Kia Carnival 2007 User Manual

CHAPTER 2:

Engine Mechanical System

2007 > J2.9L DIESEL CRDI(VGT) >

SPECIAL SERVICE TOOLS

Tool (Number and name) Illustration Use

Valve spring lifter pivot. (0K993 120 004)

Removal or installation of the valve spring

Valve spring lifter arm. (0K993 120 001)

Removal or installation of the valve spring

Valve seal installer. (09222-22001)

Installation of the valve seal

Camshaft pulley holder. (09231 - 4X100)

Installation of the camshaft

Pressure gauge adapter. (0K552 131 002)

Measurement of compression pressure

End york holder. (09517-21700)

Removal or installation of the crankshaft pulley bolt (used with 09231-H1000)

Crankshaft pulley adapter. (09231-H1000)

Removal or installation of the crankshaft pulley bolt (used with 09517-21700)

Oil pan remover. (09215-3C000)

Removal of the oil pan

2007 > J2.9L DIESEL CRDI(VGT) >

TROUBLESHOOTING

Symptom Suspect area Remedy

Engine misfire with abnormal internal lower engine noises.

Loose or improperly installed engine flywheel.

Repair or replace the flywheel as required.

Worn piston rings. (Oil consumption may or may not cause the engine to misfire.)

Inspect the cylinder for a loss of compression . Repair or replace as required.

Worn crankshaft thrust bearings. Replace the crankshaft and bearings as

required.

Engine misfire with abnormal valve train noise.

Stuck valves. (Carbon buildup on the valve stem can cause the valve not to close properly.)

Repair or replace as required.

Excessive worn or mis-aligned timing chain.

Replace the timing chain and sprocket as required.

Worn camshaft lobes. Replace the camshaft and valve lifers.

Engine misfire with coolant consumption

a. Faulty cylinder head gasket and/or

cracking or other damage to the cylinder head and engine block cooling system .

b. Coolant consumption may or may not

cause the engine to overheat.

a. Inspect the cylinder head and engine

block for damage to the coolant passages and/or a faulty head gasket.

b. Repair or replace as required.

Engine misfire with excessive oil consumption

Worn valves, valve guides and/or valve stem oil seals.

Repair or replace as required.

Worn piston rings. (Oil consumption may or may not cause the engine to misfire)

Inspection the cylinder for a loss of compression Repair or replace as required.

Engine noise on start-up, but only lasting a few seconds.

Incorrect oil viscosity. Drain the oil.

Install the correct viscosity oil.

Worn crankshaft thrust bearing. Inspect the thrust bearing and

crankshaft. Repair or replace as required.

Upper engine noise, regardless of engine speed.

Low oil pressure. Repair or replace as required.

Broken valve spring. Replace the valve spring.

Worn or dirty valve lifters. Replace the valve lifters.

Stretched or broken timing chain and/or damaged sprocket teeth.

Replace the timing chain and sprockets.

Worn timing chain tensioner, if applicable.

Replace the timing chain tensioner as required.

Worn camshaft lobes. Inspect the camshaft lobes.

Replace the camshaft and valve lifters as required.

Worn valve guides or valve stems. Inspect the valves and valve guides, then

repair as required.

Stuck valves. (Carbon on the valve stem or valve seat may cause the valve to stay open.)

Inspect the valves and valve guides, then repair as required.

Lower engine noise, regardless of engine speed.

Low oil pressure. Repair or replace damaged components

as required.

Loose or damaged flywheel. Repair or replace the flywheel.

Damaged oil pan, contacting the oil pump screen.

Inspect the oil pan. Inspect the oil pump screen. Repair or replace as required.

Oil pump screen loose, damaged or restricted.

Inspect the oil pump screen . Repair or replace as required.

Excessive piston-to-cylinder bore clearance.

Inspect the piston and cylinder bore. Repair as required.

Excessive piston pin-to-bore clearance. Inspect the piston, piston pin and the

connecting rod. Repair or replace as required.

Excessive connecting rod bearing clearance.

Inspect the following components and repair as required.

a. The connecting rod bearings.

b. The connecting rods.

c. The crankshaft.

d. The crankshaft journal.

Excessive crankshaft bearing clearance. Inspect the following components and

repair as required.

a. The crankshaft bearings.

b. The crankshaft journals.

Incorrect piston, piston pin and connecting rod installation.

