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Arrow VM1012-B Specifications

1. J9509 170 Fig 35 Tappet and Rocker Arm Assembly 4 Remove cylinder head intake manifold and exhaust manifold Refer to cylinder head removal in this section 5 Remove yoke retainer and aligning yokes Fig 36 6 Slide Hydraulic Tappet Remover I nstaller Tool through opening in block and seat tool firmly in the head of tappet 7 Pull tappet out of bore with a twisting motion If all tappets are to be removed identify tappets to ensure installation in original location 8 If the tappet or bore in cylinder block is scored scuffed or shows signs of sticking ream the bore to next oversize Replace with oversize tappet 9 54 ENGINE REMOVAL AND INSTALLATION Continued J9509 169 Fig 36 Tappet and Yoke CAUTION The plunger and tappet bodies are not interchangeable The plunger and valve must always be fitted to the original body It is advisable to work on one tappet at a time to avoid mixing of parts Mixed parts are not compatible DO NOT dis assemble a tappet on a dirty work bench INSTALLATION 1 Lubricate tappets 2 Install tappets and yoke retainers in their orig inal positions Ensure that the oil feed hole in the side of the tappet body faces up away from the crankshaft 3 Install cylinder head intake manifold and exhaust manifold Refer to cylinder head installation in this section 4 Install push rods in ori
2. VM920970 Fig 84 Liner Clamp Location FLYWHEEL CRANKSHAFT REAR SEAL CONTACT SURFACE 80218440 Fig 85 Flywheel 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 ENGINE 9 73 ENGINE ADAPTOR CRANKSHAFT SEAL RETAINER Fig 86 Crankshaft Seal SPRING PLATE ROCKER ARM ROCKER SUPPORT ANTIROTATION BRACKET f T 1 th PUSH I ROD 1 HYDRAULIC y G Sy Fig 87 Rocker Arm Components CAMSHAFT 80a2b415 9 74 ENGINE CLEANING AND INSPECTION Continued INSPECTION Use a straightedge and feeler gauge to check the flatness of the engine cylinder head and block mating surfaces Fig 88 Minimum cylinder head thickness 89 95mm 3 541 in CAUTION If only one cylinder head is found to be distorted and requires machining it will also be necessary to machine the remaining cylinders heads and end plates by a corresponding amount to maintain correct cylinder alignment J9509 167 Fig 88 Checking Cylinder Head Flatness VALVE GUIDE HEIGHT 1 Valve Guides height requirement 2 Measurement A Fig 89 13 50 14 00 mm t N E Lee SSSA xxr S Loe i AZ Kee EECH 4 ALL SS NAA NS J9509 36 Fig 89 Valve Guide Height VALVE STEM TO GU
3. OIL COOLING FASTENER JETS 4 y 7 80a20eb2 Fig 74 Oil Jets NS GS NOTE Be careful not to nick crankshaft journals 8 After removal install bearing cap on the mat ing rod J9509 172 Fig 75 Piston Assembly PISTON PIN REMOVAL 1 Secure connecting rod in a soft jawed vice 2 Remove 2 dips securing piston pin Fig 75 3 Push piston pin out of piston and connecting rod PISTON RING REMOVAL 1 Identification ID mark on face of upper and intermediate piston rings must point toward piston crown 2 Using a suitable ring expander remove upper and intermediate piston rings Fig 76 3 Remove the upper oil ring side rail lower oil ring side rail and then oil ring expander from piston 4 Carefully dean carbon from piston crowns skirts and ring grooves ensuring the 4 oil holes in the oil control ring groove are dear FITTING PISTON RINGS 1 Wipe cylinder bore dean Insert ring and push down with piston to ensure it is square in bore The ring gap measurement must be made with the ring positioning at least 12 mm 0 50 in from bottom of NS GS REMOVAL AND INSTALLATION Continued Fig 76 Piston Rings Removing and Installing cylinder bore Check gap with feeler gauge Fig 77 Top compression ring gap 25 to 50 mm 0098 to 0196 in Second compression ring gap 25 to 35 mm 0098 to 0137 in Oil control ring gap 25 to 58 mm 0
4. J9509 40 Fig 9 Valve Specification ENGINE 9 43 J9509 166 Fig 10 Checking Valve Stand Down DAL RS A AN NY A HD FQ M A UD Va E 19509 36 Fig 11 Valve Guide Height FITTING PISTON RING 1 Wipe cylinder bore dean Insert ring and push down with piston to ensure it is square in bore The ring gap measurement must be made with the ring positioning at least 12 mm 0 50 in from bottom of cylinder bore Fig 12 Check gap with feeler gauge Top compression ring gap 25 to 50mm 0098 to 0196 in Second compression ring gap 25 to 35mm 0098 to 0137 in Oil control ring gap 25 to 58mm 0098 to 0228 in 2 If ring gaps exceed dimension given new rings or cylinder liners must be fitted Keep piston rings in piston sets 3 Check piston ring to groove clearance Fig 13 Top compression ring gap 08 to 130mm 0031 to 0051 in Second compression ring gap 070 to 102mm 0027 to 0040 in Oil control ring gap 040 to 072mm 0015 to 0028 in CRANKSHAFT END PLAY 1 Attach dial indicator to engine block Fig 14 2 Move crankshaft toward front of engine and zero indicator 3 Move crankshaft toward the rear of engine and record measurement 9 44 ENGINE SERVICE PROCEDURES Continued FEELER GAUGE ox J9009 45 Fig 12 Ring Gap Measurement J9509 22 Fig 13 Piston Ring Side Clearance 4 Subtract specified crankshaf
5. 62 985 63 000 mm 2025 iiis RR UR ER 62 735 62 750 mm 20 125 i eR RE 62 860 62 875 mm Front Bearing Diameter Nominal 63 043 63 088 mm 20 25 es id pu ted a eqs 62 793 62 838 mm 70 125 ies see dd e eed 62 918 62 963 mm Clearance Between Journal and Bearing 0 043 0 103 mm Center J ournal Diameter Nominal sse 63 005 63 020 mm SA SEENEN 62 755 62 770 mm 20425 rs 62 880 62 895 mm Center Bearing Diameter Nominal 2 2 2222 63 050 63 093 mm DD ie eee te es 62 800 62 843 mm GE 62 925 62 968 mm Clearance Between Journal and Bearing 0 030 0 088 mm Rear J ournal Diameter Nominal 79 980 80 000 mm 025 en 79 730 79 750 mm e L b erri ie RE IE nomia 79 855 79 875 mm Rear Bearing Diameter Nominal 0 80 045 80 070 mm 20 25 ics ute e Was 79 795 79 820 mm 20 125 os sre os 79 920 79 945 mm Clearance Between Journal and Bearing 0 045 0 090 mm Wear Limit 0 200 mm Connecting Rod J ournal Nominal 0 53 940 53 955 mm E025 nina 53 690 53 705 mm 20425 cess eh eae le de nk 53 815 53 830 mm Connecting Rod Bearing Nominal 53 977 54 016 mm ED AE went dE open 53 727 53 766 mm OTS seira mme dar Oe 53 852 53 891 mm Clearance Between Journal and Bearing 0 022 0 076 mm Wear Limit 0 200 mm Crankshaft End Play End Play 222 626 650 454 4404 0 08 0 21 mm Adjustment Thrust Washers Thrust Washers Available
6. J9509 120 Fig 83 Cylinder Liner Installation CLEANING AND INSPECTION CYLINDER HEAD COVERS Remove any original sealer from the cover sealing surface of the engine cylinder head Remove all residue from the sealing surface using a clean dry cloth ROCKER ARMS AND PUSH RODS CLEANING Clean all the components Fig 87 with cleaning solvent Use compressed air to blow out the oil passages in the rocker arms and push rods INSPECTION Inspect the pivot surface area of each rocker arm Replace any that are scuffed pitted cracked or excessively worn Inspect the valve stem tip contact surface of each rocker arm and replace any rocker arm that is deeply pitted Inspect each push rod end for excessive wear and replace as required If any push rod is excessively worn because of lack of oil replace it and inspect the corresponding hydraulic tappet for excessive wear Inspect the push rods for straightness by rolling them on a flat surface or by shining a light between the push rod and the flat surface A wear pattern along the length of the push rod is not normal Inspect the engine cylinder head for obstruction if this condition exists CYLINDER HEAD 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 NS GS CLEANING AND INSPECTION Continued
7. 2 31 2 36 mm Thrust Washers Available 2 41 2 46 mm Thrust Washers Available 2 51 2 56 mm Main Bearing Carriers FRONE d ud Prec eem i Oregon 67 025 67 050 mm GENE serr 2x3 4 veuve es 66 670 66 690 mm R al onis ang deat edie acids 85 985 86 005 mm Liners Internal Diameter 92 000 92 010 mm 9 78 ENGINE SPECIFICATIONS Continued DESCRIPTION SPECIFICATIONS Protrusion 28 fe 20 re 0 01 0 06 mm Adjustment Shims Available Shims 222222222 0 15 mm AvailableShims ess 0 17 mm Available Shims less 0 20 mm Available Shims sess 0 23 mm Available Shims sess 0 25 mm Cylinder Head Minimum Thickness 89 95 90 05 mm Gdsket scrani eee AG e du gea ee d Steel Gasket thickness 1 42 0 1 mm 0 Holes Gasket thickness 1 62 0 1 mm 1 Holes Gasket thickness 1 52 0 1 mm 2 Holes End Plates Height on ss dada xe Rv 89 02 90 00 mm Connecting Rods Weight Without the crank bearing 1129 1195 grams Small End Bearing Internal Diameter Minimum 30 035 mm Maximum cee ke eae a 30 050 mm Crankshaft Bearings Standard Internal Diameter 53 997 54 016 mm Pistons Skirt Diameter 91 935 91 945 mm Measured at approximately 15 mm above the bottom of the skirt Piston Clearance 0 055 0 075 mm Top of Piston to Cylinder Head 0 80 0 89 mm Piston Protrusion 0
8. fe ON as I Et a SER N dea SPRING PLATE Fig 23 Rocker Arm Retaining Nut 7 Remove rocker assembly Place them on a bench in the same order as removed 8 Remove the push rods and place them on a bench in the same order as removed INSTALLATION 1 Install the push rods in the same order as removed 2 Install rocker arm assemblies in the same order as removed Tighten the rocker arm nuts to 29 4 N m 264 in Ibs torque 3 Install cylinder head cover torque nuts to 14 7 N m 132 in Ibs 4 Install coolant pressure tank 5 Install breather hose 6 Install generator bracket tighten bolts to 7 N m 4 ft Ibs 7 Connect the service valves to the A C compres sor ports if equipped with air conditioning 8 Connect battery cable NS GS VALVE SPRINGS CYLINDER HEAD NOT REMOVED This procedure can be done with the engine cylin der head installed on the block REMOVAL Each valve spring is held in place by a retainer and a set of conical valve locks The locks can be removed only by compressing the valve spring 1 Remove the engine cylinder head cover refer to cylinder head cover removal in this section 2 Remove rocker arms assemblies for access to each valve spring to be removed 3 Remove push rods Retain the push rods and rocker arms assemblies in the same order and posi tion as removed 4 Inspect the springs and retainer for cracks and possible signs of weakening 5 In
9. Fig 90 r LOAD Kg HEIGHT mm STATE P1 0 00 HI 44 65 FREE LENGTH P2 33 35 H2 38 60 VALVE CLOSED P3 90 95 H3 28 20 VALVE OPEN J9509 38 Fig 90 Valve Spring Chart NS GS CLEANING AND INSPECTION Continued HYDRAULIC TAPPETS 1 Clean all tappet parts in a solvent that will remove all varnish and carbon 2 Replace tappets that are unfit for further ser vice with new assemblies 3 If plunger shows signs of scoring or wear install a new tappet assembly If valve is pitted or valve seat on end of plunger is prevented from seat ing install a new tappet assembly OIL PUMP CLEANING Wash all parts in a suitable solvent and inspect carefully for damage or wear Fig 92 INSPECTION 1 Before installing oil pump check pump bore depth in block A and pump body height B Fig 91 Difference between A and B should be 0 020 0 082 mm 2 Check clearance between rotors Fig 93 N 4 OR J9509 8 Fig 91 Oil Pump Bore Depth PISTON AND CONNECTING ROD PISTONS 1 Piston Diameter Size Group A 91 93 91 94mm 3 6191 3 6196 in Size Group B 91 94 91 95mm 3 6196 3 6200 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 roundness 05mm 0019in ENGINE 9 75 OUTER ROTOR 80a2b416 Fig 92 Oil Pump Inner and Outer Rotors J9509 10 Fig 93 Checking
