Engine - ID4 2.2L Diesel - : Item Specification

Published: 27-Sep-2011
Engine - ID4 2.2L Diesel -

Lubricants, Fluids and Sealers
Item Specification
SAE 5W-30 engine oil (With DPF) 5W/30 – WSS–M2C934–B
SAE 5W-30 engine oil (Without DPF) 5W/30 – WSS–M2C913–B or C
Sealant — oil pan, camshaft carrier and engine front cover WSE-M4G323-A4
Cylinder Head Dimensions
Description mm
Maximum distortion — measured longitudinally and diagonally 0.10
Peak to valley height of mating surface 0.02
Cylinder head gasket thickness
Piston protrusion of 0.310 - 0.400 mm 1.1 (one tooth)
Piston protrusion of 0.401 - 0.450 mm 1.15 (two teeth)
Piston protrusion of 0.451 - 0.500 mm 1.2 (three teeth)
Oil pressure specifications
Description bar
Minimum oil pressure at idle speed 1.25
Minimum oil pressure at 2000 rpm 2.0
Description Nm lb-ft
Transmission to engine bolts 40 30
Engine mount nuts 80 59
Engine mount bolts 80 59
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Engine mount bracket bolts 63 46
Valve cover bolts 10 7
+ Rocker shaft bolts
Stage 1 10 7
Stage 2 Further 30 degrees
Timing chain guide bolts 15 11
Timing chain tensioner nut 15 11
Timing chain tensioner bolts 15 11
Oil pump chain tensioner bolts 22 16
Camshaft sprocket bolts 35 24
Fuel injection pump sprocket bolts 33 26
Generator bolts 48 35
Generator mounting bracket bolts 25 18
Exhaust gas recirculation (EGR) valve to EGR valve outlet tube bolts 10 7
EGR valve to EGR cooler bolts 23 17
Exhaust manifold to EGR cooler bolts 23 17
Intake manifold bolts 15 11
Intake manifold to EGR valve outlet tube bolts 10 7
Coolant pump bolts 23 17
Oil level indicator tube bolt 10 7
Oil pump pickup tube bolts 10 7
Oil filter housing assembly bolts 23 17
Oil pump bolts 10 7
Oil pan drain plug 23 17
Oil pressure switch 15 11
Oil pan bolts
Stage 1 7 5
Stage 2 14 10
Coolant manifold bolts 10 7
EGR cooler to cylinder head bolts 23 17
+ Cylinder head bolts A -
Engine front cover bolts 14 10
Engine front cover nuts 10 7
Glow plugs 10 7
Power steering pump bolts 23 17
Power steering pump bracket bolts 23 17
Exhaust manifold bolts 40 30
+ Exhaust manifold nuts 40 30
+ Exhaust manifold studs 20 15
Turbocharger oil return tube bolts 10 7
Turbocharger oil return tube clamp bolt 22 16
Turbocharger oil supply line banjo bolt 35 26
Engine lifting eye bolts 22 16
Crankshaft position sensor (CKP) bolt 7 5
+ Crankshaft pulley bolts
Stage 1 45 33
Crankshaft rear oil seal carrier bolts 10 7
+ Flywheel bolts
Stage 1 25 18
Stage 2 40 30
Crankshaft main bearing cap bolts
Stage 1 45 33
Stage 2 80 59
Connecting rod bearing cap bolts
Stage 1 30 22
Ladder frame bolts 23 17
Camshaft carrier bolts A -
Fuel injector clamp bolts
Stage 1 6 4
+ New nuts/bolts/studs must be installed
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A - Refer to the procedure in this section
Published: 28-Nov-2011
Engine - ID4 2.2L Diesel - Engine
Description and Operation
EXTERNAL VIEW
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OVERVIEW
The 2.2 liter diesel engine is a 4 cylinder unit with common rail fuel injection and with four valves per cylinder operated by
dual overhead camshafts. The unit is liquid cooled and turbocharged.
The cylinder block is manufactured in Compacted Graphite Iron (CGI) and is coupled with a separate aluminum 'ladder-
frame' skirt stiffener to provide a lightweight, compact and very stiff bottom end of the engine. The cylinder head and
camshaft carrier are cast aluminum. The single-piece oil sump is formed from pressed steel. The exhaust manifold is cast
iron and includes connections for the turbocharger and EGR (exhaust gas recirculation) cooler. A plastic acoustic cover is
fitted over the upper engine to absorb engine-generated noise.
Engine Structure
Item
1
2
Part Number
-
-
Description
Camshaft carrier
Cylinder head
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3 - Cylinder block
4 - Skirt stiffener
5 - Oil pan
Engine Identification Stamp
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The alpha-numeric engine type number (5 digits) and numeric identification number (12 digits) are stamped on the rear
right side of the cylinder block. These numbers are repeated on a tamper-proof engine identification label on the timing
cover.
Engine Identification Label

The engine type number, DT224, is derived from Diesel Turbo, 2.2 liter, 4 cylinder. The engine identification number is
derived from the date and time (24 hour clock) the block was manufactured, DD/MM/YY/HH/MM/SS.
CYLINDER BLOCK
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The cylinders and crankcase are contained in the cylinder block, which is of single cast CGI construction with a hollow
beam structure. With this type of construction less material is required than for a conventional cast iron block, therefore
reducing engine weight and length.
The cylinders are numbered consecutively from 1 to 4, with cylinder 1 at the front of the engine.
The cylinder bores are machined directly into the block. Cylinder cooling is achieved by coolant circulating through
chambers in the cylinder block casting.
Passages in the cylinder block distribute engine oil to the main bearings, piston cooling jets, cylinder head and
turbocharger. The passage that supplies oil to number 1 main bearing and the turbocharger contains a filter, to prevent
debris entering the turbocharger and damaging the bearings.
Piston Cooling Jets

