Hyundai Engine D4DD Manual PDF
August 28, 2022 | Author: Anonymous | Category: N/A
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Download Hyundai Engine D4DD Manual PDF...
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ENGINE MECHANICAL SYSTEM (D4DD) GENERAL DESC RIPT ION ............................................. EM -2 SPECIFICATION ......................................... EM -6
INS PECT ION .......................................... EM -72 INSTAL LATION ...... ............ ............ ............ ............ ............ ........ .. EM -73 INTAKE MAINIFOLD
SPECIAL TOOL ..... ........... ............ ............ ........... ........... ............ ......... ... EM -12
COM PON ENT S ...... ............ ............ ........... ........... ............ ........ .. EM -75
DIA GNO SIS ...... ........... ........... ............ ........... ........... ........... ........... .......... .... EM -15
RE MO VA L ...... ........... ........... ............ ........... ........... ............ ........... ....... EM -76
ADJUS TMENT ..... ........... ............ ............ ........... ........... ............ ........... ..... EM -16
INS PECT ION .......................................... EM -76 INSTAL LATION ...... ............ ............ ............ ............ ............ ........ .. EM -77
TIMING SYSTEM TIMING GEAR ASSEMBLY COM PONE NTS ...... ............ ........... ........... ............ ............ ........ .. EM -17 RE MO VA L ...... ............ ........... ........... ............ ........... ........... ............ ...... EM -19 INSPEC TION ...... ............ ............ ........... ........... ........... ........... ........ .. EM -22
EXHAUST MANIFOLD COM PON ENT S ...... ............ ............ ........... ........... ............ ........ .. EM -78 RE MO VA L ...... ........... ........... ............ ........... ........... ............ ........... ....... EM -79 INSTAL LATION ...... ............ ............ ............ ............ ............ ........ .. EM -80 AIR CLEANER
REPL ACEM ENT ...... ............ ............ ........... ........... ............ ........ EM -25
COM PON ENT S ...... ............ ............ ........... ........... ............ ........ .. EM -81
INSTAL LATION ...... ............ ............ ........... ........... ............ ......... ... EM -26
INS PECT ION .......................................... EM -85
CYLINDER HEAD ASSEMBLY
LUBRICATION SYSTEM
COM PON ENT S ..... ........... ............ ............ ........... ........... ............ ......... ... EM -31
DESC RIP TIO N ............................................. EM -86
REMOVAL ................................................... EM -33
SPECIFICATION ......................................... EM -90
DI SA SS EM BL Y ..... ........... ............ ............ ........... ........... ............ ......... ... EM -36
TROUBL ESHOOTI NG ..... ........... ........... ........... ............ .......... .... EM -92
INSPECTION ............................................... EM -37
ADJUS TMEN T ...... ........... ........... ............ ............ ........... ........... ........... ..... EM -94
REPL ACEME NT ...... ............ ............ ........... ........... ........... ........... ........ .. EM -41
OIL PUMP
RE AS SE MB LY ..... ........... ............ ........... ........... ............ ........... .......... ..... EM -43 INSTALLATION ........................................... EM -44
COM PON ENT S ...... ............ ............ ........... ........... ............ ........ .. EM -96 DI SA SS EM BL Y ...... ............ ............ ........... ........... ............ ........ .. EM -98 OIL COOLER
CRANK CASE FLYWHEEL
COM PON ENT S ...... ............ ............ ........... ........... ............ ........ .. EM -99 DI SA SS EM BL Y ...... ............ ............ ........... ........... ............ ........ .. EM -100
COM PONE NTS ...... ............ ........... ........... ............ ............ ........ .. EM -46
INSPECT ION ...... ............ ............ ............ ........... ........... ........... ....... .. EM -100
RE MO VA L ...... ............ ........... ........... ............ ........... ........... ............ ...... EM -47
RE AS SE MB LY ............... ..................... ............ ........... ........... ...... EM -101
INSPEC TION ...... ............ ............ ........... ........... ........... ........... ........ .. EM -47 INSTAL LATION ...... ............ ............ ........... ........... ............ ......... ... EM -48 CYLINDER BLOCK ASSEMBLY
COOLING SYSTEM DESC RIP TIO N ............................................. EM -102
COM PONE NTS ...... ............ ........... ........... ............ ............ ........ .. EM -50
SPECIFICATION ......................................... EM -104
RE MO VA L ...... ............ ........... ........... ............ ........... ........... ............ ...... EM -52
TROUBL ESHOOTI NG ..... ........... ........... ........... ............ .......... .... EM - 106
DI SA SS EM BL Y ...... ............ ........... ........... ............ ............ ........ .. EM -55
WATER PUMP
INSPEC TION ...... ............ ............ ........... ........... ........... ........... ........ .. EM -55
COM PON ENT S .............. .................... ........... ........... ........... ....... EM -108
RE AS SE MB LY ...... ............ ............ ........... ........... ............ ......... ... EM -61
RE MO VA L ...... ........... ........... ............ ........... ........... ............ ........... ....... EM -109
INSTAL LATION ...... ............ ............ ........... ........... ............ ......... ... EM -62
INSPECT ION ...... ............ ............ ............ ........... ........... ........... ....... .. EM -110 INSTAL LATION ...... ............ ............ ............ ........... ........... ......... ... EM -111
INTAKE AND EXHAUST SYSTEM
RADIATOR
SPECI FICAT IONS ...... ............ ........... ........... ............ ............ .......... .... EM -66
COM PON ENT S .............. .................... ........... ........... ........... ....... EM -112
TROUBL ESHOOT ING ...... ........... ........... ............ ............ ......... ... EM -67
RE MO VA L ...... ........... ........... ............ ........... ........... ............ ........... ....... EM -113
TURBO CHARGER COM PONE NTS ...... ............ ........... ........... ............ ............ ........ .. EM -69
INSPECT ION ...... ............ ............ ............ ........... ........... ........... ....... .. EM -113 INSTAL LATION ...... ............ ............ ............ ........... ........... ......... ... EM -113
RE MO VA L ...... ............ ........... ........... ............ ........... ........... ............ ...... EM -71
EM -2
ENGINE MECHANICAL SYSTEM
L GENERAL GENERA DESCRIPTION
VALVE ALVE MECHANISM 1.
Heat resistan resistantt steel steel with with surface surface treatment treatment is us used ed ffor or intake and exhaust valve. valve. T The he valve seat angle is 45 .
2.
Valve alve stem seal, seal, install installed ed to the st stem, em, adjusts adjusts the the lubricant amount on the sliding surface of valve and valve guide.
EFA0EBB7
COMBUSTION CHAMBER
1.
Combustion Combustion chamber consists consists of cylinder cylinder head, head, pispiston, injector installed to the cylinder head and valve.
NOTE Valv alve e guide guide with with car carbon bon cutter cutter is used for exhau exhaust st valve.
Valve guide Injector
3.
Va Valve lve spring spring consists consists o off two v valve alve springs h havin aving g irregular pitches. The coil directions of inner and outer springs are opposite each other.
4.
Rocke Rockerr shaf shaftt is holl hollow ow cyli cylind ndric rical al rod, rod, who whose se each each end are sealed with sealing cap. Inner space of the shaft is an engine oil passage.
5.
Steel ball ball iis s inst installed alled to the lower end of push rod rod and rocker assembly is installed to upper end.
6.
Tappet has a cyl cylindrica indricall sh shape. ape. As enlarging enlarging the c conontacting surface contacted with camshaft, it helps to prevent partial wear and to increase its durability.
Cylinder head
Valve
Piston SUDEM7001L
2.
3.
Fuel is is supplied supplied to sup supply ply pump pump through through the the fuel filter instal ins talled led to the fra frame. me. Fuel Fuel is also also supplie supplied d to inj inject ectors ors throu through gh in inje jecti ction on pip pipe e No. No. 1, 2, 2, 3 and 4 in commo common n ra rail il assembly. Combustion Combustion is a accompli ccomplished shed when fuel is iinjecte njected d directly into combustion combustion chamber chamber,, at that time explosion explosion pressure applies to the piston directly.
Outer spring Inner spring
Rocker Rocker shaft
Valve spring Valve guide
4.
For better better e efficie fficient nt cool cooling ing of combustion combustion chamber, chamber, water director is press-fit under cylinder head floor, which induces the coolant flow.
Push rod Exhaust valve Intake valve
Tappet
Camshaft SUDEM7003L
Water director
Engine coolant SUDEM7002L
GENERAL 7.
EM -3
Camshaft Camshaft assembly assembly (1) c consist onsists s of cam sensor sensor plate, plate, thrust plate, cam and journal. Camshaft gear is coupled with the idler gear A (2).
3.
Cylinder Cylinder sleev sleeve e made of spe special cial c cast ast iro iron n is pressed fit into the crankcase.
2
Crank case Cylinder sleeve
1
SUDEM7006L SUDEM7004L
CRANKCASE AND CYLINDER SLEEVE 1.
Crankc Crankcase ase is manuf manufact acture ured d firmly with with cast iron iron to prevent stress concentration and deformation.
2.
The 5 camshaft camshaft b bushes ushes are install installed ed to the camshaf camshaftt bore of the crankcase. To facilitate the removal and installation of camshaft, inner diameter of bush is tapered to the rear side.
PISTON 1.
Piston pin type type is full float type and and piston piston pi pin n is offset from thrust.
2.
Marks on the the p piston iston indicat indicate e weight, weight, part number number and oversize. The front mark indicates the front direction of the engine. NOTE When assembling a piston, let the arrow mark ( →) faced to the center of cylinder head bolt hole.
Do not remove the cam sensor plate unless it is damaged.
Weight mark Part number
Front mark
SUDEM7005L SUDEM7007L
EM -4
ENGINE MECHANICAL SYSTEM 6.
PISTON RING Piston has two compress Piston compression ion rings and one oil ring. All sl slid iding ing surf surfac aces es of rings rings are are coat coated ed with with harde hardene ned d chro chrome me..
Cranksh Crankshaft aft gear gear (1) drives drives cam camsha shaft ft gear (2 (2), ), idler gear A (3), idler gear B (4), supply pump gear (5) and oil pump gear (6). 3
Compression ring No. 1 5 2
Compression ring No. 2
Oil ring No. 3 4
6
1 SUDEM7010L
SUDEM7008L
CRANKSHAFT MAIN BEARING CRANKSHAFT 1.
Crankshaft Crankshaft is forg forged ed with high-str high-strength ength alloy alloy built built in in with balance weight.
2.
Pin, journal and oil oil seal seal slidin sliding-surf g-surface ace are are hardened hardened with high frequency heat treatment to raise the resistance against frictional wear.
3.
Through oil passage at the the pin pin and journal, oil lubrilubricates main bearing. bearing. Oil flows to the pin for the lubrication of connecting rod bearing.
4.
Crankshaft Crankshaft pulley pulley and cranksha crankshaft ft gear are installed installed at the front end of crankshaft. crankshaft. The crankshaft crankshaft pulley pulley drives alternator and water pump using V-belt.
5.
Crankshaft Crankshaft damper damper p pulley ulley absorbs the distorting distorting vibration of crankshaft.
Upper main bearing has oil groove and oil hole which matches with oil hole of the crankshaft. Divided type thrust plate is installed to the both ends of the last bearing (No.5).
Upper main bearing (No. 5) Upper main bearing (No. 1)
Thrust plate Lower main bearing
Journal
SUDEM7011L
Crankshaft gear
Oil passage Pin Crankshaft damper pulley SUDEM7009L
GENERAL
EM -5
TIMING GEAR
FLYWHEEL
1.
Timing gear is is ins installed talled in th the e timing timing gear gear case case at the front of engine.
1.
2.
Each gear gear iis s hel helical ical gear manufacture manufactured d with high precision and its surface is treated by heat to enhance the durability.
Flywh Flywheel eel is made made of forg forged ed iron iron.. Pilot Pilot beari bearing ng of tran transsmission drive pinion is disposed at the center portion. Ring gear which can be geared with starter pinion is pressed fit at the circumferential of the flywheel.
2.
Processed Processed is formed at th the e outer outer diameter diameter of th the e flyfly-
3.
Timing marks are marked marked on the the gear gear.. When assemassembling, by aligning the timing marks, gears can be engaged correctly. correctly.
wheel to measure the engine rpm.
Ring gear Camshaft gear Supply pump gear
Processed
Idler gear A Crankshaft gear
Idler gear B
SUDEM7014L
SUDEM7012L
4.
Bushes are press-fit press-fit into idler gear, gear, which which rotates idler sh shaf aftt A (1) (1) an and d id idle lerr shaf shaftt B (2 (2). ). Id Idle lerr sh shaf aftt an and d ge gear ar oi oill hole provides oil passage to lubricate lubr icate bush and gear.
1
2
SUDEM7013L
EM -6 SPECIFICATION
ENGINE MECHANICAL SYSTEM ECC41378
Standard ([ ] indicates standard diameter)
Items
Limit
Corrective action
Serial 4-cylinder 4stroke common rail system
General Type
104mm 115mm 3,907cc 17.5 17.5 : 1 1-3-4-2 140ps/2800rpm (HD65, 72,78 Narrow) 140ps/2800rpm (HD65, 72,78 Wide) 140ps/2800rpm (County) 38kgf.m/1600rpm (HD65, 72,78 Narrow) 38kgf.m/1600rpm (HD65, 72,78 Wide) 38kgf.m/1600 38kgf .m/1600rpm rpm (County) 26kg/cm²
Cylinder inner diameter Cylinder Cylinder stroke Displacement Compression ratio Firing order Maximum Maxim um output
Maximum Maximu m torque
Compression Compres sion pressure (at 200rpm) Valve timing Intake Intak e valve valve open (BTDC) Intake Intak e valve valve close (ABDC) Exhaust valve open(BBDC) Exhaust valve close (ATDC)
Adjustment (As the difference between cylinders is within 4kg/cm² ) 20kg/cm²
19 53 60 16
Valve Intake valve length Exhaust valve length Outer diameter of intake valve stem Outer diameter of exhaust valve stem Valve face angle Thickness (margin) of intake/exhaust valve head Valve clearance (when engine is cold)
137mm 137mm 8.960~8.975mm 8.925~8.940mm 45 1.5mm 0.4mm
8.85mm 8.85mm 1.2mm
Gap between valve stem and valve guide Intake Exhaust
[9] 0.04~0.06mm [9] 0.07~0.10mm
Valve guide length Intake Exhaust
Valve seat width Intake Exhaust
Replace
1.5mm 1.5mm
Valve seat Replace insert
64mm 71.5mm
Valve sinkage Intake Exhaust Push rod run out
0.15mm 0.2mm
0.75~1.25mm 0.75~1.25mm
―
2.6~3.0mm 1.8~2.2mm
0.4mm 3.6mm 2.8mm
Replace Replace
GENERAL
EM -7 Items
Outer side valve Spring Free height Load instal installed led Winding direction Out of squareness Inner side valve spring Free length Load instal installed led Winding direction Out of squareness
Standard Standa rd ([ ] ind indicates icates standard standard diameter) diamet er)
Limit
66.1mm 26.5~29.3kg 26.5~29 .3kg To the right
63mm 23.7kg
1.5mm
2.1mm
60.0mm 11.5~12.7kg Left side 1.5mm
57mm 10.3kg
104.00~104.03mm Below 0.07mm 0.07mm 0.05mm [28] 0.045~0.096mm
Clearance between piston ring and piston ring groove Clearance No.1 ring
0.106~0.170mm
0.2mm
0.07~0.11mm 0.03~0.07mm
0.15mm 0.15mm
0.25~0.40mm 0.50~0.65mm 0.20~0.40mm
1.0mm 1.5mm 1.0mm
Piston ring ring end gap No.1 ring No.2 ring Oil ring Average protrusion of piston Gasket grade A Gasket grade B Gasket grade C
Piston Piston outer diameter Clearance between piston and cylinder sleeve Piston pin Outer diameter of piston pin Clearance between piston pin and piston pin hole Clearance Cleara nce between piston pin and connectconnecting rod end bush Cylinder sleeve Cylinder sleeve Inner diameter diameter
0.2mm
Replace Replace the piston ring
Replace
Repair with with oversize or replace
0.05mm 0.1mm
Out of roundness roundness
0.005mm
Out of cylinderness
0.015mm
100.25mm Below 0.01mm Below 0.03mm
Below 0.1mm 1mm 94.9~95.1mm 94.9~95.
0.2mm 94.6mm
Cylinder head Flatness of cylinder head bottom Length from cylinder head top to bottom
Measure the average protrusion and replace the gasket with the corresponding grade gasket
103.91~103.92mm 0.080~0.130mm
104.00~104.03mm
Replace Replac e
0.2mm
0.466~0.526mm 0.526~0.588mm 0.588~0.648mm
37.994~38.00mm 37.994~38.00mm 021mm 0.007~0.021mm 0.007~0. [38] 0.025~0.046mm 0.025~0.046mm
Corrective action
2.1mm
Cylinder block Cylinder bore Torsion of upper crankcase Flatness of gasket surface Out of squareness squ areness of gasket surface e between tappet and crankcase tappet hole Clearance Clearanc
No.2 ring Oil ring
Replace Replace bush bush
Repair with oversize or replace
Repair or replace
EM -8
ENGINE MECHANICAL SYSTEM Items
Connecting rod Connecting Connect ing rod twist and distortion distortion Oil clearance clearance Connecting Connect ing rod bearing Free length of connecting rod bearing Bearing crush (measured load 600kg) Connecting rod endplay Camshaft Intake Intak e cam max. length Intake Intak e cam min. length Intake cam lift Exhaust cam max. max. length Exhaust cam min. min. length Exhaust cam cam lift endplay Camshaft endplay Camshaft e between camshaft journal and bushing Clearance Clearanc
Standard Standa rd ([ ] ind indicates icates standard standard diameter) diamet er)
Limit
― 0.04~0.099mm
0.05mm 0.2mm
―
Min. 69.5mm ― 0.6mm
34.53~34.57mm 0.15~0.45mm 47.105mm 39.910mm 7.195mm 46.979mm 39.658mm 7.321mm 0.05~0.22mm Stamp mark #1,2,3,4 ([54.5] 0.04~0.09mm) Stamp mark #5
Corrective action
Repair or replace
0.3mm
Rep Replace busing
0.15mm
([53] 0.04~0.09mm) Crankshaft Out of roundness of pin and journal Out of cylindricity cylindricity of pin and journal Crankshaft distortion (measured at journal No.1 and No.5) Crankshaft endplay
Crankshaft main bearing Crankshaft Oil clearance (#1, 2, 4, 5) Oil clearance (#3) Free length Bearing crush( measured load 500kgf) Timing gear backlash gear backlash Crankshaft gear Crankshaft gear and idler gear A Idler gear A and A and cam shaft gear Idler gear A and A and idler gear B Idler gear B and and supply pump gear Camshaft gear and power steering pump gear Crankshaft Cranks haft gear and oil pump gear Power steering pump gear and vacuum pump gear Idler gear endplay endplay
Cl Clea eara ranc nce e be betw twee een n id idle lerr busin using g and and id idle lerr sh shaf aftt Flywheel Distortion of of frictional surface Height of fri Run-out of frictional frctional frictional ictional surface surface (while installed)
Below 0.01mm 0.01mm Below 0.006mm 0.006mm Below 0.02mm 0.02mm
0.03mm 0.03mm 0.05mm
0.10~0.26mm 0.10~0.26 mm
0.4m m
0.036~0.098mm 0.036~0.098mm 8mm 0.056~0.118mm 0.056~0.11 ― 101mm 41.061~41.101mm 41.061~41.
