CHAPTER 2:

Engine Mechanical System

General information
 2004 > 2.0L DIESEL >

WARNING
1. Fuel system is subject to extremely high pressure (1350 bar).
2. Never perform any work on injection system with engine running or within 30 seconds after stopping the engine.
3. Always pay attention to safety precautions.
4. Ensure the absolute cleanliness.
5. Never remove the injectors.

2.0TCI ENGINE
SPECIFICATIONS(D4EA)
Description Specification 2.0(D4EA) Limit
General
Type In-line, Single Overhead Camshaft
Number of cylinders 4
Bore 83 mm (3.27 in.)
Stroke 92 mm (3.62 in.)
Total displacement 1991 cc (121.5 cu.in.)
Compression ratio 17.7:1
Firing order 1-3-4-2
Valve timing
Intake valve
Opens (BTDC) 7°
Closes (ABDC) 43°
Exhaust valve
Opens (BBDC) 52°
Closes (ATDC) 6°
Cylinder head
Flatness of cylinder head bottom Width directon :
surface 0.03mm (0.0012 in)
Length direction :
0.09mm (0.0036 in)

Dimensions for reworking oversize

valve seat hole 29.993-30.006 mm
Intake (1.18-1.1813 in.)
0.3 mm (0.012 in.) O.S. 30.023-30.036 mm
(1.182-1.1825 in.)
0.6 mm (0.024 in.) O.S.
25.393-25.406 mm
Exhaust (0.9997-1.0002 in)
0.3mm (0.012 in.) O.S. 25.423-25.436 mm
(1.0009-1.0014 in.)
0.6mm (0.024 in.) O.S.

Dimensions for reworking oversize

valve guide hole (both intake and
exhaust) 12.805-13.205 mm
0.05mm (0.002in.) O.S. (0.504-0.519 in.)
12.825-13.225 mm
0.25mm (0.010in.) O.S. (0.5049-0.5206 in.)
12.85-13.25 mm
0.50mm (0.020in.) O.S. (0.5059-0.5216 in.)

Camshaft
Cam height
Intake 34.697 mm (1.366 in.) 34.197 mm (1.346 in.)
Exhaust 34.570 mm (1.361 in.) 34.070 mm (1.341 in.)
Journal O.D. 28 mm (1.10 in.)
Bearing oil clearance 0.040-0.074 mm
(0.0020-0.0029 in.)
End play 0.05-0.15 mm
(0.002-0.006 in.)
Valve
Valve length
Intake 95.7 mm (3.77 in.)
Exhaust 95.4 mm (3.76 in.)
Stem O.D.
Intake 5.953 mm (0.234 in.)
Exhaust 5.925 mm (0.233 in.)
Face angle 44.5°
Thickness of valve head (margin)
Intake 1.6 mm (0.063 in.)
Exhaust 1.3 mm(0.0512 in.)
Valve stem to valve guide clearance
Intake 0.022-0.067 mm 0.1 mm (0.0039 in.)
(0.00086-0.00264 in.)
Exhaust 0.050-0.095 mm 0.15 mm (0.0059 in.)
(0.0020-0.00374 in.)
Valve guide
Length
Intake 36.5 mm (1.437 in.)
Exhaust 36.5 mm (1.437 in.)
Service over size 0.05, 0.25, 0.50 mm
(0.002, 0.010, 0.020 in.)
Valve seat
Width of seat contact 1.21mm (0.0477 in.)/
1.61mm(0.0634 in.) (IN/EX)
Seat angle 45°
Service size 0.3 mm (0.012 in.),
0.6 mm (0.024 in.) oversize
Valve spring
Free length 39.14 mm (1.541 in.) 38.14 mm (1.502 in.)
Load 21.4 kg/32 mm
(47.2 lb/1.26 in.)
at installed height
Cylinder block
Cylinder bore 83 + 0.03 mm
Out-of-round and taper of cylinder (3.27 + 0.0012 in.)
bore Less than 0.01 mm
(0.0004 in.)
Flatness of gasket surface Less than 0.05 mm 0.1 mm (0.0039 in.)
(0.0020 in.)
Piston
O.D. 82.919 - 82.951 mm
(3.26 - 3.27 in.)
Piston - to - cylinder clearance 0.069 - 0.091 mm
(0.0027 - 0.0036 in.)
Ring groove width
No. 1 1.915 - 1.945 mm
(0.075 - 0.076 in.)
No. 2 2.06 - 2.08 mm
(0.08 - 0.082 in.)
Oil 3.02 - 3.04 mm
(0.119 - 0.1196 in.)
Service size 0.25 mm (0.010 in), 0.5 mm (0.020
in.)
0.75 mm (0.030 in.), 1.00 mm (0.039
in.)
oversize
Piston ring
Side clearance
No. 1 0.083-0.115 mm
(0.00327-0.00453 in)
No. 2 0.065 - 0.11 mm
(0.00256 - 0.00433 in.)
Oil ring 0.03 - 0.07 mm
(0.00118 - 0.00275 in.)
End gap
No. 1 0.2 - 0.3 mm
(0.0079 - 0.0118 in.)
No. 2 0.3 - 0.45 mm
(0.0118 - 0.0177 in.)
Oil ring side rail 0.2 - 0.45 mm
(0.0079-0.0177 in.)
Connecting rod
Connecting rod small end I.D 28.022 - 28.034 mm
(1.103 - 1.104 in.)
Connecting rod bearing oil clearance 0.024 - 0.042 mm 0.1 mm (0.0039 in.)
(0.0009 - 0.0016 in.)
Crankshaft main bearing oil clearance 0.024-0.042 mm 0.1 mm (0.0039 in.)
(0.0009-0.0016 in.)
Crankshaft
Journal O.D. 60.002 - 60.020 mm
(2.362 - 2.363 in.)
End play 0.09 - 0.32 mm
(0.0035 - 0.0126 in.)
Flywheel
Runout 0.13 mm (0.0051in.)
Oil pressure (1500 rpm) More than
[Oil temperature is 95-105°C (203- 392.3 kPa (56.88 psi)
221°F)]
221°F)]
Oil pump
Tip clearance
Drive gear 0.12 - 0.2 mm
(0.00472-0.0078 in.)
Driven gear 0.13 -0 .23 mm
(0.0051-0.009 in.)
Side clearance 0.02 - 0.07 mm
(0.00078 - 0.0027 in.)
Relief spring
Free length 47.5 mm ( 1.835 in.)
Opening pressure 558.98±49.03 kPa
(5.7 ± 0.5 kg/cm²,
81.07 ± 7.11 psi)
Silent shaft
Front journal diameter 27.99 - 28.01 mm
(1.102 - 1.1027 in.)
Rear journal diameter 41.99 - 42.01 mm
(1.6531 - 1.6539 in.)
Oil clearance
Front 0.050 - 0.09 mm
(0.0020 - 0.0036 in.)
Rear 0.050-0.091 mm
(0.0020-0.0036 in.)
Cooling method
Cooling system quantity (Radiator) Forced circulation with electric fan
Thermostat 5 lit (5.3 U.S.qts., 4.4 Imp.qts.)
Type
Wax pellet type with jiggle valve
Normal opening temperature 85°C(185°F)
Opening temperature range 83.5°C-86.5°C (182.3°F-187.7°F)
Wide open temperature 100°C (212°F)
Radiator cap
Main valve opening pressure 107.9±14.7 kPa
(1.1±0.15 kg/cm² , 15.64±2.13 psi)
Main valve closing pressure 83.4 kPa
(0.85 kg/ cm², 12.1 psi)
Vacuum valve opening pressure -6.86 kPa
(-0.07 kg/ cm², -1.00 psi)
Air cleaner
Type Dry type
Element Unwoven cloth type
Exhaust pipe
Muffler Expansion resonance type
Suspension system Rubber hangers
Coolant temperature sensor
Type Thermister type
Resistance
20°C (68°F) 2.45±0.14 kΩ
80°C (176°F) 0.3222 kΩ

