Download Print this page

Advertisement

WORKSHOP
MANUAL
for
S
Engine Series
Applicable to S250S, S250P, S250J, S220S, S220P model
Service Department. Technical Information Edition 1st

Advertisement

   Summary of Contents for Hyundai Seasall S250S

  • Page 1

    WORKSHOP MANUAL Engine Series Applicable to S250S, S250P, S250J, S220S, S220P model Service Department. Technical Information Edition 1st...

  • Page 2

    S Engine Series Engine Mechanical System Engine Mechanical System General Cooling System Timing System Cylinder Head Assembly Engine Block Lubrication System Intake and Exhaust System Coupling System...

  • Page 3

    Engine Mechanical System General Information General Information Specifications...

  • Page 4

    Engine Mechanical System General Information Specifications...

  • Page 5

    Engine Mechanical System General Information Specifications...

  • Page 6

    Engine Mechanical System General Information Specifications Description Specifications Limit ACEA Above B4 Service oil quality should confirm to ACEA or API classification Above CH-4 Oil quality 15W-40 -15℃ above 10W-30 -20℃ ~ 40℃ 5W-30 -25℃ ~ 40℃ 0W-30 10℃ below Oil pressure(at idle) 0.8kg/㎠...

  • Page 7

    Engine Mechanical System General Information Tightening Torques Item N∙m Kgf∙m lb-ft Cylinder block Oil jet mounting 29.4~34.3 3.0~3.5 21.7~25.3 Connecting rod cap bolt 27.5~31.4+88°~92° 2.8~3.2+88°~92° 20.3~23.1+88°~92° Bedplate bolt 61.8~65.7+120°~124° 6.3~6.7+120°~124° 45.6~48.5+120°~124° Flywheel 127.4~137.2 13.0~14.0 94.0~101.3 Timing system Drive belt tensioner upper mounting 82.6~84.3 7.4~8.6 53.6~62.2...

  • Page 8

    Engine Mechanical System General Information Tightening Torques Item N∙m kgf∙m lb-ft Camshaft position sensor mounting 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7 58.8 + 88°~92° 6.0 + 88°~92° 43.4 + 88°~92° Cylinder head bolt +118°~122° +118° ~122° +118°~122° Cooling system Water pump pulley bolt 9.8 ~ 11.8...

  • Page 9

    Engine Mechanical System General Information 5) If the cylinder compression in 1 or more cylinders is Compression Pressure Inspection low, pour a small amount of engine oil into the cylinder ✍ NOTICE through the spark plug hole and repeat step1) through 3) for cylinders with low compression....

  • Page 10

    Engine Mechanical System Cooling System Special Service Tools...

  • Page 11

    Engine Mechanical System Cooling System Special Service Tools...

  • Page 12: Cooling System

    Engine Mechanical System Cooling System Cooling system Components 1. Heat exchanger assembly 5. Anode 2. Coolant pipe 6. Raw water hose 3. Coolant hose 7. Oil cooler assembly 4. Clamp 8. Sea water pump...

  • Page 13

    Engine Mechanical System Cooling System 1. Coolant Inlet fitting 6. Coolant pipe 2. Thermostat assembly 7. Coolant hose 3. Coolant outlet duct 8. Clamp 4. Coolant temp. sensor 9. O- ring 5. Coolant temp. control assembly 10.Gasket...

  • Page 14

    Engine Mechanical System Cooling System Make sure you use new O-ring after seawater pump reassemble. Removal Seawater Pump 10. Tighten seawater pump with three bolts. 11. Place hoses and clamps. 12. Complete the reassembly and start the ignition. Then check any oil leakage out of shaft. Heat Exchanger 1.

  • Page 15

    Engine Mechanical System Cooling System 4. Use L-wrench and remove end cap on both sides. 5. Use soft hammer and remove heat exchanger from housing. 6. Check condition of O-ring on both end cap. 7. Check if there is engine coolant and sea water mixture inside the heat exchanger.

  • Page 16

    Engine Mechanical System Cooling System 4. Installation is in the reverse order of removal. Thermostat ✍ NOTICE Disassembly of the thermostat would have an adverse 3. Loosen the oil cooler mounting bolts for space of the effect, causing a lowering of cooling efficiency. outlet fitting's removal.

  • Page 17

    Engine Mechanical System Cooling System 3. If excessive dirty, clean the cooling system and Tightening torque: replace coolant. 29.4 ~ 41.2Nm (3.0 ~ 4.2kgf.m, 21.7 ~ 30.4lb-ft) 4. Reinstall the cap. 4. Remove the engine coolant control assembly(A). Tightening torque: 19.6 ~ 26.5Nm (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft) 5.

  • Page 18

    Engine Mechanical System Cooling System...

  • Page 19

    Engine Mechanical System Cooling System Thermostat...

  • Page 20: Timing System

    Engine Mechanical System Timing System Timing System Timing Chain Components 1. Tensioner assembly 6. Water pump pulley flange 11. P/S oil pump 2. Bracket- tensioner 7. Water pump bearing 12. Alternator 3. Water pump pulley 8. Seal unit 13. Bracket- alternator 4.

  • Page 21

    Engine Mechanical System Timing System 1. Cap Assembly-chain case 6. Lower head seal 11. Lower O-ring 2. High pressure pump cover 7. Upper head seal 12. Hose assembly 3. Chain front cover 8. Chain oil jet 13. Chain case cap 4.

  • Page 22

    Engine Mechanical System Timing System 1. Hydraulic tensioner 6. Oil pump sprocket 11. Oil pump chain 2. Timing chain 7. Tensioner lever 12. Camshaft 3. Camshaft sprocket 8. Lower chain guide 13. Oil pump drive sprocket 4. High pressure pump sprocket 9.

