Hyundai HD 65 / 72 / 78 with engines D4DD, service e-manual (in Russian)

Content General information Chassis number plate Maintenance - general information Protecting your car from damage Preparation of instruments and measuring devices Special fixtures and fittings Parts location Cleaning parts for reuse Details Electrical system Rubber parts Measuring the dimensions of parts Determination of geometric dimensions by projection Determination of actual geometric dimensions Measurement point Checking electrical wiring Checking the fuses Electrical system maintenance Safety measures when carrying out electric welding work Recommended oils, greases and fluids Tightening torques for standard parts D4DD engine D4DD engine mechanical system Description Combustion process Valve mechanism Cylinder block and liners Piston Piston rings Crankshaft Timing gear drive Flywheel Technical data Tightening torques for screw connections Special tools Diagnostics Settings Compression Gas distribution system Gas distribution mechanism Cylinder head Replacing head parts Cylinder head assembly Rocker arm assembly Valves Checking and adjusting valve clearances Cylinder block Flywheel Cylinder block Intake and exhaust systems Technical data Tightening torques Troubleshooting Turbocharger Intake manifold Exhaust manifold Air filter Muffler Lubrication system Oil pump Oil cooler Bypass valve Pressure reducing valve Contact oil pressure switch Oil filter Lubrication of engine components Technical data Tightening torques for screw connections Maintenance standards Troubleshooting Checking the oil level Oil change Replacing the oil filter Checking oil pressure Oil pump Oil cooler Cooling system Water pump Thermostat Radiator Radiator cap Cooling fan Viscous clutch operation Technical data Maintenance Standards Troubleshooting Radiator Fuel system General section Technical data Checkout Sealant Tightening torques for screw connections Troubleshooting Fuel injection system Engine management Engine starting system Fuel tank and fuel lines Troubleshooting Algorithm Electronic engine management system Diesel engine electronic control unit (ECU) Used engine circuit diagram Removing the engine control unit Troubleshooting Tips Fuel system components Fuel filter Injectors Fuel rail Fuel pump Diagnose engine with fault codes Reading fault codes and driver complaints Using the HI-SCAN Electrical overload General information Conditions for the formation and storage of a malfunction code Technical data Rechecking for DTCs Intermittent fault checking procedures Used engine check procedures Fault codes Engine electrical (D4DD) General information Technical data Troubleshooting System preheating Charging system Launch System Starter motor Preheating system Glow plugs Fuel system and engine management system EBPO1, EBPO2 General information Specifications Fuel system (D4DC) 158 Fuel system dimensions and specifications For D4AF / D4AE / D4AL (EURO-I) engines Tightening torques (EURO-I) Engines D4DA / D4DB / D4AL (EURO-II) Tightening torques (EURO-II) D4DC engine Tightening torques (D4DC) Troubleshooting Fuel system High pressure fuel pump RLD regulator (D4AF / D4AL (EURO-I), D4DC) Regulator R801, R901 for engines D4DA / D4DB / D4AL (EURO-II) Engine management system Fuel tank BOSH high pressure fuel pump, type A High pressure fuel pump NB (EP-9) for D4DA / D4DB / D4AL (EURO-II) engines Checking details RLD regulator for D4AF / D4AL (EURO-I) / D4DC engines Regulator R801, R901 for D4DA / D4DB / D4AL engines (EURO-II) Adjustable parts and changes in control characteristics Booster pump Automatic injection timing controller Fuel Injector 6 Fuel filter Water separator Engine management system Gas pedal assembly Fuel tank Clutch General information Construction How it works Specifications Maintenance guidelines Tightening torques for screw connections Working fluid Lubricants Troubleshooting Checking the technical condition without removing parts from the car Checking and adjusting the clutch pedal Bleeding the clutch actuator Clutch release actuator Clutch pedal Master cylinder Slave cylinder Clutch cover and disc Repair of gearboxes (M2S5, M3S5) General information Specifications Maintenance guidelines Tightening torques for screw connections Troubleshooting Mechanical transmission Description and operation Single cone type Double cone type Blocking mechanism Checking the transmission oil level Oil change Mechanical transmission Gearbox Secondary shaft Lower gearshift housing Upper gear shift housing M035S5 gearbox repair General information Technical conditions Maintenance guidelines Tightening torques for screw connections Special tool Mechanical transmission Gearbox synchronization device Description Installation Gearbox Main stages of installation Selector rod and selector fork Service Procedure Output shaft Basic maintenance procedures Intermediate shaft Upper gear shift housing Service Procedure Bushing Rear cover and clutch housing Service procedure Steering General information Steering gear Tie rod Tie Rod Screw-nut steering gear (with recirculating balls) Power steering gear Power steering pump Specifications Maintenance guidelines Tightening torques for screw connections Troubleshooting steering Adjustment Checking the steering wheel play (non-power steering with power steering) Steering angle check (non-power steering / power steering) Hydraulic booster oil change Removing air from the steering Checking the power steering pump pressure Power steering pump drive belt tension adjustment Steering column and steering shaft Steering column and steering shaft Steering gear Tie rod Steering gear without power steering Steering gear Power steering gear Power steering pump Suspension General information Specifications Maintenance guidelines Tightening torque for threaded connections Lubrication Troubleshooting Front suspension Leaf spring Shock absorbers Rear suspension Layout of assemblies and parts of the rear suspension Shock absorber Braking system Specifications Front wheel brakes (drum type) Front wheel brakes (disc type) Rear wheel brakes Braking system Antilock braking system specifications Parking brake specifications Tightening torques for screw connections Nodes and parts Description Braking system Vacuum booster Brake master cylinder Normal operation Front and rear wheel brakes Front wheel brakes Rear wheel brakes Brake with two wheel cylinders Brake fluid level sensor Mountain brake Air damper Exhaust brake flap Three-way solenoid valve Rear wheel brake pressure regulator Construction Measuring device Pressure control unit Maintenance and inspection of the rear wheel brake pressure regulator Parking brake - how it works Troubleshooting Checking the condition and adjusting without removing the components from the car Bleeding the brake system Adjusting the clearance between the pads and the brake drum Hydraulic brake system with vacuum booster Vacuum booster Brake pedal Brake master cylinder Rear wheel brake pressure regulator Front wheel brakes Disc brakes Disk check Drum brakes Friction pad Rear wheel brakes Drum brakes Wheel brake cylinder Friction pad Mountain brake Parking brake Anti-lock braking system (ABS) / traction control General information Anti-lock braking system Checking the indicator of health of the ABS diagnostic functions The principle of automatic ABS diagnostics Checking electrical connectors Wiring diagram of the brake pressure control circuit Electrical diagram Electrical diagram (2) Troubleshooting ABS fault code table ABS checks according to DTC values ?? Checking the operation of the anti-lock braking system Wheel sensor output voltage test ABS modulator ABS control unit Wheel sensor Cardan shaft and axle Dimensions and specifications Tightening torques for screw connections Propeller shaft malfunctions Front axle malfunctions Rear axle General information Adjustment Cardan shaft Front propeller shaft Rear propeller shaft Front axle Wheel hub Disc brake Drum brake Bridges steering knuckle Wheel alignment Description Checkout Rear axle Wheel hub Carter Bridge Differential cup assembly Body General information Specifications Cab Cargo platform type Tightening torques for screw connections Safety Safety precautions for electric welding Outer cabin Bumper Driver's door Cab interior Dashboard Cab glazing Interior decoration Driver's seat Seat belts Heating, ventilation and air conditioning system General information Refrigerant precautions Replacing parts of the air conditioning system Air circulation pattern Specifications Maintenance guidelines Tightening torques, O-ring Flat pipe connecting piece Standard bolts and nuts Inspection without dismantling Installing the gauge block Draining refrigerant Refrigerant leak test Filling the system Inspection before driving Diagnostics using performance tests Heater and air conditioner control system Fan Heater Air conditioning Compressor Condenser fan and motor Moisture trap Evaporator unit Schematic diagram Wheels and tires General description and operating principles Tire and wheel dimensions Tightening torques for screw connections Specifications Maintenance guidelines Troubleshooting Wheels and tires Tube tire Tubeless tire Electrical equipment General information Cable and wire check Specifications Troubleshooting Ignition lock Lighting devices Instrumentation Warning and indicator lamps Windshield wiper Windscreen washer Fuses and relays Arrangement of nodes and parts Fuse box Relays, fuses Instrumentation Instrument cluster Electrical diagram Connector designs Water temperature indicator Tachometer Speedometer Open door indicator Seat belt not fastened indicator Parking brake warning lamp switch Cab tilt release sensor Alarm switch Electrical diagram Work light switch Fog light / rear fog light switch Multifunction switch Standard set Connector design as standard Windshield wiper / washer Electrical diagram Connector design Washer motor Power windows Power window control unit Window regulator motor Connector design Electrical diagram Lighting devices Headlights Direction indicators Interior lamp Fog lights Electric door locks Checkout Audio system Stereo radio Speakers Sound signals Electronic timer and alarm system (ETACS) Specifications How it works Connector Electrical diagram