Verify the piston pins and connecting rods are installed correctly. Repair as required.

Engine noise under load. Low oil pressure. Repair or replace as required.

Excessive connecting rod bearing clearance.

Inspect the following components and repair as required.

a. The connecting rod bearings.

b. The connecting rods.

c. The crankshaft.

Excessive crankshaft bearing clearance. Inspect the following components and

repair as required.

a. The crankshaft bearings.

b. The crankshaft journals.

c. The cylinder block crankshaft bearing

bore.

Engine will not crank. (crankshaft will not rotate)

Hydraulically locked cylinder.

a. Coolant/antifreeze in cylinder.

b. Oil in cylinder.

c. Fuel in cylinder.

Remove spark plugs and check for fluid. Inspect for broken head gasket. Inspect for cracked engine block or cylinder head. Inspect for a sticking fuel injector and/or leaking fuel regulator.

Broken timing chain and/or timing chain gears.

Inspect timing chain and gears. Repair as required.

Foreign material in cylinder.

a. Broken valve.

b. Piston material.

c. Foreign material.

Inspect cylinder for damaged components and/or foreign materials. Repair or replace as required.

Seized crankshaft or connecting rod bearings.

Inspect crankshaft and connecting rod bearing. Repair or replace as required.

Bent or broken connecting rod. Inspect connecting rods.

Repair or replace as required.

Broken crankshaft. Inspect crankshaft.Repair or replace as

required.

2007 > J2.9L DIESEL CRDI(VGT) >

INSPECTION

COMPESSION PRESSURE

If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure.

1. Warm up the engine until the coolant temperature becomes 80~95°C(176~203°F).

2. Remove the fuel inlet(A) and the return hose(B) from the fuel filter.

3. Crank the engine in order to exhaust fuel in the high pressure pump.

Gather residual fuel by putting the return hose into a proper vessel.

4. Remove the injection pipe, injector and washer.(Refer to FL group).

5. Measure the cylinder compression pressure. (1) Insert the SST(0K552 131 002) into the injector hole.

(2) Cranking the engine, measure the pressure.

Use the complete charging battery for the engine to crank at the speed of 350rpm or more.

(3) Do the above step 1)~2) again for each cylinder.

This work must be done in as short time as possible.

Compression pressure :

3040.05kPa (31kg/cm², 440.92psi) (325 rpm) Minimum pressure :

2745.85kPa (28kg/cm², 398.25psi) Difference between each cylinder :

294.20kPa (3.0kg/cm², 42.67psi)

(4) If, in one or more cylinders, the measured value is below the limit, fill a little engine oil into the injector holes of

the cylinders, repeat the step 1)~2) and measure the compression pressure again.

a. If the re-measured pressure becomes higher, wear or damage of the piston ring or cylinder surface can be

the cause.

b. If the re-measured pressure does not become higher, adherence or poor contact of the valves or inferior

gasket can be the cause.

6. Install the injectors, washers and the injector pipes.(Refer to FL group).

7. Install the inlet and the return hoses to the fuel filter.

TIMING BELT TENSION ADJUSTMENT

1. Remove the battery terminals (A).

2. Install the jack for oil pan.

3. Remove the engine mounting (A).

4. Remove the engine support bracket(A).

5. Remove the drive belt.

6. Remove the water pump pulley.

7. Remove the bolts(B), nut(C) and timing belt upper cover (A).

8. Turn the crankshaft pulley(A) and align its groove with the timing mark “T” of the timing belt cover. Check that the

timing mark of camshaft sprocket(B) is aligned with that of the cylinder head cover. (No.1 cylinder positioned at the TDC position)

9. Remove the crankshaft pulley bolt(A), washer(B) and crankshaft pulley(C).

Using the special tool(09517-21700, 09231-H1000), fix the crankshaft pulley and loosen the bolt(A).

10. Remove the drive belt idler(A).

11. Remove the drive belt auto-tensioner (A).

12. Remove the timing belt lower cover(A).

13. Loosen the auto-tensioner fixing bolt(A).

14. Adjust tension of the timing belt.

(1) Align the pointer(B) with the tensioner fork(back plate)(C) as shown below by turning the special washer(A)

counterclockwise with a hexagonal wrench.

(2) When the pointer(A) is aligned with the tensioner fork(back plate)(B), tighten the tensioner mounting bolts with

the special bolt fixed by a hexagonal wrench.