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Jets located in the cylinder block provide piston and piston pin lubrication and cooling. These jets spray oil on to the inside
of the piston. The oil then flows through an internal wave shaped oil cooling channel to help cool the piston crown.
Piston Oil Cooling
Item Part Number Description

A - Front of the engine
1 - Oil cooling channels
CRANKSHAFT
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1 - Crankshaft
2 - Upper main bearing shell
3 - Upper main bearing shell (No.3 is a thrust bearing)
4 - Bearing cap
5 - Lower main bearing shell
The crankshaft is forged steel and fillet rolled with induction hardened journals, which run in 5 bearings with clamped 2
layer bearing shells.
The main bearing caps are double and cross-bolted, this adds to the strength and rigidity of the engine block.
The main bearings are aluminum/tin split plain selective bearings. An oil groove in the top half of each bearing transfers
oil into the crankshaft for lubrication of the connecting rod bearings. The upper and lower shells of bearing number 3
contain integral thrust washers, which limit the end float of the crankshaft.
The arrow on the bearing caps must point towards the front of the engine and are identified as follows:
Bearing Cap Identification

1 F (front)
2 2
3 3
4 4
5 R (rear)
Crankshaft Rear Oil Seal
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1 - Rear oil seal
2 - Installation sleeve
3 - Bolt (8 off)
The crankshaft rear oil seal consists of a rubber sealing element installed in a metal case attached to the rear of the
cylinder block and skirt stiffener. A rubber gasket seals the metal case to the cylinder block and skirt stiffener.
A new crankshaft rear oil seal is supplied with an installation sleeve that must not be removed until the seal is fully
installed.
Crankshaft Front Oil Seal

1 - Front oil seal
2 - Installation sleeve
The crankshaft front oil seal consists of a PTFE (polytetrafluoroethylene) seal assembly installed in the front cover. Three
lugs on the outer case of the seal assembly engage with the front cover to lock the seal assembly in position.
A new crankshaft front oil seal is supplied with an installation sleeve that is pushed out when the seal is installed.
CONNECTING RODS AND PISTONS
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1 - Circlip
2 - Piston pin
3 - Connecting rod
4 - Connecting rod bearing
5 - Projection
6 - Bearing cap
7 - Retaining bolts
8 - Identification
9 - Bearing shell
The connecting rods are manufactured from sinter-forged steel. The selective connecting rod bearings are aluminum/tin
split plain bearings. The connecting rod bearing is 'sputter coated', which is a manufacturing process that layers the
bearing material to produce a higher load capacity for improved durability.
Engine oil for lubrication of the connecting rod bearings is supplied from the main bearings through passageways in the
crankshaft.
The connecting rods are available in 3 different lengths. For identification, the connecting rod and bearing cap are marked
with the corresponding identification code.
Piston Rings
A - Front of the engine
1 - Upper compression ring
2 - Lower compression ring
3 - Oil control ring
The pistons are made from aluminum alloy and are fitted with three rings. The piston crown incorporates a pronounced
bowl, which forms the combustion chamber and promotes the swirl and turbulence necessary for good combustion and
improved emissions. In addition, the piston also incorporates oil cooling galleries within the piston crown to enhance
piston cooling.
The arrow on the piston crowns must point towards the front of the engine.
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Each piston is installed on a wrist pin located in an aluminum/tin bushing in the connecting rod.
CYLINDER HEAD
Cylinder Head and Valves

1 - Cylinder head
2 - Outer cylinder head bolt (8 off)
3 - Inner cylinder head bolt (10 off)
4 - Intake valves (16 off)
5 - Valve collets (32 off)
6 - Spring retainer (16 off)
7 - Valve spring (16 off)
8 - Valve stem oil seal (16 off)
9 - Exhaust valve (8 off)
10 - Intake valve (8 off)
11 - Valve guide (16 off)
12 - Cylinder head gasket
13 - Valve assembly
The cylinder head is made of gravity die cast aluminum. Four valves per cylinder provides improved cylinder charging. A
compact combustion chamber and vertical fuel injectors guarantee optimum distribution of the fuel in the combustion
chamber.
Eighteen deep-seated bolts help reduce distortion and secure the cylinder head to the cylinder block. The 8 cylinder head
outer bolts are shorter than the inner bolts and are located beneath the camshafts, 4 under the inlet camshaft and 4
under the exhaust camshaft. Two hollow dowels align each cylinder head with the cylinder block.
The cylinder head has four ports machined at each cylinder location, 2 exhaust ports and 2 inlet ports. One of the inlet
ports is helical and functions as a swirl port, the other is arranged laterally as a tangential port and functions as a charge
port.
NOTE: The cylinder head cannot be reworked.
All valves are supported in sintered metal seats and guide inserts. Collets, valve collars and spring seats locate single
valve springs on both intake and exhaust valves. Valve stem seals are integrated into the spring seats.
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Camshafts

