EN Engine

2 Power Train Variation EngineA/TNASMES GEN OthersChinaChile Lambda 3.8L F (AISIN) S-3.0 V6 VGT EURO EURO EURO L V6 Common rail diesel engine (S-engine) and 3.8 L V6 gasoline engine (Lambda) are used for EN. S-engine is the first used in HMC and Lambda engine is already used for NF, TG, CM.

3 Engine Line-Up ItemS- V6 3.0 LLambda V6 3.8 L Fuel Injection typeCRDi (1600bar)MPI Displacement2,9593,778 Bore x Stroke (mm)84 x 8996 x 87 Timing systemChain Performance Output max.233 ps260 ps Torque max.45kgfm35kgfm Appearance

S-3.0 V6 E-VGT CRDi Diesel Engine

5 Specification ItemSpecificationItemSpecification Replacement (cc)2,959Glow system ISS (Instant Starting System) Bore X Stroke84 x 89Injection order Compression ratio17.8Fuel Injection typeCRDi(1,600 bar) Max power (Ps/RPM)238/4,000Fuel pressure controlInlet & Outlet Max Torque (kgfm/RPM)45/2,000Injection typePilot 2, Pilot 1, Main Idle rpm750Injector typePiezo Injector Max rpm4800EMS EDC16CP (for piezo injector)

6 Main Feature Items Performance/ Fuel Economy EmissionNVHDurabilityStarting Compacted Graphite Iron (CGI) Electronic VGT Electronic E.G.R EGR Cooler Instant Starting System (ISS) Variable Intake System Lambda Sensor Serpentine Belt Timing Chain Electronic VGTElectronic E.G.R EGR Cooler Variable Intake SystemTiming Chain

7 Main Feature ISS : Instant Starting System CGI : Compacted Graphite Iron WCC : Warm-up Catalytic Converter Electronic E.G.R CGI Cylinder Block Piezo Injector Electronic VGT Timing Chain Serpentine Belt Swirl Control Valve (EURO-3/4) WCC 4 Valve DOHC HLA I.S.S EDC16CP 32Bit (Piezo injector) Lambda Sensor(EUR3/4)

8 EURO-2 vs. EURO-4 ItemRemoved PartsEURO-4EURO-2 IN-MANI, LWR Swirl control valve actuator & valve linkage WCC Lambda sensor

9 Cylinder Block ItemFeatures Cylinder Block CGI (Compacted Graphite Iron) - Purpose : Engine power up & reduce CO2 level by Increasing max. combustion pressure (190bar) - Benefit : Reduced weight (10%) and engine length Bed Plate -Improved NVH & durability -When replacing cylinder block, the bed plate should be replaced together (Bearing cap integrated) Upper Oil Pan- Aluminum : Improved NVH Lower Oil Pan- Steel plate

10 Cylinder Block - Aluminum cylinder head - V6, 4 valves DOHC - Applied plastic head cover : weight is reduced - Integrated cam cap (ladder type) : improved NVH - Left and Right cylinder head gasket are different (3 grade gasket) - Cylinder head bolt tightening torque : 6.0kgf-m + 90˚ + 120˚ [Intake & Exhaust valve] [Plastic cover (RH)][Plastic cover (LH)]

11 Cylinder Head L: LH, R: RH Grade (A, B, C) Engine displacement [Cylinder head gasket] Oil Drain Lubrication hole for camshaft Water Jacket

12 Moving System - 4 Valve DOHC - Hollow type camshaft - Low-tension type piston ring - Piston double wave cooling gallery and oil jet Oil Jet NOcomponentRemarks 1In. camshaft Hollow type 2Ex. Camshaft 3Vacuum pumpCapa : 260cc/rev 4ValveDia. of valve: Φ6 5HLA Component of valve train

13 Moving System Main bearing size Crankshaft diameterBore sizeMain bearing (Color)Oil Clearance A AE (Green) 0.030~0.048 BD (Yellow) CC (No mark) B AD (Yellow) BC (No mark) CB (Blue) C AC (No mark) BB (Blue) CA (Red) J1 J2 J3 J4 J1 J2 J3 J4 Journal diameter mark on the crankshaft Journal diameter mark on the cylinder block

