Chapter 1.

Kappa Engine
1. Preface
2. Application
3. Specification
4. Engine Overview
5. Cylinder Block / Driving Belt
6. Moving Parts
7. Cylinder Head / Cooling circuit
8. Timing Chain / Valve Train
9. Timing Chain Marks
10. Intake / Exhaust Manifold
11. Location of EMS Components
12. EMS Components
13. GDS – Current Data at Idle

Copyright by Hyundai Motor Company. All rights reserved.

Chapter 1. Kappa Engine

2 Technical Training Team 1

 Chapter 1. Kappa Engine

1. Preface

To learn the characteristics of the newly developed

Kappa Engine.
To learn the new technology and systems implemented
Learning Goals in the Kappa Engine.
To learn the diagnostic procedures for the Kappa
Engine

The Kappa engine has two variants; 1.2 liter (for Indian market only) and 1.25 liter (for EU and
General market). This engine is already being applied for PA (i10). Several new design concepts
have been adopted in order to enhance the performance and lower emission. A new driving belt
system (referred to as ‘Stretchy type’) has been added so that the special service tool is required to
service the driving belt due to the eliminated tensioner.

In this training manual, new items and main features will be mentioned. For more detail information or
specifications, please refer to the relevant workshop manual and electrical troubleshooting manual.

Technical Training Team 1 3

Chapter 1. Kappa Engine

4 Technical Training Team 1

 Chapter 1. Kappa Engine

2. Application

Transmission Area
Engine
M/T A/T Europe General India

Kappa 1.2L
- - ○
(1,197cc)
M5EF2 -
Kappa 1.25L
○ ○ -
(1,248cc)
Gasoline
Gamma 1.4 ● ● -
M5CF1-1 A4CF1
Gamma 1.6 ● ● -

U 1.4 M5CF2-1 - ○ ○ -
Diesel
U-II 1.6 M6CF3-1 - ○ - -

●: A/T, M/T ○: M/T ONLY

PB has 6 types of engine. Those are 4 variants for gasoline (Kappa 1.2 and 1.25, Gamma 1.4 and 1.6) and
2 variants for Diesel CRDI (U-I 1.4 and U-II1.6) respectively. The Kappa engine is being used for PA (i10)
and it matches only M/T, gamma gasoline engine is being used for ELANTRA (HD) and i30 (FD). The U-II
engine is enhanced from U-I engine and it is applied in HMC model for the first time. Gamma engine has a
CVVT system but kappa engine does not. U- I 1.4 WGT and U-II 1.6 VGT engine have 2 variants; low
power and high power model.

Technical Training Team 1 5

Chapter 1. Kappa Engine

3. Specification

Kappa (PB) Epsilon (TB)

Items
I4 1.2L I4 1.25L I4 1.1L

Displacement (cc) 1,197 1,248 1,086

Bore × Stroke (mm) 71×75.6 71×78.8 67×77

Bore pitch (mm) 78.5 ← 72.5

Compression Ratio 10.5 ← 10.1

Max. Torque (kgf.m) 11.4 / 4,000rpm 11.9 / 4,000rpm 10.1

Torque (kgf.m) @ 2000rpm 10.2 10.25 8.7

Max. Power (PS) 79 / 5,200 rpm 77 / 6,000rpm 69

Max. Speed (kph) 167 170 154

◆ Engine variation is 1.2L and 1.25L

- 1.2L : PB for India market
- 1.25L : PB for Europe and General market
◆ Compression ratio is increased than epsilon engine
◆ Max. torque and power is improved than epsilon engine.
◆ Main characteristic is as following
- Timing chain / roller swing arm / HLA (Hydraulic Lash Adjuster) are applied.
- Aluminum cylinder block and intake and exhaust locations are changed
- Offset crankshaft is adopted
◆ Detail information will be explained in the following next page.

6 Technical Training Team 1

 Chapter 1. Kappa Engine

4. Engine Overview

M12 Long Reach

Roller Swing Arm, HLA Spark Plug

Timing Cover is combined with

support bracket
Stretchy Belt

Offset Crank

● Aluminum block
● Reversed intake and exhaust
● Timing chain

Development concept

Effect
Technology Performance/ Weight/siz Durabilit
Emission NVH
fuel consumption e y

Aluminum block ● ●

In/Ex location is reserved ● ● ● ●

Roller swing arm & HLA ● ● ●

Silent timing chain ● ●

Offset crank ●

12M long reach spark plug ● ●

Ladder frame ●

Support brocket combined

● ●
with timing cover

Stretch driving belt ●

◆ ECM is located rear of battery in engine room.

◆ Support bracket is combined with timing chain cover

Technical Training Team 1 7

Chapter 1. Kappa Engine

- Engine weight is reduced

- Engine size is reduced

8 Technical Training Team 1

 Chapter 1. Kappa Engine

5. Cylinder Block / Driving Belt

Cylinder Block

Oil Pump
Driving Belt SST

※ Parts No. : 09252-03100

HPDC Aluminum Block
Ladder
Ladder frame is applied
Frame Oil Filter
Stretch serpentine driving belt is used.
Oil pump is installed in block Open deck.
Oil Pan

◆ Open deck type aluminum cylinder block is applied ( high pressure die casting)
◆ Oil pump is operated by timing chain. It is not need to match timing.
◆ Stretchy type driving belt is applied
- Tensioner is not applied.
- In order to installing or removing driving belt, SST (Special Service Tool) is needed.
SST parts No: 09252-03100
- When replacing driving belt (not used again), cut the driving belt and install new one (temporary
installing tool is included with driving belt.) temporary tool can be used once or twice (not permanent –
SST will be supplied).
When overhauling engine (re-used), removing and installing by SST.

Technical Training Team 1 9

Chapter 1. Kappa Engine

Temporary installing tool

10 Technical Training Team 1

 Chapter 1. Kappa Engine

6. Moving Parts

OFFSE
T Oil Drain
Hole

▶ Reduced side force of piston

 Lowered fuel consumption and NVH
※ Offset : Bore center and Crank bore center
▶ Reduced weight – 4 balance weight
▶ Applied oil drain hole between oil ring groove and pin hole.
 Reduced oil consumption.
▶ Graphite coating (reduced friction)

1.20L 4-B/W 1.25L 8-B/W

< Crankshaft >

◆ 11mm offset crank

◆ PVD (Physical Vapor Deposition) coating is applied on piston oil ring.
- Reduced oil consumption.
- Improved anti-wear and decreased friction.
- As applying low tension piston, friction loss is decreased. (reduced fuel consumption)

PVD coating on the

surface

Technical Training Team 1 11

Chapter 1. Kappa Engine

7. Cylinder Head / Cooling circuit

Cylinder Head

▶ In-line 4 cylinder, 16 valves

▶ Engine coolant: U-Turn Flow in cylinder head
▶ M12 Long Reach Spark Plug is applied
▶ Head bolt tightening torque: 1.5kgf.m + 90° + 120°
▶ Wax type thermo-state: inlet control
▶ ECT sensor is installed on cylinder head

◆ M12 Long Reach Spark Plug

- Recently, some engine used long reach spark plug and mostly two variants of size exist in HMC.
One is M14 and the other one is M12.

※ M12/M14: It means the size of spark plug screw.

- Tightening torque : 1.5 ~ 2.5 kgf.m

- Improved cooling efficiency by expanding water jacket.
◆ Cooling circuit
- Inlet control (wax type thermostat)
- U-turn flow in cylinder head
◆ Head Bolt
- Tightening torque: 1.5kgf.m + 90˚ + 120˚
- Plastic deformation
◆ In-line 4 cylinder / 16 valves

※ Epsilon engine: In-line 4 cylinder / 12 valves

12 Technical Training Team 1

 Chapter 1. Kappa Engine

8. Timing Chain / Valve Train

Roller Swing Arm

Plastic Cover

HLA

Beehive
Valve Spring Auto-tensioner

Valve Train Timing Chain System

▶ Support bracket is combined with timing chain cover

▶ Roller swing arm & HLA (Improved fuel consumption)
▶ Beehive Valve spring (Improved fuel consumption)
Timing chain ▶ Plastic P.C.V.-Valve (Reduced weight)
▶ Silent timing chain (Improved NVH)
cover ▶ Oil pump is operated by timing chain (1 timing chain)

◆ Timing chain.
- 1 timing chain is used for 2 camshafts, crankshaft and oil pump.
- Silent-chain type

◆ End pivot swing arm type.

- Easy to apply new system ( VVL- Variable Valve Lift, CDA-Cylinder Deactivation)
- Reduced weight of moving parts
- Reduced valve training friction.
- Beehive Valve Spring is applied.

※ Beehive Valve Springs are revolutionizing performance street/strip applications. These valve springs
deliver increased valve train stability and a much lighter valve train. This is achieved with less spring
pressure for better valve control and reduced weight of both the spring and the retainer

◆ HLA (Hydraulic Lash Adjuster) is used.

- Not necessary to adjust the valve clearance.

Technical Training Team 1 13

Chapter 1. Kappa Engine

9. Timing Chain Marks

Auto-tensioner

Oil Pump Sprocket

Timing Chain System

◆ Timing Marks
- Match different color chain tooth and dot on the intake and exhaust camshaft sprocket.
- Match rest different color chain tooth and dot on crankshaft sprocket.
- Oil pump do not needed to match timing mark.
- Install auto-tensioner and then remove pin

14 Technical Training Team 1

 Chapter 1. Kappa Engine

10. Intake / Exhaust Manifold

Intake Manifold Exhaust Manifold

▶ Plastic intake manifold: Reduced weight

▶ Cast iron exhaust manifold
▶ Intake and exhaust manifold is reversed.
▶ Rosa type ISA is applied.
▶ WCC is used.

◆ Intake and exhaust manifold location is changed.

- Intake manifold is installed front side of vehicle.
- Exhaust manifold is installed cabin side.
◆ Intake manifold module
- Plastic intake manifold : reduced weight
◆ Exhaust manifold module
- Iron cast exhaust manifold is used.
- WCC (Warm-up Catalytic Converter) is applied
◆ Structure of catalytic converter.

Catalyst Thin walled carrier

Supporter : Mat. Seal

Heat Cover

Technical Training Team 1 15

Chapter 1. Kappa Engine

11. Location of EMS Components

Injector
Delivery Pipe CMP

Knock sensor Conn. Ignition Coil

TPS PCSV

MAP

Oxygen sensor

Oil Pressure S/W

ECT

CKP (at TM housing)

NO ITEM Kappa engine

Type 2X2 COIL

1 Ignition Coil Assembly
Terminal 3 Pin

Type M12 LONG REACH

2 Spark Plug Tightening Torque 1.5 ~ 2.5 kgf.m

Tip material Ni alloy

Type MECHANICAL TYPE

4 Throttle Body Assembly ISCA ROSA

Lever Material PLASTIC

Type Rectangular (SUS)

5 Delivery Pipe
Pipe section size 25.4 X 18.5 mm

Length 61.2 mm

6 Injector Flux 106g / 60s

Stream Angle 20 degree

7 PCSV MAX. Flow 3.5 ㎥/h

Type MAGNETIC
8 CKP Sensor
Terminal 2 pin

Type LSF 4.2

10 O2 SENSOR
Terminal 4 pin

16 Technical Training Team 1

 Chapter 1. Kappa Engine

Terminal 2 pin
11 KNOCK SENSOR
Type Non-Resonance / KS-4

Type HALL IC
12 CMP SENSOR
Terminal 3 pin

Type COMBINED IATS

13 MAP SENSOR
Terminal 4 pin

Technical Training Team 1 17

Chapter 1. Kappa Engine

12. EMS Components

Long reach spark plug

Rectangular delivery pipe (SUS) PCM (ECM+TCM)

154pin

▶ PCM (Power-train Control Module)

- ECM + TCM
▶ M12 Long Reach Spark Plug
▶ Mechanical type throttle valve
▶ 2X2 Ignition Coil
▶ Rectangular delivery pipe (SUS)
- No damper is required.
Throttle body 2X2 Ignition coil PCSV

◆ PCM (Powertrain Control Module).

- PCM (154pin) = ECM (94pin) + TCM (60pin).
- Operating voltage : 6.3V ~ 16V
- CAN & KW2000 communication
- SMARTRA immobilizer control.
◆ Rectangular delivery pipe (SUS) is used.
- Rectangular type can be reduced pulsation. So kappa delivery pipe do not installed damper.
◆ 2×2 ignition coil is used.
- Power transistor is installed in PCM.
- 1st cylinder and 4th cylinder / 2nd cylinder and 3rd cylinder

18 Technical Training Team 1

 Chapter 1. Kappa Engine

13. GDS – Current Data at Idle

IG ON Idle 1500rpm 3000rpm Red zone

IG ON Idle 1500rpm 3000rpm Red zone

Technical Training Team 1 19

Chapter 1. Kappa Engine

IG ON Idle 1500rpm 3000rpm Red zone

20 Technical Training Team 1