INTAKE AND EXHAUST SYSTEM

Transcription

1 EM -66 INTAKE AND EXHAUST SYSTEM ENGINE MECHANICAL SYSTEM SPECIFICATIONS Air cleaner type Element type Intercooler E08C8904 Items type Length Width Height Max rpm allowed Specifications Dry type Paper type Turbocharger (TD05H-G) 60mm 7mm 6mm 60,000rpm Maximum pressure ratio.6 Maximum exhaust gas temperature 760 C TIGHTENING TORQUE Turbocharger Intake manifold Exhaust manifold Items (Diameter Length) Screw size O.D pitch (mm) Nm kgf.m Ib-ft Turbocharger and intake pipe clamp band M Turbocharger oil pipe eyebolt M Actuator mounting flange bolt M ~.8 0.8~. 5.8~8.7 Butterfly valve shaft mounting nut (8) M ~5.5.7~.6.4~8.9 Intake manifold front hanger mounting flange bolt(0 0) Intake manifold mounting flange bolt(8 0) M ~49 3.3~5.0 4~36.4 M ~7.4.9~.8 3.8~0.4 Heater protector cover mounting bolt M Exhaust manifold assembly self lock flange nut M

2 INTAKE AND EXHAUST SYSTEM EM -67 TROUBLESHOOTING EBA6A66F Output drop Intake system Is air cleaner clogged? Replace the element Does air leak at the connection of intake system? Repair Exhaust system * Is muffler or exhaust pipe deformed? * Is carbon accumulated? Does gas leak at exhaust system? Repair or replace Repair Is exhaust brake opened? Repair or replace Turbocharger (TD05H-G) If the turbocharger is defective, replace it in the assembly unit. Any leakage at the connection of compressor cover and intake pipe? Tighten the clamp Are compressor inside, compressor cover and compressor wheel polluted? Cleaning Does turbine wheel rotate smoothly if turned by hands? Clean the carbon deposit and turbocharger. SUDEM795L

3 EM -68 ENGINE MECHANICAL SYSTEM Unusual noise and vibration Intake system Are fixing bolts and nuts of intake system fastened securely? Tighten Exhaust system Are fixing bolts and nuts of exhaust system fastened securely Repair or replace Is exhaust pipe or muffler damaged? Repair or replace Turbocharger Are bearing and rotating parts OK? Inspect the following. Deterioration of engine oil Oil filter element clogging Foreign materials in oil supply pipe. Bearing damage due to repeated sudden departures and stops. Do rotating parts rotate smoothly? Isn't turbine wheel shaft bent? Defective bearing Compressor wheel or turbine wheel damage due to the foreign materials inside. Are there any foreign materials in turbocharger? Check the intake and exhaust piper carefully for the chip of compressor or turbine wheel SUDEM796L

4 INTAKE AND EXHAUST SYSTEM EM -69 TURBOCHARGER COMPONENTS EB39DEE 4. (4., 30.5) 40. (4., 9.8) 7.8 (., 8.7) (4., 30.5). Cylinder head assembly. Exhaust manifold assembly 3. Plain washer 4. Distance piece 5. Exhaust manifold self lock flange nut (M0x.5) 6. Oil pipe 7. Turbocharger oil pipe eye bolt (M8x.5) 8. Oil return pipe 9. Turbocharger assembly 0. Self lock flange nut. Exhaust pipe Tightening Torque : Nm (kgf.m, Ib-ft) SUDEM797L

5 EM -70 ENGINE MECHANICAL SYSTEM ~4.9 (0.4~0.5,.9~3.6). Actuator. Compressor cover 3. O-ring 4. Cartridge assembly 5. Snap ring 6. Coupling 7. Turbine housing Tightening Torque : Nm (kgf.m, Ib-ft) SUDEM798L

6 INTAKE AND EXHAUST SYSTEM EM -7 REMOVAL E90F3479. Remove the turbocharger heater protector cover (). 3. Make an aligning mark on the coupling (), turbine housing (), compressor cover (3), and cartridge assembly (4). 4 3 SUDEM799L SUDEM70L. Remove the turbocharger assembly (). 4. Remove the turbine housing(). CAUTION a. Lightly tap the housing circumference with rubber hammer so that turbine housing is not damaged. b. Since turbine wheel blade is easily bent, exercise care when removing the housing. SUDEM700L SUDEM70L

7 EM Remove the compressor cover (). CAUTION a. Lightly tap the compressor cover circumference with rubber hammer so that compressor cover is not damaged. b. Since compressor wheel blade is easily bent, exercise care when removing the compressor cover. ENGINE MECHANICAL SYSTEM. Check the shaft directional clearance of shaft and turbine wheel assembly. a. Check the clearance of turbine wheel side. If the measurement exceeds the limit, replace the cartridge assembly (). SUDEM705L SUDEM703L b. Inspect the clearance of compressor wheel side. If the measurement exceeds the limit, replace the cartridge assembly (). INSPECTION EFAE884. Measure the shaft directional clearance of shaft and turbine wheel assembly. If the measurement exceeds the limit, replace the cartridge assembly (). SUDEM706L SUDEM704L

