Tài liệu tháo lắp và sửa chữa động cơ CRDi trên ô tô Huyndai phần 2

Engine (D4FA DSL1.5) GENERAL ENGINE BLOCK TIMING SYSTEM COOLING SYSTEM TIMING CHAIN ENGINE AND TRANSAXLE ASSEMBLY LUBRICATION SYSTEM CYLINDER HEAD ASSEMBLY INTAKE AND EXHAUST SYSTEM EMA -2 ENGINE (D4FA - DSL1.5) GENERAL SPECIFICATIONS E284EBC0 Description Specifications (D4FA) General Type In-line, DOHC Number of cylinders Bore 75mm (2.9528in) Stroke 84.5mm (3.3268in) Total displacement 1,493 cc (91.11 cu.in) Compression ratio 17.8 : Firing order 1-3-4-2 Valve timing Intake valve Exhaust valve Opens (BTDC) Closes (ABDC) 34 Opens (BBDC) 46 Closes (ATDC) Cylinder head 0.03mm (0.0012in) for width 0.09mm (0.0035in) for length Flatness of gasket surface Flatness of manifold mounting surface Intake 0.025mm (0.0010in) for width 0.160mm (0.0063in) for length Exhaust 0.025mm (0.0010in) for width 0.160mm (0.0063in) for length Camshaft LH camshaft Intake 35.452 ~ 35.652mm (1.3957 ~ 1.4036in) Exhaust 35.700 ~ 35.900mm (1.4055 ~ 1.4134in) RH camshaft Intake 35.537 ~ 35.737mm (1.3991 ~ 1.4070in) Exhaust 35.452 ~ 35.652mm (1.3957 ~ 1.4036in) Cam height Journal outer Diameter LH camshaft 20.944 ~ 20.960mm (0.8246 ~ 0.8252in) RH camshaft 20.944 ~ 20.960mm (0.8246 ~ 0.8252in) Bearing oil clearance 0.040 ~ 0.077mm (0.0016 ~ 0.0030in) End play 0.10 ~ 0.20mm (0.0039-0.0079in) Valve Valve length Stem outer diameter Face angle Intake 93.0mm (3.6614in) Exhaust 93.7mm (3.6890in) Intake 5.455 ~ 5.470mm (0.2148 ~ 0.2154in) Exhaust 5.435 ~ 5.450mm (0.2140 ~ 0.2146in) 45.5 ~ 45.75 Limit GENERAL EMA -3 Description Specifications (D4FA) Thickness of valve head (margin) Intake 1.1mm (0.0433in) Exhaust 1.2mm (0.0472in) Valve stem to valve guide clearance Intake 0.030 ~ 0.057mm (0.0012 ~ 0.0022in) Exhaust 0.050 ~ 0.077mm (0.0020 ~ 0.0030in) Intake 5.500 ~ 5.512mm (0.2165 ~ 0.2170in) Exhaust 5.500 ~ 5.512mm (0.2165 ~ 0.2170in) Intake 31.3 ~ 31.7mm (1.2323 ~ 1.2480in) Exhaust 31.3 ~ 31.7mm (1.2323 ~ 1.2480in) Intake 0.8 ~ 1.4mm (0.0315 ~ 0.0551in) Exhaust 1.2 ~ 1.8mm (0.0472 ~ 0.0709in) Intake 45 ~ 45 30’ Exhaust 45 ~ 45 30’ Limit Valve guide Inner diameter Length Valve seat Width of seat contact Seat angle Valve spring Free length 44.9mm (1.7677in) 17.5±0.9kg/32.0mm(38.6±2.0 lb/1.2598in) Load 31.0±1.6kg/23.5mm(68.3±3.5 lb/0.9252in) Out of squareness Less than 1.5 Cylinder block Cylinder bore 75.000 ~ 75.030mm (2.9528 ~ 2.9539in) Flatness of gasket surface Less than 0.05mm (0.0020in) (Overhaul) Less than 0.03mm (0.0012in) (Per Cylinder) Piston Piston outer diameter 74.930 ~ 74.960mm (2.9500 ~ 2.9512in) Piston to cylinder clearance 0.060 ~ 0.080mm (0.0024 ~ 0.0031in) Ring groove width No ring groove 1.83 ~ 1.85mm (0.0720 ~ 0.0728in) No ring groove 1.82 ~ 1.84mm (0.0717 ~ 0.0724in) Oil ring groove 3.02 ~ 3.04mm (0.1189 ~ 0.1197in) No ring 0.09 ~ 0.13mm (0.0035 ~ 0.0051in) No ring 0.08 ~ 0.12mm (0.0031 ~ 0.0047in) Oil ring 0.03 ~ 0.07mm (0.0012 ~ 0.0028in) No ring 0.20 ~ 0.35mm (0.0079 ~ 0.0138in) No ring 0.35 ~ 0.50mm (0.0138 ~ 0.0197in) Oil ring 0.20 ~ 0.40mm (0.0079 ~ 0.0157in) Piston ring Side clearance End gap Piston pin Piston pin outer diameter 27.995 ~ 28.000mm (1.1022 ~ 1.1024in) EMA -4 ENGINE (D4FA - DSL1.5) Description Specifications (D4FA) Piston pin hole inner