CVVT

CVVT System (Continuously Variable Valve Timing)

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1. Introduction of the CVVT System 2. CVVT System Components, Function 3. CVVT System Diagnosis 4. CVVT DTC 5. Oil specification for Beta CVVT engine 6. Waveform 7. Models with CVVT system

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CVVT(Continuously Variable Valve Timing) System The CVVT, which is installed on the exhaust camshaft controls intake valve open and close timing in order to improve engine performance. The intake valve timing is optimized by CVVT system depending on engine rpm.

Advantages of CVVT ■ Reduced Fuel Consumption : - Reduce Reduce Pumping Pumping loss because because of increasing increasing valve valve overlap overlap

■ Reduced emission : - Reduce Reduce NOx NOx by EGR effec effectt because because of valv valve e overlap overlap optim optimiza ization tion

■ Improved performance and increased torque at low speed : - Improved Improved volumetric volumetric and thermodyn thermodynamic amic efficiency efficiency by variable variable valve timing timing

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Exhaus Ex haustt Camsh C amshaft aft

Rotation Direction

CVVT

Timing C hain hain Intake Camshaft Timing Belt

Crankshaft

① Rota Ro tati tion on forc f orc e of c rankshaft rankshaft is transmi transmitt tted ed to exhaust c amshaft amshaft by timing timing belt. belt. ② Rota Ro tati tion on force fo rce of exhaust c amshaft is transmi transmitt tted ed to to intak intake e c amshaft by timing timing c hain.

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-

CVVT, OCV(Oil Control Valve)

-

OCV FILTER

-

Oil Temperature Sensor 

MAP Sensor 

Air Flow Sensor (HOT Film Type)

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CVVT Parts Location

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Valve timing variation EXHAUST

INTAKE

40CA

OVERLAP

- 240

- 120

0

120

240

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Intake Valve Timing

Beta Engine

Beta Engine with CVVT

Exhaust Valve Timing

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CVVT Oil Passage

R etard

D R A IN

A d v an c e

D R A IN Secti ction A- A

From Cylinder Block

Secti ction BB- B

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Rotating Direction of Engine

Retard

Advance

Driving condition

Intake V/Timing

Efficiency

 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

Reduced fuel consumption

11

Hold

Retard

Advance

12

Retard

Return

13

 Advance

Return

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HOUSING VANE ROTOR VANE

Retard Chamber

Advance Chamber

※ The Oil O il is suppli supplied ed to to the the ret retar ard d chamber c hamber and advanc advanc e chamber by O C V control. control.

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1. Rotor vane vane is installe installed d on exhaust-cam exhaust-camshaft shaft by bolt bolt 2. Camshaft-intake and housing of CVVT is connected by chain ( Sprocket is attached on housing. So, phase difference occurs between Housing and Rotor Vane of CVVT). 3. Rotor vane is fixed on housing by stopper pin at the position of the maximum retard retard 4. If the oil is supplied to advance chamber, Housing will be advanced and stopper pin is unlocked. 5. Timing of intake-camshaft is advanced. 6. Engine off condition. The oil is drained from the advance chamber, the housing returned to retard position and fixed by pin due to lock of position

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2.0L CCC+UCC (XD) Max.PWR : 137/6000 2.0L CCC (GK) Max.PW Max .PW R : 139/6000 2.0L CCC+UCC (XD) Max. TQ : 18.2/4500 2.0L CCC (GK) Max. TQ : 18.6/4500

MAX. POWER : 143PS/6000RPM 160

20

160

140

18

140

18

120

16

120

16

100

14

100

14

   )    S    P    (    R 80    E    W    O    P

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MAX. TORQUE : 19.0kg.m/4500RPM

60

   )   m  .   g    k    ( 12    E    U    Q    R    O    T

8

40

8

6

20

4

0

   )   m  .   g    k    ( 12    E    U    Q    R    O    T

   )    S    P    (    R 80    E    W    O    P

60

10

40

20

PERFORMANCE PERFORMANCE CURVE CURVE (G4GC (G4GC 2.0L 2.0L CVVT CVVT with with CCC) CCC)

0 1500

2000

2500

3000

3500

4000

4500

ENGINE SPEED (RPM)

