Professional Documents
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SECTION
00 DI01
ENGINE ASSEMBLY
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
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI01-3
Y220_01001
1. Coolant reservoir
6. Fuse box
2. FFH device
7. Battery
8. Fuel filter
ENGINE ASSEMBLY
DI ENG SM - 2004.4
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI01-4
Engine Structure
Front View
Rear View
Y220_01002
9. Auto tensioner
6. Alternator
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE ASSEMBLY
DI ENG SM - 2004.4
DI01-5
Top View
Y220_01003
25. Injector
ENGINE ASSEMBLY
DI ENG SM - 2004.4
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI01-6
Y220_01004
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
modulator
ENGINE ASSEMBLY
DI ENG SM - 2004.4
DI01-7
Specifications
Description
Specification
D27DT/5-cylinder
Engine
Type/Number of cylinders
Cylinder
86.2
Stroke (mm)
92.4
Displacement (cc)
2696
Compression ratio
18:1
170/4,000
34.7/1,800
Idle speed
Valve
750 50 rpm
750 50 rpm
Intake
Exhaust
Camshaft
Type
Fuel system
Fuel type
Opens (BTDC)
16
Closes (ABDC)
33
Opens (BBDC)
46
Closes (ATDC)
21
DOHC
Low sulfur diesel
Vane pump in HP pump
Oil specification
Lubrication type
6.8 ~ 8.3
Oil capacity ( )
Cooling system
Cooling type
Thermostat: Fully
Open: 100C)
Opening
temperature (C)
Type
Coolant capacity ( )
ENGINE ASSEMBLY
DI ENG SM - 2004.4
85
WAX pellet type
11.5
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI01-8
Torque [Nm]
Output [PS]
Speed [rpm]
Y220_00025
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE ASSEMBLY
DI ENG SM - 2004.4
DI01-9
Speed [rpm]
Y220_00026
ENGINE ASSEMBLY
DI ENG SM - 2004.4
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI01-10
GENERAL DIAGNOSIS
Condition
Hard Starting
Malfunction of
(With normal
Ignition System
cranking)
Faulty fuse.
Decline of
Compression
Pressure
Malfunction of
Ignition System
Decline of
Compression
Pressure
Others
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Correction
Malfunction of
Fuel System
Lack of Engine
Power
Probable Cause
ENGINE ASSEMBLY
DI ENG SM - 2004.4
DI01-11
Dragging brakes.
Decline of
Compression
Pressure
Malfunction of
Ignition System
Others
Rough Engine
Idling
Decline of
Compression
Pressure
Malfunction of
Fuel System
Malfunction of
Ignition System
Others
Engine Hesitate
(Upon pressing
accelerating
pedal, the
engine makes
delayed response This
situation is
remarkable
when cruising or
starting.)
ENGINE ASSEMBLY
DI ENG SM - 2004.4
Correction
Probable Cause
Others
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI01-12
Overtheated
Engine
Malfunction of
Fuel System
Malfunction of
Ignition System
Others
Lack of coolant.
Refill coolant.
Refill oil.
Others
Excessive
Detonation
(According to
the opening
range of Malfunction of
metallic is
made with
abnormal
explosion )
Overheat
Malfunction of
Cooling System
Malfunction of
Lubrication
System
Other
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Correction
Probable Cause
ENGINE ASSEMBLY
DI ENG SM - 2004.4
DI01-13
Excessive
Consumption of
Engine Oil
Malfunction of
Fuel System
Malfunction of
Ignition System
Malfunction of
Cooling System
Others
Refill oil.
Leakage of
Engine Oil
Oil Mixing in
Combustion
Chamber
Low Oil
Pressure
ENGINE ASSEMBLY
DI ENG SM - 2004.4
Correction
Probable Cause
Malfunction of
Lubrication
System
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI01-14
Piston, Ring,
Cylinder Noise
Connecting Rod
Noise
Crankshaft
Noise
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Correction
Probable Cause
Adjust or replace.
ENGINE ASSEMBLY
DI ENG SM - 2004.4
DI01-15
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.
4.5 If you still cannot locate the leak, try using the
powder or black light and dye method.
Powder Method
Seals
The fluid level/pressure is too high.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI01-16
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.
Y220_01005
Specifications
Compression ratio
18 : 1
Test temperature
Compression pressure
32 bar
Minimum value
18 bar
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Max. 3 bar
ENGINE ASSEMBLY
DI ENG SM - 2004.4
DI01-17
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.
Y220_01006
15 Nm
Y220_01007
Y220_01008
ENGINE ASSEMBLY
DI ENG SM - 2004.4
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI01-18
Y220_01009
At whole engine
Max. 25 %
Max. 10 %
At piston ring
Max. 20 %
Notice
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE ASSEMBLY
DI ENG SM - 2004.4
DI01-19
TIGHTENING TORQUE
NO.
