Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. 501 must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.
SENRQ778-02 Table of Contents Specifications Section Engine Design Fuel Injection Lines 85 Fuel Injection Pump (Delphi DP210 DPA and DPG fuel injection pumps) Fuel Injection Pump (Bi engines only) Fuel Injection Pump (Delphi STP) Fuel Injectors... Fuel Transfer Pump Lifter Group .. Rocker Shaft Valve Meghan Cylinder Head Valves Cylinder Head . Turbocharger .. Exhaust Manifold Camshaft Camshaft Bearings Engine Oil Filter . Engine Oil Pump Engine Oil Pressure Engine Of Bypass Valve Engine Oil Pan...
4 Specifications Section SENGHOR-02 Specifications Section 02198693 Engine Design Four Cylinder Engine (O08 OF hia Eee Illustration 1 GU0054251 Cylinder and valve location (A) Inlet valve (B) Exhaust valve Bore 105 mm {4.133 inch} SHOE co.cc 127 mm {8.000 inch) Displacement 4.4L (289 in* Cylinder arrangement In-line Type of combustion Direct injection Compression ratio Naturally aspirated engines Turbocharged engines . Turbocharged engines . Number of cylinders Valves per cylinder cine .
BENEFACTOR-02 When the camshaft is viewed from the front of the engine, the camshaft rotates in the following diction: ooh cross. Clockwise The front of the engine is opposite the flywheel end. The left side and the right side of the engine are viewed from the flywheel end. The No. 1 cylinder is the front cylinder. 01814111 Fuel Injection Lines 400873488 illustration 3 Atypical fuel line (1) Tighten the union nuts for the fuel injector to the following torque.
Specifications Section SENGHOR-02 Note: The support bracket must be installed after the coolant pump Is installed. in order to stop the distortion of the timing case, finger tighten the bolt {4) and then tighten the nut and bolt (5). Tighten the bolt (4). Tighten the bolts that hold the fuel pump to the front housing to the following torque. Delphi DPA The DPA injection pump has a support bracket that is similar to the DP 210 injection pump.
SENR9778-02 Loosen the bolt and place spacer (3) behind docking screw (2). Tighten the bolt to the following TOQUE. vexes LC A2ZNmM (9 bt) The lift of the ER fuel injection pump plunger ” 1.68 mm {0.0810 inch) Illustration § GO0Y8RA0E Instated VEEP fuel injection pump (4) Tighten the plug for the fuel injection pump plunger to the following torque. Illustration 9 GO098G29S Support bracket Note: The support bracket must be installed after the coolant pump is installed.
8 Specifications Section Illustration 1 go0sass3Y Support bracket {4) Tighten the mounting bolt to the following TOQUE. ceoviriniiserrics 44 Nem Tighten the mounting bolt and the nut to the following torque, 22 Nem (18 1b ft) Note: The support bracket must be installed after the coolant pump is installed, In order to stop the distortion of the timing case, finger tighten the bolt {4) and then tighten the nut and bolt (5). Tighten the bolt (4).
SENSOR-02 Note: Tighten the fuel filter bow! by hand. Rotate the bowl 1/8 of a turn more by hand. iD1714183 Lifter Group illustration: 14 900623433 {1} Diameter of the lifter body 18.99 to 19.01 mm (0.7475 to 0.7486 inch) Clearance of the lifter in the cylinder block bore 0.04 t0 0.09 mm {0.0015 to 0.0037 inch) 01892700 Rocker Shaft Note: The rocker shaft assembly for the 3 cylinder engine and the rocker shaft assembly for the 4 cylinder engine use the same components.
10 Specifications Section 101948595 Valve Mechanism Cover The Cover for the Four Cylinder Engine Illustration 16 900808011 Cover Tighten the bolts for the valve mechanism cover in the sequence that is shown to the following torque. Nm (7 1b) The Cover for the Three Cylinder Engine illustration 17 901018518 Cover SENR9778-02 Tighten the bolts for the valve mechanism caver in the sequence that is shown to the following TOQUE.
SENSOR-02 Outside diameter of the inlet valve QUITE iii 13.034 to 13.047 mm (0.5131 to 0.5137 inch) Interference fit of valve © guide | in cylinder head .. . 0.007 16 0.047 mm “(o: 0003 to 0.0018 inch) Length of Valve guide 51.00 to 51.50 mm 2.018 to 2.027 inch) Projection of the valve guide above the valve Spring recess (2) .comedienne 12.36 16 12.65 mm (0.486 to 0.498 inch) Note: When new valve guides are installed, new valves and new valve seat inserts must be installed.
12 Specifications Section SENGHOR-02 Recess for Exhaust Valve Seat for Naturally Aspirated Engines 9.810 to 10.040 mm (0.3901 to 0.3952 inch) 420 to 42.445 mm “ 6701 to 1.6711 inch) (C) Maximum radius 0.38 mm (0.015 inch) Recess for inlet Valve Seat for Turbocharged Engines [CT 10.910 to 11.040 mm (0.4295 to 0.4346 inch) (B) one 47.820 to 47.845 mm (C) Maximum radius {1.8826 to 1.8836 inch) 0.38 mm (0.015 inch) Recess for Exhaust Valve Seat for Turbocharged Engines (AY corers, 10.910 to 11.040 mim {0.
SENSOR-02 270 Degrees 225 Degrees lust ration 22 900802621 The head bolts require an additional torque turn procedure. The numbers (1, 3, 4) are three long cylinder head bolts. All the other bolts are short bolts, The tightening sequence is shown in the Frustration . Place the angle gauge on the top of each bolt head. Tighten the short bolts to the additional AMOUNT. ..rhetorician rears 225 degrees Place the angle gauge on the top of each bolt head. Tighten the long belts for the additional MOUNT.
14 Specifications Section SENGHOR-02 {4} Tighten the nuts to the following torque. Tighten the bolt to the following torque. Tighten the bolt to the following torque. 22 N'-m (16 1b ft) The maximum test pressure for the waste QA een 205 kPa (30 psi) The movement for the rod actuator Imm (0.0394 inch) Four Cylinder Engine Table 4 The part number for The pressure for the the turbocharger waste gate 2674A200 100 + 5 kPa (14.5040 + 0.7252 psi) 2674A201 110 £ 5 kPa (15.9544 + 0.
SENSORY-02 Three Cylinder Engine (Frustration 27 401017008 Note: The exhaust manifold must be aligned to the cylinder head. Refer to the Disassembly and Assembly manual. Tighten the exhaust manifold bolts in the sequence that is shown illustration 27 to the following torque... 33N'm (24 1b f) 01956585 Camshaft illustration 28 900987750 Checking the end play of the camshaft {1} End play of a new camshaft 0,10 to 0.55 mm (0.004 to 0.022 inch) Maximum permissible end play of a wom camshaft 0.60 mm {0.
16 Specifications Section ‘Table 7 1103 Diameters of Camshaft Journals Camshaft Journals Standard Diameter 1 50.71 to 50.74 mm (1.9965 to 1.9875 inch) 50.46 to 50.48 mm 2 {1.9865 to 1.9875 inch) 3 50.48 to 50.48 mm (1.9885 to 1.9875 inch} 4 49.95 to 49.98 mm (1.9665 to 1.9675 inch) Maximum wear on the camshaft journals 0.05 mm {0.0021 inch) SENR9778-02 1. Measure the camshaft lobe height (8). 2. Measure the base circle (7). 3.
SENSOR-02 17 Specifications Section Frustration 32 A three cylinder engine {1} Camshaft bearing The diameter for the installed camshaft DEANN overrun 50.790 to 50.850 mm {1.9996 to 2.0020 inch} 01956095 Engine Oil Filter Spin-on Oil Filter Illustration 33 900816984 {1) Seal Note: Lubricate the top of the seal with clean engine oil before installation. TYPE rivet Full flow Pressure to open engine oil filter bypass Valve eerie.
18 Specifications Section SENGHOR-02 Illustration 35 600950248 The oil pump for the balance (1) Clearance of the outer rotor fo the body .. 0.130 to 8.24 mm (0.0050 to 0.0084 inch) Illustration 36 009892236 inner rotor {2) Clearance of inner rotor to outer rotor .. 0.050 to 0.200 mm (0.0020 to 0.0079 inch) frustration 37 00688217 The end play for the rotor (3) End play of rotor assembly Inner rotor 0.04 0 0.91 mm {0.0016 to 0.0043 inch) 0.04 to 0.00 mm 0.0016 to 0.
