02 Engine Assembly

GENERAL INFORMATION
1. SPECIFICATIONS.................................. 3
2. TIGHTENING TORQUE.......................... 4
3. PRECAUTIONS...................................... 7
4. SPECIAL TOOL..................................... 9
5. GENERAL DEDICATED EQUIPMENTS.. 14
OVERVIEW AND OPERATING

PROCESS
1. MAJOR COMPONENTS......................... 15
2. EPC........................................................ 17
CONFIGURATION AND FUNCTIONS
135001 BELT SYSTEM............................. 28

161001 VACUUM PUMP............................ 37
199001 ENGINE MOUNTING..................... 40
122501 CYLINDER HEAD COVER............. 48
121401 CYLINDER HEAD.......................... 54
113018 DRIVE PLATE............................... 90
131500 CHAIN DRIVE AND GEAR DRIVE
SYSTEM....................................... 93
113001 PISTON/CRANKSHAFT/
CYLINDER BLOCK........................ 100
111501 ENGINE ASSEMBLY..................... 111
111501 ENGINE ASSEMBLY OVERHAUL. 127
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1. SPECIFICATIONS
Unit Description Specification Remark
Cylinder head Height 131.9 to 132.1 mm -
Flatness below 0.05mm -
(150mm)
below 0.075mm
(Total)
Valve recess Intake valve 0.6 to 1.0 mm -
Exhaust valve 0.6 to 1.0 mm -
Connecting rod Flatness
End play on manifold Intake manifold 0.050.08
to 0.31
mmmm -
side
Camshaft Axial end play Intake
Exhaust manifold 0.10.08
to 0.35
mmmm -
Connecting rod End play Exhaust 0.05
0.1 to
to0.35
0.31mm
mm -
Camshaft position Distance
Axial endbetween
play Camshaft
Intake
position sensor 0.1 to 0.35 mm -
0.20 to 1.80 mm -
sensor and sprocket
Exhaust 0.1 to 0.35 mm -
Valve Clearance between Intake 1.12 mm -
Camshaft position Distance
valve andbetween
piston Camshaft position sensor 0.20 to 1.80 mm -
sensor and sprocket Exhaust 1.09 mm -
Cylinder block Piston protrusion 0.475 to 0.745mm -
Piston ring TOP ring end gap 0.18 to 0.33mm -
2nd ring end gap 0.33 to 0.48mm -
3rd ring end gap 0.2 to 0.40 mm -
Offset 0.3mm -
Head gasket Piston protrusion 0.475 to 0.540 1.2t -
0.541 to 0.649 1.3t -
0.650 to 0.745 1.4t -
2. TIGHTENING TORQUE
Tool dimensions Bolt Specified torque
Part name Remarks
quantity (Nm)
Main bearing cap 12-point, 13 mm 10 Not reusable
Connecting rod cap E12 8 50 to 80 Nm
Crankshaft rear seal 10 mm 6 -

Oil pump 13 mm 3 -
Flywheel T55 8 Not reusable
Crankshaft pulley 27 mm 1 660 to 720 Nm

Not reusable
20 20 mm long
2 35 mm long
10 mm
Oil pan 2 85 mm long
2 120 mm long
13 mm 2 40 mm long
HP pump gear mounting 19 mm 1 -
nut
HP pump mounting bolt Hexagon, 6 mm 3 -
Cylinder head M14 10 Not reusable
10 mm 16 -
Camshaft cap
13 mm 4 -
Exhaust stud bolt - 10 -
Exhaust camshaft
13 mm 3 -
sprocket
Coolant temperature
24 mm 1 -
sensor
13 mm 1 -
Belt auto tensioner
17 mm 1 -
Water pump Hexagon, 5 mm 7 -
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Tool dimensions Bolt Specified torque

Part name Remarks
quantity (Nm)
Hot water inlet pipe 10 mm 2 -
15 mm 1 -
Alternator Nm
17 mm 1 -
A/C compressor 13 mm 4 -
A/C bracket 10 mm 4 -
13 mm 2 35 mm long
Intake manifold
13 mm 6 110 mm long
5 40 mm long
Oil filter & cooler 13 mm 1 120 mm long
Part name Size Bolt Specified torque torque)
2
quantity (Nm) 140 mm long
Oil pressure switch 24 mm 1 -
Cam position sensor 10 mm 1 10 to 14 Nm -
T-MAP sensor 10 mm 1 -
Exhaust manifold 12 mm 10 -
Turbocharger 13 mm 3 -
T/C support bracket
13 mm 1 -
bolt (Turbo side)
T/C support bracket
13 mm 1 -
bolt (Block side)
T/C hollow bolt 24mm 1 -
T/C oil return pipe(Block

Hexagon, 5 mm 1 -
Side)
T/C oil supply & return
Hexagon, 5 mm 1 -
pipe(Turo Side)
EGR valve 13 mm 3 -
EGR pipe bolt
10 mm 2 -
(Intake side)
EGR pipe bolt
13 mm 2 -
(EGR cooler side)
Tool dimensions Bolt Specified torque Remarks
Part name
quantity (Nm)
No. 1, 2 idle T50 1 -
bearing
Glow plug 10 mm 4 -
Part name Size Bolt Specified torque torque)
Vacuum pump 10 mm 3
quantity -
(Nm)
8 40 mm long
Timing gear case cover 10 mm 1 45 mm long
2 50 mm long
Part name Size Bolt Specified torque (Total torque)
Cylinder head cover 10 mm 21
quantity (Nm) -
Oil gauge tube 10 mm 1 -
Oil filter cap - 1 -
Fuel rail Hexagon, 6 mm 2 -
Injector clamp bolt E10 2 Not reusable
High-pressure pipe
(high pressure pump to 17 mm 1 Not reusable
fuel rail assembly)
High-pressure pipe
(Fuel rail assembly to 17 mm 4 Not reusable
injector)
Crankshaft position
Hexagon, 3 mm 1 -
sensor
Main wiring 10 mm 5 -
Intake duct 13 mm 4 -
Ladder frame 13 mm 6 -
Cylinder head front 10 mm 5 -
cover
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3. PRECAUTIONS
1) When lifting the vehicle
- Pay close attention to the safety precautions when lifting the vehicle on a jack lift as the vehicle might
slip off the jack lift.
- When working with a 4-column vehicle lift, use the center of the vehicle as a support point and chock
the wheels to prevent the vehicle from rolling.
- When work with a 2-column vehicle lift, use the jack point as a support point.
- Take care not to spill the battery electrolyte and wear protective clothing when handling the battery.
2) When working on the exhaust system

- Wear protective gloves when removing the exhaust pipe.
- Make sure that the exhaust pipe has sufficiently cooled down before working on the exhaust pipe,
because the temperature of the exhaust pipe is very hot right after the engine has been stopped.
3) When working on the fuel system

- Disconnect the negative battery terminal and prepare the service plug grip before working on the fuel
system.
- Do not smoke and avoid flames nearby when working on the fuel system.
- Keep gasoline away from the parts made of rubber or leather.
- Be sure to avoid sputtering of the fuel when removing the pipe between the high-pressure side fuel
pump and the fuel injector.
- Never remove any part of the fuel system before releasing the pressure in the fuel system.
- Even after the fuel pressure has been released, wrap a cloth or equivalent around the mountings to
reduce the potential risk of fuel sputtering to a worker or engine assembly.
- Let the engine is cooled down sufficiently before proceeding to the next procedure since the fuel
pressure on the high-pressure side will not drop until the engine is cooled down.
4) When working on the cooling system

- Do not remove the radiator reservoir cap while the engine or radiator is hot since high-pressure hot
coolant or steam may cause severe burn.
5) When working on the lubrication system
- Repeated contact with the engine oil for an extended period of time may cause skin irritation.
- Take special care when changing the engine oil to minimize possible skin contact with the used
engine oil because hazardous materials that may cause skin cancer are contained in the used
engine oil.
- Always wear the oil-resistant protective clothing and gloves when handling the engine oil, and
completely remove the used engine oil from the skin with a lot of water or waterless hand cleaner.
Never use gasoline, dilute solution or solvent to wash your skin.
- Discard the used oil and used oil filter only in the designated area to protect environment.
6) When tightening bolts

Angle tighten the components of engine in a so-called final tightening operation. The tightening procedure
is as follows:
1. Clean the contact surface and threads before tightening bolts and nuts.
2. When angle tightening without a torque wrench tighten the bolt to the specified angle, marking its
position. (paint mark to assist the work)
The location and left/right position of components are based on the direction when viewed from the
rear side.
The cylinder block is made of aluminum and can be deformed and broken easily when excessive
force is applied. Therefore, always observe the specified torque when tightening the cylinder block
to prevent its thread from being damaged.
Do not over-tighten a self tapping screw bolt as it creates threads itself.
Never reuse the used bolt if it is a angle-tightened one.
(However, a bolt with specified reuse number with the specified torque is reusable.)
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4. SPECIAL TOOL
PN & Name Special Tool Use
Part No.: T99110010A
Name:
Flywheel fixture
Usage:
Tool which holds flywheel or
drive plate so that engine can
not rotate when removing
crankshaft pulley, etc.
Part No.: Y99220182B
Name:
Remover - removing valve stem
seal
Usage:
Used to protect the rubber
valve guide from damage when
removing/installing it.
Name:
Installer - installing valve stem
seal
Usage:
Used to install valve stem seal
W99110230A
Name:
Valve spring complete
Usage:
Used to remove and install the
valve spring by compressing it.
Y99220082B W99110230A
Name:
Dial gauge - measuring piston
protrusion
Usage:
Used to measure piston
protrusion to determine cylinder
head gasket type.
Name:
Piston install guide tool
Usage:
Used to insert the piston in the
cylinder block.
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Part No.: W99110120A
Name:
Insert guide - crankshaft rear oil
seal
Usage:
Used to protect retainer from
damage and seat rear
crankshaft oil seat correctly.
Part No.: T99180010A
Name:
EURO-V injector remover
Usage:
Used to remove injector
Components of injector remover
No Part name Quantity Shape
1 Injector remover set 1set
2 Main bar 1EA
3 Cross bar 2EA
4 Main bolt holder 1EA
5 Ball bearing 1EA
No
6 Main nut - A 1EA
7 Main bolt - A 1EA

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No Part name Quantity Shape
8 Injector holder - A 1EA
9 Injector holder - B 1EA
10 Injector holder cover 1EA
11 Bar holder assembly 2set
12 Support mounting bolt 4EA
13 Main support 4EA

5. GENERAL DEDICATED EQUIPMENTS
PN & Name General tool Usage
Name:
Engine stand (1 tonne or more)
Usage:
Used to secure the removed
engine or engine with transaxle.
Use an equipment which is
designed to carry load of 1
tonne or more.
Name:
Engine crane (1 tonne or more)
Usage:
Used to move the removed
engine module with transaxle to
a working area or an engine
stand. Use an equipment which
is designed to carry load of 1
tonne or more.
Name:
Oil pan gasket remover
Usage:
Used to separate oil pan while
minimizing damage when
removing it.
Name:
Torque angle gauge
Usage:
Used to angle tighten correctly
after torque tightening.
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1. MAJOR COMPONENTS
Front view
Vacuum pump
Cam position sensor
Oil filter & cooler assembly
Power steering pump pulley
Oil pressure switch
Water pump pulley
Idler pulley No. 2
Alternator
Idler pulley No. 1
Auto tensioner
A/C compressor
Isolation damper
Rear view
E-EGR valve
Fuel temperature sensor
Fuel HP pump assembly
IMV
Coolant outlet port assembly
Coolant temperature sensor
Crankshaft position sensor
Drive plate
Right view
Front exhaust gas

temperature sensor
Oil dipstick tube &

gauge assembly
E-VGT actuator
E-VGT turbocharger
Turbocharger Hollow bolt
Oil pan
Oil drain plug
Left view
Electric throttle body
Variable swirl valve

assembly
E-EGR valve
E-EGR solenoid valve
EGR cooler
Oil cooler assembly
Thermostat assembly
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2. EPC
1115 ENGINE ASSEMBLY(DSL)
1. ENGINE ASSY
2. BRKT-ENGINE MTG
3. BRKT-ENGINE HANGER FRT
4. BRKT-ENGINE HANGER RR
5. BOLT
6. BOLT
1120 SHORT BLOCK(DSL)
1. SHORT BLOCK
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1127 CYLINDER BLOCK(DSL)
1. BLOCK ASSY-CYLINDER 22.NOZZLE ASSY-OIL INJECTION

