Motor 2,4

C100 Service Training Manual: Engine Mechanical (2.4L DOHC) Participant’s Handout

01.1-3 C100 (2.4L DOHC) Engine Mechanical

Table Of Contents

Participant’s Handout

Engine Number …………..….…..…………………….………….…………5 Engine Specification ……..….…..………………… ……..….…..…………………….………… ….………….…… .…… 6 Engine Engin e Side View …………..………………………………………….

8

Engine Engine Lubricati Lubrication on …………….… …………….………… ……………… ……………… ……………… ……………… ………… … 9 Engine Exploded View ………….………………… ………….………………………………… …………………….. …….. 10 Timing Belt ………………………… ……………………………………… …………………………… …………………………. …………. 15 15 Timing Timing Belt Adjustme Adjustment nt ………………… ………………………… ……………… ……………… ……………… ………… … 16 Acce Ac cess ssor ory y Belt Be lt ………………… ……… …………………… …………………… …………………. ………..…… .………. …. 18 Piston Piston Rings Rings Installat Installation ion ……… …………… ………… ………… ………… ………… ……….. …..…… …….… .… 19 Engine Engine Cylinder Cylinder Head Head ………… ……………… ………… ………… ………… ………… ………… ……..… ..….… .… 20 Engine Engine Intake Intake System System ……………… ……………………… ……………… ……………… ……………… …………… …… 21 E n gi g i n e E xh x h au a u s t S ys y s te t e m …… …… …… … … …… … … …… … … …… … … …… … … …. … . . …… …… 2 3 Engine Engine Cooli Cooling ng System System ………… ……………… ………… ………… ………… ………… ………… …….…… .……… … 24 Fuel Supply Supply system ……………… ……………………… ……………… ……………… ……………… …………..…… …..…… 26 Fuel Tank ………… ………………… ……………… ……………… ……….……… .……………… ……………… …………..…… …..…… 27 Fuel Pump Pump …………… ………………… ………… ………… ………… ………… ………… ………… ………… ………… ………… …… 28 Injector & Rail ……………… …………………………..……… …………..…………………… …………………………. ……………. 31 Evaporati Evaporative ve Emission Emission Canis Canister ter ………… ……………… ………… ………… ………… ……….. …..….… ….… 32

rev 01



rev 01

01.1-5

Engine number

C100 (2.4L DOHC)

1. FAM II

T

24 S E D

Engine Mechanical

012345 Engine Serial Number 000001~999999 Design specifics D : Daewoo, H : High performance L : Low end torque, R : Raised performance Fuel mixture system E : Fuel injection Z : TBI V : Carburetor L : LPG Compression Ratio G :<8.5, L : 8.5~9.0, N : 9.0~9.5 S : 9.5~10.0, X : 10.5~11.5, Y : ＞11.5 Displacement 18 : 1.8 L, 24 : 2.4 L Exhaust Emission limits C : Domestic, Others X : Europe, Euro stage II T : North America,OBD II, Euro stage III Z : EURO IV


rev 01

01.1-6

Engine Specifications

C100 (2.4L DOHC)

APPLICATION

2.4 DOHC

Engine Mechanical

Engine type Participant’s Handout

Engine General

4 Cylinder(In-Line)

Bore x Stroke (mm)

87.5 x 100

Displacement (cc)

2,405

Compression Ratio

9.6 : 1

Max Power (hp/RPM)

TBD

Max Torque (Nm/RPM)

TBD

Idle RPM

690

Initial Spark Timing (BTDC) Firing Order

Ignition Plug

Direct Ignition System

Ignition sequence

1-3-4-2

Maker

Bosch Type

Clearance

rev 01

˚

1-3-4-2

Type Coil

8

FLR8LDCU mm

0.9 ~ 1.1

01.1-7

Specifications APPLICATION

2.4 DOHC

Type

Forced feed

Coolant Capacity (L) Type

Cooling Surge Tank

Thermostat

Fan

Core

Participant’s

Down Flow

Handout

673 mm

Height

511 mm

Thickness

27 mm

Pressure Valve open

140 Kpa

Vaccum Valve open

10 Kpa

Type

Pellet

Start to open (°C)

87 ± 2

Completely open (°C)

102

Completely close (°C)

MIN 82

Type

Electric

Blades

Type

Main:5EA / Aux: 7EA 340mm + 320 mm

MPI Type

Electric Motor

Fuel Pump Displacement

TBD

Fuel pressure

TBD

Filter T ype Fuel T ank Capacity Starter

Centrifugal

Width

Fan Diameter

Fuel Delivery

Type

Cartridge 65 L Planetary Gear Reduction

Power

1.4KW

Alternator Power Type

120A

Battery

Engine Mechanical

9

Water Pump

Radiator

C100 (2.4L DOHC)

