C100 Service Training Manual: Engine Mechanical (HFV-3.2L DOHC) Participant’s Handout 01.2-3 C100 (3.2 L) Engine Mechanical Participant’s Handout Table Of Contents Engine General …………...…..………………………….………….…… 5 Engine Mechanical ……...…..…………..……………….………….…… 8 Engine Lubrication ……………………………………………………… 21 Engine Timing System ………………….……………………………… 22 Accessory Belt …………………………………………………..………. 43 Air Intake System …………………………………………………..…… 44 Exhaust System ……………………………..……………………..…… 45 Engine Cooling System ……...………………………………………… 46 Fuel Supply system ………………………………………………..…… 48 Evaporative Emission Control System …...……………………..….… 54 rev 01 01.2-4 C100 (3.2 L) Engine Mechanical Participant’s Handout rev 01 3.2L Engine : Engine general Engine number (HFV6 3.2D) 01.2-5 C100 (3.2 L) Engine Mechanical Participant’s Handout 1. Component ID 2. Engine Broadcast Code 3. Plant Code (’H’=Holden) 4. Build Year (’06’ = 2006) 5. Julian Date (’070’ = built on day 70) 6. Build Sequence Number rev 01 2 L) Engine Mechanical Participant’s Handout 3.6 3.2L DOHC kph/ kph 5.01.195 10.2L Engine : Engine general Specifications APPLICATION Max Speed (MT/AT) Vehicle Performance Min Turning Ratio (m) Engine type Bore x Stroke (mm) Displacement (cc) Compression Ratio Engine General Max Power (hp/RPM) Max Torque (Nm/RPM) Idle RPM Initial Spark Timing (BTDC) Firing Order Type Coil Ignition Plug Ignition sequence Maker Type Clearance mm 3. SAE 0W 30 Synthetic Spin-on (Full Flow) 7.75 m 6 Cylinder(HFV6) 89 x 85.2 : 1 TBD TBD 690 8˚ 1-2-3-4-5-6 Direct Ignition System 1-2-3-4-5-6 TBD TBD TBD Type Oil Type and Grade Filter Lubrication Oil Capacity (w/filter) Type Oil Engine run Pump Pressure Relief Forced feed API SJ grade.2-6 C100 (3.4 L Gerotor TBD TBD rev 01 . 60AH 650 CCA rev 01 .4KW 120A MF 12V.2-7 C100 (3.3.2 L) Engine Mechanical Participant’s Handout Cooling Type Type Fuel Delivery Fuel Pump Displacement Fuel pressure Filter Type Fuel Tank Capacity Type Starter Alternator Power Power Type Battery Capacity Cold Cranking Ampere MPI Electric Motor TBD TBD Cartridge 65 L Planetary Gear Reduction 1.2L DOHC Pressurized 9 Centrifugal Cross Flow 673 mm 511 mm 27 mm 140 Kpa 10 Kpa Pellet 87 ± 2 102 MIN 82 Electric Main:5EA / Aux: 7EA 340mm + 320 mm 01.2L Engine : Engine general Specifications APPLICATION Type Coolant Capacity (L) W ater Pump Type Radiator W idth Core Height Thickness Surge Tank Pressure Valve open Vaccum Valve open Type Thermostat Start to open (℃ ) Completely open (℃ ) Completely close (℃ ) Type Fan Blades Fan Diameter 3. The connecting rods are manufactured from powdered metal and the rod cap is separated during the manufacturing process using the fractured method. The valves are operated by two camshafts (DOHC) per cylinder bank. Each aluminium cylinder head is fitted with hardened valve seats and four valves per cylinder: two intake and two exhaust. maintenance-free valve train) • Chain Drive Timing System (life-time maintenance free) • Poly-V-Belt Accessory Drive with automatic Belt Tensioner rev 01 .2-8 C100 (3. deep skirt die cast aluminium cylinder block with cast iron cylinder liners. The crankshaft is manufactured from forged steel. Variable camshaft timing is provided via four actuators fitted at the front of each camshaft. This creates a stronger. increased performance) • 24-Valve Cylinder Head (Improved performance due to increased air flow) • Closed Coupled Catalytic Converter (Achieve Euro 4 limits) • Electronic Throttle Control (Improved drive ability comfort) • Roller finger follower and hydraulic valve lash adjuster (Low friction. Features and Benefits • Dual Continuously Variable Cam Phasing (Reduced fuel consumption. internally balanced crankcase.2L Engine : Engine mechanical General description The V6 engine features a closed V. A reluctor wheel is pressed in place onto the rear of the crankshaft for the crankshaft position sensor.01.2 L) Engine Mechanical Participant’s Handout 3. The rear bank of cylinders consists of number 1–3–5 cylinders (BANK 1) and the front bank of cylinders consists of number 2–4–6 (BANK 2). The engine firing order is 1–2–3–4–5–6. full length water jackets and six bolt main bearing caps. visually seamless rod to cap union. one each for intake and exhaust valves. The cylinders are arranged in two banks of three with a 60 degree included angle between the two banks. 2L Engine : Engine mechanical Engine over view 01.2-9 C100 (3.3.2 L) Engine Mechanical Participant’s Handout Bank 2 Bank 1 rev 01 . Bank 2 12. 3. 8. 9.2-10 C100 (3. Camshaft Cover.2L Engine : Engine mechanical Exploded view (Cylinder head cover assembly) 1. 2. Ignition Coil 15. Camshaft Cover PCV Fitting.2 L) Engine Mechanical Participant’s Handout 3. Ignition Coil Bolt 16. Camshaft Cover PCV Fitting O–Ring. Bank 2 Camshaft Cover Gasket. 