Киа карнивал мануал 2007

ɄɈɆɉȺɇɂə ɄɂȺ

Ɍɟɩɟɪɶ,ɤɨɝɞɚ ȼɵ ɫɬɚɥɢ ɜɥɚɞɟɥɶɰɟɦ ɚɜɬɨɦɨɛɢɥɹ Ʉɢɚ,ȼɵ

ɧɚɜɟɪɧɨ ɛɭɞɟɬɟ ɩɨɥɭɱɚɬɶ ɦɧɨɝɨ ɜɨɩɪɨɫɨɜ ɨɬɧɨɫɢɬɟɥɶɧɨ

ȼɚɲɟɝɨ ɚɜɬɨɦɨɛɢɥɹ,ɤɚɤ ɧɚɩɪ.: “ɑɬɨ ɷɬɨ ɡɚ ɧɚɡɜɚɧɢɟ – Ʉɢɚ?”

“Ʉɬɨ ɬɚɤɨɣ – Ʉɢɚ?” “ɑɬɨ ɷɬɨ ɡɧɚɱɢɬ – Ʉɢɚ?”

ȼɨɬ ɧɟɫɤɨɥɶɤɨ ɨɬɜɟɬɨɜ ɧɚ ɷɬɢ ɜɨɩɪɨɫɵ.ɋɧɚɱɚɥɚ ɫɥɟɞɭɟɬ

ɨɬɦɟɬɢɬɶ,ɱɬɨ ɤɨɦɩɚɧɢɹ Ʉɢɚ – ɷɬɨ ɫɚɦɵɣ ɫɬɚɪɵɣ

ɩɪɨɢɡɜɨɞɢɬɟɥɶ ɚɜɬɨɦɨɛɢɥɟɣ ɜ Ʉɨɪɟɟ.Ɉɧɚ ɢɦɟɟɬ ɛɨɥɟɟ ɱɟɦ

ɬɵɫɹɱɭ ɪɚɛɨɬɧɢɤɨɜ,ɫɬɪɟɦɹɳɢɯɫɹ ɩɪɨɢɡɜɨɞɢɬɶ

ɜɵɫɨɤɨɤɚɱɟɫɬɜɟɧɧɵɟ ɚɜɬɨɦɨɛɢɥɢ ɩɨ ɞɨɫɬɭɩɧɵɦ ɰɟɧɚɦ.

ɉɟɪɜɵɣ ɫɥɨɝ, “Ʉɢ”, ɜ ɫɥɨɜɟ “Ʉɢɚ”ɡɧɚɱɢɬ”ɜɵɣɬɢ ɜɨ ɜɟɫ

ɦɢɪ”. ȼɬɨɪɨɣ ɫɥɨɝ, “ɚ”, ɡɧɚɱɢɬ “Ⱥɡɢɚ”. ɋɥɟɞɨɜɚɬɟɥɶɧɨ,ɫɥɨɜɨ

“Ʉɢɚ”ɡɧɚɱɢɬ “ɜɵɣɬɢ ɢɡ Ⱥɡɢɢ ɜɨ ɜɟɫɶ ɦɢɪ”.

ɀɟɥɚɟɦ ȼɚɦ ɦɧɨɝɨ ɪɚɞɨɫɬɢ ɨɬ ȼɚɲɟɝɨ ɚɜɬɨɦɨɛɢɥɹ

Related Manuals for Kia Carnival 2007

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Автосервис Москва, Авиамоторная

Автосервис ЮВАО, ВАО — метро Авиамоторная:

Автосервис Серп и Молот | Автосервис Красноказарменная | Автосервис Лефортово

Ближайшие станции метро — Авиамоторная, Площадь Ильича, Шоссе Энтузиастов, Чкаловская, Бауманская, Семеновская. Ближайшие для подъезда улицы — третье транспортное кольцо (ТТК), проезд завода Серп и Молот, Лефортовский вал, Красноказарменная улица.

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Автосервис Москва, Октябрьское поле

Автосервис СЗАО, САО — метро Октябрьское поле, станция Зорге МЦК (район Щукино, Хорошёво—Мнёвники)

Ближайшие станции метро — Октябрьское поле, Полежаевская. Станция Московского Центрального Кольца — Зорге. Ближайшие для подъезда улицы — Маршала Бирюзова, Берзарина, Народного ополчения, Зорге, Куусинена, Расплетина.

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Автосервис Москва, Измайлово

Автосервис ВАО — метро Соколиная гора (район Измайлово)


Ближайшие станции метро — Соколиная гора, Партизанская, Измайлово, Шоссе Энтузиастов, Черкизовская. Ближайшие для подъезда улицы — Вернисажная, Шоссе Энтузиастов, проспект Будённого, Северо-Восточная хорда, Щербаковская улица, Большая Черкизовская улица.

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Автосервис Москва, Щелковская

Автосервис ВАО — метро Щелковская (район Гольяново)


Ближайшие станции метро — Щелковская, Черкизовская, Бульвар Рокоссовского, Первомайская, Партизанская, Измайловская. Ближайшие для подъезда улицы — Щелковское шоссе, Амурская, Сиреневый бульвар, Монтажная улица, Байкальская улица, Открытое шоссе.

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AUTO-TEXCENTER.RU

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Франшиза автосервиса, Вакансии автосервиса

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Ремонт (сервис) корейских автомобилей. Специализированный техцентр (автосервис) в Москве. Copyright © 2000-2023. Все права сохранены. Обращаем Ваше внимание на то, что данный сайт носит исключительно информационный характер и ни при каких условиях не является публичной офертой, определяемой положениями Статьи 437 (2) Гражданского кодекса Российской Федерации.

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Компания «АвтоМиг» является НЕОФИЦИАЛЬНЫМ техническим центром по обслуживанию и ремонту автомобилей марок KIA и HYUNDAI. Никакого отношения ни к официальным представителям (дилерам), ни к самим производителям транспортных средств автосервис не имеет! Все упоминания торговых знаков (марок автомобилей) на данном сайте носят исключительно ИДЕНТИФИЦИРУЮЩИЙ характер (используются не в качестве средства индивидуализации), указывают, какие именно автомобили обслуживает техцентр (в соответствии со ст. 1474, 1487 Гражданского Кодекса РФ).

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CHAPTER 6:

Automatic Transaxle
System

General Information

2007 > 2.7L V6 GASOLINE >

SPECIAL TOOLS
TOOL
(Number and name)
09200 — 38001
Engine support fixture

Illustration

Use
Removal and installation of transaxle.

2007 > 3.8L V6 GASOLINE >

SPECIFICATIONS
Engine type

DIESEL(J2.9)

GASOLINE(λ-3.8)

Transaxle type

A5HF1

A5HF1

1ST

4.497

←

2ND

2.442

←

3RD

1.686

←

4TH

1.233

←

5TH

0.868

←

REV.

4.586

←

Final gear ratio

3.333

←

T/M oil capacity(ℓ)※

10.7

10.9

Gear ratio

※ The quantity in the chart above is for the reference. The actual filling quantity of the automatic transaxle fluid must
be set according to ‘INSPECTION’ or ‘REPLACEMENT’ procesure of the automatic transaxle fluid.
Recommended transaxle oil

Diamond ATF SP Ⅲ or SK ATF SP Ⅲ

Check & Replenishment

Every one year or every 20,000km
Every one year or every 15,000km only for European contries

Replacement

Normal use

Private use

Severe use(＊)
Business use

No service required
Every 100,000km only for Australia
Every 90,000km only for European contries
Every 40,000km
Every 45,000km only for European contries

＊ Severe use(marked ‘＊’) is defined as:
1. Driving on rough road(bumpy road, gravel road, snowy road, unpaved road etc.).
2. Driving on mountain road, ascent/descent.
3. Repetition of short distance driving.
4. More than 50% operation in heavy city traffic during hot weather above 32°C(89.6°F).
5. Police car, Taxi, Commercial type operation or trailer towing, etc.

Automatic Transaxle
System

2007 > 3.8L V6 GASOLINE >

DESCRIPTION
1. Structure & Technical highlights

2. Variable Line Pressure Control
a. Description
a. Form the most suitable line pressure according to the vehicle driving condition
b. Special Features
a. VFS (Variable Force Solenoid) valve (For varying line pressure)
b. Reducing valve added(Stabilize control pressure in shiftings)
c. Effects

a. Improved power transmission efficiency and fuel consumption

3. Gear durability improvement and less-noisy gear development
a. Description
a. Optimal gear transmission ratio design from analyzing gears
b. Special Features
a. Apply High-strength gear material
b. Gear teeth width increased
c. Planetary gear (3 pinions → 4 pinions)
d. Less-noisy gear development
c. Effects
a. Durability improvement
b. Reduction of noise level
4. Case/Housing intensity reinforced
a. Description
a. Case/Housing intensity reinforced
b. Special Features
a. Converter housing intensity reinforced(Ribs added and thickness increased)
b. Most suitable stiff reinforcement through analyzing
c. Effects
a. Intensity increased and banding vibration decreased
b. NVH Performance improvement
5. New frictional material
a. Description
a. Apply new frictional material for capacity and durability improvement
b. Special Features
a. SSP (Single Sided Plate) applied only on overdrive clutch and 2nd brake
b. Apply the next generation frictional material(BWA 6100/D 0880-88)
c. Effects
a. Thermal absorption capacity improvement
b. Energy capacity and durability improvement

MECHANICAL SYSTEM
CLUTCHES AND BRAKES FOR EACH RANGE
UD
Clutch

OD
Clutch

2ND
Brake

LR Brake

REV
Clutch

RED
Brake

DIR
Clutch

OWC 1

OWC 2

P

—

—

—

O

—

O

—

—

—

R

—

—

—

O

O

O

—

—

—

N

—

—

—

O

—

O

—

—

—

1st

O

—

—

O

—

O

—

●

●

2nd

O

—

O

—

—

O

—

—

●

3rd

O

O

—

—

—

O

—

—

●

4th

—

O

O

—

—

O

—

—

●

5th

—

O

O

—

—

—

O

—

—

D

(● : Locked when driving)
FUNCTIONS OF CLUTCHES AND BRAKES
Element
Underdrive clutch

Sign
UD

Function
Connect the input shaft with the underdrive sun gear

Reverse clutch

REV

Connect the input shaft with the reverse sun gear

Overdrive clutch

OD

Connect the input shaft with the overdrive carrier

Direct clutch

DIR

Connect the direct sun gear with the direct carrier

Low& Reverse brake

LR

Fix the planetary gear and the overdrive carrier

2nd brake

2ND

Fix the reverse sun gear

Reduction brake

RED

Fix the direct sun gear

One way clutch 1

OWC 1

Control the rotational driection of the low&reverse ring gear

One way clutch 2

OWC 2

Control the rotational driection of the direct sun gear

AUTOMATIC TRANSAXLE HYDRAULIC CIRCUIT
P/N

D(1 RANGE)

D(2 RANGE)

D(3 RANGE)

D(4 RANGE)

D(5 RANGE)

R RANGE

2007 > 3.8L V6 GASOLINE >

SERVICE ADJUSTMENT PROCEDURE
Automatic transaxle fluid
INSPECTION
1. Drive the vehicle until the fluid reaches normal operating temperature [70~80°C].
2. Place the vehicle on a level surface.
3. Move the selector lever through all gear positions. This will fill the torque converter and the hudraulic system with
fluid and move the selector lever to the «N» (Neutral) or «P»(Park) position.
4. Before removing the oil level gauge, wipe all contaminants from around the oil level gauge. Then take out the oil
level gauge and check the condition of the fluid.

If the fluid smells as if it is burning, it means that the fluid has been contaminated by fine particles from the
bushes and friction materials, a transaxle overhaul may be necessary.
5. Check that the fluid level is at the HOT mark on the oil level gauge. If the fluid level is low, add automatic transaxle
fluid until the level reaches the «HOT» mark.
Auto transaxle fluid:
DIAMOND ATF SP-III, SK ATF SP-III
Quantity : 10.7ℓ(Diesel), 10.9ℓ(Gasoline)

Low fluid level can cause a variety of a abnormal conditions because it allows the pump to take in air along
with fluid. Air trapped in the hydraulic system forms bubbles, which are compressable. Therefore, pressures
will be erratic, causing delayed shifting ,slipping clutches and brakes, etc. Improper filling can also raise fluid
level too high. When the transaxle has too much fluid, gears churn up foam and acuise the same conditions
which occur with low fluid level, resulting in accelerated deterioration of automatic transaxle fluid. In either
case, air bubbles can cause overheating, and fluid oxidation, which can interfere with normal valve, clutch, and
brake operation. Foaming can also result in fluid escaping from the transaxle vent where it may be mistaken
for a leak.
6. Insert the oil level gauge securely.

When new, automatic transmission fluid should be red. The red dye is added so the assembly plant can
identify it as transmission fluid and distinguish it from engine oil or antifreeze. The red dye, which is not an
indicator of fluid quality, is not permanent. As the vehicle is driven the transmission fluid will begin to look
darker. The color may eventually appear light brown.

REPLACEMENT
If you have a fluid changer, use this changer to replace the fluid. If you do not, replace it using the following
procedure.
1. Disconnect the hose which connects the transmission and the oil cooler.
2. Start the engine and let the fluid drain out.
Running conditions : «N» range with engine idling.

The engine should be stopped within one minute after it is started. If the fluid has all drained out before then,
the engine should be stopped at that point.

the engine should be stopped at that point.
3. Romove the drain plug(A) from the bottom of the transmission case to drain the fluid.

4. Install the drain plug via the gasket, and tighten it to the specified torque.
TORQUE :
40 ~ 50Nm (400 ~ 500 kgf.cm, 29 ~ 36 lb-ft)
5. Pour the new fluid in through the oil filler tube.

Stop pouring if the full volume of fluid cannot be poured in.
6. Repeat the procedure in step (2).

Check the old fluid for contamination. If it has been contaminated, repeat the steps (5) and (6).
7. Pour the new fluid in through the oil filler tube.
8. Reconnect the hose which was disconnected in step (1) above and firmly replace the oil level gauge.(In case of
this «replace», this means after wiping off any dirt around the oil level gauge, insert it into the filler tube.)
9. Start the engine and run it at idle for 1~2 minutes.
10. Move the select lever through all positions, and then move it to the «N» position.
11. Drive the vehicle until the fluid temperature rises to the normal temperature (70~80°C), and then check the fluid
level again. The fluid level must be at the HOT mark.
12. Firmly insert the oil level gauge into the oil filler tube.

Automatic Transaxle

2007 > 3.8L V6 GASOLINE >

COMPONENTS (1)

COMPONENTS (2)

2007 > 3.8L V6 GASOLINE >

REMOVAL

a. Use a cover not to damage the vehicle surface.
b. Disconnect connectors carefully not to be damaged.

a. Mark wires or hoses for identification.
1. Remove the battery (A).

2. Disconnect the AFS connector (A).

3. Remove the air cleaner upper cover (B) by loosening the clips (A).

4. Remove the air cleaner assembly (A).

5. Disconnect the air cleaner hose (B) by loosening the clamp (A).

[2.9 DSL]

[3.8 GSL]

6. Remove the battery tray (B) by removing the four mounting bolts (A).

7. Disconnect the transaxle wire harness connectors.
(1) Remove the inhibiter switch connector (A).

(2) Remove the solenoid valve connector (A).

[2.9 DSL]

[3.8 DSL]

(3) Remove the input speed sensor connector (A).

(4) Remove the output speed sensor connector (A).

(5) Remove the vehicle speed sensor connector (A).

(6) Remove the CKP sensor connector (A).

8. Remove the shift cable by removing the bolt (A) and clip (B).

9. Disconnect the transaxle oil cooler hoses (A) from the tubes (C) by loosening the clamps (B).

10. Remove the transaxle mounting bolts (A).

[2.9 DSL]

[3.8 GSL]

11. Using the SST(09200-38001), hold the engine and transaxle assembly safely.

[2.9 DSL]

[3.8 GSL]

12. Remove the transaxle insulator mounting bolt (A).

13. Remove the front wheels.
14. Remove the power steering column joint bolt. (see ST group)
15. Lift up the vehicle.
16. Remove the under cover (A).

17. Drain transaxle oil.
18. Drain power steering oil through the return tube. (see ST group)
19. Disconnect the power steering pressure tube (A) from the power steering oil pump.

20. Disconnect the lower arm, the tie rod end ball joint, the stabilizer bar link from the front knuckle. (see SS group)
21. Remove the roll stopper mounting bolts (A,B).

22. Remove the mounting bolts from the sub frame by supporting the sub frame with a jack. (see SS group)
23. Remove drive shaft from transaxle. (See DS group).
24. Install a jack for supporting the transaxle assembly.
25. Remove the plate (A) and the drive plate bolts (B).

[2.9 DSL]

[3.8 GSL]

26. Lifting the vehicle up and lowering the jack slowly, remove the transaxle assembly.

INSTALLATION
Installation is in the reverse order of removal.
Perform the following :
a. Adjust the shift cable.
b. Refill the transaxle with fluid.
c. Refill the radiator with engine coolant.
d. Bleed air from the cooling system with the heater valve open.

e. Clean the battery posts and cable terminals with sandpaper, assemble them, and apply grease to prevent
corrosion.
1. Lowering the vehicle or lifting up a jack, install the transaxle assembly.
2. Tighten the transaxle under mounting bolts.
TORQUE:
65~85 Nm(650~850 kgf.cm, 47.0~61.5 lb-ft)
3. Install the starter motor. (see EE group).
TORQUE:
65~85 Nm(650~850 kgf.cm, 47.0~61.5 lb-ft)
4. Install the drive plate bolts (B) by turning the timing gear and the plate (A).
TORQUE:46~53 Nm(460~530 kgf.cm, 33.3~38.3 lb-ft)

[2.9 DSL]

[3.8 GSL]

5. After removing a jack, insert the drive shafts. (see DS group)
6. Install the sub frame. (see SS group).
7. Tighten the roll stopper mounting bolts (A,B)
TORQUE:
90~110 Nm(900~1100 kgf.cm, 65.1~79.5 lb-ft)

8. Connect the return tube with a clamp. (see ST group)
9. Connect the lower arm, the tie rod end ball joint, the stabilizer bar link to the front knuckle. (see SS group)
10. Connect the power steering pressure tube (A) to the power steering oil pump.

11. Install the under cover (A).

12. Install the steering column joint bolt. (see ST group).
13. Install the front wheels and tires.

14. Tighten the transaxle insulator mounting bolt (A).
TORQUE:
90~110 Nm(900~1100 kgf.cm, 65.1~79.5 lb-ft)

15. Tighten the transaxle mounting bolts (A).
TORQUE:
65~85 Nm(650~850 kgf.cm, 47.0~61.5 lb-ft)

[2.9 DSL]

[3.8 GSL]

16. Remove the SST (09200-38001) holding the engine and transaxle assembly.

[2.9 DSL]

[3.8 GSL]

17. Connect the transaxle oil cooler hoses (A) to the tubes (C) by fastening the clamps (B).

18. Install the shift cable by tightening the bolt (A) and clip (B).
TORQUE:
10~14 Nm(100~140 kgf.cm, 7.2~10.1 lb-ft)

19. Connect the transaxle wire harness connectors.
(1) Install the inhibiter switch connector (A).

(2) Install the solenoid valve connector (A).

[2.9 DSL]

[3.8 GSL]

(3) Install the input speed sensor connector (A).

(4) Install the output speed sensor connector (A).

(5) Install the vehicle speed sensor connector (A).

(6) Install the CKP sensor connector (A).

20. Install the battery tray (B) by tightening the four mounting bolts (A).

21. Connect the air cleaner hose (B) by fastening the clamp (A).

[2.9 DSL]

[3.8 GSL]

22. Install the air cleaner assembly (A).

23. Install the air cleaner upper cover (B) by fastening the clips (A).

24. Connect the AFS connector (A).

25. Install the battery (A).

Automatic Transaxle
Control System
Shift Lever

2007 > 3.8L V6 GASOLINE >

REMOVAL
1. Remove the console upper cover(A). (see BD group).

[LHD]

[RHD]

2. Remove the front console cover (A). (see BD group).

[LHD]

[RHD]

3. Disconnect the connector (A).

[LHD]

[RHD]

4. Remove the shift lever assembly mounting nuts (A).

[LHD]

[RHD]

5. Remove the shift cable mounting nut (A) and cap (B).

[LHD]

[RHD]

INSTALLATION
1. Install the shift cable mounting nut (A) and cap (B).
TORQUE:
10~14 Nm(100~140 kgf.cm, 7.3~10.2 lb-ft)

[LHD]

[RHD]

2. Install the shift lever assembly mounting nuts (A).
TORQUE:
19~24 Nm(190~240 kgf.cm, 13.8~17.5 lb-ft)

[LHD]

[RHD]

3. Connect the connector (A).

[LHD]

[RHD]

4. Install the front console cover (A). (see BD group)

[LHD]

[RHD]

5. Install the console upper cover(A). (see BD group).

[LHD]

[RHD]

DISASSEMBLY
1. Remove the power relay (A) from the bracket.

[LHD]

[RHD]

2. Remove both sides of the brackets.
3. Remove the shift lever knob (A) by removing the two screws.

[LHD]

[RHD]

4. Disconnect the solenoid connector (A) and remove the indicator panel (B).

[LHD]

[RHD]

5. Remove the switch assembly (A) and ‘P’ position switch assembly.

[LHD]

[RHD]

6. Remove the solenoid (B) and solenoid lever (A).

[LHD]

[RHD]

7. Remove the lever assembly (B) by the mounting bolt (A).

[LHD]

[RHD]

8. Remove the lever (A) and tube (B) by removing the bolt (C).

[LHD]

[RHD]

REASSEMBLY
1. Grease the tube (B) and install the lever (A) by tightening the bolt (C).
TORQUE:
8~12 Nm(80~120 kgf.cm, 5.8~8.7 lb-ft)

[LHD]

[RHD]

2. Install the lever assembly (B) by tightening the bolt (A).
TORQUE:
8~12 Nm(80~120 kgf.cm, 5.8~8.7 lb-ft)

[LHD]

[RHD]

3. Install the solenoid (B) and solenoid lever (A).

[LHD]

[RHD]

4. Install the switch assembly (A) and ‘P’ position switch assembly.
TORQUE:
1.3~1.9 Nm(13~19 kgf.cm, 0.95~1.38 lb-ft)

[LHD]

[RHD]

5. Connect the solenoid connector (A) and install the indicator panel (B).

[LHD]

[RHD]

6. Install the shift lever knob (A) by tightening the two screws.

TORQUE:
2~3 Nm(20~30 kgf.cm, 1.45~2.18 lb-ft)

[LHD]

[RHD]

7. Install both sides of the brackets.
TORQUE:
16~23 Nm(160~230 kgf.cm, 11.6~16.7 lb-ft)
8. Install the power relay (A) to the bracket.

[LHD]

[RHD]

CHAPTER 6:

Automatic Transaxle
System

General Information

2007 > 2.7L V6 GASOLINE >

SPECIAL TOOLS
TOOL
(Number and name)
09200 — 38001
Engine support fixture

Illustration

Use
Removal and installation of transaxle.

2007 > 3.8L V6 GASOLINE >

SPECIFICATIONS
Engine type

DIESEL(J2.9)

GASOLINE(λ-3.8)

Transaxle type

A5HF1

A5HF1

1ST

4.497

←

2ND

2.442

←

3RD

1.686

←

4TH

1.233

←

5TH

0.868

←

REV.

4.586

←

Final gear ratio

3.333

←

T/M oil capacity(ℓ)※

10.7

10.9

Gear ratio

※ The quantity in the chart above is for the reference. The actual filling quantity of the automatic transaxle fluid must
be set according to ‘INSPECTION’ or ‘REPLACEMENT’ procesure of the automatic transaxle fluid.
Recommended transaxle oil

Diamond ATF SP Ⅲ or SK ATF SP Ⅲ

Check & Replenishment

Every one year or every 20,000km
Every one year or every 15,000km only for European contries

Replacement

Normal use

Private use

Severe use(＊)
Business use

No service required
Every 100,000km only for Australia
Every 90,000km only for European contries
Every 40,000km
Every 45,000km only for European contries

＊ Severe use(marked ‘＊’) is defined as:
1. Driving on rough road(bumpy road, gravel road, snowy road, unpaved road etc.).
2. Driving on mountain road, ascent/descent.
3. Repetition of short distance driving.
4. More than 50% operation in heavy city traffic during hot weather above 32°C(89.6°F).
5. Police car, Taxi, Commercial type operation or trailer towing, etc.

Automatic Transaxle
System

2007 > 3.8L V6 GASOLINE >

DESCRIPTION
1. Structure & Technical highlights

2. Variable Line Pressure Control
a. Description
a. Form the most suitable line pressure according to the vehicle driving condition
b. Special Features
a. VFS (Variable Force Solenoid) valve (For varying line pressure)
b. Reducing valve added(Stabilize control pressure in shiftings)
c. Effects

a. Improved power transmission efficiency and fuel consumption

3. Gear durability improvement and less-noisy gear development
a. Description
a. Optimal gear transmission ratio design from analyzing gears
b. Special Features
a. Apply High-strength gear material
b. Gear teeth width increased
c. Planetary gear (3 pinions → 4 pinions)
d. Less-noisy gear development
c. Effects
a. Durability improvement
b. Reduction of noise level
4. Case/Housing intensity reinforced
a. Description
a. Case/Housing intensity reinforced
b. Special Features
a. Converter housing intensity reinforced(Ribs added and thickness increased)
b. Most suitable stiff reinforcement through analyzing
c. Effects
a. Intensity increased and banding vibration decreased
b. NVH Performance improvement
5. New frictional material
a. Description
a. Apply new frictional material for capacity and durability improvement
b. Special Features
a. SSP (Single Sided Plate) applied only on overdrive clutch and 2nd brake
b. Apply the next generation frictional material(BWA 6100/D 0880-88)
c. Effects
a. Thermal absorption capacity improvement
b. Energy capacity and durability improvement

MECHANICAL SYSTEM
CLUTCHES AND BRAKES FOR EACH RANGE
UD
Clutch

OD
Clutch

2ND
Brake

LR Brake

REV
Clutch

RED
Brake

DIR
Clutch

OWC 1

OWC 2

P

—

—

—

O

—

O

—

—

—

R

—

—

—

O

O

O

—

—

—

N

—

—

—

O

—

O

—

—

—

1st

O

—

—

O

—

O

—

●

●

2nd

O

—

O

—

—

O

—

—

●

3rd

O

O

—

—

—

O

—

—

●

4th

—

O

O

—

—

O

—

—

●

5th

—

O

O

—

—

—

O

—

—

D

(● : Locked when driving)
FUNCTIONS OF CLUTCHES AND BRAKES
Element
Underdrive clutch

Sign
UD

Function
Connect the input shaft with the underdrive sun gear

Reverse clutch

REV

Connect the input shaft with the reverse sun gear

Overdrive clutch

OD

Connect the input shaft with the overdrive carrier

Direct clutch

DIR

Connect the direct sun gear with the direct carrier

Low& Reverse brake

LR

Fix the planetary gear and the overdrive carrier

2nd brake

2ND

Fix the reverse sun gear

Reduction brake

RED

Fix the direct sun gear

One way clutch 1

OWC 1

Control the rotational driection of the low&reverse ring gear

One way clutch 2

OWC 2

Control the rotational driection of the direct sun gear

AUTOMATIC TRANSAXLE HYDRAULIC CIRCUIT
P/N

D(1 RANGE)

D(2 RANGE)

D(3 RANGE)

D(4 RANGE)

D(5 RANGE)

R RANGE

2007 > 3.8L V6 GASOLINE >

SERVICE ADJUSTMENT PROCEDURE
Automatic transaxle fluid
INSPECTION
1. Drive the vehicle until the fluid reaches normal operating temperature [70~80°C].
2. Place the vehicle on a level surface.
3. Move the selector lever through all gear positions. This will fill the torque converter and the hudraulic system with
fluid and move the selector lever to the «N» (Neutral) or «P»(Park) position.
4. Before removing the oil level gauge, wipe all contaminants from around the oil level gauge. Then take out the oil
level gauge and check the condition of the fluid.

If the fluid smells as if it is burning, it means that the fluid has been contaminated by fine particles from the
bushes and friction materials, a transaxle overhaul may be necessary.
5. Check that the fluid level is at the HOT mark on the oil level gauge. If the fluid level is low, add automatic transaxle
fluid until the level reaches the «HOT» mark.
Auto transaxle fluid:
DIAMOND ATF SP-III, SK ATF SP-III
Quantity : 10.7ℓ(Diesel), 10.9ℓ(Gasoline)

Low fluid level can cause a variety of a abnormal conditions because it allows the pump to take in air along
with fluid. Air trapped in the hydraulic system forms bubbles, which are compressable. Therefore, pressures
will be erratic, causing delayed shifting ,slipping clutches and brakes, etc. Improper filling can also raise fluid
level too high. When the transaxle has too much fluid, gears churn up foam and acuise the same conditions
which occur with low fluid level, resulting in accelerated deterioration of automatic transaxle fluid. In either
case, air bubbles can cause overheating, and fluid oxidation, which can interfere with normal valve, clutch, and
brake operation. Foaming can also result in fluid escaping from the transaxle vent where it may be mistaken
for a leak.
6. Insert the oil level gauge securely.

When new, automatic transmission fluid should be red. The red dye is added so the assembly plant can
identify it as transmission fluid and distinguish it from engine oil or antifreeze. The red dye, which is not an
indicator of fluid quality, is not permanent. As the vehicle is driven the transmission fluid will begin to look
darker. The color may eventually appear light brown.

REPLACEMENT
If you have a fluid changer, use this changer to replace the fluid. If you do not, replace it using the following
procedure.
1. Disconnect the hose which connects the transmission and the oil cooler.
2. Start the engine and let the fluid drain out.
Running conditions : «N» range with engine idling.

The engine should be stopped within one minute after it is started. If the fluid has all drained out before then,
the engine should be stopped at that point.

the engine should be stopped at that point.
3. Romove the drain plug(A) from the bottom of the transmission case to drain the fluid.

4. Install the drain plug via the gasket, and tighten it to the specified torque.
TORQUE :
40 ~ 50Nm (400 ~ 500 kgf.cm, 29 ~ 36 lb-ft)
5. Pour the new fluid in through the oil filler tube.

Stop pouring if the full volume of fluid cannot be poured in.
6. Repeat the procedure in step (2).

Check the old fluid for contamination. If it has been contaminated, repeat the steps (5) and (6).
7. Pour the new fluid in through the oil filler tube.
8. Reconnect the hose which was disconnected in step (1) above and firmly replace the oil level gauge.(In case of
this «replace», this means after wiping off any dirt around the oil level gauge, insert it into the filler tube.)
9. Start the engine and run it at idle for 1~2 minutes.
10. Move the select lever through all positions, and then move it to the «N» position.
11. Drive the vehicle until the fluid temperature rises to the normal temperature (70~80°C), and then check the fluid
level again. The fluid level must be at the HOT mark.
12. Firmly insert the oil level gauge into the oil filler tube.

Automatic Transaxle

2007 > 3.8L V6 GASOLINE >

COMPONENTS (1)

COMPONENTS (2)

2007 > 3.8L V6 GASOLINE >

REMOVAL

a. Use a cover not to damage the vehicle surface.
b. Disconnect connectors carefully not to be damaged.

a. Mark wires or hoses for identification.
1. Remove the battery (A).

2. Disconnect the AFS connector (A).

3. Remove the air cleaner upper cover (B) by loosening the clips (A).

4. Remove the air cleaner assembly (A).

5. Disconnect the air cleaner hose (B) by loosening the clamp (A).

[2.9 DSL]

[3.8 GSL]

6. Remove the battery tray (B) by removing the four mounting bolts (A).

7. Disconnect the transaxle wire harness connectors.
(1) Remove the inhibiter switch connector (A).

(2) Remove the solenoid valve connector (A).

[2.9 DSL]

[3.8 DSL]

(3) Remove the input speed sensor connector (A).

(4) Remove the output speed sensor connector (A).

(5) Remove the vehicle speed sensor connector (A).

(6) Remove the CKP sensor connector (A).

8. Remove the shift cable by removing the bolt (A) and clip (B).

9. Disconnect the transaxle oil cooler hoses (A) from the tubes (C) by loosening the clamps (B).

10. Remove the transaxle mounting bolts (A).

[2.9 DSL]

[3.8 GSL]

11. Using the SST(09200-38001), hold the engine and transaxle assembly safely.

[2.9 DSL]

[3.8 GSL]

12. Remove the transaxle insulator mounting bolt (A).

13. Remove the front wheels.
14. Remove the power steering column joint bolt. (see ST group)
15. Lift up the vehicle.
16. Remove the under cover (A).

17. Drain transaxle oil.
18. Drain power steering oil through the return tube. (see ST group)
19. Disconnect the power steering pressure tube (A) from the power steering oil pump.

20. Disconnect the lower arm, the tie rod end ball joint, the stabilizer bar link from the front knuckle. (see SS group)
21. Remove the roll stopper mounting bolts (A,B).

22. Remove the mounting bolts from the sub frame by supporting the sub frame with a jack. (see SS group)
23. Remove drive shaft from transaxle. (See DS group).
24. Install a jack for supporting the transaxle assembly.
25. Remove the plate (A) and the drive plate bolts (B).

[2.9 DSL]

[3.8 GSL]

26. Lifting the vehicle up and lowering the jack slowly, remove the transaxle assembly.

INSTALLATION
Installation is in the reverse order of removal.
Perform the following :
a. Adjust the shift cable.
b. Refill the transaxle with fluid.
c. Refill the radiator with engine coolant.
d. Bleed air from the cooling system with the heater valve open.

e. Clean the battery posts and cable terminals with sandpaper, assemble them, and apply grease to prevent
corrosion.
1. Lowering the vehicle or lifting up a jack, install the transaxle assembly.
2. Tighten the transaxle under mounting bolts.
TORQUE:
65~85 Nm(650~850 kgf.cm, 47.0~61.5 lb-ft)
3. Install the starter motor. (see EE group).
TORQUE:
65~85 Nm(650~850 kgf.cm, 47.0~61.5 lb-ft)
4. Install the drive plate bolts (B) by turning the timing gear and the plate (A).
TORQUE:46~53 Nm(460~530 kgf.cm, 33.3~38.3 lb-ft)

[2.9 DSL]

[3.8 GSL]

5. After removing a jack, insert the drive shafts. (see DS group)
6. Install the sub frame. (see SS group).
7. Tighten the roll stopper mounting bolts (A,B)
TORQUE:
90~110 Nm(900~1100 kgf.cm, 65.1~79.5 lb-ft)

8. Connect the return tube with a clamp. (see ST group)
9. Connect the lower arm, the tie rod end ball joint, the stabilizer bar link to the front knuckle. (see SS group)
10. Connect the power steering pressure tube (A) to the power steering oil pump.

11. Install the under cover (A).

12. Install the steering column joint bolt. (see ST group).
13. Install the front wheels and tires.

14. Tighten the transaxle insulator mounting bolt (A).
TORQUE:
90~110 Nm(900~1100 kgf.cm, 65.1~79.5 lb-ft)

15. Tighten the transaxle mounting bolts (A).
TORQUE:
65~85 Nm(650~850 kgf.cm, 47.0~61.5 lb-ft)

[2.9 DSL]

[3.8 GSL]

16. Remove the SST (09200-38001) holding the engine and transaxle assembly.

[2.9 DSL]

[3.8 GSL]

17. Connect the transaxle oil cooler hoses (A) to the tubes (C) by fastening the clamps (B).

18. Install the shift cable by tightening the bolt (A) and clip (B).
TORQUE:
10~14 Nm(100~140 kgf.cm, 7.2~10.1 lb-ft)

19. Connect the transaxle wire harness connectors.
(1) Install the inhibiter switch connector (A).

(2) Install the solenoid valve connector (A).

[2.9 DSL]

[3.8 GSL]

(3) Install the input speed sensor connector (A).

(4) Install the output speed sensor connector (A).

(5) Install the vehicle speed sensor connector (A).

(6) Install the CKP sensor connector (A).

20. Install the battery tray (B) by tightening the four mounting bolts (A).

21. Connect the air cleaner hose (B) by fastening the clamp (A).

[2.9 DSL]

[3.8 GSL]

22. Install the air cleaner assembly (A).

23. Install the air cleaner upper cover (B) by fastening the clips (A).

24. Connect the AFS connector (A).

25. Install the battery (A).

Automatic Transaxle
Control System
Shift Lever

2007 > 3.8L V6 GASOLINE >

REMOVAL
1. Remove the console upper cover(A). (see BD group).

[LHD]

[RHD]

2. Remove the front console cover (A). (see BD group).

[LHD]

[RHD]

3. Disconnect the connector (A).

[LHD]

[RHD]

4. Remove the shift lever assembly mounting nuts (A).

[LHD]

[RHD]

5. Remove the shift cable mounting nut (A) and cap (B).

[LHD]

[RHD]

INSTALLATION
1. Install the shift cable mounting nut (A) and cap (B).
TORQUE:
10~14 Nm(100~140 kgf.cm, 7.3~10.2 lb-ft)

[LHD]

[RHD]

2. Install the shift lever assembly mounting nuts (A).
TORQUE:
19~24 Nm(190~240 kgf.cm, 13.8~17.5 lb-ft)

[LHD]

[RHD]

3. Connect the connector (A).

[LHD]

[RHD]

4. Install the front console cover (A). (see BD group)

[LHD]

[RHD]

5. Install the console upper cover(A). (see BD group).

[LHD]

[RHD]

DISASSEMBLY
1. Remove the power relay (A) from the bracket.

[LHD]

[RHD]

2. Remove both sides of the brackets.
3. Remove the shift lever knob (A) by removing the two screws.

[LHD]

[RHD]

4. Disconnect the solenoid connector (A) and remove the indicator panel (B).

[LHD]

[RHD]

5. Remove the switch assembly (A) and ‘P’ position switch assembly.

[LHD]

[RHD]

6. Remove the solenoid (B) and solenoid lever (A).

[LHD]

[RHD]

7. Remove the lever assembly (B) by the mounting bolt (A).

[LHD]

[RHD]

8. Remove the lever (A) and tube (B) by removing the bolt (C).

[LHD]

[RHD]

REASSEMBLY
1. Grease the tube (B) and install the lever (A) by tightening the bolt (C).
TORQUE:
8~12 Nm(80~120 kgf.cm, 5.8~8.7 lb-ft)

[LHD]

[RHD]

2. Install the lever assembly (B) by tightening the bolt (A).
TORQUE:
8~12 Nm(80~120 kgf.cm, 5.8~8.7 lb-ft)

[LHD]

[RHD]

3. Install the solenoid (B) and solenoid lever (A).

[LHD]

[RHD]

4. Install the switch assembly (A) and ‘P’ position switch assembly.
TORQUE:
1.3~1.9 Nm(13~19 kgf.cm, 0.95~1.38 lb-ft)

[LHD]

[RHD]

5. Connect the solenoid connector (A) and install the indicator panel (B).

[LHD]

[RHD]

6. Install the shift lever knob (A) by tightening the two screws.

TORQUE:
2~3 Nm(20~30 kgf.cm, 1.45~2.18 lb-ft)

[LHD]

[RHD]

7. Install both sides of the brackets.
TORQUE:
16~23 Nm(160~230 kgf.cm, 11.6~16.7 lb-ft)
8. Install the power relay (A) to the bracket.

[LHD]

[RHD]

CHAPTER 2:

Engine Mechanical System

2007 > J2.9L DIESEL CRDI(VGT) >

SPECIAL SERVICE TOOLS
Tool (Number and name)

Illustration

Use

Valve spring lifter pivot.
(0K993 120 004)

Removal or installation of the valve spring

Valve spring lifter arm.
(0K993 120 001)

Removal or installation of the valve spring

Valve seal installer.
(09222-22001)

Installation of the valve seal

Camshaft pulley holder.
(09231 — 4X100)

Installation of the camshaft

Pressure gauge adapter.
(0K552 131 002)

Measurement of compression pressure

End york holder.
(09517-21700)

Removal or installation of the crankshaft
pulley bolt
(used with 09231-H1000)

Crankshaft pulley adapter.

Removal or installation of the crankshaft

Crankshaft pulley adapter.
(09231-H1000)

Removal or installation of the crankshaft
pulley bolt
(used with 09517-21700)

Oil pan remover.
(09215-3C000)

Removal of the oil pan

2007 > J2.9L DIESEL CRDI(VGT) >

TROUBLESHOOTING
Symptom
Engine misfire with abnormal
internal lower engine noises.

Engine misfire with abnormal
valve train noise.

Engine misfire with coolant
consumption

Engine misfire with excessive
oil consumption

Engine noise on start-up, but
only lasting a few seconds.

Suspect area

Remedy

Loose or improperly installed engine
flywheel.

Repair or replace the flywheel as
required.

Worn piston rings.
(Oil consumption may or may not cause
the engine to misfire.)

Inspect the cylinder for a loss of
compression .
Repair or replace as required.

Worn crankshaft thrust bearings.

Replace the crankshaft and bearings as
required.

Stuck valves.
(Carbon buildup on the valve stem can
cause the valve not to close properly.)

Repair or replace as required.

Excessive worn or mis-aligned timing
chain.

Replace the timing chain and sprocket
as required.

Worn camshaft lobes.

Replace the camshaft and valve lifers.

a. Faulty cylinder head gasket and/or
cracking or other damage to the
cylinder head and engine block
cooling system .
b. Coolant consumption may or may not
cause the engine to overheat.

a. Inspect the cylinder head and engine
block for damage to the coolant
passages and/or a faulty head
gasket.
b. Repair or replace as required.

Worn valves, valve guides and/or valve
stem oil seals.

Repair or replace as required.

Worn piston rings.
(Oil consumption may or may not cause
the engine to misfire)

Inspection the cylinder for a loss of
compression
Repair or replace as required.

Incorrect oil viscosity.

Drain the oil.
Install the correct viscosity oil.

Worn crankshaft thrust bearing.

Inspect the thrust bearing and
crankshaft.
Repair or replace as required.

Upper engine noise, regardless Low oil pressure.
of engine speed.
Broken valve spring.

Repair or replace as required.
Replace the valve spring.

Worn or dirty valve lifters.

Replace the valve lifters.

Stretched or broken timing chain and/or
damaged sprocket teeth.

Replace the timing chain and sprockets.

Worn timing chain tensioner, if
applicable.

Replace the timing chain tensioner as
required.

Worn camshaft lobes.

Inspect the camshaft lobes.
Replace the camshaft and valve lifters as
required.

Worn valve guides or valve stems.

Inspect the valves and valve guides, then
repair as required.

Stuck valves. (Carbon on the valve stem Inspect the valves and valve guides, then
or valve seat may cause the valve to
repair as required.
stay open.)

Lower engine noise, regardless Low oil pressure.
of engine speed.

Engine noise under load.

Engine will not crank.
(crankshaft will not rotate)

Repair or replace damaged components
as required.

Loose or damaged flywheel.

Repair or replace the flywheel.

Damaged oil pan, contacting the oil
pump screen.

Inspect the oil pan.
Inspect the oil pump screen.
Repair or replace as required.

Oil pump screen loose, damaged or
restricted.

Inspect the oil pump screen .
Repair or replace as required.

Excessive piston-to-cylinder bore
clearance.

Inspect the piston and cylinder bore.
Repair as required.

Excessive piston pin-to-bore clearance.

Inspect the piston, piston pin and the
connecting rod.
Repair or replace as required.

Excessive connecting rod bearing
clearance.

Inspect the following components and
repair as required.
a. The connecting rod bearings.
b. The connecting rods.
c. The crankshaft.
d. The crankshaft journal.

Excessive crankshaft bearing clearance.

Inspect the following components and
repair as required.
a. The crankshaft bearings.
b. The crankshaft journals.

Incorrect piston, piston pin and
connecting rod installation.

Verify the piston pins and connecting
rods are installed correctly.
Repair as required.

Low oil pressure.

Repair or replace as required.

Excessive connecting rod bearing
clearance.

Inspect the following components and
repair as required.
a. The connecting rod bearings.
b. The connecting rods.
c. The crankshaft.

Excessive crankshaft bearing clearance.

Inspect the following components and
repair as required.
a. The crankshaft bearings.
b. The crankshaft journals.
c. The cylinder block crankshaft bearing
bore.

Hydraulically locked cylinder.
a. Coolant/antifreeze in cylinder.
b. Oil in cylinder.
c. Fuel in cylinder.

Remove spark plugs and check for fluid.
Inspect for broken head gasket.
Inspect for cracked engine block or
cylinder head.
Inspect for a sticking fuel injector and/or
leaking fuel regulator.

Broken timing chain and/or timing chain
gears.

Inspect timing chain and gears.
Repair as required.

Foreign material in cylinder.
a. Broken valve.
b. Piston material.
c. Foreign material.

Inspect cylinder for damaged
components and/or foreign materials.
Repair or replace as required.

Seized crankshaft or connecting rod
bearings.

Inspect crankshaft and connecting rod
bearing.
Repair or replace as required.

Bent or broken connecting rod.

Inspect connecting rods.
Repair or replace as required.

Broken crankshaft.

Inspect crankshaft.Repair or replace as
required.

2007 > J2.9L DIESEL CRDI(VGT) >

INSPECTION
COMPESSION PRESSURE

If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure.
1. Warm up the engine until the coolant temperature becomes 80~95°C(176~203°F).
2. Remove the fuel inlet(A) and the return hose(B) from the fuel filter.

3. Crank the engine in order to exhaust fuel in the high pressure pump.

Gather residual fuel by putting the return hose into a proper vessel.
4. Remove the injection pipe, injector and washer.(Refer to FL group).
5. Measure the cylinder compression pressure.
(1) Insert the SST(0K552 131 002) into the injector hole.
(2) Cranking the engine, measure the pressure.

Use the complete charging battery for the engine to crank at the speed of 350rpm or more.
(3) Do the above step 1)~2) again for each cylinder.

This work must be done in as short time as possible.
Compression pressure :
3040.05kPa (31kg/cm², 440.92psi) (325 rpm)
Minimum pressure :
2745.85kPa (28kg/cm², 398.25psi)
Difference between each cylinder :
294.20kPa (3.0kg/cm², 42.67psi)
(4) If, in one or more cylinders, the measured value is below the limit, fill a little engine oil into the injector holes of
the cylinders, repeat the step 1)~2) and measure the compression pressure again.
a. If the re-measured pressure becomes higher, wear or damage of the piston ring or cylinder surface can be
the cause.
b. If the re-measured pressure does not become higher, adherence or poor contact of the valves or inferior
gasket can be the cause.

gasket can be the cause.
6. Install the injectors, washers and the injector pipes.(Refer to FL group).
7. Install the inlet and the return hoses to the fuel filter.

TIMING BELT TENSION ADJUSTMENT
1. Remove the battery terminals (A).

2. Install the jack for oil pan.
3. Remove the engine mounting (A).

4. Remove the engine support bracket(A).

5. Remove the drive belt.

6. Remove the water pump pulley.

7. Remove the bolts(B), nut(C) and timing belt upper cover (A).

8. Turn the crankshaft pulley(A) and align its groove with the timing mark “T” of the timing belt cover. Check that the
timing mark of camshaft sprocket(B) is aligned with that of the cylinder head cover. (No.1 cylinder positioned at the
TDC position)

9. Remove the crankshaft pulley bolt(A), washer(B) and crankshaft pulley(C).

Using the special tool(09517-21700, 09231-H1000), fix the crankshaft pulley and loosen the bolt(A).
10. Remove the drive belt idler(A).

11. Remove the drive belt auto-tensioner (A).

12. Remove the timing belt lower cover(A).

13. Loosen the auto-tensioner fixing bolt(A).

14. Adjust tension of the timing belt.
(1) Align the pointer(B) with the tensioner fork(back plate)(C) as shown below by turning the special washer(A)
counterclockwise with a hexagonal wrench.

(2) When the pointer(A) is aligned with the tensioner fork(back plate)(B), tighten the tensioner mounting bolts with
the special bolt fixed by a hexagonal wrench.
Tightening torque :
19.6~25.5Nm (2.0~2.6kgf.m, 14.5~18.8lb-ft)

(3) Remove the hexagonal wrench.

When the pointer (A) can not be aligned with the tensioner fork(back plate)(B), replace a new belt and
repeat the steps.
15. Rotate the crankshaft clockwise two revolutions in order to align the timing marks on the crankshaft sprocket, the
camshaft sprocket and high pressure pump pulley.
16. Confirm that the location of the pointer is aligned with tensioner fork (back plate).
The margin of error : ± 5°

17. Install the timing belt lower cover(A).
Tightening torque :
6.9~9.8Nm (0.7 ~ 1.0kgf.m, 5.1 ~ 7.2lb-ft)

18. Install the drive belt idler(A).
Tightening torque :
37.3Nm (3.8kgf.m, 27.5lb-ft)

19. Install the drive belt auto-tensioner (A).
Tightening torque :
15.7~22.6Nm (1.6 ~ 2.3kgf.m, 11.6 ~ 16.6lb-ft)

20. Install the crankshaft pulley bolt(A), washer(B) and crankshaft pulley (A).
Tightening torque :
376.6~411.9Nm (38.4~42.0kgf.m, 277.7~303.8lb-ft)

Using the special tool(09517-21700, 09231-H1000), tighten the bolt(A).
21. Install the bolts(B), nut(C) and timing belt upper cover (A).
Tightening torque :
6.9~9.8Nm (0.7 ~ 1.0kgf.m, 5.1 ~ 7.2lb-ft)

22. Install the water pump pulley.
Tightening torque :
5.9~9.8Nm (0.6 ~ 1.0kgf.m, 4.3 ~ 7.2lb-ft)

23. Install the drive belt.

24. Confirm that the ‘A’ part of the drivebelt auto-tensioner is positioned as shown below. If not, replace the belt.

25. Install the engine support bracket(A).
Tightening torque :
49.0~63.7Nm (5.0 ~ 6.5kgf.m, 36.2 ~ 47.0lb-ft)

26. Install the engine mounting (A).
Tightening torque :
88.3~107.9Nm (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft)
27. Remove the jack for oil pan.
28. Install the battery terminals (A).

