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ENGINE GENERAL

KYRON 2005.10

0000-00

Fuel and lubrication system

Painted  surface  of  the  body  can  be  damaged  or  rubber  products  (hoes)  can  be  corroded  if 
engine  oil  and  fuel  are  spilled  over.  If  spilled  over  engine,  foreign  materials  in  air  can  be 
accumulated on the engine damaging fuel system.

If work on the fluid system such as fuel and oil, working area should be well ventilated 
and mechanic should not smoke.
Gasket or seal on the fuel/lubrication system should be replaced with new and bolts and 
nuts should be tightened as specified.
After  removal/installation  works,  be  sure  to  check  whether  there  is  leak  on  the 
connecting section.

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If  fine  dust  or  foreign  material  enters  into  DI  engine's  fuel  system,  there  can  be  serious 
damages  between  HP  pump  and  injectors.  So,  be  sure  to  cover  removed  fuel  system 
components with cap and protect removed parts not to be contaminated with dirt. (Refer to 
cleanness in this manual while working on DI engine fuel system)

Electrical equipment

Electrical equipment should be handled more carefully.
Currently,  the  engine  is  equipped  with  a  lot  of  electrical  equipments  so  there  can  be  engine 
performance drops, incomplete combustion and other abnormals due to short and poor contact. 
Mechanics should well aware of vehicle's electrical equipment.

If  have  to  work  on  the  electrical  equipment,  be  sure  to  disconnect  battery  negative  (-) 
terminal and position the ignition switch to off if not required.
When replacing electrical equipment, use the same genuine part and be sure to check 
whether ground or connecting portions are correctly connected during installation. 
If ground or connecting portion is loosened, there can be vehicle fire or personal injury.

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Summary of Contents for Kyron D100 2005

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Page 106: ...YSTEM LAYOUT 6 LUBRICATION SYSTEM LAYOUT 7 COOLING SYSTEM LAYOUT 8 FUEL SYSTEM LAYOUT 9 FUEL SUPPLY SYSTEM 10 CLEANNESS 11 MAINTENANCE AND REPAIR 12 GUIDELINES FOR SERVICE WORK SAFETY 13 DURING SERVICE WORK FOR INSPECTION 14 DURING SERVICE WORK FOR ELECTRIC DEVICES 15 OWNER INSPECTIONS AND SERVICES 16 STANDARD BOLTS SPECIFICATIONS 3 5 10 12 14 16 18 20 22 23 28 30 34 36 37 41 ...

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Page 108: ...ENGINE GENERAL KYRON 2005 10 0000 00 0000 00 ENGINE GENERAL GENERAL 1 ENGINE ASSEMBLY LAYOUT 1 LH SIDE VIEW 2 RH SIDE VIEW ...

Page 109: ...KYRON 2005 10 0000 00 ENGINE GENERAL 3 FRONT VIEW 4 FAN BELT ...

Page 110: ...H L VGT turbo charger C Engine oil dipstick M Engine D Oil separator PCV valve N Engine oil filler cap E Vacuum pump O PWM electric fan fan shroud F EGR valve P Power steering oil reservoir G Vacuum modulator Q Fuel filter priming pump H Brake fluid reservoir R Battery I ABS ESP modulator S Fuse box J Air cleaner assembly T Washer fluid reservoir ...

Page 111: ...KYRON 2005 10 0000 00 ENGINE GENERAL 2 Engine And Sensors Camshaft Position Sensor Injector Glow Plug Common Rail Fuel Pressure Sensor Common Rail Booster Pressure Sensor ...

Page 112: ...ENGINE GENERAL KYRON 2005 10 0000 00 Knock Sensor 1 EA Water Temperature Sensor Vacuum Modulator Crankshaft Position Sensor Water temp sensor Knock sensor HP Pump ...

Page 113: ... 00 ENGINE GENERAL 3 Engine Accessories Related to ECU IP Interior Fuse Box Passenger Side Engine ECU Mounting Location Engine ECU main relay Hazard warning lamp VGT EGR vacuum modulators HFM HP pumpIMV 1 2 3 4 Installed ...

Page 114: ...ter Sensor Service Interval Fuel Filter EU Only Replace every 30 000 km Draining water from fuel filter whenever replacing the engine oil General Replace every 25 000 km Draining water from fuel filter whenever replacing the engine oil Integrated with 2 PPSs Priming Pump Fuel Filter ...

Page 115: ...N 2005 10 0000 00 ENGINE GENERAL 3 ELECTRICAL COMPONENTS AND PRE HEATING SYSTEM Glow Plug Preheat Warning Lamp Cluster Alternator Starter motor Engine compartment fuse box PTC FFH 12V 115A 12V 2 2kw Battery ...

Page 116: ...ION 1 Glow plug terminal 1 4 2 No G5 for 4 cylinders Without D20DT 3 IG1 power supply terminal 4 Glow plug control signal ECU113 5 Ground terminal 6 Battery main wire 7 Preheat completion transmit terminal No use for vehicle without remote engine start 8 K line ECU 34 ...

Page 117: ...E SYSTEM Supplying Compressed Air with Turbocharger s Operation Intake Manifold Intake outlet hose Front air duct Air cleaner Terbocharger intercooler Turbo charger Inter cooler Air cleaner To corresponding cylinders From intercooler Coolant port ...

Page 118: ...05 10 0000 00 Recirculation of Exhaust Gas when EGR Valve Operates Turbocharger Intercooler EGR valve Exhaust gas Intake com pressed air HFM Sensor Plug in sensor Air cleaner Turbo charger Temperature Sensor Pretension graph ...

Page 119: ...YRON 2005 10 0000 00 ENGINE GENERAL 5 EXHAUST SYSTEM LAYOUT DOC Diesel Catalytic Converter Exhaust Manifold To turbo charger To EGR pipe From cylinders EEGR Pipe Passage for recirculation of exhaust gas ...

Page 120: ...ill happen when blow by gas passes through baffle plates in cylinder head cover Then oil and gas will be separated due to cyclone effect after entering the oil separator inlet port Separated oil returns to oil pan via oil drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that opens closes due to pressure differences between the int...

Page 121: ...KYRON 2005 10 0000 00 ENGINE GENERAL 6 LUBRICATION SYSTEM LAYOUT Cylinder Head Cover Oil Pressure Warning Lamp Cluster Oil Pan and Baffle Plate Integrated Type Oil Strainer Oil dipstick gauge ...

Page 122: ...en when blow by gas passes through baffle plates in cylinder head cover Then oil and gas will be separated due to cyclone effect after entering the oil separator inlet port Separated oil returns to oil pan via oil drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that opens closes due to pressure differences between the intake side...

Page 123: ...T Coolant Port Water Pump Pipe Radiator Assembly Cooling Fan and Fan Clutch Coolant outlet port Thermostat inside Cylinder block Reservoir Coolant inlet hose Radiator Coolant outlet hose PWM electric fan Radiator Coolant reservoir Coolant inlet hose Return hose ...

Page 124: ...ENGINE GENERAL KYRON 2005 10 0000 00 Engine Oil Filter Cooler Oil cooler Oil filter Oil cooler Oil filter cap Oil pressure switch ...

Page 125: ...AYOUT Injector Fuel Filter Priming Pump Fuel filter Connector Priming pump HP Pump Fuel return port Venturi Low pres sure fuel supply port Fuel return port Fuel tempera ture sensor IMV connector IMV valve High pres sure fuel supply port 1 2 3 4 5 HP Pump ...

Page 126: ...ENGINE GENERAL KYRON 2005 10 0000 00 Cylinder Head Fuel return hose Fuel pipe Common rail High pressure fuel pipe Fuel rail pressure sensor 1 2 3 4 5 ...

Page 127: ...ensor determines injection order and ECU detects driver s pedal position driver s demand through electrical signal that is generated by variable resistance changes in accelerator pedal sensor Air flow hot film sensor detects intake air volume and sends the signals to ECU Especially the engine ECU controls the air fuel ratio by recognizing instant air volume changes from air flow sensor to decrease...

Page 128: ... Even in this case the HP pump still operates to supply high pressurized fuel This increases the pressure to combustion chamber over 250 bar and may cause fatal damage to engine You can compare the thickness of injector nozzle hole and hair as shown in below figure left side The right side figure shows the clearance between internal operating elements The core elements of fuel system has very high...

Page 129: ...n the wiring harnesses and connectors in engine compartment Perform the diagnosis proceee with SCAN 100 refer to DI10 DIAGNOSIS section in this manual Locate the fault If the cause is from fuel system from priming pump to injector including return line follow the step 1 through step 3 above If the problem is from HP pump fuel supply line or injector prepare the clean special tools and sealing caps...

Page 130: ...The pipes should be tightened tospecified tightening torques during installation Over or under torques out of specified range may cause damages and leaks at connections Once installed the pipes have been deformed according to the force during installtion therefore they are not reusable The copper washer on injector should be replaced with new one The injector holder bolt should be tightened to spe...

Page 131: ...y SCAN 100 after replacing the high pressure pump 7 8 To supply the fuel to transfer line of HP pump press the priming pump until it becomes hard 9 Do not crank engine before having filled pump Check the installed components again and connect the negative battery cable Start the engine and check the operating status With SCAN 100 check if there are current faults and erase the history faults 10 11...

Page 132: ...eater see fuel system System Supplement And Remedy Against Water In Fuel As mentioned above some gas stations supply fuel with excessive than specified water In the conventional IDI engine excessive water in the fuel only causes dropping engine power or engine hunting However fuel system in the DI engine consists of precise components so water in the fuel can cause malfunctions of HP pump due to p...

Page 133: ...tenance services are performed make sure all the parts are replaced and all the necessary repairs are done before driving the vehicle Always use the proper fluid and lubricants Engine Oil and Oil Filter Change Always use above the API SH grade or recommended engine oil Engine Oil Viscosity Engine oil viscosity thickness has an effect on fuel economy and cold weather operation Lower viscosity engin...

Page 134: ...rvice Check the disc brake pads or the drum brake linings Check the pad and the lining thickness carefully Tire and Wheel Inspection and Rotation Check the tires for abnormal wear or damage To equalize wear and obtain maximum tire life rotate the tires If irregular or premature wear exists check the wheel alignment and check for damaged wheels While the tires and wheels are removed inspect the bra...

Page 135: ...y personal working method skill ways and service procedures and to allow prompt correct service works Note Notice While using this manual there are a lot of Note or Notice having below meaning Note means detailed description of supplementary information on work procedure or skill Notice means precautions on tool device or part damages or personal injuries that can occur during service works Howeve...

Page 136: ...ontacted Painted surface of the body can be damaged if spilled over with oil or anti freeze Never go under vehicle if supported only with jack Never near the battery and fuel related system to flames that can cause fire like cigarette Never disconnect or connect battery terminal or other electrical equipment if ignition key is turned on While connecting the battery terminals be cautious of polarit...

Page 137: ...reign materials While removing the engine do not position the jack and others under the oil pan or engine To secure the safety use only safety hook on the engine 1 2 3 4 5 Engine and accessories Engine has a lot of precise portions so tightening torque should be correct during disassembly assembly and removal installation and service work should be done in clean ways during disassembly assembly Ma...

Page 138: ...een HP pump and injectors So be sure to cover removed fuel system components with cap and protect removed parts not to be contaminated with dirt Refer to cleanness in this manual while working on DI engine fuel system Electrical equipment Electrical equipment should be handled more carefully Currently the engine is equipped with a lot of electrical equipments so there can be engine performance dro...

Page 139: ...le and then support with chassis stand before service work Before service work be sure to disconnect battery negative terminal to prevent damages by bad wire and short 1 2 3 If service from interior of the vehicle use protection cover to prevent damage and contamination of seat and floor Brake fluid and anti freeze can damage painted surface of body So carefully handle them during service work 4 5...

Page 140: ...se on the driving and sliding surfaces before installing parts Use sealer or gasket to prevent leakage if necessary Damaged or not never reuse removed gasket Replace with new and cautious on installing directions Tighten every bolt and nut with specified torque When service work is completed check finally whether the work is performed properly or the problem is solved If work on the fuel line betw...

Page 141: ...Be careful not to throw or drop each sensor or relay Securely connect each connector until hear a click sound 1 2 3 4 5 6 7 1 Lifting Positions 4 post lift As illustrated position the vehicle on the 4 post lift securely and block the front and rear of each tire not to move during working During lifting be sure to check whether vehicle is empty Board on lift connection device installed in front of ...

Page 142: ...hese are signs that the system may be leaking or overheating Have the system inspected and repaired immediately Tires Wheels and Alignment Operation Be alert to any vibration of the steering wheel or the seats at normal highway speeds This may mean a wheel needs to be balanced Also a pull right or left on a straight level road may show the need for a tire pressure adjustment or a wheel alignment S...

Page 143: ...cold oil will not drain back to the pan fast enough to give a true oil level reading Check the coolant level in the coolant reservoir tank and add coolant if necessary Inspect the coolant Replace dirty or rusty coolant Engine Coolant Level and Condition Check the washer fluid level in the reservoir Add fluid if necessary Windshield Washer Fluid Level 3 At Least Twice A Month Tire And Wheel Inspect...

Page 144: ...Boot And Seal Inspection Inspect the front and rear suspension and the steering system for damaged loose or missing parts signs of wear or lack of lubrication Inspect the power steering line and the hoses for proper hookup binding leaks cracks chafing etc Clean and inspect the drive axle boot and seals for damage tears or leakage Replace the seals if necessary Inspect the complete system including...

Page 145: ... glove box and the console doors and any folding seat hardware Body Lubrication Service Underbody Flushing Flushing the underbody will remove any corrosive materials used for ice and snow removal and dust control At least every spring clean the underbody First loosen the sediment packed in closed areas of the vehicle Then flush the underbody with plain water Engine Cooling System Inspect the coola...

Page 146: ...ENGINE GENERAL KYRON 2005 10 0000 00 16 STANDARD BOLTS SPECIFICATIONS ...

Page 147: ...ng bolt tightening works and can adjust torque to be proper within 15 if necessary Try not to over max allowable tightening torque if not required to do so Determine extra proper tightening torque if tightens with washer or packing If tightens bolts on the below materials be sure to determine the proper torque 1 2 3 4 Aluminum alloy Tighten to 80 of above torque table Plastics Tighten to 20 of abo...

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