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 Engine Mechanical System

General Information

Engine Mechanical System

 > D 2.5 CRDI >

SPECIAL TOOLS
Tool
Illustration Use
(Number and Name)
Torque angle adapter Installation of bolts & nuts needing an angular
(09221-4A000) method

Valve spring compressor Removal and installation of intake and

(09222-22100) exhaust valves

Compression gauge & Checking engine compression pressure

adapter
(09351-27000)
(09351-4A100)

Compression gauge adapter Checking engine compression pressure

clamp
(09351-4A110)

Valve stem seal installer Installation of valve stem oil seals

(09222-4A000)

Injector remover Removal of injectors

(09351-4A000)

Hi h R l f hi h k t
High pressure pump Removal of high pressure pump sprockert
sprocket remover
(09331-4A000)

Crank shaft rear oil seal Installation of crank shaft rear oil seals
installer
(09231-4A100)

Timing chain lower front Installation of timing chain lower front cover
cover oil seal installer oil seal
(09214-4A000)

Balance shaft drive gear Removal and installation of LH balance shaft

bearing (bush) drive gear bearing (bush)
installer/remover
(09231-4A000)

Water temperature sensor Removal and installation of water temperature

socket wrench sensor
(09221-25100)
 > D 2.5 CRDI >

TROUBLESHOOTING
Symptom Probable cause Remedy
Low compression Damaged cylinder head gasket Replace gasket
Worn or damaged piston rings Replace rings
Worn piston or cylinder Repair or replace piston and/or
cylinder block
Worn or damaged valve seat Repair or replace valve and/or seat
ring
Oil pressure drop Low engine oil level Check engine oil level
Faulty oil pressure switch Replace
Clogged oil filter Replace
Worn oil pump gears or cover Replace
Thin or diluted engine oil Change and find out cause
Oil relief valve stuck (open) Repair
Excessive bearing clearance Replace
High oil pressure Oil relief valve stuck (closed) Repair
Excessive engine vibration Loose engine mounting bolt Retighten
Loose transmission mounting bolt Retighten
Loose cross member bolt Retighten
Broken transmission mounting rubber Replace
Broken engine mounting rubber Replace
Noisy valves Thin or diluted engine oil (low oil Change
pressure)
Worn or damaged valve stem or Replace
valve guide
Connecting rod and/main beaing Insufficient oil supply Check engine oil level
noise
Thin or diluted engine oil Change and find out cause
Excessive bearing clearance Replace
Low coolant level Leakage of coolant
Damaged radiator core joint Replace
Corroded or cracked hoses (radiator Replace
hose, heater hose, etc)
Faulty radiator cap valve or setting of Replace
spring
Faulty thermostat Replace
Faulty engine coolant pump Replace
Clogged radiator Foreign material in coolant Replace
Abnormally high coolant temperature Faulty thermostat Replace
Faulty radiator cap Replace
Restricted of flow in cooling system Replace
Loose or missing drive belt Adjust or replace
 Faulty engine coolant pump Replace
Faulty temperature sensor wiring Repair or replace
Faulty electric fan Repair or replace
Faulty thermo-sensor on radiator Replace
Insufficient coolant Refill coolant
Abnormally low coolant temperature Faulty thermostat Replace
Faulty temperature sensor wiring Repair or replace
Leakage from oil cooling system Loose hose and pipe connection Retighten
Blocked or collapsed hose and pipe Replace
Inoperative electrical cooling fan Damaged, fuse Replace or repair
Exhaust gas leakage Loose connections Retighten
Broken pipe or muffler Repair or replace
Abnormal noise Detached baffle plate in muffler Replace
Broken rubber hanger Replace
Pipe or muffler contacting vehicle Correct
body
Broken pipe or muffler Repair or replace
 > D 2.5 CRDI >

CHECKING COMPRESSION PRESSURE

1. Before checking engine compression, check the engine oil level. Also check that the starter motor and battery are
all in normal operating condition.
2. Start the engine and wait until the engine coolant temperature reaches 80-95°C (176-205°F).
3. Turn "OFF" the engine and remove the aircleaner element.
4. Remove the Electric Control Unit(ECU) fuse.
5. Remove the injectors.
6. Crank the engine to remove any foreign material in the cylinders.
7. Insert the compression gauge (A) into the injector hole.
8. Crank the engine and read the gauge.

Standard value :
2942 kpa (30 kg/cm², 426 psi)

9. Repeat steps 7 to 8 for all cylinders, ensuring that the pressure difference for each of the cylinders is within the
specified limit.

Limit :
Max. 98.07 kpa (1.0 kg/cm², 14.22 psi) between cylinders

10. If a cylinder's compression or pressure differential is outside the specification, add a small amount of oil through
the injector hole, and repeat steps 6 to 8.
(1) If the addition of oil causes the compression to rise, it is likely that there may be wear between the piston ring
and cylinder wall.
(2) If compression remains the same, valve seizure, poor valve seating or a compression leak from the cylinder
head gasket are all possible causes.

ADJUSTING DRIVE BELT AND TENSIONER

1. Check that the belts are not damaged and are properly placed for the pulley grooves.

• When installing the V-ribbed belt, check that the V-ribs are properly aligned.
• If noise or slippage is detected, check the belt for wear, damage, or breakage on the pulley contact
surface, and check the pulley for scoring. Also check the amount that the belt is deflected.
2. Install the belt in the following order.

A. Install the belt in RH side of the auto-tensioner pulley.

Auto-tensioner pulley(A) → Crankshaft pulley(B) → Idler(C) → Air conditioner compressor pulley (D)→ Idler(E)
→ Water pump pulley(F)
B. Install the belt in LH side of the auto-tensioner pulley.
Auto-tensioner pulley(A) → Power steering pump pulley(I) → Alternator pulley(G)
C. Loosen the belt tension by turning the auto-tensioner clockwise (about 39°), and then install the belt on the idler
between the alternator pulley and the water pump pulley.

3. The tensioner mark should be between the " * " position.

If not, replace the belt.
 > D 2.5 CRDI >

SPECIFICATIONS
DESCRIPTION SPECIFICATION LIMIT
General
Type In-line, DOHC
Number of cylinders 4
Bore 91 mm (3.58 in)
Stroke 96 mm (3.78 in)
Total displacement 2497 cc (121.5 cu.in)
Compression ratio 17.7 : 1
Firing order 1-3-4-2
Valve timing
Intake valve
Opens (BTDC) 8°
Closes (ABDC) 38°
Exhaust valve
Opens (BBDC) 52°
Closes (ATDC) 8°
Cylinder head
Flatness of gasket surface 0.15 mm (0.0059 in)
Camshaft
Cam height (LH)
Intake 40.163 mm (1.5812 in)
Exhaust 40.043 mm (1.5765 in)
Cam height (RH)
Intake 39.782 mm (1.5662 in)
Exhaust 40.456 mm (1.5928 in)
Journal outer Diameter 29.964 ~ 29.980 mm (1.1797 ~ 1.1803 in)
End play 0.10 ~ 0.20 mm (0.0039 ~ 0.0079 in)
Valve
Valve length
Intake 110.55 mm (4.352 in)
Exhaust 110.55 mm (4.352 in)
Stem outer diameter
Intake 6.965 ~ 6.980 mm (0.2742 ~ 0.2748 in)
Exhaust 6.935 ~ 6.950 mm (0.2730 ~ 0.2736 in)
Face angle 45°
Thickness of valve head (margin)
Intake 1.8 ~ 2.0 mm (0.071 ~ 0.079 in)
Exhaust 1.8 ~ 2.0 mm (0.071 ~ 0.079 in)
Valve stem to valve guide clearance
Intake 0.020 ~ 0.050 mm (0.0008 ~ 0.0020 in) 0.1mm (0.0039in)
Exhaust 0.050 ~ 0.080 mm (0.0020 ~ 0.0031 in) 0.15mm (0.0059in)
Valve guide
Length
Intake 43.3 mm (1.705 in)
Exhaust 39.4 mm (1.551 in)
Valve seat
Width of seat contact
Intake 1.5 mm (0.059 in)
Exhaust 1.7 mm (0.067 in)
Seat angle
Intake 45°
Exhaust 45°
Valve spring
Free length 48.2 mm (1.898 in)
Load 258 ± 12 N/38 mm
(26.3 ± 1.2 kg/38 mm,
569 ± 26 lb/1.496 in)

505.5 ± 24 N/28.8 mm
(51.5 ± 2.4 kg /28.8 mm,
1114.4 ± 53 lb/1.134 in)
Cylinder block
Cylinder bore 91.000 ~ 91.030 mm (3.5827 ~ 3.5839 in)
Flatness of gasket surface 0.05 mm (0.0020 in)
Piston
Piston outer diameter 90.910 ~ 90.940 mm (3.5791 ~ 3.5803 in)
Piston to cylinder clearance 0.080 ~ 0.100 mm (0.0031 ~ 0.0039 in)
Ring groove width
No. 1 ring groove 2.378 ~ 2.398 mm (0.0936 ~ 0.0944 in)
No. 2 ring groove 2.04 ~ 2.06 mm (0.0803 ~ 0.0811 in)
Oil ring groove 3.03 ~ 3.05 mm (0.1193 ~ 0.1201 in)
Piston ring
Side clearance
No. 2 ring 0.05 ~ 0.09 mm (0.0020 ~ 0.0035 in)
Oil ring 0.04 ~ 0.08 mm (0.0016 ~ 0.0031 in)
End gap
No. 1 ring 0.25 ~ 0.40 mm (0.0098 ~ 0.0157 in)
No. 2 ring 0.50 ~ 0.70 mm (0.0197 ~ 0.0276 in)
Oil ring 0.20 ~ 0.40 mm (0.0079 ~ 0.0157 in)
Piston pin
Piston pin outer diameter 32.993 ~ 32.998 mm (1.2989 ~ 1.2991 in)
Piston pin hole inner diameter 33.014 ~ 33.019 mm (12.998 ~ 1.3000 in)
Piston pin hole clearance 0.016 ~ 0.026 mm (0.0006 ~ 0.0010 in)
Connecting rod small end hole inner diameter 33.020 ~ 33.033 mm (1.3000 ~ 1.3005 in)
Connecting rod small end hole clearance 0.022 ~ 0.040 mm (0.0009 ~ 0.0016 in)
Connecting rod
Connecting rod big end inner diameter 60.000 ~ 60.018 mm (2.3622 ~ 2.3629 in)
Connecting rod bearing oil clearance 0.024 ~ 0.042 mm (0.0009 ~ 0.0016 in) 0.1mm(0.0039in)
Crankshaft
Main journal outer diameter 66.982 ~ 67.000 mm (2.6371 ~ 2.6378 in)
Pin journal outer diameter 56.982 ~ 57.000 mm (2.2434 ~ 2.2441 in)
Main bearing oil clearance 0.030 ~ 0.054 mm (0.0012 ~ 0.0021 in) 0.1mm(0.0039in)
End play 0.05 ~ 0.25 mm (0.0020 ~ 0.0098 in)
Flywheel
Runout 0.13mm(0.0051in)
Oil pump
Side clearance
Inner rotor 0.040 ~ 0.085 mm (0.0016 ~ 0.0033 in)
Outer rotor 0.050 ~ 0.100 mm (0.0020 ~ 0.0039 in)
Body clearance 0.100 ~ 0.176 mm (0.0039 ~ 0.0069 in)
Relief valve opening pressure 784.5 ± 78.4 Kpa
Balance shaft
Front journal outer diameter 48.975 ~ 49.000 mm (1.9281 ~ 1.9291 in)
Rear journal outer diameter 47.965 ~ 47.990 mm (1.8884 ~ 1.8894 in)
Front bush inner diameter 49.050 ~ 49.080 mm (1.9311 ~ 1.9323 in)
Rear bush inner diameter 48.050 ~ 48.080 mm (1.8917 ~ 1.8929 in)
Fornt bush oil clearance 0.050 ~ 0.105 mm (0.0020 ~ 0.0041 in)
Rear bush oil clearance 0.060 ~ 0.115 mm (0.0024 ~ 0.0045 in)
Engine oil
Oil quantity (Total) 9.0L (9.51 US qt, 7.91 lmp qt)
Oil quantity (Oil pan) 7.4L (7.82 US qt, 6.50 lmp qt)
Oil quantity (Drain and refill including oil filter) 8.2L(8.66 US qt, 7.21 lmp qt)
Oil quality ABOVE API CF-4 (VGT:CH-4) or ACEA B4
Cooling method
Cooling system Forced circulation with cooling fan
Coolant quantity 10L
Thermostat
Type Wax pellet type
Opening temperature 82°C (180°F)
Closing temperature 77°C (171°F)
Pull opening temperature 95°C (203°F)
Radiator cap
Main valve opening pressure 107.9±14.7 Kpa
Main valve closing pressure
Vaccum valve opening pressure
Water temperature sensor
Type Thermister type
Resistance
20°C (68°F) 2.45 ± 0.14 kΩ
80°C (176°F) 0.3222 kΩ