0.15mm 0.15mm Min 69.5mm ―
Replace thrust plate
0.062~0.159mm 0.068~0.175mm 0.062~0.160mm 0.073~0.169mm 0.075~0.160mm 0.049~0.169mm 0.075~0.160mm
Repair or replace
0.05~ 0.22m m [4 [45] 5] 0. 0.02 025~ 5~0. 0.06 06mm mm
Replace
0.3m m
Replace thru thrust st plate
0.1mm
Replace busing
Below 0.05mm
0.2mm
Repair or
24.5mm Below 0.1mm
23.5mm 0.2mm
replace
GENERAL
EM -9
TIGHTENING TIGHTENI NG TORQUE TORQUE Screw size O.D×pitch (mm)
Items (diameter × length) Cylinder block
Main bearing cap bolt
M14×2.0
Front plate flange bolt(8 ×16)
Rear oil seal slinger flange bolt(6 ×12)
Supply pump side timing gear case mounting mountin g bolt Supply pump flange bolt
Oil jet check valve Rear plate flange bolt(10 ×22) Rear stiffener bracket flange bolt(8 ×55)
Rear stiffener stiffener bracket bracket flange bolt (10×90)
Engine mounting bracket mounting bolt
Oil strainer flange bolt (8 ×40)
Oil pan mounting flange bolt (8 ×12)
4 49 9 +9 0
5 .0 +9 0
36.4+90
1 8 .6 ~2 7 .4
1 .9 ~2 .8
13.8~ 20.4
―
7.8~11.8
0 .8 ~1 .2
5.8~ 8.7
―
1 8 .6 ~2 7 .4
1 .9 ~2 .8
13.8~ 20.4
―
1 6 .7 ~2 5 .5
1 .7 ~2 .6
12.4~ 18.9
M12×1.25
2 9.4
3.0
21.8
M10×1.5
6 3.7
6.5
47.3
―
1 8 .6 ~2 7 .4
1 .9 ~2 .8
13.8~ 20.4
―
3 8 .2 ~5 8 .8
3 .9 ~6 .0
28.4~ 43.6
32.3~49
3 .3 ~5 .0
24~36.4
2 4.5
2.5
18.2
―
1 8 .6 ~2 7 .4
1 .9 ~2 .8
13.8~ 20.4
―
1 8 .6 ~2 7 .4
1 .9 ~2 .8
13.8~ 20.4
1 8. 8.6~27.4
1 .9 ~2 .8
13.8~ 20.4
1 8 .6 ~2 7 .4
1 .9 ~2 .8
13.8~ 20.4
34.3~39.2 34
3 .5 ~4 .0
25.4~ 29.1
M8×1.2
Oil level gauge mounting flange bolt(8×16)
Ib-ft
M10×1.5
Oil strainer flange bolt(8 ×16)
kgf.m
―
―
Crankcase oil line set screw Lubrication system
Nm
―
Oil pan drain plug
M14×1.5
O i l fi l ter el em ent
M26×1.5
1 9.6
2.0
14.5
Oil cooler by-pass
M16×1.5
1 9.6
2.0
14.5
Oil cooler relief valve
M16×1.5
1 9.6
2.0
14.5
Oil cooler drain plug
M14×1.5
3 4.3
3.5
25.4
Oil cooler mounting flange bolt
Oil line flange bolt Oil line eyebolt
Idler gear oil supply pipe
Turbo charger oil pipe eyebolt
Turbo charger oil pipe flange bolt(8 ×16) Oil pump pump
Oil pump pump mount mountin ing g fl flan ange ge bolt bolt(8 (8 ×55)
Cylinder head
Cylinder head mounting bolt
―
1 8 .6 ~2 7 .4
1 .9 ~2 .8
13.8~ 20.4
―
7.8~11.8
0 .8 ~1 .2
5.8~ 8.7
―
1 8 .6 ~2 2 .5
1 .9 ~2 .3
13.8~ 16.7
―
1 8 .6 ~2 2 .5
1 .9 ~2 .3
13.8~ 16.7
―
1 8 .6 ~2 2 .5
1 .9 ~2 .3
13.8~ 16.7
―
1 8 .6 ~2 7 .4
1 .9 ~2 .8
13.8~ 20.4
―
1 8 .6 ~2 7 .4
1 .9 ~2 .8
13.8~ 20.4
1 14 4 7 +9 0
1 5 .0 +9 0
109+ 90
M14×2.0
Cylinder head stud (10×25)
―
3 4.3
3.5
25.4
Cylinder head stud (10×48)
―
3 4.3
3.5
25.4
EM -10
ENGINE MECHANICAL SYSTEM Screw size size O.D×pitch O.D×pi tch (mm)
Items (diameter × length) Fan and pulley
Fan clutch clutch mounting flange bolt (8)
Fan clutch spring washer bolt(8×25)
Engine coolant temperature sensor and gauge Thermostat case flange bolt(10 ×25)
Timing system
Ti m i n g g e a r c a s e f l a n g e b o l t Rockerr cover mounting flange bolt Rocke
Cam plate and thrust plate flange bolt
Cam plate and oil drain plug
2 1 .6 ~3 2 .3
2 .2 ~3 .3
16~ 24
―
1 6 .7 ~2 5 .5
1 .7 ~2 .6
12.4~ 18.9
3.9~5.9
0 .4 ~0 .6
2.9~ 3.6
Bleeder Bleeder m system syste
2 1 .6 ~3 2 .3
2 .2 ~3 .3
16~ 24
―
2 9 .4 ~3 9 .2
3 .0 ~4 .0
21.8~ 29.1
―
3 5 .3 ~5 2 .9
3 .6 ~5 .4
26.2~ 39.3
M8×1.25
1 8 .6 ~2 7 .4 18
1 .9 ~2 .8
13.8~ 20.4
M8×1.25 1.25
1 12 2 .7 ~1 5 .7
1 .3 ~1 .6
9.5~11.6
―
1 8 .6 ~2 7 .4
1 .9 ~2 .8
13.8~ 20.4
―
5 8 .8 ~7 8 .4
6 .0 ~8 .0
43.6~ 58.2
1 8 .6 ~2 7 .4
1 .9 ~2 .8
13.8~ 20.4
1 8 .6 ~2 7 .4 18
1 .9 ~2 .8
13.8~ 20.4
0 .8 ~1 .3
5.8~ 9.5
―
Idler gear Idler gear A, B mounting bolt
M8×1.25 1.25
Blow-by return pipe and blow-by hose Protect clip flange nut
PCV blow-by return coating clip flange bolt
by return pipe mounting flange bolt Blow-by Blow-
Alternator adjust plate mounting bolt(10 ×20) nator adjust shaft mounting nut (10) Alternator Alter
nator assembly mounting bolt Alternator Alter
Vacuum pump pipe tightening bolt m pump mounting flange bolt Vacuum Vacuu Piston and connecting rod
parate mounting flange bolt Oil se separate
Alter nator Alternator and m vacuum vacuu pump
― ―
Camshaftt gear flange bolt Camshaf
y pump of flower valve Supply Suppl
Connecting rod and connecting rod bearing cap mounting bolt
Ib-ft
Thermostat cover case flange bolt
kgf.m
―
nge nut (6) Fan fla flange Thermostat Thermostat g housing housin
Nm
―
7.8~12.7
― ―
9.8~14.7
―
1 8 .6 ~2 7 .4
1 .9 ~2 .8
13.8~ 20.4
―
7.8~11.8
0 .8 ~1 .2
5.8~ 8.7
―
3 5 .3 ~5 2 .9
3 .6 ~5 .4
26.2~ 39.3
―
3 5 .3 ~5 2 .9
3 .6 ~5 .4
26.2~ 39.3
―
1 8 .6 ~2 7 .4
1 .9 ~2 .8
13.8~ 20.4
M12×134 78.4~107.8
8 .0 ~1 1
5 8 .2 ~8 0
3.9~5.9 1 8 .6 ~2 7 .4
0 .4 ~0 .6 1 .9 ~2 .8
2.9~ 3.6 13.8~ 20.4
29.4+90
3 .0 +9 0
2 1 .8 +9 0
39.2+40
4 .0 +4 0
2 9 .1 +4 0
588
60
43 6
× M6 14 M8×16
M12.5×1.25
1.0~1.5
7.3~10.9
Flywheel Flywheel and er damper damp ey pulley pull
Flywheel mounting bolt
M14×1.5
Cran Cranks ksha haft ft da damp mper er pu pull lley ey moun mounti ting ng nu nutt
M24 M24×1.5
Starter motor
Mounting Mounti ng flange bolt (12 ×25)
―
78. 78.4~107. 107.8 8
8.0~1 .0~11 1.0
58.2 8.2~80
Mounting Mounti ng flange bolt (12 ×55)
―
3 7 .2 ~5 3 .9
3 .8 ~5 .5
2 7 .6 ~4 0
―
3 7 .2 ~5 3 .9
3 .8 ~5 .5
2 7 .6 ~4 0
Mounting Mounti ng flange bolt (12) Glow plug Glow plug
Glow plug harness flange nut Plain washer nut
―
3.9~5.9
0 .4 ~0 .6
2.9~ 3.6
―
1~ 1.5
0.1~0.15
0.7~ 1.1
GENERAL
EM -11 Screw size size O.D×pitch O.D×pi tch (mm)
Items (diameter × length) Intake manifold
or mounting flange bolt Actuator Actuat
Butterfly valve shaft mounting nut (8)
Intake manifold front hanger mounting flange bolt (10×20) Intake manifold mounting flange bolt (8 ×20) Exhaust manifold
Exhaust manifold heater protector protector cover cov er mounting mounting bolt Exhaust manifold assembly self lock Exhaust e nut Flange Flang
Engine cover Turbo Turbo ger charger char Fuel em system syst
Top shield bolt screw
Injector pipe (No.1, 2, 3, 4)
―
1 6 .7 ~2 7 .4
1 .7 ~2 .8
12.4~ 20.4
―
32.3~49
3 .3 ~5 .0
24~36.4
―
1 8 .6 ~2 7 .4
1 .9 ~2 .8
13.8~ 20.4
4 1.2
4.2
30.5
7.8~11.8
0 .8 ~1 .2
5.8~ 8.7
Engine speed sensor mounting bolt
Booster pressure sensor (M.A.P) Booster mounting moun ting bolt
5.8~ 8.7
M10×1.25
Pipe Pipe (betw (betwee een n suppl supply y pump pump and and commo common n ra rail il))
Cam speed sensor mounting bolt
0 .8 ~1 .2
8.7
Fuel return A and rear plate clamp plate bolt
Sensor Sens or
7.8~11.8
1.2
Fuel return A and fuel supply hose Fuel return ect clip flange bolt protect prot
Common rail bracket Flange bolt
1 1.8
Injector Inject or nozzle bridge bolt
―
―
Common Comm on rail fuel return B mounting screw
Ib-ft
Turbo charger oil pipe eyebolt Fuel suction hose
kgf.m
M8×1.25
o charger and intake pipe clamp band Turbo Turb
Nm
M9×2.5
3.9
0.4
2.9
M8×1.25
1 1.8
1.2
8.7
―
1 4 .7 ~1 9 .6
1 .5 ~2 .0
10.9~ 14.5
―
1 6 .7 ~2 2 .5
1 .7 ~2 .3
12.4~ 16.7
―
9.8~19.6
1 .0 ~2 .0
7.3~ 14.5
―
3 .9 ~5 .9
0 .4 ~0 .6
2.9~ 3.6
―
39.2~49
4 .0 ~5 .0
29.1~ 36.4
―
3 0 .4 ~3 4 .3
3 .1 ~3 .5
22.5~ 25.4
―
2 1 .6 ~3 2 .3
2 .2 ~3 .3
16~ 24
―
39.2~49
4 .0 ~5 .0
29.1~ 36.4
―
7.8~11.8
0 .8 ~1 .2
5.8~ 8.7
―
7.8~11.8
0 .8 ~1 .2
5.8~ 8.7
―
7.8~11.8
0 .8 ~1 .2
5.8~ 8.7
EM -12 SPECIAL TOOL
ENGINE MECHANICAL SYSTEM E2E65F7D
Tool (part no. and part name)
Shape
09212-41200 09212-41200 Camshaft Camsha ft bushing remover and installer installer
Usage Installation and removal of camshaft bushing
KDDEM5015A
09246-41000 Idler gear bushing puller
Installation and removal of connecting rod bushing
KDDEM5016A
09222-83200 Piston guide clamp
Installation of piston
KDDEM5017A
09222-83300 Valve spring compressor
Instal Ins tallat lation ion and rem remov oval al of va valv lve e cot cotter ter
KDDEM5018A
09221-41100 Valve guide remover
Removal of valve guide
KDDEM5019A
GENERAL Tool (part no. and part name)
EM -13
Shape
09221-41150 Valve guide installer
Usage Installation of valve guide (Use together with 09211-41100)
KDDEM5020A
09222-45100 Valve stem seal installer
llation of valve stem seal Installation Insta
KDDEM5021A
09353-45100 Air compressor adapter
Measurement of compression pressure
KDDEM5022A
09222-83200 Piston ring tool
Installation Ins tallation and removal of piston ring
DEM5023A KD KDDEM5023A
EM -14 Tool (part no. and part name)
ENGINE MECHANICAL SYSTEM
Shape
09222-45000 Rocker bush puller
Usage Instal Ins tallat lation ion and remov removal al of roc rocke kerr bus bush h
KDDEM5024A
09211-41000 Oil seal slinger installer
Installation and removal of crankshaft Installation rear oil oil seal slinger
KDDEM5025A
GENERAL DIAGNOSIS
EM -15 E252285B
Symptom Compression pressure is excessively low
Possible cause
Cylinder head Gasket is melt Piston ring is worn or damaged Piston or cylinder is damaged Valve seat worn or damaged
Maintenance Replace gasket (check the status of head surface, block head) Replace the ring Repair or replace piston or cylinder block
Engine oil depleted Oil pressure pressure switch switch fail Oil filter clogged Oil pump gear or case is worn Engine oil viscosity is low Oil relief valve stuck (open) Excessive bearing clearance
Repair or replace valve or seat ring Add engine oil Replace oil pressure switch Replace the filter with new one Replace the gear or case Replace engine oil Repair valve Replace the bearing
Oil relief valve stuck (close)
Repair the relief valve
Connecting rod noise or main bearing noise
Improper oil supply Low oil pressure Low engine oil viscosity Excessive bearing clearance
Check the engine oil level Refer to ’oil pressure is excessively low’ Replace engine oil Replace the bearing
Excessive engine vibration
Engine mounting bolt is loose Transmission mounting bolt is loose Cross member bolt is loose Engine mounting rubber is damaged Transmission mounting rubber r ubber is damaged
Retighten Retighten Retighten Replace Replace
Engine coolant level is low
Engine coolant leak Radiator core joint is damaged Radiator and heater hose corroded and cracked Radiatorr cap valve or spring setting Radiato is defective Thermostat defect Water pump defect
Oil pressure is excessively low
Oil pressure is excessively high
Forei Foreign gn substance substance intrusion intrusion into
Replace
engine coolant coolant Thermostat is defective Radiator cap is defective Cooling system flow is defective Drive belt is loose Water pump is defective Temperature wiring is defective Radiator fan is defective Engine coolant is low
Replace Replace Replace Adjust or Replace Replace Repair or replace Repair or replace Add coolant
Thermostat is defective Temperature wiring is defective
Replace Repair or replace
Oil cooling cooling system system leaks
Hose or pipe pipe connect connection ion is loose loose Hose and pipe is cracked or damaged
Retighten Replace
Radiator fan is inoperative
D am ag e
Repair or replace
Radiator is clogged
Replace
Engine coolant temperature is abnormally high
Engine coolant temperature is abnormally low
EM -16
ENGINE MECHANICAL SYSTEM
Symptom Sympto m Ex Exha haus ustt ga gas s le leak aks s Unusuall noise Unusua
ADJUSTMENT
Possible cause
Maintenance
Conn Connec ecti tion on is loo oose se Pipe or muffler is damaged
Retighten Repair or replace
plate inside the muffler fell off Baffle plate Baffle Rubber hanger Rubber hanger is damaged Pipe or muffler or muffler interferes with the body
Replace Replace Replace Replac e Repair
Pipe or muffler muffler is damaged
Repair or or replace 7.
E148032F
Cran Crank k th the e engi engine ne and and me measu asure re the compr compres essi sion on prespressure.
COMPRESSIO COMPR ESSION N PRESSURE PRESSURE 1.
2.
CAUTION
Before Before performi performing ng on-vehi on-vehicle cle inspect inspection ion,, check check to see whether engine oil, starter motor and battery are in normal condition.
a. b.
Start the the eng engine ine and and warm warm up until until the cool coolant ant temtemperature reaches 80~90 C.
c.
3.
Stop the engine and remove remove tthe he ECM fuse. fuse.
4.
Remove Remove all inject injectors ors from cylinder cylinder head. 8.
Take care that fue fuell is not injecte injected. d. Sin Since ce compres compression sion pressure pressure var varies ies depe dependnding on the engine speed, be careful in measuring. Since Since w worn orn a amounts mounts of eac each h cylinde cylinderr are different, measure the pressure at all cylinders.
