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This is all the FSM says:
INSPECTION
PISTONS
1. Piston Diameter: Size: 91.912-91.928mm (3.6185-
3.6192 in.) Maximum wear limit .05mm (.0019 in.).
2. Check piston pin bores in piston for roundness.
Make 3 checks at 120° intervals. Maximum out of
roundness .05mm (.0019in.).
3. The piston diameter should be measured approximately
15 mm (.590 in.) up from the base.
4. Skirt wear should not exceed 0.1 mm (.00039 in.).
5. The clearance between the cylinder liner and piston
should not exceed 0.065-0.083 mm
(.0025-.0032 in.).
CONNECTING RODS
CAUTION: Connecting rod bolts must be replaced when disassembled. When assembling the connecting
rod (2), be sure that the connecting rod pawl (1) on each of the connecting rod caps is facing the rear (fly
wheel) side of the engine.
NOTE: Do Not lubricate the new connecting rod bolts. They are already coated with a anti scuff treatment.
1. Assemble connecting rod bearings (4) and bearing caps to their respective connecting rods (2) ensuring that the
serrations on the cap and reference marks are aligned.
2. Tighten connecting cap bolts to 10 N·m (88 in. lbs.).
3. Without loosening connecting rod bolts, tighten all bolts to 30N·m (22 ft.lbs.).
4. Using a torque angle gauge, tighten each bolt an additional 40°.
5. Recheck all bolt tightening with a torque wrench set to 88N·m (65 ft.lbs.).
6. Check and record internal diameter of crank end of connecting rod (2).
CAUTION: When changing connecting rods (2), DO NOT use a stamp to mark the cylinder location. Identify
the connecting rods (2) and caps location using a paint marker. All four must have the same weight and the
same number. Replacement connecting rods (2) will only be supplied in sets of four.
Connecting rods (2) are supplied in sets of four since they all must be of the same weight category. Max allowable
weight difference is 5 gr.
PISTON PINS
1. Measure the diameter of piston pin in the center and both ends.For specification, (Refer to 9 - ENGINE - SPECIFICATIONS),
(Refer to 9 - ENGINE - SPECIFICATIONS).
INSTALLATION
PISTON PIN INSTALLATION
1. Secure connecting rod (7) in soft jawed vice.
2. Lubricate piston pin (1) and piston (2) with clean
engine oil.
3. Position piston (2) on connecting rod (7).
CAUTION: Ensure arrow on piston crown and the
bearing cap numbers on the connecting rod are
on the opposite side.
4. Install piston pin (1).
5. Install snap ring (3) in piston (2) to retain piston pin
(1).
6. Remove connecting rod (7) from vice.
PISTON RINGS - INSTALLATION
1. Install rings on the pistons using a suitable ring
expander.
2. Top compression ring is tapered and chromium
plated. The second ring is of the scraper type and
must be installed with scraping edge facing bottom
of the piston. The third is an oil control ring. Ring
gaps must be positioned, before inserting piston
into the liners, as follows.
3. Top ring gap must be positioned at the #3 position
(looking at the piston crown from above).
4. Second piston ring gap should be positioned at the
#1 position.
5. Oil control ring gap should be positioned at the #2
position.
6. When assembling pistons check that components are installed in the same position as before disassembly,
determined by the numbers stamped on the crown of individual pistons. Engine cylinders are numbered starting
from gear train end of the engine. Face arrow on top of piston toward front of engine. Therefore, the numbers
stamped on connecting rod big end should face toward the injection pump side of engine. To insert piston
into cylinder use a ring compressor as shown in.
INSTALLATION
1. Before installing pistons, and connecting rod
assemblies into the bore, be sure that compression
ring gaps are staggered so that neither is in line
with oil ring rail gap.
2. Before installing the ring compressor, make sure
the oil ring expander ends are butted together.
3. Immerse the piston head and rings in clean engine
oil, slide the piston ring compressor, over the piston
and tighten. Ensure position of rings does not
change during this operation.
4. Face arrow on piston towards front of engine.
CAUTION: Care must be taken not to nick crankshaft
journal when installing pistons.
5. Rotate crankshaft so that the connecting rod journal
is on the center of the cylinder bore. Insert rod
and piston into cylinder bore and guide rod over
the crankshaft journal.
6. Guide the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on connecting rod journal.
7. Install connecting rod caps. Install rod bolts and
torque to 10N·m (88 lbs. in.). Torque bolts the next
stage to 30N·m (22 ft.lb.) plus 60°. Then with a
torque wrench set at torque to 88N·m (65 ft.lb),
make a tightening check.
8. Install cylinder head (Refer to 9 - ENGINE/CYLINDER
HEAD - INSTALLATION).
9. Install balance shaft assembly (Refer to 9 -
ENGINE/VALVE TIMING/BALANCE SHAFT -
INSTALLATION).