diameter 28.004 ~ 28.010mm (1.1025 ~ 1.1028in) Piston pin hole clearance 0.004 ~ 0.015mm (0.0002 ~ 0.0006in) Connecting rod small end hole inner diameter 28.022 ~ 28.034mm (1.1032 ~ 1.1037in) Connecting rod small end hole clearance 0.022 ~ 0.039mm (0.0009 ~ 0.0015in) Limit Connecting rod Connecting rod big end inner diameter 49.000 ~ 49.018mm (1.9291 ~ 1.9298in) Connecting rod bearing oil clearance 0.025 ~ 0.043mm (0.0010 ~ 0.0017in) Side clearance 0.050 ~ 0.302mm (0.0020 ~ 0.0119in) 0.4mm (0.0157in) Crankshaft Main journal outer diameter 53.972 ~ 53.990mm (2.1249 ~ 2.1256in) Pin journal outer diameter 45.997 ~ 46.015mm (1.8109 ~ 1.8116in) Main bearing oil clearance 0.024 ~ 0.042mm (0.0009 ~ 0.0017in) End play 0.08 ~ 0.28mm (0.0031 ~ 0.110in) Flywheel Runout 0.1mm (0.0039in) Oil pump Side clearance Inner rotor 0.040 ~ 0.085mm (0.0016 ~ 0.0033in) Outer rotor 0.040 ~ 0.090mm (0.0016 ~ 0.0035in) Body clearance 0.120 ~ 0.185mm (0.0047 ~ 0.0073in) Relief valve opening pressure 490±49.0kpa (5±0.5kg/cm², 71±7.1psi) Engine oil Oil quantity (Total) 5.3 L (5.60 US qt, 4.66 lmp qt) Oil quantity (Oil pan) 4.8 L (5.07 US qt, 4.22 lmp qt) Oil quantity (Oil filter) 0.5 L (0.53 US qt, 0.44 lmp qt) Oil quality Above API CH-4, Above ACEA B4 Oil pressure (Idle) (Oil temperature : 80 C) 78.4kpa (0.8kg/cm², 11.3psi) Cooling system Cooling method Forced circulation with cooling fan Coolant quantity 5.3 ~ 5.5L (5.60 ~ 5.81US qt, 4.66 ~ 4.84lmp qt) Thermostat Radiator cap Type Wax pellet type Opening temperature 85±1.5 C (185.0±2.7 F) (Lift : 0.35mm(0.0138in)) Pull opening temperature 100 C (212 F) (Lift : 8mm(0.3150in)) Main valve opening pressure 93.16 ~ 122.58kpa (0.95 ~ 1.25kg/cm², 13.51 ~ 17.78psi) Vacuum valve opening pressure 0.98 ~ 4.90 kpa (0.01 ~ 0.05kg/cm², 0.14 ~ 0.71 psi) 0.13mm (0.0051in) GENERAL EMA -5 Description Specifications (D4FA) Water temperature sensor Type Resistance Thermister type 20 C (68 F) 2.45±0.14 k 80 C (176 F) 0.3222 k Limit EMA -6 ENGINE (D4FA - DSL1.5) TIGHTENING TORQUE Item Quantity Tightening torque N.m kgf.m lb-ft Cylinder block Engine support bracket bolt 42.2 ~ 53.9 4.3 ~ 5.5 31.1 ~ 39.8 Piston cooling oil jet bolt 8.8 ~ 12.7 0.9 ~ 1.3 6.5 ~ 9.4 Drive belt auto tensioner bolt 18.6 ~ 27.5 1.9 ~ 2.8 13.7 ~ 20.3 Drive belt auto tensioner mounting bracket bolt 18.6 ~ 27.5 1.9 ~ 2.8 13.7 ~ 20.3 Engine mounting bracket and body fixing bolt 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0 Engine mounting insulator and engine mounting support bracket fixing nut 68.6 ~ 93.2 7.0 ~ 9.5 50.6 ~ 68.7 Engine mounting support bracket and engine support bracket fixing bolt 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0 Engine mounting support bracket and engine support bracket fixing nut 49.0 ~63.7 5.0 ~6.5 36.2 ~47.0 Transaxle mounting bracket and body fixing bolt 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0 Transaxle mounting insulator and transaxle support bracket fixing bolt 68.6 ~ 93.2 7.0 ~9.5 50.6 ~68.7 Front roll stopper bracket and sub frame fixing bolt 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0 Front roll stopper insulator and front roll stopper support bracket fixing bolt,nut 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0 Rear roll stopper bracket and sub