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Daewoo KORANDO Service Manual

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Table of Contents

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SERVICE
MANUAL
KORANDO
FOREWORD
This manual includes procedure for mainte-
nance, adjustment, service operation and re-
moval and installation of components.
All information, illustrations and specifications
contained in this manual are based on the latest
product information available at the time of
manual approval.
The right is reserved to make changes at any
time without notice.
DAEWOO MOTOR CO., LTD.
INCHON, KOREA
SECTION INDEX
FRONT MATTER
GENERAL INFORMATION
ENGINE
SUSPENSION
DRIVE LINE/AXLE
BRAKES
TRANSMISSION
STEERING
HVAC
(HEATING, VENTILATION,
AND AIR CONDITIONING)
RESTRAINTS
BODY AND ACCESSORIES
0A
0B
1
2
3
4
5
6
7
8
9

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Summary of Contents for Daewoo KORANDO

  • Page 1 STEERING The right is reserved to make changes at any time without notice. HVAC (HEATING, VENTILATION, AND AIR CONDITIONING) DAEWOO MOTOR CO., LTD. RESTRAINTS INCHON, KOREA BODY AND ACCESSORIES...
  • Page 2 PERSONAL INJURY CAUTION Appropriate service methods and proper repair procedure are essential for the safe, reliable operation of all motor vehicles, as well as for the personal safety of the person doing the repair. There are many variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skills of the people doing the work.
  • Page 3 No part of this publication may be reproduced, stored in any retrieval system or transmitted, in any form or by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Daewoo Motor Company, Lim- ited...
  • Page 4 TABLE OF CONTENTS Section 0A Front Matter Section 5 Transmission Section 5A Automatic Transmission Section 0B General Information Section 5B Manual Transmission Section 5C Clutch Section 1 Engine Section 5D1 Transfer Case (Part Time 4480) Section 1A1 M162 General Engine Information Section 5D2 Transfer Case (TOD) Section 1B1...
  • Page 5 KORANDO SERVICE MANUAL ISSUED BY OVERSEAS TECH. SERVICE DAEWOO MOTOR CO., LTD. 391-9 CHONG CHON-2DONG, PU PYUNG-GU, INCHON, KOREA TELEPHONE : 82-32-509-4161~4164 FACSIMILE : 82-32-509-4160...
  • Page 6 ENGINE CONTENTS SECTION 1A1 M162 GENERAL ENGINE INFORMATION SECTION 1B1 M162 ENGINE MECHANICAL SECTION 1D1 M162 ENGINE COOLING SECTION 1E1 M162 ENGINE ELECTRICAL SECTION 1F1 M162 ENGINE CONTROLS SECTION 1G1 M162 ENGINE INTAKE & EXHAUST SECTION 1A2 M161 GENERAL ENGINE INFORMATION SECTION 1B2 M161 ENGINE MECHANICAL SECTION 1D2 M161...
  • Page 7 SUSPENSION CONTENTS SECTION 2A SUSPENSION DIAGNOSIS SECTION 2B WHEEL ALIGNMENT SECTION 2C FRONT SUSPENSION SECTION 2D REAR SUSPENSION SECTION 2E TIRES AND WHEELS...
  • Page 8 DRIVE LINE / AXLE CONTENTS SECTION 3A FRONT DRIVE AXLE SECTION 3C PROPELLER SHAFT SECTION 3D REAR DRIVE AXLE...
  • Page 9 BRAKE CONTENTS SECTION 4A HYDRAULIC BRAKES SECTION 4B MASTER CYLINDER SECTION 4C POWER BOOSTER SECTION 4D FRONT DISC BRAKES SECTION 4E REAR DISC BRAKES SECTION 4F ANTILOCK BRAKE SYSTEM SECTION 4G PARKING BRAKE...
  • Page 10 TRANSMISSION CONTENTS SECTION 5A AUTOMATIC TRANSMISSION SECTION 5B MANUAL TRANSMISSION SECTION 5C CLUTCH SECTION 5D1 TRANSFER CASE (PART TIME 4408) SECTION 5D2 TRANSFER CASE (TOD)
  • Page 11 STEERING CONTENTS SECTION 6A POWER STEERING SYSTEM SECTION 6E STEERING WHEEL AND COLUMN...
  • Page 12 HVAC (HEATING, VENTILATION & AIR CONDITIONING) CONTENTS SECTION 7B/C MANUAL CONTROL/SEMIAUTO TEMPERATURE CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM SECTION 7D FULL AUTOMATIC TEMPERATURE CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM...
  • Page 13 RESTRAINTS CONTENTS SECTION 8A SEAT BELTS SECTION 8B SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
  • Page 14 BODY AND ACCESSORIES CONTENTS SECTION 9A BODY WIRING SYSTEM SECTION 9B LIGHTING SYSTEM SECTION 9C HORNS SECTION 9D WIPERS/WASHER SYSTEM SECTION 9E INSTRUMENTATION/DRIVER INFORMATION SECTION 9F AUDIO SYSTEM SECTION 9G INTERIOR TRIM SECTION 9H SEATS SECTION 9L GLASS AND MIRRORS SECTION 9M EXTERIOR TRIM SECTION 9N FRAME AND UNDERBODY...

  • Page 15: Table Of Contents

    SECTION 0B GENERAL INFORMATION TABLE OF CONTENTS Specifications ......0B-1 While Operating the Vehicle ... . . 0B-12 At Each Fuel Fill .
  • Page 16 0B-2 GENERAL INFORMATION Engine Application 661LA 662NA 662LA 2.0L DOCH 2.3L DOCH 3.2L DOCH Engine Type 4Cylinder 5Cylinder 5Cylinder 4Cylinder 4Cylinder 6Cylinder DIESEL DIESEL DIESEL GASOLINE GASOLINE GASOLINE Bore (mm) 89.9 90.9 89.9 Stroke (mm) 92.4 92.4 92.4 78.7 88.4 Total Displacement (cc) 2299 2874...
  • Page 17 GENERAL INFORMATION 0B-3 Auto Transmission 662LA Application 2.3L DOHC 3.2L DOHC 661LA BTRA Maker BTRA BTRA BTRA M74 4WD Type or Model M74 4WD M74 4WD M74 4WD Gear Ratio : 1st 2.741 2.741 2.741 2.741 1.508 1.508 1.508 1.508 1.000 1.000 1.000...

  • Page 18: Specifications

    0B-4 GENERAL INFORMATION Suspension Application Specifications Front Type Double Wishbone Rear Type 5 - Link Fuel System Application Specifications Fuel Pump Type Electric Motor Pump Fuel Capacity 70 L Lubricating System Lubricating Type 661LA 662NA 662LA 2.0L DOHC 2.3L DOHC 3.2L DOHC External Gear pump Oil Pump Type...

  • Page 19: Vehicle Dimensions And Weights

    GENERAL INFORMATION 0B-5 VEHICLE DIMENSIONS AND WEIGHTS Vehicle Dimensions Application Application Overall Length (mm) 4330 Overall Width (mm) 1841 Overall Height (mm) 1840 Wheel Base (mm) 2840 Tread : Front (mm) 1510 Rear (mm) 1520 Vehicle Weights Application 661LA 662NA 662LA 2.0L DOHC 2.3L DOHC...

  • Page 20: Standard Bolts Specifications

    0B-6 GENERAL INFORMATION STANDARD BOLTS SPECIFICATIONS Torque (N·m / Ib-in) Bolt* Standard Limit 0.5 N· · · · · m 0.9 N· · · · · m M3 ´ 0.5 1.3 N· · · · · m 0.7 N· · · · · m 1.2 N·...

  • Page 21: Maintenance And Repair

    GENERAL INFORMATION 0B-7 MAINTENANCE AND REPAIR MAINTENANCE AND LUBRICATION NORMAL VEHICLE USE Fuel Filter Replacement Replace the engine fuel filter every. The maintenance instructions contained in the Gasoline Engine : 60,000km (36,000 miles) maintenance schedule are based on the assumption that the vehicle will be used for the following reasons: Diesel Engine : 45,000km (24,000 miles) To carry passengers and cargo within the limitation...

  • Page 22: Scheduled Maintenance Charts (Gasoline Engine)

    0B-8 GENERAL INFORMATION SCHEDULED MAINTENANCE CHARTS (GASOLINE ENGINE) Engine Kilometers or time in months, whichever comes first MAINTENANCE INTERVAL x1,000 km MAINTENANCE ITEM Months Drive belt Engine oil & filter (1) (3) Cooling system hose & connections Engine coolant Fuel filter Fuel line &...
  • Page 23 GENERAL INFORMATION 0B-9 Chassis and Body Kilometers or time in months, whichever comes first MAINTENANCE INTERVAL x1,000 km MAINTENANCE Months ITEM Exhaust pipes & mountings Brake/Clutch fluid (3)(4) Parking brake/Brake pads F & R Brake line & connections (including booster) Manual transmission oil Clutch &...

  • Page 24: Scheduled Maintenance Charts (Diesel Engine)

    0B-10 GENERAL INFORMATION SCHEDULED MAINTENANCE CHARTS (DIESEL ENGINE) Engine MAINTENANCE INTERVAL x1,000 km MAINTENANCE Months ITEM Drive belt Engine oil & fillter (1) (3) Cooling system hose & connections Engine coolant Fuel filter Fuel line & connections Glow plug Pre - fuel filter Air cleaner Ignition timing (see NOTE 1) NOTE 1 : Injection Timing :...
  • Page 25 GENERAL INFORMATION 0B-11 Chassis and Body MAINTENANCE INTERVAL Kilometers or time in months, whichever comes first x1,000 km MAINTENANCE Months ITEM Exhaust pipes & mountings Brake/clutch fluid (3) (4) Parking brake/Brake pads (F & R) Brake line & connections (including booster) Manual transmission fluid Clutch &...

  • Page 26: Owner Inspections And Services

    0B-12 GENERAL INFORMATION 5. Add oil, if needed, to keep the oil level above the OWNER INSPECTIONS lower mark. Avoid overfilling the engine, since this AND SERVICES may cause engine damage. 6. Push the indicator all the way back down into the engine after taking the reading.

  • Page 27: Each Time The Oil Is Changed

    GENERAL INFORMATION 0B-13 Weather-Strip Lubrication AT LEAST ANNUALLY Apply a thin film silicone grease using a clean cloth. Lap and Shoulder Belts Condition and EACH TIME THE OIL IS CHANGED Operation Inspect the belt system including: the webbing, the Brake System Inspection buckles, the latch plates, the retractor, the guide loops This inspection should be done when the wheels are and the anchors.

  • Page 28: Recommended Fluids And Lubricants

    0B-14 GENERAL INFORMATION RECOMMENDED FLUIDS AND LUBRICANTS Usage Fluid/Lubricant Capacity Engine Oil Quality class - API ; SH grade or above 8.2 L 3.2L DOHC (Change with filter) ACEA ; A2 or A3 MB sheet ; 229.1 7.5 L 2.3L DOHC Viscosity - MB sheet ;...

  • Page 29: General Description And System Operation

    GENERAL INFORMATION 0B-15 Use genuine DAEWOO parts. GENERAL DESCRIPTION Discard used cotter pins, gaskets, O-rings, oil seals, AND SYSTEM OPERATION lock washers and self-locking nuts. Prepare new ones for installation. Normal function of these parts cannot be maintained if these parts are reused.

  • Page 30: Vehicle Identification Number System

    A : Standard, B : Deluxe, C : Super Deluxe 5. Body Type 2: 3-Door, 4: 3-Door Soft Top 4. Line Models L : Korando, LHD, R : Korando, RHD 3. Vehicle Type T : Passenger Car, A : Truck 2. Maker ldentification : P 1.
  • Page 31 GENERAL INFORMATION 0B-17 Manufacturer’s Plate 1.Type Approval No. 2.Vehicle Identification No. Manufacturer’s Plate Location Diesel Engine Gasoline Engine...
  • Page 32 1 : Left - Hand Drive 1 : Left - Hand Drive 2 : Right - Hand Drive 2 : Right - Hand Drive 3 : KORANDO 99 : 3.2L 910 :Non-Intercooler Engine 97 : 2.3L 920 : Intercooler Engine 94 : 2.0L...

  • Page 33: Vehicle Lifting Procedures

    GENERAL INFORMATION 0B-19 VEHICLE LIFTING PROCEDURES To raise the vehicle, place the liffting equipment only at the points indicated. Failure to use these precise positions may result in permanent vehicle body deformation. Many dealer service facilities and service stations are equipped with automative hoists that bear upon some parts of the frame in order to lift the vehicle.
  • Page 34 SECTION 1 ENGINE SECTION 1A1(M162 ENGINE) GENERAL ENGINE INFORMATION TABLE OF CONTENTS Specifications ..... . . 1A1-1 Diagnosis ......1A1-7 Engine Specifications .

  • Page 35: Engine Specifications

    1A1-2 GENERAL ENGINE INFORMATION ENGINE SPECIFICATIONS (Cont'd) Application E32 Engine Idle Speed (rpm) 700 ± 50 Fuel Injection Pressure (kg/cm²) 3 - 4 Oil Capacity (liter) Lubrication Type Forced by Gear Pump Oil Filter Type Full Flow with Paper Filter Fuel Unleaded Gasoline MSE 3.62S/3.53S (Motorsteuer Elektronik : German)

  • Page 36: Component Locator

    GENERAL ENGINE INFORMATION 1A1-3 COMPONENT LOCATOR FRONT VIEW 1 HFM Sensor 12 Intake Manifold 2 Intake Air Duct 13 Connecting Rod 3 Resonance Flap 14 Exhaust Manifold 4 Cylinder Head Cover 15 Crankshaft 5 Exhaust Camshaft 16 Engine Mounting Bracket 6 Intake Camshaft 17 Starter 7 Cylinder Head...

  • Page 37: Side View

    1A1-4 GENERAL ENGINE INFORMATION SIDE VIEW 23 Camshaft Adjuster 27 Oil Pump Drive Chain 24 Cooling Fan and Viscous Clutch 28 Oil Return Pipe 25 Piston 29 Timing Chain 26 Flywheel of Drive Plate 30 Oil Pump...

  • Page 38: Performance Curve

    GENERAL ENGINE INFORMATION 1A1-5 PERFORMANCE CURVE E32 ENGINE...

  • Page 39: Special Tools

    1A1-6 GENERAL ENGINE INFORMATION SPECIAL TOOLS SPECIAL TOOLS TABLE 000 589 10 99 01 001 589 65 09 00 Torque Wrench Socket 001 589 76 21 00 119 589 01 09 00 Compression Pressure Spark Plug Wrench Tester...

  • Page 40: Diagnosis

    GENERAL ENGINE INFORMATION 1A1-7 DIAGNOSIS OIL LEAK DIAGNOSIS Black Light and Dye Method A dye and light kit is available for finding leaks, Refer to Most fluid oil leaks are easily located and repaired by the manufacturer's directions when using the kit. visually finding the leak and replacing or repairing the 1.

  • Page 41: Engine Cranking At The Front Of Crankshaft

    1A1-8 GENERAL ENGINE INFORMATION ENGINE CRANKING AT THE FRONT OF CRANKSHAFT Preceding Work : Removal of cooling fan 1 Vibration Damper Assembly 3 Bolt ..........8.6 ± 0.9 Nm 2 Crankshaft Pulley Notice Remove the negative ground cable before proceeding the work. Rotate the pulley in normal engine rotating direction when cranking.

  • Page 42: Compression Pressure Test

    GENERAL ENGINE INFORMATION 1A1-9 COMPRESSION PRESSURE TEST 1 Compression Pressure Tester 3 Adaptor 2 Diagram Sheet 4 Sealing Cone Tools Required 001 589 76 21 00 Compression Pressure Tester 119 589 01 09 00 Spark Plug Wrench Standard Service Data Compression Ratio 10 : 1 Normal Engine Temperature...
  • Page 43 1A1-10 GENERAL ENGINE INFORMATION Measuring Procedure 1. Warm the engine up to normal operating temperature. 2. Remove the spark plugs. 3. Place the diagram sheet to compression pressure tester. 4. Connect the adaptor to compression pressure tester and install it into the spark plug hole. 5.

  • Page 44: Cylinder Pressure Leakage Test

    GENERAL ENGINE INFORMATION 1A1-11 CYLINDER PRESSURE LEAKAGE TEST 3 Engine Oil Filler Cap 6 Cylinder Pressure Leakage Tester with 4 Vibration Damper Connecting Hose Permissible Pressure Leakage At Whole Engine Max. 25 % At Valve and Cylinder Head Gasket Max. 10 % At Piston and Piston Ring Max.
  • Page 45 1A1-12 GENERAL ENGINE INFORMATION Leakage Test 1. Warm the engine up to normal operating temperature. 2. Disconnect the negative battery cable. 3. Remove the spark plugs. 4. Check the coolant level by opening the coolant surge tank cap and replenish if insufficient. 5.

  • Page 46: General Information

    GENERAL ENGINE INFORMATION 1A1-13 GENERAL INFORMATION Battery cables should be disconnected before any major CLEANLINESS AND CARE work is performed on the engine. Failure to disconnect An automobile engine is a combination of many cables may result in damage to wire harness or other machined, honed, polished and lapped surfaces with electrical parts.
  • Page 47 SECTION 1 ENGINE SECTION 1A2(M161 ENGINE) GENERAL ENGINE INFORMATION TABLE OF CONTENTS Specifications ..... . . 1A2-1 Diagnosis ......1A2-8 Engine Specifications .

  • Page 48: Engine Specifications

    1A2-2 GENERAL ENGINE INFORMATION ENGINE SPECIFICATIONS (Cont'd) Application E23 Engine E20 Engine Idle Speed (rpm) 750 ± 50 ¬ Fuel Injection Pressure (kg/cm²) 3.2 - 4.2 ¬ Oil Capacity (liter) ¬ Lubrication Type Forced by Gear Pump ¬ Oil Filter Type Full Flow with Paper Filter ¬...

  • Page 49: Component Locator

    GENERAL ENGINE INFORMATION 1A2-3 COMPONENT LOCATOR FRONT VIEW 1 HFM Sensor 12 Intake Manifold 2 Intake Air Duct 13 Cylinder Head 3 Cylinder Head Cover 14 Exhaust Manifold 4 Ignition Coil 15 Dipstick Guide Tube and Gauge 5 Spark Plug Connector 16 Connecting Rod 6 Fuel Distributor 17 Crankshaft...

  • Page 50: Side View

    1A2-4 GENERAL ENGINE INFORMATION SIDE VIEW 23 Camshaft Adjuster 29 Oil Pump Drive Chain 24 Oil Filler Cap 30 Oil Strainer 25 Engine Hanger Bracket 31 Oil Pump 26 Cooling Fan and Viscous Clutch 32 Ring Gear and Flywheel of Drive Plate 27 Oil Filter 33 Piston 28 Timing Chain...

  • Page 51: Performance Curve

    GENERAL ENGINE INFORMATION 1A2-5 PERFORMANCE CURVE E23 ENGINE...

  • Page 52: E20 Engine

    1A2-6 GENERAL ENGINE INFORMATION E20 ENGINE...

  • Page 53: Special Tools

    GENERAL ENGINE INFORMATION 1A2-7 SPECIAL TOOLS SPECIAL TOOLS TABLE 000 589 10 99 01 001 589 65 09 00 Torque Wrench Socket 001 589 76 21 00 119 589 01 09 00 Compression Pressure Spark Plug Wrench Tester...

  • Page 54: Diagnosis

    1A2-8 GENERAL ENGINE INFORMATION DIAGNOSIS OIL LEAK DIAGNOSIS Black Light and Dye Method A dye and light kit is available for finding leaks, Refer to Most fluid oil leaks are easily located and repaired by the manufacturer's directions when using the kit. visually finding the leak and replacing or repairing the 1.

  • Page 55: Engine Cranking At The Front Of Crankshaft

    GENERAL ENGINE INFORMATION 1A2-9 ENGINE CRANKING AT THE FRONT OF CRANKSHAFT Preceding Work : Removal of cooling fan 1 Vibration Damper Assembly 3 Bolt ..........8.6 ± 0.9 Nm 2 Crankshaft Pulley Notice Remove the negative ground cable before proceeding the work. Rotate the pulley in normal engine rotating direction when cranking.

  • Page 56: Compression Pressure Test

    1A2-10 GENERAL ENGINE INFORMATION COMPRESSION PRESSURE TEST 1 Compression Pressure Tester 3 Adaptor 2 Diagram Sheet 4 Sealing Cone Tools Required 001 589 76 21 00 Compression Pressure Tester 119 589 01 09 00 Spark Plug Wrench Standard Service Data Compression Ratio 10.4, 9.6 Normal Engine Temperature...
  • Page 57 GENERAL ENGINE INFORMATION 1A2-11 Measuring Procedure 1. Warm the engine up to normal operating temperature. 2. Remove the spark plugs. 3. Place the diagram sheet to compression pressure tester. 4. Connect the adaptor to compression pressure tester and install it into the spark plug hole. 5.

  • Page 58: Cylinder Pressure Leakage Test

    1A2-12 GENERAL ENGINE INFORMATION CYLINDER PRESSURE LEAKAGE TEST 3 Engine Oil Filler Cap 6 Cylinder Pressure Leakage Tester with 5 Vibration Damper Connecting Hose Permissible Pressure Leakage At Whole Engine Max. 25 % At Valve and Cylinder Head Gasket Max. 10 % At Piston and Piston Ring Max.
  • Page 59 GENERAL ENGINE INFORMATION 1A2-13 Leakage Test 1. Warm the engine up to normal operating temperature. 2. Disconnect the negative battery cable. 3. Remove the spark plugs. 4. Check the coolant level by opening the coolant surge tank cap and replenish if insufficient. 5.

  • Page 60: General Information

    1A2-14 GENERAL ENGINE INFORMATION GENERAL INFORMATION CLEANLINESS AND CARE ON-ENGINE SERVICE An automobile engine is a combination of many Caution: Disconnect the negative battery cable be- machined, honed, polished and lapped surfaces with fore removing or installing any electrical unit, or tolerances that are measured in the ten-thousanths of when a tool or equipment could easily come in con- an inch.
  • Page 61 SECTION 1 ENGINE SECTION 1A3(OM600 ENGINE) GENERAL ENGINE INFORMATION TABLE OF CONTENTS Special Tools Table ....1A3-9 Specifications ..... . . 1A3-1 Diagnosis .

  • Page 62: Engine Specifications

    1A3-2 GENERAL ENGINE INFORMATION ENGINE SPECIFICATIONS (Cont'd) Application OM 662 LA OM 661 LA Idle Speed (rpm) 720 - 820 750 - 850 Fuel Injection Pressure (bar) 135 - 143 135 - 143 Oil Capacity (liter) 8.0 - 9.5 6.5 - 8.0 Lubrication Type Forced by Gear Pump Forced by Gear Pump...

  • Page 63: Sectional View

    GENERAL ENGINE INFORMATION 1A3-3 SECTIONAL VIEW OM662LA ENGINE Front View...
  • Page 64 1A3-4 GENERAL ENGINE INFORMATION Side View...

  • Page 65: Om661La Engine

    GENERAL ENGINE INFORMATION 1A3-5 OM661LA ENGINE Front View...
  • Page 66 1A3-6 GENERAL ENGINE INFORMATION Side View...

  • Page 67: Performance Curve

    GENERAL ENGINE INFORMATION 1A3-7 PERFORMANCE CURVE OM662LA ENGINE...

  • Page 68: Om661La Engine

    1A3-8 GENERAL ENGINE INFORMATION OM661LA ENGINE...

  • Page 69: Special Tools

    GENERAL ENGINE INFORMATION 1A3-9 SPECIAL TOOLS SPECIAL TOOLS TABLE 000 589 10 99 01 001 589 65 09 00 Torque Wrench Socket 001 589 76 21 00 001 589 73 21 00 Compression Pressure Hand Vacuum Pump Tester...

  • Page 70: Diagnosis

    1A3-10 GENERAL ENGINE INFORMATION DIAGNOSIS 1. Pour the specified amount of dye into the engine OIL LEAK DIAGNOSIS oil fill tube. Most fluid oil leaks are easily located and repaired 2. Operate the vehicle normal operating conditions by visually finding the leak and replacing or repairing as directed in the kit.

  • Page 71: Compression Pressure Test

    GENERAL ENGINE INFORMATION 1A3-11 COMPRESSION PRESSURE TEST 1 Test Adapter 2 Flexible Connector 3 Compression Pressure Recorder Service Data Normal Compression Pressure 28bar Minimum Compression Pressure Approx.18bar Permissible Pressure Difference Between Individual Cylinders Max. 3bar Engine at normal operating temperature of 80°C Tools Required 000 589 65 09 00 Socket 001 589 73 21 00 Hand Vacuum Pump...
  • Page 72 1A3-12 GENERAL ENGINE INFORMATION Compression Pressure Measurement Notice Ensure that no gear is engaged and that the vehicle is protected from rolling. 1. Run the engine to be the coolant temperature 80°C. 2. Remove the fuel injection nozzle. Socket Wrench Insert 001 589 65 09 00 3.

  • Page 73: Cylinder Pressure Leakage Test

    GENERAL ENGINE INFORMATION 1A3-13 CYLINDER PRESSURE LEAKAGE TEST 1 Connector 2 Connection Piece 3 Connection Hose Permissible Pressure Leakage (Engine at Normal Operating Temperature of 80°C) At Whole Engine Max. 25 % At Valve and Cylinder Head Gasket Max. 10 % At Piston and Piston Ring Max.
  • Page 74 1A3-14 GENERAL ENGINE INFORMATION Leakage Test 1. Run the engine to be the coolant temperature 80°C. 2. Remove the fuel injection nozzle. 3. Open the coolant subtank cap. 4. Check the coolant level and replenish if necessary. 5. Open the oil filler cap. 6.

  • Page 75: General Information

    GENERAL ENGINE INFORMATION 1A3-15 GENERAL INFORMATION Battery cables should be disconnected before any CLEANLINESS AND CARE major work is performed on the engine. Failure to An automobile engine is a combination of many disconnect cables may result in damage to wire machined, honed, polished and lapped surfaces with harness or other electrical parts.
  • Page 76 SECTION 1B1 M162 ENGINE MECHANICAL CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

  • Page 77: Specifications

    1B1-2 M162 ENGINE MECHANICAL SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application N· · · · · m Power Steering Hydraulic Lines 35 - 40 A/C High Pressure and Liquid Hose 10 - 15 Radiator Support Menber Bolt 5 - 10 Fuel Supply and Return Hose to Fuel Distributor 21 - 25 Exhaust Manifold and Pipe Propeller Shaft to Transmission...
  • Page 78 M162 ENGINE MECHANICAL 1B1-3 FASTENER TIGHTENING SPECIFICATIONS (Cont’d) Application N· · · · · m Exhaust Camshaft Sproket Bolt 20 / +90° Chain Tensioner Screw Plug Chain Tensioner Assembly 72 - 88 Exhaust Camshaft Sprocket to Camshaft 20 / +90° Oil Pump Sprocket Bolt 25 - 35 Tensioning Device Bolt...

  • Page 79: Special Tools

    1B1-4 M162 ENGINE MECHANICAL SPECIAL TOOLS SPECIAL TOOLS TABLE 000 589 10 99 01 000 589 40 37 00 Torque Wrench Hose Clamp 112 589 00 72 00 000 589 72 21 00 Oil Extractor Torque Wrench 001 589 66 21 00 124 589 15 21 00 Torque Wrench Radiator Cap...
  • Page 80 M162 ENGINE MECHANICAL 1B1-5 SPECIAL TOOLS TABLE (Cont’d) 104 589 01 01 00 111 589 01 59 00 Spanner Supporting Bar 111 589 18 61 00 111 589 25 63 00 Lever Pusher Thrust Piece 116 589 06 63 00 104 589 00 37 00 Magnetic Finger Pliers...
  • Page 81 1B1-6 M162 ENGINE MECHANICAL SPECIAL TOOLS TABLE (Cont’d) 116 589 20 33 00 601 589 03 43 00 Sliding Hammer Sleeve 602 589 00 40 00 103 589 00 33 00 Engine Lock Puller 001 589 65 09 00 000 589 88 33 00 Socket Wrench Insert Puller 001 589 74 21 00...
  • Page 82 M162 ENGINE MECHANICAL 1B1-7 SPECIAL TOOLS TABLE (Cont’d) 103 589 01 63 00 615 589 01 33 00 Rivet Set Caulking Bolt 103 589 02 09 00 102 589 12 15 00 Oil Filter Drift Socket Wrench 102 589 00 15 00 601 589 03 14 00 Drift Sleeve...

  • Page 83: Maintenance And Repair

    1B1-8 M162 ENGINE MECHANICAL MAINTENANCE AND REPAIR ON-VEHICLE SERVICE ENGINE ASSEMBLY Tools Required 000 589 10 99 01 Torque Wrench 000 589 40 37 00 Hose Clamp 112 589 00 72 00 Oil Extractor 000 589 72 21 00 Torque Wrench 001 589 66 21 00 Torque Wrench 124 589 15 21 00 Radiator Cap Testing Unit Removal &...
  • Page 84 M162 ENGINE MECHANICAL 1B1-9 6. Loosen the radiator drain cock and drain the coolant. Notice Open the coolant reservoir cap. 7. Loosen the cylinder block drain plug and then drain the coolant completely. Installation Notice Tightening Torque 30 Nm Notice Replace the seal before installation of the drain plug.
  • Page 85 1B1-10 M162 ENGINE MECHANICAL 10. Remove the upper mounting bolts of radiator and then remove the radiator. 11. Remove the hydraulic pipe of power steering. Notice Completely drain the oil. 12. Discharge the refrigerant from A/C system, and disconnect the discharge pipe and suction pipe from the compressor. 13.
  • Page 86 M162 ENGINE MECHANICAL 1B1-11 14. Remove the fuel feed and return line. Notice Before removing the fuel lines, release the pressure in the fuel system. Installation Notice Tightening Torque 21 - 25 Nm 15. Remove the automatic transmission dipstick guide tube. 16.
  • Page 87 1B1-12 M162 ENGINE MECHANICAL 19. Disconnect the engine ground wire. 20. Disconnect following sensors connector. HFM sensor. Coolant temperature sensor. 2 knock sensors. Camshaft and crankshaft sensors. 21. After removing the ignition coil cover, disconnect the ignition coil connector. 22. Remove the harness cover and disconnect the 6 injection valve connectors.
  • Page 88 M162 ENGINE MECHANICAL 1B1-13 25. Separate the vacuum hose for brake booster. 26. Separate the other vacuum hoses. 27. Remove the propeller shaft from the front axle. Installation Notice Tightening Torque 81 - 89 Nm 28. By rotating the crankshaft from the front of engine, remove the 6 torque converter mounting bolts from the engine ring gear plate.
  • Page 89 1B1-14 M162 ENGINE MECHANICAL 30. Remove the transmission mounting bolts and separate the transmission from the engine. Installation Notice Tightening Torque 65 Nm 31. Remove the bolts for engine mounting bracket. Installation Notice Tightening Torque 50 - 75 Nm 32. Hook the chain to the bracket of engine and by using a hoist or crane, carefully separate the engine assembly from the vehicle.

  • Page 90: Crankcase Ventilation System

    M162 ENGINE MECHANICAL 1B1-15 CRANKCASE VENTILATION SYSTEM 1 Crankcase 13 Intake Air Duct (Cross Pipe) 2 Air Admission Port in Crankcase 14 Cylinder Head Cover 3 Oil Drain Port 15 Oil Separator 4 Filter 16 Oil Separator 5 Gasket 17 Air Admission and Vent Connection 6 A/C Bracket 18 Air Admission and Vent Connection 7 Oil Drain Pipe...
  • Page 91 1B1-16 M162 ENGINE MECHANICAL Operation at Idling and Mid-Load It show that the throttle valve (19) is closed or very partially opened and the vacuum pressure in intake manifold is high. The blowby gas in the crankcase in partial load flows into the intake manifold through the vent line (20) after passing the air conditioner bracket (6) and the filter (4).

  • Page 92: Alternator

    M162 ENGINE MECHANICAL 1B1-17 ALTERNATOR 1 Nut (M8) ......... 22.5-27.5 Nm 4 Bolt (M8 x 70, 1 piece) ....22.5-27.5 Nm 2 Bolt (M8 x 30, 3 pieces) ....22.5-27.5 Nm 5 Bolt (M8 x 75, 1 piece) ....22.5-27.5 Nm 3 Bolt (M8 x 40, 1 piece) ....

  • Page 93: Power Steering Pump And A/C Bracket

    1B1-18 M162 ENGINE MECHANICAL POWER STEERING PUMP AND A/C BRACKET Preceding Work : Removal of cooling fan and shroud 1 Vent Hose 8 A/C Bracket 2 Bolt (M8 x 91, 2 pieces) ....22.5-27.5 Nm 9 Gasket ........... Replace 3 Power Steering Pump 10 Bracket 4 Bolt (M8 x 105, 4 pieces) ....
  • Page 94 M162 ENGINE MECHANICAL 1B1-19 Removal & Installation Procedure 1. Remove the belt pulley. Installation Notice Tightening Torque 40.5 - 49.5 Nm Notice Pull the tensioning pulley clockwise as shown in the figure. 2. Disconnect the hydraulic pipe of the power steering pump and drain the oil.
  • Page 95 1B1-20 M162 ENGINE MECHANICAL 5. Disconnect the vent hose from the A/C bracket. 6. Unscrew all the mounting bolts (arrows) and remove the A/C bracket and the gasket. Installation Notice Tightening Torque 22.5 - 27.5 Nm 7. Clean the sealing surface. 8.

  • Page 96: Hydraulic Engine Mounting Insulator

    M162 ENGINE MECHANICAL 1B1-21 HYDRAULIC ENGINE MOUNTING INSULATOR Service Data...
  • Page 97 1B1-22 M162 ENGINE MECHANICAL Sectional View 1 Rubber Body 9 Lower Orifice 2 Brackek 10 Upper Orifice 3 Core 11 Diaphram 4 Lower Bolt 12 Cover Plate 5 Rubber Plunger 13 Upper Bolt 6 Plunger Plate 14 Flange Bolt 7 Rubber 15 Rivet 8 Plate 16 Fluid...
  • Page 98 M162 ENGINE MECHANICAL 1B1-23 1 Upper Nut 2 Hydraulic Installor ....62-93 Nm 3 Lower Nut ......28-47 Nm Removal and Installation Procedure 1. Unscrew the upper nut(1) on engine mounting and remove the engine. Installation Notice Tightening Torque 62 - 93 Nm 2.

  • Page 99: Poly V-Belt

    1B1-24 M162 ENGINE MECHANICAL POLY V-BELT Preceding Work : Removal of cooling fan 1 Poly V-belt 2 Belt Tensioning Pulley Removal & Installation Procedure 1. Release the belt tension by turning the belt tensioning pulley nut clockwise. 2. Remove the poly v-belt. Notice Check the belt for damage and tensioning pulley bearing point for wear and replace them if necessary.
  • Page 100 M162 ENGINE MECHANICAL 1B1-25 Poly V-Belt Arrangement 1 Belt Tensioning Pulley 5 Alternator Pulley 2 Crankshaft Belt Pulley 6 Idler 3 A/C Compressor Pulley 7 Power Steering Pump Pulley 4 Cooling Fan Pulley 8 Cooling Fan and Water Pump Pulley...

  • Page 101: Tensioning Device

    1B1-26 M162 ENGINE MECHANICAL TENSIONING DEVICE Preceding Work : Removal of poly v-belt 1 Belt (L = 2245) 3 Water Pump Pulley 2 Bolt Combi(M8 x 14, 3 pieces) + Washer 4 Nut ............22.5-27.5Nm 5 Tensioning Pulley Removal & Installation Procedure 1.
  • Page 102 M162 ENGINE MECHANICAL 1B1-27 3. Remove the 3 bolts (2) and remove the water pump pulley (arrow). Installation Notice Tightening Torque 22.5 - 27.5 Nm 4. Remove the mounting bolts(M8 x 30, 3 pieces) at the tensioning device, and remove the tensioning device (arrow). Installation Notice Tightening Torque 26 - 32 Nm...

  • Page 103: Poly V-Belt Inspection

    1B1-28 M162 ENGINE MECHANICAL POLY V-BELT INSPECTION Make marks on the belt with chalk. Rotate the engine and check the belt for damage. Notice If one of the following types of damages is found, replace the belt. 1. Rubber lumps in the base of rib. 2.
  • Page 104 M162 ENGINE MECHANICAL 1B1-29 7. Rib detached from the base of belt. 8. Splits across the rib. 9. Sections of rib torn out. 10. Splits across several ribs. 11. Splits across the back of the belt.

  • Page 105: Cylinder Head Cover

    1B1-30 M162 ENGINE MECHANICAL CYLINDER HEAD COVER 1 Ignition Cable Dust Cover 6 Cylinder Head Cover 2 Bolt (M6 x 65, 8 pieces) ......9-11 Nm 7 Gasket ........... Replace 3 Bolt (M6 x 50, 4 pieces) ......9-11 Nm 8 Spart Plug Hole Seal ......
  • Page 106 M162 ENGINE MECHANICAL 1B1-31 Removal & Installation Procedure 1. Remove the intake air duct. Installation Notice Tightening Torque 8.4 ± 0.65 Nm 2. Remove the ignition cable cover. Installation Notice Tightening Torque 9 - 10 Nm Notice Unscrew the seven (M6 x 60) bolts and remove the ignition cable cover.
  • Page 107 1B1-32 M162 ENGINE MECHANICAL CYLINDER HEAD FRONT COVER Preceding Work : Removal of cylinder head cover Removal of coolant connection fitting 1 Camshaft Position Sensor 5 Bolt (M8 x 80, 3 pieces) ....22.5-27.5 Nm 2 Magnet Assembly 6 Front Cover 3 Upper Guide Rail 7 Rubber Gasket ........
  • Page 108 M162 ENGINE MECHANICAL 1B1-33 2. Remove the cylinder head front cover (6). Installation Notice Tightening Torque 22.5 - 27.5 Nm Apply the sealant at the mating surface of the cylinder head and the front cover. 3. Remove the upper guide rail pin and the guide rail (3). Installation Notice Install it while the chain tensioner is loose.

  • Page 109: Cylinder Head

    1B1-34 M162 ENGINE MECHANICAL CYLINDER HEAD Preceding Work : Removal of cylinder head cover Removal of cylinder head front cover Removal of upper intake manifold 1 Cylinder Head Bolt (14 pieces) 4 Exhaust Camshaft Sprocket ............ 1st step 55 Nm 5 Cylinder Head 2nd step 90°...
  • Page 110 M162 ENGINE MECHANICAL 1B1-35 Tools Required 000 589 01 10 00 Box Wrench Insert 116 589 02 34 00 Screw-fixed Pin 116 589 20 33 00 Sliding Hammer Removal & Installation Procedure 1. Rotate the crankshaft so that the piston of number 1 cylinder is at TDC.
  • Page 111 1B1-36 M162 ENGINE MECHANICAL 6. Remove the guide rail fixing pin from the cylinder head using the sliding hammer (01) and the threaded pin (02). Sliding Hammer 116 589 20 33 00 Threaded Pin 116 589 02 34 00 7. Remove the cylinder head bolts in numerical order. Installation Notice 1st step 55 Nm 2nd step 90°...

  • Page 112: Timing Gear Case Cover

    M162 ENGINE MECHANICAL 1B1-37 TIMING GEAR CASE COVER Preceding Work : Removal of cylinder head front cover Removal of alternator bracket Removal of tensioning device Removal of belt pulley and vibration damper 1 Bolt (M8 x 60, 3 pieces) ....22.5-27.5 Nm 6 Seal 2 A/C Bracket 7 Timing Gear Case Cover...
  • Page 113 1B1-38 M162 ENGINE MECHANICAL 3. Remove the cooling fan and the viscous clutch. Unscrew the three bolts from the cooling fan bracket and remove the bracket (arrows). Installation Notice Tightening Torque 22.5 - 27.5 Nm 4. Remove the timing gear case cover after unscrewing the bolts (3) and (4) from the timing gear case cover and the bolt (9) from the oil pan.

  • Page 114: Crankshaft Sealing Rear Cover

    M162 ENGINE MECHANICAL 1B1-39 CRANKSHAFT SEALING REAR COVER Preceding Work : Removal of the automatic transmission drive plate 1 Bolt (M6 x 20, 6 pieces) ......9-11 Nm 4 Sleeve 2 Radial Shaft Seal 5 Bolt (M6 x 85, 2 pieces) ......9-11 Nm 3 Rear Cover 6 Washer...
  • Page 115 1B1-40 M162 ENGINE MECHANICAL Tools Required 601 589 03 43 00 Sleeve Removal & Installation Procedure 1. Unscrew the bolts (1) and (5) and remove the closing cover by pulling the rear cover lug (arrows). Notice Be careful not to damage the oil pan gasket. 2.

  • Page 116: Belt Pulley And Vibration Damper

    M162 ENGINE MECHANICAL 1B1-41 BELT PULLEY AND VIBRATION DAMPER Preceding Work : Removal of cooling fan and viscous clutch Removal of fan shroud Removal of drive belt 1 Center Bolt (M18 x 50) ..1st step 200- 220 Nm 4 Vibration Damper Assembly 2nd step 90°+10°...
  • Page 117 1B1-42 M162 ENGINE MECHANICAL Components 1 Center Bolt (M18 x 50) 2 Center Bolt Washer 3 Vibration Damper and Pulley Assembly 4 Key 5 Crankshaft Front Seal 6 Timing Gear Case Cover 7 Crankshaft Sprocket (Camshaft Driven) 8 Crankshaft Sprocket (Oil pump Driven) 9 Crankshaft 10 Oil Pan 11 Oil Pan Gasket...
  • Page 118 M162 ENGINE MECHANICAL 1B1-43 2. Remove the start motor and install the engine lock to the flywheel ring gear. 3. Remove the center bolt. Installation Notice 1st step 200 - 220 Nm Tightening Torque 2nd step 90° +10° Engine Lock 602 589 00 40 00 4.

  • Page 119: Crankshaft Front Radial Seal

    1B1-44 M162 ENGINE MECHANICAL CRANKSHAFT FRONT RADIAL SEAL Preceding Work : Removal of belt pulley and vibration damper 1 Center Bolt (M18 x 50) ........ 1st step 200-220 Nm 2nd step 90° +10° 2 Center Bolt Washer 3 Sleeve (Special Tool) 4 Crankshaft Front Seal 5 Key Tools Required...

  • Page 120: Crankshaft Rear Radial Seal

    M162 ENGINE MECHANICAL 1B1-45 CRANKSHAFT REAR RADIAL SEAL Preceding Work : Removal of flywheel or drive plate 1 Special Tool 3 Crankshaft Rear Seal 2 Special Tool Tools Required 601 589 03 43 00 Sleeve Replacement Proceudre 1. Remove the radial seal with a screw driver. Notice Use a clean cloth not to damage the radial seal mounting hole and the crankshaft.