3. BOLT 27.COVER-DUST
4. PLUG-SCREW 33.PIPE-SCREW
5. RING-SEAL 34.RING-SEAL
6. PLUG-EXPENSION 35.SEAL ASSY-CRANKSHAFT RR
16.BALL 36.GROMMET-CRANKSHAFT SEALING RR
20.BOLT 37.RING-TRIGGER
21.PIN-SPRING
1130 CRANKSHAFT AND FLYWHEEL
1. CRANKSHAFT 26.BUSHING
2. PIN-CYLINDRICAL 27.BOLT
3. KEY-CRANKSHAFT PULLEY 33.PISTON ASSY
4. SPROCKET ASSY-CRANKSHAFT 34.RING SET-PISTON
7. DISC-CRANKSHAFT VIBRATION DAMPER 35.RING-SNAP
8. BOLT 50.BEARING KIT-CONNECTING ROD
12.DAMPER ASSY-ISOLATION 51.BEARING-CONNECTING ROD STD
13.FLYWHEEL ASSY-MECH 55.BUSH-T/M
17.BOLT-FLYWHEEL MTG 56.BEARING-CRANKSHAFT THRUST UPR
18.PLATE ASSY-DRIVE 57.BEARING-CRANKSHAFT THRUST LWR
19.PLATE 58.BEARING-CRANKSHAFT MAIN UPR
21.BEARING-GROOVED BALL 59.BEARING-CRANKSHAFT MAIN LWR
22.RING-CRANKSHAFT COVER 60.BEARING-CRANKSHAFT THRUST STD
25.ROD ASSY-CONNECTING
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1214 CYLINDER HEAD AND GASKET KIT(DSL)
1. HEAD ASSY-CYLINDER 29.RING-EXHAUST VALVE SEAT

5. PLUG-EXPANSION 32.SEAL-VALVE STEM
6. BOLT-STUD 33.RETAINER-VALVE SPRING LWR
7. BOLT 34.SPRING-VALVE
11.BOLT 35.RETAINER-VALVE SPRING UPR
12.SLEEVE 36.COTTER-VALVE
13.BOLT-CYLINDER HEAD 39.FOLLOWER ASSY-FINGER
24.GASKET-CYLINDER HEAD 40.ADJUSTER ASSY-HYDRAULIC LASH
26.VALVE-INTAKE 45.WASHER-CYLINDER HEAD BOLT
27.VALVE-EXHAUST 46.BEARING-BALL
28.RING-INTAKE VALVE SEAT
1225 CYLINDER HEAD COVER AND CAMSHAFT(DSL)
1. COVER-CYLINDER HEAD 16.CLAMP

2. GASKET-CYLINDER HEAD COVER 21.CAMSHAFT ASSY-EXHAUST
3. BOLT 22.CAMSHAFT ASSY-INTAKE
4. CAP ASSY-OIL FILLER 24.COVER-CYLINDER HEAD FRT
14.HOSE ASSY-BLOW BY OUTLET 25.BOLT
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1315 CHAIN DRI(DSL)
1. CHAIN-BUSH-LWR 15.TENSIONER ASSY-HYDRAULIC

2. RAIL ASSY-CLAMPING 16.CHAIN-BUSH-UPR
3. RAIL ASSY-TENSIONER 17.BOLT
10.SPROCKET-EXHAUST CAMSHAFT 18.TENSIONER ASSY-MECHANICAL
12.BOLT 19.BOLT
1336 TIMING CASE(DSL)
1. COVER-TIMING CASE 8. PULLEY ASSY-IDLER

2. SEALING-CRANKSHAFT FRT 25.PULLEY ASSY-IDLER
3. BOLT 27.PLUG ASSY-SCREW
4. TENSIONER ASSY-BELT 28.COVER-IDLER PULLEY
5. BOLT 29.TENSIONER-BELT
7. COVER-IDLER PULLEY
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1350 BELT
1. BELT-POLY GROOVED
1610 VACUUM PUMP(DSL)
1. PUMP ASSY-VACUUM
3. BOLT
4. RING-O
1480 A/CON COMPRESSOR
1. COMPRESSOR ASSY-A/CON
2. BRKT ASSY-A/CON COMPRESSOR
3. BOLT
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1990 ENGINE MOUNTING
1. INSULATOR-ENGINE MTG FRT 8. BOLT

2. INSULATOR-ENGINE MTG RR 9. BOLT
3. INSULATOR-ENGINE MTG RR 10.BOLT
4. BRKT-ENGINE MTG RR 11.BOLT
5. BRKT-ENGINE MTG RR 12.NUT
6. BOLT-ENGINE MTG 13.NUT
7. BOLT
It is single drive type and uses FEAD (Front End Accessories Drive) design to make a compact layout.
Number Name
1 Crankshaft pulley (DDU)
2 Auto tensioner
3 Tensioner pulley
4 A/C compressor pulley
5 Alternator pulley
6 Water pump pulley
7 Idle pulley #1
8 Idle pulley #2
9 Power steering pump pulley
1. FAN BELT
(1) Overview
The fan belt used in this system is a poly-groove belt which reduces belt slip and minimizes friction and
noise. The fan belt have a long service life and can be back-bent because its bending stress is low.
Belt length : 2010mm

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2. BELT TENSIONER
(1) Overview
The torque deviation from crankshaft affects the components in belt drive system and the belt
movement. The auto tensioner system is to adjust this deviation automatically.
In D22DTR engine, one of the mechanical tensioner, pivot damped tensioner is used to keep the
damping force, system reliability and durability. The single belt drive system needs to use the automatic
belt tensioning device to transfer the power to pulleys effectively. To get this, the tensioner uses the
spring and damping unit.
(2) Location
Belt tensioner
3. CRANKSHAFT PULLEY (ISOLATION DAMPER)
(1) Overview
The strut type tensioner automatically adjusts the belt tension to provide the reliability and durability for
the system. And, the belt tension is decreased to minimize the friction loss and improve the belt
operating noise.
(2) Sectional drawing
Pulley
Axial & radial bearing
Sleeve
Hub
Isolation pulley rubber
Damper rubber
Inertia ring
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(3) Features
1. Rubber damper: Decrease crankshaft torsion
2. Improve belt NHV: Reduce unbalance speed to crankshaft due to irregular combustion
3. Minimize noise: Anti-vibration from crankshaft and belt
4. Post bonded type rubber damper: Improve durability of rubber damper
4. REMOVAL AND INSTALLATION
1) Belt & Tensioner
No.1 & No.2 Idler pulley assembly
Fan belt
NO2 NO1
NO1
NO2 Belt tensioner assembly
1. Relieve the tension of the fan belt by turning

the pivot damped tensioner bolt (19 mm) to
the arrow direction using a hinge.
Do not apply excessive force to the fully

compressed belt tensioner when
releasing the tension. Failure to do so
may lead to deformation of the belt
tensioner.
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2. Unscrew bolt A (13 mm) and B (17 mm).
3. Remove the belt tensioner assembly.
4. Unscrew the bolt (T50) and remove the No.1

idler pulley (A) and No.2 idler pulley (B).
5. Install the fan belt in the reverse order of
Fan belt removal.
No.1 & No.2 idler pulley assembly
1. Belt tensioner
2. Tensioner housing
3. Belt tensioner pulley
4. Belt tensioner pulley cover
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2) Crankshaft Pulley (Isolation Damper)
1. Remove the start motor assembly.
Refer to "START MOTOR ASSEMBLY"

under "REMOVAL AND INSTALLATION"
subsection of "STARTING SYSTEM" section
in "D22DTR ENGINE" chapter.
2. Lock the flywheel with a special service tool

(T9911 0010A).
Flywheel lock
3. Relieve the tension of the fan belt by turning

the pivot damped tensioner bolt (19 mm) to
the arrow direction using a hinge.

compressed belt tensioner when releasing
the tension. Failure to do so may lead to
deformation of the mounting bolt.
4. Remove the fan belt.

5. Unscrew the center bolt (27 mm) from the
isolation damper assembly.
6. Remove the isolation damper assembly.
7. Install the isolation damper assembly in the

reverse order of removal.
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1. OVERVIEW
Vacuum pump generates the vacuum pressure and supplies it to EGR cooler bypass solenoid. This
pump is single vane type and displacement is 210 cc/rev. The lubrication oil is supplied through the hole
in hollow shaft.
2. MOUNTING LOCATION AND COMPONENT PARTS

acuum pump Brake booster and naster
cylinder
Pump capacity: 210 cc/rev
Camshaft speed:
375 to 3,000 rpm
Lubrication temperature:
Oil: 5W30
Drive type: Driven by exhaust
Camshaft sprocket
EGR cooler bypass valve
This valve is controlled by ECU. When the engine

is cooled, the exhaust gas goes to combustion
chamber without passing through EGR cooler
because the valve is closed by vacuum pressure.
The vacuum pump is engaged to the exhaust camshaft.
Connection between vacuum pump and

exhaust camshaft
Oil supply and driving
Vacuum pump Exhaust camshaft

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1. Separate the vacuum hose clamp (A) and
disconnect the brake booster vacuum hose
(B) from the vacuum pump.
2. Unscrew the 3 mounting bolts (10 mm) for the

vacuum pump assembly.
3. Remove the vacuum pump assembly.
4. Install in the reverse order of removal.
Replace the vacuum pump O-rings with new

ones when installing.
1. OVERVIEW
D22DTR engine uses 3-point mounting type that supports the engine and transmission simultaneously.
2. MOUNTING LOCATION AND COMPONENT PARTS

Front mounting insulator (RH) Front mounting insulator (LH)
Rear mounting insulator

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3. FUNCTION
Appearance Type and function
Front mounting insulator (Left side) Type: Rubber mounting
Function:
- Supporting torque reaction
- Fitting engine and transmission
- Reducing vibration and noise from engine and
transmission
Front mounting insulator (Right side) Type: Rubber mounting

Function:
- Supporting torque reaction
transmission
Rear mounting insulato Type: Rubber mounting

Function:
- Supporting powertrain rod
transmission
1) LH Engine Mounting Insulator Assembly
1. Unscrew the 2 lower mounting nuts (12 mm)
for the LH engine mounting insulator
assembly under the vehicle.
2. Remove the fuel filter assembly.
Refer to "FUEL FILTER ASSEMBLY" under

"REMOVAL AND INSTALLATION"
subsection of "FUEL SYSTEM" section in
"D22DTR ENGINE" chapter.
3. Place the floor jack under the vehicle to

support the engine at the bottom of the engine
oil pan.
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4. Unscrew the upper mounting bolt (12 mm) for

the LH engine mounting insulator assembly.
5. Unscrew the through bolt (19 mm) for the LH

engine mounting insulator assembly.
6. Remove the LH engine mounting insulator

assembly.

2) RH Engine Mounting Insulator
1. Unscrew the 2 lower mounting nuts (12 mm)

for the RH engine mounting insulator under
the vehicle.
2. Disconnect the air cleaner hose.
3. Undo the mounting clamp (7 mm) on the hose

from the turbocharger to the intercooler and
remove it.
4. Place the floor jack under the vehicle to

support the engine at the bottom of the engine
oil pan.
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5. Unscrew the upper mounting bolt (12 mm) for

the RH engine mounting insulator assembly.
6. Unscrew the through bolt (19 mm) for the RH

engine mounting insulator assembly.
7. Remove the RH engine mounting insulator

assembly.

3) Rear Engine Mounting Insulator (For 4WD Vehicle)
1. Remove the hanger on the cross member

side of LNT & DPF.
2. Unscrew the 2 mounting nuts (14 mm) for the

rear engine mounting insulator.
3. Install the transmission jack on the bottom of

the A/T oil pan securely.
4. Unscrew the 4 mounting bolts/nuts (14 mm)

on the cross member.
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5. Remove the cross member.
6. Unscrew the 2 mounting bolts (14 mm) for

the rear engine mounting insulator.
7. Remove the rear engine mounting insulator.
Make sure that the arrow (A) faces the front

side, when installing.
1. OVERVIEW
The cylinder head cover is made of high strength plastic, and because of this, the cover is lightweight. The
cylinder head cover optimizes the oil consumption with the highly efficient oil separator (multi twister type)
mounted inside the cover.
2. COMPONENTS
Front view Rear side
3. OIL SEPARATOR
The oil separator separates the particle in blow-
PCV valve
by gas to minimize the engine oil consumption
and reduces the inflow oil from the intake system
into the combustion chamber. In other words, it
reduces the oil consumption and prevents
incomplete combustion due to oil ingress. The
separated oil returns to oil pan through the
cylinder head.
Oil separator system
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Operation process
Blow-by gas enters the separator inlet of the cylinder head cover, is filtered through the high efficiency half
twister firstly and through the oil multi twister secondly.
The separated oil drips into the cylinder head and the gas flows through the pressure control valve (PCV)
into the intake hose. This flow of gas creates a pressure difference between the intake side and crankcase
cavity which opens/closes the PCV.
1. Remove the booster vacuum hose, vacuum
inlet hose and fuel return tube.
Be careful not to damage the fuel return tube

during removal.
Plug the back leak nipple with sealing cap to

prevent dirt from entering it.
2 Remove the high pressure fuel pipes (5 off).
Replace the fuel high pressure pipe with a

new one when installing.
Plug the fuel holes of the fuel rail, injector and

high pressure pump with a sealing cap to
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3. Remove the following connectors and wiring

fasteners:
(A) HFM connector
(B) E-VGT connector
(C) Front oxygen sensor connector
(D) Front exhaust gas temperature sensor
connector
(E) Injector connector
(F) Wiring bracket mounting bolt (10 mm, 1
off)
(G) Camshaft position sensor connector
(H) Oil pressure sensor connector
(I) Glow plug connector
(J) Fuel rail pressure sensor connector
(K) Variable swirl actuator connector
(L) T-MAP sensor connector
4. Unscrew the 4 engine main wiring mounting

bolts (10 mm).
5. Unscrew the one makeup hose mounting bolt

(A, 10 mm) and one bracket mounting bolt (B,
10 mm) securing the connector.
6. Disconnect the blowby hose.
7. Unscrew a mounting bolt (10 mm) for the

engine oil dipstick tube and remove it.
8. Unscrew the 2 mounting bolts (E10) for injector

clamp.
The mounting bolt for injector clamp is not

reusable. Always replace it with a new one
when fitting.
9. Remove the injector assembly.
If the injector assembly can't be removed,

refer to "HOW TO USE INJECTOR
REMOVER" under "ENGINE CONTROL
SYSTEM" section.
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10.Remove the 17 mounting bolts (10 mm) for

the cylinder head cover assembly.
To protect the exhaust manifold from

damage, unscrew the mounting bolts in
several steps, in the
sequence shown in the picture.
- When removing: from the outside to the
inside, diagonally
- When installing: from the center to the
outside, diagonally
11.Remove the cylinder head cover assembly.
12.Install in the reverse order of removal.
Replace the cylinder head cover gasket with

a new one when installing.
1. OVERVIEW
Cylinder head contains cam position sensor, vacuum pump, intake manifold, exhaust manifold and valve
assembly. Vacuum pump and the high pressure (HP) pump are driven by Camshaft and valves are install
in vertical direction. This enables the compact layout in cylinder head assembly.
2. COMPONENTS
Finger follower & HLA Intake/exhaust Camshafts Camshaft sprocket
Cylinder head
Camshaft position sensor HP pump drive gear Vacuum pump drive
Cylinder head gasket

