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

DESCRIPTION

SPECIFICATION

Engine

2.2L CDI

Engine Description

4 Cylinder In-Line Engine

With 4-Valve Technology

Fuel Injection System

Common Rail Diesel

Injection (CDI)

Fuel

Diesel

Rated Output

85/4200 kW at RPM

Torque

250/1400-2600 Nm at

RPM

Maximum Speed

4600 RPM

Compression Ratio

18:0

Bore/Stroke

88.0/88.3 mm

Eff. Displacement

2148 cm3

STANDARD PROCEDURE

COMPRESSION TESTING ENGINE

(1) Warm up engine to operating temperature

(approximately 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 with check

valve installed into glow plug hole of cylinder to be
tested.

(7) Test compression pressure by cranking engine

with starter for at least 8 revolutions.

Fig. 1 2.2L Diesel Engine

9 - 2

ENGINE

(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 (Refer to 9 - ENGINE - STAN-
DARD PROCEDURE).

2.2L

COMPRESSION SPECIFICATION

Minimum Allowable

18 bar (261 psi.)

Maximum Allowable
Difference Between
Cylinders

3 bar (44 psi.)

Average Compression
Ratio

24 - 30 bar (348 - 435
psi)

(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).

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 cause by viewing
the paragraph below.

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.

DETERMINING PRESSURE LOSS

If a great pressure loss was detected, listen using a

stethoscope around suspected areas, such as the cyl-
inder head gasket through the air suction area, the
exhaust system, the oil filler neck, the pre-chamber,
the bore wholes of the cylinder effected or neighbor-
ing cylinders. Observe the coolant in the expansion
tank, looking for traces of bubbles.

The possible causes of pressure loss are:
• If air leak is detected through the prechamber,

cylinder bore hole, from a neighboring cylinder or air
bubbles in the coolant expansion tank, pressure loss
may be caused by the cylinder head gasket.

• If the air leak occurs in the air suction area, the

pressure loss may be caused by the intake valve(s).

• Air leak through the exhaust system, may be

caused by the exhaust valve(s).

• Air leak through the oil filler neck, may be

caused by piston, ring, or cylinder sleeve.

If none of the above evidence supports a failure,

the engine may be assembled and run until operating
temperature is reached. Reconnect engine leak down
tester on a warm engine with a few drops of clean
engine oil in the cylinder being tested. Engine oil
seals the clearance between the piston and cylinder
for a short length of time. If under this condition a
smaller pressure loss occurs for a shorter length of
time, it is possible that the cause is piston, ring or
cylinder sleeve related.

CHECKING OIL PRESSURE

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

REMOVAL).

(2) Remove oil galley plug together with seal at

timing case cover.

ENGINE

9 - 3

ENGINE - 2.2L DIESEL (Continued)

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