Motor Mehanika HD-120 PDF
Motor Mehanika HD-120 PDF
Motor Mehanika HD-120 PDF
MECHANICAL
GENERAL ..................................................................... EM- 2
SERVICE STANDARD ................................................. EM- 7
SPECIAL TOOLS ......................................................... EM-17
SERVICE PROCEDURE
Engine Disassembly Check Standard .................. EM-22
Engine Dismounting and Installation ................... EM-24
Engine ..................................................................... EM-26
Crank Shaft Pulley ................................................. EM-34
Flywheel and Flywheel Housing ........................... EM-36
Timming Gear and Camshaft ................................ EM-39
Piston, Crankshaft, Cylinder Block and oil Pan .. EM-45
Liquid Gasket and Oil Application Points ............ EM-57
TROUBLESHOOTING .................................................. EM-59
EM-2 ENGINE MECHANICAL
GENERAL
Iinjection nozzle
Construction and Operation
Cylinder head
Engine Proper
1. Combustion Chamber
The combustion chamber is made up of the cylinder head and O-ring
toroidal piston. The hole type injection nozzle is mounted to the
cylinder head together with the nozzle tube.
KKEM-000
GENERAL EM-3
2. Valve Mechanism
The valve mechanism is an overhead valve type and is con-
structed as shown.
Upper retainer
Rocker
Outer valve spring
Rocker shaft
Valve stem seal
Lower retainer
Push rod
Valve stem seal
Exhaust valve
Inlet valve
Camshaft
Tappet
KKEM-902
(a) Both intake and exhaust valves are made of surface treated heat-resistant steel to increase durability.
The valve seat angle of both valves is 45°
A valve stem seal is provided on the stem of valve to control the quantity of lubricant of the valve and valve guide sliding
portions. The inner and outer springs are different in coiled direction.
(b) To prevent abnormal vibration during high speed operation, two unevenly pitched springs are provided as valve
springs.
The inner and outer springs are different in coiled direction.
(c) The rocker is a precision forged carbon steel product.
The rocker end sliding portion is quenched.
The rocker shaft is a hollow round rod with expansion plugs at both ends to seal off the rod. The inside of the shaft
constitutes an engine oil passage.
(d) A steel ball is welded to the bottom end tapper side of the push rod, whereas a spherical concave type end cap is welded
to the top end rocker side. Both ends are carburized and hardened.
(e) The tapper is a cylindrical type and has a spherical surface which makes contact with the camshaft. The tappet can
be removed without removing the camshaft, provided that the cylinder head is removed.
(f) Because of the high cam design, the push rod is shorter, assuring higher rigidity and higher dependability against high
speed rotation.
(g) To facilitate insertion and removal of the camshaft from the rear end of the crankcase, the diameter of the camshaft
bearing is smaller toward the front.
EM-4 ENGINE MECHANICAL
KKEM-903
KKEM-905
GENERAL EM-5
The upper bearing has an oil has an oil groove, but the
lower bearing has no oil groove. Split type thrust plates are Lower main bearing
mounted to the bearing to sypport the thrust of the crankshaft.
Thrust plate
KKEM-908
EM-6 ENGINE MECHANICAL
7. Timing Gear
The timing gears are housed in the timing gear case at the front of the engine. Illustration shows the gear train.
Each gear is a helical gear machined by a shaving machine to high precision and surface-treated for enhanced
durability.
KKEM-292
A bushing is press-fitted into the idlergear which turns on the idle shaft.
The oil hole dirlled through the idler shaft and gear provides an oil passage for lubrication of bushing and gears.
8. Flywheel
Ring gear
The flywheel is made of cast iron. The pilot bearing of the Flywheel
transmission drive pinion is installed at its center. On its
periphery, the ring gear is shrink-fitted that meshes with the
starter pinion.
Less than0.03
(0.0012)
at direction B
KKEM-44
KKEM-45
KKEM-46
Cylinder head
KKEM-47
Unit : mm
Inspection Item Standard Limit Remedy Inspection Procedure
Valve seat Intake 29°45′-30° - Regrind or
angle replace valve
Exhaust 44°15′-45°45′
and /or valve
Valve face Intake 29°45′-30°
seat
angle Intake Exhaust
Exhaust 44°45′-45° KKEM-50
Ex 40.6kgf
at 50.4
KKEM-53
KKEM-54
SERVICE STANDARD EM-9
Unit : mm
KKEM-55
KKEM-57
KKEM-58
KKEM-59
Unit : mm
Inspection Item Standard Limit Remedy Inspection Procedure
Flantness of flywheel - 0.04 Replace or grind
KKEM-76
KKEM-97
KKEM-98
KKEM-99
KKEM-100
camshaft, Replace
Intake 6.66 6.58
camlift
(A-B)
Unit : mm
Inspection Item Standard Limit Remedy Inspection Procedure
Camshaft end play 0.100-0.178 0.30 Replace thrust
plate
KKEM-102
60.65-60.67 60.7
No.3
58.25-58.27 58.4
No.4
Unit : mm
Inspection Item Standard Limit Remedy Inspection Procedure
KKEM-105
KKEM-106
SERVICE STANDARD EM-13
Unit : mm
Inspection Item Standard Limit Remedy Inspection Procedure
Piston diameter 109 - Replace piston
OUTSIDE
at A:21 and/or liner DIAMETER
KKEM-167
Unit : mm
Inspection Items Standard Limit Remedy Inspection Procedure
Piston pin diameter 38.987-39.000 36.96 Replace piston,
piston pin and/or
connecting rod
Piston pin hole inside 36.987-37.003 39.05
diameter
KKEM-171
KKEM-172
KKEM-173
SERVICE STANDARD EM-15
Unit : mm
Inspection Items Standard Limit Remedy Inspection Procedure
Crankshaft pin diameter 64.94-64.96 64.80 Regrind crank-
shaft and use
undersize bearings
63.80 Replace
crankshaft
KKEM-175
KKEM-176
KKEM-177
KKEM-178
KKEM-179
EM-16 ENGINE MECHANICAL
Unit : mm
Inspection Items Standard Limit Remedy Inspection Procedure
Crankshaft journal 79.940-79.960 79.8 Regrind crank-
diameter shaft and use
undersize bearings
78.8 Replace
crankshaft
KKEM-180
KKEM-181
KKEM-182
SPECIAL TOOLS EM-17
SPECIAL TOOLS
KKST-001
KKST-002
KKST-003
KKST-004
KKST-005
EM-18 ENGINE MECHANICAL
KKST-006
KKST-007
KKST-008
KKST-009
KKST-010
SPECIAL TOOLS EM-19
KKST-011
KKST-012
KKST-013
KKST-014
KKST-015
EM-20 ENGINE MECHANICAL
KKST-016
KKST-017
KKST-018
KKST-020
Front oil seal sleeve 09231-8Y400 Installation of front oil seal sleeve
installer
KKST-021
SPECIAL TOOLS EM-21
Front oil seal sleeve 09231-8Y500 Removal of front oil seal sleeve
remover
KKST-022
KKST-023
KKST-025
KKST-026
KKST-027
EM-22 ENGINE MECHANICAL
around 80°C)
c) Charge the battery fully.
