft timing after assembly.
Fig. 89 BALANCE SHAFT ASSEMBLY

1 - BALANCE SHAFT
3 - OIL JET
4 - ENGINE BLOCK
5 - CRANKSHAFT
6 - BALANCE SHAFT RETAINING BOLTS
7 - OIL DIPSTICK TUBE RETAINER
8 - RUBBER BUSHING
9 - RETAINING BOLT
INSTALLATION
(1) Before installation of the balance shaft assembly,
the # 1 cylinder must be brought to TDC. Using special
tool VM.1051, roll engine over by hand until tool can be
inserted into engine block locking flywheel from turning
(Fig. 90). Once the # 1 cylinder is brought to TDC, the Fig. 91 BALANCE SHAFT ALIGNMENT PIN VM.1056
balance shaft assembly can be installed. 1 - VM.1056
(2) With balance shaft assembly on work bench. 2 - BALANCE SHAFT ASSEMBLY
Insert special tool VM.1056 into balance shaft assem-
9a - 56 ENGINE RG
BALANCE SHAFT (Continued)
(3) Install balance shaft assembly and retaining
bolts (Fig. 89). Torque bolts to 32.4N·m.
(5) Refill engine oil to proper level.
TIMING BELT / CHAIN

COVER(S)
REMOVAL
REMOVAL - TIMING BELT OUTER COVER
REMOVAL).
and bracket.
REMOVAL).
REMOVAL).
(7) Remove vibration damper (Refer to 9 - Fig. 92 TIMING BELT COVER (OUTER)
ENGINE/ENGINE BLOCK/VIBRATION DAMPER - 1 - SEAL
REMOVAL). 2 - TIMING BELT OUTER COVER
(8) Remove timing belt outer cover retaining bolts 3 - RETAINING BOLTS
and remove cover (Fig. 92).
(10) Remove timing belt idler pulleys (Refer to 9 -
REMOVAL - TIMING BELT INNER COVER ENGINE/VALVE TIMING/TIMING BELT IDLER
(1) Disconnect negative battery cable. PULLEY - REMOVAL).
(2) Remove engine cover (Refer to 9 - ENGINE - (11) Using special tool VM.1055, remove camshaft
REMOVAL). sprockets (Fig. 93).
(3) Remove air cleaner housing. (12) Remove timing belt tensioner (Refer to 9 -
(4) Support engine and remove right engine mount ENGINE/VALVE TIMING/TMNG BELT/CHAIN
and bracket. TENSIONER&PULLEY - REMOVAL) .
(5) Remove power steering belt (Refer to 7 - (13) Remove injection pump sprocket (Refer to 14 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS - FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
REMOVAL). TION PUMP - REMOVAL).
(6) Remove accessory drive belt (Refer to 7 - (14) Remove timing belt inner cover retaining bolts
COOLING/ACCESSORY DRIVE/DRIVE BELTS - and remove cover (Fig. 94).
REMOVAL).
ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION
REMOVAL).
(8) Remove timing belt outer cover (Refer to 9 - INSTALLATION - TIMING BELT OUTER COVER
ENGINE/VALVE TIMING/TIMING BELT / CHAIN (1) Install timing belt outer cover seal and cover
COVER(S) - REMOVAL). (Fig. 92). Torque 3mm bolts to 10.8N·m and 8mm
(9) Remove timing belt (Refer to 9 - ENGINE/ bolts to 10.8N·m.
VALVE TIMING/TIMING BELT/CHAIN AND (2) Install vibration damper (Refer to 9 - ENGINE/
SPROCKETS - REMOVAL). ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
RG ENGINE 9a - 57
TIMING BELT / CHAIN COVER(S) (Continued)
Fig. 93 CAMSHAFT SPROCKET REMOVAL/

