Hyundai D4EB EM (D4EB - Diesel 2.2) Engine Workshop Manual

Brand: Hyundai

Model: D4EB EM (D4EB - Diesel 2.2)

Category: Engine

Type: Engine Workshop Manual

Engine (D4EB -

Diesel 2.2)

GENERAL

ENGINE AND TRANSAXLE ASSEMBLY

TIMING SYSTEM

CYLINDER HEAD ASSEMBLY

ENGINE BLOCK

COOLING SYSTEM

LUBRICATION SYSTEM

INTAKE AND EXHAUST SYSTEM

EM -2 ENGINE (D4EB - DIESEL 2.2)

GENERAL

SPECIFICATIONS E18A7ADE

Description

Specifications

Limit

General

Type 1-type, SOHC

Number of cylinder

Bore 87mm(3.4252in.)

Stroke 92mm(3.6220in.)

Total displacement

2,188cc

Compression ratio

17.3:1

Firing order

1-3-4-2

Valve timing

Opens (BTDC)

Intake valve

Closes (ABDC)

Opens (BBDC)

Exhaust valve

Closes (ATDC)

Cylinder head

Less than 0.03mm (0.0012in) for width

Less than 0.09mm (0.0035in) for length

Flatness of gasket surface

Less than 0.012mm (0.0005in) for 51 × 51 mm

Camshaft

Intake 34.697mm (1.3660in)Cam height

Exhaust 34.571mm (1.3611in)

Journal outer diameter 27.947 ~ 27.960mm(1.1003 ~ 1.1008in.)

Bearing oil clearance 0.040 ~ 0.074mm (0.0016 ~ 0.0029in)

End play 0.05 ~ 0.15mm (0.0020-0.0059in)

Valve

Intake 95.5 ~ 95.9mm(3.7598 ~ 3.7756in.)Valve length

Exhaust 95.2 ~ 95.6mm(3.7480 ~ 3.7638in.)

Intake 5.933 ~ 5.953mm(0.2366 ~ 0.2344in.)Stem outer diameter

Exhaust 5.905 ~ 5.925mm(0.2325 ~ 0.2333in.)

Face angle

45.5 ~46

Intake 1.5 ~ 1.7mm(0.0591 ~ 0.0669in.)Thickness of valve-

head(margin)

Exhaust 1.2 ~ 1.4mm(0.0472 ~ 0.0551in.)

Intake 0.022 ~ 0.067mm(0.0009 ~ 0.0021in.)Valve stem to valve guide

clearance

Exhaust 0.050 ~ 0.095mm(0.0020 ~ 0.0037in.)

Valve guide

GENERAL EM -3

Description

Specifications

Limit

Intake 36.25 ~ 36.75mm(1.4272 ~ 1.4468in.)Length

Exhaust 36.25 ~ 36.75mm(1.4272 ~ 1.4468in.)

Valve spring

Free length 38.8mm (1.5276in)

Load 21.25±1.3kg/32.0mm(47.4±2.9 lb/1.2598in)

Outofsquareness

Less than 1.5

Valve seat

Seat angle

44 ~46

Intake 0.95 ~ 1.25mm(0.0374 ~ 0.0492in.)Valve contacting width

Exhaust 0.8825 ~ 1.0825mm(0.0347 ~ 0.0426in.)

Piston

Piston outer diameter 86.92 ~ 86.95mm (3.4220 ~ 3.4232in)

Piston to cylinder clearance 0.07 ~ 0.09mm (0.0028 ~ 0.0035in)

No. 1 ring

groove

2.415 ~ 2.445mm (0.0951 ~ 0.0963in.)

No. 2 ring

groove

2.06 ~ 2.08mm (0.0811 ~ 0.0819in.)

Ring groove width

Oil ring groove 3.02 ~ 3.04mm (0.1189 ~ 0.1197in.)

