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    30 views78 pages

    04-Engine (Diesel) PDF

    Uploaded by

    Wilson garcia

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    © All Rights Reserved
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    Engine [DIESEL] GENERAL WARNING .. [SPECIFICATIONS ns ‘SPECIAL TOOLS, - ‘TROUBLESHOOTING ENGINE AND TRANSAXLE ASSEMBLY TIMING SYSTEM "TIMING BELT INSPECTION INSTALLATION. CYLINDER HEAD ASSEMBLY ‘CYLINDER HEAD ‘COMPONENTS DISASSEMBLY INSPECTION... REASSEMBLY CYLINDER HEAD GOVER AND PLUG ‘COMPONENTS REMOVAL, INSTALLATION MAIN MOVING SYSTEM INSTALLATION. COOLING SYSTEM RADIATOR REMOVAL essen EMB $2 INSPECTION. EMB (52 INSTALLATION EMB “52 ENGINE COOLANT HOSTIPIPES ‘COMPONENTS... - EMB -53 INSPECTION. EMB -54 REASSEMBLY. EMB “54 REMOVAL. EMB “54 INSTALLATION EMB “54 ENGINE COOLANT PUMP ‘COMPONENTS .. INSTALLATION. RADIATOR CAP ‘COMPONENTS INSPECTION. ‘THERMOSTAT ‘COMPONENTS REMOVAL... INSPECTION INSTALLATION. LUBRICATION SYSTEM ‘OIL PUMP. ‘COMPONENTS DISASSEMBLY INSPECTION ... REASSEMBLY REMOVAL. INSTALLATION. ‘lL COOLER ENGINE BLOCK ENGINE BLOCK ‘COMPONENTS REMOVAL. INTAKE AND EXHAUST SYSTEM ‘TURBO CHARGER (TO) ‘COMPONENTS... ss EMB 71 INSPECTION... “EMB “72 EXHAUST MANIFOLD ‘COMPONENTS .. EMB-73 MUFFLER REMOVAL. EMB-74 INSTALLATION... EMB-75 INTERCOOLER ‘COMPONENTS ... EMB -76 REMOVAL... EMB -76 AIR CLEANER (ACL) ‘COMPONENTS -EMB-77 REMOVAL. EMB “78 INSPECTION’. Sc EMB-78 INSTALLATION. “EMB “78 EMB -2 ENGINE MECHANICAL SYSTEM GENERAL WARNING | soroes REMOVAL AND INSTALLATION OF INJECTOR AND HIGH PRESSURE PUMP. 1. Fuel system is subject to extremely high pressure (1350 bar) 2. Never perform any work on injection system with en- gine running or within 30 seconds atter stopping the engine. 3. Always pay attention to safety precautions. 4, Ensure the absolute cleantiness. 5. Never remove the injectors. GENERAL, SPECIFICATIONS(D3EA) Desoription ‘Specification 1.5(03EA) Limit General Tye In-line, Single Overhead Camshaft Number of cylinders 3 Bore 83 mm (8.27 in) ‘Stroke 92 mm (3.62 in) ‘Total displacement 1493 cc (91.1 cuzin.) ‘Compression ratio 4 Firing order 1-3-2 Valve timing Intake valve ‘Opens (BTDC) r Closes (ABDC) ay Exhaust valve Opens (BBDC) 52° Closes (ATOC) e ‘Cylinder head Flatness of gasket surface (0.03 mm (0.0012 in.) for width 0.09 mm (0.0035 in.) for length 0.012 mm (0.00047 in) /51 x51 Thickness of valve head (margin) Intake Exhaust Valve stem to valve guide clearance Intake 1.6 mm (0.063 in) 1.3 mm(0.0512 in.) 0.022 ~ 0.049 mm (0.00086 ~ 0.00193 in.) ‘Camshaft Cam height Intake 34.697 mm (1.966 in) 34.197 mm (1.346 in.) Exhaust 36.570 mm (1.361 in) 34.070 mm (1.341 in) Journal ©.D. 28 mm (1.10 in.) Bearing oil clearance (0.040 ~ 0.074 mm (0.0020 ~ 0.0029 in.) End play (0.05 ~ 0.15 mm (0.002 ~ 0.006 in.) Valve Valve length Intake 95.7 mm (8.77 in) Exhaust 95.4 mm (3.76 in.) Stem OD. Intake 5.953 mm (0.234 in.) Exhaust 5.925 mm (0.233 in.) Face angle 445" 0.1. mm (0.0039 in.) ‘Width of seat contact Seat angle 4.21mm (0.0477 in.) 41,61mm (0.0634 in) (INTEX) 4a ~ 44.5" Exhaust 0.050 ~ 0.077 mm (0.0020 ~ 0.0030 in.) _| 0.15 mm (0.0059 in.) ‘Valve guide Length Intake 96.5 mm (1.437 in) Exhaust 96.5 mm (1.437 in) Valve seat EMB -4 ENGINE MECHANICAL SYSTEM Description Specification 1.5(D3EA) Limit Valve spring Free length 39.14 mm (1.541 in) 38.14 mm (1.502 in.) Load 21.4 kg / 32 mm (47.2 b/ 1.26 in) at installed height Cylinder block Cylinder bore 83 + 0.03 mm (3.27 + 0.0012 in.) Flatness of gasket surface (0.042 mm (0.00165 in.) for width (0.096 mm (0.0088 in.) for length (0.012 mm (0.00047 in.) 50 x 50 (0.4 mm (0.0038 in.) Piston OD, Piston - to - cylinder clearance Ring groove width No 1 No. 2 ol Service size 82.919 ~ 82.951 mm (8.26 ~ 3.27 in) 0.069 - 0.081 mm (0.0027 ~ 0.0036 in) 1.915 ~ 1,945 mm (0.075 ~ 0.076 in.) 2.06 ~ 2.08 mm (0.08 ~ 0.082 in) 3,02 ~ 3.04 mm (0.119 ~ 0.1196 in.) 0.25 mm (0.010 in), 0.5 mm (0.020 in.) (075 mm (0.030 in.), 1.00 mm (0.039 in.) oversize Piston ring Side clearance No. 2 Oi ring End gap No. 1 No. 2 Oil ring side ral (0.065 ~ 0.11 mm (0.00256 ~ 0.00433 in) (0.03 ~ 0.07 mm (0.00118 ~ 0.00278 in.) 0.2 ~ 0.3 mm (0.0079 ~ 0.0118 in.) 0.3 ~ 0.45 mm (0.0118 ~ 0.0177 in) 02 ~ 0.45 mm (0.0079 ~ 0.0177 in) Connecting rod Connecting rod pin 0.0 Connecting rod bearing oil clearance Crankshaft main bearing oll clearance 28.022 ~ 28.034 mm (1.103 ~ 1.104 in.) (0.024 ~ 0.042 mm (0.0009 ~ 0.0016 in.) 0.024 ~ 0.042 mm (0.0009 ~ 0.0016 in.) 0.1 mm (0.0038 in.) 0.4 mm (0.0039 in} ‘Crankshaft Joumal 0.0. ‘Out-of-round of journal and pin ‘Taper of journal and pin End play Flywheel Runout 60.002 ~ 60.020 mm (2.362 ~ 2.369 in.) ‘Less than 0.015 mm (0.0006 in.) ‘Less than 0.005 mm (0.0002 in.) 0.09 ~ 0.32 mm (0.0035 ~ 0.0126 in.) 0.13 mm (0.0051in.) il pressure (1500 rpm) [Oil temperature is 95 - 105°C (203 - 221°F)) More than 250 kPa (36.26 psi) Opening pressure ll pump Tip clearance 0.12 ~ 0.2 mm (0.00472 ~ 