1 - Inlet camshaft
2 - Exhaust camshaft
The camshafts are of a hollow steel tube construction, with pressed on sintered lobes and have a machined face at the
front to accept the camshaft gear sprocket. The camshafts are retained in the cylinder head by the camshaft carrier. The
reluctor, machined towards the rear of the inlet camshaft, enables the CMP (camshaft position) sensor to provide a signal,
which enables the ECM (engine control module) to determine the position of the camshaft relative to the crankshaft.
For additional information, refer to: Electronic Engine Controls (303-14 Electronic Engine Controls - ID4 2.2L Diesel,
Description and Operation).
Camshaft Carrier
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1 - Camshaft carrier
2 - Alignment pin
3 - Bolt (20 off)
4 - Bolt (2 off)
5 - Stud
6 - Bolt
7 - Bolt
8 - Cylinder head
The aluminum camshaft carrier is located on top of the cylinder head and is retained by 24 bolts and a stud. Two
alignment pins are used to accurately locate the carrier to the cylinder head.
Rocker Arms
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1 - Bolt (10 off)
2 - Frame
3 - Rocker assembly (16 off)
The valves are operated through roller-type rocker arms with integrated hydraulic lash adjusters, actuated by the
camshaft lobes. The use of this type of actuation method helps reduce friction in the valve operating mechanism. The
rocker arms are installed in a frame located in the camshaft carrier and secured with 10 bolts.
Lash Adjuster

1 - Plunger cap
2 - Hydraulic lash adjuster body
3 - Oil hole
4 - Reservoir chamber
5 - Plunger
6 - Check ball
7 - High-pressure chamber
8 - Plunger spring
9 - Hydraulic lash adjuster
10 - Rocker arm
The body of the hydraulic lash adjuster contains a plunger and 2 chambers for oil feed and pressurized oil. The pressurized
oil is supplied to the adjusters via the main oil galleries in the cylinder head and through a hole in the side of the adjuster
body. The oil passes into a feed chamber in the adjuster and then through to a separate pressure chamber via a one-way
ball valve.
Oil flow from the pressure chamber is determined by the amount of clearance between the adjuster outer body and the
center plunger. Oil escapes up the side of the plunger every time the adjuster is operated, the downward pressure on the
plunger forcing a corresponding amount of oil in the adjuster body to be displaced. When the downward pressure from the
camshaft and rocker arm is removed (i.e. after the trailing flank of the camshaft lobe has passed), oil pressure forces the
adjuster's plunger up again. This pressure is not sufficient to effect the valve operation, but eliminates the clearance
between the finger rocker and top of the valve stem.
Cylinder Head Gasket
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1 - Dowel
2 - Grade identification holes/teeth
The cylinder head gasket is a 4-layer, laminated steel type that is available in 3 thickness grades. The choice of gasket
grade is dependent on the maximum piston protrusion in the cylinder block. The grade of a gasket is shown by the
number of identification holes and teeth incorporated into the gasket.
Two dowels ensure correct alignment of the cylinder head and gasket with the cylinder block.
CAUTION: If a cylinder head gasket is being changed, only use a new gasket with the same identification markings.
If new pistons or connecting rods are fitted, measure the maximum piston protrusion height and select the appropriate
gasket.
SKIRT STIFFENER
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1 - Cylinder block
2 - Gaskets
3 - Skirt stiffener
4 - Bolt (3 off)
5 - Bolt (19 off)
The aluminum alloy skirt stiffener is fitted to the lower cylinder block to stiffen the base structure of the engine thus
helping to reduce NVH (noise, vibration and harshness). The frame is made of high-pressure die cast aluminum and also
incorporates an oil baffle plate to reduce oil foaming and splash.
The alignment of the sides of the skirt stiffener with the cylinder block is set using a special tool. The rear face alignment
is set using a suitable straight edge.
For additional information, refer to: Engine (303-01 Engine - ID4 2.2L Diesel, Assembly).
The skirt stiffener is secured to the cylinder block with 22 bolts.
Gaskets seal the joints between the skirt stiffener and the cylinder block.
OIL PAN
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1 - Skirt stiffener
2 - Oil pan
3 - Bolt (11 off)
4 - Nut (5 off)
5 - Drain plug
The pressed steel oil pan is attached to the skirt stiffener with 11 bolts and 5 nuts. The engine oil drain plug is located in
the rear face of the oil pan.
A bead of RTV (room temperature vulcanizing) sealant seals the joint between the oil pan and the skirt stiffener.
CAMSHAFT DRIVE
Drive Gear
Item
1
2
Part Number
-
-
Description
Chain guide
Inlet camshaft sprocket
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3 - Exhaust camshaft sprocket
4 - Chain guide
5 - Tensioner blade
6 - High-pressure fuel pump sprocket
7 - Primary drive chain
8 - Lower chain guide
9 - Secondary drive chain tensioner
10 - Crankshaft sprocket
11 - Hydraulic tensioner
12 - Secondary drive chain
The primary drive chain transmits the drive from the crankshaft sprocket to the exhaust camshaft, the inlet camshaft and
the high-pressure fuel pump. The secondary drive chain transmits drive from the crankshaft sprocket to the oil pump
located on the underside of the skirt stiffener.
One bolt locates the crankshaft sprocket on the crankshaft, and three bolts are used to attach the engine crankshaft
pulley/ torsional vibration damper to the crankshaft via holes in the crankshaft sprocket. The inlet and exhaust camshaft
sprockets are aligned on their respective camshafts using a spigot tool and a timing peg. Once they are in their correct
position, three bolts are used to secure each camshaft sprocket to their camshaft.
The primary drive chain has an hydraulic tensioner, operated by engine oil, which acts on a pivoting flexible tensioner
blade. Chain guides are installed on the drive side of the primary chain. The primary chain is lubricated via an oil squirt
tube located centrally at the front of the engine block.
The secondary chain tensioner is spring operated and acts directly on the chain. The secondary chain is splash lubricated
with oil from the skirt stiffener and oil pan assembly.
Front Cover
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1 - Sealant bead
2 - Front cover
3 - Nut (2 off)
4 - Bolt (20 off)
5 - Guide pin
The pressed steel front cover is attached to the front of the cylinder block, the cylinder head and the skirt stiffener with 20
bolts and 2 nuts, and sealed with a bead of RTV silicon sealant.
When installing the front cover, a special locating tool is required, which fits in the crankshaft sprocket aperture, to aid the
alignment of the front cover.
INTAKE MANIFOLD
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1 - Intake manifold
2 - Captive nut
3 - EGR valve outlet tube mounting boss
4 - Electronic throttle mounting flange
5 - MAP (manifold absolute pressure) sensor mounting flange
The plastic intake manifold is mounted on the LH (left-hand) side of the cylinder head using 9 bolts and isolator bushes.
Rubber gaskets, integrated into the manifold, seal the joints between the manifold and the cylinder head.
Mounting flanges on the manifold provide for the attachment of the electronic throttle and the MAP sensor.
For additional information, refer to: Electronic Engine Controls (303-14 Electronic Engine Controls - ID4 2.2L Diesel,
A mounting boss on the manifold provides for the attachment of the EGR valve outlet tube.
For additional information, refer to: Engine Emission Control (303-08 Engine Emission Control - ID4 2.2L Diesel,
Captive nuts are installed in the manifold for the securing bolts of the EGR valve outlet tube and a fuel pipe bracket.
EXHAUST MANIFOLD
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1 - Gasket
2 - Exhaust manifold
3 - Turbocharger mounting flange
4 - Heat shield attachment points
5 - EGR cooler mounting flange
The cast iron exhaust manifold is secured to the RH (right-hand) side of the cylinder head using 2 nuts and 6 bolts. A
laminated metal gasket seals the manifold to the cylinder head.
A mounting flange towards the front of the manifold is provided for attachment of the turbocharger.
For additional information, refer to: Turbocharger (303-04B Fuel Charging and Controls - Turbocharger - ID4 2.2L Diesel,
A second mounting flange, located on the rear of the manifold, is provided for attachment of the EGR cooler.
For additional information, refer to: Engine Emission Control (303-08 Engine Emission Control - ID4 2.2L Diesel,
Tapped holes incorporated into bosses on the manifold provide attachment points for the exhaust heat shields.
CAMSHAFT COVER AND ENGINE COVER