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3. CYLINDER HEAD
1) Overview
The cylinder is made by gravity casting and the water jacket is integrated type.
The cylinder oil passage is drilled and sealed by Expansion plug or steel ball.
The Camshaft bearing cap is also made by casting and installed on the cylinder head.
2) Features
Location of Expansion Plugs
Front Rear
Intake side
Oil gallery expansion plug or steel ball

Coolant expansion plug (M21)
Cross flow type water jacket (improving cooling performance)
Exhaust side
Intake side
Exhaust side Intake side
4. CAMSHAFT ASSEMBLY
1) Overview
Hollow type camshaft contains cam, octagon cam, HP pump gear and intake/exhaust gears.
Camshaft operates the intake/exhaust valves, vacuum pump and HP pump, and transfers the engine
oil to vacuum pump through the internal oil passage.
2) Components
Intake/Exhaust Camshafts
Connected to Exhaust Camshaft

vacuum pump
Intake Camshaft
Octagon cam
Thrust journal (for tooling)
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5. VALVE ASSEMBLY (WITH CYLINDER HEAD)

1) Overview
1. Automatic valve clearance adjuster by hydraulic pressure (Maintenance Free) - Hydraulic lash
2. Optimized adjustment of valve clearance reduces the valve noise.
3. Roller type finger follower reduces the friction loss.
4. Vertical installation.
5. Simple and compact design reduces the moving operation (improving valve following and fuel
consumption at high speed)
2) Structure & Components
Finger follower
Hydraulic lash adjuster
Upper valve spring retainer
Valve spring
Lower valve spring retainer
Exhaust valve Intake valve

3) How to bleed HLA (Hydraulic Lash Adjuster
1. Dip the HLA in the engine oil and press (C)the

ball in the HLA gently by inserting a pin (A)
with length of 1.3 mm or less into the hole (B)
of the HLA cap.
Be careful not to press the ball too hard

since it's load is small.
2. Repeat pressing and releasing the HLA

cap while pressing the ball gently.
3. Hold the both ends of the HLA and press

them with your hand to check if the HLA
moves.
Replace the HLA with a new one if it

moves.
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4) How to troubleshoot HLA (Hydraulic Lash Adjuster)

Replace the HLA if it moves when pressing
the both ends of the HLA filled with the
engine oil with your hand.
Symptom Cause Actions to take
Noise for several This is because the oil is leaked from the
seconds HLA with the engine stopped. If the oil
Normal behavior
when starting pressure is normal, the noise will be
engine disappeared. (same as hydraulic tappet)
Noise when Air enters high pressure - Noise disappear after driving for a
starting engine chamber in HLA due to oil
after long non-use leakage entrainment and leakage
Noise after system or HLA unit
disassembling Low oil level in cylinder head oil
and reassembling passage
engine
Make sure that you do not run the
Noise when engine at 3,000 rpm or higher when
starting engine checking. Otherwise, it may result in
after excessive - Air enters high pressure
chamber in HLA due to oil damage to the HLA due to low oil level.
engine cranking
leakage
Noise right after - Insufficient oil in HLA
replacing HLA
Noise when idling Insufficient oil volume Check oil level and fill or drain oil as
right after high- necessary
speed driving
Excessive air mixed with oil Check oil supply system
Oil degradation Change oil
Check oil pressure and oil supply system
Noise occurs Low oil pressure
continuously pressure switch on oil filter and check
valve in cylinder head)
Faulty HLA Check HLA and replace it if sponge

effect occurs
- Sponge effect: Air enters high pressure chamber in HLA which allows HLA to be pressed in
with hand pressure
6. CYLINDER HEAD GASKET
1) Features
1. Sealing the cylinder gas pressure - Peak pressure: 190 bar
2. Minimizing the distortion of engine structure (cylinder head, block): profile stopper, backland stopper
Material: MLS (Multi Layer Steel), Gasket (3 layers)
3. Thickness of gasket: 3 types (1.2 /1.3 /1.4 mm)
4.
Thickness marking
Ex: 1.3t
2) Thickness of cylinder head gasket

There are three types of gasket to managing the compression ratio.
Piston protrusion
Piston protrusion Thickness

0.475 to 0.540 mm 1.2t
0.541 to 0.649 mm 1.3t
0.650 to 0.745 mm 1.4t
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1) Camshaft Assembly
1. Remove the cylinder head cover assembly.

3. Remove the vacuum pump assembly.

cylinder head front cover.
5. Detach the cylinder head front cover using a

flat-bladed screwdriver.
Take care not to damage the surrounding

parts while removing the cylinder head front
cover.
6. Remove the cylinder head front cover.
7. Rotate the isolation damper so that the timing

mark (A) is aligned with the mark (B) of the
timing gear case cover.
The position of the timing mark is at point

where the piston for No. 1 cylinder is turned
clockwise from compression TDC (TDC mark)
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8. Undo the chain tensioner plug cap (22 mm).
9. Remove the chain tensioner plug cap.
Replace the chain tensioner plug cap O-ring

with new one when installing.
10.Press the tensioner plunger using a flat

bladed screwdriver towards arrow (A)
direction to compress the hydraulic chain
tensioner and insert the mounting pin (B) to
secure it, as shown in the figure.
Use the mounting pin or 2 mm long

L-wrench.
11.Make a marking on the exhaust camshaft
sprocket (A) and upper chain bush (B).
The brass link is aligned once every 8

crankshaft rotations.
12.Secure the upper chain bush (A) and clamping

rail (B) with a cable tie (C).
13.Fit a 32 mm spanner on the octagon seating

surface (A) of the exhaust camshaft and hold
the spanner with one hand. Then unscrew the
3 mounting bolts (B, 13 mm) for the intake
camshaft sprocket.
14.Remove the exhaust camshaft sprocket.

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Cautions for installation
1. Pull the timing chain up with it parallel so

that the chain aligns to the tensioning rail
(A) and the clamping rail (B) correctly
when assembling.
2. Install the camshaft sprocket by aligning

the exhaust camshaft sprocket (C) with
the marking link (D) (brass link) on the
timing chain.
3. Check if the upper chain bush (A) gets

out of the clamping rail (B), as shown
in the figure.
4. If so, locate the upper chain bush

correctly, as shown in the figure.
15.Fit the scissors gear fixing pin (B) into the
hole (A) of the exhaust camshaft sprocket.
Always tighten the scissors gear fixing

pin to the tightening torque for the
camshaft bearing cap when fitting and
remove the fixing pin.
16.Unscrew the 4 mounting bolts (A, 13 mm)

and 18 mounting bolts (B, 10 mm) for the
camshaft bearing caps.
Unscrew the camshaft cap mounting

bolts slowly in two or more stages
according to the specific sequence
stated below.
(1) Exhaust caps: EX, 2 and 4
(2) Intake caps: IN, 6 and 9
(3) Exhaust caps: 1 and 3
(4) Intake caps: 5, 7 and 8
Always observe the tightening torques in

order to prevent the camshaft from being
damaged.
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17.Remove the camshaft bearing cap.
Apply the engine oil to the camshaft and

install the camshaft bearing cap.
18.Remove the intake/exhaust camshaft

assembly.
Apply the engine oil to the mounting parts

of the camshaft when fitting.
High pressure pump
Camshaft gear
Check if the marking of the high pressure
pump is aligned with one of the camshaft
gear when fitting.
19.Install it in the reverse order of removal.

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2) Cylinder Head Assembly
1. Drain the coolant from the radiator and engine

cylinder block screw plug.
2. Remove the engine outer belt.
3. Remove the turbocharger assembly.
Refer to "E-VGT ASSEMBLY" under

"REMOVAL AND INSTALLATION" subsection
of "TURBOCHARGER SYSTEM" section in

5. Remove the EGR cooler assembly.
Refer to "EGR COOLER ASSEMBLY" under

subsection of "EGER SYSTEM" section in
6. Remove the injector cover.
7. Remove the booster vacuum hose, vacuum

Be careful not to damage the fuel return tube

during removal.
Plug the back leak nipple with sealing

cap to prevent dirt from entering it.
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8. Remove the high pressure fuel pipes (5 off).
Plug the fuel holes of the fuel rail, injector and

high pressure pump with a sealing cap to
9. Remove the fuel return and supply tube.
10.Disconnect the variable swirl actuator

connector.
11.Unscrew the 3 mounting bolts (10 mm) on the
variable swirl actuator.
Be careful not to lose the spacer at the (A)

part.
12.Remove the link connected to the bottom of

the variable swirl actuator to the direction
indicated by the arrow.
13.Remove the variable swirl actuator assembly.

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14.Remove the following connectors and wiring

fasteners:
(A) Front oxygen sensor connector

(B) Front exhaust gas temperature sensor
connector
(C) Injector connector
(D) Wiring bracket mounting bolt (10 mm)
(E) Camshaft position sensor connector
(F) Oil pressure sensor connector
(G) T-MAP sensor connector
(H) Wiring mount
(I) Wiring bracket mounting bolt (10 mm)
(J) Glow plug connector
(K) Fuel rail pressure sensor connector
(L) E-EGR valve connector
(M) Bypass solenoid valve connector
(N) Ground (10 mm)
(O) Crank position sensor connector
(P) Fuel temperature sensor connector
(Q) IMV connector
(R) Coolant temperature sensor connector
15.Disconnect the connector C117 (A) and glow
control unit connector (B).
16.Disconnect the engine main wiring connectors

(A) and (B).
17.Remove the ground mounting bolt (A, 10 mm)

and the 2 wiring fasteners (B).
18.Unscrew the 4 mounting bolts (10 mm) for the

engine main wiring to remove the engine main
wiring.
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19.Disconnect the deaeration hose from the

cylinder head assembly.
20.Disconnect the heater outlet hose.
21.Disconnect the E-EGR valve hose.

coolant outlet port assembly.
23.Remove the coolant outlet port assembly.
24.Undo the glow plug using a 10 mm long

socket.
25.Remove the glow plug.
26.Unscrew the 2 mounting bolts (E10) for

injector clamp.

reusable. Always replace it with a new one
when fitting.
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27.Remove the injector assembly.
If the injector assembly can't be removed, refer

to "HOW TO USE INJECTOR REMOVER"
under "ENGINE CONTROL SYSTEM"
section.

the cylinder head cover.
To protect the exhaust manifold from

damage, unscrew the mounting bolts in
several steps, in the sequence shown in the
picture.
- When removing: from the outside to the
inside, diagonally
- When installing: from the center to the
outside, diagonally
29.Remove the cylinder head cover.

31.Remove the vacuum pump assembly.
32.Remove the idle bearing cap No. 2.
33.Unscrew the idle bearing mounting bolt (T50)

No. 2 and remove it.
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35.Detach the cylinder head front cover using a

flat-bladed screwdriver.

parts while removing the cylinder head front
cover.
36.Remove the cylinder head front cover.
37.Rotate the isolation damper so that the timing

mark (A) is aligned with the mark (B) of the

clockwise from compression TDC (TDC
38.Undo the chain tensioner plug cap (22 mm).
39.Remove the chain tensioner plug cap.
Replace the chain tensioner plug cap

O-ring with new one when installing.
40.Press the tensioner plunger using a flat bladed

screwdriver towards arrow (A) direction to
compress the hydraulic chain tensioner and
insert the mounting pin (B) to secure it, as
shown in the figure.
Use the mounting pin or 2 mm long

L-wrench.
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42.Make a marking on the exhaust camshaft

sprocket (A) and upper chain bush (B).
The brass link is aligned once every 8

crankshaft rotations.
43.Secure the upper chain bush (A) and

clamping rail (B) with a cable tie (C).

camshaft sprocket.