0.0078 in.) Radial clearance 0.13 ~ 0 .23 mm (0.0051 ~ 0.009 in.) Side clearance 0.02 ~ 0.07 mm (0.00078 ~ 0.0027 in.) Relief spring Free length 47.5 mm ( 1.835 in.) 570 + 50 kPa (87.67 + 7.25 psi) GENERAL, Description ‘Silent shaft Front journal diameter Rear journal diameter ‘Specification 1.5(D3EA) Limit 70.01 ~ 70.03 mm (2.756 ~ 2.757 in.) 40.01 ~ 40.03 mm (1.575 ~ 1.576 in.) ll clearance Front 0.050 ~ 0.09 mm (0.0020 ~ 0.0036 in.) Rear 0.050 ~ 0.091 mm (0.0020 ~ 0.0036 in.) Cooling method Cooling system quantity Forced circulation with electric fan 5.3 lit (6.6 US.qts., 4.66 Imp.qts.) ‘Thermostat Type ‘Wax pellet type with jiggle valve Normal opening temperature ‘85°C (185°F) Opening temperature range 83.5°C - 86.5°C (182°F - 188°F) Wide open temperature 100°C (212°F) Radiator cap Main valve opening pressure Main valve closing pressure 107.9 + 14.7 kPa (1.1 + 0.15 kg/om® , 15.64 # 2.13 psi) 83.4 kPa (0.85 kg/ cm, 12.1 psi) ‘Vacuum valve opening pressure + 6.86 kPa (- 0.07 kg/ cm, - 1.00 psi) ‘Air cleaner ‘ype Dry type Element Unwoven cloth type Exhaust pipe Muttor Expansion resonance type Suspension system Rubber hangers Coolant temperature sensor ype Thermister type Resistance 20°C (68°F) 2.45 2 0.14 ko 20°C (176"F) 0.3222 ko ‘SERVICE STANDARDS ‘Standard value Goolant concentration Tropical area 40% Other area 50% LUBRICANT Engine coolant Ethylene glycol base for aluminum radiator ‘SEALANT Engine coolant temperature sensor il pressure switch Crankshaft bed plate O.D= Outer Diameter 1L.D= Inner Diameter OS.= Oversize Diametor LOCTITE 262, three bond No. 4324 or equivalent ‘3M ATO No, 8660 or Thrae bond No, 1141E LOCTITE 5205, US. = Undersize Diameter EMB -6 ENGINE MECHANICAL SYSTEM ENGINE MECHANICAL SYSTEM TIGHTENING TORQUE Te een a Enghe powntineusar ba | 66-170 00 = 100 S- Engine mouting bracket sone. 00 etm elm Engh moating aca? Ena 0-80 600 ~ 600 e-8 Engine Suppor bach Ezine Sop 5s “90-650 wea Font ol appr baer 7 to cross member bolts 40 ~ 55 400 - $50 29 ~ 40 Front stopper nso Front ot 0-65 soo - 650 wea Real soppr banat woe 300 ea Sevcamatbor be ‘Fea rol stopper nauior 7 7 Fea st 50-65 500 ~ 680 oe a7 Tansave mowing Tanga mo 0-20 600 - 00 3-88 Tansexio nearing Transaxle wo 110 00 ~ 1100 os ~ 80 Fen! etaust pe To T Fron ovens ap 0-40 200 ~ «00 2-28 esd cover bor a0 oo 08 oF Carsten precol bal es Tein 100 B18 Canstal baring cap bak a= 50 270-00 22 arial postion sonsor Ti 70-10 328 cleaner bod nstataion a conto so or Caria oroct bo we ia 19 ere ‘Damper pulley to crankshaft ~ ane 90-98 200 - 940 2-25 alin aba 68 | a aay «er 00 + 1200+ 90" 36+ 0" + a0 Tiana a nr — co lee = Orv Ba Ato sioner a. mmole ae on Tining bo ao frie Ting bat a 0-12 100-20 7-8 Or bo ler bok rer a0 cee Font exhaust pe Font ea 20-20 200 ~ 00 uaa Oi pn ww Toa Ts Olan dan us was 350460 25-38 GENERAL EMB -; Tem Wr teem et Oircreen 0- joo = 120 78 Orpreesure wich 15-22 150 = 220, er Oi sereenbracka BoR ot 98 0 = 380 25 - 28 Ol pump cover bok 20 = 87 200 = 270, 15-20 Oi seal case bok 10-1 100 ~ 120 78 Pon cap 20-27 200 = 270 14-20 On tbo 919 90 = 190, 7-10 ‘i pup rior bo a= 10 0-100 97 “Ting bot upper eer a. 0 120 o-8 Tring bot ower cover a1 a0 - 120 6-8 Ral! plug (ol pure 2-82 120-520 oa Fywhost 7-80 700 60 ao Dive pat 70-60 700 = 600 2-88 Connecting red cap bok 25+ 90° 250 + 18+ 90" Engine coolant pup to exinder bok bok 14m a.m eo we 10 mm 10-12 100 = 120 79 Engine coolant temperate wo 55 10 - 550 0-41 Erg cena lt tng 20 - 25 200 250 15-18 ‘A loaner mounng Boke @- 10 0-100 e-7 Resonator mounting @-10 0 - 100 e-7 bike mand mounting 18-20 450 - 200 We Extaval mani ae a 20 = 3 18-28 ‘i leaner brackat bot 10-19 100-190 78 (ioe! gauge 10-12 100 120 78 Balance shaft bok sa 67 $90 = 570 we Sartor boo cinder back we 52 460 = &20 35 = 98 Tbocharger support bot 35 = 46 250 = 450, 26 = 99 rane bogpato bot 15 mm Bea 10 260-320 + 10" 2085 295 + ‘emm war a77 oar = a7 248-978 EMB -8 ENGINE MECHANICAL SYSTEM SS. ENGINE MECHANICAL SYSTEM CHECKING ENGINE OIL. 41. Position a vehicle on a level sure. 2. Turn off the engine, a vehicle that has not been used for a prolonged Period, run the engine for several minutes. Turn off the engine and wait for5 minutes atleast, and then check the oi! level. ‘8. Check thatthe engine oil evel is within the level range indicated on the ol dipstick. Ifthe oil level is found to hhave fallen tothe lower limit (the *L* mark), rafilto the "FY mark, Gnore When refiling, use the proper grade of engine oil 4. Check thatthe oils not city or mixod with coolant or ‘gasoline and ithas the proper viscosity. GENERAL, EMB-9 ‘SELECTION OF ENGINE OIL. Recommended API classification : CE OR ABOVE Recommended SAE viscosity graded : Temperature range anticipated before Recommended SAE viscosity number next oil change _ c . 40 108 zow | 15w 10W 108w so | 50 50 0 20 ry 40 | 40 0 0 50 sw L— 10 “ 0"| sw a5 5 wo | sw" 25 a3 |__| 20 *1 Restricted by driving condition and environment. *2 Not recommended for sustained high speed vehicle operation For best performance and maximum protection of all types of operation, select only those lubricants which: 1. Satisty the requirements of the API classification. 