10. 11 Remove oil separator 12 Remove connectors at coolant temperature sensor and A C compressor 13 Disconnect fuel injection pump wiring connec tors Fig 20 14 Disconnect glow plug connectors 15 Disconnect electrical connector at number 1 fuel injector 16 Raise vehicle on hoist 17 Remove right side splash shield Fig 21 NEGATIVE BATTERY COOLANT TEMPERATURE 80a137c3 SWITCH FUEL INJECTION PUMP CONNECTIONS Fig 20 Component Locations WARNING THE COOLANT IN A RECENTLY OPER ATED ENGINE IS HOT AND PRESSURIZED USE CARE TO PREVENT SCALDING BY HOT COOLANT CAREFULLY RELEASE THE PRESSURE BEFORE REMOVING THE RADIATOR DRAIN COCK AND CAP 18 Drain the cooling system refer to Group 7 Cooling 19 Lower vehicle 20 Remove Coolant pressure bottle and discon nect low coolant level sensor 21 Disconnect both heater hoses 22 Remove the lower radiator hose 23 Remove the upper radiator hose NS GS REMOVAL AND INSTALLATION Continued ACCESSORY a DRIVE BELT RIGHT SIDE SPLASH SHIELD 80213704 Fig 21 Right Side Splash Shield 24 Remove fuel line at injector pump and cap 25 Remove power steering reservoir and reposi tion 26 Remove upper radiator crossmember 27 Disconnect cooling fan module connector 28 Remove radiator support bolts It is neces sary to loosen the receiver dryer to gain access to the radiator bolts 29 Remove radi
11. 53 0 62 mm Fit Gasket 1 42 O Holes Piston Protrusion 0 73 0 82 mm Fit Gasket 1 62 1 Holes Piston Protrusion 0 63 0 72 mm Fit Gasket 1 52 2 Holes Piston Pins JD Full Floating Pin Diameter 29 990 29 996 mm Clearance eee 0 004 0 014 mm Piston Rings Clearance in Groove TOD kdo ua sh nh aw hd ne 0 080 0 130 mm Second s s dE Me d 0 070 0 102 mm Oil Control 0 040 0 072 mm Piston Rings Fitted Gap TOD hes OH Veda PEDE AA 0 25 0 50 mm Second Ae ae 0 20 0 35 mm Oil Control ua ck 0 25 0 58 mm Camshaft J ournal Diameter Front 53 460 53 480 mm Bearing Clearance 0 06 0 13 mm J ournal Diameter Center 53 460 53 480 mm Bearing Clearance 0 06 0 13 mm Journal Diameter Rear 53 460 53 480 mm Bearing Clearance 0 06 0 13 mm NS GS DESCRIPTION SPECIFICATIONS Tappets Outside Diameter 22 195 22 212 mm Rocker Gear Shaft Diameter 21 979 22 00 mm Bushing internal diameter 22 020 22 041 mm Assembly Clearance 0 020 0 062 mm Valves Intake OPENS are Dew eres ee 26 B T D C ClOS6S ides aes deer dre an nn 58 A B D C Valves E xhaust OPENS cs Lope dun dre pene dne get 64 B B D C ClOS6S ann ann en e Es 38 A T D C Valve Face Angle lites ees ES 55 30 55 50 Exlia sE 4 o NEE NEE E 45 25 45 35 Valve Head Diameter Rule EE 40 05 40 25 mm Exhaust sore na acid oO 33 8 34 0
12. 55 3 Slide special tool VM 1002 over the crank shaft gear and insert the crankshaft and carrier assembly into the crankcase in the same manner used for removal 4 Align the holes in the lower carriers with the center of the crankcase webs Fig 56 REAR MAIN BEARING 80a13865 80226413 Fig 55 Crankshaft and Carrier Bearing Assembly 5 Secure each carrier assembly to the crankcase with the main bearing oil feed and carrier locators and tighten them to 54 N m 40 ft Ibs 6 Install rear main bearing carrier onto crank shaft ensuring arrow on bearing carrier aligns with vertical web in center of crankcase 7 Install rear oil seal 8 Install new O rings in adaptor plate 9 62 ENGINE REMOVAL AND INSTALLATION Continued N VM920942 Fig 56 Main Bearing Carrier Alignment 9 Install adaptor plate and tighten bolts to 47 N m 35 ft Ibs 10 Install bolts to main bearing carrier and tighten to 26 5 N m 20 ft Ibs 11 Position flywheel and O ring on crankshaft and align bolt holes NOTE For purposes of checking crankshaft end play used flywheel bolts may be used Final assem bly requires new flywheel bolts 12 Install 2 flywheel bolts 180 apart and tighten bolts to 20 N m plus 60 15 ft Ibs plus 60 13 Attach dial indicator to engine block 14 Move crankshaft toward front of engine and zero indicator 15 Move crankshaft toward the rear of engine and record mea
13. 6 O CLOCK 80a32919 Fig 7 Alignment Timing Sprockets the second dark link on the chain with the timing mark on the camshaft sprocket Third Align the final dark link on the chain to the timing mark on the injection pump sprocket Last install the chain around the vacuum pump For injection pump timing refer to Group 14 Fuel for the proper procedure INJECTION PUMP SPROCKET Vf TIMING P O MARK a o i9 i CAMSHAFT H SPROCKET el WT TIMING A7 IE MARK CRANKSHAFT SPROCKET Fig 8 Timing Procedure NS GS VALVE AND SEAT REFACING VALVE REFACING 1 Use a valve refacing machine to reface the intake and exhaust valves to the specified angle 2 After refacing a margin of at least 4 52 4 49 mm 178 177 inch must remain Fig 9 If the mar gin is less than 4 49 mm 177 inch the valve must be replaced VALVE SEAT REFACING 1 Install a pilot of the correct size in the valve guide bore Reface the valve seat to the specified angle with a good dressing stone Remove only enough metal to provide a smooth finish 2 Use tapered stones to obtain the specified seat width when required VALVE STAND DOWN Valve stand down is to maintain the adequate com pression ratio 1 Invert cylinder head 2 Fit each valve to its respective valve guide 3 Using a straight edge and feeler gauge Fig 10 check valve head stand down Inlet valve head stand down 80 to 1 2 mm 031 to 047 in and exhaust valve
14. Bearing Carrier BOltS aan cirea E rs 44 N m 32 ft Ibs Crankshaft damper Pulley NUR mes mr ttc RR 441 N m 325 ft Ibs EGR Valve to Intake Manifold TUDE ER 26 N m 19 ft Ibs EGR Tube to EGR Valve BOWES gr anne water wat 26 Nm 19 ft Ibs Engine Mount Front Support Bracket Engine Bolts 68 N m 50 ft Ibs Support Bracket Transmission Bolts 101 N m 75 ft Ibs Support Cushion Crossmember Bolts 54 N m 40 ft Ibs Support Cushion Thru Bolt 65 N m 48 ft Ibs Engine Mount Rear Support Bracket Transmission Bolts 101 N m 75 ft Ibs Support Bracket to Engine Bracket 101 N m 75 ft Ibs Support Cushion Thru Bolt 68 N m 50 ft Ibs Engine Mount Left Transmission Mounting Bolts 54 N m 40 ft Ibs Support Cushion Thru Bolt 71 N m 53 ft Ibs Engine Mount Right Mount to Frame Rail Bolts 68 N m 50 ft Ibs Mount Bolt Horizontal 145 N m 107 ft Ibs Mount Bolt Vertical 101 N m 75 ft Ibs Right Engine Mount Bracket Bolts Rech veras 40 N m 30 ft Ibs Exhaust Pipe to Turbocharger Ee EC 28 N m 250 in Ibs Exhaust Manifold Outlet to Turbo NUES eer 32 N m 24 ft Ibs Exhaust Elbow to Turbo Ee LCE ne dea E Y 30 Nm 22 ft Ibs Exhaust Manifold Mounting NUES ae ahd a 30 N m 22 ft Ibs Flywheel Bolts See Rear Crankshaft Seal Installation Procedure Engine Adaptor Plate BONES a 2a eaedem Be 47 N m 35 ft Ibs
15. Front Timing Chain Cover Ee e 11 Nm 96 in Ibs Fuel Filter ENGINE 9 79 DESCRIPTION TORQUE NUES sus aa aan 28 N m 250 in Ibs Glow Plugs Plugs MER Mie 14 N m 120 in Ibs Idler Pulley Pump Support Bracket Nures 26 N m 228 in Ibs Idler Pulleys left handed threads Bolts EEN RR mes 47 N m 35 ft Ibs Injector Pump fuel lines NU tS uua dct ete se Nd 17 6 N m 156 in Ibs Injector Pump Sprocket NUR u 004 edges 86 3 Nm 63 ft Ibs Injector Pump Mounting N S ce as 2008 BA ee Sa ts 27 5 Nm 240 in Ibs Injector Tighten to 65 N m 48 ft Ibs Intake Manifold Mounting Nures 30 N m 264 in Ibs Main Bearing Oil Delivery Union BOIS a8 Bas wets 54 N m 40 ft Ibs Oil Feed Line To Rocker Arms Ee ECH 12 7 N m 108 in Ibs Oil Feed Line to Block BOWES areas rn 12 7 N m 108 in Ibs Oil Feel Line to Vacuum Pump BOlES Sr rasanten 16 7 N m 145 in Ibs Oil Filter Tighten to 9 8 N m 85 in Ibs Oil Filter Adaptor Fastener une id Roe 49 N m 36 ft Ibs Oil Filter Base Fastener nee 49 N m 36 ft Ibs Oil Pan Mounting BOWS u wann wie bk 12 N m 108 in Ibs Oil Pickup Tube Bolts ss rug crar ir 11 3 N m 100 in Ibs Oil Pump Mounting Bolts Los EE 27 5 N m 240 in Ibs Oil Pan Drain PUG sit a ance enn teu ar enema 54 N m 40 ft Ibs Power Steering Pressure Hose Fastener less 28 Nm 240 in Ibs Power Steering Pulley NUR Hass
16. Rotor Clearance 3 The piston diameter should be measured approximately 15 mm 590 in up from the base 4 Skirt wear should not exceed 0 1 mm 00039 in 5 The clearance between the cylinder liner and piston should not exceed 0 25 mm 0009 in 6 Make sure the weight of the pistons does not differ by more than 5 g CONNECTING ROD 1 Assemble bearing shells and bearing caps to their respective connecting rods ensuring that the serrations on the cap and reference marks are aligned 2 Tighten bearing cap bolts to 29 N m 21 ft Ibs plus 60 3 Check and record internal diameter of crank end of connecting rod 9 76 ENGINE CLEANING AND INSPECTION Continued Note When changing connecting rods all four must have the same weight and be stamped with the same number Replacement connecting rods will only be supplied in sets of four 4 Connecting rods are supplied in sets of four since they all must be of the same weight category Max allowable weight difference is 18 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 camshaft as well as the recess on the piston crown Fig 94 Lightly heat the piston in oven Insert piston pin in position and secure it with provided snap rings The Four digit numbers marked on con rod bi
17. are lubricated and cooled by oil sprayed out ENGINE 9 37 III Fig 1 Engine Code Location from jets 9 in the crankshaft mounting blocks The lubricating oil is sent to the rockers 12 through an amp ternal pipe Fig 3 A valve in the filter cartridge enables the oil to be circulated even when the car tridge is clogged Sump inlet 1 Pressure relief valve 2 Oil pump 3 Oil cooler 6 Filter cartridge 7 Crankshaft bearings 8 Jet valve 9 Turbocharger bearings 10 Camshaft bearings 11 Rockers 12 PRESSURE ES ABVITCH FEED NLINENN I EN 9509 43 ROCKER OIL FEED LINE 80a243c1 VM920901 Fig 2 Lubrication System 9 38 ENGINE DIAGNOSIS AND TESTING ENGINE DIAGNOSIS PERFORMANCE POSSIBLE CAUSES CORRECTION ENGINE WILL NOT CRANK OR CRANKS SLOWLY 1 Starting motor operating but not cranking the engine 2 Crankshaft rotation restricted 3 Starting circuit connections loose or corroded 4 Neutral safety or starter relay inoperative 5 Battery charge low 6 No voltage to starter solenoid 7 Solenoid or starter motor inoperative NS GS 1 Remove the starter motor Check for broken flywheel teeth or a broken starter motor spring 2 Rotate the engine to check for rotational resistance 3 Clean and tighten connections 4 Check starter relay supply voltage and proper operation of neutral safety switch if equipped Replace defect
18. cover or block Also take care not to damage the timing chain or compo nents located inside the timing chain cover near the edge 10 Remove timing chain cover INSTALLATION 1 Apply a continuous 3 mm bead of Silicone Sealer to timing cover install within 10 minutes tighten Torx bolts to 11 N m 96 in Ibs Fig 38 2 Install pump shaft support bracket assembly tighten nuts to 24 5 N m 216 in Ibs ENGINE 9 55 MOPAR SILICONE RUBBER ADHESIVE SEALANT J9509 7 Fig 38 Front Cover Sealer Location 3 Install Power steering air conditioning pulley tighten to 170 N m 125 ft Ibs CAUTION Correct torque on the power steering air conditioning pulley nut is important or engine dam age can occur 4 Connect water drain pipe hose at the timing cover NOTE Before installing damper be sure O ring on inside center of damper is in place 5 Install vibration damper CAUTION Correct torque on the vibration damper nut is important or engine damage can occur 6 Tighten vibration damper nut to 441 N m 325 ft Ibs 7 Install accessary drive belts Refer to Group 7 cooling for procedure 8 Install splash shield 9 Lower vehicle 10 Connect battery cable TIMING CHAIN REMOVAL 1 Disconnect battery 2 Raise vehicle on hoist 3 Remove right splash shield Fig 39 4 Remove both accessory drive belts Refer to Group 7 Cooling 9 56 ENGINE REMOVAL AND INSTALLATION Contin
