Knock Sensors
Two knock sensors are fitted to the cylinder block on the inboard side of each cylinder bank. The electrical connector of each sensor is secured to the left-hand engine cover bracket.
These piezo-electric sensors provide inputs to the ECM to indicate the detection and location of detonation during combustion.
Scheme 167
The cast iron crankshaft has undercut and rolled fillets for improved strength and six counter-balance weights make sure low levels of vibration from the four throw, five bearing configuration.
The main bearing shells are aluminum/tin split plain type. An oil groove in the top half of each bearing transfers oil into the crankshaft oilway drillings for lubrication of the connecting rod bearings. A lead/bronze thrust washer is fitted on each side of the top half of the center main bearing.
The crankshaft rear oil seal is lipped and is a press fit in the interface of the bedplate to cylinder block.
A torsional vibration crankshaft damper pulley is bolted to the front of the crankshaft.
Scheme 168
The connecting rods are manufactured from sinter-forged steel and have fracture-split bearing caps. The opposing sides of each connecting rod being fractured at the bearing horizontal center line.
The cylinder position is etched on adjoining sides of the joint to identify matching connecting rods and bearing caps. The connecting rod bearing shells are lead/bronze, split plain bearings.
Scheme 169
The pistons are open ended skirt design with small recesses for valve clearance and flat upper surfaces to reduce heat absorption. Three piston rings, two compression and one oil control, are fitted to each piston. Each piston is fitted on a gudgeon pin which is in a lead/bronze bush fitted in the connecting rod.
Scheme 170
| Item Number | Description |
|---|---|
| 1 | Primary chain tensioner |
| 2 | Primary chain |
Multi link primary and single link secondary chains drive the camshafts of each cylinder bank. The primary chains transmit the drive from sprocket on the crankshaft to a sprocket on each intake camshaft. The secondary chains transmit the drive from a second, smaller sprocket on the intake camshaft to a sprocket on the exhaust camshaft.
Each chain has a hydraulic tensioner operated by the engine lubricating system. A jet of oil from the end of each tensioner lubricates the chains. The primary chain tensioners act on pivoting flexible tensioner blades, the secondary chain tensioners act directly on the chains.
A woodruff key locates the drive sprocket on the crankshaft and these are retained in position by the crankshaft damper pulley.
Scheme 171
| Item Number | Description |
|---|---|
| 1 | Variable valve timing unit |
| 2 | Secondary chain |
| 3 | Secondary chain tensioner |
The variable valve timing units and the exhaust camshaft sprockets are non-interference. They are clamped in place on the camshafts by the retaining bolt and clamping plate/washer.
Scheme 172
| Item Number | Description |
|---|---|
| 1 | Crankshaft front oil seal |
| 2 | Poly-acrylic seal |
The aluminium-alloy timing cover accommodates the crankshaft front oil seal. Poly-acrylic seal in-groove gaskets seal the joint between the timing cover and the front face of the engine.
Scheme 173
| Item Number | Description |
|---|---|
| 1 | Cylinder head bolt |
| 2 | Coolant outlet |
| 3 | Valve lifter |
| 4 | Adjustment shim |
| 5 | Camshaft |
Cylinder heads are unique to each cylinder bank and are secured, using deep seated bolts, to the cylinder block. Two hollow dowels align each cylinder head with the cylinder block.
Each cylinder head gasket consists of a silicon beaded composite gasket with metal eyelets for the cylinder bores.
Each cylinder head incorporates dual overhead camshafts operating four valves per cylinder via solid aluminium-alloy valve lifters. A steel shim in the top of each lifter allows adjustment of valve clearances .
Collets, valve collars and spring seats locate the valve springs on the intake and exhaust valves. Valve stem seals are integrated into the spring seats.
Four 14mm spark plugs are located in a recess on the center-line of each cylinder head. For additional information, Refer to Engine Ignition .
Camshafts
The chilled cast iron camshafts are each retained by five aluminum alloy caps - location numbers 0 to 4 for the intake camshaft and 5 to 9 for the exhaust camshaft from the front.
A machined flat near the front of each camshaft enables the camshafts to be locked during the valve timing procedure.
Camshaft Sensor
The camshaft sensors are fitted to the rear of each cylinder head and are triggered by four toothed sensing rings fitted to the rear of the intake camshaft. The camshaft sensors are variable reluctance sensors that provides an input to the ECM of intake camshaft position.
Scheme 174
The valve covers are made from thermoplastic plastic; the right-hand bank cover incorporates an outlet for the part load engine breather.
The left-hand bank cover incorporates the engine oil filler cap and an outlet for the full load engine breather. Identical oil separators are incorporated inside the top of each cover. Each oil separator comprises a wire gauze packing in an open ended enclosure below the breather outlet.
Scheme 175
| Item Number | Description |
|---|---|
| 1 | Bedplate |
| 2 | Sealant track |
This is a structural casting bolted to the bottom of the cylinder block to retain the crankshaft and to further improve overall rigidity.
Main bearing clearance changes due to expansion are minimized by means of iron inserts cast into the bedplate main bearing supports.
Two hollow dowels align the bedplate with the cylinder block and the joint is sealed by a continuous bead of sealant.
The engine is mounted at two points. At the front, on each side of the engine, there is a mounting bracket with a Hydramount mounted to the subframe.
Oil is drawn from the reservoir in the oil pan and pressurized by the oil pump. The output from the oil pump is then filtered and distributed through the internal oil passages.
Where an oil cooler is fitted, the oil is cooled before entering the filter.
All moving parts are lubricated either by pressure or splash oil. Pressurized oil is also provided for operation of the variable valve timing units and the timing gear chain tensioners.
All of the oil system components are installed on the structural sump.