  • Page 23

    Engine Mechanical System Timing System Removal 2. Remove the drive belt tensioner(A). Main Bracket Assembly ✍ NOTICE Turn the ignition key switch to “OFF” position or disconnect the battery cable while removing the bracket. 3. Remove the power steering bracket. 4.

  • Page 24

    Engine Mechanical System Timing System 14. Remove the timing chain with the chain guide and the tensioner lever. 15. Remove the high pressure fuel pump sprocket (A). 16. Remove the upper head seal. 17. Remove the water pump (A) with its gasket. 11.

  • Page 25

    Engine Mechanical System Timing System Installation Applying sealant (A) on the groove and checking the O- rings (B) seated firmly, install the chain case assembly(C) within fifteen minutes. 3. Install the water pump(A) with a new gasket. Tightening Torque: 9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) - 6×16(★) 4.

  • Page 26

    Engine Mechanical System Timing System Tightening Torque: 7.8 ~ 11.8Nm (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft) - chain guide 19.6 ~ 23.5Nm (2.0 ~ 2.4kgf.m, 14.5 ~ 17.4lb-ft) - tensioner lever ✍ NOTICE If you have difficulty in installing of the lower chain guide, turn the drive plate or move the SST a little bit.

  • Page 27

    Engine Mechanical System Timing System ✍ NOTICE Install it after removing sealant from the camshaft bearing ladders. 16.Install the drive belt idler(A). Tightening Torque: 34.3 ~ 44.1Nm (3.5 ~ 4.5kgf.m, 25.3 ~ 32.5lb-ft) 15. Install the crankshaft pulley (A) with its washer (B) and tighten the mounting bolt(C).

  • Page 28

    Engine Mechanical System Timing System 2) Using other oil except steering hydraulic oil may 20. Install the drive belt idler cause noise or pump malfunction. Tightening Torque: ◉ CAUTION 34.3 ~44.1Nm (3.5 ~ 4.5kgf.m, 25.3 ~ 32.5lb-ft) Never reuse secondary O-ring or oil. 21.Install the water pump pulley(D).

  • Page 29: Cylinder Head Assembly

    Engine Mechanical System Cylinder Head assembly Cylinder Head Assembly Components 1. Valve stem seal 7. Water outlet fitting O-ring 13. Valve guide 2. Valve 8. Cylinder head gasket 14. Sealing cap 3. Valve spring 9. Cylinder head 15. Camshaft bearing ladder 4.

  • Page 30

    Engine Mechanical System Cylinder Head assembly 1. Water outlet fitting gasket 6. Sealing cap 2. Water outlet fitting 7. Camshaft bearing ladder 3. Water outlet fitting O-ring 8. Cylinder head cover 4. Cylinder head gasket 9. Engine hanger 5. Cylinder head...

  • Page 31

    Engine Mechanical System Cylinder Head assembly Removal 1. Remove the drive belt. 2. Remove the timing chain. 3. Remove the intake and exhaust manifold. 4. Remove the high pressure pipe, the injectors and the delivery pipe. 5. Remove the glow plug wiring. 6.

  • Page 32

    Engine Mechanical System Cylinder Head assembly 12. Remove the water pipe. 16. Remove the cylinder head quietly in order not to damage the gasket with the bottom part of the end. 17.Remove the cylinder head gasket(A) 13. Remove the glow plugs (A). 18.

  • Page 33

    Engine Mechanical System Cylinder Head assembly Installation 1. Clean the cylinder head and the cylinder block surfaces contacting with their gaskets. 2. Select the cylinder head gasket. 1) Measure the piston protrusion from the upper cylinder block face on the twelve places (A ~ F) for each bank) at TDC (top dead center).

  • Page 34

    Engine Mechanical System Cylinder Head assembly 3) Install the LH gasket so that the identification mark Tightening Torque: (A) faces toward the timing chain side. 1st step: 58.8N.m (6.0kgf.m, 43.4lbf-ft) 4) Install the RH gasket so that the identification mark 2nd step: 90°±...

  • Page 35

    Engine Mechanical System Cylinder Head assembly 7. Tighten the glow plugs (A). 10. After measuring the end play, remove the camshafts. Tightening Torque: 11. After applying oil, install the HLA (hydraulic lash 7.8 ~ 10.8Nm (0.8 ~ 1.1kgf.m, 5.8 ~ 8.0lb-ft) adjuster) (A) and the cam follower assembly (B).

  • Page 36

    Engine Mechanical System Cylinder Head assembly 12. Wipe out oil on the upper surface of the cylinder head. 13. Install the camshafts. ◉ CAUTION • Align the marks (A) on the sprockets. 16. Install the sealing caps (A) with applying sealant LOCTITE 5902/5900 or equivalent) on the grooves (4 places) at the circumference.

  • Page 37

    Engine Mechanical System Cylinder Head assembly 18. Apply oil on the camshafts sufficiently. 20. Install the water outlet duct (A). Tightening torque 9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) 21. Install the glow plug wiring. 22. Install the delivery pipe, the injectors and the high pressure pipe.

  • Page 38

    Engine Mechanical System Cylinder Head assembly ✍ NOTICE • Do not reuse old valve stem oil seals. • Incorrect installation of the seal could result n oil leakage through the valve guides. • Apply engine oil on a valve stem seal surface contacting with a valve guide or a valve guide outer surface before installing a valve stem seal.

  • Page 39: Cylinder Block

    Engine Mechanical System Cylinder block Cylinder block Components 1. Main bearing 7. Bearing pare set - Connecting rod 13. Oil ring 2. Crankshaft assembly 8. Connecting rod 14. Snap ring 3. Bed plate 9. Piston 15. Crankshaft key 4. Flywheel sub assembly 10.

