Copyright by Hyundai Motor Company. All rights reserved. Theta ( Θ ) GDI Engine

2 Theta (Θ) – II GDI Engine Powertrain Variation Category PlantAsanHMMA AreaDOM (09.9) GEN (09.12) Aust. (10.1) NA (10.2) Engine Spec. T/M DOMGENAust.YFA GSL Θ 2.0 LPI (Asan) - M5GF2 A5CF2 Θ-II 2.0 MPI (Asan) 161/19.8 (PS/kg.m) M6GF2 (Ulsan) A6MF1 (HPT) Θ-II 2.4 MPI (Asan) 174/23.0 (PS/kg.m) M6GF2 (Ulsan) A6MF1 (HPT) Θ-II 2.4 GDI (Hwasong) 200/25.2 (PS/kg.m) M6GF2 (Ulsan) (10.1) A6MF2 (HPT) (10.1) Θ-II 2.0 T-GDITBD A6LF2 (HPT) (10.10) Emission 06EM (GSL) EURO-5 (DSL) EURO-2/3/4 (GSL) EURO-3/5 (DSL) EURO-4 (GSL) EURO-5 (DSL) ULEV(10.2) SULEV(10.7)

3 Theta (Θ) – II GDI Engine Theta –II 2.4 GDI Displacement2,359 cc Max. Power200PS / 6,300rpm Max. Torque25.2kgf·m / 4,000rpm Features High pressure fuel system Direct injection Dual CVVT Roller chain for timing system Displacement1,998 cc Max. Power161PS / 6,200rpm Max. Torque19.8kgf·m / 4,500rpm Features Dual CVVT VIS is applied Low friction tappet Linear type oxygen sensor Theta -II 2.0 MPI

4 Theta (Θ) – II GDI Engine Items 2.4 GDI (YF)MPI (NF) Displacement (cc)2,359 Compression ratio Injection typeDirect injection (to cylinder)Port injection Bore × Stroke (mm)88 × 97 Stroke / Bore ratio1.10 Max. Power (ps)200(+13%)177 Max. Torque (kgf m) 25.2(+10%)23.0 Fuel consumption (g/kwh)330 (+2%)337 Fuel Pressure High lineMax. : 135bar( Idle : 40bar)- Low line4.5bar3.5bar Timing ChainRoller ChainSilent Chain Comparison

5 Theta (Θ) – II GDI Engine Items 2.4 GDI (YF)MPI (NF) Piston cooling jetApplied- Piston PinFull FloatingPressurized Pistonbowlflat Cylinder HeadFeatures an injector mounting hole- InjectorHigh pressure injectionLow pressure injection Fuel Pressure SensorMax. 250bar- Oil coolerApplied- Spark PlugM12 IridiumM14 Iridium Injection ControlMulti injectionSingle injection EMSContinental (Siemens) Oxygen SensorS1:Linear + S2:ZirconiaS1:Zirconia + S2:Zirconia Comparison

6 Theta (Θ) – II GDI Engine Camshaft Piston High Pressure Pump High Pressure Injector Fuel Pressure Sensor Main components

7 Theta (Θ) – II GDI Engine Effect High Pressure Pump Injector ECM Direct injection : Improved performance (13%), Decreased fuel consumption(2%), Reduced emission(50%) Direct injection : Improved performance (13%), Decreased fuel consumption(2%), Reduced emission(50%) Effect of GDI

8 Theta (Θ) – II GDI Engine Improved performance : 6~14% - Direct injection Vaporizing Lower intake air temp. higher air density and increased charge efficiency improved torque - Reduced knocking and improved performance at low speed Decreased fuel consumption : 3~5% - Increased compression ratio - Optimized gear ratio Reduced Emission : 50% - Reduced catalytic warm-up time by multi-injection Effect of GDI Theta – II 2.4 Engine RPM Torque (kgf.m ) MPI GDI MPI GDI

9 Theta (Θ) – II GDI Engine Cooling Jet Oil Filter Oil Cooler Cylinder Block Cylinder Block and Head Cylinder Head Injector Mounting GDI Combustion Chamber Injector StepStep 1Step 2Step 3 Tightening torque and angle3.5kgf·m90˚ Cylinder head bolt torque

10 Theta (Θ) – II GDI Engine [ Camshaft] Slotted High pressure pump driving lobe Slotted cam love for reducing weight Added cam lobe for high pressure pump Fuel pressure is made by camshaft Camshaft and HP Pump Bracket HP Pump BracketCylinder Head Cover Added bracket and hole on cylinder head cover for HP pump

11 Theta (Θ) – II GDI Engine Timing System Intake CVVT Exhaust CVVT Timing Mark Tensioner Crankshaft key Tensioner Arm Timing Mark Timing Chain Intake CVVT Exhaust CVVT CVVT assembly gears were also redesigned so that they are driven by roller chain Timing chain : Changed to roller chain, which is more resistant against soot.

