SsangYong Rexton Service Manual

ENGINE

SERVICE MANUAL

PYUNGTAEK, KOREA

SECTION INDEX

SERVICE

MANUAL

(vol. 1 of 2)

REXTON

FOREWORD

This manual includes procedure for maintenance, adjustment, service operation and removal and installation of components.

VOLUME 1 OF 2

GENERAL INFORMATION

ENGINE ASSEMBLY

ENGINE HOUSING

INTAKE SYSTEM

EXHAUST SYSTEM

DI0A

DI01

DI02

DI03

DI04

All information, illustrations and specifications contained in this manual are based on the latest

product information available at the time of manual approval.

The right is reserved to make changes at any time without notice.

SSANGYONG MOTOR CO., LTD.

PYUNGTAEK, KOREA

LUBRICATION SYSTEM

COOLING SYSTEM

FUEL SYSTEM

ENGINE CONTROL SYSTEM

ELECTRIC DEVICES AND SENSORS

DIAGNOSIS

DI05

DI06

DI07

DI08

DI09

DI10

DI ENGINE

CONTENTS

GENERAL INFORMATION....................DI0A

ENGINE ASSEMBLY ............................. DI01

ENGINE HOUSING ................................ DI02

INTAKE SYSTEM................................... DI03

EXHAUST SYSTEM............................... DI04

LUBRICATION SYSTEM ....................... DI05

COOLING SYSTEM ............................... DI06

FUEL SYSTEM ...................................... DI07

ENGINE CONTROL SYSTEM ............... DI08

ELECTRIC DEVICES AND SENSORS . DI09

DIAGNOSIS ........................................... DI10

SECTION DI0A

GENERAL INFORMATION

DI0A-1

00SECTION DI0A

GENERAL INFORMATION

Table of Contents

CLEANNESS ....................................... DI0A-3

STRUCTURE ...................................... DI0A-8

ENGINE CONTROLS ....................... DI0A-11

ECU related components ..............DI0A-11

Engine and sensors ..................... DI0A-12

Electrical components and

pre heating system ...................... DI0A-13

INTAKE SYSTEM ............................. DI0A-14

Intake air flow chart ...................... DI0A-15

INTAKE SYSTEM ............................. DI0A-16

Exhaust air flow chart ................... DI0A-17

LUBRICATION SYSTEM .................. DI0A-18

COOLING SYSTEM ......................... DI0A-19

Coolant flow chart ........................ DI0A-20

FUEL SYSTEM ................................. DI0A-21

Fuel supply system ...................... DI0A-22

GENERAL SPECIFICATIONS........... DI0A-23

Vehicle specifications................... DI0A-23

Maintenance ................................ DI0A-26

VEHICLE IDENTIFICATION .............. DI0A-28

HOW TO USE AND MAINTAIN WORKSHOP

MANUAL ........................................... DI0A-30

Consists of workshop manual ...... DI0A-30

Manual description ...................... DI0A-30

Guidelines for service work

safety ........................................... DI0A-31

Lifting points................................. DI0A-36

Tightening torque of standard

bolts.............................................. DI0A-37

GENERAL INFORMATION

DI ENG SM - 2004.4

CHANGED BY

EFFECTIVE DATE

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DI0A-3

CLEANNESS

Cleanness of DI Engine Fuel System and Service Procedures

The fuel system for DI engine consists of transfer (low pressure) line and high pressure line. Its highest pressure reaches over 1600 bar. Some components in injector and HP pump are machined at the micrometer 100 µm of preciseness. The pressure regulation and injector operation are done by electric source from engine ECU. Accordingly, if the internal valve is stucked due to foreign materials, injector remains open. Even in this case, the HP pump still operates to supply high pressurized fuel. This increases the pressure to combustion chamber (over 250 bar) and may cause fatal damage to engine.

You can compare the thickness of injector nozzle hole and hair as shown in below figure (left side). The right side figure shows the clearance between internal operating elements.

Valve actuator lift: 0.028 mm

Hair

The core elements of fuel system has very high preciseness that is easily affected by dust or very small foreign material. Therefore, make sure to keep the preliminary works and job procedures in next pages. If not, lots of system problems and claims may arise.

Diameter: 0.40 mm

Nozzle hole

Operating clearance:

0.002 mm

Diameter:

2.0 mm

Y220_0A035

GENERAL INFORMATION

DI ENG SM - 2004.4

CHANGED BY

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DI0A-4

Job procedures

1. Always keep the workshop and lift clean (especially, from dust).

2. Always keep the tools clean (from oil or foreign materials).

3. Wear a clean vinyl apron to prevent the fuzz, dust and foreign materials from getting into fuel system. Wash your hands and do not wear working gloves.

4. Follow the below procedures before starting service works for fuel system.

Carefully listen the symptoms and problems from customer.

Visually check the leaks and vehicle appearance on the wiring harnesses

and connectors in engine compartment.

Locate the fault. If the cause is from fuel system (from priming pump to

injector, including return line), follow the step 1 through step 3 above.

5. If the problem is from HP pump, fuel supply line or injector, prepare the clean special tools and sealing caps to perform the diagnosis for DI engine fuel system in “DIAGNOSIS” section in this manual. At this point, thoroughly clean the related area in engine compartment.

Notice

Clean the engine compartment before starting service works.

Perform the diagnosis proceee with Scan-i

(refer to “DIAGNOSIS” section in this manual).

Tool kit for high pressure line Took kit for low pressure line Removal tool box and cap kits

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GENERAL INFORMATION

DI ENG SM - 2004.4

6. Follow the job procedures. If you find a defective component, replace it with new one.

Disconnect the negative battery cable.

For safety reasons: check pressure is low before opening the HP systems (pipes)

Use special tools and torque wrench to perform the correct works.

Once disconnected, the fuel pipes between HP pump and fuel rail and between fuel rail and each injector should be replaced with new ones. The pipes should be tightened to specified tightening torques during installation. Over or under torques out of specified range may cause damages and leaks at connections. Once installed, the pipes have been deformed according to the force during installtion, therefore they are not reusable.

The copper washer on injector should be replaced with new one. The injector holder bolt should be tightened to specified tightening torque as well. If not, the injection point may be deviated from correct position, and it may cause engine disorder.

DI0A-5

Plug the disconnected parts with sealing caps, and remove the caps immediately

High pressure pump

IMV valve

Transfer pump and high

pressure pump

Fuel temperature sensor

Water separator

Water detection sensor

Fuel filter

before replacing the components.

Priming pump

Fuel pressure sensor

Injection pipe

Common rail

GENERAL INFORMATION

DI ENG SM - 2004.4

Fuel tank

Injector

Cap position Supply line Return line

Y220_0A039

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AFFECTED VIN

DI0A-6

7. Plug the removed components with clean and undamaged sealing caps and store it into the box to keep the conditions when it was installed.

8. Clear the high pressure offset value by Scan-100 after replacing the high pressure pump.

Y220_0A040

9. To supply the fuel to transfer line of HP pump press the priming pump until it becomes hard.

Warning

Do not crank engine before having filled pump.

Priming pump

Y220_0A041

10. Check the installed components again and connect the negative battery cable. Start the engine and check the operating status.

11. With Scan-i, check if there are current faults and erase the history faults.

Note

For details, refer to “DI10 Diagnosis teable”.

Y220_0A042

CHANGED BY

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GENERAL INFORMATION

DI ENG SM - 2004.4

DI Engine and Its Expected Problems and Remedies Can be Caused by Water in Fuel

SYSTEM SUPPLEMENT AGAINST PARAFFIN SEPARATION.

In case of Diesel fuel, paraffin, one of the elements, can be separated from fuel during winter and then can stick on the fuel filter blocking fuel flow and causing difficult starting finally. Oil companies supply summer fuel and winter fuel by differentiating mixing ratio of kerosene and other elements by region and season. However, above phenomenon can be happened if stations have poor facilities or sell improper fuel for the season. In case of DI engine, purity of fuel is very important factor to keep internal preciseness of HP pump and injector. Accordingly, more dense mesh than conventional fuel filter is used. To prevent fuel filter internal clogging due to paraffin separation, SYMC is using fuel line that high pressure and temperature fuel injected by injector returns through fuel filter to have an effect of built-in heater (see fuel system).

SYSTEM SUPPLEMENT AND REMEDY AGAINST WATER IN FUEL

As mentioned above, some gas stations supply fuel with excessive than specified water. In the conventional IDI engine, excessive water in the fuel only causes dropping engine power or engine hunting. However, fuel system in the DI engine consists of precise components so water in the fuel can cause malfunctions of HP pump due to poor lubrication of pump caused by poor coating film during high speed pumping and bacterization (under long period parking). To prevent problems can be caused by excessive water in fuel, water separator is installed inside of fuel filter. When fuel is passing filter, water that has relatively bigger specific

gravity is accumulated on the bottom of the filter.

DI0A-7

Y220_0A041

If water in the separator on the fuel filter exceeds a certain level, it will be supplied to HP pump with fuel, so the engine ECU turns on warning light ( ) on the meter cluster and buzzer if water level is higher than a certain level.

Due to engine layout, a customer cannot easily drain water from fuel filter directly, so if a customer checks in to change engine oil, be sure to perform water drain from fuel filter. (See fuel system for details.)

GENERAL INFORMATION

DI ENG SM - 2004.4

CHANGED BY

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AFFECTED VIN

DI0A-8

STRUCTURE

Front view

Rear view

1. TVD (Torsional Vibration Damper)

2. Air conditioner compressor

3. Power steering pump pulley

4. Idle pulley

5. Water pump pulley

6. Alternator

7. Cooling fan pulley & viscos clutch

8. Aut tensioner pulley

9. Auto tensioner

10. Poly-groove belt

11. Cam position sensor

12. Drive plate (M/T: DMF)

Y220_0A001

13. Oil filter housing

14. Vacuum pump

15. Crank position sensor

16. EGR valve

17. Power steering pump

18. EGR center pipe

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GENERAL INFORMATION

DI ENG SM - 2004.4

Top view

DI0A-9

19. Cylinder head cover

20. Intake manifold

21. Water outlet port

22. Common rail

23. Fuel pressure sensor

24. Fuel pipe

25. Injector

26. Fuel return line

27. Oil filler cap

28. Glow plug

Y220_0A002

29. Booster pressure sensor

30. Oil separator

31. Oil dipstic

32. EGR center pipe

GENERAL INFORMATION

DI ENG SM - 2004.4

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AFFECTED VIN

DI0A-10

Left side view

33. Cylinder head

34. Cylinder block

35. Oil pan

36. Drain plug

37. Turbocharger

Right side view

38. EGR - RH pipe

39. Oil separator

40. Oil dipstic

41. HP pump

Y220_0A003

42. Turbocharger vacuum modulator

43. EGR valve vacuum modulator

44. EGR valve

45. Exhaust manifold

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GENERAL INFORMATION

DI ENG SM - 2004.4

ENGINE CONTROLS

ECU RELATED COMPONENTS

DI0A-11

ECU/barometric sensor Cam position sensor

(water detection sensor)

Fuel filter

Accelerator pedal sensor

HFM sensor/intake air

temperature sensor

Pre heating time relay Main relay

Y220_0A004

GENERAL INFORMATION

DI ENG SM - 2004.4

CHANGED BY

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DI0A-12

ENGINE AND SENSORS

Injector

Glow plug

Common rail

Crankshaft position

sensor

Fuel pressure sensor

Camshaft position

sensor

HP pump

Coolant temperature

sensor

Booster pressure sensor

Knock sensor (2)

