Major Changes in D27DT Engine (By Adaptation of Big Diameter Shaft)

1. Major Changes in D27DT Engine (By Introduction of Big Diameter Shaft) Part number Part Name Changes Remark Big Dia. Shaft Small Dia. Shaft 665 010 05 05 665 010 03 05 Cylinder block(Short) Increase the size and reinforce the main bearing wall. 665 031 02 01 662 031 35 01 Crankshaft Increase the inner diameter of main bearing journal. 664 030 00 20 665 030 01 20 Connecting rod Increase the size and adapt the fracture type connecting rod. 665 030 05 03 665 030 04 03 Viscous Damper Adapt the viscous damper (bigger size). 664 052 01 03 665 052 00 03 Crankshaft sprocket Increase the inner diameter due to use of bigger center bolt. 661 991 30 67 662 991 30 68 Crankshaft key Increase the size (woodruff key) 665 997 30 46 661 997 36 46 Crankshaft front sealing Increase the outer size of damper hub. 664 990 00 40 604 990 00 40 Crankshaft damper disc 664 990 00 01 665 990 00 01 Center bolt Increase the size (M18  M20) 664 011 00 11 665 011 01 11 Main bearing cap 664 011 00 13 665 011 00 13 Thrust bearing cap 664 033 01 01 662 033 58 01 Main bearing upper shell Increase the size. 664 033 02 02 665 033 04 02 Main bearing lower shell 664 033 02 52 601 033 19 52 Thrust bearing upper shell 664 033 06 52 601 033 13 52 Thrust bearing lower shell

Part number Part name Changes Remark Big Dia. Shaft Small Dia. Shaft 664 038 01 10 662 038 01 10 Connecting rod bearing upper shell Increase the size. 664 038 01 11 601 038 46 11 Connecting rod bearing lower shell 664 011 01 71 665 011 02 71 Main bearing cap bolt Increase the length (67 → 82 mm). 664 038 00 71 161 038 30 71 Connecting rod bolt 665 180 00 43 665 180 01 43 Oil spray nozzle Change the installation type(bolt → press­in) 665 010 01 61 662 010 32 61 Baffle plate Change the space thickness due to lower installation height. 914005 006020 914005 006005 Baffle plate bolt 665 150 30 70 665 150 02 70 Alternator bracket Compatible in both shafts (small and big diameter shaft).

D27DT Small Diameter Shaft D27DT Bbig Diameter Shaft 2. Detailed Changes in D27DT 1) Cylinder Block D27DT Small Diameter Shaft D27DT Bbig Diameter Shaft ▶ Part number : 665 010 03 05 ▶ Inner dia. of main bearing cap housing : ∮ 62.5 mm ▶ Thickness of main bearing cap housing : 20 mm ▶ Location of “A” ID boss : Center of thrust bearing ▶ Part number : 665 010 05 05 ▶ Inner dia. of main bearing cap housing : ∮ 66.5 mm ▶ Thickness of main bearing cap housing : 22 mm ▶ Location of “A”ID boss : 71 mm from center of thrust bearing ※ Reasons to be changed ▷ To accommodate the Increased combustion pressure and output. ▷ To improve the engine performance (increase the inner diameter) ▷ To make the manufacturing process easier (change the ID boss location) "A"

D27DT Small Diameter shaft 3) Connecting rod D27DT Small Diameter shaft D27DT Big Diameter Shaft ▶ Part number : 665 030 01 20 ▶ Inner diameter of small end : ∮ 30 mm ▶ Inner diameter of large end : ∮ 51.6 mm ▶ Pitch between small end and large end : 145 mm ▶ Part number : 664 030 00 20 ▶ Inner diameter of large end : ∮ 54.6 mm ※ Reasons to be changed ▷ Due to change of crankshaft. ▷ To use the fracture type connecting rod. ※ Caution : · Make sure to align the connecting rods caps during installation. · Mark cylinder number on each rod.

D27DT Small Diameter Shaft 4) Viscous Damper D27DT Small Diameter Shaft D27DT Big Diameter Shaft ▶ Part number : 665 030 04 03 ▶ Inner diameter : ∮ 32 mm ▶ Inner diameter without bushing : ∮ 45 mm ▶ Total weight : 4.28 kg ▶ Part number : 665 030 05 03 ▶ Inner diameter : ∮ 34 mm ▶ Inner diameter without bushing : ∮ 48 mm ▶ Total weight : 4.30 kg ※ Reasons to be changed ▷ Due to change of crankshaft.

D27DT Small Diameter Shaft 5) Crankshaft Sprocket D27DT Small Diameter Shaft D27DT Big Diameter Shaft ▶ Part number : 665 052 00 03 ▶ Inner diameter : ∮ 32 mm ▶ Total length : 45 mm ▶ Part number : 664 052 01 03 ▶ Inner diameter : ∮ 34 mm ▶ Total length : 43 mm ※ Reasons to be changed ▷ Due to change of crankshaft

D27DT Small Diameter Shaft 2) Crankshaft D27DT Small Diameter Shaft D27DT Big Diameter Shaft ▶ Part number : 662 031 35 01 ▶ Inner diameter of crank journal : ∮ 58 mm ▶ Outer diameter of crank pin journal : ∮ 48 mm ▶ Width of crank pin : 28 mm ▶ Width of crank journal : 24 mm ▶ Part number : 665 031 02 01 ▶ Inner diameter of crank journal : ∮ 62 mm ▶ Outer diameter of crank pin journal : ∮ 51 mm ▶ Width of crank pin : 26 mm ▶ Width of crank journal : 26 mm ※ Reasons to be changed ▷ To reinforce the crankshaft ▷ To increase the design safety of crankshaft ▷ Design changes according to new line in Changwon plant. D27DT (emboss) D27DTL/P (emboss) Straight key Woodruff key

D27DT Small Diameter Shaft 6) Crankshaft Key D27DT Small Diameter Shaft D27DT Big Diameter Shaft ▶ Part umber : 662 991 30 68 ▶ Part number : 661 991 30 67 ▶ Adaptation of woodruff key ※ Reasons to be changed ▷ Due to change of crankshaft ▷ To improve the assembly process and to increase the surface pressure.

D27DT Small Diameter Shaft 7) Crankshaft FRT Seal D27DT Small Diameter Shaft D27DT Big Diameter Shaft ▶ Part number : 661 997 36 46 ▶ Inner diameter : ∮ 43.8 mm ▶ Outer diameter : ∮ 67 mm ▶ Part number : 665 997 30 46 ▶ Inner diameter : ∮ 46.8 mm ※ Reasons to be changed ▷ Due to change of crankshaft ▷ To improve the assembly process and to increase the surface pressure. Spring Spring

D27DT Small Diameter Shaft 8) Crankshaft Vibration Damper Disc D27DT Small Diameter Shaft D27DT Big Diameter Shaft ▶ Part number : 604 990 00 40 ▶ Inner diameter : ∮ 18.2 mm ▶ Outer diameter : ∮ 46 mm ▶ Part number : 664 990 00 40 ▶ Inner diameter : ∮ 20.2 mm ▶ Outer diameter : ∮ 48 mm ※ Reasons to be changed ▷ Due to change of crankshaft and center bolt.

D27DT Small Diameter Shaft 9) Center Bolt D27DT Small Diameter Shaft D27DT Big Diameter Shaft ▶ Part number : 665 990 00 01 ▶ Nominal size : M 18 ▶ Length : 50 mm ▶ Tightening torque : 325Nm + 90˚ ▶ Part number : 664 990 00 01 ▶ Nominal size : M 20 ▶ Length : 85 ㎜ ▶ Tightening torque : 200Nm + 180˚ ※ Reasons to be changed ▷ Due to change of crankshaft

D27DT Small Diameter Shaft 10) Main Bearing Cap D27DT Small Diameter Shaft D27DT Big Diameter Shaft ▶ Part number : 665 011 01 11 ▶ Inner diameter of main bearing cap : ∮ 62.5 mm ▶ Thickness of main bearing cap : 20 mm ▶ Height : 48 mm ▶ Part number : 664 011 00 11 ▶ Inner diameter of main bearing cap : ∮ 66.5 ㎜ ▶ Thickness of main bearing cap : 22 ㎜ ▶ Height : 55 ㎜ ※ Reasons to be changed ▷ Due to change of crankshaft ▷ To improve the engine performance (increase the inner diameter).

D27DT Small Diameter Shaft 11) Thrust Bearing Cap D27DT Small Diameter Shaft D27DT big Diameter Shaft ▶ Part number : 665 011 00 13 ▶ Inner diameter of main bearing cap : ∮ 62.5 mm ▶ Thickness of main bearing cap : 20 mm ▶ Height : 48 mm ▶ Part number : 664 011 00 13 ▶ Inner diameter of main bearing cap : ∮ 66.5 mm ▶ Thickness of main bearing cap : 22 mm ▶ Height : 55 mm ※ Reasons to be changed ▷ Due to change of crankshaft ▷ To improve the engine performance (increase the inner diameter)

D27DT Small Diameter Shaft 12) Main Bearing D27DT Small Diameter Shaft D27DT Big Diameter Shaft ▶ Part number : upper 662 033 58 01 lower 665 033 04 02 ▶ Inner diameter : ∮ 58 mm ▶ Outer diameter : ∮ 62.5 mm ▶ Bearing height : 17.5 mm ▶ Part number : upper 664 033 01 01 lower 664 033 02 02 ▶ Inner diameter : ∮ 62 ㎜ ▶ Outer diameter : ∮ 66.5 ㎜ ▶ Bearing height : 19 ㎜ ※ Reasons to be changed ▷ Due to change of crankshaft ▷ To secure a proper surface pressure in given conditions. UPR LWR UPR LWR

D27DT Small Diameter Shaft 13) Thrust Bearing D27DT Small Diameter Shaft D27DT Big Diameter Shaft ▶ Part number : upper 601 033 19 52 lower 601 033 13 52 ▶ Inner diameter : ∮ 65.8 mm ▶ Outer diameter : ∮ 81 mm ▶ Part number : upper 664 033 02 52 lower 664 033 06 52 ▶ Inner diameter : ∮ 69.8 mm ▶ Outer diameter : ∮ 83 mm ※ Reasons to be changed ▷ Due to change of crankshaft ▷ To secure a proper surface pressure in given conditions. UPR LWR UPR LWR

D27DT Small Diameter Shaft 14) Connecting rod Bearing D27DT Small Diameter Shaft D27DT big Diameter Shaft ▶ Part number : upper 662 038 01 10 lower 601 038 46 11 ▶ Inner diameter : ∮ 48 mm ▶ Outer diameter : ∮ 51.6 mm ▶ Bearing height : 21.8 mm ▶ Part number : upper 664 038 01 10 lower 664 038 01 11 ▶ Inner diameter : ∮ 51 mm ▶ Outer diameter : ∮ 54.6 mm ▶ Bearing height : 20 mm ※ Reasons to be changed ▷ Due to change of crankshaft ▷ To secure a proper surface pressure in given conditions. UPR UPR Changed the location of upper locating lip due to adaptation of fracture type bearing. LWR LWR

D27DT Small Diameter Shaft 15) Main Bearing Cap Bolt D27DT Small Diameter Shaft D27DT Big Diameter Shaft ▶ Part number : 665 011 02 71 ▶ Diameter : ∮ 13 mm ▶ Length : 67 mm ▶ Material : 37Cr4 or 41Cr4 ▶ Tensile strength : 1040 ~ 1160 N/㎟ ▶ Part number : 664 011 01 71 ▶ Length : 82 mm ▶ Tensile strength : 1112 ~ 1267 N/㎟ ※ Reasons to be changed ▷ To increase the length and to improve the strength due to adaptation of big diameter shaft.

D27DT Small Diameter Shaft 16) Oil Injection Nozzle D27DT Small Diameter Shaft D27DT Big Diameter Shaft ▶ Part number : 665 180 01 43 ▶ Aluminum housing type ▶ Installed on crankcase with bolts ▶ Part number : 665 180 00 43 ▶ Steel pipe type ▶ Pressed into crankcase ※ Reasons to be changed ▷ To secure the package to use the fracture type connecting rod. ▷ To reduce the cost. ▷ Auto press­in and inspection.