Injection (CDI) engine is an in-line overhead valve
diesel engine. This engine utilizes a cast iron cylin-
der block and an aluminum cylinder head. The
engine is turbocharged and intercooled. This engine
also has for valve per cylinder and dual overhead
camshafts (Fig. 1).

Fig. 1 2.7L CDI ENGINE

9 - 2

ENGINE

DESCRIPTION

SPECIFICATION

Engine

2.7L CDI

Engine Description

5 Cylinder In-Line En-

gine With 4-Valve Tech-

nology

Air Intake

Turbo-Charged Engine

with Charge Air Cooling

Fuel Injection System

2 nd. Generation Com-

mon Rail Direct Injection

(CDI)

Fuel

Diesel

Firing Order

1-2-4-5-3

Rated Output

154 HP at 3800 RPM

Torque

243 ft. lbs. at 1600-2400

RPM

Maximum Speed

4800 RPM

Compression Ratio

18:1

Bore/Stroke

3.46/3.48

Eff. Displacement

2688 cm3

STANDARD PROCEDURE

STANDARD PROCEDURE - COMPRESSION
TESTING ENGINE

(1) Warm up engine to operating temperature

(approx. 80 °C, 176°F).

(2) Shut off engine.
(3) Remove engine cover (Refer to 9 - ENGINE -

REMOVAL).

(4) Remove glow plugs (Refer to 8 - ELECTRICAL/

IGNITION CONTROL/GLOW PLUG - REMOVAL).

(5) Crank engine several times with the starter to

eliminate combustion residues in the cylinders.

(6) Insert compression tester adapter #8927 (Refer

to 9 - ENGINE - SPECIAL TOOLS) with check valve
installed into glow plug hole of cylinder to be tested.

(7) Connect compression tester hose adapter #9295

to compression gauge and test compression pressure
by cranking engine with starter for at least 8 revolu-
tions.

(8) Carry out test procedure at the remaining cyl-

inders in the same way.

(9) Compare pressure readings obtained with the

specified pressures. If the pressure reading is below
the minimum compression pressure or if the permis-
sible difference between the individual cylinders is
exceeded. Refer to cylinder leak down test.

(10) Remove compression tester and adapter from

cylinder head.

(11) Install glow plugs (Refer to 8 - ELECTRICAL/

IGNITION CONTROL/GLOW PLUG - INSTALLA-
TION).

(12) Install engine cover (Refer to 9 - ENGINE -

INSTALLATION).

COMPRESSION SPECIFICATIONS

Maximum Compression

29-35 bar (420-507 psi)

Minimum Compression

18bar (261 psi)

Permissible Difference
Between Cylinders

± 3bar (± 44 psi)

STANDARD PROCEDURE - CYLINDER LEAK
DOWN TEST

(1) Warm engine to operating temperature.

WARNING:

NOT

OPEN

COOLING

SYSTEM

UNLESS COOLANT TEMPERATURE IS BELOW 90C
(194°F). RISK OF INJURY TO SKIN AND EYES AS A
RESULT

SCALDING

WITH

HOT

COOLANT

WHICH

SPLASHES

OUT.

RISK

POISONING

FROM

SWALLOWING

COOLANT.

OPEN

CAP

SLOWLY AND RELEASE PRESSURE. STORE COOL-
ANT IN PROPER CONTAINERS ONLY. WEAR PRO-
TECTIVE

GLOVES,

CLOTHING

AND

EYE

PROTECTION.

NOTE: Turn cap carefully as far as first detent,
release pressure, then unscrew cap.

(2) Open cooling system cap at coolant recover

pressure container.

(3) Remove engine cover (Refer to 9 - ENGINE -

REMOVAL).

(4) Unscrew oil filler cap.
(5) Remove glow plugs (Refer to 8 - ELECTRICAL/

IGNITION CONTROL/GLOW PLUG - REMOVAL).

NOTE: Crank engine at crankshaft in direction of
rotation of the engine (clockwise).

(6) Position cylinder to be tested to ignition Top

Dead Center (DTC).

NOTE: Calibrate cylinder leak down tester and
remove check valve in screw-in fitting.

(7) Connect cylinder leak down tester and follow

INSPECTING Instruction.

INSPECTING

NOTE: If crankshaft rotates, install retaining lock for
crankshaft/ring gear.

(1) Pressurize cylinder with compressed air and

read off pressure loss at cylinder leak tester. If exces-
sive pressure loss exists, determine possible cause
(Refer to 9 - ENGINE - STANDARD PROCEDURE).

ENGINE

9 - 3

NOTE: If the retaining lock is installed, remove it,
rotate engine and install lock once again.