SERVICE STANDARDS

Standard value
Coolant concentration
Tropical area 40%
Other area 50%
Other area 50%

LUBRICANT
Engine coolant Ethylene glycol base for aluminum radiator

SEALANT
Engine coolant temperature sensor LOCTITE 262, three bond No. 1324 or equivalent
Oil pressure switch 3M ATD No. 8660 or Three bond No. 1141E

TIGHTENING TORQUE
Item Nm kg·cm Lb·ft
Cylinder head cover bolt 7.8-9.8 80-100 5.8-7.2
Camshaft sprocket bolt 120-150 1200-1500 88-110
Camshaft bearing cap bolt 27-30 270-300 20-22
Crankshaft position sensor 7-11 70-110 5-8
Air cleaner body installation
8-10 80-100 6-7
bolt
Crankshaft sprocket bolt 185-195 1850-1950 136-144
Damper pulley to crankshaft
30-34 300-340 22-25
sprocket
Cylinder head bolt (cold
50+120°+90° 500+120°+90° 36+120°+90°
engine)
Timing belt auto tensioner
50-55 500-550 36-40
bolt
Drive blet Auto tensioner
26-31 260-310 19-23
bolt
Timing belt auto tensioner
10-12 100-120 7-9
adjustable bolt
Drive belt idler bolt 46-51 460-510 34-38
Front exhaust pipe clamp
20-30 200-300 14-22
bolt
Oil pan 10-12 100-120 7-9
Oil pan drain plug 35-45 350-450 25-33
Oil screen 10-12 100-120 7-9
Oil pressure switch 15-22 150-220 11-16
Oil screen bracket bolt 34-38 340-380 25-28
Oil pump cover bolt 20-27 200-270 15-20
Oil seal case bolt 10-12 100-120 7-9
Plug cap 20-27 200-270 14-20
Oil jet bolt 9-13 90-130 7-10
Oil pump rotor bolt 8-10 80-100 6-97
Timing belt upper cover 8-12 80-120 6-9
Timing belt lower cover 8-12 80-120 6-9
Relief plug 42-52 420-520 31-38
Flywheel 70-80 700-800 52-59
Drive plate 70-80 700-800 52-59
Connecting rod cap bolt 25+90° 250+90° 18+90°
Engine coolant pump to
cylinder block bolt
14 mm 48-52 480-520 35-38
10 mm 10-12 100-120 7-9
Engine coolant temperature
40-55 400-550 30-41
sensor
Engine coolant inlet fiting
20-25 200-250 15-18
attaching bolt
Air cleaner mounting bolts 8-10 80-100 6-7
Resonator mounting bolt
8-10 80-100 6-7
(Nut)
Intake manifold mounting
15-20 150-200 11-14
bolt (M8)
Front exhaust manifold bolt
25-38 250-380 18-28
to cylinder block
Center exhaust pipe nuts to
30-40 300-400 22-29
catalytic converter
Center exhaust pipe bolts to
30-40 300-400 22-29
main muffler
Center exhaust pipe bolt to
10-15 100-150 7-11
bracket
Hanger bolt to body 10-15 100-150 7-11
Hanger bolt to main muffler 10-15 100-150 7-11
Exhaust manifold nuts 25-38 250-380 18-28
Oxygen sensor 40-50 400-500 29-36
Heat protector bolt to
15-20 150-200 11-14
exhaust manifold
Air cleaner bracket bolt 10-13 100-130 7-9
Exhaust manifold cover to
12-15 120-150 9-11
exhaust manifold bolt
Oxygen sensor to exhaust
40-50 400-500 29-36
manifold
Front exhaust pipe bracket
20-30 200-300 14-22
bolt
Main muffler hanger support
10-20 100-200 7-14
bracket bolt
Oil level gauge 10-12 100-120 7-9
Balance shaft bolt 53-57 530-570 39-42
Starter bolt to cylinder block 48-52 480-520 35-38
Turbocharger support bolt 35-45 350-450 26-33
Crankshaft bedplate bolt
15 mm 29.4+120° 300+120° 21.7+120°
12 mm 33.3-37.3 340-380 24.6-27.5

CHECKENG ENGINE OIL

1. Position a vehicle on a level surface.
2. Turn off the engine.

If a vehicle that has not been used for a prolonged period, run the engine for several minutes.
Turn off the engine and wait for 2 minutes at least, and then check the oil level.

3. Check that the engine oil level is with in the level range indicated on the oil dipstick. If the oil level is found to have
fallen to the lower limit (the "L" mark), refill to the "F" mark.

When refilling, use the proper grade of engine oil.

4. Check that the oil is not dirty or mixed with coolant or gasoline and it has the proper viscosity.

SELECTION OF ENGINE OIL

 For best performance and maximum protection of all types of operation, select only those lubricants which:
a. Satisfy the requirements of the API classification.
b. Have the proper SAE grade number for expected ambient temperature range.
Lubricants which do not have both SAE grade number and an API service classification on the container should
not be used.

CHANGING ENGINE OIL

1. Run the engine until it reaches normal operating temperature.
2. Turn off the engine.
3. Remove the oil filler cap and the drain plug. Drain the engine oil.
4. Tighten the drain plug to the specified torque.

Oil pan drain plug :

35-45 Nm (350-450 kg.cm, 25-33 lb.ft)

Whenever tightening the oil drain plug, use a new drain plug gasket.

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

Capacity :
Drain and refill : 5.4 lit (5.7 U.S.qts., 4.75 lmp.qts.)
Oil filter : 0.5 lit (0.53 U.S.qts., 0.44 lmp.qus.)
Total : 5.9 lit (6.23 U.S.qts., 5.19 lmp.qts)

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

6. Install the oil filler cap.

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

PROCEDURE FOR REPLACING THE OIL FILTER

1. Use a filter wrench (09263 - 27100) to remove the oil filter upper cap.
2. Installing a new oil filter on the lower case.
3. Tighten the oil filter upper cap to the specified torque.