Measure the c compres ompression sion pressu pressure re of all cylinders cylinders to see if all compression pressures are within the limit.
CAUTION Be careful that foreign materials do not intrude through the injector installation hole.
5.
6.
Cr Cran ank k the the engi engine ne to remov remove e th the e fo fore reig ign n ma mater teria ials ls from from cylinders. Install Install compression compression gauge adaptor adaptor (09353-4 (09353-45100) 5100) together get her with gasket gasket and the then, n, connec connectt the compres compressio sion n gauge.
Items
Compression pressure (200rpm)
Standard
Limit
Corrective action
Each 26kg/cm² 20kg/cm² Check cylinder Difference between cylinders
―
4kg/cm² Check
Compression pressure gauge
9.
09353-45100
SUDEM7015L
If the the compress compression ion pressure pressure differe difference nce of of any any cy cylinder linder exceeds the limit, fill some engine oil through injector hole and measure the compression pressure of the cylinder again. 1)
If the com compre pressi ssion on pres pressur sure e increase increases, s, it indicates that the piston, piston ring or cylinder wall is worn or damaged.
2)
If tthe he compressi compression on pr pressure essure does not increas increase, e, iitt indicates that valve is stuck, valve contact is poor or pressure is leaking through the cylinder head gasket.
TIMING SYSTEM
EM -17
TIMING SYSTEM TIMING TIMI NG GEAR ASSEM ASSEMBL BLY Y COMPONENTS
E2F63E1E
58.8~68.6 (6.0~7.0, 43.6~50.9)
26 25
23 22 19 17
20 21
18
11
16
10
15
18.6~27.4 (1.9~2.8, 13.8~20.4)
9 24
14
8
13 3.9~5.9 (0.4~0.6, 2.9~4.4)
7
12
6
5 4 3 60.0
2 1
Cam sensor plate
20. Thrust plate 21. Idler gear A 22. Idler shaft 23. Oil pump gear 24. Crankshaft gear 25. O-ring O-ring 26. Power steering oil pump
Tightening Torque : Torque : Nm (kgf.m, Ib-ft)
SUDEM7016L
EM -18
ENGINE MECHANICAL SYSTEM
If the cam sensor plate is not damaged, do not remove.
2 1
18.6~27.4 (1.9~2.8, 13.8~20.4) 7
8
58.8~78.4 (6.0~8.0, 43.6~58.2)
6 5 4 3
1. 2. 3. 4. 5. 6. 7. 8.
Thrust plate Semicircular key No.1 camshaft bush No.2 camshaft bush No.3 camshaft bush No.4 camshaft bush No.5 camshaft bush Sealing cap
Tightening Torque : Torque : Nm (kgf.m, Ib-ft)
SUDEM7017L
TIMING SYSTEM REMOVAL 1.
EM -19 4.
E812C03D
Remove Remove the vacu vacuum um p pump ump ((1) 1) an and d al alternator ternator assembly (2).
Loosen the alternator alternator (1) ttensio ensioner ner screw screw (2) and and reremove the V-belt(3).
2
2 1 SUDEM7021L
1 3 SUDEM7018L
2.
5.
Remove Remove the power steering pump (1).
Remove Remove the coolin cooling g ffan an (1) and auto auto cooling cooling fan coupling (2). 1
2
1
SUDEM7022L
6. SUDEM7019L
3.
Align the ti timing ming mark "0" "0" of crank crankshaft shaft damper pulle pulley y (1) (1) with with the the indi indica cato torr (2) (2) of the the timi timing ng gea gearr case case.. T The hen, n, cylinder cylind er No. 1 is positioned at TDC of compressi compression on stroke.
Remove Remove the water pump p pulley ulley (1) and water pump assembly (2).
2
2
1 1 SUDEM7023L
SUDEM7020L
EM -20 7.
ENGINE MECHANICAL SYSTEM
Remove Remove the crank crankshaft shaft damper pulley pulley nut nut (2) and reremove the crankshaft damper pulley (1).
NOTE Check the front oil seal (1) state. If it is normal, do not Check remove it.
2
1
1
SUDEM7024L
8.
Remove Remove the engin engine e coola coolant nt temp tempera erature ture se senso nsorr (1) connector and remove the thermostat housing (2) from the cylinder head.
SUDEM7027L
CAUTION Before removing Before removing the timing gear gear ca case, se, re remove move timing gear case mounting bolt (1) at the supply pump first. If the mounting bolt at the supply pump is not removed, timing gear case will not be removed. removed.
2
1 SUDEM7025L
9.
Remove Remove the the cam speed speed sensor sensor (1) (1) from the the timing timing gear case and then remove the timing gear case (2).
1
1 SUDEM7028L
2
SUDEM7026L
TIMING SYSTEM
EM -21 13. Remove Remove the idler idler gear B (1).
10. Remove Remove the front oil seal seal slinger slinger (1).
1 1 SUDEM7029L
11. Remove Remove the oil pump gear gear (1).
SUDEM7032L
14. Remove Remove the supply supply pump gea gearr (1). 1
1 SUDEM7030L
12. Remove Remove the idler idler gear A (1) (1)..
SUDEM7033L
15. Remove the camshaft assembly. assembly. 1. Re Remo move ve the the thru thrust st plat platee-mo moun unti ting ng bolt bolt (4) (4) throu through gh cam cam sens sensor or plat plate e (2) hol hole e (3) (3) of cam camsh shaf aftt gear (1).
1
4
SUDEM7031L
1
3
2 SUDEM7034L
EM -22
ENGINE MECHANICAL SYSTEM NOTE
Do not remove the cam sensor plate (2), if it is not damaged.
2.
1
When removing removing the camsha camshaft ft assembly assembly (1), handle cam bush carefully not to be damaged. 1
2
SUDEM7037L
INSPECTION 1.
EB5EDDCB
Measure Measure iinner nner diamet diameter er of idler idler gea gearr (1) and ou outer ter diamet dia meter er of idler idler shaf shaftt (2). If the gap e exce xceeds eds the limi limit, t, replace the idler gear bush.
SUDEM7035L
Reference gap between idler bush and idler shaft ([ ]indicates reference diameter): [45] 0.025~0.06mm Limit: Lim it: 0.1mm 0.1mm
16. Remove Remove the front front plate (1 (1). ).
1
1
2 SUDEM7036L
CAUTION When removing the front plate (1), do not remove the bolts (2) processed with spacers. If they were removed, assemble them based on the dowel pin and then sealant must be applied between front plate and spacers.
SUDEM7038L
2.
Measure cam max (1) and min diamete diameterr (2). (2). Replace the camshaft assembly, if it exceeds the limit. NOTE The difference between the max and min diameter is the lift of the cam
TIMING SYSTEM
EM -23
Unit: mm
Items
Intake Intak e cam Exhaust cam
Min cam diameter (2)
Max cam Cam lift diamete dia meterr (1)
39.910
47.105
7.195
39.658
46.979
7.321
CAUTION CAUTI ON Since taper cam is used, measure it as shown in the figure.
Measuring position
A
B
6.5m m
6 .5m m
SUDEM7040L
4.
Measure the d distortion istortion of c camshaft amshaft.. If iitt exceeds exceeds the limit, replace or repair it with press.
Distortion of camshaft: camshaft: 0.02mm NOTE
1
Place the Place the cams camshaf haftt on the the pre preci cisi sion on bl bloc ock k and and turn turn the the shaft in1 revolution. revolution. And read the dial indica indicator tor.. camshaft cam The distortion of the camshaft is a half of the meaement. sur ement.
2 A
B
SUDEM7039L
3.
Measure the outer diame diameter ter of of camshaft camshaft journal and the inner diameter of camshaft bush in the crankcase. If the gap exceeds the limit, repair the camshaft cam shaft bushing with oversize.
Outer diameter of camshaft camshaft journal Journal No. No. # 1, 2, 3 and 4: 54.44~54.46 54.44~54.46 mm Journal No. # 5: 52.94~52.96 52.94~52.96 mm Inner diameter of camshaft bushing Journal # 1, 2, 3 and 4: 54.5mm Journal Jou rnal # 5: 53mm 53mm Gap between camshaft journal and bushing Reference: Refe rence: [54.5] 0.04~0.09mm 0.04~0.09mm [53] 0.04~0.09mm Limit: 0.15mm
SUDEM7041L
EM -24 5.
ENGINE MECHANICAL SYSTEM
Measure the camshaf camshaftt (1) endplay endplay. If iitt e exceeds xceeds the limit, repair or replace it.
2
1
Camshaft endplay Reference: Refer ence: 0.05mm~0.22mm 0.05mm~0.22mm Limit: Lim it: 0.3mm 0.3mm
1
SUDEM7044L
c.
Idler Idler g gear ear A (1 (1)) and and id idler ler gear B (2) (2)
Reference: Refe rence: 0.062~0 0.062~0.160mm .160mm 1 SUDEM7042L
6.
Measure the bac backlash klash of each each gear and replace replace it if necessary. NOTE When measuri measuring ng the bac backla klash, sh, fix the gear gear contact contacting ing the corresponding gear and move the gear to the left and right to measure the backlash.
a.
Crankshaft Crankshaft gear (1) and idler gear A (2) (2) 2
Reference: Refer ence: 0.062~0.159mm 0.062~0.159mm
SUDEM7045L
d.
2
Idler gear B (1) (1) and and supply pump gear (2)
Reference: Refe rence: 0.073~0 0.073~0.169mm .169mm 2
1 SUDEM7043L
b.
Idler gear A (1) (1) and camshaft camshaft gear (2)
Reference: Refer ence: 0.068~0.175mm 0.068~0.175mm
1 SUDEM7046L
TIMING SYSTEM e.
EM -25
Oil pump gear (1) and crankshaft crankshaft gear (2)
Reference: Refer ence: 0.049~0.169mm 0.049~0.169mm Camshaft bush
09212-41200
SUDEM7049L 1
c.
Ins Instal talll tthe he cam camsha shaft ft bush bush (1). (1).
2 SUDEM7047L
REPLACEMENT 1.
NOTE When assemb assemblin ling g cam camsha shaft ft bu bush, sh, dis distin tingui guish sh the bush bush by the the numb number er mark marked ed outs outsid ide, e, whic which h tell tells s the install installing ing positio position. n. If the marked number numbers s are
EF56BCEF
Replacem Replacement ent of idle idlerr ge gear ar b bush ush Repla Rep lace ce id idle lerr gear gear bush bush usin using g th the e spec specia iall to tool ol (0 (0924 9246641000).
illegible, measure the inner diameter and width of the bush.
Unit: mm TION CAUTION CAU a. b.
When When assembling assembling the bush, align the bush oil hole with gear oil hole. Check Check to see whether whether the cleara clearance nce betwee between n bush and idler gear shaft satisfies the reference. Removal
Assembly
Bush No. (From the front of engine)
Carved mark
Outer diameter
Inner di Width ameter
No.1
1
58.5 19
5 4.5
33
No.2
2
58.2 69
5 4.5
22
No.3
3
58.0 19
5 4.5
22
No.4
4
57.7 69
5 4.5
22
No.5
5
57.0 19
5 3.0
22
09246-41000
Idler gear
09246-41000
Idler gear bush
Idler gear
Idler gear oil hole SUDEM7048L
2.
Replacem Replacement ent of cam camsha shaft ft bush bush a. Remov Remove e the sea seali ling ng cap from the crank crankca case se camshaft hole. b.
Remove Remove the the ca camshaft mshaft bush using the special special tool tool (09212-41200).
1
SUDEM7050L
EM -26 d.
ENGINE MECHANICAL SYSTEM Press fit tthe he bush bush using using the the special special tool (09212 - 41200) so that the camshaft bush end aligns crankcase end.
2.
Install Install the crankshaft crankshaft gear (1).
NOTE When ins instal tallin ling g the camshaf camshaftt bushin bushing, g, ali align gn the oil hole of bush with crankcase oil hole (2). 1
Camshaft bush 09212-41200
1 SUDEM7053L
3.
2
Install Install the idler shaft A (1) and iidler dler shaft B (2). CAUTION
Crankcase
SUDEM7051L
INSTALLATION 1.
EEFAD1F1
a.
Whe When n insta installing lling the idler idler sha shaft ft A and B, do no nott
b.
tighten the mounting bolts at once. Afte Afterr insta installing lling the idler idler sha shaft ft A and B, che check ck to see whether the shaft rotates smoothly.
Instal Installl the the fron frontt plat plate e (1). (1). 1
2
SUDEM7054L
1 SUDEM7052L
TIMING SYSTEM 4.
EM -27
Install Install idler idler gea gearr A and B.
1
CAUTION a.
When When installing, installing, al align ign the timing mark mark "1" of idler gear A (1) with the timing mark "1" of crankshaft gear (2). 1
2
SUDEM7057L
b.
Pres Press s fit th the e camshaf camshaftt gear assem assembl bly y (1) of tthe he cam plate (2) so that it faces outward.
2 SUDEM7055L
b.
When When installing, installing, al align ign the timing mark mark “ 4” of idler gear B (1) with the timing mark “ 4” of idler gear A (2).
2
1
1 SUDEM7058L
c.
Measure the endplay endplay between camsha camshaft ft gear (1) and thrust plate (2) and install them as the clearance to be within the reference.
Reference: Refer ence: 0.05~0. 0.05~0.22mm 22mm 2 SUDEM7056L
5.
1
Install Install the camshaft camshaft g gear ear assembly assembly.. a. Install the th thrust rust p plate late (1) (1) so that the the "F" mark of its oil hole faces to the camshaft gear (2).
2
SUDEM7059L
EM -28 d.
ENGINE MECHANICAL SYSTEM In Inst stal alll the the ca cams msha haft ft as asse semb mbly ly (1 (1)) to th the e crankcase.
6.
Install the supply pump gear gear.. CAUTION
1
When installing, align the timing mark " 5" of supWhen ply pump (1) with the timing mark "5" of idler gear B (2).
1
SUDEM7060L
2
CAUTION When insta Whe installi lling, ng, align the timing timing mark mark "2" of camshaft gear A (1) with the timing mark "2" of idler gear A (2).
SUDEM7063L
7.
Install Install the oil pum pump p ge gear ar (1). (1).
1 2
1
SUDEM7061L
SUDEM7064L
e.
Inst Instal alll the the thr thrus ustt pl plat ate e (2 (2)) moun mounti ting ng bolt (3) through the hole of camshaft cam plate hole (1).
8.
Install Install tthe he front oil seal slinger slinger (1). (1).
2 3
1 1 SUDEM7062L
SUDEM7065L
TIMING SYSTEM 9.
EM -29 11. Install the water pump pulley (1) and water pump assembly (2).
Install the front timin timing g gear gear case case (1).
Tightening Tighten ing torque: 21.6~32.3 21.6~32.3 Nm (2.2~3.3 kgf.m, 16~24 Ib-ft)
2
CAUTION a. b.
A pp pp lly y t he Loctite #5699 or equivalent on the ly sur face of timin g gear case (1), (1), and and assembly assemb then assemble assemble it within 3 minutes. Do n o ott s tart the engine within 1 hour after installing the timing gear gear case. 1
SUDEM7068L
1
12. Install the crankshaft crankshaft damp damper er pulley (1) and damper pulley mounting nut (2). Tightening Tighten ing torque: torque: 588 Nm (60 kgf.m, 436 Ib-ft)
SUDEM7066L
10. Install the the power steering steering pump (1) (1).. 1
1 2
SUDEM7069L
SUDEM7067L
EM -30
ENGINE MECHANICAL SYSTEM
13. Install the vacuum pump (1) and alternator assembly (2).
2 1 SUDEM7070L
14. Install the cooling cooling fan (1) and automatic cooling cooling fan coupling (2). 2
1 SUDEM7071L
15. Install the V-belt (1). Adjust the belt tension using the tension adjusting screw (2) of alternator.
2
1 SUDEM7072L
CYLINDER HEAD ASSEMBLY
EM -31
CYLINDER HEAD CYLINDER ASSEMBL ASSEM BLY Y COMPONENTS
E248774A
1
2
7.8~11.8 (0.8~1.2, 5.8~8.7) 12.7~15.7 (1.3~1.6, 9.5~11.6) (Not reusable) 3 4 Not reusable
11
5 6
147+90 (15+ (1 5+90 90 , 10 109+ 9+90 90 ) 7 10
8
9
Tightening Torque : Torque : Nm (kgf.m, Ib-ft)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Engine cover bolt Engine cover Cylinder head cover Cylinder head cover gasket Rocker and bracket assembly Cylinder head bolt Cylinder head assembly Cylinder head gasket Crank case Push rod Oil filler cap
SUDEM7073L
EM -32
ENGINE MECHANICAL SYSTEM
1 2 3 4 7
5
8
6
9 10 11
12
14 13
1. 2. 3. 4. 5. 6. 7.
Valve cap cap Valve cotter Valve retainer Outer side spring Inner side side spring spring Valve stem seal Push rod rod
8. Cylinder head 9. Water director 10. Intake valve 11. Exhau Exhaust st valve 12. Cylin Cylinder der head gasket 13. Tap Tappet pet 14. Crank Crankcase case
SUDEM7074L
CYLINDER HEAD ASSEMBLY REMOVAL 1.
EM -33 4.
EDE5E369
Loosen the h hexa exa-bolt -bolt (2) o off inj injector ector nozzle bridge (1) and remove the injector (3).
Remove Remove the engine cov cover(1) er(1) from from the cylinder cylinder head head cover.
2
3
1
1 SUDEM7078L
SUDEM7280L
2.
5.
Remove Remove the oil s separat eparator or (1) and b blow-b low-by y hose (2)
Remove Remove the glow plug and gl glow ow plug plug plate plate (1). (1). 2
1
1
SUDEM7079L
SUDEM7076L
3.
Remove Remove the injection injection pi pipe(1) pe(1) No 1, 2, 3 and 4 running from the common rail assembly to the injector.
6.
Remove Remove the the oil lev level el gauge (1). 1
SUDEM7080L
1 SUDEM7077L
EM -34 7.
ENGINE MECHANICAL SYSTEM 10. 10. Remov Remove e th the e tu turb rboc ochar harge gerr asse assemb mbly ly (1) from from the cyli cylinnder head.