8 INTAKE AND EXHAUST SYSTEM EM After assembling the turbocharger assembly (), turn each wheel () to see if it rotates smoothly. INSTALLATION E50867FF. When assembling the snap ring () to compressor cover (), assemble it so that the snap ring taper side (3) faces up. CAUTION When installing the snap ring, install it to the compressor cover by holding the snap with one hand. 3 SUDEM707L 4. When assembling turbocharger assembly (), fill with the engine oil through the oil hole () so that each part operates smoothly. SUDEM709L. Install the turbocharger assembly (). Tightening torque: 4. Nm (4.kgf.m, 30.5 Ib-ft) SUDEM708L SUDEM70L

9 EM -74 ENGINE MECHANICAL SYSTEM 3. Install the turbocharger heater protector cover (). Tightening torque:.8 Nm (.kgf.m, 8.7 Ib-ft) SUDEM7L

10 INTAKE AND EXHAUST SYSTEM EM -75 INTAKE MANIFOLD COMPONENTS EDBED9AC ~49 (3.3~5.0, 4~36.4) 8.6~7.4 (.9~.8, 3.8~0.4) 7.8~.8 (0.8~., 5.8~8.7). Intake manifold gasket. Intake manifold assembly 3. Actuator 4. Intake manifold front hanger Tightening Torque : Nm (kgf.m, Ib-ft) SUDEM7L

11 EM -76 ENGINE MECHANICAL SYSTEM REMOVAL EEA88FD INSPECTION EEC0B88. Remove the injection pipe ().,,3 and 4 from common rail assembly to the injector. Inspection and adjustment of the clearance between butterfly valve and Intake manifold. Secure the butterfly valve to the close state with 500mmHgormorenegativepressureappliedtothe actuator (the condition that double nuts are coherent to the bracket).. Adjust the clearance by moving the adjusting hole (A) of actuator bracket and tighten it with the bolt. Clearance between butterfly valve and Intake manifold (B): 4.0~4.5mm SUDEM73L. Remove the Intake manifold assembly (). B A Double nut Actuator SUDEM75L 3. When the internal air pressure of 3kg/cm² is applied to the actuator, it should maintain the airtight of 0.cc or less for 5 seconds. SUDEM74L 4. Butterfly valve should have the durability of 400,000 cycles at the ambient temperature of 80 C.

12 INTAKE AND EXHAUST SYSTEM EM -77 INSTALLATION EE8BA5EE. Install the injection pipe ().,,3 and 4.. Install the intake manifold (). Tightening torque: 8.6~7.4 Nm (.9~.8kgf.m, 3.8~0.4 Ib-ft) Tightening torque: 39.~49 Nm (4.0~5.0kgf.m, 9.~36.4 Ib-ft) 0.8~..9~.8 SUDEM78L SUDEM76L 0.5kgf m.5mm SUDEM77L NOTE When installing the butterfly valve (), fasten the butterfly valve shaft mounting nut () so that the identification mark ( ) faces to the direction shown in the illustration. Tightening torque: 6.7~5.5 Nm (.7~.6kgf.m,.4~8.9 Ib-ft)

13 EM -78 EXHAUST MANIFOLD ENGINE MECHANICAL SYSTEM COMPONENTS E6A9EE (4., 30.5). Cylinder head assembly. Exhaust manifold gasket 3. Exhaust manifold assembly 4. Plain washer 5. Distance piece 6. Exhaust manifold self lock flange nut (M0x.5) Tightening Torque : Nm (kgf.m, Ib-ft) SUDEM79L

14 INTAKE AND EXHAUST SYSTEM EM -79 REMOVAL E670CA. Remove the turbocharger heater protector cover (). 3. Remove the exhaust manifold heater protector cover (). SUDEM7L. Remove the turbocharger assembly. SUDEM70L 4. Remove the exhaust manifold assembly (). SUDEM73L SUDEM7L

15 EM -80 INSTALLATION EFDF4E9E ENGINE MECHANICAL SYSTEM 3. Install the turbocharger assembly.. Install the exhaust manifold assembly (). Tightening torque: 4.Nm (4.kgf.m, 30.5 Ib-ft) Tightening torque: 4.Nm (4.kgf.m, 30.5 Ib-ft) SUDEM73L. Install the exhaust manifold heater protector cover (). Tightening torque:.8nm (.kgf.m, 8.7 Ib-ft) SUDEM7L 4. Install the turbocharger heater protector cover (). Tightening torque:.8nm (.kgf.m, 8.7 Ib-ft) SUDEM7L SUDEM70L