14 Moving System (Lower connecting rod bearing is one size) Connecting rod bearing size Crankshaft diameterBore sizeBearing (Color)Oil Clearance A AC (Red)0.024~0.050 BC (Red)0.030 ~0.056 CB (Yellow)0.026 ~0.052 B AC (Red)0.030 ~0.056 BB (Yellow)0.026 ~0.052 CB (Yellow)0.032 ~0.058 C AB (Yellow)0.026 ~0.052 BB (Yellow)0.032 ~0.058 CA (Blue)0.028 ~0.054 P1 P2 P3 P4 P5 P6 A A Pin diameter mark on the crankshaft Bore diameter on the connecting rod

15 Timing System - Duplex bush timing chain is used for S-engine. - Exhaust camshaft is operated by scissors gears. - Hydraulic auto-tensioner is used for timing chain. - Oil jet is used for timing chain lubrication. - Mechanical type tensioner is used for oil pump chain. [Duplex bush chain] [Scissors gear][Oil jet]

16 Timing System Scissors gear - Purpose : Little noise reduction - It does not affect engine performance [Timing Mark] Scissors gear Intake cam gear CMP sensor target wheel LH exhaust camshaft LH intake camshaft Scissors gear DRIVE DRIVEN

17 Timing Chain Installation Auto-tensioner 4.0~5.0 Camshaft sprocket Camshaft sprocket Oil pump sprocket Tensioner lever Low chain guide Upper chain guide Oil pump tensioner Oil pump chain Camshaft 2.0~ ~ ~7.6 HP pump sprocket Timing Chain Components

18 Timing Chain Installation Preparation RH camshaft sprocket LH camshaft sprocket For RH sprocketFor LH sprocket Crankshaft sprocket 1. Install the camshaft locking tools ( A000). 2. Align the crankshaft timing position. 3. Install the upper & lower chain guides. [Camshaft locking tool ( A000)] * This tool has two components with different size. One for LH sprocket (smaller), the other for RH sprocket (bigger).

19 Timing Chain Installation Installation 1. Install the timing chain and aligns timing mark on the sprocket. [Caution] The yellow color on the timing chain are for new part. However the color can be erased with mileage. Therefore O mark can be used instead. 2. Install the tensioner lever. 3. Install the hydraulic auto-tensioner. 4. Remove the sprocket locking tools.

20 Driving Belt - Serpentine belt - Compress auto-tensioner (turn to clockwise) - Insert driving belt to water pump side P/S pump Damper pulley A/C compressor Alternator Auto-tensioner Idler 3 Idler 2 Idler 1 Compress tensioner Water pump Insert belt

21 Lubrication System Oil gallery

22 Lubrication System Oil supply circuit Camshaft Bearing Vacuum Pump Cyl. Head Pressure Regulator Valve Oil Pump Piston Cooling Jet Hydraulic Lash Adjuster Oil Cooler Chain & Tensioner Filter Compressor Turbine To Cyl. Head Crankshaft Bearing Supply Return Oil Pan

23 Lubrication System Oil pump - Oil pump : Rotary type - Relief pressure : 5.8 ± 0.5bar Chain sprocket IN & OUT rotor Oil pump cover Oil outlet Relief valve Baffle plate Oil inlet

24 Oil pump replacement - Remove the oil drain plug. - Remove the acoustic shield cover. - Remove the lower oil pan. - Remove the baffle plate. - Remove the oil pump. Oil drain plug Acoustic shield cover Lower oil pan Baffle plate Oil pump Lubrication System

25 Lubrication System Oil filter assembly Oil cooler Cap Gasket Bypass Valve Element Housing Oil Drain Valve Return Check Valve Body

26 Lubrication System Oil filter replacement - Remove the Oil filter cap with a 32mm wrench. - Move up the cap and hold it for oil drain. - Replace the filter element service kit. - Install oil filter cap. (Torque: 2.5kgfm) 32mm wrench Oil filter cap Filter element