2007 > J2.9L DIESEL CRDI(VGT) >

SPECIFICATIONS
Description

Specifications(J3 — ENG)

General
Type

In-line, DOHC

Number of cylinders

4

Bore

101.5~101.526mm (3.9961~3.9971in)

Stroke

98mm (8.8583in)

Total displacement

2,902 cc (177.08 cu.in)

Compression ratio

18.4 : 1

Firing order

1-3-4-2

Valve timing
Intake valve

Exhaust valve

Opens (ATDC)

26°

Closes (ABDC)

50°

Opens (BBDC)

72°

Closes (ATDC)

32°

Cylinder head
Flatness of gasket surface
Flatness of manifold
mounting surface

Less than 0.05mm (0.0020in)

Intake

Less than 0.15mm (0.0059in)

Exhaust

Less than 0.15mm (0.0059in)

Intake

39.397 ~ 39.597mm (1.5511 ~ 1.5589in)

Exhaust

39.4932 ~ 39.6932mm (1.5548 ~ 1.5627in)

Camshaft
Cam height

Journal outer Diameter (Intake, Exhaust)

27.941 ~ 27.960mm (1.1000 ~ 1.1008in)

Bearing oil clearance

0.040 ~ 0.080mm (0.0016 ~ 0.0031in)

End play

0.08 ~ 0.17mm (0.0031 ~ 0.0067in)

Valve
Valve length

Stem outer diameter

Intake

126.24mm (4.9701in)

Exhaust

126.24mm (4.9701in)

Intake

6.965 ~ 6.980mm (0.2742 ~ 0.2748in)

Exhaust

6.945 ~ 6.960mm (0.2734 ~ 0.2740in)

Face angle

45°

Thickness of valve
head (margin)

Intake

1.7mm (0.0669in)

Exhaust

1.6mm (0.0630in)

Valve stem to valve
guide clearance

Intake

0.030 ~ 0.065mm (0.0012 ~ 0.0026in)

Exhaust

0.050 ~ 0.085mm ( 0.0020~ 0.0033in)

Intake

52.5mm (2.0669in)

Exhaust

52.5mm (2.0669in)

Valve guide
Length
Valve seat

Limit

Width of seat contact

Intake

1.4 ~ 2.0mm (0.0551 ~ 0.0787in)

Exhaust

0.9 ~ 1.5mm (0.0354 ~0.0591 in)

Seat angle

45°

Valve spring
Free length
Load(Intake)

Load(Exhaust)

52.477mm (2.0660in)
Installed

23.45±1.87kg/40.0mm(51.7±4.1lb/1.5748 in)

Valve opened

39.15±3.13kg/31.65mm(86.3±6.9 lb/1.2461 in)

Installed

23.45±1.87kg/40.0mm(51.7±4.1lb/1.5748 in)

Valve opened

39.43±3.15kg/31.50mm(86.9±6.9 lb/1.2402 in)

Out of squareness

Less than 2°

Rocker arm and rocker arm shaft
Rocker arm inner diameter

20.000 ~ 20.027mm (0.7874 ~ 0.7885in)

Rocker arm shaft outer diameter

19.959 ~ 19.980mm (0.7858 ~ 0.7866in)

Cylinder block
Cylinder bore

101.500 ~ 101.526mm (3.9961 ~3.9971 in)

Liner inner diameter

97.100 ~ 97.126mm (3.8228~ 3.8239in)

Liner outer diameter

101.480 ~ 101.526mm ( 3.9953~ 3.9971in)

Flatness of gasket surface

Less than 0.05mm (0.0020in)

Piston
Piston outer diameter

97.015 ~ 97.030mm ( 3.8195~ 3.8201in)

Piston to cylinder clearance

0.070 ~ 0.098mm (0.0028 ~ 0.0039in)

Ring groove width

No. 1 ring groove

2.397 ~ 2.417mm ( 0.0944~0.0952 in)

No. 2 ring groove

2.05 ~ 2.07mm ( 0.0807~ 0.0815in)

Oil ring groove

3.02 ~ 3.04mm (0.1189 ~ 0.1197in)

No. 2 ring

0.06 ~ 0.10mm (0.0024~0.0039 in)

Oil ring

0.03 ~ 0.07mm (0.0012~0.0028 in)

No. 1 ring

0.25 ~ 0.40mm (0.0098~ 0.0157in)

No. 2 ring

0.40 ~ 0.55mm (0.0157~0.0217in)

Oil ring

0.20 ~ 0.40mm (0.0079 ~ 0.0157in)

Piston ring

Side clearance

End gap

Piston pin
Piston pin outer diameter

31.994 ~ 32.000mm (1.2596 ~ 1.2598 in)

Piston pin hole inner diameter

32.015 ~ 32.025mm (1.2604 ~ 1.2608 in)

Piston pin hole clearance

0.015 ~ 0.031mm (0.0006 ~ 0.0012 in)

Connecting rod small end inner diameter

32.012 ~ 32.033mm (1.2603 ~ 1.2611 in)

Connecting rod small end hole clearance

0.012 ~ -0.039mm (0.0005 ~ 0.0015 in)

Connecting rod
Connecting rod big end inner diameter

60.833 ~ 60.846mm (2.3950 ~ 2.3955 in)

Connecting rod bearing oil clearance

0.043 ~ 0.077mm (0.0017 ~ 0.0030 in)

End play

0.239~0.39 (0.0094 ~ 0.0154 in)

3°

Crankshaft
Main journal outer
diameter

NO 1, 2, 4, 5

69.995 ~ 70.015mm (2.7557 ~2.7565 in)

NO 3

69.973~69.993mm (2.7548 ~2.7556 in)

Pin journal outer diameter
Main bearing oil
clearance

57.106~57.124mm (2.2483~2.2490 in)

NO 1, 2, 4, 5

0.045 ~ 0.079mm (0.0018 ~0.0031 in)

NO 3

0.067~0.101 mm (0.0026 ~0.0040 in)

End play

0.14 ~ 0.39mm (0.0055 ~0.0154 in)

Flywheel
Runout

0.10mm (0.0039in)

0.13mm (0.0051in)

Oil pump
Relief valve opening pressure

588.40±49.0kpa(6.0±0.5kg/cm²,85.34±7.1psi)

Discharge volume

75L/min(79.25 US qt/min, 65.99 lmp qt/min)
(engine3,800rpm)

Engine oil
Oil quantity (Total)

8.0 L (8.45 US qt, 7.03 lmp qt)

Oil quantity (Oil pan)

6.0 L (6.34 US qt, 5.27 lmp qt)

Oil quantity (Drain and refill including oil filter)

6.6 L (6.97 US qt, 5.08 lmp qt)

Oil quality

ABOVE API CH-4 or ABOVE ACEA B4

Oil pressure (Idle)

78.45 kpa (0.8 kg/cm², 11.38 psi)

Cooling system
Cooling method

Forced circulation with cooling fan

Thermostat

Radiator cap

Type

Wax pellet type

Opening temperature

88±1.5 °C (190.4 ±34.7 °F)

Pull opening
temperature

100 °C (212.0 °F)

Main valve opening
pressure

93.16 ~ 122.58kpa(0.95 ~ 1.25kg/cm², 13.51
~ 17.78psi)

Water temperature sensor
Type

Thermister type

Resistance

20°C (68°F)

2.27~2.64 kΩ

80°C (176°F)

0.31~0.33 kΩ

TIGHTENING TORQUE
Tightening torque

Quantity

N.m

kgf.m

lb-ft

8

36.3 ~ 53.9

3.7 ~ 5.5

26.8 ~ 39.8

Engine mounting insulator and engine mounting
bracket fixing nuts

4

36.3 ~ 53.9

3.7 ~ 5.5

26.8 ~ 39.8

Engine support bracket and engine mounting
insulator fixing nuts

2

36.3 ~ 53.9

3.7 ~ 5.5

26.8 ~ 39.8

Item
Cylinder block
Engine support bracket bolts
Engine mounting

Transaxle mounting bracket and body fixing
bolts

4

36.3 ~ 53.9

3.7 ~ 5.5

26.8 ~ 39.8

Transaxle mounting insulator and transaxle
mounting bracket fixing bolt

1

62.8 ~ 93.2

6.4 ~ 9.5

46.3 ~ 68.7

Transaxle and transaxle mounting insulator
fixing nuts

4

36.3 ~ 53.9

3.7 ~ 5.5

26.8 ~ 39.8

8

68.6→Unfasten
bolts→29.4+90°

7.0 → Unfasten
bolts→3.0+ 90°

50.6→ Unfasten
bolts→21.7+ 90°

10

69.6~79.4+55°~65°

7.1 ~
8.1+55°~65°

51.4~58.6+55°~65°

Flywheel (DMF) bolts (M/T)

8

122.6 ~ 132.4

12.5 ~ 13.5

90.4 ~ 97.6

Drive plate bolts (A/T)

8

159.8 ~ 169.7

16.3 ~ 17.3

117.9 ~ 125.1

Timing belt upper cover bolts

5

6.9 ~ 9.8

0.7 ~ 1.0

5.1 ~ 7.2

Timing belt upper cover nut

1

6.9 ~ 9.8

0.7 ~ 1.0

5.1 ~ 7.2

Timing belt lower cover bolts

8

6.9 ~ 9.8

0.7 ~ 1.0

5.1 ~ 7.2

Crankshaft pulley bolt

1

372.7 ~ 411.9

38.0 ~ 42.0

274.9 ~ 303.8

Camshaft sprocket bolts

2

58.8 ~ 68.6

6.0 ~ 7.0

43.4 ~ 50.6

Timing belt tensioner bolt

1

20.6 ~ 25.5

2.1 ~ 2.6

15.2 ~ 18.8

Timing belt N0. 1 idler bolt

1

39.2 ~ 49.0

4.0 ~ 5.0

28.9 ~ 36.2

Timing belt N0. 2 idler bolt

1

37.3 ~ 43.1

3.8 ~ 4.4

27.5 ~ 31.8

Touch idler bolt

1

20.6 ~ 25.5

2.1 ~ 2.6

15.2 ~ 18.8

High pressure pump puli nut

1

58.8 ~ 68.6

6.0 ~ 7.0

43.4 ~ 50.6

High pressure pump and Timing belt case fixing
bolts

3

21.6 ~ 25.5

2.2 ~ 2.6

15.9 ~ 18.8

High pressure pump bracket bolts (Pump)

2

21.6 ~ 25.5

2.2 ~ 2.6

15.9 ~ 18.8

High pressure pump bracket bolts (Cylinder
block)

2

34.3 ~ 40.2

3.5 ~ 4.1

25.3 ~ 29.7

Timing belt plate bolts

6

6.9 ~ 9.8

0.7 ~ 1.0

5.1 ~ 7.2

Timing belt case bolts (8 X 25)

8

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Timing belt case bolts (8 X 45)

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Timing belt case bolts (8 X 50)

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Timing belt case nut

1

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Balancer gear bolt

1

63.7 ~ 73.5

6.5 ~ 7.5

47.0 ~ 54.2

Oil pump gear bolt

1

33.3 ~ 39.2

3.4 ~ 4.0

24.6 ~ 28.9

Idler gear bolt

1

33.3 ~ 39.2

3.4 ~ 4.0

24.6 ~ 28.9

Cylinder head cover bolts

15

8.8 ~ -10.8

0.9 ~ -1.1

6.5 ~ -8.0

Rocker arm shaft And camshaft bearing cap
bolts

10

17.7 ~ 26.5

1.8 ~ 2.7

13.0 ~ 19.5

Camshaft bearing cap nuts

10

17.7 ~ 26.5

1.8 ~ 2.7

13.0 ~ 19.5

2

7.8 ~ 11.8

0.8 ~ 1.2

5.8 ~ 8.7

Main moving system
Connecting rod cap nuts
Crankshaft main bearing cap bolts

Timing belt

Cylinder head

Front camshaft bearing cap nuts(Small nuts)

Cylinder head bolt (Long bolts)

10

39.2 + 90° + 120°

4.0 + 90° + 120°

28.9 + 90° + 120°

Cylinder head bolt (Short bolts)

8

39.2 + 90°+ 90°

4.0 + 90° + 90°

28.9 + 90°+ 90°

Cooling fan water pump pulley bolts

4

5.9 ~ 9.8

0.6 ~ 1.0

4.3 ~ 7.2

Water pump bolt (Long bolts)

3

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Water pump bolt (Short bolts)

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Water pump and generator brace fixing bolts (8
X 45)

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Thermostat housing and generator strip nuts

2

18.6 ~ 22.6

1.9 ~ 2.3

13.7 ~ 16.6

Thermostat case cover bolts

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil filter

1

21.6 ~ 24.5

2.2 ~ 2.5

15.9 ~ 18.1

Oil cooler bolts (8 X 35)

4

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil cooler bolts (8 X 50)

4

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil cooler nuts

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

29

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil pan drain plug

1

34.3 ~ 44.1

3.5 ~ 4.5

25.3 ~ 32.5

Ladder frame bolts (10 X 45)

5

31.4 ~ 46.1

3.2 ~ 4.7

23.1 ~ 34.0

Ladder frame and oil suppling pipe bolt (8X 50)

1

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Ladder frame bracket (Oil pump and ladder
frame fixing) bolts

2

31.4 ~ 46.1

3.2 ~ 4.7

23.1 ~ 34.0

Oil supplying pipe and oil pump fixing bolts (8
X16)

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil supplying pipe and Ladder frame fixing bolts
(8 X 16)

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil pump bolts(10 X 60)

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil pump bolt(8 X 30)

1

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil screen nuts

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil pressure switch

1

14.7 ~ 46.1

1.5 ~ 2.2

10.8 ~ 34.0

Intake manifold and cylinder head fixing bolts(8
X 45)

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Intake manifold and cylinder head fixing bolts(8
X 95)

4

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Intake manifold and cylinder head fixing nuts

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Intake manifold and cylinder head fixing
hexagonal wrench bolt

1

17.7 ~ 26.5

1.8 ~ 2.7

13.0 ~ 19.5

Exhaust manifold and cylinder head fixing nut

9

26.5 ~ 34.3

2.7 ~ 3.5

19.5 ~ 25.3

Exhaust manifold heat cover and exhaust
manifold fixing bolts(6X12)

3

8.8 ~ 12.7

0.9 ~ 1.3

6.5 ~ 9.4

Engine hanger bracket and exhaust manifold
fixing bolts (8 X 18)

2

17.7 ~ 26.5

1.8 ~ 2.7

13.0 ~ 19.5

Exhaust manifold and front muffler fixing nut

2

39.2 ~ 58.8

4.0 ~ 6.0

28.9 ~ 43.4

Cooling system

Lubrication system

Oil pan nuts

Intake and exhaust system

Front muffler CPF(Catalyzed Particulate Filter)
fixing nuts

2

39.2 ~ 58.8

4.0 ~ 6.0

28.9 ~ 43.4

CPF(Catalyzed Particulate Filter) main muffler
fixing nuts

2

39.2 ~ 58.8

4.0 ~ 6.0

28.9 ~ 43.4

Main muffler and tail pipe fixing nuts

2

39.2 ~ 58.8

4.0 ~ 6.0

28.9 ~ 43.4

Timing system
Timing belt

2007 > J2.9L DIESEL CRDI(VGT) >

COMPONENTS

2007 > J2.9L DIESEL CRDI(VGT) >

REMOVAL
Engine removal is not required for this procedure.
1. Remove the battery terminals (A).

2. Install the jack for oil pan.
3. Remove the engine mounting (A).

4. Remove the engine support bracket(A).

5. Remove the drive belt.

6. Remove the water pump pulley.

7. Remove the bolts(B), nut(C) and timing belt upper cover (A).

8. Turn the crankshaft pulley(A), and align its groove with timing mark “T” of the timing belt cover. Check that the
timing mark of camshaft sprocket(B) is aligned with the timing mark of cylinder head cover. (No.1 cylinder
compression TDC position)

9. Remove the crankshaft pulley bolt(A), washer(B) and crankshaft pulley (C).

Using the special tool(09517-21700, 09231-H1000), fix the crankshaft pulley and loosen the bolt(A).
10. Remove the drive belt idler(A).

11. Remove the drive belt auto-tensioner (A).

12. Remove the timing belt lower cover(A).

13. Remove the auto-tensioner(A) with the timing belt.

In reusing the timing belt, install the belt with the arrow mark facing to rotating direction.
14. Remove the timing belt sprocket(A).

15. Remove the timing belt No.1 idler(A).

16. Remove the timing belt No.2 idler(A).

17. Remove the touch idler(A).

18. Fix the high pressure pump pulley, using the setting bolt(B) for the pulley not to be rotated.

19. Remove the high pressure pulley nut(A), with the washer(B), pulley(C).

Using SST, remove the pulley. (Refer to FL group).
20. Using SST(09231-4X100), remove the camshaft pulley.

INSTALLATION
1. Using SST (09231-4X100), install the camshaft pulley.
Tightening torque :
58.8~68.6Nm (6.0~7.0kgf.m, 43.4 ~ 50.6lb-ft)

2. After installing the high pressure pump pulley(A), tighten the high pressure pump pulley nut with the setting bolt(B)
for the pulley not to be rotated.
Tightening torque :
58.8~68.6Nm (6.0~7.0kgf.m, 43.4 ~ 50.6lb-ft)

3. Install the touch idler(A).
Tightening torque :
7.8 ~ 9.8Nm (2.1~2.6kgf.m, 5.8 ~ 7.2lb-ft)

4. Install the timing belt No.2 idler(A).
Tightening torque :
7.8 ~ 9.8Nm (3.8~4.4kgf.m, 5.8 ~ 7.2lb-ft)

Ensure the location of idlers.
No.1 idler : 60mm(2.3622in)
No.2 idler : 55mm(2.1654in)

5. Install the timing belt No.1 idler(A).
Tightening torque :
7.8 ~ 9.8Nm (4.0~5.0kgf.m, 5.8 ~ 7.2lb-ft)

6. Install the timing belt sprocket(A).

7. Check that the timing mark of camshaft pulley(A), high pressure pump pulley(B) and crankshaft pulley(c).

8. Install the timing belt.
Crankshaft sprocket pulley(A)→No.2 idler(B)→High pressure pump pulley (C) → No.1 idler(D) → camshaft sprocket
pulley (E)

Because the auto-tensioner should be installed after the timing belt, be careful about the tension of the belt
before the installation of the auto-tensioner.

before the installation of the auto-tensioner.

9. Install the auto-tensioner as shown below which the tensioner fork(back plate)(A) positioned around the dowel
pin(B).

Be careful for the auto-tensioner not to be stained with oil. If so, replace the auto-tensioner with a new one.
The location of the pointer, the back plate and the special washer is as shown.
10. Adjust the tension of the timing belt.
(1) Adjust the location of the pointer (B) aligning the tensioner fork(back plate)(C) as shown below by turning the
special washer(A) counterclockwise with a hexagonal wrench.

(2) When aligning the pointer(A) with the tensioner fork(back plate)(B), tighten the tensioner mounting bolt with
fixing the special washer not to move by a hexagonal wrench.
Tightening torque :
19.6~25.5Nm (2.0~2.6kgf.m, 14.5~18.8lb-ft)

(3) Remove the hexagonal wrench.

If the pointer is not aligned with the tensioner fork(back plate), replace the belt with a new one and adjust
them again.
11. Align the timing marks of the crankshaft sprocket, the camshaft sprocket and the high pressure pump pulley by
turning the crankshaft clockwise two revolutions.
12. Check that the location of the pointer is aligned with the tensioner fork (back plate).
The margin of error : ± 5°

If the location of the pointer is not within the margin of error, repeat the steps 10)~12).
13. Install the timing belt lower cover(A).
Tightening torque :
6.9~9.8Nm (0.7 ~ 1.0kgf.m, 5.1 ~ 7.2lb-ft)

14. Install the drive belt idler(A).
Tightening torque :
37.3Nm (3.8kgf.m, 27.5lb-ft)

15. Install the drive belt auto-tensioner (A).
Tightening torque :
15.7~22.6Nm (1.6 ~ 2.3kgf.m, 11.6 ~ 16.6lb-ft)

16. Install the crankshaft pulley bolt(A), washer(B) and crankshaft pulley (A).
Tightening torque :
376.6~411.9Nm (38.4~42.0kgf.m, 277.7~303.8lb-ft)

Using the special tool(09517-21700, 09231-H1000).
17. Install the bolts(B), nut(C) and timing belt upper cover (A).
Tightening torque :
6.9~9.8Nm (0.7 ~ 1.0kgf.m, 5.1 ~ 7.2lb-ft)

18. Install the water pump pulley.
Tightening torque :
5.9~9.8Nm (0.6 ~ 1.0kgf.m, 4.3 ~ 7.2lb-ft)

19. Install the drive belt.

20. Check that the ‘A’ part of the drivebelt auto-tensioner is aligned as shown below. If not, replace the drivebelt.

21. Install the engine support bracket(A).
Tightening torque :
49.0~63.7Nm (5.0 ~ 6.5kgf.m, 36.2 ~ 47.0lb-ft)

22. Install the engine mounting (A).
Tightening torque :
88.3~107.9Nm (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft)

23. Remove the jack for oil pan.
24. Install the battery terminals (A).

INSPECTION
SPROCKETS, TENSIONER, IDLER
1. Check the camshaft sprocket, crankshaft sprocket, tensioner pulley, and idler pulley for abnormal wear, cracks, or
damage. Replace as necessary.
2. Inspect the tensioner pulley and the idler pulley for easy and smooth rotation and check for play or noise. Replace
as necessary.

3. Replace the pulley if there is a grease leak from its bearing.

TIMING BELT
1. Check the belt for oil or dust deposits.
Replace, if necessary.
Small deposits should be wiped away with a dry cloth or paper. Do not clean with solvent.
2. When the engine is overhauled or belt tension adjusted, check the carefully. If any of the following flaws are
evident, replace the belt.

a. Do not bend, twist or turn the timing belt inside out.
b. Do not allow timing belt to come into contact with oil, water and steam.

Cylinder Head Assembly

2007 > J2.9L DIESEL CRDI(VGT) >

COMPONENTS

2007 > J2.9L DIESEL CRDI(VGT) >

REMOVAL
Engine removal is not required for this procedure.

a. To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal
temperature before removing it.
b. When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.
c. To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

a. Mark all wiring and hoses to avoid misconnection.
b. Inspect the timing belt before removing the cylinder head.
c. Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
1. Remove the battery(A).

2. Drain the engine coolant.
Remove the radiator cap to speed draining.
3. Remove the intake air hose and air cleaner assembly.
(1) Disconnect the AFS(Air Flow Sensor) connector(A).

(2) Disconnect the air cleaner upper cover(A).

(3) Remove the air cleaner assembly(A).

(4) Remove the air intake hose(A).

4. Remove the radiator upper hose(A).

5. Remove the reservoir tank hose(A).

6. Remove the PCV(Positive Crankcase Ventilation) hose(A), EGR valve vacuum hose(B), EGR cooler water hose(C),
pump vacuum oil hose(D).

7. Remove the intercooler hose(A,C), pipe(B).

8. Remove the wiring connectors and clamps from cylinder head and intake manifold.
(1) Remove the generator connector (A) and ETC(Engine Coolant Temperature) sensor connector (B).

(2) Remove the injector connector(A), common rail pressure sensor connector(B), wire harness protector(C).

(3) Remove the ground cable(A) from cylinder head.

(4) Remove the knock sensor connector (A), high pressure pump fuel hose (B), high pressure pump connector(C).

(5) Remove the air conditioner condenser (A).

(6) Remove the oil pressure switch connector (A).

(7) Remove the air heater (A), CMP (Camshaft Position Sensor) connector (B).

9. Remove the injection pipe, injector. (Refer to FL- injector.)
10. Remove the exhaust manifold.
11. Remove the intake manifold.
12. Remove the timing belt.
13. Remove the hose(C, D) and pipe (E) from. the ventilation housing(A) and the air separator(B).

14. Remove the oil pipe (B) and hose(C) from the generator vacuum pump (A).

15. Remove the generator fixing bolts(B,C), nuts(D) and then the generator(A).

16. After removing the water hose(C) from the thermostat housing (B), remove the generator fixing bracket (A) and
the thermostat housing (B).

17. Remove the cylinder head cover(A).

18. Remove the timing belt plate(A).

19. Remove the rockerarm shaft(A).

20. Remove the camshaft bearing caps(A).

21. Remove the camshaft(A).

22. Remove the cylinder head bolts, then remove the cylinder head.
(1) Remove the 18 cylinder head bolts, in several steps and the sequence shown below.

Head warpage or cracking could result from removing bolts in an incorrect order.
(2) Lift the cylinder head from the dowels on the cylinder block and replace the cylinder head on wooden blocks
on a bench.

Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

INSTALLATION

a.
b.
c.
d.

Thoroughly clean all parts to be assembled.
Always use a new cylinder head and manifold gasket.
The cylinder head gasket is a metal gasket. Take care not to bend it.
Rotating the crankshaft, set the No. 1 piston at TDC.

1. Install the cylinder head gasket(A) on the cylinder block.

Ensure the installation direction.

2. Place the cylinder head quietly in order not to damage the gasket with the bottom part of the end.
3. Install the cylinder head bolts.
(1) Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts.

After measuring the length of the cylinder head bolts, replace them, if necessary.
Long bolts : 132mm(5.1968in)
Short bolts :93mm(3.6614in)
(2) Install and tighten the 18 cylinder head bolts and plate washers, in several passes, in the sequence shown.
Tightening torque :
Long bolts: 39.2Nm (4.0kgf.m, 28.9lb-ft)+ 90° + 120°
Short bolts: 39.2Nm (4.0kgf.m, 28.9lb-ft)+ 90° + 90°

4. Install the camshaft(A) on the cylinder head.

Apply sealant before assembling the front bearing caps
(LOCTITE NO. 518 or equivalent).

5. Install the bearing caps aligning the cap numbers with the direction of the arrow marks.

6. Install the rockerarm shaft assembly(A) after bearing cap.
Tightening torque :
Nuts, Bolts: 17.7~26.5Nm (1.8 ~ 2.7kgf.m, 13.0~19.5lb-ft)
Small nuts: 7.8~11.8Nm (0.8 ~ 1.2kgf.m, 5.8~8.7lb-ft)

Distinguish between the intake and the exhaust rocker arm shaft (Intake: yellow, exhaust: black).

7. Install the camshaft oil seal.
8. Install the timing belt plate(A).
Tightening torque :
6.9~9.8Nm (0.7~1.0kgf.m, 5.1~7.2lb-ft)

9. Install the cylinder head cover.
(1) Apply sealant on the cylinder head as shown below.

(2) Before installing the cylinder head cover, check the clearance (A) between dowel pin on the edge of the
camshaft and the phase sensor.
Clearance (A) :
0.5 ~ 1.5mm (0.0197 ~ 0.0591in.)

(3) Install the cover (A) to the cylinder head after the gasket.
Tightening torque :
8.8~10.8Nm (0.9~1.1kgf.m, 6.5~8.0lb-ft)

10. Install the thermostat housing (B), the generator fixing bracket (A), and the water hose(C).
Tightening torque :
18.6~27.5Nm (1.9~2.8kgf.m, 13.7~20.3lb-ft)

11. Install the generator(A) with the fixing bolts(B,C), nut(D).
Tightening torque :
38.2~58.8Nm (3.9~6.0kgf.m, 28.2~43.4lb-ft)

12. Install the oil pipe(B), hose(C) to generator pressure pump(A).
Oil pipe eyd bolt
Tightening torque :
19.6~24.5Nm (2.0~2.5kgf.m, 14.5~18.1lb-ft)

13. Install the hose(C,D) and the pipe(E) to the ventilation housing(A) and the air separator(B).

14. Install the timing belt.
15. Install the intake manifold.
16. Install the exhaust manifold.
17. Install the injection pipe, injector. (Refer to FL- injector.)
18. Install the wire harness and the clamp to the cylinder head and the intake manifold.
(1) Install the air heater(A), CMP (Camshaft Position Sensor) connector(B).

(2) Install the oil pressure switch connector(A).

(3) Install the air conditioner condenser(A).

(4) Install the knock sensor connector(A), high pressure pump fuel hose(B), high pressure pump connector(C).

(5) Install the ground cable(A) from cylinder head.

(6) Install the injector connector(A), common rail pressure sensor connector(B), wire harness protector(C).

(7) Install the generator connector(A) and the ETC(Engine Coolant Temperature) sensor connector(B).

19. Install the intercooler hose(A,C), pipe(B).

20. Install the PCV(Positive Crankcase Ventilation) hose(A), EGR valve vacuum hose(B), EGR cooler water hose(C),
pump vacuum oil hose(D).

21. Install the reservoir tank hose(A).

22. Install the radiator upper hose(A).

23. Install the intake air hose and air cleaner assembly.
(1) Install the air intake hose(A).

(2) Install the air cleaner assembly(A).

(3) Install the air cleaner upper cover(A).

(4) Install the AFS(Air Flow Sensor) connector(A).

24. Fill with engine coolant.
25. Install the battery(A).

26. Start engine and check for leaks.
27. Check the engine coolant and engine oil level.

DISASSEMBLY
1. Remove the valves.
(1) Using the SST (0K9993 120 004, 0K993 120 001), compress the valve spring and remove the retainer lock.

(2) Remove the spring retainer.
(3) Remove the valve spring.
(4) Remove the valve.
(5) Using a needle-nose pliers, remove the oil seal.
(6) Using a magnetic finger, remove the spring seat.

INSPECTION
CYLINDER HEAD
1. Inspect for flatness.
Using a precision straight edge and feeler gauge, measure the surface the contacting the cylinder block and the
manifolds for warpage.
Flatness of cylinder head gasket surface
Less than 0.05mm (0.0020in)
Flatness of manifold mating surface
Less than 0.15mm (0.0059in)

2. Inspect for cracks.
Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked,
replace the cylinder head.

VALVE AND VALVE SPRING

1. Inspect the valve stems and valve guides.
(1) Using a caliper gauge, measure the innner diameter of valve guide.
Valve guide inner diameter :
7.010~7.030mm (0.2760~0.2768in)

(2) Using a micrometer, measure the outer diameter of valve stem.
Valve stem outer diameter
Intake : 6.965~6.980mm (0.2742~0.2748in)
Exhaust : 6.945~6.960mm (0.2734~0.2740in)

(3) Subtract the valve stem outer diameter measurement from the valve guide innner diameter measurement.
Valve stem- to-guide clearance
Intake : 0.030 ~ 0.065mm (0.0012 ~ 0.0026in)
Exhaust : 0.050 ~ 0.085mm (0.0020 ~ 0.0033in)
If the clearance is greater than maximum, replace the valve and valve guide.
2. Inspect the valves.
(1) Check the valve is ground to the correct valve face angle.
(2) Check that the surface of valve for wear.
If the valve face is worn, replace the valve.
(3) Check the valve head margin thickness.
If the margin thickness is less than minimum, replace the valve.
Margin
Intake : 1.7mm (0.0669in)
Exhaust : 1.6mm (0.0630in)

(4) Check the surface of valve stem tip for wear.
If the valve stem tip is worn, replace the valve.
3. Inspect the valve seats.
(1) Check the valve seat for evidence of overheating and improper contact with the valve face.
Replace the seat if necessary.
(2) Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace it, then
recondition the seat.
(3) Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width should be within

4. Inspect the valve springs.
(1) Using a steel square, measure the out-of-square of valve spring.
(2) Using a vernier calipers, measure the free length of valve spring.
Valve spring
Free height : 52.477mm (2.0660in)
Installed load: 51.7±4.1kg/40.0mm(41.4±2.0lb/1.5748in)
Compressed load:86.3±6.9kg/31.65mm(41.4±2.0lb/1.2461in) (Intake)
86.9±6.9kg/31.50mm(41.4±2.0lb/1.2402in) (Exhaust)
Out of square : Less than 2°

If the loads is not as specified, replace the valve spring.

CAMSHAFT
1. Inspect the cam lobes.
Using a micrometer, measure the cam lobe height.
Cam height
Intake : 39.397~39.597mm (1.5511~1.5589in)
Exhaust : 39.4932~39.6932mm (1.5548~1.5627in)

If the cam lobe height is less than minimum, replace the camshaft.
2. Inspect the camshaft journal clearance.
(1) Clean the bearing caps and camshaft journals.
(2) Place the camshafts on the cylinder head.
(3) Lay a strip of plastigage across each of the camshaft journal.

(4) Install the bearing caps and tighten the bolts with specified torque.

Do not turn the camshaft.

(5) Remove the bearing caps.
(6) Measure the plastigage at its widest point.
Bearing oil clearance
Standard : 0.040 ~ 0.080mm (0.0016 ~ 0.0031in)

If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and
cylinder head as a set.
(7) Completely remove the plastigage.
(8) Remove the camshafts.
3. Inspect the camshaft end play.
(1) Install the camshafts.
(2) Using a dial indicator, measure the end play while moving the camshaft back and forth.
Camshaft end play
Standard : 0.08 ~ 0.17mm (0.0031 ~ 0.0067in)

If the end play is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and
cylinder head as a set.
(3) Remove the camshafts.

Rockerarm and rockerarm shaft
1. Inspect the rockerarm and rockerarm shaft.
(1) Measure the inner diameter of the rocker arm, using a caliper gauge.
Rockerarm inner diameter
20.000~20.027mm (0.7874~0.7885in)
(2) Measure the inner diameter of the rocker arm, using a micro meter.

Rockerarm shaft outer diameter
19.959~19.980mm (0.7858~0.7866in)
Calculate the clearance between the rocker arm and the rocker arm shaft by the difference between the inner
and outer diameter of the rocker arm.
Rockerarm and rockerarm shaft clearance
0.020~0.068mm (0.0008~0.0027in)
If the clearance is out of the specification above, replace the rocker arm and rocker arm shaft.

HLA (HYDRAULIC LASH ADJUSTER)
Sieze the ‘A’ part of the HLA filled with engine oil. If it is moved when pushed the ‘B’ part by hand, replace it.

Problem
Temporary noise when startinga
cold engine

Possible cause

Action

Normal

This noise will disappear afterthe
oil in the engine reachesthe
normal pressure.

Continuous noise when theengine
Oil leakage of the high pressurechamber on
is started after parkingmore than
the HLA, allowingair to get in.
48 hours.

Noise will disappear within
15minutes when engine runs
at2,000~3,000 rpm.If it
doesn’tdisappear, refer to step 7
below.

Continuous noise when theengine
is first started afterrebuilding
Insufficient oil in cylinder head oil gallery.
cylinder head.
Continuous noise when theengine Oil leakage of the high-pressure chamber in
is started after excessively
the HLA, allowing air to get in.
cranking the engine by the starter Insufficient oil in the HLA.
motor.

Do not run engine at a speed
higher than 3,000 rpm, as this
may damage the HLA.

Continuous noise when the
engine is running after changing
the HLA.
Continuous noise during idleafter
high engine speed.

Engine oil level too high or too low.
Excessive amount of air in theoil at high
engine speed.

Noise continues for morethan 15
minutes.

Check oil level.
Drain or add oil as necessary.
Check oil supply system

Deteriorated oil.

Check oil quality.
If deteriorated, replace with
specified type.

Low oil pressure

Check oil pressure and oil
supplysystem of each part of
engine.

Faulty HLA.

Remove the cylinder head
coverand press HLA down by
hand.If it moves, replace the HLA.

Be careful with the hot HLAs.

REASSEMBLY

a. Thoroughly clean all parts to be assembled.
b. Before installing the parts, apply fresh engine oil to all sliding and rotating surface.
c. Replace oil seals with new ones.
1. Install the valves.
(1) Install the spring seats.
(2) Using the SST (09222 — 22001), push in a new oil seal.

Do not reuse old valve stem oil seals.
Incorrect installation of the seal could result in oil leakage past the valve guides.

(3) Install the valve, valve spring and spring retainer.

Place the valve springs so that the side coated with enamel faces toward the valve spring retainer and
then installs the retainer.
(4) Using the SST(0K993 120 004, 0K993 120 001), compress the spring and install the retainer locks. After
installing the valves, ensure that the retainer locks are correctly in place before releasing the valve spring
compressor.

(5) Lightly tap the end of each valve stem two or three times with the wooden handle of a hammer to ensure
proper seating of the valve and retainer lock.

proper seating of the valve and retainer lock.

Engine
And
Transaxle Assembly

2007 > J2.9L DIESEL CRDI(VGT) >

REMOVAL

a. Use fender covers to avoid damaging painted surfaces.
b. To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

a. Mark all wiring and hoses to avoid misconnection.
1. Remove the battery(A).

2. Remove the under cover(A).

3. Drain the engine coolant.
Remove the radiator cap to speed draining.
4. Drain the engine oil.
Remove the oil filler cap to speed draining.
5. Remove the intake air hose and air cleaner assembly.
(1) Disconnect the AFS(Air Flow Sensor) connector(A).

(2) Disconnect the air cleaner upper cover(A).

(3) Remove the air cleaner assembly(A).

(4) Remove the air intake hose(A).

6. Remove the batter tray(A).

7. Remove the radiator upper hose(A).

8. Remove the radiator lower hose(A).

9. Remove the reservoir tank hose(A).

10. Remove the intercooler hose(A,C), pipe(B).

11. Remove the wire harness and the clamp from the cylinder head and the intake manifold.
(1) Remove the generator connector(A) and the ETC(Engine Coolant Temperature) sensor connector(B).

(2) Remove the injector connector(A), common rail pressure sensor connector(B), wire harness protector(C).

(3) Remove the ground cable(A) from cylinder head.

(4) Remove the knock sensor connector(A), high pressure pump fuel hose(B), high pressure pump connector(C).

(5) Remove the air conditioner condenser(A).

(6) Remove the oil pressure switch connector(A).

(7) Remove the air heater(A), CMP (Camshaft Position Sensor) connector(B).

12. Remove the transaxle wire harness connectors and control cable.
(1) Remove the inhibitor switch connector(A).

(2) Remove the solenoid valve connector(A).

(3) Remove the input shaft speed sensor connector(A).

(4) Remove the output shaft speed sensor connector(A).

(5) Remove the vehicle speed sensor connector(A).

(6) Remove the CKP(Crankshaft position sensor) connector(A).

13. Remove the shift cable(A).

14. Remove the transaxle oil cooler hoses(A).

15. Remove the ground cable(A) from transaxle.

16. Remove the fuse box.(A).

17. Remove the vacuum hose (A) from the generator.

18. Remove the heater hose(A,B).

19. Remove the starter motor connector(A).

20. Remove the front exhaust manifold(A).
Tightening torque :
39.2~58.8Nm (4.0~6.0kgf.m, 28.9~43.4lb-ft)

21. Remove the power steering pump bolt(A).

22. Remove the power steering return hose(A).

23. Remove the engine mounting support bracket(A).
Tightening torque :
88.3~107.9N.m (9.0~11.0kgf.m, 65.1~79.6lb-ft)

24. Remove the transaxle insulator mounting bolt(A).
Tightening torque :
88.3~107.9N.m (9.0~11.0kgf.m, 65.1~79.6lb-ft)

25. Remove the front tires.(Refer to DS group).
26. Remove the ABS wheel speed sensors(A).(Refer to BR group).

27. Remove the caliper and hang the caliper assembly(A).(Refer to BR group).
28. Remove the knuckle mounting bolts(B).(Refer to SS group).
29. Remove the stabilizer link fixing nut(A).(Refer to SS group).

30. Remove the steering u-joint mounting bolt(A).

31. Install the jack for supporting engine and transaxle assembly.

Support the assembly safely because the engine and transaxle assembly can be dropped down after removal
of the sub frame.
32. Remove the sub frame mounting bolts(A).
Tightening torque :
Bolt(A): 156.9~ 176.5Nm (16.0~18.0kgf.m, 115.7~ 130.2lb-ft)
Bolts(B) :44.1~58.8Nm (4.5~6.0kgf.m, 32.5~43.4lb-ft)

33. Remove the engine and transaxle assembly by lifting vehicle.

When remove the engine and transaxle assembly, be careful not to damage any surrounding parts or body
components.

INSTALLATION
Installation is in the reverse order of removal.
Perform the following :
a. Adjust the shift cable.
b. Adjust the throttle cable.
c. Refill the engine with engine oil.
d. Refill the transaxle with fluid.
e. Refill the radiator and reservoir tank with engine coolant.
f. Place the heater control knob on “HOT” positon.
g. Bleed air from the cooling system.
a. Start engine and let it run until it warms up. (until the radiator fan operates 3 or 4 times.)
b. Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be
removed from the cooling system.

removed from the cooling system.
c. Put the radiator cap on tightly, then run the engine again and check for leaks.
h. Clean the battery posts and cable terminals with sandpaper assemble them, then apply grease to prevent
corrosion.
i. Inspect for fuel leakage.
a. After assemble the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for
approximately two seconds and fuel line pressurizes.
b. Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.

Cylinder Block

3LVWRQDQG
&RQQHFWLQJ5RG

2007 > J2.9L DIESEL CRDI(VGT) >

COMPONENTS

2007 > J2.9L DIESEL CRDI(VGT) >

DISASSEMBLY
1. Install the engine to engine stand for disassembly.
2. Remove the timing belt.
3. Remove the cylinder head.
4. Remove the water pump.
5. Remove the air separator(A), hose(B).

6. Remove the oil cooler assembly(A), knock sensor(B).

7. Remove the drive belt auto-tensioner (A).

8. Remove the generator mounting bracket(A), power steering pump bracket(B).

9. Remove the A/C compressor bracket(A).

10. M/T : remove flywheel.
11. A/T : remove drive plate and mass wheel.
12. Using the SST(09215 — 3C000) remove the oil pan(A).

13. Remove the oil pump feed pipe(A) and the ladder frame bracket(B).

14. Remove the ladder frame(A) and the oil pump assembly(B).

15. Remove the balancer shaft(A) to the ladder frame.
(1) Remove the gear cover(A) to the ladder frame.

(2) Remove the balancer sprocket and the balancer gear by loosening the bolts(B).

Not to make the balance shaft be rotated, insert the 5mm-thickeness urethane rubber (B) in the balance
gear (A) for protection.

(3) Remove the thrust plate and the balance shaft.
16. Remove the timing belt case(A).

17. Check the connecting rod end play.
18. Remove the connecting rod caps and check oil clearance.
19. Remove the piston and connecting rod assemblies.
(1) Using a ridge reamer, remove all the carbon from the top of the cylinder.
(2) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

a. Keep the bearings, connecting rod and cap together.
b. Arrange the piston and connecting rod assemblies in the correct order.
20. Remove the rear oil seal case.
Remove the 5 bolts(B) and the rear oil seal case(A).

21. Remove the crankshaft bearing cap and check oil clearance.
22. Check the crankshaft end play.
23. Lift the crankshaft(A) out of the engine, being careful not to damage journals.

Arrange the main bearings and thrust bearings in the correct order.
24. Check fit between piston and piston pin.
25. Remove the piston rings.
(1) Using a piston ring expender, remove the 2 compression rings.
(2) Remove the 2 side rails and oil ring by hand.

Arrange the piston rings in the correct order only.

26. Remove the connecting rod from the piston.
Using a press, remove the piston pin from piston.

INSPECTION
CONNECTING ROD AND CRANKSHAFT
1. Check the connecting rod end play.
Using feeler gauge, measure the end play while moving the connecting rod back and forth.
End play
0.239 ~ 0.39mm (0.0094 ~ 0.0154in)

a. If out-of-tolerance, install a new connecting rod.
b. If still out-of-tolerance, replace the crankshaft.
2. Check the connecting rod bearing oil clearance.
(1) Check the match marks on the connecting rod and cap are aligned to ensure correct reassembly.

(2) Remove the 2 connecting rod cap nuts.
(3) Remove the connecting rod cap and lower bearing.
(4) Clean the crankshaft pin journal and bearing.
(5) Place a plastigage across the crankshaft pin journal.
(6) Reinstall the lower bearing and cap, and tighten the nuts.
Tightening torque :
68.6Nm (7.0 kgf.m, 50.6lb-ft) → Unfasten bolts→29.4Nm (3.0kgf.m, 21.7lb-ft) + 90°

Do not turn the crankshaft.
(7) Remove the 2nuts, connecting rod cap and lower bearing .

(8) Measure the plastigage at its widest point.
Standard oil clearance
0.043 ~ 0.077mm (0.0017 ~ 0.0030in)

(9) If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then install a new
bearings with the same color mark. (Refer to connecting rod bearing selection table)
Recheck the oil clearance.

Do not file, shim, of scrape the bearings or the caps to adjust clearance.
(10) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing. ( Refer to
connecting rod bearing selection table))
Recheck the oil clearance.

If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace
the crankshaft and start over.

If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a
wire brush or scraper. Clean them only with solvent or detergent.

Connecting rod mark location

Discrimination of connecting rod
Mark

Connecting rod big-endinner diameter

1

60.833 ~ 60.839mm
(2.3950 ~ 2.3952 in)

60.839 ~ 60.846mm
(2.3952 ~ 2.3955 in)

2
CRANKSHAFT PIN JOURNAL
Journal outer diameter
57.106~57.124mm (2.2483~2.2490in)

CONNECTING ROD BEARING MARK LOCATION

Discrimination of crankshaft pin journal
Color

Connecting rod bearing thickness

Blue

1.0828~1.832mm
(0.0720~0.0721in)

Red

1.832~1.836mm
(0.0721~0.0723in)

(11) Select the bearing by using the selection table.
Connecting rod bearing selection table
Connecting rod mark

Connecting rod bearing thickness

Oil clearance

1

Blue

0.045~0.077mm(0.0018~0.0030in)

2

Red

0.043~0.076mm(0.0017~0.0030in)

3. Check the connecting rods.
(1) When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at disassembly match.
When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the
same side.
(2) Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a severely
rough surface of the inside diameter of the small end is apparent, the rod must be replaced as well.
(3) Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is close to the
repair limit, correct the rod by a press. Any connecting rod that has been severely bent or distorted should be
replaced.
Allowable bend of connecting rod :
0.04mm / 50mm (0.0016in / 1.9685in ) or less
Allowable twist of connecting rod :
0.1mm / 50mm (0.0039in / 1.9685in) or less
4. Check the crankshaft bearing oil clearance.
(1) To check main bearing-to-journal oil clearance, remove the main bearing caps and lower bearings.

(2) Clean each main journal and lower bearing with a clean shop towel.
(3) Place one strip of plastigage across each main journal.
(4) Reinstall the lower bearings and caps, then tighten the bolts.
Tightening torque :
69.6~79.4Nm(7.1~8.1kgf.m, 51.4~58.6lb-ft)+55°~ 65°

Do not turn the crankshaft.

(5) Remove the cap and lower bearing again, and measure the widest part of the plastigage.
Standard oil clearance :
No.1, 2, 3, 5: 0.045~0.079mm (0.0018 ~0.0031 in)
No.3: 0.067~0.101 mm (0.0026 ~0.0040 in)

(6) If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then install a new
bearings with the same color mark. (Refer to crankshaft main bearing selection table).
Recheck the oil clearance.

Do not file, shim, or scrape the bearings or the cap to adjust clearance.
(7) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing. (Refer to crankshaft
main bearing selection table).
Recheck the oil clearance.

If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the
crankshaft and start over.

If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire
brush or scraper. Clean them only with solvent or detergent.
CYLINDER BLOCK CRANKSHAFT JOURNAL BORE MARK LOCATION
Letters have been stamped on the end of the block as a mark for the size of each of the 5 main journal bores.
Use them, and the numbers or letters stamped on the crank (marks for main journal size), to choose the correct
bearings.

Discrimination of cylinder block crankshaft journal bore
Mark

Cylinder block crankshaft journal bore inner diameter

A

74.066~74.075mm
(2.9160~2.9163in)

None

74.075~74.084mm
(2.9163~2.9167in)

C

74.084~74.092mm
(2.9167~2.9170in)

Crankshaft main journal mark location

Discrimination of crankshaft main journal
Mark

Crankshaft main journalouter diameter
No.1, 2, 3, 5 journal

No.3 journal

1

69.995~70.002mm(2.7557~2.7560in)

69.973~69.980mm(2.7548~2.7551in)

*

70.002~70.009mm(2.7560~2.7563in)

69.980~69.987mm(2.7551~2.7554in)

3

70.009~70.015mm(2.7563~2.7565in)

69.987~69.993mm(2.7554~2.7556in)

Crankshaft main bearing mark location

Discrimination of crankshaft bearing
Color

Crankshaft bearing thickness

Black

2.013 ~ 2.018mm(0.0793~0.0794in)

Brown

2.008 ~ 2.013mm(0.0791~0.0793in)

Green

2.003 ~ 2.008mm(0.0789~0.0791in)

Yellow

1.998 ~ 2.003mm(0.0787~0.0789in)

(8) Select the bearing by using selection table.
Crankshaft main bearing selection table
Cylinder block crankshaft journal bore mark

Crank shaft main
journal mark

A

None

C

A

(Green)

(Brown)

(Black)

*

(Yellow)

(Green)

(Brown)

C

(Yellow)

(Yellow)

(Green)

5. Check the crankshaft end play.
Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
End play
Standard: 0.14~ 0.39mm (0.0055 ~ 0.0154in)

If the end play is greater than maximum, replace the thrust bearings as a set.
6. Inspect the crankshaft main journals and pin journals.
Using a micrometer, measure the diameter of each main journal and pin journal.
Main journal outer diameter :
NO.1, 2, 3, 5: 69.995 ~ 70.015mm (2.7557 ~2.7565 in)

NO.3: 69.973~69.993 mm (2.7548 ~2.7556 in)
Pin journal outer diameter :
57.106 ~ 57.124mm (2.2483 ~2.2490 in)

CYLINDER BLOCK
1. Remove the gasket material.
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean the cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder block.
3. Inspect the top surface of cylinder block for flatness.
Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for
warpage.
Flatness of cylinder block gasket surface Standard:
Less than 0.05mm (0.0020in)

4. Inspect the cylinder bore.
Visually check the cylinder for vertical scratchs.
If deep scratchs are present, replace the cylinder block.
5. Inspect the cylinder bore diameter.
Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial direction.
Standard diameter :
97.100~97.126mm (3.8228~3.8239in)

6. Check the cylinder bore size code on the cylinder block bottom face.

Cylinder bore inner diameter mark location

Discrimination of cylinder bore inner diameter
Mark

Cylinder bore inner diameter

Y

101.513~101.526mm
(3.9966~3.9971in)

X

101.500~101.513mm
(3.9961~3.9966in)

Cylinder liner classifying mark location

The outer discrimination mark of the cylinder liner is on the outer surface of the liner and the inner mark is on
the top surface of it.

Discrimination of cylinder liner
Mark

Outer diameter (mm)

Mark

Inner diameter (mm)

3Y

101.493~101.506mm(3.9958~3.9963in)

Yellow

97.113~97.126mm(3.8233 ~ 3.8239in)

3Y

101.493~101.506mm(3.9958~3.9963in)

Blue

97.100~97.113mm(3.8228~ 3.8233in)

3X

101.480~101.493mm(3.9953 ~ 3.9958in)

Yellow

97.113~97.126mm(3.8233~3.8239in)

3X

101.480~101.493mm(3.9953 ~ 3.9958in)

Blue

97.100~97.113mm(3.8228~ 3.8233in)

Piston Outer diameter mark location

Discrimination of piston outer diameter
Mark

Piston outer diameter

A

97.015~97.030mm(3.8195~3.8201in)

B

97.030~97.045mm(3.8201~3.8207in)

7. Check the piston size mark on the piston top face.
Cylinder liner selection table
Cylinder bore mark

Cylinder liner mark

Oil clearance

Y

3Y- Yellow

0.007~0.033mm(0.0003~0.0013in)

Y

3Y- Blue

0.007~0.033mm(0.0003~0.0013in)

X

3X- Yellow

0.007~0.033mm(0.0003~0.0013in)

X

3X- Blue

0.007~0.033mm(0.0003~0.0013in)

Cylinder liner mark

Piston outer diameter
mark

Oil clearance

Yellow

B

0.068~0.096mm(0.0027~0.0038in)

Blue

A

0.070~0.098mm(0.0028~0.0039in)

Piston

PISTON AND PISTON RINGS
1. Clean the piston.
(1) Using a gasket scraper, remove the carbon from the piston top.
(2) Using a groove cleaning tool or broken ring, clean the piston ring grooves.
(3) Using solvent and a brush, thoroughly clean the piston.

Do not use a wire brush.

2. The standard measurement of the piston outside diameter is taken 47mm (1.85in) from top land of the piston.
Standard diameter :
97.015~97.045mm (3.8195 ~ 3.8207in)

3. Calculate the difference between the cylinder bore inner diameter and the piston outer diameter.
Piston-to-cylinder clearance :
0.070 ~ 0.098mm (0.0028 ~ 0.0039in)
4. Inspect the piston ring side clearance.
Using a feeler gauge, measure the clearance between new piston ring and the wall of ring groove.
Piston ring side clearance
No. 2 : 0.06 ~ 0.10mm (0.0024 ~ 0.0039in)
Oil ring : 0.03 ~ 0.07mm (0.0012 ~ 0.0028in)

If the clearance is greater than maximum, replace the piston.
5. Inspect the piston ring end gap.
To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles to
the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge. If the gap exceeds
the service limit, replace the piston rings. If the gap is too large, recheck the cylinder bore inner diameter. If the
bore is over the service limit, the cylinder block must be rebored.
Piston ring end gap
Standard
No.1 : 0.25~ 0.40mm (0.0098 ~ 0.0157in)
No.2 : 0.40 ~ 0.55mm (0.0157 ~ 0.0217in)
Oil ring : 0.20 ~ 0.40mm(0.0079 ~ 0.0157in)

PISTON PINS
1. Measure the outer diameter of piston pin.
Piston pin diameter :
31.994~32.000mm (1.2596 ~ 1.2598in)

2. Measure the piston pin-to-piston clearance.
Piston pin hole inner diameter:
32.015~32.025 mm (1.2604~1.2608 in)
0.015~0.031 mm(0.0003~0.0012 in)
3. Check the difference between the piston pin outer diameter and the connecting rod small end inner diameter.
Inside diameter of connecting rod small end bore:
32.012~32.033mm (1.2603~1.2611 in)
0.012~0.039 mm(0.0005~0.0015 in)

4. Apply oil on the piston pin when assembling.

LADDER FRAME AND BALANCE SHAFT
1. Measure the ladder frame inner diameter.
Ladder frame inner diameter
LH1

25.000 ~ 25.021 mm(0.9843~0.9851in)

LH2

54.000 ~ 54.030 mm(2.1260~2.1272in)

LH3

56.000 ~ 56.030 mm(2.2047~2.2059in)

RH1

35.000 ~ 35.025 mm(1.3780~1.3789in)

RH2

54.000 ~ 54.030 mm(2.1260~2.1272in)

RH3

56.000 ~ 56.030 mm(2.2047~2.2059in)

2. Measure the balance shaft outer diameter.
Balance shaft outer diameter
LH1

24.939 ~ 24.960 mm(0.9818~0.9827in)

LH2

53.910 ~ 53.940 mm(2.1224~2.1236in)

LH3

55.910 ~ 55.940 mm(2.2012~2.2024in)

RH1

34.925 ~ 34.950 mm(1.3750~1.3760in)

RH2

53.910 ~ 53.940 mm(2.1224~2.1236in)

RH3

55.910 ~ 55.940 mm(2.2012~2.2024in)

3. Measure the end play of the balance shaft.
0.10~0.25mm (0.0036~0.0098in)

OIL PRESSURE SWITCH
1. Check the continuity between the terminal and the body with an ohmmeter. If there is no continuity, replace the oil
pressure switch.

2. Check the continuity between the terminal and the body when the oil hole is blocked with a fine stick. If there is
continuity with a fine stick is pushed, replace the switch.

3. If there is no continuity when a 49.0kpa (0.5kg/cm², 7.1psi) pressure is applied through the oil hole, the switch is
operating properly.
Check for air leakage. If air leaks, the diaphragm is broken. Replace it.

REASSEMBLY

a. Thoroughly clean all parts to assembled.
b. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
c. Replace all gaskets, O-rings and oil seals with new parts.
1. Assemble the piston and connecting rod.
(1) Insert the piston pin and fix the piston pin clip.
(2) The piston front mark and the connecting rod front mark must face the timing belt side of the engine.

2. Install the piston rings.
(1) Install the oil ring expander and two side rails by hand.

(2) Using a piston ring expander, install the two compression rings with the code mark facing upward.
(3) Position the piston rings so that the ring ends are as shown.

3. Install the connecting rod bearings.
(1) Align the bearing (A) claw with the groove of the connecting rod and bearing cap (B).
(2) Install the bearings (A) in the connecting rod and bearing cap (B).

4. Install the crankshaft main bearings.

Upper bearings have oil grooves of the oil holes; Lower bearings do not.
(1) Aligning the bearing protrusions with the grooves of the cylinder block, push in the 5 upper bearings (A).

(2) Aligning the bearing protrusions with the grooves of the main bearing cap, and push in the 5 lower bearings.
5. Install the thrust bearings.
Install the 2 thrust bearings(A) under the No.3 journal position of the cylinder block with the oil grooves facing
outward.

6. Place the crankshaft on the cylinder block.
7. Place the main bearing caps on the cylinder block.
8. Install the main bearing cap bolts.

a. The main bearing cap bolts are tightened in 2 progressive steps.
b. If any of the bearing cap bolts is broken or deformed, replace it.
(1) Apply a light coat of engine oil on the threads of the main bearing cap bolts.
(2) Install and uniformly tighten the 10 bearing cap bolts (A), in several passes, in the sequence shown.
Tightening torque :
69.6 ~ 79.4Nm (7.1 ~ 8.1kgf.m, 51.4 ~ 58.6lb-ft) + 55° ~ 65°

(3) Check that the crankshaft turns smoothly.
9. Check the crankshaft end play.
10. Install the piston and connecting rod assemblies.

a. Before installing the piston, apply a coat of engine oil to the piston ring grooves and the cylinder bores.
b. When installing the piston pin to the piston, apply engine oil sufficiently
(1) Remove the connecting rod bearing caps and insert short sections of rubber hose over the threaded ends of
the connecting rod bolts.
(2) Install the ring compressor, checking that the rings are securely in place and positioning the piston in the
cylinder, tap it in using the wooden handle of a hammer.
(3) Stop inserting after the ring inserted in the cylinder, and check the connecting rod to crank journal alignment
before complete inserting.
(4) Apply engine oil to the bolt threads after removing rubber hose. Install the connecting rod caps with bearings,
and tighten the nuts.

and tighten the nuts.
Tightening torque :
68.9Nm (7.0kgf.m, 50.6lb-ft) → Loosened →29.4Nm (3.0kgf.m, 21.7lb-ft) + 90°

Maintain downward force on the ring compressor to prevent the rings from expending before entering the
cylinder bore.

11. Install a new gasket and rear oil seal case(A) with 5 bolts(B).
Tightening torque :
7.8 ~ 10.8Nm (0.8 ~ 1.1kgf.m, 5.8 ~ 8.0lb-ft)

Check that the mating surfaces are clean and dry.
12. Install the rear oil seal.
(1) Apply engine oil to a new oil seal lip.
(2) Tap in the rear oil seal until its surface is flush with the rear oil seal retainer edge.
13. Install the balance shaft to the ladder frame.
(1) Install the thrust plate and balance shaft to the ladder frame.
(2) Aligning the timing marks on the balance gear(A), install the balance sprocket.

(3) Tighten the balance sprocket bolt and balance gear bolt(C).
Tightening torque :
Rear balance gear bolt(C)37.3 ~ 52.0Nm (3.8 ~ 5.3kgf.m, 27.5 ~ 38.3lb-ft)
Front balance gear bolt63.7 ~ 73.5Nm (6.5 ~ 7.5kgf.m, 47.0 ~ 54.2lb-ft)

Not to make the balance shaft be rotated, insert the 5mm-thickeness urethane rubber (B) in the balance
gear (A) for protection.

(4) Install the gear cover (A) to the ladder frame and tighten the bolts (B).
Tightening torque :
18.6 ~ 25.5Nm (1.9 ~ 2.6kgf.m, 13.7 ~ 18.8lb-ft)

14. Install the oil screen with a new gasket to the oil pump.

Tightening torque :
15.7 ~ 22.6Nm (1.6 ~ 2.3kgf.m, 11.6 ~ 16.6lb-ft)
15. Install the ladder frame(A) and pump assembly(B) and tighten the bolts(C,D,E).
Tightening torque :
Bolts (C): 31.4 ~ 46.1Nm (3.2 ~ 4.7kgf.m, 23.1 ~ 34.0lb-ft)
Bolts (D): 15.7 ~ 22.6Nm (1.6 ~ 2.3kgf.m, 11.6 ~ 16.6lb-ft)
Bolts (E): 31.4 ~ 46.1Nm (3.2 ~ 4.7kgf.m, 23.1 ~ 34.0lb-ft)

Check that the timing marks on the crankshaft sprocket(A), idler(B) and balance sprocket(C) are aligned.
16. Install the oil pump supplying pipe(A) and ladder frame bracket(B) and tighten the bolts(C,D) as shown below.
Tightening torque :
15.7 ~ 22.6Nm (1.6 ~ 2.3kgf.m, 11.6 ~ 16.6lb-ft)

17. Install the timing belt case.
Length of the bolts :
(A): 25mm, (B): 45mm, (C):50mm, (D): nut
Tightening torque :
15.7 ~ 22.6Nm (1.6 ~ 2.3kgf.m, 11.6 ~ 16.6lb-ft)

18. Install the oil pan.
(1) Remove the gasket from the surface of the oil pan by using a knife or a scraper.

After checking that the contact surface is clean and dry, apply liquid gasket.
(2) Apply liquid gasket on the surface of the oil pan.
Liquid gasket: LOCTITE 5900 or equivalent.

a. Apply liquid gasket on the thread of the bolts in order to prevent oil from being leaked.
b. If the time, five minutes, passes after applying, remove the applied gasket before. Apply it again and
install it.
c. After the minimum 30 minutes passing from assembly, refill engine oil.
(3) Install the oil pan (A) and tighten the oil pan bolts uniformly in several steps.
Tightening torque :
15.7 ~ 22.6Nm (1.6 ~ 2.3kgf.m, 11.6 ~ 16.6lb-ft)

19. Install the fly wheel (manual transaxle vehicles only).
Tightening torque :
122.6 ~ 132.4Nm (12.5 ~ 13.5kgf.m, 90.4 ~ 97.6lb-ft)
20. Install the mass wheel and drive plate (automatic transaxle vehicles only).
Tightening torque :
159.8 ~ 169.7Nm (16.3 ~ 17.3kgf.m, 117.9 ~ 125.1lb-ft)

21. Install the air conditioning compressor bracket (A).
Tightening torque :
BOLT (B):
38.2 ~ 58.8Nm (3.9 ~ 6.0kgf.m, 28.2 ~ 43.4lb-ft)
BOLT (C):
18.6 ~ 27.5Nm (1.9 ~ 2.8kgf.m, 13.7 ~ 20.3lb-ft)

22. Install the generator mounting bracket (A) and the power steering pump bracket (B).
Tightening torque :
BOLT (C):
38.2 ~ 58.8Nm (3.9 ~ 6.0kgf.m, 28.2 ~ 43.4lb-ft)
BOLT (D):
34.3 ~ 53.9Nm (3.5 ~ 5.5kgf.m, 25.3 ~ 39.8lb-ft)
BOLT (E):
68.6 ~ 93.2Nm (7.0 ~ 9.5kgf.m, 50.6 ~ 68.7lb-ft)

23. Install the drive belt auto-tensioner (A).
Tightening torque :
15.7 ~ 22.6Nm (1.6 ~ 2.3kgf.m, 11.6 ~ 16.6lb-ft)

24. Install the oil cooler assembly (A) and the knock sensor (B).
Tightening torque :
Oil cooler bolts:
15.7 ~ 22.6Nm (1.6 ~ 2.3kgf.m, 11.6 ~ 16.6lb-ft)
Knock sensor bolts:
14.7 ~ 24.5Nm (1.5 ~ 2.5kgf.m, 10.8 ~ 18.1lb-ft

25. Install the air separator (A) and hose (B).
Tightening torque :
15.7 ~ 22.6Nm (1.6 ~ 2.3kgf.m, 11.6 ~ 16.6lb-ft)

26. Install the water pump, cylinder head and timing belt in order.
27. Remove the engine stand.

Cooling system

2007 > J2.9L DIESEL CRDI(VGT) >

ENGINE COOLANT REFILLING AND BLEEDING

When pouring engine coolant, be sure to shut the relay box lid and not to let coolant spill on the electrical parts of
the paint. If any coolant spills, rinse it off immediately.
1. Slide the heater temperature control lever to maximum heat. Make sure the engine and radiator are cool to the
touch.
2. Remove the radiator cap(A).