16 INTAKE AND EXHAUST SYSTEM EM -8 AIR CLEANER COMPONENTS ED5C0E < HD65/7/78 NARROW/WIDE STD/DOUBLE> Radiator reservoir. Air inlet duct 3. Air cleaner assembly 4. Air outlet duct 5. Turbocharger inlet hose 6. Intercooler inlet pipe 7. Intercooler outlet pipe 8. Radiator outlet hose 9. Radiator inlet hose 0. Dust indicator SUDEM74L

17 EM -8 ENGINE MECHANICAL SYSTEM County Inlet duct. Clamp 3. Air cleaner assembly 4. Air outlet pipe 5. Dust indicator 6. Intercooler in/out pipe 7. Radiator reservoir 8. Radiator upper hose 9. Exhaust manifold assembly 0. Turbocharger assembly SUDEM75L

18 INTAKE AND EXHAUST SYSTEM EM -83 HD65/7/ ~3.7 (0.9~.4, 6.5~0.) ~3.7 (0.9~.4, 6.5~0.). Exhaust pipe. Muffler assembly 3. Tail pipe 4. Suspend assembly 5. Bracket 6. Exhaust brake unit 7. Turbocharger assembly 8. Battery carrier Tightening Torque : Nm (kgf.m, Ib-ft) 5 3 SUDEM76L

19 EM -84 ENGINE MECHANICAL SYSTEM County Exhaust pipe. Exhaust brake unit 3. Muffler assembly 4. Tail pipe 5. Turbocharger assembly 6. Exhaust manifold assembly SUDEM77L

20 INTAKE AND EXHAUST SYSTEM EM -85 INSPECTION EBEA6F AIR CLEANER. When dust indicator turns red, which tells the filter replacement interval, replace the element. CAUTION Replace the element at least once per years. Do not reuse it after cleaning.. 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 that air-cleaner should not contain any dust or foreign material. g. Tighten the butterfly nut of element. h. Check to see if the packing at the air-cleaner assembly 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. CAUTION Genuine parts of the air-cleaner must be used. If the vehicle is driven with the air-cleaner removed, itmaybethecauseofearlyenginedamage. EXHAUST MUFFLER. Check the exhaust system for any unusual noise.. Check the exhaust muffler for connection and corrosion. 3. Check the exhaust muffler gasket for any damage.

21 EM -86 LUBRICATION SYSTEM ENGINE MECHANICAL SYSTEM DESCRIPTION E3DF9F3D FLOW CHART OF LUBRICATION SYSTEM Engine is lubricated by a gear-type oil pump that forces engine oil through the oil cooler and oil filter into the engine for lubrication of various engine parts. Main oil gallery Bypass valve Oil filter Oil pressure switch Idler gear bush Crankshaft main bearing Camshaft bush Oil cooler Orifice Timing gear Connecting rod bearing Rocker bush Oil pump Connecting bush Push rod Turbo charger Regulator valve Relief valve tappet vacuum pump oil jet piston oil strainer oil pan SUDEM78L OIL PUMP Drive gear Oil pump gear The oil pump, of a gear type, is driven by the crankshaft rotation engaged with oil pump gear. And the relief valve is installed to the oil pump so that it prevents the excessive pressure by bypassing the engine oil to oil pan when the oil pressure exceeds the specification. Relief valve B C A Oil pump case Driven gear Oil pump cover A: from oil strainer B: to oil cooler C: to oil pan SUDEM79L

22 LUBRICATION SYSTEM EM -87 OIL COOLER Oil cooler is equipment for heat exchange between the coolant and oil fed from the crankcase water jacket and oil pump, respectively. The oil cooler has a bypass valve that opens when the element () becomes clogged. REGULATOR VALVE When oil pressure in main oil gallery exceeds the specification, regulator valve () opens and some engine oil drains to the oil pan to adjust the oil pressure. SUDEM73L BYPASS VALVE SUDEM730L When the oil viscosity is high (in cold) or oil path shows high resistance depending on the element load, the bypass valve () opens and oil goes directly to oil filter without passing oil cooler. OIL PRESSURE SWITCH If the pressure of engine oil which is sent to the main oil gallery is below the specification, the built-in relay in the oil pressure switch () is closed, then the warning lamp in the instrument panel is on to inform the driver of abnormal pressure. SUDEM73L SUDEM733L

23 EM -88 OIL FILTER Oil filter uses a spin-on type paper element, in which full flow filter and bypass filter are integrated. Bypass valve is assembled to the bottom of the filter. If the element is loaded, valve opens so that engine oil goes to oil main gallery without passing through the element to prevent engine overload. LUBRICATION OF PARTS ENGINE MECHANICAL SYSTEM The engine oil routed from the oil filter to oil main gallery lubricates all engine parts as detailed below before returningtotheoilpan.. Main bearing and connecting rod bearing a. There is an oil passage () provided from the oil main gallery to each main bearing. The oil flows through the oil hole () to lubricate the main bearing and passes through the oil passage drilled into the crankshaft to lubricate the connecting rod bearings Out packing. Seaming cap 3. Bypass element assembly 4. Full-flow element assembly 5. Housing 5 SUDEM735L SUDEM734L b. The Oil jet (), installed at each cylinder oil main passage, injects engine oil into the piston () to cool the piston. This oil jet has a check valve which is opened/closed by the specified oil pressure, it prevents oil flow and oil pressure from decreasing at low pressure. SUDEM736L

