Motor 2,0 Diesel
Transcript of Motor 2,0 Diesel
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C100 Service Training Manual :
Engine Mechanical (2.0L Diesel)
Participants Handout
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Engine Mechanical
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Table Of Contents
Engine General ........ 5
Engine Mechanical ............. 8
Engine Lubrication . 22
Engine Timing system ....... 23
Accessory Belt ... 26
Engine Intake & Exhaust system .... 27
Engine Vacuum System .............. 29
PCV System ... 30
DPF system ... 31
Engine Cooling system.. 31
Turbo-Charger system.. 39
Fuel Supply system ...... 33
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Engine Mechanical
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Engine Mechanical
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Engine general
1. Engine Type (Z : Diesel)
2. Engine Size (20 : 2.0L)
3. Cam Mechanism (DOHC or SOHC)
4. Sequence Number
5. Manufacturers country (K : Korea)
6. Barcode Check
Engine number
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Engine Mechanical
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Engine general
2.0L Diesel
186 kph/ 180 kph
5.75 m
4 Cy linder(In-Line)
83 x 92
1.991
17.5 : 1
110/4000
320/2000
Compression ignition system
1-3-4-2
Forced feed
MB 229.31 5W 40
Cartridge
6.2 L
Gerotor
Bore x Stroke (mm)
APPL ICATION
Max Speed (MT/AT)
Min Turning Ratio (m)
Vehicle
Performance
Engine
General
Engine type
Displacement (cc)
Compression Ratio
Max Power (kW/RPM)
IgnitionIgnition sequence
Max Torque (Nm/RPM)
Type
Lubrication
Type
Oil Type and Grade
Filter
Oil Capacity (w/filter)
Oil Pump type
Pressurized
9
Centrifugal
Cross-flow
673 mm (Width)
511 mm (Height)
27 mm (Thickness)
137.3 Kpa
9.81 Kpa
WAX Pellet
Starts to open () 80 2
Completely open ( ) 95
Completely close ( ) MIN 75
Electric
Main:5EA / Aux: 7EA
Fan Diameter 340mm + 320 mm
Type
Coolant Capacity (L)
Cooling
Radiator
Type
Thermostat
Type
Fan
Type
Core
Blades
Water Pump
Surge TankPressure Valve open
Vaccum Valve open
Engine specifications
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Engine Mechanical
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Engine general
2.0L diesel
Electric motor in fuel tank
Depth Media
165 ~215(at 4.5 bar)
4.15 ~5.35
Common rail
3 cylinder radial plunger
695(mm) / rev
Max 1600 bar
Max 1600 bar
Cartridge
65 L
Planetary Gear Reduction
1.8KW
Alternator 125A
MF
12V- 90AH
912 CCA
Fuel
Delivery
Filter type
Displacement (/H)
Fuel pressure (bar)
Low
pressure
pump
Pump type
High
pressure
pump
Pump type
Fuel pressure
Capacity
Fuel Tank Capacity
Type
Power
APPLICATION
Cold Cranking Ampere
Power
Battery
Filter type
Displacement
Injector pressure
Filter Type
Type
Starter
Engine specifications
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Engine Mechanical
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Engine General
Engine overview
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Engine Mechanical
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Exploded view (Lower end)
Engine mechanical parts
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Engine Mechanical
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Exploded view (Lower end)
Engine mechanical parts
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Engine Mechanical
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1. Piston Ring Set
2. Piston Pin Retainer3. Piston
4. Piston Pin
5. Connecting Rod and Cap
6. Connecting RodJournal Bearing Set
7. Engine Block
8. Coolant Adapter
9. Coolant Adapter
10. Plug11. Crankshaft Journal
Bearing Set
12. Crankshaft
13. CKP Sensor Target Wheel
14. Crankshaft Rear Seal Ring
15. Crankshaft Gear
16. Crankshaft Gear Key
17. Engine Bed Plate
18. Crankshaft Bolt19. Bed Plate Bolt
20. Oil Nozzle Tube Bolt
21. Oil Nozzle Tube
22. Oil Filter Cap
23. ORing
24. Oil Filter
25. Oil Filter Housing
26. ORing
27. Oil Filter Housing Drain
Bolt Washer
28. Oil Filter Housing Drain Bolt
29. Oil Filter Housing Fitting Bolt
30. Engine Oil Cooler
31. ORing
32. Oil Cooler Outlet Hose
33. Oil Cooler Inlet Hose
34. Oil Pump Assembly
35. Oil Pressure Relief Valve
36. Oil Pressure Relief Valve Spring
37. Oil Pressure Relief Valve Gasket38. Oil Pressure Relief Valve Plug
39. Crankshaft Front Seal Ring
40. Oil Pressure Switch
41. Oil Pump Seal
42. Oil Pump Outer Rotor
43. Oil Pump Inner Rotor
44. Oil Pump Cover
45. Oil Pump Drive Gear
46. Oil Level Indicator
47. Oil Level Indicator Tube
48. Crankshaft Position Sensor
49. Oil Pan Bolt
50. Oil Pan Bolt
51. Oil Pan
52. Oil Drain Plug
53. Oil Drain Plug Washer
54. Crankshaft Balancer
55. Oil Strainer Pipe
56. Oil Strainer Pipe Seal
Exploded view (Lower end)
Engine mechanical parts
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Engine Mechanical
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1. Wheel Bearing Oil Inlet Pipe Bolt
2. Wheel Bearing Oil Inlet Pipe
3. Turbocharger
4. Wheel Bearing Oil OutletPipe Gasket
5. Wheel Bearing Oil Outlet Pipe
6. Wheel Bearing Oil Outlet Hose
7. Exhaust Manifold Gasket
8. Turbocharger Gasket
9. Exhaust Manifold
10. Thermostat Housing
11. Thermostat Housing Gasket
12. Thermostat
13. Boost Pressure Sensor
(TMAP Sensor)
14. Intake Manifold
15. Coolant Temperature Sensor16. Intake Manifold Gasket
Exploded view (Intake & Exhaust system)
Engine mechanical parts
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Engine Mechanical
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1. Engine Mount Damper (RH Side)
2. Engine Mount Bracket3. Transaxle Front Mount Damper
4. Transaxle Mount Damper (LH Side)
5. Transaxle Rear Mount Bracket (AWD/FWD)
6. Transaxle Rear Mount Damper
7. Cradle
Exploded view (Mount system)
Engine mechanical parts
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Engine Mechanical
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1. Camshaft Sprocket
2. Timing Belt Idler
3. Injection Pump Sprocket
4. Timing Belt Tensioner
5. Water Pump Pulley
6. Crankshaft Sprocket
7. Timing Belt
8. Timing Belt Rear Cover
9. Timing Belt Upper Cover
10. Timing Belt Lower Cover
11. Engine Mount Bracket
12. Crankshaft Pulley
13. Water Pump Gasket
14. Injection Pump
15. A/C compressor & AlternatorBracket
Exploded view (Timing belt system)
Engine mechanical parts
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Engine Mechanical
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This cylinder head is SOHC(Single Over Head Camshaft) type
and has only one camshaft that open 4 valves per cylinder with
the finger followers of roller type and the valve bridges. It is
similar to that of DOHC(Double Over Head Camshaft) cylinder
head.
The camshaft gear is installed in front of camshaft and the
vacuum pump is coupled in the rear of that. Because the cam
followers are of the hydraulic type, valve clearance adjustments
is not necessary.
The cylinder head is made of cast aluminum alloy for better
strength in hardness with light weight.
The combustion chamber of plate type of the cylinder head is
designed for increasing of squish and swirl efficiency and then
this is maximized to diesel combustion efficiency.
** Cylinder head bolt tightening sequence :
Tighten the cylinder head bolts to 65 Nm(47.9 lbft).
Using the angular torque gauge KM470B, tightening thecylinder head bolts another 120 degrees plus 120 degrees.
Cylinder head
Engine mechanical parts
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Engine Mechanical
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As the largest part of the engine components, the engine block
is made of cast iron. There are engine oil and coolant passages
for lubricating and cooling in the inside of engine block. On the
upper side of engine block, there is the cylinder head which has
combustion chamber. Also, the engine block has the bed plate
to support the crankshaft and decrease the engine vibration on
the lower side.
On the inside surface of the engine block, there are bore
surfaces whose the pistons of reciprocating motion assemble init and 4 oil jets to lubricate on the each bore surface.
Cylinder block
Engine mechanical parts
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Engine Mechanical
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The pistons are cast aluminum with a flat top design. Piston skirts are
coated to reduce friction. Each piston uses 2 compression rings and 1
3-piece oil control ring assembly. The piston pin is a full-floating design
and is retained to the connecting rod by clips located in each end of
the piston pin bore. The connecting rod and rod cap are positioned
and aligned by a dowel pin and retained by bolts.
Piston & Rings
Engine mechanical parts
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Engine Mechanical
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The crankshaft is made of better strength forging works design
than iron cast. It is located between the engine block and the
bed plate at 5 main journals with main bearings which have oil
clearance for lubricating. The 3rd bearing of the 5 main bearings
is thrust bearing whose the crankshaft has properly axial end
play.
4 conrod journals with the metal bearings are assembled into
the crankshaft. The bearing caps are crossbolted to enhance
structural rigidity.
On the front side of the crankshaft, there is a crankshaft gear
which drives oil pump and crankshaft balancer. On the back of
the crankshaft, there is a CKP target wheel (Crankshaft Position
Sensor).
EN-48246Timing belt adjuster-
Crankshaft holderCKP sensor target wheel
Crankshaft gear for Balancer
Crankshaft
Engine mechanical parts
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C100 (2.0l Diesel)
Engine Mechanical
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The crankshaft gear drives the 2 balancer shafts that revolve on
the opposite direction. So, the balancer counterbalances the
vibration that comes from the crank train.
It is located between the bed plate and the oil pan with the
engine oil.
Balancer gear
Crankshaft balancer
Engine mechanical parts
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Engine Mechanical
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The engine utilizes a valve fingerfollower and hydraulic lash
adjuster for valve operation. The roller is located at the middle of
valve fingerfollower and delivers the cam movement to valve
bridge in correspond to cam profile continuously.
Mark Nam e Function
a Camshaft Drive valve system
b Roller Finger Fol lower Deliver the rotat ing to valve bridge
c Hydraulic Lash Adjus ter Pivot and compensate activa- ting
and deactivating movement
d Intake-Valve Make the fresh gas flow
e Exhaust-Valve Make the exhaust gas flow
f Valve-Spring Keep the valve closed
g Valve-Bridge Activate two valve's movement
a
b
c
ed
f
g
Valve train system
Engine mechanical parts
Valve bridgeRoller finger follower
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Engine Mechanical
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Model Maintenance Remarks
C100
(2.0L Diesel)
I : 30,000 km(20,000 miles) or 2 years
R : 90,000 km(60,000 miles) or 5 years
* I : Inspection
R : Replacement
Crankshaft
High pressure
pump sprocket
CamshaftCamsprocket
Timing belt
idler
Timing belt
tensioner
Crankshaft
sprocket
Water pump
pulleyTiming belt
The crankshaft pulley assembled on the crankshaft drives the
camshaft sprocket, the water pump pulley and the high pressure
pump sprocket using a timing belt. Also, the auto timing belt
tensioner of double eccentric type assists the belt tension.
The timing belt idler which consists of a double low bearing type,
to endure big load on the wrap angle between the camshaft
sprocket and the high pressure pump sprocket.
Descriptions
Engine timing system
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Engine Mechanical
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1. Remove the vacuum pump
2. Rotate the camshaft and
align the hole on the top
point.
3. Rotate the crankshaft and
align the mark on the
crankshaft sprocket.
4. Remove the crankshaft
holder hole cap bolt(a).
5. Insert the crankshaft holder
EN48246 into the
crankshaft holder hole.(b)
Notice :
Rotate the crankshaft
sprocket a little and
simultaneously insert the
crankshaft holder.
6. Install the camshaft holder
EN48245 onto the camshaft
rear side.(c)
7. Align the high pressure pump
sprocket mark on the timing
belt rear cover mark.
Timing belt adjustment - 1
Engine timing system
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Engine Mechanical
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8. Install the camshaft sprocket with
the tightening bolt manually.
9. Install the timing belt.
10. Install the timing belt
tensioner with the tightening
bolt manually.
11.Turn the hexkey(a) tab in a
countclockwise direction to
tension the belt. Turn until thepoint aligns with the notch(b).
12. Aligning with notch, tighten
the timing belt tensioner bolt.
13. Tighten the camshaft sprocket
bolt.
Tighten
Tighten the timing belt tensioner
bolt to 25 Nm (18.4 lbin).Tighten the camshaft sprocket bolt
to 133 Nm (98.1 lbin).
14. Remove the camshaft holder
EN48245 and crankshaft
holder EN48246.
15. Turn the crankshaft in a
clockwise direction more 2
cycles and check the mark onthe crankshaft sprocket.
16. After alignment of the timing
belt, install the crankshaft
holder hole cap bolt.
Tighten
Tighten the crankshaft holder hole
cap bolt to 30 Nm.
CAUTION : The special service tools align the timing at exactlycyl. no. 1 TDC. If these special tools are not used, it will have
an inluence on engine performance and emissions.
Timing belt adjustment - 2
Engine timing system
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Engine Mechanical
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Check the accessory belt for looseness, crack, wear or tension,
replace the belt if necessary.
** Relieve method :
1) Install the accessory belt remover/installer EN48253 onto the
tensioner lever guide and rotate the tensioner at clockwise.
2) Rotate the tensioner fully and simultaneously insert tensioner spring
holding pin EN48301 to the tensioner pin hole.
3) Remove the accessory belt.
Accessory belt
Accessory belt
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Intake manifold
Coolant
temp. sensor
Thermostat & cover
Boost pressure
& temp sensor
Air Inlet
Water Inlet
Exhaust manifold
The intake manifold is used for air flow passage into the cylinder
combustion chamber and has an effect on engine torque, power,
noise, drivability, emission, fuel economy and performance.
It is made of cast aluminum alloy for better strength. A coolant
passage and thermostat housing is integrated into the intake
manifold.
The exhaust manifold is attached to the cylinder head and sends
the exhaust gas out of the combustion chamber. It is designed
to endure high pressure and high temperature and made of
HiSiMo material.
Engine Intake & Exhaust system
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1. Exhaust Manifold Heat Shield
2. PreCatalyst3. Seal Ring
4. Clamp
5. DPF Pressure Sensor
6. DPF Pressure Sensor Hose
7. Exhaust Gas TemperatureSensor 2
8. Gasket
9. Rubber Hanger
10. Exhaust Gas Temperature
Sensor 111. Exhaust Front Pipe Assembly
12. DPF(Diesel Particulate Filter)Assembly
13. DPF Heat Shield
14. Front Muffler Heat Shield
15. Front Muffler Assembly
16. Rear Muffler Assembly(RightSide)
17. Rear Muffler Assembly(LeftSide)
The function of the muffler is to reduce engine noise. It is made
up of a series of perforated tubes and baffles to break up the
sound waves and reflect them. It is made of Stainless Steel to
protect the front muffler from corrosion.
The rear muffler is to reduce broad band engine exhaust noise.
It is comprised of a series of perforated tubes and baffles to
break up the sound waves and reflect them.The adopted dual
muffler for C100 improves the efficiency to reduce flow noise.
It is made of Stainless Steel to protect the front muffler from
corrosion.
Engine Intake & Exhaust system
Exhaust system
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Engine Mechanical
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The vacuum pump provides the vacuum to the brake booster
and EGR(exhaust gas recirculation system) valve and is
installed at left upper side of engine. It is driven by the camshaft.
To brake
booster
To EGR
Solenoid valve
Part Item Specification
Type Single vane type
When brake side port is blocked
at idle : - 0.9 bar
When EGR side port is blockedat idle : - 0.7 bar
Vacuum
Vacuum pump
Engine vacuum system
Vacuum pump
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The PCV valve carries the blowby gas to the turbocharger inletof the intake system. According to the engine conditions, driving
conditions and turbocharger pressure, blowby gas flow is
different. So, the PCV valve controls the amount of blowby gas.
From blow-by gas
To Turbo
charger
PCV system
PCV valve
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Engine cooling system
FAN SPEED APPLICATION ON OFF
ECT ( ) 100 97
A/C switch
ECT ( ) 105 102
ACP ( kg/cm) 18,98 14,76
ECT
Cooling fans size 340 (Main)+ 320(Aux)
ON
Malfunction
High
Low
1. Radiator
2. Charge Air Cooler3. Main Cooling Fan Blade
4. Auxiliary Cooling Fan Blade
5. Main Cooling Fan Motor
6. Auxiliary Cooling Fan Motor7. Cooling Fan Shroud
Cooling fans
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1. Water Pump
2. Water Pump Gasket
3. Thermostat Housing
4. Thermostat Gasket
5. Thermostat
6. Boost pressure & Temperature
Sensor
7. Intake Manifold
8. Coolant Temperature Sensor
Water pump
Part Name 2.0L Diesel Remarks
Radiator Type Cross Flow
Radiator Size 673 414 27 W H x T
Coolant Capacity 10
Thermostat start to open 80 2 Complete open : 95
Thermostat
Engine cooling system
Water pump and Thermostat
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Remarks
Capacity 65 L
Fuel tank
The fuel tank stores the fuel and the tank is sealed up leakage
of vapor.
The fuel tank is made from high density polyethylene. The main
fuel tank is located in the rear of "Front muffler"and under the
body of the vehicle. The fuel tank are each sides held in place
by 2 metal straps that is able to hold from two nuts attach to the
frame. The fuel in the tank supplies to the engine through the
supply line by the pump.
The vapor that is produced in the tank is going through the line
by Roll over valve and Grade vent valve.
2. Main Fuel Pump
4 . Ring-Adaptor
3. Roll Over
Valve
1. Sub Fuel Pump5. Grade Vent Valve
Fuel tank
Fuel supply system
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The sub fuel pump module is located inside of the left side of thefuel tank. The sub fuel pump module consists of the followingmajor components:
- The fuel sender assembly
- The fuel transfer tube
The main fuel pump module is located inside of the right side ofthe fuel tank. The main fuel pump module consists of the
following major components:- The fuel level sender assembly
- The fuel pump and reservoir assembly
- The fuel filter
- The fuel pressure regulator
- The suction and return jet assembly
Main Fuel Pump Module
Sub Fuel Pump Module
Fuel supply system
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3. Fuel level gage control
The fuel level sensor changes resistance in response to the fuel
level. The engine control module (ECM) monitors the signal
circuit of the fuel level sensor in order to determine the fuel level.
When the fuel tank is full, the sensor resistance is low and the
ECM senses a low signal voltage. When the fuel tank is empty,
the sensor resistance is high and the ECM senses a high signal
voltage. The ECM uses the signal circuit of the fuel level sensor
in order to calculate the percentage of remaining fuel in the
tank. The fuel level signal is sent to ECM, the ECM sends the
message of the fuel level to the BCM and the BCM modulates
fuel level gauge in the cluster by single wire CAN.
2. Fuel level gage resis tance
System Pressure 450 kpa
Displacement 165 ~215/h
Relief pressu re min 650 kPa - max 900 kPa
Current 3.0 ~ 11.5 AMP
Status Fuel Height MAX MIN
Full Stop 228.9 40 45,5 37,0
1/2 130.6 106.2 112,8 99,4
Empty Stop 1.3 250.0 253,0 240,4
Resistance( )Float Heigh t
Fuel lev el
Fuel level Signal Remarks
FULL 3.4V 5V Ref
3/4 3.0V
1/2 2.2 2.5V
1/4 2.0V
Empty 1.4 ~ 1.5V
1. Specification of Fuel pump
Fuel supply system
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Fuel filter heater & Temperature sensor
RemarksSpecificationItemPart
115127 3.3
0.4 2Heater resistor
100187 4
Resistance
-3026,116 2,533
05,896 430
252,057 115
60596 23
NTC thermistorType
Fuel temp
Sensor
-20250WOperating
power
Off (more than 5)Less than 3Enable
condition
12VOperating
voltage
PTC ThermistorType
Fuel filterheater
Fuel filter cap
Fuel temp
Sensor (NTC)Fuel filter
heater (PTC)
The fuel filter heater relay is controlled by the ECM. When the
temperature is less than 3, the fuel filter heater relay is
commanded. Fuel temperature is measured by the ECM and
also has an influence on injection timing and quantity.
Fuel supply system
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Water In Fuel (WIF) sensor
WIF sensor
RemarksSpecificationItemPart
Over 95 CCIndicate lamp ON
Indicate lamp ONLess than 50mA
Indicate lamp OffLess than 15mAConsume current
10 16 VOperating voltage
Mechanical lead
switchFloatType
WIF
sensor
Water Draining Procedure
1. Turn the waterinfuel drain screw counterclockwise.
2. If finished, unscrew the drain screw reverse toward.
3. Do work fuel priming.
Fuel supply system
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CAUTION : It is impossible to reuse the fuel filter element if theelement is exposed to the air for over a minute.
Fuel supply system
Fuel filter replacement procedure
1. Remove the air cleaner
assembly.
2. Disconnect the fuel inlet/outlet line
from the fuel filter.
3. Disconnect the fuel heater and
temperature sensor connector. (a)
4. Disconnect the water in fuel
sensor connector.(b)
5. Remove the fuel filter
assembly from the bracket
upward.
6. Install the filter housing holder
EN48303(a) and the fuel filter
locker installer/remover EN
48304(b) to the fuel filter
assembly.
7. Turn the fuel filter lockerinstaller/remover EN48304(b)
counterclockwise.
8. Remove the fuel filter
locker(a).
9. Remove the fuel filter cap(b)
with the Oring(c).
10. Remove the fuel filter(d) in
the fuel filter housing(e).
Notice : The fuel filter cap
includes the fuel heater and
temperature sensor as one
body. Also, the fuel filter
housing includes the water in
fuel sensor as one body.
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In order for the VM2.0S diesel fuel system to work properly, the
fuel lines must be full of fuel and contain no air. If air gets into
the fuel lines, it will be necessary to prime the fuel system to
eliminate the air before operating the vehicle.
Air could have entered the system in one of the following ways:
1) The vehicle ran out of fuel.
2) The filter was removed for service or replacement.
3) The fuel lines were removed or disconnected for servicing.
4) The fuel pump was removed for servicing.
5) The fuel filter water drain cock was opened while the engine
was running
Notice :
If one or more of the above occurred, air has entered the fuel
system and you will need to prime the system prior to operating
the vehicle.
Priming procedure
1. Turn the ignition key ON at 5second intervals.
2. Turn the ignition key OFF and wait 3 seconds.3. Repeat procedure No.1 ~ 2 at 6 or 7 times.
CAUTION : Do not turn the ignition key START. The injection
pump might get damaged.
Notice : You can do fuel priming work using by SCAN tool.
Fuel supply system
Descript ion of Fuel priming
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7/28/2019 Motor 2,0 Diesel
40/40
01.3-40
C100 (2.0l Diesel)
Engine Mechanical
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