3. Loosen the drain plug(A), and drain the coolant.

4. Tighten the radiator drain plug securely.
5. Remove the coolant reservoir tank. Drain the coolant and reinstall the coolant reservoir tank. Fill the coolant
reservoir tank to the MAX mark with the coolant.
6. Mix the recommended antifreeze with an equal amount of water in a clean container.

a. Use only genuine antifreeze/coolant.
b. For best corrosion protection, the coolant concentration must be maintained year-round at 50% minimum.
Coolant concentrations less than 50% may not provide sufficient protection against corrosion of freezing.
c. Coolant concentrations greater then 60% will impair cooling efficiency and are not recommended.

a. Do not mix different brands of antifreeze/coolants.
b. Do not use additional rust inhibitors or antirust products; they may not be compatible with the coolant.
7. Pour the coolant into the radiator to the base of the filler neck, and install the radiator cap loosely.

8. Start the engine and let it run until it warms up. ( until the radiator fan operates 3 or 4 times.)
9. Turn off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed
from the cooling system.
10. Put the radiator cap on tightly, then run the engine again and check for leaks.

RADIATOR CAP TESTING
1. Remove the radiator cap, wet its seal with engine coolant, then install it no pressure tester.

2. Apply a pressure of 93.16 ~ 122.58kpa (0.95 ~ 1.25kg/cm², 13.51 ~ 17.78psi).
3. Check for a drop in pressure.
4. If the pressure drops, replace the cap.

RADIATOR LEAKGE TEST
1. Wait until engine is cool, then carefully remove the radiator cap and fill the radiator with engine coolant, then install
it on the pressure tester.
2. Apply a pressure tester to the radiator and apply a pressure of 93.16 ~ 122.58kpa (0.95 ~ 1.25kg/cm², 13.51 ~
17.78psi).

3. Inspect for engine coolant leaks and a drop in pressure.
4. Remove the tester and reinstall the radiator cap.

Check for engine oil in the coolant and/or coolant in the engine oil.

2007 > J2.9L DIESEL CRDI(VGT) >

COMPONENTS

2007 > J2.9L DIESEL CRDI(VGT) >

REMOVAL
WATER PUMP
1. Drain the engine coolant.

System is under high pressure when the engine is hot. To avoid danger of releasing scalding engine coolant,
remove the cap only when the engine is cool.
2. Remove the drive belts.
3. Remove the timing belt.
4. Remove the water pump.

THRMOSTAT

Disassembly of the thermostat would have an adverse effect, causing a lowering of cooling efficiency.
1. Drain the engine coolant so its level is below thermostat.
2. Remove the thermostat housing, gasket and thermostat.

RADIATOR
1. Drain the engine coolant.
2. Remove the radiator upper cover(A).

3. Remove the radiator upper hose(A).

4. Remove the radiator lower hose(A).

5. Remove the intercooler hose(A,C), pipe(B).

6. Remove the transaxle oil cooler hose(A).

7. Remove the cooling fan motor connector(A) diagnosis connector(B).

8. Remove the cooling fan motor assembly(A).

9. Remove the radiator upper bracket(A).

10. Remove the radiator bracket(A,B).

11. Remove the intercooler.
12. Remove the radiator.

INSTALLATION

WATER PUMP
1. Install the water pump.
(1) Install the water pump and a new gasket with the bolts, nuts(A,B,C).
Tightening torque :
15.7~22.6Nm (1.6 ~ 2.3kg-m, 11.6~16.6lb-ft)

2. Install the timing belt.
3. Install the water pump pulley, cooling fan.
4. Install the drive belt.
5. Fill with engine coolant.
6. Start engine and check for leaks.
7. Recheck engine coolant level.

THERMOSTAT
1. Install the thermostat housing, thermostat.
2. Install the thermostat bolts.
Tightening torque :
15.7~22.6Nm (1.6 ~ 2.3kgf.m, 11.6~16.6lb-ft)
3. Fill with engine coolant.
4. Start engine and check for leaks.

RADIATOR
1. Install the radiator. Installation is in the reverse order of removal.
2. Install the air conditioner condenser. (Refer to HA- air conditioner condenser).
3. Install the upper and lower radiator hoses.
4. Refill with engine coolant.
5. Start engine and check for leaks.

INSPECTION
WATER PUMP
1. Check each part for cracks, damage or wear, and replace the coolant pump assembly if necessary.
2. Check the bearing for damage, abnormal noise and sluggish rotation, and replace the coolant pump assembly if
necessary.

3. Check for coolant leakage. If coolant leaks from hole, the seal is defective. Replace the coolant pump assembly.

A small amount of «engine coolant» from the bleed hole can be weeped.

THERMOSTAT
1. Immerse the thermostat in water and gradually heat the water.

2. Check the valve opening temperature.
Valve opening temperature : 86.5~89.5°C (187.7~193.1°F)
Full opening temperature : 100°C (212°F)
If the valve opening temperature is not as specified, replace the thermostat.
3. Check the valve lift.
Valve lift : 8.5mm(0.3346in) or more at 100°C (212°F)
If the valve lift is not as specified, replace the thermostat.

Lubrication system

2007 > J2.9L DIESEL CRDI(VGT) >

COMPONENTS

2007 > J2.9L DIESEL CRDI(VGT) >

DISASSEMBLY
RELIEF PLUNGER
1. Remove the relief plunger.
Remove the plug(A), spring and relief plunger.

INSPECTION
RELIEF PLUNGER
1. Inspect the relief plunger.
Coat the plunger with engine oil and check that it falls smoothly into the plunger hole by its own weight.
If it does not, replace the relief plunger. If necessary, replace the front case.
2. Inspect the relief valve spring.
Inspect for distorted or broken relief valve spring.
Standard value
Free height : 46.3mm (1.8228in)
Load : 6.13±5% kgf/38.05mm (13.5±1.1% lb/1.4980in)

ENGINE OIL
1. Check the engine oil quality.
Check the oil deterioration, entry of water, discoloring of thinning.
If the quality is visibly poor, replace the oil.
2. Check the engine oil level.
After warning up the engine and then 5 minutes after the engine stop, oil level should be between the “L” and “F”
marks in the dipstick.
If low, check for leakage and add oil up to the “F” mark.

Do not fill with engine oil above the “F” mark.

SELECTION OF ENGINE OIL
Recommended API classification : CH- 4 OR ABOVE(5W-30)
Recommended SAE viscosity grades :

For best performance and maximum protection of all types of operation, select only those lubricants which :
a. Satisfy the requirement of the API classification.
b. Have proper SAE grade number for expected ambient temperature range.
Lubricants that do not have both an SAE grade number and API service classification on the container should not
be used.

REASSEMBLY
RELIEF PLUNGER
1. Install the relief plunger.
Install relief plunger and spring into the front case hole, and install the plug(A).
Tightening torque :
32.4~42.2Nm (3.3~4.3kgf.m, 23.9~31.1lb-ft)

REMOVAL
OIL PAN
1. Drain the engine oil.
2. Remove the RH tires.
3. Remove the RH stabilizer bar link(A).

4. Remove the front roll stopper insulator mounting bolt(A).

5. Remove the rear roll stopper insulator mounting bolt(B).

6. Remove the RH sub frame mounting bolts.
7. Tilt the sub frame(A) sideways by loosening the RH sub frame mounting bolts only.

8. Remove the plate(A) between the engine and the transaxle.

9. Using the SST(09215-3C000), remove the oil pan(A).

OIL PUMP
1. Drain the engine oil.
2. Turn the crankshaft pulley, and align its groove with timing mark “T” of the timing belt cover.
3. Remove the oil pan.
4. Remove the oil supply pipe(A), ladde frame bracket(B).

5. Remove the ladde frame(A), oil pump assembly(B).

REPLACEMENT
OIL AND FILTER

a. Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading
to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants
which may cause skin cancer.
b. Exercise caution in order to minimize the length and frequency of contact of your skin to used oil. Wear
protective clothing and gloves. Wash your skin thoroughly with soap and water, or use water-less hand
cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents.
c. In order to preserve the environment, used oil and used oil filter must be disposed of only at designated
disposal sites.
1. Drain the engine oil.
(1) Remove the oil filler cap.
(2) Remove the oil drain plug, and drain the oil into a container.

2. Replace the oil filter.
(1) Remove the oil filter.
(2) Check and clean the oil filter installation surface.
(3) Check the part number of the new oil filter is as same as old one.
(4) Apply clean engine oil to the gasket of a new oil filter.
(5) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.
(6) Tighten it an additional 3/4 turn.
Tightening torque :
21.6~24.5Nm (2.2~2.5kgf.m, 15.9~18.1lb-ft)
3. Refill with engine oil.
(1) Clean and install the oil drain plug with a new gasket.
Tightening torque :
34.3~44.1Nm (3.5~4.5kgf.m, 25.3~32.5lb-ft)
(2) Fill with fresh engine oil.
Oil Capacity
Total : 8.0 L (8.45 US qt, 7.03 lmp qt)
Oil pan : 6.0 L (6.34 US qt, 5.27 lmp qt)
Drain and refill including oil filter : 6.6 L (6.97 US qt, 5.08 lmp qt)
Oil quality : ABOVE API CH-4 or ABOVE ACEA B4
(3) Install the oil filler cap.
4. Start engine and check for oil leaks.
5. Recheck the engine oil level.

INSTALLATION
OIL PUMP
1. Install the oil screen and new gasket.
Tightening torque :
15.7~22.6Nm (1.6~2.3kgf.m, 11.6~16.6lb-ft)
2. Install the ladde frame(A), oil pump assembly(B) with the bolts(C,D,E).
Tightening torque :
Bolts(C): 31.4~46.1Nm (3.2~4.7kgf.m, 23.1~34.0lb-ft)
Bolts(D): 15.7~22.6Nm (1.6~2.3kgf.m, 11.6~16.6lb-ft)

Bolts(E): 31.4~46.1Nm (3.2~4.7kgf.m, 23.1~34.0lb-ft)

Align the timing marks on the crankshaft sprocket(A), idler(B) and balancer sprocket(C).

3. Install the oil supply pipe(A), ladde frame bracket(B) with the bolts(C,D).
Tightening torque:
15.7~22.6Nm (1.6~2.3kgf.m, 11.6~16.6lb-ft)

4. Install the oil pan.
5. Fill with engine oil.

OIL PAN
1. Install the oil pan.
(1) Using a razor blade and gasket scraper, remove all the old packing material from the gasket surfaces.

Check that the mating surfaces are clean and dry before applying liquid gasket.

(2) Apply liquid gasket as an even bead, centered between the edges of the mating surface.
Liquid gasket: LOCTITE 5900 or equivalent

a. To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes.
b. Do not install the parts if five minutes or more have elapsed since applying the liquid gasket.
Instead, reapply liquid gasket after removing the residue.
c. After assembly, wait at least 30 minutes before filling the engine with oil.
(3) Install the oil pan(A) with the bolts.
Uniformly tighten the bolts in several passes.
Tightening torque :
15.7~22.6Nm (1.6~2.3kgf.m, 11.6~16.6lb-ft)

2. Install the plate(A) between the engine and the transaxle assembly.
Tightening torque :
15.7~22.6Nm (1.6~2.3kgf.m, 11.6~16.6lb-ft)

3. Install the RH, LH sub frame mounting bolts(A,B).
Tightening torque :
156.9~176.5Nm (16.0~18.0kgf.m, 115.7~130.2lb-ft)
44.1~58.8Nm (4.5~6.0kgf.m, 32.5~43.4lb-ft)

4. Install the front roll stopper insulator mounting bolt(A).
Tightening torque :
88.3~107.9Nm (9.0~11.0kgf.m, 65.1~79.6lb-ft)

5. Install the rear roll stopper insulator mounting bolt(A).
Tightening torque :
88.3~107.9Nm (9.0~11.0kgf.m, 65.1~79.6lb-ft)

6. Install the RH stabilizer bar link(A).
Tightening torque:
98.1~117.7Nm (10.0~12.0kgf.m, 72.3~86.8lb-ft)

7. Remove the RH tires.
Tightening torque :
88.3~107.9Nm (9.0~11.0kgf.m, 65.1~79.6lb-ft)
8. Fill with engine oil

INSPECTION
RELIEF PLUNGER
1. Inspect the relief plunger.
Coat the plunger with engine oil and check that it falls smoothly into the plunger hole by its own weight.
If it does not, replace the relief plunger. If necessary, replace the front case.
2. Inspect the relief valve spring.
Inspect for distorted or broken relief valve spring.
Standard value
Free height : 46.3mm (1.8228in)
Load : 6.13±5% kgf/38.05mm (13.5±1.1% lb/1.4980in)

ENGINE OIL
1. Check the engine oil quality.
Check the oil deterioration, entry of water, discoloring of thinning.
If the quality is visibly poor, replace the oil.
2. Check the engine oil level.
After warning up the engine and then 5 minutes after the engine stop, oil level should be between the “L” and “F”
marks in the dipstick.

If low, check for leakage and add oil up to the “F” mark.

Do not fill with engine oil above the “F” mark.

SELECTION OF ENGINE OIL
Recommended API classification : CH- 4 OR ABOVE(5W-30)
Recommended SAE viscosity grades :

For best performance and maximum protection of all types of operation, select only those lubricants which :
a. Satisfy the requirement of the API classification.
b. Have proper SAE grade number for expected ambient temperature range.
Lubricants that do not have both an SAE grade number and API service classification on the container should not
be used.

Intake
and
Exhaust system

Intercooler

2007 > J2.9L DIESEL CRDI(VGT) >

COMPONENTS

Intake Manifold

2007 > J2.9L DIESEL CRDI(VGT) >

COMPONENTS

2007 > J2.9L DIESEL CRDI(VGT) >

REMOVAL
INTAKE MANIFOLD
1. Remove the air intake hose, air cleaner assembly.
2. Remove the intercooler hoses(A).

3. Remove the ground cable(A) from cylinder head.

4. Remove the air hester terminals(A) CMP(Crankshaft position sensor) connector(B).

5. Remove the injection high pressure. (Refer to FL group).
6. Remove the EGR pipe(B).
Tightening torque :
15.7 ~ 22.6Nm (1.6 ~ 2.3kgf.m, 11.6 ~ 16.6lb-ft)

7. Remove the EGR pipe
Tightening torque :
Bolts(D), Nut(E): 15.7 ~ 22.6Nm (1.6 ~ 2.3kgf.m, 11.6 ~ 16.6lb-ft)

8. Remove the EGR pipe(A).

9. Remove the intake manifold.
Tightening torque :
Bolts(A,B), Nut(C): 15.7 ~ 22.6Nm (1.6 ~ 2.3kgf.m, 11.6 ~ 16.6lb-ft)
Hexagonal wrench bolt (D): 17.7 ~ 26.5Nm (1.8 ~ 2.7kgf.m, 13.0 ~ 19.5lb-ft)

10. Installation is in the reverse order of removal with new gasket.

Exhaust Manifold

2007 > J2.9L DIESEL CRDI(VGT) >

COMPONENTS

2007 > J2.9L DIESEL CRDI(VGT) >

REMOVAL
EXHAUST MANIFOLD
1. Remove the air intake hose, air cleaner assembly.
2. Remove the intercooler hoses, pipe(A, B).

3. Remove the PCV(Positive Crankcase Ventilation) hose(A), EGR valve vacuum hose(B), EGR cooier water hose(C),
vacuum pump oil hose(D).

4. Remove the EGR pipe(B).
Tightening torque :
15.7 ~ 22.6Nm (1.6 ~ 2.3kgf.m, 11.6 ~ 16.6lb-ft)

5. Remove the EGR pipe
Tightening torque :
Bolts(D), Nut(E): 15.7 ~ 22.6Nm (1.6 ~ 2.3kgf.m, 11.6 ~ 16.6lb-ft)

6. Remove the EGR pipe(A).

7. Remove the turbo chargers water inlet pipe(A).
Tightening torque :
Eye bolt(B): 23.5~35.3Nm (2.4~3.6kgf.m, 17.4~26.0lb-ft)
Bolt(C): 8.8~12.7Nm (0.9~1.3kgf.m, 6.5~9.4lb-ft)

8. Remove the heat protector(A).
Tightening torque :
8.8~12.7Nm (0.9~1.3kgf.m, 6.5~9.4lb-ft)

9. Remove the EGR cooler(A).
Tightening torque :
26.5~34.3Nm (2.7~3.5kgf.m, 19.5~25.3lb-ft)

10. Remove the EGR valve(A).
Tightening torque :
21.6~26.5Nm (2.2~2.7kgf.m, 15.9~19.5lb-ft)

11. Remove the exhaust manifold insulator(A), engine hanger(B).
Tightening torque :
Bolts(C): 8.8~12.7Nm (0.9~1.3kgf.m, 6.5~9.4lb-ft)
Bolts(D): 17.7 ~ 26.5Nm (1.8 ~ 2.7kgf.m, 13.0 ~ 19.5lb-ft)

12. Remove the turbo charger oil inlet pipe(A), oil outlet hose(B).
Tightening torque :
11.8~17.7Nm (1.2~1.8kgf.m, 8.7~13.0lb-ft)

13. Remove the turbo charger water outlet pipe, hose(A).
Tightening torque :
23.5~35.3Nm (2.4~3.6kgf.m, 17.4~26.0lb-ft)

14. Remove the turbo charger stay(A).
Tightening torque :
30.4~36.3Nm (3.1~3.7kgf.m, 22.4~26.8lb-ft)

15. Remove the turbo charger assembly(A).
Tightening torque :
26.5~34.3Nm (2.7~3.5kgf.m,19.5~25.3lb-ft)

16. Remove the generator. (Refer to EE group).
17. Remove the thermostat case(A), oil level gauge tube(B).

18. Remove the exhaust manifold(A).
Tightening torque :
26.5~34.3Nm (2.7~3.5kgf.m,19.5~25.3lb-ft)

INSPECTION
TURBO CHARGER
1. Warm up the engine to the normal temperature.
2. After removing the hose between the intake manifold and the intercooler, install the pressure gauge with 3-way
connector.
3. Measure the maximum pressure data by starting the engine and raising up the rpm.
PRESSURE GAUGE
Not fixed pressure or low pressure

Pressure is above the standard.
(630~670mmHg/3,800rpm)

INSPECTION
a. Leakage from the intake or exhaust system
b. Inferior turbocharger
a. Leakage from the inferior actuator hose
b. Actuator defect

ACTUATOR
1. After removing the air hose from the actuator, install the pressure tester.
2. Install the dial gauge in a straight line with the actuator rod.
3. Using the pressure tester, when the pressure, 1,320~1,360Hg is applied, check whether the actuator rod is shifted
2.0mm.

If the pressure more than 1.7 kg/cm²(1,250mmHg) is applied, there is a danger which the actuator will be
damaged.
4. Replace an actuator when it is not working or pressure can not be applied.

Front Exhaust Pipe

2007 > J2.9L DIESEL CRDI(VGT) >

COMPONENTS

2007 > J2.9L DIESEL CRDI(VGT) >

REMOVAL
1. Remove the front muffler(A).
Tightening torque:
39.2~58.8Nm (4.0~6.0kgf.m, 28.9~43.4lb-ft)

2. Remove the catalytic converter(A).
Tightening torque :
39.2~58.8Nm (4.0~6.0kgf.m, 28.9~43.4lb-ft)

3. Remove the center muffler(A).
Tightening torque :
39.2~58.8Nm (4.0~6.0kgf.m, 28.9~43.4lb-ft)

4. Remove the main muffler(A).

Tightening torque :
39.2~58.8Nm (4.0~6.0kgf.m, 28.9~43.4lb-ft)

5. Remove the tail pipe(A).
Tightening torque :
39.2~58.8Nm (4.0~6.0kgf.m, 28.9~43.4lb-ft)

CHAPTER 3:

Engine Electrical System

General information

2007 > J2.9L DIESEL CRDI(VGT) >

TROUBLESHOOTING
CHARGING SYSTEM
Symptom

Suspect area

Remedy

Charging warning
indicator does not
light with ignition
switch «ON» and
engine off.

a.
b.
c.
d.

Charging warning
indicator does not go
out with engine
running. (Battery
requires frequent
recharging)

a. Drive belt loose or worn
b. Battery cable loose, corroded or worn
c. Inperior electronic voltage regulator or
generator
d. Bad wiring connection

a. Adjust belt tension or replace belt
b. Inspect cable connection, repair or replace
cable
c. Replace voltage regulator or generator
d. Repair or replace wiring

Overcharge

a. Electronic voltage regulator
b. Voltage sensing wire

a. Replace voltage regulator
b. Repair or replace wiring

Discharge

a.
b.
c.
d.
e.

a. Adjust belt tension or replace belt
b. Inspect wiring connection, repair or
replace wiring
c. Replace voltage regulator or generator
d. Inspect ground or repair
e. Replace battery

Fuse blown
Light burned out
Poor wiring connection
Inferior electronic voltage regulator

Drive belt loose or worn
Wiring connection loose or short circuit
Electronic voltage regulator or generator
Poor grounding
Worn battery

a.
b.
c.
d.

Check fuses
Replace a lamp
Tighten loose connection
Replace voltage regulator

STARTING SYSTEM
Symptom

Suspect area

Remedy

Engine will not crank

a. Battery charge low
b. Battery cables loose, corroded or worn out
c. Transaxle range switch (Vehicle with automatic
transaxle only)
d. Fuse blown
e. Starter motor faulty
f. Ignition switch faulty

a. Charge or replace battery
b. Repair or replace cables
c. Refer to AT group-automatic
transaxle
d. Replace fuse
e. Replace
f. Replace

Engine cranks slowly

a. Battery charge low
b. Battery cables loose, corroded or worn out
c. Starter motor faulty

a. Charge or replace battery
b. Repair or replace cables
c. Replace

Starter keeps running

a. Starter motor
b. Ignition switch

a. Replace
b. Replace

Starter spins but
engine will not crank

a. Short in wiring
b. Pinion gear teeth broken or starter motor
c. Ring gear teeth broken

a. Repair wiring or replace
b. Replace
c. Replace fly wheel or torque
converter

2007 > J2.9L DIESEL CRDI(VGT) >

SPECIFICATION
STARTING SYSTEM
Item

J3 common rail
Rated voltage

12V, 2.0KW

No. of pinion teeth

12

Starter
No-load charasteristics

Voltage

11.5V

Amperage

190A, MAX

Speed

3,000rpm, MIN

CHARGING SYSTEM
Item

J3 common rail
Type
Rated voltage

Generator

Voltage regulator tyqe
Regulator setting voltage

Battery

Battery voltage sensing
12V, 120A
I.C regulator built-in type
14.4 ± 0.3V

Temperature compensation

-10 ± 3mV/°C

Type

CMF 100 AH

Cold cranking amperage at-18°C (-0.4°F)
Reserve capacity
Specific gravity at 25°C (77°F)

900A
182min
1.280 ± 0.01

MF 80AH
660A
145min.
←

a. COLD CRANKING AMPERAGE is the amperage a battery can deliver for 30 seconds and maintain a terminal
voltage of 7.2V or greater at a specified temperature.
b. REVERSE CAPACITY RATING is amount of time a battery can deliver 25A and maintain a minimum terminal
voltage of 10.5V at 26.7°C(80°F)

Charging System

2007 > J2.9L DIESEL CRDI(VGT) >

DESCRIPTION
The charging system includes a battery, an generator with a built-in regulator, and the charging indicator light and
wire.
The generator has eight built-in diodes, each rectifying AC current to DC current.
Therefore, DC current appears at generator «B» terminal.
In addition, the charging voltage of this generator is regulated by the battery voltage detection system in the regulator.
The generator is regulated by the voltage detection system. The main components of the generator are the rotor,
stator, rectifier, capacitor, brushes, bearings and overrunning alternator pulley (OAP). The brush holer contains a builtin electronic voltage regulator.

2007 > 2.7L V6 GASOLINE >

ON-VEHICLE INPECTION

a. Check that the battery cables are connected to the correct terminals.
b. Disconnect the battery cables when the battery is given a quick charge.
c. Never disconnect the battery while the engine is running.

CHECK BATTERY VOLTAGE
1. If 20 minutes have not passed since the engine was stopped, turn the ignition switch ON and turn on the electrical
system (headlamp, blower motor, rear defogger etc.) for 60 seconds to remove the surface charge.
2. Turn the ignition switch OFF and turn off the electrical systems.
3. Measure the battery voltage between the negative (-) and positive (+) terminals of the battery.
Standard voltage : 12.5 ~ 12.9V at 20°C(68°F)
If the voltage is less than specification, charge the battery.

CHECK THE BATTERY TERMINALS AND FUSES
1. Check that the battery terminals are not loose or corroded.
2. Check the fuses for continuity.

INSPECT DRIVE BELT
Visually check the belt for excessive wear, frayed cords etc.
If any defect has been found, replace the drive belt.

Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should
be replaced.

VISUALLY CHECK ALTERNATOR WIRING AND LISTEN FOR ABNORMAL NOISES
1. Check that the wiring is in good condition.
2. Check that there is no abnormal noise from the alternator while the engine is running.

CHECK DISCHARGE WARNING LIGHT CIRCUIT
1. Warm up the engine and then turn it off.
2. Turn off all accessories.
3. Turn the ignition switch «ON». Check that the discharge warning light is lit.
4. Start the engine. Check that the light is lit.
If the light does not go off as specified, troubleshoot the discharge light circuit.

INSPECT CHARGING SYSTEM
VOLTAGE DROP TEST OF ALTERNATOR OUTPUT WIRE
This test determines whether or not the wiring between the alternator «B» terminal and the battery (+) terminal is good
by the voltage drop method.

PREPARATION

1. Turn the ignition switch to «OFF».
2. Disconnect the output wire from the alternator «B» terminal. Connect the (+) lead wire of ammeter to the «B»
terminal of alternator and the (-) lead wire of ammeter to the output wire. Connect the (+) lead wire of voltmeter to
the «B» terminal of alternator and the (-) lead wire of voltmeter to the (+) terminal of battery.

TEST
1. Start the engine.
2. Turn on the headlamps and blower motor, and set the engine speed until the ammeter indicates 20A.
And then, read the voltmeter at this time.

RESULT
1. The voltmeter may indicate the standard value.
Standard value: 0.2V max
2. If the value of the voltmeter is higher than expected (above 0.2V max.), poor wiring is suspected. In this case
check the wiring from the alternator «B» terminal to the battery (+) terminal. Check for loose connections, color
change due to an over-heated harness, etc. Correct them before testing again.
3. Upon completion of the test, set the engine speed at idle.
Turn off the headlamps, blower motor and the ignition switch.

OUTPUT CURRENT TEST
This test determines whether or not the alternator gives an output current that is equivalent to the normal output.

PREPARATION
1. Prior to the test, check the following items and correct as necessary.
Check the battery installed in the vehicle to ensure that it is good condition. The battery checking method is
described in the section «Battery».
The battery that is used to test the output current should be one that has been partially discharged. With a fully
charged battery, the test may not be conducted correctly due to an insufficient load.
Check the tension of the alternator drive belt. The belt tension check method is described in the section «Inspect
drive belt».
2. Turn off the ignition switch.
3. Disconnect the battery ground cable.
4. Disconnect the alternator output wire from the alternator «B» terminal.
5. Connect a DC ammeter (0 to 150A) in series between the «B» terminal and the disconnected output wire. Be sure
to connect the (-) lead wire of the ammeter to the disconnected output wire.

Tighten each connection securely, as a heavy current will flow. Do not rely on clips.
6. Connect a voltmeter (0 to 20V) between the «B» terminal and ground. Connect the (+) lead wire to the alternator «B»
terminal and (-) lead wire to a good ground.
7. Attach an engine tachometer and connect the battery ground cable.
8. Leave the engine hood open.

TEST
1. Check to see that the voltmeter reads as the same value as the battery voltage. If the voltmeter reads 0V, and the
open circuit in the wire between alternator «B» terminal and battery (-) terminal or poor grounding is suspected.
2. Start the engine and turn on the headlamps.
3. Set the headlamps to high beam and the heater blower switch to HIGH, quickly increase the engine speed to 2,500
rpm and read the maximum output current value indicated by the ammeter.

After the engine start up, the charging current quickly drops.
Therefore, the above operation must be done quickly to read the maximum current value correctly.

RESULT
1. The ammeter reading must be higher than the limit value. If it is lower but the alternator output wire is in good
condition, remove the alternator from the vehicle and test it.
Limit value : 70％ of the rated current

a. The nominal output current value is shown on the nameplate affixed to the alternator body.
b. The output current value changes with the electrical load and the temperature of the alternator itself.
Therefore, the nominal output current may not be obtained. If such is the case, keep the headlamps on the
cause discharge of the battery, or use the lights of another vehicle to increase the electrical load.
The nominal output current may not be obtained if the temperature of the alternator itself or ambient
temperature is too high.
In such a case, reduce the temperature before testing again.
2. Upon completion of the output current test, lower the engine speed to idle and turn off the ignition switch.
3. Disconnect the battery ground cable.
4. Remove the ammeter and voltmeter and the engine tachometer.
5. Connect the alternator output wire to the alternator «B» terminal.
6. Connect the battery ground cable.

REGULATED VOLTAGE TEST
The purpose of this test is to check that the electronic voltage regulator controls voltage correctly.

PREPARATION
1. Prior to the test, check the following items and correct if necessary.
Check that the battery installed on the vehicle is fully charged. The battery checking method is described in the
section «Battery».
Check the alternator drive belt tension. The belt tension check method is described in the section «Inspect drive
belt».
2. Turn ignition switch to «OFF».
3. Disconnect the battery ground cable.
4. Connect a digital voltmeter between the «B» terminal of the alternator and ground. Connect the (+) lead of the
voltmeter to the «B» terminal of the alternator. Connect the (-) lead to good ground or the battery (-) terminal.
5. Disconnect the alternator output wire from the alternator «B» terminal.

6. Connect a DC ammeter (0 to 150A) in series between the «B» terminal and the disconnected output wire.
Connect the (-) lead wire of the ammeter to the disconnected output wire.
7. Attach the engine tachometer and connect the battery ground cable.

TEST
1. Turn on the ignition switch and check to see that the voltmeter indicates the following value.
Voltage: Battery voltage
If it reads 0V, there is an open circuit in the wire between the alternator «B» terminal and the battery and the battery
(-) terminal.
2. Start the engine. Keep all lights and accessories off.
3. Run the engine at a speed of about 2,500 rpm and read the voltmeter when the alternator output current drops to
10A or less

RESULT
1. If the voltmeter reading agrees with the value listed in the regulating voltage table below, the voltage regulator is
functioning correctly. If the reading is other than the standard value, the voltage regulator or the alternator is faulty.
REGULATING VOLTAGE TABLE
Voltage regulator ambient temperature °C (°F)
-20 (-4)
20 (68)
60 (140)
80 (176)

Regulating voltage (V)
14.2
14.0
13.7
13.5

~
~
~
~

15.4
15.0
14.9
14.7

2. Upon completion of the test, reduce the engine speed to idle, and turn off the ignition switch.
3. Disconnect the battery ground cable.
4. Remove the voltmeter and ammeter and the engine tachometer.
5. Connect the alternator output wire to the alternator «B» terminal.
6. Connect the battery ground cable.

Alternator

2007 > J2.9L DIESEL CRDI(VGT) >

COMPONENT

2007 > J2.9L DIESEL CRDI(VGT) >

REPLACEMENT
1. Disconnect the battery negative terminal frist, then the positive terminal.
2. Disconnect the alternator connector(A) and «B» terminal cable(B).

3. Remove the oil pipe(B), oil hose(C) from the vacuum pump(A).

4. Remove the drive belt.

5. Remove the movnting bolts(B.C) and net(D) then remove the alternator(A).

6. Installation is the reverse of removal.

Battery

2007 > 2.7L V6 GASOLINE >

DESCRIPTION
1. The maintenance-free battery is, as the name implies, totally maintenance free and has no removable battery cell
caps.
2. Water never needs to be added to the maintenance-free battery.
3. The battery is completely sealed, except for small vent holes in the cover.

2007 > 2.7L V6 GASOLINE >

INSPECTION
BATTERY DIAGNOSTIC TEST (1)

CHECKING FLOW

LOAD TEST
1. Perform the following steps to complete the load test procedure for maintenance free batteries.
2. Connect the load tester clamps to the terminals and proceed with the test as follow:

(1) If the battery has been on charge, remove the surface charge by connect a 300ampere load for 15 seconds.
(2) Connect the voltmeter and apply the specified load.
(3) Read the voltage after the load has been applied for 15 seconds.
(4) Disconnect the load.
(5) Compare the voltage reading with the minimum and replace the battery if battery test voltage is below that
shown in the voltage table.
Voltage

Temperature

9.6V

20°C (68.0°F) and above

9.5V

16°C (60.8°F)

9.4V

10°C (50.0°F)

9.3V

4°C (39.2°F)

9.1V

-1°C (30.2°F)

8.9V

-7°C (19.4°F)

8.7V

-12°C (10.4°F)

8.5V

-18°C (-0.4°F)

a. If the voltage is greater shown in the table, the battery is good.
b. If the voltage is less than shown in the table, replace the battery.

BATTERY DIAGNOSTIC TEST (2)
1. Make sure the ignition switch and all accessories are in the OFF position.
2. Disconnect the battery cables (negative first).
3. Remove the battery from the vehicle.

Care should be taken in the event the battery case is cracked or leaking, to protect your skin from the
electrolyte.
Heavy rubber gloves (not the household type) should be wore when removing the battery.

4. Inspect the battery tray for damage caused by the loss of electrolyte. If acid damage is present, it will be necessary
to clean the area with a solution of clean warm water and baking soda. Scrub the area with a stiff brush and wipe
off with a cloth moistened with baking soda and water.
5. Clean the top of the battery with the same solution as described above.
6. Inspect the battery case and cover for cracks. If cracks are present, the battery must be replaced.
7. Clean the battery posts with a suitable battery post tool.

8. Clean the inside surface of the terminal clamps with a suitable battery cleaning tool. Replace damaged or frayed
cables and broken terminal clamps.
9. Install the battery in the vehicle.
10. Connect the cable terminals to the battery post, making sure tops of the terminals are flush with the tops of the
posts.
11. Tighten the terminal nuts securely.
12. Coat all connections with light mineral grease after tightening.

When batteries are being charged, an explosive gas forms beneath the cover of each cell. Do not smoke
near batteries being charged or which have recently been charged. Do not break live circuit at the terminals
of batteries being charged.
A spark will occur when the circuit is broken. Keep open flames away form battery.

Starting System

2007 > 2.7L V6 GASOLINE >

DESCRIPTION
The starting system includes the battery, starter, solenoid switch, ignition switch, inhibitor switch (A/T), ignition lock
switch, connection wires and the battery cable.
When the ignition key is turned to the start position, current flows and energizes the starter motor’s solenoid coil.
The solenoid plunger and clutch shift lever are activated, and the clutch pinion engages the ring gear.
The contacts close and the starter motor cranks. In order to prevent damage caused by excessive rotation of the
starter armature when the engine starts, the clutch pinion gear overruns.

2007 > J2.9L DIESEL CRDI(VGT) >

TROUBLESHOOTING
STARTER CIRCUIT

The battery must be in good condition and fully charged.
1. With the shift lever in N or P (A/T) or clutch pedal pressed (M/T), turn the ignition switch to «START»
If the starter normally cranks the engine, starting system is OK. If the starter will not crank the engine at all, go to
next step.
If it won’t disengage from the ring gear when you release key, check for the following until you find the cause.
a. Solenoid plunger and switch malfunction.
b. Dirty pinion gear or damaged overrunning clutch.
2. Check the battery condition. Check electrical connections at the battery, battery negative cable connected to the
body, engine ground cables, and the starter for looseness and corrosion. Then try starting the engine again.
If the starter cranks normally the engine, repairing the loose connection repaired the problem. The starting system
is now OK.
If the starter still does not crank the engine, go to next step.
3. Disconnect the connector from the S-terminal of solenoid. Connect a jumper wire from the B-terminal of solenoid to
the S-terminal of solenoid.
If the starter cranks the engine, go to next step.
If the starter still does not crank the engine, remove the starter, and repair or replace as necessary.
4. Check the following items in the order listed until you find the open circuit.
a. Check the wire and connectors between the driver’s under-dash fuse/relay box and the ignition switch, and
between the driver’s under-dash fuse/relay box and the starter.
b. Check the ignition switch (Refer to BE group — ignition system)
c. Check the transaxle range switch connector or ignition lock switch connector.
d. Inspect the starter relay.

STATER SOLENOID TEST
1. Disconnect the field coil wire from the M-terminal of solenoid switch.
2. Connect a 12V battery between S-terminal and the starter body.

3. Connect the field coil wire to the M-terminal.

This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning.
4. If the pinion moves out, the pull-in coil of solenoid is working properly.
If the pinion does not move, replace the solenoid.

5. Diconnect the field coil wire from the M-terminal.
6. If the pinion has moved out, the hold-in coil of the solenoid is working properly.
If the pinion moves in, replace the solenoid.

FREE RUNNING TEST
1. Place the starter motor in a vise equipped with soft jaws and connect a fully-charged 12-volt battery to starter
motor as follows.
2. Connect a test ammeter (100-ampere scale) and carbon pile rheostats shown is the illustration.
3. Connect a voltmeter (15-volt scale) across starter motor.

4. Rotate carbon pile to the off position.
5. Connect the battery cable from battery’s negative post to the starter motor body.
6. Adjust until battery voltage shown on the voltmeter reads 11volts.
7. Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and
freely.
Current : Max.190 Amps
Speed : Min. 3,000 Rpm

Starter

2007 > J2.9L DIESEL CRDI(VGT) >

COMPONENT

2007 > J2.9L DIESEL CRDI(VGT) >

REPLACEMENT
1. Disconnect the battery negative cable.
2. Remove the starter motor cable(A).

3. Remove the 2 bolts holding the starter, then remove the starter.
4. Installation is the reverse of removal.
5. Connect the battery positive cable and negative cable to the battery.

Preheating System

2007 > J2.9L DIESEL CRDI(VGT) >

INSPECT
Conditions before inspection :
Battery voltage : 12V
Cooling water temperature : Below 30°C (86°F)
(Disconnect the water temperature sensor connector).

Reconnect the water temperature sensor connector after inspection.
1. Connect voltmeter between glow plug plate and plug body (ground).
2. Check indicated value on voltmeter with ignition switch ON.
3. Check that preheat indication lamp lights for about 6 seconds and indicates battery voltage (about 9V or over) for
about 36 seconds immediately after ignition switch is turned on. [At cooling water temperature 20°C (68.0°F)]

Continuity time varies depending upon cooling water temperature.
4. After checking 3, set ignition switch at START position.
5. The system is normal if battery voltage (about 9V or over) is generated for about 6 seconds during engine cranking
and after start operation. [at cooling water temperature 20°C (68.0°F)]
6. When the voltage or continuity time is not normal, check the terminal voltage in glow control unit, and single parts.

GLOW PLUG RELAY
1. Remove the glow plug relay.
2. Inspect the relay continuity.
a. Using an ohmmeter, check that there is continuity between terminals 86 and 85.
If there is no continuity, replace the relay.
b. Check that there is no continuity between terminals 87 and 30.
If there is continuity, replace the relay.

3. Inspect the relay operation.
a. Apply battery positive voltage across terminals 85 and 85.
b. Using an ohmmeter, check that there is continuity between terminals 87 and 30.
If there is no continuity, replace the relay.

4. Install the glow plug relay.

CHAPTER 3:

Engine Electrical System

General information

2007 > 3.8L V6 GASOLINE >

TROUBLE SHOOTING
IGNITION SYSTEM
Symptom

Suspect area

Remedy

Engine will not start or Ignition lock switch
is hard to start
Ignition coil
(Cranks OK)
Spark plugs
Ignition wiring disconnected or broken

Inspect ignition lock switch, or replace as required
Inspect ignition coil, or replace as required
Inspect spark plugs, or replace as required
Repair wiring, or replace as required

Rough idle or stalls

Ignition wiring
Ignition coil

Repair wiring, or replace as required
Inspect ignition coil, or replace as required

Engine hesitates/poor
acceleration

Spark plugs and spark plug cables
Ignition wiring

Inspect spark plugs / cable, or replace as required
Repair wiring, or replace as required

Poor mileage

Spark plugs and spark plug cables

Inspect spark plugs / cable, or replace as required

CHARGING SYSTEM
Symptom

Suspect area

Remedy

Charging warning
indicator does not
light with ignition
switch «ON» and
engine off.

Fuse blown
Light burned out
Wiring connection loose
Electronic voltage regulator

Charging warning
indicator does not go
out with engine
running. (Battery
requires frequent
recharging)

Drive belt loose or worn
Battery cable loose, corroded or worn
Electronic voltage regulator or alternator
Wiring

Overcharge

Electronic voltage regulator
Voltage sensing wire

Replace voltage regulator
Repair or replace wiring

Discharge

Drive belt loose or worn
Wiring connection loose or short circuit
Electronic voltage regulator or alternator
Poor grounding
Worn battery

Adjust belt tension or replace belt
Inspect wiring connection, repair or replace
wiring
Replace voltage regulator or alternator
Inspect ground or repair
Replace battery

Check fuses
Replace light
Tighten loose connection
Replace voltage regulator
Adjust belt tension or replace belt
Inspect cable connection, repair or replace
cable
Replace voltage regulator or alternator
Repair or replace wiring

STARTING SYSTEM
Symptom

Suspect area

Remedy

Engine will not crank

Battery charge low
Battery cables loose, corroded or worn out
Transaxle range switch (Vehicle with automatic
transaxle only)
Fuse blown
Starter motor faulty
Ignition switch faulty

Charge or replace battery
Repair or replace cables
Refer to TR group-automatic transaxle
Replace fuse
Replace
Replace

Engine cranks slowly

Battery charge low
Battery cables loose, corroded or worn out
Starter motor faulty

Charge or replace battery
Repair or replace cables
Replace

Starter keeps running

Starter motor
Ignition switch

Replace
Replace

Starter spins but
engine will not crank

Ignition switch

Replace

Short in wiring
Pinion gear teeth broken or starter motor
Ring gear teeth broken

Repair wiring
Replace
Replace fly wheel or torque converter

2007 > 3.8L V6 GASOLINE >

SPECIFICATION
IGNITION SYSTEM
Items
Ignition coil

Spark plugs

Specification( 3.8L)

Primary resistance

0.62 ± 10 % (Ω)

Secondary resistance

7.0 ± 15 % (kΩ)

Unleaded

NGK

IFR5G-11

Gap

1.0 ~ 1.1 mm (0.0394 ~ 0.0433 in.)

STARTING SYSTEM
Specification

Items

3.8L
Rated voltage

12 V, 1.4 kW

No. of pinion teeth

8

Starter
No-load
characteristics

Voltage

11.5 V

Ampere

85A, MAX

Speed

2,600 rpm, MIN

CHARGING SYSTEM
Specification

Items
Type

Battery voltage sensing

Rate voltagea

13.5V, 130A

Speed in use

1,000 ~ 18,000 rpm

Voltage regulator

IC regulator built-in type

Regulator setting voltage

14.2 ~ 14.8V

Temperature compensation

-4 ± 4 mV / °C

Type

MF 68AH(3.3L) / MF 80AH(3.8L)

Cold cranking amperage [at -18°C(-0.4°F)]

600 A(3.3L) / 630 A(3.8L)

Reserve capacity

110 min(3.3L) / 130 min(3.8L)

Specific gravity [at 20°C(68°F)]

1.280 ± 0.01

Alternator

Battery

/ 3.8L

a. COLD CRANKING AMPERAGE is the amperage a battery can deliver for 30 seconds and maintain a terminal
voltage of 7.2V or greater at a specified temperature.
b. RESERVE CAPACITY RATING is amount of time a battery can deliver 25A and maintain a minimum terminal
voltage of 10.5V at 26.7°C(80.1°F).
AUTO CRUISE CONTROL SYSTEM
Items

Specification

Setting error

Within ± 1.5Km/h on level road

Vehicle speed memory variation

No variation

Setting time

0.1sec max

Resuming time

0.1sec max.

Minimum operating speed

40 ± 2Km/h

Cancel speed range

15 ± 2Km/h

Maximum memorized speed

160 ± 2Km/h

Pulling force

127N(13Kgf)

Main switch serial resistance value

3.9kΩ ± 1%

Command switch serial resistance value

SET switch : 220Ω ± 1%
RESUME switch : 910Ω ± 1%

Ignition System

2007 > 2.7L V6 GASOLINE >

DESCRITION
Ignition timing is controlled by the electronic control ignition timing system. The standard reference ignition timing data
for the engine operating conditions are preprogrammed in the memory of the ECM (Engine Control Module).
The engine operating conditions (speed, load, warm-up condition, etc.) are detected by the various sensors. Based on
these sensor signals and the ignition timing data, signals to interrupt the primary current are sent to the ECM. The
ignition coil is activated, and timing is controlled.

2007 > 3.8L V6 GASOLINE >

REMOVAL
IGNITION COIL
1. Remove the engine cover.
2. Disconnect the ignition coil connector(A).

When removing the ignition coil connector, pull the lock pin(A) and push the clip(B).

3. Remove the ignition coil (B).
4. Installation is the reverse of removal.

ON-VEHICLE INSPECTION
SPARK TEST
1. Remove the ignition coil connector(A).

When removing the ignition coil connector, pull the lock pin (A) and push the clip(B).

2. Remove bolt holding down the ignition coil.
3. Remove ignition coil from engine.
4. Using a spark plug socket, remove the spark plug.
5. Attach the spark plug to the ignition coil.
6. Reconnect ignition coil harness connector to ignition coil.
7. Ground the spark plug to the engine.

8. Check if spark occurs while engine is being cranked.

To prevent fuel being injected from injectors while the engine is being cranked, remove the fuel pump relay(A)
from the fuse box.
Crank the engine for no more than 5 ~ 10 seconds.

9. Continue to inspect other cylinders of suspected ‘no spark’ concerns.
10. Install in the reverse order of testing and removal.

INSPECT SPARK PLUG
1. Remove the ignition coil connector(A).

When removing the ignition coil connector, pull the lock pin(A) and push the clip(B).

2. Remove the ignition coil(B).
3. Using a spark plug socket, remove the spark plug.

Be careful that no contaminates enter through the spark plug holes.
4. Inspect the electrodes (A) and ceramic insulator (B).

INSPECTION OF ELECTRODES
Condition
Description

Dark deposits
a. Fuel mixture too rich
b. Low air intake

5. Check the electrode gap (A).
Standard :
Unleaded : 1.0 ~ 1.1 mm (0.0394 ~ 0.0433 in.)

INSPECT IGNITION COIL
1. Measure the primary coil resistance between terminals (+) and (-).

White deposits
a. Fuel mixture too lean
b. Advanced ignition timing
c. Insufficient plug tightening torque

Standard value: 0.62Ω ± 10%

Charging System

2007 > 2.7L V6 GASOLINE >

DESCRIPTION
The charging system included a battery, an alternator with a built-in regulator, and the charging indicator light and
wire.
The Alternator has built-in diodes, each rectifying AC current to DC current.
Therefore, DC current appears at alternator «B» terminal.
In addition, the charging voltage of this alternator is regulated by the battery voltage detection system.
The alternator is regulated by the battery voltage detection system. The main components of the alternator are the
rotor, stator, rectifier, capacitor brushes, bearings and V-ribbed belt pulley. The brush holder contains a built-in
electronic voltage regulator.

2007 > 2.7L V6 GASOLINE >

ON-VEHICLE INPECTION

a. Check that the battery cables are connected to the correct terminals.
b. Disconnect the battery cables when the battery is given a quick charge.
c. Never disconnect the battery while the engine is running.

CHECK BATTERY VOLTAGE
1. If 20 minutes have not passed since the engine was stopped, turn the ignition switch ON and turn on the electrical
system (headlamp, blower motor, rear defogger etc.) for 60 seconds to remove the surface charge.
2. Turn the ignition switch OFF and turn off the electrical systems.
3. Measure the battery voltage between the negative (-) and positive (+) terminals of the battery.
Standard voltage : 12.5 ~ 12.9V at 20°C(68°F)
If the voltage is less than specification, charge the battery.

CHECK THE BATTERY TERMINALS AND FUSES
1. Check that the battery terminals are not loose or corroded.
2. Check the fuses for continuity.

INSPECT DRIVE BELT
Visually check the belt for excessive wear, frayed cords etc.
If any defect has been found, replace the drive belt.

Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should
be replaced.

VISUALLY CHECK ALTERNATOR WIRING AND LISTEN FOR ABNORMAL NOISES
1. Check that the wiring is in good condition.
2. Check that there is no abnormal noise from the alternator while the engine is running.

CHECK DISCHARGE WARNING LIGHT CIRCUIT
1. Warm up the engine and then turn it off.
2. Turn off all accessories.
3. Turn the ignition switch «ON». Check that the discharge warning light is lit.
4. Start the engine. Check that the light is lit.
If the light does not go off as specified, troubleshoot the discharge light circuit.

INSPECT CHARGING SYSTEM
VOLTAGE DROP TEST OF ALTERNATOR OUTPUT WIRE
This test determines whether or not the wiring between the alternator «B» terminal and the battery (+) terminal is good
by the voltage drop method.

PREPARATION

1. Turn the ignition switch to «OFF».
2. Disconnect the output wire from the alternator «B» terminal. Connect the (+) lead wire of ammeter to the «B»
terminal of alternator and the (-) lead wire of ammeter to the output wire. Connect the (+) lead wire of voltmeter to
the «B» terminal of alternator and the (-) lead wire of voltmeter to the (+) terminal of battery.

TEST
1. Start the engine.
2. Turn on the headlamps and blower motor, and set the engine speed until the ammeter indicates 20A.
And then, read the voltmeter at this time.

RESULT
1. The voltmeter may indicate the standard value.
Standard value: 0.2V max
2. If the value of the voltmeter is higher than expected (above 0.2V max.), poor wiring is suspected. In this case
check the wiring from the alternator «B» terminal to the battery (+) terminal. Check for loose connections, color
change due to an over-heated harness, etc. Correct them before testing again.
3. Upon completion of the test, set the engine speed at idle.
Turn off the headlamps, blower motor and the ignition switch.

OUTPUT CURRENT TEST
This test determines whether or not the alternator gives an output current that is equivalent to the normal output.

PREPARATION
1. Prior to the test, check the following items and correct as necessary.
Check the battery installed in the vehicle to ensure that it is good condition. The battery checking method is
described in the section «Battery».
The battery that is used to test the output current should be one that has been partially discharged. With a fully
charged battery, the test may not be conducted correctly due to an insufficient load.
Check the tension of the alternator drive belt. The belt tension check method is described in the section «Inspect
drive belt».
2. Turn off the ignition switch.
3. Disconnect the battery ground cable.
4. Disconnect the alternator output wire from the alternator «B» terminal.
5. Connect a DC ammeter (0 to 150A) in series between the «B» terminal and the disconnected output wire. Be sure
to connect the (-) lead wire of the ammeter to the disconnected output wire.

Tighten each connection securely, as a heavy current will flow. Do not rely on clips.
6. Connect a voltmeter (0 to 20V) between the «B» terminal and ground. Connect the (+) lead wire to the alternator «B»
terminal and (-) lead wire to a good ground.
7. Attach an engine tachometer and connect the battery ground cable.
8. Leave the engine hood open.

TEST
1. Check to see that the voltmeter reads as the same value as the battery voltage. If the voltmeter reads 0V, and the
open circuit in the wire between alternator «B» terminal and battery (-) terminal or poor grounding is suspected.
2. Start the engine and turn on the headlamps.
3. Set the headlamps to high beam and the heater blower switch to HIGH, quickly increase the engine speed to 2,500
rpm and read the maximum output current value indicated by the ammeter.

After the engine start up, the charging current quickly drops.
Therefore, the above operation must be done quickly to read the maximum current value correctly.

RESULT
1. The ammeter reading must be higher than the limit value. If it is lower but the alternator output wire is in good
condition, remove the alternator from the vehicle and test it.
Limit value : 70％ of the rated current

a. The nominal output current value is shown on the nameplate affixed to the alternator body.
b. The output current value changes with the electrical load and the temperature of the alternator itself.
Therefore, the nominal output current may not be obtained. If such is the case, keep the headlamps on the
cause discharge of the battery, or use the lights of another vehicle to increase the electrical load.
The nominal output current may not be obtained if the temperature of the alternator itself or ambient
temperature is too high.
In such a case, reduce the temperature before testing again.
2. Upon completion of the output current test, lower the engine speed to idle and turn off the ignition switch.
3. Disconnect the battery ground cable.
4. Remove the ammeter and voltmeter and the engine tachometer.
5. Connect the alternator output wire to the alternator «B» terminal.
6. Connect the battery ground cable.

REGULATED VOLTAGE TEST
The purpose of this test is to check that the electronic voltage regulator controls voltage correctly.

PREPARATION
1. Prior to the test, check the following items and correct if necessary.
Check that the battery installed on the vehicle is fully charged. The battery checking method is described in the
section «Battery».
Check the alternator drive belt tension. The belt tension check method is described in the section «Inspect drive
belt».
2. Turn ignition switch to «OFF».
3. Disconnect the battery ground cable.
4. Connect a digital voltmeter between the «B» terminal of the alternator and ground. Connect the (+) lead of the
voltmeter to the «B» terminal of the alternator. Connect the (-) lead to good ground or the battery (-) terminal.
5. Disconnect the alternator output wire from the alternator «B» terminal.

6. Connect a DC ammeter (0 to 150A) in series between the «B» terminal and the disconnected output wire.
Connect the (-) lead wire of the ammeter to the disconnected output wire.
7. Attach the engine tachometer and connect the battery ground cable.

TEST
1. Turn on the ignition switch and check to see that the voltmeter indicates the following value.
Voltage: Battery voltage
If it reads 0V, there is an open circuit in the wire between the alternator «B» terminal and the battery and the battery
(-) terminal.
2. Start the engine. Keep all lights and accessories off.
3. Run the engine at a speed of about 2,500 rpm and read the voltmeter when the alternator output current drops to
10A or less

RESULT
1. If the voltmeter reading agrees with the value listed in the regulating voltage table below, the voltage regulator is
functioning correctly. If the reading is other than the standard value, the voltage regulator or the alternator is faulty.
REGULATING VOLTAGE TABLE
Voltage regulator ambient temperature °C (°F)
-20 (-4)
20 (68)
60 (140)
80 (176)

Regulating voltage (V)
14.2
14.0
13.7
13.5

~
~
~
~

15.4
15.0
14.9
14.7

2. Upon completion of the test, reduce the engine speed to idle, and turn off the ignition switch.
3. Disconnect the battery ground cable.
4. Remove the voltmeter and ammeter and the engine tachometer.
5. Connect the alternator output wire to the alternator «B» terminal.
6. Connect the battery ground cable.

Alternator

2007 > 2.7L V6 GASOLINE >

COMPONENT

2007 > 2.7L V6 GASOLINE >

REMOVAL
1. Disconnect the battery negative terminal first, then the positive terminal.
2. Disconnect the alternator connector, and remove the cable from alternator «B» terminal.
3. Remove the drive belt.
4. Pull out the through bolt and then remove the alternator(A).

5. Installation is the reverse of removal.

DISASSEMBLY
1. Remove the alternator cover(A) using a screw driver(B).

2. Remove the slip ring guide(A).
3. Loosen the mounting bolts(B) and disconnect the brush holder assembly(C).

4. Remove the rectifler(A) with 4 screws.

5. Remove the nut, pulley(A) and spacer.

6. Loosen the 4 through bolts(A).

7. Disconnect the rotor(A) and cover(B).

8. Reassembly is the reverse order of disassembly.

INSPECTION
INSPECT ROTOR
1. Check that there is continuity between the slip rings (A).

2. Check that there is no continuity between the slip rings and the rotor (B) or rotor shaft (C).
3. If the rotor fails either continuity check, replace the alternator.

INSPECT STATOR
1. Check that there is continuity between each pair of leads (A).

2. Check that there is no continuity between each lead and the coil core.
3. If the coil fails either continuity check, replace the alternator.

Battery

2007 > 2.7L V6 GASOLINE >

DESCRIPTION
1. The maintenance-free battery is, as the name implies, totally maintenance free and has no removable battery cell
caps.
2. Water never needs to be added to the maintenance-free battery.
3. The battery is completely sealed, except for small vent holes in the cover.

2007 > 2.7L V6 GASOLINE >

INSPECTION
BATTERY DIAGNOSTIC TEST (1)

CHECKING FLOW

LOAD TEST
1. Perform the following steps to complete the load test procedure for maintenance free batteries.
2. Connect the load tester clamps to the terminals and proceed with the test as follow:

(1) If the battery has been on charge, remove the surface charge by connect a 300ampere load for 15 seconds.
(2) Connect the voltmeter and apply the specified load.
(3) Read the voltage after the load has been applied for 15 seconds.
(4) Disconnect the load.
(5) Compare the voltage reading with the minimum and replace the battery if battery test voltage is below that
shown in the voltage table.
Voltage

Temperature

9.6V

20°C (68.0°F) and above

9.5V

16°C (60.8°F)

9.4V

10°C (50.0°F)

9.3V

4°C (39.2°F)

9.1V

-1°C (30.2°F)

8.9V

-7°C (19.4°F)

8.7V

-12°C (10.4°F)

8.5V

-18°C (-0.4°F)

a. If the voltage is greater shown in the table, the battery is good.
b. If the voltage is less than shown in the table, replace the battery.

BATTERY DIAGNOSTIC TEST (2)
1. Make sure the ignition switch and all accessories are in the OFF position.
2. Disconnect the battery cables (negative first).
3. Remove the battery from the vehicle.

Care should be taken in the event the battery case is cracked or leaking, to protect your skin from the
electrolyte.
Heavy rubber gloves (not the household type) should be wore when removing the battery.

4. Inspect the battery tray for damage caused by the loss of electrolyte. If acid damage is present, it will be necessary
to clean the area with a solution of clean warm water and baking soda. Scrub the area with a stiff brush and wipe
off with a cloth moistened with baking soda and water.
5. Clean the top of the battery with the same solution as described above.
6. Inspect the battery case and cover for cracks. If cracks are present, the battery must be replaced.
7. Clean the battery posts with a suitable battery post tool.

8. Clean the inside surface of the terminal clamps with a suitable battery cleaning tool. Replace damaged or frayed
cables and broken terminal clamps.
9. Install the battery in the vehicle.
10. Connect the cable terminals to the battery post, making sure tops of the terminals are flush with the tops of the
posts.
11. Tighten the terminal nuts securely.
12. Coat all connections with light mineral grease after tightening.

When batteries are being charged, an explosive gas forms beneath the cover of each cell. Do not smoke
near batteries being charged or which have recently been charged. Do not break live circuit at the terminals
of batteries being charged.
A spark will occur when the circuit is broken. Keep open flames away form battery.

Starting System

2007 > 2.7L V6 GASOLINE >

DESCRIPTION
The starting system includes the battery, starter, solenoid switch, ignition switch, inhibitor switch (A/T), ignition lock
switch, connection wires and the battery cable.
When the ignition key is turned to the start position, current flows and energizes the starter motor’s solenoid coil.
The solenoid plunger and clutch shift lever are activated, and the clutch pinion engages the ring gear.
The contacts close and the starter motor cranks. In order to prevent damage caused by excessive rotation of the
starter armature when the engine starts, the clutch pinion gear overruns.

2007 > 3.8L V6 GASOLINE >

STARTER CIRCUIT TROUBLESHOOTING

The battery must be in good condition and fully charged.
1. Remove the fuel pump relay(A) from the fuse box.

2. With the shift lever in N or P (A/T) or clutch pedal pressed (M/T), turn the ignition switch to «START»
If the starter normally cranks the engine, starting system is OK. If the starter will not crank the engine at all, go to
next step.
If it won’t disengage from the ring gear when you release key, check for the following until you find the cause.
a. Solenoid plunger and switch malfunction.
b. Dirty pinion gear or damaged overrunning clutch.
3. Check the battery condition. Check electrical connections at the battery, battery negative cable connected to the
body, engine ground cables, and the starter for looseness and corrosion. Then try starting the engine again.
If the starter cranks normally the engine, repairing the loose connection repaired the problem. The starting system
is now OK.
If the starter still does not crank the engine, go to next step.
4. Disconnect the connector from the S-terminal of solenoid. Connect a jumper wire from the B-terminal of solenoid to
the S-terminal of solenoid.
If the starter cranks the engine, go to next step.
If the starter still does not crank the engine, remove the starter, and repair or replace as necessary.
5. Check the following items in the order listed until you find the open circuit.
a. Check the wire and connectors between the driver’s under-dash fuse/relay box and the ignition switch, and
between the driver’s under-dash fuse/relay box and the starter.
b. Check the ignition switch (Refer to BE group — ignition system)
c. Check the transaxle range switch connector or ignition lock switch connector.
d. Inspect the starter relay.

STARTER SOLENOID TEST
1. Disconnect the field coil wire from the M-terminal of solenoid switch.
2. Connect the battery as shown. If the starter pinion pops out, it is working properly. To avoid damaging the starter,
do not leave the battery connected for more than 10 seconds.

3. Disconnect the battery from the M terminal.
If the pinion does not retract, the hold-in coil is working properly. To avoid damaging the starter, do not leave the
battery connected for more than 10 seconds.

4. Disconnect the battery also from the body. If the pinion retracts immediately, it is working properly. To avoid
damaging the starter, do not leave the battery connected for more than 10 seconds.

FREE RUNNING TEST
1. Place the starter motor in a vise equipped with soft jaws and connect a fully-charged 12-volt battery to starter
motor as follows.
2. Connect a test ammeter (100-ampere scale) and carbon pile rheostats as shown in the illustration.
3. Connect a voltmeter (15-volt scale) across starter motor.

4. Rotate carbon pile to the off position.

5. Connect the battery cable from battery’s negative post to the starter motor body.
6. Adjust until battery voltage shown on the voltmeter reads 11volts.
7. Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and
freely.
Current : 85A MAX
Speed : 2,600 rpm

Starter

2007 > 2.7L V6 GASOLINE >

COMPONENT

2007 > 2.7L V6 GASOLINE >

REMOVAL
STATATER
1. Disconnect the battery negative cable.
2. Disconnect the starter cable (A) from the B terminal (B) on the solenoid (C), then disconnect the connector (D)
from the S terminal (E).

3. Remove the 2 bolts holding the starter, then remove the starter.
4. Installation is the reverse of removal.
5. Connect the battery negative cable to the battery.

DISASSEMBLY
1. Disconnect the M-terminal (A) on the magnet switch assembly (B).

2. After loosening the 3 screws (A), detach the magnet switch assembly (B).

3. Loosen the through bolts (A).

4. Remove the brush holder assembly (A), yoke (b) and armature (C).

5. Remove the shield (A) and packing (B).

6. Remove the lever plate (A) and lever packing (B).

7. Disconnect the planet gear (A).

8. Disconnect the planet shaft assembly (A) and lever (B).

9. Press the stop ring (A) using a socket (B).

10. After removing the stopper (A) using stopper pliers (B).

11. Disconnect the stop ring (A), overrunning clutch (B), internal gear (C) and planet shaft (D).

12. Reassembly is the reverse of disassembly.

Using a suitable pulling tool (A), pull the overrunning clutch stop ring (B) over the stopper (C).

INSPECTION
ARMATURE INSPECTION AND TEST
1. Remove the starter.
2. Disassemble the starter as shown at the beginning of this procedure.
3. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage,
replace the armature.

4. Check the commutator (A) surface. If the surface is dirty or burnt, resurface with emery cloth or a lathe within the
following specifications, or recondition with #500 or #600 sandpaper (B).

5. Measure the commutator (A) runout.
a. If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips
between the segments.
b. If the commutator run out is not within the service limit, replace the armature.
Commutator runout
Standard (New): 0.02mm (0.0008in.) max
Service limit: 0.05mm (0.0020in.)

6. Check the mica depth (A). If the mica is too high (B), undercut the mica with a hacksaw blade to the proper depth.
Cut away all the mica (C) between the commutator segments. The undercut should not be too shallow, too narrow,
or v-shaped (D).
Commutator mica depth
Standard (New) : 0.5 mm (0.0197 in.)
Limit : 0.2mm (0.0079 in.)

7. Check for continuity between the segments of the commutator. If an open circuit exists between any segments,
replace the armature.

8. Check with an ohmmeter that no continuity exists between the commutator (A) and armature coil core (B), and
between the commutator and armature shaft (C). If continuity exists, replace the armature.

INSPECT STARTER BRUSH
Brushes that are worm out, or oil-soaked, should be replaced.

STARTER BRUSH HOLDER TEST
1. Check that there is no continuity between the (+) brush holder (A) and (-) brush holder (B). If there is no continuity,
replace the brush holder assembly.

2. Pry back each brush spring (A) with a screwdriver, then position the brush (B) about halfway out of its holder, and
release the spring to hold it there.

3. Install the armature in the housing, and install the brush holder. Next, pry back each brush spring again, and push
the brush down until it seats against the commutator, then release the spring against the end of the brush.

To seat new brushes, slip a strip of #500 or #600 sandpaper, with the grit side up, between the commutator
and each brush, and smoothly rotate the armature. The contact surface of the brushes will be sanded to the
same contour as the commutator.

INSPECT OVERRUNNING CLUTCH
1. Slide the overrunning clutch along the shaft.
Replace it if does not slide smoothly.
2. Rotate the overrunning clutch both ways.
Does it lock in one direction and rotate smoothly in reverse? If it does not lock in either direction of it locks in both
directions, replace it.

3. If the starter drive gear is worn or damaged, replace the overrunning clutch assembly. (the gear is not available
separately).
Check the condition of the flywheel or torque converter ring gear if the starter drive gear teeth are damaged.

CLEANING
1. Do not immerse parts in cleaning solvent. Immersing the yoke assembly and/or armature will damage the
insulation. Wipe these parts with a cloth only.
2. Do not immerse the drive unit in cleaning solvent. The overrun clutch is pre-lubricated at the factory and solvent
will wash lubrication from the clutch.
3. The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.

Starter Relay

2007 > 3.8L V6 GASOLINE >

INSPECTION
1. Remove the fuse box cover.
2. Remove the starter relay (A).

3. Using an ohmmeter, check that there is continuity between each terminal.
Terminal

Continuity

30 — 87

NO

85 — 86

YES

4. Apply 12V to terminal 85 and ground to terminal 86.
Check for continuity between terminals 30 and 87.

5. If there is no continuity, replace the starter relay.
6. Install the starter relay.
7. Install the fuse box cover.

Cruise Control System

2007 > 3.8L V6 GASOLINE >

SYSTEM BLOCK DIAGRAM

COMPONENT PARTS AND FUNCTION OUTLINE
Component part

Function

Vehicle-speed sensor

Converts vehicle speed to pulse.

Engine control module (ECM)

Receives signals from sensor and control switches;

Cruise control indicator

Illuminate when CRUISE main switch is ON (Built into
cluster)

Cruise Control switches

CRUISE main switch

Switch for automatic speed control power supply.

Resume/Accel switch

Controls automatic speed control functions by
Resume/Accel switch (Set/Coast switch)

Set/Coast switch
Cancel switch

Cancel switch
Brake-pedal switch
Transaxle range switch
(A/T)
Clutch switch (M/T)

ETS motor

Sends cancel signals to ECM

Regulates the throttle valve to the set opening by ECM.

* ETS : Electronic Throttle System

CRUISE CONTROL
Cruise control system is engaged by «ON. OFF» main switch located on right of steering wheel column. System has
the capability to cruise, coast, resume speed, and accelerate, and raise «tap-up» or lower «tap-down» set speed.
It also has a safety interrupt, engaged upon depressing brake or shifting select lever.
ECM is a speed control system that maintains a required vehicle speed at normal driving conditions.
The main components of cruise control system are mode control switches, transaxle range switch, brake switch,
vehicle speed sensor, ECM and ETS motor that connect throttle body.
ECM contains a low speed limit which will prevent system engagement below a minimum speed of 40km/h (25mph).
The operation of the controller is controlled by mode control switches located on steering wheel.
Transaxle range switch and brake switch are provided to disengage the cruise control system. The switches are on
brake pedal bracket and transaxle. When the brake pedal is depressed or select lever shifted, the cruise control
system is electrically disengaged and the throttle is returned to the idle position.

Cruise main switch
Cruise control system is engaged by pressing «ON. OFF» push button. Releasing «ON.OFF» push button release
throttle, clears cruise memory speed, and puts vehicle in a non-cruise mode.
Coast/Set switch
COAST.SET switch located on right of steering wheel column has two positions — «Normal» and «Depressed». The set
position — With COAST.SET switch depressed and then released the cruise speed will be set at the speed the vehicle
was going when COAST.SET switch was released. The coast position — With COAST.SET switch fully depressed,
driver can lower cruise speed. To decrease cruise speed, COAST.SET switch is held in, disengaging cruise control
system. When vehicle has slowed to required cruise speed, releasing COAST.SET switch will re-engage speed at new
selected speed.
The tap down — To lower vehicle speed, cruise must be engaged and operating. Tap down is done by quickly pressing
and releasing COAST.SET switch. Do not hold COAST.SET switch in depressed position.
Tap down is a function in which cruise speed car be decreased by 1mph (1.6km/h)
Resume/Accel switch
RES.ACCEL switch located on right of steering wheel column has two positions — «Normal» and «Depressed».
The resume position — With RES.ACCEL switch depressed and then release, this switch also returns cruise control
operation to last speed (Which is temporarily disengaged by Cancel switch or Brake pedal), setting when momentarily
operating RES.ACCEL switch by constant acceleration.
The accel position — With RES.ACCEL switch depressed and held in, disengaging cruise control system, when vehicle
has accelerated to required cruise speed, releasing RES.ACCEL switch will re-engage speed at new selected speed.
The tap up — To increase vehicle speed, the cruise must be engaged and operating.
Tap up is done by quickly pressing and releasing RES.ACCEL switch less than 0.5 second. Do not hold RES.ACCEL
switch in depressed position. Tap up is a function in which cruise speed can be increased by 1mph (1.6km/h).
Cancel switch
Cruise control system is temporarily disengaged by pressing «CANCEL» switch.
Cruise speed canceled by this switch will be recovered by RES.ACCEL switch

2007 > 3.8L V6 GASOLINE >

TROUBLE SYMPTOM CHARTS
TROUBLE SYMPTOM 1

TROUBLE SYMPTOM 2
Trouble symptom

Probable cause

The set vehicle speed varies greatly
Malfunction of the vehicle speed
upward or downward
sensor circuit
«Surging» (repeated alternating
acceleration and deceleration) occurs Malfunction of ECM
after setting

Remedy
Repair the vehicle speed sensor
system, or replace the part
Replace the ECM

TROUBLE SYMPTOM 3
Trouble symptom

Probable cause

Damaged or disconnected wiring of
The CC system is not canceled when the brake pedal switch
the brake pedal is depressed
Malfunction of the ECM

Remedy
Repair the harness or replace the
brake pedal switch
Replace the ECM

TROUBLE SYMPTOM 4
Trouble symptom

Probable cause

Damaged or disconnected wiring of
The CC system is not canceled when inhibitor switch input circuit
the shift lever is moved to the «N»

Remedy
Repair the harness or repair or
replace the inhibitor switch

the shift lever is moved to the «N»
position (It is canceled, however,
when the brake pedal is depressed

Improper adjustment of inhibitor
switch

replace the inhibitor switch

Malfunction of the ECM

Replace the ECM

TROUBLE SYMPTOM 5
Trouble symptom
Cannot decelerate (coast) by using
the SET switch

Probable cause

Remedy

Temporary damaged or disconnected
wiring of SET switch input circuit

Repair the harness or replace the
SET switch

Malfunction of the ECM

Replace the ECM

TROUBLE SYMPTOM 6
Trouble symptom
Cannot accelerate or resume speed
by using the RESUME switch

Probable cause

Remedy

Damaged or disconnected wiring, or
Repair the harness or replace the
short circuit, or RESUME switch input
RESUME switch
circuit
Malfunction of the ECM

Replace the ECM

TROUBLE SYMPTOM 7
Trouble symptom

Probable cause

CC system can be set while driving at Malfunction of the vehicle-speed
a vehicle speed of less than 40km/h sensor circuit
(25mph), or there is no automatic
Malfunction of the ECM
cancellation at that speed

Remedy
Repair the vehicle speed sensor
system, or replace the part
Replace the ECM

TROUBLE SYMPTOM 8
Trouble symptom

Probable cause

The cruise main switch indicator lamp Damaged or disconnected bulb of
does not illuminate (But CC system is cruise main switch indicator lamp
normal)
Harness damaged or disconnected

Remedy
Repair the harness or replace the
part.

2007 > 3.8L V6 GASOLINE >

CIRCUIT DIAGRAM

2007 > 3.8L V6 GASOLINE >

REMOVAL
1. Disconnect the battery (-) terminal.
2. Remove the driver side air bag module. (Refer to RT GR.)
3. Disconnect the cruise control switch connector and then remove the cruise control switch(A) with two screws.

4. Installation is the reverse of removal.

INSPECTION
MEASURING RESISTANCE
1. Disconnect the cruise control switch connector from the control switch.

2. Measure resistance between terminals on the control switch when each function switch is ON (switch is
depressed).
Function switch

Terminal

Resistance

Cruise Main

RH 1-2

3.9kΩ ± 1%

Cancel

RH 1-3

0Ω ± 1%

Set/Coast

RH 1-3

220Ω ± 1%

Resume/Accel

RH 1-3

910Ω ± 1%

3. If not within specification, replace switch.

MEASURING VOLTAGE
1. Connect the cruise control switch connector to the control switch.

2. Measure voltage between terminals on the harness side connector when each function switch is ON (switch is
depressed).
Function switch

Terminal

Voltage

Cruise Main

RH 1-2

—

Cancel

RH 1-3

0.0V ± 0.22V

Set/Coast

RH 1-3

1.5V ± 0.22V

Resume/Accel

RH 1-3

3.0V ± 0.22V

3. If not within specification, replace switch.

General Information

2007 > J2.9L DIESEL CRDI(VGT) >

SPECIAL TOOLS
Tool
(Number and Name)
09411-43000
Clutch disc guide

Illustration

Use
Installation of the clutch disc

2007 > J2.9L DIESEL CRDI(VGT) >

SPECIFICATION
Item

SPECIFICATION

Engine type

J2.9

Clutch operation

Hydraulic type

Clutch disc

Single dry with diaphragm

Clutch cover assembly

Self Adjusting Clutch

TIGHTENING TORQUE
Item

Nm

Kgf.cm

lb-ft

Clutch cover (6EA)

25~36

250~360

18.2~26.2

Clutch pedal bracket mounting

19~26

190~260

13.8~18.9

Regulator bolt

28~33

280~330

20.3~24

Connecting rod adjusting bolt

9~14

90~140

6.5~10.1

Clutch master cylinder mounting

12~16

120~160

8.7~11.6

Stopper bolt

8~10 or 14~20

80~100 or 140~200

5.8~7.27 or
10.1~14.5

Clutch pedal bolt/nut

25~34

250~340

18.1~24.7

SERVICE STANDARD
Item

Standard value

Clutch pedal stroke

150mm (5.91in)

Clutch pedal free play

6~13mm (0.24~0.51in)

Clutch System

2007 > J2.9L DIESEL CRDI(VGT) >

DESCRIPTION
SELF ADJUSTING CLUTCH(S.A.C.) COVER
a. As a clutch disc facing is worn away according to its durability, a cover weight is increasing and a clutch pedal
pressure can be more needed.
b. To make up for this defect, the self adjusting clutch system makes the requsted pedal pressure minimized so that
makes the maintenance cycle longer.

CONCENTRIC SLAVE CYLINDER-C.S.C.
It improves working efficiency and lowers the number and the weight of part by unifing clutch release control
parts(clutch release bearing ~ clutch release cylinder) in a manual transaxle.

OPERATION
CONCENTRIC SLAVE CYLINDER-C.S.C
When the clutch pedal is pressed, oil pressure is transmitted along the arrow directions shown below and that moves
the clutch slave cylinder and the diaphragm spring of the clutch cover.

Clutch Cover and Disc

2007 > J2.9L DIESEL CRDI(VGT) >

COMPONENTS

2007 > J2.9L DIESEL CRDI(VGT) >

REPLACEMENT
1. Remove a transaxle assembly (refer to ‘MT’-group).
2. Remove the clutch cover bolts. Not to be bent or twisted, loosen them in diagonal directions.

3. Remove the clutch cover and disc.
4. Using the SST(09411-43000), install a clutch disc and cover.

a. Replace a clutch cover and disc as a set.
* Possible problems when not following the caution
a. When replacing only a disc, slip problem can occur because of the initial clamp load loss by the adjusting
ring’s unusual work.
b. When replacing only a disc, it can be difficult to cut power because the thickness of the disc cannot be
permitted.
b. Apply grease on a disc spline part and transmission input shaft spline part as required.
* Possible problems when not following
a. When not applying: Excessively wear of splines and bad clutch operation
b. When excessively applying: Scattered grease by centrifugal force conteminates the clutch disc. Loss of friction
force can cause a slip
c. The ‘T/M SIDE’ marked surface should face the transaxle.
→ If the surface face the opposite side, there can be an interference between a disc and a flywheel surface.

5. Tighten the clutch cover.
TORQUE:
24.5~35.3Nm (250~360kgf.cm, 18.1~26.0lb-ft) (6EA)

When installing the clutch cover, tighten the bolts in diagonal directions not to be bent or twisted.

* Possible problems when not following
a. When tightening the bolt completely at a time: the clutch cover can be twisted and vibration can occur.
b. On vehicles with self adjusting clutches, it is necessary to follow this caution.
c. Not following tightening torque: There can be bad torque transmission in clutch and relaxation possibility of
bolts.

INSPECTION
1. Inspect diaphragm spring wear which is in contact with a concentric slave cylinder bearing.

2. Check the clutch cover and disc surface for wear or crack.
3. Check the clutch disc lining for slipping or oil mark.
4. Measure the depth from a clutch lining surface to a rivet. If the measured value is less than the specification below,
replace it.
Specification: 0.3mm(0.0118inch)

Clutch Master Cylinder

2007 > J2.9L DIESEL CRDI(VGT) >

REMOVAL

Do not spill brake fluid on the vehicle; it may damage the paint if brake fluid does contact the paint, wash it off
immediately with water.
1. Remove the brake fluid fron the clutch master cylinder reservoir with a syringe.
2. Clamp the clutch master cylinder hose(A). If there is no enough room for clamping, you can also clamp the hose
from the brake master cylinder side.

3. Disconnect the hose(A) from the cylinder by releasing the clutch master cylinder clamp.

4. Remove the clutch master cylinder mounting bolts(A,B).
One is the engine room, the other near the clutch pedal assembly.

5. Remove the pin and washer which connect the clutch pedal with the clutch master cylinder.
6. Remove the clutch master cylinder. It can be helpful to do this step after removing the clutch pedal mounting
bracket.

INSTALLATION
Installation is in the reverse order of removal.
After installation, bleed the clutch hydaulic system.

CONCENTRIC SLAVE CYLINDER AIR BLEEDING PROCEDURE
1. After disconnecting a cap from the concentric slave cylinder air bleeder, insert a vinyl hose in the plug.
2. Loosening the plug screw, press and release the clutch pedal about 10 times.

Hold the air bleeder body not to rotate with a spanner(A). The holding is needed when the plug loosened or
tightened.
3. Tighten the plug during the clutch pedal pressed. Afterwards, raise the pedal with a hand.
TORQUE :
25~29Nm (250~290Kgf.cm, 18.2~21.1lb-ft)
4. After pressing the clutch pedal 3 times more, loosen the plug and retighten it with the pedal pressed. Raise it
again, then.
5. Repeat the step 4 two or three times. (until there is no bubble in the fluid)

a. Do not clamp the pipe of a concentric slave cylinder.
b. Be careful not to damage O-rings.

Clutch Pedal

2007 > J2.9L DIESEL CRDI(VGT) >

ADJUSTMENT PROCEDURE
IGNITION LOCK SWITCH
1. Disconnect 2P-connector from a ignition lock switch.
2. Disconnect the ignition lock switch. (if you can install a tester with the switch fixed, this step can be omissible)
3. Check for continuity between terminals. (refer to the table below)
Clutch pedal position

Ignition lock switch

Continuity

Released

Released

NO

Pressed

Pressed

YES

If there is difference between what tested and the table above, replace the ignition lock switch with a new one.
If not, install the ignition lock switch and adjust the clutch pedal.
TORQUE :
8~10Nm (80~100kgf.cm, 5.8~7.2lb-ft)

Clutch pedal and Ignition lock switch

a. Inspect a ignition lock switch.
b. Remove the driver’s seat mat to adjust a clutch pedal.
c. No gap between a clutch master cylinder pistion and push rod can cause clutch slip.
1. Loosen and draw out the bolt until it is off the pedal surface.
2. Push and pull a clutch master cylinder push rod to satisfy the specification below.
Specification:
Clutch pedal stroke(A) — 150mm(5.91in)
Clutch pedal free play(B) — 6~13mm(0.24~0.51in)
Clutch pedal distance — 234.7mm(9.24in)

3. With no pressure on a clutch pedal, tighten the bolt until it contacts on the pedal.
4. Fix the bolt with a nut.
TORQUE :
14~20Nm (140~200kgf.cm, 10.2~14.5lb-ft)

5. Press the clutch pedal to the seat ground.
6. Adjust the ignition lock switch position with the pedal a little(23~26mm) raised.
7. Install the ignition lock switch firmly.
TORQUE:
8~10Nm (80~100kgf.cm, 5.8~7.2lb-ft)

REPLACEMENT

a. Inspect the continuity of the ignition lock switch.
b. Remove the floor mat before adjusting the clutch pedal.
1. Remove the ignition lock switch.
2. Remove the snap pin and the clevis pin(A) connecting the clutch master cylinder push rod and the clutch pedal.

3. Remove the clutch master cylinder mounting nut(A,B) and the clutch pedal mounting nut(C).

4. Remove the clutch pedal.
5. Install a new one by tightening the bolts of the clutch pedal bracket and master cylinder .
TORQUE :
19~26 Nm(19~260 kgf.cm, 13.8~18.9 Ib-ft)(Clutch pedal bracket)
12~16 Nm(120~160 kgf.cm, 8.7~11.6 Ib-ft)(Clutch master cylinder)
6. Grease the clevis pin and insert it and the snap pin.
7. Adjust the clutch pedal and the ignition lock switch.

CHAPTER 2:

Engine Mechanical System

2007 > J2.9L DIESEL CRDI(VGT) >

SPECIAL SERVICE TOOLS
Tool (Number and name)

Illustration

Use

Valve spring lifter pivot.
(0K993 120 004)

Removal or installation of the valve spring

Valve spring lifter arm.
(0K993 120 001)

Removal or installation of the valve spring

Valve seal installer.
(09222-22001)

Installation of the valve seal

Camshaft pulley holder.
(09231 — 4X100)

Installation of the camshaft

Pressure gauge adapter.
(0K552 131 002)

Measurement of compression pressure

End york holder.
(09517-21700)

Removal or installation of the crankshaft
pulley bolt
(used with 09231-H1000)

Crankshaft pulley adapter.

Removal or installation of the crankshaft

Crankshaft pulley adapter.
(09231-H1000)

Removal or installation of the crankshaft
pulley bolt
(used with 09517-21700)

Oil pan remover.
(09215-3C000)

Removal of the oil pan

2007 > J2.9L DIESEL CRDI(VGT) >

TROUBLESHOOTING
Symptom
Engine misfire with abnormal
internal lower engine noises.

Engine misfire with abnormal
valve train noise.

Engine misfire with coolant
consumption

Engine misfire with excessive
oil consumption

Engine noise on start-up, but
only lasting a few seconds.

Suspect area

Remedy

Loose or improperly installed engine
flywheel.

Repair or replace the flywheel as
required.

Worn piston rings.
(Oil consumption may or may not cause
the engine to misfire.)

Inspect the cylinder for a loss of
compression .
Repair or replace as required.

Worn crankshaft thrust bearings.

Replace the crankshaft and bearings as
required.

Stuck valves.
(Carbon buildup on the valve stem can
cause the valve not to close properly.)

Repair or replace as required.

Excessive worn or mis-aligned timing
chain.

Replace the timing chain and sprocket
as required.

Worn camshaft lobes.

Replace the camshaft and valve lifers.

a. Faulty cylinder head gasket and/or
cracking or other damage to the
cylinder head and engine block
cooling system .
b. Coolant consumption may or may not
cause the engine to overheat.

a. Inspect the cylinder head and engine
block for damage to the coolant
passages and/or a faulty head
gasket.
b. Repair or replace as required.

Worn valves, valve guides and/or valve
stem oil seals.

Repair or replace as required.

Worn piston rings.
(Oil consumption may or may not cause
the engine to misfire)

Inspection the cylinder for a loss of
compression
Repair or replace as required.

Incorrect oil viscosity.

Drain the oil.
Install the correct viscosity oil.

Worn crankshaft thrust bearing.

Inspect the thrust bearing and
crankshaft.
Repair or replace as required.

Upper engine noise, regardless Low oil pressure.
of engine speed.
Broken valve spring.

Repair or replace as required.
Replace the valve spring.

Worn or dirty valve lifters.

Replace the valve lifters.

Stretched or broken timing chain and/or
damaged sprocket teeth.

Replace the timing chain and sprockets.

Worn timing chain tensioner, if
applicable.

Replace the timing chain tensioner as
required.

Worn camshaft lobes.

Inspect the camshaft lobes.
Replace the camshaft and valve lifters as
required.

Worn valve guides or valve stems.

Inspect the valves and valve guides, then
repair as required.

Stuck valves. (Carbon on the valve stem Inspect the valves and valve guides, then
or valve seat may cause the valve to
repair as required.
stay open.)

Lower engine noise, regardless Low oil pressure.
of engine speed.

Engine noise under load.

Engine will not crank.
(crankshaft will not rotate)

Repair or replace damaged components
as required.

Loose or damaged flywheel.

Repair or replace the flywheel.

Damaged oil pan, contacting the oil
pump screen.

Inspect the oil pan.
Inspect the oil pump screen.
Repair or replace as required.

Oil pump screen loose, damaged or
restricted.

Inspect the oil pump screen .
Repair or replace as required.

Excessive piston-to-cylinder bore
clearance.

Inspect the piston and cylinder bore.
Repair as required.

Excessive piston pin-to-bore clearance.

Inspect the piston, piston pin and the
connecting rod.
Repair or replace as required.

Excessive connecting rod bearing
clearance.

Inspect the following components and
repair as required.
a. The connecting rod bearings.
b. The connecting rods.
c. The crankshaft.
d. The crankshaft journal.

Excessive crankshaft bearing clearance.

Inspect the following components and
repair as required.
a. The crankshaft bearings.
b. The crankshaft journals.

Incorrect piston, piston pin and
connecting rod installation.

Verify the piston pins and connecting
rods are installed correctly.
Repair as required.

Low oil pressure.

Repair or replace as required.

Excessive connecting rod bearing
clearance.

Inspect the following components and
repair as required.
a. The connecting rod bearings.
b. The connecting rods.
c. The crankshaft.

Excessive crankshaft bearing clearance.

Inspect the following components and
repair as required.
a. The crankshaft bearings.
b. The crankshaft journals.
c. The cylinder block crankshaft bearing
bore.

Hydraulically locked cylinder.
a. Coolant/antifreeze in cylinder.
b. Oil in cylinder.
c. Fuel in cylinder.

Remove spark plugs and check for fluid.
Inspect for broken head gasket.
Inspect for cracked engine block or
cylinder head.
Inspect for a sticking fuel injector and/or
leaking fuel regulator.

Broken timing chain and/or timing chain
gears.

Inspect timing chain and gears.
Repair as required.

Foreign material in cylinder.
a. Broken valve.
b. Piston material.
c. Foreign material.

Inspect cylinder for damaged
components and/or foreign materials.
Repair or replace as required.

Seized crankshaft or connecting rod
bearings.

Inspect crankshaft and connecting rod
bearing.
Repair or replace as required.

Bent or broken connecting rod.

Inspect connecting rods.
Repair or replace as required.

Broken crankshaft.

Inspect crankshaft.Repair or replace as
required.

2007 > J2.9L DIESEL CRDI(VGT) >

INSPECTION
COMPESSION PRESSURE

If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure.
1. Warm up the engine until the coolant temperature becomes 80~95°C(176~203°F).
2. Remove the fuel inlet(A) and the return hose(B) from the fuel filter.

3. Crank the engine in order to exhaust fuel in the high pressure pump.

Gather residual fuel by putting the return hose into a proper vessel.
4. Remove the injection pipe, injector and washer.(Refer to FL group).
5. Measure the cylinder compression pressure.
(1) Insert the SST(0K552 131 002) into the injector hole.
(2) Cranking the engine, measure the pressure.

Use the complete charging battery for the engine to crank at the speed of 350rpm or more.
(3) Do the above step 1)~2) again for each cylinder.

This work must be done in as short time as possible.
Compression pressure :
3040.05kPa (31kg/cm², 440.92psi) (325 rpm)
Minimum pressure :
2745.85kPa (28kg/cm², 398.25psi)
Difference between each cylinder :
294.20kPa (3.0kg/cm², 42.67psi)
(4) If, in one or more cylinders, the measured value is below the limit, fill a little engine oil into the injector holes of
the cylinders, repeat the step 1)~2) and measure the compression pressure again.
a. If the re-measured pressure becomes higher, wear or damage of the piston ring or cylinder surface can be
the cause.
b. If the re-measured pressure does not become higher, adherence or poor contact of the valves or inferior
gasket can be the cause.

gasket can be the cause.
6. Install the injectors, washers and the injector pipes.(Refer to FL group).
7. Install the inlet and the return hoses to the fuel filter.

TIMING BELT TENSION ADJUSTMENT
1. Remove the battery terminals (A).

2. Install the jack for oil pan.
3. Remove the engine mounting (A).

4. Remove the engine support bracket(A).

5. Remove the drive belt.

6. Remove the water pump pulley.

7. Remove the bolts(B), nut(C) and timing belt upper cover (A).

8. Turn the crankshaft pulley(A) and align its groove with the timing mark “T” of the timing belt cover. Check that the
timing mark of camshaft sprocket(B) is aligned with that of the cylinder head cover. (No.1 cylinder positioned at the
TDC position)

9. Remove the crankshaft pulley bolt(A), washer(B) and crankshaft pulley(C).

Using the special tool(09517-21700, 09231-H1000), fix the crankshaft pulley and loosen the bolt(A).
10. Remove the drive belt idler(A).

11. Remove the drive belt auto-tensioner (A).

12. Remove the timing belt lower cover(A).

13. Loosen the auto-tensioner fixing bolt(A).

14. Adjust tension of the timing belt.
(1) Align the pointer(B) with the tensioner fork(back plate)(C) as shown below by turning the special washer(A)
counterclockwise with a hexagonal wrench.

(2) When the pointer(A) is aligned with the tensioner fork(back plate)(B), tighten the tensioner mounting bolts with
the special bolt fixed by a hexagonal wrench.
Tightening torque :
19.6~25.5Nm (2.0~2.6kgf.m, 14.5~18.8lb-ft)

(3) Remove the hexagonal wrench.

When the pointer (A) can not be aligned with the tensioner fork(back plate)(B), replace a new belt and
repeat the steps.
15. Rotate the crankshaft clockwise two revolutions in order to align the timing marks on the crankshaft sprocket, the
camshaft sprocket and high pressure pump pulley.
16. Confirm that the location of the pointer is aligned with tensioner fork (back plate).
The margin of error : ± 5°

17. Install the timing belt lower cover(A).
Tightening torque :
6.9~9.8Nm (0.7 ~ 1.0kgf.m, 5.1 ~ 7.2lb-ft)

18. Install the drive belt idler(A).
Tightening torque :
37.3Nm (3.8kgf.m, 27.5lb-ft)

19. Install the drive belt auto-tensioner (A).
Tightening torque :
15.7~22.6Nm (1.6 ~ 2.3kgf.m, 11.6 ~ 16.6lb-ft)

20. Install the crankshaft pulley bolt(A), washer(B) and crankshaft pulley (A).
Tightening torque :
376.6~411.9Nm (38.4~42.0kgf.m, 277.7~303.8lb-ft)

Using the special tool(09517-21700, 09231-H1000), tighten the bolt(A).
21. Install the bolts(B), nut(C) and timing belt upper cover (A).
Tightening torque :
6.9~9.8Nm (0.7 ~ 1.0kgf.m, 5.1 ~ 7.2lb-ft)

22. Install the water pump pulley.
Tightening torque :
5.9~9.8Nm (0.6 ~ 1.0kgf.m, 4.3 ~ 7.2lb-ft)

23. Install the drive belt.

24. Confirm that the ‘A’ part of the drivebelt auto-tensioner is positioned as shown below. If not, replace the belt.

25. Install the engine support bracket(A).
Tightening torque :
49.0~63.7Nm (5.0 ~ 6.5kgf.m, 36.2 ~ 47.0lb-ft)

26. Install the engine mounting (A).
Tightening torque :
88.3~107.9Nm (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft)
27. Remove the jack for oil pan.
28. Install the battery terminals (A).

2007 > J2.9L DIESEL CRDI(VGT) >

SPECIFICATIONS
Description

Specifications(J3 — ENG)

General
Type

In-line, DOHC

Number of cylinders

4

Bore

101.5~101.526mm (3.9961~3.9971in)

Stroke

98mm (8.8583in)

Total displacement

2,902 cc (177.08 cu.in)

Compression ratio

18.4 : 1

Firing order

1-3-4-2

Valve timing
Intake valve

Exhaust valve

Opens (ATDC)

26°

Closes (ABDC)

50°

Opens (BBDC)

72°

Closes (ATDC)

32°

Cylinder head
Flatness of gasket surface
Flatness of manifold
mounting surface

Less than 0.05mm (0.0020in)

Intake

Less than 0.15mm (0.0059in)

Exhaust

Less than 0.15mm (0.0059in)

Intake

39.397 ~ 39.597mm (1.5511 ~ 1.5589in)

Exhaust

39.4932 ~ 39.6932mm (1.5548 ~ 1.5627in)

Camshaft
Cam height

Journal outer Diameter (Intake, Exhaust)

27.941 ~ 27.960mm (1.1000 ~ 1.1008in)

Bearing oil clearance

0.040 ~ 0.080mm (0.0016 ~ 0.0031in)

End play

0.08 ~ 0.17mm (0.0031 ~ 0.0067in)

Valve
Valve length

Stem outer diameter

Intake

126.24mm (4.9701in)

Exhaust

126.24mm (4.9701in)

Intake

6.965 ~ 6.980mm (0.2742 ~ 0.2748in)

Exhaust

6.945 ~ 6.960mm (0.2734 ~ 0.2740in)

Face angle

45°

Thickness of valve
head (margin)

Intake

1.7mm (0.0669in)

Exhaust

1.6mm (0.0630in)

Valve stem to valve
guide clearance

Intake

0.030 ~ 0.065mm (0.0012 ~ 0.0026in)

Exhaust

0.050 ~ 0.085mm ( 0.0020~ 0.0033in)

Intake

52.5mm (2.0669in)

Exhaust

52.5mm (2.0669in)

Valve guide
Length
Valve seat

Limit

Width of seat contact

Intake

1.4 ~ 2.0mm (0.0551 ~ 0.0787in)

Exhaust

0.9 ~ 1.5mm (0.0354 ~0.0591 in)

Seat angle

45°

Valve spring
Free length
Load(Intake)

Load(Exhaust)

52.477mm (2.0660in)
Installed

23.45±1.87kg/40.0mm(51.7±4.1lb/1.5748 in)

Valve opened

39.15±3.13kg/31.65mm(86.3±6.9 lb/1.2461 in)

Installed

23.45±1.87kg/40.0mm(51.7±4.1lb/1.5748 in)

Valve opened

39.43±3.15kg/31.50mm(86.9±6.9 lb/1.2402 in)

Out of squareness

Less than 2°

Rocker arm and rocker arm shaft
Rocker arm inner diameter

20.000 ~ 20.027mm (0.7874 ~ 0.7885in)

Rocker arm shaft outer diameter

19.959 ~ 19.980mm (0.7858 ~ 0.7866in)

Cylinder block
Cylinder bore

101.500 ~ 101.526mm (3.9961 ~3.9971 in)

Liner inner diameter

97.100 ~ 97.126mm (3.8228~ 3.8239in)

Liner outer diameter

101.480 ~ 101.526mm ( 3.9953~ 3.9971in)

Flatness of gasket surface

Less than 0.05mm (0.0020in)

Piston
Piston outer diameter

97.015 ~ 97.030mm ( 3.8195~ 3.8201in)

Piston to cylinder clearance

0.070 ~ 0.098mm (0.0028 ~ 0.0039in)

Ring groove width

No. 1 ring groove

2.397 ~ 2.417mm ( 0.0944~0.0952 in)

No. 2 ring groove

2.05 ~ 2.07mm ( 0.0807~ 0.0815in)

Oil ring groove

3.02 ~ 3.04mm (0.1189 ~ 0.1197in)

No. 2 ring

0.06 ~ 0.10mm (0.0024~0.0039 in)

Oil ring

0.03 ~ 0.07mm (0.0012~0.0028 in)

No. 1 ring

0.25 ~ 0.40mm (0.0098~ 0.0157in)

No. 2 ring

0.40 ~ 0.55mm (0.0157~0.0217in)

Oil ring

0.20 ~ 0.40mm (0.0079 ~ 0.0157in)

Piston ring

Side clearance

End gap

Piston pin
Piston pin outer diameter

31.994 ~ 32.000mm (1.2596 ~ 1.2598 in)

Piston pin hole inner diameter

32.015 ~ 32.025mm (1.2604 ~ 1.2608 in)

Piston pin hole clearance

0.015 ~ 0.031mm (0.0006 ~ 0.0012 in)

Connecting rod small end inner diameter

32.012 ~ 32.033mm (1.2603 ~ 1.2611 in)

Connecting rod small end hole clearance

0.012 ~ -0.039mm (0.0005 ~ 0.0015 in)

Connecting rod
Connecting rod big end inner diameter

60.833 ~ 60.846mm (2.3950 ~ 2.3955 in)

Connecting rod bearing oil clearance

0.043 ~ 0.077mm (0.0017 ~ 0.0030 in)

End play

0.239~0.39 (0.0094 ~ 0.0154 in)

3°

Crankshaft
Main journal outer
diameter

NO 1, 2, 4, 5

69.995 ~ 70.015mm (2.7557 ~2.7565 in)

NO 3

69.973~69.993mm (2.7548 ~2.7556 in)

Pin journal outer diameter
Main bearing oil
clearance

57.106~57.124mm (2.2483~2.2490 in)

NO 1, 2, 4, 5

0.045 ~ 0.079mm (0.0018 ~0.0031 in)

NO 3

0.067~0.101 mm (0.0026 ~0.0040 in)

End play

0.14 ~ 0.39mm (0.0055 ~0.0154 in)

Flywheel
Runout

0.10mm (0.0039in)

0.13mm (0.0051in)

Oil pump
Relief valve opening pressure

588.40±49.0kpa(6.0±0.5kg/cm²,85.34±7.1psi)

Discharge volume

75L/min(79.25 US qt/min, 65.99 lmp qt/min)
(engine3,800rpm)

Engine oil
Oil quantity (Total)

8.0 L (8.45 US qt, 7.03 lmp qt)

Oil quantity (Oil pan)

6.0 L (6.34 US qt, 5.27 lmp qt)

Oil quantity (Drain and refill including oil filter)

6.6 L (6.97 US qt, 5.08 lmp qt)

Oil quality

ABOVE API CH-4 or ABOVE ACEA B4

Oil pressure (Idle)

78.45 kpa (0.8 kg/cm², 11.38 psi)

Cooling system
Cooling method

Forced circulation with cooling fan

Thermostat

Radiator cap

Type

Wax pellet type

Opening temperature

88±1.5 °C (190.4 ±34.7 °F)

Pull opening
temperature

100 °C (212.0 °F)

Main valve opening
pressure

93.16 ~ 122.58kpa(0.95 ~ 1.25kg/cm², 13.51
~ 17.78psi)

Water temperature sensor
Type

Thermister type

Resistance

20°C (68°F)

2.27~2.64 kΩ

80°C (176°F)

0.31~0.33 kΩ

TIGHTENING TORQUE
Tightening torque

Quantity

N.m

kgf.m

lb-ft

8

36.3 ~ 53.9

3.7 ~ 5.5

26.8 ~ 39.8

Engine mounting insulator and engine mounting
bracket fixing nuts

4

36.3 ~ 53.9

3.7 ~ 5.5

26.8 ~ 39.8

Engine support bracket and engine mounting
insulator fixing nuts

2

36.3 ~ 53.9

3.7 ~ 5.5

26.8 ~ 39.8

Item
Cylinder block
Engine support bracket bolts
Engine mounting

Transaxle mounting bracket and body fixing
bolts

4

36.3 ~ 53.9

3.7 ~ 5.5

26.8 ~ 39.8

Transaxle mounting insulator and transaxle
mounting bracket fixing bolt

1

62.8 ~ 93.2

6.4 ~ 9.5

46.3 ~ 68.7

Transaxle and transaxle mounting insulator
fixing nuts

4

36.3 ~ 53.9

3.7 ~ 5.5

26.8 ~ 39.8

8

68.6→Unfasten
bolts→29.4+90°

7.0 → Unfasten
bolts→3.0+ 90°

50.6→ Unfasten
bolts→21.7+ 90°

10

69.6~79.4+55°~65°

7.1 ~
8.1+55°~65°

51.4~58.6+55°~65°

Flywheel (DMF) bolts (M/T)

8

122.6 ~ 132.4

12.5 ~ 13.5

90.4 ~ 97.6

Drive plate bolts (A/T)

8

159.8 ~ 169.7

16.3 ~ 17.3

117.9 ~ 125.1

Timing belt upper cover bolts

5

6.9 ~ 9.8

0.7 ~ 1.0

5.1 ~ 7.2

Timing belt upper cover nut

1

6.9 ~ 9.8

0.7 ~ 1.0

5.1 ~ 7.2

Timing belt lower cover bolts

8

6.9 ~ 9.8

0.7 ~ 1.0

5.1 ~ 7.2

Crankshaft pulley bolt

1

372.7 ~ 411.9

38.0 ~ 42.0

274.9 ~ 303.8

Camshaft sprocket bolts

2

58.8 ~ 68.6

6.0 ~ 7.0

43.4 ~ 50.6

Timing belt tensioner bolt

1

20.6 ~ 25.5

2.1 ~ 2.6

15.2 ~ 18.8

Timing belt N0. 1 idler bolt

1

39.2 ~ 49.0

4.0 ~ 5.0

28.9 ~ 36.2

Timing belt N0. 2 idler bolt

1

37.3 ~ 43.1

3.8 ~ 4.4

27.5 ~ 31.8

Touch idler bolt

1

20.6 ~ 25.5

2.1 ~ 2.6

15.2 ~ 18.8

High pressure pump puli nut

1

58.8 ~ 68.6

6.0 ~ 7.0

43.4 ~ 50.6

High pressure pump and Timing belt case fixing
bolts

3

21.6 ~ 25.5

2.2 ~ 2.6

15.9 ~ 18.8

High pressure pump bracket bolts (Pump)

2

21.6 ~ 25.5

2.2 ~ 2.6

15.9 ~ 18.8

High pressure pump bracket bolts (Cylinder
block)

2

34.3 ~ 40.2

3.5 ~ 4.1

25.3 ~ 29.7

Timing belt plate bolts

6

6.9 ~ 9.8

0.7 ~ 1.0

5.1 ~ 7.2

Timing belt case bolts (8 X 25)

8

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Timing belt case bolts (8 X 45)

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Timing belt case bolts (8 X 50)

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Timing belt case nut

1

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Balancer gear bolt

1

63.7 ~ 73.5

6.5 ~ 7.5

47.0 ~ 54.2

Oil pump gear bolt

1

33.3 ~ 39.2

3.4 ~ 4.0

24.6 ~ 28.9

Idler gear bolt

1

33.3 ~ 39.2

3.4 ~ 4.0

24.6 ~ 28.9

Cylinder head cover bolts

15

8.8 ~ -10.8

0.9 ~ -1.1

6.5 ~ -8.0

Rocker arm shaft And camshaft bearing cap
bolts

10

17.7 ~ 26.5

1.8 ~ 2.7

13.0 ~ 19.5

Camshaft bearing cap nuts

10

17.7 ~ 26.5

1.8 ~ 2.7

13.0 ~ 19.5

2

7.8 ~ 11.8

0.8 ~ 1.2

5.8 ~ 8.7

Main moving system
Connecting rod cap nuts
Crankshaft main bearing cap bolts

Timing belt

Cylinder head

Front camshaft bearing cap nuts(Small nuts)

Cylinder head bolt (Long bolts)

10

39.2 + 90° + 120°

4.0 + 90° + 120°

28.9 + 90° + 120°

Cylinder head bolt (Short bolts)

8

39.2 + 90°+ 90°

4.0 + 90° + 90°

28.9 + 90°+ 90°

Cooling fan water pump pulley bolts

4

5.9 ~ 9.8

0.6 ~ 1.0

4.3 ~ 7.2

Water pump bolt (Long bolts)

3

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Water pump bolt (Short bolts)

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Water pump and generator brace fixing bolts (8
X 45)

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Thermostat housing and generator strip nuts

2

18.6 ~ 22.6

1.9 ~ 2.3

13.7 ~ 16.6

Thermostat case cover bolts

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil filter

1

21.6 ~ 24.5

2.2 ~ 2.5

15.9 ~ 18.1

Oil cooler bolts (8 X 35)

4

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil cooler bolts (8 X 50)

4

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil cooler nuts

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

29

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil pan drain plug

1

34.3 ~ 44.1

3.5 ~ 4.5

25.3 ~ 32.5

Ladder frame bolts (10 X 45)

5

31.4 ~ 46.1

3.2 ~ 4.7

23.1 ~ 34.0

Ladder frame and oil suppling pipe bolt (8X 50)

1

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Ladder frame bracket (Oil pump and ladder
frame fixing) bolts

2

31.4 ~ 46.1

3.2 ~ 4.7

23.1 ~ 34.0

Oil supplying pipe and oil pump fixing bolts (8
X16)

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil supplying pipe and Ladder frame fixing bolts
(8 X 16)

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil pump bolts(10 X 60)

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil pump bolt(8 X 30)

1

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil screen nuts

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil pressure switch

1

14.7 ~ 46.1

1.5 ~ 2.2

10.8 ~ 34.0

Intake manifold and cylinder head fixing bolts(8
X 45)

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Intake manifold and cylinder head fixing bolts(8
X 95)

4

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Intake manifold and cylinder head fixing nuts

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Intake manifold and cylinder head fixing
hexagonal wrench bolt

1

17.7 ~ 26.5

1.8 ~ 2.7

13.0 ~ 19.5

Exhaust manifold and cylinder head fixing nut

9

26.5 ~ 34.3

2.7 ~ 3.5

19.5 ~ 25.3

Exhaust manifold heat cover and exhaust
manifold fixing bolts(6X12)

3

8.8 ~ 12.7

0.9 ~ 1.3

6.5 ~ 9.4

Engine hanger bracket and exhaust manifold
fixing bolts (8 X 18)

2

17.7 ~ 26.5

1.8 ~ 2.7

13.0 ~ 19.5

Exhaust manifold and front muffler fixing nut

2

39.2 ~ 58.8

4.0 ~ 6.0

28.9 ~ 43.4

Cooling system

Lubrication system

Oil pan nuts

Intake and exhaust system

Front muffler CPF(Catalyzed Particulate Filter)
fixing nuts

2

39.2 ~ 58.8

4.0 ~ 6.0

28.9 ~ 43.4

CPF(Catalyzed Particulate Filter) main muffler
fixing nuts

2

39.2 ~ 58.8

4.0 ~ 6.0

28.9 ~ 43.4

Main muffler and tail pipe fixing nuts

2

39.2 ~ 58.8

4.0 ~ 6.0

28.9 ~ 43.4

Timing system
Timing belt

2007 > J2.9L DIESEL CRDI(VGT) >

COMPONENTS

2007 > J2.9L DIESEL CRDI(VGT) >

REMOVAL
Engine removal is not required for this procedure.
1. Remove the battery terminals (A).

2. Install the jack for oil pan.
3. Remove the engine mounting (A).

4. Remove the engine support bracket(A).

5. Remove the drive belt.

6. Remove the water pump pulley.

7. Remove the bolts(B), nut(C) and timing belt upper cover (A).

8. Turn the crankshaft pulley(A), and align its groove with timing mark “T” of the timing belt cover. Check that the
timing mark of camshaft sprocket(B) is aligned with the timing mark of cylinder head cover. (No.1 cylinder
compression TDC position)

9. Remove the crankshaft pulley bolt(A), washer(B) and crankshaft pulley (C).

Using the special tool(09517-21700, 09231-H1000), fix the crankshaft pulley and loosen the bolt(A).
10. Remove the drive belt idler(A).

11. Remove the drive belt auto-tensioner (A).

12. Remove the timing belt lower cover(A).

13. Remove the auto-tensioner(A) with the timing belt.

In reusing the timing belt, install the belt with the arrow mark facing to rotating direction.
14. Remove the timing belt sprocket(A).

15. Remove the timing belt No.1 idler(A).

16. Remove the timing belt No.2 idler(A).

17. Remove the touch idler(A).

18. Fix the high pressure pump pulley, using the setting bolt(B) for the pulley not to be rotated.

19. Remove the high pressure pulley nut(A), with the washer(B), pulley(C).

Using SST, remove the pulley. (Refer to FL group).
20. Using SST(09231-4X100), remove the camshaft pulley.

INSTALLATION
1. Using SST (09231-4X100), install the camshaft pulley.
Tightening torque :
58.8~68.6Nm (6.0~7.0kgf.m, 43.4 ~ 50.6lb-ft)

2. After installing the high pressure pump pulley(A), tighten the high pressure pump pulley nut with the setting bolt(B)
for the pulley not to be rotated.
Tightening torque :
58.8~68.6Nm (6.0~7.0kgf.m, 43.4 ~ 50.6lb-ft)

3. Install the touch idler(A).
Tightening torque :
7.8 ~ 9.8Nm (2.1~2.6kgf.m, 5.8 ~ 7.2lb-ft)

4. Install the timing belt No.2 idler(A).
Tightening torque :
7.8 ~ 9.8Nm (3.8~4.4kgf.m, 5.8 ~ 7.2lb-ft)

Ensure the location of idlers.
No.1 idler : 60mm(2.3622in)
No.2 idler : 55mm(2.1654in)

5. Install the timing belt No.1 idler(A).
Tightening torque :
7.8 ~ 9.8Nm (4.0~5.0kgf.m, 5.8 ~ 7.2lb-ft)

6. Install the timing belt sprocket(A).

7. Check that the timing mark of camshaft pulley(A), high pressure pump pulley(B) and crankshaft pulley(c).

8. Install the timing belt.
Crankshaft sprocket pulley(A)→No.2 idler(B)→High pressure pump pulley (C) → No.1 idler(D) → camshaft sprocket
pulley (E)

Because the auto-tensioner should be installed after the timing belt, be careful about the tension of the belt
before the installation of the auto-tensioner.

before the installation of the auto-tensioner.

9. Install the auto-tensioner as shown below which the tensioner fork(back plate)(A) positioned around the dowel
pin(B).

Be careful for the auto-tensioner not to be stained with oil. If so, replace the auto-tensioner with a new one.
The location of the pointer, the back plate and the special washer is as shown.
10. Adjust the tension of the timing belt.
(1) Adjust the location of the pointer (B) aligning the tensioner fork(back plate)(C) as shown below by turning the
special washer(A) counterclockwise with a hexagonal wrench.

(2) When aligning the pointer(A) with the tensioner fork(back plate)(B), tighten the tensioner mounting bolt with
fixing the special washer not to move by a hexagonal wrench.
Tightening torque :
19.6~25.5Nm (2.0~2.6kgf.m, 14.5~18.8lb-ft)

(3) Remove the hexagonal wrench.

If the pointer is not aligned with the tensioner fork(back plate), replace the belt with a new one and adjust
them again.
11. Align the timing marks of the crankshaft sprocket, the camshaft sprocket and the high pressure pump pulley by
turning the crankshaft clockwise two revolutions.
12. Check that the location of the pointer is aligned with the tensioner fork (back plate).
The margin of error : ± 5°

If the location of the pointer is not within the margin of error, repeat the steps 10)~12).
13. Install the timing belt lower cover(A).
Tightening torque :
6.9~9.8Nm (0.7 ~ 1.0kgf.m, 5.1 ~ 7.2lb-ft)

14. Install the drive belt idler(A).
Tightening torque :
37.3Nm (3.8kgf.m, 27.5lb-ft)

15. Install the drive belt auto-tensioner (A).
Tightening torque :
15.7~22.6Nm (1.6 ~ 2.3kgf.m, 11.6 ~ 16.6lb-ft)

16. Install the crankshaft pulley bolt(A), washer(B) and crankshaft pulley (A).
Tightening torque :
376.6~411.9Nm (38.4~42.0kgf.m, 277.7~303.8lb-ft)

Using the special tool(09517-21700, 09231-H1000).
17. Install the bolts(B), nut(C) and timing belt upper cover (A).
Tightening torque :
6.9~9.8Nm (0.7 ~ 1.0kgf.m, 5.1 ~ 7.2lb-ft)

18. Install the water pump pulley.
Tightening torque :
5.9~9.8Nm (0.6 ~ 1.0kgf.m, 4.3 ~ 7.2lb-ft)

19. Install the drive belt.

20. Check that the ‘A’ part of the drivebelt auto-tensioner is aligned as shown below. If not, replace the drivebelt.

21. Install the engine support bracket(A).
Tightening torque :
49.0~63.7Nm (5.0 ~ 6.5kgf.m, 36.2 ~ 47.0lb-ft)

22. Install the engine mounting (A).
Tightening torque :
88.3~107.9Nm (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft)

23. Remove the jack for oil pan.
24. Install the battery terminals (A).

INSPECTION
SPROCKETS, TENSIONER, IDLER
1. Check the camshaft sprocket, crankshaft sprocket, tensioner pulley, and idler pulley for abnormal wear, cracks, or
damage. Replace as necessary.
2. Inspect the tensioner pulley and the idler pulley for easy and smooth rotation and check for play or noise. Replace
as necessary.

3. Replace the pulley if there is a grease leak from its bearing.

TIMING BELT
1. Check the belt for oil or dust deposits.
Replace, if necessary.
Small deposits should be wiped away with a dry cloth or paper. Do not clean with solvent.
2. When the engine is overhauled or belt tension adjusted, check the carefully. If any of the following flaws are
evident, replace the belt.

a. Do not bend, twist or turn the timing belt inside out.
b. Do not allow timing belt to come into contact with oil, water and steam.

Cylinder Head Assembly

2007 > J2.9L DIESEL CRDI(VGT) >

COMPONENTS

2007 > J2.9L DIESEL CRDI(VGT) >

REMOVAL
Engine removal is not required for this procedure.

a. To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal
temperature before removing it.
b. When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.
c. To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

a. Mark all wiring and hoses to avoid misconnection.
b. Inspect the timing belt before removing the cylinder head.
c. Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
1. Remove the battery(A).

2. Drain the engine coolant.
Remove the radiator cap to speed draining.
3. Remove the intake air hose and air cleaner assembly.
(1) Disconnect the AFS(Air Flow Sensor) connector(A).

(2) Disconnect the air cleaner upper cover(A).

(3) Remove the air cleaner assembly(A).

(4) Remove the air intake hose(A).

4. Remove the radiator upper hose(A).

5. Remove the reservoir tank hose(A).

6. Remove the PCV(Positive Crankcase Ventilation) hose(A), EGR valve vacuum hose(B), EGR cooler water hose(C),
pump vacuum oil hose(D).

7. Remove the intercooler hose(A,C), pipe(B).

8. Remove the wiring connectors and clamps from cylinder head and intake manifold.
(1) Remove the generator connector (A) and ETC(Engine Coolant Temperature) sensor connector (B).

(2) Remove the injector connector(A), common rail pressure sensor connector(B), wire harness protector(C).

(3) Remove the ground cable(A) from cylinder head.

(4) Remove the knock sensor connector (A), high pressure pump fuel hose (B), high pressure pump connector(C).

(5) Remove the air conditioner condenser (A).

(6) Remove the oil pressure switch connector (A).

(7) Remove the air heater (A), CMP (Camshaft Position Sensor) connector (B).

9. Remove the injection pipe, injector. (Refer to FL- injector.)
10. Remove the exhaust manifold.
11. Remove the intake manifold.
12. Remove the timing belt.
13. Remove the hose(C, D) and pipe (E) from. the ventilation housing(A) and the air separator(B).

14. Remove the oil pipe (B) and hose(C) from the generator vacuum pump (A).

15. Remove the generator fixing bolts(B,C), nuts(D) and then the generator(A).

16. After removing the water hose(C) from the thermostat housing (B), remove the generator fixing bracket (A) and
the thermostat housing (B).

17. Remove the cylinder head cover(A).

18. Remove the timing belt plate(A).

19. Remove the rockerarm shaft(A).

20. Remove the camshaft bearing caps(A).

21. Remove the camshaft(A).

22. Remove the cylinder head bolts, then remove the cylinder head.
(1) Remove the 18 cylinder head bolts, in several steps and the sequence shown below.

Head warpage or cracking could result from removing bolts in an incorrect order.
(2) Lift the cylinder head from the dowels on the cylinder block and replace the cylinder head on wooden blocks
on a bench.

Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

INSTALLATION

a.
b.
c.
d.

Thoroughly clean all parts to be assembled.
Always use a new cylinder head and manifold gasket.
The cylinder head gasket is a metal gasket. Take care not to bend it.
Rotating the crankshaft, set the No. 1 piston at TDC.

1. Install the cylinder head gasket(A) on the cylinder block.

Ensure the installation direction.

2. Place the cylinder head quietly in order not to damage the gasket with the bottom part of the end.
3. Install the cylinder head bolts.
(1) Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts.

After measuring the length of the cylinder head bolts, replace them, if necessary.
Long bolts : 132mm(5.1968in)
Short bolts :93mm(3.6614in)
(2) Install and tighten the 18 cylinder head bolts and plate washers, in several passes, in the sequence shown.
Tightening torque :
Long bolts: 39.2Nm (4.0kgf.m, 28.9lb-ft)+ 90° + 120°
Short bolts: 39.2Nm (4.0kgf.m, 28.9lb-ft)+ 90° + 90°

4. Install the camshaft(A) on the cylinder head.

Apply sealant before assembling the front bearing caps
(LOCTITE NO. 518 or equivalent).

5. Install the bearing caps aligning the cap numbers with the direction of the arrow marks.

6. Install the rockerarm shaft assembly(A) after bearing cap.
Tightening torque :
Nuts, Bolts: 17.7~26.5Nm (1.8 ~ 2.7kgf.m, 13.0~19.5lb-ft)
Small nuts: 7.8~11.8Nm (0.8 ~ 1.2kgf.m, 5.8~8.7lb-ft)

Distinguish between the intake and the exhaust rocker arm shaft (Intake: yellow, exhaust: black).

7. Install the camshaft oil seal.
8. Install the timing belt plate(A).
Tightening torque :
6.9~9.8Nm (0.7~1.0kgf.m, 5.1~7.2lb-ft)

9. Install the cylinder head cover.
(1) Apply sealant on the cylinder head as shown below.

(2) Before installing the cylinder head cover, check the clearance (A) between dowel pin on the edge of the
camshaft and the phase sensor.
Clearance (A) :
0.5 ~ 1.5mm (0.0197 ~ 0.0591in.)

(3) Install the cover (A) to the cylinder head after the gasket.
Tightening torque :
8.8~10.8Nm (0.9~1.1kgf.m, 6.5~8.0lb-ft)

10. Install the thermostat housing (B), the generator fixing bracket (A), and the water hose(C).
Tightening torque :
18.6~27.5Nm (1.9~2.8kgf.m, 13.7~20.3lb-ft)

11. Install the generator(A) with the fixing bolts(B,C), nut(D).
Tightening torque :
38.2~58.8Nm (3.9~6.0kgf.m, 28.2~43.4lb-ft)

12. Install the oil pipe(B), hose(C) to generator pressure pump(A).
Oil pipe eyd bolt
Tightening torque :
19.6~24.5Nm (2.0~2.5kgf.m, 14.5~18.1lb-ft)

13. Install the hose(C,D) and the pipe(E) to the ventilation housing(A) and the air separator(B).

14. Install the timing belt.
15. Install the intake manifold.
16. Install the exhaust manifold.
17. Install the injection pipe, injector. (Refer to FL- injector.)
18. Install the wire harness and the clamp to the cylinder head and the intake manifold.
(1) Install the air heater(A), CMP (Camshaft Position Sensor) connector(B).

(2) Install the oil pressure switch connector(A).

(3) Install the air conditioner condenser(A).

(4) Install the knock sensor connector(A), high pressure pump fuel hose(B), high pressure pump connector(C).

(5) Install the ground cable(A) from cylinder head.

(6) Install the injector connector(A), common rail pressure sensor connector(B), wire harness protector(C).

(7) Install the generator connector(A) and the ETC(Engine Coolant Temperature) sensor connector(B).

19. Install the intercooler hose(A,C), pipe(B).

20. Install the PCV(Positive Crankcase Ventilation) hose(A), EGR valve vacuum hose(B), EGR cooler water hose(C),
pump vacuum oil hose(D).

21. Install the reservoir tank hose(A).

22. Install the radiator upper hose(A).

23. Install the intake air hose and air cleaner assembly.
(1) Install the air intake hose(A).

(2) Install the air cleaner assembly(A).

(3) Install the air cleaner upper cover(A).

(4) Install the AFS(Air Flow Sensor) connector(A).

24. Fill with engine coolant.
25. Install the battery(A).

26. Start engine and check for leaks.
27. Check the engine coolant and engine oil level.

DISASSEMBLY
1. Remove the valves.
(1) Using the SST (0K9993 120 004, 0K993 120 001), compress the valve spring and remove the retainer lock.

(2) Remove the spring retainer.
(3) Remove the valve spring.
(4) Remove the valve.
(5) Using a needle-nose pliers, remove the oil seal.
(6) Using a magnetic finger, remove the spring seat.

INSPECTION
CYLINDER HEAD
1. Inspect for flatness.
Using a precision straight edge and feeler gauge, measure the surface the contacting the cylinder block and the
manifolds for warpage.
Flatness of cylinder head gasket surface
Less than 0.05mm (0.0020in)
Flatness of manifold mating surface
Less than 0.15mm (0.0059in)

2. Inspect for cracks.
Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked,
replace the cylinder head.

VALVE AND VALVE SPRING

1. Inspect the valve stems and valve guides.
(1) Using a caliper gauge, measure the innner diameter of valve guide.
Valve guide inner diameter :
7.010~7.030mm (0.2760~0.2768in)

(2) Using a micrometer, measure the outer diameter of valve stem.
Valve stem outer diameter
Intake : 6.965~6.980mm (0.2742~0.2748in)
Exhaust : 6.945~6.960mm (0.2734~0.2740in)

(3) Subtract the valve stem outer diameter measurement from the valve guide innner diameter measurement.
Valve stem- to-guide clearance
Intake : 0.030 ~ 0.065mm (0.0012 ~ 0.0026in)
Exhaust : 0.050 ~ 0.085mm (0.0020 ~ 0.0033in)
If the clearance is greater than maximum, replace the valve and valve guide.
2. Inspect the valves.
(1) Check the valve is ground to the correct valve face angle.
(2) Check that the surface of valve for wear.
If the valve face is worn, replace the valve.
(3) Check the valve head margin thickness.
If the margin thickness is less than minimum, replace the valve.
Margin
Intake : 1.7mm (0.0669in)
Exhaust : 1.6mm (0.0630in)

(4) Check the surface of valve stem tip for wear.
If the valve stem tip is worn, replace the valve.
3. Inspect the valve seats.
(1) Check the valve seat for evidence of overheating and improper contact with the valve face.
Replace the seat if necessary.
(2) Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace it, then
recondition the seat.
(3) Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width should be within

4. Inspect the valve springs.
(1) Using a steel square, measure the out-of-square of valve spring.
(2) Using a vernier calipers, measure the free length of valve spring.
Valve spring
Free height : 52.477mm (2.0660in)
Installed load: 51.7±4.1kg/40.0mm(41.4±2.0lb/1.5748in)
Compressed load:86.3±6.9kg/31.65mm(41.4±2.0lb/1.2461in) (Intake)
86.9±6.9kg/31.50mm(41.4±2.0lb/1.2402in) (Exhaust)
Out of square : Less than 2°

If the loads is not as specified, replace the valve spring.

CAMSHAFT
1. Inspect the cam lobes.
Using a micrometer, measure the cam lobe height.
Cam height
Intake : 39.397~39.597mm (1.5511~1.5589in)
Exhaust : 39.4932~39.6932mm (1.5548~1.5627in)

If the cam lobe height is less than minimum, replace the camshaft.
2. Inspect the camshaft journal clearance.
(1) Clean the bearing caps and camshaft journals.
(2) Place the camshafts on the cylinder head.
(3) Lay a strip of plastigage across each of the camshaft journal.

(4) Install the bearing caps and tighten the bolts with specified torque.

Do not turn the camshaft.

(5) Remove the bearing caps.
(6) Measure the plastigage at its widest point.
Bearing oil clearance
Standard : 0.040 ~ 0.080mm (0.0016 ~ 0.0031in)

If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and
cylinder head as a set.
(7) Completely remove the plastigage.
(8) Remove the camshafts.
3. Inspect the camshaft end play.
(1) Install the camshafts.
(2) Using a dial indicator, measure the end play while moving the camshaft back and forth.
Camshaft end play
Standard : 0.08 ~ 0.17mm (0.0031 ~ 0.0067in)

If the end play is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and
cylinder head as a set.
(3) Remove the camshafts.

Rockerarm and rockerarm shaft
1. Inspect the rockerarm and rockerarm shaft.
(1) Measure the inner diameter of the rocker arm, using a caliper gauge.
Rockerarm inner diameter
20.000~20.027mm (0.7874~0.7885in)
(2) Measure the inner diameter of the rocker arm, using a micro meter.

Rockerarm shaft outer diameter
19.959~19.980mm (0.7858~0.7866in)
Calculate the clearance between the rocker arm and the rocker arm shaft by the difference between the inner
and outer diameter of the rocker arm.
Rockerarm and rockerarm shaft clearance
0.020~0.068mm (0.0008~0.0027in)
If the clearance is out of the specification above, replace the rocker arm and rocker arm shaft.

HLA (HYDRAULIC LASH ADJUSTER)
Sieze the ‘A’ part of the HLA filled with engine oil. If it is moved when pushed the ‘B’ part by hand, replace it.

Problem
Temporary noise when startinga
cold engine

Possible cause

Action

Normal

This noise will disappear afterthe
oil in the engine reachesthe
normal pressure.

Continuous noise when theengine
Oil leakage of the high pressurechamber on
is started after parkingmore than
the HLA, allowingair to get in.
48 hours.

Noise will disappear within
15minutes when engine runs
at2,000~3,000 rpm.If it
doesn’tdisappear, refer to step 7
below.

Continuous noise when theengine
is first started afterrebuilding
Insufficient oil in cylinder head oil gallery.
cylinder head.
Continuous noise when theengine Oil leakage of the high-pressure chamber in
is started after excessively
the HLA, allowing air to get in.
cranking the engine by the starter Insufficient oil in the HLA.
motor.

Do not run engine at a speed
higher than 3,000 rpm, as this
may damage the HLA.

Continuous noise when the
engine is running after changing
the HLA.
Continuous noise during idleafter
high engine speed.

Engine oil level too high or too low.
Excessive amount of air in theoil at high
engine speed.

Noise continues for morethan 15
minutes.

Check oil level.
Drain or add oil as necessary.
Check oil supply system

Deteriorated oil.

Check oil quality.
If deteriorated, replace with
specified type.

Low oil pressure

Check oil pressure and oil
supplysystem of each part of
engine.

Faulty HLA.

Remove the cylinder head
coverand press HLA down by
hand.If it moves, replace the HLA.

Be careful with the hot HLAs.

REASSEMBLY

a. Thoroughly clean all parts to be assembled.
b. Before installing the parts, apply fresh engine oil to all sliding and rotating surface.
c. Replace oil seals with new ones.
1. Install the valves.
(1) Install the spring seats.
(2) Using the SST (09222 — 22001), push in a new oil seal.

Do not reuse old valve stem oil seals.
Incorrect installation of the seal could result in oil leakage past the valve guides.

(3) Install the valve, valve spring and spring retainer.

Place the valve springs so that the side coated with enamel faces toward the valve spring retainer and
then installs the retainer.
(4) Using the SST(0K993 120 004, 0K993 120 001), compress the spring and install the retainer locks. After
installing the valves, ensure that the retainer locks are correctly in place before releasing the valve spring
compressor.

(5) Lightly tap the end of each valve stem two or three times with the wooden handle of a hammer to ensure
proper seating of the valve and retainer lock.

proper seating of the valve and retainer lock.

Engine
And
Transaxle Assembly

2007 > J2.9L DIESEL CRDI(VGT) >

REMOVAL

a. Use fender covers to avoid damaging painted surfaces.
b. To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

a. Mark all wiring and hoses to avoid misconnection.
1. Remove the battery(A).

2. Remove the under cover(A).

3. Drain the engine coolant.
Remove the radiator cap to speed draining.
4. Drain the engine oil.
Remove the oil filler cap to speed draining.
5. Remove the intake air hose and air cleaner assembly.
(1) Disconnect the AFS(Air Flow Sensor) connector(A).

(2) Disconnect the air cleaner upper cover(A).

(3) Remove the air cleaner assembly(A).

(4) Remove the air intake hose(A).

6. Remove the batter tray(A).

7. Remove the radiator upper hose(A).

8. Remove the radiator lower hose(A).

9. Remove the reservoir tank hose(A).

10. Remove the intercooler hose(A,C), pipe(B).

11. Remove the wire harness and the clamp from the cylinder head and the intake manifold.
(1) Remove the generator connector(A) and the ETC(Engine Coolant Temperature) sensor connector(B).

(2) Remove the injector connector(A), common rail pressure sensor connector(B), wire harness protector(C).

(3) Remove the ground cable(A) from cylinder head.

(4) Remove the knock sensor connector(A), high pressure pump fuel hose(B), high pressure pump connector(C).

(5) Remove the air conditioner condenser(A).

(6) Remove the oil pressure switch connector(A).

(7) Remove the air heater(A), CMP (Camshaft Position Sensor) connector(B).

12. Remove the transaxle wire harness connectors and control cable.
(1) Remove the inhibitor switch connector(A).

(2) Remove the solenoid valve connector(A).

(3) Remove the input shaft speed sensor connector(A).

(4) Remove the output shaft speed sensor connector(A).

(5) Remove the vehicle speed sensor connector(A).

(6) Remove the CKP(Crankshaft position sensor) connector(A).

13. Remove the shift cable(A).

14. Remove the transaxle oil cooler hoses(A).

15. Remove the ground cable(A) from transaxle.

16. Remove the fuse box.(A).

17. Remove the vacuum hose (A) from the generator.

18. Remove the heater hose(A,B).

19. Remove the starter motor connector(A).

20. Remove the front exhaust manifold(A).
Tightening torque :
39.2~58.8Nm (4.0~6.0kgf.m, 28.9~43.4lb-ft)

21. Remove the power steering pump bolt(A).

22. Remove the power steering return hose(A).

23. Remove the engine mounting support bracket(A).
Tightening torque :
88.3~107.9N.m (9.0~11.0kgf.m, 65.1~79.6lb-ft)

24. Remove the transaxle insulator mounting bolt(A).
Tightening torque :
88.3~107.9N.m (9.0~11.0kgf.m, 65.1~79.6lb-ft)

25. Remove the front tires.(Refer to DS group).
26. Remove the ABS wheel speed sensors(A).(Refer to BR group).

27. Remove the caliper and hang the caliper assembly(A).(Refer to BR group).
28. Remove the knuckle mounting bolts(B).(Refer to SS group).
29. Remove the stabilizer link fixing nut(A).(Refer to SS group).

30. Remove the steering u-joint mounting bolt(A).

31. Install the jack for supporting engine and transaxle assembly.

Support the assembly safely because the engine and transaxle assembly can be dropped down after removal
of the sub frame.
32. Remove the sub frame mounting bolts(A).
Tightening torque :
Bolt(A): 156.9~ 176.5Nm (16.0~18.0kgf.m, 115.7~ 130.2lb-ft)
Bolts(B) :44.1~58.8Nm (4.5~6.0kgf.m, 32.5~43.4lb-ft)

33. Remove the engine and transaxle assembly by lifting vehicle.

When remove the engine and transaxle assembly, be careful not to damage any surrounding parts or body
components.

INSTALLATION
Installation is in the reverse order of removal.
Perform the following :
a. Adjust the shift cable.
b. Adjust the throttle cable.
c. Refill the engine with engine oil.
d. Refill the transaxle with fluid.
e. Refill the radiator and reservoir tank with engine coolant.
f. Place the heater control knob on “HOT” positon.
g. Bleed air from the cooling system.
a. Start engine and let it run until it warms up. (until the radiator fan operates 3 or 4 times.)
b. Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be
removed from the cooling system.

removed from the cooling system.
c. Put the radiator cap on tightly, then run the engine again and check for leaks.
h. Clean the battery posts and cable terminals with sandpaper assemble them, then apply grease to prevent
corrosion.
i. Inspect for fuel leakage.
a. After assemble the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for
approximately two seconds and fuel line pressurizes.
b. Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.

Cylinder Block

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2007 > J2.9L DIESEL CRDI(VGT) >

COMPONENTS

2007 > J2.9L DIESEL CRDI(VGT) >

DISASSEMBLY
1. Install the engine to engine stand for disassembly.
2. Remove the timing belt.
3. Remove the cylinder head.
4. Remove the water pump.
5. Remove the air separator(A), hose(B).

6. Remove the oil cooler assembly(A), knock sensor(B).

7. Remove the drive belt auto-tensioner (A).

8. Remove the generator mounting bracket(A), power steering pump bracket(B).

9. Remove the A/C compressor bracket(A).

10. M/T : remove flywheel.
11. A/T : remove drive plate and mass wheel.
12. Using the SST(09215 — 3C000) remove the oil pan(A).

13. Remove the oil pump feed pipe(A) and the ladder frame bracket(B).

14. Remove the ladder frame(A) and the oil pump assembly(B).

15. Remove the balancer shaft(A) to the ladder frame.
(1) Remove the gear cover(A) to the ladder frame.

(2) Remove the balancer sprocket and the balancer gear by loosening the bolts(B).

Not to make the balance shaft be rotated, insert the 5mm-thickeness urethane rubber (B) in the balance
gear (A) for protection.

(3) Remove the thrust plate and the balance shaft.
16. Remove the timing belt case(A).

17. Check the connecting rod end play.
18. Remove the connecting rod caps and check oil clearance.
19. Remove the piston and connecting rod assemblies.
(1) Using a ridge reamer, remove all the carbon from the top of the cylinder.
(2) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

a. Keep the bearings, connecting rod and cap together.
b. Arrange the piston and connecting rod assemblies in the correct order.
20. Remove the rear oil seal case.
Remove the 5 bolts(B) and the rear oil seal case(A).

21. Remove the crankshaft bearing cap and check oil clearance.
22. Check the crankshaft end play.
23. Lift the crankshaft(A) out of the engine, being careful not to damage journals.

Arrange the main bearings and thrust bearings in the correct order.
24. Check fit between piston and piston pin.
25. Remove the piston rings.
(1) Using a piston ring expender, remove the 2 compression rings.
(2) Remove the 2 side rails and oil ring by hand.

Arrange the piston rings in the correct order only.

26. Remove the connecting rod from the piston.
Using a press, remove the piston pin from piston.

INSPECTION
CONNECTING ROD AND CRANKSHAFT
1. Check the connecting rod end play.
Using feeler gauge, measure the end play while moving the connecting rod back and forth.
End play
0.239 ~ 0.39mm (0.0094 ~ 0.0154in)

a. If out-of-tolerance, install a new connecting rod.
b. If still out-of-tolerance, replace the crankshaft.
2. Check the connecting rod bearing oil clearance.
(1) Check the match marks on the connecting rod and cap are aligned to ensure correct reassembly.

(2) Remove the 2 connecting rod cap nuts.
(3) Remove the connecting rod cap and lower bearing.
(4) Clean the crankshaft pin journal and bearing.
(5) Place a plastigage across the crankshaft pin journal.
(6) Reinstall the lower bearing and cap, and tighten the nuts.
Tightening torque :
68.6Nm (7.0 kgf.m, 50.6lb-ft) → Unfasten bolts→29.4Nm (3.0kgf.m, 21.7lb-ft) + 90°

Do not turn the crankshaft.
(7) Remove the 2nuts, connecting rod cap and lower bearing .

(8) Measure the plastigage at its widest point.
Standard oil clearance
0.043 ~ 0.077mm (0.0017 ~ 0.0030in)

(9) If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then install a new
bearings with the same color mark. (Refer to connecting rod bearing selection table)
Recheck the oil clearance.

Do not file, shim, of scrape the bearings or the caps to adjust clearance.
(10) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing. ( Refer to
connecting rod bearing selection table))
Recheck the oil clearance.

If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace
the crankshaft and start over.

If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a
wire brush or scraper. Clean them only with solvent or detergent.

Connecting rod mark location

Discrimination of connecting rod
Mark

Connecting rod big-endinner diameter

1

60.833 ~ 60.839mm
(2.3950 ~ 2.3952 in)

60.839 ~ 60.846mm
(2.3952 ~ 2.3955 in)

2
CRANKSHAFT PIN JOURNAL
Journal outer diameter
57.106~57.124mm (2.2483~2.2490in)

CONNECTING ROD BEARING MARK LOCATION

Discrimination of crankshaft pin journal
Color

Connecting rod bearing thickness

Blue

1.0828~1.832mm
(0.0720~0.0721in)

Red

1.832~1.836mm
(0.0721~0.0723in)

(11) Select the bearing by using the selection table.
Connecting rod bearing selection table
Connecting rod mark

Connecting rod bearing thickness

Oil clearance

1

Blue

0.045~0.077mm(0.0018~0.0030in)

2

Red

0.043~0.076mm(0.0017~0.0030in)

3. Check the connecting rods.
(1) When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at disassembly match.
When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the
same side.
(2) Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a severely
rough surface of the inside diameter of the small end is apparent, the rod must be replaced as well.
(3) Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is close to the
repair limit, correct the rod by a press. Any connecting rod that has been severely bent or distorted should be
replaced.
Allowable bend of connecting rod :
0.04mm / 50mm (0.0016in / 1.9685in ) or less
Allowable twist of connecting rod :
0.1mm / 50mm (0.0039in / 1.9685in) or less
4. Check the crankshaft bearing oil clearance.
(1) To check main bearing-to-journal oil clearance, remove the main bearing caps and lower bearings.

(2) Clean each main journal and lower bearing with a clean shop towel.
(3) Place one strip of plastigage across each main journal.
(4) Reinstall the lower bearings and caps, then tighten the bolts.
Tightening torque :
69.6~79.4Nm(7.1~8.1kgf.m, 51.4~58.6lb-ft)+55°~ 65°

Do not turn the crankshaft.

(5) Remove the cap and lower bearing again, and measure the widest part of the plastigage.
Standard oil clearance :
No.1, 2, 3, 5: 0.045~0.079mm (0.0018 ~0.0031 in)
No.3: 0.067~0.101 mm (0.0026 ~0.0040 in)

(6) If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then install a new
bearings with the same color mark. (Refer to crankshaft main bearing selection table).
Recheck the oil clearance.

Do not file, shim, or scrape the bearings or the cap to adjust clearance.
(7) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing. (Refer to crankshaft
main bearing selection table).
Recheck the oil clearance.

If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the
crankshaft and start over.

If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire
brush or scraper. Clean them only with solvent or detergent.
CYLINDER BLOCK CRANKSHAFT JOURNAL BORE MARK LOCATION
Letters have been stamped on the end of the block as a mark for the size of each of the 5 main journal bores.
Use them, and the numbers or letters stamped on the crank (marks for main journal size), to choose the correct
bearings.

Discrimination of cylinder block crankshaft journal bore
Mark

Cylinder block crankshaft journal bore inner diameter

A

74.066~74.075mm
(2.9160~2.9163in)

None

74.075~74.084mm
(2.9163~2.9167in)

C

74.084~74.092mm
(2.9167~2.9170in)

Crankshaft main journal mark location

Discrimination of crankshaft main journal
Mark

Crankshaft main journalouter diameter
No.1, 2, 3, 5 journal

No.3 journal

1

69.995~70.002mm(2.7557~2.7560in)

69.973~69.980mm(2.7548~2.7551in)

*

70.002~70.009mm(2.7560~2.7563in)

69.980~69.987mm(2.7551~2.7554in)

3

70.009~70.015mm(2.7563~2.7565in)

69.987~69.993mm(2.7554~2.7556in)

Crankshaft main bearing mark location

Discrimination of crankshaft bearing
Color

Crankshaft bearing thickness

Black

2.013 ~ 2.018mm(0.0793~0.0794in)

Brown

2.008 ~ 2.013mm(0.0791~0.0793in)

Green

2.003 ~ 2.008mm(0.0789~0.0791in)

Yellow

1.998 ~ 2.003mm(0.0787~0.0789in)

(8) Select the bearing by using selection table.
Crankshaft main bearing selection table
Cylinder block crankshaft journal bore mark

Crank shaft main
journal mark

A

None

C

A

(Green)

(Brown)

(Black)

*

(Yellow)

(Green)

(Brown)

C

(Yellow)

(Yellow)

(Green)

5. Check the crankshaft end play.
Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
End play
Standard: 0.14~ 0.39mm (0.0055 ~ 0.0154in)

If the end play is greater than maximum, replace the thrust bearings as a set.
6. Inspect the crankshaft main journals and pin journals.
Using a micrometer, measure the diameter of each main journal and pin journal.
Main journal outer diameter :
NO.1, 2, 3, 5: 69.995 ~ 70.015mm (2.7557 ~2.7565 in)

NO.3: 69.973~69.993 mm (2.7548 ~2.7556 in)
Pin journal outer diameter :
57.106 ~ 57.124mm (2.2483 ~2.2490 in)

CYLINDER BLOCK
1. Remove the gasket material.
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean the cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder block.
3. Inspect the top surface of cylinder block for flatness.
Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for
warpage.
Flatness of cylinder block gasket surface Standard:
Less than 0.05mm (0.0020in)

4. Inspect the cylinder bore.
Visually check the cylinder for vertical scratchs.
If deep scratchs are present, replace the cylinder block.
5. Inspect the cylinder bore diameter.
Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial direction.
Standard diameter :
97.100~97.126mm (3.8228~3.8239in)

6. Check the cylinder bore size code on the cylinder block bottom face.

Cylinder bore inner diameter mark location

Discrimination of cylinder bore inner diameter
Mark

Cylinder bore inner diameter

Y

101.513~101.526mm
(3.9966~3.9971in)

X

101.500~101.513mm
(3.9961~3.9966in)

Cylinder liner classifying mark location

The outer discrimination mark of the cylinder liner is on the outer surface of the liner and the inner mark is on
the top surface of it.

Discrimination of cylinder liner
Mark

Outer diameter (mm)

Mark

Inner diameter (mm)

3Y

101.493~101.506mm(3.9958~3.9963in)

Yellow

97.113~97.126mm(3.8233 ~ 3.8239in)

3Y

101.493~101.506mm(3.9958~3.9963in)

Blue

97.100~97.113mm(3.8228~ 3.8233in)

3X

101.480~101.493mm(3.9953 ~ 3.9958in)

Yellow

97.113~97.126mm(3.8233~3.8239in)

3X

101.480~101.493mm(3.9953 ~ 3.9958in)

Blue

97.100~97.113mm(3.8228~ 3.8233in)

Piston Outer diameter mark location

Discrimination of piston outer diameter
Mark

Piston outer diameter

A

97.015~97.030mm(3.8195~3.8201in)

B

97.030~97.045mm(3.8201~3.8207in)

7. Check the piston size mark on the piston top face.
Cylinder liner selection table
Cylinder bore mark

Cylinder liner mark

Oil clearance

Y

3Y- Yellow

0.007~0.033mm(0.0003~0.0013in)

Y

3Y- Blue

0.007~0.033mm(0.0003~0.0013in)

X

3X- Yellow

0.007~0.033mm(0.0003~0.0013in)

X

3X- Blue

0.007~0.033mm(0.0003~0.0013in)

Cylinder liner mark

Piston outer diameter
mark

Oil clearance

Yellow

B

0.068~0.096mm(0.0027~0.0038in)

Blue

A

0.070~0.098mm(0.0028~0.0039in)

Piston

PISTON AND PISTON RINGS
1. Clean the piston.
(1) Using a gasket scraper, remove the carbon from the piston top.
(2) Using a groove cleaning tool or broken ring, clean the piston ring grooves.
(3) Using solvent and a brush, thoroughly clean the piston.

Do not use a wire brush.

2. The standard measurement of the piston outside diameter is taken 47mm (1.85in) from top land of the piston.
Standard diameter :
97.015~97.045mm (3.8195 ~ 3.8207in)

3. Calculate the difference between the cylinder bore inner diameter and the piston outer diameter.
Piston-to-cylinder clearance :
0.070 ~ 0.098mm (0.0028 ~ 0.0039in)
4. Inspect the piston ring side clearance.
Using a feeler gauge, measure the clearance between new piston ring and the wall of ring groove.
Piston ring side clearance
No. 2 : 0.06 ~ 0.10mm (0.0024 ~ 0.0039in)
Oil ring : 0.03 ~ 0.07mm (0.0012 ~ 0.0028in)

If the clearance is greater than maximum, replace the piston.
5. Inspect the piston ring end gap.
To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles to
the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge. If the gap exceeds
the service limit, replace the piston rings. If the gap is too large, recheck the cylinder bore inner diameter. If the
bore is over the service limit, the cylinder block must be rebored.
Piston ring end gap
Standard
No.1 : 0.25~ 0.40mm (0.0098 ~ 0.0157in)
No.2 : 0.40 ~ 0.55mm (0.0157 ~ 0.0217in)
Oil ring : 0.20 ~ 0.40mm(0.0079 ~ 0.0157in)

PISTON PINS
1. Measure the outer diameter of piston pin.
Piston pin diameter :
31.994~32.000mm (1.2596 ~ 1.2598in)

2. Measure the piston pin-to-piston clearance.
Piston pin hole inner diameter:
32.015~32.025 mm (1.2604~1.2608 in)
0.015~0.031 mm(0.0003~0.0012 in)
3. Check the difference between the piston pin outer diameter and the connecting rod small end inner diameter.
Inside diameter of connecting rod small end bore:
32.012~32.033mm (1.2603~1.2611 in)
0.012~0.039 mm(0.0005~0.0015 in)

4. Apply oil on the piston pin when assembling.

LADDER FRAME AND BALANCE SHAFT
1. Measure the ladder frame inner diameter.
Ladder frame inner diameter
LH1

25.000 ~ 25.021 mm(0.9843~0.9851in)

LH2

54.000 ~ 54.030 mm(2.1260~2.1272in)

LH3

56.000 ~ 56.030 mm(2.2047~2.2059in)

RH1

35.000 ~ 35.025 mm(1.3780~1.3789in)

RH2

54.000 ~ 54.030 mm(2.1260~2.1272in)

RH3

56.000 ~ 56.030 mm(2.2047~2.2059in)

2. Measure the balance shaft outer diameter.
Balance shaft outer diameter
LH1

24.939 ~ 24.960 mm(0.9818~0.9827in)

LH2

53.910 ~ 53.940 mm(2.1224~2.1236in)

LH3

55.910 ~ 55.940 mm(2.2012~2.2024in)

RH1

34.925 ~ 34.950 mm(1.3750~1.3760in)

RH2

53.910 ~ 53.940 mm(2.1224~2.1236in)

RH3

55.910 ~ 55.940 mm(2.2012~2.2024in)

3. Measure the end play of the balance shaft.
0.10~0.25mm (0.0036~0.0098in)

OIL PRESSURE SWITCH
1. Check the continuity between the terminal and the body with an ohmmeter. If there is no continuity, replace the oil
pressure switch.

2. Check the continuity between the terminal and the body when the oil hole is blocked with a fine stick. If there is
continuity with a fine stick is pushed, replace the switch.

3. If there is no continuity when a 49.0kpa (0.5kg/cm², 7.1psi) pressure is applied through the oil hole, the switch is
operating properly.
Check for air leakage. If air leaks, the diaphragm is broken. Replace it.

REASSEMBLY

a. Thoroughly clean all parts to assembled.
b. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
c. Replace all gaskets, O-rings and oil seals with new parts.
1. Assemble the piston and connecting rod.
(1) Insert the piston pin and fix the piston pin clip.
(2) The piston front mark and the connecting rod front mark must face the timing belt side of the engine.

2. Install the piston rings.
(1) Install the oil ring expander and two side rails by hand.

(2) Using a piston ring expander, install the two compression rings with the code mark facing upward.
(3) Position the piston rings so that the ring ends are as shown.

3. Install the connecting rod bearings.
(1) Align the bearing (A) claw with the groove of the connecting rod and bearing cap (B).
(2) Install the bearings (A) in the connecting rod and bearing cap (B).

4. Install the crankshaft main bearings.

Upper bearings have oil grooves of the oil holes; Lower bearings do not.
(1) Aligning the bearing protrusions with the grooves of the cylinder block, push in the 5 upper bearings (A).

(2) Aligning the bearing protrusions with the grooves of the main bearing cap, and push in the 5 lower bearings.
5. Install the thrust bearings.
Install the 2 thrust bearings(A) under the No.3 journal position of the cylinder block with the oil grooves facing
outward.

6. Place the crankshaft on the cylinder block.
7. Place the main bearing caps on the cylinder block.
8. Install the main bearing cap bolts.

a. The main bearing cap bolts are tightened in 2 progressive steps.
b. If any of the bearing cap bolts is broken or deformed, replace it.
(1) Apply a light coat of engine oil on the threads of the main bearing cap bolts.
(2) Install and uniformly tighten the 10 bearing cap bolts (A), in several passes, in the sequence shown.
Tightening torque :
69.6 ~ 79.4Nm (7.1 ~ 8.1kgf.m, 51.4 ~ 58.6lb-ft) + 55° ~ 65°

(3) Check that the crankshaft turns smoothly.
9. Check the crankshaft end play.
10. Install the piston and connecting rod assemblies.

a. Before installing the piston, apply a coat of engine oil to the piston ring grooves and the cylinder bores.
b. When installing the piston pin to the piston, apply engine oil sufficiently
(1) Remove the connecting rod bearing caps and insert short sections of rubber hose over the threaded ends of
the connecting rod bolts.
(2) Install the ring compressor, checking that the rings are securely in place and positioning the piston in the
cylinder, tap it in using the wooden handle of a hammer.
(3) Stop inserting after the ring inserted in the cylinder, and check the connecting rod to crank journal alignment
before complete inserting.
(4) Apply engine oil to the bolt threads after removing rubber hose. Install the connecting rod caps with bearings,
and tighten the nuts.

and tighten the nuts.
Tightening torque :
68.9Nm (7.0kgf.m, 50.6lb-ft) → Loosened →29.4Nm (3.0kgf.m, 21.7lb-ft) + 90°

Maintain downward force on the ring compressor to prevent the rings from expending before entering the
cylinder bore.

11. Install a new gasket and rear oil seal case(A) with 5 bolts(B).
Tightening torque :
7.8 ~ 10.8Nm (0.8 ~ 1.1kgf.m, 5.8 ~ 8.0lb-ft)

Check that the mating surfaces are clean and dry.
12. Install the rear oil seal.
(1) Apply engine oil to a new oil seal lip.
(2) Tap in the rear oil seal until its surface is flush with the rear oil seal retainer edge.
13. Install the balance shaft to the ladder frame.
(1) Install the thrust plate and balance shaft to the ladder frame.
(2) Aligning the timing marks on the balance gear(A), install the balance sprocket.

(3) Tighten the balance sprocket bolt and balance gear bolt(C).
Tightening torque :
Rear balance gear bolt(C)37.3 ~ 52.0Nm (3.8 ~ 5.3kgf.m, 27.5 ~ 38.3lb-ft)
Front balance gear bolt63.7 ~ 73.5Nm (6.5 ~ 7.5kgf.m, 47.0 ~ 54.2lb-ft)

Not to make the balance shaft be rotated, insert the 5mm-thickeness urethane rubber (B) in the balance
gear (A) for protection.

(4) Install the gear cover (A) to the ladder frame and tighten the bolts (B).
Tightening torque :
18.6 ~ 25.5Nm (1.9 ~ 2.6kgf.m, 13.7 ~ 18.8lb-ft)

14. Install the oil screen with a new gasket to the oil pump.

Tightening torque :
15.7 ~ 22.6Nm (1.6 ~ 2.3kgf.m, 11.6 ~ 16.6lb-ft)
15. Install the ladder frame(A) and pump assembly(B) and tighten the bolts(C,D,E).
Tightening torque :
Bolts (C): 31.4 ~ 46.1Nm (3.2 ~ 4.7kgf.m, 23.1 ~ 34.0lb-ft)
Bolts (D): 15.7 ~ 22.6Nm (1.6 ~ 2.3kgf.m, 11.6 ~ 16.6lb-ft)
Bolts (E): 31.4 ~ 46.1Nm (3.2 ~ 4.7kgf.m, 23.1 ~ 34.0lb-ft)

Check that the timing marks on the crankshaft sprocket(A), idler(B) and balance sprocket(C) are aligned.
16. Install the oil pump supplying pipe(A) and ladder frame bracket(B) and tighten the bolts(C,D) as shown below.
Tightening torque :
15.7 ~ 22.6Nm (1.6 ~ 2.3kgf.m, 11.6 ~ 16.6lb-ft)

17. Install the timing belt case.
Length of the bolts :
(A): 25mm, (B): 45mm, (C):50mm, (D): nut
Tightening torque :
15.7 ~ 22.6Nm (1.6 ~ 2.3kgf.m, 11.6 ~ 16.6lb-ft)

18. Install the oil pan.
(1) Remove the gasket from the surface of the oil pan by using a knife or a scraper.

After checking that the contact surface is clean and dry, apply liquid gasket.
(2) Apply liquid gasket on the surface of the oil pan.
Liquid gasket: LOCTITE 5900 or equivalent.

a. Apply liquid gasket on the thread of the bolts in order to prevent oil from being leaked.
b. If the time, five minutes, passes after applying, remove the applied gasket before. Apply it again and
install it.
c. After the minimum 30 minutes passing from assembly, refill engine oil.
(3) Install the oil pan (A) and tighten the oil pan bolts uniformly in several steps.
Tightening torque :
15.7 ~ 22.6Nm (1.6 ~ 2.3kgf.m, 11.6 ~ 16.6lb-ft)

19. Install the fly wheel (manual transaxle vehicles only).
Tightening torque :
122.6 ~ 132.4Nm (12.5 ~ 13.5kgf.m, 90.4 ~ 97.6lb-ft)
20. Install the mass wheel and drive plate (automatic transaxle vehicles only).
Tightening torque :
159.8 ~ 169.7Nm (16.3 ~ 17.3kgf.m, 117.9 ~ 125.1lb-ft)

21. Install the air conditioning compressor bracket (A).
Tightening torque :
BOLT (B):
38.2 ~ 58.8Nm (3.9 ~ 6.0kgf.m, 28.2 ~ 43.4lb-ft)
BOLT (C):
18.6 ~ 27.5Nm (1.9 ~ 2.8kgf.m, 13.7 ~ 20.3lb-ft)

22. Install the generator mounting bracket (A) and the power steering pump bracket (B).
Tightening torque :
BOLT (C):
38.2 ~ 58.8Nm (3.9 ~ 6.0kgf.m, 28.2 ~ 43.4lb-ft)
BOLT (D):
34.3 ~ 53.9Nm (3.5 ~ 5.5kgf.m, 25.3 ~ 39.8lb-ft)
BOLT (E):
68.6 ~ 93.2Nm (7.0 ~ 9.5kgf.m, 50.6 ~ 68.7lb-ft)

23. Install the drive belt auto-tensioner (A).
Tightening torque :
15.7 ~ 22.6Nm (1.6 ~ 2.3kgf.m, 11.6 ~ 16.6lb-ft)

24. Install the oil cooler assembly (A) and the knock sensor (B).
Tightening torque :
Oil cooler bolts:
15.7 ~ 22.6Nm (1.6 ~ 2.3kgf.m, 11.6 ~ 16.6lb-ft)
Knock sensor bolts:
14.7 ~ 24.5Nm (1.5 ~ 2.5kgf.m, 10.8 ~ 18.1lb-ft

25. Install the air separator (A) and hose (B).
Tightening torque :
15.7 ~ 22.6Nm (1.6 ~ 2.3kgf.m, 11.6 ~ 16.6lb-ft)

26. Install the water pump, cylinder head and timing belt in order.
27. Remove the engine stand.

Cooling system

2007 > J2.9L DIESEL CRDI(VGT) >

ENGINE COOLANT REFILLING AND BLEEDING

When pouring engine coolant, be sure to shut the relay box lid and not to let coolant spill on the electrical parts of
the paint. If any coolant spills, rinse it off immediately.
1. Slide the heater temperature control lever to maximum heat. Make sure the engine and radiator are cool to the
touch.
2. Remove the radiator cap(A).

3. Loosen the drain plug(A), and drain the coolant.

4. Tighten the radiator drain plug securely.
5. Remove the coolant reservoir tank. Drain the coolant and reinstall the coolant reservoir tank. Fill the coolant
reservoir tank to the MAX mark with the coolant.
6. Mix the recommended antifreeze with an equal amount of water in a clean container.

a. Use only genuine antifreeze/coolant.
b. For best corrosion protection, the coolant concentration must be maintained year-round at 50% minimum.
Coolant concentrations less than 50% may not provide sufficient protection against corrosion of freezing.
c. Coolant concentrations greater then 60% will impair cooling efficiency and are not recommended.

a. Do not mix different brands of antifreeze/coolants.
b. Do not use additional rust inhibitors or antirust products; they may not be compatible with the coolant.
7. Pour the coolant into the radiator to the base of the filler neck, and install the radiator cap loosely.

8. Start the engine and let it run until it warms up. ( until the radiator fan operates 3 or 4 times.)
9. Turn off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed
from the cooling system.
10. Put the radiator cap on tightly, then run the engine again and check for leaks.

RADIATOR CAP TESTING
1. Remove the radiator cap, wet its seal with engine coolant, then install it no pressure tester.

2. Apply a pressure of 93.16 ~ 122.58kpa (0.95 ~ 1.25kg/cm², 13.51 ~ 17.78psi).
3. Check for a drop in pressure.
4. If the pressure drops, replace the cap.

RADIATOR LEAKGE TEST
1. Wait until engine is cool, then carefully remove the radiator cap and fill the radiator with engine coolant, then install
it on the pressure tester.
2. Apply a pressure tester to the radiator and apply a pressure of 93.16 ~ 122.58kpa (0.95 ~ 1.25kg/cm², 13.51 ~
17.78psi).

3. Inspect for engine coolant leaks and a drop in pressure.
4. Remove the tester and reinstall the radiator cap.

Check for engine oil in the coolant and/or coolant in the engine oil.

2007 > J2.9L DIESEL CRDI(VGT) >

COMPONENTS

2007 > J2.9L DIESEL CRDI(VGT) >

REMOVAL
WATER PUMP
1. Drain the engine coolant.

System is under high pressure when the engine is hot. To avoid danger of releasing scalding engine coolant,
remove the cap only when the engine is cool.
2. Remove the drive belts.
3. Remove the timing belt.
4. Remove the water pump.

THRMOSTAT

Disassembly of the thermostat would have an adverse effect, causing a lowering of cooling efficiency.
1. Drain the engine coolant so its level is below thermostat.
2. Remove the thermostat housing, gasket and thermostat.

RADIATOR
1. Drain the engine coolant.
2. Remove the radiator upper cover(A).

3. Remove the radiator upper hose(A).

4. Remove the radiator lower hose(A).

5. Remove the intercooler hose(A,C), pipe(B).

6. Remove the transaxle oil cooler hose(A).

7. Remove the cooling fan motor connector(A) diagnosis connector(B).

8. Remove the cooling fan motor assembly(A).

9. Remove the radiator upper bracket(A).

10. Remove the radiator bracket(A,B).

11. Remove the intercooler.
12. Remove the radiator.

INSTALLATION

WATER PUMP
1. Install the water pump.
(1) Install the water pump and a new gasket with the bolts, nuts(A,B,C).
Tightening torque :
15.7~22.6Nm (1.6 ~ 2.3kg-m, 11.6~16.6lb-ft)

2. Install the timing belt.
3. Install the water pump pulley, cooling fan.
4. Install the drive belt.
5. Fill with engine coolant.
6. Start engine and check for leaks.
7. Recheck engine coolant level.

THERMOSTAT
1. Install the thermostat housing, thermostat.
2. Install the thermostat bolts.
Tightening torque :
15.7~22.6Nm (1.6 ~ 2.3kgf.m, 11.6~16.6lb-ft)
3. Fill with engine coolant.
4. Start engine and check for leaks.

RADIATOR
1. Install the radiator. Installation is in the reverse order of removal.
2. Install the air conditioner condenser. (Refer to HA- air conditioner condenser).
3. Install the upper and lower radiator hoses.
4. Refill with engine coolant.
5. Start engine and check for leaks.

INSPECTION
WATER PUMP
1. Check each part for cracks, damage or wear, and replace the coolant pump assembly if necessary.
2. Check the bearing for damage, abnormal noise and sluggish rotation, and replace the coolant pump assembly if
necessary.

3. Check for coolant leakage. If coolant leaks from hole, the seal is defective. Replace the coolant pump assembly.

A small amount of «engine coolant» from the bleed hole can be weeped.

THERMOSTAT
1. Immerse the thermostat in water and gradually heat the water.

2. Check the valve opening temperature.
Valve opening temperature : 86.5~89.5°C (187.7~193.1°F)
Full opening temperature : 100°C (212°F)
If the valve opening temperature is not as specified, replace the thermostat.
3. Check the valve lift.
Valve lift : 8.5mm(0.3346in) or more at 100°C (212°F)
If the valve lift is not as specified, replace the thermostat.

Lubrication system

2007 > J2.9L DIESEL CRDI(VGT) >

COMPONENTS

2007 > J2.9L DIESEL CRDI(VGT) >

DISASSEMBLY
RELIEF PLUNGER
1. Remove the relief plunger.
Remove the plug(A), spring and relief plunger.

INSPECTION
RELIEF PLUNGER
1. Inspect the relief plunger.
Coat the plunger with engine oil and check that it falls smoothly into the plunger hole by its own weight.
If it does not, replace the relief plunger. If necessary, replace the front case.
2. Inspect the relief valve spring.
Inspect for distorted or broken relief valve spring.
Standard value
Free height : 46.3mm (1.8228in)
Load : 6.13±5% kgf/38.05mm (13.5±1.1% lb/1.4980in)

ENGINE OIL
1. Check the engine oil quality.
Check the oil deterioration, entry of water, discoloring of thinning.
If the quality is visibly poor, replace the oil.
2. Check the engine oil level.
After warning up the engine and then 5 minutes after the engine stop, oil level should be between the “L” and “F”
marks in the dipstick.
If low, check for leakage and add oil up to the “F” mark.

Do not fill with engine oil above the “F” mark.

SELECTION OF ENGINE OIL
Recommended API classification : CH- 4 OR ABOVE(5W-30)
Recommended SAE viscosity grades :

For best performance and maximum protection of all types of operation, select only those lubricants which :
a. Satisfy the requirement of the API classification.
b. Have proper SAE grade number for expected ambient temperature range.
Lubricants that do not have both an SAE grade number and API service classification on the container should not
be used.

REASSEMBLY
RELIEF PLUNGER
1. Install the relief plunger.
Install relief plunger and spring into the front case hole, and install the plug(A).
Tightening torque :
32.4~42.2Nm (3.3~4.3kgf.m, 23.9~31.1lb-ft)

REMOVAL
OIL PAN
1. Drain the engine oil.
2. Remove the RH tires.
3. Remove the RH stabilizer bar link(A).

4. Remove the front roll stopper insulator mounting bolt(A).

5. Remove the rear roll stopper insulator mounting bolt(B).

6. Remove the RH sub frame mounting bolts.
7. Tilt the sub frame(A) sideways by loosening the RH sub frame mounting bolts only.

8. Remove the plate(A) between the engine and the transaxle.

9. Using the SST(09215-3C000), remove the oil pan(A).

OIL PUMP
1. Drain the engine oil.
2. Turn the crankshaft pulley, and align its groove with timing mark “T” of the timing belt cover.
3. Remove the oil pan.
4. Remove the oil supply pipe(A), ladde frame bracket(B).

5. Remove the ladde frame(A), oil pump assembly(B).

REPLACEMENT
OIL AND FILTER

a. Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading
to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants
which may cause skin cancer.
b. Exercise caution in order to minimize the length and frequency of contact of your skin to used oil. Wear
protective clothing and gloves. Wash your skin thoroughly with soap and water, or use water-less hand
cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents.
c. In order to preserve the environment, used oil and used oil filter must be disposed of only at designated
disposal sites.
1. Drain the engine oil.
(1) Remove the oil filler cap.
(2) Remove the oil drain plug, and drain the oil into a container.

2. Replace the oil filter.
(1) Remove the oil filter.
(2) Check and clean the oil filter installation surface.
(3) Check the part number of the new oil filter is as same as old one.
(4) Apply clean engine oil to the gasket of a new oil filter.
(5) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.
(6) Tighten it an additional 3/4 turn.
Tightening torque :
21.6~24.5Nm (2.2~2.5kgf.m, 15.9~18.1lb-ft)
3. Refill with engine oil.
(1) Clean and install the oil drain plug with a new gasket.
Tightening torque :
34.3~44.1Nm (3.5~4.5kgf.m, 25.3~32.5lb-ft)
(2) Fill with fresh engine oil.
Oil Capacity
Total : 8.0 L (8.45 US qt, 7.03 lmp qt)
Oil pan : 6.0 L (6.34 US qt, 5.27 lmp qt)
Drain and refill including oil filter : 6.6 L (6.97 US qt, 5.08 lmp qt)
Oil quality : ABOVE API CH-4 or ABOVE ACEA B4
(3) Install the oil filler cap.
4. Start engine and check for oil leaks.
5. Recheck the engine oil level.