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1 - Engine cover
2 - Camshaft cover
LUBRICATION SYSTEM
Item
1
2
Part Number
-
-
Description
Oil cooler
Oil filter
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3 - Oil pressure switch
4 - Feedback tube
5 - Oil pick-up tube
6 - Dipstick
7 - Oil pump
8 - Secondary drive chain
9 - Turbocharger oil feed tube
10 - Dipstick outer tube
11 - Turbocharger oil drain tube
12 - Oil temperature/low level sensor
The engine is lubricated by a forced feed oil circulation system. The main components of the system are:
Oil pick-up
Oil pump
Oil filter and cooler assembly.
Oil Pick-up
The plastic oil pick-up is immersed in the oil reservoir to provide a supply to the oil pump at all normal vehicle attitudes. A
mesh screen in the inlet prevents debris from entering the oil system.
Oil Pump
The oil pump is located on the LH front underside of the skirt stiffener and is secured by 4 bolts. The unit is a spur gear
pump driven by the crankshaft sprocket via the secondary drive chain. An integral pressure relief valve diverts oil back to
the inlet side of the pump to limit the pump outlet pressure.
Oil Filter and Cooler Assembly
The oil filter and cooler assembly is attached to the LH side of the skirt stiffener and consists a full-flow, disposable
canister-type filter and an oil cooler attached to a casting. The casting aligns with the oil galleries in the skirt stiffener and
is sealed by a gasket.
The engine cooling system cools the oil in the oil cooler and is regulated by means of a separate thermostat, which
prevents the flow of coolant through the oil cooler when the engine is cold, ensuring the engine oil warms up quickly. The
thermostat opens at 75±2 °C (167±35 °F).
Oil to and from the oil cooler passes through galleries in the skirt stiffener. Hoses from the engine cooling system are
connected to 2 pipes on the oil cooler for the supply and return of coolant.
An oil pressure switch is located in the casting to sense the pressure of the oil as it leaves the oil filter and cooler
assembly. A warning lamp in the instrument cluster illuminates if low oil pressure is detected.
For additional information, refer to: Instrument Cluster (413-01 Instrument Cluster, Description and Operation).
Lubrication System Operation
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Oil is drawn through the oil pick-up into the oil pump, then supplied to the oil filter and cooler assembly through the oil
galleries in the skirt stiffener. After passing through the filter, a proportion of the oil (controlled by a restrictor in the oil
filter housing) passes through the oil cooler. The return flow from the oil cooler combines with the remainder of the oil
from the filter, then passes through the skirt stiffener into the cylinder block main oil gallery.
The main oil gallery has drillings that direct the oil to the cylinder head and the main bearings. Cross drillings in the
crankshaft main bearings carry the oil to the connecting rod big-end bearings. Oil galleries in the cylinder head carry the
oil to the camshafts and the hydraulic lash adjusters.
Oil at reduced pressure is directed towards the cylinder head via a restrictor in the cylinder block/cylinder head locating
dowel. Oil then passes through a drilling in the cylinder head to the camshaft carrier, where it is directed via separate
galleries to the camshaft bearings and hydraulic tappet housings. Return oil from the cylinder head drains into the sump
via the cylinder head bolt passages.
Published: 11-May-2011
Diagnosis and Testing
Overview
As diagnosis of the different areas of the engine is covered in other sections and by general procedures, this section is
limited to an oil pressure test.
For specific areas of the engine, refer to the general procedures in this section and the relevant section of the manual.
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart
Mechanical Electrical
Engine oil level
Coolant level
Transmission fluid level
Fuses
Fuel level
Wiring harness
Coolant leaks
Electrical connector(s)
Oil leaks
Injectors
Fuel leaks
Glow plugs
Visibly damaged or worn parts
5 volt sensor supply
Loose or missing nuts or bolts
Sensor(s)
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Fuel contamination/grade/quality
Viscous fan solenoid
Sensor fitment/condition
Engine control module (ECM)
Viscous fan and solenoid
Routing of pipework etc. to avoid vibrations
Contact anywhere between the driveline and chassis
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding
to the next step.
4. Use the approved diagnostic system or a scan tool to retrieve any diagnostic trouble codes (DTCs) before moving
onto the symptom chart or DTC index.
Oil Pressure Check
NOTE: Prior to checking the engine oil pressure, a road test of 6 miles (10 kilometres), must be carried out. Do not
attempt to attain engine normal operating temperature by allowing the engine to idle.
1. WARNINGS:
The spilling of hot engine oil is unavoidable during this procedure, care must be taken to prevent scalding.
Failure to follow this instruction may result in personal injury.
Wear protective gloves.
Remove the oil pressure sensor.

