Jeep Liberty 2.8L Diesel 2006, Liberty 2.8L Diesel 2005 User Manual

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Page 1

GROUP TAB LOCATOR

Maintenance Schedules

Cooling - 2.5L / 2.8L Diesel

7 8E 8F

11 14 21 25

Service Manual Comment Forms (Rear of Manual)

Electronic Control Modules Engine Systems Ignition Control

Engine

Exhaust System and Turbocharger Fuel System Automatic Transmission - 545RFE Emissions Control - 2.5L / 2.8L Turbo Diesel

Page 2

KJ MAINTENANCE SCHEDULES 0 - 1

MAINTENANCE SCHEDULES

TABLE OF CONTENTS

page

MAINTENANCE SCHEDULES FOR ALL

MARKETS EXCEPT U.S., CANADA and MEXICO

DESCRIPTION — DIESEL ENGINES .........1

MAINTENANCE SCHEDULES FOR ALL MARKETS EXCEPT U.S., CANADA and MEXICO

DESCRIPTION — DIESEL ENGINES

Maintenance Schedule Information not included in this section, is located in the appropriate Owner’s Manual.

There are two maintenance schedules that show the required service for your vehicle.

First is Schedule “B”. It is for vehicles that are operated under the conditions that are listed below and at the beginning of the schedule.

• Extensive engine idling.

• Driving in dusty conditions.

• More than 50% of your driving is at sustained

high speeds during hot weather, above 32° C (90° F).

• Trailer towing.

• Taxi, police, or delivery service (commercial ser-

vice).

NOTE: Most vehicles are operated under the conditions listed for Schedule (B(.

Second is Schedule “A”. It is for vehicles that are not operated under any of the conditions listed under Schedule 9B9.

Use the schedule that best describes your driving conditions. Where time and mileage are listed, follow the interval that occurs first.

CAUTION: Failure to perform the required maintenance items may result in damage to the vehicle.

At Each Stop for Fuel

• Check the engine oil level about 5 minutes after a fully warmed engine is shut off. Checking the oil level while the vehicle is on level ground will improve the accuracy of the oil level reading. Add oil only when the level is at or below the ADD or MIN mark.

• Check the windshield washer solvent and add if

required.

Once a Month

• Check the tire pressure and look for unusual

wear or damage.

• Inspect the battery and clean and tighten the

terminals as required.

• Check the fluid levels of coolant reservoir, brake master cylinder, power steering and transmission and add as needed.

• Check all lights and all other electrical items for correct operation.

At Each Oil Change

• Change the engine oil filter.

• Inspect the exhaust system.

• Inspect the brake hoses.

• Check the manual transmission fluid level — if

equipped.

• Check the coolant level, hoses, and clamps.

• Inspect engine accessory drive belts. Replace as

necessary.

• Inspect for the presence of water in the fuel filter/water separator unit.

• Rotate the tires.

Schedule “B”

Follow schedule “B” if you usually operate your

vehicle under one or more of the following conditions.

• Extensive engine idling.

• Driving in dusty conditions.

• More than 50% of your driving is at sustained

high speeds during hot weather, above 32° C (90° F).

• Trailer towing.

• Taxi, police, or delivery service (commercial ser-

vice).

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0 - 2 MAINTENANCE SCHEDULES KJ

MAINTENANCE SCHEDULES FOR ALL MARKETS EXCEPT U.S., CANADA and MEXICO (Continued)

Kilometers 10 000 km 20 000 km 30 000 km 40 000 km 50 000 km

Change the engine oil and engine oil filter. XXXXX Inspect the ball joints. XXXXX Inspect engine accessory drive belt. XXXX Replace engine accessory drive belt. X Inspect the engine air filter element.

Replace as necessary. Replace the engine air filter element. X X Replace the engine timing belt. X Inspect idler pulleys and timing belt

tensioner‡. Replace fuel filter/water separator unit. X X Inspect the brake linings. XXXXX Drain and refill the front and rear axle fluid. X X Drain and refill automatic transmission fluid

and replace transmission main sump filter.

XXX

Kilometers 60 000 km 70 000 km 80 000 km 90 000 km 100 000 km

Change the engine oil and engine oil filter. XXXX X Inspect the ball joints. XXXX X Inspect engine accessory drive belt. XXXX X Replace engine accessory drive belt. X Inspect the engine air filter element.

Replace as necessary. Replace the engine air filter element. X X X Inspect idler pulleys and timing belt

tensioner‡. Replace the engine timing belt. X Inspect the brake linings. XXXX X Drain and refill the front and rear axle fluid. X X X Replace the fuel filter/water separator unit. X X X Drain and refill the transfer case fluid. X Drain and refill the automatic transmission

fluid and replace transmission main sump filter.

Page 4

KJ MAINTENANCE SCHEDULES 0 - 3

MAINTENANCE SCHEDULES FOR ALL MARKETS EXCEPT U.S., CANADA and MEXICO (Continued)

Kilometers 110 000 km 120 000 km 130 000 km 140 000 km 150 000 km 160 000 km

Change the engine oil and engine oil filter.

Inspect the ball joints. XXXXXX Inspect the engine air filter

element. Replace as necessary.

Replace the engine air filter element.

Inspect engine accessory drive belt.

Replace engine accessory drive belt.

Inspect the idler pulleys and timing belt tensioner‡.

Replace the engine timing belt.

Inspect the brake linings. XXXXXX Drain and refill the front and

rear axle fluid. Replace the fuel filter/water

separator unit. Flush and replace the engine

coolant. Drain and refill automatic

transmission fluid and replace transmission filter (s).

XXXXXX

XXX

XXXX X

XXX

Inspection and service should also be performed anytime a malfunction is observed or suspected. Retain all receipts.

‡ Replace if there is superficial wear, bearing clearance, or evident grease leak.

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0 - 4 MAINTENANCE SCHEDULES KJ

MAINTENANCE SCHEDULES FOR ALL MARKETS EXCEPT U.S., CANADA and MEXICO (Continued)

Schedule “A”

Kilometers 20 000 km 40 000 km 60 000 km 80 000 km 100 000 km

Change the engine oil and engine oil filter.

Inspect the ball joints. XXXXX Inspect the brake linings. X X Inspect the engine air filter element.

Replace as necessary. Replace the engine air filter element. X X Inspect the engine accessory drive belt. XXXXX Replace the engine accessory drive

belt. Replace the fuel filter/water separator

unit. Inspect idler pulleys, and timing belt

tensioner‡. Replace the engine timing belt. X Inspect the transfer case fluid. X

XXXXX

XXX

XXXXX

Kilometers 120 000 km 140 000 km 160 000 km 180 000 km

Change the engine oil and engine oil filter. X X X X Inspect the ball joints. X X X X Inspect the brake linings. X X Inspect the engine accessory drive belt. X X X X Inspect the engine air filter element. Replace

as necessary. Replace the engine air filter element. X X Replace the fuel filter/water separator unit. X X X X Flush and replace the engine coolant. X Inspect the transfer case fluid. X Drain and refill the transfer case fluid. X Drain and refill automatic transmission fluid

and replace transmission filter (s).

Inspection and service should also be performed anytime a malfunction is observed or suspected. Retain all receipts.

‡ Replace if there is superficial wear, bearing clearance, or evident grease leak.

WARNING: You can be badly injured working on or around a motor vehicle. Do only that service work for which you have the knowledge and the right equipment. If you have any doubt about your ability to perform a service job, take your vehicle to a competent mechanic.

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KJ COOLING - 2.5L/2.8L TURBO DIESEL 7 - 1

COOLING - 2.5L/2.8L TURBO DIESEL

TABLE OF CONTENTS

page page

COOLING - 2.5L/2.8L TURBO DIESEL

DESCRIPTION - COOLING SYSTEM .........1

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - COOLING

SYSTEM FLOW CHECK .................1

DIAGNOSIS AND TESTING - COOLING

SYSTEM AERATION ....................1

DIAGNOSIS AND TESTING - COOLING

SYSTEM LEAK TEST....................2

DIAGNOSIS AND TESTING - ON-BOARD

DIAGNOSTICS (OBD) ...................2

DIAGNOSIS AND TESTING - COOLING

SYSTEM .............................3

COOLING - 2.5L/2.8L TURBO DIESEL

DESCRIPTION - COOLING SYSTEM

The cooling system regulates engine operating temperature. It allows the engine to reach normal operating temperature as quickly as possible, maintains normal operating temperature and prevents overheating.

The cooling system also provides a means of heating the passenger compartment. The cooling system is pressurized and uses a centrifugal water pump to circulate coolant throughout the system. A separate and remotely mounted, pressurized coolant tank using a pressure/vent cap is used.

COOLING SYSTEM COMPONENTS

The cooling system consists of:

• Charge Air Cooler

• Electric Cooling Fans

• A aluminum-core radiator with plastic side

tanks

• A separate pressurized coolant tank

• A pressure/vent cap on the coolant tank

• Fan shroud

• Thermostat

• Coolant

• Low coolant warning lamp

• Coolant temperature gauge

• Water pump

• Hoses and hose clamps

STANDARD PROCEDURE - COOLING

SYSTEM - REVERSE FLUSHING ...........7

CLEANING .............................8

INSPECTION ...........................8

SPECIFICATIONS

SPECIFICATIONS - COOLING SYSTEM

CAPACITY ............................8

SPECIFICATIONS - TORQUE .............8

ACCESSORY DRIVE .......................9

ENGINE ...............................16

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - COOLING SYSTEM FLOW CHECK

To determine whether coolant is flowing through

the cooling system, use the following procedures:

(1) If engine is cold, idle engine until normal operating temperature is reached. Then feel the upper radiator hose. If it is hot, coolant is circulating.

WARNING: DO NOT REMOVE THE COOLING SYSTEM PRESSURE CAP WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR.

(2) Remove pressure/vent cap when engine is cold, idle engine until thermostat opens, you should observe coolant flow while looking down in the coolant recovery pressure container. Once flow is detected install the pressure/vent cap.

DIAGNOSIS AND TESTING - COOLING SYSTEM AERATION

Low coolant level in a cross flow radiator will equalize in both tanks with engine off. With engine at running and at operating temperature, the high pressure inlet tank runs full and the low pressure outlet tank drops, resulting in cooling system aeration. Aeration will draw air into the water pump resulting in the following:

• High reading shown on the temperature gauge.

• Loss of coolant flow through the heater core.

• Corrosion in the cooling system.

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7 - 2 COOLING - 2.5L/2.8L TURBO DIESEL KJ

COOLING - 2.5L/2.8L TURBO DIESEL (Continued)

• Water pump seal may run dry, increasing the

risk of premature seal failure.

• Combustion gas leaks into the coolant can also

cause aeration.

DIAGNOSIS AND TESTING - COOLING SYSTEM LEAK TEST

WARNING: THE WARNING WORDS “DO NOT OPEN HOT” ON THE RADIATOR PRESSURE CAP IS A SAFETY PRECAUTION. WHEN HOT, PRESSURE BUILDS UP IN COOLING SYSTEM. TO PREVENT SCALDING OR INJURY, THE RADIATOR CAP SHOULD NOT BE REMOVED WHILE THE SYSTEM IS HOT OR UNDER PRESSURE.

With engine not running, remove pressure/vent cap from the coolant recovery pressure container and wipe the filler neck sealing seat clean. The coolant level in the recovery pressure container should be full.

Attach the Cooling System Tester 7700 or equivalent to the radiator, as shown in (Fig. 1) and apply 104 kPa (15 psi) pressure. If the pressure drops more than 13.8 kPa (2 psi) in 2 minutes, inspect all points for external leaks.

All radiator and heater hoses should be shaken while at 104 kPa (15 psi), since some leaks occur only while driving due to engine movement.

If there are no external leaks, after the gauge dial shows a drop in pressure, detach the tester. Start engine and run until the thermostat opens, allowing the coolant to expand. Reattach the cooling system tester. If the needle on the dial fluctuates it indicates a combustion leak, usually a head gasket leak.

WARNING: WITH TOOL IN PLACE, PRESSURE WILL BUILD UP RAPIDLY. EXCESSIVE PRESSURE BUILT UP, BY CONTINUOUS ENGINE OPERATION, MUST BE RELEASED TO A SAFE PRESSURE POINT. NEVER PERMIT PRESSURE TO EXCEED 138 kPa (20 psi).

If the needle on the dial does not fluctuate, raise the engine rpm a few times. If an abnormal amount of coolant or steam emits from the tailpipe, it may indicate a coolant leak caused by a faulty head gasket, cracked engine block, or cracked cylinder head.

There may be internal leaks that can be determined by removing the oil dipstick. If water globules appear intermixed with the oil it will indicate an internal leak in the engine. If there is an internal leak, the engine must be disassembled for repair.

DIAGNOSIS AND TESTING - ON-BOARD DIAGNOSTICS (OBD)

COOLING SYSTEM RELATED DIAGNOSTICS

The Engine Control Module (ECM) has been programmed to monitor certain cooling system components. If the problem is sensed in a monitored circuit often enough to indicated an actual problem, a DTC is stored. The DTC will be stored in the ECM memory for eventual display to the service technician. (Refer to 25 - EMISSIONS CONTROL - DESCRIPTION).

Fig. 1 PRESSURE TESTING COOLING SYSTEM

1 - COOLANT PRESSURE TESTER 2 - COOLANT RECOVERY PRESSURE CONTAINER

ACCESSING DIAGNOSTIC TROUBLE CODES

To read DTC’s and to obtain cooling system data, (Refer to 25 - EMISSIONS CONTROL - DESCRIPTION).

ERASING TROUBLE CODES

After the problem has been repaired, use the DRBIIIt scan tool to erase a DTC. Refer to the appropriate Powertrain Diagnostic Procedures service information for operation of the DRBIIIt scan tool.

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KJ COOLING - 2.5L/2.8L TURBO DIESEL 7 - 3

COOLING - 2.5L/2.8L TURBO DIESEL (Continued)

DIAGNOSIS AND TESTING - COOLING SYSTEM

Establish what driving conditions caused the complaint. Abnormal loads on the cooling system such as the following may be the cause:

(1) PROLONGED IDLE, VERY HIGH AMBIENT TEMPERATURE, SLIGHT TAIL WIND AT IDLE, SLOW TRAFFIC, TRAFFIC JAMS, HIGH SPEED OR STEEP GRADES.

• Idle with A/C off when temperature gauge is at

end of normal range.

(2) TRAILER TOWING:

Consult Trailer Towing section of owners manual. Do not exceed limits.

(3) RECENT SERVICE OR ACCIDENT REPAIR:

Determine if any recent service has been performed on vehicle that may effect cooling system. This may be:

COOLING SYSTEM DIAGNOSIS-DIESEL ENGINE

CONDITION POSSIBLE CAUSES CORRECTION

TEMPERATURE GAUGE

READS LOW

1. Diesel engines, due to their inherent efficiency are slower to warm up than gasoline powered engines, and will operate at lower temperatures when the vehicle is unloaded.

2. Is the temperature gauge connected to the temperature gauge coolant sensor on the engine?

3. Is the temperature gauge operating OK?

4. Coolant level low in cold ambient temperatures accompanied with poor heater performance.

5. Improper operation of internal heater doors or heater controls.

• Engine adjustments (incorrect timing)

• Slipping engine accessory drive belt

• Brakes (possibly dragging)

• Changed parts (incorrect water pump)

• Reconditioned radiator or cooling system refill-

ing (possibly under filled or air trapped in system).

NOTE: If investigation reveals none of the previous items as a cause for an engine overheating complaint, refer to following Cooling System Diagnosis charts.

These charts are to be used as a quick-reference

only.

1. The low gauge reading may be normal. Refer to thermostats in the manual text for information. See Thermostat Diagnosis-Diesel Engine.

2. Check, the engine temperature sensor connector in the engine compartment.

3. Check gauge operation. Repair as necessary.

4. Check coolant level in the coolant tank. Inspect system for leaks. Repair leaks as necessary. Refer to the Coolant section for WARNINGS and precautions before removing the pressure cap.

5. Inspect heater and repair as necessary. Refer to Heating and Air Conditioning for procedures.

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7 - 4 COOLING - 2.5L/2.8L TURBO DIESEL KJ

COOLING - 2.5L/2.8L TURBO DIESEL (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

TEMPERATURE GAUGE

READS HIGH. COOLANT

MAY OR MAY NOT BE LOST

OR LEAKING FROM

COOLING SYSTEM

1. Trailer is being towed, a steep hill is being climbed, vehicle is operated in slow moving traffic, or engine is being idled with very high ambient (outside) temperature and the air conditioning is on. Higher altitudes could aggravate these conditions.

2. Temperature gauge reading incorrectly.

3. Coolant low in coolant tank and radiator.

4. Pressure cap not installed tightly. If cap is loose, boiling point of coolant will be lowered.

5. Poor seals at pressure/vent cap. 5. (a) Check condition of cap and

6. Freeze point of antifreeze not correct. Mixture may be too rich.

7. Coolant not flowing through system.

8. Radiator or A/C condenser fins are dirty or clogged.

9. Radiator core is corroded or plugged.

10. Aftermarket A/C installed without proper A/C condenser.

11. Dragging Brakes. 11. Check and correct as

12. Non-factory bug screen is being used reducing air flow.

13. Thermostat partially or completely shut. This is more prevalent on high mileage vehicles.

14. Cylinder head gasket leaking. 14. Check cylinder head gasket for

15. Heater core leaking. 15. Check heater core for leaks.

1. This may be a temporary condition and repair is not necessary. Turn off the air conditioning and attempt to drive the vehicle without any of the previous conditions. Observe the temperature gauge. The gauge should return to the normal range. If the gauge does not return to normal range, determine the cause for the overheating and repair.

2. Check gauge. Refer to I/P group.

3. Check for coolant leaks and repair as necessary.

4. Tighten cap.

cap seals. (b) Check condition of coolant tank filler neck. Make sure it does not leak pressure.

6. Check antifreeze. Adjust antifreeze-to-water ratio as required.

7. Check for coolant flow in coolant tank with engine warm and thermostat open. Coolant should be observed flowing through the tank. If flow is not observed, determine reason for lack of flow and repair as necessary.

8. Clean debris from radiator or A/C condenser

9. Have radiator re-cored or replaced.

10. Install proper A/C condenser.

necessary.

12. Only a factory screen should be used.

13. Check thermostat and replace if necessary.

leaks. Repair as necessary.

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KJ COOLING - 2.5L/2.8L TURBO DIESEL 7 - 5

COOLING - 2.5L/2.8L TURBO DIESEL (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

TEMPERATURE GAUGE

READING IS INCONSISTENT

(FLUCTUATES, CYCLES OR

IS ERRATIC)

1. During cold weather operation, with the heater blower in the high position, the gauge reading may drop slightly. Fluctuation is also influenced by loads, outside temperature and extended idle time with diesel engines.

2. Temperature gauge or engine mounted gauge sensor defective or shorted. Also, corroded or loose wiring in this circuit.

3. Gauge reading rises when vehicle is brought to a stop after heavy use (engine still running).

4. Gauge reading high after starting a warm-up (hot) engine.

5. Coolant level low in the coolant tank (air will build up in the cooling system causing the thermostat to open late).

6. Cylinder head gasket leaking allowing exhaust gases to enter the cooling system causing the thermostat to open late.

7. Water pump impeller loose on shaft.

8. Loose accessory drive belt (water pump slipping).

9. Air leak on the suction side of the water pump allowing air to build up in the cooling system causing the thermostat to open late.

1. A normal condition. No correction is necessary.

2. Check operation of gauge and repair as necessary.

3. A normal condition. No correction needed. Gauge should return to normal range after vehicle is driven.

4. A normal condition. No correction needed. Gauge should return to normal after a few minutes of engine operation.

5. Check and correct coolant leaks.

6. (a) Check for cylinder head gasket leaks with a commercially available leak tester. (b) Check for coolant in engine oil. Inspect for white steam emitting from exhaust system. Repair as necessary.

7. Check water pump and replace as necessary.

8. Check and correct as necessary.

9. Locate leak and repair as necessary.

PRESSURE CAP IS

BLOWING OFF STEAM

AND/OR COOLANT.

TEMPERATURE GAUGE

READING MAY BE ABOVE

NORMAL BUT NOT HIGH.

COOLANT LEVEL MAY BE

HIGH IN COOLANT TANK

COOLANT LOSS TO THE

GROUND WITHOUT

PRESSURE CAP BLOWOFF.

GAUGE IS READING HIGH

OR HOT

1. Pressure relief valve in pressure/ vent cap is defective.

2. Head gasket leak or cracked cylinder head.

1. Coolant leaks in radiator, cooling system hoses, water pump, or engine.

1. Check condition of pressure/ vent cap and cap seals.

2. Repair as necessary.

1. Pressure test cooling system and repair as necessary.

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7 - 6 COOLING - 2.5L/2.8L TURBO DIESEL KJ

COOLING - 2.5L/2.8L TURBO DIESEL (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

HOSE OR HOSES

COLLAPSE WHEN ENGINE

IS COOLING

NOISY FAN 1. Cooling fan blades loose. 1. Replace cooling fan assembly.

INADEQUATE AIR

CONDITIONER

PERFORMANCE (COOLING

SYSTEM SUSPECTED)

1. Vacuum created in cooling system on engine cool-down is not being relieved through pressure/vent cap.

2. Cooling fan blades striking a surrounding object.

3. Air obstructions at radiator or A/C condenser.

1. Radiator and/or A/C condenser is restricted, obstructed or dirty (insects, leaves, etc.)

2. Engine is overheating (heat may be transferred from radiator to A/C condenser. High Under hood temperatures due to engine overheating may also transfer heat to A/C condenser).

3. The cooling system is equipped with air seals at the radiator and/or A/C condenser. If these seals are missing or damaged, not enough air flow will be pulled through the radiator and A/C condenser.

1. Cap relief valve stuck. Replace if necessary.

2. Locate point of fan blade contact and repair as necessary.

3. Remove obstructions or clean debris from radiator or A/C condenser.

1. Remove restriction or clean debris from radiator or A/C condenser.

2. Correct overheating condition.

3. Check for missing or damaged air seals. Repair as necessary.

INADEQUATE HEATER

PERFORMANCE. MAY BE

ACCOMPANIED BY LOW

GAUGE READING

1. Diesel engines, due to their inherent efficiency are slower to warm up than gasoline powered engines, and will operate at lower temperatures when the vehicle is unloaded.

2. Coolant level low. 2. Pressure test cooling system.

3. Obstruction in heater hose fitting at engine.

4. Heater hose kinked. 4. Locate kinked area. Repair as

5. Water pump is not pumping water to heater core. When the engine is fully warmed up, both heater hoses should be hot to the touch. If only one of the hoses is hot the water pump may not be operating correctly. The accessory drive belt may also be slipping causing poor water pump operation.

1. The lower gauge reading may be normal.

Repair leaks as necessary.

3. Remove heater hoses and check for obstructions. Repair as necessary.

necessary.

5. Refer to water pumps in this group. Repair as necessary. If a slipping belt is detected, refer to Engine Accessory Drive Belts in this group. Repair as necessary.

Page 12

KJ COOLING - 2.5L/2.8L TURBO DIESEL 7 - 7

COOLING - 2.5L/2.8L TURBO DIESEL (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

HEAT ODOR 1. Various heat shields are used at

certain drive line components. One or more of these shields may be missing.

2. Is temperature gauge reading above the normal range?

3. Is the Cooling fan operating correctly?

4. Has undercoating been applied to any unnecessary components?

STEAM IS COMING FROM

FRONT OF VEHICLE NEAR

GRILL AREA WHEN

WEATHER IS WET, ENGINE

IS WARMED UP AND

RUNNING, AND VEHICLE IS

STATIONARY.

TEMPERATURE GAUGE IS

IN NORMAL RANGE

COOLANT ODOR 1. Coolant color is not necessarily an

1. During wet weather, moisture (snow, ice, or rain condensation) on the radiator will evaporate when the thermostat opens. This opening allows heated water into the radiator. When the moisture contacts the hot radiator, steam may be emitted. This usually occurs in cold weather with no fan or air flow to blow it away.

indication of adequate corrosion or temperature protection. Do not rely on coolant color for determining condition of coolant.

1. Locate missing shields. Repair or replace as necessary.

2. Refer to the previous Temperature Gauge Reads High in these Diagnostic Charts. Repair as necessary.

3. Refer to Cooling System Fan in this group for diagnosis. Repair as necessary.

4. Clean undercoating as necessary.

1. Occasional steam emitting from this area is normal. No repair is necessary.

1. Refer to Coolant in this group for antifreeze tests. Adjust antifreeze-to-water ratio as necessary.

COOLANT LEVEL CHANGES

IN COOLANT TANK.

TEMPERATURE GAUGE IS

IN NORMAL RANGE

1. Level changes are to be expected as coolant volume fluctuates with engine temperature. If the level in the tank was between the HOT and COLD marks at normal engine operating temperature, the level should return to within that range after operation at elevated temperatures.

STANDARD PROCEDURE - COOLING SYSTEM REVERSE FLUSHING

CAUTION: The cooling system normally operates at 97-to-110 kPa (14-to -16 psi) pressure. Exceeding this pressure may damage the radiator or hoses.

Reverse flushing of the cooling system is the forcing of water through the cooling system. This is done using air pressure in the opposite direction of normal coolant flow. It is usually only necessary with very dirty systems with evidence of partial plugging.

1. This a normal condition. No repair necessary.

CHEMICAL CLEANING

If visual inspection indicates the formation of sludge or scaly deposits, use a radiator cleaner (Mopar Radiator Kleen or equivalent) before flushing. This will soften scale and other deposits and aid the flushing operation.

CAUTION: Be sure instructions on the container are followed.

REVERSE FLUSHING RADIATOR

Disconnect the radiator hoses from the radiator fittings. Attach a section of radiator hose to the radiator bottom outlet fitting and insert the flushing gun. Connect a water supply hose and air supply hose to the flushing gun.

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7 - 8 COOLING - 2.5L/2.8L TURBO DIESEL KJ

COOLING - 2.5L/2.8L TURBO DIESEL (Continued)

CAUTION: The cooling system normally operates at 97-to-110 kPa (14- to-16 psi) pressure. Exceeding this pressure may damage the radiator or hoses.

Allow the radiator to fill with water. When radiator is filled, apply air in short blasts allowing radiator to refill between blasts. Continue this reverse flushing until clean water flows out through rear of radiator cooling tube passages. For more information, refer to operating instructions supplied with flushing equipment. Have radiator cleaned more extensively by a radiator repair shop.

REVERSE FLUSHING ENGINE

Drain the cooling system (Refer to 7 - COOLING STANDARD PROCEDURE). Disconnect the radiator upper hose from the radiator and attach the flushing gun to the hose. Disconnect the radiator lower hose from the water pump. Attach a lead away hose to the water pump inlet fitting.

CAUTION: Be sure that the heater control valve is closed (heat off). This is done to prevent coolant flow with scale and other deposits from entering the heater core.

Connect the water supply hose and air supply hose to the flushing gun. Allow the engine to fill with water. When the engine is filled, apply air in short blasts, allowing the system to fill between air blasts. Continue until clean water flows through the lead away hose. For more information, refer to operating instructions supplied with flushing equipment.