Y220_0A005

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AFFECTED VIN

GENERAL INFORMATION

DI ENG SM - 2004.4

ELECTRICAL COMPONENTS AND PRE HEATING SYSTEM

Glow plug Pre heating time relay

DI0A-13

Starter motor

BatteryFuse box

Alternator

Y220_0A006

GENERAL INFORMATION

DI ENG SM - 2004.4

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

DI0A-14

INTAKE SYSTEM

Air cleaner assembly Intake duct hoseHFM sensor Intake manifold

Intake outlet hose Turbocharger Intercooler Inlet hose

Y220_0A007

CHANGED BY

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AFFECTED VIN

GENERAL INFORMATION

DI ENG SM - 2004.4

INTAKE AIR FLOW CHART

Air cleaner side

DI0A-15

Intake valve (in combustion chamber)

Intake manifold

HFM sensor

Turbocharger (compressor)

Engine

Intake hose (inner)Intake hose (outlet) Intercooler

Y220_0A008

GENERAL INFORMATION

DI ENG SM - 2004.4

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

DI0A-16

INTAKE SYSTEM

Muffler Exhaust manifold EGR valve

Vacuum modulatorTurbocharger Catalytic converter EGR pipe

Y220_0A009

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GENERAL INFORMATION

DI ENG SM - 2004.4

EXHAUST AIR FLOW CHART

Exhaust gas

DI0A-17

Exhaust pipeCatalytic converter Muffler

Ambient

air

Turbocharger

(turbine side)

Turbocharger booster

Exhaust manifold

EGR vacuum modulator

To turbocharger booster

Turbocharger booster vacuum modulator

EGR valve

EGR pipe

Y220_0A010

GENERAL INFORMATION

DI ENG SM - 2004.4

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

DI0A-18

LUBRICATION SYSTEM

Cylinder head cover

Oil dipstic PCV valve

Engine oil filter

housing

Engine oil pump Oil pan Engine oil cooler

Engine oil pressure

switch

Y220_0A011

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GENERAL INFORMATION

DI ENG SM - 2004.4

COOLING SYSTEM

DI0A-19

Coolant reservoir

Water pump

Radiator assembly

Cooling fan and fan

clutch

Y220_0A013

GENERAL INFORMATION

DI ENG SM - 2004.4

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

DI0A-20

COOLANT FLOW CHART

Coolant reservoir

Heater

Oil cooler

Intake manifold

Thermostat

Water pump

Inner hose

Coolant outlet port

Outlet hose

Cooling fan

Radiator

Y220_0A014

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AFFECTED VIN

GENERAL INFORMATION

DI ENG SM - 2004.4

FUEL SYSTEM

Fuel return hose Fuel pressure pipe Common rail Fuel filter

DI0A-21

Injector HP pump Priming pump

Y220_0A015

GENERAL INFORMATION

DI ENG SM - 2004.4

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

DI0A-22

FUEL SUPPLY SYSTEM

Fuel pressure sensor

High pressure pump

IMV valve

Low and high

pressure pump

Fuel temperature

sensor

Water separator

Fuel filter

Water detection

sensor

Prining pump

Common rail

High pressure pipe

Label (C21)

Injector

Sensors

Fuel tank

Components:

- High pressure fuel pump

- Fuel injectors

ECU

- Fuel rails

- Electroc control unit (ECU)

- Fuel pressure sensor

- Various sensors and actuators

HFM sensor

Cam position sensor

Crank position sensor

Knock sensor etc.

Supply line Return line ECU communication line

Y220_0A016

According to input signals from various sensors, engine ECU calculates driver’s demand (position of the accelerator pedal) and then controls overall operating performance of engine and vehicle on that time.

ECU receives signals from sensors via data line and then performs effective engine air-fuel ratio controls based on those signals. Engine speed is measured by crankshaft speed (position) sensor and camshaft speed (position) sensor determines injection order and ECU detects driver’s pedal position (driver’s demand) through electrical signal that is generated by variable resistance changes in accelerator pedal sensor. Air flow (hot film) sensor detects intake air volume and sends the signals to ECU. Especially, the engine ECU controls the air-fuel ratio by recognizing instant air volume changes from air flow sensor to decrease the emissions (EGR valve control). Furthermore, ECU uses signals from coolant temperature sensor and air temperature sensor, booster pressure sensor and barometric sensor as compensation signal to respond to injection starting, pilot injection set values, various operations and variables.

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GENERAL INFORMATION

DI ENG SM - 2004.4

GENERAL SPECIFICATIONS

VEHICLE SPECIFICATIONS

DI0A-23

Vehicle Dimension

(mm)

Y220_0A017

GENERAL INFORMATION

DI ENG SM - 2004.4

CHANGED BY

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DI0A-24

Specifications

Systems Items Diesel Remark

General Overall length (mm)

Overall width (mm)

Overall height (mm)

4,720 (4,785)

1,870

1,760 (1,830)

( ): optional

item

Engine

Gross vehicle weight (kg)

Curb weight (kg)

Min. turning radius (m)

Ground clearance (mm)

Fuel

Fuel tank capacity

Model

No. of cyl./Compression ratio

Total displacement

Camshaft arrangement

Max. power

Max. torque

Injection timing

Idle speed

Cooling system

Coolant capacity

Lubrication

Max. oil capacity

AT: 2450 (2510), MT: 2405 (2465)

AT: 1995 (2055), MT: 1950 (2010)

5.6

200

Diesel

80

D27DT

5/18:1

2,696 cc

DOHC

170 ps/4,000 rpm

34.7 kg•m/1,800 rpm

ATDC 4° ± 1°(at idle)

760 ± 50 rpm

Water-cooled/forced circulation

Approx. 11.5

Gear pump, forced circulation

9.3

Manual

Turbo charger and cooling type

Type

transmission

Automatic transmission

Model

Type

st

1

nd

2

rd

3

th

4

th

5

Rev.

st

1

nd

2

rd

3

th

4

th

5

Rev. 1

Rev. 2

Turbo charger, air-cooled

Remote control, floor change type

IDI Engine 4.007

2.367

1.473

1.000

0.872

3.700

DI Engine 4.315

2.475

1.536

1.000

0.807

3.591

Electronic

Floor change type

2.742

1.508

1.000

0.708

-

st

nd

2.429

-

3.595

2.186

1.405

1.000

0.831

3.162

1.926

2.742

1.508

1.000

0.708

-

2.429

-

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GENERAL INFORMATION

DI ENG SM - 2004.4

Specifications (Cont’d)

DI0A-25

Systems

Transfercase

Model

Type

Gear ratio

Clutch

Type

Disc type

Power steering

Front axle

Type

Steering angle

Drive shaft type

Axle housing type

Rear axle

Drive shaft type

Axle housing type

Brake

Master cylinder type

Booster type

Type

Parking brake

Suspension

Front

Rear

Air conditioner

Electrical

Refrigerant

Compressor type

Battery type/Capacity (V-AH)

Starter capacity (V-kW)

Alternator capacity (V-A)

Items

High

Low

Inner

Outer

Inner

Outer

Diesel

Part-time

Planetary gear type

1.000 : 1

2.483 : 1

Hydraulic [A/T: Torque converter]

Dry single diaphragm type

[A/T: 3 elements 1 stage 2 phases]

Rack and pinion

'

36° 17

32° 40

'

Ball joint type

Build-up type

Semi-floating type

Build-up type

Tandem type

Vacuum booster

Disc

Drum (Disc)

Cable type (internal expansion)

Wishbone + Coil spring

5-link + Coil spring

R134a

Vane type

MF / 12 - 90

Diesel : 12 - 2.2, Gasoline : 12 - 1.8

IDI

DI

Gasoline

12 - 75 (12 - 90)

12 - 140 (12 - 115)

12 - 115

Remark

( ): optional item

GENERAL INFORMATION

DI ENG SM - 2004.4

CHANGED BY

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DI0A-26

MAINTENANCE

Major Components and Service Interval

* Use only Ssangyong Genuine Parts.

Components Service Interval Remarks

Engine oil and oil filter

Gasoline engine

DI diesel

Daily Weekly

O-

engine

IDI diesel

O-

engine

Coolant

Brake pipe and hose

Brake pad, shoe and

O-

--

disc

Air cleaner element

Gasoline engine

DI diesel

-O

engine

IDI diesel

-O

engine

Fuel filter

Gasoline

-

engine

DI diesel engine

IDI diesel

--

engine

Auto-

4-speed

--

matic transmission oil

5-speed

Manual transmission

--

oil

Transfer case oil

Axle oil

Air conditioner air

--

filter

Spark plug (gasoline

--

engine)

Initial change: 10,000 km

Replace at every 15,000 km

Initial change: 5,000 km

Replace at every 10,000 km or 12 months

More frequent maintenance is required if the vehicle is operated under severe condition.

Severe conditions?

- Frequent low-speed operation as in stop-and-go traffic

- When most trips are less than 6 km (in winter, less than 16 km)

- Driving in sandy, dusty, and salty road

- Driving in mountainous areas

- Extensive idling or high load operation such as towing a trailer

Replace at every 60,000 km or 3 years

Initial inspection: 1,000 km

Inspect at every 20,000 km, replace if necessary

Inspect at every 10,000 km, check or adjust if necessary

Clean at every 15,000 km,

Replace at every 60,000 km

Initial clean: 5,000 km,

If vehicle is operated under dusty or sandy area, frequently clean and inspect the air cleaner system. If necessary, replace the air cleaner element.

Clean at every 10,000 km, replace if necessary,

Replace at every 30,000 km

Replace at every 60,000 km

-

Replace at every 30,000 km (Drain the water from fuel filter at every 10,000 km)

Replace at every 40,000 km

Inspect at every 30,000 km or 1 year, replace if necessary (replace at every 60,000 km if the vehicle is operated

More frequent maintenance is required if the vehicle is operated under severe condition.

- Driving in unpaved road

- Towing a trailer

under severe conditions)

Inspect at every 10,000 km,

Replace at every 60,000 km

Inspect at every 10,000 km,

Replace at every 60,000 km (but, frequently chexk the leaks)

Replace at every 30,000 km

Replace at every 10,000 km

More frequent maintenance is required if the vehicle is operated under severe condition.

