Hyundai Terracan User Manual

Engine

Mechanical

System

ENGINE (KJ2.9 TCI DOHC DIESEL-COMMON RAIL SYSTEM)	........EM- 2
LUBIRICATION SYSTEM ...................................................................	EM-52
COOLING SYSTEM ............................................................................	EM-59
INTAKE AND EXHAUST SYSTEM.....................................................	EM-65

ENGINE (KJ2.9 TCI DOHC DIESEL-COMMON RAIL SYSTEM)

SPECIAL SERVICE TOOLS ...............................................................	EMa-2
SYMPTOM-RELATED DIAGNOSTIC PROCEDURE .........................	EMa-4
SPECIFICATION .................................................................................	EMa-7
ON-VEHICLE SERVICE PROCEDURES............................................	EMa-8
REMOVAL AND REPLACEMENT PROCEDURES..........................	EMa-16
DISASSEMBLY, INSPECTION AND REASSEMBLY PROCEDURE..........	EMa-24

EM-2	ENGINE (KJ2.9 TCI DOHC DIESEL-COMMON RAIL SYSTEM)

SPECIAL SERVICE TOOLS

Engine

Special service tools

0K130 990 007

Engine stand

Used to disassemble and assemble engine.

0K410 101 004

Hanger, engine stand

Used to disassemble and assemble engine.

0K993 120 004

Pivot, valve spring lifter

Used to remove and install valve.

0K710 120 004

Installer, valve seal

Used to install valve seal.

0K130 160 010

Centering tool, clutch disc

Used to install clutch disc and clutch cover.

0K552 111 001

Holder, camshaft pulley

Used to install camshaft pulley.

0K552 131 002

Adapter, compression gauge

Used to measure compression pressure.

0K993 120 001

Arm, valve spring lifter

Used to remove and install valve.

	SPECIAL SERVICE TOOLS	EM-3

0K993 120 006

Remover, valve seal

Used to remove valve seal.

0K590 111 001

Ring gear brake set

Used to prevent engine rotation.

0K130 111 004

Holder, coupling flange

Used to remove camshaft gear.

EM-4	ENGINE (KJ2.9 TCI DOHC DIESEL-COMMON RAIL SYSTEM)

SYMPTOM-RELATED DIAGNOSTIC PROCEDURE

Engine

Diagnostic chart

Problem		Possible Cause	Action to be taken
Insufficient power	Insufficient compression caused by:
smoke generation	1.	Contaminated air cleaner element
	2.	Loose hose connection between compressor
		and intercooler
	3.	Leakage from intake manifold
	4.	Leakage from exhaust manifold
	5.	Leakage from turbocharger mounting flange
	6.	Interference between turbocharger compressor
		turbine and case
	7.	Blocked duct between air cleaner and turbocharger
		compressor
	8.	Blocked duct between compressor and intake manifold
	9.	Interference between intake and exhaust manifolds
	10.	Leakage from valve seat
	11.	Seized valve stem
	12.	Weak or broken valve spring
	13.	Failed cylinder head gasket
	14.	Cracked or distorted cylinder head
	15.	Sticking, damaged, or worn piston ring
	16.	Cracked or worn piston
	Malfunction of fuel system
	Slipping clutch
	Wrong tire size
	Restricted exhaust system
	system
Excessive oil	Abnormal engine oil viscosity		Replace
consumption	Leakage from turbocharger compressor		Repair
	(adhesion of oil to housing or wheel)
	Leakage turbocharger turbine		Repair
	Worn or sticking piston ring or groove		Replace
	Worn piston or cylinder		Repair or replace
	Bad valve seal		Replace
	Worn valve stem or guide		Replace
Engine cranks	Malfunction of fuel system
normally, but does	Malfunction of electrical system
not start
	Restricted exhaust system
	Timing belt and/or related parts		Replace
	Low compression
	Camshaft worn
Blue smoke out of	Usually caused by oil burning in the combustion chamber from:		Replace
exhaust	worn rings, worn valve guides, worn valve seals or failed
	cylinder head gasket
	Contaminated air cleaner element
	Loose hose connection between compressor and intercooler		Tighten
	Leakage from intake manifold		Repair
	Blocked oil filter		Replace
	Blocked duct between air cleaner and turbocharger compressor		Repair
	Leakage from turbocharger compressor		Repair