Remove the lead away hose, flushing gun, water supply hose and air supply hose. Remove the thermostat housing (Refer to 7 - COOLING/ENGINE/ENGINE COOLANT THERMOSTAT - REMOVAL). Install the thermostat and housing with a replace-

ment gasket (Refer to 7 - COOLING/ENGINE/ENGINE COOLANT THERMOSTAT INSTALLATION). Connect the radiator hoses. Refill the cooling system with the correct antifreeze/water mixture (Refer to 7 - COOLING - STANDARD PROCEDURE).

CLEANING

Drain cooling system and refill with clean water. Refer to procedures in this section. Run engine with pressure/vent cap installed until upper radiator hose is hot. Stop engine and drain water from system. If water is dirty; fill, run, and drain system again, until water runs clear.

INSPECTION

After performing a cleaning/flush procedure, inspect all hoses, clamps and connections for deterioration and leaks. Inspect radiator and heater core for leaks.

SPECIFICATIONS

SPECIFICATIONS - COOLING SYSTEM CAPACITY

SPECIFICATIONS

DESCRIPTION SPECIFICATION

Cooling System With Auxiliary Heater

Cooling System With Out Auxiliary Heater

16.6 Liters (17.5 qts.)

13.8 Liters (14.6 qts.)

SPECIFICATIONS - TORQUE

2.5L/2.8L DIESEL - TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Accessory Drive Belt Idler

Bolt

Accessory Drive Belt

Tensioner Bolt

Cooling Fan Support Bolts 47.1 35 —

Thermostat Housing Bolts 27.5 21 —

Water Pump Housing Nuts 24.4 18 215

53 39 —

47.1 35 —

Page 14

KJ ACCESSORY DRIVE 7 - 9

ACCESSORY DRIVE

TABLE OF CONTENTS

page page

ACCESSORY DRIVE

SPECIFICATIONS - ACCESSORY BELT

TENSION .............................9

BELT TENSIONERS

DESCRIPTION ..........................9

OPERATION ............................9

REMOVAL .............................10

INSTALLATION .........................10

DRIVE BELT

DESCRIPTION .........................11

ACCESSORY DRIVE

SPECIFICATIONS - ACCESSORY BELT TENSION

ACCESSORY DRIVE

BELT

2.5L/2.8L DIESEL ENGINE

A/C Compressor/

Generator

Power Steering Belt Dynamic Tensioner

GAUGE

Dynamic Tensioner

OPERATION-ACCESSORY DRIVE BELT ......11

DIAGNOSIS AND TESTING - ACCESSORY

DRIVE BELT .........................11

REMOVAL .............................13

INSTALLATION .........................13

IDLER PULLEYS

REMOVAL .............................14

INSTALLATION .........................15

BELT TENSIONERS

DESCRIPTION

This engine is equipped with a spring loaded automatic belt tensioner (Fig. 1). This tensioner maintains constant belt tension at all times and requires no maintenance or adjustment.

CAUTION: Do not attempt to check belt tension with a belt tension gauge on vehicles equipped with an automatic belt tensioner.

OPERATION

WARNING: THE AUTOMATIC BELT TENSIONER ASSEMBLY IS SPRING LOADED. DO NOT ATTEMPT TO DISASSEMBLE THE TENSIONER ASSEMBLY.

Fig. 1 ACCESSORY BELT ROUTING

1 - IDLER PULLEY 2 - GENERATOR 3 - IDLER PULLEY 4 - A/C COMPRESSOR 5 - COOLING FAN SUPPORT 6 - VIBRATION DAMPER 7 - BELT TENSIONER 8 - POWER STEERING PUMP 9 - ACCESSORY DRIVE BELT 10 - VISCOUS HEATER

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7 - 10 ACCESSORY DRIVE KJ

BELT TENSIONERS (Continued)

The automatic belt tensioner maintains correct belt tension using a coiled spring within the tensioner housing. The spring applies pressure to the tensioner arm pressing the arm into the belt, tensioning the belt.

If a new belt is being installed, the arrow must be within approximately 3 mm (1/8 in.) of indexing mark. Belt is considered new if it has been used 15 minutes or less. If this specification cannot be met, check for:

• The wrong belt being installed (incorrect length/

width)

• Worn bearings on an engine accessory (A/C compressor, power steering pump, water pump, idler pulley or generator)

• A pulley on an engine accessory being loose

• Misalignment of an engine accessory

• Belt incorrectly routed.

REMOVAL

(1) Disconnect negative battery cable.

(2) Remove accessory drive belt (Fig. 2)(Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL).

(3) Remove belt tensioner retaining bolt and remove tensioner from bracket (Fig. 3).

Fig. 2 ACCESSORY BELT ROUTING

1 - IDLER PULLEY 2 - GENERATOR 3 - IDLER PULLEY 4 - A/C COMPRESSOR 5 - COOLING FAN SUPPORT 6 - VIBRATION DAMPER 7 - BELT TENSIONER 8 - POWER STEERING PUMP 9 - ACCESSORY DRIVE BELT 10 - VISCOUS HEATER

Fig. 3 BELT TENSIONER ASSEMBLY

1 - ACCESSORY BELT TENSIONER RETAINING BOLT 2 - POWER STEERING PUMP PULLEY 3 - BELT TENSIONER 4 - BRACKET 5 - POWER STEERING PUMP 6 - POWER STEERING PUMP RETAINING BOLTS 7 - POWER STEERING PUMP PULLEY RETAINING BOLTS

INSTALLATION

(1) Install belt tensioner on bracket (Fig. 3). Torque retaining bolt to 47.1N·m.

(2) Install accessory drive belt (Fig. 2)(Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION).

(3) Connect negative battery cable.

Page 16

KJ ACCESSORY DRIVE 7 - 11

DRIVE BELT

DESCRIPTION

The accessory drive belt is a serpentine type belt (Fig. 4). Satisfactory performance of these belts depends on belt condition and proper belt tension.

DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT

VISUAL DIAGNOSIS

When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from rib to rib (Fig. 5), are considered normal. These are not a reason to replace the belt. However, cracks running along a rib (not across) are not normal. Any belt with cracks running along a rib must be replaced (Fig. 5). Also replace the belt if it has excessive wear, frayed cords or severe glazing.

Refer to ACCESSORY DRIVE BELT DIAGNOSIS CHART for further belt diagnosis.

Fig. 4 ACCESSORY BELT ROUTING

1 - IDLER PULLEY 2 - GENERATOR 3 - IDLER PULLEY 4 - A/C COMPRESSOR 5 - COOLING FAN SUPPORT 6 - VIBRATION DAMPER 7 - BELT TENSIONER 8 - POWER STEERING PUMP 9 - ACCESSORY DRIVE BELT 10 - VISCOUS HEATER

OPERATION-ACCESSORY DRIVE BELT

The accessory drive belts form the link between the engine crankshaft and the engine driven accessories.

Fig. 5 BELT WEAR PATTERN

1 - NORMAL CRACKS BELT OK 2 - NOT NORMAL CRACKS REPLACE BELT

NOISE DIAGNOSIS

Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to resolve a noise condition, inspect all of the accessory drive pulleys for alignment, glazing, or excessive end play.

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7 - 12 ACCESSORY DRIVE KJ

DRIVE BELT (Continued)

ACCESSORY DRIVE BELT DIAGNOSIS CHART

CONDITION POSSIBLE CAUSES CORRECTION

RIB CHUNKING (One or more ribs has separated from belt body)

RIB OR BELT WEAR 1. Pulley misaligned 1. Align pulley(s)

BELT SLIPS 1. Belt slipping because of

1. Foreign objects imbedded in pulley grooves.

2. Installation damage 2. Replace belt

2. Abrasive environment 2. Clean pulley(s). Replace belt if

3. Rusted pulley(s) 3. Clean rust from pulley(s)

4. Sharp or jagged pulley groove tips

5. Belt rubber deteriorated 5. Replace belt

insufficient tension

2. Belt or pulley exposed to substance that has reduced friction (belt dressing, oil, ethylene glycol)

3. Driven component bearing failure (seizure)

4. Belt glazed or hardened from heat and excessive slippage

1. Remove foreign objects from pulley grooves. Replace belt.

necessary

4. Replace pulley. Inspect belt.

1. Inspect/Replace tensioner if necessary

2. Replace belt and clean pulleys

3. Replace faulty component or bearing

4. Replace belt.

LONGITUDAL BELT CRACKING 1. Belt has mistracked from pulley

groove

2. Pulley groove tip has worn away rubber to tensile member

9GROOVE JUMPING9 (Belt does not maintain correct position on pulley)

BELT BROKEN (Note: Identify and correct problem before new belt is installed)

1. Incorrect belt tension 1. Inspect/Replace tensioner if

2. Pulley(s) not within design tolerance

3. Foreign object(s) in grooves 3. Remove foreign objects from

4. Pulley misalignment 4. Align component

5. Belt cordline is broken 5. Replace belt

1. Incorrect belt tension 1. Replace Inspect/Replace

2. Tensile member damaged during belt installation

3. Severe misalignment 3. Align pulley(s)

4. Bracket, pulley, or bearing failure 4. Replace defective component

1. Replace belt

2. Replace belt

necessary

2. Replace pulley(s)

grooves

tensioner if necessary

2. Replace belt

and belt

Page 18

KJ ACCESSORY DRIVE 7 - 13

DRIVE BELT (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

NOISE (Objectionable squeal, squeak, or rumble is heard or felt while drive belt is in operation)

TENSION SHEETING FABRIC FAILURE (Woven fabric on outside, circumference of belt has cracked or separated from body of belt)

CORD EDGE FAILURE (Tensile member exposed at edges of belt or separated from belt body)

1. Incorrect belt tension 1. Inspect/Replace tensioner if necessary

2. Bearing noise 2. Locate and repair

3. Belt misalignment 3. Align belt/pulley(s)

4. Belt to pulley mismatch 4. Install correct belt

5. Driven component induced

vibration

1. Tension sheeting contacting

stationary object

2. Excessive heat causing woven

fabric to age

3. Tension sheeting splice has

fractured

1. Incorrect belt tension 1. Inspect/Replace tensioner if

2. Belt contacting stationary object 2. Replace belt

3. Pulley(s) out of tolerance 3. Replace pulley

4. Insufficient adhesion between

tensile member and rubber matrix

5. Locate defective driven component and repair

1. Correct rubbing condition

2. Replace belt

3. Replace belt

necessary

4. Replace belt

REMOVAL

NOTE: The belt routing schematics are published from the latest information available at the time of publication. If anything differs between these schematics and the Belt Routing Label, use the schematics on Belt Routing Label. This label is located in the engine compartment.

CAUTION: DO NOT LET TENSIONER ARM SNAP BACK TO THE FREEARM POSITION, SEVERE DAMAGE MAY OCCUR TO THE TENSIONER.

Belt tension is not adjustable. Belt adjustment is maintained by an automatic (spring loaded) belt tensioner.

(1) Disconnect negative battery cable.

(2) Rotate belt tensioner until it contacts its stop. Remove belt, then slowly rotate the tensioner into the freearm position.

INSTALLATION

Belt tension is not adjustable. Belt adjustment is maintained by an automatic ( spring load ) belt tensioner.

(1) Check condition of all pulleys.

CAUTION: When installing the serpentine accessory drive belt, the belt MUST be routed correctly. If not, the engine may overheat due to the water pump rotating in the wrong direction.

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7 - 14 ACCESSORY DRIVE KJ

DRIVE BELT (Continued)

(2) Install new belt. Route the belt around all pulleys except the idler pulley (Fig. 6). Rotate the tensioner arm until it contacts its stop position. Route the belt around the idler and slowly let the tensioner rotate into the belt. Make sure the belt is seated onto all pulleys (Fig. 6).

IDLER PULLEYS

REMOVAL

CAUTION: The retaining bolts on the idler pulleys are left hand thread.

(1) Disconnect negative battery cable.

(2) Remove accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL).

(3) Remove idler pulley retaining bolts and pulleys (Fig. 7) (Fig. 8).

Fig. 6 ACCESSORY BELT ROUTING

1 - IDLER PULLEY 2 - GENERATOR 3 - IDLER PULLEY 4 - A/C COMPRESSOR 5 - COOLING FAN SUPPORT 6 - VIBRATION DAMPER 7 - BELT TENSIONER 8 - POWER STEERING PUMP 9 - ACCESSORY DRIVE BELT 10 - VISCOUS HEATER

Fig. 7 COOLING FAN SUPPORT

1 - IDLER PULLEY 2 - COOLING FAN SUPPORT 3 - RETAINING BOLTS 4 - ENGINE LIFT HOOK

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KJ ACCESSORY DRIVE 7 - 15

IDLER PULLEYS (Continued)

INSTALLATION

(1) Install idler pulleys and retaining bolts (Fig. 7) (Fig. 8). Torque bolts to 53N·m.

(2) Install accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).

(3) Connect negative battery cable.

Fig. 8 VIBRATION DAMPER AND IDLER PULLEY

1 - VIBRATION DAMPER/CRANKSHAFT PULLEY RETAINING BOLTS 2 - VIBRATION DAMPER/CRANKSHAFT PULLEY 3 - IDLER PULLEY

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7 - 16 ENGINE KJ

ENGINE

TABLE OF CONTENTS

page page

COOLANT

STANDARD PROCEDURE

STANDARD PROCEDURE—DRAINING

COOLING SYSTEM ....................16

STANDARD PROCEDURE - COOLING

SYSTEM FILLING .....................17

STANDARD PROCEDURE - REFILLING

COOLING SYSTEM ....................17

COOLANT RECOVERY PRESS CONTAINER

DESCRIPTION .........................17

OPERATION ...........................17

COOLING FAN

REMOVAL

REMOVAL - COOLING FAN ..............17

REMOVAL - COOLING FAN SUPPORT .....17

CLEANING ............................17

INSPECTION ..........................17

INSTALLATION

INSTALLATION - COOLING FAN ..........18

INSTALLATION - COOLING FAN SUPPORT . . 18

COOLANT SYSTEM HOSES

REMOVAL

REMOVAL - UPPER RADIATOR HOSE .....18

REMOVAL - HEATER CORE HOSES .......18

INSTALLATION

INSTALLATION - UPPER RADIATOR HOSE . . 19

INSTALLATION – HEATER CORE HOSES . . . 19

ENGINE COOLANT TEMP SENSOR

DESCRIPTION .........................19

OPERATION ...........................19

REMOVAL .............................20

INSTALLATION .........................20

ENGINE COOLANT THERMOSTAT

DESCRIPTION .........................20

OPERATION ...........................20

REMOVAL .............................20

INSTALLATION .........................21

FAN DRIVE VISCOUS CLUTCH

DESCRIPTION .........................21

OPERATION ...........................22

DIAGNOSIS AND TESTING - FAN DRIVE

VISCOUS CLUTCH ....................22

REMOVAL .............................22

INSTALLATION .........................23

RADIATOR

REMOVAL .............................23

INSTALLATION .........................24

WATER PUMP

DESCRIPTION .........................24

OPERATION ...........................24

REMOVAL - WATER PUMP ................24

CLEANING ............................24

INSTALLATION .........................25

RADIATOR PRESSURE CAP

DESCRIPTION .........................25

OPERATION ...........................25

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - COOLING

SYSTEM PRESSURE CAP...............25

DIAGNOSIS AND TESTING - PRESSURE

RELIEF TEST ........................25

CLEANING ............................26

INSPECTION ..........................26

HOSE CLAMPS

DESCRIPTION - HOSE CLAMPS ...........26

OPERATION - HOSE CLAMPS .............27

COOLANT

STANDARD PROCEDURE

STANDARD PROCEDURE—DRAINING COOLING SYSTEM

WARNING: DO NOT REMOVE THE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR DRAINCOCK WITH SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM COOLANT CAN OCCUR.

(1) DO NOT remove radiator cap first. With engine cold, raise vehicle on a hoist and locate radiator draincock.

NOTE: Radiator draincock is located on the Right/ lower side of radiator facing to rear of vehicle.

(2) Attach one end of a hose to the draincock. Put the other end into a clean container. Open draincock and drain coolant from radiator. This will empty the coolant reserve/overflow tank. The coolant does not have to be removed from the tank unless the system is being refilled with a fresh mixture. Remove radiator cap and continue draining cooling system.

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KJ ENGINE 7 - 17

COOLANT (Continued)

STANDARD PROCEDURE - COOLING SYSTEM FILLING

Remove pressure/vent cap and fill system, using a 50/50 mix of Mopart Antifreeze/Coolant, 5 Year/100,000 Mile Formula and distilled water.

Continue filling system until full. Be careful not

to spill coolant on drive belts or the generator.

Fill coolant recovery pressure container to at least the MAX mark with 50/50 solution. It may be necessary to add coolant to the coolant recovery pressure container after three or four warm up/cool down cycles to maintain coolant level between the MAX and MIN mark. This will allow trapped air to be removed from the system.

STANDARD PROCEDURE - REFILLING COOLING SYSTEM

(1) Tighten the radiator draincock and the cylinder block drain plug(s) (if removed).

CAUTION: Failure to purge air from the cooling system can result in an overheating condition and severe engine damage.

As the engine cools, a vacuum is formed in the cooling system of both the radiator and engine. Coolant will then be drawn from the coolant tank and returned to a proper level in the radiator.

The coolant reservoir/overflow system has a radiator mounted pressurized cap, an overflow tube, and a plastic coolant reservoir/overflow tank, mounted to the right side of the cowl. It is mounted to the cowl with two nuts on top, and a slide bracket on the bottom.

OPERATION

The pressure chamber keeps the coolant free of trapped air, provides a volume for expansion and contraction, and provides a convenient and safe method for checking and adjusting coolant level at atmospheric pressure. It also provides some reserve coolant to cover minor leaks, evaporation or boiling losses. The overflow chamber allows coolant recovery in case of an overheat.

COOLING FAN

(2) Fill system using a 50/50 mixture of ethyleneglycol antifreeze and low mineral content water, until coolant remains in the bottom of the coolant reserve/ overflow. Install radiator cap.

(3) With heater control unit in the HEAT position, operate engine with radiator cap in place.

(4) After engine has reached normal operating temperature, shut engine off and allow it to cool. When engine is cooling down, coolant will be drawn into the radiator from the reserve/overflow tank.

(5) Add coolant to reserve/overflow tank as necessary. Only add coolant to the reserve/overflow

tank when the engine is cold. Coolant level in a warm engine will be higher due to thermal expansion.

COOLANT RECOVERY PRESS CONTAINER

DESCRIPTION

This system works along with the radiator pressure cap. This is done by using thermal expansion and contraction of the coolant to keep the coolant free of trapped air. It provides:

• A volume for coolant expansion and contraction.

• A convenient and safe method for checking/ad-

justing coolant level at atmospheric pressure. This is done without removing the radiator pressure cap.

• Some reserve coolant to the radiator to cover

minor leaks and evaporation or boiling losses.

REMOVAL

REMOVAL - COOLING FAN

(1) (Refer to 7 - COOLING/ENGINE/FAN DRIVE

VISCOUS CLUTCH - REMOVAL)

REMOVAL - COOLING FAN SUPPORT

(1) Disconnect negative battery cable.

(2) Remove fan drive viscous clutch and fan assembly (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - REMOVAL).

(3) Remove cooling fan support from engine block (Fig. 1).

CLEANING

Clean the fan blades using a mild soap and water. Do not use an abrasive to clean the blades.

INSPECTION

WARNING: DO NOT ATTEMPT TO BEND OR STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN SPECIFICATIONS.

CAUTION: If fan blade assembly is replaced because of mechanical damage, water pump and fan drive viscous clutch should also be inspected. These components could have been damaged due to excessive vibration.

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7 - 18 ENGINE KJ

COOLING FAN (Continued)

COOLANT SYSTEM HOSES

REMOVAL

REMOVAL - UPPER RADIATOR HOSE

(1) Drain cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE).

(2) Disconnect upper radiator hose from thermostat housing (Fig. 2).

(3) Disconnect upper radiator hose from radiator and remove from vehicle (Fig. 2).

Fig. 1 COOLING FAN SUPPORT

1 - IDLER PULLEY 2 - COOLING FAN SUPPORT 3 - RETAINING BOLTS 4 - ENGINE LIFT HOOK

(1) Remove fan blade assembly from fan drive vis-

cous clutch (four bolts).

(2) Lay fan on a flat surface with leading edge facing down. With tip of blade touching flat surface, replace fan if clearance between opposite blade and surface is greater than 2.0 mm (.090 inch). Rocking motion of opposite blades should not exceed 2.0 mm (.090 inch). Test all blades in this manner.

(3) Inspect fan assembly for cracks, bends, loose rivets or broken welds. Replace fan if any damage is found.

INSTALLATION

INSTALLATION - COOLING FAN

(1) (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - INSTALLATION)

INSTALLATION - COOLING FAN SUPPORT

(1) Install cooling fan support to engine block (Fig.

1). Torque bolts to 47.1N·m.

(2) Install fan drive viscous clutch and fan assembly (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - INSTALLATION).

(3) Connect negative battery cable.

Fig. 2 UPPER RADIATOR HOSE

1 - FAN SHROUD 2 - HOSE CLAMP 3 - UPPER RADIATOR HOSE 4 - THERMOSTAT HOUSING

REMOVAL - HEATER CORE HOSES

(1) Drain cooling system (Refer to 7 - COOLING/

ENGINE/COOLANT - STANDARD PROCEDURE).

(2) Remove engine cover from engine (Refer to 9 -

ENGINE COVER - REMOVAL).

(3) Disconnect heater core supply line at heater core and viscous heater (Fig. 3). Remove hose from vehicle.

(4) Disconnect heater core return line from heater core and EGR cooler (Fig. 3). Remove hose from vehicle.

Page 24

KJ ENGINE 7 - 19

COOLANT SYSTEM HOSES (Continued)

ENGINE COOLANT TEMP SENSOR

DESCRIPTION

The engine coolant temperature sensor threads into a coolant passage in the cylinder head (Fig. 4). New sensors have sealant applied to the threads.

Fig. 3 HEATER CORE COOLANT HOSES

1 - HEATER CORE TO VISCOUS HEATER HOSE 2 - MOUNTING STUD 3 - HOSE CLAMP 4 - HOSE CLAMP 5 - HEATER CORE TO EGR COOLER HOSE

INSTALLATION

INSTALLATION - UPPER RADIATOR HOSE

(1) Install upper radiator hose on radiator and

thermostat housing (Fig. 2).

(2) Reposition hose clamps in proper position. (3) Refill cooling system to proper level (Refer to 7

- COOLING/ENGINE/COOLANT - STANDARD PROCEDURE).

INSTALLATION – HEATER CORE HOSES

(1) Connect heater core supply hose to heater core and viscous heater. Position hose clamps into proper position.

(2) Connect heater core return hose to heater core and EGR cooler. Position hose clamps into proper position.

(3) Install engine cover to engine (Refer to 9 ENGINE COVER - INSTALLATION).

(4) Refill cooling system to proper level (Refer to 7

- COOLING/ENGINE/COOLANT - STANDARD PROCEDURE).

Fig. 4 CYLINDER HEAD ASSEMBLY

1 - CYLINDER HEAD BOLT 2 - GLOW PLUG 3 - COOLANT TEMPERATURE SENSOR 4 - CYLINDER HEAD ALIGNMENT DOWEL 5 - GLOW PLUG HARNESS 6 - CYLINDER LINER 7 - CYLINDER BLOCK 8 - CYLINDER HEAD GASKET 9 - CYLINDER HEAD 10 - ROCKER ARM ASSEMBLIES

OPERATION

The coolant temperature (ECT) sensor is a negative temperature coefficient (NTC) thermistor (resistance varies inversley with temperature). This means at cold tempertures its resistance is high so the voltage signal will be high. As coolant temperture increases, resistance decreases and the signal voltage will be low. This allows the sensor to provide an analog voltage signal to the ECM.

Page 25

7 - 20 ENGINE KJ

ENGINE COOLANT TEMP SENSOR (Continued)

REMOVAL

WARNING: DO NOT REMOVE OR LOOSEN THE COOLANT PRESSURE/VENT CAP, CYLINDER BLOCK DRAIN PLUGS, OR THE DRAINCOCK WHEN THE SYSTEM IS HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM THE COOLANT CAN OCCUR.

(1) Disconnect negative battery cable.

(2) Drain the cooling system. (Refer to 7 - COOLING/ENGINE/COOLANT - STANDARD PROCEDURE)

(3) Disconnect coolant temperature sensor electrical connector (Fig. 5).

(4) Remove coolant temperature sensor from cylinder head (Fig. 5).

INSTALLATION

(1) Install coolant temperature sensor in cylinder

head (Fig. 5).

(2) Connect coolant temperature sensor electrical

connector (Fig. 5).

(3) Refill cooling system. (Refer to 7 - COOLING/

ENGINE/COOLANT - STANDARD PROCEDURE)

(4) Connect negative battery cable.

ENGINE COOLANT THERMOSTAT

DESCRIPTION

A pellet-type thermostat controls the operating temperature of the engine by controlling the amount of coolant flow to the radiator (Fig. 6).

OPERATION

The thermostat starts to open at 80°C (176°F). Above this temperature, coolant is allowed to flow to the radiator. This provides quicker engine warmup and overall temperature control.

The same thermostat is used for winter and summer seasons. An engine should not be operated without a thermostat, except for servicing or testing. Operating without a thermostat causes other problems. These are: longer engine warmup time, unreliable warmup performance, increased exhaust emissions and crankcase condensation. This condensation can result in sludge formation.

Fig. 5 CYLINDER HEAD ASSEMBLY

REMOVAL

NOTE: The thermostat is not serviced separately. The thermostat and housing must be replaced as an assembly.

(1) Disconnect negative battery cable.

(2) Remove engine cover (Refer to 9 - ENGINE COVER - REMOVAL).

(3) Partially drain cooling system (Refer to 7 COOLING/ENGINE/COOLANT - STANDARD PROCEDURE).

(4) Disconnect upper radiator hose and bypass hoses at thermostat housing.

(5) Remove thermostat housing retaining bolts, support bracket (2.8L) and housing from cylinder head, discard gasket (Fig. 7).

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KJ ENGINE 7 - 21

ENGINE COOLANT THERMOSTAT (Continued)

Fig. 6 THERMOSTAT HOUSING

1 - THERMOSTAT HOUSING GASKET 2 - THERMOSTAT HOUSING 3 - TURBOCHARGER OIL SUPPLY LINE BANJO BOLT 4 - THERMOSTAT HOUSING RETAINING BOLTS 5 - BRASS WASHER 6 - EXHAUST MANIFOLD GASKET 7 - EXHAUST MANIFOLD 8 - EXHAUST MANIFOLD HEATSHIELD 9 - EXHAUST MANIFOLD HEATSHIELD RETAINING BOLTS 10 - OIL RETURN HOSE 11 - HOSE CLAMPS 12 - EXHAUST MANIFOLD RETAINING NUTS 13 - TURBOCHARGER DOWNPIPE STUDS 14 - TURBOCHARGER DOWN PIPE GASKET 15 - TURBOCHARGER DOWNPIPE 16 - TURBOCHARGER DOWNPIPE RETAINING NUT

INSTALLATION

(1) Clean old gasket material from cylinder head

and thermostat housing.