TIGHTENING TORQUE
* Bolt size = Diameter x Length
Tightening torque
ITEM Quantity
N.m kgf.m lb-ft
Main bearing cap bolt 10 127.5 ~ 137.3 13 ~ 14 94.0 ~ 101.3
58.8 → Loosen → 6.0 → Loosen → 43.4 → Loosen →
Connecting rod cap nut 8 (32.4~36.3) + (3.3~3.7) + (23.9~26.8) +
(60~64°) (60~64°) (60~64°)
Oil jet bolt 4 29.4 ~ 34.3 3.0 ~ 3.5 21.7 ~ 25.3
Crank shaft pulley bolt 1 274.6 ~ 294.2 28 ~ 30 202.5 ~ 217.0
Rear oil seal case bolt 5 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Rear plate bolt 2 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Flywheel bolt 8 127.5 ~ 137.3 13 ~ 14 94.0 ~ 101.3
Water pump bolt (8 x 30) 5 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Water pump bolt (8 x 45) 2 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Oil cooler fixing nut 4 17.7 ~ 24.5 1.8 ~ 2.5 13.0 ~ 18.1
Oil cooler cover bolt (8 x 35 ) 8 19.6 ~ 25.5 2.0 ~ 2.6 14.5 ~ 18.8
Oil cooler cover bolt (8 x 60) 3 19.6 ~ 25.5 2.0 ~ 2.6 14.5 ~ 18.8
Oil pump bolt (8 x 22) 2 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Oil pump bolt (10 x 35) 1 42.2 ~ 53.9 4.3 ~ 5.5 31.1 ~ 39.8
Oil pump bolt (10 x 60) 1 42.2 ~ 53.9 4.3 ~ 5.5 31.1 ~ 39.8
Oil screen bolt 2 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Oil feed pipe bolt 3 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Oil filter assembly 1 21.6 ~ 24.5 2.2 ~ 2.5 15.9 ~ 18.1
Oil pan bolt 2 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil level gauge bolt 1 11.8 ~ 14.7 1.2 ~ 1.5 8.7 ~ 10.8
Bed plate bolt (6 x 18) 3 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Bed plate bolt (6 x 30) 1 3 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Bed plate bolt (8 x 45) 8 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Bell housing cover bolt 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pressure switch 1 14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~ 15.9
Cylinder head cover bolt 1 6 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Camshaft cap bolt 20 13.7 ~ 14.7 1.4 ~ 1.6 10.1 ~ 10.8
Cylinder head bolt 18 49.0+120°+90° 5.0 + 120°+90° 36.2+120°+90°
TDC sensor bolt 1 6.9-10.8 0.7-1.1 5.1-8.0
Water temperature sensor 1 29.4 ~ 39.2 3.0 ~ 4.0 21.7 ~ 28.9
Glow plug 4 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
Glow plug plate nut 4 0.8 ~ 1.5 0.08 ~ 0.15 0.6 ~ 1.1
Engine hanger bolt 4 18.6 ~ 28.4 1.9 ~ 2.9 13.7 ~ 21.0
Thermostat housing bolt 2 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Exhaust manifold lock nut 8 16.7 ~ 25.5 1.7 ~ 2.6 12.3 ~ 18.8
Exhaust manifold heat protector bolt 3 14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~ 15.9
Turbo charger nut 3 49.0 ~ 68.6 5.0 ~ 7.0 36.2 ~ 50.6
Turbo charger fitting nut 4 26.5 ~ 31.4 2.7 ~ 3.2 19.5 ~ 23.1
Turbo charger oil return pipe bolt 2 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Turbo charger oil inlet pipe bolt 2 13.7 ~ 18.6 1.4 ~ 1.9 10.1 ~ 13.7
Turbo charger water inlet pipe bolt 2 34.3 ~ 49.0 3.5 ~ 5.0 25.3 ~ 36.2
Turbo charger heat protector bolt 3 14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~ 15.9
Intake manifold bolt (8 x 112) 4 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
Intake manifold bolt (8 x 32) 2 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
Intake manifold nut 4 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
EGR valve bolt 2 16.7 ~ 25.5 1.7 ~ 2.6 12.3 ~ 18.8
EGR pipe nut 4 16.7 ~ 25.5 1.7 ~ 2.6 12.3 ~ 18.8
Timing chain lower under cover bolt (6 x 14) 4 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain lower under cover bolt (8 x 22) 1 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Timing chain lower under cover bolt (8 x 30) 3 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Timing chain lower under cover bolt (8 x 40) 1 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
LH balance shaft driven gear bolt 1 33.3 ~ 39.2 3.4 ~ 4.0 24.6 ~ 28.9
LH balance shaft sprocket nut 1 49.0 ~ 58.8 5.0 ~ 6.0 36.2 ~ 43.4
RH balance shaft sprocket bolt 1 33.3 ~ 39.2 3.4 ~ 4.0 24.6 ~ 28.9
Timing chain guide "A" bolt (upper) 1 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain guide "A" bolt (lower) 1 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Timing chain lever "A" bolt 1 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Timing chain auto tensioner "A" bolt 2 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Timing chain guide "B" (1) bolt 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain guide "B" (2) bolt 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain auto tensioner "B" bolt 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain lower front cover bolt (8 x 22) 1 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Timing chain lower front cover bolt (8 x 40) 1 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Timing chain lower front cover bolt (8 x 50) 6 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Timing chain lower front cover bolt (8 x 70) 6 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Timing chain lower front cover bolt (8 x 80) 4 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Timing chain upper front cover bolt (6 x 14) 4 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain upper front cover bolt (6 x 22) 9 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain upper front cover bolt (8 x 22) 1 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Timing chain upper front cover bolt (8 x 40) 1 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Timing chain upper under cover nut 1 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain guide "C" (1) bolt 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain guide "C" (2) bolt 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain lever "C" bolt 1 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Timing chain auto tensioner "C" bolt 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
High pressure pump sprocket nut 1 64.7 ~ 74.5 6.6 ~ 7.6 47.7 ~ 55.0
Camshaft sprocket bolt 2 93.2 ~ 117.7 9.5 ~ 12 68.7 ~ 86.8
Timing chain upper front cover bolt 9 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
High pressure pump bracket bolt (8 x 35) 2 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
High pressure pump bracket bolt (8 x 38) 2 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
High pressure pump fixing nut 3 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
Common rail fixing bolt 3 14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~ 15.9
Injector clamp bolt 4 27.5 ~ 33.3 2.8 ~ 3.4 20.3 ~ 24.6
High pressure pipe (pump to rail) 1 24.5 ~ 28.4 2.5 ~ 2.9 18.1 ~ 21.0
High pressure pipe (injector to rail) 4 24.5 ~ 28.4 2.5 ~ 2.9 18.1 ~ 21.0
Water pump pulley nut 4 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Alternator bracket bolt (8 x 60) 2 18.6 ~ 27.5 1.9 ~ 2.8 13.7 ~ 20.3
Alternator bracket bolt (8 x 35) 2 18.6 ~ 27.5 1.9 ~ 2.8 13.7 ~ 20.3
Alternator fixing bolt nut (upper) 1 18.6 ~ 27.5 1.9 ~ 2.8 13.7 ~ 20.3
Alternator fixing bolt nut (lower) 1 18.6 ~ 27.5 1.9 ~ 2.8 13.7 ~ 20.3
Power steering pump bracket bolt (8 x 30) 1 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Power steering pump bracket bolt (8 x 40) 3 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Power steering pump bracket bolt (8 x 75) 2 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Power steering pump fixing bolt (upper) 1 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Power steering pump fixing bolt (lower) 1 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Air conditioner compressor fixing bolt 4 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Drive belt pulley fixing bolt 3 47.1 ~ 53.0 4.8 ~ 5.4 34.7 ~ 39.1
Drive belt auto tensioner fixing bolt 1 47.1 ~ 53.0 4.8 ~ 5.4 34.7 ~ 39.1
Starter fixing bolt 2 26.5 ~ 33.3 2.7 ~ 3.4 14.5 ~ 24.6
Engine support bracket bolt 2 47.1 ~ 51.0 4.8 ~ 5.2 34.7 ~ 37.6
 Engine Mechanical System

Timing System - Timing Chain

Engine Mechanical System

> D 2.5 CRDI >

COMPONENTS
 > D 2.5 CRDI >

REPLACEMENT
TIMING CHAIN LOWER FRONT COVER OIL SEAL
1. With the timing chain lower front cover oil seal installed, install the oil seal using the special tool (09214-4A000).

Apply engine fluid to the circumference of oil seal lip.

DISASSEMBLY
TIMING CHAIN "C"
1. Rotate the crankshaft pulley to align the timing mark(A) with TDC(B), in which No.1 piston locates at the top dead
center of compression stroke.

2. Remove the timing chain upper front cover(A).

3. Remove the cylinder head cover.
4. Holding the slot of the camshaft with the spanner, loosen the bolts for the high-pressure pump sprocket and
camshaft sprocket.

5. Insert the SST(09311-4A00) into timing chain upper cover.

And then remove the high pressure pump and sprocket.

Loosen the high pressure pump fixing bolts first working.

6. Remove the timing chain auto-tensioner "C"(A).

Before removing auto-tensioner "C", install a set pin(B) (Ø2.5mm steel wire) after compressing the tensioner
so that inner parts are not missing during disassembly.

7. Remove the timing chain lever "C"(A).

8. Remove the timing chain guide "C(1)(A), C(2)(B)".

9. Remove the LH and RH camshaft sprocket bolts.
10. Remove the timing chain "C"(A) with the camshaft sprocket.

11. Remove the timing chain upper under cover(A).

TIMING CHAIN "B"

1. Remove the timing chain "C".
2. Remove the crankshaft pulley(B).
3. Remove the oil pan.
4. Remove the timing chain lower front cover(A).

5. To prevent the rotation of RH balance shaft(A), remove the plug(B) at the side of cylinder block and insert the
screwdriver(C) (or bolt) with an 8 mm(0.32in) diameter into the plughole more than 60 mm (2.4in).

6. Loosen the RH balance shaft sprocket bolt(A).

7. Remove the timing chain auto-tensioner "B"(A).

Before removing auto-tensioner "B", install a set pin (Ø2.5mm wire) after compressing the tensioner.

8. Remove the timing chain guide "B(1)(A), B(2)(B)".

9. Remove the RH balance shaft sprocket bolt.

10. Remove the timing chain "B"(A) with the RH balance shaft sprocket.

TIMING CHAIN "A"

1. Remove the timing chain "C" and "B".
2. Loosen the high-pressure pump sprocket.
3. Remove the timing chain auto-tensioner "A"(A).

Before removing auto-tensioner "A", install a set pin (Ø2.5mm wire) after compressing the tensioner.

4. Remove the timing chain lever "A"(A).

5. Remove the timing chain guide "A"(A).

6. Remove the timing chain "A"(B) with the high-pressure pump sprocket(A).

Remove thoroughly sealant and oil etc left at the sealing surface after remove the chain cover and oil pan. (If
any impurities are left at the sealing face, oil may leak after reassembly even with the sealant application.)
 REASSEMBLY
TIMING CHAIN "A"
1. Check the worn of timing chain, lever, guide and sprocket and replace them if necessary.
2. Choose proper high pressure pump sprocket after measuring protrusion of sprocket
A. Assemble a high-pressure pump sprocket (Grade A) tentatively to high-pressure pump.
B. Install a gauge to the cylinder block as shown illustration. And then turn the high pressure pump sprocket once
by using a wrench.

C. Choose proper sprocket grade according to average of maximum and minimum value of gauge.

Grade Color Protrusion (mm(in))

A Blue 34.2-35.0 (1.3465-1.3780)
B White 33.4-34.2 (1.3150-1.3465)
C Red 35.0-35.8 (1.3780-1.4094)

3. Install the crankshaft sprocket as the timing mark of crankshaft sprocket aligns with the timing mark(A) of lower
under cover(B), at which No.1 piston locates at the top dead center of compression stroke.
 In installing crankshaft sprocket, apply oil to the O ring inside the sprocket.

4. Align the timing mark of LH balance sprocket(A) with the timing mark of timing chain lower under cover(B).

5. Check the LH balance shaft(A) whether it is located at the right position. To prevent the rotation of balance shaft,
remove plug(B) at the side of cylinderblock. Insert screwdriver(C) (or bolt) with an 8 mm (0.32in) diameter into the
plughole and check whether it slides more than 60 mm(2.4in).
 When the screwdriver (or bolt) depth is about 25-30mm(1-1.2in), rotate LH balance shaft sprocket 1 revolution.
And insert the screwdriver (or bolt) again to check whether it slides more than 60mm(2.4in).

6. Assemble the upper bolt of timing chain guide "A"(A) tentatively.

7. Align the timing marks of sprocket and chain when high-pressure pump sprocket is not installed to pump.
8. Using the chain connected to the high-pressure pump sprocket, install as the timing marks of LH balance shaft
sprocket(A) and crankshaft sprocket align with each other.
9. Assemble the high-pressure pump sprocket to the high-pressure pump tentatively.
10. Install the other bolt of the timing chain guide "A" at the lower side and tighten it.

Tightening torque :
Upper bolt(A) :
9.8-11.8 N.m(1.0-1.2 kgf.m, 7.2-8.7 lb-ft)
Lower bolt(B) :
19.6-26.5N.m(2.0-2.7 kgf.m, 14.5-19.5 lb-ft)
11. Install the timing chain lever "A"(A).