4. Oil Fill O–Ring 11. Bank 2 14. Bank 2 Camshaft Cover.01. 7. Bank 1 Camshaft Cover Spark Plug Port Seal Camshaft Cover Bolt Camshaft Cover Bolt Insulator Ignition Coil Bolt Thread Insert Oil Fill Cap 10. Camshaft Cover PCV Fitting Orifice. Bank 1 13. Bank 1 Camshaft Cover Gasket. 6. Spark Plug rev 01 . 5. Bank 1 Cylinder Head Bolt Cylinder Head Front Bolt Cylinder Head Coolant Hole Threaded Plug Spark Plug Sleeve Cylinder Head Oil Gallery Expansion Plug 15.2 L) Engine Mechanical Participant’s Handout 1.2-11 C100 (3. Valve Rocker Arm Assembly 13. Bank 2 21. Valve Spring 16. Hydraulic Valve Lash Adjuster Assembly 14. Intake Valve 12. 5. 6. 9. Cylinder Head Camshaft Cap Bolt 26. 3. Cylinder Head. Bank 1 24. Bank 1 23.3. Intake Camshaft. Bank 1 Cylinder Head Gasket. Exhaust Camshaft. Exhaust Camshaft. Exhaust Valve 11.2L Engine : Engine mechanical Exploded view (Cylinder head assembly) 01. 7. Cylinder Head Camshaft Front Thrust Bearing Cap 19. Bank 2 Cylinder Head Gasket. 2. Valve Spring Cap 17. Bank 2 Cylinder Head. Engine Coolant Temperature Sensor 10. Cylinder Head Camshaft Cap – Intermediate 25. Bank 2 22. 8. 4. Cylinder Head Oil Galley Check Valve 27. Intake Camshaft. Camshaft Oil Seal Ring 20. Valve Stem Oil Seal rev 01 . Valve Stem Key 18. 2.Cylinder Head Gasket Variable Intake Manifold (VIM) Control Valve rev 01 . 3. Upper Intake Manifold Throttle Body Assembly Upper Intake Manifold . 4.Lower Intake Manifold Gasket Fuel Injector Wiring Harness Fuel Rail Fuel Injector Lower Intake Manifold Lower Intake Manifold . 6. 8.2L Engine : Engine mechanical Exploded view (Intake manifold assembly) 1.to .01.2 L) Engine Mechanical Participant’s Handout 3.2-12 C100 (3. 5. 9. 7.to . Camshaft Position Sensor O–ring 16. 7.2 L) Engine Mechanical Participant’s Handout 1. Crankshaft Balancer Bolt 14. Camshaft Position Actuator Solenoid Valve Bolt 19. Camshaft Position Sensor 15.2L Engine : Engine mechanical Exploded view (Front cover) 01. Camshaft Position Sensor Bolt 17. 6.3. Engine Front Cover Locating Pin Engine Front Cover Bolt. Coolant Pump Pulley 11. 4.2-13 C100 (3. 3. M8 Engine Front Cover Seal Coolant Pump Assembly Coolant Pump Bolt Coolant Pump Gasket 10. 5. 8. Coolant Pump Pulley Bolt 12. 9. Crankshaft Balancer 13. 2. Camshaft Position Actuator Solenoid Valve Seal rev 01 . Camshaft Position Actuator Solenoid Valve 18. M10 Engine Front Cover Engine Front Cover Gasket Engine Front Cover Bolt. Bank 1 28. Bank 1 21. Bank 2 29. Bank 1 26. Secondary Timing Chain Tensioner Gasket. 10. Secondary Timing Chain Tensioner Bolt. Bank 1 24. Secondary Timing Chain. Bank 1 Secondary Timing Chain. Bank 2 Secondary Timing Chain Tensioner. 4.01. 7. Bank 1 22. 16. Bank 1 25. Bank 2 19. Bank 2 Secondary Timing Chain Shoe Bolt. Secondary Timing Chain Shoe Bolt. Secondary Timing Chain Guide Bolt. Bank 1 27. 8. Intake Camshaft Position Actuator. Crankshaft Sprocket Lower Primary Timing Chain Guide Primary Timing Chain Tensioner Primary Timing Chain Tensioner Bolt Lower Primary Timing Chain Guide Bolt Primary Timing Chain Upper Primary Timing Chain Guide Upper Primary Timing Chain Guide Bolt Camshaft Intermediate Driveshaft Sprocket Bolt Camshaft Intermediate Driveshaft Sprocket. Bank 2 30. Bank 2 Secondary Timing Chain Shoe.2L Engine : Engine mechanical Exploded view (Timing chain components) 1. Secondary Timing Chain Shoe. 14. Camshaft Position Actuator Bolt 31. Exhaust Camshaft Position Actuator. Bank 2 Secondary Timing Chain Guide Bolt. Bank 2 Camshaft Intermediate Driveshaft Sprocket. 2. 11. Bank 2 20. rev 01 18. Intake Camshaft Position Actuator. 17. Secondary Timing Chain Tensioner. Secondary Timing Chain Guide. Bank 2 Secondary Timing Chain Tensioner Bolt. Bank 1 23. Secondary Timing Chain Tensioner Gasket.2 L) Engine Mechanical Participant’s Handout 3. 5. 6. 15. 13. Bank 1 .2-14 C100 (3. Bank 1 32. 3. Exhaust Camshaft Position Actuator. 9. Engine Block Oil Gallery Expansion Plug. Crankshaft Rear Oil Seal Housing Assembly 21. 3. Piston and Connecting Rod Assembly Crankshaft Bearing Cap Crankshaft Bearing Thrust Cap Crankshaft Bearing Cap Inboard Bolt Crankshaft Bearing Cap Outboard Bolt Crankshaft Bearing Cap Side Bolt. Piston Oil Nozzle Bolt Crankshaft Lower Bearing rev 01 .3mm 19. Short Crankshaft Bearing Cap Side Bolt. Piston Oil Nozzle 7. 11. 20 mm 18. Engine Block Coolant Drain Threaded Plug.2L Engine : Engine mechanical Exploded view (Engine block assembly) 01. 8.2-15 C100 (3. 2. 10 mm Crankshaft Crankshaft Sprocket Locating Pin 13. 14 mm 16. 6. Crankshaft Upper Thrust Bearing #3 14. Engine Block Oil Gallery Threaded Plug. 14 mm 17. 9. Crankshaft Rear Oil Seal Housing Assembly Bolt 22. 10. Engine Block Oil Gallery Threaded Plug. Engine Block Core Coolant Expansion Plug. Long Engine Block Oil Gallery Expansion Plug.3. 14 mm 15. 12. 4. Crankshaft Upper Bearing 25. 