Part I Supplement covers fuel filter locations, glow plug testing, and more

PART I.
DECEMBER 1992ON
GENERAL SPECIFICATIONS, LI,IBRICATION AND
MAINTENANCE' ENGINE' FI,IEL SYSTEM' CLUTCH'
,
MANUAL TRANSMISSION
I. GENERAL SPECIFICATIONS
Towing capacity:
With trailer brakesStationWagonwith
m a n ua a
l n s m i s s.i .o. n. . . . . . . . . . - . - . . . . 2 8 0 0 k g
A11othermodels . . . . . . . . . - . . . . . . . . . . . . . 2 500 kg
Withouttrailerbrakes .. - . . . . . . . . . . . . . . . . . 750kg
2. LUBRICATION AND MAINTENANCE
SERCII'E PROCEDURES
To RenewFul Filtrs
The procedureto renew the main fuel filter and drain
the water trap is ihe sameas tbe one describedin the main
pan of this manual.
A seondsmall tuel filter is located inside tbe tuel
retum pipe banjo bolt, on the injection pump. ff the main
tuel filter is really dirty or the engine is blowinq black
smoke.this filter shouldbe checked.This small filler cannot
be,epararedfrom rhebaniobolr.howerer.aher removing
the bolt it is usually possibleto cleanthe gauze(1.) Remoythe fuel retum pipe banjo bolt liom the
Injec0onpump.Di.cardrhewa\her'.
(2) Using an aerosol type carbuettor cleaner,clean
the inside of the filter. Also checkthat the small hole ;n the
banjobolt is clear.
If the liller cannotbe satisfaclorily cleaned.renew the

banjobolt asan assembly.
(3) Using new washers,install the banjobolt to the
injectionpumpandtightensecurely.
(4) Bleed the tuel systern,as dscribedin the Fuel
Systemsectionin the main part of the manual.
3. ENGINE - 4.2 IITRE
SPECIFICATIONS - Models from August 1995
Valvespringlength
( r e cd o l o u
4 m
co
r d e ) . . . . . . . . . . . . . . . . . . . .5 3 . m
limit - . - . . - . . . . . . . . . . . 2.3nm
Vai! springsquareness
Cmshafl standardlobe
height(inletandexhausr). . . . . . - . . . . . 41.88- 41.92mm
Valvel;fterdimeter . - . - . . . . . . . . .. 25.960- 25.9-10
n\1\
Valvelifter holediamerer. . . . . . . . . . 26.000- 26.033nn
CAMSIIAFT, TIMING GEARS AT\'DFRONT
ENGINE PLATE
Models from August 1995 bave the brake booster
\dcuumpump mounred
lo rhe red of he Limingco\er
insteadof the altemafor.
The procedure to remove and iistall th camshafl.
timing gearsandfront engineplate on thescmodelsremains
as describedin the main manual with attenlionlo the
followingpoinls:
(l) If theftontengineplaleis to beremoved.
it will be
necessary
to removethe bolts retainingthe bml vacuum
pumpto theengineplate(2) Ensurefiat rhe O rings on the vacuumpump de
renewedpriorto installingtheengineplatc.
(3) Tighten the vacuum pump retaining bolts to a
torqueof 16 19NItl.
REAR CRANKSIIAFT OIL SEAL ,
The procedureto rcnew the rear crmkshaft oil seal
in th9 main manuaiwith ataention
to
remains$ described
thefollowingpointapplicable
to modelsfrom Augusl1995:
(1) Theoil sealis integralwith theretainerandcrnnot
be renewedseparately.
4. FUEL SYSTEM
CLOW PLUC CONTROL UNIT
on models
Theglow plugcontrolunitwinng conneclor
froln August 1995 is different from earlier models.
A second stnall fuelfiller is located inside thcf!lreturn

line banio bolt. A bleeder valve is tlso localed on top of
the boli
:Z55
Supplement -
Patl I
December1992on
However.the prccedurefor testingthe control unit remains

!s descnbedin ihe mapin manualwith atteniionto the
followingponrtsl
(l) Referto the acconpanying
illustrationto idendli
terninalson model,fron Augusl
theconlrolunitconnector
r995.
(2) ID operation(8) of the tesr procedurein the main
manua| connectthe test lamp betweenterminalstkee and
TransferCase
Front drive sprocketend float
(.12/92on) . . . . . . . . . . . .. . . . . . . . . . . . . . 0 20 0.51nr!
TtrANUALTRANS}IISSION
renainsbasicallythesame
The FS5MoA transmission
exceptthxt the numberof teelhon the input shaftgearhas
been increasedlo 27 and the countershafi driven geal
in thenain manual
rcmainasdescribed
A1lprocedurcs
lvith lhe auenlionlo thefollowingpoint:
To checkrheseniceabilityof thesecondandfiird gcar
measurethe cleara.cc as
synch.oniserring assemblies,
in
the
illuslrations.
shown
(3) ln operation(9) ol the lest procedurein the main

manual, connecl the lest lamp betweenterminals four and
erght.
.. ','t a
-, ,,t:....i:d
Glow plug control unit location. Th inset shows th

wiring connectorterminal idsntification viwe.l lrom
rhe harness side olthe connactor.
ringto synchroniser
Measuringthe innarsynchroniser
mustexceed0.2mm.
Theheightdifference
coneclearance.
5. CLUTCH AND MANUAL TRANSMISSTON

SPECIFICATIONS
Clutch
Clutchpedalheight:
12192 8195. . . . . . . . . . . . . . . . . . . . . . 205- 215 nrn
210 220mm
Frum8/95
Mrstercylindermountingnut
t i g h t e n li o
n rgq u( e8 / 9 o5 n ). . . . . . . . . . . . . . . 1 2 - 1 8 N n
Manual Transmission
Firsi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2621
second. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.455:1
T h i d. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 1 . 4 2 2 : 1
F o u r l.h. . . . . . . . . . . ._. . . . . . . . . . . . . . . . . . 1 . 0 0r0 i
F i f l h. . . . . . . . . . . . .- .. . . . . . . . . . . .- .. . . .0 . 8 5 0 1 1
R e v e r .s. e. . . . . . . . . . . . . . . . . . . . . . . . . .3 . 9 ' 1 1 : I
ringto gearclearance:
Synchroniser
l * i ^ "l *
lqsq0ffi-_-"
,***"*,"f
li.
I :*"7
, l
TsUBGEAF_t
r"&
A
10CI
dV
!
}{,
. . . . 1 . 0 0 - 1 . 4 5 n r m Transfercasecountershaft dismantled. Componerlts

Allcxcept secondand third . .
marked * were deletedlrom l0/91. Components marked
"
070mm
Limii
. .
# hav boen deleted from 12192.
h l r d . . . . . . . . . . - . . R e t e tr o i l l u s t r a t i o n s
S e c o n d a nt d
256
Supplenent Part l. December 1992on

TRANSFER CASE
The transfer case rernains unchangedexcept for the
deletion of the snap ring and spacerfrom the fmnt of rhe
countenhafton modelsfrom December1992.
From Aigust 1995,the spacerat the front of the input
shift andthe spaceradjacentto the mainshaftcentrebearing
Measuringth6 out6r synchroniserring io synch.onlsel

coneclearance,Theclearancomust xceed0.2 mm.
257
STEERING. FRONT SUSPENSION,BRAKES,

ELECTRICAL SYSTEM
1. STEERING
SPECIFICATIONS
Stcring Gear
M o d e. l. . . . . . . . . . . . . . . . . . . .- . . . . . . . : . . . . . . P B 6 9 K
Steerhg Pump
Fluid pressureat idle:
Hardtopand
Stationwagonmodels. . .. . . . . . .. 8 140- 8 728kPa
Utility and
C a bC h a s smi so d e l. s. . . . . . . . . . . . 1 1 5 9 ' l 7 4 8k P a
DESCRIPIION
The stedng gear on aI models has been revised.All
procedursremain as describedin the main manual with
attentionto the following points:
(l) The sectorshaft dust cover, snapring and spacer
have bendeleled.The adjustingscrewlocknut O dng and
washerhavebeendeletd.
(2) A flexible sealis installedbetweenthe outersector
shajl seal and the roller bearing in tbe housing. When
installing the flexible seal.ensuredratthe groovedendofthe
sealfacestle bearing.
(3) A flexible seal is installed to the sector shaft
cover. When instaling the flexible seal, ensure that the
groovedend of the sealfacesthe bearing.
2. FRONT SUSPENSION
On coil spring models from OctobAr1994.the torque
wrench setting for the front pan})ardrod to axie nut is
91- 121Nm.
To Check Operation
(l) Discomectthevacuumhosefrom thevacuumpump.
(2) Connecta vacuumgaugeto the vacuumPumphose
fitting.
(3) With the engine {unning above 1 000 rpm, the
\acuunlhouldno' be le.sthatr86.6I'Pa.Ifrhelacuum s
lessthan specified,renewtbe vacuumpump.
To Removeand Instell
(l) Disconnectlhe vacuumhose liom the vacuum
pump
i2) Remove the bolts and sealing washersretai.ing
the oi! pipe to the vacuum pump and the cylinder block.
Discardthe sealingwashe$.
(3) Remove the bolt ftoln the oil pipe hackei and
witbdraw the oil pipe.
(4) Reinovethe bolts retaining the vacuumpump to
the front engineplate and renove the vacuumpump lrom
the vehicle.Discardthe O rings.
(5) ff necessary,
removethe bolt retainingthe vacuum
hose banjo fifting and unscrew the check valve liom the
Checkthal air can be blown tkough the checkvalve in
Installalionis a reversalof the removalproceduie
ensunngthai all sealingva-sbersed O rings are renewed.
4. ELECTRICAL SYSTEM
SPECIFICATIONS
Comeringtamp buib
3. BRAXES
TORQUE WRE\CH SETTINGS
Models from August 1995
Vacuumpumpcheckvalve. . . .. . . . . - . - . - . . 29 Vacuumbanjo fitting bolt . - . - . . . . . . . . . . . . . 29
b o l t s. . . . . . . . . . l 2
Vacuumpum
o iplp i p eu n i o n
Mastercylindermountingnuts . . . . . . . .. . . . . l2 i o u n t i n ug t s. . . . . - . . . . . . . . . . . 1 3
S e r vuon i m
At the time of publication, no replacementpafis were

availablefor this pump apad from the O rings and sealing
s a5hers.
dealerif tne\ scuumpump15
Con'ulraDauthonsed
faulty.
34 Nm
34 Nm
1 5N m
15Nm
16Nm
VACUUM PUMP
On modelsfrom August 1995,the brake vacuumpump
is mountedto the rear of the enginetiming cover below ihe
injectionpumpatrdt driren b) rheriminggears.
21W
CORNERINC LAMP
To RenewBulb
(1) Removethe comeringlamp assemblyretaining
sffewsandrcmovethelampassembly.
(2) Rotatc the buib holder in an anticlockwisedirection alrd remove the bulb holder from the lamp assembly.
(3) DeFess the bulb. rotateit in an anticiockwise
diiection andremovethe bulb frorn the bulb holder.
(4) Instal the bulb in a reversemannerto removal;
ensuringftat the bulb holder is free from corrosionand ihal
the bulb is of the corretvoltageandwattage-
258
Supplement- Part 1. December1992 on
Renewingthe corneringlsmp bulb

Renewingrhe map lamp bulb.
(5) lnstalthe lampa$elnblyto thevehicle.
MAP LAMP
To RnewBulb
(1) Usinga smallscrewdriver,
caretullyprisettie lens
frorn ihe lamp body.
(2) Depress rhe bulb. rolate it in an annclockwise
directionand removeth bulb from the bulb holdef.
(3) Instal the bulb in a reversemanner 10 removal.
ensuringthat the bulb is of the conect voltageand waltage.
(4) lnstalthelensto thelampbody.
SOUNDSYSTEM
The radio cassetteon late models is equippedwith a
securir,code.lf thepoqer,uppl)ro rheradjocr.,ere intemlpted,the codewill be erasedandthe unil will be inoperativeundl the correctcodenumberis entered.ff the code
numberis not known, refer to an authonseddealer.
To EnaerSecurity Code
(1) Switch th radio On. If the display indicates
"CODE',
Foceedasfollows.
tffit
I.
I
::f,*.
i."Jxi"";.:"Ji" [. ff;i: ] f;fi*"
Wiring diagramlorlhe reardemisterfrom August1395andrhe corneringlamps.
259
Supplement- Part I December1992on

(2) Pressany butlon ercept Ejct. The display should
hdicate "0000".
(3) Pressthe station selectbuttons l, 2, 3 and 4 the
requind mmber of times to display the oEect security
For example,if the secwity code is 8476, pressthe 1
button eigh rimes, tie 2 tiutron four times, tlrc 3 button
seventimes andthe 4 button sir times.
(4) Pless the "A'bulton to entr the code. lf the

(-",
tlre code trtercdwas incorrect.
display indicaied
Wait len secoodsa repeatthe procedure.
If an incorect code is entercdmor than twice tlEre
will be a f5 minute delayperiod betweeneachattempt-The
unit will allow only F,redy attemptsto dnterthe code.Any
subsequentattempt will lock the unit permarcndy which
will require the unit to be retumedto an authoriseddealer.
260
PART 2. 2.8 TITRE TURBO DIESEL

LUBRICATION AND MAINTENANCE
SPECIFICATIONS
PowersteeringpumpNew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 I I rum
U s e d . . . . . . . . . . . . . . . . . . . . . . . . . 1. .0. -.1. 2 m m
L i m i .t . . . . . . . . . . . .- .. . . . . .- . . . . . . . . . . 1. 4 n m
Comprcssionpressulel
S t a n d a. r. d. . . . . . . . . . . . . . . . . . . . . . . . . 3
. &0kPa
Minimum
. .. .. .. ... ... . . .. . . . . . . . . . . 2 4 5 2 k P
Maximun variation
betwencylinders . . . . . . . . . . . . . . . . - . . . . . 4m kPa
Idle speed . . . . . - . . . . . . . . . . . . . . . . . . . . . 650 - 700 rpm
I n j e c t ti o
i nni n g . . . . . . . . . . . . . . . . . . . . . . . . .8. '.B T D C
LI]BRICATION
Engher
* L u b r i c a n t . . . . . . . . . . .2 0 w ' 4 0 o r 2 0 w - 5 0 C C M C
PDI or PD2
SumpcapacityW i t hf i l t e r- . . . . . . . . . . .
. . . . . . . . . . . . . . 6 . 4l i t r e s
.. . .s.?litres
Withoutfilter
Cooling system:
Capacity . . . . . . - . - . . . . . . . . . . . . . . . . . . . 12.4litres
Coolant
Type . . . . . . . . . . . . . . . . . . . Erhyleneglycol inlibitor
1. SERVICEPROCEDTJBES
Ratio . . . . . . . . . . . . . . . . . . . . . . 30%inhbitor to 707,
FT]EL FILTERS
sofl water
To Renelv
Manual tansmission:
Two tuel filters areusedon 2.8 litre models.The proc
Lubricant
.. .. . .. .. .. . .. . . .. . . . SAE80W90GL4
C a p a c i.t.y . . . . . . . . . . . . . . . . . . . - . . . 5 . 1 l i t r e s dureaorenewthe mah fuel filter anddrarnthe water trap is
the sameasthe onedescribedin themain paIt ofthis manual.
Tmnsfercase:
A second small fuel filter is located inside the tuel
Lubricant
N o m a l t e ; p e r a t u r e s . . . . . . . . . . . S A E 8 0 W - 9 0 G L 4 retum line barjo bolt, on theinjec.ion pump.ff tlle main tuel
filter is realty dilrty or the engirc is blowing black smoke,
Over 40'C . . . . . . . . . . . . . . . . . . . . . . . SAE 140GL4
this filter should be chcked.This smafl filter cannot be
C a p a c i t.y. . . . . . - . . . . . . . . . . . . . . . . . . . . . 1 . 9l i t r e s
separatedftom the banjo bolt, however,after removingthe
Front differential lubricad:
bolt it is usuallypossibleto cleanthe gauze.
Normaltemperatures
.... .. .. . . . SAE 80W-90 GL5
(1) Removetrc tuel retum line banjo bolt ftom the
O v e r 4 o ' .C. . . . . . . . . . . . . . . . . . . . . . S A 8 E 1 , $ G t /
injection pump.Discardrhe washers.
Capacity-...... - . . . . . . . . . . . . . . . . . . . . . 5.4litres
Reardifferential lubricad:
Nornal tempemtues . . . . . . . . SAfELS 80W-90 GL5
Over40'C . . . . . . . . . . . . . . . . . . . . SAE LS I40 CLs
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 litres
* CCMC PDl or PD2 rated oit is strongly recoffnended
however,API CD oil may be used.
NOTE: Thelubncant level capaciriesshownqre
apqoitute only. The cotect lubricant level
shouA be che&ed at thefiller plry or dipsnck
TTINE.IIP
F i r i nogr d e .r . . . - . . . . - . . . . . . . . . . . . . . . . . . 1 - 5 - 3 - 6 - 2 - 4
Driv belt defletionat 98 N (10 kg)
appliedpIessure:
Allemator
New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 l l rnm
Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 14 turl
Limit . . . . . . . . . . . . . . . . . . . . . - . . . . . . . . . . . 17 Inm
Air condjtionercompressor
N e w. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 S r r l l n
2.8litro manual transmissionliller and drain plug
U s e d . . . . . . . . . . . . . . . . . . . . . . -. . . . .7 - 9 m m
'
'
'
1
1
r
u
n
L i m i t. . . . . . . . . . . . . . . .
26r
Supplement- Part 2. 2,8 Litre Turbo
A seclnd smallfuelliltr is locatd:nsiderhe Iuel rturn

lin banioboll.
When loOseningthe inictor pipe union nuts use two

spannersto prevotdamageto the iniectors.
(2) Using an aerosol type ca$urettor cleaner,clean

the insideof the filter. Enswe that the bleedhole in dre bolt
is clear.
ff the filter camot be cleaned.rcnew the banjo bolt and
filter asan assembly.
(3) Using new washers.instal the banjo bolt to the
injectionpump andtighten securly.
(4) Bled dre fuel system,using the Focedure that
follows.
(2) Depressthe lift punp on top of the filter housing

place
a finger over the oudet pipe. With the finger stil
and
over the outletpipe, releasethe lilt pump.Repeatthis pfocedure until tuel beginsto flow ftom the filter housing.
(3) Instal thefuel hoseto the filtr housingandtighten
the retainingclamp.
(4) Operatethe lift pump until a resistanceto movement is felt. Attempt to stad the engine as normal. The
engineshouldstartafter two or threeattempts.
(5) ff the engine will not stan, it is likely that air
bubbtesaretrappedin the injector pipes,proceedasfollows:
(a) Operatethe lift purnp again until a resistanceis
felt and then loosen the injector pipe unionsapproximately
rwo rumr ftomeachinjecror
TO BLEED FTJELSYSTEM
(1) Remove the ortlet hose from the fuel filter
housingandplacea containerbeneaththe oudei pipe on the
filterhousing.
NOTE: Use tuo spa ners when loosentugthe

injectionpipes.Oneon thepipe and the otheron
the rctum pipe nut to hold the injector and
preventdamage.
N0TE: This is the hose that tuns bert)eenthe

fueljltet hrusinsandtheinjecnonpunp.
(b) Have ,n ,ssistant operatethe starter motor for

short periods of 5 - 7 secondswith a cool down inteflal
betweneachstartingperiod.Tighteneachpipe union asthe
tuel beginsto flo\r from the loosenedinjection pipes.
(c) As the air is removedfrom the pipes the engine
may attemptto run. lf so allow the engineto idle andtighten
,ny looseinjection pipes.
Fuelfilterand liftpump location.
AIR CLEANER
To Service
(1) Loosenthe clanp retainingthe air inlt duct to the
air cleanercover and the air iDletpipe andremovethe duct.
(2) Renove rle bolts retahing the air cleanercover
andslide the coverftom the housing.
(3) Rernove the air cleaner element ftom the alr
cleanerhousing.
(,1) Cleanthe insideof the ai. cleanerhousingandthe
cover with a clern dampcloth.
96.9
- Part2. 2.8 Litre Turbo

