Engine

Copyright by Hyundai Motor Company. All rights reserved.

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Power train Application
Power/Torque (PS/kgf m)

EU (LHD/RHD)
WGN
(8P)

GEN (LHD/RHD)
WGN
(9/12P)

AUST. (RHD)
WGN
(8P)

Engine

Transmission

VAN
(2/5P)

VAN
(2/5P)

VAN
(2/5P)

A-2.5 VGT M5SR1 A5SR2 M5TR1 100 / 23.0 AW30-43 M5TR1 170 / 40.0
(WGT : 136/35.0) (VGT/ WGT)

(VGT/ WGT

Diesel
D4BH TCI-2.5

Gasoline

-2.4 FR
AW30-40

175 / 23.2
-

(9P ONLY)

Note 1)

VGT (Variable Geometry Turbo charger) only

Note 2) WGT: Europe only (for lower engine power)

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C/Rail A - engine
Engine Displacement (cc) Max. Power (PS / RPM) Max. Torque (kgfm / RPM) A 2.5 VGT 2497 170 / 3800 40.0 / 2000 Timing Chain 2nd generation C/Rail (1600bar) Increased power 30 PS (vs A1) VGT Electrical EGR Feature Duty control Turbocharger - WGT BOSCH C/Rail Serpentine belt Air dam type intercooler EGR cooler Lambda sensor is Installed

3
A 2.5 WGT 2497 136 / 3800 35.0 / 2000

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D4BH TCI 2.5
Engine Displacement (cc) Max. Power (PS / RPM) D4BH TCI 2.5 2476 100 / 3800 23.0 / 2000

Max. Torque (kgfm / RPM)

Air dam type intercooler Balance-shaft for improving Feature NVH Covec F EGR and Cooler Satisfied Euro 3 emission

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Theta 2.4 engine
Engine Displacement (cc) Max. Power (PS / RPM) Theta 2.4 CVVT 2359 175 / 6000 23.2 / 4250

Max. Torque (kgfm / RPM)

Reduced engine weight 22Kg (vs A1) Increased power Feature 39 PS (vs A1) Timing Chain CVVT FF type theta engine

A- 2.5 Engine

Copyright by Hyundai Motor Company. All rights reserved.

TQ - ENGINE
Comparison (TQ vs A1)
System Item A1-WGT EURO 3 TQ VGT EURO 4 Remarks

Injector

CRIP1 / 6-HOLE

CRIP2.2 / 8-HOLE (IQA) 1600bar +PRV

Fuel system / EMS

Max. Rail pressure

1350bar

ECM
H/P Pump

16 bit CP3.2

32 bit CP1H Sensor is used for compensating amount of injection

Sensor

Added Sensor

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Comparison (TQ vs A1)
System Item A1-WGT EURO 3 TQ VGT EURO 4 Remarks

EGR cooler and Valve EGR cooler

Compressor inlet

EGR valve location is changed

EGR COOLER

EGR Valve

EGR Valve

Changed turbocharger (WGT VGT)

Intake / Exhaust system

Turbocharger

improved torque at low rpm Reduced emission Improved performance

Compressor outlet

Intercooler intercooler intercooler

Air dam type improved efficiency Increased capacity ( 4.25.7)

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Comparison (TQ vs A1)
System Item A1-WGT EURO 3 TQ VGT EURO 4 Remarks

Catalytic Converter WCC

Added Warm up Catalytic Converter ( WCC ) MT only Euro 4 : WCC+UCC (M/T only)
Euro 3 : UCC only Euro 2 : without catalytic converter

Intake / Exhaust system

UCC
UCC

H/PROTECTOR

Exhaust layout

VGT EX FITTING(WCC) H/PROTECTOR

VGT

WCC

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Comparison (TQ vs A1)
System Item A1-WGT EURO 3 TQ VGT EURO 4
Vacuum pump cap

10

Remarks

Head

Changed shape of EGR Cooler nipple & hose

Vacuum pump is moved to alternator

Head / cooling

Water inlet fitting

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Comparison (TQ vs A1)
System Item A1-WGT EURO 3 TQ VGT EURO 4 Remarks

11

Changed material (Aluminum Plastic)

Head / cooling

Head cover

Oil separator is removed

Changed combustion chamber for satisfying emission regulation

Moving

Piston

Adopted piston bushing - improved stiffness

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Comparison (TQ vs A1)
Model

12

contents
A1 [A-WGT] Max. Fuel pressure High Pump Max. Supplied capacity type type Max. No of Injection 1350 bar 677mm3/rev CP3.2 Classified injector 2~3 times TQ [A-VGT(EURO-4)] 1600 bar 843mm3/rev CP1H IQA injector 3~4 times

Injector

Max. pressure of injection

Min. amount of injection Min. interval of injection Max. pressure

1350 bar
1.5 mm3/st 1.8 ms 1350 bar Inlet control 16 bit 121 PIN

1600 bar
1.0 mm3/st 0.8 ms 1600 bar Inlet / Outlet control 32 bit 154 PIN

Common rail Pressure control CPU ECM No of PIN

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Timing Chain
- Maintenance free timing chain and chain guide adapted - Composed by 3 chains : A, B and C - Shorten engine length
Timing Chain Timing Chain C

13

Tensioner Chain guide

Timing Chain B

Timing Chain A

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Timing Chain A
- Drive crankshaft pulley, high pressure pump and RH balance shaft

14

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Timing Chain B
- Drive Crankshaft pulley, oil pump and LH balance shaft pulley - Aligned all timing mark together in initial installation - Proper lubrication for timing chain and chain guide
15 teeth

15

13 teeth 12 teeth

Tensioner

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Timing Chain C
- Drive high pressure pump intake and exhaust cam sprocket
5teeth

16

Auto Tensioner

High Pressure Pump sprocket

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Caution for timing chain
- Replacing work for timing chain A and B is not possible in condition of engine installation while timing chain C is possible. - Alignment between each sprocket and timing belt should be in spec. especially in timing chain C. - There are 3 types of high pressure pump sprocket supplied related to high pressure pump. Every time when you are in replacing work, you have to check the clearance between high pressure pump end and pump sprocket end and choose the right size of sprocket for proper installation.