Cautions for installation
1. Pull the timing chain up with it parallel so

that the chain aligns to the tensioning rail
(A) and the clamping rail (B) correctly
when assembling.
2. Install the camshaft sprocket by aligning

the exhaust camshaft sprocket (C) with
the marking link (D) (brass link) on the
timing chain.
3. Check if the upper chain bush (A) gets

out of the clamping rail (B), as shown
in the figure.
4. If so, locate the upper chain bush

correctly, as shown in the figure.
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46.Fit the scissors gear fixing pin (B) into the

hole (A) of the exhaust camshaft sprocket.
Always tighten the scissors gear fixing

pin to the tightening torque for the
camshaft bearing cap when fitting and
remove the fixing pin.

camshaft bearing caps.
Unscrew the camshaft cap mounting

bolts slowly in two or more stages
according to the specific sequence
stated below.
(1) Exhaust caps: EX, 2 and 4
(2) Intake caps: IN, 6 and 9
(3) Exhaust caps: 1 and 3
(4) Intake caps: 5, 7 and 8
Always observe the tightening torques in

order to prevent the camshaft from being
damaged.
48.Remove the camshaft bearing cap.
Apply the engine oil to the camshaft and

install the camshaft bearing cap.
49.Remove the intake/exhaust camshaft

assembly.
Apply the engine oil to the mounting parts

of the camshaft when fitting.
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50.Remove the camshaft lower cap.
51.Remove the finger follower & hydraulic lash

adjuster assembly.
Stand the assembly vertically during removal.
Check the hydraulic lash adjuster (HLA). (see

"BLEEDING HLA & TROUBLESHOOTING"
in this section)
52.Unscrew the mounting bolt (T50) for the

tensioner rail assembly.
53.Remove the tensioner rail assembly.

54.Unscrew the mounting bolt (T50) for the
clamping rail assembly.
55.Unscrew the 3 hexagon mounting bolts (6

mm) at the front side of cylinder head
assembly.
Always replace the mounting bolts with new

ones when installing.
56.Remove the 10 mounting bolts (M14) for the

cylinder head assembly.
Unscrew the cylinder head assembly

mounting bolts in two or more stages
according to the following order:
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- Unscrew the bolts with the numerical order in the figure.
85Nm
Tightening process
Place the marks 1st angle 2nd angle 3rd angle
Torque wrench
(cylinder head/bolt) tightening tightening tightening
85 Nm
57.Remove the cylinder head assembly.
Remove the cylinder head assembly by

turning its rear part clockwise slightly since
there is insufficient space for the high
pressure pump, dash panel, oil cooler & oil
cooler module and cylinder head.
58.Remove the cylinder head gasket.
- Replace the cylinder head gasket with a new

one when installing.
- Apply the sealant to the position (A) prior to
installing the cylinder head gasket.
59.Remove the following parts from the removed

cylinder head assembly:
- E-EGR valve assembly
- Fuel rail assembly
- Intake manifold
- Exhaust manifold
- Fuel high pressure pump
60.Install in the reverse order of removal.

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Measuring the piston protrusion and Selecting the cylinder head gasket
Measure the piston tip protrusion and install the cylinder head gasket with the corresponding thickness
of the protruded piston.
1. Set up the gauge for piston protrusion (A)

to the cylinder block (B) and adjust it to
zero point.
Special service tool: Y99 22 012 2B
Before measuring it, remove the foreign

materials and the gasket residue on the
mating surface of the cylinder block.
2. Measure the protrusion in the axial direction.

Measure each point 3 or more times and
calculate the average value (total 8
measurement points).
3. Install the cylinder head gasket with a

corresponding thickness of the protruded
piston.
Protrusion of piston Thickness of gasket
0.475~0.540mm 1.2t
0.541~0.649mm 1.3t
0.650~0.745mm 1.4t
Thickness mark
of gasket
Replace the gasket with new one and
Thickness of gasket: 1.3T make sure that the surface of the steel
gasket face upwards.
1. OVERVIEW
The drive plate drives the power train system with the power received from the start motor when the
engine is started. This plate is installed to the crankshaft and connected to the torque converter of A/T
transmission to transfer the engine torque to the drive system.
2. MOUNTING LOCATION
Drive plate
Front view Rear view
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1. Remove the automatic transmission
assembly.
See "MANUAL TRANSMISSION

ASSEMBLY" under "REMOVAL AND
INSTALLATION" subsection of "6-SPEED
M/T SYSTEM" in "CHASSIS" chapter.
2. Secure the drive plate using a special tool

(T99110010A).
Drive plate holder
3. Remove the 8 mounting bolts (T55) for the

drive plate.
4. Remove the plate.

5. Remove the drive plate.
Drive plate 6. Install in the reverse order of removal.
Triggering
Plate
Do not work with a triggering near a magnetic

tool or equipment, as the triggering can lose
magnetic properties easily by an external
magnetic field or scratches on the surface.
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1. OVERVIEW
D22DTR engine uses single stage chain drive system. The timing chain drives the exhaust side and
geardrive the intake side.
The timing chain is single bush type. The upper chain drives HP pump connected to intake camshaft by
driving exhaust cam shift sprocket, and lower chain drives oil pump to lubricate the engine.
2. COMPONENTS
Chain upper bush Exhaust camshaft sprocket
Type: single bush Number of teeth: 42 EA

Connecting link: 112EA
Tensioner rail
Installed to left hand side of the

upper chain, supports the chain,
serves as a guide rail when
driving the chain and transfers
the tension from the hydraulic
Clamping rail
tensioner to the upper chain
Installed to right hand side of
the upper chain, supports the
Hydraulic tensioner chain and serves as a guide
when driving the chain
Device which maintains tension
of the upper chain constant by
pushing the tensioner rail,
operated by oil pressure and
tension of spring in the Mechanical tensioner
tensioner
Device which maintains tension
Crankshaft sprocket of the lower chain constant,
operated by spring tension and
1. Primary chain number of serves as a guide rail for the
teeth: 21EA (1st row) lower chain
2. Oil Pump chain number
of teeth: 25EA (2nd row)
Lower chain bush
Oil pump sprocket
Type: single bush
Number of teeth: 33EA Connecting link: 60 EA
The brass links on timing chain are aligned with the timing marks on crankshaft sprocket and
camshaft sprocket by eight turns of crankshaft.
3. TIMING CHAIN
(1) Timing chain
- Simple layout: optimized timing, enhanced

NVH
- Single stage layout: minimized chain load
- The brass link on crankshaft is at symmetric
position of that on camshaft.
Chain upper bush

- Single bush type (112 EA)
Chain lower bush
- Single bush type (60 EA)
4. TENSIONER (HYDRAULIC)
Tensioner adjusts the chain tension to keep it tight during engine running. This reduces the wear in
guide rail and spoke.
Hydraulic tensioner assembly
1. Operating principle
- Use the spring tension in tensioner and hydraulic pressure
2. Tensioner type
- Compensation and impact absorbing
3. Static and dynamic force
- Spring + Hydraulic pressure
Plunger
Check valve
Housing Spring
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5. TENSIONER ASSEMBLY (MECHANICAL)

Operating principle
- Use only spring tension
Tensioner type
- Compensation and impact absorbing
Static and dynamic force
- Spring
6. RAIL ASSEMBLY
The guide rail is used for optimizing the movement of chain drive system. And it also prevents the chain
from contacting each other when the chain is loose, and reduces the chain wear.
The guide rail is made of plastic, nylon, Teflon, etc. The guide rail is specially required when the distance
between two spokes is too great. It pushes the chain with constant force so that the chain can work
smoothly. The guide rail is fitted by pins.
Tensioner guide rail Clamping guide rail

7. TIMING GEAR CASE COVER
- Major function: Protecting the chain drive system, minor function: Shielding the chain noise.
- Install crankshaft front seal and screw plug on the timing gear case cover.
Location of chain tensioner

screw plug
A671 997 01 46
Crankshaft front seal
- Do not touch the inner lip of crankshaft front seal.

- Be careful not to damage the screw thread when removing the lock pin to release the chain
tensioner.
- Be careful not to damage the O-ring when installing the screw plug.
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Timing gear case cover (TGCC)
Timing gear case cover Oil seal
Screw plug
8. HOW TO CHECK ENGINE TIMING
Camshaft
Rotate the engine and check whether the cam

nose position (A) is at 12 o'clock using the oil
filler cap on the cylinder head cover.
For crankshaft pulley
Timing mark Rotate the crankshaft pulley to align the pulley

OT
marking with the timing mark.

Pulley marking
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Timing marks on intake & exhaust camshafts
Exhaust Intake Align the timing marks. (two timing marks for
intake camshaft gear, one timing mark for
exhaust camshaft gear)
For exhaust camshaft sprocket
Check whether the mark (A) on the exhaust

camshaft sprocket is at 12 o'clock.
For crankshaft sprocket
Check whether the mark (C) on the crankshaft

sprocket is at 6 o'clock.
- The brass links (B) and (D) on timing chain are aligned with the timing marks on crankshaft
sprocket and camshaft sprocket by eight turns of crankshaft.
- Align the each sprocket mark with the brass links on the timing chain when installing the timing
chain.
1. OVERVIEW
The D22DTR engine is of FR(Front engine Rear wheel drive) type and installed in longitudinal to the
direction of travel. The crankshaft and the cylinder block convert the combustion and compression
energy to the rotating energy.
2. COMPONENTS
Cylinder block
Connecting rod Piston
Crankshaft
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3. PISTON
1) Overview
The piston assembly mainly consists of piston,
top ring, second ring, oil ring, piston pin and
snap ring. This assembly transfers the
expansion energy generated by combustion in
the engine to the crankshaft through the
connecting rod. The reciprocating power is
converted into rotary power in this process.
Wide bowl type (CR 16.5) Material: B2+ Ring #2
Piston cooling
gallery for
Ring #1 connecting rod
Oil ring
Piston pin &

snap ring
Cooling jet
Skirt coating: MoS2
3) Functions For Each Part
The piston transfers the explosion energy from engine to connecting rod. Especially in the direct injection
diesel engine, it provides the combustion space and largely effects to the engine performance and exhaust
gas.
Piston ring
- Ring #1 (top ring): Prevents the high pressurized combustion gas from leaking into crank chamber, and
prevents the engine oil getting into combustion chamber.
- Ring #2: Scrapes the engine oil on the cylinder bore, and prevents the leaked combustion gas
from #1 ring from leaking into the crank chamber.
- Oil ring: Scrapes the engine oil on the cylinder bore.
Piston pin
- Connects the piston the connecting rod, and transfers the reciprocating motion of piston to connecting
rod directly.
Snap ring
- Locks the piston pin.
4) Assembling Piston Ring

1.
from the opening of the top ring.
Top ring
2.
the opening of the second ring.
Second ring 3.
from the opening of the oil ring.
Oil ring
Coil spring
Oil ring
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Selecting piston oversize
Top of piston Top of cylinder block
Piston Cylinder bore

Engine
Part No. Marking No. -
672 037 00 01 - -
672 037 01 01 A A
672 037 02 01 X X
D22DTR
672 037 03 01 B B
672 037 04 01 +5 -
672 037 05 01 +10 -
4. CONNECTING ROD
1) Overview
Connecting rod converts the reciprocating movement of piston to the rotating movement of crankshaft.
The big end is connected to connecting rod bearing and the crank pin journal, and the small end is
connected to the piston pin.
Piston pin bush
Connecting rod
Connecting rod upper bearing
Connecting lower bearing
Connecting rod cap
Connecting rod cap bolt

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3) Selecting Crankshaft Pin Journal Bearing

- The connecting rod bearing contains 3 sets of 3 grades in upper and lower sections.
- Three sets in the table below have nearly same oil clearance (0.015~0.063 mm) of bearing.
- Identification: Coloe mark on bearing side surface
Connecting Upper bearing Lower bearing Journal Oil

No rod/ Bore diameter of clearance of
diameter in Grade Bearing Grade Bearing crank pin bearing
big end thickness thickness
1 1.804 1.812 0.017

R B
54.600 1.808 1.815 50.935 0.063
2 1.808 1.809 0.016

Y Y
1.812 1.812 0.062
3 54.614 1.812 1.806 50.960 0.015

B R
1.816 1.809 0.061
Min. 0.015
Oil clearance of connecting rod bearing
Max. 0.063
5. CRANKSHAFT
1) Overview
Crankshaft is installed on the cylinder block.
Upper thrust bearing
Crankshaft main bearing upper Crankshaft main bearing upper
Crank pin journal Main journal
Lower thrust bearing
Crankshaft main bearing lower Crankshaft main bearing lower

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3) Selecting Crankshaft Main Bearing