  • Page 40

    Engine Mechanical System Cylinder block 6. Remove the bedplate Removal 7. Lift the crankshaft (A) out of the block, being careful 1. Remove the connecting rod caps. not to damage journals. ✍ NOTICE ✍ NOTICE Mark the connecting rod caps to be able to reassemble Arrange the main bearings and thrust bearings in the in the original position and direction.

  • Page 41

    Engine Mechanical System Cylinder block Tightening Torque: Inspection 27.5 ~ 31.4Nm (2.8 ~ 3.2kgf.m, 20.3 ~ 23.1lb-ft) + Connecting Rod 88˚~92˚ 1. Check the connecting rod bearing oil clearance. ✍ NOTICE 1) Check the marks on the connecting rod and rod cap •...

  • Page 42

    Engine Mechanical System Cylinder block 10) If the plastic gauge shows the clearance is still Discrimination Of Crankshaft Pin Journal incorrect, try the larger or smaller bearing. Recheck the oil clearance. ✍ NOTICE If the proper clearance still cannot be obtained after using the appropriate larger or smaller bearings, Connecting Rod Bearing Mark Location replace the crankshaft and restart measuring...

  • Page 43

    Engine Mechanical System Cylinder block 2. Check the connecting rods. Tightening Torque: 29.4 ~ 33.3Nm (3.0 ~ 3.4kgf.m, 21.7 ~ 24.6lb-ft) 1) When reinstalling, make sure that cylinder numbers 6) Tighten the No.1~16 bolts in two steps with the put on the connecting rod and cap at disassembly specified torque and angle below.

  • Page 44

    Engine Mechanical System Cylinder block Standard oil clearance: Crankshaft Journal Bore Mark Location 0.030 ~ 0.048mm (0.0012 ~ 0.0019in) 10) If the plastic gauge measurement is too wide or too narrow, remove the bearings and then install new bearings with the same color mark. Recheck the oil clearance.

  • Page 45

    Engine Mechanical System Cylinder block Crankshaft Main Bearing Mark Location 3. Inspect the crankshaft main journals and pin Discrimination Of Crankshaft Main Bearing journals. Using a micrometer, measure the diameter of each main journal and pin journal. Main journal diameter: 75.982 ~ 76.000mm (2.9914 ~ 2.9921in) Pin journal diameter: 12) Select the suitable bearing by using the selection...

  • Page 46

    Engine Mechanical System Cylinder block Cylinder Block 1. Remove the gasket material. Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block. 2. Clean the cylinder block Using a soft brush and solvent, thoroughly clean the cylinder block. 3.

  • Page 47

    Engine Mechanical System Cylinder block 8. Select the piston related to cylinder bore class. Piston-to-cylinder clearance: Piston-to-cylinder clearance: 0.064 ~ 0.084mm (0.0025 ~ 0.0033in) 0.064 ~ 0.084mm (0.0025 ~ 0.0033in) ✍ NOTICE When boring the cylinders, finish all of the cylinders to the same oversize.

  • Page 48

    Engine Mechanical System Cylinder block 4. Inspect the piston ring side clearance. Using a feeler gauge, measure the clearance between new piston ring and the wall of ring groove. Piston ring side clearance No.1: 0.102 ~ 0.146mm (0.0040 ~ 0.0057in.) No.2: 0.08 ~ 0.12mm (0.0031 ~ 0.0047in.) Oil ring: 0.03 ~ 0.07mm (0.0012 ~ 0.0028in.) If the clearance is out of the specification above...

  • Page 49

    Engine Mechanical System Cylinder block 3. Check the difference between the piston pin outer diameter and the connecting rod small end inner diameter. Piston pin-to-connecting rod interference: 0.020 ~ 0.037mm (0.0008 ~ 0.014in) 3. Place the crankshaft(A) on the cylinder block. Installation ✍...

  • Page 50

    Engine Mechanical System Cylinder block 4) Tighten the No.17~25 bolts with the specified torque below. Tightening Torque: 29.4 ~ 33.3Nm (3.0 ~ 3.4kgf.m, 21.7 ~ 24.6lb-ft) - 1 step 6. Install the bedplate bolts. ✍ NOTICE • The bedplate bolts are tightened in several progressive steps.

  • Page 51

    Engine Mechanical System Cylinder block 10. Install the piston rings. 1) No.1 and No.2 piston rings - assemble the rings with the 'Y' marks on the edge of the rings facing the cylinder head side. One end gap is placed at 180˚ ✍...

  • Page 52

    Engine Mechanical System Cylinder block 1) Remove the connecting rod caps, and slip short sections of rubber hose over the threaded ends of the connecting rod bolts. 2) Install a ring compressor, check that the rings are securely in place, position the piston in the cylinder, and tap it in using the wooden handle (A) of a hammer.

  • Page 53: Lubrication System

    Engine Mechanical System Lubrication System Lubrication System Components 1. Upper oil pan 5. Hose - oil outlet 9. Washer - Plain 2. Lower oil pan 6. Hose - oil inlet 10. Joint - I 3. Oil level gauge assembly 7. Ear Clamp 11.

  • Page 54

    Engine Mechanical System Lubrication System 1. Oil filter assembly 3. Oil pressure sensor 2. Oil cooler assembly 4. Rear oil seal...

  • Page 55

    Engine Mechanical System Lubrication System...

  • Page 56

    Engine Mechanical System Lubrication System Replacement Oil and Filter ◉ CAUTION 1) Remove the filter paper assembly (A). • Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, 2) Replace the filter paper assembly and O-ring (B) with leading to dryness, irritation and dermatitis.