d) Remove the air cleaner.
b. Measurement
a) Remove the nozzle holders completely.
b) Install the gauge adapter in the nozzle holder hole.
c) For the vehicles installed manual engine stop control;
Remove the engine stop cable from the engine stop
lever connected to engine stop position by tape or
string.
d) For the vehicles installed electric engine stop control;
Remove the engine stop motor harness after turning
the engine starter key to “OFF” position.
e) Connect a compression gauge to the gauge adapter.
f) Drive the engine with the starter and read the compres-
sion pressure.
CAUTION
Do not operate the starter for more than 15 seconds at
once.
CAUTION
Make sure no pressure leaks through sealing face.
SERVICE PROCEDURE EM-23
WARNING
Do not connect electric harness to engine stop motor, when
engine starter key is at “ON” position.
If starter key is at “ON” position, engine stop motor operates
simultaneously then the link of engine stop motor and engine
stop lever of fuel injection pump operate resulting in possible
damages of hand.
Unit : kg/cm2
Compression pressure Difference between
Engine model Engine speed(rpm)
Standard Limit each cylinder
WARNING
Do not drain coolant or engine oil while engine or radiator is
hot because it may cause burn.
3. Disconnect the oil pressure line of power steering and drain oil.
CAUTION
Please refer power steering maintenance section for the
details.
CAUTION Engine
Do not operate engine. stop
position
Bracket stop
b) Check whether engine stop lever of fuel injection pump is cable mounting Engine operating position
at engine operation position, and disconnect the connector KKFL-022
CAUTION
• Disconnect battery cable from the (-) terminal
of the battery and remove electric line.
• Cover the hole of pipe, hose and pump so that
no dust inflow.
CAUTION
Be careful not to damage the radiator core.
CAUTION
Please refer “transmission and transmission control” main-
tenance section for the details.
10. Connect cable from the engine hanger to the hanger bracket at
the front of the engine and to the hanger brackets at the upper
flywheel housing at the rear of the engine. Loose the cable a bit
and raise the hanger by using the hoist.
11. Remove the engine mounting nuts (both sides of front and
rear).
12. Lift the engine hanger so that the cables are fully tightened, and
then after checking that the cables are securely hooked on the
hanger brackets, lift the engine assembly gently and remove it
from the vehicle.
KKEM-911
Installation
Install engine assembly.
Install engine assembly by reversed order of dismounting.
CAUTION
Check the leaks of oil, fuel, coolant or air.
CAUTION
Do not start the engine yet.
CAUTION
Check engine stop and start after adjustment.
Adjusting nut
KKEM-912
EM-26 ENGINE MECHANICAL
Engine
Cylinder Head
OVERHAUL
KKEM-09
SERVICE PROCEDURE EM-27
KKEM-931
EM-28 ENGINE MECHANICAL
Disassembly
Disconnect fuel pipe and nozzle assembly.
KKEM-19
KKEM-20
KKEM-20A
Lift the cylinder head from the dowels and place it on the
wooden block.
Moving up and down
1. If the cylinder head is difficult to lift, insert the chisel between the
cylinder head and block to leverage.
Assembly
Clean the cylinder head completely with the solvent.
CAUTION
Be careful not to damage the cylinder head surface.
KKEM-23
Apply lapping compound lightly to the valve face. Install the valve
using a special tool, tap and rotate the valve against the seat.
KKEM-24
CAUTION
• Grinding of valves and valve seats should only be per-
formed when hand lapping does not result in proper
seating.
• Recheck the valve sink after grinding at all times.
KKEM-25-1 KKEM-25
Intake Exhaust
KKEM-26
KKEM-974
remover: 09211-8Y000)
3. Install the valve guide. (Valve guide installer: 09211-8Y100)
84.75mm 86.25mm
CAUTION
Apply engine oil lightly to the outer circumference of valve
guide before installation. KKEM-30
Install the lower spring seat and valve first. Then apply engine
oil to the lip of the stem seal and push the guide with a special
tool.
Special tool: valve stem seal installer(09222-93000)
CAUTION
• Check for any cracks or damages of rubber, after valve
stem seal installation.
• If the tip that touches the lower spring seat is worn or
KKEM-772/KKEM-971
deformed, do not use the special tool.
SERVICE PROCEDURE EM-31
Cylinder head
KKEM-952
CAUTION
Damaged O-ring cause oil leaks, overheating or crack of head.
KKEM-34
3. Stick the nozzle sleeve into the cylinder head tight using a
Special tool
Nozzle sleeve
special tool. Insert the seat press (special tool) into nozzle
sleeve. Push the ball slowly through the hole with the special
tool so that the end of nozzle sleeve be fastened tight to the
cylinder head. Cylinder head
Special tool
Special tool: (nozzle sleeve installer: 09222-8Y300)
KKEM-35
CAUTION
• Apply the engine oil to the contact points of all parts.
• Check the valves whether they are installed to the right
cylinders.
• Since the valve spring has various pitches, install them as
the painted parts facing downward.
KKEM-36
Pressing the upper spring seat, install the valve stem key tight to the
valve spring seat.
CAUTION
• When pressing with valve spring press, be careful not to
damage the stem seal by the touch with upper seat.
• Push the valve stem gently by the hammer for the precise
installation of valve stem key. KKEM-951
EM-32 ENGINE MECHANICAL
Apply the engine oil to the rocker arm shaft and bushing.
CAUTION
Check whether the rocker arm shaft is installed as the “UP”
mark facing upward. Disassemble may cause the melting of
valve stem.