- Driving in sandy, dusty, and unpaved road

- Excessive operation of air conditioner or heater

Replace at every 60,000 km

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GENERAL INFORMATION

DI ENG SM - 2004.4

Lubrication Chart

Lubricant Capacity Classification

DI0A-27

Diesel

Engine oil

Gasoline

Engine coolant (Antifreeze and soft water mixed)

Manual transmission oil

Brake/Clutch fluid (Level must be maintained between MAX & MIN level)

Power steering fluid

Automatic transmission fluid

IDI Engine

DI Engine

G23D

G32D/G28D

IDI Engine

DI Engine

G23D

G32D/G28D

6.0 ~ 8.0 L

6.8 ~ 8.3 L

5.5 ~ 7.5 L

7.0 ~ 9.0 L

10.5 ~ 11.0 L

11.0 ~ 12.0 L

10.0 ~ 10.5 L

11.3 ~ 11.5 L

4WD: 3.6 L, 2WD: 3.4 L

Properly

1.1 L

4-speed: 9.5 L

5-speed: 8.0 L

Quality class**

API : CG grade or above,

ACEA : B2, B3 or B4

MB sheet : 229.1/3 (preferable)

Viscosity

Quality class**

MB sheet No. 224.1

API : SJ grade or above,

ACEA : A2 or A3

MB sheet : 229.1/3 (preferable)

Viscosity

MB sheet No. 224.1

MB sheet 325.0

BASF GLYSANTIN G05-11,

HOECHST GENANTIN SUPER 8023/14

®

ATF DEXRON

II, III,

ATF S-2, S-3, S-4, TOTAL FLUID ATX

SAE J 1703, DOT 3 or DOT 4

®

ATF DEXRON

II, III

CASTROL TQ 95

SHELL or FUCHS ATF 3353

Transfer case fluid

IDI Engine

DI Engine

Part time

Full time(TOD)

1.2 ~ 1.4 L

1.4 ~ 1.5 L

ATF DEXRON

®

II, III,

ATF S-4, TOTAL FLUID ATX

Gasoline

Front

Axle fluid

Rear

Wheel bearing grease

Propeller shaft grease - Front/Rear

Full time(TOD)

1.4 ~ 1.5 L

2.2 L

Properly

1.4 ~ 1.5 L

SAE 80W/90, API GL-5

SHELL Retinax “A” grade

ALVANIA EP#2

* Please contact Ssangyong Dealer for approved alternative fluid.

**In only case not available MB 229.1 or 229.3, API or ACEA oil may be accepted, however it would rather recommend

to shorten the change interval around 30%.

IDI: Indirect Injection

DI: Direct Injection

GENERAL INFORMATION

DI ENG SM - 2004.4

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

DI0A-28

VEHICLE IDENTIFICATION

1. Vehicle identification Number

Vehicle identification number (VIN) is is on the right front axle upper frame.

[KPTPOA19S1P 122357]

K.. Nation (K: Korea)

P .. Maker Identification (P: Ssangyong Motor Company)

T .. Vehicle Type (T: Passenger car - 4WD)

P .. Line Models (P: Rexton)

O . Body Type (O: 5-door)

A.. Trim Level (A: Standard, B: Deluxe,

C: Super deluxe)

1 .. Restraint System (0: No seatbelts, 1: 3-point

seatbelts, 2: 2-point seatbelt)

9 .. Engine Type (9: 3199cc, In-line 6 cylinders, Gasoline E32)

(D: 2874cc, Il-line 5 cylinders, Diesel)

S .. Check Digit (S: All area except North America)

1 .. Model Year (1: 2001, 2: 2002, 3: 2003)

P .. Plant Code (P: Pyungtaek plant)

122357 (Production serial number)

Y220_0A018

2. Certification Label

The certification label is affixed on the bottom of driver’s side B-pillar.

Y220_0A019

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GENERAL INFORMATION

DI ENG SM - 2004.4

3. Engine Serial Number

The engine serial number is stamped on the lower area of cylinder block in exhaust manifold side.

4. Manual Transmission Number

The transmission label is affixed on the upper area of clutch housing.

DI0A-29

Y220_0A020

5. Automatic Transmission Number

The transmisson label is affixed on the right area of transmission housing.

6. Transfer Case Number

The transfer case label is affixed on the transfer case housing.

Y220_0A021

GENERAL INFORMATION

DI ENG SM - 2004.4

Y220_0A022

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DI0A-30

HOW TO USE AND MAINTAIN WORKSHOP MANUAL

CONSISTS OF WORKSHOP MANUAL

1. Group: The manual is divided in large group like engine, transmission, axle and others and this group is also divided in small group by vehicle state.

2. Small group: Each small group consists of general, vehicle service, unit repair and special tool usage.

MANUAL DESCRIPTION

• The contents of the manual consist of operational

principle of system, specifications, diagnosis, removal/ installation on vehicle, inspections, disassembly/ assembly of removed assembly, special tool usage. Not providing simple removal/installation information but focused on to describe much more functions, roles and principles of system.

• Every automotive term like part name on the manual

is the same in parts catalog, technical bulletin and drawings to avoid confusion among them.

Abbreviation of small group and page

Consists of Small Group

1. Contents: In small group, included subjects and detailed subjects are described in.

2. General: In the general, summary of the small group (assembly), function and operational principle, specifications, structure and components, diagnosis and circuit diagram are described in.

3. Vehicle service: Service works on the vehicle like replacement of parts and inspection repairs are described in the order of repair works with actual photos and illustrations. Also cautions in service works, references and inspection methods after completion of service are described in.

4. Disassembly and assembly of unit assembly: Detailed service works like disassembly, inspection, adjustment and assembly on removed component (assembly) are described in with systematic contents and photo illustration.

Vehicle model

Describes information on the manual like modification, application date, applicable V.I.N

Bolded: Notice, Installation Notice,

Note

Describes small group name, model and publication date

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GENERAL INFORMATION

DI ENG SM - 2004.4

GUIDELINES FOR SERVICE WORK SAFETY

DI0A-31

General

To maintain and operate the vehicle under optimum state by performing safe service works, the service works should be done by following correct methods and procedures.

Accordingly, the purpose of this manual is to prevent differences that can be caused by personal working method, skill, ways and service procedures and to allow prompt/ correct service works.

Note, Notice

While using this manual, there are a lot of Note or Notice having below meaning.

Note

Note means detailed description of supplementary information on work procedure or skill.

Notice

Notice means precautions on tool/device or part damages or personal injuries that can occur during service works.

However, above references and cautions cannot be inclusive measures, so should have habits of taking concerns and cautions based on common senses.

Y220_0A024

Cautions on Inspection/Service

Notice

During service works, be sure to observe below general items for your safety.

•

For service works, be sure to disconnect battery negative (-) terminal if not starting and inspection.

•

While inspecting vehicle and replacing various consumable parts, be sure to take caution not to damage vehicle and injure people.

•

Engine and transmission may be hot enough to burn you. So inspect related locations when they cooled down enough.

•

If engine is running, keep your clothing, tools, hair and hands away from moving parts.

•

Even when the ignition key is turned off and positioned to LOCK, electrical fan can be operated while working on near around electrical fan or radiator grille if air conditioner or coolant temperature rises.

•

Every oil can cause skin trouble. Immediately wash out with soap if contacted.

•

Painted surface of the body can be damaged if spilled over with oil or anti-freeze.

•

Never go under vehicle if supported only with jack.

•

Never near the battery and fuel related system to flames that can cause fire like cigarette.

•

Never disconnect or connect battery terminal or other electrical equipment if ignition key is turned on.

•

While connecting the battery terminals, be cautious of polarities (+, –) not to be confused.

•

There are high voltage and currency on the battery and vehicle wires. So there can be fire if shortcircuited.

•

Do not park while running the engine in an enclosed area like garage. There can be toxication with CO, so make sufficient ventilation.

•

The electrical fan works electrically. So the fan can be operated unexpectedly during working causing injuries if the ignition key is not in LOCK position. Be sure to check whether ignition key is in LOCK position before work.

•

Be careful not to touch hot components like catalytic converter, muffler and exhaust pipe when the engine is running or just stopped. They may burn you badly.

GENERAL INFORMATION

DI ENG SM - 2004.4

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DI0A-32

Guidelines on Engine Service

To prevent personal injuries and vehicle damages that can be caused by mistakes during engine and unit inspection/ repair and to secure optimum engine performance and safety after service works, basic cautions and service work guidelines that can be easily forgotten during engine service works are described in.

Cautions before service works

• Before work on engine and each electrical equipment, be sure to disconnect battery negative (-) terminal.

• Before service works, be sure to prepare the works by cleaning and aligning work areas.

• Always position the ignition switch to OFF if not required. If not, there can be electrical equipment damages or personal injuries due to short-circuit or ground by mistake.

• There should be no leak from fuel injection system (HP pump, fuel hose, high pressure pipe) of the D27DT engine. So they should be protected from foreign materials.

• While removing the engine, do not position the jack and others under the oil pan or engine. To secure the safety, use only safety hook on the engine.

Engine and accessories

Engine has a lot of precise portions so tightening torque should be correct during disassembly/assembly and removal/installation and service work should be done in clean ways during disassembly/assembly.

Maintaining working area clean and cautious service administration is essential element of service works while working on the engine and each section of the vehicle. So the mechanics should well aware of it.

• While removing the engine, related parts (bolts, gaskets, etc.) should be aligned as a group.

• While disassembling/assembling internal components of the engine, well aware of disassembly/assembly section in this manual and clean each component with engine oil and then coat with oil before installation.

• While removing engine, drain engine oil, coolant and fuel in fuel system to prevent leakage.

• During service work of removal/installation, be sure to check each connected portions to engine not to make interference.

Fuel and lubrication system

Painted surface of the body can be damaged or rubber products (hoes) can be corroded if engine oil and fuel are spilled over. If spilled over engine, foreign materials in air can be accumulated on the engine damaging fuel system.

• If work on the fluid system such as fuel and oil, working area should be well ventilated and mechanic should not smoke.

• Gasket or seal on the fuel/lubrication system should be replaced with new and bolts and nuts should be tightened as specified.

• After removal/installation works, be sure to check whether there is leak on the connecting section.

If fine dust or foreign material enters into DI engine’s fuel system, there can be serious damages between HP pump and injectors. So, be sure to cover removed fuel system components with cap and protect removed parts not to be contaminated with dirt. (Refer to cleanness in this manual while working on DI engine fuel system)

Electrical equipment

Electrical equipment should be handled more carefully. Currently, the engine is equipped with a lot of electrical equipments so there can be engine performance drops, incomplete combustion and other abnormals due to short and poor contact. Mechanics should well aware of vehicle’s electrical equipment.

• If have to work on the electrical equipment, be sure to disconnect battery negative (-) terminal and position the ignition switch to off if not required.

• When replacing electrical equipment, use the same genuine part and be sure to check whether ground or connecting portions are correctly connected during installation. If ground or connecting portion is loosened, there can be vehicle fire or personal injury.

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GENERAL INFORMATION

DI ENG SM - 2004.4

During Service Work - Inspection

1. Before lifting up the vehicle with lift, correctly support the lifting points and lift up.

2. When using a jack, park the vehicle on the level ground and block front and rear wheels. Position the jack under the frame and lift up the vehicle and then support with chassis stand before service work.

3. Before service work, be sure to disconnect battery negative (-) terminal to prevent damages by bad wire and short.

DI0A-33

Y220_0A025

4. If service from interior of the vehicle, use protection cover to prevent damage and contamination of seat and floor.

5. Brake fluid and anti-freeze can damage painted surface of body. So carefully handle them during service work.

6. Use recommended and specified tools to increase efficiency of service work.

7. Use only genuine spare parts.

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GENERAL INFORMATION

DI ENG SM - 2004.4

Y220_0A028

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8. Never reuse cotter pin, gasket, O-ring, oil seal, lock washer and self-locking nut. Replace them with new.

If reused, normal functions cannot be maintained.

9. Align the disassembled parts in clean according to disassembling order and group for easy assembling.

10. According to installing positions, the bolts and nuts have different hardness and design. So be careful not to mix removed bolts and nuts each other and align them according installing positions.