Tightening torque :
19.6-26.5 N.m(2.0-2.7 kgf.m, 14.5-19.5 lb-ft)

12. Install the timing chain auto-tensioner "A"(A), and remove a set pin(B) from the auto-tensioner.

Tightening torque :
19.6-26.5 N.m(2.0-2.7 kgf.m, 14.5-19.5 lb-ft)
 After assembling timing chain, check whether chain is assembled within the rail at both sides.

13. Remove the screwdriver (or bolt) from the plughole and install the plug(A).

Tightening torque :
14.7-21.6 N.m(1.5-2.2 kgf.m, 10.8-15.9 lb-ft)

TIMING CHAIN "B"

1. Check the worn of timing chain, lever, guide and sprocket and replace them if necessary.
2. Install the timing chain "A".
3. Check the RH balance shaft(A) whether it is located at the right position. To prevent the rotation of balance shaft,
insertthe screwdriver(C) (or bolt) intothe plughole(B) at the side of cylinder block and check whether it slides more
than 60 mm(2.4in).
4. Install the space washer(A) from RH balance shaft.

5. Using the chain connected to RH balance shaft sprocket, install as the timing marks(A) of crankshaft sprocket and
oil pump sprocket align with each other.

6. Assemble the RH balance shaft sprocket to the balance shaft tentatively.

7. Install the timing chain guide "B(1)(A), B(2)(B)".

Tightening torque :
9.8-11.8 N.m(1.0-1.2 kgf.m, 7.2-8.7 lb-ft)
8. Install the timing chain auto-tensioner "B"(A), and remove the set pin(B) from the auto-tensioner.

Tightening torque :
9.8-11.8 N.m(1.0-1.2 kgf.m, 7.2-8.7 lb-ft)

9. Assemble the RH balance shaft sprocket bolt(A).

Tightening torque :
33.3-39.2 N.m(3.4-4.0 kgf.m, 24.6-28.9 lb-ft)
10. Remove the screwdriver (or bolt) from the plughole(A) and install the plug.

Tightening torque :
14.7-21.6 N.m(1.5-2.2 kgf.m, 10.8-15.9 lb-ft)

11. Apply the sealant(A) at the timing chain lower front cover.

Sealant type : Lotite #5902

Bead width : 2-4 mm(0.08-0.16 in)
12. Install the timing chain lower front cover(A).
Tightening torque
Bolt Size Quantity
N-m (kg-m, lb-ft)
A 8 x 80 4 EA 9.8-11.8 (1.0-1.2, 14.5-19.5)
B 8 x 70 1 EA 19.6-26.5 (2.0-2.7, 14.5-19.5)
C 8 x 50 3 EA 19.6-26.5 (2.0-2.7, 14.5-19.5)
D 8 x 40 1 EA 19.6-26.5 (2.0-2.7, 14.5-19.5)
E 8 x 22 1 EA 19.6-26.5 (2.0-2.7, 14.5-19.5)

* Bolt Size = Diameter x Length

13. Install the oil pan.

Then apply the sealant additionally to prevent the oil leak to the overlapping part (T-joint: 4 points right and
left ofthe engine), where bed plate, timing chain lower under cover, timing chain lower front cover and oil pan
overlap.

TIMING CHAIN "C"

1. Check the worn of the timing chain, lever, guide and sprocket and replace them if necessary.
2. Install the timing chain "A" and "B".
3. Apply the sealant(A) at the timing chain upper under cover.

Sealant type : Lotite #5902

Bead width : 2-4 mm (0.08-0.16 in)

Then apply the sealant additionally to prevent the oil leak to the overlapping part (T-joint : 2 points right and
left of the engine), where cylinder head, timing chain cover plate and timing chain upper under cover overlap.

4. Install the timing chain upper under cover(A).

Tightening torque
Bolt Size Quantity
 Bolt Size Quantity
N-m (kg-m, lb-ft)
A 6 x 14 4 EA 9.8-11.8 (1.0-1.2, 14.5-19.5)
B 6 x 22 9 EA 19.6-26.5 (2.0-2.7, 14.5-19.5)
C 8 x 22 1 EA 19.6-26.5 (2.0-2.7, 14.5-19.5)
D 8 x 40 1 EA 19.6-26.5 (2.0-2.7, 14.5-19.5)
E Nut 1 EA 9.8-11.8 (1.0-1.2, 7.2-8.7)

* Bolt Size = Diameter x Length

5. Assemble the LH camshaft sprocket(A) tentatively, and align the timing mark with that of timing chain upper under
cover.
6. Align the RH camshaft dowel pin(A) with the timing mark(B) of the timing chain upper under cover.

7. Align the timing marks of sprocket and chain when RH camshaft sprocket is not installed to the camshaft.
8. Using the chain connected to the RH camshaft sprocket, install as the timing marks of high-pressure pump
sprocket and LH camshaft sprocket align with each other.

9. Assemble the RH camshaft sprocket to the RH camshaft tentatively.

10. Install the timing chain guide "C(1)(A), C(2)(B)".
 Tightening torque :
9.8-11.8 N.m(1.0-1.2 kgf.m, 7.2-8.7 lb-ft)

11. Install the timing chain lever "C"(A).

Tightening torque :
19.6-26.5 N.m(2.0-2.7 kgf.m, 14.5-19.5 lb-ft)

12. Install the timing chain auto-tensioner "C"(A), and remove the set pin(B) from the auto-tensioner.

Tightening torque :
9.8-11.8 N.m(1.0-1.2 kgf.m, 7.2-8.7 lb-ft)
13. Assemble the high-pressure pump sprocket bolt.

Tightening torque :
64.7-74.5 N.m (6.6-7.6 kgf.m, 47.7-55.0 lb-ft)

14. Assemble camshaft sprocket bolt.

Tightening torque :
93.2-117.7 N.m (9.5-12 kgf.m, 68.7-86.8 lb-ft)

Then assemble the damper pulley to the crankshaft tentatively and align the timing mark of the damper pulley
to that of chain cover. And check whether timing mark of the camshaft positions at the right place finally.

15. Apply the sealant(A) at the timing chain upper front cover.

Sealant type : Lotite #5902

Bead width : 2-4 mm (0.08-0.16 in)

16. Install the timing chain upper front cover(A).

Tightening torque :
19.6-26.5 N.m(2.0-2.7 kgf.m, 14.5-19.5 lb-ft)
 Engine Mechanical System

Cylinder Head Assembly - Cylinder Head

Engine Mechanical System

> D 2.5 CRDI >

COMPONENTS
 > D 2.5 CRDI >

REMOVAL
1. Remove the timing chain "C"
2. Remove the high pressure pipe(A) and the injector(B).(See "FL" group)

• Never perform any work on injection system with engine running or within 30 seconds after stopping the
engine.
• Always pay attention to safety precautions.

When remove the injectors, set the special tool (09351-4A000) to where the injector holder removed, install a
slide hammer on the special tool, using the hammer, tap upward to remove the injector.

3. Remove the vacuum pump(A).

4. Remove the cylinder head cover(A).

5. Remove the exhaust manifold.

6. emove the intake manifold.
7. Remove the delivery pipe(A).

8. Remove the water temperature sensor(A) and TDC sensor(B).

9. Remove the glow plug(A).

INSTALLATION
1. Install the glow plug (A).

Tightening torque :
Glow plug :
15-20 N.m (1.5-2.0 kgf.m, 11-15 lb-ft)
Glow plug plate nut :
0.8-1.5 N.m (8-15 kgf.m, 0.6-1.1 lb-ft)
2. Install the TDC sensor (B).

Tightening torque :
6.9-10.8 N.m (0.7-1.1 kgf.m, 5.1-8.0 lb-ft)

3. Install the water temperature sensor (A).

Tightening torque :
29.4-39.2 N.m (3-4 kgf.m, 21.7-28.9 lb-ft)

4. Install the delivery pipe (A).

Tightening torque :
14.7-21.6 N.m (1.5-2.2 kgf.m, 6.8-15.9 lb-ft)
5. Install the exhaust manifold and intake manifold.
6. Install the vacuum pump (A).

Tightening torque :
9.8-11.8 N.m (1.0-1.2 kgf.m, 7.2-8.7 lb-ft)

7. Install the cylinder head cover (A).

Tightening torque :
9.8-11.8 N.m (1.0-1.2 kgf.m, 7.2-8.7 lb-ft)
8. Install the injector and high pressure pipe.
9. Install the timing chain "C".

DISASSEMBLY
1. Remove the cam shaft sprocket.
2. Remove the cam shaft bearing cap(A).

3. Remove the cam shaft(A).

4. Remove the cam shaft carrier(A).

5. Remove the cam follow(A).

6. Remove the HLA(A).

7. Remove the cylinder head bolts(A).

8. Remove the cylinder block.
9. Using the special tool(09222-22100), remove the valve.

10. Remove the valve stem seal(A).

INSPECTION
CAMSHAFT

Do not rotate the camshaft during inspection.

1. Put the cam shaft and the camshaft bearing caps(A) on the cylinder head, and then tighten the bolts to the
specified torque with the following sequence below.

Specified torque
13.7 ~ 15.7 N.m(1.4 ~ 1.6 kgf.m,10.1~11.6 lb-ft)

2. Check the camshaft journals for wear. If the journals are badly worn, replace the camshaft.

End play: 0.10 - 0.20 mm (0.0039 - 0.0079 in)

3. Clean the camshaft bearing surfaces in the cylinder head then set the camshaft back in place.
4. Install the camshaft bearing caps and tighten the bolts to the specified torque.
5. Remove the camshaft bearing caps, and then measure the widest portion of the plastic gage on each journal.
6. Check the cam lobes for damage. If the lobe is damaged or worn excessively, replace the camshaft.

Cam height (LH) :

Intake : 40.163 mm (1.5812 in)
Exhaust : 40.043 mm (1.5765 in)
Cam height (RH) :
Intake : 39.782 mm (1.5662 in)
Exhaust : 40.456 mm (1.5928 in)

CAM FOLLOW (ROCKER ARM)

1. Check rotation of the roller. If they do not rotate smoothly or are loose, replace them.
2. Check the roller surface. Replace if there is any dent, damage or evidence of seizure.
3. Check the valve contact surface for possible damage or evidence of seizure. Replace if necessary.
VALVE AND VALVE GUIDE
1. Inspect each valve for following. Replace of resurface if necessary.
A. Damage or bent stem.
B. Roughness or damage to face.
C. Roughness or damage to face.
2. Check valve head margin thickness(A). Replace if necessary.

Margin thickness :
Intake, Exhaust: 1.8-2.0 mm (0.071-0.079 in)

3. Measure valve length.

Valve length :
Intake, Exhaust : 110.55 mm (4.352 in)

4. Measure valve stem diameter.

Valve stem diameter :

Intake : 6.965-6.980 mm (0.2742-0.2748 in)
Exhaust : 6.935-6.950 mm (0.2730-0.2736 in)
5. Measure valve guide inner diameter.

Inner diameter
Intake, Exhaust :
7.000-7.015 mm (0.2756-0.2762 in)

6. Measure valve stem to guide clearance(C) by subtract outer diameter of valve stem(B) from inner diameter of
corresponding valve guide(A).

Clearance :
Intake : 0.020-0.050 mm (0.0008-0.0020 in)
Exhaust : 0.050-0.080 mm (0.0020-0.0031 in)
7. If clearance exceeds maximum, replace valve and/or cylinder head

VALVE SEAT
1. Inspect contact surface of valve seat and valve face for following.
A. Roughness
B. Damage
2. If necessary, resurface valve seat with a 45°(Intake), 45°(Exhaust) valve seat cutter and/or resurface valve face.

3. Apply a thin coat of Prussian blue to valve face.

4. Check valve seating by rotating valve against seat.
A. If blue does not appear 360° around valve face, replace valve.
B. If blue does not appear 360° around valve seat, resurface valve seat.

5. Check seat contact width (A).

Seat contact width :

Intake: 1.3-1.7 mm (0.0512-0.0669 in)
Exhaust: 1.5-1.9 mm (0.0591-0.0748 in)
6. Check that valve seating position is at center of valve face.
A. If seating position is too high (low), correct valve seat with a 45° (Intake), 45° (Exhaust) cutter.

7. Seat the valve to the valve seat with a lapping compound.

VALVE SPRING
1. Inspect each valve spring for cracks or damage.
2. Check free length and out-of-square. Replace if necessary.

Free length: 48.2 mm (1.898 in)

Out-of-square: Below 1.5°

3. Check spring pressure, and replace it if necessary.

 Spring pressure :
258 ± 12 N / 38 mm
(26.3±1.2 kg/38 mm, 569 ± 26 lb / 1.496 in)
505.5 ± 24 N/ 28.8 mm
(51.5±2.4 kg/28.8 mm, 1114.4 ± 53 lb / 1.134 in)

CYLINDER HEAD
1. Inspect the cylinder head for damage, cracks and leakage of water and oil. Replace the cylinder head if necessary.
2. Measure cylinder head distortion in seven directions shown in figure.

Distortion : 0.15 mm (0.0059 in)

3. Measure manifold contact surface distortion in four directions shown in figure.

4. If distortion exceeds specification, grind surface or replace cylinder head.

REASSEMBLY
1. Install a new valve stem seal to the valve guide using the special tool (09222-4A000).

• Do not reuse the used valve stem seal.

• When installing the valve stem seal, using the special tool is needed, not to leak the fluid.