24 LUBRICATION SYSTEM EM -89. Camshaft Camshaft bushings are lubricated by the oil flowing through the oil passages leading from the oil main gallery to each bushing. 3. Valve mechanism The engine oil that has lubricated. camshaft bushing passes through the oil hole and pipe provided at the top portion of crankcase to the cylinder head. The engine oil then goes through the front rocker shaft bracket into the rocker shaft, lubricating each rocker bushing. At the same time, it lubricates valve cap and valve stem of the rocker. The oil then passes through the push rod holes in the cylinder head and crankcase to lubricate the tappets and camshaft cams before returning to the oil pan. Front rocker shaft bracket Rocker shaft Push rod Tappet Camshaft cam SUDEM737L

25 EM -90 ENGINE MECHANICAL SYSTEM SPECIFICATION EADD3ED OIL COOLER Bypass valve open Item Regulator oil pump valve open 3.5~4.5kg/cm²(36~49kpa) 5~7kg/cm²(490~686kpa) Specification OIL PUMP Head gear Item Specification Module.0 Pressure angle 0 N0. of gear teeth 36 distortion angle 9.5 Backlash (mm) 0.049~0.5 Pump rotation (rpm) 550~300 Oil Temperature ( C) -5~30 Oil in use SAE 0W~30W Injection pressure MPa (kgf/cm²) 0.4(4) Injection amount (l /min) 5 Relief valve operating pressure MPa (kgf/cm²).±0. (±) OIL FILTER Filtration capacity Pressure loss Item Full-flow : above 700cm³ By-pass : above 400cm³ Below 0.5kgf/cm² Bypass opening pressure MPa (kgf/cm²) 98±0 (.0±0.) Bypass pressure loss MPa (kgf/cm²) 57±0 (.6±0.) LUBRICANT Specification Item Types Oil grade Engine oil API classification grade CF 4 or more SAE 0W-30 Grade CF-4 or more Oil viscosity (temperature applied) ) 0~40 C : SAE 30 ) above -0 C: SAE 0W-40 3) above -5 C: SAE 5W-40 4) -0~40 C : SAE 0W-30 5) below 0 C: SAE 5W-30 Oil capacity Oil pan : 8l Total capacity : 9l

26 LUBRICATION SYSTEM EM -9 SERVICE STANDARD Item minal value ([ ] indicates base diameter) Limit Corrective action and remarks Oil pressure At idle ~5kg/cm² 0.5kg/cm² Adjust ( oil temperature 70~90 ) At max speed 3~5kg/cm² kg/cm² Adjust Oil pump Oil cooler Oil pump case and gear teeth end clearance 0.0~ Replace Difference between oil pump case depth and gear height (sinkage) 0.0~ Replace Driven gear to driven shaft clearance [0]0.04~ Replace Drive gear end play 0.03 Relief valve opening pressure 0~kg/cm² Replace Bypass valve pressure 3.5~4.5kg/cm² Replace Opening pressure of regulator valve 5.0~7.0kg/cm² Replace Unit : mm TIGHTENING TORQUE Item (Diameter length) Size OD pitch (mm) Nm kgf.m Ib-ft Oil strainer flange bolt (8 6) - 8.6~7.4.9~.8 3.8~0.4 Oil strainer flange bolt (8 40) - 8.6~7.4.9~.8 3.8~0.4 Oil pan mounting flange bolt (8 ) M8. 8.6~7.4.9~.8 3.8~0.4 Oil level gauge mounting flange bolt (8 6) - 8.6~7.4.9~.8 3.8~0.4 Oil pan drain plug M ~ ~ ~9. Oil filter element M Oil cooler bypass M Oil cooler relief valve M Oil cooler drain plug M ~ ~ ~3.7 Oil cooler mounting flange bolt - 8.6~7.4.9~.8 3.8~0.4 Oil line flange bolt - 7.8~.8 0.8~. 5.8~8.7 Oil line eye bolt - 8.6~.5.9~.3 3.8~6.7 Idler gear oil supply pipe ~ ~ ~6.8 Turbooilpipeeyebolt - 8.6~.5.9~.3 3.8~6.7 Turbo oil pipe flange bolt (8 6) - 8.6~7.4.9~.8 3.8~0.4 Oil pump mounting flange bolt (8 55) - 8.6~7.4.9~.8 3.8~0.4