5000

5500

20

6000

15 0 0

PERFORMANCE PERFORMANCE CURVE CURVE (G4GC (G4GC 2.0L 2.0L with with CCC) CCC)

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4 20 00

2 50 0

3 000

35 00

40 00

ENG.SPEED (rpm)

45 00

5 00 0

5 50 0

60 00

 – 

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• Location Location : End of of the exhaust exhaust camsha camshaft ft • Type Type of CVVT : vane vane type type • Operat Operation ion range range : 40 40± 2˚ Crank angle (20± 1˚ Camshaft angle) • Oper Operat ation ion Cond Conditi ition on

① Oil Temperature range : -40 ~ +130˚C ② Oil Pressure range : 0 ~ 1000kPa ③ Engine speed range : 650 ~ 6000 rpm • Stoppe Stopperr Pin Relea Release se Press Pressure ure Minimum Release

54kPa

F ully Release

191kPa

 – 

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BOLT, HEXA

CHIP, VANE SEAL

LOCK  P IN

SPROCKET

 – 

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① This pin on the camshaft camshaft should should be smooth smoo thly ly insert inserted ed and asse assembled mbled w ith ith the the hole on C VVT. Matching pin

② Tighten the bolt to Assemble the CVVT and the Camshaft. (Apply the oil on the bolt before tightening it.)

CVVT BOLT

ROTOR VANE Camshaft CVVT A SSY SSY

 – 

C VVT side view view

O il Supp Supplly for fo r Retard Retard C hamber ham ber O il Supp Supplly for Advanc A dvance e C hamber ham ber

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C am shaft si sid e view view

 –  Engine Rotation

Maximum Retard

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Retard Chamber 

Advance Chamber 

Middle

Maximum Advance

Positioned between ATDC 11 and BTDC29 (Maximum o peration peration angle of CVVT is 40 deg ree ree of c rank rank ang ang le) le)

The opening timing of intake valve will be advanced, if the housing is rotated to engine rotation directi direc tion on.. (T ( T he intake intake valve valve is opened op ened at AT A T DC 11 in maximum retard retard posit p osition, ion, the intake intake valve valve is opened op ened at BTDC BTD C 29 in maximum maximum advanc e posi po sittion)

 – 

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be operated due to the external impact. ① Dropped one cannot be reused – CVVT may not be

② Keep the tightening torque of CVVT bolt while tightening it. (Specification : 6.6 ~ 7.8 kgf m) - Lower than than specification specification : Bolt can be loosened and CVVT is separated separated from the camshaft, it may result in the damage of engine. - Higher Higher than spec. : CVVT CVVT may not not be operat operated ed due to the plastic deformation. deformation.

③ Do not overhaul CVVT even though CVVT is suspected and send defected parts to the parts supplier. - Because CVVT is assembled by using the unique unique tool, it may not be operated if it is overhauled and reassembled reassembled in the shop. If CVVT was overhauled, overhauled, it should be be replaced replaced with new one. one.

※ Do not loosen or reassemble this bolt. If it is overhauled, it should be replaced with new one.

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④ Be c areful areful the cleanne cleanness ss of C of C VVT oil pas pass sage on the the cy lin inder der head, head, cy lin inder der bloc bloc k and camshaft. - To p revent event the O C V mal malfuncti function on by foreig foreig n mat materi erial ⑤ Avoid Av oid the scratc scratc h on surface surface of o f the the rotor rotor vane w hen the the CVVT is inst install alled on the c amshaft amshaft.. (Do not depress CVVT strongly and do not rotate relatively while the pin of the camshaft is not inserted into the hole on CVVT.) - The res response of the the CVVT c an be decreas decreased ed by oil leak eakage because because of scrat scratch d amage. amage. Matching pin

O il Leakage Leakage c an be oc c urre urred d

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Scratch

⑥ Do not hold hold the the C VVT asse assembl mblyy b ut hold hold the the camshaft camshaft by the vice when the the tighten ighten the the mounting bolt of the CVVT. - C VVT may may not be operat operated ed due to to the the plas plasttic deforma deformattion.

