check engine MERCEDES-BENZ SPRINTER 2005 Service Service Manual

DESCRIPTION SPECIFICATION
Engine 2.7L CDI
Engine Description 5 Cylinder In-Line Engine
With 4-Valve Technology
Air Intake Turbo-Charged Engine
with Charge Air Cooling
Fuel Injection System Common Rail Diesel
Injection (CDI)
Fuel Diesel
Firing Order 1-2-4-5-3
Rated Output 125/4200 kW at RPM
Torque 400/1600-2400 Nm at
RPM
Maximum Speed 4800 RPM
Compression Ratio 19:1
Bore/Stroke 88.0/88.4 mm
Eff. Displacement 2688 cm3
STANDARD PROCEDURE
STANDARD PROCEDURE - COMPRESSION
TESTING ENGINE
(1) Warm up engine to operating temperature
(approx. 80 ÉC, 176ÉF).
(2) Shut off engine.
(3) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(4) Remove glow plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - REMOVAL).
(5) Crank engine several times with the starter to
eliminate combustion residues in the cylinders.
(6) Insert compression tester adapter #8927 (Refer
to 9 - ENGINE - SPECIAL TOOLS) with check valve
installed into glow plug hole of cylinder to be tested.
(7) Connect compression tester hose adapter #9295
to compression gauge and test compression pressure
by cranking engine with starter for at least 8 revolu-
tions.
(8) Carry out test procedure at the remaining cyl-
inders in the same way.
(9) Compare pressure readings obtained with the
specified pressures. If the pressure reading is below
the minimum compression pressure or if the permis-
sible difference between the individual cylinders is
exceeded. Refer to cylinder leak down test.
(10) Remove compression tester and adapter from
cylinder head.
(11)
Install glow plugs (Refer to 8 - ELECTRICAL/IG-
NITION CONTROL/GLOW PLUG - INSTALLATION).
(12) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
COMPRESSION SPECIFICATIONS
Maximum Compression 29-35 bar (420-507 psi)
Minimum Compression 18bar (261 psi)
Permissible Difference
Between Cylinders  3bar (  44 psi)
STANDARD PROCEDURE - CYLINDER LEAK
DOWN TEST
(1) Warm engine to operating temperature.
WARNING: DO NOT OPEN COOLING SYSTEM UNLESS
COOLANT TEMPERATURE IS BELOW 90C (194ÉF).
RISK OF INJURY TO SKIN AND EYES AS A RESULT OF
SCALDING WITH HOT COOLANT WHICH SPLASHES
OUT. RISK OF POISONING FROM SWALLOWING
COOLANT. OPEN CAP SLOWLY AND RELEASE PRES-
SURE. STORE COOLANT IN PROPER CONTAINERS
ONLY. WEAR PROTECTIVE GLOVES, CLOTHING AND
EYE PROTECTION.
NOTE: Turn cap carefully as far as first detent,
release pressure, then unscrew cap.
(2) Open cooling system cap at coolant recover
pressure container.
(3) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(4) Unscrew oil filler cap.
(5) Remove glow plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - REMOVAL).
NOTE: Crank engine at crankshaft in direction of
rotation of the engine (clockwise).
(6) Position cylinder to be tested to ignition Top
Dead Center (DTC).
NOTE: Calibrate cylinder leak down tester and
remove check valve in screw-in fitting.
(7) Connect cylinder leak down tester and follow
INSPECTING Instruction.
INSPECTING
NOTE: If crankshaft rotates, install retaining lock for
crankshaft/ring gear.
(1) Pressurize cylinder with compressed air and
read off pressure loss at cylinder leak tester. If exces-
sive pressure loss exists, determine possible cause
(Refer to 9 - ENGINE - STANDARD PROCEDURE).
NOTE: If the retaining lock is installed, remove it,
rotate engine and install lock once again.
(2) Carry out test of other cylinders in the firing
order of engine.