(2) Carry out test of other cylinders in the firing

order of engine.

CYLINDER LEAK DOWN VALUES

CYLINDER LEAK
DOWN PERMISSIBLE
TOTAL LOSS

± 25%

CYLINDER LEAK
DOWN PERMISSIBLE
LOSS AT VALVES AND
CYLINDER HEAD

± 10%

CYLINDER LEAK
DOWN PERMISSIBLE
LOSS AT PISTON AND
RINGS

± 20%

STANDARD PROCEDURE - DETERMINING CYL-
INDER PRESSURE LOSS

If an increased pressure loss was found with the

cylinder leak test, inspect the engine by listening at
the cylinder head gasket, air intake area, exhaust, oil
fill opening and where injectors and glow plugs enter
the cylinder head. Also check the engine coolant in
the radiator or expansion reservoir for the formation
of bubbles.

Possible causes for the pressure loss are:

POSSIBLE CAUSE FOR PRESSURE LOSS

CONDITION

POSSIBLE

CAUSES

CORRECTION

AIR LOSS
THROUGH
GLOW PLUG,
INJECTOR, AD-
JACENT CYL-
INDERS, OR
AIR BUBBLES
IN COOLANT

1. Sealing Sur-
faces

Repair Sealing
Surfaces

2. Gaskets

2. Replace
Component or
Gasket

3. Cylinder
Head Gasket

3. Replace Cyl-
inder Head
Gasket

AIR LOSS
THROUGH AIR
INTAKE AREA

1. Sealing Sur-
faces

1. Remove Cyl-
inder Head for
Further Inspec-
tion

CONDITION

POSSIBLE

CAUSES

CORRECTION

2. Intake
Valves and
Seats

2. Replace
Valves, Guides
or Seats

AIR LOSS
THROUGH EX-
HAUST

Sealing Surfac-
es

Remove Cylin-
der Head for
Further Inspec-
tion

2. Exhaust
Valves and
Seats

2. Replace
Valves, Guides
or Seats

AIR LOSS
THROUGH OIL
FILL OPENING

1. Sealing Sur-
faces

Remove Engine
for Further In-
spection

2. Pistons, Pis-
ton Rings

2. Replace Pis-
tons or Piston
Rings

It is possible to pin point the pressure loss of the

relevant cylinder by spraying with clean engine oil.
Engine oil seals off the gap between the piston and
cylinder wall briefly. If a reduced pressure loss now
occurs for a short time, the cause is very likely to be
the pistons, piston rings or cylinder contact surfaces
of the relevant cylinder.

Determining the cause can be falsified by the posi-

tion of the piston ring joints. If suspicion exists that
the loss of pressure is caused by the piston ring
joints being positioned directly one above the other,
fit the parts to the engine and repeat this test after
running the engine for a short time.

REMOVAL

REMOVAL - ENGINE COVER

(1) Remove the retaining screws and remove cover

(Fig. 2).

9 - 4

ENGINE

REMOVAL

WARNING: NO SPARKS, OPEN FLAMES OR SMOK-
ING. RISK OF POISONING FROM INHALING AND
SWALLOWING FUEL. RISK OF INJURY TO EYES
AND SKIN FROM CONTACT WITH FUEL. POUR
FUELS ONLY INTO SUITABLE AND APPROPRI-
ATELY MARKED CONTAINERS. WEAR PROTECTIVE
CLOTHING.

WARNING: RISK OF INJURY TO SKIN AND EYES
FROM SCALDING WITH HOT COOLANT. RISK OF
POISONING FROM SWALLOWING COOLANT. DO
NOT OPEN COOLING SYSTEM UNLESS COOLANT
TEMPERATURE IS BELOW 90°C (194°F). OPEN CAP
SLOWLY TO RELEASE PRESSURE. STORE COOL-
ANT IN SUITABLE AND APPROPRIATELY MARKED
CONTAINER.

WEAR

PROTECTIVE

GLOVES,

CLOTHES, AND EYE WEAR.

(1) Disconnect the negative battery cable.

NOTE: REPLACE THE AIR CONDITIONING DRIER
WHEN EVER THE AIR CONDITIONING SYSTEM IS
OPENED.

(2) Drain cooling system (Refer to 7 - COOLING/

ENGINE/COOLANT - STANDARD PROCEDURE).

(3) Evacuate and recover air conditioning system

(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE).

(4) Remove the front grille and fascia assembly.

(5) Disconnect the engine wiring harness at the

cabin side and carefully guide though the cowl into
the engine area.

Fig. 2 ENGINE COVER

1 - ENGINE COVER
2 - FASTENERS

ENGINE

9 - 5

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