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ENGINE MECHANI-
CAL SYSTEM
(D4DD)
GENERAL
DESCRIPTION ............................................. EM -2
SPECIFICATION ......................................... EM -6
SPECIAL TOOL ........................................... EM -12
DIAGNOSIS ................................................. EM -15
ADJUSTMENT ............................................. EM -16
TIMING SYSTEM
TIMING GEAR ASSEMBLY
COMPONENTS ..................................... EM -17
REMOVAL .............................................. EM -19
INSPECTION .......................................... EM -22
REPLACEMENT .................................... EM -25
INSTALLATION ...................................... EM -26
CYLINDER HEAD ASSEMBLY
COMPONENTS ........................................... EM -31
REMOVAL ................................................... EM -33
DISASSEMBLY ........................................... EM -36
INSPECTION ............................................... EM -37
REPLACEMENT .......................................... EM -41
REASSEMBLY ............................................ EM -43
INSTALLATION ........................................... EM -44
CRANK CASE
FLYWHEEL
COMPONENTS ..................................... EM -46
REMOVAL .............................................. EM -47
INSPECTION .......................................... EM -47
INSTALLATION ...................................... EM -48
CYLINDER BLOCK ASSEMBLY
COMPONENTS ..................................... EM -50
REMOVAL .............................................. EM -52
DISASSEMBLY ..................................... EM -55
INSPECTION .......................................... EM -55
REASSEMBLY ...................................... EM -61
INSTALLATION ...................................... EM -62
INTAKE AND EXHAUST SYSTEM
SPECIFICATIONS ....................................... EM -66
TROUBLESHOOTING ................................ EM -67
TURBO CHARGER
COMPONENTS ..................................... EM -69
REMOVAL .............................................. EM -71
INSPECTION .......................................... EM -72
INSTALLATION ...................................... EM -73
INTAKE MAINIFOLD
COMPONENTS ..................................... EM -75
REMOVAL .............................................. EM -76
INSPECTION .......................................... EM -76
INSTALLATION ...................................... EM -77
EXHAUST MANIFOLD
COMPONENTS ..................................... EM -78
REMOVAL .............................................. EM -79
INSTALLATION ...................................... EM -80
AIR CLEANER
COMPONENTS ..................................... EM -81
INSPECTION .......................................... EM -85
LUBRICATION SYSTEM
DESCRIPTION ............................................. EM -86
SPECIFICATION ......................................... EM -90
TROUBLESHOOTING ................................ EM -92
ADJUSTMENT ............................................. EM -94
OIL PUMP
COMPONENTS ..................................... EM -96
DISASSEMBLY ..................................... EM -98
OIL COOLER
COMPONENTS ..................................... EM -99
DISASSEMBLY ..................................... EM -100
INSPECTION .......................................... EM -100
REASSEMBLY ...................................... EM -101
COOLING SYSTEM
DESCRIPTION ............................................. EM -102
SPECIFICATION ......................................... EM -104
TROUBLESHOOTING ................................ EM - 106
WATER PUMP
COMPONENTS ..................................... EM -108
REMOVAL .............................................. EM -109
INSPECTION .......................................... EM -110
INSTALLATION ...................................... EM -111
RADIATOR
COMPONENTS ..................................... EM -112
REMOVAL .............................................. EM -113
INSPECTION .......................................... EM -113
INSTALLATION ...................................... EM -113
EM -2
GENERAL
DESCRIPTION
COMBUSTION
CHAMBER
EFA0EBB7
1.
Combustion chamber consists of cylinder head, piston, injector installed to the cylinder head and valve.
Valve guide
Cylinder head
Valve
Injector
Piston
SUDEM7001L
2.
Fuel is supplied to supply pump through the fuel filter installed to the frame. Fuel is also supplied to injectors through injection pipe No. 1, 2, 3 and 4 in common rail assembly.
3.
Combustion is accomplished when fuel is injected directly into combustion chamber, at that time explosion pressure applies to the piston directly.
4.
For better efficient cooling of combustion chamber, water director is press-fit under cylinder head floor, which induces the coolant flow.
ENGINE MECHANICAL SYSTEM
VALVE MECHANISM
1.
Heat resistant steel with surface treatment is used for intake and exhaust valve. The valve seat angle is 45 .
2.
Valve stem seal, installed to the stem, adjusts the lubricant amount on the sliding surface of valve and valve guide.
NOTE
Valve guide with carbon cutter is used for exhaust valve.
3.
Valve spring consists of two valve springs having irregular pitches. The coil directions of inner and outer springs are opposite each other.
4.
Rocker shaft is hollow cylindrical rod, whose each end are sealed with sealing cap. Inner space of the shaft is an engine oil passage.
5.
Steel ball is installed to the lower end of push rod and rocker assembly is installed to upper end.
6.
Tappet has a cylindrical shape. As enlarging the contacting surface contacted with camshaft, it helps to prevent partial wear and to increase its durability.
Outer spring
Inner spring
Rocker
Rocker shaft
Push rod
Tappet
Valve spring
Valve guide
Exhaust valve
Intake valve
Camshaft
SUDEM7003L
Water director
Engine coolant
SUDEM7002L
GENERAL
7.
Camshaft assembly (1) consists of cam sensor plate, thrust plate, cam and journal. Camshaft gear is coupled with the idler gear A (2).
2
EM -3
3.
Cylinder sleeve made of special cast iron is pressed fit into the crankcase.
Crank case
Cylinder sleeve
1
SUDEM7004L
CRANKCASE AND CYLINDER SLEEVE
1.
Crankcase is manufactured firmly with cast iron to prevent stress concentration and deformation.
2.
The 5 camshaft bushes are installed to the camshaft bore of the crankcase.
To facilitate the removal and installation of camshaft, inner diameter of bush is tapered to the rear side.
Do not remove the cam sensor plate unless it is damaged.
SUDEM7006L
PISTON
1.
Piston pin type is full float type and piston pin is offset from thrust.
2.
Marks on the piston indicate weight, part 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.
Weight mark
Part number
Front mark
SUDEM7005L
SUDEM7007L
EM -4
PISTON RING
Piston has two compression rings and one oil ring. All sliding surfaces of rings are coated with hardened chrome.
Compression ring No. 1
ENGINE MECHANICAL SYSTEM
6.
Crankshaft gear (1) drives camshaft gear (2), idler gear A (3), idler gear B (4), supply pump gear (5) and oil pump gear (6).
3
5
2
Compression ring No. 2
Oil ring No. 3
4
SUDEM7008L
CRANKSHAFT
1.
Crankshaft is forged with high-strength alloy built in with balance weight.
2.
Pin, journal and oil seal sliding-surface are hardened with high frequency heat treatment to raise the resistance against frictional wear.
3.
Through oil passage at the pin and journal, oil lubricates main bearing. Oil flows to the pin for the lubrication of connecting rod bearing.
4.
Crankshaft pulley and crankshaft gear are installed at the front end of crankshaft. The crankshaft pulley drives alternator and water pump using V-belt.
5.
Crankshaft damper pulley absorbs the distorting vibration of crankshaft.
Journal
Crankshaft gear
6 1
SUDEM7010L
CRANKSHAFT MAIN BEARING
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)
Lower main bearing
Thrust plate
SUDEM7011L
Crankshaft damper pulley
Pin
Oil passage
SUDEM7009L
GENERAL
TIMING GEAR
1.
Timing gear is installed in the timing gear case at the front of engine.
2.
Each gear is helical gear manufactured with high precision and its surface is treated by heat to enhance the durability.
3.
Timing marks are marked on the gear. When assembling, by aligning the timing marks, gears can be engaged correctly.
Camshaft gear
Supply pump gear
EM -5
FLYWHEEL
1.
Flywheel is made of forged iron. Pilot bearing of transmission 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 is formed at the outer diameter of the flywheel to measure the engine rpm.
Ring gear
Processed
Idler gear A
Crankshaft gear
Idler gear B
SUDEM7012L
4.
Bushes are press-fit into idler gear, which rotates idler shaft A (1) and idler shaft B (2). Idler shaft and gear oil hole provides oil passage to lubricate bush and gear.