Capacity Cold Cranking Ampere

MF 12V- 60AH 650 CCA

rev 01



rev 01

Engine side view

01.1-9

Engine Lubrication

C100 (2.4L DOHC) Engine Mechanical


ITEMS

2.4L DOHC

Lub. Type

Forced feed

Engine Oil

5W30 SL

Oil Replacement with filter

Normal condition : 10,000 km / 6 mths Severe condition : 5,000 km / 3 mths

Oil Capacity (w/filter)

4.5L

Oil Pump Pressure

30 Kpa at Idle

Oil Pump Relief Pressure

4.0 ± 0.5 kg/cm2

rev 01



rev 01

Engine Exploded View Upper End

01.1-11

Engine Exploded View

C100 (2.4L DOHC)

Upper End 1 . Nut 2 . Engine Beautification Cover

28. Exhaust Gas Recirculation Valve

Engine Mechanical

Gasket

3 . Bolt

29. Cylinder Head

4 . Oil Filler Cap

30. Exhaust Manifold Gasket

Participant’s

5 . Bolt

31. Exhaust Manifold 32. Nut

Handout

6 . Cylinder Head Cover 7 . Cylinder Head Cover Gasket 8 . Tappet Adjuster 9 . Valve Key . 10 . Valve Spring Cap 11 . Valve Spring 12 . Valve Stem Seal

33. Exhaust Manifold Heat Shield 34. Cylinder Head Gasket 35. Bolt 36. Thermostat Housing 37. Thermostat Housing Gasket 38. Stud 39. Sleeve

13. Valve Spring Seat

40. Plug

14. Valve Guide

41. Bolt

15. Intake Valve Seat Ring

42. Camshaft Position Sensor

16. Exhaust Valve Seat Ring

43. Oil Gallery Plug 44. Exhaust Camshaft

17. Intake Valve 18. Exhaust Valve 19. Bolt 20. Front Camshaft Cap 21. Head Bolt 22. Bolt 23. Intermediate Camshaft Cap

45. Seal Ring 46. Camshaft Gear 47. Washer 48. Camshaft Gear Bolt 49. Intake Camshaft 50. Intake Manifold Gasket 51. Intake Manifold

24. Exhaust Gas Recirculation Adapter

52. Throttle Body Gasket

25. Exhaust Gas Recirculation Adapter

53. Throttle Body

Gasket 26. Bolt 27. Exhaust Gas Recirculation Valve

54. Nut 55. Evaporative Emission Canister Purge Solenoid

rev 01



rev 01

Engine Exploded View Lower End

01.1-13

Engine Exploded View

C100 (2.4L DOHC)

Lower End 2. Bearing Set

37. Oil Filter 38. Bypass Valve

3. Connecting Rod Bolt

39. Pressure Relief Valve Plunger

1. Connecting Rod Cap

4. Piston Ring Set 5. Piston Pin 6. Piston 7. Engine Block

40. Pressure Relief Valve Spring 41. Seal Ring 42. Pressure Relief Valve Plug 43. Rear Timing Belt Cover 45. Special Bolt

9. Water Jacket Cap 10. Bolt (Manual Transaxle)

46. Idler Pulley 47. Stud

11. Flywheel (Manual Transaxle)

48. Nut

12. Flexible Plate (Automatic Transaxle) 13. Bolt (Automatic Transaxle)

49. Bolt 50. Tensioner

14. Seal Ring

51. Bolt

15. Crankshaft

52. Thrust Inner Washer

17. Screw 18. Crankshaft Balancer Unit Assembly 19. Bolt 20. Oil Pan Scraper

54. Crankshaft Gear 55. Thrust Outer Washer 56. Bolt 57. Camshaft Drive Belt

21. Bolt 22. Oil Suction Pipe

60. Bolt

23. Oil Pan

61. Bushing Plug

24. Oil Pan Drain Plug

62. Bushing

25. Sleeve

63. Oil Gallery Plug

26. Gasket

64. Bolt

28. Oil Pump Cover 29. Ring Gear 30. Gear 31. Oil Pressure Switch 32. Washer

Handout

53. Woodruff Key

58. Gasket 59. Front Timing Belt Cover

27. Bolt

Participant’s

44. Bolt

8. Sleeve

16. Reluctor Ring

Engine Mechanical

65. Water Pump 66. Seal Ring 67. Crankshaft Position Sensor 68. Bolt 69. Knock Sensor 70. Bolt 71. Oil Filter Adapter

33. Washer 34. Oil Duct Outlet Plug 35. Connecting Piece 36. Seal Ring

rev 01

01.1-14 C100 (2.4L DOHC)

