H21/32 Fuel Injection Valve Assembly Drawing & Part List UR SA WE (1-stud) BUS Y YB ass eee | ae |oe Part List Postion | pao Deserpton ary | Wala | omara Sue Not 1 52.100 | Fuel injection valve set be 52.002 | O-ring 4 5 52.005 | Dowel pin 2 6 52.006 | Nozzle nut a. 7 2.007 | Adjust bolt 1 8 62.008 | Spring 1 9 52.009 | Spindle 1 10 52.010 | O-ring 1 "1 52.011 | Nut 1 12 52.012 | Atomizer assembly 1 TE HYUNDATHEAVY INDUSTRIES CO.,LTD. Engine & Machinery Division D5.0TSSI> LIMSEN H21/32 Fuel Injection Valve Maintenance Procedure ams on a M.52.000E | m1 | 0 ae SA WS (1-stud) aulaad SA SA Seco) WI] SSIES BAM BALSA In case that the exhaust temperature of a AOD! Ue BP, oe VA MES Salloy zAal particular cylinder deviates considerably from the Of BIC, Isa UE WUCLE AE KA others, dismount and inspect the fuel injection valve EH MA tds FSHe Me Rasta! Ves carefully. The possible causes are an incorrect Sol Ch. oie SA WSS wel aCe ye| eal mounting of fue! injection valve, or uneven injection (of fuel oil to combustion chamber, or wrong valve opening pressure. In order to check correct operation of the fuel injection valve, functional test should be performed by means of the hand pump before mounting the fuel injection valve. Dismantling Fuel Injection Valve from Cyl. Head 1 Y= es Boch 2. XII (BS Se SAL MSONAL ela UCL 1. Unscrew the nuts (A) 2. Dismantle the support (B) from fuel injection valve. c———* Ag D la_95.110 | Fig. Dismantling THYUNDAIHEAVY INDUSTRIES CO.,LTD. of fuel injection valve (212 ey Engine & Machinery Division ‘OS0T1SSTFuel Injection Valve 2 BAP WY (1-stud) Maintenance Procedure Auda at H21/32 M.52.000E | M2 3. Je 13) dol Ba) 27B az ZN SOO 48 asic. ea ar 4. BAP DO|= (C)B qyoiUict. 5. Fa SP) UE OS SOW 1a BA we 2 AeIC| SOI BroLeCy 6. OR BN WHO SSS mol mAtstcy WERE 2 390 eva yo asa PINE, ete AP MEO] Diss Ala 1, Ae 29) Bo] Ste A WER AapatAtol 487) atc. NOGA: 2 OS NAAM Be Su Ho LE oF0r enc 3. Install the removal device on the fuel injection valve as shown in fig 1 Removal device : [@|_ 95.110 | ‘Take out the injection pipe (C). Pull out the fuel injection valve from the cylinder head by rotating the nut (D) of removal device. 6. Clean the fuet injection vaive and nozzle. Take care not to damage or clog the nozzle holes. Function Test of Fuel Injection Valve 4. Mount the fuel injection valve on the’ testing device as shown in fig 2. Testing device : (SF|_95.600_] The pin (E) should be fitted to the groove in testing holder correctly White Paper High Prossure Pump’ FFig.2 Functional test of fuel injection valve (21a AF 8 7185 AIGA) "A HYUNDAI HEAVY INDUSTRIES CO.,LTD. Engine & Machinery Division 0501550LIMSEN Fuel Injection Valve Ce AP YS (1-stud) Maintenance Procedure Alaa BA H21/32 Becton No] Page | Row M.52.000E | M3 | 0 WM 92 ease er 28 mo 4 A ORING, 222 S16 MADE EM PE Be] a Mz WY eel I WS HB QOL 450 bard! SIX) BOL, ofeHst z 2 BAO We} BY HY VIS ZAOIIAS, 1 2a UE (MB BEC 2 Ba algal Mao Of wo] He gets 3. MS WY e210 bar 4 ZAaH LIZICE 4. Yl ABO] SSI, BY UALS wat sat UE (MS Sa AUS wzeICh. M222 : 100Nm (Molycote © ) 1. 2a! 29} Bor ae » atch Meta : rt 96,600 | HOF NIGH Le SW Bee VR O70 enich 2. aa US (HE Eoeet MAAICLAW 3-8) 2 Agua <8 UE (DS Sow ER 20) 50 se a com ce YEH BASIOI Dowel pind! HEM PU1 Ach Dowel vinthoal #91 2 3, Bt NAB AK) 2. Connect the high pressure pipe to the fuel injection valve. 