27 Cooling System Water pump RH Cylinder Block LH Cylinder Block Cylinder Head Cylinder Head Oil cooler EGR Cooler PTC Heater Thermostat Radiator Coolant capacity5Thermostat fully open temp. 95 Thermostat typeWax pallet typeControl typeInlet control Thermostat opening temp. 82 Cooling fan controlLOW,HIGH

28 Fuel System Fuel flow Throttle RH INJ.

29 Fuel System ItemsSpecification Fuel Tank (Steel)78 L Fuel Pressure 4.5 kg/ Fuel PumpElectric motor Fuel pump motor Fuel return tube Fuel tank

30 Fuel System Fuel pressure Fuel Pressure at Idle [Fuel filter HP pump, Fuel filter Injector return line] Fuel Pressure at Idle [HP pump Fuel filter] Engine ON (Filter Pump)IG ON (filter Pump)Engine ON (Pump Filter)

31 High Pressure Pump S-engine : CP3.2+U-engine : CP3.2 Capacity : 866 mm3/rev Max pressure : 1600 bar Fuel temperature sensor is adapted. Gear pump is not adapted. Capacity : 677 mm3/rev Max pressure : 1600 bar No fuel temperature sensor Gear pump is integrated.

32 High Pressure Pump Removal Preparation HP pump service cover Glow control module Engine support bracket

33 High Pressure Pump Removal 1. Remove the engine support bracket. 2. Remove the glow control module mounting bolts. 3. Remove the HP pump service cover 4. Remove the HP pump sprocket lock nut. Preparation

34 High Pressure Pump Removal 5. Install the HP pump puller. ( A000) HP pump puller. ( A000) Preparation

35 High Pressure Pump Removal Removal 1. Remove the inlet upper manifold. 2. Remove the oil filter. 3. Remove the inlet lower manifold. 4. Remove the HP pump mounting bolts. Inlet upper manifoldInlet lower manifoldOil filter [Inlet lower manifold assembly]

36 High Pressure Pump Removal 4. Tighten the screw of the HP pump puller. 5. Remove the HP pump. [HP pump assembly] Removal

37 Dual Pressure Control Components Condition Pressure valve Pump sideRail side StartingOPENCLOSED Low speedOPENControl Middle speed ~Control FailsafeLimp-homeOPEN Operation Pressure Control Valve (Rail pressure regulator) Inlet Metering Valve (Fuel pressure regulator) Rail pressure regulator Fuel pressure regulator Rail + Fuel pressure regulator Injection amount RPM

38 Dual Pressure Control Output signal

39 Dual Pressure Control Current data

40 Piezo Injector - Advantage : Engine power up & lower emission due to enhanced injection response time Reduced injector size & weight (490g 270g) - Disadvantage : Maximum operating voltage is 200V. If an injector is short to ground, be careful of electric shock. [Piezo injector] [Solenoid injector]

41 Piezo Injector Connector Pressure valve Piezo-actuator Hydraulic coupler Nozzle needle Start injection Power supplied (Charge) Piezo expansion Amplification Control valve open Opened Nozzle needle Power supplied (Discharge) Piezo contraction Pressure reduction Closed control valve Closed Nozzle needle Pressure control valve Stop injection Construction

42 Piezo Injector Piezo - Ceramic Internal electrode External electrode (Each internal electrode are connected) Around 90 - Piezo effect : piezo generates voltage by external force (ex. pressure sensor, map sensor). - Polarization : piezo deforms certain direction by voltage. - The piezo stack connected parallel functions like capacitor. - The length of a 90 piezo stack extends to 1.5~2% by maximum 200V. (current : less than 20A, minimum voltage applying time : 125 μs) - Stroke of actuator depends on the number of piezo stacks Concept of piezo actuator

43 Piezo Injector Process of polarization of the piezo actuator before polarization no preferred direction of domains, piezo electrically inactive Expansion due to electrical field E, P P during polarization alignment of domains after polarization mostly remaining alignment of domains Usable stroke Remanent expansion

44 Piezo Injector Operating principle (hydraulic coupler) - Hydraulic piston inside the hydraulic coupler amplifies the operating force from piezo actuator as much as the surface difference of upper piston & lower piston and increase the operating stroke. - For normal operation of the coupler, 1~10bar remains on the fuel return line (low pressure line). Low pressure line (1~10bar) Voltage Piezo Hydraulic Coupler (Amplifier) Amplifier Pressure Rail pressure Amplifier pre. 10 bar 1 bar Leakage (P s >P sys ) Refilling (P s

45 Piezo Injector Operating principle (pressure control part) Needle openedNeedle closed Control valve Needle Inlet By-pass Closed By-pass opened Inlet Outlet Control outlet Volume Initial position Inlet Rail pressure Leakage pressure Control volume pressure

46 Piezo Injector [Piezo- Injector] [Solenoid Injector] Solenoid Control current Amateur operating Fuel pressure inside injector Injection Pattern Piezo injector vs. Solenoid injector - Injector response : no delay time between the voltage and the stroke - Control current : only controls injection starting current and ending current.

47 Piezo Injector IVA (Injector Voltage Adjustment) * IVA (Injector Voltage Adjustment) : Characteristics of piezo injector - Function : Calibration of actuator/control valve stroke at the factory - Reason : Injector individual voltage demand caused by mechanical margin deviation of actuator and injector. (ex. Seat diameter of control valve, piston friction, relationship of voltage and stroke) - Class : 1 st ~ 15 th class according to operating voltage AIAK8NG * Injector code = IQA + IVA * IQA : Injector Quantity Adjustment

48 Piezo Injector Output signal Injector voltage Injector current Pilot2Pilot1Main

49 Piezo Injector Current output of injector #1 Voltage output of injector #1 Output signal

50 Back-leak Rail Installation & Removal Plug Plug Bush Plug fixing (4EA)

51 Back-leak Rail Installation & Removal Installation Before assembling the return line, confirm plug fixing condition and plug bush is lifted. Push the plug to vertical direction until make clicker sound from injector nipple

52 Back-leak Rail Installation & Removal Confirm installed condition by moving plug Install plug bush until hear click sound Installation

53 Back-leak Rail Installation & Removal Removal Press both knob and lift up plug bush Lift up plug vertical direction from injector nipple at lifted plug bush

54 Back-leak Rail Installation & Removal Case study - Cause : One plug fixing is broken. Because of excessive installation without the plug bush fully up. - Symptom : Fuel leaks from the injector nipple

55 Clamp Cap Information For S-engine, U-engine and J-engine s below table, the intake manifold hose clamp is covered with the cap (A) and the cap head (B). When tightening torque of the clamp cap head reaches its specification (0.5~0.7 kgf-m(3.6~5.1 lbf-ft)), the clamp cap head is broken out. The purpose of this clamp cap head type is to have the recommended tightening torque for the intake manifold hose clamp in production line. S/U/J Engine Before torqueAfter torqueAfter removing the cap A : Clamp cap B : Torque control cap

56 Clamp Cap Information 1) Plier out the intake manifold clamp cap. 2) Tighten or loosen the clamp using a flat head screwdriver. Service procedure

57 Semi Active Mounting - Only for Front Roll Stopper - Improved idle vibration by 5~10dB - Solenoid valve is controlled by ECM control module (not engine ECM but independent one) Solenoid valve Vacuum pump ECM Controller B+ Engine speed signal

58 Semi Active Mounting Operating conditionSolenoid valve Engine ON ~ 920 RPMON (Idle) 920 ~ 1000 RPMPrevious condition 1000 RPM ~OFF (Driving) Engine OFFOFF Alternator L voltageSolenoid valve 9V ~ON 2~9VPrevious condition ~ 2VOFF Operation Engine shake orifice Idling orifice ECM OFF ECM ON 1) Except idle condition – High damping 2) Idle condition – Low dynamic stiffness

59 Oil Separator Oil Gas

60 Inputs & Outputs APS1, 2 Brake, Clutch S/W CKPS & CMPS BPS, IAT RPS MAF sensor ECT A/C S/W Injector Fuel pressure E - EGR Cooling Fan PTC ISS BOSCH ECM (EDC16CP) Swirl Control CAN Communication A/C compressor Warning lamp APT Lambda Sensor PRV FTS FPV

61 Acceleration Position Sensor 1,2 - Sensor 1 : For injection amount and timing (torque request signal) - Sensor 2 : Sensor 1 monitoring, preventing sudden starting - Failsafe : 1,250 rpm fix ASP Brake switch

62 Rail Pressure Sensor - Failsafe : Rail pressure 360bar (36MPa) fix Engine speed limitation rpm

63 Fuel Temperature Sensor Temperature ( ) Resistance ( ) ~ ~ ~ ~ ~ ~ ~ ~ Function : Detects the fuel inlet temperature at high pressure pump If the fuel temperature is over 80, max. engine rpm is limited 3000rpm

64 Fuel Temperature Sensor Current data

65 Crankshaft Position Sensor - Inductive type - Information of engine speed and injection timing - Engine off if fails (cannot restart)

66 Crankshaft Position Sensor 2 - Hall IC type - Information of engine speed and injection timing - Limp-home function starts if fails while driving but cannot restart

67 Boost Pressure Sensor (BPS) - BPS is installed on surge tank to measure the absolute intake manifold pressure. - Used for control for E-VGT (Electrical Variable Geometry Turbocharger) - Failsafe : Limp-home (limited injection) RH Head lamp 1 Voltage (V) Pressure (kPa)

68 Air Flow Sensor 5 - Type : Hot-film type - Used for injection amount and EGR amount control - Failsafe : Limp-home (limited injection) [Sensor output][Location]

69 Lambda Sensor (EURO-4) - Detects oxygen density of exhaust gas - Accurate EGR control - Injection amount correction - Reduction of injection amount at engine full load condition to reduce smoke caused rich air- fuel mixture at high engine load condition. - Failsafe : no EGR control, no injection amount correction

70 Swirl Control Valve (EURO-3/4) - Optimize intake air swirl condition according to engine load - At low/Mid speed + low engine load : Increase the swirl for optimal combustion Increase EGR rate (valve closed increasing swirl reducing exhaust gas/power up/better fuel economy) - At other engine conditions : valve opened increasing inlet air flow increasing torque SCV Actuator [Replace as a set]

71 Swirl Control Valve (EURO-3/4) - Valve flap : Normally open type - Working ECT : over 70 degree celsius - Initialization : for cleaning and learning of the max. & min. position Key off : Fully open Close (2~3 times)

72 Electronic VGT Vane Control Actuator [ Vacuum type VGT ] [ S-3.0 Engine EVGT ] Compressor Turbine Actuator Bearing housing Boost pressure (Kpa) Over shooting E-VGT Time (sec.) VGT - Maker : Borg Warner (Actuator : Siemens VDO) - Benefit : Stable intake air control (Less hysteresis)

73 Electronic VGT VGT is operated by control actuator. ECM decide target boost pressure by input data (engine RPM, APS, Boost pressure sensor, ECT, VSS), and control electronic motor actuator valve by PWM. - Low speed : reduced exhaust passage maximized speed energy (Remove turbo lag) - High speed : exhaust passage is expansion reduced exhaust pressure Operation Increased speed Increased quantity ConditionSolenoid valve duty (+)ActuatorVane Low speed Low load Pull the rod High speed High load Push the rod 20% 80%

74 Electronic VGT Current data

75 Glow System (ISS : Instant Starting System) - Reduced Glow time : 2~3 seconds to Glow time is decided by engine coolant temperature - Self diagnosis function for each glow plug - GCU (Glow Control Unit) can use CAN communication - PWM control GCU

76 Glow System (ISS : Instant Starting System) ItemsISSConventional Type Hardware Heating time (1000 ) Within 2 secWithin 10 sec Operating voltage4V ~ 12V12V Power consumption41W97W At low battery voltageStableReduced performance Software Active control according to engine speed/load YesNo Communication with ECMCANRelay Protect overheat functionG/P and GCU controlG/P control System comparison

77 Glow System (ISS : Instant Starting System) Output signal

78 Glow System (ISS : Instant Starting System)