(2) Install thermostat housing with gasket and support bracket (2.8L) to cylinder head (Fig. 7). Torque bolts to 27.5N·m.

(3) Connect coolant bypass hose and upper radiator hose to thermostat housing.

(4) Refill cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE).

Fig. 7 THERMOSTAT HOUSING ASSEMBLY

1 - THERMOSTAT HOUSING GASKET 2 - THERMOSTAT HOUSING 3 - RETAINING BOLTS 4 - CYLINDER HEAD 5 - CYLINDER HEAD COVER/INTAKE MANIFOLD

(5) Install engine cover (Refer to 9 - ENGINE

COVER - INSTALLATION).

(6) Connect negative battery cable.

FAN DRIVE VISCOUS CLUTCH

DESCRIPTION

CAUTION: If the viscous fan drive is replaced because of mechanical damage, the cooling fan blades should also be inspected. Inspect for fatigue cracks, loose blades, or loose rivets that could have resulted from excessive vibration. Replace fan blade assembly if any of these conditions are found. Also inspect water pump bearing and shaft assembly for any related damage due to a viscous fan drive malfunction.

The thermal viscous fan drive (Fig. 8) is a siliconefluid-filled coupling used to connect the fan blades to the fan support bracket assembly. The coupling allows the fan to be driven in a normal manner. This is done at low engine speeds while limiting the top speed of the fan to a predetermined maximum level at higher engine speeds.

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7 - 22 ENGINE KJ

FAN DRIVE VISCOUS CLUTCH (Continued)

On the 2.5L Diesel engine, a viscous fan is stan-

dard.

Fig. 8 Viscous Fan Drive - Typical

1 - VISCOUS FAN DRIVE 2 - THERMOSTATIC SPRING 3 - MOUNTING NUT TO WATER PUMP HUB

OPERATION

A thermostatic bimetallic spring coil is located on the front face of the viscous fan drive unit. This spring coil reacts to the temperature of the radiator discharge air. It engages the viscous fan drive for higher fan speed if the air temperature from the radiator rises above a certain point. Until additional engine cooling is necessary, the fan will remain at

a reduced rpm regardless of engine speed. Normally less than three hundred (300) rpm.

Only when sufficient heat is present, will the viscous fan drive engage. This is when the air flowing through the radiator core causes a reaction to the bimetallic coil. It then increases fan speed to provide the necessary additional engine cooling.

Once the engine has cooled, the radiator discharge temperature will drop. The bimetallic coil again reacts and the fan speed is reduced to the previous disengaged speed.

DIAGNOSIS AND TESTING - FAN DRIVE VISCOUS CLUTCH

If the fan assembly free-wheels without drag (the fan blades will revolve more than five turns when spun by hand), replace the fan drive. This spin test must be performed when the engine is cool.

For the following test, the cooling system must be in good condition. It also will ensure against excessively high coolant temperature.

WARNING: BE SURE THAT THERE IS ADEQUATE FAN BLADE CLEARANCE BEFORE DRILLING.

(1) Drill a 3.18-mm (1/8-in) diameter hole in the

top center of the fan shroud.

(2) Obtain a dial thermometer with an 8 inch stem (or equivalent). It should have a range of -18° to 105°C (0° to 220° F). Insert thermometer through the hole in the shroud. Be sure that there is adequate clearance from the fan blades.

(3) Connect a tachometer and an engine ignition timing light (timing light is to be used as a strobe light).

(4) Block the air flow through the radiator. Secure a sheet of plastic in front of the radiator (or air conditioner condenser). Use tape at the top to secure the plastic and be sure that the air flow is blocked.

(5) Be sure that the air conditioner (if equipped) is turned off.

WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.

(6) Start the engine and operate at 2400 rpm. Within ten minutes the air temperature (indicated on the dial thermometer) should be up to 93° C (200° F). Fan drive engagement should have started to occur at between 91° to 96° C (195° to 205° F). Engagement is distinguishable by a definite increase in fan flow noise (roaring). The timing light also will indicate an increase in the speed of the fan.

(7) When the air temperature reaches 93° C (200° F), remove the plastic sheet. Fan drive disengage- ment should have started to occur at between 62° to 85° C (145° to 185° F). A definite decrease of fan flow noise (roaring) should be noticed. If not, replace the defective viscous fan drive unit.

REMOVAL

(1) Disconnect negative battery cable.

NOTE: The thermal viscous fan drive/fan blade assembly is attached (threaded) to fan support.

(2) Remove fan blade/viscous fan drive assembly from water pump using special tool 6958 spanner wrench, by turning mounting nut counterclockwise as viewed from front (Fig. 9) (Fig. 10). Threads on viscous fan drive are RIGHT HAND.

(3) Do not attempt to remove fan/fan drive viscous clutch assembly from vehicle at this time.

(4) Do not unbolt fan blade assembly from fan drive viscous clutch at this time.

(5) Remove fan shroud to radiator bolts.

(6) Remove fan shroud and fan blade/fan drive viscous clutch assembly as a complete unit from vehicle.

Page 28

KJ ENGINE 7 - 23

FAN DRIVE VISCOUS CLUTCH (Continued)

(7) After removing fan blade/fan drive viscous clutch assembly, do not place viscous clutch in horizontal position. If stored horizontally, silicone fluid in the fan drive viscous clutch could drain into its bearing assembly and contaminate lubricant.

(8) Remove four bolts securing fan blade assembly to fan drive viscous clutch.

INSTALLATION

(1) Assemble fan blade to viscous fan drive. Tighten mounting bolts to 27 N·m (20 ft. lbs.) torque.

NOTE: The viscous fan and fan shroud must be installed as an assembly.

(2) Gently lay fan and viscous drive into fan shroud.

(3) Install the fan shroud to radiator mounting bolt. Torque bolts to 5.5N·m.

(4) Thread the fan and viscous drive onto the fan support and tighten nut using special tool 6958 spanner wrench.

Fig. 9 FAN DRIVE VISCOUS CLUTCH - TYPICAL

1 - SPECIAL TOOL 6958 SPANNER WRENCH 2-FAN

(5) Connect negative battery cable.

RADIATOR

Fig. 10 COOLING FAN AND VISCOUS CLUTCH

1 - COOLING FAN AND FAN DRIVE VISCOUS CLUTCH ASSEMBLY 2 - FAN SUPPORT

REMOVAL

(1) Disconnect negative battery cable.

(2) Drain cooling system (Refer to 7 - COOLING/ ENGINE - STANDARD PROCEDURE).

(3) Remove engine oil fill cap.

(4) Remove engine cover (Refer to 9 - ENGINE COVER - REMOVAL).

(5) Remove air filter assembly from the engine bay.

(6) Recover and evacuate the refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - STANDARD PROCEDURE) and (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE).

(7) Disconnect high side refrigerant line from the upper radiator support bracket.

(8) Remove upper radiator support bracket retaining bolts and remove the support bracket.

(9) Remove high side refrigerant line retaining nut and remove the line from the condenser assembly. Position the line out of the way.

(10) Unbolt cooling fan from cooling fan support.

(11) Remove fan shroud retaining bolts and remove the fan and shroud as an assembly.

(12) Disconnect charge air cooler hoses from the charge air cooler.

(13) Disconnect engine coolant hoses from the radiator.

(14) Disconnect coolant reservoir hose from the radiator.

Page 29

7 - 24 ENGINE KJ

RADIATOR (Continued)

(15) Remove low side refrigerant line retaining nut and remove the line from the condenser assembly. Position the line out of the way.

(16) Remove condenser assembly retaining bolts and remove the condenser from the vehicle.

(17) Remove power steering cooler retaining bolts and unclip the air deflectors from both sides of the radiator (cooling module) assembly.

(18) Lift cooling module assembly out of the engine bay.

(19) Remove radiator retaining bolts and remove the cooling system module from vehicle.

(20) Separate charge air cooler from radiator.

INSTALLATION

(1) Install radiator on the charge air cooler and install retaining bolts.

(2) Install radiator (cooling module) assembly in the engine bay.

(3) Install power steering cooler retaining bolts and clip the air deflectors on both sides of the radiator (cooling module) assembly.

(4) Install condenser assembly and retaining bolts.

(5) Install low side refrigerant line and retaining nut.

(6) Connect coolant reservoir hose on the radiator.

(7) Connect engine coolant hoses on the radiator.

(8) Connect charge air cooler hoses on the charge air cooler.

(9) Install fan and fan shroud assembly and retaining bolts.

(10) Install cooling fan assembly to cooling fan support.

(11) Install high side refrigerant line and retaining nut.

(12) Install upper radiator support bracket and retaining bolts.

(13) Connect high side refrigerant line on the upper radiator support bracket.

(14) Evacuate and re-charge the refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE).

(15) Install air filter assembly in the engine bay.

(16) Install engine cover (Refer to 9 - ENGINE COVER - INSTALLATION).

(17) refill cooling system (Refer to 7 - COOLING/ ENGINE - STANDARD PROCEDURE).

(18) Connect negative battery cable.

WATER PUMP

DESCRIPTION

The water pump on the 2.5L/2.8L CRD diesel has a die cast aluminum housing. It bolts to a aluminum housing which attaches to the engine block.

OPERATION

The water pump is used to circulate coolant through the cooling system. The coolant is pumped through the engine block, cylinder head, heater core, EGR cooler, viscous heater, and radiator.

REMOVAL - WATER PUMP

(1) Disconnect negative battery cable.

(2) Drain cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE).

(3) Remove timing belt inner and outer covers (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).

(4) Remove water pump retaining bolts and pump (Fig. 11).

Fig. 11 WATER PUMP LOCATION

1 - CYLINDER HEAD 2 - ENGINE BLOCK 3 - OIL COOLER 4 - OIL FILTER HOUSING 5 - WATER PUMP

CLEANING

Clean gasket mating surfaces as necessary.

Page 30

KJ ENGINE 7 - 25

WATER PUMP (Continued)

INSTALLATION

(1) Clean mating surfaces of water pump housing

and engine block as necessary.

(2) Place new o-ring in groove in water pump housing. Install water pump and retaining bolts. Torque bolts to 24.4N·m.

(3) Install both inner and outer timing belt covers (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).

(4) Refill cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE).

(5) Connect negative battery cable.

RADIATOR PRESSURE CAP

DESCRIPTION

The cooling system pressure cap is located on the coolant recovery pressure container. The cap construction includes; stainless steel swivel top, rubber seals, and retainer, main spring, and a spring loaded valve (Fig. 12).

through a connecting hose. If valve is stuck shut,

or the coolant recovery hose is pinched, the radiator hoses will be collapsed on cool down. Clean the vent valve (Fig. 12) and inspect coolant recovery hose routing, to ensure proper sealing when boiling point is reached.

The gasket in the cap seals the filler neck, so that vacuum can be maintained, allowing coolant to be drawn back into the radiator from the reserve tank.

If the gasket is dirty or damaged, a vacuum may not be achieved, resulting is loss of coolant and eventual overheating due to low coolant level in radiator and engine.

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - COOLING SYSTEM PRESSURE CAP

Dip the pressure cap in water. Clean any deposits off the vent valve or its seat and apply cap to end of the Pressure Cap Test Adaptor that is included with the Cooling System Tester 7700. Working the plunger, bring the pressure to 104 kPa (15 psi) on the gauge. If the pressure cap fails to hold pressure of at least 97 kPa (14 psi), replace the pressure cap.

Fig. 12 Cooling System Pressure Cap Filler Neck

1 - OVERFLOW NIPPLE 2 - MAIN SPRING 3 - GASKET RETAINER 4 - STAINLESS-STEEL SWIVEL TOP 5 - RUBBER SEALS 6 - VENT VALVE 7 - PRESSURE BOTTLE 8 - FILLER NECK

OPERATION

The cooling system is equipped with a pressure cap that releases excessive pressure; maintaining a range of 97-124 kPa (14-18 psi).

The cooling system will operate at higher than atmospheric pressure. The higher pressure raises the coolant boiling point thus, allowing increased radiator cooling capacity.

There is also a vent valve in the center of the cap. This valve also opens when coolant is cooling and contracting, allowing the coolant to return to cooling system from coolant reserve system tank by vacuum

CAUTION: The Cooling System Tester Tool is very sensitive to small air leaks that will not cause cooling system problems. A pressure cap that does not have a history of coolant loss should not be replaced just because it leaks slowly when tested with this tool. Add water to the tool. Turn tool upside down and recheck pressure cap to confirm that cap is bad.

If the pressure cap tests properly while positioned on Cooling System Tester (Fig. 13), but will not hold pressure or vacuum when positioned on the filler neck. Inspect the filler neck and cap top gasket for irregularities that may prevent the cap from sealing properly.

DIAGNOSIS AND TESTING - PRESSURE RELIEF TEST

The pressure cap upper gasket (seal) pressure relief can be checked by removing the overflow hose at the radiator filler neck nipple (Fig. 14). Attach the Radiator Pressure Tool to the filler neck nipple and pump air into the radiator. Pressure cap upper gasket should relieve at 69-124 kPa (10-18 psi) and hold pressure at 55 kPa (8 psi) minimum.

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7 - 26 ENGINE KJ

RADIATOR PRESSURE CAP (Continued)

WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT 15 MINUTES BEFORE REMOVING CAP. THEN PLACE A SHOP TOWEL OVER THE CAP AND WITHOUT PUSHING DOWN ROTATE COUNTERCLOCKWISE TO THE FIRST STOP. ALLOW FLUIDS TO ESCAPE THROUGH THE OVERFLOW TUBE AND WHEN THE SYSTEM STOPS PUSHING COOLANT AND STEAM INTO THE CRS TANK AND PRESSURE DROPS PUSH DOWN AND REMOVE THE CAP COMPLETELY. SQUEEZING THE RADIATOR INLET HOSE WITH A SHOP TOWEL (TO CHECK PRESSURE) BEFORE AND AFTER TURNING TO THE FIRST STOP IS RECOMMENDED.

Fig. 13 Testing Cooling System Pressure Cap

1 - PRESSURE CAP 2 - PRESSURE TESTER

Fig. 14 Radiator Pressure Cap Filler Neck

1 - OVERFLOW NIPPLE 2 - MAIN SPRING 3 - GASKET RETAINER 4 - STAINLESS-STEEL SWIVEL TOP 5 - RUBBER SEALS 6 - VENT VALVE 7 - PRESSURE BOTTLE 8 - FILLER NECK

CLEANING

Use only a mild soap to clean the pressure cap.

INSPECTION

Hold the cap in your hand, top side up (Fig. 14). The vent valve at the bottom of the cap should open. If the rubber gasket has swollen, preventing the valve from opening, replace the cap.

Hold the cleaned cap in your hand, upside down. If any light can be seen between vent valve and the rubber gasket, replace the cap. Do not use a

replacement cap that has a spring to hold the vent shut.

A replacement cap must be of the type designed for coolant reserve systems. This design ensures coolant return to the radiator.

HOSE CLAMPS

DESCRIPTION - HOSE CLAMPS

The cooling system utilizes spring type hose clamps. If a spring type clamp replacement is necessary, replace with the original Mopart equipment spring type clamp.

There is no need to remove the radiator cap at any

time except for the following purposes:

(1) Check and adjust coolant freeze point. (2) Refill system with new coolant. (3) Conducting service procedures. (4) Checking for vacuum leaks.

WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER

6094) (Fig. 15). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS.

Page 32

KJ ENGINE 7 - 27

HOSE CLAMPS (Continued)

CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only a original equipment clamp with matching number or letter (Fig. 15).

OPERATION - HOSE CLAMPS

The spring type hose clamp applies constant tension on a hose connection. To remove a spring type hose clamp, only use constant tension clamp pliers designed to compress the hose clamp.

Fig. 15 Spring Clamp Size Location

1 - SPRING CLAMP SIZE LOCATION

Page 33

Page 34

KJ ELECTRONIC CONTROL MODULES 8E - 1

ELECTRONIC CONTROL MODULES

TABLE OF CONTENTS

page page

ENGINE CONTROL MODULE

DESCRIPTION ..........................1

OPERATION ............................1

STANDARD PROCEDURE - PCM/ECM/SKIM

PROGRAMMING - DIESEL ...............2

ENGINE CONTROL MODULE

DESCRIPTION

The ECM is located in the left side of engine compartment attached to the left inner fender behind the battery (Fig. 1).

REMOVAL .............................4

INSTALLATION ..........................4

monitoring is called on-board diagnostics. Certain criteria must be met for a diagnostic trouble code to be entered into the ECM memory. The criteria may be a range of: engine rpm, engine temperature, time or other input signals to the ECM. If all of the criteria for monitoring a system or circuit are met, and a problem is sensed, then a DTC will be stored in the ECM memory. It is possible that a DTC for a monitored circuit may not be entered into the ECM memory, even though a malfunction has occurred. This may happen when the monitoring criteria have not been met. The ECM compares input signal voltages from each input device with specifications (the established high and low limits of the input range) that are programmed into it for that device. If the input voltage is not within the specifications and other trouble code criteria are met, a DTC will be stored in the ECM memory.

Fig. 1 ENGINE CONTROL MODULE (ECM)

REMOVAL/INSTALL

1 - ECM ELECTRICAL CONNECTORS 2 - ENGINE CONTROL MODULE (ECM) 3 - ECM MOUNTING BRACKET 4 - ECM MOUNTING BRACKET MOUNTING STUDS 5 - MOUNTING BRACKET RETAINING NUTS

OPERATION

The ECM has been programmed to monitor different circuits of the diesel fuel injection system. This

ECM OPERATING MODES

As input signals to the ECM change, the ECM adjusts its response to the output devices. For example, the ECM must calculate a different fuel quantity and fuel timing for engine idle condition than it would for a wide open throttle condition. There are several different modes of operation that determine how the ECM responds to the various input signals.

Ignition Switch On (Engine Off)

When the ignition is turned on, the ECM activates the glow plug relay for a time period that is determined by engine coolant temperature, atmospheric temperature and battery voltage.

Engine Start-Up Mode

The ECM uses the engine temperature sensor and the crankshaft position sensor (engine speed) inputs to determine fuel injection quantity.

Normal Driving Modes

Engine idle, warm-up, acceleration, deceleration and wide open throttle modes are controlled based on all of the sensor inputs to the ECM. The ECM uses

Page 35

8E - 2 ELECTRONIC CONTROL MODULES KJ

ENGINE CONTROL MODULE (Continued)

these sensor inputs to adjust fuel quantity and fuel injector timing.

Limp-In Mode

If there is a fault detected with the accelerator pedal position sensor, the ECM will set the engine speed at 1100 RPM.

Overspeed Detection Mode

If the ECM detects engine RPM that exceeds 5200 RPM, the ECM will set a DTC in memory and illuminate the MIL until the DTC is cleared.

After-Run Mode

The ECM transfers RAM information to ROM and performs an Input/Output state check.

MONITORED CIRCUITS

The ECM is able to monitor and identify most driveability related trouble conditions. Some circuits are directly monitored through ECM feedback circuitry. In addition, the ECM monitors the voltage state of some circuits and compares those states with expected values. Other systems are monitored indirectly when the ECM conducts a rationality test to identify problems. Although most subsytems of the engine control module are either directly or indirectly monitored, there may be occasions when diagnostic trouble codes are not immediately identified. For a trouble code to set, a specific set of conditions must occur and unless these conditions occur, a DTC will not set.

DIAGNOSTIC TROUBLE CODES

Each diagnostic trouble code (DTC) is diagnosed by following a specific procedure. The diagnostic test procedure contains step-by-step instruction for determining the cause of the DTC as well as no trouble code problems. Refer to the appropriate Diesel Powertrain Diagnostic Manual for more information.

HARD CODE

A DTC that comes back within one cycle of the ignition key is a hard code. This means that the problem is current every time the ECM/SKIM checks that circuit or function. Procedures in this manual verify if the DTC is a hard code at the beginning of each test. When the fault is not a hard code, an intermittent test must be performed. NOTE: If the DRBIIIt displays faults for multiple components (i.e. ECT, VSS, IAT sensors) identify and check the shared circuits for possible problems before continuing (i.e. sensor grounds or 5-volt supply circuits). Refer to the appropriate schematic to identify shared circuits. Refer to the appropriate Diesel Powertrain Diagnostic Manual for more information.

INTERMITTENT CODE

A DTC that is not current every time the ECM/ SKIM checks the circuit or function is an intermittent code. Most intermittent DTCs are caused by wiring or connector problems. Problems that come and go like this are the most difficult to diagnose; they must be looked for under specific conditions that cause them. NOTE: Electromagnetic (radio)

interference can cause an intermittent system malfunction. This interference can interrupt com-

munication between the ignition key transponder and the SKIM. The following checks may assist you in identifying a possible intermittent problem:

• Visually inspect the related wire harness connectors. Look for broken, bent, pushed out, loose fitting or corroded terminals.

• Visually inspect the related wire harness. Look for chafed, pierced or partially broken wire.

• Refer to hotlines or technical service bulletins that may apply.

Refer to the appropriate Diesel Powertrain Diag-

nostic Manual for more information.

ECM DIAGNOSTIC TROUBLE CODES

IMPORTANT NOTE: Before replacing the ECM for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most ECM driver/control circuit failures are caused by internal failures to components (i.e. relays and solenoids) and shorted circuits (i.e. sensor pullups, drivers and ground circuits). These faults are difficult to detect when a double fault has occurred and only one DTC has set. If the DRBIIIt displays faults for multiple components (i.e.VSS, ECT, Batt Temp, etc.) identify and check the shared circuits for possible problems before continuing (i.e. sensor grounds or 5-volt supply circuits). Refer to the appropriate wiring diagrams to identify shared circuits. Refer to the appropriate Diesel Powertrain Diagnostic Manual for more information.

STANDARD PROCEDURE - PCM/ECM/SKIM PROGRAMMING - DIESEL

NOTE: Before replacing the PCM/ECM for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM/ECM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set.

Page 36

KJ ELECTRONIC CONTROL MODULES 8E - 3

ENGINE CONTROL MODULE (Continued)

PCM/SKIM PROGRAMMING

When a PCM (JTEC) and the SKIM are replaced at the same time perform the following steps in order:

(1) Program the new PCM (JTEC)

(2) Program the new SKIM

(3) Replace all ignition keys and program them to the new SKIM.

ECM/SKIM PROGRAMMING

When an ECM (Bosch) and the SKIM are replaced at the same time perform the following steps in order:

(1) Program the new SKIM

(2) Program the new ECM (Bosch)

PROGRAMMING THE ECM (Bosch)

(1) To program the VIN, connect the DRB IIIt and turn the ignition on.

(2) Select Engine from the main menu. The DRB IIIt will require the VIN to be entered before continuing.

(3) Select ENTER to update the VIN. The DRB IIIt will display the updated VIN.

(4) If the engine is equipped with air conditioning, the ECM A/C function must be enabled. Enable the ECM A/C function as follows:

• Using the DRB IIIt select ENGINE, MISCEL-

LANEOUS, then ENABLE/DISABLE A/C

• Push 1 to enable A/C. DRB IIIt screen should

display A/C Activated.

PROGRAMMING THE PCM (JTEC)

The SKIS Secret Key is an ID code that is unique to each SKIM. This code is programmed and stored in the SKIM, PCM and transponder chip (ignition keys). When replacing the PCM it is necessary to program the secret key into the new PCM using the DRB IIIt. Perform the following steps to program the secret key into the PCM.

(1) Turn the ignition switch on (transmission in park/neutral).

(2) Use the DRB IIIt and select THEFT ALARM, SKIM then MISCELLANEOUS.

(3) Select PCM REPLACED (GAS ENGINE).

(4) Enter secured access mode by entering the vehicle four-digit PIN.

(5) Select ENTER to update PCM VIN.

NOTE: If three attempts are made to enter secure access mode using an incorrect PIN, secured access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned off. Also monitor

the battery state and connect a battery charger if necessary).

(6) Press ENTER to transfer the secret key (the

SKIM will send the secret key to the PCM).

(7) Press Page Back to get to the Select System menu and select ENGINE, JTEC (diesel only), MISCELLANEOUS, and SRI MEMORY CHECK.

(8) The DRB IIIt will ask, Is odometer reading between XX and XX? Select the YES or NO button on the DRB IIIt. If NO is selected, the DRB IIIt will read, Enter odometer Reading<From I.P. odometer>. Enter the odometer reading from the Instrument Panel and press ENTER.

PROGRAMMING THE SKIM

(1) Turn the ignition switch on (transmission in park/neutral).

(2) Use the DRB IIIt and select THEFT ALARM, SKIM then MISCELLANEOUS.

(3) Select PCM REPLACED (GAS ENGINE).

(4) Program the vehicle four-digit PIN into SKIM.

(5) Select COUNTRY CODE and enter the correct country.

NOTE: Be sure to enter the correct country code. If the incorrect country code is programmed into SKIM, the SKIM must be replaced.

(6) Select YES to update VIN (the SKIM will learn the VIN from the PCM).

(7) Press ENTER to transfer the secret key (the PCM will send the secret key to the SKIM).

(8) Program ignition keys to SKIM.

NOTE: If the PCM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM.

PROGRAMMING IGNITION KEYS TO THE SKIM

(1) Turn the ignition switch on (transmission in park/neutral).

(2) Use the DRB IIIt and select THEFT ALARM, SKIM then MISCELLANEOUS.

(3) Select PROGRAM IGNITION KEY’S.

(4) Enter secured access mode by entering the vehicle four-digit PIN.

NOTE: A maximum of eight keys can be learned to each SKIM. Once a key is learned to a SKIM it (the key) cannot be transferred to another vehicle.

If ignition key programming is unsuccessful, the DRB IIIt will display one of the following messages:

Programming Not Attempted - The DRB IIIt attempts to read the programmed key status and there are no keys programmed into SKIM memory.

Page 37

8E - 4 ELECTRONIC CONTROL MODULES KJ

ENGINE CONTROL MODULE (Continued)

Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKIM is unable to program key due to one of the following:

• faulty ignition key transponder

• ignition key is programmed to another vehicle.

8 Keys Already Learned, Programming Not Done SKIM transponder ID memory is full.

(5) Obtain ignition keys to be programmed from customer (8 keys maximum).

(6) Using the DRB IIIt, erase all ignition keys by selecting MISCELLANEOUS and ERASE ALL CURRENT IGN. KEYS.

(7) Program all ignition keys.

Learned Key In Ignition - Ignition key transponder ID is currently programmed in SKIM memory.

REMOVAL

(1) Disconnect negative battery cable.

(2) Disconnect ECM electrical connectors (Fig. 2).

(3) Remove ECM bracket to inner fender retaining nuts (Fig. 2).

(4) Remove ECM and bracket assembly from vehicle (Fig. 2).

(5) Separate ECM from bracket.

INSTALLATION

(1) Install ECM on bracket (Fig. 2).

(2) Position ECM and bracket assembly in vehicle (Fig. 2).

