PRODUKT NIEDOSTĘPNY
WYMIANA USZCZELKI GŁOWICY
Labor Operations: Click to display a list of Labor Operations associated with this procedure
Special Tools: Click to display a list of tools used in this procedure
| WARNING: |
| NO FIRE, OPEN FLAMES OR SMOKING. SERVICE VEHICLES IN WELL VENTILATED AREAS. RISK OF POISONING FROM INHALING OR SWALLOWING FUEL. RISK OF INJURY FROM SKIN AND EYE CONTACT WITH FUEL. WEAR PROTECTIVE CLOTHING. |
| NOTE: | Thoroughly clean all mating surfaces with appropriate solvents and blow out bolt holes, to assure that no grease or oil is present during reassembly. |
| NOTE: | If piston or connecting rods have been replaced, measure piston projection. |
| NOTE: | Check facing cylinder head contact surface. |
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| 1. | Position the cylinder head and gasket properly on engine using the dowel pins as guide. |
| NOTE: | Inspect all cylinder head bolts for defects and stretching before installation. |
The M12 cylinder head bolts must be torqued in 3 stages.
| 2. | Install cylinder head assembly on engine block. |
| 3. | Install M12 cylinder head bolts finger tight. |
| 4. | Torque bolts in numeric order starting with number 1 to 60 N·m (44 lbs.in.). |
| 5. | Install M8 timing chain cover to cylinder head bolts. Tighten to 20N·m (177 lbs.in.). |
| 6. | Tighten M12 cylinder head bolts in numeric order starting with number 1 an additional 90° . |
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| 7. | Connect vacuum hose at turbocharger waste gate solenoid. |
| 8. | Connect intake manifold inlet tube (3) at intake manifold (1). |
| 9. | Connect EGR valve to mixing chamber pipe at EGR valve (refer to section 25). |
| 10. | Connect oil dip stick tube. Tighten to 14 N·m (124 lbs. in.). |
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| 11. | Install intermediate timing chain gear (5). |
| 12. | Install camshafts - INSTALLATION). |
| 13. | Install vacuum pump |
| 14. | Install high pressure pump |
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| 15. | Install cylinder head front cover (5) and top guide rail (1) |
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| 16. | Install timing chain tensioner (1) with new seal (2). Tighten to 80N·m (59 lbs.ft.). |
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| 17. | Remove Camshaft Locking Pin (1). |
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| 18. | Install cylinder head cover (2) - INSTALLATION). |
| 19. | camshaft position sensor connector (1). |
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| 20. | Reposition engine electrical harness and connect the fuel injector (1), glow plug (2), and coolant temperature electrical connectors. |
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| 21. | Install fuel injectors (5) and high pressure lines (3) (refer to section 24). |
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| 22. | Raise vehicle on hoist. |
| 23. | Install turbocharger support bracket (1). Tighten bolts to 30N·m (22 lbs.ft.). |
| 24. | Install oil return flow line at turbocharger. |
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| 25. | Remove Crankshaft Lock (2). |
| 26. | Install starter. |
| 27. | Install charge air distribution pipe refer to section 11). |
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| 28. | Install engine compartment lower silencer (1) and accessory drive belt splash shield (2). |
| 29. | Lower vehicle. |
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| 30. | Install air cleaner housing (6) and turbocharger air intake hose (1). |
| 31. | Install coolant recovery pressure container (refer to section 7) . |
| 32. | Connect upper radiator hose to thermostat housing. |
| 33. | Install radiator closure panel |
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| 34. | Install front grille assembly (2) |
| 35. | Refill cooling system with proper coolant mixture to proper level (refer to section 7). |