10. Install oil pump pickup tube (Refer to 9 - ENGINE/
LUBRICATION/OIL PUMP - INSTALLATION).
11. Install oil pan (Refer to 9 - ENGINE)
SPECIFICATIONS
ENGINE SPECIFICATIONS
GENERAL DESCRIPTION
DESCRIPTION SPECIFICATION
Engine Type R2816K5A
Weight 270Kg (595 lbs.) dry
Number of Cylinders 4
Bore 94 mm
Stroke 100 mm
Displacement 2776cc
Injection Order 1-3-4-2
Compression Ratio 17.5:1 (± 0.5)
Maximum Power 120 kW (163 H.P.) @ 3800 RPM
Peak Torque 400 N·m (295 ft.lb.) @ 1800 RPM
Cylinder Compression (Max. Difference Between
Cylinders
5 Bar (72.5 psi)
Minimum Oil Pressure (Warm) 0.7 Bar (10 psi.) @ Idle
2 Bar (29 psi.) @ 3800 RPM
DESCRIPTION SPECIFICATION
Metric Standard
Front Journal Diameter-Nominal 62.985-63.005 mm 2.479-2.480 in
Front Journal Diameter- minus 0.25 62.735-62.755 mm 2.469-2.470 in.
Front Bearing Diameter-Nominal 63.005-63.034 mm 2.480-2.481 in.
Front Bearing Diameter-minus 0.25 62.755-62.784 mm 2.471-2.478 in
Clearance Between the Journal and
Bearing
0.00-0.049 mm 0.000-0.001 in.
Center Journal Diameter-Nominal 63.005-63.020 mm 0.001-0.003 in.
Center Journal Diameter-minus 0.25 62.775-62.770 mm 2.470-2.471
Center Bearing Diameter-Nominal 63.005-63.020 mm 2.480-2.481 in.
Center Bearing Diameter-minus
0.25
62.775-62.770 mm 2.470-2.471 in.
Clearance Between Journal and
Bearing
0.008-0.051 mm 0.0003-0.0002 in
Rear Journal Diameter-Nominal 89.980-90.000 mm 3.542-3.543 in
Rear Journal Diameter- minus 0.25 89.730-99.750 mm 3.532-3.927 in.
Rear Bearing Diameter-Nominal 90.045-90.065 mm 3.545-3.546 in.
Rear Bearing Diameter- minus 0.25 89.795-89.815 mm 3.535-3.536 in.
Clearance Between Journal and
Bearing
0.045-0.080 mm 0.001-0.003 in.
Connecting Rod Journal-Nominal 53.940-53.955 mm 2.123-2.124 in.
Connecting Rod Journal- minus
0.25
53.690-53.705 mm 2.113-2.114 in.
Connecting Rod Bearing-Nominal 53.997-54.016 mm 2.125-2.126 in.
Connecting Rod Bearing- minus
0.25
53.727-53.766 mm 2.115-2.116 in.
Clearance Between Journal and
Bearing
0.022-0.076 mm 0.0008-0.0029 in.
Crankshaft End Play 0.080-0.280 mm 0.003-0.011 in.
Adjustment Thrust Washers Thrust Washers
Thrust Washers Available 2.31-2.36 mm 0.090-0.092 in.
2.41-2.46 mm 0.094-0.096 in.
2.51-2.56 mm 0.098-0.100
Carrier with Thrush Washers
Installed
27.670-27.820 mm 1.089-1.095 in.
MAIL BEARING CARRIERS
DESCRIPTION SPECIFICATION
Metric Standard
Internal Diameter-Front 67.025-67.050 mm 2.638-2.639 in.
Internal Diameter-Center 66.670-66.690 mm 2.624-2.624 in.
Internal Diameter-Rear 85.985-86.005 mm 3.385-3.386 in.
DESCRIPTION SPECIFICATION
Metric Standard
Internal Diameter 091.997-92.015 mm. 3.621-3.622 in.
Protrusion 0.00-0.05 mm 0.00-0.001 in.
Available Adjustment Shims 0.15 mm 0.005 in.
0.17 mm 0.006 in.
0.20 mm 0.007 in.
0.23 mm 0.009
0.25 mm 0.0098
CYLINDER HEAD
DESCRIPTION SPECIFICATION
Metric Standard
Minimum Thickness 94.95-95.05 mm. 3.738-3.742 in.
Gasket Thickness 1.32 mm ± 0.08, 0 notches 0.0051 in. ± 0.003, 0 notches
1.42 mm ± 0.08, 1 notch 0.051 in. ± 0.003, 1 notch
1.52 mm ± 0.08, 2 notches 0.059 in. ± 0.003, 1 notches
CONNECTING RODS
DESCRIPTION SPECIFICATION
Metric Standard
Small end Bearing Internal Diameter 32.035-32.050 mm 1.2612-1.2618 in.