2. Have the proper SAE grade number for expected ‘ambient temperature range. Lubricants which do not have both SAE grade num- ‘ber and an API service classification on the container ‘should not be used. EMB -10 CHANGING ENGINE OIL, 41. Run the engine unt it reaches normal operating tem- perature, 2. Tum off the engine. 3, Remove the oil filer cap and the drain plug. Drain the engine oil 4. Tighten the drain plug to the specified torque. Tightening torque Oil pan drain plu 35 ~ 45 Nm (350 ~ 450 kg.cm, 25 ~ 33 Ib.) Gnore Whenever tightening the oil drain plug, use a new ‘rain plug gasket. 5. Fill new engine oil through the oil filer cap opening Capacity Drain and refill: 4.3 it (4.88 US.ats., 4.07 Imp.ats) Oilfiter : 0.5 it (0.53 US.ats., 0.44 imp.qus.) Total : 4,8 lit (5.45 U.S.qts., 4.54 Imp.qts) nore Do not overfil. This will cause oil aeration and loss of oil pressure. 6. Install the ol filer cap. 7. Start and run the engine. 8. Tum off the engine and then check the ol level. Add ollif necessary. ENGINE MECHANICAL SYSTEM REPLACING THE OIL FILTER All Hyundai Motor Company engines are equipped with a high quality, disposable oil fiter. The quality of aftermarket replacoment fiters is considerably diverso, High quality roptacoment filters should be used to assure the most efficient service. PROCEDURE FOR REPLACING THE OIL FILTER 1. After loosening the drain plug and copper washer, drain a small quantity of oll from the fier. ‘Aer loosening the plastic upper cap until the O-ring in the lower caso is visible, completely dain ol fom the fiter. (Use fit wrench. 08269-27100) Remove the upper cap. Be sure that the oil fter el- ‘ement is removed withthe plastic upper cap simulta- neously, Replace the oil fiter element and O-ring with new Tighten the oil fiter upper cap tothe specified torque. Oil fiter 28 ~ 25 Nm (230 ~ 250 kg.em, 17 ~ 18 a) 6. After replacing the copper washer in drain plug with a ‘New one, install to the alulminum lower case. (Speci- fied torque : 8-10 Nm, 80-100 kg.cm, 5.9-7.4 Ib) GENERAL, EMB -11 7. Startand run the engine and checkfor engine ollleak. RADIATOR CAP PRESSURE TEST 8. After turning off the engine, check theolllevelandadd 1. _Use an adapter to attach the cap to the tester. oil as necessary, Increase the pressure until the gauge stops moving. Main valve opening pressure : 107.9 kPa + 14.7 kPa (1.1 + 0.15 kg/ome, 15.64 = 2.19) Main valve closing pressure 83.4 kPa (0.85 kPa (0.85 kglom*, 12.1 psi) 3. Check that the pressure level is maintained at or above the limit. 4, Replace the radiator cap if the reading does not re- main at or above the limit. wn Gaore CHECKING COOLANT LEAK Bo sure hat tho cap clean boo testng, since rust ihe forign mata wilcausean 1. Loosen the ator ap, fore wading, oni oP sea ce. 2. Confirm that the coolant level is up to the filer neck. 3. Install a radiator cap tester to the radiator filer neck ‘and apply 150 KPa (2ipsi, 1.53 kg/em#) pressure. Hold for two minutes in that condition while checking {or leakage from the radiator, hoses or connections. Gore 1. Radiator coolant may be extremely hot. Do not ‘open the system because hot, or scalding water could gush out causing personal injury. Allow the vehicle to coo! before servicing this system. When the testeris removed, be carefulnot to spil any coolant from it. Bo sure to clean away completely any trom the area. {Be careful when instaling and removing the tester and when testing, not fo deform the filer neck of the radlator. ‘4. Ifthere is leakage, repair or replace with the appropri- ate part. EMB -12 ‘SPECIFIC GRAVITY TEST 1. Measure the specific gravity of the coolant with a hy- Crankshatt pul), 3. When installing the belt on the pulley, make sure it is centered on the pulley. 1 Vebbed bat Pott Q caution 1. When installing the V- ribbed belt, check that the V- ribs are properly aligned. 2. Htnolse or slippage is detected, check the belt for wear, damage, or breakage on the pul- ley contact surface, and check the pulley for ‘scoring. Also check the amount that the belt Is deflected. EMB -14 ENGINE MECHANICAL SYSTEM Se ENGINE MECHANICAL SYSTEM 4. The tensioner mark should be between the “* posi- tion not, replace the bot. GENERAL, SPECIAL TOOLS EMB -15 ‘Tool (Number and name) Ballanceshaft drive gear and comshaft oil seal installer (09214-32000) Mlustration Use Installation of the ballance shaft drive ‘gear on crankshaft and camshaft ol seal Front case oil seal installer Installation of the front case oll seal (08231-27100) ‘Valve spring compressor Removal and installation of inlet (08222-27300) land exhaust valves: Valve stom oll seal installer (09222-27200) Installation of valve stom oil seals ‘Crankshaft rear oll seal installer (09231-27000) Injector oll seal installer (09351-27401) ~ \ A \ Installation ofthe crankshaft real oll seal