Tightening torque :

19.6~25.5Nm (2.0~2.6kgf.m, 14.5~18.8lb-ft)

(3) Remove the hexagonal wrench.

When the pointer (A) can not be aligned with the tensioner fork(back plate)(B), replace a new belt and repeat the steps.

15. Rotate the crankshaft clockwise two revolutions in order to align the timing marks on the crankshaft sprocket, the

camshaft sprocket and high pressure pump pulley.

16. Confirm that the location of the pointer is aligned with tensioner fork (back plate).

The margin of error : ± 5°

17. Install the timing belt lower cover(A).

Tightening torque :

6.9~9.8Nm (0.7 ~ 1.0kgf.m, 5.1 ~ 7.2lb-ft)

18. Install the drive belt idler(A).

Tightening torque :

37.3Nm (3.8kgf.m, 27.5lb-ft)

19. Install the drive belt auto-tensioner (A).

Tightening torque :

15.7~22.6Nm (1.6 ~ 2.3kgf.m, 11.6 ~ 16.6lb-ft)

20. Install the crankshaft pulley bolt(A), washer(B) and crankshaft pulley (A).

Tightening torque :

376.6~411.9Nm (38.4~42.0kgf.m, 277.7~303.8lb-ft)

Using the special tool(09517-21700, 09231-H1000), tighten the bolt(A).

21. Install the bolts(B), nut(C) and timing belt upper cover (A).

Tightening torque :

6.9~9.8Nm (0.7 ~ 1.0kgf.m, 5.1 ~ 7.2lb-ft)

22. Install the water pump pulley.

Tightening torque :

5.9~9.8Nm (0.6 ~ 1.0kgf.m, 4.3 ~ 7.2lb-ft)

23. Install the drive belt.

24. Confirm that the 'A' part of the drivebelt auto-tensioner is positioned as shown below. If not, replace the belt.

25. Install the engine support bracket(A).

Tightening torque :

49.0~63.7Nm (5.0 ~ 6.5kgf.m, 36.2 ~ 47.0lb-ft)

26. Install the engine mounting (A).

Tightening torque :

88.3~107.9Nm (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft)

27. Remove the jack for oil pan.

28. Install the battery terminals (A).

2007 > J2.9L DIESEL CRDI(VGT) >

SPECIFICATIONS

Description Specifications(J3 - ENG) Limit

General

Type In-line, DOHC

Number of cylinders 4

Bore 101.5~101.526mm (3.9961~3.9971in)

Stroke 98mm (8.8583in)

Total displacement 2,902 cc (177.08 cu.in)

Compression ratio 18.4 : 1

Firing order 1-3-4-2

Valve timing

Intake valve

Opens (ATDC) 26°

Closes (ABDC) 50°

Exhaust valve

Opens (BBDC) 72°

Closes (ATDC) 32°

Cylinder head

Flatness of gasket surface Less than 0.05mm (0.0020in)

Flatness of manifold mounting surface

Intake Less than 0.15mm (0.0059in)

Exhaust Less than 0.15mm (0.0059in)

Camshaft

Cam height

Intake 39.397 ~ 39.597mm (1.5511 ~ 1.5589in)

Exhaust 39.4932 ~ 39.6932mm (1.5548 ~ 1.5627in)

Journal outer Diameter (Intake, Exhaust) 27.941 ~ 27.960mm (1.1000 ~ 1.1008in)

Bearing oil clearance 0.040 ~ 0.080mm (0.0016 ~ 0.0031in)

End play 0.08 ~ 0.17mm (0.0031 ~ 0.0067in)

Valve

Valve length

Intake 126.24mm (4.9701in)

Exhaust 126.24mm (4.9701in)

Stem outer diameter

Intake 6.965 ~ 6.980mm (0.2742 ~ 0.2748in)

Exhaust 6.945 ~ 6.960mm (0.2734 ~ 0.2740in)

Face angle 45°

Thickness of valve head (margin)

Intake 1.7mm (0.0669in)

Exhaust 1.6mm (0.0630in)

Valve stem to valve guide clearance

Intake 0.030 ~ 0.065mm (0.0012 ~ 0.0026in)

Exhaust 0.050 ~ 0.085mm ( 0.0020~ 0.0033in)

Valve guide

Length

Intake 52.5mm (2.0669in)