VAENGINE 9 - 3
ENGINE (Continued)

CYLINDER LEAK DOWN VALUES
CYLINDER LEAK DOWN
PERMISSIBLE TOTAL
LOSS  25%
CYLINDER LEAK DOWN
PERMISSIBLE LOSS AT
VALVES AND CYLINDER
HEAD  10%
CYLINDER LEAK DOWN
PERMISSIBLE LOSS AT
PISTON AND RINGS  20%
STANDARD PROCEDURE - DETERMINING
CYLINDER PRESSURE LOSS
If an increased pressure loss was found with the
cylinder leak test, inspect the engine by listening at
the cylinder head gasket, air intake area, exhaust, oil
fill opening and where injectors and glow plugs enter
the cylinder head. Also check the engine coolant in
the radiator or expansion reservoir for the formation
of bubbles.
Possible causes for the pressure loss are:
POSSIBLE CAUSE FOR PRESSURE LOSS
CONDITION POSSIBLE
CAUSESCORRECTION
AIR LOSS
THROUGH
GLOW PLUG,
INJECTOR,
ADJACENT
CYLINDERS,
OR AIR
BUBBLES IN
COOLANT1. Sealing
SurfacesRepair Sealing
Surfaces
2. Gaskets 2. Replace
Component or
Gasket
3. Cylinder
Head Gasket3. Replace
Cylinder Head
Gasket
AIR LOSS
THROUGH AIR
INTAKE AREA1. Sealing
Surfaces1. Remove
Cylinder Head
for Further
Inspection
2. Intake Valves
and Seats2. Replace
Valves, Guides
or Seats
CONDITION POSSIBLE
CAUSESCORRECTION
AIR LOSS
THROUGH
EXHAUSTSealing
SurfacesRemove
Cylinder Head
for Further
Inspection
2. Exhaust
Valves and
Seats2. Replace
Valves, Guides
or Seats
AIR LOSS
THROUGH OIL
FILL OPENING1. Sealing
SurfacesRemove Engine
for Further
Inspection
2. Pistons,
Piston Rings2. Replace
Pistons or
Piston Rings
It is possible to pin point the pressure loss of the
relevant cylinder by spraying with clean engine oil.
Engine oil seals off the gap between the piston and
cylinder wall briefly. If a reduced pressure loss now
occurs for a short time, the cause is very likely to be
the pistons, piston rings or cylinder contact surfaces
of the relevant cylinder.
Determining the cause can be falsified by the posi-
tion of the piston ring joints. If suspicion exists that
the loss of pressure is caused by the piston ring
joints being positioned directly one above the other,
fit the parts to the engine and repeat this test after
running the engine for a short time.
REMOVAL
REMOVAL - ENGINE COVER
(1) Remove the retaining screws and remove cover
(Fig. 2).
REMOVAL
WARNING: RISK OF INJURY TO SKIN AND EYES
FROM SCALDING WITH HOT COOLANT. RISK OF
POISONING FROM SWALLOWING COOLANT. DO
NOT OPEN COOLING SYSTEM UNLESS COOLANT
TEMPERATURE IS BELOW 90ÉC (194ÉF). OPEN CAP
SLOWLY TO RELEASE PRESSURE. STORE COOL-
ANT IN SUITABLE AND APPROPRIATELY MARKED
CONTAINER. WEAR PROTECTIVE GLOVES,
CLOTHES, AND EYE WEAR.
CAUTION: STORE OR DISCARD ALL FLUIDS IN
SUITABLE AND APPROPRIATELY MARKED CON-
TAINERS.
(1) Disconnect the negative battery cable.
9 - 4 ENGINEVA
ENGINE (Continued)

(11) Install the transmission cooler lines to trans-
mission.(Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - NAG1 - INSTALLATION) for
correct sequence and torque specification.
(12) Install transmission electrical connector and
shifter hardware.Refer to (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/AUTOMATIC - NAG1 - INSTAL-
LATION) for correct sequence and torque
specification.
(13) Install the steering gear and tighten in two
stages. 25 N´m (18.5 lbs. ft.), then 45 N´m (33 lbs. ft.)
plus 90É.
(14) Install the crank sensor.
(15) Install the starter.
(16) Connect the ground strap (left side).
(17) Align and install the exhaust and bracket
(Refer to 11 - EXHAUST SYSTEM/EXHAUST PIPE -
INSTALLATION).
(18) Lower the vehicle.
(19) Install the air inlet hose at the turbocharger
(Fig. 3).