Supplement
(2) If necessary,loosenthe altematorpivot boli and
the locknut and adjustthe belt tensionto achieveihe specified deflectionby rotating the adjustingbolt.
(3) Wler $e specifieddeflectionis achieved.tighten
the pivot bolt andlocknut.
Steering Pump Drive Blt
(1) Apply a pressureof 98 newtons(10 kg) njdway
betweenthe steeringpump pulley andthe cranlGhaftpuUey.
The drive belt should deflect the amount listed in
Specifications.
(2) ff necessary,loosenthe steeringpump pivot bolt
and the lock bolt and adjustthe belt tensionlo achievethe
specfied deflectionby rotating the adjustingbolt.
(3) When the specifieddeflectionis acbieved.tighten
the pivot bolt and lock bolt.
Air cleaner assembly.
(5) Instal fte new element and then the cover io the alr
cleaner housing and tighten the retaining bolts securely.
(6) Instal the air inlet duct and tighten the clamps
2. MAINTENANCE PROCEDURES
TO ADJUSTVAL}'E CTEARANCES
Hydrauliclifters are mountedbetweenthe overhead
camshaftand each valve, negatingthe need for any valve
by dirty oil blockingthe
Noisyliftersareusuallycaused
small intemal passages.Oil changesat dre rccommended
intervals are slrongly recommendedto preventlifter prob
Arrows indicatsthedrive bentension measuringpoints.
TO ADJUST DRIVE BELTS
Alternator Drive Blts
(l) Apply a pressureof 98 newtons(10 kg) midway
betweenthe aitemalorpulley andthe cranksh.Jtpultey-The
drive belt shoulddeflectthe amountlisted in SpecincarioN.
Air Corditioning Drive Belt

(l) Apply a pressure
of 98 newtons(10 kg) midway
betweenthe compressorpuiley and the crankshaftpulley.
The drive belt should deflecl the amount iisted in
Specificatiors.
(2) If necessary,
loosentbe idler pulleytock bolt and
adjusrthe belt tensionto achievethe specifieddeflection by
rotatingthe adjustingbolt.
(3) Whenthe specifieddeflectionis achieved,tighten
the lock bolt.
TO ADJUST IDLE SPEED
(l) Run theengineuntil it reachesoperatingtemper
(2) Ensurethat all electdcal accessoriesaI switched
Off andthe handtfuotde cableis fully released.
(3) If necessary,connecta tachometerto the engine
following the instrumentmanufactuersinstructions.
\OfL: I usinga pulse^pc ta.honctcrana.he:d
to tht Lo I ihjp.tor pec. loosen thp r;p?
w)untinS clampsto obtain an accuratereadinS.
Altrnatorinstalledshowingthe adiustingbolts.
263
Supplement Part2. 2.8Lirre Tufto
Enginecompartmentshowingthe variousmaintenanc6items.
Locationol the idlespeedand dashpotadiustingscrws.
The idle-upspeedadjustingpoint on air conditioned

modolsls locatdon the sid6 of the inioclionpump.
(4) Adjust the idle speedscrewon rhe injection pump

if the idle speedis not 650 ?00 rym. Ensue that the
locknur is securewhenthe idle speedis conecl.
(5) on air conditionedmodels,check the idle-up
speedasfollows:
(a) Ensurethat thereis a I mm gap betwnthe idle

control lever on the injection pump and the idle-up
diaphragmlink with the an conditionerOff(b) Check that the idte speedincreasesto 800 + 50
rpm when the ail conditioner is switched On. If the idle
20{
Supplement- Part 2. 2.8 Litre Turbo

speeddoes not increaseas specified, rotate the adjusting
screw in the end of.the idle-up diapkagm to achievethe
specifiedenginespeed.
(6) Checkthe dashpotadjustmentas fbllows:
(a) Slc,wlyopenfte thrcttleto approximatelyI 800rpm.
Stan to closethe thmttle slowly waichingtie dashpot.The
dashpotsbouldcontactlhe adjustingscrewwhen the engrne
speedrcachesI 300+ 200rprn.
O) If necessary,loosen the iocknut and ium the
dashpot adjusting scrcw to achieve the speified conlact
speed.Ensue that the locknut is securcwhenthe dashpotis

correctly adjusted.
3. SERVICE SCHEDULE
The servicing rqujrementsfor modelsfitted with lhe
2.8 litre diesel engineis basically th sameas listed in dre
Lubrication and Maintenancesec.ionin the main parl of ihe
manual,exceptfor the timing belt. The timing belt musi be
renewedevery 100000 kilomeaes.
265
ROADSIDETROUBLE SHOOTING
I. TO CHECKTHE EI,.ECTRICAL
SYSTEM
(1) Switch the ignition On ard check for nstrument
waming lanp ilumination.
(c) Check that the earth lead ftom the battery to the
engineor body ftame is not brokenandthat the connections
arecleanandsecure.
(d) Check that the lead ftom tbe batteryto the si.arter
motor solenoidis intact wilh a cleanand secureconnection.
NOTE: The glow plug waming lanp n the

itsttunent cluster should illaninate briefly to
indicate co ect operation of the glow plugs. If
the waming lamp doesnot illuminate, the elow
pllrq circuit nat befaultr. Ihis i,i be indnated
b, an engine which ntn8 o|er rcatrily but k
relactant to start whencold.
(2) Attempt to start the vohicle, checking that the
starter rotates the engine et a steadyspeed.If the engine
rotatescofrectly, proceedto opemtion(5).
(3) Switch the headlampsOn andcheckfor good lislrt
Shouldthe lampsnot illuminate or the startermotor noi
rotatethe engine.procedas{ollows:
(a) Disconnectthe battery terrninals and clean both
terminals and posts. Connect the temrinals and tighten
fimrly but not excessively.
NOTE: A battery lea.l t.rminal that is not
makinggoo.l contact \rill usualt becone wam
ajier aftemptingto crunk the engine.
Cove. raised showing the location of various relays,

fusiblelinksand fuses.
(b) Inspect the fusible links adjacentto rhe battery.

(e) Il the enginewill still not rotate,removethe cover
from the relays as shom in the illusarationand bypassthe
stanerrelay by bridging the two thick wircs on the starter
motor relay using a suitable heary duty jumper lead. Be
caretulnor to short the leadto earth(the vehiclebody) or the
tusible lint will blow.
CAUTION: when the wi/es arc brideed on thz
rclay, the ensi e 'ill crank rcEa less ol the
position oJ the ignition key. Ensure,that the
whicle is in NeutftL and the h''1dbrckeisf.nnb
applied.
If the enginecrcnk, checkthe starler rclat
atul naner rclat circuit 6ing thz ||iring diagrum
in theEle.ticdl sectionin thisSupplenlent.
Fusible links, viewedwith the cover removed.
(f) Where necessarycarry out repairs to the faults

indrcaled
In operarion.
rb).rc'. {drandre).
(4) Repeatoperations(2) and (3). Should $e startei
motor still not operate,or the lamps not illuminate, one or
morc of the following faults may be the cause:
266

SOLENOID
faulty glow plugs are suspected, test the glow plugs as

describedin the Fuel System section of this supplement.
(6) For further checkson the electrical system,refer to
the Electrical and Fuel System sectionsof this supplement.
2. TO CHECK FUEL SYSTEM
Relay cover raised showing the starter relay.

(a) No starter motor operation or lamps: Battery flat
or defective.
(b) Lamps illuminate but no starter operation: Starter
motor relay faulty, starter motor or solenoid defective, ignition/starter switch faulty. Starter motor drive jammed in
mesh with flywheel ring gear.
(c) Lamps dim and starter motor operation sluggish:
Discharged battery or fault in starter motor or solenoid,
battery flat due to broken drive belt or defective alternator,
faulty battery due to cell breakdown.
(5) If the battery and startermotor operation prove satisfactory, but the engine still fails to start, continue as follows:
(a) Place the probe of a test lamp on a glow plug
terminal or the bridging strap and connect the lead of the test
lamp to a good earth on the cylinder block. Switch the ignition Off for a minimum of l0 seconds.
(b) Have an assistant switch the ignition On and
ensurethat the test lamp illuminates for a short period.
(c) If the test lamp does not illuminate, it indicates
that there is a fault in the glow plug circuit. Check the blue
fusible link adjacentto the battery.
(d) ff the test lamp illuminates, it indicates correct
operation of the glow plug circuit up to the glow plugs. If
The procedure to check the fuel system is basically the

same as that described in the main part of this manual with
attentionto the following points:
(l) Refer to the Lubrication and Maintenance section
of this supplementfor a procedure to bleed the fuel system.
O) Due to better accesson the 2.8 litre model, if the
fuel cut solenoid is suspected of being faulty, it can be
removed and the plunger withdrawn to get the vehicle
mobile. Refer to the illustration for the location of the solenoid and the layout of the components.
Reinstall the body of the solenoid and the engine should
run if the solenoid was faulty.
NOTE: Before removing the fuel cut solenoid
the area around it must be spotlessly clean to
prevent dirt etc entering the injection pump and
causing damage.
Also it should be kept in mind thut it will be
necessaryto stall the engine in gear to switch it
Off, with thefuel cut solenoid disabled. The solenoid systemmust be repaired as soon as possible.
NUr*"*
{4
-<>
f o nrr,re
t st"'*n-ii
\ f f i
il,,.,fl
Fuel cut solenoid installed. Inset shows components.
3. TO CHECK MECHAMCAL SYSTEM
Checking for power at the glow plug bridging strap'
The procedure to check the mechanical system is basically the same as that described in the main part of this
manual with attention to the following points.
(1) When referring to the main part of this manual,
after removing the radiator cap and checking for a'loss of
coolant, remove the oil filler cap and observe the camshaft
while an assistantrotates the crankshaft.
267
- Part 2. 2.8 Litre Turbo

Supplement
Crankshaft pulley set at bottom dead centre (BDCI.

Upper timing belt cover removed. The timing belt is
correctly installed when the camshaft and injection
pump sprocket marks align as shown and the crankshaft
pulley BDG mark also aligns.
(2) If the camshaft does not turn, it is likely that the
timing belt is broken. Refer to the Timing Belt heading in
this supplement. If the timing belt has broken in service, the
engine will have probably suffered damage requiring an
engine overhaul.
(3) If the camshaft does turn, the timing belt could

possibly have jumped a tooth, altering the valve timing. In
this case, remove the upper timing belt cover from the
engine and check that the timing marks on the injection
pump and camshaft are aligned.
When these marks are aligned, the crankshaft pulley
main notch should align with the bolt head shown on the
illustration. If the marks do not align, the engine should not
be run until the cause of the timing belt jumping a tooth has
been rectified. Refer to the Engine section in this supplement.
268
ENGINE
SPECIFICATIONS
ENGINEASSEMBLY
OHC diesel
. 6 cylinderturbocharged
Type .
with indirectinjection
RD28T
Model
...2826cc
Capacity
. . 85 kw at 4 400 rpm
Poweroutput(DIN) .
235Nm at2 4OOrpm
Torque(DII.{) .
85mm
Bore. .
83 mm
Stroke
....1-5-3-6-2-4
Firingorder
...8'BTDC
Injectiontiming
..21.2:l
Compressionratio.
pressure:
Compression
.--. standard
...2452b.Pa
Minimum
Maximum variationbetween
cylinders
CYLINDERHEAD
....Onepiece
Type.
...Aluminiumalloy
Material
Maximum cylinder head/block
.....0.1 mmtotal
distortion
Minimum cylinder headheight
.....Renewable
Valveguidetype.
Renewable
Valve seattype . .
Valve seatrecessdiameterin
cylinderhead(for oversizedseats):
....41.432-4I.454mm
I n l e t.
. .35.432- 35.454mm
Exhaust
......45"
Valveseatangle.
Valve seatcontact
facediameter:
..38.6-38.8mm
Inlet.
31.6- 31.8mm
Exhaust
Valve seatinstalleddepth:
Inlet ..
. 2.1 * 0.05mm
Exhaust
VALVES AND SPRINGS
Valve headdiameter:
I n l e t.
Exhaust
Valve length:
Inlet.
Exhaust
Valve stemtip grinding limit . .
Valve stemdiameter:
6.965- 6.980mm
Inlet .
. . . . 6 . 9 4 5- 6 . 9 6 0 m m
Exhaust
Valve stemto guideclearance:
Standard..0.02-0.05mm
Inlet.
0.04- 0.07mm
Exhaust
. .0.1mm
Limit .
7.000-7.018mm
Valveguideinnerdiameter.. . . .
Valve seatangle .
Valve margin:
Standard..1.35-l.65mm
Inlet.
1.65- 1.95mm
Exhaust
..0.5 mm
Limit .
..Omm
Valveclearance....
Valve springfree length:
.42.25 mm
Outerspring
. . 36"57mm
Innerspring
Valve springsquareness
limit:
...1.9mm
Outerspring
....1.6mm
[nnerspring
Hydrauliclifter outsidediameter . . . .34.959-34.975 mm
Hydraulic lifter guide
...34.998-35.018mm
insidediameter...
Clearancebetweenlifter and
0.023- 0.059mm
lifter guide
Valve guideouterdiameter:
..11.023- 11.034mm
Standard
. . 11.233- II.234 mm
Serviceoversize
Cylinderheadvalveguidehole
diameter:
..10.985-10.996mm
Standard
. . I 1.185- 1l. 196mm
Serviceoversize
. .0.037- 0.049mm
fit of valveeuide.
Interference
CAMSHAFT
Camshaftjournal to bearing
clearance:
....0.045-0.086mm
Standard
..O.lmm
Limit.
Innerdiameterof
. . . ._.30.000- 30.021mm
camshaftbearing
Outerdiameterof
.29.935-29.995mm
....
camshaftjournal
. . 3 9 . 0- 3 9 . 2 m m
Lessthan0.02mm
Camshaftrunout
32I -32.2mm
. . . . .. .. . . . 0.065-0.169mm
Camshaft
endfloat
. . . . 1 0 1 . 5 3 - 1 0 1 . 9 7 m m Camshaftlobeheight:
47.65- 47 i70mm
Inlet .
. . 1 0 1 . 3 8 -1 0 1 . 8 2 m m
E
x
h
a
u
s
t
.
.
.
.
4
9.15-49.20mm
. . Lessthan0.2 mm
0.15mm
Camshaftlobewearlimit . .
269

CYLINDERBLOCK
Type.
Material
Cylinder block face
distortionlimit.
Borediameter.....
Maximumwearlimit
Maximum ovality
Maximum taper .
Main bearingjournal diameter
Maximum difference between
main bearingjournals
....6cylinderinline
...Castiron
...0.10mm
....85.00-85.05mm
.....0.20mm
.0.015 mm
. 0.010 mm
58.645 - 58.672 mm
. . . .0.05 mm
0.50mm (marked"50") .
. 85.460- 85.510mm
l.00 mm (marked"100")
. 85.960- 86.010mm
Pistonskirt to cylinder
boreclearance.....
....0.030-0.050mm
Pistonring sideclearance:
StandardTop..
0.060-0.093mm
Second
. . . . . 0 . 0 4 0 - 0 . 0 7m
3m
L i m i t.
..0.1mm
Pistonring gap(measured
85 mm
from the top of thebore):
Top..
..0.12-0.30mm
Second
;.....
.0.38-0.53mm
Limit.
..0.4mm
Gudgeonpin holediameter
. . .26.991-26.999 mm
Gudgeonpin outerdiameter
. .26.994* 27.000mm
Gudgeonpinfitinpiston.
.. -0.004-0mm
Gudgeonpin oil clearancein
- 0.044mm
connectingrod . .
O.O25
CRANKSHAFT AND MAIN BEARINGS