Timing gear shaft
KKEM-38
CAUTION No 1 support
Check whether the oil hole of rocker arm assembly number 1
support coincides with the shaft oil hole. Incorrect installation
may cause the burning of whole valve assembly.
CAUTION
When using the new cylinder head gasket, clean the surface
of the cylinder head, cylinder block and head gasket free of all
KKEM-40
dirt, water and grease.
3. Install the cylinder head over the dowels on the cylinder block.
4. Apply the engine oil to the both ends of push rods and install in
the right order.
5. Install rocker arm assembly to the cylinder head and check
whether push rod contacts adjusting screws.
CAUTION
Unfasten the lock nut loose and raise the adjusting screw fully
to the maximum. KKEM-41
CAUTION
Flywheel side
Pan side
Apply engine oil at the thread of bolts and at the lower part of
bolt head.
1-26 blots (at the cylinder head bolts)
27-32 bolts (additional bolts)
KKEM-42
SERVICE PROCEDURE EM-33
Rear
Front
KKEM-43
EM-34 ENGINE MECHANICAL
COMPONENTS
For Truck 5
8
7
6
4
2
T=6500kgf-cm 1
For Bus
1. Nut
2. Spacer
3. Bolt
4. Crank shaft pulley
5. Crank shaft damper
6. O-ring
7. Sleeve
8. O-ring
KKEM-941
SERVICE PROCEDURE EM-35
CAUTION
• Use the plug, if needed.
• Do not remove the crankshaft pulley, if it is not necessary.
(Front) KKEM-66
Assembly
Replace the crankshaft front oil seal sleeve, if needed.
1. Remove the oil seal sleeve by using the special tool (Front oil Special tool
seal remover: 09231-8Y500, sliding hammer: 09450 -8Y000).
2. Install the new sleeve (Special tool: front oil seal sleeve
installer: 09231-8Y400) Install the new O-ring to the sleeve,
apply the enough oil to the center part of the pulley. Use the
crankshaft sleeve press to insert the crankshaft sleeve. Then KKEM-751
COMPONENTS
7
10
5 T=1900kgf.cm
3
1 8
KKEM-761
KKEM-761
SERVICE PROCEDURE EM-37
Assembly
Replace the oil seal, if needed.
1. Remove the oil seal.
2. Lightly apply the engine oil to the outer circumference of oil
seal, and install the oil seal to the flywheel housing. (Special
tool: 09231-8Y100). Check whether the oil seal is securely
installed to the flywheel housing.
KKEM-70
CAUTION
Apply the oil seal lubrication grease (Lithium based) to the oil
seal rib.
CAUTION
Apply the adhesive to the flywheel housing so that the O-ring
is not detached. Install the flywheel housing.
KKEM-71
KKEM-973
CAUTION
Do not overheat the ring gear.
KKEM-72
CAUTION
Do not overheat the ring gear.
KKEM-73
EM-38 ENGINE MECHANICAL
2. Insert the flywheel into the guide bar gently as flywheel touches
the collar knock, and push it fully to be securely installed.
3. Apply the engine oil to the surface of flywheel bolt bearing and
threads of flywheel bolts. Fasten the flywheel bolts tentatively
Guide bar
by hands.
4. Remove the bars, and fasten the remaining two flywheel bolts
tentatively as described in no 3.
5. When fastening the bolts, fasten them gradually and slowly with KKEM-981
the specified torques. And then loosen them a little bit and
fasten them again by the specified order and torques. Fastening order “O” mark
Crankshaft collar
WARNING
Be careful not to drop the flywheel, since it is heavy.
CAUTION
• Align the “O” marks of flywheel and crankshaft collar
knock to be coincided.
• When fastening bolts, apply the engine oil the bolts threads
KKEM-75
and flywheel face.
DESCRIPTION
7 6
4
B 3
2
C
5
OVERHAUL 13 A
16 1
T=320 15
18
7 12
6
17
8 13
16 12
15
14
4 2 T=250
T=2800
13
11
5
T=1600
10
9
3
1 T=2100
13
T=Tightening torque : kgf·cm
1. Crank shaft gear 9. Injection pump gear thrust plate 18. Camshaft
2. Idler gear 10. Collar
3. Fuel injection pump drive gear 11. Injection pump drive shaft A. Match marks "1"
4. Camshaft gear 12. Key B. Match marks "2"
5. Engine oil pump drive gear 13. Thrust plate C. Match marks "3"
6. Air compressor idler gear 14. Bushing
7. Air compressor drive gear 15. Pin
8. Power steering pump drive gear 16. Idler gear shaft
(If so fitted) 17. Camshaft thrust plate
KKEM-291
EM-40 ENGINE MECHANICAL
OVERHAUL
Tacho sensor
Disassembly
Disassemble crankshaft pulley.
Removal of camshaft
Remove thrust plate set blots, and remove camshaft and gear.
CAUTION
Rotate the camshaft slowly so that the bearing should not be
damaged.
KKEM-85
KKEM-86
EM-42 ENGINE MECHANICAL
Assembly
Replace drive shaft oil seal sleeve of fuel injection pump, if needed.
Sleeve
1. Remove sleeve by using special tools.
a. Place the puller (1) and (2) on sleeves.
b. Hook the puller between shaft and sleeve.
c. Insert the puller (3).
Drive shaft
d. Fasten the center bolt (4) after inserting puller, and remove
sleeve.
Sleeve
KKEM-87
2. Insert shaft sleeve along with the new O-ring by using special
tool.
a. Install O-ring (5) inside of the press (6).
b. Insert oil seal sleeve into press with new O-ring and insert
it into drive sleeve.
c. Tap the part (A) lightly with hammer to connect the edge of
the press with shaft edge (B) and then oil sleeve is positioned. Sleeve
CAUTION O-ring
O-ring KKEM-88
Distance from the shaft edge to sleeve end (c): 85.2 – 85.8 mm
KKEM-89
SERVICE PROCEDURES EM-43
KKEM-331
CAUTION
Check whether gear (1) is securely installed to collar (2) and
shaft (3).
KKEM-91
CAUTION
• When installing gear to camshaft,
• Heat the gear with the hot water (approximately 100°C) and
install gear to camshaft by using the press.
• When fastening the bolts, apply the engine oil to the bolts
thread and nut surfaces. KKEM-92
Install camshaft.