REFER to: Engine Oil Pressure (EOP) Sensor (303-14 Electronic Engine Controls - ID4 2.2L Diesel, Removal and
Installation).
2. Install the oil pressure gauge and the oil pressure gauge connector.
3. Check and top-up the engine oil, if required.
4. Start and run the engine.
5. Note the oil pressure readings with the engine running at idle and at 2,000 rpm.
REFER to: Specifications (303-01 Engine - ID4 2.2L Diesel, Specifications).
6. Turn off the engine.
7. Remove the special tools.
8. Install the oil pressure sensor.

REFER to: Engine Oil Pressure (EOP) Sensor (303-14 Electronic Engine Controls - ID4 2.2L Diesel, Removal and
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Installation).
9. Check and top-up the engine oil, if required.
For a complete list of all diagnostic trouble codes that could be logged on this vehicle, please refer to Section 100-00.
REFER to: How To Use This Manual (100-00 General Information, Description and Operation).
Published: 11-May-2011
Engine - ID4 2.2L Diesel - Engine Oil Draining and Filling
General Procedures
1. WARNING: Do not work on or under a vehicle supported only

by a jack. Always support the vehicle on safety stands.
Raise and support the vehicle.

For additional information, refer to: Lifting (100-02, Description and
Operation).
2. Loosen the oil filter cover 3 turns and allow the engine oil to drain.
3. NOTE: Position cloth to collect fluid spillage.
Remove the oil filter cover and oil filter element.
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4. Remove and discard the oil filter element.
Remove and discard the oil filter cover O-ring
seal.
5. Drain the engine oil.

Position a container to collect the engine oil.
Remove and discard the drain plug.
Allow the engine oil to drain.
6. Install a new drain plug.

Clean the component mating faces.
Tighten the drain plug to 23 Nm (17 lb.ft).
Remove the container.
7. Install a new oil filter cover O-ring seal.

Clean the components.
Lubricate the O-ring seal with clean engine oil.
8. Install a new oil filter element to the oil filter cover.
9. Install the oil filter cover and oil filter element.

Tighten the oil filter cover to 35 Nm (26 lb.ft).
10. Fill the engine with the recommended oil to the correct level.
11. Connect the battery ground cable.

For additional information, refer to: Battery Connect (414-01,
General Procedures).
12. Check and top-up the engine oil.
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Content not found
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Published: 08-Dec-2011
Engine - ID4 2.2L Diesel - Crankshaft Pulley
Removal and Installation
Special Tool(s)
Aligner, Engine Front Cover
303-1310
Removal
1. For additional information, refer to: Battery Disconnect and Connect
(414-01 Battery, Mounting and Cables, General Procedures).
2. For additional information, refer to: Cooling Fan (303-03 Engine

Cooling - ID4 2.2L Diesel, Removal and Installation).
3. Torque: 10Nm
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4.
5. NOTE: Apply the foot and hand brake, select 1st gear to
prevent crankshft rotation.
Torque:
1. Stage : Run down 3 bolts to 20Nm
4. Stage : Turn on all 45degrees
5. Stage : Turn on all 45degrees
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Installation
1. To install, reverse to removal procedure.
Engine - ID4 2.2L Diesel - Crankshaft Front Seal
Special Tool(s)
Remover/Installer,Front Oil Seal
303-679
Removal