Piston ring

No. 1 ring 0.083 ~ 0.137mm (0.0033 ~ 0.0054in)

No. 2 ring 0.065 ~ 0.110mm (0.0026 ~ 0.0043in)

Side clearance

Oil ring 0.03 ~ 0.07mm (0.0012 ~ 0.0028in)

No. 1 ring 0.25 ~ 0.40mm (0.0098 ~ 0.0157in)

No. 2 ring 0.40 ~ 0.60mm (0.0157 ~ 0.0236in)

End gap

Oil ring 0.20 ~ 0.40mm (0.0079 ~ 0.0157in)

Piston pin

Piston pin outer diameter 27.995 ~ 28.000mm (1.1022 ~ 1.1024in)

Connecting rod

Connecting rod bearing oil clearance 0.024 ~ 0.042mm(0.0009 ~ 0.0017in.)

Crankshaft

Main journal outer diameter 60.002 ~ 60.020mm (2.3623 ~ 2.3630in.)

Pin journal outer diameter 50.008 ~ 50.026mm (1.9688 ~ 1.9695in.)

Main bearing oil clearance 0.024 ~ 0.042mm(0.0009 ~ 0.0017in.)

0.1mm

End play 0.09 ~ 0.32mm (0.0035 ~ 0.126in)

Cylinder block

Cylinder bore 87mm(3.4252in.)

Flywheel

Runout 0.45mm(0.0177in.)

Oil pump

EM -4 ENGINE (D4EB - DIESEL 2.2)

Description

Specifications

Limit

Tip clearance 0.12 ~ 0.20mm(0.0047 ~ 0.0079in.)Side clearance

Radial clearance 0.13 ~ 0.23mm(0.0051 ~ 0.0091in.)

Cooling system

Cooling method Forced circulation with electrical fan

Coolant quantity 8.4L(8.88US qt, 7.39lmp qt)

Type Wax pellet type

Opening

temperature

85±1.5 C (185±34.7 F)

Fully opened

temperature

100 C(213F)

Thermostat

Full lift 8mm (0.3150in.) or more

GENERAL EM -5

TIGHTENING TORQUE

ITEM N.m kgf.m lb.ft

Engine mounting bracket nuts/bolts(engine side)

63.7 ~ 83.4 6.5 ~ 8.5 47.0 ~ 61.5

Engine mounting bracket nuts(body side)

63.7 ~ 83.4 6.5 ~ 8.5 47.0 ~ 61.5

Engine mounting insulator bolt

78.5 ~ 98.1 8.0 ~ 10.0 57.9 ~ 72.3

Engine support bracket bolt

42.2 ~ 53.9 4.3 ~ 5.5 31.1 ~ 39.8

Front roll stopper bracket sub frame member bolt

49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0

Front roll stopper insulator bolt/nut

78.5 ~ 98.1 8.0 ~ 10.0 57.9 ~ 72.3

Rear roll stopper bracket sub frame member bolt

49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0

Rear roll stopper insulator bolt/nut

78.5 ~ 98.1 8.0 ~ 10.0 57.9 ~ 72.3

Transaxle mounting bracket bolt(transaxle side)

63.7 ~ 83.4 6.5 ~ 8.5 47.0 ~ 61.5

Transaxle mounting bracket bolt(body side)

63.7 ~ 83.4 6.5 ~ 8.5 47.0 ~ 61.5

Cylinder head cover bolt

7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2

Camshaft sprocket bolt

122.6 ~ 137.3 12.5 ~ 14.0 90.4 ~ 101.3

Camshaft bearing cap bolt

26.0 ~ 28.9 2.7 ~ 3.0 19.2 ~ 21.3

Air cleaner body mounting bolt

7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2

Crankshaft bolt

196.1 ~ 205.9 20.0 ~ 21.0 144.7 ~ 151.9

Damper pulley bolt

29.4 ~ 33.3 3.0 ~ 3.4 21.7 ~ 24.6

Cylinder head bolt(at cold)

63.7 + 120 +120 6.5 + 120 + 120 47.0 + 120 +120

Timing belt auto tensioner bolt

49.0 ~ 53.9 5.0 ~ 5.5 36.2 ~ 39.8

Drive belt auto tensioner bolt

25.5 ~ 30.4 2.6 ~ 3.1 18.8 ~ 22.4

Timing belt auto tensioner adjusting bolt

9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Drive belt idler bolt

45.1 ~ 50.0 4.6 ~ 5.1 33.3 ~ 36.9

Oil pan bolt

9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Oil pan drain plug

34.3 ~ 44.1 3.5 ~ 4.5 25.3 ~ 32.5

Oil screen

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

Oil filter fitting

47.1 ~ 51.0 4.8 ~ 5.2 34.7 ~ 37.6

Oil filter

22.6 ~ 24.5 2.3 ~ 2.5 16.6 ~ 18.1

Oil jet bolt

8.8 ~ 12.7 0.9 ~ 1.3 6.5 ~ 9.4

Oil pump cover bolt

7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2

Oil pump assembly

19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5

Oil lever gauge

9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Plug cap

7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2

Timing belt upper cover

7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7

Timing belt lower cover

7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7

Flywheel

68.6 ~ 78.5 7.0 ~ 8.0 50.6 ~ 57.9

Connecting rod cap bolt

24.5 + 90 2.5 + 90 18.1 + 90

Water pump and cylinder block bolt

47.1 ~ 51.0 4.8 ~5.2 34.7 ~ 37.6

EM -6 ENGINE (D4EB - DIESEL 2.2)

ITEM N.m kgf.m lb.ft

Water inlet mounting bolt

9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Crankshaft bedplate bolt(15mm)-bearing

cap bolt(M11 x 1.5P)

19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1

Crankshaft bedplate bolt(12mm)-bearing

cap bolt(M8 x 1.25P)

29.4 ± 2.0 + 120 3.0 ± 0.2 + 120 21.7 ± 1.4 + 120

Balance shaft assembly mounting bolt

33.0 ~ 37.0 3.4 ~ 3.8 24.4 ~ 27.3

Intake manifold and cylinder head

mounting bolt/nut

52.0 ~ 55.9 5.3 ~ 5.7 38.3 ~ 41.2

Exhaust manifold and cylinder head mounting nut

14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~ 15.9

Turbocharger supporting bolt

29.4 ~ 34.3 3.0 ~ 3.5 21.7 ~ 25.3

Turbocharger heat protector mounting bolt

34.3 ~ 44.1 3.5 ~ 4.5 25.3 ~ 32.5

Heater pipe protector mounting bolt

16.7 ~ 21.6 1.7 ~ 2.2 12.3 ~ 15.9

Exhaust manifold and front muffler mounting nut

7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2

Frontmufflerandcatalyticconvertormounging nut

39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4

Catalyticcovertor and center mufflermounting nut

39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4

Center muffler and main muffler mounting nut

39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4

Subframe mounting bolts/nuts

68.6 ~ 88.3 7.0 ~ 9.0 50.6 ~ 65.1

Subframe mounting bolts

137.3 ~ 156.9 14.0 ~ 16.0 101.3 ~ 115.7

Injector holder mounting bolts

39.2 ~ 53.9 4.0 ~ 5.5 28.9 ~ 39.8

GENERAL EM -7

TROUBLESHOOTING E72E93DD

Symptom Suspect

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.

Engine misfire with abnormal

internal lower engine noises.

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 belt

Replace the timing belt and sprocket

as required.

Engine misfire with abnormal

valve train noise.

Worn camshaft lobes. Replace the camshaft and valve lifters.

Engine misfire with coolant

consumption.

• Faulty cylinder head gasket and/or

cranking or other damage to the

cylinder head and engine block

cooling system.

• Coolant consumption may not cause

theenginetooverheat.

• Inspect the cylinder head and

engine block for damage to

the coolant passages and/or a

faulty head gasket.

• Repair or replace as required.

Worn valves, valve guides and/or

valve stem oil seals.

Repair or replace as required.Engine misfire with excessive

oil consumption.

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.

Incorrect oil viscosity. • Drain the oil

• Install the correct viscosity oil.

Engine noise on start-up, but

only lasting a few seconds.

Worn crankshaft thrust bearing. • Inspect the thrust bearing and

crankshaft.

• Repair or replace as required.

Low oil pressure. Repair or replace as required.

Broken valve spring. Replace the valve spring

Worn or dirty valve lifters. Replace the valve lifters.

Stretchedorbrokentimingbeltand/or

damaged sprocket teeth.

Replace the timing belt and sprockets.

Worn timing chain tensioner, if applicable.

Replace the timing chain tensioner

as required.

Worn camshaft lobes. • Inspect the camshaft lobes.

• Replace the timing camshaft and

valve lifters as required.

Worn valve guides or valve stems.

Inspect the valves and valve guides,

then repair as required.

Upperengine noise,regardless

of engine speed.

Stuck valves.

(Carbon on the valve stem or valve seat

may cause the valve to stay open.)

Inspect the vlaves and valve guides,

then repair as required.

EM -8 ENGINE (D4EB - DIESEL 2.2)

Symptom Suspect

Remedy

Low oil pressure.

Repair or replace damaged components

as required.

Loose or damaged flywheel. Repair or replace the flywheel.

Damaged oil pan, contacting the

oil pump screen.

• Inspect the oil pan.

• Inspect the oil pump screen.

• Repair or replace as required.

Oil pump screen loose, damage

or restired.

• Inspect the oil pump screen.

• Repair or replace as required.

Excessive piston-to-cylinder bore

clearance.

• Inspect the piston and cylinder bore.

• Repair as required.

Excessivepistonpin-toboreclearance. • Inspect the piston, piston pin and

the connecting rod.

• Repair or replace as required.

Excessive connecting rod bearing

clearance

Inspect the following components

and repair as required.

• The connecting rod bearings.

• The connecting rods.

• The crankshaft.

• The crankshaft journal.

Excessive crankshaft bearing clearance Inspect the following components

and repair as required.

• The crankshaft bearings.

• The crankshaft journals.

Lower engine noise,regardless

of engine speed.

Incorrect piston, piston pin and

connecting rod installation

• Verifythepistonpinsandconnecting

rods are installed correctly.

• Repair as required.

Low oil pressure Repair or replace as required.

Excessive connecting rod bearing

clearance

Inspect the following components

and repair as required.

• The connecting rod bearings.

• The connecting rods.

• The crankshaft

Engine noise under load

Excessive crankshaft bearing clearnace Inspect the following components,

and repair as required.

• The crankshaft bearings.

• The crankshaft journals.

• The cylinswe block crankshaft

bearing bore.

GENERAL EM -9

Symptom Suspect

Remedy

Hydraulically cylinder

• Coolant/antifreeze in cylinder.

• Oil in cylinder.

• Fuel in cylinder

1. Removeinjectorsandcheckforfluid.

2. Inspect for broken head gasket.

3. Inspect for cranked engine black

or cylinder head.

4. Inspect for a sticking fuel injector

and/or leaking fuel regulator.

Broken timing chain and/or timing

chain gears.

1. Inspect timing chain and gears.

2. Repair as required.

Material cylinder

• Broken valve

• Piston material

• Foreign meterial

1. Inspect cylinder for damaged

components and/or foreign

materials.

2. Repair or replace as required.

Seized crankshaft or connecting

rod bearings.

1. Inspect crankshaft and connecting

rod bearing.

2. Repair as required.

Bent or broken connecting rod. 1. Inspect connectong rods.

2. Repair as required.

Engine will not crank-crakshaft

will not rotate

Broken crankshaft 1. Inspect crankshaft.

2. Repair as required.

EM -10 ENGINE (D4EB - DIESEL 2.2)

SPEICAL SERVICE TOOLS E764F48B

Tool (Number and name) Illustration Use

Camshaft oil seal installer

(09212-27100)

ACIE003A

Installation of the camshaft oil seal

Valve spring compressor

(09222-27300)

ACIE004A

Removal and installation of intake

and exhaust valves

Valve stem oil seal installer

(09222-27200)

ACIE005A

Installation of valve stem oil seals

Crankshaft rear oil seal installer

(09231-27000)

ACIE006A

Installation of the crankshaft real oil seal

Front case oil seal installer

(09231-27100)

ACIE003A

Installation of the front case oil se

GENERAL EM -11

Tool (Number and name) Illustration Use

Injector oil seal installer

(09351-27401)

ACIE007A

Installation of the injector oil seal

Compression gauge adapter

(09351-27000)

(09351-27100)

ACIE002A

Checking engine compression pressure

Oil

filter wrench

(092

63-2E000)

ACI

E008A

Rem

oval and installation of oil filter

For t

he rest area except Europe LHD

Oil filter wrench

(09263-27000)

ACIE008A

Removal and installation of oil filter

For Europe LHD

EM -12 ENGINE (D4EB - DIESEL 2.2)

ENGINE AND TRANSAXLE

ASSEMBLY

REMOVAL E1706BBE

CAUTION

• Make sure jacks and safety stands are placed

properly.

• Make sure the vehicle will not roll off stands

and fall while you are working under it.

• Use fender covers to avoid damaging painted

surface.

• Unplug the wiring connectors carefully while

holding the connector portion to avoid dam-

age.

• Mark all wiring and hoses to avoid miscon-

nection.

Also, be sure that they do not contact other

wiring or hoses or interfere with other parts.

1. Remove the air duct(A).

SCMEM6001D

2. Remove the battery terminals and the battery assem-

bly(A).

SCMEM6002D

3. Remove the intercooler system.

1) Disconnect the connector(C) related to the

BPS(Boost Pressure Sensor)(A) and the

VGT(Variable Geometry Turbocharger) sole-

noid valve(B).

SCMEM6003D

2) Disconnect the intercooler hoses(A).

3) Disconnect the VGT(Variable Geometry Tur-

bocharger) solenoid valve vaccum hoses(B).

4) Remove the intercooler hose assembly(C).

Tightening torque :

7.8 ~ 11.8N.m(0.8~1.2kgf.m, 5.8 ~ 8.7lb-ft)

SCMEM6004D

ENGINE AND TRANSAXLE ASSEMBLY EM -13

4. Remove the under cover(A).

SCMEM6005D

5. Drain engine coolant and remove the radiator cap to

speed draining.

6. Remove the drain plug(A) and the radiator lower

hose(B).

SCMEM6006D

7. Remove the air cleaner assembly.

1) Disconnect the AFS(Air Flow Sensor) connec-

tor(A).

2) After removing the air intake hose clamp, loosen

the air cleaner assembly mounting bolts(2EA).

3) Remove the air cleaner assembly(B).

SCMEM6007D

8. Remove the battery tray(A), loosening the mounting

bolts(4EA).

SCMEM6008D

9. Disconnect the ECU(Engine Control Unit) connec-

tors(A) and remove its mounting bolts(B).

SCMEM6009D

EM -14 ENGINE (D4EB - DIESEL 2.2)

10. Remove the engine cover(A).

SCMEM6010D

11. Remove the hose between the intercooler and the in-

take system.

12. Remove the engine wirings.

1) Disconnectthe railpressure sensorconnector(A)

and the ECT(Engine Coolant Temperature) sen-

sor connector(B).

SCMEM6011D

2) Disconnect the camshaft position sensor con-

nector(A), the rail pressure regulator connec-

tor(B), the swirl valve actuator connector(C), the

electronic throttle body actuator connector(D),

the oil pressure switch connector(E) and the

crankshaft position sensor connector(F) and re-

move the connector/wire harness protector(G).

SCMEM6012D

3) Disconnect the EGR(Exhaust Gas Recirculation)

solenoid valve connector(A), the glow plug(B),

the fuel pressure regulator valve connector(C),

the injector(D) and the connector/wire harness

protector(E).

4) Disconnect the ground lines(F).

SCMEM6013D

13. Disconnect the ground line from the cylinder head(A).

SCMEM6014D

ENGINE AND TRANSAXLE ASSEMBLY EM -15

14. Remove the fuel hose(A) and the fuel temperature

sensor connector(B).

SCMEM6015D

15. Disconnect the brake booster vacuum hose(A) and

the heater hoses(B).

SCMEM6016D

16. Disconnect the upper radiator hose(A).

SCMEM6017D

17. Disconnect the battery cables to the fuse relay box

by removing the nuts.

18. Disconnect the front lamp connector(B).

SCMM16004L

19. Remove the wirings related to the transaxle.

1) Disconnect the back up lamp switch connec-

tor(A).

2) Disconnect the neutral switch connector(B).

SCMEM6019D

3) Disconnect the vehicle speed sensor.

EM -16 ENGINE (D4EB - DIESEL 2.2)

20. Remove the shift cable assembly(A), the clip(B) and

the pin(C).

SCMM16005L

21. Remove the concentric slave cylinder with clamping

the tube(A).

22. Remove the groung line mounting bolts(B) from the

transaxle.

SCMEM6021D

23. Drain power steering oil.

24. Disconnect the power steering oil hose(A).

SCMEM6022D

25. Remove the c

lips(B) from the right side wheel

guide(A).

SCMEM6023D

26. Disconnect the power steering lower hose(A).

SCMEM6024D

ENGINE AND TRANSAXLE ASSEMBLY EM -17

27. Recover air-conditioning refrigerant and remove the

high low pressure hoses.(Refer to ’HA’ group).

28. Remove the steering column universal joint mounting

bolt(A).

29. Disconnect the EPS(Electronic Power Steering) sen-

sor connector(B).

SCMEM6025D

30. Remove the front wheels and tires.

31. Remove the wheel speed sensor(A).(Refer to ’SS’

group).

SCMEM6060D

32. After removing the mounting bolts(A) and the

caliper(B), bind it up to the coil spring of the strut.

SCMDS6005D

33. Remove the strut assembly by removing the stabi-

lizer bar(A) link nuts(B) and the strut lower mounting

bolts(B).(Refer to ’SS’ group).

SCMSS6504D

SCMEM6062D

EM -18 ENGINE (D4EB - DIESEL 2.2)

34. Remove the front muffler(A).

Tightening torque :

39.2 ~ 58.8N.m(4.0 ~ 6.0kgf.m, 28.9 ~ 43.4lb-ft)

SCMEM6044D

35. Dis

connect the propeller shaft(A).(Refer to ’DS’

gro

up).

Tightening torque :

49.0 ~ 68.6N.m(5.0 ~ 7.0kgf.m, 36.2 ~ 50.6lb-ft)

SCMEM6026D

NOTE

The propeller shaft is tightened by left-handed screw

bolts.

36. Installajackundertheengineandtransaxleassembly

for supporting.

37. Remove the engine stay(A) and the engine mounting

bracket(B).

Tightening torque :

Bolts, Nut(C): 39.2 ~ 53.9N.m(4.0 ~ 5.5kg.m,

28.9 ~ 39.8lb-ft)

Bolts, Nut(D): 63.7 ~ 83.4N.m(6.5 ~ 8.5kg.m,

47.0 ~ 61.5lb-ft)

SCMEM6027D

38. Rem

ove the transaxle mounting(A).(Refer to ’MT/AT’

gro

up).

SCMEM6028D

39. Remove the subframe mounting bolts and nuts.

Tightening torque :

Bolts, Nuts: 68.6 ~ 88.3N.m(7.0 ~ 9.0kg.m,

50.6 ~ 65.1lb-ft)

Bolts: 137.3 ~ 156.9N.m(14.0 ~ 16.0kg.m,

101.3 ~ 115.7lb-ft)

ENGINE AND TRANSAXLE ASSEMBLY EM -19

40. Remove the engine and transaxle assembly by lifting

the vehicle.

NOTE

When removing the engine and transaxle assembly,

be careful not to damage any surrounding parts or

body components.

INSTALLATION EE394374

Installation is in the reverse order of removal.

Perform the following :

• Adjust the shift cable.

• Adjust the throttle cable.

• Refill the engine with engine oil.

• Refill the transaxle with fluid.

• Refill the radiator and reservoir tank with engine

coolant.

• Place the heater control knob on HOT position.

• Bleed air from the cooling system.

- Start engine and let it run until it warms up. (until

the radiator fan operates 3 or 4 times.)

- Turn Off the engine. Check the level in the radia-

tor, add coolant if needed. This will allow trapped

air to be removed from the cooling system.

- Puttheradiatorcapontightly,thenruntheengine

again and check for leaks.

• Clean the battery posts and cable terminals with

sandpaper assemble them, then apply grease to

prevent corrosion.

• Inspect for fuel leakage.

- After assemble the fuel line, turn on the ignition

switch (do not operate the starter) so that the fuel

pump runs for approximately two seconds and

fuel line pressurizes.

- Repeat this operation two or three times, then

check for fuel leakage at any point in the fuel line.

EM -20 ENGINE (D4EB - DIESEL 2.2)

TIMING

SYSTEM

COMPONENTS E32DA029

NOTE

· See page EM-26 for how to postion the crankshaft and

pulley before installing the belt.

· Mark the direction of rotation on the belt before removing

· Do not use the upper cover and low cover for storing

removed items.

· Clean the upper cover and low cover before installing.

7.8 ~ 11.8 (0.8 ~ 1.2, 5.75 ~ 8.70)

10 45 ~ 49 (4.5 ~ 4.9, 33.19 ~ 36.14)

43 ~ 55 (4.3 ~ 5.5,

31.72 ~ 40.57)

7.8 ~ 11.8 (0.8 ~ 1.2

5.75 ~ 8.70)

185 ~ 195 (18.5 ~ 19.5, 136 ~ 144)

50 ~ 55

(5.0 ~ 5.5,

36.88 ~ 40.57)

125 ~ 140

(12.5 ~ 14.0,

92.19 ~ 103.26)

26 ~ 31 (2.6 ~ 3.1,

19.18 ~ 22.86)

TORQUE : N.m (kgf.m, lb-ft)

46 ~ 51

(4.6 ~ 5.1,

33.93 ~ 37.62)

30 ~ 34 (3.0 ~ 3.4, 22 ~ 25)

1. Damper pulley

2. Timing belt lower cover

3. Engine support bracket

4. Timing belt upper cover

5. Timing belt

6. Alternator and vacuum pump assembly

7. Power steering pump

8. Air conditioning compressor

9. Camshaft sprocket

10. Timing belt idler

11. Timing belt tensioner

12. Idler

SCMM16001L

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Hyundai D4EB EM (D4EB - Diesel 2.2) Engine Workshop Manual

Brand: Hyundai

Model: D4EB EM (D4EB - Diesel 2.2)

Category: Engine

Type: Engine Workshop Manual

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Hyundai D4EB EM (D4EB - Diesel 2.2) Engine Workshop Manual

Hyundai D4EB EM (D4EB - Diesel 2.2) Engine Workshop Manual

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