3. Pump slowly by hand, and check the valve ‘opening pressure and spray pattern. Valve opening pressure : 450 bar (BREE Don't put hands near spray area during tosting. High injection pressure may damage to the human body. Adjustment of Valve Opening Pressure If the valve opening pressure is not 450 bar, adjust opening pressure as following process. 1. Loosen the locking nut (F). 2. Turn the adjusting screw (G) slowly and check valve opening pressure while pumping. 3. Adjust the valve opening pressure by the step of 10 bar. 4, When pressure setting is finished, tighten the nut (F) with a torque spanner to fix the adjusting screw. Tightening torque : 100 Nm ( with molycote ) Dismantling of Fuel valve Nozzle The testing device can be used for dismantling nozzles of fuel valve, 1. Mount the fuel injection valve on the testing device as shown in fig 2 (@{_95.600_] The pin (E) should be fitted to the groove in testing holder correctly. Loosen the locking nut (F). 3. Remove the sealing gasket (K) (refer to fig.3) Loosen the nozzle nut(J) with a torque spanner. Testing device PEER Carbon between nozzle and nozzle ‘nut can make Dowel pin broken when dismantling nozzle. Be careful of damage of ‘dowel pin. DSOTSS: LIMSEN 421/32 [ Fuel Injection Valve Maintenance Procedure eraser tae ™.52.000E | m4 | 0 | 2 SAP WY (1-stud) aula AA : oe BABS) at QY SS FYOl Ya) ACI, ae SS solat B MBC ot, BA VENSICL Ge AL MEK@ehol AOS UEILIAL QL O13] PALO] SHIEH, BS Jaa AE AOR mAHaHOH BIC. cS UES} Sol Se Wes MZOl sich Sol, De 59 ZO |e fu ‘0 Jaa SIC ASS MO! SEch 22 SA BES eC aso) BAD, UE (OE EN Aer, Ech "A HYUNDAI HEAVY INDUSTRIES CO,, Cleaning of Nozzle hole If some of holes are clogged, the nozzle should be dismantled and cleaned. Cleaning too! for nozzle : (S-|_95.700 | ‘After cleaning the nozzle, reassemble the fuel valve and repeat the above function test. If the spray pattern is not normal or still clogged, scrab the nozzle and replace with new ones, Remove carbon, and clean the nozzle nut and nozzle. Especially clean surface for contact between the nozzle nut and nozzle as fig.5 in order to prevent leakage of gas by abnormal contact. ‘Assembling of Fuel valve Nozzle The testing device can be used for dismanting nozzles of fuel valve. 1. Mount the fuel injection valve on the testing device as shown in fig 2 Testing device : [@-|_95.600_] The pin (E) should be fitted to the groove in testing holder correctly. 2. Loosen the locking nut (F). 3. Insert Dowel pin(to be supplied with spare nozzles) in Pin hole. 4. Connect the nozzle nut with nozzle in fuel valve body. 5. Tighten the nozzle nut(J) with a torquespanner. (with SW32 Deep impact socket) (refer to fig.4) Tightening torque : 300 Nm (with motycote 1000 or copasiip) 6. Install the sealing gasket(K) on nozzle, (refer to fig.3) Mounting Fuel Injection Valve on Cyl. Head 1. Replace the O-rings with new ones, and clean fuel injection valve and cylinder head 2. Mount the fuel injection valve on the cylinder head, and tighten the nuts (A) slightly. Engine & Machinery Division TSOTSIMSEN H21/32 Fuel Injection Valve Maintenance Procedure BeaionWo. | Page | Rew M.52.000E | M5 | 0 ee SAPS (1-stud) aulda BA 8 OB stele HEM Ie Bm A ROOF LICE. 2 ©: 200 Nm (molycote =) 3 UE (WS Masih Sl sto} Asa} 4] 221 62 Zor eat sto = VzOr tal oLzt woy 2144 we FUE Ww #SEEAOL 2144 10 Nn -> 30 Nm -> 60 Nn (molycote ©) fim 53.000 MGM Sealing gasket(K) Fig.3 Sealing gasket(s!a! W220) NozzI a \ Contact surface Contact surface N\ Nozzle nut (a) Fig.5 Nozzle nut and nozzie( tc 11 3} tz). IYUNDAI HEAVY INDUSTRIES CO,, LTD. The pin (E) should be fitted to the ‘groove in cylinder head