Installation of the injector oil seal 6 ENGINE MECHANICAL SYSTEM ‘Tool (Number and name) Mlustration Use ‘Compression gaugeaadapter ‘Checking engine compression pressure (09351-27000) (08351-27100) (i fiter wrentch Removal and installation of ol fiter (09263-27100) GENERAL EMB -17 TROUBLESHOOTING | cxtarczo Simpiom Probable cause Remedy Low compression | Damaged ayinder head gasket Replace gasket Worn or damaged piston rings Replace rings Repair or replace piston an Worn piston or eyinder Ropar or repace piston and / il pressure drop ‘Worn or damaged viave seat Low engine oil level Repair or replace valve and/or seat ring ‘Check engine oil level Faulty oll pressure switch Replace: fColgged oll fiter | Replace ‘Worn oil pump rotor or cover Replace “Thin or diluted engine oll (Change and find out cause il reliot valve stuck (open) Repair Excessive bearing clearance Replace: High oll pressure | Oil relist valve stuck (closed) Repair Excessive engine | Loose ol stopper (front, rear) Re = tighton —_ Loose transaxle mount bracket Fe = tighten Loose engine mount bracket Re = tighten ‘Loose center member Broken transaxle mount insulator ‘Broken enhine mount insul f Broken engine roll stopper insulator Noisy valves Thin or diluted engine oil (low oil pressure) ‘Worn or damaged valve stem or valve guide Replace Connecting rod and / | insufficient oil supply Check engine oil level main bearing noise | Thin or diuted engine oi ‘Change and find out cause Excessive bearing clearance Replace Timing bett noise | incorrect belt tension (Timing belt tensioner, ‘Adjust belt tension timing belt) Low coolant level | Leakage of coolant Damaged radiator core joint Replace Comore reached hoses (radiator hose, Replace Faulty radiator cap valve or setting of spring Replace Faulty thermostat Replace Faulty engine coolant pump. Replace Clogged radiaotr Foreign material in coolant Replace EMB -18 ENGINE MECHANICAL SYSTEM ‘Stmptom Probable cause Remedy ‘Abnormally high | Faulty thermostat Replace Coolant temperature | Fauity radiator cap Replace Restricted of flow in cooling system Replace {Loose or missing drive belt ‘Adjust or replace Faulty engine coolant pump Replace Faulty temperature sensor wiring Faulty electric fan Repair or replace: Repair or replace Fauly reo - soso 6 dao Farle Teen colt Fit coor Fomaly ow | Fauty Bort Felco Coolant temperature Faulty temperature sensor wiring Repair or replace Toatage fom at |Loss has ac pipe conecion Patgion cooling system Blocked or collapsed hose and pipe Replace Tope eta | managed, so loo opt Eihas as wate | Lowe comecns Fagen Bron ipo o mul Fak or vac ‘Abnormal noise Detached battle pklate in muffler Replace Brokon uber hangr epic Pie muti otacing whi bo Corea Bron pie rma Foal ooo GENERAL EMB-19 ENGINE AND TRANSAXLE ASSEMBLY cous 4. Disconnect the air hose and remove the intercooler. 1. Remove the battery. 2. Remove the engine cover. 3. Detach the air duct and the air cleaner. EMB -20 5. Disconnect the engine harness connectors. 1. Engine wiring connectors (injector, No 1 TDC. ‘sensor, etc.) 2. Coolant temperature sensor. 3. Alternator connector, ol pressure gauge connec- tor. 7 ENGINE MECHA AL SYSTEM For a vehicle with automatic transaxles, disconnect the transaxle oil cooler hoses. Gore When disconnecting hoses, make identification marks to avoid making any mistake when installing them again. QS caution Be earful nt to api any of oor fd cut of te hoses. Plug the openings to prevent the entry of foreign material. Disconnect the radiator upper and lower hoses on the ‘engine side thon remove the radiator assembly. Disconnect the EGR vacuum hose. Remove the main fuel line at the common rail (sup- ply/raturn, 4. Back up lamp switch connector. 5. ATT solenoid, inhibitor switch connector. 6. Drain the engine coolant and remove the engine ‘coolant reservoir tank. GENERAL EMB -21 12, Disconnect the heater hoses (inlet and outlet) on the 15. Remove the transaxle ground. ‘engine side. 18, Disconnect transaxle. the speedometer cable trom the 414, Disconnect the clutch cable or control cable from the 17: Disconnect the power steering suction hose and re- transaxle, turn hose from the pump. EMB -22, ENGINE MECHANICAL SYSTEM ENGINE MECHANICAL SYSTEM 18. Disconnect the air conditioner pipe. 19. Detach the steering dust cover in the engine compart- ‘ment and then disconnect the gear box universal joint bot. NOTE ‘Make sure to make identification marks between the universal joint and the gear box for reassembly. 24, Attach a chains or cables to the engine. Use an en- ine hoist or a chain hoist to slightly raise the engine. 20. Raise the vehicle and then remove the front te, 21. Remove the caliper assembly from the knuckle, Tie ‘using wire, hang it from the suspension, 22. Loosen the strut lower bolt and then remove it GENERAL, 25. Putthe special fixture on the T/M jack and then adjust itto the sub-frame, Nove (Check thatal the cables, harness connector and hose are disconnected from the engine and transaxle as- ‘sembly. 