9-1436 Engine Mechanical - 1.

3L (LDV) Diesel

Engine/Propulsion
Engine Mechanical - 1.3L (LDV) Diesel
Specifications
Object-ID=2390679 Owner=Thess, Stephan LMD=01-Sep-2011 LMB=Kuhse, Ben

Fastener Tightening Specifications

Specification
Application Metric English
Air Conditioning Compressor Bracket Bolt 22 Y 16 lb ft
Camshaft Housing Bolt 18 Y 13 lb ft
Camshaft Housing Stud 25 Y 18 lb ft
Camshaft Position Sensor Bolt 9Y 80 lb in
Camshaft Sprocket Bolt 150 Y 111 lb ft
Catalytic Converter Bracket nuts 25 Y 18 lb ft
Catalytic Converter Clamp 25 Y 18 lb ft
Catalytic Converter Heat Shield Bolt 9Y 80 lb in
Connecting Rod Bearing Cap Bolt 20 Y+40° 15 lb ft+40°
Crankshaft Position Sensor Bolt 9Y 80 lb in
Crankshaft Sprocket Bolt 50 Y+90° 37 lb ft+90°
Cylinder Head Bolt 40 Y+90°+90° 30 lb ft+90°+90°
Cylinder Head Core Hole Plug 15 Y 11 lb ft
Diesel Fuel Separator Bolt 9Y 80 lb in
Drive Belt Tensioner Bolt 50 Y 37 lb ft
Engine Control Module Wiring Harness Bracket Bolt 22 Y 16 lb ft
Engine Coolant Thermostat Bolt 25 Y 18 lb ft
Engine Flywheel Bolt 15 Y+35° 11 lb ft+35°
Engine Lift Front Bracket Bolt 25 Y 18 lb ft
Engine Mount Bolt to Body 60 Y 44 lb ft
Engine Mount Bolt to Engine Mount Bracket 55 Y 41 lb ft
Engine Mount Bracket Bolt 60 Y 44 lb ft
Engine Oil Cooler Inlet Pipe Bolt 9Y 80 lb in
Exhaust Gas Recirculation Pipe Bolt to Exhaust Gas Recirculation Valve
25 Y 18 lb ft
Cooler
Exhaust Gas Recirculation Pipe Bolt to Exhaust Manifold 9Y 80 lb in
Exhaust Gas Recirculation Valve Cooler Bolt 22 Y 16 lb ft
Exhaust Gas Recirculation Valve Vacuum Tank Bolt 8Y 71 lb in
Exhaust Gas Recirculation Valve Vacuum Tank Bracket Bolt 22 Y 16 lb ft
Exhaust Manifold Heat Shield Nut 9Y 80 lb in
Exhaust Manifold Nut 15 Y+30° 11 lb ft+30°
Exhaust Pressure Sensor Bolt 7Y 62 lb in
Exhaust Pressure Sensor Bracket Bolt 9Y 80 lb in
Exhaust Pressure Sensor Pipe Bolt 9Y 80 lb in
Exhaust Temperature Sensor 45 Y 33 lb ft
Exhaust Temperature Sensor Connector Bracket Bolt 22 Y 16 lb ft
Fuel Injector Bracket Nut 20 Y 15 lb ft
Fuel Injection Fuel Feed Pipe Nut M12 24 Y 18 lb ft

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1437
Fastener Tightening Specifications (cont'd)
Specification
Application Metric English
Fuel Injection Fuel Feed Pipe Nut M14 28 Y 21 lb ft
Fuel Injection Pump Bolt 15 Y 11 lb ft
Fuel Rail Bolts 25 Y 18 lb ft
Fuel Rail Bracket Bolt 25 Y 18 lb ft
Generator Bolt 22 Y 16 lb ft
Generator Bracket Bolt 22 Y 16 lb ft
Glow Plug 10 Y 89 lb in
Glow Plug Wiring Harness Bracket Bolt 22 Y 16 lb ft
Heated Oxygen Sensor 45 Y 33 lb ft
Intake Manifold Bolt 25 Y 18 lb ft
Lower Crankcase Inner Bolt 20 Y+80° 15 lb ft+80°
Lower Crankcase Outer Bolt 30 Y 22 lb ft
Oil Filter Cap 25 Y 18 lb ft
Oil Filter Housing Bolt 9Y 80 lb in
Oil Level Indicator Tube Bolt 9Y 80 lb in
Oil Pan Bolt 9Y 80 lb in
Oil Pan Nut 9Y 80 lb in
Oil Pump Cap Bolt 6Y 53 lb in
Oil Pump Housing Bolt 9Y 80 lb in
Oil Pump Suction Pipe Bolt 6Y 53 lb in
Piston Oil Nozzle Bolt 9Y 80 lb in
Positive Crankcase Ventilation Oil Separator Bolt 9Y 80 lb in
Positive Crankcase Ventilation Oil Separator Hose Bracket Bolt 9Y 80 lb in
Positive Crankcase Ventilation Pipe Bracket Bolt 8Y 71 lb in
Positive Crankcase Ventilation Tube Bolt 9Y 80 lb in
Starter Bolt 25 Y 18 lb ft
Starter Stud 25 Y 18 lb ft
Thermostat Bypass Pipe Bolt 9Y 80 lb in
Thermostat Bypass Pipe Bracket Bolt 9Y 80 lb in
Throttle Body Adapter Bolt 8Y 71 lb in
Throttle Body Bolt 8Y 71 lb in
Throttle Body Support Bolt 9Y 80 lb in
Timing Chain Guide Bolt 9Y 80 lb in
Timing Chain Tensioner Bolt 9Y 80 lb in
Timing Chain Tensioner Shoe Bolt 25 Y 18 lb ft
Transmission Support Brace Bolt to Engine Block 30 Y 22 lb ft
Turbocharger Nut 25 Y 18 lb ft
Turbocharger Oil Feed Pipe Bolt 22 Y 16 lb ft
Turbocharger Wastegate Actuator Vacuum Control Solenoid Valve Splash
9Y 80 lb in
Shield Nut
Vacuum Pump Bolt 20 Y 15 lb ft
Water Pump Nut 9Y 80 lb in

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9-1438 Engine Mechanical - 1.3L (LDV) Diesel
Object-ID=2473216 Owner=Thess, Stephan LMD=30-Jul-2012 LMB=Hinzmann, Rene

Engine Mechanical Specifications

Specification
Application Metric English
General Data
RPO LDV
Engine Type 4 Cylinder inline
Displacement 1248 ccm 76.2 cu in
Bore Diameter 69.6 mm 2.7 in
Stroke 82.0 mm 3.2 in
Bore Distance 77.0 mm 3.0 in
Compression Ratio 16.8:1
Output @ Engine Speed 55 kW / 4000 RPM
Torque @ Engine Speed 180 Y / 1750 RPM 133 lbf ft / 1750 RPM
Idle Speed 800 RPM
No-Load max. Speed 5200 RPM
Compression 1800 kPa 26107 PSI
Leakage of Pressure <25% per Cylinder
Injection Pressure of the Common Rail System 1400 bar 20305 PSI
Engine Management
ECM Type EDC 17
Injection Pressure Pump Type Bosch CP1K
Injector Type CRIP 2 MI
Firing Order 1–3–4–2
Glow Plug Type – Cylinder 1 and 4 with Pressure Sensor
Glow Plug Type – Cylinder 2 and 3 without Pressure Sensor
Glow Plug Voltage 4.4 Volt
Drive Belt
Drive Belt Length – without Air Conditioning 1182 mm 46.54 in
Drive Belt Length – with Air Conditioning 1320 mm 51.97 in
Oil Circulation System
Engine Oil Filling with Oil Filter 3.2 L 3.4 quarts
Engine Oil Filling between “min.” and “max.” 1.0 L 1.06 quarts
Engine Oil Quality – European Countries Dexos2
Engine Oil Quality – Non European Countries ACEA A3/B4
Engine Oil Viscosity 0W–30, 5W–30, 10W–30, 0W–40, 5W–40, 10W–40

Disposal of Engine Oil For disposal the engine oil follow safety regulations
and national legislation.
Oil Consumption / 1000 km 0.4 L 0.42 quarts
Oil Pump
Oil Pump Type Rotor Pump
Oil Pressure with idle speed and under hot running conditions >100 kPa / 800 RPM
Oil Pressure with 4000 RPM under hot running conditions 300-350 kPa / 4000 RPM
Radial Clearance between driven gear wheel and housing 0.10–0.23 mm 0.0039–0.0091 in
Axial Clearance between oil pump cover contact surface and gear wheel 0.025–0.075 mm 0.00098–0.00295 in
Coolant System
Filling 6.2 L 6.55 quarts
Type of Coolant Pump Centrifugal Pump

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1439
Engine Mechanical Specifications (cont'd)
Specification
Application Metric English
Delivery Rate with 4500 RPM 132 L / min 34.87 gal / min
Thermostat
Type Outlet Thermostat System
Start to Opening 88°C 190.4°F
Fully Open 103°C 217.4°F
Cylinder Head Gasket
Cylinder Head Gasket Thickness / Piston Projection Dimension – 0.67–0.77 mm / 0.028– 0.0264–0.0303 in /
Gasket without Hole 0.127 mm 0.00110–0.00500 in
Cylinder Head Gasket Thickness / Piston Projection Dimension – 0.77–0.87 mm / 0.128– 0.0303–0.0343 in /
Gasket with 1 Hole 0.227 mm 0.00504–0.00894 in
Cylinder Head Gasket Thickness / Piston Projection Dimension – 0.87–0.97 mm / 0.228– 0.0343–0.0382 in /
Gasket with 2 Holes 0.327 mm 0,00900–0,01287 in
Cylinder Head
Cylinder Head Height 105.50 ± 0.05 mm 4.154 ± 0.002 in
Maximum Sag of Cylinder Head 0.10 mm 0.0039 in
Valve Seat Angle at Valve Head 45° ± 20° 45° ± 0.33°
Valve Guide External Diameter Standard 10.010–10.030 mm 0.3941–0.3949 in
Valve Guide External Diameter Oversizing I 0.05 mm 0.00197 in
Valve Guide External Diameter Oversizing II 0.10 mm 0.0039 in
Valve Guide External Diameter Oversizing III 0.25 mm 0.0098 in
Valve Guide Internal Diameter 6.020–6.038 mm 0.2370–0.2377 in
Valves
Valve Stem Diameter – Intake 5.90–5.94 mm 0.2323–0.2339 in
Valve Stem Diameter – Exhaust 5.90–5.94 mm 0.2323–0.2339 in
Valve Spring Length – Unstressed 37.90 mm 1.49 in
Valve Spring Length – 16.2–18.0 daN 31.0 mm 1.22 in
Valve Spring Length – 36.1–39.5 daN 23.5 mm 0.93 in
Valve Diameter Intake / Exhaust 21.47 mm 0.85 in
Intake Cam – Nominal Stroke 6.4 mm 0.25 in
Exhaust Cam – Nominal Stroke 7.5 mm 0.30 in
Engine Block
Engine Block Height 212.55 mm 8.37 in
Conrod Length 131.33 mm 5.17 in
Compression Height 40.43 mm 1.59 in
Engine Height – Crank Center to Top 450 mm 17.72 in
Engine Length – From Engine Block rear face to front pulley 432.5 mm 17.03 in
Cylinder Sleeve
Cylinder Sleeve Diameter – Class A 69.600–69.610 mm 2.7401–2.7405 in
Cylinder Sleeve Diameter – Class B 69.610–69.620 mm 2.7405–2.7409 in
Cylinder Sleeve Diameter – Class C 69.620–69.630 mm 2.7409–2.7413 in
Tapering of Cylinder Sleeve <0.010 mm <0.00039 in
Oval Status of Cylinder Sleeve ±0.005 mm ±0.0002 in
Oversize Cylinder Sleeve Diameter 0.1 mm 0.0039 in
Camshaft
Camshaft Bearing Journal Diameter – 1. Bearing Journal 38.500–38.515 mm 1.5157–1.5163 in

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9-1440 Engine Mechanical - 1.3L (LDV) Diesel
Engine Mechanical Specifications (cont'd)
Specification
Application Metric English
Camshaft Bearing Journal Diameter – 2. Bearing Journal 38.000–38.015 mm 1.4961–1.4967 in
Camshaft Bearing Journal Diameter – 3. Bearing Journal 30.000–30.015 mm 1.1811–1.1817 in
Camshaft Axial Clearance 0.15–0.34 mm 0.0059–0.0134 in
Camshaft Housing
Camshaft Bearing Diameter – 1. Bearing 38.545–38.570 mm 1.5175–1.5185 in
Camshaft Bearing Diameter – 2. Bearing 38.045–38.070 mm 1.4978–1.4988 in
Camshaft Bearing Diameter – 3. Bearing 30.045–30.070 mm 1.1829–1.1839 in
Connecting Rod
Con Rod Bearing Bushing Internal Diameter 23.006–23.012 mm 0.9057–0.9060 in
Con Rod Bearing Clearance 0.03–0.062 mm 0.0012–0.0024 in
Con Rod Bearing Journal Diameter – Class A 42.591–42.600 mm 1.6768–1.6772 in
Con Rod Bearing Journal Diameter – Class B 42.582–42.591 mm 1.6765–1.6768 in
Con Rod Big End Bore Diameter 45.734–45.744 mm 1.8005–1.8009 in
Con Rod Bearing Shell – Class A (red) 1.546–1.552 mm 0.0609–0.0611 in
Con Rod Bearing Shell – Class B (blue) 1.550–1.556 mm 0.0610–0.0613 in
Con Rod Bearing Shell Thickness Oversize 0.127 mm 0.005 in
Main Bearing Shell Thickness Oversize 0.127 mm 0.005 in
Crankshaft
Axial Clearance 0.055–0.265 mm 0.0022–0.0104 in
Main Bearing Clearance 0.028–0.048 mm 0.0011–0.0019 in
Main Bearing Journal Diameter – Class A 50.994–51.000 mm 2.0076–2.0079 in
Main Bearing Journal Diameter – Class B 50.988–50.994 mm 2.0074–2.0076 in
Main Bearing Journal Diameter – Class C 50.982–50.988 mm 2.0072–2.0074 in
Main Bearing Journal Undersize 0.127 mm 0.005 in
Bearing Bore Diameter in Cylinder Block – Class A 54.710–54.714 mm 2.1539–2.1541 in
Bearing Bore Diameter in Cylinder Block – Class B 54.714–54.718 mm 2.1541–2.1542 in
Bearing Bore Diameter in Cylinder Block – Class C 54.718–54.722 mm 2.1542–2.1544 in
Main Bearing Shells – Class A – Red 1.836–1.841 mm 0.0723–0.0725 in
Main Bearing Shells – Class B – Blue 1.841–1.846 mm 0.0725–0.0727 in
Main Bearing Shells – Class C – Yellow 1.846–1.851 mm 0.0727–0.0729 in
Axial Thrust Washers 2.310–2.360 mm 0.0910–0.0929 in
Piston
Piston Diameter – Class A 69.520–69.530 mm 2.7370–2.7374 in
Piston Diameter – Class B 69.530–69.540 mm 2.7374–2.7378 in
Piston Diameter – Class C 69.540–69.550 mm 2.7378–2.7382 in
Piston Projection Dimension 0.028–0.327 mm 0.0011–0.0129 in
Piston Pin Diameter 22.982–22.987 mm 0.9048–0.9050 in
Piston Pin Eye Diameter 22.990–22.996 mm 0.9051–0.9054 in
Clearance Piston Pin in Piston 0.003–0.014 mm 0.0001–0.0006 in
Clearance Piston Pin in Con Rod 0.019–0.030 mm 0.0007–0.0012 in
Piston Weight Difference ± 0.008 kg
Piston Rings
Compression Ring 1 – Thickness 1.970–1.995 mm 0.0776–0.0785 in
Compression Ring 2 – Thickness 1.470–1.490 mm 0.0579–0.0587 in

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1441
Engine Mechanical Specifications (cont'd)
Specification
Application Metric English
Oil Scraper Ring – Thickness 1.970–1.990 mm 0.0776–0.0783 in
Compression Ring 1 – Axial Clearance 0.09–0.13 mm 0.0035–0.0051 in
Compression Ring 2 – Axial Clearance 0.04–0.08 mm 0,0016–0.0031 in
Oil Scraper Ring – Axial Clearance 0.03–0.07 mm 0.0012–0.0028 in
Compression Ring 1 – Gap 0.20–0.30 mm 0.0079–0.0118 in
Compression Ring 2 – Gap 1.0–1.5 mm 0.0394–0.0591 in
Oil Scraper Ring – Gap 0.25–0.50 mm 0.0098–0.0197 in

Component Locator
Disassembled Views
Object-ID=2370726 Owner=Thess, Stephan LMD=01-Sep-2011 LMB=Kuhse, Ben

Fuel Rail
SIO-ID=2370697 LMD=25-Nov-2009

2192187
Legend
(1) Fuel Rail Bolts (6) Fuel Injector Nut
(2) Fuel Rail (7) Fuel Injector Washer
(3) Fuel Feed Pipe- Fuel Injection Pump to (8) Fuel Injector Washer - Conical
Fuel Rail (9) Fuel Injector Bracket
(4) Fuel Injection Pump (10) Fuel Injector Gasket
(5) Fuel Injection Pump Bolts (11) Fuel Injector
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9-1442 Engine Mechanical - 1.3L (LDV) Diesel
(12) Fuel Feed Pipe– Fuel Rail to Fuel Injector (13) Fuel Rail Pressure Sensor

2014 - Spin Service Manual (5618083) - (Misc Draft) - 6/7/13

 Engine Mechanical - 1.3L (LDV) Diesel 9-1443

Camshaft Housing
SIO-ID=2370699 LMD=25-Nov-2009

2192189
Legend
(1) Engine Sight Shield Stud (11) Camshaft Intake Sprocket
(2) Camshaft Housing Stud (12) Camshaft Exhaust Sprocket Bolt
(3) Fuel Injector Seal (13) Camshaft Exhaust Sprocket
(4) Engine Sight Shield Stud Bracket Bolt (14) Camshaft Housing Gasket
(5) Engine Sight Shield Stud Bracket (15) Exhaust Camshaft
(6) Vacuum Pump Bolt (16) Intake Camshaft
(7) Vacuum Pump (17) Camshaft Position Sensor
(8) Fuel Injection Pump (18) Camshaft Position Sensor Bolt
(9) Fuel Injection Pump Bolt (19) Engine Sight Shield Stud Bracket
(10) Camshaft Intake Sprocket Bolt

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9-1444 Engine Mechanical - 1.3L (LDV) Diesel

Cylinder Head
SIO-ID=2370701 LMD=25-Nov-2009

2192192
Legend
(1) Cylinder Head Bolt (8) Camshaft Cover Locating Pin
(2) Valve Stem Key (9) Cylinder Head
(3) Valve Spring Retainer (10) Exhaust Manifold Stud
(4) Valve Spring (11) Cylinder Head Gasket
(5) Valve Stem Oil Seal (12) Exhaust Valve
(6) Valve Rocker Arm (13) Intake Valve
(7) Valve Lifter

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1445

Exhaust System
SIO-ID=2370702 LMD=25-Nov-2009

2192194
Legend
(1) Turbocharger Oil Feed Pipe
(2) Turbocharger Oil Feed Pipe Bolt
(3) Turbocharger Oil Feed Pipe Gasket
(4) Turbocharger Nut
(5) Turbocharger Wastegate Actuator
Vacuum Control Solenoid Valve Splash
Shield Nut
(6) Turbocharger Wastegate Actuator
Vacuum Control Solenoid Valve Splash
Shield
(7) Turbocharger
(8) Turbocharger Oil Return Hose Clamp
(9) Turbocharger Oil Return Hose
(10) Turbocharger Exhaust Pipe Gasket
(11) Exhaust Manifold Stud
(12) Engine Lift Front Bracket
(13) Engine Lift Front Bracket Bolt
(14) Exhaust Manifold Heat Shield Nut
(15) Exhaust Manifold Stud
(16) Exhaust Manifold Heat Shield –
Right Side
(17) Exhaust Manifold Heat Shield – Left Side
(18) Exhaust Manifold Heat Shield Nut
(19) Exhaust Manifold Nut
(20) Exhaust Manifold
(21) Exhaust Manifold Gasket

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9-1446 Engine Mechanical - 1.3L (LDV) Diesel

Intake System
SIO-ID=2370703 LMD=25-Nov-2009

2192195
Legend
(1) Intake Manifold gasket (7) Throttle Body Adapter Seal
(2) Intake Manifold (8) Throttle Body Adapter
(3) Manifold Absolute Pressure Sensor (9) Throttle Body
(4) Manifold Absolute Pressure Sensor Bolt (10) Throttle Body Bolts
(5) Intake Manifold Upper Bolt (11) Throttle Body Seal
(6) Intake Manifold Lower Bolt (12) Throttle Body Adapter Bolts

2014 - Spin Service Manual (5618083) - (Misc Draft) - 6/7/13

 Engine Mechanical - 1.3L (LDV) Diesel 9-1447

Timing Chain System

SIO-ID=2370706 LMD=25-Nov-2009

2192196
Legend
(1) Camshaft Sprocket Bolt (7) Timing Chain Guide Bolt
(2) Camshaft Sprocket (8) Crankshaft Sprocket
(3) Camshaft Timing Chain (9) Timing Chain Tensioner Arm Bolt
(4) Timing Chain Oil Nozzle Bolt (10) Timing Chain Tensioner Arm
(5) Timing Chain Oil Nozzle (11) Timing Chain Tensioner
(6) Timing Chain Guide (12) Timing Chain Tensioner Bolts

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9-1448 Engine Mechanical - 1.3L (LDV) Diesel

Oil Filter Adapter

SIO-ID=2370707 LMD=25-Nov-2009

2192197
Legend
(1) Oil Filter Cap (4) Oil Filter Housing with Oil Cooler
(2) Oil Filter Cap Seal (5) Oil Filter Housing Bolts
(3) Oil Filter (6) Oil Filter Housing Gasket

2014 - Spin Service Manual (5618083) - (Misc Draft) - 6/7/13

 Engine Mechanical - 1.3L (LDV) Diesel 9-1449

Oil Pump without Start/Stop System

SIO-ID=2370708 LMD=09-Jan-2012

2192201
Legend
(1) Oil Pump Housing Plug (12) Oil Pump Outer Drive Adapter
(2) Oil Pump Housing Plug Seal (13) Oil Pressure Relief Valve Plug
(3) Oil Pump Housing Bolt (14) Oil Pressure Relief Valve Seal
(4) Oil Pump Housing (15) Oil Pressure Relief Valve Spring
(5) Oil Pump Housing Gasket (16) Oil Pressure Relief Valve Piston
(6) Oil Pump Cap Bolts (17) Oil Pump Housing Nut
(7) Oil Pump Suction Pipe Bolts (18) Oil Pump Seal
(8) Oil Pump Suction Pipe (19) Oil Pump Housing Cover Seal
(9) Oil Pump Suction Pipe Gasket (20) Oil Pump Housing Cover
(10) Oil Pump Cap (21) Oil Pump Housing Cover Bolts
(11) Oil Pump Inner Drive Adapter

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9-1450 Engine Mechanical - 1.3L (LDV) Diesel

Piston, Connecting Rod and Bearing

SIO-ID=2370709 LMD=25-Nov-2009

2192198
Legend
(1) Piston Pin (10) Lower Main Bearing Shell
(2) Piston (11) Oil Pan Buffle
(3) Piston Pin Retainer (12) Oil Pan Buffle Bolt
(4) Piston Ring Set (13) Lower Crankcase Bolt
(5) Connecting Rod Bearing (14) Lower Crankcase Bolt
(6) Crankshaft Thrust Bearing (15) Lower Crankcase
(7) Upper Main Bearing Shell (16) Engine Block
(8) Crankshaft Rear Oil Seal (17) Connecting Rod Bolt
(9) Crankshaft (18) Connecting Rod with Cap

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1451

Engine Block
SIO-ID=2370710 LMD=25-Nov-2009

2192199
Legend
(1) Engine Block Core Hole Plug (6) Engine Block Core Hole Plug
(2) Cylinder Head Location Pin (7) Transmission Location Pin
(3) Engine Block (8) Lower Crankcase Location Pin
(4) Crankshaft Position Sensor (9) Piston Oil Nozzle
(5) Crankshaft Position Sensor Bolt (10) Piston Oil Nozzle Bolt

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9-1452 Engine Mechanical - 1.3L (LDV) Diesel
Engine Identification
Object-ID=2370727 Owner=Thess, Stephan LMD=08-Nov-2011 LMB=Baker, Sandie

Engine Number

2192374

Note: The engine identification number must be

stamped to the cylinder block in case of engine
replacement.
The engine number is stamped to the engine block (1).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1453
Diagnostic Information and
Procedures
Object-ID=2370728 Owner=Thess, Stephan LMD=15-Dec-2009 LMB=Thess, Stephan

Base Engine Misfire with Abnormal Internal Lower Engine Noises

Condition Actions
Abnormalities (server cracking, Abnormalities in the accessory drive belt and/or components may cause engine RPM
bumps or missing areas) in the variations, noises similar to faulty lower engine and also lead to a misfire condition. A misfire
accessory drive belt code may be present without an actual misfire condition.
1. Inspect the accessory drive components.
2. Repair or replace all damaged components.
Worn, damaged, or misaligned A misfire code may be present without an actual misfire condition.
accessory drive components or 1. Inspect the accessory drive components.
excessive pulley runout
2. Repair or replace all damage components.
Loose and/or damaged A misfire code may be present without an actual misfire condition.
crankshaft pulley 1. Repair or replace all damaged components.
2. Inspect crankshaft pulley and pulley bolt.
Loose and/or damaged flywheel A misfire code may be present without an actual misfire condition.
1. Inspect flywheel and flywheel attaching bolts.
2. Repair or replace all damaged components.
Excessive piston‐to‐cylinder bore 1. Perform cylinder leak down and compression tests.
clearance 2. Inspect the piston, piston rings and cylinder bore.
3. Repair or replace all damaged components.
Excessive crankshaft thrust Severely worn thrust surfaces on the crankshaft and/or thrust bearing may permit for and aft
bearing clearance movement of the crankshaft and create a misfire code without an actual misfire condition.
1. Inspect the crankshaft end play and crankshaft thrust bearings.
2. Repair or replace all damaged components.

Object-ID=2370729 Owner=Thess, Stephan LMD=25-Nov-2009 LMB=Thess, Stephan

Base Engine Misfire with Abnormal Valve Train Noise

Condition Action
Loose, worn or damaged valve bridge 1. Inspect valve bridge and finger‐follower.
and finger‐follower 2. Repair or replace all damaged components.
Broken valve springs 1. Inspect valve springs.
2. Repair or replace all damaged components.
Sticking valve Carbon on the valve stem or valve seat may cause the valve to stick.
1. Inspect valves and valve guides.
2. Repair or replace all damaged components.
Worn or faulty camshaft lobes 1. Inspect camshaft lobes.
2. Repair or replace all damaged components.

Object-ID=2370732 Owner=Thess, Stephan LMD=28-May-2010 LMB=Thess, Stephan

Base Engine Misfire with Coolant Consumption

Inspection Action
DEFINITION: Base engine misfire with coolant consumption
Preliminary Inspection Verify that there are no external coolant leaks. Refer to Symptoms - Engine Cooling on
page 9‑1014.
Isolate Affected Cylinders • Cylinder balance test with scan tool
• Cooling system pressurization
• Inspection of glow plugs
• Compression test

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9-1454 Engine Mechanical - 1.3L (LDV) Diesel
Base Engine Misfire with Coolant Consumption (cont'd)
Inspection Action
EGR System Inspection • Inspect EGR valve and intake system for evidence of coolant leakage.
• Replace the EGR cooler if any problem is found.
Cylinder Head Gasket Leakage • Remove cylinder heads of the affected cylinder bank and inspect for damage.
• Replace components as necessary.
Cylinder Head or Engine Block • Inspect the cylinder head for cracks.
Damage . • Inspect the cylinder block for damage.
• Inspect the cylinder block to head mating surface for straightness.
• Replace components as necessary.

Object-ID=2370735 Owner=Thess, Stephan LMD=18-Oct-2012 LMB=Kuhse, Ben

Base Engine Misfire with Excessive Oil Consumption

Condition Action
Worn valve guides 1. Inspect the valves and valve guides.
2. Repair or replace all damaged components.
Worn valve stem oil seals 1. Inspect the valve stem oil seals.
2. Repair or replace all damaged components.
Excessive piston‐to‐cylinder bore 1. Perform compression tests to determine the cause.
clearance 2. Inspect the piston rings for low ring tension, broken or worn rings.
3. Inspect cylinder bore.
4. Repair or replace all damaged components.

Object-ID=2370737 Owner=Thess, Stephan LMD=03-Aug-2010 LMB=Thess, Stephan

Base Engine Misfire without Internal Engine Noises

Condition Action
Abnormalities (severe cracking, Abnormalities in the accessory drive belt and/or components may cause engine RPM
bumps or missing areas) in the variations, noises similar to a faulty lower engine and also lead to a misfire condition.
accessory drive belt. Also worn, A misfire code may be present without an actual misfire condition.
damaged, or misaligned accessory 1. Inspect the accessory drive components.
drive components or excessive pulley
runout. 2. Repair or replace all damaged components.

Loose and/or damaged crankshaft A misfire code may be present without an actual misfire condition.
pulley 1. Inspect crankshaft pulley and pulley bolt
2. Repair or replace all damaged components.
Loose and/or damaged flywheel A misfire code may be present without an actual misfire condition.
1. Inspect flywheel and flywheel attaching bolts.
2. Repair or replace all damaged components.
Restricted exhaust system A severe restriction in the exhaust flow can cause significant loss of engine
performance and may set a misfire code. Possible causes of restrictions include
collapsed or dented pipes, plugged mufflers and/or catalytic converters. Repair or
replace all damaged components.
Air in fuel system 1. Inspect fuel filter, fuel system for leaks and/or restrictions.
2. Repair or replace all damaged components.
Bent and/or worn valve bridge and 1. Inspect valve bridge and valve finger‐follower.
finger‐follower 2. Repair or replace all damaged components.
Sticking valve Carbon on the valve stem or valve seat may cause the valve to stick.
1. Inspect valves and valve guides.
2. Repair or replace all damaged components.
Damaged or misaligned timing gears 1. Inspect timing gears.
2. Replace all damaged components.
Worn or faulty camshaft lobes 1. Inspect camshaft lobes.
2. Repair or replace all damaged components.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1455
Base Engine Misfire without Internal Engine Noises (cont'd)
Condition Action
Excessive piston‐to‐cylinder bore 1. Perform compression tests.
clearance 2. Inspect the piston, piston rings and cylinder bore.
3. Repair or replace all damaged components.
Faulty cylinder head gaskets and/or 1. Perform compression tests.
cracking or other damage to the 2. Inspect the piston, piston rings and cylinder bore.
cylinder heads and engine block
cooling system passages. (Coolant 3. Repair or replace all damaged components.
consumption may or may not cause
the engine to overheat.)

Object-ID=2370774 Owner=Thess, Stephan LMD=25-Nov-2009 LMB=Thess, Stephan

Upper Engine Noise, Regardless of Engine Speed

Condition Action
Low oil pressure Insufficient or poor oil supply to valve train.
1. Perform oil pressure test.
2. Repair or replace all damaged components.
Improper lubrication to the valve 1. Inspect valve rocker arm, hydraulic valve lifter, oil pump and engine block oil
finger‐follower galleries.
2. Repair or replace all damaged components.
Worn or damaged valve finger‐ 1. Inspect valve rocker arm, hydraulic valve lifter,
follower 2. Repair or replace all damaged components.
Sticking valve Carbon on the valve stem or valve seat may cause the valve to stick.
1. Inspect valves and valve guides.
2. Repair or replace all damaged components.
Worn or faulty camshaft lobes 1. Inspect camshaft lobes.
2. If damaged replace camshaft and all valve finger‐followers.
Damaged or misaligned timing gears 1. Inspect timing gears.
2. Replace all damaged components.

Object-ID=2370775 Owner=Thess, Stephan LMD=03-Aug-2010 LMB=Thess, Stephan

Coolant in Combustion Chamber

Cause Correction
DEFINITION: Excessive white smoke and/or coolant type odor coming from the exhaust pipe may indicate coolant in the
combustion chamber. Low coolant levels, an inoperative cooling fan, or a faulty thermostat may lead to an overtemperature
condition which may cause engine component damage.
• A slower than normal cranking speed may indicate coolant entering the combustion chamber. Refer to Engine Will Not Crank
- Crankshaft Will Not Rotate on page 9‑1471.
• Remove the glow plugs and inspect for glow plugs saturated by coolant or coolant in the cylinder bore.
• Inspect by performing a cylinder leakage test. Refer to Cylinder Leakage Test on page 9‑1467. During this test, excessive air
bubbles within the coolant may indicate a faulty gasket or damaged component.
• Inspect by performing a cylinder compression test. Two cylinders side-by-side on the engine block, with low compression,
may indicate a failed cylinder head gasket. Refer to Engine Compression Test on page 9‑1463.
Faulty cylinder head gasket Replace the cylinder head gasket and components as required. Refer to Cylinder Head
Replacement on page 9‑1522 and Cylinder Head Cleaning and Inspection on page 9‑1659.
Warped cylinder head Replace the cylinder head and gasket. Refer to Cylinder Head Replacement on
page 9‑1522.
Cracked cylinder head Replace the cylinder head and gasket. Refer to Cylinder Head Replacement on
page 9‑1522.
Cracked cylinder liner Replace the components as required.

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9-1456 Engine Mechanical - 1.3L (LDV) Diesel
Coolant in Combustion Chamber (cont'd)
Cause Correction
Cylinder head or block porosity Replace the components as required.

Object-ID=2370776 Owner=Thess, Stephan LMD=03-Aug-2010 LMB=Thess, Stephan

Coolant in Engine Oil

Cause Correction
DEFINITION: Excessive white smoke and/or coolant type odor coming from the exhaust pipe may indicate coolant in the
combustion chamber. Low coolant levels, an inoperative cooling fan, or a faulty thermostat may lead to an overtemperature
condition which may cause engine component damage.
• A slower than normal cranking speed may indicate coolant entering the combustion chamber. Refer to Engine Will Not Crank
- Crankshaft Will Not Rotate on page 9‑1471.
• Remove the glow plugs and inspect for glow plugs saturated by coolant or coolant in the cylinder bore.
• Inspect by performing a cylinder leakage test. Refer to Cylinder Leakage Test on page 9‑1467. During this test, excessive air
bubbles within the coolant may indicate a faulty gasket or damaged component.
• Inspect by performing a cylinder compression test. Two cylinders side-by-side on the engine block, with low compression,
may indicate a failed cylinder head gasket. Refer to Engine Compression Test on page 9‑1463.
Faulty cylinder head gasket Replace the cylinder head gasket and components as required. Refer to Cylinder Head
Replacement on page 9‑1522 and Cylinder Head Cleaning and Inspection on page 9‑1659.
Warped cylinder head Replace the cylinder head and gasket. Refer to Cylinder Head Replacement on
page 9‑1522.
Cracked cylinder head Replace the cylinder head and gasket. Refer to Cylinder Head Replacement on
page 9‑1522.
Cracked cylinder liner Replace the components as required.
Cylinder head or block porosity Replace the components as required.

Drive Belt Chirping, Squeal, and 3. The noise may be an internal engine noise.
Removing the drive belts one at a time and
Whine Diagnosis operating the engine for a brief period will verify the
Object-ID=3405319 Owner=Youkhana, Karem LMD=16-Apr-2013 LMB=Smith, Craig noise is related to the drive belt. When removing
the drive belt the water pump may not be operating
and the engine may overheat. Also DTCs may set
Diagnostic Aids when the engine is operating with the drive belts
• A chirping or squeal noise may be intermittent due removed.
to moisture on the drive belts or the pulleys. It may 4. Inspect all drive belt pulleys for pilling. Pilling is the
be necessary to spray a small amount of water on small balls or pills or it can be strings in the drive
the drive belts in order to duplicate the customers belt grooves from the accumulation of rubber dust.
concern. If spraying water on the drive belt
duplicates the symptom, cleaning the belt pulleys 6. Misalignment of the pulleys may be caused from
may be the probable solution. improper mounting of the accessory drive
component, incorrect installation of the accessory
• If the noise is intermittent, verify the accessory drive component pulley, or the pulley bent inward
drive components by varying their loads making or outward from a previous repair. Test for a
sure they are operated to their maximum capacity. misaligned pulley using a straight edge in the
An overcharged A/C system, power steering pulley grooves across two or three pulleys. If a
system with a pinched hose or wrong fluid, or a misaligned pulley is found refer to that accessory
generator failing are suggested items to inspect. drive component for the proper installation
• A chirping, squeal or whine noise may be caused procedure for that pulley.
by a loose or improper installation of a body or 10. Inspecting of the fasteners can eliminate the
suspension component. Other items of the vehicle possibility that a wrong bolt, nut, spacer, or washer
may also cause the noise. was installed.
• The drive belts will not cause a whine noise. 12. Inspecting the pulleys for being bent should
Test Description include inspecting for a dent or other damage to
the pulleys that would prevent the drive belt from
The numbers below refer to the step numbers on the not seating properly in all of the pulley grooves or
diagnostic table. on the smooth surface of a pulley when the back
2. The noise may not be engine related. This step is side of the belt is used to drive the pulley.
to verify that the engine is making the noise. If the
engine is not making the noise do not proceed
further with this table.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1457
14. This test is to verify that the drive belt tensioner
operates properly. If the drive belt tensioner is not
operating properly, proper belt tension may not be
achieved to keep the drive belt from slipping which
could cause a squeal noise.
15. This test is to verify that the drive belt is not too
long, which would prevent the drive belt tensioner
from working properly. Also if an incorrect length
drive belt was installed, it may not be routed
properly and may be turning an accessory drive
component in the wrong direction.
16. Misalignment of the pulleys may be caused from
improper mounting of the accessory drive
component, incorrect installation of the accessory
drive component pulley, or the pulley bent inward
or outward from a previous repair. Test for a
misaligned pulley using a straight edge in the
pulley grooves across two or three pulleys. If a
misaligned pulley is found refer to that accessory
drive component for the proper installation
procedure for that pulley.
17. This test is to verify that the pulleys are the correct
diameter or width. Using a known good vehicle
compare the pulley sizes.
19. Replacing the drive belt when it is not damaged or
there is not excessive pilling will only be a
temporary repair.

Drive Belt Chirping, Squeal, and Whine Diagnosis

Step Action Yes No
Caution: SIO-ID=2052166 LMD=24-Jan-2008 Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the
composition of the drive belt. Failure to follow this recommendation will damage the drive belt.
DEFINITION: The following items are indications of chirping:
• A high pitched noise that is heard once per revolution of the drive belt or a pulley.
• Chirping may occur on cold damp start-ups and will subside once the vehicle reaches normal operating temp.
DEFINITION: The following items are indications of drive belt squeal:
• A loud screeching noise that is caused by a slipping drive belt. This is unusual for a drive belt with multiple ribs.
• The noise occurs when a heavy load is applied to the drive belt, such as an air conditioning compressor engagement
snapping the throttle, or slipping on a seized pulley or a faulty accessory drive component.
DEFINITION: The following items are indications of drive belt whine:
• A high pitched continuous noise.
• The noise may be caused by an accessory drive component failed bearing.
Did you review the Drive Belt Symptom operation and perform the Go to Symptoms -
1 necessary inspections? Engine Mechanical on
Go to Step 2 page 9‑1476
Verify that there is a chirping, squeal or whine noise.
2
Does the engine make the chirping squeal or whine noise? Go to Step 3 Go to Diagnostic Aids
1. Remove the drive belt.
If the engine has multiple drive belts, remove the belts one at a
time and perform the test below each time a belt is removed.
3 2. Operate the engine for no longer than 30–40 seconds.
3. Repeat this test if necessary by removing the remaining Go to Symptoms -
belt(s). Engine Mechanical on
Does the chirping, squeal or whine noise still exist? page 9‑1476 Go to Step 4
If diagnosing a chirping noise, inspect for severe pilling exceeding
1/3 of the belt groove depth.
4
If diagnosing a squeal or whine noise, proceed to step 13.
Do the belt grooves have pilling? Go to Step 5 Go to Step 6
Clean the drive belt pulleys with a suitable wire brush.
5
Did you complete the repair? Go to Step 20 Go to Step 6

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9-1458 Engine Mechanical - 1.3L (LDV) Diesel
Drive Belt Chirping, Squeal, and Whine Diagnosis (cont'd)
Step Action Yes No
Inspect for misalignment of the pulleys.
6
Are any of the pulleys misaligned? Go to Step 7 Go to Step 8
Replace or repair any misaligned pulleys.
7
Did you complete the repair? Go to Step 20 Go to Step 8
Inspect for bent or cracked brackets.
8
Did you find any bent or cracked brackets? Go to Step 9 Go to Step 10
Replace any bent or cracked brackets.
9
Did you complete the repair? Go to Step 20 Go to Step 10
Inspect for improper, loose or missing fasteners.
10
Did you find the condition? Go to Step 11 Go to Step 12
Caution: Refer to Fastener Caution on page 0‑9.
1. Tighten any loose fasteners. Refer to Fastener Tightening
11 Specifications on page 9‑1436.
2. Replace any improper or missing fasteners.
Did you complete the repair? Go to Step 20 Go to Step 12
Inspect for a bent pulley.
12
Did you find the condition? Go to Step 18 Go to Step 19
Inspect for an accessory drive component seized bearing or a faulty
accessory drive component.
13 Did you find and correct the condition?
If diagnosing a whine noise and the condition still exist, proceed to
Diagnostic Aids. Go to Step 20 Go to Step 14
Test the drive belt tensioner for proper operation. Refer to Drive Belt
14 Tensioner Diagnosis on page 9‑1463
Did you find and correct the condition? Go to Step 20 Go to Step 15
Inspect for the correct drive belt length.
15
Did you find and correct the condition? Go to Step 20 Go to Step 16
Inspect for misalignment of a pulley.
16
Did you find and correct the condition? Go to Step 20 Go to Step 17
Inspect for the correct pulley size.
17
Did you find and correct the condition? Go to Step 20 Go to Diagnostic Aids
Replace the bent pulley.
18
Did you complete the repair? Go to Step 20 Go to Step 19
Replace the drive belt. Refer to Air Conditioning Compressor Belt
Replacement on page 9‑1581, Generator and Power Steering Pump
19 Belt Replacement on page 9‑1583 or Water Pump, Air Conditioning
Compressor, and Generator Belt Replacement on page 9‑1584.
Did you complete the repair? Go to Step 20 Go to Diagnostic Aids
Operate the system in order to verify the repair.
20
Did you correct the condition? System OK Go to Step 3

Drive Belt Falls Off and Excessive If the drive belt is the incorrect length, the drive belt
tensioner may not keep the proper tension on the
Wear Diagnosis drive belt.
Object-ID=3405324 Owner=Youkhana, Karem LMD=16-Apr-2013 LMB=Smith, Craig Excessive wear on a drive belt is usually caused by an
incorrect installation or the wrong drive belt for the
Diagnostic Aids application.
If the drive belt repeatedly falls off the drive belt pulleys, Minor misalignment of the drive belt pulleys will not
this is because of pulley misalignment. cause excessive wear, but will probably cause the drive
belt to make a noise or to fall off.
An extra load that is quickly applied on released by an
accessory drive component may cause the drive belt to Excessive misalignment of the drive belt pulleys will
fall off the pulleys. Verify the accessory drive cause excessive wear but may also make the drive belt
components operate properly. fall off.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1459
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This inspection is to verify the condition of the drive
belt. Damage may of occurred to the drive belt
when the drive belt fell off. The drive belt may of
been damaged, which caused the drive belt to fall
off. Inspect the belt for cuts, tears or sections of
ribs missing.
4. Misalignment of the pulleys may be caused from
improper mounting of the accessory drive
component, incorrect installation of the accessory
drive component pulley, or the pulley bent inward
or outward from a previous repair. Test for a
misaligned pulley using a straight edge in the
pulley grooves across two or three pulleys. If a
misaligned pulley is found refer to that accessory
drive component for the proper installation
procedure of that pulley.
5. Inspecting the pulleys for being bent should
include inspecting for a dent or other damage to
the pulleys that would prevent the drive belt from
not seating properly in all of the pulley grooves or
on the smooth surface of a pulley when the back
side of the belt is used to drive the pulley.
6. Accessory drive component brackets that are bent
or cracked will let the drive belt fall off.
7. Inspecting of the fasteners can eliminate the
possibility that a wrong bolt, nut , spacer, or washer
was installed. Missing. loose, or the wrong
fasteners may cause pulley misalignment from the
bracket moving under load. Over tightening of the
fasteners may cause misalignment of the
accessory component bracket.
13. The inspection is to verify the drive belt is correctly
installed on all of the drive belt pulleys. Wear on
the drive belt may be caused by mis-positioning
the drive belt by one groove on a pulley.
14. The installation of a drive belt that is two wide or
two narrow will cause wear on the drive belt. The
drive belt ribs should match all of the grooves on all
of the pulleys.
15. This inspection is to verify the drive belt is not
contacting any parts of the engine or body while
the engine is operating. There should be sufficient
clearance when the drive belt accessory drive
components load varies. The drive belt should not
come in contact with an engine or a body
component when snapping the throttle.