  • Page 121: Crankshaft

    1B1-46 M162 ENGINE MECHANICAL CRANKSHAFT Preceding Work : Removal of engine assembly Removal of timing gear case cover Removal of cylinder head Removal of oil pump Removal of oil shield 1 12-sided Stretch Bolt ..55 Nm x 90°, Iubricate 4 Lower Thrust Bearing 2 Crank Shaft Bearing Cap 5 Crank Shaft...
  • Page 122 M162 ENGINE MECHANICAL 1B1-47 Arrangement of the Thrust Bearing and the Main Bearing 1 Upper Main Bearing A Crankcase Side 2 Upper Thrust Bearing B Bearing Cap Side (Oil Pan Side) 3 Crankshaft C Axial Fit Bearing (Number 5 Bearing Point) 4 Lower Main Bearing D Radial Bearing 5 Lower Thrust Bearing...
  • Page 123 1B1-48 M162 ENGINE MECHANICAL Color Dot Marking Crankshaft Journal Diameter (mm) Blue 57.960 - 57.965 Yellow 57.955 - 57.960 57.950 - 57.955 White 57.945 - 57.950 Violet 57.940 - 57.945 Selection of Crankshaft Main Bearing 1. Crankcase Side There are seven punching marks on the mating surface to oil pan.
  • Page 124 M162 ENGINE MECHANICAL 1B1-49 Removal & Installation Procedure 1. Unscrew the connecting rod bearing cap bolt and remove the bearing cap. Installation Notice Tightening Torque 40 Nm + 90° Make sure that the upper and lower bearing shells do not change each other. Coat the bearing shell with engine oil.
  • Page 125 1B1-50 M162 ENGINE MECHANICAL Inspection 1. If the length ‘L’ of the crankshaft bearing cap bolt exceeds 63.8mm, replace it. 2. Make sure the crankshaft bearing cap is properly seated on the cylinder block (arrows). 3. Measure and record the inner diameter of the crankshaft bearing.
  • Page 126 M162 ENGINE MECHANICAL 1B1-51 Service Data Standard (Crankshaft Main Bearing Gap) Item Measuring Position Gap (mm) Main Bearing Journal Static condition :0.015 - 0.039 ( NO. 1, 5, 7) Radial Dynamic condition: 0.031 - 0.051 (Consider the expansion 0.011 - 0.016) Axial 0.010 - 0.254 Main Bearing Journal...

  • Page 127: Flywheel / Driven Plate

    1B1-52 M162 ENGINE MECHANICAL FLYWHEEL / DRIVEN PLATE Preceding Work : Removal of manual or automatic transmission 1 Flywheel Mounting Bolt (M10 x 22, 8 pieces) 3 Driven Plate (A/T) ..........1st step 45+5 Nm 4 Dowel Pin 2nd step +90° +10° 2 Plate Service Data Standard (Stretch Bolt) Nominal Size...

  • Page 128: Bolt (M6 X 65, 8 Pieces)

    M162 ENGINE MECHANICAL 1B1-53 Removal & Installation Procedure 1. Unscrew the stretch bolt. Installation Notice 1st step 45+5 Nm Tightening Torque 2nd step 90° + 10° Replace the bolt when the stretch side diameter (d) of the flywheel mounting bolt is less than 8.0mm. For the stretch bolt tightening, keep the socket wrench and Tommy-bar to be 90°...

  • Page 129: Camshaft Adjuster

    1B1-54 M162 ENGINE MECHANICAL CAMSHAFT ADJUSTER 1 Bolt (M6 x 16, 3 pieces) ......9-11 Nm 13 Camshaft Sprocket and Position Indicator (b) 2 Electromagnetic Actuator (2 Pin Connector) 14 Adjuster piston 3 Bolt ............35 Nm 15 Flange bolt (M7 x 13, 3 pieces) 4 Armature ..........

  • Page 130: Bolt (M6 X 50, 4 Pieces)

    M162 ENGINE MECHANICAL 1B1-55 Removal & Installation Procedure 1. Turn the crankshaft to the direction of engine rotation and position the no.1 cylinder piston at TDC which the camshaft is positioned at OT. 2. Remove the cylinder head front cover. 3.
  • Page 131 1B1-56 M162 ENGINE MECHANICAL 7. Remove the camshaft sprocket (13) and adjust piston (14), and remove the flange shaft (16) from the intake camshaft (22) after removing the bolt (15). Installation Notice 1st step 18 - 22 Nm Tightening Torque 2nd step 90°...

  • Page 132: Camshaft Sprocket Bolt

    M162 ENGINE MECHANICAL 1B1-57 CAMSHAFT SPROCKET BOLT Intake Flange Shaft Bolt 1st step 18 - 22 Nm Tightening Torque 2nd step 90° ± 5° Notice The sprocket bolts are designed to be used only once, so always replace with new one. C.

  • Page 133: Camshaft

    1B1-58 M162 ENGINE MECHANICAL CAMSHAFT Preceding Work : Removal of cylinder head cover, removal of coolant connection fitting 1 Chain Tensioner Assembly ....72-88 Nm 5 Intake Camshaft Sprocket 2 Exhaust Camshaft Sprocket 6 Chain 3 Upper Guide Rail 7 Wrench (Special Tool) 4 Cylinder Head Front Cover...
  • Page 134 M162 ENGINE MECHANICAL 1B1-59 Tools Required 000 589 01 10 00 Box Wrench Insert 104 589 01 01 00 Spanner Removal Procedure 1. Turn the crankshaft and position the No. 1 cylinder piston at BTDC 30°. 2. Remove the alternator. 3.

  • Page 135: Installation Procedure

    1B1-60 M162 ENGINE MECHANICAL 8. Unscrew the intake side bolts (8, 11, 13, 14) and the exhaust side bolts (1, 4, 6, 7). 9. Loosen the remaining bolts and unscrew the intake and exhaust side camshaft bearing cap bolts. Notice Number the camshaft bearing cap bolts when removing them, so that they don’t get mixed up.
  • Page 136 M162 ENGINE MECHANICAL 1B1-61 4. Turn the intake camshaft adjuster to the direction of camshaft rotation by hard until it stops and then install the chain. Notice Make sure that the camshaft sprocket and timing chain are aligned with marks. Intake camshaft adjuster should be in retarded position.
  • Page 137 1B1-62 M162 ENGINE MECHANICAL 8. Install the upper guide rail and cylinder head front cover. 9. Install the alternator.

  • Page 138: Camshaft Timing Position

    M162 ENGINE MECHANICAL 1B1-63 CAMSHAFT TIMING POSITION Preceding Work : Removal of cylinder head cover Removal of cylinder head front cover 1 Chain Tensioner Assembly 4 Cylinder Head Front Cover 2 Exhaust Camshaft Sprocket 5 Wrench (Special Tool) 3 Upper Guide Rail 6 Adjustment Hole Fitting Pin ( f 4.0 mm)
  • Page 139 1B1-64 M162 ENGINE MECHANICAL Tools Required 104 589 01 01 00 Spanner Inspection 1. Position the No.1 cylinder piston to TDC (OT) by turning the crankshaft. Notice When the OT mark on vibration damper is aligned with timing gear case cover, the intake and exhaust cam of cylinder will make the slope to the center and will face up.
  • Page 140 M162 ENGINE MECHANICAL 1B1-65 9. Install the chain to the exhaust camshaft sprocket and install it to the camshaft. Installation Notice (Sprocket Bolt) 1st step 18 - 22 Nm Tightening Torque 2nd step 90° ± 5° The sprocket bolt is designed to be used only once, so replace with new one.

  • Page 141: Valve Spring

    1B1-66 M162 ENGINE MECHANICAL VALVE SPRING Preceding Work : Removal of camshaft Removal of spark plug 1 Valve Tappet Assembly 7 Connecting Hose 2 Valve Cotter 8 Thrust Piece 3 Upper Retainer 9 Slide 4 Valve Spring ..Check, Replace if necessary 10 Adjust Bolt 5 Valve Stem Seal 11 Lever Pusher...
  • Page 142 M162 ENGINE MECHANICAL 1B1-67 Tools Required 111 589 01 59 00 Supporting Bar 111 589 18 61 00 Lever Pusher 111 589 25 63 00 Thrust Piece 116 589 06 63 00 Magnetic Finger Removal & Installation Procedure 1. Place the supporting bar (12) and the slide (9) at the camshaft bearing cap (Nos 1 &...
  • Page 143 1B1-68 M162 ENGINE MECHANICAL 8. Install the lever pusher (11) and the thrust piece (8) to the slide (9). Lever Pusher 111 589 18 61 00 9. Mount the thrust piece (8) vertically to the valve spring retainer (3). 10. Make the thrust piece (8) and the slide (9) perpendicular to each other.
  • Page 144 M162 ENGINE MECHANICAL 1B1-69 Test (Upper and Lower Valve Tappet and Valve Cotter) Upper Valve Spring Retainer Size (mm) 12.3 Lower Valve Spring Retainer Thickness (mm) 0.8 - 1.0 Valve Cotter Size (mm) 9.2 - 9.8...

  • Page 145: Valve Stem Seal

    1B1-70 M162 ENGINE MECHANICAL VALVE STEM SEAL Preceding Work : Removal of valve spring 1 Drift (Special Tool) 2 Valve Stem Seal 3 Protective Sleeve Tools Required 104 589 00 37 00 Pliers 119 589 00 43 00 Drift Replacement Procedure 1.

  • Page 146: Chain Tensioner

    M162 ENGINE MECHANICAL 1B1-71 CHAIN TENSIONER 1 Screw Plug ..........40 Nm 5 Snap Ring 2 Seal 6 Thrust Pin 3 Filler Pin 7 Chain Tensioner Housing ..... 72-88 Nm 4 Compression Spring 8 Seal Removal Procedure 1. Position the No.1 cylinder to TDC (OT). Notice Remove the oil filler cap at adjustment position, and check whether the intake camshaft cam’s lobe (arrow) stays in the...
  • Page 147 1B1-72 M162 ENGINE MECHANICAL 4. Carefully unscrew the screw plug (1), and remove the seal (2). Notice For the removal of screw plug, be careful that it can be jumped out due to the force of compression spring. Remove the screw plug only when the seal and compression spring are damaged.
  • Page 148 M162 ENGINE MECHANICAL 1B1-73 4. Lightly apply the grease to the seal (2) and install the screw plug (1). Installation Notice Tightening Torque 40 Nm 5. Check for leaks by operating the engine. Sectional View 1 Screw Plug 13 Chain Tensioner Housing 2 Ball (Nonreturn Valve) 14 Seal 3 Compression Spring...

  • Page 149: Timing Chain

    1B1-74 M162 ENGINE MECHANICAL TIMING CHAIN Preceding Work : Removal of cylinder head cover Removal of spark plug 1 Pin 5 Link 2 New Timing Chain 6 Center Plate 3 Timing Chain (Used) 7 Outer Plate 4 Wedge...
  • Page 150 M162 ENGINE MECHANICAL 1B1-75 Tools Required 000 589 58 43 00 Chain Assembly 103 589 01 63 00 Rivet Set 001 589 72 21 00 Torque Wrench Replacement Procedure 1. Position the No.1 cylinder to TDC (OT). 2. Insert the f 4mm pin to the intake and exhaust camshaft flange not to rotate camshaft.
  • Page 151 1B1-76 M162 ENGINE MECHANICAL 6. Remove the outer plate (7) with the screw driver and remove the link (5). 7. Connect the new timing chain (2) to the used timing chain (3) with the link (5), center plate (6, thickness 1.6mm), and the outer plate (7).
  • Page 152 M162 ENGINE MECHANICAL 1B1-77 12. Place the outer plate (7, thickness 1.2mm) inside the thrust piece (b). 13. Install the assembly tool above the link and tighten the spindle (c) until a block is felt. 14. Place the assembly tool. 15.
  • Page 153 1B1-78 M162 ENGINE MECHANICAL 17. Rivet the link pin. Check the condition and it again if necessary. 18. Install the chain tensioner. Installation Notice Screw Plug 40 Nm Tightening Torque Tensioner Assembly 72 - 88 Nm 19. Check the camshaft timing position.

  • Page 154: Tensioning Rail

    M162 ENGINE MECHANICAL 1B1-79 TENSIONING RAIL Preceding Work : Removal of timing gear case cover 1 Tensioning Rail 2 Plastic Guide 3 Tensioning Rail Pin 4 Guide Rail Removal & Installation Procedure 1. Put the assembly mark at the camshaft sprocket and the timing chain with the paint (arrow).

  • Page 155: Cylinder Head Guide Rail

    1B1-80 M162 ENGINE MECHANICAL CYLINDER HEAD GUIDE RAIL Preceding Work : Removal of cylinder head cover 1 Chain Tensioner 2 Upper Guide Rail 3 Upper Guide Rail Pin 4 Wrench (Special Tool) Tools Required 104 589 01 01 00 Spanner Removal &...

  • Page 156: Crankcase Guide Rail

    M162 ENGINE MECHANICAL 1B1-81 CRANKCASE GUIDE RAIL Preceding Work : Removal of timing gear case cover 1 Guide Rail 2 Plastic Guide 3 Guide Rail Pin 4 Tensioning Rail Removal & Installation Procedure 1. Put the assembly mark at the camshaft sprocket and the timing chain with the paint (arrow).

  • Page 157: Crankshaft Sprocket

    1B1-82 M162 ENGINE MECHANICAL CRANKSHAFT SPROCKET Preceding Work : Removal of oil pan Removal of tensioning rail Removal of crank case guide rail 1 Oil Pump Chain Tensioner 6 Bolt (M8 x 20, 1 piece) / Washer ..29-35 Nm 2 Oil Pump Chain Bushing 7 Oil Pump Sprocket 3 Oil Pump Chain Spring...
  • Page 158 M162 ENGINE MECHANICAL 1B1-83 Tools Required 615 589 01 33 00 Puller Removal & Installation Procedure 1. Put the assembly mark at the crankshaft sprocket (4) and the timing chain (10) with the paint (arrow). Installation Notice Align the assembly marks on cranshaft sprocket and timing chain.

  • Page 159: Piston

    1B1-84 M162 ENGINE MECHANICAL PISTON Preceding Work : Removal of engine Removal of cylinder head Removal of oil pan Removal of oil pump Removal of baffle plate 1 Connecting Rod Bearing Cap 4 Piston 2 Connecting Rod 5 Snap Ring 3 Connecting Rod Bolt (M9 x 52, 12 pieces) 6 Piston Pin ............
  • Page 160 M162 ENGINE MECHANICAL 1B1-85 Tools Required 001 589 72 21 00 Torqued Wrench 000 589 04 14 00 Clamping Strap Removal Procedure 1. Unscrew the connecting rod bolt (3) and remove the cap. 2. Remove the connecting rod and the piston upward. Notice Make sure that the bearing cap and shell are not changed each other.
  • Page 161 1B1-86 M162 ENGINE MECHANICAL 1. Check the piston ring gap and apply the engine oil to the piston pin and the connecting rod bushing. 2. Connect the piston and the connecting rod by pressing in the piston pin (6) and install the snap ring to the groove. 3.

  • Page 162: Connecting Rod

    M162 ENGINE MECHANICAL 1B1-87 CONNECTING ROD Preceding Work : Removal of piston 1 Connecting Rod Bushing 2 Oil Gallery 3 Balance Weight 4 Connecting Rod Bolt (M9 x 52, 12 m pieces) .. 1st step 40+5 Nm 2nd step 90°+10° 5 Fit Sleeve 6 Upper Connecting Rod Bearing 7 Lower Connecting Rod Bearing...
  • Page 163 1B1-88 M162 ENGINE MECHANICAL Inspection 1. Measure the basic bore of the connecting rod bearing. Notice If the basic bore exceeds the value of 51.614mm, replace the bearing or check the connecting rod. 2. Check connecting rod bolts. Length When New (L) 51.7 - 52 mm Max.

  • Page 164: Piston Ring

    M162 ENGINE MECHANICAL 1B1-89 PISTON RING Preceding Work : Removal of piston 1 Piston Compression Ring 2 Piston Compression Ring 3 Piston Oil Ring 5 Coil Spring and Control Ring 6 Hook Spring Tools Required 000 589 51 37 00 Clamping Strap Replacement Procedure 1.
  • Page 165 1B1-90 M162 ENGINE MECHANICAL 2. Remove the piston ring with a pliers. Clamping Strap 000 589 51 37 00 3. For installation, position the piston ring to be the ‘TOP’ mark on the piston ring upward and arrange the piston ring ends to be 120°...

  • Page 166: Oil Pan

    M162 ENGINE MECHANICAL 1B1-91 OIL PAN 1 Gasket ........... Replace 5 Bolt (M6 x 85) ..........10 Nm 2 Bolt (M6 x 22, 6 pieces) ......10 Nm 6 Bolt (M8 x 40) ..........25 Nm 3 Drain Plug (M6 x 20) ......... 25 Nm 7 Bolt (M10) ..........
  • Page 167 1B1-92 M162 ENGINE MECHANICAL Oil Circulation 1 Oil Pump 19 Oil Supply (To Intake Camshaft) 2 Oil Gallery (to oil filter) 20 Oil Supply (To Exhaust Camshaft Bearing) 3 Oil Filter 21 Oil Supply (To Intake Camshaft Bearing) 4 Oil Pressure Switch 22 Oil Gallery (Oil Supply to Exhaust Valve Tappet) 5 Main Oil Gallery 23 Oil Gallery (Oil Supply to Exhaust Valve Tappet)

  • Page 168: Engine Oil And Oil Filter Element

    M162 ENGINE MECHANICAL 1B1-93 ENGINE OIL AND OIL FILTER ELEMENT Tools Required 103 589 02 09 00 Oil Filter Socket Wrench Replacement Procedure 1. Install the socket wrench”7” (special tool : 103 589 02 09 00) on the oil filter cover (2). Notice Make the screw cover removable by tightening the bolt at the side of the socket wrench (special tool).
  • Page 169 1B1-94 M162 ENGINE MECHANICAL 9. Fill up engine oil through the engine oil filler opening (3). 10. Check for oil leaks at normal engine temperature after starting the engine. 11. Stop the engine and wait 5 minutes. Check the oil level and fill up as specified if necessary. 3 Oil Filler Cap 4 Dipstick Gauge...

  • Page 170: Oil Filter

    M162 ENGINE MECHANICAL 1B1-95 OIL FILTER Preceding Work : Removal of starter motor Removal of upper intake manifold 1 Coolant Line 5 Bolt ............23 Nm 2 O-ring ............ Replace 6 Oil Filter 3 Clip 7 Gasket ........... Replace 4 Hose...
  • Page 171 1B1-96 M162 ENGINE MECHANICAL Removal & Installation Procedure 1. Drain the coolant from the crank case. 2. Remove the each coolant line and hose. 3. Remove the oil filter bolt and then remove the oil filter. Installation Notice Tightening Torque 23 Nm Notice Replace the oil filter gasket.

  • Page 172: Oil Pump

    M162 ENGINE MECHANICAL 1B1-97 OIL PUMP Preceding Work : Removal of oil pan 1 Bolt (M8 x 20, 1 piece) ......29-35 Nm 4 Spring Pin 2 Sprocket (Oil Pump Drive) 5 Oil Pump 3 Bolt (M8 x 35, 3 pieces) ....22.5-27.5 Nm...
  • Page 173 1B1-98 M162 ENGINE MECHANICAL Removal & Installation Procedure 1. Remove the bolt (1) from the oil pump drive sprocket (2) and separate the gear and the oil pump drive chain. Installation Notice Tightening Torque 29 - 35 Nm 2. Unscrew the oil pump mounting bolts (3). Installation Notice Tightening Torque 22.5 - 27.5 Nm...

  • Page 174: Oil Pressure Relief Valve

    M162 ENGINE MECHANICAL 1B1-99 OIL PRESSURE RELIEF VALVE Preceding Work : Removal of oil pan 1 Screw Plug ..........50 Nm 3 Guide Pin 2 Compression Spring 4 Piston Removal & Installation Procedure 1. Remove the screw plug (1). Installation Notice Tightening Torque 50 Nm 2.

  • Page 175: Oil Non-Return Valve

    1B1-100 M162 ENGINE MECHANICAL OIL NON-RETURN VALVE Preceding Work : Removal of timing gear case cover 1 Oil Non-return Valve Functions The non-return valve prevents the oil in the chain tensioner from drying up. In other words, it stops oil-returning in order to prevent the oil in the chain tensioner from getting dry.

  • Page 176: Oil Dipstick Guide Tube

    M162 ENGINE MECHANICAL 1B1-101 OIL DIPSTICK GUIDE TUBE 1 Oil Dipstick Level Gauge 3 O-ring 2 Oil Dipstick Guide Tube 4 Bolt (M6 x 12, 1 piece) ......9-11 Nm Removal & Installation Procedure 1. Pull out the oil dipstick level gauge (1). 2.

  • Page 177: Unit Repair

    1B1-102 M162 ENGINE MECHANICAL UNIT REPAIR OIL GALLERY IN CRANKCASE Preceding Work : Removal of crankshaft, removal of oil spray nozzle 1 Plug 3 Round Bar ........f 11 x 750 mm 2 Steel Ball Cleaning Procedure 1. Remove the plug (1) with a screwdriver. 2.
  • Page 178 M162 ENGINE MECHANICAL 1B1-103 1 Plug ............Replace 3 Screw Plug 2 Main Oil Gallery Tools Required 102 589 12 15 00 Drift Sealing Procedure 1. Enlarge the end of main oil gallery (4) to be diameter of 16mm, depth of 15mm. 2.

  • Page 179: Oil Gallery In Cylinder Head

    1B1-104 M162 ENGINE MECHANICAL OIL GALLERY IN CYLINDER HEAD Preceding Work : Removal of cylinder head Removal of camshaft Removal of tappet 1 Screw Plug ..........15 Nm 3 Steel Ball ( f 8mm) 2 Seal Cleaning Procedure 1. Remove the screw plug (1) and the seal (2). Installation Notice Tightening Torque 15 Nm...
  • Page 180 M162 ENGINE MECHANICAL 1B1-105 Sealing Procedure 1. Remove the screw plug (1) and the seal. Installation Notice Tightening Torque 15 Nm 2. Remove the steel ball from the oil gallery (4), (5), (6) and (7) using the round bar (12, f 6 x 700 mm). 3.
  • Page 181 1B1-106 M162 ENGINE MECHANICAL 8. Make a screw hole at the oil gallery using M10 x 1 thread. 9. All the oil gallery should be cleaned with the compressed air. 10. Apply the Loctite 270 to new plug and press in using a suitable drift (arrow).

  • Page 182: Core Plugs In Crankcase

    M162 ENGINE MECHANICAL 1B1-107 CORE PLUGS IN CRANKCASE Preceding Work : Draining of the coolant 1 Core Plug ..........Replace...
  • Page 183 1B1-108 M162 ENGINE MECHANICAL Tools Required 102 589 00 15 00 Drift Replacement Procedure 1. Remove the intake and exhaust manifolds. 2. Pull back the core plug until the end of one side comes out using the screw driver. 3. Pull out the plug carefully using a pliers. 4.

  • Page 184: Cylinder Bore

    M162 ENGINE MECHANICAL 1B1-109 CYLINDER BORE Group Code Letter and Cylinder Bore Size Cylinder Bore Size (mm) Group Code Letter of Cylinder Piston Type to be Used f 89.900 - f 90.906 A or X f 89.906 - f 89.912 A, X or B f 89.912 - f 89.918 X or B...
  • Page 185 1B1-110 M162 ENGINE MECHANICAL Service Data Standard Wear Limit in Longitudinal and Transverse Direction 0.1 mm Permissible Deviation of Cylinder Out-of-round When new 0.007 mm Wear limit 0.05 mm Permissible Deviation of Rectangular Cylinder Height (Except Chamfered Area) 0.05 mm Basic Peak-to-valley Height After Final Honing and Brushing 0.003 - 0.006 mm Chamfer Angle...

  • Page 186: Crankcase Mating Surface

    M162 ENGINE MECHANICAL 1B1-111 CRANKCASE MATING SURFACE Service Data Standard Height of The Crankcase “H” (When new) 282.25 - 282.35mm Minimum Height After Milling 281.95mm Flatness Crankcase Upper Mating Surface 0.03mm Crankcase Lower Mating Surface 0.04mm Permissible Deviation of Parallelism of The Axial Direction 0.1mm Upper to Lower Mating Surface...
  • Page 187 1B1-112 M162 ENGINE MECHANICAL Chamfering Procedure 1. Chamfer angle : 60° 2. Polish the lower chamfered area evenly with a grinder after finishing the chamfering with a suitable tool (e.g., hand milling cutter).

  • Page 188: Cylinder Head Mating Surface

    M162 ENGINE MECHANICAL 1B1-113 CYLINDER HEAD MATING SURFACE Preceding Work : Removal of valves Service Data Standard Overall Height of Cylinder Head 135.9 - 136.0 mm Minimum Height After Machining 135.5 mm Flatness Axial Direction 0.08 mm Transverse Direction 0.0 mm Distance ‘T’...
  • Page 189 1B1-114 M162 ENGINE MECHANICAL Measurement of Mating Surface 1. Measure the height (H) of the cylinder head (refer to Service data standard ). 2. Check the mating surface of the cylinder head. 3. Mill the sharp edge of the combustion chamber. 4.
  • Page 190 SECTION 1B2 M161 ENGINE MECHANICAL CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
  • Page 191 1B2-2 M161 ENGINE MECHANICAL SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application N· · · · · m Power Steering Hydraulic Lines 35 - 40 A/C High Pressure and Liquid Hose 10 - 15 Radiator Support Menber Bolt 5 - 10 Fuel Supply and Return Hose to Fuel Distributor 21 - 25 Exhaust Manifold and Pipe Propeller Shaft to Transmission...
  • Page 192 M161 ENGINE MECHANICAL 1B2-3 FASTENER TIGHTENING SPECIFICATIONS (Cont’d) Application N· · · · · m Exhaust Camshaft Sproket Bolt 20 / +90° Chain Tensioner Screw Plug Chain Tensioner Assembly 72 - 88 Exhaust Camshaft Sprocket to Camshaft 20 / +90° Oil Pump Sprocket Bolt 25 - 35 Tensioning Device Bolt...

  • Page 193: Special Tools

    1B2-4 M161 ENGINE MECHANICAL SPECIAL TOOLS SPECIAL TOOLS TABLE 000 589 10 99 01 000 589 40 37 00 Torque Wrench Hose Clamp 112 589 00 72 00 000 589 72 21 00 Oil Extractor Torque Wrench 001 589 66 21 00 124 589 15 21 00 Torque Wrench Radiator Cap...
  • Page 194 M161 ENGINE MECHANICAL 1B2-5 SPECIAL TOOLS TABLE (Cont’d) 104 589 01 01 00 111 589 01 59 00 Spanner Supporting Bar 111 589 18 61 00 111 589 25 63 00 Lever Pusher Thrust Piece 116 589 06 63 00 104 589 00 37 00 Magnetic Finger Pliers...
  • Page 195 1B2-6 M161 ENGINE MECHANICAL SPECIAL TOOLS TABLE (Cont’d) 116 589 20 33 00 601 589 03 43 00 Sliding Hammer Sleeve 602 589 00 40 00 103 589 00 33 00 Engine Lock Puller 001 589 65 09 00 000 589 88 33 00 Socket Wrench Insert Puller 001 589 74 21 00...
  • Page 196 M161 ENGINE MECHANICAL 1B2-7 SPECIAL TOOLS TABLE (Cont’d) 103 589 01 63 00 615 589 01 33 00 Rivet Set Caulking Bolt 103 589 02 09 00 102 589 12 15 00 Oil Filter Drift Socket Wrench 102 589 00 15 00 601 589 03 14 00 Drift Sleeve...
  • Page 197 1B2-8 M161 ENGINE MECHANICAL SPECIAL TOOLS TABLE (Cont’d) 617 589 00 10 00 116 589 01 34 00 Wrench Socket Threaded Bolt 104 589 00 40 00 111 589 03 15 00 Holder Insert Pin...

  • Page 198: Maintenance And Repair

    M161 ENGINE MECHANICAL 1B2-9 MAINTENANCE AND REPAIR ON-VEHICLE SERVICE ENGINE ASSEMBLY Tools Required 000 589 10 99 01 Torque Wrench 000 589 40 37 00 Hose Clamp 112 589 00 72 00 Oil Extractor 000 589 72 21 00 Torque Wrench 001 589 66 21 00 Torque Wrench 124 589 15 21 00 Radiator Cap Testing Unit Removal &...
  • Page 199 1B2-10 M161 ENGINE MECHANICAL 6. Loosen the radiator drain cock and drain the coolant. Notice Open the coolant reservoir cap. 7. Loosen the cylinder block drain plug and then drain the coolant completely. Installation Notice Tightening Torque 30 Nm Notice Replace the seal before installation of the drain plug.
  • Page 200 M161 ENGINE MECHANICAL 1B2-11 10. Remove the upper mounting bolts of radiator and then remove the radiator. 11. Remove the hydraulic pipe of power steering. Notice Completely drain the oil. 12. Discharge the refrigerant from A/C system, and disconnect the discharge pipe and suction pipe from the compressor. 13.
  • Page 201 1B2-12 M161 ENGINE MECHANICAL 14. Remove the fuel feed and return line. Notice Before removing the fuel lines, release the pressure in the fuel system. Installation Notice Tightening Torque 21 - 25 Nm 15. Remove the automatic transmission dipstick guide tube. 16.
  • Page 202 M161 ENGINE MECHANICAL 1B2-13 19. Disconnect the engine ground wire. 20. Disconnect following sensors connector. HFM sensor. Coolant temperature sensor. 2 knock sensors. Camshaft and crankshaft sensors. 21. After removing the ignition coil cover, disconnect the ignition coil connector. 22. Remove the harness cover and disconnect the 6 injection valve connectors.
  • Page 203 1B2-14 M161 ENGINE MECHANICAL 24. Remove the automatic transmission oil cooler line. 25. Separate the vacuum hose for brake booster. 26. Separate the other vacuum hoses. 27. Remove the propeller shaft from the front axle. Installation Notice Tightening Torque 81 - 89 Nm 28.
  • Page 204 M161 ENGINE MECHANICAL 1B2-15 29. Remove the exhaust manifold and exhaust pipe. Installation Notice Tightening Torque 30 Nm 30. Remove the transmission mounting bolts and separate the transmission from the engine. Installation Notice Tightening Torque 65 Nm 31. Remove the bolts for engine mounting bracket. Installation Notice Tightening Torque 50 - 75 Nm...

  • Page 205: Crankcase Ventilation System

    1B2-16 M161 ENGINE MECHANICAL CRANKCASE VENTILATION SYSTEM Operation at Idling and Mid-Load 1 HFM Sensor 11 Oil Separation Chamber (Mid-Load at Idling) 2 Cylinder Head Cover 12 Crank Chamber 3 Oil Spearation Chamber (Full-Load or Over 13 Oil Return Pipe Mid-Load) 14 Oil Pan 4 Intake Air Duct (Cross Pipe)
  • Page 206 M161 ENGINE MECHANICAL 1B2-17 Operation at Idling and Mid-Load The throttle valve(6) is closed or very partially opened, and the vacuum pressure in intake manifold is high. The blow-by gas and the fresh air that is additionally supplied through the vent connection(D) in the crankcase in partial load gets supplied to the combustion chamber from the crank chamber(12) through the oil separation chamber(11), air- conditioner bracket(10), vent line(9), and restrictor(7)
  • Page 207 1B2-18 M161 ENGINE MECHANICAL Operation When Full-Load at Partial Load 1 HFM Sensor 11 Oil Separation Chamber (Mid-Load at Idling) 2 Cylinder Head Cover 12 Crank Chamber 3 Oil Spearation Chamber (Full-Load or Over 13 Oil Return Pipe Mid-Load) 14 Oil Pan 4 Intake Air Duct (Cross Pipe) 15 Timing Gear Case Cover 5 Vent Line (Full-Load or Over Mid-Load)
  • Page 208 M161 ENGINE MECHANICAL 1B2-19 Operation When Full-Load at Partial Load The throttle valve (6) is partially opened or fully opened. The air flows very rapidly through the vent line(5)s connection(D) and the intake air duct when full-load at partial load. Consequently, most of the low-by gases are supplied to the combustion chamber through the timing gear case cover(15), chain housing(17), oil separation chamber(3),...

  • Page 209: Alternator

    1B2-20 M161 ENGINE MECHANICAL ALTERNATOR 1 Bolt (M8 X 40, 3 pieces) ....22.5-27.5 Nm 3 Bolt (M8 X 85, 1 piece) ....22.5-27.5 Nm 2 Bolt (M8 X 70, 2 pieces) ....22.5-27.5 Nm 4 Alternator Bracket Removal & Installation Procedure 1.

  • Page 210: Power Steering Pump And A/C Bracket

    M161 ENGINE MECHANICAL 1B2-21 POWER STEERING PUMP AND A/C BRACKET Preceding Work : Removal of cooling fan and shroud Removal of drive belt 1 Nut ..........35.2-28.8 Nm 5 A / C Bracket 2 Washer 6 A / C Compressor 3 Belt Pulley 7 Bolt ..........
  • Page 211 1B2-22 M161 ENGINE MECHANICAL Removal & Installation Procedure 1. Remove the belt pulley after removal of poly v-belt. Installation Notice Tightening Torque 40.5 - 49.5 Nm Notice Pull the tensioning pulley counterclockwise as shown in the figure. 2. Disconnect the hydraulic pipe of the power steering pump and drain the oil.
  • Page 212 M161 ENGINE MECHANICAL 1B2-23 5. Disconnect the vent hose from the A/C bracket. 6. Unscrew all the mounting bolts (arrows) and remove the A/C bracket and the gasket. Installation Notice Tightening Torque 22.5 - 27.5 Nm 7. Clean the sealing surface. 8.

  • Page 213: Hydraulic Engine Mounting Insulator

    1B2-24 M161 ENGINE MECHANICAL HYDRAULIC ENGINE MOUNTING INSULATOR Service Data...
  • Page 214 M161 ENGINE MECHANICAL 1B2-25 Sectional View 1 Rubber Body 9 Lower Orifice 2 Brackek 10 Upper Orifice 3 Core 11 Diaphram 4 Lower Bolt 12 Cover Plate 5 Rubber Plunger 13 Upper Bolt 6 Plunger Plate 14 Flange Bolt 7 Rubber 15 Rivet 8 Plate 16 Fluid...
  • Page 215 1B2-26 M161 ENGINE MECHANICAL 1 Upper Nut 2 Hydraulic Installer ....62-93 Nm 3 Lower Nut ......28-47 Nm Removal and Installation Procedure 1. Unscrew the upper nut(1) on engine mounting and remove the engine. Installation Notice Tightening Torque 62 - 93 Nm 2.

  • Page 216: Poly V-Belt

    M161 ENGINE MECHANICAL 1B2-27 POLY V-BELT Preceding Work : Removal of cooling fan 3 Belt Tensioner 1 Poly V-belt (2,155 mm) 2 Belt Tensioning Pulley Removal & Installation Procedure 1. Release the belt tension by turning the stud on the cap with 12 sided wrench or spanner counterclockwise.
  • Page 217 1B2-28 M161 ENGINE MECHANICAL Poly V-belt Arrangement 1 Belt Tensioning Pulley 5 Alternator Pulley 2 Crankshaft Belt Pulley 7 Power Steering Pump Pulley 3 A/C Compressor Pulley 8 Water Pump Pulley...

  • Page 218: Tensioning Deivce

    M161 ENGINE MECHANICAL 1B2-29 TENSIONING DEVICE Preceding Work : Removal of tensioning device shock absorber 1 Bolt (M8 x 75, 2 pieces) + 3 Tensioning Device Washer .......... 22.5-27.5 Nm 4 Stud bolt 2 Bolt (M8 x 25, 1 pieces) + 5 Tensioning Arm Washer ..........

  • Page 219: Tensioning Device Shock Absorber

    1B2-30 M161 ENGINE MECHANICAL TENSIONING DEVICE SHOCK ABSORBER 1 End Cover 5 Tensioning Device 2 Nut ..........40.5-49.5 Nm 6 Bolt (M8 X 35) + Washer ....22.5-27.5 Nm 3 Tensioning Pulley 7 Shock Absorber 4 Bolt (M8 X 25) + Washer ....22.5-27.5 Nm Removal &...

  • Page 220: Poly V-Belt Inspection

    M161 ENGINE MECHANICAL 1B2-31 POLY V-BELT INSPECTION Make marks on the belt with chalk. Rotate the engine and check the belt for damage. Notice If one of the following types of damages is found, replace the belt. 1. Rubber lumps in the base of rib. 2.
  • Page 221 1B2-32 M161 ENGINE MECHANICAL 5. Cord torn out at the side. 6. Outer cords frayed. 7. Rib detached from the base of belt. 8. Splits across the rib. 9. Sections of rib torn out. 10. Splits across several ribs.
  • Page 222 M161 ENGINE MECHANICAL 1B2-33 11. Splits across the back of the belt.

  • Page 223: Cylinder Head Cover

    1B2-34 M161 ENGINE MECHANICAL CYLINDER HEAD COVER 1 Ignition Coil Cover 4 Cylinder Head Cover 2 Spark Plug Connector 5 Gasket ........... Replace 3 Bolt (M6 X 45 : 4 pieces, M6 X 60 : 6 pieces) ..........10 ± 1 Nm...
  • Page 224 M161 ENGINE MECHANICAL 1B2-35 Removal & Installation Procedure 1. Remove the intake air duct. Installation Notice Tightening Torque 9 - 11 Nm 2. Remove the ignition coil cover. Installation Notice Tightening Torque 9 - 10 Nm Notice Release 3 screws from the ignition cover and remove the cover for M161 Engine coil.
  • Page 225 1B2-36 M161 ENGINE MECHANICAL CYLINDER HEAD FRONT COVER Preceding Work : Removal of cylinder head cover Removal of thermostat housing assembly Removal of engine hanger bracket 1 Bolt (M6 X 16, 3 pieces) ......9-11 Nm 6 Front Cover (E20 : M161.940) 2 Camshaft Adjuster 7 Sleeve 3 Bolt (M8 X 35, 2 pieces) ....
  • Page 226 M161 ENGINE MECHANICAL 1B2-37 2. Remove the cylinder head front cover. Installation Notice Tightening Torque (3) 22.5 - 27.5 Nm Tightening Torque (4) 9 - 11 Nm Apply the sealant at the mating surface of the cylinder head and the front cover. 3.

  • Page 227: Cylinder Head

    1B2-38 M161 ENGINE MECHANICAL CYLINDER HEAD Preceding Work : Removal of cylinder head cover Removal of cylinder head front cover Removal of intake manifold Removal of cylinder head lower line (intake manifold side) 1 Cylinder Head Bolt (M12 X 100, 10 pieces) 3 Camshaft Bearing cap ....
  • Page 228 M161 ENGINE MECHANICAL 1B2-39 Tools Required 617 589 00 10 00 Wrench Socket 116 589 20 33 00 Sliding Hammer 116 589 01 34 00 Threaded Bolt 001 589 66 21 00 Torque Wrence 104 589 00 40 00 Holder Removal &...
  • Page 229 1B2-40 M161 ENGINE MECHANICAL 6. Remove the in take camshaft sprocket (E20 engine). 7. Remove the camshaft adjuster (E23, M161.973 engine). Installation Notice (Flange Bolt) 1st step 18 - 22 Nm Tightening Torque 2nd step 85° - 95° Notice The flange bolt is designed to be used only once, so always replace with new one.

  • Page 230: Gasket

    M161 ENGINE MECHANICAL 1B2-41 10. Remove the cylinder head bolts in the reverse order of the numerics (No.10 ® No.1). Installation Notice Tighten the bolts as numerical order with specified torque (No.1 ® No.10). 1st step 55 ± 5 Nm 2nd step + 90°...
  • Page 231 1B2-42 M161 ENGINE MECHANICAL 15. Check the length of the cylinder head bolt. When New 100 mm Length of the bolt(L) Max. Length 105 mm Notice Replace the bolt if the measured length exceed the max. length. 16. Installation should follow the removal procedure in the reverse order.

  • Page 232: Timing Gear Case Cover

    M161 ENGINE MECHANICAL 1B2-43 TIMING GEAR CASE COVER Preceding Work : Removal of viscous clutch Removal of cylinder head front cover Removal of tensioning device Removal of water pump Removal of oil filter element Removal of oil pan Removal of alternator bracker 1 Bolt (M8 X 60, 3 Pieces) ....
  • Page 233 1B2-44 M161 ENGINE MECHANICAL Tools Required 001 589 72 21 00 Torque Wrench 116 589 20 33 00 Sliding Hammer 116 589 01 34 00 Threaded Bolt Removal & Installation Procedure 1. Remove the power steering belt pulley and A/C compressor bracket.
  • Page 234 M161 ENGINE MECHANICAL 1B2-45 8. Unscrew the bolts (A). Installation Notice Tightening Torque 22.5 - 27.5 Nm 9. Remove the belt pulley and vibration damper. Installation Notice (Center Bolt) 1st step 180 - 220 Nm Tightening Torque 2nd step 80° - 100° 10.

  • Page 235: Crankshaft Sealing Rear Cover

    1B2-46 M161 ENGINE MECHANICAL CRANKSHAFT SEALING REAR COVER Preceding Work : Removal of the automatic transmission drive plate or flywheel 1 Bolt (M6 x 20, 6 pieces) ......9-11 Nm 4 Sleeve 2 Radial Shaft Seal 5 Bolt (M6 x 85, 2 pieces) ......9-11 Nm 3 Rear Cover 6 Washer...
  • Page 236 M161 ENGINE MECHANICAL 1B2-47 Tools Required 601 589 03 43 00 Sleeve Removal & Installation Procedure 1. Unscrew the bolts (1) and (5) and remove the closing cover by pulling the rear cover lug (arrows). Notice Be careful not to damage the oil pan gasket. 2.

  • Page 237: Belt Pulley And Vibration Damper

    1B2-48 M161 ENGINE MECHANICAL BELT PULLEY AND VIBRATION DAMPER Preceding Work : Removal of cooling fan and viscous clutch Removal of fan shroud Removal of drive belt 1 Center Bolt 5 Vibration Damper Assembly (M18 X 55) ....... 1st step 200-220 Nm 6 Key 2nd step 90°...
  • Page 238 M161 ENGINE MECHANICAL 1B2-49 Components 1 Center Bolt (M18 x 50) 2 Center Bolt Washer 3 Vibration Damper and Pulley Assembly 4 Key 5 Crankshaft Front Seal 6 Timing Gear Case Cover 7 Crankshaft Sprocket (Camshaft Driven) 8 Crankshaft Sprocket (Oil pump Driven) 9 Crankshaft 10 Oil Pan 11 Oil Pan Gasket...
  • Page 239 1B2-50 M161 ENGINE MECHANICAL 2. Remove the start motor and install the engine lock to the flywheel ring gear. 3. Remove the center bolt. Installation Notice 1st step 180 - 220 Nm Tightening Torque 2nd step + 90° Engine Lock 602 589 00 40 00 4.

  • Page 240: Crankshaft Front Radial Seal

    M161 ENGINE MECHANICAL 1B2-51 CRANKSHAFT FRONT RADIAL SEAL Preceding Work : Removal of belt pulley and vibration damper 1 Center Bolt (M18 x 50) ....... 1st step 200-220 Nm 2nd step 90° +10° 2 Center Bolt Washer 3 Sleeve (Special Tool) 4 Crankshaft Front Seal 5 Key Tools Required...

  • Page 241: Crankshaft Rear Radial Seal

    1B2-52 M161 ENGINE MECHANICAL CRANKSHAFT REAR RADIAL SEAL Preceding Work : Removal of flywheel or drive plate 1 Special Tool 3 Crankshaft Rear Seal 2 Special Tool Tools Required 601 589 03 43 00 Sleeve Replacement Proceudre 1. Remove the radial seal with a screw driver. Notice Use a clean cloth not to damage the radial seal mounting hole and the crankshaft.

  • Page 242: Crankshaft

    M161 ENGINE MECHANICAL 1B2-53 CRANKSHAFT Preceding Work : Removal of engine Removal of cylinder head Removal of timing gear case cover Removal of crankcase sealing rear cover Removal of oil pan Removal of baffle plate Removal of oil pump 1 Bearing Cap Bolt (M8 X 55-10 pieces) ....
  • Page 243 1B2-54 M161 ENGINE MECHANICAL Arrangement of the Thrust Bearing and the Main Bearing 1 Upper Main Bearing A Crankcase Side 2 Upper Thrust Bearing B Bearing Cap Side (Oil Pan Side) 3 Crankshaft 4 Lower Main Bearing 5 Lower Thrust Bearing 1 - 8 Weight Balance/Color Marking Point j1 - j5 Journal Main Bearing #1 - #5 Color Dot Marking...
  • Page 244 M161 ENGINE MECHANICAL 1B2-55 Color Dot Marking Crankshaft Journal Diameter (mm) Blue 57.960 - 57.965 Yellow 57.955 - 57.960 57.950 - 57.955 White 57.945 - 57.950 Violet 57.940 - 57.945 Selection of Crankshaft Main Bearing 1. Crankcase Side There are seven punching marks on the mating surface to oil pan.
  • Page 245 1B2-56 M161 ENGINE MECHANICAL Removal & Installation Procedure 1. Unscrew the connecting rod bearing cap bolt and remove the bearing cap. Installation Notice Tightening Torque 40 Nm + 90° Make sure that the upper and lower bearing shells do not change each other. Coat the bearing shell with engine oil.
  • Page 246 M161 ENGINE MECHANICAL 1B2-57 Inspection 1. If the length ‘L’ of the crankshaft bearing cap bolt exceeds 63.8mm, replace it. 2. Make sure the crankshaft bearing cap is properly seated on the cylinder block (arrows). 3. Measure and record the inner diameter of the crankshaft bearing.
  • Page 247 1B2-58 M161 ENGINE MECHANICAL Service Data Standard (Crankshaft Main Bearing Gap) Item Measuring Position Gap (mm) Main Bearing Journal Static condition :0.015 - 0.039 ( NO. 1, 5, 7) Radial Dynamic condition: 0.031 - 0.051 (Consider the expansion 0.011 - 0.016) Axial 0.010 - 0.254 (Connecting Rod Bearing Gap)

  • Page 248: Flywheel/Driven Plate

    M161 ENGINE MECHANICAL 1B2-59 FLYWHEEL/DRIVEN PLATE Preceding Work : Removal of manual or automatic transmission 1 Flywheel Mounting Bolt 3 Driven Plate (A/T) (M10 x 22, 8 pieces) ....1st Step 45 Nm 4 Dowel Pin 2nd Step 90°+10° 5 Flywheel (M/T) 2 Plate Service Data Standard (Stretch Bolt) Nominal Size...
  • Page 249 1B2-60 M161 ENGINE MECHANICAL Removal & Installation Procedure 1. Unscrew the stretch bolt. Installation Notice 1st step 45 Nm Tightening Torque 2nd step 90°+10° Replace the bolt when the stretch side diameter (d) of the flywheel mounting bolt is less than 8.0mm. For the stretch bolt tightening, keep the socket wrench and Tommy-bar to be 90°...

  • Page 250: Camshaft Adjuster

    M161 ENGINE MECHANICAL 1B2-61 CAMSHAFT ADJUSTER 1 Bolt (M6 X 16, 3 pieces) ......9-11 Nm 11 Flange Bolt 2 Cylinder Head Front Cover (M7 X 13, 3 pieces) ....1st Step 20±2 Nm 3 Bolt ............35 Nm 2nd Step 90° ± 5° Rotation Added 4 Armature 12 Flange Shaft 5 Roll Pin...
  • Page 251 1B2-62 M161 ENGINE MECHANICAL Removal & Installation Procedure 1. Turn the crankshaft and position the No.1 cylinder piston at ATDC 20°. Notice Turn the crankshaft in the direction of engine rotation. 2. Remove the cylinder head front cover. 3. Put the alignment marks (arrows) on the camshaft sprocket and the timing chain.
  • Page 252 M161 ENGINE MECHANICAL 1B2-63 7. Unscrew the bolt (3) from the armature (4) and remove the roll pin, and remove the armature. Installation Notice Tightening Torque 35 Nm 8. Unscrew the nut (6) and remove the seal cover (7). Installation Notice Tightening Torque 60- 70 Nm Notice...

  • Page 253: Camshaft Sprocket Bolt

    1B2-64 M161 ENGINE MECHANICAL CAMSHAFT SPROCKET BOLT Intake Flange Shaft Bolt 1st step 20 Nm Tightening Torque 2nd step + 90° Notice The sprocket bolts are designed to be used only once, so always replace with new one. C. M7 x 13 Collar Bolt Torx-T30 e.

  • Page 254: Camshaft

    M161 ENGINE MECHANICAL 1B2-65 CAMSHAFT Preceding Work : Removal of cylinder head cover Removal of camshaft adjust actuator and cylinder head front cover 1 Bolt (M7 X 13, 3 pieces) ..1st Step 18-22 Nm 4b Camshaft Adjuster and Camshaft Sprocket (E23) 2nd Step 90°+ 5°...
  • Page 255 1B2-66 M161 ENGINE MECHANICAL Tools Required 000 589 01 10 00 Box Wrench Insert 104 589 01 01 00 Spanner Removal & Installation Procedure 1. Turn the crankshaft and position the No.1 cylinder piston at ATDC20°. 2. Put the alignment marks (arrows) on the camshaft sprocket and the timing chain.
  • Page 256 M161 ENGINE MECHANICAL 1B2-67 7. Remove the bearing cap, and remove the intake and the exhaust camshaft. Installation Notice Tightening Torque 22.5 - 27.5 Nm Notice Check the numbers on the bearing cap not to be miked 8. Apply the engine oil on the valve tappet and camshaft bearing.

  • Page 257: Camshaft Timing Position

    1B2-68 M161 ENGINE MECHANICAL CAMSHAFT TIMING POSITION Preceding Work : Removal of cylinder head cover Removal of cylinder head front cover 1 Insert Pin ( f 6.5mm, Special Tool) 5 Exhaust Camshaft Sprocket 2 Intake Camshaft Sprocket 6 Bolt (M7 X 13, 3 pieces) ..1st step 20 ± 2 Nm 3 Camshaft Bearing Cap 2nd step 90°...

  • Page 258: Inspection Procedure

    M161 ENGINE MECHANICAL 1B2-69 Tools Required 104 589 01 01 00 Spanner 111 589 03 15 00 Insert Pin Inspection Procedure 1. Position the No.1 cylinder piston to ATDC 20° by turning the crankshaft Notice When the ATDC 20° mark on vibration damper is aligned with timing gear case cover, the intake and exhaust cam of cylinder will make the slope to the center and will face up.
  • Page 259 1B2-70 M161 ENGINE MECHANICAL Adjustment Procedure 1. Position the No.1 cylinder to ATDC 20° . 2. Remove the chain tensioner. 3. Remove the exhaust camshaft sprocket. 4. Adjust the timing position with inserting the insert pin ( f 6.5mm, 111 589 03 15 00) into the No.1 and No.4 camshaft bearing cap hole and flange hole while rotating the camshaft by using wrench (104 589 01 01 00).

  • Page 260: Valve Spring

    M161 ENGINE MECHANICAL 1B2-71 VALVE SPRING Preceding Work : Removal of camshaft Removal of spark plug 1 Valve Tappet Assembly 7 Connecting Hose 2 Valve Cotter 8 Thrust Piece 3 Upper Retainer 9 Slide 4 Valve Spring ..Check, Replace if necessary 10 Adjust Bolt 5 Valve Stem Seal 11 Lever Pusher...
  • Page 261 1B2-72 M161 ENGINE MECHANICAL Tools Required 111 589 01 59 00 Supporting Bar 111 589 18 61 00 Lever Pusher 111 589 25 63 00 Thrust Piece 116 589 06 63 00 Magnetic Finger Removal & Installation Procedure 1. Place the supporting bar (12) and the slide (9) at the camshaft bearing cap (Nos 1 &...
  • Page 262 M161 ENGINE MECHANICAL 1B2-73 8. Install the lever pusher (11) and the thrust piece (8) to the slide (9). Lever Pusher 111 589 18 61 00 9. Mount the thrust piece (8) vertically to the valve spring retainer (3). 10. Make the thrust piece (8) and the slide (9) perpendicular to each other.
  • Page 263 1B2-74 M161 ENGINE MECHANICAL Test (Upper and Lower Valve Tappet and Valve Cotter) Upper Valve Spring Retainer Size (mm) 12.3 Lower Valve Spring Retainer Thickness (mm) 0.8 - 1.0 Valve cotter Size (mm) 9.2 - 9.8...

  • Page 264: Valve Stem Seal

    M161 ENGINE MECHANICAL 1B2-75 VALVE STEM SEAL Preceding Work : Removal of valve spring 1 Drift (Special Tool) 2 Valve Stem Seal 3 Protective Sleeve Tools Required 104 589 00 37 00 Pliers 119 589 00 43 00 Drift Replacement Procedure 1.

  • Page 265: Chain Tensioner

    1B2-76 M161 ENGINE MECHANICAL CHAIN TENSIONER 1 Screw Plug ..........40 Nm 5 Snap Ring 2 Seal 6 Thrust Pin 3 Filler Pin 7 Chain Tensioner Housing ..... 72-88 Nm 4 Compression Spring 8 Seal Removal Procedure 1. Position the number 1 cylinder to ATDC 20°. Notice Remove the oil filler cap at adjustment position, and check whether the intake camshaft cam’s lobe (arrow) stays in the...
  • Page 266 M161 ENGINE MECHANICAL 1B2-77 4. Carefully unscrew the screw plug (1), and remove the seal (2). Notice For the removal of screw plug, be careful that it can be jumped out due to the force of compression spring. Remove the screw plug only when the seal and compression spring are damaged.
  • Page 267 1B2-78 M161 ENGINE MECHANICAL 4. Lightly apply the grease to the seal (2) and install the screw plug (1). Installation Notice Tightening Torque 40 Nm 5. Check for leaks by operating the engine. Sectional View 1 Screw Plug 13 Chain Tensioner Housing 2 Ball (Nonreturn Valve) 14 Seal 3 Compression Spring...

  • Page 268: Timing Chain

    M161 ENGINE MECHANICAL 1B2-79 TIMING CHAIN Preceding Work : Removal of cylinder head cover Removal of spark plug 1 Pin 5 Link 2 New Timing Chain 6 Center Plate 3 Timing Chain (Used) 7 Outer Plate 4 Wedge...
  • Page 269 1B2-80 M161 ENGINE MECHANICAL Tools Required 000 589 58 43 00 Chain Assembly 103 589 01 63 00 Rivet Set 001 589 72 21 00 Torque Wrench Replacement Procedure 1. Position the No.1 cylinder to ATDC 20°. 2. Insert the pin to the intake and exhaust camshaft flange. 3.
  • Page 270 M161 ENGINE MECHANICAL 1B2-81 6. Remove the outer plate (7) with the screw driver and remove the link (5). 7. Connect the new timing chain (2) to the used timing chain (3) with the link (5), center plate (6, thickness 1.6mm), and the outer plate (7).
  • Page 271 1B2-82 M161 ENGINE MECHANICAL 12. Place the outer plate (7, thickness 1.2mm) inside the thrust piece (b). 13. Install the assembly tool above the link and tighten the spindle (c) until a block is felt. 14. Place the assembly tool. 15.
  • Page 272 M161 ENGINE MECHANICAL 1B2-83 17. Rivet the link pin. Check the condition and it again if necessary. 18. Install the chain tensioner. Installation Notice Screw Plug 40 Nm Tightening Torque Tensioner Assembly 72 - 88 Nm 19. Check the camshaft timing position.

  • Page 273: Tensioning Rail

    1B2-84 M161 ENGINE MECHANICAL TENSIONING RAIL Preceding Work : Removal of cylinder head 1 Sliding Rail Pin 3 Timing Gear Case Cover 2 Sliding Rail Removal & Installation Procedure 1. Remove the timing gear case cover (3). Notice Be careful not to damage the gasket. 2.

  • Page 274: Cylinder Head Guide Rail

    M161 ENGINE MECHANICAL 1B2-85 CYLINDER HEAD GUIDE RAIL Preceding Work : Removal of cylinder head cover 1 Bolt (M6 X 45, 2 pieces) ....9-11 Nm 2 Guide Rail Removal & Installation Procedure 1. Position the number 1 cylinder to ATDC20° guide rail. 2.

  • Page 275: Crankcase Guide Rail

    1B2-86 M161 ENGINE MECHANICAL CRANKCASE GUIDE RAIL Preceding Work : Removal of timing gear case cover 1 Guide Rail Pin 3 Timing Gear Case Cover 2 Guide Rail Removal & Installation Procedure 1. Remove the timing gear case cover (3). Notice Be careful not to damage the gasket when removing/ installing the timing gear case cover.

  • Page 276: Crankshaft Sprocket

    M161 ENGINE MECHANICAL 1B2-87 CRANKSHAFT SPROCKET Preceding Work : Removal of oil pan Removal of tensioning rail Removal of crank case guide rail Removal of cylinder head 1 Oil Pump Chain Tensioner 6 Bolt (M8 x 20, 1 piece) / Washer ..29-35 Nm 2 Oil Pump Chain Spring 7 Oil Pump Sprocket 3 Oil Pump Chain Bushing (Pin)
  • Page 277 1B2-88 M161 ENGINE MECHANICAL Tools Required 615 589 01 33 00 Caulking Bolt Removal & Installation Procedure 1. Put the assembly mark at the crankshaft sprocket (4) and the timing chain (10) with the paint (arrow). Installation Notice Align the assembly marks on cranshaft sprocket and timing chain.

  • Page 278: Piston

    M161 ENGINE MECHANICAL 1B2-89 PISTON Preceding Work : Removal of engine Removal of cylinder head Removal of oil pan Removal of oil pump Removal of baffle plate 1 Connecting Rod Bearing Cap 4 Piston 2 Connecting Rod 5 Snap Ring 3 Connecting Rod Bolt 6 Piston Pin (M9 x 52, 8 pieces) ......
  • Page 279 1B2-90 M161 ENGINE MECHANICAL Tools Required 001 589 72 21 00 Torqued Wrench 000 589 04 14 00 Clamping Strap Removal Procedure 1. Unscrew the connecting rod bolt (3) and remove the cap. 2. Remove the connecting rod and the piston upward. Notice Make sure that the bearing cap and shell are not changed each other.
  • Page 280 M161 ENGINE MECHANICAL 1B2-91 1. Check the piston ring gap and apply the engine oil to the piston pin and the connecting rod bushing. 2. Connect the piston and the connecting rod by pressing in the piston pin (6) and install the snap ring to the groove. 3.

  • Page 281: Connecting Rod

    1B2-92 M161 ENGINE MECHANICAL CONNECTING ROD Preceding Work : Removal of piston 1 Connecting Rod Bushing 2 Oil Gallery 3 Balance Weight 4 Connecting Rod Bolt (M9 x 52, 8 pieces) .... 1st step 40 Nm 2nd step 90° 5 Fit Sleeve 6 Upper Connecting Rod Bearing 7 Lower Connecting Rod Bearing 8 BearingShell Lug...
  • Page 282 M161 ENGINE MECHANICAL 1B2-93 Inspection 1. Measure the basic bore of the connecting rod bearing. Notice If the basic bore exceeds the value of 51.614mm, replace the bearing or check the connecting rod. 2. Check connecting rod bolts. Length When New (L) 51.7 - 52 mm Max.

  • Page 283: Piston Ring

    1B2-94 M161 ENGINE MECHANICAL PISTON RING Preceding Work : Removal of piston 1 Piston Compression Ring (Top Ring) 2 Piston Compression Ring (2nd Ring) 3 Piston Oil Ring 5 Spacer 6 Side Rail Tools Required 000 589 51 37 00 Clamping Strap Replacement Procedure 1.
  • Page 284 M161 ENGINE MECHANICAL 1B2-95 2. Remove the piston ring with a pliers. Clamping Strap 000 589 51 37 00 3. For installation, position the piston ring to be the ‘TOP’ mark on the piston ring upward and arrange the piston ring ends to be 120°...

  • Page 285: Oil Pan

    1B2-96 M161 ENGINE MECHANICAL OIL PAN 1 Bolt 5 Bolt 2 Bolt 6 Oil Pan 3 Bolt 7 Gasket 4 Bolt 1. Remove the drain plug and drain the oil completely. 2. Unscrew the bolts and remove the oil pan and gasket. Notice Arrange the bolts according to each size.

  • Page 286: Oil Pump

    M161 ENGINE MECHANICAL 1B2-97 Oil Circulation 1 Oil Strainer 16 Oil Supply (To Chain Tensioner) 2 Oil Pump 17 Camshaft 3 Oil Pan 18 Cam Bearing 4 Oil Non-Return Valve 19 Valve 5 Oil Filter 20 Oil Gallery (Supply Oil to Intake Tappet) 6 Oil Filter Bypass Valve 21 Oil Gallery (Supply Oil to Exhaust Tappet) 7 Main Oil Gallery...
  • Page 287 1B2-98 M161 ENGINE MECHANICAL ENGINE OIL AND OIL FILTER ELEMENT 1 Oil Filter Cover .......... 25 Nm 4 Oil Drain Plug 2 O-ring ............ Replace 5 Oil Filter Bypass Valve 3 Oil Filter Element 6 Oil Filter Cap...

  • Page 288: Replacement Procedure

    M161 ENGINE MECHANICAL 1B2-99 Tools Required 103 589 02 09 00 Oil Filter Socket Wrench Replacement Procedure 1. Install the socket wrench”7” (special tool : 103 589 02 09 00) on the oil filter cover (2). Notice Make the screw cover removable by tightening the bolt at the side of the socket wrench (special tool).
  • Page 289 1B2-100 M161 ENGINE MECHANICAL OIL PUMP Preceding Work : Removal of oil pan 1 Bolt (M8 X 35, 3 piece) ....22.5-27.5 Nm 6 Washer 2 Oil Pump 7 Sprocket (Oil Pump Drive) 3 Oil Strainer Assembly 8 Chain (Oil Pump Drive) 4 Bolt (M6 X 12, 2 pieces) ......
  • Page 290 M161 ENGINE MECHANICAL 1B2-101 Removal & Installation Procedure 1. Unscrew the bolt (6) from the oil pump drive sprocket and separate the oil pump drive chain. Installation Notice Tightening Torque 29 - 35 Nm 2. Unscrew the bolts (4,5) and remove the oil strainer assembly (3).

  • Page 291: Oil Pressure Relief Valve

    1B2-102 M161 ENGINE MECHANICAL OIL PRESSURE RELIEF VALVE Preceding Work : Removal of oil pan 1 Screw Plug ..........50 Nm 3 Guide Pin 2 Compression Spring 4 Piston Removal & Installation Procedure 1. Remove the screw plug (1). Installation Notice Tightening Torque 50 Nm 2.

  • Page 292: Oil Non-Return Valve

    M161 ENGINE MECHANICAL 1B2-103 OIL NON-RETURN VALVE Preceding Work : Removal of timing gear case cover 1 Oil Non-Return Valve Functions The non-return valve prevents the oil in the chain tensioner from drying up. In other words, it stops oil-returning in order to prevent the oil in the chain tensioner from getting dry.

  • Page 293: Oil Dipstick Guide Tube

    1B2-104 M161 ENGINE MECHANICAL OIL DIPSTICK GUIDE TUBE 1 Oil Dipstick Level Gauge 4 Bolt (M6 X 16, 1 piece) ......9-11 Nm 2 Oil Dipstick Guide Tube 5 Clamp 3 O-ring Removal & Installation Procedure 1. Pull out the oil dipstick level gauge (1). 2.

  • Page 294: Unit Repair

    M161 ENGINE MECHANICAL 1B2-105 UNIT REPAIR CORE PLUGS IN CRANKCASE Preceding Work : Draining of the coolant 1 Core Plug ..........Replace...
  • Page 295 1B2-106 M161 ENGINE MECHANICAL Tools Required 102 589 00 15 00 Drift Replacement Procedure 1. Remove the intake and exhaust manifolds. 2. Pull back the core plug until the end of one side comes out using the screw driver. 3. Pull out the plug carefully using a pliers. 4.

  • Page 296: Cylinder Bore

    M161 ENGINE MECHANICAL 1B2-107 CYLINDER BORE Group Code Letter and Cylinder Bore Size Piston Type to be Used Group Code Letter of Cylinder Cylinder Bore Size (mm) Engine A or X f 90.906 - f 90.912 A, X or B f 90.906 - f 90.912 X or B f 90.912 - f 90.918...
  • Page 297 1B2-108 M161 ENGINE MECHANICAL Type Group Code Letter Cylinder Bore Size (mm) f 89.900 - f 90.906 Standard Size E20 : f 89.9 f 89.906 - f 89.912 f 89.912 - f 89.918 E23 : f 90.9 1st Repair Size f 90.150 - f 90.156 f 89.156 - f 90.162 (Standard Size + 0.25)

  • Page 298: Crankcase Mating Surface

    M161 ENGINE MECHANICAL 1B2-109 CRANKCASE MATING SURFACE Service Data Standard Height of the Crankcase “H” (When New) 289.35 - 289.45mm Minimum Height After Milling 289.05mm Flatness Crankcase Upper Mating Surface 0.03mm Crankcase Lower Mating Surface 0.04mm Permissible Deviation of Parallelism of the Axial Direction 0.1mm Upper to Lower Mating Surface...
  • Page 299 1B2-110 M161 ENGINE MECHANICAL Chamfering Procedure 1. Chamfer angle : 75° 2. Polish the lower chamfered area evenly with a grinder after finishing the chamfering with a suitable tool (e.g., hand milling cutter).

  • Page 300: Cylinder Head Mating Surface

    M161 ENGINE MECHANICAL 1B2-111 CYLINDER HEAD MATING SURFACE Preceding Work : Removal of valves Service Data Standard Overall Height of Cylinder Head 135.9 - 136.0 mm Minimum Height After Machining 135.5 mm Flatness Axial Direction 0.08 mm Transverse Direction 0.0 mm Distance ‘T’...
  • Page 301 1B2-112 M161 ENGINE MECHANICAL Measurement of Mating Surface 1. Measure the height (H) of the cylinder head (refer to Service data standard ). 2. Check the mating surface of the cylinder head. 3. Mill the sharp edge of the combustion chamber. 4.
  • Page 302 SECTION 1B3 OM600 ENGINE MECHANICAL CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

  • Page 303: Specifications

    1B3-2 OM600 ENGINE MECHANICAL SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Engine Assembly N· · · · · m Application 28 - 47 Skid Plate Bolt Drain Plug Bolt 3 - 7 Coolong Fan Shroud Bolt 8 - 18 Control Linkage Nut Clutch Linkage Cylinder Nut 20 - 34 Exhaust Manifold Bolt Propeller Shaft Bolt &...
  • Page 304 OM600 ENGINE MECHANICAL 1B3-3 Cylinder Head Application N· · · · · m Camshaft Bearing Cap Bolt Camshaft Sprocket Bolt 25 / 90° Exhaust Pipe Bolt& Nut Chain Tensioner Injection Nozzle Intake Manifold Not Injection Nozzle Pipe Not Oil Dipstick Tube Bolt Screw Plug M18 x 15 Cam Support &...

  • Page 305: Special Tools

    1B3-4 OM600 ENGINE MECHANICAL SPECIAL TOOLS SPECIAL TOOLS TABLE 603 589 00 09 00 603 589 00 40 00 Serration Wrench Counter Holder 657 589 03 63 00 000 589 77 03 00 Sliding Hammer Box Wrench Insert 601 589 00 66 00 602 589 00 40 00 Counter Sink Engine Lock...

  • Page 306: Special Tools Table

    OM600 ENGINE MECHANICAL 1B3-5 SPECIAL TOOLS TABLE (Cont’d) 116 589 03 07 00 115 589 34 63 00 T Type Socket Wrench 601 589 00 10 00 Cylinder Head Bolt 102 601 589 00 25 00 102 589 12 15 00 102 589 00 15 00 f f f f f f f f f f...
  • Page 307 1B3-6 OM600 ENGINE MECHANICAL SPECIAL TOOLS TABLE (Cont’d) 601 589 08 15 00 103 589 00 33 00 Drift Puller 001 589 53 21 00 601 589 03 14 00 Dial Gauge Sleeve 601 589 07 21 00 601 589 03 43 00 Depth Gauge Oil Seal Assembler 667 589 01 21 00...
  • Page 308 OM600 ENGINE MECHANICAL 1B3-7 SPECIAL TOOLS TABLE (Cont’d) 363 589 02 21 00 116 589 07 15 00 Dial Gauge Holder Drift 000 589 33 33 00 000 589 04 14 00 Counter Support Tensioning Strap 000 589 25 33 00 102 589 03 40 00 Internal Extractor Magnetic Bar...
  • Page 309 1B3-8 OM600 ENGINE MECHANICAL SPECIAL TOOLS TABLE (Cont’d) 601 589 02 59 00 667 584 02 63 00 Supporting Bridge Supporting Bar 667 589 00 31 00 104 589 00 37 00 Press Lever Pliers 116 589 06 63 00 601 589 02 43 00 Magnetic Finger Drift...
  • Page 310 OM600 ENGINE MECHANICAL 1B3-9 SPECIAL TOOLS TABLE (Cont’d) 601 589 02 23 00 601 589 05 15 00 Go/No Go Gauge Drift (for Intake) 105 589 03 15 00 601 589 06 15 00 Drift (for Intake) Drift (for Exhaust) 103 589 02 15 00 000 589 10 53 00 Drift (for Exhaust)
  • Page 311 1B3-10 OM600 ENGINE MECHANICAL SPECIAL TOOLS TABLE (Cont’d) 001 589 32 21 00 124 589 15 21 00 Dial Gauge Tester 001 589 53 21 00 667 589 02 21 00 Dial Gauge TDC Pulse Generator 000 589 58 43 00 501 589 73 21 00 Chain Assembling Vacuum Pump...
  • Page 312 OM600 ENGINE MECHANICAL 1B3-11 SPECIAL TOOLS TABLE (Cont’d) 000 589 14 21 00 601 589 00 08 00 Tester Flange 001 589 65 09 00 116 589 02 34 00 Serration Wrench Thread Bolt 000 589 00 68 00 667 589 04 63 00 Cleaning Set Retaining Plate 601 589 05 21 00...

  • Page 313: Maintenance And Repair

    1B3-12 OM600 ENGINE MECHANICAL MAINTENANCE AND REPAIR ON-VEHICLE SERVICE ENGINE ASSEMBLY Removal & Installation Procedure 1. Disconnect the negative terminal of battery. 2. Remove the hood.
  • Page 314 OM600 ENGINE MECHANICAL 1B3-13 3. Remove the skid plate. Installation Notice Tightening Torque 28 - 47 Nm 4. Remove the radiator drain cock and drain the coolant. Notice Open the coolant reservoir tank cap. 5. Remove the drain plug (1) and seal (2) from the cylinder block and drain the coolant completely.
  • Page 315 1B3-14 OM600 ENGINE MECHANICAL 8. Disconnect the upper coolant hose from the radiator. 9. Loosen the bolt and remove the coolant pipe and cooling fan shroud. Tightening Torque 3 -7 Nm 10. Remove the hoses (air intake to intercooler, intercooler to intake duct).
  • Page 316 OM600 ENGINE MECHANICAL 1B3-15 12. Remove the hose(air cleaner to turbocharger) with blow by hose. 13. Disconnect the air cleaner intake hose and remove the air cleaner cover and element. 14. Disconnect the coolant hose from the water inlet. 15. Remove the air-conditioner lines from the compressor. Notice Evacuate the refrigerant before removal.
  • Page 317 1B3-16 OM600 ENGINE MECHANICAL 16. Remove the power steering pump lines. Notice Completely drain the fluid. 17. Disconnect the fuel feed line with prefilter from the feed pump on injection pump. 18. Vehicle with automatic transmission. Remove the hydraulic lines (19, 20) from oil cooler (2). 19.
  • Page 318 OM600 ENGINE MECHANICAL 1B3-17 21. Remove the fuel lines from the fuel filter and cover the filter with plug. 22. Disconnect the brake booster hose from vacuum pump. 23. Disconnect the other vacuum lines. 24. Disconnect the ground cable. 25. Disconnect the alternator wires. 26.
  • Page 319 1B3-18 OM600 ENGINE MECHANICAL 27. Disconnect the preheating time relay sensor plug. 28. Disconnect the coolant temperature sensor plug. 29. Disconnect the accelerator cable from the control linkage. Installation Notice Tightening Torque 8 - 18 Nm 30. Loosen the connection of control pressure cable (an arrow) used in auto transmission.
  • Page 320 OM600 ENGINE MECHANICAL 1B3-19 31. Separate the exhaust pipe flange from the turbo charger. Installation Notice Tightening Torque 30 Nm 32. Loosen the installing bolt of clutch release cylinder and remove the clutch release cylinder. Installation Notice Tightening Torque 20 - 34 Nm 33.
  • Page 321 1B3-20 OM600 ENGINE MECHANICAL 37. Loosen the engine mounting bracket nut. Installation Notice Tightening Torque 50 - 75 Nm 38. Remove the engine assembly from the vehicle by using a hoist or crane. 39. Installation should follow the removal procedure in the reverse order.

  • Page 322: Poly V-Belt

    OM600 ENGINE MECHANICAL 1B3-21 POLY V-BELT 1 Nut ............. 23Nm 4 Spring 2 Tensioning Lever 5 Tensioning Lever 3 Bolt 6 Poly V-Belt...
  • Page 323 1B3-22 OM600 ENGINE MECHANICAL Removal & Installation Procedure 1. Remove the nut. 2. Push the tensioning lever in direction of arrow with a rod (F12 ´ 180mm) and pull out the bolt to the rear. 3. Push back the tensioning lever (arrow direction) to release the spring tension and remove the belt.

  • Page 324: Tensioning Device

    OM600 ENGINE MECHANICAL 1B3-23 TENSIONING DEVICE Preceding Work : Removal of cooling fan 1 Bolt ............21Nm 10 Tensioning Pulley 2 Damper 11 Socket Bolt ..........29Nm 3 Nut ............. 21Nm 12 Closing Cover 4 Tensioning Lever 13 Washer 5 Guide Rail Pin 14 Tensioning Lever 6 Bolt 15 Fit Bolt ............
  • Page 325 1B3-24 OM600 ENGINE MECHANICAL Removal & Installation Procedure 1. Remove the nut. Installation Notice Tightening Torque 10 Nm 2. Push the tensioning lever in direction of arrow with a rod ( F12 ´ 180mm ) and push out the bolt to the rear. 3.
  • Page 326 OM600 ENGINE MECHANICAL 1B3-25 6. Pull off the tensioning lever (4) from guide rail pin. 7. Remove the spring (17). Installation Notice Insert spring (17) with color coding (blue/violet) facing up. 8. Pry off the closing cover (12) and remove the socket bolt (11) and then remove the tensioning pulley (10).

  • Page 327: Poly V-Belt Alignment & Inspection

    1B3-26 OM600 ENGINE MECHANICAL POLY V-BELT ALIGNMENT & INSPECTION Without Air Conditioner With Air Conditioner...
  • Page 328 OM600 ENGINE MECHANICAL 1B3-27 Inspection Procedure Mark poly V-belt at a clearly visible point with chalk. Rotate the engine and check the belt. Notice If one of the following types of damage is found, replace the belt. 1. Rubber lumps in the base of rips. 2.
  • Page 329 1B3-28 OM600 ENGINE MECHANICAL 7. Belt detached from the base of rip. 8. Splits across the rips. 9. Sections of rip torn out. 10. Splits across several rips. 11. Splits across the back.

  • Page 330: Prechamber

    OM600 ENGINE MECHANICAL 1B3-29 PRECHAMBER Preceding Work : Removal of glow plug Removal of fuel injection nozzle 1 Threaded Ring ........130 Nm 3 Cylinder Head 2 Prechamber...
  • Page 331 1B3-30 OM600 ENGINE MECHANICAL Tools Required 603 589 00 09 00 Serration Wrench 667 589 03 63 00 Sliding Hammer Removal & Installation Procedure 1. Using the serration wrench (4), remove the threaded ring (1). Serration Wrench 603 589 00 09 00 2.
  • Page 332 OM600 ENGINE MECHANICAL 1B3-31 Assembly Procedure Notice In case the prechambers are reused, inspect the prechambers thoroughly, if the ball pin by heat and fire is broken, it can not be used. 1. Clean the sealing surface of the prechamber. 2.

  • Page 333: Milling Of Prechamber Sealing Surface

    1B3-32 OM600 ENGINE MECHANICAL MILLING OF PRECHAMBER SEALING SURFACE 1 Drift 4 Counter Sink (Special Tool - 601 589 00 66) 2 Sleeve 5 Cylinder Head 3 Milling Cutter Tools Required 601 589 00 66 00 Counter Sink 667 589 00 23 00 Height Gauge Milling of the Prechamber Sealing Surface Notice The prechamber sealing surface may only be remachined...
  • Page 334 OM600 ENGINE MECHANICAL 1B3-33 1. Remove the injection nozzle. 2. Remove the prechamber. 3. Cover the prechamber bore to avoid any chips dropping into the combustion chamber. 4. Remove the protective sleeve from the countersink and rotate the countersink into the prechamber bore to be machined as far as the stop.
  • Page 335 1B3-34 OM600 ENGINE MECHANICAL 8. Remeasure size ‘X’ and compare it with the first measurement and determine the thickness of spacer ring. Size before machining 25.7 mm Size after machining 25.5 mm The spacer ring should be selected so that it is at least 0.1mm and not more than 0.3mm thicker than the measured on the sealing surface.

  • Page 336: Tdc (Tdc Sensor Bracket) Setting

    OM600 ENGINE MECHANICAL 1B3-35 TDC (TDC SENSOR BRACKET) SETTING Preceding Work : Removal of No.1 cylinder prechamber 1 Measuring Device 2 Dial Gauge 3 Cylinder Head 4 Piston ..........Set at TDC Tools Service 001 589 32 21 00 Dial Gauge 601 589 07 21 00 Deqth Gauge 667 589 01 21 00 Fixing Device Notice...
  • Page 337 1B3-36 OM600 ENGINE MECHANICAL Setting (with cylinder head installed) 1. Remove the prechamber of No. 1 cylinder. 2. Position the piston of No.1 cylinder at BTDC 10. 3. Install the measuring device into the prechamber bore and position the dial gauge with a preload of 5mm. Dial Gauge 001 589 53 21 00 Depth Gauge 601 589 07 21 00 4.
  • Page 338 OM600 ENGINE MECHANICAL 1B3-37 CYLINDER HEAD 1 Fuel Injection Pipe ........18Nm 21 Camshaft Drive Sprocket ....... Replace 2 Cylinder Head 22 Washer 3 Gasket ........... Replace 23 Bolt(12-Sided) ........25Nm + 90° 4 Bolt ............25Nm 24 Sliding Rail 5 Washer 25 Sliding Rail Pin 6 Clamp...
  • Page 339 1B3-38 OM600 ENGINE MECHANICAL Tightening Torque stage1 10 Nm Cylinder Bolts (12-sided socket head) (Engine cold) stage2 35 Nm stage3 180° M8 Cylinder Head Bolts 25 Nm Tools Required 000 589 77 03 00 Box Wrench Insert 001 589 65 09 00 Socket Wrench Insert 102 589 03 40 00 Magnetic Bar 116 589 02 34 00 Threaded Pin 116 589 03 07 00 Type Socket Wrench...
  • Page 340 OM600 ENGINE MECHANICAL 1B3-39 Notice The cylinder head may only be removed when the engine has cooled down. The cylinder head is removed together with the exhaust manifold. As the cylinder head bolts undergo a permanent tightening. They require to be replaced if they exceed the maximum lengthes indicated in the table.
  • Page 341 1B3-40 OM600 ENGINE MECHANICAL Disassembly Procedure 1. Completely drain the coolant from the radiator and cylinder block. 2. Remove the cooling fan shroud. 3. Hold the fan with counter holder and remove the bolt and then remove the cooling fan. Notice Keep the fan in vertical position.
  • Page 342 OM600 ENGINE MECHANICAL 1B3-41 8. Remove the air cleaner cover and element and then remove the air cleaner housing. 9. Remove the oil return hose and plug. Notice Cover them to prevent chips from coming into. 10. Unscrew the EGR pipe mounting bolts onto the exhaust manifold.
  • Page 343 1B3-42 OM600 ENGINE MECHANICAL 14. Pull out the accelerator control linkage. 15. Remove the fuel injection line(1) from the fuel injection nozzle(12). Box Wrench Inset 000 589 77 03 00 16. Remove the fuel injection line from the fuel injection pump. Box Wrench Insert 000 589 77 03 00 17.
  • Page 344 OM600 ENGINE MECHANICAL 1B3-43 18. Disconnect the booster hose connected to intake manifold. 19. Remove the intake manifold and gasket. 20. Remove the cylinder head cover and gasket with the blow- by gas hose. 21. Disconnect the glow plug cables.
  • Page 345 1B3-44 OM600 ENGINE MECHANICAL 22. Remove the cable channel. 23. Disconnect the cables from the glow plug sensor and coolant temperature sensor. 24. Remove the heater pipe bracket from the oil filter. 25. Pry off the clamp and push the heater feed pipe forward and then pull out the pipe.
  • Page 346 OM600 ENGINE MECHANICAL 1B3-45 26. Disconnect the fuel lines from the fuel filter. 27. Disconnect the fuel lines from the injection pump. 28. Remove the fuel filter(35). 29. Remove the fuel injection nozzle(12) and nozzle washer(11). Socket Wrench Insert 001 589 65 09 00...
  • Page 347 1B3-46 OM600 ENGINE MECHANICAL 30. Rotate the crankshaft and set the No.1 cylinder at TDC. Notice Do not rotate the crankshaft to the opposite direction of engine revolution. 31. Place alignment marks on the camshaft gear and timing chain. 32. Ensure that the camshaft and the bearing cap marking are aligned.
  • Page 348 OM600 ENGINE MECHANICAL 1B3-47 34. Remove the turbocharger. 35. Remove the exhaust manifold and gasket. 36. Remove the chain tensioner and seal. 37. Remove the bolt and separate the drive sprocket(21). Notice During removal, be careful not to drop the sprocket and chain into the timing case.
  • Page 349 1B3-48 OM600 ENGINE MECHANICAL 38. Remove the camshaft bearing cap bolts according to the numerical sequence. Notice Remove the No.1 bolts first and then remove the No. 2 bolts. Do not remove the bolts at a time completely but remove them step by step evenly or camshaft can be seriously damaged.
  • Page 350 OM600 ENGINE MECHANICAL 1B3-49 41. Remove the bolt(32). 42. Separate the spring and pull out the tensioning lever(31). 43. Pry off the closing cover. Remove the bolt and then remove the idle pulley. 44. Using the sliding hammer(36) and the threaded pin(37), pull out the sliding rail pins(25, 26) and remove the sliding rail(24).
  • Page 351 1B3-50 OM600 ENGINE MECHANICAL 45. Remove the vacuum line from the vacuum pump. 46. Disconnect the vacuum pipe from thermo valve. 47. Remove the socket bolts(13) of the chain box. T Type Socket Wrench 116 589 03 07 00 Magnetic Bar 102 589 03 40 00 48.
  • Page 352 OM600 ENGINE MECHANICAL 1B3-51 OM 661LA 49. Remove the cylinder head(2) and gasket(3).
  • Page 353 1B3-52 OM600 ENGINE MECHANICAL Assembly Procedure 1. Replace the cylinder head gasket. 2. Install the cylinder head onto the crankcase. Notice Align the cylinder head holes with the guide pins. 3. Measure the length(L) of cylinder head bolts. Notice If the max. length is exceeded, replace the bolts. Length(L) Thread Dia.
  • Page 354 OM600 ENGINE MECHANICAL 1B3-53 5. Tighten the cylinder head bolts to specified torque and torque angle. Stage 1 15 Nm Stage 2 35 Nm Torque Angle 90 ° Wait For 10 minutes Torque Angle 90° OM 661LA OM 662LA 6. Install the socket bolts in the chain box. Tightening Torque 25 Nm 7.
  • Page 355 1B3-54 OM600 ENGINE MECHANICAL 8. Connect the vacuum lines to the vacuum pump. 9. Install the fuel filter and connect the pipe. Tightening Torque 25 Nm Notice Be careful not to be confused the connections and hoses. 10. Connect the fuel pipe to the injection pump. 11.
  • Page 356 OM600 ENGINE MECHANICAL 1B3-55 12. Install the idle pulley and fit the closing cover. Tightening Torque 25 Nm 13. Insert the tensioning lever(31) and install the spring. 14. Install the damper. Tightening Torque 23 Nm Notice Insert the tensioning lever bolts onto the mounting hole. 15.
  • Page 357 1B3-56 OM600 ENGINE MECHANICAL 17. Coat the camshaft with oil and install the camshaft on the cylinder head to be TDC mark(arrow) upward. 18. Measure the axial end play of the camshaft. End Play 0.06 - 0.21mm Notice If out of standard, adjust it with the proper thickness of locking washer.
  • Page 358 OM600 ENGINE MECHANICAL 1B3-57 21. Position the camshaft on marking and install the camshaft sprocket. Notice Align the alignment marks on the chain and sprocket. 22. Check the TDC position of the crankshaft. 23. Install the camshaft sprocket bolt. Tightening Torque 25 Nm + 90°...
  • Page 359 1B3-58 OM600 ENGINE MECHANICAL Notice Measure the max. length ‘L’ and replace the bolt if it exceeds 53.6mm. 24. Install the exhaust manifold and gasket. 25. Install the turbocharger. 26. Install the exhaust pipe onto the turbocharger. Tightening Torque 25 Nm...
  • Page 360 OM600 ENGINE MECHANICAL 1B3-59 27. Replace the seal and then install the chain tensioner(27). Tightening Torque 80 Nm 28. Remove the engine lock. 29. Insert the nozzle washer into the hole to face round part downward. 30. Install the fuel injection nozzle. Tightening Torque 40 Nm 31.
  • Page 361 1B3-60 OM600 ENGINE MECHANICAL 33. Replace the gasket and install the cylinder head cover. Tightening Torque 10 Nm 34. Install the blow-by hose. 35. Connect the wires to the coolant temperature sensor and the glow plug sensor. 36. Replace the intake manifold gasket. 37.

  • Page 362: Cylinder Head

    OM600 ENGINE MECHANICAL 1B3-61 38. Replace the O-ring of heater feed pipe and install it to the cylinder head. Notice For installation, clean the hole. 39. Install the bracket of heater feed pipe to the oil filter. 40. Install the fuel pipe and the accelerator control linkage. 41.
  • Page 363 1B3-62 OM600 ENGINE MECHANICAL 42. Install the poly V-belt. Notice Be careful not to contaminate the belt. 43. By inserting a rod into the tensioning lever upper hole and pulling the rod, install the bolt and then tighten the nut. Tightening Torque 23 Nm 44.

  • Page 364: Timing Case Cover

    OM600 ENGINE MECHANICAL 1B3-63 TIMING CASE COVER Preceding Work : Removal of the cooling fan Rmoval of the V-belt tensioning device Removal of the vibration damper and hub Removal of the alternator 1 Bolt ............10Nm 13 Bolt ............32Nm 2 Cylinder Head Cover 14 Timing Case Cover 3 Gasket ...........
  • Page 365 1B3-64 OM600 ENGINE MECHANICAL Tools Required 116 589 03 07 00 Socket Wrench Removal Procedure 1. Remove the fan clutch and cooling fan belt pulley. 2. Drain the engine oil completely. 3. Remove the oil dipstick tube bracket bolts. 4. Remove the crankshaft pulley. 5.
  • Page 366 OM600 ENGINE MECHANICAL 1B3-65 9. Disconnect the pipes of power steering pump and remove the belt pulley. Notice Be careful not to lose the key. 10. Remove the nut and pull out the bolt and then remove the power steering pump. 11.
  • Page 367 1B3-66 OM600 ENGINE MECHANICAL 13. Remove the camshaft. 14. Remove the socket bolts(4) in the chain box. Socket Wrench 115 589 03 07 00 15. Remove the injection pump. Notice See the ‘Removal of fuel injection pump’. 16. Remove the oil pan bolts (8, 9) in the area of the timing case cover (14).
  • Page 368 OM600 ENGINE MECHANICAL 1B3-67 Installation Procedure 1. Thoroughly clean the sealing surface and apply sealant. 2. Install the timing case cover. Notice Tightening Torque 10 Nm Bolts arrangement 1.M6 x 60 2.M6 x 70 3.M6 x 40 3. Tighten the socket bolts in the chain box. Tightening Torque 23 Nm 4.
  • Page 369 1B3-68 OM600 ENGINE MECHANICAL 5. Install the flange, vibration damper and crankshaft belt pulley. Notice Replace front radial seal if necessary. 6. Install the alternator bracket. 25 Nm Front Tightening Torque 25 Nm Side 7. Install the alternator. 25 Nm Upper Tightening Torque 25 Nm...
  • Page 370 OM600 ENGINE MECHANICAL 1B3-69 10. Install the fuel filter. Tightening Torque 25 Nm 11. Install the vacuum pump. Tightening Torque 10 Nm 12. Install the power steering pump. Tightening Torque 23 Nm 13. Install the power steering pump pulley. Tightening Torque 32 Nm 14.
  • Page 371 1B3-70 OM600 ENGINE MECHANICAL 15. Install the guide pulley (22) and fit the closing cover (20). Tightening Torque 23 Nm 16. Replace the gasket (3) and install the cylinder head cover (2). Tightening Torque 10 Nm 17. Install the cooling fan belt pulley and fan clutch. 18.

  • Page 372: Crankshaft End Cover

    OM600 ENGINE MECHANICAL 1B3-71 CRANKSHAFT END COVER Preceding Work : Removal of flywheel and driven plate. 1 Crankshaft Flange 4 Radial Seal ..........Replace 2 End Cover ......Clean, Loctite 573 5 Dowel Sleeve 3 Bolt ......... 10Nm, Loctite 573 6 Bolt .........
  • Page 373 1B3-72 OM600 ENGINE MECHANICAL Tools Required 601 589 03 43 00 Oil Seal Assmbler Removal Procedure 1. Remove the bolts (3, 6) from end cover, By pulling out the lugs (arrow), remove the cover. Notice Be careful not to damage the oil pan gasket. 2.
  • Page 374 OM600 ENGINE MECHANICAL 1B3-73 5. Coat a little oil on the sealing lip of new radial seal and contacting surface. Notice Don’t use grease. 6. Insert the new radial seal (4) onto the oil seal assembler (7). Notice The sealing lip of the repair radial seal is offset to the inside by 3mm to ensure that it does not run in any groove which the standard radial seal may have left on the crankshaft flange.

  • Page 375: Vibration Damper And Hub

    1B3-74 OM600 ENGINE MECHANICAL VIBRATION DAMPER AND HUB Preceding Work : Removal of the cooling fan Removal of poly V-belt 1 Bolt ............10Nm 6 Bolt ..........200Nm + 90° 2 Cooling Fan Belt Pulley 7 Washer 3 Socket Bolt ..........23Nm 8 Straight Pin 4 Crankshaft Belt Pulley 9 Hub...
  • Page 376 OM600 ENGINE MECHANICAL 1B3-75 Sectional View 3 Socket Bolt 9 Hub 4 Crankshaft Belt Pulley 11 Radial Seal 5 Vibration Damper 12 Timing Gear Case Cover 6 Bolt 13 Key 7 Washer 14 Crankshaft Sprocket 8 Straight Pin 16 Crankshaft Notice The mounting position of vibration damper is fixed by straight pin (8).
  • Page 377 1B3-76 OM600 ENGINE MECHANICAL Removal Procedure 1. Remove the starter motor and install the engine lock into the wheel ring gear. Engine Lock 602 589 00 40 00 2. Remove the poly V-belt. 3. Remove the cooling fan. Notice Keep the fan in vertical position. 4.
  • Page 378 OM600 ENGINE MECHANICAL 1B3-77 7. Remove the socket bolts (3) and then remove the belt pulley (4) and vibration damper (5). 8. Remove the washer and bolt. 9. Remove the hub by using a puller. Puller 103 589 00 33 00 10.
  • Page 379 1B3-78 OM600 ENGINE MECHANICAL Installation Procedure 1. Install the hub. Notice Exactly align the woodruff key and the groove of hub (arrow). 2. Install the washer (7) and tighten the bolt (6). Washer (new) : 1 EA 200 Nm + 90° 3.
  • Page 380 OM600 ENGINE MECHANICAL 1B3-79 5. Install the timing sensor bracket. Notice See the ‘TDC setting’. 6. Install the cooling fan pulley. Tightening Torque 10 Nm 7. Install the cooling fan. 8. Install the fan belt. 9. Remove the engine lock.

  • Page 381: Crankshaft Front Radial Seal

    1B3-80 OM600 ENGINE MECHANICAL CRANKSHAFT FRONT RADIAL SEAL 1 Radial Seal 3 Woodruff Key 2 Timing Case Cover Tools Required 601 589 03 14 00 Sleeve...
  • Page 382 OM600 ENGINE MECHANICAL 1B3-81 Notice The sealing lip of the repair radial seal is offset to the inside by 2mm to ensure that is does not run in any groove which the standard radial seal may have left on the crankshaft flange.

  • Page 383: Crankshaft Ball Bearing

    1B3-82 OM600 ENGINE MECHANICAL CRANKSHAFT BALL BEARING 1 Spacer 3 Ball Bearing 2 Cover ......... Replace 4 Bolt ........45Nm + 90° Notice Manual transmission only. Tools Required 000 589 33 33 00 Counter Support 000 589 25 33 00 Internal Extractor Removal &...

  • Page 384: Crankshaft

    OM600 ENGINE MECHANICAL 1B3-83 CRANKSHAFT Preceding Work : Removal of the end cover Removal of the piston Removal of the crankshaft sprocket 3 Crankshaft Main Bearing Shells (Upper) 7 Thrust Bearings (Lower) 4 Trust Bearings (Upper) 8 Crankshaft Bearing Cap 5 Crankshaft 9 Crankshaft Bearing Cap (Fit Bearing) 6 Crankshaft Main Bearing Shells (Lower)
  • Page 385 1B3-84 OM600 ENGINE MECHANICAL Thrust Washer and Bearing Arrangement OM662LA Engine 3 Crankshaft Main Bearing Shells (Upper) A Radial Bearings 4 Thrust Bearings (Upper) B Radial and Axial Bearings (Thrust Bearing) 5 Crankshaft 6 Crankshaft Main Bearing Shells (Lower) 7 Thrust Bearings (Lower) Notice The gaps between the bearing shell and bore and between the bearing shell and journal are different...
  • Page 386 OM600 ENGINE MECHANICAL 1B3-85 OM661LA Engine 3 Crankshaft Main Bearing Shells (Upper) A Radial Bearings 4 Thrust Bearings (Upper) B Radial and Axial Bearings (Thrust Bearing) 5 Crankshaft 6 Crankshaft Main Bearing Shells (Lower) 7 Thrust Bearings (Lower) Notice The gaps between the bearing shell and bore and between the bearing shell and journal are different each other.
  • Page 387 1B3-86 OM600 ENGINE MECHANICAL Crankshaft Standard and Repair Sizes Crankshaft bearing Thrust bearing Thrust bearing journal diameter journal width journal diameter 24.500 - 24.533 Standard size 50.950 - 57.965 47.950 - 47.965 24.600 - 24.633 24.700 - 24.733 Repair size 1 57.500 - 57.715 47.700 - 47.715 24.900 - 24.933...
  • Page 388 OM600 ENGINE MECHANICAL 1B3-87 Matching Crankshaft Bearing Shells to Basic Bearing Bore in Crankshaft Marking of basic bearing bore in lower Color code of relevant crankshaft parting surface bearing shell 1 punch mark or blue Blue or white-blue Yellow or white-yellow 2 punch marks or yellow Red or white-red 3 punch marks or red...
  • Page 389 1B3-88 OM600 ENGINE MECHANICAL Removal & Installation Procedure 1. Remove the bearing cab bolt. 2. Remove the bearing caps (8). Notice The crankshaft bearing caps are marked with stamped numbers. Remove the bearing cap from the vibration damper side. 3. Remove the crankshaft bearing caps (9) and lower thrust bearings (7).
  • Page 390 OM600 ENGINE MECHANICAL 1B3-89 8. Thoroughly clean the oil gallery. 9. Select a proper new bearing shells with reference to table. 10. Coat the new bearing shells with oil and insert into the crankcase and into the crankshaft bearing caps. Notice Do not mix up upper and lower crankshaft bearing shells.
  • Page 391 1B3-90 OM600 ENGINE MECHANICAL 15. Measure radial clearance of crankshaft bearing (G). Clearance ‘G’ 0.027 - 0.051mm Notice If ‘G’ is out of standard, replace the bearing shells and adjust the radial clearance of crankshaft bearing. Example) Measured value ‘E’ = 57.700mm Measured value ‘F’...
  • Page 392 OM600 ENGINE MECHANICAL 1B3-91 Notice If the max. length of bolts(L) exceed 63.8mm, replace them. 19. Coat the new crankshaft with engine oil and place it on the crankcase. 20. Install the crankshaft bearing caps according to marking and tighten the bolts. Tightening Torque 55 Nm + 90°...
  • Page 393 1B3-92 OM600 ENGINE MECHANICAL 24. Insert the new connecting rod bearing shells into the connecting rod and connecting rod bearing cap and tighten the 12-sided stretch bolts (11). Tightening Torque 40 Nm + 90° 25. Measure inner diameter of connecting rod bearing. 26.

  • Page 394: Flywheel

    OM600 ENGINE MECHANICAL 1B3-93 FLYWHEEL Preceding Work : Removal of the transmission Removal of the clutch 1 Oil Pan 4 12-Sided Stretch Bolt .... Check, 45Nm + 90° 2 Straight Pin 5 Drive Plate (Automatic Transmission) 3 Flywheel 6 Flywheel (Automatic Transmission)
  • Page 395 1B3-94 OM600 ENGINE MECHANICAL Manual transmission flywheel OM662LA OM661LA Automatic transmission flywheel...
  • Page 396 OM600 ENGINE MECHANICAL 1B3-95 Tools Required 602 589 00 40 00 Engine Lock Removal & Installation Procedure 1. Install the engine lock. Engine Lock 602 589 02 40 00 2. Remove the 12-sided stretch bolts (4). Installation Notice Tightening Torque 45 Nm + 90°...
  • Page 397 1B3-96 OM600 ENGINE MECHANICAL 4. Remove the flywheel (6) and driven plate (5), if equipped with automatic transmission. Installation Notice Correctly align the position of dowel pin (2). 5. Installation should follow the removal procedure in the reverse order.

  • Page 398: Machining Of Flywheel

    OM600 ENGINE MECHANICAL 1B3-97 MACHINING OF FLYWHEEL 1 Flywheel OM662LA OM661LA Machining of Flywheel Notice Flywheels which have scorch marks, scoring or cracks in the clutch surface should be machined by grinding or precision-turning. If the scores or cracks are severe than permissible specifications, replace the flywheel.

  • Page 399: Flywheel Ring Gear

    1B3-98 OM600 ENGINE MECHANICAL FLYWHEEL RING GEAR Preceding Work : Removal of flywheel 1 Ring Gear 3 Centering Collar Diameter 2 Flywheel Tools Required 001 589 53 21 00 Dial Gauge 363 589 02 21 00 Dial Gauge Holder...
  • Page 400 OM600 ENGINE MECHANICAL 1B3-99 Replacement Procedure 1. Drill a hole into the ring gear (1) (arrow) and snap with a chisel. 2. Thoroughly clean the collar surfaces of ring gear. 3. Measure diameter (a) of centering collar. Notice If out of standard, replace the flywheel. Diameter ‘a’...
  • Page 401 1B3-100 OM600 ENGINE MECHANICAL 6. Measure axial runout of ring gear (1) on a surface plate. Limit Max. 0.4mm Notice For correct measurement, put the flywheel on the flat measuring board. Dial Gauge 001 589 53 21 00 Dial Gauge Holder 363 589 02 21 00...

  • Page 402: Hydraulic Valve Clearance Compensation Element Check

    OM600 ENGINE MECHANICAL 1B3-101 HYDRAULIC VALVE CLEARANCE COMPENSATION ELEMENT CHECK 1 Cylinder Head Cover 4 Valve Tappet 2 Bolt ............10Nm 5 Cylinder Head 3 Gasket ........... Replace...
  • Page 403 1B3-102 OM600 ENGINE MECHANICAL Checking Procedure Notice The noise which continues short time during short travel (frequent starting of the engine) or engine starting after a long time storage is normal operating conditions. So, it does not need to be repaired. Determine the malfunctions in valve clearance compensation device with noise through following tests.

  • Page 404: Valve Tappets

    OM600 ENGINE MECHANICAL 1B3-103 VALVE TAPPETS Preceding Work : Removal of camshaft 1 Valve Tappet 4 Seal ............Replace 2 Cylinder Head 5 Screw Plug 3 Oil Gallery Tools Required 102 589 03 40 00 Magnetic Bar...
  • Page 405 1B3-104 OM600 ENGINE MECHANICAL Replacement Procedure 1. Pull out the valve tappet (1). Magnetic Bar 102 589 03 40 00 2. Remove the plug (5) and blow compressed air into the oil gallery (3). At this time, check that the outlet bores(arrow) at the seat of the valve tappet are clear.

  • Page 406: Valve Springs Check

    OM600 ENGINE MECHANICAL 1B3-105 VALVE SPRINGS CHECK Preceding Work : Removal of valve spring 1 Valve Spring 2 Spring Scale Service Data At preloaded Outer diameter Wire diameter Free length Length Tension (new) Limit 33.1mm 4.20mm 50.0mm 27mm 680 - 740N 612N...
  • Page 407 1B3-106 OM600 ENGINE MECHANICAL VALVE SPRINGS (CYLINDER HEAD REMOVED) 1 Valve Tappet 6 Stud Bolt ............ 12Nm 2 Valve Cotters 7 Washer 3 Spring Retainer 8 Nut ..........Replace, 25Nm 4 Valve Spring ... Check, replace if necessary 9 Exhaust Manifold 5 Cylinder Head...
  • Page 408 OM600 ENGINE MECHANICAL 1B3-107 Tools Required 102 589 03 40 00 Magnetic Bar 116 589 06 63 00 Magnetic Finger 601 589 01 59 00 Assembling Board 601 589 02 59 00 Supporting Bridge 667 589 00 31 00 Press Lever Removal &...
  • Page 409 1B3-108 OM600 ENGINE MECHANICAL 5. Using the press lever (14), press the spring retainer downward and remove the valve cotters (2) with magnetic finger (15). Notice Be careful not to damage guide bore of the valve tappet. Press Lever 667 589 00 31 00 Magnetic Finger 116 589 06 63 00 6.

  • Page 410: Valve Springs (Cylinder Head Installed)

    OM600 ENGINE MECHANICAL 1B3-109 VALVE SPRINGS (CYLINDER HEAD INSTALLED) Preceding Work : Removal of camshaft 1 Valve Tappet 4 Valve Spring ..Check, replace if necessary 2 Valve Cotters 5 Timing Chain 3 Spring Retainer 6 Cylinder Head Notice Remove the valve springs only when the piston is at TDC. Tools Required 102 589 03 40 00 Magnetic Bar 116 589 06 63 00 Magnetic Finger...
  • Page 411 1B3-110 OM600 ENGINE MECHANICAL Removal & Installation Procedure 1. Remove the valve tappet (1) with magentic lifter. Notice Place the valve tappets upside down (open end upward) Magentic Liter 102 589 03 40 00 2. Install the holding wheel (7) into the timing chain of camshaft sprocket piston.
  • Page 412 OM600 ENGINE MECHANICAL 1B3-111 6. Remove the spring retainer(3) and spring (4). 7. Check the valve spring and replace if necessary. 8. Insert valve spring (4) with the color coding (arrow) facing down and insert valve spring Retainer(3). 9. By press the spring retainer(3) with press lever (90), install the valve cotters with magnetic finger (10).

  • Page 413: Valve Stem Seals

    1B3-112 OM600 ENGINE MECHANICAL VALVE STEM SEALS Preceding Work : Removal of camshaft. 1 Valve Tappet 4 Valve Spring ... Check, replace if necessary 2 Valve Cotters 5 Valve Stem Seal 3 Spring Retainer 6 Valve Notice Remove the valve stem seals when the piston is positioned at TDC.
  • Page 414 OM600 ENGINE MECHANICAL 1B3-113 Tools Required 667 589 00 31 00 Press Lever 104 589 00 37 00 Pliers 102 589 03 40 00 Magnetic Lifter 603 589 01 40 00 Holding Wheel 601 589 02 43 00 Drift 116 589 06 63 00 Magnetic Finger 667 589 02 63 00 Supporting Bar B : Exhaust valve stem seal A : Intake valve stem seal...
  • Page 415 1B3-114 OM600 ENGINE MECHANICAL Replacement Procedure 1. Remove the valve tappet (1) with magnetic lifter. Notice Place the valve tappets upside down (open end upward). Magnetic Lifter 102 589 03 40 00 2. Install the holding wheel (7) into the timing chain (11). Holding Wheel 603 589 01 40 00 3.
  • Page 416 OM600 ENGINE MECHANICAL 1B3-115 6. Remove the spring retainer(3) and valve spring (4). 7. Remove the valve stem seal (5). Pliers 104 589 00 37 00 8. Insert the cap (12) onto the valve (6) and install the new valve stem seal (5) and then remover the cap. Drift 601 589 02 43 00 9.

  • Page 417: Check And Replacement Of Valve Guides

    1B3-116 OM600 ENGINE MECHANICAL CHECK AND REPLACEMENT OF VALVE GUIDES Preceding Work : Removal of cylinder head Removal of valve spring Removal of valve 1 Cylinder Head 3 Valve Seat Ring 2 Valve Guide a Basic Bore Diameter Service Data Overlap Valve Guide Basic Bore...
  • Page 418 OM600 ENGINE MECHANICAL 1B3-117 Notice Measure center (arrow) of the valve guide and if the inner diameter ‘A’ exceeds standard value, replace the guide. Tools Required 000 589 10 53 00 Reamer (for Exhaust) 000 589 10 68 00 Cylinder Brush 000 589 21 53 00 Reamer (for Intake) 102 589 00 23 00 GO / NO GO Gauge (for Intake) 103 589 02 15 00 Drift (for Exhaust)

  • Page 419: Checking Procedure

    1B3-118 OM600 ENGINE MECHANICAL Checking Procedure 1. Thoroughly clean the valve guide bore using a cylinder brush. Cylinder Brush 000 589 10 68 00 2. Insert the GO/NO GO gauge into the valve guide bore. If the NO GO side is inserted fully, replace the valve guide (Intake 8mm, Exhaust 9mm).
  • Page 420 OM600 ENGINE MECHANICAL 1B3-119 4. Reaming basic bore in cylinder head (repair size). - Thoroughly remove carbon deposits in cylinder head. Notice Particularly remove the insides of the valve seat rings. - Remove the elevation (arrow) of intake valve seat rings. - Select correct broaching tool and guide sleeve (refer to the table).
  • Page 421 1B3-120 OM600 ENGINE MECHANICAL 5. Heat the cylinder head (1) in a wear tank to approx. 80°C. 6. Cool down the new valve guide (2) with liquid nitrogen. Notice Do not touch the cooled valve guide by hand. Super Cooling box 346 589 00 63 00 7.
  • Page 422 OM600 ENGINE MECHANICAL 1B3-121 9. If necessary, ream the valve guide bore evenly. Notice Never turn the reamer against the direction of rotation. Reamer (for Exhaust) 000 589 10 53 00 Reamer (for Intake) 000 589 21 53 00...

  • Page 423: Valve Seat Rings

    1B3-122 OM600 ENGINE MECHANICAL VALVE SEAT RINGS Preceding Work : Removal of valve Checking of valve guide, replace if necessary Removal of prechamber 1 Cylinder Head Valve Seat Ring Outer Diameter 2 Valve Seat Ring D1 Valve Seat Ring Inner Diameter 3 Valve Guide D2 Basic Bore Diameter A Height (Cylinder Head Upper / Lower Surface)
  • Page 424 OM600 ENGINE MECHANICAL 1B3-123 Commercial Tools Cylinder Head Clamping Device Hunger D-8000 München 70 Type Ventilknecht K2000 Order No. 221 00 100 Valve Seat Turning Tool Hunger D-8000 München 70 Type VDS 1A Order No. 236 03 308 Ring Seat Turning Tool Hunger D-8000 München 70 Type RDS 1...
  • Page 425 1B3-124 OM600 ENGINE MECHANICAL Removal Procedure 1. Measure dimension ‘A’. Limit 142.5mm 2. Clamp the cylinder head with clamping device. 3. Cut groove into the valve seat ring so that dimension ‘C’ is approx. 2mm and dimension ‘E’ is approx. 6mm. 4.
  • Page 426 OM600 ENGINE MECHANICAL 1B3-125 8. Turn over the cylinder head. 9. Remove the tensioning head (4) and valve seat ring (2) with drift (14mm) and removal tool. 10. Clean the basic bore of valve seat ring. 11. Measure the basic bore diameter (D2) and outer diameter (D) of the new valve seat ring (standard size).
  • Page 427 1B3-126 OM600 ENGINE MECHANICAL 15. Hang the cylinder head (1) to the lifting device and heat in a water tank to approx. 80°C. 16. Cool down new valve seat ring (2) into the cooling box with liquid nitrogen. Notice Do not touch the cooled valve seat rings with hand. Super Cooling Box 345 589 00 63 00 17.

  • Page 428: Check And Machining Of Valves

    OM600 ENGINE MECHANICAL 1B3-127 CHECK AND MACHINING OF VALVES Preceding Works : Removal of cylinder head Removal of the vale spring Removal of the valve I Valve Length Y Half Camshaft Basic Bore Diameter W Camshaft Cam Basic Diameter Z Distance (Cylinder Head Cover Parting Surface - X Distance (Camshaft Basic Bore - Valve Stem) Valve Stem)

  • Page 429: Exhaust Valve

    1B3-128 OM600 ENGINE MECHANICAL Intake Valve Exhaust Valve Item Intake Valve Exhaust Valve Valve disc diameter ‘d’ 34.90 - 35.10 mm 37.90 - 38.10 mm Valve disc height ‘h’ 1.7 mm 1.7 mm Setting angle “a”o r machining the valve 45°...
  • Page 430 OM600 ENGINE MECHANICAL 1B3-129 Tools Required 001 589 32 21 00 Dial Gauge Commercial Tool Valve corn grinding machine Checking and Machining Procedure 1. Clean the valves and do visual check. Valves with wobbled valve disc, with worn or scored valve stem should be replaced.
  • Page 431 1B3-130 OM600 ENGINE MECHANICAL 5. Clean the vales, valve seats and valve guides. 6. Coat the valve stem with oil and insert it into valve guide. 7. Insert the valves (1) into the valve guides according to marking. 8. Measure amount by which the valve arrears ‘a’. Arrears ‘a’...
  • Page 432 OM600 ENGINE MECHANICAL 1B3-131 11. The distance ‘x’ (camshaft basic bore - valve stem). ‘x’ = ‘z’ - ‘y’. Determine the valve to use according to this measurement (See ‘matching valves’) Example) Measured value ‘w’ = 38.2 mm Measured value ‘z’ = 36.5 mm Value ‘y’...

  • Page 433: Machining Of Valve Seat

    1B3-132 OM600 ENGINE MECHANICAL MACHINING OF VALVE SEAT Preceding Work : Removal of prechamber Removal and inspection of valve, replace if necessary Inspection of valve guide, replace if necessary 1 Valve a Valve Arreare 2 Valve Seat Ring b Valve Seat Width 3 Cylinder Head a Valve Seat Angle 4 Valve Guide...
  • Page 434 OM600 ENGINE MECHANICAL 1B3-133 Service Data Item Intake Exhaust Valve arrears ‘a’ 0.1 - 0.7 mm 0.1 - 0.7 mm Valve seat width ‘b’ 1.2 - 1.7 mm 1.5 - 2.0 mm Valve seat angle ‘ ’ 45° 45° Valve seat free angle ‘ ’...
  • Page 435 1B3-134 OM600 ENGINE MECHANICAL Machining Procedure Valve machining is required : - When the valve is leaking. - When replacing the valve. - When replacing the valve guide. - When replacing the valve seat or valve seat ring. 1. Machine the valve seat (a=45°). 2.
  • Page 436 OM600 ENGINE MECHANICAL 1B3-135 5. Insert the valve (1) into the valve guide according to marking and measure amount by which the valve arrears ‘a’. Arrears ‘a’ 0.1 - 0.7mm 6. Measure camshaft cam basic circle diameter (w). 38 ± 0.2mm Diameter ‘w’...
  • Page 437 1B3-136 OM600 ENGINE MECHANICAL I Length of Valve y Half Camshaft Basic Bore Diameter w Camshaft Cam Basic Circle Diameter z Distance (Cylinder head cover parting surface - . x Distance (Camshaft basic bore - valve stem) valve stem) 8. Measure ‘x’ (Camshaft basic bore - valve stem). ‘x’...

  • Page 438: Camshaft Timing Test

    OM600 ENGINE MECHANICAL 1B3-137 CAMSHAFT TIMING TEST Preceding Work : Removal of glow plug 1 Cylinder Head Cover 4 Valve Tappet 2 Bolt ............10Nm 5 Cylinder Head 3 Gasket ........... Replace Timing Intake valve Exhaust valve Condition of camshaft Open Close Open...
  • Page 439 1B3-138 OM600 ENGINE MECHANICAL Tools Required 001 589 53 21 00 Dial Gauge 363 589 02 21 00 Dial Gauge Holder 366 589 00 21 05 Extension Measurement Procedure 1. Remove the cylinder head cover. 2. Rotate the engine in the direction of engine rotation until the intake valve of no.

  • Page 440: Camshaft

    OM600 ENGINE MECHANICAL 1B3-139 CAMSHAFT Preceding Work : Removal of cylinder head cover 1 Bolt ............25Nm 8 Cylinder Head 2 Washer 9 Oil Pan 3 Camshaft Bearing Cap 10 Camshaft Sprocket 4 Camshaft 11 Washer 5 Dowel Pin 12 12-Sided Bolt (M11) ..... Check, 25Nm + 90° 6 Locking Washer 13 Gasket ...........
  • Page 441 1B3-140 OM600 ENGINE MECHANICAL Tools Required 602 589 00 40 00 Engine Lock Removal Procedure 1. Rotate the crankshaft and position the piston of No.1 cylinder at TDC. Notice Do not rotate the crankshaft in the opposite direction of engine rotation. In this position, the markings of the camshaft/camshaft bearing cap (arrow) must be aligned.
  • Page 442 OM600 ENGINE MECHANICAL 1B3-141 4. Remove the bolt and then remove the camshaft sprocket. Notice During removal, be careful not to drop the sprocket with chain. Remove the chain carefully and then pull out the sprocket. 5. Remove the chain tensioner. 6.
  • Page 443 1B3-142 OM600 ENGINE MECHANICAL 7. Remove the camshaft bearing cap. 8. Pull off the camshaft. Notice Be careful not to miss front locking washer. 9. Pull out the locking washer. Notice Check the condition of locking washer and replace if necessary.
  • Page 444 OM600 ENGINE MECHANICAL 1B3-143 5. Tighten the camshaft bearing cap bolts acccording to installation order. Tightening Torque 25 Nm Notice Tighten the No. 1 bolts (light arrow) by one revolution in stages first and then tighten the No.2 bolts (dark arrow). OM 662LA OM 661LA 6.
  • Page 445 1B3-144 OM600 ENGINE MECHANICAL Notice If max. length ‘L’ of the 12-sided bolt exceeds 53.6mm, replace it. 8. Install the chain tensioner. Tightening Torque 80 Nm Notice Replace the seal. Before installation, by pumping in the oil approx. 10 times, fill the oil.

  • Page 446: Chain Tensioner

    OM600 ENGINE MECHANICAL 1B3-145 CHAIN TENSIONER 1 Chain Tensioner ........80Nm 2 Seal ............Replace...
  • Page 447 1B3-146 OM600 ENGINE MECHANICAL Notice Always install the chain tensioner to be filled with oil. Place the chain tensioner in engine oil up to over the collar on the hexagon head with the thrust pin facing up. Slowly push down the thrust pin as far as the stop 7~10 times with the aid of a press or a column drill Faulty chain tensioners should be replaced completely.

  • Page 448: Timing Chain

    OM600 ENGINE MECHANICAL 1B3-147 TIMING CHAIN Preceding Work : Removal of glow plug Removal of chain tensioner Removal of cooling fan Removal of cylinder head cover 1 Chain Link 2 Timing Chain 3 Camshaft Sprocket 4 Outer Plate...
  • Page 449 1B3-148 OM600 ENGINE MECHANICAL Tools Required 000 589 58 43 00 Chain Assembling Device Replacement Procedure 1. Cover over the chain box with cleaning rag and grind off both chain pins (arrow) at a chain link (1) of the timing chain. 2.
  • Page 450 OM600 ENGINE MECHANICAL 1B3-149 7. Insert the new chain link (1) to connect the chain. 8. Insert the new outer plate (4) into the fitting tool (8) and then the outer plate will be held by a magnet. Chain Assembling Device 000 589 58 43 00 9.
  • Page 451 1B3-150 OM600 ENGINE MECHANICAL 11. Place the fitting tool (8) onto the chain link and rivet the chain pins one by one. Tightening Torque 35 - 40 Nm 12. Check the riveting of chain pins and re-rivet if necessary. 13. Remove the wire. 14.

  • Page 452: Tensioning Rail

    OM600 ENGINE MECHANICAL 1B3-151 TENSIONING RAIL Preceding Work : Removal of cylinder head Removal of timing case cover 1 Tensioning Rail 2 Bearing Pin Notice The plastic coating of the tensioning rail can not be replaced.

  • Page 453: Cylinder Head Guide Rail

    1B3-152 OM600 ENGINE MECHANICAL CYLINDER HEAD GUIDE RAIL Preceding Work : Removal of the cooling fan Removal of poly V-belt Removal of chain tensioner 1 Cylinder Head Cover 9 Bearing Pin ......Sealing Compound 2 Bolt ............10Nm 10 Guide Rail 3 Gasket ...........
  • Page 454 OM600 ENGINE MECHANICAL 1B3-153 Tools Required 115 589 02 34 00 Sliding Hammer 116 589 20 33 00 Threaded Pin Removal Procedure 1. Removal the cylinder head cover. 2. Pull off the tensioning lever (7) and remove from the spring (15).
  • Page 455 1B3-154 OM600 ENGINE MECHANICAL 6. Pull out the bearing pins (9, 11) with sliding hammer and remove the guide rail 10. Sliding Hammer 116 589 20 33 00 Threaded Pin 116 589 02 34 00 Installation Procedure 1. Apply collar of both bearing pins with sealing compound. 2.
  • Page 456 OM600 ENGINE MECHANICAL 1B3-155 In this position, the marking on the camshaft / camshaft bearing cap (arrow) must also be aligned. 5. Install the guide pulley (12). Tightening Torque 23 Nm 6. Attach the tensioning lever (7) to the spring (15) and install. 7.

  • Page 457: Timing Case Cover Guide Rail

    1B3-156 OM600 ENGINE MECHANICAL TIMING CASE COVER GUIDE RAIL Preceding Work : Removal of cylinder head cover 1 Bearing Pin 5 Crankshaft 2 Bearing Pin 6 Spring 3 Guide Rail 7 Bushing 4 Oil Pump Chain 8 Tensioning Lever...
  • Page 458 OM600 ENGINE MECHANICAL 1B3-157 Removal Procedure 1. Pull out the tensioning lever (8) together with the spring (6) and guide rail (3) far enough until the tensioning lever has moved passed the oil pump chain (4) and is resting against the crankshaft (5) 2.

  • Page 459: Crankshaft Sprocket

    1B3-158 OM600 ENGINE MECHANICAL CRANKSHAFT SPROCKET Preceding Work : Removal of oil pan Removal of timing case cover 1 12-Sided Stretch Bolt (M11) .. Check, 25Nm + 90° 11 Bolt ............25Nm 2 Washer 12 Crankshaft Sprocket 3 Camshaft Sprocket 13 Crankshaft 4 Timing Chain 14 Key...
  • Page 460 OM600 ENGINE MECHANICAL 1B3-159 Special Tools 116 589 07 15 00 Drift 102 589 05 33 00 Puller Removal 1. Pull out the tensioning lever (19) together with the spring (17) and guide rail (16) far enough until the tensioning lever has passed the oil pump chain (9) and is resting against the crankshaft (13).
  • Page 461 1B3-160 OM600 ENGINE MECHANICAL 5. Place alignment marks (arrow) on the timing chain (4) and crankshaft sprocket (12). 6. Remove the key(15). 7. Place alignment marks (arrow) on the timing chain (4) and camshaft sprocket (3). 8. Remove the chain tensioner. 9.
  • Page 462 OM600 ENGINE MECHANICAL 1B3-161 Installation 1. Put the same alignment mark on the new crankshaft sprocket as in the old sprocket. Notice Check the timing chain, camshaft sprocket, injection pump timing sprocket, oil pump chain and oil pump sprocket for wear and replace if necessary.
  • Page 463 1B3-162 OM600 ENGINE MECHANICAL Notice If the max. length ‘L’ of the stretch bolt exceeds 53.6mm, replace it. 5. Fit the oil pump chain (9) on the crankshaft sprocket (12) and insert the oil pump sprocket (8) into the oil pump chain and then install it on the oil pump.

  • Page 464: Piston

    OM600 ENGINE MECHANICAL 1B3-163 PISTON Preceding Work : Removal of the cylinder head Removal of the oil pump 1 Oil Ring 8 Connecting Rod 2 2nd Ring 9 Connecting Rod Upper Bearing Shell 3 Top Ring 10 Connecting Rod Lower Bearing Shell 4 Snap Ring ..........
  • Page 465 1B3-164 OM600 ENGINE MECHANICAL Service Data Max. 0.12 mm Piston clearance 0.735 - 0.965 mm Piston crown protrusion in TDC position 26.012 - 26.018 mm Connecting rod bushing diameter Connecting Rod Bolt Dimensions Thread M9 x 1 -0.1 Stretch shaft(C) diameter (new) Minimum stretch shaft diameter (C) 7.1 mm Length(L)(new)
  • Page 466 OM600 ENGINE MECHANICAL 1B3-165 Removal 1. Remove combustion residues from the cylinder bores. 2. Remove the connecting rod bolts (12) and then remove the connecting rod bearing caps(11). 3. Remove the connecting rod bearing shells (9, 10). Notice Be careful not mix the bearing caps and shells each other. 4.
  • Page 467 1B3-166 OM600 ENGINE MECHANICAL Installation 1. Fit the piston onto the connecting rod so that the arrow (15) and the locking slot (16) are facing in direction of the vehicle. 2. Coat the piston pin (15) with engine oil and insert it by hand. Notice Do not heat up the piston.
  • Page 468 OM600 ENGINE MECHANICAL 1B3-167 6. Coat the cylinder bore, connecting rod bearing journal, connecting rod bearing shell and piston with oil. 7. Compress the piston rings with a tensioning strap (7). Tensioning Strap 000 589 04 14 00 8. Insert the piston assembly into the cylinder with a wooden stick (18).
  • Page 469 1B3-168 OM600 ENGINE MECHANICAL 12. Coat the bolts (12) with oil and then tighten the bolts. Tightening Torque 40Nm + 90° 13. Rotate the crankshaft and check axial clearance between the connecting rod and crankshaft. 14. Measure clearance between the piston crown and cylinder Standard Max.

  • Page 470: Oil Filter

    OM600 ENGINE MECHANICAL 1B3-169 OIL FILTER 1 Nut ............25 Nm 6 Bolt (M6) ............ 10Nm 2 Oil Filter ............. Cover 7 Oil Pressure Switch 3 O-Ring ........... Replace 8 Gasket 4 Oil Filter ....Element Replace If necessary 9 Bolt ............25 Nm 5 Oil Filter Housing...
  • Page 471 1B3-170 OM600 ENGINE MECHANICAL Removal & Installation Procedure 1. Remove the oil filter cover and then drain the oil. 2. Remove the oil pressure switch line. 3. Remove the oil filter housing. 4. Clean the sealing surface. 5. Installation should follow the removal procedure in the reverse order.

  • Page 472: Oil Pan

    OM600 ENGINE MECHANICAL 1B3-171 OIL PAN OM661LA OM662LA 1 Gasket ........... Replace 6 Lower Oil Pan 2 Upper Oil Pan 7 Combination Bolt ........25 Nm 3 Combination Bolt ........10 Nm 8 Drain Plug ..........25 Nm 4 Combination Bolt ........10 Nm 9 Washer Seal ..........
  • Page 473 1B3-172 OM600 ENGINE MECHANICAL Oil Circulation...
  • Page 474 OM600 ENGINE MECHANICAL 1B3-173 Oil Filter a From Oil Pump b To Main Oil Gallery c To Oil Pan...

  • Page 475: Oil Spray Nozzle

    1B3-174 OM600 ENGINE MECHANICAL OIL SPRAY NOZZLE 1 Fitting Sleeve 3 Combination Bolt ........10 Nm 2 Oil Spray Nozzle A Oil Duct Disassembly Procedure 1. Remove oil pan or crankshaft. 2. Loose the bolt and then remove the nozzle.

  • Page 476: Oil Pump

    OM600 ENGINE MECHANICAL 1B3-175 OIL PUMP 1 Oil Pump 5 Screw Plug ..........50 Nm 2 Piston 6 Combination Bolt ........25 Nm 3 Pressure Spring 7 Oil Strainer 4 Guide Pin 8 Bracket Disassembly Procedure 1. Remove the oil pan. 2.
  • Page 477 1B3-176 OM600 ENGINE MECHANICAL 3. Unscrew the oil strainer bracket bolt. Tightening Torque 10 Nm 4. Remove the oil pump. 5. Unscrew the screw plug and remove the relief valve. 6. Installation should follow the removal procedure in the reverse order.

  • Page 478: Unit Repair

    OM600 ENGINE MECHANICAL 1B3-177 UNIT REPAIR CYLINDER HEAD PRESSURE LEAKAGE TEST Preceding Work : Removal of the cylinder head Removal of the exhaust manifold Removal of the valve 1 Feed Pipe 2 Bolt 3 Return Connection 4 Gasket ..............Replace 5 Coolant Gallery ...........

  • Page 479: Facing Cylinder Head Mating Surface

    1B3-178 OM600 ENGINE MECHANICAL FACING CYLINDER HEAD MATING SURFACE Preceding Work : Removal of prechamber Cylinder head pressure leakage test 1 Valve B Longitudinal Direction 2 Cylinder Head C Transverse Direction 3 Prechamber a Valve Arrears A Height of Cylinder Head b Prechamber Protrusion Service Data Height ‘A’...
  • Page 480 OM600 ENGINE MECHANICAL 1B3-179 Measurement Procedure 1. Measure height ‘A’. Limit 142.5 mm Notice If the height is less than 142.5mm, replace the cylinder head. 2. Insert the valve (1) and measure valve arrears ‘a’. Valve arrears ‘a’ 0.1 - 0.7 mm Notice If out of standard, machine the valve seat.

  • Page 481: Replacement Of Crankcase Core Plug

    1B3-180 OM600 ENGINE MECHANICAL REPLACEMENT OF CRANKCASE CORE PLUG Left Right Core plug ............34mm Core plug ............34mm OM661LA - 2EA OM661LA - 2EA OM662LA - 3EA OM662LA - 3EA Left Right Core plug ............17mm Core plug ............34mm OM661LA - 1EA OM661LA - 1EA...
  • Page 482 OM600 ENGINE MECHANICAL 1B3-181 Tools Required 102 589 00 15 00 Drift 102 589 12 15 00 Drift Replacement Procedure 1. Completely drain the coolant. 2. Remove any parts which impede access. (Example : transmission, injection pump) 3. Place the screwdriver to the deepdrawn edge of the core plug and pull forward and then rotate 90°.

  • Page 483: Facing Crankcase Contacting Surface

    1B3-182 OM600 ENGINE MECHANICAL FACING CRANKCASE CONTACTING SURFACE 1 Crankcase B Longitudinal Direction 2 Crankcase Contacting Surface C Transverse Direction H Chamfer Height Y Height (crankcase upper surface - crankcase b Chamfer Angle lower surface) Service Data Height ‘Y’ Min. 299.62 mm Permissible unevenness of contacting surface In longitudinal direction (B) 0.06 mm...

  • Page 484: Oil Gallery Steel Ball

    OM600 ENGINE MECHANICAL 1B3-183 OIL GALLERY STEEL BALL Preceding Work : Removal of cooling fan Removal of the coolant pump housing Removal of the flywheel and driven plate 1 Steel Ball ..........15mm 2 Screw Plug M16 x 1.5 ....Loctite 241,50Nm Notice The screw plug (2) has to be installed as a repair solution if the steel ball (1) is leaking.
  • Page 485 1B3-184 OM600 ENGINE MECHANICAL 3 Steel Ball ..........17mm 5 Screw Plug M18 x 1.5 ........ 50Nm 4 Seal Notice The seal (4) and screw plug (5) have to be installed as a repair solution if the steel ball (3) is leaking. Tools Required 601 589 08 15 00 Drift...
  • Page 486 OM600 ENGINE MECHANICAL 1B3-185 Removal & Installation Procedure 1. Remove the timing case cover. 2. By inserting a round bar (6) approx. 0.7m from the back to the front side through the oil gallery, knock out the steel balls (1,3). Notice Be careful not to damage the bores of the steel balls.
  • Page 487 1B3-186 OM600 ENGINE MECHANICAL Installation of screw plug Notice If steel ball leaks again, install the screw plug. 1. Remove the steel ball. 2. Tap thread into the bores of the oil gallery. Notice Front bore : M18 ´ 1.5, depth 10mm Rear bore : M16 ´...

  • Page 488: Cylinder Bore Measurement

    OM600 ENGINE MECHANICAL 1B3-187 CYLINDER BORE MEASUREMENT Longitudinal Direction Transverse Direction c, d, e. Measuring Point Crankcase Contacting Surface TDC of 1st Piston Ring BDC of Ring Service Data Standard size Code letter ‘A’ 89.000 - 89.006mm Code letter ‘X’ 89.006 - 89.012mm Code letter ‘B’...
  • Page 489 SECTION 1D1 M162 ENGINE COOLING CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
  • Page 490 1D1-2 M162 ENGINE COOLING FASTENER TIGHTENING SPECIFICATIONS Application N· · · · · m Coolant Drain Plug Engine Hanger Bracket and Coolant Outlet 22.5 - 27.5 Port Bolt Thermostat Cover Bracket Bolt 9 - 11 Oil Cooler Pipe Line Bolt 9 - 11 Cooling Fan Bolt 9 - 11...

  • Page 491: Special Tools

    M162 ENGINE COOLING 1D1-3 SPECIAL TOOLS SPECIAL TOOLS TABLE 124 589 15 21 00 603 589 00 40 Tester Counter Holder...

  • Page 492: Diagnosis

    1D1-4 M162 ENGINE COOLING DIAGNOSIS SYSTEM LEAKAGE TEST Tools Required 124 589 15 21 00 Tester Test Procedure 1. Loosen the cap a little and release pressure and remove the cap. Notice For the risk of scalding, cap must not be opened unless the coolant temperature is below 90°C.

  • Page 493: Maintenance And Repair

    M162 ENGINE COOLING 1D1-5 MAINTENANCE AND REPAIR ON-VEHICLE SERVICE COOLANT DRAIN AND FILL UP Draning & Filling up Procedure 1. Loosen the cap a little and release pressure and remove the cap. Notice For the risk of scalding, the cap must not be opened unless the coolant temperature is below 90 2.

  • Page 494: Clamp

    1D1-6 M162 ENGINE COOLING 6. Remove the de-aeration hose clamp in the coolant pump and remove the de-aeration hose. 7. Fill up the coolant through the coolant reservoir tank. Notice Match the anti-freeze and the water ratio to 50 : 50. Supplement the coolant until the coolant overflows to the deaeration hose.

  • Page 495: Coolant Connection Fitting

    M162 ENGINE COOLING 1D1-7 COOLANT CONNECTION FITTING Preceding Work : Removal of cooling fan shroud 1 Bolt (M8 X 100, 2 pieces) ....22.5-27.5 Nm 4 O-ring 2 Engine Hanger Bracket 5 Hose Mounting Clamp 3 Coolant Outlet Port 6 Hose Removal &...

  • Page 496: Bolt

    1D1-8 M162 ENGINE COOLING WATER PUMP Preceding Work : Removal of V-belt Removal of air admission housing 1 Air Admission Housing 8 Coolant Hose 2 Oil Cooler Pipe Line 9 Inlet Coolant Hose 3 Seal ............Replace 10 Coolant Pump 4 Bolt ............
  • Page 497 M162 ENGINE COOLING 1D1-9 Removal & Installation Procedure 1. Drain the coolant. 2. Disconnect the coolant pump wire connector. 3. Loosen the hose clip and dsconnect all hoses from the coolant pump 4. Remove the coolant line bolts (4) and then remove the coolant line (2).

  • Page 498: Thermostat

    1D1-10 M162 ENGINE COOLING THERMOSTAT 1 Thermostat Cover 5 Bolt (M6 X 25, 3 pieces) ......9-11 Nm 2 Thermostat 6 Hose Mounting Clamp 3 O-ring 7 Heater Hose 4 Thermostat Cover Bracket Removal & Installation Procedure 1. Drain the coolant from the radiator. 2.

  • Page 499: Oil Cooler Pipe Line

    M162 ENGINE COOLING 1D1-11 OIL COOLER PIPE LINE Preceding Work : Removal of upper intake manifold 1 Upper Intake Manifold 4 Oil Cooler Pipe Line 2 Bolt (M6 X 35, 1 piece) ......9-11 Nm 5 O-ring ............ Replace 3 Bolt (M6 X 16, 2 pieces) ......9-11 Nm Removal &...

  • Page 500: Cooling Fan And Viscous Clutch

    1D1-12 M162 ENGINE COOLING COOLING FAN AND VISCOUS CLUTCH Preceding Work : Removal of cooling fan shroud 1 Cooling Fan Pulley 4 Bolt (M6 X 12, 4 pieces) ......9-11 Nm 2 Viscous Clutch 5 Bolt (M10 X 45, 1 piece) ....40.5-49.5 Nm 3 Cooling Fan...
  • Page 501 M162 ENGINE COOLING 1D1-13 Tools Required 603 589 00 40 00 Counter Holder Removal & Installation Procedure 1. Hold the cooling fan pulley using the counter holder (special tool : 603 589 00 40 00) and remove the cooling fan after unscrewing the four bolts (4).

  • Page 502: Cooling Fan Shroud

    1D1-14 M162 ENGINE COOLING COOLING FAN SHROUD 1 Clip 4 Fan Shroud Assembly 2 Lower Fan Shroud 5 Radiator 3 Bolt Removal & Installation Procedure 1. Pull out the 2 clips (1) from the fan shroud assembly. 2. Remove the lower fan shroud (2). Notice For installation, exactly align the lower fan shroud pin into the hole of the fan shroud assembly (4) and insert the...
  • Page 503 M162 ENGINE COOLING 1D1-15 RADIATOR Preceding Work : Removal of cooling fan shroud 1 Radiator Inlet Coolant Hose 6 Bolt 2 Radiator Outlet Coolant Hose 7 Insulator 3 Make Up Coolant Hose 8 Stopper 4 Automatic Transmission Oil Cooling Hose 9 Bolt .............
  • Page 504 1D1-16 M162 ENGINE COOLING Removal & Installation Procedure 1. Drain coolant from the radiator. 2. Remove the coolant thermo connector from the radiator. 3. Remove the each coolant hoses. 4. Remove the automatic transmission oil cooling hose. Installation Notice Tightening Torque 14 Nm 5.
  • Page 505 SECTION 1D2 M161 ENGINE COOLING CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
  • Page 506 1D2-2 M161 ENGINE COOLING FASTENER TIGHTENING SPECIFICATIONS N· · · · · m Application Coolant Drain Plug 22.5 - 27.5 Engine Hanger Bracket and Coolant Outlet Port Bolt 9 - 11 Thermostat Cover Bracket Bolt Oil Cooler Pipe Line Bolt 9 - 11 9 - 11 Cooling Fan Bolt...

  • Page 507: Special Tools

    M161 ENGINE COOLING 1D2-3 SPECIAL TOOLS SPECIAL TOOLS TABLE 124 589 15 21 00 603 589 00 40 Tester Counter Holder 111 589 02 01 00 111 589 00 40 00 Open End Wrench Open End Wrench...

  • Page 508: Diagnosis

    1D2-4 M161 ENGINE COOLING DIAGNOSIS SYSTEM LEAKAGE TEST Tools Required 124 589 15 21 00 Tester Test Procedure 1. Loosen the cap a little and release pressure and remove the cap. Notice For the risk of scalding, cap must not be opened unless the coolant temperature is below 90°C.

  • Page 509: Maintenance And Repair

    M161 ENGINE COOLING 1D2-5 MAINTENANCE AND REPAIR ON-VEHICLE SERVICE COOLANT DRAIN AND FILL UP Draning & Filling up Procedure 1. Loosen the cap a little and release pressure and remove the cap. Notice For the risk of scalding, the cap must not be opened unless the coolant temperature is below 90oC.
  • Page 510 1D2-6 M161 ENGINE COOLING 6. Remove the de-aeration hose clamp in the coolant pump and remove the de-aeration hose. 7. Fill up the coolant through the coolant reservoir tank. Notice Match the anti-freeze and the water ratio to 50 : 50. Supplement the coolant until the coolant overflows to the deaeration hose.

  • Page 511: Cooling Fan And Viscous Clutch

    M161 ENGINE COOLING 1D2-7 COOLING FAN AND VISCOUS CLUTCH 1 Bolt (M6 X 14, 3 piece) ......9-11 Nm 3 Viscous Clutch 2 Cooling Fan 4 Union Nut (Left Threaded Screw) ... 40.5-49.5 Nm...
  • Page 512 1D2-8 M161 ENGINE COOLING Tools Required 111 589 02 01 00 Open End Wrench 111 589 00 40 00 Open End Wrench Removal & Installation Procedure 1. Install the holder (special tool : 111 589 00 40 00) to the bolt at the pulley as shown in the right figure to hold the pulley.

  • Page 513: Coolant Pump

    M161 ENGINE COOLING 1D2-9 COOLANT PUMP Preceding Work : Removal of viscous clutch 1 Bolt (M6 X 45, 1 piece) ......9-11 Nm 7 Coolant Pump Pulley 2 Bolt (M6 X 95, 1 piece) ......9-11 Nm 8 Coolant Inlet Hose 3 Bolt (M6 X 25, 4 piece) ......
  • Page 514 1D2-10 M161 ENGINE COOLING Tools Required 124 589 15 21 00 Tester Removal & Installation Procedure 1. Drain the coolant. 2. Disconnect the coolant hoses (8, 9, 10). 3. Tak off the drive belt. 4. Unscrew the four bolts (6) from coolant pump pulley and remove the pulley (7).

  • Page 515: Thermostat

    M161 ENGINE COOLING 1D2-11 THERMOSTAT 1 Bolt (M6 X 25, 3 pieces) ......9 -11 Nm 4 Coolant Outlet Hose 2 Thermostat Cover 5 Thermostat 3 De-aeration Hose 6 O-ring Removal & Installation Procedure 1. Drain the coolant from the radiator. 2.

  • Page 516: Thermostat Housing Assembly

    1D2-12 M161 ENGINE COOLING THERMOSTAT HOUSING ASSEMBLY Preceding Work : Removal of viscous clutch 1a Bolt (M6 X 95, 2 pieces) ......9-11 Nm 4 De-aeration Hose 1b Bolt (M8 X 75, 2 pieces) ....22.5-27.5 Nm 5 Coolant Outlet Hose 1c Bolt (M8 X 35, 1 piece) ....
  • Page 517 M161 ENGINE COOLING 1D2-13 Removal & Installation Procedure 1. Drain the coolant. 2. Remove the de-aeration hose (4), coolant outlet hose (5) and coolant bypass hose (6). 3. Disconnect the coolant temperature sensor connector. 4. Unscrew the bolt (1c) and pry off the tensioning device shock absorber (7).

  • Page 518: Removal And Installation Of Cooling Fan Shroud

    1D2-14 M161 ENGINE COOLING REMOVAL AND INSTALLATION OF COOLING FAN SHROUD 1 Fan Suroud Assembly 2 Bolt (M6 X 16, 2 pieces) ......3-7 Nm Removal & Installation Procedure 1. Unscrew two bolts from cooling fan shroud and remove the shrud. Installation notice Tightening Torque 3 - 7 Nm...

  • Page 519: Removal And Installation Of Radiator

    M161 ENGINE COOLING 1D2-15 REMOVAL AND INSTALLATION OF RADIATOR Preceding Work : Removal of cooling fan shroud 1 Inlet Hose 7 Bolt (M6 X 20, 4 pieces) ......3-7 Nm 2 Hose (to Engine) 8 Insulator 3 Hose (to 3-way Connector) 9 Radiator Bracket 4 Make-up Hose (to Coolant Reservoir) 10 Radiator...
  • Page 520 1D2-16 M161 ENGINE COOLING Removal & Installation Procedure 1. Drain coolant from the radiator. 2. Remove the coolant thermo connector from the radiator. 3. Remove the each coolant hoses. 4. Remove the automatic transmission oil cooling hose. Installation Notice Tightening Torque 14 Nm 5.
  • Page 521 SECTION 1D3 OM600 ENGINE COOLING Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

  • Page 522: Diagnosis

    1D3-2 OM600 ENGINE COOLING DIAGNOSIS COOLING CIRCULATION A Thermostat G Deaeration Line B Radiator H Reservoir D From Heater E Hose...

  • Page 523: Thermostat Operation

    OM600 ENGINE COOLING 1D3-3 THERMOSTAT OPERATION Operation 1. At warming up Valve closes until temperature of coolant reaches to 85°C. B. From Radiator C. From Crankcase D. To Crankcase 2. At partial opening. Valve opens partially as temperature of coolant is maintained between 85-100°C.

  • Page 524: Cooling System Leakage Test

    1D3-4 OM600 ENGINE COOLING COOLING SYSTEM LEAKAGE TEST Tools Required 124 589 15 21 00 Tester Test 1. Loosen the pressure cap by 1 notch and remove the cap after. Notice Do not remove radiator cap when coolant is above 90°C. 2.

  • Page 525: Maintenance And Repair

    OM600 ENGINE COOLING 1D3-5 MAINTENANCE AND REPAIR ON-VEHICLE SERVICE DRAIN AND FILLING OF COOLANT Preceding Work : Removal of skid plate Drain / Filling 1. Loosen the pressure cap of reservoir by 1 notch and remove pressure and then loosen the cap. Notice Do not remove radiator cap when coolant is above 90°C.

  • Page 526: Coolant Pump

    1D3-6 OM600 ENGINE COOLING COOLANT PUMP Preceding Work : Removal of cooling fan Removal of V-belt 1 Tensioning Lever 4 Belt Pulley 2 Gasket ........... Replace 5 Bolt ............10 Nm 3 Bolt ............10 Nm 6 Coolant Pump...
  • Page 527 OM600 ENGINE COOLING 1D3-7 Removal & Installation Procedure 1. Loose the bolts(5) and remove the pulley (4). Installation Notice Tightening Torque 10 Nm 2. Loose the bolts (3). Installation Notice Tightening Torque 10 Nm 3. Pull the tensioning lever(1) to the arrow direction. 4.

  • Page 528: Coolant Pump Housing

    1D3-8 OM600 ENGINE COOLING COOLANT PUMP HOUSING Preceding Work : Removal of coolant pump Removal of thermostat Removal of alternator 1 Gasket ........... Replace 5 Coolant Hose 2 Coolant Pump Housing 6 Return Pipe 3 Connector 7 O-Ring 4 Bolt ............10 Nm 8 Temperature Sensor Notice The bolt on the arrow should be installed last.
  • Page 529 OM600 ENGINE COOLING 1D3-9 Removal & Installation Procedure 1. Disconnect the connector(3). 2. Separate the coolant hose (5) and return pipe(6). 3. Remove the bolts(4) evenly. Installation Notice Tightening Torque 10 Nm Notice Clean gasket residues on the sealing surface of coolant pump and replace the gasket.

  • Page 530: Cooling Fan Clutch

    1D3-10 OM600 ENGINE COOLING COOLING FAN CLUTCH 1 Belt Pulley 4 Socket Bolt ..........45 Nm 2 Cooling Fan Clutch 5 Socket Bolt ..........10 Nm 3 Cooling Fan Tools Required 603 589 00 40 00 Counter Holder...
  • Page 531 OM600 ENGINE COOLING 1D3-11 Removal & Installation Procedure 1. Hold the bolt pulley with counter holder and remove the bolt(4). Counter Holder 603 589 00 40 00 Installation Notice Tightening Torque 45 Nm 2. Remove the socket bolt(5) and then remove the cooling fan(3) and fan clutch(2).

  • Page 532: Radiator

    1D3-12 OM600 ENGINE COOLING RADIATOR Preceding : Removal of cooling fan shroud 1 Radiator Inlet Hose ....OM662LA : 220mm 5 Spring Clamp ..........OM661LA : 321mm 6 Bolt ............3-7 Nm 2 Radiator outlet Hose 7 Radiator 3 Radiator Deaeration Tube & Hose 8 Spring Clamp 4 Clamp 9 Bolt ............
  • Page 533 OM600 ENGINE COOLING 1D3-13 Removal & Installation Procedure 1. Drain coolant from the radiator. 2. Remove the coolant thermoswich connector from radiator. 3. Remove the each coolant hose. 4. Remove the auto T/M oil cooling hose and cooling line. Installation Notice Hose : 29 - 40Nm Tightening Torque 5.

  • Page 534: Cooling Sub-System

    1D3-14 OM600 ENGINE COOLING COOLING SUB - SYSTEM 1 Radiator 7 Mounting Bracket 2 Cooling Fan Shroud 8 Make-up Cooling Hose 3 Bolt ............3-7Nm 9 Bolt ............3-7Nm 4 Cooling Fan Shroud 10 Cooling Reservoir-tank Cap 5 Radiator Deaieration Hose 11 Cooling Reservoir-tank...
  • Page 535 OM600 ENGINE COOLING 1D3-15 Removal & Installation Procedure Cooling Fan Shroud 1. Remove the radiator deaeration hose and tube. Installation Notice Tightening Torque 3 - 7 Nm Tightening torque 3-7Nm 2. Check the shroud. 3. Installation should follow the removal procedure in the reverse order.

  • Page 536: Thermostat

    1D3-16 OM600 ENGINE COOLING THERMOSTAT 1 Thermostat 4 Coolant Hose 2 Seal ............Replace 5 Bolt ............10Nm 3 Thermostat Housing Cover...
  • Page 537 OM600 ENGINE COOLING 1D3-17 Removal & Installation Procedure 1. Drain the coolant completely. 2. Disconnect the coolant hose(4) from the thermostat housing cover(3). 3. Remove the bolts(5) and then remove the thermostat(1) and housing cover(3) Installation Notice Align the groove on thermostat and the housing cover rib(arrow).
  • Page 538 SECTION 1E1 M162 ENGINE ELECTRICAL CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

  • Page 539: Battery Specifications

    1E1-2 M162 ENGINE ELECTRICAL STARTING MOTOR SPECIFICATIONS Application Description Voltage 12 V Output Power 1.7 KW BATTERY SPECIFICATIONS Application Description Capacity 90 Ah Specific Gravity ³ 1.24 Max. Tolerance Between Cells ³ 0.04 FASTENER TIGHTENING SPECIFICATIONS Application N·m Alternator Terminal B+Nut 14 - 18 Alternator Terminal D+Nut 4 - 5...

  • Page 540: Special Tools

    M162 ENGINE ELECTRICAL 1E1-3 SPECIAL TOOLS SPECIAL TOOLS TABLE 120 589 02 09 00 Spark Plug Wrench...

  • Page 541: Maintenance And Repair

    1E1-4 M162 ENGINE ELECTRICAL MAINTENANCE AND REPAIR ON-VEHICLE SERVICE ALTERNATOR Preceding Work : Removal of the drivebelt Removal & Installation Procedure 1. Disconnect the negative battery terminal. 2. Unscrew the nut and disconnect the terminal (1). Installation Notice Tightening Torque 14 - 18 Nm 3.

  • Page 542: Starting Motor

    M162 ENGINE ELECTRICAL 1E1-5 STARTING MOTOR Removal & Installation Procedure 1. Disconnect the ground cable. 2. Unscrew the nut and disconnect the battery cable(1). Installation Notice Tightening Torque 12 - 15 Nm 3. Unscrew the nut and disconnect the engine electric wire (2).

  • Page 543: Battery

    1E1-6 M162 ENGINE ELECTRICAL BATTERY 1 Cable Terminal (-) 7 Battery holddown Bracket 2 Cable Terminal Cap (-) 8 Battery Clamp Bolt 3 Cable Terminal Cap (+) 9 Battery 4 Nut 10 Sub Tray 5 Fuseblink Box 11 Battery Tray 6 Terminal (+) Removal &...

  • Page 544: Spark Plug

    M162 ENGINE ELECTRICAL 1E1-7 SPARK PLUG Preceding Work : Removal of intake air duct 1 Ignition Coil Cable Cover T1/1 Ignition Coil : Cylinder 2 and 5 2 Bolt (M6 X 60, 7 pieces) ......9-11 Nm T1/2 Ignition Coil : Cylinder 3 and 4 3 Spark Plug T1/3 Ignition Coil : Cylinder 1 and 6...
  • Page 545 1E1-8 M162 ENGINE ELECTRICAL Tools Required 120 589 09 00 Spark Plug Wrench Replacement Procedure 1. Remove the seven bolts (2) and remove the ignition cable cover. Installation Notice Tightening Torque 9 - 11 Nm 2. Remove the two bolts (M6 X 25) from each ignition cable and remove the ignition cable.

  • Page 546: Ignition Cable

    M162 ENGINE ELECTRICAL 1E1-9 IGNITION CABLE Preceding Work : Removal of intake air duct 1 Control Cable Connection 5a,5b Secondary Voltage Connection 2 Ignition Cable E Iron Core 3 Spark Plug Connector L2 Primary Ignition Coil 4 Coupling Plug L1 Secondary Ignition Coil...
  • Page 547 1E1-10 M162 ENGINE ELECTRICAL Functions 1. Firing order : 1-5-3-6-2-4 2. The ignition cables are located on the cylinder head cover. Each ignition coil provides the high voltage to two spark plugs simultaneously. T1/1 : cylinder 2 and 5 T1/2 : cylinder 3 and 4 T1/3 : cylinder 1 and 6 3.
  • Page 548 M162 ENGINE ELECTRICAL 1E1-11 Circuit Diagram Inspection & Maintenance Procedure (for MSE) 1. While the ignition switch is in 'OFF' position, remove the wiring connectors (1 and 15) from ignition coil and measure the primary resistance between terminal No.1 and No.15. Specified Value 0.9 - 1.6 W (20°C) Notice...

  • Page 549: Unit Repair

    1E1-12 M162 ENGINE ELECTRICAL UNIT REPAIR BATTERY Inspection Notice When charging the battery, do not leave the inflammable objects around it. When checking the electrolyte of battery, put on an eye protector and gloves. 1. Inspect the surface of the battery and replace if any defects were found on it.
  • Page 550 SECTION 1E2 M161 ENGINE ELECTRICAL CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

  • Page 551: Starting Motor Specifications

    1E2-2 M161 ENGINE ELECTRICAL STARTING MOTOR SPECIFICATIONS Application Description Voltage 12 V Output Power 1.2 KW BATTERY SPECIFICATIONS Application Description Capacity 90 Ah Specific Gravity ³ 1.24 Max. Tolerance Between Cells ³ 0.04 FASTENER TIGHTENING SPECIFICATIONS Application N·m Alternator Terminal B+Nut 14 - 18 Alternator Terminal D+Nut 4 - 5...

  • Page 552: Special Tools

    M161 ENGINE ELECTRICAL 1E2-3 SPECIAL TOOLS SPECIAL TOOLS TABLE 120 589 02 09 00 Spark Plug Wrench...

  • Page 553: Maintenance And Repair

    1E2-4 M161 ENGINE ELECTRICAL MAINTENANCE AND REPAIR ON-VEHICLE SERVICE ALTERNATOR Preceding Work : Removal of the drivebelt Removal & Installation Procedure 1. Disconnect the negative battery terminal. 2. Unscrew the nut and disconnect the terminal (1). Installation Notice Tightening Torque 14 - 18 Nm 3.

  • Page 554: Starting Motor

    M161 ENGINE ELECTRICAL 1E2-5 STARTING MOTOR Removal & Installation Procedure 1. Disconnect the ground cable. 2. Unscrew the nut and disconnect the battery cable(1). Installation Notice Tightening Torque 12 - 15 Nm 3. Unscrew the nut and disconnect the engine electric wire (2).

  • Page 555: Battery

    1E2-6 M161 ENGINE ELECTRICAL BATTERY 1 Cable Terminal (-) 7 Battery holddown Bracket 2 Cable Terminal Cap (-) 8 Battery Clamp Bolt 3 Cable Terminal Cap (+) 9 Battery 4 Nut 10 Sub Tray 5 Fuseblink Box 11 Battery Tray 6 Terminal (+) Removal &...

  • Page 556: Spark Plug

    M161 ENGINE ELECTRICAL 1E2-7 SPARK PLUG Preceding Work : Removal of intake air duct 1 Screw (3 pieces) ........ 9 - 11 Nm 6 Bolts (M6 X 25, 4 pieces) ....9 - 11 Nm 2 Adaptor (3 pieces) 7 Ignition Coil (T1/1) 3 Ignition Coil Cable Cover 8 Coupling Plug 4 Spark Plug Connector...
  • Page 557 1E2-8 M161 ENGINE ELECTRICAL Replacement Procedure 1. Unscrew the three screws(1) and remove the ignition coil cable cover Installation Notice Tightening Torque 9 - 11Nm 2. Disconnect the cable from ignition coil and spark plug. 3. Unscrew two bolts(M6 X 25) from each ignition coil and remove the ignition coil(arrow) .

  • Page 558: Ignition Cable

    M161 ENGINE ELECTRICAL 1E2-9 IGNITION CABLE Preceding Work : Removal of intake air duct 1 Control Cable Connection 5a,5b Secondary Voltage Connection 2 Ignition Cable E Iron Core 3 Spark Plug Connector L2 Primary Ignition Coil 4 Coupling Plug L1 Secondary Ignition Coil...
  • Page 559 1E2-10 M161 ENGINE ELECTRICAL Removal & Installation Procedure 1. Disconnect the battery negative cable. 2. Unscrew the 3 screws and remove the ignition cable duct cover. Installation Notice Tightening Torque 9 - 11 Nm 3. Seperate the cable from the ignition cable and the spark plug.
  • Page 560 M161 ENGINE ELECTRICAL 1E2-11 Inspection & Maintenance (for E2.3 MSE) 1. Measure the primary resistance between the cable terminals 1 and 15 after removing the ignition cable wiring connector (1 and 15) with ignition switch OFF. Notice Replace the ignition coil if out of the specified resistance. Specified Value 0.9 - 1.6 W 2.

  • Page 561: Unit Repair

    1E2-12 M161 ENGINE ELECTRICAL UNIT REPAIR BATTERY Inspection Notice When charging the battery, do not leave the inflammable objects around it. When checking the electrolyte of battery, put on an eye protector and gloves. 1. Inspect the surface of the battery and replace if any defects were found on it.
  • Page 562 SECTION 1E3 OM600 ENGINE ELECTRICAL Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

  • Page 563: Maintenance And Repair

    1E3-2 OM600 ENGINE ELECTRICAL MAINTENANCE AND REPAIR ON-VEHICLE SERVICE GLOW PLUG 1 Wiring Harness 3 Wire Terminal 2 Nut .............. 4 Nm 4 Glow Plug Preheating System General information The preheating system consists of control, coolant temperature sensor and glow plugs. Control relay - preheating time.
  • Page 564 OM600 ENGINE ELECTRICAL 1E3-3 1. Preheating time - control relay. Control relay functions as followings : Switching of preheating current. Indication of preheating finish. Control of preheating sequence. Indication of fault. 2. Coolant temperature sensor. Coolant temperature sensor senses coolant’s temperature and signals it to the preheating relay continuously.
  • Page 565 1E3-4 OM600 ENGINE ELECTRICAL Preheating system operation 1. Preheating before start. Preheating time is different by coolant temperature and it is on until the glow indicator light goes off. 2. Preheating after start. Preheating continues for max. 60 seconds to rise in characteristic of warming-up on engine after starting too.
  • Page 566 OM600 ENGINE ELECTRICAL 1E3-5 Removal & Installation Procedure 1. Disconnect the negative terminal of battery. 2. Remove the nut (2). 3. Remove the glow plug (4). 4. Install the glow plug (4). Tightening Torque 20 Nm 5. Tighten the nut (2). Tightening Torque 4 Nm...

  • Page 567: Alternator

    1E3-6 OM600 ENGINE ELECTRICAL ALTERNATOR Preceding Work : Removal of poly V-belt 1 Cooling Fan 4 Alternator 2 Bolt ............45Nm 5 Plug Connection 3 Bolt ............45Nm...
  • Page 568 OM600 ENGINE ELECTRICAL 1E3-7 Removal & Installation Procedure 1. Disconnect the negative terminal of the battery. 2. Disconnect the plug connection (5). 3. OM 662 Engine Align the groove of cooling fan with bolt (2) (arrow). 4. Remove the bolts (2, 3) and take out the alternator. Tightening Torque 45 Nm 5.

  • Page 569: Washer

    1E3-8 OM600 ENGINE ELECTRICAL STARTER MOTOR 1 Starter Motor 3 Nut ............. 15Nm 2 Washer 4 Bolt ............48Nm Removal & Installation Procedure 1. Disconnect the battery terminals. 2. Disconnect the starter motor cable harnesses. 3. Remove the bolts and then remove the starter motor. 4.
  • Page 570 SECTION 1F1 M162 ENGINE CONTROLS CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
  • Page 571 1F1-2 M162 ENGINE CONTROLS SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application N·m Fuel Return and Supply Line 25 - 30 Fuel Distributor Assembly Bolt 22.5 - 27.5 Pressure Test Connector 21.6 - 26.4 Fuel Inlet and Outlet Line 25 - 30 Fuel Filter Mounting Bracket Bolt 4 - 8 Crankshaft Position Sensor Bolt 9 - 11...

  • Page 572: Special Tools Table

    M162 ENGINE CONTROLS 1F1-3 SPECIAL TOOLS SPECIAL TOOLS TABLE 129 589 00 21 00 106 589 00 21 00 Test Box Pressure Tester 119 589 04 63 00 210201 Pressure Hose Adaptor Line 210 589 08 63 00 ECU Test Cable...

  • Page 573: Schematic And Routing Diagrams

    1F1-4 M162 ENGINE CONTROLS SCHEMATIC AND ROUTING DIAGRAMS...

  • Page 574: Diagnosis

    M162 ENGINE CONTROLS 1F1-5 DIAGNOSIS SELF DIAGNOSIS SOCKET PIN NUMBERS AND DESCRIPTIONS 1 Ground 11 Remote Engine Start Unit(PIN 10) 2 Ignition 1 12 - 3 Battery Power Supply (Fuse NO.17) 13 Brake System 4 REKES :PIN 6 (ABS 5.3:PIN 11, ABS/ABD 5.3:PIN 46) 5 Engine Speed Signal :MSE PIN 60 14 MSE 3.62S/3.53S(ECU Data Output:PIN 58) 6 TCCU(Part-time)

  • Page 575: Self Diagnosis Failure Code

    1F1-6 M162 ENGINE CONTROLS SELF DIAGNOSIS FAILURE CODE Failure Fa ilure Description Description code code Coolant temperature sensor open Purge valve open/short Coolant temperature sensor short Condenser fan(HI) relay short(PWR) Coolant temperature sensor signal failure Condenser fan(HI) relay short(GND) Intake temperature sensor open No.1 knock sensor signal failure Intake temperature sensor short No.2 knock sensor signal failure...
  • Page 576 M162 ENGINE CONTROLS 1F1-7 Failure Failure Description Description code code Short learning control failure Cruise control acceleration failure Lambda control failure (rich stop) Cruise control deceleration failure Lambda control failure (lean stop) ECU failure(RAM) Lambda idle adaptation failure(above rich ECU failure(EPROM) threshold) Servo motor control output inter-ruption Lambda idle adaptation failure(below lean...
  • Page 577 1F1-8 M162 ENGINE CONTROLS Failure Failure Description Description code code No.5 injector open/short(GND) Control lever dual operation(CPU2) No.6 injector short(PWR) Control lever safety terminal failure(CPU2) No.6 injector open/short(GND) Unusual pedal position variation(CPU2) Variable intake air valve short(PWR) Unusal throttle position variation(CPU2) Variable intake air valve open/short(GND) Unusal throttle control data(CPU2) Cam actuator short(PWR)

  • Page 578: Test Box Connection

    M162 ENGINE CONTROLS 1F1-9 TEST BOX CONNECTION 1 ECU 01 Test Box 2 Test Coupling(No.1 - 60) 02 ECU Test Cable 3 Test Coupling(No.61 - 120) 4 Multi-tester Tools Required 129 589 00 21 00 Test Box 210 589 08 63 00 ECU Test Cable...

  • Page 579: Fuel Injection System Test (Mse3.62)

    1F1-10 M162 ENGINE CONTROLS FUEL INJECTION SYSTEM TEST (MSE3.62) Failure Test Specified Item Checking method Requirement Possible cause code step value Þ 1.0 ECU:power Ignition:ON 11 -14V Þ 1.1 · · · · · · · Þ 1.2 supply · - terminal 30(TM.30) Þ...
  • Page 580 M162 ENGINE CONTROLS 1F1-11 Test Specified Failure Item Checking method Requirement Possible cause step value code Þ 4.0 · · · · · HFM sensor Ignition:ON 0.9 - 1.1V Þ 4.1 - 4.3 · · signal Cable · · Engine:in Idle 1.3 - 1.7V External air inflow ·...
  • Page 581 1F1-12 M162 ENGINE CONTROLS Specified Test Failure Item Checking method Requirement Possible cause value step code Þ 6.0 · · · · · Fuel pump Ignition:ON 11 - 14V Cable · · relay: (Fuel pump relay will (approx.1- Fuel pump relay ·...
  • Page 582 M162 ENGINE CONTROLS 1F1-13 Test Specified Failure Item Checking method Requirement Possible cause step value code Þ 8.0 · · · · · ECU: Engine:in cranking or refer to figure Cable · · - RPM signal idle · output - Voltage Engine:in cranking 6.0 - 7.0 V ·...
  • Page 583 1F1-14 M162 ENGINE CONTROLS Failure Test Specified Item Checking method Requirement Possible cause code step value - Internal Ignition:OFF(injector 14 - 17 W · resistance temperature is 20° C) (No.1 injector) Þ 12.0 · · · · · No.2 When the coolant ·...
  • Page 584 M162 ENGINE CONTROLS 1F1-15 Test Specified Failure Item Checking method Requirement Possible cause step code value - Internal Ignition:OFF(injector 14 - 17 W · resistance temperature is 20° C) (No.3 injector) Þ 14.0 · · · · · No.4 When the coolant ·...
  • Page 585 1F1-16 M162 ENGINE CONTROLS Test Specified Failure Item Checking method Requirement Possible cause code step value - Internal Ignition:OFF(injector 14 - 17 W · resistance temperature is 20° C) (No.5 injector) Þ 16.0 No.6 When the coolant Cable 194, · · · · · ·...
  • Page 586 M162 ENGINE CONTROLS 1F1-17 Test Specified Failure Item Checking method Requirement Possible cause step code value Þ 18.1 Camshaft Ignition:OFF 8 - 12 W Cable · · · · · · · Camshaft actuator actuator: · Diagnosis Solenoid socket resistance 226, Engine:in idling Mechanical failure of...
  • Page 587 1F1-18 M162 ENGINE CONTROLS Test Specified Failure Item Checking method Requirement Possible cause step value code Þ 22.1 CAN module Ignition:OFF 115 - 125 W Cable · · · · · · · - disconnect the ABS, ABD, ASR resistance in ·...
  • Page 588 M162 ENGINE CONTROLS 1F1-19 Reference Figures Figure 3. Injection Valve Wave(at idle speed) Figure2. RPM Sgnal Output Figure 4. Injection Valve Wave(at sharp Figure 5. Purge Control Valve Operationg Wave acceleration)

  • Page 589: Ignition System Test

    1F1-20 M162 ENGINE CONTROLS IGNITION SYSTEM TEST Failure Test Specified Item Checking method Requirement Possible cause code step value ECU:power 11 - 14V Þ 1.1 · · · · · · Þ 1.2 supply · - terminal 30(TM.30) Þ 1.1 Ground Ignition:ON 11 - 14V...
  • Page 590 M162 ENGINE CONTROLS 1F1-21 Test Specified Failure Item Checking method Requirement Possible cause step value code Cable Þ 4.0 · · · · · Ignition · Ignition:ON 11 -14 V · coil(T1/2) · Ignition coil(T1/2) Fuse No.17 - No.3,4 · Cylinder ·...
  • Page 591 1F1-22 M162 ENGINE CONTROLS Test Specified Failure Item Checking method Requirement Possible cause step value code - Voltage Engine:in cranking The value will · (alternating) be changed in 1.2 - 1.7 V Ignition:ON · Cable Þ 7.1 · · · · · Camshaft 11 -14 V ·...
  • Page 592 M162 ENGINE CONTROLS 1F1-23 Test Specified Failure Item Checking method Requirement Possible cause step value code · · · · · Ignition Þ 10.0 Engine:in cranking 200 - 350 V Þ 10.1 · · coil(T1/3) (starter operating) - primary coil - Measuring range: voltage 400 V...
  • Page 593 1F1-24 M162 ENGINE CONTROLS Reference Figures Figure 6. Crankshaft Position Sensor Signal Figure 7. Camshaft Position Sensor Signal Voltage Identifying the No.1 - 2 Missing Teeth Figure 8. Signal Function Crank Angle Cylinder Crankshaft Position Sensor Signal Camshaft Position Sensor Signal RPM Signal...

  • Page 594: Idling Control And Electronic Pedal System Test

    M162 ENGINE CONTROLS 1F1-25 IDLING CONTROL AND ELECTRONIC PEDAL SYSTEM TEST Failure Specified Test Item Checking method Requirement Possible cause code value step 160, Þ 1.0 Pedal valve Ignition:ON Þ 1.1 · · · · · · · 161, Cable sensor: Position of ·...
  • Page 595 1F1-26 M162 ENGINE CONTROLS Failure Test Specified Item Checking method Requirement Possible cause code step value Throttle valve Position of · potentiometer 2 accelerator pedal: - Closed throttle 4.0 - 4.6 V position - Full throttle with 0.3 - 0.9 V kick down Þ...

  • Page 596: Air Conditioner Control System Test

    M162 ENGINE CONTROLS 1F1-27 AIR CONDITIONER CONTROL SYSTEM TEST Specified Failure Test Item Checking method Requirement Possible cause value code step Þ 1.0 Engine:In idling Þ 5.1 · · · · · · · Cable conditioner Air conditioner · · signal: switch : ON/OFF Thermo amp...

  • Page 597: Fuel Pressure And Internal Leakage Test

    1F1-28 M162 ENGINE CONTROLS FUEL PRESSURE AND INTERNAL LEAKAGE TEST Preparation 01 Pressure Tester 02 Pressure Hose 03 Measuring Beaker Connection of the Equipment 1. Turn the ignition switch to "OFF" position. 2. Remove the air cleaner cross pipe. 3. Remove the cap on fuel pressure test plug and connect the pressure hose and pressure tester.
  • Page 598 M162 ENGINE CONTROLS 1F1-29 Test Specified Failure Item Checking method Requirement Possible cause step value code Þ 1.0 · · · · · Fuel Connect the fuel Engine:in idling 3.2 - 3.6 bar Þ Fuel pump test · · pressure:in pressure test plug to - Close the valve Fuel pressure...

  • Page 599: Fuel Pump Test

    1F1-30 M162 ENGINE CONTROLS FUEL PUMP TEST Preparation 1 ECU 03 Test Box 2 Test Coupling(No.1-60) 04 ECU Test Cable 3 Test Coupling(No.61-120) 4 Stop Watch 5 Measuring Beaker Connection of the Equipment 1. Turn the ignition switch to "OFF" position. 2.
  • Page 600 M162 ENGINE CONTROLS 1F1-31 Test Specified Failure Item Checking method Requirement Possible cause step value code Þ 1.0 · · · · · Fuel pump: Ignition:ON 1 liter of fuel Þ 2.0 · · - Fuel supply - Disconnect the fuel supply for Check the fuel line ·...

  • Page 601: Injector Test

    1F1-32 M162 ENGINE CONTROLS INJECTOR TEST Preparation 1 ECU 03 Test Box 2 Test Coupling(No.1-60) 04 ECU Test Cable 3 Test Coupling(No.61-120) 4 Measuring Beaker 5 Shop Made Cable Connection of the Equipment 1. Connect the test box to the ECU as shown in the figure. 2.
  • Page 602 M162 ENGINE CONTROLS 1F1-33 Test Specified Failure Item Checking method Requirement Possible cause value code step Þ 1.0 · · · · · Injector: Ignition:ON There should · - Leakage test - Remove the fuel be no leaks distributor and fuel and later injector with a unit.

  • Page 603: Maintenance And Repair

    1F1-34 M162 ENGINE CONTROLS MAINTENANCE AND REPAIR ON-VEHICLE SERVICE Appearance 1 Cover 5 Pin 2 Plate Vehicle Side : Number 13 - 60 3 Connector Engine Side : Number 73 - 120 4 Flat Pin A Vehicle Connector : Black Vehicle Side : Number 1 - 12 B Engine Connector : Gray Engine Side : Number 61 - 72...
  • Page 604 M162 ENGINE CONTROLS 1F1-35 Location Engine ECU is located at the inside of cowl side trim in right bottom of instrument panel of passenger side. Removal & Installation Procedure 1. Turn the ignition switch to "OFF" position. 2. Disconnect the battery negative cable 3.
  • Page 605 1F1-36 M162 ENGINE CONTROLS ECU Pin Numbers and Descriptions Vehicle Connector Pin No. Description Abbreciation Starter motor TM.50 TM.50 Electronic ground Lambda probe 1 heating LSH1 Power ground TM.31 TM.31 V-BATTERY TM.87 TM.87 V-BATTERY TM.30 TM.30 Immobilizer crypto read WFS I/O WFS O Immobilizer crypto write Lambda probe 1 ground...
  • Page 606 M162 ENGINE CONTROLS 1F1-37 Pin No. Decription Abbreciation Brake switch Air conditioning clutch relay KLIKU Starter control 1 START Pedal potentiometer 1 ground Pedal potentiometer 1 supply SP1+5V Fuel pump relay Tank purge valve Engine fan CAN-Low CAN L CAN-High CAN H Clutch switch KLIMA...
  • Page 607 1F1-38 M162 ENGINE CONTROLS Engine Connector Abbreciation Pin No. Decription Injector-cylinder 2 Injector-cylinder 4 Injector-cylinder 1 Injector-cylinder 6 Injector-cylinder 5 Injector-cylinder 3 E-GAS motor plus E-GAS motor minus Power ground TM.31 TM.31 Ignition coil cylinder 1+6 ZSC16 ZSA25 Ignition coil cylinder 2+5 Ignition coil cylinder 3+4 ZSB34 Camshaft control...
  • Page 608 M162 ENGINE CONTROLS 1F1-39 Pin No. Description Abbreciation Hot film air mass signal E-GAS potentiometer ground E-GAS potentiometer 2 signal IP2S E-GAS potentiometer 1 signal IP1S Intake manifold resonance flap Crankshaft sensor ground Crankshaft sensor signal NOWE- Camshaft sensor ground Hot film air mass ground Camshaft sensor signal NOWE+...
  • Page 609 1F1-40 M162 ENGINE CONTROLS Application E32 ENG, E32 ENG, 4speed A/T Pin No. Description Abbreviation Remarks 5speed M/T (BTRA) Starter motor TM.50 TM.50 Electronic ground Lambda probe 1 heating LSH1 Power ground TM.31 TM.31 V-BATTERY TM.87 TM.87 V-BATTERY TM.30 TM.30 Immobilizer crypto read WFS I/O Immobilizer crypto write...
  • Page 610 M162 ENGINE CONTROLS 1F1-41 E32 ENG, E32 ENG, 4speed A/T Abbreviation Pin No. Description Remarks 5speed M/T (BTRA) Pedal potentiometer 1 ground Pedal potentiometer 1 supply SP1+5V Fuel pump relay Tank purge valve Engine fan CAN-Low CAN L CAN-High CAN H Clutch switch Air conditioning KLIMA...
  • Page 611 1F1-42 M162 ENGINE CONTROLS E32 ENG, E32 ENG, 4speed A/T Pin No. Description Abbreviation Remarks 5speed M/T (BTRA) Injector-cylinder 2 Injector-cylinder 4 Injector-cylinder 1 Injector-cylinder 6 Injector-cylinder 5 Injector-cylinder 3 E-GAS motor plus E-GAS motor minus Power ground TM.31 TM.31 Ignition coil cylinder 1+6 ZSC16 Ignition coil cylinder 2+5...
  • Page 612 M162 ENGINE CONTROLS 1F1-43 E32 ENG, E32 ENG, 4speed A/T Pin No. Description Abbreviation Remarks 5speed M/T (BTRA) Intake manifold resonance flap Crankshaft sensor ground Crankshaft sensor signal Camshaft sensor ground NOWE- Hot film air mass ground Camshaft sensor signal NOWE+ Hot film air mass supply V-REF.HFM...
  • Page 613 1F1-44 M162 ENGINE CONTROLS Removal & Installation Procedure when removing the ECU only 1. Turn the ignition switch to "OFF" position. 2. Disconnect the negative battery cable. 3. Disconnect the couplings from ECU. 4. Unscrew the left and right bolt (3) on bolt (1) and auxiliarly bracket and remove the auxiliarly bracket from the bracket assembly (2).

  • Page 614: Fuel Pressure Regulator

    M162 ENGINE CONTROLS 1F1-45 FUEL PRESSURE REGULATOR 1 Vacuum Hose 4 O-ring ............. replace 2 Circlip 5 O-ring ............. replace 3 Fuel Pressure Regulator...
  • Page 615 1F1-46 M162 ENGINE CONTROLS Removal & Installation Procedure 1. Remove the fuel pressure test connector. 2. Discharge the pressure in fuel supply system by pressing the service valve. 3. Disconnect the vacuum hose. 4. Disconnect the circlip and remove the fuel pressure regulator.
  • Page 616 M162 ENGINE CONTROLS 1F1-47 Function of the Fuel Pressure Regulator The fuel pressure regulator maintains the fuel pressure in the fuel line with the pressure of 3.2 bars to 3.8 bars according to the intake manifold pressure. This operating pressure cannot be changed, and the fuel injection volume will be only determined by the injection time.
  • Page 617 1F1-48 M162 ENGINE CONTROLS The pressure difference between the fuel pressure and the intake manifold is approx. 3.2 bars during idling. 1. Fuel Pressure Regulator 2. Intake Manifold 3. Fuel Return(to fuel tank) 4. Fuel Supply(from fuel pump) 7. Fuel Pressure(approx. 3.2 bars) 8.