27 EM -9 ENGINE MECHANICAL SYSTEM TROUBLESHOOTING EBA856F Is oil pressure decreasing? Is oil level proper? Check for oil leaks or mixture with coolant. Repair the damaged parts and replenish it with oil to the proper level. Is the oil viscosity normal? Replace the oil with the proper viscosity. Check fuel supply. Do the oil pressure switch and gauge unit work? Replace. Is the filter element clogged? Replace the element. Is the oil strainer clogged? Is oil pump locked? Is pipe cracked? Repair or replace the faulty parts. Do the relief valve and regulator valve work? Repair or replace. Is there any damage or wear at the oil pump body? Replace the faulty parts Is connecting rod or main bearing worn? Repair or replace the faulty parts SUDEM738L

28 LUBRICATION SYSTEM EM -93 Excessive oil consumption Check the following items for a leakage Oil filter Oil cooler Oil pan Oil pipe Oil cover Repair the leaking parts. Is oil leaking from the oil seals of front and rear crankshaft? Repair or replace the faulty parts. Is any damage in cooling system? Repair the damage of oil cooler and water jacket etc. Check the abrasion of the engine bearing which causes a leakage of oil. Repair or replace. SUDEM739L

29 EM -94 ADJUSTMENT ECFE874F ENGINE OIL CHANGE ENGINE MECHANICAL SYSTEM ENGINE OIL INSPECTION. Park the vehicle on the flat surface.. Stop the engine.. Stop the engine after warming up and remove the oil filler cap () on the cylinder head cover(). NOTE a. Warm up the engine for minutes if the vehicle has not been inspected. b. Stop the engine and wait for 5 minutes at least to measure the oil level. 3. If the oil level is below L mark of the gauge, refill the oiluptomarkf. NOTE When refilling, oil should be same kind with the one in the pan. SUDEM74L. Loosen the drain plug () of oil pan to drain engine oil. Good SUDEM740L 4. Check the oil for pollution, mixture with coolant and viscosity. 3. Tighten the drain plug with the specified torque. SUDEM74L Tightening torque : 34.3~44. Nm (3.5 ~ 4.5kgf.m, 5.4~3.7 Ib-ft) CAUTION If oil drain plug is not tightened to the specified torque or gasket is reused, it may cause oil leakage or thread wear. Be sure to replace the gasket with new one at every oil change.

30 LUBRICATION SYSTEM EM Fill in the new engine oil into the oil filler. NOTE Overfilling may cause oil saturation or pressure drop. Oil capacity Oil pan : 8l Total capacity : 9l 5. Close oil filler cap. 6. Start the engine. 7. Stop the engine and check the oil level. Refill the engine oil if necessary. OIL FILTER REPLACEMENT OIL PRESSURE CHECK Remove regulator valve assembly and install pressure gauge (). Warm up the engine until the temperature reaches 70~90 C. Measure the oil pressure at idle speed and max speed. If the readings are below the limit, disassemble and check the lubrication system. Item Standard Limit load min rpm.5kg/cm² 0.5kg/cm² load max rpm 3~5kg/cm² kg/cm². Remove the oil filter () using oil filter wrench.. Apply engine oil on the gasket surface before installing oil filter. 3. Install the oil filter with the specified torque. Tightening torque : 7.6~.6 Nm (.8~. kgf.m, 3.~6.0 Ib-ft) SUDEM744L SUDEM743L 4. Start the engine and check the oil leakage. 5. Stop the engine and check oil level. Refill engine oil as needed.

31 EM -96 OIL PUMP ENGINE MECHANICAL SYSTEM COMPONENTS E68A ~7.4 (.9 ~.8, 3.8~0.4) 34.3~39. (3.5 ~ 4.0, 5.4~9.) 4 8.6~7.4 (.9 ~.8, 3.8~0.4) 6 8.6~7.4 (.9 ~.8, 3.8~0.4) 3. Crankcase. Oil strainer 3. O-ring 4. Oil pan drain plug 5. Oil pan 6. Stiffener Tightening Torque : Nm (kgf.m, Ib-ft) SUDEM745L

32 LUBRICATION SYSTEM EM ~7.4 (.9 ~.8, 3.8~0.4) Oil pump assembly. O-ring 3. Crankshaft gear 4. O-ring 5. Oil pump case assembly 6. Snap ring 7. Relief valve 8. Spring 9. Seat 0. Oil pump cover. O-ring. Drive gear 3. Driven gear Tightening Torque : Nm (kgf.m, Ib-ft) SUDEM746L

33 EM -98 DISASSEMBLY EE5D4AF9. If the clearance between the end of the drive () and driven gear () and oil pump case exceeds the limit, replace those parts. Clearance between oil pump case and gear tooth end Standard : 0.0~0.9mm Limit : 0.mm ENGINE MECHANICAL SYSTEM 3. Measure the clearance between driven gear and driven shaft. If the clearance exceeds the limit, replace the parts. Clearance between driven gear and driven shaft Standard : 0.04~0.07mm Limit : 0.5mm 4. Measure the play of drive gear end, if the measurement exceeds the limit, replace the parts. Standard play of drive gear end : 0.03mm SUDEM747L. Measure the difference between the drive and driven gears tooth end height and the oil pump case depth. If the measurement exceeds the limit, replace the parts. Difference between oil pump case and gear tooth end height. (Sinkage) Standard : 0.0~0.07mm Limit : 0.8mm SUDEM749L 5. Check the opening pressure of relief valve, replace the parts if they exceeds the limit. Standard of relief valve opening pressure : 0~kg/cm² SUDEM748L

34 LUBRICATION SYSTEM EM -99 OIL COOLER COMPONENTS ECAC 9.6 (.0, 4.5) (., 8.7) ~39. (3.5 ~ 4.0, 5.4~9.) 9.6 (.0, 4.5) (.0, 4.5) Tightening Torque : Nm (kgf.m, Ib-ft) 3. Oil cooler element. Oil cooler body assembly 3. Plug 4. Spring 5. Bypass valve 6. Plug 7. Spring 8. Regulator valve 9. Out packing 0. Seaming cap assembly. Bypass element assembly. Full flow assembly 3. Housing SUDEM750L

35 EM -00 ENGINE MECHANICAL SYSTEM DISASSEMBLY EEA50548 INSPECTION EC9C5BDC. Remove the exhaust manifold.. Cover oil cooler element () and connect hose to the engine oil filler. And immerse it into the water tank.. Apply air pressure of 3kg/cm² to hose side and check the oil cooler element. 3. Check air leakage. If air leaks, replace the oil cooler element. SUDEM75L. Remove the oil filter () and oil cooler assembly (). SUDEM754L 4. Check the pressure of oil cooler bypass valve and regulator valve opening pressure. Replace them if necessary. Bypass valve pressure : 3.5~4.5kg/cm² Regulator valve opening pressure : 5.0~7.0kg/cm² SUDEM75L 3. Disassemble oil cooler element () from oil cooler. 5. Oil pressure switch inspection a. Remove oil pressure switch from oil cooler. b. Check the continuity between oil pressure switch terminal () and body(3) using a tester(). If there is no continuity, replace the switch. 3 SUDEM753L SUDEM755L

36 LUBRICATION SYSTEM EM -0 c. Insert the slim rod () into oil hole of oil pressure switchandcheckthecontinuity. If there is continuity, replace the parts because it is faulty. SUDEM756L CLEANING. Check the oil path and bypass valve of the oil cooler element for carbon deposits and sludge formation. If contaminated, wash it in cleaning oil.. 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 pump installation surface.

37 EM -0 COOLING SYSTEM DESCRIPTION COOLING SYSTEM EC3B53CC Water pump cools down the engine by circulating the coolant forcibly as shown in the illustration below. Thermostat THERMOSTAT ENGINE MECHANICAL SYSTEM. The thermostat, of a bottom bypass configuration, has a valve controlled by a special wax enclosed in a pellet.. The wax changes from solid to liquid as it is heated, involving volumetric change for regulation the flow of coolant. The valve position changes depending on the coolant temperatures regulate the flow rate of coolant into the radiator and water pump (bypass side), thus controlling coolant temperature. B At low temperature At high temperature Radiator WATER PUMP Water pump Cooling fan SUDEM757L Water pump, a centrifugal type, is driven by the V-belt from the crankshaft pulley. A unit seal is installed between impeller and water pump that prevents leakage of coolant. There is a drain hole provided at the bottom of the water pump case, which ensures that water should leak from the unit seal, does not enter bearings. The water pump is mounted on the timing gear case provided with a suction pipe and swirl chamber. An Impeller, pressed fit into the one end of water pump shaft, has the combination blade, which feeds coolant under pressure into the engine. B A : from cylinder head B : to radiator C : to water pump C A SUDEM759L 3. A jiggle valve is installed in the air plug hole of thermostat, which heats up the coolant temperature rapidly to put the engine temperature to the normal one. When engine stops, and coolant flows as jiggle valve falls down by its weight so that air in the engine is led to radiator through the clearance between the jiggle valve and the breather hole. When the engine starts, coolant flow into the radiator and jiggle valve is pushed up by the water pressure. As a result, valve covers the air plug hole to prevent the coolant from leaking through the hole. A <When engine is off> <When engine is on> C A A B B A; from the radiator B: from the thermostat C: to the crank case SUDEM758L A : air B : water SUDEM760L

