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vm 2.5 manual

vm 2.5 manual

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Published by: jeepfreak2121 on Sep 07, 2009
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2.5L VM DIESEL
INDEX
page page
GENERAL INFORMATION
ENGINE IDENTIFICATION . . . . . . . . . . . . . . . . . 37GENERAL SPECIFICATION . . . . . . . . . . . . . . . . 36
DESCRIPTION AND OPERATION
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . 37
DIAGNOSIS AND TESTING
ENGINE DIAGNOSIS—MECHANICAL . . . . . . . . . 0ENGINE DIAGNOSIS—PERFORMANCE . . . . . . 38HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . 39
SERVICE PROCEDURES
CHANGING ENGINE OIL AND FILTER . . . . . . . 40CHECKING OIL LEVEL . . . . . . . . . . . . . . . . . . . 40CRANKSHAFT END PLAY . . . . . . . . . . . . . . . . . 43FITTING PISTON RING . . . . . . . . . . . . . . . . . . . 43TIMING PROCEDURE . . . . . . . . . . . . . . . . . . . . 41VALVE AND SEAT REFACING . . . . . . . . . . . . . . 42
REMOVAL AND INSTALLATION
CAMSHAFT BEARINGS. . . . . . . . . . . . . . . . . . 60CAMSHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 59CRANKSHAFT MAIN BEARINGS. . . . . . . . . . . . 60CRANKSHAFT SPROCKET. . . . . . . . . . . . . . . . 58CRANKSHAFT—REMOVAL. . . . . . . . . . . . . . . . 71CYLINDER HEAD COVER. . . . . . . . . . . . . . . . . 47CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . 49CYLINDER LINER. . . . . . . . . . . . . . . . . . . . . . . 70ENGINE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . 46ENGINE MOUNT—FRONT. . . . . . . . . . . . . . . . 44ENGINE MOUNT—REAR. . . . . . . . . . . . . . . . . 45ENGINE MOUNT—RIGHT. . . . . . . . . . . . . . . . . 44HYDRAULIC TAPPETS. . . . . . . . . . . . . . . . . . . 53HYDRAULIC TENSIONER. . . . . . . . . . . . . . . . . 59INJECTION PUMP. . . . . . . . . . . . . . . . . . . . . . . 54MOUNT—LEFT SIDE. . . . . . . . . . . . . . . . . . . . 45OIL FILTER ADAPTER AND OIL COOLER. . . . . 64OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63OIL PUMP PRESSURE RELIEF VALVE . . . . . . . 64OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63PISTONS AND CONNECTING ROD . . . . . . . . . 68REAR CRANKSHAFT OIL SEAL . . . . . . . . . . . . 71ROCKER ARMS AND PUSH RODS . . . . . . . . . . 48TIMING CHAIN COVER OIL SEAL . . . . . . . . . . . 54TIMING CHAIN COVER . . . . . . . . . . . . . . . . . . . 55TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . 55VACUUM PUMP . . . . . . . . . . . . . . . . . . . . . . . . 64VALVE SPRINGS—CYLINDER HEAD NOT REMOVED . . .. . . . . . 48VALVES AND VALVE SPRINGS—HEAD OFF . . . 53VIBRATION DAMPER . . . . . . . . . . . . . . . . . . . . 54
DISASSEMBLY AND ASSEMBLY
HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . 71
CLEANING AND INSPECTION
CRANKSHAFT MAIN BEARING. . . . . . . . . . . . . 76CRANKSHAFT. . . . . . . . . . . . . . . . . . . . . . . . . 76CYLINDER HEAD COVERS. . . . . . . . . . . . . . . . 72CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . 72CYLINDER LINER. . . . . . . . . . . . . . . . . . . . . . . 77HYDRAULIC TAPPETS. . . . . . . . . . . . . . . . . . . 75OIL PAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77OIL PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75PISTON AND CONNECTING ROD. . . . . . . . . . . 75ROCKER ARMS AND PUSH RODS. . . . . . . . . . 72TIMING CHAIN COVER. . . . . . . . . . . . . . . . . . . 74VALVES AND VALVE SPRINGS. . . . . . . . . . . . . 74
SPECIFICATIONS
2.5L VM DIESEL. . . . . . . . . . . . . . . . . . . . . . . . 77TORQUE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
SPECIAL TOOLS
2.5L VM DIESEL. . . . . . . . . . . . . . . . . . . . . . . . 80
GENERAL INFORMATION
GENERAL SPECIFICATION
Type . . . . . . . . . . . . . . . . . . . . . . . . 425CLIEE (36B)Displacement . . . . . . . . . . . . . . . . . . . 2.5L (2499 cc)Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.00 mmStroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94.00 mmCompression Ratio . . . . . . . . . . . . . . . . . . . . 20.95:1Vacuum at Idle . . . . . . . . . . 600 mm/Hg (23.6 In/Hg)Thermostat Opening . . . . . . . . . . . . . . . . 80°C
2°CGenerator Rating . . . . . . . . . . . . Bosch 50/120 AmpCooling System Capacity . . . . . . . . . . . . . . 9.5 LiterType . . . . . . . . . . . . . . . . . . . . . . . . 425CLIEE (36B)Power Steering Capacity . . . . . . . . . . . . . 0.75 LiterEngine Oil Capacity . . . . . . . . . . . . . 6.8 Liters WithOil Filter ChangeTiming System . Pushrod Operated Overhead valves,With Chain-Driven Camshaft.Air Intake . . . . . . . . . . . . . . . . . . . . . . . . Dry FilterFuel Feed . . . . . . . . . . . Vacuum Pump Incorporatedin Injection Pump.Fuel System . . . . . . . . . . . . . Indirect Fuel Injection(Precombustion Chamber)Combustion Cycle . . . . . . . . . . . . . . . . . . . . 4 StrokeCooling System . . . . . . . . . . . . . . . . . . Water Cooled
9 - 36 ENGINE
NS/GS
 
Type . . . . . . . . . . . . . . . . . . . . . . . . 425CLIEE (36B)Injection Pump . . . . . . . . . . . . . . . . . . Rotary PumpElectronically Controlled.Lubrication . . . . . . . . . . . . . Pressure Lubrication byRotary Pump, Full-Flow Filtration.Engine Rotation . . . . . . . . . . . . . . Clockwise ViewedFrom Front Cover.
ENGINE IDENTIFICATION
The engine model code (3-digit number/letter code)and serial number are stamped on the forward facingside of the engine block (Fig. 1).
DESCRIPTION AND OPERATION
LUBRICATION SYSTEM
The pressurized system (Fig. 2) uses a rotary pump(3) located in the front of the engine block, driven bya gear which meshes directly with the crankshaftgear. All the oil sent to every lubricated part is fil-tered. The pump sends the oil through a pressurerelief valve (2) to the filter (7) and through galleriesin the crankcase to the crankshaft bearings (8), cam-shaft bearings (11) and turbocharger (10). The pistonpins, connecting rod small ends and insides of thepistons are lubricated and cooled by oil sprayed outfrom jets (9) in the crankshaft mounting blocks. Thelubricating oil is sent to the rockers (12) through anexternal pipe (Fig. 3). A valve in the filter cartridgeenables the oil to be circulated even when the car-tridge is clogged.Sump inlet (1). Pressure relief valve (2). Oil pump(3). Oil cooler (6). Filter cartridge (7). Crankshaftbearings (8). Jet valve (9). Turbocharger bearings(10). Camshaft bearings (11). Rockers (12).
Fig. 1 Engine Code Location Fig. 2 Lubrication System Fig. 3 Lubrication Lines 
NS/GS
ENGINE 9 - 37
GENERAL INFORMATION (Continued)
 
DIAGNOSIS AND TESTING
ENGINE DIAGNOSIS—PERFORMANCE
CONDITION POSSIBLE CAUSES CORRECTION
ENGINE WILL NOT CRANK ORCRANKS SLOWLY1. Starting motor operating, but not crankingthe engine.1. Remove the starter motor. Check for brokenflywheel teeth or a broken starter motor spring.2. Crankshaft rotation restricted. 2. Rotate the engine to check for rotationalresistance.3. Starting circuit connections loose orcorroded.3. Clean and tighten connections.4. Neutral safety or starter relay inoperative. 4. Check starter relay supply voltage andproper operation of neutral safety switch (ifequipped). Replace defective parts.5. Battery charge low. 5. Check Battery voltage. Replace battery if acharge cannot be held.6. No voltage to starter solenoid. 6. Check voltage to solenoid. If necessary,replace the solenoid.7. Solenoid or starter motor inoperative. 7. Replace starter motor.ENGINE CRANKS, BUT WILLNOT START, NO SMOKE1. No fuel in supply tank. 1. Fill fuel supply.2. Electrical fuel shutdown solenoid notoperating.2. Check for loose wires and verify that thefuel shutdown solenoid is functioning. Checkfor fault codes in the ECU.3. Fuel injection system defective: Crankingspeed sensor. Loose connection betweenECU and harness. No power supply to theECU. Loose connection between injectionpump and harness.3. Check for fault codes at ECU. Refer toGroup 14, Fuel System for repairs procedures.4. Air intake or exhaust plugged. 4. Remove the obstruction.5. Fuel filter plugged. 5. Drain fuel/water separator and replace fuelfilter.6. Excessive fuel inlet restriction. 6. Check for restriction. Correct cause.7. Injection pump not getting fuel or fuel isaerated.7. Check fuel flow/bleed fuel system.8. One or more injectors worn or notoperating properly.8. Check/replace bad or improperly operatinginjectors.9. Camshaft out of time. 9. Check/correct timing chain sprocketalignment.ENGINE HARD TO START, ORWILL NOT START, SMOKE FROMEXHAUST1. Incorrect starting procedure. 1. The fuel shutoff solenoid control must be inthe run position. Ensure the proper procedureis being used.2. Cranking speed to slow. 2. Check the battery, starter motor and look forloose or corroded wiring connections.3. Cylinder head heater plugs defective. 3. Verify system is working. Verify connectionbetween heater plug relay and ECU.Repair/replace inoperative parts.4. Insufficient intake air 4. Inspect or replace air filter and check forobstruction in air supply.5. Air in fuel system or the fuel supply isinadequate.5. Check the fuel flow through the filter andbleed system. Locate and eliminate the airsource.6. Contaminated fuel. 6. Verify by operating the engine with cleanfuel from a temporary tank. Check for thepresence of gasoline. Drain and flush fuelsupply tank. Replace fuel/water separator filter.7. Fuel screen plugged. 7. Check fuel screen.8. One or more injectors worn or notoperating properly.8. Check/replace improperly operatinginjectors.9. Injector pump out of time. 9. Check pump timing. Refer to Group 14,Fuel System for procedure.10. Engine compression low. 10. Check compression to identify theproblem.11. Fuel injection system defective. 11. Vacuum modulator defective causing EGRto open in cold condition. Check for faultcodes in the ECU.
9 - 38 ENGINE
NS/GS

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