frame fixing bolt 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0 Rear roll stopper insulator and rear roll stopper support bracket fixing bolt,nut 49.0 ~63.7 5.0 ~6.5 36.2 ~47.0 Connecting rod cap bolt 12.7 + 90 1.3 + 90 9.4 + 90 Crankshaft main bearing cap bolt (long) 10 24.5 + 90 2.5 + 90 18.1 + 90 Crankshaft main bearing cap bolt (short) 10 32.4 ~ 36.3 3.3 ~ 3.7 23.9 ~ 26.8 Flywheel bolt (M/T) 68.6 ~ 78.5 7.0 ~ 8.0 50.6 ~ 57.9 Drive plate bolt (A/T) 68.6 ~ 78.5 7.0 ~ 8.0 50.6 ~ 57.9 Timing chain cover bolt (8 X 70) 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5 Timing chain cover bolt (8 X 60) 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5 Timing chain cover bolt (8 X 35) 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5 Timing chain cover bolt (6 X 35) 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7 Timing chain cover bolt (6 X 28) 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7 Timing chain case bolt (8 X 22) 24.5 ~ 30.4 2.5 ~ 3.1 18.1 ~ 22.4 Timing chain case bolt (8 X 32) 18.6 ~ 27.5 1.9 ~ 2.8 13.7 ~ 20.3 Timing chain case bolt (6 X 35) 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7 Engine mounting Main moving system Timing chain GENERAL EMA -7 Item Quantity Tightening torque N.m kgf.m lb-ft Engine hanger (front) 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1 Crankshaft pulley bolt 225.6 ~ 245.2 23.0 ~ 25.0 166.4 ~ 180.8 Camshaft chain sprocket bolt 68.6 ~ 73.5 7.0 ~ 7.5 50.6 ~ 54.2 High pressure pump chain sprocket bolt 64.7 ~ 74.5 6.6 ~ 7.6 47.7 ~ 55.0 Timing chain guide (1) bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7 Timing chain guide (2) bolt 9.8 ~ 13.7 1.0 ~ 1.4 7.2 ~ 10.1 Timing chain "A" auto tensioner bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7 Timing chain "C" auto tensioner bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7 Engine cover bolt 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7 Cylinder head cover bolt 13 6.9 ~ 9.8 0.7 ~ 1.0 5.1 ~ 7.2 Camshaft bearing cap bolt (Reamer bolt) 16 12.7 ~ 13.7 1.3 ~ 1.4 9.4 ~ 10.1 Camshaft bearing cap bolt (Standard bolt) 12.7 ~ 13.7 1.3 ~ 1.4 9.4 ~ 10.1 Engine hanger bolt (Front) 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1 Engine hanger bolt (Rear) 47.1 ~ 51.0 4.8 ~ 5.2 34.7 ~ 37.6 Cylinder head bolt 10 49.0+90 +120 5.0+90 +120 36.2+90 +120 Water pump pulley bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7 Water pump bolt (8 X 50) 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1 Water pump bolt (8 X 70) 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1 Thermostat housing bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7 Thermostat housing nut 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7 Water return pipe assembly bolt 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1 Water temperature sensor 24.5 ~ 34.3 2.5 ~ 3.5 18.1 ~ 25.3 Water outlet fitting nut 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1 Oil filter assembly bolt 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5 Oil cooler assembly bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7 Oil filter upper cap 24.5 2.5 18.1 Oil level gauge bolt 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5 Oil pan bolt (6 X 20) 16 