Exhaust 52.5mm (2.0669in)

Valve seat

Width of seat contact

Intake 1.4 ~ 2.0mm (0.0551 ~ 0.0787in)

Exhaust 0.9 ~ 1.5mm (0.0354 ~0.0591 in)

Seat angle 45°

Valve spring

Free length 52.477mm (2.0660in)

Load(Intake)

Installed 23.45±1.87kg/40.0mm(51.7±4.1lb/1.5748 in)

Valve opened 39.15±3.13kg/31.65mm(86.3±6.9 lb/1.2461 in)

Load(Exhaust)

Installed 23.45±1.87kg/40.0mm(51.7±4.1lb/1.5748 in)

Valve opened 39.43±3.15kg/31.50mm(86.9±6.9 lb/1.2402 in)

Out of squareness Less than 2° 3°

Rocker arm and rocker arm shaft

Rocker arm inner diameter 20.000 ~ 20.027mm (0.7874 ~ 0.7885in)

Rocker arm shaft outer diameter 19.959 ~ 19.980mm (0.7858 ~ 0.7866in)

Cylinder block

Cylinder bore 101.500 ~ 101.526mm (3.9961 ~3.9971 in)

Liner inner diameter 97.100 ~ 97.126mm (3.8228~ 3.8239in)

Liner outer diameter 101.480 ~ 101.526mm ( 3.9953~ 3.9971in)

Flatness of gasket surface Less than 0.05mm (0.0020in)

Piston

Piston outer diameter 97.015 ~ 97.030mm ( 3.8195~ 3.8201in)

Piston to cylinder clearance 0.070 ~ 0.098mm (0.0028 ~ 0.0039in)

Ring groove width

No. 1 ring groove 2.397 ~ 2.417mm ( 0.0944~0.0952 in)

No. 2 ring groove 2.05 ~ 2.07mm ( 0.0807~ 0.0815in)

Oil ring groove 3.02 ~ 3.04mm (0.1189 ~ 0.1197in)

Piston ring

Side clearance No. 2 ring 0.06 ~ 0.10mm (0.0024~0.0039 in)

Oil ring 0.03 ~ 0.07mm (0.0012~0.0028 in)

End gap

No. 1 ring 0.25 ~ 0.40mm (0.0098~ 0.0157in)

No. 2 ring 0.40 ~ 0.55mm (0.0157~0.0217in)

Oil ring 0.20 ~ 0.40mm (0.0079 ~ 0.0157in)

Piston pin

Piston pin outer diameter 31.994 ~ 32.000mm (1.2596 ~ 1.2598 in)

Piston pin hole inner diameter 32.015 ~ 32.025mm (1.2604 ~ 1.2608 in)

Piston pin hole clearance 0.015 ~ 0.031mm (0.0006 ~ 0.0012 in)

Connecting rod small end inner diameter 32.012 ~ 32.033mm (1.2603 ~ 1.2611 in)

Connecting rod small end hole clearance 0.012 ~ -0.039mm (0.0005 ~ 0.0015 in)

Connecting rod

Connecting rod big end inner diameter 60.833 ~ 60.846mm (2.3950 ~ 2.3955 in)

Connecting rod bearing oil clearance 0.043 ~ 0.077mm (0.0017 ~ 0.0030 in)

End play 0.239~0.39 (0.0094 ~ 0.0154 in)

Crankshaft

Main journal outer diameter

NO 1, 2, 4, 5 69.995 ~ 70.015mm (2.7557 ~2.7565 in)

NO 3 69.973~69.993mm (2.7548 ~2.7556 in)

Pin journal outer diameter 57.106~57.124mm (2.2483~2.2490 in)

Main bearing oil clearance

NO 1, 2, 4, 5 0.045 ~ 0.079mm (0.0018 ~0.0031 in)

NO 3 0.067~0.101 mm (0.0026 ~0.0040 in)

End play 0.14 ~ 0.39mm (0.0055 ~0.0154 in)

Flywheel

Runout 0.10mm (0.0039in) 0.13mm (0.0051in)

Oil pump

Relief valve opening pressure 588.40±49.0kpa(6.0±0.5kg/cm²,85.34±7.1psi)

Discharge volume

75L/min(79.25 US qt/min, 65.99 lmp qt/min) (engine3,800rpm)

Engine oil

Oil quantity (Total) 8.0 L (8.45 US qt, 7.03 lmp qt)

Oil quantity (Oil pan) 6.0 L (6.34 US qt, 5.27 lmp qt)

Oil quantity (Drain and refill including oil filter) 6.6 L (6.97 US qt, 5.08 lmp qt)

Oil quality ABOVE API CH-4 or ABOVE ACEA B4

Oil pressure (Idle) 78.45 kpa (0.8 kg/cm², 11.38 psi)

Cooling system

Cooling method Forced circulation with cooling fan

Thermostat

Type Wax pellet type

Opening temperature 88±1.5 °C (190.4 ±34.7 °F)

Pull opening temperature

100 °C (212.0 °F)

Radiator cap

Main valve opening pressure

93.16 ~ 122.58kpa(0.95 ~ 1.25kg/cm², 13.51 ~ 17.78psi)

Water temperature sensor

Type Thermister type

Resistance

20°C (68°F) 2.27~2.64 kΩ

80°C (176°F) 0.31~0.33 kΩ

TIGHTENING TORQUE

Item

Quan-

tity

Tightening torque

N.m kgf.m lb-ft

Cylinder block

Engine support bracket bolts 8 36.3 ~ 53.9 3.7 ~ 5.5 26.8 ~ 39.8

Engine mounting

Engine mounting insulator and engine mounting bracket fixing nuts

4 36.3 ~ 53.9 3.7 ~ 5.5 26.8 ~ 39.8

Engine support bracket and engine mounting insulator fixing nuts

2 36.3 ~ 53.9 3.7 ~ 5.5 26.8 ~ 39.8

Transaxle mounting bracket and body fixing bolts

4 36.3 ~ 53.9 3.7 ~ 5.5 26.8 ~ 39.8

Transaxle mounting insulator and transaxle mounting bracket fixing bolt

1 62.8 ~ 93.2 6.4 ~ 9.5 46.3 ~ 68.7

Transaxle and transaxle mounting insulator fixing nuts

4 36.3 ~ 53.9 3.7 ~ 5.5 26.8 ~ 39.8

Main moving system

Connecting rod cap nuts 8

68.6→Unfasten

bolts→29.4+90°

7.0 → Unfasten bolts→3.0+ 90°

50.6→ Unfasten

bolts→21.7+ 90°

Crankshaft main bearing cap bolts 10 69.6~79.4+55°~65°

7.1 ~

8.1+55°~65°

51.4~58.6+55°~65°

Flywheel (DMF) bolts (M/T) 8 122.6 ~ 132.4 12.5 ~ 13.5 90.4 ~ 97.6

Drive plate bolts (A/T) 8 159.8 ~ 169.7 16.3 ~ 17.3 117.9 ~ 125.1

Timing belt

Timing belt upper cover bolts 5 6.9 ~ 9.8 0.7 ~ 1.0 5.1 ~ 7.2

Timing belt upper cover nut 1 6.9 ~ 9.8 0.7 ~ 1.0 5.1 ~ 7.2

Timing belt lower cover bolts 8 6.9 ~ 9.8 0.7 ~ 1.0 5.1 ~ 7.2

Crankshaft pulley bolt 1 372.7 ~ 411.9 38.0 ~ 42.0 274.9 ~ 303.8

Camshaft sprocket bolts 2 58.8 ~ 68.6 6.0 ~ 7.0 43.4 ~ 50.6

Timing belt tensioner bolt 1 20.6 ~ 25.5 2.1 ~ 2.6 15.2 ~ 18.8

Timing belt N0. 1 idler bolt 1 39.2 ~ 49.0 4.0 ~ 5.0 28.9 ~ 36.2

Timing belt N0. 2 idler bolt 1 37.3 ~ 43.1 3.8 ~ 4.4 27.5 ~ 31.8

Touch idler bolt 1 20.6 ~ 25.5 2.1 ~ 2.6 15.2 ~ 18.8

High pressure pump puli nut 1 58.8 ~ 68.6 6.0 ~ 7.0 43.4 ~ 50.6

High pressure pump and Timing belt case fixing bolts

3 21.6 ~ 25.5 2.2 ~ 2.6 15.9 ~ 18.8

High pressure pump bracket bolts (Pump) 2 21.6 ~ 25.5 2.2 ~ 2.6 15.9 ~ 18.8

High pressure pump bracket bolts (Cylinder block)

2 34.3 ~ 40.2 3.5 ~ 4.1 25.3 ~ 29.7

Timing belt plate bolts 6 6.9 ~ 9.8 0.7 ~ 1.0 5.1 ~ 7.2

Timing belt case bolts (8 X 25) 8 15.7 ~ 22.6 1.6 ~ 2.3 11.6 ~ 16.6

Timing belt case bolts (8 X 45) 2 15.7 ~ 22.6 1.6 ~ 2.3 11.6 ~ 16.6

Timing belt case bolts (8 X 50) 2 15.7 ~ 22.6 1.6 ~ 2.3 11.6 ~ 16.6

Timing belt case nut 1 15.7 ~ 22.6 1.6 ~ 2.3 11.6 ~ 16.6

Balancer gear bolt 1 63.7 ~ 73.5 6.5 ~ 7.5 47.0 ~ 54.2

Oil pump gear bolt 1 33.3 ~ 39.2 3.4 ~ 4.0 24.6 ~ 28.9

Idler gear bolt 1 33.3 ~ 39.2 3.4 ~ 4.0 24.6 ~ 28.9

Cylinder head

Cylinder head cover bolts 15 8.8 ~ -10.8 0.9 ~ -1.1 6.5 ~ -8.0

Rocker arm shaft And camshaft bearing cap bolts

10 17.7 ~ 26.5 1.8 ~ 2.7 13.0 ~ 19.5

Camshaft bearing cap nuts 10 17.7 ~ 26.5 1.8 ~ 2.7 13.0 ~ 19.5

Front camshaft bearing cap nuts(Small nuts) 2 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7

Cylinder head bolt (Long bolts) 10 39.2 + 90° + 120° 4.0 + 90° + 120° 28.9 + 90° + 120°

Cylinder head bolt (Short bolts) 8 39.2 + 90°+ 90° 4.0 + 90° + 90° 28.9 + 90°+ 90°

Cooling system

Cooling fan water pump pulley bolts 4 5.9 ~ 9.8 0.6 ~ 1.0 4.3 ~ 7.2

Water pump bolt (Long bolts) 3 15.7 ~ 22.6 1.6 ~ 2.3 11.6 ~ 16.6

Water pump bolt (Short bolts) 2 15.7 ~ 22.6 1.6 ~ 2.3 11.6 ~ 16.6

Water pump and generator brace fixing bolts (8 X 45)

2 15.7 ~ 22.6 1.6 ~ 2.3 11.6 ~ 16.6

Thermostat housing and generator strip nuts 2 18.6 ~ 22.6 1.9 ~ 2.3 13.7 ~ 16.6

Thermostat case cover bolts 2 15.7 ~ 22.6 1.6 ~ 2.3 11.6 ~ 16.6

Lubrication system

Oil filter 1 21.6 ~ 24.5 2.2 ~ 2.5 15.9 ~ 18.1

Oil cooler bolts (8 X 35) 4 15.7 ~ 22.6 1.6 ~ 2.3 11.6 ~ 16.6

Oil cooler bolts (8 X 50) 4 15.7 ~ 22.6 1.6 ~ 2.3 11.6 ~ 16.6

Oil cooler nuts 2 15.7 ~ 22.6 1.6 ~ 2.3 11.6 ~ 16.6

Oil pan nuts 29 15.7 ~ 22.6 1.6 ~ 2.3 11.6 ~ 16.6

Oil pan drain plug 1 34.3 ~ 44.1 3.5 ~ 4.5 25.3 ~ 32.5

Ladder frame bolts (10 X 45) 5 31.4 ~ 46.1 3.2 ~ 4.7 23.1 ~ 34.0

Ladder frame and oil suppling pipe bolt (8X 50) 1 15.7 ~ 22.6 1.6 ~ 2.3 11.6 ~ 16.6

Ladder frame bracket (Oil pump and ladder frame fixing) bolts

2 31.4 ~ 46.1 3.2 ~ 4.7 23.1 ~ 34.0

Oil supplying pipe and oil pump fixing bolts (8 X16)

2 15.7 ~ 22.6 1.6 ~ 2.3 11.6 ~ 16.6

Oil supplying pipe and Ladder frame fixing bolts (8 X 16)

2 15.7 ~ 22.6 1.6 ~ 2.3 11.6 ~ 16.6

Oil pump bolts(10 X 60) 2 15.7 ~ 22.6 1.6 ~ 2.3 11.6 ~ 16.6

Oil pump bolt(8 X 30) 1 15.7 ~ 22.6 1.6 ~ 2.3 11.6 ~ 16.6

Oil screen nuts 2 15.7 ~ 22.6 1.6 ~ 2.3 11.6 ~ 16.6

Oil pressure switch 1 14.7 ~ 46.1 1.5 ~ 2.2 10.8 ~ 34.0

Intake and exhaust system

Intake manifold and cylinder head fixing bolts(8 X 45)

2 15.7 ~ 22.6 1.6 ~ 2.3 11.6 ~ 16.6

Intake manifold and cylinder head fixing bolts(8 X 95)

4 15.7 ~ 22.6 1.6 ~ 2.3 11.6 ~ 16.6

Intake manifold and cylinder head fixing nuts 2 15.7 ~ 22.6 1.6 ~ 2.3 11.6 ~ 16.6

Intake manifold and cylinder head fixing hexagonal wrench bolt

1 17.7 ~ 26.5 1.8 ~ 2.7 13.0 ~ 19.5

Exhaust manifold and cylinder head fixing nut 9 26.5 ~ 34.3 2.7 ~ 3.5 19.5 ~ 25.3

Exhaust manifold heat cover and exhaust manifold fixing bolts(6X12)

3 8.8 ~ 12.7 0.9 ~ 1.3 6.5 ~ 9.4

Engine hanger bracket and exhaust manifold fixing bolts (8 X 18)

2 17.7 ~ 26.5 1.8 ~ 2.7 13.0 ~ 19.5

Exhaust manifold and front muffler fixing nut 2 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4

Front muffler CPF(Catalyzed Particulate Filter) fixing nuts

2 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4

CPF(Catalyzed Particulate Filter) main muffler fixing nuts

2 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4

Main muffler and tail pipe fixing nuts 2 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4

Timing system

Timing belt

2007 > J2.9L DIESEL CRDI(VGT) >

COMPONENTS

2007 > J2.9L DIESEL CRDI(VGT) >

REMOVAL

Engine removal is not required for this procedure.

1. Remove the battery terminals (A).

2. Install the jack for oil pan.

3. Remove the engine mounting (A).

4. Remove the engine support bracket(A).

5. Remove the drive belt.

6. Remove the water pump pulley.

7. Remove the bolts(B), nut(C) and timing belt upper cover (A).

8. Turn the crankshaft pulley(A), and align its groove with timing mark “T” of the timing belt cover. Check that the timing mark of camshaft sprocket(B) is aligned with the timing mark of cylinder head cover. (No.1 cylinder compression TDC position)

9. Remove the crankshaft pulley bolt(A), washer(B) and crankshaft pulley (C).

Using the special tool(09517-21700, 09231-H1000), fix the crankshaft pulley and loosen the bolt(A).

10. Remove the drive belt idler(A).

11. Remove the drive belt auto-tensioner (A).

12. Remove the timing belt lower cover(A).

13. Remove the auto-tensioner(A) with the timing belt.

In reusing the timing belt, install the belt with the arrow mark facing to rotating direction.

14. Remove the timing belt sprocket(A).

15. Remove the timing belt No.1 idler(A).

16. Remove the timing belt No.2 idler(A).

17. Remove the touch idler(A).

18. Fix the high pressure pump pulley, using the setting bolt(B) for the pulley not to be rotated.

19. Remove the high pressure pulley nut(A), with the washer(B), pulley(C).

Using SST, remove the pulley. (Refer to FL group).

20. Using SST(09231-4X100), remove the camshaft pulley.

INSTALLATION

1. Using SST (09231-4X100), install the camshaft pulley.

Tightening torque :

58.8~68.6Nm (6.0~7.0kgf.m, 43.4 ~ 50.6lb-ft)

2. After installing the high pressure pump pulley(A), tighten the high pressure pump pulley nut with the setting bolt(B) for the pulley not to be rotated.

Tightening torque :

58.8~68.6Nm (6.0~7.0kgf.m, 43.4 ~ 50.6lb-ft)

3. Install the touch idler(A).

Tightening torque :

7.8 ~ 9.8Nm (2.1~2.6kgf.m, 5.8 ~ 7.2lb-ft)

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