26. Remove the engine mounting bracket and the transaxle mounting bracket. 28. Remove the engine and transaxle assembly as a unit. EMB -24 ENGINE MECHANICAL SYSTEM TIMING SYSTEM TIMING BELT COMPONENTS esiaco Crankshaft damper puley Crankshaft sprocket TIMING SYSTEM REMOVAL exec: Q caution Rotate the crankshaft clockwise and align the tim- ing marks to set the No. 1 cylinder’s piston to ToC. At this time, the timing marks of the camshaft ‘sprocket and cylinder head should coincide with eachother and the dowel pin of the camshaft ‘sprocket should be at the upper side. 1. Remove the crankshaft pulley and dirve belt. 2. Rlompve the timing belt cover. Remove the engine support bracket. 4. Using the boss bolt, rotate the tensioner to align the stop plate with the housing hole, and then engage the fixing pin. Boss bot Fring pin '5. Using a hexagonal wrench, loosen the stop bolt. (Do not remove it) 6. Using the boss bot, rotate the tensioner assembly to Clockwise direction until not rotate. EMB -26 7. Tighten the stop bot. 8. Remove the timing bet. pore {Ifthe timing belt is reused, make an arrow mark indl- ‘cating the turning direction (or the front of the engine) to make sure that the belt is reinstalled in the same direction as before. ‘9. Remove the pivot bolt and then remove the auto ten- ENGINE MECHANICAL SYSTEM INSPECTION coscaxe SPROCKETS, TENSIONER PULLEY AND IDLER PULLEY 1. Check the camshaft sprocket, crankshaft sprocket, tensioner pulley and idler pulley for abnormal wear, cracks or damage. Replace if necessary. 2. Inspect the tensioner pulley and the idler pulley for ‘easy and smooth rotation and check for play or noise. Replace it necessary, 3. Replace the pulley i there is a grease leak from it s bearing. AUTO TENSIONER, 1. Check the auto tensioner for leaking and replace if necessary. 2. Check the rod end for wear or damage and replace it necessary. TIMING SYSTEM. EMB -27 TIMING BELT 2, When the engine is overhauled or bet tension is ad- justed, check the bet carefully If any ofthe following 41. Check the belt for oi or dust deposit. Replace if nec- flaws are evident, replace the belt with a new one. essary, Small deposits should be wiped away with @ ‘ry cloth or paper. Do not clean with solvent. Description Flaw conditions 1. Hardened back surface of rubber ‘Back susriace is glossy, Non - elastic and so hard that, when your fingernail is pressed into it, no mark is produced ama aT Ttanesorma os eon oo KS Xe 44. Badly worn out teeth (initial stage) “Tooth flank shows canvas on the load side (Fluffy canvas fibers, rubber changed into white color and unclear canvas texture) Xe EMB. ENGINE MECHANICAL SYSTEM Description Flaw conditions 5. Baaly worn out teeth (last stage) “Tooth flank worn and runner exposed on load side (tooth wiath reduced) Auber Sepoed 6 Cracked tooth bottom rite 7. Missing tooth “oot misting and cans Teor apoted '&. Badly wom side of bet Rounded bt sido -Avomal wear Fay canvas She) 9. Cracked side of bok ’ TIMING SYSTEM INSTALLATION 41. Install the crankshaft sprocket onto the crankshaft. Q cauTion Pay attention to the direction of the flange. fit Is installed in the wrong direction, a broken belt could result. 2. Install the special washer and sprocket bolt to the crankshaft and then tighten the sprocket bolt. Tightening torque Crankshaft sprocket bolt: 185 ~ 195 Nm (1850 ~ 1950 kg.cm, 136 ~ 144 It) TIMING BELT 1. Check timing mark. = Crankshaft side : Timing mark at orankshatt ‘sprocket and timing pin at oll pump housing. = Camshaft side : Timing mark at camshaft ‘sprocket and head. 2. Install tensioner. ‘3. Install the auto tensioner. 4. Tighten the pivot bolt. Tightening torque 50 ~ 55 Nm (500 ~ 550 kg.cm, 37 ~ 40.6 Ibst) EMB -29 5. Install timing bet. 6. Loosen the stop bolt. (Tensioner arm will move and tighten timing bet) 7. Rotate engine more than 2 revelutions (Check timing 8 Tighten stop bott. 8. Remove the pin. EMB -30 ENGINE MECHANICAL SYSTEM ENGINE MECHANICAL SYSTEM CYLINDER HEAD ASSEMBLY CYLINDER HEAD COMPONENTS covowce T :50 (500, 36) + 120" + 90° §——— PRetainer lock S— Valve spring retainer — anve stom soa! Cylinder head gasket ‘TORQUE : Nm (kg.cm, Ib-ft) CYLINDER HEAD ASSEMBLY DISASSEMBLY 1. move the cylinder head bolts in the order shown in the illustration, KOGA 2. Using the special tool (09222 - 27300) remove the valve spring retainer lock. Then remove the spring retainer, valve spring, spring seat and valve. (Wore ‘Arrange these parts so that they can be reinstalied in their original positions. EMB -31 INSPECTION | cesiice CYLINDER HEAD 1 Check the cylinder head for racks, damage and ‘coolant leakage. I cracked, replace the cylinder head. Remove scale, sealing compound and carbon de- Posits completely. After cleaning the oll passages, ap- ply compressed air to verify that the passages are not clogged. Check the cylinder head surface for flatness inthe di- rection as shown in th illustration. If flatness exceeds. ‘service limit in any