5. Cylinder Head Locating Pin 24. 34.2 L) Engine Mechanical Participant’s Handout 1. Transaxle Locating Pin 20. Oil Pan Locating Pin 23. 2L Engine : Engine mechanical Exploded view Piston & connecting rod) 1.01.2 L) Engine Mechanical Participant’s Handout 3. 3. 2. Piston Oil Control Ring Spacer . Piston Oil Control Rail Ring rev 01 12. 8. Connecting Rod Connecting Rod Bolt Connecting Rod Bush Lower Connecting Rod Bearing Higher Connecting Rod Bearing Piston Piston Pin Piston Pin Retainer Piston Upper Compression Ring 10. 9. Piston Lower Compression Ring 11.2-16 C100 (3. 4. 7. 6. 5. 3.3.2 L) Engine Mechanical Participant’s Handout 1.2-17 C100 (3. 2. 5.2L Engine : Engine mechanical Exploded view (Oil pan assembly) 01. 4. Oil Deflector Oil Pump Suction Pipe Oil Pan Oil Pan Drain Plug Engine Oil Level Sensor rev 01 . 7. 3.2 L) Engine Mechanical Participant’s Handout 3. 4. 6. 2. Transaxle Front Mount Assembly Engine Mount Adapter Support Bracket Engine Mount Assembly Cradle Assembly Transaxle Mount Assembly Transaxle Rear Mount Bracket Transaxle Rear Mount rev 01 .2L Engine : Engine mechanical Exploded view (Engine mount system) 1.01.2-18 C100 (3. 5. 3.3. 2. 3 and 4 as below sequence 01. Tighten the camshaft bearing cap attaching bolt to 10 Nm (89 lb– in) as below sequence . The primary timing chain connects the crankshaft sprocket with the left–hand and right–hand intermediate drive shaft sprockets. ** Camshaft bolt tightening sequence : 1. 2 Loosen the center intake camshaft bearing cap bolts 1 and 2. right–hand secondary and left– hand secondary).2L Engine : Engine mechanical Camshaft and Bearings Three timing chains are fitted (primary. Retighten the center camshaft bearing cap bolts 1.2 L) Engine Mechanical Participant’s Handout [ Bank 1 camshaft bearing direction ] [ Bank 2 camshaft bearing direction ] rev 01 .2-19 C100 (3. and the center exhaust camshaft bearing cap bolts 3 and 4. 4.2-20 C100 (3. The top compression ring is plasma sprayed. Lower oil control ring position Upper oil control ring position Top ring position Oil control ring expander position Second ring position rev 01 [ Piston rings installation ] . while the second compression ring is cast iron Napier.01.2 L) Engine Mechanical Participant’s Handout 3. 2.2L Engine : Engine mechanical Piston and Rings The piston assembly is fitted with two low tension compression rings and one multi-piece oil control ring. The oil control ring incorporates a steel expander and two Chrome plated steel rails. The cast aluminium pistons incorporate a polymer coated skirt to reduce friction. 5. 3. [ Piston and Rings ] 1. 6. Normal condition : 30. 7.2L DOHC rev 01 . Lower Primary Timing Chain Guide Lower Primary Timing Chain Guide Bolt Oil Pump Housing Oil Pump Cover Oil Pump Gerotor Outer Ring Oil Pump Gerotor Inner Ring Oil Pump Cover Bolt Oil Pressure Relief Valve Bore Plug Oil Pressure Relief Valve Spring 10.2-21 C100 (3. Severe condition : 15. Oil Pressure Relief Valve 11.2 L) Engine Mechanical Participant’s Handout 1. Type Engine Oil Oil Replacement with filter Oil Capacity (w/filter) Oil Pump Pressure Forced feed API SJ grade SAE 0W -30 Synthetic oil .4L 69 Kpa at Idle (138 Kpa at 2000 rpm) 3.2L Engine : Engine lubrication Oil pump 01. Oil Pressure Relief Valve Bore Plug Retainer Clip 12. 3. 2.000 km / 12 months . 5. Oil Pump Bolt ITEMS Lub.3. 4. 9. 8.000 km / 6 months 7. 2L Engine : Engine timing system Timing chains 1. Camshaft Intermediate Drive Chain Sprocket Timing Mark – Bank 2 10. Secondary Timing chain Bright Plated Link – Bank1 14.2 L) Engine Mechanical Participant’s Handout 3. 6. Camshaft Intermediate Drive Chain – Bank 1 15. Exhaust Camshaft Position (CMP) Actuator Timing Mark – Bank 1 16.2-22 C100 (3. 2. Crankshaft Sprocket Timing Mark 13. Camshaft Intermediate Drive Chain Sprocket – Bank 1 11. 8. Inlet Camshaft Position (CMP) Actuator Timing Mark – Bank 1 rev 01 . 3. Intake Camshaft Position (CMP) Actuator Timing Mark – Bank 2 Secondary Timing Chain Bright Plated Link – Bank 2 Exhaust Camshaft Position (CMP) Actuator Timing Mark – Bank 2 Secondary Timing Chain – Bank 2 Primary Timing chain Camshaft Intermediate Drive Chain Sprocket Timing Mark – Bank 2 Primary Camshaft Intermediate Drive Chain Sprocket – Bank 2 Primary Timing Chain Bright Plated Link 9. Crankshaft Sprocket 12. 4.01. 5. 7. Crankshaft Sprocket Timing Mark rev 01 .2 L) Engine Mechanical Participant’s Handout 1. 2.3. 5.2-23 C100 (3. 8. 9. 6. Intake Camshaft Position (CMP) Actuator Timing Mark – Bank 2 Secondary Timing Chain Bright Plated Link – Bank2 Exhaust Camshaft Position (CMP) Actuator Timing Mark – Bank 2 Secondary Timing Chain – Bank 2 Primary Timing Chain Camshaft Intermediate Driveshaft Sprocket Timing Mark – Bank 2 Camshaft Intermediate Driveshaft Sprocket – Bank2 Primary Timing Chain Bright Plated Link Camshaft Intermediate Driveshaft Sprocket Timing Mark – Bank 2 10. 