Oil filter : 23-25 Nm (230-250 kg.cm, 17-18 lb.ft)

4. Start and run the engine and check for engine oil leak.
5. After turning off the engine, check the oil level and add oil as necessary.

CHECKING COOLANT LEAK

1. Loosen the radiator cap.
2. Confirm that the coolant level is up to the filler neck.
3. Install a radiator cap tester to the radiator filler neck and apply 150 KPa (21psi, 1.53 kg/cm²) pressure. Hold it for
two minutes in that condition while checking for leakage from the radiator, hoses or connections.

a. Radiator coolant may be extremely hot. Do not open the system because hot, or scalding water could gush
out causing personal injury. Allow the vehicle to cool before servicing this system.
b. When the tester is removed, be careful not to spill any coolant from it.
c. Be sure to clean away completely any from the area.
d. Be careful when installing and removing the tester and when testing, not to deform the filler neck of the
radiator.

4. If there is leakage, repair or replace with the appropriate part.

RADIATOR CAP PRESSURE TEST

1. Use an adapter to attach the cap to the tester.
2. Increase the pressure until the gauge stops moving.
 Main valve opening pressure :
107.9kPa±14.7kPa (1.1±0.15 kg/cm², 15.64±2.13)
Main valve closing pressure :
83.4 kPa (0.85 kg/cm², 12.1 psi)

3. Check that the pressure level is maintained at or above the limit.

4. Replace the radiator cap if the reading does not remain at or above the limit.

Be sure that the cap is clean before testing, since rust or other foreign material on the cap seal will cause an
incorrect reading.

SPECIFIC GRAVITY TEST

1. Measure the specific gravity of the coolant with a hydrometer.
2. Measure the coolant temperature and calculate the concentration from the relation between the specific gravity and
temperature, using the following table for reference.
RELATION BETWEEN COOLANT CONCENTRATION AND SPECIFIC GRAVITY

Coolant temperature °C (°F) and specific gravity Safe Coolant

Freezing
operating concentration
temperature
10 (50) 20 (68) 30 (86) 40 (104) 50 (122) temperature (Specific
°C (°F)
°C (°F) volume)
1.054 1.050 1.046 1.042 1.036 -16 (3.2) -11 (12.2) 30%
1.063 1.058 1.054 1.049 1.044 -20 (-4) -15 (5) 35%
1.071 1.067 1.062 1.057 1.052 -25 (-13) -20 (-4) 40%
1.079 1.074 1.069 1.064 1.058 -30 (-22) -25 (-13) 45%
1.087 1.082 1.076 1.070 1.064 -36 (-32.8) -31 (-23.8) 50%
1.095 1.090 1.084 1.077 1.070 -42 (-44) -37 (-35) 55%
1.103 1.098 1.092 1.084 1.076 -50 (-58) -45 (-49) 60%

a. If the concentration of the coolant is below 30%, its anti-corrosion properties will be adversely affected.
b. if the concentration is above 60%, both the anti-freeze and engine cooling property will decrease, affecting
the engine adversely. For these reasons, be sure to maintain the concentration level within the specified
range.
c. Do not mix types of anti-freeze.

RECOMMENDED COOLANT
Antifreeze Mixture ratio of anti freeze in coolant
ETHYLENE GLYCOL BASE FOR ALUMINUM 50% [Except tropical areas]
40% [Tropical areas]
 40% [Tropical areas]

CHECKING COMPRESSION PRESSURE

1. Before checking engine compression, check the engine oil level. Also check that the starter motor and battery are
all in normal operating condition.
2. Start the engine and wait until the engine coolant temperature reaches 80-95°C (176-205°F).
3. Turn off the engine and remove the aircleaner element.
4. Remove the injectors.
5. Crank the engine to remove any foreign material in the cylinders.
6. Insert the compression gauge (09351 - 27000) into the injector hole.
7. Crank the engine and read the gauge.

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

8. Repeat steps 6 to 7 for all cylinders, ensuring that the pressure difference for each of the cylinders is within the
specified limit.

Limit :
Max. 100 kpa (1.0 kg/cm² ,14 psi) between cylinders

9. If a cylinder's compression or pressure differential is outside the specification, add a small amount of oil through the
injector hole, and repeat steps 6 to 8.
a. If the addition of oil causes the compression to rise, it is likely that there may be wear between the piston ring
and cylinder wall.
b. If compression remains the same, valve seizure, poor valve seating or a compression leak from the cylinder
head gasket are all possible causes.
 2004 > 2.0L DIESEL >

SPECIAL TOOLS
Tool (Number and name) Illustration Use
Balance shaft bearing remover Removal and installation of balance
installer shaft rear bearing (use with 09212-
(09212-27000) 32300)

Ballanceshaft drive gear and Installation of the ballance shaft drive

comshaft oil seal installer gear on crankshaft and camshaft oil
(09214-32000) seal

Front case oil seal installer Installation of the front case oil seal
(09231-27100)

Valve guide remover Removal of valve guides

(09222-27100)

Valve spring compressor Removal and installation of inlet and

(09222-27300) exhaust valves

Valve stem oil seal installer Installation of valve stem oil seals
(09222-27200)

Valve guide installer Installation of valve guides

(09222-27000)

Crankshaft rear oil seal installer Installation of the crankshaft real oil
Crankshaft rear oil seal installer Installation of the crankshaft real oil
(09231-27000) seal

Injector oil seal installer Installation of the injector oil seal

(09351-27400)

Compression gauge adapter Checking engine compression

(09351-27000) pressure
(09351-27100)

Oil filter wrentch Removal and installation of oil filter

(09263-27100)
 2004 > 2.0L DIESEL >

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

Timing belt
2004 > 2.0L DIESEL >

COMPONENTS
 2004 > 2.0L DIESEL >

REMOVAL
1. Remove the crankshaft pulley and dirve belt.
2. Remove the timing belt cover.
3. Remove the auto tensioner.

Rotate the crankshaft clockwise and align the timing marks to set the No. 1 cylinder's position to TDC.
At this time, the timing mark of the camshaft sprocket and the top surface of the cylinder head should coincied
(Refer to "A")
The timing mark of the crankshaft sprocket and the dowel pin of oil pump housing should coincied (Refer to
"B")

4. Remove the timing belt.

If the timing belt is reused, make an arrow mark indicating the turning direction (or the front of the engine) to
make sure that the belt is reinstalled in the same direction as before.

