2 02

CYLINDER HEAD/CYLINDER BLOCK

CYLINDER HEAD

Cylinder head bolt

Oil Return Check Valve

System Characteristics
1. 4-valve DOHC valve mechanism
2. Swirl and tangential port
3. 4-bolt type cylinder head bolt
4. Water jacket integrated casting
5. Integrated chain housing and cylinder head
Intake manifold Exhaust manifold
6. Oil gallery: drilled and sealing with cap and screw plug

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Cylinder Head Pressure Leakage Test

GENERAL
Preceding Works:
1. Removal of cylinders
2. Removal of intake and exhaust manifold

ASSY
3. Removal of valves

Test Procedures

HOUSING
1. Place the pressure plate on a flat-bed work bench.

EXHAUST I N T A K E
LUB
2. Install the cylinder head on the pressure plate.

Tightening torque 60 Nm

COOLING
3. Immerse the cylinder head with the pressure plate
into warm water (approx. 60°C) and pressurize with
compressed air to 2 bar.

FUEL
NOTICE

CONTROL
• Examine the cylinder head for air bubbling. If the air
bubbles are seen, replace the cylinder head.

SENSOR
Cylinder Head Mating Surface Check
Specifications
Height “A” (cylinder head parting surface - cylinder head cover parting surface) 140.9 ~ 141.1 mm
Minimum height after machining 140.9 mm
Flatness In longitudinal direction 0.075 mm
In transverse direction 0.075 mm
Permissible variation of parallelism of top parting surface to bottom in longitu-
within 0.1 mm
dinal direction
Peak-to-valley height 0.004 mm
Valve recess “a” Intake valve 0.74 ~ 0.86 mm
Exhaust valve -0.15 ~ 0.15 mm

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Measurement
1. Measure the cylinder head height “A”.
Limit Over 140.9 mm

NOTICE
• If the height is less than the limit, the cylinder head
must be replaced.

2. Insert the valves into the valve guides and measure

the recesses.

Valve recess “a” Intake Valve 0.74 ~ 0.86

Exhaust Valve -0.15 ~ 0.15

NOTICE
• If the measured value is out of the specified range,
machine the valve seat as much as necessary un-
til the specified value is achieved.

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GENERAL
Cylinder Head
Disassembly
Preceding Works:

ASSY
1. Disconnect the negative battery cable.
2. Apply the parking brake and place the chocks under
the tires. (transmission “N” position)

HOUSING
EXHAUST I N T A K E
1. Remove the EGR pipe.

LUB
COOLING
2. Disconnect the injector fuel lines, connector and

FUEL
preglow plug connector. Remove the cylinder head
cover.

CONTROL
CAUTION
• Cover the openings of fuel line with the protective
caps.

SENSOR
3. Rotate the crankshaft pulley to align the OT marks.
1) Align the mark (notch) on sprocket for cylinder
No.1 (exhaust) and for cylinder No.6 (intake).
(align the cylinder No.1 OT)

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4. Mark on the timing chain, intake camshaft sprocket

and exhaust camshaft sprocket for timing setting
during installation.

5. Remove the chain tensioner after removing the EGR

pipe and oil dipstick.

6. Remove the high pressure pump and mark on the

high pressure pump sprocket.

7. Remove the camshaft position sensor.

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8. Hold the camshafts and remove the intake camshaft

GENERAL
sprocket and exhaust camshaft sprocket.

ASSY
HOUSING
EXHAUST I N T A K E
9. Remove the upper guide rail with a sliding hammer.

LUB
COOLING
10. Remove the oil cooler and the intake manifold.

11. Remove the cylinder head bolts according to the FUEL

CONTROL
SENSOR
numerical sequence.
1) M8 x 25: 2EA
2) M8 x 50: 2EA
3) M12 x 177: 9EA
4) M12 x 158: 1EA (vacuum pump side)

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12. Remove the cylinder head.

CAUTION
• Inspect the cylinder head mating surface.
• Store the removed injectors and glow plugs so that
they will not be damaged.
• If there is a sign of oil leakage on the cylinder head
gasket, replace it with new one.

13. Measure the piston protrusion from the mating

surface.

Standard 0.765 ~ 1.055 mm

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Reassembly

GENERAL
1. Measure the length of cylinder head bolts.
1) If the maximum length is exceeded by 2 mm,
replace the cylinder head bolt.

ASSY
HOUSING
EXHAUST I N T A K E
2. Install the cylinder head with the steel gasket.

NOTICE
• Make sure to place the “TOP” mark upward.

LUB
COOLING
3. Tighten the cylinder head bolts to specified torque

FUEL
and torque angle.

Step 1: 20 ± 2.0 Nm

CONTROL
Tightening torque Step 2: 85 ± 5.0 Nm
Step 3: 360° (120° x 3) + 10°

SENSOR
NOTICE
• Apply the oil on the bolt thread when installing.
• Always insert new washer first.
• The bolts at vacuum pump side are shorter than others.