Drive Belt Falls Off and Excessive Wear Diagnosis

Step Action Yes No
DEFINITION: The drive belt falls off the pulleys or may not ride correctly on the pulleys.
DEFINITION: Wear at the outside ribs of the drive belt due to an incorrectly installed drive belt.
Did you review the Drive Belt Symptom operation and perform the Go to Symptoms -
1 necessary inspections? Engine Mechanical on
Go to Step 2 page 9‑1476
If diagnosing high wear, proceed to step 13.
If diagnosing a drive belt that falls off, inspect for a damaged
2
drive belt.
Did you find the condition? Go to Step 3 Go to Step 4

2014 - Spin Service Manual (5618083) - (Misc Draft) - 6/7/13

9-1460 Engine Mechanical - 1.3L (LDV) Diesel
Drive Belt Falls Off and Excessive Wear Diagnosis (cont'd)
Step Action Yes No
Install a new drive belt. Refer to Air Conditioning Compressor Belt
Replacement on page 9‑1581, Generator and Power Steering Pump
3 Belt Replacement on page 9‑1583 or Water Pump, Air Conditioning
Compressor, and Generator Belt Replacement on page 9‑1584.
Does the drive belt continue to fall off? Go to Step 4 System OK
Inspect for misalignment of the pulleys.
4
Did you find and repair the condition? Go to Step 12 Go to Step 5
Inspect for a bent or dented pulley.
5
Did you find and repair the condition? Go to Step 12 Go to Step 6
Inspect for a bent or a cracked bracket.
6
Did you find and repair the condition? Go to Step 12 Go to Step 7
Inspect for improper, loose or missing fasteners.
7
Did you find loose or missing fasteners? Go to Step 8 Go to Step 9
Caution: Refer to Fastener Caution on page 0‑9.
1. Tighten any loose fasteners. Refer to Fastener Tightening
8 Specifications on page 9‑1436.
2. Replace improper or missing fasteners.
Does the drive belt continue to fall off? Go to Step 9 System OK
Test the drive belt tensioner for operating correctly. Refer to Drive
9 Belt Tensioner Diagnosis on page 9‑1463.
Does the drive belt tensioner operate correctly? Go to Step 11 Go to Step 10
Replace the drive belt tensioner. Refer to Drive Belt Tensioner
10 Replacement on page 9‑1537.
Does the drive belt continue to fall off? Go to Step 11 System OK
Inspect for failed drive belt idler and drive belt tensioner pulley
11 bearings.
Did you find and repair the condition? Go to Step 12 Go to Diagnostic Aids
Operate the system in order to verify the repair.
12
Did you correct the condition? System OK Go to Step 2
Inspect the drive belt for the proper installation. Refer to Air
Conditioning Compressor Belt Replacement on page 9‑1581,
Generator and Power Steering Pump Belt Replacement on
13 page 9‑1583 or Water Pump, Air Conditioning Compressor, and
Generator Belt Replacement on page 9‑1584.
Did you find this condition? Go to Step 16 Go to Step 14
Inspect for the proper drive belt.
14
Did you find this condition? Go to Step 16 Go to Step 15
Inspect for the drive belt rubbing against a bracket, hose, or wiring
15 harness.
Did you find and repair the condition? Go to Step 17 Go to Diagnostic Aids
Replace the drive belt.Refer to Air Conditioning Compressor Belt
Replacement on page 9‑1581, Generator and Power Steering Pump
16 Belt Replacement on page 9‑1583 or Water Pump, Air Conditioning
Compressor, and Generator Belt Replacement on page 9‑1584.
Did you complete the replacement? Go to Step 17 —
Operate the system in order to verify the repair.
17
Did you correct the condition? System OK —

2014 - Spin Service Manual (5618083) - (Misc Draft) - 6/7/13

 Engine Mechanical - 1.3L (LDV) Diesel 9-1461
Drive Belt Rumbling and Vibration
Diagnosis
Object-ID=3405312 Owner=Youkhana, Karem LMD=16-Apr-2013 LMB=Smith, Craig

Diagnostic Aids
The accessory drive components can have an affect on
engine vibration. Vibration from the engine operating
may cause a body component or another part of the
vehicle to make rumbling noise. Vibration can be
caused by, but not limited to the A/C system over
charged, the power steering system restricted or the
incorrect fluid, or an extra load on the generator. To
help identify an intermittent or an improper condition,
vary the loads on the accessory drive components.
The drive belt may have a rumbling condition that can
not be seen or felt. Sometimes replacing the drive belt
may be the only repair for the symptom.
If replacing the drive belt, completing the diagnostic
table, and the noise is only heard when the drive belts
are installed, there might be an accessory drive
component with a failure. Varying the load on the
different accessory drive components may aid in
identifying which component is causing the rumbling
noise.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This test is to verify that the symptom is present
during diagnosing. Other vehicle components may
cause a similar symptom.
3. This test is to verify that one of the drive belts is
causing the rumbling noise or vibration. Rumbling
noise may be confused with an internal engine
noise due to the similarity in the description.
Remove only one drive belt at a time if the vehicle
has multiple drive belts. When removing the drive
belts the water pump may not be operating and the
engine may overheat. Also DTCs may set when
the engine is operating with the drive belts
removed.
4. Inspecting the drive belts is to ensure that they are
not causing the noise. Small cracks across the ribs
of the drive belt will not cause the noise. Belt
separation is identified by the plays of the belt
separating and may be seen at the edge of the belt
our felt as a lump in the belt.
5. Small amounts of pilling is normal condition and
acceptable. When the pilling is severe the drive
belt does not have a smooth surface for proper
operation.
9. Inspecting of the fasteners can eliminate the
possibility that the wrong bolt, nut, spacer,
or washer was installed.
11. This step should only be performed if the water
pump is driven by the drive belt. Inspect the water
pump shaft for being bent. Also inspect the water
pump bearings for smooth operation and
excessive play. Compare the water pump with a
known good water pump.
12. Accessory drive component brackets that are bent,
cracked, or loose may put extra strain on that
accessory component causing it to vibrate.
2014 - Spin Service Manual (5618083) - (Misc Draft) - 6/7/13
9-1462 Engine Mechanical - 1.3L (LDV) Diesel
Drive Belt Rumbling and Vibration Diagnosis
Step Action Yes No
DEFINITION: The following items are indications of drive belt rumbling:
• A low pitch tapping, knocking, or thumping noise heard at or just above idle.
• Heard once per revolution of the drive belt or a pulley.
• Rumbling may be caused from:
– Pilling, the accumulation of rubber dust that forms small balls (pills) or strings in the drive belt pulley groove
– The separation of the drive belt
– A damaged drive belt
DEFINITION: The following items are indications of drive belt vibration:
• The vibration is engine-speed related.
• The vibration may be sensitive to accessory load.
Did you review the Drive Belt Symptom operation and perform the Go to Symptoms -
1 necessary inspections? Engine Mechanical on
Go to Step 2 page 9‑1476
Verify that there is a rumbling noise or that the vibration is engine
2 related.
Does the engine make the rumbling noise or vibration? Go to Step 3 Go to Diagnostic Aids
1. Remove the drive belt.
If the engine has multiple drive belts, remove the belts one at a
time and perform the test below each time a belt is removed.
3 2. Operate the engine for no longer than 30–40 seconds.
3. Repeat this test if necessary by removing the remaining Go to Symptoms -
belt(s). Engine Mechanical on
Does the rumbling or vibration still exist? page 9‑1476 Go to Step 4
Inspect the drive belts for wear, damage, separation, sections of
4 missing ribs, and debris build-up.
Did you find any of these conditions? Go to Step 7 Go to Step 5
Inspect for severe pilling of more than 1/3 of the drive belt pulley
5 grooves.
Did you find severe pilling? Go to Step 6 Go to Step 7
1. Clean the drive belt pulleys using a suitable wire brush.
6 2. Reinstall the drive belts.
Did you correct the condition? Go to Step 8 Go to Step 7
Install a new drive belt.
7
Did you complete the replacement? Go to Step 8 Go to Step 9
Operate the system in order to verify the repair.
8
Did you correct the condition? System OK Go to Step 9
Inspect for improper, loose or missing fasteners.
9
Did you find any of these conditions? Go to Step 10 Go to Step 11
Caution: Refer to Fastener Caution on page 0‑9.
1. Tighten any loose fasteners. Refer to Fastener Tightening
10 Specifications on page 9‑1436.
2. Replace improper or missing fasteners.
Did you complete the repair? Go to Step 12 Go to Step 11
Inspect for bent or cracked brackets.
11
Did you find and correct the condition? Go to Step 12 Go to Diagnostic Aids

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1463
Drive Belt Rumbling and Vibration Diagnosis (cont'd)
Step Action Yes No
Operate the system in order to verify the repair.
12
Did you correct the condition? System OK Go to Step 3

Object-ID=3405334 Owner=Youkhana, Karem LMD=16-Apr-2013 LMB=Smith, Craig

Drive Belt Tensioner Diagnosis

Step Action Yes No
Caution: SIO-ID=2050155 LMD=21-Jan-2008 Allowing the drive belt tensioner to snap into the free position may result in damage to the
tensioner.
1. Remove the drive belt. Refer to Water Pump, Air Conditioning
Compressor, and Generator Belt Replacement on
1 page 9‑1584.
2. Inspect the drive belt tensioner pulley.
Is the drive belt tensioner pulley loose or misaligned? Go to Step 4 Go to Step 2
Rotate the drive belt tensioner.
2 Does the tensioner rotate without any unusual resistance or
binding? Go to Step 3 Go to Step 4
1. Use a torque wrench in order to measure the torque required to
move the tensioner off of the stop.
2. Use a torque wrench on a known good tensioner in order to
3 measure the torque required to move the tensioner off of
the stop.
Is the first torque reading within 10 percent of the second torque
reading? System OK Go to Step 4
Replace the drive belt tensioner. Refer to Drive Belt Tensioner
4 Replacement on page 9‑1537.
Is the repair complete? System OK —

Engine Compression Test

Object-ID=2370782 Owner=Thess, Stephan LMD=26-Apr-2013 LMB=Kuhse, Ben

Special Tools
• EN-46783 Thread Adapter
• EN-46791 Adapter, Compression Tool
For equivalent regional tools refer to Special Tools on
page 9‑1711.
Removal Procedure
1. Remove the fuel injection fuel feed pipe. Refer to
Fuel Injection Fuel Feed Pipe Removal - Fuel Rail
to Fuel Injector on page 9‑1637.
2. Remove the fuel injector. Refer to Fuel Injector
Removal on page 9‑1638.

2191259

Caution: Refer to CELL Link Error - Link target cell

(cell ID 256922) is invalid for this publication.
on page ?‑?.
Caution: Refer to CELL Link Error - Link target cell
(cell ID 256922) is invalid for this publication.
on page ?‑?.

2014 - Spin Service Manual (5618083) - (Misc Draft) - 6/7/13

9-1464 Engine Mechanical - 1.3L (LDV) Diesel
3. Clean the injector sealing surfaces in the cylinder Caution: Refer to Fastener Caution on page 0‑9.
head using EN-47632 cleaning tool (1) in following 4. Install fuel injector bracket nut and tighten to
procedure: 20 Y (15 lb ft).
• first take the brush side to loosen the dirt. 5. Install EN-46783 thread adapter (3) to EN-46791
• second take the sponge side to remove the dirt. adapter (1).

2027870 2192372

4. Remove the front compartment fuse block Note: Use a compression plotter with a measuring
cover (1). range of 10–40 bar(145- 580 PSI).
5. Remove the fuel pump relay. 6. Install compression plotter to EN-46783 thread
adapter.
Compression Test Cylinder 1 7. Connect the battery negative cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9‑53.
8. Check the compression of cylinder 1.
Note: A second technician is required.
Start engine for approximate 4 seconds.
Note: Engine speed at least 200 RPM.
9. Remove EN-46791 adapter (1) from cylinder 1.

2192351

Note: EN-46791 adapter can only be installed in pairs

along with the fuel injector (cylinder 1 and 2 or cylinder
3 and 4).
1. Install EN-46791 adapter (1) with fuel injector (2)
and fuel injector bracket in cylinder 1 with a NEW
fuel injector gasket.
2. Install fuel injector spherical washer
3. Install fuel injector conical washer
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 Engine Mechanical - 1.3L (LDV) Diesel 9-1465
Compression Test Cylinder 2 6. Install compression plotter to EN-46783 thread
adapter.
Note: A second technician is required.
7. Check the compression of cylinder 2.
Note: Engine speed at least 200 RPM.
8. Start engine for approximate 4 seconds.
Note: A second technician is required.
9. Check the compression of cylinder 2
10. Remove EN-46791 adapter (1) from cylinder 2.
Compression Test Cylinder 3

2192351

Note: EN-46791 adapter can only be installed in pairs

along with the fuel injector (cylinder 1 and 2 or cylinder
3 and 4).
1. Install EN-46791 adapter (1) with fuel injector (2)
and fuel injector bracket in cylinder 2 with a NEW
fuel injector gasket.
2. Install fuel injector spherical washer.
3. Install fuel injector conical washer.
Caution: Refer to Fastener Caution on page 0‑9.
4. Install fuel injector bracket nut and tighten to 2192351
20 Y (15 lb ft).
Note: EN-46791 adapter can only be installed in pairs
5. Install EN-46783 thread adapter (3) to EN-46791 along with the fuel injector (cylinder 1 and 2 or cylinder
adapter (1). 3 and 4).
1. Install EN-46791 adapter (1) with fuel injector (2)
and fuel injector bracket in cylinder 3 with a NEW
fuel injector gasket.
2. Install fuel injector spherical washer.
3. Install fuel injector conical washer.
Caution: Refer to Fastener Caution on page 0‑9.
4. Install fuel injector bracket nut and tighten to
20 Y (15 lb ft).
5. Install EN-46783 thread adapter (3) to EN-46791
adapter (1).

2192372

Note: Use a compression plotter with a measuring

range of 10-40 bar(145- 580 PSI).

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9-1466 Engine Mechanical - 1.3L (LDV) Diesel
3. Install fuel injector conical washer.
Caution: Refer to Fastener Caution on page 0‑9.
4. Install fuel injector bracket nut and tighten to
20 Y (15 lb ft).
5. Install EN-46783 thread adapter (3) to EN-46791
adapter (1).

2192372

Note: Use a compression plotter with a measuring

range of 10–40 bar(145- 580 PSI).
6. Install compression plotter to EN-46783 thread
adapter.
7. Check the compression of cylinder 3.
Note: A second technician is required.
2192372
Start engine for approximate 4 seconds. Note: Use a compression plotter with a measuring
Note: Engine speed at least 200 RPM. range of 10–40 bar(145- 580 PSI).
8. Remove EN-46791 adapter (1) from cylinder 3. 6. Install compression plotter to EN-46783 thread
adapter.
Compression Test Cylinder 4 7. Check the compression of cylinder 4
Note: A second technician is required.
Start engine for approximate 4 seconds.
Note: Engine speed at least 200 RPM.
8. Remove EN-46791 adapter (1) from cylinder 4.
Note: Maximum pressure difference 1.5 bar(22 PSI).
9. Compare compression values from cylinder 1–4
Installation Procedure
1. Disconnect the battery negative cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9‑53.
2. Install the fuel pump relay.

2192351

Note: EN-46791 adapter can only be installed in pairs

along with the fuel injector (cylinder 1 and 2 or cylinder
3 and 4).
1. Install EN-46791 adapter (1) with fuel injector (2)
and fuel injector bracket in cylinder 4 with a NEW
fuel injector gasket.
2. Install fuel injector spherical washer.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1467

2027870 2191259

3. Install the front compartment fuse block cover (1) Caution: Refer to CELL Link Error - Link target cell
(cell ID 256922) is invalid for this publication.
4. Install fuel Injector. Refer to Fuel Injector on page ?‑?.
Installation on page 9‑1695.
3. Clean the injector sealing surfaces in the cylinder
5. Install fuel Injection fuel feed pipe. Refer to Fuel head using EN-47632 cleaning tool (1) in following
Injection Fuel Feed Pipe Installation - Fuel Rail to procedure:
Fuel Injector on page 9‑1695.
3.1. Take the brush side to loosen the dirt.
Cylinder Leakage Test 3.2. Take the sponge side to remove the dirt.
Object-ID=2370784 Owner=Thess, Stephan LMD=26-Apr-2013 LMB=Kuhse, Ben

Special Tools
• EN-46791 Adapter, Compression Tool
• EN-46783 Thread Adapter
For equivalent regional tools, refer to Special Tools on
page 9‑1711.
Removal Procedure
1. Remove fuel injection fuel feed pipe. Refer to Fuel
Injection Fuel Feed Pipe Removal - Fuel Rail to
Fuel Injector on page 9‑1637.
2. Remove fuel injector. Refer to Fuel Injector
Removal on page 9‑1638.

2192181

4. Remove oil pump housing plug (1) from oil pump

housing (3).
5. Remove oil pump housing plug seal (2).

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9-1468 Engine Mechanical - 1.3L (LDV) Diesel

2191131 2192213

6. Remove camshaft position sensor bolt (1). Note: The marking is necessary to adjust the TDC of
the individual cylinders.
7. Remove camshaft position sensor (2).
9. Make a marking on the oil pump housing (1) and 4
check marks on the camshaft sprocket bolt (2).

2192212

Note: Second technician required.

2191131
8. Set cylinder 1 to TDC of combustion stroke.
10. Install camshaft position sensor (2).
Turn crankshaft in direction of engine rotation by
the crankshaft sprocket bolt until the rear edge of Caution: Refer to Fastener Caution on page 0‑9.
the elevation for the camshaft sensor (2) is aligned 11. Install camshaft position sensor bolt (1) and tighten
with the front edge of the installation aperture for to 9 Y (80 lb in).
the camshaft sensor (1). 12. Remove engine coolant surge tank cup.
13. Remove oil level indicator.
Test Procedure Cylinder 1
1. Calibrate pressure loss meter.
2. Engage 4th gear and put the handbrakes on.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1469
10. Check pressure loss in cylinder 1.
• Max. pressure difference between the individual
cylinders 10% approx.
• The pressure loss per cylinder should not
exceed 25%.
• Check escaping air to localize the damage on:
– Intake ducts
– Exhaust system
– Oil dipstick guide tube
– Oil filler port
11. Remove the fuel injector bracket nut cylinder 1
and 2.
12. Remove the fuel injector conical washer.
13. Remove the fuel injector spherical washer.
14. Remove the fuel injector cylinder 2 and pressure
loss tester with EN-46791 adapter from cylinder 1.
Test Procedure Cylinder 3
2192351 Note: EN-46791 adapter can only be installed in pairs
Note: EN-46791 adapter can only be installed in pairs along with the fuel injector, cylinder 1 and 2 or cylinder 3
along with the fuel injector, cylinder 1 and 2 or cylinder 3 and 4.
and 4. 1. Install the pressure loss tester with EN-46791
3. Install the pressure loss tester with EN-46791 adapter with fuel injector and fuel injector bracket
adapter (1) with fuel injector (2) and fuel injector in cylinder 3 with NEW fuel injector gasket.
bracket in cylinder 1 with NEW fuel injector gasket. 2. Install the fuel injector spherical washer.
4. Install the fuel injector spherical washer. 3. Install the fuel injector conical washer.
5. Install the fuel injector conical washer. 4. Install the fuel injector bracket nut and tighten to
6. Install fuel injector bracket nut and tighten to 20 Y (15 lb ft).
20 Y (15 lb ft). 5. Put the vehicle in neutral.
7. Install EN-46783 thread adapter (3) to EN-46791 6. Turn the engine 180° by crankshaft.
adapter (1). Note: Note the alignment marking on camshaft
sprocket bolt.
6.1. Turn the crankshaft in the direction of the
engine rotation by the bolt on the torsional
vibration damper flange
6.2. Engage the 4th gear.
7. Pressurize the cylinder 3.
8. Check the pressure loss in cylinder 3.
• Max. pressure difference between the individual
cylinders 10% approx.
• The pressure loss per cylinder should not
exceed 25%.
• Check escaping air to localize the damage on:
– Intake ducts
– Exhaust system
– Oil dipstick guide tube
– Oil filler port
9. Remove the fuel injector bracket nut cylinder 3
and 4.
2192352 10. Remove the fuel injector conical washer.
11. Remove the fuel injector spherical washer.
8. Install pressure loss tester (2) to EN-46783 thread
adapter (1). 12. Remove the fuel injector cylinder 4 and pressure
loss tester with EN-46791 adapter from cylinder 3.
9. Pressurize cylinder 1.

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9-1470 Engine Mechanical - 1.3L (LDV) Diesel
Test Procedure Cylinder 4 7. Pressurize cylinder 2.
Note: EN-46791 adapter can only be installed in pairs 8. Check pressure loss in cylinder 2.
along with the fuel injector, cylinder 1 and 2 or cylinder 3 • Max. pressure difference between the individual
and 4. cylinders 10% approx.
1. Install the pressure loss tester with EN-46791 • The pressure loss per cylinder should not
adapter with fuel injector and fuel injector bracket exceed 25%.
in cylinder 4 with NEW fuel injector gasket. • Check escaping air to localize the damage on:
2. Install the fuel injector spherical washer. – Intake ducts
3. Install the fuel injector conical washer. – Exhaust system
4. Install fuel injector bracket nut and tighten to – Oil dipstick guide tube
20 Y (15 lb ft). – Oil filler port
5. Put the vehicle in neutral. 9. Remove the fuel injector bracket nut cylinder 1
6. Turn the engine 180° by crankshaft. and 2.
Note: Note alignment marking on camshaft 10. Remove the fuel injector conical washer.
sprocket bolt. 11. Remove the fuel injector spherical washer.
• Turn crankshaft in the direction of the engine 12. Remove the fuel injector cylinder 1 and pressure
rotation by the bolt on the torsional vibration loss tester with EN-46791 adapter from cylinder 2.
damper flange
• Engage 4th gear
Installation Procedure
7. Pressurize cylinder 4. 1. Install the oil level indicator.
8. Check pressure loss in cylinder 4: 2. Install the engine coolant surge tank cup.
• Max. pressure difference between the individual
cylinders 10% approx.
• The pressure loss per cylinder should not
exceed 25%.
• Check escaping air to localize the damage on:
– Intake ducts
– Exhaust system
– Oil dipstick guide tube
– Oil filler port
9. Remove the fuel injector bracket nut cylinder 3
and 4.
10. Remove the fuel injector conical washer.
11. Remove the fuel injector spherical washer.
12. Remove the fuel injector cylinder 3 and pressure
loss tester with EN-46791 adapter from cylinder 4.
Test Procedure Cylinder 2
Note: EN-46791 adapter can only be installed in pairs
along with the fuel injector, cylinder 1 and 2 or cylinder 3
and 4. 2192181

1. Install the pressure loss tester with EN-46791 3. Install oil pump housing plug seal (2).
adapter with fuel injector and fuel injector bracket 4. Install the oil pump housing plug (1) from oil pump
in cylinder 2 with NEW fuel injector gasket. housing (3) and tighten with 22 Y (16 lb ft).
2. Install the fuel injector spherical washer. 5. Install the fuel Injector. Refer to Fuel Injector
3. Install the fuel injector conical washer. Installation on page 9‑1695.
4. Install the fuel injector bracket nut and tighten to 6. Install the fuel Injection fuel feed pipe. Refer to
20 Y (15 lb ft). Fuel Injection Fuel Feed Pipe Installation - Fuel
5. Put the vehicle in neutral. Rail to Fuel Injector on page 9‑1695.
6. Turn the engine 180° by crankshaft.
Note: Note alignment marking on camshaft
sprocket bolt.
6.1. Turn the crankshaft in the direction of the
engine rotation by the bolt on the torsional
vibration damper flange
6.2. Engage the 4th gear.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1471
Object-ID=2370743 Owner=Thess, Stephan LMD=25-Nov-2009 LMB=Thess, Stephan

Engine Noise on Start-Up, but Only Lasting a Few Seconds

Cause Correction
Incorrect oil filter without anti-drainback feature Install the correct oil filter.
Incorrect oil viscosity Drain the engine oil and replace with the correct viscosity oil.
High stationary hydraulic lash adjuster (SHLA), valve lifter, leak Replace the SHLAs, valve lifters, as required.
down rate
Worn crankshaft thrust bearing • Inspect the thrust bearing and crankshaft.
• Repair or replace as required.
Damaged or faulty oil filter by-pass valve • Inspect the oil filter by-pass valve for proper operation.
• Repair or replace as required.

Object-ID=2370744 Owner=Thess, Stephan LMD=25-Nov-2009 LMB=Thess, Stephan

Engine Noise Under Load

Cause Correction
Low oil pressure Insufficient or poor oil supply to components.
1. Perform oil pressure test.
2. Repair or replace all damaged components.
Loose and/or damaged flywheel 1. Inspect the flywheel and flywheel attaching bolts.
2. Repair or replace all damaged components.
Excessive piston‐to‐cylinder bore 1. Inspect the piston rings for low ring tension, broken or worn rings, inspect
clearance cylinder bore.
2. Repair or replace all damaged components.
Excessive crankshaft thrust bearing 1. Inspect the crankshaft end play and crankshaft thrust bearings.
clearance 2. Repair or replace all damaged components.
Excessive crankshaft bearing 1. Inspect the crankshaft bearings and crankshaft journals.
clearance 2. Repair or replace all damaged components.

Object-ID=2370745 Owner=Thess, Stephan LMD=25-Nov-2009 LMB=Thess, Stephan

Engine Will Not Crank - Crankshaft Will Not Rotate

Cause Correction
Seized accessory drive system 1. Inspect the accessory drive system components.
component 2. Repair or replace all damaged components.
Hydraulically locked cylinder 1. Inspect for broken head gasket(s).
• Coolant/antifreeze in cylinder 2. Inspect for cracked engine block or cylinder head.
• Oil in cylinder 3. Inspect for a sticking fuel injector.
• Fuel in cylinder
Seized manual transmission 1. Disengage the clutch.
2. Rotate crankshaft at the pulley.
Material in cylinder • Inspect the cylinder for damaged components and/or foreign materials.
• Broken valve • Repair or replace as required.
• Piston material
• Foreign material
Seized crankshaft or connecting rod • Inspect the crankshaft and connecting rod bearings.
bearing • Repair as required.
Bent or broken connecting rod • Inspect the connecting rods
• Repair as required.
Broken crankshaft • Inspect the crankshaft.
• Repair as required.

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9-1472 Engine Mechanical - 1.3L (LDV) Diesel
Fuel in Engine Oil
Object-ID=2370746 Owner=Thess, Stephan LMD=25-Nov-2009 LMB=Thess, Stephan

DEFINITION: If fuel is suspected of leaking into the

crankcase, the following procedure should be
performed to verify the condition.
• Remove the oil level indicator and allow oil to drop
onto a clean white paper towel.
• If the oil is diluted with fuel, it will become apparent
as the towel wicks the fuel away from the drop of
oil on the towel. The fuel will expand out in a ring
around the oil droplet.
• If fuel dilution is apparent, inspect the vehicle for
aftermarket performance accessories that may
cause damage to the injection pump. After repairs
are completed, perform the test again to verify the
condition is corrected.
• If no fuel dilution is present, verify the oil level and
correct as needed.
Object-ID=2370747 Owner=Thess, Stephan LMD=25-Nov-2009 LMB=Thess, Stephan

Lower Engine Noise, Regardless of Engine Speed

Condition Action
Worn accessory drive components 1. Inspect the accessory drive components.
(abnormalities such as severe 2. Repair or replace all damaged components.
cracking, bumps or missing areas in
the accessory drive belt and / or
misalignment of the system
components.)
Low oil pressure Insufficient or poor oil supply to crankshaft and connecting rod bearings.
1. Perform oil pressure test.
2. Repair or replace all damaged components.
Leaking and/or sticking fuel injection 1. Inspect the cylinder balance with scan tool to help locate the cylinder that is the
nozzle (A stuck fuel injection nozzle source of the noise.
can cause a noise similar to a 2. If you cannot locate the cylinder that is the source of the noise, diagnose the
damaged piston, rod or rod bearing.) engine for mechanical damage.
3. If it has been determined that the fuel injection nozzle is causing the noise,
replace the fuel injection nozzle.
Loose and/or damaged crankshaft 1. Inspect crankshaft pulley and pulley bolt.
pulley 2. Repair or replace all damaged components.
Loose and/or damaged flywheel 1. Inspect flywheel and flywheel attaching bolts.
2. Repair or replace all damaged components.
Excessive piston pin‐to‐bore 1. Inspect the piston, piston pin, and the connecting rod.
clearance 2. Repair or replace all damaged components.
Misaligned or bent connecting rod 1. Inspect connecting rod and connecting rod bearings.
2. Repair or replace all damaged components.
Excessive connecting rod bearing 1. Inspect the connecting rod bearings, connecting rods, crankshaft and crankshaft
clearance journals.
2. Repair or replace all damaged components.
Excessive crankshaft bearing 1. Inspect the crankshaft bearings and crankshaft journals.
clearance 2. Repair or replace all damaged components.

Oil Pressure Diagnosis and Testing For equivalent regional tools, refer to Special Tools on
page 9‑1711.
Object-ID=2370785 Owner=Thess, Stephan LMD=03-Aug-2010 LMB=Thess, Stephan

Removal Procedure
Special Tools 1. Open the hood.
• GE-498-B Oil Pressure Gage 2. Remove the engine sight shield. Refer to Engine
• EN-135 Adapter Oil Pressure Check Sight Shield Replacement on page 9‑1577.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1473
3. Disconnect the oil pressure sensor wiring Installation Procedure
harness plug.
Caution: Refer to Fastener Caution on page 0‑9.
1. Install the oil pressure sensor and a NEW seal ring
and tighten to 32 Y (24 lb ft).
2. Connect the oil pressure sensor wiring
harness plug.
3. Install the engine sight shield. Refer to Engine
Sight Shield Replacement on page 9‑1577.
4. Close the hood.

Oil Consumption Diagnosis

Object-ID=2370748 Owner=Thess, Stephan LMD=17-Aug-2012 LMB=Hinzmann, Rene

Explanation
Note: Oil consumption for a combustion engine refers
to the amount of oil consumed as a result of the
combustion process. Oil consumption is not to be
equated with oil loss resulting from leaks from
components such as the oil pan and cylinder head
cover.
• The role of the engine oil is to:
2192389
1. Separate surfaces that slide against each
4. Remove the oil pressure sensor (1) and the other by means of an oil film, i.e. to prevent
seal ring. dry friction.
2. Dissipate heat generated by friction.
Measurement Procedure 3. Lead away combustion residue.
• This task involves the consumption of a certain
amount of oil. It is therefore wrong to assume that
future enhancements of the combustion engine
may produce an engine which has zero oil
consumption.
• Outside operating conditions, driving style and
manufacturing tolerances do, however, have an
impact on oil consumption.
• It is imperative that oil be filled when the level has
fallen below the "MIN" mark on the dipstick.
• It is also important to ensure that the oil level is not
above the "MAX" mark on the dipstick as this
could result in increased oil consumption.
• As oil consumption is affected by technical factors,
the conclusion is reached that the engine does not
consume oil in special operating conditions that
lead to oil dilution.
• During conditions such as frequent cold starts and
driving before the engine reaches operating
temperature, it is only the oil flowing back to the oil
2192391
pan that carries away scalding fuel components
and precipitates. This "dilutes" the oil and leads to
1. Install the EN-135 adapter (2). the erroneous assumption that the engine
2. Install the GE-498-B gage (1) to the EN-135 consumes no oil.
adapter (2). • Such diluted oil loses its ability to lubricate and
3. Start the engine. could cause engine damage if the prescribed oil
change intervals are not observed.
4. Check the oil pressure. At idle speed, the oil
pressure must be higher than 100 kPa (1 bar) and • Driving in predominately urban traffic and
the oil temperature must be 80°C (170°F) or more. frequently running a cold engine at rpms above
idle speed are the main causes of oil dilution.
5. Turn off the engine.
6. Remove the GE-498-B gage.
7. Remove the EN-135 adapter.

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9-1474 Engine Mechanical - 1.3L (LDV) Diesel
• As oil consumption does not stabilize until after a
few thousand kilometers of travel, oil consumption
measurements are not reliable until after a
distance of about 7,500 km.
• The oil standard is merely used for monitoring and
cannot be used for measurement purposes. In
principle, the engine must have stopped for at
least 5 minutes or 10 minutes before checking the
oil level. If the maximum amount of oil added
during an oil change does not agree with the max.
on the oil dip stick, then this will be accounted for
by the necessary manufacturing tolerances.
Meassuring Procedure
Note: All information on permissible engine oil
consumption and capacities are found in the Owner's
Manual.
1. Before measuring consumption, ensure that the
engine is not losing oil due to leakage.
2. The check is carried out with the vehicle parked on
a level surface with the engine at operating
temperature (engine oil temperature at least 80
°C).
3. Drain the engine oil immediately after switching off
the engine - drainage time = approx. 30 minutes
(this value has been obtain through technical
trials).
4. The quantity of drained engine oil is determined via
a measuring container. The container is then filled
with fresh oil up to the maximum engine oil
capacity minus the volume remaining in the
unchanged oil filter.
5. With this engine oil quantity, the customer should
be able to travel at 1000 km without needing to top
up engine oil (the distance profile and customer
driving style should be maintained).
6. Then, the preceding procedure (points 1 and 2)
should be repeated with the exact same engine
drainage time.
7. The oil quantity now "missing" from the measuring
container is equal to the engine oil consumption for
that distance.
8. Oil consumption is calculated as follows:
• (filled oil quantity (l) – drained oil quantity (l)) /
total distance driven (km) x 1000 = oil
consumption (l/1000 km)
Object-ID=2370749 Owner=Thess, Stephan LMD=22-Jan-2010 LMB=Thess, Stephan

Oil Leak Diagnosis

Step Action Yes No
Caution: SIO-ID=2052166 LMD=24-Jan-2008 Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the
composition of the drive belt. Failure to follow this recommendation will damage the drive belt.
DEFINITION: You can repair most fluid leaks by first, visually locating the leak, repairing or replacing the component, or by
resealing the gasket surface. Once the leak is identified, determine the cause of the leak. Repair the cause of the leak as well as
the leak itself.
1. Operate the vehicle until it reaches normal operating
temperature. Refer to Engine Mechanical Specifications on
page 9‑1438.
1 2. Park the vehicle on a level surface, over a large sheet of paper
or other clean surface.
3. Wait 15 minutes.
4. Check for drippings. Go to Step 2 System OK

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1475
Oil Leak Diagnosis (cont'd)
Step Action Yes No
Are drippings present?
Can you identify the type of fluid and the approximate location of
2
the leak? Go to Step 10 Go to Step 3
1. Visually inspect the suspected area. Use a small mirror to
assist in looking at hard-to-see areas.
2. Check for leaks at the following locations:
• Sealing surfaces
3
• Fittings
• Cracked or damaged components
Can you identify the type of fluid and the approximate location of
the leak? Go to Step 10 Go to Step 4
1. Completely clean the entire engine and surrounding
components.
2. Operate the vehicle for several miles at normal operating
temperature and at varying speeds.
3. Park the vehicle on a level surface, over a large sheet of paper
4 or other clean surface.
4. Wait 15 minutes.
5. Identify the type of fluid, and the approximate location of
the leak.
Can you identify the type of fluid and the approximate location of
the leak? Go to Step 10 Go to Step 5
1. Visually inspect the suspected area. Use a small mirror to
assist in looking at hard to see areas.
2. Check for leaks at the following locations:
• Sealing surfaces
5
• Fittings
• Cracked or damaged components
Can you identify the type of fluid and the approximate location of
the leak? Go to Step 10 Go to Step 6
1. Completely clean the entire engine and surrounding
components.
2. Apply an aerosol-type powder, for example, baby powder or
foot powder, to the suspected area.
6 3. Operate the vehicle for several miles at normal operating
temperature and at varying speeds.
4. Identify the type of fluid, and the approximate location of the
leak, from the discolorations in the powder surface.
Can you identify the type of fluid and the approximate location of
the leak? Go to Step 10 Go to Step 7
1. Visually inspect the suspected area. Use a small mirror to
assist in looking at hard to see areas.
2. Check for leaks at the following locations:
• Sealing surfaces
7
• Fittings
• Cracked or damaged components
Can you identify the type of fluid and the approximate location of
the leak? Go to Step 10 Go to Step 8
Use GE-42220 Lamp, 12 Volt UV in order to identify the type of fluid,
and the approximate location of the leak. Refer to the
8 manufacturer's instructions when using the tool.
Can you identify the type of fluid and the approximate location of
the leak? Go to Step 10 Go to Step 9

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9-1476 Engine Mechanical - 1.3L (LDV) Diesel
Oil Leak Diagnosis (cont'd)
Step Action Yes No
1. Visually inspect the suspected area. Use a small mirror to
assist in looking at hard to see areas.
2. Check for leaks at the following locations:
• Sealing surfaces
9
• Fittings
• Cracked or damaged components
Can you identify the type of fluid and the approximate location of
the leak? Go to Step 10 System OK
1. Inspect the engine for mechanical damage. Special interest
should be shown to the following areas:
2. Inspect the engine for customer modifications.
• Higher than recommended fluid levels
• Higher than recommended fluid pressures
• Plugged or malfunctioning fluid filters or pressure bypass
valves
10 • Improperly tightened or damaged fasteners
• Cracked or porous components
• Improper sealants or gaskets where required
• Improper sealant or gasket installation
• Damaged or worn gaskets or seals
• Damaged or worn sealing surfaces
Is there mechanical damage, or customer modifications to the
engine? Go to Step 11 System OK
Repair or replace all damaged or modified components.
11 —
Did you complete the repair? Go to Step 1

Symptoms - Engine Mechanical • Verify the exact operating conditions under which
the concern exists. Note factors such as engine
Object-ID=2370750 Owner=Thess, Stephan LMD=25-Nov-2009 LMB=Thess, Stephan
RPM, ambient temperature, engine temperature,
amount of engine warm-up time, and other
Strategy Based Diagnostics specifics.
1. Perform a diagnostic system check before using • Compare the engine sounds, if applicable, to a
the symptom tables, if applicable. known good engine and make sure you are not
2. Review the system operations in order to trying to correct a normal condition.
familiarize yourself with the system functions. Intermittent
Refer to Disassembled Views on page 9‑1441,
Engine Component Description on page 9‑1709, Test the vehicle under the same conditions that the
Lubrication Description on page 9‑1710. customer reported in order to verify the system is
operating properly.
All diagnosis on a vehicle should follow a logical
process. Strategy based diagnostics is a uniform Symptom List
approach for repairing all systems. The diagnostic flow
may always be used in order to resolve a system Refer to a symptom diagnostic procedure from the
problem. The diagnostic flow is the place to start when following list in order to diagnose the symptom:
repairs are necessary. • Base Engine Misfire without Internal Engine
Noises on page 9‑1454
Visual/Physical Inspection • Base Engine Misfire with Abnormal Internal Lower
• Inspect the easily accessible or visible system Engine Noises on page 9‑1453
components for obvious damage or conditions • Base Engine Misfire with Abnormal Valve Train
which could cause the symptom. Noise on page 9‑1453
• Check for the correct oil level, proper oil viscosity, • Base Engine Misfire with Coolant Consumption on
and correct filter application. page 9‑1453
• Base Engine Misfire with Excessive Oil
Consumption on page 9‑1454
• Upper Engine Noise, Regardless of Engine Speed
on page 9‑1455
• Lower Engine Noise, Regardless of Engine Speed
on page 9‑1472

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1477
• Engine Will Not Crank - Crankshaft Will Not
Rotate on page 9‑1471
• Engine Compression Test on page 9‑1463
• Oil Consumption Diagnosis on page 9‑1473
• Oil Pressure Diagnosis and Testing on
page 9‑1472
• Turbocharger Whine Noise on page 9‑1478
• Turbocharger Hissing Noise on page 9‑1477
• Turbocharger Oil Leak From Compressor Seal on
page 9‑1477
• Turbocharger Oil Leak From Turbine Seal on
page 9‑1477
• Turbocharger Lack of Oil Supply on page 9‑1477
• Drive Belt Chirping, Squeal, and Whine Diagnosis
on page 9‑1456
• Drive Belt Rumbling and Vibration Diagnosis on
page 9‑1461
• Drive Belt Falls Off and Excessive Wear
Diagnosis on page 9‑1458
Object-ID=2370751 Owner=Thess, Stephan LMD=25-Nov-2009 LMB=Thess, Stephan

Turbocharger Hissing Noise

Condition Action
Air inlet leaks or obstructions Inspect the turbocharger inlet pipes/hoses for leaks or obstructions.
Leaking charge air cooler/pipes/hoses Inspect the charge air cooler/pipes/hoses for leaks or obstructions.
Leaking or restricted exhaust system 1. Inspect the exhaust system for a leak.
2. Inspect the exhaust system for a restrictions.
Intake system leaks or obstructions 1. Inspect the intake manifold for a leak.
2. Inspect the intake manifold for restrictions.

Object-ID=2370752 Owner=Thess, Stephan LMD=25-Nov-2009 LMB=Thess, Stephan

Turbocharger Lack of Oil Supply

Condition Action
Restricted oil supply pipe Inspect for restricted turbocharger oil supply pipe.
Leakage of oil at the oil supply pipe Inspect for the turbocharger oil supply pipe.

Object-ID=2370753 Owner=Thess, Stephan LMD=13-Mar-2012 LMB=Schulte, Jill

Turbocharger Oil Leak From Compressor Seal

Condition Action
Note: Oil in the turbocharger air inlet pipe, oil on the compressor wheel, and oil throughout the charge air cooler system is
normal with a closed PCV system. Do not attempt repairs for this condition.
Restricted air system Inspect for clogged air filter element or restricted air inlet system.
Restricted exhaust system Inspect for a restricted exhaust.
Leaking exhaust system Inspect for exhaust manifold leaks.
Poor oil drainage from turbocharger Inspect for restricted turbocharger oil drain pipe.
Restricted crankcase ventilation Inspect for restricted crankcase ventilation system.
system
Worn internal engine components Inspect for excessive blowby or engine oil consumption.

Object-ID=2370754 Owner=Thess, Stephan LMD=25-Nov-2009 LMB=Thess, Stephan

Turbocharger Oil Leak From Turbine Seal

Condition Action
Poor oil drainage from turbocharger Inspect for a restricted turbocharger oil drain pipe.

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9-1478 Engine Mechanical - 1.3L (LDV) Diesel
Turbocharger Oil Leak From Turbine Seal (cont'd)
Condition Action
Restricted crankcase ventilation Inspect for a restricted crankcase ventilation system.
system
Worn internal engine components Inspect for excessive blowby or engine oil consumption.

Object-ID=2370755 Owner=Thess, Stephan LMD=03-Aug-2010 LMB=Thess, Stephan

Turbocharger Whine Noise

Condition Action
Some whine noise is normal. Compare to a known good vehicle.
Leaking charge air cooler/pipes/hoses Inspect for leaks in charge air cooler/pipes/hoses.
Worn turbocharger bearings • Inspect the turbocharger bearings. Refer to Turbocharger Lack of Oil Supply on
page 9‑1477.
• If the turbocharger bearings are worn or damaged, repair or replace the
turbocharger.
Intake system leaks or obstructions Inspect the intake manifold for leaks or obstructions.

3. Remove the fuel injection pump (2). Refer to Fuel

Repair Instructions - On Vehicle Injection Pump Replacement on page 9‑742.

Exhaust Camshaft Replacement

Object-ID=2551938 Owner=Youkhana, Karem LMD=23-Feb-2011 LMB=Youkhana, Karem

Special Tools
EN-46781 Fixing Tool
For equivalent regional tools, refer to Special Tools on
page 9‑1711.
Removal Procedure
1. Remove the camshaft housing cover gasket. Refer
to Camshaft Housing and Cover Gasket
Replacement on page 9‑1484.

2191131

4. Remove the camshaft position sensor bolt (1).

5. Remove the camshaft position sensor (2). Refer to
Camshaft Position Sensor Replacement on
page 9‑707.

2190846

Note: Do not tilt the fuel injection pump actuator (1) at

the timing gear groove (4).
2. Remove the fuel injection pump bolts (3).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1479

2190960 2190962

6. Remove the exhaust cylinder head core hole Note: EN-46781 fixing tool (1) must be install in
plug (2) from camshaft housing (1). horizontal position.
7. Remove the intake cylinder head core hole plug (3) 10. Install the EN-46781 fixing tool (1) onto the
from camshaft housing (1). exhaust side and intake side.
8. Clean the threads from cylinder head core hole
plugs and camshaft housing.