Lubricate the camshaft and install the camshaft assembly to
cylinder block.
CAUTION
When installing camshaft, rotate the camshaft slowly so that
the bearing is not damaged.
KKEM-93
CAUTION
Make sure that oil hole faces downward. If it doesn’t, idler gear
shaft and bushing will be damaged. Oil hole
Crank shaft
KKEM-94
EM-44 ENGINE MECHANICAL
CAUTION
• If installed wrong, it may cause improper injection timing
and finally engine damage or engine performance deterio-
ration will be resulted.
KKEM-95
• When fastening bolts, apply the engine oil to the bolts
threads and surface.
OVERHAUL
T=800~1200
KKEM-107
EM-46 ENGINE MECHANICAL
OVERHAUL
3
1 2
2
6
7
5
T=400~500
Disassembly
Disassemble piston along with connecting rod.
1. Remove the carbon dirt of the cylinder liners by scrubbing the
liner edges to the circumference direction by scrapper or sand
paper (No. 150).
KKEM-124
2. Pull out the piston and connecting rod assembly out of upper
“O” mark
cylinder.
CAUTION
• Disassemble connecting rod, as connecting rod do not
touch the cooling jet.
• Arrange the piston and connecting rod caps orderly.
KKEM-421
CAUTION
Preheat the piston for about 5 minutes by soaking in the hot
water of 80 - 90°C, before disassembling pins.
KKEM-126
CAUTION
• Since piston rings are made of special forgery and brittle,
handle them with special care.
• Distinguish the rings by the equivalent cylinders and
separate them each other.
KKEM-422
KKEM-431
SERVICE PROCEDURES EM-49
Assembly
Check piston cooling jet position.
CAUTION
• Do not disassemble cooling jet except disassembly in-
spection or when it is necessary.
• When cooling jet is disassembled, replace the cooling jet
check valve of cylinders.
KKEM-130
Target plate
Cylinder block
KKEM-132
WARNING
Engine oil is extremely flammable.
Spray test should be performed at the places where ventila-
Spray
tion is excellent.
Target
φ 10mm
Abnormal Normal
KKEM-133
EM-50 ENGINE MECHANICAL
7. If the spray of the cooling jet is scattered around the target plate,
readjust the nozzle.
KKEM-134
9. After checking piston cooling jet position, install the cooling jet
on the cylinder block by using the right bolts (with soft washer).
10. After installing piston, check the interference of cooling jet and
piston when the piston is at the bottom dead center position.
KKEM-136
SERVICE PROCEDURES EM-51
Insert the cylinder liners into the cylinder block. Liner identification mark
1. When installing the new cylinder liner, check the mark of (Cylinder No.1, cylinder No.2,…..
cylinder No.6 from the front.)
cylinder block with mark of liner.
CAUTION
When installing the cylinder liner and block, be careful to
choose the right ones.
In case of using the new cylinder liner, check the X,Y and Z
mark of cylinder liner flange with the same marks of upper Vehicle moving direction
cylinder block.
KKEM-461
2. When reusing the liner, install the liner at the right position by
coinciding the assembly marks that was drawn before the
disassembly.
Assembly mark
KKEM-138
CAUTION
• Use the new one, if the liner has been dropped.
• Handle with care so that the liner is not damaged.
KKEM-139
EM-52 ENGINE MECHANICAL
Install O-ring to end plate and install this assembly to the O-ring
cylinder block.
CAUTION
End plate
• Take care not to damage the cylinder block and end plate
in installing. Besides, apply the liquid gasket around the KKEM-141
Special tool
Replace the crankshaft rear oil seal sleeve, if needed.
1. Remove the crankshaft sleeve using special tool.
(Rear oil seal sleeve remover: 09231 – 8Y300) Assembly
Grind the crankshaft pin or journal and use the undersize bearing, Unit: mm
if necessary.
Outer diameter
Undersize
CAUTION Pin Journal
• When crankshaft pin or journal is worn out, 4 different
0.25US 64.69-64.71 79.69-79.71
types of under size bearing can be used.
0.50US 64.44-64.46 79.44-79.46
0.25 mm, 0.50 mm, 0.75 mm, 1.00 mm
• Bearing set consists of upper and lower bearing. So it 0.75US 64.19-64.21 79.19-79.21
should be replaced by the set. 1.00US 63.94-63.96 78.94-78.96
Good Defect
KKEM-144
SERVICE PROCEDURES EM-53
CAUTION
• Install the bearing with oil hole to the block side, and
bearing without the oil hole to the bearing cap side.
• Apply the clean engine oil to the bearing surface.
CAUTION
Apply the engine oil to each thrust bearing surface.
KKEM-145
KKEM-146
6. Fasten the cap bolts by the following order.
Unit: kgf-cm
#1, #2, #3, #5, #6, #7 #4
+2° +2°
700 + 57° 0 700 + 52° 0
Timing gear side
CAUTION
• Apply the engine oil to the lower part of bolt thread and
head.
• Check whether the crankshaft rotates smoothly.
• Check the clearance of crankshaft end. KKEM-147
EM-54 ENGINE MECHANICAL
CAUTION
Operate the press slowly and gently.
CAUTION
• Unbalance champering cause the wrong grinding of
pressed bushing, and finally results in the melting during
Connection rod
installation.
• Remove the dust from the inside of the hole. KKEM-491
CAUTION
Misalignment of oil holes may cause insufficient lubrication
and melting.
KKEM-155
b. The new piston pin inserted to the piston pin bushing must
be rotated easily without shaking.
SERVICE PROCEDURES EM-55
CAUTION
• Use the new retainer ring.
• Heat the piston for about 5 minutes by soaking it into the
Alignment mark
water of 80 –90°C.
KKEM-412
CAUTION
Identification
Apply the engine oil to piston ring. mark
2. Connect the end of coil expander, and install the coil inside the Ring number Shape
piston ring by letting the gap of piston ring should be at the 180°
distant from the joint part of the coil. Top
Number 2
Oil
KKEM-512
3. Align the piston ring, as the gap positions of rings are equal.
Connection
KKEM-159
Engine front
Oil jet
“O” mark
KKEM-511
EM-56 ENGINE MECHANICAL
CAUTION
• Check whether the O-mark of upper piston is at the engine
Tappet chamber
front (crank pulley) side. KKEM-521
KKEM-522
Ailgnment
KKEM-421
CAUTION
• Apply the engine oil at the lower part of bolt threads and
nuts.