19. fuel system or the fuel supply is inadequate 6 Contaminated fuel 7 Fuel screen plugged 8 One or more injectors worn or not operating properly 9 Injector pump out of time 10 Engine compression low 11 Fuel injection system defective 1 The fuel shutoff solenoid control must be in the run position Ensure the proper procedure is being used 2 Check the battery starter motor and look for loose or corroded wiring connections 3 Verify system is working Verify connection between heater plug relay and ECU Repair replace inoperative parts 4 Inspect or replace air filter and check for obstruction in air supply 5 Check the fuel flow through the filter and bleed system Locate and eliminate the air source 6 Verify by operating the engine with clean fuel from a temporary tank Check for the presence of gasoline Drain and flush fuel supply tank Replace fuel water separator filter 7 Check fuel screen 8 Check replace improperly operating injectors 9 Check pump timing Refer to Group 14 Fuel System for procedure 10 Check compression to identify the problem 11 Vacuum modulator defective causing EGR to open in cold condition Check for fault codes in the ECU NS GS DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES ENGINE 9 39 CORRECTION LUBRICATING OIL PRESSURE LOW 1 Low oil level 2 Oil viscosity thin diluted or wrong specification 3 Imprope
20. m 36 Ibs 3 Install oil filter and tighten to 9 8 N m 85 in Ibs and add oil VACUUM PUMP REMOVAL 1 Disconnect the battery cable 2 Raise vehicle on hoist 3 Remove right splash shield Fig 63 4 Remove accessary drive belts Refer to Group 7 Cooling 5 Remove vibration damper nut NOTE Crankshaft damper nut is left thread handed NS GS REMOVAL AND INSTALLATION Continued ACCESSORY G DRIVE BELT RIGHT SIDE SPLASH SHIELD 80a137c4 Fig 63 Splash Shield 6 Remove vibration damper 7 Remove power steering air conditioning pulley nut Remove pulley CAUTION Remove old thread sealant from threads on pump 8 Remove pump shaft support bracket assembly Fig 64 CAUTION When separating the timing chain cover from the block take care not to damage the mating surface of the timing chain cover 9 Remove timing chain cover ENGINE 9 65 STEERING PUMP 80a18d35 OIL PUMP DRIVE GEAR poll P 80a18d30 Fig 65 Oil Pump Drive Gear 10 Remove oil pump drive gear on crankshaft Fig 65 11 Remove lower chain guide Fig 68 12 Rotate crankshaft to align timing marks on injection pump sprocket camshaft sprocket and crankshaft sprocket with three dark plated links on timing chain Fig 66 CAUTION It could take up to 70 crankshaft revolu tions to align sprocket timing marks with the dark chain links If the chain i
21. mm Valve Head Stand Down Intake ee de dace dose atacan 1 08 1 34 mm Exhaust eee 1 99 1 25 mm Valve Stem Diameter Intake 5 oad ie a Xie 7 940 7 960 mm Exhaust nud ee Eu 7 922 7 940 mm Valve Clearance in Guide Intake iiu Zet r erum ade 0 040 0 075 mm EXliausb uiui a 0 060 0 093 mm Valve Guide Inside Diameter 8 0 8 015 mm Fitted Height 13 5 14 0 mm Valve Spring Free Length us 44 65 mm Fitted Length 38 6 mm Load at Fitted Length 34 6 Kg Load at Top of Lift 92 5 496 Kg Number of Coils 5 33 Valve Timing Oil Pressure at 4000 TPM 3342044 RE ER rw 3 0 to 4 5 bar Oil at 90 100 C Pressure Relief ValveOpens 6 38 bar Pressure Relief Valve Free Length 57 5 mm Oil Pump Outer Rotor End Float 0 03 0 09 mm Inner Rotor End Float 0 03 0 09 mm Outer Rotor to Body Diameter Clearance 0 130 0 230 mm Rotor Body to Drive Gear Clearance Pump Not Fitted 3 27 3 73 mm TORQUE DESCRIPTION TORQUE Generator Mounting Bracket BOWES uae Reds 47 N m 35 ft Ibs NS GS SPECIFICATIONS Continued DESCRIPTION TORQUE Camshaft Locating Plate OME ven ee ee ar ween 11 N m 96 in Ibs Camshaft Sprocket Bolt 19 6 N m 60 170 in lbs 60 Cylinder Head Bolts See Cylinder Head Installation Procedure Connecting Rod BOltS eos kou 29 5 N m 60 22 ft Ibs 460 Crankshaft
22. stand down 79 to 1 19 mm 031 to 047 in 4 If valve head stand down is not in accordance with above discard original valves check stand down with new valves and recut valve seat inserts to obtain correct stand down VALVE GUIDE HEIGHT 1 Valve Guides height requirement 2 Measurement A Fig 11 13 50 14 00 mm VALVE STEM TO GUIDE CLEARANCE MEASUREMENT 1 Measure and record internal diameter of valve guides Valve guide internal diameter is 8 0 to 8 015 mm 3149 to 3155 in 2 Measure valve stems and record diameters Intake valve stem diameter 7 94 to 7 96 mm 3125 to 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 095 mm 0023 to 0037 in 4 If valve stem dearance in valve guide exceeds tolerances new valve guides must be installed NS GS SERVICE PROCEDURES Continued INTAKE 56 0 56 20 EXHAUST EXHAUST 54 20 54 40 MEASUREMENT INTAKE A 7 940 7 960 7 922 7 940 B 8 00 8 015 8 000 8 015 0 990 1 250 LD 22 008 EI 180220 G 41 962 41 985 35 964 35 987 H 42 070 42 086 36 050 36 066 7 007 05 3 11 3 26 3 10 3 25
23. the timing mark on the crankshaft sprocket Next align the sec ond dark link on the chain with the timing mark on NS GS REMOVAL AND INSTALLATION Continued ah _ CHAIN OIL FEED TENSIONER LINE e p uem Se Ko NIC Ne LSP ER ZA EN Er Ss A V IO OEC Ko eile oF VACUUM Z 9 Le S 80a18d31 Fig 70 Hydraulic Tensioner and Oil Feed Line CAMSHAFT SPROCKET N CRANKSHAFT SPROCKET 80a18d32 Fig 71 Vacuum Pump Removal the camshaft sprocket Third align the final dark link on the chain to the timing mark on the injection pump sprocket Last install the chain around the vacuum pump Fig 73 3 Install hydraulic tensioner 4 Install hydraulic tensioner oil feed line 5 Install hydraulic tensioner blade Torque bolt to 28 N m 260 in Ibs 6 Install lower chain guide 7 Install oil pump drive gear on crankshaft ENGINE 9 67 O RING VACUUM PUMP RP ROTOR BLADES 80a2b414 Fig 72 Vacuum Pump Assembly INJECTION PUMP SPROCKET Ip y ae a gt TIMING MARK 7 FIT i VACUUM 4 P PUMP Ai Q RISE S i TIMING I O MARK a o i9 i CAMSHAFT n H SPROCKET y Aj AC DU TIMING AC ei MARK CRANKSHAFT SPROCKET se Fig 73 Timing Chain Procedure 8 Install timing chain cover Refer to installation procedure outlined in this section 9 Install pump shaft support bracket assembly Tighten nuts to 24 5 N m 216 in Ibs CAUTION Correct torque on the power steerin
24. 098 to 0228 in FEELER GAUGE en J9009 45 Fig 77 Ring Gap Measurement 2 If ring gaps exceed dimension given new rings or cylinder liners must be fitted Keep piston rings in piston sets 3 Check piston ring to groove clearance Fig 78 Top compression ring gap 08 to 130 mm 0031 to 0051 in Second compression ring gap 070 to 102 mm 0027 to 0040 in Oil control ring gap 040 to 072 mm 0015 to 0028 in PISTON RINGS INSTALLATION 1 Install rings on the pistons using a suitable ring expander Fig 76 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 Fig 79 ENGINE 9 69 J9509 22 Fig 78 Piston Ring Side Clearance J9509 171 Fig 79 Piston Ring Identification Ring gaps must be positioned before inserting piston into the liners as follows Fig 80 3 Top ring gap must be positioned at 30 degrees to the right of the combustion chamber recess look ing at the piston crown from above 4 Second piston ring gap should be positioned on the opposite side of the combustion chamber recess 5 Oil control ring gap to be located 30 degrees to the left of combustion chamber recess 6 When assembling pistons check that compo nents are installed in the same position as before dis assembly determined by the numbers st
25. 13 Cylinder Retainers VM 1016 Flywheel Locking Tool VM 1014 Cylinder Head Bolt Wrench M12 VM 1018 80a1aa48 Timing Cover Oil Seal Installer VM 1015 Cylinder Head Bolt Wrench M14 VM 1019 Li 80alaadb 80alaadc NS GS SPECIAL TOOLS Continued Adapter Oil Filter VM 1020 u 80alaade 80alaadd Adapter Cylinder Leakage Tester VM 1021 Support Brackets Engine Removal Installation VM 1026 ENGINE 9 83 NN E pee 80a1aa51 Camshaft Locating Plate Alignment VM 1028 80a1aa52 Crankshaft Sprocket Installer VM 1029 9 84 ENGINE SPECIAL TOOLS Continued Pd Locating Pin Crankshaft Sprocket VM 1030 dto 80a1aa54 80a1aa53 Camshaft Sprocket Locking Tool VM 1031 Ne Injection Pump Sprocket Locking Tool VM 1032 NS GS
26. 9 36 ENGINE NS GS 2 5L VM DIESEL INDEX page GENERAL INFORMATION DEER 37 DIAGNOSIS AND TESTING ENGINE DIAGNOSIS MECHANICAI 0 ENGINE DIAGNOSIS PFRFORMANCH 38 HYDRAULIC TAPPETS 39 SERVICE PROCEDURES an Sih Beth is 40 CHECKING OILLEVEL 2 2 ee 40 CRANKSHAFT END PLAM 43 FITTING PISTON RING 43 TIMING PROCEDURE 41 VALVE AND SEAT REFACING 42 REMOVAL AND INSTALLATION PETRA 60 E DEER 59 CRANKSHAFT MAIN BEARINGS 60 CRANKSHAFT SPROCKET 58 ERANKSHAFT REMOVAI 71 CYLINDER HEAD COVER 47 NDER HERAN a or Bor He 49 EYLINDERLINER 0 05 70 ENGINE ASSEMBLY aa ooonn aonana 46 ee 44 NGINE MOUN REAR uas ER 45 rti suem Da 44 HYDRA APPELS 2E nate a 53 EET 59 INJECTION GOUM I eee ee eee 54 MOUNT LEFT SIDE 45 DIL FILTER ADAPTER AND OIL COOLER 64 GENERAL INFORMATION GENERAL SPECIFICATION Type aem Ree E E 425CLIEE 36B Displacement 2 5L 2499 cc BONG sce Hanke Ge Da a a da a 92 00 mm Stroke ENEE e RA x 94 00 mm Compression Ratio 000 0s eee 20 95 1 Vacuum at Idle 600 mm Hg 23 6 I n H 9 Thermostat Opening 80 C 2 C Generator Rating Bosch 50 120 Amp Cooling System Capacity 9 5 Liter TORQUE EE 78 SPECIAL TOOLS rr 80 TY
27. D GASKET INTAKE gt MANIFOLD GASKET EXHAUST MANIFOLD R 80a20ebf Fig 26 EGR Valve and Tube 15 Remove lift eye and brake vacuum tube at rear of exhaust manifold 16 Remove the support strut from block to turbo charger exhaust elbow 17 Remove Exhaust manifold Refer to Group 11 Exhaust System and Intake Manifold 18 Remove oil line at pressure switch 19 Remove oil feed line for rocker arm assemblies Fig 27 9 50 ENGINE REMOVAL AND INSTALLATION Continued ROCKER OIL FEED LINE OIL PRESSURE SWITCH FEED NLINENN SE Mi Va Zei OIL X PRESSURE KH SWITCH N PORT L amp T NN Fig 27 Rocker Arm Oil Feed Lines 20 Remove Crankcase breather hose from valve cover 21 Remove the engine cylinder head cover 22 Remove the injector sensor wire at the con nector and glow plug Connectors OIL PRESSURE FEED f 80a243c1 NOTE The attachment point for the injector sensor wire at the injector is not a connector The connec tor is located in the wire 4 to 6 inches away from the injector 23 Remove injector fuel lines from injectors to pump 24 Remove fuel injectors with tool VM 1012A Fig 28 and Fig 29 Refer to Group 14 Fuel Sys tem J9509 31 Fig 28 Fuel Injector Tool VM 1012A NS GS 80a13f92 Fig 29 Fuel Injector 25 Remove rocker retaining nuts Fig 30 ROCKER ARM ROCKER ARM ASSEMBLY RETAINING
28. DE asus san wa ae amie ae 425CLIEE 36B Power Steering Capacity 0 75 Liter Engine Oil Capacity 6 8 Liters With Oil Filter Change Timing System Pushrod Operated Overhead valves With Chain Driven Camshaft Air Intake Dry Filter Fuel Feed Vacuum Pump Incorporated in Injection Pump Fuel System Indirect Fuel Injection Precombustion Chamber Combustion Cyde 2222 4 Stroke Cooling System Water Cooled NS GS GENERAL INFORMATION Continued Type zwi aan ae 425CLIEE 36B Injection Pump Rotary Pump Electronically Controlled Lubrication Pressure Lubrication by Rotary Pump Full Flow Filtration Engine Rotation Clockwise Viewed From Front Cover ENGINE IDENTIFICATION The engine mode code 3 digit number letter code and serial number are stamped on the forward facing side of the engine block Fig 1 DESCRIPTION AND OPERATION LUBRICATION SYSTEM The pressurized system Fig 2 uses a rotary pump 3 located in the front of the engine block driven by a gear which meshes directly with the crankshaft gear All the oil sent to every lubricated part is fil tered The pump sends the oil through a pressure relief valve 2 to the filter 7 and through galleries in the crankcase to the crankshaft bearings 8 cam shaft bearings 11 and turbocharger 10 The piston pins connecting rod small ends and insides of the pistons