SUDEM7014L
1
2
SUDEM7013L
EM -6
SPECIFICATION
ECC41378
General Type
Cylinder inner diameter
Cylinder stroke
Displacement
Compression ratio
Firing order
Maximum output
Items
Maximum torque
Compression pressure (at 200rpm)
Valve timing
Intake valve open (BTDC)
Intake valve close (ABDC)
Exhaust valve open(BBDC)
Exhaust valve close (ATDC)
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)
Gap between valve stem and valve guide
Intake
Exhaust
Valve guide length
Intake
Exhaust
Valve sinkage
Intake
Exhaust
Push rod run out
Valve seat width
Intake
Exhaust
ENGINE MECHANICAL SYSTEM
Standard
([ ] indicates standard diameter)
Serial 4-cylinder 4stroke common rail system
104mm
115mm
3,907cc
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/1600rpm (County)
26kg/cm ²
Limit
20kg/cm ²
Corrective action
Adjustment
(As the difference between cylinders is within 4kg/cm ² )
19
53
60
16
137mm
137mm
8.960~8.975mm
8.925~8.940mm
45
1.5mm
0.4mm
[9] 0.04~0.06mm
[9] 0.07~0.10mm
8.85mm
8.85mm
1.2mm
0.15mm
0.2mm
Replace
64mm
71.5mm
0.75~1.25mm
0.75~1.25mm
―
1.5mm
1.5mm
0.4mm
Valve seat
Replace insert
Replace
2.6~3.0mm
1.8~2.2mm
3.6mm
2.8mm
Replace
GENERAL
Items
Outer side valve Spring
Free height
Load installed
Winding direction
Out of squareness
Inner side valve spring
Free length
Load installed
Winding direction
Out of squareness
Cylinder block
Cylinder bore
Torsion of upper crankcase
Flatness of gasket surface
Out of squareness of gasket surface
Clearance between tappet and crankcase tappet hole
Clearance between piston ring and piston ring groove
No.1 ring
No.2 ring
Oil ring
Piston ring end gap
No.1 ring
No.2 ring
Oil ring
Average protrusion of piston
Gasket grade A
Gasket grade B
Gasket grade C
Standard
([ ] indicates standard diameter)
66.1mm
26.5~29.3kg
To the right
1.5mm
60.0mm
11.5~12.7kg
Left side
1.5mm
104.00~104.03mm
Below 0.07mm
0.07mm
0.05mm
[28] 0.045~0.096mm
0.106~0.170mm
0.07~0.11mm
0.03~0.07mm
0.25~0.40mm
0.50~0.65mm
0.20~0.40mm
0.466~0.526mm
0.526~0.588mm
0.588~0.648mm
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 between piston pin and connecting rod end bush
Cylinder sleeve
Inner diameter
Out of roundness
Out of cylinderness
Cylinder head
Flatness of cylinder head bottom
Length from cylinder head top to bottom
Limit
63mm
23.7kg
2.1mm
57mm
10.3kg
2.1mm
0.2mm
0.2mm
0.2mm
0.15mm
0.15mm
1.0mm
1.5mm
1.0mm
EM -7
Corrective action
Replace
Replace
Replace the piston ring
Replace
103.91~103.92mm
0.080~0.130mm
Measure the average protrusion and replace the gasket with the corresponding grade gasket
Repair with oversize or replace
37.994~38.00mm
0.007~0.021mm
[38] 0.025~0.046mm
104.00~104.03mm
0.005mm
0.015mm
Below 0.1mm
94.9~95.1mm
0.05mm
0.1mm
Replace
Replace bush
100.25mm
Below
0.01mm
Below
0.03mm
Repair with oversize or replace
0.2mm
94.6mm
Repair or replace
EM -8
Items
Connecting rod
Connecting rod twist and distortion
Oil clearance
Connecting rod bearing
Free length of connecting rod bearing
Bearing crush (measured load 600kg)
Connecting rod endplay
Camshaft
Intake cam max. length
Intake cam min. length
Intake cam lift
Exhaust cam max. length
Exhaust cam min. length
Exhaust cam lift
Camshaft endplay
Clearance between camshaft journal and bushing
Crankshaft
Out of roundness of pin and journal
Out of cylindricity of pin and journal
Crankshaft distortion
(measured at journal No.1 and No.5)
Crankshaft endplay
ENGINE MECHANICAL SYSTEM
Standard
([ ] indicates standard diameter)
Limit
Corrective action
―
0.04~0.099mm
―
34.53~34.57mm
0.15~0.45mm
0.05mm
0.2mm
Min.
69.5mm
―
0.6mm
Repair or replace
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
([53] 0.04~0.09mm)
Below 0.01mm
Below 0.006mm
Below 0.02mm
0.10~0.26mm
0.036~0.098mm
0.056~0.118mm
―
41.061~41.101mm
0.3mm
0.15mm
Replace busing
0.03mm
0.03mm
0.05mm
0.4mm
0.15mm
0.15mm
Min 69.5mm
―
Replace thrust plate
Replace
Crankshaft main bearing
Oil clearance (#1, 2, 4, 5)
Oil clearance (#3)
Free length
Bearing crush( measured load 500kgf)
Timing gear backlash
Crankshaft gear and idler gear A
Idler gear A and cam shaft gear
Idler gear A and idler gear B
Idler gear B and supply pump gear
Camshaft gear and power steering pump gear
Crankshaft gear and oil pump gear
Power steering pump gear and vacuum pump gear
Idler gear endplay
Clearance between idler busing and idler shaft
Flywheel
Distortion of frictional surface
Height of frictional surface
Run-out of frictional surface (while installed)
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
0.05~0.22mm
[45] 0.025~0.06mm
Below 0.05mm
24.5mm
Below 0.1mm
Repair or replace
0.3mm
0.1mm
0.2mm
23.5mm
0.2mm
Replace thrust plate
Replace busing
Repair or replace
GENERAL
TIGHTENING TORQUE
Items (diameter × length)
Cylinder block
Lubrication system
Oil pump
Cylinder head
Main bearing cap bolt
Front plate flange bolt(8 × 16)
Rear oil seal slinger flange bolt(6 × 12)
Supply pump side timing gear case mounting bolt
Supply pump flange bolt
Oil jet check valve
Rear plate flange bolt(10 × 22)
Rear stiffener bracket flange bolt(8 × 55)
Rear stiffener bracket flange bolt (10 × 90)
Engine mounting bracket mounting bolt
Crankcase oil line set screw
Oil strainer flange bolt(8 × 16)
Oil strainer flange bolt (8 × 40)
Oil pan mounting flange bolt (8 × 12)
Oil level gauge mounting flange bolt(8 × 16)
Oil pan drain plug
Oil filter element
Oil cooler by-pass
Oil cooler relief valve
Oil cooler drain plug
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 mounting flange bolt(8 × 55)
Cylinder head mounting bolt
Cylinder head stud (10 × 25)
Cylinder head stud (10 × 48) kgf.m
5.0+90
1.9~2.8
0.8~1.2
1.9~2.8
1.9~2.8
1.9~2.8
1.9~2.8
3.5~4.0
2.0
2.0
2.0
3.5
1.9~2.8
0.8~1.2
1.9~2.3
1.9~2.3
1.9~2.3
1.9~2.8
1.7~2.6
3.0
6.5
1.9~2.8
3.9~6.0
3.3~5.0
2.5
1.9~2.8
1.9~2.8
15.0+90
3.5
3.5
Screw size
O.D×pitch
(mm)
M14 × 2.0
―
―
―
―
―
―
―
―
―
M14 × 2.0
―
―
―
M12 × 1.25
M10 × 1.5
―
―
―
M10 × 1.5
―
―
M8 × 1.2
―
M14 × 1.5
M26 × 1.5
M16 × 1.5
M16 × 1.5
M14 × 1.5
―
Nm
49+90
18.6~27.4
7.8~11.8
18.6~27.4
16.7~25.5
29.4
63.7
18.6~27.4
38.2~58.8
32.3~49
24.5
18.6~27.4
18.6~27.4
18.6~27.4
18.6~27.4
34.3~39.2
19.6
19.6
19.6
34.3
18.6~27.4
7.8~11.8
18.6~22.5
18.6~22.5
18.6~22.5
18.6~27.4
18.6~27.4
147+90
34.3
34.3
EM -9
Ib-ft
36.4+90
13.8~20.4
5.8~8.7
13.8~20.4
12.4~18.9
21.8
47.3
13.8~20.4
28.4~43.6
24~36.4
18.2
13.8~20.4
13.8~20.4
13.8~20.4
13.8~20.4
25.4~29.1
14.5
14.5
14.5
25.4
13.8~20.4
5.8~8.7
13.8~16.7
13.8~16.7
13.8~16.7
13.8~20.4
13.8~20.4
109+90
25.4
25.4
EM -10 ENGINE MECHANICAL SYSTEM
Items (diameter × length)
Fan and pulley
Thermostat housing
Timing system
Bleeder system
Alternator and vacuum pump
Fan clutch mounting flange bolt (8)
Fan clutch spring washer bolt(8 × 25)
Fan flange nut (6)