Engine Exploded View Engine Mount system

Engine Mechanical


1. Transaxle Front Mount Assembly 2. Engine Mount Adapter Support Bracket 3. Engine Mount Assembly 4. Cradle Assembly 5. Transaxle Mount Assembly 6. Transaxle Rear Mount Bracket 7. Transaxle Rear Mount

rev 01

01.1-15

Timing Belt



Specification Model

ID

C100

Length

Maintenance

TBD

I : 30,000 km R : 120,000 km

Remarks

* I : Inspection R : Replacement

rev 01

01.1-16

Timing Belt Adjustment (1)

C100 (2.4L DOHC) a. Remove the front cover Engine Mechanical

b. Rotate the crankshaft clockwise one full turn and

Participant’s

align the timing mark of the crankshaft sprocket to the

Handout

rear cover notch.

c. Align the timing mark of the intake cam sprocket and the exhaust cam sprocket .

d. Loosen the automatic tensioner fixing bolt (1). 1

e. Rotate the tensioner hex-key tab (2) counterclockwise to give the highest tension. 2

f. Rotate the hex-key tab clockwise until the adjust arm pointer is aligned with the notch of the tensioner bracket

rev 01

Timing Belt Adjustment (2)

01.1-17 C100 (2.4L DOHC)

g. Tighten the tensioner bolt Engine Mechanical


h. Rotate the crankshaft two turns clockwise

i. Check the tensioner pointer for the right position

rev 01

01.1-18

Accessory Belt

C100 (2.4L DOHC) After checking the alternator belt , air conditioning / steering belt , air Engine Mechanical

conditioning belt , power steering belt , for looseness, crack, wear or tension, replace the belt if necessary.


** Relieve method : Rotate the drive belt tensioner clockwise.

PART NAME

rev 01

2.4 DOHC

V-belt inspection

30,000km / 18 months

V-belt replacement


01.1-19

Piston Rings Installation


Oil Ring Rail Gap

Piston Mark

Piston Oil Ring And Top Compression Ring


Second Compression Ring Oil Ring Rail Gap

[ Piston Ring Installation ]

Top Compression Ring Second Compression Ring Oil Ring Set

[ Piston Ring Cut-away ]

rev 01

01.1-20

Engine Cylinder Head


New adopted engine has dual outlet exhaust and low restriction induction/ exhaust.


** Cylinder head bolt tightening sequence : Tighten the cylinder head bolts to 25 Nm (18 lb–ft) and turn the bolts another 3 turns of 90 using the angular torque gauge KM–470–B.

rev 01

01.1-21

Engine Intake System

C100 (2.4L DOHC)

Air Intake system

Engine Mechanical


PART NAME Air Cleaner

2.4 DOHC Remote type / 12L

Element Effective Area

4000 cm2

Element Replacement


Element material Main Resonator Volume

Non-woven Fabric 3.8L

rev 01

01.1-22 C100 (2.4L DOHC)

Engine Intake System(2) Intake manifold

Engine Mechanical

Participant’s

Runner ends blended to larger cylinder head inlet ports

EGR passage revised to clear throttle body.

Handout

PCV port added which satisfies OBD2 diagnostics if required. (Throttle body has no PCV port.)

Intake manifold and Throttle body

Revised throttle body mounting pattern. Throttle body size increased.

Support brace mounting position changed to facilitate power take-off unit clearance.

rev 01

01.1-23

Engine Exhaust System



1. Pup Converter

5. UCC Heat Shield

2. Exhaust Front Pipe Mounting Bracket

6. Front Muffler Assembly

3. Exhaust Front Pipe Assembly

7. Front Muffler Heat Shield

4. Underbody Catalytic Converter

8. Rear Muffler Heat Shields

(UCC)

9. Rear Muffler Assembly

PART NAME

2.4 DOHC

Pup Converter

1.14 L

Underbody Converter

0.90 L

Exhaust Front Muffler

10 L

Exhaust Rear Muffler

2 x 11.5 L

rev 01

01.1-24

Engine Cooling System - 1



1. Radiator Upper Bracket

6. Main Cooling Fan Motor

2. Lower Radiator Bumper

7. Auxiliary Cooling Fan Motor

3. Radiator

8. Cooling Fan Shroud Assembly

4. Main Cooling Fan

9. Coolant Drain Cock

5. Auxiliary Cooling Fan

FAN SPEED Low

High

APPLICATION

ON

OFF

ECT ( Degr. C)

96

93

A/C switch ECT ( Degr. C)

100

97

ACP ( kg/㎠)

18.98

14.76

ECT

rev 01

ON

Malfunction

01.1-25

Engine Cooling System - 1

C100 (2.4L DOHC)

Water pump and Thermostat

Engine Mechanical


1. Seal Ring 2. Thermostat 3. Thermostat Housing 4. Thermostat Housing Mounting Bolt 5. Water Pump Mounting Bolt 6. Water Pump 7. Seal Ring