Remove Remove tthe he intake intake manifold manifold assembly assembly (1). 1
1
2
SUDEM7081L SUDEM7084L
NOTE Do not remove the actuator (2) of the intake manifold if its operation is normal.
8.
11. Loosen the exhaust exhaust manifo manifold ld mounting nut (1) and then remove exhaust manifold (2).
Remove Remove the thermostat thermostat housin housing g (1). 2
1
1
SUDEM7085L
12. Remove the cylinder head cover (1). SUDEM7082L
1
9.
Remove Remove the turbocharger turbocharger heater heater protecto protectorr cover cover (1) and exhaust manifold heater protector cover (2). 1
2
SUDEM7086L
SUDEM7083L
CYLINDER HEAD ASSEMBLY
EM -35 14. Remove the rocker arm and rocker brac bracket ket assembly (1).
13. Remove Remove the cylinder cylinder head bolts. bolts. NOTE a.
1
Since push rod rod is pressin pressing g the rocker, rocker, loosen the rocke roc kerr adjusti adjusting ng screw screws s (1) to remove remove the cyl cylind inder er head bolts (2).
2
1 SUDEM7089L
15. Remove the cylinder head assembly (1). 1 SUDEM7087L
b.
When remo removin ving g the cy cylin linder der head head bolts, bolts, rremo emove ve them according to the sequence as shown in the following figure.
1 3
5
9
11 7
13
14
17 15
10
6
2
12 16
4 8 SUDEM7090L
SUDEM7088L
EM -36
ENGINE MECHANICAL SYSTEM DISASSEMBLY
16. Remove the cylinder head gasket (1).
ECC7ED4F
ROCKER AND ROCKER SHAFT BRACKET ASSEMBLY
CAUTION When re Whe remov moving ing the cylinde cylinderr head head ga gaske sket, t, be care careful ful not to da dama mage ge the cylind cylinde er he hea ad and and crankcase. 1
1.
Remov Remove e the set bol boltt from from the the fron frontt rock rocker er shaft shaft bracket.
2.
Remove Remove the front and rear rear rock rocker er shaft shaft br brack acket. et.
3.
Remove Remove the rocker rocker assembly assembly..
4.
Remove Remove the rocker rocker shaft shaft sp spring ring from from the rocker rocker shaft. shaft.
5.
Remove Remove the rocker rocker shaft shaft bracket bracket No.2, No.2, 3 and 4 and then, remove the rocker shaft.
Rocker bush
SUDEM7091L
Rocker
Rocker shaft
Rear rocker
Set bolt
shaft bracket
17. Remove Remove the valve valve tappet (1). (1). Rocker shaft spring Rocker assembly 1
Front rocker shaft bracket SUDEM7093L
VALVE ALVE AND CYLINDER HEAD ASSEMBL ASSEMBLY Y 1.
Remo Remov ve the the valv alve cott cotter er (2) (2) with with push pushin ing g the the valv alve spri spring ng (1) (1) evenly enly us usin ing g the the spec specia iall tool tool (09222-83300).
09222-83300 SUDEM7092L
2 1
SUDEM7094L
CYLINDER HEAD ASSEMBLY 2.
EM -37
Remove Remove the retainer retainer (1), valve valve spring spring (2), valve valve stem seal seal (3) and inta intake ke and and exhaus xhaustt valv valve e fr from om th the e cyli cylind nder er head.
4.
Remove Remove the cylinder cylinder gaske gaskett (1). CAUTION When removing the cylinder head gasket, check the cylinder head and crankcase for any damage.
CAUTION Valve stem seal should be replaced with n ew one.
1
1 2
3
4
SUDEM7097L SUDEM7095L
3.
Remove Remove the the wat water er di director rector (1) from from the cylinde cylinderr head. head. NOTE
INSPECTION
E5264C2D
1.
Check to see see whether whether valve valve cap (1) (1) and retaine retainerr (2) have any irregular wear.
2.
Check the in intake take and exhaust exhaust valv valve e (3) ffor or any stuck, stuck, crack or damage.
If water director is corroded, remove it. If not, leave it.
1 2
1 SUDEM7096L
3 SUDEM7098L
EM -38 3.
ENGINE MECHANICAL SYSTEM
Check the v valve alve tappet (1) ffor or any any damage damage or wear. wear.
5.
Insp Inspec ectt the the out out of squa square rene ness ss (A), (A), free free leng length th (B), (B), load load installed (C) of valve spring, replace it if any of them exceeds the limit. Items
1
Outer side Valve spring
Inner side Valve spring
Standard
Free length Load installed
Limit
66.1mm
63m m
27.9±1 ±1.4 .4k kg
23.7kg 7kg
Out of squareness
1 .5m m
2.1m m
Free length
60m m
57m m
12.1±0 ±0.6 .6k kg
10.3kg 3kg
1 .5m m
2.1m m
Load installed
Out of squareness
SUDEM7099L
4.
Measure the ro rock cker er inner inner diameter diameter and rocke rockerr shaft shaft outer diameter. Replace the bush of rocker, rocker, if the gap exceeds the limit. Items
Standard
A
Inner diameter of rocker bush
18.980~18.993mm
Outer diameter of rocker shaft
19.05~19.09mm
Gap
Limit
0. 0.0 06~ 6~0. 0.11 11mm mm
―
C
―
B
0. 0.2m 2mm m
SUDEM7101L
6.
Measure Measure tthe he out outer er diamete diameterr of tapp tappet et (1) and and inn inner er diameterr of crankcas diamete crankcase e tappet hole (2). Replace the tappet if the gap exceeds the limit.
Reference: 0.045~0 Reference: 0.045~0.096mm .096mm Limit: Lim it: 0.2mm 0.2mm
SUDEM7100L
1
SUDEM7102L
CYLINDER HEAD ASSEMBLY
EM -39 8.
2
Measure Measure the def deformat ormation ion of cylinde cylinderr head bottom bottom face.. If the measurement exceeds face exceeds the limit, limit, repair it with surface grinder or replace it.
Flatness of cylinder head Reference: Refer ence: 0.05mm Limit: Lim it: 0.2mm 0.2mm NOTE Deformation of cylinder head bottom is measured at the position as show shown n in the following following figure. figure.
SUDEM7103L
7.
Measure Measure the runrun-out out of of push push rod (1). Replac Replace e it iiff it exceeds the limit.
Limit of pushrod pushrod run-out: 0.4mm
SUDEM7105L
9.
1
SUDEM7104L
Measure the outer diameter of valve stem. If the measurement sur ement is below the limit, replace the valve stem.
Outer diameter of valve stem Outer ― Intake Intake valve erence : 8.96~8. 8.96~8.97mm 97mm Reference Ref Limit Lim it : 8. 8.85m 85mm m Exhaust haust valve ― Ex Reference Ref erence : 8.93~8. 8.93~8.94mm 94mm Limitt : 8. Limi 8.85m 85mm m
SUDEM7106L
EM -40
ENGINE MECHANICAL SYSTEM
10. Measure the inner diameter of valve guide and outer diameter of valve stem. If the clearance exceeds the limit, replace the valve guide. Clearance between valve stem and valve guide ― Intake Reference: Refer ence: 0.04~0.06mm 0.04~0.06mm
c.
Measure the seat contact area (A).
Area of the valve seat contact ― Intake Reference: Refer ence: 2.8± 0.2mm Limit: Lim it: 3.6 3.6mm mm ― Exhaust Reference: 2.0± 0.2mm Reference: Limit: Lim it: 2.8 2.8mm mm
Limit: 0.15mm ― Exhaust Reference: Refer ence: 0.07~0.10mm 0.07~0.10mm Limit: Lim it: 0.2mm 0.2mm
A
SUDEM7109L
SUDEM7107L SUDEM7107L
11. Check the contacting state of valv valve e seat and valve. valve. a. Apply light blue coating coating on the valve valve surface. surface. b. Check the valve valve contacting contacting state by pressing pressing the valve to the valve seat. CAUTION Be careful that valve does not turn, when valve seat is pressed by valve.
Normal
Abnormal
Abnormal
SUDEM7108L
CYLINDER HEAD ASSEMBLY REPLACEMENT
EM -41 VALVE ALVE SEAT REPAIR
E03FAF94
1.
REPLACEMENT OF ROCKER BUSH 1.
Remove Remove the bush bush from from rocker rocker using using the the special special tool tool (09222-45000).
Repair the v valve alve face using valv valve e ref refacer acer (1). (1). CAUTION Valve seat angle is 45 .
2.
Press Press fit the bush bush into rock rocker er using using the special special tool tool (09222-45000). NOTE When pressing fit bush into rocker, let the chamber side of the rocker be inserted first. CAUTION When pressing fit, align the bush oil hole with rocker oil hole. At removing
At installing 1
09222-45000
SUDEM7112L
2.
To repair repair the v valve alve seat, use the valve valve seat cutter cutter or valve seat grinder (1). After grinding, insert the #400 or equivalent sand paper between cutter and valve seat and grind lightly.
Rocker chamber
CAUTION Rocker bush
Repair the valve seat Repair seat width and valve sinkage to satisfy the specified limit.
Rocker SUDEM7110L
REPALCEMENT REP ALCEMENT OF VALVE ALVE GUIDE Remov Remo ve the the valv alve gu guid ide e us usiing th the e sp spec ecia iall to tool ol (09221-41100). (0922141100). Install Install the valve guide using using the special tool (09221-41150, 09221-41100). At removing
1
At installing
09221-41100 09221-41150
18mm SUDEM7113L
Valve guide
Valve guide SUDEM7111L
EM -42 3.
ENGINE MECHANICAL SYSTEM
Install Install the valv valve e seat using the caulking caulking tool body body (1) (1) and locking ring (2).
5.
Apply the the compound compound e evenl venly y ov over er the valv valve e seat surface (1). CAUTION
CAUTION a.
Press the valve seat (3) with the chamferred side of the locking ring. And then, caulk caulk it to the cylinder head head as the r ing faces the other side. Installing
Caulking
b.
1
Val ve ve s te tem (2) s h ho ou ull d b e f rre ee f rro o m an y compoun com pound. d. Use the medium medium mesh mesh (mesh (mesh be betwe twee en 120 and 150 50)) compound compound at fir first st and finish the grinding with the fine mesh compound (above 200 mesh) Mix the c compo ompound und with some some engin engine e oil to apply evenly.
2
2
1
3 SUDEM7114L
4.
Grind the the seat width (A) and valve valve sin sinkage kage (B) (B) to be be within the standard. Valve Valv e and valve seat should touch evenly all over the surface.
Valve seat width (A) Reference: 2.6~3.0mm (Intake) (Intake) 1.8~2.2mm (Exhaust) Limit: 3.6mm (Intake) (Intake) 2.8mm (Exhaust) Valve sinkage (B) Reference: Refe rence: 1.5mm
SUDEM7116L
6.
Place the valve on the valve seat using the v valve alve lapper (1). Tap the valve with turning the valve slightly slightly.. Clean the compound with diesel or equivalent. Apply the engine oil and check whether the contact surface is securely positioned.
Limit: Lim it: 1.2mm 1.2mm 1
A
SUDEM7117L
B
SUDEM7115L
CYLINDER HEAD ASSEMBLY REASSEMBLY
EM -43 2.
EBF48CA7
Install Install tthe he intake intake a and nd exhaust exhaust valve. valve.
ROCKER AND ROCKER SHAFT ASSEMBLY 1.
Install Install rocker rocker sha shaft ft br brac acket ket No. No. 1, 2, 3 and and 4 to the the rocker shaft.
2.
Install the rocker rocker shaft spring.
3.
Apply engine engine oil oil on the the roc rocker ker bush, bush, and and then install install the bush to the rocker.
4.
Install the rocker rocker assembly assembly..
5.
Install the front front and and rear rear rocker rocker shaft bracket. bracket.
6.
Install the front front an and d rear rock rocker er shaft shaft brack bracket et set bo bolts. lts. SUDEM7118L
Tightening Tighten ing torque: torque: 7.8~11.8 Nm (0.8~1.2 kgf.m, 5.8~8.7 Ib-ft)
3.
Apply the eng engine ine oil oil on the v valve alve stem se seal al lilip p and install sta ll the the valv valve e st stem em seal seal usin using g the the spec specia iall tool tool (092 (092222245100). NOTE
Rocker bush
Rocker
Tap the seal until the special tool (09222-45100) contacts the cylinder head.
Rocker shaft
Rear rocker shaft bracket
Set bolt
09222-45100
Rocker shaft spring Rocker assembly
Valve
Front rocker shaft bracket
Cylinder head SUDEM7093L
Valve stem seal
VALVE AND CYLINDER HEAD ASSEMBLY 1.
Install the water director director to the cylinder cylinder head. head. SUDEM7119L
CAUTION When installing the vavle stem seal (1), use the new one.
1 SUDEM7096L
EM -44
ENGINE MECHANICAL SYSTEM 1
1
SUDEM7120L
4.
Install the retainer, valve spring and valve cotter using the special tool (09222-83300). 09222-83300
SUDEM7097L
b.
Selection Selection a and nd assembly assembly of cylinder cylinder he head ad gasket. Select Select the cylinder head gasket according t o the piston protrusion amount.
Average piston protrusion
Gasket size
Gasket thickness
0.466~0.526
A
1.35±0.03
0.526~0.588
B
1.40±0.03
0.588~0.648
C
1.45±0.03
Unit : mm Measuring gauge of piston protrusion SUDEM7121L
INSTALLATION
EDA3BF2F
1.
Assembly Assembly is perf performed ormed in the re revers verse e order order of disassembly.
2.
Installation Installation of cylind cylinder er head gasket. gasket. CAUTION When hen ins insta talli lling ng the cylind cylinder er he hea ad gaske gaskett (1), c ylinder ylinder head head installing installing surface surface should be free f rom r om any impurities or foreign materials such as oil. a. A ssembl ssemble e the cylinder cylinder hea head so that that "UP" "UP" mark of the cylinder head head g asket asket faces to the cylinder head.
SUDEM7122L
NOTE If the max protrusion of the piston is 0.05mm more than than av aver erage age protru protrusi sion on,, then then us use e the the gr grad ade e up (A (A→ →B) gasket.
CYLINDER HEAD ASSEMBLY
EM -45 Cylinder No. Valve
1
2
3
4
In- ExInExInExInExtake haust take haust take haust take haust
TDC of No.1
○
○
TDC of No.4 A
B
3)
Checking Checking and and adjusting adjusting of valve valve clearan clearance ce NOTE Check Chec k an and d ad adju just st th the e va valv lve e cl clea eara rance nce whil while e th the e engin engine e is cold.
1)
○
×
×
×
×
C SUDEM7123L
3.
○
Crank Crank the en engin gine e with th the e cranki cranking ng han handle dle and and align align the needle to "0" position position of cranksh crankshaft aft damper pulley pulley (side marked with No. No. 1 through 4). Or align it to the "0" position position of crankshaft crankshaft damper pulley (side marked No. 2 to 3). (This is at the TDC of comopression stroke of cylinder No. 1).
Me Meas asure ure th the e clea cleara ranc nce e betw betwee een n roc rocke kerr and and valv valve e cap using the thickness gauge. a. If the valve clearance exceeds the reference e, loosen the lock nut (2) and adjust the value, valu rance with thickness gauge by turning clearance clea the adjusting adjusting screws. b. After the valve clearance adjustment, fix the stin ing g scre screw w usin using g the the scre screw w drive drive (3) and and adjust adju en the lock nut securely. fasten fast NOTE
Make sure to check whether the valve clearance satisfies the reference after valve clearance adjustment.
3
2
1
SUDEM7125L
1 SUDEM7124L
2)
At the the TDC of c compress ompression ion stroke stroke of cylinder cylinder No. No. 1, check and adjust the clearance of the valve with "O" mark at the following following table table.. And then, turn the crankshaft in one turn to check and ad just the valve clearance of remaining valves with "X"mark.
EM -46
ENGINE MECHANICAL SYSTEM
ASE CRANKCASE CRANKC FLYWHEEL COMPONENTS
E60B5C72
39.2+40 (4+4 (4 +40 0 , 29 29.1 .1+4 +40 0) 7 4 3
5
2 1 8 6
7
1. 2. 3. 4. 5. 6. 7. 8.
Front plate Gasket Crankcase Rear plate Rear oil seal Pilot bearing Flywheel Flywheel mounting bolt
Tightening Torque : Torque : Nm (kgf.m, Ib-ft)
SUDEM7126L
CRANKCASE REMOVAL 1.
EM -47 4.
EECFB3A9
Remove Remove the the rear oil seal slinger slinger (1). (1).
Remove Remove the flywheel flywheel moun mounting ting bolt (1), (1), and then reremove the flywheel (2).
2
1 SUDEM7130L
1 SUDEM7127L
2.
Remove Remove the the rear plate plate mo mount unting ing bolt bolt (1), (1), and then remove the rear plate (2).
INSPECTION 1.
Distorsion Distorsion check of frictional frictional surfa surface ce a. Put tthe he flywheel flywheel (2) on on the precision precision table (1) and b. c.
2
EE08EBFD
set up the dial indicator (3). Mov Move e the dial iindicat ndicator or on the fl flywheel ywheel friction frictional al surface to measure the distortion. If the the dis distortion tortion of the friction frictional al sur surfac face e e exceeds xceeds the limit, regrind the frictional surface.
Distortion of the frictional surface Reference: Refer ence: Below 0.05mm 0.05mm Limit: Lim it: 0.2 0.2mm mm
3
1
2 SUDEM7128L
3.
Remove Remove the rear oil oil sea seall mounting mounting bolt (1), (1), and then remove the rear oil seal (2).
1 SUDEM7131L
2 1 SUDEM7129L
EM -48 2.
ENGINE MECHANICAL SYSTEM
Repair of the frictional frictional surfa surface ce Repair the frictional surface with the surface grinder.
INSTALLATION 1.
CAUTION a.
After After repairing repairing the frictiona frictionall surface, surface, check check whether the frictional surface is parallel with
b.
surface A with in 0.1mm. 0.1mm. Check Che ck the frictional surface surface (size (size B) whether whether its height is within the limit.
E561D9B1
Install Install the rear rear oil seal s slinger linger using tthe he special special to tool ol (09211-41000).
Height to the frictional surface surface (B) Reference: Refer ence: 24.5mm Limit: 23.5mm
09211-41000
SUDEM7133L
19.7mm
Dowel pin 09211-41000 B A
SUDEM7132L
3.