4.2L Engine : Engine timing system Primary and Bank 2 secondary timing chains 01. 7. Camshaft Intermediate Drive shaft Sprocket – Bank1 11. 3. Crankshaft Sprocket 12. Note : Ensure that the crankshaft sprocket is installed with the timing mark (1) visible. and Tool No.2-24 C100 (3. rotate the camshafts in an anti–clockwise direction. EN 46105–1 (1) onto the rear of the bank 2 cylinder head camshafts (2). 2. EN 46105 onto the camshafts. 4.01.1 1. Slide the crankshaft sprocket on the crankshaft until the crankshaft sprocket contacts the step in the crankshaft. EN 46105–2 onto the rear of the bank 1 cylinder head camshafts.3. rev 01 . Ensure that Tool No. CAUTION : All camshafts must be locked in place before installation of any timing chains. EN 46105 is fully seated onto the camshafts.2 L) Engine Mechanical Participant’s Handout 3. There should be no need to rotate the camshaft more than 45 degrees.2L Engine : Engine timing system Bank 2 secondary timing chain installation procedure . CAUTION : In order to install Tool No. Install Tool No. Install the crankshaft sprocket (1) onto the crankshaft (2) by aligning the keyway to the key on the crankshaft. 2 L) Engine Mechanical Participant’s Handout A.2L Engine : Engine timing system Bank 2 secondary timing chain installation procedure . Align the bright plated timing chain link (1) with the bank 2 exhaust camshaft position actuator sprocket alignment circle mark (2). 6. NOT the triangular mark. CAUTION : When aligning the bank 2 secondary timing chain to the camshaft actuator sprockets. ensure the circular timing marks on the sprocket are used. rotate the crankshaft in a clockwise direction until the crankshaft sprocket timing mark (2) is aligned with the indexing mark (3) on the oil pump housing. Ensure there are two bright links located on top of each of the camshaft actuator sprockets. C. B.3. rev 01 . Install the bank 2 secondary timing chain (1) aligning the chain in the following manner: 01.2-25 C100 (3. Using Tool No. EN46111 (1).2 5. Wrap the secondary timing chain around both bank 2 actuator drive sprockets. CAUTION : The bank 2 camshaft intermediate driveshaft sprocket (1) is marked with the letters LB and ’FRONT’.2 L) Engine Mechanical Participant’s Handout 3.2-26 C100 (3. Ensure the bank 2 camshaft intermediate driveshaft sprocket is selected and orientated correctly. and the bank 1 sprocket (2) is marked with the letters RB and ’FRONT’ Ensure the correct sprocket is used and the ’FRONT’ text is facing forwards when installed.2L Engine : Engine timing system Bank 2 secondary timing chain installation procedure . Install the bank 2 camshaft intermediate driveshaft sprocket to the cylinder block.3 D. 7. Place the bank 2 secondary timing chain around the left– hand camshaft intermediate driveshaft inner sprocket. 8. Align the bright plated timing chain link (1) with the intake camshaft position actuator sprocket alignment circle mark(2). with the bright plated timing chain link (1) aligned with the access hole (2) in the outer sprocket. 9. .01. Tighten rev 01 Tighten the camshaft ntermediate driveshaft sprocket attaching bolt to 66 Nm (49 lb–ft). 2 L) Engine Mechanical Participant’s Handout 12.2L Engine : Engine timing system Bank 2 secondary timing chain installation procedure . Ensure the correct shoe is used when installing to the Bank 2 side in this procedure and that the letters ’LH” are facing the front of the vehicle when installed.2-27 C100 (3. Tighten the secondary timing chain guide attaching bolt to 23 Nm (17 lb–ft). Install the bank 2 secondary timing chain guide (1). 13. Ensure the bank 2 secondary timing chain guide is selected and orientated correctly. CAUTION : The bank 2 secondary timing chain shoe (2) is marked with the letters LH on the back face of the timing chain shoe. 11. Ensure the bank 2 secondary timing chain shoe is selected and orientated correctly.3. Ensure the correct shoe is used when installing to the bank 2 side.4 10. 01. CAUTION : The bank 2 secondary timing chain guide is marked with the letters LH. Verify the Bank 2 secondary timing chain timing mark alignments (1 to 6). rev 01 . 2L Engine : Engine timing system Bank 2 secondary timing chain installation procedure . use a suitably sized flat blade screwdriver (1) to wind the plunger in a clockwise direction. Ensure the bank 2 secondary timing chain tensioner is selected and orientated correctly. into the tensioner shaft (2). Install the tensioner shaft (1) into the bank 2 secondary timing chain tensioner body (2).01.before tightening the attaching bolt. Note : To reset the tensioner. 15. 16. rev 01 . Note : Ensure secondary timing chain shoe is clear of the Bank 2 secondary timing chain tensioner mounting pad. Reset the bank 2 secondary timing chain tensioner.2 L) Engine Mechanical Participant’s Handout 3.2-28 C100 (3. 