Size
Quantity
Tightening Torque
Oil nozzle
M6 x 22
10 1
M11 x 62
12
M9 x 52
Rear cover
M6 x 20
10 1
Oil pump
M8 x 35SOC
25 2.5
M6 x 20
10
10 1
M6 x 16
10 1
M6 x 40
10 1
M6 x 60
10 1
M6 x 70
10 1
M8 x 80SOC
25 2.5
Flywheel
M10 x 30
Crankshaft hub
M18 x 50
M6 x 20
24
10 1
M6 x 35
10 1
M6 x 38
10 1
M6 x 40
25 2.5
M8 x 40
25 2.5
M14 x 1.5-8-1
65 5
M7 x 16
20 2 x 90 + 10
M8 x 25
M8 x 50
M12 x 177
11
M12 x 158
Step3: 3 x 90 + 10
M8 x 60
24
25 2.5
M8
10
15 1.5
25 2.5
90 10
1
2
3
8
9
10
Name
T.G.C.C
Oil pan
11
12
13
14
15
Camshaft cap
16
Stud bolt
17
M11 x 52
55 5
90 10
40 5
90 10
45 5
90 10
325 33
90 10
25 2.5
Step1: 20 Nm 2 Nm
Step2: 85 Nm 5 Nm
18
Chain tensioner
M22
65 5
19
M14
22 2.2
ENGINE ASSEMBLY
DI ENG SM - 2004.4
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI01-20
NO.
20
Name
Auto tensioner
Size
Quantity
Tightening Torque
M8 x 45(LOWER)
32 3
M12 x 90
82 6
21
M6 x 50
10 1
22
M6 x 12
10 1
23
M6 x 12
10 1
24
Alternator bracket
M8 x 32
25 2.5
25
Alternator
M10 x 90
46 4.6
26
M8 x 95
46 4.6
M8 x 25
25 2.5
assembly
M8 x 60
25 2.5
M6 x 14
10 1.0
bracket assembly
M8 x 16
25 2.5
M8 x 45
25 2.5
M8 x 130
25 2.5
27
28
29
Intake manifold
30
Bracket
M6 x 16
10 1.0
31
Knock sensor
M8 x 28
20 2.6
32
M8 x 16
12 1.7
33
M6 x 16
10 1.0
34
Exhauster manifold
M8
10
40 4
35
M8
25 2.5
36
32 3.2
37
Nut
M8
25 2.5
38
Combination bolt
M8 x 22
25 2.5
39
25 2.5
20 2.0
M6 x 16 (T/C side)
10 1.0
10 1.0
M8 x 22
25 2.5
M6 x 16
10 1.0
M8 x 22
35 2.0
M6 x 16
10 1.0
M8 x 16
25 2.5
M8
35 2.0
44
M5
15 3
45
Vacuum pump
M6 x 20
10 1.0
M6 x 25
10 1.0
M6 x 65
10 1.0
M6 x 85
10 1.0
M6 x 35
21
23 2.3
40
41
42
43
46
47
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE ASSEMBLY
DI ENG SM - 2004.4
DI01-21
NO.
Name
Size
Quantity
Tightening Torque
M6 x 16SOC
10 1.0
48
Vacuum modulator
49
M6 x 16
10 1.0
50
M6 x 16
10 1.0
M8 x 35SOC
25 2.5
M8 x 50SOC
25 2.5
M8 x 55SOC
25 2.5
M8 x 35SOC
25 2.5
51
52
53
M6 x 60
54
M6 x 19
10 1.0
55
M6 x 16
10 1.0
56
M5 x 17
0.8 0.4
57
GAP
58
59
Wiring
60
61
62
63
64
ENGINE ASSEMBLY
DI ENG SM - 2004.4
10 1.0
180 + 20
0.7 ~ 1.5
1
M6 x 16
10 1.0
M8 x 16
25 2.5
M8 x 40
25 2.5
M8 x 100
25 2.5
NUT
25 2.5
0.765 ~ 1.055
0.05 ~ 0.31
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI01-22
Right
2. Transmission Mounting
Y220_01010
Notice
ENGINE ASSEMBLY
DI ENG SM - 2004.4
DI01-23
Y220_01011
Y220_01012
12 1.2 Nm
Y220_01013
Y220_01014
ENGINE ASSEMBLY
DI ENG SM - 2004.4
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
Y220_01016
Y220_01017
Y220_01021
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE ASSEMBLY
DI ENG SM - 2004.4
DI01-25
10. Loosen the hose clamp on intake air hose of turbo charger
and remove the intake air hose.
Y220_01022
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.
Y220_01018
13. Loosen the clamps and remove the intake air hose from
the turbo charger.
Y220_01020
Y220_01023
ENGINE ASSEMBLY
DI ENG SM - 2004.4
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
17. Remove the power steering inlet pipe and the outlet hose
from the power steering pump.
Notice
25 2.5 Nm
Y220_01028
10 Nm
Y220_01029
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE ASSEMBLY
DI ENG SM - 2004.4
DI01-27
19. Remove the supply inlet, supply outlet and return hose
from the fuel filter.
Notice
Y220_01030
Y220_01031
Y220_01032
Y220_01033
ENGINE ASSEMBLY
DI ENG SM - 2004.4
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
Y220_01035
Note
25 2.5 Nm
25 2.5 Nm
Y220_01036
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
Cooling fan pulley bolt
10 1.0 Nm
Y220_01038
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE ASSEMBLY
DI ENG SM - 2004.4
DI01-29
27. Remove the radiator shroud.
Installation Notice
Tightening torque
10 1.0 Nm
Y220_01039
Note
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.
Y220_01041
Note
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
55 5 Nm
ENGINE ASSEMBLY
DI ENG SM - 2004.4