Large End Internal Diameter 53.997-54.016 mm 2.125-2.126 in.
PISTONS
DESCRIPTION SPECIFICATION
Metric Standard
Skirt Diameter (measured at
approximately 10 mm above the
bottom of the skirt)
93.912-93.928 mm. 3.6973-3.6979 in.
Piston Clearance 0.010-0.22 mm 0.0003-0.0008 in.
Top of Piston to Cylinder Head 0.69-0.83 mm 0.027-0.032 in.
Piston Protrusion 0.460-0.609 mm Fit Gasket,
Number (1.32mm), 0 hole
0.018-0.023 in. Fit Gasket, Number
(0.051 in.), 0 notches
0.610-0.709 Fit Gasket, Number
(1.42 mm) 1 hole
0.024-0.027 in. Fit Gasket, Number
(0.055 in.) 1 notch or hole
0.710-0.810 Fit Gasket, Number
(1.52 mm), 2 holes
0.027-0.031 in. Number (0.059 in) 2
notches or holes
DESCRIPTION SPECIFICATION
Metric Standard
Type Full Floating
Pin Diameter 32.004-32.010 mm 1.259-1.260 in.
Clearance 0.010-0.020 mm 0.0003-0.0007 in.
PISTON RINGS
DESCRIPTION SPECIFICATION
Metric Standard
Clearance in Groove
Top Compression Ring 0.078-0.137 mm 0.003-0.005 in.
Second Compression Ring 0.070-0.110 mm 0.002-0.004 in.
Oil Control (Steel Rails) 0.40-0.080 mm 0.001 - 0.003 in.
Fitted Gap
Top Compression Ring .030-0.45 mm 0.011-0.017 in.
Second Compression Ring 0.030 - 0.050 mm 0.0011 - 0.0019 in.
Oil Ring (Steel Ring) .025 - 0.50 mm .0009 - .0019 in.
CAMSHAFT
DESCRIPTION SPECIFICATION
Metric Standard
Journal Diameter-Front 29.960-29.980 mm 1.179-1.180 in.
Bearing Clearance 0.03-0.08 mm 0.001-0.003 in.
Journal Diameter-Center 39.250-39.270 mm 1.545-1.546 in.
Bearing Clearance 0.03-0.08 mm 0.001-0.003 in
Journal Diameter-Rear 39.250-39.270 mm 1.545-1.546 in.
Bearing Clearance 0.03-0.08 mm 0.001-0.003 in.
Camshaft End Play 0.10-0.55mm 0.004-0.021 in.
HYDRAULIC LIFTER
DESCRIPTION SPECIFICATION
Metric Standard
Outside Diameter 11.994 ± 0.006 mm 0.472 ± 0.0002 in.
VALVES
DESCRIPTION SPECIFICATION
Metric Standard
Face Angle-Intake 45° 25’-55° 35’ mm -
Face Angle-Exhaust 45° 25’-45° 35’ mm -
Intake Valve Opens 15.6° ± 2° A.T.D.C. -
Intake Valve Closes 64.4° ± 2° A.B.D.C. -
Exhaust Valve Opens 66° ± 2° B.B.D.C. -
Exhaust Valve Closes 32° ± 2° A.T.D.C. -
Head Diameter-Intake 32.30-32.50 mm 1.271-1.279 in.
Head Diameter-Exhaust 30.80-31.00 mm 1.212-1.220 in.
Stem Diameter-Intake 5.952-5.970 mm 0.234-0.235 in.
Stem Diameter-Exhaust 5.942-5.960 mm 0.233-0.234 in.
Clearance in Guide-Intake 0.030-0.060 mm 0.001-0.002 in.
Clearance in Guide-Exhaust 0.040-0.070 mm 0.001-0.002 in.
VALVE GUIDE
DESCRIPTION SPECIFICATION
Metric Standard
Inside Diameter 6.00-6.012 mm 0.2362-0.2366 in.
Fitted Height-Intake 14.5-15.0 mm 0.570-0.590 in.
Fitted Height-Exhaust 16.5-17.0 mm 0.649-0.669 in.
VALVE SPRING
DESCRIPTION SPECIFICATION
Metric Standard
Free Length 45.26 mm 1.781 in.
Fitted Length 38.0 mm 1.496 in.
Load at Fitted Length 182 ± 5-10% Kg -
Load at Top of Lift 395 ± 5% Kg -
Number of Coils 8 -
LUBRICATION
DESCRIPTION SPECIFICATION
Metric Standard
Pressure Relief Valve Opens 6.50 bar 94 psi
Pressure Relief Valve Spring-Free
Length
51.5 mm 2.02 in.
OIL PUMP
DESCRIPTION SPECIFICATION
Metric Standard
Outer Rotor End Float 0.060-0.160 mm 0.002-0.006 in.