Oil is returned to the oil pan under gravity through large drain holes in the cylinder heads and the engine block to make sure quick return of the oil.
Oil Pick-Up
The plastic molded oil pick-up is attached to the underside of the structural sump. It is immersed in the oil reservoir to provides a supply to the oil pump during all normal vehicle attitudes. A castellated inlet allows the supply to be maintained after any deformation of the sump pan (e.g. after grounding). A mesh screen in the inlet prevents debris from entering the oil system.
Oil Pressure Switch
Installed at the right front of the structural sump, the oil pressure switch connects a ground input to the instrument cluster when oil pressure is present. This switch operates at a pressure of 0,15 to 0,41 bar (2.2 to 5.9 lbf.in2).
Oil Pump
The oil pump is fitted at the front of the engine and is driven directly by the crankshaft. The inlet and outlet ports align with oil passages in the bedplate, with a rubber coated metal gasket to seal the pump to bedplate interface.
An integral pressure relief valve regulates pump outlet pressure at 4,5 bar (65.25lbf.in2).
Oil Pan
The oil pan/sump comprises an aluminium-alloy structural sump bolted to the bedplate and a pressed steel pan with integral sump plug, bolted to the structural sump.
Oil Filler Cap
The oil filler cap is located on the top of the left-hand bank valve cover.
Windage Tray
A windage tray attached to the top of the structural sump isolates the oil pan from the disturbed air flow, caused by the rotation of the crankshaft; preventing oil aeration and improving oil drainage.
Crankcase Ventilation
The engine is ventilated through a part-load and a full-load breather; one on each valve cover. These flexible plastic hoses incorporate O-ring seals and quick release connectors.
The part-load breather ventilates the left-hand valve cover (left-hand bank) and feeds onto the throttle body adaptor and the purge valve. This breather is connected between the oil separator in the cover and the induction elbow.
The full-load breather ventilates the right-hand cover (right-hand bank) and is connected between the oil separator in the cover and the air intake duct between the mass air flow (MAF ) sensor and the throttle body.
The MAF sensor unit combines the two sensors: one for air flow and one for air inlet temperature. It is a hot wire sensor that provides an input which is (approximately) proportional to the mass air flow into the engine.
Each valve cover oil separator consists of wire gauze packed into an open ended enclosure in the top of the cover, below the breather outlet.
Ignition System
The 14mm spark plugs, one per cylinder, locate in recesses along the center-line of each cylinder head. The on-plug ignition coils are secured to the valve covers.
Scheme 176
| Item Number | Description |
|---|---|
| 1 | Variable valve timing (VCT) oil control unit |
| 2 | Variable valve timing (VCT) oil control solenoid |
| 3 | Bush carrier |
The variable valve timing system improves both low speed and high speed engine performance, engine idle quality and exhaust emissions. It is an infinitely variable system operating on the intake camshafts only. There is the equivalent of 48° of crankshaft movement between the retarded and advanced positions. Engine oil pressure operates the system under the control of the ECM.
For additional information, Refer to Engine System - General Information .
Camshafts LH - In-Vehicle Procedures
Special Tools Tool Illustration Tool Name Tool Number Camshaft setting 303-530 Timing chain tensioning tool 303-532 Crankshaft setting, main tool 303-645
Crankshaft Front Seal - In-Vehicle Procedures
Special Tools Tool Illustration Tool Name Tool Number Installer, crankshaft front seal 303-750 Remover, crankshaft front seal 303-751
Crankshaft Pulley - In-Vehicle Procedures
Special Tools Tool Illustration Tool Name Tool Number Locking Tool, Crankshaft Pulley 303-191 Adapter for 303-191/303-588 303-191-02 Remover, Crankshaft Pulley 303-588
Scheme 177
- Remove the cooling fan motor and shroud. Refer to «Cooling Fan Motor and Shroud»(ref-311046-S28772974112009032300000) .
- Remove the accessory drive belt . Refer to «Accessory Drive Belt»(ref-311044-S41080257832009032300000) .
- Using special tools, retain the crankshaft pulley. Remove and discard the crankshaft pulley bolt.
- Remove the special tools.
- Using special tools, remove the crankshaft pulley. Collect the locking ring. Remove and discard the O-ring seal.
- Remove the special tools.
- Remove the crankshaft front seal. Refer to «Crankshaft Front Seal»(ref-311051-S04178196572009032300000) .
- Clean all crankshaft pulley mating faces.
Crankshaft Rear Seal - In-Vehicle Procedures
Special Tools Tool Illustration Tool Name Tool Number Crankshaft rear seal remover/replacer 303-538
Scheme 178
Scheme 179
Scheme 180
- Remove the flexplate. Refer to «Flexplate - In-Vehicle Procedures»(ref-311051-S00607721332009032300000) .
- Install the special tool.
- Reposition the special tool retaining nuts.
- Using the special tool pierce the seal face and provide a pilot hole for the self-tapping screws.
- Loosen the special tool retaining nuts.
- Install the special tool self-tapping screws.
- Using the special tool remove and discard the crankshaft rear seal.
Oil Pump - In-Vehicle Procedures
Special Tools Tool Illustration Tool Name Tool Number Camshaft setting 303-530 Timing chain tensioning tool 303-532 Crankshaft setting, main tool 303-645
Secondary Timing Chain Tensioner - In-Vehicle Procedures
Special Tools Tool Illustration Tool Name Tool Number 12mm Ribe bit socket 303-1077A Camshaft setting tool 303-530 Timing chain tensioning tool 303-532 Crankshaft setting, main tool 303-645
Scheme 181
Timing Drive Components - In-Vehicle Procedures
Special Tools Tool Illustration Tool Name Tool Number Camshaft setting tool 303-530 Timing chain tensioning tool 303-532 Crankshaft setting tool 303-645