Replacement of flywheel ring gear a. When removing the ring gear (1), heat the ring gearr evenly using acetylene torch or equivalent gea tools too ls and then remove the ring gear by tapping the circumference the circumference with rod or hammer. b. When installing, heat the ring gear with piston heater hea ter for 3 minutes (about 100 C). And then, in inse sert rt the ring ring gear gear so tha thatt th the e un-c un-cha hamf mfere ered d gear gear faces to flywheel. 1
The chamfer was machined.
SUDEM7279L
Crankshaft Rear oil seal slinger
SUDEM7134L
CRANKCASE 2.
EM -49
Apply the sealant sealant (Locti (Loctite te #5699) #5699) to the rear rear oil oil seal seal (1), and then install the rear oil seal.
Tightening Tighten ing torque: torque: 7.8~11.8 Nm (0.8~1.2 kgf.m, 5.8~8.7 Ib-ft)
4.
Instal Installl the flywhee flywheell (1). (1).
Tightening Tighten ing torque: 39.2Nm+ 39.2Nm+40 40 (4.0kgf.m+40 , 29.1 Ib-ft+40 )
1
Sealant
1 SUDEM7138L SUDEM7135L
1 SUDEM7136L
3.
Install Install the rear rear p plat late e (1). (1).
Tightening Tighten ing torque: torque: 63.7 Nm (6.5 kgf.m, 47.3 Ib-ft)
1
SUDEM7137L
EM -50
ENGINE MECHANICAL SYSTEM
CYLINDER CYLIN DER BLOCK ASSEMBL ASSEMBLY Y COMPONENTS
EBC859AD
1 2 3 6 4 5
7
8
9
10 11
12
29.4+90 (3.0 (3 .0+9 +90 0 , 21.8 21.8+9 +90 0)
Tightening Torque : Torque : Nm (kgf.m, Ib-ft)
18.6~27.4 (1.9~2.8, 13.8~20.4)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Compressio Compres sion n ring ring No. No.1 1 Compres Com pressio sion n ring ring No. No.2 2 Oill rin Oi ring g No. No. 3 Sna nap p rin ing g Piston Pis istton pin Conn Co nnec ectin ting g ro rod d Connec Con necting ting rod rod upper upper bear bearing ing Cran ankc kcas ase e Connecting rod lower bearing Connecting rod cap Oil pan
SUDEM7139L
CRANKCASE
EM -51
29.4 (3.0, 21.8)
1
3
2
4 9 588 (60.0, 436) 12
8
5
10 11
6
7
49+90 (5.0 (5 .0+9 +90 0 , 36.4 36.4+9 +90 0)
1. 2. 3. 4. 5. 6.
Oil je jet Oil jet mou mountin nting g bolt bolt Upper Upp er main bear bearing ing Thru Th rust st pl plat ate e Rearr oil Rea oil seal seal sling slinger er Lower Low er main bea bearing ring
7. 8. 9. 10. 11. 12.
Main bear Main bearing ing ca cap p Crank Cr ankshaf shaftt asse assembl mbly y Semi Se micir circu cular lar key key Crankshaft gear Front oil seal slinger slinger Crankshaft pulley
Tightening Torque : Torque : Nm (kgf.m, Ib-ft)
SUDEM7140L
EM -52
ENGINE MECHANICAL SYSTEM
REMOVAL
EE4DAE0F
1.
Remove Remove the engine and transaxle. transaxle.
2.
Remove Remove the flywheel flywheel and rear plate.
3.
Remove Remove tthe he intak intake e an and d exhaust exhaust manifold. manifold.
4.
Remove Remove e the cylinder cylinder head head assembly assembly..
5.
Remo Remov ve the the supp supply ly pu pump mp (1 (1)) and and co comm mmon on ra rail il as asse semmbly (2). 2 SUDEM7143L
8.
Remove Remove oil cooler assemb assembly ly..
1 1
SUDEM7281L
6.
Remove Remove the V-belt (1) an and d remo remove ve the alternator alternator assembly (2).
SUDEM7144L
2
9.
Remo Remov ve timi timing ng gear gear trai train n [(oi [(oill pump pump gear gear (6), (6), camshaft assembly (2), idler gear A (3), idler supply pump gear (5)), and then remove front plate. 3
5 2
1 SUDEM7142L
7.
Align the timing timing mark (2~3 side) of cranksh crankshaft aft damper pulley to the compression TDC of cylinder No. 1. NOTE As for the removal of cooling fan pulley, pulley, crankshaft damper pulley and timing gear case, refer to the removall procedu mova procedure re of timing system.
4
6
1 SUDEM7145L
CRANKCASE
EM -53
10. Remove Remove the power steering steering pump (1 (1). ).
13. Remove Remove the oil strainer strainer (1).
1
1
SUDEM7146L
11. Remove Remove the starter motor assemb assembly ly (1).
SUDEM7149L
14. Remove rear oil seal (1) and oil seal slinger (2).
1
1 SUDEM7147L
SUDEM7150L
12. Remove Remove the oil pan (1). 1
2 SUDEM7151L
SUDEM7148L
EM -54
ENGINE MECHANICAL SYSTEM
15. Remove the connecting rod bearing cap (1).
1 2
NOTE Make marks at the connecting rod and cap to be reassembled correctly.
3 1
SUDEM7154L
18. Remove the crankshaft (1) from the cylinder b block. lock. CAUTION SUDEM7152L
Handle the crankshaft carefully so that the journal Handle is not damaged.
16. Remove the piston and connecting rod assembly (1) from cylinder block.
1
1
SUDEM7155L
19. Remove the oil jet (1) from the cylinder b block. lock.
SUDEM7153L
1
17. Remove the front, rear and main bearing caps. a. Remove Remove the the ffront ront bearing cap and rear end bearing cap. cap. Rem Remov ove e the thrust plat plate e (2) from the rear-bearing cap (1). b. Remove Remove th the e main beari bearing ng cap cap (1) and and bearing bearing (3).
SUDEM7156L
CRANKCASE DISASSEMBLY
EM -55 4.
E190BEAB
Remove Remove the connect connecting ing rod ((1) 1) ffrom rom the piston. piston.
PISTON AND CONNECTING ROD ASSEMBLY 1.
Remove Remove the piston ring u using sing the special special tool (0922283200).
1
SUDEM7160L
09222-83200
INSPECTION SUDEM7157L
2.
CYLINDER BLOCK
Remove Remove the the piston piston p pin in snap snap ring (2 (2)) using using the snap snap ring pliers (1).
a. b. c.
1
2
EBE61DCA
NOTE Befo Before re rrepairing epairing,, clean clean each part to remov remove e dust, dust, oil, carbon and fur. Bef Before ore cle cleanin aning g the cylinde cylinderr block, block, check check wate water r leakage or damages. Rem Remov ove e the a adhe dhesiv sives es at each each oil oil ho hole le using using air air brush and check whether any hole is clogged.
1.
In addition addition to the visual visual chec check k about about scratch, scratch, rust an and d corrosion, inspect the slight scratches with precipitant. Repair or replace replace it if needed.
2.
Measu Measure re the the twi twist st of cyli cylinde nderr bloc block k usin using g st stra raig ight ht edge edge (1) and thick thickness ness gau gauge ge (2). Measur Measure e them by placing placing the straight edge as shown in the following figure. NOTE
SUDEM7158L
3.
When measuring, cylinder upper block should be free from foreign materials such as gasket piece.
Remove Remove tthe he piston piston pin (1) from the piston.
CAUTION When grinding the cylinder block, grind it as the piston protrusion does not exceed exceed the refere reference. nce.
1
SUDEM7159L
EM -56
ENGINE MECHANICAL SYSTEM a.
Flatness figure of cylinder block Reference Refer ence : Below 0.07 0.07mm mm Limit Lim it : 0.2mm 0.2mm
Me Meas asure ure the inne innerr diam diamet eter er of cyl cylin inder der slee sleeve ve ususing the cylinder gauge (1).
Inner diameter of cylinder sleeve: 104.00~104.03mm 1 1
2 SUDEM7161L SUDEM7161L SUDEM7162L
3.
Check the cylinder cylinder wall tto o see if it is crack cracked ed or damdamaged. If it is abnormal, repair (oversize) (oversize) or replace the cylinder sleeve.
4.
Measure Measure the cylind cylinder er sleeve sleeve ID using using the cylinder cylinder gauge. If it is excessively worn, repair it with oversize and replace the piston and piston ring.
b.
Measure the outer diameter diameter o off pi piston ston skirt at the the posi positi tion on,, wh whic ich h is 85m 85mm m down down from from the the uppe upperr pispiston.
Outer diameter of piston: 103.91~103.92mm
Clearance between piston and cylinder sleeve : 0.080~0.130mm
CAUTION 1. 2.
3.
4. 5.
When When repla replacing cing pi piston, ston, piston ring should should be replaced together. Ev Eve en if only only one cylin cylinde derr needs needs boring, boring, all cylinder walls should be grinded with oversize at the same time. Measure the most most se seriou riously sly worn cylin cylinde der r wall wa ll and and se sele lect ct the oversiz oversize e ba base sed d on the measurement. Available Available oversizes oversizes are +0.25 +0.25,, +0.5 +0.50, 0, +0.75 +0.75 and +1.00. Pi sto ston n and c on onne nec c ttii on on ro rod d s houl houl d be re re-placed with the new one which has identical weight and grade with the old one.
SUDEM7163L
CRANKCASE
EM -57 4.
PISTON 1.
Check each piston to s see ee whe whether ther it is damaged. damaged.
2.
Check whether the p piston iston pin (1) (1) is installed installed correct correctly ly in the piston hole. If any defect is found, replace the piston and piston
Measure the cleara clearance nce b between etween piston pin and connecting rod end.
Outer diameter of piston pin: 38mm Inner diameter of connecting rod end: 38mm Clearance Reference: 0.025~0.046mm Clearance Cleara nce Limit Limit:: 0.1mm
pin as an Piston pinassembly. should slide into the piston hole smoothly when it is pushed by hand.
1
SUDEM7166L SUDEM7164L
3.
Measure the cleara clearance nce between piston pin and piston hole by measuring the inner diameter of piston pin (1) and piston boss.
Inner diameter diameter of piston boss: 38mm Outer diameter of piston pin: 38mm Clearance Reference: 0.007~0.021mm Clearance Clearan ce Limit: 0.05mm
PISTON PIST ON RING 1.
Check the piston piston ri ring ng ffor or any any da damage, mage, unusua unusuall wea wearr or breakage. If damaged, replace the ring.
2.
When replaci replacing ng th the e piston, piston, replac replace e the piston pin ttoogether.
3.
Measure the c clearan learance ce be between tween piston ring and and the the wall of the ring groove, using a feeler gauge. Piston ring
1
SUDEM7165L
Ring No.1 Ring No.2
Oil ring
Standard
Limit
0.106~0.170mm 0.07~0.11mm
0.2 m m 0.1 5m m
0.03~0.07mm
0.1 5m m
1
SUDEM7167L
EM -58 4.
ENGINE MECHANICAL SYSTEM
After After installi installing ng the pis piston ton ring to the the cylinder cylinder bore, bore, push the piston ring to the vertical direction direction with the piston.
CRANKSHAFT 1.
Measure the endplay endplay of crankshaft. crankshaft.
Crankshaft endplay Reference :0.10~0.26mm Limit: Lim it: 0.4 0.4mm mm
Piston ring end gap Ring No.1: No.1: 0.25~0.40mm 0.25~0.40mm Ring No.2: No.2: 0.50~0.65mm 0.50~0.65mm Oil ring: ring: 0.20~0.40mm 0.20~0.40mm
a. b.
If th the e endpl endplay ay exce exceeds eds the the limi limit, t, repl replac ace e the the thrus thrustt plate with the oversize. Ove Oversiz rsizes es of the the thrust thrust plate plate are + +0.1 0.15, 5, +0.30, +0.30, and +0.45.
SUDEM7169L
2.
SUDEM7168L
Measure the oil gap o off cr cranksha ankshaft ft m main ain bearing bearing.. a. Remov Remove e the main bearing cap. b. Measure the oil gap of main bearing. 1)
Remo Remove ve the oi oill or other fore foreign ign mat materia erials ls from main journal and main bearing surface.
2)
Place the plastic gauge along with the shaft dition of the journal. rection rec
CRANKCASE 3)
EM -59
Install Install the main bearing cap and and fasten fasten the bolt. bolt.
3.
Tightening Tighten ing torque: 49.0 Nm+90 (5.0kgf.m+90 , 36.4 Ib-ft+90 )
Measure Measure roun roundnes dness s and cylindri cylindricit city y of cranksha crankshaft ft journal and pin. If the measurement exceeds the limit, repair it with under size.
Roundness of crankshaft Roundness crankshaft Reference : less than 0.01mm , Limit : 0.03mm Cylindricity of crankshaft Reference : less than 0.006mm , Limit : 0.03mm
SUDEM7170L
4)
Remove Remove th the e main main beari bearing ng cap and and measure measure oil oil gap at each journal. SUDEM7172L
Oil gap of journal #1, 2, 4 and 5 Reference: 0.036~0.098mm, Limit: 0.15mm Oil gap of journal #3 Reference: 0.056~0.118mm, Limit: 0.15mm
4.
Check to see see ifif tthe he c cranks rankshaft haft is bent. Install the dial gauge of crankshaft center journal, and check the bending of the crankshaft.
Bending of the crankshaft Standard : Below 0.02mm 0.02mm Limitt : 0.05mm Limi 0.05mm NOTE Actual bending is a half of the measurement.
SUDEM7171L
5)
If the oil ga gap p of tthe he mai main n bearing bearing is excessi excessively vely large, replace the main bearing.
SUDEM7173L
EM -60
ENGINE MECHANICAL SYSTEM d.
CONNECTING ROD BEARING 1.
Befor Before e remov removin ing g the the con conne nect ctin ing g rod cap cap, meas measur ure e the connecting rod endplay. endplay. If the gap exceeds the rrefereference, replace the connecting rod.
Remove Remove the connec connecting ting rod bearing cap and measure the oil gap at each pin journal.
Connecting rod oil gap Reference: Refe rence: 0.040~0 0.040~0.099mm .099mm Limit: Lim it: 0.2mm 0.2mm
Connecting rod endplay Reference: Refer ence: 0.15~0.45mm 0.15~0.45mm Limit: 0.6mm Limit: 0.6mm
SUDEM7176L
e.
If the the oil gap iis se excessi xcessively vely large, large, repl replace ace tthe he connecting rod bearing.
SUDEM7174L
2.
Measure the oil gap o off th the e connectin connecting g rod bearing. 1)
Remove Remove the connecting connecting rod cap. cap.
2)
Measure Measure the oil gap gap of the connecti connecting ng rod rod bearbearing. a. Remove Remove the oil or fforeign oreign materials materials from from pin pin journal and connecting rod bearing bear ing surface. b. Place Place the plas plastic tic g gaug auge e on the the shaft shaft of pin pin journal along with its direction. c. Ins Instal talll the c conn onnecti ecting ng rod rod bearing bearing cap cap and and
3.
Length of the connecting connecting rod bearing. Length of the Connecting rod bearing (1) is measured at the free free sta state te.. If the the measu measure reme ment nt is belo below w the the limi limit, t, replace the upper and lower bearing.
Length of the connect connecting ing rod bearing Limit: above above 69.5mm
CAUTION Bearing should not be arti Bearing artificia ficially lly expa xpande nded d to reuse.
fasten the bolt. Tightening Tighten ing torque: 29.4 Nm+90 (3.0kgf.m+90 , 21.8 Ib-ft+90 )
1
SUDEM7177L
SUDEM7175L
CRANKCASE REASSEMBLY
EM -61 2.
E49D5D90
Apply engine oil a att the piston rod e end nd and piston pin hole, and then install the piston pin (1).
PISTON AND CONNECTING ROD ASSEMBLY 1.
Install Install the piston ring using using the the special special tool tool (09222(0922283200).
1
09222-83200 SUDEM7180L
3.
Install Install the the piston piston pin snap snap ring (2 (2)) usin using g snap rin ring g pliers (1).
SUDEM7178L
NOTE a. b.
Instal Installl the p pist iston on ring ring so that that open open end end of the the pispiston ring faces to the direction shown in the figure. In Inst stal alll the oil ring ring expan expande derr spring spring to be pos posiitioned at at 180 direct direction ion with the the oil ring end. end. Otherwise, expander spring may be loosened.
Oil r ing expander expander spring
1
2
Compression ring No. 1
Engine front
SUDEM7181L
Compression ring No. 2
Oil ring
SUDEM7179L
EM -62
ENGINE MECHANICAL SYSTEM
INSTALLATION 1.
3.
EE5ABFA8
Install Install the cranks crankshaft haft (1) to to the cylind cylinder er b block. lock.
Install Install oil oil jet jet ((1) 1) tto o th the e cylinder cylinder block. block.
CAUTION Handle crankshaft carefully not to be damaged.
1
1
SUDEM7182L
2.
Install Install thrust thrust plate plate (1) and upper upper main main bearing bearing (2) (2) to the crankcase.
b. c.
d.
4.
Install the ffront, ront, rear and main bearing caps. a.
CAUTION a.
SUDEM7184L
Install Install the thrust plate plate with the oil grooveless grooveless side toward the crankcase. Align Align the lug groove groove of cra crankca nkcase se with with the lug of main bearing. Since Since th there ere is oil hole at upper upper bear bearing, ing, ta take ke care not to be interchanged with lower bearing. Apply Apply engine engine oil oil on the all all over over the sliding sliding surface.
Insert Insert the the lower lower main main beari bearing ng (1) into into beari bearing ng cap cap (2). NOTE
Check to see whether the main bearing lug matches main bearing cap lug groove.
b.
Instal Installl thru thrust st pl plate ate (3) to the rrear-bea ear-bearing ring c cap. ap. 3 2
2 1
SUDEM7185L
1 SUDEM7183L
CRANKCASE c.
EM -63
Install Install the the main main bearing bearing cap cap with the the specif specified ied torque.
b.
Wh Whe en insta installi lling ng conne connectin cting g rod cap cap,, al align ign mark (1) on connecting rod big end cap with mark (2) (2) on connecting rod cap.
Tightening Tighten ing torque: 49.0 Nm+90 (5.0kgf.m + 90 , 36.4 Ib-ft+90 )
1
2
1 SUDEM7188L
c. SUDEM7186L
5.