SYMPTOM-RELATED DIAGNOSTIC PROCEDURE		EM-5
Problem	Possible Cause	Action to be taken
White smoke out of	Usually caused by water vapor, which is a normal by product	None required
exhaust	of combustion on cold days.
	Excessive white smoke with engine warmed up could be	Repair or replace
	caused by a failed cylinder head or intake gasket, could also
	be cracked block, cylinder head or intake manifold.
Black smoke out of	Malfunction of fuel system
exhaust	Malfunction of emission system
Abnormal combustion	Sticking or burned valve	Replace
	Weak or broken valve spring	Replace
	Carbon accumulation in combustion chamber	Eliminate the carbon
Poor idling	Malfunction of fuel system
	Malfunction of emission system
	Uneven cylinder compression	Repair
	Poor valve to valve seat contact	Repair or replace
	Broken valve spring	Repair
	Failed cylinder head gasket	Replace
Turbocharger noise	Contaminated air cleaner element	Replace
	Foreign material in intake duct or compressor housing	Clean
	Foreign material between intake manifold and compressor	Clean
	Foreign material in engine exhaust system	Clean
	Carbon deposit on turbine housing	Clean
	Interference between turbocharger rotating parts	Repair or replace
	Loose connecting parts of intake and exhaust system	Tighten
Engine knocks when	Loose or worn accessory drive belt/tensioner	Replace if necessary
hot and at idle	Improper oil viscosity	Install proper oil viscosity for
		expected temperature
	Excessive piston pin clearance	Install new piston pin and/or
		connecting rod
	Connecting rod alignment	Check and replace
	Insufficient piston to bore clearance	Hone and fit new pistons
	Faulty timing belt tensioner or guide	Replace
	Loose damper pulley	Tighten or replace
Slight noise at idle,	Valve spring clicking on cap, off square or broken	Repair or replace
becomes louder as engine	Excessive stem to guide clearance	Repair
speed is increased	Excessive valve seat runout	Repair
	Holed exhaust pipe	Replace
Engine knoks when cold	Excessive piston to wall clearance	Replace
	Loose or broken damper pulley	Tighten or replace
Knock increase with	Excessive piston to bore clearance	Replace piston
torque	Bent connecting rod	Replace
Engine has heavy knock	Broken damper pulley	Replace
when hot and torque is	Accessory belts too tight or damaged	Adjust or replace belt
applied	Belt tensioner damaged	Replace
	Flywheel cracked or loose clutch plate	Replace flywheel or clutch plate
	Excessive main bearing clearance	Repair
	Excessive rod bearing clearance	Repair

EM-6	ENGINE (KJ2.9 TCI DOHC DIESEL-COMMON RAIL SYSTEM)
Problem	Possible Cause	Action to be taken
Engine has light knock	Improper timing	Check timing
when hot and under	Piston pin and/or connecting rod	Replace
light lood conditions	Poor quality fuel	Replace
	Exhaust leak at manifold	Tighten or replace
	Excessive rod bearing clearance	Repair
Engine knocks on initial	Improper oil viscosity	Install proper oil viscosity
start up and knock lasts		for expected temperature
only a few seconds
Interference of	Damaged compressor blades due to external cause	Repair or replace
turbocharger, poor	Interference of turbine and compressor blades with housing	Repair or replace
rotation	Excessive deposit on compressor housing or wheel	Clean or repair
	Excessive carbon deposit on the back of turbine blade	Clean or repair
	Burn out of center housing	Replace
Leakage from	Excessive initial oil applying	Burn it normally
turbocharger turbine shaft	Blocked crankcase breather	Repair
	Obstacle in turbocharger oil drain line	Clean and repair
	Burn out of center housing	Clean and replace
	Wear on turbocharger bearing, bearing bore or shaft journal	Repair or replace
	Excessive crankcase oil	Correct oil amount
Leakage from	Contaminated air cleaner element	Replace
turbocharger compressor	Blocked duct between compressor and air cleaner	Repair
	Loose compressor and intake system connecting duct	Tighten
	Leakage from intake manifold	Repair
	Obstacle in turbocharger oil drain line	Repair or replace
	Blocked blowby passage in crankcase	Repair
	Worn or damaged compressor blades	Clean or replace
	Wear or turbocharger bearing bore, bearing or shaft journal	Replace
Wear on turbocharger	Contaminated oil	Replace
bearing, bore or shaft	Insufficient oil supply	Check
journal	Obstacle in turbocharger oil supply line	Check and repair
	Plugged oil filter	Replace
	Poor oil pump operation	Check and repair