Mating surface of crankshaft sprocket
Bottom of cylinder block

Selection of lower main bearing
Selection of upper main bearing
Selection of bearing according to pin punch & Mark Color Thickness of main
color bearing (mm)
Mark Color Thickness of main V Violet +0.030
2.25
bearing +0.025
* Blue 66.500~66.506 W White +0.025
2.25
+0.020
** Yellow 66.506~66.513
R Red +0.020
*** Red 66.513~66.519 2.25 +0.015
Y Yellow +0.015
2.25 +0.010
B Blue +0.010
2.25 +0.005
6. CYLINDER BLOCK
1) Structure
Blow-by gas hole
Cylinder head supply hole
Oil return hole
Expansion plugs (3 for intake)
Expansion plugs (4 for exhaust)
Screw plugs (2 EA)
Turbocharger oil
return pipe mounting
Engine numbering mark

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Engine numbering mark

The bottom side of water jacket is desgined as sine wave to strengthen the structure of crankcase. The
main flow of coolant starts from outlet port of water pump and goes along the longitudinal direction of
engine. The coolant passage from cylinder head to inlet port of water pump is integrated in cylinder head.
Water jacket core
The engine oil from oil pump is supplied to the main oil gallery through oil channel, oil filter module and
cross bore in cylinder block without using external pipes. This oil is supplied to main bearing, cylinder
head and MBU. And, it is sprayed to the chain through the chain tensioner connected to cross bore.
Crankcase cross bore for oil supply

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1. Drain the coolant from the radiator and engine

cylinder block screw plug.
2. Remove the battery.
Refer to "BATTERY" under "REMOVAL AND

INSTALLATION" subsection of "CHARGING
SYSTEM" section in "D22DTR ENGINE"
chapter.
3. Remove the automatic transmission assembly.
See "MANUAL TRANSMISSION

ASSEMBLY" under "REMOVAL AND
INSTALLATION" subsection of "6-SPEED
M/T SYSTEM" in "CHASSIS" chapter.
4. Remove the hood panel assembly.
Refer to "HOOD PANEL ASSEMBLY" under

"REMOVAL AND INSTALLATION" of "BODY
EXTERIOR" section in "BODY" chapter.

6. Remove the front end cover.
7. Remove the snorkel assembly.
8. Disconnect the hose between the intercooler

and the engine.
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9. Separate the 2 deaeration radiator hose

mounting clamps using a plier.
10.Disconnect the deaeration radiator hose.
11.Unscrew the radiator outlet hose mounting

clamp (A, 7 mm) and bracket mounting bolt
(B, 10 mm).
12.Undo the mounting clamp (7 mm) for the

radiator outlet hose under the vehicle.
13.Disconnect the radiator outlet hose.
14.Unscrew the 2 radiator inlet hose mounting

clamps (7 mm).
15.Remove the radiator inlet hose.
16.Disconnect the PWM controller connector.

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17.Carry out the following works:

(A) Disconnect the HFM connector.
(B) Remove the bypass hose clamp.
(C) Undo the mounting clamp (10 mm) on
the hose from the air cleaner to the
turbocharger hose.
(D) Fixing clips for air cleaner upper
housing (2 off)
18.Remove the air cleaner upper housing and

hose assembly.
19.Remove the air cleaner.
20.Undo the 2 mounting clamp (7 mm) on the

hose from the turbocharger to the intercooler.
21.Disconnect the hose between the
turbocharger and intercooler.
22.Disconnect the deaeration hose from the

cylinder block
23.Disconnect the makeup hose from the

coolant reservoir tank assmebly.
24.Disconnect the front oxygen sensor

connector (A) and remove the wiring fastener
(B).
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25.Unscrew the one ground mounting bolt (12

mm) from the cylinder block.
26.Unscrew the 2 mounting nuts (12 mm) for the

front exhaust pipe and remove it.
27.Disconnect the engine main wiring

connectors (A) and (B) and 2 wiring
fasteners (C) and unscrew the ground
mounting bolt (10 mm).
28.Open the cap of the power steering oil

reservoir tank and collect the oil completely
using an oil suction unit.
Avoid getting power steering oil in your skin

or the vehicle body.
29.Remove the power steering oil suction hose.
30.Unscrew the eye bolt (24 mm) securing the

power steering oil supply pipe.
- Keep clean the other parts from the

residual oil when disconnecting the pipe
and hose.
- Fit the sealing cap to the power steering
pump and oil supply pipe.
31.Unscrew the one mounting bolt (10 mm) for

the power steering oil supply pipe.
32.Unscrew the ground mounting bolt (A, 12

mm) and the 2 wiring fasteners (B) for the
battery negative cable.
0000-00
33.Disconnect the connector C117 (A) and glow

control unit connector (B).
34.Remove the fuel return and supply tube.
35.Disconnect the vacuum tube (A) and fuel

return tube (B).
36.Disconnect the heater inlet/outlet hoses.

37.Unscrew the mounting bolt (12 mm) on the
A/C compressor assembly to remove the A/C
pipe.

PWM electric fan assembly.
39.Remove the PWM electric fan assembly.
40.Connect the engine crane hook to the engine

hanger bracket.
0000-00
41.Unscrew the LH/RH engine mounting

insulator through mounting bolt (19 mm).
42.Remove the engine assembly while paying

attention to interference.
Lift up the engine assembly by turning it anti-

clockwise since interference occurs when
removing the engine.
43.Disconnect the heater inlet/outlet hoses from

the removed engine assembly.
44.Remove the booster vacuum hose, vacuum
45.Unscrew the one mounting bolt (13 mm) for

the battery negative cable.
46.Disconnect the battery negative cable.
47.Remove the coolant outlet pipe and hose.

0000-00
48.Disconnect the front exhaust gas temperature

sensor connector (A) and E-VGT actuator
connector (B).
49.Unscrew the following mounting bolts to the

cylinder block:
(A) Turbocharger support bracket

mounting bolt(13 mm, 1 off)
(B) Oil supply pipe mounting bolt
(24 mm, 1 off)
(C) Oil return pipe mounting bolt
(hexagon, 5 mm, 2 off)
50.Unscrew the 3 mounting nuts (13 mm) for the

turbocharger assembly.
51.Remove the turbocharger assembly.

52.Unscrew the 3 mounting bolts (30mm)
53.Remove the LH mounting bracket.
54.Unscrew the 4 mounting bolts (30mm)
55.Remove the RH mounting bracket.

0000-00
56.Install the engine mounting brackets to set up

on the engine stand.
Part number : LH 6622233604

RH 6622233504
Pay particular attention to the location of the

bolt holes.
57.Install the engine assembly on the engine
stand.
58.Install the engine assembly on the vehicle in

the reverse order of removal.
Start the engine and check if the coolant

flows through the deaeration hose.
If the coolant does not flow, bleed the air
from the engine cooling system (Refer to
Chapter "Cooling System").
See "FILLING COOLANT AND BLEEDING"

under "COOLING SYSTEM" section in
0000-00
- Remove the engine assembly from the vehicle (refer to "ENGINE ASSEMBLY" under
this subsection).
- Install the engine assembly to the engine stand.
1) Dismantling Engine For Overhaul

1. Remove the 10 mounting nuts (17 mm) for the
fuel high pressure pipe.
- Plug the openings of the fuel rail and high

pressure pump and injector nozzles with
seal caps after removing the fuel high
pressure pipe.
- Replace the fuel high pressure pipe with a
new one when installing.
Block diagram for fuel high pressure pipe

2. Disconnect the following connectors:
(A) Front exhaust gas temperature sensor

connector
(B) Injector connector
(C) Fuel rail pressure sensor connector
(D) Variable swirl actuator connector
(E) Oil pressure switch connector
(F) Camshaft position sensor connector
(G) E-EGR valve connector
(H) EGR bypass solenoid valve connector
(I) Crankshaft position sensor connector
(J) Electric throttle body connector
(K) T-MAP sensor connector
(L) Glow plug connector
(M) Fuel temperature sensor connector
(N) Coolant temperature sensor connector
(O) IMV (Inlet Metering Valve) connector
Glow plug connector
(C) Remove the glow plug connector with

long nose pliers
0000-00
3. Remove the engine compartment main wiring

mounting brackets and engine ground.
(A) Wiring brackets (2 mounting bolts, 10 mm)

(B) Ground and wiring bracket
(1 mounting bolt, 10 mm)
(C) Ground (1 mounting bolt, 10 mm)
4. Unscrew the 4 engine main wiring mounting

bolts (10 mm).
5. Remove the engine main wiring.
6. Turn the pivot damped tensioner bolt (A) to the

arrow direction using a belt tensioner relief tool
to relieve the tension and remove the fan belt.

compressed auto tensioner when releasing
deformation of the belt tensioner.
7. Remove the 1 mounting bolt (A, 17 mm) and 1
mounting bolt (B, 13 mm) for the pivot damped
tensioner.
8. Remove the pivot damped tensioner.
Auto tensioner assembly
1 Belt tensioner
2 Tensioner housing
3 Belt tensioner pulley
4 Belt tensioner pulley cover
9. Remove the covers from the fan belt idle

pulleys No. 1 (A) and 2 (B).
0000-00
10.Unscrew a mounting bolt (T50) and remove the

idle pulleys No. 1 (A) and No. 2 (B).
Idler pulley Idler pulley 1 Idler pulley cover No. 1

assembly No. 2 assembly No. 1
2 Idler pulley No. 1
3 Idle pulley No. 1 mounting bolt
4 Idler pulley cover No. 2
11.Unscrew the 4 mounting bolts (13 mm) for

the A/C compressor.
12.Remove the A/C compressor.

13.Unscrew the mounting bolt (A)(17 mm) and
mounting bolt (B)(15 mm) for the alternator.
14.Remove the alternator.
Press the bushing to the bracket into arrow

direction in order to facilitate assembling.
15.Unscrew the mounting bolt and nut (A, 13

mm) and 2 mounting bolts (B, 13 mm) for the
power steering oil pump assembly.
0000-00
16.Remove the power steering oil pump

assembly.
17.Unscrew a mounting bolt (10 mm) for the oil

dipstick tube.
18.Remove the oil dipstick tube.
Replace the O-ring with a new one when

installing.
19.Separate the front exhaust temperature sensor

connector from the mounting bracket and
unscrew a bracket mounting bolt (10 mm) to
remove it.
20.Unscrew the front exhaust gas temperature
sensor mounting nut (17 mm).
21.Remove the front exhaust gas temperature

sensor.

mm) for the exhaust manifold LH/RH heat
protectors.
23.Remove the LH/RH heat protectors.

0000-00
24.Unscrew the 10 mounting nuts (12 mm) for

the exhaust manifold.
Replace the mounting nuts with new ones

when installing the exhaust manifold.
Exhaust manifold mounting bolts
To protect the exhaust manifold from damage, unscrew the mounting bolts in several steps, in the
- When removing: from the outside to the inside, diagonally
- When installing: from the center to the outside, diagonally
25.Remove the exhaust manifold.

26.Remove the exhaust manifold gasket.
exhaust manifold gasket
Replace the gasket with a new one when

installing.

and 2 mounting bolts (B, 13 mm) for the EGR
cooler pipe.
28.Remove the EGR cooler pipe.
EGR cooler pipe gasket

(A) To intake duct (B) To E-EGR valve

installing.
0000-00

the intake duct.
30.Remove the intake duct.

installing.
Intake duct gasket
31.Disconnect the vacuum hose from the EGR

bypass actuator.
32.Undo the spring clamp to disconnect the

EGR cooler outlet hose for the EGR cooler
assembly.
EGR cooler assembly.
34.Remove the EGR cooler assembly.

installing.
EGR cooler gasket
35.Unhook the 2 mounting clamps for the EGR

valve hose.
0000-00
36.Remove the EGR valve hose.
37.Unscrew the 3 mounting bolts (13mm) for the

E-EGR valve assembly.
38.Remove the E-EGR valve assembly.
The intake manifold gasket and E-EGR valve

gasket are connected to each other.
Therefore, it is possible to replace the
corresponding gasket only by cutting the (A)
part of new gasket when the intake manifold is
not removed at the same time.
intake manifold assembly.
Mounting bolts for intake manifold
To protect the intake manifold from damage, unscrew the mounting bolts in several steps, in the
40.Remove the intake manifold assembly.

installing.
Intake manifold gasket
0000-00
41.Undo the 3 spring clamps and disconnect the

EGR cooler inlet hose (A) and hot water inlet
hose (B).
42.Unscrew the 8 mounting bolts (13 mm) for the oil filter & cooler assembly.
No. Tool dimensions Bolt length (mm) Tightening torque

quantity
(mm)
A 40 5
B 13 120 1
C 140 2
43.Remove the oil filter & cooler assembly.

installing.
O-rings for oil filter &

cooler assembly

mm) for the fuel rail assembly.
45.Remove the fuel rail assembly.
46.Unscrew the glow plug using a long socket

(10 mm).
Be careful not to apply physical shocks to the

ceramic glow plugs, when handling them.
Always use a hand tool with a torque wrench
when removing/installing. Using an air tool is
prohibited to prevent damage to the plugs.
0000-00
47.Remove the glow plug.