Thermostat cover case flange bolt
Engine coolant temperature sensor and gauge
Thermostat case flange bolt(10 × 25)
Timing gear case flange bolt
Rocker cover mounting flange bolt
Cam plate and thrust plate flange bolt
Cam plate and oil drain plug
Camshaft gear flange bolt
Idler gear A, B mounting bolt
Supply pump of flower valve
Blow-by return pipe and blow-by hose
Protect clip flange nut
Oil separate mounting flange bolt
PCV blow-by return coating clip flange bolt
Blow-by return pipe mounting flange bolt
Alternator adjust plate mounting bolt(10 × 20)
Alternator adjust shaft mounting nut (10)
Alternator assembly mounting bolt
Vacuum pump pipe tightening bolt
Vacuum pump mounting flange bolt
Piston and connecting rod
Flywheel and damper pulley
Starter motor
Connecting rod and connecting rod bearing cap mounting bolt
Flywheel mounting bolt
Crankshaft damper pulley mounting nut
Glow plug
Mounting flange bolt (12 × 25)
Mounting flange bolt (12 × 55)
Mounting flange bolt (12)
Glow plug harness flange nut
Plain washer nut
Screw size
O.D×pitch
(mm)
―
―
―
―
M12.5
× 1.25
M14
M24
―
―
―
―
―
×
×
1.5
1.5
―
―
M8 × 1.25
M8 × 1.25
―
―
―
M8 × 1.25
―
―
―
―
―
―
―
―
M12 × 134
M6 × 14
M8 × 16
Nm
9.8~14.7
18.6~27.4
7.8~11.8
35.3~52.9
35.3~52.9
18.6~27.4
78.4~107.8
3.9~5.9
18.6~27.4
29.4+90
39.2+40
588
78.4~107.8
37.2~53.9
37.2~53.9
3.9~5.9
1~1.5
21.6~32.3
16.7~25.5
3.9~5.9
21.6~32.3
29.4~39.2
35.3~52.9
18.6~27.4
12.7~15.7
18.6~27.4
58.8~78.4
18.6~27.4
18.6~27.4
7.8~12.7
kgf.m
2.2~3.3
1.7~2.6
0.4~0.6
2.2~3.3
3.0~4.0
3.6~5.4
1.9~2.8
1.3~1.6
1.9~2.8
6.0~8.0
1.9~2.8
1.9~2.8
0.8~1.3
1.0~1.5
1.9~2.8
0.8~1.2
3.6~5.4
3.6~5.4
1.9~2.8
8.0~11
0.4~0.6
1.9~2.8
3.0+90
4.0+40
60
8.0~11.0
3.8~5.5
3.8~5.5
0.4~0.6
0.1~0.15
Ib-ft
7.3~10.9
13.8~20.4
5.8~8.7
26.2~39.3
26.2~39.3
13.8~20.4
58.2~80
2.9~3.6
13.8~20.4
21.8+90
29.1+40
436
58.2~80
27.6~40
27.6~40
2.9~3.6
0.7~1.1
16~24
12.4~18.9
2.9~3.6
16~24
21.8~29.1
26.2~39.3
13.8~20.4
9.5~11.6
13.8~20.4
43.6~58.2
13.8~20.4
13.8~20.4
5.8~9.5
GENERAL
Intake manifold
Exhaust manifold
Engine cover
Turbo charger
Fuel system
Sensor
Items (diameter × length)
Actuator mounting flange bolt
Butterfly valve shaft mounting nut (8)
Intake manifold front hanger mounting flange bolt (10 × 20)
Intake manifold mounting flange bolt (8 × 20)
Exhaust manifold heater protector cover mounting bolt
Exhaust manifold assembly self lock
Flange nut
Top shield bolt screw
Turbo charger and intake pipe clamp band
Turbo charger oil pipe eyebolt
Fuel suction hose
Common rail fuel return B mounting screw
Fuel return A and fuel supply hose protect clip flange bolt
Fuel return A and rear plate clamp plate bolt
Injector pipe (No.1, 2, 3, 4)
Injector nozzle bridge bolt
Common rail bracket Flange bolt
Pipe (between supply pump and common rail)
Engine speed sensor mounting bolt
Cam speed sensor mounting bolt
Booster pressure sensor (M.A.P) mounting bolt
Screw size
O.D×pitch
(mm)
―
―
M8
M10
―
―
×
×
―
―
―
―
―
―
―
1.25
―
M9 × 2.5
M8 × 1.25
―
―
―
―
1.25
Nm
7.8~11.8
16.7~27.4
32.3~49
18.6~27.4
11.8
41.2
7.8~11.8
3.9
11.8
14.7~19.6
16.7~22.5
9.8~19.6
3.9~5.9
39.2~49
30.4~34.3
21.6~32.3
39.2~49
7.8~11.8
7.8~11.8
7.8~11.8
EM -11
Ib-ft
5.8~8.7
12.4~20.4
24~36.4
13.8~20.4
8.7
30.5
5.8~8.7
2.9
8.7
10.9~14.5
12.4~16.7
7.3~14.5
2.9~3.6
29.1~36.4
22.5~25.4
16~24
29.1~36.4
5.8~8.7
5.8~8.7
5.8~8.7
kgf.m
0.8~1.2
1.7~2.8
3.3~5.0
1.9~2.8
1.2
4.2
0.8~1.2
0.4
1.2
1.5~2.0
1.7~2.3
1.0~2.0
0.4~0.6
4.0~5.0
3.1~3.5
2.2~3.3
4.0~5.0
0.8~1.2
0.8~1.2
0.8~1.2
EM -12
SPECIAL TOOL
E2E65F7D
Tool (part no. and part name)
09212-41200
Camshaft bushing remover and installer
09246-41000
Idler gear bushing puller
09222-83200
Piston guide clamp
Shape
ENGINE MECHANICAL SYSTEM
Usage
Installation and removal of camshaft bushing
KDDEM5015A
Installation and removal of connecting rod bushing
KDDEM5016A
Installation of piston
09222-83300
Valve spring compressor
KDDEM5017A
Installation and removal of valve cotter
09221-41100
Valve guide remover
KDDEM5018A
Removal of valve guide
KDDEM5019A
GENERAL
Tool (part no. and part name)
09221-41150
Valve guide installer
09222-45100
Valve stem seal installer
Shape
EM -13
Usage
Installation of valve guide
(Use together with 09211-41100)
KDDEM5020A
Installation of valve stem seal
09353-45100
Air compressor adapter
09222-83200
Piston ring tool
KDDEM5021A
Measurement of compression pressure
KDDEM5022A
Installation and removal of piston ring
KDDEM5023A
EM -14
Tool (part no. and part name)
09222-45000
Rocker bush puller
Shape
ENGINE MECHANICAL SYSTEM
Usage
Installation and removal of rocker bush
09211-41000
Oil seal slinger installer
KDDEM5024A
Installation and removal of crankshaft rear oil seal slinger
KDDEM5025A
GENERAL
DIAGNOSIS
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
Oil pressure is excessively low
Engine oil depleted
Oil pressure 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
Oil pressure is excessively high
Connecting rod noise or main bearing noise
Excessive engine vibration
Engine coolant level is low
Oil relief valve stuck (close)
Improper oil supply
Low oil pressure
Low engine oil viscosity
Excessive bearing clearance
Engine mounting bolt is loose
Transmission mounting bolt is loose
Cross member bolt is loose
Engine mounting rubber is damaged
Transmission mounting rubber is damaged
Engine coolant leak
Radiator core joint is damaged
Radiator and heater hose corroded and cracked
Radiator cap valve or spring setting is defective
Thermostat defect
Water pump defect
Radiator is clogged
Engine coolant temperature is abnormally high
Foreign substance intrusion into engine 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
Engine coolant temperature is abnormally low
Thermostat is defective
Temperature wiring is defective
Oil cooling system leaks Hose or pipe connection is loose
Hose and pipe is cracked or damaged
Radiator fan is inoperative
Damage
EM -15
Maintenance
Replace gasket (check the status of head surface, block head)
Replace the ring
Repair or replace piston or cylinder block
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
Repair the relief valve
Check the engine oil level
Refer to ’oil pressure is excessively low’
Replace engine oil
Replace the bearing
Retighten
Retighten
Retighten
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust or Replace
Replace
Repair or replace
Repair or replace
Add coolant
Replace
Repair or replace
Retighten
Replace
Repair or replace
EM -16
Symptom
Exhaust gas leaks
Unusual noise
Possible cause
Connection is loose
Pipe or muffler is damaged
Baffle plate inside the muffler fell off
Rubber hanger is damaged
Pipe or muffler interferes with the body
Pipe or muffler is damaged
ADJUSTMENT
E148032F
COMPRESSION PRESSURE
1.
