DI01-30

29. Remove the transmission mounting bolts and separate the engine assembly from the transmission assembly.

Y220_01041

Note
1. Before unscrewing the transmission mounting
bolts, remove the starter motor.

Installation Notice

Mounting bolt 55 ± 5 Nm

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
 DI01-31

30. Remove the engine assembly mounting nuts at both sides.

Installation Notice

Mounting Nut 55 ± 5 Nm

Y220_01042

31. Hook the chain on the engine brackets and carefully 32. Put the removed engine assembly on the safety stand.
pull out the engine assembly from the vehicle by using
a hoist or crane.

Y220_01043

ENGINE ASSEMBLY CHANGED BY

DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI01-32

DISASSEMBLY AND REASSEMBLY

COMPONENTS AND SPECIAL TOOLS

Injector puller Glow plug puller Fuel pipe wrench Sealing caps

Injector copper washer

puller

Engine lock

Valve remover/installer Pulley lock/wrench HP pump lock HP pump bearing puller

Y220_01044

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
 DI01-33

Inspection Before Disassembly and

Reassembly
Preparations and Preceding Works
1. Remove the cylinder block drain plug and seal and
completely drain the residual coolant from the cylinder
block.

Tightening torque 30 Nm

Notice
Y220_01045

Replace the seal with new one once removed.

2. When the fan belt is installed, gently pump the belt shock
absorber mounting bolt (M19) 3 times.
3. Take off the fan belt while pushing the mounting bolt (M19).

Y220_01046

4. Loosen the oil drain plug and completely drain the engine
oil.

Drain plug 25 ± 2.5 Nm

Y220_01047

ENGINE ASSEMBLY CHANGED BY

DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI01-34

Accessories - Removal and Installation

PCV valve and oil separator EGR valve pipe (LH, Center, RH)

Power steering pump

Turbo charger

Cooling fan clutch

Auto tensioner

Alternator

Fuel return hose

Cable and connector

Oil filter assembly

EGR valve

Air conditioner compressor Start motor

Mounting bracket
Y220_01048

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
 DI01-35

• The engine accessories can be removed without any specific order. In general, remove the components from top
to bottom. However, be careful not to splash the lubricants to engine and body when disassembly. Especially,
avoid getting into other components.

Removal and Installation Order of Major Accessories

1. Vacuum Modulator * Camshaft Position Sensor

* Crankshaft Position Sensor
* Injector Fuel Line Connector
* Glow Plug Connector
2. Engine Cables and Connectors * Fuel Return Hose
* High/Low Pressure Hoses in HP Pump
* Ground Cables
* Fuel Pressure Sensor Connector
3. Fuel Hoses * Booster Pressure Sensor Connector
* Knock Sensor Connector
* Coolant Temperature Sensor Connector
* HP Pump: Fuel Temperature Sensor (Green)
3-1. EGR Valve Assembly IMV (Brown)

4. Oil Filter Assembly

4-1. Belt Tensioning Assembly

5. Power Steering Pump Assembly

6. Air Conditioner Compressor Assembly

7. PCV Valve Assembly + Oil Dipstick Tube

8. Turbo Charger Alternator Assembly

ENGINE ASSEMBLY CHANGED BY

DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI01-36

1. Remove the fuel pipes.

A. Remove the fuel supply pipes between each
cylinder and common rail with a special tool.
Installation Notice

Tightening torque 40 ± 4.0 Nm

Y220_01049

Notice

1. Plug the openings of injector nozzle and common

rail with sealing caps after removed the fuel pipes.

Y220_01050

2. Replace the pipes with new ones. Be careful not

to be mixed the fuel pipes because the pipe
appearance of #1 and #3 cylinders and #2 and #4
are same each other.

No. 1 No. 3 No. 2 No. 4 No. 5

Y220_01051

B. Remove the high fuel pressure pipe mounting bolts

with a special tool.
- High fuel pressure supply pipe at common rail
side
Installation Notice

Tightening torque 40 ± 4 Nm

Y220_01052

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
 DI01-37

C. High fuel pressure supply pipe at HP pump side

Installation Notice

Tightening torque 40 ± 4.0 Nm

Y220_01053

D. Unscrew the bracket mounting bolts and remove the

high fuel pressure supply pipes.