11. To inspect and assemble, clean the parts.

12. Securely clean the parts that related with oil not to be affected by viscosity of oil.

13. Coat oil or grease on the driving and sliding surfaces before installing parts.

14. Use sealer or gasket to prevent leakage if necessary.

15. Damaged or not, never reuse removed gasket. Replace with new and cautious on installing directions.

16. Tighten every bolt and nut with specified torque.

17. When service work is completed, check finally whether the work is performed properly or the problem is solved.

18. If work on the fuel line between priming pump and injector (including return line), be sure to cover the removed parts with cap and be careful not to expose the connecting passage and removed parts to external foreign materials or dust. (Refer to cleanness.)

19. If remove high pressure fuel supply pipe between HP pump and fuel rail and high pressure fuel pipe between fuel rail and each injector, be sure to replace them with new.

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GENERAL INFORMATION

DI ENG SM - 2004.4

During Service Work for Electric Devices

Notice

Be careful not to modify or alter electrical system and electrical device. Or there can be vehicle fire or serious damage.

1. Be sure to disconnect battery negative (-) terminal during every service work. Before disconnecting battery negative (-) terminal, turn off ignition key.

2. Replace with specified capacity of fuse if there is bad, blown or short circuited fuse. If use electrical wire or steel wire other than fuse, there can be damages on the various electrical systems. If replaced with over-capacity fuse, there can be damages on the related electrical device and fire.

3. Every wire on the vehicle should be fastened securely not to be loosened with fixing clip.

4. If wires go through edges, protect them with tape or other materials not to be damaged.

DI0A-35

Y220_0A031

5. Carefully install the wires not to be damaged during installation/removal of parts due to interference.

6. Be careful not to throw or drop each sensor or relay.

7. Securely connect each connector until hear a “click”

sound.

Y220_0A032

GENERAL INFORMATION

DI ENG SM - 2004.4

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LIFTING POINTS

Lifting Positions

1. 4-post lift

As illustrated, position the vehicle on the 4-post lift securely and block the front and rear of each tire not to move during working.

Notice

During lifting, be sure to check whether vehicle is empty.

•

Board-on lift connection device installed in front of vehicle should be positioned in front of sill locating under the front door.

•

Install lift connecting device on the edge of front and rear of board-on lift.

Warning

•

Be sure to use attachment during lifting to prevent the lift from contacting with body floor.

•

While lifting the vehicle, widen the lift floor as far as possible to stabilize between vehicle front and rear. When fixing the lift floor, be careful not to contact with brake tube and fuel lines.

2. Safety jack and safety stand

If lift up the vehicle with safety jack and stand, should be more careful during works.

Warning

•

Never be under the vehicle if supported with only jack. If have to be under the vehicle, be sure to use safety

block.

•

Use wheel block in front and rear of every wheel.

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GENERAL INFORMATION

DI ENG SM - 2004.4

TIGHTENING TORQUE OF STANDARD BOLTS

Tightening Torque By Bolt Specification

DI0A-37

Bolt

Diameter

M3

M4

M5

M6

M8

M10

M12

M14

M16

M18

M20

M22

M24

Pitch

0.5

0.7

0.8

1.0

1.25

1.5

1.25

1.75

1.5

Tightening Torque (kg.cm)

Standard Tightening Torque

4T

5

12

24

41

88

190

350

330

550

830

1,200

1,700

2,300

2,900

7T

9

20

40

68

160

330

310

580

550

910

1,100

2,000

2,800

3,800

4,900

9T

13

30

57

99

230

470

450

840

790

1,300

2,000

2,900

4,000

5,400

7,000

Max. Allowable Tightening Torque

4T

7

16

32

55

130

260

250

460

440

730

1,100

1,600

2,200

3,000

3,900

7T

12

27

53

91

210

430

420

770

730

1,200

1,900

2,700

3,700

5,000

6,500

9T

17

40

77

130

310

620

600

1,100

1,000

1,900

2,700

3,800

5,300

7,200

9,400

2.0

1. Metric bolt strength is embossed on the head of each bolt. The strength of bolt can be classified as 4T, 7T,

8.8T, 10.9T, 11T and 12.9T in general.

2. Observe standard tightening torque during bolt tightening works and can adjust torque to be proper within 15 % if necessary. Try not to over max. allowable tightening torque if not required to do so.

2,800

4,700

6,800

3,800

6,300

9,100

Y220_0A034

3. Determine extra proper tightening torque if tightens with washer or packing.

4. If tightens bolts on the below materials, be sure to determine the proper torque.

• Aluminum alloy: Tighten to 80 % of above torque table.

• Plastics: Tighten to 20 % of above torque table.

GENERAL INFORMATION

DI ENG SM - 2004.4

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MEMO

.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................

SECTION DI01

ENGINE ASSEMBLY

00SECTION DI01

ENGINE ASSEMBLY

DI01-1

Table of Contents

STRUCTURE AND FUNCTION DESCRIPTIONS ........ DI01-3

D27DT engine ........................................................ DI01-3

Engine performance curve ..................................... DI01-8

General diagnosis................................................. DI01-10

DIAGNOSTIC INFORMATION AND PROCEDURE .. DI01-15

Oil leak diagnosis.................................................. DI01-15

Compression pressure test .................................. DI01-16

Cylinder pressure leakage test ............................ DI01-18

Tightening torque.................................................. DI01-19

REMOVAL AND INSTALLATION .............................. DI01-22

Engine mounting ................................................... DI01-22

DISASSEMBLY AND REASSEMBLY........................ DI01-32

Components and special tools ............................. DI01-32

ENGINE ASSEMBLY

DI ENG SM - 2004.4

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DI01-3

STRUCTURE AND FUNCTION DESCRIPTIONS

D27DT ENGINE

Major Components in Engine and Engine Compartment

The advanced electronically controlled D27DT engine that has high pressure fuel system has been introduced to this vehicle. It satisfies the strict emission regulation and provides improved output and maximum torque.

1. Coolant reservoir

2. FFH device

3. Brake fluid reservoir

4. Washer fluid reservoir

5. Common rail

6. Fuse box

7. Battery

8. Fuel filter

9. Power steering pump

10. Priming pump

Y220_01001

11. EGR valve

12. Air cleaner assembly

13. Turbo charger

14. Oil dipstick

ENGINE ASSEMBLY

DI ENG SM - 2004.4

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DI01-4

Engine Structure

Front View

Rear View

1. TVD (Torsional Vibration Damper)

2. Air conditioner compressor

3. Power steering pump pulley

4. Idle pulley

5. Coolant pump pulley

6. Alternator

7. Viscos fan clutch

8. Auto tensioner pulley

9. Auto tensioner

10. Poly-grooved belt

11. Cam position sensor

12. Drive plate (MT: DMF)

Y220_01002

13. Oil filter

14. Vacuum pump

15. Crank position sensor

16. EGR valve

17. Power steering pump

18. EGR to center pipe

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Top View

DI01-5

19. Cylinder head cover

20. Intake manifold

21. Water outlet port

22. Common rail

23. Fuel pressure sensor

24. Fuel pipe

25. Injector

26. Fuel return line

27. Oil filler cap

28. Glow plug

Y220_01003

29. Booster pressure sensor

30. PCV valve and oil separator

31. Oil dipstick

32. EGR-LH pipe

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DI01-6

Left Side View

Right Side View

33. Cylinder head

34. Cylinder block

35. Oil pan

36. Drain plug

37. Turbo charger

38. EGR-RH pipe

39. PCV valve and oil separator

40. Oil dipstick

41. High pressure pump

Y220_01004

42. Turbo charger booster vacuum

modulator

43. EGR valve vacuum modulator

44. EGR valve

45. Exhaust manifold

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ENGINE ASSEMBLY

DI ENG SM - 2004.4

Specifications

DI01-7

Description Specification

Engine

Cylinder

Displacement (cc)

Compression ratio

Maximum output (ps/rpm)

Maximum torque (kg.m/rpm)

Idle speed

Valve

Camshaft

Fuel system

Type/Number of cylinders

Inner diameter (mm)

Stroke (mm)

For Manual Transmission

For Automatic Transmission

Intake

Opens (BTDC)

Closes (ABDC)

Exhaust

Opens (BBDC)

Closes (ATDC)

Type

Fuel type

Fuel pump type

Fuel supply pressure

D27DT/5-cylinder

86.2

92.4

2696

18:1

170/4,000

34.7/1,800

750 ± 50 rpm

16°

33°

46°

21°

DOHC

Low sulfur diesel

Vane pump in HP pump

HP pump inlet port: max. 400 mbar

HP pump outlet port (with IMV fully open): over 1,050 bar

Lubrication system

Cooling system

Water separation in fuel filter

Fuel tank capacity (

)

Oil specification

Lubrication type

Oil filter type

Oil capacity (

)

Cooling type

Cooling fan operation type

Thermostat: Fully Open: 100°C)

Opening temperature (°C)

Type

Coolant capacity (

)

at every 10,000 km

80

SAE 10W40, 5W40

(MB Sheet 229.1, 229.3 approved oil)

Forced delivery

Full flow, filter element type

6.8 ~ 8.3

Water cooling type

Belt operated typr

85

WAX pellet type

11.5

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DI ENG SM - 2004.4

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DI01-8

ENGINE PERFORMANCE CURVE

Output and Torque

Output [PS]

Torque [Nm]

Speed [rpm]

Y220_00025

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Oil Temperature/Pressure and Boost Pressure

DI01-9

Boost pressure [bar] Oil pressure [bar]

Oil temperature [C]

Speed [rpm]

Y220_00026

ENGINE ASSEMBLY

DI ENG SM - 2004.4

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DI01-10

GENERAL DIAGNOSIS

Condition

Hard Starting (With normal cranking)

Malfunction of Ignition System

Malfunction of Fuel System

Decline of Compression Pressure

Others

Probable Cause

Faulty fuse.

•

Faulty spark plug.

•

Electric leakage at the high

•

tension cable.

Poor connection of the high

•

tension cable or lead wires.

Improper ignition timing.

•

Faulty ignition coil.

•

Lock of fuel in the fuel tank.

•

Dirty or clogged fuel filter.

•

Clogged fuel pipe.

•

Malfunction of the fuel pump.

•

Malfunction of the fuel injector.

•

The foreign material in the fuel

•

tank.

Poor tightening spark plug.

•

Cracked cylinder head gasket.

•

Inadequate the valve clearance.

•

Leakage of the valve clearance.

•

Interference of the valve stem.

•

Low elasticity or damage of the

•

valve spring.

Abnormal interference of pistons

•

and cylinders.

Excessive wear of pistons,

•

rings, or cylinders.

Broken timing belt.

•

Loosening, damage or leakage

•

of the vacuum hose.

Leakage of intake system.

•

Correction

• Replace the fuse.

• Clean, adjust the plug gap or replace.

Replace the cable.

•

Replace the cable or wires.

•

Adjust the ignition timing.

•

Replace the ignition coil.

•

Feed the fuel.

•

Replace the filter.

•

Clean the fuel pipe.

•

Replace the fuel pump.

•

Replace the injector.

•

Clean the fuel tank.

•

Tighten to the specified torque.

•

Compression

Replace the gasket.

•

Adjust the clearance.

•

Repair the valve.

•

Replace the valve or the valve

•

guide.

Replace the valve spring.