17.5 14. Tighten Tighten the bank 2 secondary timing chain shoe bolt to 23 Nm (17 lb–ft). Install the bank 2 secondary timing chain shoe (1). EN 46112 (1) is not inserted into the tensioner body (2). this will cause damage to the engine. Install a new bank 2 secondary timing chain tensioner gasket (1) to the tensioner (2). 20. 18. Place the bank 2 secondary timing chain tensioner (2) into position and loosely install the bolts (1) to the cylinder head.3. Slowly release pressure on the bank 2 secondary timing chain tensioner. The tensioner should remain compressed. 19.2-29 C100 (3. Compress the tensioner shaft into the body and lock the bank 2 secondary timing chain tensioner by inserting Tool No.2 L) Engine Mechanical Participant’s Handout rev 01 . 23. EN 46112 into the access hole in the side of the tensioner body. 01. 21.6 CAUTION : If Tool No.2L Engine : Engine timing system Bank 2 secondary timing chain installation procedure . Ensure the bank 2 secondary timing chain tensioner mounting surface on the Bank 2 cylinder head does not have any burrs or defects that would affect the sealing of the new gasket. 22. the tensioner shaft (3) will remain in the locked position and no tension will be placed on the timing chain. Install the bank 2 secondary timing chain tensioner bolts through tensioner and gasket. Release the bank 2 secondary timing chain tensioner (1) by pulling out Tools No. Verify the proper placement of the bank 2 secondary timing chain tensioner gasket tab (1).7 24.2-30 C100 (3. 27.2 L) Engine Mechanical Participant’s Handout 3. EN 46112 (2) and unlocking the tensioner shaft. Tighten the bank 2 secondary timing chain tensioner bolts (2).01.2L Engine : Engine timing system Bank 2 secondary timing chain installation procedure . Tighten Tighten the bank 2 secondary timing chain tensioner bolts to 23 Nm (17 lb–ft). Verify the bank 2 secondary timing chain timing mark alignments (1 to 6). rev 01 . 25. 26. 2. Ensure the bank 1 camshaft intermediate driveshaft sprocket is selected and orientated correctly.2L Engine : Engine timing system Primary timing chain installation procedure . and the bank 2 sprocket (1) is marked with the letters LB and ’FRONT’ Ensure the correct sprocket is used and the FRONT text is facing forwards when installed.3. Install the bank 1 camshaft intermediate driveshaft sprocket(2). Ensure that the crankshaft sprocket timing mark (1) is aligned with the indexing mark (2) on the oil pump housing. Install the bank 2 secondary timing chain components.2 L) Engine Mechanical Participant’s Handout rev 01 . 4.1 1. Tighten Tighten the bank 1 camshaft intermediate driveshaft sprocket attaching bolt to 65 Nm (48 lb–ft).2-31 C100 (3. CAUTION : The bank 1 camshaft intermediate driveshaft sprocket (2) is marked with the letters RB and ’FRONT’. 3. 01. 6.2-32 C100 (3.2 5. The bank 1 camshaft intermediate driveshaft sprocket Timing mark (1) will align with a bright plated primary timing chain link (2). B.01. Wrap the primary timing chain around the large sprockets of each camshaft intermediate driveshaft sprocket and the crankshaft sprocket aligning the brightened chain links as follows: A.2 L) Engine Mechanical Participant’s Handout 3.2L Engine : Engine timing system Primary timing chain installation procedure . The bank 2 camshaft intermediate driveshaft sprocket timing mark (1) will align with a bright plated primary timing chain link (2). Install the primary timing chain(1). rev 01 . 2L Engine : Engine timing system Primary timing chain installation procedure .3 C.3. Ensure all the timing marks (1. If the primary timing chain lower guide must be replaced. the oil pump assembly (2) must be replaced. 8. 5 and 6).2 L) Engine Mechanical Participant’s Handout 7.2-33 C100 (3. rev 01 . 01. The crankshaft sprocket timing mark (1) will align with a bright plated timing chain link (2). 2 and 3) are properly aligned with the bright plated timing chain links (4. The primary timing chain lower guide is not serviced separately. Note : Do not remove the primary timing chain lower guide (1). Ensure the primary timing chain upper guide is selected and orientated correctly. Reset the primary timing chain tensioner.2 L) Engine Mechanical Participant’s Handout 3. 11.2L Engine : Engine timing system Primary timing chain installation procedure .2-34 C100 (3. Install the primary timing chain upper guide bolts (2). rev 01 . Install the tensioner shoe assembly (1) into the primary timing chain tensioner body (2). use a suitably sized flat blade screwdriver (1) to wind the plunger in a clockwise direction. 12. Tighten Tighten the primary timing chain upper guide bolts to 23 Nm (17 lb–ft). Install the primary timing chain upper guide (1).4 9. into the tensioner shaft (2). 