INSTALLATION
OIL PUMP
1. Install the oil screen and new gasket.
Tightening torque :
15.7~22.6Nm (1.6~2.3kgf.m, 11.6~16.6lb-ft)
2. Install the ladde frame(A), oil pump assembly(B) with the bolts(C,D,E).
Tightening torque :
Bolts(C): 31.4~46.1Nm (3.2~4.7kgf.m, 23.1~34.0lb-ft)
Bolts(D): 15.7~22.6Nm (1.6~2.3kgf.m, 11.6~16.6lb-ft)

Bolts(E): 31.4~46.1Nm (3.2~4.7kgf.m, 23.1~34.0lb-ft)

Align the timing marks on the crankshaft sprocket(A), idler(B) and balancer sprocket(C).

3. Install the oil supply pipe(A), ladde frame bracket(B) with the bolts(C,D).
Tightening torque:
15.7~22.6Nm (1.6~2.3kgf.m, 11.6~16.6lb-ft)

4. Install the oil pan.
5. Fill with engine oil.

OIL PAN
1. Install the oil pan.
(1) Using a razor blade and gasket scraper, remove all the old packing material from the gasket surfaces.

Check that the mating surfaces are clean and dry before applying liquid gasket.

(2) Apply liquid gasket as an even bead, centered between the edges of the mating surface.
Liquid gasket: LOCTITE 5900 or equivalent

a. To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes.
b. Do not install the parts if five minutes or more have elapsed since applying the liquid gasket.
Instead, reapply liquid gasket after removing the residue.
c. After assembly, wait at least 30 minutes before filling the engine with oil.
(3) Install the oil pan(A) with the bolts.
Uniformly tighten the bolts in several passes.
Tightening torque :
15.7~22.6Nm (1.6~2.3kgf.m, 11.6~16.6lb-ft)

2. Install the plate(A) between the engine and the transaxle assembly.
Tightening torque :
15.7~22.6Nm (1.6~2.3kgf.m, 11.6~16.6lb-ft)

3. Install the RH, LH sub frame mounting bolts(A,B).
Tightening torque :
156.9~176.5Nm (16.0~18.0kgf.m, 115.7~130.2lb-ft)
44.1~58.8Nm (4.5~6.0kgf.m, 32.5~43.4lb-ft)

4. Install the front roll stopper insulator mounting bolt(A).
Tightening torque :
88.3~107.9Nm (9.0~11.0kgf.m, 65.1~79.6lb-ft)

5. Install the rear roll stopper insulator mounting bolt(A).
Tightening torque :
88.3~107.9Nm (9.0~11.0kgf.m, 65.1~79.6lb-ft)

6. Install the RH stabilizer bar link(A).
Tightening torque:
98.1~117.7Nm (10.0~12.0kgf.m, 72.3~86.8lb-ft)

7. Remove the RH tires.
Tightening torque :
88.3~107.9Nm (9.0~11.0kgf.m, 65.1~79.6lb-ft)
8. Fill with engine oil

INSPECTION
RELIEF PLUNGER
1. Inspect the relief plunger.
Coat the plunger with engine oil and check that it falls smoothly into the plunger hole by its own weight.
If it does not, replace the relief plunger. If necessary, replace the front case.
2. Inspect the relief valve spring.
Inspect for distorted or broken relief valve spring.
Standard value
Free height : 46.3mm (1.8228in)
Load : 6.13±5% kgf/38.05mm (13.5±1.1% lb/1.4980in)

ENGINE OIL
1. Check the engine oil quality.
Check the oil deterioration, entry of water, discoloring of thinning.
If the quality is visibly poor, replace the oil.
2. Check the engine oil level.
After warning up the engine and then 5 minutes after the engine stop, oil level should be between the “L” and “F”
marks in the dipstick.

If low, check for leakage and add oil up to the “F” mark.

Do not fill with engine oil above the “F” mark.

SELECTION OF ENGINE OIL
Recommended API classification : CH- 4 OR ABOVE(5W-30)
Recommended SAE viscosity grades :

For best performance and maximum protection of all types of operation, select only those lubricants which :
a. Satisfy the requirement of the API classification.
b. Have proper SAE grade number for expected ambient temperature range.
Lubricants that do not have both an SAE grade number and API service classification on the container should not
be used.

Intake
and
Exhaust system

Intercooler

2007 > J2.9L DIESEL CRDI(VGT) >

COMPONENTS

Intake Manifold

2007 > J2.9L DIESEL CRDI(VGT) >

COMPONENTS

2007 > J2.9L DIESEL CRDI(VGT) >

REMOVAL
INTAKE MANIFOLD
1. Remove the air intake hose, air cleaner assembly.
2. Remove the intercooler hoses(A).

3. Remove the ground cable(A) from cylinder head.

4. Remove the air hester terminals(A) CMP(Crankshaft position sensor) connector(B).

5. Remove the injection high pressure. (Refer to FL group).
6. Remove the EGR pipe(B).
Tightening torque :
15.7 ~ 22.6Nm (1.6 ~ 2.3kgf.m, 11.6 ~ 16.6lb-ft)

7. Remove the EGR pipe
Tightening torque :
Bolts(D), Nut(E): 15.7 ~ 22.6Nm (1.6 ~ 2.3kgf.m, 11.6 ~ 16.6lb-ft)

8. Remove the EGR pipe(A).

9. Remove the intake manifold.
Tightening torque :
Bolts(A,B), Nut(C): 15.7 ~ 22.6Nm (1.6 ~ 2.3kgf.m, 11.6 ~ 16.6lb-ft)
Hexagonal wrench bolt (D): 17.7 ~ 26.5Nm (1.8 ~ 2.7kgf.m, 13.0 ~ 19.5lb-ft)

10. Installation is in the reverse order of removal with new gasket.

Exhaust Manifold

2007 > J2.9L DIESEL CRDI(VGT) >

COMPONENTS

2007 > J2.9L DIESEL CRDI(VGT) >

REMOVAL
EXHAUST MANIFOLD
1. Remove the air intake hose, air cleaner assembly.
2. Remove the intercooler hoses, pipe(A, B).

3. Remove the PCV(Positive Crankcase Ventilation) hose(A), EGR valve vacuum hose(B), EGR cooier water hose(C),
vacuum pump oil hose(D).

4. Remove the EGR pipe(B).
Tightening torque :
15.7 ~ 22.6Nm (1.6 ~ 2.3kgf.m, 11.6 ~ 16.6lb-ft)

5. Remove the EGR pipe
Tightening torque :
Bolts(D), Nut(E): 15.7 ~ 22.6Nm (1.6 ~ 2.3kgf.m, 11.6 ~ 16.6lb-ft)

6. Remove the EGR pipe(A).

7. Remove the turbo chargers water inlet pipe(A).
Tightening torque :
Eye bolt(B): 23.5~35.3Nm (2.4~3.6kgf.m, 17.4~26.0lb-ft)
Bolt(C): 8.8~12.7Nm (0.9~1.3kgf.m, 6.5~9.4lb-ft)

8. Remove the heat protector(A).
Tightening torque :
8.8~12.7Nm (0.9~1.3kgf.m, 6.5~9.4lb-ft)

9. Remove the EGR cooler(A).
Tightening torque :
26.5~34.3Nm (2.7~3.5kgf.m, 19.5~25.3lb-ft)

10. Remove the EGR valve(A).
Tightening torque :
21.6~26.5Nm (2.2~2.7kgf.m, 15.9~19.5lb-ft)

11. Remove the exhaust manifold insulator(A), engine hanger(B).
Tightening torque :
Bolts(C): 8.8~12.7Nm (0.9~1.3kgf.m, 6.5~9.4lb-ft)
Bolts(D): 17.7 ~ 26.5Nm (1.8 ~ 2.7kgf.m, 13.0 ~ 19.5lb-ft)

12. Remove the turbo charger oil inlet pipe(A), oil outlet hose(B).
Tightening torque :
11.8~17.7Nm (1.2~1.8kgf.m, 8.7~13.0lb-ft)

13. Remove the turbo charger water outlet pipe, hose(A).
Tightening torque :
23.5~35.3Nm (2.4~3.6kgf.m, 17.4~26.0lb-ft)

14. Remove the turbo charger stay(A).
Tightening torque :
30.4~36.3Nm (3.1~3.7kgf.m, 22.4~26.8lb-ft)

15. Remove the turbo charger assembly(A).
Tightening torque :
26.5~34.3Nm (2.7~3.5kgf.m,19.5~25.3lb-ft)

16. Remove the generator. (Refer to EE group).
17. Remove the thermostat case(A), oil level gauge tube(B).

18. Remove the exhaust manifold(A).
Tightening torque :
26.5~34.3Nm (2.7~3.5kgf.m,19.5~25.3lb-ft)

INSPECTION
TURBO CHARGER
1. Warm up the engine to the normal temperature.
2. After removing the hose between the intake manifold and the intercooler, install the pressure gauge with 3-way
connector.
3. Measure the maximum pressure data by starting the engine and raising up the rpm.
PRESSURE GAUGE
Not fixed pressure or low pressure

Pressure is above the standard.
(630~670mmHg/3,800rpm)

INSPECTION
a. Leakage from the intake or exhaust system
b. Inferior turbocharger
a. Leakage from the inferior actuator hose
b. Actuator defect

ACTUATOR
1. After removing the air hose from the actuator, install the pressure tester.
2. Install the dial gauge in a straight line with the actuator rod.
3. Using the pressure tester, when the pressure, 1,320~1,360Hg is applied, check whether the actuator rod is shifted
2.0mm.

If the pressure more than 1.7 kg/cm²(1,250mmHg) is applied, there is a danger which the actuator will be
damaged.
4. Replace an actuator when it is not working or pressure can not be applied.

Front Exhaust Pipe

2007 > J2.9L DIESEL CRDI(VGT) >

COMPONENTS

2007 > J2.9L DIESEL CRDI(VGT) >

REMOVAL
1. Remove the front muffler(A).
Tightening torque:
39.2~58.8Nm (4.0~6.0kgf.m, 28.9~43.4lb-ft)

2. Remove the catalytic converter(A).
Tightening torque :
39.2~58.8Nm (4.0~6.0kgf.m, 28.9~43.4lb-ft)

3. Remove the center muffler(A).
Tightening torque :
39.2~58.8Nm (4.0~6.0kgf.m, 28.9~43.4lb-ft)

4. Remove the main muffler(A).

Tightening torque :
39.2~58.8Nm (4.0~6.0kgf.m, 28.9~43.4lb-ft)

5. Remove the tail pipe(A).
Tightening torque :
39.2~58.8Nm (4.0~6.0kgf.m, 28.9~43.4lb-ft)

General Information

2007 > J2.9L DIESEL CRDI(VGT) >

SPECIAL TOOLS
Tool
(Number and Name)
09411-43000
Clutch disc guide

Illustration

Use
Installation of the clutch disc

2007 > J2.9L DIESEL CRDI(VGT) >

SPECIFICATION
Item

SPECIFICATION

Engine type

J2.9

Clutch operation

Hydraulic type

Clutch disc

Single dry with diaphragm

Clutch cover assembly

Self Adjusting Clutch

TIGHTENING TORQUE
Item

Nm

Kgf.cm

lb-ft

Clutch cover (6EA)

25~36

250~360

18.2~26.2

Clutch pedal bracket mounting

19~26

190~260

13.8~18.9

Regulator bolt

28~33

280~330

20.3~24

Connecting rod adjusting bolt

9~14

90~140

6.5~10.1

Clutch master cylinder mounting

12~16

120~160

8.7~11.6

Stopper bolt

8~10 or 14~20

80~100 or 140~200

5.8~7.27 or
10.1~14.5

Clutch pedal bolt/nut

25~34

250~340

18.1~24.7

SERVICE STANDARD
Item

Standard value

Clutch pedal stroke

150mm (5.91in)

Clutch pedal free play

6~13mm (0.24~0.51in)

Clutch System

2007 > J2.9L DIESEL CRDI(VGT) >

DESCRIPTION
SELF ADJUSTING CLUTCH(S.A.C.) COVER
a. As a clutch disc facing is worn away according to its durability, a cover weight is increasing and a clutch pedal
pressure can be more needed.
b. To make up for this defect, the self adjusting clutch system makes the requsted pedal pressure minimized so that
makes the maintenance cycle longer.

CONCENTRIC SLAVE CYLINDER-C.S.C.
It improves working efficiency and lowers the number and the weight of part by unifing clutch release control
parts(clutch release bearing ~ clutch release cylinder) in a manual transaxle.

OPERATION
CONCENTRIC SLAVE CYLINDER-C.S.C
When the clutch pedal is pressed, oil pressure is transmitted along the arrow directions shown below and that moves
the clutch slave cylinder and the diaphragm spring of the clutch cover.

Clutch Cover and Disc

2007 > J2.9L DIESEL CRDI(VGT) >

COMPONENTS

2007 > J2.9L DIESEL CRDI(VGT) >

REPLACEMENT
1. Remove a transaxle assembly (refer to ‘MT’-group).
2. Remove the clutch cover bolts. Not to be bent or twisted, loosen them in diagonal directions.

3. Remove the clutch cover and disc.
4. Using the SST(09411-43000), install a clutch disc and cover.

a. Replace a clutch cover and disc as a set.
* Possible problems when not following the caution
a. When replacing only a disc, slip problem can occur because of the initial clamp load loss by the adjusting
ring’s unusual work.
b. When replacing only a disc, it can be difficult to cut power because the thickness of the disc cannot be
permitted.
b. Apply grease on a disc spline part and transmission input shaft spline part as required.
* Possible problems when not following
a. When not applying: Excessively wear of splines and bad clutch operation
b. When excessively applying: Scattered grease by centrifugal force conteminates the clutch disc. Loss of friction
force can cause a slip
c. The ‘T/M SIDE’ marked surface should face the transaxle.
→ If the surface face the opposite side, there can be an interference between a disc and a flywheel surface.

5. Tighten the clutch cover.
TORQUE:
24.5~35.3Nm (250~360kgf.cm, 18.1~26.0lb-ft) (6EA)

When installing the clutch cover, tighten the bolts in diagonal directions not to be bent or twisted.

* Possible problems when not following
a. When tightening the bolt completely at a time: the clutch cover can be twisted and vibration can occur.
b. On vehicles with self adjusting clutches, it is necessary to follow this caution.
c. Not following tightening torque: There can be bad torque transmission in clutch and relaxation possibility of
bolts.

INSPECTION
1. Inspect diaphragm spring wear which is in contact with a concentric slave cylinder bearing.

2. Check the clutch cover and disc surface for wear or crack.
3. Check the clutch disc lining for slipping or oil mark.
4. Measure the depth from a clutch lining surface to a rivet. If the measured value is less than the specification below,
replace it.
Specification: 0.3mm(0.0118inch)

Clutch Master Cylinder

2007 > J2.9L DIESEL CRDI(VGT) >

REMOVAL

Do not spill brake fluid on the vehicle; it may damage the paint if brake fluid does contact the paint, wash it off
immediately with water.
1. Remove the brake fluid fron the clutch master cylinder reservoir with a syringe.
2. Clamp the clutch master cylinder hose(A). If there is no enough room for clamping, you can also clamp the hose
from the brake master cylinder side.

3. Disconnect the hose(A) from the cylinder by releasing the clutch master cylinder clamp.

4. Remove the clutch master cylinder mounting bolts(A,B).
One is the engine room, the other near the clutch pedal assembly.

5. Remove the pin and washer which connect the clutch pedal with the clutch master cylinder.
6. Remove the clutch master cylinder. It can be helpful to do this step after removing the clutch pedal mounting
bracket.

INSTALLATION
Installation is in the reverse order of removal.
After installation, bleed the clutch hydaulic system.

CONCENTRIC SLAVE CYLINDER AIR BLEEDING PROCEDURE
1. After disconnecting a cap from the concentric slave cylinder air bleeder, insert a vinyl hose in the plug.
2. Loosening the plug screw, press and release the clutch pedal about 10 times.

Hold the air bleeder body not to rotate with a spanner(A). The holding is needed when the plug loosened or
tightened.
3. Tighten the plug during the clutch pedal pressed. Afterwards, raise the pedal with a hand.
TORQUE :
25~29Nm (250~290Kgf.cm, 18.2~21.1lb-ft)
4. After pressing the clutch pedal 3 times more, loosen the plug and retighten it with the pedal pressed. Raise it
again, then.
5. Repeat the step 4 two or three times. (until there is no bubble in the fluid)

a. Do not clamp the pipe of a concentric slave cylinder.
b. Be careful not to damage O-rings.

Clutch Pedal

2007 > J2.9L DIESEL CRDI(VGT) >

ADJUSTMENT PROCEDURE
IGNITION LOCK SWITCH
1. Disconnect 2P-connector from a ignition lock switch.
2. Disconnect the ignition lock switch. (if you can install a tester with the switch fixed, this step can be omissible)
3. Check for continuity between terminals. (refer to the table below)
Clutch pedal position

Ignition lock switch

Continuity

Released

Released

NO

Pressed

Pressed

YES

If there is difference between what tested and the table above, replace the ignition lock switch with a new one.
If not, install the ignition lock switch and adjust the clutch pedal.
TORQUE :
8~10Nm (80~100kgf.cm, 5.8~7.2lb-ft)

Clutch pedal and Ignition lock switch

a. Inspect a ignition lock switch.
b. Remove the driver’s seat mat to adjust a clutch pedal.
c. No gap between a clutch master cylinder pistion and push rod can cause clutch slip.
1. Loosen and draw out the bolt until it is off the pedal surface.
2. Push and pull a clutch master cylinder push rod to satisfy the specification below.
Specification:
Clutch pedal stroke(A) — 150mm(5.91in)
Clutch pedal free play(B) — 6~13mm(0.24~0.51in)
Clutch pedal distance — 234.7mm(9.24in)

3. With no pressure on a clutch pedal, tighten the bolt until it contacts on the pedal.
4. Fix the bolt with a nut.
TORQUE :
14~20Nm (140~200kgf.cm, 10.2~14.5lb-ft)

5. Press the clutch pedal to the seat ground.
6. Adjust the ignition lock switch position with the pedal a little(23~26mm) raised.
7. Install the ignition lock switch firmly.
TORQUE:
8~10Nm (80~100kgf.cm, 5.8~7.2lb-ft)

REPLACEMENT

a. Inspect the continuity of the ignition lock switch.
b. Remove the floor mat before adjusting the clutch pedal.
1. Remove the ignition lock switch.
2. Remove the snap pin and the clevis pin(A) connecting the clutch master cylinder push rod and the clutch pedal.

3. Remove the clutch master cylinder mounting nut(A,B) and the clutch pedal mounting nut(C).

4. Remove the clutch pedal.
5. Install a new one by tightening the bolts of the clutch pedal bracket and master cylinder .
TORQUE :
19~26 Nm(19~260 kgf.cm, 13.8~18.9 Ib-ft)(Clutch pedal bracket)
12~16 Nm(120~160 kgf.cm, 8.7~11.6 Ib-ft)(Clutch master cylinder)
6. Grease the clevis pin and insert it and the snap pin.
7. Adjust the clutch pedal and the ignition lock switch.

CHAPTER 2:

Engine Mechanical System

2007 > 3.8L V6 GASOLINE >

SPECIAL SERVICE TOOLS
Tool (Number and name)

Illustration

Use

Crankshaft front oil seal
installer
(09231-3C100)

Installation of the front oil seal

Flywheel stopper
(09231-3C300)

Removal and installation of the flywheel and
crankshaft pulley.

Torque angle adapter
(09221-4A000)

Installation of bolts & nuts needing an angular
method

Valve stem seal remover
(09222-29000)

Remover of the valve stem seal

Valve stem seal remover
(09222-3C100)

Installation of the valve stem seal

Valve spring compressor &
holder
(09222-3K000)
(09222-3C300)

Removal and installation of the intake or
exhaust valve
A : 09222-3K000
B : 09222-3C300 (holder)

Crankshaft rear oil seal
installer
(09231-3C200)
(09231-H1100)

Installation of the crankshaft rear oil seal
A : 09231-3C200
B : 09231-H1100

Oil pan remover

Removal of oil pan

Oil pan remover
(09215-3C000)

Removal of oil pan

Oil filter wrench
(09263-3C100)

Removal and installation of the oil filter
housing cover

2007 > 3.8L V6 GASOLINE >

TROUBLESHOOTING
Symptom
Engine misfire with
abnormal internal
lower engine noises.

Suspect area
Worn crankshaft bearings.
Loose or improperly installed engine drive
plate.

Replace the crankshaft and bearings as
required.
Repair or replace the drive plate as required.

Worn piston rings.
(Oil consumption may or may not cause the
engine to misfire.)

Inspect the cylinder for a loss of compression.
Repair or replace as required.

Worn crankshaft thrust bearings
Engine misfire with
abnormal valve train
noise.

Engine misfire with
coolant consumption.

Engine misfire with
excessive oil
consumption.

Repair or replace as required.

Excessive worn or mis-aligned timing chain.

Replace the timing chain and sprocket as
required.

Worn camshaft lobes.

Replace the camshaft and valve lifters.

a. Malfunctioning cylinder head gasket and/or
cranking or other damage to the cylinder
head and engine block cooling system.
b. Coolant consumption may or may not
cause the engine to overheat.
Worn valves, guides and/or valve stem oil
seals.
Worn piston rings.
(Oil consumption may or may not cause the
engine to misfire)

a. Inspect the cylinder head and engine
block for damage to the coolant passages
and/or a malfunctioning head gasket.
b. Repair or replace as required.
Repair or replace as required.
a. Inspect the cylinder for a loss of
compression.
b. Repair or replace as required.
a. Drain the oil.
b. Install the correct viscosity oil.
a. Inspect the thrust bearing and crankshaft.
b. Repair or replace as required.

Low oil pressure.

Repair or replace as required.

Broken valve spring.

Replace the valve spring.

Worn or dirty valve lifters.

Replace the valve lifters.

Stretched or broken timing chain and/or
damaged sprocket teeth.

Replace the timing chain and sprockets.

Worn timing chain tensioner, if applicable.

Replace the timing chain tensioner as
required.

Worn camshaft lobes.

Lower engine
noise,regardless of

Replace the crankshaft and bearings as
required.

Stuck valves.
(Carbon buildup on the valve stem)

Engine noise on start- Incorrect oil viscosity.
up, but only lasting a
few seconds.
Worn crankshaft thrust bearing.
Upper engine
noise,regardless of
engine speed.

Remedy

a. Inspect the camshaft lobes.
b. Replace the timing camshaft and valve
lifters as required.

Worn valve guides or valve stems.

Inspect the valves and valve guides,then
repair as required.

Stuck valves. (Carbon on the valve stem or
valve seat may cause the valve to stay open.

Inspect the valves and valve guides, then
repair as required.

Worn drive belt, idler, tensioner and bearing.

Replace as required.

Low oil pressure.

Repair or required.

noise,regardless of
engine speed.

Loose or damaged drive plate.
Damaged oil pan, contacting the oil pump
screen.

a. Inspect the oil pan.
b. Inspect the oil pump screen.
c. Repair or replace as required.

Oil pump screen loose, damaged or
restricted.

a. Inspect the oil pump screen.
b. Repair or replace as required.

Excessive piston-to-cylinder bore clearance.

a. Inspect the piston, piston pin and cylinder
bore.
b. Repair as required.

Excessive piston pin-to-piston clearance.

a. Inspect the piston, piston pin and the
connecting rod.
b. Repair or replace as required.

Excessive connecting rod bearing clearance

Inspect the following components and repair
as required.
a. The connecting rod bearings.
b. The connecting rods.
c. The crankshaft pin journals.

Excessive crankshaft bearing clearance.

Inspect the following components, and repair
as required.
a. The crankshaft bearings.
b. The crankshaft main journals.
c. The cylinder block.

Incorrect piston, piston pin and connecting rod
installation
Engine noise under
load.

Repair or replace the drive plate.

a. Verify the piston pins and connecting rods
are installed correctly.
b. Repair as required.

Low oil pressure

Repair or replace as required.

Excessive connecting rod bearing clearance .

Inspect the following components andrepair
as required :
a. The connecting rod bearings.
b. The connecting rods.
c. The crankshaft.

Excessive crankshaft bearing clearance.

Inspect the following components, andrepair
as required.
a. The crankshaft bearings.
b. The crankshaft main journals.
c. The cylinder block.

Engine will not crank- Hydraulically locked cylinder.
crankshaft will not
a. Coolant/antifreeze in cylinder.
rotate.
b. Oil in cylinder.
c. Fuel in cylinder.

a. Remove spark plugs and check for fluid.
b. Inspect for broken head gasket.
c. Inspect for cracked engine block or
cylinder head.
d. Inspect for a sticking fuel injector and/or
leaking fuel regulator.

Broken timing chain and/or timing chain
and/or timing chain gears.

a. Inspect timing chain and gears.
b. Repair as required.

Material in cylinder.
a. Broken valve
b. Piston material
c. Foreign material

a. Inspect cylinder for damaged components
and/or foreign materials.
b. Repair or replace as required.

Seized crankshaft or connecting rod bearings.

a. Inspect crankshaft and connecting rod
bearing.
b. Repair as required.

Bent or broken connecting rod.

a. Inspect connecting rods.
b. Repair as required.

Broken crankshaft.

a. Inspect crankshaft.
b. Repair as required.

2007 > 2.7L V6 GASOLINE >

Compression pressure inspection

If the there is lack of power, excessive oil consumption or poor fuel economy, measure the compression
pressure.
1. Warm up the engine until the normal operating temperature becoming 80~95°C(176~203°F).
2. Remove the surge tank.
3. Remove the ignition coil connectors(B) and ignition coils.

4. Using a 16mm plug wrench, remove the 6 spark plugs.
5. Check cylinder compression pressure.
(1) Insert a compression gauge into the spark plug hole.
(2) Open the throttle fully.
(3) With the fully-open throttle in cranking, measure the compression pressure.

Always use a fully charged battery to get the engine speed of 250 rpm or more.
Repeat steps 1) through 3) for each cylinder.

This measurement must be done in as short a time as possible.
Compression pressure: 1,176.79kPa (12.0kgf/cm², 170.68psi) — 200 ~ 250rpm
Minimum pressure: 1,029.69kPa (10.5kgf/cm², 149.34psi)
Difference between cylinders: 98.07kPa (1.0kgf/cm², 14.22psi)
(4) If the compression pressure in 1 or more cylinders is lower than the specification above, pour a small amount
of engine oil into the cylinder through the spark plug hole, repeat the steps (1) through (3) for the cylinder and
measure the pressure again.
a. If adding oil increases the pressure up, the piston rings or cylinder bores might be worn or damaged.
b. If the pressure doesn’t increase, a valve may be sticking or seating may be improper, or there may be
leakage from the gasket.
6. Reinstall the spark plugs.
7. Install the ignition coils and connect ignition coil connectors.
8. Install the surge tank.

VALVE CLEARANCE INSPECTION AND ADJUSTMENT

Inspect and adjust the valve clearance when the engine is cold (Engine coolant temperature : 20°C
±5°C(59~77°F)) and cylinder head is installed on the cylinder block.

1. Remove the engine cover.
2. Remove air cleaner assembly.
3. Remove the surge tank.
4. Remove the cylinder head cover.
(1) Disconnect the ignition coil connector and remove the ignition coil.
(2) Remove the cylinder head cover.

5. Set the piston of the No.1 cylinder to TDC(Top Dead Center) position.
(1) Turn the crankshaft pulley clockwise and align its groove with the timing mark «T» of the timing chain cover.
(2) Check that the timing marks of the camshaft sprocket are in straight line on that of the cylinder head cover
surface as shwn in the illustration. It makes the piston of the No.1 cylinder position at TDC.

If not, turn the crankshaft one revolution clockwise.
6. Inspect the intake and the exhaust valve clearance.
(1) With the piston of the No.1 cylinder positioning at TDC, the valves which can be measured its clearance are as
shown below.

Measurement method.
a. Using a thickness gauge, measure the clearance between the tappet and the base circle of camshaft.
b. Record the out-of-specification valve clearance measurements. They will be used later to determine the
required adjusting tappet for replacement.

Specification
Limit (Engine coolant temperature : 20°C [68°F])
Intake : 0.10 ~ 0.30mm (0.0039 ~ 0.0118in.)
Exhaust : 0.20 ~ 0.40mm (0.0079 ~ 0.0157in.)
(2) Turn the crankshaft pulley one revolution (360°) clockwise and align the groove with the timing mark «T» of the
timing chain cover.
(3) With the piston of the No.4 cylinder positioning at TDC, the valves which can be measured its clearance are as
shown below.

7. Adjust the intake and the exhaust valve clearances.
(1) Set the piston of the No.1 cylinder to the TDC/position.
(2) Remove the timing belt.
(3) Remove the camshaft bearing caps(A, B).

(4) Remove the camshaft assembly.
(5) Remove MLA(Mechanical Lash Adjuster)s.
(6) Measure the thickness of the removed tappet using a micrometer.

(7) Calculate the thickness of a new tappet so that the valve clearance comes within the specified value.
T : Thickness of removed tappet
A : Measured valve clearance

N : Thickness of new tappet
Intake : N = T + [A — 0.20mm(0.0079in.)]
Exhaust : N = T + [A — 0.30mm (0.0118in.)]
(8) Select a new tappet with a thickness as close as possible to the calculated value.

Tappets are available with 41different size increments of 0.015mm (0.0006in.) from 3.00mm (0.118in.) to
3.600mm (0.1417in.)
(9) Place a new tappet on the cylinder head.

Apply engine oil on the periphery surface of the selected tappet.
(10) Install the intake and exhaust camshafts.
(11) Install the bearing caps.
(12) Install the timing belt.
(13) Turn the crankshaft two revolutions in the operating direction(clockwise) and realign crankshaft sprocket and
camshaft sprocket timing marks(A).
(14) Recheck the valve clearance.
Specification (Engine coolant temperature: 20°C[68°F])
Intake : 0.17 ~ 0.23mm (0.0067 ~ 0.0090in.)
Exhaust : 0.27 ~ 0.33mm (0.0106 ~ 0.0129in.)

2007 > 3.8L V6 GASOLINE >

SPECIFICATION
Description

Specifications

General
Type

V-type, DOHC

Number of cylinders

6

Bore

96mm(3.7795in)

Stroke

87.0mm(3.4252in)

Total displacement

3.778cc(230.55cu.in.)

Compression ratio

10.4

Firing order

1-2-3-4-5-6

Valve timing
Intake

Exhaust

Opens(ATDC)

10°

Closes(ABDC)

62°

Opens(BBDC)

42°

Closes(ATDC)

6°

Cylinder head
Flatness of gasket surface

Less than 0.05mm (0.0019in.)
[Less than 0.02mm (0.0008in.) / 150×150]

Flatness of manifold
mounting

Intake

Less than 0.1mm(0.0039in.)
[Less than 0.03mm(0.001in)/110×110]

Exhaust

Less than 0.1mm(0.0039in.)
[Less than 0.03mm(0.001in)/110×110]

Camshaft
Cam height

LH
Camshaft

Intake

RH
Camshaft

Intake

Journal outer diameter LH ,RHcamshaft

46.8mm(1.8425in.)

Exhaust 45.8mm (1.8031in.)
46.8mm(1.8425in.)

Exhaust 45.8mm (1.8031in.)
Intake

No.1: 27.964 ~ 27.980mm (1.1009 ~
1.1016in.)
No.2,3,4: 23.954 ~ 23.970mm (0.9430 ~
0.9437in.)

Exhaust No.1: 27.964 ~ 27.980mm (1.1009 ~
1.1016in.)
No.2,3,4: 23.954 ~ 23.970mm (0.9430 ~
0.9437in.)
Bearing oil clearance

LH ,RHcamshaft

Intake

No.1: 0.020 ~ 0.057mm (0.0008 ~ 0.0022in.)
No.2,3,4: 0.030 ~ 0.067mm (0.0012 ~
0.0026in.)

Exhaust No.1: 0.020 ~ 0.057mm (0.0008 ~ 0.0022in.)
No.2,3,4: 0.030 ~ 0.067mm (0.0012 ~
0.0026in.)
End play

0.02 ~ 0.18mm (0.0008 ~ 0.0071in.)

Valve
Valve length

Stem outer diameter

Intake

105.27mm(4.1445in.)

Exhaust

105.50mm (4.1535in.)

Intake

5.465 ~ 5.480mm (0.2151 ~ 0.2157in.)

Exhaust

5.458 ~ 5.470mm (0.2149 ~ 0.2153in.)

Limit

Face angle

45.25° ~ 45.75°

Thickness of
valvehead(margin)

Intake

1.56 ~ 1.86mm(0.06142 ~ 0.07323in.)

Exhaust

1.73 ~ 2.03mm(0.06811 ~ 0.07992in.)

Valve stem to valve
guide clearance

Intake
Exhaust

0.020 ~ 0.047mm (0.00078 ~ 0.00185in.)

0.07mm
(0.00275in.)

0.030 ~ 0.054mm (0.00118 ~ 0.00212in.)

0.09mm
(0.00354in.)

Valve guide
Inner diameter

Length

Intake

5.500 ~ 5.512mm (0.2165 ~ 0.2170in.)

Exhaust

5.500 ~ 5.512mm (0.2165 ~ 0.2170in.)

Intake

41.8 ~ 42.2mm (1.6457 ~ 1.6614in.)

Exhaust

41.8 ~ 42.2mm (1.6457 ~ 1.6614in.)

Intake

1.15 ~ 1.45mm(0.05118 ~ 0.05709in.)

Exhaust

1.35 ~ 1.65mm(0.05315 ~ 0.06496in.)

Intake

44.75° ~ 45.20°

Exhaust

44.75° ~ 45.20°

Valve seat
Width of seat contact

Seat angle

Valve spring
Free length

43.86mm (1.7267in.)

Load

19.3±0.8kg/34.0mm (42.7±1.8 lb/1.3386in.)
42.3±1.3kg/24.2mm (93.3±2.9 lb/0.9527in.)

Out of squareness

Less than 1.5°

MLA
MLA outer diameter

Intake

34.964 ~ 34.980mm (1.3765 ~ 1.3772in.)

Exhaust

34.964 ~ 34.980mm (1.3765 ~ 1.3772in.)

Cylinder head tappet
bore inner diameter

Intake

35.000 ~ 35.025mm (1.3779 ~ 1.3789in.)

Exhaust

35.000 ~ 35.025mm (1.3779 ~ 1.3789in.)

MLA to tappet bore
clearance

Intake

0.020 ~ 0.061mm (0.0008 ~ 0.0024in.)

0.07mm(0.0027in.)

Exhaust

0.020 ~ 0.061mm (0.0008 ~ 0.0024in.)

0.07mm(0.0027in.)

0.17 ~ 0.23mm (0.0067 ~ 0.0090in.)

0.10 ~ 0.30mm
(0.0039 ~
0.0118in.)

0.27 ~ 0.33mm (0.0106 ~ 0.0129in.)

0.20 ~ 0.40mm
(0.0078 ~
0.0157in.)

Valve clearance
Intake

Exhaust

Cylinder block
Cylinder bore

96.00 ~ 96.03mm (3.7795 ~ 3.7807in.)

Flatness of gasket surface

Less than 0.05mm (0.0019in.)
[Less than 0.02mm (0.0008in.) / 150×150]

Piston
Piston outer diameter

95.96 ~ 95.99mm(3.7779 ~ 3.7791in.)

Piston to cylinder clearance

0.03 ~ 0.05mm(0.0012 ~ 0.0020in.)

Ring groove width

No. 1 ring groove
No. 2 ring groove
Oil ring groove

1.22 ~ 1.24mm (0.0480 ~ 0.0488in.)

1.26mm
(0.0496in.)

1.22 ~ 1.24mm (0.0480 ~ 0.0488in.)

1.26mm
(0.0496in.)
2.05mm

Oil ring groove

2.01 ~ 2.03mm (0.0791 ~ 0.0799in.)

2.05mm
(0.0807in.)

No. 1 ring

0.03 ~ 0.07mm (0.0012 ~ 0.0027in.)

0.1mm (0.004in.)

No. 2 ring

0.03 ~ 0.07mm (0.0012 ~ 0.0027in.)

0.1mm (0.004in.)

Oil ring

0.06 ~ 0.15mm (0.0024 ~ 0.0059in.)

0.2mm (0.008in.)

No. 1 ring

0.17 ~ 0.32mm (0.0067 ~ 0.0126in.)

0.6mm (0.0236in.)

No. 2 ring

0.32 ~ 0.47mm (0.0126 ~ 0.0185in.)

0.7mm (0.0275in.)

Oil ring

0.20 ~ 0.70mm (0.0078 ~ 0.0275in.)

0.8mm (0.0315in.)

Piston ring
Side clearance

End gap

Piston pin
Piston pin outer diameter

23.001 ~ 23.006mm (0.9055 ~ 0.9057in.)

Piston pin hole inner diameter

23.016 ~ 23.021mm (0.9061 ~ 0.9063in.)

Piston pin hole clearance

0.01 ~ 0.02mm (0.0039 ~ 0.0078in.)

Connecting rod small end inner diameter

22.974 ~ 22.985mm (0.9045 ~ 0.9049in.)

Connecting rod small end hole clearance

-0.032 ~ -0.016mm (-0.0012 ~ 0.0006in.)

Connecting rod
Connecting rod big end innerdiameter

58.000 ~ 58.018mm(2.2834 ~2.2842in.)

Connecting rod bearing oil clearance

0.038 ~ 0.056mm (0.0015 ~ 0.0022in.)

Side clearance

0.1 ~ 0.25mm (0.0039 ~ 0.0098in.)

Crankshaft
Main journal outer diameter

68.942 ~ 68.960mm (2.7142 ~ 2.7149in.)

Pin journal outer diameter

54.954 ~ 54.972mm (2.1635 ~ 2.1642in.)

Main bearing oil clearance

0.022 ~ 0.040mm (0.0008 ~ 0.0016in.)

End play

0.10 ~ 0.28mm (0.0039 ~ 0.0110in.)

Oil pump
Relief valve opening pressure

450 ~ 550kPa
(4.59 ~ 5.61kgf/cm²,65.28 ~ 79.79psi)

Engine oil
Oil quantity (Total)

6.0 L (6.34 US qt, 5.27 lmp qt)

Oil quantity (Oil pan)

5.5 L (5.81 US qt, 4.83 lmp qt)

Oil quantity (Drain and refill including oil filter)

5.2 L (5.49 US qt, 4.57 lmp qt)

Oil quality

ABOVE API SJ / SL or SAE 5W-20

Oil pressure

130kPa(1.32kgf/cm²,18.77psi)
[at 1000rpm,110°C(230°F)]

Cooling system
Cooling method

Forced circulation with electrical fan

Coolant quantity

8.6L(9.09U.S.qts,7.57lmp.qts)

Thermostat

Radiator cap

Type

Wax pellet type

Opening temperature

82±2°C (179.6±35.6°F)

Fully openedtemperature

95°C (203°F)

Full lift

10mm (0.3937in.)

Main valve opening
pressure

93.16 ~ 122.58kpa
(0.95 ~ 1.25kg/cm², 13.51 ~ 17.78psi)

Vacuum valve opening
pressure

0.98 ~ 4.90 kpa
(0.01 ~ 0.05kg/cm², 0.14 ~ 0.71 psi)

Water temperature sensor
Type

Thermister type

Type

Thermister type

Resistance

20°C (68°F)

2.31 ~ 2.59KΩ

80°C(176°F)

0.3222 KΩ

TIGHTENING TORQUE
Item

Quantity

Nm

kgf.m

lb-ft

Crankshaft pulley bolt

1

284.2 ~ 303.8

29.0 ~ 31.0

209.76 ~ 224.22

Timing chain cover bolt B

17

18.62 ~ 21.56

1.9 ~ 2.2

13.74 ~ 15.91

Timing chain cover bolt C

4

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Timing chain cover bolt D

1

58.80 ~ 68.80

6.0 ~ 7.0

43.40 ~ 50.63

Timing chain cover bolt E

1

58.80 ~ 68.80

6.0 ~ 7.0

43.40 ~ 50.63

Timing chain cover bolt F

2

24.50 ~ 26.46

2.5 ~ 2.7

18.08 ~ 19.53

Timing chain cover bolt G

4

21.56 ~ 23.52

2.2 ~ 2.4

15.91 ~ 17.36

Timing chain cover bolt H

1

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Timing chain cover bolt I

1

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Timing chain cover bolt J

1

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Cam to cam guide bolt

4

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Timing chain auto tensioner bolt

2

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Timing chain auto tensioner nut

2

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Timing chain guide bolt

4

19.60 ~ 24.50

2.0 ~ 2.5

14.17 ~ 18.08

Oil pump chain cover bolt

3

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Oil pump chain tensioner bolt

1

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Oil pump chain guide bolt

2

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Oil pump chain sprocket bolt

1

18.62 ~ 21.56

1.9 ~ 2.2

13.74 ~ 15.91

Lower oil pan bolt

13

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Drive belt auto tensioner bolt(M12)

1

96.04 ~ 99.96

9.8 ~ 10.2

70.88 ~ 73.78

Drive belt auto tensioner bolt(M8)

1

17.64 ~ 21.56

1.8 ~ 2.2

13.02 ~ 15.91

Drive belt idler bolt

1

53.90 ~ 57.82

5.5 ~ 5.9

39.78 ~ 42.67

OCV(oil control valve) bolt

2

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Cylinder head bolt

16

Cylinder head bolt

1

18.62 ~ 23.52

1.9 ~ 2.4

13.74 ~ 17.36

CVVT & exhaust cam sprocket bolt

4

64.68 ~ 76.44

6.6 ~ 7.8

47.74 ~ 56.42

Camshaft bearing cap bolt

32

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Cylinder head cover bolt

38

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Connecting rod bearing bolt

12

19.60 + 90°

2.0 + 90°

14.46 + 90°

Main bearing cap inner bolt(M11)

8

49.00 + 90°

5.0 + 90°

36.16 + 90°

Main bearing cap outer bolt(M8)

8

19.60 + 120°

2.0 + 120°

14.46 + 120°

Main bearing cap side bolt(M8)

6

29.40 ~ 31.36

3.0 ~ 3.2

21.70 ~ 23.14

Oil drain cover bolt

6

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Rear oil seal case bolt

6

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Baffle plate bolt

12

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Upper oil pan bolt

16

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Knock sensor bolt

2

15.68 ~ 23.52

1.6 ~ 2.4

11.57 ~ 17.36

Drive plate bolt cap

8

71.54 ~ 75.46

7.3 ~ 7.7

52.80 ~ 55.69

39.2 + 120° + 90° 4.0 + 120° + 90°

28.93+ 120° +
90°

Oil filter cap

24.50

2.5

18.08

Oil drain bolt cap

1

34.30 ~ 44.10

3.5 ~ 4.5

25.31 ~ 32.55

Oil pump bolt

3

19.6 ~ 23.5

2.0 ~ 2.4

14.5 ~ 17.4

Oil filter body bolt

10

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Oil filter body cover bolt

11

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Water vent hose bolt(Timing chain cover bolt L)

2

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Water pump bolt(Timing chain cover bolt K)

1

21.56 ~ 26.46

2.2 ~ 2.7

15.91 ~ 19.53

Water pump bolt

4

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Water pump pulley bolt

4

7.84 ~ 9.80

0.8 ~ 1.0

5.78 ~ 7.23

Water temp. control nut

4

18.62 ~ 23.52

1.9 ~ 2.4

13.74 ~ 17.36

Water temp. control bolt

2

Water inlet pipe bolt

3

16.66 ~ 19.60

1.7 ~ 2.0

12.30 ~ 14.47

Air vent pipe bolt

2

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Intake manifold bolt

6

18.62 ~ 23.52

1.9 ~ 2.4

13.74 ~ 17.36

Intake manifold nut

2

18.62 ~ 23.52

1.9 ~ 2.4

13.74 ~ 17.36

Surge tank bolt (M8 × 25)

3

18.62 ~ 23.52

1.9 ~ 2.4

13.74 ~ 17.36

Surge tank bolt (M6 × 106)

2

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Surge tank nut

1

18.62 ~ 23.52

1.9 ~ 2.4

13.74 ~ 17.36

Breather pipe bolt

2

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Surge tank bracket bolt rear (M10 × 18 )

2

27.44 ~ 31.36

2.8 ~ 3.2

20.25 ~ 23.14

Surge tank bracket bolt front (M8 × 16)

2

18.62 ~ 23.52

1.9 ~ 2.4

13.74 ~ 17.36

ETC bracket bolt

2

15.68 ~ 25.48

1.6 ~ 2.6

11.57 ~ 18.80

Exhaust manifold nut

16

39.20 ~ 44.10

4.0 ~ 4.5

28.93 ~ 32.55

Heat proctor bolt

8

3.9 ~ 5.9

0.4 ~ 0.6

2.89 ~ 4.34

Front muffler

2

39.20 ~ 58.80

4.0 ~ 6.0

28.93 ~ 43.40

18.62 ~ 23.52

1.9 ~2.4

13.74 ~ 17.36

COMPRESSION

If the there is lack of power, excessive oil consumption or poor fuel economy, measure the compression
pressure.
1. Warm up and stop engine.
Allow the engine to warm up to normal operating temperature.
2. Remove the surge tank.
3. Remove the ignition coil connectors(A) and ignition coils(B).

4. Remove the spark plugs.
Using a 16mm plug wrench, remove the 6 spark plugs.

5. Check cylinder compression pressure.
(1) Insert a compression gauge into the spark plug hole.
(2) Fully open the throttle.
(3) After 7 times of cranking the engine, measure the compression pressure.

Always use a fully charged battery to obtain engine speed of 250 rpm or more.
Repeat steps 1) through 3) for each cylinder.

This measurement must be done in as short a time as possible.
Compression pressure :
1,225kPa (12.5kgf/cm², 177psi) — 200 ~ 250rpm
Minimum pressure :
1,078kPa (11.0kgf/cm², 156psi)
(4) If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder
through the spark plug hole and repeat steps (a) through (c) for cylinders with low compression.
a. If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or
damaged.
b. If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the
gasket.
6. Reinstall the spark plugs.
7. Install the ignition coil and ignition coil connectors.
8. Install the surge tank.

VALVE CLEARANCE INSPECTION AND ADJUSTMENT

Inspect and adjust the valve clearance when the engine is cold (Engine coolant temperature : 20°C) and cylinder
head is installed on the cylinder block.
1. Remove the engine cover.
2. Remove air cleaner assembly.
3. Remove the surge tank.
4. Remove the cylinder head cover.
(1) Disconnect the ignition coil connector and remove the ignition coil.
(2) Disconnect the breather pipe assembly(A) from the cylinder head cover.

(3) Loosen the cylinder head cover bolts and then remove the cover(A) and gasket.

5. Set No.1 cylinder to TDC/compression.
(1) Turn the crankshaft pulley and align its groove with the timing mark «T» of the lower timing chain cover.

(2) Check that the mark(A) of the camshaft timing sprockets are in straight line on the cylinder head surface as
shown in the illustration.
If not, turn the crankshaft one revolution (360°)

Do not rotate engine counterclockwise

6. Inspect the valve clearance.
(1) Check only the valve indicated as shown. [No. 1 cylinder : TDC/Compression] measure the valve clearance.

Measurement method.

a. · Using a thickness gauge, measure the clearance between the tappet and the base circle of camshaft.
· Record the out-of-specification valve clearance measurements. They will be used later to determine the
required replacement adjusting tappet.
Valve clearance
Specification
Engine coolant temperature : 20°C [68°F]
Limit
Intake : 0.10 ~ 0.30mm (0.0039 ~ 0.0118in.)
Exhaust : 0.20 ~ 0.40mm (0.0079 ~ 0.0157in.)
(2) Turn the crankshaft pulley one revolution (360°) and align the groove with timing mark «T» of the lower timing
chain cover.

Do not rotate engine counterclockwise
(3) Check only valves indicated as shown. [NO. 4 cylinder : TDC/compression]. Measure the valve clearance.
(Refer to procedure step1))

7. Adjust the intake and exhaust valve clearance.
(1) Set the No.1 cylinder to the TDC/compression.
(2) Remove the timing chain.

Before removing the timing chain, mark the RH/LH timing chain with an identification based on the location
of the sproket because the identification mark on the chain for TDC(Top Dead Center) can be erased.
(3) Remove the camshaft bearing caps(A).

(4) Remove the camshaft assembly(A).

(5) Remove MLAs.
(6) Measure the thickness of the removed tappet using a micrometer.

(7) Calculate the thickness of a new tappet so that the valve clearance comes within the specified value.
Valve clearance(Engine coolant temperature: 20°C[68°F])
T : Thickness of removed tappet
A : Measured valve clearance
N : Thickness of new tappet
Intake : N = T + [A — 0.20mm(0.0079in.)]
Exhaust : N = T + [A — 0.30mm (0.0118in.)]
(8) Select a new tappet with a thickness as close as possible to the calculated value.

Shims are available in 41size increments of 0.015mm (0.0006in.) from 3.00mm (0.118in.) to 3.600mm
(0.1417in.)
(9) Place a new tappet on the cylinder head.

Appling engine oil at the selected tappet on the periphery and top surface.
(10) Install the intake and exhaust camshaft.
(11) Install the bearing caps
(12) Install the timing chain.
(13) Turn the crankshaft two turns in the operating direction(clockwise) and realign crankshaft sprocket and
camshaft sprocket timing marks(A).

(14) Recheck the valve clearance.
Valve clearance (Engine coolant temperature: 20°C[68°F])
[Specification]
Intake : 0.17 ~ 0.23mm (0.0067 ~ 0.0090in.)
Exhaust : 0.27 ~ 0.33mm (0.0106 ~ 0.0129in.)

Timing system
Timing belt

2007 > 3.8L V6 GASOLINE >

COMPONENT

2007 > 3.8L V6 GASOLINE >

REMOVAL

a. Use fender covers to avoid damaging painted surfaces.
b. To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

a. Mark all wiring and hoses to avoid misconnection.
b. Turn the crankshaft pulley so that the No.1 piston is at top dead center.
1. Disconnect the battery negative cable (A).

2. Remove the engine cover (A).

3. Remove the intake air hose and air cleaner assembly.
(1) Disconnect the MAF sensor connector (A).
(2) Disconnect the breather hose (B) from air intake hose.
(3) Remove the intake air hose and air cleaner assembly(C).

4. Remove the RH front wheel.
5. Remove the under cover (A).

6. Remove the side cover.
7. Loosen the drain plug and drain the engine coolant.
8. Drain the engine oil.
9. Remove the surge tank.
(1) Disconnect the RH oxygen sensor connector (A) and loosen the power steering hose mounting bolts (B).

(2) Disconnect the RH injector connector (A) and ignition coil connector (B).

(3) Disconnect the PCSV connector (A), MAP sensor connector (B) and PCSV hose.

(4) Disconnect the ETC connector (A) and knock sensor connector (B).

(5) Disconnect the OCV connector (A) and knock sensor connector (B).

(6) Disconnect the LH front oxygen sensor connector (A).

(7) Disconnect the LH ignition coil connector (A), injector connector (B), condenser connector (C) and ground (D),
and remove the wiring harness protector (E).

(8) Disconnect the LH CMPS (A) and oil pressure switch connector (B).

(9) Remove the ETC bracket (A).
(10) Disconnect the water hoses (B) from ETC.
(11) Disconnect the PCV hose (C).

(12) Disconnect the brake vacuum hose.
(13) Remove the surge tank stay (A).

(14) Remove the connector bracket (A) from surge tank.

(15) Remove the surge tank (A).

Cover the inlet of intake manifold with a clean woven stuff or vinyl cover to prevent foreign materials from
entering.
10. Remove the cylinder head cover.
(1) Remove the connector bracket (A) from LH cylinder head cover.

(2) Disconnect the RH ignition coil connector (A), condenser connector (B) and remove the wiring bracket (C).

(3) Remove the LH, RH ignition coil.
(4) Remove the LH, RH cylinder head cover (A).

11. Using SST (09215-3C000) remove lower oil pan (A).

Be careful not to damage the contact surfaces of upper oil pan and lower oil pan.
12. Set a jack to the upper oil pan.

13. Remove the coolant reservoir tank.
14. Remove the engine mounting bracket (A).

15. Set No.1 cylinder to TDC/compression.
(1) Turn the crankshaft pulley and align its groove with the timing mark «T» of the lower timing chain cover.

Do not rotate engine counterclockwise.

(2) Check that the mark (A) of the camshaft timing sprockets are in straight line on the cylinder head surface as
shown in the illustration.
If not, turn the crankshaft one revolution (360°).

Do not rotate engine counterclockwise.
16. Remove the drive belt (A).

17. Using SST (09231-3C300) remove the crankshaft damper pulley (A).

18. Lift up the engine assembly to using the jack.

19. Remove the drive belt idler (A).

20. Remove the drive belt auto tensioner (A).

21. Remove the water pump pulley (A).

22. Remove the timing chain cover (A).

Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover.

Before removing the timing chain, mark the RH/LH timing chain with an identification based on the location of
the sprocket because the identification mark on the chain for TDC (Top Dead Center) can be erased.
23. Install a set pin after compressing the timing chain tensioner.

24. Remove the RH cam-to-cam guide (A).

25. Remove the RH timing chain auto tensioner (A) and RH timing chain tensioner arm (B).

26. Remove the RH timing chain.
27. Remove the RH timing chain guide (A).

28. Remove the oil pump chain cover (A).

29. Remove the oil pump chain tensioner assembly (A).

30. Remove the oil pump chain guide (A).

31. Remove the oil pump chain sprocket (A) and oil pump chain (B).

32. Remove the crankshaft sprocket (A) (Oil pump & RH camshaft drive).

33. Install a set pin after compressing the LH timing chain tensioner.

34. Remove the LH cam-to-cam guide (A).

35. Remove the LH timing chain auto tensioner (A) and LH timing chain tensioner arm (B).

36. Remove the LH timing chain.
37. Remove the LH timing chain guide (A).

38. Remove the crankshaft sprocket (A) (LH camshaft drive).

39. Remove the tensioner adapter assembly (A).

Inspection

Sprockets, Chain Tensioner, Chain Guide, Chain Tensioner Arm
1. Check the camshaft sprocket and crankshaft sprocket for abnormal wear, cracks, or damage. Replace as
necessary.
2. Inspect the tensioner arm and chain guide for abnormal wear, cracks, or damage. Replace as necessary.
3. Check that the tensioner piston moves smoothly when the ratchet pawl is released with thin rod.

INSTALLATION
1. Install the jack to the upper oil pan.
2. The key (A) of crankshaft should be aligned with the timing mark (B) of timing chain cover. As a result of this, the
piston of No.1 cylinder is placed at the top dead center on compression stroke.

3. Install the tensioner adapter assembly (A).

4. Install the crankshaft sprocket (A) (LH camshaft drive).

5. Install the LH timing chain guide (A).
Tightening torque :
19.60 ~ 24.50N.m(2.0 ~ 2.5kgf.m, 14.17 ~ 18.08lb-ft)

6. Install LH timing chain.
To install the timing chain with no slack between each shaft (cam, crank), follow the procedure below.
Crankshaft sprocket → Timing chain guide → Exhaust camshaft sprocket(C) → Intake camshaft sprocket(D).
The timing mark of each sprocket should be matched with timing mark (color link) of timing chain at installing timing
chain.

7. Install the LH timing chain tensioner arm(B).
Tightening torque :
18.62 ~ 21.56N.m(1.9 ~ 2.2kgf.m, 13.74 ~ 15.91lb-ft)
8. Install the LH chain tensioner (A).
Tightening torque :
9.80 ~ 11.76N.m(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

9. Install the LH cam-to-cam guide (A).
Tightening torque :
9.80 ~ 11.76N.m(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

10. Install the crankshaft sprocket (A) (Oil pump & RH camshaft drive).

11. Install the oil pump chain (B) and oil pump sprocket (A).
Tightening torque :
18.62 ~ 21.56N.m(1.9 ~ 2.2kgf.m, 13.74 ~ 15.91lb-ft)

12. Install the RH timing chain guide (A).
Tightening torque :
19.60 ~ 24.50N.m(2.0 ~ 2.5kgf.m, 14.17 ~ 18.08lb-ft)

13. Install the RH timing chain.
To install the timing chain with no slack between each shaft (cam, crank), follow the procedure below.
Crankshaft sprocket (A) → Intake camshaft sprocket (B) → Exhaust camshaft sprocket (C).
The timing mark of each sprocket should be matched with timing mark (color link) of timing chain at installing
timing chain.