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| 36. | Connect negative battery (1) cable located under passenger seat. |
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CYLINDER HEAD FRONT COVER
Labor Operations: Click to display a list of Labor Operations associated with this procedure
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| NOTE: | Thoroughly clean all mating surfaces with appropriate solvents to assure that no grease or oil is present during reassembly. |
| NOTE: | Dowel pins are used as a guide during assembly and must remain in the proper position to assure a good sealing surface. |
| 1. | Apply sealant to the marked surfaces with a bead thickness of 1.5 ± 0.5 mm. |
| NOTE: | Install front cover of cylinder head within 10 minutes after applying sealant. Do not spread sealing bead. |
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| 2. | Raise locking pawl (3) of top guide rail and guide front cover (5) onto guide pins. |
| 3. | Install bolts attaching front cover (5) Tighten bolts to 14N·m (124 lbs. in.). |
| NOTE: | Timing chain tensioner must be installed with a new seal. |
| 4. | Install timing chain tensioner (7) and new seal (6) |
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| 5. | Connect negative battery (1) cable located under passenger seat. |
| 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 clothes. |
| 6. | Start the engine and inspect for leaks. |
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CYLINDER HEAD GUIDE RAIL
Labor Operations: Click to display a list of Labor Operations associated with this procedure
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| 1. | Carefully position the top guide rail (1) onto the dowel pins (4). |
| 2. | Counter hold the camshaft with an open end wrench and install driver of inlet camshaft sprocket. Tight bolt to 50N·m (37 lbs. ft.). |
| 3. | Carefully raise locking pawl (3) of top guide rail (1) and install cylinder head front cover |
| 4. | Install timing chain tensioner (7) with new seal (6) |
| 5. | Install cylinder head cover (2) - INSTALLATION). |
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| 6. | Reconnect negative battery (1) cable. |
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| 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 CLOTHES. |
| 7. | Start engine and inspect for leaks. |
| 8. | Install engine cover (2) |
Engine, 2.2L Diesel CAMSHAFT INSTALLATION
Labor Operations: Click to display a list of Labor Operations associated with this procedure
Special Tools: Click to display a list of tools used in this procedure
| CAUTION: | The camshafts are sensitive to fracturing. Ensure they are installed free of stress. |
| CAUTION: | Pay attention to assignment of camshafts. Camshaft code numbers are visible on the thrust collar of the axial bearing. |
| CAUTION: | Oil bucket tappets and camshaft bearing points. Inspect ease of operation of bucket tappets. |
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| 1. | Install inlet (3) and exhaust (2) camshafts. |
| CAUTION: | Install camshafts so that the two holes in camshaft sprockets are positioned opposite and the markings of the camshaft and camshaft bearing cap are aligned. |
| 2. | Align inlet (3) and exhaust (2) camshafts at axial bearing - STANDARD PROCEDURE). |
| 3. | Position piston of cylinder #1 to 30° TDC. |
| NOTE: | Pay attention to markings on camshaft bearing caps. |
| 4. | Install camshaft bearing caps in the proper order. Tighten bolts to 9N·m (80 lbs. in.). |
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| CAUTION: | Do not rotate engine counter clockwise. |
| 5. | Position the piston of cylinder #1 to ignition TDC. |
| NOTE: | Pay attention to markings on camshaft bearing caps. |
| 6. | Install the bearing caps in reverse order at the same point. Tighten bearing cap bolts evenly in steps each of 1 turn. |
| NOTE: | The piston of cylinder #1 must be positioned at ignition TDC when the inlet camshaft is locked. |
| 7. | Insert Camshaft Locking Pin (7) in through the first camshaft bearing cap into the whole in the camshaft sprocket. |
| NOTE: | Do Not use old camshaft sprocket bolts. |
| 8. | Fit exhaust camshaft sprocket with timing chain (1) onto exhaust camshaft paying attention to position of dowel pin. Tighten bolt to 18N·m (159 lbs.in.). |
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| 9. | Install timing chain tensioner (1) with new seal (2) |
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| 10. | Inspect/Set basic position of camshafts - STANDARD PROCEDURE). |
| 11. | Remove Crankshaft Lock . |
| 12. | Install starter. |
| 13. | Remove Camshaft Locking Pin (7). |
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| 14. | Install cylinder head cover (2) - INSTALLATION). |
| NOTE: | Refer to the appropriate injector servicing procedures for cleaning of injectors and recesses. |
| 15. | Clean and install injectors |
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| 16. | Connect negative battery (1) cable. |
| 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. |
| 17. | Start engine and inspect for leaks. |
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| 18. | Install engine cover (2) |
TABELA WARTOŚCI MOMENTÓW DOKRĘCANIA
DESCRIPTION |
N·m |
Ft. Lbs. |
In. Lbs. |
|---|---|---|---|
| Crankcase Ventilation | |||
| Screw-Air Charge Distribution Pipe to Air Charge Distribution Panel | 11 | - | 97 |
| Cylinder Head | |||
| 8m-Bolt- Cylinder Head to Timing Case Cover | 20 | 15 | - |
| Bolt-Front Cover to Cylinder Head | 14 | - | 124 |
| 12m-Bolt-Cylinder Head to Crankcase (3 stages, torque, torque angle, torque angle) | 60, 90°, 90° | 44, 90°, 90° | - |
| Crankcase, Timing Case Cover, End Cover | |||
| Bolt-Crankshaft Bearing Cap to Crankcase (2 stages, torque, torque angle) | 55, 90° | 40, 90° | - |
| Bolt-End Cover to Crankcase | 9 | - | 80 |
| Bolt-Timing Case Cover to Crankcase | 20 | 15 | - |
| Plug-Coolant Drain to Crankcase | 30 | 22 | - |
| Oil Pan | |||
| 6m-Bolt-Oil Pan to Crankcase | 9 | - | 80 |
| 8m-Bolt-Oil Pan to Crankcase | 20 | 15 | - |
| Bolt-Oil Pan to End Cover | 9 | - | 80 |
| Bolt-Oil Pan to Timing Case Cover | 9 | - | 80 |
| Bolt-Oil Pan to Transmission Bell Housing | 40 | 30 | - |
| Plug-Pil Pan to Oil Drain | 47 | 35 | - |
| Connecting Rod | |||
| Bolt-Connecting Rod Cap to Connecting Rod (3 stage, 1AND2 torque, 3 torque angle) | 5,25,90° | - | 44,221, 90° |
| Crankshaft | |||
| Bolt-Crankshaft Bearing Cap (2 stage, 1 torque, 2 torque angle | 55,90° | 40.5, 90° | - |
| Flywheel, Driven Plate, Vibration Damper, Starter Ring Gear | |||
| 8.8m-Bolt-Central Bolt of Vibration Damper (2 stage, 1 torque, 2 torque angle) | 200,90° | 147.5, 90° | - |
| 10.9m-Bolt-Central Bolt of Vibration Damper (2 stage, 1 torque, 2 torque angle) | 325,90° | 240, 90° | - |
| Bolt-Stretch Shank for Flywheel or 2 Mass Flywheel to Crankshaft (2 stage, 1 torque, 2 torque angle) | 45,90° | 33, 90° | |
| Turbo Charger | |||
| Bolt-Oil Feed Line to Cylinder Head | 9/22 | - | 80-194 |
| Bolt-Oil Feed Line to Turbo Charger | 30 | 22 | - |
| Bolt-Turbo Charger Support | 30 | 22 | - |
| Bolt-Turbo Charger Support to Crankcase | 20 | - | 177 |
| Bolt-Oil Outlet Line to Turbo Charger | 9 | - | 80 |
| Connection-Flange of Exhaust Manifold to Turbo Charger | 30 | 22 | - |
| Connection-Turbo Charger to Front Catalytic Converter | 30 | 22 | - |
| Charge Air Pipe/Charge Air Cooling | |||
| Bolt-Charge Air Distribution Pipe | 16 | - |
141 |
| Bolt-Inlet Port Shut Off Positioning Motor to Air Charge Distribution Pipe | 9 | - | 80 |
| Bolt-Support to Charge Air Distribution Pipe | 20 | - | 177 |
| Bolt-Support to Engine Bracket | 40 | 30 | - |
| Clamp-Charge Air Pipes/Hoses | 3 | - | 27 |
| Belt Tensioning Device | |||
| Bolt-Guide Pully to Coolant Pump | 35 | 26 | - |
| Bolt-Guide Pully to Timimg Case Cover | 35 | 26 | - |
| Bolt-V-Belt Tensioning Device to Tensioning Pully | 36 | 26.5 | - |
| Bolt-V-Belt Tensioning Device to Timing Case Cover | 30 | 22 | - |
| Exhaust Manifold | |||
| Nut-Exhaust Manifold at Cylinder Head | 30 | 22 | - |
| Position Sensor | |||
| Nut/Bolt-Camshaft Position Sensor to Cylinder Head Cover | 11 | - | 97 |
| Nut/Bolt-Crankshaft Position Sensor to Engine Block | 8 | - | 70 |
| Pre-Glow System | |||
| Cylinder Head to Glow Plug | 12 | - | 106 |
| Starter | |||
| Bolt-Starter to Crankcase | 42 | 31 | - |
| Nut-Connection of Circuit 30 | 14 | - | 124 |
| Nut-Connection of Circuit 50 | 6 | - | 53 |
| Alternator | |||
| Bolt-Generator to Timing Case Cover | 20 | 15 | - |
| Bolt-Generator to Cooler Housing | 6 | - | 53 |
| Bolt-Cooler Housing of Generator to Crankcase | 20 | - | 177 |
| Nut-B+ Circuit to Generator | 13-18 | - | 115-159 |
| Nut-D+ Circuit to Generator | 5 | - | 44 |
| Nut-Collar to V-Belt Pully | 80 | 59 | - |
| Oil Pump | |||
| Bolt-Oil Pump to Crankcase | 18 | - | 133 |
| Bolt-Oil Pipe to Crankshaft Bearing Cap | 8 | - | 70 |
| Oil Filter | |||
| Screw Cap to Oil Filter | 25 | 18.5 | - |
| Oil Cooling System | |||
| Bolt-Oil-Water Heat Exchanger to Timing Cover Case | 15 | - | 133 |
| Oil Level Pressure | |||
| Bolt-Dip Stick Guide Tube to Cylinder Head | 14 | - | 123 |
| Bolt-Oil Level Sensor to Oil Pan | 14 | - | 123 |
| Coolant Pre- Heater | |||
| Coolant Pre-Heater in Engine Block | 35 | 26 | - |
| Engine Cooling General | |||
| Bolt-Belt Pully to Coolant Pump | 8-35 | 6-26 | - |
| Bolt-Coolant Pump to Timing Case Cover 6m/8m | 14/20 | 10-15 | - |
| Bolt-Thremostat Housing to Cylinder Head | 9 | - | 80 |
| Coolant Drain Plug to Crankcase | 30 | 22 | - |
| Engine Suspension, Engine Mount, Engine Bracket | |||
| Bolt-Engine Bracket to Crankcase (2 stage, torque, torque angle) | 20, 90° | 15, 90° | - |
| Bolt-Engine Mount to Engine Bracket | 55 | 40.5 | - |
| Bolt-Front Engine Mount to Front Axle Carrier | 35 | 26 | - |
| Bolt-Rear Engine Cross Member to Body | 40 | 30 | - |
| Bolt-Rear Engine Mount to Rear Engine Cross Member | 35 | 26 | - |
| Bolt/Nut- Rear Engine Mount to Transmission | 40 | 26 | - |
| Bolt-Shrowd to Engine Bracket | 10 | - | 88.5 |
| Nut-Front Engine Mount to Engine Bracket | 65 | 48 | - |
| Nut-Engine Mount to Vehicle Frame | 35 | 26 | - |
| Fuel Filter | |||
| Bolt-Clip to Fuel Filter | 8 | - | 70 |
| Bolt- Fuel Filter to Charge Air Distribution Pipe | 14 | - | 124 |
| Exhaust System | |||
| Bolt- Catalytic Converter Bracket to Crankcase | 20 | - | 177 |
| Clamp-Connection Between Front Exhaust Pipe and Rear Exhaust System | 55 | 41 | - |
| Clip-Front Catalytic Converter to Engine Mount | 20 | - | 177 |
| Nut-Bracket to Tail Pipe | 55 | 40.5 | - |
| Nut-Exhaust Bracket to Threaded Plate of Center Exhaust Pipe | 20 | - | 177 |
| Support-Exhaust Bracket on Transmission | 20 | - | 177 |
| Refrigerant Compressor | |||
| Bolt-Refrigerant Compressor to Timing Case Cover | 20 | - | 177 |
| Bolt-Refrigerant Compressor to Bracket | 20 | - | 177 |
| Bolt-Refrigerant Lines to Refrigerant Compressor | 20 | - | 177 |
| Timing Chain, Chain Tensioner | |||
| Bolt-Camshaft Sprocket to Exhaust Camshaft | 18 | - | 159 |
| Bolt-Intermediate Gear of High Pressure Pump to Cylinder Head | 40 | 29.5 | - |
| Timing Chain Tensioner to Timing Case Cover | 80 | 59 | - |
| Camshaft | |||
| Bolt-Camshaft Bearing Cap to Cylinder Head | 9 | - | 80 |
| Bolt-Driver to Inlet Camshaft | 50 | 37 | - |
| Common Rail Diesel Injection | |||
| Bolt-Bango Bolt of Leak Oil Line to Rail | 20 | - | 177 |
| Bolt-Bracket to High Pressure Pump | 9 | - | 80 |
| Bolt-High Pressure Pump to Cylinder Head | 14 | - | 124 |
| Bolt-Pre-delivery Pump to Top Cover of Cylinder Head | 9 | - | 80 |
| Bolt-Pressure Control Valve to Rail (2 stage, torque) | 3, 5 | - | 26, 44 |
| Bolt-Rail to Cylinder Head | 14 | - | 124 |
| Bolt-Shutoff Valve to Cylinder Head | 8 | - | 70 |
| Nut-Pressure Line | |||