mm) for the high pressure pump.
The mark on the

high pressure pump
is aligned with mark
on the intake
camshaft sprocket if
the engine chain
timing marks are
lined up.
49.Remove the high pressure pump assembly.

coolant outlet port assembly.
51.Remove the coolant outlet port assembly.

installing.
O-ring for coolant outlet port

hot water inlet pipe.
53.Unscrew the 2 mounting bolts (E10) for injector

clamp.

reusable. Always replace it with a new one.
54.Free the injector using a special tool.
Refer to "INJECTOR" under "REMOVAL

AND INSTALLATION" subsection of
"ENGINE CONTROL SYSTEM" section in
"ENGINE" chapter.
0000-00
55.Remove the injector.
The injectors of the vehicle may have been

replaced before. Therefore, check the actual
C3I value of each cylinder with a SIW
diagnostic equipment before installing the
injectors.
Checking C3I code when installing the injector
The C3I code for injector specification (B) is

engraved on the cylinder head cover (A) for
each cylinder. Fit the correct cylinder for the
C3I code.
(A) on cylinder head cover (B) on injector
C3I
Cylinder no.
Engine serial number and C3I code for each injector on two labels in C3I code marked on the upper
cylinder head cover side of injector
C3I [Improved Individual Injector Calibration]
C3I code Totally 20 digits

(use Arabian numbers (1~9) and Alphabet except I, O, Q, V)
MDP learning When idling and driving
Numbers of nozzle Eight
56.Install the new copper washer for injector.
Replace the copper washer with a new one

when installing.
Copper washer
If the injector copper washer is installed to the

cylinder head, remove it with a special service
tool.
(part number:
Y99220022B)

the cylinder head cover.
0000-00
Mounting bolts for cylinder head cover
To protect the cylinder head cover from damage, unscrew the mounting bolts in several steps, in
the sequence shown in the picture.
58.Remove the cylinder head cover.

installing.
Cylinder head cover gasket
vacuum pump.
60.Remove the vacuum pump.
The slot parts of the vacuum pump are parallel

to each other as shown in the figure if the
engine chain timing marks are lined up. Align
the slots when installing.
O-ring (vacuum pump)

installing.
61.Unscrew the mounting bolt (10 mm) for the

camshaft position sensor.
62.Remove the camshaft position sensor.
Check the condition of the O-ring for the

camshaft position sensor and replace it with
new one, if necessary.
0000-00

64.Remove the cylinder head front cover as


parts while removing the front cover.
65.Remove the cylinder head front cover as

Marks to align the timing
- Check whether the mark (A) on the

exhaust camshaft sprocket is at 12 o'clock.
The brass link (B) on timing chain are aligned

with the timing marks on crankshaft sprocket
and camshaft sprocket by eight turns of
crankshaft.
- Rotate the crankshaft pulley to align the

Timing mark crankshaft pulley marking (C) with the
timing mark (D).
OT mark

Crankshaft pulley mark
66.Undo the hydraulic tensioner plug cap (22

mm).
67.Remove the hydraulic tensioner plug cap..
O-ring for hydraulic tensioner

plug cap
0000-00
68.Compress the hydraulic chain tensioner to fix

it.
Press the tensioner plunger into (A) using a flat bladed screwdriver (B) towards arrow (C) direction to
compress the hydraulic chain tensioner and insert the tensioner mounting pin or L wrench (D) with 2
mm of diameter as shown in the figure.
69.Make marks on the exhaust camshaft

sprocket (A) and upper chain bush (B) and tie
up the upper chain bush (B) and clamping rail
(C) to each other with a cable tie. (The brass
links are aligned by eight turns of crankshaft.)
70.Fit a 32mm spanner on the octagon seating

camshaft sprocket.
72.Install the scissors gear mounting pin into the

exhaust camshaft gear (A) groove.
Be sure to install the mounting pin prior to

removing the camshaft.
Markings on timing gear
Exhaust camshaft Intake camshaft

0000-00
73.Unscrew the 4 mounting bolts (A, 13 mm) and 18 mounting bolts (B, 10 mm) for the camshaft bearing
caps.
Unscrew the camshaft cap mounting bolts

slowly in two or more stages according to
the specific sequence stated below.
(1) Exhaust cams: EX, 2, 4

(2) Intake cams: IN, 6, 9
(3) Exhaust cams: 1, 3
(4) Intake cams: 5, 7, 8
74.Remove the 11 camshaft bearing caps.

75.Remove the intake and exhaust camshafts.
Intake camshaft
Exhaust
camshaft
76.Remove the No. 1 lower cap.
77.Remove the 16 finger flower & hydraulic lash

adjuster assemblies.
78.Unscrew the mounting bolt (A, T50) for the

tensioner rail and the mounting bolt (B, T50) for
the clamping rail.
0000-00
79.Remove the tensioner rail.
Lift up the timing chain to remove the

tensioner rail as shown in the figure.

mm) for the cylinder head.
Replace the bolts with a new one when

installing.
81.Remove the 10 mounting bolts (M14 mm) for the cylinder head.
M14 mm beat socket
Sequence Tightening torque

1
2
To protect the cylinder head from damage, remove the bolts in sequence as follows:
82.Remove the mounting bolt (A) and washer (B)
for the cylinder head.
Do not reuse the cylinder head mounting bolt

and washer.
83.Remove the cylinder head.
When removing the cylinder head with it fitted

to the glow plug, be careful not to damage
the glow plug, since the broken pieces may
enter inside the cylinder and damage the
engine if the glow plug is exposed to an
impact, which results in breakage of it.
84.Remove the cylinder head gasket.
85.Secure the drive plate with the flywheel fixture.
Flywheel fixture
(Part No.: T99110010A)
0000-00
86.Unscrew the crankshaft pulley center bolt (27

mm).

1
2
87.Remove the crankshaft pulley.
88.Remove the 8 mounting bolts (T55) for the

drive plate assembly.

1
2
89.Remove the drive plate (A) and plate (B).

90.Remove the trigger ring.
Do not work with a trigger ring near a magnetic

tool or equipment, as the triggering can lose
magnetic properties easily by an external
magnetic field or scratches on the surface.
91.Unscrew the hexagon mounting bolt (4 mm)

for the crankshaft position sensor.
92.Remove the crank position sensor.
93.Unscrew and remove the 4 mounting bolts (10

mm) for the A/C compressor.
0000-00
94.Unscrew the oil pan mounting bolts.
Mounting bolts for oil pan
No. Tool dimensions Bolt length Tightening

Quantity
(mm) (mm) torque
A 10 20 20
B 10 35 2
C 10 85 2
D 10 120 2
E 13 40 2
To prevent the oil pan from being deformed, unscrew the mounting bolts in several steps, in the
95.Separate the oil pan using a flat bladed (-)
screwdriver.
96.Remove the oil pan.

ladder frame.
98.Remove the ladder frame.

0000-00

the crankshaft rear seal.
Remove the crankshaft rear seal.
Remove the front oil seal with a special

service tool (oil seal puller).
Oil seal puller

(part number: X99360130A)
Unscrew the mounting bolts for the timing
gear case cover.
Mounting bolts for timing gear case cover
No. Tool dimensions Bolt length Quantity Tightening

(mm) (mm) torque
A 17 55 3
B 10 40 7
C 10 50 3
D 10 45 1
To prevent the timing gear case cover (TGCC) from being deformed, unscrew the mounting
bolts in several steps, in the sequence shown in the picture.
0000-00
Remove the timing gear case cover

(TGCC).
Place to separate timing

gear case cover
Unscrew the 2 hexagon mounting bolts (5

mm) for the hydraulic tensioner.
Remove the hydraulic tensioner.
Remove the cable tie (A) securing the

clamping rail and remove the upper chain
bush.
Unscrew the 2 mounting bolts (T50) for
clamping rail.
Remove the clamping rail.
Pull the oil pump chain tensioner to the

arrow (A) direction (A) and insert the
mounting pin or L-wrench with 2 mm of
diameter (B) into the hole to secure it.
Unscrew the mounting bolt (T50) for the oil

pump chain tensioner.
0000-00
Remove the oil pump chain tensioner.
Unscrew the 3 hexagon mounting bolts (6

mm) for the oil pump.
Pull out the oil pump (A), lower chain bush

(B), and crankshaft sprocket (C) at the
same time.
Make sure not to lose the half-moon shaped

key when removing the crankshaft sprocket.
Half-moon shaped key

Remove the carbon on the top of each
cylinder block combustion chamber (A) to
facilitate the removal of piston assembly.
Turn the crankshaft and work on the No.

1 and 4 cylinders first, and then No. 2 and
3 cylinders.
Unscrew the 2 mounting bolts (E10) for the

connecting rod cap.

1
2
Remove the connecting rod cap.
Make a paint mark on each cylinder before

removing the connecting rod cap.
Remove the piston assembly.
Use the same procedures for the rest of

piston assemblies. Remove the No. 1 and
No. 4 piston assemblies first, and then the
No. 2 and No. 3 piston assemblies.
0000-00
Piston assembly
- Remove the piston pin after separating

the snap ring from the removed piston.
- Separate the piston and connecting rod.
- Remove the piston ring from the piston and
put them together.
Replace the piston ring, bearing and snap

ring with new ones.
Name
1 Piston
2 Connecting rod
3 Connecting rod cap
4 Connecting rod upper bearing
5 Connecting rod lower bearing
6 Piston pin
7 Snap ring
8 Top ring
9 Secondary ring
10 Oil ring
Unscrew the 10 mounting bolts (12-point, 13
mm) for the crankshaft main journal bearing
caps.

1
2
Mounting bolts for crankshaft main journal bearing caps
To protect the crankshaft from damage, remove the bolts in sequence as follows:
Remove the crankshaft main journal

bearing cap.
Make paint marks on each cylinder before

removing the crankshaft main journal bearing
caps.
0000-00
Remove the crankshaft.
Remove the 2 upper thrust bearings from

the No. 3 main journal.
Upper thrust bearing
Remove the 5 crankshaft upper main

journal bearings.
2) Inspection
(1) V-belt
Put a chalk mark on the belt.
Check the belt for any damage by rotating the
engine.
Replace the belt if any damage is found as

described below:
1. Rubber piece in the belt rib base

2. Dust or sand
3. Rib shaped in wedge

4. Exposed belt cord on the rib base
5. Torn tension cord

6. Worn outer tension cord
0000-00
7. Stripped rib on belt base
8. Cracked rib in lateral direction

9. Torn rib
10.Cracked rib in several lateral directions
11.Crack on back side of belt in lateral

direction
(2) Cylinder Block
Measuring cylinder block bore
1. Wipe out the cylinder bore.

2. Measure the bore size in axial direction and
vertical direction on 3 points (1, 2, 3) with a
bore gauge.
Measuring points 1, 2, 3
A. Axial direction
B. Vertical direction
a. Piston position at TDC
b. Piston position at BTDC
c. Oil ring position between TDC and BTDC
0000-00
(3) Crankshaft
Measuring crankshaft bearing bore
Measure the bore of the crankshaft bearing with
a bore gauge.
- Measure the values at 2 points (1, 2).

Measure the values at the A, B and C as
- If the average value of B and C is less than
the value of A, then it can be used as actual
average value. If the average value of B
and C is greater than the value of A, then
the value of A can be used as actual
average value.
Crankshaft Journal
Measure the bore of the crankshaft bearing
journal with a micro meter.
- Measure the values at 3 points (A, B, C) and

calculate the average value.
- If the average values of the bearing bore and
journal diameter are not within the specified
range, replace the bearing shell.
Crankshaft end play test
Location
Magnetic base part: Cylinder block side
Dial gauge: In front of crankshaft
Specified value (mm)

0.100 ~ 0.266
(4) Piston and Connecting Rod
Install the compression rings (top ring, second

ring) and oil ring to the piston using a piston ring
mounting tool.
- Check the piston ring for damage, wear and

crack. Replace a damaged piston ring, if
necessary.
- When replacing the piston, the piston ring
should be replaced
The opening section of the piston oil ring should
- Install the No.1 and No. 2 compression rings

with the marks facing upwards.
- Thickness of no. 1 piston ring > Thickness of
no. 2 piston ring
- Put the oil ring with the opening section
positioned on the other side of the base
opening.
- The oil ring has no direction.
- Make sure that the openings of the piston
are not overlapped.
0000-00
Back clearance
1. Insert the piston ring being measured in the
cylinder block.
2. Measure the inner diameter of piston ring.
3. Measure the outer diameter of piston ring
groove on the piston.
4. (Piston ring inner diameter) - (Piston ring
groove outer diameter) = (Back Clearance)
Items Specified value

No. 1 compression ring
Side clearance
1. Measure the height of piston ring.
2. Measure the height of piston ring groove on
the piston.
3. (Piston ring groove height) - (Piston ring
height) = (Side Clearance)

Piston end gap

1. Insert the piston ring being measured in the
cylinder block.
2. Measure the end gap of piston ring.

0.18 ~ 0.33mm

0.33 ~ 0.48mm
No. 3 oil ring 0.20 ~ 0.40mm

3) Assembling After Overhaul
1. Clean the cylinder bore, connecting rod, connecting rod bearing shell and piston thoroughly with
compressed air.
Top of cylinder block Bottom of cylinder block
1. Head bolt seat 4. Oil jet

2. Oil return groove 5. Oil feeding hole
3. Coolant passage groove 6. Oil return groove
The oil spray nozzle injects the oil to the inside of the piston.
Make sure that the oil spray nozzle pipe does not contact
the connecting rod.
0000-00
2. Select the crankshaft main bearing.