5. Remove the camshaft sprockets.

INSPECTION
Sprockets, Tensioner Pulley and Idler Pulley
1. Check the camshaft sprocket, crankshaft sprocket, tensioner pulley and idler pulley for abnormal wear, cracks or
damage. Replace if necessary.
 damage. Replace if necessary.
2. Inspect the tensioner pulley and the idler pulley for easy and smooth rotation and check for play or noise. Replace if
necessary.
3. Replace the pulley if there is a grease leak from it s bearing.

Auto Tensioner
1. Check the auto tensioner for leaking and replace if necessary.
2. Check the rod end for wear or damage and replace if necessary.

Timing Belt
1. Check the belt for oil or dust deposit. Replace if necessary. Small deposits should be wiped away with a dry cloth
or paper. Do not clean with solvent.
2. When the engine is overhauled or belt tension is adjusted, check the belt carefully. If any of the following flaws are
evident, replace the belt with a new one.

Description Flaw conditions

1. Hardened back surface of rubber Back surface is glossy, Non-elastic and so hard that,
when your fingernail is pressed into it, no mark is
produced.
2. Cracked back surface of rubber

3. Cracked or separating canvas

4. Badly worn out teeth (initial stage) Tooth flank shows canvas on the load side (Fluffy canvas
fibers, rubber changed into white color and unclear
canvas texture)

5. Badly worn out teeth (last stage) Tooth flank worn and rubber exposed on load side (tooth
width reduced)

6. Cracked tooth bottom

7. Missing tooth
7. Missing tooth

8. Badly worn side of belt

9. Cracked side of belt

INSTALLATION
1. Install the crankshaft sprocket onto the crankshaft.

Pay attention to the direction of the flange. If it is installed in the wrong direction, a broken belt could result.

2. Install the special washer and sprocket bolt to the crankshaft and then tighten the sprocket bolt.

Tightening torque
Crankshaft sprocket bolt :
185 - 195 Nm (1850 - 1950 kg·cm, 136 - 144 lb.ft)

3. Install the auto tensioner.

TIMING BELT
1. Check timing mark.
a. Crankshaft side : Timing mark at crankshaft sprocket and timing pin at oil pump housing.
b. Camshaft side : Timing mark at camshaft sprocket and head.
2. Install tensioner.
3. Install timing belt.
4. Rotate engine more than 2 revelutions (Check timing mark).

5. Tighten stop bolt.

Cylinder Head Assembly
Camshaft
2004 > 2.0L DIESEL >

COMPONENTS
 2004 > 2.0L DIESEL >

DISASSEMBLY
1. Disconnect the negative terminal from the battery.
2. Remove the breather hose from the cylinder head cover.
3. Remove the timing belt cover.
4. Remove the head cover and cam shaft position sensor.
5. Loosen the camshaft sprocket bolts then remove the camshaft sprockets.
6. Loosen the camshaft bearing cap bolts and remove the bearing caps, camshafts, rocker arms and lash adjusters.

WARNING
1. Fuel system is subject to extremely high pressure (1350 bar).
2. Never perform any work on injection system with engine running or within 30 seconds after stopping the engine.
3. Always pay attention to safety precautions.
4. Ensure the absolute cleanliness.
5. Never remove the injectors.

INSPECTION
ROCKER ARMS
1. Check rotation of the roller. If they do not rotate smoothly or are loose, replace them.
2. Check the roller surface. Replace if there is any dent, damage or evidence of seizure.
3. Check the valve contact surface for possible damage or evidence of seizure. Replace if necessary.

CAMSHAFTS
1. Check the camshaft journals for wear. If the journals are badly worn, replace the camshaft.
2. Check the cam lobes for damage. If the lobe is damaged or worn excessively, replace the camshaft.

Cam height
[Standard]
Intake : 34.697 mm (1.366 in.)
Exhaust : 34.570 mm (1.361 in.)
[Limit]
Intake : 34.197 mm (1.346 in.)
Exhaust : 34.070 mm (1.341 in.)
 REASSEMBLY
1. Install the camshafts on the cylinder head.

Apply engine oil to journals and cams of the camshafts.

2. Install the bearing caps.

3. Check that the camshaft can be easily turned by hand. After checking, remove the bearing caps and the camshafts,
and then install the rocker arms.
4. Make sure that the dowel pins on the camshaft sprocket ends are located on the top.

5. Tighten the bearing caps to the specified torque in two or three increments as shown.

Tighten the rocker arms uniformly.

Tightening torque
Bearing cap bolts:
27 - 30 Nm (270 - 300 kg.cm, 20 - 22 lb.ft)

6. Using the special tools, camshaft oil seal Installer. Be sure to apply engine oil to the external surface of the oil
seal.
Insert the oil seal along the camshaft front end and install it by driving the installer with a hammer until the oil seal
is fully seated.
7. Install the camshaft sprocket bolts to the specified torque.

Tightening torque
Camshaft sprocket bolts :
125 - 140 Nm (1250 - 1400 kg.cm, 90 - 101 lb.ft)

8. Install the head cover.

Tightening torque
Rocker cover bolts : 7.8-9.8 N·m (80-100 kg·cm, 5.8-7.2 lb·ft)
Valve
2004 > 2.0L DIESEL >

COMPONENTS
 2004 > 2.0L DIESEL >

DISASSEMBLY
1. Rmove the cylinder head bolts in the order shown in the illustration.

2. Using the special tool (09222 - 27300) remove the valve spring retainer lock. Then remove the spring retainer,
valve spring, spring seat and valve.

Arrange these parts so that they can be reinstalled in their original positions.

3. Remove the valve stem seals with pliers.

Do not reuse the valve stem seals.

INSPECTION
Cylinder head
1. Check the cylinder head for cracks, damage and coolant leakage. If cracked, replace the cylinder head.
2. Remove scale, sealing compound and carbon deposits completely. After cleaning the oil passages, apply
compressed air to verify that the passages are not clogged.
3. Check the cylinder head surface for flatness in the direction as shown in the illustration. If flatness exceeds service
limit in any direction, either replace the cylinder head or machine the cylinder head matching surface lightly.

Flatness of cylinder head bottom surface

Standard :
Width direction : 0.03mm (0.0012 in)
Length direction : 0.09mm (0.0036 in)
Limit : 0.2 mm ( 0.008 in.)

Valves
1. Using a wire brush, clean the valve thoroughly.

2. Check each valve for wear, damage and distortion of the head and the stem at B Position. Replace, if necessary. If
stem end, A, is hollowed out or worn, resurface as necessary.This correction must be limited to a minimum. Also
resurface thevalve face.
Replace the valve if the margin has decreased to less than the service limit.

Margin
[Standard]
Intake 1.6 mm (0.063 in.)
Exhaust 1.3 mm (0.0512 in.)
Valve Springs
1. Check the free height of each valve spring. If they exceed the service limit, replace the springs.
2. Using a square, test the squareness of each spring. If a spring is excessively out- of-square, replace it.

