Page 803 of 3229

SymptomPossible CauseAction
cas ingsCrankcaseventi lat ion s yst emPi st on ring blow-by
Carry out a compres s ion tes t, GO to Pinpoint Test A.
Internal oil l eaks (leaks int o cool antor combus t ion chamber) Note: T hismay be indicated by theproduction of blue smoke from theexhaust
Gas ket sSealsHos esDamaged/Crackedcas ingsW orn valve gui desW orn cyli nderbores /pi s tonsBroken pi st on rings
Check for t races of oil in the coolant. Check for evidenceof oi l i n t he combus t ion chambers (depos it s on t he glowpl ugs , et c). Confirm oi l cons umpti on and vehi cl e us agewit h the owner/driver. Carry out an oil consumpt ion t es t,GO t o Pinpoint Test B.
• NOTE: As t he checks s ugges ted here are open to i nterpretat ion, they s hould be us ed as a gui de only. Descripti ons ofnois es, et c, are i n general t erms, s o depend on a degree of experi ence on t he part of t he t echnician.
Symptom C hart, NVHSymptomPossible CauseAction
Ratt le/ti cki ng from t op ofengineVal ve gear noi seCamshaft bearing nois eCamshaft chain noi s eTens ioner nois eVacuum pump noi s eHigh pres s ure fuel pumpnoi s eInject or leaki ng
Check t he engi ne oil l evel and pres s ure, GO t o Pi npoint Tes tC. . Check t he functi on of the hydrauli c t appet s and condit ionof cams haft l obes and beari ngs. Check the cams haft chainsand tens ioners , vacuum pump and high pres s ure fuel pump.Carry out i njector l eak t es t
Squeaking/Creaking/Squealfrom front of engineAcces sory dri ve bel tAcces sory dri ve bel ttens ionerDri ven component s onaccess ory dri ve bel t
Check t he acces sory dri ve belt and dri ven components .REFER t o: Acces s ory Drive (303-05B Acces sory Drive - TD42.2L Di es el, Di agnos is and Tes t ing).
W hi ne/Slap/Growl fromfront of engi neAcces sory dri ve bel tAcces sory dri ve bel ttens ionerDri ven component s onaccess ory dri ve bel tTimi ng bel t nois eTimi ng bel t t ens ionernoi s e
Check t he acces sory dri ve belt and dri ven components .REFER t o: Acces s ory Drive (303-05B Acces sory Drive - TD42.2L Di es el, Di agnos is and Tes t ing).Check t he t imi ng bel t and t ens ioners for nois e/damage
Knock from l ower half ofengine (oft en wors e wi th acold engine)
Engi ne oil level/pres surelowPis ton s l apPis ton pi n nois eConnecti ng rod beari ngnoi s e
Check t he engi ne oil l evel and pres s ure, GO t o Pi npoint Tes tC. . Check for debri s i n the engi ne oil, check condit ion ofengi ne components
Knock/Rumble from lowerhalf of engine (oft en wors eon overrun)
Engi ne oil level/pres surelowMain beari ng nois e
Check t he engi ne oil l evel and pres s ure, GO t o Pi npoint Tes tC. . Check for debri s i n the engi ne oil, check condit ion ofengi ne components
W hi ne/W hi st leInt ake ai r s ys t em l eaksDamaged turbocharger(when nois e emanat ingfrom rear of engine)
Check for loose/damaged intake ai r sys tem components .Check for excess i ve turbocharger shaft fl oat Note: a smallamount of turbocharger shaft float is normal/acceptable.Check for general damage t o t urbocharger
Mi sfire/Rough runningElect roni c engi ne cont rol sFuel charging andcont rolsInt ake ai r s ys t em l eaksExhaus t gas recirculat ion(EGR) s yst emBurnt/s ti cki ng val vesW orn val ve guidesW orn cyl inderbores/pis t onsBroken pis ton ri ngsDamaged/Cracked cas ings
For el ect ronic engine controls .REFER t o: Electroni c Engine Controls (303-14B ElectronicEngi ne Cont rol s - TD4 2.2L Dies el , Diagnosi s and Test ing).For fuel charging and cont rols sys tems tes ts .REFER t o: Fuel Chargi ng and Cont rol s (303-04B Fuel Chargingand Cont rol s - TD4 2.2L Dies el , Diagnosi s and Test ing).Check i nt ake air s yst em for damage/leaks . For EGR s ys temtes ts .REFER t o: Engi ne Emi ss ion Cont rol (303-08B Engi ne Emis s ionCont rol - TD4 2.2L Dies el, Diagnos is and Tes ti ng).Check for damaged engine component s . Carry out acompress i on tes t, GO t o Pinpoint Test A.
Pinpoint Tests
• NOTE: W here reference is made to 's uit abl e equi pment', this refers t o s tandard workshop equipment . Refer to theoperati ng ins t ructi ons for your own equipment when performing any t es t s .
PINPOINT TEST A : CHECK THE CYLINDER COMPRESSIONS
W ARNING: Only compres s ion t es ters abl e t o read the hi gher compres si on pres s ures found i n dies el engi nes shouldbe us ed. Fai lure to foll ow t his i ns t ructi on may resul t in personal injury.
Page 807 of 3229
Publi s hed: 11-May-2011
Engine - TD4 2.2L Diesel - Camshaft Timing
General Procedures
Special T ool(s)
303-1270Ti ming Pi n, Cranks haft
303-1277Ti ming Pi n, Cams haft
Remove t he cover and dis connect the bat tery ground cabl e.
Refer t o: Specificati ons (414-00 Bat tery and Charging Sys tem -General Informat ion, Specificati ons).
