Engine (D4EB -

Diesel 2.2)
GENERAL ENGINE BLOCK

ENGINE AND TRANSAXLE ASSEMBLY COOLING SYSTEM

TIMING SYSTEM LUBRICATION SYSTEM

CYLINDER HEAD ASSEMBLY INTAKE AND EXHAUST SYSTEM

EM -2 ENGINE (D4EB - DIESEL 2.2)

GENERAL
SPECIFICATIONS E18A7ADE

Description Specifications Limit

General
Type 1-type, SOHC
Number of cylinder 4
Bore 87mm(3.4252in.)
Stroke 92mm(3.6220in.)
Total displacement 2,188cc
Compression ratio 17.3:1
Firing order 1-3-4-2
Valve timing
Intake valve Opens (BTDC) 7
Closes (ABDC) 35
Exhaust valve Opens (BBDC) 52
Closes (ATDC) 6
Cylinder head
Flatness of gasket surface Less than 0.03mm (0.0012in) for width
Less than 0.09mm (0.0035in) for length
Less than 0.012mm (0.0005in) for 51 × 51 mm
Camshaft
Cam height Intake 34.697mm (1.3660in)
Exhaust 34.571mm (1.3611in)
Journal outer diameter 27.947 ~ 27.960mm(1.1003 ~ 1.1008in.)
Bearing oil clearance 0.040 ~ 0.074mm (0.0016 ~ 0.0029in)
End play 0.05 ~ 0.15mm (0.0020-0.0059in)
Valve
Valve length Intake 95.5 ~ 95.9mm(3.7598 ~ 3.7756in.)
Exhaust 95.2 ~ 95.6mm(3.7480 ~ 3.7638in.)
Stem outer diameter Intake 5.933 ~ 5.953mm(0.2366 ~ 0.2344in.)
Exhaust 5.905 ~ 5.925mm(0.2325 ~ 0.2333in.)
Face angle 45.5 ~ 46
Thickness of valve- Intake 1.5 ~ 1.7mm(0.0591 ~ 0.0669in.)
head(margin)
Exhaust 1.2 ~ 1.4mm(0.0472 ~ 0.0551in.)
Valve stem to valve guide Intake 0.022 ~ 0.067mm(0.0009 ~ 0.0021in.)
clearance
Exhaust 0.050 ~ 0.095mm(0.0020 ~ 0.0037in.)
Valve guide
GENERAL EM -3

Description Specifications Limit

Length Intake 36.25 ~ 36.75mm(1.4272 ~ 1.4468in.)
Exhaust 36.25 ~ 36.75mm(1.4272 ~ 1.4468in.)
Valve spring
Free length 38.8mm (1.5276in)
Load 21.25±1.3kg/32.0mm(47.4±2.9 lb/1.2598in)
Out of squareness Less than 1.5
Valve seat
Seat angle 44 ~ 46
Valve contacting width Intake 0.95 ~ 1.25mm(0.0374 ~ 0.0492in.)
Exhaust 0.8825 ~ 1.0825mm(0.0347 ~ 0.0426in.)
Piston
Piston outer diameter 86.92 ~ 86.95mm (3.4220 ~ 3.4232in)
Piston to cylinder clearance 0.07 ~ 0.09mm (0.0028 ~ 0.0035in)
Ring groove width No. 1 ring
2.415 ~ 2.445mm (0.0951 ~ 0.0963in.)
groove
No. 2 ring
2.06 ~ 2.08mm (0.0811 ~ 0.0819in.)
groove
Oil ring groove 3.02 ~ 3.04mm (0.1189 ~ 0.1197in.)
Piston ring
Side clearance No. 1 ring 0.083 ~ 0.137mm (0.0033 ~ 0.0054in)
No. 2 ring 0.065 ~ 0.110mm (0.0026 ~ 0.0043in)
Oil ring 0.03 ~ 0.07mm (0.0012 ~ 0.0028in)
End gap No. 1 ring 0.25 ~ 0.40mm (0.0098 ~ 0.0157in)
No. 2 ring 0.40 ~ 0.60mm (0.0157 ~ 0.0236in)
Oil ring 0.20 ~ 0.40mm (0.0079 ~ 0.0157in)
Piston pin
Piston pin outer diameter 27.995 ~ 28.000mm (1.1022 ~ 1.1024in)
Connecting rod
Connecting rod bearing oil clearance 0.024 ~ 0.042mm(0.0009 ~ 0.0017in.)
Crankshaft
Main journal outer diameter 60.002 ~ 60.020mm (2.3623 ~ 2.3630in.)
Pin journal outer diameter 50.008 ~ 50.026mm (1.9688 ~ 1.9695in.)
Main bearing oil clearance 0.024 ~ 0.042mm(0.0009 ~ 0.0017in.) 0.1mm
End play 0.09 ~ 0.32mm (0.0035 ~ 0.126in)
Cylinder block
Cylinder bore 87mm(3.4252in.)
Flywheel
Runout 0.45mm(0.0177in.)
Oil pump
EM -4 ENGINE (D4EB - DIESEL 2.2)