Valve spring
[Standard]
Free height : 38.7 mm(1.52 in.)
Load : 21.4 kg / 32 mm (47.2 lb / 1.26 in.)
Out of square : 1.5° or less
[Limit]
Free height : 37.7 mm (1.48 in.)
Out of square : 4°

Valve Guides

Valve stem-to-guide clearance

[Standard]
Intake : 0.020 - 0.067 mm (0.0008 - 0.0026 in.)
Exhaust : 0.050 - 0.095 mm (0.0020 - 0.0037 in.)
[Limit]
Intake : 0.1 mm (0.0040 in)
Exhaust : 0.15 mm (0.0059 in.)

RECONDITIONING VALVE SEAT

REPLACING THE Valve Seat RING
1. Cut away the inner face of the valve seat to reduce the wall thickness.

2. Enlarge the diameter of the valve seat so that it matches the specified oversize hole diameter of the new valve seat
ring.
3. Heat the cylinder head to about 250°C(480°F) and press-fit an oversize seat ring for the bore in the cylinder head.
4. Using lapping compound, lap the valve to the new seat.

Valve seat contact width :

IN : 1.21mm (0.0477 in.)
EX : 1.61 mm (0.0634 in.)

Valve Seat Insert Oversizes

Description Size mm(in.) Size mark Oversize 0hole diameter
I.D. mm (in.)
Intakevalve 0.3 (0.012) O.S. 30 29.993-30.006(1.18-1.1813)
Seat ring 0.6 (0.024) O.S. 60 30.023-30.036(1.182-
1.1825)
Exhaust valve 0.3 (0.012) O.S. 30 25.393-25.406(0.9997-
1.0002)
Seat ring 0.6 (0.024) O.S 60 25.423-25.436(1.0009-
1.0014)
Replacing Valve Guide
1. Using the special tool (09222 - 27000), withdraw the old valve guide toward the bottom of cylinder head.
2. Recondition the valve guide hole so that it can match the newly press-fitted oversize valve guide.

3. Using the special tool (09222-21200 A, B), press-fit the valve guide. The valve guide must be press-fitted from the
upper side of the cylinder head.

Do not install a valve guide unless it is oversize.

4. After the valve guide is press-fitted, insert a new valve and check for proper stem-to-guide clearance.
5. After the valve guide is replaced, check that the valve is seated properly. Recondition the valve seats as
necessary.

Valve Guide Oversizes

Over size mm(in.) Size mark Oversize valve guide hole size mm
(in.)
0.05(0.002) 5 12.805-13.205(0.504-0.519)
0.25(0.010) 25 12.825-13.225(0.5049-0.5206)
0.50(0.020) 50 12.85-13.25(0.5059-0.5216)

REASSEMBLY

a. Clean each part before assembly.

b. Apply engine oil to the sliding and rotating parts.

1. Install the spring seats.

2. Using a special tool (09222-27200), tap the seal in position lightly.
 a. Do not reuse old valve stem seals.
b. Incorrect installation of the seal could result in oil leakage past the valve guides.

3. Apply engine oil to each valve. Insert the valve into the valve guide. Avoid pushing the valve into the seal by force.
After inserting the valve, check that it moves smoothly.

4. Place valve springs so that the side coated with enamel faces the valve spring retainer and then install the retainer.

5. Using the special tool (09222 - 27300), compress the spring and install the retainer locks. After installing the
valves,ensure that the retainer locks are correctly in place before releasing the valve spring compressor.

When the spring is compressed, Check that the valve stem seal is not pressed against the bottom of the
retainer.

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

8. Verify the identification marks on the cylinder head gasket.

9. Install the gasket so that the surface with the identification mark faces toward the cylinder head
10. Tighten the bolts to the specified torque.
Tightening torque :
49 Nm (500 kg.cm, 36.21 lb.ft)+120°+ 90°
Cylinder Head
2004 > 2.0L DIESEL >

COMPONENTS
 2004 > 2.0L DIESEL >

REMOVAL

Fuel system is subject to extremely high pressure.

Thus never perform any work on injection system with engine running or within 30 seconds after shutting off
engine.

1. Disconnect the battery negative cable.

2. Remove the intercooler assembly.
3. Disconnect the injector connector, fuel pipe and fuel return hose from the injector.

The hexagonal portion in the high pressure fuel inlet port in the injector should be stationary in order not to
loosen the high pressure fuel inlet port when unfastening the high pressure pipe.

4. Remove the plug and then remove sliding clamp mounting bolt.

Carefully turn the plug and remove it.

5. Install the special tool(injector remover (No.09351-27200)&sliding hammer(No.09527-11100)) to the hole where
thesliding clamp mounting bolt was removed and connect the injector remover to the sliding calmp.

6. After loosening the injector by hitting the sliding hammer upward, remove the special tool. And then remove the
sliding clamp and injector.
7. Remove the gasket from the injector nozzle tip.

8. Insert the injector hole brush tool(No.09351-27300) into the injector mounting hole and then clean cylinder head
bore and sealing surface and blow out.

9. Remove the timing belt upper cover, rocker cover (8mm bolt, 8EA) and rocker cover gasket.
 Installation
1. Install the rocker cover, gasket and timing belt upper cover.

Use rocker cover mounting bolts and tighten bolts to the specification in order as below.

Torque
Rocker cover bolt : 0.8-1.0 kg-m

2. Insert a new gasket into injector nozzle tip.

If necessary, apply small quantity of grease to bond injdector.
3. Install the injector and the sliding clamp with clamp bolt and then install new plug.

Torque
Screwing clamp bolt : 2.7±0.2kg-m

a. Use caution not to touch the nozzle tip during injector installation.
b. Do not reuse the plug.
After applying the engine oil on the gasket, install the new plug.
4. Reinstall all removed components in reverse order.

Torque
High-pressure pipe : 1.8-2.3 kg-m

Tighten the high pressure hose with fixing the hexagonal portion in the injector.

5. Connector the battery nagative cable.

Cylinder Block
Piston and Connecting Rod
2004 > 2.0L DIESEL >

COMPONENTS
 2004 > 2.0L DIESEL >

INSPECTION
PISTON
1. Check each piston for scuffing, scoring, wear and other defects. Replace any piston that is defective.
2. Check that the piston pin fits in the piston pin hole.
Replace any piston and pin assembly that is defective.
The piston pin must be smoothly pressed by hand into the pin hole (at room temperature)

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

Standard Value : Ring - to - ring groove clearance

No. 1 : 0.083 - 0.115 mm (0.00327 - 0.00453 in.)
No. 2 : 0.065 - 0.11 mm (0.00256 - 0.00433 in.)
Oil ring : 0.03 - 0.07 mm (0.00118 - 0.00275 in.)