12 Theta (Θ) – II GDI Engine Slotted Crankshaft Piston BOWL Piston Ring Oil Ring Side Ring Top Ring Slotted Moving System Changed items Spark plug (M14 M12)Chain tensioner BSM

13 Theta (Θ) – II GDI Engine Fuel Pressure Sensor (FPS) High Pressure Fuel Pump Tube Injector Fuel pressure : Low pressure : 4.5bar, High pressure : 135bar Fuel tank(low pressure pump) High pressure pump Fuel rail Injector GDI Fuel System

14 Theta (Θ) – II GDI Engine High pressure pump Fuel pressure regulator valve Rated pressure : 135bar Max. flow : 125L/h Piston type : 1 piston Stroke : 3.5mm 0.9 cc/cam revolution FPRV resistance : 0.5Ω Supplier : Kefico Engine RPMIdle1,5006,300Fail Fuel Pressure (bar) 4090~ GDI Fuel System – HP Pump & Fuel Pressure Regulator Valve

15 Theta (Θ) – II GDI Engine GDI Fuel System – HP Pump & Fuel Pressure Regulator Valve High-Pressure Pump Structure Relief Valve Cam Drive Damper Low-PressureHigh- Pressure

16 Theta (Θ) – II GDI Engine Fuel Tank Fuel Filter Fuel Pump Fuel Pressure Sensor Injectors Fuel Rail Relief Valve Damper Flow Control Valve High-Pressure Fuel Pump Fuel Flow Cam Piston GDI Fuel System – HP Pump & Fuel Pressure Regulator Valve

17 Theta (Θ) – II GDI Engine GDI Fuel System – HP Pump & Fuel Pressure Regulator Valve [ ] Chamber Delivery Chamber Rail Fuel Input Fuel Return Fuel Pressurization and Discharge Fuel Discharge Intake Supply Chamber High-Pressure Pump Mechanism Voltage Current

18 Theta (Θ) – II GDI Engine Cam lobe Roller Tappet HP Pump Bracket Tappet Bracket O-ring Align HP Pump Insert hole Set lobe of HP pump to BDC Coat the tappet with engine oil Coat the insert hole of bracket with engine oil Coat the O-ring with engine oil Align tappet mark and bracket mark and insert Tighten 2 bolts simultaneously or loose fit and then tighten (Tightening torque : 1.3~1.5kgf·m) Dont reuse bolt Whenever installing HP pump, use new O-ring GDI Fuel System – HP Pump & Fuel Pressure Regulator Valve HP pump assemble method

19 Theta (Θ) – II GDI Engine It is possible to crank 18,000 stroke without fuel ex) If cranking is 300rpm, 18,000/4lobe× 300 = 15mins Never crank for more than 15 minutes without fuel If cranking time excess than the limit time, durability is lowing because internal lubricant coating is worn out GDI Fuel System – HP Pump & Fuel Pressure Regulator Valve

20 Theta (Θ) – II GDI Engine 6 Hole Operating pressure : 165bar Flow: 14.7g/s (at 100bar) Supplier : Continental Injector Hole GDI Fuel System – Injector Fuel Pressure Sensor Fuel Rail SUS FPS : 250 Bar Supplier : Continental

21 Theta (Θ) – II GDI Engine GDI Fuel System – Injector Injector Coil Valve Body O-Ring Connector Needle Supply Tube Armature Spring Combustion Chamber Seal Fuel Supply Spray Generator Swirl Disc

22 Theta (Θ) – II GDI Engine Injector current Injector voltage Hole Rise Peak / Hold C1 20V 40V 60V 0V Approx. 1ms 3A 13A 55V 13A GDI Fuel System – Injector Preparation Hole Rise Peak/Hold

23 Theta (Θ) – II GDI Engine Injector protect cap Whenever removing cap, Use expansion pliers Rail protect cap GDI Fuel System – Injector Injector protect cap After removing the injector cap, you must complete the installation within one hour. Leaving an injector unprotected (without a cap) for an extended duration of time allows the seal to expand and makes it difficult to insert and install the injector. If the thread has expanded, replace the protection cap to compress the seal.

24 Theta (Θ) – II GDI Engine O-ring Combustion Chamber Seal Clip #2 #1 #3 Do not reuse clips, O-ring and bolts When inserting the injector into the head, be careful not to damage the injector tip Do not use a fuel rail assembly that has been dropped. When storing injector and rail, install protect cap Caution GDI Fuel System – Injector Injector assemble method Remove the injector caps. Coat the O-ring with engine oil Assemble the fuel rail by tightening bolts in following order and in accordance with tightening torque (1.9~2.4kgf·m)

25 Theta (Θ) – II GDI Engine HP Pump Fuel Rail HP Tube Clip Protect cap Position the HP tube and tighten the nut by hands Install the clip (using torque wrench ) Tighten the tube nut (using torque wrench) Remove protect cab before assembling When repairing system, use new tube. Assemble procedure GDI Fuel System – High Pressure Tube 90 ˚ HP tube tightening torque3.0±0.3 kgf·m Clip bolt tightening torque1.0±0.2 kgf·m

26 Theta (Θ) – II GDI Engine Pressure (bar) RPS characteristics(5V) Diagnosis range under 4% Output (%) Supply current : 5~12mA Supply voltage : 5V Range of measurement : 250 bar GDI Fuel System – High Pressure Sensor Diagnosis range over 96%

27 Theta (Θ) – II GDI Engine ECM Automatic Transmission + Immobilizer Automatic Transmission + No Immobilizer Manual Transmission + Immobilizer Manual Transmission + No Immobilizer ECM Specifications ItemSpecification EMSContinental CPU32bit ModelSIM2K-240 Pins196 pin Weight1050g HousingAluminum Die Cast Injector DriverDC to DC 55V Dimensions212×215×38 Location Engine Room (near the battery) Operating Temperatures -40 ~ 105 ECM Specifications

28 Theta (Θ) – II GDI Engine Input and output

29 Theta (Θ) – II GDI Engine Cranking : injection at compression stroke For making rich condition near spark plug Heating catalytic converter : injection at intake and compression stroke Normal driving : injection at intake stroke For good air/fuel mixture Injection Timing CyclePowerExhaustIntakeCompression GDI Normal driving At cranking Catalytic Converter Heating MPI Fuel Injection 0 ˚(TDC)180 ˚360 ˚540 ˚720 ˚ Crank Angle Fuel Injection

30 Theta (Θ) – II GDI Engine Evaporation control Filter Canister Throttle Valve Cylinder CCV PCSV FTPS Fuel Tank P L Fuel Level Sensor [ PCSV ] CCV PCSV FTPS

31 Theta (Θ) – II GDI Engine Engine Coolant Temperature > 50 Ambient Temperature > -10 Time after starting > engine 100 revolutions Fuel Level: 15% ~ 85% No malfunctions/errors (No DTC). Battery Voltage: > 10V Upon a leakage test failure, the system retries after 60 seconds. Leakage Testing Mode Conditions Detect fault : Diameter > 1mm Diagnosis Time: During 30sec at idle condition, after satisfying leakage testing mode conditions Warning lamp on condition: Second driving cycle Evaporation control

32 Theta (Θ) – II GDI Engine Evaporation control Evaporation Check Excessive Leakage Check Excessive Leak Closed Open PCSV Open (stuck) FTPS CCV PCSV Excessive Pressure Fuel Cap Open Delay Small Leakage Check Closed Open Closed Stabilization Pressure Recovery

33 Theta (Θ) – II GDI Engine Dual CVVT BottomTopBottom Top Bottom Valve Lift Exhaust IntakeExhaust Intake Valve Lift Exhaust OCV Exhaust CVVT assembly Intake CamshaftExhaust Camshaft Intake CMP Sensor Exhaust CMP Sensor Intake OCV Intake CVVT assembly

34 Theta (Θ) – II GDI Engine TDC BDC Dual CVVT EX BDCTDCBDC IN BDC EX TDCBDC IN BDC EX TDC BDC IN Internal EGR Low Speed / High Load - Intake backflow prevention (improved volumetric efficiency) - Increased expansion/contraction work. High Speed / Load -Improved volumetric efficiency. Low Speed / Load - Stable combustion. - Reduced valve overlap Partial Load - Massive internal EGR (increased fuel efficiency, reduced NOx). - Reduced pumping loss - Increased expansion work. - Reduced HC. EX IN RPM Load Partial Load