N u m b e r om
f ainbearings
........7
Crankshaft end float:
Standard
0.05 - 0.18 mm
Limit .
..0.3.mm
Main bearingjournal diameter
G r a d e0
..54.967 -54.975mm
'Gradel ...:
. . . . 5 4 . 9 5 9 - 5 4 . 9 6 7 m m LUBRICATION
Grade?
. .54.951- 54.968mm
Oil pressureat idle speed
. More than78 kPa
Big end journal diameter
Oil pressureat 3 000rpm . .
.319 * 425kPa
G r a d e0
..49968-49974mm
Oil pumpclearance:
G r a d eI
..49.961-49.968mm
Outerrotorto housing
. 0.11- 0.20mm
Main bearing oil clearance:
Outerrotorto crescent
.0.21- 0.32mm
Standard
....0.036-0.063mm
Innerrotorto crescent
.0.22- 0.33mm
Limit .
.0.12 mm
Rotor endclearanceBig end bearingoil clearance:
Innerrotor
. . . . 0 . 0 5- 0 . 0 9 m m
Standard
....0.031-0.051mm
Outerrotor
Limit .
Inner rotor to housingoil
.0.11mm
Maximum journal ovality
0.005 mm
clearance
. . . . . 0 . 1 1 - 0 . 1 5m m
Maximum journal taper
. .0.005 mm
TURBOCHARGER
Maximumcrankshaftrunout
..1...
0.1mm
Maximum flywheel runout
. 0.1 mm
Type.
...WatercooledGarrettT25
CONNECTING RODS AND BEARINGS
Connecting rod centre distance
. . . . 140 mm
Maximum connecting
rod bend and twist
. .0.025 flrm per 100 mm
Connecting rod small
end bore diameter
. . . .27 .025 - 27.038 mm
Connectingrod big end
borediameter....
...53.000-53.013mm
Connecting rod pide clearance:
Standard
. .0.2- Q3 mm
Maximum
... ..0.4mm
PISTONS AND GUDGEON PINS
Piston diameter (mcasured 14.5 mm
from the bottom of the piston skirt):
StandardGradel ......
..84.960-84.970mm
Grade2
..84.970-84.980mm
G r a d e3
..84.980-84.990mm
Grade4
..84.990-85.000mm
Grade5
..85.000-85.010mm
Oversize 0.02 mm (marked"STD")
84.980- 85.030mm
Wastegate
actuator
openingdistance
Turbineshaftendfloat .
3.80mm with 85 - 90 kPa

appliedto the
wastegatediaphragm
. 0.013- 0.097mm
TORQUE WRENCH SETTINGS

Alternatorpivot bolt
. . .63 - 77 Nm
Alternatoradjustingbracketbolts
..
. . . 30-40Nm
A l t e r n a t o r a d j u s t e r.n. u t
.....12-15Nm
Alternatorpivot bracketto
enginebolts..
..43-58Nm
Camshaftsprocketbolt..
..."123-132Nm
Camshaftbearingcapnuts
. . . . 18- 22 Nm
Connectingrod bearingcapnuts:
First stage
. . 14- 16Nm
S e c o n d s t a .g e
....37-45Nm
Coolantoutlethousingnuts .
. . 16- 21 Nm
Crankshaftpulleyretainingbolt
. . . . L42- 152Nm
Cylinderheadbolts:
M12 boltsFirst stage
29 Nm'
Secondstage .
. 113Nm
ThAd stage
Loosenall boltscompletely
270

Fourthstage.
Fifthstage
M8bolts
EGRvalveretainingnuts..
Engine pipe to exhaust
elbownuts
Fancouplingretainingnuts..
Flywheelbolts..
Glowplugs
Injection pump rear
bracket to engine
Injection pump sprocket nut . .
Injection pump rear bracket:
Topumpbolts.
To enginebolts .
Injectors
I n j e c t o r p i p e u n i o n n u t.s
Injectorreturnpipenuts..
Main bearing cap bolts
Manifold nuts and bolts:
M10 .
M8..
Oilcoolerbracketbolts..
...29Nm
.....118- 127Nm
...16-2lNm
...16-19Nm
.....22-29Nm
....7-8Nm
....137 - l57Nm
....15-20Nm
22 - 29 Nm
. 54 - 6l Nm
...16-21Nm
. .22 - 29 Nm
. 58 - 69 Nm
.....22-25Nm
....39-49Nm
. 69 - 78 Nm
.....10-12Nm
O i l p u m p r e t a i n i n g b o. .l .t rs. . .
......
16-21Nm
Oilpumppickupbolts..
Pistonoiljetplugs.
....:.....30-40Nm
4-8Nm
Rockercoverbolts
Rocker cover mounted
. . . .16 - 22 Nm
Yacuumpump nuts
.....29 -39Nm
Sumpplug
7-8Nm
Sumpbolts
Thermostat cover bolts
. 16 - 21 Nm
Timing belt tensionerlocknut
. .32 - 40 Nm
Timing belt tensioner
pivotTorxbolt..
.....10-12Nm
Timing belt idler pulley bolt
. . . 32 - 40 Nm
Turbocharger retaining nuts . .
.23 - 29 Nm
Waterpumpbolts.
....16-21Nm
1. ENGII{E MECHAI\NCALTROUBLE
SHOOTING
2.8LITRE MODELS
. . . . . 2 5- 2 9 N m
.....16-20Nm
.....16-21Nm
Using the following trouble shooting additions in

conjunction with the main part of the manual will assist in
locating engine problems.
VACUUM
PUMP
ROCKER
COVER
INLET
MANIFOLD
EXHAUST
MANIFOLD
Left hand side of the 2.8 litre turbo engine.
27r
Supptement- Part 2. 2.8 Litre Turbo

Noisy Valve Operation
(1) Leaking or worn hydraulic lifters: Check and
renew the hydraulic lifters as described under the Camshaft
and Hydraulic Lifters heading.
Excessive Oil Consumption
(1) Worn or damaged turbo bearing seals: Remove
the turbo to inlet manifold pressure hose and inspect for
excessive amounts of oil. If faulty refer the turbo to a
specialistfor overhaul or renewal.
Engine Will Not Rotate
(1) Timing belt broken: Remove the upper timing belt
cover and check the belt. If the belt is broken, remove the
cylinder head and check the engine for damage.Repair the
damageand renew the timing belt.
2. DESCRIPTION
The RD28T is a turbocharged, six cylinder, diesel
engine with 2.8 litres capacity. The engine has a single overhead camshaft, indirect injection and glow plug assisted
starting. The camshaft runs directly in the cylinder head in
seven bearings and acts directly onto hydraulic lifters,

negating the need to adjust valve clearances.
The cylinder head is aluminium alloy and is equipped
with precombustion chambers that can be removed if
absolutely necessary.Different thickness head gaskets are
available and piston protrusion must be measured on
assemblyto ensurethat the correct gasket is fitted.
Rotators are fitted to the exhaustvalves to ensurelonger
life for the valves.
A water cooled turbocharger is mounted to the exhaust
manifold and boost pressure is controlled by a wastegate.
When boost pressurebecomes excessive a diaphragm acts
on the wastegatewhich opens a port allowing exhaustgas to
bypass the turbine blades. This slows the blades, in turn
reducing the amount of boost.
A blow off valve is installed to the front of the inlet
manifold to prevent the engine being damagedby excessive
pressureshould the wastegatemalfunction.
Unlike the 4.2 litre engine, this engine does not have
renewable cylinder liners, but if the cylinder bores wear, the
engine can be bored out and oversize pistons are available.
A timing belt drives the camshaft and the injection
pump from the crankshaft. Belt tension is controlled by a
INJECTION
PUMP
IMING BEI.
COVEB
CRANKSHAFT
PULLEY
Right hand side of the 2.8 litre turbo engine.
272

tensioner pulley which is adjusted by spring tension and
'
then locked. The timing belt must be renewed every
100 000 kms to prevent serious engine damage.
A crescenttype oil pump is mounted at the front of the
engine and is driven directly by the crankshaft.
The crankshaft is supported by seven main bearings
using a cradle arrangementto provide extra rigidity to the
bottom end of the engine.
The gudgeon pins are fully floating when the engine is
at operating temperature. The gudgeon pins are retained
with snaprings.
An oil cooler is mounted to the oil filter housing above
the disposableoil filter. Both the oil cooler and oil filter are
equipped with relief valves to allow sufficient supply of oil
to the engine should either component become blocked.
Removingthe 2.8 litre engine'
3. ENGIIIE ASSEMBLY
TO REMOVEAND INSTALL
TO R.EMOVE
(1) Disconirect the negative battery terminal.
(2) Remove the stoneguardfrom beneaththe front of
the vehicle and disconnect the insert from the bottom of the
fan shroud.
(3) Remove the screws retaining the radiator shroud
to the radiator and manoeuvre the shroud from the radiator.
(4) Remove the nuts retaining the fan coupling to the
water pump and remove the fan and coupling as an assembly
from the engine.
NOTE: Do not store the coupling, laying on the
mounting flange as the silicon Jluid can weep
from the coupling over a period of time.
(5) Loosen the adjusters and remove the drive belts
from the engine.
(6) Slide the fan pulley from the water pump.
(7) Have an assistantplace the transmissionin 4th gear
and apply the footbrake to secure the crankshaft and then
loosen and remove the crankshaft pulley retaining bolt using a
long breaker and socket. Keep the thick washer with the bolt.
(8) Slide the crankshaft pulley from the crankshaft. If
the crankshaftpulley is tight, a puller can be used to remove
the pulley from the crankshaft. Ifmore clearanceis required
for the puller, drain the cooling system and remove the radiator referring to the relevant information in this supplement
and the main part of the manual.
(9) Remove the bolts retaining the timing belt covers
to the engine and remove the upper cover first, then the
lower cover.
(10) Remove the front guide plate from the crankshaft
sprocket noting its installed direction.
(11) Temporarily instal the crankshaft pulley retaining
bolt and rotate the crankshaft until the timing marks on each
The removal and installation procedure for the 2.8 litre

engineis similar to that of the 4.Zlitre enginedescribedin the
main part of the manual with attention to the following
points:
(l) The ducting for the turbochargeris different.
(2) The wiring of the 2.8 litre varies, and wiring for
such components as the throttle position sensor and EGR
vacuum switching valves should be clearly marked to make
installationeasier.
(3) The 2.8 litre engine is slightly shorter thanthe 4.2
litre engine, therefore it is not necessaryto rembve the radiator to remove the engine. However, it is recommendedthat
a suitable sheet of plywood is placed over the rear of the
radiator to prevent damage should the engine swing forward
while being lifted from the vehicle'
4. TIMING BELT
The timing belt must be renewed every 100 000 kilometres regardless of age. Failure to renew the timing belt
at the designated interval can cause serious engine
damage. If the timing belt breaks in service, the valves
can hit the pistons.
..
Removinga tight crankshaftpulleyusinga three leg
puller.
273

(l) Inspect the sprockets for foreign material on the
teeth or wear and damage. If necessary, the crankshaft
sprocket can be slid from the end ofthe crankshaft.Use care
not to lose the key or rear guide plate. If the camshaft
gprocketneedsto be removed, refer to the camshaft heading
in this section fbr the procedure.
If the injection pump sprocket needs to be removed,
refer to the Fuel System section in this supplement for the
procedure.
(2) Check the tensioner spring, compare the spring to
a new one if its condition is suspect.Renew the spring as
necessary.
(3) Turn the tensioner pulley and the idler pulley by
hand and check for wear and roughness in the bearing.
Check the contact surface for wear and damage.Renew the
pulley(s) if the contact surface is worn or damagedor if the
bearing is unserviceable.
A T30 Torx socket is necessaryif the tensioner pulley
needsto be removed and the tensioner must be aligned with
the pin on the front of the cylinder block on installation.
(4) If the timing belt has done little work and is to be
used again, inspect the belt for wear or damage.Check the
belt thoroughly for peeling, cracking or hardening of the
rubber. Check to ensure that the belt is not contaminated
with coolant or oil. Renew the belt and rectify the leak if
contamination is evident.
NOTE: When inspecting the timing belt do not
bend, twist or turn the belt inside out as damage
could occur.
Timing covers removed showing the timing belt, and

sprockets correctly aligned prior to belt removal.
(5) If the timing belt is damaged on one side only,

check the belt guide plates and the alignment of the various
sprockets.
drive sprocket and the engine are aligned. In this position the
engine will be on No 1 cylinder BDC expansion stroke and
the crankshaft sprocket key will be at the bottom.
(12) If the timing belt has done very little work and is
to be used again, mark the timing belt with an arrow to show
the direction of rotation.
(13) Loosen the timing belt tensioner and loosen the
tensioner retaining nut and lever the tensioner away from the
belt. Tighten the locknut to hold the tensioner against spring
tension.
'
(14) Slide the timing belt from the sprockets.
NOTE: Do not rotate the crankshaft or camshajl
with the timing belt removedbecausethe valves
could hit the pistons, causing damage.
TO CLEAN AND INSPECT
NOTE: Do not wash the timing belt, timing
sprockets or tensioner pulleys in solvent. Keep
thesecomponentsfree of oil, greaseand coolant"
Wipe the components with a clean cloth if
required.
Levering the tensioner away from the timing belt.
274
CRACKS
SEPARATION
MISSINGTEETH
WORNTEETH
Check the timing belt for the illustrated faults.

To Install
'
Installation is a reversal of the removal procedure with
attention to the following Points:
( I ) If the crankshaft drive sprocket has been removed,
ensurethat the rear guide plate is installed correctly with the
smooth rounded side towards the belt (concave side towards
the engine).
(2) If the other sprockets have been removed, ensure
that they are installed correctly and the retaining nut or bolt
is tightened to the specified torque.
CRANKSHAFT
PULLEY
GUIDE
PLATES
--.rs
tS))
rN@V.7
v \
BOLT
c>
SPROCKET
512LO{A
Crankshaft pulley and associated components.

(3) Ensure that all the marks on the drive sprockets are
still aligned with the marks on the engine and instal the
timing belt without any slack along the top of or on the
tension (manifold) side of the belt. If installing the original
belt, ensure that the arrow on the belt is facing the direction
of rotation.
NOTE: When installing a new timing belt a
genuine timing belt is recommendedbecause it
has white lines and Qn arrow printed on it. The
arrow should point toward the front of the
engine and the lines should alignwith the marks
on each sprocket.
(4) Loosen the timing belt tensioner locknut and

allow the spring to tension the timing belt and tighten the
' tensionerlocknut to the specified torque.
Check that the three sprockets have not moved and the
timing marks between the engine and the sprocketsare still
aligned. Also if using a genuine timing belt, ensurethat the
white lines on the timing belt are still aligned with the marks
on the three sprockets.
(5) Rotate the crankshaft slowly two revolutions in a
clockwise direction when looking at the crankshaft sprocket,
ensuring that the crankshaft turns freely allowing for normal
compression pressure.If the engine locks up the timing is
not correctly set and the belt should be removed and the
installation procedurerepeated.
(6) Align the mark on the crankshaft and oil pump
housing and ensure that the camshaft and injection pump
sprocket timing marks are correctly aligned.
(7) Ensure that the engine revolution sensor wire is
securely clipped to the cover plate.
(8) When certain that the timing belt is correctly
installed, remove the crankshaft pulley retaining bolt. Instal
the outer guide plate to the crankshaft sprocket. Instal the
timing covers to the engine and tighten the retaining bolts.
(9) Instal the crankshaft pulley, ensure that the thick
washer is between the head of the bolt and the pulley, and
tighten the retaining bolt to the specified torque.
NOTE: Place the vehicle in fourth gear and
have an assistantapply thefootbrake to prevent
the engine rotatinS.
(10) Instal the fan pulley and viscous coupling/fan
assembly to the water pump and tighten the retaining nuts to
the specified torque.
(11) Instal the drive belts and adjustthem as describedin
the Lubrication and Maintenance section in this supplement'
(12) Instal the radiator shroud, engaging the bottom of
the shroud at the bottom of the radiator and tighten the
retaining bolts. Working beneath the vehicle clip the insert
to the main part of the shroud. Instal the stoneguard.
(13) If drained, fill the cooling system with the specified type and quantity of engine coolant. Refer to the
Cooling and Heating Systems section in this supplement.
(14) Road test the vehicle and check for correct engine
performance.
5. CAMSHAFT AND IfYDRAUUC UFTERS

SpeciatEquipmentRequired:
To Remove and Instal Timing Belt Tensioner and
Front Cover: T30 Torx socket
TO REMOVE AND INSTAL
(l) Disconnect the negative battery terminal.
(2\ Where fitted, remove the vacuum pump from the
top of the rocker cover. Refer to the Brakes section in this
supplement,if necessary.
(3) Remove the retaining bolts and lift the rocker
cover from the engine.
275

Supplement
camshaft or the bearing journals on the cylinder head may
result. Discard the oil seal.
(11) Lift each hydraulic lifter from the cylinder head
and place upside down, on a clean cloth. Labeithe cloth so
that the lifters can be returned to their original positions in
the cylinder head.
.
.
NOTE: Airwill enter the hydraulic lifters if they

are not stored as described above.
If a suitable long tray is available, store the
lifters immersedin clean engine oil.
(12) Inspect the camshaft lobes for pitting or scoring.

Renew the camshaft and lifters if necessary.
(13) If the camshaft is in good condition, measurethe
height of each lobe using a micrometer and compare with
Specifications.
(14) Check the camshaftjournals for scoring or pitting
and if serviceable, measure the diameter of the camshaft
bearing journals. Renew the camshaft if the diameter is less
than Specifications.
(15) Instal the bearing caps to the cylinder head and
using a dial gauge, measure the inside diameter of the
bearing journals. Renew the cylinder head if the journal
diameter exceeds Specifications.
Looseningthe camshaftsprocketbolt.
(4) Remove the timing belt as previously described in
this section.
NOTE: Do not rotate the cranlcshart with the
timing belt removed or the pistons will hit the
valves.
(5) Secure the camshaft with a suitable spanner on the
hexagonal provided and remove the camshaft sprocket bolt.
Remove the sprocket from the camshaft.
(6) Remove the spring from the timing belt tensioner
and then remove the tensioner from the front cover using a
T30 Torx socket. Disconnect the engine revolution sensor
connector, disengage the grommet from the cover and pass
the sensor wiring through the cover.
(7) Remove the cover plate from the front of the
cylinder head. A T30 Torx socket is required.
(8) Mount a dial gauge to the cylinder head with the
plunger bearing againsl the front of the camshaft and check
that the camshaft end float is as listed in Specifications.
NOTE: The camshaft dowel pin must be at thb
top i,hen removed from the cylinder head and
must be retumed to the same position. If the
camshart is not returned to the original positi.on
the valves may be forced into the pistons when
tightening the camshaft bearing cap bolts.
(9) Progressively loosen the camshaft bearing cap
retaining bolts, starting from each end and working towards
the centre of the cylinder head. Lift each bearing cap straight
from the head.
(10) Lift the camshaft from the cylinder head keeping it
level. Do not lift the camshaft on an angle or damage to the
ffi
Camshaft and hydraulic lifter.
(16) Measure the diameter of each hydraulic lifter and
the corresponding hydraulic lifter bore in the cylinder head
and compare to Specifications. Calculate the difference
between the two measurements to give the oil clearance
between the lifter and the bore. This should be between
0.023 - 0.059 mm. Renew the lifter or cylinder head if either
measurementexceedsSpecifications.
(17) If the lifters were noisy when removed, they
should be taken to an engine reconditioning specialist to be
checked. Alternatively they should be renewed.
attention to the following points:
(l) If a new camshaft has been installed, new or
reground lifters must be installed.
(2) If using the old camshaft and lifters, instal the
lifters to the position noted during removal. Apply a liberal
coating of engine oil to the bearing journals.
(3) Instal the camshaft squarely onto the cylinder
head with the dowel pin at the top as noted on removal.
NOTE: Failure to instal the camshaft with the
dowel pin at the top will cause the valves to be
forced onto the pistons qs the bearing caps are
tightened.
276

(11) Where applicable, instal the vacuum pump using a
new gasket and tighten the retaining nuts to the specified
torque.
6. IT{ANIFOLDS
(l) Disconnectthe negativebatteryterminal.
(2). Drain the enginecoolantby removingthe drain
plug from beneaththe radiator.Use a cleancontainerif the
coolantis to be usedagain.
(3) Mark and disconnectthe various vacuum and
pressurehosesfrom aroundthemanifoldsandturbo.
When installing the camshaft the dowel pin must be at

the top.
(4) Instal the bearing caps and progressively tighten
the retaining bolts to the specified torque starting from the
centre of the cylinder head and working towards the outside
of the cylinder head.
NOTE: If a new camshaft has been installed,
coat the lobes liberally with moly grease to
prevent initial wear on startup.
(5) Squarely drive a new oil seal into the front
camshaftbearing housing.
(6) Instal the cover plate to the front of the cylinder
head and tighten the retaining bolts securely. Passthe engine
revolution sensor through the cover plate, ensuring that the
rubber grommet is securely attached to the cover. Connect
the wiring connector and ensure that the wiring is clear of
the injection pump drive sprocket or where the timing belt
willrun.
(7) Instal the timing belt tensioner to the cover plate
and tighten the Torx bolts securely. Instal the tensioner spring.
(8) Instal the camshaft drive sprocket, secure the
camshaft on the-hexagonal portion and tighten the retaining
bolt to the specified torque.
NOTE: Trapped air in the hydraulic lifters can
hold the valves open partially. The manufactwrer
recommends thnt. the engine not be rotated for
approximately 30 minutes after installing the
camshnft to allow the hydraulic lifters to reach
their set lengths.
(9) Instal the timing belt as described previously in
this section.
(10) Apply some Permatex Ultra Grey or equivalent
sealant to the base of the camshaft front bearing cap and the
half moon on the rear of the rocker cover. Instal the rocker
cover using a new gasket and tighten the retaining bolts
progressively to the specified torque.
Turbo and associated components installed.