2. Using the special tool (09222-4A000), remove the valve.

3. Select the cylinder head gasket.

(1) Measure the piston protrusion (8 places) from the upper face of the cylinder block and calculate the average of
the 8 piston protrusion.
(2) Select the gasket from the grade A to C in the table below using the average of the 8 piston protrusion.Even if
only 1 point is over than the limit of piston protrusion at each grade, 1 grade upper gasket than specified below.
4. Install the cylinder head assembly with the cylinder head gasket.

Tightening torque :
49.0 N.m (5.0 kgf.m, 36.2 lb-ft) + 120° + 90°

Always use new cylinder head bolts.

5. Install the HLA(A) to the cylinder head.

(1) Until installing HLA shall be held upright so that diesel oil in HLA should not spill and assured that dust does
not adhere to HLA.
(2) HLA shall be inserted tenderly to the cylinder head not to spill diesel oil from HLA. In case of spilling, air bent
shall be done in accordance with the air bent procedure.

6. Install the cam follow(A) (rocker arm) on the HLA and valve.
7. Install the camshaft carrier (A) on the cylinder head.

8. Install the camshaft (A) on the camshaft carrier.

In assembling camshaft cap, all pistons to be in the middle position between TDC and BDC not to interfere
 with valves.

9. Install the camshaft caps (A).

Tightening torque :
13.7-15.7 N.m (1.4-1.6 kgf.m, 10.1-11.6 lb-ft)

10. Install the camshaft sprocket.

Tightening torque :
93.2-117.7 N.m (9.5-12.0 kgf.m, 68.7-86.8 lb-ft)
 Engine Mechanical System

Engine & Transaxle Assembly

Engine Mechanical System

> D 2.5 CRDI >

COMPONENTS
 > D 2.5 CRDI >

REMOVAL (A/T EQUIPPED VEHICLE)

1. Remove the engine hood.
2. Remove the engine cover(A) and seal board(B).

3. Drain the engine coolant after removing drain plug(A).

Remove the radiator cap to speed draing.

4. Remove the transmission oil drain plug(A).

5. Remove the battery and battery tray(A).

6. Remove the inter cooler hose and pipe on the intake manifold side(A).

7. Disconnect the air cleaner hose(A).

8. Disconnect the engine coolant reservoir tank hose and the heater hose.
9. Remove the inter cooler hose on the turbo charger side.
10. Loosen the drive belt tension by turning auto-tensioner with spanner, and then remove the drive belt.
11. Disconnect the radiator upper hose(A) and lower hose.
12. Remove the radiator cowl upper cover(B).

13. Remove the cooling fan(C).

14. Remove the radiator cowl lower cover.
15. Remove the fixing bolt of air-con condenser and ATF oil cooler bracket from the radiator assembly.
16. Disconnect the ATF oil hoses.
17. Remove the radiator assembly from engine room, after remove the radiator assembly bracket fixing nut.
18. Drain the power steering oil.
19. Disconnect the power steering pump hose and pipe.
20. Disconnect the alternator "B" terminal(A) and connector(B).
21. Remove the vacuum hose(C).

22. Disconnect the earth terminal and the glow plug connector(D).
23. Disconnect the water temperature sensor connector.
24. Disconnect the high pressure connector(B).
25. Disconnect the TDC sendor connector(C).
26. Disconnect the inject connector(D).
27. Disconnect the map sensor connector(E).
28. Disconnect the thorought flat funtion valve connector(F).
29. Remove the EGR cooler water hose(G).

30. Remove the fuel hose from the high pressure pump.
31. Disconnect the earth terminal from the cylinder block.
32. Remove the transmission oil level gauge pipe.
33. Remove the rear propeller shaft(A).

34. Remove the front propeller shaft(A).

35. Remove the front exhaust pipe(A) and muffler(B).

36. Remove the shift cable from the transmission.

37. Disconnect the connectors from the transmission.(See TR group)
38. Remove the transmission oil pipes.
39. Remove the drive plate-to-torque converter fixing bolts (6EA), after remove the bell housing cover. Rotate crank
shaft pulley to gain access to all bolts.
40. Remove the starter.
41. Remove the transmission housing fixing bolts.
42. Remove the transmission mounting(A) and the cross member(B) after support the transmission by using a jack.

43. Remove the transmission from the vehicle.

44. Remove the engine mounting.
45. Remove the engine assembly from engine room, by using a engine crane.

INSTALLATION (A/T EQUIPPED VEHICLE)

1. Install the engine assembly to engine room, by using a engine crane.
2. Install the engine mounting(A).

Tightening torque
68.6-88.3 N.m ( 7.0- 9.0 kgf.m, 50.6-65.1 lb-ft)
3. Install the transmission to the vehicle by using a jack.
4. Install the transmission mounting(A) and the cross member(B).

Tightening torque
Transmission to Mounting:
39.2-56.9 N.m( 4.0- 5.8 kgf.m, 28.9-42.0 lb-ft)
Mounting to Cross member :
19.6-28.4 N.m( 2.0-2.9 kgf.m, 14.5-21.0 lb-ft)
Cross member to Frame :

5. Install the transmission housing fixing bolts.

6. Install the starter.

Tightening torque
26.5-33.3 N.m (2.7-3.4 kgf.m, 19.5-24.6 lb-ft)

7. Install the drive plate-to-torque converter fixing bolts (6EA). Rotate crank shaft pulley to gain access to all bolts.
8. Install the bell housing cover.

Tightening torque
9.8-11.8 N.m(1.0-1.2 kgf.m, 7.2-8.7 lb-ft)

9. Install the transmission oil pipe.

10. Reconnect the connectors (8EA) to the transmission.
11. Install the shift cable to the transmission.
12. Install the front exhaust pipe and muffler.

Tightening torque
42.2-60.8 N.m(4.3-6.2 kgf.m, 31.1-44.8 lb-ft)

13. Install the front propeller shaft.

 Tightening torque
Part time 4WD :
26.5·29.4 N.m (2.6-3.0 kgf.m, 18.8-21.7 lb-ft)
Full time 4WD :
49.0-58.8 N.m (5.0-6.0 kgf.m, 36.2-43.4 lb-ft)

14. Install the rear propeller shaft.

Tightening torque
49.0-58.8 N.m (5.0-6.0 kgf.m, 36.2-43.4 lb-ft)

15. Install the transmission oil level gauge pipe.

16. Install the earth terminal to the cylinder block.
17. Reconnect the vacuum hoses to the EGR valve and intake manifold.
18. Reconnect the fuel hose to the high pressure pump.
19. Reconnect the injector, TDC sensor, water temperature sensor and starter connector.
20. Install the air conditioner compressor to the cylinder block.

Tightening torque
19.6-24.5 N.m (2.0-2.5 kgf.m, 14.5-18.1 lb-ft)

21. To install all of parts, follow the removal procedures in the reverse order.
22. Refill the transmission oil and the power steering oil and then check for leaks.
23. Refill the engine coolant and then check for leaks.
 Engine Mechanical System

Cylinder Block - Cylinder Block

Engine Mechanical System

> D 2.5 CRDI >

COMPONENTS
 > D 2.5 CRDI >

REMOVAL
1. Remove the engine and transaxle assembly from the vehicle.
2. Remove the fly wheel or drive plate.
3. Remove the timing chain
4. Remove the intake manifold and exhaust manifold.
5. Remove the cylinder head assembly.
6. Remove the oil lever gage assembly.
7. Remove the power steering pump.
8. Remove the power steering pump bracket (A).

9. Remove the thermostat housing (A) and heater pipe (B).

10. Remove the oil cooler.
11. Remove the water pump.
12. Remover the timing lower under cover (A).

13. Remove the fuel pump (A).

14. Remove the fuel pump bracket (A).

15. Remove the air compressor. (See HA group - compressor)
16. Remove the oil screen and oil supply pipe.
17. Remove the bet plate (A).

18. Remove the oil pump.

19. Remove the balance shaft (A) from cylinder block.
20. Remove the rear oil seal case (A).

INSTALLATION
1. Install the rear oil seal (A).

Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
2. Temporarily install a new rear oil seal to the oil seal case and install the special tool (09231-4A100) through the
rear oil seal case.

Apply engine fluid to the circumference of oil seal lip.

3. Apply engine fluid to the balance shaft journal and balance shaft bearing (bush).
4. Install the balance shaft(A) into cylinder block.

5. Install the oil pump.

6. Apply sealant on the timing chain lower under cover after clean foreign material. And Install the bet plate (A).
Tightening torque
Bolt Size Quantity
N.m (kgf.m, lb-ft)
A 6 x 14 4 EA 9.8-11.8 (1.0-1.2, 7.2-8.7)
B 8 x 22 1 EA 19.6-26.5 (2.0-2.7, 14.5-19.5)
C 8 x 30 1 EA 19.6-26.5 (2.0-2.7, 14.5-19.5)
D 8 x 40 1 EA 19.6-26.5 (2.0-2.7, 14.5-19.5)

* Bolts size = Diameter x Length

7. Install the oil screen and oil supply pipe.
8. Install the air compressor. (See HA group)
9. Install the fuel pump bracket (A).

Tightening torque :
19.6 ~ 26.5N.m (2.0~ 2.7kgf.m, 14.5~19.5lb-ft)
10. Install the fuel pump (A).

Tightening torque :
14.7 ~ 19.6N.m (1.5~ 2.0kgf.m, 10.8~14.5lb-ft)

11. Install the balance shaft drive gear (A) and driven gear (B) on the timing chain lower under cover.

Drive gear and driven gear cover (C) :

Tightening torque :
7.8-11.8 N.m (0.8-1.2 kgf.m, 5.8-8.7 lb-ft)
 Align timing mark (D) on the drive gear (A) and driven gear (B).

12. Apply sealant (A) on the timing chain lower under cover after clean foreign material.

Sealant type: Lotite #5902

Bead width: 2 - 4mm (0.08 - 0.16 in)
13. Install the timing chain lower under cover (A).
Tightening torque
Bolt Size Quantity
N.m (kgf.m, lb-ft)
A 6 x 14 4 EA 9.8-11.8 (1.0-1.2, 7.2-8.7)
B 8 x 22 1 EA 19.6-26.5 (2.0-2.7, 14.5-19.5)
C 8 x 30 3 EA 19.6-26.5 (2.0-2.7, 14.5-19.5)
D 8 x 40 1 EA 19.6-26.5 (2.0-2.7, 14.5-19.5)

*Bolts size = Diameter x Length

14. Insert a screw driver(C) in the cylinder block plug hole (B). Because, prevent rotation of balance shaft (A).

15. Install the LH balance shaft driven gear bolt (A) (8 x 16).

Tightening torque :
33.3 ~ 44.1N.m (3.4~ 4.0kgf.m, 24.6~32.5lb-ft)

16. Install the balance shaft sprocket.

Tightening torque :
LH balance shaft sprocket nut :
49.0-58.8 N.m (5.0-6.0 kgf.m, 36.2-43.4 lb-ft)
RH balance shaft sprocket bolt (8 x 16) :
 33.3-39.2 N.m (3.4-4.0 kgf.m, 24.6-28.9 lb-ft)

17. Install plug on the cylinder block after remove driver.

Tightening torque (plug) :

14.7-21.6 N.m (1.5-2.2 kgf.m, 10.8-15.9 lb-ft)

18. Install the water pump.

19. Install the oil cooler.
20. Install the thermostat housing (A) and heater pipe (B).

Tightening torque :
Thermostat housing: 19.6~26.5 N.m (2.0-2.7 kgf.m, 14.5 – 19.5 lb-ft)
Heater pipe: 7.8-11.8 N.m (0.8~1.2 kgf.m, 5.8-8.7 lb-ft)

21. Install the power steering pump bracket (A).

Tightening torque :
19.6~26.5 N.m (2.0-2.7 kgf.m, 14.5-19.5 lb-ft)
22. Install the power steering pump.(See ST group)
23. Install the oil gage assembly (A).

Tightening torque :
19.6~26.5 N.m (2.0~2.7 kgf.m, 14.5~19.5 lb-ft)

24. Install the cylinder head.

25. Install the intake manifold and exhaust manifold.
26. Install the timing chain.
27. Install the fly wheel or drive plate.
28. Install the engine and trans axle.

DISASSEMBLY
1. Remove the connecting rod bearing cap (A) and bearing (B).
 Mark the connecting rod bearing caps to be able to reassemble in the original position and direction.

2. Remove the piston and connecting rod assembly from the cylinder block.
3. Remove the main bearing cap (A) and bearing (B).

4. Remove the clank shaft (A) from cylinder block.

Clank shaft being careful not to damage the journals.

5. Remove the oil jet (A).

MAIN JOURNAL BEARING

1. Check the cylinder block main bearing bore size code.

Record the cylinder block main bearing bore size code letters on cylinder block as shown.
Reading order is from left to right with front main bearing bore size code shown first.
 CYLINDER BLOCK MAIN BEARING BORE DIAMETER
Code Cylinder block main bearing bore diameter (mm (in))
A 71.000 - 71.008 (2.7953 - 2.7956)
B 71.006 - 71.016 (2.7956 - 2.7959)
C 71.016 - 71.024 (2.7957 - 2.7962)

2. Check the crankshaft main journal size code.

Record the main journal size code letters on the crankshaft balance weight.
Reading order is from left to right as shown, with No. 1 main journal size code shown first.