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Center Bolt

CVVT Ass’y

1. Fix the camshaft using the vice. (Avoid the damage on the cam or journal) 2. Make sure whether CVVT is rotated or not. (should not be rotated)

Camshaft

3. Using some tape or other things, clog every holes except one hole (nearest to CVVT) designated by black arrow on the right side figure.

Vise

 – 

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4. Apply the air of 100kPa into the hole which is not clogged in procedure ‘3’. - This is to relea release se the lock lock pin inside inside of CVVT. CVVT. - Even though CVVT is not rotated by hand, it can be rotated naturally naturally depends on the strength of air  pressure. - The lock pin pin may not not be released released if there there is a leakag leakage e when the the air is applie applied. d. (Lower than pin releasing pressure) 5. Rotate CVVT by hand in the direction of advance (red arrow on the figure) under the condition ‘4’. - CVVT should should be rotated rotated smoothly smoothly in the direction direction of of advance advance and retar retard d if the lock pin pin was released. released. (However, the air pressure is released and CVVT is returned to maximum retarded position, it cannot be rotated if the lock pin is locked again.) - The overall rotating angle of CVVT from maximum retarded to maximum advanced position is 20 degrees. 6. Replace with new one if there is a faulty. Rotate CVVT up to maximum retarded position to lock the lock pin if there is no problem.

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OCV Specification

① Voltage : 12V ② Coil Resistance : 7.4± 0.5Ω(at 20℃ ) ③ Control current : 100 ～ 1000 mA ④ Insulation Resistance : over 50MΩ (at 500V) ⑤ Assembly air-tightness : Leakage test - Leakage should be less than 1.0㎤/min(Apply air pressure 200 kPa) Operation condition OIL Temp Tempera eratur ture e Range Range : -40 ～ +130℃ OIL Pressure Range : 0 ～ 1000 kPa Voltage Range : 10 ～ 16 V

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 – 

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STATOR SUB ASS'Y COIL ASS'Y

RING RING SEAL O CV

PLU NGER A SS' SS'Y

RING RING SEA L OCV

SPOOL

SPRING, PLUNGER

YOKE ASS'Y BRACKET

GU IDE, SPRING SPRING

RING RING SEA L OCV

SLEEVE, VALVE

 – 

① Dropped one cannot be reused. - OCV may may not be operated operated,, If itit was deformed deformed due due to the external external impact,

② When the OCV is replaced, be careful the cleanness to avoid the inflow of foreign substance in CVVT. - OCV locking locking due to the inflow of foreign substance substance will result result in malfunction malfunction of CVVT

③ Don't touch the OCV sleeve to prevent that a foreign substance flow in CVVT, When you repair  the CVVT.

④ When OCV is installed to engine, - Don't use use a OCV yoke as a handle handle or hook hook when the the engine engine is moved. moved. - To prevent prevent the deformat deformation ion of OCV. substance,, you must replace replace with new OCV. ⑤ If OCV is stuck with a foreign substance (even thought you remove a foreign substance, don't reused OCV.)

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 – 

30

OCV

1

2

Batter Batteryy Power Po wer after main relay 

11 OC V contr control EC M

 – 

Idle condition

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2000rpm full load condition

93% d ut utyy at a t osc osciillosc oscop ope e funct func tion is equals to 7% d ut utyy at a t c ur urre ren n t da datta. O sc illoscop oscope e : (+) duty, duty, C ur urrrent data : (- ) dut d uty  y 

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Check resistance of OCV

① Disconnect OCV connector. ② Measure resistance of OCV - Specifi Specificati cation on : 6.9 6.9 ~ 7.9 7.9 Ω (20℃ )

③ If out of range, replace with new one. Check the operation of OCV

① Disassemble OCV from cylinder head. ② Connect the Battery. - Check that SPOOL SPOOL is is moved moved toward toward (#2 direction)

③ Disconnect to Battery - Check that that SPOOL is is returned returned (#3 (#3 direction) direction)

③ 2 3

 – 

① OCV spool is locked when the foreign substance clogged between OCV sleeve and spool. ② If the CVVT is not operated. The camshaft’s real position and target position is not matched. ③ If it is fixed at advanced position. The engine vibration and engine stop occurred at the engine idle condition.