•

Replace the piston ring.

•

Replace the ring or the piston

•

and boring or replace the cylinder.

Replace the belt.

•

Connect the hose correctly or

•

replace it.

Replace intake system.

•

Lack of Engine Power

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Decline of Compression Pressure

Malfunction of Ignition System

Refer to above in this page.

•

Improper ignition timing.

•

Faulty spark plug.

•

Electric leakage or poor

•

connection of the high tension cable.

Refer to above in this page.

•

Adjust the ignition timing.

•

Adjust or replace the spark plug.

•

Connect the cable correctly or

•

replace it.

ENGINE ASSEMBLY

DI ENG SM - 2004.4

GENERAL DIAGNOSIS (Cont’d)

DI01-11

Condition

Lack of Engine Power

Rough Engine Idling

Malfunction of Fuel System

Others

Decline of Compression Pressure

Malfunction of Fuel System

Malfunction of Ignition System

Probable Cause

Clogged fuel pipe.

•

Clogged or contaminated fuel

•

filter.

Clogged exhaust system.

•

Clogged or contaminated air

•

cleaner element.

Leak of the intake manifold

•

gasket.

Dragging brakes.

•

Refer to “Compression Pressure

•

Test”.

Clogged fuel pipe.

•

Clogged or contaminated fuel

•

filter.

Malfunction of the fuel pressure

•

regulator.

Malfunction of the spark plug.

•

Electric leakage or poor connec-

•

tion of the high tension cable.

Correction

Clean the pipe.

•

Replace the filter.

•

Check and repair the system.

•

Clean or replace the air cleaner

•

element.

Replace the gasket.

•

Repair or replace the brakes.

•

Refer to “Compression Pressure

•

Test”.

Clean the pipe.

•

Replace the filter.

•

Replace the regulator.

•

Adjust or replace the spark plug.

•

Connect the cable correctly or

•

replace it.

Others

Engine Hesitate (Upon pressing accelerating pedal, the engine makes delayed response This situation is remarkable when cruising or starting.)

Decline of Compression Pressure

Malfunction of Ignition System

Others

Poor ignition timing.

•

Malfunction of the ignition coil.

•

Clogged or contaminated air

•

cleaner element.

Leak of the intake manifold

•

gasket.

Poor connection or damage or

•

leakage of the vacuum hose.

Refer to “Compression Pressure

•

Test”.

Poor ignition timing.

•

Poor spark plug or Poor adjust-

•

ment of the plug gap.

Electric leakage or poor connec-

•

tion of the high tension cable.

Malfunction of the air cleaner

•

system.

Leak of the intake manifold

•

gasket.

Adjust the ignition timing.

•

Replace the ignition coil.

•

Clean or replace the air cleaner

•

element.

Replace the gasket.

•

Connect the hose correctly or

•

replace it.

Refer to “Compression Pressure

•

Test”.

Adjust the ignition timing.

•

Replace the plug or adjust the

•

gap.

Connect the cable correctly or

•

replace it.

Clean or replace the air cleaner

•

system.

Replace the gasket.

•

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DI01-12

GENERAL DIAGNOSIS (Cont’d)

Condition

Engine Surging (Engine power makes fluctuation in a fixed speed and speed changes without operating the accelerating pedal.)

Excessive Detonation (According to the opening range of Malfunction of metallic is made with abnormal explosion )

Overheat

Decline of Compression Pressure

Malfunction of Fuel System

Malfunction of Ignition System

Others

Overtheated Engine

Malfunction of Fuel System

Malfunction of Ignition System

Others

Malfunction of Cooling System

Malfunction of Lubrication System

Other

Probable Cause

Refer to “Compression Pressure

•

Test”.

Clogged fuel pipe.

•

Clogged or contaminated fuel

•

filter.

Malfunction of the fuel pressure

•

regulator.

Malfunction of the spark plug.

•

Electric leakage or poor

•

connection of the high tension cable.

Poor ignition timing.

•

Leak of the intake manifold

•

gasket.

Leakage of the vacuum hose.

•

Refer to “Overheat” in this page.

•

Abnormal spark plug.

•

Poor ignition timing.

•

Electric leakage or poor

•

connection of the high tension cable.

Clogged or contaminated fuel

•

filter and fuel pipe.

Leak of the intake manifold

•

gasket.

Excessive carbon deposit due to

•

abnormal combustion.

Lack of coolant.

•

Malfunction of the thermostat.

•

Malfunction of the cooling fan.

•

Poor water pump performance.

•

Clogged or leaky radiator.

•

Poor engine oil.

•

Blocking oil filter or strainer.

•

Lack of engine oil.

•

Poor oil pump performance.

•

Leakage of oil

•

Damaged cylinder head gasket.

•

Correction

Refer to “Compression Pressure

•

Test”.

Clean the pipe.

•

Replace the filter.

•

Replace the fuel pressure

•

regulator.

Adjust or replace the spark plug.

•

Connect the cable correctly or

•

replace it.

Adjust the ignition timing.

•

Clean or replace the gasket.

•

Connect the hose correctly or

•

replace it.

Refer to “Overheat” in this page.

•

Replace the spark plug.

•

Adjust the ignition timing

•

Connect the cable correctly or

•

replace it.

Clean or replace the fuel filter

•

and the fuel pipe.

Replace the gasket.

•

Remove the carbon.

•

Refill coolant.

•

Replace the thermostat.

•

Check or replace the cooling

•

fan.

Replace the pump.

•

Clean, repair or replace the

•

radiator.

Replace engine oil with the

•

specified one.

Clean or repair the oil filter or the

•

strainer.

Refill oil.

•

Replace or repair the pump.

•

Repair.

•

Replace the gasket.

•

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ENGINE ASSEMBLY

DI ENG SM - 2004.4

GENERAL DIAGNOSIS (Cont’d)

DI01-13

Condition

Poor Fuel Consumption

Excessive Consumption of Engine Oil

Decline of Compression Pressure

Malfunction of Fuel System

Malfunction of Ignition System

Malfunction of Cooling System

Others

Leakage of Engine Oil

Oil Mixing in Combustion Chamber

Low Oil Pressure

Malfunction of Lubrication System

Probable Cause

Refer to “Compression Pressure

•

Test”.

Leakage of the fuel tank or the

•

fuel pipe.

Improper ignition timing.

•

Abnormal spark plug

•

(Excessive carbon deposit, inadequate gap, burnt electrode).

Electric leakage or poor

•

connection of the high tension cable.

Malfunction of the thermostat.

•

Improperly installed valve.

•

Low pressure of tires.

•

Loosened oil drain plug.

•

Loosened oil pan bolt.

•

Loosened oil filter.

•

Loosened oil pressure switch.

•

Leakage of camshaft front oil

•

seal.

Leakage of crankshaft front oil

•

seal.

Leakage at the cylinder head

•

cover gasket.

Damage of the cylinder head

•

gasket.

Stuck piston ring.

•

Worn piston or cylinder.

•

Worn piston ring or ring groove.

•

Inadequate position of the piston

•

ring cutting part.

Abrasion or damage of the valve

•

system.

Inadequate oil viscosity.

•

Loosening of the oil pressure

•

switch.

Lack of engine oil.

•

Blocking oil strainer.

•

Lowered function of the oil

•

pump.

Abrasion or damage of the oil

•

pump relief valve.

Correction

Refer to “Compression Pressure

•

Test”.

Repair or replace the fuel tank or

•

the fuel pipe

Adjust the ignition timing.

•

Replace the plug.

•

Connect the cable normally or

•

replace it.

Repair the thermostat.

•

Repair or replace the valve.

•

Adjust the pressure of tires.

•

Tighten the plug.

•

Tighten the bolt. Engine Oil

•

Tighten the filter.

•

Tighten the switch.

•

Replace the seal.

•

Replace the seal.

•

Replace the gasket.

•

Replace the gasket.

•

Remove carbon and replace the

•

ring.

Replace the piston or the

•

cylinder.

Replace the piston or ring.

•

Adjust the position.

•

Replace the valve system.

•

Replace with the specified one.

•

Tighten the switch.

•

Refill oil.

•

Clean the strainer.

•

Replace the pump.

•

Replace the valve.

•

ENGINE ASSEMBLY

DI ENG SM - 2004.4

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

DI01-14

GENERAL DIAGNOSIS (Cont’d)

Condition

Valve NoiseEngine Noise

Piston, Ring, Cylinder Noise

Connecting Rod Noise

Crankshaft Noise

Probable Cause

Inadequate valve clearance

•

Abrasion of valve stem or guide.

•

Weak valve spring.

•

Abrasion of the piston, the ring

•

or the cylinder.

Abrasion of the connecting rod

•

bearing.

Loosened the connecting rod

•

nut.

Abrasion of the crankshaft

•

bearing.

Abrasion of the crankshaft

•

journal.

Loosened bearing cap bolt.

•

Excessive clearance of the

•

crankshaft thrust bearing.

Low oil pressure.

•

Correction

Adjust the valve clearance.

•

Replace the valve stem or the

•

guide.

Replace the spring.

•

Boring the cylinder or replace

•

the piston, the ring or the cylinder.

Replace the bearing.

•

Tighten to the specified torque

•

Replace the bearing.

•

Grind or replace the crankshaft

•

journal.

Tighten to the specified torque.

•

Adjust or replace.

•

Refer to “Low Oil Pressure” in

•

this section.

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE ASSEMBLY

DI ENG SM - 2004.4

DIAGNOSTIC INFORMATION AND PROCEDURE

DI01-15

OIL LEAK DIAGNOSIS

Most fluid oil leaks are easily located and repaired by visually finding the leak and replacing or repairing the necessary parts. On some occasions a fluid leak may be difficult to locate or repair. The following procedures may help you in locating and repairing most leaks.

Finding the Leak

1. Identify the fluid. Determine whether it is engine oil, automatic transmission fluid, power steering fluid, etc.

2. Identify where the fluid is leaking from.

2.1 After running the vehicle at normal operating temperature, park the vehicle over a large sheet of paper.

2.2 Wait a few minutes.

2.3 You should be able to find the approximate location of the leak by the drippings on the paper.

3. Visually check around the suspected component. Check around all the gasket mating surfaces for leaks. A mirror is useful for finding leaks in areas that are hard to reach.

4. If the leak still cannot be found, it may be necessary to clean the suspected area with a degreaser, steam

or spray solvent.

4.1 Clean the area well.

4.2 Dry the area.

4.3 Operate the vehicle for several miles at normal operating temperature and varying speeds.

4.4 After operating the vehicle, visually check the suspected component.

4.5 If you still cannot locate the leak, try using the powder or black light and dye method.

Black Light and Dye Method

A dye and light kit is available for finding leaks, Refer to the manufacturer's directions when using the kit.

1. Pour the specified amount of dye into the engine oil fill tube.

2. Operate the vehicle normal operating conditions as directed in the kit.

3. Direct the light toward the suspected area. The dyed fluid will appear as a yellow path leading to the source.

Repairing the Leak

Once the origin of the leak has been pinpointed and traced back to its source, the cause of the leak must be determined in order for it to be repaired properly. If a gasket is replaced, but the sealing flange is bent, the new gasket will not repair the leak. The bent flange must be repaired also. Before attempting to repair a leak, check for the following conditions and correct them as they may cause a leak.

Gaskets

• The fluid level/pressure is too high.