(3) Install ECM bracket to inner fender retaining nuts (Fig. 2).

(4) Connect ECM electrical connectors (Fig. 2).

(5) Connect negative battery cable.

Fig. 2 ENGINE CONTROL MODULE (ECM)

REMOVAL/INSTALL

1 - ECM ELECTRICAL CONNECTORS 2 - ENGINE CONTROL MODULE (ECM) 3 - ECM MOUNTING BRACKET 4 - ECM MOUNTING BRACKET MOUNTING STUDS 5 - MOUNTING BRACKET RETAINING NUTS

Page 38

KJ ENGINE SYSTEMS 8F - 1

ENGINE SYSTEMS

TABLE OF CONTENTS

page page

BATTERY

DESCRIPTION ..........................1

OPERATION ............................1

DIAGNOSIS AND TESTING - BATTERY .......2

STANDARD PROCEDURE

STANDARD PROCEDURE - SPIRAL PLATE

BATTERY CHARGING ...................2

BATTERY

DESCRIPTION

Vehicles equipped with a diesel engine utilize a spiral wound plate designed battery with recombination technology. This is a maintenance-free battery that is capable of delivering more power than a conventional battery. This additional power is required by a diesel engine during cold cranking.

Spiral plate technology takes the elements of traditional batteries - lead and sulfuric acid - to the next level. By tightly winding layers of spiral grids and acid-permeated vitreous separators into cells, the manufacturer has developed a battery with more power and service life than conventional batteries the same size. The spiral plate battery is completely, permanently sealed. Through gas recombination, hydrogen and oxygen within the battery are captured during normal charging and reunited to form the water within the electrolyte, eliminating the need to add distilled water. Therefore, these batteries have non-removable battery vent caps. Water cannot be added to this battery.

The acid inside an spiral plate battery is bound within the vitreous separators, ending the threat of acid leaks. This feature allows the battery to be installed in any position anywhere in the vehicle.

Spiral plate technology is the process by which the plates holding the active material in the battery are wound tightly in coils instead of hanging flat, like conventional batteries. This design has a lower internal resistance and also increases the active material surface area.

WARNING: NEVER EXCEED 14.4 VOLTS WHEN CHARGING A SPIRAL PLATE BATTERY. PERSONAL INJURY AND/OR BATTERY DAMAGE MAY RESULT.

STANDARD PROCEDURE - USING MICRO

420 BATTERY TESTER ..................4

Due to the maintanance-free design, distilled water cannot be added to this battery. Therefore, if more than 14.4 volts are used during the spiral plate battery charging process, water vapor can be exhausted through the pressure-sensitive battery vents and lost for good. This can permanently damage the spiral plate battery. Never exceed 14.4 volts when charging a spiral plate battery. Personal injury and/or battery damage may result.

Batteries are used to store electrical energy potential in a chemical form. When an electrical load is applied to the battery terminals, an electrochemical reaction occurs within the battery. This reaction causes the battery to discharge electrical current.

OPERATION

The battery is designed to store electrical energy in a chemical form. When an electrical load is applied to the terminals of the battery, an electrochemical reaction occurs. This reaction causes the battery to discharge electrical current from its terminals. As the battery discharges, a gradual chemical change takes place within each cell. The chemical changes within the battery are caused by the movement of excess or free electrons between the positive and negative plate groups. This movement of electrons produces a flow of electrical current through the load device attached to the battery terminals.

The battery is vented to release excess hydrogen gas that is created when the battery is being charged or discharged. However, even with these vents, hydrogen gas can collect in or around the battery. If hydrogen gas is exposed to flame or sparks, it may ignite. If the battery is equipped with removable cell caps, add distilled water whenever the electrolyte level is below the top of the plates. If the battery cell caps cannot be removed, the battery must be replaced if the electrolyte level becomes low.

Page 39

8F - 2 ENGINE SYSTEMS KJ

BATTERY (Continued)

DIAGNOSIS AND TESTING - BATTERY

The battery must be completely charged and the terminals should be properly cleaned and inspected before diagnostic procedures are performed. Refer to Battery System Cleaning for the proper cleaning procedures, and Battery System Inspection for the proper battery inspection procedures. Refer to Standard Procedures for the proper battery charging procedures.

MICRO 420 BATTERY TESTER

The Micro 420 automotive battery tester is designed to help the dealership technicians diagnose the cause of a defective battery. Follow the instruction manual supplied with the tester to properly diagnose a vehicle. If the instruction manual is not available refer to the standard procedure in this section, which includes the directions for using the Micro 420 battery tester.

WARNING: IF THE BATTERY SHOWS SIGNS OF FREEZING, LEAKING OR LOOSE POSTS, DO NOT TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY MAY ARC INTERNALLY AND EXPLODE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT.

STANDARD PROCEDURE

STANDARD PROCEDURE - SPIRAL PLATE BATTERY CHARGING

Vehicles equipped with a diesel engine utilize a unique spiral plate battery. This battery has a maximum charging voltage that must not be exceeded in order to restore the battery to its full potential, failure to use the following spiral plate battery charging procedure could result in damage to the battery or personal injury.

Battery charging is the means by which the battery can be restored to its full voltage potential. A battery is fully-charged when:

• Micro 420 battery tester indicates battery is OK.

• Open-circuit voltage of the battery is 12.65 volts

or above.

• Battery passes Load Test multiple times.

WARNING: IF THE BATTERY SHOWS SIGNS OF FREEZING, LEAKING, LOOSE POSTS OR LOW ELECTROLYTE LEVEL, DO NOT TEST, ASSISTBOOST, OR CHARGE. THE BATTERY MAY ARC INTERNALLY AND EXPLODE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT.

WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN AND AROUND THE BATTERY. DO NOT SMOKE, USE FLAME, OR CREATE SPARKS NEAR THE BATTERY. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT.

WARNING: THE BATTERY CONTAINS SULFURIC ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID CONTACT WITH THE SKIN, EYES, OR CLOTHING. IN THE EVENT OF CONTACT, FLUSH WITH WATER AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT OF THE REACH OF CHILDREN.

A battery that will not accept a charge is faulty, and must be replaced. Further testing is not required. A fully-charged battery must be tested to determine its cranking capacity. A battery that is fully-charged, but does not pass the Micro 420 or load test, is faulty and must be replaced.

NOTE: Completely discharged batteries may take several hours to accept a charge. Refer to Standard Procedures for the proper battery charging procedures.

CAUTION: Always disconnect and isolate the battery negative cable before charging a battery. Charge the battery directly at the battery terminals. Do not exceed 14.4 volts while charging a battery.

CAUTION: The battery should not be hot to the touch. If the battery feels hot to the touch, turn off the charger and let the battery cool before continuing the charging operation. Damage to the battery may result.

After the battery has been charged to 12.6 volts or greater, perform a load test to determine the battery cranking capacity. Refer to Battery Diagnosis and Testing for the proper battery test procedures. If the battery will endure a load test, return the battery to service. If the battery will not pass a load test, it is faulty and must be replaced.

Clean and inspect the battery hold downs, tray, terminals, posts, and top before completing battery service. Refer to Battery System Cleaning for the proper battery system cleaning procedures, and Battery System Inspection for the proper battery system inspection procedures.

Page 40

KJ ENGINE SYSTEMS 8F - 3

BATTERY (Continued)

CHARGING A COMPLETELY DISCHARGED BATTERY – SPIRAL PLATE BATTERY

The following procedure should be used to recharge a completely discharged battery. Unless this procedure is properly followed, a good battery may be needlessly replaced.

(1) Measure the voltage at the battery posts with a voltmeter, accurate to 1/10 (0.10) volt (Fig. 1). Refer to Battery Removal and Installation for access instructions. If the reading is below ten volts, the battery charging current will be low. It could take several hours before the battery accepts a current greater than a few milliamperes. Such low current may not be detectable on the ammeters built into many battery chargers.

Fig. 1 Voltmeter Accurate to 1/10 Volt (Connected)

(2) Disconnect and isolate the battery negative cable. Connect the battery charger leads. Some battery chargers are equipped with polarity-sensing circuitry. This circuitry protects the battery charger and the battery from being damaged if they are improperly connected. If the battery state-of-charge is too low for the polarity-sensing circuitry to detect, the battery charger will not operate. This makes it appear that the battery will not accept charging current. See the instructions provided by the manufacturer of the battery charger for details on how to bypass the polarity-sensing circuitry.

(3) Battery chargers vary in the amount of voltage and current they provide. The amount of time required for a battery to accept measurable charging current at various voltages is shown in the Charge Rate Table. If the charging current is still not measurable at the end of the charging time, the battery is faulty and must be replaced. If the charging current is measurable during the charging time, the battery may be good and the charging should be completed in the normal manner.

SPIRAL-PLATE BATTERY CHARGE RATE TABLE

Voltage Minutes

14.4 volts maximum up to 10 minutes

13.0 to 14 volts up to 20 minutes

12.9 volts or less up to 30 minutes

CHARGING TIME REQUIRED

The time required to charge a battery will vary,

depending upon the following factors:

• Battery Capacity - A completely discharged heavy-duty battery requires twice the charging time of a small capacity battery.

• Temperature - A longer time will be needed to charge a battery at -18° C (0° F) than at 27° C (80° F). When a fast battery charger is connected to a cold battery, the current accepted by the battery will be very low at first. As the battery warms, it will accept a higher charging current rate (amperage).

• Charger Capacity - A battery charger that supplies only five amperes will require a longer charging time. A battery charger that supplies eight amperes will require a shorter charging time.

• State-Of-Charge - A completely discharged bat- tery requires more charging time than a partially discharged battery. Electrolyte is nearly pure water in a completely discharged battery. At first, the charging current (amperage) will be low. As the battery charges, the specific gravity of the electrolyte will gradually rise.

The Battery Charging Time Table gives an indication of the time required to charge a typical battery at room temperature based upon the battery state-ofcharge and the charger capacity.

SPIRAL-PLATE BATTERY CHARGING TIME

TABLE

Charging

Amperage

Open Circuit

Voltage

12.25 to 12.49 6 hours 3 hours

12.00 to 12.24 10 hours 5 hours

10.00 to 11.99 14 hours 7 hours Below 10.00 18 hours 9 hours

5 Amps 8 Amps

Hours Charging @ 21°

C (70° F)

Page 41

8F - 4 ENGINE SYSTEMS KJ

BATTERY (Continued)

STANDARD PROCEDURE - USING MICRO 420 BATTERY TESTER

Fig. 2 MIDTRONICS TESTER

Always use the Micro 420 Instruction Manual that was supplied with the tester as a reference. If the Instruction Manual is not available the following procedure can be used:

WARNING: ALWAYS WEAR APPROPRIATE EYE PROTECTION AND USE EXTREME CAUTION WHEN WORKING WITH BATTERIES.

BATTERY TESTING

(1) If testing the battery OUT-OF-VEHICLE, clean the battery terminals with a wire brush before testing. If the battery is equipped with side post terminals, install and tighten the supplied lead terminal stud adapters. Do not use steel bolts. Failure to properly install the stud adapters, or using stud adapters that are dirty or worn-out may result in false test readings.

(2) If testing the battery IN-THE-VEHICLE, make certain all of the vehicle accessory loads are OFF, including the ignition. The preferred test position is at the battery terminal. If the battery is not accessible, you may test using both the positive and negative jumper posts. Select TESTING AT JUMPER POST when connecting to that location.

(3) Connect the tester (Fig. 2) to the battery or jumper posts, the red clamp to positive (+) and the black clamp to negative (–).

NOTE: Multiple batteries connected in parallel must have the ground cable disconnected to perform a battery test. Failure to disconnect may result in false battery test readings.

NOTE: When testing the battery in a PT Cruiser, always test at the battery terminals

(4) Using the ARROW key select in or out of vehi-

cle testing and press ENTER to make a selection.

(5) If not selected, choose the Cold Cranking Amp (CCA) battery rating. Or select the appropriate battery rating for your area (see menu). The tester will then run its self programmed test of the battery and display the results. Refer to the test result table noted below.

CAUTION: If REPLACE BATTERY is the result of the test, this may mean a poor connection between the vehicle’s cables and battery exists. After disconnecting the vehicle’s battery cables from the battery, retest the battery using the OUT-OF-VEHICLE test before replacing.

(6) While viewing the battery test result, press the CODE button and the tester will prompt you for the last 4 digits of the VIN. Use the UP/DOWN arrow buttons to scroll to the correct character; then press ENTER to select and move to the next digit. Then press the ENTER button to view the SERVICE CODE. Pressing the CODE button a second time will return you to the test results.

BATTERY TEST RESULTS

GOOD BATTERY Return to service

GOOD - RECHARGE Fully charge battery and

return to service

CHARGE & RETEST Fully charge battery and

retest battery

REPLACE BATTERY Replace the battery and

retest complete system

BAD-CELL REPLACE Replace the battery and

retest complete system

NOTE: The SERVICE CODE is required on every warranty claim submitted for battery replacement.

Page 42

KJ IGNITION CONTROL 8I - 1

IGNITION CONTROL

TABLE OF CONTENTS

page page

CAMSHAFT POSITION SENSOR

DESCRIPTION ..........................1

OPERATION ............................2

REMOVAL .............................2

INSTALLATION ..........................2

GLOW PLUG

DESCRIPTION ..........................2

CAMSHAFT POSITION SENSOR

DESCRIPTION

The camshaft position (CMP) sensor is mounted in the top of cylinder head cover/intake manifold at the rear of the engine (Fig. 1) (Fig. 2) The CMP sensor is a hall effect device.

OPERATION ............................2

REMOVAL .............................2

INSTALLATION ..........................3

GLOW PLUG RELAY

DESCRIPTION ..........................4

OPERATION ............................4

Fig. 1 CAMSHAFT POSITION SENSOR

Fig. 2 CAMSHAFT POSITION (CMP) SENSOR

1 - CAMSHAFT POSITION (CMP) SENSOR

Page 43

8I - 2 IGNITION CONTROL KJ

CAMSHAFT POSITION SENSOR (Continued)

OPERATION

The CMP sensor is a hall effect switch. A tooth made of a ferromagnetic material is attached to the camshaft. When this tooth passes the CMP sensor an electronic signal is created. This signal is then sent to the engine control module (ECM). This signal is used by the ECM to determine which cylinder has just entered its compression phase.

REMOVAL

(1) Disconnect negative battery cable.

(2) Remove engine cover (Refer to 9 - ENGINE COVER - REMOVAL).

(3) Disconnect CMP sensor electrical connector (Fig. 3).

(4) Remove CMP sensor retaining bolt and remove sensor from cylinder head cover/intake manifold (Fig.

3).

GLOW PLUG

DESCRIPTION

Glow plugs are used to help start a cold or cool engine (Fig. 4). The glow plugs will heat up and glow to heat the combustion chamber of each cylinder. An individual glow plug is used for each cylinder. Each glow plug is threaded into the left side of the cylinder head below the cylinder head cover/intake manifold.

Fig. 3 CAMSHAFT POSITION (CMP) SENSOR

1 - CAMSHAFT POSITION (CMP) SENSOR

INSTALLATION

(1) Lubricate O-ring on new CMP sensor and

install in cylinder head cover/intake manifold (Fig.

3). (2) Install retaining bolts. Torque to 10.8N·m. (3) Connect sensor electrical connector. (4) Install engine cover (Refer to 9 - ENGINE

COVER - INSTALLATION).

(5) Connect negative battery cable.

Fig. 4 GLOW PLUG

OPERATION

Each glow plug will momentarily draw approximately 25 amps of electrical current during the initial key “ON” cycle. This is on a cold or cool engine. After heating the current draw will drop to approximately 9–12 amps per plug.

Total momentary cuurent draw for all four glow plugs is approximately 100 amps on a cold engine dropping to a total of approximately 40 amps after the plugs are heated.

Electrical operation of the glow plugs is controlled by two glow plug relays. Each glow plug relay controls two glow plugs. Refer to glow plug relays for more information.

REMOVAL

(1) Disconnect negative battery cable.

(2) Remove generator (Refer to 8 - ELECTRICAL/ CHARGING/GENERATOR - REMOVAL).

(3) Disconnect glow plug electrical connectors (Fig.

6).

NOTE: The intake manifold inlet tube must be removed to remove the cylinder # 3 glow plug (Fig.

5).

Page 44

KJ IGNITION CONTROL 8I - 3

GLOW PLUG (Continued)

Fig. 5 INTAKE MANIFOLD AIR INLET TUBE

1 - CYLINDER HEAD COVER/INTAKE MANIFOLD 2 - AIR INLET TUBE GASKET 3 - INTAKE MANIFOLD AIR INLET TUBE 4 - RETAINING BOLTS

(4) Remove glow plugs from cylinder head (Fig. 6).

INSTALLATION

(1) Install glow plugs into cylinder head (Fig. 6). (2) Connect glow plug electrical connectors (Fig. 6). (3) Install intake manifold air inlet tube (Fig. 5). (4) Install generator (Refer to 8 - ELECTRICAL/

CHARGING/GENERATOR - INSTALLATION).

(5) Connect negative battery cable.

Fig. 6 CYLINDER HEAD ASSEMBLY

Page 45

8I - 4 IGNITION CONTROL KJ

GLOW PLUG RELAY

DESCRIPTION

There are two glow plug relays. These relays are located in the Power Distribution Center (PDC) in the engine compartment (Fig. 7).

OPERATION

When the ignition (key) switch is place in the ON position, a signal is sent to the ECM relating current engine coolant temperature. This signal is sent from the engine coolant temperature sensor.

After receiving this signal, the ECM will determine if, when and for how long of a period the glow plug relays should be activated. This is done before, during and after the engine is started. Whenever the glow plug relays are activated, it will control the 12 volt 100 amp circuit for the operation of the four glow plugs. Each relay control two glow plugs.

The Glow Plug lamp is tied to this circuit. Lamp operation is also controlled by the ECM.

With a cold engine, the glow plug relays and glow plugs may be activated for a maximum time of 200 seconds. Refer to the following Glow Plug Control chart for a temperature/time comparison of the glow plug relay operation.

In this chart, Pre-Heat and Post-Heat times are mentioned. Pre-Heat is the amount of time the glow plug relay control circuit is activated when the ignition (key) is switched ON, without the engine running. Post-Heat is the amount of time the glow plug relay control circuit is activated after the engine is operated. The Glow Plug lamp will not be activated during the post-heat cycle.

Fig. 7 GLOW PLUG RELAYS

1 - A/C COMPRESSOR CLUTCH RELAY 2 - VISCOUS HEATER RELAY 3 - ASD RELAY 4 - GLOW PLUG (3 + 4) RELAY #2 5 - CLUTCH SWITCH OVERRIDE RELAY 6 - GLOW PLUG (1 + 2) RELAY #1 7 - STARTER RELAY 8 - FUEL HEATER RELAY

Engine

Coolant

Temperature

9Key ON9

Wait-To

Start Lamp

9ON9

(Seconds)

Pre-Heat

Cycle (Glow

Plugs On

Seconds)

Post-Heat (Seconds)

-30C 10 SEC. 35 SEC. 200 SEC.

-10C 10 SEC. 23 SEC. 180 SEC. +10C 1 SEC. 21 SEC. 160 SEC. +30C 1 SEC. 20 SEC. 140 SEC. +40C 1 SEC. 19 SEC. 70 SEC. +70C 1 SEC. 16 SEC. 20 SEC.

Cycle

Page 46

KJ ENGINE 9 - 1

ENGINE

TABLE OF CONTENTS

page page

ENGINE - 2.5L/2.8L TURBO DIESEL

DESCRIPTION

DESCRIPTION - 2.5L/2.8L COMMON RAIL

DIESEL ENGINE .......................3

DESCRIPTION - ENGINE COVER ..........3

REMOVAL

REMOVAL ............................3

REMOVAL - ENGINE COVER .............5

INSTALLATION

INSTALLATION ........................5

INSTALLATION - ENGINE COVER ..........6

SPECIFICATIONS

SPECIFICATIONS - 2.8L COMMON RAIL

DIESEL ENGINE .......................6

SPECIFICATIONS - TORQUE .............8

SPECIAL TOOLS ........................11

CYLINDER HEAD

STANDARD PROCEDURE

STANDARD PROCEDURE - VALVE

SERVICE ............................15

STANDARD PROCEDURE - MEASURING

PISTON PROTRUSION .................17

REMOVAL .............................17

CLEANING ............................19

INSPECTION ..........................19

INSTALLATION .........................19

CAMSHAFT OIL SEAL(S)

REMOVAL .............................21

INSTALLATION .........................22

CAMSHAFT(S)

DESCRIPTION .........................22

OPERATION ...........................22

REMOVAL .............................22

INSTALLATION .........................23

CYLINDER HEAD COVER

DESCRIPTION .........................24

REMOVAL .............................24

INSTALLATION .........................24

ROCKER ARMS

DESCRIPTION .........................26

OPERATION ...........................26

REMOVAL .............................26

INSTALLATION .........................27

HYDRAULIC LIFTERS

DESCRIPTION .........................27

REMOVAL .............................28

INSPECTION ..........................28

INSTALLATION .........................28

ENGINE BLOCK

DESCRIPTION .........................28

CRANKSHAFT

DESCRIPTION .........................28

OPERATION ...........................28

STANDARD PROCEDURE - CHECKING

CRANKSHAFT END PLAY ...............28

REMOVAL .............................28

INSTALLATION .........................30

CRANKSHAFT MAIN BEARINGS

REMOVAL .............................31

INSTALLATION .........................32

CRANKSHAFT OIL SEAL - FRONT

REMOVAL .............................33

INSTALLATION .........................34

CRANKSHAFT OIL SEAL - REAR

REMOVAL .............................35

INSTALLATION .........................35

CYLINDER LINERS

DESCRIPTION .........................35

REMOVAL .............................35

INSPECTION ..........................36

INSTALLATION .........................36

PISTON & CONNECTING ROD

DESCRIPTION .........................37

STANDARD PROCEDURE - PISTON RING

FITTING .............................37

REMOVAL .............................37

INSPECTION ..........................39

INSTALLATION .........................40

VIBRATION DAMPER

REMOVAL .............................41

INSTALLATION .........................42

INTERNAL VACUUM PUMP

DESCRIPTION .........................42

REMOVAL .............................42

INSTALLATION .........................42

ENGINE COVER - FRONT

DESCRIPTION .........................43

REMOVAL .............................43

INSTALLATION .........................44

OIL

DESCRIPTION .........................44

OIL FILTER ADAPTER

DESCRIPTION .........................45

OIL PAN

REMOVAL .............................45

INSTALLATION .........................45

Page 47

9 - 2 ENGINE KJ

OIL PRESSURE RELIEF VALVE

DESCRIPTION .........................46

REMOVAL .............................47

INSTALLATION .........................47

OIL PRESSURE SENSOR/SWITCH

DESCRIPTION .........................47

OPERATION ...........................47

OIL PUMP

REMOVAL

REMOVAL - OIL PUMP PICKUP TUBE ......47

REMOVAL - OIL PUMP .................48

INSTALLATION

INSTALLATION - OIL PUMP PICKUP TUBE . . 48

INSTALLATION - OIL PUMP ..............48

OIL JET

DESCRIPTION .........................49

REMOVAL .............................49

INSTALLATION .........................50

INTAKE MANIFOLD

DESCRIPTION .........................50

REMOVAL .............................50

INSTALLATION .........................50

EXHAUST MANIFOLD

REMOVAL .............................50

INSTALLATION .........................50

VALVE TIMING

STANDARD PROCEDURE - LOCKING ENGINE

90 DEGREES AFTER TDC ...............50

BALANCE SHAFT

DESCRIPTION .........................51

OPERATION ...........................51

REMOVAL .............................51

INSTALLATION .........................51

TIMING BELT / CHAIN COVER(S)

REMOVAL

REMOVAL - TIMING BELT INNER COVER . . . 52 REMOVAL - TIMING BELT OUTER COVER . . 53

INSTALLATION

INSTALLATION - TIMING BELT INNER

COVER .............................54

INSTALLATION - TIMING BELT OUTER

COVER .............................54

TIMING BELT IDLER PULLEY

REMOVAL .............................54

INSTALLATION .........................55

TIMING BELT/CHAIN AND SPROCKET(S)

REMOVAL .............................55

INSTALLATION .........................56

TIMING BELT/CHAIN TENSIONER & PULLEY

REMOVAL .............................57

INSTALLATION .........................58

ADJUSTMENTS

ADJUSTMENT - TIMING BELT TENSIONER . 58

Page 48

KJ ENGINE 9 - 3

ENGINE - 2.5L/2.8L TURBO DIESEL

DESCRIPTION

DESCRIPTION - 2.5L/2.8L COMMON RAIL DIESEL ENGINE

The 2.5 Liter (2500cc) and 2.8L (2800cc) four-cylinder “common rail” direct injection engines are very simular in design and operability with a few differences. The 2.5L is the engine of choise from the manual transmission and the 2.8L for the automatic transmission. Both 4 cylinder “common rail” direct injection engines are an in-line overhead valve design. The engines utilize a cast iron cylinder block and an aluminum cylinder head with four valves per cylinder and dual overhead cam shafts. Both engins are turbocharged and intercooled. Differences include a longer crankshaft gear, larger cylinder bore and larger intake ducts in the cylinder head of the 2.8L. The 2.8L is also equipped with a EGR cooler. (Fig. 1).

DESCRIPTION SPECIFICATION Displacement 2.5L (2499 cc) Displacement 2.8L (2900cc) Bore - 2.5L 92.00 mm Bore - 2.8L 94.00 mm Stroke 94.00 Compression Ratio 17.5:1 Vacuum at Idle 700 mm/Hg (27.5 In/Hg) Belt Tension Automatic Belt Tensioner Thermostat Opening 80°C ± 2°C Generator Rating Denso 12V-95A Cooling System Capacity 13.8 Liters W/O Auxiliary

Heater

16.6 Liters With Auxiliary

Heater Engine Oil Capacity 6.0L W/Filter Change Timing System Belt Driven DOHC

Overhead Camshafts Air Intake Dry Filter With

Turbocharger and Charge

Air Cooler Fuel Supply Vane Pump Incorporated

In Injection Pump Fuel System Direct Fuel Injection

Common Rail System Combustion Cycle 4 Stroke

DESCRIPTION SPECIFICATION

Cylinder Compression Difference Between Cylinders

Cooling System Water Cooling Injection Pump Rotary Pump and

Lubrication Pressure Lubricated By

Minimum Oil Pressure (Warm)

Engine Rotation Clockwise Viewed From

Fig. 1 2.5L/2.8L COMMON RAIL DIESEL ENGINE

5 Bar

Electronically Managed

Rotary Pump

0.7 Bar at Idle 2 Bar at 3800 rpm

Front Cover

DESCRIPTION - ENGINE COVER

The engine cover is made of plastic and used cos-

metically to cover the top of the engine (Fig. 2).

REMOVAL

(1) Disconnect negative battery cable. (2) Disconnect under hood lamp from the hood

assembly.

(3) With assistance from another person, remove

the hood assembly from the vehicle.