4. Place a piston ring in the cylinder bore and set it square by pushing it down with piston.
5. Measure the end clearance using a thickness gauge.
 Standard Value : End gap
No. 1 : 0.2 - 0.3 mm (0.0079 - 0.0118 in.)
No. 2 : 0.30 - 0.45 mm (0.0118 - 0.0177 in.)
Oil ring : 0.2 - 0.45 mm (0.0079 - 0.0177 in.)
Limit : 0.8 mm (0.0315 in.)

CONNECTING ROD BEARING

1. Check the bearing surfaces for uneven contact pattern, streaks, scratches, and seizure. If defects are evident,
replace. If the surfaces are seriously nicked and seized, check also the crankshaft. If the crankshaft is also
damaged, replace the crankshaft or grind to undersize for reuse.

2. Measure the connecting rod bearing I.D. and crankshaft pin O.D. If the clearance (oil clearance) exceeds the limit,
replace the bearing and, if necessary, the crankshaft. Or, grind the crankshaft to an undersize and, at the same
time, replace the bearing with an undersize.

Standard value :
0.024 - 0.042 mm (0.0009 - 0.0016 in.)
Limit : 0.10 mm (0.0039 in.)

INSTALLATION
CONNECTING ROD, PISTION PIN AND PISTON
1. Match the piston with the connecting rod.
2. Line up the front marks and insert the piston pin. The piston pin must be smoothly pressed by hand into position.
Replace the piston pin if there is excessive play.
PISTON RING
1. Install the oil ring expander and oil ring to the piston. Then, install No.2 piston ring and No.1 piston ring, in that
order. Make sure that the ring side, on which manufacturer and size marks are stamped, faces to the piston crown.

2. Position ends of piston and oil (side rail, spacer) rings as illustrated.

3. Insert the piston and connecting rod assembly from above the top of cylinder. Ensure that the front mark on piston
crown and that (ID mark) on the connecting rod face toward the front of engine (to the crank pulley side).
4. Clamp firm the piston rings with the ring band and install the piston assembly into cylinder. Do not strike it hard into
the piston, as broken piston ring or damaged crank pin could result.

5. Tighten the connecting red cap bolts.

Tightening torque
Connecting rod cap bolts :
25 Nm (250 kg·cm, 18·4 lb·ft) + 90°
 Re-use of the bolt must be limited to 3 times.

6. Make sure the clearance of connecting rod big end side.

Standard Value : 0.10 - 0.35 mm (0.0039 - 0.0138 in.)

Limit : 0.4 mm (0.0157 in.)
Crankshaft
2004 > 2.0L DIESEL >

COMPONENTS
 2004 > 2.0L DIESEL >

DISASSEMBLY
1. Remove the timing belt, oil pump assembly, flywheel, cylinder head assembly and oil pan. For details, refer to the
respective chapters.
2. Remove the rear plate and the rear oil seal.
3. Remove the connecting rod caps.

Mark the main bearing caps to be able to reassembl in the original position and direction.

4. Remove the bedplate and the crankshaft. Keep the bearings in order according to the cap number.

INSPECTION
Crankshaft
1. Check the crankshaft journals and pins for damage, uneven wear and cracks. Also check the oil holes for
restrictions. Repair or replace any defective part.
2. Inspect the crankshaft journal for taper and out-of-round.

Standard value
Crankshaft journal O.D :
60.002 - 60.020 mm (2.362 - 2.363 in.)
Crankshaft pin O.D :
50.008 - 50.026 mm(1.969 - 1.9695 in.)

Main Bearings and Connecting Rod Bearings

Measuring Oil Clearance

Standard value
Oil clearance
Crankshaft main bearing :
0.024 - 0.042 mm (0.0009 - 0.0017 in.)
Connecting rod bearing :
0.024 - 0.042 mm (0.0009 - 0.0017 in.)
Limit : 0.1 mm (0.0039 in.)
How to Use Plastigauge
1. Remove oil, grease and any other dirt from the bearings and journals.
2. Cut the plasticgauge to the same length as the width of the bearing and place it in parallel with the journal,
avoiding the oil holes.
3. Install the crankshaft, bearings and caps and tighten them to the specified torques. During this operation, do not
turnthe crankshaft. Remove the caps. Measure the width of the plasticgauge at the widest part by using the scale
printed on the gauge package. If the clearance exceeds the service limit, the bearing should be replaced or an
undersize bearing should be used. When installing a new crankshaft, be sure to use standard size bearings. If the
standard clearance can not be obtained even after replacing the bearing, the journal and pin should be ground to
thr undersize and a bearing of the corresponding size should be installed.

Oil Seal
Bedplate

Standard value: 0.09 - 0.32 mm (0.0035 - 0.026 in.)

Drive Plate (A/T)

Flywheel (M/T)
1. Check the clutch disc contacting surface of the flywheel for damage and wear. Replace the flywheel if excessively
damaged or worn.
2. Check the clutch disc contacting surface of the flywheel for run-out.

Flywheel run-out : 0.13mm(0.0051 in.)

3. Check the ring gear for damage, cracks and wear. Replace if necessary.

REASSEMBLY
1. Install a grooved main bearing (upper bearing) on the cylinder block side.
2. Install a grooveless main bearing (lower bearing) on the main bearing cap side.
3. Lower center thrust bearing is grooveless. Upper center thrust bearing is grooveed.

1. Apply engine oil to journals and pins. Install the crankshaft.

2. Install the bedplate with the arrow mark directed toward the front of the engine.
3. Tighten the bed plate bolts to the specified torque.

Bed plate bolts :

15 mm : 29.4 Nm (300 kg·cm, 21.7 lb·ft) + (120°)
12 mm :
33.3 - 37.3 Nm (340 - 380 kg·cm,24.6 - 27.5 lb·ft)

4. Cap bolts should be tightened evenly in 4 to 5 increments before they are tightened to the specified torque.
5. Make sure that the crankshaft turns freely and check the end play of the crankshaft.
6. Using a special tool (09231 - 27000). Install the oil seal in the oil seal case. A new oil seal should be used.

7. Install the rear plate to the cylinder block.

8. Install the flywheel assembly and tighten the bolts to the specified torque.

Flywheel bolt :
70 - 80 Nm (700 - 800kg.cm, 52 - 59 lb.ft)

9. Install the adapter plate to the cylinder block.

10. Install the drive plate and tighten the bolts to the specified torque.

Drive plate : 70 - 80 Nm (700 - 800kg.cm, 52 - 59 lb.ft)

Engine Mounts
2004 > 2.0L DIESEL >

COMPONENTS
Cooling system
Water Pump
2004 > 2.0L DIESEL >

COMPONENTS
 2004 > 2.0L DIESEL >

REMOVAL
1. Drain the coolant and disconnect the coolant pump inlet pipe.
2. Remove the drive belt and engine support bracket.
3. Remove the timing belt covers and the timing belt tensioner.
4. Remove the engine coolant pump mounting bolts.
5. Remove the engine coolant pump assembly from the cylinder block.