SPECIFICATION			EM-7
SPECIFICATION
Engine
Specification
		Engine model	KJ 2.9TCI DOHC-COMMON RAIL SYSTEM
Item
Type			Diesel, 4-Cycles
Number of cylinders			4-Cylinder in-line
Combustion chamber			Re-entrant
Displacement		cu. in (cc)	177 (2902)
Bore and stroke		in (mm)	3.82 X 3.85 (97.1 X 98)
Compression ratio			19.3
Compression pressure		psi (kPa, kg/cm2)-rpm	426.6 (2943, 30) - 200
Valve timing	Intake	Open	BTDC 26°
		Closed	ABDC 50°
	Exhaust	Open	BBDC 50°
		Closed	ATDC 29°
Valve clearance(cold engine)		Intake	0 : Maintenance-free
	in (mm)	Exhaust	0 : Maintenance-free
Idle speed		rpm	800 ±100
Injection order			1-3-4-2

EM-8	ENGINE (KJ2.9 TCI DOHC DIESEL-COMMON RAIL SYSTEM)

ON-VEHICLE SERVICE PROCEDURE

Engine oil

1.Be sure the vehicle is on level ground.

2.Warm up the engine to normal operating temperature and stop it.

3.Wait for 5 minutes.

4.Remove the oil level gauge and check the oil level and condition.

AGX010A022

5. Add or replace oil if necessary.

Engine coolant

Coolant level

WARNING

A)NEVER REMOVE THE RADIATOR CAP WHILE THE ENGINE IS HOT.

B)WRAP A THICK CLOTH AROUND THE CAP WHEN REMOVING IT.

1.Verify that the coolant level is near the radiator filler neck.

2.Check that the level in the coolant reservoir is between the “Full” and “Low” marks.

AV2A10020

3. Add coolant if necessary.

Coolant quality

1.Verify that there is no build up of rust or scale around the radiator cap of radiator filler neck.

2.Verify that the coolant is free of oil.

3.Replace the coolant if necessary.

ON-VEHICLE SERVICE PROCEDURE

Drive belt

Inspection

1.Check the drive belts for wear, cracks, and fraying. Replace if necessary.

2.Verify that the drive belts are correctly mounted on the pulleys.

3. Verify that “
mark. If two
auto-tensioner is good. If not align as shown , re-
install the	tensioner or replace the drive belt.

2	1
	AV2A10B001
4. Check the	drive belt deflection by applying

moderate pressure (22 lb, 98 N, 10 kg) midway

AV2A10B002

between the pulleys.

Caution

a)Measure the belt deflection between the pulleys.

b)Consider the belt as a new one if it has been used on a running engine for less than five minutes.

c)Check the belt deflection when the engine is cold or at least 30 minutes after the engine is stopped.

A/C belt deflection:

New one: 0.28~0.35 in (7~9 mm)

Used one: 0.35~0.43 in (9~11 mm)

EM-9

Adjustment

AN9010018-1

1.Loosen the idler pulley mounting bolt.

2.Adjust the belt deflection by turning the adjusting bolt.

Deflection (When applying 22 lb, 98 N, 10 kg) New one: 0.28~0.35 in (7~9 mm)

Used one: 0.35~0.43 in (9~11 mm)

3.After making the adjustment, tighten the idler pulley mounting bolt.

Tightening torque:

28~38 lb-ft (37~52N•m, 3.8~5.3 kg-m)

Replacement

1.Raise the vehicle and support it with safety stands.

2.Remove the RH side wheel.

3.Loosen the idle pulley mounting bolt.

4.Remove the A/C drive belt.

5.Lower the auto tensioner with spanner and then remove the drive belt.

AV2A10B038

6.Lower the auto tensioner with spanner and then install the drive belt.

7.Install the A/C drive belt.

8.Check the A/C drive belt deflection.

EM-10	ENGINE (KJ2.9 TCI DOHC DIESEL-COMMON RAIL SYSTEM)

Timing belt

Removal

1.Raise vehicle and support it with safety stands.

2.Remove the radiator upper hose.

3.Remove the fuel filter hoses still connected.

4.Remove the No.3 engine mounting rubber.

No.3 engine mounting rubber

AV2A10B039A

5. Remove the No.3 engine mounting bracket.

AV2A10B040

6.Remove the RH side wheel.

7.Remove the A/C drive belt.

8.Remove the drive belt.

9.Remove the auto tensioner.

10.Remove the water pump pulley.

11.Remove the crankshaft pulley.

12.Remove the upper timing belt cover.

13.Remove the lower timing belt cover.

14.Rotate crankshaft and align timing mark on timing belt pulley with timing mark on engine block.

Camshaft pulleys

EX	IN
IN	EX

	Crankshaft	High pressure
		pump pulley
	pulley
		BV2A10B001

15.Remove the auto tensioner.

16.Remove the timing belt.

ON-VEHICLE SERVICE PROCEDURE

Replacement

1.Check that timing mark on timing belt pulley, camshaft pulley and high pressure pump pulley is aligned with timing mark on engine.

Camshaft pulleys

EX	IN
	Idler No.1
IN	EX

Touch

idler

	Auto	High
	tensioner
		pressure
	Crankshaft	pump pulley
	pulley	Idler No.2
		BV2A10B001

2.Install the timing belt.

1)The timing belt is installed in sequence crank shaft pulley, idler No.2, high pressure pump pulley, idler No.1 and camshaft pulley.

Notice

a)The auto-tensioner must be mounted onto the engine after the timing belt is installed.

b)Keep the tension of timing belt when install timing belt.

3.Install the auto-tensioner.

1)Install the auto-tensioner as shown illust. The dowel pin has to be located between the tensioner fork (back plate).

Back plate	Dowel pin

Special washer

Pointer	Lock bolt

Timing belt

BV2A10B004

2) Pretighten the auto-tensioner.

Tightening torque:

2.9lb-ft (3.9N•m , 0.4kg-m)

EM-11

Notice

a)Oil must not get in contact with the tensioner. The tensioner has to be replaced by a new one, if it is oily.

b)The positions of the pointer, the back plate and the special washer are in accordance to the illust.

4.Check again if the alignment marks of camshafts, crankshaft and high pressure pump are aligned with the marks on the timing case.

5.Adjust the auto-tensioner, and then tighten it.

1)Align the pointer to the back plate by rotating the special washer in counter-clockwise using the hexagon wrench as shown illust.

Back plate

Pointer

Special washer

BV2A10B005

2)Tighten the auto-tensioner lock bolt with holding the special washer by the hexagon wrench when the pointer is aligned with the back plate.

Tightening torque :

17.4lb-ft (23.5N•m , 2.4kg-m)

Pointer
Hexagon	Torque wrench
wrench

BV2A10B006

3) Remove the hexagon wrench.

EM-12	ENGINE (KJ2.9 TCI DOHC DIESEL-COMMON RAIL SYSTEM)

Notice

If the pointer can not be aligned with the back plate, then a new belt has to be used.

6.Rotate the crankshaft two full revolutions in clockwise to align the TDC mark.

7.Check again if the alignment marks of camshafts, crankshaft and high pressure pump are aligned with the marks on the timing case.

8.Check the alignment of the pointer and back plate.

Back plate

Pointer

BV2A10B007

Allowance misalignment : 5°

9.If the misalignment between pointer and back plate is bigger than 5°, repeat step 4~8.

10.Install the upper and lower timing belt cover.

Tightening torque:

5.1~7.2 lb-ft (6.9~9.8 N•m, 70~100 kg-cm)

11.Install the crankshaft pulley.

Tightening torque:

253~289 lb-ft (343~392 N•m, 35~40 kg-m)

12.Install the water pump pulley.

Tightening torque:

13.0~20.9 lb-ft (17.6~28.4 N•m, 1.8~2.9 kg-m)

13.Install the auto tensioner.

Tightening torque:

13.0~20.9 lb-ft (17.6~28.4 N•m, 1.8~2.9 kg-m)

14.Install the drive belt and A/C drive belt.

15.Install the RH side wheel.

Tightening torque:

65~79 lb-ft (88~108 N•m, 9.0~11.0 kg-m)

16.Install the No.3 engine mounting bracket.

Tightening torque:

26.7~39.8 lb-ft (36.2~53.9 N•m, 3.7~5.5 kg-m)

17.Install the No.3 engine mounting rubber.

Tightening torque:

Nut: 49.1~68.7 lb-ft (66.7~93.1 N•m, 6.8~9.5 kg-m) Bolt: 62.9~86.0 lb-ft (85.3~116.7 N•m, 8.7~11.9 kg-m)

Nut

Bolt	AV2A10B039A

18.Install the fuel filter.

19.Install the radiator hose.

20.Fill engine coolant with specified type and amount.

21.Start engine and then check for leaks.

	ON-VEHICLE SERVICE PROCEDURE	EM-13

Compression pressure

Inspection

1.Warm up the engine upto the normal operating temperature, then stop the engine and disconnect the connector of fuel cut solenoid.

2.Remove all injection pipes, nozzles and washers.

3.Attach the SST to the nozzle hole.

4.Measure the compression pressure during cranking.

	Engine model	KJ2.9 TCI DOHC
Item		COMMON RAIL SYSTEM
Compression pressure	Normal	426.6(2943, 30)-200
psi (kPa, kg/cm2)-rpm	Limit	383.9(2649, 27)-200
Cylinder-to-cylinder pressure difference		below 42.7(294,3.0)
psi (kPa, kg/cm2)

5.Do above step 3~4 again for each cylinder.

6.If the measure value is below the limit, consider it as abrasion or damage of piston and piston ring, misalignment of valve, damage of gasket, and etc..

Ladder frame and balance shaft

Removal

1.Remove oil pan.

2.Adjust the V groove TDC mark on the outside of pulley to the TDC mark “T” on the timing cover, by rotating the crank shaft pulley.

BTDC T 10

Adjust the

TDC mark

Designate the position with marking pen

AV2A10B031

3.For timing check, loosen the 3 balance gear cover bolts on the back of ladder frame and check the balance gear assembly mark.

Notice

To prevent the balance shaft from being falled out, tighten the 1 of 3 balance gear cover bolts by hand into the thrust plate center.

Gear cover bolt	Thrust plate	AV2A10B006

4.When reassembling after checking the balance gear assembly mark, mark the chain link with marking pen that is matched with Ø0.12 in (3 mm) round TDC mark to adjust the timing.

Notice

Disregard the 2 yellow points on the chain link because

it is only available for engine assembly.

EM-14	ENGINE (KJ2.9 TCI DOHC DIESEL-COMMON RAIL SYSTEM)

Balancer sprocket

Marking

AV2A10B032

5.Loosen balance sprocket bolt.

Notice

Insert the 0.2 in (5 mm) urethane rubber between balance gear to prevent the balance shaft from rotating and the balance gear from damaging.

LH RH

Ladder frame

Thrust plate

Urethane rubber

AV2A10B033

6.When disassembling the balance sprocket, hold the balance sprocket by one hand with pushing the thrust plate slightly then the balance separates from the neck of balance shaft.

7.When disassembling ladder frame, separate the oil feeding pipe from the oil pump by loosening the oil feeding pipe bolt.

Oil feeding pipe bolt

Ladder frame fastener bolt

AV2A10B036

8.Loosen the ladder frame fastener bolt. Remove ladder frame.

Replacement

1.Measure end play of balance shaft.

End play: 0.0039~0.0098 in (0.1~0.25 mm)

2.Install the balance shaft and thrust plate assembly into the ladder frame.

Notice

To prevent the balance shaft from being falled out, tighten the 1 of 3 balance gear cover bolts by hand into the thrust plate center.

3.Install the ladder frame into block. Check the dowel pin of ladder frame is matched with lower surface of block and insert the oil level gauge into the ladder frame hole.

Tightening torque (ladder frame bolt):

32.5lb-ft (44 N•m, 4.5 kg-m)

4.Install crankshaft sprocket, oil pump sprocket, guide and chain tensioner.

5.Adjust balance shaft sprocket position mark with chain link mark, and then insert the sprocket into the neck of balance shaft.

Notice

For smooth operation, pull the thrust plate out and hold, and then push the sprocket into the balance shaft.

Marking

AV2A10B032

6.Push the end of chain tensioner plunger utmost and then install the chain tensioner lever between chain and chain tensioner.

ON-VEHICLE SERVICE PROCEDURE	EM-15

AV2A10B027A

7.Tighten balance sprocket bolt.

Notice

Insert the 0.2 in (5 mm) urethane rubber between balance gear to prevent the balance shaft from rotating and the balance gear from damaging.

Tightening torque:
Mark 10T:	50.6 lb-ft (68.6	N•m, 7 kg-m)
Mark 8T:	43.4 lb-ft (58.8	N•m, 6 kg-m)

8.Rotate the crankshaft pulley 2 times and make the chain 1 rotating fully, check the adjustment between crankshaft pulley TDC mark and timing cover TDC mark after checking the balance gear assembly mark. If not, readjustment is needed.

Notice

The chain link mark position is only efficient to assembly, but it is not matched after 2 rotation of crankshaft pulley.

Timing check is only possible through the balance shaft gear.

LH RH

Balance shaft gear

AV2A10B081

9.Loosen the bolt on the thrust plate, and install the gear cover and tighten 3 bolts.

Tightening torque:

16.6lb-ft (23 N•m, 2.3 kg-m)

LH RH

Gear cover

16.6 Ib-ft (23N•m, 2.3 kg-m)

AV2A10B035

10.Install the oil feeding pipe into the ladder frame, oil pump and block and then tighten bolts.

16.6 lb-ft (23 N•m, 2.3 kg-m) Oil feeding pipe bolt

Oil strainer

Ladder frame bolt

32.5 lb-ft (44 N•m, 4.5 kg-m)

AV2A10B036

11.Install the oil pan.

12.Fill engine oil with specified type and amount.

13.Start engine and then check for leaks.