INSTALLATION
3 - IDLER PULLEYS
5 - VM.1055 Fig. 94 TIMING BELT COVER - INNER
1 - TIMING BELT COVER TO CYLINDER HEAD COVER GASKET
(3) Install accessory drive belt (Refer to 7 - COOL- 2 - TIMING BELT COVER TO FRONT ENGINE COVER SEAL
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL- 3 - RUBBER GROMMET
LATION). 4 - BUSHING
(4) Install power steering belt (Refer to 7 - COOL- 5 - TIMING BELT COVER - INNER
6 - RETAINING BOLT
7 - RETAINING BOLT
LATION).
8 - RETAINING BOLT
(5) Install right engine mount. 9 - BUSHING
(6) Install air cleaner housing. 10 - RUBBER GROMMET
INSTALLATION).
(8) Connect negative battery cable. (6) Install timing belt idler pulleys (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT IDLER
INSTALLATION - TIMING BELT INNER COVER PULLEY - INSTALLATION).
(7) Install timing belt and tensioner (Refer to 9 -
(1) Install timing belt inner cover to engine front
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
cover seal (Fig. 94).
AND SPROCKETS - INSTALLATION) .
(2) Install timing belt inner cover to cylinder head
cover gaskets (Fig. 94).
(3) Install timing belt inner cover and retaining
bolts (Fig. 94). Torque 10mm bolts to 47.1N·m and
8mm bolts to 10.8N·m.
(4) Install injection pump sprocket (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - INSTALLATION).
(5) Install camshaft sprockets (Fig. 93). Torque
bolts to 108N·m.
9a - 58 ENGINE RG
TIMING BELT / CHAIN COVER(S) (Continued)
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
INSTALLATION).
(11) Install power steering belt (Refer to 7 - COOL-
LATION).
(12) Install right engine mount assembly.
INSTALLATION).
TIMING BELT IDLER PULLEY

REMOVAL
REMOVAL).
mount.
REMOVAL).
REMOVAL).
(7) Remove vibration damper (Refer to 9 - Fig. 95 TIMING BELT AND SPROCKETS
ENGINE/ENGINE BLOCK/VIBRATION DAMPER - 1 -CAMSHAFT SPROCKETS
REMOVAL). 2 - INJECTION PUMP SPROCKET
(8) Remove timing belt outer cover (Refer to 9 - 3 - INJECTION PUMP SPROCKET RETAINING NUT
ENGINE/VALVE TIMING/TIMING BELT / CHAIN 4 - TIMING BELT
COVER(S) - REMOVAL). 5 - TIMING BELT TENSIONER RETAINING BOLT
(9) Remove timing belt (Refer to 9 - ENGINE/ 6 - TIMING BELT TENSIONER
VALVE TIMING/TIMING BELT/CHAIN AND 7 - TENSIONER ALIGNMENT PIN
8 - IDLER PULLEY
9 - CAMSHAFT SPROCKET RETAINING BOLT
NOTE: Idler pulley retaining bolts are LHD thread.
(5) Install accessory drive belt (Refer to 7 - COOL-
(10) Remove timing belt idler pulleys (Fig. 95). ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
INSTALLATION (6) Install power steering belt (Refer to 7 - COOL-
(1) Install timing belt idler pulleys (Fig. 95). ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
Torque bolts to 47.1N·m. LATION).
(2) Install timing belt (Refer to 9 - ENGINE/ (7) Install right engine mount.
VALVE TIMING/TIMING BELT/CHAIN AND (8) Install air cleaner housing.
SPROCKETS - INSTALLATION) . (9) Install engine cover (Refer to 9 - ENGINE -
(3) Install timing belt outer cover (Refer to 9 - INSTALLATION).
ENGINE/VALVE TIMING/TIMING BELT / CHAIN (10) Connect negative battery cable.
LATION).
RG ENGINE 9a - 59
TMNG BELT/CHAIN
TENSIONER
REMOVAL
REMOVAL).
mount.
REMOVAL).
REMOVAL).
REMOVAL).
(9) Loosen and remove timing belt tensioner (Fig.
96).
INSTALLATION
(1) Install timing belt tensioner and retaining bolt Fig. 96 TIMING BELT AND SPROCKETS
(Fig. 96). 1 -CAMSHAFT SPROCKETS
(2) Adjust timing belt tensioner (Refer to 9 - 2 - INJECTION PUMP SPROCKET
ENGINE/VALVE TIMING/TMNG BELT/CHAIN 3 - INJECTION PUMP SPROCKET RETAINING NUT
TENSIONER&PULLEY - ADJUSTMENTS) . 4 - TIMING BELT
(3) Install timing belt outer cover (Refer to 9 - 5 - TIMING BELT TENSIONER RETAINING BOLT
6 - TIMING BELT TENSIONER
7 - TENSIONER ALIGNMENT PIN
8 - IDLER PULLEY
(4) Install vibration damper (Refer to 9 - ENGINE/ 9 - CAMSHAFT SPROCKET RETAINING BOLT
LATION).
(5) Install accessory drive belt (Refer to 7 - COOL- (6) Install power steering belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL- ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION). LATION).
(7) Install right engine mount.
INSTALLATION).
9a - 60 ENGINE RG
ADJUSTMENTS
ADJUSTMENT - TIMING BELT TENSIONER
(1) With timing belt outer cover removed and tim-
ing belt installed.
(2) Loosen timing belt tensioner (Fig. 97).
Fig. 98 TIMING BELT TENSIONER ALIGNMENT