14. Install the RH timing chain tensioner arm (B).
Tightening torque :
18.62 ~ 21.56N.m(1.9 ~ 2.2kgf.m, 13.74 ~ 15.91lb-ft)
15. Install the RH timing chain auto tensioner (A).
Tightening torque :
9.80 ~ 11.76N.m(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

16. Install the RH cam-to-cam guide (A).
Tightening torque :
9.80 ~ 11.76N.m(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

17. Install the oil pump chain guide (A).
Tightening torque :
9.80 ~ 11.76N.m(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

18. Install the oil pump chain tensioner assembly (A).
Tightening torque :
9.80 ~ 11.76N.m(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

19. Pull out the pins of hydraulic tensioners (LH & RH).

20. Install the oil pump chain cover (A).

Tightening torque :
9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

21. After rotating crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm the timing mark.

Always turn the crankshaft clockwise.
22. Install the timing chain cover.
(1) The sealant locations on chain cover and on counter parts (cylinder head, cylinder block, and lower oil pan)
must be free of engine oil and ETC.
(2) Before assembling the timing chain cover, the liquid sealant TB1217H should be applied on the gap between
cylinder head and cylinder block.
The part must be assembled within 5 minutes after sealant was applied.
Bead width : 2.5mm(0.1in.)

(3) After applying liquid sealant TB1217H on the timing chain cover.
The part must be assembled within 5 minutes after sealant was applied.
Sealant should be applied without discontinuity.
Bead width : 2.5mm(0.1in.)

(4) Install the new gasket (A) to the timing chain cover.

During timing cover installation, care not to take off applied sealant on the timing cover by contact with
other parts.
(5) The dowel pins on the cylinder block and holes on the timing chain cover should be used as a reference in
order to assemble the timing chain cover to be in exact position.
Tightening torque :
B(17) :18.62 ~ 21.56N.m (1.9 ~ 2.2kgf.m, 13.74 ~ 15.91lb-ft)
C(4) :9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
D(1) :58.80 ~ 68.80N.m (6.0 ~ 7.0kgf.m, 43.40 ~ 50.63lb-ft)
E(1) :58.80 ~ 68.80N.m (6.0 ~ 7.0kgf.m, 43.40 ~ 50.63lb-ft)
F(2) :24.50 ~ 26.46N.m (2.5 ~ 2.7kgf.m, 18.08 ~ 19.53lb-ft)
G(4) :21.56 ~ 23.52N.m (2.2 ~ 2.4kgf.m, 15.91 ~ 17.36lb-ft)
H(1) :9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
I(1) :9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
J(1) :9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
K(4) :9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
L(1):21.56 ~ 26.46N.m (2.2 ~ 2.7kgf.m, 15.91 ~ 19.53lb-ft) — New bolt

(6) The firing and/or blow out test should not be performed within 30 minutes after the timing chain cover was
assembled.
23. Install the water pump pulley (A).
Tightening torque :
7.84 ~ 9.80N.m(0.8 ~ 1.0kgf.m, 5.78 ~ 7.23lb-ft)

24. Install the drive belt auto tensioner (A).
Tightening torque :
Bolt(B):81.39 ~ 85.32N.m (8.3 ~ 8.7kgf.m, 60.03 ~ 62.93lb-ft)
Bolt(C):17.64 ~ 21.56N.m (1.8 ~ 2.2kgf.m, 13.02 ~ 15.91lb-ft)

25. Install the drive belt idler (A).
Tightening torque :
52.92 ~ 57.82N.m(5.4 ~ 5.9kgf.m, 39.06 ~ 42.67lb-ft)

26. Lower the engine assembly by using the jack.
27. Using SST (09231-3C100), install timing chain cover oil seal.

28. Using SST (09231-3C300) install the crankshaft damper pulley (A).
Tightening torque :
284.2~303.8N.m (29.0~31.0kgf.m, 209.76~224.22lb-ft)

29. Install the drive belt (A).
Crankshaft pulley → A/C pulley → idler pulley → alternator pulley → water pump pulley → P/S pump pulley→
tensioner pulley.
Rotate auto tensioner arm in the counterclockwise moving auto tensioner pulley bolt with wrench.
After putting belt on auto tensioner pulley, release the auto tensioner pulley slowly.

30. Install the cylinder head cover.
(1) The hardening sealant located on the upper area between timing chain cover and cylinder head should be
removed before assembling cylinder head cover.
(2) After applying sealant (TB1217H), it should be assembled within 5 minutes.
Bead width: 2.5mm(0.1in.)

(3) The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was
assembled.
(4) Install the cylinder head cover bolts as following method.
Tightening torque :
9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

Do not reuse cylinder head cover gasket.
(5) Install the ignition coil.
(6) Connect the RH ignition coil connector (A), the condenser connector (B) and install the wiring bracket (C).

(7) Install the connector bracket (A) to the LH cylinder head cover.

31. Install the surge tank and wiring connectors.
(1) Install the surge tank (A).
Tightening torque :
9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

(2) Install the connector bracket (A) to the surge tank.
Tightening torque :
6.86 ~ 10.78N.m (0.7 ~ 1.1kgf.m, 5.06 ~ 7.96lb-ft)

(3) Install the surge tank stay.
Tightening torque :
27.44 ~ 31.36N.m (2.8 ~ 3.2kgf.m, 20.25 ~ 23.14lb-ft)

(4) Connect the brake vacuum hose.
(5) Connect the PCV hose (C).
(6) Connect the water hoses (B) to the ETC.
(7) Install the ETC bracket (A).

(8) Connect the LH CMPS connector (A) and oil pressure switch connector(B).

(9) Install the wiring harness protector (E) and connect the LH ignition coil connector (A), injector connector (B),
condenser connector (C) and ground (D).

(10) Connect the LH front oxygen sensor connector (A).

(11) Connect the OCV connector (A) and knock sensor connector (B).

(12) Connect the ETC connector (A) and knock sensor connector (B).

(13) Connect the PCSV connector (A), MAP sensor connector (B) and PCSV hose.

(14) Connect the RH injector connector (A) and ignition coil connector (B).

(15) Connect the RH oxygen sensor connector (A) and tighten the power steering hose mounting bolts (B).

32. Install the engine mounting bracket (A).
Tightening torque :

88.3 ~ 107.9N.m (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft)

33. Install the coolant reservoir tank.
34. Remove the jack from the upper oil pan.
35. Install lower oil pan.
(1) Using a gasket scraper, remove all the old packing material from the gasket surfaces.
(2) Before assembling the oil pan, the liquid sealant TB1217H should be applied on oil pan.
Bead width : 2.5mm(0.1in.).
But marked area(*) to be 5.0mm(0.2in.)

a.
b.
c.
d.

Make clean the sealing face before assembling two parts.
Remove harmful foreign matters on the sealing face before applying sealant.
When applying sealant gasket, sealant must not be protruded into the inside of oil pan.
To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.

(3) Install the lower oil pan (A).
Tightening torque :
9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

36. Install the side cover.
Tightening torque :
8.8 ~ 10.8N.m (0.9 ~ 1.1kgf.m, 6.5 ~7.9lb-ft)
37. Install the under cover (A).
Tightening torque :
8.8 ~ 10.8N.m (0.9 ~ 1.1kgf.m, 6.5 ~7.9lb-ft)

38. Install the RH front wheel.
Tightening torque :
88.3 ~ 107.9N.m (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft)
39. Install the intake air hose and air cleaner assembly.
(1) Install the intake air hose and air cleaner assembly(C).
(2) Connect the breather hose (B) to the air intake hose.
(3) Connect the MAF sensor connector (A).

40. Install the engine cover (A).

41. Connect the battery negative cable (A).

a.
b.
c.
a.
b.

Refill engine with engine oil.
Refill radiator and reservoir tank with engine coolant.
Bleed air from the cooling system.
Start engine and let it run until it warms up. (until the radiator fan operates 3 or 4 times.)
Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to
be removed from the cooling system.
c. Put radiator cap on tightly, then run the engine again and check for leaks.

Cylinder Head Assembly

2007 > 3.8L V6 GASOLINE >

COMPONENTS

2007 > 3.8L V6 GASOLINE >

REMOVAL

a. Use fender covers to avoid damaging painted surfaces.
b. To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal operating
temperature before removing it.
c. When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.
d. To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

a. Mark all wiring and hoses to avoid misconnection.
b. Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
Engine removal is required for this procedure.
1. Remove exhaust manifold.
2. Remove intake manifold.
3. Remove timing chain.
4. Remove water temperature control assembly.
5. Remove camshaft bearing cap(A).

6. Remove camshaft assembly(A).

7. Remove cylinder head bolts, then remove cylinder head.
(1) Uniformly loosen and remove the 16 cylinder head bolts, in several passes, in the sequence shown. Remove
the 16 cylinder head bolts and plate washers.

Head warpage or cracking could result from removing bolts in an incorrect order.
(2) Lift the cylinder head from the dowels on the cylinder block and place the cylinder head on wooden blocks on a
bench.

Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

INSTALLATION

a.
b.
c.
d.

Thoroughly clean all parts to be assembled.
Always use a new head and manifold gasket.
The cylinder head gasket is a metal gasket. Take care not to bend it.
Rotate the crankshaft, set theNo.1 piston at TDC.

1. Install the cylinder head.
a. The sealant locations on cylinder head and cylinder block must be free from contamination.
b. Apply sealant on cylinder block top face before assembling cylinder head gaskets.
The part must be assembled within 5 minutes after sealant was applied.

Refer to below illustration to apply the sealant.

Bead width : 2.0~3.0 mm
Sealant locations : 1.0~1.5mm from block surface
Recommended sealant :Liquid sealant TB1217H

c. Apply sealant on cylinder head gaskets after assembling cylinder head gaskets on cylinder block.
The part must be assembled within 5 minutes after sealant was applied.

Be careful of the installation direction.

d. Install the cylinder head.

Remove the extruded sealant after assembling cylinder heads.

2. Place the cylinder head carefully in order not to damage the gasket with the bottom part of the end.
3. Install cylinder head bolts.
(1) Do not apply engine oil on the threads and under the heads of the cylinder head bolts.
(2) Using SST(09221-4A000), install and tighten the cylinder head bolts and plate washers, in several passes, in
the sequence shown.
Tightening torque
1st step: 37.3~41.2Nm(3.8~4.2kgf.m, 27.5~30.4 lbf.ft)
2nd step:120° ± 2°
3rd step: 90° ± 2°

Always use new cylinder head bolt.

4. Install the CVVT and camshaft sprocket.
Tightening torque
64.68 ~ 76.44Nm(6.6 ~ 7.8 kgf.m, 47.74 ~ 56.4lb-ft)

a. Install camshaft-inlet to dowel pin of CVVT assembly .
Ensure that the camshaft oil inlet is not obstructed.
b. Hold the hexagonal head wrench portion of the camshaft with a vise, and install the bolt and CVVT
assembly.
c. Do not rotate CVVT assembly when camshaft is installed to dowel pin of CVVT assembly.
5. Install camshafts(A).

a. Apply a light coat of engine oil on camshaft journals.
b. Assemble the key groove of camshaft rear side to the same level of head top surface.
c. Ensure that the camshaft components are installed in the correct locations.

Intake camshaft

LH

RH

A: 30mm(1.1811in.)
B: 27mm(1.0630in.)

A: 27mm(1.0630in.)
B: 30mm(1.1811in.)

Exhaust camshaft

LH

RH

A: 27mm(1.0630in.)

A: 30mm(1.1811in.)

6. Install camshaft bearing caps.
Assemble camshaft bearing caps as the order below.
Tightening torque
5.9Nm(0.6kgf.m, 4.3lb-ft) — 1st step
9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft) — 2nd step

Ensure that the cam bearing caps are installed in the correct location and direction. Refer to the table below.

A : L(LH),R(RH)
B : I(Intake),None(Exhaust)
C : Journal number
D : Front mark

Rotate the crankshaft not to contact the valves to the pistons by making the pistons below 10mm(0.3937in.)
from the top of cylinder block.
7. Install water temperature control assembly.
8. Install timing chain.
9. Check and adjust valve clearance.
10. Install the exhaust manifold.
11. Install the intake manifold.

DISASSEMBLY

Identify MLA, valves and valve springs as they are removed so that each item can be reinstalled in its original
position.
1. Remove MLAs(A).

2. Remove valves.
(1) Using SST(09222-3K000, 09222-3C300), compress the valve spring and remove retainer lock.

(2) Remove the spring retainer.
(3) Remove the valve spring.
(4) Remove the valve.
(5) Using SST(09222-29000), remove the valve stem seal.

Do not reuse old valve stem seals.
3. Remove OCV(A).

INSPECTION
CYLINDER HEAD
1. Inspect for flatness.
Using a precision straight edge and feeler gauge, measure the surface the contacting the cylinder block and the
manifolds for warpage.
Flatness of cylinder head gasket surface
Standard : Less than 0.05mm(0.002in.)[Less than 0.02mm(0.0008in.)/150×150]

Flatness of manifold gasket surface
Standard : Less than 0.03mm(0.001in)/110×110

2. Inspect for cracks.
Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked,
replace the cylinder head.

VALVE AND VALVE SPRING
1. Inspect valve stems and valve guides.
(1) Using a caliper gauge, measure the inside diameter of the valve guide.
Valve guide I.D.
Intake / Exhaust : 5.500 ~ 5.512mm (0.216 ~ 0.217in.)

(2) Using a micrometer, measure the diameter of the valve stem.
Valve stem O.D.
Intake : 5.465 ~ 5.480mm (0.2151 ~ 0.2157in.)
Exhaust : 5.458 ~ 5.470mm (0.2149 ~ 0.2153in.)

(3) Subtract the valve stem diameter measurement from the valve guide inside diameter measurement.
Valve stem-to-guide clearance
[Standard]
Intake : 0.020 ~ 0.047mm (0.0008 ~ 0.0018in.)
Exhaust : 0.030 ~ 0.054mm (0.0012 ~ 0.0021in.)
[Limit]
Intake : 0.07mm (0.0027in.)
Exhaust : 0.09mm (0.0035in.)
2. Inspect valves.
(1) Check the valve is ground to the correct valve face angle.
(2) Check that the surface of the valve for wear.
If the valve face is worn, replace the valve.
(3) Check the valve head margin thickness.
If the margin thickness is less than minimum, replace the valve.
Margin
[Standard]
Intake : 1.56 ~ 1.86mm(0.06142 ~ 0.07323in.)
Exhaust : 1.73 ~ 2.03mm(0.06811 ~ 0.07992in.)

(4) Check the valve length.
Length
Intake : 105.27mm (4.1445in)
Exhaust : 105.50mm (4.1535in)
(5) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, replace the valve.
3. Inspect valve seats
Check the valve seat for evidence of overheating and improper contact with the valve face.
If the valve seat is worn, replace cylinder head.
Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace cylinder head.
Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width should be within
specifications and centered on the valve face.
4. Inspect valve springs.
(1) Using a steel square, measure the out-of-square of the valve spring.
(2) Using a vernier calipers, measure the free length of the valve spring.
Valve spring
[Standard]
Free height : 43.86mm (1.7267in.)

Out-of-square : 1.5°

MLA
1. Inspect MLA.
Using a micrometer, measure the MLA outside diameter.
MLA O.D.
Intake/Exhaust : 34.964 ~ 34.980mm(1.3765 ~ 1.3771in.)
2. Using a caliper gauge, measure MLA tappet bore inner diameter of cylinder head.
Tappet bore I.D.
Intake/Exhaust : 35.000 ~ 35.025mm(1.3779 ~ 1.3789in.)
3. Subtract MLA outside diameter measurement from tappet bore inside diameter measurement.
MLA to tappet bore clearance
[Standard]
Intake/Exhaust : 0.020 ~ 0.061mm(0.0008 ~ 0.0024in.)
[Limit]
Intake/Exhaust : 0.07mm(0.0027in.)

CAMSHAFT
1. Inspect cam lobes.
Using a micrometer, measure the cam lobe height.
Cam height
[Standard value]
Intake : 46.8mm (1.8425in.)
Exhaust : 45.8mm (1.8031in.)

If the cam lobe height is less than standard, replace the camshaft.
2. Inspect camshaft journal clearance.
(1) Clean the bearing caps and camshaft journals.
(2) Place the camshafts on the cylinder head.
(3) Lay a strip of plastigage across each of the camshaft journal.

(4) Install the bearing caps.

Do not turn the camshaft.
(5) Remove the bearing caps.
(6) Measure the plastigage at its widest point.
Bearing oil clearance
[Standard value]
Intake
No.1 journal : 0.020 ~ 0.057mm (0.0008 ~ 0.0022in.)
No.2,3,4 journal : 0.030 ~ 0.067mm (0.0012 ~ 0.0026in.)
Exhaust
No.1 journal : 0.020 ~ 0.057mm (0.0008 ~ 0.0022in.)
No.2,3,4 journal : 0.030 ~ 0.067mm (0.0012 ~ 0.0026in.)

If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace cylinder head.
(7) Completely remove the plastigage.
(8) Remove the camshafts.
3. Inspect camshaft end play.
(1) Install the camshafts.
(2) Using a dial indicator, measure the end play while moving the camshaft back and forth.

Camshaft end play
[Standard value] : 0.02 ~ 0.18mm(0.0008 ~ 0.0071in.)

If the end play is greater than maximum, replace the camshaft. If necessary, replace cylinder head.
(3) Remove the camshafts.

CVVT ASSEMBLY
1. Inspect CVVT assembly.
(1) Check that the CVVT assembly will not turn.
(2) Apply vinyl tape to the retard hole except the one indicated by the arrow in the illustration.

(3) Wind tape around the tip of the air gun and apply air of approx. 150kpa(1.5kgf/cm², 21psi) to the port of the
camshaft.
(Perform this order to release the lock pin for the maximum delay angle locking.)

When the oil splashes, wipe it off with a shop rag.
(4) Under the condition of (3), turn the CVVT assembly to the advance angle side (the arrow marked direction in
the illustration) with your hand.
Depending on the air pressure, the CVVT assembly will turn to the advance side without applying force by
hand. Also, If excessive air leaks from the port, the lock pin may not be fully released.

(5) Except the position where the lock pin meets at the maximum delay angle, let the CVVT assembly turn back
and forth and check the movable range and that there is no resistance to movement.
Standard: Movable smoothly in the range about 22.5°
(6) Turn the CVVT assembly with your hand and lock it at the maximum delay angle position (counter clockwise).

REASSEMBLY

Thoroughly clean all parts to be assembled.
Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
Replace oil seals with new ones.
1. Install valves.
(1) Using SST(09222-3C100), push in a new oil seal.

Do not reuse old valve stem seals.
Incorrect installation of the seal could result in oil leakage past the valve guides.

(2) Install the valve, valve spring and spring retainer.

Place valve springs so that the side coated with enamel faces toward the valve spring retainer and then
installs the retainer.
(3) Using the SST(09222 — 3K000, 09222-3C300), compress the spring and install the retainer locks. After
installing the valves, ensure that the retainer locks are correctly in place before releasing the valve spring
compressor.

(4) Lightly tap the end of each valve stem two or three times with the wooden handle of a hammer to ensure
proper seating of the valve and retainer lock.
2. Install MLAs.
Check that the MLA rotates smoothly by hand.

MLA can be reinstalled in its original position.
3. Install OCV(A).
Tightening torque
9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

a. To install OCV with gray colored connector into RH bank.
b. To install OCV with black colored connector into LH bank.

a.
b.
c.
d.

Do not reuse the OCV when dropped.
Keep the OCV assembly clean.
Do not hold the OCV sleeve during servicing.
When the OCV is installed on the engine, do not move the engine by holding the OCV yoke.

Engine
And
Transaxle Assembly

2007 > 3.8L V6 GASOLINE >

REMOVAL

a. Use fender covers to avoid damaging painted surfaces.
b. To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

a. Mark all wiring and hoses to avoid misconnection.
1. Remove the engine cover(A).

2. Recover refrigerant, opening the high & low pressure pipe caps and connecting the refrigerant station(Refer to HA
group).
3. Disconnect the neagative terminal from the battery and remove the battery(A).

4. Remove the intake air hose and air cleaner assembly.
(1) Disconnect the MAF connector(A).
(2) Disconnect the breather hose(B) from air cleaner hose.
(3) Remove the intake air hose and air cleaner assembly(C).

5. Remove the battery tray(A).

6. Remove the radiator grille upper cover(A).

7. Disconnect the RH and LH oxygen sensor connectors(A, B).

8. Remove the radiator upper and lower hoses(A).

9. Disconnect the automatic transaxle fluid cooler hoses(A).

10. Disconnect the high and low pressure pipes from the radiator or the compressor.
11. Disconnect engine wiring.
(1) Remove the engine room fuse and relay box cover(A).
(2) Disconnect the PCM connectors(B).
(3) Disconnect the FAM connectors(C)(Refer to HA group).

(4) Unscrew the FAM mounting bolts(D-3EA) and take the FAM(E) out of the splash shield(F).
(5) Disconnect the connector(G) from the splash shield(B).

12. Disconnect the transaxle wire harness connector and remove the transaxle control cable(Refer to TR group).
13. Remove heater hose(A).

14. Remove the brake vacuum hose(A).

15. Remove power steering pump hose(Refer to ST group).
16. Remove front wheels(Refer to DS group).
17. Remove the radiator grille upper cover(A) for convenience sake.

18. Disconnect the power steering return hose(A).

19. Remove the radiator support upper member assembly(A) for convenience sake.

The bottom side bolt(A) which can be seen after removing the under cover should be loosened for removal of
the radiator support upper member assembly.

20. Remove the under cover(A).

21. Drian engine oil.
22. Coolant should be drained before heater hose removal.
23. Remove front exhaust pipe(A).

24. Disconnect the wheel speed sensor and the stabilizer bar link(Refer to SS group).
25. Remove the caliper assembly and suspend it with a wire(Refer to DS group).
26. Supporting the engine and transaxle assembly with sub frame, remove the engine mounting bracket(A).

27. Remove the transaxle insulator mounting bolt(A).

28. Supporting the engine and transaxle assembly with a jack, remove the sub frame with the engine and transaxle
assembly.

When remove the engine and transaxle assembly, be careful not to damage any surrounding parts or body
components.

INSTALLATION
Installation is in the reverse order of removal.
Perform the following :
a. Adjust the shift cable.
b. Refill the engine with engine oil.
c. Refill the transaxle with fluid.
d. Refill the radiator with engine coolant.
e. Bleed air from the cooling system with the heater valve open.
f. Clean the battery posts and cable terminals with sandpaper assemble them, then apply grease to prevent
corrosion.
g. Inspect for fuel leakage.
After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for
approximately two seconds and fuel line pressurizes.
Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.

Cylinder Block

3LVWRQDQG
&RQQHFWLQJ5RG

2007 > 2.7L V6 GASOLINE >

COMPONENTS

2007 > 3.8L V6 GASOLINE >

REMOVAL

a. Use fender covers to avoid damaging painted surfaces.
b. To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

a.
b.
c.
d.

Mark all wiring and hoses to avoid misconnection.
Inspection the timing belt before removing the cylinder head.
Turn the crankshaft pulley so that the No.1 piston is at top dead center.
Engine removal is required for this procedure.

1. Remove exhaust manifold.
2. Remove intake manifold.
3. Remove timing chain.
4. Remove water temperature control assembly.
5. Remove cylinder head.
6. Remove oil pump.
7. Remove oil filter assembly.
8. Remove A/C compressor(A) from engine.

9. Remove generator(A) from engine.

10. Remove power steering pump(A) from engine.

INSTALLATION
1. Install power steering pump.
2. Install generator.
3. Install air conditioner compressor
4. Install oil filter assembly.
5. Install oil pump.
6. Install cylinder head.
7. Install water temperature control assembly.
8. Install timing chain.
9. Install intake manifold.
10. Install exhaust manifold.

DISASSEMBLY
1. Remove drive plate.
2. Remove knock sensor(A).

3. Remove upper oil pan(A).

4. Remove baffle plate(A).

5. Remove rear oil seal case(A).

6. Remove oil drain cover(A).

7. Check the connecting rod end play.
8. Check the connecting rod cap oil clearance.
9. Remove piston and connecting rod assemblies.
(1) Using a ridge reamer, remove all the carbon from the top of the cylinder.
(2) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

a. Keep the bearings, connecting rod and cap together.
b. Arrange the piston and connecting rod assemblies in the correct order.
10. Remove crankshaft main bearing cap and check oil clearance.
11. Check the crankshaft end play.
12. Lift the crankshaft(A) out of engine, being careful not to damage journals.

Arrange the main bearings and thrust bearings in the correct order.
13. Check fit between piston and piston pin.
Try to move the piston back and forth on the piston pin. If any movement is felt, replace piston and piston pin as a
set.
14. Remove piston rings.
(1) Using a piston ring expender, remove the 2 compression rings.
(2) Remove 2 side rails and the spacer by hand.

Arrange the piston rings in the correct order only.
15. Disconnect connecting rod from piston.
Using a press, remove the piston pin from piston.
(Press-in load : 800 ~ 1400kg (1764 ~ 3086lb)

INSPECTION
CONNECTING ROD AND CRANKSHAFT
1. Check the connecting rod end play.
Using a feeler gauge, measure the end play while moving the connecting rod back and forth.
Standard end play : 0.1~ 0.25mm(0.004 ~ 0.010in.)

a. If out-of-tolerance, install a new connecting rod.
b. If still out-of-tolerance, replace the crankshaft.
2. Check the connecting rod bearing oil clearance.
(1) Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
(2) Remove 2 connecting rod cap bolts.
(3) Remove the connecting rod cap and bearing half.

(4) Clean the crank pin and bearing.
(5) Place plastigage across the crank pin.
(6) Reinstall the bearing half and cap, and torque the bolts.
Tightening torque
19.6Nm (2.0kgf.m, 14.46lb-ft) + 90°

Do not turn the crankshaft.
(7) Remove 2 bolts, connecting rod cap and bearinghalf.
(8) Measure the plastigage at its widest point.
Standard oil clearance
0.038 ~ 0.056mm(0.0015 ~ 0.0022in.)

(9) If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new,
complete bearing with the same color mark (select the color as shown in the next column), and recheck the
clearance.

Do not file, shim, or scrape the bearings or the caps to adjust clearance.
(10) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed
above or below that one), and check clearance again.

If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace
the crankshaft and start over.

If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a
wire brush or scraper. Clean them only with solvent or detergent.

CONNECTING ROD MARK LOCATION

DISCRIMINATION OF CONNECTING ROD
CLASS

MARK

INSIDE DIAMETER

0

a

58.000 ~ 58.006mm
(2.2834 ~ 2.2837in.)

1

b

58.006 ~ 58.012mm
(2.2837 ~ 2.2839in.)

2

c

58.012 ~ 58.018mm
(2.2839 ~ 2.2842in.)

CLASS

MARK

OUTSIDE DIAMETER OF PIN

I

1 or A

54.966 ~ 54.972mm
(2.1640 ~ 2.1642in.)

II

2 or B

54.960 ~ 54.966mm
(2.1638 ~ 2.1640in.)

III

3 or C

54.954 ~ 54.960mm
(2.1635 ~ 2.1638in.)

CRANKSHAFT PIN MARK LOCATION
DISCRIMINATION OF CRANKSHAFT

DISCRIMINATION OF CRANKSHAFT

PLACE OF IDENTIFICATION MARK (CONNECTING ROD BEARING)

DISCRIMINATION OF CONNECTING ROD BEARING
CLASS

MARK

THICKNESS OF BEARING

E

BLUE

1.514 ~ 1.517mm
(0.0596 ~ 0.0597in.)

D

BLACK

1.511 ~ 1.514mm
(0.0595 ~ 0.0596in.)

C

BROWN

1.508 ~ 1.511mm
(0.0594 ~ 0.0595in.)

B

GREEN

1.505 ~ 1.508mm
(0.0593 ~ 0.0594in.)

A

YELLOW

1.502 ~ 1.505mm
(0.0591 ~ 0.0593in)

(11) Selection
CONNECTING ROD IDENTIFICATION MARK

CRANKSHAFT
INDENTIFICATION MARK

0(a)

1(b)

2(c)

1 or A

A
(YELLOW)

B
(GREEN)

C
(BROWN)

2 or B

B
(GREEN)

C
(BROWN)

D
(BLACK)

3 or C

C
(BROWN)

D
(BLACK)

E
(BLUE)

3. Check the crankshaft bearing oil clearance.
(1) To check main bearing-to-journal oil clearance, remove the main bearing caps and bearing halves.
(2) Clean each main journal and bearing half with a clean shop tower.
(3) Place one strip of plastigage across each main journal.
(4) Reinstall the bearings and caps, then torque the bolts.
Tightening torque
49.00Nm(5.0 kgf.m, 36.16lb-ft) + 90°
19.60 Nm(2.0 kgf.m, 14.46lb-ft)+ 120°
29.40 ~ 31.36Nm(3.0 ~ 3.2 kgf.m, 21.70 ~ 23.14lb-ft)

Do not turn the crankshaft.
(5) Remove the cap and bearing again, and measure the widest part of the plastigage.
Standard oil clearance
0.022 ~ 0.040mm (0.0009 ~ 0.0016in.)

(6) If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new,
complete bearing with the same color mark (select the color as shown in the next column), and recheck the
clearance.

Do not file, shim, or scrape the bearings or the caps to adjust clearance.
(7) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed
above or below that one), and check clearance again.

If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the
crankshaft and start over.

If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire
brush or scraper. Clean them only with solvent or detergent.
Crankshaft bore mark location
Letters have been stamped on the block as a mark for the size of each of the 5 main journal bores.
Use them, and the numbers or bar stamped on the crank (marks for main journal size), to choose the correct
bearings.

DISCRIMINATION OF CYLINDER BLOCK
CLASS

MARK

INSIDE DIAMETER

a

A

73.500 ~ 73.506mm
(2.8937 ~ 2.8939in.)

b

B

73.506 ~ 73.512mm
(2.8939 ~ 2.8942in.)

c

C

73.512 ~ 73.518mm
(2.8942 ~ 2.8944in.)

CRANKSHAFT JOURNAL MARK LOCATION
DISCRIMINATION OF CRANKSHAFT

DISCRIMINATION OF CRANKSHAFT
CLASS

MARK

OUTSIDE DIAMETER OF JOURNAL

I

1 or A

68.954 ~ 68.960mm
(2.7147 ~ 2.7150in.)

II

2 or B

68.948 ~ 68.954mm
(2.7145 ~ 2.7147in.)

III

3 or C

68.942 ~ 68.948mm
(2.7142 ~ 2.7145in.)

PLACE OF IDENTIFICATION MARK (CRANKSHAFT BEARING)

DISCRIMINATION OF CRANKSHAFT BEARING
CLASS

MARK

THICKNESS OF BEARING

E

BLUE

2.277 ~ 2.280mm
(0.0896 ~ 0.0897in.)

D

BLACK

2.274 ~ 2.277mm
(0.0895 ~ 0.0896in.)

C

BROWN

2.271 ~ 2.274mm
(0.0894 ~ 0.0895in.)

B

GREEN

2.268 ~ 2.271mm
(0.0893 ~ 0.0894in.)

A

YELLOW

2.265 ~ 2.268mm
(0.0892 ~ 0.0893in.)

SELECTION
CRANKSHAFT BORE IDENTIFICATION MARK

CRANKSHAFT
IDENTIFICATION MARK

a(A)

b(B)

c(C)

1 or A

A
(YELLOW)

B
(GREEN)

C
(BROWN)

2 or B

B
(GREEN)

C
(BROWN)

D
(BLACK)

3 or C

C
(BROWN)

D
(BLACK)

E
(BLUE)

3 or C

(BROWN)

(BLACK)

(BLUE)

4. Check crankshaft end play.
Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard end play
0.10 ~ 0.28mm (0.0039 ~ 0.0110in.)

If the end play is greater than maximum, replace the thrust bearings as a set.
Thrust bearing thickness
2.41 ~ 2.45mm(0.0949 ~ 0.0964in.)
5. Inspect main journals and crank pins
Using a micrometer, measure the diameter of each main journal and crank pin.
Main journal diameter : 68.942 ~ 68.960mm (2.7142 ~ 2.7149in.)
Crank pin diameter : 54.954 ~ 54.972mm (2.1635 ~ 2.1642in.)

CONNECTING RODS
1. When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at disassembly match. When
a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the same
side.
2. Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a severely rough
surface of the inside diameter of the small end is apparent, the rod must be replaced as well.
3. Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is close to the repair
limit, correct the rod by a press. Any connecting rod that has been severely bent or distorted should be replaced.
Allowable bend of connecting rod :
0.05mm / 100mm (0.0020 in./3.94 in.) or less
Allowable twist of connecting rod :
0.1mm / 100mm (0.0039 in./3.94 in.) or less

CYLINDER BLOCK
1. Remove gasket material.
Using a gasket scraper, remove all the gasketmaterial from the top surface of the cylinder block.
2. Clean cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder block.
3. Inspect top surface of cylinder block for flatness.
Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for
warpage.
Flatness of cylinder block gasket surface
Standard : Less than 0.05mm(0.0020 in.),Less than 0.02mm(0.0008in.) / 150 x 150

4. Inspect cylinder bore diameter
Visually check the cylinder for vertical scratchs.
If deep scratches are present, replace the cylinder block.
5. Inspect cylinder bore diameter
Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial directions.
Standard diameter
96.00 ~ 96.03mm (3.7795 ~ 3.7807in.)

6. Check the cylinder bore size code on the cylinder block.

Class

Size code

Cylinder bore inner diameter

A

A

96.00~96.01mm
(3.7795 ~ 3.7799in.)

B

B

96.01~96.02mm
(3.7799 ~ 3.7803in.)

C

C

96.02~96.03mm
(3.7803 ~ 3.7807in.)

Class

Size code

Piston outer diameter

A

A

95.96~95.97mm
(3.7779 ~ 3.7783in.)

B

B

95.97~95.98mm
(3.7783 ~ 3.7787in.)

C

C

95.98~95.99mm
(3.7787 ~ 3.7791in.)

7. Check the piston size code on the piston top face.

8. Select the piston related to cylinder bore class.
Clearance : 0.03 ~ 0.05mm(0.0012 ~ 0.0020in.)

PISTON AND RINGS
1. Clean piston
(1) Using a gasket scraper, remove the carbon from the piston top.
(2) Using a groove cleaning tool or broken ring, clean the piston ring grooves.
(3) Using solvent and a brush, thoroughly clean the piston.

Do not use a wire brush.
2. The standard measurement of the piston outside diameter is taken 14 mm (0.5512 in.) from the bottom of the
piston.

Standard diameter
95.96 ~ 95.99mm (3.7779~ 3.7791in.)

3. Calculate the difference between the cylinder bore diameter and the piston diameter.
Piston-to-cylinder clearance
0.03 ~ 0.05mm(0.0012 ~ 0.0020in.)
4. Inspect the piston ring side clearance.
Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove.
Piston ring side clearance
Standard
No.1 : 0.03 ~ 0.07mm (0.0012 ~ 0.0027in.)
No.2 : 0.03 ~ 0.07mm (0.0012 ~ 0.0027in.)
Oil ring : 0.06 ~ 0.15mm (0.0024 ~ 0.0059in.)
Limit
No.1 : 0.1mm (0.004in.)
No.2 : 0.1mm (0.004in.)
Oil ring : 0.2mm (0.008in.)

If the clearance is greater than maximum, replace the piston.
5. Inspect piston ring end gap.
To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles to
the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge. If the gap exceeds
the service limit, replace the piston ring. If the gap is too large, recheck the cylinder bore diameter. If the bore is
over the service limit, the cylinder block must be replaced.
Piston ring end gap
Standard
No.1 : 0.17 ~ 0.32mm (0.0067 ~ 0.0126in.)
No.2 : 0.32 ~ 0.47m (0.0126 ~ 0.0185in.)
Oil ring : 0.20 ~ 0.70mm (0.0079 ~ 0.0275in.)
Limit
No.1 : 0.6mm (0.0236in.)
No.2 : 0.7mm (0.0275in.)
Oil ring : 0.8mm (0.0315in.)

PISTON PINS
1. Measure the diameter of the piston pin.
Piston pin diameter
23.002 ~ 23.006mm (0.9056 ~ 0.9057in.)

2. Measure the piston pin-to-piston clearance.
Piston pin-to-piston clearance
0.009 ~ 0.017mm (0.0004 ~ 0.0007in.)
3. Check the difference between the piston pin diameter and the connecting rod small end diameter.
Piston pin-to-connecting rod interference
-0.032 ~ -0.017mm (-0.0012 ~ -0.0007in.)

REASSEMBLY

a. Thoroughly clean all parts to assembled.
b. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
c. Replace all gaskets, O-rings and oil seals with new parts.

1. Assemble piston and connecting rod.
(1) Use a hydraulic press for installation.
(2) The piston front mark and the connecting rod front mark must face the timing belt side of the engine.

2. Install piston rings.
(1) Install the oil ring spacer and 2 side rails by hand.
(2) Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
(3) Position the piston rings so that the ring ends are as shown.

3. Install connecting rod bearings.
(1) Align the bearing claw with the groove of the connecting rod or connecting rod cap.
(2) Install the bearings(A) in the connecting rod and connecting rod cap(B).

4. Install main bearings.

Upper bearings have an oil groove of oil holes; Lower bearings do not.
(1) Align the bearing claw with the claw groove of the cylinder block, push in the 4 upper bearings.
(2) Align the bearing claw with the claw groove of the main bearing cap, and push in the 4 lower bearings(A).

5. Install thrust bearings.
Install the 2 thrust bearings(A) under the No.3 journal position of the cylinder block with the oil grooves facing
outward.

6. Place crankshaft on the cylinder block.

7. Place main bearing caps on cylinder block.
8. Install main bearing cap bolts.
(1) Install and uniformly tighten the bearing cap bolts, in several passes, in the sequence shown.
Tightening torque
Main bearing cap bolt
49.00Nm(5.0 kgf.m, 36.16lb-ft) + 90° (1 ~
19.60 Nm(2.0 kgf.m, 14.46lb-ft)+ 120° (9 ~ 16)
29.40 ~ 31.36Nm(3.0 ~ 3.2 kgf.m, 21.70 ~ 23.14lb-ft) (17 ~ 22)

a. Always use new main bearing cap bolt.
b. If any of the bearing cap bolts in broken or deformed, replace it.

Use SST( 09221-4A000 ), install main bearing cap bolts.

(2) Check that the crankshaft turns smoothly.
9. Check crankshaft end play.
10. Install piston and connecting rod assemblies.

Before installing the pistons, apply a coat of engine oil to the ring grooves and cylinder bores.
(1) Install the ring compressor, check that the bearing is securely in place, then position the piston in the cylinder,
and tap it in using the wooden handle of a hammer.
(2) Stop after the ring compressor pops free, and check the connecting rod-to-check journal alignment before
pushing the piston into place.
(3) Apply engine oil to the bolt threads. Install the rod caps with bearings, and torque the bolts.
Tightening torque
19.6Nm (2.0kgf.m, 14.46lb-ft) + 90°
Use SST(09221-4A000), install connecting rod bearing cap bolts.

a. Always use new connecting rod bearing cap bolt.
b. Maintain downward force on the ring compressor to prevent the rings from expanding before entering
the cylinder bore.

11. Check the connecting rod end play.
12. Install oil drain cover.
Tightening torque
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68b-ft)

a.
b.
c.
d.
e.

Ensure the sealing face is clean before assembling two parts.
Remove harmful foreign matters on the sealing face before applying sealant
Be assembling oil drain cover, the liquid sealant TB1217H should be applied oil drain cover.
The part must be assembled within 5 minutes after sealant was applied.
Apply sealant to the inner threads of the bolt holes.

13. Install rear oil seal case.
Tightening torque
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.67lb-ft)

a.
b.
c.
d.
e.

Make clean the sealing face before assembling two parts.
Remove harmful foreign matters on the sealing face before applying sealant
Be assembling rear oil seal case, the liquid sealant TB1217H should be applied rear oil seal case.
The part must be assembled within 5 minutes after sealant was applied.
Apply sealant to the inner threads of the bolt holes.

14. Using SST(09231-3C200, 09231-H1100), install rear oil seal.

15. Install baffle plate.
Install and uniformly tighten the baffle plate bolts, in several passes, in the sequence shown.
Tightening torque
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

16. Install upper oil pan.
a. Using a gasket scraper, remove all the old packing material from the gasket surfaces.
b. Before assebling the oil pan, the liquid sealant TB1217H should be applied on upper oil pan.
The part must be assembled within 5 minutes after the sealant was applied.
Bead width : 2.5mm(0.1in.)

a.
b.
c.
d.

Ensure the sealing face is clean before assembling two parts.
Remove harmful foreign matters on the sealing face before applying sealant
When applying sealant gasket, sealant must not be protruded into the inside of oil pan.
To prevent leakage of oil, apply sealant gasket ot the inner threads of the bolt holes.

c. Install upper oil pan.
Uniformly tighten the bolts in several passes.
Tightening torque
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

17. Install knock sensor.
Tightening torque
15.68 ~ 23.52Nm (1.6 ~ 2.4kgf.m, 11.57 ~ 17.36lb-ft)

18. Install drive plate.
Tightening torque
71.54 ~ 75.46Nm (7.3 ~ 7.7kgf.m, 52.80 ~ 55.69lb-ft)

Cooling system

2007 > 3.8L V6 GASOLINE >

ENGINE COOLANT REFILLING AND BLEEDING

Never remove the radiator cap when the engine is hot. Serious scalding could be caused by hot fluid under high
pressure escaping from the radiator.

When pouring engine coolant, be sure to shut the relay box lid and not to let coolant spill on the electrical parts or
the paint. If any coolant spills, rinse it off immediately.
1. Make sure the engine and radiator are cool to the touch.
2. Remove radiator cap.
3. Loosen the drain plug, and drain the coolant.
4. Tighten the radiator drain plug securely.
5. Remove, drain and reinstall the reservoir. Fill the tank halfway to the «F» mark with water, then up to the «F» mark
with antifreeze.
6. Fill fluid mixture with coolant and water(4 : 6) slowly through the radiator cap. Push the upper/lower hoses of the
radiator to ensure proper air bleeding.

a. Use only genuine antifreeze/coolant.
b. For best corrosion protection, the coolant concentration must be maintained year-round at 50% minimum.
Coolant concentrations less than 50% may not provide sufficient protection against corrosion or freezing.
c. Coolant concentrations greater then 60% will impair cooling efficiency and are not recommended.

a. Do not mix different brands of antifreeze/coolants.
b. Do not use additional rust inhibitors or antirust products; they may not be compatible with the coolant.
7. Start the engine.
When the cooling fan operates and coolant circulates, refill coolant through the radiator cap.
8. Repeat 7 until the cooling fan cycles 3 ~ 5times and bleed air sufficiently out of the cooling system.
9. Install the radiator cap and fill the reservoir tank to the «MAX» line with coolant.
10. Run the vehicle under idle until the cooling fan operates 2 ~ 3 times.
11. Stop the engine and wait until the cooling system is cool to the touch.
12. Repeat 6 to 11 until the coolant level doesn’t fall any more, bleed air out of the cooling system.

Proper cooling system operation depends on the absence of trapped air within the system. It is essential that
the cooling system be properly filled and bled before returning the vehicle to service.

CAP TESTING
1. Remove the radiator cap, wet its seal with engine coolant, then install it no pressure tester.

2. Apply a pressure of 93 ~ 123kPa (0.95 ~ 1.25kgf/cm², 14 ~ 19psi)
3. Check for a drop in pressure.
4. If the pressure drops, replace the cap.

TESTING
1. Wait until engine is cool, then carefully remove the radiator cap and fill the radiator with engine coolant, then install
it on the pressure tester.

2. Apply a pressure tester to the radiator and apply a pressure of 93 ~ 123kPa (0.95 ~ 1.25kgf/cm² 14 ~18psi).
3. Inspect for engine coolant leaks and a drop in pressure.
4. Remove the tester and reinstall the radiator cap.

Check for engine oil in the coolant and/or coolant in the engine oil.

2007 > 3.8L V6 GASOLINE >

COMPONENT

2007 > 3.8L V6 GASOLINE >

REMOVAL
WATER PUMP
1. Drain the engine coolant.

System is under high pressure when the engine is hot. To avoid danger of releasing scalding engine coolant,
remove the cap only when the engine is cool.
2. Remove drive belt(A).

3. Remove the 4 bolts and pump pulley(A).

4. Remove the water pump(A) and gasket.

WATER TEMPERATURE CONTROL ASSEMBLY
1. Drain the engine coolant.
2. Remove air cleaner assembly.

3. Disconnect radiator upper and lower hose(A).

4. Disconnect ECT connector.
5. Disconnect heater hose, water vent hose and water hose from water temperature control assembly.
6. Remove wiring protector.
7. Remove water temperature control assembly(A).

THERMOSTAT

Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency. Do not remove
the thermostat, even if the engine tends to overheat.
1. Drain engine coolant so its level is below thermostat.
2. Remove water inlet(A) and thermostat(B).

RADIATOR
1. Drain the engine coolant.
2. Remove the radiator grille upper cover(A).

3. Remove the radiator support upper member assembly(A) for convenience sake.

The bottom side bolt(A) which can be seen after removing the under cover should be loosened for removal of
the radiator support upper member assembly.

4. Disconnect radiator upper and lower hoses(A).

5. Disconnect transaxle oil cooler hoses(A).(Refer to TR group)

6. Disconnect the radiator fan connectors(A).

7. Disconnect the pressure lines(A) from the radiator assembly(B).

8. Seperate the condenser(A) from the radiator assembly(B) by removing the bolts(C).

9. Remove the radiator bracket.
10. Remove the radiator assembly.
11. Remove the radiator cooling fan(A).

INSTALLATION
WATER PUMP
1. Install the water pump(A) and a new gasket(B) with 12 bolts.
Tightening torque
21.56 ~ 23.52Nm (2.2 ~ 2.4kgf.m, 15.91 ~ 17.36lb-ft)
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

Make clean the contact face before assembly.

2. Install the 4 bolts and pump pulley(A).
Tightening torque
7.84 ~ 9.80Nm (0.8 ~ 1.0kgf.m, 5.78 ~ 7.23lb-ft)

3. Install drive belt(A).

4. Fill with engine coolant.
5. Start engine and check for leaks.
6. Recheck engine coolant level.

WATER TEMPERATURE CONTROL ASSEMBLY

Make clean the contact face before assembly.
1. Install water temperature control assembly(B) and new gasket(A).
Tightening torque
18.62 ~ 23.52Nm (1.9 ~ 2.4kgf.m, 13.74 ~ 17.36lb-ft)

Use new O-rings(C) when reassembling.
2. Connect water hoses to the water temperature control assembly.
3. Install wiring protector.
4. Connect ECT connector.
5. Connect radiator upper and lower hose(A).

6. Install air cleaner assembly.
7. Fill with engine coolant.
8. Start engine and check for leaks.
9. Recheck engine coolant level.

THERMOSTAT
1. Place thermostat in thermostat housing.
(1) Install the thermostat with the jiggle valve upward.
(2) Install a new thermostat(B).

2. Install water inlet(A).
Tightening torque
16.66 ~ 19.60Nm (1.7 ~ 2.0kgf.m, 12.30 ~ 14.47lb-ft)
3. Fill with engine coolant.
4. Start engine and check for leaks.

RADIATOR
1. Install the radiator fan(A) to the radiator.
Tightening torque
4.9 ~ 7.8Nm (0.5 ~ 0.8kgf.m, 3.6 ~ 5.8lb-ft)

2. Install the radiator assembly to the vehicle.
3. Install the radiator bracket.
4. Fix the condenser with the radiator assembly.
Tightening torque
4.9 ~ 7.8Nm (0.5 ~ 0.8kgf.m, 3.6 ~ 5.8lb-ft) — D
6.9 ~ 9.8Nm (0.7 ~ 1.0kgf.m, 5.1 ~ 7.2lb-ft) — C

5. Connect the radiator fan connectors(A).

6. Connect the pressure lines(A) to the radiator assembly(B).

7. Connect transaxle oil cooler hoses(A).(Refer to TR group)

8. Connect radiator upper and lower hoses(A).

9. Install the radiator support upper member assembly(A).

10. Install the radiator grille upper cover(A).

11. Fill with engine coolant.
12. Start engine and check for leaks.
13. Recheck engine coolant level.

INSPECTION
WATER PUMP
1. Check each part for cracks, damage or wear, and replace the coolant pump assembly if necessary.
2. Check the bearing for damage, abnormal noise and sluggish rotation, and replace the coolant pump assembly if
necessary.
3. Check for coolant leakage. If coolant leaks from hole, the seal is malfunctioning. Replace the coolant pump
assembly.

A small amount of «weeping» from the bleed hole is normal.

THERMOSTAT
1. Immerse the thermostat in water and gradually heat the water.

2. Check the valve opening temperature.
Valve opening temperature : 82°C (177°F)
Full opening temperature : 95°C (205°F)
If the valve opening temperature is not as specified, replace the thermostat.
3. Check the valve lift.
Valve lift : Min. 10mm (0.4in.) at 95°C (205°F)
If the valve lift is not as specified, replace the thermostat.

Lubrication system

2007 > 3.8L V6 GASOLINE >

OIL AND FILTER

a. Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading
to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants
which may cause skin cancer.
b. Exercise caution in order to minimize the length and frequency of contact of your skin to used oil. Wear
protective clothing and gloves. Wash your skin thoroughly with soap and water, or use water-less hand
cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents.
c. In order to preserve the environment, used oil and used oil filter must be disposed of only at designated
disposal sites.
1. Park the car on level ground.
Start the engine and let it warm up.
2. Turn the engine off and open the hood.
Remove the engine cover.
3. Loosen the oil filter cap by turining it clockwise with SST (09263-3C100). Allow 5 minutes for the oil in the filter
assembly to drain.

4. Drain the engine oil.
a. Remove the oil filler cap.
b. After lifting the car, remove the oil drain plug and drain the oil into a container.
5. Replace oil filter.
a. Disconnect the oil filter cap from oil filter body.
b. Remove the oil filter element.
c. Check and clean the oil filter installation surface.
d. Check the part number of the new oil filter is as same as old one.
e. Install new oil filter element(A) and two new O-rings(B).

f. Apply clean engine oil to the new O-rings.

Lightly screw the oil filter cap into place, and tighten it until the O-ring contacts the seat.
g. Finally tighten it again by specified tightening torque.
Tightening torque
24.50Nm (2.5kgf.m, 18.08lb-ft)
6. Refill with engine oil.
a. Install the oil drain plug with a new gasket.
Tightening torque
34.3 ~ 44.1Nm (3.5 ~ 4.5kgf.m, 25.3 ~ 32.5lb-ft)
b. Fill with fresh engine oil, after removing the engine oil level gauge.
Capacity
Total : 6.0 L (6.34 US qt, 5.27 lmp qt)
Oil pan : 5.5 L (5.81 US qt, 4.83 lmp qt)
Drain and refill including oil filter : 5.2 L (5.49 US qt, 4.57 lmp qt)
Oil quality : ABOVE API SJ / SL or SAE 5W-20
c. Install the oil filler cap and oil level gauge.
7. Start the engine and check to be sure no oil is leaking from the drain plug or oil filter.
8. Recheck engine oil level.

INSPECTION
1. Check engine oil quality.
Check the oil for deterioration, entry of water, discoloring or thinning.
If the quality is visibly poor, replace the oil.
2. Check engine oil level.
After warming up the engine and then 5 minutes after the engine stop, oil level should be between the «L» and «F»
marks on the dipstick.
If low, check for leakage and add oil up to the «F» mark.

Do not fill with engine oil above the «F» mark.

SELECTION OF ENGINE OIL
Recommended API classification : Above SJ or SL
Recommended SAE viscosity grades : 5W-20
If 5W-20 engine oil is not available, 5W-30 or secondary recommanded engine oil for carrespanding temperature
range can be used.

For best performance and maximum protection of all types of operation, select only those lubricants which :
a. Satisfy the requirement of the API classification.
b. Have proper SAE grade number for expected ambient temperature range.
Lubricants that do not have both an SAE grade number and API service classification on the container should not
be used.

2007 > 3.8L V6 GASOLINE >

COMPONENT

2007 > 3.8L V6 GASOLINE >

REMOVAL
Oil pump
1. Drain engine oil.
2. Using SST(09215-3C000) remove lower oil pan(A).

Be careful not to damage the contact surfaces of upper oil pan and lower oil pan.
3. Remove oil pump chain cover(A).

4. Remove oil pump chain sprocket(A).

5. Remove oil pump(A).

Oil filter assembly
1. Loosen the oil filter cap by turining it clockwise with SST (09263-3C100). Allow 5 minutes for the oil in the filter
assembly to drain.
2. Remove surge tank and intake manifold.
3. Disconnect oil pressure switch connector.
4. Drain the engine coolant.
5. Disconnect water hoses from ETC.
6. Remove water temperature control assembly.
7. Disconnect water vent hose(A).
8. Remove oil filter body cover(B).

9. Remove oil filter body.(A).

Be careful of the knock sensor connector.

INSTALLATION

Oil pump
1. Install oil pump(A).
Tightening torque
19.6 ~ 23.5Nm (2.0 ~ 2.4kgf.m, 14.5 ~ 17.4lb-ft)

Always use a new O-ring(B).

2. Install oil pump sprocket(A)and oil pump chain on the oil pump.
Tightening torque
18.62 ~ 21.56Nm (1.9 ~ 2.2kgf.m, 13.74 ~ 15.91lb-ft)

3. Install oil pump chain cover(A).
Tightening torque
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

4. Install lower oil pan.
a. Using a gasket scraper, remove all the old packing material from the gasket surfaces.
b. Before assembling the oil pan, the liquid sealant TB1217H should be applied on upper oil pan.
The part must be assembled within 5 minutes after the sealant was applied.
Bead width : 2.5mm(0.1in.)
But marked area(＊) to be 5.0mm(0.2in.)

a.
b.
c.
d.

Ensure the sealing face is clean before assembling two parts.
Remove harmful foreign matters on the sealing face before applying sealant
When applying sealant gasket, sealant must not be protruded into the inside of oil pan.
To prevent leakage of oil, apply sealant gasket ot the inner threads of the bolt holes.

c. Install lower oil pan.
Uniformly tighten the bolts in several passes.
Tightening torque
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

d. After assembly, wait at least 30 minutes before filling the engine with oil.

OIL FILTER ASSEMBLY
1. Install oil filter body(A) and new O-rings.
Tightening torque
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

a. All rubber gasket must be no damaged by assembling parts.
b. Be careful of the knock sensor connector.
c. Always use a new O-ring
2. Install oil filter body cover(B) and new gasket on the oil filter body.
Tightening torque
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

3. Connect water vent hose(A)
Tightening torque
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
4. Install water temperature control assembly.
5. Connect water hoses on the ETC.
6. Connect oil pressure switch connector.
7. Install intake manifold and surge tank.
8. Fill with engine coolant.
9. Start engine and check for leaks.
10. Recheck engine coolant level.

INSPECTION
OIL PRESSURE SWITCH
1. Check the continuity between the terminal and the body with an ohmmeter.
If there is no continuity, replace the oil pressure switch.

2. Check the continuity between the terminal and the body when the fine wire is pushed. If there is continuity even
when the fine wire is pushed, replace the switch.
3. If there is no continuity when a 50kpa (7psi) vacuum is applied throgh the oil hole, the switch is operaing properly.
Check for air leakage. If air leaks, the diaphragm is broken. Replace it.

Intake
and
Exhaust system

2007 > 3.8L V6 GASOLINE >

COMPONENT

2007 > 3.8L V6 GASOLINE >

REMOVAL
INTAKE MANIFOLD

a. Use fender covers to avoid damaging painted surfaces.
b. To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

a. Mark all wiring and hoses to avoid misconnection.
1. Remove the engine cover(A).