(4) Drain cooling system (Refer to 7 - COOLING/

ENGINE/COOLANT - STANDARD PROCEDURE).

(5) Remove engine cover (Refer to 9 - ENGINE -

REMOVAL).

Page 49

9 - 4 ENGINE KJ

ENGINE - 2.5L/2.8L TURBO DIESEL (Continued)

(6) Remove air filter assembly from the engine bay. (7) Recover refrigerant from A/C system (Refer to

24 - HEATING & AIR CONDITIONING/PLUMBING

- STANDARD PROCEDURE). (8) Disconnect high side refrigerant line from the

upper radiator support bracket.

(9) Remove upper radiator support bracket retain-

ing bolts and remove the support bracket.

(10) Remove high side refrigerant line retaining

nut and remove the line from the condenser assembly. Position the line out of the way.

(11) Remove cooling fan and fan drive viscous

clutch assembly.

(12) Remove fan shroud retaining bolts and

remove fan assembly and shroud together.

(13) Disconnect charge air cooler hoses from

charge air cooler.

(14) Disconnect engine coolant hoses from engine

assembly.

(15) Disconnect coolant reservoir hose from radia-

tor.

(16) Remove low side refrigerant line retaining nut

and remove line from the condenser assembly. Position the line out of the way.

(17) Remove condenser assembly retaining bolts

and remove condenser from the vehicle.

(18) Remove power steering cooler retaining bolts

and unclip air deflectors from both sides of the radiator (cooling module) assembly.

(19) Lift cooling module assembly out of the engine

bay.

(20) Remove charge air cooler hose from the intake

manifold.

(21) Remove high side refrigerant line from A/C

compressor and remove high side line from the engine bay.

(22) Remove coolant reservoir retaining nuts and

clips retaining electrical harness, position reservoir aside to allow access to remaining hoses.

(23) Disconnect remaining hoses from coolant res-

ervoir and remove reservoir from the engine bay.

(24) Remove accessory drive belt from the engine

(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).

(25) Accessing bolts through the pump pulley,

remove power steering pump retaining bolts and position pump aside with lines still attached.

(26) Remove engine cover mounting bracket

retaining bolts and remove the bracket from the top of the engine.

(27) Disconnect four large electrical connectors

near the rear of the right front fenderwell.

(28) Disconnect heater core inlet and outlet hoses

from the heater core.

(29) Remove generator from engine (Refer to 8 ELECTRICAL/CHARGING/GENERATOR - REMOVAL). This will provide access to the wires beneath it.

(30) Remove low side refrigerant line retaining nuts from accumulator and compressor and remove from engine bay.

(31) Trace engine wiring and disconnect electrical connectors and tie straps one at a time untill all wiring is disconnected from the engine assembly. When all the engine electrical harness is disconnected fold the harness over the left front fenderwell.

(32) Remove coolant elbow retaining bolts from rear of the water pump.

(33) Disconnect coolant hoses leading from the coolant elbow and remove coolant elbow from engine.

(34) Remove oil cooler adapter.

(35) Raise and support the vehicle.

(36) Remove oil filter and adaptor assemby.

(37) Remove starter motor from engine (Refer to 8

- ELECTRICAL/STARTING/STARTER MOTOR REMOVAL).

(38) Remove chassis ground wire above starter mounting location on the engine block.

(39) Remove exhaust inlet pipe retaining bolts and disconnect exhaust pipe from turbocharger.

(40) Remove transmission to engine retaining bolts.

(41) Lower vehicle.

(42) Connect a suitable lifting device to engine assembly.

(43) Remove right side engine mount from engine block.

(44) Disconnect crankshaft position sensor, located on the right rear of the engine.

(45) Disconnect oil pressure sensor, located between the engine block and the turbocharger. Make certain everything is disconnected from the engine assembly.

(46) Place a floor jack under the transmission to support the transmission.

(47) With engine and transmission supported by a lifting device carefully separate the engine from the transmission.

(48) Lift the engine assembly out of the engine bay.

Page 50

KJ ENGINE 9 - 5

ENGINE - 2.5L/2.8L TURBO DIESEL (Continued)

REMOVAL - ENGINE COVER

(1) Remove oil fill cap and oil dipstick. (2) Carefully lift engine engine cover from corners

to remove from mounting bracket (Fig. 2).

Fig. 2 ENGINE COVER REMOVAL/INSTALLATION

1 - ENGINE COVER BRACKET 2 - ENGINE COVER 3 - RETAINING BOLTS

INSTALLATION

(1) Install engine assembly in the engine bay.

(2) Line up the transmission input shaft with the corresponding hole in the clutch assembly (2.5L). Install the transmission assembly on the engine block mounted dowel pins (2.8L) if possible. If this proves to difficult removal of the transmission may be required.

(3) Connect oil pressure sensor, located between the engine block and the turbocharger.

(4) Connect crankshaft position sensor, located on the right rear of the engine.

(5) Install right side engine mount on the engine block.

(6) Disconnect lifting device from the engine assembly.

(7) Raise and support the vehicle.

(8) Install all transmission to engine retaining

bolts.

(9) Install exhaust inlet pipe and retaining bolts. (10) Install chassis ground wire above starter

mounting location on the engine block.

(11) Install starter motor on the engine. (12) Install oil filter and cooler assembly. (13) Lower vehicle. (14) Install oil cooler adapter. (15) Install coolant elbow and retaining bolts and

connect the hoses leading from it.

(16) Trace engine wiring and connect electrical connectors and tie straps one at a time until all wiring is connected on engine assembly.

(17) Install low side refrigerant line.

(18) Install generator on the engine (Refer to 8 ELECTRICAL/CHARGING/GENERATOR - INSTALLATION).

(19) Connect heater core inlet and outlet hoses at heater core.

(20) Connect four large electrical connectors near rear of the right front fenderwell.

(21) Install engine cover mounting bracket and retaining bolts.

(22) Accessing bolts through the pump pulley, install the power steering pump and retaining bolts.

(23) Install accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION).

(24) Install coolant reservoir and connect hoses.

(25) Install coolant reservoir retaining nuts.

(26) Install high side refrigerant line on compressor.

(27) Install charge air cooler hose on intake manifold.

(28) Install cooling module assembly in the engine bay.

(29) Install power steering cooler and retaining bolts and clip the air deflectors on both sides of the radiator (cooling module) assembly.

(30) Install condenser assembly and retaining bolts.

(31) Install low side refrigerant line and retaining nut.

(32) Connect coolant reservoir hose on radiator.

(33) Connect engine coolant hoses on engine.

(34) Connect charge air cooler hoses on charge air cooler.

(35) Install fan shroud with cooling fan assembly inside the shroud and install the shroud retaining bolts.

(36) Connect cooling fan and fan drive viscous clutch assembly to fan support.

(37) Install high side refrigerant line and retaining nut.

Page 51

9 - 6 ENGINE KJ

ENGINE - 2.5L/2.8L TURBO DIESEL (Continued)

(38) Install upper radiator support bracket and

retaining bolts.

(39) Connect high side refrigerant line on the

upper radiator support bracket.

(40) Charge refrigerant system (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING STANDARD PROCEDURE).

(41) Install air filter assembly.

(42) Install engine cover (Refer to 9 - ENGINE COVER - REMOVAL).

(43) Install engine oil fill cap.

(44) Fill cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE).

(45) With assistance from another person, install hood assembly on the vehicle.

(46) Connect under hood lamp on the hood assembly.

(47) Connect negative battery cable.

INSTALLATION - ENGINE COVER

(1) Align engine cover with mounting bracket. Push down firmly on all four corners of engine cover to snap in place (Fig. 2).

(2) Install oil dipstick tube.

(3) Install oil fill cap.

SPECIFICATIONS

SPECIFICATIONS - 2.8L COMMON RAIL DIESEL ENGINE

ENGINE SPECIFICATIONS

DESCRIPTION SPECIFICATION

Type R2816K3.05A

Number of Cylinders 4

Bore 94 mm

Stroke 94 mm

Displacement 2800cc

Injection Order 1-3-4-2

Compression Ratio 17.5:1 (± 0.5)

Maximum Power 105kW (140 HP) @ 4000

RPM

Peak Torque 320Nm (32.6 kgm) @

2000 RPM

Cylinder Compression

(Max. Difference Between

Cylinders)

Minimum Oil Pressure

(Warm)

2 Bar @ 3800 RPM

5 Bar

0.7 Bar @ Idle

DESCRIPTION SPECIFICATION

CRANKSHAFT

Front Journal Diameter

Nominal 62.985-63.005 mm

-0.25 62.735-62.755 mm

Front Bearing Diameter

Nominal 63.045-63.074 mm

-0.25 62.795-62.824 mm

Clearance Between

Journal and Bearing

Center Journal Diameter

Nominal 63.005-63.020 mm

-0.25 62.755-62.770 mm

Center Bearing Diameter

Nominal 63.005-63.020 mm

-0.25 62.755-62.770 mm

Clearance Between

Journal and Bearing

Rear Journal Diameter

Nominal 89.980-90.000 mm

-0.25 89.730-99.750 mm

Rear Bearing Diameter

Nominal 90.045-90.065 mm

-0.25 89.795-89.815 mm

Clearance Between

Journal and Bearing

Connecting Rod Journal

Nominal 53.940-53.955 mm

-0.25 53.690-53.705 mm

Connecting Rod Bearing

Nominal 53.977-54.016 mm

-0.25 53.727-53.766 mm

Clearance Between

Journal and Bearing Crankshaft End Play

End Play 0.080-0.280 mm

Adjustment Thrust Washers

Thrust Washers Available 2.31-2.36 mm

Carrier with thrust

washers installed

0.040-0.089 mm

0.008-0.051 mm

0.045-0.080 mm

0.022-0.076 mm

2.41-2.46 mm

2.51-2.56 mm

27.670-27.820 mm

Page 52

KJ ENGINE 9 - 7

ENGINE - 2.5L/2.8L TURBO DIESEL (Continued)

DESCRIPTION SPECIFICATION

MAIN BEARING CARRIERS

Internal Diameter

Front 67.025-67.050 mm

Center 66.670-66.690 mm

Rear 85.985-86.005 mm

LINERS

Internal Diameter 93.997-94.015 mm

Protrusion 0.00-0.05 mm

Adjustment Shims

Available Shims 0.15 mm

0.17 mm

0.20 mm

0.23 mm

0.25 mm

CYLINDER HEAD

Minimum Thickness 94.95-95.05 mm

Gasket Thickness 1.32 mm ± 0.08, 0

notches

1.42 mm ± 0.08, 1 notch

1.52 mm ± 0.08, 2 notches

CONNECTING RODS

Small End Bearing

Internal Diameter

Large End Internal

Diameter

PISTONS

Skirt Diameter (measured

at approximately 10 mm above the bottom of the

skirt)

Piston Clearance 0.010-0.022 mm

Top of Piston to Cylinder

Head

Piston Potrusion 0.49-0.60 Fit Gasket

32.035-32.050 mm

53.977-54.016 mm

93.912-93.928 mm

0.69-0.83 mm

Number (1.32), 0 notches

or holes

0.61-0.70 Fit Gasket

Number (1.42), 1 notch

or hole

0.71-0.83 Fit Gasket

Number (1.52), 2 notches

or holes

DESCRIPTION SPECIFICATION

PISTON PINS

Type Full Floating

Pin Diameter 31.990-31.996 mm

32.000-32.004

Clearance 0.010-0.020 mm

0.004-0.012

PISTON RINGS

Clearance in Groove

Top 0.078-0.137 mm

Second 0.065-0.110 mm Oil Control 0.035-0.080 mm Fitted Gap

Top 0.30-0.45 mm

Second 0.30-0.50 mm Oil Control 0.25-0.50 mm

CAMSHAFT

Journal Diameter–Front 29.960-29.980 mm

Bearing Clearance 0.03-0.08 mm

Journal Diameter–Center 39.250-39.270 mm

Bearing Clearance 0.03-0.08 mm

Journal Diameter–Rear 39.250-39.270 mm

Bearing Clearance 0.03-0.08 mm

HYDRAULIC LIFTER

Outside Diameter 11.994 ± 0.006 mm

VALVES

Intake Valve

Opens 15.6° ± 2° A.T.D.C.

Closes 64.4° ± 2° A.B.D.C.

Exhaust Valve

Opens 66° ± 2° B.B.D.C. Closes 32° ± 2° A.T.D.C.

Face Angle

Intake 45° 25’-55° 35’

Exhaust 45° 25’-45° 35’

Head Diameter

Intake 32.30-32.50 mm

Exhaust 30.80-31.00 mm

Head Stand Down

Intake 1.08-1.34 mm

Exhaust 0.99-1.25 mm

Stem Diameter

Intake 5.952-5.970 mm

Exhaust 5.942-5.960 mm

Page 53

9 - 8 ENGINE KJ

ENGINE - 2.5L/2.8L TURBO DIESEL (Continued)

DESCRIPTION SPECIFICATION

Clearance in Guide

Intake 0.030-0.060 mm

Exhaust 0.040-0.070 mm

VALVE GUIDE

Inside Diameter 6.00-6.012 mm

Fitted Height

Intake 14.5-15.0 mm

Exhaust 16.5-17.0 mm

VALVE SPRINGS

Free Length 45.26 mm

Fitted Length 38.00 mm

Load at Fitted Length 182 ± 5-10% Kg

Load at Top of Lift 395 ± 5% Kg

DESCRIPTION SPECIFICATION

Number of Coils 8

LUBRICATION

Pressure Relief Valve

Opens

Pressure Relief Valve

Spring-Free Length

OIL PUMP Outer Rotor End Float 0.060-0.160 mm Inner Rotor End Float 0.060-0.160 mm

Outer Rotor to Body

Diameter Clearance

Rotor Body to Drive Gear

Clearance (pump not

fitted)

6.50 bar

51.5 mm

0.130-0.240 mm

0.90-1.50 mm

SPECIFICATIONS - TORQUE

2.5L/2.8L DIESEL TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Oil Pump Bolts 10.8 8 96

Vacuum Pump Bolts 10.8 8 96

Crankshaft Gear Bolts 10.8 8 96

Crankshaft Position

Sensor Bolts

Flywheel Bolts - 2.5L 3 stages, 50N·m

clockwise then 25N·m

plus 90° cross sequence

Flywheel Bolts - 2.8L 3 stages, 50N·m

clockwise then 25N·m

plus 60° cross sequence

Cylinder Head Bolts -

Refer to the Service

Procedure

Reluctor Wheel Bolts 14.6 11 130

Rear Main Bearing

Support Bolts

Oil Cooler to Engine Block

Bolt

Oil Cooler Mounting Stud 50 37 —

Water Pump Housing Nuts 24.4 18 212

Connecting Rod Bolts -

Refer to the Service

Procedure

Balance Shaft Bolts 32.4 24 —

Oil Jet Bolts 10.8 8 96

10.8 8 96

37/18 —

27.5 21 240

47.1 35 —

Page 54

KJ ENGINE 9 - 9

ENGINE - 2.5L/2.8L TURBO DIESEL (Continued)

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Oil Pump Pick-up Tube 32.4 24 —

Oil Pan Bolts 11.8 8 96

Structural Support to

Engine and Transmission

Bolts

Crankshaft Hub Bolt 275 203 —

Crankshaft Pulley Bolts 32.4 24 —

Front Engine Cover Bolts 6 — 53

Transmission to Engine

Bolts

Cylinder Head Cover /

Intake Manifold Bolts

Camshaft Timing Access

Bolts

Camshaft Access Plugs 80 59 —

Oil Separator Bolts 10.8 8 96

Camshaft Position Sensor

Bolt

Boost Pressure / Intake

Air Temp. Sensor Bolts

Accessory Drive Bracket

Bolts

Accessory Drive Belt Idler

Pulley Bolt

Vacuum Line Fitting Bolt 56.9 42 —

Fuel Pump Nuts 27.5 21 —

Fuel Line Fittings at Pump 27.5 21 —

Fuel Rail Retaining Bolts 24.5 18 217

Inner Timing Belt Cover

Bolts 8mm 10.8 8 96

10mm 45.1 33 —

Outer Timing Belt Cover

Bolts 3mm 6 — 54 8mm 10.8 8 96

Engine Mount Bracket to

Cylinder Head Bolts

Structural Support to

Engine and Transmission

Bolts

Intake Inlet Tube Bolts 10.1 8 89 Camshaft Sprocket Bolts 108 80 — Camshaft Timing Access

Bolts

45.1 33 —

83.4 62 —

24.5 18 —

10.8 8 96

5.4 — 48

45.1 33 —

53 39 —

45.1 33 —

45.1 33

24.5 18 212

Page 55

9 - 10 ENGINE KJ

ENGINE - 2.5L/2.8L TURBO DIESEL (Continued)

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Timing Belt Idler Pulley

Bolt

Timing Belt Tensioner Bolt 29.4 22 —

Fuel Injection Pump Gear

Nut

Fuel Injection Pump

Retaining Nuts

Engine Lift Hook Bolts 45.1 33 —

Thermostat Housing Bolts 24.5 18 —

Turbocharger Oil Supply

Line Fitting

Turbocharger Oil Return

Line Bolts

Exhaust Manifold Nuts 32.4 24 —

Exhaust Manifold Heat

Shield

Exhaust Manifold

Heatshield Bolts EGR Valve Nuts 32.4 24 —

Coolant Pipe to EGR

Valve Bolts

Turbocharger Downpipe

Nuts

Turbocharger Bracket

Bolts

Vibration Damper to

Crankshaft Hub Bolts

Crankshaft Support Bolts 44.1 33 —

Turbocharger to Exhaust

Manifold Nuts

47.1 35 —

88.3 65 —

24.4 18 212

24.5 18 217

10.8 — 96

24.5 18 217

27.5 21 —

32.4 24 —

47.1 35 —

27.5 21 —

32.4 24 —

Page 56

KJ ENGINE 9 - 11

ENGINE - 2.5L/2.8L TURBO DIESEL (Continued)

SPECIAL TOOLS

VM.1054 RELIEF VALVE REMOVER/CENTRAL

VM.1050 CRANKSHAFT REAR SEAL INSTALLER

CARRIER PIN REMOVER/INSTALLER

VM.1052 INTAKE CAMSHAFT ALIGNMENT PIN

VM.1053 EXHAUST CAMSHAFT ALIGNMENT PIN

VM.1055 CAMSHAFT/HIGH PRESSURE INJECTION

PUMP GEAR HOLDER

VM.1056 BALANCE SHAFT LOCKING PIN

Page 57

9 - 12 ENGINE KJ

ENGINE - 2.5L/2.8L TURBO DIESEL (Continued)

VM.1062 POWER STEERING PUMP INSTALLER

VM.1059 OIL PRESSURE RELIEF VALVE INSTALLER

VM.1060 OIL JET REMOVER /INSTALLER

VM.1061 FRONT COVER AND FRONT OIL SEAL

INSTALLER

VM.1063 FUEL INJECTOR REMOVER

Page 58

KJ ENGINE 9 - 13

ENGINE - 2.5L/2.8L TURBO DIESEL (Continued)

VM.1064 POWER STEERING PUMP GEAR

REMOVER

VM.1067 HIGH PRESSURE PUMP REMOVER

VM.1065 PISTON RING COMPRESSOR

VM.1066 VALVE COVER ALIGNMENT PINS

VM.1069 CRANKSHAFT REM/INSTALL SLEEVE

VM.1070 FLYWHEEL LOCKING TOOL

Page 59

9 - 14 ENGINE KJ

ENGINE - 2.5L/2.8L TURBO DIESEL (Continued)

VM.1072 COMPRESSION TESTER ADAPTER

VM.1075 FLYWHEEL ALIGNMENT PINS

VM.1073 CRANKSHAFT FRONT BEARING

REMOVER/INSTALLER

VM.1074 TIMING BELT RETAINER

VM.8872 TDC LOCATING PIN

VM.8873 90 DEGREES AFTER TDC LOCATING PIN

Page 60

KJ ENGINE 9 - 15

CYLINDER HEAD

STANDARD PROCEDURE

STANDARD PROCEDURE - VALVE SERVICE

This procedure is done with the engine cylinder

head removed from the block.

DISASSEMBLY

(1) Remove the engine cylinder head from the cylinder block. Refer to cylinder head removal and installation in this section.

(2) Use Valve Spring Compressor Tool and compress each valve spring.

(3) Remove the valve locks, retainers, and springs.

(4) Use a smooth stone or a jewelers file to remove any burrs on the top of the valve stem, especially around the groove for the locks.

(5) Remove the valves, and place them in a rack in the same order as removed.

VALVE CLEANING

(1) Clean all carbon deposits from the combustion chambers, valve ports, valve stems, valve stem guides and head.

(2) Clean all grime and gasket material from the engine cylinder head machined gasket surface.

INSPECTION

(1) Inspect for cracks in the combustion chambers and valve ports.

(2) Inspect for cracks on the exhaust seat.

(3) Inspect for cracks in the gasket surface at each coolant passage.

(4) Inspect valves for burned, cracked or warped heads.

(5) Inspect for scuffed or bent valve stems.

(6) Replace valves displaying any damage.

(7) Check valve spring height (Fig. 3).

VALVE REFACING

(1) Use a valve refacing machine to reface the intake and exhaust valves to the specified angle.

(2) After refacing, a margin of at least 4.52-4.49 mm (.178-.177 inch) must remain (Fig. 4). If the margin is less than 4.49 mm (.177 inch), the valve must be replaced.

Fig. 3 VALVE SPRING CHART

LOAD Kg HEIGHT mm STATE

P1 0.00 H1 45.26 FREE LENGTH P2 182-5

P3 395±5% H3 28.20 VALVE OPEN

+10%

H2 38.00 VALVE CLOSED

VALVE SEAT REFACING

(1) Install a pilot of the correct size in the valve guide bore. Reface the valve seat to the specified angle with a good dressing stone. Remove only enough metal to provide a smooth finish.

(2) Use tapered stones to obtain the specified seat width when required.

VALVE STAND DOWN

Valve stand down is to maintain the adequate compression ratio.

(1) Invert cylinder head.

(2) Fit each valve to its respective valve guide.

(3) Using a straight edge and feeler gauge, check valve head stand down: Inlet valve head stand down

1.08 to 1.34 mm (.042 to .052 ins.) and exhaust valve stand down .99 to 1.25 mm (.035 to .049 ins.).

(4) If valve head stand down is not in accordance with above, discard original valves, check stand down with new valves and recut valve seat inserts to obtain correct stand down.

Page 61

9 - 16 ENGINE KJ

CYLINDER HEAD (Continued)

VALVE GUIDES

(1) Valve Guides height requirement.

(2) Measurement A (Fig. 5): 16.50 - 17.00 mm. Measurment B : 14.50 - 15.00 mm.

Fig. 4 VALVE SPECS.

MEASUREMENT INTAKE EXHAUST

A 7.940-7.960 7.922-7.940 B 8.00-8.015 8.000-8.015 C 1.08-1.34 0.990-1.250

D 2.2 ± 0.08 2.09

E 1.80-2.20 1.65-2.05 F 2.73-3.44 2.45-3.02 G 41.962-41.985 35.964-35.987 H 42.070-42.086 36.050-36.066

I 7.14-7.19 7.00-7.05

L 3.11-3.26 3.10-3.25

+0.07

20.09

Fig. 5 VALVE GUIDE HEIGHT

VALVE STEM-TO-GUIDE CLEARANCE MEASUREMENT

(1) Measure and record internal diameter of valve guides. Valve guide internal diameter is 8.0 to 8.015 mm (.3149 to .3155 ins.).

(2) Measure valve stems and record diameters. Intake valve stem diameter 7.94 to 7.96 mm (.3125 to .3133 in). Exhaust valve stem diameter 7.92 to 7.94 mm (.3118 to .31215 in).

(3) Subtract diameter of valve stem from internal diameter of its respective valve guide to obtain valve stem clearance in valve guide. Clearance of inlet valve stem in valve guide is .040 to .075 mm (.0015 to .0029 in). Clearance of exhaust valve stem in valve guide is .060 to .093 mm (.0023 to .0036 in).

(4) If valve stem clearance in valve guide exceeds tolerances, new valve guides must be installed.

Page 62

KJ ENGINE 9 - 17

CYLINDER HEAD (Continued)

STANDARD PROCEDURE - MEASURING PISTON PROTRUSION

(1) Use special tool VM.1010 with dial indicator

special tool VM.1013 (Fig. 6).

Fig. 6 PISTON PROTRUSION

(2) Bring the piston of cylinder no. 1 exactly to top

dead center.

(3) Zero the dial indicator on the cylinder block

mating surface.

Setup the dial indicator on the piston crown

(4) (above the center of the piston pin) 5mm (1/8 in.) from the edge of the piston and note the measurement.

(5) Repeat the procedure with the rest of the cylinders.

(6) Establish the thickness of the steel gasket by averaging the four piston potrusion readings.

Measure Dimension (mm) 0.49-0.60 Cylinder Head Gasket

Thickness (mm) Piston Clearance (mm) 0.72-0.83

Measure Dimension (mm) 0.61-0.70 Cylinder Head Gasket

Thickness (mm) Piston Clearance (mm) 0.72-0.81

Measure Dimension (mm) 0.71-0.83 Cylinder Head Gasket

Thickness (mm) Piston Clearance (mm) 0.69-0.81

1.32 No Holes or Notches

1.42 1 Hole or Notch

1.52 2 Holes or Notches

REMOVAL

(1) Disconnect negative battery cable. (2) Remove engine cover and bracket (Refer to 9 -

ENGINE COVER - REMOVAL).

(3) Drain cooling system (Refer to 7 - COOLING/

ENGINE/COOLANT - STANDARD PROCEDURE).

(4) Remove radiator core support.

(5) Remove cooling fan and fan drive viscous clutch assembly (Refer to 7 - COOLING/ENGINE/ FAN DRIVE VISCOUS CLUTCH - REMOVAL).

(6) Remove accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL).

(7) Remove accessory drive belt tensioner and both idler pulleys, Idler pulley bolts are L.H. thread- .(Refer to 7 - COOLING/ACCESSORY DRIVE/BELT TENSIONERS - REMOVAL).

(8) Remove power steering pump pulley.

(9) Remove front engine lift bracket.

(10) Remove cooling fan support (Refer to 7 COOLING/ENGINE/RADIATOR FAN - REMOVAL).

(11) Remove generator and support bracketing(Refer to 8 - ELECTRICAL/CHARGING/GENERATOR REMOVAL).

(12) Remove viscous heater.

(13) Remove vibration damper.

(14) Remove throttle cable assembly and set aside.

(15) Disconnect main engine wiring harness connectors from right inner wheel housing.

(16) Disconnect main engine wiring harness ancillary components and set harness aside.

(17) Remove air cleaner housing.

(18) Disconnect EGR cooler assembly water inlet pipe.

(19) Remove EGR cooler from exhaust manifold (2.8L), Disconnect coolant pipe (2.5L).(Refer to 25 EMISSIONS CONTROL/EXHAUST GAS RECIRCULATION/VALVE COOLER - REMOVAL).

(20) Remove exhaust manifold heat shield (Fig. 7).

(21) Remove turbocharger heat shield retaining bolt and position shield aside (Fig. 9).

(22) Remove turbocharger oil feed line from turbocharger (Fig. 9).

(23) Raise and support vehicle.

(24) Disconnect exhaust stabilizer bracket at lower exhaust manifold (Fig. 9).

(25) Disconnect exhaust system bracket at transmission crossmember.

(26) Lower the vehicle and remove the exhaust manifold retaining nuts.

(27) Slide the exhaust manifold and turbocharger off of exhaust manifold studs (Fig. 9).

(28) Remove coolant hoses at thermostat housing.

Page 63

9 - 18 ENGINE KJ

CYLINDER HEAD (Continued)

(31) Disconnect fuel pump high pressure line at fuel rail (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - REMOVAL).

(32) Disconnect oil dip stick tube from intake manifold.

(33) Disconnect brake booster line bracket from intake manifold and set aside.

(34) Remove fuel injectors (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR REMOVAL).

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

(35) Remove timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).

(36) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL).

(37) Using VM.1055, remove both camshaft gears (Fig. 8).

Fig. 7 THERMOSTAT HOUSING

(29) Disconnect fuel return hose from fuel injectors and set aside (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - REMOVAL).

(30) Remove fuel injector pressure lines (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - REMOVAL).

Fig. 8 CAMSHAFT GEAR REMOVAL/INSTALLATION

1 - TIMING BELT INNER COVER 2 - CAMSHAFT SPROCKET 3 - IDLER PULLEYS 4 - CAMSHAFT SPROCKET 5 - VM.1055

Page 64

KJ ENGINE 9 - 19

CYLINDER HEAD (Continued)

(38) Remove timing belt inner cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).

(39) Remove cylinder head cover/intake manifold (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).

(40) Remove rocker arm and lifter assemblies from cylinder head. Be sure to keep in same order as

removed.

(41) Remove cylinder head cover/intake manifold gasket from cylinder head.

(42) Disconnect glow plug and engine coolant temperature electrical connectors.

(43) Remove turbocharger outlet to charge air cooler hose.

(44) Remove cylinder head bolts.

(45) Remove cylinder head assembly from engine block (Fig. 9).

CLEANING

Thoroughly clean the engine cylinder head and cylinder block mating surfaces. Clean the intake and exhaust manifold and engine cylinder head mating surfaces. Remove all gasket material and carbon.

Check to ensure that no coolant or foreign material has fallen into the tappet bore area.

Remove the carbon deposits from the combustion chambers and top of the pistons.

Fig. 9 CYLINDER HEAD ASSEMBLY

INSPECTION

Use a straightedge and feeler gauge to check the flatness of the engine cylinder head and block mating surfaces.

The minimum cylinder head thickness is 89.95mm (3.541 in.).

INSTALLATION

CAUTION: Piston protrusion must be measured to determine cylinder head gasket thickness if one or more cylinder liners have been replaced (Refer to 9 ENGINE/CYLINDER HEAD - STANDARD PROCEDURE).

NOTE: If cylinder liner(s) have not been removed, the same thickness head gasket that was removed can be used.

(1) Clean and inspect gasket mating surfaces. (2) Position correct head gasket on engine block. (3) Place cylinder head on engine block.

Page 65

9 - 20 ENGINE KJ

CYLINDER HEAD (Continued)

CAUTION: New cylinder head bolts must be used.

(4) Tighten cylinder head bolts following procedure below.

Cylinder Head Bolt Torquing Procedure

(1) Lubricate cylinder head bolts with engine oil.

(2) Torque bolts to 30N·m in numerical starting with bolt #1 (Fig. 10).

(3) Tighten all bolts an additional 50°, starting with bolt #4 then 5-6-7-8-9-10-1-2-3-11-12-13-14-1516-17-18 (Fig. 10).

(4) Finally tighten all bolts an additional 75° in numerical order starting with bolt #1 (Fig. 10).

Fig. 10 CYLINDER HEAD TORQUE SEQUENCE

(5) Slide exhaust manifold and turbocharger on exhaust manifold studs (Fig. 11).

(6) Install exhaust manifold retaining nuts. Torque nuts to 32.4N·m.

(7) Install exhaust manifold heat shield. Torque bolts to 27.5N·m.

(8) Install turbocharger outlet to charge air cooler pipe.

(9) Install upper radiator hose.

(10) Connect glow plug and coolant temperature sensor electrical connectors.

(11) Install new cylinder head cover/intake manifold gasket.

(12) Install rocker arm and lifter assemblies.Be

sure to put rocker arm and lifter assemblies in same location as removed.

(13) Install cylinder head cover/intake manifold(Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).

Fig. 11 THERMOSTAT HOUSING

(14) Install timing belt inner cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).

(15) Using VM.1055, install both camshaft gears and tighten bolts finger tight.

(16) Install timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION).

Page 66

KJ ENGINE 9 - 21

CYLINDER HEAD (Continued)

(17) Using VM.1055, torque cam gear retaining

bolts to 108 N·m. (Fig. 12).

Fig. 12 CAMSHAFT GEAR REMOVAL/INSTALLATION

1 - TIMING BELT INNER COVER 2 - CAMSHAFT SPROCKET 3 - IDLER PULLEYS 4 - CAMSHAFT SPROCKET 5 - VM.1055

(18) Install timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).

(19) Remove crankshaft and both camshaft locking pins at this time (Refer to 9 - ENGINE/ VALVE TIMING - STANDARD PROCEDURE) .

(20) Install fuel injectors (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR INSTALLATION).

(21) Install brake booster line bracket to intake manifold.

(22) Install oil dip stick tube to intake manifold.

(23) Connect fuel pump high pressure line to fuel rail.

(24) Install fuel injector pressure lines.

(25) Connect fuel return hose to fuel injectors.

(26) Connect engine coolant hoses to thermostat housing.

(27) Raise vehicle.

(28) Reconnect exhaust system bracket at transmission crossmember.

(29) Connect exhaust stabilizer bracket to lower exhaust manifold (Fig. 11).

(30) Install turbocharger oil feed line to turbocharger.

(31) Lower vehicle.

(32) Install turbocharger heat shield. (33) Install exhaust manifold heat shield. (34) Install EGR cooler assembly and connect

engine coolant hoses.

(35) Install air cleaner housing. (36) Install main engine wiring harness and con-

nect all ancillary electrical components.

(37) Install throttle cable assembly. (38) Install viscous heater. (39) Install vibration damper. (40) Install generator (Refer to 8 - ELECTRICAL/

CHARGING/GENERATOR - INSTALLATION).

(41) Install cooling fan support (Refer to 7 COOLING/ENGINE/RADIATOR FAN - INSTALLATION).

(42) Install front engine lift bracket.

(43) Install power steering pump pulley.

(44) Install accessory drive belt tensioner and both idler pulleys. Idler pulley retaining bolts are L.

H. Thread.

(45) Install accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION).

(46) Install cooling fan and fan drive viscous clutch assembly (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - INSTALLATION).

(47) Install upper radiator core support.

(48) Refill cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE).

(49) Install engine cover and bracket (Refer to 9 ENGINE COVER - INSTALLATION).

(50) Connect negative battery cable.

(51) Start engine and inspect for leaks (Refer to 14

- FUEL SYSTEM - WARNING).

CAMSHAFT OIL SEAL(S)

REMOVAL

(1) Disconnect negative battery cable.

(2) Remove cooling fan and fan drive viscous clutch assembly (Refer to 7 - COOLING/ENGINE/ FAN DRIVE VISCOUS CLUTCH - REMOVAL).

(3) Remove accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL).

(4) Remove fan support (Refer to 7 - COOLING/ ENGINE/RADIATOR FAN - REMOVAL).

(5) Remove vibration damper.

(6) Remove outer timing belt cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).

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9 - 22 ENGINE KJ

CAMSHAFT OIL SEAL(S) (Continued)

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

(7) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL).

(8) Using VM.1055, remove both camshaft gears (Fig. 13).

(8) Install accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).

(9) Install cooling fan and fan drive viscous clutch assembly (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - INSTALLATION).

(10) Connect negative battery cable.

CAMSHAFT(S)

DESCRIPTION

The camshafts are made of gray cast iron with eight machined lobes and four bearing journals (Fig.

14).

Fig. 13 CAMSHAFT GEAR REMOVAL/INSTALLATION

1 - TIMING BELT INNER COVER 2 - CAMSHAFT SPROCKET 3 - IDLER PULLEYS 4 - CAMSHAFT SPROCKET 5 - VM.1055

(9) Remove both camshaft oil seals.

INSTALLATION

(1) Install new camshaft oil seal using VM.1057. (2) Install camshaft sprockets and tighten retain-

ing bolts finger tight.

(3) Install timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION).

(4) Torque camshaft sprockets to 108 N·m using VM.1055 to hold sprockets (Fig. 13).

(5) Install outer timing belt cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).

(6) Install vibration damper.

(7) Install cooling fan support (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION).

Fig. 14 CAMSHAFTS

1 - INTAKE CAMSHAFT 2 - EXHAUST CAMSHAFT

OPERATION

When the camshaft rotates the lobes actuate the hydraulic lifters and rocker arms, forcing downward on the rocker arms which opens the valves.

REMOVAL

(1) Disconnect negative battery cable.

(2) Remove engine cover and bracket (Refer to 9 ENGINE - REMOVAL).

(3) Drain cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE).

(4) Remove cooling fan and fan drive viscous clutch assembly (Refer to 7 - COOLING/ENGINE/ FAN DRIVE VISCOUS CLUTCH - REMOVAL).

(5) Remove accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL).

(6) Remove cooling fan support (Refer to 7 COOLING/ENGINE/RADIATOR FAN - REMOVAL).

(7) Remove vibration damper.

(8) Remove generator (Refer to 8 - ELECTRICAL/ CHARGING/GENERATOR - REMOVAL).

Page 68

KJ ENGINE 9 - 23

CAMSHAFT(S) (Continued)

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

(9) Remove timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).

(10) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL).

(11) Remove timing belt inner cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).

(12) Remove cylinder head cover/intake manifold (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).

(13) With cylinder head cover/intake manifold on work bench, remove plugs at rear of cylinder head cover/intake manifold.

(14) Remove camshaft oil seals (Fig. 15).

(15) Remove snapring and thrust washer from camshaft (Fig. 15).

(16) Slide camshaft through access hole at rear of cylinder head cover/intake manifold.

1 - INTAKE CAMSHAFT 2 - SNAPRING 3 - CAMSHAFT OIL SEAL 4 - THRUST WASHER 5 - CYLINDER HEAD COVER/INTAKE MANIFOLD 6 - EXHAUST MANIFOLD

Fig. 15 CAMSHAFT ASSEMBLY

INSTALLATION

(1) Lubricate camshafts with Mopart Engine Oil Supplement, or equivalent.

(2) Carefully install camshafts into access holes in rear of cylinder head cover/intake manifold.

(3) Install thrust washer, snapring, and camshaft oil seal (Fig. 15).

(4) Install access hole plugs and gaskets at rear of cylinder head cover/intake manifold. Torque plugs to 80N·m.

(5) Install cylinder head cover/intake manifold on engine block (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).

(6) Install timing belt inner cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).

(7) Install timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION).

(8) Install timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).

(9) Install generator (Refer to 8 - ELECTRICAL/ CHARGING/GENERATOR - INSTALLATION).

(10) Install vibration damper.

(11) Install cooling fan support (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION).

(12) Install accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION).

(13) Install cooling fan and fan drive viscous clutch assembly (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - INSTALLATION).

(14) Refill cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE).

(15) Connect negative battery cable.

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9 - 24 ENGINE KJ

CYLINDER HEAD COVER

DESCRIPTION

The cylinder head cover is made of cast aluminum

and is also the intake manifold on this engine (Fig.

16).

Fig. 16 CYLINDER HEAD COVER/INTAKE

MANIFOLD

REMOVAL

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

(1) Disconnect negative battery cable. (2) Remove engine cover and bracket (Refer to 9 -

ENGINE - REMOVAL).

(3) Drain cooling system (Refer to 7 - COOLING/

ENGINE/COOLANT - STANDARD PROCEDURE).

(4) Remove cooling fan and fan drive viscous drive assembly (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - REMOVAL).

(5) Remove accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL).

(6) Remove cooling fan support (Refer to 7 COOLING/ENGINE/RADIATOR FAN - REMOVAL).

(7) Remove generator (Refer to 8 - ELECTRICAL/ CHARGING/GENERATOR - REMOVAL).

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

(8) Rotate engine until 90° after TDC is reached. Install both camshaft locking pins and the crankshaft locking pin. (Refer to 9 - ENGINE/VALVE TIMING STANDARD PROCEDURE)

(9) Remove outer timing belt cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).

(10) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL).

(11) Remove inner timing belt cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).

(12) Disconnect camshaft position sensor, boost pressure/intake air temperature sensor, EGR solenoid, and fuel pressure sensor electrical connectors.

(13) Disconnect vacuum lines at EGR solenoid.

(14) Position electrical harness out of way.

(15) Remove fuel injectors (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR REMOVAL).

(16) Remove fuel rail (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL RAIL - REMOVAL).

(17) Remove oil dipstick tube retaining bolt at intake manifold inlet.

(18) Disconnect oil separator outlet hose at separator.

(19) Remove turbo inlet tube retaining bolt at intake manifold.

(20) Disconnect EGR tube at intake manifold inlet tube.

(21) Remove cylinder head cover/intake manifold retaining bolts (Fig. 17).

(22) Lift cylinder head cover/intake manifold from cylinder head (Fig. 17).

NOTE: When removing rocker arm and lifter assemblies, be sure to keep them in order as they were removed from the cylinder head. Always keep lifters in an upright position when removed from cylinder head.

(23) Remove rocker arm and lifter assemblies from cylinder head.

(24) Remove cylinder head cover/intake manifold gasket from cylinder head.

INSTALLATION

(1) Clean and inspect sealing surfaces.

(2) Install new gasket on cylinder head.

Page 70

KJ ENGINE 9 - 25

CYLINDER HEAD COVER (Continued)

Fig. 17 CYLINDER HEAD COVER/INTAKE

MANIFOLD ASSEMBLY

1 - CYLINDER HEAD COVER/INTAKE MANIFOLD BOLTS(LONG) 2 - CYLINDER HEAD COVER/INTAKE MANIFOLD 3 - CYLINDER HEAD 4 - CYLINDER HEAD COVER/INTAKE MANIFOLD GASKET 5 - CYLINDER HEAD COVER/INTAKE MANIFOLD BOLTS(SHORT)

(3) Install rocker arm and lifter assemblies in cyl-

inder head. Be sure to put rocker arm and lifter

assemblies in same location as removed.

(4) Install cylinder head cover/intake manifold

alignment studs in cylinder head (Fig. 18).

(5) Install cylinder head cover/intake manifold

over alignment stud.

NOTE: Be sure to lubricate cylinder head cover/intake manifold retaining bolts with engine oil before assembly. If new bolts are being installed, DO NOT lubricate before assembly.

(6) Install two cylinder head cover/intake manifold

retaining bolts and tighten finger tight.

(7) Remove alignment studs and install remaining

retaining bolts. Tighten retaining bolts finger tight.

(8) Torque cylinder head cover/intake manifold

retaining bolts following procedure below.

Fig. 18 CYLINDER HEAD COVER ALIGNMENT

STUDS VM.1066

1 - CYLINDER HEAD COVER/INTAKE MANIFOLD STUDS VM.1066 2 - CYLINDER HEAD

CYLINDER HEAD COVER/INTAKE MANIFOLD TIGHTENING PROCEDURE

• Alternate between bolts #11 and #16 to seat cylinder head cover/intake manifold on cylinder head (Fig. 19). Torque bolts to 7 N·m.

• Torque all cylinder head cover/intake manifold retaining bolts to 25 N·m in numerical order starting with #1 and ending with #16 (Fig. 19).

Fig. 19 CYLINDER HEAD COVER/INTAKE

MANIFOLD TIGHTENING SEQUENCE

(9) Connect EGR tube at intake manifold inlet

tube. Torque clamp to 10.8 N·m.

(10) Install turbo inlet tube retaining bolt at

intake manifold. Torque bolt to 27.5 N·m.

Page 71

9 - 26 ENGINE KJ

CYLINDER HEAD COVER (Continued)

(11) Connect oil separator outlet hose at separator. (12) Install oil dipstick tube retaining bolt at

intake manifold inlet. Torque bolt to 10 N·m.

(13) Install power steering pump reservoir in

bracket.

(14) Install fuel rail (Refer to 14 - FUEL SYSTEM/

FUEL DELIVERY/FUEL RAIL - INSTALLATION).

(15) Install fuel injectors and fuel injector supply lines (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - INSTALLATION).

(16) Connect vacuum lines at EGR solenoid.

(17) Connect camshaft position sensor, boost pressure/intake air temperature sensor, EGR solenoid, and fuel pressure sensor electrical connectors.

(18) Install inner timing belt cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).

(19) Install timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION).

(20) Install outer timing belt cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).

(21) Remove crankshaft and both camshaft locking pins (Refer to 9 - ENGINE/VALVE TIMING - STANDARD PROCEDURE).

(22) Install vibration damper.

(23) Install generator (Refer to 8 - ELECTRICAL/ CHARGING/GENERATOR - INSTALLATION).

(24) Install cooling fan support (Refer to 7 COOLING/ENGINE/RADIATOR FAN - INSTALLATION).

(25) Install accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION).

(26) Install cooling fan and fan drive viscous clutch assembly (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - INSTALLATION).

(27) Refill cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE).

(28) Install engine cover and bracket (Refer to 9 ENGINE - INSTALLATION).

(29) Connect negative battery cable.

ROCKER ARMS

DESCRIPTION

The rocker arms are made of stamped steel (Fig. 20).

OPERATION

The rocker arms are used as a link between the camshaft and valves. As the camshaft rotates the lobes of the camshafts apply downward pressure on the rocker arms. This pressure is then transmitted to the valves which causes the valves to open.

REMOVAL

ENGINE/COOLANT - STANDARD PROCEDURE). clutch assembly (Refer to 7 - COOLING/ENGINE/

FAN DRIVE VISCOUS CLUTCH - REMOVAL). COOLING/ACCESSORY DRIVE/DRIVE BELTS -

REMOVAL). COOLING/ENGINE/RADIATOR FAN - REMOVAL).

ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).

VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL).

Fig. 20 CYLINDER HEAD ASSEMBLY

(1) Disconnect negative battery cable. (2) Drain cooling system (Refer to 7 - COOLING/

(3) Remove cooling fan and fan drive viscous

(4) Remove accessory drive belt (Refer to 7 -

(5) Remove cooling fan support (Refer to 7 (6) Remove vibration damper.

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

(8) Remove timing belt (Refer to 9 - ENGINE/

Page 72

KJ ENGINE 9 - 27

ROCKER ARMS (Continued)

(9) Remove inner timing belt cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).

(10) Remove cylinder head cover/intake manifold (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).

(11) Remove rocker arms from lifters (Fig. 21).

(10) Install cooling fan support (Refer to 7 - COOL-

ING/ENGINE/RADIATOR FAN - INSTALLATION).

(11) Install accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION).

(12) Install cooling fan and fan drive viscous clutch assembly (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - INSTALLATION).

(13) Refill cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE).

(14) Connect negative battery cable.

HYDRAULIC LIFTERS

DESCRIPTION

Valve lash is controlled by hydraulic tappets located inside the cylinder head, in tappet bores below the camshafts (Fig. 22).

Fig. 21 ROCKER ARM ASSEMBLY

1 - ROCKER ARM ASSEMBLY 2 - CYLINDER HEAD COVER/INTAKE MANIFOLD 3 - HYDRAULIC LIFTER 4 - CYLINDER HEAD 5 - VALVE

INSTALLATION

(1) Clean and inspect gasket sealing surfaces. (2) Install new gasket on cylinder head.

(3) Lubricate lifter ball end of lifter(s), valve(s), and rocker arm roller(s) with Mopart Engine Oil Supplement or equivlalent.

(4) Connect rocker arm(s) to lifter and reposition on valve(s).

(5) Install cylinder head cover/intake manifold (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).

(6) Install inner timing belt cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).

(7) Install timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION).

(8) Install outer timing belt cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).

(9) Install vibration damper.

Fig. 22 CYLINDER HEAD ASSEMBLY

Page 73

9 - 28 ENGINE KJ

HYDRAULIC LIFTERS (Continued)

REMOVAL

(1) (Refer to 9 - ENGINE/CYLINDER HEAD/ ROCKER ARM / ADJUSTER ASSY - REMOVAL)

INSPECTION

Clean each lifter assembly in cleaning solvent to remove all varnish and sludge deposits. Inspect for indications of scuffing on the side and base of each lifter body.

INSTALLATION

(1) (Refer to 9 - ENGINE/CYLINDER HEAD/ ROCKER ARM / ADJUSTER ASSY - INSTALLATION)

ENGINE BLOCK

DESCRIPTION

The 2.5L/2.8L CRD Diesel engine uses a cast iron engine block with wet cast iron cylinder liners (Fig.

23).

Fig. 23 ENGINE BLOCK

CRANKSHAFT

DESCRIPTION

The crankshaft for the 2.5L and the 2.8L is a forged steel type design with five main bearing journals. The crankshaft is located at the bottom of the engine block and is held in place with three main bearing supports (Fig. 24). There is a difference between crankshafts on the 2.5L and the 2.8L. The

2.5L has a smooth front surface, where as the 2.8L has a groove. The crankshafts ARE NOT interchangeable.

OPERATION

The crankshaft transfers force generated by combustion within the cylinder bores to the flywheel or flexplate.

Fig. 24 CRANKSHAFT ASSEMBLY TYPICAL

1 - CRANKSHAFT SUPPORT HALVE 2 - MAIN BEARING HALVE 3 - CRANKSHAFT 4 - MAIN BEARING HALVE 5 - CRANKSHAFT SUPPORT HALVE 6 - MAIN BEARING SUPPORT BOLTS 7 - WASHERS

STANDARD PROCEDURE - CHECKING CRANKSHAFT END PLAY

(1) Mount a dial indicator to a stationary point at rear of engine. Locate the probe perpendicular against the flywheel (Fig. 25).

(2) Move the crankshaft all the way to the front of its travel.

(3) Zero the dial indicator.

(4) Move the crankshaft all the way to the rear and read dial indicator. For crankshaft end play clearances (Refer to 9 - ENGINE - SPECIFICATIONS) .

REMOVAL

(1) Remove engine from vehicle (Refer to 9 ENGINE - REMOVAL).

(2) Mount engine on an engine stand.

Page 74

KJ ENGINE 9 - 29

CRANKSHAFT (Continued)

(6) Remove timing belt inner cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).

(7) Remove cylinder head cover/intake manifold (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).

(8) Remove cylinder head (Refer to 9 - ENGINE/ CYLINDER HEAD - REMOVAL).

(9) Remove flywheel.

(10) Remove rear main bearing support/adapter plate retaining bolts and remove adapter plate (Fig.

26).

(11) Remove rear main bearing support by threading two retaining bolts in holes provided. Tighten bolts equally to push main bearing support out of block (Fig. 26).

Fig. 25 CHECKING CRANKSHAFT ENDPLAY

1 - FLYWHEEL RETAINING BOLTS 2 - DIAL INDICATOR 3 - FLYWHEEL 4 - TRANSMISSION ADAPTER PLATE BOLT 5 - TRANSMISSION ADAPTER PLATE 6 - REAR MAIN BEARING SUPPORT 7 - O-RING 8 - O-RING 9 - ALIGNMENT DOWEL 10 - CRANKSHAFT 11 - RELUCTOR WHEEL 12 - RELUCTOR WHEEL RETAINING BOLTS 13 - REAR MAIN BEARING SUPPORT RETAINING BOLTS 14 - TRANSMISSION ADAPTER PLATE BOLT 15 - DIAL INDICATOR 16 - FLEXPLATEADAPTER 17 - FLEXPLATEADAPTER RETAINING BOLTS 18 - ALIGNMENT DOWEL

(3) Drain engine oil and remove oil filter.

(4) Remove timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).

(5) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL).

Fig. 26 REAR MAIN BEARING SUPPORT REMOVAL

1 - BOLTS 2 - REAR MAIN BEARING SUPPORT 3 - CRANKSHAFT

(12) Remove front engine cover (Refer to 9 ENGINE/ENGINE BLOCK/ENGINE COVER REMOVAL).

(13) Remove crankshaft sprocket.

(14) Remove oil pan (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL).

(15) Remove oil pump pickup tube (Refer to 9 ENGINE/LUBRICATION/OIL PUMP - REMOVAL).

Page 75

9 - 30 ENGINE KJ

CRANKSHAFT (Continued)

(16) Remove balance shaft assembly (Refer to 9 ENGINE/VALVE TIMING/BALANCE SHAFT REMOVAL).

(17) Remove oil jets (Refer to 9 - ENGINE/LUBRICATION/OIL JET - REMOVAL).

(18) Remove piston and connecting rod assemblies (Refer to 9 - ENGINE/ENGINE BLOCK/PISTON & CONNECTING ROD - REMOVAL).

(19) Slide special tool VM.1069 on crankshaft (Fig.

27).

Fig. 27 CRANKSHAFT SLEEVE VM.1069

1 - CRANKSHAFT SLEEVE VM.1069 2 - ENGINE BLOCK

(20) Using special tool VM.1054, remove crankshaft support retainers and o-rings (Fig. 28).

(21) Slide crankshaft out rear of engine block.

INSTALLATION

(1) Install crankshaft in engine block. Be sure to align oil holes in crankshaft supports and engine block.

(2) Install crankshaft support retainers (Fig. 29).

(3) Remove special tool VM.1069 from crankshaft (Fig. 27).

(4) Install crankshaft sprocket.

(5) Install front engine cover (Refer to 9 ENGINE/ENGINE BLOCK/ENGINE COVER INSTALLATION).

(6) Install rear main bearing support in engine block (Fig. 26). Be sure to align oil hole in rear

main bearing support with hole in block.

(7) Install adapter plate and retaining bolts. Torque bolts to 27.5N·m.

Fig. 28 CRANKSHAFT SUPPORT RETAINERS/

BALANCE SHAFT OIL FEED

1 - CRANKSHAFT SUPPORT RETAINERS/BALANCE SHAFT OIL FEED 2 - O-RINGS (3) 3 - ENGINE BLOCK 4 - CRANKSHAFT SUPPORT RETAINER/BALANCE SHAFT OIL FEED REMOVER - INSTALLER VM.1054

Fig. 29 CRANKSHAFT SUPPORT RETAINERS/

BALANCE SHAFT OIL FEED ALIGNMENT PINS

1 - ENGINE BLOCK 2 - ALIGNMENT PINS VM 1079

Page 76

KJ ENGINE 9 - 31

CRANKSHAFT (Continued)

(8) Install flywheel.

(9) Install piston and connecting rod assemblies (Refer to 9 - ENGINE/ENGINE BLOCK/PISTON & CONNECTING ROD - INSTALLATION).