17

Cylinder Block

Color Blue
HP Pump Sprocket

Thickness (mm) 34.2-35.0 33.4-34.2 35.0-35.8

Sprocket A B C

White Red

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Data Analysis (Idling Condition)

18

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Data Analysis Actuation Test

19

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Burner Type Heating System Layout

20

Exhaust pipe

Burner

Coolant outlet Coolant inlet

Fuel feeding
ECU
Radiator
Thermostat

Intake pipe Combustion air fan Heat exchanger Coolant Outlet

Air feeding
Engine

Heater
Heater

Water pump

Coolant inlet Oil feeding

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Burner
Combustion air fan ECU Internal temp. sensor

21

Air-inlet Heat-exchanger

Evaporator

Warm water outlet

Water-inlet Fuel inlet by dosing pump

Exhaust gas out Burning chamber

Glow plug

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Burner Type Heating System Location - Burner

22

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Burner Type Heating System Location Dosing Pump (Fuel Motor)

23

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Heater Control Logic
B+ Voltage Ambient temp. by ambient S/W Coolant Temp. by internal temp sensor Combustion air fan

24

E C U

Dosing pump Glow plug

Operating Condition
1. 2. Operating condition : below coolant temp. 78oC & ambient temp. 2oC Working procedure Cleaning : combustion air fan & glow plug on (for 30sec) Pre-filling : dosing pump on (for 3sec) Combustion : glow plug, combustion air fan, dosing pump on (for 121sec) Full load : combustion air fan, dosing pump 100% on Specification Heater capacity Power consumption Full mode 5.0kW 0.63l/h Half mode 2.5kW 0.32l/h

Fuel consumption

37W

13W

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Off Condition
1.

25

When engine off Dosing pump stop Cleaning operating : burn out remain fuel inside burner 100%, combustion air fan & water pump on Other parts are stopped When coolant temp. over 78oC Dosing pump stop Cleaning operating : burn out remain fuel inside burner 100%, combustion air fan & water pump on Water pump working but other parts are stopped

2.

What is cleaning
** Purpose of cleaning : Burning out remain fuel and foreign material after combustion then emit exhaust gas

When engine off burner operating noise can be occurred but that is normal sound (cleaning sound) - Engine off during full load operation : cleaning time 175 sec - Engine off during half load operation : cleaning time 100sec

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Wiring Diagram
Fuse(20A) HMC WIR'G HCC WIR'G

26

Battery(+) Ground(-) Diagnosis

1 2

To Heater

Ambient SW 1 1 3 2 3 To Heater

Alternator(+)

2 4

4
Dosing Pump 5 1 5 2 Ambient temp. sensor &dosing pump Burner main connector 6

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DTC & Data Analysis

27

Actuation Test

D4BH TCI Engine

Copyright by Hyundai Motor Company. All rights reserved.

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Timing Belt

29

RH Balance Shaft

LH Balance Shaft

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Valve Clearance

30

Standard Value : 0.25mm

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Injection Timing Adjustment

31

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System Overview (Covec F)

32

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System components
Control Sleeve Position (CSP) Sensor Injection system

33

GE Actuator

Vehicle

Pump Speed Sensor (Np)

Pump speed Sensor (Np) Sensors Control Sleeve Position Switches Sensor (CSP) Battery voltage Fuel Temp. Sensor Compensation Resistor Timing Position Sensor

Engine Control Module

Injection pump GE Actuator Timing Control Valve (TCV)

Additional Control
EGR valve Glowplugs MIL

Timing Control Valve (TCV) with Timer Position Sensor (TPS)

Fuel injection quantity Injection timing

EGR control Glow control Diagnosis

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GE - Actuator, TCV and TPS
Sensor yoke Fixed plate Return spring

34

Rotor and Core

Shaft Ball pin Sensor coil Shaft Control sleeve Movable plate Magnet

Current (A)

B TPS

Rotors rotational angle ()

TCV

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NP sensor, CSP

35

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Fuel Temperature Sensor, Fuel Cut Valve

36

No. 11 Ground

No. 7 Fuel temperature sensor signal

Fuel Cut Valve

Theta 2.4L Engine

Copyright by Hyundai Motor Company. All rights reserved.

TQ - ENGINE
Changing Items
SYSTEM Main Feature - light weight
: Aluminum cylinder block

38

Main Features

Figure

- High Stiffness
: Added rib and adopted cone-shaped type

cohesion face with T/M

Reduced vibration and noise

Aluminum Block

- FR type theta engine is adopted firstly

Added rib Cone-shaped type

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Changing Items
SYSTEM Main Features Main Features - Intake manifold is changed Figure

39

(Plastic Aluminum)
- Throttle body with ISA instead of ETC - MAP is used instead of MAF Driving Belt - Exhaust manifold is changed (Stainless steel Cast iron) - Location of Oil filter is changed - Alternator and steering pump are moved
Alternator Auto-tensioner A/C compressor Water Pump Steering Pump

- Reduce tension of driving belt