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7 Oil pan bolt (6 X 65) 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7 Oil pan bolt (6 X 85) 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7 Oil pan and transaxle fixing bolt 29.4 ~ 41.2 3.0 ~ 4.2 21.7 ~ 30.4 Oil pan drain plug 34.3 ~ 44.1 3.5 ~ 4.5 25.3 ~ 32.5 Oil screen bolt 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5 Oil screen nut 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7 Oil pressure switch 14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~ 15.9 Cylinder head Cooling system Lubrication system EMA -8 ENGINE (D4FA - DSL1.5) Item Quantity Tightening torque N.m kgf.m lb-ft Intake and exhaust system Intake manifold and cylinder head fixing nut 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5 Intake manifold and cylinder head fixing bolt 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5 Exhaust manifold and cylinder head fixing nut 29.4 ~ 34.3 3.0 ~ 3.5 21.7 ~ 25.3 Exhaust manifold heat cover and exhaust manifold fixing bolt 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5 WCC assembly fixing nut 29.4 ~ 34.3 3.0 ~ 3.5 21.7 ~ 25.3 Air cleaner lower cover fixing bolt 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2 Throttle body and surge tank fixing bolt 18.6 ~ 27.5 1.9 ~ 2.8 13.7 ~ 20.3 Exhaust manifold and front muffler fixing nut 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4 Front muffler fixing clip bolt 29.4 ~ 39.2 3.0 ~ 4.0 21.7 ~ 28.9 Front muffler and center muffler fixing nut 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4 Center muffler and main muffler fixing nut 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4 GENERAL EMA -9 COMPESSION PRESSURE INSPECTION EA53A61E NOTE Always use a fully charged battery to obtain engine speed of 300rpm or more NOTE 4) If the there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure Warm up and stop engine Allow the engine to warm up to normal operating temperature Remove the injectors(A) (Refer to FL Gr.) A NOTE This measurement must be done in as short a time as possible Compression pressure(Standard) : 2,353kPa (24.0kg/cm², 341psi) (260 rpm) Minimum pressure : 2,059kPa (21.0kg/cm², 298psi) Difference between each cylinder : 294.20kPa (3.0kg/cm², 42.67psi) or less 5) LCGF003A Check the cylinder compression pressure 1) Insert a compression gauge into the injector hole ECKD001X 2) Fully open the throttle 3) While cranking the engine, measure the compression pressure Repeat step 1) though 3) for each cylinder If the cylinder compression in or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat step 1) through 3) for cylinders with low compression • If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged • If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket Reinstall the injectors EMA -10 ENGINE (D4FA - DSL1.5) TROUBLESHOOTING E2396869 Symptom Engine misfire with abnormal internal lower engine noises Engine misfire with abnormal valve train noise Engine misfire with coolant consumption Suspect area Remedy Loose or improperly installed engine flywheel Repair or replace the flywheel as required Worn piston rings (Oil consumption may or may not cause the engine to misfire.) Inspect the cylinder for a loss of compression