2551946

11. Remove the exhaust camshaft sprocket bolt (1).

2190961
12. Remove the exhaust camshaft sprocket (2).
9. Mark the location as shown above EN-46781 fixing 13. Remove the EN-46781 fixing tool on the
tool (1). exhaust side.

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9-1480 Engine Mechanical - 1.3L (LDV) Diesel

2551948 2551946

14. Remove the exhaust camshaft (1). 2. Install the EN-46781 fixing tool on the
exhaust side.
Installation Procedure 3. Install the exhaust camshaft sprocket (2).
Caution: Refer to Fastener Caution on page 0‑9.
4. Install the exhaust camshaft sprocket bolt (1) and
tighten to 150 Y (111 lb ft).
5. Remove the EN-46781 fixing tool from the
exhaust side.

2551948

1. Install the exhaust camshaft (1).

Note: Clean the contact surfaces from camshaft,
camshaft sprocket and camshaft sprocket bolt.
Coat the camshaft bearing surfaces with engine oil.
2190960

6. Install the exhaust cylinder head core hole plug (2)

and intake cylinder head core hole (3) to the
camshaft housing (1) and tighten to
15 Y (11 lb in)

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1481
Camshaft Exhaust Sprocket
Replacement
Object-ID=2551954 Owner=Youkhana, Karem LMD=07-Feb-2011 LMB=Youkhana, Karem

Special Tools
EN-46781 Fixing Tool
For equivalent regional tools, refer to Special Tools on
page 9‑1711.
Removal Procedure
1. Remove the camshaft housing cover gasket. Refer
to Camshaft Housing and Cover Gasket
Replacement on page 9‑1484.

2191131

7. Install the camshaft position sensor (2).

8. Install the camshaft position sensor bolt (1) and
tighten to 9 Y (80 lb in). Refer to Camshaft
Position Sensor Replacement on page 9‑707.

2190846

Note: Do not tilt the fuel injection pump actuator (1) at

the timing gear groove (4).
2. Remove the fuel injection pump bolts (3).
3. Remove the fuel injection pump (2). Refer to Fuel
Injection Pump Replacement on page 9‑742.

2190846

9. Install a NEW fuel injection pump seal.

Note: Do not tilt the fuel injection pump actuator (1) at
timing gear groove (4).
10. Install the fuel injection pump (2).
11. Install the fuel injection pump bolts (3) and tighten
to 15 Y (11 lb ft). Refer to Fuel Injection Pump
Replacement on page 9‑742.
12. Connect the wiring harness plug to the fuel
injection pump.
13. Install the camshaft housing cover gasket. Refer to
Camshaft Housing and Cover Gasket
Replacement on page 9‑1484.

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9-1482 Engine Mechanical - 1.3L (LDV) Diesel

2191131 2190961

4. Remove the camshaft position sensor bolt (1). 9. Mark the location as show above EN-46781 fixing
5. Remove the camshaft position sensor (2). Refer to tool (1).
Camshaft Position Sensor Replacement on
page 9‑707.

2190962

Note: EN-46781 fixing tool (1) must be install in

2190960 horizontal position.
6. Remove the exhaust cylinder head core hole 10. Install the EN-46781 fixing tool (1) onto the
plug (2) from camshaft housing (1). exhaust side and intake side.
7. Remove the intake cylinder head core hole plug (3)
from camshaft housing (1).
8. Clean the threads from cylinder head core hole
plugs and camshaft housing.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1483

2551946 2190960

11. Remove the exhaust camshaft sprocket bolt (1). 5. Install the exhaust cylinder head core hole plug (2)
12. Remove the exhaust camshaft sprocket (2). and intake cylinder head core hole (3) to the
camshaft housing (1) and tighten to
13. Remove the EN-46781 fixing tool on the 15 Y (11 lb in).
exhaust side.
Installation Procedure
Note: Clean the contact surfaces from camshaft,
camshaft sprocket and camshaft sprocket bolt.
Coat the camshaft bearing surfaces with engine oil.

2191131

6. Install the camshaft position sensor (2).

7. Install the camshaft position sensor bolt (1) and
tighten to 9 Y (80 lb in). Refer to Camshaft
Position Sensor Replacement on page 9‑707.
2551946

1. Install the EN-46781 fixing tool on the

exhaust side.
2. Install the exhaust camshaft sprocket (2).
Caution: Refer to Fastener Caution on page 0‑9.
3. Install the exhaust camshaft sprocket bolt (1) and
tighten to 150 Y (111 lb ft).
4. Remove the EN-46781 fixing tool from the
exhaust side.

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9-1484 Engine Mechanical - 1.3L (LDV) Diesel

2190846 2666291

8. Install a NEW fuel injection pump seal. 2. Remove the air cleaner outlet (1). Refer to Air
Note: Do not tilt the fuel injection pump actuator (1) at Cleaner Outlet Duct Replacement on page 9‑703.
timing gear groove (4).
9. Install the fuel injection pump (2).
10. Install the fuel injection pump bolts (3) and tighten
to 15 Y (11 lb ft). Refer to Fuel Injection Pump
Replacement on page 9‑742.
11. Connect the wiring harness plug to the fuel
injection pump.
12. Install the camshaft housing cover gasket. Refer to
Camshaft Housing and Cover Gasket
Replacement on page 9‑1484.

Camshaft Housing and Cover Gasket

Replacement
Object-ID=2857547 Owner=Youkhana, Karem LMD=07-Nov-2012 LMB=Youkhana, Karem

Special Tools
• EN-328-B Slide Hammer
• EN-955-1 Locking Tool
• EN-6015 Plug 2563036
• EN-46781 Fixing Tool
3. Remove the air cleaner assembly (1). Refer to Air
• EN-46785 Fixing Tool Cleaner Assembly Replacement on page 9‑706.
• EN-46786 Remover
• EN-47632 Cleaning Tool
• EN-48244 Engine Assembly Remove/Install
Pallet Supporter
• EN-48559 Protective Caps
• EN-49802 Cradle Supporter
• EN-50620 Powertrain Supporters
• EN-51070 Engine Mount Simulator
For equivalent regional tools, refer to Special Tools on
page 9‑1711.
Removal Procedure
1. Remove the engine sight shield. Refer to Engine
Sight Shield Replacement on page 9‑1577.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1485

2371706 2371708

4. Disconnect the air conditioning compressor wiring 12. Disconnect the (ECM) electrical wiring harness
harness plug (3). connectors from the engine control module.
5. Disconnect the exhaust temperature sensor wiring 13. Disconnect the 4 fuel injector wiring harness
harness plug (5). plugs (8).
6. Unclip the retainer clip (4) from the exhaust 14. Disconnect the fuel rail sensor wiring harness
temperature sensor wiring harness bracket. plug (1).
7. Disconnect the turbocharger wastegate sensor 15. Disconnect the manifold absolute pressure sensor
wiring harness plug (2). wiring harness plug (2).
8. Unclip the retainer clip (6) from the oil filter 16. Disconnect the oxygen sensor wiring harness
housing. plug (3).
9. Disconnect the turbocharger wastegate actuator 17. Disconnect the exhaust pressure sensor wiring
vacuum control solenoid valve wiring harness harness plug (4).
plug (1). 18. Disconnect the throttle body wiring harness
10. Unclip the retainer clip from the turbocharger plug (5).
wastegate actuator vacuum control solenoid valve 19. Remove the 2 wiring harness bracket bolts (6).
bracket.
20. Disconnect the glow plug wire wiring harness
11. Unclip the 3 retainer clips from: plug (7).
• Engine lift bracket (5) 21. Disconnect the mass airflow sensor wiring
• Engine sight shield stud bracket (4) harness plug.
• Oil filler tube (2) 22. Disconnect the oil temperature sensor wiring
harness plug from the oil temperature sensor.
23. Disconnect the crankshaft position sensor wiring
harness plug from the crankshaft position sensor.
24. Remove the turbocharger. Refer to Turbocharger
Replacement on page 9‑1578.

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9-1486 Engine Mechanical - 1.3L (LDV) Diesel

2552576

25. Remove the charge air cooler outlet pipe (2) to

throttle body (3) bolts (1).
26. Remove the fuel return hose diesel fuel separator
to injection pump. Refer to Fuel Return Hose
Replacement - Diesel Fuel Separator to Injection
Pump on page 9‑751.

2552471
27. Disconnect the fuel feed front pipe (1). Refer to
Fuel Feed Front Pipe Replacement on page 9‑733.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1487

2190846 2190824

Note: Do not tilt the fuel injection pump actuator (1) at 32. Remove the vacuum pump bolts (2).
the timing gear groove (4).
33. Remove the vacuum pump (1).
28. Remove the fuel injection pump bolts (3). Note: Do not tilt the vacuum pump actuator at the
29. Remove the fuel injection pump (2). Refer to Fuel timing gear groove (3).
Injection Pump Replacement on page 9‑742.
34. Remove the vacuum pump gasket.

2191131
2190867
30. Remove the camshaft position sensor bolt (1).
35. Remove the fuel injection fuel rail (3). Refer to Fuel
31. Remove the camshaft position sensor (2). Refer to Injection Fuel Rail Assembly Replacement on
Camshaft Position Sensor Replacement on page 9‑766.
page 9‑707.

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9-1488 Engine Mechanical - 1.3L (LDV) Diesel
45. Remove the fuel Injectors (1) with the 2 fuel injector
brackets (7).
46. Remove the fuel injector seals (5).
47. Close the Injector nozzles with the
EN-48559 caps.
48. Remove the fuel injector gaskets (6) from the
camshaft housing.

2190819

36. Unclip in the 4 fuel infector fuel return hose retainer

springs (6).
37. Remove the fuel injector fuel return hose (1) to the
4 fuel infectors.
38. Remove the fuel return hose clamp (5).
39. Remove the fuel return hose (2) from the fuel
infector pump.
2191136
40. Remove the fuel separator bolt (4).
41. Remove the fuel injector fuel return hose with the 49. Remove the glow plug wire (1). Refer to Glow Plug
fuel separator (3). Wire Replacement on page 9‑761.

2190504
2190870

42. Remove the fuel injector bracket nuts (2). 50. Disconnect the positive crankcase ventilation pipe
connector (3) from the positive crankcase
43. Remove the fuel injector conical washers (3). ventilation oil separator.
44. Remove the fuel injector spherical washers (4). 51. Disconnect the positive crankcase ventilation pipe
Note: Injectors are to be removed only in pairs. If the connector wiring harness plug.
Injectors does not removed by hand use the EN-46786 52. Remove the vacuum hose from the turbocharger
remover with the EN-328-B hammer. wastegate actuator vacuum control solenoid valve.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1489
53. Remove the positive crankcase ventilation pipe
bracket bolts (2).
54. Remove the positive crankcase ventilation pipe (1).
55. Position the EN-49802 cradle supporter with
EN-50620 powertrain supporters, and EN-48244
engine assembly remove/install pallet supporter.

2191981

62. Remove the intake camshaft housing core hole

plug (1) from the camshaft housing.
63. Clean the threads at the camshaft housing and the
camshaft housing core hole plug.

2563005

56. Mark the location of the bolts (1) before removing.

57. Remove the right side engine mount bolts (1) and
mount . Refer to Engine Mount Replacement on
page 9‑1538.

2190961

64. Mark the location as shown above (1) the

EN-46781 fixing tool.

2190411

58. Remove the engine mount bracket bolts (3).

59. Remove the engine lift bracket (2).
60. Remove the engine mount bracket (1).
61. Install EN-51070 Engine Mount Simulator.

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9-1490 Engine Mechanical - 1.3L (LDV) Diesel

2191978 2371733

Note: The EN-46781 fixing tool (1) must be installed in 72. Remove the 4 oil pump housing closure cover
horizontal position. bolts (4).
65. Install the EN-46781 fixing tool (1) into the 73. Remove the oil pump housing closure cover (1)
intake side. from the oil pump housing (3).
Note: If the EN-46781 fixing tool does not rotate any 74. Remove the oil pump housing closure cover
longer, the tool is correctly engaged. gasket (2).
66. Turn the crankshaft at the crankshaft sprocket bolt Note: Do NOT remove the camshaft sprocket bolt.
carefully, until the EN-46781 fixing tool (1) 75. Loosen the camshaft sprocket bolt.
engages at the intake camshaft.
67. Raise the vehicle.
Note: Turn the crankshaft carefully until EN-46785
fixing tool engages in the flywheel.
68. Install the EN-46785 fixing tool (1).
69. Lower the vehicle.

2371739

76. Tension the timing chain tensioner (1).

77. Fix the timing chain tensioner position with the
EN-955-1 locking tool (2).

2192181

70. Remove the oil pump housing plug (1) from the oil
pump housing (3).
71. Remove the oil pump housing plug seal (2).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1491

2191979 2371737

Note: Turn the crankshaft carefully until EN-46785 80. Remove the camshaft sprocket bolt.
fixing tool (1) engages in the flywheel.
81. Remove the camshaft sprocket from the exhaust
78. If equipped with manual transmission (F17-5 camshaft using a bent piece of rigid wire (1).
speed), install the EN-46785 fixing tool (1).

2371741
2666309

Note: Turn the crankshaft carefully until EN-46785 82. Remove the oil pump housing bolts (1) from the oil
fixing tool (1) engages in the flywheel. pump housing (2) and camshaft housing.

79. If equipped with manual transmission (M20-6

speed), Install the EN-46785 fixing tool (1).

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9-1492 Engine Mechanical - 1.3L (LDV) Diesel
1. Remove the upper oil pump housing gasket.
1.1. Cut into the elastomer sealing lips (arrows)
using a sharp knife pressed against the
cylinder head.
1.2. With a plastic spatula, loosen the seal from the
timing case and carefully snap it off at the
designated point (1).
1.3. Remove the upper oil pump housing gasket.
Note: Make sure that no residues remain at the joint
between the timing case and cylinder head, and that no
bits of the gasket fall into the timing case.
2. Remove any gasket residue and clean all sealing
surfaces thoroughly.

2191137

Note: Take note that there are different bolt lengths.

83. Remove the camshaft housing bolts (2).
84. Remove the camshaft housing studs (1).
Note: Carefully lever the camshaft housing off timing
case gasket with plastic wedge and use a rubber mallet
to knock it off the timing case. Place the camshaft
housing on suitable support.
85. Remove the camshaft housing (3).
86. Remove the camshaft housing gasket (4).
Installation Procedure

2371743

3. Fit the NEW oil pump housing gasket (1).

2371742

2371744

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1493
Note: 7. Clean all sealing surfaces.
•Using a sharp knife, cut into the elastomer 8. Apply silicone sealing compound to the transitions
sealing lips (arrows) at the breaking points of between the cylinder head and oil pump
the new gasket. housing (1).
• It is essential for the cutting tool (1) to have a 9. Install NEW camshaft housing gasket.
straight cutting surface. 10. Apply silicone sealing compound to the transitions
4. Cut the NEW oil pump housing gasket off at the between the camshaft housing gasket and oil
breaking points (arrow). pump housing.

2191137
2371745

Note: The upper new gasket and the old lower gasket 11. Install the camshaft housing (3).
must not be allowed to overlap. Note: Tightening the camshaft housing studs in
5. Fit NEW oil pump housing gasket (1) to the contact sequence until the camshaft housing is lying evenly on
surface between the cylinder block and the timing the cylinder head.
case until the seal lies flush on the cylinder head 12. Loosely install the camshaft housing studs (1).
and timing case (arrows) and the holes in the
gasket and the timing case match up. Note: Mind at different bolt length.
6. Clean any oil and grease of the exhaust camshaft, 13. Loosely install the camshaft housing bolts (2).
camshaft sprocket, camshaft sprocket bolt and 14. Carefully align the camshaft housing on the oil
thread in exhaust camshaft. pump housing, using a rubber mallet.

2371746 2371741

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9-1494 Engine Mechanical - 1.3L (LDV) Diesel
15. Install the oil pump housing bolts (1) to the oil 18. Tighten the 5 oil pump housing bolts (13–17) in
pump housing (2) and camshaft housing and sequence as shown:
tighten the bolts carefully until the camshaft 18.1. Tighten first pass and in sequence as shown
housing is in contact with the oil pump housing. to 4 Y (35 lb in).
18.2. Tighten second pass and in sequence as
shown to 9 Y (80 lb in).

2191904

Caution: Refer to Fastener Caution on page 0‑9.

16. Tighten the camshaft cover bolts and the camshaft 2371747
cover studs in sequence as shown and first pass:
19. Install the camshaft sprocket to the exhaust
• For camshaft housing bolts M7 to 12 Y camshaft.
(106 lb in).
19.1. Using a suitable tool (1), place the drive gear
• For camshaft housing studs M8 to 15 Y on the exhaust camshaft.
(11 lb ft).
19.2. Loosely install camshaft sprocket bolt.
17. Tighten the camshaft cover bolts and the camshaft
cover studs in sequence as shown and final pass:
• For camshaft housing bolts M7 to 18 Y
(13 lb ft).
• For camshaft housing studs M8 to 25 Y
(18 lb ft).

2371739

20. Remove the EN-955-1 locking tool (2) from timing

chain tensioner (1).

2191909

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1495

2371748 2666309

Note: A second mechanical must tighten the timing 23. If equipped with manual transmission (M20-6
chain tensioner (1) with a suitable tool (2) while the speed), EN-46785 fixing tool (1).
timing chain is being tightened.
21. Tighten the camshaft sprocket bolt to 150 Y
(111 lb ft).

2191979

24. Remove the EN-46785 fixing tool (1).

2191979

22. If equipped with manual transmission (F17-5

speed), EN-46785 fixing tool (1).

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9-1496 Engine Mechanical - 1.3L (LDV) Diesel

2191978 2192181

25. Remove the EN-46781 fixing tool (1). 32. Install the oil pump housing plug seal (2).
26. Turn the crankshaft 720 degrees (2 turns) in the 33. Install the oil pump housing plug (1) to the oil pump
direction of engine rotation. housing (3) and tighten to 9 Y (80 lb in).
27. Check the camshaft timing. Refer to Camshaft
Timing Chain Inspection on page 9‑1647.
28. Remove EN-51070 Engine Mount Simulator.

2191981

34. Install the intake camshaft housing core hole

plug (1) to the camshaft housing and tighten to
2371733 15 Y (11 lb ft).
29. Install the oil pump housing closure cover
gasket (2).
30. Install the oil pump housing closure cover (1) to the
oil pump housing (3).
31. Install the 4 oil pump housing closure cover
bolts (4) and tighten to 9 Y (80 lb in).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1497

2190411 2191136

35. Install the engine mount bracket (1). 40. Install the glow plug wire (1). Refer to Glow Plug
36. Install the engine lift bracket (2). Wire Replacement on page 9‑761.
37. Install the 4 engine mount bracket bolts (3) and
tighten to 60 Y (44 lb ft).

2191259

41. Clean the injector sealing surfaces in the cylinder

2563005 head using EN-47632 cleaning tool (1) in following
procedure:
38. Install the right side engine mount bolts (1) and
tighten to 50 Y (37 lb ft) plus 70 degrees. 41.1. First take the brush side to loosen the dirt.
39. Remove the EN-49802 cradle supporter with 41.2. Second take the sponge side to remove
EN-50620 powertrain supporters, and EN-48244 the dirt.
engine assembly remove/install pallet supporter.

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9-1498 Engine Mechanical - 1.3L (LDV) Diesel

2190870 2191131

42. Install the 4 NEW fuel injector gaskets (6) to the 50. Install the camshaft position sensor (2).
camshaft housing. 51. Install the camshaft position sensor bolt (1) and
43. Remove the EN-48559 caps from the injector tighten to 9 Y (80 lb in). Refer to Camshaft
nozzles. Position Sensor Replacement on page 9‑707.
44. Install the 4 NEW fuel injector seals (5) to the fuel
injectors.
45. Install the 4 fuel injectors (1) with the 2 fuel injector
brackets (7).
46. Install the 2 fuel injector spherical washers (4).
47. Install the 2 fuel injector conical washer (3).
48. Install the 2 fuel injector bracket nuts (2) and
tighten to 20 Y (15 lb ft).

2190504

52. Install the positive crankcase ventilation pipe (1).

53. Install the vacuum hose to the turbocharger
wastegate actuator vacuum control solenoid valve.
54. Connect the positive crankcase ventilation pipe
connector wiring harness plug.
55. Install the positive crankcase ventilation pipe
bracket bolts (2) and tighten to 8 Y (71 lb in).
2190867

49. Install the fuel injection fuel rail (3). Refer to Fuel
Injection Fuel Rail Assembly Replacement on
page 9‑766.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1499

2190846

56. Install a NEW fuel injection pump seal.

Note: Do not tilt the fuel injection pump actuator (1) at
timing gear groove (4).
57. Install the fuel injection pump (2).
58. Install the fuel injection pump bolts (3) and tighten
to 15 Y (11 lb ft). Refer to Fuel Injection Pump
Replacement on page 9‑742.
59. Connect the wiring harness plug to the fuel
injection pump.

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9-1500 Engine Mechanical - 1.3L (LDV) Diesel

2552471
60. Connect the fuel feed front pipe (1). Refer to Fuel
Feed Front Pipe Replacement on page 9‑733.

2190450

64. Install the turbocharger (1). Refer to Turbocharger

Replacement on page 9‑1578.
2552576

61. Install a NEW charge air cooler inlet air pipe

gasket.
62. Install the charge air cooler inlet air pipe to the
turbocharger.
63. Install the charge air cooler inlet air pipe bolts (1)
and tighten to 10 Y (89 lb in).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1501

2371708 2371707

65. Connect the (ECM) electrical wiring harness 78. Connect the camshaft sensor wiring harness plug
connectors from the engine control module. (1) to the camshaft sensor (3).
66. Connect the glow plug wire wiring harness plug (7). 79. Clip in the 3 retainer clips to:
67. Connect the camshaft position sensor wiring • Engine lift bracket (5)
harness plug. • Engine sight shield stud bracket (4)
68. Install the 2 wiring harness bracket bolts (6) and • Oil filler tube (2)
tighten to 9 Y (80 lb in).
80. Clip in the retainer clip to the turbocharger
69. Connect the throttle body wiring harness plug (5). wastegate actuator vacuum control solenoid valve
70. Connect the exhaust pressure sensor wiring bracket.
harness plug (4).
71. Connect the oxygen sensor wiring harness
plug (3).
72. Connect the manifold absolute pressure sensor
wiring harness plug (2).
73. Connect the fuel rail sensor wiring harness
plug (1).
74. Connect the 4 fuel injector wiring harness
plugs (8).
75. Connect the oxygen sensor wiring harness plug.
76. Connect the mass airflow sensor wiring
harness plug.
77. Connect the oil temperature sensor wiring harness
plug from the oil temperature sensor.

2371706

81. Connect the turbocharger wastegate actuator

vacuum control solenoid valve wiring harness
plug (1).
82. Clip the retainer clip (6) from the oil filter housing.
83. Connect the turbocharger wastegate sensor wiring
harness plug (2).
84. Clip the retainer clip (4) from the exhaust
temperature sensor wiring harness bracket.

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9-1502 Engine Mechanical - 1.3L (LDV) Diesel
85. Connect the exhaust temperature sensor wiring Camshaft Housing Replacement
harness plug (5).
Object-ID=2552012 Owner=Youkhana, Karem LMD=23-Feb-2011 LMB=Youkhana, Karem
86. Connect the air conditioning compressor wiring
harness plug (3).
Special Tools
87. Clip the retainer clip from the turbocharger
wastegate actuator vacuum control solenoid valve EN-46781 Fixing Tool
bracket. For equivalent regional tools, refer to Special Tools on
88. Install the turbocharger wastegate actuator pipe. page 9‑1711.
Refer to Turbocharger Wastegate Actuator Removal Procedure
Vacuum Control Solenoid Valve Vacuum Tube
Replacement on page 9‑774. 1. Remove the camshaft housing cover gasket. Refer
to Camshaft Housing and Cover Gasket
Replacement on page 9‑1484.

2563036

89. Install the air cleaner assembly (1). Refer to Air 2190846
Cleaner Assembly Replacement on page 9‑706. Note: Do not tilt the fuel injection pump actuator (1) at
the timing gear groove (4).
2. Remove the fuel injection pump bolts (3).
3. Remove the fuel injection pump (2). Refer to Fuel
Injection Pump Replacement on page 9‑742.

2666291

90. Install the air cleaner outlet (1). Refer to Air

Cleaner Outlet Duct Replacement on page 9‑703.
91. Install the engine sight shield. Refer to Engine
Sight Shield Replacement on page 9‑1577. 2191131

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1503
4. Remove the camshaft position sensor bolt (1).
5. Remove the camshaft position sensor (2). Refer to
Camshaft Position Sensor Replacement on
page 9‑707.

2190961

12. Mark the location as show above EN-46781 fixing

tool (1).

2190824

6. Remove the vacuum pump bolts (2).

7. Remove the vacuum pump (1).
Note: Do not tilt the vacuum pump actuator at the
timing gear groove (3).
8. Remove the vacuum pump gasket.

2190962

Note: EN-46781 fixing tool (1) must be install in

horizontal position.
13. Install the EN-46781 fixing tool (1) onto the
exhaust side and intake side.

2190960

9. Remove the exhaust cylinder head core hole

plug (2) from camshaft housing (1).
10. Remove the intake cylinder head core hole plug (3)
from camshaft housing (1).
11. Clean the threads from cylinder head core hole
plugs and camshaft housing.

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9-1504 Engine Mechanical - 1.3L (LDV) Diesel

2551946 2551998

14. Remove the exhaust camshaft sprocket bolt (1). 18. Remove intake camshaft sprocket bolt (1).
15. Remove the exhaust camshaft sprocket (2). 19. Remove intake camshaft sprocket (2).
16. Remove the EN-46781 fixing tool on the 20. Remove EN-46781 fixing tool on intake side.
exhaust side.

2552004
2551948
21. Remove the intake camshaft (1)
17. Remove the exhaust camshaft (1).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1505
Installation Procedure

2551948

5. Install the exhaust camshaft (1).

2552004
Note: Clean the contact surfaces from camshaft,
1. Install the intake camshaft (1). camshaft sprocket and camshaft sprocket bolt.
Coat the camshaft bearing surfaces with engine oil.

2371759

Note: Clean the contact surfaces from camshaft , 2551946

camshaft sprocket and camshaft sprocket bolt Coat
camshaft bearing surfaces with engine oil. 6. Install the EN-46781 fixing tool on the
exhaust side.
2. Install EN-46781 fixing tool on intake side.
7. Install the exhaust camshaft sprocket (2).
3. Install intake camshaft sprocket (2).
Caution: Refer to Fastener Caution on page 0‑9.
4. Install intake camshaft sprocket bolt (1) and tighten
to 150 Y (111 lb ft). 8. Install the exhaust camshaft sprocket bolt (1) and
tighten to 150 Y (111 lb ft).
9. Remove the EN-46781 fixing tool from the
exhaust side.

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9-1506 Engine Mechanical - 1.3L (LDV) Diesel

2190960 2190846

10. Install the exhaust cylinder head core hole plug (2) 13. Install a NEW fuel injection pump seal.
and intake cylinder head core hole (3) to the Note: Do not tilt the fuel injection pump actuator (1) at
camshaft housing (1) and tighten to timing gear groove (4).
15 Y (11 lb ft).
14. Install the fuel injection pump (2).
15. Install the fuel injection pump bolts (3) and tighten
to 15 Y (11 lb ft). Refer to Fuel Injection Pump
Replacement on page 9‑742.
16. Connect the wiring harness plug to the fuel
injection pump.

2191131

11. Install the camshaft position sensor (2).

12. Install the camshaft position sensor bolt (1) and
tighten to 9 Y (80 lb in) Refer to Camshaft
Position Sensor Replacement on page 9‑707.
2190824

17. Install a NEW vacuum pump gasket.

Note: Do not tilt the vacuum pump actuator at the
timing gear groove (3).
18. Install the vacuum pump (1).
19. Install the vacuum pump bolts (2) and tighten to
20 Y (15 lb ft).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1507
20. Install the camshaft housing cover gasket. Refer to
Camshaft Housing and Cover Gasket
Replacement on page 9‑1484.

Intake Camshaft Replacement

Object-ID=2552019 Owner=Youkhana, Karem LMD=07-Feb-2011 LMB=Youkhana, Karem

Special Tools
EN-46781 Fixing Tool
For equivalent regional tools, refer to Special Tools on
page 9‑1711.
Removal Procedure
1. Remove the camshaft housing cover gasket. Refer
to Camshaft Housing and Cover Gasket
Replacement on page 9‑1484.

2191131

4. Remove the camshaft position sensor bolt (1).

5. Remove the camshaft position sensor (2). Refer to
Camshaft Position Sensor Replacement on
page 9‑707.

2190846

Note: Do not tilt the fuel injection pump actuator (1) at

the timing gear groove (4).
2. Remove the fuel injection pump bolts (3).
3. Remove the fuel injection pump (2). Refer to Fuel
Injection Pump Replacement on page 9‑742.

2190824

6. Remove the vacuum pump bolts (2).

7. Remove the vacuum pump (1).
Note: Do not tilt the vacuum pump actuator at the
timing gear groove (3).
8. Remove the vacuum pump gasket.

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9-1508 Engine Mechanical - 1.3L (LDV) Diesel

2190960 2190962

9. Remove the exhaust cylinder head core hole Note: EN-46781 fixing tool (1) must be install in
plug (2) from camshaft housing (1). horizontal position.
10. Remove the intake cylinder head core hole plug (3) 13. Install the EN-46781 fixing tool (1) onto the
from camshaft housing (1). exhaust side and intake side.
11. Clean the threads from cylinder head core hole
plugs and camshaft housing.

2551998

14. Remove intake camshaft sprocket bolt (1).

2190961
15. Remove intake camshaft sprocket (2).
12. Mark the location as shown above EN-46781 fixing 16. Remove EN-46781 fixing tool on intake side.
tool (1).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1509

2552004 2371759

17. Remove the intake camshaft (1). Note: Clean the contact surfaces from camshaft ,
camshaft sprocket and camshaft sprocket bolt Coat
Installation Procedure camshaft bearing surfaces with engine oil.
2. Install EN-46781 fixing tool on intake side.
3. Install intake camshaft sprocket (2).
Caution: Refer to Fastener Caution on page 0‑9.
4. Install the intake camshaft sprocket bolt (1) and
tighten to 150 Y (111 lb ft).
5. Remove the EN-46781 fixing tool from the
intake side.

2552004

1. Install the intake camshaft (1).

2190960

6. Install the exhaust cylinder head core hole plug (2)

and intake cylinder head core hole (3) to the
camshaft housing (1) and tighten to
15 Y (11 lb in).

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9-1510 Engine Mechanical - 1.3L (LDV) Diesel

2191131 2190824

7. Install the camshaft position sensor (2). 13. Install a NEW vacuum pump gasket.
8. Install the camshaft position sensor bolt (1) and Note: Do not tilt the vacuum pump actuator at the
tighten to 9 Y (80 lb in). Refer to Camshaft timing gear groove (3).
Position Sensor Replacement on page 9‑707.
14. Install the vacuum pump (1).
15. Install the vacuum pump bolts (2) and tighten to
20 Y (15 lb ft).
16. Install the camshaft housing cover gasket. Refer to
Camshaft Housing and Cover Gasket
Replacement on page 9‑1484.

Camshaft Intake Sprocket

Replacement
Object-ID=2552026 Owner=Youkhana, Karem LMD=07-Feb-2011 LMB=Youkhana, Karem

Special Tools
EN-46781 Fixing Tool
For equivalent regional tools, refer to Special Tools on
page 9‑1711.
Removal Procedure
1. Remove the camshaft housing cover gasket. Refer
to Camshaft Housing and Cover Gasket
Replacement on page 9‑1484.
2190846

9. Install a NEW fuel injection pump seal.

Note: Do not tilt the fuel injection pump actuator (1) at
timing gear groove (4).
10. Install the fuel injection pump (2).
11. Install the fuel injection pump bolts (3) and tighten
to 15 Y (11 lb ft). Refer to Fuel Injection Pump
Replacement on page 9‑742.
12. Connect the wiring harness plug to the fuel
injection pump.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1511

2190846 2190824

Note: Do not tilt the fuel injection pump actuator (1) at 6. Remove the vacuum pump bolts (2).
the timing gear groove (4).
7. Remove the vacuum pump (1).
2. Remove the fuel injection pump bolts (3). Note: Do not tilt the vacuum pump actuator at the
3. Remove the fuel injection pump (2). Refer to Fuel timing gear groove (3).
Injection Pump Replacement on page 9‑742.
8. Remove the vacuum pump gasket.

2191131
2190960
4. Remove the camshaft position sensor bolt (1).
9. Remove the exhaust cylinder head core hole
5. Remove the camshaft position sensor (2). Refer to plug (2) from camshaft housing (1).
Camshaft Position Sensor Replacement on
page 9‑707. 10. Remove the intake cylinder head core hole plug (3)
from camshaft housing (1).
11. Clean the threads from cylinder head core hole
plugs and camshaft housing.

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9-1512 Engine Mechanical - 1.3L (LDV) Diesel

2190961 2551998

12. Mark the location as shown above EN-46781 fixing 14. Remove intake camshaft sprocket bolt (1).
tool (1). 15. Remove intake camshaft sprocket (2).
16. Remove EN-46781 fixing tool on intake side.
Installation Procedure

2190962

Note: EN-46781 fixing tool (1) must be install in

horizontal position.
2371759
13. Install the EN-46781 fixing tool (1) onto the
exhaust side and intake side. Note: Clean the contact surfaces from camshaft ,
camshaft sprocket and camshaft sprocket bolt Coat
camshaft bearing surfaces with engine oil.
1. Install EN-46781 fixing tool on intake side.
2. Install intake camshaft sprocket (2).
Caution: Refer to Fastener Caution on page 0‑9.
3. Install the intake camshaft sprocket bolt (1) and
tighten to 150 Y (111 lb ft).
4. Remove the EN-46781 fixing tool from the
intake side.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1513

2190960 2190846

5. Install the exhaust cylinder head core hole plug (2) 8. Install a NEW fuel injection pump seal.
and intake cylinder head core hole plug (3) to the Note: Do not tilt the fuel injection pump actuator (1) at
camshaft housing (1) and tighten to timing gear groove (4).
15 Y (11 lb in).
9. Install the fuel injection pump (2).
10. Install the fuel injection pump bolts (3) and tighten
to 15 Y (11 lb ft). Refer to Fuel Injection Pump
Replacement on page 9‑742.
11. Connect the wiring harness plug to the fuel
injection pump.

2191131

6. Install the camshaft position sensor (2).

7. Install the camshaft position sensor bolt (1) and
tighten to 9 Y (80 lb in). Refer to Camshaft
Position Sensor Replacement on page 9‑707.
2190824

12. Install a NEW vacuum pump gasket.

Note: Do not tilt the vacuum pump actuator at the
timing gear groove (3).
13. Install the vacuum pump (1).
14. Install the vacuum pump bolts (2) and tighten to
20 Y (15 lb ft).

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9-1514 Engine Mechanical - 1.3L (LDV) Diesel
15. Install the camshaft housing cover gasket. Refer to
Camshaft Housing and Cover Gasket
Replacement on page 9‑1484.

Camshaft Timing Chain and

Sprocket Replacement
Object-ID=2552688 Owner=Youkhana, Karem LMD=23-Feb-2011 LMB=Youkhana, Karem

Special Tools
• EN-955-1 Locking Tool Timing Chain Tensioner
• EN-956-1 Extension
• EN-6347 Holder
For equivalent regional tools, refer to Special Tools on
page 9‑1711.
Removal Procedure
1. Remove the oil pump housing. Refer to Oil Pump
Housing Replacement on page 9‑1596.
2191113

3. Remove the timing chain tensioner bolts (1).

4. Remove the timing chain tensioner (2).

2191110

2. Install the timing chain tensioner EN-955-1 locking

tool (1).

2552271

5. Remove the timing chain tensioner shoe bolt (1).

6. Remove the timing chain tensioner shoe (2).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1515

2552266 2191126

7. Remove the timing chain guide bolts (1). 12. Remove the camshaft sprocket bolt (1).
8. Remove the timing chain guide (2). Note: Remove the camshaft sprocket (2) from the
camshaft at first, then remove the timing chain from the
crankshaft sprocket (3).
13. Remove the camshaft sprocket (2) with the timing
chain (4).
Installation Procedure

2191125

9. Install the EN-6347 holder (1) with the EN-956-1

extension (4) to the camshaft sprocket (2).
Note: Counterhold the camshaft sprocket with
EN-6347 holder and EN-956-1 extension.
10. Loosen the camshaft sprocket bolt (3). 2191126

11. Remove the EN-6347 holder with the EN-956-1 Note: Install the timing chain to the crankshaft
extension from the camshaft sprocket. sprocket (3) at first.
1. Install the camshaft sprocket (2) with the timing
chain (4).
Note: Do not tighten the camshaft sprocket bolt.
2. Install the camshaft sprocket bolt (1).

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9-1516 Engine Mechanical - 1.3L (LDV) Diesel

2552266 2191113

3. Install the timing chain guide (2). Note: Fix the timing chain tensioner position with the
EN-955-1 locking tool.
Caution: Refer to Fastener Caution on page 0‑9.
4. Install the timing chain guide bolts (1) and tighten 7. Install the timing chain tensioner (2).
to 9 Y (80 lb in). 8. Install the timing chain tensioner bolts (1) and
tighten to 9 Y (80 lb in).

2552271
2191110
5. Install the timing chain tensioner shoe (2).
6. Install the timing chain tensioner shoe bolt (1) and 9. Remove the EN-955-1 locking tool (1) from the
tighten to 25 Y (18 lb ft). timing chain tensioner.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1517

2191125

10. Install the EN-6347 holder (1) with the EN-956-1

extension (4) to the camshaft sprocket (2).
Note: Counterhold the camshaft sprocket with the
EN-6347 holder and the EN-956-1 extension.
11. Tighten the camshaft sprocket bolt (3) to
150 Y (111 lb ft).
12. Remove the EN-6347 holder with the EN-956-1
extension from the camshaft sprocket.
13. Install the oil pump housing. Refer to Oil Pump
Housing Replacement on page 9‑1596.

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9-1518 Engine Mechanical - 1.3L (LDV) Diesel
Engine Flywheel Replacement
Object-ID=2551909 Owner=Youkhana, Karem LMD=20-Apr-2012 LMB=Diamond, Jodi

2551908

Engine Flywheel Replacement

Callout Component Name
Preliminary Procedure
Remove the clutch pressure and driven plate. Refer to Clutch Pressure and Driven Plate Replacement (Except LDC Engine) on
page 17‑335 or Clutch Pressure and Driven Plate Replacement (LDC Engine) on page 17‑336.
Special Tools
• EN-652 Flywheel Holder.
• EN-470–B Torque Wrench
For equivalent regional tools, refer to Special Tools on page 9‑1711.
Flywheel Fastener (Qty: 8)
Caution: Refer to Fastener Caution on page 0‑9.
1
Tighten
15 Y (11 lb ft) plus 35°
Flywheel
Procedure
Inspect the engine flywheel for the following:
2 1. Stress cracks around the engine flywheel.
2. Cracks at welded areas that retain the ring gear onto the engine flywheel.
3. Damaged or missing ring gear teeth.
4. Do not attempt to repair the welded areas that retain the ring gear to the engine flywheel plate. Install a new
engine flywheel.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1519
Crankshaft Pulley Replacement
Object-ID=2551834 Owner=Youkhana, Karem LMD=07-Apr-2011 LMB=Youkhana, Karem

2551831

Crankshaft Pulley Replacement

Callout Component Name
Preliminary Procedures
Remove Drive belt. Refer to Water Pump, Air Conditioning Compressor, and Generator Belt Replacement on page 9‑1584 or
Generator and Power Steering Pump Belt Replacement on page 9‑1583.
Crankshaft Pulley Bolt (Qty: 4)
Caution: Refer to Fastener Caution on page 0‑9.
1 Tip: Counterhold the crankshaft pulley at the centering bolt.
Tighten
25 Y (18 lb ft)
2 Crankshaft Pulley

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9-1520 Engine Mechanical - 1.3L (LDV) Diesel
Crankshaft Sprocket Replacement
Object-ID=2552812 Owner=Youkhana, Karem LMD=16-Dec-2010 LMB=Youkhana, Karem

2552811

Crankshaft Sprocket Replacement

Callout Component Name
Preliminary Procedure
Remove camshaft timing chain. Refer to Camshaft Timing Chain and Sprocket Replacement on page 9‑1514.
1 Crankshaft Sprocket

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1521
Crankshaft Rear Oil Seal Installation Procedure
Replacement
Object-ID=2552762 Owner=Youkhana, Karem LMD=16-Dec-2010 LMB=Youkhana, Karem

Special Tools
• EN-4500 Oil Seal Remover
• EN-46777 Rear Oil Seal Installer
For equivalent regional tools, refer to Special Tools on
page 9‑1711.
Removal Procedure
1. Remove the Flywheel. Refer to Engine Flywheel
Replacement on page 9‑1518.

2191876

1. Place the EN-46777-20 Installer (1) on the

EN-46777-10 Installer (3).
2. Slide the crankshaft rear oil seal (2) across the
EN-46777-20 Installer (1) onto the EN-46777-10
Installer (3).
3. Remove the EN-46777-20 Installer (1) from the
EN-46777-10 Installer (3).

2191190

Note: Be careful do not damage the sealing surfaces.

2. Remove the crankshaft rear oil seal (2) with
EN-4500 remover (1).

2191877

Note: Use a mallet to install the crankshaft rear oil seal

into the right fitting position.
4. Install the crankshaft rear oil seal (1) with the
EN-46777-10 installer (2).
5. Install the Flywheel. Refer to Engine Flywheel
Replacement on page 9‑1518

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9-1522 Engine Mechanical - 1.3L (LDV) Diesel
Cylinder Head Replacement
Object-ID=2580876 Owner=Youkhana, Karem LMD=23-Jul-2012 LMB=Youkhana, Karem

Special Tools
• EN-301 Bridge
• EN-470-B Angle Meter
• GE-571-B Gauge
For equivalent regional tools, refer to Special Tools on
page 9‑1711.
Removal Procedure
1. Remove the camshaft housing cover gasket. Refer
to Camshaft Housing and Cover Gasket
Replacement on page 9‑1484.
2. Remove the inlet radiator inlet hose. Refer to
Radiator Inlet Hose Replacement (LJ1 LMD) on
page 9‑1040 or Radiator Inlet Hose Replacement
(LDV) on page 9‑1041 or Radiator Inlet Hose
Replacement (L2B) on page 9‑1042 or Radiator
Inlet Hose Replacement (LDC) on page 9‑1043. 2579986

4. Remove the oil pump housing bolts (1) from the oil
pump housing and the cylinder head.

2371791

Note: Place clean rags (2) in the opening to prevent

the bolt from falling into the timing case. 2191155

3. Remove the upper timing chain guide bolt (1). 5. Loosen the 10 cylinder head bolts in sequence as
shown.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1523
10. Remove the oil pump housing gasket carefully.
10.1. Cut into the elastomer sealing lips (arrows)
using a sharp knife pressed against the
cylinder head.
10.2. With a plastic spatula, loosen the gasket from
the oil pump housing and carefully snap it off
at the designated point (1).
10.3. Remove the oil pump housing gasket.
10.4. Remove any gasket residue and clean all
sealing surfaces.
11. Remove the exhaust manifold. Refer to Exhaust
Manifold Removal on page 9‑1630.
12. Remove the glow plugs. Refer to Glow Plug
Removal on page 9‑1631.
13. Remove the engine coolant thermostat. Refer to
Engine Coolant Thermostat Removal on
page 9‑1635.
14. Remove the exhaust gas recirculation valve cooler.
Refer to Exhaust Gas Recirculation Valve Cooler
2580014 Removal on page 9‑1634.
6. Remove and DISCARD the cylinder head bolts (1). 15. Remove the intake manifold. Refer to Intake
Manifold Removal on page 9‑1636.
7. Remove the cylinder head (2).
16. Disassemble the cylinder head. Refer to Cylinder
7.1. Carefully slide the cylinder head from the oil Head Disassemble on page 9‑1657.
pump housing and remove it.
17. Transfer parts as necessary.
7.2. Carefully lever the cylinder head off the timing
case gasket with plastic wedge and use a Installation Procedure
rubber mallet to knock it off the timing case.
1. Assemble the cylinder head. Refer to Cylinder
Place the cylinder head on wooden blocks
Head Assemble on page 9‑1661.
with the help of a second person.
2. Install the intake manifold. Refer to Intake Manifold
8. Remove the cylinder head gasket (3).
Installation on page 9‑1697.
9. Secure the timing chain with a cable tie.
3. Install the exhaust gas recirculation valve cooler.
Refer to Exhaust Gas Recirculation Valve Cooler
Installation on page 9‑1700.
4. Install the engine coolant thermostat. Refer to
Engine Coolant Thermostat Installation on
page 9‑1698.
5. Install the glow plugs. Refer to Glow Plug
Installation on page 9‑1703.
6. Install the exhaust manifold. Refer to Exhaust
Manifold Installation on page 9‑1703.
Note: Ensure that the cylinder head and the cylinder
block sealing surfaces are clear of oil, grease and old
gasket material.
7. Clean the sealing surfaces.
8. Inspect the flatness of the cylinder head and the
cylinder block sealing surfaces.