(10) Install oil jets (Refer to 9 - ENGINE/LUBRICATION/OIL JET - INSTALLATION).

(11) Install balance shaft assembly (Refer to 9 ENGINE/VALVE TIMING/BALANCE SHAFT INSTALLATION).

(12) Install oil pump pickup tube (Refer to 9 ENGINE/LUBRICATION/OIL PUMP - INSTALLATION).

(13) Install oil pan (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - INSTALLATION).

(14) Install cylinder head (Refer to 9 - ENGINE/ CYLINDER HEAD - INSTALLATION).

(15) Install cylinder head cover/intake manifold (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).

(16) Install timing belt inner cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).

(17) Install timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION).

(18) Install timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).

(19) Install engine in vehicle.

(20) Fill engine oil with proper oil to correct level.

CRANKSHAFT MAIN BEARINGS

REMOVAL

The engine must be removed from vehicle and completely disassembled to replace the front main bearing.

CRANKSHAFT MAIN BEARINGS

NOTE: Identify the correct crankshaft by noting the smooth surface on the front of the 2.5L crankshaft and the groove on the front of the 2.8L crankshaft.

(1) With crankshaft assembly removed from engine.

(2) Remove crankshaft supports from crankshaft and remove bearing halves from supports (Fig. 30).

Fig. 30 CRANKSHAFT ASSEMBLY

1 - CRANKSHAFT SUPPORT HALVE 2 - MAIN BEARING HALVE 3 - CRANKSHAFT 4 - MAIN BEARING HALVE 5 - CRANKSHAFT SUPPORT HALVE 6 - MAIN BEARING SUPPORT BOLTS 7 - WASHERS

Page 77

9 - 32 ENGINE KJ

CRANKSHAFT MAIN BEARINGS (Continued)

CRANKSHAFT FRONT MAIN BEARING

(1) Using special tool VM.1073 push front main bearing out of front of engine block (Fig. 31).

Fig. 31 FRONT MAIN BEARING REMOVAL

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

INSTALLATION

CRANKSHAFT MAIN BEARINGS

NOTE: Identify the correct crankshaft by noting the smooth surface on the front of the 2.5L crankshaft and the groove on the front of the 2.8L crankshaft.

(1) Install bearing halves in crankshaft supports.

(2) Lubricate crankshaft and main bearings with clean engine oil.

(3) Install crankshaft supports on crankshaft (Fig.

32). Torque bolts to 44.1N·m.

Fig. 32 CRANKSHAFT ASSEMBLY

1 - CRANKSHAFT SUPPORT HALVE 2 - MAIN BEARING HALVE 3 - CRANKSHAFT 4 - MAIN BEARING HALVE 5 - CRANKSHAFT SUPPORT HALVE 6 - MAIN BEARING SUPPORT BOLTS 7 - WASHERS

Page 78

KJ ENGINE 9 - 33

CRANKSHAFT MAIN BEARINGS (Continued)

FRONT CRANKSHAFT MAIN BEARING

(1) Using special tool VM.1073, push front crankshaft main bearing in engine block (Fig. 33).

Fig. 33 FRONT MAIN BEARING INSTALLATION

1 - FRONT CRANKSHAFT MAIN BEARING 2 - ENGINE BLOCK 3 - SPECIAL TOOL VM.1073

CRANKSHAFT OIL SEAL - FRONT

REMOVAL

(1) Disconnect negative battery cable.

(2) Remove cooling fan and fan drive viscous clutch assembly (Refer to 7 - COOLING/ENGINE/ FAN DRIVE VISCOUS CLUTCH - REMOVAL).

(3) Remove accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL).

(4) Remove cooling fan support (Refer to 7 COOLING/ENGINE/RADIATOR FAN - REMOVAL).

(5) Remove vibration damper/crankshaft pulley (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL).

(6) Remove outer timing belt cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).

(7) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL).

(8) Remove timing belt inner cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).

NOTE: Crankshaft hub retaining bolt has left hand thread.

(2) Be sure oil hole in bearing lines up with oil gal-

lery in engine block (Fig. 34).

Fig. 34 FRONT MAIN BEARING ALIGNMENT

1 - ENGINE BLOCK 2 - OIL HOLE IN BEARING 3 - FRONT CRANKSHAFT MAIN BEARING

(3) Reassemble engine and install in vehicle.

Fig. 35 FRONT ENGINE COVER

1 - CRANKSHAFT HUB RETAINING BOLT 2 - FRONT COVER RETAINING BOLTS 3 - FRONT COVER 4 - ENGINE BLOCK 5 - FRONT ENGINE COVER ALIGNMENT DOWEL 6 - CRANKSHAFT HUB

Page 79

9 - 34 ENGINE KJ

CRANKSHAFT OIL SEAL - FRONT (Continued)

(9) Remove crankshaft hub.

(10) Remove front engine cover (Fig. 35) (Refer to 9 - ENGINE/ENGINE BLOCK/ENGINE COVER REMOVAL) .

(11) With cover on work bench, pry out old seal.

INSTALLATION

CAUTION: Do Not use a hammer to install the crankshaft oil seal.

NOTE: To prevent potential oil leaks, DO NOT touch the front crankshaft inner seal. Always handle the seal from the outer diameter.

(1) Clean engine block and front engine cover sealing surfaces.

(2) Install crankshaft oil seal on VM.1061 (Fig.

36).

(3) Place sleeve for VM.1061 on pressbench as shown (Fig. 36).

(4) Position VM.1061 and press in new seal into front engine cover (Fig. 36).

(5) Install front engine cover on engine (Refer to 9

- ENGINE/ENGINE BLOCK/ENGINE COVER INSTALLATION).

(6) Install crankshaft hub and retaining bolt. Torque bolt to 304N·m.

(7) Install timing belt inner cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).

(8) Install timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION).

(9) Install timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).

(10) Install vibration damper/crankshaft pulley (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION).

1 - VM.1061 2 - FRONT ENGINE COVER 3 - PRESS BENCH 4 - SLEEVE FROM VM.1061

(11) Install cooling fan support (Refer to 7 - COOL-

ING/ENGINE/RADIATOR FAN - REMOVAL).

(12) Install accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION).

(13) Install cooling fan and fan drive viscous clutch assembly (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - INSTALLATION).

(14) Connect negative battery cable.

Fig. 36 VM.1061 PLACEMENT

Page 80

KJ ENGINE 9 - 35

CRANKSHAFT OIL SEAL REAR

REMOVAL

This must be done with either the engine or trans-

mission removed from vehicle.

(1) Remove flywheel assembly. (2) Pry out old crankshaft oil seal.

INSTALLATION

NOTE: To prevent potential oil leaks, DO NOT touch the rear crankshaft inner seal. Always handle the seal from the outer diameter.

(1) Using special tool VM.1050, install rear crank-

shaft oil seal in rear main bearing support (Fig. 37).

CYLINDER LINERS

DESCRIPTION

The cylinder wall liner used on this engine is of the wet design. O-rings are used to seal the liner to the engine block.

REMOVAL

(1) Remove engine from vehicle.

(2) With engine completely disassembled, use special tool VM.1001 to remove liner assembly (Fig. 38).

Fig. 37 REAR CRANKSHAFT OIL SEAL

INSTALLATION USING VM.1050

1 - SPECIAL TOOL VM.1050 2 - REAR MAIN BEARING SUPPORT 3 - OIL PAN 4 - ENGINE TO TRANSMISSION ADAPTER PLATE

(2) Install engine or tranmission in vehicle.

Fig. 38 CYLINDER LINER REMOVER

Page 81

9 - 36 ENGINE KJ

CYLINDER LINERS (Continued)

(3) Tighten bolt on VM.1001 to remove liner from

block (Fig. 39).

Fig. 40 LINER INSPECTION

Fig. 39 CYLINDER LINER REMOVAL

1 - SPECIAL TOOL VM.1001 2 - CYLINDER LINER 3 - ENGINE BLOCK

(4) Remove shims from cylinder liner or cylinder

block recess. Keep shims with each cylinder liner.

INSPECTION

The cylinder walls should be checked for out-ofround and taper with a dial bore gauge. The cylinder bore out-of-round is 0.100 mm (.0039 in.) maximum and cylinder bore taper is 0.100 mm (.0039 in.) maximum. If the cylinder walls are badly scuffed or scored, new liners should be installed and honed, and new pistons and rings fitted.

Measure the cylinder bore at three levels in directions A and B (Fig. 40). Top measurement should be 10 mm (3/8 in.) down and bottom measurement should be 10 mm (3/8 in.) up from the bottom bore.

INSTALLATION

(1) Carefully clean liner and engine block, and degrease the engine block where it comes into contact with the liners. Install the liners in the engine block as shown, rotating them back and forth by 45° in order to guarantee correct positioning (Fig. 41).

NOTE: All Measurements Must Be Taken On the High Pressure Pump Side.

Fig. 41 LINER INSTALLATION

1 - CYLINDER LINER 2 - SHIMS 3 - O-RINGS 4 - BLOCK LEDGE 5 - ENGINE BLOCK

(2) Measure the liner recess relative to block deck with a dial indicator mounted on a special tool VM-1010 A.. Zero dial gauge on block deck.

(3) Move dial gauge to cylinder liner record reading on dial gauge.

(4) Remove liner and special tool.

(5) Then select the correct shim thickness to give proper protrusion (0.00 - 0.05 mm).

(6) Fit the shim and the O-rings onto the liner.

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KJ ENGINE 9 - 37

CYLINDER LINERS (Continued)

(7) Lubricate the lower liner location in the block.

(8) Fit the liners in the crankcase making sure that the shim is positioned correctly in the seat. Lock the liners in position using special tool (VM.1076) and bolts (Fig. 42).

Fig. 42 LINER CLAMP LOCATION

1 - ENGINE BLOCK 2 - LINER RETAINER VM.1076 3 - CYLINDER LINER

(9) Recheck the liner protrusion. It should be 0.00

- 0.05 mm.

(10) Reassemble engine.

(11) Install engine in vehicle.

PISTON & CONNECTING ROD

DESCRIPTION

The pistons are of a free floating design. Oil jets in the engine block lubricate and cool the piston and pin assembly. The connecting rods have a pressed in place wrist pin bushing which is lubricated by the oil jets (Fig. 43).

STANDARD PROCEDURE - PISTON RING FITTING

(1) Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore. The ring gap measurement must be made with the ring positioning at least 12 mm (0.50 in.) from bottom of cylinder bore (Fig. 44). Check gap with feeler gauge. Top compression ring gap .30 to .45mm (.0118 to .0177 in.). Second compression ring gap .30 to .45mm

Fig. 43 PISTON AND CONNECTING ROD ASSEMBLY

1 - PISTON PIN 2 - PISTON 3 - SNAP RING 4 - PAINTED CONNECTING ROD ALIGNMENT NUMBERS 5 - CONNECTING ROD BOLT 6 - CONNECTING ROD BEARING 7 - CONNECTING ROD 8 - SNAP RING

(.0118 to .0177 in.). Oil control ring gap .25 to .50mm (.0098 to .0196 in.).

(2) If ring gaps exceed dimension given, new rings or cylinder liners must be fitted. Keep piston rings in piston sets.

(3) Check piston ring to groove clearance (Fig. 45). Top compression ring gap .080 to .130mm (.0031 to .0051 in.). Second compression ring gap .070 to .110mm (.0027 to .0043 in.). Oil control ring gap .040 to .080mm (.0015 to .0031 in.).

REMOVAL

(1) Disconnect negative battery cable.

(2) Remove cylinder head (Refer to 9 - ENGINE/ CYLINDER HEAD - REMOVAL).

(3) Raise vehicle on hoist.

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9 - 38 ENGINE KJ

PISTON & CONNECTING ROD (Continued)

NOTE: Be careful not to nick or scratch crankshaft journals

(9) After removal, install bearing cap on the mating rod and mark pistons with matching cylinder number when removed from engine block.

PISTON PIN - REMOVAL

(1) Secure connecting rods in a soft jawed vice.

(2) Remove 2 snap rings securing piston pin (Fig.

46).

(3) Push piston pin out of piston and connecting rod (Fig. 46).

Fig. 44 RING END GAP MEASUREMENT

1 - FEELER GAUGE

Fig. 45 PISTON RING TO GROOVE CLEARANCE

(4) Remove oil pan (Refer to 9 - ENGINE/LUBRI-

CATION/OIL PAN - REMOVAL).

(5) Remove oil pump pickup tube.(Refer to 9 -

ENGINE/LUBRICATION/OIL PUMP - REMOVAL)

(6) Remove balance shaft assembly (Refer to 9 ENGINE/VALVE TIMING/BALANCE SHAFT REMOVAL).

(7) Remove top ridge of cylinder bores with a ridge reamer before removing pistons from cylinder block.

Be sure to keep top of pistons covered during this operation.

(8) Piston and connecting rods must be removed from top of cylinder block. Rotate crankshaft so that each connecting rod is centered in cylinder bore.

Fig. 46 PISTON AND CONNECTING ROD ASSEMBLY

1 - PISTON PIN 2 - PISTON 3 - SNAP RING 4 - CONNECTING ROD ALIGNMENT NUMBERS 5 - CONNECTING ROD BOLT 6 - CONNECTING ROD BEARING 7 - CONNECTING ROD 8 - SNAP RING

PISTON RING - REMOVAL

(1) ID mark on face of top and second piston rings

must point toward piston crown.

Page 84

KJ ENGINE 9 - 39

PISTON & CONNECTING ROD (Continued)

(2) Using a suitable ring expander, remove top and second piston rings (Fig. 47).

Fig. 47 PISTON RINGS - REMOVAL/INSTALLATION

(3) Remove upper oil ring side rail, lower oil ring side rail and then the oil expander from piston.

(4) Carefully clean carbon from piston crowns, skirts and ring grooves ensuring the 4 oil holes in the oil control ring groove are clear.

(3) Without loosening connecting rod bolts, tighten

all bolts to 88N·m.

(4) Check and record internal diameter of crank

end of connecting rod.

CAUTION: When changing connecting rods, DO NOT use a stamp to mark the cylinder location. Identify the connecting rods and caps location using a paint marker. All four must have the same weight and the same number. Replacement connecting rods will only be supplied in sets of four (Fig. 48).

Connecting rods are supplied in sets of four since they all must be of the same weight category. Max allowable weight difference is 5 gr.

NOTE: Lightly heat the piston in oven. Insert piston pin in position and secure it with provided snap rings.

INSPECTION

PISTONS

(1) Piston Diameter: Size: 91.912-91.928mm (3.6185-3.6192 in.) Maximum wear limit .05mm (.0019 in.).

(2) Check piston pin bores in piston for roundness. Make 3 checks at 120° intervals. Maximum out of roundness .05mm (.0019in.).

(3) The piston diameter should be measured approximately 15 mm (.590 in.) up from the base.

(4) Skirt wear should not exceed 0.1 mm (.00039 in.).

(5) The clearance between the cylinder liner and piston should not exceed 0.065-0.083 mm (.0025-.0032 in.).

CONNECTING RODS

CAUTION: When assembling the connecting rod, be sure that the pawl on each of the connecting rod caps is facing the rear (fly wheel) side of the engine (Fig. 48).

(1) Assemble bearing shells and bearing caps to their respective connecting rods ensuring that the serrations on the cap and reference marks are aligned (Fig. 48).

(2) Tighten connecting cap bolts to 29 N·m (21 ft. lbs.) plus 60°.

Fig. 48 CONNECTING ROD IDENTIFICATION

1 - CONNECTING ROD PAWL 2 - CONNECTING ROD 3 - PAINTED CYLINDER IDENTIFIER 4 - CONNECTING ROD BEARINGS 5 - CONNECTING ROD

After having coated threads with Molyguard,

tighten con rod bolts to 29 N·m (21 ft. lbs.) plus 60°.

PISTON PINS

(1) Measure the diameter of piston pin in the cen-

ter and both ends.

(2) Piston pin diameter is 31.992 to 31.996mm

(1.259524 in to 1.259681 in.).

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9 - 40 ENGINE KJ

PISTON & CONNECTING ROD (Continued)

INSTALLATION

PISTON PIN INSTALLATION

(1) Secure connecting rod in soft jawed vice.

(2) Lubricate piston pin and piston with clean engine oil.

(3) Position piston on connecting rod (Fig. 49).

CAUTION: Ensure arrow on piston crown and the bearing cap numbers on the connecting rod are on the opposite side.

(4) Install piston pin (Fig. 49).

(5) Install clips in piston to retain piston pin (Fig.

49).

PISTON RINGS - INSTALLATION

(1) Install rings on the pistons using a suitable

ring expander (Fig. 50).

Fig. 50 PISTON RINGS-INSTALLATION

(2) Top compression ring is tapered and chromium plated. The second ring is of the scraper type and must be installed with scraping edge facing bottom of the piston. The third is an oil control ring. Ring gaps must be positioned, before inserting piston into the liners, as follows.

(3) Top ring gap must be positioned at the #3 position (looking at the piston crown from above) (Fig.

51).

(4) Second piston ring gap should be positioned at the #1 position (Fig. 51).

(5) Oil control ring gap should be positioned at the #2 position (Fig. 51).

Fig. 49 PISTON AND CONNECTING ROD ASSEMBLY

1 - PISTON PIN 2 - PISTON 3 - SNAP RING 4 - CONNECTING ROD ALIGNMENT NUMBERS 5 - CONNECTING ROD BOLT 6 - CONNECTING ROD BEARING 7 - CONNECTING ROD 8 - SNAP RING

(6) Remove connecting rod from vice.

Fig. 51 PISTON RING GAP LOCATION

3 - TOP COMPRESSION RING GAP POSITION 1 - SECOND COMPRESSION RING GAP POSITION 2 - OIL CONTROL RING GAP POSITION

(6) When assembling pistons check that components are installed in the same position as before disassembly, determined by the numbers stamped on the crown of individual pistons. Engine cylinders are numbered starting from gear train end of the engine.

Page 86

KJ ENGINE 9 - 41

PISTON & CONNECTING ROD (Continued)

Face arrow on top of piston toward front of engine. Therefore, the numbers stamped on connect-

ing rod big end should face toward the injection pump side of engine. To insert piston into cylinder use a ring compressor as shown in (Fig. 52).

INSTALLATION

(1) Before installing pistons, and connecting rod assemblies into the bore, be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap (Fig. 51).

(2) Before installing the ring compressor, make sure the oil ring expander ends are butted together.

(3) Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston and tighten (Fig. 52). Ensure position of rings does not change during this operation.

(4) Face arrow on piston towards front of engine.

NOTE: Be careful not to nick crankshaft journals.

(5) Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert rod and piston into cylinder bore and guide rod over the crankshaft journal.

the next stage to 30N·m (22 ft.lb.) plus 60°. Then torque to 88N·m (65 ft.lb).

Fig. 52 PISTON INSTALLATION USING VM.1065

1 - PISTON 2 - VM.1065 PISTON RING COMPRESSOR 3 - ENGINE BLOCK

(6) Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal.

(7) Install connecting rod caps (Fig. 53). Install rod bolts and torque to 10N·m (88 lbs. in.). Torque bolts

Fig. 53 PISTON AND CONNECTING ROD

INSTALLATION

1 - PISTON AND CONNECTING ROD ASSEMBLY 2 - FOUR DIGIT NUMBER 3 - CONNECTING ROD BOLT 4 - FOUR DIGIT NUMBER

(8) Install cylinder head (Refer to 9 - ENGINE/

CYLINDER HEAD - INSTALLATION).

(9) Install balance shaft assembly (Refer to 9 ENGINE/VALVE TIMING/BALANCE SHAFT INSTALLATION).

(10) Install oil pump pickup tube (Refer to 9 ENGINE/LUBRICATION/OIL PUMP - INSTALLATION).

(11) Install oil pan (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - INSTALLATION).

(12) Connect negative battery cable.

VIBRATION DAMPER

REMOVAL

(1) Disconnect negative battery cable.

(2) Remove viscous cooling fan and shrowd (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - REMOVAL).

(3) Remove accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL).

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9 - 42 ENGINE KJ

VIBRATION DAMPER (Continued)

(4) Remove vibration damper retaining bolts and

damper (Fig. 54).

Fig. 55 VACUUM PUMP

(2) Remove cooling fan and fan drive viscous clutch assembly (Refer to 7 - COOLING/ENGINE/ FAN DRIVE VISCOUS CLUTCH - REMOVAL).

(3) Remove accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL).

(4) Remove cooling fan support (Refer to 7 COOLING/ENGINE/RADIATOR FAN - REMOVAL).

(5) Remove vibration damper/crankshaft pulley (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL).

(6) Remove outer timing belt cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN

Fig. 54 VIBRATION DAMPER

1 - VIBRATION DAMPER/CRANKSHAFT PULLEY RETAINING BOLTS 2 - VIBRATION DAMPER/CRANKSHAFT PULLEY 3 - IDLER PULLEY

INSTALLATION

(1) Install vibration damper and retaining bolts.

Torque bolts to 27.5N·m.

(2) Install accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).

(3) Install viscous fan and fan shrowd (Refer to 7 COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - INSTALLATION).

(4) Connect negative battery cable.

COVER(S) - REMOVAL).

(7) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL).

(8) Remove timing belt inner cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).

NOTE: Crankshaft hub has LHD thread.

(9) Remove crankshaft hub.

(10) Remove front engine cover (Refer to 9 ENGINE/ENGINE BLOCK/ENGINE COVER REMOVAL).

(11) Remove crankshaft sprocket (Fig. 56).

(12) Remove vacuum pump (Fig. 56).

INTERNAL VACUUM PUMP

DESCRIPTION

The diesel engine uses a internal vacuum pump. This vacuum pump is mounted in the front of the engine block under the engine front cover (Fig. 55). The vacuum pump is driven by a sprocket on the crankshaft.

REMOVAL

(1) Disconnect negative battery cable.

INSTALLATION

NOTE: Verify the 3 blades on the vacuum pump are in place and correctly assembled. The tapered edge should be on the outer side. Make sure the pump rotates before installation.

(1) Lubricate vacuum pump components and

install in engine block (Fig. 57). Torque bolts to

10.8N·m. (2) Install crankshaft sprocket. Torque bolts to

10.8N·m.

Page 88

KJ ENGINE 9 - 43

INTERNAL VACUUM PUMP (Continued)

(3) Install front engine cover (Refer to 9 -

ENGINE/ENGINE BLOCK/ENGINE COVER INSTALLATION).

(4) Install front crankshaft hub. Torque bolt to

304N·m.

(5) Install timing belt inner cover (Refer to 9 -

ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).

(6) Install timing belt (Refer to 9 - ENGINE/

VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION).

(7) Install timing belt outer cover (Refer to 9 -

ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).

(8) Install vibration damper/crankshaft pulley

(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION).

(9) Install cooling fan support (Refer to 7 - COOL-

ING/ENGINE/RADIATOR FAN - INSTALLATION).

(10) Install accessory drive belt (Refer to 7 -

COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION).

(11) Install cooling fan and fan drive viscous clutch

assembly (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - INSTALLATION).

Fig. 56 OIL PUMPAND VACUUM PUMP

1 - VACUUM PUMP 2 - CRANKSHAFT SPROCKET 3 - OIL PUMP 4 - ENGINE BLOCK 5 - CRANKSHAFT

(12) Connect negative battery cable.

ENGINE COVER - FRONT

DESCRIPTION

The front engine cover on this engine is a stamped

steel cover which covers the oil pump and vacuum pump.

Fig. 57 VACUUM PUMP COMPONENTS

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

REMOVAL

(1) Disconnect negative battery cable. (2) Remove cooling fan and fan drive viscous

clutch assembly (Refer to 7 - COOLING/ENGINE/ FAN DRIVE VISCOUS CLUTCH - REMOVAL).

(3) Remove accessory drive belt (Refer to 7 -

COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL).

(4) Remove cooling fan support (Refer to 7 -

COOLING/ENGINE/RADIATOR FAN - REMOVAL).

(5) Remove vibration damper (Refer to 9 -

ENGINE/ENGINE BLOCK/VIBRATION DAMPER REMOVAL).

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

ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).

Page 89

9 - 44 ENGINE KJ

ENGINE COVER - FRONT (Continued)

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

(7) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL).

(8) Remove timing belt inner cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).

NOTE: Crankshaft hub has left hand thread.

(9) Remove crankshaft hub.

(10) Remove front engine cover (Fig. 58).

INSTALLATION

(1) Clean engine block and front engine cover sealing surfaces.

(2) Apply a continous 3mm bead of Silicone Sealer to cover, install within 10 minutes. Torque bolts to

11.8N·m. (Fig. 58).

(3) Install crankshaft hub. Torque bolt to 304N·m.

(4) Install timing belt inner cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).

(5) Install timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION).

(6) Install timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION)

(7) Install vibration damper (Refer to 9 - ENGINE/ ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION).

(8) Install cooling fan support (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION).

(9) Install accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).

1 - CRANKSHAFT HUB RETAINING BOLT 2 - FRONT COVER RETAINING BOLTS 3 - FRONT COVER 4 - ENGINE BLOCK 5 - FRONT ENGINE COVER ALIGNMENT DOWEL 6 - CRANKSHAFT HUB

(10) Install cooling fan and fan drive viscous clutch assembly (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - INSTALLATION).

(11) Connect negative battery cable.

OIL

DESCRIPTION

Refer to the appropriate owner manual for oil specifications.

Fig. 58 FRONT ENGINE COVER

Page 90

KJ ENGINE 9 - 45

OIL FILTER ADAPTER

DESCRIPTION

An oil filter adapter is used on this vehicle to relocate the oil filter for easier access when servicing (Fig. 59).

Fig. 59 OIL FILTER ADAPTER

1 - WATER PUMP HOUSING STUDS 2 - WATER PUMP HOUSING RETAINING NUTS 3 - O-RING 4 - O-RING 5 - O-RING 6 - OIL FILTER ADAPTER TO OIL COOLER RETAINING BOLT 7 - LOCK WASHER 8 - OIL FILTER ADAPTER TO ENGINE BLOCK RETAINING BOLT 9 - OIL COOLER ASSEMBLY 10 - OIL COOLER TO ENGINE BLOCK RETAINING BOLT 11 - OIL FILTERADAPTER ASSEMBLY 12 - ENGINE BLOCK

OIL PAN

REMOVAL

(1) Disconnect negative battery cable. (2) Remove engine cover (Refer to 9 - ENGINE -

REMOVAL).

NOTE: When installing engine support fixture, care must be taken not to damage the hood ajar switch mounted to the right inner fender.

(3) Install engine support fixture, special tool

#8534.

(4) Raise vehicle on hoist. (5) Remove both front wheel and tire assemblies. (6) Remove front skid plate (if equipped). (7) Drain engine oil.

(8) Remove front axle assembly (Refer to 3 - DIFFERENTIAL & DRIVELINE/FRONT AXLE REMOVAL).

(9) Loosen both engine mount through bolts.

(10) Lower vehicle.

(11) Raise engine using support fixture, special tool #8534, until the viscous fan almost touches the fan shroud.

(12) Raise vehicle on hoist.