• Fasten the nut again, even if the nut is fully fastened.
SERVICE PROCEDURES EM-57
(a) Timing gear cover Where contacts the cylinder block 1.5-2.5
Liquid gasket
Liquid gasket
KKEM-571
(b) Flywheel housing Flange face where contacts cylinder block 1.5-2.5
Liquid gasket
(c) Intake manifold Flange face where contacts cylinder head 1.5-2.5
Liquid gasket
KKEM-572
EM-58 ENGINE MECHANICAL
Unit: mm
Liquid gasket
KKEM-581
(e) Coolant pipe (for the Flange face where contacts coolant pump 1.5-2.5
model, which adopts
air compressor)
Liquid gasket
KKEM-582
3. Components disassembly
When disassembling each component, try to lift various parts in turn instead of lifting only one side of the flange.
CAUTION
Oil pan flange are deformed sometimes in removing oil pan.
Therefore, insert several plates along the circumference and remove the oil pan using screwdrivers.
TROUBLESHOOTING EM-59
THOUBLESHOOTING
Symptom Possible cause Remedy/Prevention
Engine Coolant
overheating • Insufficient coolant • Add coolant.
• Defective thermostat • Replace the thermostat.
• Overflow of coolant due to leakage of • Repair.
exhaust into cooling system
• Coolant leakage from cylinder head gasket • Repair gasket.
• Defective coolant pump • Repair or replace.
Radiator
• Clogged with rust and scale • Clean radiator.
• Clogged with iron oxide due to leakage • Clean coolant passage and
of exhaust into cooling system correct exhaust leakage.
• Clogged radiator core due to mud • Clean radiator.
or other debris
• Defective radiator cap pressure valve • Replace radiator cap
Abnormal combustion
• Incorrect injection timing • Adjust injection timing
• Reduced injection pressure • Adjust injection pressure.
• Poor fuel • Use good quality fuel.
• Poor nozzle spray • Adjust or replace nozzle.
• Unsatisfactory automatic timer true angle • Repair or replace timer.
Other problems
• Defective or deteriorated engine oil • Change engine oil.
• Unsatisfactory operation of oil pump • Replace or repair.
• Insufficient oil • Add oil.
Excessive oil Pistons, cylinder liners, and piston rings
consumption • Wear of piston ring and cylinder liner • Replace piston rings and cylinder liner.
• Worn, sticking or broken piston rings • Replace piston rings and cylinder liner.
• Insufficient tension on piston rings • Replace piston rings and cylinder liner.
• Unsuitable oil (viscosity too low) • Change oil as required.
• Incorrectly fitted piston rings (upside down) • Replace piston rings.
• Gaps of piston rings in line with each other • Reassemble piston rings.
Valve and valve guides
• Worn valve steam • Replace valve and valve guide.
• Worn valve guide • Replace valve guide.
• Incorrectly fitted valve stem seal • Replace stem seal.
• Excessive lubricant on rocker arm • Check clearance between rocker arm and shaft.
EM-60 ENGINE MECHANICAL
Nozzles
• Uneven injection pressure • Adjust.
• Poor nozzle spray • Adjust or replace nozzle.
• Carbon deposit on nozzle tip • Remove carbon.
• Seized needle valve • Replace nozzle.
EM-62 ENGINE MECHANICAL
GENERAL
Engine lubrication is accomplished by forced lubrication system using gear pump. The engine oil in the oil pan in drawn
up through the oil strainer by the oil pump and force-fed to the filer and oil cooler to lubricate all parts.
Turbo charger
A
Air compressor Oil cooler
Inj.pump
A
Camshaft Piston
Crankshaft Journal
A B
Oil pump
Shafty valve A
Regulator valve
A
Safety valve
A : to oil pan
B : to crankshaft
KKLU-591
SPECIFICATIONS LU-3
SPECIFICATIONS
Items Specification Remarks
SERVICE STANDARD
Unit : mm (in)
KKLU-194
KKLU-195
KKLU-196
KKLU-197
SERVICE STANDARD LU-5
Unit : mm (in)
KKLU-198
KKLU-202
LU-6 LUBRICATION SYSTEM
Tightening torque
Unit : kg·m
D6DA
Items Remarks
Size Torque
Oil pump cover bolt M8 x 1.25 1.8~2.7
Oil cooler nut M8 x 1.0 1.0~1.5
Oil filter cartridge M38 x 1.5 4.0~5.0
Oil cooler bypass valve M22 x 1.5 3.0~4.0
Oil jet check valve M12 x 1.5 2.7~3.2
Main relief valve cylinder (Cylinder block side) M28 x 1.5 8.0~12.0
Regulator valve M22 x 1.5 3.0~4.0
Oil cooler plug M20 x 1.5 2~3
SERVICE PROCEDURES LU-7
SERVICE PROCEDURES
Oil Pump and Oil Strainers
COMPONENTS
Installation
O-ring
Oil strainer installation
Oil strainer
1. Fasten bolts 1,2 and 3 tentatively.
2. Center cylinder block with the bolt hole of the bracket.
3. Fasten the bolt 3 tentatively.
4. Fasten the bolts 1,2 and 3 with the specific torques.
CAUTION KKLU-190
Assembly
Disassemble and inspect the safety valve of oil pump, if needed.
1. Remove safety valve from the cylinder block.
KKLU-191
KKLU-192
KKLU-193
SERVICE PROCEDURES LU-9
OVERHAUL
KKLU-631
LU-10 LUBRICATION SYSTEM
Disassembly
Remove the oil filter element
Using special tool, loosen the nuts of oil filter and oil cooler.
Assembly
Oil filter element installation.
1. Apply some oil to the new filter gasket.
2. Fasten the new filter by hand until the gasket touches the cover.
Then, using special tool, fasten it again by 1/4 – 1 rotation.