2341691

Note: Do NOT damage the sealing lip (2). Make sure

that no residues remain at the joint between the oil
pump housing and cylinder block, and that no bits of
the gasket fall into the timing case.

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9-1524 Engine Mechanical - 1.3L (LDV) Diesel
11. Measure the piston projection dimensions at all
pistons.

2371802

Note:
• A second technician is required. 2191886
• The timing chain must be tightened to prevent
the chain from slipping when the crankshaft is 12. Select the cylinder head gasket with the correct
turned. identification marks:
• Carefully lay the camshaft drive gear on the 12.1. Piston projection 0.028–0.127 mm (0.001–
web on the timing case. 0.005 in) , choose cylinder head gasket with
identification mark - with out holes.
9. Set piston of cylinder 1 to TDC.
12.2. Piston projection 0.128–0.227 mm (0.005–
9.1. Using a suitable tool (2), press the camshaft 0.009 in) , choose cylinder head gasket with
drive gear (1) up and fix. identification mark - one hole.
9.2. Turn the crankshaft in the direction of engine 12.3. Piston projection 0.228–0.327 mm (0.009–
rotation at the crankshaft balancer. 0.013 in) , choose cylinder head gasket with
9.3. Release the timing chain. identification mark - two holes.

2189544 2371797

10. Install the EN-301 bridge (2) along with the 13. Fit the NEW oil pump housing gasket. Using a
GE-571-B gauge (1). sharp knife, cut into the elastomer sealing lips
Note: The largest piston projection is decisive for the (arrows) at the breaking points of the new gasket.
selection of the cylinder head gasket with the
corresponding marking.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1525

2371744 2371799

Note: It is essential for the cutting tool (1) to have a 16. Clean all sealing surfaces.
straight cutting surface.
Note: If the sealing tab (2) is damaged, remove this
14. Cut the NEW oil pump housing gasket off at the with a suitable cutter and apply sealant to the timing
breaking points (arrow). case contact surface.
17. Apply silicone sealing compound to the transitions
between the cylinder block and oil pump
housing (1).

2371798

Note: The upper new gasket and the old lower gasket
must not be allowed to overlap.
15. Fit the NEW oil pump housing gasket (1) to the 2371800
contact surface between the cylinder block and the Note: The bolts must be inserted in the bores shown
timing case until the seal lies flush on the cylinder above the cylinder head.
block and timing case (arrows) and the holes in the
gasket and the timing case match up. 18. Install the timing case gasket (1).
18.1. Place the NEW oil pump housing gasket (1)
on the oil pump housing.
18.2. Loosely install the 2 bolts (2) to fix the
camshaft housing gasket.

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9-1526 Engine Mechanical - 1.3L (LDV) Diesel

2371801 2191888

19. Apply silicone sealing compound to the transitions Caution: Refer to Fastener Caution on page 0‑9.
between the engine block and oil pump Caution: Refer to Torque-to-Yield Fastener Caution on
housing (1). page 0‑10.
20. Install the NEW cylinder head gasket. 26. Tighten the cylinder head bolts in sequence as
21. Apply silicone sealing compound to the transitions shown and in the following order:
between the cylinder head gasket and oil pump 26.1. Tighten the bolts in sequence as shown to
housing. 40 Y (30 lb ft).
26.2. Tighten in sequence as shown to an
additional 90 degrees. Use the EN-470-B
angle meter.
26.3. Tighten in sequence as shown to an
additional 90 degrees. Use the EN-470-B
angle meter.

2580014

22. Install the cylinder head (2).

23. Loosely install the 10 NEW cylinder head bolts (1).
24. Carefully align the cylinder head to the timing case,
using a rubber mallet.
Note: Do NOT tighten the bolts. 2371797

25. Install the 3 oil pump housing bolts to the Note: Place clean rags in the opening to prevent the
cylinder head. bolt from falling into the timing case.
27. Install upper timing chain guide bolt (1) and tighten
to 9 Y (80 lb in).
28. Remove the clean rags.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1527

2579986

29. Install the upper timing chain guide bolt (1).

29.1. Tighten first pass and in sequence as shown
to 4 Y (35 lb in).
29.2. Tighten final pass and in sequence as shown
to 9 Y (80 lb in).
30. Install the inlet radiator inlet hose. Refer to
Radiator Inlet Hose Replacement (LJ1 LMD) on
page 9‑1040 or Radiator Inlet Hose Replacement
(LDV) on page 9‑1041 or Radiator Inlet Hose
Replacement (L2B) on page 9‑1042 or Radiator
Inlet Hose Replacement (LDC) on page 9‑1043.
31. Install the camshaft housing cover gasket. Refer to
Camshaft Housing and Cover Gasket
Replacement on page 9‑1484.

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9-1528 Engine Mechanical - 1.3L (LDV) Diesel
Drive Belt Idler Pulley Replacement
Object-ID=2752183 Owner=Youkhana, Karem LMD=17-Jan-2012 LMB=Lavigne, Matthew

2752182

Drive Belt Idler Pulley Replacement

Callout Component Name
Preliminary Procedure
Remove the drive belt. Refer to Generator and Power Steering Pump Belt Replacement on page 9‑1583.
Drive Belt Idler Pulley Fastener
Caution: Refer to Fastener Caution on page 0‑9.
1
Tighten
25 Y (18 lb ft)
Drive Belt Idler Pulley
2 Procedure
Transfer components as necessary.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1529
Oil Pan Replacement
Object-ID=2559647 Owner=Youkhana, Karem LMD=17-Jan-2012 LMB=Youkhana, Karem

Special Tools
EN-37228 Separation Tool
For equivalent regional tools, refer to Special Tools on
page 9‑1711.
Removal Procedure
1. Disconnect the battery negative cable. Refer
Battery Negative Cable Disconnection and
Connection on page 9‑53.
2. If equipped with front suspension frame skid plate,
remove the front suspension frame skid plate.
Refer to Drivetrain and Front Suspension Frame
Skid Plate Replacement on page 3‑136.
3. Remove the Exhaust Front Pipe. Refer to Exhaust
Front Pipe Replacement (LJ1,LMD) on
page 9‑1903 or Exhaust Front Pipe Replacement
(LDV) on page 9‑1904 or Exhaust Front Pipe 2559532
Replacement (L2B) on page 9‑1906 or Exhaust
Front Pipe Replacement (LDC) on page 9‑1908. 7. Remove the transmission support brace bolts (1).
4. Place a drain pan under the oil drain plug.

2559526

2551849 8. Remove the transmission support brace bolts (1).

5. Remove the oil drain plug (1). 9. Remove the transmission support brace (2).
Caution: Refer to Fastener Caution on page 0‑9.
6. Install a NEW oil pan drain plug gasket and the oil
pan drain plug (1) and tighten to 14 Y (124 lb in)
after draining the engine oil.

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9-1530 Engine Mechanical - 1.3L (LDV) Diesel

2190926 2190929

10. Remove the 2 oil pan nuts (1). 13. Remove the oil pan (1).
11. Remove the 13 oil pan bolts (2).
Installation Procedure
1. Clean the sealing surfaces.

2190927

12. Loosen carefully the oil pan (2) from the lower 2191932
cylinder block with the EN-37228 separation
Note: The complete installation procedure of the oil
tool (1).
pan should be done in 10 minutes.
2. Apply silicone sealing compound (2) to the oil pan
sealing surface (1). The thickness of the sealing
bead (1) should be 3.0 - 4.0 mm (0.118 - 0.157 in).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1531

2190929 2191934

3. Install the oil pan (1). 6. Tighten the oil pan bolts and oil pan nuts in
sequence as shown:
• Tighten in first step to 4 Y (35 lb in).
• Tighten in final step to 9 Y (80 lb in).

2190926

4. Hand tighten the oil pan nuts (1).

5. Hand tighten the oil pan bolts (2).
2559526

7. Install the transmission support brace (2).

8. Install the transmission support brace bolts (1) and
tighten to 30 Y (22 lb ft).

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9-1532 Engine Mechanical - 1.3L (LDV) Diesel

2559532 2191981

9. Install the transmission support brace bolts (1) and 3. Remove the intake camshaft housing core hole
tighten to 40 Y (30 lb ft). plug (1) from the camshaft housing.
10. Install the exhaust front pipe. Refer to Exhaust 4. Clean the threads at the camshaft housing and the
Front Pipe Replacement (LJ1,LMD) on camshaft housing core hole plug.
page 9‑1903 or Exhaust Front Pipe Replacement
(LDV) on page 9‑1904 or Exhaust Front Pipe
Replacement (L2B) on page 9‑1906 or Exhaust
Front Pipe Replacement (LDC) on page 9‑1908.
11. If equipped with front suspension frame skid plate,
install the front suspension frame skid plate. Refer
to Drivetrain and Front Suspension Frame Skid
Plate Replacement on page 3‑136.
12. Connect the battery negative cable. Refer Battery
Negative Cable Disconnection and Connection on
page 9‑53.

Oil Pump Seal Replacement

Object-ID=2560292 Owner=Youkhana, Karem LMD=20-Apr-2012 LMB=Diamond, Jodi

Special Tools
• EN-470-B Angular Torque Wrench
• EN-662-C Holding Wrench
• EN-46775 Centering Tool Oil Pump Housing
• EN-46781 Fixing Tool
• EN-46785 Fixing Tool 2190961

For equivalent regional tools, refer to Special Tools on 5. Mark the location as shown above EN-46781 fixing
page 9‑1711 tool (1).
Removal Procedure
1. Remove the crankshaft pulley. Refer to Crankshaft
Pulley Replacement on page 9‑1519.
2. Remove the fuel injector rail. Refer to Fuel
Injection Fuel Rail Assembly Replacement on
page 9‑766.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1533

2191978 2666309

Note: The EN-46781 fixing tool (1) must be installed in 10. If equipped with manual transmission (M20-6
horizontal position. speed), install the EN-46785 fixing tool (1) to fixing
6. Install the EN-46781 fixing tool (1) into the hole (2).
intake side.
Note: If the EN-46781 fixing tool (1) does not rotate
any longer, the tool is correctly engaged.
7. Turn the crankshaft at the crankshaft sprocket bolt
carefully, until the EN-46781 fixing tool (1)
engages at the intake camshaft.
8. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1‑25.

2190969

11. Install the EN-662-C holding wrench (2).

12. Install the bolts.
Note: Mind the left-hand thread.
13. Loosen the crankshaft sprocket bolt (1).

2191979

Note: Turn the crankshaft carefully until EN-46785

fixing tool (1) engages in the flywheel.
9. If equipped with manual transmission (F17-5
speed), install the EN-46785 fixing tool (1) to
fixing hole.

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9-1534 Engine Mechanical - 1.3L (LDV) Diesel
Installation Procedure

2190971

Note: Mind the left-hand thread.

2372550
14. Remove and DISCARD the crankshaft sprocket
bolt (1) by turning clockwise. Note: Slide the oil pump seal (2) over the flange
15. Remove the flange (2). sealing surface (arrow).
1. Install the oil pump seal (2) to the flange (1).

2191847

2372551
16. Remove the oil pump seal (1).
2. Position the flange (2) with the oil pump seal (3) to
the crankshaft.
3. Tighten carefully the flange bolt (1) to limit stop.
4. Remove the flange bolt (1)
5. Remove the flange (2).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1535

2373026 2190969

6. Position the EN-46775 centering tool (2) with the Caution: Refer to Fastener Caution on page 0‑9
plane surface onto the oil pump housing. Note: Mind the left-hand thread.
7. Tighten carefully the flange bolt (1) until the 11. Install the EN-662-C holding wrench (2) and install
EN-46775 centering tool flush with oil pump the bolts.
housing (arrow). Caution: Refer to Torque-to-Yield Fastener Caution on
8. Remove the flange bolt and the EN-46775 page 0‑10
centering tool. 12. Install the NEW crankshaft sprocket bolt tighten (1)
to 50 Y (37 lb ft).
13. Tighten the crankshaft sprocket bolt to additional
90°. Use the EN-470-B torque wrench.

2190971

9. Install the flange (2).

10. Loosely install the NEW crankshaft sprocket
bolt (1). 2191979

14. If equipped with manual transmission (F17-5

speed), remove the EN-46785 fixing tool (1).

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9-1536 Engine Mechanical - 1.3L (LDV) Diesel

2666309 2191981

15. If equipped with manual transmission (M20-6 19. Install the intake camshaft housing core hole
speed), remove the EN-46785 fixing tool (1). plug (1) to the camshaft housing and tighten to
16. Lower the vehicle. 15 Y (11 lb ft).
20. Install the fuel injector rail. Refer to Fuel Injection
Fuel Rail Assembly Replacement on page 9‑766.
21. Install the crankshaft pulley. Refer to Crankshaft
Pulley Replacement on page 9‑1519.

2191978

17. Remove the EN-46781 fixing tool (1) from the

intake side.
18. Check the camshaft timing. Refer to Camshaft
Timing Chain Inspection on page 9‑1647.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1537
Drive Belt Tensioner Replacement
Object-ID=2551839 Owner=Youkhana, Karem LMD=31-May-2011 LMB=Youkhana, Karem

2551836

Drive Belt Tensioner Replacement

Callout Component Name
Preliminary Procedures
Remove Drive Belt. Refer to Water Pump, Air Conditioning Compressor, and Generator Belt Replacement on page 9‑1584 or
Generator and Power Steering Pump Belt Replacement on page 9‑1583.
Drive Belt Tensioner Bolt
Caution: Refer to Fastener Caution on page 0‑9.
1
Tighten
50 Y (37 lb ft)
Drive Belt Tensioner
2
Note: If equipped with power steering pump, remove the idler before removing the tensioner.

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9-1538 Engine Mechanical - 1.3L (LDV) Diesel
Engine Mount Replacement
Object-ID=2551804 Owner=Youkhana, Karem LMD=10-Feb-2012 LMB=Youkhana, Karem

2551800

Engine Mount Replacement

Callout Component Name
Preliminary Procedures
1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement on page 9‑706.
2. Install the engine support fixture. Refer to Engine Support Fixture (South America) on page 9‑1620 or Engine Support
Fixture (Except South America) on page 9‑1622.
3. Prior to removing the mount, mark the mount location using spray paint or a marker for correct positioning during
installation.
Engine Mount Bracket to Mount Bolt (Qty: 3)
Caution: Refer to Fastener Caution on page 0‑9.
1 Tip: Use NEW bolts whenever mount is removed.
Tighten
50 Y (37 lb ft) plus 60–75 degrees
Engine Mount Bracket Bolt
Tip: Ensure to use a NEW bolt whenever the mount is removed.
2
Tighten
62 Y (46 lb ft)
Engine Mount Nut (Qty: 2)
3 Tighten
62 Y (46 lb ft)
4 Engine Mount

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1539
Engine Mount Bracket Replacement
Object-ID=2551812 Owner=Youkhana, Karem LMD=13-Jul-2012 LMB=Troczynski, Darryl

2551808

Engine Mount Bracket Replacement

Callout Component Name
Preliminary Procedures
1. Remove the drive belt idler pulley. Refer to Drive Belt Idler Pulley Replacement on page 9‑1528.
2. Remove the engine mount. Refer to Engine Mount Replacement on page 9‑1538.
Engine Mount Bracket Bolt (Qty: 4)
Caution: Refer to Fastener Caution on page 0‑9.
1
Tighten
60 Y (44 lb ft)
2 Engine Lift Bracket
3 Engine Mount Bracket

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9-1540 Engine Mechanical - 1.3L (LDV) Diesel
Engine Replacement (Top Removal)
Object-ID=2739308 Owner=Youkhana, Karem LMD=15-Oct-2012 LMB=Lavigne, Matthew

Removal Procedure
1. Remove the battery and battery tray. Refer to
Battery Tray Replacement on page 9‑66.
2. Recover the refrigerant. Refer to Refrigerant
Recovery and Recharging on page 10‑15.
3. Remove the engine sight shied. Refer to Engine
Sight Shield Replacement on page 9‑1577.
4. Drain the cooling system. Refer to Cooling System
Draining and Filling (Static Fill) on page 9‑1026 or
Cooling System Draining and Filling (GE 47716) on
page 9‑1026.
5. Remove air inlet grille panel. Refer to Air Inlet Grille
Panel Replacement on page 4‑348.
6. Remove the plenum water deflector support. Refer
to Plenum Water Deflector Support Replacement
on page 4‑347. 2539745

8. Remove the junction block cover (1).

2563036

7. Remove the air cleaner assembly (1). Refer toAir 2504689

Cleaner Assembly Replacement on page 9‑706.
9. Remove the positive battery cable nut (1) from the
junction block.
10. Remove the positive battery cable (2) from the
junction block.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1541

2539757 2839321

11. Remove the junction block nut (1). 17. Remove the ground nuts (1) and reposition the
12. Remove the junction block bolts (2). wiring harness (2) aside.
13. Disconnect the wiring harness from the junction 18. Remove the positive cable nut (3) and reposition
block base. the wiring harness (4) aside.
14. Remove the junction block (3) from the base.
15. Disconnect the wiring harness plug from the front
compartment fuse block.

2666812

19. Disconnect the body wiring harness connector (1).

2539762

16. Reposition the wiring harness (1) on top of the

engine.

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9-1542 Engine Mechanical - 1.3L (LDV) Diesel

2666814 2562977

20. Disconnect the glow plug control module harness 23. Remove the radiator surge tank and position aside.
connector (1). Refer to Radiator Surge Tank Replacement on
page 9‑1032 or Radiator Surge Tank Replacement
(LDV,LDC) on page 9‑1033 or Radiator Surge Tank
Replacement (L2B) on page 9‑1034.
24. Disconnect the fan connector.
25. Remove the radiator. Refer to Radiator
Replacement (LJ1 LKF LMD without Automatic
Transmission) on page 9‑1091 or Radiator
Replacement (LDV) on page 9‑1092 or Radiator
Replacement (L2B, LDC) on page 9‑1095 or
Radiator Replacement (LJ1 LMD with Automatic
Transmission) on page 9‑1096.

2552576

21. Remove the charge air cooler outlet air hose (2) to
throttle body (3) bolts (1). Refer Charge Air Cooler
Outlet Air Hose Replacement on page 9‑709.
22. Remove the front bumper fascia. Refer to Front
Bumper Fascia Replacement on page 3‑53

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1543

2560706
26. Disconnect the power steering fluid reservoir inlet 28. Remove the power steering gear inlet hose O-ring
hose (1) from the power steering pump. Refer to seal (2) and discard the seal.
Power Steering Pump Inlet Hose Replacement
(L2B, LJ1, LMD) on page 15‑36 or Power Steering
Pump Inlet Hose Replacement (LDV) on
page 15‑37 or Power Steering Pump Inlet Hose
Replacement (LDC) on page 15‑38.

2560825

27. Disconnect the power steering gear inlet hose (3)

from the power steering pump (1).

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9-1544 Engine Mechanical - 1.3L (LDV) Diesel

2563368
29. Remove the power steering reservoir (1) from
chassis and place aside.

2839482

30. Remove the glow plug control module bracket (2).

31. Remove the glow plug control module bracket (1).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1545

2753863
32. Remove the turbocharger wastegate actuator Hand Drive) on page 5‑196 or Power Brake
solenoid valve (3). Refer to Turbocharger Booster Vacuum Check Valve and Hose
Wastegate Actuator Vacuum Control Solenoid Replacement (LDC) on page 5‑196 or Power
Valve Replacement on page 9‑773. Brake Booster Vacuum Check Valve and Hose
Replacement (LDV - Left Hand Drive) on
page 5‑197 or Power Brake Booster Vacuum
Check Valve and Hose Replacement (LDV - Right
Hand Drive) on page 5‑198 or Power Brake
Booster Vacuum Check Valve and Hose
Replacement (L2B - Left Hand Drive) on
page 5‑199.

2742554

33. Disconnect the power vacuum brake booster hose

quick connect (1) from the vacuum pump port.
Refer to Power Brake Booster Vacuum Check
Valve and Hose Replacement (LJ1, LMD) on
page 5‑193 or Power Brake Booster Vacuum
Check Valve and Hose Replacement (L2B - Right 2562814

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9-1546 Engine Mechanical - 1.3L (LDV) Diesel
34. Disconnect the heater inlet hose (1) from the
heater core. Refer to Heater Inlet Hose
Replacement (LDV) on page 10‑89 or Heater Inlet
Hose Replacement (LJ1, LMD) on page 10‑91 or
Heater Inlet Hose Replacement (LDC) on
page 10‑92 or Heater Inlet Hose Replacement
(L2B) on page 10‑93.

2562817

35. Disconnect the heater outlet hose (1) from the

heater core. Refer to Heater Outlet Hose
Replacement (LJ1 LMD) on page 10‑95 or Heater
Outlet Hose Replacement (LDV) on page 10‑96 or
Heater Outlet Hose Replacement (LDC) on
page 10‑97 or Heater Outlet Hose Replacement
(L2B) on page 10‑99.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1547

2506637
36. Remove the air conditioning compressor (2). Refer 38. Remove air conditioning compressor and
to Air Conditioning Compressor Replacement condenser hose (2) from refrigerant hose.
(LDV) on page 10‑17 or Air Conditioning 39. Remove air conditioning compressor and
Compressor Replacement (LJ1, LMD) on condenser hose from the vehicle.
page 10‑18 or Air Conditioning Compressor
Replacement (L2B) on page 10‑19 or Air 40. Cap off the A/C hose to prevent contamination.
Conditioning Compressor Replacement (LDC) on
page 10‑20.

2551885

41. Disconnect the fuel feed pipe (1). Refer to Plastic

2497621 Collar Quick Connect Fitting Service on
37. Remove air conditioning compressor and page 9‑774.
condenser hose nut (1).

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9-1548 Engine Mechanical - 1.3L (LDV) Diesel

2551883 2192386

42. Disconnect the fuel return pipe (1). Refer to Plastic 48. Remove the upper transmission to engine bolts (1)
Collar Quick Connect Fitting Service on and separate the engine from transmission.
page 9‑774.
43. Remove the front exhaust pipe. Refer to Exhaust
Front Pipe Replacement (LJ1,LMD) on
page 9‑1903 or Exhaust Front Pipe Replacement
(LDV) on page 9‑1904 or Exhaust Front Pipe
Replacement (L2B) on page 9‑1906 or Exhaust
Front Pipe Replacement (LDC) on page 9‑1908.
44. Remove the turbocharger. Refer to Turbocharger
Replacement on page 9‑1578.

2917133

49. Install the crane tool (2).

50. Detach the engine (1) from the transmission.

2666890

45. If equipped with manual transmission (M20-6

speed), remove the lower transmission bolts (1,2).
46. Discount any electrical connectors as needed.
47. Disconnect any additional transmission hoses as
necessary.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1549

2551800
51. Mark the location of the bolts before removing. 56. Transfer parts as necessary.
52. Remove the engine mount (4). Refer to Engine
Mount Replacement on page 9‑1538. Installation Procedure
53. Discount any electrical connectors as needed.
54. Disconnect any additional transmission hoses as
necessary.

2917130

1. Install an engine lifting device to the engine lift

brackets.
2917130 Note: When lowering the engine, pay attention on the
Note: When raising the engine, pay attention to the plenum water deflector support.
plenum water deflector support. Note: Support the transmission assembly when
55. Remove the engine (1). placing the engine.

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9-1550 Engine Mechanical - 1.3L (LDV) Diesel
2. Install the engine (1) into the vehicle.

2192386

3. Install the upper transmission bolts (1) and tighten

to 60 Y (44 lb ft).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1551

2551800
4. Install the right side engine mount (4). Refer to 6. If equipped with manual transmission (M20-6
Engine Mount Replacement on page 9‑1538. speed), install the lower transmission bolts (1,2)
5. Install the front exhaust pipe. Refer Exhaust Front and tighten to 60 Y (44 lb ft).
Pipe Replacement (LJ1,LMD) on page 9‑1903 or
Exhaust Front Pipe Replacement (LDV) on
page 9‑1904 or Exhaust Front Pipe Replacement
(L2B) on page 9‑1906 or Exhaust Front Pipe
Replacement (LDC) on page 9‑1908.

2551883

7. Connect the fuel return pipe (1).

2666890

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9-1552 Engine Mechanical - 1.3L (LDV) Diesel

2551885

8. Connect the fuel feed pipe (1).

9. Install the radiator. Refer to Radiator Replacement
(LJ1 LKF LMD without Automatic Transmission) on
page 9‑1091 or Radiator Replacement (LDV) on
page 9‑1092 or Radiator Replacement (L2B, LDC)
on page 9‑1095 or Radiator Replacement (LJ1
LMD with Automatic Transmission) on
page 9‑1096.

2497621

10. Install air conditioning compressor and condenser

hose (2) to the refrigerant hose.
11. Install air conditioning compressor and condenser
hose nut (1) and tighten nut to 22 Y (16 lb ft).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1553

2506637
12. Install the air conditioning compressor (2). Refer to 13. Install the radiator surge tank (1). Refer to Radiator
Air Conditioning Compressor Replacement (LDV) Surge Tank Replacement on page 9‑1032 or
on page 10‑17 or Air Conditioning Compressor Radiator Surge Tank Replacement (LDV,LDC) on
Replacement (LJ1, LMD) on page 10‑18 or Air page 9‑1033 or Radiator Surge Tank Replacement
Conditioning Compressor Replacement (L2B) on (L2B) on page 9‑1034.
page 10‑19 or Air Conditioning Compressor 14. Connect the fan connector.
Replacement (LDC) on page 10‑20.

2562814
2562977
15. Connect the heater inlet hose to the heater
core (1). Refer to Heater Inlet Hose Replacement
(LDV) on page 10‑89 or Heater Inlet Hose
Replacement (LJ1, LMD) on page 10‑91 or Heater
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9-1554 Engine Mechanical - 1.3L (LDV) Diesel
Inlet Hose Replacement (LDC) on page 10‑93 or Check Valve and Hose Replacement (LDV - Left
Heater Inlet Hose Replacement (L2B) on Hand Drive) on page 5‑198 or Power Brake
page 10‑93. Booster Vacuum Check Valve and Hose
Replacement (LDV - Right Hand Drive) on
page 5‑198 or Power Brake Booster Vacuum
Check Valve and Hose Replacement (L2B - Left
Hand Drive) on page 5‑199.

2562817

16. Connect the heater outlet hose to the heater

core (1). Refer to Heater Outlet Hose Replacement
(LJ1 LMD) on page 10‑95 or Heater Outlet Hose
Replacement (LDV) on page 10‑96 or Heater
Outlet Hose Replacement (LDC) on page 10‑97 or
Heater Outlet Hose Replacement (L2B) on
page 10‑99.

2742554

17. Connect the power vacuum brake booster hose

quick connect (1) to the vacuum pump port. Refer
to Power Brake Booster Vacuum Check Valve and
Hose Replacement (LJ1, LMD) on page 5‑193 or
Power Brake Booster Vacuum Check Valve and
Hose Replacement (L2B - Right Hand Drive) on
page 5‑193 or Power Brake Booster Vacuum
Check Valve and Hose Replacement (LDC) on
page 5‑196 or Power Brake Booster Vacuum

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1555

2753863
18. Install the turbocharger wastegate actuator
solenoid valve (3). Refer to Turbocharger
Wastegate Actuator Vacuum Control Solenoid
Valve Replacement on page 9‑773.

2839482

19. Install the glow plug control module bracket (2).

20. Install the glow plug control module (1).

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9-1556 Engine Mechanical - 1.3L (LDV) Diesel

2563368
21. Install the power steering reservoir (1) from chassis
and place aside.

2560825

22. Install a new power steering gear inlet hose O-ring

seal (2).
23. Connect the power steering gear inlet hose (3) to
the power steering pump (1) and tighten 34 Y
(25 lb ft).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1557

2560706
24. Connect the power steering fluid reservoir inlet
hose (1) from the power steering pump. Refer to
Power Steering Pump Inlet Hose Replacement
(L2B, LJ1, LMD) on page 15‑36 or Power Steering
Pump Inlet Hose Replacement (LDV) on
page 15‑37 or Power Steering Pump Inlet Hose
Replacement (LDC) on page 15‑38.

2666812

26. Connect the body wiring harness connector (1).

2552576

25. Install the charge air cooler outlet air hose (2) to
throttle body (3) bolts (1). Refer Charge Air Cooler
Outlet Air Hose Replacement on page 9‑709.

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9-1558 Engine Mechanical - 1.3L (LDV) Diesel

2666814 2539762

27. Connect the glow plug control module harness 30. Clip in the wiring harness plugs (1).
connector (1).

2539757
2839321
31. Install the junction block to the base.
28. Install the ground nuts (1) and tighten to 32. Install the junction block bolts (2) and tighten to
10 Y (89 lb in). 5 Y (44 lb in).
29. Install the positive cable nut (3) and reposition the 33. Install the junction block nut (1) and tighten to
wiring harness (4) aside. 5 Y (44 lb in).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1559

2504689 2563036

34. Position the positive battery cable to the junction 37. Install the air cleaner assembly (1).
block. 38. Install the plenum water deflector support. Refer to
35. Install the positive battery cable nut (2) and tighten Plenum Water Deflector Support Replacement on
to 10 Y (89 lb in). page 4‑347.
39. Install air inlet grille panel. Refer to Air Inlet Grille
Panel Replacement on page 4‑348.
40. Install the battery and battery tray. Refer to Battery
Tray Replacement on page 9‑66.
41. Evacuate and charge the refrigerant system. Refer
Refrigerant Recovery and Recharging on
page 10‑15.
42. Fill the cooling system. Refer to Cooling System
Draining and Filling (Static Fill) on page 9‑1026 or
Cooling System Draining and Filling (GE 47716) on
page 9‑1026.
43. Install the engine sight shied. Refer to Engine Sight
Shield Replacement on page 9‑1577.

Engine Replacement (Bottom

Removal)
Object-ID=2785963 Owner=Youkhana, Karem LMD=28-Feb-2013 LMB=Baker, Sandie

Special Tools
• CH-50619 Pins-Cradle Alignment
2539745
• CH-49376 Wheel Hub Holder
36. Install the junction block cover (1). • DT-50186 Wheel Hub Holder
• DT-50188 Wheel Drive Shaft Remover
For equivalent regional tools, refer to Engine
Mechanical Specifications on page 9‑1438.
Removal Procedure
1. Remove the battery and battery tray. Refer to
Battery Tray Replacement on page 9‑66.
2. Recover the refrigerant. Refer to Refrigerant
Recovery and Recharging on page 10‑15.
3. Remove the engine sight shied. Refer to Engine
Sight Shield Replacement on page 9‑1577.

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9-1560 Engine Mechanical - 1.3L (LDV) Diesel
4. Remove the front tire and wheel assembly. Refer
Tire and Wheel Removal and Installation on
page 16‑57.
5. Remove the front bumper fascia. Refer to Front
Bumper Fascia Replacement on page 3‑53.
6. Drain the cooling system. Refer to Cooling System
Draining and Filling (Static Fill) on page 9‑1026 or
Cooling System Draining and Filling (GE 47716) on
page 9‑1026.
7. Remove the lower intermediate steering shaft.
Refer Intermediate Steering Shaft Replacement
(LHD) on page 15‑80 or Intermediate Steering
Shaft Replacement (RHD) on page 15‑81.

2504689

10. Remove the positive battery cable nut (1) from the
junction block.
11. Remove the positive battery cable (2) from the
junction block.

2563036

8. Remove the air cleaner assembly (1). Refer to Air

Cleaner Assembly Replacement on page 9‑706.

2539757

12. Remove the junction block nut (1).

13. Remove the junction block bolts (2).
14. Disconnect the wiring harness from the junction
block base.
15. Remove the junction block (3) from the base.
16. Disconnect the wiring harness plug from the front
compartment fuse block.

2539745

9. Remove the junction block cover (1).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1561

2539762 2666812

17. Reposition the wiring harness (1) on top of the 19. Disconnect the body wiring harness connector (1).
engine.

2666814
2539765
20. Disconnect the glow plug control module harness
18. Remove the ground nuts (1) and reposition the connector (1).
wiring harness (2) aside.

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9-1562 Engine Mechanical - 1.3L (LDV) Diesel

2512974 2562814

21. Remove the power brake booster vacuum check 25. Disconnect the heater inlet hose (1) from the
valve (1) from the power vacuum brake booster. heater core. Refer to Heater Inlet Hose
22. Disconnect the electrical connector and remove Replacement (LDV) on page 10‑89 or Heater Inlet
the brake booster hose (1). Hose Replacement (LJ1, LMD) on page 10‑91 or
Heater Inlet Hose Replacement (LDC) on
page 10‑92 or Heater Inlet Hose Replacement
(L2B) on page 10‑93.

2028267

Note: Before disconnecting the clutch actuator cylinder

front pipe, remove the clutch/brake fluid from the
2562817
reservoir tank.
23. Remove the clutch actuator cylinder front pipe 26. Disconnect the heater outlet hose (1) from the
retaining clip (1). heater core. Refer to Heater Outlet Hose
Replacement (LJ1 LMD) on page 10‑95 or Heater
24. Disconnect the clutch actuator cylinder front Outlet Hose Replacement (LDV) on page 10‑96 or
pipe (2) from the clutch actuator cylinder pipe Heater Outlet Hose Replacement (LDC) on
elbow. page 10‑97 or Heater Outlet Hose Replacement
(L2B) on page 10‑99.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1563
32. Disconnect the shift lever and selector lever cable
from the shift lever and selector lever cable
bracket.

2512882

27. If equipped with manual transmission (F17-5

speed), disconnect the shift lever and selector
lever cable end (1) from the transmission shift lever
2562977
and selector lever.
28. Pull the cable retainers (2) to release the shift lever 33. Remove the radiator surge tank (1) and position
and selector lever cable from the shift lever and aside. Refer to Radiator Surge Tank Replacement
selector lever cable bracket. on page 9‑1032 or Radiator Surge Tank
29. Disconnect the shift lever and selector lever cable Replacement (LDV,LDC) on page 9‑1033 or
from the shift lever and selector lever cable Radiator Surge Tank Replacement (L2B) on
bracket. page 9‑1034.
34. Disconnect the fan connector.

2551785
2497621
30. If equipped with manual transmission (M20-6
speed), disconnect the shift lever and selector 35. Remove air conditioning compressor and
lever cable end (1) from the transmission shift lever condenser hose nut (1).
and selector lever. 36. Remove air conditioning compressor and
31. Pull the cable retainers (2) to release the shift lever condenser hose (2) from refrigerant hose.
and selector lever cable from the shift lever and 37. Remove air conditioning compressor and
selector lever cable bracket. condenser hose from the vehicle.
38. Cap off the A/C hose to prevent contamination.

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9-1564 Engine Mechanical - 1.3L (LDV) Diesel

2551885 2666856

39. Disconnect the fuel feed pipe (1). Refer to Plastic 41. Install the DT-50186 (4 wheel nut) or CH-49376 (5
Collar Quick Connect Fitting Service on wheel nut) tool (1) to the wheel hub with the
page 9‑774. wheel nuts.

2551883 2666888

40. Disconnect the fuel return pipe (1). Refer to Plastic 42. Remove the wheel drive shaft nut (1) from the
Collar Quick Connect Fitting Service on wheel drive shaft.
page 9‑774. 43. Remove the DT-50186 (4 wheel nut) or CH-49376
(5 wheel nut) tool from the wheel hub.
44. Remove the DT-50186 tool from the wheel hub.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1565

2539770 2539785

45. Remove the upper stabilizer shaft link nut (1). 48. Remove the steering linkage outer tie rod nut (1).
46. Disconnect the stabilizer shaft link (2) from the 49. Separate the steering linkage outer tie rod (2) from
front strut. the steering knuckle. Refer to Steering Linkage
Outer Tie Rod Replacement on page 15‑29.
50. Separate the control arm ball joint from the steering
knuckle. Refer Lower Control Arm Replacement on
page 16‑14.
51. Using the DT-50188 remover (2), separate the
wheel drive shaft from the steering knuckle (1).
52. Remove the upper stabilizer shaft link from the
absorber on both sides. Refer to Stabilizer Shaft
Link Replacement on page 16‑8.
53. Remove the front exhaust pipe. Refer to Exhaust
Front Pipe Replacement (LJ1,LMD) on
page 9‑1903 or Exhaust Front Pipe Replacement
(LDV) on page 9‑1904 or Exhaust Front Pipe
Replacement (L2B) on page 9‑1906 or Exhaust
Front Pipe Replacement (LDC) on page 9‑1908.

2497213

47. Remove the control arm ball joint to the steering

knuckle bolt and nut (1, 2). Refer Lower Control
Arm Replacement on page 16‑14.
2562992

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9-1566 Engine Mechanical - 1.3L (LDV) Diesel
54. If equipped with manual transmission (F17-5
speed), remove the lower oil pan to transmission
lower bolts (1).

2563005

57. Mark the location of the bolts (1) before removing.

58. Remove the right side engine mount bolts (1).
2586149 Refer to Engine Mount Replacement on
Note: Use a suitable tool to support the powertrain. page 9‑1538.

55. Remove the drivetrain and front suspension

frame (5). Refer to Drivetrain and Front
Suspension Frame Replacement on page 3‑137.

2512886

59. Remove and DISCARD the left transmission

mount to bracket bolts (1).
2666890 60. Remove the left transmission mount to body
bolts (2).
56. If equipped with manual transmission (M20-6
speed), remove the lower transmission bolts (1, 2). 61. Remove the left transmission mount to
body nut (3).
62. Remove the transmission mount (4) from the
vehicle.
63. Disconnect any additional electrical connections as
necessary.
64. Raise the vehicle until the powertrain is clear for
removal.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1567
Installation Procedure
1. Remove the engine from the engine stand.

2563026

65. If equipped with manual transmission (F17-5

speed), remove the upper transmission to engine
bolts (1) and separate the engine and 2666892
transmission.
2. If equipped with manual transmission (M20-6
66. Discount any electrical connectors as needed. speed), install the upper transmission to engine
67. Disconnect any additional transmission hoses as bolts (1) and tighten to 60 Y (44 lb ft).
necessary. 3. Place the powertrain into the front frame.
4. Slowly lower the body onto the powertrain.

2666892

68. If equipped with manual transmission (F17-5 2563026

speed), remove the upper transmission to engine
bolts (1) and separate the engine and 5. Install the transmission to the engine.
transmission. Caution: Refer to Fastener Caution on page 0‑9.
69. Discount any electrical connectors as needed. 6. If equipped with manual transmission (F17-5
70. Disconnect any additional transmission hoses as speed), install the upper transmission to engine
necessary. bolts (1) and tighten to 60 Y (44 lb ft).
71. Install the engine to the engine stand. 7. Place the powertrain into the front frame.
72. Transfer parts as necessary. 8. Slowly lower the body onto the powertrain.

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9-1568 Engine Mechanical - 1.3L (LDV) Diesel

2512886 2586149

9. Install the left transmission mount (4) to the 14. Install the drivetrain and front suspension
vehicle. frame (5). Refer to Drivetrain and Front
10. Install the transmission mount to body bolts (2) and Suspension Frame Replacement on page 3‑137.
tighten to 62 Y (46 lb ft).
11. Install the transmission mount to body nut (3) and
tighten to 62 Y (46 lb ft).
12. Install the NEW left transmission mount to
transmission bolts (1) and tighten to
50 Y (37 lb ft) plus 60 degrees.

2539811

15. Using CH-50619 pins-cradle alignment (1).

2563005

13. Install the right side engine mount bolts (1) and
tighten to 50 Y (37 lb ft) plus 70 degrees.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1569

2539810 2666890

16. Align the frame and body through alignment 20. If equipped with manual transmission (M20-6
hole (2). speed), install the lower transmission bolts (1, 2)
17. Remove the lift table. and tighten to 60 Y (44 lb ft).
21. Install the front exhaust pipe. Refer Exhaust Front
Pipe Replacement (LJ1,LMD) on page 9‑1903 or
Exhaust Front Pipe Replacement (LDV) on
page 9‑1904 or Exhaust Front Pipe Replacement
(L2B) on page 9‑1906 or Exhaust Front Pipe
Replacement (LDC) on page 9‑1908.

2562992

18. If equipped with manual transmission (F17-5

speed), install the lower oil pan to transmission
lower bolts (1) and tighten to 60 Y (44 lb ft).
19. Install the front exhaust pipe. Refer Exhaust Front
Pipe Replacement (LJ1,LMD) on page 9‑1903 or 2539785
Exhaust Front Pipe Replacement (LDV) on
page 9‑1904 or Exhaust Front Pipe Replacement 22. Inset the wheel drive shaft to the steering knuckle.
(L2B) on page 9‑1906 or Exhaust Front Pipe 23. Install the steering linkage outer tie rod nut (1) and
Replacement (LDC) on page 9‑1908. tighten to 65 Y (44 lb ft).
24. Install the steering linkage outer tie rod to the
steering knuckle. Refer to Steering Linkage Outer
Tie Rod Replacement on page 15‑29.

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9-1570 Engine Mechanical - 1.3L (LDV) Diesel

2666856

28. Install the DT-50186 wheel hub holder (4 wheel

nut) or CH-49376 wheel hub holder (5 wheel nut)
wheel hub holder (1) to the wheel hub with the
wheel nut.

2497213

25. Install the control arm ball joint to the steering

knuckle bolt and nut (1, 2). Refer Lower Control
Arm Replacement on page 16‑14.

2666888

29. Remove the DT-50186 (4 wheel nut) or CH-49376

(5 wheel nut) Wheel Hub Holder from the
wheel hub.
30. Install the wheel drive shaft nut (1) and tighten to
250 Y (184 lb ft).

2539770

26. Connect the stabilizer shaft link (2).

27. Install the upper stabilizer shaft link nut (1) and
tighten to 65 Y (44 lb ft).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1571

2551883 2497621

31. Connect the fuel return pipe (1). 33. Install air conditioning compressor and condenser
hose (2) to the refrigerant hose.
34. Install air conditioning compressor and condenser
hose nut (1) and tighten nut to 22 Y (16 lb ft).

2551885

32. Connect the fuel feed pipe (1).

2562977

35. Install the radiator surge tank (1). Refer to Radiator

Surge Tank Replacement on page 9‑1032 or
Radiator Surge Tank Replacement (LDV,LDC) on
page 9‑1033 or Radiator Surge Tank Replacement
(L2B) on page 9‑1034.
36. Connect the fan connector.

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9-1572 Engine Mechanical - 1.3L (LDV) Diesel

2512882 2028267

37. If equipped with manual transmission (F17-5 Note: The clutch actuator cylinder front pipe must
speed), connect the shift lever and selector lever engage noticeably.
cable ends (1) to the transmission shift lever and 42. Connect the clutch actuator cylinder front pipe (2)
selector lever. to the clutch actuator cylinder pipe elbow.
38. Install the shift lever and the selector lever 43. Lock the clutch actuator cylinder front pipe
cable (3) to the shift lever and the selector lever retaining clip (1).
cable bracket.

2562814
2551785
44. Connect the heater inlet hose to the heater
39. If equipped with manual transmission (M20-6 core (1). Refer to Heater Inlet Hose Replacement
speed), connect the shift lever and the selector (LDV) on page 10‑89 or Heater Inlet Hose
lever cable ends (1) to the transmission shift lever Replacement (LJ1, LMD) on page 10‑91 or Heater
and the selector lever. Inlet Hose Replacement (LDC) on page 10‑92 or
40. Pull the cable retainers (2), then position the shift Heater Inlet Hose Replacement (L2B) on
lever and the selector lever cable in the shift lever page 10‑93.
and the selector lever cable bracket.
41. Release the cable retainers (2) to connect the shift
lever and the selector lever cable to the shift lever
and the selector lever cable bracket.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1573

2562817 2666812

45. Connect the heater outlet hose to the heater 48. Connect the body wiring harness connector (1).
core (1). Refer to Heater Outlet Hose Replacement
(LJ1 LMD) on page 10‑95 or Heater Outlet Hose
Replacement (LDV) on page 10‑96 or Heater
Outlet Hose Replacement (LDC) on page 10‑97 or
Heater Outlet Hose Replacement (L2B) on
page 10‑99.

2666814

49. Connect the glow plug control module harness

connector (1).

2512974

46. Install the power brake booster vacuum check

valve (1) to the power vacuum brake booster.
47. Connect the power vacuum brake booster vacuum
sensor electrical connector, if equipped.

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9-1574 Engine Mechanical - 1.3L (LDV) Diesel

2539765 2539757

50. Install the ground nuts (1) and tighten to 52. Install the junction block to the base.
10 Y (89 lb in). 53. Install the junction block bolts (2) and tighten to
5 Y (44 lb in).
54. Install the junction block nut (1) and tighten to
5 Y (44 lb in).