Repair or replace as required Worn crankshaft thrust bearings Replace the crankshaft and bearings as required Stuck valves (Carbon buildup on the valve stem can cause the valve not to close properly.) Repair or replace as required Excessive worn or mis-aligned timing chain Replace the timing chain and sprocket as required Worn camshaft lobes Replace the camshaft and valve lifters • Faulty cylinder head gasket and/or cracking or other damage to the cylinder head and engine block cooling system • Coolant consumption may or may not cause the engine to overheat • Inspect the cylinder head and engine block for damage to the coolant passages and/or a faulty head gasket • Repair or replace as required Engine misfire with excessive oil consumption Worn valves, valve guides and/or valve stem oil seals Repair or replace as required Worn piston rings (Oil consumption may or may not cause the engine to misfire) Inspect the cylinder for a loss of compression Repair or replace as required Engine noise on start-up, but only lasting a few seconds Incorrect oil viscosity Drain the oil Refill with the correct viscosity oil Worn crankshaft thrust bearing Inspect the thrust bearing and crankshaft Repair or replace as required Upper engine noise, regardless of engine speed Low oil pressure Repair or replace as required Broken valve spring Replace the valve spring Worn or dirty valve lifters Replace the valve lifters Stretched or broken timing chain and/or damaged sprocket teeth Replace the timing chain and sprockets Worn timing chain tensioner, if applicable Replace the timing chain tensioner as required Worn camshaft lobes Inspect the camshaft lobes Replace the camshaft and valve lifters as required Worn valve guides or valve stems Inspect the valves and valve guides, then repair as required Stuck valves (Carbon on the valve stem or valve seat may cause the valve to stay open.) Inspect the valves and valve guides, then repair as required EMA -84 ENGINE (D4FA - DSL1.5) THERMOSTAT RADIATOR Place the thermostat in thermostat housing with new gasket Install the radiator Install the radiator upper brack(A, B) Install the water outlet fitting(A) Tightening torque : 19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1 lb-ft) Tightening torque : 6.9 ~ 10.8N.m (0.7 ~ 1.1kgf.m, 5.1 ~ 8.0lb-ft) A A ACJF045A ADJF048A Fill with engine coolant Start engine and check for leaks B ACJF046A COOLING SYSTEM EMA -85 Install the cooling fan mounting bolts(A, B) Install the upper radiator hose(A) and lower radiator hose(B) Tightening torque : 6.9 ~ 10.8N.m (0.7 ~ 1.1kgf.m, 5.1 ~ 8.0lb-ft) Install the ATF(Automatic Transaxle Fluid) Oil cooler hoses(C) A A B C ACJF043A B ACJF044A Connect the fan motor connector(A) A ACJF042A ACJF010A Fill with engine coolant Start engine and check for leaks EMA -86 ENGINE (D4FA - DSL1.5) LUBRICATION SYSTEM COMPONENT E206D0D5 19.6 ~ 26.5 (2.0 ~ 2.7, 14.5 ~ 19.5) 9.8 ~ 11.8 (1.0 ~ 1.2, 7.2 ~ 8.7) 19.6 ~ 26.5 (2.0 ~ 2.7, 14.5 ~ 19.5) 19.6 ~ 26.5 (2.0 ~ 2.7, 14.5 ~ 19.5) 9.8 ~ 11.8 (1.0 ~ 1.2, 7.2 ~ 8.7) 9.8 ~ 11.8 (1.0 ~ 1.2, 7.2 ~ 8.7) TORQUE : N.m(kgf.m, lbf.ft) Oil filter cap Oil filter Oil filter housing & oil cooler assembly Timing chain cover Oil pan Oil strainer LCGF124A LUBRICATION SYSTEM EMA -87 OIL AND FILTER