Hyundai HD 65 / 72 / 78 with engines D4DD repair 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

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