2539762

51. Clip in the wiring harness plugs (1).

2504689

55. Position the positive battery cable to the junction

block.
56. Install the positive battery cable nut (2) and tighten
to 10 Y (89 lb in).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1575
64. Fill the cooling system. Refer to Cooling System
Draining and Filling (Static Fill) on page 9‑1026 or
Cooling System Draining and Filling (GE 47716) on
page 9‑1026.
65. Install the engine sight shied. Refer to Engine Sight
Shield Replacement on page 9‑1577.

Engine Oil and Oil Filter

Replacement
Object-ID=2551851 Owner=Youkhana, Karem LMD=02-May-2012 LMB=Youkhana, Karem

Removal Procedure
1. Remove the air cleaner duct. Refer to Air Cleaner
Outlet Duct Replacement on page 9‑703.
2. Place a collecting pan underneath the oil filter.

2539745

57. Install the junction block cover (1).

2551850

3. Remove the oil filter cap (1).

4. Remove the oil filter cap seal (2).
Caution: SIO-ID=2052887 LMD=24-Jan-2008 This engine uses a
special high performance oil filter. Use of any other filter
2563036 may lead to filter failure and/or severe engine damage.
5. Remove and properly dispose of the oil filter
58. Install the air cleaner assembly (1). Refer to Air insert (3).
Cleaner Assembly Replacement on page 9‑706.
Caution: Refer to Fastener Caution on page 0‑9.
59. Install the lower intermediate steering shaft bolt .
Refer Intermediate Steering Shaft Replacement 6. Install a NEW oil filter (3) and a NEW seal (2) and
(LHD) on page 15‑80 or Intermediate Steering tighten the oil filter cap (1) to 25 Y (18 lb ft).
Shaft Replacement (RHD) on page 15‑81. 7. Raise the vehicle. Refer to Lifting and Jacking the
60. Install the battery and battery tray. Refer to Battery Vehicle on page 1‑25.
Tray Replacement on page 9‑66. 8. Place a collecting pan underneath the oil drain
61. Install the front tire and wheel assembly. Refer to plug .
Tire and Wheel Removal and Installation on
page 16‑57.
62. Install the front bumper fascia. Refer to Front
Bumper Fascia Replacement on page 3‑53.
63. Evacuate and charge the refrigerant system. Refer
Refrigerant Recovery and Recharging on
page 10‑15.

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9-1576 Engine Mechanical - 1.3L (LDV) Diesel
4. Refill the engine oil. Refer to Engine Mechanical
Specifications on page 9‑1438.
5. Reset the service interval indicator.

2551849

9. Remove the oil drain plug (1).

Installation Procedure
1. Clean the oil drain plug thread and the thread in
the oil pan.

2551849

2. Install a NEW seal to the oil drain plug (1).

Caution: Refer to Fastener Caution on page 0‑9.
3. Install the oil drain plug to the oil pan and tighten to
14 Y (124 lb in).
Caution: SIO-ID=2051003 LMD=23-Jan-2008 Using engine oils of
any viscosity other than those viscosities
recommended could result in engine damage.
Note:
• Use specified volume of engine oil with the
specified viscosity class.
• Start the engine and allow it to run until the oil
pressure control indicator goes off.
• Inspect the engine oil level.
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 Engine Mechanical - 1.3L (LDV) Diesel 9-1577
Engine Sight Shield Replacement
Object-ID=2551823 Owner=Youkhana, Karem LMD=31-May-2011 LMB=Youkhana, Karem

2551821

Engine Sight Shield Replacement

Callout Component Name
Engine Sight Shield
1 Procedure
Ensure the engine sight shield retainers are in place before installing the shield.

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9-1578 Engine Mechanical - 1.3L (LDV) Diesel
Turbocharger Replacement
Object-ID=2558453 Owner=Youkhana, Karem LMD=17-Jan-2012 LMB=Smith, Craig

Removal Procedure
1. Disconnect the battery negative cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9‑53.
2. Remove the engine sight shield. Refer to Engine
Sight Shield Replacement on page 9‑1577.

2552135

6. Remove catalytic converter 2). Refer to Oxidation

Catalytic Converter Replacement (LDV) on
page 9‑1909.

2666291

3. Remove the air cleaner outlet (1). Refer to Air

Cleaner Outlet Duct Replacement on page 9‑703.

2190431

7. Remove the turbocharger oil feed pipe bolt (2) from

the turbocharger (1).
8. Remove the turbocharger oil feed pipe gasket (3).
9. Remove the turbocharger oil feed pipe bolt (5) from
the oil filter housing (7).
10. Remove the turbocharger oil feed pipe gasket (6).
11. Remove the turbocharger oil feed pipe (4).

2190421

4. Remove the turbocharger wastegate actuator

vacuum control solenoid valve splash shield
nuts (2).
5. Remove the turbocharger wastegate actuator
vacuum control solenoid valve splash shield (1).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1579

2551863 2190450

12. Remove the turbocharger oil return hose 17. Remove the turbocharger nuts (3).
clamps (1). 18. Remove the turbocharger (1) from the exhaust
13. Remove the turbocharger oil return hose (2) from manifold.
the turbocharger and the oil filter housing. 19. Remove the turbocharger gasket (2).
Installation Procedure

2371790

14. Remove charge air cooler inlet air pipe bolts (3).
2190450
15. Remove charge air cooler inlet air pipe (4) from the
turbocharger (1). 1. Install a NEW turbocharger gasket (2).
16. Disconnect the wiring harness connector before 2. Install the turbocharger (1) to the exhaust manifold.
removing the turbocharger. Caution: Refer to Fastener Caution on page 0‑9.
3. Install the turbocharger nuts (3) and tighten to
25 Y (18 lb ft).
4. Connect the wiring harness connector before
removing the turbocharger.

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9-1580 Engine Mechanical - 1.3L (LDV) Diesel

2371790 2190431

5. Install a NEW charge air cooler inlet air pipe 10. Install the turbocharger oil feed pipe (4).
gasket (2). 11. Install the NEW turbocharger oil feed pipe
6. Install the charge air cooler inlet air pipe (4) to the gasket (6).
turbocharger (1). 12. Install the turbocharger oil feed pipe bolt (5) to the
7. Install the charge air cooler inlet air pipe bolts (3) oil filter housing (7) and tighten to 22 Y (16 lb ft).
and tighten to 10 Y (89 lb in). 13. Install the NEW turbocharger oil feed pipe
gasket (3).
14. Install the turbocharger oil feed pipe bolt (2) to the
turbocharger (1) and tighten to 22 Y (16 lb ft).

2551863

8. Install the turbocharger oil return hose (2) to the

turbocharger and the oil filter housing.
2552135
9. Install the turbocharger oil return hose clamps (1).
15. Install the catalytic converter (2). Refer to
Oxidation Catalytic Converter Replacement (LDV)
on page 9‑1909.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1581
Air Conditioning Compressor Belt
Replacement
Object-ID=2565975 Owner=Youkhana, Karem LMD=31-May-2011 LMB=Youkhana, Karem

Removal Procedure
1. Remove the front wheelhouse liner inner front
extension. Refer to Front Wheelhouse Liner Inner
Front Extension Replacement on page 3‑142

2190421

16. Install the turbocharger wastegate actuator

vacuum control solenoid valve splash shield (1).
17. Install the turbocharger wastegate actuator
vacuum control solenoid valve splash shield nuts
(2) and tighten to 9 Y (80 lb in).

2560814

2. Cut the air conditioning (A/C) belt (1) with a

appropriate cutting tool as shown.
3. Remove and discard the air conditioning (A/C)
belt (1).
Installation Procedure

2666291

18. Install the air cleaner outlet (1). Refer to Air

Cleaner Outlet Duct Replacement on page 9‑703.
19. Install the engine sight shield. Refer to Engine
Sight Shield Replacement on page 9‑1577.
20. Connect the battery negative cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9‑53.

2560816

1. Position a NEW air conditioning (A/C) belt (1) on

the crankshaft pulley (3) and air conditioning (A/C)
compressor (2) as shown.

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9-1582 Engine Mechanical - 1.3L (LDV) Diesel
Note: Push the on belt while rotating the crankshaft
pulley.
2. Using a socket and ratchet on the crankshaft pulley
bolt (4), rotate the crankshaft in the direction of the
arrow until the belt (1) is fully installed on the air
conditioning (A/C) compressor (2).

2560818

3. After the belt is on the air conditioning (A/C)

compressor pulley (2) , rotate the crankshaft (3) an
additional complete revolution and ensure the air
conditioning (A/C) belt (1) is fully seated on the
crankshaft (3) and air conditioning (A/C)
compressor (2).
4. Install the front wheelhouse liner inner front
extension. Refer to Front Wheelhouse Liner Inner
Front Extension Replacement on page 3‑142

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1583
Generator and Power Steering Pump Belt Replacement
Object-ID=2565984 Owner=Youkhana, Karem LMD=08-Feb-2011 LMB=Youkhana, Karem

2560840

Generator and Power Steering Pump Belt Replacement

Callout Component Name
Preliminary Procedure
1. Remove the front wheelhouse liner inner front extension. Refer to Front Wheelhouse Liner Inner Front Extension
Replacement on page 3‑142.
2. Remove the air conditioning (A/C) belt. Refer to Air Conditioning Compressor Belt Replacement on page 9‑1581.
Drive Belt Tensioner
1
Rotate the drive belt tensioner counterclockwise to release the drive belt tension.
Drive Belt
Procedure
2
1. Slide the drive belt off of the belt idler pulley.
2. Slowly release the drive belt tensioner.

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9-1584 Engine Mechanical - 1.3L (LDV) Diesel
Water Pump, Air Conditioning 3. Remove the drive belt (1).
Compressor, and Generator Belt Installation Procedure
Replacement
Object-ID=2565994 Owner=Youkhana, Karem LMD=10-Apr-2013 LMB=Lavigne, Matthew

Special Tools
EN-6130 Fixing Pin
For equivalent regional tools, refer to Special Tools on
page 9‑1711.
Removal Procedure
1. Remove the front wheelhouse liner Inner front
extension. Refer to Front Wheelhouse Liner Inner
Front Extension Replacement on page 3‑142.

2557465

1. Install the drive belt (1).

2557458

2. Release tension to the drive belt tensioner by

rotating counterclockwise (1) and lock with
EN-6130 pin (2).

2557458

2. Release tension to the tensioner by rotating

counterclockwise (1).
Note: Allow tensioner to slide back slowly.
3. Remove EN-6130 pin (2).
4. Apply tension to the tensioner clockwise (1).
5. Install the front wheelhouse liner Inner front
extension. Refer to Front Wheelhouse Liner Inner
Front Extension Replacement on page 3‑142.

2557465

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1585
Intake Manifold Replacement
Object-ID=2560575 Owner=Youkhana, Karem LMD=20-Apr-2012 LMB=Diamond, Jodi

Removal Procedure
1. Disconnect the battery negative cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9‑53.
2. Remove the engine sight shield. Refer to Engine
Sight Shield Replacement on page 9‑1577.

2190513

7. Remove the exhaust pressure sensor pipe bolt (1)

from the throttle body support.
8. Remove the exhaust pressure sensor pipe bolt (3)
from the exhaust pressure sensor bracket.
9. Remove the exhaust pressure sensor pipe
clamp (4).
10. Remove the exhaust pressure sensor pipe (2).
11. Remove the exhaust gas recirculation pipe. Refer
to Exhaust Gas Recirculation Pipe Replacement
2371694 on page 9‑719.
3. Remove the charge air cooler outlet air hose
bolts (3).
4. Remove the charge air cooler outlet air hose (4)
from the throttle body (1) and hang aside.
5. Remove the charge air cooler outlet air hose
seal (2).
6. Remove the throttle body assembly. Refer to
Throttle Body Assembly Replacement on
page 9‑770.

2190510

12. Remove the throttle body support bolts (2).

13. Remove the exhaust gas recirculation valve cooler.
Refer to Exhaust Gas Recirculation Valve
Replacement on page 9‑721.
14. Remove the oil level indicator tube. Refer to Oil
Level Indicator Tube Replacement on
page 9‑1592.

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9-1586 Engine Mechanical - 1.3L (LDV) Diesel
15. Remove the positive crankcase ventilation oil 23. Remove the 2 exhaust pressure sensor connector
separator. Refer to Positive Crankcase Ventilation bracket bolts (1).
Oil Separator Replacement on page 9‑1605. 24. Remove the exhaust pressure sensor connector
bracket.

2190504

2756838
16. Disconnect the positive crankcase ventilation pipe
connector (3) from the positive crankcase 25. Remove the 2 positive crankcase ventilation oil
ventilation oil separator. separator hose bracket bolts (1).
17. Disconnect the positive crankcase ventilation pipe 26. Remove the positive crankcase ventilation oil
connector wiring harness plug. separator hose bracket.
18. Remove the vacuum hose from the turbocharger 27. Remove the generator and power steering pump
wastegate actuator vacuum control solenoid valve. bracket. Refer to Generator and Power Steering
19. Remove the positive crankcase ventilation pipe Pump Bracket Replacement (LDV) on page 9‑75.
bracket bolts (2).
20. Remove the positive crankcase ventilation pipe (1).
21. Remove the fuel feed pipe. Refer to Fuel Feed
Pipe Replacement on page 9‑734.
22. Remove the fuel return pipe. Refer to Fuel Return
Pipe Replacement on page 9‑749.

2190721

28. Remove the intake manifold upper bolts (3).

29. Remove the intake manifold lower bolts (4).
30. Remove the intake manifold (2).
31. Remove the intake manifold gaskets (1).
2756837 32. Disassemble the intake manifold. Refer to Intake
Manifold Disassemble on page 9‑1655.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1587
Installation Procedure
1. Assemble the intake manifold. Refer to Intake
Manifold Assemble on page 9‑1656.

2756838

9. Install the 2 positive crankcase ventilation oil

separator hose bracket bolts (1).
10. Install the positive crankcase ventilation oil
2190721 separator hose bracket.
2. Install the NEW intake manifold gaskets (1). 11. Install the fuel return pipe. Refer to Fuel Return
3. Install the intake manifold (2). Pipe Replacement on page 9‑749.
Caution: Refer to Fastener Caution on page 0‑9. 12. Install the fuel feed pipe. Refer to Fuel Feed Pipe
Replacement on page 9‑734.
4. Install the intake manifold lower bolts (4) and the 5
intake manifold upper bolts (3) and tighten to
25 Y (18 lb in).
5. Connect the throttle body wiring harness plug.
6. Install the generator and power steering pump
bracket. Refer to Generator and Power Steering
Pump Bracket Replacement (LDV) on page 9‑75.

2190504

13. Install the positive crankcase ventilation pipe (1).

14. Install the vacuum hose to the turbocharger
wastegate actuator vacuum control solenoid valve.
15. Connect the positive crankcase ventilation pipe
connector wiring harness plug.
2756837 16. Install the positive crankcase ventilation pipe
7. Install the 2 exhaust pressure sensor connector bracket bolts (2) and tighten to 8 Y (71 lb in).
bracket bolts (1). 17. Install the positive crankcase ventilation oil
8. Install the exhaust pressure sensor connector separator. Refer to Positive Crankcase Ventilation
bracket. Oil Separator Replacement on page 9‑1605.

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9-1588 Engine Mechanical - 1.3L (LDV) Diesel
18. Install the oil level indicator tube. Refer to Oil Level 26. Install the exhaust pressure sensor pipe bolt (3) to
Indicator Tube Replacement on page 9‑1592. the exhaust pressure sensor bracket and tighten to
19. Install the exhaust gas recirculation valve cooler. 9 Y (80 lb in).
Refer to Exhaust Gas Recirculation Valve 27. Install the exhaust pressure sensor pipe bolt (1) to
Replacement on page 9‑721. the throttle body support and tighten to 9 Y
(80 lb in).

2190510
2371694
20. Install the throttle body support (1).
21. Install the throttle body support bolts (2) and 28. Install a NEW charge air cooler outlet air hose
tighten to 9 Y (80 lb in). seal (2).
22. Install the exhaust gas recirculation pipe. Refer to 29. Install the charge air cooler outlet air hose (4) to
Exhaust Gas Recirculation Pipe Replacement on the throttle body (1).
page 9‑719. 30. Install the charge air cooler outlet air hose bolts (3)
23. Install the throttle body assembly. Refer to Throttle and tighten to 10 Y (89 lb in).
Body Assembly Replacement on page 9‑770. 31. Install the engine sight shield. Refer to Engine
Sight Shield Replacement on page 9‑1577.
32. Connect the battery negative cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9‑53.

Oil Filler Tube Replacement

Object-ID=2556866 Owner=Youkhana, Karem LMD=02-May-2012 LMB=Smith, Craig

Removal Procedure
1. Remove the engine sight shield. Refer to Engine
Sight Shield Replacement on page 9‑1577.

2190513

24. Install the exhaust pressure sensor pipe (2).

25. Install the exhaust pressure sensor pipe clamp (4).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1589
Installation Procedure

2556301

2. Cut the positive crankcase ventilation oil separator

hose clamp from the oil fill tube (1). 2556303

3. Remove the positive crankcase ventilation oil 1. Install the oil filler tube (2) to the oil pump housing.
separator hose (2). 2. Install the oil filler tube bolts (1) and tighten to 9 Y
(80 lb in)

2556303

4. Remove the oil filler tube bolts (1). 2556301

5. Remove the oil filler tube (2) from the oil pump 3. Install the positive crankcase ventilation oil
housing. separator hose clamp (1).
4. Install the positive crankcase ventilation oil
separator hose.

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9-1590 Engine Mechanical - 1.3L (LDV) Diesel
Oil Filter Housing Replacement
Object-ID=2557282 Owner=Youkhana, Karem LMD=30-Jun-2011 LMB=Youkhana, Karem

Removal Procedure
1. Disconnect the battery negative cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9‑53.
2. Drain the cooling system. Refer to Cooling System
Draining and Filling (Static Fill) on page 9‑1026 or
Cooling System Draining and Filling (GE 47716) on
page 9‑1026.
3. Remove the oxidation catalytic converter. Refer to
Oxidation Catalytic Converter Replacement (LDV)
on page 9‑1909.
4. Remove the turbocharger. Refer to Turbocharger
Replacement on page 9‑1578.

2371691

9. Remove the radiator outlet hose clamp (2).

10. Remove the radiator outlet hose (3) from the
engine oil cooler (1).

2190446

5. Remove the thermostat bypass pipe bolts (1) from

the oil filter housing.
6. Remove the thermostat bypass pipe bracket
bolt (4).
7. Remove the thermostat bypass pipe gasket (5).
8. Hang the thermostat bypass pipe aside. 2190448

11. Remove the oil filter housing bolts (2).

12. Remove the oil filter housing (1).
13. Remove the oil filter housing gasket (3).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1591
Installation Procedure

2190446

6. Install a NEW thermostat bypass pipe gasket (5).

2190448
7. Install the thermostat bypass pipe (2).
1. Install a NEW oil filter housing gasket (3). 8. Install the thermostat bypass pipe bolts (1) to the
2. Install the oil filter housing (1). oil filter housing and tighten to 9 Y (80 lb in).
Caution: Refer to Fastener Caution on page 0‑9. 9. Install the thermostat bypass pipe bracket bolt (4)
3. Install the oil filter housing bolts (2) and tighten to and tighten to 9 Y (80 lb in).
9 Y (80 lb in). 10. Install the turbocharger. Refer to Turbocharger
Replacement on page 9‑1578.
11. Install the oxidation catalytic converter. Refer to
Oxidation Catalytic Converter Replacement (LDV)
on page 9‑1909.
12. Connect the battery negative cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9‑53.
13. Fill the cooling system. Refer to Cooling System
Draining and Filling (Static Fill) on page 9‑1026 or
Cooling System Draining and Filling (GE 47716) on
page 9‑1026.

2371691

4. Install the radiator outlet hose (3) to the engine oil

cooler (1).
5. Install the radiator outlet hose clamp (2).

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9-1592 Engine Mechanical - 1.3L (LDV) Diesel
Oil Level Indicator Tube Replacement
Object-ID=2551861 Owner=Youkhana, Karem LMD=09-Jan-2012 LMB=Lavigne, Matthew

2551854

Oil Level Indicator Tube Replacement

Callout Component Name
Preliminary Procedure
1. Remove the engine sight shield. Refer to Engine Sight Shield Replacement on page 9‑1577.
2. Remove the air inlet grille panel and position out of the way. Refer to Air Inlet Grille Panel Replacement on page 4‑348.
Exhaust Pressure Sensor Pipe Bolt.
Caution: Refer to Fastener Caution on page 0‑9.
1
Tighten
9 Y (80 lb in)
Oil Level Indicator Tube bolt
2 Tighten
9 Y (80 lb in)
Oil Level Indicator Tube Gasket
3 Procedure
Use a NEW oil level indicator tube gasket whenever removing the tube.
Oil Level Indicator Tube
4
Note: Remove the upper extension cover before removing the oil level indicator tube.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1593
Camshaft Replacement
Object-ID=2562389 Owner=Youkhana, Karem LMD=31-May-2011 LMB=Youkhana, Karem

Special Tools
EN-46781 Fixing Tool.
For equivalent regional tools, refer to Special Tools on
page 9‑1711.
Removal Procedure
1. Remove the camshaft housing cover gasket. Refer
to Camshaft Housing and Cover Gasket
Replacement on page 9‑1484.
2. Remove the vacuum pump. Refer to Vacuum
Pump Assembly Replacement on page 9‑727.
3. Remove the fuel injection pump. Refer to Fuel
Injection Pump Replacement on page 9‑742.
4. Remove the camshaft position sensor. Refer to
Camshaft Position Sensor Replacement on
page 9‑707.
2190961

8. Mark the location as shown above EN-46781 fixing

tool (1).

2190960

5. Remove the exhaust cylinder head core hole

plug (2) from the camshaft housing (1).
2190962
6. Remove the intake cylinder head core hole plug (3)
from the camshaft housing (1). Note: EN-46781 fixing tool (1) must be installed in
horizontal position.
7. Clean the threads from the cylinder head core hole
plugs and the camshaft housing. 9. Install the EN-46781 fixing tool (1) onto the
exhaust side and intake side.

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9-1594 Engine Mechanical - 1.3L (LDV) Diesel

2371758 2371759

10. Remove the exhaust camshaft sprocket bolt (2). 15. Remove the intake camshaft sprocket bolt (1).
11. Remove the exhaust camshaft sprocket (3). 16. Remove the intake camshaft sprocket (2).
12. Remove the EN-46781 fixing tool on the 17. Remove the EN-46781 fixing tool from the
exhaust side. intake side.
13. Remove the exhaust camshaft (1). 18. Remove the intake camshaft (3).

2551948 2552004

14. Remove the exhaust camshaft (1). 19. Remove the intake camshaft (1).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1595
Installation Procedure

2551948

6. Install the exhaust camshaft (1).

2552004

1. Install the intake camshaft (1).

2371758

Note: Clean the contact surfaces from camshaft ,

2371759 camshaft sprocket and camshaft sprocket bolt.
Note: Clean the contact surfaces from camshaft , Coat camshaft bearing surfaces with engine oil.
camshaft sprocket and camshaft sprocket bolt. 7. Install the exhaust camshaft (1).
Coat camshaft bearing surfaces with engine oil. 8. Install the EN-46781 fixing tool on exhaust side.
2. Install the intake camshaft (3). 9. Install the exhaust camshaft sprocket (3).
3. Install the EN-46781 fixing tool on the intake side. 10. Install the exhaust camshaft sprocket bolt (2) and
4. Install the intake camshaft sprocket (2). tighten to 150 Y (111 lb ft).
Caution: Refer to Fastener Caution on page 0‑9. 11. Remove the EN-46781 fixing tool from the
5. Install the intake camshaft sprocket bolt (1) and exhaust side.
tighten to 150 Y (111 lb ft).

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9-1596 Engine Mechanical - 1.3L (LDV) Diesel
3. Remove the water pump. Refer to Water Pump
Replacement (LDV) on page 9‑1080 or Water
Pump Replacement (LJ1, LMD) on page 9‑1082 or
Water Pump Replacement (L2B) on page 9‑1083
or Water Pump Replacement (LDC) on
page 9‑1084.
4. Remove the drive belt tensioner. Refer to Drive
Belt Tensioner Replacement on page 9‑1537.
5. Remove the engine mount bracket. Refer to
Engine Mount Bracket Replacement on
page 9‑1539.

2190960

12. Install the exhaust cylinder head core hole plug (2)
and intake cylinder head core plug to the camshaft
housing (1). and tighten to 15 Y (11 lb ft)
13. Install the camshaft position sensor. Refer to
Camshaft Position Sensor Installation on
page 9‑1687.
14. Install the fuel injection pump. Refer to Fuel
Injection Pump Installation on page 9‑1696.
15. Install the vacuum pump. Refer to Vacuum Pump
Installation on page 9‑1697.
16. Install the camshaft position sensor. Refer to 2371723
Camshaft Position Sensor Replacement on
page 9‑707 6. Remove the 2 oil filler tube bolts (2, 3).
17. Install the fuel injection pump. Refer to Fuel 7. Remove the oil filler tube (1) from the oil pump
Injection Pump Replacement on page 9‑742. housing (4).
18. Install the vacuum pump. Refer to Vacuum Pump 8. Remove the turbocharger. Refer to Turbocharger
Assembly Replacement on page 9‑727. Replacement on page 9‑1578.
19. Install the camshaft housing cover gasket. Refer to
Camshaft Housing and Cover Gasket
Replacement on page 9‑1484.

Oil Pump Housing Replacement

Object-ID=2562630 Owner=Youkhana, Karem LMD=13-Jul-2012 LMB=Troczynski, Darryl

Special Tool
• EN-470-B Torque Wrench
• EN-662-C Holding Wrench
• EN-46781 Fixing Tool Camshaft
• EN-46785 Fixing Tool Crankshaft
• EN-46775 Centering Tool Oil Pump Housing
For equivalent regional tools, refer to Special Tools on
page 9‑1711.
Removal Procedure
1. Remove the oil pan. Refer to Oil Pan Replacement
on page 9‑1529.
2. Remove the crankshaft pulley. Refer to Crankshaft 2190960
Pulley Replacement on page 9‑1519.
9. Remove the exhaust camshaft housing core hole
plug (2) from the camshaft housing.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1597
10. Clean the threads at the camshaft housing and the
camshaft housing core hole plug.

2191979

Note: Turn the crankshaft carefully until EN-46785

fixing tool (1) engages in the flywheel.
2190961
15. If equipped with manual transmission (F17-5
11. Mark the location shown above EN-46781 fixing speed), install the EN-46785 fixing tool (1).
tool (1).

2666309
2190962 Note: Turn the crankshaft carefully until EN-46785
Note: The EN-46781 fixing tool (1) must be installed in fixing tool (1) engages in the flywheel.
horizontal position.
16. If equipped with manual transmission (M20-6
12. Install the EN-46781 fixing tool (1) into the speed), install the EN-46785 fixing tool (1).
exhaust side.
Note: If the EN-46781 fixing tool (1) does not rotate
any longer, the tool is correctly engaged.
13. Turn the crankshaft at the crankshaft sprocket bolt
carefully, until the EN-46781 fixing tool (1)
engages at the intake camshaft.
Note: Verify that the flywheel spot to assemble the
EN-46785 fixing tool crankshaft is downside.
14. Raise the vehicle.

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9-1598 Engine Mechanical - 1.3L (LDV) Diesel

2190969 2830825

17. Install the EN-662-C wrench (2). 22. Remove the oil pump housing bolts (3).
18. Install the bolts. 23. Remove the oil pump housing nuts (4).
19. Loosen the crankshaft sprocket bolt (1) by turning 24. Remove the oil pump housing (2).
clockwise. 25. Remove the oil pump housing gasket (1).
26. Disassemble the oil Pump. Refer to Oil Pump
Disassemble on page 9‑1677.

2190971

Note: Mind the left-hand thread.

20. Remove and DISCARD the crankshaft sprocket 2191847

bolt (1). 27. Remove the oil pump seal (1).

21. Remove the flange (2).
Installation Procedure
1. Assemble the oil pump. Refer to Oil Pump
Assemble on page 9‑1678.
2. Ensure that EN-46781 fixing tool and EN-46785
fixing tool are already installed.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1599

2666791 2191923

Note: The oil pump housing must be fitted within 5. Install the oil pump housing (2) with the EN-46775
10 minutes of applying the silicone sealing compound. fixing tool (1).
3. Apply silicone sealing compound to the transitions
between the cylinder head and camshaft housing
(1), between the cylinder block and cylinder head
(2) and between cylinder block and lower
crankcase (3).

2191909

6. Tighten the oil pump housing bolts and the oil

pump housing nuts in sequence as shown:
• In first step and in sequence as shown, tighten
2191922 to 4 Y (35 lb in).
• In second step and in sequence as shown,
4. Install the oil pump housing gasket (1). tighten to 9 Y (80 lb in).
• Remove the EN-46775 fixing tool.

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9-1600 Engine Mechanical - 1.3L (LDV) Diesel

2372550 2373026

Note: Slide the oil pump seal over the flange sealing 12. Position EN-46775 centering tool (2) with the
the surface (arrow). plane surface at the oil pump housing.
7. Install the oil pump seal (2) to the flange (1). 13. Tighten carefully the flange bolt (1) until the
EN-46775 centering tool flush with oil pump
housing (arrow).
14. Remove the flange bolt and the EN-46775
centering tool.

2372551

8. Position the flange (2) with the oil pump seal (3) to
the crankshaft.
9. Tighten carefully the flange bolt (1) to limit stop.
2190971
10. Remove the flange bolt (1).
11. Remove the flange (2). 15. Install the flange (2).
16. Loosely install the NEW crankshaft sprocket
bolt (1).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1601

2190969 2666309

17. Install the EN-662-C wrench (2). 22. If equipped with manual transmission (M20-6
18. Install the 2 bolts. speed), remove the EN-46785 fixing tool (1).
Caution: Refer to Fastener Caution on page 0‑9. 23. Lower the vehicle.
Caution: Refer to Torque-to-Yield Fastener Caution on
page 0‑10.
Note: Mind the left-hand thread.
19. Tighten the crankshaft sprocket bolt (1) to 50 Y
(37 lb ft).
20. Tighten the crankshaft sprocket bolt to additional
90°. Use the EN-470-B wrench.

2190962

24. Remove the EN-46781 fixing tool (1) from the

exhaust side.
25. Inspect the camshaft timing chain. Refer to
Camshaft Timing Chain Inspection on
page 9‑1647.

2191979

21. If equipped with manual transmission (F17-5

speed), remove the EN-46785 fixing tool (1).

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9-1602 Engine Mechanical - 1.3L (LDV) Diesel
33. Install the crankshaft pulley. Refer to Crankshaft
Pulley Replacement on page 9‑1519.
34. Install the oil pan. Refer to Oil Pan Replacement on
page 9‑1529.

Positive Crankcase Ventilation Oil

Separator Drain Hose Replacement
Object-ID=2560669 Owner=Youkhana, Karem LMD=17-Jan-2012 LMB=Youkhana, Karem

Removal Procedure
1. Disconnect the battery negative cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9‑53.
2. If equipped with front suspension frame skid plate,
remove the front suspension frame skid plate.
Refer to Drivetrain and Front Suspension Frame
Skid Plate Replacement on page 3‑136.
3. Remove the exhaust gas recirculation valve
vacuum tank. Refer to Exhaust Gas Recirculation
2190960
Valve Vacuum Tank Replacement (With Start /
26. Install the new exhaust camshaft housing core Stop) on page 9‑726 or Exhaust Gas Recirculation
hole plug (2) to the camshaft housing and tighten to Valve Vacuum Tank Replacement (Without Start /
15 Y (11 lb ft). Stop) on page 9‑727.
27. Install the turbocharger. Refer to Turbocharger
Replacement on page 9‑1578.

2372528

4. Remove the positive crankshaft ventilation oil

2371723 separator drain hose clamp (1) from the positive
crankshaft ventilation oil separator (2).
28. Install the oil filler tube (1) to the oil pump
housing (4). 5. Remove the positive crankshaft ventilation oil
separator drain hose clamp (4) from the positive
29. Install the oil filler tube bolts (2, 3) and tighten to crankshaft ventilation tube (3).
9 Y (80 lb in).
6. Remove the positive crankshaft ventilation oil
30. Install the water pump. Refer to Water Pump separator drain hose (5).
Replacement (LDV) on page 9‑1080 or Water
Pump Replacement (LJ1, LMD) on page 9‑1082 or
Water Pump Replacement (L2B) on page 9‑1083
or Water Pump Replacement (LDC) on
page 9‑1084.
31. Install the engine mount bracket. Refer to Engine
Mount Bracket Replacement on page 9‑1539.
32. Install the drive belt tensioner. Refer to Drive Belt
Tensioner Replacement on page 9‑1537.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1603
Installation Procedure

2556301

3. Cut the positive crankcase ventilation oil separator

2372528 hose clamp from the oil fill tube (1).
1. Slid the clamp (4) onto the hose (5) and install to 4. Remove the positive crankcase ventilation oil
the positive crankshaft ventilation tube (3). separator hose (2).
2. Slid the clamp (1) onto the hose (5) and install to 5. If equipped with front suspension frame skid plate,
the positive crankshaft ventilation oil separator (2). remove the front suspension frame skid plate.
3. Install the exhaust gas recirculation valve vacuum Refer to Drivetrain and Front Suspension Frame
tank. Refer Exhaust Gas Recirculation Valve Skid Plate Replacement on page 3‑136
Vacuum Tank Replacement (With Start / Stop) on 6. Remove the exhaust gas recirculation valve
page 9‑726 or Exhaust Gas Recirculation Valve vacuum tank. Refer to Exhaust Gas Recirculation
Vacuum Tank Replacement (Without Start / Stop) Valve Vacuum Tank Replacement (With Start /
on page 9‑727. Stop) on page 9‑726 or Exhaust Gas Recirculation
4. If equipped with front suspension frame skid plate, Valve Vacuum Tank Replacement (Without Start /
Install the front suspension frame skid plate. Refer Stop) on page 9‑727.
to Drivetrain and Front Suspension Frame Skid
Plate Replacement on page 3‑136.
5. Connect the battery negative cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9‑53.

Positive Crankcase Ventilation Oil

Separator Hose Replacement
Object-ID=2560644 Owner=Youkhana, Karem LMD=29-Nov-2011 LMB=Miller, Ann

Removal Procedure
1. Disconnect the battery negative cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9‑53.
2. Remove the engine sight shield. Refer to Engine
Sight Shield Replacement on page 9‑1577.

2190511

7. Remove the exhaust gas recirculation valve cooler

(2). Refer to Exhaust Gas Recirculation Valve
Cooler Replacement (With Auxiliary Pump) on

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9-1604 Engine Mechanical - 1.3L (LDV) Diesel
page 9‑722 or Exhaust Gas Recirculation Valve Installation Procedure
Cooler Replacement (Wthout Auxiliary Pump) on
page 9‑724.

2372533

2372533 1. Install the positive crankcase ventilation oil

separator (5).
8. Remove the positive crankcase ventilation pipe (1)
from the positive crankcase ventilation oil Caution: Refer to Fastener Caution on page 0‑9.
separator (5). 2. Install the 2 positive crankcase ventilation oil
9. Remove the positive crankcase ventilation oil separator bolts (4) and tighten to 9 Y (80 lb in).
separator hose clamp (3). 3. Slid the clamp (6) on the hose (7) and install to the
10. Remove the positive crankcase ventilation oil positive crankcase ventilation oil separator (5).
separator hose (2) from the positive crankcase 4. Slid the clamp (3) on the hose (2) and install to the
ventilation oil separator (5). positive crankcase ventilation oil separator (5).
11. Remove the positive crankcase ventilation oil 5. Install the positive crankcase ventilation oil
separator drain hose clamp (6). separator drain hose clamp (6).
12. Remove the positive crankcase ventilation oil 6. Install the positive crankcase ventilation oil
separator drain hose (7) from the positive separator hose (2) to the positive crankcase
crankcase ventilation oil separator (5). ventilation oil separator (5).
13. Remove the 2 positive crankcase ventilation oil 7. Install the positive crankcase ventilation oil
separator bolts (4). separator hose clamp (3).
14. Remove positive crankcase ventilation oil 8. Install the positive crankcase ventilation pipe (1) to
separator (5). the positive crankcase ventilation oil separator (5).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1605
13. Install the positive crankcase ventilation oil
separator hose.
14. Instal the engine sight shield. Refer to Engine Sight
Shield Replacement on page 9‑1577.
15. Connect the battery negative cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9‑53.

Positive Crankcase Ventilation Oil

Separator Replacement
Object-ID=2560646 Owner=Youkhana, Karem LMD=20-Apr-2012 LMB=Diamond, Jodi

Removal Procedure

2190511

9. Install the exhaust gas recirculation valve

cooler (2). Refer to Exhaust Gas Recirculation
Valve Cooler Replacement (With Auxiliary Pump)
on page 9‑722 or Exhaust Gas Recirculation Valve
Cooler Replacement (Wthout Auxiliary Pump) on
page 9‑724.
10. Install the exhaust gas recirculation valve vacuum
tank. Refer to Exhaust Gas Recirculation Valve
Vacuum Tank Replacement (With Start / Stop) on
page 9‑726 or Exhaust Gas Recirculation Valve
Vacuum Tank Replacement (Without Start / Stop)
on page 9‑727.
11. If equipped with front suspension frame skid plate,
install the front suspension frame skid plate. Refer
to Drivetrain and Front Suspension Frame Skid 2190511
Plate Replacement on page 3‑136
1. Remove the exhaust gas recirculation valve cooler
(2). Refer to Exhaust Gas Recirculation Valve
Cooler Replacement (With Auxiliary Pump) on
page 9‑722 or Exhaust Gas Recirculation Valve
Cooler Replacement (Wthout Auxiliary Pump) on
page 9‑724.
2. Remove the exhaust gas recirculation valve
vacuum tank. Refer to Exhaust Gas Recirculation
Valve Vacuum Tank Replacement (With Start /
Stop) on page 9‑726 or Exhaust Gas Recirculation
Valve Vacuum Tank Replacement (Without Start /
Stop) on page 9‑727.

2556301

12. Install the positive crankcase ventilation oil

separator hose clamp (1).

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9-1606 Engine Mechanical - 1.3L (LDV) Diesel
Note: Ensure to install the a NEW clamp before
installing any of the hoses.
1. Install the positive crankcase ventilation oil
separator (5).
Caution: Refer to Fastener Caution on page 0‑9.
2. Install the 2 positive crankcase ventilation oil
separator bolts (4) and tighten to 9 Y (80 lb in).
3. Install the positive crankcase ventilation oil
separator drain hose (7) to the positive crankcase
ventilation oil separator (5).
4. Install the positive crankcase ventilation oil
separator hose (2) to the positive crankcase
ventilation oil separator (5).
5. Install the positive crankcase ventilation pipe (1) to
the positive crankcase ventilation oil separator (5).
6. Install the exhaust gas recirculation valve vacuum
tank. Refer to Exhaust Gas Recirculation Valve
Vacuum Tank Replacement (With Start / Stop) on
page 9‑726 or Exhaust Gas Recirculation Valve
2372533 Vacuum Tank Replacement (Without Start / Stop)
on page 9‑727.
3. Remove the positive crankcase ventilation pipe (1)
from the positive crankcase ventilation oil
separator (5).
4. Remove the positive crankcase ventilation oil
separator hose clamp (3).
5. Remove the positive crankcase ventilation oil
separator hose (2) from the positive crankcase
ventilation oil separator (5).
6. Remove the positive crankcase ventilation oil
separator drain hose clamp (6).
7. Remove the positive crankcase ventilation oil
separator drain hose (7) from the positive
crankcase ventilation oil separator (5).
8. Remove the 2 positive crankcase ventilation oil
separator bolts (4).
9. Remove positive crankcase ventilation oil
separator (5).
Installation Procedure

2190511

7. Install the exhaust gas recirculation valve

cooler (2). Refer to Exhaust Gas Recirculation
Valve Cooler Replacement (With Auxiliary Pump)
on page 9‑722 or Exhaust Gas Recirculation Valve
Cooler Replacement (Wthout Auxiliary Pump) on
page 9‑724.

2372533

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1607
Positive Crankcase Ventilation Hose/ Installation Procedure
Pipe/Tube Replacement
Object-ID=2560698 Owner=Youkhana, Karem LMD=11-Jan-2012 LMB=Youkhana, Karem

Removal Procedure
1. Remove the exhaust gas recirculation valve
vacuum tank. Refer to Exhaust Gas Recirculation
Valve Vacuum Tank Replacement (With Start /
Stop) on page 9‑726 or Exhaust Gas Recirculation
Valve Vacuum Tank Replacement (Without Start /
Stop) on page 9‑727.

2190506

1. Install a NEW positive crankcase ventilation tube

gasket (5).
Caution: Refer to Fastener Caution on page 0‑9.
2. Install the positive crankcase ventilation tube (4)
and bolts (3) and tighten to 9Y(80 lb in).
3. Slid the clamp (2) onto the hose (1) and install
hose to the positive crankcase ventilation tube (4)
4. Install the exhaust gas recirculation valve vacuum
tank. Refer Exhaust Gas Recirculation Valve
2190506 Vacuum Tank Replacement (With Start / Stop) on
page 9‑726 or Exhaust Gas Recirculation Valve
2. Remove the positive crankcase ventilation oil
Vacuum Tank Replacement (Without Start / Stop)
separator drain hose clamp (2).
on page 9‑727.
3. Remove the positive crankcase ventilation oil
separator drain hose (1) from the positive Timing Chain Guide Replacement
crankcase ventilation tube (4).
Object-ID=2552269 Owner=Youkhana, Karem LMD=14-Dec-2010 LMB=Youkhana, Karem
4. Remove the positive crankcase ventilation tube
bolts (3).
Special Tools
5. Remove the positive crankcase ventilation
tube (4). EN-955-1 Locking Tool Timing Chain Tensioner
6. Remove the positive crankcase ventilation tube For equivalent regional tools, refer to Special Tools on
gasket (5). page 9‑1711.
Removal Procedure
1. Remove the oil pump housing. Refer to Oil Pump
Housing Replacement on page 9‑1596.

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9-1608 Engine Mechanical - 1.3L (LDV) Diesel
Installation Procedure

2191110

2. Tension the timing chain tensioner in direction as

shown (arrow). 2552266

3. Fix the timing chain tensioner position with the 1. Install the timing chain guide (2).
EN-955-1 locking tool (1). Caution: Refer to Fastener Caution on page 0‑9.
2. Install the timing chain guide bolts (1) and tighten
to 9 Y (80 lb in).

2552266

4. Remove the timing chain guide bolts (1).

5. Remove the timing chain guide (2). 2191110

3. Remove the EN-955-1 locking tool (1) from the

timing chain tensioner.
4. Install the oil pump housing. Refer to Oil Pump
Housing Replacement on page 9‑1596.

2014 - Spin Service Manual (5618083) - (Misc Draft) - 6/7/13

 Engine Mechanical - 1.3L (LDV) Diesel 9-1609
Timing Chain Oil Nozzle 5. Remove the timing chain tensioner shoe (1).
Replacement
Object-ID=2552262 Owner=Youkhana, Karem LMD=08-Feb-2011 LMB=Youkhana, Karem

Special Tools
EN-955-1 Locking Tool Timing Chain Tensioner
For equivalent regional tools, refer to Special Tools on
page 9‑1711.
Removal Procedure
1. Remove the oil pump housing. Refer to Oil Pump
Housing Replacement on page 9‑1596.

2552260

6. Remove the timing chain oil nozzle bolts (1).

7. Remove the timing chain oil nozzle (2).
Installation Procedure

2191110

2. Tension the timing chain tensioner in direction as

shown above.
3. Fix the timing chain tensioner position with the
EN-955-1 locking tool (1).

2552260

1. Install the timing chain oil nozzle (2).

Caution: Refer to Fastener Caution on page 0‑9.
2. Install the timing chain oil nozzle bolts (1) and
tighten to 6 Y (53 lb in).

2191119

4. Remove the timing chain tensioner shoe bolt (2).

2014 - Spin Service Manual (5618083) - (Misc Draft) - 6/7/13
9-1610 Engine Mechanical - 1.3L (LDV) Diesel
Removal Procedure
1. Remove oil pump housing. Refer to Oil Pump
Housing Replacement on page 9‑1596.

2191119

3. Install the timing chain tensioner shoe (1).

4. Install the timing chain tensioner shoe bolt (2) and
tighten to 25 Y (18 lb ft).
2191110

2. Tension the timing chain tensioner in direction as

shown above.
3. Fixing timing chain tensioner position with
EN-955-1 locking tool (1).