KKLU-201
TROUBLESHOOTING LU-11
TROUBLESHOOTING
Symptom Probable cause Remedy Remarks
Does not Low oil level
increase • Oil leakage in the cooling system Repair and add oil
oil pressure • Oil leakage
Poor oil viscosity
• Oil aging Replace
• Fuel added in oil
Faulty oil pressure switch Replace
Clogged oil filter element Replace element
Clogged oil strainer, Loosen oil line connector, Repair or replace
pipe crack faulty of relief valve and by pass valve
Abrasion or damage in oil pump Replace
Excessive oil Oil leakage in engine Repair or replace Refer Engine Body
consumption Oil leakage in crankshaft oil seal Repair or replace
Oil leakage in cooling system Repair or replace
• Defect of water jacket in oil cooler
Abnormal compression Check compression Refer Engine Body
INTAKE AND
EXHAUST
GENERAL .............................................................. IE - 2
SPECIFICATIONS ................................................. IE - 5
SERVICE PROCEDURES
GENERAL
Air Intake System
<5ton>
Duct assembly
Inter cooler
Air cleaner
<8ton>
Duct assembly
Air cleaner
Inter cooler
KKIE-006/KKIE-007
GENERAL IE-3
Aero town
Duct assembly
Inter cooler
Air cleaner
assembly
Turbo charger
KKIE-005
Aero town
Muffler assembly
Pipe assembly
Muffler inlet
Pipe assembly
Muffler outlet
KKIE-000
SPECIFICATIONS IE-5
SPECIFICATIONS
Engine model D6DA Remarks
Air cleaner type Dry air cleaner type
Element type Paper type
Super charger Turbo charger Water cooled
IE-6 INTAKE AND EXHAUST
SERVICE STANDARDS
Unit : mm
ITEM STANDARD LIMIT REMEDY REMARK
exhaust manifold
KKIE-248
Air leakage in inter cooler Doesn't have any air - Replace intercooler
leakage in 2.0kg/mm²
air pressure
KKIE-771
SPECIAL TOOLS IE-7
SPECIAL TOOL
clamp
KKST-024
IE-8 INTAKE AND EXHAUST
SERVICE PROCEDURE
Air Intake and Exhaust System
8 8
5
4
7 6
1 2 3
14
13
12
10
2EA 9
4EA
11
15
1. Exhaust manifold gasket 7. Exhaust manifold seal ring 13. Intake elbow 1
2. Spacer 8. Expand ring 14. Intake elbow 2
3. Exhaust manifold front 9. Intake pipe joint 15. Intake elbow pipe
4. Exhaust manifold middle 10. Air heater gasket (wire mash)
5. Exhaust manifold rear 11. Air heater
6. Intake manifold 12. Air heater gasket
SERVICE PROCEDURE IE-9
Installation
Intake Pipe Installation
Install the intake manifold.
Exhaust Manifold Assembly (Assembly Type)
1. As shown in the seal ring installation to the exhaust manifold,
install them by keeping the same distance between seal rings
Liquid gasket
to prevent the leak of gas and oil.
KKIE-802
Special tool: Exhaust manifold compression ring clamp (09285
– 8Y000)
Liquid gasket
KKIE-803
Upward
Expander ring
Downward
KKIE-811
KKIE-812
IE-10 INTAKE AND EXHAUST
Spacers (2)
Manifold
Assembling method Stud
Combination I
Gasket
Nuts (2)
I Except 7 and 9
Exhaust manifold
II 7, 9
Exhaust manifold
Stud
3. Fasten the flange nut by hands. II
Gasket
Nuts (1)
CAUTION Spacers (1) KKIE-813
KKIE-814
SERVICE PROCEDURE IE-11
<5ton>
Braket upper
2
Braket lower
1
7
4
8
5
6
9
<8.5ton>
2
Bracket upper
1
4
11 Bracket lower
7
6
9
8 5
10
12
Stay-air cleaner
Disassembly
1. Clamp-boot 8. Clamp hose
2. Duct assembly upper 9. Hose-air cleaner to engine
3. Rubber-boot 10. Resonator-rear
4. Resonator front 11. Band air cleaner
5. Clamp hose 12. Air cleaner assembly
6. Duct assembly lower
7. Clamp hose
<Aero Town>
4
3
Disassembly Procedure
1. Hose-duct to free cleaner
2. Free cleaner assembly
3. Duct air outlet
4. Hose-air cleaner to engine
5. Air cleaner assembly
6. Holder-air cleaner
Air Cleaner
6
Deterioration damage
5
Deterioration, 4
Gasket damage 3
2
1. Wing nut
1 2. Cover
3. Sealing
4. Wing nut
5. Element
6. Air cleaner body
KKIE-022
3. Inspection of element
After the element has been cleaned, put an electric lamp inside
the element to check for damage and pin holes. If there are thin
portions in the filter paper, replace the element. If the packing
on the top surface of the element is broken, replace the
packing.
4. Cleaning of air cleaner body
Clean the inside of the air cleaner body and discharge the
deposited dust.
KKIE-024
SERVICE PROCEDURE IE-15
Muffler
<5ton>
2.1~2.6 kgf.m
1
2.1~2.6 kgf.m
5 6
6
5 4 4
2 4~4.5 kgf.m
1
8
4~4.5 kgf.m
7
2.1~2.6 kgf.m
KKIE-010
IE-16 INTAKE AND EXHAUST
<8.5ton>
4.5~6.0 kg.m
4
3
2
6
1
5
1. Pipe assembly
2. Bracket pipe
3. Cushion rubber
4. Bracket muffler
5. Muffler assembly
6. Pipe assembly
<Aero town> 5
6
1
3
7
8
1. Gasket
4
2. Exhaust brake
3. Pipe assembly muffler inlet
4. Clamp
5. Muffler assembly
6. Cushion rubber
7. Bracket
8. Pipe assembly muffler outlet
KKIE-003/KKIE-001
SERVICE PROCEDURE IE-17
Turbo Charger
Piston ring
Oil inlet
Bearing housing
Compressor wheal
Shaft and turbine wheel
Oil outlet
Compressor cover
Exhaust gas inlet
Waste gate
KKIE-025
The turbocharger uses the energy of the exhaust gases to feed Exhaust gas
more air under pressure into the engine.
The exhaust gases are accelerated in the turbine housing and Compressed air
4
3
12
5
19
11
10
8 17
6
7
22
15
9
13
14
16 21
20
18
Management Instructions
Attentions in driving
1. Check the engine oil level, and check whether the oil pressure
increases normally after engine start.
2. Avoid from sudden start or acceleration immediately after
engine start and drive the vehicle after enough idling.
3. If abnormal conditions like strange noise, vibration, output
decrease or excessive smoke, pull over the car and check the
car.