10. Note : To reset the tensioner.01. Ensure that the primary timing chain tensioner is being installed. 13. 2L Engine : Engine timing system Primary timing chain installation procedure . 17. the plunger will remain in the locked position and no tension will be placed on the timing chain. EN 46112 into the access hole in the side of the body. 16. 14. Ensure the primary timing chain tensioner mounting surf ace on the engine block does not have any burrs or defects that would affect the sealing of the new gasket.2 L) Engine Mechanical Participant’s Handout rev 01 . EN 46112 (1) is not inserted into the tensioner body.3. 19. Compress the shoe assembly into the body (2) and lock the primary timing chain tensioner by inserting Tool No.5 CAUTION : If Tool No. Install the primary timing chain tensioner bolts (3) through tensioner and gasket. Slowly release pressure on the primary timing chain tensioner.2-35 C100 (3. 15. Install a new primary timing chain tensioner gasket (1) to the tensioner (2). The primary timing chain tensioner should remain compressed. 18. Place the primary timing chain tensioner (2) into position and loosely install the bolts (1) to the engine block. 01. 2 L) Engine Mechanical Participant’s Handout 3. EN 46112 (2) and unlocking the tensioner shaft.2-36 C100 (3.01. 22.2L Engine : Engine timing system Primary timing chain installation procedure . rev 01 . 21.6 20. 23. Verify the proper placement of the primary timing chain tensioner gasket tab (1). Remove Tool No. Tighten Tighten the primary timing chain tensioner bolts to 23 Nm (17 lb–ft). 24. Verify the primary and bank 2 secondary timing chain timing mark alignments (1 to 12). EN 46105 from the bank 2 and bank 1 cylinder head camshafts. Release the primary timing chain tensioner (1) by pulling out Tool No. Tighten the primary timing chain tensioner bolts (2). EN 46105–2 (1) onto the rear of the bank 2 cylinder head camshafts (2). 01. CAUTION : In order to install Tool No.2 L) Engine Mechanical Participant’s Handout 3. Install Tool No.1 1. rev 01 .2L Engine : Engine timing system Bank 1 secondary timing chain installation procedure . 4. rotate the camshafts. There should be no need to rotate the camshaft more than 45 degrees. Using Tool No. EN 46105–1 (1) onto the rear of the bank 1cylinder head camshafts (2). Install the primary timing chain components. EN 46105 onto the camshafts.3.2-37 C100 (3. Install Tool No. EN46111 (1). rotate the crankshaft in a clockwise direction until the crankshaft sprocket timing mark (2) is aligned with the indexing mark (3) on the oil pump housing. 2. . C. B.2L Engine : Engine timing system Bank 1 secondary timing chain installation procedure . NOT the circular mark.01. Wrap the secondary timing chain around both bank 1 actuator drive sprockets.2 5.2 L) Engine Mechanical Participant’s Handout 3.2-38 C100 (3. that the triangular timing marks (1) on the sprocket are used. Align the bright plated timing chain link (2) with the exhaust actuator sprocket rev 01 alignment triangle mark. CAUTION : Ensure that when aligning the bank 1 secondary timing chain to the bank 1 camshaft actuator sprockets. Install the bank 1 secondary timing chain (1) onto the camshaft actuators (2) and the right hand camshaft intermediate driveshaft sprocket (3) aligning the chain in the following manner: A. Place the secondary timing chain around the bank 1 camshaft intermediate driveshaft outer sprocket. aligning the bright plated timing chain link (1) with the alignment access hole (2) in the inner sprocket. 3 D. Tighten Tighten the secondary timing chain guide bolts to 23 Nm (17 lb–ft). Ensure that the bank 1 drive shoe is used when installing to the bank 1 side in this procedure and that the letters ’RH” are facing the front of the vehicle when installed. 01. 6. rev 01 . 9. Align the bright plated timing chain link (1) with the intake actuator sprocket alignment triangle mark (2). CAUTION : The bank 1 secondary camshaft drive shoe is marked with the letters ’RH’. Ensure the bank 1 secondary timing chain shoe is selected and orientated correctly. Position the chain guide (2). 7.2-39 C100 (3.3.2 L) Engine Mechanical Participant’s Handout CAUTION : Ensure that the bank 1 secondary timing chain guide is used when installing to the Bank 1 side in this procedure.2L Engine : Engine timing system Bank 1 secondary timing chain installation procedure . Ensure that the bank 1 secondary timing chain guide is selected and orientated correctly. 8. Ensure the primary timing chain upper guide is selected and orientated correctly. into the tensioner shaft (2). Ensure the bank 1 secondary timing chain tensioner is selected and orientated correctly. Tighten Tighten the bank 1 secondary timing chain shoe attaching bolt to 23 Nm (17 lb–ft). Reset the bank 1 secondary timing chain tensioner.01. rev 01 . 