(13) Support the front cradle assembly with a suitable lifting devise.

(14) Mark the front cradle to under body position to assure proper alignment during assembly.

(15) Remove both inner rail cradle alignment bolts in the front wheel housing.

(16) Loosen both power steering gear retaining bolts, leave the retaining nuts on the bolts.

(17) Loosen both front cradle mounting bolts.

(18) Loosen both rear cradle mounting bolts.

(19) Remove all oil pan retaining bolts and lower oil pan (Fig. 60).

(20) Lower front cradle using the suitable lifting devise until enough clearance is obtained to remove the oil pan.

INSTALLATION

(1) Clean oil pan and sealing surfaces. Inspect oil pan and engine block.

(2) Install oil pan, gasket, and retaining bolts (Fig.

60).

(3) Torque oil pan bolts to 11.8N·m (104 lbs.in.)..

(4) Raise the front cradle using a suitable lifting devise and align the cradle with the underbody marks made during the removal procedure.

(5) Torque the cradle mounting bolts to 122 N·m (90 lbs. ft.).

(6) Torque the inner rail mounting bolts to 47 N·m (35 lbs. ft.).

Page 91

9 - 46 ENGINE KJ

OIL PAN (Continued)

(13) Install front axle skid plate (if equipped)(Refer to 13 - FRAME & BUMPERS/FRAME/FRONT SKID PLATE - INSTALLATION).

(14) Install both front wheel and tire assemblies(Refer to 22 - TIRES/WHEELS/WHEELS - STANDARD PROCEDURE) tighten to 115–155 N·m (85–115 lbs. ft.).

NOTE: When removing engine support fixture, care must be taken not to damage the hood ajar switch mounted to the right inner fender well (if equipped).

(15) Lower the vehicle and remove the engine support fixture.

(16) Refill engine to proper level with the correct viscosity engine oil.

(17) Connect negative battery cable.

(18) Start engine and inspect for leaks.

(19) Install engine cover (Refer to 9 - ENGINE INSTALLATION).

(20) Perform complete front wheel alignment (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT STANDARD PROCEDURE).

Fig. 60 OIL PAN AND PRESSURE RELIEF VALVE

1 - STRUCTURAL SUPPORT TO ENGINE BLOCK RETAINING BOLT 2 - STRUCTURAL SUPPORT 3 - OIL PAN 4 - STRUCTURAL SUPPORT TO TRANSMISSION ADAPTER PLATE RETAINING BOLT 5 - OIL PRESSURE SWITCH 6 - OIL PRESSURE SWITCH ADAPTER 7 - OIL PRESSURE RELIEF VALVE PLUNGER 8 - OIL PRESSURE RELIEF VALVE SPRING 9 - O-RING 10 - OIL PRESSURE RELIEF VALVE CAP 11 - OIL PAN GASKET 12 - OIL PAN RETAINING BOLTS

(7) Torque the steering gear mounting bolts to

162N·m (120 lbs. ft.).

(8) Remove the cradle support devise and lower

the vehicle.

(9) Lower the engine using support fixture, special tool #8534, until the engine mount through bolts are seated in the cradle.

(10) Raise the vehicle.

(11) Torque engine mount through bolts to 88N·m (65 lbs. ft.).

(12) Install front axle assembly(Refer to 3 - DIFFERENTIAL & DRIVELINE/FRONT AXLE INSTALLATION).

OIL PRESSURE RELIEF VALVE

DESCRIPTION

The oil pressure relief valve mounts in the front of the engine block and is used to control oil flow through the engines lubrication system (Fig. 61).

Fig. 61 OIL PRESSURE RELIEF VALVE

1 - O-RING 2 - OIL PRESSURE RELIEF VALVE CAP 3 - OIL PRESSURE RELIEF VALVE SPRING 4 - OIL PRESSURE RELIEF VALVE PLUNGER

Page 92

KJ ENGINE 9 - 47

OIL PRESSURE RELIEF VALVE (Continued)

REMOVAL

(1) Remove engine oil pan (Refer to 9 - ENGINE/

LUBRICATION/OIL PAN - REMOVAL).

(2) Using special tool VM.1054, remove oil pres-

sure relief valve from engine block (Fig. 62).

Fig. 62 OIL PRESSURE RELIEF VALVE REMOVAL

1 - VM.1054 2 - OIL PRESSURE RELIEF VALVE 3 - ENGINE BLOCK 4 - OIL PUMP

INSTALLATION

(1) Thoroughly clean all components and relief

valve pocket in cylinder block.

(2) Lubricate all oil pressure relief valve compo-

nents with engine oil.

(3) Install oil pressure relief valve plunger, spring,

and cap.

(4) Using special tool VM.1059, push oil pressure

relief valve cap in untill flush with engine block (Fig.

63). (5) Install oil pan (Refer to 9 - ENGINE/LUBRI-

CATION/OIL PAN - INSTALLATION).

Fig. 63 OIL PRESSURE RELIEF VALVE

INSTALLATION

1 - VM.1059 2 - OIL PRESSURE RELIEF VALVE 3 - ENGINE BLOCK 4 - OIL PUMP

OIL PRESSURE SENSOR/ SWITCH

DESCRIPTION

The oil pressure switch is located on the right side of the engine block. The switch screws into the engines main oil gallery.

OPERATION

The oil pressure sensor uses three circuits. They are:

• A signal circuit to the ECM.

• A sensor ground circuit through the ECM.

• A 5 volt reference circuit from the ECM.

The oil pressure sensor returns a voltage signal back to the ECM relating oil pressure. Ground for the sensor is supplied by the ECM.

OIL PUMP

REMOVAL

REMOVAL - OIL PUMP PICKUP TUBE

(1) Disconnect negative battery cable.

(2) Raise vehicle on hoist.

Page 93

9 - 48 ENGINE KJ

OIL PUMP (Continued)

(3) Remove oil pan (Refer to 9 - ENGINE/LUBRI-

CATION/OIL PAN - REMOVAL).

(4) Remove oil pump pickup tube retaining bolt

and pull pickup tube from engine block (Fig. 64)

(8) Remove timing belt inner cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).

(9) Remove front engine cover (Refer to 9 ENGINE/ENGINE BLOCK/ENGINE COVER REMOVAL).

(10) Remove crankshaft sprocket (Fig. 65).

(11) Remove oil pump retaining bolts and remove pump from engine block (Fig. 65).

Fig. 64 OIL PUMP PICKUP TUBE ASSEMBLY

1 - BALANCE SHAFT 2 - OIL JET RETAINING BOLT 3 - OIL JET 4 - ENGINE BLOCK 5 - CRANKSHAFT 6 - O- RING(S) 7 - BALANCE SHAFT RETAINING BOLTS 8 - OIL DIPSTICK TUBE RETAINER 9 - RUBBER BUSHING 10 - RETAINING BOLT

REMOVAL - OIL PUMP

(1) Disconnect negative battery cable.

(2) Remove cooling fan and fan drive viscous clutch assembly (Refer to 7 - COOLING/ENGINE/ FAN DRIVE VISCOUS CLUTCH - REMOVAL).

(3) Remove accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL).

(4) Remove cooling fan support (Refer to 7 COOLING/ENGINE/RADIATOR FAN - REMOVAL).

(5) Remove vibration damper (Refer to 9 ENGINE/ENGINE BLOCK/VIBRATION DAMPER REMOVAL).

(6) Remove timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).

(7) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL).

Fig. 65 OIL PUMPAND VACUUM PUMP

1 - VACUUM PUMP 2 - CRANKSHAFT SPROCKET 3 - OIL PUMP 4 - ENGINE BLOCK 5 - CRANKSHAFT

INSTALLATION

INSTALLATION - OIL PUMP PICKUP TUBE

(1) Lubricate o-ring on oil pump pickup tube with

engine oil.

(2) Install pickup tube in engine block and install

retaining bolt. Torque bolt to 32.4N·m. (Fig. 64).

(3) Install oil pan (Refer to 9 - ENGINE/LUBRI-

CATION/OIL PAN - INSTALLATION).

(4) Refill engine oil to proper level. (5) Connect negative battery cable.

INSTALLATION - OIL PUMP

(1) Lubricate oil pump rotor with engine oil. (2) Install oil pump in bore in engine block.

Page 94

KJ ENGINE 9 - 49

OIL PUMP (Continued)

(3) Install oil pump retaining bolts. Torque bolts to

10.8N·m.

(4) Install crankshaft sprocket. Torque bolts to

10.8N·m.

(5) Install front engine cover (Refer to 9 ENGINE/ENGINE BLOCK/ENGINE COVER INSTALLATION).

(6) Install timing belt inner cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).

(7) Install timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION).

(8) Install timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).

(9) Install vibration damper (Refer to 9 - ENGINE/ ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION).

(10) Install cooling fan support (Refer to 7 COOLING/ENGINE/RADIATOR FAN - INSTALLATION).

(11) Install accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION).

(12) Install cooling fan and fan drive viscous clutch assembly (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - INSTALLATION).

(13) Connect negative battery cable.

REMOVAL

CAUTION: Use caution when removing and installing oil jets. Damage to oil jet nozzle could cause severe engine damage.

NOTE: Remove oil jets before removing piston, crankshaft liners.

(1) Disconnect negative battery cable. (2) Raise vehicle on hoist. (3) Remove oil pan (Refer to 9 - ENGINE/LUBRI-

CATION/OIL PAN - REMOVAL).

(4) Using special tool VM.1060 to hold oil jet. Remove oil jet retaining bolt and remove oil jet from engine block (Fig. 67).

OIL JET

DESCRIPTION

There are four oil jets installed in the engine block. These oil jets are used to cool and lubricate the piston assemblies (Fig. 66).

Fig. 66 OIL JET ASSEMBLY

1 - RETAINING BOLT 2 - OIL JET 3 - O-RING

Fig. 67 OIL JET REMOVAL/INSTALLATION

1 - SPECIAL TOOL VM.1060 2 - OIL JET 3 - CONNECTING ROD 4 - CRANKSHAFT

Page 95

9 - 50 ENGINE KJ

OIL JET (Continued)

INSTALLATION

CAUTION: Use caution when removing and installaing oil jets. Damage to oil jet nozzle could cause severe engine damage.

NOTE: Carefully install the oil jets After assembling the engine liners, crankshaft and pistons.

(1) Lubricate o-ring on oil jet.

(2) Using special tool VM.1060, install oil jet in engine block (Fig. 67).

(3) Install oil jet retaining bolt. Torque bolt to

10.8N·m.

(4) Install oil pan (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - INSTALLATION).

(5) Refill engine oil to proper level.

(6) Connect negative battery cable.

INTAKE MANIFOLD

DESCRIPTION

(Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - DESCRIPTION)

REMOVAL

(1) (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL)

INSTALLATION

(1) (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION)

EXHAUST MANIFOLD

REMOVAL

(1) (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER SYSTEM/TURBOCHARGER REMOVAL)

INSTALLATION

(1) (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER SYSTEM/TURBOCHARGER - INSTALLATION)

VALVE TIMING

STANDARD PROCEDURE - LOCKING ENGINE 90 DEGREES AFTER TDC

(1) Disconnect negative battery cable.

(2) Rotate engine by hand until special tool VM.8873 can be install in engine to transmission adapter plate on right side of engine, looking at the engine from the flywheel. This will lock the engine at 90° after TDC.

(3) Remove engine cover (Refer to 9 - ENGINE COVER - REMOVAL).

(4) Remove EGR valve and EGR cooler to exhaust manifold retaining nuts.

(5) Reposition EGR valve assembly out of way.

(6) Remove plug in cylinder head cover/intake manifold and insert VM.1053 to lock exhaust camshaft in position.

(7) Remove generator (Refer to 8 - ELECTRICAL/ CHARGING/GENERATOR - REMOVAL).

(8) Remove plug in cylinder head cover/intake manifold and insert VM.1052 to lock intake camshaft in position.

(9) At this point the timing belt can be removed for service.

(10) After engine service is completed and timing belt reinstalled, remove both camshaft locking pins from cylinder head cover/intake manifold.

(11) Install both camshaft access plugs.

(12) Remove 90° after TDC engine locking pin.

(13) Install generator (Refer to 8 - ELECTRICAL/ CHARGING/GENERATOR - INSTALLATION).

(14) Install engine cover (Refer to 9 - ENGINE COVER - INSTALLATION).

(15) Connect negative battery cable.

Page 96

KJ ENGINE 9 - 51

BALANCE SHAFT

DESCRIPTION

The 2.5L and 2.8L Common Rail Diesel engine is equipped with two nodular cast iron balance shafts in a cast aluminum carrier. The balance shaft assembly is mounted to the engine block (Fig. 68).

REMOVAL

(1) Disconnect negative battery cable. (2) Raise vehicle on hoist. (3) Remove oil pan (Refer to 9 - ENGINE/LUBRI-

CATION/OIL PAN - REMOVAL).

(4) Remove oil pump pickup tube (Refer to 9 -

ENGINE/LUBRICATION/OIL PUMP - REMOVAL).

(5) Remove balance shaft assembly (Fig. 69).

Fig. 68 OIL PICK-UP TUBE AND BALANCE SHAFT

ASSEMBLY

1 - BALANCE SHAFT RETAINING BOLTS 2 - BALANCE SHAFT ASSEMBLY 3 - OIL JET RETAINING BOLT 4 - OIL JET 5 - CENTRAL CARRIER PINS 6 - ENGINE BLOCK 7 - CENTRAL CARRIER PIN O-RINGS 8 - OIL PUMP PICK UP TUBE O-RINGS 9 - OIL PUMP PICK-UP TUBE 10 - OIL PICK UP TUBE RETAINING BOLT

OPERATION

The balance shaft is driven by the crankshaft. The balance shafts are connected by heelical gears. The dual-counter rotating shafts decrease second order vertical shaking forces caused by component movement.

Fig. 69 OIL PICK-UP TUBE AND BALANCE SHAFT

ASSEMBLY

INSTALLATION

(1) Before installation of the balance shaft assembly, the # 1 cylinder must be brought to TDC. Using special tool VM.8872, roll engine over by hand until tool can be inserted into engine to transmission adpater plate locking flywheel from turning. Once the # 1 cylinder is brought to TDC, the balance shaft assembly can be installed (Fig. 70).

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9 - 52 ENGINE KJ

BALANCE SHAFT (Continued)

Fig. 70 TDC ALIGNMENT

1 - ENGINE BLOCK 2-STARTER 3 - STRUCTURAL SUPPORT 4 - TDC ALIGNMENT PIN 5 - ENGINE OIL PICK UP TUBE 6 - BALANCE SHAFT ASSEMBLY

(2) With balance shaft assembly on work bench. Insert special tool VM.1056 into balance shaft assembly (Fig. 71). This will ensure proper balance shaft and crankshaft timing after assembly.

(3) Install balance shaft assembly and retaining bolts. Torque bolts to 32.4N·m.

(4) Install oil pump pickup tube (Refer to 9 ENGINE/LUBRICATION/OIL PUMP - INSTALLATION).

(5) Install oil pan (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - INSTALLATION).

(6) Refill engine oil to proper level.

(7) Connect negative battery cable.

Fig. 71 BALANCE SHAFT ALIGNMENT PIN VM.1056

1 - VM.1056 2 - BALANCE SHAFT ASSEMBLY

TIMING BELT / CHAIN COVER(S)

REMOVAL

REMOVAL - TIMING BELT INNER COVER

(1) Disconnect negative battery cable. (2) Remove engine cover (Refer to 9 - ENGINE

COVER - REMOVAL).

(3) Remove cooling fan and fan drive viscous clutch assembly (Refer to 7 - COOLING/ENGINE/ FAN DRIVE VISCOUS CLUTCH - REMOVAL).

(4) Remove accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL).

(5) Remove cooling fan support (Refer to 7 COOLING/ENGINE/RADIATOR FAN - REMOVAL).

(6) Remove vibration damper (Refer to 9 ENGINE/ENGINE BLOCK/VIBRATION DAMPER REMOVAL).

Page 98

KJ ENGINE 9 - 53

TIMING BELT / CHAIN COVER(S) (Continued)

(7) Remove timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).

(8) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL).

(9) Remove timing belt idler pulleys (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT IDLER PULLEY - REMOVAL).

(10) Using special tool VM.1055, remove camshaft sprockets (Fig. 72).

Fig. 72 CAMSHAFT SPROCKET REMOVAL/

INSTALLATION

1 - TIMING BELT INNER COVER 2 - CAMSHAFT SPROCKET 3 - IDLER PULLEYS 4 - CAMSHAFT SPROCKET 5 - VM.1055

(11) Remove timing belt tensioner (Refer to 9 ENGINE/VALVE TIMING/TMNG BELT/CHAIN TENSIONER&PULLEY - REMOVAL).

(12) Remove injection pump sprocket (Refer to 14 FUEL SYSTEM/FUEL DELIVERY/FUEL INJECTION PUMP - REMOVAL).

(13) Remove timing belt inner cover retaining bolts and remove cover (Fig. 73).

REMOVAL - TIMING BELT OUTER COVER

(1) Disconnect negative battery cable.

(2) Remove engine cover (Refer to 9 - ENGINE COVER - REMOVAL).

(3) Remove cooling fan and fan drive viscous clutch assembly (Refer to 7 - COOLING/ENGINE/ FAN DRIVE VISCOUS CLUTCH - REMOVAL).

Fig. 73 TIMING BELT COVER - INNER

1 - BANJO FITTING 2 - BRASS WASHERS 3 - FUEL INLET LINE 4 - FUEL OUTLET LINE 5 - BANJO FITTING 6 - INJECTION PUMP RETAINING NUT 7 - INJECTION PUMP 8 - MOUNTING STUDS 9 - INNER TIMING COVER SEAL 10 - INNER TIMING COVER 11 - RETAINING BOLT 12 - RETAINING BOLT 13 - RETAINING BOLT 14 - HOSE CLAMP 15 - CYLINDER HEAD COVER/INTAKE MANIFOLD 16 - FUEL RETURN LINE TO INJECTION PUMP 17 - HOSE CLAMP 18 - FUEL RETURN JUNCTION BLOCK RETAINING BOLT 19 - FUEL RETURN JUNCTION BLOCK

(4) Remove accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL).

(5) Remove cooling fan support (Refer to 7 COOLING/ENGINE/RADIATOR FAN - REMOVAL).

(6) Remove vibration damper (Refer to 9 ENGINE/ENGINE BLOCK/VIBRATION DAMPER REMOVAL).

Page 99

9 - 54 ENGINE KJ

TIMING BELT / CHAIN COVER(S) (Continued)

(7) Remove timing belt outer cover retaining bolts

and remove cover (Fig. 74).

Fig. 74 TIMING BELT OUTER COVER

1 - TIMING BELT 2 - TIMING BELT OUTER COVER 3 - TIMING BELT OUTER COVER RETAINING BOLTS

INSTALLATION

INSTALLATION - TIMING BELT INNER COVER

(1) Install timing belt inner cover to engine front

cover seal.

(2) Install timing belt inner cover to cylinder head

cover gaskets.

(3) Install timing belt inner cover and retaining bolts. Torque 10mm bolts to 47.1N·m and 8mm bolts to 10.8N·m.

(4) Install injection pump sprocket (Refer to 14 FUEL SYSTEM/FUEL DELIVERY/FUEL INJECTION PUMP - INSTALLATION).

(5) Install camshaft sprockets. Torque bolts to 108N·m.

(6) Install timing belt idler pulleys (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT IDLER PULLEY - INSTALLATION).

(7) Install timing belt and tensioner (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION).

(8) Install timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).

(9) Install vibration damper (Refer to 9 - ENGINE/ ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION).

(10) Install cooling fan support (Refer to 7 COOLING/ENGINE/RADIATOR FAN - INSTALLATION).

(11) Install accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION).

(12) Install cooling fan and fan drive viscous clutch assembly (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - INSTALLATION).

(13) Install engine cover (Refer to 9 - ENGINE COVER - INSTALLATION).

(14) Connect negative battery cable.

INSTALLATION - TIMING BELT OUTER COVER

(1) Install timing belt outer cover seal and cover. Torque 3mm bolts to 10.8N·m and 8mm bolts to

10.8N·m.

(2) Install vibration damper (Refer to 9 - ENGINE/ ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION).

(3) Install cooling fan support (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION).

(4) Install accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).

(5) Install cooling fan and fan drive viscous clutch assembly (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - INSTALLATION).

(6) Install engine cover (Refer to 9 - ENGINE COVER - INSTALLATION).

(7) Connect negative battery cable.

TIMING BELT IDLER PULLEY

REMOVAL

(1) Disconnect negative battery cable.

(2) Remove engine cover (Refer to 9 - ENGINE COVER - REMOVAL).

(3) Remove cooling fan and fan drive viscous clutch assembly (Refer to 7 - COOLING/ENGINE/ FAN DRIVE VISCOUS CLUTCH - REMOVAL).

(4) Remove accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL).

(5) Remove cooling fan support (Refer to 7 COOLING/ENGINE/RADIATOR FAN - REMOVAL).

(6) Remove vibration damper (Refer to 9 ENGINE/ENGINE BLOCK/VIBRATION DAMPER REMOVAL).

(7) Remove timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).

(8) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL).

Page 100

KJ ENGINE 9 - 55

TIMING BELT IDLER PULLEY (Continued)

NOTE: Idler pulley retaining bolts are left hand thread.

(9) Remove timing belt idler pulleys (Fig. 75).

(5) Install cooling fan support (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION).

(6) Install accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).

(7) Install cooling fan and fan drive viscous clutch assembly (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - INSTALLATION) .

(8) Install engine cover (Refer to 9 - ENGINE COVER - INSTALLATION).

(9) Connect negative battery cable.

TIMING BELT/CHAIN AND SPROCKET(S)

REMOVAL

CAUTION: BEFORE REMOVING THE TIMING BELT, THE ENGINE MUST BE PLACED AT 90° AFTER TDC. FAILURE TO DO SO MAY RESULT IN VALVE AND/OR PISTON DAMAGE DURING ASSEMBLY. (Refer to 9 - ENGINE/VALVE TIMING - STANDARD PROCEDURE)

Fig. 75 TIMING BELT AND SPROCKETS

1 -CAMSHAFT SPROCKETS 2 - INJECTION PUMP SPROCKET 3 - INJECTION PUMP SPROCKET RETAINING NUT 4 - TIMING BELT 5 - TIMING BELT TENSIONER RETAINING BOLT 6 - TIMING BELT TENSIONER 7 - TENSIONER ALIGNMENT PIN 8 - IDLER PULLEY 9 - CAMSHAFT SPROCKET RETAINING BOLT

INSTALLATION

(1) Install timing belt idler pulleys. Torque bolts to

47.1N·m. (2) Install timing belt (Refer to 9 - ENGINE/

VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION).

(3) Install timing belt outer cover (Refer to 9 -

ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).

(4) Install vibration damper (Refer to 9 - ENGINE/

ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION).

(1) Disconnect negative battery cable. (2) Remove engine cover (Refer to 9 - ENGINE

COVER - REMOVAL).

(3) Remove cooling fan and fan drive viscous clutch assembly (Refer to 7 - COOLING/ENGINE/ FAN DRIVE VISCOUS CLUTCH - REMOVAL).

(4) Remove accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL).

(5) Remove cooling fan support (Refer to 7 COOLING/ENGINE/RADIATOR FAN - REMOVAL).

(6) Bring piston #1 to TDC, turn crankshaft until notch on the crankshaft hub is at the 12 o’clock position.

(7) Looking at the engine from the belt side, rotate the crankshaft 90° clockwise.

(8) Install the 90° alignment pin into the crankcase threaded hole on the right side of the engine to lock the crankcase (make sure the crankshaft does not rotate).

(9) Remove vibration damper (Refer to 9 ENGINE/ENGINE BLOCK/VIBRATION DAMPER REMOVAL).

(10) Paint mark the crankshaft hub and the oil pump cover (this will be useful during the timing check).

(11) Remove the alternator.

(12) Remove the intake and exhaust camshaft plugs from the camshaft cover, to introduce the camshaft timing pins (if the engine is timed correctly, the pins can be installed).

Jeep Liberty 2.8L Diesel 2006, Liberty 2.8L Diesel 2005 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

GROUP TAB LOCATOR

MAINTENANCE SCHEDULES FOR ALL MARKETS EXCEPT U.S., CANADA and MEXICO

DESCRIPTION — DIESEL ENGINES

Schedule “B”

Schedule “A”

COOLING - 2.5L/2.8L TURBO DIESEL

DIAGNOSIS AND TESTING

DESCRIPTION - COOLING SYSTEM

COOLING SYSTEM COMPONENTS

DIAGNOSIS AND TESTING - COOLING SYSTEM FLOW CHECK

DIAGNOSIS AND TESTING - COOLING SYSTEM AERATION

DIAGNOSIS AND TESTING - COOLING SYSTEM LEAK TEST

DIAGNOSIS AND TESTING - ON-BOARD DIAGNOSTICS (OBD)

COOLING SYSTEM RELATED DIAGNOSTICS

ACCESSING DIAGNOSTIC TROUBLE CODES

ERASING TROUBLE CODES

DIAGNOSIS AND TESTING - COOLING SYSTEM

CHEMICAL CLEANING

REVERSE FLUSHING RADIATOR

REVERSE FLUSHING ENGINE

CLEANING

INSPECTION

SPECIFICATIONS

SPECIFICATIONS - COOLING SYSTEM CAPACITY

SPECIFICATIONS - TORQUE

ACCESSORY DRIVE

ACCESSORY DRIVE

BELT TENSIONERS

SPECIFICATIONS - ACCESSORY BELT TENSION

DESCRIPTION

OPERATION

REMOVAL

INSTALLATION

DRIVE BELT

DESCRIPTION

DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT

VISUAL DIAGNOSIS

OPERATION-ACCESSORY DRIVE BELT

NOISE DIAGNOSIS

REMOVAL

INSTALLATION

IDLER PULLEYS

REMOVAL

INSTALLATION

ENGINE

COOLANT

STANDARD PROCEDURE

STANDARD PROCEDURE—DRAINING COOLING SYSTEM

STANDARD PROCEDURE - COOLING SYSTEM FILLING

STANDARD PROCEDURE - REFILLING COOLING SYSTEM

OPERATION

COOLING FAN

COOLANT RECOVERY PRESS CONTAINER

DESCRIPTION

REMOVAL

REMOVAL - COOLING FAN

REMOVAL - COOLING FAN SUPPORT

CLEANING

INSPECTION

COOLANT SYSTEM HOSES

REMOVAL

REMOVAL - UPPER RADIATOR HOSE

INSTALLATION

INSTALLATION - COOLING FAN

INSTALLATION - COOLING FAN SUPPORT

REMOVAL - HEATER CORE HOSES

ENGINE COOLANT TEMP SENSOR

DESCRIPTION

INSTALLATION

INSTALLATION - UPPER RADIATOR HOSE

INSTALLATION – HEATER CORE HOSES

OPERATION

REMOVAL

INSTALLATION

ENGINE COOLANT THERMOSTAT

DESCRIPTION