29. DS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING 36 Operate the engine with the radiator cap off Inspect for leaks and continue operating the engine until the thermostat opens Add coolant if required VALVES AND VALVE SPRINGS HEAD OFF This procedure is done with the engine cylinder head removed from the block REMOVAL 1 Remove the engine cylinder head from the cyl inder block Refer to cylinder head removal 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 INSTALLATION 1 Fit each valve to its respective valve guide NOTE If valves and valve seats have been refaced refer to Service Procedures in this section Follow The Valve Stand Down procedure ENGINE 9 53 2 Install lower washer and spring 3 Install upper spring collar and compress valve spring with spring compressor tool Install split cone retainers HYDRAULIC TAPPETS REMOVAL 1 Remove coolant pressure bottle 2 Remove cylinder head cover Refer to cylinder head cover removal in this section 3 Remove rocker assembly and push rods Iden tify push rods to ensure installation in original loca tion Fig 35
30. E E N N 1 SPECIAL TOOL ENGINE DOLLY 6135 803137c2 Fig 22 Engine Removal 45 Lower vehide so weight of only the engine and transmission is on the dolly and cradle assem bl y 46 Remove left side splash shield to gain access to thru bolt for left side mount 47 Remove right engine mount and left side mount Refer to procedure outlined in this section 48 Raise vehicle slowly It may be necessary to move the engine transmission assembly on the dolly to allow for removal around body 49 Reverse removal procedure for installation CYLINDER HEAD COVER REMOVAL 1 Disconnect the battery cables 2 Remove generator bracket 3 Remove breather hose 4 Remove coolant pressure tank 5 Remove cylinder head cover INSTALLATION 1 Install cylinder head cover torque nuts to 23 5 N m 208 in Ibs 2 Install coolant pressure tank 3 Install breather hose 4 Install generator bracket tighten bolts to 7 N m 4 ft Ibs 9 48 ENGINE REMOVAL AND INSTALLATION Continued 5 Connect battery cable ROCKER ARMS AND PUSH RODS REMOVAL 1 Disconnect the battery cables 2 Remove generator bracket 3 Remove breather hose 4 Remove coolant pressure tank 5 Remove cylinder head cover 6 Remove rocker retaining nuts Fig 23 ROCKER ARM ROCKER ARM ASSEMBLY RETAININGN Sep NUTS a gt i G 4 GG a MENS M ANT VA SAK VW LEHE oO i Q WV Z a Ikea 20 o r hI
31. E OF USED ENGINE OIL PROPERLY CONTACT YOUR DEALER OR GOVERN MENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA NS GS SERVICE PROCEDURES Continued Run engine until achieving normal operating tem perature 1 Position the vehicle on a level surface and turn engine off 2 Remove oil fill cap 3 Hoist vehide Refer to Hoisting and J acking Recommendations 4 Place a suitable drain pan under crankcase drain 5 Remove drain plug from crankcase and allow oil to drain into pan Fig 5 Inspect drain plug threads for stretching or other damage Replace drain plug if damaged PAN 80a137c8 Fig 5 Oil Drain Plug 6 Install drain plug in crankcase 7 Lower vehicle and fill crankcase with specified type and amount of engine oil 8 Install oil fill cap 9 Start engine and inspect for leaks 10 Stop engine and inspect oil level ENGINE OIL ENGINE OIL QUALITY Use only oils conforming to API American Petro leum Institute quality SG SG CD or CCMC G4 Use only Diesel engine oil meeting standard MIL 2104C or API service classification SG CD or CCMM PD1 OIL VISCOSITY Grade 15W 40 is recommended for temperatures between 35 C to 10 C 95 F to 14 F Low viscosity oils must have the proper API quality or the CCMC G5 designation Low viscosity oils are preferred when minimum temperatures consistently fall below 12 C 10 F ENGINE 9 41 ENGINE OIL FILTER CHANGE 1 Position a dr
32. End Play 24 Install pistons and connecting rod assemblies refer to piston and connecting rods in this section 25 Install oil pick up tube and tighten bolts to 25 N m 18 ft Ibs 26 Install oil pan refer to oil pan installation in this section 27 Install timing chain Refer to procedure in this section 28 Install vacuum pump Tighten screws to 20 N m 15 ft Ibs retaining NS GS REMOVAL AND INSTALLATION Continued CAUTION The vacuum pump must be centered in the block and tighten with two bolts Ensure that the pump spins freely If vacuum pump drags or does not spin freely loosen bolts and perform pro cedures again 29 Before installing oil pump check pump bore depth in block A and pump body height B Fig 58 Difference between A and B should be 0 020 0 082 mm 0007 to 0032 in J9509 8 Fig 58 Oil Pump Bore Depth 30 Install oil pump and tighten retaining screws to 27 N m 20 ft Ibs Check for normal backlash between pump and crankshaft gears 31 Install oil pump drive Gear 32 Install front cover Refer to procedure in this section 33 Install vibration damper Refer to procedure in this section 34 Install cylinder heads Refer to procedure in this section 35 Install rocker arms and push rods Refer to procedure in this section 36 Install cylinder head cover Refer to procedure in this section 37 Install accessary drive system 38 Install engine i
33. IDE CLEARANCE MEASUREMENT 1 Measure and record internal diameter of valve guides Valve guide internal diameter is 8 0 to 8 015 mm 3149 to 3155 in 2 Measure valve stems and record diameters Intake valve stem diameter 7 94 to 7 96 mm 3125 to 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 NS GS 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 095 mm 0023 to 0037 in 4 If valve stem clearance in valve guide exceeds tolerances new valve guides must be installed TIMING CHAIN COVER Be sure mating surfaces of chain case cover and cylinder block are clean and free from burrs VALVES AND VALVE SPRINGS VALVE CLEANING Clean all carbon deposits from the combustion chambers valve ports valve stems valve stem guides and heads Clean all grime and gasket material from the engine cylinder head machined gasket surfaces INSPECTION Inspect for cracks in the combustion chambers and valve ports Inspect for cracks on the exhaust seat Inspect for cracks in the gasket surface at each coolant passage Inspect valves for burned cracked or warped heads Inspect for scuffed or bent valve stems Replace valves displaying any damage Check valve spring height
34. N 4 jh 17 Ado GG gt at d P dl Lo LAS 2677 GC SS Men Se e ARM_ LATE AN 80324304 Qo v2 SS V E y Fig 30 Rocker Arm Retaining Nut 26 Remove rocker assemblies Place them on a bench in the same order as removed 27 Remove the push rods and place them on a bench in the same order as removed 28 Mark cylinder heads to ensure installation in there original position 29 Remove the engine cylinder head bolts with special tool VM 1018 and VM 1019 NS GS REMOVAL AND INSTALLATION Continued 30 Remove the engine cylinder heads and gasket NOTE A single steel head gasket is used for 4 cyl inder heads Fig 33 31 Stuff clean lint free shop towels into the cyl inder bores CYLINDER HEAD GASKET NOTE If cylinder wall liners have not been removed the same thickness head gasket removed may be used CAUTION Piston protrusion must be measured to determine cylinder head gasket thickness if one or more cylinder wall liners have been replaced Cylinder head gaskets are available in three thick ness The different thicknesses are marked with identification holes one two or none Fig 33 The gasket is to be installed DRY DO NOT use a gas ket sealing compound on the gasket 1 Use special tool VM 1010 with dial indicator special tool VM 1013 Fig 31 TY 950933 Fig 31 Measuring Piston Protrusion 2 Bring the piston of cylinder no 1 exactly to top dead ce
35. N m 240 in Ibs 3 Install oil pump drive gear on crankshaft 4 Install front cover Refer to Timing Chain Cover Installation in this section 5 Install pump shaft support bracket assembly CAUTION Correct torque on the vibration damper nut is important or engine damage can occur 6 Install vibration damper Torque nut to 441 N m 325 ft Ibs 7 Install both accessory drive belts Refer to Group 7 Cooling 8 Install right splash shield OIL PUMP PRESSURE RELIEF VALVE REMOVAL 1 Remove oil pan 2 Remove clip retaining relief valve 3 Remove relief valve cap spring and plunger Fig 61 4 Check relief valve spring length Relief valve spring free length is 57 5mm 2 263 in If spring length is less or spring is distorted it must be replaced 5 Check plunger for scoring replace if necessary NS GS J9509 165 Fig 61 Oil Pressure Relief Valve INSTALLATION 1 Thoroughly clean all components and relief valve pocket in cylinder block 2 Fit plunger spring and cap into block 3 Compress spring and install retaining clip Ensure clip is completely seated in groove OIL FILTER ADAPTER AND OIL COOLER REMOVAL 1 Remove oil filter 2 Remove oil cooler adapter bolt 3 Remove oil cooler Fig 62 INSTALLATION 1 Install oil cooler with new gasket tighten oil cooler adapter bolt to 60 N m 44 ft Ibs 2 Install oil filter adapter to oil cooler and tighten to 49 N
36. ain pan under the oil filter 2 Using a suitable oil filter wrench loosen filter 3 Rotate the oil filter counterclockwise to remove it from the oil filter base Fig 6 OIL FILTER 80ababfo Fig 6 Oil Filter 4 When filter separates from base tip gasket end upward to minimize oil spill Remove filter from vehi de 5 With a cloth wipe clean the gasket sealing sur face of oil and grime OIL FILTER INSTALLATION 1 Lightly lubricate oil filter gasket with engine oil 2 Thread filter onto the base When gasket makes contact with sealing surface hand tighten fil ter one full turn do not over tighten 3 Add oil verify crankcase oil level and start engine Inspect filter area for oil leaks TIMING PROCEDURE CAUTION It could take up to 70 crankshaft revolu tions to align sprocket timing marks with the dark chain links If the chain is removed Fig 7 before the sprocket marks are in their proper locations you must first loosen the rocker arm supports before rotating crankshaft or camshaft sprockets This will prevent the valves from hitting the pistons Installing timing chain Fig 8 Starting at the crankshaft align the dark link on the chain to the timing mark on the crankshaft sprocket Next align 9 42 ENGINE SERVICE PROCEDURES Continued CAMSHAFT SPROCKET TIMING MARK 11 O CLOCK VACUUM PUMP KR INJECTION C PUMP SPROCKET TIMING MARK 3 O CLOCK CRANKSHAFT SPROCKET TIMING MARK
37. amped on the crown of individual pistons Engine cylinders are numbered starting from gear train end of the engine Face chamber recess side of piston towards camshaft Therefore the numbers stamped on con 9 70 ENGINE REMOVAL AND INSTALLATION Continued rod big end should also face in the same direction To insert piston into cylinder use a ring compressor as shown in Fig 81 PISTON PIN INSTALLATION 1 Secure connecting rod in soft jawed vice 2 Lubricate piston pin and piston with clean oil 3 Position piston on connecting rod CAUTION Ensure combustion recess in piston crown and the bearing cap numbers on the con necting rod are on the same side 4 Install piston pin 5 Install clips in piston to retain piston pin 6 Remove connecting rod from vice PISTON 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 80 J9509 23 Fig 80 Piston Ring Gap Location J9509 25 Fig 81 Installing Piston NS GS 2 Before installing the ring compressor make sure the oil ring expander ends are butted and the rail gaps located as shown in Fig 80 3 Immerse the piston head and rings in clean engine oil slide the ring compressor over the piston and tighten with the special wrench Fig 81 Ensure position of rings does not change dur i