  • Page 57

    Engine Mechanical System Lubrication System ✍ NOTICE For best performance and maximum protection of all types of operation, select only those lubricants which: 1. Satisfy the requirement of the API or ACEA classification. 2. Have proper SAE grade number for expected ambient temperature range 3.

  • Page 58

    Engine Mechanical System Lubrication System in the crankshaft, aligning the No.1 piston at the Engine Oil BDC(bottom dead center). 1. Check the engine oil quality. Check the oil 5. Install the oil pump chain (B) and the oil pump deterioration, entry of water, discoloring of thinning. If chain tensioner and remove the pin from the tensioner.

  • Page 59

    Engine Mechanical System Lubrication System 4. Apply liquid gasket on the upper oil pan assembly shown as below. Liquid gasket: LOCTITE 5900 or equivalent ✍ NOTICE • Apply sealant cautiously to prevent sealant from coming in the oil pan during installation. •...

  • Page 60

    Engine Mechanical System Lubrication System Liquid gasket: LOCTITE 5900 or equivalent ✍ NOTICE • Apply sealant cautiously to prevent sealant from coming in the oil pan during installation. • After applying sealant, assemble the oil pan in fifteen minutes. 7. Tighten the mounting bolts with the order and the Oil Filter And Cooler Assembly specified torque below.

  • Page 61: Intake And Exhaust System

    Engine Mechanical System Intake and Exhaust System Intake and Exhaust System Inter-cooler Component 1. Intercooler hose 4. Intercooler pipe 2. Intercooler assembly 5. Anode 3. Clamp...

  • Page 62

    Engine Mechanical System Intake and Exhaust System Intake Manifold Components 1. Gasket – Rubber, Upper 6. Boost Pressure sensor 2. Manifold assembly – Inlet lower 7. Gasket - Pipe 3. Manifold assembly – Inlet Upper 8. Bracket – Intake manifold 4.

  • Page 63

    Engine Mechanical System Intake and Exhaust System ◉ CAUTION Removal Take CAUTION avoid intercooler fin damage. Intercooler 10. Clean housing and intercooler and heat exchanger into housing. 11. Install new O-ring. 12. Check the direction of end cap on both sides for assembly.

  • Page 64

    Engine Mechanical System Intake and Exhaust System Installation 1. Install the inlet manifold gaskets(A). 14. Remove the inlet lower manifold assembly(A). 2. Install the inlet lower manifold assembly(A). ◉ CAUTION ◉ CAUTION The inlet lower manifold assembly (A) is the assembly The inlet lower manifold assembly (A) is the assembly including the swirl control actuator (B).

  • Page 65

    Engine Mechanical System Intake and Exhaust System 11. Install the high pressure fuel pipe(rail to rail). 12. Install the fuel feed and return hose or pipe Tightening Torque: 9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) 13. Install the CMP sensor. Tightening Torque: 9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) 14.

  • Page 66

    Engine Mechanical System Intake and Exhaust System Exhaust Manifold Component 1. Gasket-Turbocharger outlet 6. Gasket-Exhaust manifold 11. Clamp- Bellows 2. Exhaust pipe 7. Exhaust elbow 12. Bracket-Exhaust elbow 3. Gasket-Exhaust pipe 8. Exhaust pipe 13. Heat Protector-Ex. pipe (LH) 4. Exhaust manifold (LH) 9.

  • Page 67

    Engine Mechanical System Intake and Exhaust System Turbocharger (TC) Component 1. Turbo charger 6. I-bolt joint 2. Pipe-oil return 7. Nut- Oil feed pipe 3. Gasket 8. Exhaust pipe 4. O-Ring 9. Gasket-T/C oil drain 5. Pipe-Oil feed 10. Heat protector – T/C...

  • Page 68

    Engine Mechanical System Intake and Exhaust System Removal 8. Remove the oil feed pipe and the blow-by hose(C). Tightening Torque: 18.6 ~ 25.5Nm (1.9 ~ 2.6kgf.m, 13.7 ~ 18.8lb-ft) – oil feed pipe nut (A) 26.5 ~ 32.4Nm (2.7 ~ 3.3kgf.m, 19.5 ~ 23.9lb-ft) – oil feed pipe eye bolt (B) 9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) - oil feed pipe mounting bolt (D)

  • Page 69

    Engine Mechanical System Intake and Exhaust System 10. Cool off the engine and remove manifold ◉ CAUTION Contacts with exhaust manifold after engine operation may cause serious injury when manifold has not cooled off. 12. Installation is in the reverse order of removal. 13.

  • Page 70

    Engine Mechanical System Coupling System Coupling System Shaft Drive ✍ NOTICE Use locking compound LOCTITE 242 on threads. Stern Drive 1. Loosen 12 bolts 2. Loosen 2 nuts, Remove housing. 3. Loosen 6 bolts, Remove coupling. 1. Loosen 13 bolts 2.

  • Page 71: Engine Electrical System

    S Engine Series Engine Electrical System Engine Electrical System General Charging System Starting System Preheating System...

  • Page 72: General Information

    Engine Electrical System General Information General information Specifications Charging system Starting system Items Specification Rated voltage 12V, 2.2kW No. of pinion teeth Starter Voltage No-load characteristics Ampere 130A, MAX Speed 3,600 rpm, MIN Preheating system...

  • Page 73

    Engine Electrical System General Information Troubleshooting Charging system...

  • Page 74

    Engine Electrical System General Information Starting system Special service tools...

  • Page 75

    Engine Electrical System Charging System Charging system Alternator...