(4) Loosen the clamps retaining the air inlet duct and
air inlet pipe to the air cleaner top cover and the turbo.
Remove the bolt retaining the air inlet pipe to the manifold
and manoeuvreit from the engine. Place a clean cloth in the
turbo turbine port to prevent the entry of dirt.
(5) Loosen the clamps retaining the turbo pressurehose
between the turbo and inlet manifold and remove the hose.
NOTE: Excessive oil inside the hose indicates
turbo seal problems.
(6) Remove the flare nut retaining the EGR pipe to the
exhaust manifold.
(7) Progressively loosen and remove the inlet manifold retaining nuts and bolts and remove the inlet manifold
from the engine.
(8) Remove the retaining nuts and lower the engine
pipe from the outlet elbow.
(9) Remove the banjo bolts retaining the two coolant
pipes and oil supply pipe to the engine. Discard the copper
washers.
(10) Remove the bolts retaining the oil drain pipe
flange to the turbo and remove the pipe from the turbo.
Discard the gasket.
(11) Remove the retaining bolts completely and then
manoeuvre the exhaust manifold and turbo from the engine.
277

Supplement
lnlet and exhaust manifold retaining bolt tightening

sequenGe,
cleaner housing. Instal the air inlet pipe retaining bolt and
tighten securely.
(8) Connect any vacuum and pressure hoses previously removed to the positions noted on removal.
(9) Fill the cooling system with coolant using the
procedure in the Cooling and Heating Systems section of
this suplement.
EXHAUST
i'ANIFOLD
7. TURBOCHARGER
The turbocharger operates at very high speeds and
temperatures.It is assembledwith very fine tolerancesand
should only be dismantled and overhauled by a turbo
specialist.The inspection procedurewill assistin diagnosing
any suspectedwear in the turbo and wastegate actuator.
Manifolds and turbo components,

,. NQTE: Use care not to drop the manifuld and
turbo assemblyas damage will occur.
(I2) Itnecessary, check the turbo as described later in
this section.
(13) Check that the manifolds are not warped using a
straight edge and feeler gauges. Consult a cylinder head
specialist if the manifolds are warped.
(1) Ensure that the manifold mating faces on the
cylinder head and exhaustflange are clean.
(2) Instal a new manifold gasket onto the manifold
studs and instal the exhaust manifold and turbo to the
engine.
(3) Using a new gasket,instal the oil drain pipqflange
to the turbo and tighten the retaining bolts to the specified
torque. Using new washers,instal the two coolant pipes and
the oil supply pipe to the turbo. Tighten the banjo bolts
securely.
(4) Instal the inlet manifold and tighten all of the
manifold retaining nuts progressively to the specified
torque. Refer to the illustration for the tightening sequence.
(5) Connect the turbo pressurehose between the inlet
rnanifold and the turbo. Ensure that the clamps are secure.
(6) Instal the engine pipe to the exhaust outlet elbow
using a new gasket and tighten the nuts securely.
(7) Remove the cloth from the turbo turbine port and
instal the air inlet duct and pipe between the turbo and air
Wastegate and turbine, viewed with exhaust elbow

removed.
(1) Remove the manifolds as previously described.
(2) Using a small screwdriver, move the lock plate
tabs away from the turbo retaining nuts.
(3) Remove the retaining nuts and remove the turbo
from the exhaustmanifold. Discard the gasket.
(4) If necessary,remove the heat shield then remove
the elbow from the furbo.
attention to the followingpoints:
278

Supplement
(1) If removed, instal the elbow to the turbo using a
new gasket and tighten the retaining bolts to the specified
torque. Instal the heat shield to the turbo and tighten the
retaining bolts securely.
(2) Always use a new gasketwhen installing the turbo.
(3) Use new lock plates and tighten the retaining nuts
to the specified torque. Bend the lock plates againstthe nuts.
(4) Instal the manifolds as previously described.
TO CHECK AND INSPECT
Turbine Shaft End Float
(1) Remove the turbo as previously described and
secureit in a vice.
(2) Ensure that excessive amounts of oil are not
present in the turbo to inlet manifold pressure hose.
Excessive oil indicates a faulty turbo seal.
(3) Rotate the turbine shaft and ensurethat no binding
occurs. Check the that the blades do not contact the housing
when moved radially.
(4) Mount a dial gauge with the plunger bearing
againstthe turbine shaft.
(5) Check the end float by attempting to move the
turbine shaft while observing the dial gauge. If the turbo is
serviceable,the end float will be between 0.013 - 0.097 mm.
Ghecking the wastegate opening distance using

compressed air, a pressure gauge and a dial gauge.
disconnect the diaphragm from the linkage and try to free up
the linkage using penatrating oil. Ifthe penatrating oil frees
up the linkage, be sure to clean away the oil with carburettor
cleaner to prevent the oil turning to carbon and causing
further problems. If the linkage cannot be freed, refer the
turbo to a turbo specialistor an authoriseddealer.
(3) Attempt to blow through the wastegatediaphragm
and check that there are no leaks or holes in the diaphragm.
Renew the diaphragm if necessary.
(4) With the diaphragm connected to the linkage,
position a dial gauge with the plunger bearing against the
wastegatediaphragm pushrod.
(5) The pushrod should extend 3.80 mm when 85 - 90
kPa air pressure is applied to the diaphragm. Renew the
diaphragm if it does not extend as specified.
NOTE: Use care when testing as the diaphragm
may teqr if rnore than 98 kPa of air pressure is
applied to it.
E. CYLIhIDER
HEAI)
Special Equipment Required:

To Remove Upper Cover Plate - T30 Torx socket
To Dismantle and Assemble - Valve spring
compressor
To Inspect - Micrometers, straight edge
To Rcmove Injectors -27 mm fube socket
Checking the turbine shaft end float using a dial gauge.

(6) If the turbo fails any of the above tests, refer the
unit to a turbo specialist or an authorised dealer who will
advise if the unit can be overhauled or whether a new turbo
should be fitted.
Wastegate
(1i Remove the turbo as previously described and
secureit in a vice.
(2) Manually open and close the wastegateto ensure
that it is not binding or seized. If the wastegateis seized,

(1) Disconnect the negative battery terminal.
(2) Remove the drain plug from beneath the radiator
and drain the coolant from the radiator.
(3) Where fitted, remove the vacuum pump from the
top of the rocker cover. Refer to the Brakes section in this
*%l"t"i:xT'tff
cover from the engine.
279
"tainingboltsandlift therocker

Supplement
NOTE: The camshaft dowel pin must be at the
top when removing and installing the cylinder
head. If the camshaft is not retumed to the
original position, the valves may be forced into
the pistons when installing the cylinder head.
Loosening the camshaft sprocket bolt.

(5) Remove the timing belt as previously describedin
this section.
(6) Remove the manifolds and turbo as previously
described.
(7) Secure the camshaft with a suitable spanner on the

hexagonal part provided and remove the camshaft sprocket
bolt. Remove the sprocket from the camshaft.
(8) Remove the spring from the timing belt tensioner
and then remove the tensioner from the front cover using a
T30 Torx socket.
Disconnect the engine revolution sensor connectoT,
disengage the grommet and unhook the wiring from the
front cover and pass the sensor wiring through the cover.
(9) Remove the cover plate from the front of the
cylinder head. A T30 Torx socket is required.
(10) Loosen the injection pipe clamp bolts.
(11) Using two spanners,remove the injection pipes
from the injectors and injection pump. One spanner to turn
the pipe union and the other to hold the injector return pipe
nut. Plug the end of the injectors and injection pump to
prevent the entry of dirt.
(12) Hold the injector with a spanner and remove the
return pipe nut. Repeat this on all of the injectors.
Disconnect the fuel hose from the return pipe and remove
the return pipe and the washers from the injectors. Note that
the washers go under the pipe and not on top.
(13) Remove the bridging straps from the glow plugs
and place clear of the work area.
Location of various cylinder head components,
280
rnorur
Cylinder head bolt loosening sequence.
(14) Disconnect the wiring connectorsfrom the coolant

temperature sensor, engine revolution sensor and the
temperaturegauge senderunit.
(15) Disconnect the heater hose from the cylinder
head.
(16) Progressively loosen and remove the cylinder
head bolts in the sequenceillustrated. Ensure that the small
(M8) bolts are not forgotten. With the aid of an assistant,
remove the cylinder head from the engine.
(17) Remove the old cylinder head gasket and note the
number of holes on the gasket.
(18) The mating faces of the cylinder head and block
must be perfectly clean before installing the head. Using a
sharp scraper,carefully remove all traces of gasket material
from the cylinder head and block face, using care to prevent
foreign material entering the cylinders.
(19) Ensure that the precombustionchambersare clean

and not cracked. If necessary,take the head to a cylinder
head specialist to have the precombustion chambers
removed and cleaned. If is necessaryto heat the cylinder
headto 150 - 160"C when installing the chambers.
(20) Inspect the cylinder block for damage.
(21) Check the cylinder block face for distortion diagonally and lengthwise using a straight edge and feeler gauges.
Compare the result to Specifications. If the cylinder block is
distorted, it will be necessaryto remove and dismantle the
engine and consult an engine reconditioning specialist.
Machining of the cylinder block is possible, if the distortion
does not exceed Specifications.
(l) Ensure that the cylinder head bolt threads in the
block are clean and dry. Clean the threadswith a suitable tap
if necessary.
(2) Ensure that the threads on the cylinder head bolts
are clean. Apply a smearof engine oil to the threads.
(3) Check again that the cylinder head and cylinder
block mating faces are perfectly clean and free of old gasket
naterial.
(4) If the cylinder head gasket only is being renewed,
instal a new gasketwith the samenumber of holes as the old
easket.
NOTE: Using Permatex Gasket Remover or

equivalent will quickly and easily dissolve any
traces of old gasket material.
--
n
tr6-;.' O' -o/ n - /
"O
u6-o
A
"O
- - OV r .o) : a \"O
-O
"O
"O
Cylinder head gasket showing the identification holes'

The gasket illustrated has three holes and is a grade G'
A\lJ
tl6
c t)-s-o)(j
^-
g@"@"j
:;z\__o^_b?1J
Checkthe cylinder head for distortion using a feeler
gauge and a straight edge. lt is common to find a
dePressionin area A.
Measure the piston protrusion with the piston on TDG at

the four points illustrated.
6)A't
6'-tr

Supplement
(5) If pistons, cylinder block, crankshaft, connecting
rods or main or big end bearing have been renewed, the
piston protrusion must be calculatedto determine the correct
thickness of the new head gasket.Proceedas follows:
(a) Mount a dial gauge on a magnetic base to the top
of the cylinder block with the plunger bearing on the block
face.Zerc the dial gauge.
(b) Very carefully swing the dial gauge until it is on
the top of the piston, ensuring that it is still zeroed at the
height of the cylinder block. Rotate the crankshaft noting the
highest reading on the dial gauge,indicating TDC. Note this
reading and repeat the procedure on all four points illustrated, noting each dial gauge reading.
(c) Repeat operations (a) and (b) on the remaining
pistons,noting the readings.
(d) Calculate the average projection height of the
pistons and then round off the average value.
(e) Select a gasket from the table below that is within
the averagevalue determined in steps(b), (c) and (d).
PistonProtrusion
Grade
Lessthan0.79mm
0.79 - 0.875mm
Morethan0.875mm
(0 Tighten the two M8 bolts (No 15 and 16 on the

illustration) to 16 - 2l Nm.
(9) Instal the upper cover plate to the front of the
cylinder head and then instal the camshaft drive sprocket.
(10) Instal the heater hose and connect the coolant
temperature sensor, engine revolution sensor and temperature gauge senderunit wiring connectors.
INJECTOR SIDE
(6) If moved, set the crankshaft and injection pump to

Nol cylinder BDC, aligning the marks on the timing belt
sprocketswith the marks on the engine. If necessary,rotate
the camshaft until the dowel is at the top (the inlet valve on
Nol cylinder should have just closed).
(7) Instal the cylinder head gasket and then instal the
cylinder head, ensuring that it is positioned correctly over
the locating dowels.
(8) Instal the cylinder head bolts and tighten them as
follows:
(a) Following the tightening sequence, tighten all the
cylinder head bolts, except the two M8 bolts to 29 Nm.
(b) In the same sequence,tighten all the cylinder head
bolts, exceptthe two M8 bolts to 113 Nm.
NOTE: Alternately where an angle wrench

is available, instead of tensioning the bolts to
118 - 127 Nm, tighten the bolts an additional
60 - 65".
Numberof holes
(c) Using the cylinder head bolt loosening sequence,

loosen the cylinder head bolts completely.
(d) Following the tightening sequence,tighten all of
the cylinder head bolts, except the two M8 bolts to 29 Nm.
(e) In the same sequence,tighten all the cylinder head
bolts, except the two M8 bolts to 118 - 127 Nm.
rnorur
Cylinder head tightening sequence.
.lgq
The lower injector sealing washers must be installed as

shown.
(11) If removed, instal the injectors using new sealing
washers and tighten to the specified torque. Refer to the illustration for the installed direction of the lower sgaling washers.
(12) Instal new washers to the injectors and instal the
return pipe. Tighten the retaining nuts to the specified torque
and connect the return hose.
(13) If removed, instal the glow plugs ensuring that the
ones with the black insulating band above the hexagonal
part of the glow plug are installed to No 4, 5 and 6 cylinders.
(14) Instal the bridging straps to the glow plugs and
tighten the retaining nuts.
(15) Instal the injection pipes to the injectors and injection pump. Tighten the pipes at the pump end and then
tighten the pipe clamps. Leave the pipes loose at the injectors to bleed the air from the systern.
(16) Instal the manifolds and turbo as previously
described.
(17) Instal the drain plug to the bottom of the radiator
and fill the cooling system with coolant using the procedure in
the Cooling and Heating Systems section in this supplement.
(18) Bleed the fuel system using the procedure in
the Lubrication and Maintenance section in this supplement.
(19) Run the engine and check for leaks. If necessary,
adjust the idle speed as described in the Lubrication and
Maintenance section of this supplement.

NOTE: The hydraulic lifiers may be noisy for a
short period of time until the engine oil extends
the lifiers to their required lengths.
TO DISMANTLE.INSPECT AND ASSEMBLE
Overhauling a cylinder head is not usually financially
viable for the home mechanic,and is recommendedthat it be
referred to a cylinder head specialist who has the necessary
knowledge and equipment to determine the serviceability of
the unit.
The proceduresto dismantle, inspect and assemblethe
cylinder head are similar to the ones covered under the same
heading in the main part of this manual, with attention to the
following points:
(l) Remove the camshaft from the cylinder head as
previously described.
(2) Remove the hydraulic lifters from the cylinder
head as previously described. As each lifter is removed,
attempt to compressit. If the lifter is easily compressedit is
reccommendedthat it be referred to an engine reconditioner
who will determine the serviceability of the lifter.
(2) Remove the stoneguardand bracing from beneath

the sump.
(3) Remove the sump bolts/nuts starting at each end
of the sump in the centre and working around to the centre of
the sides of the sump.
(4) Bump the sump with a rubber mallet if the sealant
adhesionmakes removal difficult.
NOTE: In extreme cases,it may be necessaryto
cut the sealant using a seal cutter or an old knift
and a hammer. Take care not to damage the
mating faces. Do not use the seal cutter on alloy
s of the engi ne.
component
NOTE: For an engine reconditioner to accu'

rately diagnosis each hydraulic lifter, they need
to be cleaned, bled and then immersedin a test
fluid. The time takenfor each lifter to compress
under a set weight will determine its serviceabiliry.
When removed from the engine, the
hydraulic lifiers should be stored upside down,
preferably immersed in clean engine oil.
Sump removed showing the oil pump pickup.

(5) Remove the retaining bolts and remove the oil
pump pickup from the engine. Discard the O ring.
(6) Clean the engine sump and oil.pump pickup in
cleaning solvent. Ensure that the strainer is not damagedor
restricted.
(7) Scrapethe old sealantfrom the cylinder block and
sump mating faces.
(1) Using a new O ring instal the oil pump pickup and
tighten the retaining bolts to the specified torque.
lllustration showing the difference between the inlet

valve spring retaanerand the exhaust valve rotator.
(3) The exhaust valves ate fitted with a rotator. When
removed ensure that they ctrn be easily rotated. On assembly,
ensurethat the rotators go back on the exhaustvalves.
PICKUP
9. ENGINE STJMPAITD OIL PT.JMP
TO REMOVEAND INSTAL
--21
(l) Drain the engine oil into a suitable container.

