2007 Liberty KJ Factory Service Manual 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
  


CRANKSHAFT

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.
  


LINERS

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
  		  


PISTON PINS

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.
  

TORQUE

2.8L DIESEL TORQUE SPECIFICATIONS

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
  
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
  
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
  		 —