38. an 170 N m 125 ft Ibs Rear Crankshaft Bearing Carrier BOWES aan ee 10 8 N m 95 in Ibs Rocker Arm Cover Bolts ek ENEE 4 d 14 7 N m 132 in Ibs Rocker Arm Mounting NUES a prania aae iia 29 4 Nm 264 in Ibs Power Steering Pump Mounting NULS sermo A A Een 24 5 Nm 216 in Ibs Turbocharger Mounting Nures 32 N m 288 in Ibs 9 80 ENGINE SPECIFICATIONS Continued DESCRIPTION TORQUE Turbocharger Oil Delivery Bolt wann aaa as 27 5 N m 240 in Ibs Turbocharger Oil Drain Bolts susce eas 10 8 N m 95 in Ibs Vacuum Pump Mounting BOlES Loss oed eee Stee 10 8 N m 95 in Ibs Water Manifold Mounting BIOS aa an 11 8 N m 108 in Ibs Water Pump Pulley BOWS 5e een an 27 5 Nm 240 in Ibs NS GS SPECIAL TOOLS 2 5L VM DIESEL 803fd6a1 Crankshaft Sprocket Remover VM 1000A 803fd6a2 Cylinder Liner Puller VM 1001 e amp DU 803fd6a3 Crankshaft Bearing Remover Installer VM 1002 NS G S CCCL ENGINE 9 81 SPECIAL TOOLS Continued 803fd6a9 803fd6a5 Cylinder Head Guide Studs VM 1009 Crankshaft Remover Installer Sleeve VM 1004 J 80a1aa43 803fd6a6 Cylinder Liner Protrusion Tool VM 1010 Torque Angle Gauge VM 1005 SS ES WAS 80a1aa45 803fd6a7 Injector Socket Remover Installer VM 1012A Cylinder Head Bolt Wrench VM 1006A 9 82 ENGIN E m ee NS GS SPECIAL TOOLS Continued 7 0 B0a1aa46 80a1aa49 Dial Indicator Gauge VM 10
39. ator and fans as an assembly 30 Remove accessory drive belt generator power steering Refer to Group 7 for procedure 31 Remove both power steering lines at pump and cap both lines NOTE It is not necessary to discharge A C system for engine removal 32 Remove A C compressor Secure compressor away from engine for clearance during engine removal 33 Remove Generator and adjusting bracket NOTE Do not remove the mounting base from the generator It is aligned at the factory and cannot be realigned in the field 34 Hoist vehicle 35 Remove exhaust pipe at turbo outlet 36 Remove connections at starter 37 Remove power steering high pressure line bracket at rear of oil pan 38 Remove both driveshafts from transaxle Refer to Group 2 Suspension and Driveshafts 39 Disconnect clutch cable at transaxle 40 Remove reinforcement plate on lower cross member 41 Remove front and rear engine mounts Refer to procedure outlined in this section 42 Drain engine oil and remove oil filter if neces sary ENGINE 9 47 43 Mount both special tool engine support brack ets VM 1026 to cylinder block Fig 22 44 Using engine dolly and cradle assembly with 4 adjustable posts align posts with holes in the engine support brackets SPECIAL TOOL TWO ADAPTER PLATES l TE pipe Aa SPECIAL TOOL A ADJUSTABLE POSTS 6848 SPECIAL TOOL ENGINE CRADLE 6710A VAI
40. d CYLINDER HEAD REMOVAL 1 Disconnect the battery cable WARNING DO NOT REMOVE THE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR DRAIN COCK WITH THE SYSTEM HOT AND PRES SURIZED BECAUSE SERIOUS BURNS FROM THE COOLANT CAN OCCUR 2 Drain the cooling system Refer to Group 7 Cooling 3 Remove wiper module Refer to Group 8K Windshield Wiper Unit Removal for procedure 4 Remove coolant pressure bottle 5 Remove intercooler hose at intake manifold Fig 24 6 Remove intercooler hose at turbocharger inter cooler tube TURBOCHARGER TO ee INTERCOOLER TUBE EU TUBE TO TUBE TO LO TURBOCHARGER R tap HOSE INTERCOOLER ASSEMBLY RADIATOR CLOSURE PANEL BRACE INTERCOOLER TO INTAKE MANIFOLD HOSE INTERCOOLER RUBBER MOUNTS 9311 6 Fig 24 Intercooler Assembly 7 Remove the upper radiator hose 8 Remove water manifold 9 Disconnect the heater hoses and coolant pres sure bottle hoses 10 Disconnect EGR tube from EGR valve Fig 26 11 Remove exhaust pipe from turbocharger elbow and 12 Disconnect oil feed line from turbo Fig 25 13 Disconnect oil drain line from turbo 14 Remove Intake manifold Refer to Group 11 Exhaust System and Intake Manifold Sa ENGINE 9 49 aa TURBOCHARGER EXHAUST OUTLET OIL DRAIN ELBOW 80a243c2 Fig 25 Turbocharger EGR TUBE EGR VALVE O INTAKE MANIFOLD EXHAUST MANIFOL
41. d rocker arm as valve closes In either case tappet assembly should be removed for inspec tion and cleaning NS GS 4 The valve train generates a noise very much like a light tappet noise during normal operation Care must be taken to ensure that tappets are mak ing the noise In general if more than one tappet seems to be noisy its probably not the tappets SERVICE PROCEDURES CHECKING OIL LEVEL To assure proper engine lubrication the engine oil must be maintained at the correct level Check the oil level at regular intervals such as every fuel stop The best time to check the oil level is about 5 min utes after a fully warmed up engine is shut off or before starting the vehicle after it has sat overnight Checking the oil while the vehide is on level ground will improve the accuracy of the oil level readings Fig 4 OIL FILL 7 803137c0 Fig 4 Checking Engine Oil CHANGING ENGINE OIL AND FILTER Change engine oil and filter at mileage and time intervals described in the Maintenance Schedule ENGINE OIL CHANGE WARNING NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL CONTAMINANTS IN USED ENGINE OIL CAUSED BY INTERNAL COMBUSTION CAN BE HAZARDOUS TO YOUR HEALTH THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER DO NOT WASH SKIN WITH GASOLINE DIESEL FUEL THINNER OR SOLVENTS HEALTH PROBLEMS CAN RESULT DO NOT POLLUTE DISPOS
42. eck internal diameter of bearings 3 If internal diameter of original bearing is being checked and figures are not within specifications new bearings must be used 4 Check crankshaft main bearing journals to bearing clearances Clearances of main bearings is 03 to 088mm 0011 to 0035 in OIL PAN Remove all gasket material from cylinder block Be careful not gouge pan sealing surface CYLINDER LINER INSPECTION The cylinder walls should be checked for out of round and taper with dail bore gauge The cylinder bore out of round is 0 100 mm 0039 inch maximum and cylinder bore taper is 0 100 mm 0 0039 inch maximum 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 97 Top measurement should be 10 mm 3 8 inch down and bottom measurement should be 10 mm 3 8 inch up from bottom of bore J9509 13 Fig 97 Liner Inspection SPECIFICATIONS 2 5L VM DIESEL DESCRIPTION SPECIFICATIONS TyDe sah eit ea pe Dres 425CLIEE 36B Number of Cylinder 2 2222222 n nee nn 4 BIOL Soy a en ai shane 92 mm It GE tae faded ete ded 94 mm Capadty 2 46 nur EE REFERS 2499 5 cm3 Injection Order lusus 1 3 4 2 Compression Ratio 5 21 1 0 5 ENGINE 9 77 DESCRIPTION SPECIFICATIONS Crankshaft Front J ournal Diameter Nominal
43. ef valve retainer cap When tappet noise is due to aeration it may be intermittent or constant and usually more than 1 tappet will be noisy When oil level and leaks have been corrected operate the engine at fast idle Run engine for a suf ficient time to allow all of the air inside the tappets to be bled out TAPPET NOISE DIAGNOSIS 1 To determine source of tappet noise operate engine at idle with cylinder head covers removed 2 Feel each valve spring or rocker arm to detect noisy tappet The noisy tappet will cause the affected spring and or rocker arm to vibrate or feel rough in operation NOTE Worn valve guides or cocked springs are sometimes mistaken for noisy tappets If such is the case noise may be dampened by applying side thrust on the valve spring If noise is not apprecia bly reduced it can be assumed the noise is in the tappet Inspect the rocker arm push rod sockets and push rod ends for wear 3 Valve tappet noise ranges from light noise to a heavy click A light noise is usually caused by exces sive leak down around the unit plunger or by the plunger partially sticking in the tappet body cylinder The tappet should be replaced A heavy click is caused by a tappet check valve not seating or by for eign particles becoming wedged between the plunger and the tappet body This will cause the plunger to stick in the down position This heavy click will be accompanied by excessive clearance between the valve stem an
44. fer to CRANKSHAFT MAIN REMOVAL in this section REAR CRANKSHAFT OIL SEAL REMOVAL 1 Remove transmission Refer to Group 21 Transmission for removal procedure 2 Remove flywheel BEARING NOTE Inspect O ring in flywheel Fig 85 3 Remove rear crankshaft oil seal from retainer Fig 86 CAUTION When removing seal from retainer take care not to damage retainer INSTALLATION 1 Install crankshaft oil seal CAUTION Use NEW flywheel bolt for the following procedure 2 Install new O ring on flywheel Install fly wheel The 6 flywheel bolts must be tightened as fol lows a Torque the 6 flywheel bolts to 60 N m 44 ft Ibs b Loosen 2 of the 6 bolts 180 apart Torque the 2 bolts to 20 N m 180 in Ibs Then using a torque angle gauge rotate the 2 bolts 65 additional C Loosen the next 2 bolts 180 apart and follow the same procedure d Loosen the last 2 bolts 180 apart and follow the same procedure 3 Install Transmission Refer to procedure in Group 21 Transmission DISASSEMBLY AND ASSEMBLY HYDRAULIC TAPPETS DISASSEMBLE AND ASSEMBLE 1 Pry out plunger retainer spring clip 2 Clean varnish deposits from inside of tappet body above plunger cap 3 Invert tappet body and remove plunger cap plunger check valve check valve spring check valve retainer and plunger spring Check valve could be flat or ball Assemble tappets in reverse order 9 72 ENGINE NS GS
45. g air conditioning pulley nut is important or engine dam age can occur 9 68 ENGINE REMOVAL AND INSTALLATION Continued 10 Install power steering air conditioning pulley Tighten nut to 170 N m 125 ft Ibs CAUTION Correct torque on the crankshaft vibra tion damper nut is important or engine damage can occur 11 Install crankshaft vibration damper Torque to 441 N m 325 ft Ibs 12 Install both accessory drive belts Refer to Group 7 Cooling 13 Install splash shield 14 Lower vehicle 15 Connect battery PISTONS AND CONNECTING ROD REMOVAL 1 Disconnect the battery cable 2 Remove cylinder heads refer to cylinder head removal in this section 3 Raise vehide on host 4 Remove oil pan refer to oil pan removal in this section 5 Remove top carbon ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block Be sure to keep tops of pistons covered during this operation Mark piston with matching cylinder number 6 Pistons and connecting rods must be removed from top of cylinder block Rotate crankshaft so that each connecting rod is centered in cylinder bore 7 Remove connecting rod cap Push each piston and rod assembly out of cylinder bore CAUTION During piston and rod removal DO NOT rotate piston and connecting rod or damage to the oil jets extending out into the cylinder bore will occur Fig 74 CYLINDER BLOCK r
46. g end and rod cap must be on the same side as the camshaft Fig 94 After having coated threads with Molyguard tighten con rod bolts to 29 N m 21 ft Ibs plus 60 CAMSHAFT SIDE IF 2 DIGIT NUMBER FOR WEIGHT CATEGORY A DIGIT REFERENCE NUMBERS FOR CORRECT ASSEMBLING J9509 24 Fig 94 Connecting Rod Identification PISTON PIN 1 Measure the diameter of piston pin in the cen ter and both ends Fig 95 2 Piston pin diameter is 29 990 to 29 996mm 1 1807 to 1 1809 in CRANKSHAFT CRANKSHAFT J OURNALS 1 Using a micrometer measure and record crank shaft connecting rod journals take reading of each journal 120 apart Crankshaft journal diameter is 53 84 to 53 955mm 2 1196 to 2 1242 in 2 Crankshaft journals worn beyond limits or show signs of out of roundness must be reground or replaced Minimum reground diameter is 53 69mm 2 1137 in NS GS J9509 172 Fig 95 Piston Connecting Rod and Pin BEARING TO J OURNAL CLEARANCE Compare internal diameters of connecting rod with crankshaft journal diameter Maximum clearance between connecting rod and crankshaft journals 022 to 076mm 0008 to 0029 in Fig 96 2 Lt EN 777777 77773 J9509 39 Fig 96 Bearing Clearance CRANKSHAFT MAIN BEARING INSPECTION 1 Fit main bearing carriers together and torque to 42 N m 31 ft Ibs NS GS CLEANING AND INSPECTION Continued 2 Ch
47. ginal positions 5 Install rocker arms in original positions 6 Install cylinder head cover Refer to cylinder valve cover installation in this section 7 Start and operate engine Warm up to normal operating temperature CAUTION To prevent damage to valve mechanism engine must not be run above fast idle until all hydraulic tappets have filled with oil and have become quiet VIBRATION DAMPER REMOVAL 1 Disconnect the battery cable 2 Raise vehicle on hoist 3 Remove right side lower splash shield 4 Remove generator power steering belt Refer to Group 7 Cooling 5 Remove water pump belt Refer to Group 7 Cooling NS GS 6 Remove engine starter Refer to Group 8B for procedure 7 Install flywheel locking tool VM 1014 to pre vent engine rotation NOTE Crankshaft damper nut is left thread handed 8 Remove vibration damper nut 9 Remove vibration damper No special tool is needed for removal CAUTION If thread sealant is used it is important to remove all the old thread sealant from the threads on the crankshaft INSTALLATION NOTE Before installing damper be sure the O ring inside the center of the damper is in its grove 1 Install vibration damper CAUTION Correct torque on the vibration damper nut is important or engine damage can occur 2 Install vibration damper nut and tighten to 441 N m 325 ft Ibs 3 Remove flywheel engine starter 4 Install both acce
48. hell oil holes are not in exact alignment remove and install them correctly Install a new core hole plug at the rear of camshaft Be sure this plug does not leak CRANKSHAFT MAIN BEARINGS REMOVAL 1 Disconnect battery cable 2 Remove engine from vehicle refer to engine removal in this section 3 Install engine to engine stand 4 Remove accessary drive system 5 Remove cylinder head cover refer to cylinder head cover removal in this section 6 Remove rocker arm and push rods refer to rocker arm and push rod section in this section 7 Remove intake exhaust manifold and turbo charger refer to Group 11 Exhaust System and Intake Manifold 8 Remove water manifold 9 Remove oil feed lines to rocker arms 10 Remove cylinder heads 11 Remove oil pan and oil pick up 12 Remove piston and connecting rods from crankshaft journals 13 Remove pistons and connecting rods from block 14 Remove vibration damper Refer to procedure in this section 15 Remove front cover Refer to procedure in this section NS GS 16 Remove oil pump drive gear 17 Remove timing chain Refer to procedure in this section 18 Install special tool VM 1004 onto crankshaft over gear Fig 52 9509 26 Fig 52 Crankshaft Special Tool VM 1004 19 Remove main bearing oil feed and carrier locators from block 20 Remove flywheel engine block 21 Remove thrust bearings from rear main bear ing carr
49. ier Fig 53 22 Slide crankshaft and bearing carriers rear ward to rear of block If you encounter difficulty in removing the complete assembly as previously described slide the assembly rearward sufficiently to gain access to the main bearing carrier bolts Mark the carriers for assembly and remove the bolts two for each carrier Fig 54 23 Separate the two halves of each carrier remove from the crankshaft and temporarily reas semble the carriers Fig 55 Withdraw the crank shaft through the rear of the crankcase and adaptor plate from INSTALLATION NOTE Assemble engine according to sequence described thus saving time and preventing dam ages to engine components Clean parts with a suit able solvent and dry them with compressed air before assembly Use new gaskets where applicable and torque wrenches for correct tightening of com ponents NS GS ENGINE 9 61 REMOVAL AND INSTALLATION Continued MAIN BEARING REAR CENTER SUPPORT 3 HOUSING THRUST WASHER TIMING CHAIN SPROCKET FRONT MAIN BEARING VM920954 Fig 54 Carrier Bolts 1 Thoroughly dean crankcase and oil passages and blow dry with compressed air 2 Install new main bearing shells in each of the carrier halves Assemble the carriers to the crank shaft journals ensuring that the carriers are installed in their original locations Secure each car rier with the two bolts tightening evenly to 42 N m 31 ft Ibs Fig
50. il feed line tighten to 16 7 N m 145 in Ibs 4 Install hydraulic tensioner blade Tighten Bolt to 28 N m 260 in Ibs 5 Install lower chain guide 6 Install oil pump drive gear on crankshaft 9 58 ENGINE REMOVAL AND INSTALLATION Continued INJECTION PUMP SPROCKET I CG E TIMING 7 MARK 7 y VACUUM 4 E Se pump A4 Q NIIT VU j TIMING 8 MARK a o i9 i CAMSHAFT n H SPROCKET N Aj AC L TIMING AC ei MARK CRANKSHAFT SPROCKET en Fig 47 Timing Chain Procedure 7 Install timing chain cover Refer to installation procedure outlined in this section 8 Install pump shaft support bracket assembly Tighten nuts to 24 5 N m 216 in Ibs 9 Install power steering air conditioning pulley Tighten nut to 170 N m 125 ft Ibs CAUTION Correct torque on the power steering air conditioning pulley nut is important or engine dam age can occur 10 Install crankshaft vibration damper Torque to 441 N m 325 ft Ibs CAUTION Correct torque on the crankshaft vibra tion damper nut is important or engine damage can occur 11 Install both accessory drive belts Refer to Group 7 Cooling 12 Install splash shield 13 Lower vehide 14 Connect battery CRANKSHAFT SPROCKET REMOVAL 1 Remove vibration damper Refer to procedure in this section 2 Remove timing chain cover Refer to procedures in this section 3 Remove oil pump drive gear on crankshaft 4 Remove oil
51. ive parts 5 Check Battery voltage Replace battery if a charge cannot be held 6 Check voltage to solenoid If necessary replace the solenoid 7 Replace starter motor ENGINE CRANKS BUT WILL NOT START NO SMOKE 1 No fuel in supply tank 2 Electrical fuel shutdown solenoid not operating 3 Fuel injection system defective Cranking speed sensor Loose connection between ECU and harness No power supply to the ECU Loose connection between injection pump and harness 4 Air intake or exhaust plugged 5 Fuel filter plugged 6 Excessive fuel inlet restriction 7 Injection pump not getting fuel or fuel is aerated 8 One or more injectors worn or not operating properly 9 Camshaft out of time 1 Fill fuel supply 2 Check for loose wires and verify that the fuel shutdown solenoid is functioning Check for fault codes in the ECU 3 Check for fault codes at ECU Refer to Group 14 Fuel System for repairs procedures 4 Remove the obstruction 5 Drain fuel water separator and replace fuel filter 6 Check for restriction Correct cause 7 Check fuel flow bleed fuel system 8 Check replace bad or improperly operating injectors 9 Check correct timing chain sprocket alignment ENGINE HARD TO START OR WILL NOT START SMOKE FROM EXHAUST 1 Incorrect starting procedure 2 Cranking speed to slow 3 Cylinder head heater plugs defective 4 Insufficient intake air 5 Air in
52. lies and oil pressure switch to 13 N m 112 in Ibs 18 Install push rods and rocker arm assemblies tighten nut to 29 4 N m 264 in Ibs 19 Install fuel injectors use tool VM 1012 refer to Group 14 Fuel System 20 Install valve cover tighten nuts to 14 7 N m 132 in Ibs NS GS REMOVAL AND INSTALLATION Continued 21 Connect crankcase breather hose 22 Connect the injector sensor wire connector and the glow plug connectors 23 Install oil feed line tighten banjo bolts to 12 7 N m 108 in Ibs and oil drain line to turbo 24 Install water manifold tighten bolts to 12 N m 106 in Ibs 25 Install exhaust pipe to turbo elbow tighten bolts to 28 N m 250 in Ibs 26 Install the support strut from block to turbo charger exhaust elbow 27 Install EGR tube to EGR valve tighten bolts to 26 N m 19 ft Ibs 28 Install intercooler hoses at intake manifold 29 Install coolant pressure bottle and hoses 30 Install wiper module Refer to Group 8K Windshield Wiper Unit Installation for procedure 31 Install intercooler hose at turbocharger tube 32 Install fuel injector lines from the pump to injectors tighten nuts to 17 6 N m 156 Ibs 33 Connect the upper radiator hose 34 Connect negative cable to battery 35 Fill the cooling system Check for leaks WARNING USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING DO NOT STAND IN DIRECT LINE WITH THE FAN DO NOT PUT HAN
53. n vehicle Refer to procedure in this section 39 Fill engine with the correct amount of fluids specified 40 Connect battery cable ENGINE 9 63 OIL PAN REMOVAL 1 Disconnect battery cable 2 Raise vehicle on hoist 3 Drain oil 4 Remove oil pan bolts Fig 59 Remove oil pan 80a137c8 Fig 59 Oil Pan INSTALLATION 1 Install oil pan Apply a continuous 3 mm bead of Silicone Sealer to oil pan install within 10 min utes 2 Install oil pan bolts and torque bolts to 11 N m 8 ft Ibs 3 Install oil drain plug tighten to 79 N m 58 ft Ibs 4 Lower vehicle 5 Fill engine with proper amount of oil 6 Connect battery cable OIL PUMP REMOVAL 1 Raise vehicle on hoist 2 Remove right splash shield 3 Remove both accessory drive belts Refer to Group 7 Cooling 4 Remove pump shaft support bracket assembly 5 Remove vibration damper Refer to Vibration Damper Removal in this section NOTE Crankshaft damper nut is left thread handed 6 Remove front cover Refer to Timing Chain Cover Removal in this section 7 Remove oil pump drive gear at crankshaft Fig 60 8 Remove oil pump 9 64 ENGINE REMOVAL AND INSTALLATION Continued OIL PUMP DRIVE GEAR LD 7 ET 80a18d30 Fig 60 Oil Pump Drive Gear INSTALLATION 1 Install new O ring and lubricate with clean engine oil 2 Install oil pump and tighten retaining screws to 27 5
54. ner recess relative to block deck with a dial indicator mounted on a Special tool VM 1010 A All the measurements must be taken on camshaft side 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 NS GS REMOVAL AND INSTALLATION Continued J9509 12 Fig 82 Cylinder Liner Removal 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 Apply LOCTITE 275 to the corner of the liner seat Apply LOCTITE 275 uniformly to the upper part of the liner at area 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 1016 and bolts Fig 84 Clean the residual LOCTITE on the upper surface of the block deck 9 Recheck the liner protrusion It should be 0 01 0 06 mm NOTE A period of six hours must elapse between the liners being installed and engine start up If engine assembly is not continued after liner instal lation the liners need to be clamped for twelve hours minimum 10 Refer to Cylinder Head Removal and Installa tion procedure in this section To measure piston pro trusion for installation of proper head gasket thickness ENGINE 9 71 CRANKSHAFT REMOVAL Re
55. ng Plate Alignment 3 Tighten locating bolt to 11 N m 96 in Ibs torque Be sure to align the timing marks as shown in timing chain installation procedure 4 Install camshaft sprocket center bolt and tighten to 19 6 N m 60 170 in Ibs 60 Remove sprocket holding tool 5 Install hydraulic tappets and retaining yokes 6 Install cylinder heads 7 Push rods and rocker arm assemblies In there original location 8 Install valve cover 9 Install Timing case cover 9 60 ENGINE REMOVAL AND INSTALLATION Continued 10 Install Vibration damper 11 Reinstall Engine CAMSHAFT BEARINGS This procedure requires that the engine is removed from the vehide REMOVAL 1 With engine completely disassembled drive out rear cam bearing core hole plug 2 Install proper size adapters and horseshoe washers part of Camshaft Bearing Remover I nstaller Tool at back of each bearing shell Drive out bearing shells Fig 50 INSTALLATION 1 Install new camshaft bearings with Camshaft Bearing Remover Installer Tool by sliding the new camshaft bearing shell over proper adapter 2 Position rear bearing in the tool Install horse shoe lock and by reversing removal procedure care fully drive bearing shell into place 3 Install remaining bearings in the same man ner Bearings must be carefully aligned to bring oil holes into full register with oil passages from the main bearing If the camshaft bearing s
56. ng this operation 4 Face chamber recess side of piston towards camshaft 5 Install connecting rod bolt protectors on rod bolts 6 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 CAUTION During piston and rod installation DO NOT rotate piston and connecting rod or damage to the oil jets extending out into the cylinder bore will occur Fig 74 7 Tap the piston down in cylinder bore using a hammer handle At the same time guide connecting rod into position on connecting rod journal 8 Install rod caps Install nuts on cleaned and oiled rod bolts and tighten nuts to 29 5 N m 22 ft Ib plus 60 CYLINDER LINER REMOVAL 1 Remove cylinder heads refer to cylinder head removal in this section 2 Remove Oil pan refer to oil pan removal in this section 3 Remove pistons refer to piston removal in this section 4 Use tool VM 1001 to remove liners Fig 82 5 Remove shims from cylinder liner or cylinder block recess Keep shims with each cylinder liner INSTALLATION 1 Carefully clean residual sealer from liner and crankcase and degrease the crankcase where it comes into contact with the liners Referring to Fig 83 install the liners in the crankcase as shown A rotating them back and forth by 45 in order to guar antee correct positioning 2 Measure the li
57. nter 3 Zero the dial indicator on the cylinder block mating surface 4 Setup the dial indicator on the piston crown above the center of the piston pin 5mm 1 8 in from the edge of the piston and note the measure ment Fig 32 5 Repeat the procedure with the rest of the cyl inders 6 Establish the thickness of the gasket for all four cylinder heads on the basis of the greatest pis ton protrusion Fig 33 ENGINE 9 51 Measured dimension mm 0 53 0 62 Cyl head gasket thickness mm 1 42 Piston clearance Imml aaaea 0 80 0 89 Measured dimension mm 0 63 Cyl head gasket thickness mm 1 52 Piston clearance Imm 0 80 0 89 d dimension Imml 0 73 Cyl head gasket thickness mm 1 62 Piston clearance Imml eee 0 80 0 89 J9509 164 Fig 32 Piston Protrusion Chart HOLES CAN BE LOCATED AT THE RIGHT FRONT CORNER OF THE CYLINDER BLOCK HOW TO IDENTIFY GASKET THICKNESS NO HOLES und 30 dee rawni 1 42 mm 2 HOLES 2 1 52 mm THOLE 208 085 tinei oana noki 1 62 mm 80a2b412 Fig 33 Head Gasket Identification INSTALLATION CYLINDER HEAD 1 Remove the shop towels from the cylinder bores Coat the bores with dean engine oil 2 Install cylinder head alignment VM 1009 3 After determining the correct head gasket thickness clean the block and head mating surfaces place the engine cylinder head gasket
58. o service camshaft Fig 50 the engine must be removed from vehicle BEARINGS Dr MEN CAMSHAFT CAMSHAFT SPROCKET LOCATING PLATE 80a18d36 Fig 50 Camshaft Assembly 2 Remove valve cover removal in this section 3 Remove rocker arms and push rods Identify push rods to ensure installation in there original location 4 Remove cylinder head Refer to cylinder head removal in this section 5 Remove hydraulic tappets Refer to tappet removal in this section Refer to valve cover ENGINE 9 59 6 Remove vibration damper Refer to vibration damper removal in this section 7 Remove power steering pulley 8 Remove pump shaft support bracket 9 Remove timing chain cover Refer to timing chain cover removal in this section 10 Remove timing chain Refer to removal proce dure in this section 11 Install camshaft sprocket holding tool VM 1031 to lock the camshaft sprocket in place 12 Remove camshaft sprocket bolt and remove sprocket Fig 50 13 Remove locating plate and reinstall sprocket and bolt finger tight 14 Remove camshaft INSTALLATION 1 Coat the camshaft journals with clean engine oil and carefully install the camshaft 2 Install camshaft locating plate alignment tool on block then install locating plate Fig 51 SPECIAL INJECTION TOOL B PUMP VM 1028 SPROCKET b eo N O ne 27 1 N CAMSHAFT LOCATING PLATE a 80a35411 Fig 51 Locati
59. ol down completely Then retorque the head bolts as fol lows 13 Central bolts A L Starting from bolt A slacken and retorque it immediately to 30 N m 65 Rotate the bolt an additional 65 Then proceed in the same way bolt by bolt following alphabetical order as indicated 14 Side bolts M1 M2 Without slackening torque bolts M1 then bolts M2 to 90 N m 66 ft Ibs 15 Tighten intake nuts to 30 N m 22 ft Ibs and exhaust manifolds nuts to 30 N m 22 ft Ibs speci fied torque after completing Phase 2 16 If the engine cylinder head is to be replaced and the original valves used measure the valve stem diameter Only standard size valves can be used with a service replacement engine cylinder head unless the replacement head valve stem guide bores are J9509 41 Fig 34 Engine Cylinder Head Bolt Tightening Sequence 9 1st Phase Tightening Head Bolts Fig 34 Central bolts A L Tighten all bolts starting with bolt A then B C D E F G H I L to 30 N m Repeat the operation with the same torque Following the same sequence rotate each bolt through an angle of 70 using angle torque tool Then rotate the bolts an additional 70 following tightening sequence 10 Then tighten the 14mm bolts with special tool VM 1018 in the following manner reamed to accommodate oversize valve stems Remove all carbon buildup and reface the valves 17 Tighten oil feed lines for rocker arm assem b
60. on NS GS REMOVAL AND INSTALLATION Continued 7 Torque engine mount top bolt Vertical to 101 N m 75 ft Ibs 8 Torque engine mount thru bolt Horizontal to 145 N m 107 ft Ibs 9 Torque engine mount to frame bolts to 68 N m 50 ft Ibs RIGHT ENGINE TOP SUPPORT MOUNT BRACKET BOLT A on CALCE So Be P AV ENGINE 9 45 5 Disconnect both shifter cables at transmission Remove the retainers holding the cables to the mount Fig 19 6 Remove the mount assembly 7 Reverse removal procedure for installation 8 Install mount assembly Torque bolts at engine ENGINE SUPPORT BRACKET ENGINE MOUNT mM TO FRAME BOLTS 80a1384c Fig 16 Right Engine Mount VM Diesel MOUNT LEFT SIDE 1 Raise vehicle on hoist and remove left front wheel 2 Remove inner splash shield 3 Support the transmission with a transmission jack 4 Remove the insulator thru bolt from the mount Fig 17 5 Remove the transmission mount bolts and remove mount It may be necessary to lower trans mission slightly to remove mount 6 Reverse removal procedure for installation 7 Install mount Torque transmission mount bolts to 54 N m 40 ft Ibs 8 Align mount into frame bracket with transmis sion jack install thru bolt Torque thru bolt to 71 N m 53 ft Ibs ENGINE MOUNT REAR 1 Raise vehide on hoist 2 Support the engine and transmission assembly with a transmission jack
61. over the dow els 4 Place the engine cylinder head over the dowels studs CAUTION Engine cylinder head bolts can be reused up to three times 9 52 ENGINE REMOVAL AND INSTALLATION Continued 5 Tighten the engine cylinder head bolts in sequence according to the following procedure Fig 34 a The threads and underside heads of the bolts should be lubricated Use the cylinder head align ment studs tool number VM 1009 Position the heads on the block and secure with the ten large center bolts and spacers clamps finger tight only b Ensure that the various clamps are installed correctly and the head gasket remain in their proper position completely covered Then lubricate and install the eight small bolts also finger tight 6 Loosen assembly oil feed line for rocker arm assemblies 7 Install the intake and exhaust manifolds with new gaskets partially tightening the nuts to a max imum of 5 N m 44 in Ibs This will align the heads refer to Group 11 Exhaust System and Intake Man ifold for the proper procedures Install lift eye and brake vacuum tube at this time 8 Then tighten the 12mm bolts with special tool VM 1019 in the following manner NS GS 11 Side bolts M1 M2 Tighten M1 bolts to 30 N m then rotate them 85 5 Tighten M2 bolts to 30 N m then rotate them 85 5 12 2nd Phase After 20 minutes of engine oper ation at operating temperature allow engine to co
62. pump NS GS 5 Remove timing chain Refer to procedure in this section 6 Remove vacuum pump 7 Install crankshaft sprocket remover VM 1000A and remove sprocket Fig 48 SPECIAL TOOL VM 1000A Oe CH ex c CRANKSHAFT 80238301 Fig 48 Crankshaft Sprocket Removal INSTALLATION 1 Install crankshaft sprocket alignment pin VM 1030 into hole in crankshaft Fig 49 SPROCKET SPECIAL TOOL VM 1029 J D Q lag E B SPECIAL TOOL VM 1030 CRANKSHAFT 80a38302 Fig 49 Crankshaft Sprocket Installation 2 Heat new crankshaft sprocket NS GS REMOVAL AND INSTALLATION Continued 3 Align notch in sprocket with alignment pin in crankshaft 4 Using crankshaft sprocket installer VM 1029 press on the new sprocket 5 Remove alignment pin 6 Install vacuum pump CAUTION The vacuum pump must be centered in the block and tighten with two bolts Ensure that the pump spins freely If vacuum pump drags or does not spin freely loosen bolts and perform pro cedures again 7 Install timing chain 8 Install oil pump 9 Install oil pump drive gear on crankshaft 10 Install timing chain cover 11 Install vibration damper CAUTION Correct torque on the crankshaft vibra tion damper nut is important or engine damage can occur HYDRAULIC TENSIONER Refer to Timing Chain Removal and Installation in this section CAM SHAFT REMOVAL 1 T
63. rankshaft or camshaft sprockets This will prevent the valves from hitting the pistons 11 Remove lower chain guide Fig 44 12 Remove hydraulic tensioner blade Fig 45 13 Remove hydraulic tensioner oil feed line Fig 46 14 Remove hydraulic tensioner NS GS REMOVAL AND INSTALLATION Continued 15 Remove timing chain CAMSHAFT SPROCKET TIMING MARK 11 O CLOCK VACUUM PUMP b CRANKSHAFT SPROCKET TIMING MARK 6 O CLOCK INJECTION PUMP SPROCKET TIMING MARK 3 O CLOCK 80a32919 Fig 43 Alignment Timing Sprockets GUIDE 1 us W quit CRANKSHAFT 80a18d33 Fig 44 Lower Chain Guide INSTALLATION 1 Install timing chain Starting at the crankshaft align the dark link on the chain to the timing mark on the crankshaft sprocket Next align the second dark link on the chain with the timing mark on the camshaft sprocket Third Align the final dark link on the chain to the timing mark on the injection pump ENGINE 9 57 J TIMING CHAIN y e SC C AS y aM T C Lf ge NS Wee D X CAMSHAFT SPROCKET 80a18d34 Fig 45 Tensioner Blade _ CHAIN OIL FEED TENSIONER LINE Ln EE S S ZI Mi EIN Mn VACUUM Z 9 CAMSHAFT e ESNSPROCKET Fig 46 Hydraulic Tensioner and Oil Feed Line 80a18d31 sprocket Last install the chain around the vacuum pump Fig 47 2 Install hydraulic tensioner 3 Install hydraulic tensioner o
64. reduce the oil change intervals 4 Check and replace the oil cooler 5 Check the breather tube area for signs of oil loss 6 Inspect air duct for evidence of oil transfer 7 Perform blow by check Repair as required COMPRESSION KNOCKS 1 Air in fuel system 2 Poor quality fuel or water gasoline contaminated fuel 3 Engine Overloaded 4 Improperly operating injectors 5 Fuel injection system defective 1 Bleed the fuel system refer to Group 14 Fuel System 2 Verify by operating from a temporary tank with good fuel Clean and flush the fuel supply tank Replace fuel water separator 3 Verify the engine load rating is not being exceeded 4 Check and replace injectors 5a Instrumented injection 5b Timing solenoid of the fuel pump 5c Pre and post heat time of the glow plugs Check the fault codes in the ECU EXCESSIVE ENGINE NOISES HYDRAULIC TAPPETS Before disassembling any part of the engine to cor rect tappet noise check the oil pressure If vehicle has no oil pressure gauge install a reliable gauge at 1 Drive belt squeal insufficient tension or abnormally high loading 2 Intake air and exhaust leak 3 Excessive valve lash 4 Turbocharger noise 5 Power function knock 6 Fuel injection system defective 1 Inspect the drive belts Make sure water pump pulley generator and power steering all turn freely 2 Refer to excessive exhaust smoke Engine Diagnosis and Te