  • Page 76

    Engine Electrical System Charging System Replacement 1. Remove from the (-) terminal of the battery 2. Remove from the (+) terminal of the battery 3. After pressing the auto-tensioner with a wrench remove the drive belt 4. Remove the tow alternator mounting bolts. 3.0 ~ 4.2 kgf∙m 5.

  • Page 77

    Engine Electrical System Charging System Inspection 6. Unsolder the 3 stator leads(A) Rotor 1. Check that there is continuity between the slip Rings(A). 7. Loosen the 4 through bolts(A) 2. Check that there is no continuity between the Slip rings and the rotor(B) or rotor shaft(C) 3.

  • Page 78: Starting System

    Engine Electrical System Starting System Starting system When the ignition key is turned to the start position, starting the engine again. current flows and energizes the starter motor's solenoid If the starter cranks normally the engine, repairing the coil. loose connection repaired the problem. The starting The solenoid plunger and clutch shift lever are system is now OK.

  • Page 79

    Engine Electrical System Starting System Stator Solenoid Test Free Running Test 1. Disconnect the field coil wire from the M-terminal of 1. Place the starter motor in a vise equipped with soft solenoid switch. jaws and connect a fully-charged 12-volt battery to 2.

  • Page 80

    Engine Electrical System Starting System Components...

  • Page 81

    Engine Electrical System Starting System Replacement 1. Disconnect the starter motor cable(A) from the B terminal of the solenoid and the connector (B)from the S terminal. 4. Check the commutator(A) surface. If the surface is dirty or burnt, resurface with emery cloth or a lathe within the following specifications, or recondition with #500 or #600 sandpaper(B).

  • Page 82

    Engine Electrical System Starting System • If the commutator run out is not within the service limit, replace the armature. ------------------------------------ Standard (New) : 0.02mm (0.0008in.) max Service limit : 0.05mm (0.0020in.) ------------------------------------ 9. Check with an ohmmeter that no continuity exists between the commutator(A) and armature coil core(B), and between the commutator and armature shaft(C).

  • Page 83

    Engine Electrical System Starting System Starter Brush Holder Cleaning Check that there is no continuity between the (+) brush 1. Do not immerse parts in cleaning solvent. holder(A) and (-) plate(B). If there is continuity, replace Immersing the yoke assembly and/or armature will the brush holder assembly.

  • Page 84

    Engine Electrical System Preheating System Preheating System seconds and indicates battery voltage (about 9V or over) for about 36 seconds immediately after ignition General Description switch is turned on. [At cooling water temperature20°C Preheating on Diesel engine improves cold starting with (68.0°F)] glow plug which heat combustion chamber.

  • Page 85

    Engine Electrical System Preheating System heating pin is pressed in. In the heating pin there are Inspection The specified electrical data below are related to the the heating spiral and the sensor spiral, both are connected in series and embedded in a ceramic mass. nominal voltage and to an ambient temperature of 22.5~23.5℃(72.5~74.3℉) on new glow plugs.

  • Page 86

    Engine Electrical System Preheating System [Preheating time before starting] [Preheating time after starting] Schematic diagram...

  • Page 87: Fuel System

    S Engine Series Fuel System Fuel System General Diesel Control System Fuel Delivery System (Diagnosis Trouble Code)

  • Page 88

    Fuel System General Information General Information Specification Fuel Delivery System Items Specification Fuel injection System Type Common rail direct injection(CRDI) Fuel Return System Type Return type Fuel Pressure Max. Pressure 1,600 bar Fuel Filter Type High pressure type (Built in engine room) Type Mechanical, Plunger pumping type High Pressure Fuel Pump...

  • Page 89

    Fuel System General Information Actuators Crankshaft Position Sensor(CKPS) ① Type : Magnetic field sensitive type ② Specification Injector ① Type : Piezo injector ② Specification Rail Pressure Sensor (RPS) ① Type : Piezo-resistive pressure sensor type ② Specification Fuel Pressure Regulator Valve ①...

  • Page 90

    Fuel System General Information Tightening Torques Engine Control System Item N∙m Kgf∙m lb-ft Boost pressure sensor installation bolts 6.9~10.8 0.7~1.1 5.1~8.0 Engine coolant temperature sensor installation 39.2~54.0 4.0~5.5 28.9~39.8 Camshaft position sensor installation bolt 9.8~11.8 1.0~1.2 7.2~8.7 Crankshaft position sensor installation bolt 9.8~11.8 1.0~1.2 7.2~8.7...

  • Page 91

    Fuel System General Information Special Service Tools...

  • Page 92

    Fuel System General Information Basic Troubleshooting Guide 1. Bring engine to Workshop 2. Analyze Problem About the conditions and environment relative to the issue(Make Problem Analysis Sheet) 3. Verify Symptom, and then Check DTC and Freeze Frame Data Connect G-Scan to Diagnostic Link Connector Never erase DTC and freeze frame data before completing step 2 MIL /DTC in Problem Analysis Sheet 4.

  • Page 93

    Fuel System General Information Problem Analysis sheet 1. Engine information Engine No. ECU Part NO. Production date ROM ID Run time (hours) Customer TEL 2. Symptoms 3. Environment □ Constant □ Sometimes □ Once only Problem frequency □ Other □ Fine □ Cloudy □ Rainy □ Snowy Weather □...

  • Page 94

    Fuel System General Information Basic Inspection Procedure 4. Repair or replace the component that has a problem. The measured resistance at high temperature after 5. Verify that the problem has disappeared with the vehicle running may be high or low. So all resistance road test must be measured at ambient temperature (20℃, 68℉), ●...