Before performing on-vehicle inspection, check to see whether engine oil, starter motor and battery are in normal condition.
2.
Start the engine and warm up until the coolant temperature reaches 80~90 C.
3.
Stop the engine and remove the ECM fuse.
4.
Remove all injectors from cylinder head.
CAUTION
Be careful that foreign materials do not intrude through the injector installation hole.
5.
Crank the engine to remove the foreign materials from cylinders.
6.
Install compression gauge adaptor (09353-45100) together with gasket and then, connect the compression gauge.
Compression pressure gauge
ENGINE MECHANICAL SYSTEM
Maintenance
Retighten
Repair or replace
Replace
Replace
Repair
Repair or replace
7.
Crank the engine and measure the compression pressure.
CAUTION a.
Take care that fuel is not injected.
b.
Since compression pressure varies depending on the engine speed, be careful in measuring.
c.
Since worn amounts of each cylinder are different, measure the pressure at all cylinders.
8.
Measure the compression pressure of all cylinders to see if all compression pressures are within the limit.
Items
Standard
Limit
Corrective action
Compression pressure
(200rpm)
Each cylinder
Difference between cylinders
26kg/cm ² 20kg/cm ² Check
― 4kg/cm ² Check
09353-45100
SUDEM7015L
9.
If the compression pressure difference of any cylinder exceeds the limit, fill some engine oil through injector hole and measure the compression pressure of the cylinder again.
1) If the compression pressure increases, it indicates that the piston, piston ring or cylinder wall is worn or damaged.
2) If the compression pressure does not increase, it indicates that valve is stuck, valve contact is poor or pressure is leaking through the cylinder head gasket.
TIMING SYSTEM
TIMING SYSTEM
TIMING GEAR ASSEMBLY
COMPONENTS
E2F63E1E
25
26
58.8~68.6
(6.0~7.0, 43.6~50.9)
18.6~27.4
(1.9~2.8, 13.8~20.4)
14
3.9~5.9
(0.4~0.6,
2.9~4.4)
12
13
15
16
17
18
19
20 21
22
23
6
7
5
60.0
1
2
3
4
8
24
9
10
11
Cam sensor plate
20. Thrust plate
21. Idler gear A
22. Idler shaft
23. Oil pump gear
24. Crankshaft gear
25. O-ring
26. Power steering oil pump
EM -17
Tightening Torque : Nm (kgf.m, Ib-ft)
SUDEM7016L
EM -18
If the cam sensor plate is not damaged, do not remove.
18.6~27.4
(1.9~2.8,
13.8~20.4)
1
2
58.8~78.4
(6.0~8.0, 43.6~58.2)
3
4
5
6
Tightening Torque : Nm (kgf.m, Ib-ft)
ENGINE MECHANICAL SYSTEM
7
8
1. Thrust plate
2. Semicircular key
3. No.1 camshaft bush
4. No.2 camshaft bush
5. No.3 camshaft bush
6. No.4 camshaft bush
7. No.5 camshaft bush
8. Sealing cap
SUDEM7017L
TIMING SYSTEM
REMOVAL
E812C03D
1.
Loosen the alternator (1) tensioner screw (2) and remove the V-belt(3).
EM -19
4.
Remove the vacuum pump (1) and alternator assembly (2).
2
2
1
1
3
SUDEM7018L
2.
Remove the cooling fan (1) and auto cooling fan coupling (2).
2
5.
Remove the power steering pump (1).
1
SUDEM7021L
1
SUDEM7019L
3.
Remove the water pump pulley (1) and water pump assembly (2).
2
SUDEM7022L
6.
Align the timing mark "0" of crankshaft damper pulley
(1) with the indicator (2) of the timing gear case. Then, cylinder No. 1 is positioned at TDC of compression stroke.
2
1
SUDEM7020L
1
SUDEM7023L
EM -20
7.
Remove the crankshaft damper pulley nut (2) and remove the crankshaft damper pulley (1).
ENGINE MECHANICAL SYSTEM
NOTE
Check the front oil seal (1) state. If it is normal, do not remove it.
2 1
SUDEM7024L
8.
Remove the engine coolant temperature sensor (1) connector and remove the thermostat housing (2) from the cylinder head.
1
SUDEM7027L
CAUTION
Before removing the timing gear case, remove 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.
2
1
SUDEM7025L
9.
Remove the cam speed sensor (1) from the timing gear case and then remove the timing gear case (2).
1
1
SUDEM7028L
2
SUDEM7026L
TIMING SYSTEM
10. Remove the front oil seal slinger (1).
13. Remove the idler gear B (1).
EM -21
11. Remove the oil pump gear (1).
1
1
SUDEM7029L
14. Remove the supply pump gear (1).
1
SUDEM7032L
1
12. Remove the idler gear A (1).
1
SUDEM7030L SUDEM7033L
15. Remove the camshaft assembly.
1.
Remove the thrust plate-mounting bolt (4) through cam sensor plate (2) hole (3) of camshaft gear (1).
SUDEM7031L
4
2
1 3
SUDEM7034L
EM -22
NOTE
Do not remove the cam sensor plate (2), if it is not damaged.
2.
When removing the camshaft assembly (1), handle cam bush carefully not to be damaged.
1
16. Remove the front plate (1).
1
ENGINE MECHANICAL SYSTEM
SUDEM7035L
2
SUDEM7037L
INSPECTION
EB5EDDCB
1.
Measure inner diameter of idler gear (1) and outer diameter of idler shaft (2). If the gap exceeds the limit, replace the idler gear bush.
Reference gap between idler bush and idler shaft ([
]indicates reference diameter): [45] 0.025~0.06mm
Limit: 0.1mm
1
1
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.
2
SUDEM7038L
2.
Measure cam max (1) and min diameter (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
Unit: mm
Items
Intake cam
Exhaust cam
Min cam diameter (2)
39.910
39.658
Max cam diameter (1)
47.105
Cam lift
7.195
46.979
7.321
EM -23
CAUTION
Since taper cam is used, measure it as shown in the figure.
Measuring position
A
6.5mm
B
6.5mm
A B
2
1
SUDEM7040L
4.
Measure the distortion of camshaft. If it exceeds the limit, replace or repair it with press.
Distortion of camshaft: 0.02mm
NOTE
Place the camshaft on the precision block and turn the camshaft in1 revolution. And read the dial indicator.
The distortion of the camshaft is a half of the measurement.
SUDEM7039L
3.
Measure the outer diameter of camshaft journal and the inner diameter of camshaft bush in the crankcase.
If the gap exceeds the limit, repair the camshaft bushing with oversize.
Outer diameter of camshaft journal
Journal No. # 1, 2, 3 and 4: 54.44~54.46 mm
Journal No. # 5: 52.94~52.96 mm
Inner diameter of camshaft bushing
Journal # 1, 2, 3 and 4: 54.5mm
Journal # 5: 53mm
Gap between camshaft journal and bushing
Reference: [54.5] 0.04~0.09mm
[53] 0.04~0.09mm
Limit: 0.15mm
SUDEM7041L
EM -24
5.
Measure the camshaft (1) endplay. If it exceeds the limit, repair or replace it.
Camshaft endplay
Reference: 0.05mm~0.22mm
Limit: 0.3mm
1
ENGINE MECHANICAL SYSTEM
2
1
SUDEM7044L c.
Idler gear A (1) and idler gear B (2)
Reference: 0.062~0.160mm
1
SUDEM7042L
6.
Measure the backlash of each gear and replace it if necessary.
NOTE
When measuring the backlash, fix the gear contacting the corresponding gear and move the gear to the left and right to measure the backlash.
a.
Crankshaft gear (1) and idler gear A (2)
Reference: 0.062~0.159mm
2
2
SUDEM7045L d.
Idler gear B (1) and supply pump gear (2)
Reference: 0.073~0.169mm
2
1 b.
Idler gear A (1) and camshaft gear (2)
Reference: 0.068~0.175mm
SUDEM7043L
1
SUDEM7046L
TIMING SYSTEM
e.
Oil pump gear (1) and crankshaft gear (2)
Reference: 0.049~0.169mm
EM -25
Camshaft bush
09212-41200
1
2
SUDEM7047L
REPLACEMENT
EF56BCEF
1.
Replacement of idler gear bush
Replace idler gear bush using the special tool (09246-
41000).
CAUTION a.
When assembling the bush, align the bush oil hole with gear oil hole.
b.