REPLACEMENT CAUTION • Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer • Exercise caution in order to minimize the length and frequency of contact of your skin to used oil Wear protective clothing and gloves Wash your skin thoroughly with soap and water, or use water-less hand cleaner, to remove any used engine oil Do not use gasoline, thinners, or solvents • In order to preserve the environment, used oil and used oil filter must be disposed of only at designated disposal sites 4) EF3CA4CE After the rubber seal seats, tighten the oil filter clockwise Tightening torque : 24.5N.m(2.5kgf.m, 18.1lb-ft) Refill with engine oil 1) Clean and install the oil drain plug with a new gasket Tightening torque : 34.3 ~ 44.1N.m (3.5 ~ 4.5kgf.m, 25.3 ~ 32.5lb-ft) 2) Fill wih fresh engine oil Oil Capacity Total : 5.3 L (5.60 US qt, 4.66 lmp qt) Oil pan : 4.8 L (5.07 US qt, 4.22 lmp qt) Oil filter : 0.5 L (0.53 US qt, 0.44 lmp qt) Drain the engine oil CAUTION 1) Remove the oil filler cap 2) Loosen the oil filter cap until O-ring(C) appears Be careful for oil not to overflow 3) Remove the oil drain plug, and drain the oil into a container When filling engine oil, fill half of full capacity and the remainings in 10 minutes 3) Install the oil filler cap Start engine and check for oil leaks Replace the oil filter(B) Recheck the engine oil level 1) INSPECTION Remove the oil filter upper cap(A) Check the engine oil quality Check the oil deterioration, entry of water, discoloring of thinning If the quality is visibly poor, replace the oil Check the engine oil level After warning up the engine and then minutes after the engine stop, oil level should be between the "L" and "F" marks in the dipstick If low, check for leakage and add oil up to the "F" mark A C B D NOTE Do not fill with engine oil above the "F" mark ACGF035A 2) Replace the O-ring(C,D) of oil filter cap with a new one Inspect the threads and O-ring(C,D) Wipe off the seat on the oil filter cap, then apply a light coat of oil to the oil filter upper cap O-ring(C,D) 3) Install the new oil filter by hand to the upper cap EMA -88 ENGINE (D4FA - DSL1.5) SELECTION OF ENGINE OIL Recommended API classification : CH-04 OR ABOVE Recommended ACEA classification : B4 OR ABOVE Recommended SAE viscosity grades : Temperature range anticipated before next oil change 40 104 Recommended SAE viscosity number 30 20W 15W 10W 40 68 20 50 10 32 14 -10 -20 -4 -25 -13 -30 -40 5W -30 -40 0W -30 *1 *2 *1 Restricted by driving condition and environment Not recommended for sustained high speed vehicle operation LDJF007A NOTE For best performance and maximum protection of all types of operation, select only those lubricants which : Satisfy the requirement of the API classification Have proper SAE grade number for expected ambient temperature range Lubricants that not have both an SAE grade number and API service classification on the container should not be used LUBRICATION SYSTEM REMOVAL EMA -89 DISASSEMBLY E706E185 E4CE52B1 OIL PUMP RELIEF PLUNGER Drain the engine oil Remove the drive belts Turn the crankshaft pulley, and align its groove with timing mark "T" of the timing chain cover Remove the Oil pan Remove the timing chain cover EMA-18~22, step1~24) Remove the oil pump cover(A) from the timing chain cover Remove the relief plunger Remove the plug(A), spring(B) and relief plunger(C) (Refer to C B A A ACGF116A LCGF115A Remove the inner rotor and outer rotor EMA -90 ENGINE (D4FA - DSL1.5) INSPECTION REASSEMBLY E1596F2A Inspect the relief plunger Coat the plunger with engine oil and check that it falls smoothly into the plunger hole by its own weight If it does not, replace the relief plunger If necessary, replace the front case Inspect the rotor side clearance Using a feeler gauge and precision straight edge, measure the clearance between the rotors and precision straight edge Side clearance Outer rotor 0.04 ~ 0.09mm (0.0016 ~ 0.0035in) Inner rotor 0.04 ~ 0.085mm (0.0016 ~ 0.0033in) If the side clearance is greater than maximum, replace the rotors as a set If necessary, replace the front case E7FFCFF4 RELIEF PLUNGER Install the relief plunger Install relief plunger(C) and spring(B) into the front case hole, and install the plug(A) Tightening torque : 25.5 ~ 34.3N.m (2.6 ~ 3.5kgf.m, 18.8 ~ 25.3lb-ft) C B A ACGF116A LUBRICATION SYSTEM INSTALLATION EMA -91 E465BA84 OIL PUMP Install the oil pump 1) Place the inner and outer rotors into front case with the marks facing the oil pump cover side 2) Install the oil pump cover(A) to timing chain cover with the screws Tightening torque : 5.9 ~ 8.8N.m (0.6 ~ 0.9kgf.m, 4.3 ~ 6.5lbf.ft) A LCGF115A Check that the oil pump turns freely Install the timing chain cover (Refer to EMA-29~33) Install the oil pan Install the drive belts Fill with engine oil EMA -92 ENGINE (D4FA - DSL1.5) INTAKE AND EXHAUST SYSTEM INTAKE MANIFOLD E57F3CD0 COMPONENT 21.6 ~ 27.5 (2.2 ~ 2.8, 15.9 ~ 20.3) 29.4 ~ 34.3 (3.0 ~ 3.5, 21.7 ~ 25.3) 29.4 ~ 34.3 (3.0 ~ 3.5, 21.7 ~ 25.3) 29.4 ~ 34.3 (3.0 ~ 3.5, 21.7 ~ 25.3) 14.7 ~ 19.6 (1.5 ~ 2.0, 10.8 ~14.5) 14.7 ~ 19.6 (1.5 ~ 2.0, 10.8 ~14.5) 9.8 ~ 14.7 (1.0 ~ 1.5, 7.2 ~ 10.8) 21.6 ~ 27.5 (2.2 ~ 2.8, 15.9 ~ 20.3) 9.8 ~ 11.8 (1.0 ~ 1.2, 7.2 ~ 8.7) 14.7 ~ 19.6 (1.5 ~ 2.0, 10.8 ~14.5) 9.8 ~ 11.8 (1.0 ~ 1.2, 7.2 ~ 8.7) TORQUE : Nm(kgf.m, Ib-ft) Intake manifold Intake manifold gasket Swirl valve actuator EGR valve & pipe assembly Catalytic converter assembly Turbo charger oil return pipe Turbo charger & exhaust manifold assembly Exhaust manifold gasket LDJF008A INTAKE AND EXHAUST SYSTEM EMA -93 EXHAUST PIPE COMPONENT 29.4 ~ 39.2 (3.0 ~ 4.0, 21.7 ~ 28.9) 29.4 ~ 39.2 (3.0 ~ 4.0, 21.7 ~ 28.9) TORQUE : Nm(kgf.m, Ib-ft) Front muffler Center muffler Main muffler LDJF009A EMA -94 REMOVAL ENGINE (D4FA - DSL1.5) E7366CB8 Remove the swirl valve actuator rod(A) INTAKE MANIFOLD Remove the vacuum solenoid valve(A) A Tightening torque : 7.8 ~ 9.8 Nm (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft) KDNF001B A Remove the swirl valve actuator(A) Tightening torque : Bolt(B) : 9.8 ~ 11.8 Nm (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft) Bolt(C) : 6.9 ~ 10.8 Nm (0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lb-ft) ADJF030A Remove the engine harness protector(A) mounting bolts Tightening torque : 7.8 ~ 9.8 Nm (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft) B A C ADJF033A A Remove the high pressure pipe(A) (Refer to FL Gr.) ADJF031A A ADJF034A INTAKE AND EXHAUST SYSTEM EMA -95 Remove the fuel temperature sensor mounting bolt(A) (Refer to FL Gr.) B D D C A A C ADJF053A ADJF035A Remove the vacuum pipe(A) mounting bolt Remove the intake manifold(A) Tightening torque : 14.7 ~ 19.6 Nm (1.5 ~ 2.0 kgf.m, 10.8 ~ 14.5 lb-ft) Tightening torque : 6.9 ~ 10.8 Nm (0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lb-ft) A A EDNG001A ADJF036A Remove the EGR cooler and EGR valve assembly(A) Tightening torque : Nut(B) : 29.4 ~ 34.3 Nm (3.0 ~ 3.5 kgf.m, 21.7 ~ 25.3 lb-ft) Bolt(C) : 21.6 ~ 27.5 Nm (2.2 ~ 2.8 kgf.m, 15.9 ~ 20.3 lb-ft) Bolt Nut(D) : 14.7 ~ 19.6 Nm (1.5 ~ 2.0 kgf.m, 10.8 ~ 14.5 lb-ft) 10 Remove the intake manifold gasket(A) A LCGF033A 11 Installation is in the reverse order of removal EMA -96 ENGINE (D4FA - DSL1.5) EXHAUST MANIFOLD Remove the heat protector(A) B Tightening torque : 14.7 ~ 19.6 Nm (1.5 ~ 2.0 kgf.m, 10.8 ~ 14.5 lb-ft) D D C A C ADJF053A Remove the catalytic converter stay(A) Tightening torque : 21.6 ~ 27.5 Nm (2.2 ~ 2.8 kgf.m, 15.9 ~ 20.3 lb-ft) A LCGF117A Remove the water hose (A) from the EGR cooler and the thermostat housing A ADJF040A A ADJF038A Remove the catalytic converter(A) Tightening torque : 29.4 ~ 34.3 Nm (3.0 ~ 3.5 kgf.m, 21.7 ~ 25.3 lb-ft) Remove the EGR cooler and the EGR valve assembly(A) Tightening torque : Nut(B) : 29.4 ~ 34.3 Nm (3.0 ~ 3.5 kgf.m, 21.7 ~ 25.3 lb-ft) Bolt(C) : 21.6 ~ 27.5 Nm (2.2 ~ 2.8 kgf.m, 15.9 ~ 20.3 lb-ft) Bolt Nut(D) : 14.7 ~ 19.6 Nm (1.5 ~ 2.0 kgf.m, 10.8 ~ 14.5 lb-ft) A ADJF041A INTAKE AND EXHAUST SYSTEM EMA -97 Remove the inter cooler hose(A) and the oil return pipe(B) Tightening torque : Nut(C) : 9.8 ~ 14.7 Nm (1.0 ~ 1.5 kgf.m, 7.2 ~ 10.8 lb-ft) Bolt(D) : 14.7 ~ 19.6 Nm (1.5 ~ 2.0 kgf.m, 10.8 ~ 14.5 lb-ft) Remove the turbo charger and exhaust manifold assembly(A) Tightening torque : 29.4 ~ 34.3 Nm (3.0 ~ 3.5 kgf.m, 21.7 ~ 25.3 lb-ft) C B A A ADJF043A D ADJF051A Remove the exhaust manifold gasket(A) Remove the eye bolt(A) from the turbo charger oil feeding pipe Tightening torque : 13.7 ~ 18.6 Nm (1.4 ~ 1.9 kgf.m, 10.1 ~ 13.7 lb-ft) A A LCGF037A 10 Installation is in the reverse order of removal LCGF118A EMA -98 ENGINE (D4FA - DSL1.5) EXHAUST PIPE Remove the front muffler heat protector(A) Remove the main muffler(A) Tightening torque : 29.4 ~ 39.2 Nm (3.0 ~ 4.0 kgf.m, 21.7 ~ 28.9 lb-ft) Tightening torque : 7.8 ~ 11.8 Nm (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft) Remove the front muffler(B) Tightening torque : 29.4 ~ 39.2 Nm (3.0 ~ 4.0 kgf.m, 21.7 ~ 28.9 lb-ft) A ACJF054A A B ADJF026A Remove the center muffler(A) Tightening torque : 29.4 ~ 39.2 Nm (3.0 ~ 4.0 kgf.m, 21.7 ~ 28.9 lb-ft) A ACJF050A Installation is in the reverse order of removal ... 1 .2, 7 .2 ~ 8.7) 15 13 14 19.6 ~ 26 .5 (2. 0 ~ 2. 7, 14.5 ~ 19.5) 12 9.8 ~ 11.8 (1.0 ~ 1 .2, 7 .2 ~ 8.7) 42. 2 ~ 53.9 (4.3 ~ 5.5, 31.1 ~ 39.8) 9.8 ~ 11.8 (1.0 ~ 1 .2, 7 .2 ~ 8.7) 19.6 ~ 24 .5 (2. 0 ~ 2. 5,... 2. 5, 14.5 ~ 18.1) 11 10 22 5.6 ~ 24 5 .2 (23 .0 ~ 25 .0, 166.4 ~ 180.8) 18.6 ~ 27 .5 (1.9 ~ 2. 8, 13.7 ~ 20 .3) 18.6 ~ 27 .5 (1.9 ~ 2. 8, 13.7 ~ 20 .3) 9.8 ~ 11.8 (1.0 ~ 1 .2, 7 .2 ~ 8.7) TORQUE : N.m(kgf.m,... (0.00 12 ~ 0.0 022 in) Exhaust 0.050 ~ 0.077mm (0.0 020 ~ 0.0030in) Intake 5.500 ~ 5.512mm (0 .21 65 ~ 0 .21 70in) Exhaust 5.500 ~ 5.512mm (0 .21 65 ~ 0 .21 70in) Intake 31.3 ~ 31.7mm (1 .23 23 ~ 1 .24 80in)