  • Page 618: Bolt

    M162 ENGINE CONTROLS 1F1-49 FUEL DISTRIBUTOR Preceding Work : Removal of intake air duct 1 Vacuum Hose 5 Bolt (M8 X 50) ........ 22.5-27.5 Nm 2 Fuel Return Line ........25-30Nm 6 Fuel Distributor 3 Fuel Supply Line ........25-30Nm 7 O-ring ........
  • Page 619 1F1-50 M162 ENGINE CONTROLS Removal & Installation Procedure 1. Discharge the fuel pressure from the fuel pressure test connector. 2. Disconnect the battery ground cable. 3. Disconnect the vacuum hose from the fuel pressure regulator. 4. Remove the cable guide. 5.
  • Page 620 M162 ENGINE CONTROLS 1F1-51 8. Remove the injectors and the fuel distributor carefully. 9. Installation should follow the removal procedure in the reverse order. 10. Check for fuel pressure and internal leakage by operating the engine. Fuel Pressure Test 1. Turn the ignition switch to "OFF" position. 2.
  • Page 621 1F1-52 M162 ENGINE CONTROLS Internal Leakage Test 1. Connect the fuel pressure gauge to the fuel pressure test connector. 2. Stop the engine for approx. 30 minutes and then check the fuel pressure changes. Pressure Change Possible Cause Fuel leakage at the ·...

  • Page 622: Injector

    M162 ENGINE CONTROLS 1F1-53 INJECTOR Preceding Work : Removal of fuel distributor 1 O-ring ........rplace, if damaged 4 O-ring ........replace, if damaged 2 Injector Bracket 5 Fuel Distributor 3 Injector...
  • Page 623 1F1-54 M162 ENGINE CONTROLS Removal & Installation Procedure 1. Remove the O-ring. Check for damage and replace it if necessary. 2. Remove the injector bracket from the injector. Installation Notice Exactly seat the anti-twist lock into the square groove in injector.
  • Page 624 M162 ENGINE CONTROLS 1F1-55 The Injector Spray Pattern Check 1. Connect the test box (129 589 00 21 00) to the ECU. 2. Disconnect the connector from connector. 3. Disconnect the fuel distributor and injector with a unit from engine without removing the fuel supply and return line. Notice Prepare the beaker for taking the poping fuel.

  • Page 625: Fuel Filter

    1F1-56 M162 ENGINE CONTROLS FUEL FILTER 1 Fuel Filter 3 Inlet 2 Outlet Removal & Installation Procedure 1. Open the fuel tank cap and remove the fuel tank pressure. 2. Remove the fuel at (2) and in (3). Installation Notice Tightening Torque 25 - 30 Nm 3.

  • Page 626: Fuel Pump

    M162 ENGINE CONTROLS 1F1-57 FUEL PUMP 1 Reservoir Tank 2 Fuel Sensor (float/arm) 3 Resistance 4 Wiring Connector 5 Fuel Supply Pipe 7 Float 10 Flange and Harness Assembly 11 Fuel Pump 12 Spring 13 Thermister Housing 14 Thermister 15 Resistor Card and Wiper 16 Float Arm Requirements for Fuel Pump Item...
  • Page 627 1F1-58 M162 ENGINE CONTROLS 1 Fuel Pump Connector Wiring 5 Fuel Return Pipe 2 Fuel Return Pipe 6 Fuel Supply Pipe 3 Fuel Supply Pipe 7 Float 4 Bolts 8 Ground Stud (Sender "-") Harness Location & Connector COLOR Pump "+" 2.0 BR Thermister "+"...
  • Page 628 M162 ENGINE CONTROLS 1F1-59 Tools Required 661 589 00 46 00 Cap Remover Removal & Installation Procedure 1. Disconnect the negative battery cable. 2. Disconnect the harness connector (1). 3. Disconnect the fuel supply (6) and return (5) pipes. 4. Using a special tool, Unscrew the eight fuel retaining bolts and remove the pump from fuel tank.
  • Page 629 1F1-60 M162 ENGINE CONTROLS Measure the Fuel Delivery From the Fuel Pump 1. Disconnect the return pipe from fuel distributor and insert the appropriate hose into it. 2. Place the hose end into the beaker with the minimum capacity of 1Liter. 3.

  • Page 630: Purge Switchover Valve

    M162 ENGINE CONTROLS 1F1-61 PURGE SWITCHOVER VALVE 1 Purge Switchover Valve 2 Line to Engine 3 Line to Canister 4 Canister Functions The fuel vaporization control system is installed to inhibit the fuel vaporized gas from discharging into the atmosphere. The fuel vaporized gas that is accumulated in the canister abstracts through the purge switchover valve purification during the engine combustion (except the decreasing mode) and coolant...
  • Page 631 1F1-62 M162 ENGINE CONTROLS Test 1. Maintain the normal temperature and idling state by operating the engine. 2. Connect the ECU terminal No.11 and No.34 and check for normal operation through the output waves using the scanner. Notice Test during purge control switchover valve operation after the minimum of 1 minute after the engine turned on.

  • Page 632: Vacuum System

    M162 ENGINE CONTROLS 1F1-63 VACUUM SYSTEM 1 Purge Control Valve 10 Vacuum Line Rubber Hose 11 Vacuum Tube(Gray, 270mm) 2 Molded Hose 12 Molded Hose 3 Insulator 13 Rubber Cap 4 Fuel Tube 18 Rubber Hose 5 Molded Hose 19 Vacuum Tube(Brown or Black, 770mm) 6 Idle Regulator 20 Rubber Hose 7 Resonance Flap...

  • Page 633: Crankshaft Position Sensor

    1F1-64 M162 ENGINE CONTROLS CRANKSHAFT POSITION SENSOR 1 Crankshaft Position Sensor 3 Segment 2 Bolt (M6 X 14) ........9 -11Nm 4 Flywheel Removal & Installation Procedure 1. Disconnect the wiring connector at the crankshaft position sensor. 2. Unscrew the bolt and remove the crankshaft position sensor unit.
  • Page 634 M162 ENGINE CONTROLS 1F1-65 Crankshaft Position Sensor Resistance Inspection 1. Disconnect the coupling "E" of ECU while the ignition switch is in "OFF" position. 2. Measure the resistance between the coupling terminal pin No.99 and No.100 using a multimeter. Specified Value 1050 - 1400 W Notice Measure the insulator resistance of the crankshaft position...

  • Page 635: Camshaft Position Sensor

    1F1-66 M162 ENGINE CONTROLS CAMSHAFT POSITION SENSOR 1 Bolt (M6 X 14) ......... 9-11Nm 3 Shim 2 Camshaft Position Sensor 5 O-ring Removal & Installation Procedure 1. Disconnect the wiring connector from the camshaft position sensor. 2. Unscrew the bolt (2) and remove the camshaft position sensor.
  • Page 636 M162 ENGINE CONTROLS 1F1-67 Camshaft Position Sensor Signal Voltage Inspection 1. Connect the test box to the ECU. 2. Measure the voltage between the ECU terminal No.11 and No.106 while the engine speed is at idle. Specified Value 1.2 - 1.7 V Notice The signal voltage will be changed in the range of 1.2~1.7V.

  • Page 637: Hot Film Air Mass (Hfm) Sensor

    1F1-68 M162 ENGINE CONTROLS HOT FILM AIR MASS (HFM) SENSOR 1 Housing 4 Connector 2 Protector Net 5 Hot film Sensor 3 Electronic Housing 6 Measuring Port Removal & Installation Procedure 1. Turn the HFM sensor coupling in the direction shown in the figure in the right so that it gets separated from the contact surface.
  • Page 638 M162 ENGINE CONTROLS 1F1-69 Circuit Diagram 1 Housing 2 Electronic Housing 3 Connector : Heat Resistance : Temperature Resistance : Sensor Resistance...
  • Page 639 1F1-70 M162 ENGINE CONTROLS HFM Sensor Input Voltage Inspection 1. Measure the HFM sensor signal voltage between the ECU terminal No.81 and No.105. Specified Value (coolant temperature is over 70°C) Iginition"ON” 0.9 - 1.1 V Engine at idle 1.3 - 1.7 V If the measured value is not within the specified value, the possible cause may be in cable or HFM sensor in itself.

  • Page 640: Oxygen Sensor

    M162 ENGINE CONTROLS 1F1-71 OXYGEN SENSOR 1 Electricity Wire 2 Oxygen Sensor Housing 3 Sensor Ceramic 4 Electrode (Internal) 5 Electrode (External) 6 Heating Coil 7 Open Space 8 Protector Tube Functions The oxygen sensor optimizes the combustion (Air-Fuel Ratio 14.7:1) and resets the Air-fuel ratio in the ECU after sensing the amount of oxygen from the exhaust gases to diminish the exhaust gases.
  • Page 641 1F1-72 M162 ENGINE CONTROLS Oxygen Sensor Signal Voltage Inspection 1. Measure the oxygen sensor signal voltage between the ECU terminal No.11 and No.9. Maintain the engine speed ia at idle while the coolant temperature is over 80°C. Specified Value -0.2 - 1.0 V If the measured value is not within the specified value, the possible cause may be in cable, oxygen sensor or ECU.

  • Page 642: Knock Sensor

    M162 ENGINE CONTROLS 1F1-73 KNOCK SENSOR Functions Vibration of the engine block is transmitted to the sensor and transferred to the ECU in the form of an alternating voltage signal via a shielded cable. The knock sensor is fastened to the engine block to recognize knocking in all cylinders.

  • Page 643: Coolant Temperature Sensor

    1F1-74 M162 ENGINE CONTROLS COOLANT TEMPERATURE SENSOR 1 Artificial Resin Housing 4 Connector 2 Metal Housing 5 Coolant Temperature Sensor 3 NTC (negative temperature coefficient) Resistor Removal & Installation Procedure 1. Remove the pressure by opening the pressure cap in the coolant subtank.
  • Page 644 M162 ENGINE CONTROLS 1F1-75 Inspection 1. Measure the coolant sensor input voltage between the ECU terminal No.79 and No.78 while the ignition switch in "ON" position. Temperature (° C) Voltage (V) 3.57 1.22 0.78 allowable error :±5% 2. Measure the resistance between the coolant temperature sensor terminal No.1 and No.4 with the coolant temperature sensor disconnected.
  • Page 645 1F1-76 M162 ENGINE CONTROLS Service Data Temperature(° C) Resistance(W) Voltage(V) Temperature(°C) Resistance(W) Voltage(V) 48,550 4.8991 1.8632 27,000 4.8214 1.5132 15,670 4.7001 1.2179 9,450 4.5215 0.9775 5,890 4.4273 0.7806 3,790 3.9562 0.6255 2,500 3.5714 111.6 0.5020 1,692 3.1426 88.0 0.4044 1,170 2.6959 71.2 0.3323...

  • Page 646: Accelerator Pedal Module

    M162 ENGINE CONTROLS 1F1-77 ACCELERATOR PEDAL MODULE 1 Accelerator Pedal 4 6-Pin Connector 2 Accelerator Pedal Sensor 5 Kick Down Switch 3 Bolts (2 Pieces) ........4-8 Nm 6 Nut (1 Piece) ..........4-8 Nm Removal and Installation Procedure 1. Disconnect the 6-pin connector (arrow). 2.
  • Page 647 1F1-78 M162 ENGINE CONTROLS Accelerator Pedal Sensor Connector(Sensor Side) Potentiometer 1. Pin no. 3 :Red Pin no. 1 :Yellow Pin no. 5 :Brown Potentiometer 2. Pin no. 6 :Violet Pin no. 4 :Green Pin no. 2 :White Accelerator Pedal Sensor Connector(Vehicle Side) Potentiometer 1.
  • Page 648 SECTION 1F2 M161 ENGINE CONTROLS CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
  • Page 649 1F2-2 M161 ENGINE CONTROLS SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application N·m Fuel Return and Supply Line 25 - 30 Fuel Distributor Assembly Bolt 22.5 - 27.5 Pressure Test Connector 21.6 - 26.4 Fuel Inlet and Outlet Line 25 - 30 Fuel Filter Mounting Bracket Bolt 4 - 8 Crankshaft Position Sensor Bolt 9 - 11...

  • Page 650: Special Tools Table

    M161 ENGINE CONTROLS 1F2-3 SPECIAL TOOLS SPECIAL TOOLS TABLE 129 589 00 21 00 106 589 00 21 00 Test Box Pressure Tester 119 589 04 63 00 210201 Pressure Hose Adaptor Line 210 589 08 63 00 ECU Test Cable...

  • Page 651: Schematic And Routing Diagrams

    1F2-4 M161 ENGINE CONTROLS SCHEMATIC AND ROUTING DIAGRAMS...
  • Page 652 M161 ENGINE CONTROLS 1F2-5...

  • Page 653: Diagnosis

    1F2-6 M161 ENGINE CONTROLS DIAGNOSIS SELF DIAGNOSIS SOCKET PIN NUMBERS AND DESCRIPTIONS 1 Ground 12 - 2 Ignition 1 13 Brake System 3 Battery Power Supply (Fuse NO.17) (ABS 5.3:PIN 11, ABS/ABD 5.3:PIN 46) 4 REKES :PIN 6 14 MSE 3.62S/3.53S(ECU Data Output:PIN 58) 5 Engine Speed Signal :MSE PIN 60 15 TOD(PIN 20) 6 TCCU(Part-time)

  • Page 654: Self Diagnosis Failure Code (For E23 Eng)

    M161 ENGINE CONTROLS 1F2-7 SELF DIAGNOSIS FAILURE CODE (FOR E23 ENG) Failure Fa ilure Description Description code code Coolant temperature sensor open No ignition voltage output (No.1 ignition coil : 1, 4 cylinder) Coolant temperature sensor short No ignition voltage output (No.2 ignition coil : 2, 3 cylinder) Coolant temperature sensor signal failure Cranshaft position sensor adaption failure Intake temperature sensor open...
  • Page 655 1F2-8 M161 ENGINE CONTROLS Failure Failure Description Description code code learning control failure(lean, high load) Uncoded ECU Low throttle position sensor(IP1) voltage ECU failure(NVRAM checksum failure) High throttle position sensor(IP1) voltage ECU failure(coding ID checksum failure) Low throttle position sensor(IP2) voltage ECU failure(coding checksum failure) High throttle position sensor(IP2) voltage ECU failure(programing checkusm failure)
  • Page 656 M161 ENGINE CONTROLS 1F2-9 Failure Failure Description Description code code A/C compressor relay open/short(GND) AD converter failure(CPU2) Decel limit defected by CPU2 Pedal position sensor setpoint fault berween Accel limit defected by CPU2 CPU1 and CPU2 Cruise control lever double input(CPU2) Position setpoint fault berween CPU1 and Cruise control lever safety terminal CPU2...

  • Page 657: Test Box Connection

    1F2-10 M161 ENGINE CONTROLS TEST BOX CONNECTION 1 ECU 01 Test Box 2 Test Coupling(No.1 - 60) 02 ECU Test Cable 3 Test Coupling(No.61 - 120) 4 Multi-tester Tools Required 129 589 00 21 00 Test Box 210 589 08 63 00 ECU Test Cable...

  • Page 658: Fuel Injection System Test

    M161 ENGINE CONTROLS 1F2-11 FUEL INJECTION SYSTEM TEST Failure Test Specified Item Checking method Requirement Possible cause code step value Þ 1.0 ECU:power Ignition:ON 11 -14V Þ 1.1 · · · · · · · Þ 1.2 supply · - terminal 30 (TM.30) Þ...
  • Page 659 1F2-12 M161 ENGINE CONTROLS Test Specified Failure Item Checking method Requirement Possible cause step value code Þ 4.0 · · · · · HFM sensor Ignition:ON 0.9 - 1.1V Þ 4.1 - 4.3 · · signal Cable · · Engine:in Idle 1.3 - 1.7V External air inflow ·...
  • Page 660 M161 ENGINE CONTROLS 1F2-13 Specified Test Failure Item Checking method Requirement Possible cause value step code Þ 6.0 · · · · · Fuel pump Ignition:ON 11 - 14V Cable · · relay: (Fuel pump relay will (approx.1- Fuel pump relay ·...
  • Page 661 1F2-14 M161 ENGINE CONTROLS Test Specified Failure Item Checking method Requirement Possible cause step value code Þ 8.0 · · · · · ECU: Engine:in cranking refer to figure Cable · · - RPM signal or idle · output - Voltage Engine:in cranking 6.0 - 7.0 V ·...
  • Page 662 M161 ENGINE CONTROLS 1F2-15 Failure Test Specified Item Checking method Requirement Possible cause code step value - Internal Ignition:OFF (injector 14 - 17 W · resistance temperature is 20°C) (No.1 injector) Þ 12.0 · · · · · No.2 When the coolant ·...
  • Page 663 1F2-16 M161 ENGINE CONTROLS Failure Test Specified Item Checking method Requirement Possible cause code step value - Internal Ignition:OFF (injector 14 - 17 W · resistance temperature is 20° C) (No.3 injector) Þ 14.0 · · · · · No.4 cylinder When the coolant ·...
  • Page 664 M161 ENGINE CONTROLS 1F2-17 Failure Test Specified Item Checking method Requirement Possible cause code step value Þ 15.1 Camshaft Ignition:OFF 8 - 12 W Cable · · · · · · · Camshaft actuator actuator: · Diagnosis Solenoid socket resistance (E23 only) 226, Engine:in idling...
  • Page 665 1F2-18 M161 ENGINE CONTROLS Failure Test Specified Item Checking method Requirement Possible cause code step value Þ 19.1 CAN module Ignition:OFF 115 - 125 W Cable · · · · · · · - disconnect the ABS, ABD, ASR resistance in ·...
  • Page 666 M161 ENGINE CONTROLS 1F2-19 Reference Figures Figure 2. Injection Valve Wave(at idle speed) Figure1. RPM Sgnal Output Figure 3. Injection Valve Wave(at sharp Figure 4. Purge Control Valve Operationg Wave acceleration)

  • Page 667: Ignition System Test

    1F2-20 M161 ENGINE CONTROLS IGNITION SYSTEM TEST Failure Test Specified Item Checking method Requirement Possible cause code step value Þ 1.0 ECU:power Ignition:ON 11 - 14V Þ 1.1 · · · · · · · Þ 1.2 supply · - terminal 30 (TM.30) Þ...
  • Page 668 M161 ENGINE CONTROLS 1F2-21 Failure Test Specified Item Checking method Requirement Possible cause code step value Cable Þ 4.0 · · · · · Ignition Ignition:ON 11 -14 V · · coil(T1/2) Ignition coil(T1/2) · Fuse No.17 - No.2,3 · Cylinder Engine:in cranking >...
  • Page 669 1F2-22 M161 ENGINE CONTROLS Failure Test Specified Possible cause Item Checking method Requirement code step value Þ 7.0 Ignition Engine:in cranking 200 - 350 V Þ 7.1 · · · · · · · coil(T1/1) (starter operating) - Primary coil - Measuring range: voltage 400 V...
  • Page 670 M161 ENGINE CONTROLS 1F2-23 Failure Test Specified Item Checking method Requirement Possible cause code step value Þ 9.1 · · · · · Ignition coil Remove the high 6 - 8.5 KW Ignition coil T1/1 · · Ignition coil (T1/1, T1/2) (T1/1, T1/2) tension cable of Ignition coil T1/2...
  • Page 671 1F2-24 M161 ENGINE CONTROLS Reference Figures Figure 5. Crankshaft Position Sensor Signal Figure 6. Camshaft Position Sensor Signal Voltage Identifying the No.1 - 2 Missing Teeth Figure 7. Signal Function Crank Angle Cylinder Crankshaft Position Sensor Signal Camshaft Position Sensor Signal RPM Signal...

  • Page 672: Idling Control And Electronic Pedal System Test

    M161 ENGINE CONTROLS 1F2-25 IDLING CONTROL AND ELECTRONIC PEDAL SYSTEM TEST Failure Specified Test Item Checking method Requirement Possible cause code value step 160, Þ 1.0 Pedal valve Ignition:ON Þ 1.1 · · · · · · · 161, Cable sensor: Position of ·...
  • Page 673 1F2-26 M161 ENGINE CONTROLS Failure Test Specified Item Checking method Requirement Possible cause code step value Throttle valve Position of · potentiometer accelerator pedal: - Closed throttle 4.0 - 4.6 V position - Full throttle with 0.3 - 0.9 V kick down Þ...

  • Page 674: Air Conditioner Control System Test

    M161 ENGINE CONTROLS 1F2-27 AIR CONDITIONER CONTROL SYSTEM TEST Specified Failure Test Item Checking method Requirement value code step Þ 1.0 Engine:In idling Þ 5.1 · · · · · · · Cable conditioner Air conditioner · · signal: switch:ON/OFF Thermo amp ·...

  • Page 675: Fuel Pressure And Internal Leakage Test

    1F2-28 M161 ENGINE CONTROLS FUEL PRESSURE AND INTERNAL LEAKAGE TEST Preparation 01 Pressure Tester 02 Pressure Hose 03 Measuring Beaker Connection of the Equipment 1. Turn the ignition switch to "OFF" position. 2. Remove the air cleaner cross pipe. 3. Remove the cap on fuel pressure test plug and connect the pressure hose and pressure tester.
  • Page 676 M161 ENGINE CONTROLS 1F2-29 Test Specified Failure Item Checking method Requirement Possible cause step value code Þ 1.0 · · · · · Fuel Connect the fuel Engine:in idling 3.2 - 3.6 bar Þ Fuel pump test · · pressure:in pressure test plug to - Colse the valve Fuel pressure...

  • Page 677: Fuel Pump Test

    1F2-30 M161 ENGINE CONTROLS FUEL PUMP TEST Preparation 1 ECU 03 Test Box 2 Test Coupling(No.1-60) 04 ECU Test Cable 3 Test Coupling(No.61-120) 4 Stop Watch 5 Measuring Beaker Connection of the Equipment 1. Turn the ignition switch to "OFF" position. 2.
  • Page 678 M161 ENGINE CONTROLS 1F2-31 Test Specified Failure Item Checking method Requirement Possible cause step value code Þ 1.0 · · · · · Fuel pump: Ignition:ON 1 liter of fuel Þ 2.0 · · - Fuel supply - Disconnect the fuel supply for Fuel line ·...

  • Page 679: Injector Test

    1F2-32 M161 ENGINE CONTROLS INJECTOR TEST Preparation 1 ECU 03 Test Box 2 Test Coupling(No.1-60) 04 ECU Test Cable 3 Test Coupling(No.61-120) 4 Measuring Beaker 5 Shop Made Cable Connection of the Equipment 1. Connect the test box to the ECU as shown in the figure. 2.
  • Page 680 M161 ENGINE CONTROLS 1F2-33 Test Specified Failure Item Checking method Requirement Possible cause value code step Þ 1.0 · · · · · Injector: Ignition:ON There should Þ 2.0 · · - Leakage - Remove the fuel be no leaks Injector ·...

  • Page 681: Maintenance And Repair

    1F2-34 M161 ENGINE CONTROLS MAINTENANCE AND REPAIR ON-VEHICLE SERVICE Appearance 1 Cover 5 Pin 2 Plate Vehicle side : number 13 - 60 3 Connector Engine side : number 73 - 120 4 Flat pin A Vehicle Connector : Black Vehicle side : number 1 - 12 B Engine Connector : Gray Engine side : number 61 - 72...
  • Page 682 M161 ENGINE CONTROLS 1F2-35 Location Engine ECU is located at the inside of cowl side trim in right bottom of instrument panel of passenger side. Removal & Installation Procedure 1. Turn the ignition switch to "OFF" position. 2. Disconnect the battery negative cable 3.
  • Page 683 1F2-36 M161 ENGINE CONTROLS ECU Pin Numbers and Descriptions Vehecle Connector Pin No. Description Abbreviation Starter motor TM.50 TM.50 Electronic ground Lambda probe 2 heating LSH2 Lambda probe 1 heating LSH1 Power ground TM.31 TM.31 V-BATTERY TM.87 TM.87 V-BATTERY TM.30 TM.30 Immobilizer crypto read WFS I/O...
  • Page 684 M161 ENGINE CONTROLS 1F2-37 Pin No. Description Abbreviation Brake switch Air conditioning clutch relay KLIKU Pedal potentiometer 1 ground Pedal potentiometer 1 supply SP1+5V Fuel pump relay Tank purge valve Engine fan(IGH) CAN-Low CAN L CAN-High CAN H KLIMA Air conditioning Electronic traction signal Pedal potentiometer 1 signal SP1S...
  • Page 685 1F2-38 M161 ENGINE CONTROLS Engine Connector Abbreviation Pin No. Description Injector-cylinder 1 Injector-cylinder 2 Injector-cylinder 3 Injector-cylinder 4 E-GAS motor plus E-GAS motor minus Power ground TM.31 TM.31 ZSB23 Ignition coil cylinder 2+3 Ignition coil cylinder 1+4 ZSA14 Camshaft control EGR (Exhaust Gas Recirculation) Second air pump relay Engine coolant temperature...
  • Page 686 M161 ENGINE CONTROLS 1F2-39 Pin No. Description Abbreviation Hot film air mass signal Pressure sensor supply V-REF.PS E-GAS potentiometer ground E-GAS potentiometer 2 signal IP2S E-GAS potentiometer 1 signal IP1S Crankshaft sensor ground Crankshaft sensor signal PSAUG Intake manifold pressure signal Intake manifold pressure ground NOWE- Camshaft sensor ground...
  • Page 687 1F2-40 M161 ENGINE CONTROLS Application E23 ENG, E23 ENG, E20 ENG, Pin No. Description Abbreviation 5speed A/T 4speed A/T 4speed A/T Starter motor TM.50 TM.50 Electronic ground Lambda probe 2 heating LSH2 Lambda probe 1 heating LSH1 Power ground TM.31 TM.31 V-BATTERY TM.87 TM.87...
  • Page 688 M161 ENGINE CONTROLS 1F2-41 E23 ENG, E23 ENG, E20 ENG, Pin No. Description Abbreviation 5speed A/T 4speed A/T 4speed A/T Pedal potentiometer 1 ground Pedal potentiometer 1 supply SP1+5V Fuel pump relay Tank purge valve Engine fan CAN-Low CAN L CAN-High CAN H Air conditioning...
  • Page 689 1F2-42 M161 ENGINE CONTROLS E23 ENG, E23 ENG, E20 ENG, Pin No. Description Abbreviation 5speed A/T 4speed A/T 4speed A/T Injector-cylinder 1 Injector-cylinder 2 Injector-cylinder 3 Injector-cylinder 4 E-GAS motor plus E-GAS motor minus Power ground TM.31 TM.31 Ignition coil cylinder 2+3 ZSB23 Ignition coil cylinder 1+4 ZSA14...
  • Page 690 M161 ENGINE CONTROLS 1F2-43 E23 ENG, E23 ENG, E20 ENG, Pin No. Description Abbreiation 5speed A/T 4speed A/T 4speed A/T Crankshaft sensor ground Crankshaft sensor signal Camshaft sensor ground NOWE- Hot film air mass ground Camshaft sensor signal NOWE+ Hot film air mass supply V-REF.HFM E-GAS potentiometer supply V-REF.DK...
  • Page 691 1F2-44 M161 ENGINE CONTROLS Removal & Installation Procedure · · · · · When removing the ECU only 1. Turn the ignition switch to "OFF" position. 2. Disconnect the negative battery cable. 3. Disconnect the couplings from ECU. 4. Unscrew the left and right bolt (3) on bolt (1) and auxiliarly bracket and remove the auxiliarly bracket from the bracket assembly (2).

  • Page 692: Fuel Pressure Regulator

    M161 ENGINE CONTROLS 1F2-45 FUEL PRESSURE REGULATOR 1 Vacuum Hose 4 O-ring ............. replace 2 Circlip 5 O-ring ............. replace 3 Fuel Pressure Regulator...
  • Page 693 1F2-46 M161 ENGINE CONTROLS Removal & Installation Procedure 1. Remove the fuel pressure test connector. 2. Discharge the pressure in fuel supply system by pressing the service valve. 3. Disconnect the vacuum hose. 4. Disconnect the circlip and remove the fuel pressure regulator.
  • Page 694 M161 ENGINE CONTROLS 1F2-47 Function of the Fuel Pressure Regulator The fuel pressure regulator maintains the fuel pressure in the fuel line with the pressure of 3.2 bars to 3.8 bars according to the intake manifold pressure. This operating pressure cannot be changed, and the fuel injection volume will be only determined by the injection time.
  • Page 695 1F2-48 M161 ENGINE CONTROLS The pressure difference between the fuel pressure and the intake manifold is approx. 3.2 bars during idling. 1. Fuel pressure Regulator 2. Intake Manifold 3. Fuel Return(to fuel tank) 4. Fuel Supply(from fuel pump) 7. Fuel Pressure(approx. 3.2 bars) 8.

  • Page 696: Fuel Distributor

    M161 ENGINE CONTROLS 1F2-49 FUEL DISTRIBUTOR Preceding Work : Removal of intake air duct 1 Fuel Distributor 9 Fuel Return Line 2 Circlip 10 Seal Ring 3 Fuel Pressure Regulator 11 Hollow Bolt ........22.5-27.5 Nm 4 O-ring 12 Clamp 5 Fuel Pressure Test Connector 13 Bolt (M8 X 22) ........
  • Page 697 1F2-50 M161 ENGINE CONTROLS Removal & Installation Procedure 1. Discharge the fuel pressure from the fuel pressure test connector by pushing service valve (arrow). 2. Disconnect the battery ground cable. 3. Disconnect the vacuum hose from the fuel pressure regulator. 4.
  • Page 698 M161 ENGINE CONTROLS 1F2-51 8. Pull out the injector from intake manifold and remove the fuel distributor. Notice Replace the injector O-ring with new one. 9. Installation should follow the removal procedure in the reverse order. 10. Check for fuel pressure and internal leakage by operating the engine.
  • Page 699 1F2-52 M161 ENGINE CONTROLS Fuel Pressure Test 1. Turn the ignition switch to "OFF" position. 2. Remove the fuel pressure test connector. 3. Connect the fuel pressure gauge to the fuel pressure test connector. 4. Test the fuel pressure at idling by operating the engine. Vacuum Hose Connected (bar) 3.2 - 3.6 Vacuum Hose Disconnected (bar)
  • Page 700 M161 ENGINE CONTROLS 1F2-53 Internal Leakage Test 1. Connect the fuel pressure gauge to the fuel pressure test connector. 2. Stop the engine for approx. 30 minutes and then check the fuel pressure changes. Pressure Change Possible Cause Fuel leakage at the ·...

  • Page 701: Injector

    1F2-54 M161 ENGINE CONTROLS INJECTOR Preceding Work : Removal of fuel distributor 1 O-ring ......... Replace, if damaged 4 O-ring ......... Replace, if damaged 2 Injector Bracket 5 Fuel Distributor 3 Injector...
  • Page 702 M161 ENGINE CONTROLS 1F2-55 Removal & Installation Procedure 1. Remove the O-ring. Check for damage and replace it if necessary. 2. Remove the injector bracket from the injector. Installation Notice Exactly seat the anti-twist lock into the square groove in injector.
  • Page 703 1F2-56 M161 ENGINE CONTROLS The Injector Spray Pattern Check 1. Connect the test box (129 589 00 21 00) to the ECU. 2. Disconnect the connector from connector. 3. Disconnect the fuel distributor and injector with a unit from engine without removing the fuel supply and return line. Notice Prepare the beaker for taking the poping fuel.

  • Page 704: Fuel Filter

    M161 ENGINE CONTROLS 1F2-57 FUEL FILTER 1 Fuel Filter 3 Inlet 2 Outlet Removal & Installation Procedure 1. Open the fuel tank cap and remove the fuel tank pressure. 2. Remove the fuel out (2) and in (3). Installation Notice Tightening Torque 25 - 30 Nm 3.

  • Page 705: Fuel Pump

    1F2-58 M161 ENGINE CONTROLS FUEL PUMP 1 Reservoir Tank 2 Fuel Sensor (float/arm) 3 Resistance 4 Wiring Connector 5 Fuel Supply Pipe 7 Float 10 Flange and Harness Assembly 11 Fuel Pump 12 Spring 13 Thermister Housing 14 Thermister 15 Resistor Card and Wiper 16 Float Arm Requirements for Fuel Pump Item...
  • Page 706 M161 ENGINE CONTROLS 1F2-59 1 Fuel Pump Connector Wiring 5 Fuel Return Pipe 2 Fuel Return Pipe 6 Fuel Supply Pipe 3 Fuel Supply Pipe 7 Float 4 Bolts 8 Ground Stud (Sender "-") Harness Location & Connector COLOR Pump "+" 2.0 BR Thermister "+"...
  • Page 707 1F2-60 M161 ENGINE CONTROLS Tools Required 661 589 00 46 00 Cap Remover Removal & Installation Procedure 1. Disconnect the negative battery cable. 2. Disconnect the harness connector (1). 3. Disconnect the fuel supply (6) and return (5) pipes. 4. Using a special tool, Unscrew the eight fuel retaining bolts and remove the pump from fuel tank.
  • Page 708 M161 ENGINE CONTROLS 1F2-61 Measure the Fuel Delivery From the Fuel Pump 1. Disconnect the return pipe from fuel distributor and insert the appropriate hose into it. 2. Place the hose end into the beaker with the minimum capacity of 1Liter. 3.

  • Page 709: Purge Switchover Valve

    1F2-62 M161 ENGINE CONTROLS PURGE SWITCHOVER VALVE 1 Purge Control valve 2 Line to engine 3 Line to canister 4 Canister Functions The fuel vaporization control system is installed to inhibit the fuel vaporized gas from discharging into the atmosphere. The fuel vaporized gas that is accumulated in the canister abstracts through the purge switchover valve purification during the engine combustion (except the decreasing mode) and coolant...
  • Page 710 M161 ENGINE CONTROLS 1F2-63 Test 1. Maintain the normal temperature and idling state by operating the engine. 2. Connect the ECU terminal No.11 and No.34 and check for normal operation through the output waves using the scanner. Notice Test during purge control switchover valve operation after the minimum of 1 minute after the engine turned on.

  • Page 711: Vacuum System

    1F2-64 M161 ENGINE CONTROLS VACUUM SYSTEM Manual Transmission 1 Purge Switchover Valve 8 Fuel Pressure Regulator 2 Molded Hose 9 Vacuum Line Rubber Hose (40 mm) 3 Fuel Tube (270 mm) 10 Vacuum Tube (Gray, 540 mm) 4 Clamp 11 Rubber Cap 5 Molded Hose 12 Molded Hose 6 Intake Manifold...
  • Page 712 M161 ENGINE CONTROLS 1F2-65 Automatic Transmission 15 Manual Transmission A. To Canister 16 Distributor B. To Auto Locking Hub...

  • Page 713: Crankshaft Position Sensor

    1F2-66 M161 ENGINE CONTROLS CRANKSHAFT POSITION SENSOR 1 Crankshaft Position Sensor (connector) 3 Sensor Unit 2 Bolt (M6 X 14) ........9-11 Nm Removal & Installation Procedure 1. Disconnect the wiring connector at the crankshaft position sensor. 2. Unscrew the bolt (2) and remove the crankshaft position sensor unit (3).
  • Page 714 M161 ENGINE CONTROLS 1F2-67 Crankshaft Position Sensor Resistance Inspection 1. Disconnect the coupling "E" of ECU while the ignition switch is in "OFF" position. 2. Measure the resistance between the coupling terminal pin No.99 and No.100 using a multimeter. Specified Value 1050 - 1400 W Notice Measure the insulator resistance of the crankshaft position...

  • Page 715: Camshaft Position Sensor

    1F2-68 M161 ENGINE CONTROLS CAMSHAFT POSITION SENSOR 1 Bolt (M6 X 14) ......... 9-11Nm 3 Shim 2 Camshaft Position Sensor 5 O-ring Removal & Installation Procedure 1. Disconnect the wiring connector from the camshaft position sensor. 2. Unscrew the bolt (2) and remove the camshaft position sensor.
  • Page 716 M161 ENGINE CONTROLS 1F2-69 Camshaft Position Sensor Signal Voltage Inspection 1. Connect the test box to the ECU. 2. Measure the voltage between the ECU terminal No.11 and No.106 while the engine speed is at idle. Specified Value 1.2 - 1.7 V Notice The signal voltage will be changed in the range of 1.2-1.7V.

  • Page 717: Hot Film Air Mass (Hfm) Sensor

    1F2-70 M161 ENGINE CONTROLS HOT FILM AIR MASS (HFM) SENSOR 1 Housing 4 Connector 2 Protector Net 5 Hot film Sensor 3 Electronic Housing 6 Measuring Port Removal & Installation Procedure 1. Turn the HFM sensor coupling in the direction shown in the figure in the right so that it gets separated from the contact surface.
  • Page 718 M161 ENGINE CONTROLS 1F2-71 Circuit Diagram 1 Housing 2 Electronic Housing 3 Connector : Heat Resistance : Temperature Resistance : Sensor Resistance...
  • Page 719 1F2-72 M161 ENGINE CONTROLS HFM Sensor Input Voltage Inspection 1. Measure the HFM sensor signal voltage between the ECU terminal No.81 and No.105. Specified Value (coolant temperature is over 70°C) Iginition"ON” 0.9 - 1.1 V Engine at idle 1.3 - 1.7 V If the measured value is not within the specified value, the possible cause may be in cable or HFM sensor in itself.

  • Page 720: Oxygen Sensor

    M161 ENGINE CONTROLS 1F2-73 OXYGEN SENSOR 1 Electricity Wire 2 Oxygen Sensor Housing 3 Sensor Ceramic 4 Electrode (Internal) 5 Electrode (External) 6 Heating Coil 7 Open Space 8 Protector Tube Functions The oxygen sensor optimizes the combustion (Air-Fuel Ratio 14.7:1) and resets the Air-fuel ratio in the ECU after sensing the amount of oxygen from the exhaust gases to diminish the exhaust gases.
  • Page 721 1F2-74 M161 ENGINE CONTROLS Oxygen Sensor Signal Voltage Inspection 1. Measure the oxygen sensor signal voltage between the ECU terminal No.11 and No.9. Maintain the engine speed ia at idle while the coolant temperature is over 80°C. Specified Value -0.2 - 1.0 V If the measured value is not within the specified value, the possible cause may be in cable, oxygen sensor or ECU.

  • Page 722: Knock Sensor

    M161 ENGINE CONTROLS 1F2-75 KNOCK SENSOR Functions Vibration of the engine block is transmitted to the sensor and transferred to the ECU in the form of an alternating voltage signal via a shielded cable. The knock sensor is fastened to the engine block to recognize knocking in all cylinders.

  • Page 723: Coolant Temperature Sensor

    1F2-76 M161 ENGINE CONTROLS COOLANT TEMPERATURE SENSOR 1 Artificial Resin Housing 4 Connector 2 Metal Housing 5 Coolant Temperature Sensor 3 NTC (negative temperature coefficient) Resistor Removal & Installation Procedure 1. Remove the pressure by opening the pressure cap in the coolant subtank.
  • Page 724 M161 ENGINE CONTROLS 1F2-77 Inspection 1. Measure the coolant sensor input voltage between the ECU terminal No.79 and No.78 while the ignition switch in "ON" position. Temperature (°C) Voltage (V) 3.57 1.22 0.78 allowable error :±5% 2. Measure the resistance between the coolant temperature sensor terminal No.1 and No.4 with the coolant temperature sensor disconnected.
  • Page 725 1F2-78 M161 ENGINE CONTROLS Service Data Temperature(° C) Resistance(W) Voltage(V) Temperature(°C) Resistance(W) Voltage(V) 48,550 4.8991 1.8632 27,000 4.8214 1.5132 15,670 4.7001 1.2179 9,450 4.5215 0.9775 5,890 4.4273 0.7806 3,790 3.9562 0.6255 2,500 3.5714 111.6 0.5020 1,692 3.1426 88.0 0.4044 1,170 2.6959 71.2 0.3323...

  • Page 726: Accelerator Pedal Module

    M161 ENGINE CONTROLS 1F2-79 ACCELERATOR PEDAL MODULE 1 Accelerator Pedal 4 6-Pin Connector 2 Accelerator Pedal Sensor 5 Kick down Switch 3 Bolts (2 Pieces) ........4-8 Nm 6 Nut (1 piece) ..........4-8 Nm Removal and Installation Procedure 1. Disconnect the 6-pin connector(arrow). 2.
  • Page 727 1F2-80 M161 ENGINE CONTROLS Accelerator Pedal Sensor Connector(Sensor Side) Potentiometer 1. Pin no. 3 :Red Pin no. 1 :Yellow Pin no. 5 :Brown Potentiometer 2. Pin no. 6 :Violet Pin no. 4 :Green Pin no. 2 :White Accelerator Pedal Sensor Connector(Vehicle Side) Potentiometer 1.
  • Page 728 SECTION 1F3 OM600 ENGINE CONTROLS Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

  • Page 729: Maintenance And Repair

    1F3-2 OM600 ENGINE CONTROLS MAINTENANCE AND REPAIR ON-VEHICLE SERVICE FUEL SYSTEM 1 Fuel Injection Pump 6 Fuel Return Hose 2 Fuel Feed Pump 7 Injection Line 3 Overflow Valve 8 Fuel Tank 4 Injection Nozzle 9 Fuel Filter 5 Pre-filter 10 Choke Orifice...

  • Page 730: Fuel Injection Pump Coding

    OM600 ENGINE CONTROLS 1F3-3 FUEL INJECTION PUMP CODING Model Code OM661 LA Engine PES 4M 55C 320 RS 167 OM662 LA Engine PES 5M 55C 320 RS 168 Fuel Injection Pump Code Example) PES 5M 55C 320 RS 168 Pump Self-Driven End Flange Mounting Number of Cylinders (5EA)

  • Page 731: Fuel Tank

    1F3-4 OM600 ENGINE CONTROLS FUEL TANK 1 Fuel Tank 8 Fuel Return Tube 2 The Sender of Fuel Tank 9 Filter Hose 3 2-way Check Valve 10 Fuel Tank Hose 4 Pre Filter 11 Fuel Filler Cap 5 Front Fuel Filler Neck 12 Clip 6 Rear Fuel Filler Neck 13 Clip...

  • Page 732: Vacuum Control System Test

    OM600 ENGINE CONTROLS 1F3-5 VACUUM CONTROL SYSTEM TEST 2 Engine Cut-Off Valve (Ignition Key Switch) 8 30° Thermovalve 3 Auto-locking Hub Solenoid Valve 9 Fuel Injection Pump 4 Engine Stop Valve Unit 10 Filter with Restriction 5 PLA Vacuum Unit (Idle Speed Adjustment) 11 Check Valve 6 Engine 12 Modulating Pressure Line (Automatic T/M)
  • Page 733 1F3-6 OM600 ENGINE CONTROLS Tools Required 001 589 73 21 00 Vacuum Pump 201 589 13 21 00 Vacuum Tester 667 589 00 21 00 TDC pulse generator Commercial Tools e.g. Bosch MOT 001.03 Digital tester Sun DIT 9000 e.g. Ahlborn, Therm 2263-2 Temperature measuring instrument with test probe Eichenfeldstrabe 1 - 3 WB24...
  • Page 734 OM600 ENGINE CONTROLS 1F3-7 Test step 1 Connect vacuum pump (14) with Y adapter to PLA vacuum unit (5). Run engine at idle speed. = > Vacuum 500 mbar Lines and connections leaking. Faulty PLA vacuum unit. (Remove the connection hose from vacuum pump) Connect vacuum pump (14) direct to PLA vacuum unit (5) and pressurize with vacuum.
  • Page 735 1F3-8 OM600 ENGINE CONTROLS Detach line downstream of air admission filter (13). Vacuum drops. Faulty thermovalve Fit the line onto air admission filter. Built up vacuum with vacuum pump. Detach the plug from air admission line. Vacuum drops. Faulty filter with restriction. Go to test step 2.
  • Page 736 OM600 ENGINE CONTROLS 1F3-9 Test step 2 Connect vacuum pump (14) with Y adapter to PLA vacuum unit (5). Run the engine at idle speed. Vacuum drops to ‘0’ at approx. 30°C of the thermovalve. Faulty thermovalve. Defective filter with restriction. Stop the engine.