• The crankcase ventilation system is malfunctioning.

• The fasteners are tightened improperly or the threads are dirty or damaged.

• The flanges or the sealing surface is warped.

• There are scratches, burrs or other damage to the sealing surface.

• The gasket is damaged or worn.

• There is cracking or porosity of the component.

• An improper seal was used (where applicable).

Powder Method

1. Clean the suspected area.

2. Apply an aerosol-type powder (such as foot powder) to the suspected area.

3. Operate the vehicle under normal operating conditoins.

4. Visually inspect the suspected component. You should be able to trace the leak path over the white powder surface to the source.

ENGINE ASSEMBLY

DI ENG SM - 2004.4

Seals

• The fluid level/pressure is too high.

• The crankcase ventilation system is malfunctioning.

• The seal bore is damaged (scratched, burred or nicked).

• The seal is damaged or worn.

• Improper installation is evident.

• There are cracks in the components.

• The shaft surface is scratched, nicked or damaged.

• A loose or worn bearing is causing excess seal wear.

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

DI01-16

COMPRESSION PRESSURE TEST

The compression pressure test is to check the conditions of internal components (piston, piston ring, intake and exhaust vale, cylinder head gasket). This test provides current engine operating status.

Notice

• Before cranking the engine, make sure that the test wiring, tools and persons are keeping away from moving components of engine (e.g., belt and cooling fan).

• Park the vehicle on the level ground and apply the parking brake.

• Do not allow anybody to be in front of the vehicle.

Specifications

Compression ratio

Test temperature

Compression pressure Normal value

Minimum value

Permissible pressure difference between individual cylinders

Y220_01005

18 : 1

at normal operating temperature (80°C)

32 bar

18 bar

Max. 3 bar

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE ASSEMBLY

DI ENG SM - 2004.4

Measuring Procedure

Notice

•

Disconnect the fuel rail pressure sensor connector to cut off the fuel injection.

•

Discharge the combustion residues in the cylinders before testing the compression pressure.

•

Apply the parking brake before cranking the engine.

1. Warm the engine up to normal operating temperature (80°C).

2. Disconnect the fuel rail pressure sensor connector to cut off the fuel injection.

3. Place the diagram sheet to compression pressure tester.

DI01-17

4. Remove the glow plugs and install the compression pressure tester into the plug hole.

Tightening torque (Tester) 15 Nm

5. Crank the engine for approx. 10 seconds by using the start motor.

6. Record the test result and measure the compression pressure of other cylinders with same manner.

7. If the measured value is not within the specifications, perform the cylinder pressure leakage test.

Y220_01006

Y220_01007

ENGINE ASSEMBLY

DI ENG SM - 2004.4

Y220_01008

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

DI01-18

CYLINDER PRESSURE LEAKAGE TEST

If the measured value of the compression pressure test is not within the specifications, perform the cylinder pressure leakage test.

Y220_01009

Permissible Pressure Leakage

Test temperature

At whole engine

At valve and cylinder head gasket

At piston ring

at normal operating temperature (80°C)

Max. 25 %

Max. 10 %

Max. 20 %

Notice

• Perform the pressure in order: 1 - 2 - 3 - 4 - 5

• Do not test the cylinder pressure leakage with wet type test procedure. (do not inject the engine oil into the combustion chamber)

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE ASSEMBLY

DI ENG SM - 2004.4

TIGHTENING TORQUE

DI01-19

1

Oil nozzle

2

Main bearing cap

3

Connecting rod cap

4

Rear cover

5

Oil pump

6

Oil baffle plate assembly

7

T.G.C.C

8

Flywheel

9

Crankshaft hub

SizeName Tightening TorqueNO.

M6 x 22

M11 x 62

M9 x 52

M6 x 20

M8 x 35SOC

M6 x 20

M6 x 16

M6 x 40

M6 x 60

M6 x 70

M8 x 80SOC

M10 x 30

M18 x 50

M6 x 20

Quantity

5

12

5

6

3

10

1

6

3

2

1

8

1

24

10 ± 1

55 ± 5

90° ± 10°

40 ± 5

90° ± 10°

10 ± 1

25 ± 2.5

10 ± 1

25 ± 2.5

45 ± 5

90° ± 10°

325 ± 33

90° ± 10°

10 ± 1

10

Oil pan

11

High pressure pump assembly

12

High pressure pump sprocket assembly

13

High pressure pump bracket

14

Cylinder head assembly

15

Camshaft cap

16

Stud bolt

Camshaft sprocket (Intake)

17

Camshaft sprocket (Exhaust)

18

Chain tensioner

19

Coolant temperature sensor

M6 x 35

M6 x 38

M6 x 40

M8 x 40

M14 x 1.5-8-1

M7 x 16

M8 x 25

M8 x 50

M12 x 177

M12 x 158

M8 x 60

M8

M11 x 52

M22

M14

3

4

1

3

2

11

1

24

10

1

10 ± 1

25 ± 2.5

65 ± 5

20 ± 2 x 90° + 10°

25 ± 2.5

Step1: 20 Nm ± 2 Nm

Step2: 85 Nm ± 5 Nm

Step3: 3 x 90° + 10°

25 ± 2.5

15 ± 1.5

25 ± 2.5

90° ± 10°

65 ± 5

22 ± 2.2

ENGINE ASSEMBLY

DI ENG SM - 2004.4

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

DI01-20

20

Auto tensioner

21

Water pump assembly

22

Water pump pulley

23

Hot water inlet pipe assembly

24

Alternator bracket

25

Alternator

26

Air conditioner compressor assembly

Air conditioner compressor bracket

27

assembly

Air conditioner compressor sub

28

bracket assembly

29

Intake manifold

30

Bracket

31

Knock sensor

32

Camshaft position sensor

33

Booster pressure sensor

34

Exhauster manifold

35

Turbo charger assembly

36

Turbo charger adaptor piece

37

Nut

38

Combination bolt

39

T/C oil supply pipe

40

T/C oil return pipe

41

EGR valve assembly

42

EGR-LH pipe bolt

SizeNameNO.

M8 x 45(LOWER)

M12 x 90

M6 x 50

M6 x 12

M8 x 32

M10 x 90

M8 x 95

M8 x 25

M8 x 60

M6 x 14

M8 x 16

M8 x 45

M8 x 130

M6 x 16

M8 x 28

M8 x 16

M6 x 16

M8

M8 x 22

M6 x 16

(Cylinder block side)

M16 (T/C side)

M6 x 16 (T/C side)

M6 x 16

(Cylinder block side)

M8 x 22

M6 x 16

M8 x 22

Quantity

1

7

4

2

4

2

4

1

3

1

6

1

2

1

2

10

4

1

2

Tightening Torque

32 ± 3

82 ± 6

10 ± 1

25 ± 2.5

46 ± 4.6

25 ± 2.5

10 ± 1.0

25 ± 2.5

10 ± 1.0

20 ± 2.6

12 ± 1.7

10 ± 1.0

40 ± 4

25 ± 2.5

32 ± 3.2

25 ± 2.5

20 ± 2.0

10 ± 1.0

25 ± 2.5

10 ± 1.0

35 ± 2.0

EGR combination bolt

43

EGR-RH pipe nut

44

Glow plug cable nut

45

Vacuum pump

46

Cooling fan bracket assembly

47

Cylinder head cover

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

M6 x 16

M8 x 16

M8

M5

M6 x 20

M6 x 25

M6 x 65

M6 x 85

M6 x 35

21

4

2

5

3

5

1

3

10 ± 1.0

25 ± 2.5

35 ± 2.0

15 ± 3

10 ± 1.0

23 ± 2.3

ENGINE ASSEMBLY

DI ENG SM - 2004.4

DI01-21

48

Vacuum modulator

49

WDT combination bolt

50

Oil dipstick tube

51

Oil filter assembly

52

Fuel rail assembly

53

Injector clamp washer

54

Fuel pipe clip (H-C)

55

Fuel pipe clip (C-I)

56

Crankshaft position sensor

57

Crankshaft position sensor

58

Fuel pressure sensor

59

Wiring

60

Intake manifold bracket

NameNO.

Size

M6 x 16SOC

M6 x 16

M8 x 35SOC

M8 x 50SOC

M8 x 55SOC

M8 x 35SOC

M6 x 60

M6 x 19

M6 x 16

M5 x 17

GAP

M6 x 16

M8 x 16

M8 x 40

Quantity

4

3

1

2

1

3

5

1

5

1

5

2

Tightening Torque

10 ± 1.0

25 ± 2.5

10 ± 1.0

180 + 20°

10 ± 1.0

0.8 ± 0.4

0.7 ~ 1.5

10 ± 1.0

25 ± 2.5

61

Power steering pump

62

Piston protrusion

Clearance between connecting rod

63

and pin boss

64

End play of crankshaft

M8 x 100

NUT

NEW: 0.100 ~ 0.245 mm // USED: 0.300 mm

2

5

25 ± 2.5

0.765 ~ 1.055

0.05 ~ 0.31

ENGINE ASSEMBLY

DI ENG SM - 2004.4

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

DI01-22

REMOVAL AND INSTALLATION

ENGINE MOUNTING

1. Side Mountings

Left

Right

2. Transmission Mounting

3. Exhaust Manifold and Pipe 4. Cables and Connectors

Y220_01010

Notice

1. Disconnect the negative battery cable before removal.

2. Drain the engine oil.

3. Drain the engine coolant.

4. Be careful not to splash the fuel to the vehicle body. It may cause a fire or vulcanization of rubber products.

Make sure to block the fuel related hoses before removal.

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE ASSEMBLY

DI ENG SM - 2004.4

Engine Assembly - Removal

1. Disconnect the negative battery cable.

Notice

If not necessary, place the ignition switch at “OFF” position.

2. Remove the engine hood assembly.

Note

Refer to “Body” section.

DI01-23

Y220_01011

3. Remove the skid plate under the engine compartment.

Installaiton Notice

Tightening torque 12 ± 1.2 Nm

4. Loosen the radiator drain cock and drain the coolant.

Notice

1. Be careful not to contact with coolant. If contacted, wash with soap and water to ensure all coolant is removed.

2. Use only designated coolant.

3. Open the coolant reservoir cap to help the draining.

Y220_01012

Y220_01013

ENGINE ASSEMBLY

DI ENG SM - 2004.4

Y220_01014

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

DI01-24

5. Loosen the cylinder block drain plug (under the intake manifold) and drain the coolant completely.

6. Retighten the drain plug with the specified tightening torque.

Tightening torque 30 Nm

Y220_01015

7. Remove the inlet hose (1) and the heater hose (2) under the radiator.

Notice

Be careful not to damage the rubber hose.

Y220_01016

8. Remove the coolant outlet hose over the radiator.

Notice

Be careful not to damage the rubber hose.

Y220_01017

9. Remove the radiator grille and loosen the hose clamp on the outlet port of turbo intercooler.

Note

For the removal and installation of radiator grille, refer to “Cooling System” section.

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

Y220_01021

ENGINE ASSEMBLY

DI ENG SM - 2004.4

10. Loosen the hose clamp on intake air hose of turbo charger and remove the intake air hose.

11. Separate the outlet hose of oil separator from the intake air hose of turbo charger.

12. Loosen the clamp on the intake air duct hose of turbo charger at the air cleaner side and separate the hose from the air cleaner housing.