correctly. Tightening torque : 200 Nm (with molycote) 3. Tighten the nuts (A) [4] _ Insert the injection pipe correctly as shown in fig. 6, and tighten the nut (H). Tightening torque : 10 Nm -> 30 Nm -> 60 Nm by three steps (with motycote) Tightening orders: Fig.6 Mounting of Fuel injoction valve( ea At wet EH) Engine & Machinery Division WEOTSST2 LIMSEN H21/32 Fuel Injection Pipe Block ae SA HOE Be (mono) Assembly Drawing & Part List BAYS YES YSE Becton Ne. —] Page | Rew M.53.000A | A1 | 4 (a M.21.000 | Part List Pontion | PartNo. Description Ta. | MQ | Remarks 1 See Note 1 53.118 | Hex nut (M12) 2 me 53.106 _| Stud (M12) 2 ts 53.108 | Disc 2 i 53.114 _| Hex. socket bolt (M12) 2 5 53.201 | Fuel delivery block 1 3.51 6 53.112 | Plug (PF1/8) 1 7 53.109 | Plugging piece 1 8 53.107 | Bush 1 [on 9 | sanz [o-ring 2 10 53.105 _| Injection pipe 1 0.36 n 53.116 | O-ring 1 RHYUNDAI HEAVY INDUSTRIES CO.,LTD. Engine & Machinery Division 04.10° MSEN H21/32 — ao Fuel Injection Pipe Maintenance Procedure Block M.53.000A | M1 | 0 42 Det BF(mono) Avlaa Bat a2 ze esol wa el Tightening procedure 82 EA HE e HAL MEO Bal ol NSS 2 oleh ote Bue CA) Bega Se UE HA Sol We} BEIM ZAWIOe a zatcy M2 BME | 10Nn > 30Nm > 6ONM SEA) AGM: Va} B83 10Nme PI) P29 H2-> HI 2a BOE 30NmE P29 PID HI > HE SA: FE 60Nme PI~>P2-> H2-> HI ee In case of overhauling or replacement of Fuel injection pump, Fuel injection valve, dismantling and assembling Fuel injection pipe block is required. Then, Tighten torque by 3-step according to the position orders of the nut. Tightening torque : 10Nm -> 30Nm -> 60Nm (3 stops) Tightening orders : 1": by ightening torque 10Nm PI P2->H2>H1 2" : by tightening torque 30Nm P2>P1>H1>H2 3 : by tightening torque 60Nm PI>P2>H2>Ht @ Of Le r A 1 = ot | — ‘e. ao > H2 @ Jo po Fig Boting no. of Fue! injection pipe block(2i? at #5) SE U8) TAHYUNDAI HEAVY INDUSTRIES CO, LTD. Engine & Machinery Division OnTTSSIMSEN [ Fuel Feed Pipe Arangement | Fuel Feed Pipe Arrangement a2 23 Moz waa H21/32 ‘Sections M.53.300 | A1 Assembly Drawing & Part List Cael eae ees cere M.41.100 Part List on [Patte | Omen Teme [eae] ee | ne 1 | 53.320 | Hex socket head bolt 15 | 18 | 21 | 24 | 27 2 | 53.321 | Hex. socket head bolt 8 | 10 | 12 | 1 | 16 3 | 53.300 | Clamping piece glee lee s|ri ae 4 | 53310 | o-ing to | 12 | 14 | 16 | 18 5 | 53.304 | End block (Aft) afatafa[a 6 | 53.328 | Connection block secret 7 [| 53.329 | Block eat 3 | 53.318 | Oxing az | 40 | 48 | 56 | 64 @ | 53.302 | Connecting pipe 3 | 10 | 12] 14 | 16 | 126 a EYUNDAT HEAVY INDUSTRIES CO, LTD. Engine & Machinery Division 1791Lim SEN H21/32, H25/33 Fuel Oil Filter Assembly Drawing & Part List | “on™? | P| * M.53.400 | At | 4 ZA HYUNDATHEAVY INDUSTRIES CO.,LTD. Engine & Machinery Division OaTIDYs MSEN H21/32, H25/33 Fuel Oil Filter ‘Assembly Drawing & Part List | “"°""? | Ps" | 53.400 | A2 | 4 AGE YTS ASS Part list Position Qty | Weight nao? | Part No. Description ieee a Remarks / See Note 1 53.401 | Fuel oil pump complete 1 2 53.402. | Filter element 2 3 53.403. | Nut (M10) 8 5s | 33405 1 6 53.406 | Plug screw 2 7 | 83.407 | Gasket 2 8 53.408 | Drain cock 2 os 53.409 | Gasket a 53.470 | Fixing bolt 1 1 | s34n [disc 2 12 | 53.412 | Gasket 2 13 53.413 | Counter nut 2 7 14 53.414 | Sealing screw 2 15, 53.415 | Handle oe 2 16 53.416 | Split pin - oe] a7 | 83.417 | washer 2 18 53.418 | Nut 2 : z : 19 | 53.419 | Stud bot (M10) 8 20 | 58.420 | Spring washer 8 HYUNDAI HEAVY INDUSTRIES CO, LTD. Engine & Machinory Division Darby