  • Page 737: Vacuum Pump(Sectional View)

    1F3-10 OM600 ENGINE CONTROLS VACUUM PUMP (SECTIONAL VIEW) 2 Suction Valve 16 Roller Cam 4 Piston 17 Piston Rod 5 Pressure Valve 21 Inner Return Spring 6 Safety Valve 23 Upper Spring Retainer 7 O-Ring 28 Piston Ring 8 Pump Housing 30 Seal Ring 9 Pump Cover 31 Oil Return Valve...

  • Page 738: Vacuum Pump Test

    OM600 ENGINE CONTROLS 1F3-11 VACUUM PUMP TEST 1 Fuel Filter 3 Ancillaries Connection 2 Vacuum Line 4 Vacuum Tester Tools Required 201 589 13 21 00 Vacuum Tester...
  • Page 739 1F3-12 OM600 ENGINE CONTROLS Test Procedure 1. Remove the fuel filter (1) and keep the filter not to be damaged from running engine. 2. Remove the vacuum line (2) from ancillaries connection (3). 3. Connect the vacuum tester (4) to the ancillaries connection (3).

  • Page 740: Vacuum Pump

    OM600 ENGINE CONTROLS 1F3-13 VACUUM PUMP Preceding Work : Remove the poly V-belt 1 Bolt ............10Nm 4 Vacuum Line (Brake Booster) 2 Vacuum Pump 5 Gasket ........... Replace 3 Vacuum Line (Ancillaries)
  • Page 741 1F3-14 OM600 ENGINE CONTROLS Removal & Installation Procedure 1. Remove the vacuum line (3, 4). 2. Remove the bolts (1) evenly. Notice If necessary, rotate the engine until the pressure on the tappet of the vacuum pump is released. 3. Remove the vacuum pump (2). 4.

  • Page 742: Vacuum Unit Replacement

    OM600 ENGINE CONTROLS 1F3-15 VACUUM UNIT REPLACEMENT 1 Bracket 2 Bolt 3 Vacuum Unit 4 Vacuum Line 5 Seal ..........Replace...

  • Page 743: Idle Speed Adjustment

    1F3-16 OM600 ENGINE CONTROLS IDLE SPEED ADJUSTMENT Service Data Engine Idle Speed OM661LA Engine 750 - 850 rpm OM662LA Engine 720 - 820 rpm Tools Required 667 589 00 21 00 TDC Pulse Generato Commercial Tool e.g. Bosch, MOT 001.03 Digital tester Sun, DIT 9000 Adjustment...
  • Page 744 OM600 ENGINE CONTROLS 1F3-17 5. Ensure not to damage the idle spring in the governor and adjust idle speed by turning the PLA unit (5) slowly. Clockwise RPM Decrease Counterclockwise RPM Increase Notice Do not rotate the PLA unit over ½ turn from the position marking.

  • Page 745: Fuel Pump Test

    1F3-18 OM600 ENGINE CONTROLS FUEL PUMP TEST Notice Before test, replace the fuel filter cartridge and fuel prefilter. Fuel Feed Test 1. Disconnect the fuel return line (1) and seal up it with plug. 2. Insert the plastic hose (5) and put the end into the measuring beaker (6).
  • Page 746 OM600 ENGINE CONTROLS 1F3-19 Fuel Pressure Test...
  • Page 747 1F3-20 OM600 ENGINE CONTROLS Tools Required 617 589 04 21 00 Tester 1. Disconnect the fuel line (2) from the fuel filter. 2. Remove the banjo bolt (4) from the fuel injection pump and remove the seals (3) and fuel line (2). 3.

  • Page 748: Fuel Pump

    OM600 ENGINE CONTROLS 1F3-21 FUEL PUMP 1 Fuel Injection Pump 5 Gasket ........... Replace 2 Pressure Line ..........13Nm 6 Spring Lock Washer 3 Suction Line 7 Hexagon Nuts 4 Hose Clip ..........Replace 8 Fuel Pump...

  • Page 749: Injection Nozzle Test

    1F3-22 OM600 ENGINE CONTROLS INJECTION NOZZLE TEST Preceding Work : Removal of fuel injection nozzle 1. Fuel Injection Nozzle ..... New : 115 - 125bar 2 Tester Used : min. 100bar 3 Valve A Closed Spray = good B Stringy Spray = poor...
  • Page 750 OM600 ENGINE CONTROLS 1F3-23 Tools Required 000 589 14 27 00 Tester Notice When testing the injection nozzle, do not place your hand into the spray of a nozzle. The spray will penetrate deep into the skin and destroy the tissue. 1.
  • Page 751 1F3-24 OM600 ENGINE CONTROLS 5. Opening pressure test : Open the valve (3) and slowly operate the hand lever at tester (approx. 1 stroke / second) and measure opening pressure. New Nozzle 115 - 125bar Used Nozzle Min. 100bar Difference Between Nozzles Max.

  • Page 752: Nozzle Washer

    OM600 ENGINE CONTROLS 1F3-25 INJECTION NOZZLES 1 Fuel Injection Nozzle ......35-40Nm 2 Fuel Return Hose 3 Plug 4 Nozzle Washer ........Replace 5 Fuel Injection Pipe ........18Nm...
  • Page 753 1F3-26 OM600 ENGINE CONTROLS Tools Required 001 589 65 09 00 Serration Wrench Removal & Installation Procedure 1. Remove the plastic clip from the injection pipe 2. Remove the fuel return hose. 3. Disconnect the injection pipes from the injection nozzles and push them to the side.

  • Page 754: Injection Nozzle Repair

    OM600 ENGINE CONTROLS 1F3-27 INJECTION NOZZLE REPAIR Preceding Work : Removal of fuel injection nozzle 5 Intermediate Disc 1 Nozzle Holder 6 Nozzle Needle 2 Steel Washer 7 Nozzle Body 3 Compression Spring 8 Nozzle Tensioning Nut ........ 80Nm 4 Thrust Pin...

  • Page 755: Repair Procedure

    1F3-28 OM600 ENGINE CONTROLS Tools Required 001 589 65 09 00 Socket Wrench Insert 000 589 00 68 00 Cleaning Set Repair Procedure 1. Clamp the nozzle holder (1) in a vice and remove the nozzle tensioning nut (8). Notice Use protective jaws for clamping.
  • Page 756 OM600 ENGINE CONTROLS 1F3-29 7. Check the fuel injection nozzle and adjust opening pressure if necessary. Opening pressure adjustment Disassemble the fuel injection nozzle and replace the steel washer (2). Notice Each 0.05mm thickness of the washer results in a pressure difference of approx.

  • Page 757: Cylinder Head Bolt

    1F3-30 OM600 ENGINE CONTROLS REMOVAL AND INSTALLATION OF INJECTION TIMING DEVICE Preceding Work : Removal of vacuum pump 1 Cylinder Head Cover 10 Washer 2 Bolt ............10Nm 11 Bolt (Left-Hand Thread) ......46Nm 3 Gasket ........... Replace 12 Camshaft Sprocket 4 Fuel Injection Pump 13 Washer 5 Seal ............
  • Page 758 OM600 ENGINE CONTROLS 1F3-31 Tools Required 601 589 00 08 00 Flange 601 589 05 21 00 Locking Screw 116 589 20 33 00 Sliding Hammer 116 589 02 34 00 Threaded Bolt 667 589 04 63 00 Retaining Plate Removal &...
  • Page 759 1F3-32 OM600 ENGINE CONTROLS 4. Position the no.1 cylinder at ATDC 15°. Notice Do not rotate the engine with camshaft sprocket bolt or opposite direction of the engine rotation. 5. Remove the plug (6) and seal (5) from the fuel injection pump and collect oil in a suitable vessel.
  • Page 760 OM600 ENGINE CONTROLS 1F3-33 8. Remove the chain tensioner (17). Installation Notice Tightening Torque 80 Nm Notice Replace the seal (16). 9. Pull out the 12-sided stretch bolt (14) and washer and remove the camshaft sprocket (12). 10. Pull out the bolt (11) and washer (10). Notice Be careful that the bolt is left-hand thread.
  • Page 761 1F3-34 OM600 ENGINE CONTROLS 12. Push back the timing chain with retaining plate (26) and remove the injection timing device (9). Retaining Plate 667 589 04 63 00 13. Installation should follow the removal procedure in the reverse order. 14. After assembling the engine, check start of delivery and adjust if necessary.

  • Page 762: Injection Timing Device

    OM600 ENGINE CONTROLS 1F3-35 INJECTION TIMING DEVICE Preceding Work : Removal of injection timing device 1 Cam Sprocket ........... Check 4 Segment Flange and Drive Hub 2 Bushing ............ Check 5 Compression Springs 3 Governor Weights...
  • Page 763 1F3-36 OM600 ENGINE CONTROLS Disassembly & Assembly 1. Remove the governor weights (3). 2. Pull out the compression springs (5) and cam sprocket (1) from the segment flange (4). 3. Knock out the bushing with a proper drift. 4. Installation should follow the removal procedure in the reverse order.

  • Page 764: Start Of Delivery Test (Position Sensor, Riv Method)

    OM600 ENGINE CONTROLS 1F3-37 START OF DELIVERY TEST (POSITION SENSOR, RIV METHOD) 1 Position Sensor 4 Seal ............Replace 2 Battery 5 Screw Plug ..........30Nm 3 Fuel Injection Pump Service Data Start of Delivery (RIV) ATDC 14° - 16°...

  • Page 765: Test Procedure

    1F3-38 OM600 ENGINE CONTROLS Tools Required 617 589 08 21 00 Position Sensor Test Procedure 1. Remove the screw plug (5) and seal (4) and collect oil in a suitable vessel. 2. Install the position sensor (1) into the governor housing of the injection pump to be the guide pin of the position sensor facing up.
  • Page 766 OM600 ENGINE CONTROLS 1F3-39 Digital Tester, RIV Method (Connection Diagram for Testers Without Adapter) 1 Fuel Injection Pump 4 TDC Pulse Sender Unit 2 Rl Sensor 5 Battery 3 Digital Tester...
  • Page 767 1F3-40 OM600 ENGINE CONTROLS (Connection Diagram for Testers With Adapter) 1 Fuel Injection Pump 4 TDC Pulse Sender Unit 2 Rl Sensor 5 Battery 3 Digital Tester 6 Rl Pulse Generator Service Data Start of Delivery (RIV) ATDC 14° - 16° Idle Speed OM661LA : 720 - 820 rpm, OM662LA : 750 - 850 rpm...
  • Page 768 OM600 ENGINE CONTROLS 1F3-41 Tools Required 617 589 09 21 00 Rl Sensor 617 589 10 21 00 Timing Tester 667 589 00 21 00 TDC Pulse Generator Commercial Tools Item Tools Digital Tester With Pulse Generator Bosch, MOT 001.03 Hartmann &...
  • Page 769 1F3-42 OM600 ENGINE CONTROLS After Testing Preceding Work : Start of delivery test Position Sensor (RIV method) 1 Adjusting Screw 4 Bolt ............23Nm 2 Bolt ............23Nm 5 Scale ..Rl start of delivery = 14° - 16° ATDC 3 Fuel Injection Pump...
  • Page 770 OM600 ENGINE CONTROLS 1F3-43 Tools Required 617 589 08 21 00 Position Sensor Adjustment Procedure 1. Position the No. 1 cylinder at ATDC 15° Notice Do not rotate the engine in opposite direction of engine rotation. 2. Remove the bolt (2) at the supporting bracket. 3.
  • Page 771 1F3-44 OM600 ENGINE CONTROLS Digital tester (RIV Method) 1 Bolt ............23Nm 3 Bolt ............23Nm 2 Adjusting Screw ..To the right : start of delivery retarded To the left : start of delivery advanced Service Data Start of Delivery (RIV) ATDC 14°...
  • Page 772 OM600 ENGINE CONTROLS 1F3-45 Adjustment Procedure 1. Remove the bolt (3) at the supporting bracket. 2. remove the bolts (1) at the timing case cover. 3. Run the engine at idle speed. 4. Turn the adjusting screw (2) until the specification (15° ± 1° ATDC) is indicated on the digital tester.

  • Page 773: Bolt

    1F3-46 OM600 ENGINE CONTROLS FUEL INJECTION PUMP Preceding Work : Removal of vacuum pump Removal of air cleaner housing Removal of intake manifold 18 Chain Tensioner......... 80Nm 24 Oil Pan 19 Seal ............Replace 25 Fuel Injection Pump 20 Bolt(Left-Hand Thread) ......46Nm 26 Seal ............
  • Page 774 OM600 ENGINE CONTROLS 1F3-47 Removal Procedure 1. Position then no.1 cylinder at 15° ATDC. Notice Do not rotate the engine in opposition direction of engine rotation. 2. Remove the connecting rod (9). 3. Disconnect the vacuum lines (13, 14). 4. Remove the accelerator control damper (10). (Manual transmission vehicle) 5.
  • Page 775 1F3-48 OM600 ENGINE CONTROLS 10. Install the assembly cage (29) and remove the bolt (20) and pull off the washer (21). Notice Be careful that the bolt (20) is left hand thread. Assembly Cage 601 589 05 14 00 11. Remove the chain tensioner (18) and seal (19). 12.
  • Page 776 OM600 ENGINE CONTROLS 1F3-49 Installation Procedure 1. Remove the screw plug (27) and seal (26) and collect oil in a vessel. 2. Insert flange (31) onto the injection pump camshaft and turn until the cam of the governor is visible in the hole. Flange 601 589 00 08 00 3.
  • Page 777 1F3-50 OM600 ENGINE CONTROLS 5. Coat the new seal (23) with engine oil and install it. 6. Insert the fuel injection pump (25) and tighten the bolts (22). Tightening Torque 23 Nm 7. Remove the locking screw (32). 8. Tighten the bolt(12). Tightening Torque 23 Nm 9.
  • Page 778 OM600 ENGINE CONTROLS 1F3-51 11. Assemble the plastic clip (8). 12. Connect the vacuum line (13, 14). 13. Connect the connecting rod (9). 14. connect the accelerator control damper (10). (Manual transmission vehicle) 15. Install the chain tensioner. 16. Install the vacuum pump. 17.
  • Page 779 SECTION 1G1 M162 ENGINE INTAKE & EXHAUST TABLE OF CONTENTS Intake Air Duct ..... . . 1G1-4 Specifications ..... . . 1G1-1 Intake Manifold .

  • Page 780: Maintenance And Repair

    1G1-2 M162 ENGINE INTAKE & EXHAUST MAINTENANCE AND REPAIR ON-VEHICLE SERVICE AIR CLEANER 1 Element Assembly 4 Shield Assembly-Air Intake 2 Cleaner Assembly-Air 5 Braket Assembly-Air Cleaner Mounting 3 Shield Cover-Air Intake 6 Braket Assembly-Shield Surport...
  • Page 781 M162 ENGINE INTAKE & EXHAUST 1G1-3 Removal & Installation Procedure 1. Release the clamp securing HFM sensor and air cleaner. 2. Disengage the air cleaner assembly and HFM sensor assembly. 3. Unserew the mounting bolt(6) from the bracket. Installation Notice Tightening Torque 22.5 - 27.5 Nm 4.

  • Page 782: Nut

    1G1-4 M162 ENGINE INTAKE & EXHAUST INTAKE AIR DUCT 1 Clamp 2 Sleeve 3 Nut 4 Clamp 5 Intake Air Duct Removal & Installation Procedure 1. Remove the clamp (1) and disconnect the HFM sensor. 2. Remove the nut (3) (arrow). 3.

  • Page 783: Intake Manifold

    M162 ENGINE INTAKE & EXHAUST 1G1-5 INTAKE MANIFOLD Preceding Work : Removal of fuel distributor and injection valve 1 Bolt (M6 X 40, 4 pieces) ......9-11 Nm 13 Bolt (M6 x 40, 4 pieces) ......9-11 Nm 2 Softcap 14 Throttle Body - Electric 3 Resonance Flap 15 Gasket ...........
  • Page 784 1G1-6 M162 ENGINE INTAKE & EXHAUST Removal & Installation Procedure Upper Intake Manifold 1. Disconnect the vacuum hose (8,9). 2. Loosen the clip (22). 3. Remove the upper intake manifold (5) after unscrewing the bolt (6). Installation Notice Tightening Torque 22.5 - 27.5 Nm Notice Check the gasket and replace it if necessary.

  • Page 785: Resonance Flap

    M162 ENGINE INTAKE & EXHAUST 1G1-7 RESONANCE FLAP 1 Soft Cap (2) 4 Vacuum Hose 2 Bolt (M6 x 25, 4 pieces) ......9-11 Nm 5 Resonance Flap 3 O-ring 6 Gasket ........... Replace Removal & Installation Procedure 1. Remove the 2 soft caps (1). 2.
  • Page 786 1G1-8 M162 ENGINE INTAKE & EXHAUST Function Description A pneumatically actuated resonance flap (5) is located on the intake manifold, and will be opened and closed by load, which operates resonance flap according to engine and controlled by ECU and rpm. 1.

  • Page 787: Exhaust Manifold

    M162 ENGINE INTAKE & EXHAUST 1G1-9 EXHAUST MANIFOLD Preceding Work : Removal of air cleaner 1 Nut ............36-44 Nm 3 Exhaust Manifold 2 Gasket ........... Replace...
  • Page 788 1G1-10 M162 ENGINE INTAKE & EXHAUST Tools Required 103 589 01 39 00 Caulking Bolt Removal & Installation Procedure 1. Remove the flange bolt from the exhaust manifold, and disconnect the front exhaust pipe. Installation Notice Tightening Torque 30 Nm Notice Check for nut damages and replace the nut if necessary.
  • Page 789 M162 ENGINE INTAKE & EXHAUST 1G1-11 Removal and Installation of Exhaust Line 1 Exhaust Manifold 10 Nut 2 Rivet Nut 11 Gasket ........... Replace 3 Bolt ............30 Nm 12 Rubber Pad 4 Front Pipe 13 Nut ............28-47 Nm 5 Oxygen Sensor 14 Center Muffler 6 Bolt ............
  • Page 790 SECTION 1G2 M161 ENGINE INTAKE & EXHAUST TABLE OF CONTENTS Specifications ..... . . 1G2-1 Air Intake Shield ..... . 1G2-4 Intake Air Duct .

  • Page 791: Maintenance And Repair

    1G2-2 M161 ENGINE INTAKE & EXHAUST MAINTENANCE AND REPAIR ON-VEHICLE SERVICE AIR CLEANER 1 Air Cleaner Assembly 4 Air Duct Hose 2 Element Assembly 6 Bolt (M8 × 30 ) ........22.5-27.5 Nm 3 Insulator...
  • Page 792 M161 ENGINE INTAKE & EXHAUST 1G2-3 Removal & Installation Procedure 1. Release the clamp securing HFM sensor and air cleaner. 2. Disengage the air cleaner assembly and HFM sensor assembly. 3. Unserew the mounting bolt(6) from the bracket. Installation Notice Tightening Torque 22.5 - 27.5 Nm 4.

  • Page 793: Air Intake Shield

    1G2-4 M161 ENGINE INTAKE & EXHAUST AIR INTAKE SHIELD Preceding Work : Removal of air cleaner 1 Air Cleaner Assembly 5 Air Inlet Duct 3 Insulator 7 Bolt (M6 × 35 ) ........... 9-11 Nm 4 Air Duct Hose Removal & Installation Procedure 1.

  • Page 794: Intake Air Duct

    M161 ENGINE INTAKE & EXHAUST 1G2-5 INTAKE AIR DUCT 1 Clamp 2 Sleeve 3 HFM Sensor 4 Intake Air Duct 5 Blow-by Hose 7 Clamp(2 pieces) 8 Intake Air Duct Mounting Bracket Removal & Installation Procedure 1. Release the clamp (1) and intake air duct. 2.
  • Page 795 1G2-6 M161 ENGINE INTAKE & EXHAUST 3. Release the clamp (7) and remove the intake air duct. Notice Completely fit the intake air duct with the mounting bracket (8).

  • Page 796: Intake Manifold

    M161 ENGINE INTAKE & EXHAUST 1G2-7 INTAKE MANIFOLD Preceding Work : Removal of intake air duce Removal of fuel distributor and injector 1 Bolt (M6 X 40, 6 pieces) ....22.5-27.5 Nm 5 Idle Regulator 2 Intake Manifold 6 Intermediate Flange 3 Gasket (2 pieces) ........
  • Page 797 1G2-8 M161 ENGINE INTAKE & EXHAUST Removal & Installation Procedure 1. Disconnect the battery ground cable. 2. Remove idle speed control plug connector (arrow). 3. Disconnect the brake booster vacuum line and other vacuum lines. 4. Disconnector the rod from bearing bracket assembly and remove the connection piece (8).

  • Page 798: Exhaust Manifold

    M161 ENGINE INTAKE & EXHAUST 1G2-9 EXHAUST MANIFOLD 1 Oxygen Sensor ......49.5-60.5 Nm 5 Exhaust Manifold 2 Bolt (4 pieces) ........9-11 Nm 6 Flange Bolt & Exhaust Pipe 3 Upper Cover Mounting Nut ..........30 Nm 4 Nut (11 pieces)....... 31.5-38.5 Nm 7 Gasket ...........
  • Page 799 1G2-10 M161 ENGINE INTAKE & EXHAUST 4. Unscrew the eleven nuts (4) and remove the exhaust manifold (5) and gasket (7). Installation Notice Tightening Torque 31.5 - 38.5 Nm 5. Replace the gasket (7) with new one. 6. Installation should follow the removal procedure in the reverse order.
  • Page 800 M161 ENGINE INTAKE & EXHAUST 1G2-11 Removal and Installation of Exhaust Line 1 Pipe Assembly-Exhaust Front 9 Muffler Assembly-Complete 2 Converter Assembly-Complete 10 Pipe Assembly-Tail Exhaust 3 Gasket 11 Nut-Hex Flang (M8X1.25) 4 Hanger-Converter Mounting 12 Bolt-Hex (M8X1.25X55) 5 Ring 13 Bolt-Hex (M10X1.25X35) 6 Gasket-E/Pipe to Manifold 14 Nut-Hex Flang (M10X1.25)
  • Page 801 SECTION 1G3 OM600 ENGINE INTAKE & EXHAUST Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

  • Page 802: Maintenance And Repair

    1G3-2 OM600 ENGINE INTAKE & EXHAUST MAINTENANCE AND REPAIR ON-VEHICLE SERVICE AIR CLEANER AND INLET DUCT & HOSE Air Intake Shield Assembly 5 Bolt ............9-11Nm Air Cleaner Assembly 6 House Mounting Bracket 7 Clamp Air Cleaner Element ... Clean : 20,000km 8 Engine Cover Assembly (Turbo) Replace : 60,000km...
  • Page 803 OM600 ENGINE INTAKE & EXHAUST 1G3-3 Removal & Installation Procedure 1. Loosen the air duct hose clamp and then remove the air cleaner and air duct hose. 2. Disconnect the air cleaner housing cover clamp and remove the cover and element. Clean every 20,000km Operating Interval...

  • Page 804: Intake And Exhaust Manifold

    1G3-4 OM600 ENGINE INTAKE & EXHAUST INTAKE AND EXHAUST MANIFOLD 1 Nut ..........22.5-27.5 Nm 7 Stud Bolt .......... 9.9-12.1 Nm 2 Washer 8 Bolt (M8) ........22.5-27.5 Nm 9 Intake Duct 3 Support Assembly Bar 10 Intake Duct Gasket 4 Nut ..........
  • Page 805 OM600 ENGINE INTAKE & EXHAUST 1G3-5 Exhaust Line 1 Heat Protector Assembly 6 Muffler 2 Heat Protector Floor 7 Mounting 3 Exhaust Front Pipe Assembly 8 Heat Protector Front Floor 4 Ring 9 Tail Exhaust Pipe Assembly 5 Exhaust Rear Pipe Assembly...
  • Page 806 1G3-6 OM600 ENGINE INTAKE & EXHAUST Removal & Installation Procedure 1. Remove the bolt from the exhaust manifold and then remove the front exhaust pipe. Installation Notice Tightening Torque 15 - 18 Nm Notice When tightening the nut(3), maintain the clearance between exhaust manifold(1) and front exhaust pipe.

  • Page 807: Turbocharger

    OM600 ENGINE INTAKE & EXHAUST 1G3-7 TURBOCHARGER CHARGE AIR SYSTEM DIAGRAM 1 Turbocharger Oil Inlet 6 Air Inlet 2 Turbine Wheel 7 Exhaust Gas Outlet 3 Waste Gate 8 Compressed Air Flow 4 Oil Outlet 9 Intercooler 5 Compressor Wheel 10 Cylinder...

  • Page 808: Intercooler

    1G3-8 OM600 ENGINE INTAKE & EXHAUST INTERCOOLER 1 Hoses 5 Cover 2 Pipes 6 Bolts 3 Hoses 7 Screws 4 Intercooler 8 Bolts...
  • Page 809 OM600 ENGINE INTAKE & EXHAUST 1G3-9 Removal & Installation Procedure 1. Remove the hose connected to turbocharger and intake duct. 2. Remove the protective cover. 3. Loosen the clamps and remove the pipe and hose connected to intercooler. 4. Unscrew the mounting bolts and remove the intercooler. 5.

  • Page 810: Turbocharger Assembly

    1G3-10 OM600 ENGINE INTAKE & EXHAUST TURBOCHARGER ASSEMBLY 1 Oil Supply Line 3 Nuts 2 Oil Return Line 4 Turbocharger...
  • Page 811 OM600 ENGINE INTAKE & EXHAUST 1G3-11 Removal & Installation Procedure 1. Remove the 2 hoses connected to intercooler. 2. Remove the hose(air cleaner to turbocharger) with blow by hose. 3. Disconnect the oil supply pipe. 4. Remove the oil return pipe. 5.
  • Page 812 1G3-12 OM600 ENGINE INTAKE & EXHAUST 7. Remove the turbocharger disconnecting the exhaust pipe from the turbocharger. 8. Installation should follow the removal procedure in the reverse order.
  • Page 813 SECTION 2A SUSPENSION DIAGNOSIS TABLE OF CONTENTS Specifications ......2A-1 Damping Force Control Logic ... . . 2A-6 Normal Control .

  • Page 814: General Specifications

    2A-2 SUSPENSION DIAGNOSIS GENERAL SPECIFICATIONS (Cont'd) Application Description Body Power Voltage (V) 4.75 - 5.25 Vertical and Less than 10 Consuming Current (mA) Lateral Acceleration Output Current (mA) Less than 2.0 Sensor Operating Characteristics (Vertical Acceleration Sensor) (Lateral Acceleration Sensor) Output Voltage Output Voltage 4.25...

  • Page 815: Diagnosis

    SUSPENSION DIAGNOSIS 2A-3 DIAGNOSIS GENERAL DIAGNOSIS Problems in the steering, the suspension, the tires, and vehicle first. If possible, do this road test with the the wheels involve several systems. Consider all systems customer. when you diagnose a complaint. Some problems, such Proceed with the following preliminary checks.
  • Page 816 2A-4 SUSPENSION DIAGNOSIS Steering Instability Checks Action Incorrect Front wheel Alignment Replace Worn or Loosened Lower Arm Bushing Repair or Replace Vehicle Bottoming Checks Action Worn or Broken Coil Spring Replace...

  • Page 817: Input & Output Devices And Damping

    SUSPENSION DIAGNOSIS 2A-5 INPUT & OUTPUT DEVICES AND DAMPING FORCE CONTROL LOGIC INPUT & OUTPUT DEVICES Damping force of shock absorber will rotate shock absorber control rod in 3 modes by driving actuator on the upper shock absorber when signaled from ECS. Rotary valve in the shock absorber will control hydraulic flow according to rotation of control rod to adjust damping force of shock absorber in SOFT«...

  • Page 818: Damping Force Control Logic

    2A-6 SUSPENSION DIAGNOSIS DAMPING FORCE CONTROL LOGIC Control Logic that applies on damping force variable suspension is comprised of road sensing driving comfort control logic to increase driving comfort and vehicle speed sensing control logic, anti-roll control logic and anti-dive control logic to secure control safety.

  • Page 819: Self-Diagnosis

    SUSPENSION DIAGNOSIS 2A-7 SELF-DIAGNOSIS ECS-ECU indicates ECS circuit defectives to the driver by flickering ECS indicator lamp in the meter cluster 0.5 second of interval if there are defectives. Code Defects Judging Conditions Set Time Remedy Set Time Release Conditions Body vertical When sensor output Stop anti-...

  • Page 820: Actuator Inspection

    2A-8 SUSPENSION DIAGNOSIS ACTUATOR INSPECTION Output position of the actuator should be changed as below when battery voltage is applied between actuator connector terminals. Connector Battery Voltage Position of The Actuator Output Remark terminal 1 (White) SOFT Mode 2 (Black) OPEN 3 (Red) 1 (White)

  • Page 821: Schematic And Routing Diagrams

    SUSPENSION DIAGNOSIS 2A-9 SCHEMATIC AND ROUTING DIAGRAMS...
  • Page 822 2A-10 SUSPENSION DIAGNOSIS Connector Pin Number and Circuits Circuit Circuit Ignition Chassis Ground Actuator R-MEDIUM Actuator R-HEAD Actuator R-SOFT Actuator F-MEDIUM Actuator F-HEAD Actuator F-SOFT Select Switch Brake Switch Speed Sensor Wheel G Sensor Lateral G Sensor Wheel G Sensor Ground Lateral G Sensor Ground Vertical G Sensor Ground Vertical G Sensor...

  • Page 823: Self Diagnosis Test

    3. Turn the ignition switch to 'ON' position. 4. Select "Elctronic control vehicle diagnosis" from function selection display and press "Enter". 5. Select "Korando ('98 model year)" from vehicle model selection display and press 'Enter'. 6. Select "Elctronic suspension system (ECS)" from control system selection display and press 'Enter'.
  • Page 824 2A-12 SUSPENSION DIAGNOSIS Self - Diagnosis List Fault Defects Service Hint Code 1. Check sensor supply voltage Vertical Acceleration Sensor Condition - IGN ON Standard value - voltage between pin 11 and 8 of ECU : 4.5 - 5.0V 2. Check sensor output voltage. Condition - IGN ON Standard value - voltage between pin 20 and 11 of ECU : 0.5 - 4.5V...
  • Page 825 SECTION 2B WHEEL ALIGNMENT TABLE OF CONTENTS Wheel Alignment ..... . . 2B-6 Specifications ......2B-1 General Description and System Wheel Alignment Specifications .

  • Page 826: Diagnosis

    2B-2 WHEEL ALIGNMENT DIAGNOSIS TIRE DIAGNOSIS Irregular and Premature Wear Irregular and premature tire wear has many causes. Some of them are incorrect inflation pressures, lack of regular rotation, poor driving habits, or improper wheel alignment. Rotate the tires if : The front tire wear is different from the rear.

  • Page 827: Radial Tire Lead/Pull

    WHEEL ALIGNMENT 2B-3 3. Road test the vehicle. If there is improvement, install the original tires to find the offending tire. If there is no a straight improvement, install good tires in place of all four offending tires. 4. Install original tires one at a time to find the offending tire.
  • Page 828 2B-4 WHEEL ALIGNMENT Radial Tire Lead/Pull Diagnosis Chart Step Action Values(s) 1. Perform wheel alignment preliminary inspection. 2. Check the brakes for dragging. 3. Road test the vehicle. Go to Step 2 System OK Does the vehicle lead/pull? 1. Cross switch the front tire and wheel assemblies. 2.

  • Page 829: Vibration Diagnosis

    WHEEL ALIGNMENT 2B-5 VIBRATION DIAGNOSIS Preliminary Checks Wheel imbalance causes most highway speed vibration Prior to performing any work, always road test the car problems. A vibration can remain after dynamic and perform a careful visual inspection for: balancing because: Obvious tire and wheel runout.

  • Page 830: Maintenance And Repair

    2B-6 WHEEL ALIGNMENT MAINTENANCE AND REPAIR ON-VEHICLE SERVICE WHEEL ALIGNMENT Vehicle Height 1. Check the tire for proper inflation. 2. Measure ‘A’ from the center of the lower arm rear mounting bolt end to the ground. 3. Measure ‘B’ from the center of the steering knuckle shaft to the ground.
  • Page 831 WHEEL ALIGNMENT 2B-7 Camber 1. Remove the free wheel hub. 2. Measure camber with a wheel alignment equipment. Specification 0°±30’ 3. If camber measurements are not within specification, adjust it by increasing or decreasing the number of adjusting shims (1) inserted between the upper arm shaft and cross bracket. Camber Change Adjusting Shims Increasing 1ea...
  • Page 832 2B-8 WHEEL ALIGNMENT 3. If caster measurements are not within specification, adjust it by increasing 1ea (rear) or decreasing 1ea (front). Caster Change FRONT Adjusting Shims Increasing 1ea Decreasing 1ea 0.4 small - 11’ + 11’ 1.6 small - 43’ + 43’...

  • Page 833: General Description And System Operation

    WHEEL ALIGNMENT 2B-9 GENERAL DESCRIPTION AND SYSTEM OPERATION FOUR WHEEL ALIGNMENT CASTER The first responsibility of engineering is to design safe Caster is the tilting of the uppermost point of the steering steering and suspension systems. Each component axis either forward or backward from the vertical when must be strong enough to withstand and absorb extreme viewed from the side of the vehicle.
  • Page 834 SECTION 2C FRONT SUSPENSION TABLE OF CONTENTS Torsion Bar ......2C-6 Specifications ......2C-1 Front Lower and Upper Arm .
  • Page 835 2C-2 FRONT SUSPENSION FASTENER TIGHTENING SPECIFICATIONS Stabilizer Bar Application Stabilizer Bar Retaining Nut 30 - 45 Stabilizer Bar Link Nut 60 - 80 Lower Arm Nut 16 - 22 Torsion Bar Application Torque Arm Bolt 40 - 60 60 - 80 Lower and Upper Arm Application Upper Arm Nut...

  • Page 836: Component Locator

    FRONT SUSPENSION 2C-3 COMPONENT LOCATOR FRONT SUSPENSION 5 Stabilizer Bar Link 1 Shock Absorber 6 Stabilizer Bar 2 Upper Arm 7 Suspension Bumper 3 Steering Knuckle 4 Lower Arm...

  • Page 837: Maintenance And Repair

    2C-4 FRONT SUSPENSION MAINTENANCE AND REPAIR ON-VEHICLE SERVICE FRONT STABILIZER BAR 7 Outer Washer 1 Front Stabilizer Bar 8 Bushing 2 Bolt ............30-45 Nm 9 Center Washer 3 Fixing Cap 10 Lower Arm 4 Bushing 11 Bushing 5 Nut ............60-80 Nm 12 Outer Washer 6 Stabilizer Bar Link Assembly 13 Nut ............
  • Page 838 FRONT SUSPENSION 2C-5 Removal & Installation Procedure 1. Remove the connecting nuts (1) from stabilizer bar link. Tightening Torque 16 - 22 Nm Installation Notice 2. Remove the connecting nuts (2) of the stabilizer bar and link and then remove the link. Tightening Torque 60 - 80 Nm Installation Notice...

  • Page 839: Torsion Bar

    2C-6 FRONT SUSPENSION TORSION BAR 1 Nut 7 Torsion Bar 2 Torque Arm 8 Dust Cover 3 Washer 9 Height Control Arm Assembly 4 Bolt ..........M10, 40-60 Nm 10 Height Control Bolt End Piece M12, 60-80 Nm 11 Height Control Bolt 5 Torsion Bar End Seat 12 Height Control Seat 6 Dust Cover...
  • Page 840 FRONT SUSPENSION 2C-7 Removal & Installation Procedure 1. Remove the fixing nuts and bolts of the shock absorber and lower arm connection. Installation Notice Tightening Torque 60 - 80 Nm 2. Remove the connecting nuts of the stabilizer bar link to the lower arm.

  • Page 841: Front Lower And Upper Arm

    2C-8 FRONT SUSPENSION FRONT LOWER AND UPPER ARM Preceding Work : Removal of the torsion bar spring Removal of the steering knuckle and drive shaft 1 Nut ........... 120-140 Nm 10 Cotter Pin ..........Replace 2 Fulcrum Pin and Upper Arm Assembly 11 Nut ...........
  • Page 842 FRONT SUSPENSION 2C-9 Removal & Installation Procedure 1. Remove the shock absorber. Installation Notice Distance between the nut end 6 - 9 mm Upper and the screw end Tightening Torque Lower 60 - 80 Nm 2. Remove the fulcrum pin mounting bolts and nuts and remove the upper arm assembly.

  • Page 843: Front Shock Absorber

    2C-10 FRONT SUSPENSION FRONT SHOCK ABSORBER 1 Front Shock Absorber 4 Center Washer 2 Washer 5 Actuator Mounting Bracket 3 Bush 6 Nut ............40-60Nm...
  • Page 844 FRONT SUSPENSION 2C-11 Removal & Installation Procedure 1. Disconnect actuator connector and unscrew bolt and remove actuator assembly. Notice When installing the actuator to the mounting bracket, the wiring should face the front of the frame. 2. Unscrew the upper nut (6). Notice When screwing the nut, actuator contacting surface of the mounting bracket and rod end should be 0.5 - 1.5mm.

  • Page 845: Axle Vertical Acceleration Sensor (Wheel G Sensor)

    2C-12 FRONT SUSPENSION AXLE VERTICAL ACCELERATION SENSOR (WHEEL G SENSOR) 1 Axle Vertical Acceleration Sensor (wheel G 2 Extension Wiring sensor) 3 Bolt (M6) ..........20 - 30Nm Removal & Installation Procedure 1. Disconnect extension wiring connector (2) from the axle vertical acceleration sensor.

  • Page 846: Vertical And Lateral Sensor

    FRONT SUSPENSION 2C-13 VERTICAL AND LATERAL SENSOR Removal & Installation Procedure 1. Disconnect vertical sensor and lateral sensor connectors. Notice When connecting the connectors, connector connection of the lateral sensor (2) should be in the right and connector connection of the vertical sensor (1) should face downward. 2.

  • Page 847: Ecs (Ecu)

    2C-14 FRONT SUSPENSION ECS (ECU) 1 Electronically Controlled Suspension (ECU) 4 Parking Brake Lever 2 Connector 5 Over Voltage Protection Relay 3 Bolts (2 pieces) Removal & Installation Procedure 1. Disconnect each connectors from the console box and remove the console box. 2.
  • Page 848 SECTION 2D REAR SUSPENSION TABLE OF CONTENTS Heating ......2D-3 Specifications ......2D-1 Component Locator .
  • Page 849 2D-2 REAR SUSPENSION DIAGNOSIS NOISE(DURING STRAIGHT DRIVING) Check Action Lack of Oil Replenish Low Viscosity of Oil Replace Insufficient Oil Replace Excessive Backlash of Ring Gear Adjust Worn or Damaged Tooth of Ring and Pinion Gear Replace Worn or Damaged Drive Pinion Bearing Replace Worn Spline of Side Bearing and Side Gear Replace...
  • Page 850 REAR SUSPENSION 2D-3 HEATING Check Action Lack of Oil Replenish Insufficient Backlash of Gears Adjust Excessive Preload of Bearing Adjust...
  • Page 851 2D-4 REAR SUSPENSION COMPONENT LOCATOR 1 Spring Seat 5 Upper Arm 2 Coil Spring 6 Lower Arm 3 Lateral Rod 7 Connecting Link 4 Shock Absorber 8 Stabilizer Bar...
  • Page 852 REAR SUSPENSION 2D-5 MAINTENANCE AND REPAIR ON-VEHICLE SERIVCE REAR SUSPENSION (5 - LINK) 1 Spring Seat 5 Upper Arm 2 Coil Spring 6 Lower Arm 3 Lateral Rod 7 Connecting Link 4 Shock Absorber 8 Stabilizer Bar...
  • Page 853 2D-6 REAR SUSPENSION Removal & Installation Procedure Stabilizer bar 1. Remove the upper nut of the connecting link. Installation Notice Distance Between the Nut 10 - 13 mm end and the Screw end Tightening Torque 16 - 22 Nm 2. Remove the stabilizer bar cap fixing bolts (arrow) and remove the stabilizer bar.
  • Page 854 REAR SUSPENSION 2D-7 Shock Absorber. 1. Remove the lower mounting nut. Installation Notice Tightening Torque 50 - 65 Nm 2. Remove the upper mounting nut and remove the shock absorber. Installation Notice Distance between the nut 6 - 9 mm end and the screw end Tightening Torque 30 - 45 Nm...
  • Page 855 2D-8 REAR SUSPENSION 2. Remove the lower arm fixing nut from the frame. Installation Notice Tightening Torque 150 - 180 Nm 3. Remove the lower arm fixing nut from the rear axle and remove the lower arm. Installation Notice Tightening Torque 150 - 180 Nm...

  • Page 856: Rear Shock Absorber

    REAR SUSPENSION 2D-9 REAR SHOCK ABSORBER 1 Rear Shock Absorber 4 Center Washer 2 Washer 5 Actuator Mounting Bracket 3 Bush 6 Nut (M12 x 1.25) ......... 40 - 60Nm...
  • Page 857 2D-10 REAR SUSPENSION Removal & Installation Procedure 1. Disconnect actuator connector and unscrew bolt and remove actuator assembly. Notice When installing the actuator to the mounting bracket, the wiring should face outward of the frame. Actuator wiring should be fixed 40 - 50mm away from the wiring ends when fixing it with the frame open clip.
  • Page 858 SECTION 2E TIRES AND WHEELS TABLE OF CONTENTS Specifications ......2E-1 Wheel Disc ......2E-3 Component Locator .

  • Page 859: Diagnosis

    2E-2 TIRES AND WHEELS DIAGNOSIS WEAR PATTERN DIAGNOSIS Wear Pattern Possible Cause Remedy Adjust Wear on Both Tread Shoulders Under Inflation Adjust Wear on Tread Center Over Inflation Adjust Tread Torn Out Under Inflation Incorrect Camber or Toe-in Adjust One-sided Tread Wear Incorrect Toe-in Adjust Feather Edging of Tread...

  • Page 860: Radial Tire

    TIRES AND WHEELS 2E-3 IDENTIFICATION RADIAL TIRE P 215/75 R 15 94 H M+S Section Height Four Season Mud & Snow Speed Rating (max. 210km/h) Load Range (below 670kg) Diameter Rim Diameter (inch) Radial Tire Aspect Ratio = (Section Height ¸ Section Width) x 100 Section Width (mm) Passenger Car...

  • Page 861: Component Locator

    2E-4 TIRES AND WHEELS COMPONENT LOCATOR WHEEL AND TIRE 1 Wheel Bolts ....Steel Wheel : 80-120 Nm 4 Tire ......Aluminium Wheel : 110-130 Nm 5 Steel Wheel Weight Balance 2 Steel Wheel 6 Hub Cap 3 Aluminium Wheel...