Install piston and c connecti onnecting ng rod rod assembl assembly y.
d.
CAUTION a.
Wh Whe en insta installi lling ng piston, piston, assembl ssemble e it so tha thatt front mark (1) of the piston faces to the front side. Asse Assemble mble so that that the arr arrow ow mark mark (→) of piston head faces to the center of cylinder hea head d bolt hole.
In s stt a all l p iis s to to n an d c o on nn ne ec ttii ng ng r od od t o t h he e crankshaft pin journal using the special tool (09222-83200).
09222-83200 1
SUDEM7189L
SUDEM7187L
EM -64 e.
ENGINE MECHANICAL SYSTEM Tighten Tighten the connecting rod cap with specifie specified d torque.
7.
Apply the sealant sealant (Loctit (Loctite e #5699) #5699) tto o the rear oil oil s seal, eal, and then install the rear oil seal (1).
Tightening Tighten ing torque: 29.4 Nm+90 (3.0kgf.m + 90 , 21.8 Ib-ft+90 )
1 SUDEM7192L
8.
Install Install the oil strain strainer er ((1). 1).
SUDEM7190L
6.
Inst Instal alll rear rear oil oil seal seal sli slinge ngerr usin using g th the e speci special al tool (09211-41000).
1
SUDEM7193L
09211-41000
SUDEM7191L
CRANKCASE 9.
EM -65
Install Install the oil pan (1). 1
SUDEM7194L
10. After installing the cylinder block assembly assembly,, measure the piston protrusion. protrusion. Install Install the right cylinder head gasket.
NOTE As for the cylinder head gasket selection and assembly, refer to the cylinder head assembly procedure.
11. Install the timi timing ng syste system. m. 12. Install the the flywheel and and rear plate plate.. 13. Install the cylinder head assembly assembly.. 14. Install intake and exhaust manifold. 15. Install engine engine accessorie accessories. s.
EM -66
ENGINE MECHANICAL SYSTEM
INTAKE AND EXHA INTAKE EXHAUST UST SYSTEM SPECIFICATIONS
E08C8904
Items
Specifications
A i r c l eaner ty pe
Dr y type
Element type
Paper type type
Intercooler
Turbocharger (TD05H-12G)
Length
260mm
Width
172mm
Height
216mm
Max rpm allowed
Maximum pressure ratio Maximum exhaust Maximum exhaust gas temperature
160,000rpm 2.6
760 C
TIGHTENING TIGHTENI NG TORQUE TORQUE Items (Diameter×Length (Diameter×Length)) Turbocharger Intake manifold
Exhaust manifold
Screw size O.D×pitch (mm)
Nm
kgf.m
Ib-ft
M9×2.5
3.9
0.4
2.9
Turbocharger oil pipe eyebolt
M8×1.25
16.7
1.7
12.4
Actuator mounting flange bolt
M6×1.0
7 .8 ~1 1 .8 7.
0.8~ 1.2
5.8~ 8.7
Bu Butt tter erfl fly y valv alve sh shaf aftt mo moun unti ting ng nut (8 (8))
M8×1.25
16.7~25.5 16
1.7~ 2.6
12.4~ 18.9
Intake manifold front hanger mounting flange bolt(10×20)
M10×1.5
3 2.3~ 49 32
3.3~ 5.0
2 4 ~3 6 .4
Intake manifold mounting flange bolt(8 ×20)
M8×1.25
18.6~27.4 18
1.9~ 2.8
13.8~ 20.4
Heat ate er prot rotector cover mou oun nting bo bollt
M8×1.25
11.8
1.2
8.7
Exhaust manifold assembly self lock flange nut
M10×1.25
41.2
4.2
30.5
Turboc urbocha harg rger er and in inta take ke pi pipe pe cl clamp amp band band
INTAKE AND EXHAUST SYSTEM TROUBLESHOOTING
EM -67
EBA6A66F
Output drop
Intake system
Yes
Is air cleaner clogged?
Replace the element
No Does air leak at the connection of intake system?
Yes
Repair
Exhaust system
* Is muffler or exhaust pipe deformed?
Yes
* Is carbon accumulated?
Repair or replace
No Does gas leak at exhaust system?
Yes
Repair
No Is exhaust brake opened?
Yes
Repair or replace
Turbocharger (TD05H-12G)
If the turbocharger is defective, replace it in the assembly unit.
Any leakage at the connection of compressor cover and intake pipe?
Yes
Tighten the clamp
No Are compressor inside, compressor cover and compressor wheel polluted?
Yes
Cleaning
No Does turbine wheel rotate smoothly if turned by hands?
No
Clean the carbon deposit and turbocharger.
SUDEM7195L
EM -68
ENGINE MECHANICAL SYSTEM
Unusual noise and vibration
Intake system
Are fixing bolts and nuts of intake system fastened securely?
No Tighten
Yes Exhaust system
Are fixing bolts and nuts of exhaust system fastened securely
No
Repair or replace
Yes Yes
Is exhaust pipe or muffler damaged?
Repair or replace
Turbocharger
Are bearing and rotating parts OK?
No
Inspect the following. Deterioration of engine oil Oil filter element clogging Foreign materials in oil supply pipe. Bearing damage due to repeated sudden departures and stops.
No
Defective bearing Compressor wheel or turbine wheel damage due to the foreign materials inside.
Yes
Do rotating parts rotate smoothly? Isn't turbine wheel shaft bent?
Yes
Are there any foreign materials in turbocharger?
Yes
Check the intake and exhaust piper carefully for the chip of compressor or turbine wheel
SUDEM7196L
INTAKE AND EXHAUST SYSTEM
EM -69
TURBOCHARGER COMPONENTS
E2B39DEE
41.2 (4.2, 30.5)
11
40.2 (4.1, 29.8)
7 11.8 (1.2, 8.7) 10
5 6
4
3
2
1
9
8
41.2 (4.2, 30.5)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Cylinderr head Cylinde head assem assembly bly Exhaus Exh austt manifol manifold d assembly assembly Plain Pl ain wa wash sher er Dist Di stan ance ce pi piece ece Exhaust Exhau st manifold manifold self lock lock flange flange nut (M10x1. (M10x1.25) 25) Oil pi pipe pe Turbocharger Turbo charger oil pipe eye bolt bolt (M8x1.25) (M8x1.25) Oill retur Oi return n pipe pipe Turboch Tur bocharge argerr assem assembly bly Self lock flange flange nut nut Exhaust Exhau st pipe
Tightening Torque : Torque : Nm (kgf.m, Ib-ft)
SUDEM7197L
EM -70
ENGINE MECHANICAL SYSTEM
7 6 5
3 2
4
3.9~4.9 (0.4~0.5, 2.9~3.6)
1
1. 2. 3. 4. 5.
Actuator Compressor cover O-ring Cartridge assembly Snap ring
6. Coupling 7. Turbine Turbin e housing
Tightening Torque : Torque : Nm (kgf.m, Ib-ft)
SUDEM7198L
INTAKE AND EXHAUST SYSTEM REMOVAL 1.
EM -71 3.
E90F3479
Remove Remove the turboch turbocharger arger heater protector protector cove coverr (1) (1)..
Make Make an ali alignin gning g mark on th the e couplin coupling g (1), tur turbine bine housing (2), compressor cover (3), and cartridge assembly (4). 1
1
2
4 3 SUDEM7201L
SUDEM7199L
2.
Remove Remove the turbocharger turbocharger assembly assembly (1).
4.
Remove Remove the turbine housing housing(1). (1).
1
a.
b.
CAUTION Lig Lightl htly y tap tap the hou housing sing circumf circumfe ere rence nce with with rubber hammer hammer so th at turbine housing is n ot damaged. Since Since turbi turbine ne wheel wheel blade blade is ea easily sily be bent, nt, exexercise care care when removing the hou sing.
SUDEM7200L
1 SUDEM7202L
EM -72 5.
ENGINE MECHANICAL SYSTEM
Remove Remove the compressor compressor cover cover (1).
2.
CAUTION a.
Lightly Lightly tap tap the compressor compressor cover cover circumf circumfererence with rubber hamme hammerr so that compressor cover is not damaged.
b.
Since compressor whe wheel el blade is easily easily bent, ex exercise ercise care when removing the compressor cover.
Check the s shaft haft directi directional onal clearance clearance o off shaft shaft and turbine wheel wh eel assembly. a. Check the clearance clearance of tturbine urbine wheel side. If the measurement exceeds the limit, replace the cartridge assembly (1).
1
SUDEM7205L
b.
1
Inspec Inspectt th the e clearan clearance ce o off co compresso mpressorr whe wheel el side. side. If the mea measur suremen ementt excee exceeds ds the lim limit, it, replac replace e the cartridge assembly (1).
SUDEM7203L
INSPECTION 1.
1
EFAE8284
Measure the shaft shaft d directio irectional nal clearan clearance ce of shaft and turbine wheel assembly. assembly. If the measurement exceeds the limit, replace the cartridge assembly (1).
1
SUDEM7206L
SUDEM7204L
INTAKE AND EXHAUST SYSTEM 3.
EM -73
After assembling assembling the turbocha turbocharger rger assembly assembly (1), (1), turn turn each wheel (2) to see if it rotates smoothly.
INSTALLATION 1.
E50867FF
When assem assembl bling ing th the e snap ri ring ng (1) to c comp ompress ressor or cover (2), assemble it so that the snap ring taper side (3) faces up.
2
CAUTION When installing the snap ring, install it to the comWhen pressor cover by holding th e snap with one hand. 1 3
SUDEM7207L
4.
When assembling assembling turbocharger turbocharger assembly assembly (1), fill with the engine engine oil oil through through th the e oil hole hole (2) so that that each part part operates smoothly. smoothly. 2 1
2
SUDEM7209L
2.
Install the turbocharger turbocharger assemb assembly ly (1).
Tightening Tighten ing torque: torque: 41.2 Nm (4.2kgf.m, 30.5 Ib-ft)
1 SUDEM7208L
1
SUDEM7210L
EM -74 3.
ENGINE MECHANICAL SYSTEM
Install Install the turboch turbocharger arger heater protector protector cover cover (1).
Tightening Tighten ing torque: torque: 11.8 Nm (1.2kgf.m, 8.7 Ib-ft)
1
SUDEM7211L
INTAKE AND EXHAUST SYSTEM
EM -75
INTAKE INT AKE MANIFOLD COMPONENTS
EDBED9AC
1 2
4 3 32.3~49 (3.3~5.0, 24~36.4) 18.6~27.4 (1.9~2.8, 13.8~20.4)
1. 2. 3. 4.
7.8~11.8 (0.8~1.2, 5.8~8.7)
Intake manifold gasket Intake manifold assembly Actuator Intake manifold front hanger
Tightening Torque : Torque : Nm (kgf.m, Ib-ft)
SUDEM7212L
EM -76 REMOVAL 1.
ENGINE MECHANICAL SYSTEM INSPECTION
EEA818FD
Remove Remove the the injec injectio tion n pipe pipe (1) No. No. 1,2,3 1,2,3 and 4 from common rail assembly to the injector.
EEC01B88
Inspection and adjustment of the clearance between butterfly valve and Intake manifold 1.
Secur Secure e the bu butte tterf rfly ly val valve ve to the close close stat state e with with 500mmHg or more negativ negative e pressure applied to the actuator (the condition that double nuts are coherent to the bracket).
2.
Adjust the cleara clearance nce b by y mo moving ving the a adjusti djusting ng ho hole le (A (A)) of actuator bracket and tighten it with the bolt.
Clearance between butterfly valve and Intake Intak e manifold manifold (B): 4.0~4.5mm 1 SUDEM7213L
2.
Remove Remove tthe he Intake Intake manifo manifold ld assembly assembly (1).
B
1
A
Double nut Actuator
SUDEM7215L SUDEM7215L
SUDEM7214L
3.
When the iinter nternal nal a air ir pr press essure ure of of 3kg 3kg/cm /cm² is applied to the actuator, it should maintain the airtight of 0.1cc or less for 5 seconds.
4.
Butterfly Butterfly valve valve should have have the durabi durability lity o off 400,000 400,000 cycles at the ambient temperature of 80 C.
INTAKE AND EXHAUST SYSTEM INSTALLATION 1.
EM -77 2.
EE8BA5EE
Install the intake intake manif manifold old (1).
Install Install the injec injection tion pipe ((1) 1) No No.1, .1, 2,3 2,3 and 4.
Tightening Tighten ing torque: 39.2~49 Nm (4.0~5.0kgf.m, 29.1~36.4 Ib-ft)
Tightening Tighten ing torque: 18.6~27.4 18.6~27.4 Nm (1.9~2.8kgf.m, 13.8~20.4 Ib-ft) 1
0.8~1.2
1.9~2.8 1 SUDEM7218L
SUDEM7216L
0.5kgf•m
2
1 1.5mm SUDEM7217L
NOTE When installing the butt butterfly erfly valve valve (1), fasten the butterfly valve shaft mounting nut (2) so that the identification mark (▽ (▽) faces to the direction shown in the illustration.
Tightening Tighten ing torque: 16.7~25.5 16.7~25.5 Nm (1.7~2.6kgf.m, 12.4~18.9 Ib-ft)
EM -78
ENGINE MECHANICAL SYSTEM
EXHAUST EXHA UST MANIFOLD COMPONENTS
E6A9EE49
6 5 4
3
2 1
41.2 (4.2, 30.5)
1. 2. 3. 4. 5. 6.
Cylinder head assembly Exhaust manifold gasket Exhaust manifold assembly Plain washer Distance piece Exhaust manifold self lock flange nut (M10x1.25)
Tightening Torque : Torque : Nm (kgf.m, Ib-ft)
SUDEM7219L
INTAKE AND EXHAUST SYSTEM REMOVAL 1.
EM -79 3.
E670C1A1
Remove Remove the exhaust exhaust manifo manifold ld he heater ater p protecto rotectorr cov cover er (1).
Remove Remove the turboch turbocharger arger heater protector protector cove coverr (1) (1)..
1
1 SUDEM7222L SUDEM7220L
4. 2.
Remove Remove the exhaust exhaust manifold manifold assemb assembly ly (1).
Remove Remove the turbocharger turbocharger assembly assembly.. 1
1 SUDEM7223L
SUDEM7221L
EM -80 INSTALLATION 1.
ENGINE MECHANICAL SYSTEM 3.
EFDF4E9E
Install Install the the exhaust exhaust manifold manifold assembly assembly (1).
Install Install the turbocharger turbocharger assemb assembly ly..
Tightening Tighten ing torque: torque: 41.2Nm (4.2kgf.m, 30.5 Ib-ft)
Tightening Tighten ing torque: torque: 41.2Nm (4.2kgf.m, 30.5 Ib-ft)
1
1 SUDEM7223L SUDEM7221L SUDEM7221L
2.
Inst Instal alll the the exha exhaus ustt mani manifo fold ld heate heaterr prote protect ctor or cove coverr (1 (1). ). 4.
Tightening Tighten ing torque: torque: 11.8Nm (1.2kgf.m, 8.7 Ib-ft)
Install Install the turboch turbocharger arger heater protec protector tor c cove overr (1) (1)..
Tightening Tighten ing torque: torque: 11.8Nm (1.2kgf.m, 8.7 Ib-ft)
1
1 SUDEM7222L SUDEM7220L
INTAKE AND EXHAUST SYSTEM
EM -81
AIR CLEANER COMPONENTS
ED215C0E
< HD65/72/78 NARROW/WIDE STD/DOUBLE>
2
2
9 6
1 5
10
10
7 7
3
8 4
3
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Radiator Radiat or res reserv ervoir oir Airr inl Ai inlet et du duct ct Air clea cleaner ner asse assembl mbly y Airr out Ai outle lett duct duct Turboc Tur bochar harger ger inle inlett hose hose Interc Int ercoole oolerr inlet inlet pipe Interc Int ercool ooler er outlet outlet pip pipe e Radiat Rad iator or outl outlet et hos hose e Radiat Rad iator or inle inlett hose hose Dust indicat indicator or
SUDEM7224L
EM -82
ENGINE MECHANICAL SYSTEM
County 7
10
6 5
9
3 4 2
1
8
6
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Inlett du Inle duct ct Clamp Air clea cleaner ner asse assembl mbly y Airr outle Ai outlett pipe pipe Dust Du st ind indic icato atorr Interc Int ercool ooler er in/out in/out pip pipe e Radiat Rad iator or res reservo ervoir ir Radiat Rad iator or upp upper er hos hose e Exhaus Exh austt manifol manifold d assembl assembly y Turbocharger assembly
SUDEM7225L
INTAKE AND EXHAUST SYSTEM
EM -83
HD65/72/78
7
8.8~13.7 (0.9~1.4, 6.5~10.2)
6 1 8
8.8~13.7 (0.9~1.4, 6.5~10.2) 4
2 5 1. 2. 3. 4. 5. 6. 7. 8.
Exhaust pipe Muffler assembly Tail pipe Suspend assembly Bracket Exhaust brake unit Turbocharger assembly Battery carrier
3
Tightening Torque : Torque : Nm (kgf.m, Ib-ft)
SUDEM7226L
EM -84
ENGINE MECHANICAL SYSTEM
County
5
6
2 1
3
4
1. 2. 3. 4. 5. 6.
Exhaust pipe Exhaust brake unit Muffler assembly Tail pipe Turbocharger assembly Exhaust manifold assembly
SUDEM7227L
INTAKE AND EXHAUST SYSTEM INSPECTION
EB12EA6F
AIR CLEANER 1.
When dust dust indica indicator tor tu turns rns red, which which tells tells the filte filterr replacement interval, replace the element. CAUTION Replace the element at least once per 2 years. Do not reuse it after clea cleaning. ning.
2.
Replacement Replacement of air cleaner cleaner filter. filter. a. Loosen the clamp clamp of the the air air cleaner cleaner assembly assembly.. b. Remove Remove the lowe lowerr cap of air air cleaner cleaner assembl assembly y. c. Loosen butterfly butterfly nut of element. element. d. Remove Remove the elemen element. t. e. Clean the inside of a air ir cleaner cleaner thoroughly thoroughly.. f. Replace the air cleaner cleaner element with new one. CAUTION When replacing the element, element, exercise exercise caution that air-cleaner material. should not contain any dust or foreign
g. h.
i. j.