Description Specifications Limit

Side clearance Tip clearance 0.12 ~ 0.20mm(0.0047 ~ 0.0079in.)
Radial clearance 0.13 ~ 0.23mm(0.0051 ~ 0.0091in.)
Cooling system
Cooling method Forced circulation with electrical fan
Coolant quantity 8.4L(8.88US qt, 7.39lmp qt)
Thermostat Type Wax pellet type
Opening
85±1.5 C (185±34.7 F)
temperature
Fully opened
100 C (213 F)
temperature
Full lift 8mm (0.3150in.) or more
GENERAL EM -5

TIGHTENING TORQUE

ITEM N.m kgf.m lb.ft

Engine mounting bracket nuts/bolts(engine side) 63.7 ~ 83.4 6.5 ~ 8.5 47.0 ~ 61.5
Engine mounting bracket nuts(body side) 63.7 ~ 83.4 6.5 ~ 8.5 47.0 ~ 61.5
Engine mounting insulator bolt 78.5 ~ 98.1 8.0 ~ 10.0 57.9 ~ 72.3
Engine support bracket bolt 42.2 ~ 53.9 4.3 ~ 5.5 31.1 ~ 39.8
Front roll stopper bracket sub frame member bolt 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
Front roll stopper insulator bolt/nut 78.5 ~ 98.1 8.0 ~ 10.0 57.9 ~ 72.3
Rear roll stopper bracket sub frame member bolt 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
Rear roll stopper insulator bolt/nut 78.5 ~ 98.1 8.0 ~ 10.0 57.9 ~ 72.3
Transaxle mounting bracket bolt(transaxle side) 63.7 ~ 83.4 6.5 ~ 8.5 47.0 ~ 61.5
Transaxle mounting bracket bolt(body side) 63.7 ~ 83.4 6.5 ~ 8.5 47.0 ~ 61.5
Cylinder head cover bolt 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Camshaft sprocket bolt 122.6 ~ 137.3 12.5 ~ 14.0 90.4 ~ 101.3
Camshaft bearing cap bolt 26.0 ~ 28.9 2.7 ~ 3.0 19.2 ~ 21.3
Air cleaner body mounting bolt 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Crankshaft bolt 196.1 ~ 205.9 20.0 ~ 21.0 144.7 ~ 151.9
Damper pulley bolt 29.4 ~ 33.3 3.0 ~ 3.4 21.7 ~ 24.6
Cylinder head bolt(at cold) 63.7 + 120 + 120 6.5 + 120 + 120 47.0 + 120 + 120
Timing belt auto tensioner bolt 49.0 ~ 53.9 5.0 ~ 5.5 36.2 ~ 39.8
Drive belt auto tensioner bolt 25.5 ~ 30.4 2.6 ~ 3.1 18.8 ~ 22.4
Timing belt auto tensioner adjusting bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Drive belt idler bolt 45.1 ~ 50.0 4.6 ~ 5.1 33.3 ~ 36.9
Oil pan bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pan drain plug 34.3 ~ 44.1 3.5 ~ 4.5 25.3 ~ 32.5
Oil screen 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pressure switch 14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~ 15.9
Oil filter fitting 47.1 ~ 51.0 4.8 ~ 5.2 34.7 ~ 37.6
Oil filter 22.6 ~ 24.5 2.3 ~ 2.5 16.6 ~ 18.1
Oil jet bolt 8.8 ~ 12.7 0.9 ~ 1.3 6.5 ~ 9.4
Oil pump cover bolt 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Oil pump assembly 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Oil lever gauge 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Plug cap 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Timing belt upper cover 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Timing belt lower cover 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Flywheel 68.6 ~ 78.5 7.0 ~ 8.0 50.6 ~ 57.9
Connecting rod cap bolt 24.5 + 90 2.5 + 90 18.1 + 90
Water pump and cylinder block bolt 47.1 ~ 51.0 4.8 ~5.2 34.7 ~ 37.6
EM -6 ENGINE (D4EB - DIESEL 2.2)

ITEM N.m kgf.m lb.ft

Water inlet mounting bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Crankshaft bedplate bolt(15mm)-bearing
19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
cap bolt(M11 x 1.5P)
Crankshaft bedplate bolt(12mm)-bearing
29.4 ± 2.0 + 120 3.0 ± 0.2 + 120 21.7 ± 1.4 + 120
cap bolt(M8 x 1.25P)
Balance shaft assembly mounting bolt 33.0 ~ 37.0 3.4 ~ 3.8 24.4 ~ 27.3
Intake manifold and cylinder head
52.0 ~ 55.9 5.3 ~ 5.7 38.3 ~ 41.2
mounting bolt/nut
Exhaust manifold and cylinder head mounting nut 14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~ 15.9
Turbocharger supporting bolt 29.4 ~ 34.3 3.0 ~ 3.5 21.7 ~ 25.3
Turbocharger heat protector mounting bolt 34.3 ~ 44.1 3.5 ~ 4.5 25.3 ~ 32.5
Heater pipe protector mounting bolt 16.7 ~ 21.6 1.7 ~ 2.2 12.3 ~ 15.9
Exhaust manifold and front muffler mounting nut 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Front muffler and catalytic convertor mounging nut 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4
Catalytic covertor and center muffler mounting nut 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4
Center muffler and main muffler mounting nut 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4
Subframe mounting bolts/nuts 68.6 ~ 88.3 7.0 ~ 9.0 50.6 ~ 65.1
Subframe mounting bolts 137.3 ~ 156.9 14.0 ~ 16.0 101.3 ~ 115.7
Injector holder mounting bolts 39.2 ~ 53.9 4.0 ~ 5.5 28.9 ~ 39.8
GENERAL EM -7

TROUBLESHOOTING E72E93DD

Symptom Suspect Remedy

Engine misfire with abnormal Loose or improperly installed Repair or replace the flywheel
internal lower engine noises. engine flywheel. as required.
Worn piston rings Inspect the cylinder for a loss
(Oil consumption may or may not of compression.
cause the engine to misfire.) Repair or replace as required.
Worn crankshaft thrust bearings. Replace the crankshaft and bearings
as required.
Engine misfire with abnormal Stuck valves Repair or replace as required
valve train noise. (Carbon buildup on the valve stem can
cause the valve not to close properly.)
Replace the timing belt and sprocket
Excessive worn or mis-aligned timing belt
as required.
Worn camshaft lobes. Replace the camshaft and valve lifters.
Engine misfire with coolant • Faulty cylinder head gasket and/or • Inspect the cylinder head and
consumption. cranking or other damage to the engine block for damage to
cylinder head and engine block the coolant passages and/or a
cooling system. faulty head gasket.
• Coolant consumption may not cause • Repair or replace as required.
the engine to overheat.
Engine misfire with excessive Worn valves, valve guides and/or Repair or replace as required.
oil consumption. valve stem oil seals.
Worn piston rings. • Inspect the cylinder for a loss
(Oil consumption may or may not of compression.
cause the engine to misfire) • Repair or replace as required.
Engine noise on start-up, but Incorrect oil viscosity. • Drain the oil
only lasting a few seconds. • Install the correct viscosity oil.
Worn crankshaft thrust bearing. • Inspect the thrust bearing and
crankshaft.
• Repair or replace as required.
Upper engine noise, regardless Low oil pressure. Repair or replace as required.
of engine speed.
Broken valve spring. Replace the valve spring
Worn or dirty valve lifters. Replace the valve lifters.
Stretched or broken timing belt and/or
Replace the timing belt and sprockets.
damaged sprocket teeth.
Replace the timing chain tensioner
Worn timing chain tensioner, if applicable.
as required.
Worn camshaft lobes. • Inspect the camshaft lobes.
• Replace the timing camshaft and
valve lifters as required.
Inspect the valves and valve guides,
Worn valve guides or valve stems.
then repair as required.
Stuck valves. Inspect the vlaves and valve guides,
(Carbon on the valve stem or valve seat then repair as required.
may cause the valve to stay open.)
EM -8 ENGINE (D4EB - DIESEL 2.2)

