Engine Alpha II Engine Published by Hyundai Motor company , september 2005 Alpha II Engine Introduction Alpha engine is already used in LC 1.6 liter without CVVT Main differences form 1.6 liter are - Using CVVT system - Individual Ignition System - Surge tank Volume - Intake runner length and size - Throttle bode size (48 to 52mm) - Cylinder Block Strength - Can communication for DTC - PCM (ECM with TCM) with chips inside - PCM Location Engine Line Up MC has types of engine for gasoline for Diesel CRDI As already mentioned, MC’s gasoline is not for the first used in HMC It is alredy adopted in LC 1.6 with non CVVT model In case of Alpha 1.6 and 1.4 DOHC, it is designed by HMC and now producing both HMC and KMC The assembly line of this engine is in Ulsan plant This engine has been quite widely used in HMC side Available model of this engine is Matrix, Gets, Accent, XD Elantra and so on from 1993 That’s why it has a lot of reliability in quality Now Alpha 1.6 liter with CVVT we are developing 3th generation of this engine Project name is Gamma You can see this Gamma engine from 2006 In case of MC 2nd generation of Alpha engine is used Basic mode of Alpha is 1.5 but it has three more 1.3, 1.4 and 1.6 liter Except 1.3 & 1.4 liter both 1.5 and 1.6 liter have CVVT system But only 1.6 liter with CVVT engine is used for MC export 1.5 liter with CVVT is only for domestic U 1.5 liter CRDI engine is quite new one Main target area of this is for European and domestic Amazingly it can produce 110 ps target horse power with 1.5 liter New technology with this is VGT turbo charger with CRDI CP3 system It has line-up by engine displacement 1.1, 1.5 and 1.6 liter Later we will introduce euro U 1.5 liter CRDI with VGT emission engine with this Changed Items-1 In case of main moving parts such as piston, piston ring, camshaft, crankshaft, connecting rod, cylinder head, cylinder head gasket and cylinder block, any parts can not be shared together between 1.4 and 1.6 The reason why those can not be inter changeable is mainly from adopting CVVT system and enlarged cylinder bore size in 1.6 liter Only Intake and exhaust valve mechanism related items can be shared 1.6 Intake Camshaft Target Wheel Graphite coated piston is used so as to increase lubrication and decrease slapping noise since there was some noise and oil consumption problems before with alpha engine without any graphite coated piston Camshaft target wheel in 1.6 liter has target wheel Each duration from low to high, high to low has 180 degree increasing more control accuracy with CVVT control In case of 1.4 liter dowel pin type target wheel is still used 1.6 Cylinder Head Changed Items-2 One big change from 1.6 liter Alpha is PCM location PCM is located just after air cleaner housing Also water proof PCM is used because of the location position Using engine room side PCM location can have advantages such as reducing wire harness length so as to decrease production cost and wire harness electrical problem and maintenance easy, In case of Alpah 1.6, Bosch M7.9.1 version of software is used but MC uses Bosch M7.9.8 version with CVVT system Main features of M7.9.8 are chips CPU, 400MHz internal clock, waterproof, 154 pin connector, wheel speed sensor interface integrated, 768K flash memory and so on To make communication to PCM with hi-scan pro, you must use can interface module since CAN communication protocol is used instead of KWP2000 for DTC only in Gasoline engine Using can protocol communication speed is increased from 10kbps to 38.4kbps There are two terminals for CAN communication in 16 OBD connector So when you try communication, you must use this •Direction : Describe PCM location with advantages and CAN protocol for DTC CVVT System is quite similar to Beta 2.0’s Exhaust cam shaft is driven by crankshaft Between intake and exhaust, chain is used with CVVT actuation Individual ignition system is applied to 1.6 liter only so as to increase efficiency and accuracy in control TR is in ECM side Specification Exhaust Valve Intake Valve Duration : 228˚ Duration : 236˚ Full Advance Full Retard TDC TDC ATDC 10˚ TDC BTDC 32˚ ATDC 8˚ 82˚ BBDC 46˚ 122˚ ABDC 56˚ ABDC 16˚ BDC BDC BDC Valve timing for 1.6 liter engine is as shown in the table The half value of 82 degree in full advance or 122 degree in full retard is used as “CVVT set position” Two types of spark plugs are used, NGK and Champion Using one type of spark plug for all cylinders is recommended Parts List MAF for 1.6 liter Inductive type CKP sensor is used Typically when you use Bosch EMS system, CKP sensor type is from inductive type contrary to Siemens of hall IC type Of course these days there isn’t any board to share both hall or inductive in CKP sensor Main reason why Bosch prefer to use inductive type is it doesn’t need any power supply for sensor operation For example a vehicle is driving on rough road, suddenly micro cut off happens in power supply to sensor then the vehicle will stall immediately because of no power to sensor in hall IC type On the other hand, since inductive type doesn’t need any power supply the vehicle will still move When it comes to MAF sensor, sensor supplier is changed from Bosch to Siemens In case of previous Bosch HFM type revere flow detection MAF sensor, even though it has more accuracy but sensor tip can be easily damaged by foreign materials resulting in fuel system problems Sensor reliability is increased using Siemens MAF sensor but accuracy can be lower than Bosch’s When you install MAF sensor you must be careful to installation direction MAP for 1.4 liter Other sensors or actuators are no differences except individual ignition system which is newly adopted •Direction : Explain CKP sensor and MAF sensor here Others don’t have any change RLFS Fuel System Available Vehicle XD, LC, FC, MC Filter Interval 60,000 KM (Depends on the region) Advantage : Because of the circulation of fuel from fuel tank to heated fuel delivery pipe, conventional return type fuel system compared to RLFS which fuel is regulated in fuel pump module inside of fuel tank can produce much more evaporated high temperature gas Reducing circulating fuel line as shown in the picture, RLFS maintains lower fuel temperature and reduces evaporative gas by 25 ~ 30% Main items consist of RLFS are fuel pump module including fuel filter and fuel pressure regulator submerged in fuel tank Fuel Pump Module Disassembling Procedure : Descrewed two bolts hidden in rear seat Disconnect fuel pump connector Carefully open fuel tank cap and take out the fuel pump module Disassemble one by one carefully and replace fuel filter Fuel Pump Circuit 10 Battery Fuel Cut Switch F/Pump Relay Main Relay Fuel Pump PCM (V) ① ② ③ ④ ⑤ Ig On B+ B+ B+ ⇒ B+ Starting B+ ⇒ B+ B+ B+ B+ ⇒ Running B+ B+ B+ Spark Plug Inspection ① ② ⑤ ⑥ 53 ③ ④ Spark Plug No.1 No.2 No.3 No.4 Condition ① ① ① ① kΩ 4.4 4.4 44.6 44.6 Gap(mm) 1.1 1.1 1.1 1.1 Type Good/Bad BKR5ES-11( Good Good ) RC10YC4( Good ) Good Injector 54 Injecto r No.1 PCM Pin No Description Main Relay B+ C01-2 50 No.1 control Function : Electronically controlled fuel injector is a solenoid valve which supplies exactly calculated amount of fuel to engine for optimum combustion under various engine load and speed To meet air fuel ratio required in system ECM regulates fuel injection quantity as controlling injector solenoid operating duration referring air flow to cylinders and output signals from oxygen sensor For this precise control, quick response of solenoid is required Related DTC : P0201, P0202, P0203, P0204, P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271 Injector Test - Injector / Connector 55 No.1 No.2 No.3 No.4 Voltage ①/② 13 3.4 13 3.4 13 3.4 13 3.4 Good/Bad (Ig On) G G G G G G G G Injector (Ω) 14.1 14.1 14.1 14.1 Good/Bad G G G G Injector Test - 56 □ Leakage Test Leakage/Cylinder Good/Bad G G G G □ Operation Sound Sound/Cylinder Good/Bad G G G G Injector Test - 57 □ Leakage Test Leakage/Cylinder Good/Bad G G G G □ Actuation Test with Hi-scan Pro Actuation/Cylinder Good/Bad G G G G Injector Test - 58 Cylinder Drop rpm 560 560 560 560 Good Bad Good Good Good Good Injector Test - 59 Duration/Cylinder At Idle(ms) 2.8 2.8 2.8 2.8 2,000 (ms) 2.5 2.5 2.5 2.5 Fuel Cut rpm 6,500 Re starting rpm 1,280 CVVT System 60 Rotating Direction of Engine PIN STOPPER CVVT CHAIN-TIMING CAMSHAFT-SPROCKET CAMSHAFT-EXHAUST Retard CHAIN SPROCKET HOUSING ROTOR VANE BELT-TIMING Advance CAMSHAFT-INTAKE Driving condition Intake / Timing Why ? At low load Retard Stable combustion At high load & high speed Retard Improved performance At high load & low speed Advance Improved Torque At middle condition Advance Increase fuel consumption CVVT Operation Hold Retard ROTOR VANE 61 Advance Advance Retard HOUSING VANE EX IN TDC BDC C/Angle Ignition EX BDC IN TDC BDC C/Angle V/Lift Ignition BDC P D P V/Lift V/Lift D P Ignition EX BDC IN TDC BDC C/Angle OCV 62 OCV PCM Pin No Description C01-2 49 OCV control Main Relay B+ Function : Different from the existing fixed cam phase angle type, CVVT is the device which varies cam phase angle continuously to be optimum It operates by engine oil pressure OCV controls the amount and direction of oil delivered to CVVT module by oil valve which is connected to a solenoid If there is more degree differences between target angle and real then it goes to limphome function and sets DTC of P0011 or P0012 Related DTC : P0011, P0012, P0075, P0076 OCV Control 63 OCV is controlled by ECM with PWM but the duty is so various depending on engine load Maximum advance of intake cam timing is set around 1800 ~ 2500rpm range It is controlled mainly by engine load CVVT Practice-1 64 □ Timing Chain Align Check □ Auto Tensioner Check □ Air Test □ Oil Filter Clogging Check CVVT Practice - 65 Item/rpm Idle 1500 3000 4500 Camshaft Position 25.5 0.5 3.8 12.6 CVVT Duty (%,Open) 42 43 42 Adaptation Angle #1 124.1 124.1 124.1 124.1 CVVT Practice - 66 □ Test 1 Resistance : 7.6Ω Voltage output - No.1 Pin to GND : 3.2V - No.2 Pin to GND : 13.2V □ Test Symptom : When you supply direct power to OCV at idle condition, regardless of ECM’s intension, it will go on advanced in intake valve timing This additionally inhaled air will make engine fluctuated at idle If you have this kind of fluctuation at idle simply disconnect OCV whether it is recovered or no CVVT Practice - Advanced in Valve Timing Approximately 30 degree Since Each CKP tooth becomes degree in CKP angle 67 .. .Alpha II Engine Introduction Alpha engine is already used in LC 1.6 liter without CVVT Main differences form 1.6... Control 31 ④ ② ⑤ ① ③ Low-Speed On ① ② ③ ④ ⑤ (V) 12 12 Alpha II Engine Management System In case of Alpha engine? ??s ECM, it is mounted in engine room compartment as mentioned before To measure... this engine Project name is Gamma You can see this Gamma engine from 2006 In case of MC 2nd generation of Alpha engine is used Basic mode of Alpha is 1.5 but it has three more 1.3, 1.4 and 1.6 liter