Using a new washer instal the sump plug with the rounded
edge of the washer toward the head of the plug and tighten to
17 13 I
11 15 195;2cD?
lllustration showing the tightening sequence of the

sump bolts.
283

(2) Apply a 3.5 - 4.5 mm bead of Permatex Ultra
Grey or equivalent sealantto the sump on the inner side of
the sump bolt holes.
(3) Instal the sump to the engine and tighten the
retaining bolts firmly but not excessively,in the order shown
in the illustration.
(4) Allow at least 30 minutes before refilling with
engine oil.
10. OIL PIJMP AND REGUI.ATOR
Special Equipment Required:
To Remove Lower Cover Plate -
VALVE
HOUSING
SEAL
*Mat4=
\>"
-g*
COVER
T30 ToIx socket

(1) Remove the engine sump as previously described.
(2) Remove the timing belt as previously describedin
this section.
(3) Remove the timing belt drive sprocket from the
crankshaft gathering the key and the rear guide plate from
behind the sprocket. Note the installed position of the rear
guide plate.
(4) Remove the bolt retaining the timing belt idler
pulley and remove the pulley from the engine.
(5) Remove the T30 Torx bolts retaining the lower
cover and remove the cover from the engine.
(6) Remove the bolts retaining the oil pump housing
and manoeuvre the housing from the engine. Discard the
gasket.
(7) Supporting the oil pump housing upside down on
two pieces of timber,.tap the front oil seal from the housing
using a suitable tube or mandrel.
(8) Remove the oil pressure regulator valve plug from
the bottom of the oil pump housing. Discard the washer and
remove the spring and valve from the housing.
(9) Remove the screws from the rear of the oil pump
housing and remove the cover from the housing. Mark the
inner and outer rotors to ensure that they will run in the
dame direction when returned to the housing.
*-f f i h
(10) Check the oil pump as describedunder the Check

and Inspect heading that follows.
(1) Ensure that the oil pump housing, oil pump cover
and engine mating faces are clean.
(2) Instal the rotors, ensuring the marks made on
removal are visible and the groove on the inner rotor is
towards the pump cover.
\
\
l*
M
s = t
I
scREws
t1u
WASHEB
Oil pump components.
l #
"olo ffi
Oil pump housing, gasket and seal.
NOTE: It is recommended to pack the space

between the rotors with petroleum jelly. This
will achieve rapid buildup of oil pressure when
starting the engine.
(3) Instal the pump cover and tighten the retaining

screws securely.
(4) Lubricate the oil pressure regulator valve piston
with clean engine oil. Instal the piston and the spring to the
housing.
(5) Instal a new sealing washer to the retaining plug
and tighten securely.
(6) Using a suitable mandrel or tube that engageson the
outer edge of the seal, instal a new crankshaft oil seal squarely
into the front of the oil pump housing, with the seal lip facing
inwards. Apply multipurpose greaseto the oil seal lip.
NOTE: Place the oil pump housing on wooden
blocks when installing the seal to prevent
damage to the mating surface of the housing.
lf
,w
S "'u..
s.\
lu
t{t
(7) Instal the new gasket to the engine and instal the
oil pump housing. Tighten the bolts to the specified torque.
(8) Instal the engine sump as previously described.
(9) Instal the lower cover and timing belt idler pulley
to the engine.
(10) Instal the inner guide plate to the crankshaft.Instal
the drive sprocketto the crankshaft ensuring that it engages
correctly on the drive key.
284

Supplement
Oil seal correctly installed to oil pump housing.

NOTE: Ensure that the smooth side of the guide
plate is towards the timing belt.
Measuring the outer rotor to housing clearance.
(11) Instal the timing belt as previously described in
this section.
TO CHECKAND INSPECT
(l) Clean the oil pump componentsand the oil pump
housing with solvent and blow dry with compressed air.
Altematively, use a lint free cloth to dry the components.
(2) Inspect the rotors and the oil pump housing for
signs of excessivewear and renew componentsas necessary.
(3) Instal the rotors to the oil pump housing and
proceed as follows:
(a) Measure the clearancebetween the outer rotor to
housing using feeler gauges.
(b) Measure the clearancebetween the outer rotor tip
to the crescentusing feeler gauges.
(c) Measure the clearancebetween the inner rotor tip
and the crescentusing feeler gauges.
(d) Measure the end clearancebetween the rotors and
the housing, using a straight edge and feeler gauges.
(e) Remove the inner rotor from the trousing and
measure the inside diameter of the rotor. This is measurement A.
Measure the diameter of the raised portion of the oil
pump housing, where the inner rotor runs. This is measurement B.
Subtracting measurementA from B will give the oil
clearance.
Compare the measurementsto Specifications. Renew
componentsas necessary.
(4) Coat the oil pump regulartor valve with clean
engine oil and check that the valve slides smoothly into the
housing under its own weight. Ifbinding occurs, renew the
valve and/or the housing.
Measuring the oil pump inner rotor to housing end

clearance.
(5) Check the regulator valve spring for breakage or
distortion. Renew the spring if its condition is suspect.
1I. PISTONOIL JETS

The piston oiljets used in the 2.8 litre engine are basically the same as the ones listed in the main part of this
manual. The oil jets lubricate and cool the underside of the
piston and connecting rod and contain a one way valve in
the plug. Refer to the main part of this manual for a procedure to remove, instal and check the piston oil jets and
plugs.
285

13. OIL COOI ER AIID REIIEF VALVE
A leaking oil cooler can causeengine oil dilution.
(1) Place a container beneath the oil filter housing.
(2) Drain the engine coolant by removing the drain
plug from beneath the radiator.
(3) Remove the two hoses from the oil cooler and
move them clear of the oil cooler. Remove any spilt coolant
from around the oil cooier.
(4) Unscrew the oil cooler cap using a spanneron the
hexagonal portion and slide the cooler from the oil filter
housing.
Sump removed showing one of the piston oil iets.

12. OIL FILTER RELIEF VALVE
TO INSPECT AND RENEW
(1) Remove the oil filter from the engine.
(2) Clean any oil from around the oil filter relief valve.
(3) Using a piece of welding wire, depressthe ball on
the oil filter relief valve and check that it springs back when
pressureis released.
(4) If the valve requires renewal, proceed as follows:
(a) Using a small screwdriver, lever the valve
assembly from the oil filter housing using care not to
damagethe housing.
(b) Instal the new relief valve to the housing and taB
into position with a small socket that will fit around the
outside edge of the valve.
(5) Instal a new oil filter after placing a smear of oil
around the seal on the filter.
\
\
Oil cooler and filter housing showing the positions of

the relief valves.
Oil filter removed showing the oil filter and cooler

housing mounting bolts.
(5) If necessary,the oil cooler can be tested for leaks

by passing water through it with a garden hose with one
outlet partially blocked.
(6) With the oil cooler removed, the oil cooler pressure relief valve will be visible in the oil filter housing. It
can be removed in the sameway as the oil filter relief valve.
(1) If removed instal the oil cooler relief valve using
the proceduredescribedfor the oil filter relief valve.
286

(2) Place the oil cooler into position on the oil filter
housing using a new sealing ring and O ring. Coat the rings
sparingly with clean engine oil. Ensure that the adapter is
tight before installing and tightening the cap securely.
(3) Connect the coolant hoses to the oil cooler and
tighten the clamps securely.
(4) Fill the cooling system with the specified type of
coolant. Refer to the Cooling and Heating Systems section
in this supplement.
(5) Check the engine oil level and top up if necessary.
Add the big end journal grade number for a specific

cylinder to the gracleriumber for the connecting rod of the
same cylinder. The total is the big end bearing grade. Refer
to the chart.
NOTE: If the crankshaft is machined, these
meesurementswill not be usable. Refer the
crankshaft to an engine specialist to determine
the bearings required.
Connectingrod Big end bearing

gradenumber grade number
14. PISTONS, COIYNECTINGRODS AND

CYUNDER BLOCK
Big end
grade number
The procedures listed under the same heading in the

main part of this manual can be used to check the condition
of the pistons, connecting rods and cylinder block. Use the
specificationslisted in this supplement.
Unlike the 4.2 litre diesel engine, the cylinder block
covered in this supplement does not have renewable
cylinder liners but the cylinders can be bored out to the
nearest oversize if worn. If the block is worn beyond
machinable limits, consult an engine reconditioning
specialist or renew the block.
,o
0
1
+
+
1
0
1
1
TO INSPECT PISTONS AND CONNECTING RODS

The procedures to check the pistons and connecting
rods are the same as listed in the main part of the workshop
manual, except when measuring the piston diameter, as
describedin the main part of this manual, take the reading at
90" to the gudgeonpin hole and 14.5mm from the bottom of
the piston skirt.
The 2.8 litre engine uses graded big end bearings and
gradedjournals. If a standardbearing is worn and the crankshaft is still serviceable, determine the correct grade of
bearing required as follows.
The crankshafthas two rows of numbers marked on the
side of the No I crankshaftcounter weight. The upper row of
numbers are the big errdjoumal gradesfor cylinders I to 6.
The connecting rods are also graded and are marked
near the cap with a number.
15. CRANKSHAFTAND MAIN BEARINGS

The crankshaft removal and installation proceduresare
similar to the ones listed in the main part of this manual. The
main difference on the 2.8litre engine is that the crankshaft
is supportedby a main bearing cradle, instead of individual
bearingcaps.
When removing the cradle, start by removing the outer
bolts, progressively working towards the centre bolts. When
tightening the bolts, start at the centre of the cradle and work
outwards in two or three stages.
The main bearing shells are similar to the ones for the
4.2litre engine, that is the shells with oil grooves must go in
the cylinder block and any oil holes must align to prevent
lubricationproblems.
When the pistons are assembled to the crankshaft,
ensure that the piston protrusion is checked to ensure that
the correct cylinder head gasketis used.Refer to the heading
Cylinder Head in this section.
BIGENDGRADENo.
1.6
CYLINDERS
MAIN BEARING GRADE No.
BEARINGS 1.7
.-;;;:;j
w M w w
-ibq
;b\
_ .-.-=\
w f f i f
y, a*"1
ks
rrojrn.
Line drawing of the crankshaft showing the location of
the big end and main bearing iournal grade numbers.
M a i n b e a r i n g c r a d l e a n d b e a r i n g s .T h e b e a r i n g i t t e l l t
that go in the cradle are plain, the bearing shellsthat
'
that go in the cylinder block are grooved.
287

hand side of the block on the sump mating flange. Each
number is stampedalongsidethe relevant main bearing.
Add the cylinder block grade number for a specific
main bearing to the grade number from the crankshaft for
the samemain bearingjournal. The total is the main bearing
grade. Refer to the chart.
NOTE: If the crankshaft is machined, these
meesurementswill not be usable. Refer the
crankshaft to an engine reconditioning specialist
to deternqinethe bearings required.
Cylinderblock
journalgrade
number
Main bearing cradle removed showing the thrust plate
faces on the centre main bearing.
Similar to the big end bearings, the main bearing journals and bearing shells are graded. If a standardbearing is
worn and the crankshaft is still serviceable, determine the
conect grade of bearing as follows.
The crankshaft has two rows of numbers marked on the
side of the No I crankshaft counter weight. The lower row
of numbers are the main bearing journal gradesfor journals
1to7.
The crankshaft bores in the cvlinder block are also
graded. The grade numbers are marked underneath the right
288
Crankshaftmain Main bearing

journalgrade grade number
number
0
1
+
+
1
0
0
1
2
+
+
+
2
1
0
+
+
2
1
COOLING AI\TDHEATING SYSTEMS

SPECIFICATIONS
Cooling systemcapacity
Coolant:
Type .
Ratio.
.l2.4litres
Ethylene glycol inhibitor
...30VoinhibitortoT0Eo
soft water
Thermostat:
Type..
Openingtemperature
Fullyopen
Minimum valve lift at 90'C
Radiator fan type
Fanretainingbolts..
Lower radiator hose cross over
pipemountingbolts
Radiatormountingbolts.
Thermostatcover bolts
Viscouscouplingnuts..
Wateroutletbolts.
Water pump housing retaining bolts:
Short bolts
Long bolts
Water pump retaining bolts . .
.....Waxpellet
....82'C
.......90"C
. . . . 10 mm
. Viscous coupling
.....7 -8Nm
Cylinder block coolant drain plug.
....10- l2Nm
.4-5Nm
. 16 - 21 Nm
..7-8Nm
....16-2lNm
. 16 - 2l Nm
. 43 - 58 Nm
. .25 - 35 Nm
1. BADTATOR
TO DRAINAND REFILL
As a certain amount of water always remains in the
heater unit and cylinder block, using a coolant concentrate
rather than pre-mixed coolant is strongly recommended.
(l) Move the heatercontrols to the Hot position.
(2) Place a container beneath the radiator drain plug
and remove the plug from the radiator. Remove the radiator
cap and allow the coolant to drain into the container.
(3) When the coolant stops flowing from the radiator drain plug, remove the drain plug from the cylinder
block.
(4) When the coolant stops flowing from the cylinder
block drain plug, temporarily instal both drain plugs and fill
the cooling system with clean, clear water. Remove the
drain plugs and allow the systemto drain. Repeatthis procedure until the water flowing from the cooling system
appears clean and then instal both drain plugs and tighten
securely.
(5) Remove the reserve tank from the vehicle and
using a bottle brush and clean water, clean the inside of the
tank.
(6) Loosen the clamp and remove the bleed plug from
the heater pipe. Work out the required amount of inhibitor
(approx 3.7 litres in most cases) to make up the correct
30/10 ratio of coolant and add this to the cooling system.
Top up the system with clean, clear water until the mixture
begins to flow from the bleed plug and then instal the plug.
(l) Run the engine at idle with the radiator cap
removed and top up the cooling system as necessary.When
the systemappearsfull, instal the radiator cap and switch the
engine Off.
(8) Loosen the bleeder valve on the top radiator hose
and squeezethe radiator hose until the coolant begins to
flow from the bleeder screw.
289
Heater pipe bleed plug location.
- Part 2. 2.8Litre Turbo

Supplement
(1) Ensure that the mating faces between the thermostat bover and the engine are clean and free of old sealant.
(2) Instal the thermostat to the engine with the jiggle
valve facing uppermost.
(3) Apply a bead of Permatex Ultra Grey or equivalent sealant to the thermostat cover. Instal the cover and
tighten the retaining bolts to the specified torque.
(4) Instal the lower radiator hose and tighten the hose
clamp securely.
(5) Wait at least 30 minuteq to allow the sealant to dry
before filling the cooling system as previously described.
3. WATER PT.'MP
SpecialEquipment Required:
To Removeand Instal Water Pump Housing T30 Torx socket
Top radiator hose bleeder valve.
(9) When the coolant flows from the screw, tighten
the bleeder valve while still squeezing the top radiator hose.
(10) Top up the reserve tank with the correct mixture of
coolant to the Max mark.
2. THERMOSTAT
TO REMOVE AI\D INSTAL
(l) Drain the cooling system as previously described'
(2) Loosen the hose clamp and remove the lower radiator hose from the thermostat cover.
(3) Remove the retaining bolts and then remove the
thermostat cover from the engine. Noting the installed position (iggle valve uppermost), remove the thermostat.
Refer to the main part of this manual for a procedure to
test the thermostat, using the specifications listed in this
supplement.
''
TO REMOYE AND INSTAL

(l) Drain the coolingsystemaspreviouslydescribed.
(2) Remove the crankshaft pulley and timing belr
covers as describedunder the Timing Belt headingin the
Enginesectionof this supplement.
(3) Remove the retaining bolts and withdraw the
waterpumpfrom the engine.
(4) Check the serviceability of the water purnp, as
describedunderthe WaterPumpheadingin the main part of
this manual.
(5) If the water pump housing is corroded or
damaged,it can be removed from the cylinder block as
follows:
(a) Remove the timing belt from the engine as
describedin the Enginesectionof this supplement.
O) Remove the injection pump from the engine.
Refer to the Fuel Systemsectionsin the main part of this
manualandthis supplementfor a guide.
Timing belt covers removed showing the water pump.
The thermostat is located under the thermostat cover.
290
Water pump and water pump housing, viewed with the

timing belt and lower cover removed.
(c) Remove the bolt retaining the timing belt idler
pulley and remove the pulley from the engine.
(d) Remove the bolts retaining the lower cover and
remove the cover from the engine.
(d) Remove the bolts retaining the water pump
housing to the engine.Note the positions of eachbolt as there
are different sized bolts used on the water pump housing.
(e) Remove all of the old sealant from the water pump
housing and engine.

(1) If removed, instal the water pump housing as
follows:
(a) Apply a 2 - 3 mm bead of PermatexUltra Grey or
equivalent sealant to the groove in the rear of the water
pump housing. Instal the housing ensuring that the bolts go
back to the correct positions noted previously and tighten
the retaining bolts to the specified torque.
(b) Instal the injection pump. Refer to the Fuel
System section in this supplement and in the main part of
this manual for a guide.
(c) Instal the lower cover and the timing belt idler
pulley to the engine.
(d) Instal the timing belt to the engine as describedin
the Engine section of this supplement.
(2) Ensure that the gasket mating faces on the water
pump and the water pump housing are free of old gasket
material.
(3) Instal a new gasketonto the water pump and instal
the water pump to the engine. Tighten the retaining bolts to
(4) Instal the timing belt covers, fan assembly, drive
belts and radiator shrouds.Refer to the Timing Belt heading
in the Engine section of this supplement,if necessary.
(5) Fill the cooling system with coolant as previously
described.
(6) If the water pump housing was removed, bleed the
fuel system as described in the Lubrication and Maintenance
section of this supplement.
29r
FUEL A}{D EMISSION CONTROL SYSTEMS

SPECIFICATIONS
INJECTION PUMP
Type
Engineidle speed
Injectiontiming :.....
INJECTOR
Type..
Openingpressure:
N e wn o z z l e
Usednozzle
2. INJECTION
Rotary
. . . 650- 700 rpm
...8'BTDC
.Pintlenozzle
.....12259 -I3239hJa
. . . . . 1 32 3 9 - l 4 0 2 4 Y J a
GLOW PLUGS
Coolanttemperaturesensor
resistance:
At3"C
Ar 30'C
At 80'C
Injectionpurnpdrive
sprocketnut...
Injectionpumpnuts
Injectionpumpbracketnuts .
I n j e c t o r p i p e u n i o n n .u t s
Injector
Returnpipenuts
Glowplugs
..5.01(l
. 1.710
.0.3 ko
PT.JMP
The injection pump removal and installation procedure

is similar to that described in the main part of this manual,
with attention to the following points:
(1) On the 2.8 litre engine, the injection pump is
driven by the timing belt.
(2) A boost compensator device is mounted to the top
of the injection pump. This device increasesthe amount of
fuel available in proportion to the boost pressure from the
turbo. It is important that the hose clipped to the timing belt
cover is in good condition and not blocked or split.
(3) To remove the injection pump, first remove the
timing belt as described in the Engine section of this supplement. The sprocket is then removed by securing it with a
screwdriver against the water pump housing. Then refer to
the main part of this manual for the injection pump removal
and installation procedures.
.54-65Nm
....16-21Nm
. .22 - 29 Nm
.....22-25Nm
. 59 - 69 Nm
39 - 49 Nm
....15-20Nm
1. FUEL SYSTEM TROUBLE

SHOOTING
Thefuel systemtroubleshootingfor the 2.8litre engine
is similar to the 4.2 litre engine with attention to the
followingpoints:
EngineLacks Power
(1) Operation(6) in the main manualdoesnot apply
to the 2.8 litre enginebecauseit is equippedwith hydraulic
valvelifters.
or leaking:
(2) Boostcompensator
hosedisconnected
hosecarefullyfor deteroriaCheckthe boostcompensator
tion andrenewif necessary.
(3) Boost compensator
devicefaulty: Have a diesel
specialistchecktheboostcompensator.
(4) Low turbo boostpressure:Checkthe turbo ducts
and hosesfor restrictions.If no faults can be found havea
specialistcheck the turbo boost pressureand overhaulor
renewtheturboif necessary.
292
fnjection pump installed, 2.8 litre models.

