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  • 2.5L VM DIESEL

    INDEX

    page page

    GENERAL INFORMATIONENGINE IDENTIFICATION . . . . . . . . . . . . . . . . . 37GENERAL SPECIFICATION . . . . . . . . . . . . . . . . 36

    DESCRIPTION AND OPERATIONLUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . 37

    DIAGNOSIS AND TESTINGENGINE DIAGNOSISMECHANICAL . . . . . . . . . 0ENGINE DIAGNOSISPERFORMANCE . . . . . . 38HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . 39

    SERVICE PROCEDURESCHANGING ENGINE OIL AND FILTER . . . . . . . 40CHECKING OIL LEVEL . . . . . . . . . . . . . . . . . . . 40CRANKSHAFT END PLAY . . . . . . . . . . . . . . . . . 43FITTING PISTON RING . . . . . . . . . . . . . . . . . . . 43TIMING PROCEDURE . . . . . . . . . . . . . . . . . . . . 41VALVE AND SEAT REFACING . . . . . . . . . . . . . . 42

    REMOVAL AND INSTALLATIONCAMSHAFT BEARINGS . . . . . . . . . . . . . . . . . . 60CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59CRANKSHAFT MAIN BEARINGS . . . . . . . . . . . . 60CRANKSHAFT SPROCKET . . . . . . . . . . . . . . . . 58CRANKSHAFTREMOVAL . . . . . . . . . . . . . . . . 71CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . 47CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . 49CYLINDER LINER . . . . . . . . . . . . . . . . . . . . . . . 70ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 46ENGINE MOUNTFRONT . . . . . . . . . . . . . . . . 44ENGINE MOUNTREAR . . . . . . . . . . . . . . . . . 45ENGINE MOUNTRIGHT . . . . . . . . . . . . . . . . . 44HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . 53HYDRAULIC TENSIONER . . . . . . . . . . . . . . . . . 59INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . 54MOUNTLEFT SIDE . . . . . . . . . . . . . . . . . . . . 45OIL FILTER ADAPTER AND OIL COOLER . . . . . 64

    OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63OIL PUMP PRESSURE RELIEF VALVE . . . . . . . 64OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63PISTONS AND CONNECTING ROD . . . . . . . . . 68REAR CRANKSHAFT OIL SEAL . . . . . . . . . . . . 71ROCKER ARMS AND PUSH RODS . . . . . . . . . . 48TIMING CHAIN COVER OIL SEAL . . . . . . . . . . . 54TIMING CHAIN COVER . . . . . . . . . . . . . . . . . . . 55TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . 55VACUUM PUMP . . . . . . . . . . . . . . . . . . . . . . . . 64VALVE SPRINGS

    CYLINDER HEAD NOT REMOVED . . . . . . . . . 48VALVES AND VALVE SPRINGSHEAD OFF . . . 53VIBRATION DAMPER . . . . . . . . . . . . . . . . . . . . 54

    DISASSEMBLY AND ASSEMBLYHYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . 71

    CLEANING AND INSPECTIONCRANKSHAFT MAIN BEARING . . . . . . . . . . . . . 76CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 76CYLINDER HEAD COVERS . . . . . . . . . . . . . . . . 72CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . 72CYLINDER LINER . . . . . . . . . . . . . . . . . . . . . . . 77HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . 75OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75PISTON AND CONNECTING ROD . . . . . . . . . . . 75ROCKER ARMS AND PUSH RODS . . . . . . . . . . 72TIMING CHAIN COVER . . . . . . . . . . . . . . . . . . . 74VALVES AND VALVE SPRINGS . . . . . . . . . . . . . 74

    SPECIFICATIONS2.5L VM DIESEL . . . . . . . . . . . . . . . . . . . . . . . . 77TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

    SPECIAL TOOLS2.5L VM DIESEL . . . . . . . . . . . . . . . . . . . . . . . . 80

    GENERAL INFORMATION

    GENERAL SPECIFICATION

    Type . . . . . . . . . . . . . . . . . . . . . . . . 425CLIEE (36B)Displacement . . . . . . . . . . . . . . . . . . . 2.5L (2499 cc)Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.00 mmStroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94.00 mmCompression Ratio . . . . . . . . . . . . . . . . . . . . 20.95:1Vacuum at Idle . . . . . . . . . . 600 mm/Hg (23.6 In/Hg)Thermostat Opening . . . . . . . . . . . . . . . . 80C62CGenerator Rating . . . . . . . . . . . . Bosch 50/120 AmpCooling System Capacity . . . . . . . . . . . . . . 9.5 Liter

    Type . . . . . . . . . . . . . . . . . . . . . . . . 425CLIEE (36B)Power Steering Capacity . . . . . . . . . . . . . 0.75 LiterEngine Oil Capacity . . . . . . . . . . . . . 6.8 Liters With

    Oil Filter ChangeTiming System . Pushrod Operated Overhead valves,

    With Chain-Driven Camshaft.Air Intake . . . . . . . . . . . . . . . . . . . . . . . . Dry FilterFuel Feed . . . . . . . . . . . Vacuum Pump Incorporated

    in Injection Pump.Fuel System . . . . . . . . . . . . . Indirect Fuel Injection

    (Precombustion Chamber)Combustion Cycle . . . . . . . . . . . . . . . . . . . . 4 StrokeCooling System . . . . . . . . . . . . . . . . . . Water Cooled

    9 - 36 ENGINE NS/GS

  • Type . . . . . . . . . . . . . . . . . . . . . . . . 425CLIEE (36B)Injection Pump . . . . . . . . . . . . . . . . . . Rotary Pump

    Electronically Controlled.Lubrication . . . . . . . . . . . . . Pressure Lubrication by

    Rotary Pump, Full-Flow Filtration.Engine Rotation . . . . . . . . . . . . . . Clockwise Viewed

    From Front Cover.