Check to see whether the clearance between bush and idler gear shaft satisfies the reference.
Removal Assembly
SUDEM7049L c.
Install the camshaft bush (1).
NOTE
When assembling camshaft bush, distinguish the bush by the number marked outside, which tells the installing position.
If the marked numbers are illegible, measure the inner diameter and width of the bush.
Unit: mm
Bush No.
(From the front of engine)
No.1
No.2
No.3
No.4
No.5
Carved mark
1
2
3
4
5
Outer diameter
58.519
58.269
58.019
57.769
57.019
Inner diameter
54.5
54.5
54.5
54.5
53.0
Width
33
22
22
22
22
Idler gear
09246-41000
09246-41000
Idler gear
Idler gear bush Idler gear oil hole
SUDEM7048L
2.
Replacement of camshaft bush a.
Remove the sealing cap from the crankcase camshaft hole.
b.
Remove the camshaft bush using the special tool
(09212-41200).
1
SUDEM7050L
EM -26
d.
Press fit the bush using the special tool (09212
- 41200) so that the camshaft bush end aligns crankcase end.
NOTE
When installing the camshaft bushing, align the oil hole of bush with crankcase oil hole (2).
1
Camshaft bush
09212-41200
ENGINE MECHANICAL SYSTEM
2.
Install the crankshaft gear (1).
SUDEM7051L
1
SUDEM7053L
3.
Install the idler shaft A (1) and idler shaft B (2).
CAUTION a.
When installing the idler shaft A and B, do not tighten the mounting bolts at once.
b.
After installing the idler shaft A and B, check to see whether the shaft rotates smoothly.
INSTALLATION
EEFAD1F1
1.
Install the front plate (1).
2
Crankcase
1
2
SUDEM7054L
1
SUDEM7052L
TIMING SYSTEM
4.
Install idler gear A and B.
CAUTION a.
When installing, align the timing mark "1" of idler gear A (1) with the timing mark "1" of crankshaft gear (2).
1
1
EM -27
2
SUDEM7057L b.
Press fit the camshaft gear assembly (1) of the cam plate (2) so that it faces outward.
2
SUDEM7055L b.
When installing, align the timing mark “ 4 ” of idler gear B (1) with the timing mark “ 4 ” of idler gear A (2).
1
2
2
SUDEM7056L
5.
Install the camshaft gear assembly.
a.
Install the thrust plate (1) so that the "F" mark of its oil hole faces to the camshaft gear (2).
1
SUDEM7058L c.
Measure the endplay between camshaft gear (1) and thrust plate (2) and install them as the clearance to be within the reference.
Reference: 0.05~0.22mm
1
2
SUDEM7059L
EM -28
d.
Install the camshaft assembly (1) to the crankcase.
1
ENGINE MECHANICAL SYSTEM
6.
Install the supply pump gear.
CAUTION
When installing, align the timing mark "5" of supply pump (1) with the timing mark "5" of idler gear
B (2).
1
SUDEM7060L
CAUTION
When installing, align the timing mark "2" of camshaft gear A (1) with the timing mark "2" of idler gear A (2).
1
2
7.
Install the oil pump gear (1).
2
SUDEM7063L
SUDEM7061L e.
Install the thrust plate (2) mounting bolt (3) through the hole of camshaft cam plate hole (1).
1
8.
Install the front oil seal slinger (1).
SUDEM7064L
3
2
1
SUDEM7062L
1
SUDEM7065L
TIMING SYSTEM
9.
Install the front timing gear case (1).
Tightening torque: 21.6~32.3 Nm
(2.2~3.3 kgf.m, 16~24 Ib-ft)
CAUTION a.
Apply the Loctite #5699 or equivalent on the assembly surface of timing gear case (1), and then assemble it within 3 minutes.
b.
Do not start the engine within 1 hour after installing the timing gear case.
EM -29
11. Install the water pump pulley (1) and water pump assembly (2).
2
1
1
SUDEM7068L
12. Install the crankshaft damper pulley (1) and damper pulley mounting nut (2).
Tightening torque: 588 Nm
(60 kgf.m, 436 Ib-ft)
SUDEM7066L
10. Install the power steering pump (1).
1
1
2
SUDEM7069L
SUDEM7067L
EM -30
13. Install the vacuum pump (1) and alternator assembly
(2).
ENGINE MECHANICAL SYSTEM
2
1
SUDEM7070L
14. Install the cooling fan (1) and automatic 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
CYLINDER HEAD
ASSEMBLY
COMPONENTS
E248774A
1
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)
2
11
147+90
(15+90 , 109+90 )
10
Tightening Torque : Nm (kgf.m, Ib-ft)
EM -31
5
3
4
Not reusable
6
7
8
9
1. Engine cover bolt
2. Engine cover
3. Cylinder head cover
4. Cylinder head cover gasket
5. Rocker and bracket assembly
6. Cylinder head bolt
7. Cylinder head assembly
8. Cylinder head gasket
9. Crank case
10. Push rod
11. Oil filler cap
SUDEM7073L
EM -32
7
2
6
1
3
4
5
13
9
10
11
ENGINE MECHANICAL SYSTEM
8
12
14
1. Valve cap
2. Valve cotter
3. Valve retainer
4. Outer side spring
5. Inner side spring
6. Valve stem seal
7. Push rod
8. Cylinder head
9. Water director
SUDEM7074L
CYLINDER HEAD ASSEMBLY
REMOVAL
EDE5E369
1.
Remove the engine cover(1) from the cylinder head cover.
EM -33
4.
Loosen the hexa-bolt (2) of injector nozzle bridge (1) and remove the injector (3).
2
3
1
SUDEM7280L
2.
Remove the glow plug and glow plug plate (1).
1
1
SUDEM7078L
5.
Remove the oil separator (1) and blow-by hose (2)
2
1
SUDEM7076L
3.
Remove the injection pipe(1) No 1, 2, 3 and 4 running from the common rail assembly to the injector.
6.
Remove the oil level gauge (1).
1
SUDEM7079L
SUDEM7080L
1
SUDEM7077L
EM -34
7.
Remove the intake manifold assembly (1).
1
ENGINE MECHANICAL SYSTEM
10. Remove the turbocharger assembly (1) from the cylinder head.
1
2
SUDEM7081L
NOTE
Do not remove the actuator (2) of the intake manifold if its operation is normal.
8.
Remove the thermostat housing (1).
SUDEM7084L
11. Loosen the exhaust manifold mounting nut (1) and then remove exhaust manifold (2).
2
1
1
SUDEM7082L
9.
Remove the turbocharger heater protector cover (1) and exhaust manifold heater protector cover (2).
1
12. Remove the cylinder head cover (1).
1
2
SUDEM7085L
SUDEM7086L
SUDEM7083L
CYLINDER HEAD ASSEMBLY
13. Remove the cylinder head bolts.
NOTE a.
Since push rod is pressing the rocker, loosen the rocker adjusting screws (1) to remove the cylinder head bolts (2).
2
EM -35
14. Remove the rocker arm and rocker bracket assembly
(1).
1
1
SUDEM7087L b.
When removing the cylinder head bolts, remove them according to the sequence as shown in the following figure.
15. Remove the cylinder head assembly (1).
1
SUDEM7089L
3
7
1 5 9 13 14 10 6
11
15
17
16
12
8
2
4
SUDEM7090L
SUDEM7088L
EM -36
16. Remove the cylinder head gasket (1).
CAUTION
When removing the cylinder head gasket, be careful not to damage the cylinder head and crankcase.
1
ENGINE MECHANICAL SYSTEM
DISASSEMBLY
ECC7ED4F
ROCKER AND ROCKER SHAFT BRACKET
ASSEMBLY
1.
Remove the set bolt from the front rocker shaft bracket.
2.
Remove the front and rear rocker shaft bracket.
3.
Remove the rocker assembly.
4.
Remove the rocker shaft spring from the rocker shaft.
5.
Remove the rocker shaft bracket No.2, 3 and 4 and then, remove the rocker shaft.
17. Remove the valve tappet (1).
1
Rocker bush
Rocker
Rocker shaft
SUDEM7091L
Set bolt
Rear rocker shaft bracket
SUDEM7092L
Rocker shaft spring
Rocker assembly
Front rocker shaft bracket
SUDEM7093L
VALVE AND CYLINDER HEAD ASSEMBLY
1.
Remove the valve cotter (2) with pushing the valve spring (1) evenly using the special tool
(09222-83300).
09222-83300
2
1
SUDEM7094L
CYLINDER HEAD ASSEMBLY
2.
Remove the retainer (1), valve spring (2), valve stem seal (3) and intake and exhaust valve from the cylinder head.