11. 13. Position the bank 1 secondary timing chain shoe(1).2 L) Engine Mechanical Participant’s Handout 3. use a suitably sized flat blade screwdriver (1) to wind the plunger in a clockwise direction. Note : To reset the tensioner.4 10. Install the tensioner shaft (1) into the bank 1 secondary timing chain tensioner body (2). 12.2-40 C100 (3.2L Engine : Engine timing system Bank 1 secondary timing chain installation procedure . EN 46112 (1) is not inserted into the tensioner body (2). Install a new bank 1 secondary timing chain tensioner gasket (1) to the tensioner (2). 19. 17. 15.5 CAUTION : If Tool No. Slowly release pressure on the bank 1 secondary timing chain tensioner.2L Engine : Engine timing system Bank 1 secondary timing chain installation procedure . EN 46112 into the access hole in the side of the tensioner body. this will cause damage to the engine. Ensure the bank 1 secondary timing chain tensioner mounting surface on the bank 1 cylinder head does not have any burrs or defects that would affect the sealing of the new tensioner gasket.2 L) Engine Mechanical Participant’s Handout rev 01 . Install the bank 1 secondary timing chain tensioner bolts (3) through the tensioner and gasket.3. 14. The tensioner should remain compressed. Place the bank 1 secondary timing chain tensioner (2) into position and loosely install the bolts (1) to the engine block. 18. 01. the plunger will remain in the locked position and no tension will be placed on the timing chain. 16. Compress the tensioner shaft into the body and lock the tensioner by inserting Tool No.2-41 C100 (3. 24. Remove Tool No.2 L) Engine Mechanical Participant’s Handout 3. 23. Verify all primary and secondary timing chain timing mark alignments (1 to 18). rev 01 .6 20. Tighten the bank 1 secondary timing chain tensioner bolts (2). EN 46112 (2) and unlocking the tensioner plunger. Tighten Tighten the bank 1 secondary timing chain tensioner bolts to 23 Nm (17 lb–ft). Release the bank 1 timing chain tensioner (1) by pulling out Tool No. 26. 21.2L Engine : Engine timing system Bank 1 secondary timing chain installation procedure . Reinstall the engine front cover assembly. EN 46105 and EN 46105–2 from the both cylinder head camshafts.2-42 C100 (3. Verify the proper placement of the bank 1 secondary iming chain tensioner gasket tab (1). 25.01. 22. Reinstall the spark plugs. 7. 4. crack. 5. Power steering pump Water pump Belt tensioner Crankshaft Alternator Idler Compressor ** Relieve method : Rotate the drive belt tensioner clockwise. 6.2-43 C100 (3. 3. replace the belt if necessary. 2. air conditioning / steering belt . wear or tension. power steering belt . for looseness. 01. air conditioning belt .2 L) Engine Mechanical Participant’s Handout 1.2L Engine : Accessory Belt After checking the alternator belt .3. rev 01 . 9. 3.01.2 L) Engine Mechanical Participant’s Handout 3. Air Cleaner Rear Resonator 11. 2.8L . 4. PCV Hose PART NAME Air Cleaner Element Effective Area Element Replacement Element material Main Resonator Volume rev 01 3. 7.000㎞ / 24 months Non-woven Fabric 3. Mass Air Flow (MAF) Sensor Assembly 13. Air Intake Duct 15. Air Cleaner Outlet Elbow Hose 14. 6.2L Engine : Air intake system 1. 5. Air Cleaner Upper Housing Air Cleaner Element Seal Air Cleaner Element Air Cleaner Snorkel Assembly Lower Intake Air Duct Air Cleaner Resonator Duct Seal Air Cleaner Resonator Duct Assembly 8. Air Cleaner Lower Housing 12.2-44 C100 (3.2 DOHC Remote type / 12L 4000 cm2 40. Air cleaner aFront Resonator Air Cleaner Resonator Seal 10. 4. Exhaust Front Pipe to UCC Gasket PART NAME Pup Converter Underbody Converter Exhaust Front Muffler Exhaust Rear Muffler 3. UCC Heat Shield 17.14 ℓ 0. 6.3. 11. 5.2L DOHC 1. 8. 2.2L Engine : Exhaust system 01. Rear Muffler Heat Shields 10. 3.90 ℓ 10ℓ 11. Front Muffler to Rear Muffler Gasket 15. Bank 2 13. Bank 1 12.2 L) Engine Mechanical Participant’s Handout 1. Rear Muffler Assembly Lower Heated Oxygen Sensor.5ℓ X 2EA rev 01 . Bank 2 Exhaust Manifold. Bank 2 Pup Converter. Bank 2 16. 7. 9. Front Muffler Heat Shield Exhaust Front Pipe 18. Front Muffler Assembly Pup Converter.2-45 C100 (3. Bank1 14. Bank 1 Lower Heated Oxygen Sensor. Bank 1 Upper Heated Oxygen Sensor. Underbody Catalytic Converter (UCC) Upper Heated Oxygen Sensor. UCC to Front Muffler Gasket Exhaust Manifold. Main Cooling Fan Motor 7. Auxiliary Cooling Fan FAN SPEED Low APPLICATION ECT ( ℃ ) A/C switch ECT ( ℃ ) High ACP ( Kpa) ECT 6.2 L) Engine Mechanical Participant’s Handout 3. Radiator Upper Bracket 2. Auxiliary Cooling Fan Motor 8. Coolant Drain Cock ON 100 ON 110 1760 Malfunction 107 1347 OFF 97 rev 01 .01. Main Cooling Fan 5. Radiator 4.2L Engine : Engine cooling system Cooling fans 1. Lower Radiator Bumper 3. Cooling Fan Shroud Assembly 9.2-46 C100 (3. 