Tighten the butterfly butterfly nut of element. element. Check to se see e if the p packin acking g at the air-cleaner air-cleaner assembly is correctly installed. If correctly installed, install the lower cap. Fix the lower cap by tightening tightening the clamp. clamp. Press the dust indicator reset button so that the red color disappears. CAUTION
Genuine parts of the air-clea Genuine air-cleaner ner must be used. If the vehicle is driven with the air-cleaner removed, it may be the cause of early engine damage.
EXHAUST MUFFLER 1.
Check the exhaust exhaust system for any unusual unusual noise. noise.
2.
Check the exhaust exhaust muffler for connection connection and and corrocorrosion.
3.
Check the exhaust exhaust muffle mufflerr gasket gasket for for any any damage. damage.
EM -85
EM -86
ENGINE MECHANICAL SYSTEM
ATION SYSTEM LUBRICA LUBRIC DESCRIPTION
E3DF9F3D
FLOW CHART OF LUBRICATION SYSTEM Engine is lubricated by a gear-type oil pump that forces Engine is engine engin e oil oil thro throug ugh h the the oi oill co cool oler er and and oi oill fi filt lter er in into to th the e en engi gine ne for lubrication of various engine parts.
Main oil gallery
Bypass valve
Crankshaft mainbearing
Camshaft bush
Timing
Connecting
Rocker
gear
rod bearing
bush
Oil pressure switch
Idler gear bush
Oil filter
Oil coo coole lerr
Ori Orific fice e
Connecting bush
Oil pump Regulator valve
Relief valve
Push rod
Turbo charger vacuum pump
tappet
oil jet piston
oil pan oil strainer
SUDEM7228L
OIL PUMP
Drive gear
Oil pump gear
Relief valve
The oil pump, of a gear type, is driven by the crankshaft rotation engaged with oil pump gear. And the relief valve is installed to the oil pump p ump so that it prevents the excessive pressure by bypassing the engine oil to oil pan when the oil pressure exceeds the specification.
B
C
Oil pump cover A
Driven gear
Oil pump case
A: from oil strainer B: to oil cooler C: to oil pan SUDEM7229L
LUBRICATION SYSTEM
EM -87
OIL COOLER
REGULAT REGU LATOR OR VAL VALVE VE
Oil cooler is equipment for heat exchange between the coolant and oil fed from the crankcase water jacket and oil pump, respectively. The oil cooler has a bypass valve that opens when the element (1) becomes clogged.
When oil pressure in main oil gallery exceeds the specification, regulator valve (1) opens and some engine oil drains to the oil pan to adjust the oil pressure.
1
1
SUDEM7232L SUDEM7230L
OIL PRESSURE SWITCH
BYPASS VALVE VALVE When the oil viscosity is high (in cold) or oil path shows high resistance depending on the element load, the bypass valve (1) opens and oil goes directly to oil filter without passing oil cooler.
If the pressure of engine oil which is sent to the main oil gallery is below the specificat specification, ion, the built built-in -in relay in the oil pressure switch (1) is closed, then the warning lamp in the instrument panel is on to inform the driver of abnormal pressure.
1 1 SUDEM7231L
SUDEM7233L
EM -88
ENGINE MECHANICAL SYSTEM
OIL FILTER FILTER
LUBRICATION LUBRICA TION OF PARTS
Oil filter uses a spin-on type paper element, in which full flow filter filter and bypas bypass s filter are integrated. integrated. Bypass valve valve is assembled assembled to the bottom of the filter. If the element is loaded, valve opens so that engine oil goes to oil main gallery without passing through throu gh the element to prevent en-
The engine oil routed from the oil filter to oil main gallery lubricates all engine parts as detailed below before returning to the oil pan.
gine overload.
1.
Main bearing and connect connecting ing rod bearing a.
1 2
There is an oil passage (1) provid provided ed fro from m the oil main gallery to each main bearing. The oil flows thro throug ugh h the the oil oil hole hole (2) (2) to lubr lubric icat ate e the the ma main in bear bear-ing and passes through the oil passage drilled into into the cran cranks ksha haft ft to lubri lubrica cate te the the con conne nect ctin ing g rod rod bearings. 1
3
1. 2. 3. 4. 5.
4
Out packing Seaming cap Bypass element element assembly assembly Full-flow element element assembly assembly Housing
2
5 SUDEM7235L
SUDEM7234L
b.
The Oi Oill je jett (1) (1),, in installe stalled d at each cylinder cylinder oil oil main main passage, passag e, injects engine oil into the piston (2) to cooll the pisto coo piston. n. Thi This s oil jet has a che check ck va valv lve e which is opened/closed by the specified oil pressure, it prevents oil flow and oil pressure from decreasing at low pressure. 1
2 SUDEM7236L
LUBRICATION SYSTEM
EM -89
2.
Cams Camsha haft ft Camshaft bushings are lubricated by the oil flowing through the oil passages leading from the oil main gallery to each bushing.
3.
Valve alve mechani mechanism sm The engine engine oil that has lubricat lubricated ed No. 1 camshaft camshaft bush bushin ing g pas passe ses s throu through gh th the e oi oill hole hole and and pipe pipe pr prov ovid ided ed at the top portion of crankcase to the cylinder head. The engi engine ne oil oil the then n goes goes thr throu ough gh th the e front front rocke rockerr shaf shaftt bracket into the rocker shaft, lubricating each rocker bushing. At the same time, it lubricates valve cap and valve stem of the rocker. rocker. The oil then passes through the the push push rod rod hole holes s in the cyl cylind inder er head head and and cr cran ankc kcas ase e to lubricate the tappets and camshaft cams before returning to the oil pan. Front rocker shaft bracket
Rocker shaft
Push rod Tappet Camshaft cam SUDEM7237L
EM -90
ENGINE MECHANICAL SYSTEM
SPECIFICATION
EADD3E2D
OIL COOLER Item
ication Specification Specif
3.5~4.5kg/cm²(361~419kpa)
Bypass valve open Regulator Regul ator oil pump valve open
5~7kg 5~7kg/cm /cm²(490~686kpa)
OIL PUMP Item Head gear
Specification
Module
2.0
Pressure Pressur e angle
N0. of gear gear teeth teeth distortion distortio n angle
36
19.5
Backlash (mm) Pump rotation (rpm)
20
0.049~0.151
550~3100
Oil Temperature ( C)
-25~130
Oil in use
SAE 10W~30W
Injection Inject ion press pressure ure MPa (kgf/cm²)
0 . 4 (4 )
Injection amount (ℓ /min)
25
Relief valve operating pressure MPa (kgf/cm²)
1.1± 0.1 (11± 1)
OIL FILTER FILTER Item
ecification Sp Specification
Full-flow : above 1700cm³ By-pass : above above 2400cm³
Filtration capacity essure loss Pr Pressure
low 0.5kgf/cm 0.5kgf/cm² Be Below
Bypass opening pressure MPa (kgf/cm ²) By Bypass pass pressure loss MPa (kgf/cm²)
9 8 ± 2 0 (1 . 0 ± 0 . 2 )
15 157±20 7±20 (1.6±0.2)
LUBRICANT Item
Types
Engin Eng ine e oil oil
API clas classi sifi ficat catio ion n gr grad ade e CF—4 or more SAE 10W-30
Oil grade Grade CF-4 or more
Oil viscosity viscosity (temperature (temperature applied) 1) 0~40 C : SAE 30 2) above -10 C: SAE 20W-40 3) above -15 C: SAE 15W-40 4) -20~40 C : SAE 10W-30 5) below 10 C: SAE 15W-30
Oil capacity capacity Oil pan : 8 ℓ Total capaci capacity ty : 9 ℓ
LUBRICATION SYSTEM
EM -91
SERVICE ST STANDARD ANDARD
Item
Nominal value ([ ] indicates base diameter)
Limit 0.5kg/cm²
Oil pressure ( oi oill temperature 70~90℃)
At idle
1~ 5k g/c m ²
A t m ax s peed
3~ 5k g/c m ²
Oil pump
Oil pump case and gear teeth end clearance
Difference between oil pump case depth and gear height (sinkage) Dri Driven gea earr to driv riven shaft clearanc nce e
Oil cooler
2kg/cm²
Adjust Adjust
0 .1 0 ~0 . 1 9
0.2
Replace
0 .0 1 ~0 . 0 7
0.18
Replace
0.15
Replace
[20] 20]0.04~0 ~0.0 .07 7
Drive gear end play
Corrective action and remarks
0.03
Relief valve opening pressure
10~12kg/cm²
Replace
Bypass valve pressure
3.5~ 4.5k g/c m ²
Replace
Opening pressure of regulator valve
5.0~ 7.0k g/c m ²
Replace
Unit : mm TIGHTENING TIGHTENI NG TORQUE TORQUE
Size OD × pitch (mm)
Oil strainer flange bolt (8 ×16)
Oil strainer flange bolt (8 ×40)
Item (Diameter × length)
Oil pan mounting flange bolt (8 ×12)
Nm
kgf.m
Ib-ft
-
1 8 .6 ~2 7 .4
1.9~2.8
13.8~20.4
-
1 8 .6 ~2 7 .4
1.9~2.8
13.8~20.4
1 8 .6 ~2 7 .4
1.9~2.8
13.8~20.4
1 8 .6 ~2 7 .4
1.9~2.8
13.8~20.4
3 4 .3 ~3 9 .2
3.5~4.0
25.4~29.1
M8×1.2
Oil level gauge mounting flange bolt (8×16)
-
Oil pan drain plug
M14×1.5
Oil filter element
M26×1.5
19.6
2.0
14. 5
Oil cooler bypass
M16×1.5
19.6
2.0
14. 5
Oil cooler relief valve
M16×1.5
19.6
2.0
14. 5
Oil cooler drain plug
M14×1.5
3 4 .3 ~4 4 .1
3.5~4.5
25.4~32.7
-
1 8 .6 ~2 7 .4
1.9~2.8
13.8~20.4
-
7 .8 ~1 1 .8
0.8~1.2
5 . 8 ~8 .7
-
1 8 .6 ~2 2 .5
1.9~2.3
13.8~16.7
-
5 8 .8 ~8 3 .3
6.0~8.5
43.6~61.8
-
1 8 .6 ~2 2 .5
1.9~2.3
13.8~16.7
-
1 8 .6 ~2 7 .4
1.9~2.8
13.8~20.4
-
1 8 .6 ~2 7 .4
1.9~2.8
13.8~20.4
Oil cooler mounting flange bolt
Oil line flange bolt Oil line eye bolt
Idler gear oil supply pipe Turbo oil pipe eye bolt
Turbo oil pipe flange bolt (8 ×16) Oil pump mounting flange bolt bolt (8 ×55)
EM -92
ENGINE MECHANICAL SYSTEM
TROUBLESHOOTING
EBA1856F
Is oil pressure decreasing? Yes
Is oil level proper?
No
Check for oil leaks or mixture with coolant. Repair the damaged parts and replenish it with oil to the proper level.
Yes
Is the oil viscosity normal?
No
Replace the oil with the proper viscosity. Check fuel supply.
Yes
Do the oil pressure switch and gauge unit work?
No
Replace.
Yes Is the filter element clogged?
Yes
Replace the element.
No Is the oil strainer clogged? Is oil pump locked? Is pipe cracked?
Yes
Repair or replace the faulty parts.
No No Do the relief valve and regulator valve work?
Repair or replace.
Yes
Is there any damage or wear at the oil pump body?
Yes
Replace the faulty parts
No
Is connecting rod or main bearing worn?
Yes
Repair or replace the faulty parts
SUDEM7238L
LUBRICATION SYSTEM
EM -93
Excessive oil consumption
Check the following items for a leakage Oil filter Oil cooler Oil pan Oil pipe Oil cover
Yes
Repair the leaking parts.
No
Is oil leaking from the oil seals of front and rear crankshaft?
No
Repair or replace the faulty parts.
Yes
Is any damage in cooling system?
No
Repair the damage of oil cooler and water jacket etc.
Yes
Check the abrasion of the engine bearing which causes a leakage of oil.
No
Repair or replace.
SUDEM7239L
EM -94
ENGINE MECHANICAL SYSTEM
ADJUSTMENT
ENGINE OIL CHANGE
ECFE874F
1.
ENGINE OIL INSPECTION 1.
Park the vehicle vehicle on tthe he flat flat surface. surface.
2.
Stop Stop the the engi engine ne..
Stop the the engine engine a after fter w warming arming up and remov remove e the oil filler cap (2) on the cylinder head cover(1). 2
1
NOTE a. b.
3.
Warm Warm up the engine engine fo forr minutes minutes if the vehic vehicle le has not been inspected. Stop the the engine engine and wait wait ffor or 5 minutes minutes at least to measure the oil level.
If the oil level level is below below L m mark ark of the gauge, gauge, refill refill the oil up to mark F. NOTE When refilling, oil should be same kind with the one in the pan.
SUDEM7241L
2.
Loosen the dr drain ain pl plug ug (1 (1)) of oil pan pan to drain engine oil.
Good
1 SUDEM7240L SUDEM7242L
4.
Check the oil oil for for pol pollution lution,, mixture mixture with coolant coolant and viscosity.
3.
Tighten the drain drain plug with the s specifi pecified ed to torque. rque.
Tightening Tighten ing torque : 34.3~44.1 34.3~44.1 Nm (3.5 ~ 4.5kgf.m, 25.4~32.7 Ib-ft)
CAUTION If oil drain plug is not tightened to the specified t orque or gasket is reused, it may cause oil leakage or thread wear. Be sure to replace the gasket w ith new one at every oil change.
LUBRICATION SYSTEM 4.
EM -95
Fill in the new e engine ngine oil into into the the oil filler. filler.
OIL PRESSURE CHECK
NOTE Overfilling may cause oil saturation or pressure drop.
Oil capacity Oi Oill pan pan : 8ℓ Total capacity capacity : 9ℓ 5.
Remove regulator valve assembly and install pressure gauge gau ge (1). Warm Warm up the engi engine ne until until the temperatu temperature re reaches 70~90 C. Measure the oil pressure at idle speed and and max sp speed eed.. If the readin readings gs are belo below w the the limi limit, t, disassemble and check the lubrication system. Item
Close Close oil filler filler cap cap..
6.
Sta Start the engine.
7.
Stop the the en engin gine e and c chec heck k the oil lev level. el. Refill Refill the the engine oil if necessary.
Standard
No load load min min rpm rpm
1.5k 1. 5kg/ g/cm cm²
No load load max max rpm
3~5k 3~5kg/ g/cm cm²
Limit 0.5kg/cm²
2kg/cm²
1
LTER REPLACEMENT RE PLACEMENT OIL FI FIL 1.
Remove Remove the oil filter (1) us using ing oil oil filter filter wrench.
2.
Apply Apply engin engine e oil oil on the gasket gasket surfac surface e befo before re installing oil filter.
3.
Install the oil oil ffilter ilter with the specified specified torque. torque.
Tightening Tighten ing torque : 17.6~21.6 17.6~21.6 Nm (1.8~2.2 kgf.m, 13.1~16.0 Ib-ft) SUDEM7244L
1 SUDEM7243L
4.
Start the the engine engine and check the oil leakage. leakage.
5.
Stop the engine engine and c check heck oil level. level. Refill engine oil as needed.
EM -96
ENGINE MECHANICAL SYSTEM
OIL PUMP COMPONENTS
E68A3564
4.1 5
18.6~27.4 (1.9 ~ 2.8, 13.8~20.4)
34.3~39.2 (3.5 ~ 4.0, 25.4~29.1)
18.6~27.4 (1.9 ~ 2.8, 13.8~20.4)
4
18.6~27.4 (1.9 ~ 2.8, 13.8~20.4)
6
2
3
1
1. 2. 3. 4. 5. 6.
Crankcase Oil strainer O-ring Oil pan drain plug Oil pan Stiffener
Tightening Torque : Torque : Nm (kgf.m, Ib-ft) SUDEM7245L
LUBRICATION SYSTEM
18.6~27.4 (1.9 ~ 2.8, 13.8~20.4)
EM -97
2
1
4
3
13
12
11 8 6 5
7
9
10
1. Oil pump assembly 2. O-ring 3. Crankshaft gear 4. O-ring 5. Oil pump case assembly 6. Snap ring 7. Relief valve 8. Spring 9. Seat 10. Oil pump cover 11. O-ring 12. Drive gear 13. Driven gear
Tightening Torque : Torque : Nm (kgf.m, Ib-ft) SUDEM7246L
EM -98 DISASSEMBLY 1.
ENGINE MECHANICAL SYSTEM 3.
EE5D4AF9
If the clearance clearance between between the end end of the drive drive (1) (1) and driven gear (2) and oil pump case exceeds the limit, replace those parts.
Clearance between oil pump case and gear tooth end Standard : 0.10~0.19mm 0.10~0.19mm Limit Lim it : 0.2mm 0.2mm
Measu Measure re the the clea cleara ranc nce e betwe between en driv driven en gear and driv driven shaf shaft. t. If the clea cleara ranc nce e exce exceed eds s the lim limit it,, replace the parts.
Clearance between driven gear and driven shaft Standard Standar d : 0.04~0.07mm 0.04~0.07mm Limit Lim it : 0.15mm 0.15mm 4.
Measure the pl play ay o off drive drive gear end, if the measuremeasurement exceeds the limit, replace the parts.
Standard play of drive gear end : 0.03mm
2
1 SUDEM7247L
2.
Measure the difference difference betwee between n the drive and driven driven gears toot gears tooth h end end heig height ht and and th the e oi oill pump pump case case dept depth. h. If the meas measure urement ment ex excee ceeds ds the limit, limit, replac replace e the parts. parts. SUDEM7249L
Difference between oil pump case and gear tooth end height. (Sinkage) Standard : 0.01~0.07mm 0.01~0.07mm Limit Lim it : 0.18mm 0.18mm
5.
Check the op opening ening pressu pressure re of relief valve, valve, repl replace ace the parts if they exceeds the limit.
Standard of relief valve opening pressure : 10~12kg/cm²
SUDEM7248L
LUBRICATION SYSTEM
EM -99
OIL COOLER COMPONENTS
E221CA2C
19.6 (2.0, 14.5) 1
6 7
8
11.8 (1.2, 8.7) 2
34.3~39.2 (3.5 ~ 4.0, 25.4~29.1)
5 4
9
3
10
19.6 (2.0, 14.5)
11
12
13
19.6 (2.0, 14.5)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Oil cooler element Oil cooler body assembly Plug Spring Bypass valve Plug Spring Regulator valve Out packing Seaming cap assembly Bypass element assembly Full flow flow assembly Housing
Tightening Torque : Torque : Nm (kgf.m, Ib-ft) SUDEM7250L
EM -100
ENGINE MECHANICAL SYSTEM
DISASSEMBLY 1.
INSPECTION
EEA50548
Remove Remove the exhaust exhaust manifold. manifold.
EC9C5BDC
1.
Cover Cover oil cooler elemen elementt (1) and co connect nnect hose to the engine oil filler. And immerse it into the water tank.
2.
Apply air pressur pressure e of 3kg/cm² to hose side and check the oil cooler element.
3.
Check air leakage. leakage. If ai airr leaks, leaks, replace replace the oil cooler element.
SUDEM7251L
2.
Remove Remove the oil ffilter ilter (1) an and d oil cooler assembly assembly (2). (2). 2 1 SUDEM7254L
4.
Check Check the pres pressur sure e of oil cooler cooler bypass bypass v valv alve e and regulator regulat or valv valve e opening press pressure. ure. Replace the them m if necessary.
Bypass valve pressure : 3.5~4.5kg/cm² Regulator valve opening pressure : 5.0~7.0kg/cm² 5.
1 SUDEM7252L
3.
Disassemble Disassemble oil cooler cooler element (1) from from oil cooler. cooler. 1
Oil pressure pressure swit switch ch inspection inspection a. Remov Remove e oi oill p pressure ressure switc switch h ffrom rom oil oil cooler cooler.. b. Check the contin continuity uity between oil pressure pressure s switch witch terminal (2) and body(3) using a tester(1). If there is no continuity continuity,, replace the switch. 1
2
SUDEM7253L
3
SUDEM7255L
LUBRICATION SYSTEM c.
EM -101
Insert the the sl slim im rod rod (1) into oil hole of oil oil pressure pressure switch and check the continuity. If there is continuity, replace the parts because it is faulty.
1
SUDEM7256L
CLEANING 1.
Check the oil oil path and b bypass ypass valve valve of the the oil cooler element for carbon deposits and sludge formation. If contaminated, wash it in cleaning oil.
2.
If much much scale is evid evident ent on the el eleme ement nt and cover cover,, clean it.
REASSEMBLY
EC45CF49
Assembly is made in the reverse order of disassembly. When installing oil cooler, align oil cooler with the th e oil pump installation surface.
EM -102
ENGINE MECHANICAL SYSTEM
G SYSTEM COOLING COOLIN DESCRIPTION
THERMOSTAT 1.
The therm thermos osta tat, t, of a bot botto tom m bypas bypass s conf config igur urat atio ion, n, has has a valve controlled by a special wax enclosed in a pellet.
2.
The wax wax changes changes from from so solid lid to liquid as it is heated, heated,
EC3B53CC
COOLING SYSTEM Water pump pump cools down the engine by circulating the coolant forcibly as shown in the illustration below. coolant
involving volumetric change for regulation the flow of coolant. The valve position changes depending on the coolant temperatures regulate the flow rate of coolant into the radiator and water pump (bypass side), thus controlling coolant temperature.
Thermostat
At low At high temperature temperature
B
Radiator
Water pump Cooling fan A
SUDEM7257L
A : from cylinder head B : to radiator C : to water pump
WATER WA TER PUMP Water ater pump pump,, a cent centrif rifug ugal al type type,, is dri drive ven n by the VV-bel beltt from from the crankshaft pulley. A unit seal is installed between impeller and water pump that prevents leakage of coolant. There is a drain hole provided at the bottom of the water pump case, which ensures that water should leak from the unit seal, does not enter bearings. The water pump is mounted on the timing gear case provided with a suction pipe and swirl chamber. An Impeller, pressed fit into the one end of water pump shaft, has the combination blade, which feeds coolant under pressure into the engine.
C SUDEM7259L
3.
A jigg jiggle le valv alve is inst instal alle led d in the the air air plug plug hole hole of ther thermo mo-stat, which heats up the coolant temperature rapidly to put the engine temperature to the normal one. When engine stops, and coolant flows as jiggle valve falls down by its weight so that air in the engine is led to radiator through the cleara clearance nce between the jiggle valve and the breather hole. When the engine starts, coolant flow into the radiator and jiggle valve is pushed up by the water pressure. As a result, valve covers the air plug hole to prevent the coolant from leaking through the hole.
B
A
C
A
A
B
B
A; from the radiator B: from the thermostat C: to the crank case SUDEM7258L
1
A : air B : water SUDEM7260L
COOLING SYSTEM
EM -103
RADIATOR The radiator radiator,, which consists of tube-and-corruga tube-and-corrugated-fi ted-fin n type typ e core, core, not only cools the engine engine coolant coolant but also also separates vapor from liquid water and regulates pressure in the cooling system.
1.
When When the the air air te temp mper erat atur ure e in the rad radia iato torr is hig high, h, bimetal is deformed and opens the reservoir valve.
2.
Since Since the fluid (silic (silicon on oil) ke keeps eps flo flowing wing,, viscos viscosity ity between the coupling case and rotor increases, and the fan mounted to the case has the similar speed of shaft. Viscosity Viscosity varies varies with the fluid amount (silicon oil).
3.
When When the the air air tem tempe pera ratu ture re falls alls,, the bime bimeta tall is oper operat ated ed to clo close se the valv valve e and and the the flui fluid d retu returns rns to the the rese reserv rvoi oirr. It resu result lts s in a quic quick k spee speed d dec decre reas ase e by slidi sliding ng betw betwee een n the coupling case and rotor.
Radiator cap
Working area
Silicon oil storage area
Radiator
Coupling case Rotor
SUDEM7261L
Bimetal
RADIATOR RADIA TOR CAP Radiator cap regulates the pressure in the cooling system. When the pressure exceeds the predetermined level, the pressure valve compresses the pressure spring to release the excessive pressure to the air. As the coolant temperature drops and forms a vacuum in the radiator radiator,, the vent valve opens to admit air into the radiator, thus preventing the radiator from being deformed by the vacuum.
Coupling shaft
SUDEM7263L
OPERATION OPERA TION OF AUTOCOOL AUTOCOOL FAN COUPLING
Pump protrusion Pump hole
Fluid (silicon oil)
When pressure forms
Pump chamber A
Valve
Separator plate When vacuum forms Pump protrusion B
Pump hole
Pump chamber
A : to the reservoir tank B : from the reservoir tank SUDEM7262L
AUTO COLLING FAN Autoc Autocoo ooll fa fan n coupl couplin ing g is the the devi device ce to cont control rol the fa fan n spee speed d according to the engine coolant temperature. The bimetal
SUDEM7264L
detects the air temperature running through the radiator and varies the fluid coupling coupling flows to control the fan speed.
EM -104
ENGINE MECHANICAL SYSTEM
SPECIFICATION
EC630CCE
Item
Specification
C ool i ng m eth od
Water cooling, forced circulation
Coolant capacity capacity
20ℓ (includes engine, radiator and heater)
Water pump V-belt
Type
Volute pump
Drive
V-belt
Quantity
Thermostat
2EA
Type
Wax-pellet, bottom bypass (installed with jiggle valve)
Valve opening Temperature 82 C Fan
Type
N y l o n + G F3 0 % , s u c t i o n
Autocool fan coupling
Type
Fluid coupling type (viscosity)
Fl u i d
Silicon oil
Type
Tube-and corrugate-fin
Radiator
Cap type
P re s s u re t y p e
SERVICE STANDARDS Nominal value ( 〔 〕 indicates base diameter)
Item
Fan rotation (Autocool fan coupling) Water pump
-
Interference between pump shaft and flange
〔 17 〕 0.08~0.10mm
Limit
More than 2~3 revs. Up to 2 times
Gap between pump shaft and impeller 〔 13 〕 0.03~0.06mm Pump case to impeller installed dimension Thermostat Radiator
Valve opening temperature Valve lift / temperature Pressure cap opening Pressure pressure
80~84 C Above Above 10 / 95 C
nominal
negative
Between power steering pump and crankshaft pulley
Replace Replace Replace
Replace Replace
Below 0.05kg/cm²
Air-con compressor and tension pulley
Replace
Replace
Reser voir tank inner pressure Between alternator and water pump
Correction and remarks
0.83~1.10kg/cm²
Radiator check pressure
V-belt deflection
20.8~21.7mm
1.4k g/c m ²
Replace
0.5k g/ m m ²
Replace
12~16mm
adjust
4~6mm
16~20mm
adjust
adjust
COOLING SYSTEM
EM -105
TIGHTENING TIGHTENI NG TORQUE TORQUE Description (diameter x length)
Screw size OD×Pitch ( ㎜ )
Nm
kgf.m
Ib-ft
Fan clutch spring washer bolt (8×25)
M8×1.25
16.7~ 25.5
1 .7 ~2 .6
12.4~ 18.9
Fan clutch nut(6)
M6×1.0
3.9~ 5.9
0 .4 ~0 .6
2.9~ 3.6
Fan clutch mounting flange bolt(8)
M8×1.25
21.6~ 32.3
2 .2 ~3 .3
16~ 24
Thermostat cover case flange bolt
M8×1.25
21.6~ 32.3
2 .2 ~3 .3
16~ 24
PT 3/8
29.4~ 39.2
3 .0 ~4 .0
21.8~ 29.1
Thermostat case flange bolt(10×25)
M10×1.5
35.3~ 52.9
3 .6 ~5 .4
26.2~ 39.3
Radiator fan shroud mounting bolt
M6×1.0
4.9~ 6.9
0 .5 ~0 .7
3.6~ 5.1
Radiator mounting bolt
M8×1.25
11.8~ 14.7
1 .2 ~1 .5
8.7~ 10.9
Reser voir tank mounting bolt
M8×1.25
8.8~ 13.7
0 .9 ~1 .4
6.5~ 10.2
35.3~ 52.9
3 .6 ~5 .4
26.2~ 39.3
18.6~ 27.4
1 .9 ~2 .8
13.8~ 20.4
Coolant temperature sensor and gauge
Alternator adjusting plate mounting bolt(10×20) Alternat Alternator or adjusti adjusting ng shaft shaft mounti mounting ng nut (10) (10)
-
EM -106
ENGINE MECHANICAL SYSTEM
TROUBLE SHOOT SHOOTING ING
E37CE1A7
Overheat Yes
Is the tension of V-belt normal?
No
Adjust the tension of the belt and after checking the belt, replace it if necessary.
No
Add the coolant, and if there is a leak, check the cooling system.
Yes
Clean the radiator core and adjust the deformation of core if necessary.
Yes
Is coolant level proper? Yes
Is there any clogged radiator fan?
No Is coolant polluted or rusted?
Yes
Clean the cooling system
No Is thermostat operating?
No
Replace the thermostat
Yes Does water pump work properly?
No
Replace the water pump
Yes Is there any leak in the auto cooling fan coupling?
Yes
Replace the fan coupling
No Check the all possible causes of overheating.
SUDEM7265L
COOLING SYSTEM
EM -107
There is heavy loss of coolant.
Yes
Is the radiator hose leaking? No
No
Does the hose clamp tighten properly?
Yes
Cracked or damaged hose?
Yes
Is the radiator core leaking?
Tighten the clamp.
Replace the hose.
Repair or replace the radiator.
No Yes
Is the water pump leaking?
Replace the O-ring
No Is the radiator pressure pump leaking? No
Yes Is the pressure range correct correct in the pressure valve? Is gasket in good condition?
No
Replace the pressure valve.
Yes Any gas in the coolant leaked from cylinder head gasket?
No
Replace the cylinder head gasket.
Yes
Is the oil cooler leaking? No
Are bolts tightened properly?
No
Tighten the bolts.
Yes Defective or damaged O-ring?
Yes
Replace.
Check the possible leaking spots of the engine.
SUDEM7266L
EM -108
ENGINE MECHANICAL SYSTEM
WATER PUMP COMPONENTS
E27DE054
9
21.6~32.3 (2.2~3.3, 16~24) 35.3~52.9 (3.6~5.4, 26.2~39.3)
16.7~25.5 (1.7~2.6, 12.4~18.9)
5
3 2 1
7
6 8
4
21.6~32.3 (2.2~3.3, 16~24)
3.9~5.9 (0.4~0.6, 2.9~4.4)
1. 2. 3. 4. 5. 6. 7. 8. 9.
Cooling fan Autocool fan coupling Coupling plate Water pump pulley V-belt Water pump assembly O-ring Crankshaft damper pulley Thermostat housing
Tightening Torque : Torque : Nm (kgf.m, Ib-ft)
SUDEM7267L
COOLING SYSTEM REMOVAL
EM -109 4.
E9DD1BEE
1.
Remove Remove the coolan coolantt dra drain in plug plug and drain the coolant. coolant.
2.
Loosen the alternato alternatorr (1) tensio tension n adjusting adjusting screw screw (2) and remove V-belt (3).
Remove Remove wa water ter pump pump pul pulle ley(1) y(1) an and d wate waterr pump asassembly(2). 1
3 2
2
SUDEM7270L
5. 1 SUDEM7268L
3.
Remove Remove the cooling cooling ffan an (1) and autocoo autocooll ffan an coupling coupling (2).
Disas Disasse semb mble le the the cool coolan antt temp temper erat ature ure sens sensor or conne connecctor and remove the thermostat housing(1) from the cylinder head. a. b. c. d.
Remov Remove e the thermostat thermostat cover. cover. Rem Remov ove e the thermosta thermostat. t. Disa Disasse ssembl mble e the b bypa ypass ss pip pipe e from the the thermothermostat case. Remov Remove e the coolant coolant ttempera emperature ture sensor sensor..
1
2
1 SUDEM7269L
SUDEM7271L
EM -110
ENGINE MECHANICAL SYSTEM
INSPECTION
V-BELT TENSION CHECK
EE28BF77
WATER WA TER PUMP 1.
Insp Inspect ect the the crac crack, k, damag damage, e, and and wear wear of th the e parts parts,, and and replace the water pump, if necessary.
2.
Insp Inspect ect the bearin bearing g to see any damag damage, e, unus unusua uall noise, and poor revolution, and replace it, if necessary.
3.
Check Check the le leaka akage ge of th the e seal unit unit and and replace replace the the water pump, if necessary.
Adjust the belt tension to obtain the specified belt deflection when the center of each belt is pressed hard with a force of 10 kgf. Deflection between the alternato Deflection alternator(1) r(1) and water pump(2) pump (2) : 12~16mm 12~16mm
CAUTION a.
THERMOSTAT 1.
2.
Heat the the wa water ter to see iiff the thermostat thermostat v valve alve operates operates properly. Measure the tempera temperature ture when the valve valve starts starts openopening and is fully open. Item
c.
Specification
Valve Valv e opening temperature Valve lift / temperature
b.
Sin Since ce a slack slack belt belt may cause cause ov overh erhea eating ting or undercharge, undercha rge, adjust adjust the tension t o th e specification. An e exce xcessive ssively ly tight b bel eltt ma may y re result sult in possipossible damages damages of the belt or bearing. bearing. All of two VV-be belts lts shou should ld be repla replace ced d as a complete set.
80~84 C 2
more than 10 / 95 C
1
SUDEM7273L
SUDEM7272L
COOLING SYSTEM INSTALLATION 1.
EM -111 3.
EBC443E9
Install the c cooling ooling fan(1 fan(1)) and coolin cooling g fan fan co coupling upling(2). (2).
Install thermostat thermostat housing( housing(1) 1) to to tthe he cylinde cylinderr head. head.
1 2
1 SUDEM7269L
SUDEM7271L
2.
Install the water pump(1) and water water pump pulley(2) pulley(2) to the timing gear case.
Tightening Tighten ing torque : 16.7~25.5 16.7~25.5 Nm (1.7~2.6kgf.m, 12.4~18.9 Ib-ft)
4.
Install Install the V-belt( V-belt(1) 1) and adjust the tension tension using the alternator mounting nuts and adjusting bolts(2).
V-belt tension ; 12~16mm deflection (with a force of 10kg)
2
2
1
1 SUDEM7275L
SUDEM7274L
EM -112
ENGINE MECHANICAL SYSTEM
RADIATOR COMPONENTS
EFAA2107
4.9~6.9 (0.5~0.7, 3.6~5.1)
4 5
3 2 8 6 7
1 11.8~14.7 (1.2~1.5, 8.7~10.9) 11.8~14.7 (1.2~1.5, 8.7~10.9)
1. Rod 2. Plate 3. Intercooler 4. Radiator cap 5. Radiator hose upper 6. Radiator hose lower 7. Radiator 8. Shroud
Tightening Torque : Torque : Nm (kgf.m, Ib-ft)
SUDEM7276L
COOLING SYSTEM REMOVAL
EM -113 2.
ECA657F6
1.
Remove Remove the the rod from the radiator. radiator.
2.
Remove Remove tthe he intercoo intercooler ler from the radiator radiator..
3.
Remove Remove the the reservoir reservoir tank and bracket. bracket.
4.
Remove Remove the the radiator radiator ho hose se upper upper and radiat radiator or hose hose lower.
5.
Remove Remove the radiat radiator or sh shroud roud a and nd remove remove the radiator radiator..
INSPECTION
Check the opening pressur pressure e of radiator radiator c cap(1). ap(1). a. Connect the cap tester(2 tester(2)) to the radiator radiator c cap(1). ap(1). b. Apply the pressure pressure un until til the indicator indicator holds. holds. c. If th the e indica indicator tor d does oes not not hold hold ffor or about about 10 secseconds, then replace the radiator cap.
Valve opening pressure of the pressure valve :0.83~1.10kg/cm ²
1
EF6FFDCE
1.
Check the existen existence ce of fore foreign ign material materials s between between radiator fins.
2.
Check Check radia radiato torr fins fins for any damag damage e and and rep repai airr if needed.
3.
Check the rradiato adiatorr for for any corrosi corrosion, on, damage damage or rust.
4.
Check the rradiator adiator hose for any crack, crack, damage damage or deterioration.
2
SUDEM7278L
RADIATOR RADIA TOR CAP 1.
Check the radiator radiator cap ffor or an any y damage, damage, crack crack or deterioration.
Deterioration
Deterioration
SUDEM7277L
INSTALLATION
E52F2A5F
Install the parts in the reverse order of removal.
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