(20) Connect the vacuum hose at the turbocharger
(Fig. 3).
(21) Connect the coolant supply and return hoses
(Fig. 3).(22) Connect the brake booster vacuum hose at the
vacuum pump (Fig. 3).
(23) Connect the refrigerant lines (Fig. 3).
(24) Connect the fuel lines at the filter assembly
(Fig. 3).
(25) Connect the power steering hoses (Fig. 3).
(26) Install the radiator/charge air cooler and
hose(s) assemblies (Refer to 7 - COOLING/ENGINE/
RADIATOR - INSTALLATION).
(27) Install A/C condenser.
(28) Install air cleaner housing, sensors, and hoses
(Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR
CLEANER HOUSING - INSTALLATION).
(29) Route the engine wiring harness inside the
vehicle and connect.
(30) Install the front grill assembly.
(31) Install and align the hood.
(32) Connect the negative battery cable.
(33) Check and fill engine oil.
(34) Fill cooling system to proper level with the
appropriate coolant.
(35) Evacuate and recharge air conditioning.
(36) Check and refill all ancillary system fluid lev-
els.
(37) Start engine and inspect for leaks.
SPECIFICATIONS - TORQUE SPECIFICATIONS
2.7L DIESEL
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Crankcase Ventilation
Screw-Air Charge
Distribution Pipe to Air
Charge Distribution Panel11 - 9 7
Cylinder Head
8m-Bolt- Cylinder Head to
Timing Case Cover20 15 -
Bolt-Front Cover to
Cylinder Head14 - 124
12m-Bolt-Cylinder Head to
Crankcase (3 stages,
torque, torque angle,
torque angle)60, 90É, 90É 44 -
Crankcase, Timing Case
Cover, End Cover
Bolt-Crankshaft Bearing
Cap to Crankcase (2
stages, torque, torque
angle)55, 90É 40 -
Bolt-End Cover to
Crankcase9-80
9 - 8 ENGINEVA
ENGINE (Continued)

(5) Carefully raise locking pawl of top slide rail
and remove front cover at cylinder head (Fig. 15).
(6) Insert a locking pin through 1st camshaft bear-
ing cap into the hole in the inlet camshaft sprocket.
(7) Counter hold the camshaft with an open end
wrench to avoid damage and unbolt driver of inlet
camshaft sprocket.
(8) Remove top guide rail.
INSTALLATION
INSTALLATION - CYLINDER HEAD
WARNING: (Refer to 14 - FUEL SYSTEM - WARN-
ING)
NOTE: Thoroughly clean all mating surfaces with
appropriate solvents and blow out bolt holes, to
assure that no grease or oil is present during reas-
sembly.
NOTE: If piston or connecting rods have been
replaced, measure piston protrusion.
NOTE: Check facing cylinder head contact surface.
(1) Position the cylinder head and gasket properly
on engine using the dowel pins as guide (Fig. 14).
NOTE: Inspect all cylinder head bolts for defects
and stretching before installation (Refer to 9 -
ENGINE/CYLINDER HEAD - STANDARD PROCE-
DURE).
CYLINDER HEAD BOLT TORQUE SEQUENCE
The M12 cylinder head bolts must be torqued
in 3 stages.
(1) Install M12 cylinder head bolts finger tight
(Fig. 14).
(2) Torque bolts in numeric order starting with
number 1 to 60 N´m (44 lbs.in.) (Fig. 16).
(3) Install M8 timing chain cover to cylinder head
bolts. Tighten to 20N´m (177 lbs.in.).
(4) Tighten M12 cylinder head bolts in numeric
order starting with number 1 an additional 90É (Fig.
16).
(5) Tighten M12 cylinder head bolts in numeric
order starting with number 1 an additional 90É again
(3 stages). (Fig. 16).
(2) Install fuel return flow line between rail and
high pressure pump (Fig. 13).
(3) Connect the coolant hoses to the thermostat
housing (Fig. 13).(4) Connect the coolant pipe at the cylinder head
(Fig. 13).
(5) Reconnect transmission oil dip stick tube.
Tighten to 14 N´m (124 lbs. in.) (Fig. 13).
(6) Reconnect the turbocharger to the exhaust
manifold. Tighten to 30N´m (22 lbs.ft.) (Fig. 13).
(7) Install oil return flow line with new seals at
turbocharger. Tighten bolt of supply line to turbo-
charger to 18N´m (160 lbs. in.) and bolt of supply line
to cylinder head to 9N´m (80 lbs. in.) (Fig. 13)
(8) Install charge air distribution pipe (Refer to 11
- EXHAUST SYSTEM/TURBOCHARGER SYSTEM -
INSTALLATION).
(9) Install and properly route the engine wiring
harness, making appropriate connections.
(10) Install high pressure fuel pump intermediate
gear (Fig. 13).
(11) Install high pressure pump (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - INSTALLATION).
(12) Install the camshaft housing to cylinder head
(Fig. 13).
(13) Install the tappets (Fig. 13).
(14) Install camshafts (Refer to 9 - ENGINE/CYL-
INDER HEAD/CAMSHAFT(S) - INSTALLATION).
(15) Install top guide rail (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION).
(16) Install front cover at cylinder head (Refer to 9
- ENGINE/CYLINDER HEAD - INSTALLATION).
(17) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(18) Install fuel high pressure pipes and injectors
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
FUEL INJECTOR - INSTALLATION).
(19) Install timing chain tensioner with new gas-
ket. (Refer to 9 - ENGINE/VALVE TIMING/TIMING
Fig. 16 CYLINDER HEAD BOLT TORQUE
SEQUENCE
VAENGINE 9 - 25
CYLINDER HEAD (Continued)

(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) Remove camshaft sprocket locking pin.
(4) Carefully raise locking pawl of top guide rail
and install front cover at cylinder head.
(5) Install timing chain tensioner with new gasket
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLA-
TION).
(6) Install engine cover (Refer to 9 - ENGINE/
CYLINDER HEAD/CYLINDER HEAD COVER(S) -
INSTALLATION).
(7) Reconnect negative battery cable.
WARNING: US 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.
(8) Start engine and inspect for leaks.
CAMSHAFT(S)
STANDARD PROCEDURE - CHECKING
CAMSHAFT POSITION
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE
COVER - REMOVAL).
WARNING: (Refer to 14 - FUEL SYSTEM - WARN-
ING)
(3) Remove injectors (Refer to 14 - FUEL SYS-
TEM/FUEL INJECTION/FUEL INJECTOR -
REMOVAL).
(4) Clean injectors and recesses(Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - STANDARD PROCEDURE).
(5) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
NOTE: Rotate engine at crankshaft only. DO NOT
crank engine at the camshaft and DO NOT rotate
the engine backward.
(6) Position piston of cylinder #1 to ignition TDC.
(7) Insert the locking pin (special tool #8929)
through first camshaft bearing cap into the hole in
the left inlet camshaft sprocket (Fig. 18).
NOTE: The two markings in the inlet camshaft
sprockets must be positioned opposite and mark-ings of camshaft and camshaft bearing cap must be
aligned. If not, perform basic position of camshafts.
(8) Remove locking pin from camshaft bearing cap
hole.
(9) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(10) Install injectors (Refer to 14 - FUEL SYS-
TEM/FUEL INJECTION/FUEL INJECTOR -
INSTALLATION).
Fig. 18 CHECKING CAMSHAFT POSITION
1 - CAMSHAFT SPROCKET ALIGNMENT DOTS
2 - CAMSHAFT LOCK POSITION
3 - INTAKE CAMSHAFT SPROCKET
4 - CAMSHAFT AND BEARING CAP ALIGNMENT MARKS
5 - CAMSHAFT LOCKING PIN (SPECIAL TOOL #8929)
6 - INTAKE CAMSHAFT SPROCKET
VAENGINE 9 - 27
CYLINDER HEAD (Continued)

(10) Position piston of #1 cylinder to ignition TDC.
(11) Install camshafts and check basic position
(Refer to 9 - ENGINE/CYLINDER HEAD/CAM-
SHAFT(S) - INSTALLATION).
(12) Install top guide rail (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
(13) Install front cover at cylinder head (Refer to 9
- ENGINE/CYLINDER HEAD - INSTALLATION).
(14) Install timing chain tensioner with new gas-
ket (Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLATION)
(15) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(16) Install glow plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - INSTALLA-
TION).
WARNING: SERVICE VEHICLES IN A WELL VENTI-
LATED AREA AND AVOID IGNITION SORCES. RISK
OF INJURY TO SKIN AND EYES FROM FUEL JET
FLOWING OUT.
(17) Install injectors (Refer to 14 - FUEL SYS-
TEM/FUEL INJECTION/FUEL INJECTOR -
INSTALLATION).
(18) Reconnect negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN ADIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(19) Start the engine and inspect for leaks.Care
must be taken to observe the fuel system warning
(Refer to 14 - FUEL SYSTEM - WARNING)
(20) Install engine cover (Refer to 9 - ENGINE
COVER - INSTALLATION).
INSTALLATION - VALVES
WARNING: Valves must be kept in their original
positions in cylinder head. Failure to do so will
result in engine damage.
NOTE: Inspect all valves, springs and retainers for
wear or damage. Replace as necessary.
(1) Install valves in their original position in the
cylinder head.
(2) Install lower valve spring retainer.
(3) Install valve stem seal.
(4) Install valve spring.
(5) Install valve spring retainer.
NOTE: Using tool, screw retaining fork into
threaded edge of cylinder head and position thrust
piece vertically at the top of each valve spring
retainer.
NOTE: Ensure that the valve keepers are seated
properly.
(6) Using a suitable valve spring compressor, com-
press valve spring and install valve keepers.
(7) Repeat steps 3 through 7 for each valve as nec-
essary.
(8) Remove valve assembly from cylinder head.
(9) Install cylinder head on engine block (Refer to
9 - ENGINE/CYLINDER HEAD - INSTALLATION).
(10) Install glow plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - INSTALLA-
TION).
(11) Connect negative battery cable.
WARNING: US EXTREME CAUTION WHEN THE
ENGINE IS IN OPERATION. 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.
(12) Start engine and check for leaks. Care must
be taken to observe the fuel system warning (Refer to
14 - FUEL SYSTEM - WARNING)
(13) Install engine cover (Refer to 9 - ENGINE
COVER - INSTALLATION).
Fig. 25 VALVE SEAL INSTALLATION
1 - DRIFT
2 - PROTECTIVE COVER
3 - VALVE
VAENGINE 9 - 33
VALVE SPRINGS (Continued)

CAUTION: The crankshaft bearing caps are num-
bered consecutively, beginning with the first crank-
shaft bearing cap at the front of the engine.
Attention must be paid to the way crankshaft bear-
ing caps fit.
(5) Unbolt crankshaft bearing caps (Fig. 28).
(6) Inspect crankshaft bearing caps and bolts for
wear and stretching.
(7) Remove crankshaft.
INSTALLATION
CAUTION: Oil the bearing shells before inserting
crankshaft.CAUTION: Oil grooves in the thrust washers must
point toward the thrust collars of the crankshaft.
CAUTION: Thrust washers in the bearing cap each
have two retaining lugs as a anti-twist lock.
CAUTION: Oil thread and head contact surfaces of
bolts that retain the crankshaft bearing caps;
tighten bolts from inside to outside, beginning at
the fit bearing. Rotate crankshaft to check clear-
ance.
(1) Install crankshaft.
CAUTION: The crankshaft bearing caps are num-
bered consecutively, beginning with the first crank-
shaft bearing cap at the front of the engine.
Attention must be paid to the way the crankshaft
bearing caps fit.
(2) Install the crankshaft bearing caps. Tighten
bolts in two stages. 55N´m (40.5 lbs. ft.), then 90É.
(3) Install the pistons (Refer to 9 - ENGINE/EN-
GINE BLOCK/PISTON & CONNECTING ROD -
INSTALLATION).
(4) Install the end cover (Refer to 9 - ENGINE/EN-
GINE BLOCK/CRANKSHAFT OIL SEAL - REAR -
INSTALLATION).
(5) Install the timing case cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(6) Install the engine (Refer to 9 - ENGINE -
INSTALLATION).
(7) Fill the crankcase with the correct engine oil,
to the proper level. Refer to the owners manual for
specifications.
(8) Fill the cooling system with the proper coolant,
to the proper level (Refer to 7 - COOLING/ENGINE/
COOLANT - STANDARD PROCEDURE).
(9) Connect the negative battery 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 CLOTHES.
(10) Start engine and inspect for leaks. Care must
be taken to observe the fuel system warning (Refer to
14 - FUEL SYSTEM - WARNING).
Fig. 28 CRANKSHAFT ASSEMBLY
1 - BEARING HALVES IN ENGINE BLOCK
2 - THRUST WASHERS IN ENGINE BLOCK
3 - CRANKSHAFT
4 - BEARING HALVES IN MAIN BEARING CAPS
5 - MAIN BEARING CAPS
6 - THRUST WASHERS IN MAIN BEARING CAPS
7 - MAIN BEARING BOLTS
9 - 36 ENGINEVA
CRANKSHAFT (Continued)

PISTON & CONNECTING ROD
DESCRIPTION
The pistons are of a free floating design. Oil jets in
the engine block lubricate and cool the piston and pin
assembly. The connecting rods have a pressed in
place wrist pin bushing which is lubricated by the oil
jets (Fig. 33).
STANDARD PROCEDURE
STANDARD PROCEDURE - CHECKING AND
REPAIRING CONNECTING RODS
NOTE: Connecting rods with blue discoloration,
cross scores or notches must be replaced. Com-
pensate for different weights by milling off the bal-
ancing weight.
(1) Inspect connecting rod for discoloring, cross
scores and notches.NOTE: Connecting rod and bearing cap are marked
in sets and attached with two sleeves.
(2) Bolt connecting rod bearing cap to connecting
rod. Tighten connecting rod bearing caps to initial
specification (Refer to 9 - ENGINE/ENGINE BLOCK/
PISTON & CONNECTING ROD - INSTALLATION).
NOTE: If the maximum permissible diameter is
exceeded, grind off contact surface of connecting
rod bearing cap by a Maximum of 0.02mm.
(3) Using a dial indicator, measure connecting rod
bearing basic bore, repair as necessary (Fig. 34).
NOTE: If excessive wear is present, press in new
connecting rod bushings.
(4) Measure connecting rod bushing inner diame-
ter (Fig. 34).
(5) Inspect wristpin bushing.
(6) Measure piston pin end play in connecting rod
bushing.
Fig. 32 CRANKSHAFT LOCK #8932
1 - RETAINING BOLTS 3 - CRANKSHAFT LOCK #8932
2 - INSPECTION COVER 4 - RETAINING BOLTS
9 - 40 ENGINEVA
FLYWHEEL (Continued)

CAUTION: Assemble the piston and connecting rod
so that the arrow is pointing in the direction of
travel (in the opposite direction of power flow). The
marking on the connecting rod is pointing toward
the inlet side.
(3) Assemble piston and connecting rod (Fig. 37).
(4) Insert piston pin by hand (Fig. 37).
CAUTION: Care must be taken not to damage the
piston.
(5) Insert circle clip of piston pin into groove on
piston (Fig. 37).
(6) Using the appropriate clean engine oil, clean
the cylinder bores, connecting rod bearing journals,
connecting rod bearing shells and pistons.
CAUTION: Offset the piston ring gaps by 120É.
(7) Position a ring compressor over piston and
rings. Tighten ring compressor (Fig. 38).Ensure that
ring position does not change during this oper-
ation.
CAUTION: Rotate the crankshaft sufficiently so that
the connecting rod does not touch the connectingrod journal when the piston is pushed onto the cyl-
inder bore.
(8) Install piston with arrow pointing in the direc-
tion of travel (in the opposite direction to power flow)
(the marking on the connecting rod should be point-
ing toward the inlet side). (Fig. 38).
(9) Clean and inspect the connecting rod bolts.
CAUTION: Assure that the correct top and bottom
connecting rod bearings shells are used in accor-
dance with the markings.
CAUTION: The anti-twist locks of the connecting
rod bearing shells must be located in the slots of
the connecting rod bearing caps.
(10) Insert connecting rod bearing shell into con-
necting rod bearing cap.
CAUTION: The markings on the connecting rod and
connecting rod cap must be lined up.
(11) Install connecting rod bearing cap. Tighten
bolts in 3 stages, 5N´m (44 lbs in), 25N´m (221 lbs
in), 90É.
(12) Rotate crankshaft fully and check the clear-
ance.
(13) Install oil pump (Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - INSTALLATION).
(14) Install engine oil pan and oil pan drain plug
(Refer to 9 - ENGINE/LUBRICATION/OIL PAN -
INSTALLATION).
CAUTION: Install a cylinder head gasket of standard
thickness or a cylinder head gasket of repair thick-
ness depending on piston protrusion.
(15) Measure piston protrusion (Refer to 9 -
ENGINE/ENGINE BLOCK - STANDARD PROCE-
DURE).
(16) Install cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
(17) Install engine (Refer to 9 - ENGINE -
INSTALLATION).
(18) Fill the crankcase with correct engine oil, to
proper level. Refer to owners manual for specifica-
tions.
(19) Fill the cooing system with proper coolant, to
the proper level (Refer to 7 - COOLING/ENGINE/
COOLANT - STANDARD PROCEDURE).
(20) Connect negative battery 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 CLOTHES.
Fig. 37 PISTON AND CONNECTING ROD ASSEMBLY
1 - CIRCLE CLIP
2 - PISTON PIN
3 - PISTON ASSEMBLY
4 - CONNECTING ROD ALIGNMENT MARKINGS
5 - CONNECTING ROD BOLTS
6 - CONNECTING ROD CAP
7 - CONNECTING ROD
9 - 44 ENGINEVA
PISTON & CONNECTING ROD (Continued)

NOTE: If grooves can be felt in the belt pulley/vibra-
tion damper during inspection, the pulley/damper
must be replaced.
(6) Inspect hub at belt pulley/vibration damper for
wear grooves.
(7) Replace front crankshaft seal.
INSTALLATION
NOTE: Align parallel key, fix in place with grease.
Turn to ensure the slot is aligned with parallel key
in crankshaft.
NOTE: Front crankshaft seal must be replaced
before installing the belt pulley/vibration damper.
(1) Position the belt pulley/vibration damper.
(2) Install crankshaft center bolt and washer.
Tighten bolt in two stages. M8.8 bolt to 200N´m (148
lbs. ft.) then 90É, M10.9 bolt to 325N´m (240 lbs. ft.)
then 90É.
(3) Remove the retaining lock for the crankshaft/
ring gear (Fig. 43).
NOTE: Inspect accessory drive belt for wear.
Replace as necessary.
(4) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(5) Reconnect negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS IN OPERATION. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(6) Start vehicle and inspect for leaks.
VACUUM PUMP
DESCRIPTION
The vacuum pump is operated by a slotted exten-
sion attached to the vacuum pump shaft. The vac-
uum pump shaft slotted extension fits into, and is
driven by, the exhaust camshaft gear.
The vacuum pump is a constant displacement,
vane-type pump. Vacuum is generated by vanes
mounted in the pump rotor. The rotor is located in
the pump housing and is pressed onto the pump
shaft.
The vacuum pump rotating components are inter-
nally lubricated.The vacuum pump is not serviceable and must be
replaced as a unit. Do not disassemble or attempt to
repair the pump.
OPERATION
Vacuum pump output is transmitted to the Heater,
Electronic, Vacuum, Air Conditioner (HEVAC) and
speed control, systems through a supply hose. The
hose is connected to an outlet port on the pump hous-
ing and uses an in-line check valve to retain system
vacuum when vehicle is not running.
Pump output ranges from a minimum of 8.5 to 25
inches vacuum.
The pump rotor and vanes are rotated by the pump
drive gear. The drive gear is operated by the exhaust
camshaft gear.
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove vacuum line at vacuum pump (Fig.
44).
NOTE: Observe position of driver on rear of pump.
(3) Remove vacuum pump and seals (Fig. 44)
(4) Clean all sealing surfaces.
Fig. 44 VACUUM PUMP
1 - VACUUM PUMP
2 - VACUUM LINE
3 - O-RING
4 - O-RING
5 - EXHAUST CAMSHAFT
6 - BOLTS
9 - 48 ENGINEVA
VIBRATION DAMPER (Continued)