Symptom Suspect Remedy

Lower engine noise, regardless Repair or replace damaged components
Low oil pressure.
of engine speed. as required.
Loose or damaged flywheel. Repair or replace the flywheel.
Damaged oil pan, contacting the • Inspect the oil pan.
oil pump screen. • Inspect the oil pump screen.
• Repair or replace as required.
Oil pump screen loose, damage • Inspect the oil pump screen.
or restired. • Repair or replace as required.
Excessive piston-to-cylinder bore • Inspect the piston and cylinder bore.
clearance. • Repair as required.
Excessive piston pin-to bore clearance. • Inspect the piston, piston pin and
the connecting rod.
• Repair or replace as required.
Excessive connecting rod bearing Inspect the following components
clearance and repair as required.
• The connecting rod bearings.
• The connecting rods.
• The crankshaft.
• The crankshaft journal.
Excessive crankshaft bearing clearance Inspect the following components
and repair as required.
• The crankshaft bearings.
• The crankshaft journals.
Incorrect piston, piston pin and • Verify the piston pins and connecting
connecting rod installation rods are installed correctly.
• Repair as required.
Engine noise under load Low oil pressure Repair or replace as required.
Excessive connecting rod bearing Inspect the following components
clearance and repair as required.
• The connecting rod bearings.
• The connecting rods.
• The crankshaft
Excessive crankshaft bearing clearnace Inspect the following components,
and repair as required.
• The crankshaft bearings.
• The crankshaft journals.
• The cylinswe block crankshaft
bearing bore.
GENERAL EM -9

Symptom Suspect Remedy

Engine will not crank-crakshaft Hydraulically cylinder 1. Remove injectors and check for fluid.
will not rotate • Coolant/antifreeze in cylinder. 2. Inspect for broken head gasket.
• Oil in cylinder. 3. Inspect for cranked engine black
• Fuel in cylinder or cylinder head.
4. Inspect for a sticking fuel injector
and/or leaking fuel regulator.
Broken timing chain and/or timing 1. Inspect timing chain and gears.
chain gears. 2. Repair as required.
Material cylinder 1. Inspect cylinder for damaged
• Broken valve components and/or foreign
• Piston material materials.
• Foreign meterial 2. Repair or replace as required.
Seized crankshaft or connecting 1. Inspect crankshaft and connecting
rod bearings. rod bearing.
2. Repair as required.
Bent or broken connecting rod. 1. Inspect connectong rods.
2. Repair as required.
Broken crankshaft 1. Inspect crankshaft.
2. Repair as required.
EM -10 ENGINE (D4EB - DIESEL 2.2)

SPEICAL SERVICE TOOLS E764F48B

Tool (Number and name) Illustration Use

Camshaft oil seal installer Installation of the camshaft oil seal
(09212-27100)

ACIE003A

Valve spring compressor Removal and installation of intake

(09222-27300) and exhaust valves

ACIE004A

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

ACIE005A

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

ACIE006A

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

ACIE003A