2191110

5. Remove the EN-955-1 locking tool (1) from the

timing chain tensioner.
6. Install the oil pump housing. Refer to Oil Pump
Housing Replacement on page 9‑1596.
2552271

Timing Chain Tensioner Shoe 4. Remove timing chain tensioner shoe bolt (1).
Replacement 5. Remove timing chain tensioner shoe (2).
Object-ID=2552286 Owner=Youkhana, Karem LMD=08-Feb-2011 LMB=Youkhana, Karem

Special Tools
EN-955-1 Locking Tool Timing Chain Tensioner
For equivalent regional tools, refer to Special Tools on
page 9‑1711.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1611
Installation Procedure For equivalent regional tools, refer to Special Tools on
page 9‑1711.
Removal Procedure
1. Remove the oil pump housing. Refer to Oil Pump
Housing Replacement on page 9‑1596.

2552271

1. Install timing chain tensioner shoe (2).

Caution: Refer to Fastener Caution on page 0‑9.
2. Install timing chain tensioner shoe bolt (1) and
2191110
tighten to 25 Y (18 lb ft).
2. Tension the timing chain tensioner in direction as
shown above.
3. Fix the timing chain tensioner position with the
EN-955-1 locking tool (1).

2191110

3. Remove EN-955-1 locking tool (1) from timing

chain tensioner.
4. Install oil pump housing. Refer to Oil Pump
2191113
Housing Replacement on page 9‑1596.
4. Remove the timing chain tensioner bolts (1).
Timing Chain Tensioner 5. Remove the timing chain tensioner (2).
Replacement
Object-ID=2552290 Owner=Youkhana, Karem LMD=08-Feb-2011 LMB=Youkhana, Karem

Special Tools
EN-955-1 Locking Tool Timing Chain Tensioner

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9-1612 Engine Mechanical - 1.3L (LDV) Diesel
Installation Procedure Turbocharger Oil Feed Pipe
Replacement
Object-ID=2551870 Owner=Youkhana, Karem LMD=31-May-2011 LMB=Youkhana, Karem

Removal Procedure
1. Disconnect the battery negative cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9‑53.
2. Remove the engine sight shield. Refer to Engine
Sight Shield Replacement on page 9‑1577.

2191113

Note: Fix the timing chain tensioner position with

EN-955 locking tool.
1. Install the timing chain tensioner (2).
Caution: Refer to Fastener Caution on page 0‑9.
2. Install the timing chain tensioner bolts (1) and
tighten to 9 Y (80 lb in).

2666291

3. Remove the air cleaner outlet rear duct (1). Refer

to Air Cleaner Outlet Duct Replacement on
page 9‑703.

2191110

3. Remove the EN-955-1 locking tool (1) from the

timing chain tensioner.
4. Install the oil pump housing. Refer to Oil Pump
Housing Replacement on page 9‑1596.

2190421

4. Remove the turbocharger wastegate actuator

vacuum control solenoid valve splash shield
nuts (2).

2014 - Spin Service Manual (5618083) - (Misc Draft) - 6/7/13

 Engine Mechanical - 1.3L (LDV) Diesel 9-1613
5. Remove the turbocharger wastegate actuator 4. Install the NEW turbocharger oil feed pipe
vacuum control solenoid valve splash shield (1). gaskets (3).
5. Install the turbocharger oil feed pipe bolt (2) to the
turbocharger (1) and tighten to 22 Y (16 lb ft).

2190431

6. Remove the turbocharger oil feed pipe bolt (2) from

2190421
the turbocharger (1).
7. Remove the turbocharger oil feed pipe gaskets (3). 6. Install the turbocharger wastegate actuator
8. Remove the turbocharger oil feed pipe bolt (5) from vacuum control solenoid valve splash shield (1).
the oil filter housing (7). 7. Install the turbocharger wastegate actuator
9. Remove the turbocharger oil feed pipe gaskets (6). vacuum control solenoid valve splash shield
nuts (2) and tighten to 9 Y (80 lb in).
10. Remove the turbocharger oil feed pipe (4).
Installation Procedure

2666291

8. Install the air cleaner outlet rear duct (1). Refer to

2190431 Air Cleaner Outlet Duct Replacement on
1. Install the turbocharger oil feed pipe (4). page 9‑703.
2. Install the NEW turbocharger oil feed pipe 9. Install the engine sight shield. Refer to Engine
gaskets (6). Sight Shield Replacement on page 9‑1577.
3. Install the turbocharger oil feed pipe bolt (5) to the 10. Connect the battery negative cable. Refer to
oil filter housing (7) and tighten to 22 Y (16 lb ft). Battery Negative Cable Disconnection and
Connection on page 9‑53.

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9-1614 Engine Mechanical - 1.3L (LDV) Diesel
Turbocharger Oil Return Hose Installation Procedure
Replacement
Object-ID=2551869 Owner=Youkhana, Karem LMD=17-Jan-2012 LMB=Youkhana, Karem

Removal Procedure
1. Disconnect the battery negative cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9‑53.
2. Remove the engine sight shield. Refer to Engine
Sight Shield Replacement on page 9‑1577.

2551863

1. Slid the clamps (1) onto the turbocharger oil return

hose (2) and install to the oil filter housing.

2666291

3. Remove the air cleaner outlet rear duct (1). Refer

to Air Cleaner Outlet Duct Replacement on
page 9‑703.

2666291

2. Install the air cleaner outlet rear duct (1). Refer to

Air Cleaner Outlet Duct Replacement on
page 9‑703.
3. Install the engine sight shield. Refer to Engine
Sight Shield Replacement on page 9‑1577.
4. Connect the battery negative cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9‑53.

2551863

4. Remove the turbocharger oil return hose

clamps (1).
5. Remove the turbocharger oil return hose (2) from
the turbocharger and the oil filter housing.
2014 - Spin Service Manual (5618083) - (Misc Draft) - 6/7/13
 Engine Mechanical - 1.3L (LDV) Diesel 9-1615
Turbocharger Wastegate Actuator Pipe Replacement
Object-ID=2560014 Owner=Youkhana, Karem LMD=19-Jan-2012 LMB=Lavigne, Matthew

2560008

Turbocharger Wastegate Actuator Pipe Replacement

Callout Component Name
Preliminary Procedures
1. Remove the Engine Sight Shield. Refer to Engine Sight Shield Replacement on page 9‑1577.
2. Remove the turbocharger wastegate actuator pipe to exhaust gas recirculation valve vacuum tank. Refer to Exhaust Gas
Recirculation Valve Vacuum Tank Replacement (With Start / Stop) on page 9‑726 or Exhaust Gas Recirculation Valve
Vacuum Tank Replacement (Without Start / Stop) on page 9‑727.
1 Positive Crankcase Ventilation Pipe
Positive Crankcase Ventilation Pipe fastener (Qty 2)
Caution: Refer to Fastener Caution on page 0‑9.
2
Tighten
8 Y (71 lb in)
Positive Crankcase Ventilation Pipe
3 Procedure
Disconnect the positive crankcase ventilation pipe connector from the positive crankcase ventilation oil
separator.

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9-1616 Engine Mechanical - 1.3L (LDV) Diesel
Valve Lifter Replacement Installation Procedure
Object-ID=2552238 Owner=Youkhana, Karem LMD=08-Feb-2011 LMB=Youkhana, Karem

Removal Procedure
1. Remove the camshaft housing cover gasket. Refer
to Camshaft Housing and Cover Gasket
Replacement on page 9‑1484.

2191139

Note: Clip in the valve lifter to the valve rocker arm.

Mind to the centring link on the retaining spring (3).
1. Install the valve lifters (2) to the valve rocker
arms (1).
2. Coat the valve lifters with engine oil.
2191138

Note: Set aside in the order removed.

2. Remove the valve rocker arms (1) with the valve
lifter.

2191138

Note: If the valve lifters are reused, the valve lifter

must be installed in their original position.
3. Install the valve rocker arms (1) with the valve lifter.
2191139 4. Install the camshaft housing cover gasket. Refer to
Note: Unclip the valve lifter from valve rocker arm in Camshaft Housing and Cover Gasket
direction as shown above. Mind to the centring link on Replacement on page 9‑1484.
retaining spring (3).
3. Remove the valve lifters (2) from the valve rocker
arms (1).

2014 - Spin Service Manual (5618083) - (Misc Draft) - 6/7/13

 Engine Mechanical - 1.3L (LDV) Diesel 9-1617
Valve Stem Oil Seal and Valve Spring
Replacement
Object-ID=2552148 Owner=Youkhana, Karem LMD=14-Dec-2010 LMB=Youkhana, Karem

Special Tools
• EN-835-A Installer
• EN-840 Pliers
• EN-6086 Spring And Wedge Replacer Kit
• EN-6086-4 Shaft
• EN-6086-6 Support
• EN-6086-7 Lever
• EN-6086-8 Handle
• EN-6086-11 Demounting Piece
• EN-6086-12 Adapter
• EN-6086-17 Hose
• EN-6086-100-1 Mounting Piece
• EN-6086-100-10 Plunger
2372555
• EN-46791 Adapter
• EN-46783 Thread Adapter 3. Install the EN-6086 replacer kit.
For equivalent regional tools, refer to Special Tools on • Install the 2 EN-6086-6 support (1)
page 9‑1711. • Install the EN-6086-8 handle (2) with the
EN-6086-4 shaft (3).
Removal Procedure
1. Remove the 16 valve lifters. Refer to Valve Lifter
Replacement on page 9‑1616.

2372556

Note: Blind hole thread, note injector stud length.

2372554
4. Install the fuel injector stud (5).
5. Install the EN-46791 adapter (3) and the
2. Remove the 2 cylinder head guide sleeves (1). EN-46783 thread adapter (2) with the fuel
injector (4) and fuel injector bracket to the
cylinder 1.
Caution: Refer to Fastener Caution on page 0‑9.
6. Install the fuel injector bracket nut (6) and tighten to
20 Y (15 lb ft).
7. Install the EN-6086-17 hose (1).

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9-1618 Engine Mechanical - 1.3L (LDV) Diesel
Installation Procedure

2372557

8. Install the EN-6086-7 lever (3) to the EN-6086-8

handle (1). 2372559

9. Install the EN-6086-12 adapter (2) and 1. Install the NEW valve stem seal (3) to the valve
EN-6086-11 demounting piece (4) to the lever (3). shaft (2).
10. Subject cylinder 1 with compressed air. 2. Use the EN-835-A installer (2) to push down the
Note: The EN-6086-11 demounting piece must be valve stem oil seal.
applied parallel to the valve retainers in order to prevent 3. Install the valve spring and the valve spring
damage to the tools or the valve train components. retainer.
11. Press down the valve springs and the upper valve
spring retainers until the valve keys are discharged
from spring load. Remove the valve keys.
12. Remove the valve spring retainer and valve spring.

2189662

4. Prepare the EN-6086-100-1 mounting piece for the

valve key installation. The mounting piece must be
assembled in the following order:
2372558 • Support (6)
13. Remove the valve stem oil seal. Use the EN-840 • Bushing (5)
pliers (1). • Spring (4)
• EN-6086-100-10 plunger (3)
• Screw connection (2)
• Lever adapter (1)

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1619

2189663 2372556

5. Install the valve keys (1) to the mounting piece (2) 10. Remove the EN-6086-17 hose (1).
as shown and fix them with the bushing. 11. Remove the fuel injector bracket nut (6).
12. Remove the EN-46791 adapter (3) and the
EN-46783 thread adapter (2) with the fuel
injector (4) and fuel injector bracket from the
cylinder 1.
13. Remove the fuel injector stud (5).
14. Repeat the procedure for all additional valve
springs.

2372561

6. Install the EN-6086-100-1 mounting piece (1) to

the lever.
7. Push the mounting piece slightly down until the
valve keys are engaged in evidence.
8. Repeat the procedure for additional intake valve
spring cylinder 1.
2372555
9. Convert the EN-6086 replacer kit for the exhaust
valves cylinder 1. 15. Remove the EN-6086 replacer kit.
• Remove the EN-6086-8 handle (2) with the
EN-6086-4 shaft (3).
• Remove the 2 EN-6086-6 supports (1).

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9-1620 Engine Mechanical - 1.3L (LDV) Diesel
16. Install the 2 cylinder head guide sleeves (1).
17. Install the 16 valve lifters. Refer to Valve Lifter
Replacement on page 9‑1616.

Repair Instructions - Off Vehicle

2372554

Engine Support Fixture (South America)

Object-ID=3405306 Owner=Youkhana, Karem LMD=16-Apr-2013 LMB=Smith, Craig

2768004

Engine Support Fixture (South America)

Callout Component Name
Preliminary Procedures
1. Remove the air inlet grille panel side seal. Refer to Air Inlet Grille Panel Side Seal Replacement on page 4‑349.

2014 - Spin Service Manual (5618083) - (Misc Draft) - 6/7/13

 Engine Mechanical - 1.3L (LDV) Diesel 9-1621
Engine Support Fixture (South America) (cont'd)
Callout Component Name
2. Remove the engine sight shield. Refer to Engine Sight Shield Replacement on page 9‑1577.
3. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement on page 9‑703.
4. Reposition the radiator surge tank. Refer to Radiator Surge Tank Replacement on page 9‑1032 or Radiator Surge Tank
Replacement (LDV,LDC) on page 9‑1033 or Radiator Surge Tank Replacement (L2B) on page 9‑1034.
5. Remove and reposition the turbocharger wastegate actuator vacuum control solenoid valve bracket ONLY. Refer to
Turbocharger Wastegate Actuator Vacuum Control Solenoid Valve Replacement on page 9‑773.
Special Tools
• EN-28467-300 Engine Support Fixture Adapter
• EN-28467-518 Main Support Beam
• EN-28467–100 Engine Support Foot Module
• EN-28467-1A Cross Bracket
• EN-28467-2A Radiator Tube Shelf Assembly
• EN-28467-4A Engine Support Fixture Leg
• EN-28467-6A Adapter Engine Support
• EN-28467-9 Quick-Release Pin
• J-28467-8A Hook Assembly
For equivalent regional tools, refer to Special Tools on page 9‑1270.
Engine Support Fixture Adapter Leg (Qty: 2)
1 Procedure
Install the bracket to fender frame. Do not install on top of fender lip.
2 Main Support Beam
3 Cross Bracket (Qty: 2)
Engine Support Fixture Leg (Qty: 2)
4 Procedure
Adjust the length of the engine support fixture leg.
5 Radiator Tube Shelf Assembly (Qty: 2)
6 Hook Assembly (Qty: 2)

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9-1622 Engine Mechanical - 1.3L (LDV) Diesel
Engine Support Fixture (Except • EN-47650 Retainer Frame Kit
• EN-47650-30 Extension of EN-47650 Retainer
South America) Frame Kit
Object-ID=3405308 Owner=Youkhana, Karem LMD=16-Apr-2013 LMB=Smith, Craig • EN-47650-40 Front Adapter (short) of EN-47650
Retainer Frame Kit
Special Tools • EN-47650-100 Adapter
• EN-47649 Engine Bridge Kit • EN-47650-250 Front Adapter
• EN-47649-100 Engine Bridge Bracket of For equivalent regional tools, refer to Special Tools on
EN-47649 Engine Bridge Kit page 9‑1711.
Engine Bridge Retainer Frame Assemble

2652362
Note: The engine bridge base frame should be
Checkpoint Dimension Specific Feature / Optional attached to the engine bridge tool trolley during the
135 mm assembling procedure.
a -
(5.31 in)
1. Replace the EN-47650-40 front adapter (short)
374 mm with the EN-47650-250 front adapter (long) (5).
b -
(14.724 in)
2. Remove the EN-47650-30 extension (1). Re-install
115 mm the end stopper (7) to the side bars then.
c -
(4.53 in)
205 mm Use EN-47650-250 Front
d
(8.07 in) Adapter (long)

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1623
3. Adjust the 2 engine bridge base frame outer bars to
the engine bridge base frame cross bar, so that the
dimensions a and b are adjusted and tighten the
fastener hexagons (2).
4. Adjust the EN-47650-250 front adapter (long) at
the hexagon (4), so that the dimension d is
adjusted and tighten the fasteners.
5. Adjust the EN-47650-250 front adapter (long) to
the cross bar, so that the dimension c is adjusted
and tighten the fastener hexagons (3, 6).
Engine Bridge And Base Frame
Installation
1. Remove the air inlet grille panel. Refer to Air Inlet
Grille Panel Replacement on page 4‑348.

2652351

6. With the aid of an assistant install the EN-47650

frame (1) to the vehicle. If necessary readjust the
outer bars for appropriate fitting.

2652352

Caution: SIO-ID=2186990 LMD=09-Sep-2008 To avoid paint

damage, use protective covers on the fenders.
Note: Mind the left and right side marking.
2. Install the right EN-47650-100 adapter (1) to the
right front wheelhouse panel inner rear brace.
3. Fasten the adapter with the brace (3) and the
bolt (2) of the EN-47650-100 adapter.
4. Install the left EN-47650-100 adapter to the left 2652353
front wheelhouse panel inner rear brace. Note: Use same procedure for left side.
5. Fasten the adapter with the brace and the bolt of
the EN-47650-100 adapter. 7. Secure the EN-47650 frame on the EN-47650-100
adapter (2) with the safety pin (3).
Note: Use same procedure for left side.
8. Fix the EN-47650 frame to the EN-47650-100
adapter by tightening the 2 mounting bolts.

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9-1624 Engine Mechanical - 1.3L (LDV) Diesel

2652354 2652366

Note: Use same procedure for left side. 14. Install the EN-47649-100 feet (3) to EN 47649
9. The EN-47650-250 front adapter (2) should be bridge in the shown position.
positioned as shown. If necessary, readjust the tie 15. Loosely install the mounting bolt (2) and the
bar (3) until the EN-47650-250 front adapter proper appropriate nut on both sides.
contacts the front end upper bar. Then fasten the 16. Adjust the EN-47649-100 feet so that the adjuster
thumb wheel (4). bolt can be installed to the shown bore and tighten.
Note: Use same procedure for left side. 17. Tighten the mounting bolt (2) and the nut.
10. Secure the EN-47650-250 front adapter by
positioning the hook (5) with the thumb wheel (1).

2652365

Note: Secure the chain boxes using the hook chains

2652355 on the outside of the engine bride.
Note: Use same procedure for left side. 18. Install the EN-47649 bridge (1) with the aid of an
11. Install the EN-47650-50 rail (1) to the EN-47650 assistant to the EN-47650 frame (2).
frame. 19. The exact position of the EN-47649 bridge on the
12. Position the EN-47650-50 rail so that it contacts EN-47650 frame depends on the engine
the guide piece (2). transmission combination and is described in the
13. Secure the EN-47650-50 rail with the safety pin (3). appropriate replacement procedures.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1625
Engine Bridge And Base Frame
Removal

2652354

Note: Use same procedure for left side.

3. Loosen the hook (5) of the EN-47650-250 front
2652365 adapter with the thumb wheel (1).
Note: Secure the chain boxes with hook chains on the 4. Loosen the thumb wheel (4).
outside of the engine bride. 5. Rotate the tie bar (3) until the feet of the
1. Remove the EN-47649 bridge (1) with the aid of an EN-47650-250 front adapter (2) are free from the
assistant from the EN-47650 frame (2). front end upper bar.

2652367 2652353

2. Remove both EN-47650-50 rails (1) from the 6. Loosen the 2 mounting bolts (1).
EN-47650 frame. 7. Remove the safety pin (3) from the EN-47650-100
adapter (2).

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9-1626 Engine Mechanical - 1.3L (LDV) Diesel
Engine Mount Bracket Removal
Object-ID=2286473 Owner=Thess, Stephan LMD=03-Aug-2010 LMB=Thess, Stephan

2652351

8. With the aid of an assistant remove the EN-47650

frame (1) from the vehicle.
2190411

1. Remove the 4 engine mount bracket bolts (3).

2. Remove the engine lift bracket (2).
3. Remove the engine mount bracket (1).

Drive Belt Tensioner Removal

Object-ID=2286469 Owner=Thess, Stephan LMD=03-Aug-2010 LMB=Thess, Stephan

2652352

9. Remove both EN-47650-100 adapters (1) from the

left and the right front wheelhouse panel inner rear
braces.
10. Install the air inlet grille panel. Refer to Air Inlet
Grille Panel Replacement on page 4‑348.

2190412

1. Remove the drive belt tensioner bolt (1).

2. Remove the drive belt tensioner (2).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1627
Crankshaft Pulley Removal Exhaust Temperature Sensor
Object-ID=2286467 Owner=Thess, Stephan LMD=03-Aug-2010 LMB=Thess, Stephan Removal
Object-ID=2286459 Owner=Thess, Stephan LMD=03-Aug-2010 LMB=Thess, Stephan

2190415

1. Remove the 4 crankshaft pulley bolts (3). 2190418

Hold against on the centering bolt (2). 1. Unclip the exhaust temperature sensor (2) from the
2. Remove the crankshaft pulley (1). exhaust temperature sensor connector bracket (3).
2. Remove the exhaust temperature sensor (2) from
Water Pump Removal the catalytic converter (1).
Object-ID=2286463 Owner=Thess, Stephan LMD=21-Nov-2011 LMB=Kuhse, Ben
Catalytic Converter Heat Shield
Removal
Object-ID=2286454 Owner=Thess, Stephan LMD=03-Aug-2010 LMB=Thess, Stephan

2190417

1. Remove the 4 water pump nuts (3).

2. Remove the water pump (1).
2190419
3. Remove and DISCARD the water pump seal (2).
1. Remove the upper catalytic converter heat shield
bolt (1).
2. Remove the 4 catalytic converter heat shield
bolts (3).

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9-1628 Engine Mechanical - 1.3L (LDV) Diesel
3. Remove the catalytic converter heat shield (2). 4. Remove the exhaust pressure sensor hose (2)
from the catalytic converter (4).
Catalytic Converter Removal 5. Loosen the catalytic converter clamp (3).
Object-ID=2286450 Owner=Thess, Stephan LMD=03-Aug-2010 LMB=Thess, Stephan 6. Remove the 2 catalytic converter bracket nuts (6).
7. Remove the catalytic converter (4) from the
Special Tools catalytic converter bracket (7) and the
EN-6129 Oxygen Sensor Remover / Installer turbocharger (1).
For equivalent regional tools refer to Special Tools on 8. Remove the catalytic converter clamp (3).
page 9‑1711. 9. Remove the catalytic converter gasket.

Turbocharger Oil Feed Pipe Removal

Object-ID=2286442 Owner=Thess, Stephan LMD=01-Sep-2011 LMB=Kuhse, Ben

2190420

1. Remove the heated oxygen sensor (1) from the

heated oxygen sensor connector bracket.
2. Remove the heated oxygen sensor (1) with the 2190431
EN-6129 remover / installer from the catalytic
converter (2). 1. Remove the turbocharger oil feed pipe bolt (2) from
the turbocharger (1).
2. Remove the 2 turbocharger oil feed pipe
gaskets (3).
3. Remove the turbocharger oil feed pipe bolt (5) from
the oil filter housing (7).
4. Remove the 2 turbocharger oil feed pipe
gaskets (6).
5. Remove the turbocharger oil feed pipe (4).

2190422

3. Remove the exhaust pressure sensor hose

clamp (5).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1629
Turbocharger Oil Return Hose 3. Remove the thermostat bypass pipe clamp (3) from
the thermostat housing.
Removal 4. Remove the thermostat bypass pipe (2).
Object-ID=2286438 Owner=Thess, Stephan LMD=03-Aug-2010 LMB=Thess, Stephan
5. Remove the thermostat bypass pipe gasket (5).

Oil Filter Housing Removal

Object-ID=2286431 Owner=Thess, Stephan LMD=03-Aug-2010 LMB=Thess, Stephan

2190432

1. Remove the 2 turbocharger oil return hose

clamps (3).
2. Remove the turbocharger oil return hose (2) from 2190448
the turbocharger (1) and the oil filter housing (4).
1. Remove the 4 oil filter housing bolts (2).
Thermostat Bypass Pipe Removal 2. Remove the oil filter housing (1).
Object-ID=2286434 Owner=Thess, Stephan LMD=03-Aug-2010 LMB=Thess, Stephan 3. Remove the oil filter housing gasket (3).

Turbocharger Wastegate Actuator

Vacuum Control Solenoid Valve
Splash Shield Removal
Object-ID=2286428 Owner=Thess, Stephan LMD=03-Aug-2010 LMB=Thess, Stephan

2190446

1. Remove the 2 thermostat bypass pipe bolts (1)

from the oil filter housing.
2. Remove the thermostat bypass pipe bracket
bolt (4).
2190421

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9-1630 Engine Mechanical - 1.3L (LDV) Diesel
1. Remove the 3 turbocharger wastegate actuator 2. Remove the engine lift front bracket (2).
vacuum control solenoid valve splash shield 3. Remove the exhaust manifold heat shield left
nuts (2). side nut (4).
2. Remove the turbocharger wastegate actuator 4. Remove the exhaust manifold heat shield left
vacuum control solenoid valve splash shield (1). side (1).
Turbocharger Removal
Object-ID=2286425 Owner=Thess, Stephan LMD=03-Aug-2010 LMB=Thess, Stephan

2190452

5. Remove the exhaust manifold heat shield right

side nut (1).
2190450 6. Remove the exhaust manifold heat shield right
side (2).
1. Remove the 3 turbocharger nuts (3)
2. Remove the turbocharger (1) from the exhaust
manifold.
3. Remove the turbocharger gasket (2).

Exhaust Manifold Removal

Object-ID=2286424 Owner=Thess, Stephan LMD=03-Aug-2010 LMB=Thess, Stephan

2190454

7. Remove the 10 exhaust manifold nuts (3).

8. Remove the exhaust manifold (2).
9. Remove the exhaust manifold gasket (1).

2190451

1. Remove the engine lift front bracket bolt (3).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1631
Glow Plug Removal Exhaust Gas Recirculation Valve
Object-ID=2837668 Owner=Thess, Stephan LMD=25-Apr-2012 LMB=Kuhse, Ben Vacuum Tank Removal
Object-ID=2286413 Owner=Thess, Stephan LMD=03-Aug-2010 LMB=Thess, Stephan
Special Tools
EN-48390 Remover/Installer Glow Plugs 9 mm
For equivalent regional tools, refer to Special Tools on
page 9‑1711.

2190488

1. Remove the upper turbocharger wastegate

actuator pipe (1).
2739171 2. Remove the lower turbocharger wastegate
actuator pipe (4).
Remove the 4 glow plugs (1) from the cylinder head,
use the EN-48390 remover. 3. Remove the 2 exhaust gas recirculation valve
vacuum tank bolts (2).
Generator Removal 4. Remove the exhaust gas recirculation valve
Object-ID=2286419 Owner=Thess, Stephan LMD=03-Aug-2010 LMB=Thess, Stephan
vacuum tank (3) from the exhaust gas recirculation
valve vacuum tank bracket (5).

Generator Bracket Removal

Object-ID=2286411 Owner=Thess, Stephan LMD=03-Aug-2010 LMB=Thess, Stephan

2190486

1. Remove the upper generator bolt (4).

2. Remove the 2 lower generator bolts (3).
3. Remove the generator (1) from the generator 2190492

bracket (2).

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9-1632 Engine Mechanical - 1.3L (LDV) Diesel
1. Unclip the turbocharger wastegate actuator pipe 2. Remove the 2 positive crankcase ventilation pipe
from the turbocharger wastegate actuator pipe clip. bracket bolts (2).
2. Remove the 2 exhaust gas recirculation valve 3. Remove the positive crankcase ventilation pipe (1).
vacuum tank bracket bolts (2).
3. Remove the exhaust gas recirculation valve Positive Crankcase Ventilation Tube
vacuum tank bracket (1). Removal
Object-ID=2286403 Owner=Thess, Stephan LMD=03-Aug-2010 LMB=Thess, Stephan

2190493

4. Remove the 3 generator bracket bolts (2).

2190506
5. Remove the generator bracket (1).
1. Remove the 2 positive crankcase ventilation tube
Positive Crankcase Ventilation Pipe bolts (3)
Removal 2. Remove the positive crankcase ventilation tube
gasket (5).
Object-ID=2286408 Owner=Thess, Stephan LMD=03-Aug-2010 LMB=Thess, Stephan
3. Remove the positive crankcase ventilation oil
separator drain hose clamp (2).
4. Remove the positive crankcase ventilation tube (4)
from the positive crankcase ventilation oil
separator drain hose (1).

2190504

1. Disconnect the positive crankcase ventilation pipe

connector (3) from the positive crankcase
ventilation oil separator.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1633
Positive Crankcase Ventilation Oil 1. Remove the oil level indicator tube bolt (2).
2. Remove the oil level indicator tube (1).
Separator Removal
Object-ID=2286397 Owner=Thess, Stephan LMD=03-Aug-2010 LMB=Thess, Stephan
3. Remove the oil level indicator gasket from the
cylinder block.

Exhaust Gas Recirculation Pipe

Removal
Object-ID=2286387 Owner=Thess, Stephan LMD=10-May-2012 LMB=Hinzmann, Rene

2190507

1. Unclip the positive crankcase ventilation oil

separator hose from the retainer clip (1).
2. Remove the positive crankcase ventilation oil
separator hose clamp (2).
2190509
3. Remove the 2 positive crankcase ventilation oil
separator bolts (4) 1. Remove 2 exhaust gas recirculation pipe bolts (1)
4. Remove the positive crankcase ventilation oil from exhaust gas recirculation valve cooler.
separator (3). 2. Remove 3 exhaust gas recirculation pipe bolts (5)
from intake manifold.
Oil Level Indicator and Tube 3. Remove exhaust gas recirculation pipe (3).
Removal 4. Remove exhaust gas recirculation pipe seal (2).
Object-ID=2286393 Owner=Thess, Stephan LMD=03-Aug-2010 LMB=Thess, Stephan 5. Remove exhaust gas recirculation pipe gasket (4).

2190508

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9-1634 Engine Mechanical - 1.3L (LDV) Diesel
Exhaust Gas Recirculation Valve Starter Removal
Cooler Removal Object-ID=2289727 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

Object-ID=2289318 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2190512

2190510 1. Remove the starter bolt (1).

1. Remove the 2 throttle body support bolts (2). 2. Remove the starter stud (3).
2. Remove the throttle body support (1). 3. Remove the starter (2).

Engine Oil Cooler Inlet Pipe Removal

Object-ID=2289731 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2190511

3. Remove the 3 exhaust gas recirculation valve

cooler bolts (3).
4. Remove the exhaust gas recirculation valve 2190514
cooler (2).
1. Remove the 2 engine oil cooler inlet pipe bolts (2).
5. Remove the exhaust gas recirculation valve cooler
gasket (1). 2. Remove the engine oil cooler inlet pipe (1).
3. Remove the engine oil cooler inlet pipe seal from
the cylinder block.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1635
Exhaust Pressure Sensor Pipe 2. Remove the exhaust pressure sensor (2) from the
exhaust pressure sensor bracket (1).
Removal
Object-ID=2289734 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan Engine Coolant Thermostat Removal
Object-ID=2293688 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2190513

1. Remove the exhaust pressure sensor pipe bolt (1) 2190713

from the throttle body support. 1. Remove the 2 engine coolant thermostat bolts (1).
2. Remove the exhaust pressure sensor pipe bolt (3) 2. Remove the engine coolant thermostat (2).
from the exhaust pressure sensor bracket.
3. Remove the exhaust pressure sensor pipe
clamp (4).
4. Remove the exhaust pressure sensor pipe (2).

Exhaust Pressure Sensor Removal

Object-ID=2289736 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2190714

3. Remove the engine coolant temperature sensor

retainer clip (5) from the engine coolant
thermostat (1).
4. Remove the engine coolant temperature
sensor (3).
5. Remove the engine coolant temperature sensor
2190515 gasket (4).
1. Remove the exhaust pressure sensor bolt (3). 6. Remove the engine coolant thermostat gasket (2).

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9-1636 Engine Mechanical - 1.3L (LDV) Diesel
Throttle Body Assembly Removal Diesel Fuel Separator Removal
Object-ID=2293689 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan Object-ID=2294510 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2190720 2190819

1. Remove the 3 throttle body bolts (3). 1. Unclip the 4 fuel injection fuel return hose retaining
2. Remove the throttle body (2) from the throttle body clips (6) in direction of the arrow.
adapter (1). 2. Remove the 4 fuel return hose connectors (1) from
3. Remove the throttle body gasket (4). the 4 fuel injectors.
3. Remove the diesel fuel separator bolt (4).
Intake Manifold Removal 4. Remove the fuel return hose clamp (5).
Object-ID=2293690 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan 5. Remove the fuel return hose (2) from the fuel
injection pump.
6. Remove the diesel fuel separator (3).

Vacuum Pump Removal

Object-ID=2354686 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2190721

1. Remove the 5 intake manifold upper bolts (3).

2. Remove the 4 intake manifold lower bolts (4).
3. Remove the intake manifold (2).
4. Remove the 4 intake manifold gaskets (1). 2190824

1. Remove the 2 vacuum pump bolts (2).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1637
2. Remove the vacuum pump (1). Fuel Injection Pump Removal
Note: Do not tilt the vacuum pump actuator at the Object-ID=2299099 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan
timing gear groove (3).
3. Remove the vacuum pump gasket.

Fuel Injection Fuel Feed Pipe

Removal - Fuel Injection Pump to
Fuel Rail
Object-ID=2299098 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

Special Tools
EN-6368 Set of Plugs
For equivalent regional tools, refer to Special Tools on
page 9‑1711.

2190846

1. Remove the 3 fuel injection pump bolts (3).

2. Remove the fuel injection pump (2)
Note: Do not tilt the fuel injection pump actuator (1) at
the timing gear groove (4).
3. Remove the fuel injection pump seal.

Fuel Injection Fuel Feed Pipe

Removal - Fuel Rail to Fuel Injector
Object-ID=2299100 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2190826 Special Tools

1. Remove the fuel injection fuel feed pipe nut M14 EN-6368 Set of Plugs
from the fuel rail (1). For equivalent regional tools, refer to Special Tools on
2. Remove the fuel injection fuel feed pipe nut M12 page 9‑1711.
from the fuel injection pump (3).
3. Remove the fuel injection fuel feed pipe (2).
4. Close all open connections with the EN-6386
plugs.

2190866

2014 - Spin Service Manual (5618083) - (Misc Draft) - 6/7/13

9-1638 Engine Mechanical - 1.3L (LDV) Diesel
1. Remove the 4 fuel injection fuel feed pipe nuts M14
from the fuel rail (2).
2. Remove the 4 fuel injection fuel feed pipe nuts M12
from the 4 fuel injectors (3).
3. Remove the 4 fuel injection fuel feed pipes (1).
4. Close all open connections with the EN-6386
plugs.

Fuel Rail Removal

Object-ID=2299101 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2190870

1. Remove the 2 fuel injector bracket nuts (2).

2. Remove the 2 fuel injector conical washers (3).
3. Remove the 2 fuel injector spherical washers (4).
4. Remove the 4 fuel Injectors (1) with the 2 fuel
injector brackets (7).
Note: Injectors are to be removed only in pairs. If the
Injectors does not removed by hand use the EN-46786
remover with the GE-328-B sliding hammer.
5. Remove the 4 fuel injector seals (5).
6. Close the Injector nozzles with the EN-48559
2190867
protective caps.
1. Remove the 3 fuel rail bracket bolts (1). 7. Remove the 4 fuel injector gaskets (6) from the
2. Remove the engine lift bracket (2). camshaft housing.
3. Remove the fuel rail (3) with the fuel rail
bracket (4). Oil Pan Removal
Object-ID=2299104 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

Fuel Injector Removal

Object-ID=2299102 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan Special Tools
EN-37228 Separation Tool
Special Tools For equivalent regional tools, refer to Special Tools on
• GE-328-B Sliding Hammer page 9‑1711.
• EN-46786 Remover
• EN-48559 Injector Protective Caps
For equivalent regional tools, refer to Special Tools on
page 9‑1711.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1639

2190924 2190926

Note: For vehicles with air conditioning 5. Remove the 2 oil pan nuts (1).
1. Remove the 4 air conditioning compressor bracket 6. Remove the 13 oil pan bolts (2).
bolts (2).
2. Remove the air conditioning compressor
bracket (1).

2190927

7. Loosen carefully the oil pan (2) from the lower

cylinder block with the EN-37228 separation
2190925
tool (1).
3. Remove the 4 transmission support brace bolts (2).
4. Remove the transmission support brace (1).

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9-1640 Engine Mechanical - 1.3L (LDV) Diesel

2190929 2190960

8. Remove the oil pan (1). 2. Remove the cylinder head core hole plug –
exhaust (2) from the camshaft housing (1).
Oil Pump Housing Removal 3. Remove the cylinder head core hole plug –
Object-ID=2303946 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan intake (3) from the camshaft housing (1).
4. Clean the threads from the cylinder head core hole
Special Tools plugs and the camshaft housing.
• EN-662-C Holding Wrench
• EN-46778 Fixing Tool Crankshaft
• EN-46781 Fixing Tool Camshaft
For equivalent regional tools, refer to Special Tools on
page 9‑1711.

2190961

5. Marking (arrow) the 2 EN-46781 fixing tool (1).

2190953

1. Turn the crankshaft at the crankshaft sprocket

bolt (3) in engine direction of rotation (arrow), until
the EN-46778 fixing tool (1) to engage with the
drilling at the flywheel (2) and the cylinder block.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1641

2190962 2190971

Note: The EN-46781 fixing tool (1) must be installed in 11. Remove the crankshaft sprocket bolt (1).
horizontal position.
12. Remove the flange (2).
6. Install the EN-46781 fixing tool (1) onto the
exhaust side and the intake side.
Note: If the EN-46781 fixing tool does not rotate any
longer, the EN-46781 fixing tool is correctly engaged.
7. Turn the crankshaft at crankshaft sprocket bolt
carefully, until the EN-46778 fixing tool (1)
engages at the intake camshaft and the exhaust
camshaft.

2190963

13. Remove the 14 oil pump housing bolts (3).

14. Remove the 3 oil pump housing nuts (4).
15. Remove the oil pump housing (2).
16. Remove the oil pump housing gasket (1).

2190969

8. Install the EN-662-C Holding Wrench (2).

9. Install the 2 bolts.
Note: Mind the left-hand thread.
10. Loosen the crankshaft sprocket bolt (1).

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9-1642 Engine Mechanical - 1.3L (LDV) Diesel
Timing Chain Tensioner Removal Timing Chain Tensioner Shoe
Object-ID=2303951 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan Removal
Object-ID=2303956 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan
Special Tools
EN-955 Locking Tool Timing Chain Tensioner
For equivalent regional tools, refer to Special Tools on
page 9‑1711.

2191119

1. Remove the timing chain tensioner shoe bolt (2).

2. Remove the timing chain tensioner shoe (1).
2191110

1. Tension the timing chain tensioner in direction as Timing Chain Guide Removal
shown (arrow). Object-ID=2303962 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2. Fix the timing chain tensioner position with the

EN-955 locking tool (1).

2191121

2191113 1. Remove the 2 timing chain guide bolts (2).

3. Remove the 2 timing chain tensioner bolts (1). 2. Remove the timing chain guide (1).
4. Remove the timing chain tensioner (2).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1643
Camshaft Sprocket Removal Note: Remove the camshaft sprocket (2) from the
Object-ID=2303972 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan
camshaft at first then remove the timing chain from the
crankshaft sprocket (3).
Special Tools 5. Remove the camshaft sprocket (2) with the timing
• EN-956-1 Extension chain (4).
• EN-6347 Holder
Camshaft Timing Chain Adjustment
For equivalent regional tools, refer to Special Tools on Object-ID=2473773 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan
page 9‑1711.
Special Tools
• EN-470-B Torque Angle Sensor
• EN-662-C Holding Wrench
• EN-46781 Fixing Tool Camshaft
• EN-46778 Fixing Tool Crankshaft, if the
transmission is removed
• EN-46785 Fixing Tool Crankshaft, if the
transmission is Installed
For equivalent regional tools, refer to Special Tools on
page 9‑1711.
Removal Procedure
1. Remove the crankshaft pulley. Refer to Crankshaft
Pulley Removal on page 9‑1627.
2. Remove the catalytic converter heat shield. Refer
to Catalytic Converter Heat Shield Removal on
page 9‑1627.
3. Remove the catalytic converter. Refer to Catalytic
Converter Removal on page 9‑1628.
2191125 4. Remove the turbocharger oil feed pipe. Refer to
Turbocharger Oil Feed Pipe Removal on
1. Install the EN-6347 holder (1) with the EN-956-1 page 9‑1628.
extension (4) to the camshaft sprocket (2).
5. Remove the turbocharger oil return hose. Refer to
2. Loosen the camshaft sprocket bolt (3). Turbocharger Oil Return Hose Removal on
Note: Counterhold the camshaft sprocket with the page 9‑1629.
EN-6347 holder and the EN-956-1 extension. 6. Remove the turbocharger wastegate actuator
3. Remove the EN-6347 holder with the EN-956-1 vacuum control solenoid valve splash shield. Refer
extension from the camshaft sprocket. to Turbocharger Wastegate Actuator Vacuum
Control Solenoid Valve Splash Shield Removal on
page 9‑1629.
7. Remove the turbocharger. Refer to Turbocharger
Removal on page 9‑1630.

2191126

4. Remove the camshaft sprocket bolt (1).

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9-1644 Engine Mechanical - 1.3L (LDV) Diesel

2191980 2192181

Note: No pressure on the fuel injection fuel rail, if the 14. Remove the oil pump housing plug (1) from the oil
fuel injection fuel rail bracket is dismantled. pump housing (3).
8. Remove the 2 fuel injection fuel rail bolts (3). 15. Remove the oil pump housing plug seal (2).
9. Remove the 3 fuel injection fuel rail bracket
bolts (2) and (5).
10. Remove the fuel injection fuel rail bracket with the
rear engine lift bracket (1).

2190961

16. Mark (arrow) the 2 EN-46781 fixing tool (1).

2190960

11. Remove the cylinder head core hole plug –

exhaust (2) from the camshaft housing (1).
12. Remove the cylinder head core hole plug –
intake (3) from the camshaft housing (1).
13. Clean the threads from the cylinder head core hole
plugs and the camshaft housing.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1645

2191978 2191897

Note: The EN-46781 fixing tool (1) must be install in Note: If the transmission is removed.
horizontal position.
20. Turn the crankshaft carefully until the EN-46778
17. Install the EN-46781 fixing tool (1) into the fixing tool (1) engages with the bore at flywheel (2)
intake side. and the cylinder block.
Note: If the EN-46781 fixing tool does not rotate any
longer, the tool is correctly engaged.
18. Turn the exhaust camshaft carefully at the
camshaft sprocket bolt, until the EN-46781 fixing
tool (1) engages at the intake camshaft.

2190969

21. Install the EN-662-C holding wrench (2).

22. Install the 2 bolts.
Note: Mind the left-hand thread.
2191979 23. Loosen the crankshaft sprocket bolt (1).
Note: If the transmission is installed.
19. Turn the crankshaft carefully until the EN-46785
fixing tool (1) engages in the flywheel.

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9-1646 Engine Mechanical - 1.3L (LDV) Diesel
29. Tighten the crankshaft sprocket bolt (1) to
50 Y (37 lb ft)..
30. Tighten the crankshaft sprocket bolt (1) to an
additional 90°, use EN-470-B torque angle.
31. Remove the 2 bolts.
32. Remove the EN-662-C holding wrench (2).
33. Remove the 2 EN-46781 fixing tool from the intake
camshaft and the exhaust camshaft.
34. Remove the EN-46785 fixing tools and the
EN-46778 fixing tool.
35. Turn crankshaft the 720° in the direction of the
engine rotation at the crankshaft sprocket bolt.
36. Check the position of the camshafts. Refer to
Camshaft Timing Chain Inspection on
page 9‑1647.
Installation Procedure

2192182

Note: Counterhold at the camshaft sprocket bolt with

the aid of a second technician.
24. Loosen the camshaft intake sprocket bolt (1).
25. Rotate the exhaust camshaft 15° against the
direction of engine rotation.
26. Install the EN-46781 fixing tool at the cylinder head
core hole exhaust side.
Note: If the EN-46781 fixing tool does not rotate any
longer, the EN-46781 fixing tool is correctly engaged.
27. Turn the exhaust camshaft at the camshaft
sprocket bolt in direction of the engine rotation until
the EN-46781 fixing tool engages in the exhaust
camshaft.
Caution: Refer to Fastener Caution on page 0‑9.
Note: Counterhold at the camshaft sprocket bolt, use a
second person.
28. Tighten the camshaft intake sprocket bolt to 2192181

150 Y (111 lb ft). 1. Install the oil pump housing plug seal (2).
2. Install the oil pump housing plug (1) to the oil pump
housing (3) and tighten to 20 Y (15 lb ft).