direction, ether replace the eylin- der head or machine the cylinder head matching sur- face lightly. Fiatness of cylinder head gasket surface 0.03 mm (0.0012 in.) for width (0.09 mm (0.0035 in.) for longth 0.012 mm (0.00047 in.) 51 x 51 EMB -32 VALVES, 1. Using a wire brush, clean the valve thoroughly. ‘Check each valve for wear, damage and distortion of the head and the stem at B Position. Replace, itnec- ‘essary. If stem end, A, is hollowed out or worn, resur- face as necessary. This correction must be limited to ‘a minimum. Also resurface the valve face. Replace the valve ifthe margin has decreased to less than the service limit. Margin [Standare Intake : 1.6 mm (0.063 in) Exhaust : 1.3 mm (0.0512 in) 4 ‘ ast Margin VALVE SPRINGS 1. Check the free height of each valve spring. If they ‘exceed the service limit, replace the springs, Using a square, test the squareness of each spring. la spring is excessively out- of-square, replace it. Valve spring (Standard) Free height : 99.14 mm (1.54 in) Load : 21.4 kg / 32 mm (47.2 ib/ 1.26 in.) Out of square : 1.5° or less. imi) Free height : 38.14 mm (1.50 in.) Out of square : 4° ENGINE MECHANICAL SYSTEM Outot-square epee i Check the valve stem-to-guide clearance. Ifthe clearance ‘@xco0ds the service limit, replace the valve guide with the next oversize part. VALVE GUIDES. Valve stom - to - guide clearance {Standard} Intake : 0.022 ~ 0.087 mm (0.00087 ~ 0.0028 in.) Exhaust : 0.05 ~ 0.095 mm (0.0020 -0.0037 in.) {Limit Intake : 0.1 mm (0.0040 in) Exhaust: 0.15 mm (0.0059 in) Va guido ‘Stem dlametor Guide inde samotor RECONDITIONING VALVE SEAT ‘Check tho valve seat for overheating and unequal contact with the valve face. Recondition or replace the seat if nec- ‘essary. Before reconditioning the seat, check the valve uide for wear. I the valve guide is worn, replace it and then recondition the seat. Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width ‘should be within specticatons and centered on the valve ace. After reconditioning, tho valve and valve seat should be lapped lightly with a lapping compound, eee CYLINDER HEAD ASSEMBLY REASSEMBLY coucoss OTE 1. Clean each part before assembly. 2. Apply engine oll o the sliding and rotating parts. 1. Install the spring seats, 2. Using a special tool (09222 - 27200), tap the seal in position lightly. NOTE Do not reuse old valve stem seals. ‘= Incorrect installation of the sea! could result in olf leakage past the valve guides. 3. Apply engine oll to each valve. Insert the valve into the valve guide. Avoid pushing the valve into the seal by force, After inserting the valve, check that it moves ‘smoothly. 4, Place valve springs so that the side coated with enamel faces the valve spring retainer and then install the retainer. Spring Retainer Enamel coated so ping ‘em so Spring seat '5. Using the special tool (09222 - 27300), compress the spring and install the retainer locks. “Aterinstalling the valves, ensure that the retainer locks are correctly inplace before releasing the valve spring compressor. EMB -33 When the spring is compressed, Check that the valve ‘stem seal is not pressed against the bottom of the retainer, Clean both gasket surtaces of the cylinder block and cylinder head. ‘Select the cylinder head gasket. 1) Measure the piston protrusion from the upper cylinder block face on 6 places at T.D.C. Measure ‘on the crankshaft centerline considering the pis ton migration EMB -34 2) Select the gasket in the table below using the average value of 6 piston protrusions. Even if only 1 point is over than the limit of piston protrusion at each grade, 1 grade upper gasket than specitied below. ENGINE MECHANICAL SYSTEM Displacement 15 ‘Average of piston protrusion | 0.194 ~ 0.337 mm. 0.397 ~ 0.440 mm (0.440 ~ 0.542 mm (0.0076 - 0.013 in.) (0.013 ~ 0.017 in.) (0.017 - 0.021 in.) ‘Gasket thickness 1.13 = 0.05 mm 1.23 + 0.05 mm 1.33 = 0.05 mm (0.0445 + 0.0019 in.) (0.0484 + 0.0019 in.) (0.0528 + 0.001 Limit of each rank extent 0.43 mm (0.0169 in.) (0.59 mm (0.0208 in.) = Identification cade 8. Install the gasket so that the surface with the identii- cation mark faces toward the cylinder head. 9. Tighten the bolts to the specified torque. SOMATTgIosS o ‘ Tightening torque : 50 Nm ( kg.om, 36.9 thst) + 120° + 90° S| TI CYLINDER HEAD ASSEMBLY. EMB -35 CYLINDER HEAD COVER AND PLUG COMPONENTS | ccosss TORQUE : Nm (kg.cm, Ib.ft) EMB -36 ENGINE MECHANICAL SYSTEM REMOVAL scx 2. Push the plug assembly into the hole and then turn the handle to the let. 1. Smoothly pull and turn the handle to the right. 2. Pullout the pulg assembly. After using (-) driver to increase the clearance be- tween cylinder head cover and plug assembly. Whenever installing the plug, always replace a new 3. Using a special tool (09351 - 27401), install the injoc- INSTALLATION | cxcrou tor oll seal 1. Apply ol to the gasket ofthe plug, MAIN MOVING SYSTEM. EMB -37 MAIN MOVING SYSTEM CAM SHAFT COMPONENTS exorseo 7: 26.5 -29.5 (265-295, 20-22) (fe Baan cap T2125 -140 (1250-1400, 92 - 109) TORQUE : Nm (kg.cm, Ib.ft) EMB -38 ENGINE MECHANICAL SYSTEM ENGINE MECHANICAL SYSTEM DISASSEMBLY cusaro 1. Disconnect the negative terminal from the battery 2. Drain the engine coolant, 3. Remove the breather hose between the air intake hose and the head cover. 