Note
Special tool: Fuel pipe remover and installer

Y220_01055
Y220_01054

ENGINE ASSEMBLY CHANGED BY

DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI01-38

2. Disconnect the vacuum hoses and module cables from the vacuum modulator.

Notice

Put the installation marks on the modulator hoses and connectors.

To EGR valve
EGR vacuum booster
vacuum modulator

Turbo charger
booster vacuum
modulator

From vacuum pump

To turbo charger
booster

Y220_01056

A. Remove the vacuum modulator bracket.

(Upper: 10 M x 2, Lower: 10M x 2)
Installation Notice

Upper bolt 25 ± 2.5 Nm

Lower bolt 25 ± 2.5 Nm

Y220_01057

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
 DI01-39

3. Disconnect the wiring harnesses and connectors from the engine.

Fuel return hose Injector fuel line Glow plug connector

connector

Camshaft position Crankshaft position

sensor sensor

HP pump connector Oil pressure switch

Fuel temperature
Sensor

IMV

Coolant temperature Booster pressure sensor Fuel pressure sensor

Knock sensor connector connector connector
sensor connector

Y220_01058

ENGINE ASSEMBLY CHANGED BY

DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI01-40

A. Remove the cable assembly from the engine.

Important
1. If possible, remove the cables after removing the
fuel pipes. It make the operation easier and protect
the cables and connectors.

Y220_01059

2. Remove the cable screws and ground cable, and

then remove the engine cable assembly.

Notice
• Be careful not to damage the HP pump connecting
pipe (venturi) while removing the fuel hose from
the HP pump.

Y220_01060

4. Disconnect the high and low fuel pressure hoses from

the HP pump.

Notice

• Be careful not to damage the hose connections.

• Plug the openings in HP pump immediately after
disconnecting the hoses.

Y220_01061

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
 DI01-41

5. Remove the EGR valve and EGR valve pipe.

A. Disconnect the vacuum hose from the EGR valve.
B. Unscrew the EGR valve bolts and EGR #1 pipe
connecting bolts and remove the EGR valve and steel
gasket.
Installation Notice

EGR valve bolt 25 ± 2.5 Nm

EGR valve and
25 ± 2.5 Nm
center pipe bolt

Y220_01062

C. Remove the EGR valve #1 pipe.

Installation Notice

Center pipe bolt 35 ± 3.5 Nm

Center pipe and #1 pipe
35 ± 3.5 Nm
bolt and nut

Notice
The EGR #2 pipe should be replaced with new one.

Y220_01063

D. Unscrew the EGR valve #3 pipe (2) mounting bolts

and remove the pipe from the exhaust manifold.
Installation Notice
Tightening torque 35 ± 3.5 Nm

Notice
1. The EGR #3 pipe should be replaced with new
one.
2. Make sure that the convex surface of new steel Y220_01064
gasket is facing to the bolts.

6. Remove the oil filter assembly.

A. Remove the oil cooler hose.

Y220_01065

ENGINE ASSEMBLY CHANGED BY

DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI01-42

B. Remove the oil filter assembly mounting bolts.

Notice

Be careful not to flow out the residual oil from the

engine. If flown out, immediately wipe it out.

Y220_01066

C. Remove the oil filter assembly from the cylinder block.

Installation Notice
- Replace the oil filter gasket with new one.

Tightening torque 25 ± 2.5 Nm

Y220_01067

7. Remove the belt tensioning device.

A. Remove the shock absorber lower mounting bolt.
Installation Notice

Tightening torque 32 ± 3 Nm

Y220_01068

B. Remove the shock absorber upper mounting bolt.

Installation Notice

Tightening torque 82 ± 6 Nm

Y220_01069

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
 DI01-43

C. Remove the belt tensioning device.

Notice

• To prevent the oil leaks, store the removed shock

absorber assembly with standing up.
• For air bleeding, pump the shock absorber around
3 times after installation.
• Be careful not to damage the rubber parts of the
shock absorber when removing.
• To prevent the oil leaks, remove the bolts from bottom
to top section. On the contrary, when installing,
tighten the bolts from top to bottom section. Y220_01070

7. Remove the power steering pump assembly.

A. Remove the power steering pump mounting bolts.
Installation Notice

Tightening torque 25 ± 2.5 Nm

Notice

Be careful not to flow out the oil.

Y220_01071

B. Remove the power steering pump assembly from the

engine.

Notice

To prevent the oil leaks, store the removed power

steering pump assembly with standing up.

Y220_01072

8. Remove the air conditioner compressor assembly.

A. Unscrew the bolts and remove the air conditioner
compressor assembly.
Installation Notice

Tightening torque 25 ± 2.5 Nm

Y220_01073

ENGINE ASSEMBLY CHANGED BY

DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI01-44

B. Unscrew the bolts and remove the air conditioner

mounting bracket.
Installation Notice

Front bolt 25 ± 2.5 Nm

Side bolt 25 ± 2.5 Nm

Y220_01074

9. Remove the PCV valve assembly.

A. Remove the PCV valve hose.

Y220_01075

B. Remove the PCV valve hose connected to the engine

oil hose.

Y220_01076

C. Unscrew the PCV valve mounting bolts and remove

the PCV valve assembly.
Installation Notice

Tightening torque 10 ± 1.0 Nm

Y220_01077

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
 DI01-45

10. Remove the oil dipstick tube assembly.

Unscrew the bracket bolts and remove the dipstick tube
with O-ring.
Installation Notice
Insert new O-ring into the oil dipstick tube before
installation.

Y220_01078

Installation Notice

Tightening torque 10 ± 1.0 Nm

Y220_01079

11. Remove the turbo charger assembly.

A. Unscrew the bolts and remove the oil supply pipe.
Installation Notice

Upper bolt (M19) 25 ± 2.5 Nm

Lower bolt (M17) 20 ± 2.0 Nm

Y220_01080

B. Unscrew the bolts and remove the oil return pipe.

Installation Notice
• Make sure to install the gasket with correct direction.

Tightening torque 10 ± 1.0 Nm

Y220_01081

ENGINE ASSEMBLY CHANGED BY

DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI01-46

C. Unscrew the turbo charger mounting bracket bolts.

Installation Notice

Tightening torque 25 ± 2.5 Nm

Y220_01082

D. Unscrew the turbo charger mounting bolts to exhaust

manifold.

Notice

Use only 12 1/2 wrench.

Installation Notice

Tightening torque 25 ± 2.5 Nm

Y220_01083

E. Remove the turbo charger assembly.

Y220_01084

12. Remove the alternator assembly.

A. Unscrew the bolts and remove the alternator.

Note
Alternator Capacity: 140 A

Installation Notice

Tightening torque 46 ± 4.6 Nm

Y220_01085

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
 DI01-47

B. Remove the alternator mounting bracket.

Installation Notice

M13 bolt 25 ± 2.5 Nm

Torx 6 bolt 25 ± 2.5 Nm

Y220_01086

ENGINE ASSEMBLY CHANGED BY

DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI01-48

Engine - Disassembly and Reassembly

1. Unscrew the injector nozzle holder bolts (12-sided) and
remove the injector bracket.
Installation Notice

9 ± 1.0 Nm,
Tightening torque
190° + 10°

Y220_01089

2. Remove the injectors with a injector extractor (special

tool).

Notice

• Be careful not to take off the sealing caps on the

injectors and fuel system.
• Replace the copper washers with new ones when
installing.

Y220_01090

3. If the copper washer is in injector hole, remove it with a

special tool as shown in the figure.

Y220_01092

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
 DI01-49

4. Remove the glow plugs with a special tool.

Installation Notice

Tightening torque 15 ± 3 Nm

Y220_01091

5. Unscrew the Torx bolts and remove the common rail from
the engine.
Installation Notice

Tightening torque 25 ± 2.5 Nm

Notice
Plug the openings with sealing cap.

Y220_01087

6. Remove the booster sensor from the engine.

Installation Notice

Tightening torque 10 ± 1.0 Nm

Y220_01088

7. Unscrew the bolt and remove the camshaft position

sensor.
Installation Notice

Tightening torque 12 ± 1.7 Nm

• Apply Loctite on the thread before installation.

Y220_01093

ENGINE ASSEMBLY CHANGED BY

DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI01-50

8. Unscrew the bolts and remove the cooling fan pulley while
holding it with a special tool.

Tightening torque 10 ± 1.0 Nm

Y220_01094

9. Remove the cooling fan belt idle pulley while holding it

with a special tool.