CAUTION
Valve stem seal should be replaced with new one.
1
2
EM -37
4.
Remove the cylinder gasket (1).
CAUTION
When removing the cylinder head gasket, check the cylinder head and crankcase for any damage.
1
3
4
SUDEM7095L
3.
Remove the water director (1) from the cylinder head.
NOTE
If water director is corroded, remove it. If not, leave it.
SUDEM7097L
INSPECTION
E5264C2D
1.
Check to see whether valve cap (1) and retainer (2) have any irregular wear.
2.
Check the intake and exhaust valve (3) for any stuck, crack or damage.
1
2
1
SUDEM7096L
3
SUDEM7098L
EM -38
3.
Check the valve tappet (1) for any damage or wear.
1
SUDEM7099L
4.
Measure the rocker inner diameter and rocker shaft outer diameter. Replace the bush of rocker, if the gap exceeds the limit.
Standard Limit Items
Inner diameter of rocker bush
Outer diameter of rocker shaft
Gap
18.980~18.993mm
19.05~19.09mm
0.06~0.11mm
―
―
0.2mm
ENGINE MECHANICAL SYSTEM
5.
Inspect the out of squareness (A), free length (B), load installed (C) of valve spring, replace it if any of them exceeds the limit.
Outer side
Valve spring
Inner side
Valve spring
Items
Free length
Load installed
Out of squareness
Free length
Load installed
Out of squareness
Standard
66.1mm
27.9±1.4kg
1.5mm
60mm
12.1±0.6kg
1.5mm
Limit
63mm
23.7kg
2.1mm
57mm
10.3kg
2.1mm
A
B
C
SUDEM7101L
6.
Measure the outer diameter of tappet (1) and inner diameter of crankcase tappet hole (2). Replace the tappet if the gap exceeds the limit.
Reference: 0.045~0.096mm
Limit: 0.2mm
SUDEM7100L
1
SUDEM7102L
CYLINDER HEAD ASSEMBLY
2
SUDEM7103L
7.
Measure the run-out of push rod (1). Replace it if it exceeds the limit.
Limit of pushrod run-out: 0.4mm
EM -39
8.
Measure the deformation of cylinder head bottom face. If the measurement exceeds the limit, repair it with surface grinder or replace it.
Flatness of cylinder head
Reference: 0.05mm
Limit: 0.2mm
NOTE
Deformation of cylinder head bottom is measured at the position as shown in the following figure.
1
SUDEM7104L
SUDEM7105L
9.
Measure the outer diameter of valve stem. If the measurement is below the limit, replace the valve stem.
Outer diameter of valve stem
― Intake valve
Reference : 8.96~8.97mm
Limit : 8.85mm
― Exhaust valve
Reference : 8.93~8.94mm
Limit : 8.85mm
SUDEM7106L
EM -40
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: 0.04~0.06mm
Limit: 0.15mm
― Exhaust
Reference: 0.07~0.10mm
Limit: 0.2mm
ENGINE MECHANICAL SYSTEM
c.
Measure the seat contact area (A).
Area of the valve seat contact
― Intake
Reference: 2.8± 0.2mm
Limit: 3.6mm
― Exhaust
Reference: 2.0± 0.2mm
Limit: 2.8mm
A
SUDEM7109L
SUDEM7107L
11. Check the contacting state of valve seat and valve.
a.
Apply light blue coating on the valve surface.
b.
Check the valve contacting state by 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
E03FAF94
REPLACEMENT OF ROCKER BUSH
1.
Remove the bush from rocker using the special tool
(09222-45000).
2.
Press fit the bush into rocker using the special 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
VALVE SEAT REPAIR
1.
Repair the valve face using valve refacer (1).
CAUTION
Valve seat angle is 45 .
EM -41
09222-45000
Rocker chamber
Rocker
Rocker bush
SUDEM7110L
REPALCEMENT OF VALVE GUIDE
Remove the valve guide using the special tool
(09221-41100). Install the valve guide using the special tool (09221-41150, 09221-41100).
At removing At installing
09221-41100
09221-41150
1
SUDEM7112L
2.
To repair the valve seat, use the valve seat cutter or valve seat grinder (1). After grinding, insert the #400 or equivalent sand paper between cutter and valve seat and grind lightly.
CAUTION
Repair the valve seat width and valve sinkage to satisfy the specified limit.
1
18mm
Valve guide
SUDEM7113L
Valve guide
SUDEM7111L
EM -42
3.
Install the valve seat using the caulking tool body (1) and locking ring (2).
CAUTION
Press the valve seat (3) with the chamferred side of the locking ring. And then, caulk it to the cylinder head as the ring faces the other side.
Installing Caulking
1
ENGINE MECHANICAL SYSTEM
5.
Apply the compound evenly over the valve seat surface (1).
CAUTION a.
Valve stem (2) should be free from any compound.
Use the medium mesh (mesh between 120 and 150) compound at first and finish the grinding with the fine mesh compound (above 200 mesh) b.
Mix the compound with some engine oil to apply evenly.
2
2
1
3
SUDEM7114L
4.
Grind the seat width (A) and valve sinkage (B) to be within the standard.
Valve and valve seat should touch evenly all over the surface.
Valve seat width (A)
Reference: 2.6~3.0mm (Intake)
1.8~2.2mm (Exhaust)
Limit: 3.6mm (Intake)
2.8mm (Exhaust)
Valve sinkage (B)
Reference: 1.5mm
Limit: 1.2mm
SUDEM7116L
6.
Place the valve on the valve seat using the valve lapper (1). Tap the valve with turning the valve slightly.
Clean the compound with diesel or equivalent. Apply the engine oil and check whether the contact surface is securely positioned.
1
A
SUDEM7117L
B
SUDEM7115L
CYLINDER HEAD ASSEMBLY
REASSEMBLY
EBF48CA7
ROCKER AND ROCKER SHAFT ASSEMBLY
1.
Install rocker shaft bracket No. 1, 2, 3 and 4 to the rocker shaft.
2.
Install the rocker shaft spring.
3.
Apply engine oil on the rocker bush, and then install the bush to the rocker.
4.
Install the rocker assembly.
5.
Install the front and rear rocker shaft bracket.
6.
Install the front and rear rocker shaft bracket set bolts.
Tightening torque: 7.8~11.8 Nm
(0.8~1.2 kgf.m, 5.8~8.7 Ib-ft)
Rocker bush
Rocker
Rocker shaft
2.
Install the intake and exhaust valve.
EM -43
SUDEM7118L
3.
Apply the engine oil on the valve stem seal lip and install the valve stem seal using the special tool (09222-
45100).
NOTE
Tap the seal until the special tool (09222-45100) contacts the cylinder head.
Set bolt
Rear rocker shaft bracket
Rocker shaft spring
Rocker assembly
Front rocker shaft bracket
SUDEM7093L
VALVE AND CYLINDER HEAD ASSEMBLY
1.
Install the water director to the cylinder head.
Cylinder head
09222-45100
Valve
Valve stem seal
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 and assembly of cylinder head gasket.
Select the cylinder head gasket according to the piston protrusion amount.
Average piston protrusion
0.466~0.526
0.526~0.588
0.588~0.648
Gasket size
A
B
C
Gasket thickness
1.35±0.03
1.40±0.03
1.45±0.03
Unit : mm
Measuring gauge of piston protrusion
SUDEM7121L
INSTALLATION
EDA3BF2F
1.
Assembly is performed in the reverse order of disassembly.
2.
Installation of cylinder head gasket.
CAUTION
When installing the cylinder head gasket (1), cylinder head installing surface should be free from any impurities or foreign materials such as oil.
a.
Assemble the cylinder head so that "UP" mark of the cylinder head gasket faces to the cylinder head.
SUDEM7122L
NOTE
If the max protrusion of the piston is 0.05mm more than average protrusion, then use the grade up
(A → B) gasket.
CYLINDER HEAD ASSEMBLY
A B C
SUDEM7123L
3.
Checking and adjusting of valve clearance
NOTE
Check and adjust the valve clearance while the engine is cold.
1) Crank the engine with the cranking handle and align the needle to "0" position of crankshaft damper pulley (side marked with No. 1 through
4). Or align it to the "0" position of crankshaft damper pulley (side marked No. 2 to 3). (This is at the TDC of comopression stroke of cylinder
No. 1).
EM -45
Cylinder
No.
1 2 3 4
Valve
Intake
Exhaust
Intake
Exhaust
Intake
Exhaust
Intake
Exhaust
TDC of
No.1
TDC of
No.4
○ ○ ○
× ×
○
× ×
3) Measure the clearance between rocker and valve cap using the thickness gauge.
a.
If the valve clearance exceeds the reference value, loosen the lock nut (2) and adjust the clearance with thickness gauge by turning the adjusting screws.
b.
After the valve clearance adjustment, fix the adjusting screw using the screw drive (3) and fasten the lock nut securely.
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 TDC of compression stroke of cylinder No.
1, check and adjust the clearance of the valve with "O" mark at the following table. And then, turn the crankshaft in one turn to check and adjust the valve clearance of remaining valves with
"X"mark.
EM -46
CRANKCASE
FLYWHEEL
COMPONENTS
E60B5C72
ENGINE MECHANICAL SYSTEM
1
2
3
4
5
7
39.2+40
(4+40 , 29.1+40 )
6
7
8
1. Front plate
2. Gasket
3. Crankcase
4. Rear plate
5. Rear oil seal
6. Pilot bearing
7. Flywheel
8. Flywheel mounting bolt
Tightening Torque : Nm (kgf.m, Ib-ft)
SUDEM7126L
CRANKCASE
REMOVAL
EECFB3A9
1.
Remove the flywheel mounting bolt (1), and then remove the flywheel (2).
4.
Remove the rear oil seal slinger (1).
EM -47
2
1
SUDEM7127L
2.
Remove the rear plate mounting bolt (1), and then remove the rear plate (2).
2
1
SUDEM7130L
INSPECTION
EE08EBFD
1.
Distorsion check of frictional surface a.
Put the flywheel (2) on the precision table (1) and set up the dial indicator (3).
b.
Move the dial indicator on the flywheel frictional surface to measure the distortion.
c.
If the distortion of the frictional surface exceeds the limit, regrind the frictional surface.
Distortion of the frictional surface
Reference: Below 0.05mm
Limit: 0.2mm
3
1
SUDEM7128L
3.
Remove the rear oil seal mounting bolt (1), and then remove the rear oil seal (2).
2
1
SUDEM7131L
1
2
SUDEM7129L
EM -48
2.
Repair of the frictional surface
Repair the frictional surface with the surface grinder.
CAUTION a.
After repairing the frictional surface, check whether the frictional surface is parallel with surface A within 0.1mm.
b.
Check the frictional surface (size B) whether its height is within the limit.
Height to the frictional surface (B)
Reference: 24.5mm
Limit: 23.5mm
ENGINE MECHANICAL SYSTEM
INSTALLATION
E561D9B1
1.
Install the rear oil seal slinger using the special tool
(09211-41000).
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 gear evenly using acetylene torch or equivalent tools and then remove the ring gear by tapping the circumference with rod or hammer.
b.
When installing, heat the ring gear with piston heater for 3 minutes (about 100 C). And then, insert the ring gear so that the un-chamfered gear faces to flywheel.
1
Crankshaft
Rear oil seal slinger
SUDEM7134L
The chamfer was machined.
SUDEM7279L
CRANKCASE
2.
Apply the sealant (Loctite #5699) to the rear oil seal
(1), and then install the rear oil seal.
Tightening torque: 7.8~11.8 Nm
(0.8~1.2 kgf.m, 5.8~8.7 Ib-ft)
EM -49
4.
Install the flywheel (1).
Tightening torque: 39.2Nm+40
(4.0kgf.m+40 , 29.1 Ib-ft+40 )
Sealant 1
1
SUDEM7135L
SUDEM7138L
1
3.
Install the rear plate (1).
Tightening torque: 63.7 Nm
(6.5 kgf.m, 47.3 Ib-ft)
SUDEM7136L
1
SUDEM7137L
EM -50
CYLINDER BLOCK ASSEMBLY
COMPONENTS
EBC859AD
1
2
3
6
4
5
7
8
9
ENGINE MECHANICAL SYSTEM
10
11
29.4+90
(3.0+90 , 21.8+90 )
18.6~27.4
(1.9~2.8, 13.8~20.4)
Tightening Torque : Nm (kgf.m, Ib-ft)
12
3. Oil ring No. 3
5. Piston
8. Connecting rod upper bearing
9. Crankcase
10. Connecting rod lower bearing
11. Connecting rod cap
12. Oil pan
SUDEM7139L
CRANKCASE EM -51
1
2
588 (60.0, 436)
12
11
10
9
8
29.4 (3.0, 21.8)
3
4
5
6
7
49+90
(5.0+90 , 36.4+90 )
7. Main bearing cap
2. Oil jet mounting bolt
3. Upper main bearing
5. Rear oil seal slinger
6. Lower main bearing
10. Crankshaft gear
11. Front oil seal slinger
12. Crankshaft pulley
Tightening Torque : Nm (kgf.m, Ib-ft)
SUDEM7140L
EM -52
REMOVAL
EE4DAE0F
1.
Remove the engine and transaxle.
2.
Remove the flywheel and rear plate.
3.
Remove the intake and exhaust manifold.
4.
Remove e the cylinder head assembly.
5.
Remove the supply pump (1) and common rail assembly (2).
2
ENGINE MECHANICAL SYSTEM
8.
Remove oil cooler assembly.
SUDEM7143L
1
1
SUDEM7281L
6.
Remove the V-belt (1) and remove the alternator assembly (2).
2
SUDEM7144L
9.
Remove timing gear train [(oil pump gear (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 mark (2~3 side) of crankshaft damper pulley to the compression TDC of cylinder No. 1.
NOTE
As for the removal of cooling fan pulley, crankshaft damper pulley and timing gear case, refer to the removal procedure of timing system.
6
1
4
SUDEM7145L
CRANKCASE
10. Remove the power steering pump (1).
1
13. Remove the oil strainer (1).
1
EM -53
11. Remove the starter motor assembly (1).
SUDEM7146L
SUDEM7149L
14. Remove rear oil seal (1) and oil seal slinger (2).
1
12. Remove the oil pan (1).
1
SUDEM7147L
1
SUDEM7150L
SUDEM7148L
2
SUDEM7151L
EM -54
15. Remove the connecting rod bearing cap (1).
NOTE
Make marks at the connecting rod and cap to be reassembled correctly.
1
2
ENGINE MECHANICAL SYSTEM
1
3
SUDEM7152L
16. Remove the piston and connecting rod assembly (1) from cylinder block.
SUDEM7154L
18. Remove the crankshaft (1) from the cylinder block.
CAUTION
Handle the crankshaft carefully so that the journal is not damaged.
1
1
SUDEM7153L
17. Remove the front, rear and main bearing caps.
a.
Remove the front bearing cap and rear end bearing cap. Remove the thrust plate (2) from the rear-bearing cap (1).
b.
Remove the main bearing cap (1) and bearing
(3).
SUDEM7155L
19. Remove the oil jet (1) from the cylinder block.
1
SUDEM7156L
CRANKCASE
DISASSEMBLY
E190BEAB
PISTON AND CONNECTING ROD ASSEMBLY
1.
Remove the piston ring using the special tool (09222-
83200).
EM -55
4.
Remove the connecting rod (1) from the piston.
1
09222-83200
SUDEM7157L
2.
Remove the piston pin snap ring (2) using the snap ring pliers (1).
1
2
3.
Remove the piston pin (1) from the piston.
SUDEM7158L
SUDEM7160L
INSPECTION
EBE61DCA
CYLINDER BLOCK
NOTE a.
Before repairing, clean each part to remove dust, oil, carbon and fur.
b.
Before cleaning the cylinder block, check water leakage or damages.
c.
Remove the adhesives at each oil hole using air brush and check whether any hole is clogged.
1.
In addition to the visual check about scratch, rust and corrosion, inspect the slight scratches with precipitant. Repair or replace it if needed.
2.
Measure the twist of cylinder block using straight edge
(1) and thickness gauge (2). Measure them by placing the straight edge as shown in the following figure.
NOTE
When measuring, cylinder upper block should be free from foreign materials such as gasket piece.
CAUTION
When grinding the cylinder block, grind it as the piston protrusion does not exceed the reference.
1
SUDEM7159L
EM -56
Flatness figure of cylinder block
Reference : Below 0.07mm
Limit : 0.2mm
1
ENGINE MECHANICAL SYSTEM
a.
Measure the inner diameter of cylinder sleeve using the cylinder gauge (1).
Inner diameter of cylinder sleeve: 104.00~104.03mm
1
2
SUDEM7161L
3.
Check the cylinder wall to see if it is cracked or damaged. If it is abnormal, repair (oversize) or replace the cylinder sleeve.
4.
Measure the cylinder sleeve ID using the cylinder gauge. If it is excessively worn, repair it with oversize and replace the piston and piston ring.
Clearance between piston and cylinder sleeve :
0.080~0.130mm
CAUTION
1.
When replacing piston, piston ring should be replaced together.
2.
Even if only one cylinder needs boring, all cylinder walls should be grinded with oversize at the same time.
3.
Measure the most seriously worn cylinder wall and select the oversize based on the measurement.
4.
Available oversizes are +0.25, +0.50, +0.75
and +1.00.
5.
Piston and connection rod should be replaced with the new one which has identical weight and grade with the old one.
SUDEM7162L b.
Measure the outer diameter of piston skirt at the position, which is 85mm down from the upper piston.
Outer diameter of piston: 103.91~103.92mm
SUDEM7163L
CRANKCASE
PISTON
1.
Check each piston to see whether it is damaged.
2.
Check whether the piston pin (1) is installed correctly in the piston hole.
If any defect is found, replace the piston and piston pin as an assembly.
Piston pin should slide into the piston hole smoothly when it is pushed by hand.
EM -57
4.
Measure the clearance between 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 Limit: 0.1mm
1
SUDEM7164L
3.
Measure the clearance between piston pin and piston hole by measuring the inner diameter of piston pin (1) and piston boss.
Inner diameter of piston boss: 38mm
Outer diameter of piston pin: 38mm
Clearance Reference: 0.007~0.021mm
Clearance Limit: 0.05mm
1
SUDEM7166L
PISTON RING
1.
Check the piston ring for any damage, unusual wear or breakage. If damaged, replace the ring.
2.
When replacing the piston, replace the piston pin together.
3.
Measure the clearance between piston ring and the wall of the ring groove, using a feeler gauge.
Piston ring
Ring No.1
Ring No.2
Oil ring
Standard
0.106~0.170mm
0.07~0.11mm
0.03~0.07mm
Limit
0.2mm
0.15mm
0.15mm
SUDEM7165L 1
SUDEM7167L
EM -58
4.
After installing the piston ring to the cylinder bore, push the piston ring to the vertical direction with the piston.
Piston ring end gap
Ring No.1: 0.25~0.40mm
Ring No.2: 0.50~0.65mm
Oil ring: 0.20~0.40mm
ENGINE MECHANICAL SYSTEM
CRANKSHAFT
1.
Measure the endplay of crankshaft.
Crankshaft endplay
Reference :0.10~0.26mm
Limit: 0.4mm
a.
If the endplay exceeds the limit, replace the thrust plate with the oversize.
b.
Oversizes of the thrust plate are +0.15, +0.30, and +0.45.
SUDEM7168L
SUDEM7169L
2.
Measure the oil gap of crankshaft main bearing.
a.
Remove the main bearing cap.
b.
Measure the oil gap of main bearing.
1) Remove the oil or other foreign materials from main journal and main bearing surface.
2) Place the plastic gauge along with the shaft direction of the journal.
CRANKCASE
3) Install the main bearing cap and fasten the bolt.
Tightening torque: 49.0 Nm+90
(5.0kgf.m+90 , 36.4 Ib-ft+90 )
EM -59
3.
Measure roundness and cylindricity of crankshaft journal and pin.
If the measurement exceeds the limit, repair it with under size.
Roundness of crankshaft
Reference : less than 0.01mm , Limit : 0.03mm
Cylindricity of crankshaft
Reference : less than 0.006mm , Limit : 0.03mm
SUDEM7170L
4) Remove the main bearing cap and measure oil gap at each journal.
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
SUDEM7172L
4.
Check to see if the crankshaft 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
Limit : 0.05mm
NOTE
Actual bending is a half of the measurement.
SUDEM7171L
5) If the oil gap of the main bearing is excessively large, replace the main bearing.
SUDEM7173L
EM -60
CONNECTING ROD BEARING
1.
Before removing the connecting rod cap, measure the connecting rod endplay. If the gap exceeds the reference, replace the connecting rod.
Connecting rod endplay
Reference: 0.15~0.45mm
Limit: 0.6mm
ENGINE MECHANICAL SYSTEM
d.
Remove the connecting rod bearing cap and measure the oil gap at each pin journal.
Connecting rod oil gap
Reference: 0.040~0.099mm
Limit: 0.2mm
SUDEM7174L
2.
Measure the oil gap of the connecting rod bearing.
1) Remove the connecting rod cap.
2) Measure the oil gap of the connecting rod bearing.
a.
Remove the oil or foreign materials from pin journal and connecting rod bearing surface.
b.
Place the plastic gauge on the shaft of pin journal along with its direction.
c.
Install the connecting rod bearing cap and fasten the bolt.
Tightening torque: 29.4 Nm+90
(3.0kgf.m+90 , 21.8 Ib-ft+90 )
SUDEM7176L e.
If the oil gap is excessively large, replace the connecting rod bearing.
3.
Length of the connecting rod bearing.
Length of the Connecting rod bearing (1) is measured at the free state. If the measurement is below the limit, replace the upper and lower bearing.
Length of the connecting rod bearing
Limit: above 69.5mm
CAUTION
Bearing should not be artificially expanded to reuse.
1
SUDEM7177L
SUDEM7175L
CRANKCASE
REASSEMBLY
E49D5D90
PISTON AND CONNECTING ROD ASSEMBLY
1.
Install the piston ring using the special tool (09222-
83200).
EM -61
2.
Apply engine oil at the piston rod end and piston pin hole, and then install the piston pin (1).
1
09222-83200
SUDEM7178L
NOTE a.
Install the piston ring so that open end of the piston ring faces to the direction shown in the figure.
b.
Install the oil ring expander spring to be positioned at 180 direction with the oil ring end. Otherwise, expander spring may be loosened.
Oil r ing ex pander spr ing Compr ession r ing No. 1
SUDEM7180L
3.
Install the piston pin snap ring (2) using snap ring pliers (1).
1
2
Engine fr ont
SUDEM7181L
Compr ession r ing No. 2 Oil r ing
SUDEM7179L
EM -62
INSTALLATION
EE5ABFA8
1.
Install oil jet (1) to the cylinder block.
1
ENGINE MECHANICAL SYSTEM
3.
Install the crankshaft (1) to the cylinder block.
CAUTION
Handle crankshaft carefully not to be damaged.
1
SUDEM7182L
2.
Install thrust plate (1) and upper main bearing (2) to the crankcase.
CAUTION a.
Install the thrust plate with the oil grooveless side toward the crankcase.
b.
Align the lug groove of crankcase with the lug of main bearing.
c.
Since there is oil hole at upper bearing, take care not to be interchanged with lower bearing.
d.
Apply engine oil on the all over the sliding surface.
SUDEM7184L
4.
Install the front, rear and main bearing caps.
a.
Insert the lower main bearing (1) into bearing cap
(2).
NOTE
Check to see whether the main bearing lug matches main bearing cap lug groove.
b.
Install thrust plate (3) to the rear-bearing cap.
3
2
2
1
SUDEM7185L
1
SUDEM7183L
CRANKCASE
c.
Install the main bearing cap with the specified torque.
Tightening torque: 49.0 Nm+90
(5.0kgf.m + 90 , 36.4 Ib-ft+90 )
EM -63
b.
When installing connecting rod cap, align mark (1) on connecting rod big end cap with mark (2) on connecting rod cap.
1
SUDEM7186L
5.
Install piston and connecting rod assembly.
CAUTION a.
Install piston and connecting rod to the crankshaft pin journal using the special tool
(09222-83200).
2 1
SUDEM7188L c.
When installing piston, assemble it so that front mark (1) of the piston faces to the front side.
d.
Assemble so that the arrow mark ( → ) of piston head faces to the center of cylinder head bolt hole.
09222-83200
1
SUDEM7189L
SUDEM7187L
EM -64
e.
Tighten the connecting rod cap with specified torque.
Tightening torque: 29.4 Nm+90
(3.0kgf.m + 90 , 21.8 Ib-ft+90 )
ENGINE MECHANICAL SYSTEM
7.
Apply the sealant (Loctite #5699) to the rear oil seal, and then install the rear oil seal (1).
SUDEM7190L
6.
Install rear oil seal slinger using the special tool
(09211-41000).
8.
Install the oil strainer (1).
1
1
SUDEM7192L
SUDEM7193L
09211-41000
SUDEM7191L
CRANKCASE
9.
Install the oil pan (1).
1
SUDEM7194L
10. After installing the cylinder block assembly, measure the piston protrusion. 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 timing system.
12. Install the flywheel and rear plate.
13. Install the cylinder head assembly.
14. Install intake and exhaust manifold.
15. Install engine accessories.
EM -65
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