4. Stop the engine after enough idling instead of stopping the
engine immediately after pull over. (Sudden engine stop may
damage the turbo charger)
CAUTION
If the car is driven without air-cleaner filter, dust and dirt
may cause a detrimental damage to engine and turbo-
charger. Check and replace the oil periodically since oil
deficiency, oil deterioration and pollution are critical causes
of engine and turbocharger defect. If the car is started or
accelerated suddenly after start, or engine is stopped
immediately after pull over, oil supply to the turbocharger
is discontinued to cause the bearing melting inside the
turbocharger, which rotates with high speed (90,000 – 100,
000 rpm). Therefore, perform enough idling.
Treatment instruction
1. Use the genuine parts when replacing air cleaner and engine
oil filter.
2. Clean and change the air cleaner filter periodically.
3. As for the engine oil, use the standard oil recommended by our
company, which is better or equivalent to API C, D class.
4. Check engine oil leaks or any abnormal noise from turbo-
charger frequently.
5. Check the exhaust pipe periodically to prevent gas leak.
IE-20 INTAKE AND EXHAUST
Intercooler
From turbocharger
The intercooler is the air -to-air heat exchange system using a
corrugated-fin heat exchanger installed in front of the radiator.
The intake air compressed by the turbocharger to have high
temperature is cooled through heat exchange with the
atmosphere. The resultant highdensity air is sent into the To inlet manifold
engine cylinders.
This improves the combustion efficiency and as a result, the
fuel economy and power output, while reducing harmful ex-
haust gases to a minimum. KKIE-009
TROUBLE SHOOTING IE-21
TROUBLE SHOOTING
Sympton Probalbe cause Remedy
Low output Insufficient intake air
o Loaded air cleaner element Clean
o Air suction (with dust and other foreign matter) Repair
from intake system
o Defective turbocharger
o Intake shutter kept closed Check
Low exhaust efficiency
o Deformed front pipe, muffler and/or tail pipe Replace
(large exhaust resistance)
o Exhaust brake valve kept closed Adjust
Whitish and much ex- Incorrect injection timing Adjust
haust gas Low compression pressure Check
Low quality fuel Replace
Defective turbocharger
o Oil leaks due to worn piston ring, and/or insert Replace
o Damaged oil seal due to clogged oil return pipe Replace
Dark and much exhaust Loaded air cleaner element Clean
gas Trouble in engine proper Check
Nonuniform fuel injection amount to cylinders Adjust
Incorrect injection timing Adjust
Abnormal noise and/or Poor connection of intake and exhaust systems Correct
vibration from intake Deformed front pipe, mufler or tail pipe(large exhaust resistance) Replace
and exhaust system
Turbo charger makes Rotor rubbing on adjacent parts beacause of worn bearings :
abnormal noises and o Failure of oil supply-clogged or damaged oil screen and oil line. Check oil line, condition
vibration o Unadequate oil filtering or solid matter in oil line. of oil and oil filter
o Contaminated oil
Unbalaced rotor Disassemble and repair.
o Foreign material in air inlet system or exhaust manifold and Also check air inlet
striking wheel system.
o Bent shaft
IE-22 INTAKE AND EXHAUST
GENERAL
The engine is cooled by forced circulation of coolant by the water pump.
KKCL-721
SPECIFICATION CL-3
SPECIFICATION
Item Specification Remark
SERVICE STANDARD
Unit : kgf-cm2
KKCL-236
0.9 0.75-1.05
KKCL-237
KKCL-239
CAUTION
Check the opening pressure of coolant filter cap valve written on the cap.
If the cap pressure is not correctly controlled, due to the abnormal high pressure of coolant system, hoses may
be disconnected and burnt and engine may be damaged.
SERVICE STANDARD CL-5
Tightening torque
Unit : kg·m
D6DA
Item Remark
Size Torque
Cooling fan nut and bolt M8 x 1.25 2.2
Cooling fan coupling nut and bolt M10 x 1.5 4.4
Water pump pulley and nut M10 x 1.5 4.8
CL-6 COOLING SYSTEM
SERVICE PROCEDURE
Cooling Pump
COMPONENTS
1. Fan coupling
2. Pulley center
3. Shaft assembly
4. Seal
5. Case
6. Gasket
7. Vane
8. Cover
OVERHAUL
KKCL-731
SERVICE PROCEDURE CL-7
Disassembly
Vane and shaft removal
Using the press, push the shaft end.
KKCL-222
KKCL-223
CAUTION
After removing seal from case, replace it with the new one.
(Do not reuse)
KKCL-224
Assembly
Shaft assembly installation
Insert shaft assembly into the case.
CAUTION
Let the bearing side coincides with shaft fringe.
KKCL-225
A: 18mm
KKCL-226
CL-8 COOLING SYSTEM
Seal Installation
1. Apply some liquid seal around the cooling seal and case
2. Install the seal.
CAUTION
Replace the seal with the new one.
KKCL-227
Vane assembly
Insert the vane into the shaft.
CAUTION
Push the vane until the vane face touches the shaft end.
KKCL-228
KKCL-229
KKEM-582
SERVICE PROCEDURE CL-9
Thermostat
Assembly chart
1
1. Thermostat cover
2
2. Gasket
3
3. Thermostat
4 4. Thermostat case
KKCL-761
CAUTION
Check the valve opening temperature (T1) written on the 0°C Temperature
10°C
thermostat seat. T1°C T2°C KKCL-232
Assembly KKCL-234
Radiator
Radiator consists of the upper tank, radiator core, lower tank and
Upper tank
other components. It functions to cool down the heated coolant
through circulating inside the engine. Coolant passes through the Radiator core
radiator core, which consists of many tubes and pins and goes back
to the water pump by way of upper tank and lower tank. The
external air cool coolant as it passes the radiator core. Lower tank
KKCL-236
Disassembly
Remove the radiator.
WARNING
To prevent the risk of burn, do not drain the coolant when the
engine and radiator are hot.
CAUTION
When disassembling or reassembling radiator, take care not
to damage the radiator core.
SERVICE PROCEDURE CL-11
Cooling Fan
COMPONENTS
2
T=250
T = torque : kgf-cm
1. Fan clutch
2. Cooling fan
T=480 3. Fan coupling
KKCL-781
3. Other factors
Check whether the temperature sensor (bimetal) contains dust
or mud. If it is the case, it may cause inconstant cooling,
overheating or overcooling. Remove the mud or dust from the
bimetal surface using brush or equivalents. Do not apply the
excessive force. Do not paint the fan or fan clutch.