2190969

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1647
10. Install the turbocharger wastegate actuator
vacuum control solenoid valve splash shield. Refer
to Turbocharger Wastegate Actuator Vacuum
Control Solenoid Valve Splash Shield Installation
on page 9‑1704.
11. Install the turbocharger oil return hose. Refer to
Turbocharger Oil Return Hose Installation on
page 9‑1705.
12. Install the turbocharger oil feed pipe. Refer to
Turbocharger Oil Feed Pipe Installation on
page 9‑1706.
13. Install the catalytic converter. Refer to Catalytic
Converter Installation on page 9‑1706.
14. Install the catalytic converter heat shield. Refer to
Catalytic Converter Heat Shield Installation on
page 9‑1707.
15. Install the crankshaft pulley. Refer to Crankshaft
Pulley Installation on page 9‑1708.

Camshaft Timing Chain Inspection

2190960
Object-ID=2473776 Owner=Thess, Stephan LMD=01-Sep-2011 LMB=Kuhse, Ben
3. Clean the threads from the cylinder head core hole
plugs and the camshaft housing. Special Tools
4. Install the cylinder head core hole plug – intake (3) • EN-46778 Fixing Tool Crankshaft
to the camshaft housing (1) and tighten to
• EN-46781 Fixing Tool Camshaft
15 Y (11 lb ft).
• EN-46785 Fixing Tool Crankshaft
5. Install the cylinder head core hole plug –
exhaust (2) to the camshaft housing (1) and tighten For equivalent regional tools, refer to Special Tools on
to 15 Y (11 lb ft). page 9‑1711.
Removal Procedure

2191980

6. Install the fuel injection fuel rail bracket with the 2191980
rear engine lift bracket (1). Note: No pressure on the fuel injection fuel rail, if the
7. Install the 3 fuel injection fuel rail bracket bolts (2) fuel injection fuel rail bracket is dismantled.
and (5) and tighten to 25 Y (18 lb ft).
1. Remove the 2 fuel injection fuel rail bolts (3).
8. Install the 2 fuel injection fuel rail bolts (3) and
2. Remove the 3 fuel injection fuel rail bracket
tighten to 25 Y (18 lb ft).
bolts (2) and (5).
9. Install the turbocharger. Refer to Turbocharger
3. Remove the fuel injection fuel rail bracket with the
Installation on page 9‑1704.
rear engine lift bracket (1).

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9-1648 Engine Mechanical - 1.3L (LDV) Diesel

2191981 2191978

4. Remove the camshaft housing core hole plug - Note: The EN-46781 fixing tool (1) must be install in
intake (1) from the camshaft housing. horizontal position.
5. Clean the threads at the camshaft housing and the 2. Install the EN-46781 fixing tool (1) into the
camshaft housing core hole plug. intake side.
Note: If the EN-46781 fixing tool does not rotate any
Inspection Procedure longer, the tool is correctly engaged.
3. Turn the crankshaft at the crankshaft sprocket bolt
carefully, until the EN-46778 fixing tool (1)
engages at the intake camshaft.

2190961

1. Mark (arrow) the 2 EN-46781 fixing tool (1).

2191979

Note: If the transmission is installed.

4. Turn the crankshaft carefully until the EN-46785
fixing tool (1) engages in the flywheel.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1649

2191897 2191980

Note: If the transmission is removed. 2. Install the fuel injection fuel rail bracket with the
5. Turn the crankshaft carefully until the EN-46778 rear engine lift bracket (1).
fixing tool (1) engages with the drilling at the 3. Install the 3 fuel injection fuel rail bracket bolts (2)
flywheel (2) and the cylinder block. and (5) and tighten to 25 Y (18 lb ft).
6. If the EN-46778 fixing tool or the EN-46785 fixing 4. Install the 2 fuel injection fuel rail bolts (3) and
tool and the EN-46781 fixing tool does not engage, tighten to 25 Y (18 lb ft).
refer to Camshaft Timing Chain Adjustment on
page 9‑1643. Crankshaft Sprocket Removal
Installation Procedure Object-ID=2303998 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2191981
2191127
Caution: Refer to Fastener Caution on page 0‑9.
Remove the crankshaft sprocket (1) from the
1. Install the cylinder head core hole plug – intake (1) crankshaft (2).
to the camshaft housing and tighten to
15 Y (11 lb ft).

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9-1650 Engine Mechanical - 1.3L (LDV) Diesel
Crankshaft Position Sensor Removal Camshaft Housing Removal
Object-ID=2304003 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan Object-ID=2304043 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2191128 2191132

1. Remove the crankshaft position sensor bolt (2). 1. Remove the engine control module wiring harness
2. Remove the crankshaft position sensor (1). bracket bolt (2).
2. Remove the engine control module wiring harness
Camshaft Position Sensor Removal bracket (1) left side.
Object-ID=2304009 Owner=Thess, Stephan LMD=01-Sep-2011 LMB=Kuhse, Ben

2191133

2191131
3. Remove the 2 engine control module wiring
harness bracket bolts (2).
1. Remove the camshaft position sensor bolt (1). 4. Remove the engine control module wiring harness
2. Remove the camshaft position sensor (2). bracket (1) right side.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1651
Valve Lifter Removal
Object-ID=2304049 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2191136

5. Remove the 2 glow plug wiring harness bracket

bolts (2).
6. Remove the glow plug wiring harness bracket (1). 2191138

Note: Set aside in the order removed.

1. Remove the 16 valve rocker arms with valve
lifter (1).

2191137

Note: Take note that there are different bolt lengths.

7. Remove the 16 camshaft housing bolts (2).
8. Remove the 2 camshaft housing studs (1). 2191139
9. Remove the camshaft housing (3). Note: Unclip the valve lifter from the valve rocker arm
10. Remove the camshaft housing gasket (4). in direction as shown (arrow). Mind to the centring link
on the retaining spring (3).
2. Remove the 16 valve lifters (2) from valve
rocker arm (1)

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9-1652 Engine Mechanical - 1.3L (LDV) Diesel
Cylinder Head Removal Piston, Connecting Rod, and Bearing
Object-ID=2304054 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan Removal
Object-ID=2322785 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2191155

1. Loosen the 10 cylinder head bolts in sequence as 2191159

shown. 1. Remove the 6 oil pan baffle bolts (1).

2. Remove the oil pan baffle (2).

2191156

2. Remove the 10 cylinder head bolts (1). 2191160

3. Remove the cylinder head (2). Note: The EN-46778 fixing tool should not be installed.
4. Remove the cylinder head gasket (3). 3. Set the crankshaft to TDC of combustion stroke of
cylinder 1
4. Remove the 4 connecting rod bearing cap bolts (4)
from the cylinder 2 and 3.
Note: Note the marking (2) of the connecting rod
bearing caps. Set aside in the order removed.
Note: The shear surfaces of the connecting rod and
the connecting rod bearing cap form a unique fit and
must not be swapped or damaged. Do not lay down on
the shear surfaces

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1653
5. Remove the 2 connecting rod bearing caps (3) Note: The shear surfaces of the connecting rod and
from the cylinder 2 and 3. the connecting rod bearing cap form a unique fit and
Note: Set aside in the order removed. must not be swapped or damaged. Do not lay down on
the shear surfaces.
6. Remove the 2 connecting rod lower bearings (1).
11. Remove the 2 connecting rod bearing caps (3)
from the cylinder 1 and 4.
Note: Set aside in the order removed.
12. Remove the 2 connecting rod lower bearings (1).

2191163

Note: Note the marking (2) of the connecting rod. Set

aside in the order removed.
7. Push the 2 pistons with the connecting rod (1) from
the cylinder 2 and 3 upwards. 2191165

8. Remove the 2 connecting rod upper bearings (3) Note: Note the marking (2) of the connecting rod. Set
from the cylinder 2 and 3. aside in the order removed.
9. Turn the crankshaft through 180° and set the 13. Push the 2 pistons with connecting rod (1) from the
crankshaft to TDC of combustion stroke of cylinder 1 and 4 upwards.
cylinder 2. Note: Set aside in the order removed.
14. Remove the 2 connecting rod upper bearings (3)
from the cylinder 1 and 4.

2191164

10. Remove the 4 connecting rod bearing cap bolts (4)

from the cylinder 1 and 4.
Note: Note the marking (2) of the connecting rod
bearing caps. Set aside in the order removed.

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9-1654 Engine Mechanical - 1.3L (LDV) Diesel
Oil Filter Housing Disassemble 1. Install the exhaust temperature sensor connector
bracket (5) to the oil filter housing (4).
Object-ID=2322787 Owner=Thess, Stephan LMD=12-Jan-2011 LMB=Thess, Stephan
Caution: Refer to Fastener Caution on page 0‑9.
2. Install the exhaust temperature sensor connector
bracket bolt (6) and tighten to 22 Y (16 lb ft).
3. Install a NEW oil filter (3) to the oil filter cap (1).
4. Install a NEW oil filter cap seal (2).
5. Install the oil filter cap (1) and tighten to 25 Y
(18 lb ft).

Water Pump Cleaning and Inspection

Object-ID=2322789 Owner=Thess, Stephan LMD=05-Aug-2009 LMB=Thess, Stephan

Cleaning Procedure
Caution: SIO-ID=2050460 LMD=22-Jan-2008 Do not immerse the
water pump in solvent. The solvent may enter the water
pump's permanently lubricated bearings and cause
premature bearing failure.
1. Remove the old gasket material from the water
pump sealing surfaces.
2. Clean all excess dirt and debris from the water
pump housing.
2191168
Inspection Procedure
Note: The oil filter housing and the oil cooler can not
be separated.
1. Remove the oil filter cap (1).
2. Remove the oil filter cap seal (2).
3. Remove the oil filter (3).
4. Remove the exhaust temperature sensor
connector bracket bolt (6).
5. Remove the exhaust temperature sensor
connector bracket (5) from the oil filter housing (4).

Oil Filter Housing Assemble

Object-ID=2322788 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2191171

1. Rotate the water pump hub (2).

Note: The water pump hub and impeller should turn
straight and smoothly. If the hub wobbles, is noisy,
or feels rough when rotated, replace the water pump.
2. Inspect the exterior of the water pump for the
following:
• Damage to the water pump bolt holes (1)
• Damage to the water pump gasket sealing
surface (3)
• Damage, corrosion or restrictions
3. Repair or replace the water pump as necessary.
2191168

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1655
Intake Manifold Disassemble
Object-ID=2322790 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2191173

5. Remove the manifold absolute pressure sensor

bolt (2).
2191172
6. Remove the manifold absolute pressure
sensor (1).
1. Remove the 2 exhaust pressure sensor bracket
bolts (1).
2. Remove the exhaust pressure sensor bracket (2).

2191175

7. Remove the 3 throttle body adapter bolts (3).

2191174
8. Remove the throttle body adapter (1).
9. Remove the throttle body adapter seal (2).
3. Remove the 2 positive crankcase ventilation oil
separator hose bracket bolts (2).
4. Remove the positive crankcase ventilation oil
separator hose bracket (1).

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9-1656 Engine Mechanical - 1.3L (LDV) Diesel
Intake Manifold Cleaning and 3. Install the 3 throttle body adapter bolts (3) and
tighten to 8 Y (71 lb in).
Inspection
Object-ID=2322795 Owner=Thess, Stephan LMD=05-Aug-2009 LMB=Thess, Stephan

2191173

4. Install the manifold absolute pressure sensor (1).

2191177 5. Install the manifold absolute pressure sensor
1. Inspect the intake manifold (1) for damage. bolt (2) and tighten.
2. Clean the throttle body sealing surface (2).
3. Clean the intake manifold to cylinder head sealing
surfaces (3).
4. Replace the intake manifold as necessary.

Intake Manifold Assemble

Object-ID=2322797 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2191174

6. Install the positive crankcase ventilation oil

separator hose bracket (1).
7. Install the 2 positive crankcase ventilation oil
separator hose bracket bolts (2) and tighten to
9 Y (80 lb in).

2191175

1. Install a NEW throttle body adapter seal (2).

2. Install the throttle body adapter (1).
Caution: Refer to Fastener Caution on page 0‑9.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1657
1. Install the cylinder head (1) to the EN-6215-1
mounting table (2) along with the EN-6215-5
sidewise support (3). Fix the cylinder head with the
appropriate short bolts.

2191172

8. Install the exhaust pressure sensor bracket (2).

9. Install the 2 exhaust pressure sensor bracket
bolts (1) and tighten to 9 Y (80 lb in).
2189658
Cylinder Head Disassemble
2. Install the EN-6215-4 handle (1) to the EN-6215-1
Object-ID=2322798 Owner=Thess, Stephan LMD=14-Jan-2011 LMB=Thess, Stephan
mounting table.
Special Tools
• EN-840 Pliers/Remover
• EN-849 Assembly Tray
• EN-6086 Spring And Wedge Replacer Kit
• EN-6167 Support Set
• EN-6171 Release Tool
• EN-6215 Mounting Equipment
For equivalent regional tools, refer to Special Tools on
page 9‑1711.

2189659

3. Install the 4 EN-6167-1 braces (1) in order to

support the valves.

2189657

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9-1658 Engine Mechanical - 1.3L (LDV) Diesel

2189654 2189656

4. Install the 4 EN-6167-2 bolts (2) in compound with 6. Install the EN-6086-7 lever (2) to the handle (1).
the 4 EN-6167-2 special nuts (3) in order to fix the 7. Install the EN-6086-11 demounting piece (4) in
EN-6167-1 brace. Install a suitable bolt (1) to justify compound with the lever adapter (3) to the lever.
the special nut.
Note: The demounting piece must be applied parallel
to the valve retainers in order to prevent damage to the
tools or the valve train components.
8. Press down the valve springs and the upper valve
spring retainers until the valve keys are discharged
from spring load. Remove the valve keys.

2189655

5. Solve the valve retainers with an easy hammer hit.

Use a rubber hammer (1) and the EN-6171 release
tool (2).

2189687

Note: Place the valve springs, the upper valve spring

retainers and the valve keys to EN-849 assembly tray
to ensure they will be installed in their original position.
9. Remove the valve stem oil seals (2). Use the
EN-840 pliers (1).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1659
2. If any of the above conditions exist on the
camshaft bearing surfaces, replace the
cylinder head.
3. Inspect the cylinder head for the following:
• Cracks, damage or pitting in the combustion
chambers.
• Debris in the oil galleries – Continue to clean
the galleries until all debris is removed.
• Coolant leaks or damage to the deck face
sealing surface – If coolant leaks are present,
measure the surface warpage as described
under cylinder head measurement - deck
flatness inspection.
• Damage to any gasket surfaces.
• Burnt or eroded areas in the combustion
chamber.
• Cracks in the exhaust ports and combustion
chambers.
• External cracks in the water passages.
2189686 • Restrictions in the intake or exhaust passages.
10. Remove the valves and the lower valve spring • Restrictions in the cooling system passages.
retainers and place to the EN-849 assembly tray • Rusted, damaged or leaking core plugs.
(1) to ensure they will be installed in their original 4. If the cylinder head is cracked or damaged, it must
position. be replaced. No welding or patching of the cylinder
head is allowed.
Cylinder Head Cleaning and
Inspection Valve Inspection And Measurement
Object-ID=2364004 Owner=Thess, Stephan LMD=11-Apr-2013 LMB=Kuhse, Ben

Special Tools
• EN-301 Gauge Bar
• GE-571–B Gauge
• EN-6216 Gauge
• EN-6216–200/300/400 Gauge Instruments
For equivalent regional tools, refer to Special Tools on
page 9‑1711.
Cleaning Procedure
1. Remove any old thread sealant, gasket material or
sealant.
2. Clean all cylinder head surfaces with non-corrosive
cleaning solvent.
Warning: Refer to Safety Glasses Warning on
page 0‑6.
3. Blow out all the oil galleries using compressed air.
4. Remove any carbon deposits from the combustion
2189690
chamber.
1. Clean the valves of carbon and oil. Carbon can be
Visual Inspection removed with a wire brush.
1. Inspect the cylinder head camshaft bearing 2. Inspect the valves for the following conditions:
surfaces for the following conditions:
2.1. Inspect the valve faces for burning and
• Excessive scoring or pitting cracking (1). If pieces are broken, replace the
• Discoloration from overheating valve and inspect the corresponding piston
• Deformation from excessive wear and cylinder head area for damage.
• If the camshaft bearing journals appear to be 2.2. Inspect the valve for straightness and
scored or damaged, you must replace the distortion (2). Distorted valve must be
cylinder head. DO NOT machine the camshaft replaced.
bearing journals.

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9-1660 Engine Mechanical - 1.3L (LDV) Diesel
2.3. Inspect the valve stem for wear (3). Cylinder Head Measurement
2.4. Inspect the valve key grooves for chipping and
wear (4) and (5). Replace the valve if chipped
or worn.

2189666

1. Inspect the cylinder head sealing surface for

2189668
flatness. Use a straightedge (1).
2. Measure the sag of the cylinder head with a feeler
3. Measure the valve length (2). Use a slide gauge. The maximum sag of cylinder head must
gauge (1). Refer to Engine Mechanical be0.1 mm (0.0039 in).
Specifications on page 9‑1438 to find the permitted
values.

2189672

2189667 3. Prepare the gauge for valve stem to guide

clearance measurement. Assemble the EN-6216
4. Measure the valve stem diameter. Use a gauge and the EN-6216–200/300/400 gauge
micrometer gauge (2). Refer to Engine Mechanical instruments as followed:
Specifications on page 9‑1438 to find the permitted
values. Note the measurement results. 3.1. Install the extension (5) to the support (4).
3.2. Install the inside caliper (2) to the
extension (5).
3.3. Install the gauge (3) to the support (4) and
pretension to 1 mm (0.0394 in).
3.4. Install the calibration washer (1) as shown to
justify the gauge.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1661
3.5. Adjust the gauge to 0 mm (0 in) by rotating 9. Install the EN-571–B gauge to the EN-301 gauge
the instrument dial. bar and measure the valve assembly height. Refer
3.6. Cautious remove the calibration washer (1). to Engine Mechanical Specifications on
page 9‑1438 to find the permitted values.

Cylinder Head Assemble

Object-ID=2322800 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

Special Tools
• EN-835-A Installer
• EN-840 Pliers / Remover
• EN 6086 Spring And Wedge Replacer Kit
• EN-6167 Support Set
• EN-6215 Mounting Equipment
For equivalent regional tools, refer to Special Tools on
page 9‑1711.
Note: Lubricate the valve guides and the valve stems
with engine oil.
Note: Examine that the valves will be installed in their
original position.
1. Install the 16 valves to the cylinder head.

2189673

4. Measure the valve guide inner diameter (2) as

shown in different areas (3). Use the EN-6216
Gauge (1) and gauge instruments. Note the
measurement results. Refer to Engine Mechanical
Specifications on page 9‑1438 to find the permitted
values.
5. Substract the valve stem diameter from valve
guide inner diameter to calculate the valve stem to
guide clearance. Refer to Engine Mechanical
Specifications on page 9‑1438 to find the permitted
values.
6. Turn the cylinder head upside down.

2189659

2. Install the EN-6167-1 braces (1) in order to

support the valves.

2189670

7. Loosely install one valve to the cylinder head (3).

8. Place the EN-301 gauge bar (2) to the cylinder
head sealing surface.

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9-1662 Engine Mechanical - 1.3L (LDV) Diesel

2189654 2189658

3. Fix the EN-6167-1 braces with the EN-6167-2 7. Install the EN-6215-4 handle (1) to the EN-6215-1
bolts (2) along with the EN-6167-2 special mounting table.
nuts (3).
Note: Examine that the valve spring retainers will be
installed in their original position.
4. Install the 16 lower valve spring retainers.

2189662

Note: A wrong combination of mounting piece and

plunger can cause damage to the plunger or the
valve keys.
2189715 8. Prepare the EN-6086–100-1 mounting piece for
the valve key installation. The mounting piece must
5. Install the NEW 16 valve stem oil seals (1). Use be assembled in the following order:
EN-835-A installer (2) to push down the valve
stem oil seals. 8.1. Support (6)
Note: Examine that the valve springs and the valve 8.2. Bushing (5)
spring retainers will be installed in their original 8.3. Spring (4)
position. 8.4. EN-6086-100-10 plunger (3)
6. Install the 16 valve springs and the 16 upper valve 8.5. Screw connection (2)
spring retainers. 8.6. Lever adapter (1)

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1663
Piston and Connecting Rod
Disassemble
Object-ID=2322801 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2189663

9. Install the valve keys (1) to the mounting piece (2)

as shown and fix them with the bushing.

2189594

1. Remove the piston rings. Use a piston ring plier (1).

2189656

10. Install the EN-6086-7 lever (2) along with the lever
adapter (3) and the mounting piece (4) to the
handle (1).
11. Push the mounting piece slightly down until the 2191182
valve keys are engaged in evidence.
2. The piston rings are ordered as followed:
12. Repeat the procedure on the remaining 15 valves.
• Upper compression ring (1)
13. Remove the cylinder head from the EN-6215-1
mounting table. • Lower compression ring (2)
• Oil ring (3)

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9-1664 Engine Mechanical - 1.3L (LDV) Diesel
2. Inspect the connecting rod for the following:
• Signs of being twisted, bent, nicked or cracked
• Scratches or abrasion on the connecting rod
bearing seating surfaces
Piston

2189593

Note: Clamp the connecting rod.

3. Remove the 2 piston pin retainer (1).
4. Remove the piston pin (2).
5. Remove the piston (3) from the connecting rod (4).

Piston, Connecting Rod, and Bearing 156168

Cleaning and Inspection 1. Clean the piston with a cleaning solvent. DO NOT
Object-ID=2322802 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan wire brush any parts of the piston.
2. Clean the piston ring grooves.
Visual Inspection And Cleaning 3. Inspect the piston on the following:
Procedure • Cracked ring lands, skirts or pin bosses
• Ring grooves for nicks
Connecting Rod
• Eroded areas on the top of the piston (1)
• Scuffed or damaged skirts (2)
• Worn piston pin bores (3)
4. If there is any excessive wear, replace the piston.
5. Measure the clearance between piston pin and
piston bore. Use the following procedure:
Piston And Connecting Rod
Measurement Procedure
Piston Pin To Connecting Rod Bore And Piston
Bore Clearance
1. Measure clearance between piston pin and
connecting rod bore. Use the following procedure:
1.1. Measure the piston pin outside diameter.
1.2. Measure the connecting rod bore diameter.
1.3. Substract the piston ring diameter from the
connecting rod diameter.
1.4. The clearance should be 0.019 mm–
0.030 mm (0.0007 in–0.0012 in).
479859 2. If there is excessive clearance, replace the
Warning: Refer to Safety Glasses Warning on piston pin.
page 0‑6. 3. If there is still excessive clearance, replace the
connecting rod.
1. Clean the connecting rods in solvent and dry with
compressed air. 3.1. Measure the piston pin outside diameter.
3.2. Measure the piston bore diameter.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1665
3.3. Substract the piston pin diameter from the
piston bore diameter.
3.4. The clearance should be 0.004 mm–
0.014 mm (0.0002 in–0.0006 in).
4. If there is excessive clearance, replace the
piston pin.
5. If there is still excessive clearance, replace the
piston.
Piston Ring Clearance

2189597

3. Measure the piston ring side clearance as

shown (1). Compare the measurements with those
provided below:
• The upper compression ring side clearance
should be 0.11 mm–0.15 mm (0.0043 in–
0.0059 in).
• The lower compression ring side clearance
should be 0.05 mm–0.09 mm (0.0020 in–
0.0035 in).
2189596 • The oil ring side clearance should be
0.03 mm–0.07 mm (0.0012 in–0.0028 in).
1. Install the piston rings to the cylinder as shown (1)
and measure the piston ring end gap. Compare the 4. If the clearance is greater than the provided
measurements with those provided below: specifications, replace the piston rings.
• The upper compression ring end gap should be 5. If the clearance is still to great, replace the pistons.
0.20 mm–0.30 mm (0.0078 in–0.0118 in). Connecting Rod Bearing Clearance (With
• The lower compression ring end gap should be Micrometer Gauge Internal Measuring Device)
1.00 mm–1.50 mm (0.0394 in–0.0591 in). 1. Install the connecting bearings and the connecting
• The oil ring end gap should be 0.25 mm– rod bearing caps.
0.50 mm (0.0098 in–0.0197). 2. Tighten the connecting rod bearing cap bolts in the
2. If the clearance is greater than the provided following sequence:
specifications, the piston rings must be replaced. Caution: Refer to Fastener Caution on page 0‑9.
Note: The old bolts can be reused for the measuring
procedure.
2.1. Tighten the connecting rod bearing cap bolts
to 20 Y (15 lb ft).
2.2. Tighten the bolts to an additional 40°.

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9-1666 Engine Mechanical - 1.3L (LDV) Diesel
Piston and Connecting Rod
Assemble
Object-ID=2322804 Owner=Thess, Stephan LMD=28-May-2010 LMB=Thess, Stephan

2189741

3. Measure the connecting rod bearing diameters at

3 points as shown (1). Use a internal measuring
device.
4. Calculate the average connecting rod inner
diameter. 2189594

Formula: 1. result + 2. result + 3. result / 3 1. Install the piston rings. Use a piston ring plier (1).

2189634
2191182

5. Measure the connecting rod journal diameter at 2. The piston rings must be ordered as followed:
2 points between (1) and (3) and between (2)
and (4). Use a micrometer gauge. • Upper compression ring (1)
6. Calculate the average connecting rod journal • Lower compression ring (2)
diameter. • Oil ring (3)
Formula: 1. result + 2. result / 2. 3. The piston ring joints must be displaced 120° to
7. Subtract the average connecting rod journal each other.
diameter from the average connecting rod bearing
diameter in order to determine the connecting rod
bearing clearance.
The clearance should be 0.030 mm–
0.062 mm (0.0012 in–0.0024 in).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1667

2189607 2189550

Note: Lubricate the piston pin and the piston bore with 2. Remove and DISCARD the 8 engine flywheel
engine oil. bolts (2).
4. Install the connecting rod (3) to the piston (2). 3. Remove the engine flywheel (1).
Note: The marks (4) on the connecting rod must show
in direction to the mark (1) on the top of the piston. Crankshaft Rear Oil Seal Removal
Object-ID=2364061 Owner=Thess, Stephan LMD=23-Oct-2009 LMB=Thess, Stephan
5. Install the piston pin (5).
Note: The 2 piston pin retainer (6) must be positioned
in region of measurement maximum 30° as shown in Special Tools
the extensional graphic position (I). EN-4500 Remover Oil Seal
6. Install the 2 piston pin retainer (6). For equivalent regional tools refer to Special Tools on
page 9‑1711
Engine Flywheel Removal
Object-ID=2364056 Owner=Thess, Stephan LMD=15-Sep-2010 LMB=Thess, Stephan

Special Tools
EN-652 Fixing Tool
For equivalent regional tools, refer to Special Tools on
page 9‑1711.
1. Install the EN-652 fixing tool in order to fix the
engine flywheel.

2191190

Note: Be careful do not damage the sealing surfaces.

Remove the crankshaft rear oil seal (2) with EN-4500
remover (1),

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9-1668 Engine Mechanical - 1.3L (LDV) Diesel
Crankshaft and Bearing Removal 4. Install the EN-571-B dial gauge (2) with the
bracket (1) to the timing side of the engine block.
Object-ID=2370786 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan
Note: If the value for the crankshaft axial play does not
correspond with the permissible axial play, regrind the
Special Tools crankcase seat and use suitable oversize thrust
EN-571-B Dial Gauge bearings. For oversize thrust bearings, refer to Engine
For equivalent regional tools, refer to Special Tools on Mechanical Specifications on page 9‑1438.
page 9‑1711. 5. Measure the crankshaft axial play. For permissible
axial play, refer to Engine Mechanical
Specifications on page 9‑1438.

2191191

1. Remove the 10 lower crankcase bolts M8 (3).

2191192
2. Remove the 10 lower crankcase bolts M10 (2).
Note: Mark the installation position. Set aside in order
Note: Carefully detach from engine block using removed.
suitable tool. Do not damage sealing surfaces.
6. Remove the 5 crankshaft lower bearings (2) from
3. Remove the lower crankcase (1). the crankcase.
7. Remove the crankshaft (1).
Note: Mark the installation position. Set aside in order
removed.
The middle crankshaft bearing contains the thrust
bearing.
8. Remove the 5 crankshaft upper bearings (3).

Crankshaft and Bearing Cleaning

and Inspection
Object-ID=2370207 Owner=Thess, Stephan LMD=23-Nov-2011 LMB=Horsch, Magdalena

Cleaning Procedure
1. Clean the crankshaft with solvent.
2. Thoroughly clean all oil passages and inspect for
restrictions or burrs.
Warning: Refer to Safety Glasses and Compressed
Air Warning on page 0‑6.
3. Dry the crankshaft with compressed air.
2191227

Note: The check is conducted with the crankshaft

bearing shells installed in the cylinder block and the
flywheel removed. The crankshaft is only loosely fitted
in the cylinder block.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1669
Visual Inspection

52053

3. Inspect the crankshaft bearings for excessive

2191863 scoring or discoloration.
1. Inspect the 5 crankshaft bearing journals (1) and 4. Inspect the crankshaft bearings for dirt or debris
4 connecting rod bearing journals (2) for wear: imbedded into the bearing material.
• grooves or scoring
• scratches
• pitting or imbedded bearing material

52056

Note: If the lower half of the bearing is worn or

damaged, both upper and lower halves should be
replaced.
52051
Generally, if the lower half is suitable for use, the upper
2. Inspect crankshaft bearings for craters or pockets. half should also be suitable for use.
Flattened sections on the bearing halves also
5. Inspect the crankshaft bearings for improper
indicate fatigue.
seating indicated by bright, polished sections of the
bearing.

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9-1670 Engine Mechanical - 1.3L (LDV) Diesel
Check Crankshaft Bearing Clearance
(With Micrometer Gage Internal
Measuring Device)

2191868

Note: Do not rotate the crankshaft.

2. Lay on 5 times plastigage (flexible plastic thread)
axially over the entire width of the crankshaft
2191864
bearing journal (1).
3. Install the 5 lower crankshaft bearing shells.
1. Measurement the crankshaft bearing journal
diameter with a micrometer gauge at the
measuring points (I) and (II).
2. Calculate the average crankshaft bearing journal
diameter. Formula: 1. result + 2. result / 2.
Refer to Engine Mechanical Specifications on
page 9‑1438 for the recommended limits.
Note: Different classes of bearing shells can be used
for a crankshaft bearing to reduce bearing clearance.
The stronger of the two bearing shells must be inserted
in the crankcase.
3. Crankshaft bearing clearance is calculated by
using:
• Crankshaft bearing bore diameter, refer to
Engine Block Cleaning and Inspection on
page 9‑1672.
• Crankshaft bearing journal diameter
• Crankshaft bearing shell thickness
4. Determine the crankshaft bearing clearance.
Calculation formula: average crankshaft bearing
bore diameter minus average crankshaft bearing 2191837
journal diameter minus crankshaft bearing shell
4. Install the lower crankcase (1).
thickness from lower crankcase minus crankshaft
bearing shell thickness from engine block. 5. Loosely install the 10 lower crankcase inner
bolts (2).
Refer to Engine Mechanical Specifications on
page 9‑1438 for the recommended limits. 6. Loosely install the 10 lower crankcase outer
bolts (3).
Check Crankshaft Bearing Clearance
(With Plastigage)
1. Install crankshaft with the 5 upper crankshaft
bearing shells at the engine block.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1671

2191838 2191837

Caution: Refer to Fastener Caution on page 0‑9. 10. Remove the 10 lower crankcase outer bolts (3).
7. Tighten the 10 lower crankcase inner bolts in 11. Remove the 10 lower crankcase inner bolts (2).
sequence as shown and in the following order:
12. Remove the lower crankcase (1).
• Tighten the bolts in sequence as shown to 20
Y (15 lb ft).
• Tighten in sequence as shown to an additional
80 degrees.

2191869

Note: When reading the value, do not confuse

millimeters and inches on the measuring scale.
2191839 13. Measure the crankshaft bearing play.
8. Tighten the 10 lower crankcase outer bolts in • Compare the width of the flattened plastic
sequence as shown to 30 Y (22 lb ft). thread (1) to the measuring scale (2).
9. Detach the crankcase. • Permissible crankshaft bearing play, refer to
Engine Mechanical Specifications on
page 9‑1438.

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9-1672 Engine Mechanical - 1.3L (LDV) Diesel
Engine Block Disassemble
Object-ID=2322805 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2191201

4. Remove the 7 engine block core hole plugs (1).

2191198

1. Remove the 2 transmission locating pins (1).

2. Remove the 2 lower crankcase location pins (2).

2191202

5. Remove the 4 piston oil nozzle bolts (1).

6. Remove the 4 piston oil nozzles (2).

2191200
Engine Block Cleaning and
Inspection
3. Remove the 2 cylinder head location pins (1).
Object-ID=2354566 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

Special Tools
EN-8087 Gauge
For equivalent regional tools, refer to Special Tools on
page 9‑1711.
Cleaning Procedure
1. Remove any old thread sealant, gasket material or
sealant.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1673
2. Clean all the following areas with solvent:
• Sealing surfaces
• Cooling passages
• Oil passages
• Bearing journals
3. Clean all threaded and through holes with solvent.
Warning: Refer to Safety Glasses and Compressed
Air Warning on page 0‑6.
4. Dry the engine block with compressed air.
Visual Inspection
1. Inspect the crankshaft bearings journals for
damage or spun bearings. The crankshaft bearing
journals are not repairable, if the crankshaft
bearing journals are damaged the engine block
assembly must be replaced.
2. Inspect all sealing and mating surfaces for
damage, repair or replace the engine block
assembly if necessary.
2189636
3. Inspect all threaded and through holes for damage
or excessive debris. 2. Inspect the engine block as shown for deflection.
4. Inspect all bolts for damage, if damaged replace Use a straightedge (1).
with NEW bolts only. Cylinder Sleeve Diameter Inspection
5. Inspect the cylinder walls for cracks or damage.
The cylinder sleeves are not serviced separately,
if the cylinders are damaged the cylinder block
assembly must be replaced.
6. Inspect the engine block for cracks. Do not repair
any cracks. If cracks are found, the cylinder block
assembly must be replaced.
Measuring Procedure
Engine Block Flatness Inspection

2191840

1. For classification the cylinder bore diameters see

marking of the cylinder bore classification (1) on
engine block.

2189637

1. Inspect the engine block as shown for distortion.

Use a straightedge (1).

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9-1674 Engine Mechanical - 1.3L (LDV) Diesel

2026767 2191837

Note: If the cylinder sleeve measurements are not 2. Install the lower crankcase (1).
within the recommended limits, ream the cylinder bores
with the recommended oversizes. Refer to Engine Note: Install without crankshaft and bearings for
Mechanical Specifications on page 9‑1438. measure the bearing bore diameter in cylinder block.
2. Inspect the cylinder bores using the EN-8087 3. Loosely install the 10 lower crankcase inner
gauge (1). Inspect for the following items: bolts (2).
• Wear of cylinder sleeve 4. Loosely install the 10 lower crankcase outer
bolts (3).
• Cylinder sleeve diameter
• Tapering of cylinder sleeve
• Oval status of cylinder sleeve
Refer to Engine Mechanical Specifications on
page 9‑1438 for the recommended limits.
Bearing Bore Diameter In Cylinder Block Inspection

2191838

Caution: Refer to Fastener Caution on page 0‑9.

5. Tighten the 10 lower crankcase inner bolts in
sequence as shown and in the following order:
• Tighten the bolts in sequence as shown to
20 Y (15 lb ft)
2191198 • Tighten in sequence as shown to an
additional 80°
1. Install the 2 lower crankcase location pins (2).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1675

2191839 2026766

6. Tighten the 10 lower crankcase outer bolts in 8. Inspect the bearing bore diameter in cylinder block
sequence as shown to 30 Y (22 lb ft). using the EN-8087 gauge (1). Refer to Engine
Mechanical Specifications on page 9‑1438 for the
recommended limits.

2191841

7. For classification the bearing bore diameter in 2191837

cylinder block see marking of the main bearing
journal diameter classification (1) on crankshaft. 9. Remove the 10 lower crankcase outer bolts (3).
10. Remove the 10 lower crankcase inner bolts (2).
11. Remove the lower crankcase (1).

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9-1676 Engine Mechanical - 1.3L (LDV) Diesel

2191198 2191201

12. Remove the 2 lower crankcase location pins (2). Note: Ensure the NEW engine block core hole plugs
are installed to the proper depth.
Engine Block Assemble 3. Install the 7 NEW engine block core hole plugs (1).
Object-ID=2354568 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2191200

2191202
4. Install the 2 cylinder head location pins (1).

1. Install the 4 piston oil nozzles (2).

Caution: Refer to Fastener Caution on page 0‑9.
2. Install the 4 piston oil nozzle bolts (1) and tighten
to 9 Y (80 lb in)

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1677

2191198 2191845

5. Install the 2 transmission locating pins (1). 4. Remove the 5 oil pump cap bolts (1).
6. Install the 2 lower crankcase location pins (2). 5. Remove the oil pump cap (2).
6. Remove the oil pump inner drive adapter (3).
Oil Pump Disassemble 7. Remove the oil pump outer drive adapter (4).
Object-ID=2354570 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2191847

2191844 8. Remove the oil pump seal (1).

1. Remove the 2 oil pump suction pipe bolts (1).
2. Remove the oil pump suction pipe (3).
3. Remove the oil pump suction pipe gasket (2).

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9-1678 Engine Mechanical - 1.3L (LDV) Diesel
Oil Pump Cleaning and Inspection Axial Clearance Inspection
Object-ID=2354629 Owner=Thess, Stephan LMD=04-Jun-2010 LMB=Thess, Stephan

Cleaning Procedure
1. Remove any old thread sealant, gasket material or
sealant.
2. Clean all the following areas with solvent:
• Sealing surfaces
• Oil passages
• Inner and outer drive adapters
3. Clean all threaded and through holes with solvent.
Warning: Refer to Safety Glasses and Compressed
Air Warning on page 0‑6.
4. Dry the oil pump housing with compressed air.
Measuring Procedure
Install the oil pump outer and inner drive adapter.
Radial Clearance Inspection
2191849

Check axial clearance between contact surface of oil

pump housing and upper surface of drive adapters with
straightedge (2) and feeler gauge (1). Refer to Engine
Mechanical Specifications on page 9‑1438 for
permissible clearance.

Oil Pump Assemble

Object-ID=2354631 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2191848

Check radial clearance between oil pump housing (1)

and outer drive adapter (2) with feeler gauge (3). Refer
to Engine Mechanical Specifications on page 9‑1438
for permissible clearance.

2191845

1. Install the oil pump outer drive adapter (4).

2. Install the oil pump inner drive adapter (3).
3. Install the oil pump cap (2).
Caution: Refer to Fastener Caution on page 0‑9.
4. Install the 5 oil pump cap bolts (1) and tighten to
6 Y (53 lb in).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1679

2191844 2191873

5. Install the oil pump suction pipe gasket (2). Note: Ensure that guide lugs are properly seated. If the
old crankshaft bearing shells was reused, set it in as
6. Install the oil pump suction pipe (3). removed.
7. Install the 2 oil pump suction pipe bolts (1) and
tighten to 6 Y (53 lb in). 4. Install the 5 lower crankshaft bearing shells (1) into
the crankcase (2).
Crankshaft and Bearing Installation 5. Coat the crankshaft bearing shells with engine oil.
Object-ID=2370787 Owner=Thess, Stephan LMD=16-Sep-2010 LMB=Thess, Stephan

2191875

Note: The complete installation procedure of the lower

2191871 crankcase should be done in 10 minutes.
Note: Ensure that guide lugs (arrows) are properly 6. Apply silicone sealing compound to the engine
seated. Note position of thrust bearing (1) at middle block. The thickness of the sealing bead (1) should
crankshaft bearing. be 2.5–3. 5 mm (0.0984–0.1378 in).
If the old crankshaft bearing shells was reused, set it in
as removed.
1. Install the 5 upper crankshaft bearing shells into
the engine block.
2. Coat the crankshaft bearing shells with engine oil.
3. Insert the crankshaft into the engine block.

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9-1680 Engine Mechanical - 1.3L (LDV) Diesel

2191191 2191839

7. Install the lower crankcase (1). 11. Tighten the 10 lower crankcase outer bolts in
8. Loosely install 10 NEW lower crankcase sequence as shown to 30 Y (22 lb ft).
bolts M10 (2).
9. Loosely install the 10 lower crankcase bolts M8 (3). Crankshaft Rear Oil Seal Installation
Object-ID=2364062 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

Special Tools
EN-46777 Installer Crankshaft Rear Oil Seal
For equivalent regional tools, refer to Special Tools on
page 9‑1711.

2191838

Caution: Refer to Fastener Caution on page 0‑9.

Caution: Refer to Torque-to-Yield Fastener Caution on
page 0‑10.
10. Tighten the 10 lower crankcase inner bolts in
sequence as shown and in the following order:
• Tighten the bolts in sequence as shown to 20 2191876

Y (15 lb ft). 1. Place the EN-46777‐20 Installer (1) on the

• Tighten in sequence as shown to an EN-46777‐10 Installer (3).
additional 80°. 2. Slide the crankshaft rear oil seal (2) across the
EN-46777‐20 Installer (1) onto the EN-46777‐10
Installer (3).
3. Remove the EN-46777‐20 Installer (1) from the
EN-46777‐10 Installer (3).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1681
Caution: Refer to Torque-to-Yield Fastener Caution on
page 0‑10.
4. Install 8 NEW engine flywheel bolts (2) and tighten
in the following order:
4.1. Tighten the bolts to 15 Y(11 lb ft).
4.2. Tighten to an additional 35°. Use a EN-470-B
angle torque wrench.
5. Remove the EN-652 fixing tool.

Piston, Connecting Rod, and Bearing

Installation
Object-ID=2354633 Owner=Thess, Stephan LMD=16-Sep-2010 LMB=Thess, Stephan

2191877

Note: Use a mallet to install the crankshaft rear oil seal

into the right fitting position.
4. Install the crankshaft rear oil seal (1) with the
EN-46777‐10 installer (2).

Engine Flywheel Installation

Object-ID=2364063 Owner=Thess, Stephan LMD=16-Sep-2010 LMB=Thess, Stephan

Special Tools
• EN-470-B Torque Wrench
• EN-652 Fixing Tool
For equivalent regional tools, refer to Special Tools on
page 9‑1711.
2191881
1. Install the EN-652 fixing tool in order to fix the
Note: Install the 4 connecting rod bearing shells with
engine flywheel.
oil bore (3) into the connecting bearing caps (2).
2. Recut the 8 threads in the crankshaft.
If the old connecting rod bearing shells will be reused,
install in their original position.
1. Install the 8 connecting rod bearing shells (1).

2189550

3. Install the engine flywheel (1).

Caution: Refer to Fastener Caution on page 0‑9.
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9-1682 Engine Mechanical - 1.3L (LDV) Diesel

2191884 2191164

2. The arrow (2) on the piston head must point to the Note: Note marking (2) of the connecting rod
timing side. bearing caps.
Note: The connecting rod bearing caps must be 9. Install the 2 connecting rod bearing caps (3) with
installed in their original position. connecting rod lower bearing shells (1) into
cylinder 1 and 4.
3. Note the marking (1) of the connecting rod and
connecting rod cap. Caution: Refer to Fastener Caution on page 0‑9.
4. The piston ring joints must be displaced 120° to Caution: Refer to Torque-to-Yield Fastener Caution on
each other. page 0‑10.
5. Set the crankshaft to TDC of combustion stroke of 10. Install the 4 NEW connecting rod bearing cap
cylinder 2. bolts (4) to the cylinder 1 and 4 and tighten in
following order:
6. Coat all pistons and cylinder bores with engine oil.
• Tighten the bolts in first step to 20 Y (15 lb ft).
• Tighten the bolts to an additional 40°.
11. Turn crankshaft through 180° and set crankshaft to
TDC of combustion stroke of cylinder 1.

2191165

7. Install a piston ring compressor in order to

compress the piston rings.
8. Install the 2 pistons with connecting rods (1) and 2191163
connecting rod upper bearing shells (3) into
cylinder 1 and 4. 12. Install a piston ring compressor in order to
compress the piston rings.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1683
13. Install the 2 pistons with connecting rod (1) with
connecting rod upper bearing shells (3) into
cylinder 2 and 3.

2189544

3. Install the EN-301 bridge (2) in compound with the

GE-571-B gauge (1).
2191160 Note: The largest piston projection is decisive for the
Note: Note marking (2) of the connecting rod selection of the cylinder head gasket with the
bearing caps. corresponding marking.

14. Install the 2 connecting rod bearing caps (3) with 4. Measure the piston projection dimensions at all
the connecting rod lower bearing shells (1) into pistons.
cylinder 2 and 3.
15. Install the 4 NEW connecting rod bearing cap
bolts (4) to cylinder 2 and 3 and tighten in following
order:
• Tighten the bolts in first step to 20 Y (15 lb ft).
• Tighten the bolts to an additional 40°.