38 COOLING SYSTEM EM -03 RADIATOR The radiator, which consists of tube-and-corrugated-fin type core, not only cools the engine coolant but also separates vapor from liquid water and regulates pressure in the cooling system. Radiator cap. When the air temperature in the radiator is high, bimetal is deformed and opens the reservoir valve.. Since the fluid (silicon oil) keeps flowing, viscosity between the coupling case and rotor increases, and thefanmountedtothecasehasthesimilarspeedof shaft. Viscosity varies with the fluid amount (silicon oil). 3. When the air temperature falls, the bimetal is operated to close the valve and the fluid returns to the reservoir. It results in a quick speed decrease by sliding between the coupling case and rotor. Radiator Silicon oil storage area Working area Rotor Coupling case SUDEM76L Bimetal RADIATOR CAP Radiator cap regulates the pressure in the cooling system. When the pressure exceeds the predetermined level, the pressure valve compresses the pressure spring to release theexcessivepressuretotheair. As the coolant temperature drops and forms a vacuum in the radiator, the vent valve opens to admit air into the radiator, thus preventing the radiator from being deformed by the vacuum. Coupling shaft OPERATION OF AUTOCOOL FAN COUPLING <At high temperature> Pump protrusion Pump hole SUDEM763L A When pressure forms Fluid (silicon oil) Valve Pump chamber B When vacuum forms Separator plate <At low temperature> Pump protrusion Pump hole A : to the reservoir tank B : from the reservoir tank Pump chamber SUDEM76L AUTO COLLING FAN Autocool fan coupling is the device to control the fan speed according to the engine coolant temperature. The bimetal detects the air temperature running through the radiator and varies the fluid coupling flows to control the fan speed. SUDEM764L

39 EM -04 ENGINE MECHANICAL SYSTEM SPECIFICATION EC630CCE Cooling method Coolant capacity Water pump Item Type Drive Specification Water cooling, forced circulation 0l (includes engine, radiator and heater) Volute pump V-belt V-belt Quantity EA Thermostat Type Valve opening Temperature Wax-pellet, bottom bypass (installed with jiggle valve) 8 C Fan Type Nylon + GF30%, suction Autocool fan coupling Radiator SERVICE STANDARDS Water pump Thermostat Radiator V-belt deflection Item Type Fluid Type Cap type Fluid coupling type (viscosity) Silicon oil Tube-and corrugate-fin Pressure type minal value ( indicates base diameter) Fan rotation (Autocool fan coupling) - Interference between pump shaft and flange ~0.0mm Limit More than ~3 revs. Uptotimes Correction and remarks Replace Replace Gap between pump shaft and impeller ~0.06mm Replace Pump case to impeller installed dimension 0.8~.7mm Replace Valve opening temperature 80~84 C Replace Valve lift / temperature Above0/95C Replace Pressure cap opening pressure nominal negative 0.83~.0kg/cm² Below 0.05kg/cm² Replace Radiator check pressure.4kg/cm² Replace Reservoir tank inner pressure 0.5kg/mm² Replace Between alternator and water pump ~6mm adjust Between power steering pump and crankshaft pulley 4~6mm adjust Air-con compressor and tension pulley 6~0mm adjust

40 COOLING SYSTEM EM -05 TIGHTENING TORQUE Description (diameter x length) Screw size OD Pitch ( mm ) Nm kgf.m Ib-ft Fan clutch spring washer bolt (8 5) M ~5.5.7~.6.4~8.9 Fan clutch nut(6) M ~ ~0.6.9~3.6 Fan clutch mounting flange bolt(8) M8.5.6~3.3.~3.3 6~4 Thermostat cover case flange bolt M8.5.6~3.3.~3.3 6~4 Coolant temperature sensor and gauge PT 3/8 9.4~ ~4.0.8~9. Thermostat case flange bolt(0 5) M ~ ~5.4 6.~39.3 Radiator fan shroud mounting bolt M ~ ~ ~5. Radiator mounting bolt M8.5.8~4.7.~.5 8.7~0.9 Reservoir tank mounting bolt M ~ ~.4 6.5~0. Alternator adjusting plate mounting bolt(0 0) ~ ~5.4 6.~39.3 Alternator adjusting shaft mounting nut (0) - 8.6~7.4.9~.8 3.8~0.4

41 EM -06 ENGINE MECHANICAL SYSTEM TROUBLE SHOOTING E37CEA7 Overheat Is the tension of V-belt normal? Adjust the tension of the belt and after checking the belt, replace it if necessary. Is coolant level proper? Add the coolant, and if there is a leak, check the cooling system. Is there any clogged radiator fan? Clean the radiator core and adjust the deformation of core if necessary. Is coolant polluted or rusted? Clean the cooling system Is thermostat operating? Replace the thermostat Does water pump work properly? Replace the water pump Is there any leak in the auto cooling fan coupling? Replace the fan coupling Check the all possible causes of overheating. SUDEM765L

42 COOLING SYSTEM EM -07 There is heavy loss of coolant. Is the radiator hose leaking? Does the hose clamp tighten properly? Tighten the clamp. Cracked or damaged hose? Replace the hose. Is the radiator core leaking? Is the water pump leaking? Repair or replace the radiator. Replace the O-ring Is the radiator pressure pump leaking? Is the pressure range correct in the pressure valve? Is gasket in good condition? Replace the pressure valve. Any gas in the coolant leaked from cylinder head gasket? Replace the cylinder head gasket. Is the oil cooler leaking? Are bolts tightened properly? Defective or damaged O-ring? Tighten the bolts. Replace. Check the possible leaking spots of the engine. SUDEM766L

43 EM -08 WATER PUMP ENGINE MECHANICAL SYSTEM COMPONENTS E7DE ~3.3 (.~3.3, 6~4) 35.3~5.9 (3.6~5.4, 6.~39.3) 6.7~5.5 (.7~.6,.4~8.9) ~3.3 (.~3.3, 6~4) 3.9~5.9 (0.4~0.6,.9~4.4) Tightening Torque : Nm (kgf.m, Ib-ft). Cooling fan. Autocool fan coupling 3. Coupling plate 4. Water pump pulley 5. V-belt 6. Water pump assembly 7. O-ring 8. Crankshaft damper pulley 9. Thermostat housing SUDEM767L

44 COOLING SYSTEM EM -09 REMOVAL E9DDBEE. Remove the coolant drain plug and drain the coolant.. Loosen the alternator () tension adjusting screw () and remove V-belt (3). 4. Remove water pump pulley() and water pump assembly(). 3 SUDEM770L SUDEM768L 3. Remove the cooling fan () and autocool fan coupling (). 5. Disassemble the coolant temperature sensor connector and remove the thermostat housing() from the cylinder head. a. Remove the thermostat cover. b. Remove the thermostat. c. Disassemble the bypass pipe from the thermostat case. d. Remove the coolant temperature sensor. SUDEM769L SUDEM77L

45 EM -0 INSPECTION EE8BF77 V-BELT TENSION CHECK ENGINE MECHANICAL SYSTEM WATER PUMP. Inspect the crack, damage, and wear of the parts, and replace the water pump, if necessary.. Inspect the bearing to see any damage, unusual noise, and poor revolution, and replace it, if necessary. 3. Check the leakage of the seal unit and replace the water pump, if necessary. THERMOSTAT. Heat the water to see if the thermostat valve operates properly.. Measure the temperature when the valve starts opening and is fully open. Adjust the belt tension to obtain the specified belt deflection when the center of each belt is pressed hard with a forceof0kgf. Deflection between the alternator() and water pump() : ~6mm CAUTION a. Since a slack belt may cause overheating or undercharge, adjust the tension to the specification. b. An excessively tight belt may result in possible damages of the belt or bearing. c. All of two V-belts should be replaced as a complete set. Item Valve opening temperature Valve lift / temperature Specification 80~84 C more than 0 / 95 C SUDEM773L SUDEM77L

46 COOLING SYSTEM EM - INSTALLATION EBC443E9 3. Install the cooling fan() and cooling fan coupling().. Install thermostat housing() to the cylinder head. SUDEM769L SUDEM77L. Install the water pump() and water pump pulley() to the timing gear case. Tightening torque : 6.7~5.5 Nm (.7~.6kgf.m,.4~8.9 Ib-ft) 4. Install the V-belt() and adjust the tension using the alternator mounting nuts and adjusting bolts(). V-belt tension ; ~6mm deflection (with a force of 0kg) SUDEM775L SUDEM774L

47 EM - RADIATOR ENGINE MECHANICAL SYSTEM COMPONENTS EFAA07 4.9~6.9 (0.5~0.7, 3.6~5.) ~4.7 (.~.5, 8.7~0.9).8~4.7 (.~.5, 8.7~0.9). Rod. Plate 3. Intercooler 4. Radiator cap 5. Radiator hose upper 6. Radiator hose lower 7. Radiator 8. Shroud Tightening Torque : Nm (kgf.m, Ib-ft) SUDEM776L

48 COOLING SYSTEM EM -3 REMOVAL ECA657F6. Remove the rod from the radiator.. Remove the intercooler from the radiator. 3. Remove the reservoir tank and bracket. 4. Remove the radiator hose upper and radiator hose lower.. Check the opening pressure of radiator cap(). a. Connect the cap tester() to the radiator cap(). b. Apply the pressure until the indicator holds. c. If the indicator does not hold for about 0 seconds, then replace the radiator cap. Valve opening pressure of the pressure valve :0.83~.0kg/cm² 5. Remove the radiator shroud and remove the radiator. INSPECTION EF6FFDCE. Check the existence of foreign materials between radiator fins.. Check radiator fins for any damage and repair if needed. 3. Check the radiator for any corrosion, damage or rust. 4. Check the radiator hose for any crack, damage or deterioration. SUDEM778L RADIATOR CAP. Check the radiator cap for any damage, crack or deterioration. INSTALLATION E5FA5F Install the parts in the reverse order of removal. Deterioration Deterioration SUDEM777L