SENDER-02 Illustration 39 400989519 Idler gear and pump gear Note: Replace the idler gear bolt (5) and the nut for the oil pump gear (6). (5) Tighten th the idler gear bolt to the following torque, ern Ww 2ND-m (181b ft) Note: Set the engine to the TC position, Refer to Testing and Adjusting , "Finding Top Center Position for No. 1 Piston”. Install the balance. Refer to the Disassembly and Assembly manual. Install the gear for the oil pump and tighten the nut (6).
20 Specifications Section SENGHOR-02 01958107 Engine Oil Bypass Valve Installed in the Oil Pump Frustration 43 00919893 Typical engine ofl pump Frustration 44 900921877 Relief valve and spring (1) Tighten the plug for the relief valve to the following torque. 35N-m Plunger Diameter of the plunger 19.186 to 19.211 mm (0.7554 to 0.7563 inch) Clearance of plunger in bore .. 0.0390 0.114 mm (0.0015 to 0.
SENR9778-02 21 Specifications Section 102242667 Engine Oil Pan Front sealant Illustration 47 Applying sealant (1) Apply 1861108 Power part silicone rubber sealant to the cylinder block and fo the timing case. Note: Apply a sealant bead of 3.5 mm (0.1378 inch} that is shown in illustration 47. Rear sealant Note: install the rear oil seal before sealant is applied to the bridge. frustration 48 900990255 Applying sealant (2) Apply 1861108 Power part silicone rubber sealant to the bridge.
22 Specifications Section SENSOR-02 The cast iron oil pan Illustration 50 The cast iron off pan Note: The rear face of the cast iron oil pan (5) must be aligned to the rear face of the cylinder block. (8) The maximum allowed value of the rear face misalignment... 0.1 mm (0.0038 inch } (6) Bok Tighten the front four bolts. Refer to illustration 49. Tighten the remaining bolts and the nuts that fasten the engine oil pan to the cylinder block to the following torque. Note: The sealant is applied to new bolts.
SENSOR-02 {3) Screws Tighten the screws for the cover plate with a plastic valve mechanism cover to the following torque. Tighten the screws for the cover plate with a metal valve mechanism cover to the following torque. Diaphragm (8) Cap {8} Spring 900926200 Frustration 53 (7) Owing Note: Apply 21820221 Power part red rubber grease to the O-ring before installing the breather pipe in the valve mechanism cover. {8) Tighten the bolts that secure the breather pipe to the cylinder head to the following torque.
24 Specifications Action SENSOR-02 Water Temperature Regulator Frustration 56 900906121 A typical water temperature regulator Opening temperature 79°16 84°C {174 * fo 151 °F) Ult opening temperature 93 °C {199 °F) Minimum stroke at full open temperature 10 mm (0.3937 inch) 01904383 Water Pump Illustration 57 goCs16851 Tightening sequence Note: Apply 21820117 Power part threadlike nut lock to the first three threads of the bolts before installation.
SENGHOR-02 Diameter of the bore in the cylinder block for the number 2 camshaft Journal 50.546 to 50,597 mm (1.9900 to 1.9920 inch) Diameter of the bore in the cylinder block for the number 3 camshaft journal 50.038 to 50.089 mm .9700 to 1.9720 inch) (4) Main bearings for the four cylinder engine Bore in the cylinder block for the main bearings 80.416 to 80.442 mm (3.1660 to 8.
Specifications Section Diameter of the bore in the cylinder block for the number 3 camshaft Journal cnn, 50.5486 to 50.597 mm (1.9900 to 1.9920 inch) Diameter of the bore in the cylinder block for the number 4 camshaft Journal 50.038 to 50.089 mm (1.8700 to 1.9720 inch) (11) Main bearings for the three cylinder engine Bore in the cylinder block for the main DEBATING cove Irene 80.416 to 80.442 mm {3.1660 to 3.
SENDER-02 27 Specifications Section 2.4510 2.50 mm Oversize thickness (0.097 to 0.098 inch} {3} The crankshaft gear Maximum permissible temperature of the gear for installation on the crankshaft 180 °C (356 °F) Note: The timing mark is toward the outside of the crankshaft when the gear is installed on the crankshaft. Note: All new turbocharged engines and turbocharged aftercare engines have crankshafts that are nitrocellulose.
28 Specifications Section SENSOR-02 Table & The undersized diameter of the Crankshaft Journals NUMBER 0.25 mm {0.010 inch) 0.51 mm (0.020 inch} 0.76 mm (0.030 inch) 1 75.909 mm (2.9885 inch) to | 75.648 mm (2.9783 inch) to | 75.399 mm (2.9685 inch} to 75.930 mm (2.9894 inch} 75.670 mm (2.9791 inch) 75.420 mm (2.3693 inch) 2 63.220 ram (2.4890 inch) to | 82.960 mm (2.4787 inch} io | 62.708 mm (2.4688 inch) to 63.240 mim {2.4898 inch) 82.982 mm (2.4796 inch) 62.728 mm {2.4896 inch) 39.47 mm 3 (1.
30 Specifications Section SENGHOR-02 Table 10 The undersized diameter of the Crankshaft Journals 3.96 mim (0.1589 inch) NUMBER 0.25 mm (0.010 inch) 0.51 mm {0.020 inch) 0.76 mm {0.030 inch) 9 75.926 mm (2.9802 inch) fo | 75.672 nim (2.9792 inch) to | 75.418 mm (2.9692 Inch) to 75.906 mm (2.9884 inch} 75.851 mm (2.9784 inch) 75.397 mm (2.9684 inch) 2 63.236 mm (2.4896 inch) to | 62.982 mm (2.4796 inch) to | 62.728 mm (2.4696 inch) to 63.216 mm {2.4888 inch) 62.862 mm (2.4788 inch) 62.708 mm {2.4688 inch) 39.
SENRQ778-02 400915076 [lust ration 66 (5) Tighten bolts 1, 2, 3,4, 5,6, 7, and 10 in the sequence that is shown in illustration 66 to the following torque. ...nonviolence ec 22 Nem (16 I 1} Remove the alignment tool, Tighten bolts 8 and 9 in the sequence that is shown in illustration 66 to the following torque. 01958137 Connecting Rod Bearing Journal Refer to the Specifications Module, “Crankshaft” topic for information on the undersized crankshaft journals.
32 Specifications Section SENSORY-02 01950155 Connecting Rod Nucleation 87 LOYALTIES The mating surfaces of the connecting rod are produced by hydraulically fracturing the forged connecting rod. (1) Tighten the tor screws for the connecting rod to the following torque. Tighten the tor screws for the connecting rod again to the following torque. TON'-m (52 Ib ft) Tighten the tor screws for the connecting rod for an additional 120 degrees.
SENORITA-02 Illustration 68 400807744 (3) Diameter of the parent bore for the piston pin... 43.01 to 43.04 mm (1.693 to 1.694 inch) (4) Distance between the parent bores [. 219.05 to 219.10 mm (8.624 to 8.626 inch) (8) Diameter for the parent bore for the connecting rod bearing 87.2110 67.22 mm {2.6480 to 2.6465 inch) 33 Specifications Section Treble 14 Length Grades for Connecting Rods Grade Letter | Color Code Length {Y) 185.728 to 165.761 mm F Red (6.5247 to 6.5260 inch) 165.682 0 165.715 mm (6.
34 Specifications Section Ring 08D ov vrmeeccrninennins 0.30 to 0.55 mm K .0118 to 0.0216 inch) Note: When you install a new top compression ring, make sure that the word “TOP” is facing the top of the piston. New top piston rings have a red identification mark which must be on the left of the ring end gap when the top piston ring is installed on an upright piston. {2} Intermediate compression ring The shape of the intermediate compression NG is .
SENR9778-02 Piston Cooling Jet Alignment Frustration 73 401008929 (2) Piston cooling jet (3) Red {4} Cylinder block Use the following procedure in order to check the alignment of the piston cooling jet. 1. Insert rod (3) inch the end of the piston cooling jet (2). Rod (3) has a diameter of 1.70 mm {0.067 inch). Rod (3) must protrude out of the top of the cylinder block. 2. Dimension (A) is 55.25 mm (2.1752 inch) and dimension (0.5512 inch}.
36 Specifications Section 01912958 Gear Group (Front) The 1104 mechanical engines use two types of fuel injection pumps. The fuel injection pump can be either a Delphi 210 fuel injection pump or a Bosch EVE fuel injection pump. Illustration 76 90235886 Gear train {1} Fuel injection pump drive gear Tighten the nut to the following torque. Release the lock on the fuel injection pump shaft. Torque the nut to the following torque. Number of teeth .
SENR9778-02 Bore diameter of crankshaft gear .. 47.625 to 47.650 mm (1.8750 to 1.8760 inch) Outside diameter of crankshaft AUD err inn 47.625 to 47.645 mm {1.8750 to 1.8758 inch) Clearance of gear on crankshaft -. 0.020 to +0.020 mm to +0.0008 inch) Number of teeth cocoon 34 {5} Oil pump idler gear inside diameter of oil pump idler gear bearing co.cc 16.012 to 16,038 mm (0.6304 to 0.6314 inch} Outside diameter of oil pump idler gear Shaft cee 15.966 to 15.984 mm {0.6286 to 0.
38 Specifications Section 2234222 Flywheel Frustration 79 00584712 Standard flywheel (1) Flywheel ring gear Heat the flywheel ring gear! to the following temperature. . 250 °C (480 °F) Note: Do not use an oxyacetylene torch to heat the flywheel ring gear. (2) Flywheel (3) Lott Tighten the flywheel halts to the following TOQUE. eerie L105 Nem (77 th ft) Non-standard flywheel Note: A special flywheel is aligned to a dowel on the crankshaft.
SENRQ778-02 Note: Lubricate the threads of the bolts with clean engine oil before installation. {1) Tighten the three bolts for the crankshaft pulley to the following torque. 115 Note: Recheck the torque of the bolts (1) twice. {2) Thrust block (3) Crankshaft pulley Non-standard pulley Illustration 82 0126584 (1) T Mark (2) Alignment mark Note: The marks (1 and 2) on the pulley must he vertical when the pulley is installed on the engine. Number one piston of the engine must be at top dead center.
40 Specifications Section SENRQ778-02 01968387 Alternator 12 Volt and 24 Volt Alternator hesitation TT Gl0gEe541 A typical alternator (1) Tighten terminal nut *W" to the following TOQUE. oii 2Nm{17 bin) (2) Tighten terminal nut “D+" to the following TOQUE. rein 4.3 Nm {bin) (3) Tighten terminal nut “B+” to the following torque. ooo 43 Nm (38 bin) tighten 1 the '¢ pulley n nut ut (not shown) to the following torque. .. . 80N-m (59h ft) Alignment of the alternator pulley to the crankshaft Pulpy oie 0.
SENSOR-02 1958653 Starter Motor 24 Volt Starter Motor 41 Specifications Section Frustration 85 The 24 volt starter motor which shows the electrical connections (1) Tighten the negative terminal nut to the following Torque. vices Tighten the positive terminal nut to the following torque. L21Nm (5b) (3) Tighten the solenoid terminal to the following TORQUE. Rated VOYAGE career 24 volts Pull in voltage .
42 Specifications Section 12 Volt Starter Motor SENDER-02 Illustration 86 The 12 volt starter motor which shows the electrical connections (1) Tighten the solenoid terminal to the following torque. ee. . (2) Tighten the positive terminal nut to the following torque. ee GNM Tighten the negative terminal nut to the following Torque.
SENDER-02 Index A Alternator 12 Vito and 24 Vat Alternator V-Belt.. rrr Cc Camshaft Camshaft Bearings. Connecting Rod... Connecting Rod Bearing Journal. Crankcase Breather... Engine model DK and D. Crankshaft Crankshaft Pulley Non-standard pulley Crankshaft Seals Cylinder Block.. Four Cylinder Engine .. Three Cylinder Engine Cylinder Four Cylinder engine: 12 Four Cylinder Engine . 13 Three Cylinder engine. 12 Three Cylinder Engine 13 Cylinder Head Valves . E Engine Design Four Cylinder Engine ..
Starter Motor. 12 Volt Start 24 Vito Starter Motor T Table of Contents. Turbocharger Four Cylinder Eng in Three Cylinder Engine Vv Valve Mechanism Cover. os The Cover for the Four Cylinder Engine . The Cover for the Three Cylinder Engine w Water Pump. Water Temperature Regulator and Housing Water Temperature Regulator.