INSTALLATION
1. Clean the gasket surfaces of the engine coolant pump body and the cylinder block.
2. Install the new O-ring onto the groove on the front end of the engine coolant pipe, then wet the O-ring with water.
Do not apply oil or grease.

3. Install a new engine coolant pump gasket and engine coolant pump assembly. Tighten the bolts to the specified
torque.

Tightening torque
Engine coolant pump bolt :
10 mm : 10 - 12 Nm (100 - 120kg·cm, 7 - 9 lb·ft)
14 mm : 48 - 52 Nm (480 - 520 kg·cm, 35 - 38lb·ft)

4. Install the timing belt tensioner and timing belt. Adjust the timing belt tension, then install the timing belt covers.
5. Refill the coolant.
6. Run the engine and check for leaks.

INSPECTION
1. Check the pump for cracks, damage or wear. Replace the pump assembly if necessary.
2. Check the bearing for damage, abnormal noise, and sluggish rotation. Replace the pump assembly if necessary.
3. Check the seal for leaks. Replace the pump assembly if necessary.
4. Check for engine coolant leakage. If the engine coolant leaks, the seal is defective. Replace the engine coolant
pump assembly.
Thermostat
2004 > 2.0L DIESEL >

COMPONENTS
 2004 > 2.0L DIESEL >

REMOVAL
1. Drain the coolant so its level is below the thermostat.
2. Remove the inlet fitting and gasket.
3. Remove the thermostat.

INSTALLATION
1. Check that the flange of the thermostat is correctly seated in the socket of the thermostat housing.
2. Install the inlet fitting.

Engine coolant inlet fitting bolt :

19.6-24.5 Nm (200-250kg.cm, 14.5-18.1 lb.ft)

3. Refill the coolant.

INSPECTION
1. Heat the thermostat as shown in the illustration.
2. Check that the valve operates properly.
3. Verify the temperature at which the valve begins to open.

Valve opening temperature : 83.5-86.5°C(182.3-187.7°F)

Full opening temperature : 100°C(212°F)
Radiator
2004 > 2.0L DIESEL >

COMPONENTS
 2004 > 2.0L DIESEL >

REMOVAL
1. Disconnect the ground cable from the battery terminal.
2. Disconnect the fan motor connector.
3. Loosen the radiator drain plug to drain the coolant.
4. Disconnect the upper and lower hoses and overflow tube after making marks on the radiator hose and the hose
clamp. to ease. reassembly.
5. For vehicles with automatic transaxles, disconnect the oil cooler hoses from the automatic transaxle.

Cover or plug the hose and inlets of the radiator so that dust and other foreign materials can not enter after
the hose is disconnected from the radiator.

6. Remove the radiator upper mounting bolt.

7. Remove the radiator together with the fan motor.
8. Remove the radiator fan motor and condenser fan motor from the radiator.

INSTALLATION
1. Fill the radiator and reservoir tank with clean coolant mixture.
2. Run the engine until the coolant has warmed up enough so that the thermostat valve is open. Then, stop the
engine.
3. Remove the radiator cap and pour the coolant into the filler neck of the radiator. Fill the reservoir tank with the
coolant to the upper level. Replace the radiator cap.
4. Check that there are no leaks from the radiator, hoses or connections.

INSPECTION
1. Check for foreign material between the radiator fins.
2. Check the radiator fins for damage and straighten if necessary.
3. Check the radiator for corrosion, damage, rust or scale.
4. Check the radiator hoses for cracks, damage or deterioration.
5. Check the reservoir tank for damage.
6. Check the automatic transaxle oil cooler hoses for cracking, damage or deterioration (only A/T).
Radiator Cap
2004 > 2.0L DIESEL >

COMPONENTS
 2004 > 2.0L DIESEL >

INSPECTION
1. Check the radiator cap for damage, cracks or weakening.

2. Connect the tester to the radiator cap.

3. Increase the pressure until the indicator stops moving.
4. Replace the radiator cap if the reading does not hold steady for about 10 seconds.
Cooling Fan Motor
Assembly
2004 > 2.0L DIESEL >

COMPONENTS
 2004 > 2.0L DIESEL >

REMOVAL
1. Disconnect the ground cable from the battery cable.
2. Disconnect the connectors from the fan motor and the harness from the shroud.
3. For vehicles with automatic transaxles, remove the oil cooler hose from the shroud.
4. Remove the four bolts holding the shroud.
5. Remove the shroud with the fan motor.
6. Remove the fan mounting clip and detach the fan from the fan motor.
7. Remove the three screws and detach the fan motor.

INSTALLATION

a. Make sure the cooling fan does not come into contact with the shroud when installed.
b. After installation, make sure there is no unusual noise or vibration when the fan is rotating.

INSPECTION
Radiator Fan Motor
1. Check that the radiator fan rotates when battery voltage is applied between the terminals (as shown in the table
below).
2. Check that abnormal noise is not produced while the motor is turning.
Radiator Fan Motor Relay
1. Remove the radiator fan motor relay (High and Low) from the relay box in the engine bay.

2. Check the continuity of the terminals "2" and "4" with an ohmmeter.
Item Terminal No. Yes or No
ON Terminal 1-3 Continuity
Terminal 1-3 Non continuity
OFF
Terminal 2-4 Continuity
Engine Coolant Hose
Pipes
2004 > 2.0L DIESEL >

COMPONENTS
 2004 > 2.0L DIESEL >

COOLANT TEMPERATURE SENSOR

REMOVAL
1. Drain the coolant to a level below the bottom of the sensor.
2. Disconnect the ground cable from the battery and then remove the sensor connector.
3. Remove the coolant sensor.

INSTALLATION
1. Tighten the coolant temperature sensor to the specified torque after applying the sealant to the screw area.

Recommened sealant :
Threebond No. 1324N or LOCTITE 262
The coolant temperature sensor :
20-40Nm (200-400 kg.cm, 14-29 lb.ft)

2. Connect the sensor to the harness.

3. Connect the ground cable to the battery.
4. Refill the engine coolant.

INSPECTION
REASSEMBLY

a. Do not apply oil or grease to engine coolant pipe O-ring.

b. Keep the engine coolant pipe connections free of sand, dust, etc.
c. Insert the engine coolant pipe into the end of the engine coolant pump inlet.
d. Whenever installing the engine coolant inlet pipe, always replace the O-ring with a new one.
Lubrication System
Oil Pump
2004 > 2.0L DIESEL >

COMPONENT

COMPONENTS
 2004 > 2.0L DIESEL >

REMOVAL
OIL PRESSURE SWITCH
DISASSEMBLY

INSPECTION
OIL COOLER
1. The oil filter mounting surface must be free from damage.
2. Check for cracks and oil leaks.
3. Make sure that the relief plunger slides smoothly and the relief spring is not damaged.