1.
2. W ARNING: Make sure t o s upport the vehicle wit h axles tands .
Rais e and s upport t he vehi cl e.
2.
Remove t he RH front wheel and t ire.
Refer t o: W heel and Ti re (204-04 W heel s and Tires, Removal andInst all at ion).
3.
Remove t he s tart er mot or.
Refer t o: Start er Motor (303-06B Starti ng Sys t em - TD4 2.2L Dies el,Removal and Ins tall ati on).
4.
5.
Page 816 of 3229
Publi s hed: 11-May-2011
Engine - TD4 2.2L Diesel - Intake Manifold
Removal and Inst all ati on
Removal
Di sconnect t he bat t ery ground cable.
Refer t o: Specificati ons (414-00 Bat tery and Charging Sys tem -General Informat ion, Specificati ons).
1.
2. W ARNING: Make sure t o s upport the vehicle wit h axles tands .
Rais e and s upport t he vehi cl e.
2.
Remove t he fuel fi lt er.
Refer t o: Fuel Fil ter (310-01B Fuel Tank and Lines - TD4 2.2L Dies el ,Removal and Ins tall ati on).
3.
4.
5.
Page 822 of 3229
"Make s ure t hat a new component i s ins t al led. "
Make s ure that t he mat ing faces are clean and free of foreign
mat eri al .
Inst all t he EGR pipe.
T orque: 10 Nm At tach t he s pi ll ret urn li ne.
11.
Connect and s ecure t he fuel inject or wiring harnes s electrical
connectors.
T orque: 10 Nm 12.
Inst all t he breather li ne.
13.
Inst all t he fuel fi lt er.
Refer t o: Fuel Fil ter (310-01B Fuel Tank and Lines - TD4 2.2L Dies el ,
Removal and Ins tall ati on).
14.
Connect t he batt ery ground cable.
Refer t o: Specificati ons (414-00 Bat tery and Charging Sys tem -
General Informat ion, Specificati ons).
15.
Page 823 of 3229
Publi s hed: 11-May-2011
Engine - TD4 2.2L Diesel - Crankshaft Pulley
Removal and Inst all ati on
Special T ool(s)
303-1270Ti ming Pi n, Cranks haft
303-1272Locki ng Tool , Flywheel
303-1277Ti ming Pi n, Cams haft
Removal
• NOTE: Removal s t eps in t his procedure may cont ain i nst all ati on det ail s.
Remove t he cover and dis connect the bat tery ground cabl e.
Refer t o: Specificati ons (414-00 Bat tery and Charging Sys tem -General Informat ion, Specificati ons).
1.
2. W ARNING: Make sure t o s upport the vehicle wit h axles tands .
Rais e and s upport t he vehi cl e.
2.
Remove t he s tart er mot or.
Refer t o: Start er Motor (303-06B Starti ng Sys t em - TD4 2.2L Dies el,Removal and Ins tall ati on).
3.
Remove t he acces sory dri ve bel t.
Refer t o: Acces sory Dri ve Belt (303-05B Acces sory Drive - TD4 2.2LDi es el, Removal and Ins tal lat ion).
4.
Remove t he front wheel .
Refer t o: W heel and Ti re (204-04 W heel s and Tires, Removal andInst all at ion).
5.
Page 826 of 3229
Publi s hed: 11-May-2011
Engine - TD4 2.2L Diesel - Crankshaft Front Seal
Removal and Inst all ati on
Special T ool(s)
303-1274Inst all er, Cranks haft Front Seal
303-1300Remover, Cranks haft Seal
Removal
1. W ARNING: Make sure t o s upport the vehicle wit h axles tands .
Rais e and s upport t he vehi cl e.
1.
Remove t he cover and dis connect the bat tery ground cabl e.
Refer t o: Specificati ons (414-00 Bat tery and Charging Sys tem -General Informat ion, Specificati ons).
2.
Remove t he ti ming bel t.
Refer t o: Timi ng Belt (303-01B Engi ne - TD4 2.2L Dies el , Removaland Inst all at ion).
3.
Page 828 of 3229
Make s ure that t he component is cl ean, free of foreignmat eri al and l ubricant.
Make s ure that t hes e component s are ins tal led t o t he notedremoval posi ti on.
Inst all t he cranks haft key and s procket .
Inst all t he new t imi ng belt .
Refer t o: Timi ng Belt (303-01B Engi ne - TD4 2.2L Dies el , Removaland Inst all at ion).
3.
Connect t he batt ery ground cable and ins tall t he cover.
Refer t o: Specificati ons (414-00 Bat tery and Charging Sys tem -General Informat ion, Specificati ons).
4.
Page 829 of 3229
Publi s hed: 11-May-2011
Engine - TD4 2.2L Diesel - Crankshaft Rear Seal
Removal and Inst all ati on
Special T ool(s)
100-012Sl ide Hammer
303-1271Inst all er, Seal
303-538Remover/Ins t al ler, Cranks haft Oi l Seal
308-615Remover, Seals
Removal
Di sconnect t he bat t ery ground cable.
Refer t o: Specificati ons (414-00 Bat tery and Charging Sys tem -General Informat ion, Specificati ons).
1.
2. W ARNING: Make sure t o s upport the vehicle wit h axles tands .
Rais e and s upport t he vehi cl e.
2.
Manual model s: Remove t he flywheel .
Refer t o: Fl ywheel (303-01B Engi ne - TD4 2.2L Dies el , Removal andInst all at ion).
3.
Automat ic model s: Remove t he flexplate.
Refer t o: Fl expl ate (303-01B Engine - TD4 2.2L Dies el, Removal andInst all at ion).
4.