Specifications
| Description | Specification |
|---|---|
| Engine oil, SAE 5W-30 | WSS-M2C-913B A1 |
| Sealant | WSE M4G323-A4 (Loctite 5910) |
| Sealant (camshaft caps) | ESK M4G269-A (Loctite 518) |
| Hose assembly surfactant | WSE N99C45-A2 |
Lubricants, Fluids, Sealers and Adhesives
| Description | Liters |
|---|---|
| Engine oil, initial fill | 7.7 |
| Engine oil, service fill with oil filter change | 6.6 |
Capacities
| Description | Nm |
|---|---|
| Accessory drive belt idler pulley retaining bolt | 47 |
| Accessory drive belt idler pulley mount bracket retaining bolts | 80 |
| Accessory drivebelt tensioner retaining bolt | 47 |
| Air conditioning compressor retaining bolts | 25 |
| Air conditioning compressor mounting bracket retaining bolts | 25 |
| A/C manifold retaining bolt | 20 |
| Camshaft bearing caps retaining bolts | A |
| Camshaft position sensor retaining bolt | 10 |
| Camshaft hub retaining bolts | A |
| Camshaft pulley retaining bolts | 23 |
| Crankshaft pulley retaining bolt | A |
| Crankshaft position sensor retaining bolt | 5 |
| Coolant inlet housing | 10 |
| Cylinder head retaining bolts | A |
| Engine mount retaining nuts to crossmember | 63 |
| Engine mount bracket to engine mount retaining nut | 48 |
| Engine mount bracket to engine block retaining bolts | 90 |
| Engine wiring harness retaining bracket | 4 |
| Exhaust manifold heat shield retaining bolts | 10 |
| Exhaust manifold retaining bolts | 23 |
| Flexplate retaining bolts | A |
| Fuel injection pump | 23 |
| Fuel injection pump pulley retaining nut | 50 |
| Fuel injector retaining bolts | 10 |
| Generator retaining bolts | 47 |
| Generator mount bracket retaining bolts | 23 |
| Glow plugs | 10 |
| Knock sensor retaining nuts | 20 |
| Oil cooler to cylinder block retaining bolt | 10 |
| Oil level indicator tube retaining bolt | 10 |
| Oil pan retaining bolts | 10 |
| Oil pump to engine block retaining bolts | 10 |
| Oil pan drain plug | 25 |
| Oil separator pipe retaining bolts | 10 |
| Oil filter | 25 |
| Piston cooling jet retaining bolt | 10 |
| Power steering bracket retaining bolts | 23 |
| Power steering pump retaining bolts | 22 |
| Primary timing chain tensioner retaining bolts | 12 |
| Starter motor retaining bolts | 48 |
| Timing belt tensioner retaining bolt | 24 |
| Timing belt idler pulley retaining bolt | 45 |
| Water pump retaining bolts | 10 |
| Water pump pulley retaining bolts | 24 |
| Water pump outlet pipe retaining bolts | 10 |
| Valve cover retaining bolts | 10 |
| Vacuum pump retaining bolts | 23 |
| Vacuum pump retaining nuts | 13 |
Torque Specifications
A = refer to the procedure for the correct torque sequence
Scheme 387
The 2.7 liter engine consists of a six cylinder 60-degree 'Enclosed Vee' configuration liquid cooled Compacted Graphite Iron (CGI) with the cylinder bores machined directly into the block.
Viewed from the driving position, the right-hand cylinder bank is numbered 1 to 3, from the front of the vehicle and the left-hand cylinder bank are numbered 4 to 6, from the front of the vehicle.
Knock Sensors
The knock sensor registers increased vibrations which occur due to increased combustion noise. The ECM uses the signal as a correction factor for calculating the quantity of fuel to be injected during the injection phase.
Scheme 388
| Item Number | Description |
|---|---|
| 1 | Oil pump drive |
| 2 | Main bearing journal |
| 3 | Big end journal |
| 4 | Rear drive flange |
| 5 | Rear oil seal location |
| 6 | Trigger wheel location |
The crankshaft is forged steel and fillet rolled with induction hardened journals, which run in four bearings with clamped two layer bearing shells. The upper and lower shells of bearing number four are flanged, which limits the end float of the crankshaft. The main bearing caps are double bolted and cross bolted to increase the strength and rigidity of the engine block.
The rear main oil seal and retainer assembly is a one piece unit and is supplied with its own plastic fitting sleeve. The seal and retainer have two locating dowels and ten fixing bolts. In addition the retainer has a location for the crankshaft position sensor.
A torsional vibration crankshaft damper pulley is bolted to the front of the crankshaft.
The crankshaft trigger wheel is located on the rear of the crankshaft. It is pressed onto the crank using a special tool which also precisely aligns the trigger wheel for crankshaft position and timing. The trigger wheel consists of 60 magnets minus two for ECM crankshaft position reference and synchronization. The magnets cannot be seen on the trigger wheel, which therefore can only be positioned using a special tool.
Scheme 389
| Item Number | Description |
|---|---|
| 1 | Special tool |
| 2 | Trigger wheel |
If the trigger is removed for any reason, then a new trigger wheel MUST be fitted.
Scheme 390
| Item Number | Description |
|---|---|
| 1 | Connecting rod bolts |
| 2 | Connecting rod |
| 3 | Piston |
| 4 | Gudgeon pin |
| 5 | Circlips |
| 6 | Connecting rod identification |
In production the connecting rods are fitted in sets of six. The connecting rods are offset fracture split. Each connecting rod is marked (etched) with the cylinder number on either side of the fracture split line.
The pistons are made from aluminum alloy and fitted with three rings. The piston crown incorporates a pronounced bowl. This forms the combustion chamber which promotes swirl and turbulence, necessary for good combustion and improved emission. In addition, the piston skirt, which comes into contact with the cylinder bore, has molybdenum-coated surfaces. These counteract scoring of the cylinder and piston, therefore helping to increase engine life.
The piston also incorporates a double wave gallery within the piston crown to enhance piston cooling. The piston is supplied with oil by spray jets which are located in the engine block oil gallery. This ensures optimum piston cooling due to the high temperatures that are generated by the combustion process.
The arrows on the piston crown point to the front of the engine.
Scheme 391
| Item Number | Description |
|---|---|
| 1 | Ring gap oil control |
| 2 | Ring gap upper compression |
| 3 | Spiral joint oil control |
| 4 | Ring gap lower compression |
| 5 | Upper compression ring |
| 6 | Lower compression ring |
| 7 | Oil control ring |
All pistons are common single grade/single part number for all engines.
The piston top ring is a taper type and is fitted with a taper to the top of the piston. All rings marked 'top' are assembled with top to uppermost. All rings must be spaced evenly around the piston before installing. The circumference gap of the double bevelled oil control ring must be opposite to the spiral control joint.
Piston bowl volume is 20.025cc and the compression ratio is 17.3:1.