NOTE: When the timing marks on the crankshaft, camshafi and injection pump sprockets
are aligned, the engine is on No I cylinder BDC
of the expansion stroke.
3. AIR CLEANER.
Fuel cut solenoid installed. Inset shows components.

This is dffirent to the 4.2 litre engine in the
main part of the manual where, when the marl<s
are aligned, the engine is at No I cylinder TDC
on the compression stroke.
(4) The fuel cut solenoid can be removed on this
model without dismantling the injection pump. To remove
the solenoid, proceed as follows:
(a) Ensurb that the area around the solenoid is spotlessly
clean to prevent dirt entering the injection pump.
(b) Disconnect the fuel cut solenoid connector and
remove the connector from the holder on the injection pump.
(c) Using a suitable spanner, unscrew the solenoid
from the injection pump, gathering the O ring, spring and
plunger.
Installation is a reversal of the removal procedure,
ensuring a new O ring is used.
TO REMOYE AND INSTALL

(l) Disconnect the small vacuum hose from the air
inlet duct.
(2) Loosen the clamp retaining the air inlet duct to the
air cleaner cover and the air inlet pipe and remove the duct.
(3) Remove the bolts retaining the air cleanercover to
the air cleanerhousing and slide the cover from the housing.
(4) Remove the air cleaner element from the air
cleanerhousing.
(5) Disconnect the EGR VSV wiring connector from
the front of the air cleaner housing.
(6) Suitably mark and disconnect the vacuum hoses
from the EGR valve and the steel pipe from the vacuum
pump. Position the hoses so that they can be removed with
the air cleaner housing.
(7) Working in the passengerside front wheel arch,
remove the two nuts retaining the air cleaner housing to the
inner guard.
(8) Working in the engine compartment, remove the
bolts retaining the air cleaner housing to the inner guard.
Manoeuvre the air cleaner housiing from the vehicle using
care not to damage the VSVs on the radiator support panel.
(1) Clean the inside of the air cleanerhousing and the
cover with a damp cloth.
(2) Manoeuvre the air cleaner housing into position in
the engine compartrnent using care not to damage the VSVs.
(3) Connect the wiring connector to the EGR VSVs.
(4) Instal the air cleaner housing retaining nuts and
bolts and tighten securely.
(5) Instal the air cleaner element and the cover and
tighten the retaining bolts securely
(6) Instal the air inlet duct and tighten the clamps
securely.
(7) Connect the hoses to the EGR valve, the vacuum
pump pipe and the air inlet duct.
Air cleaner components.
293

GLOW PLUG RBLAYS
To Test
(l) Remove the relavs from the vehicle.
(2) Using an ohmmlter, check that continuity exists
between terminals I and2 but not between terminals 3 and
5. On relay No 2, check that continuity also exists between
terminals 3 and 4.
(3) Apply battery power to terminals 1 and 2 and
check that continuity exists between terminals 3 and 5. On
relay No 2 ensure that continuity does not exist between 3
and 4.
(4) Renew the relay/s if necessary.
4. PREHEAT SYSTEM
The Quick Glow system used on the 2.8 litre engine,
usestwo relays and a glow plug in each cylinder. A control
unit mounted inside the vehicle controls the glow plug operating times according to signals received from the coolant
temperaturesensor,engine revolution sensor,vehicle speed
sensorand the throttle position sensor.The control unit also
controls the operation of the EGR valve, as explained later
in this supplement.
Two types of glow plugs are used. Type A glow plugs
are distinguished by the presenceof a black band above the
hexagonal portion of the plug. Type B glow plugs, without
the black bandsare installed to cylinders No l, 2 and 3. Type
A glow plugs are installed to cylinders No 4, 5 and 6.
The glow plug system operates in two modes: quick
preheatingmode and heat retaining mode.
Quick preheating mode supplies battery voltage to all
of the glow plugs to quickly heat them when the control
unit determinesthe engine temperatureis below a predetermined level. In this mode, the control unit does not energise
the No 2 glow plug relay, allowing the second bridging
strap on No 4, 5 and 6 cylinders to earth these three glow
plugs.
In heat retaining mode, the control unit energises the
No 2 glow plug relay, supplying battery power along the
second bridging strap on No 4, 5 and 6 cylinders. This
supplies a low current power feed to all of the glow plugs,
keeping the glow plugs temperature constant until the
control unit receives a coolant temperature sensor reading
indicating engine temperature is high enough to allow the
engine to run without the glow plugs.
GLOW PLUGS
To Test and Renew
The glow plugs should be tested while installed. The
manufacturer recommends that the glow plugs only be
re.movedfrom the cylinder head to be renewed.
The procedure to renew the glow plugs is similar to the
one described in the main part of this manual. Renew any
glow plugs that are open circuited.
Fl-sFlEl
FlElEl-dl
OHMMETER
WPEA
OHMMETER
Relaycover removed showing the glow plug relays.

Inset shows the terminal identification for each relay.
COOLANT TEMPERATURE SENSOR
To Test and Renew
The coolant temperature sensor is installed in the right
hand side, rear of the cylinder head beside the temperature
gauge sender.
The procedure to test and renew the coolant temperafure
sensor is similar to the one described in the main part of this
manual. Refer to Specifications in this supplement for the
coolant temperaturesensorresistances.
NOTE: The coolant temperature sensor

resistance can also be checked between
terminals 33 and 34 of the control unit wiring
connector, af-ter disconnecting the connector
from the control unit.
'-l
Connect a voltmeter between the terminals of the

coolanttemperatur'sensor
wiring connectorand switch the
ignition On. The volqneter should read 5 volts. Use the
wiring diagramsto tace the faults if 5 volts is not available.
TYPEB
TYPE B
lllustration showing the points to test the glow plug

resistance. Type A is for cylinders 4,5 and 6, Type B
is for cylinders 1,2 and 3.
START SIGNAL INPUT

To Test
(1) Disconnectthe startermotor switchwire ( the small
gaugewire) from the startermotor solenoid.
294
- Part 2. 2.8Litre Turbo

Supplement
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(4) Instal the timing belt as described in the Engine
(2) Ensure that the transmissionis in Neutral.

(3) Disconnect the wiring connector from the control
unit. Refer to the Control Unit heading in this supplement.
(4) Connect a test lamp to terminal 2l of the control
unit connector and check that the test lamp illuminates when
the ignition is switched to the Start position.
Use the wiring diagrams in this supplement to trace the
fault if necessary.
(5) When the test is complete, connect the wiring to
the control unit and startermotor.
ENGINE REVOLUTION SENSOR
To Remove and Instal
(1) Remove the timing belt as describedin the Engine
(2) Using a screwdriver, secure the injection pump
sprocketto the water pump housing and loosen the injection
pump sprocket retaining nut.
(3) Remove the nut and sprocket from the injection
pump shaft.
(4) Disconnect the wiring from the engine revolution
sensorand feed the wiring through the upper cover. Unhook
the wiring from upper cover.
To Check
(1) Remove the control unit from the kick panel,
leaving the wiring connectedto control unit.
(2) Backprobe terminal 23 of the control unit wiring
connector, with the positive probe of a voltmeter. Connect
the negative probe to a good earth and set the meter to AC
volts. With the engine idling, check that there is approximately 0.5 volts AC.
(3) If the voltage is not as specified, switch the engine
off and disconnect the wiring connector from the engine
revolution sensor.
Check that 5 volts (DC) is available at the yellow/blue
wire with the ignition On.
Backprobing the control unit wiring connector.
Timing belt removed showing the engine revofution

sensor and the hook that retains the sensor cable.
(5) Remove the bolts retaining the sensorto the water
pump housing and remove the sensorfrom the engine.
(1) Instal the sensor and tighten the retaining bolts
securely.
(2) Instal the injection pump sprocket and tighten the
retaining nut securely.
(3) Pass the wiring through the upper cover and
ensure the wiring is secured'to the hook on the rear cover.
Connect the engine revolution sensorwiring connector.
(4) If the voltage is not as specified, check the wiring

between the control unit and the engine revolution sensor.
Also check the power supply and earth circuits going into
the control unit. Ifno fault can be found, renew the control
unit.
(5) Check the resistancebetween the terminals of the
engine revolution sensor.Renew the sensorif the resistance
is not approximately 700 ohms.
VEHICLE SPEED SENSOR SIGNAL
To Test
The control unit receives a vehicle speedsignal from the
speedometeras-semblyin the instrument cluster. Therefore,
ensure that the speedometer is working before proceeding.
If the speedometeris not working test the speedsensoras
describedin the Electrical System section in the main manual.
If the speedsensoris fauhy it should be renewed.
(1) Raise the rear of the vehicle and support on
chassisstands.
(2\ Place the transmission in Neutral and release the
handbrake.
296

(3) Remove the control unit from the kick panel,
disconnect the wiring and back probe terminal 22 (orange
wire) of the control unit wiring connector.
(4) Check that the ohmmeter fluctuates between open
circuit and continuity while slowly rotating the rear
propeller shaft. If the ohmmeter does not fluctuate, check
the wiring betweeninstrument cluster and control unit for an
open circuit.
NOTE: Any fluctuation from open circuit is
consideredsatisfactory. The ohmmeter does not
have to show 0 ohms.
CONTROL UNIT
(1) Remove the sill panel retaining screws.
(2) Remove the screw retaining the driver side kick
panel. Raise the front of the sill panel and pull the kick panel
rearwood to disengageit from the body. Remove the kick
panel from the vehicle.
(3) Remove the bolts retaining the control unit and
partially remove the control unit.
(4) Disconnect the wiring connectorsfrom the control
unit and remove it from the vehicle.
Installation is a reversal of the removal procedure,
ensuring that connectors are securely fitted to the control
unit.
5. EGR VALVE AND CONTROL SYSTEM

The exhaust gas recirculation (EGR) valve, when open,
recirculatesexhaustgasesback through the inlet manifold to
lower the combustion temperaturesinside the engine.
The lower combustion temperaturesresult in a reduction in an exhaust pollutant known as Oxides of Nitrogen
(NOx).
The preheat system and the EGR valve share the same
control unit. The signals received from the coolant temperature sensor,engine revolution sensorand the throttle position sensor determine the time and amount the EGR valve
opens.
Two vacuum switching valves (VSVs) allows vacuum
to open the EGR. Vacuum is supplied by the vacuum pump
on the back of the alternator or on the top of the rocker
cover, dependingon the model.
The valves are opened electrically by an internal solenoid, energised by the control unit. When the control unit
earths terminals 3 and 4, the EGR valve is fully opened. If
the control unit earths terminal 3 only, the EGR valve is
opened half way. When the control unit does not earth the
VSVs, the EGR valve is closed.
EGRvalve location.
Glow plug and EGR control unit location, viewed with

t h e k a c kp a n e l r e m o v e d . I n s e t s h o w s t h e t e r m i n a l
identification, viewed froln the harness side of the
connegtor.
To Test Power Supply and Earth Circuits
(1) Disconnect the control unit wiring connectors as
previouslydescribed.
(2) With the ignition On, check for battery power at
terminals27 and35.
If power is unavailable, check the 10 amp Engine
control fuse.
(3) Check for continuity to earth at terminals 7,17,28
and 36.
THROTTLE POSITION SENSOR (TPS)

To Test and Renew
(1) Disconnect the wiring connector from the TPS
and check that there is continuity to earth at terminal C and
5 volts at terminal A with the ignition On.
If 5 volts is not available, use the.wiring diagram in this
supplement to trace the wiring from the TPS to the control
unit and"alsocheck the control unit power supply and earth
circuits. If no fault can be found, renew the control unit.
(2) Connect the wiring to the TPS.
(3) With the ignition On, backprobe the centre
terminal of the TPS wiring connector (terminal B) with a
voltmeter. Check that the voltage steadily increasesas the
thottle is opened. At full throttle, the voltage should be
approximately 4 volts.
(4) If the TPS is not outputting voltage steadily, it
should be renewed.
297

Supplement
NOTE: On early models, this fuse may be rated
at I0 amps instead of 20.
(5) Check the wiring for continuity between the
control unit terminals 3 (brown/white wire) and 4
(browr/yellow wire) and the VSV wiring connector terminals 3 and 4.
(6) Test the condition of VSV using the following
procedures:
(a) Check that air can be blown from port B to C, but
not from A to B of the vsv.
(b) Apply battery voltage between terminals I and 4
of the VSV connector and check that air can be blown from
port A to B, but not from B to C.
(c) Apply battery voltage between terminals 2 and 3
of the VSV connector and repeatoperation (b) on the second
VSV.
(d) Renew the VSVs as an assemblyif necessary.
Throttle position sensor and wiring connector. Inset
shows the terminal identification.
VACUUM SWITCHING VALVES (VSVs)

To Test and Renew
(1) Disconnect the wiring connector and the vacuum
hoses from the EGR valve and the vacuum supply pipe,
mounted on the cylinder head.
(2) Disconnect the air inlet air duct from the air inlet
pipe and remove the air cleaner cover, air inlet duct and the
air cleaner element from the vehicle.
(3) Remove the air cleaner housing and the VSVs
from the vehicle as a unit.
(4) With the ignition On, check that there is battery
voltage at terminals I and 2 of the VSV wiring connector.
Check the 20 anry Engine Control fuse.
c
512COIO
VSV port identification.

EGR VALVE
To Test and Renew
(1) Run the engine until it reachesoperating temperature.
(2) Disconnect the vacuum hosesfrom.the EGR valve
and the vacuum supply pipe, mounted on the cylinder head.
(3) Connect a vacuum hose between the EGR valve
and the vacuum supply pipe.
The vacuum switching valves are located on the air

cleaner housing. Inset shows the terminal identification.
Applying vacuum to the EGRvalve to check its

serviceability.
298

The air control valve also maintains a constant pressure
within the crankcase.
On early models the air control valve may be located
near the front of the engine but its function is the same.
NOTE: An extra piece of vacuum hose may be

required to do this. Alternatively, with the
vacuum hoses still connected to the EGR valve
and the VSV, disconnect the wiring connector
from the VSV and earth terminals 3 and 4.
(4) With the engine running, place a finger on the
undersideof the EGR valve againstthe diaphragm,the valve
should be felt to open when vacuum is supplied to it.
NOTE: The engine speed may also be heqrd to
alter.
(5) Check that the valve closes when the vacuum
supply is removed.
(6) Renew the valve if necessary. If renewing the
valve, check that the supply pipe is not blocked with carbon.
Renew the pipe if necessary.
COOLANT TEMPERATT]RE SENSOR AND ENGINE
REVOLUTION SENSOR
Signals from the coolant temperaturesensorand engine
revolution sensor are used by the control unit to determine
the time and amount the EGR valve is opened.Refer to the
Preheat System heading for a procedure to check these
components.
AIR CONTROL VALVE

(l) Releasethe hose clamps and disconnectthe hoses
from the air control valve.
(2) Remove the bolts retaining the air control valve to
the rocker cover and remove the valve from the rocker cover.
(1) Check that the valve and hoses are clear and not
blocked with carbon.
(2) Ensure that valve is seatedcorrectly on the rocker
cover and tighten the retaining bolts securely.
(3) Instal the hosesto the air control valve.
To Check
(1) Remove the air control valve as previously
described.
(2) Check that air can be blown from the outlet port
(the port that connects to the rocker cover) to the inlet port.
Renew the valve if it is blocked or restricted.
CONTROL UNIT
Removal, installation and checking the power supply
and earth circuits to the control unit are covered under the
PreheatSystemheading.
6. CRANKCASE VENTIIATION SYSTEM

A sealedengine ventilation system is used on 2.8 litre
engines. A breather pipe draws fumes from the crankcase
thr-oughthe rocker cover and into the air control valve. An
oil separatorin the rocker cover removes most of the engine
oil, which is retumed to the crankcase"and the fumes are
passedthrough the valve into the inlet manifold where they
go through the combustion process.
t
i
I
*
i."+*
299
Location of the air control valve.
CLUTCH AI{D MANUAL TRANSMISSION

Gearratios:
First.
Second
Thtd .
Fourth
Fifth .
Reverse
Gearendfloat:
r. CLUTCH
The clutch mechanismfitted to 2.8litre models is basically the same design as that fitted to 4.2 litre models with
the following changes:
(1) A smaller 240 x 160 x 3.5 mm driven plate is used
instead of the 275 x 160 x 3.5 mm unit fitted to the larger
engine.The pressureplate is also reducedin size to suit.
(2) The driven plate specification changed lightly.
The maximum spline backlash is reduced to 0.7 mm at
115 mm from the hub centre.
(3) The flywheel to crankshaftbolts torque is reduced
to 137 - 157 Nm.
(4) All other componentsuse the same specifications
but care must be taken when ordering parts to get the correct
ones for the 2.8 litre model.
....j.
......
.0.23 - 0.33 mm
First. second.third and fifth .
....0.33 -0.43 mm
Mainshaftreverse
. 0.10 - 0.25 mm
shaft
.
Counter
0.30 - 0.53 mm
Reverseidler .
Synchroniserring to gear clearance:
1.05- 1.30mm
Standard
..0.7 mm
Limit .
. 0.1 mm
Snap ring clearancelimit . .
Lubricant:
..... SAE80W90GL4
Grade.
.....5.1litres
Capacity
Torque Wrench Settings
Transmissionto engine bolts:
A l l e x c e p t 6 5 m m b o l t s.
65mmbolts.
Front propeller shaft nuts and bolts .
Rear propeller shaft nuts and bolts .
Extension housing to clutch
housingbolts..
F r o n t c o v e r b o l .t s
Bearing retainer bolts .
Reverse/fifth shift rod bolt . .
Interlock sleevebolt
Interlock sleeveplug
Control housing bolts .
Glutch releaselever and bearing.

l. i*
2. MANUAL TRANSMISSION -".,.''

' SpecialEquipmentRequired:
To Dismantleand AssembleTransmissionPuller set,pressand pressplates,dinl gauge
SPECIFICATIONS
Model
Type
..29- 39Nm
.....39-49Nm
. . 78 - 88 Nm
. .93 - 108 Nm
.31-42Nm
.....16-21Nm
. 16 - 21 Nm
. .25 - 29 Nm
. . . 31 - 42 Nm
. . . 19 - 25 Nm
. 16 - 2l Nm
DESCRIPTION
The FS5R30A transmission, installed to 2.8 litre
models, has five forward speedsand reverse with synchro*. Fe& operating on all gearsincluding reverse.
All dt the-,forward gears are helical cut and run in
constant m6sh'*ith the counter shaft. The first, second and
third gearsare supportedon the mainshaft by roller bearings,
the fifth gear is buppo.rtedon the counter shaft by a roller
bearing and the reverseidler gear is supportedon the reverse
idler shaft by roller bearihgs.
Gear selection is achieved by coupling the required gear
to a synchroniserassembly'usingthe intemal splines of the
synchronisersleevewhich mesh with the synchroniserteeth'
of the required gear. Synchronisation is achieved when the
synchroniser ring contacts the cone on the side of the gear,
Ft;;
'i::I1?f,
synchromesh on all gears

including reverse
..4.061:
.2.357:
.1.490:
..1.000:
. .0.862:
......4.125:
300
REVERSE
LAMP SWITCH
HANDBRAKEDRUM
BREATHER
HOSES
SPEED SENSOR
EXTENSION HOUSING
TRANSMISSION
FILLER PLUG
,NT OUTPUT
FLANGE
TRANSFER CASE DFAIN PLUG
Right hand side of the transmission and transfer case.

bringing the gear and the synchroniserassemblyto the same
speedand allowing smooth engagemnt.
The input shaft rotates in a ball bearing located in the
front of the transmission.The input shaft also housesa roller
bearing that supportsthe front of the mainshaft'
Tf,e mainshaft rotates in bearings located in the carrier
plate and the extension housing while the counter shaft is
iupported by bearings located in the clutch housing and the
carrier plate.
ThL transmission varies in design from that of the 4'2
litre models in that no rear oil seal is used' Instead sealeris
applied to the mating face of the transmission and transfer
caseanOthe area in the extension housing fills with oil'
If the seal in the front of the transfer case is faulty,
transmission oil could be pumped into the transfer case or
vica versa, so it is important that regular oil level checks are
made in both units to ensurethat the seal is serviceable'
The transfer case is similar to that used for 4'2 litre
models, except that sealantmust be used between it and the
transmissionto Preventleaks.
Refer to the main part of this manual for fdsmission
trouble shooting and proceduresrelating tollF transfer case'
case be removed first as described in the main part of the

manual to reduce the weight and length of the assembly'
Refer to Partz, Manual Transmission in the main part
of this manual for the removal and installation procedure
with attention to the following points:
(1) Drain the transmission oil into a suitable large
container.
TRANSMISSION ASSEMBLY
To Remove and Install
Due to the reduced weight of the FS5R30A transmission, it is possible to remove the transmission and transfer
case from the vehicle as a unit if necessary'The point of
balance of the assembly is behind the crossmemberto the
rear of the vehicle. Howeverrif attempting this procedure at
home without a hoist, it is recommended that the transfer
Gear lever and spring removed from the gear lever

housing.
301
TRANSFEBCASE
LEVEF
CLUTCHHOUSING
GEARLEVER
HOUSING
EXTENSION
TRANSFER CASE
4WDSW]TCH
CABRIERPLATE
INTERLOCK
SLEEVE
Left hand side of the transmission and transfer case.

TO DISMANTLE
NOTE: Have another tlat tray or similar ready

when the transfer case is removed to catch the
oil remaining in the extensionhousing.
(2) Following the removal of the gear and transfer
lever boots, remove the large circlip from around the
gear lever. Lift the lever from the transmission, gathering
the spring. Place a piece of rag over the hole in the transmission to prevent the entry of dirt while removing the
transmission.
(3) Remove the bolts from the transfer case leyer
bracket to the extension housing to allow removal of the
upper bolts on the left hand side of the transfer case.
(4) When removing the clutch slave cylinder, remove
the bolts securing the hydraulic pipe support bracket to the
engine.
(1) Apply Permatex Ultra Grey or equivalent sealant
to the mating face when installing the control housing and.
gear lever assembly to the transmission and instal the
spring and ball. Instal the retaining bolts to tfte locations
shown in the illustration and tighten to the specified
torque.
(2) Apply Permatex Ultra Grey or equivalent sealant
to the engine and clutch housing mating faces prior to installation.
(3) Ensure that the mating faces of the transmission
and transfer caseare clean of old sealant and apply a bead of
Permatex Ultra Grey or equivalent sealant to the mating face
before installing the transfer case.
NOTE: It is good practice to note the positions

of the transmission components as they are
removedto ensure correct assembly.
(1) Remove the transmission assembly as previously
described and clean the external surfaces of the assembly
ensuring that the cleaning solvent does not enter the clutch
releasebearing.
(2) Remove the clutch releaselever and bearing from
the clutch housing.
(3) Unscrew the plug and remove the check spring
and ball from the interlock sleeve located beneath the
transfer case lever on the extension housing. Remove the
retaining bolt and remove the interlock sleeve.Remove and
discard the O ring.
' i"
NOTE: If the check spring and ball are not

,removedprior to removing the sleeve, the ball
may,fall. into the transmission.
(4) Remove gear lever housing and the spring and ball
from the hole in the extension housing to gear lever control
housing mating face.
(5) Using a punch, remove the roll pin retaining the
selector bracket to the shift rail.
(6) Remove the bolts and remove the extension
housing rear baffle plate from the rear of the extensioh
housing. Using a soft face hammer, remove the extension
housing from the carrier plate.
302

Supplement
(10) Mount the carrier plate in a vice equipped with
soft jaws and remove the bolt retaining the reverse/fifth shift
rod to the reverse shift fork. Withdraw the shift rod from the
carrier plate.
striking lever and the interlock to the shift rail. Withdraw
the shift rail from the carrier plate and remoYe the striking
lever and interlock and the first/second, third/fourth and
reverse shift forks noting the installed positions to aid
assembly.
fifth shift fork to the shift rail. Withdraw the shift rail and
remove the shift fork.
(13) Measure the end float of the first, second, third
and reverse mainshaft gears and the counter shaft fifth gear
using feeler gauges.
If the end float of a gear is not within the specified
range, thoroughly check the relevant gear and associated
components for wear and renew the faulty components as
necessary.
(14) Slide the reversecoupling sleevefrom the reverse
hub noting the direction of the sleeve.Remove the snapring
from the rear of the mainshaft and using a hammer and
punch, remove the retainer and C rings.
(15) Remove the snapring and washer from the rear of
the counter shaft and remove the bearing and the reverse
drive gear using a puller.
(16) Remove the reverseidler gear, bearings and thrust
washers from the reverse idler shaft noting the direction of
the thrust washers.
(17) Instal a puller with the legs positioned behind the
reverse gear and remove the bearing, spacer, reverse hub,
reverse gear and roller bearings from the mainshaft noting
the direction of the reversehub.
Front cover viewed with the release lever and thrust

bearing removed.
(7) Remove the front cover retaining bolts and
remove the cover and gasket using a lever inserted through
the clutch release lever aperture in the clutch housing.
Remove and discard the oil seal from the cover.
(8) Remove the snap rings from the input shaft
bearing outer race and the shift rail. Withdraw the washer
from the shift rail.
(9) Support the rear ofthe mainshaft and separatethe
clutch housing from the carrier plate using a soft face
hammer. Remove the thrust bearing and shim from the front
of the counter shaft.
BoLr-g
ROLL
PIN
\/
FEVERSE
SHIFTFORK
.1ST/
SNAP
RING
a
\\\,, vt,
WASHER
.*hur
SHIFT
RAIL
RoIL
3RD/4TH
t'SHtFTFoRK
PIN
Transmissionselestorcomponents.
303
-.b*-sentltc
"
@,
2)--etue
" qfJ
y'"
PLUNGER
o R11c \^
SLEEVE
-WASHER
INTERLOCK
'
SHIFT
sELEcroR
BFACKET
^/
U
REVEFSE/sTH
SHIFTROD
%
f
\.)

SNAP
RING
..Tu=_
;)bdq
BEAI
'@WQf""{"
EXTENSION
HOUSING
REVERSE
DRIVEN GEAB
'
o*ufitroR
-sYNcHRoNrsER
\'
"t
"iq
sLEEvE
^* dN\O!
'V
I ^KN@Y":\,
.,o,,,T*.oo
**\L
lffi,G*"
RE'EB'E
DBT'E.EAF
Fu=f(ffi
V\:;,"".
La,-a\\\JH L >"EbnL-[)@7VF ffr7KEYS BEARINGS
{ffi*,,sb@e?t
\
\
I
REVERSE
IDLER GEAR
PIN
Transmission rear components.

(26) Mount the counter shaft in a press and remove the
(18) Remove the fifth gear synchroniser sleeve with
rear thrust bearing noting the installed direction. Remove
the fifth and reverse synchroniser rings and keys noting the
the snap ring from the front of the counter shaft and withinstalled direction of the sleeve and keys to ensure correct
draw the collar, conical spring, sub gear and.ball.
installation.
(27) If renewing the input shaft bearing, remove the
(19) Remove the reverse gear roller bearing sleeve
snap ring from the input shaft. Mount the shaft in a press
from the mainshaft using a puller.
(20) Instal a puller with the legs positioned behind the
with press plates supporting the bearing and remove the
bearing.
fifth gear and remove the reverse cone, fifth gear and the
(28) Using suitable mandrels, remove the bearings
reverseidler shaft simultaneously.
(21) Support the carrier plate in a press with press
from the carrier plate, extensionhousing and clutch housing.
plates and press the mainshaft and counter shaft alternately
TO CHECKAND INSPECT
until they are removed from the carrier plate. Note the
(l) Wash all components in cleaning solvent and dry
gear.
As the counter
installed direction of the mainshaft fifth
with compressedair, if available.
shaft is removed, support and remove the input shat, roller
(2) Check all components for wear, damage and
bearing and spacer from the mainshaft.
(22) Remove the bolts and remove the bearing relErgqr, -. jis@rtlon, particularly the shaftsand gears.
'*pheck
(3)
the bearings for wear, cracks and pitting
from the carrier plate.
(23) Remove the washer, ball, first geag'ind roiler
and ensurri:thatthey rotate smoothly.
':: r
(4) Mark the components of each synchroniser
bearing from the mainshaft.
(24) Mount the mainshaft in a press-witli press plates
assembly and slowly slide the sleeve off the synchroniser
hub, noting the installed direction of the synchroniser sleeve
supporting the second gear and remove:'the first gear roller
-hot
and keys. Take care
to misplace the keys when the
bearing sleeve, firsVsecond synchroniser assembly, second.
sleeve is removed as they are under spring tension and
gear and the roller bearing.
ensure that the components from each assembly are not
(25) Remove the snap ring from the front of the main'
mixed.
shaft and mount the mainshaft in a press with press plates
(5) Inspectthe synchroniserhubs and sleevesfor wear
supporting the third gear. Remove the third/fourth synchroand damage, particularly the splines and keyways.
niser assembly, third gear and the roller bearing.
304
Using a feeler gauge to measure the synchroniser ring

to gear clearance.
Check all of the bearings for smooth operation.

(6) Inspect the synchroniser inserts for wear and
damage and the springs for damage, distortion and loss of
tension.
(7) Check the synchroniser rings for cracks and
distortion. With the exception of the reverse synchroniser
ring, push each synchroniser ring onto its respective gear
until it seatsand measurethe synchroniserring to gear clearanceusing feeler gauges.Renew the synchronizerring if the
clearanceexceedsthe specified limit.
(8) Position the reverse cone on a flat surface and
push the reverse synchroniser ring onto the cone. Using a
dial gauge,rneasurethe distancebetween the rear face of the
cone and the synchroniser ring. If the distance exceeds0.7
mm, renew the reversesynchroniserring.
(9) Inspect the shift rails and forks for wear, damage
and distortion and check that the sliding surfaces are
smooth. Check the striking lever and interlock for wear and
damage.
(10) Inspect the carrier plate, clutch housing and extension housing for cracks, wear and damage.
(11) Renew all unserviceablecomponentsas necessary.
NOTE: All snap rings, roll pins and O rings
must be renewed. The snap rings are available
in varying thickness and the size required can
be determined only during assembly It is
advisable to renew all bearings and oil seals.
TOASSEMBLE
NOTE: When sealant is specified on assembly,
use Permatex Ultra Grey or equivalent.
CARRIEA
PLATE
\
\
BEANNG
RETAINER
512LDtA
Transmission housings and associated components.
305

(1) Instal the bearings into the housings, ensuring that
the counter shaft rear bearing is level with the extension
housing and the snap ring in the mainshaft bearing outer
race is facing towards the rear of the carrier plate.
NOTE: If the mainshaft bearing has not been
renewed, a new snop ring must be installed to
the bearing.
(2) Instal the bearing retainer to the carrier plate and
tighten the bolts to the specified torque.
(3) Instal the bearing to the input shaft using a press.
ensuring that the snap ring groove in the outer race is positioned away from the gear. Do not instal the snapring to the
outer race at this stage.
(4) Instal the inner snap ring to the input shaft and
measure the side clearance between the snap ring and the
groove. Compare the clearance to the Specifications and
instal a new snapring of the required thickness.
(5) Apply multipurpose lithium basegreaseto the ball
and instal it to the counter shaft. Assemble the sub gear,
conical spring and collar to the counter shaft ensuring that
the dished side of the spring is facing towards the gear.
(6) Instal the snap ring to the counter shaft and tap it
into position using a suitable size mandrel placed over the
end ofthe shaft.
(7) Using a brass drift and hammer, instal the rear
thrust bearing to the counter shaft in the direction noted
during removal.
(8) Assemble the componentsof the first/second and
the third/fourth synchroniser assemblies in the positions
marked during dismantling. Ensure that the ends of the

springs do not hook into the same insert.
(9) Lubricate the third gear roller bearing with the
specified lubricant and instal it onto the mainshaft.
(10) Place the third/fourth synchroniser assembly and
synchroniser ring onto the third gear and instal it onto the
mainshaft using a press,ensuring that the taperedside of the
synchroniser hub and sleeve is facing towards the front of
the mainshaft.
(11) Measure the side clearancebetween the snap ring
and the groove. Compare the clearanceto Specificationsand
instal a new snapring of the required thickness.
Correct positioning of the synchro spring and keys.
. sYircHBoNrsER
$ir+
nfro;.W'"
.,-
Transmissionfront components.
306

NOTE: The reverse idler rear thrust washers
are available in 1.97 and 2.07 mm thicknesses.
(12) Lubricate the second gear roller bearing with the

specified lubricant and instal it from the opposite end of the
mainshaft.
(13) Place the firsVsecond synchroniser assembly and
synchroniser ring onto the second gear and instal it onto the
mainshaft using a press while supporting the second gear
with pressplates.
(14) Place the first gear roller bearing sleeve and
washer onto the mainshaft and instal the sleeveusing a press
while supporting the washer with press plates. Withdraw the
washer from the mainshaft.
(15) Lubricate the first gear roller bearing with the
specified lubricant and instal the bearing and first gear onto
the mainshaft.
(16) Apply multipurpose lithium basegreaseto the ball
and washer and instal them to the mainshaft.
(17) If the transmission housing, counter shaft thrust
bearing, sub gear component or counter shaft has been
renewed,check the counter shaft end float as follows:
(a) Assemble the counter shaft into the carrier plate
and instal the thrust bearing to the front of the counter shaft.
(b) Invert the clutch housing and instal the carrier
plate and counter shaft into the clutch housing ensuring that
the mating faces contact. Do not instal the counter shaft
front bearing shim at this stage.
(c) Instal and tighten two retaining bolts.
(d) Mount a dial gauge to the carrier plate with the
plunger against the end of the counter shaft. Move the
counter shaft up and down and note the reading on the dial
gauge.
(e) Compare the end float with the following table to
determine the required counter gear shim thickness.
(19) Mount the carrier plate in a vice equipped with

soft jaws and apply multipurpose lithium base greaseto the
counter shaft and mainshaft bearings.
(20) Insert the rear of the mainshaft into the carrier
plate while tapping the bearing retainer with a soft face
hammer. To allow for the installation of the counter shaft,
do not instal the mainshaft completely.
(21) Instal the fourth gear synchroniser ring to the
third/fourth synchroniser hub on the mainshaft using thick
grease,ensuring that the grooves in the ring align with the
inserts.
(22) Lubicate the roller bearing and instal the bearing
and spacer into the input shaft and instal the input shaft to
the mainshaft.
(23) While supporting the input shaft, position the
counter shaft so that the teeth on the sub gear and counter
shaft are aligned to enable the counter shaft and input shaft
gears to mesh. Instal the counter shaft into the carrier plate
while lifting the upper roller of the bearing with a screwdriver.
(24) Instal the mainshaft and counter shaft completely
into the carrier plate by pulling on the mainshaft while
tapping the rear of the plate with a soft face hammer.
(25) Support the front of the counter shaft and using a
suitable mandrel or tube, drive the fifth gear roller bearing
sleeveonto the rear of the counter shaft.
(26) Drive the fifth gear onto the mainshaft in the
direction noted during the removal, using a suitable mandrel
or tube.
(27) Instal the carrier plate and shafts into the clutch
SHIM THICKNESS
END FLOAT
housing.
(28) Lubricate the fifth gear roller bearing with the
....0.88mm
0.93-l.O2rnm..
specified lubricant and instal the bearing to the counter
....0.96mm
I.O3-l.l2mm..
shaft.
....1.04mm
l.l3-1.22mm..
(29) Instal the reverse idler shaft and the fifth gear
....1.12mm
1.23-1.32rnm..
ensuring that the shaft retaining pin is
1
.
2
8
m
m
simultaneously,
....
1.33 l.42mm . .
in
the
recess.
located
.
.
.
.
1
.
3
6
m
m
1.43-1.52rnm..
(30) Drive the reversecone onto the counter shaft and
..'.1.44mm
1.53-1.62mm..
the reverse gear roller bearing sleeve onto the mainshaft
using a mandrel.
(18) If the extension housing, the reverse idler gear,
(31) Assemble the reverse synchroniser ring and
shaft or thrust washer have been renewed, check the reverse
inserts to the fifth gear synchroniser sleeve in the direction
idler gear end float as follows:
noted during dismantling. Instal the assemblyto the counter
(a) Instal the reverse idler rear thrust washer to the
dismantling.
noted
during
extensionhousing in the direction
* shaft ensuring that the bevelled side of the sleeve is facing
"-,F1a,*'ri{rom
the carrier plate and instal the fifth gear synchro(b) Assemble the reverse idler front thruffJflsidEff
niser ftng*t
roller bearings and gear to the reverse idler -shaffand instal
(32) Idstal-thereversegear onto the counter shaft using
the assemblf into tfie extension housing, S3ri}ing that the
nrandt'4or tube.
a
suitable
diSrnantling.
noted
during
installed
as
thrust washer is
(33) Instal the {everse idler front thrust washer to the
(c) Mount a dial gauge to the e$e#ion housing with
reverse idler shaft in fite direction noted during dismantling.
the plunger
-(d) - against the end of the revdrse idler shaft.
(34) Lubricate the'mainshaft reverse gear and the
Position a straight edge agirossthe mating face on
reverse
idler gear roller bearings with the specified lubriidler
reverse
the
hold
housing
and
the extension
itrhgainst
cant and instal the bearings and gears to their respective
shaft. Raise the shaft until it bufts against the staight edge
shafts.
and note the reading on the dial gauge.
(35) Instal the reverse idler rear thrust washer to the
If the end float is not within the specified range, instal a
idler shaft in the direction noted durine dismantline.
reverse
thickness.
required
the
of
washer
rear
thrust
idler
reverse
307

(36) Drive the reverse hub and spacer onto the mainshaft using a mandrel or tube, ensuring that the recessedside
of the hub is facing towards the carrier plate as noted during
dismantling.
(37) Instal the rear bearings onto the counter shaft and
mainshaft using a mandrel.
(38) Remove the carrier plate and shafts from the
clutch housing and mount the plate in a vice equipped with
soft jaws.
(39) Using feeler gauges, measure the side clearance
between the C rings and the groove in the mainshaft. If the
clearance exceeds0.1 mm, instal new C rings of the required
thickness.
(40) Instal the C rings and the retainer using a brass
drift and instal the snap ring.
(41) Instal the spacer to the rear of the counter shaft
and measure the side clearance between the snap ring and
the groove. If the snap ring clearance is more than 0.1 mm,
instal a new snap ring of the required thickness.
(42) Instal the reverse coupling sleeve to the reverse
hub ensuring that the bevelled side of the sleeve is facing
towards the reverse hub as noted during dismantling.
(43) Measure the end float of the frst, second, third
and reverse mainshaft gears and the counter shaft fifth gear
using feeler gauges.
If the end float of a gear is not within the specified
range, dismantle the transmission, thoroughly check the
relevant gear and associatedcomponents for wear and renew
the faulty components as necessary.
(44) Instal the fifth shift fork to the fifth gear synchroniser sleeve, insert the shift rail through the fork into the
carrier plate and instal a new roll pin.
(45) Assemble the reverse shift fork onto the reverse
coupling sleeve and insert the shift fork through the fork and
the carrier plate.
(46) Instal the first/second shift fork, striking lever and
interlock and the third/fourth shift fork as noted during
dismantling and instal the shift rail.
(47) Instal a new roll pin into the striking lever and
check that the shift shaft operates smoothly.
(48) Instal the reverse/fifth shift rod, apply Permatex
Lock Nut or equivalent to the threads of the retaining bolt
and tighten to the specified torque.
(49) Apply multipurpose lithium base grease to the
counter shaft front bearine shim and instal the shim to the
clutch housing.
The gear lever housing bolts are different. A = 13mm

head bolts. B = 12mm head bolts.
(5a) Apply multipurpose lithium base grease to the lip

of a new oil seal and instal the seal into the front cover.
(55) Using a new gasket, instal the front cover to the
clutch housing and instal the retaining bolts, ensuring that
sealant is applied to the lower three bolts located adjacent to
the clutch release lever aperture.
(56) Apply transmission oil to the rear bearing and
instal the bearing into the extension housing.
(57) Apply sealant to the carrier plate mating face.
Instal the extension housing while guiding the selector
bracket onto the shift rail ensuring that the mating faces
contact. Tighten the retaining bolts to the specified torque.
(58) Drive a new roll pin into the selectorbracket using
a punch.
(50) Apply an unbrokenbead of sealantto the clutch

housing mating face ensuring that the sealant enci
the
bolt holes. Instal the carrier plate and shafts
mating faces contact.
(51) Instal a new O ring and the chc.dFbdf and spring
to the interlock sleeveusing multipr$rose lithium base

grease,instal the sleeveand tighten$t{etaining bolt to the
specified torque.
(52) Apply sealant to the thrmd of the interlock plug
and tighten to the specified torque.
(53) Instal the washer to the front of the shift rail and
instal new snap rings to the shift rail and the input shaft
bearing outer race.
Rear view of the transmbsion with transfer case
removed.
308

(59) Instal the ball and spring to the extension housing.
Apply sealant to the extension housing and gear lever
housing mating face. Instal the housing and the retaining
bolts to the positions shown in the illustration.
(60) Instal the clutch release lever and bearing and
instal the transmission assembly as previously described.
(61) Apply a bead of sealantto the transmissionextension housing casing before installing the transfer case.
TRANSFER CASE
The transfer case fitted to the 2.8 litre models is basically the same as the one fitted to the 4.2 litre models with
(1) It is necessaryto drain transmission oil prior to
removing the transfer case.
(2) If necessary,the transfer caseinner shift lever seal
can be renewed as follows:
(a) Remove the cotter pin nut from the control lever
on the transfer caseand drive the cotter pin from lever using
a brass drift. Discard the cotter pin.
NOTE: The cotter pin is tightly fitted and may
defor easily. It is recommendedthat a new one
befitted on installation.
(b) Slide the control lever from the inner shift lever. It
may be necessaryto use a puller.
(c) Lever the seal from the transfer case.
^.$-.:"
Transfer case with control lever removed showing the

inner shift lever oil seal.
(a) Lubricate a new seal with clean transmission oil
and instal it to the transfer case.
(b) Instal the control lever over the inner shift lever
and instal a new cotter pin. Tighten the cotter pin securely
and check the transfer case oil level as previously
described.
(3) Use Permatex Ultra Grey or equivalent sealant
when it is necessaryto seal transfer casecomponents.
",o"_
309
.-..%.
REAR A)(LE AND BRAKES

2. BRAKES
I. REAR A}OE
VACUUM PUMP
On models with the 2.8 litre engine built prior to August
1995, refer to the main part of the manual for proceduresto
remove, instal and inspect the vacuum pump mounted to the
rear of the alternator.
On models from August 1995, the vacuum pump is
mounted to the top of the rocker cover and is operated by a
lobe on the camshaft.The vacuum pump is a sealedunit and
cannot be dismantled. If faultv. it should be renewed as an
assembly.
The rear axle on 2.8 litre models is a H233B unit similar

to the one fitted to coil spring versions of this vehicle with
the4.2litre engine.
The ratio of the front and rear axles for this model is
4.625:1
The construction of the limited slip differential centre
has changed for the 2.8 litre model with the addition of
thrust washers installed on the pinions and more friction
discsand plates.
More torque is required to get this differential centre to
slip.
A chart is included for comparing the 2.8 litre model to
the 4.2litre model.

(1) Disconnect the vacuum hoses from the vacuum
pump
(2) Remove the oil filler cap and rotate the crankshaft
pulley until No 1 cylinder inlet valve cam lobe is pointing
straight up.
(3) Rotate the crankshaft anticlockwise 240'.
(4) Progressively loosen and remove the retaining
nuts and then remove the vacuum pump from the rocker
cover.
(l) Ensure that the mating faces between the vacuum
pump and rocker cover are free of old gasket material.
LIMITED SLIP DIFFERENTIALCOMPARISONCHART

2.8 LITRE MODELS
4.2 LITRE MODELS
Difterential
slip torque
294 to 392 Nm
76 to 137 Nm
Friction discs
Friclion olales
Sorinq discs
Sprinq plates
' 1 0x 1 . 5 m m
12 x 1.5 or 1.6 mm
2 x 1.5 mm
2x1.5mm
4x2.0mm
4 x 1 . 9 ,2 . 0 o r 2 . 1 m m
NIL
4x2.0mm
Wear limit of
platgs and discs
0.1 mm
0.1 mm
Distortion of
plates and discs
0.08 mm Max.
0.08 mm Mar.
PINIONS
^ffiq*,*
.,@^n/m,
GUIDE
I
DTFFEFENTTAL
cA\sE
SPRING
Dlsc
-Ar
fa\vlt
.rEilt
Al
'.\l:a
tt \L{
ll v
N$\N
0$)'
"lN
8lX?@-r,? u
mop"
@\
CLUTCH
PACK
GUIDE
lElE/
\iC/
^
trl
v /
T d
THBUST
WASHERS
PLATE
Limited slip differential components. 2.8 litre models.
310
Supplement- Part 2. 2.8 [-itre Turbo
Vacuum tanks and check valve. Late model shown'

If the vacuum reading now increases, check for a
vacuum leak at one of the vacuum tanks, vacuum hoses,
pipes or the brake booster. Renew or repair componentsas
necessary.
If the vacuum reading remains low, renew the vacuum
pump.
Rocker cover and vacuum pump components'
(2) Using a new gasket, instal the vacuum pump.
Instal and tighten the retaining nuts to the specified torque.
(3) Instal the vacuum hoses.
To Check
(l) Disconnect the small vacuum hose from the
vacuum pump and connect a vacuum gauge.
(2) With the engine idling, the vacuum gauge should
read minus 80 kPa.
(3) If the vacuum is less than Specifications, crimp
the large vacuum hose coming from the vacuum pump and
check the reading.
CHECKVALVES
(1) Disconnect the clips and remove the check valves
from the vehicle.
NOTE: Some models mav have onh one check
valve.
(2) Blow through the valve and check that air can be
blown in one direction, but not the other. Renew faulty
check valve/s if necessary.
(3) Instal the check valve to the hoses ensuring that
the valve is connected so that air can be blown toward the
vacuum pump.
311
CONVERSION TABLES
newton metre (Nm)

newton metre (Nm)
newton metre (Nm)
.t.
x8.9
xO.74
x 0.102
=lbin
= lb ft
= kgm
x 0.113
x 1.36
x 9.81
= Nm
= Nm
= Nm
degreescelcius("C)
degreesfahrenheit("F)
VOLUI,IE
,]],:
, : i rt i ::':fliig$sttbk:,r
' , , . tI
kilopascal(kPa)
kilopascal(kPa)
kilopascal(kPa)
megapascal(MPa)
Bar
x 4.0
x 0.30
x 0.145
.l4S
x
x 14.5
= in HzO
= in Hg
= psi
= psi
= psi
i ' :l
..:.,
.,,' j ,.'!l!!|lBli|l;'' r:
,,,,...r 1 ,,.
x 0.03937 = inch
millimetre(mm)
(1 inch = 25.4 mm exactly)
x 0.3937 = inch
centimetre(cm) 10 mm
x 0.3937 = inch
metre (m) 1000 mm
= foot
x 3.28
metre (m)
= mile
x 0.62
kilometre(km) 1000 m
= kPa
xO.249
= kPa
x 3.38
= kPa
x 6.89
x 0.00689 = MPa
x 0.0689 = Bar
,
millimelrez(mm2)
centimetre2(cm2)
metre2(m2)
metre2(m2)
hectare(ha) 10,000m2
kilometre2(km2)
x25.4
x2.54
x2.54
x 0.305
x 1.61
282.44
mpg
mpg =
litre (L) i 000 mL

litre (L)
'1ooo
metre3(m3)
L
x 1.06
x 0.22
x 1.3
= quart
= gallon
= yard3
x 0.946
x 4.55
x 0,76
=L
=L
= m3
gram (g)
kilogram(kg) 1000g
metrictonne (t) 1000 kg
x 0.035
x2.2
x 1.1
newton(n)
kilonewton(kN)
x 0.225
x 225
x 0.061
x 61
=mL
MASS
= cm
= mm
=m
= km
= ounce
x28.3
= pound
x 0.454
= ton(short) x 0.907
=g
= kg
=t
FORCE
= mm2
x 645
= cm2
x 6.45
x 0.0929 = m2
= m2
x 0.836
= ha
x 0.405
= km2
x 2.59
i'
x 1.34
x 0.948
x0.74
::,'i:..
...t:
=N
x 4.45
x 0.00445 = kN
= horsepowefx 0.746
= Btu/s
x 1.055
=ftlb/s
x1.36
= kW
= kW
=W
FLOW
cu. cm/min
litres/min
282.48
L/100km
= pound
= pound
POWER
kilowatt(kW)
kilowatt(kW)
watt (w)
..'
FUEL6@u*tfipf,rcill
U 1 0 0k m =
x 16.4
x 0.016
x 29.6
= cm3
x 0.034
= rnch3
= inch3
= oz-liq
centimetre3(cm3)
litre
m i l l i l i t r (em L )
( 1 m L= 1 c m 3 )
= mm
: AffiA,'l
x 0 . 0 0 1 5 5= i n c h 2
x 0.155 = inch2
= foot2
x 10.8
= yardz
x 1.2
= acre
x2.47
= mile2
x 0.39
TElilPERATU*E
= ( " F* 3 2 ) - : 1 . 8
= ( " C x 1 . 8 )+ 3 2
x 16.39 = cu.inlmin x 0.061

x 0.2642 = gallon/min x 3.785
= cu.cm/min
= litres/min
ANDMILLIMETRE
EQUIVALENTS
DECIMAL
1/64
1132
3/64
1/16
5/64
3132
7/64
1/8
9t64
5132
11t64
3/16
13t64
7/32
15/64
1t4
17/64
9t32
19/64
5/16
21t64
11t32
0.01562s
0.03125
0.046875
0.0625
0.o78125
0.09375
0.109375
0.1250
0.140625
0.15625
0.171875
0.1875
0.203125
0.21875
o.234375
0.2500
0.265625
o.28125
0.296875
0.3125
o.328125
0.34375
0.397
0.794
1. 1 9 1
1.588
1.984
2.381
z.I t6
3.175
3.572
t oAo
4.366
4.763
5 . 15 9
5;556
3.UJJ
6.350
6.747
7.144
7.541
7.938
8.334
8.731
23/64
3/8
25/64
13/32
27/64
7/16
29t64
15/32
31t64
1t2
33/64
17t32
35t64
9/16
37t64
1S/32
39t64
5/8
41t64
21132
43164
11 / 1 6
0.359375
0.3750
0.390625
0.40625
0.421875
0.4375
0.453125
0.46875
0.484375
0.5000
0.515625
0.53125
0.546875
0.5625
0.578125
0.59375
0.609375
0.6250
0.640625
0.65625
0.671875
0.6875
312
,i*s.{
9 . 12 8
9.525
9.922
10.319
10 . 7 16
11 . 11 3
11.509
11.906
12.303
12.700
13.09.7
13.494
13.891
14.288
14.684
15.081
15.478
15.875
16.272
16.669
17.066
17.463
45t64
47/64
3/4
4S/64
25t32
51/64
13116
53/64
27/32
cc/o4
7t8
JIIOl
29/32
59/64
15/16
61t64
31/32
63164
1
0 703125
4.71875
0,734375
0.7500
0.765625
0.78125
0.796875
0.8125
0.828125
0.84375
0.859375
0.8750
0.890625
0.90625
0.921875
0.9375
0.9531
25
0.96875
0.984375
1.000
lmm = .03937"
. 0 0 1 "= . 0 2 5 4 m m
17.859
18.256
18,653
19.050
1S.447
19.844
20.241
20.638
21.034
2 1. 4 3 1
21.828
22.225
22.622
23.019
23.416
23.813
24.209
24.606
25.003
25.400

Part I Supplement covers fuel filter locations, glow plug testing, and more

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Part I Supplement covers fuel filter locations, glow plug testing, and more

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PART I.

If the liller cannotbe satisfaclorily cleaned.renew the

A second stnall fuelfiller is located inside thcf!lreturn

However.the prccedurefor testingthe control unit remains

(3) ln operation(9) ol the lest procedurein the main

Glow plug control unit location. Th inset shows th

5. CLUTCH AND MANUAL TRANSMISSTON

. . . . 1 . 0 0 - 1 . 4 5 n r m Transfercasecountershaft dismantled. Componerlts

Supplenent Part l. December 1992on

Measuringth6 out6r synchroniserring io synch.onlsel

STEERING. FRONT SUSPENSION,BRAKES,

At the time of publication, no replacementpafis were

Supplement- Part 1. December1992 on

Renewingthe corneringlsmp bulb

i."Jxi"";.:"Ji" [. ff;i: ] f;fi*"

Wiring diagramlorlhe reardemisterfrom August1395andrhe corneringlamps.

Supplement- Part I December1992on

(4) Pless the "A'bulton to entr the code. lf the

PART 2. 2.8 TITRE TURBO DIESEL

Supplement- Part 2. 2,8 Litre Turbo

A seclnd smallfuelliltr is locatd:nsiderhe Iuel rturn

When loOseningthe inictor pipe union nuts use two

(2) Using an aerosol type ca$urettor cleaner,clean

(2) Depressthe lift punp on top of the filter housing

NOTE: Use tuo spa ners when loosentugthe

N0TE: This is the hose that tuns bert)eenthe

(b) Have ,n ,ssistant operatethe starter motor for

Fuelfilterand liftpump location.

- Part2. 2.8 Litre Turbo

Air Corditioning Drive Belt

Supplement Part2. 2.8Lirre Tufto

Locationol the idlespeedand dashpotadiustingscrws.

The idle-upspeedadjustingpoint on air conditioned

(4) Adjust the idle speedscrewon rhe injection pump

(a) Ensurethat thereis a I mm gap betwnthe idle

Supplement- Part 2. 2.8 Litre Turbo

speed.Ensue that the locknut is securcwhenthe dashpotis

NOTE: The glow plug waming lanp n the

Cove. raised showing the location of various relays,

(b) Inspect the fusible links adjacentto rhe battery.

Fusible links, viewedwith the cover removed.

(f) Where necessarycarry out repairs to the faults

Supplement- Part 2. 2.8 Litre Turbo

faulty glow plugs are suspected, test the glow plugs as

2. TO CHECK FUEL SYSTEM

Relay cover raised showing the starter relay.

The procedure to check the fuel system is basically the

Fuel cut solenoid installed. Inset shows components.

3. TO CHECK MECHAMCAL SYSTEM

Checking for power at the glow plug bridging strap'

- Part 2. 2.8 Litre Turbo

Crankshaft pulley set at bottom dead centre (BDCI.

(3) If the camshaft does turn, the timing belt could

Supplement- Part 2. 2.8 Litre Turbo

CRANKSHAFT AND MAIN BEARINGS

3.80mm with 85 - 90 kPa

TORQUE WRENCH SETTINGS

Supplement- Part 2. 2.8 Litre Turbo

Using the following trouble shooting additions in

Left hand side of the 2.8 litre turbo engine.

Supptement- Part 2. 2.8 Litre Turbo

seven bearings and acts directly onto hydraulic lifters,