A. There are five punch marks on the bottom of the
cylinder block (oil pan contact surface). These
punch marks match to the mounting locations of
each main bearing. Therefore, select the
crankshaft upper main bearing according to these
punch marks.
B. Select the lower main bearing that is engaged to
the crankshaft bearing cap by the mark on the
crankshaft sprocket mounting surface.
Bottom of cylinder block Mating surface of crankshaft sprocket
Selection of lower main bearing
Selection of upper main bearing
Selection of bearing according to pin

punch & color Mark Color Thickness of main
bearing (mm)
Thickness of main
Mark Color +0.030
bearing V Violet 2.25 +0.025
* Blue 66.500~66.506
+0.025
W White 2.25
** Yellow 66.506~66.513 +0.020
*** Red 66.513~66.519 +0.020
R Red 2.25
+0.015
Y Yellow 2.25 +0.015

+0.010
2.25 +0.010
B Blue
+0.005
3. Install the upper bearing shell on the crankshaft.
- Check the color of new main bearing and

align the key grooves (A) and oil grooves (B)
of the cylinder block.
.
- Apply the engine oil to the upper bearing

shell.
Make sure the oil holes of the bearing are

aligned with the oil passages in cylinder
block.
4. Place the crankshaft on the cylinder block.
5. Fit the upper thrust bearings to the No. 3 main

journal.
- Install the thrust bearing so that its oil

groove (A) faces outward.
- Remove the foreign materials on the thrust
bearing.
- Insert the bearing after applying the engine
oil.
0000-00
6. Apply the engine oil to the bearing contact

surface of the crankshaft.
7. Fit the crankshaft lower main journal bearing

(A) to the bearing cap (B).
Check the color of new main journal bearing

and align the key groove (A) of the bearing
with that of the bearing cap.
8. Install the crankshaft main journal bearing caps

to the cylinder block excepting No. 3 main
journal bearing cap.
9. Fit the lower thrust bearing to the No. 3 main

journal bearing cap.
- Fit the thrust bearing so that its oil groove

(A) faces outward.
- Fit the bearings after applying the engine
oil.
10.Fit the No. 3 main journal bearing cap to the
cylinder block.
11.Tighten the 10 mounting bolts (12-point, 13

mm) for the crankshaft main journal bearing
caps to the specified torque followed by
specific angle shown below.

1
2
Mounting bolts for crankshaft main journal bearing caps
Angle tightening procedures
Reference point
Tighten the mounting bolts to the tightening torque

firstly, make paint marking on each bolt and carry
out angle tightening secondly according to the right
sequence.
To protect the crankshaft from damage, install the bolts in sequence as follows:
0000-00
Check the main journal end play of the

crankshaft after installing the main journal
bearing caps.
Specified value (mm)

0.100 ~ 0.266
Selecting piston oversize

Top of piston Top of cylinder block
Piston Cylinder bore

Engine
Part NO Marking NO. -
672 037 00 01 - -
672 037 01 01 A A
672 037 02 01 X X
D22DTR
672 037 03 01 B B
672 037 04 01 +5 -
672 037 05 01 +10 -
Selecting crankshaft pin journal bearing
- The connecting rod bearing contains 3 sets of 3 grades in upper and lower sections. (Example: R-
B, Y-Y, B-R)
- Three sets in the table below have nearly same oil clearance (0.015~0.063 mm) of bearing
considering machining tolerance of the connecting rod and crankshaft pin journal diameters.
Identified with color mark on bearing side surface.
Con. rod upper bearing Con. rod lower bearing Crank pin Oil clearance
Con/Rod
No Big End journal of bearing
Bore Dia. Bearing Bearing diameter
Grade Grade
thickness thickness
1.804 1.812 0.017
1 R B
54.600 1.808 1.815 50.935 0.063
1.808 1.809 0.016
2 Y Y
1.812 1.812 0.062
54.614 1.812 1.806 50.960 0.015
3 B R
1.816 1.809 0.061
Min. 0.015
Oil clearance of connecting rod bearing
Max. 0.063
13.Assemble the piston assembly.
Replace the piston ring, bearing and snap

ring with new ones.
14.Install the piston assembly to the cylinder

block using the following procedure.
0000-00
How to install piston assembly
Check the paint marks on the piston

assembly and connecting rod caps as
shown in the picture. Do not mix up.
When installing the piston assembly to the

engine, check the arrow on top of the
piston.
To pulley To flywheel
To pulley To flywheel
A. Apply engine oil to the piston surface and

piston ring.
- The opening section of the piston ring

should be positioned at an interval of
- Make sure not to mix up the piston with

cell.
B. Insert the piston assembly (B) into the
piston compression tool (A, Y9922 017 2B).
C. Insert the piston assembly by putting it onto

the cylinder block and pushing to the arrow
direction.
the No. 1 and 4 cylinders first, and then No.

2 and 3 cylinders.
Be careful of the damage due to the

interference between the piston and oil jet.
Make sure that the oil jet is securely

positioned in the piston groove.
Oil jet hole
D. Apply engine oil to the crankshaft.

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E. Install the connecting rod cap for each

cylinder.
F. Tighten the 2 mounting bolts (E10 mm) for

the connecting rod cap to the specified
torque.

1
2
Connecting rod mounting bolts
Angle tightening procedures
Reference point Reference point
Make a paint mark on Angle tighten the bolts

each bolt after the 1st further following the
torque tightening. table.
15.Insert the crankshaft sprocket into the half-
moon shaped key groove.
Make sure not to lose the half-moon shaped

key when installing the crankshaft sprocket.
Half-moon shaped key
16.Install the oil pump (A) and lower chain bush

(B).
17.Torque tighten the 3 hexagon mounting bolts

(6 mm) for the oil pump to the specified torque.
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18.Install the mechanical tensioner.
19.Tighten the mounting bolt (T50) for the

mechanical tensioner to the specified torque.
20.Remove the mounting pin (A) for the

mechanical tensioner.
21.Install the clamping rail.

22.Tighten the 2 mounting bolts (T50) for the
clamping rail to the specified torque.
23.Install the hydraulic tensioner assembly.
24.Tighten the 2 hexagon mounting bolts (5 mm)

for the hydraulic tensioner to the specified
torque.
25.Install the upper chain bush to the crankshaft

sprocket.
Align the brass link (A) with the crankshaft

timing mark (B) to install the upper chain
bush.
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26.Secure the upper chain bush to the clamping

rail with a cable tie.
27.Apply sealant to the timing gear case cover

(TGCC).
Sealant part number: 661 989 56 A0
28.Install the timing gear case to the cylinder block

while aligning the pin grooves of the timing gear
case cover (TGCC) with the cylinder pins (A) on
the cylinder block.
29.Check the step difference (2 off) between the

timing gear case cover (TGCC) and cylinder
block.
Flatness
Within 0.2 mm
specification
30.Torque tighten the mounting bolts for the
timing gear case cover to the specified torque.
Mounting bolts for timing gear case cover
Tool dimensions Bolt length Tightening

No. Quantity
(mm) (mm) torque
A 17 55 3
B 10 40 7
C 10 50 4
To prevent the timing gear case cover (TGCC) from being deformed, unscrew the mounting
bolts in several steps, in the sequence shown in the picture.
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31.Temporarily install the front oil seal to the

32.Install the new front oil seal with a front oil seal
fitting tool.
33.Install the ladder frame and tighten the 6

mounting bolts (13 mm) to the specified
torque.
34.Install the special tool to the crankshaft.
Special tool
(Part number: W99110120A)
35.Apply sealant to the crankshaft rear seal.
Sealant part number: 661 989 56 A0
36.Install the crankshaft rear seal.
Apply the grease to inside of the crankshaft

rear seal prior to installation.
37.Check the step difference between the

crankshaft rear seal and the cylinder block.
Flatness
Within 0.2 mm
specification
38.Tighten the 6 mounting bolts (10 mm) for the

crankshaft rear seal to the specified torque.
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39.Fit the wiring (A) and dust cover (B) of the

crankshaft position sensor.
40.Tighten the hexagon mounting bolt (4 mm) for

the crankshaft position sensor to the specified
torque.
41.Install the trigger ring.
42.Install the drive plate (A) and plate (B).

43.Secure the drive plate using a flywheel
fixture.
Flywheel fixture
(Part No.: T99110010A)
44.Tighten the 8 mounting bolts (T55) for the drive

plate to the specified torque.

1
2
Angle tightening procedures for drive plate mounting bolt
Make a paint mark on each bolt after the 1st torque Angle tighten the bolts further following the table.
tightening.
Tighten the mounting bolts in several stages diagonally when tightening firstly.
0000-00
45.Apply sealant on the oil pan before fitting it.
Take care not to spill the remaining oil in the oil pan.
For installation
- Clean away the foreign materials from the oil pan.
- Apply the specified sealant to the oil pan evenly.
- Sealant part no.: 661 989 57 20
46.Check the step difference between the oil pan and

the cylinder block.
Flatness
Within 0.2 mm
specification
47.Torque tighten the mounting bolts for the oil
pan to the specified torque.
Mounting bolts for oil pan
Tool dimensions Bolt length (mm) Tightening torque

No. Quantity
(mm)
A 10 20 20
B 10 35 2
C 10 85 2
D 10 120 2
E 13 40 2
To prevent the oil pan from being deformed, unscrew the mounting bolts in several steps, in the
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48.Install the A/C compressor brackets.
49.Tighten the A/C compressor mounting

brackets to the specified torque.
50.Install the crankshaft pulley.
51.Secure the drive plate with the flywheel fixture.
Flywheel fixture
(Part No.: T99110010A)
52.Tighten the center bolt (27 mm) for the
crankshaft pulley to the specified torque.

1
2
Angle tightening procedures for drive plate mounting bolt
Make a paint mark on each bolt after the 1st torque Angle tighten the bolts further following the table.
tightening.
53.Measure the piston protrusion.
Refer to "CYLINDER HEAD ASSEMBLY"

under "REMOVAL AND INSTALLATION" in
this section.
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54.Apply the sealant to the contact surface (A)

between the cylinder block and timing gear
case cover.
Sealant part number: 661 989 57 20
55.Measure the piston protrusion to select a

cylinder head gasket with proper thickness.
- Always replace the cylinder head gasket with

a new one when installing.
- Remove the foreign materials and the gasket
residual on the top surface of the cylinder
block and cylinder head before installing the
cylinder head gasket.
Gasket grade mark
56.Install the cylinder head.
When fitting the cylinder head with it fitted to

the glow plug, be careful not to damage the
glow plug, since the broken pieces may enter
inside the cylinder and damage the engine if
the glow plug is exposed to an impact, which
results in breakage of it.
57.Fit the mounting bolt (A) and washer (B) for
the cylinder head.
Replace the bolt and washer with new ones

when installing.
58.Tighten the 10 mounting bolts (M14) for the

cylinder head to the specified torque.

1
2
Installation of mounting bolts for cylinder head
To protect the cylinder head from damage, install

the bolts in sequence as follows:
- When removing: from the outside to the inside,
diagonally
- When installing: from the center to the outside,
diagonally
Do not reuse the mounting bolts for the cylinder
head.
Tightening process for cylinder head bolts

Paint mark 1st angle 2nd angle 3rd angle
Torque wrench
(Cylinder head / tightening tightening tightening
head bolt)
0000-00

for the cylinder head to the specified torque.
60.Install the tensioner rail.
Lift up the timing chain to install the tensioner

rail as shown in the figure.
61.Tighten the mounting bolt (A, T50) for the

tensioner rail and the mounting bolt (B, T50)
for the clamping rail to the specified torque.
62.Install the finger flower & hydraulic lash

adjuster assemblies (16 EA) and apply the
engine oil.
63.Install the No. 1 lower cap to the cylinder head.
64.Apply the engine oil to the mounting parts of

the camshaft.
65.Install the intake and exhaust camshafts.