65. rly operating pressure switch gauge 4 Relief valve stuck open 5 Plugged oil filter 6 Oil cooler was replaced shipping plugs left in cooler 7 Worn oil pump 8 Suction tube loose or seal leaking 9 Worn bearing or wrong bearing installed 10 Oil jets under piston loose or bad fit 1a Check and fill with clean engine oil 1b Check for severe external oil leaks that could reduce the pressure 2 Verify the correct oil is being used Check for oil dilution 3 Verify the pressure switch is functioning correctly If not replace switch gauge 4 Check replace valve 5 Change oil filter Oil filter change interval may need to be revised 6 Check removed shipping plugs 7 Check replace oil pump 8 Check and replace seal 9 Inspect and replace connecting rod or main bearings check and replace piston cooling oil jet 10 Check oil jets position LUBRICATING OIL LOSS LUBRICATING OIL LOSS CONT External oil leaks Crankcase being overfilled Incorrect oil specification or viscosity Oil cooler leak High blow by forcing oil out the breather Turbocharger leaking oil into the air intake Piston rings not sealing oil being consumed by the engine 1 Visually inspect for oil leaks Repair as required 2 Verify that the correct dipstick is being used 3a Make sure the correct oil is being used 3b Look for reduced viscosity from dilution with fuel 3c Review
66. s removed Fig 67 before the sprocket marks are in their proper locations you must first loosen the rocker arm supports before rotating crankshaft or camshaft sprockets This will prevent the valves from hitting the pistons 9 66 ENGINE REMOVAL AND INSTALLATION Continued INJECTION PUMP SPROCKET CC E TIMING 7 MARK 7 y VACUUM 4 di Se pump A4 Q NIIT VU j TIMING 8 MARK a o i9 i CAMSHAFT H SPROCKET N Aj AC L TIMING AC ei MARK CRANKSHAFT SPROCKET Fig 66 Timing Marks 13 Remove hydraulic tensioner blade Fig 69 14 Remove hydraulic tensioner oil feed line Fig 70 15 Remove hydraulic tensioner 16 Remove timing chain 17 Remove vacuum pump Fig 71 CAMSHAFT SPROCKET TIMING MARK 11 O CLOCK VACUUM PUMP 9 INJECTION C PUMP SPROCKET TIMING MARK 3 O CLOCK CRANKSHAFT SPROCKET TIMING MARK 6 O CLOCK 80a32919 Fig 67 Alignment Timing Sprockets INSTALLATION 1 Install vacuum pump with new O ring Fig 72 W ui LOWER CHAIN J TIMING CHAIN NS GS m 80a18d33 CRANKSHAFT Fig 68 Lower Chain Guide 80a18d34 Fig 69 Hydraulic Tensioner Blade CAUTION The vacuum pump must be centered in the block and tighten with two bolts Ensure that the pump spins freely If vacuum pump drags or does not spin freely loosen bolts and perform pro cedures again 2 Install timing chain Starting at the crankshaft align the dark link on timing chain to
67. so it will not rotate 3 Remove the thru bolt from the insulator at crossmember connection Fig 18 4 Remove the bolts holding the mount to the engine and transmission THRU BOLT LOCATION LEFT SIDE MOUNT A TPN m MOUNT BOLTS 7 U Bu o Di N pi A TRANSMISSION N TRANSMISSION 7 80a13793 Fig 17 Left Side Mount VM Diesel and transmission to 101 N m 75 ft Ibs 9 Align insulator at crossmember and install thru bolt Torque to 68 N m 50 ft Ibs 9 46 ENGINE REMOVAL AND INSTALLATION Continued STARTER V Lo RS TU 4 cr I U bx I Q MOUNT THRU BOLT N f LOCATION FOR gt CROSSMEMBER Qj Su amp TRANSMISSION 80a13795 CONNECTION Fig 18 Rear Engine Mount VM Diesel RETAINERS 80a137c9 Fig 19 Shift Cables at Rear Mount ENGINE ASSEMBLY REMOVAL 1 Disconnect the battery 2 Remove the air deaner assembly and inlet hose 3 Remove both hoses at intercooler and engine 4 Disconnect EGR vacuum hose 5 Disconnect brake booster vacuum hose shift tower 8 Disconnect transaxle wiring at speed sensor crank sensor and backup light switch 9 Remove both transmission shift cables at trans OIL SEPARATOR NS GS 6 Disconnect oil pressure switch connector Fig 20 7 Disconnect Wiring harness bracket at transaxle mission 10 Remove negative battery cable at cylinder block Fig 20
68. ssary drive belts Refer to Group 7 Cooling 5 Install right splash shield 6 Lower vehicle 7 Connect the battery cable TIMING CHAIN COVER OIL SEAL REMOVAL 1 Disconnect the battery cable 2 Remove vibration damper Refer to vibration damper removal in this section 3 Pry out seal Fig 37 locking tool and install INSTALLATION Remove the oil seal ring The seating diameter must be 68 000 68 030 mm 1 Install new seal using special tool VM 1015 2 Install vibration damper Refer to vibration damper installation in this section 3 Connect the battery cable INJECTION PUMP For removal and installation of injection pump refer to Group 14 Fuel NS GS REMOVAL AND INSTALLATION Continued J9509 4 Fig 37 Front Cover Seal TIMING CHAIN COVER REMOVAL 1 Disconnect the battery cable 2 Raise vehicle on hoist 3 Remove right splash shield 4 Remove accessary drive belts Refer to Group 7 Cooling 5 Remove vibration damper nut NOTE Crankshaft damper nut is thread left handed 6 Remove vibration damper 7 Remove power steering air conditioning pulley nut Remove pulley CAUTION Remove old pump loctite from threads on 8 Remove pump shaft support bracket assembly 9 Disconnect the water drain pipe hose at the timing cover CAUTION When separating the timing chain cover from the block take care not to damage the mating surface of the timing chain
69. stall an air hose adaptor in the fuel injector hole 6 Connect an air hose to the adapter and apply air pressure slowly Maintain at least 621 kPa 90 psi of air pressure in the cylinder to hold the valves against their seats 7 Tap the retainer or tip with a rawhide hammer to loosen the lock from the retainer Use Valve Spring Compressor Tool to compress the spring and remove the locks 8 Remove valve spring and retainer Inspect the valve stems especially the grooves An Arkansas smooth stone should be used to remove nicks and high spots INSTALLATION 1 Install valve spring and retainer 2 Compress the valve spring with Valve Spring Compressor Tool and insert the valve locks Release the spring tension and remove the tool Tap the spring from side to side to ensure that the spring is seated properly on the engine cylinder head 3 Disconnect the air hose Remove the adaptor from the fuel injector hole and install the fuel injec tor 4 Repeat the procedures for each remaining valve spring to be removed 5 Install the push rods Ensure the bottom end of each rod is centered in the plunger cap seat of the hydraulic valve tappet 6 Install the rocker arm assemblies at their orig inal location 7 Tighten the rocker arm assembly nut to 106 N m 78 ft Ibs torque 8 Install the engine cylinder head cover refer to cylinder head cover installation in this section NS GS REMOVAL AND INSTALLATION Continue
70. sting 3 Make sure the rocker arms are not bent Defective hydraulic lash adjuster 4 Check turbocharger impeller and turbine wheel for housing contact 5 Check and replace rod and main bearings 6a Instrumented injection 6b Timing solenoid of the fuel pump 6c Pre and post heat time of the glow plugs Check the fault codes in the ECU the pressure sending unit The pressure should be between 3 5 bars to 5 0 bars at 4000 RPM Check the oil level after the engine reaches normal operating temperature Allow 5 minutes to stabilize 9 40 ENGINE DIAGNOSIS AND TESTING Continued oil level check dipstick The oil level in the pan should never be above the FULL mark or below the ADD OIL mark on dipstick Either of these 2 condi tions could be responsible for noisy tappets OIL LEVEL HIGH If oil level is above the FULL mark it is possible for the connecting rods to dip into the oil With the engine running this condition could create foam in the oil pan Foam in oil pan would be fed to the hydraulic tappets by the oil pump causing them to lose length and allow valves to seat noisily OIL LEVEL LOW Low oil level may allow oil pump to take in air When air is fed to the tappets they lose length which allows valves to seat noisily Any leaks on intake side of oil pump through which air can be drawn will cre ate the same tappet action Check the lubrication system from the intake strainer to the pump cover including the reli
71. surement 16 Subtract specified crankshaft end play from figure obtained Crankshaft end play 0 08 to 0 21 mm 0 0032 to 0 0083 in 17 Select thrust washers which will give correct end play 18 Remove tools and flywheel 19 Lubricate thrust washer halves and fit them into the rear main bearing carrier 20 To verify correct end play install 2 flywheel bolts 180 apart and tighten bolts to 20 N m plus 60 15 ft Ibs plus 60 21 Measure crankshaft end play with a dial gauge Crankshaft end play should not exceed 0 08 0 21 mm 0 0032 to 0 0083 in Fig 57 If end clear ance exceeds these values install oversize thrust washer NS GS CAUTION Use NEW flywheel bolt for the following procedure 22 Install new O ring on flywheel Install fly wheel The 6 flywheel bolts must be tightened as fol lows a Torque the 6 flywheel bolts to 60 N m 44 ft Ibs b Loosen 2 of the 6 bolts 180 apart Torque the 2 bolts to 20 N m 180 in Ibs Then using a torque angle gauge rotate the 2 bolts 65 additional C Loosen the next 2 bolts 180 apart and follow the same procedure d Loosen the last 2 bolts 180 apart and follow the same procedure 23 Install Transmission Refer to procedure in Group 21 Transmission FLYWHEEL THRUST WASHER O RING MEE THREE ENGINE cel THICKNESSES ADAPTER AVAILABLE PLATE CRANKSHAFT 80a18d3e Fig 57 Measuring Crankshaft
72. t end float from figure obtained Crankshaft end float 0 08 to 0 21mm 5 Select thrust washer which will give correct end float 6 Refer to crankshaft main bearing Installation if not in specification NOTE If engine is disassembled refer to Crank shaft Main Bearing Removal and Installation for this procedure 9509 20 Fig 14 Measuring Crankshaft End Play REMOVAL AND INSTALLATION ENGINE MOUNT FRONT 1 Disconnect battery 2 Remove lower air dam at front fascia 3 Remove the bolts holding tow bracket and front mount to the lower crossmember 4 Remove thru bolt in engine mount Fig 15 Remove mount 5 Reverse removal procedure for installation 6 Torque engine mount thru bolt to 65 N m 48 ft Ibs 7 Torque crossmember bolts for tow bracket and engine mount to 54 N m 40 ft Ibs FRONT ENGINE TOW MOUNT BRACKET THRU BOLT LOCATION TOW EYE 80a13799 Fig 15 Front Engine Mount and Tow Bracket ENGINE MOUNT RIGHT 1 Remove the right engine mount top support bracket bolt Fig 16 2 Remove the load on the engine motor mounts by carefully supporting the engine and transmission assembly with a floor jack 3 Remove the engine mount to frame bolts 4 Remove the thru bolt from the mount assembly Remove insulator 5 If replaceing or removing right engine mount bracket the torque on the mounting bolts is 40 N m 30 ft Ibs 6 Reverse removal procedure for installati
73. ued ACCESSORY a DRIVE BELT RIGHT SIDE SPLASH SHIELD 80213704 Fig 39 Splash Shield 5 Remove crankshaft vibration damper Refer to removal procedure outlined in this section 6 Remove power steering air conditioning pulley nut Remove pulley CAUTION Remove old thread sealant from threads on pump 7 Remove pump shaft support bracket assembly Fig 40 Ne P UPPORT BRACKET STEERING PUMP 80a18d35 CRANKSHAFT FASTENERS Fig 40 Pump Shaft Support Bracket 8 Remove timing chain cover Refer to removal procedure outlined in this section 9 Remove oil pump drive gear attached to crank shaft Fig 41 10 Rotate crankshaft to align timing marks on injection pump sprocket camshaft sprocket and crankshaft sprocket with three dark plated links on timing chain Fig 42 CAUTION It could take up to 70 crankshaft revolu tions to align sprocket timing marks with the dark chain links If the chain is removed Fig 43 before NS GS OIL PUMP DRIVE GEAR N BA Re e DS i 80a18d30 Fig 41 Oil Pump Drive Gear INJECTION PUMP SPROCKET I ai E TIMING MARK 7 HIT j VACUUM 4 E PUMP A4 Q COP d f TIMING I O MARK a o i9 i CAMSHAFT i SPROCKET y Aj AC DU TIMING AC ei MARK CRANKSHAFT SPROCKET E Fig 42 Timing Marks the sprocket marks are in their proper locations you must first loosen the rocker arm supports before rotating c

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