2. Remove the intake air hose and air cleaner assembly.
(1) Disconnect the MAF connector(A).
(2) Disconnect the breather hose(B) from air cleaner hose.
(3) Remove the intake air hose and air cleaner assembly(C).

3. Disconnect RH oxygen sensor connector(A).

4. Disconnect RH injector connector(A) and ignition coil connector(B).

5. Disconnect PCSV connector(A), MAP sensor connector(B) and PCSV hose.

6. Disconnect ETC connector(A) and knock sensor connector(B).

7. Remove ETC bracket(A).
8. Disconnect water hoses(B) from ETC.
9. Disconnect PCV(C) hose.

10. Disconnect brake vacuum hose.
11. Remove surge tank stay.
12. Remove connector bracket(A) from surge tank.

13. Remove surge tank(A).

14. Disconnect breather Pipe assembly(A).

15. Disconnect LH injector connector.

16. Remove the delivery pipe and intake manifold together.

EXHAUST MANIFOLD
1. Remove under cover(A).

2. Disconnect LH,RH rear oxygen sensor connector from bracket.
3. Remove front muffler(A).

4. Remove oil level gauge(A).
5. Disconnect LH front oxygen sensor connector(B) from bracket.

6. Remove LH heat protector(A).

7. Remove LH exhaust manifold.
8. Disconnect RH front oxygen sensor connector from bracket.

9. Remove RH heat protector.
10. Remove RH exhaust manifold.

INSTALLATION
INTAKE MANIFOLD
1. Install intake manifold and new gasket on the cylinder head.
Tightening torque
1st : 3.9 ~ 5.9Nm (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-ft)
2st : 18.62 ~ 23.52Nm (1.9 ~ 2.4kgf.m, 13.74 ~ 17.36lb-ft)
3st : Repeat 2nd step twice or move.

Be careful of the installation direction.
a — h : 1st step order

1 ~ 8 : 2nd step order

2. Install delivery pipe.(Refer to FL group)
3. Connect LH injector connector.
4. Connect breather Pipe assembly.
Tightening torque
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
5. Install surge tank.
Tightening torque
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
6. Install connector bracket on the surge tank.
Tightening torque
6.86 ~ 10.78Nm (0.7 ~ 1.1kgf.m, 5.06 ~ 7.96lb-ft)
7. Install surge tank stay.
Tightening torque
27.44 ~ 31.36Nm (2.8 ~ 3.2kgf.m, 20.25 ~ 23.14lb-ft)
8. Connect brake vacuum hose.
9. Connect PCV hose.
10. Connect water hoses to ETC.
11. Install ETC bracket.
Tightening torque
15.68 ~ 25.48Nm (1.6 ~ 2.6kgf.m, 11.57 ~ 18.80lb-ft)
12. Connect ETC connector and knoch sensor connector.
13. Connect PCSV connector, MAP sensor connector and PCSV hoe.
14. Connect RH injector connector and ignition coil connector.
15. Connect RH oxygen sensor connector.
16. Install air cleaner upper cover and in take hose.
17. Connect MAF(A) and breather hose.

EXHAUST MANIFOLD
1. Install new gasket and exhaust manifold.
Tightening torque
39.2 ~ 44.1Nm(4.0 ~ 4.5kgf.m, 28.92 ~ 32.53lb-ft)
2. Install heat protector.
Tightening torque
3.9 ~ 5.9Nm(0.4 ~ 0.6kgf.m, 2.89 ~ 4.34lb-ft)
3. Install front muffler.
Tightening torque
39.2 ~ 58.8N.m(4.0 ~ 6.0kgf.m, 28.92 ~ 43.37lb-ft)
4. Connect oxygen sensor connector.
5. Install under cover.

CHAPTER 7:

Manual Transaxle

General Information

2007 > J2.9L DIESEL CRDI(VGT) >

SPECIFICATIONS
Model

M5HF2

Related engine

J2.9WGT

J2.9VGT

Torque [Nm (kgf.m, lb-ft)

350 (35, 253)

Full length [mm(in)]

392.5 (15.45)

Weight [N(kgf, lbf)]

673.7 (68.7, 151)

Oil capacity

1.85ℓ

Oil replacement

Normal

Private

—

Business

100,000 Km

Severe use

Gear ratio

100,000 Km

1st

3.600

3.438

2nd

1.875

1.800

3rd

1.205

1.154

4th

0.818

0.818

5th

0.768

0.768

Reverse

4.320

4.050

Reduction gear ratio

4.500(1-4th gear)/3.706(5,R gear)

Lubricant

SAE 75W/85, API GL — 4

SYNCRONIZED RING ASSEMBLY
1st

2nd

3rd

4th

5th

Reverse

Type

Triple

←

←

Double

←

←

Material

Brass +Carbon

←

←

Brass

Brass

Brass +
Carbon

Key type

Assembly of key, ball and
spring

←

←

←

←

←

Hub&Sleeve
FITTING

Minor Dia. Fit

←

←

←

←

←

Clutch gear chamfer

Symmetrical chamfer

Asymmetrical
chamfer

←

←

←

Symmetrical
chamfer

2007 > J2.9L DIESEL CRDI(VGT) >

DESCRIPTION
VQ Diesel (J2.9) model has the manual transaxle (M5HF2).
IMPROVEMENT
ITEM

Better shift feeling

Better duability
Cost saving&Convenience

Improvement
a.
b.
c.
d.

New shift pattern
Multi cone synchronizer system
Module of control system
New type of poppet ball

a. Optimizing strength of shift control system
b. Optimizing strength of housing and cases (for NVH)
c. Carbonized material for synchronized rings
a. Permanent oil (low viscosity)

This new shift pattern has the same shift direction for both 1st and Reverse which is convenient when on traffic jam or
parking (1↔R).
You should pull the lower part of the shift lever to shift in reverse.

SHIFT CONTROL SYSTEM
● SHIFT CONTROL SYSTEM
The module of the shift control system improves shift feeling and quality of the part itself.

New type of poppet ball

Items

M5HF2

M5AF3, M5BF2

Character

Easy shifting

Medium shifting

SYNCHRONIZER SYSTEM
COMPONENTS

SYNCHRONIZER TYPE
Both triple cone (1st-3rd) and double cone (4th-R) synchronizer rings, which have more friction surfaces, improve shift
feeling.

CLUTCH GEAR CHAMFER

Manual Transaxle System

2007 > J2.9L DIESEL CRDI(VGT) >

COMPONENTS

2007 > J2.9L DIESEL CRDI(VGT) >

REMOVAL

a. Use a cover not to damage the vehicle surface.
b. Disconnect connectors carefully not to be damaged.

a. Mark wires or hoses for identification not to be confused.
1. Remove the battery (A).

2. Disconnect the AFS connector (A).

3. Remove the air cleaner upper cover (B) by loosening the clips (A).

4. Remove the air cleaner assembly (A) by removing the two mounting bolts.

5. Disconnect the air cleaner hose (B) by loosening the clamp (A).

6. Remove the battery tray (B) by removing the four mounting bolts (A).

7. Remove the ground wire (A) from the transaxle case.

8. Remove the vehicle speed sensor connector (A).

9. Remove the shift cable by removing the bolt (A) and clip (B).

10. Disconnect the «N» (A) and the «R» (B) position switch.

11. Remove C.S.C (Concentric Slave Cylinder) tube which is being clamped.
12. Remove the CKP sensor from the clutch housing assembly.
13. Remove the mounting bolts of upper part of the transaxle.
14. Support the engine and transaxle by using the special tool (09200-38001).
15. Remove the transaxle insulator (B) and the bracket (C) by removing the bolts (A).

16. Remove the front wheels and tires. (see SS group)
17. Remove the steering column joint bolt. (see ST group)
18. Lift up the vehicle.
19. Remove the under cover.
20. Drain power steering oil through the return tube. (see ST group)
21. Disconnect the power steering pressure hose (A) from the power steering oil pump.

22. Disconnect the lower arm, the tie rod end ball joint, the stabilizer bar link from the front knuckle. (see SS group)
23. Remove the roll stopper mounting bolts.
24. Remove the mounting bolts from the sub frame by supporting the sub frame with a jack. (see SS group)
25. Remove the drive shafts from the transaxle. (see DS group)
26. Remove the plate between the engine and transaxle.
27. Disconnect the starter motor connector and remove the starter motor. (see EE group)
28. Remove the mounting bolts of lower part of the transaxle, brackets (A,B), and the left side cover and remove the
transaxle assembly by supporting it with a jack.

INSTALLATION
Installation is in the reverse order of removal.
Perform the following :
a. Adjust the shift cable.
b. Refill the transaxle with fluid.
c. Refill the radiator with engine coolant.
d. Bleed air from the cooling system with the heater valve open.
e. Clean the battery posts and cable terminals with sandpaper, assemble them, and apply grease to prevent
corrosion.
1. Lowering the vehicle or lifting up a jack, install the transaxle assembly.
2. Tighten the transaxle under mounting bolts.
TORQUE:
65~85 Nm(650~850 kgf.cm, 47.0~61.5 lb-ft)
3. Install the plate between the engine and transaxle.
TORQUE :
8~11 Nm(80~110 kgf.cm, 5.8~8.0 lb-ft)
4. Install the brackets.
TORQUE :
19~26 or 38~53Nm (190~260 or 380~530kgf.cm, 13.8~18.9 or 27.3~38.5lb-ft)
5. Install the starter motor and connect the starter motor connector. (see EE group)
6. Install the drive shafts to the transaxle. (See «DS» group)
7. Install the transaxle insulator (B) and mounting bracket (C) by tightening the bolts (A).
TORQUE:
60~80 Nm (600~800 kgf.cm, 43.6~58.2 lb-ft)

8. Install the sub frame. (see SS group)
TORQUE:
60~80 Nm(600~800 kgf.cm, 65.1~79.5 lb-ft)
9. Connect the return tube(B) with a clamp(A). (see ST group)

10. Connect the lower arm, the tie rod end ball joint, the stabilizer bar link to the front knuckle. (see SS group)
11. Connect the power steering pressure hose (A) to the power steering oil pump.

12. Install the under cover.
13. Install the steering column joint bolt. (see ST group)
14. Refill transaxle oil through the inlet hole (A).
TORQUE:
30~35 Nm(300~350 kgf.cm, 21.8~25.4 lb-ft)

15. Install the front wheels and tires. (see SS group)
16. Tighten the transaxle mounting bolts and remove the SST (09200-38001) holding the engine and transaxle
assembly.
TORQUE:
70~91 or 38~53Nm(700~910 or 380~530 kgf.cm, 50.9~66.2 or 27.6~38.5 lb-ft)
17. Install the CKP sensor to the clutch housing assembly.
TORQUE:
9~10 Nm(90~100 kgf.cm, 6.5~7.3 lb-ft)
18. Install the C.S.C (Concentric Slave Cylinder) tube and loosen the tube.
19. Connect the «N» (A) and the «R» (B) position switch.

20. Install the shift cable(A) by tightening the clip (C) and pin (B).

21. Install the vehicle speed sensor connector (A).

22. Install the ground wire (A) from the transaxle case.

23. Install the battery tray (B) by removing the four mounting bolts (A).

24. Connect the air cleaner hose (B) by tightening the clamp (A).

25. Install the air cleaner assembly (A) by tightening the two mounting bolts.

26. Install the air cleaner upper cover (B) by tightening the clips (A).

27. Connect the AFS connector (A).

28. Install the battery (A).

Shift Lever

2007 > J2.9L DIESEL CRDI(VGT) >

COMPONENTS

2007 > J2.9L DIESEL CRDI(VGT) >

REMOVAL
1. Remove the console upper cover(A). (see BD group)

[LHD]

[RHD]

2. Remove the front console cover. (see BD group)
3. Remove the shift cable and the select cable by removing the pin (A) and clip (B).

[LHD]

[RHD]

4. Remove the shift lever assembly mounting nuts (A).

[LHD]

[RHD]

INSTALLATION
1. Install the shift lever assembly mounting nuts (A).
TORQUE:
18~27 Nm(180~270 kgf.cm, 13.1~19.6 lb-ft)

[LHD]

[RHD]

2. Install the shift cable and the select cable by installing the pin (A) and clip (B).

[LHD]

[RHD]

When adjusting the cable, follow the instruction as :

[LHD]

[RHD]

Place the shift lever in «N» position.
a. Insert the eye end (A).
b. Install the snap pin (B).
c. Insert the lock piece (C).
d. Clamp the locking clamp (D).

3. Install the front console cover. (see BD group)
4. Install the console upper cover(A). (see BD group)

[LHD]

[RHD]

DISASSEMBLY
1. Remove both sides of the brackets.
2. Remove the shift lever knob (A) by rotating counterclockwise and remove the spring (B), damper, and skirt (C).

[LHD]

[RHD]

REASSEMBLY
Reassembling is in reverse order of disassembling.
TORQUE(bracket mounting bolts):
18~27 Nm(180~270 kgf.cm, 13.1~19.6 lb-ft)

Manual Transaxle Shift
Control

2007 > J2.9L DIESEL CRDI(VGT) >

COMPONENTS

CHAPTER 7:

Manual Transaxle

General Information

2007 > J2.9L DIESEL CRDI(VGT) >

SPECIFICATIONS
Model

M5HF2

Related engine

J2.9WGT

J2.9VGT

Torque [Nm (kgf.m, lb-ft)

350 (35, 253)

Full length [mm(in)]

392.5 (15.45)

Weight [N(kgf, lbf)]

673.7 (68.7, 151)

Oil capacity

1.85ℓ

Oil replacement

Normal

Private

—

Business

100,000 Km

Severe use

Gear ratio

100,000 Km

1st

3.600

3.438

2nd

1.875

1.800

3rd

1.205

1.154

4th

0.818

0.818

5th

0.768

0.768

Reverse

4.320

4.050

Reduction gear ratio

4.500(1-4th gear)/3.706(5,R gear)

Lubricant

SAE 75W/85, API GL — 4

SYNCRONIZED RING ASSEMBLY
1st

2nd

3rd

4th

5th

Reverse

Type

Triple

←

←

Double

←

←

Material

Brass +Carbon

←

←

Brass

Brass

Brass +
Carbon

Key type

Assembly of key, ball and
spring

←

←

←

←

←

Hub&Sleeve
FITTING

Minor Dia. Fit

←

←

←

←

←

Clutch gear chamfer

Symmetrical chamfer

Asymmetrical
chamfer

←

←

←

Symmetrical
chamfer

2007 > J2.9L DIESEL CRDI(VGT) >

DESCRIPTION
VQ Diesel (J2.9) model has the manual transaxle (M5HF2).
IMPROVEMENT
ITEM

Better shift feeling

Better duability
Cost saving&Convenience

Improvement
a.
b.
c.
d.

New shift pattern
Multi cone synchronizer system
Module of control system
New type of poppet ball

a. Optimizing strength of shift control system
b. Optimizing strength of housing and cases (for NVH)
c. Carbonized material for synchronized rings
a. Permanent oil (low viscosity)

This new shift pattern has the same shift direction for both 1st and Reverse which is convenient when on traffic jam or
parking (1↔R).
You should pull the lower part of the shift lever to shift in reverse.

SHIFT CONTROL SYSTEM
● SHIFT CONTROL SYSTEM
The module of the shift control system improves shift feeling and quality of the part itself.

New type of poppet ball

Items

M5HF2

M5AF3, M5BF2

Character

Easy shifting

Medium shifting

SYNCHRONIZER SYSTEM
COMPONENTS

SYNCHRONIZER TYPE
Both triple cone (1st-3rd) and double cone (4th-R) synchronizer rings, which have more friction surfaces, improve shift
feeling.

CLUTCH GEAR CHAMFER

Manual Transaxle System

2007 > J2.9L DIESEL CRDI(VGT) >

COMPONENTS

2007 > J2.9L DIESEL CRDI(VGT) >

REMOVAL

a. Use a cover not to damage the vehicle surface.
b. Disconnect connectors carefully not to be damaged.

a. Mark wires or hoses for identification not to be confused.
1. Remove the battery (A).

2. Disconnect the AFS connector (A).

3. Remove the air cleaner upper cover (B) by loosening the clips (A).

4. Remove the air cleaner assembly (A) by removing the two mounting bolts.

5. Disconnect the air cleaner hose (B) by loosening the clamp (A).

6. Remove the battery tray (B) by removing the four mounting bolts (A).

7. Remove the ground wire (A) from the transaxle case.

8. Remove the vehicle speed sensor connector (A).

9. Remove the shift cable by removing the bolt (A) and clip (B).

10. Disconnect the «N» (A) and the «R» (B) position switch.

11. Remove C.S.C (Concentric Slave Cylinder) tube which is being clamped.
12. Remove the CKP sensor from the clutch housing assembly.
13. Remove the mounting bolts of upper part of the transaxle.
14. Support the engine and transaxle by using the special tool (09200-38001).
15. Remove the transaxle insulator (B) and the bracket (C) by removing the bolts (A).

16. Remove the front wheels and tires. (see SS group)
17. Remove the steering column joint bolt. (see ST group)
18. Lift up the vehicle.
19. Remove the under cover.
20. Drain power steering oil through the return tube. (see ST group)
21. Disconnect the power steering pressure hose (A) from the power steering oil pump.

22. Disconnect the lower arm, the tie rod end ball joint, the stabilizer bar link from the front knuckle. (see SS group)
23. Remove the roll stopper mounting bolts.
24. Remove the mounting bolts from the sub frame by supporting the sub frame with a jack. (see SS group)
25. Remove the drive shafts from the transaxle. (see DS group)
26. Remove the plate between the engine and transaxle.
27. Disconnect the starter motor connector and remove the starter motor. (see EE group)
28. Remove the mounting bolts of lower part of the transaxle, brackets (A,B), and the left side cover and remove the
transaxle assembly by supporting it with a jack.

INSTALLATION
Installation is in the reverse order of removal.
Perform the following :
a. Adjust the shift cable.
b. Refill the transaxle with fluid.
c. Refill the radiator with engine coolant.
d. Bleed air from the cooling system with the heater valve open.
e. Clean the battery posts and cable terminals with sandpaper, assemble them, and apply grease to prevent
corrosion.
1. Lowering the vehicle or lifting up a jack, install the transaxle assembly.
2. Tighten the transaxle under mounting bolts.
TORQUE:
65~85 Nm(650~850 kgf.cm, 47.0~61.5 lb-ft)
3. Install the plate between the engine and transaxle.
TORQUE :
8~11 Nm(80~110 kgf.cm, 5.8~8.0 lb-ft)
4. Install the brackets.
TORQUE :
19~26 or 38~53Nm (190~260 or 380~530kgf.cm, 13.8~18.9 or 27.3~38.5lb-ft)
5. Install the starter motor and connect the starter motor connector. (see EE group)
6. Install the drive shafts to the transaxle. (See «DS» group)
7. Install the transaxle insulator (B) and mounting bracket (C) by tightening the bolts (A).
TORQUE:
60~80 Nm (600~800 kgf.cm, 43.6~58.2 lb-ft)

8. Install the sub frame. (see SS group)
TORQUE:
60~80 Nm(600~800 kgf.cm, 65.1~79.5 lb-ft)
9. Connect the return tube(B) with a clamp(A). (see ST group)

10. Connect the lower arm, the tie rod end ball joint, the stabilizer bar link to the front knuckle. (see SS group)
11. Connect the power steering pressure hose (A) to the power steering oil pump.

12. Install the under cover.
13. Install the steering column joint bolt. (see ST group)
14. Refill transaxle oil through the inlet hole (A).
TORQUE:
30~35 Nm(300~350 kgf.cm, 21.8~25.4 lb-ft)

15. Install the front wheels and tires. (see SS group)
16. Tighten the transaxle mounting bolts and remove the SST (09200-38001) holding the engine and transaxle
assembly.
TORQUE:
70~91 or 38~53Nm(700~910 or 380~530 kgf.cm, 50.9~66.2 or 27.6~38.5 lb-ft)
17. Install the CKP sensor to the clutch housing assembly.
TORQUE:
9~10 Nm(90~100 kgf.cm, 6.5~7.3 lb-ft)
18. Install the C.S.C (Concentric Slave Cylinder) tube and loosen the tube.
19. Connect the «N» (A) and the «R» (B) position switch.

20. Install the shift cable(A) by tightening the clip (C) and pin (B).

21. Install the vehicle speed sensor connector (A).

22. Install the ground wire (A) from the transaxle case.

23. Install the battery tray (B) by removing the four mounting bolts (A).

24. Connect the air cleaner hose (B) by tightening the clamp (A).

25. Install the air cleaner assembly (A) by tightening the two mounting bolts.

26. Install the air cleaner upper cover (B) by tightening the clips (A).

27. Connect the AFS connector (A).

28. Install the battery (A).

Shift Lever

2007 > J2.9L DIESEL CRDI(VGT) >

COMPONENTS

2007 > J2.9L DIESEL CRDI(VGT) >

REMOVAL
1. Remove the console upper cover(A). (see BD group)

[LHD]

[RHD]

2. Remove the front console cover. (see BD group)
3. Remove the shift cable and the select cable by removing the pin (A) and clip (B).

[LHD]

[RHD]

4. Remove the shift lever assembly mounting nuts (A).

[LHD]

[RHD]

INSTALLATION
1. Install the shift lever assembly mounting nuts (A).
TORQUE:
18~27 Nm(180~270 kgf.cm, 13.1~19.6 lb-ft)

[LHD]

[RHD]

2. Install the shift cable and the select cable by installing the pin (A) and clip (B).

[LHD]

[RHD]

When adjusting the cable, follow the instruction as :

[LHD]

[RHD]

Place the shift lever in «N» position.
a. Insert the eye end (A).
b. Install the snap pin (B).
c. Insert the lock piece (C).
d. Clamp the locking clamp (D).

3. Install the front console cover. (see BD group)
4. Install the console upper cover(A). (see BD group)

[LHD]

[RHD]

DISASSEMBLY
1. Remove both sides of the brackets.
2. Remove the shift lever knob (A) by rotating counterclockwise and remove the spring (B), damper, and skirt (C).

[LHD]

[RHD]

REASSEMBLY
Reassembling is in reverse order of disassembling.
TORQUE(bracket mounting bolts):
18~27 Nm(180~270 kgf.cm, 13.1~19.6 lb-ft)

Manual Transaxle Shift
Control

2007 > J2.9L DIESEL CRDI(VGT) >

COMPONENTS

General Information

2007 > J2.9L DIESEL CRDI(VGT) >

SPECIAL TOOLS
Tool
(Number and Name)
09411-43000
Clutch disc guide

Illustration

Use
Installation of the clutch disc

2007 > J2.9L DIESEL CRDI(VGT) >

SPECIFICATION
Item

SPECIFICATION

Engine type

J2.9

Clutch operation

Hydraulic type

Clutch disc

Single dry with diaphragm

Clutch cover assembly

Self Adjusting Clutch

TIGHTENING TORQUE
Item

Nm

Kgf.cm

lb-ft

Clutch cover (6EA)

25~36

250~360

18.2~26.2

Clutch pedal bracket mounting

19~26

190~260

13.8~18.9

Regulator bolt

28~33

280~330

20.3~24

Connecting rod adjusting bolt

9~14

90~140

6.5~10.1

Clutch master cylinder mounting

12~16

120~160

8.7~11.6

Stopper bolt

8~10 or 14~20

80~100 or 140~200

5.8~7.27 or
10.1~14.5

Clutch pedal bolt/nut

25~34

250~340

18.1~24.7

SERVICE STANDARD
Item

Standard value

Clutch pedal stroke

150mm (5.91in)

Clutch pedal free play

6~13mm (0.24~0.51in)

Clutch System

2007 > J2.9L DIESEL CRDI(VGT) >

DESCRIPTION
SELF ADJUSTING CLUTCH(S.A.C.) COVER
a. As a clutch disc facing is worn away according to its durability, a cover weight is increasing and a clutch pedal
pressure can be more needed.
b. To make up for this defect, the self adjusting clutch system makes the requsted pedal pressure minimized so that
makes the maintenance cycle longer.

CONCENTRIC SLAVE CYLINDER-C.S.C.
It improves working efficiency and lowers the number and the weight of part by unifing clutch release control
parts(clutch release bearing ~ clutch release cylinder) in a manual transaxle.

OPERATION
CONCENTRIC SLAVE CYLINDER-C.S.C
When the clutch pedal is pressed, oil pressure is transmitted along the arrow directions shown below and that moves
the clutch slave cylinder and the diaphragm spring of the clutch cover.

Clutch Cover and Disc

2007 > J2.9L DIESEL CRDI(VGT) >

COMPONENTS

2007 > J2.9L DIESEL CRDI(VGT) >

REPLACEMENT
1. Remove a transaxle assembly (refer to ‘MT’-group).
2. Remove the clutch cover bolts. Not to be bent or twisted, loosen them in diagonal directions.

3. Remove the clutch cover and disc.
4. Using the SST(09411-43000), install a clutch disc and cover.

a. Replace a clutch cover and disc as a set.
* Possible problems when not following the caution
a. When replacing only a disc, slip problem can occur because of the initial clamp load loss by the adjusting
ring’s unusual work.
b. When replacing only a disc, it can be difficult to cut power because the thickness of the disc cannot be
permitted.
b. Apply grease on a disc spline part and transmission input shaft spline part as required.
* Possible problems when not following
a. When not applying: Excessively wear of splines and bad clutch operation
b. When excessively applying: Scattered grease by centrifugal force conteminates the clutch disc. Loss of friction
force can cause a slip
c. The ‘T/M SIDE’ marked surface should face the transaxle.
→ If the surface face the opposite side, there can be an interference between a disc and a flywheel surface.

5. Tighten the clutch cover.
TORQUE:
24.5~35.3Nm (250~360kgf.cm, 18.1~26.0lb-ft) (6EA)

When installing the clutch cover, tighten the bolts in diagonal directions not to be bent or twisted.

* Possible problems when not following
a. When tightening the bolt completely at a time: the clutch cover can be twisted and vibration can occur.
b. On vehicles with self adjusting clutches, it is necessary to follow this caution.
c. Not following tightening torque: There can be bad torque transmission in clutch and relaxation possibility of
bolts.

INSPECTION
1. Inspect diaphragm spring wear which is in contact with a concentric slave cylinder bearing.

2. Check the clutch cover and disc surface for wear or crack.
3. Check the clutch disc lining for slipping or oil mark.
4. Measure the depth from a clutch lining surface to a rivet. If the measured value is less than the specification below,
replace it.
Specification: 0.3mm(0.0118inch)

Clutch Master Cylinder

2007 > J2.9L DIESEL CRDI(VGT) >

REMOVAL

Do not spill brake fluid on the vehicle; it may damage the paint if brake fluid does contact the paint, wash it off
immediately with water.
1. Remove the brake fluid fron the clutch master cylinder reservoir with a syringe.
2. Clamp the clutch master cylinder hose(A). If there is no enough room for clamping, you can also clamp the hose
from the brake master cylinder side.

3. Disconnect the hose(A) from the cylinder by releasing the clutch master cylinder clamp.

4. Remove the clutch master cylinder mounting bolts(A,B).
One is the engine room, the other near the clutch pedal assembly.

5. Remove the pin and washer which connect the clutch pedal with the clutch master cylinder.
6. Remove the clutch master cylinder. It can be helpful to do this step after removing the clutch pedal mounting
bracket.

INSTALLATION
Installation is in the reverse order of removal.
After installation, bleed the clutch hydaulic system.

CONCENTRIC SLAVE CYLINDER AIR BLEEDING PROCEDURE
1. After disconnecting a cap from the concentric slave cylinder air bleeder, insert a vinyl hose in the plug.
2. Loosening the plug screw, press and release the clutch pedal about 10 times.

Hold the air bleeder body not to rotate with a spanner(A). The holding is needed when the plug loosened or
tightened.
3. Tighten the plug during the clutch pedal pressed. Afterwards, raise the pedal with a hand.
TORQUE :
25~29Nm (250~290Kgf.cm, 18.2~21.1lb-ft)
4. After pressing the clutch pedal 3 times more, loosen the plug and retighten it with the pedal pressed. Raise it
again, then.
5. Repeat the step 4 two or three times. (until there is no bubble in the fluid)

a. Do not clamp the pipe of a concentric slave cylinder.
b. Be careful not to damage O-rings.

Clutch Pedal

2007 > J2.9L DIESEL CRDI(VGT) >

ADJUSTMENT PROCEDURE
IGNITION LOCK SWITCH
1. Disconnect 2P-connector from a ignition lock switch.
2. Disconnect the ignition lock switch. (if you can install a tester with the switch fixed, this step can be omissible)
3. Check for continuity between terminals. (refer to the table below)
Clutch pedal position

Ignition lock switch

Continuity

Released

Released

NO

Pressed

Pressed

YES

If there is difference between what tested and the table above, replace the ignition lock switch with a new one.
If not, install the ignition lock switch and adjust the clutch pedal.
TORQUE :
8~10Nm (80~100kgf.cm, 5.8~7.2lb-ft)

Clutch pedal and Ignition lock switch

a. Inspect a ignition lock switch.
b. Remove the driver’s seat mat to adjust a clutch pedal.
c. No gap between a clutch master cylinder pistion and push rod can cause clutch slip.
1. Loosen and draw out the bolt until it is off the pedal surface.
2. Push and pull a clutch master cylinder push rod to satisfy the specification below.
Specification:
Clutch pedal stroke(A) — 150mm(5.91in)
Clutch pedal free play(B) — 6~13mm(0.24~0.51in)
Clutch pedal distance — 234.7mm(9.24in)

3. With no pressure on a clutch pedal, tighten the bolt until it contacts on the pedal.
4. Fix the bolt with a nut.
TORQUE :
14~20Nm (140~200kgf.cm, 10.2~14.5lb-ft)

5. Press the clutch pedal to the seat ground.
6. Adjust the ignition lock switch position with the pedal a little(23~26mm) raised.
7. Install the ignition lock switch firmly.
TORQUE:
8~10Nm (80~100kgf.cm, 5.8~7.2lb-ft)

REPLACEMENT

a. Inspect the continuity of the ignition lock switch.
b. Remove the floor mat before adjusting the clutch pedal.
1. Remove the ignition lock switch.
2. Remove the snap pin and the clevis pin(A) connecting the clutch master cylinder push rod and the clutch pedal.

3. Remove the clutch master cylinder mounting nut(A,B) and the clutch pedal mounting nut(C).

4. Remove the clutch pedal.
5. Install a new one by tightening the bolts of the clutch pedal bracket and master cylinder .
TORQUE :
19~26 Nm(19~260 kgf.cm, 13.8~18.9 Ib-ft)(Clutch pedal bracket)
12~16 Nm(120~160 kgf.cm, 8.7~11.6 Ib-ft)(Clutch master cylinder)
6. Grease the clevis pin and insert it and the snap pin.
7. Adjust the clutch pedal and the ignition lock switch.

CHAPTER 6:

Automatic Transaxle
System

General Information

2007 > 2.7L V6 GASOLINE >

SPECIAL TOOLS
TOOL
(Number and name)
09200 — 38001
Engine support fixture

Illustration

Use
Removal and installation of transaxle.

2007 > 3.8L V6 GASOLINE >

SPECIFICATIONS
Engine type

DIESEL(J2.9)

GASOLINE(λ-3.8)

Transaxle type

A5HF1

A5HF1

1ST

4.497

←

2ND

2.442

←

3RD

1.686

←

4TH

1.233

←

5TH

0.868

←

REV.

4.586

←

Final gear ratio

3.333

←

T/M oil capacity(ℓ)※

10.7

10.9

Gear ratio

※ The quantity in the chart above is for the reference. The actual filling quantity of the automatic transaxle fluid must
be set according to ‘INSPECTION’ or ‘REPLACEMENT’ procesure of the automatic transaxle fluid.
Recommended transaxle oil

Diamond ATF SP Ⅲ or SK ATF SP Ⅲ

Check & Replenishment

Every one year or every 20,000km
Every one year or every 15,000km only for European contries

Replacement

Normal use

Private use

Severe use(＊)
Business use

No service required
Every 100,000km only for Australia
Every 90,000km only for European contries
Every 40,000km
Every 45,000km only for European contries

＊ Severe use(marked ‘＊’) is defined as:
1. Driving on rough road(bumpy road, gravel road, snowy road, unpaved road etc.).
2. Driving on mountain road, ascent/descent.
3. Repetition of short distance driving.
4. More than 50% operation in heavy city traffic during hot weather above 32°C(89.6°F).
5. Police car, Taxi, Commercial type operation or trailer towing, etc.

Automatic Transaxle
System

2007 > 3.8L V6 GASOLINE >

DESCRIPTION
1. Structure & Technical highlights

2. Variable Line Pressure Control
a. Description
a. Form the most suitable line pressure according to the vehicle driving condition
b. Special Features
a. VFS (Variable Force Solenoid) valve (For varying line pressure)
b. Reducing valve added(Stabilize control pressure in shiftings)
c. Effects

a. Improved power transmission efficiency and fuel consumption

3. Gear durability improvement and less-noisy gear development
a. Description
a. Optimal gear transmission ratio design from analyzing gears
b. Special Features
a. Apply High-strength gear material
b. Gear teeth width increased
c. Planetary gear (3 pinions → 4 pinions)
d. Less-noisy gear development
c. Effects
a. Durability improvement
b. Reduction of noise level
4. Case/Housing intensity reinforced
a. Description
a. Case/Housing intensity reinforced
b. Special Features
a. Converter housing intensity reinforced(Ribs added and thickness increased)
b. Most suitable stiff reinforcement through analyzing
c. Effects
a. Intensity increased and banding vibration decreased
b. NVH Performance improvement
5. New frictional material
a. Description
a. Apply new frictional material for capacity and durability improvement
b. Special Features
a. SSP (Single Sided Plate) applied only on overdrive clutch and 2nd brake
b. Apply the next generation frictional material(BWA 6100/D 0880-88)
c. Effects
a. Thermal absorption capacity improvement
b. Energy capacity and durability improvement

MECHANICAL SYSTEM
CLUTCHES AND BRAKES FOR EACH RANGE
UD
Clutch

OD
Clutch

2ND
Brake

LR Brake

REV
Clutch

RED
Brake

DIR
Clutch

OWC 1

OWC 2

P

—

—

—

O

—

O

—

—

—

R

—

—

—

O

O

O

—

—

—

N

—

—

—

O

—

O

—

—

—

1st

O

—

—

O

—

O

—

●

●

2nd

O

—

O

—

—

O

—

—

●

3rd

O

O

—

—

—

O

—

—

●

4th

—

O

O

—

—

O

—

—

●

5th

—

O

O

—

—

—

O

—

—

D

(● : Locked when driving)
FUNCTIONS OF CLUTCHES AND BRAKES
Element
Underdrive clutch

Sign
UD

Function
Connect the input shaft with the underdrive sun gear

Reverse clutch

REV

Connect the input shaft with the reverse sun gear

Overdrive clutch

OD

Connect the input shaft with the overdrive carrier

Direct clutch

DIR

Connect the direct sun gear with the direct carrier

Low& Reverse brake

LR

Fix the planetary gear and the overdrive carrier

2nd brake

2ND

Fix the reverse sun gear

Reduction brake

RED

Fix the direct sun gear

One way clutch 1

OWC 1

Control the rotational driection of the low&reverse ring gear

One way clutch 2

OWC 2

Control the rotational driection of the direct sun gear

AUTOMATIC TRANSAXLE HYDRAULIC CIRCUIT
P/N

D(1 RANGE)

D(2 RANGE)

D(3 RANGE)

D(4 RANGE)

D(5 RANGE)

R RANGE

2007 > 3.8L V6 GASOLINE >

SERVICE ADJUSTMENT PROCEDURE
Automatic transaxle fluid
INSPECTION
1. Drive the vehicle until the fluid reaches normal operating temperature [70~80°C].
2. Place the vehicle on a level surface.
3. Move the selector lever through all gear positions. This will fill the torque converter and the hudraulic system with
fluid and move the selector lever to the «N» (Neutral) or «P»(Park) position.
4. Before removing the oil level gauge, wipe all contaminants from around the oil level gauge. Then take out the oil
level gauge and check the condition of the fluid.

If the fluid smells as if it is burning, it means that the fluid has been contaminated by fine particles from the
bushes and friction materials, a transaxle overhaul may be necessary.
5. Check that the fluid level is at the HOT mark on the oil level gauge. If the fluid level is low, add automatic transaxle
fluid until the level reaches the «HOT» mark.
Auto transaxle fluid:
DIAMOND ATF SP-III, SK ATF SP-III
Quantity : 10.7ℓ(Diesel), 10.9ℓ(Gasoline)

Low fluid level can cause a variety of a abnormal conditions because it allows the pump to take in air along
with fluid. Air trapped in the hydraulic system forms bubbles, which are compressable. Therefore, pressures
will be erratic, causing delayed shifting ,slipping clutches and brakes, etc. Improper filling can also raise fluid
level too high. When the transaxle has too much fluid, gears churn up foam and acuise the same conditions
which occur with low fluid level, resulting in accelerated deterioration of automatic transaxle fluid. In either
case, air bubbles can cause overheating, and fluid oxidation, which can interfere with normal valve, clutch, and
brake operation. Foaming can also result in fluid escaping from the transaxle vent where it may be mistaken
for a leak.
6. Insert the oil level gauge securely.

When new, automatic transmission fluid should be red. The red dye is added so the assembly plant can
identify it as transmission fluid and distinguish it from engine oil or antifreeze. The red dye, which is not an
indicator of fluid quality, is not permanent. As the vehicle is driven the transmission fluid will begin to look
darker. The color may eventually appear light brown.

REPLACEMENT
If you have a fluid changer, use this changer to replace the fluid. If you do not, replace it using the following
procedure.
1. Disconnect the hose which connects the transmission and the oil cooler.
2. Start the engine and let the fluid drain out.
Running conditions : «N» range with engine idling.

The engine should be stopped within one minute after it is started. If the fluid has all drained out before then,
the engine should be stopped at that point.

the engine should be stopped at that point.
3. Romove the drain plug(A) from the bottom of the transmission case to drain the fluid.

4. Install the drain plug via the gasket, and tighten it to the specified torque.
TORQUE :
40 ~ 50Nm (400 ~ 500 kgf.cm, 29 ~ 36 lb-ft)
5. Pour the new fluid in through the oil filler tube.

Stop pouring if the full volume of fluid cannot be poured in.
6. Repeat the procedure in step (2).

Check the old fluid for contamination. If it has been contaminated, repeat the steps (5) and (6).
7. Pour the new fluid in through the oil filler tube.
8. Reconnect the hose which was disconnected in step (1) above and firmly replace the oil level gauge.(In case of
this «replace», this means after wiping off any dirt around the oil level gauge, insert it into the filler tube.)
9. Start the engine and run it at idle for 1~2 minutes.
10. Move the select lever through all positions, and then move it to the «N» position.
11. Drive the vehicle until the fluid temperature rises to the normal temperature (70~80°C), and then check the fluid
level again. The fluid level must be at the HOT mark.
12. Firmly insert the oil level gauge into the oil filler tube.

Automatic Transaxle

2007 > 3.8L V6 GASOLINE >

COMPONENTS (1)

COMPONENTS (2)

2007 > 3.8L V6 GASOLINE >

REMOVAL

a. Use a cover not to damage the vehicle surface.
b. Disconnect connectors carefully not to be damaged.

a. Mark wires or hoses for identification.
1. Remove the battery (A).

2. Disconnect the AFS connector (A).

3. Remove the air cleaner upper cover (B) by loosening the clips (A).

4. Remove the air cleaner assembly (A).

5. Disconnect the air cleaner hose (B) by loosening the clamp (A).

[2.9 DSL]

[3.8 GSL]

6. Remove the battery tray (B) by removing the four mounting bolts (A).

7. Disconnect the transaxle wire harness connectors.
(1) Remove the inhibiter switch connector (A).

(2) Remove the solenoid valve connector (A).

[2.9 DSL]

[3.8 DSL]

(3) Remove the input speed sensor connector (A).

(4) Remove the output speed sensor connector (A).

(5) Remove the vehicle speed sensor connector (A).

(6) Remove the CKP sensor connector (A).

8. Remove the shift cable by removing the bolt (A) and clip (B).

9. Disconnect the transaxle oil cooler hoses (A) from the tubes (C) by loosening the clamps (B).

10. Remove the transaxle mounting bolts (A).

[2.9 DSL]

[3.8 GSL]

11. Using the SST(09200-38001), hold the engine and transaxle assembly safely.

[2.9 DSL]

[3.8 GSL]

12. Remove the transaxle insulator mounting bolt (A).

13. Remove the front wheels.
14. Remove the power steering column joint bolt. (see ST group)
15. Lift up the vehicle.
16. Remove the under cover (A).

17. Drain transaxle oil.
18. Drain power steering oil through the return tube. (see ST group)
19. Disconnect the power steering pressure tube (A) from the power steering oil pump.

20. Disconnect the lower arm, the tie rod end ball joint, the stabilizer bar link from the front knuckle. (see SS group)
21. Remove the roll stopper mounting bolts (A,B).

22. Remove the mounting bolts from the sub frame by supporting the sub frame with a jack. (see SS group)
23. Remove drive shaft from transaxle. (See DS group).
24. Install a jack for supporting the transaxle assembly.
25. Remove the plate (A) and the drive plate bolts (B).

[2.9 DSL]

[3.8 GSL]

26. Lifting the vehicle up and lowering the jack slowly, remove the transaxle assembly.

INSTALLATION
Installation is in the reverse order of removal.
Perform the following :
a. Adjust the shift cable.
b. Refill the transaxle with fluid.
c. Refill the radiator with engine coolant.
d. Bleed air from the cooling system with the heater valve open.

e. Clean the battery posts and cable terminals with sandpaper, assemble them, and apply grease to prevent
corrosion.
1. Lowering the vehicle or lifting up a jack, install the transaxle assembly.
2. Tighten the transaxle under mounting bolts.
TORQUE:
65~85 Nm(650~850 kgf.cm, 47.0~61.5 lb-ft)
3. Install the starter motor. (see EE group).
TORQUE:
65~85 Nm(650~850 kgf.cm, 47.0~61.5 lb-ft)
4. Install the drive plate bolts (B) by turning the timing gear and the plate (A).
TORQUE:46~53 Nm(460~530 kgf.cm, 33.3~38.3 lb-ft)

[2.9 DSL]

[3.8 GSL]

5. After removing a jack, insert the drive shafts. (see DS group)
6. Install the sub frame. (see SS group).
7. Tighten the roll stopper mounting bolts (A,B)
TORQUE:
90~110 Nm(900~1100 kgf.cm, 65.1~79.5 lb-ft)

8. Connect the return tube with a clamp. (see ST group)
9. Connect the lower arm, the tie rod end ball joint, the stabilizer bar link to the front knuckle. (see SS group)
10. Connect the power steering pressure tube (A) to the power steering oil pump.

11. Install the under cover (A).

12. Install the steering column joint bolt. (see ST group).
13. Install the front wheels and tires.

14. Tighten the transaxle insulator mounting bolt (A).
TORQUE:
90~110 Nm(900~1100 kgf.cm, 65.1~79.5 lb-ft)

15. Tighten the transaxle mounting bolts (A).
TORQUE:
65~85 Nm(650~850 kgf.cm, 47.0~61.5 lb-ft)

[2.9 DSL]

[3.8 GSL]

16. Remove the SST (09200-38001) holding the engine and transaxle assembly.

[2.9 DSL]

[3.8 GSL]

17. Connect the transaxle oil cooler hoses (A) to the tubes (C) by fastening the clamps (B).

18. Install the shift cable by tightening the bolt (A) and clip (B).
TORQUE:
10~14 Nm(100~140 kgf.cm, 7.2~10.1 lb-ft)

19. Connect the transaxle wire harness connectors.
(1) Install the inhibiter switch connector (A).

(2) Install the solenoid valve connector (A).

[2.9 DSL]

[3.8 GSL]

(3) Install the input speed sensor connector (A).

(4) Install the output speed sensor connector (A).

(5) Install the vehicle speed sensor connector (A).

(6) Install the CKP sensor connector (A).

20. Install the battery tray (B) by tightening the four mounting bolts (A).

21. Connect the air cleaner hose (B) by fastening the clamp (A).

[2.9 DSL]

[3.8 GSL]

22. Install the air cleaner assembly (A).

23. Install the air cleaner upper cover (B) by fastening the clips (A).

24. Connect the AFS connector (A).

25. Install the battery (A).

Automatic Transaxle
Control System
Shift Lever

2007 > 3.8L V6 GASOLINE >

REMOVAL
1. Remove the console upper cover(A). (see BD group).

[LHD]

[RHD]

2. Remove the front console cover (A). (see BD group).

[LHD]

[RHD]

3. Disconnect the connector (A).

[LHD]

[RHD]

4. Remove the shift lever assembly mounting nuts (A).

[LHD]

[RHD]

5. Remove the shift cable mounting nut (A) and cap (B).

[LHD]

[RHD]

INSTALLATION
1. Install the shift cable mounting nut (A) and cap (B).
TORQUE:
10~14 Nm(100~140 kgf.cm, 7.3~10.2 lb-ft)

[LHD]

[RHD]

2. Install the shift lever assembly mounting nuts (A).
TORQUE:
19~24 Nm(190~240 kgf.cm, 13.8~17.5 lb-ft)

[LHD]

[RHD]

3. Connect the connector (A).

[LHD]

[RHD]

4. Install the front console cover (A). (see BD group)

[LHD]

[RHD]

5. Install the console upper cover(A). (see BD group).

[LHD]

[RHD]

DISASSEMBLY
1. Remove the power relay (A) from the bracket.

[LHD]

[RHD]

2. Remove both sides of the brackets.
3. Remove the shift lever knob (A) by removing the two screws.

[LHD]

[RHD]

4. Disconnect the solenoid connector (A) and remove the indicator panel (B).

[LHD]

[RHD]

5. Remove the switch assembly (A) and ‘P’ position switch assembly.

[LHD]

[RHD]

6. Remove the solenoid (B) and solenoid lever (A).

[LHD]

[RHD]

7. Remove the lever assembly (B) by the mounting bolt (A).

[LHD]

[RHD]

8. Remove the lever (A) and tube (B) by removing the bolt (C).

[LHD]

[RHD]

REASSEMBLY
1. Grease the tube (B) and install the lever (A) by tightening the bolt (C).
TORQUE:
8~12 Nm(80~120 kgf.cm, 5.8~8.7 lb-ft)

[LHD]

[RHD]

2. Install the lever assembly (B) by tightening the bolt (A).
TORQUE:
8~12 Nm(80~120 kgf.cm, 5.8~8.7 lb-ft)

[LHD]

[RHD]

3. Install the solenoid (B) and solenoid lever (A).

[LHD]

[RHD]

4. Install the switch assembly (A) and ‘P’ position switch assembly.
TORQUE:
1.3~1.9 Nm(13~19 kgf.cm, 0.95~1.38 lb-ft)

[LHD]

[RHD]

5. Connect the solenoid connector (A) and install the indicator panel (B).

[LHD]

[RHD]

6. Install the shift lever knob (A) by tightening the two screws.

TORQUE:
2~3 Nm(20~30 kgf.cm, 1.45~2.18 lb-ft)

[LHD]

[RHD]

7. Install both sides of the brackets.
TORQUE:
16~23 Nm(160~230 kgf.cm, 11.6~16.7 lb-ft)
8. Install the power relay (A) to the bracket.

[LHD]

[RHD]

CHAPTER 4:

Emission Control System

General Information

2007 > 3.8L V6 GASOLINE >

SCHEMATIC DIAGRAM

2007 > 3.8L V6 GASOLINE >

DESCRIPTION
Components
Crankcase Emission System
a. Positive Crankcase Ventilation (PCV)
valve
Evaporative Emission System
a. Evaporative emission canister
b. Purge Control Solenoid Valve (PCSV)
Exhaust Emission System
a. MFI system (air-fuel mixture control
device)
b. Three-way catalytic converter

Function

Remarks

HC reduction

Variable flow rate type

HC reduction
HC reduction

Duty control solenoid valve

CO, HC, NOx reduction
CO, HC, NOx reduction

Heated oxygen sensor feedback type
Monolithic type

2007 > 2.7L V6 GASOLINE >

COMPONENT LOCATION

1

Purge Control Solenoid Valve (PCSV)

2

Positive Crankcase Ventilation (PCV) Valve

3

Canister

4

Catalytic Converter (Bank 1)

5

Catalytic Converter (Bank 2)

2007 > 2.7L V6 GASOLINE >

TROUBLESHOOTING
Symptom
Engine will not start or hard to
start

Suspect area
Vacuum hose disconnected or damaged

Repair or replace

Malfunction of the Purge Control Solenoid
Valve

Repair or replace

Vacuum hose disconnected or damaged

Repair or replace

Malfunction of the PCV valve

Replace

Malfunction of the evaporative emission
canister purge system

Check the system; if there is a
problem, check related
components parts

Positive crankcase ventilation line clogged

Check positive crankcase
ventilation system

Rough idle or engine stalls

Excessive oil consumption

Remedy

2007 > 3.8L V6 GASOLINE >

TIGHTENING TORQUES
Item
Positive Crankcase Ventilation Valve

N·m

kgf·m

lbf·m

8.0 ~ 12.0

0.8 ~ 1.2

6.0 ~ 8.0

SPECIFICATIONS
▷ Specification
Item

Specification

Coil Resistance (Ω)

19.0 ~ 22.0 Ω [20°C (68°F)]

Crankcase Emission
Control System

2007 > 3.8L V6 GASOLINE >

COMPONENTS

2007 > 3.8L V6 GASOLINE >

INSPECTION
1. Disconnect the ventilation hose from the positive crankcase ventilation (PCV) valve. Remove the PCV valve from
the rocker cover and reconnect it to the ventilation hose.
2. Run the engine at idle and put a finger on the open end of the PCV valve and make sure that intake manifold
vacuum can be felt.

The plunger inside the PCV valve will move back and forth.

Positive Crankcase
Ventilation (PVC)
Valve

2007 > 2.7L V6 GASOLINE >

OPERATION

Engine condition

Not running

Engine condition

Idling or decelerating

PCV valve

Not operating

PCV valve

Fully operating

Vacuum passage

Restricted

Vacuum passage

Small

Engine condition

Normal operation

Engine condition

Accelerating and high load

PCV valve

Properly operating

PCV valve

Slightly operating

Vacuum passage

Large

Vacuum passage

Very large

2007 > 3.8L V6 GASOLINE >

REMOVAL
1. Remove the valve pad (A) and disconnect the vacuum hose (B).

2. Remove the PCV Valve.

INSTALLATION
Install the PCV valve and tighten to the specified torque.
PCV Valve installation : 7.8 ~ 11.8 N·m (0.8 ~ 1.2 kgf·m, 5.8 ~ 8.7lbf·ft)

INSPECTION
1. Remove the PCV valve.
2. Insert a thin stick(A) into the PCV valve(B) from the threaded side to check that the plunger moves.
3. If the plunger does not move, the PCV valve is clogged. Clean it or replace.

Evaporative Emission
Control System

2007 > 2.7L V6 GASOLINE >

DESCRIPTION

2007 > 2.7L V6 GASOLINE >

INSPECTION
1. Disconnect the vacuum hose from the throttle body, and connect a vacuum pump to the vacuum hose.
2. Check the following points when the engine is cold [engine coolant temperature 60°C(140°F) or below] and when it
is warm [engine coolant temperature 80°C(176°F) or higher].
WHEN ENGINE IS COLD
Engine operating condition
Idling
3,000 rpm

Applied vacuum

Result

50 kPa
(7.3 psi)

Vacuum is held

Applied vacuum

Result

WHEN ENGINE IS WARM
Engine operating condition
Idling
Within 3 minutes after engine start at 3,000
rpm
After 3 minutes have passed after engine
start at 3,000 rpm

50 kPa
(7.3 psi)
Try to apply vacuum
50 kPa
(7.3 psi)

Vacuum is held
Vacuum is released
Vacuum will be held momentarily,
after which, it will be released

Canister

2007 > 2.7L V6 GASOLINE >

REMOVAL
1. Disconnect the vacuum hoses (A,B).

2. Remove the canister assembly (A) with unscrewing the two mounting bolts (B).

3. Open the canister upper cover (A) with unfastening the four bolts (B) and remove the canister (C) from the canister
lower cover (D).

INSTALLATION
Install the canister according to the reverse order of «REMOVAL» procedure.

INSPECTION
1. Look for loose connections, sharp bends or damage to the fuel vapor lines.
2. Look for distortion, cracks or fuel damage.
3. After removing the canister, inspect for cracks, damage or saturated canister.

Purge Control Solenoid
Valve
(PCSV)

2007 > 3.8L V6 GASOLINE >

INSPECTION

When disconnecting the vacuum hose, make an identification mark on it so that it can be reconnected to its
original position.
1. Disconnect the vacuum hose from the solenoid valve.
2. Detach the harness connector.
3. Connect a vacuum pump to the nipple which is connected to intake manifold.
4. Apply vacuum and check when voltage is applied to the PCSV and when the voltage is discontinued.
Battery voltage

Normal condition

When applied

Vacuum is released

When discontinued

Vacuum is maintained

5. Measure the resistance between the terminals of the solenoid valve.
PCSV coil resistance(Ω) :
19.0 ~ 22.0Ω at 20°C (68°F)

DESCRIPTION
Purge Control Solenoid Valve (PCSV) is installed on the surge tank and controls the passage between the canister
and the intake manifold. It is a solenoid valve and is open when the PCM grounds the valve control line. When the
passage is open (PCSV ON), fuel vapors stored in the canister is transferred to the intake manifold.

SPECIFICATION
Item

Specification

Coil Resistance (Ω)

19.0 ~ 22.0Ω at 20°C (68°F)

SCHEMATIC DIAGRAM

Fuel Filler cap

2007 > 2.7L V6 GASOLINE >

DESCRIPTION

Exhaust Emission Control
System

2007 > 2.7L V6 GASOLINE >

DESCRIPTION
Modifications to the combustion chamber, intake manifold, camshaft and ignition system form the basic control system.
These items have been integrated into a highly effective system which controls exhaust emissions while maintaining
good driveability and fuel economy.

AIR/FUEL MIXTURE CONTROL SYSTEM [MULTIPORT FUEL INJECTION (MFI) SYSTEM]
This in turn allows the engine to produce exhaust gases of the proper composition to permit the use of a three way
catalyst. The three way catalyst is designed to convert the three pollutants (1) hydrocarbons (HC), (2) carbon
monoxide (CO), and (3) oxides of nitrogen (NOx) into harmless substances. There are two operating modes in the MFI
system.
1. Open Loop air/fuel ratio is controlled by information programmed into the ECM.
2. Closed Loop air/fuel ratio is adjusted by the ECM based on information supplied by the oxygen sensor.

CVVT
(Continuously Variable
Valve Timing)
System

2007 > 2.7L V6 GASOLINE >

DESCRIPTION

The CVVT (Continuously Variable Valve Timing) which is installed on the exhaust camshaft controls intake valve open
and close timing in order to improve engine performance.
The intake valve timing is optimized by CVVT system depending on engine rpm.
This CVVT system improves fuel efficiency and reduces NOx emissions at all levels of engine speed, vehicle speed,
and engine load by EGR effect because of valve over-lap optimization.
The CVVT changes the phase of the intake camshaft via oil pressure.
It changes the intake valve timing continuously.

OPERATION
The CVVT system makes continuous intake valve timing changes based on operating conditions.
Intake valve timing is optimized to allow the engine to produce maximum power.
Cam angle is advanced to obtain the EGR effect and reduce pumping loss. The intake valve is closed quickly to
reduce the entry of the air/fuel mixture into the intake port and improve the changing effect.
Reduces the cam advance at idle, stabilizes combustion, and reduces engine speed.
If a malfunction occurs, the CVVT system control is disabled and the valve timing is fixed at the fully retarded position.

1. The above figure shows the relative operation structures of the housing vane to the rotor vane.
2. If the CVVT is held a certain control angle, to hold this state, oil is replenished as much as oil leaks from the oil
pump.
The OCV (Oil-flow Control Valve) spool location at this time is as follows.
Oil pump → Advance oil chamber (Little by little open the inflow side to the advance oil chamber) → Almost close the
drain side
Be sure there might be a difference in the position according to the engine running state (rpm, oil temperature, and oil
pressure).