2.5L VM DIESELINDEXpage pageGENERAL INFORMATIONENGINE IDENTIFICATION ... 37GENERAL SPECIFICATION ... 36DESCRIPTION AND OPER

(7) Torque engine mount top bolt (Vertical) to 101N·m (75 ft. lbs.)(8) Torque engine mount thru bolt (Horizontal) to145 N·m (107 ft. lbs.)(9) Torque e

ENGINE ASSEMBLYREMOVAL(1) Disconnect the battery.(2) Remove the air cleaner assembly and inlethose.(3) Remove both hoses at intercooler and engine.(4)

(24) Remove fuel line at injector pump and cap.(25) Remove power steering reservoir and reposi-tion.(26) Remove upper radiator crossmember.(27) Discon

(5) Connect battery cable.ROCKER ARMS AND PUSH RODSREMOVAL(1) Disconnect the battery cables.(2) Remove generator bracket.(3) Remove breather hose.(4)

CYLINDER HEADREMOVAL(1) Disconnect the battery cable.WARNING: DO NOT REMOVE THE CYLINDERBLOCK DRAIN PLUGS OR LOOSEN THE RADIATORDRAIN COCK WITH THE SY

(20) Remove Crankcase breather hose from valvecover(21) Remove the engine cylinder head cover.(22) Remove the injector sensor wire at the con-nector,

(30) Remove the engine cylinder heads and gasket.NOTE: A single steel head gasket is used for 4 cyl-inder heads (Fig. 33).(31) Stuff clean lint free s

(5) Tighten the engine cylinder head bolts insequence according to the following procedure (Fig.34):a. The threads and underside heads of the boltssho

(21) Connect crankcase breather hose.(22) Connect the injector sensor wire connector,and the glow plug connectors.(23) Install oil feed line, tighten

CAUTION: The plunger and tappet bodies are notinterchangeable. The plunger and valve mustalways be fitted to the original body. It is advisableto work

Type ...425CLIEE (36B)Injection Pump ...Rotary PumpElectronically Controlled.Lubrication ...Pressure Lub

TIMING CHAIN COVERREMOVAL(1) Disconnect the battery cable.(2) Raise vehicle on hoist.(3) Remove right splash shield.(4) Remove accessary drive belts.

(5) Remove crankshaft vibration damper. Refer toremoval procedure outlined in this section.(6) Remove power steering/air conditioning pulleynut. Remov

(15) Remove timing chain.INSTALLATION(1) Install timing chain. Starting at the crankshaftalign the dark link on the chain to the timing markon the cra

(7) Install timing chain cover. Refer to installationprocedure outlined in this section.(8) Install pump shaft support bracket assembly.Tighten nuts t

(3) Align notch in sprocket with alignment pin incrankshaft.(4) Using crankshaft sprocket installer VM.1029press on the new sprocket.(5) Remove alignm

(10) Install Vibration damper.(11) Reinstall Engine.CAMSHAFT BEARINGSThis procedure requires that the engine is removedfrom the vehicle.REMOVAL(1) Wit

(1) Thoroughly clean crankcase and oil passages,and blow dry with compressed air.(2) Install new main bearing shells in each of thecarrier halves. Ass

(9) Install adaptor plate and tighten bolts to 47N·m (35 ft. lbs.).(10) Install bolts to main bearing carrier andtighten to 26.5 N·m (20 ft. lbs.).(11

CAUTION: The vacuum pump must be centered inthe block and tighten with two bolts. Ensure thatthe pump spins freely. If vacuum pump drags ordoes not sp

INSTALLATION(1) Install new O-ring and lubricate with cleanengine oil.(2) Install oil pump and tighten retaining screwsto 27.5 N·m (240 in. lbs.).(3)

DIAGNOSIS AND TESTINGENGINE DIAGNOSIS—PERFORMANCECONDITION POSSIBLE CAUSES CORRECTIONENGINE WILL NOT CRANK ORCRANKS SLOWLY1. Starting motor operating,

(6) Remove vibration damper.(7) Remove power steering/air conditioning pulleynut. Remove pulley.CAUTION: Remove old thread sealant from threadson pump