2. For additional information, refer to: Crankshaft Pulley (303-01

Engine - ID4 2.2L Diesel, Removal and Installation).
3. CAUTION: Make sure the mating faces are clean,

before the sealant is applied.
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NOTE: A new crankshaft front oil seal is supplied with
an alignment sleeve that will be pushed out during
installation.
Tool: 303-679 (Remover/Installer,Front Oil Seal)
Installation
1. Tool: 303-679 (Remover/Installer,Front Oil Seal)
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Engine - ID4 2.2L Diesel - Crankshaft Rear Seal
Removal
2. For additional information, refer to: Flywheel (303-01 Engine - ID4

2.2L Diesel, Removal and Installation).

4.
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Installation
1. NOTE: Clean the component mating faces.
Check the 2 foam pads are located on the ladder frame

gasket.
If the ladder frame gasket tabs are present, trim using
a suitable tool flush to the engine block and ladder
frame.
Apply a thin layer of sealant to the areas shown.
2. CAUTIONS:
A new crankshaft rear seal is supplied with an
alignment sleeve that must not be removed until the
crankshaft rear seal is fully installed. Failure to follow
this instruction may result in damage to the vehicle.
Install the new crankshaft rear seal within five

minutes of applying the recommended sealant.
Do not add the sealant anywhere other than the

area shown.
Using the recommended sealant completely fill the

square areas shown.
For additional information, refer to: Specifications (303-
01 Engine - ID4 2.2L Diesel, Specifications).
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3. Torque:
1. Stage : Hand start all bolts and tighten to 5Nm
2. Stage : Tighten the bolts to 9.5Nm in below
sequence
3. Stage: Repeat to 9.5 Nm below sequence
4. Remove and discard the seal alignment sleeve.
5. To install, reverse the removal procedure.

Published: 14-Oct-2011
Engine - ID4 2.2L Diesel - Cylinder Head
Removal


3. For additional information, refer to: Camshafts (303-01 Engine - ID4

4. For additional information, refer to: Intake Manifold (303-01 Engine

- ID4 2.2L Diesel, Removal and Installation).
5. Torque: 30Nm
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6. Torque: 25Nm
7.
1. Stage 1: Tighten the M10 bolts and nuts to 15
Nm (11 lb.ft).
2. Stage 2: Tighten the M10 bolts and nuts to 35
Nm (26 lb.ft).
8. Torque: 3Nm
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9.
10. NOTE: Do not disassemble further if the component is
removed for access only.
Torque: 13Nm
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Installation
1. CAUTION: Make sure that the mating faces are clean

and free from foreign material.
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NOTE: Measure the piston protrusion of each cylinder at
top dead center (TDC).
Measure the distance between the piston crown and the

cylinder block at the points indicated.
2. Determine the cylinder head gasket thickness.

For additional information, refer to: Specifications (303-01 Engine -
ID4 2.2L Diesel, Specifications).
3. CAUTIONS:
The thickness of the new cylinder head gasket

depends on the piston protrusion (hole/tooth marked).
Make sure that the mating faces are clean and

free from foreign material.
Fit new cylinder head gasket, dry, to cylinder block.
4. CAUTION: Make sure that the mating faces are clean and free
from foreign material.
NOTE: New bolts must be installed.
With assistance, install the cylinder head.

1. Stage 1: Tighten bolts 1 through 10 to 10Nm.
9. Stage 9: Tighten bolts 1 through 10 to 90 degrees.
10. Stage 10: Tighten bolts 11 through 18 to 90 degrees.
11. Stage 11: Tighten the M6 bolt to 10Nm (7 lb.ft).
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Engine - ID4 2.2L Diesel - Engine Mount LH
Removal
NOTE: Some variation in the illustrations may occur, but the essential information is always correct.
1. Disconnect the battery ground cable. For additional information,

refer to:
For additional information, refer to: Battery Disconnect and Connect
2. 3. Remove the cooling fan upper shroud.
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3. Remove the air cleaner outlet pipe. For additional information, refer
to:
For additional information, refer to: Air Cleaner Outlet Pipe (303-12
Intake Air Distribution and Filtering - ID4 2.2L Diesel, Removal and
Installation).
4. Remove the RH engine mount nut.
5. Disconnect the charher air cooler outlet hose.

7. Using a suitable hydraulic jack, raise the engine to a

maximum of 45 mm (1.77 inches).
8. Remove the LH engine mount.

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Installation
2. Tighten to 80 Nm (59 lb.ft).

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Engine - ID4 2.2L Diesel - Engine Mount RH
Removal
NOTE: Some variation in the illustrations may occur, but the essential information is always correct.
1. Disconnect the battery ground cable. For additional information,

refer to:
For additional information, refer to: Battery Disconnect and Connect
2. 3. Remove the cooling fan upper shroud.
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3. Remove the LH engine mount nut.
4. Remove the turbocharger heat shield.
to:
For additional information, refer to: Air Cleaner Outlet Pipe (303-12
Intake Air Distribution and Filtering - ID4 2.2L Diesel, Removal and
Installation).
6. Disconnect the charger air cooler inlet hose.
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8. Using a suitable hydraulic jack, raise the engine to a
maximum of 45 mm (1.77 inches).
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9. Remove the RH engine mount.
Installation

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Engine - ID4 2.2L Diesel - Exhaust Manifold
Removal

3. For additional information, refer to: Turbocharger (303-04B Fuel

Charging and Controls - Turbocharger - ID4 2.2L Diesel, Removal
and Installation).
4. Torque: 10Nm
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5. Torque: 9Nm
6. Torque: 10Nm
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7. CAUTION: Make sure that the mating faces are
clean and free from foreign material.
Installation
1. NOTE: Install a new gasket.
1. Stage 1: Tighten the M10 bolts and nuts to

15Nm (11 lb.ft).
2. Stage 3: Tighten the M10 bolts and nuts to
35Nm (26 lb.ft).
3. Stage 4: Repeat the M10 bolts and nuts to
35Nm (26 lb.ft).
4. Tighten the M8 bolts to 25Nm (18 lb.ft).
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Engine - ID4 2.2L Diesel - Intake Manifold
Removal
NOTE: Removal steps in this procedure may contain installation details.
1. For additional information, refer to: Exhaust Gas Recirculation (EGR)

Valve (303-08 Engine Emission Control - ID4 2.2L Diesel, Removal
and Installation).
2. For additional information, refer to: Throttle Body (303-04A Fuel

Charging and Controls - ID4 2.2L Diesel, Removal and Installation).
3.
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4.
5.
6. Torque Stage 1: 8Nm, Stage 2: 23Nm
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7. CAUTION: Make sure that all openings are sealed.
Use new blanking caps.
NOTE: Clean the component mating faces.
Torque: 15Nm
8. Torque: 3Nm
Installation
1. To install, reverse the removal procdedure.
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Published: 27-Sep-2011
Engine - ID4 2.2L Diesel - Oil Pan
Removal
1. Raise the vehicle on lift.
2. Drain the engine oil.

For additional information, refer to: Engine Oil Draining and Filling
(303-01 Engine - ID4 2.2L Diesel, General Procedures).
3. Remove the 16 oil pan bolts.
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4. CAUTION: CAUTION: Avoid damage to the oil
pan mating face of the cylinder block. Failure to
follow this instruction may cause damage to the
vehicle.
Remove the engine oil pan.
5. CAUTION: CAUTION: Avoid damage to the oil pan mating face

of the cylinder block. Failure to follow this instruction may cause
damage to the vehicle.
Remove the sealant from the engine.
Installation
1. NOTE: Clean the cylinder block mating faces.

1. NOTE: Clean the cylinder block mating faces.
Apply a 3mm bead of sealer WSE-M4G323-A4 to the

oil pan.
2. NOTE: Tighten the bolts in the sequence shown.
Install the oil pan.

1. Tighten the oil pan bolts.
2. Stage 1: Torque to 7NM
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3. Stage 2: Torque to 14NM
3. Lower the vehicle.
4. Remove the engine oil filler cap.
5. Fill the engine with the recommended oil to the correct level.
6. Install the engine oil filler cap.
7. Check and top-up the engine oil.

For additional information, refer to: Engine Oil Draining and Filling
(303-01 Engine - ID4 2.2L Diesel, General Procedures).
8. Close the bonnet.

Engine - ID4 2.2L Diesel - Oil Pump
Removal

Raise the vehicle on lift.
3. Remove the engine oil pan.

For additional information, refer to: Oil Pan (303-01 Engine - ID4
4. NOTE: Install the special tool so that the tool face

aligns with the oil pump sprocket.
Install the special tool to the engine block.
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5. NOTE: Remove and discard the O-ring seal.
Remove the oil pickup pipe.

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6. Remove the oil pump.
7. NOTE: Do not disassemble further if the component is

removed for access only.
Remove the oil pump outlet pipe.

Installation
1. Install the oil pump outlet pipe.
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2. NOTE: Do not tighten the bolts at this stage.
Install the oil pump so the sprocket touches the special

tool.
3. Torque: 10Nm
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4. Remove the special tool.
5. Torque: 10Nm
5. Torque: 10Nm
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6. Torque: 10Nm
7. Install the engine oil pan

For additional information, refer to: Oil Pan (303-01 Engine - ID4
.

Engine - ID4 2.2L Diesel - Timing Cover
Special Tool(s)
Aligner, Engine Front Cover
303-682
Removal

3. For additional information, refer to: Cooling System Draining, Filling

and Bleeding (303-03 Engine Cooling - ID4 2.2L Diesel, General
Procedures).
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4. For additional information, refer to: Accessory Drive Component
Bracket (303-05 Accessory Drive - ID4 2.2L Diesel, Removal and
Installation).
5. For additional information, refer to: Crankshaft Front Seal (303-01

Engine - ID4 2.2L Diesel, Removal and Installation).
6. NOTE: Remove and discard the O-ring seal.
Torque: 23Nm
7. Torque: 23Nm
8. CAUTION: Make sure that the mating faces are
clean and free from foreign material.
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Installation
1. CAUTIONS:
A new engine timing cover must be installed.

Failure to follow this instruction may result in damage
to the vehicle.
Install the engine timing cover within five minutes

of applying the sealer. Failure to follow this instruction
may result in damage to the vehicle.
Make sure the mating faces are clean, before the

sealant is applied.
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2. CAUTION: Make sure the mating faces are clean,
before the sealant is applied.
3. WARNING: Make sure that the engine timing cover does not
come into contact with the engine until correct position is obtained.
Tool: 303-682 (Aligner, Engine Front Cover)

1. Stage 1: Tighten the M6 bolts and nuts to 5 Nm
2. Stage 2: Tighten the M6 bolts and nuts to 10 Nm
3. Stage 3: Repeat the M6 bolts and nuts to 10 Nm
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Engine - ID4 2.2L Diesel - Flywheel
Removal

3. For additional information, refer to: Clutch Disc and Pressure Plate
(308-01 Clutch - Vehicles With: MT82 6-Speed Manual
Transmission, Removal and Installation).
4.
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Installation
1. NOTE: Clean the component mating faces.
NOTE: New bolts must be installed.
NOTE: Tighten the bolts in the sequence shown.
Install the flywheel.

1. Stage 1: Tighten the bolts 1 through 8 to 25 Nm
(18 lb.ft).
2. Stage 2: Tighten the bolts 1 through 8 to 45 Nm
(33 lb.ft).
3. Stage 3: Tighten the bolts 1 through 8 a further
45 degrees.
2. For additional information, refer to: Clutch Disc and Pressure Plate
(308-01 Clutch - Vehicles With: MT82 6-Speed Manual
Transmission, Removal and Installation).
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Removal
Removal
1. For additional information, refer to: Air Conditioning (A/C) System
Recovery, Evacuation and Charging (412-00 Climate Control System
- General Information, General Procedures).

Raise the vehicle on a twin-post lift.

4.
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Procedures).

7.
8.
9.
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10.
11.
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13.
12.
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15.
14.
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17.
16.
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19.
18.
20.
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22.
21.
20.
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23.
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24. CAUTIONS:
CAUTION: Remove and discard the O ring seals.
CAUTION: Make sure that all openings are sealed.

Use new blanking caps.
25.
27.
26.
25.
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28. NOTE: Vehicles with diesel particulate filter (DPF).
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29.
30.
30.
31.
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32. NOTE: Remove and discard the gasket.
33.
33.
34.
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35.
36.
38.
37.
36.
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39. CAUTION: Care must be taken to avoid damage to surrounding
components.
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Installation
Installation
1. CAUTION: Care must be taken to avoid damage to surrounding

components.
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2. Torque: 23Nm
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3. Torque: 80Nm
4. NOTE: Make sure a new gasket is installed.

5. Torque: 10Nm
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7. Torque: 40Nm
8. Torque: 40Nm
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9. Torque: 40Nm
10. Torque: 25Nm
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12.
15.
14.
13.
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15.
16. Torque: 3Nm
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17. Torque: 3Nm
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18.
19. NOTE: Remove and discard the blanking caps.
NOTE: Make sure that a new seals are installed.
Torque: 30Nm
20. Torque: 35Nm
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21. Torque: 12Nm
22.
22.
23. Torque: 10Nm
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24.
25.
27.
26.
25.
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29.
28.
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31.
30.
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32.
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34.
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Procedures).
37. For additional information, refer to: Air Conditioning (A/C) System
Recovery, Evacuation and Charging (412-00 Climate Control System
- General Information, General Procedures).

Engine - ID4 2.2L Diesel - : Item Specification

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What are the main components of the engine?

What are the main components of the engine?

What are the torque specifications for installing the engine?

What are the torque specifications for installing the engine?

Published: 27-Sep-2011

Engine - ID4 2.2L Diesel -

Engine Identification Label

Piston Cooling Jets

Piston Oil Cooling

Item Part Number Description

Bearing Cap Identification

Crankshaft Front Oil Seal

Item Part Number Description

CONNECTING RODS AND PISTONS

Cylinder Head and Valves

Item Part Number Description

NOTE: The cylinder head cannot be reworked.

Item Part Number Description

Item Part Number Description

Cylinder Head Gasket

Item Part Number Description

The skirt stiffener is secured to the cylinder block with 22 bolts.

Item Part Number Description

CAMSHAFT COVER AND ENGINE COVER

Oil Filter and Cooler Assembly

Lubrication System Operation

Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical or electrical damage.

Oil Pressure Check

Wear protective gloves.

Remove the oil pressure sensor.

4. Start and run the engine.

6. Turn off the engine.

7. Remove the special tools.

8. Install the oil pressure sensor.

9. Check and top-up the engine oil, if required.

1. WARNING: Do not work on or under a vehicle supported only

Raise and support the vehicle.

3. NOTE: Position cloth to collect fluid spillage.

Remove the oil filter cover and oil filter element.

5. Drain the engine oil.

6. Install a new drain plug.

7. Install a new oil filter cover O-ring seal.

9. Install the oil filter cover and oil filter element.

11. Connect the battery ground cable.

12. Check and top-up the engine oil.

2. For additional information, refer to: Cooling Fan (303-03 Engine

1. WARNING: Do not work on or under a vehicle supported only

Raise and support the vehicle.

2. For additional information, refer to: Crankshaft Pulley (303-01

3. CAUTION: Make sure the mating faces are clean,

Tool: 303-679 (Remover/Installer,Front Oil Seal)

2. For additional information, refer to: Flywheel (303-01 Engine - ID4

3. WARNING: Do not work on or under a vehicle supported only

Raise and support the vehicle.

Check the 2 foam pads are located on the ladder frame

Install the new crankshaft rear seal within five