1 - TENSIONER SPRING STOP
4 - TIMING BELT
Fig. 97 TIMING BELT TENSIONER ADJUSTMENT

1 - TIMING BELT IDLER PULLEY
TIMING BELT/CHAIN AND
2 - ENGINE FRONT COVER SPROCKETS
3 - CRANKSHAFT HUB
5 - TIMING BELT
REMOVAL
CAUTION: Before removing the timing belt, the
(3) Align timing belt tensioner spring stop with engine must put at 90° after TDC. Failure to do so
tensioner as shown (Fig. 98) and torque timing belt could result in valve and/or piston damage during
tensioner retaining bolt to 34.7N·m. reassembly. (Refer to 9 - ENGINE/VALVE TIMING -
(4) Rotate engine 2 complete revolution and then STANDARD PROCEDURE)
recheck tensioner alignment. Readjust tensioner
alignment as necessary. (1) Disconnect negative battery cable.
REMOVAL).
(3) Remove air cleaner housing assembly.
mount.
REMOVAL).
REMOVAL).
REMOVAL).
RG ENGINE 9a - 61
TIMING BELT/CHAIN AND SPROCKETS (Continued)
(9) Loosen timing belt tensioner and remove tim-
ing belt (Fig. 99).
Fig. 100 INJECTION PUMP GEAR TIMING MARKS

1 - TIMING MARK ON COVER
2 - TIMING MARK ON INJECTION PUMP SPROCKET
3 - INJECTION PUMP SPROCKET
(3) Install timing belt.

(4) Adjust the timing belt tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TMNG BELT/CHAIN
TENSIONER&PULLEY - ADJUSTMENTS) .
(5) Remove both camshaft alignment pins from cyl-
inder head cover/intake manifold and engine locking
pin from engine block (Refer to 9 - ENGINE/VALVE
TIMING - STANDARD PROCEDURE).
Fig. 99 TIMING BELT AND SPROCKETS ENGINE/VALVE TIMING/TIMING BELT / CHAIN
1 -CAMSHAFT SPROCKETS COVER(S) - INSTALLATION).
2 - INJECTION PUMP SPROCKET (7) Install vibration damper (Refer to 9 - ENGINE/
3 - INJECTION PUMP SPROCKET RETAINING NUT ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
4 - TIMING BELT LATION).
5 - TIMING BELT TENSIONER RETAINING BOLT (8) Install accessory drive belt (Refer to 7 - COOL-
6 - TIMING BELT TENSIONER ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
7 - TENSIONER ALIGNMENT PIN LATION).
8 - IDLER PULLEY
(9) Install power steering belt (Refer to 7 - COOL-
9 - CAMSHAFT SPROCKET RETAINING BOLT
LATION).
INSTALLATION (10) Install right engine mount.
(1) With both camshaft alignment pins still (11) Install air cleaner housing.
installed and the engine locked at 90° after TDC. (12) Install engine cover (Refer to 9 - ENGINE -
(2) Align timing mark on injection pump sprocket INSTALLATION).
with timing mark on timing belt (Fig. 100). (13) Connect negative battery cable.