4. Pull the timing chain over the cylinder head and install
the upper guide rail.

NOTICE
• Make sure that the convex surface of upper guide
rail faces to front side
• Be careful not to alter the timing point of high pres-
sure pump.

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5. Install the intake and exhaust camshaft sprockets

and the timing chain.

Tightening torque 25 Nm + 90°

NOTICE
• If the sprocket bolt is stretched over 0.9 mm, re-
place it with new one.
• Always install the intake camshaft sprocket first.

1) Make sure that the upper guide rail is installed

with proper direction.

2) Make sure that the timing chain is securely

seated on the guide rails.

NOTICE
• Make sure that the markings on camshaft sprocket
and timing chain are aligned.

6. Install the chain tensioner.

Tightening torque 65 ± 5.0 Nm

NOTICE
• Make sure that the EGR steel gasket is properly
installed.

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7. Rotate the crankshaft pulley two revolutions and

GENERAL
ensure that the OT mark on the crankshaft pulley
and the OT mark on the camshaft pulley are aligned.

ASSY
NOTICE
• If the markings are not aligned, reinstall the cylin-
der head.

HOUSING
EXHAUST I N T A K E
8. Install the cylinder head cover and the high pressure
pump housing.

NOTICE
• Apply the sealant on the bolt threads when install-
ing the high pressure pump.

LUB
COOLING
9. Remove the protective caps from the injector and

FUEL
install the new fuel supply pipes.

NOTICE

CONTROL
• The fuel pipes are not reusable to keep the clean-
ness and parts damage.

SENSOR

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Intake/Exhaust-Removal/Installation
1. Remove the cylinder head assembly.

2. Install the removed cylinder head on the assembly

board (special tool) and set the supporting bar and
lever (special tool) on the cylinder head.

3. Push the valve spring seat down with the lever and
remove the valve cotter, valve seat and valve spring.

4. Remove the valves from the cylinder head.

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Special Tools and Equipment

GENERAL
Name and Part Number Application

Y99220092B

ASSY
Compression pressure measuring
adapter and gauge

HOUSING
EXHAUST I N T A K E
Y99220082B
Supporting bar and lever

LUB
COOLING
Y99220162B

FUEL
Guide pin extractor

CONTROL
SENSOR
Y99220112B
Intake manifold guide pin

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CAMSHAFT ASSEMBLY
Preceding Work: Removal of cylinder head cover

Intake Camshaft and

Finger Follower and HLA Exhaust Camshaft Camshaft Sprockets

Cylinder Head

Camshaft Position Sensor Chain Tensioner

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Camshaft Position Sensor

GENERAL
Gap

ASSY
HOUSING
EXHAUST I N T A K E
Hall voltage

<Location of Camshaft Position Sensor> <Operation Principle of Hall Sensor>

The camshaft position sensor uses hall-effect to set the camshaft position and metallic-magnetic-material sensor
end is attached on the camshaft and then rotates with it. If sensor protrusion passes camshaft position sensor’s

LUB
semi-conductor wafer, magnetic field changes direction of electron on the semi-conductor wafer to the current flow
direction that passes through wafer from the right angle. When operation power is supplied from camshaft position
sensor, camshaft hall sensor generates signal voltage. The signal voltage will be 0V if protrusion and camshaft

COOLING
position sensor are near and 5 V if apart.
ECU can recognize that the No. 1 cylinder is under compression stroke by using this voltage signal (hall voltage).
The rotating speed of camshaft is half of the crankshaft and controls engine’s intake and exhaust valves. By install-
ing sensor on the camshaft, can recognize specific cylinder’s status, compression stroke or exhaust stroke, by

FUEL
using camshaft position when the piston is moving toward TDC (OT). Especially when started first, it is difficult to
calculate the stroke of a specific cylinder with only crankshaft position sensor.
Accordingly, camshaft position sensor is necessary to identify the cylinders correctly during initial starting. However,

CONTROL
when engine is started, ECU learns every cylinder of the engine with crankshaft position sensor signals so can run
the engine even though the camshaft position sensor is defective during engine running.

Pulse generation Cam angle ± 6°

SENSOR
Sensor air gap 0.45 ~ 1.80 mm
Tightening torque 10 ~ 14 Nm
Operating temperature - 40 ~ 130°C

Ground

Camshaft sensor

<Circuit Diagram of Camshaft Position Sensor>

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Disassembly
Preceding Works:
1. Disconnect the negative battery cable.
2. Apply the parking brake and place the chocks under
the tires. (transmission “N” position)

1. Remove the EGR pipe.

2. Disconnect the injector fuel lines, connector and

preglow plug connector. Remove the cylinder head
cover.