PART NAME

2.4 DOHC

Radiator Type

Cross Flow

Radiator Size

673 × 511 × 27

Coolant Capacity Thermostat start to open Cooling Fans

REMARK

W ×HxT

9L 87 ±2 degr. C

Complete open : 102 Degr. C

Diameter 340 + Diameter 320

Main + Aux

rev 01

01.1-26

Fuel Supply system

C100 (2.4L DOHC) The fuel system is a returnless on-demand design. The fuel pressure Engine Mechanical

regulator is a part of the main fuel pump module. An electric turbine style fuel pump attaches to the main fuel pump


module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter, past the fuel pressure regulator, and through the fuel feed pipe to the fuel injection system. The fuel pressure regulator has a T-joint that diverts the needed fuel to the fuel rail with the unused fuel dropping back into the reservoir of the main fuel tank module. The main fuel pump module contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times.

3 4

2 1

1. Under body pipe line 2. Canister 3. Fuel tank 4. Fuel filter

rev 01

01.1-27

Fuel Tank The fuel tank stores the fuel and the tank is sealed up leakage of vapor. The fuel tank is made from high density polyethylene. The main fuel


tank is located in the rear of "Front muffler"and under the body of the vehicle. The fuel tank are each sides held in place by 2 metal straps that is able to hold from two nuts attach to the frame. The fuel in the tank supplies to the engine through the supply line by the pump.


The vapor that is produced in the tank is going through the line by Roll over valve and Grade vent valve, vapor pressure in the t ank is discharged to the Canister and it doesn't make the tank over. 5. Grade Vent Valve 1. Sub Fuel Pump

2. Main Fuel Pump

3. Roll Over Valve

4 . Ring-Adaptor

Fuel tank Capacity

Remarks 65 L

rev 01


Fuel pump - 1 Main Fuel Pump Module The main fuel pump module is located inside of the right side of the fuel tank. The main fuel pump module consists of the following major components:


• The fuel level sender assembly • The fuel pump and reservoir assembly • The fuel filter • The fuel pressure regulator • The suction and return jet assembly Sub Fuel Pump Module The sub fuel pump module is located inside of the left side of the fuel tank. The sub fuel pump module consists of the following major components: • The fuel sender assembly • The fuel transfer tube Sub Flange

Main Level Sender Ass’y

Main Pump

Support Pole

Level Sender Ass’y Suction Jet Ass’y

Check Valve

Reservoir Body

Return Jet

Main MRA

rev 01

Sub MRA

01.1-29

Fuel pump – 2

C100 (2.4L DOHC)

1. Specifications

Engine Mechanical

System Pressure

410 kpa

Displacement (12.0V / 410kPa)

100L/h

Relief pressure (12.0V)

min 600 kPa - max 900 kPa

Current (12.0V / 410kPa)

8 AMP

Fuel filter replacement

60,000 km / 36 months


2. Fuel Level Gage Resistance

FUEL LEVEL Status

Fuel Height

Full Stop

228.9

1/2 Empty Stop

Float Height

Resistance( Ω) MAX

MIN

40

45.5

37.0

130.6

106.2

112.8

99.4

1.3

250.0

253.0

240.4

3. Fuel Level Gage Control The fuel level sensor changes resistance in response to the fuel level. The engine control module (ECM) monitors the signal circuit of the fuel level sensor in order to determine the fuel level. When the fuel tank is full, the sensor resistance is low and the ECM senses a low signal voltage. When the fuel tank is empty, the sensor resistance is high and the ECM senses a high signal voltage. The ECM uses the signal circuit of the fue llevel sensor in order to calculate the percentage of remaining fuel in the tank. The fuel level signal is sent to ECM, the ECM sends the message of the fuel level to the BCM and the BCM modulates fuel level gauge in the cluster by single wire CAN. FUEL LEVEL

SIGNAL

REMARK

FULL

3.4V

5V Ref

3/4

3.0V

1/2

2.2 ~ 2.5V

1/4

2.0V

EMPTY

1.4 ~ 1.5V

rev 01


Fuel pump – 3 4. Fuel Pressure Regulator The fuel pressure regulator is installed inside the fuel pump. It is referenced by the fuel tank pressure instead of the vacuum


rev 01

pressure, which is roughly the same as the atmospheric pressure. Pressure

Condition

410 Kpa

Engine running

600 ~ 900 Kpa

Relief pressure

01.1-31

Injector & Rail



1. Injector specification

Application

2.4 L DOHC

Static flow rate

194 ± 4% (g/min)

Spray type

Dual spray type

Injection type

Sequential

Color

Black

Resistance(Ω)

12 ± 5%

rev 01

Motor 2,4

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