Intake camshaft
- Line up the timing marks of the intake/

exhaust camshaft gear when installing.
- Make sure that the fixing pin of the exhaust
camshaft scissors gear may not drop into
the timing case during work.
Exhaust camshaft
Check points when installing intake/exhaust

camshafts
1. Check the timing marks of the
intake/exhaust camshaft gears.
2. Check whether the No. 1 nose of the
intake camshaft is located at 12 o'clock.
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66.Apply the engine oil to the camshaft and

install the 11 camshaft bearing caps.
Installation procedures of intake/exhaust camshaft bearing caps
Tighten the camshaft cap mounting bolts

slowly in two or more stages according to
the specific sequence stated below.
(1) Intake cams: 5, 7, 8

(2) Exhaust cams: 1, 3
(3) Intake cams: IN, 6, 9
(4) Exhaust cams: EX, 2, 4
67.Remove the fixing pin from the exhaust
camshaft scissors gear.
Always remove the fixing pin after fitting the

camshaft bearing cap.
Exhaust camshaft Intake camshaft
68.Install the exhaust camshaft sprocket.
Notes on exhaust camshaft sprocket installation

A. Pull the timing chain up with it parallel so that
the chain aligns to the tensioner rail (A) and
the clamping rail (B) correctly when
assembling.
B. Install the camshaft sprocket by aligning the

exhaust camshaft sprocket (C) with the brass
link (D) on the timing chain.
0000-00
C. Seat the exhaust camshaft sprocket (C) on the

camshaft (E) and temporarily fit the mounting
bolt.
Re-check the alignment between the timing

chain and the clamping/tensioner rail when
seating the camshaft.

surface (A) of the intake camshaft and hold the
spanner with one hand. Then torque tighten
the 2 mounting bolts (B, 13 mm) for the
exhaust camshaft sprocket to the specified
torque.
70.Remove the fixing pin from the hydraulic

tensioner.
71.Remove the cable tie at the clamping rail.

Marks to align the timing
- Check whether the mark (A) on the exhaust

camshaft sprocket is at 12 o'clock.
The brass link (B) on timing chain are aligned

with the timing marks on crankshaft sprocket
and camshaft sprocket by eight turns of
crankshaft.
- Rotate the crankshaft pulley to align the

Timing mark crankshaft pulley marking (C) with the
timing mark (D).
OT mark

Crankshaft pulley mark
72.Fit the hydraulic tensioner plug (22 mm).
O-ring for hydraulic tensioner

plug cap
73.Tighten the hydraulic tensioner plug cap (22

mm) to the specified torque.
0000-00
74.Install the high pressure pump assembly.
Cautions for installing high pressure pump assembly
O-rings
- Replace the high pressure pump O-rings with new ones.

- Align the timing mark of the high pressure pump gear with one of the intake camshaft
gear.
- The mark on the high pressure pump is aligned with timing mark on the intake camshaft gear if
the engine chain timing marks are lined up.

for the high pressure pump assembly to the
specified torque.
76.Apply the sealant to the cylinder head front
cover.
Sealant part number: 661 989 57 20
77.Install the cylinder head front cover.

cylinder head front cover to the specified
torque.
79.Install the camshaft position sensor and

torque tighten the 1 mounting bolt (10 mm) to
the specified torque.
0000-00
80.Install the vacuum pump.
The slot parts of the vacuum pump are parallel

to each other as shown in the figure if the
engine chain timing marks are lined up. Fit the
slots when assembling.
Replace the O-rings (A) and (B) for the

vacuum pump with new ones when installing.
81.Torque tighten the 3 mounting bolts (10 mm)

for the vacuum pump to the specified torque.
82.Install the cylinder head cover.

installing.
Cylinder head cover gasket
cylinder head cover to the specified torque.
Mounting bolts for cylinder head cover
To protect the cylinder head cover from damage, unscrew the mounting bolts in several steps, in
84.Install the new copper washer for injector.
Replace the copper washer with a new one

when installing.
Copper washer
0000-00
85.Remove the injector.
The injectors of the vehicle may have been

replaced before. Therefore, check the actual
C3I value of each cylinder with a SIW
diagnostic equipment before installing the
injectors.
Checking C3I code when installing the injector
The C3I code for injector specification (B) is

engraved on the cylinder head cover (A) for
each cylinder. Fit the correct cylinder for the
C3I code.
(A) on cylinder head cover (B) on injector
C3I
Cylinder no.
Engine serial number and C3I code for each injector on two labels in C3I code marked on the upper
cylinder head cover side of injector
C3I [Improved Individual Injector Calibration]
C3I code Totally 20 digits

(use Arabian numbers (1~9) and Alphabet except I, O, Q, V)
MDP learning When idling and driving
Numbers of nozzle Eight
86.Tighten the 2 injector clamp mounting bolts
(E10) to the specified torque.

reusable. Always replace it with a new one.
87.Install the glow plug.
Be careful not to apply physical shocks to the

ceramic glow plugs, when handling them.
Always use a hand tool with a torque wrench
when removing/installing. Using an air tool is
prohibited to prevent damage to the plugs.
88.Torque tighten the glow plug to the specified

torque using a long socket (10 mm).
Glow plug should be assembled after engine

cooled enough.
And then GCU characterization must be
executed.
89.Install the fuel rail.

0000-00

mm) for the fuel rail assembly.
91.Connect the hot water inlet pipe.

hot water inlet pipe to the specified torque.
93.Install the coolant outlet port assembly.

installing.
O-ring for coolant outlet port
coolant outlet port assembly to the specified
torque.
95.Install the oil filter & cooler assembly.

installing.
O-rings for oil filter &
cooler assembly
96.Tighten the 8 mounting bolts (13 mm) for the oil filter & cooler assembly to the specified torque.
Tool dimensions Bolt length (mm) Tightening torque

No. Quantity
(mm)
A 40 5
B 13 120 1
C 140 2
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97.Connect the hot water inlet hose.
98.Connect the EGR cooler inlet hose.
99.Tighten the mounting clamps on the EGR

cooler inlet hose and hot water inlet hose to
If the EGR cooler inlet hose and hot water

inlet hose are installed incorrectly, the
coolant does not circulate normally.
Since the clamp on the oil cooler assembly

may interfere with the intake manifold when
connecting the EGR cooler inlet hose, make
sure that the bolt part of the clamp is located
at position (A).
100. Install the intake manifold.

installing.
Intake manifold gasket
101. Tighten the 8 mounting bolts (13 mm) for the

exhaust manifold to the specified torque.
Mounting bolts for intake manifold
To protect the intake manifold from damage, unscrew the mounting bolts in several steps, in the
0000-00
102. Install the E-EGR valve assembly.
The intake manifold gasket and E-EGR

valve gasket are connected to each other.
Therefore, it is possible to replace the
corresponding gasket only by cutting the (A)
part of new gasket when the intake manifold
is not removed at the same time.

E-EGR valve assembly to the specified
torque.
104. Connect the EGR valve hose.

105. Hook the 2 EGR valve hose mounting
clamps.
106 . Install the EGR cooler assembly.

installing.
EGR cooler gasket
107. Tighten the 4 mounting bolts (13 mm) for

the EGR cooler assembly to the specified
torque.
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108. Connect the EGR cooler outlet hose and

tighten the mounting clamp to the specified
torque.
109. Connect the vacuum hose to the EGR

bypass solenoid valve.
110. Install the intake duct.

installing.
Intake duct gasket
111. Torque tighten the 4 mounting bolts (13

mm) for the intake duct to the specified
torque.
112. Connect the EGR cooler pipe.
EGR cooler pipe gasket

(A) To intake duct (B) To E-EGR valve

installing.
113. Tighten the 2 mounting bolts (A, 10 mm)

EGR cooler pipe to the specified torque.
114. Install the exhaust manifold gasket.
exhaust manifold gasket

installing.
0000-00
115. Install the exhaust manifold.
116. Torque tighten the 10 mounting nuts (12

mm) for the exhaust manifold to the
specified torque.
Replace the mounting nuts with new ones

when installing the exhaust manifold.
Exhaust manifold mounting bolts
To protect the exhaust manifold from damage, unscrew the mounting bolts in several steps, in
117. Install the LH/RH heat protectors.
118. Tighten the 4 hexagon mounting bolts (5

mm) for the LH/RH heat protectors to the
specified torque.
119. Install the mounting bracket for the front

exhaust temperature sensor connector.
120. Tighten the mounting bolt (10 mm) for front

exhaust temperature sensor connector to
0000-00
121. Install the front exhaust gas temperature

sensor.
Pay attention to the installation direction

since it may interfere with the turbocharger
when installing.
122. Torque tighten the mounting nut (17 mm) for

the front exhaust temperature sensor to the
specified torque.
123. Install the mounting bracket to the front

exhaust temperature sensor connector.
124. Fit the oil dipstick tube.

installing.
125. Tighten the mounting bolt (10 mm) for the oil
dipstick tube to the specified torque.
126. Install the power steering oil pump

assembly.
127. Tighten the mounting bolt and nut (A, 13

mm) and 2 mounting bolts (B, 13 mm) for
the power steering oil pump assembly to
0000-00
128. Install the alternator.
When installing the alternator assembly, press

the bushing to the bracket into arrow direction
in order to facilitate assembling.
129. Torque tighten the mounting bolt (A, 17

mm) and bolt (B, 15 mm) for the alternator
to the specified torque.
130. Install the A/C compressor.
131. Unscrew the 4 mounting bolts (13 mm) for

the A/C compressor.
132. Install the idle pulleys No.1 (A) and No.2 (B).
Idler pulley Idler pulley 1 Idler pulley cover No. 1

assembly No. 2 assembly No. 1
4 Idler pulley cover No. 2
133. Tighten the mounting bolts (T50) for the

idle pulleys No.1 (A) and 2 (B) to the
specified torque.
134. Fit the covers of the fan belt idle pulleys

No.1 (A) and 2 (B).
0000-00
135. Install the pivot damped tensioner.
Auto tensioner assembly
1 Belt tensioner
2 Tensioner housing
3 Belt tensioner pulley
4 Belt tensioner pulley cover
136. Tighten the mounting bolt (A, 17 mm) and

mounting bolt (B, 13 mm) for the pivot
damped tensioner to the specified torque.
137. Turn the pivot damped tensioner bolt (A) to

the arrow direction using a belt tensioner
relief tool to relieve the tension and remove
the fan belt.

compressed auto tensioner when releasing
deformation of the belt tensioner.
138. Fit the engine main wiring.

engine main wiring to the specified torque.
140. Install the engine compartment main wiring

mounting brackets and engine ground.
(A) Wiring brackets (2 mounting bolts, 10 mm)

(B) Ground and wiring bracket
(1 mounting bolt, 10 mm)
(C) Ground (1 mounting bolt, 10 mm)
0000-00
141. Fit the following connectors:
(A) Front exhaust gas temperature sensor

connector
(B) Injector connector
(C) Fuel rail pressure sensor connector
(D) Variable swirl actuator connector
(E) Oil pressure switch connector
(F) Camshaft position sensor connector
(G) E-EGR valve connector
(H) EGR bypass solenoid valve connector
(I) Crankshaft position sensor connector
(J) Electric throttle body connector
(K) T-MAP sensor connector
(L) Glow plug connector
(M) Fuel temperature sensor connector
(N) Coolant temperature sensor connector
(O) IMV (Inlet Metering Valve) connector
142. Connect the 5 fuel pipes and tighten the 10
mounting nuts (17 mm) to the specified
torque.
Replace the high pressure pipe with a new

one when installing.
Block diagram for fuel high pressure pipe

02 Engine Assembly

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GENERAL INFORMATION

OVERVIEW AND OPERATING

CONFIGURATION AND FUNCTIONS

135001 BELT SYSTEM............................. 28

Main bearing cap 12-point, 13 mm 10 Not reusable

Connecting rod cap E12 8 50 to 80 Nm

Crankshaft rear seal 10 mm 6 -

Flywheel T55 8 Not reusable

Crankshaft pulley 27 mm 1 660 to 720 Nm

Cylinder head M14 10 Not reusable

Tool dimensions Bolt Specified torque

T/C hollow bolt 24mm 1 -

T/C oil return pipe(Block

2) When working on the exhaust system

3) When working on the fuel system

4) When working on the cooling system

6) When tightening bolts

Part No.: Y99220182B

Part No.: Y99220142B

Part No.: Y99220172B

PN & Name Special Tool Use

Part No.: T99180010A

No Part name Quantity Shape

1 Injector remover set 1set

2 Main bar 1EA

3 Cross bar 2EA

4 Main bolt holder 1EA

5 Ball bearing 1EA

6 Main nut - A 1EA

7 Main bolt - A 1EA

No Part name Quantity Shape

8 Injector holder - A 1EA

9 Injector holder - B 1EA

10 Injector holder cover 1EA

11 Bar holder assembly 2set

12 Support mounting bolt 4EA

13 Main support 4EA

Cam position sensor

Oil filter & cooler assembly

Power steering pump pulley

Oil pressure switch

Water pump pulley

Idler pulley No. 2

Idler pulley No. 1

Fuel temperature sensor

Fuel HP pump assembly

Coolant outlet port assembly

Coolant temperature sensor

Crankshaft position sensor

Front exhaust gas

Oil dipstick tube &

Turbocharger Hollow bolt

Oil drain plug

Electric throttle body

Variable swirl valve

E-EGR solenoid valve

Oil cooler assembly

1127 CYLINDER BLOCK(DSL)

1. BLOCK ASSY-CYLINDER 22.NOZZLE ASSY-OIL INJECTION

1214 CYLINDER HEAD AND GASKET KIT(DSL)