CRANKSHAFT MAIN JOURNAL DIAMETER

Code Crankshaft main journal diameter (mm (in))
A 66.994 - 67.000 (2.6376 - 2.6378)
B 66.988 - 66.994 (2.6373 - 2.6376)
C 66.982 - 66.988 (2.6371 - 2.6373)

3. Choose proper main journal bearing in below table.

MAIN JOURNAL BEARING SELECTION TABLE
Cylinder block main bearing bore size code
Main journal bearing
A B C
A Green Yellow None
Crankshaft pin journal size code B Yellow None Blue
 C None Blue Red

Main journal bearing oil clearance :

0.030 - 0.054 mm (0.0012 - 0.0021 in)

MAIN JOURNAL BEARING THICKNESS

Main journal bearing thickness
Color
(mm (in))
Red 1.994 - 1.997 (0.0785 - 0.0786)
Blue 1.991 - 1.994 (0.0784 - 0.0785)
None 1.988 - 1.991 (0.0783 - 0.0784)
Yellow 1.985 - 1.988 (0.0781 - 0.0783)
Green 1.982 - 1.985 (0.0780 - 0.0781)

CONNECTING ROD BEARING

1. Check the connecting rod big-end bore size code(A).

Record the connecting rod big-end bore size code letters on connecting rod cap as shown.

CONNECTING ROD BIG-END DIAMETER

Code Connecting rod big-end diameter mm (in)
A 60.000 - 60.006 (2.3622 - 2.3624)
B 60.006 - 60.012 (2.3624 - 2.3627)
C 60.012 - 60.018 (2.3627 - 2.3629)

2. Check the crankshaft pin journal size code(A).

Record the pin journal size code letters on the No. 1 crankshaft balance weight.
Reading order is from left to right as shown, with No. 1 pin journal size code shown first.
 CRANKSHAFT PIN JOURNAL DIAMETER
Code Crankshaft pin journal diameter mm (in)
A 56.994 - 57.000 (2.2439 - 2.2441)
B 56.988 - 56.994 (2.2436 - 2.2439)
C 56.982 - 56.988 (2.2434 - 2.2436)

3. Choose proper connecting rod bearing in below table.

CONNECTING ROD BEARING SELECTION TABLE

Connecting rod big-end bore size code

Connecting rod bearing
A B C
1 Green Yellow None
Crankshaft pin journal size code 2 Yellow None Blue
3 None Blue Red

Connecting rod bearing oil clearance :

0.024 - 0.042 mm (0.0009 - 0.0017 in)

CONNECTING ROD BEARING THICKNESS

Color Connecting rod bearing thicknessmm (in)
Red 1.497 - 1.500 (0.0589 - 0.0591)
Blue 1.494 - 1.497 (0.0588 - 0.0589)
None 1.491 - 1.494 (0.0587 - 0.0588)
Yellow 1.488 - 1.491 (0.0586- 0.0587)
Green 1.485 - 1.488 (0.0585 - 0.0586)

PISTON
1. Check the cylinder bore size code on the cylinder block bottom face.
Code Cylinder bore inner diameter (mm (in))
A 91.000-91.010 (3.5827-3.5831)
B 91.010-91.020 (3.5831-3.5835)
 C 91.020-91.030 (3.5835-3.5839)

2. Check the piston size code(A) on the piston top face.

Code Piston outer diameter (mm (in))
A 90.910-90.920 (3.5791-3.5795)
B 90.920-90.930 (3.5795-3.5799)
C 90.930-90.940 (3.5799-3.5803)

3. Select the piston related to cylinder bore size code.

Oil clearance : 0.080-0.100 mm (0.0031-0.0039 in)

LH BALANCE SHAFT DRIVE GEAR BEARING (BUSH)

1. Use the special tool (09231-4A000) to install or remove the LH balance shaft drive gear bearing.
2. To remove the bearing, install the special tool (09231-4A000).
3. When installing the bearing, apply enough fluid to the bearing surface and cover.
4. Press-fit the bearing after aligning the bearing oil hole with the timing chain lower under cover oil hole.

INSPECTION
CONNECTING ROD BAERING
1. Before removing the connecting rod cap, measure connecting rod side clearance. If side clearance exceeds
specification, replace the connecting rod.

Side clearance : 0.05 - 0.25 mm (0.0020 - 0.0098 in)

2. Remove the connecting rod cap.

3. Measure connecting rod bearing oil clearance.
A. Remove all foreign material and oil from the pin journals and connecting rod bearing surface.
B. Position a plastic gauge atop the pin journals in axial direction.
C. Install the connecting rod cap and tighten bolts.

Tightening torque :
58.8 N.m (6.0 kgf.m, 43.4 lb-ft) → Loosen → 32.4~36.3 N.m (3.3~3.7 kgf.m, 23.9~26.8 lb-ft) +
 60~64°

Always use new connecting rod cap bolts.

D. Remove the connecting rod cap, and measure oil clearance at each journal.

Oil clearance :
0.024 - 0.042 mm (0.0009 - 0.0017 in)

4. If oil clearance exceeds specification, replace the connecting rod bearing.

CRANK SHAFT MAIN BEARING

1. Before removing the main bearing cap, measure crankshaft end play. If end play exceeds specification, replace the
thrust bearing.

End play: 0.05 - 0.25 mm (0.0020 - 0.0098 in)

2. Remove the main bearing cap.

3. Measure main bearing oil clearance.
A. Remove all foreign material and oil from the main journals and main bearing surface.
B. Position a plastic gauge atop the main journals in axial direction.
C. Install the main bearing cap and tighten bolts.
 Tightening torque :
127.5-137.3 N.m (13-14 kgf.m, 94.0-101.3 lb-ft)

D. Remove the main bearing cap, and measure oil clearance at each journal.

Oil clearance :
0.024 - 0.042 mm (0.0009 - 0.0017 in)

4. If oil clearance exceeds specification, replace the main bearing.

PISTON
1. Check each piston for scuffing, scoring, wear and other defects. Replace any piston that is defective.
2. Check that the piston pin fits in the piston pin hole. Replace any piston and pin assembly that is defective.
The piston pin must be smoothly pressed by hand into the pin hole (at room temperature).
 Piston pin outer diameter :
32.993-32.998 mm (1.2989-1.2991 in)
Piston pin hole inner diameter :
33.014-33.019mm (1.2998-1.3000 in)
Connecting rod small-end inner diameter :
33.020-33.033 mm (1.3000-1.3005 in)

PISTON RING
1. Check each piston ring for breakage, damage and abnormal wear. Replace the defective rings.
2. When the piston requires replacement, its ring should also be replaced.
3. Measure the clearance between piston ring and ring groove.

Piston ring side clearance :

No.2 ring : 0.05-0.09 mm (0.0020-0.0035 in)
Oil ring : 0.04-0.08 mm (0.0016-0.0031 in)

4. Place a piston ring in the cylinder bore and set it square by pushing it down with piston.

Eng gap :
No.1 ring : 0.25-0.40 mm (0.0098-0.0157 in)
No.2 ring : 0.50-0.70 mm (0.0197-0.0276 in)
Oil ring : 0.20-0.40 mm (0.0079-0.0157 in)
CYLINDER BLOCK

• Before inspection and repair, clean parts to remove dirt, oil, carbon, deposits, and scale.
• Before cleaning the cylinder block, be sure to check for evidences of water leaks and damage.
• Remover contaminants from oil holes with compressed air and, at the same time, make sure that they are not
blocked.

1. Check for scratches, rust, and corrosion. Use also a flaw-detecting agent for the check. If defects are evident,
correct or replace.
2. Using a straightedge and thickness gauge, check the cylinder block top surface for flatness. Lay the straightedge
long ways and crossways as indicated by A, B,... in illustration. If flatness is flatness is not within the limit, replace
the cylinder block top surface is free from any traces of gasket material.

Standard value :
0.05 mm (0.002 in.)
Limit: 0.1 mm (0.004 in.)
3. Check cylinder wall for scratches and seizure.
If defects are evident, correct (to oversize) or replace.
4. Using cylinder gauge, measure the cylinder bore.
If it wears out excessively, bore the cylinder to oversize and replace the piston and piston rings.
Measurement points are as shown.

Standard value :
91.000 - 91.030 mm (3.5827-3.5839 in)

REASSEMBLY
1. Install the oil jet (A).

Tightening torque :
 29.4 ~ 34.3N.m (3 ~ 3.5kgf.m, 21.7 ~ 25.3lb-ft)

2. Install the main bearing (A).

3. Install the thrust bearing (B).

4. Install the clank shaft (A).

5. Check the main bearing, cap number. And then Install the main bearing (A) and bearing (B).
 Tightening torque :
127.5 ~ 137.3N.m (13 ~ 14kgf.m, 94.0 ~101.3lb-ft)

6. Check the front mark of the piston and connecting rod.

7. Line up the front marks and insert the piston pin. The piston pin must be smoothly pressed by hand into position.
8. Install the snap ring.
9. Install the piston rings.
A. Install the oil ring expander and 2 side rails by hand.
B. Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
C. Position the piston rings so that the ring ends are as shown.

10. Insert the piston and connecting rod assembly from above the top of cylinder. Ensure that the front mark (A) on
the piston crown and that (front mark) on the connecting rod face toward the front of engine (to the crankshaft
pulley side).

11. Clamp firm the piston rings with the ring band and install the piston assembly into cylinder. Do not strike it hard
into the piston, as broken piston ring or damaged crankshaft pin journal could result.
12. Install the connecting rod bearing (B).
13. Install the connecting rod and cap (A) to crankshaft pin journal.

Tightening torque :
58.8 N.m (6.0 kgf.m, 43.4 lb-ft) → Loosen → 32.4~36.3 N.m (3.3~3.7 kgf.m, 23.9~26.8 lb-ft) +
60~64°

Always use new connecting rod cap bolts.

 Engine Mechanical System

Cooling System

Engine Mechanical System

> D 2.5 CRDI >

COMPONENTS
 > D 2.5 CRDI >

REMOVAL
WATER PUMP
1. Remove the drain plug(A).

2. Remove the radiator cowl cover.

3. Remove the drive belt(A).

Loosen the water pulley bolt first, and remove the drive belt.

4. Remove the water pump pulley.

5. Remove the water pump(A) from cylinder block.
Thermostat
1. Drain the coolant so its lever is below the thermostat.
2. Remove the water inlet fitting(A).

3. Remove the thermostat.

INSTALLATION
WATER PUMP
1. Install the water pump (A) with new gasket to the cylinder block.

Tightening torque :
A bolts (8 x 45) 2EA :
19.6-26.5 N.m (2.0-2.7 kgf.m, 14.5-19.5 lb-ft)
B bolts (8x45) 2EA:
19.6-26.5 N.m (2.0-2.7 kgf.m, 14.5-19.5 lb-ft)
2. Install the cooling fan.
3. Install the drive belt.
4. Install the radiator cowl upper cover.
5. Refill the engine coolant.

THERMOSTAT
1. Check that the flange of the thermostat is correctly seated in the socket of the thermostat housing.
2. Install the inlet fitting (A).

Tightening torque :
Engine coolant inlet fitting bolt :
19.6 - 26.5 N.m(2.0-2.7kgf.m, 14.5-19.5 lb-ft)

3. Refill the coolant.

 INSPECTION
WATER PUMP
1. Check the pump for cracks, damage of wear. Replace the water pump assembly if necessary.
2. Check the bearing for damage, abnormal noise, and sluggish rotation. Replace the water pump assembly if
necessary.
3. Check the bearing for damage, abnormal noise, and sluggish rotation. Replace the water pump assembly if
necessary.

THERMOSTAT
1. Check that the valve operates properly.
2. Verify the temperature at which the valve begins to open.
ITEM SPECIFICATION
Valve opening temperature 82°C(180°F)
Valve closing temperature 77°C(171°F)
Full opening temperature 95°C(203°F)
 Engine Mechanical System

Lubrication System

Engine Mechanical System

> D 2.5 CRDI >

COMPONENTS
 > D 2.5 CRDI >

INSPECTION
OIL PUMP
1. Make sure the outer rotor and inner rotor turn smoothly with no excessive play between them.
2. Check the side clearance and body clearance.

Side clearance :
Inner rotor: 0.040-0.085 mm (0.0016-0.0033 in)
Outer rotor: 0.050-0.100 mm (0.0020-0.0039 in)
Body clearance (Between outer rotor and body) :
0.100-0.176 mm (0.0039-0.0069 in)

3. If clearance is excessive, replace the oil pump.

OIL COOLER
1. Inspect visually the core for clogging or damage, and replace it if a problem is found.

OIL COOLER BY-PASS VALVE

1. Check that the valve operates properly.
2. Verify the temperature at which the valve (A) begins to open.
Temperature Lift
Item
°C (°F) mm (in)
Valve opening temperature 91.5-94.5 (196.7-202.1) 0.05 (0.002)
Full opening Full opening 97-103 (206.6-217.4) 5 (0.197)
Full lift 150 (302) Below 11 (0.433)
OIL RELIEF VALVE
1. Check the relief plunger for wear or damage.
2. Check the relief spring for weak.

Free length: 52.5mm (2.0669in)

3. Check the relief spring (A) of pressure.

Spring pressure :
6.7kg/40.1mm (14.8 lb/1.5787in)
8.7/36.3mm (19.2 lb/1.4291in)

REMOVAL
OIL PUMP
1. Drain engine oil.
2. Remove the timing chain "C" and "B".
3. Remove the oil pan. Refer to "Oil pan (A)".
4. Remove the oil screen (A) from the oil pump.