4, Remove the air cleanor. 5. Remove the timing belt cover. 6. Remove the head cover and disconnect camshaft po- sition sensor. 7. Loosen the camshatt sprocket bolts then remove the camshaft sprockets. 8. Loosen the camshaft bearing cap bolts and remove ‘the bearing caps, camshafts, rocker arms and lash adjusters. WARNING REMOVAL AND INSTALLATION OF INJECTOR AND HIGH PRESSURE PUMP. 1. Fuel systom is subject to extremely high pressure (1350 bar). 2. Never perform any work on injection system with en- gine running or within 30 seconds after stopping the ‘engine. 3. Always pay attention to safety precautions. 4. Ensure the absolute cleantiness, 5. Never remove the injectors. INSPECTION ROCKER ARMS Check totation of the roller. If they do not rotate ‘smoothly or are loose, replace them, 2. Check the roller surface. Replace if there is any dent, damage or evidence of seizure. 3. Check the valve contact surface for possible damage or evidence of seizure, Replace if necessary. CAMSHAFTS 1. Cheok the camshaft journals for wear. Ifthe journals are badly worn, replace the camshaft. 2. Check the cam lobes for damage. Ifthe lobe is dam- aged or worn excessively, replace the camshatt, ‘Cam height {Standard} Intake : 34.697 mm (1.366 in) Exhaust : 34.570 mm (1.981 in.) [Lima Intake : 34.197 mm (1.46 in) Exhaust : 34.070 mm (1.941 in) MAIN MOVING SYSTEM. REASSEMBLY | exrcon, 1. Install tho camstatts onthe cylinder head Gnore Apply engine oll to journals and cams of the camshatts 2. Install the bearing caps. 3. Check that the camshaft can be easily tumed by hand. After checking, remove the bearing caps and the camshafts, and then install the rocker arms. 4, Make sure that the dowel pins on the camshaft ‘sprocket ends are located on the top. 00221-21000 ‘camshaft » | Ot soa ‘5. Tighton the bearing caps tothe specified torque in two or three increments as shown. Tighten the rocker arms uniformly. Tightening torque Bearing cap bolts: 26.5 ~ 29.5 Nm (265 ~ 295 kg.cm, 20 ~ 22 Ibst) EMB -39 6. Using the special tools, camshaft ol seal Installer. Be ‘sure to apply engine oil to the external surface of the «il seal. Insert the oil seal along the camshaft front end and install it by driving the installer with a hammer until the oil seal is fully seated, 7. Install the camshaft sprocket bolts to the specified torque. Tightening torque Camshaft sprocket bolts : 125 ~ 140 Nm (1250 ~ 1400 kg.om, 92 108 Ibs) 8. Install the rocker cover. Tightening torque Rocket cover bolts : 8 ~ 10 Nm (80 ~ 100 kg.cm, 6 ~ 7 Ibst) EMB -40 ENGINE MECHANICAL SYSTEM COUNTER BALANCE SHAFT COMPONENTS | caro Oil pump housing T: 28-92 (280-320, 20.7-23.6) TORQUE : Nm (kg-cm, Ib-ft) MAIN MOVING SYSTEM DISASSEMBLY 1 2 3. 7 eeusrce 8. Remove the timing belt. Refer to "Timing Bett." Remove all the oil pan bolt. ‘Tap the oil pan with a rubber hammer and remove the pan. Remove the oil screen and O-ring. Remove the oil pump housing. Remove the oil pressure switch. ‘824mm (0.9m) 4, 2. 1s a 1 3 EMB -41 Disassembly the balance shaft assembly. Femove the oll pump housing mounting bolts and re- ‘move the oll pump housing assembly and O-ring from the onder block. 10. Remove the oil pump rotor from the oll pump housing. INSPECTION | eccorcco OIL PUMP HOUSING ‘Check all oil holes for clogging. Clean the holes it necessary. Check the balance shaft bearing for wear, damago and seizure. If there is anything wrong with the bear- ing, replace the balance shaft case. ‘Check the front case for cracks and other damage. Replace a cracked or damaged front case. BALANCE SHAFT (Check the journals for wear or seizure. If excessive woar or seizure is evident, check the bearing carefully. necessary, replace the balance shatt. EMB -42 ENGINE MECHANICAL SYSTEM OL SEAL 3. Apply sealant to the groove of the oil pump housing as shown, 1. Check the oil seal lp for wear and damage. Replace the oll seal if necessary, ‘Check the ol sea ip for deterioration. Replace the oil seal if necessary. REASSEMBLY csouos 41. Installa balance shaft assembly tothe cylinder block. Sealant : Loctite 5900 or gquivalant GQnore 1. Apply sealant approximately 2.5 + 0.5 mm (0.098 POo19in) in tckness. 2. Aer he application of the sealant, install he ol : pump housing within § minutes. 2. Using the special too, the crankshaft front oil soal_ 4 Install anew O - ring to the ol pump housing and installer (09231-27100), install the crankshaft front oil tighten the flange bolts temporarily. al ito the ol pump housing. — 5. Install the oil pump housing with a new O = ring. Tighten bots to the spectiod torque. — Tightening torque it pump housing : 20 ~ 27 Nm (200 ~ 270 kg.om, 14 ~ 20 Ibst) MAIN MOVING SYSTEM 6. Apply sealant to the groove of the pan flange as shown, ‘Sealane : Loctite 5900 or equivalent Gore 1. Apply sealant approximately 3 2 0.5 mm (0.12 = 0.019 in) in thickness. 