EM -66 ENGINE MECHANICAL SYSTEM INTAKE AND EXHAUST SYSTEM SPECIFICATIONS E08C8904 Items Specifications Air cleaner type Dry type Element type Paper type type Turbocharger (TD05H-12G) Length 260mm Width 172mm Height 216mm Max rpm allowed 160,000rpm Maximum pressure ratio 2.6 Intercooler Maximum exhaust gas temperature 760 C TIGHTENING TORQUE Items (Diameter×Length) Screw size O.D×pitch (mm) Nm kgf.m Ib-ft Turbocharger and intake pipe clamp band M9× 2.5 3.9 0.4 2.9 Tur- bocharger Turbocharger oil pipe eyebolt M8× 1.25 16.7 1.7 12.4 Actuator mounting flange bolt M6× 1.0 7.8~11.8 0.8~1.2 5.8~8.7 Butterfly valve shaft mounting nut (8) M8× 1.25 16.7~25.5 1.7~2.6 12.4~18.9 Intake manifold front hanger mounting flange bolt(10× 20) M10× 1.5 32.3~49 3.3~5.0 24~36.4 Intake manifold Intake manifold mounting flange bolt(8 × 20) M8× 1.25 18.6~27.4 1.9~2.8 13.8~20.4 Heater protector cover mounting bolt M8× 1.25 11.8 1.2 8.7 Exhaust manifold Exhaust manifold assembly self lock flange nut M10× 1.25 41.2 4.2 30.5
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EM -66 ENGINE MECHANICAL SYSTEM
INTAKE AND EXHAUSTSYSTEM
SPECIFICATIONS E08C8904
Items Specifications
Air cleaner type Dry type
Element type Paper type
type Turbocharger (TD05H-12G)
Length 260mm
Width 172mm
Height 216mm
Max rpm allowed 160,000rpm
Maximum pressure ratio 2.6
Intercooler
Maximum exhaust gastemperature 760 C
TIGHTENING TORQUE
Items (Diameter×Length)Screw sizeO.D×pitch
(mm)Nm kgf.m Ib-ft
Turbocharger and intake pipe clamp band M9×2.5 3.9 0.4 2.9Tur-bocharger Turbocharger oil pipe eyebolt M8×1.25 16.7 1.7 12.4
1. Remove the turbocharger heater protector cover (1).
1
SUDEM7199L
2. Remove the turbocharger assembly (1).
1
SUDEM7200L
3. Make an aligning mark on the coupling (1), turbinehousing (2), compressor cover (3), and cartridge as-sembly (4).
1
2
3
4
SUDEM7201L
4. Remove the turbine housing(1).
CAUTION
a. Lightly tap the housing circumference withrubber hammer so that turbine housing is notdamaged.
b. Since turbine wheel blade is easily bent, ex-ercise care when removing the housing.
1
SUDEM7202L
EM -72 ENGINE MECHANICAL SYSTEM
5. Remove the compressor cover (1).
CAUTION
a. Lightly tap the compressor cover circumfer-ence with rubber hammer so that compressorcover is not damaged.
b. Since compressor wheel blade is easily bent,exercise care when removing the compressorcover.
1
SUDEM7203L
INSPECTION EFAE8284
1. Measure the shaft directional clearance of shaft andturbine wheel assembly. If the measurement exceedsthe limit, replace the cartridge assembly (1).
1
SUDEM7204L
2. Check the shaft directional clearance of shaft and tur-bine wheel assembly.a. Check the clearance of turbine wheel side. If the
measurement exceeds the limit, replace the car-tridge assembly (1).
1
SUDEM7205L
b. Inspect the clearance of compressor wheel side.If the measurement exceeds the limit, replace thecartridge assembly (1).
1
SUDEM7206L
INTAKE AND EXHAUST SYSTEM EM -73
3. After assembling the turbocharger assembly (1), turneach wheel (2) to see if it rotates smoothly.
2
1
SUDEM7207L
4. When assembling turbocharger assembly (1), fill withthe engine oil through the oil hole (2) so that each partoperates smoothly.
2
1
SUDEM7208L
INSTALLATION E50867FF
1. When assembling the snap ring (1) to compressorcover (2), assemble it so that the snap ring taper side(3) faces up.
CAUTION
When installing the snap ring, install it to the com-pressor cover by holding the snap with one hand.
21
3
SUDEM7209L
2. Install the turbocharger assembly (1).
Tightening torque: 41.2 Nm(4.2kgf.m, 30.5 Ib-ft)
1
SUDEM7210L
EM -74 ENGINE MECHANICAL SYSTEM
3. Install the turbocharger heater protector cover (1).
1. Remove the injection pipe (1) No. 1,2,3 and 4 fromcommon rail assembly to the injector.
1
SUDEM7213L
2. Remove the Intake manifold assembly (1).
1
SUDEM7214L
INSPECTION EEC01B88
Inspection and adjustment of the clearance between but-terfly valve and Intake manifold
1. Secure the butterfly valve to the close state with500mmHg or more negative pressure applied to theactuator (the condition that double nuts are coherentto the bracket).
2. Adjust the clearance by moving the adjusting hole (A)of actuator bracket and tighten it with the bolt.
Clearance between butterfly valve andIntake manifold (B):4.0~4.5mm
B
A
Double nut
Actuator
SUDEM7215L
3. When the internal air pressure of 3kg/cm² is appliedto the actuator, it should maintain the airtight of 0.1ccor less for 5 seconds.
4. Butterfly valve should have the durability of 400,000cycles at the ambient temperature of 80 C.
When installing the butterfly valve (1), fasten the but-terfly valve shaft mounting nut (2) so that the identi-fication mark (▽) faces to the direction shown in theillustration.
1. When dust indicator turns red, which tells the filterreplacement interval, replace the element.
CAUTIONReplace the element at least once per 2 years.Do not reuse it after cleaning.
2. Replacement of air cleaner filter.a. Loosen the clamp of the air cleaner assembly.b. Remove the lower cap of air cleaner assembly.c. Loosen butterfly nut of element.d. Remove the element.e. Clean the inside of air cleaner thoroughly.f. Replace the air cleaner element with new one.
CAUTION
When replacing the element, exercise caution thatair-cleaner should not contain any dust or foreignmaterial.
g. Tighten the butterfly nut of element.h. Check to see if the packing at the air-cleaner as-
sembly is correctly installed. If correctly installed,install the lower cap.
i. Fix the lower cap by tightening the clamp.j. Press the dust indicator reset button so that the
red color disappears.
CAUTIONGenuine parts of the air-cleaner must be used. Ifthe vehicle is driven with the air-cleaner removed,it may be the cause of early engine damage.
EXHAUST MUFFLER
1. Check the exhaust system for any unusual noise.
2. Check the exhaust muffler for connection and corro-sion.
3. Check the exhaust muffler gasket for any damage.
EM -86 ENGINE MECHANICAL SYSTEM
LUBRICATION SYSTEM
DESCRIPTION E3DF9F3D
FLOW CHART OF LUBRICATION SYSTEM
Engine is lubricated by a gear-type oil pump that forcesengine oil through the oil cooler and oil filter into the enginefor lubrication of various engine parts.
Main oil gallery
Bypass valve
Oil filterOil pressure switch
Idler gear bush
Crankshaft main bearing
Camshaft bush
Oil cooler OrificeTiming gear
Connecting rod bearing
Rocker bush
Regulator valve
Oil pump
Relief valve
Connecting bush Push rod
Turbo charger
tappet vacuum pump
oil jet
piston
oil strainer
oil pan
SUDEM7228L
OIL PUMP
The oil pump, of a gear type, is driven by the crankshaftrotation engaged with oil pump gear. And the relief valveis installed to the oil pump so that it prevents the excessivepressure by bypassing the engine oil to oil pan when theoil pressure exceeds the specification.
A
BC
Relief valve
Drive gear Oil pump gear
Oil pump cover
Driven gear
Oil pump case
A: from oil strainerB: to oil coolerC: to oil pan
SUDEM7229L
LUBRICATION SYSTEM EM -87
OIL COOLER
Oil cooler is equipment for heat exchange between thecoolant and oil fed from the crankcase water jacket andoil pump, respectively. The oil cooler has a bypass valvethat opens when the element (1) becomes clogged.
1
SUDEM7230L
BYPASS VALVE
When the oil viscosity is high (in cold) or oil path showshigh resistance depending on the element load, the by-pass valve (1) opens and oil goes directly to oil filter with-out passing oil cooler.
1
SUDEM7231L
REGULATOR VALVE
When oil pressure in main oil gallery exceeds the spec-ification, regulator valve (1) opens and some engine oildrains to the oil pan to adjust the oil pressure.
1
SUDEM7232L
OIL PRESSURE SWITCH
If the pressure of engine oil which is sent to the main oilgallery is below the specification, the built-in relay in theoil pressure switch (1) is closed, then the warning lamp inthe instrument panel is on to inform the driver of abnormalpressure.
1
SUDEM7233L
EM -88 ENGINE MECHANICAL SYSTEM
OIL FILTER
Oil filter uses a spin-on type paper element, in which fullflow filter and bypass filter are integrated. Bypass valveis assembled to the bottom of the filter. If the element isloaded, valve opens so that engine oil goes to oil maingallery without passing through the element to prevent en-gine overload.
1. Out packing2. Seaming cap3. Bypass element assembly4. Full-flow element assembly5. Housing
1
2
3
4
5
SUDEM7234L
LUBRICATION OF PARTS
The engine oil routed from the oil filter to oil main gallerylubricates all engine parts as detailed below before return-ing to the oil pan.
1. Main bearing and connecting rod bearinga. There is an oil passage (1) provided from the oil
main gallery to each main bearing. The oil flowsthrough the oil hole (2) to lubricate the main bear-ing and passes through the oil passage drilledinto the crankshaft to lubricate the connecting rodbearings.
1
2
SUDEM7235L
b. The Oil jet (1), installed at each cylinder oil mainpassage, injects engine oil into the piston (2) tocool the piston. This oil jet has a check valvewhich is opened/closed by the specified oil pres-sure, it prevents oil flow and oil pressure from de-creasing at low pressure.
1
2
SUDEM7236L
LUBRICATION SYSTEM EM -89
2. CamshaftCamshaft bushings are lubricated by the oil flowingthrough the oil passages leading from the oil maingallery to each bushing.
3. Valve mechanismThe engine oil that has lubricated No. 1 camshaftbushing passes through the oil hole and pipe providedat the top portion of crankcase to the cylinder head.The engine oil then goes through the front rocker shaftbracket into the rocker shaft, lubricating each rockerbushing. At the same time, it lubricates valve cap andvalve stem of the rocker. The oil then passes throughthe push rod holes in the cylinder head and crankcaseto lubricate the tappets and camshaft cams beforereturning to the oil pan.
Front rocker shaft bracket
Rocker shaft
Push rod
Tappet
Camshaft cam
SUDEM7237L
EM -90 ENGINE MECHANICAL SYSTEM
SPECIFICATION EADD3E2D
OIL COOLER
Item Specification
Bypass valve open 3.5~4.5kg/cm²(361~419kpa)
Regulator oil pump valve open 5~7kg/cm²(490~686kpa)
If oil drain plug is not tightened to the specifiedtorque or gasket is reused, it may cause oil leak-age or thread wear. Be sure to replace the gasketwith new one at every oil change.
LUBRICATION SYSTEM EM -95
4. Fill in the new engine oil into the oil filler.
NOTEOverfilling may cause oil saturation or pressure drop.
Oil capacityOil pan : 8ℓTotal capacity : 9ℓ
5. Close oil filler cap.
6. Start the engine.
7. Stop the engine and check the oil level. Refill theengine oil if necessary.
OIL FILTER REPLACEMENT
1. Remove the oil filter (1) using oil filter wrench.
2. Apply engine oil on the gasket surface before in-stalling oil filter.
3. Install the oil filter with the specified torque.
5. Stop the engine and check oil level. Refill engine oilas needed.
OIL PRESSURE CHECK
Remove regulator valve assembly and install pressuregauge (1). Warm up the engine until the temperaturereaches 70~90 C. Measure the oil pressure at idle speedand max speed. If the readings are below the limit,disassemble and check the lubrication system.
1. If the clearance between the end of the drive (1) anddriven gear (2) and oil pump case exceeds the limit,replace those parts.
Clearance between oil pump case and gear tooth endStandard : 0.10~0.19mmLimit : 0.2mm
2
1
SUDEM7247L
2. Measure the difference between the drive and drivengears tooth end height and the oil pump case depth. Ifthe measurement exceeds the limit, replace the parts.
Difference between oil pump case and geartooth end height.(Sinkage)Standard : 0.01~0.07mmLimit : 0.18mm
SUDEM7248L
3. Measure the clearance between driven gear anddriven shaft. If the clearance exceeds the limit,replace the parts.
Clearance between driven gear and driven shaftStandard : 0.04~0.07mmLimit : 0.15mm
4. Measure the play of drive gear end, if the measure-ment exceeds the limit, replace the parts.
Standard play of drive gear end :0.03mm
SUDEM7249L
5. Check the opening pressure of relief valve, replacethe parts if they exceeds the limit.
Standard of relief valve opening pressure :10~12kg/cm²
LUBRICATION SYSTEM EM -99
OIL COOLER
COMPONENTS E221CA2C
1. Oil cooler element 2. Oil cooler body assembly 3. Plug 4. Spring 5. Bypass valve 6. Plug 7. Spring 8. Regulator valve 9. Out packing10. Seaming cap assembly11. Bypass element assembly12. Full flow assembly13. Housing
1
19.6 (2.0, 14.5)
19.6 (2.0, 14.5)
19.6 (2.0, 14.5)
11.8 (1.2, 8.7)
34.3~39.2(3.5 ~ 4.0, 25.4~29.1)
6
78
9
10
11
12
13
2
34
5
Tightening Torque : Nm (kgf.m, Ib-ft)
SUDEM7250L
EM -100 ENGINE MECHANICAL SYSTEM
DISASSEMBLY EEA50548
1. Remove the exhaust manifold.
SUDEM7251L
2. Remove the oil filter (1) and oil cooler assembly (2).
2
1
SUDEM7252L
3. Disassemble oil cooler element (1) from oil cooler.
1
SUDEM7253L
INSPECTION EC9C5BDC
1. Cover oil cooler element (1) and connect hose to theengine oil filler. And immerse it into the water tank.
2. Apply air pressure of 3kg/cm² to hose side and checkthe oil cooler element.
3. Check air leakage. If air leaks, replace the oil coolerelement.
1
SUDEM7254L
4. Check the pressure of oil cooler bypass valve andregulator valve opening pressure. Replace them ifnecessary.
5. Oil pressure switch inspectiona. Remove oil pressure switch from oil cooler.b. Check the continuity between oil pressure switch
terminal (2) and body(3) using a tester(1).If there is no continuity, replace the switch.
1
2 3
SUDEM7255L
LUBRICATION SYSTEM EM -101
c. Insert the slim rod (1) into oil hole of oil pressureswitch and check the continuity.If there is continuity, replace the parts because itis faulty.
1
SUDEM7256L
CLEANING
1. Check the oil path and bypass valve of the oil coolerelement for carbon deposits and sludge formation. Ifcontaminated, wash it in cleaning oil.
2. If much scale is evident on the element and cover,clean it.
REASSEMBLY EC45CF49
Assembly is made in the reverse order of disassembly.When installing oil cooler, align oil cooler with the oil pumpinstallation surface.
EM -102 ENGINE MECHANICAL SYSTEM
COOLING SYSTEM
DESCRIPTION EC3B53CC
COOLING SYSTEM
Water pump cools down the engine by circulating thecoolant forcibly as shown in the illustration below.
Thermostat
Radiator
Cooling fanWater pump
SUDEM7257L
WATER PUMP
Water pump, a centrifugal type, is driven by the V-belt fromthe crankshaft pulley. A unit seal is installed between im-peller and water pump that prevents leakage of coolant.There is a drain hole provided at the bottom of the waterpump case, which ensures that water should leak fromthe unit seal, does not enter bearings. The water pump ismounted on the timing gear case provided with a suctionpipe and swirl chamber.An Impeller, pressed fit into the one end of water pumpshaft, has the combination blade, which feeds coolant un-der pressure into the engine.
C
A
B
A; from the radiatorB: from the thermostatC: to the crank case
SUDEM7258L
THERMOSTAT
1. The thermostat, of a bottom bypass configuration, hasa valve controlled by a special wax enclosed in a pel-let.
2. The wax changes from solid to liquid as it is heated,involving volumetric change for regulation the flow ofcoolant.The valve position changes depending on the coolanttemperatures regulate the flow rate of coolant into theradiator and water pump (bypass side), thus control-ling coolant temperature.
C
A
B At high temperature
A : from cylinder headB : to radiatorC : to water pump
At low temperature
SUDEM7259L
3. A jiggle valve is installed in the air plug hole of thermo-stat, which heats up the coolant temperature rapidlyto put the engine temperature to the normal one.When engine stops, and coolant flows as jiggle valvefalls down by its weight so that air in the engine is ledto radiator through the clearance between the jigglevalve and the breather hole.When the engine starts, coolant flow into the radiatorand jiggle valve is pushed up by the water pressure.As a result, valve covers the air plug hole to preventthe coolant from leaking through the hole.
1
A A
B B
<When engine is off> <When engine is on>
A : airB : water
SUDEM7260L
COOLING SYSTEM EM -103
RADIATOR
The radiator, which consists of tube-and-corrugated-fintype core, not only cools the engine coolant but alsoseparates vapor from liquid water and regulates pressurein the cooling system.
Radiator cap
Radiator
SUDEM7261L
RADIATOR CAP
Radiator cap regulates the pressure in the cooling system.When the pressure exceeds the predetermined level, thepressure valve compresses the pressure spring to releasethe excessive pressure to the air.As the coolant temperature drops and forms a vacuumin the radiator, the vent valve opens to admit air into theradiator, thus preventing the radiator from being deformedby the vacuum.
When pressure forms
When vacuum forms
A
B
A : to the reservoir tankB : from the reservoir tank
SUDEM7262L
AUTO COLLING FAN
Autocool fan coupling is the device to control the fan speedaccording to the engine coolant temperature. The bimetaldetects the air temperature running through the radiatorand varies the fluid coupling flows to control the fan speed.
1. When the air temperature in the radiator is high,bimetal is deformed and opens the reservoir valve.
2. Since the fluid (silicon oil) keeps flowing, viscositybetween the coupling case and rotor increases, andthe fan mounted to the case has the similar speed ofshaft. Viscosity varies with the fluid amount (siliconoil).
3. When the air temperature falls, the bimetal is operatedto close the valve and the fluid returns to the reservoir.It results in a quick speed decrease by sliding betweenthe coupling case and rotor.
Working areaSilicon oil storage area
Rotor
Bimetal
Coupling shaft
Coupling case
SUDEM7263L
OPERATION OF AUTOCOOL FAN COUPLING
<At high temperature> Pump protrusion
Pump hole
Fluid (silicon oil)
Valve
Separator plate
Pump chamber
<At low temperature>Pump protrusion
Pump hole
Pump chamber
SUDEM7264L
EM -104 ENGINE MECHANICAL SYSTEM
SPECIFICATION EC630CCE
Item Specification
Cooling method Water cooling, forced circulation
Coolant capacity 20ℓ (includes engine, radiator and heater)
3. Remove the cooling fan (1) and autocool fan coupling(2).
2
1
SUDEM7269L
4. Remove water pump pulley(1) and water pump as-sembly(2).
1
2
SUDEM7270L
5. Disassemble the coolant temperature sensor connec-tor and remove the thermostat housing(1) from thecylinder head.a. Remove the thermostat cover.b. Remove the thermostat.c. Disassemble the bypass pipe from the thermo-
stat case.d. Remove the coolant temperature sensor.
1
SUDEM7271L
EM -110 ENGINE MECHANICAL SYSTEM
INSPECTION EE28BF77
WATER PUMP
1. Inspect the crack, damage, and wear of the parts, andreplace the water pump, if necessary.
2. Inspect the bearing to see any damage, unusualnoise, and poor revolution, and replace it, if neces-sary.
3. Check the leakage of the seal unit and replace thewater pump, if necessary.
THERMOSTAT
1. Heat the water to see if the thermostat valve operatesproperly.
2. Measure the temperature when the valve starts open-ing and is fully open.
Item Specification
Valve opening temperature 80~84 C
Valve lift / temperature more than 10 / 95 C
SUDEM7272L
V-BELT TENSION CHECK
Adjust the belt tension to obtain the specified belt deflec-tion when the center of each belt is pressed hard with aforce of 10 kgf.
Deflection between the alternator(1) and waterpump(2) : 12~16mm
CAUTIONa. Since a slack belt may cause overheating or
undercharge, adjust the tension to the speci-fication.
b. An excessively tight belt may result in possi-ble damages of the belt or bearing.
c. All of two V-belts should be replaced as acomplete set.
1
2
SUDEM7273L
COOLING SYSTEM EM -111
INSTALLATION EBC443E9
1. Install thermostat housing(1) to the cylinder head.
1
SUDEM7271L
2. Install the water pump(1) and water pump pulley(2) tothe timing gear case.
4. Remove the radiator hose upper and radiator hoselower.
5. Remove the radiator shroud and remove the radiator.
INSPECTION EF6FFDCE
1. Check the existence of foreign materials between ra-diator fins.
2. Check radiator fins for any damage and repair ifneeded.
3. Check the radiator for any corrosion, damage or rust.
4. Check the radiator hose for any crack, damage or de-terioration.
RADIATOR CAP
1. Check the radiator cap for any damage, crack or de-terioration.
Deterioration
Deterioration
SUDEM7277L
2. Check the opening pressure of radiator cap(1).a. Connect the cap tester(2) to the radiator cap(1).b. Apply the pressure until the indicator holds.c. If the indicator does not hold for about 10 sec-
onds, then replace the radiator cap.
Valve opening pressure of the pressure valve:0.83~1.10kg/cm²
1
2
SUDEM7278L
INSTALLATION E52F2A5F
Install the parts in the reverse order of removal.