CL-12 COOLING SYSTEM
TROUBLESHOOTING
Symptom Probable cause Remedy Remarks
Over heat Defection V-belt
• Defective tension Adjust
• Belt cut Replace
Clogged cooling pipe Clean
Faulty thermostat Replace
Faulty water pump
• Loosen water pump shaft with flange Replace
• Loosen water pump shaft with impeller
• Defect impeller
• Poor clearance impeller and case
Clogged radiator fin Clean
Faulty auto cooling fan coupling
• Faulty bi-metal Replace
• Faulty auto cooling fan coupling body
• Clogged bi-metal Clean
Faulty cooling fan Replace
Low coolant Add
Over cool Faulty thermostat Replace
Coolant is Faulty radiator hose
very fast • Loosen hose connection Retighten
deminish • Crack or damage cooling hose Replace
Faulty radiator
• Loosen radiator core from body Replace
• Loosen pressure cap
Faulty water pump
• Faulty seal Replace
• Faulty oil seal
• Defective pump gasket
Faulty oil cooler Replace Refer Lubrication
system
Defective thermostat gasket Replace
Faulty heater hose
• Loosen hose connection Retighten
• Crack or damage hose Replace
Faulty cylinder head gasket Replace Refer Engine
AIR
COMPRESSOR
GENERAL ............................................................. AC - 2
SPECIFICATIONS ................................................ AC - 3
SERVICE PROCEDURE....................................... AC - 6
GENERAL
Description
A 13
6 12
3
2 14 4
5 7
8
11 9
15
11
16
10
17
KKAC-031
SPECIFICATIONS AC-3
SPECIFICATIONS
ITEM SPECIFICATION REMARKS
KKAC-103
KKAC-112
D
Clearance between connect- 0.017-0.083 0.1 Replace
ing rod and crank pin
KKAC-113
AC-4 AIR COMPRESSOR
Unit : mm
ITEM STANDARD LIMIT REMEDY REMARKS
(skirt part)
KKAC-115
T=tightening
L=Loosening
KKAC-116
KKAC-121
KKAC-123
SERVICE STANDARD AC-5
Unit : mm
ITEM STANDARD LIMIT REMEDY REMARKS
ring
Oil ring 0.2-0.70 1.0
KKAC-124
KKAC-125
Bearing
holder
KKAC-126
AC-6 AIR COMPRESSOR
SERVICE PROCEDURE
Disassembly and Assembly
T=300~350
1
Do not disassembly the
cylinder head center bolt.
6
9 7
2 8
T=300
3
T=230~260
4
5 10 11
T=250~300
20 21 22
13
19
18
17
14 15
T=1,100~1.300
Disassembly
Remove the drive gear.
1. Remove the lock nut from the compressor drive gear.
CAUTION
Drive gear may be damaged, if lock nut is not fully loosened.
KKAC-071
2. Pull the gear form the shaft, and remove the woodruff key.
KKAC-072
CAUTION
• Since the piston rings are so brittle, which are made by
special forgery, handle with special care.
• When reusing the piston rings, align the parts orderly to
prevent the mis-assembly first of all.
CAUTION
Before disassembling pin, heat the piston for about 5 minutes
with the hot water of 80-90°C (176°F ~ 194°F).
KKAC-075
AC-8 AIR COMPRESSOR
KKAC-081
CAUTION
Before assembly, make sure to apply the engine oil to every
frictional part and replace the O-ring and gaskets with the new
ones.
CAUTION
Check whether the assembly marks coincide.
2. Apply the enough engine oil to the connecting rod bolts and
Assembly mark
threads, and fasten the bolts.
KKAC-082
KKAC-083
SERVICE PROCEDURE AC-9
KKAC-091
Limit: 1.0 mm
KKAC-092
Assemble piston
CAUTION
Apply the engine oil to the slippery places of the parts, and
Ring face
then assemble them.
1. Assemble the piston ring. When assembling piston ring to
piston, check whether the skirt is at the bottom and use special
tool. Assemble the piston ring as the ring face identification Identification mark
mark faces upward. KKAC-093
Top ring
No. 2 ring, Oil ring
No.3 ring
KKAC-093
CAUTION
Heat the piston for about 5 minutes with the hot water of
approximately 80-90°C (176-194°F). KKAC-094
AC-10 AIR COMPRESSOR
CAUTION
When assembling O-ring to cylinder liner and cylinder head, No.2 ring Oil ring
be careful not to be twisted.
CAUTION
Packing thickness (upper part, lower part).
Packing must be replaced after used once.
CAUTION
Do not apply the excessive force in assembling pin to the
holes.
Take care so that dust and dirt are not included.
Do not disassemble the cylinder head assembly (center bolt).
CAUTION
Abide by the fastening torque (300 – 350kg-cm ).
KKAC-102
Abide by the fastening torque of center bolt (250 – 300 kg-cm).
(Do not disassemble the center bolt nor apply any torque).
TROUBLE SHOOTING AC-11
TROUBLE SHOOTING
Sympton Probably cause Remedy
Malfunction of Unloader valve
unloader valve o Stickly Clean or replace
o Deflection or wear Repair or replace unloader
valve assembly
Air pipe and joints
o Air leakage Replace or tighten pipe joints
Pressure regulator
o Function Adjust and/or repair pressure
regulator.
Noisy operation Piston
o Wear of piston pin boss or piston pin Replace it
o Seized, damaged or worn connecting rod small end Replace it
o Worn piston or liner Replace it
o Damaged or seized piston Replace it
o Inclusion of foreign matter on top surface of the piston Replace piston
o Carbon deposit Clean piston
Valve
o Inlet valve is lowered excessively Repair or replace
o Loosened discharge valve holder Tighten it
Bearing
o Damaged or worn ball bearing and/or connecting Replace bearing
rod metal
Charging efficiency Valve
dropped o Abnormal wear, damage, or poor contact Replace valve assembly
Piston, liner, and piston rings
o Worn piston and liner Replace
o Seized piston Replace piston, piston rings
and liner
o Worn or broken piston ring Replace it
Air pipe and joints
o Leakage of high pressure air Replace or tighten pipe joint
o Clogged air pipe Replace
Air cleaner
o Clogged element Clean or replace element
AC-12 AIR COMPRESSOR