Tightening torque 10 ± 1.0 Nm

Y220_01095

10. Unscrew the bolts and remove the cooling fan bracket
assembly (timing chain cover).

Tightening torque 10 ± 1.0 Nm

Y220_01096

11. Unscrew the bolts and remove the cylinder head cover.

Tightening torque 10 ± 1.0 Nm

Y220_01097

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
 DI01-51

12. Turn over the engine and remove the oil pan.
Installation Notice

Tightening torque Nm
M6 x 20: 24 EA 10 ± 1.0
M6 x 35: 2 EA 10 ± 1.0
M6 x 85: 2 EA 10 ± 1.0
M8 x 40: 4 EA 25 ± 2.5

Y220_01100

Installation Notice
Remove the oil seal residues from the oil pan and
apply the liquid gasket on the parting surface.

Y220_01101

13. Unscrew the nuts and remove the exhaust manifold.

Installation Notice

Tightening torque 40 ± 4.0 Nm

Y220_01102

Notice

The exhaust manifold gasket is removed along with

the exhaust manifold. Mark the installation direction
to prevent wrong installation. Otherwise, it may cause
a sealing trouble.

Y220_01103

ENGINE ASSEMBLY CHANGED BY

DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI01-52

14. Unscrew the bolts and remove the thermostat.

Installation Notice

Tightening torque 10 ± 1.0 Nm

Notice
Be careful not to flow out the residual coolant.

Y220_01104

15. Unscrew the bolts and remove the water pump.

Installation Notice

Tightening torque 10 ± 1.0 Nm

Y220_01105

16. Unscrew the bolts and remove the water pump housing.
Installation Notice

Tightening torque 10 ± 1.0 Nm

Notice
Be careful not to flow out the residual coolant.

Y220_01106

17. Unscrew the bolts and remove the coolant inlet port from
the intake manifold.
Installation Notice

Tightening torque 25 ± 2.5 Nm

Notice
Be careful not to get the coolant into the intake
manifold and engine.

Y220_01107

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
 DI01-53

18. Unscrew the bolts and remove the intake manifold

assembly.
Installation Notice

Tightening torque 25 ± 2.5 Nm

Y220_01108

Notice

Replace the gasket with new one once removed.

Y220_01109

19. Remove the vacuum pump from the cylinder head.

Installation Notice

Tightening torque 10 ± 1.0 Nm

Y220_01110

20. Install the engine lock (special tool) onto the flywheel
ring gear so that the engine will not rotate.

Y220_01111

ENGINE ASSEMBLY CHANGED BY

DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI01-54

21. Remove the chain tensioner.

Preceding works: removal of EGR pipe and oil dipstick
tube

Tightening torque 65 ± 5.0 Nm

Y220_01119

22. Pull out the lock pin and remove the upper chain guide
bracket.

Y220_01112

23. Unscrew the bolt and remove the intake camshaft

sprocket.
Installation Notice

25 ± 2.5 Nm,
Tightening torque
90° + 10°

Y220_01113

24. Unscrew the bolt and remove the exhaust camshaft

sprocket.
Installation Notice

25 ± 2.5 Nm,
Tightening torque
90° + 10°

Y220_01114

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
 DI01-55

25. Remove the camshaft bearing cap bolts so that the

tightening force can be relieved evenly. Exhaust
• Intake: #1, #3, #6
• Exhaust: #7, #9, #12
* However, there is no specific removal sequence.

Intake Y220_01115

• Intake: #2, #4, #5

• Exhaust: #8, #10, #11
* Do not remove the bolts at a time completely. Remove
them step by step evenly or camshaft can be seriously
damaged.
Installation Notice

Tightening torque 25 ± 2.5 Nm

Y220_01116

26. Remove the intake and exhaust camshafts from the

cylinder head.

Y220_01117

27. Remove the finger follower and the HLA device.

Notice
• Avoid contact with hot metal parts when removing
the HLA device immediately after stopping the
engine.
• Be careful not to be contaminated by foreign
materials.
• To prevent the oil leaks, store the removed finger
follower and HLA device with standing up.
• If the HLA can be easily pressed in by hand, it
indicates the oil inside of HLA has been flown out.
In this case, replace it with new one. Y220_01118

ENGINE ASSEMBLY CHANGED BY

DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI01-56

28. Pull out the pin and remove the timing chain guide from
the engine.

Y220_01120

29. Remove the cylinder head bolts according to the

numerical sequence.

Installation Notice

Tightening torque Nm
M8 x 25: 2 EA 25 ± 2.5
M8 x 50: 2 EA 25 ± 2.5
M12 x 177: 11 EA
85 ± 5 Nm,
M12 x 158: 1 EA
3 x 90° + 10°
(Vacuum pump side)
Y220_01121

30. Measure the length of cylinder head bolts.

• If the maximum length is exceeded by 2 mm, replace
the cylinder head bolt.

Length when new Maximum Limit

177 mm 179 mm
158 mm 160 mm

Y220_01122

31. Remove the cylinder head.

Notice

• Inspect the cylinder head surface.

• Store the removed injectors and glow plugs so that
they will not be damaged.

Y220_01123

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
 DI01-57

32. Measure the piston protrusion from the parting surface.

• Specified Value: 0.765 ~ 1.055 mm

Y220_01124

33. Remove the cylinder head gasket.

Installation Notice
• Replace the cylinder head gasket with new one.
Make sure to place the “TOP” mark upward.
1. Put the steel gasket on the cylinder block and
position the cylinder head.

Y220_01125

2. Tighten the cylinder head bolts to specified torque

and torque angle.
Step 1 20 ± 2.0 Nm
Tightening torque Step 2 85 ± 5.0 Nm
Step 3 90 ± (3 times) + 10°

• Apply the oil on the bolt thread when installing.

• Always insert new washer first.
• The bolts (12) at vacuum pump side are shorter
than others.
Y220_01126

34. Turn over the engine and remove the baffle plate.
Installation Notice

Tightening torque 10 ± 1.0 Nm

Y220_01127

ENGINE ASSEMBLY CHANGED BY

DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI01-58

35. Unscrew the bolts and remove the oil strainer assembly.
Installation Notice

Tightening torque 25 ± 2.5 Nm

Y220_01128

36. Remove the piston assembly from the cylinder block.

A. Unscrew the bearing cap bolts.
Installation Notice

Step 1 55 ± 5.0 Nm
Step 2 90° + 10°

* Tighten the bolts from #1 cap.

Y220_01129

Installation Notice
* Align the oil grooves in bearing cap and connecting
rod.

B. Remove the bearing caps and lower bearing shells.

Y220_01130

C. Remove the piston assembly through the cylinder.

Notice
Do not mix up upper and lower crankshaft bearing
shells.

Y220_01131

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
 DI01-59

D. Remove the snap ring piston pin from the piston.

E. Disassemble the piston and connecting rod.
F. Remove the piston rings from the piston.

Installation Notice
Replace the piston ring, bearing and snap ring with
new ones.

Y220_01132

37. Lock the flywheel and remove the center bolt and
crankshaft pulley.
Installation Notice

325 ± 33 Nm,
Tightening torque
90° + 10°

Y220_01133

38. Remove the timing chain cover assembly.

A. Remove the cover bolts.
Installation Notice
Tightening torque 10 ± 1.0 Nm

Y220_01134

B. Hold the timing chain and remove the timing chain

cover by tapping it with a rubber hammer and a
screwdriver.

Installation Notice
Apply the sealant on the parting surface.

Y220_01135

ENGINE ASSEMBLY CHANGED BY

DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI01-60

39. Remove the timing chain guide rail and timing chain.

Y220_01136

40. Remove the HP pump bolts and the HP pump bracket

bolts.

Y220_01138

• Remove the HP pump assembly.

Y220_01139

41. Remove the crankshaft sprocket with a special tool.

Y220_01137

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
 DI01-61

42. Remove the flywheel and the crankshaft strainer.

Installation Notice

45 ± 5.0 Nm,
Tightening torque
90° + 10°

43. Unscrew the bolts and remove the crankshaft bearing

caps.
Installation Notice

55 ± 5.0 Nm,
Tightening torque
90° + 10°

Y220_01140

Notice

• Remove the bearing cap bolts from inside to outside

with a pair.
• Do not mix up the crankshaft bearing caps and
shells.

Y220_01141

Note

• Install in the reverse order of removal.

• Tighten the fasteners with the specified tightening torques.
• Replace the gaskets and bearings with new ones.
• Make sure to install the gaskets in correct direction.

ENGINE ASSEMBLY CHANGED BY

DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN