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

01.195 10.4 L Gerotor TBD TBD rev 01 .2 L) Engine Mechanical Participant’s Handout 3.2L 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 3.2L DOHC kph/ kph 5.75 m 6 Cylinder(HFV6) 89 x 85. SAE 0W 30 Synthetic Spin-on (Full Flow) 7.6 3.2 : 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.

3.2L 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 3.4KW 120A MF 12V.60AH 650 CCA rev 01 .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 01.2-7 C100 (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.

one each for intake and exhaust valves. The crankshaft is manufactured from forged steel. maintenance-free valve train) • Chain Drive Timing System (life-time maintenance free) • Poly-V-Belt Accessory Drive with automatic Belt Tensioner rev 01 . The valves are operated by two camshafts (DOHC) per cylinder bank. 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. Each aluminium cylinder head is fitted with hardened valve seats and four valves per cylinder: two intake and two exhaust. A reluctor wheel is pressed in place onto the rear of the crankshaft for the crankshaft position sensor.2-8 C100 (3. Variable camshaft timing is provided via four actuators fitted at the front of each camshaft. The cylinders are arranged in two banks of three with a 60 degree included angle between the two banks.01.2 L) Engine Mechanical Participant’s Handout 3. The engine firing order is 1–2–3–4–5–6.2L Engine : Engine mechanical General description The V6 engine features a closed V. full length water jackets and six bolt main bearing caps. 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). Features and Benefits • Dual Continuously Variable Cam Phasing (Reduced fuel consumption. visually seamless rod to cap union. deep skirt die cast aluminium cylinder block with cast iron cylinder liners.The connecting rods are manufactured from powdered metal and the rod cap is separated during the manufacturing process using the fractured method. This creates a stronger. internally balanced crankcase.

3.2 L) Engine Mechanical Participant’s Handout Bank 2 Bank 1 rev 01 .2L Engine : Engine mechanical Engine over view 01.2-9 C100 (3.

Ignition Coil 15. Ignition Coil Bolt 16.2L Engine : Engine mechanical Exploded view (Cylinder head cover assembly) 1. Oil Fill O–Ring 11. Bank 1 13. Bank 1 Camshaft Cover Gasket. Bank 2 12. 3. 9. Camshaft Cover. Camshaft Cover PCV Fitting O–Ring.2-10 C100 (3. 7. Camshaft Cover PCV Fitting Orifice. 6. 4. Bank 2 Camshaft Cover Gasket. Spark Plug rev 01 . Bank 1 Camshaft Cover Spark Plug Port Seal Camshaft Cover Bolt Camshaft Cover Bolt Insulator Ignition Coil Bolt Thread Insert Oil Fill Cap 10. 8.2 L) Engine Mechanical Participant’s Handout 3. 2. 5.01. Bank 2 Camshaft Cover. Camshaft Cover PCV Fitting. Bank 2 14.

4. 6. Valve Rocker Arm Assembly 13. Intake Camshaft. Bank 2 21. Engine Coolant Temperature Sensor 10. 9.2-11 C100 (3.2 L) Engine Mechanical Participant’s Handout 1. Cylinder Head Camshaft Front Thrust Bearing Cap 19. 2. Valve Stem Key 18. Bank 1 23.3. Bank 2 Cylinder Head. Valve Spring Cap 17. Cylinder Head Oil Galley Check Valve 27. Bank 1 Cylinder Head Gasket. Exhaust Camshaft. 3. Intake Camshaft. 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. Bank 2 22. Bank 2 Cylinder Head Gasket. Intake Valve 12.2L Engine : Engine mechanical Exploded view (Cylinder head assembly) 01. Exhaust Camshaft. Cylinder Head Camshaft Cap – Intermediate 25. 5. Valve Spring 16. Hydraulic Valve Lash Adjuster Assembly 14. 8. 7. Cylinder Head. Camshaft Oil Seal Ring 20. Bank 1 24. Cylinder Head Camshaft Cap Bolt 26. Exhaust Valve 11. Valve Stem Oil Seal rev 01 .

7.to .2 L) Engine Mechanical Participant’s Handout 3.Lower Intake Manifold Gasket Fuel Injector Wiring Harness Fuel Rail Fuel Injector Lower Intake Manifold Lower Intake Manifold . 8. 2. 5. 6.2L Engine : Engine mechanical Exploded view (Intake manifold assembly) 1. Upper Intake Manifold Throttle Body Assembly Upper Intake Manifold .Cylinder Head Gasket Variable Intake Manifold (VIM) Control Valve rev 01 .to . 3.01. 9.2-12 C100 (3. 4.

3. 9. Camshaft Position Actuator Solenoid Valve Seal rev 01 . 3. Camshaft Position Sensor O–ring 16. Coolant Pump Pulley Bolt 12. Crankshaft Balancer 13. Coolant Pump Pulley 11. M10 Engine Front Cover Engine Front Cover Gasket Engine Front Cover Bolt. 8.2-13 C100 (3. Engine Front Cover Locating Pin Engine Front Cover Bolt. Camshaft Position Actuator Solenoid Valve 18. 2.2 L) Engine Mechanical Participant’s Handout 1. 4. Camshaft Position Sensor Bolt 17. 7. 6. Crankshaft Balancer Bolt 14.2L Engine : Engine mechanical Exploded view (Front cover) 01. M8 Engine Front Cover Seal Coolant Pump Assembly Coolant Pump Bolt Coolant Pump Gasket 10. Camshaft Position Sensor 15. 5. Camshaft Position Actuator Solenoid Valve Bolt 19.

Exhaust Camshaft Position Actuator. Bank 2 Camshaft Intermediate Driveshaft Sprocket. 10. Secondary Timing Chain Tensioner Gasket. Bank 2 Secondary Timing Chain Guide Bolt. Intake Camshaft Position Actuator. rev 01 18. Bank 1 23. Bank 2 30. Bank 1 24. 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 1 32. Secondary Timing Chain Shoe Bolt. Bank 2 Secondary Timing Chain Tensioner Bolt. Camshaft Position Actuator Bolt 31. 8. Intake Camshaft Position Actuator. Secondary Timing Chain Guide Bolt. Bank 2 29.2 L) Engine Mechanical Participant’s Handout 3.2-14 C100 (3. Secondary Timing Chain Guide. Secondary Timing Chain Tensioner Gasket. Bank 1 Secondary Timing Chain. Bank 2 Secondary Timing Chain Tensioner. Bank 1 25. 17. 15. 4. 7. 9. 3. Bank 2 Secondary Timing Chain Shoe Bolt.2L Engine : Engine mechanical Exploded view (Timing chain components) 1. 13. Secondary Timing Chain Shoe. Bank 2 19. Secondary Timing Chain. Exhaust Camshaft Position Actuator. Bank 1 . Bank 1 27. Bank 2 Secondary Timing Chain Shoe. 5. Secondary Timing Chain Tensioner Bolt. 2. 6. 16.01. Secondary Timing Chain Tensioner. 11. Bank 1 28. Bank 2 20. Bank 1 21. 14. Bank 1 22. Bank 1 26.

3. 14 mm 17. 10. 2. 14 mm 16. Crankshaft Upper Bearing 25. 14 mm 15. 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. 10 mm Crankshaft Crankshaft Sprocket Locating Pin 13. Oil Pan Locating Pin 23. Piston Oil Nozzle 7. 11. 12.2L Engine : Engine mechanical Exploded view (Engine block assembly) 01.3. Piston Oil Nozzle Bolt Crankshaft Lower Bearing rev 01 . Crankshaft Upper Thrust Bearing #3 14. 20 mm 18. Transaxle Locating Pin 20. Engine Block Oil Gallery Threaded Plug. 8. Cylinder Head Locating Pin 24. 4.2 L) Engine Mechanical Participant’s Handout 1. Crankshaft Rear Oil Seal Housing Assembly Bolt 22. Engine Block Core Coolant Expansion Plug. 34. Engine Block Oil Gallery Threaded Plug.3mm 19. 6. Engine Block Coolant Drain Threaded Plug. Engine Block Oil Gallery Expansion Plug. 5. 9. Long Engine Block Oil Gallery Expansion Plug. Crankshaft Rear Oil Seal Housing Assembly 21. Short Crankshaft Bearing Cap Side Bolt.2-15 C100 (3.

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. 6.2 L) Engine Mechanical Participant’s Handout 3. 8. Piston Oil Control Ring Spacer .2-16 C100 (3. 4. Piston Lower Compression Ring 11. 7. 9. Piston Oil Control Rail Ring rev 01 12. 3. 2. 5.01.2L Engine : Engine mechanical Exploded view Piston & connecting rod) 1.

Oil Deflector Oil Pump Suction Pipe Oil Pan Oil Pan Drain Plug Engine Oil Level Sensor rev 01 . 4. 2.2L Engine : Engine mechanical Exploded view (Oil pan assembly) 01.3. 3.2 L) Engine Mechanical Participant’s Handout 1.2-17 C100 (3. 5.

7. 2.2-18 C100 (3.01. 6. 3. 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 . 5.2 L) Engine Mechanical Participant’s Handout 3.2L Engine : Engine mechanical Exploded view (Engine mount system) 1. 4.

2. ** Camshaft bolt tightening sequence : 1. and the center exhaust camshaft bearing cap bolts 3 and 4. The primary timing chain connects the crankshaft sprocket with the left–hand and right–hand intermediate drive shaft sprockets.2L Engine : Engine mechanical Camshaft and Bearings Three timing chains are fitted (primary. right–hand secondary and left– hand secondary). 3. Retighten the center camshaft bearing cap bolts 1. Tighten the camshaft bearing cap attaching bolt to 10 Nm (89 lb– in) as below sequence .2-19 C100 (3. 2 Loosen the center intake camshaft bearing cap bolts 1 and 2.3.2 L) Engine Mechanical Participant’s Handout [ Bank 1 camshaft bearing direction ] [ Bank 2 camshaft bearing direction ] rev 01 . 3 and 4 as below sequence 01.

2-20 C100 (3. 4. 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 ] . The cast aluminium pistons incorporate a polymer coated skirt to reduce friction.2 L) Engine Mechanical Participant’s Handout 3. 3. [ Piston and Rings ] 1. while the second compression ring is cast iron Napier. The oil control ring incorporates a steel expander and two Chrome plated steel rails. 5. 2.01. The top compression ring is plasma sprayed.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.

5.000 km / 6 months 7. 8.4L 69 Kpa at Idle (138 Kpa at 2000 rpm) 3.000 km / 12 months . 3. Oil Pump Bolt ITEMS Lub. Oil Pressure Relief Valve 11. Type Engine Oil Oil Replacement with filter Oil Capacity (w/filter) Oil Pump Pressure Forced feed API SJ grade SAE 0W -30 Synthetic oil .3. 9.2-21 C100 (3. 7. 6. 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. Normal condition : 30.2L Engine : Engine lubrication Oil pump 01.2 L) Engine Mechanical Participant’s Handout 1. 4. 2.2L DOHC rev 01 . Severe condition : 15. Oil Pressure Relief Valve Bore Plug Retainer Clip 12.

5.2 L) Engine Mechanical Participant’s Handout 3. Exhaust Camshaft Position (CMP) Actuator Timing Mark – Bank 1 16. Inlet Camshaft Position (CMP) Actuator Timing Mark – Bank 1 rev 01 . Secondary Timing chain Bright Plated Link – Bank1 14. 7. 3. Camshaft Intermediate Drive Chain – Bank 1 15.2L Engine : Engine timing system Timing chains 1. 4. 8. Crankshaft Sprocket Timing Mark 13.01.2-22 C100 (3. Camshaft Intermediate Drive Chain Sprocket Timing Mark – Bank 2 10. 6. Crankshaft Sprocket 12. 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. Camshaft Intermediate Drive Chain Sprocket – Bank 1 11. 2.

Crankshaft Sprocket Timing Mark rev 01 . 2. 9.3. 8. Crankshaft Sprocket 12. 6. 5.2L Engine : Engine timing system Primary and Bank 2 secondary timing chains 01. 3.2 L) Engine Mechanical Participant’s Handout 1. 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. 7. 4. Camshaft Intermediate Drive shaft Sprocket – Bank1 11.2-23 C100 (3.

and Tool No. Slide the crankshaft sprocket on the crankshaft until the crankshaft sprocket contacts the step in the crankshaft.3. 4. There should be no need to rotate the camshaft more than 45 degrees.2 L) Engine Mechanical Participant’s Handout 3. 2. Install the crankshaft sprocket (1) onto the crankshaft (2) by aligning the keyway to the key on the crankshaft.1 1.01. EN 46105–1 (1) onto the rear of the bank 2 cylinder head camshafts (2). CAUTION : In order to install Tool No. rotate the camshafts in an anti–clockwise direction.2-24 C100 (3. EN 46105 onto the camshafts. CAUTION : All camshafts must be locked in place before installation of any timing chains. rev 01 . Note : Ensure that the crankshaft sprocket is installed with the timing mark (1) visible. EN 46105–2 onto the rear of the bank 1 cylinder head camshafts.2L Engine : Engine timing system Bank 2 secondary timing chain installation procedure . Install Tool No. EN 46105 is fully seated onto the camshafts. Ensure that Tool No.

EN46111 (1).2 5. Using Tool No.2 L) Engine Mechanical Participant’s Handout A. Install the bank 2 secondary timing chain (1) aligning the chain in the following manner: 01. Ensure there are two bright links located on top of each of the camshaft actuator sprockets.3. 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. Wrap the secondary timing chain around both bank 2 actuator drive sprockets.2L Engine : Engine timing system Bank 2 secondary timing chain installation procedure .2-25 C100 (3. CAUTION : When aligning the bank 2 secondary timing chain to the camshaft actuator sprockets. 6. NOT the triangular mark. rev 01 . ensure the circular timing marks on the sprocket are used. C. Align the bright plated timing chain link (1) with the bank 2 exhaust camshaft position actuator sprocket alignment circle mark (2). B.

8. 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. . 9. 7.2 L) Engine Mechanical Participant’s Handout 3.2-26 C100 (3. CAUTION : The bank 2 camshaft intermediate driveshaft sprocket (1) is marked with the letters LB and ’FRONT’. Install the bank 2 camshaft intermediate driveshaft sprocket to the cylinder block. Ensure the bank 2 camshaft intermediate driveshaft sprocket is selected and orientated correctly. with the bright plated timing chain link (1) aligned with the access hole (2) in the outer sprocket. Tighten rev 01 Tighten the camshaft ntermediate driveshaft sprocket attaching bolt to 66 Nm (49 lb–ft). Align the bright plated timing chain link (1) with the intake camshaft position actuator sprocket alignment circle mark(2).2L Engine : Engine timing system Bank 2 secondary timing chain installation procedure .3 D.01. Place the bank 2 secondary timing chain around the left– hand camshaft intermediate driveshaft inner sprocket.

CAUTION : The bank 2 secondary timing chain shoe (2) is marked with the letters LH on the back face of the timing chain shoe. 01. Ensure the bank 2 secondary timing chain shoe is selected and orientated correctly. 11.4 10. CAUTION : The bank 2 secondary timing chain guide is marked with the letters LH. Install the bank 2 secondary timing chain guide (1).3. 13. 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. rev 01 . Tighten the secondary timing chain guide attaching bolt to 23 Nm (17 lb–ft). Ensure the correct shoe is used when installing to the bank 2 side. Ensure the bank 2 secondary timing chain guide is selected and orientated correctly. Verify the Bank 2 secondary timing chain timing mark alignments (1 to 6).2L Engine : Engine timing system Bank 2 secondary timing chain installation procedure .2 L) Engine Mechanical Participant’s Handout 12.

01. 16. Note : Ensure secondary timing chain shoe is clear of the Bank 2 secondary timing chain tensioner mounting pad. 15. Reset the bank 2 secondary timing chain tensioner. Install the tensioner shaft (1) into the bank 2 secondary timing chain tensioner body (2). Install the bank 2 secondary timing chain shoe (1).2 L) Engine Mechanical Participant’s Handout 3. Tighten Tighten the bank 2 secondary timing chain shoe bolt to 23 Nm (17 lb–ft). use a suitably sized flat blade screwdriver (1) to wind the plunger in a clockwise direction. Note : To reset the tensioner. into the tensioner shaft (2).5 14. rev 01 .2L Engine : Engine timing system Bank 2 secondary timing chain installation procedure .before tightening the attaching bolt. Ensure the bank 2 secondary timing chain tensioner is selected and orientated correctly.2-28 C100 (3. 17.

21. Place the bank 2 secondary timing chain tensioner (2) into position and loosely install the bolts (1) to the cylinder head.2 L) Engine Mechanical Participant’s Handout rev 01 . Compress the tensioner shaft into the body and lock the bank 2 secondary timing chain tensioner by inserting Tool No.3. the tensioner shaft (3) will remain in the locked position and no tension will be placed on the timing chain. EN 46112 (1) is not inserted into the tensioner body (2). this will cause damage to the engine. 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. 18. Slowly release pressure on the bank 2 secondary timing chain tensioner. The tensioner should remain compressed. Install the bank 2 secondary timing chain tensioner bolts through tensioner and gasket. EN 46112 into the access hole in the side of the tensioner body. 20. 01. 22.6 CAUTION : If Tool No.2L Engine : Engine timing system Bank 2 secondary timing chain installation procedure . 23. 19.2-29 C100 (3. Install a new bank 2 secondary timing chain tensioner gasket (1) to the tensioner (2).

Release the bank 2 secondary timing chain tensioner (1) by pulling out Tools No. EN 46112 (2) and unlocking the tensioner shaft. rev 01 . 27. Verify the bank 2 secondary timing chain timing mark alignments (1 to 6).2 L) Engine Mechanical Participant’s Handout 3. 25. Tighten the bank 2 secondary timing chain tensioner bolts (2).7 24.2-30 C100 (3.2L Engine : Engine timing system Bank 2 secondary timing chain installation procedure .01. Tighten Tighten the bank 2 secondary timing chain tensioner bolts to 23 Nm (17 lb–ft). Verify the proper placement of the bank 2 secondary timing chain tensioner gasket tab (1). 26.

2-31 C100 (3. Install the bank 1 camshaft intermediate driveshaft sprocket(2).3. 01. 2. Ensure that the crankshaft sprocket timing mark (1) is aligned with the indexing mark (2) on the oil pump housing. 4. 3. Install the bank 2 secondary timing chain components. Tighten Tighten the bank 1 camshaft intermediate driveshaft sprocket attaching bolt to 65 Nm (48 lb–ft).1 1.2 L) Engine Mechanical Participant’s Handout rev 01 . 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. CAUTION : The bank 1 camshaft intermediate driveshaft sprocket (2) is marked with the letters RB and ’FRONT’.

2 L) Engine Mechanical Participant’s Handout 3. rev 01 . Install the primary timing chain(1).01. B.2 5. The bank 1 camshaft intermediate driveshaft sprocket Timing mark (1) will align with a bright plated primary timing chain link (2). The bank 2 camshaft intermediate driveshaft sprocket timing mark (1) will align with a bright plated primary timing chain link (2).2-32 C100 (3. 6.2L Engine : Engine timing system Primary timing chain installation procedure . 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.

5 and 6).2L Engine : Engine timing system Primary timing chain installation procedure . the oil pump assembly (2) must be replaced. 01. Note : Do not remove the primary timing chain lower guide (1). 2 and 3) are properly aligned with the bright plated timing chain links (4. If the primary timing chain lower guide must be replaced.3. The crankshaft sprocket timing mark (1) will align with a bright plated timing chain link (2). Ensure the primary timing chain upper guide is selected and orientated correctly.3 C. The primary timing chain lower guide is not serviced separately. rev 01 .2 L) Engine Mechanical Participant’s Handout 7.2-33 C100 (3. Ensure all the timing marks (1. 8.

10. 13. Install the primary timing chain upper guide (1). Tighten Tighten the primary timing chain upper guide bolts to 23 Nm (17 lb–ft).01. Install the primary timing chain upper guide bolts (2). into the tensioner shaft (2). 11. Install the tensioner shoe assembly (1) into the primary timing chain tensioner body (2).4 9. Ensure that the primary timing chain tensioner is being installed.2 L) Engine Mechanical Participant’s Handout 3.2L Engine : Engine timing system Primary timing chain installation procedure . Reset the primary timing chain tensioner. rev 01 .2-34 C100 (3. Note : To reset the tensioner. use a suitably sized flat blade screwdriver (1) to wind the plunger in a clockwise direction. 12.

the plunger will remain in the locked position and no tension will be placed on the timing chain.5 CAUTION : If Tool No.2L Engine : Engine timing system Primary timing chain installation procedure . EN 46112 (1) is not inserted into the tensioner body.2 L) Engine Mechanical Participant’s Handout rev 01 .2-35 C100 (3. The primary timing chain tensioner should remain compressed. Place the primary timing chain tensioner (2) into position and loosely install the bolts (1) to the engine block. Compress the shoe assembly into the body (2) and lock the primary timing chain tensioner by inserting Tool No. Install the primary timing chain tensioner bolts (3) through tensioner and gasket. Slowly release pressure on the primary timing chain tensioner. EN 46112 into the access hole in the side of the body. 16. 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. 18. 14. Install a new primary timing chain tensioner gasket (1) to the tensioner (2). 15. 19. 17. 01.3.

23. Release the primary timing chain tensioner (1) by pulling out Tool No. 21. Tighten the primary timing chain tensioner bolts (2).2L Engine : Engine timing system Primary timing chain installation procedure . Tighten Tighten the primary timing chain tensioner bolts to 23 Nm (17 lb–ft). EN 46105 from the bank 2 and bank 1 cylinder head camshafts.2-36 C100 (3. EN 46112 (2) and unlocking the tensioner shaft. Remove Tool No.01. 22. Verify the proper placement of the primary timing chain tensioner gasket tab (1).6 20. rev 01 .2 L) Engine Mechanical Participant’s Handout 3. 24. Verify the primary and bank 2 secondary timing chain timing mark alignments (1 to 12).

There should be no need to rotate the camshaft more than 45 degrees. EN46111 (1). rotate the camshafts. EN 46105–2 (1) onto the rear of the bank 2 cylinder head camshafts (2). Install Tool No. Using Tool No.2 L) Engine Mechanical Participant’s Handout 3. 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.3. Install Tool No.1 1.2L Engine : Engine timing system Bank 1 secondary timing chain installation procedure . 2.2-37 C100 (3. 01. EN 46105–1 (1) onto the rear of the bank 1cylinder head camshafts (2). Install the primary timing chain components. 4. EN 46105 onto the camshafts. CAUTION : In order to install Tool No. rev 01 .

2L Engine : Engine timing system Bank 1 secondary timing chain installation procedure . B.2 L) Engine Mechanical Participant’s Handout 3. CAUTION : Ensure that when aligning the bank 1 secondary timing chain to the bank 1 camshaft actuator sprockets. Place the secondary timing chain around the bank 1 camshaft intermediate driveshaft outer sprocket.2-38 C100 (3.01. C. . Wrap the secondary timing chain around both bank 1 actuator drive sprockets. aligning the bright plated timing chain link (1) with the alignment access hole (2) in the inner sprocket. 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. Align the bright plated timing chain link (2) with the exhaust actuator sprocket rev 01 alignment triangle mark.2 5. that the triangular timing marks (1) on the sprocket are used. NOT the circular mark.

01.2 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 . 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.3 D. rev 01 . 8. CAUTION : The bank 1 secondary camshaft drive shoe is marked with the letters ’RH’.2-39 C100 (3.3. Align the bright plated timing chain link (1) with the intake actuator sprocket alignment triangle mark (2). Position the chain guide (2). Ensure the bank 1 secondary timing chain shoe is selected and orientated correctly. 7. Ensure the primary timing chain upper guide is selected and orientated correctly. 6. 9. Ensure that the bank 1 secondary timing chain guide is selected and orientated correctly.

2 L) Engine Mechanical Participant’s Handout 3.4 10. 12.2L Engine : Engine timing system Bank 1 secondary timing chain installation procedure .01. Ensure the bank 1 secondary timing chain tensioner is selected and orientated correctly.2-40 C100 (3. Tighten Tighten the bank 1 secondary timing chain shoe attaching bolt to 23 Nm (17 lb–ft). Note : To reset the tensioner. 13. use a suitably sized flat blade screwdriver (1) to wind the plunger in a clockwise direction. Install the tensioner shaft (1) into the bank 1 secondary timing chain tensioner body (2). 11. into the tensioner shaft (2). rev 01 . Reset the bank 1 secondary timing chain tensioner. Position the bank 1 secondary timing chain shoe(1).

Install the bank 1 secondary timing chain tensioner bolts (3) through the tensioner and gasket. 16. 17. 14. 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. Slowly release pressure on the bank 1 secondary timing chain tensioner.2L Engine : Engine timing system Bank 1 secondary timing chain installation procedure . the plunger will remain in the locked position and no tension will be placed on the timing chain. 15. EN 46112 into the access hole in the side of the tensioner body.2 L) Engine Mechanical Participant’s Handout rev 01 . 19. 18.3. Install a new bank 1 secondary timing chain tensioner gasket (1) to the tensioner (2). 01.5 CAUTION : If Tool No. EN 46112 (1) is not inserted into the tensioner body (2). 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. Compress the tensioner shaft into the body and lock the tensioner by inserting Tool No.2-41 C100 (3.

2-42 C100 (3. 25. Remove Tool No. 24. Verify the proper placement of the bank 1 secondary iming chain tensioner gasket tab (1). Release the bank 1 timing chain tensioner (1) by pulling out Tool No.6 20. 26. Reinstall the spark plugs. Tighten the bank 1 secondary timing chain tensioner bolts (2). EN 46105 and EN 46105–2 from the both cylinder head camshafts.2L Engine : Engine timing system Bank 1 secondary timing chain installation procedure . Tighten Tighten the bank 1 secondary timing chain tensioner bolts to 23 Nm (17 lb–ft). 21. 23. EN 46112 (2) and unlocking the tensioner plunger. Verify all primary and secondary timing chain timing mark alignments (1 to 18).2 L) Engine Mechanical Participant’s Handout 3.01. Reinstall the engine front cover assembly. 22. rev 01 .

5. air conditioning / steering belt .2 L) Engine Mechanical Participant’s Handout 1. 7. air conditioning belt .2-43 C100 (3.2L Engine : Accessory Belt After checking the alternator belt . replace the belt if necessary. 01. Power steering pump Water pump Belt tensioner Crankshaft Alternator Idler Compressor ** Relieve method : Rotate the drive belt tensioner clockwise. crack.3. 2. rev 01 . wear or tension. 4. for looseness. 3. 6. power steering belt .

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 Outlet Elbow Hose 14. 3. 7. 2.2-44 C100 (3. Air cleaner aFront Resonator Air Cleaner Resonator Seal 10.8L . 5. 6. Air Cleaner Lower Housing 12. PCV Hose PART NAME Air Cleaner Element Effective Area Element Replacement Element material Main Resonator Volume rev 01 3. Air Cleaner Rear Resonator 11.01. 9.2 L) Engine Mechanical Participant’s Handout 3.000㎞ / 24 months Non-woven Fabric 3. 4. Air Intake Duct 15.2 DOHC Remote type / 12L 4000 cm2 40.2L Engine : Air intake system 1. Mass Air Flow (MAF) Sensor Assembly 13.

2 L) Engine Mechanical Participant’s Handout 1. 8. 4. Underbody Catalytic Converter (UCC) Upper Heated Oxygen Sensor. UCC Heat Shield 17. UCC to Front Muffler Gasket Exhaust Manifold. 3. 2. Rear Muffler Heat Shields 10.2-45 C100 (3.5ℓ X 2EA rev 01 . 6. Bank 2 Pup Converter. Rear Muffler Assembly Lower Heated Oxygen Sensor. Bank 1 Lower Heated Oxygen Sensor.3. Exhaust Front Pipe to UCC Gasket PART NAME Pup Converter Underbody Converter Exhaust Front Muffler Exhaust Rear Muffler 3. Bank 1 12. Front Muffler to Rear Muffler Gasket 15. Bank 1 Upper Heated Oxygen Sensor. 7.14 ℓ 0.2L Engine : Exhaust system 01. Bank 2 Exhaust Manifold. Front Muffler Assembly Pup Converter. 9. Front Muffler Heat Shield Exhaust Front Pipe 18.2L DOHC 1. 11. Bank 2 13. 5. Bank1 14. Bank 2 16.90 ℓ 10ℓ 11.

Auxiliary Cooling Fan FAN SPEED Low APPLICATION ECT ( ℃ ) A/C switch ECT ( ℃ ) High ACP ( Kpa) ECT 6. Radiator Upper Bracket 2.2 L) Engine Mechanical Participant’s Handout 3.2-46 C100 (3. Auxiliary Cooling Fan Motor 8. Main Cooling Fan 5.01. Coolant Drain Cock ON 100 ON 110 1760 Malfunction 107 1347 OFF 97 rev 01 . Radiator 4.2L Engine : Engine cooling system Cooling fans 1. Main Cooling Fan Motor 7. Cooling Fan Shroud Assembly 9. Lower Radiator Bumper 3.

5.3. 6. 7.2-47 C100 (3. 3.2L Engine : Engine cooling system Water pump and Thermostat 01. 9. 2.2 L) Engine Mechanical Participant’s Handout 1. 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 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 . 4. 8.

2L Engine : Fuel supply system Description of Fuel supply system The fuel system is a returnless on-demand design. past the fuel pressure regulator. An electric turbine style fuel pump attaches to the main fuel pump module inside the fuel tank. Fuel filter rev 01 .01. Canister 3.2 L) Engine Mechanical Participant’s Handout 3. The fuel pressure regulator is a part of the main fuel pump module. The main fuel pump module contains a reverse flow check valve.2-48 C100 (3. and through the fuel feed pipe to the fuel injection system. 3 4 2 1 1. 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. 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. The fuel pump supplies high pressure fuel through the fuel filter. Fuel tank 4. Under body pipe line 2.

2-49 C100 (3.2L Engine : Fuel supply system Fuel tank The fuel tank stores the fuel and the tank is sealed up leakage of vapor. 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.2 L) Engine Mechanical Participant’s Handout 3. The fuel in the tank supplies to the engine through the supply line by the pump. Main Fuel Pump 01. Roll Over Valve 4 .3. Grade Vent Valve 1. 5. Sub Fuel Pump 2. vapor pressure in the tank is discharged to the Canister and it doesn't make the tank over. 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. The vapor that is produced in the tank is going through the line by Roll over valve and Grade vent valve.

2-50 C100 (3. The sub fuel pump module consists of the following major components: • The fuel sender assembly • The fuel transfer tube rev 01 . 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.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.01.2 L) Engine Mechanical Participant’s Handout 3.

3 40 106. the sensor resistance is high and the ECM senses a high signal voltage.0 MIN 37. the sensor resistance is low and the ECM senses a low signal voltage. 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.0 99.4 ~ 1.0 MAX 45. The engine control module (ECM) monitors the signal circuit of the fuel level sensor in order to determine the fuel level.0V) Curre nt (12. FUEL LEVEL FULL 3/4 1/2 1/4 EMPTY SIGNAL 3.4V 3.0V 2.8 253.000miles / 10 years 01.2L Engine : Fuel supply system Specification of Fuel pump Syste m Pre ssure Displa ce m e nt (12.9 130.max 900 kPa 8 AMP 100.2 L) Engine Mechanical Participant’s Handout Fuel Level Gage Resistance FUEL LEVEL Float He ight Status Full Stop 1/2 Empty Stop Fuel Height 228.2-51 C100 (3.0V / 410kPa ) Fue l filte r re pla ce m e nt 410 kpa 100ℓ /h min 600 kPa .2 250.3.2 ∼ 2.0V / 410kPa ) Re lie f pre ssure (12.4 240. When the fuel tank is full.5V 2.4 Resistance(Ω ) Fuel Level Gage Control The fuel level sensor changes resistance in response to the fuel level. The fuel level signal is sent to ECM.5V rev 01 REMARK 5V Ref .0V 1.5 112. When the fuel tank is empty.6 1. The ECM uses the signal circuit of the fuel level sensor in order to calculate the percentage of remaining fuel in the tank.

2L Engine : Fuel supply system Fuel Pressure Regulator The fuel pressure regulator is installed inside the fuel pump.2 L) Engine Mechanical Participant’s Handout 3. It is referenced by the fuel tank pressure instead of the vacuum pressure. which is roughly the same as the atmospheric pressure. Pressure 410 Kpa 600 ~ 900 Kpa Condition Engine running Relief pressure rev 01 .01.2-52 C100 (3.

6 rev 01 .2-53 C100 (3.2L Engine : Fuel supply system Injector and Rail 01.2 L) Engine Mechanical Participant’s Handout Injector specification Application Static flow rate Spray type Injection type Injection angle Resistance(Ω ) 3.2 L DOHC 193.3.6 (g/min) Single spray type(4 holes) Sequential 15 ˚ 11.4 ~12.

Once certain conditions are met. ※ Capacity : 900cc [ Canister ] [ Purge control solenoid ] rev 01 . the electronic control module (ECM) activates the controlled canister purge solenoid allowing the fuel vapors to be drawn into the engine cylinders and burned.2 L) Engine Mechanical Participant’s Handout 3.2-54 C100 (3.2L Engine : Evaporative emission control system Canister The evaporative emission canister is an emission control device containing activated charcoal granules. The evaporative emission canister is used to store fuel vapors from the fuel tank.01.