OIL PRESSURE SWITCH

1. Connect a tester (ohm range) between the terminal and the body of the switch to check for continuity. The switch
is normal if there is continuity. If there is no continuity, replace the switch.

2. Insert a thin rod in the oil hole of the switch and push it in lightly. The switch is normal if no continuity is detected
(infinite resistance on the tester). If there is continuity, replace the switch.

3. Apply a 0.5 kg/cm² pressure to the oil hole.

The switch is normal if there is no continuity.
Also check for air leaks. If any air leaks are detected, the cause may be a broken diaphragm. Replace the switch if
it leaks.
OIL JET, CHECK VALVE
1. Check the oil jet and check valve for clogging.
2. Check the oil jet for damage and deformation.

INSPECTION
1. Install the outer and inner gear into the front case and make sure that they turn smoothly with no excessive play
between them.
2. Check the side clearance (drive gear and drivengear))

Standard: 0.02 - 0.07 mm (0.00078 - 0.0027 in.)

3. Check the tip clearance.

Drive gear : 0.12 - 0.2 mm (0.00472 - 0.0078 in.)

Driven gear : 0.13 - 0.23 mm (0.0051 - 0.009 in.)

INSTALLATION
OIL PRESSURE SWITCH

The sealant must not get into the thread top surface. Use care not to torque excessively.

INSTALLATION

When installing the gears, be sure to apply engine oil to the entire surfaces of the gears.
Oil Cooler
2004 > 2.0L DIESEL >

COMPONENTS
 2004 > 2.0L DIESEL >

REMOVAL
1. Remove the oil filter.
2. Remove the coolant hose from the oil cooler.
3. Remove the oil filter fitting.
4. Remove the oil cooler from the oil pump.

INSPECTION
1. Check for oil leaks.
2. Check the oil cooler for damage.
Front Case
2004 > 2.0L DIESEL >

COMPONENTS
 2004 > 2.0L DIESEL >

DISASSEMBLY
1. Remove the timing belt. Refer to "Timing Belt."
2. Remove all the oil pan bolts.
3. Tap the oil pan with a rubber hammer and remove the pan.
4. Remove the oil screen and gasket.
5. Remove the front case assembly.
6. Remove the oil pressure switch.

7. Remove all the balance shaft bolt.

8. Disassembly the balance shaft assembly.

9. Remove the front case mounting bolts and remove the front case assembly and gasket from the cylinder block.
10. Remove the oil pump gears from the front case.

INSPECTION
Front Case
1. Check all oil holes for clogging. Clean the holes if necessary.
2. Check the balance shaft bearing for wear, damage and seizure. If there is anything wrong with the bearing, replace
the bearing.
3. Check the front case for cracks and other damage.
4. Replace a cracked or damaged front case.
Balance Shaft
1. Check the journals for wear or seizure.
2. If excessive wear or seizure is evident, check the bearing carefully.
3. If necessary, replace the balance shaft bearing or the shaft itself.

Oil Seal
1. Check the oil seal lip for wear and damage. Replace the oil seal if necessary.
2. Check the oil seal lip for deterioration. Replace the oil seal if necessary.

REASSEMBLY
1. Apply engine oil to the gear and align the two timing marks.

2. Apply Locitite272 to the drive gear and intermediate gear bolt.

3. Using the special tool, the crankshaft front oil seal installer (09231-27100), install the crankshaft front oil seal into
the front case.
4. Install a new front case gasket to the front case assembly and tighten the flange bolts temporarily.
5. Install the front case assembly with a new gasket. Tighten bolts to the specified torque.

Tightening torque
Front case assembly :
20-27Nm(200-270kg.cm, 14-20 lb.ft)

6. Install a balance shaft assembly to the cylinder block.

7. Apply sealant to the groove of the pan flange as shown.

a. Apply sealant approximately 4 mm (0.16 in.) in thickness.

b. After the application of the sealant, install the oil pan within 15 minutes.

8. Install the oil pan and tighten the bolts to the specified torque.
 Tightening torque
Oil pan bolt : 10-12Nm(100-120kg.cm, 7-9 lb.ft)

9. Using a 24 mm deep socket, install the oil pressure switch after applying sealant to the threaded area.

Sealant : Threebond 1104 or equivalent

Do not torque the oil pressure switch excessively.

Tightening torque
Oil pressure switch : 15-22Nm(150-220kg.cm, 11-16 lb.ft)
Intake and Exhaust System
Air Cleaner
2004 > 2.0L DIESEL >

COMPONENTS
Intercooler
2004 > 2.0L DIESEL >

COMPONENTS
 2004 > 2.0L DIESEL >

REMOVAL
1. Remove the intercooler cover.
2. Remove the air hoses.
3. Remove the intercooler assembly.
4. Remove the intercooler bracket.
Exhaust Manifold
2004 > 2.0L DIESEL >

COMPONENTS
Turbo Charger
2004 > 2.0L DIESEL >

COMPONENTS

COMPONENTS
 2004 > 2.0L DIESEL >

DISASSEMBLY
1. Before removal, make the matching mark on compressor cover bearing housing and turbine housing.

Be sure not to damage the compressor and turbine wheel blade.

2. Loosen the assembly and tap the housing by plastic hammer when removing the housing.

3. Remove the snap ring using snap ring filler.

4. Remove by tapping the compressor cover of cartridge assembly with plastic hammer.

CLEANING
1. Use a heavy duty carbon solvent to loosen the carbon from the parts.
 Do not use caustic solutions, wire brushes, or wire wheels to remove carbon deposits from any turbo charger
part.

2. A small, closed, agitated cleaning tank and solvent will give the best results.

3. After the carbon is loosened, use a hard, bristle type brush and remove all dirt particles.

4. Clean all drilled passages with air under pressure and put oil on cleaned parts to prevent corrosion.

INSPECTION
1. Check the inner housing contacting turbine wheel for crack, pitching and other damages caused by overheat.
2. Make sure that the waste gate valve lever operates freely by hands.
3. Make sure there are no damages on the inner housing surface contacting compressor wheel.

4. Turbine wheel and shaft assemblies with cracks in the blades or broken blades can not be used again. If the
blades are slightly bent, it can be used again but severely bent blades can not be reused.
 blades are slightly bent, it can be used again but severely bent blades can not be reused.

5. Check if there are foreign materials disturbing the oil flow in the oil passage of cartridge assembly.

WASTE GATE INSPECTION

1. Check the waste gate rod operation under the pressure below.

Nominal Value : 131.4 kPa (1.34 kgf / cm²)

REASSEMBLY
1. Apply engine oil to new O-ring and insert the O-ring to the groove of cartridge assembly.

2. Assemble cartridge assembly and compressor cover matching the mark.

3. Install the snap ring as shown in the figure.

4. Before reassembly, make sure that the turbine housing matching mark is matched with compressor cover and
cartridge assembly.
Mufler
2004 > 2.0L DIESEL >

COMPONENTS