Hyundai Seasall S250S Instruction manual

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

S Engine Series 1 Engine Mechanical System
Engine Mechanical System
General
Cooling System
Timing System
Cylinder Head Assembly
Engine Block
Lubrication System
Intake and Exhaust System
Coupling System

Engine Mechanical System 2General Information
General Information
Specifications

Engine Mechanical System 3General Information
Specifications

Engine Mechanical System 4General Information
Specifications

Engine Mechanical System 5General Information
Specifications
Description Specifications Limit
Oil quality
ACEA Above B4 Service oil quality
should confirm to
ACEA or API
classification
API Above CH-4
SAE
15W-40 -15℃above
10W-30 -20℃~ 40℃
5W-30 -25℃~ 40℃
0W-30 10℃below
Oil pressure(at idle) 0.8kg/㎠(7.85kPa, 1.14psi)
Cooling system
Cooling method Forced circulation with sea water pump
Coolant quantity 12L (12.68US qt, 10.56lmp qt)
Thermostat
Type Wax pellet type
Opening temperature 82±2℃(176.0~183.2℉)
(Lift : 0.35mm(0.0138in)
Full opening temperature 92℃(197.6℉)
(Lift : 10mm(0.3939in) or more)
Turbochager
EVGT cooling method Sea water cooling type
Actuator Electrical
Turbine Control type Variable Geometry Turbocharger(VGT)

Engine Mechanical System 6General 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
Drive belt tensioner lower mounting 28.4~34.3 2.9~3.5 21.0~25.3
Timing chain case bolt(M6) 7.8~11.8 0.8~1.2 5.8~8.7
Timing chain case bolt(M8) 19.6~25.5 2.0~2.6 14.5~18.8
High pressure fuel pump 64.7~74.5 6.6~7.6 47.7~55.0
Timing chain tensioner lever bolt 19.6~23.5 2.0~2.4 14.5~17.4
Timing chain guide bolt 7.8~11.8 0.8~1.2 5.7~8.7
Damper pulley bolt 186.3~205.9+58°~62° 19.0~21.0+58°~62° 137.4~151.9+58°~62°
Alternator bracket 19.6~26.5 2.0~2.7 14.5~19.5
Alternator 29.4~41.2 3.0~4.2 21.7~30.4
Front chain cover bolt(M6) 7.8~11.8 0.8~1.2 5.8~8.7
Front chain cover bolt(M8) 19.6~25.5 2.0~2.6 14.5~18.8
Chain cap assembly bolt 7.8~11.8 0.8~1.2 5.8~8.7
Drive belt idler 34.3~44.1 3.5~4.5 25.3~32.5
Idler pulley 34.3~44.1 3.5~4.5 25.3~32.5
Cylinder head
Fuel feed and return tube 9.8~11.8 1.0~1.2 7.2~8.7
Engine hanger bolt 19.6~26.5 2.0~2.7 14.5~19.5
Water outlet fitting 9.8~11.8 1.0~1.2 7.2~8.7
Cylinder head cover bolt 9.8~11.8 1.0~1.2 7.2~8.7
Camshaft bearing ladder bolt 13.7~15.7 1.4~1.6 10.1~11.6

Engine Mechanical System 7General 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
Cylinder head bolt 58.8 + 88°~92°
+118°~122° 6.0 + 88°~92° +118° ~122° 43.4 + 88°~92° +118°~122°
Cooling system
Water pump pulley bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Water pump bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Thermostat housing 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Water outlet duct bolts 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Lubrication system
Oil pump assembly 19.6 ~ 26.5 2.0 ~ 2.7 14.5~ 19.5
Oil pump chain tensioner 7.6~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Baffle plate 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil filter and cooler assembly 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Oil gauge bracket 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil filter cap 24.5 2.5 18.1
Upper oil pan bolt 1 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Upper oil pan bolt 2 29.4 ~ 33.3 3.0 ~ 3.4 21.7 ~ 24.6
Lower 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 bolt 14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~ 15.9
Intake and exhaust system
Inlet lower manifold assembly 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Inlet upper manifold assembly 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Turbocharger oil return pipe bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Turbocharger oil feed pipe nut 18.6 ~ 25.5 1.9 ~ 2.6 13.7 ~ 18.8
Turbocharger oil feed pipe eyebolt 26.5 ~ 32.4 2.7 ~ 3.3 19.5 ~ 23.9
Turbocharger oil feed pipe mounting
bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Turbocharger mounting bolt 29.4 ~ 34.3 3.0 ~ 3.5 21.7 ~ 35.3
Turbocharger and exhaust pipe
assembly mounting bolt 40.2 ~ 53 4.1 ~ 5.5 29.7 ~ 39.8
Turbocharger and exhaust pipe
assembly mounting bolt 29.4 ~ 34.3 3.0 ~ 3.5 21.7 ~ 25.3
Exhaust manifold mounting 29.4 ~ 34.3 3.0 ~ 3.5 21.7 ~ 25.3

Engine Mechanical System 8General Information
Compression Pressure Inspection
✍NOTICE
• If the there is lack of power, excessive oil
consumption or poor fuel economy, measure the
compression pressure.
• Whenever removing injectors for compression
pressure inspection replace the gaskets with new ones
and tighten them with the specified torque.
1. Warm up engine until the normal operating
temperature (80~95°C (176-203℉)).
2. Remove the injectors. (Refer to Injector in FL Group)
3. Check the cylinder compression pressure.
1) Insert a compression gauge SST(00200-0T004，
00200-0T005) into the injector hole.
2) Fully open the throttle.
3) While cranking the engine, measure the
compression pressure.
✍NOTICE
Always use a fully charged battery to obtain engine
speed of 220rpm or more
. 4) Repeat step 1) though 3) for each cylinder
✍NOTICE
This measurement must be done in as short a time as
possible.
Compression pressure :
2,745.85kPa (28.0kg/cm², 398.25psi) (220 rpm)
Minimum pressure :
2,255.52kPa (23.0kg/cm², 327.14psi)
5) If the cylinder compression in 1 or more cylinders is
low, pour a small amount of engine oil into the cylinder
through the spark plug hole and repeat step1)
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.
• If pressure doesn't rise despite dropping oil on the
pistons because of low pressure in the neighboring
cylinders, it can be caused by a poor cylinder head
gasket or stained oil or coolant in the cylinder head.
4. Reinstall the injectors. (Refer to Injector in FL Group)

Engine Mechanical System 9Cooling System
Special Service Tools

Engine Mechanical System 10 Cooling System
Special Service Tools

Engine Mechanical System 11 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

Engine Mechanical System 12 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

Engine Mechanical System 13 Cooling System
Removal
Seawater Pump
1. Remove clamps and hoses connect to sea water
pump inlet and outlet.
2. Remove three bolts fixing cylinder block.
Tightening torque:
11.8 ~ 14.7Nm (1.2~1.5kgf.m, 8.7 ~ 10.8lb-ft)
3. Remove impeller housing cover.
4. Remove impeller inside the seawater pump using
tools.
5. Check the condition of impeller and bushing.
6. Check the condition of cam
7. Apply soap water on impeller when assembling the
impeller and reassemble towards rotation direction.
◉CAUTION
Take CAUTION in order the direction of curved fan to
be in the right direction when using the impeller.
8. Reassemble aligning axis of impeller shaft and
engine cam.
9. Apply lubricant O-rings on inserting parts and cover
and assembly.
◉CAUTION
Make sure you use new O-ring after seawater pump
reassemble.
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. Open the drain plug to remove engine coolant from
heat exchanger.
2. Remove all hoses and clamps connected to heat
exchanger.
3. Unscrew three bolts fixing heat exchanger.
Tightening torque:
44.1 ~ 49.0Nm (4.5 ~5.0kgf.m, 32.5 ~ 36.2lb-ft)

Engine Mechanical System 14 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.
8. Check tube condition.
9. Check anode condition.
◉CAUTION
Make sure heat exchanger tubes are not damaged.
10. Clean housing and heat exchanger and install heat
exchanger into housing.
11. Install new O-ring on both sides.
12. Check the direction of end cap on both sides for
assembly.
13. Install new anode.
Oil cooler
1. Drain hydraulic oil in reserve oil tank and line and
dissemble power steering pump
2. Remove hoses and clamps connected to pumps
3. Unscrew three bolts fixing cooler
Tightening torque:
44.1 ~ 49.0Nm (4.5 ~5.0kgf.m, 32.5 ~ 36.2lb-ft)
4. Use L-wrench and remove end cap on both sides.
5. Remove tube bundle out of housing using soft
hammer.
6. Check the condition of O-ring on both end cap
7. Check to see any sea water intake into oil cooler
8. Check the condition of oil cooler tube bundle
◉CAUTION
Take CAUTION avoid oil cooler tube damage.
9. Clean housing and assemble tube bundle with new
O-ring.
Water Pump
1. Drain engine coolant
☢WARNING
The system is under high pressure when the engine is
hot. To avoid danger of releasing scalding engine
coolant, remove the cap only when the engine is cool.
2. Remove the drive belt.
3. Remove the water pump(A).
Tightening torque:
9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

Engine Mechanical System 15 Cooling System
4. Installation is in the reverse order of removal.
Thermostat
✍NOTICE
Disassembly of the thermostat would have an adverse
effect, causing a lowering of cooling efficiency.
1. Drain the engine coolant so its level is below
thermostat.
2. Remove the thermostat with its gasket after taking off
the water inlet fitting (A) from the engine coolant control
assembly.
Tightening torque:
7.8 ~ 9.8Nm (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
3. Installation is in the reverse order of removal. Water
Outlet Duct and Fitting
Water outlet and fitting
1. Remove the intake and the exhaust manifold system.
2. Remove the water outlet duct(A).
Tightening torque:
9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
3. Loosen the oil cooler mounting bolts for space of the
outlet fitting's removal.
4. Remove the water outlet fitting(A).
Tightening torque:
9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Engine Coolant Control Assembly
1. Drain engine coolant.
☢WARNING
The system is under high pressure when the engine is
hot. To avoid danger of releasing scalding engine
coolant, remove the cap only when the engine is cool.
2. Remove the drive belt.
3. Remove the alternator (A).

Engine Mechanical System 16 Cooling System
Tightening torque:
29.4 ~ 41.2Nm (3.0 ~ 4.2kgf.m, 21.7 ~ 30.4lb-ft)
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. Installation is in the reverse order of removal.
Check Engine Coolant Level at Reservoir
1. The engine coolant level should be between the
'MAX' and 'MIN' lines, when the engine is cold. If low,
check for leaks and add quality-qualified engine coolant.
If you can't get any quality-qualified coolant, add similar
high quality mono-ethylene glycol based non-silicate,
non-amine, non-nitrite, and non-borate coolant or
equivalent to 'MAX' line.
Check Engine Coolant Quality
1. Wait until engine is cool, and then carefully remove
the cap.
2. Check if there is any excessive deposit of rust or
scale around the cap.
3. If excessive dirty, clean the cooling system and
replace coolant.
4. Reinstall the cap.

Engine Mechanical System 17 Cooling System

Engine Mechanical System 18 Cooling System
Thermostat

Engine Mechanical System 19 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. Stay - tensioner bracket 9. Water pump impeller 14. Drive belt
5. Water pump 10. Water pump gasket