DI01-25

Y220_01022

13. Loosen the clamps and remove the intake air hose from the turbo charger.

14. Loosen the clamp on the inlet hose of intercooler.

Y220_01018

Y220_01020

ENGINE ASSEMBLY

DI ENG SM - 2004.4

Y220_01023

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

DI01-26

15. Loosen the clamp on the intake manifold and remove the intake air hose.

Y220_01024

16. Remove the exhaust pipe mounting nuts from the turbo charger.

Installation Notice

Tightening torque 25 ± 2.5 Nm

Y220_01027

Y220_01028

17. Remove the power steering inlet pipe and the outlet hose from the power steering pump.

Notice

Plug the openings of hoses and pump with caps not to flow out the oil.

Installation Notice

Inlet pipe union nut

25 ± 2.5 Nm

18. Remove the vacuum hose from the brake booster.

Installation Notice

Vacuum pipe union nut

10 Nm

(at vacuum pump side)

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

Y220_01029

ENGINE ASSEMBLY

DI ENG SM - 2004.4

19. Remove the supply inlet, supply outlet and return hose from the fuel filter.

Notice

1. When separating the hoses from the fuel filter,

plug the openings with caps so that the contaminants will not get into the fuel system.

2. Mark on all the hoses not to be mixed each other.

20. Remove the engine oil heater outlet hose.

21. Disconnect the cables from the cylinder block and other components.

(e.g., coolant temperature sensor cable and oil temperature switch)

DI01-27

Y220_01030

22. Disconnect the engine ground cable and the alternator “+” terminal cable.

Notice

Make sure to properly tighten the cable nuts when installing. Otherwise, it may cause a poor ground or electric charging problem.

23. Disconnect the “ST” terminal and “+” terminal cables from the starter motor.

Notice

Make sure to properly tighten the cable nuts when installing. Otherwise, it may cause an engine starting problem.

Y220_01031

Y220_01032

ENGINE ASSEMBLY

DI ENG SM - 2004.4

Y220_01033

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

DI01-28

24. Disconnect the air conditioner compressor connector and remove the inlet and outlet pipes from the compressor.

Y220_01034

25. For the automatic transmission equipped vehicle, remove the oil cooler pipes.

Y220_01035

Y220_01036

Note

The oil cooler pipes are connected to cylinder block at both sides and bottom area of oil with brackets.

Installation Notice

Pipe mounting bracket bolt

Pipe hose (radiator side)

union nut

25 ± 2.5 Nm

26. Set up the special to the cooling fan pulley and remove the cooling fan assembly. To make the removal easier, loosen the radiator shroud.

Installation Notice

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

Cooling fan pulley bolt 10 ± 1.0 Nm

Y220_01038

ENGINE ASSEMBLY

DI ENG SM - 2004.4

27. Remove the radiator shroud.

Installation Notice

Tightening torque 10 ± 1.0 Nm

28. Take off the fan belt from the engine.

DI01-29

Y220_01039

Note

1. Insert a tool into the belt tensioner and rotate it counterclockwise to take off the fan belt.

2. After installation of the fan belt, pump the belt tensioner 3 to 4 times.

Y220_01040

ENGINE ASSEMBLY

DI ENG SM - 2004.4

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

DI01-30

29. Remove the transmission mounting bolts and separate the engine assembly from the transmission assembly.

Note

1. Before unscrewing the transmission mounting bolts, remove the starter motor.

Installation Notice

Mounting bolt 55 ± 5 Nm

Y220_01041

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE ASSEMBLY

DI ENG SM - 2004.4

30. Remove the engine assembly mounting nuts at both sides.

Installation Notice

Mounting Nut 55 ± 5 Nm

DI01-31

31. Hook the chain on the engine brackets and carefully pull out the engine assembly from the vehicle by using a hoist or crane.

Y220_01042

32. Put the removed engine assembly on the safety stand.

ENGINE ASSEMBLY

DI ENG SM - 2004.4

Y220_01043

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

DI01-32

DISASSEMBLY AND REASSEMBLY

COMPONENTS AND SPECIAL TOOLS

Injector puller

Injector copper washer

puller

Fuel pipe wrench Sealing capsGlow plug puller

Engine lock

Valve remover/installer Pulley lock/wrench HP pump lock HP pump bearing puller

Y220_01044

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE ASSEMBLY

DI ENG SM - 2004.4

Inspection Before Disassembly and Reassembly

Preparations and Preceding Works

1. Remove the cylinder block drain plug and seal and completely drain the residual coolant from the cylinder block.

Tightening torque 30 Nm

DI01-33

Notice

Replace the seal with new one once removed.

2. When the fan belt is installed, gently pump the belt shock absorber mounting bolt (M19) 3 times.

3. Take off the fan belt while pushing the mounting bolt (M19).

4. Loosen the oil drain plug and completely drain the engine oil.

Drain plug 25 ± 2.5 Nm

Y220_01045

Y220_01046

ENGINE ASSEMBLY

DI ENG SM - 2004.4

Y220_01047

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

DI01-34

Accessories - Removal and Installation

Turbo charger

PCV valve and oil separator

Alternator

EGR valve pipe (LH, Center, RH)

Power steering pump

Cooling fan clutch

Auto tensioner

Air conditioner compressor

Fuel return hose

Cable and connector

Oil filter assembly

EGR valve

Start motor

Mounting bracket

Y220_01048

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE ASSEMBLY

DI ENG SM - 2004.4

DI01-35

• The engine accessories can be removed without any specific order. In general, remove the components from top to bottom. However, be careful not to splash the lubricants to engine and body when disassembly. Especially, avoid getting into other components.

Removal and Installation Order of Major Accessories

1. Vacuum Modulator

2. Engine Cables and Connectors

3. Fuel Hoses

3-1. EGR Valve Assembly

4. Oil Filter Assembly

* Camshaft Position Sensor

* Crankshaft Position Sensor

* Injector Fuel Line Connector

* Glow Plug Connector

* Fuel Return Hose

* High/Low Pressure Hoses in HP Pump

* Ground Cables

* Fuel Pressure Sensor Connector

* Booster Pressure Sensor Connector

* Knock Sensor Connector

* Coolant Temperature Sensor Connector

* HP Pump: Fuel Temperature Sensor (Green)

IMV (Brown)

4-1. Belt Tensioning Assembly

5. Power Steering Pump Assembly

6. Air Conditioner Compressor Assembly

7. PCV Valve Assembly

8. Turbo Charger

+

Oil Dipstick Tube

Alternator Assembly

ENGINE ASSEMBLY

DI ENG SM - 2004.4

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

DI01-36

1. Remove the fuel pipes.

A. Remove the fuel supply pipes between each

cylinder and common rail with a special tool.

Installation Notice

Tightening torque 40 ± 4.0 Nm

Y220_01049

Notice

1. Plug the openings of injector nozzle and common rail with sealing caps after removed the fuel pipes.

No. 1 No. 3 No. 2 No. 4 No. 5

Y220_01050

2. Replace the pipes with new ones. Be careful not to be mixed the fuel pipes because the pipe appearance of #1 and #3 cylinders and #2 and #4 are same each other.

Y220_01051

B. Remove the high fuel pressure pipe mounting bolts

with a special tool.

- High fuel pressure supply pipe at common rail side

Installation Notice

Tightening torque 40 ± 4 Nm

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

Y220_01052

ENGINE ASSEMBLY

DI ENG SM - 2004.4

C.High fuel pressure supply pipe at HP pump side

Installation Notice

Tightening torque 40 ± 4.0 Nm

D. Unscrew the bracket mounting bolts and remove the

high fuel pressure supply pipes.

Note

Special tool: Fuel pipe remover and installer

DI01-37

Y220_01053

Y220_01055

Y220_01054

ENGINE ASSEMBLY

DI ENG SM - 2004.4

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

DI01-38

2. Disconnect the vacuum hoses and module cables from the vacuum modulator.

Notice

Put the installation marks on the modulator hoses and connectors.

Turbo charger

booster vacuum

modulator

EGR vacuum booster

vacuum modulator

To turbo charger

booster

To EGR valve

From vacuum pump

Y220_01056

Y220_01057

A. Remove the vacuum modulator bracket.

(Upper: 10 M x 2, Lower: 10M x 2)

Installation Notice

Upper bolt

Lower bolt

25 ± 2.5 Nm

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE ASSEMBLY

DI ENG SM - 2004.4

3. Disconnect the wiring harnesses and connectors from the engine.

DI01-39

Fuel return hose

Camshaft position

sensor

Injector fuel line

connector

Glow plug connector

Crankshaft position

sensor

Knock sensor connector

Fuel temperature Sensor

IMV

Coolant temperature

sensor connector

Booster pressure sensor

connector

Oil pressure switchHP pump connector

Fuel pressure sensor

connector

Y220_01058

ENGINE ASSEMBLY

DI ENG SM - 2004.4

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

DI01-40

Y220_01059

A. Remove the cable assembly from the engine.

Important

1. If possible, remove the cables after removing the fuel pipes. It make the operation easier and protect the cables and connectors.

2. Remove the cable screws and ground cable, and then remove the engine cable assembly.

Notice

•

Be careful not to damage the HP pump connecting pipe (venturi) while removing the fuel hose from the HP pump.

Y220_01060

4. Disconnect the high and low fuel pressure hoses from the HP pump.

Notice

•

Be careful not to damage the hose connections.

•

Plug the openings in HP pump immediately after disconnecting the hoses.

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

Y220_01061

ENGINE ASSEMBLY

DI ENG SM - 2004.4

5. Remove the EGR valve and EGR valve pipe.

2

A. Disconnect the vacuum hose from the EGR valve.

B. Unscrew the EGR valve bolts and EGR #1 pipe

connecting bolts and remove the EGR valve and steel gasket.

Installation Notice

DI01-41

EGR valve bolt

EGR valve and

center pipe bolt

25 ± 2.5 Nm

C. Remove the EGR valve #1 pipe.

Installation Notice

Center pipe bolt

Center pipe and #1 pipe

bolt and nut

35 ± 3.5 Nm

Notice

The EGR #2 pipe should be replaced with new one.

D. Unscrew the EGR valve #3 pipe (2) mounting bolts

and remove the pipe from the exhaust manifold.

Installation Notice

Y220_01062

Y220_01063

Tightening torque 35 ± 3.5 Nm

Notice

1. The EGR #3 pipe should be replaced with new one.

2. Make sure that the convex surface of new steel gasket is facing to the bolts.

6. Remove the oil filter assembly.

A. Remove the oil cooler hose.

Y220_01064

Y220_01065

ENGINE ASSEMBLY

DI ENG SM - 2004.4

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

DI01-42

B. Remove the oil filter assembly mounting bolts.

Notice

Be careful not to flow out the residual oil from the engine. If flown out, immediately wipe it out.

Y220_01066

C. Remove the oil filter assembly from the cylinder block.

Installation Notice

- Replace the oil filter gasket with new one.

Tightening torque 25 ± 2.5 Nm

Y220_01067

7. Remove the belt tensioning device.

A. Remove the shock absorber lower mounting bolt.

Installation Notice

Tightening torque 32 ± 3 Nm

Y220_01068

B. Remove the shock absorber upper mounting bolt.

Installation Notice

Tightening torque 82 ± 6 Nm

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

Y220_01069

ENGINE ASSEMBLY

DI ENG SM - 2004.4

C. Remove the belt tensioning device.

Notice

• To prevent the oil leaks, store the removed shock

absorber assembly with standing up.