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 – 

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Relate Parts

CVVT

2 mg

OCV

1 mg

OCV Filter 

0.1 mg

Oil Filter ~ OCV

2 mg

Entrance of oil path (OCV ~ Camshaft)

1 mg

Camshaft inside oil path

1 mg

Parts

Oil path

Foreign substance quantity (Max)

TOTAL

7.1 mg

Size

Max 0.4 mm

 – 

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① Be c are areful ful not to to infl inflow ow the forei fo reigg n substance substance w hil hile e remove or o r inst instal alll the the CVVT C VVT rel relat ated ed part p arts. s. - C V V T A S S ’Y - O CV C V A SS, Y - O C V F ililter - OT S(O il Tempe Temperratur ure e Se Sens nsor or)) - Ca Cam msh af t AS ASS S’Y - H E A D B O LT L T e tc . ② Befo Before re reins reinsttal alli ling ng , you y ou have to w as ash h the the relat related ed part p arts. s. ③ Wear the the co at ated ed g loves ins insttea ead d o f the the cott c otton on g loves.

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BOLT

WASHER

Attention t he cleanliness ① When OCV Filter was replaced, ensure the - Prevent Prevent that OCV OCV LOCK by foreign foreign materia materiall

② When OCV Filter reassemble, replace the Washer with new one - remove the the foreign foreign material material by Air Gun, Gun, and clean up up by the ether. ether. Confirm problem of OCV Filter  Disassemble Disassemble the OCV Filter Filter and check that foreign materials materials were trapped. trapped. - If necessary, necessary, replace replace or clean clean up by by Air Gun

FILTER

 – 

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4. Auto Tensioner  Setting auto-ten auto-tensioner sioner before before installation installation on the cylinder cylinder head

① Compress Compress auto auto tension tensioner er to retrac retractt it ② Insert the Stopper Pin ③ Assemble the tensioner to the cylinder head

Stopper Pin

② ①

 – 

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Assemble Assemble camshaft and

Install Auto Tensioner as Fig

chain to head (caution : timing) timing )

Attention

① Keep the tightening Assemble 2 bolts (Torqu (Torque e 0.8 ~ 1.0 1.0 kgf m)

Remove Stopper Pin

torque

② Timing ( Match the Timing Mark of the Sprocket and the Timing Chain)

 – 

5. OTS (Oil Temperature Sensor) The OTS located on the passage of the engine oil. The CVVT is operated by the engine oil. The oil density is changed according to the its temperature. The control signal of the OCV is compensated by ECM depending on OTS signal. The OTS is required in order to measure the temperature and it use a NTC type resistor.

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 – 

40

O TS

Temperature

76

52

Resistance Ground

Signal

ECM

 – 

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6. Timing Chain ① Align the timing marks ② Install the Timing chain as figure * The timing chain of CVVT engine is different from current current Beta engine engine which is not equipped CVVT system. Vendor and chain pitch are different

T iming iming Mark ark

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1) Start the engine at idle. 2) Test 2 items as shown in the below table at the idle condition. Condition

Test

Remark

1

Disconnect the OCV connector.

Check the engine condition.

To check the CVVT position at maximum retarded.

2

Connect battery voltage to the OCV connector.

Check the engine vibration and engine stop at engine idle condition.

To check the CVVT movement to advanced position.

3) If problems are found by above test, Check each parts as following order. Valve Timing → Sensor, ECU Output signal → CVVT ASS’Y → OCV → OCV Filter  * Refer to the parts inspection method in previous slides

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CKP + CMP Waveform

Idle condition, Maximum retarded CVVT CVVT operation operation can be checked by waveform which which is is comparison comparison between between CKP CKP and and CMP. CMP.

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CKP + CMP Waveform

1200RPM with load (Increasing load slowly)

Maximum advanced, Full load condition

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DTC

Descriptions

P0010

Camshaft Position Actuator Circuit

P0075

Intake Valve Control Solenoid Circuit(B1) (OCV)

P0076

Intake Valve Control Solenoid Circuit -Low(B1) (OCV)

P0077

Intake Valve Control Solenoid Circuit -High(B1) (OCV)

P0196

Engine Oil Temperature Sensor Range/Performance Range/Performance

P0197

Engine Oil Temperature Sensor Low Input

P0198

Engine Oil Temperature Sensor High Input

P0341

Camshaft Position Sensor Range

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P0010

Camshaft Position Actuator Circuit

Camshaft is mis-aligned exceed 5 degree of CA from target position, when the CVVT is operating. Example) 1. Insufficient Insufficient oil flow flow such as cloggin clogging, g, stuck of OCV, OCV, Oil leakage leakage from CVVT assembly. 2. Improper operation of CVVT assembly. P0341

Camshaft Position Sensor Range

Camshaft position is mis-matched with crankshaft position, when the CVVT is not operating (fully retarded position). Example) 1. Mis-aligned Mis-aligned the timing timing belt or the timing timing chain chain 2. Damaged Damaged CMP CMP or CKP sensin sensing g teeth, teeth, 3. Wrong signal of CMP or CKP sensor 

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NO. 1 3 2 5 4 7 6 9 8 10 11 12 13 14 16 17 18 19 20

I t em Descr i pt pt i on on BATTERY VOLTAGE COOLAN LANT TEMP. SENSOR COOLANT TEMP. SENSOR( V) OI L TEMP. SENSOR OI L TE TEMP.  SE SENSOR( V) I NT. AI R TEMP. SNSR I NT. AI R TEMP. SNSR( V) THROTTLE P. SENSOR THROTTLE P. P. SENSOR( V) ADAPTED PTED THROTTLE GRANKI NG SI GNAL I DLE STATUS PART LOAD ST STATUS MASS AI R FL FLOW VEHI CLE SPEED ENGI NE SPEED TARGET I DLE SPEED TRANS. RANGE SW A/ C SWI TCH

Uni t V 。 C mV 。 C mV 。 C mV 。 mV 。 OFF/ ON OFF/ ON OFF/ ON Kg/ h Km/ h r pm r pm P, N/ DRI VE OFF/ ON

Appl i cat cat i on on on HI - SCAN ( Compar e wi t h Hi - scan scan PRO)

X X X X X

X

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21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 38 39 46 43

A/ C PR PRESSURE SW A/ C COMP. RE RELAY OXYGEN SNSR- B1 B1/ S1 S1 OXYGEN SNSR- B1/ S2 I GNI TI ON TI MI NG I NJ . DURATI ON- B1 A/ F CLOSED LOOP LONE FUEL TRI M- I DLE LONE FUEL TRI M- P/ P/ LO LOAD O2 SNSR HEAT. DUTY- B1/ S1 O2 SNSR HEAT. DUTY- B1/ S2 I DLE SPEED ACTUATOR DUTY EVAP. PURGE VALVE DUTY I GNI TI TI ON DWEL TI ME CAMSHAFT POSI TI ON CAMSHAFT POSI TI ON- TA TAR RGET CVVT STATUS CVVT ACTUATI ON STATUS CVVT DUTY CONTROL STATUS CVVT VALVE DUTY

OFF/ ON OFF/ ON mV mV 。 mS mS % % % % % mS 。 CRK  。 CRK 

%

X

X

X

X X

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North America

Domestic/EU/General(Include Middle East)/Australia

※ When using using the hig hig h visco visco sity sity oil (15W40 (15W40 above) , sometimes sometimes CVVT wo uld not operate at the cold condition. We rec ommend 10W30 10W30 or lower visco sity sity oil.

SAE

ILSAC

GF-I or above

API

SH or above

Models with CVVT system

VANE TYPE

TOYOTA

SUBARU SUBARU HELICAL TYPE

TOYOTA JAGUAR JAGUAR

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V6 3.0L

LEXUS RX300, ES300 New Previa etc.

L6 2.0L

LEXUS IS200 etc.

L6 3.0L/2.5L

CROWN(GDI)

L4 1.OL 1.OL

YARIS etc.

H4 2.0L/2.5L 2.0L/2. 5L

LEGACY etc.

V8 4.0L

LEXUS LS400 etc.

L4 2.0l

CARINA CARINA etc

V8 4.0L

XK8 etc