  • Page 95

    Fuel System General Information Connector Inspection Procedure 1. Handling of Connector a. Never pull on the wiring harness when disconnecting connectors. e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot be accessed from harness side b. When removing the connector with a lock, press or pull locking lever.

  • Page 96

    Fuel System General Information • Continuity Check • Voltage Check If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity Check Method) or Step 3 (Voltage Check Method) as shown Below 3.

  • Page 97

    Fuel System General Information b. Disconnect connector (B), and measure for Check Short Circuit resistance between connector (C) and (B1) and 1. Test Method for Short to Ground Circuit between (B2) and (A) as shown in [FIG. 3]. • Continuity Check with Chassis Ground In this case the measured resistance between If short to ground circuit occurs as shown in [FIG.

  • Page 98

    Fuel System General Information b. Disconnect connector (B), and measure the resistance between connector (A) and chassis ground, and between (B1) and chassis ground as shown in [FIG. 7]. The measured resistance between connector (B1) and chassis ground is 1Ω or less. The short to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).

  • Page 99

    Fuel System General Information SYMPTOM TROUBLESHOOTING GUIDE TABLE (SYMPTOM 1) ENGINE DOES NOT START • Faulty starter • Faulty fuel filter • Not connected fuel feed line • Clogged low pressure fuel circuit • Leakage in high pressure fuel circuit •...

  • Page 100

    Fuel System General Information • Injector needle stuck (injection possible over • Gasoline in fuel a certain pressure) • ECM program error or hardware (SYMPTOM 4) UNSTABLE IDLING • Not connected fuel return line at injector • Faulty glow system •...

  • Page 101

    Fuel System General Information SYMPTOM 8) BURST NOISE • Intermittent faulty fuel line connection stuck, jammed • Clogged exhaust system • Rail pressure regulator valve contaminated, • No rail pressure sensor signal stuck, jammed • Fuel pressure regulator valve contaminated, •...

  • Page 102

    Fuel System General Information • Faulty low pressure fuel pump a certain pressure) • Poor injector washer, no washer or two washer • Injector jammed open installed • Gasoline in fuel • Carbon deposit on the injector (sealed holes) • ECM program error or hardware •...

  • Page 103

    Fuel System General Information (SYMPTOM 17) SMOKES (BLACK, WHITE, BLUE) WHEN ACCELERATING • Compensation of individual injector not adapted • Poor tightening of injector clamp • Clogged air filter • Poor injector O-ring, no O-ring or two O-ring installed • Bad fuel quality or water ingress in fuel •...

  • Page 104: Engine Control System

    Fuel System Diesel Control System Engine Control System completely read and recorded. Description Inspection Procedure (Using Generic Scan Tool 1. Engine is hard to start or does not start at all. 2. Unstable idle. 1. Turn OFF the ignition switch. 3.

  • Page 105

    Fuel System Diesel Control System Component Location 1. ECU Box 1. ECU Box 7. Engine Oil Gauge 7. Engine Oil Gauge 2. Coolant Expansion Tank 2. Coolant Expansion Tank 8. Acceleration Lever Sensor 8. Acceleration Lever Sensor 3. Engine Oil Cap 3.

  • Page 106

    Fuel System Diesel Control System ECM(ENGINE CONTROL MODULE) 1. ECM Harness connector CONNECTOR(CSD-A) CONNECTOR(CSD-K) 2. ECM Terminal Function Connector [CSD-A] Description Condition Type Level Injector (Cylinder #2) [Low]control output Injector (Cylinder #4) [Low] control output Engine run Injector (Cylinder #6) [Low] control output Fuel Pressure Regulator Valve control Engine run output...

  • Page 107

    Fuel System Diesel Control System Injector (Cylinder #1) [High] control output Injector (Cylinder #3) [High] control output Engine Run Injector (Cylinder #5) [High] control output Sensor ground Always 0 ~ 0.5V Rail Pressure Sensor(RPS) signal input Engine Run Analog 0.5 ~ 4.5V Boost Pressure Sensor(BPS) signal input Engine Run Analog...

  • Page 108

    Fuel System Diesel Control System 0.7 ~ 0.8V Accelerator Position Sensor (APS) #1 signal input Idle 3.8 ~ 4.4V Accelerator Position Sensor (APS) #2 0.275 ~ 0.475V signal input Idle 1.75 ~ 2.35V Sensor power (+5V) IG ON 4.9 ~ 5.1V Fuel Pump Relay control output OFF / ON Battery Voltage / Max 1.0 V...

  • Page 109

    Fuel System Diesel Control System ECM Circuit Diagram – 1 EOI_UNIT...

  • Page 110

    Fuel System Diesel Control System ECM Circuit Diagram – 2...

  • Page 111

    Fuel System Diesel Control System ECM Circuit Diagram – 3 Connector [ECU-K] Connector [ECU-A] Description Description Power ground Injector (Cylinder #2) [Low]control output Battery power Injector (Cylinder #4) [Low] control output Power ground Injector (Cylinder #6) [Low] control output Battery power Fuel Pressure Regulator Valve control output Battery power Rail Pressure Regulator Valve control output...

  • Page 112

    Fuel System Diesel Control System EOI (Engine Operating Indicator System)Circuit Diagram - 1...

  • Page 113

    Fuel System Diesel Control System EOI (Engine Operating Indicator System)Circuit Diagram - 2 Connector [EOI] Description Ignition power Main relay power Permanent power Not used Not used Coolant temperature signal Not used Check lamp Oil pressure signal Not used Water detection signal RPM signal Not used Not used...

  • Page 114

    Fuel System Diesel Control System Injector Description ☢ WARNING As the Piezo-Injector operates under maximum DC 200V, there may be a risk of an electric shock caused by shorted control line etc. So when repairing the injector or its wiring, disconnect the battery negative (-) terminal from the battery and wait for about 30 seconds.

  • Page 115

    Fuel System Diesel Control System Operation Principle PIEZO ACTUATOR The Piezo Actuator is made up of several floors of cylindrical piezo-ceramic (height: approximately 90㎛). This lengthens by from 1.5% through 2.0% of its length if voltage is applied (Piezoelectric Converse Effect) and this length is “Stroke”.

  • Page 116

    Fuel System Diesel Control System PRESSURE CONTROL VALVE The Pressure Control Valve is located under the hydraulic coupler and controls the needle by amplified actuator's output. NEEDLE The needle is located under the pressure control valve and finally opens or closes the injection hole.

  • Page 117

    Fuel System Diesel Control System Specification Circuit Diagram...

  • Page 118

    Fuel System Diesel Control System Removal ☢ WARNING • As the Piezo-Injector operates under maximum DC 200V, there may be a risk of an electric shock caused by shorted control line etc. So when repairing the injector or its wiring, disconnect the battery negative (-) terminal from the battery and wait for about 30 seconds.

  • Page 119

    Fuel System Diesel Control System ✍ NOTICE 5. Remove the injector pad (B). [DISCONNECTION-INJECTOR RETURN LINE] 6. Unscrew the injector clamp bolt (A), and then remove 1. Pull the plug bush upward with the plug grip pressed. the injector. ✍ NOTICE 2.

  • Page 120

    Fuel System Diesel Control System Injector Specific Data input 4 perform the test in accordance with the message ✍ NOTICE * (+) correction value: Injection quantity is less than the others. * (-) correction value: Injection quantity is more than the others.

  • Page 121

    Fuel System Diesel Control System Boost Pressure sensor & IATS#2 Function And Operation Principle. The Boost Pressure Sensor (BPS) is installed on the intercooler assembly and measures the pressure of the compressed air in turbocharger. By using this signal, the ECM controls the Variable Geometry Turbocharger (VGT).

  • Page 122

    Fuel System Diesel Control System Intake Air Temperature Sensor (IATS#1) Intake Air Temperature Sensor (IATS) uses a Negative Temperature Characteristics (NTC) thermistor and senses intake air temperature. Two intake air temperature sensors are installed in this engine.

  • Page 123

    Fuel System Diesel Control System Engine Coolant Temperature Sensor (ECTS) Function And Operation Principle The Engine Coolant Temperature Sensor (ECTS) is located in the engine coolant passage of the cylinder for detecting the engine coolant temperature. The ECTS uses a thermistor which resistance is in inverse proportion to the temperature (NTC: Negative Temperature Coefficient).

  • Page 124

    Fuel System Diesel Control System Component Inspection 1. Turn ignition switch OFF. 2. Disconnect the engine coolant temperature sensor connector. 3. Remove the sensor. 4. After immersing the thermistor of the sensor into engine coolant, measure resistance between ECTS signal terminal and ground terminal . 5.

  • Page 125

    Fuel System Diesel Control System Camshaft Position Sensor (CMPS) Function And Operation Principle .The Camshaft Position Sensor (CMPS) is installed on the cylinder head cover and detects the camshaft position. This is a hall sensor and has a hall-effect IC which output voltage changes when magnetic field is made on the IC with current flow It is related with Crankshaft Position Sensor (CKPS) and detects the piston position of the each cylinder which the CKPS can't detect.

  • Page 126

    Fuel System Diesel Control System Crankshaft Position Sensor (CKPS) Function And Operation Principle The Crankshaft Position Sensor (CKPS) is installed on the flywheel housing and detects the crankshaft position. By using this signal, the ECM can calculate the piston position of each cylinder and the engine speed for sequential injection.

  • Page 127

    Fuel System Diesel Control System Accelerator Position Sensor (APS) Function And Operation Principle The Accelerator Pedal Position Sensor (APS) is installed on the accelerator pedal assembly and consists of the two potentiometers which have independent circuit (power, signal output, and ground) individually. This system makes the ECM recognize the driver's intention even if one sensor is broken.

  • Page 128

    Fuel System Diesel Control System Rail Pressure Sensor (RPS) Function And Operation Principle The Rail Pressure Sensor (RPS) is installed at the end of the common rail (bank 1) and measures the instantaneous fuel pressure in the common rail. The sensing element (semiconductor device) built in the sensor converts the pressure to voltage signal.

  • Page 129

    Fuel System Diesel Control System Fuel Temperature Sensor (FTS) Function And Operation Principle The Fuel Temperature Sensor (FTS) is installed on the high pressure fuel pump and measures the temperature of the fuel supplied from the fuel tank (via fuel filter). The FTS uses a thermistor which resistance is in inverse proportion to the temperature (NTC: Negative Temperature Coefficient).

  • Page 130

    Fuel System Diesel Control System Fuel Pressure Control Valve (High pressure pump side) Function And Operation Principle The Fuel Pressure Regulator Valve and the Rail Pressure Regulator Valve are installed on high pressure pump and common rail (bank 2) respectively. These valves control fuel inlet (feed) from fuel tank via fuel filter and outlet (return) to fuel tank of high pressure fuel circuit.

  • Page 131

    Fuel System Diesel Control System Rail Pressure Regulator Valve (rail side) Function And Operation Principle The Fuel Pressure Regulator Valve and the Rail Pressure Regulator Valve are installed on high pressure pump and common rail (bank 2) respectively. These valves control fuel inlet (feed) from fuel tank via fuel filter and outlet (return) to fuel tank of high pressure fuel circuit.

  • Page 132

    Fuel System Diesel Control System Water Sensor Function And Operation Principle The Water Sensor is installed on bottom end of fuel filter and detects presence of water in fuel. When the water amount reaches the predetermined level, the sensor sends the warning signal to the ECM. ✍...

  • Page 133

    Fuel System Diesel Control System Electric VGT Control Actuator Function And Operation Principle The Electric VGT Control Actuator is installed on the turbocharger. It operates the vain in the Variable Geometry Turbocharger (VGT) and regulates the compressed air amount by the ECM's PWM signal. This valve consists of a DC motor which actuates the vane, a 2-step gear which increases torque of the DC motor, a position sensor which detects status of the vane, an electric control unit which drives the DC motor, and a reset spring which resets the de-energized vane to its open position.

  • Page 134: Fuel Delivery System

    Fuel Delivery System Fuel System Fuel Delivery System Fuel Line 1. High Pressure Fuel Pipe (High Pressure Fuel Pump ↔ Common Rail) 2. High Pressure Fuel Pipe (Common Rail ↔ Injector) 3. High Pressure Fuel Pipe (Common Rail ↔ Common Rail) 4.

  • Page 135

    Fuel Delivery System Fuel System Common Rail Fuel Injection System (CRDI) Rail pressure Rail pressure sensor sensor Pump Pump return return pressure pressure Common rail Common rail regulator regulator Rail Rail High High valve valve pressure pressure pressure pressure regulator regulator pump pump...

  • Page 136

    Fuel Delivery System Fuel System Fuel Filter Component Removal 4. Disconnect the injector return tube quick-connector 5. Unscrew the fuel filter bracket installation nuts and 1 . Turn ignition switch OFF and disconnect the then remove the fuel filter from the engine. . negative (-) battery cable.

  • Page 137

    Fuel Delivery System Fuel System High Pressure Pump Component Removal 1. Turn ignition switch OFF and disconnect the negative (-) battery cable. 2. Remove the inlet upper manifold assembly (A). 4. Disconnect the fuel inlet tube quick-connector (A) and the fuel return tube quick-connector (B). &...

  • Page 138

    Fuel Delivery System Fuel System 5. Remove the high pressure fuel pipe (C). 12. Install the supporter (B) [SST No.: 00200-0T016] on 6. Remove the engine oil filter (D) the sprocket with the bolts (A) [SST No.: 7. Unscrew the three high pressure fuel pump mounting 00200-0T016].

  • Page 139

    Fuel Delivery System Fuel System Common Rail Component ▪ Keep cleanly the parts and the working area. Removal ▪ Pay attention to a foreign substance. ☢ WARNING ▪ Just before installing injector, tube or hose, remove As the Piezo-Injector operates under maximum DC the protect-cap attached on them.

  • Page 140

    Fuel System Fuel Delivery System [Common Rail (Bank 1)] Installation 1. Turn ignition switch OFF and disconnect the 1. Installation is reverse of removal. negative (-) battery cable. ✍ NOTICE 2. Disconnect the rail pressure sensor connector (A). 1.When installing the high pressure fuel pipe, apply the specified tightening torques with the special service tool [SST No.: 09314-3A000].

  • Page 141

    Fuel System Diagnosis Trouble Code DTC (Diagnosis Trouble Code) LIST P code DESCRIPTION P0016 Crankshaft Position – Camshaft Position Correlation P0047 Turbocharger Boost Control Solenoid Circuit Low P0048 Turbocharger Boost Control Solenoid Circuit High P0069 Manifold Absolute Pressure – Barometric Pressure Correlation P0087 Fuel Rail/System Pressure - Too Low P0088...

  • Page 142

    Fuel System P code DESCRIPTION P0238 Turbocharger Boost Sensor "A" Circuit High P0252 Pump Pressure Regulation Valve Circuit P0253 Pump Pressure Regulation Valve Circuit Low P0254 Pump Pressure Regulation Valve Circuit High P0261 Cylinder 1 - Injector Circuit Low P0262 Cylinder 1 - Injector Circuit High P0263 Cylinder 1 Contribution/Balance...

  • Page 143

    Fuel System P code DESCRIPTION P0611 Injector Circuit Error P062D Injector Bank1 Error P062E Injector Bank2 Error P0642 Sensor Reference Voltage “A” Circuit Low P0643 Sensor Reference Voltage “A” Circuit High P0650 Malfunction Indicator Lamp(MIL) Control Circuit P0652 Sensor Reference Voltage “B” Circuit Low P0653 Sensor Reference Voltage “B”...

  • Page 144

    Fuel System P code DESCRIPTION P1670 Invalid Injector IQA/C2I P1671 Injector IQA Checksum Error P1679 EMS Data Fail (Data frame, CS, Message error) P1694 EMS Message Error P1695 EMS Memory Error P1697 HI-SCAN message Error P2009 Intake Manifold Runner Control Circuit Low(Bank 1) P2010 Intake Manifold Runner Control Circuit High(Bank 1) P2015...

  • Page 145

    Fuel System...

  • Page 146

    Fuel System...

  • Page 147

    Fuel System...

  • Page 148

    Fuel System...

  • Page 149

    Fuel System...

  • Page 150

    WORKSHOP MANUAL HYUNDAI SEASALL MARINE ENGINE ENGINE SERIES www.hyundai-seasall.com 460-26 Sam-dong, Uiwang-si, Gyeonggi-do 437-815, Korea Fax : +82-70-8244-8555 l Tel : +82-70-8620-8035 l seasall.info@hyundai-seasall.com Copyright © 2012 Hyundai SeasAll Co., Ltd. All Rights Reserved.

This manual also for:

S250p, S250j, S220s, S220p

Comments to this Manuals

Symbols: 0
Latest comments: