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SECTION 1B

ENGINE MECHANICAL - 2.0 DIESEL

Caution : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical erminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

SPECIFICATIONS

Engine Specifications

Application
Unit
Description
Camshaft
Lift - Intake
mm (in)
34.501 (1.3583)
Lift - Exhaust
mm (in)
34.337 (1.3519)
Bending
mm (in)
0.025 (0.00098)
Journal Outer Diameter : No.1
mm (in)
Φ27.947~27.960 (Φ1.1003~1.1008)
Journal Outer Diameter : No.2
mm (in)
Φ27.947~27.960 (Φ1.1003~1.1008)
Journal Outer Diameter : No.3
mm (in)
Φ27.947~27.960 (Φ1.1003~1.1008)
Journal Outer Diameter : No.4
mm (in)
Φ27.947~27.960 (Φ1.1003~1.1008)
Journal Outer Diameter : No.5
mm (in)
Φ27.947~27.960 (Φ1.1003~1.1008)
Trust Clearance (End Play)
mm (in)
0.05~0.15 (0.0020~0.0060)
Cylinder Head
Journal Inner Diameter : No.1
mm (in)
Φ28.000~28.021 (Φ1.1021~1.1032)
Journal Inner Diameter : No.2
mm (in)
Φ28.000~28.021 (Φ1.1021~1.1032)
Journal Inner Diameter : No.3
mm (in)
Φ28.000~28.021 (Φ1.1021~1.1032)
Journal Inner Diameter : No.4
mm (in)
Φ28.000~28.021 (Φ1.1021~1.1032)
Journal Inner Diameter : No.5
mm (in)
Φ28.000~28.021 (Φ1.1021~1.1032)
Journal Clearance
mm (in)
0.04~0.074 (0.00157~0.00291)
Height
mm (in)
129.9~130.1 (5.1142~5.1220)
Surface Flatness Deformation
mm (in)
0.13 overall 0.05 in 100 (0.00511 overall 0.0020 in 3.9370)
Manifolds Surface Deformation
mm (in)
0.13 overall 0.05 in 100 (0.00511 overall 0.0020 in 3.9370)
Valve
Deviation
mm (in)
0.038 (0.0015)
Seat Inner Diameter - Intake
mm (in)
Φ27.000 (Φ1.0630)
Seat Inner Diameter - Exhaust
mm (in)
Φ22.7 (Φ0.8937)
Face Diameter - Intake
mm (in)
Φ28.47~28.73 (Φ1.1209~1.1311)
Face Diameter - Exhaust
mm (in)
Φ24.27~24.53 (Φ0.9555~0.9657)
Inner Diameter - Intake
mm (in)
Φ5.975~6.000 (0.2352~0.2362)
Inner Diameter - Exhaust
mm (in)
Φ5.975~6.000 (0.2352~0.2362)
Valve Stem Outer Diameter - Intake
mm (in)
Φ5.573~5.953 (Φ0.2194~0.2344)
Valve Stem Outer Diameter - Exhaust
mm (in)
Φ5.905~5.925 (Φ0.2325~0.2333)
Valve Length - Intake
mm (in)
93.59~93.61 (3.6846~3.6854)
Valve Length - Exhaust
mm (in)
93.59~93.61 (3.6846~3.6854)
Valve Spring - Free Length
mm (in)
38.500 (1.5157)
Cylinder
Diameter
mm (in)
83.000 (3.2677)
Taper (Maximum)
mm (in)
0.05/100 (0.0020/3.9370)
Out of Round
mm (in)
0.006 (0.00024)
Piston
Diameter
mm (in)
83.000 (3.2677)
Clearance
mm (in)
0.070~0.090 (0.0028~0.0035)
Piston Ring
Groove Clearance - Top Ring
mm (in)
0.090 (0.0035)
Groove Clearance - 2nd Ring
mm (in)
0.070~0.110 (0.0028~0.0043)
Groove Clearance - Oil Ring
mm (in)
0.030~0.070 (0.0012~0.0028)
End Gap - Top Ring
mm (in)
0.200~0.350 (0.0079~0.0138)
End Gap - 2nd Ring
mm (in)
0.400~0.600 (0.0157~0.0236)
End Gap - Oil Ring
mm (in)
0.200~0.400 (0.0079~0.0157)
Piston Pin
Diameter
mm (in)
Φ27.993~27.998 (Φ1.1021~1.1023)
Length
mm (in)
66.800~67.000 (2.6299~2.6378)
Clearance
mm (in)
0.102 ~ 0.307 (0.0040~0.0121)
Connecting Rod
Thrust Clearance (End Play)
mm (in)
0.1~0.35 (0.0039~0.0138)
Width
mm (in)
29.900~27.950 (1.1772~1.1004)
Diameter - Piston Pin
mm (in)
Φ30.987~31.013 (Φ1.2200~1.2210)
Diameter - Crankshaft
mm (in)
Φ53.000~53.018 (Φ2.0866~2.0873)
Journal Bearing Oil Clearance
mm (in)
0.024 ~ 0.042 (0.0009~0.0017)
Crankshaft
Thrust Clearance (End Play)
mm (in)
0.09~0.32 (0.0039~0.0138)
Journal Outer Diameter
mm (in)
main : Φ60.002~60.020 (Φ2.3623~2.3630)
pin : Φ50.008~50.026 (Φ1.9688~1.9695)
Journal Bearing Oil Clearance
mm (in)
0.024~0.042 (0.00094~0.00165)
Cylinder Block
Piston Protrusion Limit
mm (in)
0.194~0.542 (0.00764~0.02134)
Head Surface Deformation
mm (in)
0.06 (0.00236)
Flatness
mm (in)
0.1 (0.00394)