Caravan 2.5TD

Uploaded by

Copyright:

Available Formats

Caravan 2.5TD

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Caravan 2.5TD

Uploaded by

Copyright:

Available Formats

RG ENGINE 9a - 1

ENGINE 2.5L TURBO DIESEL ENGINE BLOCK

ENGINE 2.5L TURBO DIESEL DESCRIPTION SPECIFICATION

DESCRIPTION - ENGINE COVER

Fig. 2 ENGINE COVER

Fig. 1 2.5L COMMON RAIL DIESEL ENGINE

(10) Disconnect high pressure line at pump (Fig.

Fig. 7 UPPER AND LOWER RADIATOR HOSES

Fig. 8 ENGINE COMPONENT LOCATIONS Fig. 9 REAR ENGINE VIEW

PLUMBING/REFRIGERANT - STANDARD PROCE-

REMOVAL - ENGINE COVER

INSTALLATION (24) Connect brake booster vacuum supply line.

SPECIFICATIONS DESCRIPTION SPECIFICATION

DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION

Bearing Clearance 0.03-0.08 mm OIL PUMP

HYDRAULIC LIFTER Outer Rotor End Float 0.060-0.160 mm

Outside Diameter 11.994 ± 0.006 mm Inner Rotor End Float 0.060-0.160 mm

VALVES Outer Rotor to Body 0.130-0.240 mm

DESCRIPTION N·m Ft. Lbs. In. Lbs.

DESCRIPTION N·m Ft. Lbs. In. Lbs.

VM.1013 DIAL INDICATOR

VM.1005 TORQUE ANGLE GAUGE

VM.1016 CYLINDER RETAINER

VM.1010 CYLINDER LINER PROTRUSION TOOL

VM.1054 RELIEF VALVE REMOVER/CENTRAL

VM.1055 CAMSHAFT/INJECTION PUMP GEAR

VM.1056 BALANCE SHAFT LOCKING PIN

VM.1061 FRONT OIL SEAL INSTALLER

VM.1062 POWER STEERING PUMP INSTALLER

VM.1059 OIL PRESSURE RELIEF VALVE INSTALLER

VM.1060 OIL JET REMOVER /INSTALLER

VM.1068 90 DEGREES AFTER TDC ALIGNMENT PIN

VM.1069 CRANKSHAFT REM/INSTALL SLEEVE

VM.1065 PISTON RING COMPRESSOR

VM.1066 CYLINDER HEAD COVER ALIGNMENT

VM.1072 COMPRESSION TESTER ADAPTER

VM.1075 FLYWHEEL ALIGNMENT PINS

VM.1073 CRANKSHAFT FRONT BEARING VM.1077 POWER STEERING BELT REMOVER

VM.1078 POWER STEERING BELT INSTALLER

VALVE CLEANING Fig. 11 VALVE SPRING CHART

INSPECTION VALVE STAND DOWN

Fig. 13 VALVE GUIDE HEIGHT

STANDARD PROCEDURE - MEASURING

CAUTION: Before removing the cylinder head cover/

(9) Remove timing belt outer cover (Refer to 9 -

Measure Dimension 0.61-0.70

Measure Dimension 0.71-0.83

Fig. 17 EXHAUST MANIFOLD AND

NOTE: If cylinder liner(s) have not been removed,

(1) Clean and inspect gasket mating surfaces.

CAUTION: New cylinder head bolts must be used.

(4) Tighten cylinder head bolts following procedure

Cylinder Head Bolt Torquing Procedure

(10) Remove timing belt outer cover (Refer to 9 -

CYLINDER HEAD COVER(S) (8) Remove accessory drive belt (Refer to 7 -

Fig. 22 CYLINDER HEAD COVER/INTAKE

(1) Disconnect negative battery cable.

Fig. 25 CYLINDER HEAD COVER/INTAKE

(27) Remove cylinder head cover/intake manifold