(13) Remove hydraulic tensioner blade (Fig. 69).(14) Remove hydraulic tensioner oil feed line (Fig.70).(15) Remove hydraulic tensioner.(16) Remove tim

the camshaft sprocket. Third align the final dark linkon the chain to the timing mark on the injectionpump sprocket. Last install the chain around the

(10) Install power steering/air conditioning pulley.Tighten nut to 170 N·m (125 ft. lbs.).CAUTION: Correct torque on the crankshaft vibra-tion damper

cylinder bore. Check gap with feeler gauge (Fig. 77).Top compression ring gap .25 to .50 mm (.0098 to.0196 in.). Second compression ring gap .25 to .3

rod big end should also face in the same direction. Toinsert piston into cylinder, use a ring compressor asshown in (Fig. 81).PISTON PIN—INSTALLATION(

(5) Then select the correct shim thickness to giveproper protrusion (0.01 - 0.06 mm).(6) Fit the shim and the O-rings onto the liner.(7) Lubricate the

CLEANING AND INSPECTIONCYLINDER HEAD COVERSRemove any original sealer from the cover sealingsurface of the engine cylinder head.Remove all residue fro

Check to ensure that no coolant or foreign materialhas fallen into the tappet bore area.Remove the carbon deposits from the combustionchambers and top

INSPECTIONUse a straightedge and feeler gauge to check theflatness of the engine cylinder head and block matingsurfaces (Fig. 88).Minimum cylinder hea

CONDITION POSSIBLE CAUSES CORRECTIONLUBRICATING OIL PRESSURELOW1. Low oil level. 1a. Check and fill with clean engine oil.1b. Check for severe externa

HYDRAULIC TAPPETS(1) Clean all tappet parts in a solvent that willremove all varnish and carbon.(2) Replace tappets that are unfit for further ser-vic

Note: When changing connecting rods, all fourmust have the same weight and be stamped with thesame number. Replacement connecting rods willonly be sup

(2) Check internal diameter of bearings.(3) If internal diameter of original bearing is beingchecked and figures are not within specifications,new bea

DESCRIPTION SPECIFICATIONSProtrusion ...0.01–0.06 mmAdjustment ...ShimsAvailable Shims: ...0.15

DESCRIPTION TORQUECamshaft Locating PlateBolt ...11N·m(96in.lbs.)Camshaft SprocketBolt ...19.6 N·m + 60° (170 in. lbs. + 60°)C

DESCRIPTION TORQUETurbocharger Oil DeliveryBolt ...27.5 N·m (240 in. lbs.)Turbocharger Oil DrainBolts ...10.8 N·m (95 in

Crankshaft Remover/Installer Sleeve VM.1004Torque Angle Gauge VM.1005Cylinder Head Bolt Wrench VM.1006ACylinder Head Guide Studs VM.1009Cylinder Liner

Dial Indicator Gauge VM.1013Flywheel Locking Tool VM.1014Timing Cover Oil Seal Installer VM.1015Cylinder Retainers VM.1016Cylinder Head Bolt Wrench M1

Adapter Oil Filter VM.1020Adapter Cylinder Leakage Tester VM.1021Support Brackets Engine Removal/InstallationVM.1026Camshaft Locating Plate Alignment

Locating Pin Crankshaft Sprocket VM.1030Camshaft Sprocket Locking Tool VM.1031Injection Pump Sprocket Locking Tool VM.10329 - 84 ENGINE NS/GSSPECIAL T

oil level, check dipstick. The oil level in the panshould never be above the FULL mark or below theADD OIL mark on dipstick. Either of these 2 condi-t

Run engine until achieving normal operating tem-perature.(1) Position the vehicle on a level surface and turnengine off.(2) Remove oil fill cap.(3) Ho

the second dark link on the chain with the timingmark on the camshaft sprocket. Third Align the finaldark link on the chain to the timing mark on thei

FITTING PISTON RING(1) Wipe cylinder bore clean. Insert ring and pushdown with piston to ensure it is square in bore. Thering gap measurement must be

(4) Subtract specified crankshaft end float fromfigure obtained. Crankshaft end float 0.08 to0.21mm.(5) Select thrust washer which will give correcten