Fastener Tightening Specifcations

Application
N•m
Lb-Ft
Lb-In
A/C Compressor and Alternator Bracket Bolt
35
25.8
-
A/C Compressor Lower Bolt
23
17
-
Accessory Belt Idler Bolt
52
38.4
-
Air Cleaner Assembly Bolt
6
-
53.1
Air Cleaner Upper Housing Screw
2
-
17.7
Beauty Cover Bolt
8
-
70.8
Beauty Cover Bracket Bolt
11
97.4
-
Bed Plate Inner Bolt
25+45°+90°
18.4+45°+90°
-
Bed Plate Outer Bolt
35
25.8
-
Camshaft Cap Bolt
28
20.7
-
Camshaft Sprocket Bolt
133
98.1
-
Charge Air Cooler Bolt
8.5
-
75.2
Charge Air Cooler Inlet Pipe
8
-
70.8
Connecting Rod Cap Bolt
25+90°
18.4+90°
-
Coolant Return Pipe retaining Bolt
9
-
79.7
CPS Target Wheel bolt
12
8.9
-
Cradle Mounting Bolt
155
114.3
-
Cradle Support Bracket Bolt
50
36.9
-
Crankshaft Balancer Bolts
55
40.6
-
Crankshaft Holder Hole Cap Bolt
30
22.1
-
Crankshaft Pulley Bolt
34
25.1
-
Crankshaft Sprocket Nut
235
173.3
-
Cylinder Head Bolt
65+120°+120°
47.9+120°+120°
-
Cylinder Head Cover Bolt
12
8.9
-
EGR Retaining Nut (Engine Wiring Harness Bracket Nut)
20
14.8
-
Engine Block Ground Bolt
25
18.4
-
Engine Lift Bracket Retaining Nut
28
20.7
-
Engine Lift Stud
28
20.7
-
Engine Mount Bracket Bolt
45
33.1
-
Engine Mount Bracket Retaining Bolt
50
36.9
-
Engine Mount Frame Side Bracket Retaining Bolt\
100
73.8
-
Engine Mount Frame Side Bracket Retaining Nut
90
66.4
-
Engine Wiring Splice Pack Tightening Bolt
15
11.1
-
Exhaust Manifold Heat Sheild Nut and Bolt
20
14.8
-
Exhaust Manifold Nuts
33
24.3
-
Exhaust Manifold Stud
16
11.8
-
Flexible Plate Tightening Bolt
105
77.4
-
Flywheel Tightening Bolt
105
77.4
-
Fuel Pipe-to-Common Rail Retaining Bolt
10
-
88.5
Fuel Pipe-to-Injection Pump Retaining Bolt (to Cylinder Head Cover)
25
18.4
-
Fuel Pipe-to-Injection Pump Retaining Bolt (to Intake Manifold)
9
-
79.7
Function Block Retaining Bolt
11
-
97.4
Glow Plug Fuse Box Retaining bolt
10
-
88.5
Glow Plug Module Retaining Nut
14
10.3
-
Injection Pump Sprocket Nut
70
51.6
-
Intake Manifold Bolts and Nuts
23
17
-
Intake Manifold Stud
16
11.8
-
Oil Filter Cap
25
18.4
-
Oil Filter Housing Adapter Plate
40
29.5
-
Oil Filter Housing Fitting Bolt
50
36.9
-
Oil Level Indicator Tube Bolt
11
-
97.4
Oil Nozzle Tube Retaining Bolt
23
17.7
-
Oil Pan Flange-to-Transaxle Bolts
50
36.9
-
Oil Pan Tightening Bolt
11
-
97.4
Oil Pump Tightening Bolt
24
17.7
-
Oil Strainer Bolt
11
-
97.4
PCV Valve Adapter Bolt
11
-
97.4
PCV Valve Bolt
11
-
97.4
Power steering bracket retainin bolt
25
18.4
-
Power Steering Pump Bolt
25
18
-
Resonator Assembly Retaining Bolt
6
-
53.1
Tensioner Retaining Bolt
48
35.4
-
Timing Belt Idler Retaining Bolt
52
38.4
-
Timing Belt Lower Cover Bolt
11
-
97.4
Timing Belt Rear Cover Bolt
11
-
97.4
Timing Belt Tensioner Bolt
25
18.4
-
Timing Belt Upper Cover Bolt
11
-
97.4
Transaxle Front Mount Retaining Bolt
50
36.9
-
Transaxle Front Mount–to–Transaxle Through Bolt
90
66.4
-
Transaxle Rear Mount Bracket Retaining Bolt
90
66.4
-
Transaxle Rear Mount Retaining Bolt
90
66.4
-
Transaxle Rear Mount–to–Bracket Through Bolt
90
66.4
-
Transaxle Tightening Bolt (Bed Plate-to-Transaxle)
75
55.3
-
Turbocharger Inlet Duct Bolt
3
-
26.6
Water Pump Inlet Pipe Retaining Bolt
23
17
-

SPECIAL TOOLS

Special Tools Table


C7A52A15
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DW110-030
Engine Overhaul Stand

C7A52A16
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DW100-010
Fuel Pressure Gauge

C7A52A17
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DW110-060
Engine Support Fixture

KM135
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KM-135
Oil Pressure Gauge Adapter

KM498B
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KM-498-B
Oil Pressure Gauge

C7A52A18
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09916-14510
Valve Spring Compressor

EN-48243
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EN-48243
Engine Assembly Remove/Install Pallet

EN-48244
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EN-48244
Engine Assembly Remove/Install Pallet Supporter

C7A52A02
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EN-48245
Timing Belt Adjuster - Camshaft Holder

C7A52A03
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EN-48246
Timing Belt Adjuster - Crankshaft Holder

C7A52A04
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EN-48247
Valve Spring Compression Adapter

C7A52A05
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EN-48249
Piston Ring Compressor

C7A52A06
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EN-48250
Crankshaft Front Oil Seal Installer

C7A52A07
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EN-48251
Crankshaft Rear Oil Seal Installer

C7A52A08
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EN-48252
Camshaft Oil Seal Installer

C7A52A09
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EN-48253
Accessory Belt Remover/Installer

C7A52A10
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EN-48300
Tensioner Remover/Installer

C7A52A11
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EN-48952
Tensioner Spring Holder Pin

C7A52A19
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EN-48248
Cylinder Compression Pressure Gauge


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