Inner Rotor End Float 0.060-0.160 0.002-0.006 in.
Outer Rotor to Body Diameter
Clearance
0.130-0.240 mm 0.005-0.009 in.
Rotor Body to Drive Gear Clearance
(pump not fitted)
0.90-1.50 mm 0.035-0.059 in.
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Oil Pump Bolts 10.8 8 96
Vacuum Pump Bolts 10.8 8 96
Vacuum Pump Pipe to
Block
56.9 42 —
Crankshaft Gear Bolts 10.8 8 96
Crankshaft Position
Sensor Bolts
10.8 8 96
Flywheel Bolts - 2.8L, Refer to the Service Procedure
Flex Plate Bolts - 2.8L, Refer to the Service Procedure
Cylinder Head Bolts - Refer to the Service Procedure
Reluctor Wheel Bolts 14.6 11 130
Rear Main Bearing
Support Bolts
27.5 21 240
Oil Cooler to Engine Block
Bolt
47.1 35 —
Engine Block Plug In Front
Of Oil Cooler
58.8 43 —
Oil Cooler Mounting Stud 50 37 —
Oil Level Indicator to
Cylinder Head Cover
10.8 — 96
Oil Level Indicator Tube to
Pan
10.8 — 96
Water Pump Housing Nuts 24.4 18 212
Connecting Rod Bolts -
Refer to the Service
Procedure
Balance Shaft Bolts 32.4 24 —
Oil Jet Bolts 10.8 8 96
Oil Pump Pick-up Tube 32.4 24 —
Oil Pan Bolts 11.8 8 96
Structural Support to
Engine and Transmission
Bolts
45.1 33 —
Crankshaft Hub Bolt 275 203 —
Crankshaft Pulley Bolts 32.4 24 —
Front Engine Cover Bolts 6 — 53
Transmission to Engine
Bolts
83.4 62 —
Cylinder Head Cover /
Intake Manifold Bolts
24.5 18 —
Camshaft Timing Access
Bolts
24.5 18 —
Camshaft Access Plugs 80 59 —
Oil Separator Bolts 10.8 8 96
Camshaft Position Sensor
Bolt
10.8 8 96
Boost Pressure / Intake Air
Temp. Sensor Bolts
5.4 — 48
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Glow Plug 12.5 — 110
Accessory Drive Bracket
Bolts
45.1 33 —
Accessory Drive Belt Idler
Pulley Bolt
53 39 —
Vacuum Line Fitting Bolt 56.9 42 —
Fuel Pump Nuts 27.5 21 —
Fuel Line Fittings at Pump 27.5 21 —
Fuel Rail Retaining Bolts 24.5 18 217
Inner Timing Belt Cover
Bolts
8mm 10.8 8 96
10mm 45.1 33 —
Outer Timing Belt Cover
Bolts
3mm 6 — 54
8mm 10.8 8 96
Engine Mount Bracket to
Cylinder Head Bolts
45.1 33 —
Structural Support to
Engine and Transmission
Bolts
45.1 33 —
Intake Inlet Tube Bolts 10.1 8 89
Camshaft Sprocket Bolts 108 80 —
Camshaft Timing Access
Bolts
24.5 18 212
Timing Belt Idler Pulley
Bolt
47.1 35 —
Timing Belt Tensioner Bolt 29.4 22 —
Fuel Injection Pump Gear
Nut
88.3 65 —
Fuel Injection Pump
Retaining Nuts
24.4 18 212
Engine Lift Hook Bolts 45.1 33 —
Thermostat Housing Bolts 24.5 18 —
Turbocharger Oil Supply
Line Fitting
24.5 18 217
Turbocharger Oil Return
Line Bolts
10.8 — 96
Exhaust Manifold Nuts 36 26.5 —
Exhaust Manifold Heat
Shield
24.5 18 217
Exhaust Manifold
Heatshield Bolts
27.5 21 —
EGR Valve Bolts 24.5 18 —
EGR Air Control Valve to
Cylinder Head Cover
10.8 — 96
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Coolant Pipe to EGR
Valve Bolts
24.5 18 —
Turbocharger Downpipe
Nuts
32.4 24 —
Turbocharger Support
Bracket Bolts
24.5 18 —
Vibration Damper to
Crankshaft Hub Bolts
27.5 21 —
Crankshaft Support Bolts 44.1 33 —
Turbocharger to Exhaust
Manifold Nuts
32.4 24 —
_________________
Silver 2006 KJ 2.8L CRD Limited:
GDE ECO Tune / Fumoto Valve / E-Tecno GX3123 7v Glow Plugs / 2nd Gen Fuel Head / Mishimoto RED Hoses / Rockers/Lifters @ 114k / Hayden FC + 11 Blade Nylon / Sears P1 Battery / Transgo 45RFE-HD2 Reprogramming Kit / Timken Front Bearings
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