5. Remove the oil feed pipe (A) from the oil pump and bed plate.

6. Remove the bet plate.

7. Remove the oil pump assembly (A) from the cylinder block.
OIL COOLER
1. Drain engine coolant and engine oil.
2. Remove the engine oil filter.
3. Remove the oil cooler assembly (A) from the cylinder block.

4. Remove the oil cooler (B) from the oil cooler cover (A).

5. Remove the oil cooler by-pass valve (A) and the relief valve (B) from the oil cooler cover.
 OIL AND FILTER REPLACEMENT
1. Run the engine until it reaches normal operating temperature.
2. Turn off the engine.
3. Remove the oil filler cap and the drain plug. Drain the engine oil.
4. Tighten the drain plug (A) to the specified torque.

Tightening torque
Oil pan drain plug :
35 ~ 45 N.m (3.5 ~ 4.5 kgf.m, 25 ~ 33 Ib-ft)
 Whenever tightening the oil drain plug, use a new drain plug gasket.

5. Fill new engine oil through the oil filler cap opening.

Capacity :
Total : 9.0L (9.51 US qt, 7.91 lmp qt)
Oil pan : 7.4L (7.82 US qt, 6.50 lmp qt)
Drain and refill including oil filter : 8.2L(8.66 US qt, 7.21 lmp qt)
Oil quality : ABOVE API CF-4 (VGT:CH-4) or ACEA B4

Do not overfill. This will cause oil aeration and loss of oil pressure.

6. Install the oil filler cap.

7. Start and run the engine.
8. Turn off the engine and then check the oil level. Add oil if necessary.

OIL FITER
1. Use a filter wrench to remove the oil filter.
2. Before installing the new oil filter on the engine, apply clean engine oil of the surface of the rubber gasket.
3. Tighten the oil filter (A) of the specified torque.

Oil filter :
22 ~ 25 N.m (2.2 ~ 2.5 kgf.m, 16 ~ 18 lb-ft)
4. Start and run the engine and check for engine oil leaks.
5. After stopping the engine, check the oil level and add oil as necessary.

INSTALLATION
OIL PUMP
1. Install the oil pump assembly to the cylinder block.
Quantity Tightening torque
Bolt Size Quantity
N.m (kgf.m, lb-ft)
A 10 x 35 1 EA 42.2-53.9 (4.3-5.5, 31.1-39.8)
B 10 x 60 1 EA 42.2-53.9 (4.3-5.5, 31.1-39.8)
C 8 x 22 2 EA 19.6-26.5 (2.0-2.7, 14.5-19.5)

* Bolts size = Diameter x Length

2. Install the bet plate.

3. Install the oil feed pipe (A) to the oil pump and bed plate.

Tightening torque :
19.6 ~ 26.5 N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft)
4. Install the oil screen (A) to the oil pump.

5. Install the oil pan (A).

Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

6. Install the timing chain "B" and "C". Refer to "Timing chain".
7. Refill engine oil and check for oil leak.
OIL COOLER
1. Install the oil cooler by-pass valve (A) and the relief valve (B) to the oil cooler cover.

Tightening torque :
Oil cooler by-pass valve :
49.0 ~ 58.8 N.m (5 ~ 6kgf.m, 36.2 ~ 43.4lb-ft)
Relief valve plug :
39.2 ~ 49.0 N.m (4 ~ 5 kgf.m, 28.9 ~ 36.2 lb-ft)

2. Install the oil cooler (B) to oil cooler cover (A).

Tightening torque :
17.7 ~ 24.5 N.m (1.8 ~ 2.5 kgf.m, 13.0 ~ 18.1lb-ft)

3. Install the oil cooler assembly (A) to the cylinder block with new gasket.
Tightening torque
Bolt Size Quantity
N.m (kgf.m, lb-ft)
A 8 x 35 8 EA 19.6-25.5 (2.0-2.6, 14.5-18.8)
B 8 x 60 3 EA (2.0-2.6, 14.5-18.8)

* Bolts size = Diameter x Length

4. Install the engine oil filter.

Tightening torque :
19.6 ~ 24.5 N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1lb-ft)

5. Refill the engine oil and engine coolant.

6. Check for oil and coolant leak.
 Engine Mechanical System

Intake and Exhaust System - Intake Manifold

Engine Mechanical System

> D 2.5 CRDI >

COMPONENTS
 > D 2.5 CRDI >

REMOVAL
1. Remove the vacuum line(A, B).

2. Remove the high pipe bracket(A) and the coolant temperature sensor connector(B).

3. Remove the high pump fuel hose bracket(A).

4. Remove the EGR pipe(A).

5. Remove the EGR valve(A).

6. Remove the EGR cooler(A).

7. Remove the intake manifold.

INSTALLATION
1. Install the intake manifold with new gasket.
Tightening torque
Bolt Size Quantity
N.m (kgf.m, lb-ft)
14.7 ~ 19.6
A 8 x 112 4 EA
(1.5 ~ 2.0, 10.8 ~ 14.5)
14.7 ~ 19.6
B 8 x 32 4 EA
(1.5 ~ 2.0, 10.8 ~ 14.5)
14.7 ~ 19.6
C nuts 2 EA
(1.5 ~ 2.0, 10.8 ~ 14.5)

* Bolts size = Diameter x Length

2. Install the EGR cooler(A).

Tightening torque :
27.5 ~ 31.4N.m (2.8 ~ 3.2kgf.m, 20.3 ~ 23.1lb-ft)

3. Install the EGR valve(A).

Tightening torque :
27.5 ~ 31.4N.m (2.8 ~ 3.2kgf.m, 20.3 ~ 23.1lb-ft)

4. Install the EGR pipe(A).

Tightening torque :
27.5 ~ 31.4N.m (2.8 ~ 3.2kgf.m, 20.3 ~ 23.1lb-ft)
5. Install the high pump fuel hose bracket(A).

6. Install teh high pipe bracket(A) and coolant temperature sensor connector(B).

7. Install the vacuum line(A, B).

 Engine Mechanical System

Intake and Exhaust System - Exhaust

Manifold

Engine Mechanical System

> D 2.5 CRDI >

COMPONENTS
 > D 2.5 CRDI >

REMOVAL
1. Remove the oil separator(A).

2. Remove the heater protectors(A).

3. Remove the oil hose(A) and coolant hose(B) from the turbo charger.

4. Remove the EGR pipe(A).

5. Remove the turbo charge bracket(A) and bolt(B).
6. Remove the exhaust manifold(A).

INSTALLATION
1. Install the exhaust manifold gasket(A).

2. Install the turbo charge oil feed line(A).

3. Install the exhaust manifold(A) from cylinder head.

Tightening torque :
 16.7 ~ 25.5N.m(1.7 ~ 2.6kgf.m, 12.3 ~ 18.8lb-ft)

4. Install the bolt(B) from turbo charge bracket(A).

Tightening torque :
14.7 ~ 19.6N.m(1.5 ~ 2.0kgf.m, 10.8 ~ 14.5lb-ft)

5. Install the EGR pipe(A).

Tightening torque :
27.5 ~ 31.4N.m(2.8 ~ 3.2kgf.m, 20.3 ~ 23.1lb-ft)

6. Install the oil hose(A) and coolant hose(B) from turbo charge.
7. Install the heater protector(A).

Tightening torque :
14.7 ~ 21.6N.m(1.5 ~ 2.2kgf.m, 10.8 ~ 15.9lb-ft)
8. Install the oil sperator(A).

Tightening torque :
7.8 ~ 9.8N.m(0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
 Engine Electrical System

General Information

Engine
cal System

 > D 2.5 CRDI >

TROUBLESHOOTING
CHARGING SYSTEM
Symptom Suspect Area Remedy
Charging warning indicator Fuse blown Check fuses
does not light with ignition Light burned out Replace light
switch "ON" and engine off Wiring connection loose Tighten loose connections
Electronic voltage regulator Replace voltage regulator
Charging warning indicator Drive belt loose or worn Adjust tension or replace drive belt
does not go out with engine Battery cables loose, corroded or worn Repair or replace cavles
running (Battery requires Fuse blown Check fuses
frequent recharging) Fusible link blown Replace fusible link
Electronic voltage regulator or generator Test generator
Wiring Repair wiring
Engine hesitates/poor Drive belt loose or worn Adjust tension or replace drive belt
acceleration Wiring connection loose or open circuit Tighten loose connection or repair
Overcharge wiring
Fusible link blown Replace fusible link
Poor grounding Repair
Electronic voltage regulator or generator Test generator, if faulty, repair or
Worn battery replace
Electronic voltage regulator Replace battery
Voltage sensing wire Replace voltage regulator
Repair wire

STARTING SYSTEM
Symptom Suspect Area Remedy
Engine will not crank Battery charge low Charge or replace battery
Battery cables loose, corroded or worn out Repair or replace cables
Transaxle range switch (Vehicle with Adjust or replace switch
automatic transaxle only)
Fusible link blown Replace fusible link
Starter motor faulty Repair starter motor
Ignition switch faulty Inspect
Engine cranks slowly Battery charge low Charge or replace battery
Battery cables loose, corroded or worn out Repair or replace cables
Starter motor Repair starter motor
Starter keeps running Starter motor Repair starter motor
Ignition switch Inspect
Starter spins but engine will Short in wiring Repair wiring
not crank Pinion gear teeth broken or starter motor Repair starter motor
Ring gear teeth broken Replace flywheel ring gear or torque
converter

CRUISE CONTROL SYSTEM

Before troubleshooting :
- Check the ECM(10A), Horn(10A), ECU #3(10A) and ECU B+(15A) fuse in the under - hood fuse/relay box.
- Check that the horn sounds.
 - Check the tachometer to see if it works properly.

Symptom Suspect Area See Page

Cruise control cannot be set Remocon switch See page EE-34
Brake switch See page EE-35
A/T gear position switch See page TR group-automatic
transaxle
Cruise control unit See page EE-6
Cruise control cannot be set but Dimming circuit in gauge See page EE-6
indicator light does not go on Cruise control unit See page EE-6
Cruise speed is noticeably higher or Vehicle speed sensor See page TR group-automatic
lower than what was set Cruise control unit and actuator cable transaxle
deflection See page EE-35
Cruise control unit See page EE-6
Excessive overshooting or Cruise control unit and actuator cable See page EE-35
undershooting when trying to set speed deflection See page TR group-automatic
Vehicle speed sensor transaxle
Cruise control unit See page EE-6
Speed fluctuation on a flat road with Vehicle speed sensor See page TR group-automatic
cruise control set Cruise control unit and actuator cable tranxaxle
deflection See page EE-35
Cruise control unit See page EE-8
Vehicle does not decelerate or Remocon switch See page EE-57
accelerate accordingly when Cruise control unit See page EE-6
SET/RESUME/CANCEL button is
pushed
See page TR group-automatic
Cruise control does not cancel when A/T gear position switch
tranxaxle
shift lever is moved to N position (A/T) Cruise control unit
See page EE-6
Set speed is not cancelled when brake Brake switch See page EE-35
pedal is pushed Cruise control unit See page EE-6
Cruise control will not cancel when Remocon switch See page EE-34
main switch is pushed OFF Cruise control unit See page EE-6
Cruise control will not cancel when Remocon switch See page EE-34
CANCEL button is pushed Cruise control unit See page EE-6
Set speed will not resume when Remocon switch See page EE-34
RESUME button (with main switch on, Cruise control unit See page EE-6
when set speed is temporarily
cancelled)
The transmission shifts down slower Troubleshooting the cruise control See page EE-6
than normal when going up a hill with communication circuit
the cruise control on (A/T)
 > D 2.5 CRDI >

SPECIFICATION
STARTING SYSTEM
Item Specifications
Type Reduction drive (with planetary gear)
Rated voltage 12V, 2.2KW
No. of pinion teeth 10
Starter
Voltage 11V
No-load charasteristics Amperage 130A, MAX
Speed 4,500rpm, MIN

CHARGING SYSTEM
Item Specifications
Type Battery voltage sensing
Rated voltage 13.5V, 110A
Alternator Voltage regulator I.C regulator built-in type
Regulator setting voltage 14.4 ± 0.3V
Temperrature compensation -10 ± 3mV/°C
Type MF 100 AH
Cold cranking amperage at-18°C (0°F) 850A
Battery
Reserve capacity 182min
Specific gravity at 20°C (77°F) 1.280 ± 0.01

- COLD CRANKING AMPERAGE is the amperage a battery can deliver for 30 seconds and maintain a terminal
voltage of 7.2V or greater at a specified temperature.
- REVERSE CAPACITY RATING is amount of time a battery can deliver 25A and maintain a minimum terminal
voltage of 10.5V at 26.7°C(80°F)

PREHEATING SYSTEM
Item Specifications
Rated voltage DC 12V
Glow plug
Current 250MΩ
Rated voltage DC 12V
Operating voltage range DC 9V ~ DC 16V
Glow plug relay
Operating temperature range -40°C ~ 120°C
Rated load current DC 12V, 70A
 Engine Electrical System

Charging System

Engine Electrical System

 > D 2.5 CRDI >

DESCRIPTION
The conventional internal voltage detection type alternator controls the charging voltage regardless of the battery
condition and according to the external load change so that it sometimes causes battery under or over charging or
causes flickering of meters and lamps due to ripples of generated voltage resulting from load fluctuation. The figure
below show the internal circuits of the alternator and voltage regulator.
 > D 2.5 CRDI >

ON-VEHICLE INSPECTION

• Check that the battery cables are connected to the correct terminals.
• Disconnect the battery cables when the battery is given a quick charge.
• Do not perform tests with a high voltage insulation resistance tester.
• Never disconnect the battery while the engine is running.

CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES

1. Check that the battery terminals are not loose or corroded.
2. Check the fusible link and fuses for continuity.

INSPECT DRIVE BELT

1. Visually check the belt for excessive wear, frayed cords etc.
If any defect has been found, replace the drive belt.

Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it
should be replaced.

2. Using a belt tension gauge, measure the drive belt tension.

VISUALLY CHECK ALTERNATOR WIRING AND LISTEN FOR ABNORMAL NOISES

1. Check that the wiring is in good condition.
2. Check that there is no abnormal noise from the alternator while the engine is running.

CHECK DISCHARGE WARNING LIGHT CIRCUIT

1. Warm up the engine and then turn it off.
2. Turn off all accessories.
3. Turn the ignition switch "ON". Check that the discharge warning light is it.
4. Start the engine. Check that the light goes off.

INSPECT CHARGING SYSTEM

VOLTAGE DROP TEST OF ALTERNATOR OUTPUT WIRE
This test determines whether or not the wiring between the alternator "B" terminal and the battery (+) terminal is good
by the voltage drop method.

PREPARATION
1. Turn the ignition switch to "OFF".
 To find abnormal conditions of the connection, actions should not be taken on the two terminals and each
connection during the test.

2. Connect a digital voltmeter between the alternator "B" terminal and battery (+) lead wire to the battery (+) terminal.
Connect the (+) lead wire of the voltmeter to the "B" terminal and the (-) lead wire to the battery (+) terminal.

CONDITIONS FOR THE TEST

1. Start the engine.
2. Switch on the headlamps, blower motor and so on. And then, read the voltmeter under this condition.

RESULT
1. The voltmeter may indicate the standard value.

0.2V max.

2. If the value of the voltmeter is higher than expected (above 0.2V max.), poor wiring is suspected. In this case
check the wiring from the alternator "B" terminal to the fusible link to the battery (+) terminal. Check for loose
connections, color change due to an overheated harness, etc. Correct them before testing again.
3. Upon completion of the test, set the engine speed at idle. Turn off the head lamps, blower motor and the ignition
switch.

OUTPUT CURRENT TEST

This test determines whether or not the alternator gives an output current that is equivalent to the nominal output.

PREPARATION
1. Prior to the test, check the following items and correct as necessary.
Check the battery installed in the vehicle to ensure that it is in good condition. The battery checking method is
described in "BATTERY".
The battery that is used to test the output current should be one that has been partially discharged. With a fully
charged battery, the test may not be conducted correctly due to an insufficient load.
Check the tension of the alternator drive belt.
2. Turn off the ignition switch.
3. Disconnect the battery ground cable.
4. Disconnect the alternator output wire from the alternator "B" terminal.
5. Connect a DC ammeter (0 to 150A) in series between the "B" terminal and the disconnected output wire. Be sure
to connect the (-) lead wire of the ammeter to the disconnected output wire.

Tighten each connection securely, as a heavy current will flow. Do not rely on clips.

6. Connect a voltmeter (0 to 20V) between the "B" terminal and ground. Connect the (+) lead wire to the alternator "B"
terminal and (-) lead wire to a good ground.
7. Attach an engine tachometer and connect the battery ground cable.
8. Leave the engine hood open.

TEST
1. Check to see that the voltmeter reads as the same value as the battery voltage. If the voltmeter reads 0V, and the
open circuit in the wire between the alternator "B" terminal and battery (-) terminal, a blown fusible link or poor
grounding is suspected.
2. Start the engine and turn on the headlights.
3. Set the headlights to high beam and the heater blower switch to HIGH, quickly increase the engine speed to 2,500
rpm and read the maximum output current value indicated by the ammeter.

After the engine starts up, the charging current quickly drops. Therefore, the above operation must be done
quickly to read the maximum current value correctly.

RESULT
1. The ammeter reading must be higher than the limit value. If it is lower but the alternator output wire is in good
condition, remove the alternator from the vehicle and test it.

Limit value : 50% of the reated currend.

• The nominal output current value is shown on the nameplate affixed to the alternator body.
• The output current value changes with the electrical load and the temperature of the alternator itself.
Therefore, the nominal output current may not be obtained. If such is the case, keep the headlights on the
cause discharge of the battery, or use the lights of another vehicle to increase the electrical load.
The nominal output current may not be obtained if the temperature of the alternator itself or ambient
temperature is too high.
In such a case, reduce the temperature before testing again.

2. Upon completion of the output current test, lower the engine speed to idle and turn "OFF" the ignition switch.
3. Disconnect the battery ground cable.
4. Remove the ammeter and voltmeter and the engine tachometer.
5. Connect the alternator output wire to the alternator "B" terminal.
6. Connect the battery ground cable.

REGULATED VOLTAGE TEST

The purpose of this test is to check that the electronic voltage regulator controls voltage correctly.

PREPARATION
1. Prior to the test, check the following items and correct if necessary.
Check that the battery installed on the vehicle is fully charged. For battery checking method, see "BATTERY".
 Check the alternator drive belt tension.
2. Turn ignition switch to "OFF".
3. Disconnect the battery ground cable.
4. Connect a digital voltmeter between the "B" terminal of the alternator and ground. Connect the (+) lead of the
voltmeter to the "B" terminal of the alternator. Connect the (-) lead to good ground or the battery (-) terminal.
5. Disconnect the alternator output wire from the alternator "B" terminal.
6. Connect a DC ammeter (0 to 150A) in series between the "B" terminal and the disconnected output wire. Connect
the (-) lead wire of the ammeter to the disconnected output wire.
7. Attach the engine tachometer and connect the battery ground cable.

TEST
1. Turn on the ignition switch and check to see that the voltmeter indicates the following value.

Battery voltage

2. If it reads 0V, there is an open circuit in the wire between the alternator "B" terminal and the battery and the battery
(-), or the fusible link is blown.
3. Start the engine. Keep all lights and accessories off.
4. Run the engine at a speed of about 2,500 rpm and read the voltmeter when the alternator output current drops to
10A or less.

RESULT
1. If the voltmeter reading agrees with the value listed in the Regulating Voltage Table below, the voltage regulator is
functioning correctly. If the reading is other than the standard value, the voltage regulator or the alternator is faulty.
REGULATING VOLTAGE TABLE
Voltage regulator ambient temperature °C (°F) Regulating voltage (V)
-30 (-22) 14.2 ~ 15.3
25 (77) 14.2 ~ 14.8
135 (275) 13.3 ~ 14.8

2. Upon completion of the test, reduce the engine speed to idle, and turn off the ignition switch.
3. Disconnect the battery ground cable.
4. Remove the voltmeter and ammeter and the engine tachometer.
5. Connect the alternator output wire to the alternator "B" terminal.
6. Connect the battery ground cable.
 Engine Electrical System

Charging System - Alternator

Engine Electrical System

> D 2.5 CRDI >

COMPONENTS
 > D 2.5 CRDI >

REPLACEMENT
1. Disconnect the battery negative terminal frist, then the positive terminal.
2. Disconnect the alternator connector(A) and "B" terminal cable(B) from the alternator.
3. Remove the drive belt.

4. Remove the through bolt and the alternator(A).

5. Installation is the reverse of removal.

DISASSEMBLY
1. Remove the nuts and bolts frist, and cover(A).

2. Remve the brush holder assembly(A).

3. Remove the regulator(A).

4. Remove the alternator pulley(A).

5. Remove the rear bracket nuts(A).

6. Separate the front bracket(A), rotor(B) rear bracket(C).

7. Installation is the reverse of removal.

INSPECTION
INSPECT ROTOR
1. Check that there is continuity between the slip rings(A).

2. Check that there is no continuity between the slip rings and the rotor(B) or rotor shaft(C).
3. If the rotor fails either continuity check, replace the alternator.

INSPECT STATOR
1. Check that there is continuity between each pair of leads(A).

2. Check that there is no continuity between each lead and the coil core.
3. If the coil fails either continuity check, replace the generator.
 Engine Electrical System

Charging System - Battery

Engine Electrical System

 > D 2.5 CRDI >

DESCRIPTION
1. The maintenance-free battery is, as the name implies, totally maintenance free and has no removable battery cell
caps.
2. Water never needs to be added to the maintenance-free battery.
3. The battery is completely sealed, except for small vent holes in the cover.
 > D 2.5 CRDI >

INSPECTION
BATTERY DIAGNOSTIC TEST(1)
CHECKING FLOW

LOAD TEST
1. Perform the following steps to complete the load test procedure for maintenance free batteries.
2. Connect the load tester clamps to the terminals and proceed with the test as follow :
A. If the battery has been on charge, remove the surface charge by connect a 300 ampere load for 15 seconds.
B. Connect the voltmeter and apply the specified load.
C. Read the voltage after the load has been applied for 15 seconds.
D. Disconnect the load.
E. Compare the voltage reading with the minimum and replace the battery if battery test voltage is below that
shown in the voltage table.
 Voltage Temperature
9.6 20°C (70°F) and above
9.5 16 °C (60 °F)
9.4 10 °C (50 °F)
9.3 4 °C (40 °F)
9.1 -1 °C (30 °F)
8.9 -7 °C (20 °F)
8.7 -12 °C (10 °F)
8.5 -18 °C (0 °F)

- If the voltage is less than shown in the table, the battery is good.
- If the voltage is greater than shown in the table, replace the battery.

BATTERY DIAGNOSTIC TEST

1. Make sure the ignition switch and all accessories are in the OFF position.
2. Disconnect the battery cables (negative first).
3. Remove the battery from the vehicle.

Care should be taken in the event the battery case is cracked or leaking, to protect your skin from the
electrolyte. Heavy rubber gloves (not the household type) should be worn when removing the battery.

4. Inspect the battery carrier for damage caused by the loss of electrolyte. If acid damage is present, it will be
necessary to clean the area with a solution of clean warm water and baking soda. Scrub the area with a stiff brush
and wipe off with a cloth moistened with baking soda and water.
5. Clean the top of the battery with the same solution as described in Step(3).
6. Inspect the battery case and cover for cracks. If cracks are present, the battery must be replaced.
7. Clean the battery posts with a suitable battery post tool.
8. Clean the inside surface of the terminal clamps with a suitable battery cleaning tool. Replace damaged or frayed
cables and broken terminal clamps.
9. Install the battery in the vehicle.
10. Connect the cable terminals to the battery post, making sure the tops of the terminals are flush with the tops of
the posts.
11. Tighten the terminal nuts securely.
12. Coat all connections with light mineral grease after tightening.
When batteries are being charged, an explosive gas forms beneath the cover of each cell. Do not smoke
near batteries being charged or which have recently been charged. Do not break live circuits at the terminals
of batteries being charged. A spark will occur when the circuit is broken. Keep open flames away from the
battery.
 Engine Electrical System

Starting System

Engine Electrical System

 > D 2.5 CRDI >

DESCRIPTION
The starting system includes the battery, starter motor, solenoid switch, ignition switch, inhibitor switch(A/T), ignition
lock switch, connection wires and the battery cable.
When the ignition key is turned to the start position, current flows and energizes the starter motor's solenoid coil.
The solenoid plunger and clutch shift lever are activated, and the clutch pinion engages the ring gear.
The contacts close and the starter motor cranks. In order to prevent damage caused by excessive rotation of the
starter armature when the engine starts, the clutch pinion gear overruns.
 > D 2.5 CRDI >

INSPECTION
STARTER TEST

The air temperature must be between 59 and 100°F (15 and 38°C) before testing.

Recommended procedure :
• Use a starter system tester.
• Connect and operate the equipment in accordance with the manufacturer's instructions.
• Test and troubleshoot as described.
Alternate Procedure :
• Use the following equipment :
- Ammeter, 0~400A
- Voltmeter, 0~20V (accurate within 0.1 volt)
- Tachometer, 0~1,200 rpm
• Hook up a voltmeter and ammeter as shown.

After this test, or any subsequent repair, reset the ECM/PCM to clear any codes.

Check the Starter Engagement :

1. Remove the ECM(B+) fuse from the fuse/relay box.
2. Turn the ignition switch to START (III) with the shift lever in N or P position (A/T) or with the clutch pedal
depressed (M/T). The starter should crank the engine.
A. If the starter does not crank the engine, go to step 3.
B. If it cranks the engine erratically or too slowly, go to "Check for Wear and Damage" on the next page.
3. Check the battery, battery positive cable, ground, starter cut relay, and the wire connections for looseness and
corrosion. Test again.
If the starter still does not crank the engine, go to step 4.
4. Unplug the connector from the starter.
5. Connect a jumper wire from the battery positive (+) terminal to the solenoid terminal.
The starter should crank the engine.
A. If the starter still does not crank the engine, remove it, and diagnose its internal problem.
B. If the starter cranks the engine, go to step 6.
6. Check the ignition switch.
7. Check the starter relay.
8. Check the A/T gear position switch (A/T) or the clutch interlock switch (M/T).
9. Check for an open in the wire between the ignition switch and starter.