  • Page 862: Maintenance And Repair

    TIRES AND WHEELS 2E-5 MAINTENANCE AND REPAIR ON-VEHICLE SERVICE WHEELS AND TIRES Removal & Installation Procedure 1. Inspection of tire Check tread area for tread surface, crack, damage by nail in or stones. Replace or repair if necessary. 2. Wear limit. 1.6mm Limit Replace the tire if tread-wear indicator of the tread...
  • Page 863 2E-6 TIRES AND WHEELS 4. Tire pressure inspection. Tire pressure. Front & Rear 2.1kg/cm (30PSI) (P235/75R15) Check tread contact with road. Notice If underinflated, tire may come away from the wheel during rapid steering. An overinflated tire will cause a hard riding and uneven wear.
  • Page 864 TIRES AND WHEELS 2E-7 To correct unbalance, install equal weights 180° opposite each other, one on the inside of the wheel and one on the outside, at the point of unbalance. Balance Weight 0.4oz 0.7oz 1.10oz 1.40oz 1.80oz 2.1oz 6. Cautions for installation and removal. Clean the mounting surfaces of hub and wheel.
  • Page 865 SECTION 3A FRONT DRIVE AXLE TABLE OF CONTENTS Specifications ......3A-1 Maintenance and Repair ....3A-6 General Specifications .
  • Page 866 3A-2 FRONT DRIVE AXLE FASTENER TIGHTENING SPECIFICATIONS Steering Knuckle and Drive Shaft Application Drive Shaft to Front Axle Inner Shaft 25 - 35 Wheel Speed Sensor 85 - 105 Drive Shaft Cover Bolt 50 - 60 Locking Hub Washer Screw 2 - 4 Hub Flange Bolt 70 - 90...

  • Page 867: Component Locator

    FRONT DRIVE AXLE 3A-3 COMPONENT LOCATOR FRONT AXLE 1 Drive Shaft 5 Brake Disc 2 Axle Housing Mounting Bolt 6 Hub-Wheel 3 Axle Housing 7 Locking Hub 4 Cross Member...
  • Page 868 3A-4 FRONT DRIVE AXLE AUTO-LOCKING HUB 1 Cap 11 Body 2 Filter 12 Return Spring 3 Vacuum Diaphragm 13 Bearing 4 Diaphragm Retainer 14 O-ring 5 Piston 15 Retaining Ring 6 Bolt (M10) 16 Inner Drive Gear 7 Lock Washer 17 Oil Seal 8 O-ring 18 Oil Seal Race...
  • Page 869 FRONT DRIVE AXLE 3A-5 VACUUM CIRCUIT 1 Engine 6 Auto locking Hub Solenoid Valve 2 Vacuum Pump 7 T-connector Hose 3 3-way Connector 8 Hub Hose (left) 4 T-connector 9 Hub Hose (right) 5 Check Valve...

  • Page 870: On-Vehicle Service

    3A-6 FRONT DRIVE AXLE MAINTENANCE AND REPAIR ON-VEHICLE SERVICE VACUUM LINE 1 Vacuum Auto-locking Hub Assembly 12 Check Valve 2 Bolt ............50-60 Nm 13 Hose (L :100, green) 3 Cam Washer 14 Auto Locking Hub Solenoid Valve 4 Auto-locking Hub Cap 15 Bolt 5 Retainer Ring 16 Hose (L :100, green)
  • Page 871 FRONT DRIVE AXLE 3A-7 Removal & Installation Procedure 1. Be careful not to change the valve when connecting the check valve and each hose. 2. Adjust the clearance between the retainer ring (5) and locking hub (7) using the shim(6). Normal Max.
  • Page 872 3A-8 FRONT DRIVE AXLE STEERING KNUCKLE AND DRIVE SHAFT 1 Front Axle Inner Shaft 4 Bolt ............45-60 Nm 2 Front Axle Drive Shaft 5 Steering Knuckle 3 Spring Washer...
  • Page 873 FRONT DRIVE AXLE 3A-9 Removal & Installation Procedure 1. Remove the tire. Installation Notice Steel Wheel 80 - 120 Nm Tightening Torque Aluminum Wheel 110 - 130 Nm 2. Remove the autolocking hub vacuum hose. 3. With ABS Remove the wheel speed sensor from the steering knuckle. Installation Notice Tightening Torque 6 - 8 Nm...
  • Page 874 3A-10 FRONT DRIVE AXLE With part time transfer case. 5-1. Remove the cover mounting bolts and pull off the cover. Installation Notice Tightening Torque 50 - 60 Nm 5-2. Remove the snap ring of the drive shaft and pull off the hub body.
  • Page 875 FRONT DRIVE AXLE 3A-11 6-2. Unscrew the bolts and remove hub flange. Installation Notice Tightening Torque 70 - 90 Nm Before installation, apply loctite on the mating surface. Remove the hub nut with special tool. Tightening Torque 15 Nm Remove the hub and disk assembly. Remove the disk brake dust shield.
  • Page 876 3A-12 FRONT DRIVE AXLE 10. Remove the cotter pin and slotted nut and then remove the steering knuckle arm and tie-rod. Installation Notice Tightening Torque 35 - 45 Nm Replace the cotter pin with new one. 11. Remove the cotter pin and nut from the steering knuckle arm and upper arm ball joint connection.
  • Page 877 FRONT DRIVE AXLE 3A-13 14. Remove the drive shaft mounting bolts and remove the drive shaft. Installation Notice Tightening Torque 45 - 60 Nm Observe the tighening torque and sequence. 15. Installation should follow the removal precedure in the reverse order.
  • Page 878 3A-14 FRONT DRIVE AXLE FRONT AXLE Preceding Work : Removal of the front axle drive shaft Removla of the steering gear box 1 Axle Mounting Bracket 9 Bushing 2 Breather Hose 10 Nut ............. 95-142 Nm 3 Bolt (Rear) 11 Front Axle Assembly 4 Nut .............
  • Page 879 FRONT DRIVE AXLE 3A-15 Removal & Installation Procedure 1. Remove the propeller shaft from the front axle input shaft. Notice Before removal, place the alignment marks. Installation Notice Tightening Torque 70 - 80 Nm 2. Remove the breather hose. 3. Remove the axle housing mounting nuts (1) from the cross member.
  • Page 880 3A-16 FRONT DRIVE AXLE UNIT REPAIR AXLE HOUSING Preceding Work : Removal of the axle housing...
  • Page 881 FRONT DRIVE AXLE 3A-17 1 Front Axle Housing Mounting Bracket 20 Bearing 2 Inner Shaft (Left) 21 Oil Slinger 3 Bolt ............55-65 Nm 22 Drive Pinion 4 Oil Seal ..........Replace 23 Oil Filler Plug ........28-41 Nm Apply Grease to the Sealing Rib 24 Bolt ............
  • Page 882 3A-18 FRONT DRIVE AXLE Disassembly Procedure 1. Remove the drain plug and drain the oil. Reinstall the drain plug. Installation Notice Tightening Torque 28 - 41 Nm 2. Unscrew the axle housing and housing mounting bracket bolts and remove the bracket and inner shaft assembly. 3.
  • Page 883 FRONT DRIVE AXLE 3A-19 5. Unscrew the bearing cap bolts and remove the bearing caps. Pull out the differential carrier assembly. Notice Place alignment marks on the bearing cap not to change the caps before removal. When pulling out the differential carrier assembly, be careful not to damage the axle housing.
  • Page 884 3A-20 FRONT DRIVE AXLE 2. Assemble the parts of the drive pinion. Tightening Torque of the 240 - 310 Nm Lock Nut 3. Assemble the parts of the differential carrier. Tightening Torque of the 75 - 90 Nm Ring Gear Bolts 4.
  • Page 885 FRONT DRIVE AXLE 3A-21 6. Measure backlash of the drive pinion and ring gear. Specified Value 0.13 - 0.20 mm 7. Install the axle housing cover. Tightening Torque 39 - 46 Nm 8. Assemble the parts of the front axle shaft and housing mounting bracket.
  • Page 886 3A-22 FRONT DRIVE AXLE Inspection of Ring Gear Tooth Contact Pattern Normal Contact Apply gear-marking compound (prussian blue / red lead) on the ring gear teeth. Rotate the ring gear and check the tooth contact pattern. Abnormal Contact Possible Cause Remedy Tooth Contact pattern 1.
  • Page 887 SECTION 3C PROPELLER SHAFT TABLE OF CONTENTS Specifications ......3C-1 Maintenance and Repair ....3C-3 General Specifications .
  • Page 888 3C-2 PROPELLER SHAFT COMPONENT LOCATOR M/T & A/T (PART-TIME T/C) 1 Flange Yoke 7 Oil Seal 2,3 3-Journal Cross and Bearing Kit (Including Snap 8 Split Washer Ring) 9 Slip Tube Shaft 4 Slip Yoke Assembly 10 Tube 5 Grease Nipple 11 Tube Yoke 6 Dust Cap 12 Flange Yoke...
  • Page 889 PROPELLER SHAFT 3C-3 MAINTENANCE AND REPAIR ON-VEHICLE SERVICE PROPELLER SHAFT 1 Front Axle 6 Transfer Case 2 Bolt ............70-80 Nm 7 Bolt ............81-89 Nm 3 Front Propeller Shaft (661LA/662LA) 8 Rear Propeller Shaft 4 Front Propeller Shaft (E32) 9 Bolt ............
  • Page 890 3C-4 PROPELLER SHAFT Removal Procedure 1. Place alignment marks and remove the propeller shaft. 2. Place alignment marks before removing the spider. 3. Using a snap ring pliers, remove the snap ring. 4. Slightly tapping the yoke shoulder using a brass hammer, remove the bearing.
  • Page 891 PROPELLER SHAFT 3C-5 5. If difficult to remove, clamp the yoke side in a vise and tap off the needle bearing, using a proper tool. 6. Disassemble the universal joint parts. As axles move up and down, universal joints allow drive angles to change without binding propeller shaft.
  • Page 892 3C-6 PROPELLER SHAFT 3. Clearance between the spider and bearing. Standard Limit 0.03 - 0.098 mm 0.25 mm 4. Propeller shaft runout Using a dial indicator, measure propeller shaft runout by turning the shaft. If runout exceeds limit, replace the propeller shaft or correct it using a press.
  • Page 893 PROPELLER SHAFT 3C-7 Installation Procedure Clean the disassembled parts and replace them if damaged. 1. Align the alignment marks of the yoke and assemble the spider, bearing and snap ring. 2. Apply grease to the inner of the bearing cap of the needle roller bearing and assemble the needle roller.
  • Page 894 SECTION 3D REAR DRIVE AXLE TABLE OF CONTENTS Noise ....... 3D-4 Specifications .

  • Page 895: General Specifications

    3D-2 REAR DRIVE AXLE GENERAL SPECIFICATIONS(Cont'd) Application Description 4.89 Reduction Ratio A/T (MB) 4.55 4.55 A/T (MB) 4.55 A/T (BTRA) 5.86 3.73 A/T (MB) 3.73 A/T (BTRA) 4.89 1.9 L Oil Capacity SEA 80W/90, API GL - 5 Oil Specification FASTENER TIGHTENING SPECIFICATIONS N·...

  • Page 896: Diagnosis

    REAR DRIVE AXLE 3D-3 DIAGNOSIS NOISE (DURING STRAIGHT DRIVING) Action Checks Lack of Oil Replenish Low Viscosity of Oil Replace Insufficient Oil Replace Excessive Backlash of Ring Gear Adjust Worn or Damaged Tooth of Ring and Pinion Gear Replace Worn or Damaged Drive Pinion Bearing Replace Bent Axle Housing Replace...

  • Page 897: Vibration

    3D-4 REAR DRIVE AXLE VIBRATION Checks Action Faulty Connection of Sliding Joint Adjust Bent Propeller Shaft Replace Symmetry of Universal Joint Snap Ring Adjust Loosened Yoke Bolts Tighten NOISE Checks Action Worn or Damaged Universal Joint Bearing Replace Adjust or Replace Fallen Off Universal Joint Snap Ring Tighten Loosened Yoke Connection...

  • Page 898: Component Locator

    REAR DRIVE AXLE 3D-5 COMPONENT LOCATOR 1 Spring Seat 5 Upper Arm 2 Coil Spring 6 Lower Arm 3 Lateral Rod 7 Connecting Link 4 Shock Absorber 8 Stabilizer Bar...

  • Page 899: Gasket

    3D-6 REAR DRIVE AXLE MAINTENANCE AND REPAIR ON-VEHICLE SERVICE AXLE SHAFT 1 Brake Disc 7 Parking Brake Lining and Back Plate Assembly 2 Dust Plug 8 Caliper Assembly 3 Rear Axle Shaft 9 Gasket 4 Nut ............50-65 Nm 10 Bolt ............ 85-100 Nm 5 Washer 11 Rear Axle Housing 6 Parking Brake Cable...
  • Page 900 REAR DRIVE AXLE 3D-7 Removal & Installation Procedure 1. Remove the tire. Installation Notice Steel Wheel 80 - 120 Nm Tightening Torque Aluminum Wheel 110 - 130 Nm 2. Release the parking brake. 3. Remove the bolts and the brake caliper. Installation Notice Be careful not to damage the brake hose.
  • Page 901 3D-8 REAR DRIVE AXLE 6. Remove the plug from the axle shaft flange and remove the inner shaft mounting nuts. Installation Notice Tightening Torque 50 - 65 Nm 7. Remove the axle shaft, parking brake lining and back plate assembly. 8.

  • Page 902: Axle

    REAR DRIVE AXLE 3D-9 AXLE Removal & Installation Procedure 1. Lift up the vehicle and support the frame safely. 2. Remove the axle shaft. 3. Remove the propeller shaft from the rear axle input shaft. Installation Notice Tightening Torque 81 - 89 Nm Notice Place alignment marks before removal.
  • Page 903 3D-10 REAR DRIVE AXLE 6. Separate the lower shock absorber from the axle housing. Installation Notice Tightening Torque 50 - 65 Nm 7. Remove the upper arm mounting nuts and remove the upper arm form the axle housing. Installation Notice Tightening Torque 150 - 180 Nm 8.

  • Page 904: Unit Repair

    REAR DRIVE AXLE 3D-11 UNIT REPAIR AXLE HOUSING Preceding Work : Removal of the axle shaft Removal of the axle housing 1 Drive Pinion Lock Nut ...... 240-310 Nm 17 Bolt ............ 87-124 Nm 2 Washer 18 Bearing 3 Companion Flange 19 Shim 4 Pinion Oil Seal 20 Ring Gear...
  • Page 905 3D-12 REAR DRIVE AXLE Disassembly Procedure 1. Remove the drain plug and drain the oil. Reinstall the drain plug. Tightening Torque 28 - 42Nm 2. Remove the axle housing cover. Notice Clean the cover and housing contact surface. 3. Remove the bearing cap bolts and remove the bearing caps. Pull out the differential carrier assembly.
  • Page 906 REAR DRIVE AXLE 3D-13 5. Remove the drive pinion lock nut. Disassemble the parts of the drive pinion. Assembly Procedure 1. Clean the all parts and check the followings. Check the ring gear and drive pinion for wear or damage. If damaged, replace it as set.
  • Page 907 3D-14 REAR DRIVE AXLE 4. Measure backlash of the side gear and pinion gear. Specified Value 0 - 0.05 mm 5. Install the differential carrier assembly into the axle housing. Tightening Torque of The 48 - 69 Nm Bearing Cap Bolts Notice Be careful no to change the caps.
  • Page 908 REAR DRIVE AXLE 3D-15 Inspection of Ring Gear Tooth Contact Pattern Normal Contact Apply gear-marking compound (prussian blue / red lead) on the ring gear teeth. Rotate the ring gear and check the tooth contact pattern. Abnormal Contact Tooth Contact pattern Possible Cause Remedy 1.
  • Page 909 3D-16 REAR DRIVE AXLE LSD (LIMITED SLIP DIFFERENTIAL) 1 Limited Slip Differential Assembly 9 Shaft, Hub (Right) 2 Shaft, Hub (Left) 10 Thrust Washer 3 Shim 11 Face Cam (Right) 4 Thrust Washer 12 Cage 5 Face Cam (Left) 13 Thrust Bearing 6 Cam Whillom 14 Plate Spring 7 Thrust Bearing...
  • Page 910 REAR DRIVE AXLE 3D-17 Inspection Remove the LSD assembly and check the pre-load torque. If necessary, replace LSD assembly. Procedure 1. Fix the right shaft of LSD to the special tool (A). 2. Install the special tool (B) to the left shaft and rotate counterclockwise and check the pre-load torque.
  • Page 911 SECTION 4A HYDRAULIC BRAKES Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

  • Page 912: Diagnosis

    4A-2 HYDRAULIC BRAKES DIAGNOSIS NOISE OR VEHICLE VIBRATION WHEN APPLIED BRAKE Check Action Incorrectly Mounted Back Plate or Caliper Repair Loosened Bolt of Back Plate or Caliper Retighten Crack or Uneven Wear of Brake Drum or Disc Replace Pad or Lining Sticking to Contact Surface Replace Excessive Clearance Between Caliper and Pad Repair...

  • Page 913: Increasing Pedal Stroke

    HYDRAULIC BRAKES 4A-3 INCREASING PEDAL STROKE (PEDAL GOES TO FLOOR) OR BRAKE DRAGGING Check Action Air in Brake system Bleeding Fluid Leaking Repair Excessive Clearance Between Push Rod and M/cylinder Adjust Parking Brake is not Fully Released Repair Incorrect Adjustment of Parking Brake Adjust Weak Return Spring of Brake Pedal Replace...

  • Page 914: Component Locator

    4A-4 HYDRAULIC BRAKES COMPONENT LOCATOR 1 Actuation Assembly (Booster + TMC) 7 Brake Hose 2 ABS Control Unit 8 Rear Tube 3 Master Cylinder 2nd Tube (Secondary) 9 Bolt ............25-35 Nm 4 Master Cylinder 1st Tube (Primary) 10 2-way Connector 5 Front Tube (LH) 11 3-way Connector 6 Front Tube (RH)

  • Page 915: Abs / Abd

    HYDRAULIC BRAKES 4A-5 ABS / ABD 1 Actuation Assembly (Booster + TMC) 6 Front Tube (RH) 2 Master Cylinder 1st Tube (Primary) 7 Rear Tube (RH) 3 Master Cylinder 2nd Tube (Secondary) 8 Rear Tube (LH) 4 Hydraulic Modulator 9 2-way Connector 5 Front Tube (LH)

  • Page 916: Non-Abs/Abd

    4A-6 HYDRAULIC BRAKES NON-ABS/ABD 1 Actuation Assembly (Booster + TMC) 5 2-way Connector 2 3-way Connector 6 Rear Tube 3 Front Tube (LH) 7 3-way Connector 4 Front Tube (RH) 8 LCRV...

  • Page 917: Maintenance And Repair

    HYDRAULIC BRAKES 4A-7 MAINTENANCE AND REPAIR ON-VEHICLE SERVICE BLEEDING THE BRAKES For Master Cylinder Replacement 1. Add oil after master cylinder replacement. 2. Run the engine and depress the brake pedal several times to build pressure and then keep the pedal fully depressed. 3.
  • Page 918 4A-8 HYDRAULIC BRAKES For Hydraulic Unit Replacement 1. Add oil after hydraulic unit replacement. 2. Run the engine and depress the pedal several times to build pressure and then keep the pedal fully depressed. 3. Loosen hydraulic pipe screws at the hydraulic unit outlets to bleed air.

  • Page 919: Brake Pedal

    HYDRAULIC BRAKES 4A-9 BRAKE PEDAL 1 Clevis Pin 8 Return Spring 2 Brake Pedal 9 Pedal Mounting Bracket 3 Stop Lamp Switch 10 Washer 4 Pad 11 Nut ............16-32 Nm 5 Nut ............21-35 Nm 12 Bolt ............8-18 Nm 6 Yoke Pin 13 Stopper Bolt ..........
  • Page 920 4A-10 HYDRAULIC BRAKES Removal & Installation Procedure 1. Remove the stop lamp switch connector. 2. Remove the clevis pin and disconnect the brake booster push rod. Notice Install in the upper hole (1), in case of Mando brake and in the below hole (2), incase of PBR brake. Install the snap pin fully in the hole of clevis pin.
  • Page 921 HYDRAULIC BRAKES 4A-11 Adjustment Procedure 1. Pedal Height Height (A) 150 mm (From the carpet) Notice If pedal height is not in specified value, loosen the stop lamp nut (B) and adjust the pedal height. 2. Pedal Stroke Mando : 138 mm Stroke (C) PBR : 132 mm Notice...

  • Page 922: Lcrv (Load Conscious Reducing Valve)

    4A-12 HYDRAULIC BRAKES LCRV (LOAD CONSCIOUS REDUCING VALVE) 1 Brake Tube (from the master cylinder) 5 LCRV Assembly 2 Brake Tube (from the rear brake) 6 Connecting Link 3 LCRV Bracket 7 Spring Washer 4 Bolt ............12 Nm 8 Nut ............14-18 Nm...
  • Page 923 HYDRAULIC BRAKES 4A-13 Construction LCRV consists of sensing part and hydraulic control part. 1. Sensing Part It detects the changes of vehicle height caused by vehicle load. It consists of load sensing spring and control lever which change according to vehicle load. 2.
  • Page 924 4A-14 HYDRAULIC BRAKES LCRV Setting Method 1. LCRV setting should be performed with unladen vehicle condition. 2. Install the connecting rod (a) to the No.1 hole. 3. Adjust the clearance “X” to be 0 mm and tighten the bolt (c) using the lock nut (b).
  • Page 925 SECTION 4B MASTER CYLINDER TABLE OF CONTENTS Specifications ......4B-1 On-Vehicle Service ..... 4B-2 Fastener Tightening Specifications .
  • Page 926 4B-2 MASTER CYLINDER MAINTENANCE AND REPAIR ON-VEHICLE SERVICE BOOSTER AND BRAKE MASTER CYLINDER MANDO 1 Nut ............14-22 Nm 9 Seal 2 Washer 10 Spacer 3 Master Cylinder Assembly 11 Nut ............8-18 Nm 4 Oil Level Sensor 12 Front Tube (LH) 5 Check Valve 13 Front Tube (RH) 6 Booster...
  • Page 927 MASTER CYLINDER 4B-3 Removal & Installation Procedure 1. Remove the oil level sensor connector. 2. Remove the tube from the master cylinder. Installatione Notice Tightening Torque 15 - 19 Nm Notice Be careful not to drop the oil when removing the tube. If the oil is dropped, promptly sweep up.
  • Page 928 4B-4 MASTER CYLINDER 6. Loosen the nut of booster and remove the booster from the dash panel. Installation Notice Tightening Torque 8 - 18 Nm 7. Installation should follow the removal procedure in the reverse order. 8. Add the fluid and bleed. 9.
  • Page 929 SECTION 4C POWER BOOSTER TABLE OF CONTENTS Specifications ......4C-1 On-Vehicle Service ..... 4C-2 General Specifications .
  • Page 930 4C-2 POWER BOOSTER MAINTENANCE AND REPAIR ON-VEHICLE SERVICE BOOSTER AND BRAKE MASTER CYLINDER MANDO 1 Nut ............14-22 Nm 9 Seal 2 Washer 10 Spacer 3 Master Cylinder Assembly 11 Nut ............8-18 Nm 4 Oil Level Sensor 12 Front Tube (LH) 5 Check Valve 13 Front Tube (RH) 6 Booster...
  • Page 931 POWER BOOSTER 4C-3 Removal & Installation Procedure 1. Remove the oil level sensor connector. 2. Remove the tube from the master cylinder. Installation Notice Tightening Torque 15 - 19 Nm Notice Be careful not to drop the oil when removing the tube. If the oil is dropped, promptly sweep up.
  • Page 932 4C-4 POWER BOOSTER 6. Loosen the nut of booster and remove the booster from the dash panel. Installation Notice Tightening Torque 8 - 18 Nm 7. Installation should follow the removal procedure in the reverse order. 8. Add the fluid and bleed. 9.
  • Page 933 POWER BOOSTER 4C-5 PEDAL STROKE INSPECTION 1. Start the engine and stop it after one or two minutes. Depress the brake pedal several times. If the pedal goes down furthest the first time, but gradually rises after the second or third time, brake booster is normal. If there is no change in pedal stroke, the brake booster is abnormal.
  • Page 934 SECTION 4D FRONT DISC BRAKES TABLE OF CONTENTS Specifications ......4D-1 Front Disc Brake ..... . . 4D-2 Unit Repair .

  • Page 935: Front Disc Brake

    4D-2 FRONT DISC BRAKES MAINTENANCE AND REPAIR ON-VEHICLE SERVICE FRONT DISC BRAKE Preceding Work : Removal of wheels and tires 1 Eye-Hose Bolt ........25-35 Nm 7 Front Disc Assembly 2 Gasket ........... Replace 8 Brake Pad 3 Brake Hose 9 Brake Hose and Nut ......
  • Page 936 FRONT DISC BRAKES 4D-3 Removal & Installation Procedure 1. MANDO Brake Remove the hose mounting nut and disconnect the hose. Installation Notice Tightening Torque 25 - 35 Nm 2. PBR Brake Remove the eye-hose bolt and disconnect the hose. Installation Notice Tightening Torque 15 - 18 Nm 3.
  • Page 937 4D-4 FRONT DISC BRAKES 5. Pull out the brake pads. Replace pads if necessary. Notice Always change the all pads on one wheel at a time. 6. Installation should follow the removal procedure in the reverse order. 7. Bleed the air from the system.
  • Page 938 FRONT DISC BRAKES 4D-5 UNIT REPAIR FRONT DISC BRAKE Inspection Procedure 1. Clean all components and visually check the followings. Check the cylinder and piston for wear, rust or damage. Check the caliper body and guide pin for wear, damage or crank.
  • Page 939 SECTION 4E REAR DISC BRAKES TABLE OF CONTENTS Specifications ......4E-1 Rear Disc Brake ..... . . 4E-2 Unit Repair .

  • Page 940: Rear Disc Brake

    4E-2 REAR DISC BRAKES MAINTENANCE AND REPAIR ON-VEHICLE SERVICE REAR DISC BRAKE Preceding Work : Removal of wheels and tires 1 Rear Brake Disc Assembly 7 Brake Hose 2 Brake Pad 8 Gasket ........... Replace 3 Brake Caliper 9 Eye-Hose Bolt ........15-18 Nm 4 Gasket ...........
  • Page 941 REAR DISC BRAKES 4E-3 Removal & Installation Procedure 1. Remove the eye-hose bolt and disconnect the hose. Installation Notice Tightening Torque 15 - 18 Nm 2. Unscrew the mounting bolts and remove the brake caliper assembly. Installation Notice Tightening Torque 85 - 105 Nm 3.
  • Page 942 4E-4 REAR DISC BRAKES UNIT REPAIR REAR DISC BRAKE Inspection Procedure 1. Clean all components and visually check the followings. Check the cylinder and piston for wear, rust or damage. Check the caliper body and guide pin for wear, damage or crank.
  • Page 943 SECTION 4F ANTILOCK BRAKE SYSTEM Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

  • Page 944: Schematic And Routing Diagrams

    4F-2 ANTILOCK BRAKE SYSTEM SCHEMATIC AND ROUTING DIAGRAMS...
  • Page 945 ANTILOCK BRAKE SYSTEM 4F-3...

  • Page 946: Component Locator

    4F-4 ANTILOCK BRAKE SYSTEM COMPONENT LOCATOR ABS, ABS/ABD 5.3 1 ABS/ABD Hydraulic Unit (with ECU in cose of ABS 4 ABS Warning Indicator Light only) 5 Diagnosis Connector 2 ABS/ABD ECU Unit (in case of ABD) 6 Front Wheel Speed Sensor 3 Rear Wheel Speed Sensor...

  • Page 947: Abd System Description

    ANTILOCK BRAKE SYSTEM 4F-5 ABD SYSTEM DESCRIPTION General: The Automatic Brake Differential Lock (ABD) is a traction system by means of brake intervention only, available in a low speed range (< 60kph). It workes on m-split roads with sidewise different friction coefficients. The spinning driven wheel is braked and the drive torque can be transferred to the wheel on the high- m side.
  • Page 948 4F-6 ANTILOCK BRAKE SYSTEM Temperature Model: ABD operation is a high thermal load for the brakes. To avoid any damages at the brakes, the disk temperature is calculated with a mathematical model for each driven wheel separately. After ignition on, the calculation starts with 30° C and then three different phases are evaluated separately and added: ABD operation, braking and coling phase.

  • Page 949: Self Diagnosis

    ANTILOCK BRAKE SYSTEM 4F-7 SELF DIAGNOSIS ABS, ABS/ABD 5.3 Initialization 1. Turn the ignition switch to "ON" position. 2. Using a service connector, ground the No.13 terminal of diagnosis socket and No.1 ground terminal for 3-4 seconds. Notice If it is over 5 seconds, initialization will not be performed. 3.
  • Page 950 4F-8 ANTILOCK BRAKE SYSTEM Diagnosis the Flash Code [Ex] Time Differences of Normal Code 01 : TW1<T<Te<TW2 Time Differences of Fault Code 15 : TW1<T<Te<TW2 Time Characteristics 1. Initialization Tba < 5.0 sec. Tba 1.8 - 2.2 sec. 2. Output of Fault Code TW1 = 1.8 - 2.2 sec.

  • Page 951: Defect Codes

    ANTILOCK BRAKE SYSTEM 4F-9 DEFECT CODES Defect Code Application Description Normal Defective ECU Replace the ECU Front/left Wheel Speed Check resistance of the wheel speed sensor : 1.280KW Sensor (Wire) - 1.920KW Check wire for ground and open. Replace the sensor. Front/right Wheel Speed Check resistance of the wheel speed sensor : 1.280KW Sensor (Wire)
  • Page 952 4F-10 ANTILOCK BRAKE SYSTEM Description Defect Code Application output voltage > 70 mV - When measured in oscilloscope : output voltage ³ 120 mV/P-P Replace the sensor. Check wire for ground and open. Rear/left Wheel Speed Check connection of the wheel speed sensor con- Sensor (Signal) nector and ECU side connector.
  • Page 953 ANTILOCK BRAKE SYSTEM 4F-11 Description Application Defect Code Check each valve by using SCANER's solenoid valve Front / left INLET Valve overriding function. Check connection of connector and terminals in the ECU hydraulic modulator. Check each valve by using SCANER's solenoid valve Front / left OUTLET Valve overriding function.
  • Page 954 4F-12 ANTILOCK BRAKE SYSTEM Description Defect Code Application (When connector is removed) Replace the hydraulic modulator. Check each valve by using SCANER's solenoid valve Rear / right OUTLET Valve overriding function. Check connection of connector and terminals in the ECU hydraulic modulator. Check terminals for open or short.
  • Page 955 ANTILOCK BRAKE SYSTEM 4F-13 Application Defect Code Description when switch knob (planger) is pressed by 3mm : ¥ - Each ends resistance value of the switch when switch knob(plunger) is not pressed : less than 200 mW When brake is applied : ECU (ABS:No.14, ABD:No.48) terminal 11 - 14 V or VBattery.
  • Page 956 4F-14 ANTILOCK BRAKE SYSTEM Application Defect Code Description Check connection between connectors. Acceleration Sensor Signal (Signal) Check relevant wires for open or short. (When connector is removed) Check and replace the acceleration sensor. Replace the ECU. Check voltage between ECU side ground (ABD:No.1, ABS:No.15 pin) and acceleration sensor side ground (ABD:No.1, ABS:No.15 pin / ECU side ABD:No.39, ABS:No.30 pin)

  • Page 957: Maintenance And Repair

    ANTILOCK BRAKE SYSTEM 4F-15 MAINTENANCE AND REPAIR ON-VEHICLE SERVICE WHEEL SPEED SENSOR 1 Bolt 4 Bolt 2 Front Wheel Speed Sensor 5 Rear Wheel Speed Sensor 3 Knuckle 6 Rear Axle...
  • Page 958 4F-16 ANTILOCK BRAKE SYSTEM Removal & Installation Procedure ABS Hydraulic Unit 1. Release the ABS wiring connector locking lever in arrow direction and remove the connector. Notice Do not force the connector when releasing in arrow direction. For installation of the connetor, align and firmly seat the connector of the hydraulic unit and wiring connector while keeping the locking lever upward and then push it down.

  • Page 959: Hydraulic Circuit

    ANTILOCK BRAKE SYSTEM 4F-17 HYDRAULIC CIRCUIT ABS 5.3 Pressure Increased 6 Accumulator Chamber 1 Master Cylinder 7 Inlet Valve for Each Wheel 2 Hydraulic Unit 8 Outlet Valve for Each Wheel 3 Damping Chamber 9 Front Wheel 4 Return Pump 10 Rear Wheel 5 Return Pump Motor...
  • Page 960 4F-18 ANTILOCK BRAKE SYSTEM Pressure Decreased 1 Master Cylinder 6 Accumulator Chamber 2 Hydraulic Unit 7 Inlet Valve for Each Wheel 3 Damping Chamber 8 Outlet Valve for Each Wheel 4 Return Pump 9 Front Wheel 5 Return Pump Motor 10 Rear Wheel...
  • Page 961 ANTILOCK BRAKE SYSTEM 4F-19 Pressure Maintained 1 Master Cylinder 6 Accumulator Chamber 2 Hydraulic Unit 7 Inlet Valve for Each Wheel 3 Damping Chamber 8 Outlet Valve for Each Wheel 4 Return Pump 9 Front Wheel 5 Return Pump Motor 10 Rear Wheel...
  • Page 962 4F-20 ANTILOCK BRAKE SYSTEM ABS/ABD 5.3 Pressure Increased 1 Master Cylinder 7 Inlet Valve for Each Wheel 2 Hydraulic Unit 8 Outlet Valve for Each Wheel 3 Damping Chamber 9 Wheel 4 Return Pump 10 Prime Valve (ASV) 5 Return Pump Motor 11 Pilot Valve (USV) 6 Accumulator Chamber 12 Check Valve...
  • Page 963 ANTILOCK BRAKE SYSTEM 4F-21 Pressure Decreased 1 Master Cylinder 7 Inlet Valve for Each Wheel 2 Hydraulic Unit 8 Outlet Valve for Each Wheel 3 Damping Chamber 9 Wheel 4 Return Pump 10 Prime Valve (ASV) 5 Return Pump Motor 11 Pilot Valve (USV) 6 Accumulator Chamber 12 Check Valve...
  • Page 964 4F-22 ANTILOCK BRAKE SYSTEM Pressure Maintained (Hold) 1 Master Cylinder 7 Inlet Valve for Each Wheel 2 Hydraulic Unit 8 Outlet Valve for Each Wheel 3 Damping Chamber 9 Wheel 4 Return Pump 10 Prime Valve (ASV) 5 Return Pump Motor 11 Pilot Valve (USV) 6 Accumulator Chamber 12 Check Valve...

  • Page 965: Fastener Tightening Specifications

    SECTION 4G PARKING BRAKE Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

  • Page 966: Component Locator

    4G-2 PARKING BRAKE COMPONENT LOCATOR PARKING BRAKE 1 Parking Brake Lever 5 Nut 2 Bolt ............8-18 Nm 6 Bolt ............8-18 Nm 3 Front Parking Brake Cable 7 Rear Parking Brake Cable 4 Equalizer 8 Brake Disc...

  • Page 967: Maintenance And Repair

    PARKING BRAKE 4G-3 MAINTENANCE AND REPAIR ON-VEHICLE SERVICE PARKING BRAKE Removal & Installation Procedure 1. Disconnect the parking brake indicator switch connector. 2. Disconnect the right and left cable from equalizer while parking brake lever is released. 3. Unscrew 8 bolts and remove the parking brake lever assembly.
  • Page 968 4G-4 PARKING BRAKE 5. Remove the retainer with a screwdriver and disconnect the brake cable. 6. Installation should follow the removal procedure in the reverse order.
  • Page 969 SECTION 5A AUTOMATIC TRANSMISSION TABLE OF CONTENTS Specifications ......5A-2 Bands ......5A-45 One Way Clutches .

  • Page 970: Specifications

    5A-2 AUTOMATIC TRANSMISSION SPECIFICATIONS MODEL PART NUMBERS AND APPLICATIONS Torque Converter DWMC P/NO Transmission Engine Version 36100-05420 (1) 0574-000001 (9) 661LA 179K 160K 36100-05430 (1) 0574-000002 (8) 36100-05410 (1) 0574-000004 (10) 662LA(Turbo) 160K 179K 36100-05440 (1) 0574-000005 (7) MODEL SPECIFICATIONS Application Descriprtion Torque Converter...

  • Page 971: Clutch Pack Details

    AUTOMATIC TRANSMISSION 5A-3 CLUTCH PACK DETAILS 0574-000001, 0574-000004, 0574-000002 0574-000005 Composition 6(2) 5(2) Steel Composition 5(2) Steel 4(2) Composition 5(2) Steel 4(2) Composition 4(1) Steel 4(1) Note : Numbers in brackets indicate number of selective thickness steel plates required to achieve specifed clutch pack clearance...

  • Page 972: Special Tools

    5A-4 AUTOMATIC TRANSMISSION SPECIAL TOOLS SPECIAL TOOLS TABLE Part Number Description 0555 - 332083 Solenoid / Thermistor, Electronic Tester 0555 - 336046 Solenoid, Bench Tester 0555 - 336256 Transmission Bench Cradle 0555 - 336257 Pump Puller 0555 - 336258 Pin Remover / Installer Tool (Cross Shaft / Detent Lever) 0555 - 336259 Clutch Spring Compressor 0555 - 336260...

  • Page 973: Schematic And Routing Diagrams

    AUTOMATIC TRANSMISSION 5A-5 SCHEMATIC AND ROUTING DIAGRAMS...
  • Page 974 5A-6 AUTOMATIC TRANSMISSION...

  • Page 975: Shift Pattern Diagram

    AUTOMATIC TRANSMISSION 5A-7 SHIFT PATTERN DIAGRAM 661LA NORMAL MODE...

  • Page 976: 661La Power Mode

    5A-8 AUTOMATIC TRANSMISSION 661LA POWER MODE...

  • Page 977: 662La Normal Mode

    AUTOMATIC TRANSMISSION 5A-9 662LA NORMAL MODE...

  • Page 978: 662La Power Mode

    5A-10 AUTOMATIC TRANSMISSION 662LA POWER MODE...

  • Page 979: 662La Low Mode

    AUTOMATIC TRANSMISSION 5A-11 662LA LOW MODE...

  • Page 980: E32 Power Mode

    5A-12 AUTOMATIC TRANSMISSION E32 POWER MODE...

  • Page 981: E32 Normal Mode

    AUTOMATIC TRANSMISSION 5A-13 E32 NORMAL MODE...

  • Page 982: E32 Low Mode

    5A-14 AUTOMATIC TRANSMISSION E32 LOW MODE...

  • Page 983: E23 Power Mode

    AUTOMATIC TRANSMISSION 5A-15 E23 POWER MODE...

  • Page 984: E23 Normal Mode

    5A-16 AUTOMATIC TRANSMISSION E23 NORMAL MODE...

  • Page 985: E23 Low Mode

    AUTOMATIC TRANSMISSION 5A-17 E23 LOW MODE...

  • Page 986: Introduction

    5A-18 AUTOMATIC TRANSMISSION INTRODUCTION The BTR Automotive Model 74 Four Speed Automatic Transmission is an electronically controlled overdrive four speed unit with a lock-up torque converter. The lock-up torque converter results in lower engine speeds at cruise and eliminates unnecessary slippage. These features benefit the customer through improved fuel economy and noise reduction.
  • Page 987 AUTOMATIC TRANSMISSION 5A-19 Figure 1.1 - Conventional VS Electronic Transmission Control System...

  • Page 988: Operator Interfaces

    5A-20 AUTOMATIC TRANSMISSION OPERATOR INTERFACES There are three operator interfaces associated with the four speed transmission. They are: The gear select lever The driving mode selector The indicator light These operator interfaces are described below. GEAR SELECT LEVER OPERATION The transmission uses a conventional selector lever. The selector lever can be moved from one position to another within the staggered configuration of the selector lever gate to positively indicate the gear -selection as shown on figure 2.1.

  • Page 989: Driving Mode Selector

    AUTOMATIC TRANSMISSION 5A-21 Table 2.1 - Gear Selections Inhibited Above Downshift Type First gear operation only with inhibited engagement as a function of vehicle RANGE ‘1’ (MANUAL ‘1’): speed. Engine braking is applied with reduced throttle. First and second gear operation with inhibited engagement of second gear, as RANGE ‘2’...

  • Page 990: Control Systems

    5A-22 AUTOMATIC TRANSMISSION CONTROL SYSTEMS GENERAL There are two control systems associated with the transmission. The electronic control system monitors vehicle parameters and adjusts the transmission performance. The hydraulic control system implements the electronic control system commands. ELECTRONIC CONTROL SYSTEM The electronic control system is comprised of sensors, a TCU and seven solenoids.
  • Page 991 AUTOMATIC TRANSMISSION 5A-23 Table 3.1 - Temperature / Resistance Characteristics Temperature (° ° ° ° ° C) Resistance (Ohms) Minimum Maximum 13,638 17,287 5,177 6,616 2,278 2,723 135 (Overheat Mode Threshold) Figure 3.2 - Temperature / Resistance Characteristics...
  • Page 992 5A-24 AUTOMATIC TRANSMISSION Transmission Control Unit(TCU) The TCU is an in-vehicle micro-processor based transmission management system. It is usually mounted in the vehicle cabin, under the instrument panel, under the seat, behind the side kick panels or under the floor in the footwell on the passenger side.
  • Page 993 AUTOMATIC TRANSMISSION 5A-25 If the transmission sump temperature exceeds 135°C, the TCU will impose converter lock-up at lower vehicle speeds and in some vehicles flashes the mode indicator lamp. This results in maximum oil flow through the external oil cooler and eliminates slippage in the torque converter. Both these actions combine to reduce the oil temperature in the transmission.
  • Page 994 5A-26 AUTOMATIC TRANSMISSION Throttle Position Sensor The throttle position sensor(TPS) is a resistance potentiometer mounted on the throttle body of the engine. It transmits a signal to the TCU proportional to the throttle plate opening. The potentiometer is connected to the TCU by three wires: 5 volts positive supply, earth and variable wiper voltage.
  • Page 995 AUTOMATIC TRANSMISSION 5A-27 Table 3.3 - Readings for Resistance/Shift Lever Positions Shift Lever Position Resistance (OHMS) 1k - 1.4k Manual 1 Manual 2 1.8k - 2.2k 3k - 3.4k Manual 3 Drive 4.5k - 4.9k 6.8k - 7.2k Netural 10.8k - 11.2k Reverse Park 18.6k - 19k...
  • Page 996 5A-28 AUTOMATIC TRANSMISSION Table 3.4 - Solenoid States and Functions Solenoids 1 and 2 S1 and S2 are normally open On/off solenoids that set the selected gear. These solenoids determine static gear position by operating the shift valves. Refer to table 3.5. Note that S1 and S2 solenoids also send signal pres- sure to allow or prohibit rear band engagement.
  • Page 997 AUTOMATIC TRANSMISSION 5A-29 Table 3.6- Solenoid Operation During Gearshifts Shift To Initiate Shift Typical S5 Current Ramp To Complete Shift S1 OFF 750mA to 600mA S4 OFF S4 ON S1 OFF S3 OFF S2 OFF 850mA to 750mA S4 OFF S3 ON S4 ON S2 OFF...
  • Page 998 5A-30 AUTOMATIC TRANSMISSION Solenoid Valve Symbols (On/off Solenoids) The solenoid symbol shown adjacent to each solenoid on the hydraulic system schematics indicates the state of the oil flow through the solenoid valve with the power On or 0ff. Refer to figure 3.6 for the On/off operational details of NO solenoid valves.

  • Page 999: Hydraulic Control System

    AUTOMATIC TRANSMISSION 5A-31 K-Line The K-line is typically used for obtaining diagnostic information from the TCU. A computer with a special interface is connected to the TCU and all current faults, stored faults, runtime parameters are then available. The stored fault codes can also be cleared.
  • Page 1000 5A-32 AUTOMATIC TRANSMISSION Figure 3.7 - Hydraulic Control Circuit...

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