CAUTION
• Cover the openings of fuel line with the protective
caps.

3. Rotate the crankshaft pulley to align the OT marks.

1) Align the mark (notch) on sprocket for cylinder
No.1 (exhaust) and for cylinder No.6 (intake).
(align the cylinder No.1 OT)

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4. Mark on the timing chain, intake camshaft sprocket

GENERAL
and exhaust camshaft sprocket for timing setting
during installation.

ASSY
HOUSING
EXHAUST I N T A K E
5. Remove the chain tensioner after removing the EGR
pipe and oil dipstick.

LUB
COOLING
6. Remove the high pressure pump and mark on the

FUEL
high pressure pump sprocket.

7. Remove the camshaft position sensor. CONTROL

SENSOR

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8. Hold the camshafts and remove the intake camshaft

sprocket and exhaust camshaft sprocket.

9. Remove the camshaft bearing cap bolts so that

the tightening force can be relieved evenly.
1) Exhaust: #1, #3, #5
2) Intake: #6, #8, #10
However, there is no specific removal sequence.

3) Do not remove the bolts at a time completely.

Remove them step by step evenly or camshaft
can be seriously damaged.
4) Remove the exhaust camshafts and then
remove the intake camshaft.
• Exhaust: #2, #4
• Intake: #7, #9

10. Remove the finger follower and the HLA device.

Finger Follower

HLA

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GENERAL
Reassembly Finger Follower

1. Install the HLA device and finger follower. Check

the HLA device with the diagnosis procedures before

ASSY
installation.

NOTICE

HOUSING
• Perform the air bleeding process if it has been
stored for a extended period of time.
HLA
• Make sure that it is properly installed on the locat-
ing pin.

EXHAUST I N T A K E
2. Place the bearing cap with the OT marks on both
camshafts facing upward.

NOTICE
• Apply the sealant on the cap (#12) for the vacuum
pump when installing.

LUB
Part number: 661 989 56 A0 (DB2210)
• Apply the oil on the bearing journals before
installation.

COOLING
3. Tighten the camshaft bearing cap bolts.

FUEL
1) Intake: #7, #9
2) Exhaust: #2, #4

3) Intake: #6, #8, #10 CONTROL

SENSOR

4) Exhaust: #1, #3, #5

Tightening torque 25 Nm

NOTICE
• Check the finger follower positions and align if
needed.

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4. Install the intake and exhaust camshaft sprockets

and the timing chain.

Tightening torque 25 Nm + 90°

NOTICE
• If the sprocket bolt is stretched over 0.9 mm, re-
place it with new one.
• Always install the intake camshaft sprocket first.

1) Make sure that the upper guide rail is installed

with proper direction.

2) Make sure that the timing chain is securely

seated on the guide rails.

NOTICE
• Make sure that the markings on camshaft sprocket
and timing chain are aligned.

5. Install the chain tensioner.

Tightening torque 65 ± 5.0 Nm

NOTICE
• Make sure that the EGR steel gasket is properly
installed.

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6. Rotate the crankshaft pulley two revolutions and

GENERAL
ensure that the OT mark on the crankshaft pulley
and the OT mark on the camshaft pulley are aligned.

ASSY
NOTICE
• If the markings are not aligned, reinstall the cylin-
der head.

HOUSING
EXHAUST I N T A K E
7. Install the cylinder head cover and the high pressure
pump housing.

NOTICE
• Apply the sealant on the bolt threads when install-
ing the high pressure pump.

LUB
COOLING
8. Remove the protective caps from the injector and

FUEL
install the new fuel supply pipes.

NOTICE

CONTROL
• The fuel pipes are not reusable to keep the clean-
ness and parts damage.

SENSOR

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Special Tools and Equipment

Name and Part Number Application

Y99220152B
HLA remover

Y99220142B
Stem seal installer

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TIMING CHAIN ASSEMBLY

GENERAL
Chain Drive System

ASSY
System Layout

HOUSING
EXHAUST I N T A K E
Oil injecting direction

LUB
COOLING
FUEL
CONTROL
1. Exhaust camshaft sprocket 7. Oil pump tensioner

SENSOR
2. Upper guide rail 8. Oil pump sprocket
3. Intake camshaft sprocket 9. Crankshaft sprocket
4. Clamping guide rail 10. Oil nozzle
5. HP pump sprocket 11. Tensioner guide rail
6. Lower guide rail 12. Chain tensioner

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Chain
1. Chain type: Double Bush
2. Pitch: 9.525 mm
3. Load limits: 19,000 N
4. No. of links: 148 EA
5. Overall length: 1409.7 mm
6. Replace when the chain is extended by 0.5 % from overall length (Replace if extended by over 7.0485 mm)

Chain Tensioner

Check valve

* Check valve opening pressure: 0.2 ~ 0.5 bar

The major function of tensioner is optimizing the movement of chain drive system by using spring constant and oil
pressure in the tensioner.
The tensioner performs function of adjusting chain tension to be always tight, not loose, while engine running. By
doing so, can reduce wears of each guide rail and sprocket.