Cylinder Head Installation

Object-ID=2354637 Owner=Thess, Stephan LMD=16-Sep-2010 LMB=Thess, Stephan

Special Tools
• EN-301 Measuring Bridge
• EN-470-B Torque Angle Sensor
• GE-571-B Dial Gauge
• EN-46778 Fixing Tool Crankshaft
For equivalent regional tools, refer to Special Tools on
page 9‑1711.
Note: Ensure that the cylinder head and the cylinder
block sealing surfaces are clear of oil, grease and old
gasket material. 2191886

1. Clean the sealing surfaces 5. Select the cylinder head gasket with the correct
2. Inspect the flatness of cylinder head and cylinder identification marks:
block sealing surfaces 5.1. Piston projection 0.028 - 0.127 mm (0.0011 -
0.005), choose the cylinder head gasket with
identification mark – without holes.
5.2. Piston projection 0.128 - 0.227 mm (0.005 -
0.00894), choose the cylinder head gasket
with identification mark – 1 hole.
5.3. Piston projection 0.228 - 0.327 mm (0.00898-
0.01287), choose the cylinder head gasket
with identification mark – 2 holes.

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9-1684 Engine Mechanical - 1.3L (LDV) Diesel

2191897 2191895

6. Turn the crankshaft in the engine direction of Note: Use a rubber mallet to adjust the cylinder head.
rotation until the EN-46778 fixing tool (1) to The overhang of the timing side should be under 0.1
engage with the drilling at flywheel (2) and cylinder mm (0.00394 in).
block. 10. Align the cylinder head (1) to the engine block (3)
with a straightedge (2).

2191156
2191888
7. Install the cylinder head gasket (3).
Caution: Refer to Fastener Caution on page 0‑9.
8. Install the cylinder head (2).
Caution: Refer to Torque-to-Yield Fastener Caution on
9. Loosely install 10 NEW cylinder head bolts (1). page 0‑10.
11. Tighten the 10 cylinder head bolts in sequence as
shown and in the following order:
• Tighten the bolts in sequence as shown to
40Y (30 lb ft).
• Tighten in sequence as shown to an additional
90°. Use EN-470-B anglemeter.
• Tighten in sequence as shown to an additional
90°. Use EN-470-B anglemeter.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1685
Valve Lifter Installation For equivalent regional tools, refer to Special Tools on
page 9‑1711.
Object-ID=2354640 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2190962

2191139 Note: The EN-46781 fixing tool (1) must be install in

Note: Clip in the valve lifter to valve rocker arm. Mind horizontal position.
to the centring link on retaining spring (3). 1. Install the EN-46781 fixing tool (1) on the exhaust
1. Install the 16 valve lifters (2) to the valve side and intake side.
rocker arm (1).
2. Coat the 16 valve lifter with engine oil.

2191137

2. Install a NEW camshaft housing gasket (4).

2191138
3. Install the camshaft housing (3).
Note: If the valve lifters are reused, the valve lifter 4. Loosely install the 2 camshaft housing studs (1).
must be installed in their original position.
Note: Mind the different bolt length.
3. Install the 16 valve rocker arms with valve lifter (1).
5. Loosely install the 16 camshaft housing bolts (2).
Camshaft Housing Installation
Object-ID=2354643 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

Special Tools
EN-46781 Fixing Tool Camshaft

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9-1686 Engine Mechanical - 1.3L (LDV) Diesel
8. Tighten the 16 camshaft cover bolts and the 2
camshaft cover studs in sequence as shown and
final step:
• For camshaft housing bolts M7 to 18
Y (13 lb ft).
• For camshaft housing studs M8 to 25
Y (18 lb ft).

2191900

Note: Use a rubber mallet to adjust the camshaft

housing. The overhang at the timing side should be
under 0.1 mm (0.00394 in).
6. Alignment the camshaft housing (1) to the cylinder
head (3) with a straightedge (2).

2191136

9. Install the glow plug wiring harness bracket (1).

10. Install the 2 glow plug wiring harness bracket
bolts (2) and tighten to 22 Y (16 lb ft).

2191904

Caution: Refer to Fastener Caution on page 0‑9

7. Tighten the 16 camshaft cover bolts and the 2
camshaft cover studs in sequence as shown and
first step:
• For camshaft housing bolts M7 to 12
Y (106 lb in). 2191133

• For camshaft housing studs M8 to 15 11. Install the engine control module wiring harness
Y (11 lb ft). bracket (1) right side.
12. Install the engine control module wiring harness
bracket bolt (2) and tighten to 22 Y (16 lb ft).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1687
Crankshaft Position Sensor
Installation
Object-ID=2354649 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2191132

13. Install the engine control module wiring harness

bracket (1) left side.
14. Install the engine control module wiring harness
bracket bolt (2) and tighten to 22 Y (16 lb ft).
2191128

Camshaft Position Sensor 1. Install the crankshaft position sensor (1).

Installation Caution: Refer to Fastener Caution on page 0‑9
Object-ID=2354646 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan 2. Install the crankshaft position sensor bolt (2) and
tighten to 9 Y (80 lb in).

Crankshaft Sprocket Installation

Object-ID=2354656 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2191131

1. Install the camshaft position sensor (2).

Caution: Refer to Fastener Caution on page 0‑9
2. Install the camshaft position sensor bolt (1) and 2191127
tighten to 9 Y (80 lb in).
Install the crankshaft sprocket (1) to the crankshaft (2).

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9-1688 Engine Mechanical - 1.3L (LDV) Diesel
Camshaft Sprocket Installation 4. Tighten the camshaft sprocket bolt (3) to
150 Y (111 lb ft)
Object-ID=2354668 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan
Note: Counterhold the camshaft sprocket with the
EN-6347 holder and the EN-956-1 extension.
Special Tools
• EN-956-1 Extension 5. Remove the EN-6347 holder with the EN-956-1
extension from the camshaft sprocket.
• EN-6347 Holder
For equivalent regional tools, refer to Special Tools on Timing Chain Guide Installation
page 9‑1711.
Object-ID=2354672 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2191126

Note: Install the timing chain to the crankshaft 2191121

sprocket (3) at first.
1. Install the timing chain guide (1).
1. Install the camshaft sprocket (2) along with the Caution: Refer to Fastener Caution on page 0‑9
timing chain (4).
2. Install the 2 timing chain guide bolts (2) and tighten
2. Install the camshaft sprocket bolt (1). to 9 Y (80 lb in).

2191125

3. Install the EN-6347 holder (1) with the EN-956-1

extension (4) to the camshaft sprocket (2).
Caution: Refer to Fastener Caution on page 0‑9

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1689
Timing Chain Tensioner Shoe 1. Install the timing chain tensioner (2).
Caution: Refer to Fastener Caution on page 0‑9.
Installation
Object-ID=2354674 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan
2. Install the 2 timing chain tensioner bolts (1) and
tighten to 9 Y (80 lb in).

2191119 2191110

1. Install the timing chain tensioner shoe (1). 3. Remove the EN-955 locking tool (1) from timing
2. Install the timing chain tensioner shoe bolt (2) and chain tensioner.
tighten to 25 Y (18 lb ft).
Oil Pump Housing Installation
Timing Chain Tensioner Installation Object-ID=2473890 Owner=Thess, Stephan LMD=16-Sep-2010 LMB=Thess, Stephan

Object-ID=2354676 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

Special Tools
Special Tools • EN-470–B Angular Torque Wrench
EN-955 Locking Tool Timing Chain Tensioner • EN-662-C Holding Wrench
For equivalent regional tools, refer to Special Tools on • EN-46775 Centering Tool Oil Pump Housing
page 9‑1711. • EN-46778 Fixing Tool Crankshaft
• EN-46781 Fixing Tool Camshaft
For equivalent regional tools, refer to Special Tools on
page 9‑1711.

2191113

Note: Fix the timing chain tensioner position with the

EN-955 locking tool.

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9-1690 Engine Mechanical - 1.3L (LDV) Diesel

2190962 2191927

1. Ensure that the EN-46781 fixing tool (1) is already Note: The oil pump housing must be fitted within
installed on the exhaust side and the intake side. 10 minutes of applying the silicone sealing compound.
4. Apply silicone sealing compound to the transitions
between the cylinder head and the camshaft
housing (1) and between the cylinder block and the
cylinder head (2).

2191897

2. Ensure that the EN-46778 fixing tool (1) is already

installed to engage with the drilling at flywheel (2)
and the cylinder block.
2191922
3. Clean the sealing surface.
5. Install the oil pump housing gasket (1).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1691

2191923 2372550

6. Install the oil pump housing (2) with the EN-46775 Note: Slide the oil pump seal over the flange sealing
fixing tool (1). surface (arrow).
9. Install the oil pump seal (2) to the flange (1).

2191909

Caution: Refer to Fastener Caution on page 0‑9. 2372551

7. Tighten the 14 oil pump housing bolts and the 3 oil 10. Position the flange (2) with the oil pump seal (3) to
pump housing nuts in sequence as shown: the crankshaft.
7.1. In first step and in sequence as shown, tighten 11. Tighten carefully the flange bolt (1) to limit stop.
to 4 Y (35 lb in).
12. Remove the flange bolt (1).
7.2. In second step and in sequence as shown,
tighten to 9 Y (80 lb in). 13. Remove the flange (2).
8. Remove the EN-46775 fixing tool.

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9-1692 Engine Mechanical - 1.3L (LDV) Diesel

2373026 2190969

14. Position the EN-46775 centering tool (2) with the 19. Install the EN-662-C wrench (2).
plane surface onto the oil pump housing. 20. Install the 2 bolts.
15. Tighten carefully the flange bolt (1) until the Caution: Refer to Torque-to-Yield Fastener Caution on
EN-46775 centering tool flush with oil pump page 0‑10.
housing (arrow).
21. Tighten the crankshaft sprocket bolt (1) to
16. Remove flange bolt EN-46775 centering tool. 50 Y (37 lb ft).
22. Tighten the crankshaft sprocket bolt to additional
90°. Use the EN-470–B torque wrench.

2190971

Note: Mind the left-hand thread.

17. Install the flange (2). 2190962

18. Loosely install the NEW crankshaft sprocket 23. Remove the EN-46781 fixing tool (1) from the
bolt. (1). exhaust side and the intake side.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1693

2191897 2191932

24. Remove the EN-46778 fixing tool (1) from the Note: The complete installation procedure of the oil
flywheel (2) and the cylinder block. pan should be done in 10 minutes.
25. Inspect the camshaft timing chain. Refer to 2. Apply silicone sealing compound (2) to the oil pan
Camshaft Timing Chain Inspection on sealing surface (1). The thickness of the sealing
page 9‑1647. bead (1) should be 3.0 – 4.0 mm (0.118 –
0.157 in).

2190960
2190929
26. Clean the threads from the cylinder head core hole
plugs and the camshaft housing. 3. Install the oil pan (1).
27. Install the cylinder head core hole plug - intake (3)
to the camshaft housing (1) and tighten to
15 Y (11 lb ft).
28. Install the cylinder head core hole plug -
exhaust (2) to the camshaft housing (1) and tighten
to 15 Y (11 lb ft).

Oil Pan Installation

Object-ID=2354678 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

1. Clean the sealing surfaces.

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9-1694 Engine Mechanical - 1.3L (LDV) Diesel

2190926 2190925

4. Hand tighten the 2 oil pan nuts (1). 7. Install the transmission support brace (1).
5. Hand tighten the 13 oil pan bolts (2). 8. Install the 4 transmission support brace bolts (2)
and tighten to 30 Y (22 lb ft).

2191934

Caution: Refer to Fastener Caution on page 0‑9 2190924

6. Tighten the 13 oil pan bolts and the 2 oil pan nuts in Note: For vehicles with air conditioning
sequence as shown: 9. Install the air conditioning compressor bracket (1).
• Tighten in first step to 4 Y (35 lb in). 10. Install the 4 air conditioning compressor bracket
• Tighten in second step to 9 Y (80 lb in). bolts (2) and tighten to 22 Y (16 lb ft)

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1695
Fuel Injector Installation 2. Install the 4 NEW fuel injector gaskets (6) to the
camshaft housing.
Object-ID=2357162 Owner=Thess, Stephan LMD=26-Apr-2013 LMB=Kuhse, Ben
3. Remove the EN-48559 protective caps from the
injector nozzles.
Special Tools
4. Install the 4 NEW fuel injector seals (5) to the fuel
• EN-47632 Cleaning Tool injectors.
• EN-48559 Injector Protective Caps 5. Install the 4 fuel Injectors (1) with the 2 fuel injector
For equivalent regional tools, refer to Special Tools on brackets (7).
page 9‑1711. 6. Install the 2 fuel injector spherical washers (4).
7. Install the 2 fuel injector conical washer (3).
Caution: Refer to Fastener Caution on page 0‑9
8. Install the 2 fuel injector bracket nuts (2) and
tighten to 20 Y (15 lb ft).

Fuel Rail Installation

Object-ID=2357164 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2191259

Caution: Refer to CELL Link Error - Link target cell

(cell ID 256922) is invalid for this publication.
on page ?‑?.
1. Clean the injector sealing surfaces in the cylinder
head, using the EN-47632 cleaning tool (1) in
following procedure:
1.1. Use the brush side to loosen the dirt.
1.2. Use the sponge side to remove the dirt. 2190867

1. Install the fuel rail (3) along with the fuel rail
bracket (4).
2. Install the engine lift bracket (2).
Caution: Refer to Fastener Caution on page 0‑9
3. Install the 3 fuel rail bracket bolts (1) and tighten to
25 Y (18 lb ft).

Fuel Injection Fuel Feed Pipe

Installation - Fuel Rail to Fuel Injector
Object-ID=2364005 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

Note: Loosen the fuel rail, in order spannings in the

fuel pipes with installation to avoid.
1. Loosen the 2 fuel rail bolts.

2190870

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9-1696 Engine Mechanical - 1.3L (LDV) Diesel
3. Install the 3 fuel injection pump bolts (3) and
tighten to 15 Y (11 lb ft).

Fuel Injection Fuel Feed Pipe

Installation - Fuel Injection Pump to
Fuel Rail
Object-ID=2364006 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2190866

2. Install the 4 fuel injection fuel feed pipes (1).

Caution: Refer to Fastener Caution on page 0‑9
3. Install the 4 fuel injection fuel feed pipe nuts M12 to
the 4 fuel injectors (3) and tighten to
24 Y (18 lb ft).
4. Install the 4 fuel injection fuel feed pipe nuts M14 to
the fuel rail (2) and tighten to 28 Y (21 lb ft).
5. Tighten the 2 fuel rail bolts to 25 Y (18 lb ft). 2190826

Fuel Injection Pump Installation 1. Install the fuel injection fuel feed pipe (2).
Object-ID=2357166 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan Caution: Refer to Fastener Caution on page 0‑9
2. Install the fuel injection fuel feed pipe nut M12 to
the fuel injection pump (3) and tighten to
24 Y (18 lb ft).
3. Install the fuel injection fuel feed pipe nut M14 to
the fuel rail (1) and tighten to 28 Y (21 lb ft).

2190846

1. Install the NEW fuel injection pump seal.

Note: Do not tilt the fuel injection pump actuator (1) at
the timing gear groove (4).
2. Install the fuel injection pump (2).
Caution: Refer to Fastener Caution on page 0‑9.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1697
Vacuum Pump Installation 3. Install the fuel return hose clamp (5).
Object-ID=2364048 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan Caution: Refer to Fastener Caution on page 0‑9
4. Install the diesel fuel separator bolt (4) and tighten
to 9 Y (80 lb in).
5. Clip in the 4 fuel injection fuel return hose retaining
clips (6).
Note: The fuel return hose connectors must engage in
the 4 fuel injection fuel return hose retaining clips (6)
audibly.
6. Install the 4 fuel return hose connectors (1) to the
4 fuel injectors.

Intake Manifold Installation

Object-ID=2357171 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2190824

1. Install a NEW vacuum pump gasket.

Note: Do not tilt the vacuum pump actuator at the
timing gear groove (3).
2. Install the vacuum pump (1).
Caution: Refer to Fastener Caution on page 0‑9
3. Install the 2 vacuum pump bolts (2) and tighten to
20 Y (15 lb ft).

Diesel Fuel Separator Installation

Object-ID=2357168 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan
2190721

1. Install 4 NEW intake manifold gaskets (1).

2. Install intake manifold (2).
Caution: Refer to Fastener Caution on page 0‑9
3. Install 4 intake manifold lower bolts (4) and 5 intake
manifold upper bolts (3) and tighten to
25 Y (18 lb ft).

2190819

1. Install the diesel fuel separator (3).

2. Install the fuel return hose (2) to the fuel
injection pump.

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9-1698 Engine Mechanical - 1.3L (LDV) Diesel
Throttle Body Assembly Installation 2. Install the engine coolant temperature sensor
gasket (4) to the engine coolant temperature
Object-ID=2357172 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan
sensor (3).
3. Install the engine coolant temperature sensor (3).
4. Install the engine coolant temperature sensor
retainer clip (5) to the engine coolant
thermostat (1).

2190720

1. Install the throttle body gasket (4) into the throttle

body adapter (1).
2. Install the throttle body (2) to the throttle body 2190713
adapter (1).
Caution: Refer to Fastener Caution on page 0‑9 5. Install the engine coolant thermostat (2).
3. Install the 3 throttle body bolts (3) and tighten to Caution: Refer to Fastener Caution on page 0‑9
8 Y (71 lb in). 6. Install the 2 engine coolant thermostat bolts (1) and
tighten to 25 Y (18 lb ft).
Engine Coolant Thermostat
Installation Exhaust Pressure Sensor Installation
Object-ID=2357176 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan
Object-ID=2357175 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2190515
2190714

1. Install a NEW engine coolant thermostat gasket (2) 1. Install the exhaust pressure sensor (2) to the
into the thermostat housing (1). exhaust pressure sensor bracket (1).
Caution: Refer to Fastener Caution on page 0‑9
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 Engine Mechanical - 1.3L (LDV) Diesel 9-1699
2. Install the exhaust pressure sensor bolt (3) and Engine Oil Cooler Inlet Pipe
tighten to 7 Y (62 lb in).
Installation
Exhaust Pressure Sensor Pipe Object-ID=2357182 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

Installation
Object-ID=2357181 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2190514

1. Install a NEW engine oil cooler inlet pipe seal into

2190513 the cylinder block.
2. Install the engine oil cooler inlet pipe (1).
1. Install the exhaust pressure sensor pipe (2).
Caution: Refer to Fastener Caution on page 0‑9
2. Install the exhaust pressure sensor pipe clamp (4).
3. Install the 2 engine oil cooler inlet pipe bolts (2) and
Caution: Refer to Fastener Caution on page 0‑9 tighten to 9 Y (80 lb in).
3. Install the exhaust pressure sensor pipe bolt (3) to
the exhaust pressure sensor bracket and tighten Starter Installation
to 9 Y (80 lb in).
Object-ID=2357186 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan
4. Install the exhaust pressure sensor pipe bolt (1) to
the throttle body support and tighten to
9 Y (80 lb in).

2190512

1. Install the starter (2).

Caution: Refer to Fastener Caution on page 0‑9

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9-1700 Engine Mechanical - 1.3L (LDV) Diesel
2. Install the starter stud (3) and tighten to 5. Install the 2 throttle body support bolts (2) and
25 Y (18 lb ft). tighten to 9 Y (80 lb in).
3. Install the starter bolt (1) and tighten to
25 Y (18 lb ft). Exhaust Gas Recirculation Pipe
Installation
Exhaust Gas Recirculation Valve Object-ID=2357190 Owner=Thess, Stephan LMD=10-May-2012 LMB=Hinzmann, Rene
Cooler Installation
Object-ID=2357188 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2190509

1. Install a NEW exhaust gas recirculation pipe

2190511
gasket (4) to the exhaust gas recirculation pipe.
1. Install a NEW exhaust gas recirculation valve 2. Install the exhaust gas recirculation pipe seal (2) to
cooler gasket (1). the exhaust gas recirculation pipe.
2. Install the exhaust gas recirculation valve 3. Install the exhaust gas recirculation pipe (3).
cooler (2). Caution: Refer to Fastener Caution on page 0‑9
Caution: Refer to Fastener Caution on page 0‑9 4. Install the 3 exhaust gas recirculation pipe bolts (5)
3. Install the 3 exhaust gas recirculation valve cooler to the intake manifold and tighten to
bolts (3) and tighten to 22 Y (16 lb ft). 9 Y (80 lb in).
5. Install the 2 exhaust gas recirculation pipe bolts (1)
to the exhaust gas recirculation valve cooler and
tighten to 25 Y (18 lb ft).

2190510

4. Install the throttle body support (1).

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1701
Oil Level Indicator and Tube Caution: Refer to Fastener Caution on page 0‑9
2. Install the 2 positive crankcase ventilation oil
Installation separator bolts (4) and tighten to 9 Y (80 lb in).
Object-ID=2357192 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan
3. Install the positive crankcase ventilation oil
separator hose clamp (2).
4. Clip in the positive crankcase ventilation oil
separator to the retainer clip (1).

Positive Crankcase Ventilation Tube

Installation
Object-ID=2357498 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2190508

1. Install a NEW oil level indicator gasket to the

cylinder block.
2. Install the oil level indicator tube (1).
Caution: Refer to Fastener Caution on page 0‑9
3. Install the oil level indicator tube bolt (2) and
tighten to 9 Y (80 lb in).
2190506
Positive Crankcase Ventilation Oil
1. Install a NEW positive crankcase ventilation tube
Separator Installation gasket (5).
Object-ID=2357496 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan
2. Install the positive crankcase ventilation tube (4) to
the positive crankcase ventilation oil separator
drain hose (1).
3. Install the positive crankcase ventilation oil
separator drain hose clamp (2).
Caution: Refer to Fastener Caution on page 0‑9
4. Install the 2 positive crankcase ventilation tube
bolts (3) and tighten to 9 Y (80 lb in).

2190507

1. Install the positive crankcase ventilation oil

separator (3).

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9-1702 Engine Mechanical - 1.3L (LDV) Diesel
Positive Crankcase Ventilation Pipe 2. Install the 3 generator bracket bolts (2) and tighten
to 22 Y (16 lb ft).
Installation
Object-ID=2357499 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2190492

3. Install the exhaust gas recirculation valve vacuum

2190504 tank bracket (1).
1. Install the positive crankcase ventilation pipe (1). 4. Install the 2 exhaust gas recirculation valve
vacuum tank bracket bolts (2) and tighten to
2. Connect the positive crankcase ventilation pipe 22 Y (16 lb ft).
connector (3) to the positive crankcase ventilation
oil separator. 5. Clip in the turbocharger wastegate actuator pipe to
the turbocharger wastegate actuator pipe clip.
Caution: Refer to Fastener Caution on page 0‑9
3. Install the 2 positive crankcase ventilation pipe Exhaust Gas Recirculation Valve
bracket bolts (2) and tighten to 8 Y (71 lb in).
Vacuum Tank Installation
Generator Bracket Installation Object-ID=2357532 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

Object-ID=2357526 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2190488

2190493 1. Install the exhaust gas recirculation valve vacuum

tank (3) to the exhaust gas recirculation valve
1. Install the generator bracket (1).
vacuum tank bracket (5).
Caution: Refer to Fastener Caution on page 0‑9
Caution: Refer to Fastener Caution on page 0‑9
2014 - Spin Service Manual (5618083) - (Misc Draft) - 6/7/13
 Engine Mechanical - 1.3L (LDV) Diesel 9-1703
2. Install the 2 exhaust gas recirculation valve
vacuum tank bolts (2) and tighten to
8 Y (71 lb in).
3. Install the lower turbocharger wastegate actuator
pipe (4).
4. Install the upper turbocharger wastegate actuator
pipe (1).

Generator Installation
Object-ID=2357536 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2739171

Caution: Refer to Fastener Caution on page 0‑9.

Install the 4 glow plugs (1) to the cylinder head and
tighten to 10 Y (89 lb in), using the EN-48390
installer.

Exhaust Manifold Installation

Object-ID=2357544 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2190486

1. Install the generator (1) to the generator

bracket (2).
Caution: Refer to Fastener Caution on page 0‑9
2. Install the 2 lower generator bolts (3) and tighten to
22 Y (16 lb ft).
3. Install the upper generator bolt (4) and tighten to
22 Y (16 lb ft).

Glow Plug Installation

Object-ID=2837670 Owner=Thess, Stephan LMD=25-Apr-2012 LMB=Kuhse, Ben

Special Tools
EN-48390 Remover/Installer Glow Plugs 9 mm
For equivalent regional tools, refer to Special Tools on
page 9‑1711.
2190454

1. Install a NEW exhaust manifold gasket (1).

2. Install the exhaust manifold (2).
Caution: Refer to Fastener Caution on page 0‑9.
3. Install the 10 exhaust manifold nuts (3) and tighten
it in 2 steps:
3.1. In first step tighten to 15 Y (11 lb ft).
3.2. In an additional step tighten to 30°.

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9-1704 Engine Mechanical - 1.3L (LDV) Diesel
Turbocharger Installation
Object-ID=2357546 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2190452

4. Install the exhaust manifold heat shield right

side (2).
5. Install the exhaust manifold heat shield right side 2190450
nut (1) and tighten to 9 Y (80 lb in).
1. Install a NEW turbocharger gasket (2).
2. Install the turbocharger (1) to the exhaust manifold.
Caution: Refer to Fastener Caution on page 0‑9.
Note: Coat the thread with assembly paste.
3. Install the 3 turbocharger nuts (3) and tighten to
25 Y (18 lb ft).

Turbocharger Wastegate Actuator

Vacuum Control Solenoid Valve
Splash Shield Installation
Object-ID=2357550 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2190451

6. Install the exhaust manifold heat shield left side (1).

7. Install the exhaust manifold heat shield left side
nut (4) and tighten to 9 Y (80 lb in).
8. Install the engine lift front bracket (2).
9. Install the engine lift front bracket bolt (3) and
tighten to 25 Y (18 lb ft).

2190421

2014 - Spin Service Manual (5618083) - (Misc Draft) - 6/7/13

 Engine Mechanical - 1.3L (LDV) Diesel 9-1705
1. Install the turbocharger wastegate actuator Turbocharger Oil Return Hose
vacuum control solenoid valve splash shield (1).
Caution: Refer to Fastener Caution on page 0‑9.
Installation
Object-ID=2357565 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan
2. Install the 3 turbocharger wastegate actuator
vacuum control solenoid valve splash shield
nuts (2) and tighten to 9 Y (80 lb in).

Oil Filter Housing Installation

Object-ID=2357562 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2190432

1. Install the turbocharger oil return hose (2) to the

turbocharger (1) and the oil filter housing (4).
2. Install the 2 turbocharger oil return hose
clamps (3).
2190448

1. Install a NEW oil filter housing gasket (3).

Thermostat Bypass Pipe Installation
Object-ID=2357567 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan
2. Install the oil filter housing (1).
Caution: Refer to Fastener Caution on page 0‑9.
3. Install the 4 oil filter housing bolts (2) and tighten to
9 Y (80 lb in).

2190446

1. Install a NEW thermostat bypass pipe gasket (5).

2. Install the thermostat bypass pipe (2).
3. Install the thermostat bypass pipe clamp (3) to the
thermostat housing.
Caution: Refer to Fastener Caution on page 0‑9.

2014 - Spin Service Manual (5618083) - (Misc Draft) - 6/7/13

9-1706 Engine Mechanical - 1.3L (LDV) Diesel
4. Install the 2 thermostat bypass pipe bolts (1) to the
oil filter housing and tighten to 9 Y (80 lb in).
5. Install the thermostat bypass pipe bracket bolt (4)
and tighten to 9 Y (80 lb in).

Turbocharger Oil Feed Pipe

Installation
Object-ID=2357569 Owner=Thess, Stephan LMD=07-Oct-2009 LMB=Thess, Stephan

2190422

1. Pre-install the catalytic converter clamp (3) to the

catalytic converter (4).
2. Install the catalytic converter (4) to the catalytic
converter bracket (7) and the turbocharger (1).
Caution: Refer to Fastener Caution on page 0‑9.
3. Install the catalytic converter clamp (3) and tighten
to 25 Y (18 lb ft).
4. Install the 2 catalytic converter bracket nuts (6) and
2190431 tighten to 25 Y (18 lb ft).
5. Install the exhaust pressure sensor hose (2) to the
1. Install turbocharger oil feed pipe (4). catalytic converter (4).
2. Install 2 NEW turbocharger oil feed pipe gasket (6). 6. Install the exhaust pressure sensor hose clamp (5).
Caution: Refer to Fastener Caution on page 0‑9.
3. Install turbocharger oil feed pipe bolt (5) to oil filter
housing (7) and tighten to 22 Y (16 lb ft).
4. Install 2 NEW turbocharger oil feed pipe gasket (3).
5. Install turbocharger oil feed pipe bolt (2) to
turbocharger (1) and tighten to 22 Y (16 lb ft).

Catalytic Converter Installation

Object-ID=2357571 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

Special Tools
EN-6129 Oxygen Sensor Remover / Installer
For equivalent regional tools, refer to Special Tools on
page 9‑1711

2190421

7. Install the turbocharger wastegate actuator

vacuum control solenoid valve splash shield (1).
8. Install the 3 turbocharger wastegate actuator
vacuum control solenoid valve splash shield
nuts (2) and tighten to 9 Y (80 lb in).

2014 - Spin Service Manual (5618083) - (Misc Draft) - 6/7/13

 Engine Mechanical - 1.3L (LDV) Diesel 9-1707
Exhaust Temperature Sensor
Installation
Object-ID=2357578 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2190420

9. Install the heated oxygen sensor (1) with the

EN-6129 remover / installer to the catalytic
converter (2) and tighten to 45 Y (33 lb ft).
10. Install the heated oxygen sensor (1) to the heated
oxygen sensor connector bracket. 2190418

Caution: Refer to Fastener Caution on page 0‑9.

Catalytic Converter Heat Shield 1. Install the exhaust temperature sensor (2) to the
Installation catalytic converter (1) and tighten to
Object-ID=2357573 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan
45 Y (33 lb ft).
2. Clip in the exhaust temperature sensor (2) to the
exhaust temperature sensor connector bracket (3).

Water Pump Installation

Object-ID=2357579 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2190419

1. Install the catalytic converter heat shield (2).

Caution: Refer to Fastener Caution on page 0‑9.
2. Install the 4 catalytic converter heat shield bolts (3)
and tighten to 9 Y (80 lb in). 2190417

3. Install the upper catalytic converter heat shield 1. Install a NEW water pump seal (2) to the water
bolt (1) and tighten to 9 Y (80 lb in). pump (1).
2. Install the water pump (1).
Caution: Refer to Fastener Caution on page 0‑9.
2014 - Spin Service Manual (5618083) - (Misc Draft) - 6/7/13
9-1708 Engine Mechanical - 1.3L (LDV) Diesel
3. Install the 4 water pump nuts (3) and tighten to 2. Install the drive belt tensioner bolt (1) and tighten
9 Y (80 lb in). to 50 Y (37 lb ft).

Crankshaft Pulley Installation Engine Mount Bracket Installation

Object-ID=2357580 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan Object-ID=2357586 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

2190415 2190411

1. Install the crankshaft pulley (1). 1. Install the engine mount bracket (1).
Caution: Refer to Fastener Caution on page 0‑9. 2. Install the engine lift bracket (2).
Note: Hold against at the centering bolt (2). Caution: Refer to Fastener Caution on page 0‑9.
2. Install the 4 crankshaft pulley bolts (3) and tighten 3. Install the 4 engine mount bracket bolts (3) and
to 25 Y (18 lb ft). tighten to 60 Y (44 lb ft).

Drive Belt Tensioner Installation Description and Operation

Object-ID=2357582 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan

Cleanliness and Care

Object-ID=2370757 Owner=Thess, Stephan LMD=14-Jan-2011 LMB=Thess, Stephan

An automobile engine is a combination of many of the

following surfaces:
• Machined
• Honed
• Polished
• Lapped
The tolerances of these surfaces are measured in the
ten-thousandths of an inch. When you service any
internal engine part, cleanliness and care are
important. Apply a liberal coating of engine oil to the
friction areas during assembly in order to protect and
lubricate the surfaces on initial operation. Throughout
this section, practice proper cleaning and protection
procedures to the machined surfaces and to the friction
areas.
Whenever you remove the valve train components,
keep the components in order. Follow this procedure in
order to install the components in the same locations
2190412
and with the same mating surfaces as when removed.
1. Install the drive belt tensioner (2). Warning: Refer to Battery Disconnect Warning on
Caution: Refer to Fastener Caution on page 0‑9. page 0‑4.

2014 - Spin Service Manual (5618083) - (Misc Draft) - 6/7/13

 Engine Mechanical - 1.3L (LDV) Diesel 9-1709
Disconnect the negative battery cables before you lubrication of the engine. The oil pressure regulator
perform any major work on the engine. prevents that too much engine oil is entering the
lubricating passages.
Drive Belt System Description Piston And Connecting Rod
Object-ID=2370758 Owner=Thess, Stephan LMD=14-Jan-2011 LMB=Thess, Stephan
The pistons are aluminum pistons with top land. The
The drive belt system consists of the following connecting rods are fractured steel connecting rods
components: with bushing. The piston pin is floating the connecting
• The drive belt rod bore.
• The drive belt tensioner Cylinder Head
• The crankshaft pulley This cylinder head is double over head camshaft
• The accessory drive components: (DOHC) type and has 2 camshafts that open 4 valves
– The generator per cylinder with tappets. The cylinder head is made of
cast aluminum alloy for better strength in hardness with
– The A/C compressor, if equipped light weight.
– The water pump
The drive belt system uses one belt. The drive belt is Camshaft And Valve Train
thin so that it can bend backward and has several ribs Intake and exhaust camshaft are connected to each
to match the grooves in the pulleys. The drive belt is other with gears. The intake camshaft has a camshaft
made of EPDM and has different layers of ply sprocket which is driven by the timing chain. The valve
containing either fiber cloth or cords for reinforcement. actuation occurs by hydraulic valve lifters and valve
Both sides of the drive belt may be used to drive the rocker arms which are located between cam and valve
different accessory drive components. When the back stem.The valve clearences are self adjusting.
side of the drive belt is used to drive a pulley, the pulley
is smooth. Intake Manifold
The drive belt is pulled by the crankshaft balancer The intake manifold is the air flow passage to the
pulley across the accessory drive component pulleys. cylinder combustion chamber through the throttle body
The drive belt tensioner keeps constant tension on the and has an effect on engine torque, power, noise,
drive belt to prevent the drive belt from slipping. The drivability, emission, fuel economy and performance.
drive belt tensioner arm will move when loads are The intake air amount is regulated by vacuum
applied to the drive belt by the accessory drive controlled flaps.
components and the crankshaft. Exhaust Manifold
The drive belt system may have an idler pulley, which is
used to add wrap to the adjacent pulleys. Some The exhaust manifold is located to the cylinder head
systems use an idler pulley in place of an accessory and send the turbocharger the exhaust gas out of the
drive component when the vehicle is not equipped with combustion chamber. It is designed to endure on high
the accessory. pressure and high temperature.
Turbocharger
Engine Component Description The turbocharger is located between exhaust manifold
Object-ID=2370788 Owner=Thess, Stephan LMD=25-Nov-2009 LMB=Thess, Stephan
and catalytic converter with diesel particulate filter.
It consists of an exhaust gas turbine and a fresh air
Cylinder Block turbine which are connected to each other by a rod.
The exhaust gas turbine is driven by the exhaust gas
The cylinder hollow frame structured 4 cylinder in-line. and the fresh air turbine is driven by the exhaust gas
The block has 5 crankshaft bearings with the thrust turbine. The fresh air turbine creates compressed air
bearing located on the third bearing from the front of the which is cooled down in the charger air cooler. The
engine. charge air cooling increases the air density. The
Crankshaft cooled, compressed air is discharged under pressure to
the engine. The turbocharger has a vacuum controlled
The crankshaft is a steel crankshaft. It is supported in 5 variable turbine geometry which modulates the charge
main journals with main bearings which have oil pressure to the engine speed and load.
clearance for lubricating. The 3rd bearing of the 5 main
bearing is the thrust bearing whose the crankshaft has Exhaust Gas Recirculation System
properly axial end play. The recirculation of exhaust gas to the combustion
Oil Pump chamber causes a reduction of NOx - emissions. The
reduction of exhaust gas emissions can be increased
The oil pump is a rotor pump located in the oil pump by the cooling of the recirculating exhaust gas. Therefor
housing on the timing side and driven by the a exhaust gas recirculation cooler with exhaust gas
crankshaft. The oil pump draws engine oil from the oil recirculation valve is located between exhaust manifold
pan and feeds it under pressure to the various parts of and cylinder head.
the engine. At high engine speeds, the oil pump
supplies a much higher amount of oil than required for

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9-1710 Engine Mechanical - 1.3L (LDV) Diesel
Fuel Injection System Separating Components
The engine is equipped with a common rail direct • Use incorporated pry points to separate
injection system. A high pressure fuel pump, driven by components using an RTV sealing system.
the timing belt discharges the fuel to the fuel rail, where • Do not try to separate RTV sealed components by
the fuel is stored with pressure up to 160 Mpa (23206 prying against other engine components.
psi). The fuel is injected by electronic controlled fuel
injectors direct to the combustion chamber. • Pry points are positioned so no other vital engine
components are damaged when they are used.
Lubrication Description Cleaning Gasket Surfaces
Object-ID=2370761 Owner=Thess, Stephan LMD=06-Aug-2010 LMB=Thess, Stephan
• Use care to avoid gouging or scraping the sealing
surfaces.
The system includes a sheet metal oil pan and an oil
suction pipe. The oil suction pipe is bolted into the oil • Use a plastic or wood scraper in order to remove
pump housing and seals to the oil pump housing with a all the sealant from the components.
gasket. Do not use any other method or technique to
The oil pump is mounted to the front of the engine block remove the sealant or the gasket material from
and pulls oil from the oil suction pipe through the lower a part.
passage in the engine block. The oil pump then directs • Do not use abrasive pads, sand paper, or power
the flow of pressurized oil back through the upper tools to clean the gasket surfaces.
passage in the block to the right side of the engine – These methods of cleaning can cause damage
block where the oil filter adapter and engine oil cooler to the component sealing surfaces.
are mounted. – Abrasive pads also produce a fine grit that the
The oil filter adapter and the engine oil cooler are oil filter cannot remove from the engine oil.
mounted with a gasket to the right side of the engine This fine grit is an abrasive and can cause
block. The oil filter adapter incorporates a internal engine damage.
bottom-access, spin‐on oil. Oil flows through the lower
passage in the oil filter adapter and through the oil filter. Assembling Components
Filtered oil travels back through the upper passage of
the oil filter adapter and back into the engine block. • Assemble components using only the sealant,
or equivalent, that is specified in the service
Oil is directed up and across the engine block front procedure.
through several drilled passages that feed oil to the
cylinder head, oil to the passage for the main bearings • Sealing surfaces must be clean and free of debris
and piston oil nozzles. or oil.
Each cylinder head passage directs oil into the cylinder • Specific components such as crankshaft oil seals
head where it is directed to oiling circuits for the or valve stem oil seals may require lubrication
stationary hydraulic lifter assemblies (SHLAs) and the during assembly.
camshaft bearing journals. • Components requiring lubrication will be identified
The oil passage that supplies oil to the main bearings in the service procedure.
also supplies oil to the piston-cooling oil nozzles. Each • Apply only the amount of sealant specified in the
oil nozzles is mounted between opposing cylinder service procedure to a component.
bores and directs oil to the bores to provide extra • Do not allow the sealant to enter into any blind
cooling and control piston temperatures. threaded holes, as the sealant may prevent the
Oil returns to the oil pan the cast oil drain back fastener from clamping properly or cause
passages on the outboard walls of the cylinder heads component damage when tightened.
and engine block. Note: Do not overtighten the fasteners.

Replacing Engine Gaskets • Tighten the fasteners to the proper specifications.

Object-ID=2370763 Owner=Thess, Stephan LMD=25-Nov-2009 LMB=Thess, Stephan
Separating Parts
Object-ID=2370767 Owner=Thess, Stephan LMD=14-Jan-2011 LMB=Thess, Stephan
Gasket Reuse and Applying Sealant
• Do not reuse any gasket unless specified. In addition to the room temperature vulcanizing (RTV)
sealant's sealing capabilities, the RTV sealants may
• Gaskets that can be reused will be identified in the
form an adhesive bond between the components. This
service procedure.
may make the components difficult to remove or to
• Do not apply sealant to any gasket or sealing separate. Pry points have been provided in the
surface unless specified in the service procedure. components that utilize RTV as the sealing system. Pry
points are positioned so they can be used without
damaging other vital engine components.

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1711
Use of Room Temperature Illustration Tool Number / Description
Vulcanizing (RTV) and Anaerobic
Sealant
Object-ID=2370768 Owner=Thess, Stephan LMD=25-Nov-2009 LMB=Thess, Stephan
DT-113-2-A
KM-113-2-A
Pipe Joint Compound J-03289-20
Note: Three types of sealer are commonly used in Bracket with EN-6215
engines. These are RTV sealer, anaerobic gasket
eliminator sealer, and pipe joint compound. The correct
sealer and amount must be used in the proper location
to prevent oil leaks. DO NOT interchange the 3 types of 1936789

sealers. Use only the specific sealer or the equivalent

as recommended in the service procedure.
• Pipe joint compound is a pliable sealer that does
not completely harden. This type sealer is used
where 2 non-rigid parts, such as the oil pan and EN-135
the engine block, are assembled together. KM-135
• Do not use pipe joint compound in areas where Oil Pressure Gauge Adapter
extreme temperatures are expected. These areas
include: exhaust manifold, head gasket, or other
surfaces where gasket eliminator is specified.
1843602
• Follow all safety recommendations and directions
that are on the container.
To remove the sealant or the gasket material, refer
to Replacing Engine Gaskets on page 9‑1710
• Apply the pipe joint compound to a clean surface.
EN–301
Use a bead size or quantity as specified in the
procedure. Run the bead to the inside of any bolt KM–301
holes. Do not allow the sealer to enter any blind Measuring Bridge
threaded holes, as it may prevent the bolt from
clamping properly or cause component damage
when the bolt is tightened.
2190203
• Apply a continuous bead of pipe joint compound to
one sealing surface. Sealing surfaces to be
resealed must be clean and dry.
• Tighten the bolts to specifications. Do not
overtighten the bolts. EN-470-B
KM-470-B
Special Tools and Equipment analog to EN-45059
J-45059
Object-ID=2743306 Owner=Thess, Stephan LMD=26-Nov-2011 LMB=Kuhse, Ben Angle Meter

Illustration Tool Number / Description

1282416

CH-6129
KM-6129
EN-652
J-39194-C
KM-652
8396350
Flywheel Holder
Oxygen Sensor Wrench

2191102
1938128

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9-1712 Engine Mechanical - 1.3L (LDV) Diesel
Illustration Tool Number / Description Illustration Tool Number / Description

EN-662-C EN-6086
KM-662-C MKM-6086
8995063 Spring And Wedge
Holding Wrench Replacer Kit

2190222 2190205

EN-840
KM-840 EN-6167
J-36017 KM-6167
8394157 Adapter Set
Pliers / Remover

2190198 2026885

EN-849 EN-6215
KM-849 KM-6215
Assembly Tray Mounting Equipment

2026927 2190200

EN-6347
EN-955
KM-6347
KM-955
32025019
Locking Pins
Counter Stay

2191100 2026939

EN-956-1 EN-8087
KM-956-1 J-8087
Extension Cylinder Bore Gauge

2026928 5110

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 Engine Mechanical - 1.3L (LDV) Diesel 9-1713
Illustration Tool Number / Description Illustration Tool Number / Description

EN-37228
KM-J-37228 EN-46783
J-37228 Thread Adapter,
5-8840-2153-0 Compression Tool
Separation Tool

2190209 2192580

EN-46775 EN-46785
Centering Tool Positioning Tool

2192575 2192581

EN-46786
EN-46777 32 025 13
Installer Remover Injector in
conjunction with EN-328-B

2192577 2192582

EN-46791
EN-46778
32 025 047
Fixing tool
Adapter, Compression Tool

2192578 2192583

EN-47632
EN-46781
32 025 010
Adjusting Tool
Cleaner Injector Shaft

2192579 2019102

2014 - Spin Service Manual (5618083) - (Misc Draft) - 6/7/13

9-1714 Engine Mechanical - 1.3L (LDV) Diesel
Illustration Tool Number / Description Illustration Tool Number / Description

GE-498-B
KM-498-B
EN-48559
CH-48027
Injector Protective Caps
J-21867-A
Oil Pressure Gauge

2192574 1844744

GE-571-B
EN-48390
MKM-571-B
Remover / Installer Glow
J-8001
Plugs
Dial Gauge

2192585 2190204

GE-328-B
KM-328-B
J-23907-1 or J-02619-A
Remover Sliding Hammer

1941118

2014 - Spin Service Manual (5618083) - (Misc Draft) - 6/7/13