STARTER SOLENOID TEST

1. Disconnect the wires from the Sterminal and the M terminal.
2. Connect the battery as shown. If the starter pinion pops out, it is working properly. To avoid damaging the starter,
do not leave the battery connected for more than 10 seconds.
3. Disconnect the battery from the M terminal.
If the pinion does not retract, the hold-in coil is working properly. To avoid damaging the starter, do not leave the
battery connected for more than 10 seconds.

4. Disconnect the battery also from the body. If the pinion retracts immediately, it is working properly.
To avoid damaging the starter, do not leave the battery connected for more than 10 seconds.

FREE RUNNING TEST

1. Place the starter motor in a vise equipped with soft jaws and connecta fully-charged 12-volt battery to starter motor
as follows :
2. Connect a test ammeter (100-ampere scale) and carbon pile rheostatas shown is the illustration.
3. Connect a voltmeter (15-volt scale) across starter motor.
4. Rotate carbon pile to the off position.
5. Connect the battery cable from battery's negative post to the starter motor body.
6. Adjust until battery voltage shown on the voltmeter reads 11 volts.
7. Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and
freely :

: Max. 120 Amps

: Min. 4,000 rpm
 CLEANING
1. Do not immerse parts in cleaning solvent. Immersing the yoke assembly and/or armature will damage the
insulation. Wipe these parts with a cloth only.
2. Do not immerse the drive unit in cleaning solvent. The overrun clutch is pre-lubricated at the factory and solvent
will wash lubrication from the clutch.
3. The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.
 Engine Electrical System

Starting System - Starter

Engine Electrical System

> D 2.5 CRDI >

COMPONENTS
 > D 2.5 CRDI >

INSPECTION
ARMATURE INSPECTION AND TEST
1. Remove the starter.
2. Disassemble the starter as shown at the beginning of this procedure.
3. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage,
replace the armature.

4. Measure the commutator (A) runout.

A. If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips
between the segments.
B. If the commutator runout is not within the service limit, replace the armature.

Commutator Runout
Standard (New) : 0.02mm (0.001 in.) max.
Service limit : 0.05mm (0.002 in.)

5. Check for continuity between the segments of the commutator. If an open circuit exists between any segments,
replace the armature.

6. Check with an ohmmeter that no continuity exists between the commutator (A) and armature coil core (B), and
between the commutator and armature shaft (C). If continuity exists, replace the armature.
INSPECT STARTER BRUSH

STARTER BRUSH HOLDER TEST

INSPECT OVERRUNNING CLUTCH

1. Slide the overrunning clutch along the shaft.
Replace it if does not slide smoothly.
2. Rotate the overrunning clutch (A) both ways.
Does it lock in one direction and rotate smoothly in reverse? If it does not lock in either direction or it locks in both
directions, replace it.

3. If the starter driver gear (B) is worn or damaged, replace the overrunning clutch assembly: the gear is not available
separately.
Check the condition of the flywheel or torque converter ring gear if the starter drive gear teeth are damaged.

DISASSEMBLY
1. Remove the magnetic swich "M" terminal(A) and magnetic swich(C).

2. Remove the brusth spring by(B) using screw driver, the disconnect the brush(C) from the brush holder.
Disconnect the rear bracket(D), brush holder(E) and armature(F).

3. Remove the yoke assembly with the front bracket(B) and pinion shift lever assembly(C).
4. Remove the over running clutch assembly(A).

5. Using a screw driver(A), remove the rear bracket packing(C) and key(D).

6. Separat the rear bracket(A), brush holder(B), armature(C).

7. Reassembly is the reverse of disassembly

- When installing the brush spring(A), take care not to break the brush edge part(B).
- When installing the yoke(C) and front bracket(D), align the mark(E) on the yoke to mark the range of the
front bracket.

REPLACMENT
1. Disconnect the negative cable.
2. Disconnect the stater cable from the "B" teminal(B) on the solenoid then disconnect the "S" teminal connector(A).
3. Remove the 2bolts holding the stater, then remove the stater(C).
4. Installation is the reverse of removal.
 Engine Electrical System

Cruise Control System

Engine Electrical System

 > D 2.5 CRDI >

SYSTEM BLOCK DIAGRAM

COMPONENT PARTS AND FUNCTION OUTLINE

Component part Function

Vehicle-speed sensor Converts vehicle speed to pulse.
Engine control module (ECM) Receives signals from sensor and control switches;
Cruise control indicator Illuminate when CRUISE main switch is ON (Built into
cluster)
Cruise Control switches CRUISE main switch Switch for automatic speed control power supply.
Resume/Accel switch Controls automatic speed control functions by
Set/Coast switch Resume/Accel switch (Set/Coast switch)

Cancel switch Cancel switch

Brake-pedal switch
Sends cancel signals to ECM
Transaxle range switch
(A/T)
Clutch switch (M/T)
ETS motor Regulates the throttle valve to the set opening by ECM.

* ETS : Electronic Throttle System

CRUISE CONTROL
Cruise control system is engaged by "ON/OFF" main switch located on right of steering wheel column. System has the
capability to cruise, coast, resume speed, and accelerate, and raise "tab-up" or lower "tab-down" set speed.
It also has a safety interrupt, engaged upon depressing brake or shifting select lever.
ECM is a speed control system that maintains a required vehicle speed at normal driving conditions.
The main components of cruise control system are mode control switches, transaxle range switch, brake switch,
vehicle speed sensor, ECM and ETS motor that connect throttle body.
ECM contains a low speed limit which will prevent system engagement below a minimum speed of 40km/h (25mph).
The operation of the controller is controlled by mode control switches located on steering wheel.
Transaxle range switch and brake switch are provided to disengage the cruise control system. The switches are on
brake pedal bracket and transaxle. When the brake pedal is depressed or select lever shifted, the cruise control
system is electrically disengaged and the throttle is returned to the idle position.
Cruise main switch
Cruise control system is engaged by pressing "ON/OFF" push button. Releasing "ON/OFF" push button release
throttle, clears cruise memory speed, and puts vehicle in a non-cruise mode.
Coast/Set switch
COAST/SET switch located on right of steering wheel column has two positions - "Normal" and "Depressed". The set
position - With COAST/SET switch depressed and then released the cruise speed will be set at the speed the vehicle
was going when COAST/SET switch was released. The coast position - With COAST/SET switch fully depressed,
driver can lower cruise speed. To decrease cruise speed, COAST/SET switch is held in, disengaging cruise control
system. When vehicle has slowed to required cruise speed, releasing COAST/SET switch will re-engage speed at new
selected speed.
The tab down - To lower vehicle speed, cruise must be engaged and operating. Tab down is done by quickly pressing
and releasing COAST/SET switch. Do not hold COAST/SET switch in depressed position.
Tab down is a function which will cause the cruise control 's speed of vehicle to decrease by 1 mph (1.6km/h)
Resume/Accel switch
RES/ACCEL switch located on right of steering wheel column has two positions - "Normal" and "Depressed".
The resume position - With RES/ACCEL switch depressed and then release, this switch also returns cruise control
operation to last speed (Which is temporarily disengaged by Cancel switch or Brake pedal), setting when momentarily
operating RES/ACCEL switch by constant acceleration.
The accel position - With RES/ACCEL switch depressed and held in, disengaging cruise control system, when vehicle
has accelerated to required cruise speed, releasing RES/ACCEL switch will re-engage speed at new selected speed.
The tab up - To increase vehicle speed, the cruise must be engaged and operating.
Tab up is done by quickly pressing and releasing RES/ACCEL switch less than 0.5 second. Do not hold RES/ACCEL
switch in depressed position. Tab up is a function in which cruise speed can be increased by 1mph (1.6km/h).
Cancel switch
Cruise control system is temporarily disengaged by pressing "CANCEL" switch.
Cruise speed canceled by this switch will be recovered by RES/ACCEL switch
 > D 2.5 CRDI >

TROUBLE SYMPTOM CHARTS

TROUBLE SYMPTOM 1

TROUBLE SYMPTOM 2

Trouble symptom Probable cause Remedy

The set vehicle speed varies greatly Malfunction of the vehicle speed Repair the vehicle speed sensor
upward or downward sensor circuit system, or replace the part
"Surging" (repeated alternating
acceleration and deceleration) occurs Malfunction of ECM Check input and output signals at
after setting ECM

TROUBLE SYMPTOM 3

Trouble symptom Probable cause Remedy

 Damaged or disconnected wiring of Repair the harness or replace the
The CC system is not canceled when the brake pedal switch brake pedal switch
the brake pedal is depressed Check input and output signals at
Malfunction of the ECM signals
ECM

TROUBLE SYMPTOM 4

Trouble symptom Probable cause Remedy

Damaged or disconnected wiring of
inhibitor switch input circuit Repair the harness or repair or
The CC system is not canceled when
the shift lever is moved to the "N" Improper adjustment of inhibitor replace the inhibitor switch
position (It is canceled, however, switch
when the brake pedal is depressed
Check input and output signals at
Malfunction of the ECM signals
ECM

TROUBLE SYMPTOM 5

Trouble symptom Probable cause Remedy

Temporary damaged or disconnected Repair the harness or replace the
Cannot decelerate (coast) by using wiring of SET switch input circuit SET switch
the SET switch Check input and output signals at
Malfunction of the ECM signals
ECM

TROUBLE SYMPTOM 6

Trouble symptom Probable cause Remedy

Damaged or disconnected wiring, or
Repair the harness or replace the
short circuit, or RESUME switch input
Cannot accelerate or resume speed RESUME switch
circuit
by using the RESUME switch
Check input and output signals at
Malfunction of the ECM signals
ECM

TROUBLE SYMPTOM 7

Trouble symptom Probable cause Remedy

CC system can be set while driving at Malfunction of the vehicle-speed Repair the vehicle speed sensor
a vehicle speed of less than 40km/h sensor circuit system, or replace the part
(25mph), or there is no automatic Check input and output signals at
cancellation at that speed Malfunction of the ECM signals
ECM

TROUBLE SYMPTOM 8

Trouble symptom Probable cause Remedy

The cruise main switch indicator lamp Damaged or disconnected bulb of

Repair the harness or replace the
does not illuminate (But CC system is cruise main switch indicator lamp
part.
normal) Harness damaged or disconnected
 Engine Electrical System

Cruise Control System - Cruise Control

Switch

Engine Electrical System

> D 2.5 CRDI >

CIRCUIT DIAGRAM
 > D 2.5 CRDI >

MEASURING RESISTANCE
1. Disconnect the cruise control switch connector from the control switch.

2. Measure resistance between terminals on the control switch when each function switch is ON (switch is
depressed).
Function switch Terminal Resistance
Cruise Main 7-9 3.9kΩ ± 1%
Cancel 8-9 0Ω ± 1%
Set/Coast 8-9 220Ω ± 1%
Resume/Accel 8-9 910Ω ± 1%

3. If not within specification, replace switch.

MEASURING VOLTAGE
1. Connect the cruise control switch connector to the control switch.

2. Measure voltage between terminals on the harness side connector when each function switch is ON (switch is
depressed).
Function switch Terminal Voltage
Cruise Main 7-9 -
 Cancel 8-9 0.0V ± 0.25V
Set/Coast 8-9 1.5V ± 0.25V
Resume/Accel 8-9 3.0V ± 0.25V

3. If not within specification, replace switch.

REMOVAL
1. Disconnect the battery (-) terminal.
2. Remove the driver side air bag module. (Refer to RT GR.)
3. Disconnect the cruise control switch connector and then remove the cruise control switch(A) with two screws.

4. Installation is the reverse of removal.

 Engine Electrical System

Preheating System

Engine Electrical System

> D 2.5 CRDI >

COMPONENTS
 > D 2.5 CRDI >

INSPECT PREHEATING SYSTEM

Conditions before inspection :
Battery voltage : 12V
1. Connect voltmeter between glow plug plate and plug body (ground).
2. Check indicated value on voltmeter with ignition switch ON.
3. Check that preheat indication lamp lights for about 6 seconds and indicates battery voltage (about 9V or over) for
about 36 seconds immediately afterignitionswitch is turned on. [At cooling water temperature 20°C (68°F)]

Continuity time varies depending upon cooling water temperature.

4. After checking 3, set ignition switch at START position.

5. The system is normal if battery voltage (about 9V or over) is generatedforabout 6 seconds during engine cranking
and after start operation. [at coolingwater temperature 20°C (68°F)]
6. When the voltage or continuity time is not normal, check the terminal voltage in glow control unit, and single parts.

INSPECT GLOW PLUS

1. Check the continuity between the terminal and body as illustrated. Replaceif discontinuity or with large resistance.

Standard value : 0.25Ω

Remove oil from plug before measuring as glow plug resistance is verysmall.

2. Check for rust on glow plug plate.

3. Check glow plug for damage.

INSPECT GLOW PLUG RELAY

1. Remove the glow plug relay.
2. Inspect the relay continuity.
 A. Using an ohmmeter, check that there is continuity between terminals 2 and 4.
If there is no continuity, replace the relay.
B. Check that there is no continuity between terminals 1 and 5.
If there is continuity, replace the relay.

3. Inspect the relay operation.

A. Apply battery positive voltage across terminals 2 and 4.
B. Using an ohmmeter, check that there is continuity between terminals 1 and 5.
If there is no continuity, replace the relay.

4. Install the glow plug relay.