2. After the application ofthe sealant, install the olf pan within 5 minutes. 7. Install the oil pan and tighten the bots tothe specified torque. Tightening torque lllpan bolt : 10 ~ 12.Nm (100 ~ 120 kg.cm, 7 ~ 9 Ibi) 8. Using a 24 mm deep socket, install the oil pressure switch after applying sealant to the threaded area. ‘Sealant : Threebond 1104 or equivalent NOTE Do .not torque the oil pressure switch excessively. Tightening torque Oil pressure switch : 15 ~ 22 Nm (150 ~ 220 kg.cm, 11 ~ 16 24mm (09 in.) ‘Apply sealant EMB -43 EMB -44 CRANK SHAFT COMPONENTS | comes ENGINE MECHANICAL SYSTEM 730-94 (800-340, 22-25) Crankshaft damper puiley T: 185-195 (1850 - 1960, 198-144) ‘TORQUE : Nm (kg.cm, Ib-ft) @ 770-80 (700 - 800, 52-59) Crankshatt Bedplate DISASSEMBLY | eorzour 2. Remove the rear plate and the rear oil seal, 1. Remove the timing bel, front case, flywheel, cylinder 3. Remove the connecting rod caps. head assembly and oll pan. For details, refer to the respective chapters. 4, Remove the bedplate and the crankshaft. Keep the bboarings in order according to the cap number. EMB -45 INSPECTION CRANKSHAFT 1. Check the crankshaft journals and pins for damage, Uneven wear and cracks. Also check the oil holes for, restrictions. Repair or replace any detective part. Inspect the crankshaft journal for taper and out-of- round. ‘Standard value Crankshaft journal O.D. : (60.002 ~ 60.020 mm (2.962 ~ 2.963 in.) Crankshaft pin 0.0. : {50,008 ~ 50.026 mm (1.969 ~ 1.9695 in.) MAIN BEARINGS AND CONNECTING ROD BEARINGS ‘Visually inspect each bearing for pooling, metting, seizure and improper contact. Replace any defective bearings. MEASURING OIL CLEARANCE ‘Check the oil clearance by measuring the outside diameter Cf the.crankshatt journal as wol as the the inside diameter ‘of the béaring. The clearance can be obtained by calcu- lating the difference between the measured diameters. Standard vos Of cowrance Crank man boar: 024 0.082 en (DO009 ~ 0.0017 in) Conecing fod boarng Can 0842 en (0.009 ~ 0.0017 in) Bent 04 mm (@ong9 im) HOW TO USE PLASTIGAUGE Plastigauge may be used to measure the clearance. 1. Remove oil, grease and any other dit from the bear- ings and journals. 2, Cutthe plasticgauge to the same length as the width ‘of the bearing and place it in parallel with the journal, avoiding the cil holes. 3, Install the crankshaft, bearings and caps and tighten them to the specified torques. During this operation, do not turn the crankshaft. Remove the caps. Me: ‘sure the width of the plastiogaugo at the widest part by using the scale printed on the gauge package. If the clearance exceeds the service limit, the bearing should be replaced or an undersize bearing should be used. When installing a new crankshaft, be sure to use standard size bearings. If the standard clearance ‘can not be obtained even after replacing the bearing, the journal and pin should be ground to the undersize and a bearing of the corresponding size should be in- stalled. OW SEAL, ‘Check the front and rear ol seals for damage or worn sur- faces. Replace any seat that is defective. EMB -46 BEDPLATE Aer installing the bedplate, make sure the crankshatt turns smoothly and the end play is correct. Ifthe end play exceeds the limit, replace the crankshaft bearings. ‘Standard value : 0.09 ~ 0.32 mm (0.0036 ~ 0.026 in) DRIVE PLATE (AT) Replace distorted, damaged, or cracked drive plats. FLYWHEEL (WT) 1. Check the clutch disc contacting surface of the fly wheel for damage and wear. Replace the flywhee! if excessively damaged or worn, 2. Check the clutch disc contacting surface of the fly- wheel for run - out. Limit Flywheel run - out : 0.13 mm (0.0051 in.) 3. Check the ring gear for damage, cracks and wear. Replace if necessary. ENGINE MECHANICAL SYSTEM REASSEMBLY 1. Install a grooved main bearing (upper bearing) on the cylinder block side. 2. Install a grooveless main bearing (lower bearing) on the main bearing cap side. 3. Lower center thrust bearing is grooveless. Upper con ter thrust bearing is grooved. Vv Ss Upper boarng (oN. 134) Lower bearing (oe No. 1.3.4) SO. ‘Trnust bearing (or upper) Thrust bearing (or ower) 4, Apply engine oilto journals and pins. Install the crank- shaft. 5. Install the bodplat. (Apply Loctite 5205) 6. Tighten the bodplat bots to the specified torque. Tightening torque Bedplate bolts : 15 mm : 28 ~ 32 Nm (280 ~ 320 kg.om, 207 ~ 23.6) + 120° 12 mm : 93.7 ~ 37.7 Nm (397 ~ 377 kg.cm, 27.8 tot) 7. Bedplate bolts should be tightened nly in 4 to 5 ine ‘crements before they are tightened to the specified torque. 8. Make sure that the crankshaft tums freely and check the end play of the crankshaft. MAIN MOVING SYSTEM. 8. Using @ special too! (09231 - 27000). Install the o seal in the oil seal case. A new oll seal should be used

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