65 ± 5.0 Nm
Tightening torque
(Installed on the cylinder head)

Guide Rail
Guide rail is used to optimize the movement of chain drive system like tensioner.
Guide rail can prevent chain slap when chain is extended and reduce chain wears.
Guide rail is needed especially when the distance between the sprockets are too long.
The material is plastic.

1. Location of guide rail

1) Tensioner guide rail: Between crankshaft sprocket and exhaust camshaft sprocket
2) Upper guide rail: Between exhaust camshaft sprocket and intake camshaft sprocket
3) Clamping guide rail: Between intake camshaft sprocket and HP pump sprocket
4) Lower guide rail: Between HP pump sprocket and crankshaft sprocket

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Timing Setting

GENERAL
ASSY
HOUSING
EXHAUST I N T A K E
LUB
Sprocket
marking:
4 points

COOLING
(Gold marking)

FUEL
CONTROL
1. Check marking links on the chain (Gold marking)
2. Locate a point with two continuous marking links and align it to a marking on crankshaft sprocket ( )

SENSOR
3. Align respective marking link to each camshaft sprocket (intake and exhaust) marking ( )
4. Align another marking link to HP pump sprocket marking ( )

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Removal and Installation

1. Remove the cylinder head assembly.

2. Remove the oil pan.
3. Remove the chain guide rail with a sliding hammer.
4. Remove the chain cover.

5. Remove the oil pump drive chain.

6. Remove the upper guide rail while pushing the
retaining spring with a screwdriver.
7. Remove the lower guide rail.
8. Remove the oil pump drive chain.

9. Remove the tensioner guide rail.

10. Remove the timing chain.
11. Install in the reverse order of removal.

NOTICE
• Thoroughly clean the removed components before
installing.

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CYLINDER BLOCK

GENERAL
ASSY
Deep head bolt thread to prevent the
deformation at cylinder bore surfaces

HOUSING
EXHAUST I N T A K E
LUB
Water jacket design to in-
crease the cooling efficiency

COOLING
FUEL
CONTROL
Cambering type skirt to reduce the noise

SENSOR

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System Characteristics
1. Rib design by considering strength against engine vibrations and weight
2. Cambering type skirt design on case housing wall to reduce the engine noise
3. Water jacket design to increase the cooling efficiency of cylinder bore bridge
4. Deep head bolt thread to prevent the deformation at cylinder bore surfaces
5. Reinforcement of strength
1) Main bearing housing / Main bearing cap
2) Extended main bearing cap bolt
6. Reducing the noise, vibration and harshness (NVH)
1) Minimize the vibration by adding external ribs
2) Adding the ribs around oil pan mating surface

Knock Sensor
Two knock sensors are located on the cylinder block (intake manifold side).
To detect engine vibration under abnormal combustion, knock sensor has piezoelectric element fixed on the
vibration plate and this vibration plate is fixed on the base. If happens knocking, pistons or connecting rods
vibrate and occurs heavy sounds that hit metal. Knock sensor is used to detect those knockings caused by
abnormal combustions. It controls idling stabilities and turns on the engine warning light when detects injector
damages. And also controls pilot injection very precisely during MAP learning.
When knock sensor is defective, engine ECU corrects injection timing based on MAP values like engine speed,
intake air volume and coolant temperature.

Before checking the knock sensor unit, be sure to check the tightening torque of the sensor and connector
connecting conditions.
Insulating resistance Min. 1 MΩ
Resonance frequency 25 kHz
Operating temperature - 40 ~ 150°C
26 ± 8 mV/g (at 5 kHz)
Output voltage 22 ~ 37 mV/g (3 ~ 10 kHz)
22 ~ 57 mV/g (10 ~ 20 kHz)
Tightening torque 20 ± 5 Nm

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GENERAL
ASSY
HOUSING
EXHAUST I N T A K E
<Location of Knock Sensor>

1. Sensor housing 6. Upper contact plate

2. Nut 7. Piezo element
3. Disc spring 8. Lower contact plate

LUB
4. Weight 9. Body
5. Insulation disc 10. Terminal

COOLING
FUEL
NOTICE

CONTROL
• The knock sensor should be tightened with the specified tightening torque. Otherwise, the engine output may
be decreased and the “ENGINE CHECK” warning lamp may come on. The internal resistance of the sensor is
approx. 4.7 kW.

SENSOR
Ground
Knock
sensor
Signal

Signal

Knock
sensor
Ground
(Except D20DT)

<Circuit Diagram of Knock Sensor>

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