2. 6. 8. 3. 9. 7.2 L) Engine Mechanical Participant’s Handout 1.2L DOHC Cross Flow 673 × 511 × 27 9ℓ 87 ±2℃ Φ 340 + Φ 320 Complete open : 102℃ Main + Aux W ×HxT REMARK Radiator Type Radiator Size Coolant Capacity Thermostat start to open Cooling Fans rev 01 . Water Pump Pulley Bolt Water Pump Pulley Water Pump Bolt Water Pump Water Pump to Engine Front Cover Gasket Thermostat Housing Bolt Thermostat Housing Thermostat Thermostat Housing to Engine Block Gasket PART NAME 3.2L Engine : Engine cooling system Water pump and Thermostat 01. 4.3. 5.2-47 C100 (3. The fuel pressure regulator is a part of the main fuel pump module. Fuel filter rev 01 .2L Engine : Fuel supply system Description of Fuel supply system The fuel system is a returnless on-demand design. Fuel tank 4.2 L) Engine Mechanical Participant’s Handout 3. The fuel pressure regulator as 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. and through the fuel feed pipe to the fuel injection system. The main fuel pump module contains a reverse flow check valve. The fuel pump supplies high pressure fuel through the fuel filter. Under body pipe line 2. An electric turbine style fuel pump attaches to the main fuel pump module inside the fuel tank. past the fuel pressure regulator. 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.2-48 C100 (3. 3 4 2 1 1. Canister 3.01. 3. Sub Fuel Pump 2.2-49 C100 (3. Grade Vent Valve 1. vapor pressure in the tank is discharged to the Canister and it doesn't make the tank over. 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 vapor that is produced in the tank is going through the line by Roll over valve and Grade vent valve. The fuel in the tank supplies to the engine through the supply line by the pump.2 L) Engine Mechanical Participant’s Handout 3.2L Engine : Fuel supply system Fuel tank The fuel tank stores the fuel and the tank is sealed up leakage of vapor. Main Fuel Pump 01. 5. Ring-Adaptor Fuel tank Capacity 65 L Remarks rev 01 . The main fuel tank is located in the rear of "Front muffler"and under the body of the vehicle. The fuel tank is made from high density polyethylene. Roll Over Valve 4 . 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 rev 01 .2L Engine : Fuel supply system Main Fuel Pump Module The main fuel pump module is located inside of the right side of the fuel tank.2 L) Engine Mechanical Participant’s Handout 3.01.2-50 C100 (3. 0V / 410kPa ) Fue l filte r re pla ce m e nt 410 kpa 100ℓ /h min 600 kPa . the sensor resistance is high and the ECM senses a high signal voltage.3 40 106.4 ~ 1.0V 2.2 L) Engine Mechanical Participant’s Handout Fuel Level Gage Resistance FUEL LEVEL Float He ight Status Full Stop 1/2 Empty Stop Fuel Height 228.3.000miles / 10 years 01. When the fuel tank is empty.0 99. The engine control module (ECM) monitors the signal circuit of the fuel level sensor in order to determine the fuel level.4 240. the sensor resistance is low and the ECM senses a low signal voltage.2 ∼ 2.5V 2.max 900 kPa 8 AMP 100.9 130.4V 3.2L Engine : Fuel supply system Specification of Fuel pump Syste m Pre ssure Displa ce m e nt (12.5 112.0V / 410kPa ) Re lie f pre ssure (12.5V rev 01 REMARK 5V Ref . FUEL LEVEL FULL 3/4 1/2 1/4 EMPTY SIGNAL 3.0V) Curre nt (12.0 MIN 37.8 253. When the fuel tank is full.6 1. The fuel level signal is sent to ECM.2 250.0 MAX 45. 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.0V 1.4 Resistance(Ω ) Fuel Level Gage Control The fuel level sensor changes resistance in response to the fuel level. The ECM uses the signal circuit of the fuel level sensor in order to calculate the percentage of remaining fuel in the tank.2-51 C100 (3. 2-52 C100 (3. Pressure 410 Kpa 600 ~ 900 Kpa Condition Engine running Relief pressure rev 01 .2 L) Engine Mechanical Participant’s Handout 3. which is roughly the same as the atmospheric pressure.2L Engine : Fuel supply system 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 pressure.01. 2 L) Engine Mechanical Participant’s Handout Injector specification Application Static flow rate Spray type Injection type Injection angle Resistance(Ω ) 3.2-53 C100 (3.6 (g/min) Single spray type(4 holes) Sequential 15 ˚ 11.6 rev 01 .4 ~12.2L Engine : Fuel supply system Injector and Rail 01.2 L DOHC 193.3. 2 L) Engine Mechanical Participant’s Handout 3.01.2L Engine : Evaporative emission control system Canister The evaporative emission canister is an emission control device containing activated charcoal granules.2-54 C100 (3. the electronic control module (ECM) activates the controlled canister purge solenoid allowing the fuel vapors to be drawn into the engine cylinders and burned. Once certain conditions are met. ※ Capacity : 900cc [ Canister ] [ Purge control solenoid ] rev 01 . The evaporative emission canister is used to store fuel vapors from the fuel tank.