Hyundai D4DD) Engine Workshop Manual

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Hyundai D4DD) Engine Workshop Manual | Manualzz

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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