    ENGINE IDENTIFICATIONThe engine model code (3-digit number/letter code)

    and serial number are stamped on the forward facingside of the engine block (Fig. 1).

    DESCRIPTION AND OPERATION

    LUBRICATION SYSTEMThe pressurized system (Fig. 2) uses a rotary pump

    (3) located in the front of the engine block, driven bya gear which meshes directly with the crankshaftgear. All the oil sent to every lubricated part is fil-tered. The pump sends the oil through a pressurerelief valve (2) to the filter (7) and through galleriesin the crankcase to the crankshaft bearings (8), cam-shaft bearings (11) and turbocharger (10). The pistonpins, connecting rod small ends and insides of thepistons are lubricated and cooled by oil sprayed out

    from jets (9) in the crankshaft mounting blocks. Thelubricating oil is sent to the rockers (12) through anexternal pipe (Fig. 3). A valve in the filter cartridgeenables the oil to be circulated even when the car-tridge is clogged.

    Sump inlet (1). Pressure relief valve (2). Oil pump(3). Oil cooler (6). Filter cartridge (7). Crankshaftbearings (8). Jet valve (9). Turbocharger bearings(10). Camshaft bearings (11). Rockers (12).

    Fig. 1 Engine Code Location

    Fig. 2 Lubrication System

    Fig. 3 Lubrication Lines

    NS/GS ENGINE 9 - 37

    GENERAL INFORMATION (Continued)

  • DIAGNOSIS AND TESTING

    ENGINE DIAGNOSISPERFORMANCE

    CONDITION POSSIBLE CAUSES CORRECTION

    ENGINE WILL NOT CRANK ORCRANKS SLOWLY

    1. Starting motor operating, but not crankingthe engine.

    1. Remove the starter motor. Check for brokenflywheel teeth or a broken starter motor spring.

    2. Crankshaft rotation restricted. 2. Rotate the engine to check for rotationalresistance.

    3. Starting circuit connections loose orcorroded.

    3. Clean and tighten connections.

    4. Neutral safety or starter relay inoperative. 4. Check starter relay supply voltage andproper operation of neutral safety switch (ifequipped). Replace defective parts.

    5. Battery charge low. 5. Check Battery voltage. Replace battery if acharge cannot be held.

    6. No voltage to starter solenoid. 6. Check voltage to solenoid. If necessary,replace the solenoid.

    7. Solenoid or starter motor inoperative. 7. Replace starter motor.

    ENGINE CRANKS, BUT WILLNOT START, NO SMOKE

    1. No fuel in supply tank. 1. Fill fuel supply.2. Electrical fuel shutdown solenoid notoperating.

    2. Check for loose wires and verify that thefuel shutdown solenoid is functioning. Checkfor fault codes in the ECU.

    3. Fuel injection system defective: Crankingspeed sensor. Loose connection betweenECU and harness. No power supply to theECU. Loose connection between injectionpump and harness.

    3. Check for fault codes at ECU. Refer toGroup 14, Fuel System for repairs procedures.

    4. Air intake or exhaust plugged. 4. Remove the obstruction.5. Fuel filter plugged. 5. Drain fuel/water separator and replace fuel

    filter.6. Excessive fuel inlet restriction. 6. Check for restriction. Correct cause.7. Injection pump not getting fuel or fuel isaerated.

    7. Check fuel flow/bleed fuel system.

    8. One or more injectors worn or notoperating properly.

    8. Check/replace bad or improperly operatinginjectors.

    9. Camshaft out of time. 9. Check/correct timing chain sprocketalignment.

    ENGINE HARD TO START, ORWILL NOT START, SMOKE FROMEXHAUST

    1. Incorrect starting procedure. 1. The fuel shutoff solenoid control must be inthe run position. Ensure the proper procedureis being used.

    2. Cranking speed to slow. 2. Check the battery, starter motor and look forloose or corroded wiring connections.

    3. Cylinder head heater plugs defective. 3. Verify system is working. Verify connectionbetween heater plug relay and ECU.Repair/replace inoperative parts.

    4. Insufficient intake air 4. Inspect or replace air filter and check forobstruction in air supply.

    5. Air in fuel system or the fuel supply isinadequate.

    5. Check the fuel flow through the filter andbleed system. Locate and eliminate the airsource.

    6. Contaminated fuel. 6. Verify by operating the engine with cleanfuel from a temporary tank. Check for thepresence of gasoline. Drain and flush fuelsupply tank. Replace fuel/water separator filter.

    7. Fuel screen plugged. 7. Check fuel screen.8. One or more injectors worn or notoperating properly.

    8. Check/replace improperly operatinginjectors.

    9. Injector pump out of time. 9. Check pump timing. Refer to Group 14,Fuel System for procedure.

    10. Engine compression low. 10. Check compression to ident

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