• For air bleeding, pump the shock absorber around

3 times after installation.

• Be careful not to damage the rubber parts of the

shock absorber when removing.

• To prevent the oil leaks, remove the bolts from bottom

to top section. On the contrary, when installing, tighten the bolts from top to bottom section.

7. Remove the power steering pump assembly.

A. Remove the power steering pump mounting bolts.

Installation Notice

Tightening torque 25 ± 2.5 Nm

Notice

DI01-43

Y220_01070

Be careful not to flow out the oil.

B. Remove the power steering pump assembly from the

engine.

Notice

To prevent the oil leaks, store the removed power steering pump assembly with standing up.

8. Remove the air conditioner compressor assembly.

A. Unscrew the bolts and remove the air conditioner

compressor assembly.

Installation Notice

Y220_01071

Y220_01072

Tightening torque 25 ± 2.5 Nm

ENGINE ASSEMBLY

DI ENG SM - 2004.4

Y220_01073

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

DI01-44

B. Unscrew the bolts and remove the air conditioner

mounting bracket.

Installation Notice

Y220_01074

Y220_01075

Front bolt

Side bolt

9. Remove the PCV valve assembly.

A. Remove the PCV valve hose.

25 ± 2.5 Nm

B. Remove the PCV valve hose connected to the engine

oil hose.

Y220_01076

C. Unscrew the PCV valve mounting bolts and remove

the PCV valve assembly.

Installation Notice

Tightening torque 10 ± 1.0 Nm

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

Y220_01077

ENGINE ASSEMBLY

DI ENG SM - 2004.4

10. Remove the oil dipstick tube assembly.

Unscrew the bracket bolts and remove the dipstick tube with O-ring.

Installation Notice

Insert new O-ring into the oil dipstick tube before installation.

Installation Notice

Tightening torque 10 ± 1.0 Nm

DI01-45

Y220_01078

11. Remove the turbo charger assembly.

A. Unscrew the bolts and remove the oil supply pipe.

Installation Notice

Upper bolt (M19)

Lower bolt (M17)

B. Unscrew the bolts and remove the oil return pipe.

Installation Notice

• Make sure to install the gasket with correct direction.

Tightening torque 10 ± 1.0 Nm

Y220_01079

25 ± 2.5 Nm

20 ± 2.0 Nm

Y220_01080

ENGINE ASSEMBLY

DI ENG SM - 2004.4

Y220_01081

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

DI01-46

C. Unscrew the turbo charger mounting bracket bolts.

Installation Notice

Tightening torque 25 ± 2.5 Nm

Y220_01082

D. Unscrew the turbo charger mounting bolts to exhaust

manifold.

Notice

Use only 12 1/2 wrench.

Installation Notice

Tightening torque 25 ± 2.5 Nm

Y220_01083

E. Remove the turbo charger assembly.

Y220_01084

12. Remove the alternator assembly.

A. Unscrew the bolts and remove the alternator.

Note

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

Alternator Capacity: 140 A

Installation Notice

Tightening torque 46 ± 4.6 Nm

Y220_01085

ENGINE ASSEMBLY

DI ENG SM - 2004.4

B. Remove the alternator mounting bracket.

Installation Notice

DI01-47

M13 bolt

Torx 6 bolt

25 ± 2.5 Nm

Y220_01086

ENGINE ASSEMBLY

DI ENG SM - 2004.4

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

DI01-48

Engine - Disassembly and Reassembly

1. Unscrew the injector nozzle holder bolts (12-sided) and remove the injector bracket.

Installation Notice

Y220_01089

Y220_01090

Tightening torque

9 ± 1.0 Nm,

190° + 10°

2. Remove the injectors with a injector extractor (special tool).

Notice

• Be careful not to take off the sealing caps on the

injectors and fuel system.

• Replace the copper washers with new ones when

installing.

3. If the copper washer is in injector hole, remove it with a special tool as shown in the figure.

Y220_01092

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

ENGINE ASSEMBLY

DI ENG SM - 2004.4

4. Remove the glow plugs with a special tool.

Installation Notice

Tightening torque 15 ± 3 Nm

5. Unscrew the Torx bolts and remove the common rail from the engine.

Installation Notice

Tightening torque 25 ± 2.5 Nm

Notice

DI01-49

Y220_01091

Plug the openings with sealing cap.

6. Remove the booster sensor from the engine.

Installation Notice

Tightening torque 10 ± 1.0 Nm

7. Unscrew the bolt and remove the camshaft position sensor.

Installation Notice

Y220_01087

Y220_01088

Tightening torque 12 ± 1.7 Nm

• Apply Loctite on the thread before installation.

ENGINE ASSEMBLY

DI ENG SM - 2004.4

Y220_01093

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

DI01-50

8. Unscrew the bolts and remove the cooling fan pulley while holding it with a special tool.

Tightening torque 10 ± 1.0 Nm

Y220_01094

9. Remove the cooling fan belt idle pulley while holding it with a special tool.

Tightening torque 10 ± 1.0 Nm

Y220_01095

10. Unscrew the bolts and remove the cooling fan bracket assembly (timing chain cover).

Tightening torque 10 ± 1.0 Nm

Y220_01096

11. Unscrew the bolts and remove the cylinder head cover.

Tightening torque 10 ± 1.0 Nm

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

Y220_01097

ENGINE ASSEMBLY

DI ENG SM - 2004.4

12. Turn over the engine and remove the oil pan.

Installation Notice

DI01-51

Tightening torque

M6 x 20: 24 EA

M6 x 35: 2 EA

M6 x 85: 2 EA

M8 x 40: 4 EA

Nm

10 ± 1.0

25 ± 2.5

Installation Notice

Remove the oil seal residues from the oil pan and apply the liquid gasket on the parting surface.

Y220_01100

Y220_01101

13. Unscrew the nuts and remove the exhaust manifold.

Installation Notice

Tightening torque 40 ± 4.0 Nm

Notice

The exhaust manifold gasket is removed along with the exhaust manifold. Mark the installation direction to prevent wrong installation. Otherwise, it may cause a sealing trouble.

Y220_01102

ENGINE ASSEMBLY

DI ENG SM - 2004.4

Y220_01103

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

DI01-52

14. Unscrew the bolts and remove the thermostat.

Installation Notice

Tightening torque 10 ± 1.0 Nm

Notice

Be careful not to flow out the residual coolant.

Y220_01104

15. Unscrew the bolts and remove the water pump.

Installation Notice

Tightening torque 10 ± 1.0 Nm

Y220_01105

16. Unscrew the bolts and remove the water pump housing.

Installation Notice

Tightening torque 10 ± 1.0 Nm

Notice

Be careful not to flow out the residual coolant.

Y220_01106

17. Unscrew the bolts and remove the coolant inlet port from the intake manifold.

Installation Notice

Tightening torque 25 ± 2.5 Nm

Notice

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

Be careful not to get the coolant into the intake manifold and engine.

Y220_01107

ENGINE ASSEMBLY

DI ENG SM - 2004.4

18. Unscrew the bolts and remove the intake manifold assembly.

Installation Notice

Tightening torque 25 ± 2.5 Nm

Notice

Replace the gasket with new one once removed.

DI01-53

Y220_01108

19. Remove the vacuum pump from the cylinder head.

Installation Notice

Tightening torque 10 ± 1.0 Nm

20. Install the engine lock (special tool) onto the flywheel ring gear so that the engine will not rotate.

Y220_01109

Y220_01110

ENGINE ASSEMBLY

DI ENG SM - 2004.4

Y220_01111

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

DI01-54

21. Remove the chain tensioner.

Preceding works: removal of EGR pipe and oil dipstick tube

Tightening torque 65 ± 5.0 Nm

Y220_01119

22. Pull out the lock pin and remove the upper chain guide bracket.

Y220_01112

23. Unscrew the bolt and remove the intake camshaft sprocket.

Installation Notice

25 ± 2.5 Nm,

Tightening torque

90° + 10°

Y220_01113

24. Unscrew the bolt and remove the exhaust camshaft sprocket.

Installation Notice

25 ± 2.5 Nm,

Tightening torque

90° + 10°

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

Y220_01114

ENGINE ASSEMBLY

DI ENG SM - 2004.4

25. Remove the camshaft bearing cap bolts so that the tightening force can be relieved evenly.

• Intake: #1, #3, #6

• Exhaust: #7, #9, #12

* However, there is no specific removal sequence.

DI01-55

Exhaust

• Intake: #2, #4, #5

• Exhaust: #8, #10, #11

* Do not remove the bolts at a time completely. Remove

them step by step evenly or camshaft can be seriously damaged.

Installation Notice

Tightening torque 25 ± 2.5 Nm

26. Remove the intake and exhaust camshafts from the cylinder head.

Intake

Y220_01115

Y220_01116

27. Remove the finger follower and the HLA device.

Notice

• Avoid contact with hot metal parts when removing

the HLA device immediately after stopping the engine.

• Be careful not to be contaminated by foreign

materials.

• To prevent the oil leaks, store the removed finger

follower and HLA device with standing up.

• If the HLA can be easily pressed in by hand, it

indicates the oil inside of HLA has been flown out. In this case, replace it with new one.

ENGINE ASSEMBLY

DI ENG SM - 2004.4

Y220_01117

Y220_01118

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

DI01-56

28. Pull out the pin and remove the timing chain guide from the engine.

Y220_01120

29. Remove the cylinder head bolts according to the numerical sequence.

Installation Notice

Y220_01121

Y220_01122

Tightening torque

M8 x 25: 2 EA

M8 x 50: 2 EA

Nm

25 ± 2.5

M12 x 177: 11 EA

85 ± 5 Nm,

M12 x 158: 1 EA

(Vacuum pump side)

3 x 90° + 10°

30. Measure the length of cylinder head bolts.

• If the maximum length is exceeded by 2 mm, replace the cylinder head bolt.

Length when new

177 mm

158 mm

Maximum Limit

179 mm

160 mm

31. Remove the cylinder head.

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

Notice

• Inspect the cylinder head surface.

• Store the removed injectors and glow plugs so that they will not be damaged.

Y220_01123

ENGINE ASSEMBLY

DI ENG SM - 2004.4

32. Measure the piston protrusion from the parting surface.

• Specified Value: 0.765 ~ 1.055 mm

33. Remove the cylinder head gasket.

Installation Notice

• Replace the cylinder head gasket with new one. Make sure to place the “TOP” mark upward.

1. Put the steel gasket on the cylinder block and

position the cylinder head.

DI01-57

Y220_01124

2. Tighten the cylinder head bolts to specified torque

and torque angle.

Tightening torque

• Apply the oil on the bolt thread when installing.

• Always insert new washer first.

• The bolts (12) at vacuum pump side are shorter than others.

34. Turn over the engine and remove the baffle plate.

Installation Notice

Tightening torque 10 ± 1.0 Nm

Y220_01125

Step 1 20 ± 2.0 Nm

Step 2 85 ± 5.0 Nm

Step 3 90 ± (3 times) + 10°

Y220_01126

ENGINE ASSEMBLY

DI ENG SM - 2004.4

Y220_01127

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

SsangYong Rexton Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual