Copyright by Hyundai Motor Company. All rights reserved. Engine

2 FD - ENGINE Application EngineEUGeneralM / EastAustraliaNA Gasoline γ – 1.4 γ – 1.6 β – 2.0 Diesel U – 1.6 D – 2.0 Gamma 1.4L and 1.6L : Newly developed 4 cylinder gasoline engine Applied to HD Elantra. Gamma 1.4L and Common Rail D 2.0L are only for EU market

3 FD - ENGINE Gamma engine Engineγ CVVTγ CVVT Displacement (cc) Max. Power (PS / RPM) 109 / / 6200 Max. Torque (kgf·m / RPM) 14.0 / / 4200 Feature Timing Chain Individual Ignition Shim-less MLA (Solid tappet) CVVT standard Plastic Intake manifold (Reversed intake and exhaust manifold) BOSCH PCM Crankshaft offset : 10mm Serpentine belt Stainless steel exhaust manifold

4 FD - ENGINE Beta engine Engineβ CVVT Displacement (cc) 1975 Max. Power (PS / RPM) 143 / 6000 Max. Torque (kgf·m / RPM) 19.0 / 4500 Feature SULEV Emission Dual layer metal head gasket Timing belt auto tensioner CVVT Siemens PCM CAN Diagnosis Aluminum oil pan

5 FD - ENGINE U engine EngineU VGT Displacement (cc) 1582 Max. Power (PS / RPM) 115 / 4000 Max. Torque (kgf·m / RPM) 26.0 / 2000 Feature VGT Turbo Charger Euro 4 Emission Swirl Control Valve Timing Chain Electrical EGR & EGR cooler Lambda Sensor Throttle flap Serpentine belt Bed Plate

6 FD - ENGINE D engine EngineD – 2.0 VGT Displacement (cc) 1991 Max. Power (PS / RPM) 140 / 4000 Max. Torque (kgf·m / RPM) 31.0 / 2000 Feature VGT Turbo Charger Euro 4 Emission Swirl Control Valve Electrical EGR & EGR cooler Lambda Sensor Throttle flap Serpentine belt CPF

Copyright by Hyundai Motor Company. All rights reserved. Gamma Engine

8 FD - ENGINE Item CostWeight Performance NVH Endurance Effect Remark Al cylinder block Reverse In/Ex Mani CVVT Solid Tappet Timing Chain Serpentine belt Integrated ECU/TCU SUS Ex/Mani Ladder Frame Emission Offset crank MLA (Shimless type)CVVT EX manifoldTiming chain Serpentine belt

9 FD - ENGINE Timing Chain For Gamma For Theta CVVT ASSYEX Camshaft

10 FD - ENGINE Ignition and PCM CAN CAN Adaptor Individual ignition control PCM - Integrated PCM (Power train Control Module) ECM + TCM - Waterproof computer Assembly, connector - CAN (Controller Area Network) Diagnosis - CAN & KW2000 Communication - Pin : 154 pin ( Pin) - Operation voltage : 6.3 V ~ 16 V

11 FD - ENGINE MLA (Mechanical Lash Adjuster) Valve Clearance Intake : 0.2 ± 0.03mm (0.17 ~ 0.23 mm) Exhaust : 0.25 ± 0.03 mm (0.22 ~ 0.28 mm) Tappet 41 kinds tappet are supplied. Thickness : ~ mm Size and parts number of Tappets for gamma and mu engine are same

12 FD - ENGINE CVVT (Continuously Variable Valve Timing) CVVT OCVFilter CVVT - Type : vane type - Angle : 50˚(Retard ~ Advanced) - CVVT is a standard

13 FD - ENGINE Full RetardFull Advance Intake ValveExhaust Valve Duration : 236˚ Duration : 223˚ TDC BDC ATDC 3˚ BBDC 40˚ TDC BDC ATDC 10˚ ABDC 63˚ TDC BDC BTDC 40˚ ABDC 16˚ CVVT (Continuously Variable Valve Timing)

14 FD - ENGINE Exhaust and Intake Manifold Reversed intake manifold - Decreasing intake air temp. - Easy to repair injector - Increasing Impact absorb area Intake Manifold - Plastic Intake Manifold (improve flow resistance) - Intake resonator (reduce pulsation resistance, noise) Exhaust Manifold Type - With WCC - Stainless Steel manifold

15 FD - ENGINE Water Pump Alternator A/C compressor Idler Driving Belt – Serpentine type Driving belt - Serpentine type (One-Belt type) - With MDPS - Weight and size is reduced

16 FD - ENGINE Center of Cylinder bore Center of Crankshaft Offset Crankshaft Offset Crankshaft offset - For reducing fuel consumption - To increase inertia moment offset crank shaft is used

17 FD - ENGINE Cylinder Head - Aluminum block - Tightening Torque 2.0kgf-m + 90˚ + 100˚ Use 10mm double hexagon wrench - Cap marking Cylinder Head NOINEX 1I1E1 2I2E2 3I3E3 4I4E4 Gamma 10mm double hexagon Theta 12mm double hexagon Cylinder Head Bolt

18 FD - ENGINE Manual TransaxleInput VariableECU PIN NO. With OBD-II ABS / ESPABS / ESP moduleK 64 CBSFR WSS K 79, K 58 (K 64 open) Without OBD-II ABS / ESP VSS K 64 CBSK 64 Auto TransaxleInput VariablePCM PIN NO. With OBD-II ABS / ESPABS / ESP moduleK 20 CBSFR WSSA 60, A 45 Without OBD-II ABS / ESP PG-B in A/T K 20 CBSK 20 FR side WSS VSS (Vehicle Speed Sensor)

19 FD - ENGINE

20 FD - ENGINE

21 FD - ENGINE

Copyright by Hyundai Motor Company. All rights reserved. Beta Engine

23 FD - ENGINE Auto-tensioner for timing belt Tensioner - Mechanical tensioner Auto-tensioner - Increased endurance - Reduced noise (from timing belt) CVVT - CVVT is standard - Angle : 45˚(Retard ~ Advanced) Auto-Tensioner Idler Noise is generated

24 FD - ENGINE Changing Parts 1 Graphite coating - Reduced noise / friction - Low-tension piston ring - Improved fuel efficiency Resonator - Improved engine performance at middle speed Exhaust manifold - Added wall : reduced interference - Improved torque at low speed - Improved power at high speed Graphite coating Resonator #1/#4 PORT #2/#3 PORT Section View

25 FD - ENGINE Inside type Changing Parts 2 PCM / ECM - Engine room type (located on air cleaner side) - Water proof Air flow sensor - Changed direct type to indirect type (except N/A) (MAF sensor MAP sensor) Direct typeIndirect type

Copyright by Hyundai Motor Company. All rights reserved. Common Rail U-Engine

27 FD - ENGINE Electrical E.G.R Throttle flap CRDi system EURO-3: 1300bar EURO-4: 1600bar VGT Timing chain Serpentine belt SCV (Swirl Control Valve) DOC (Diesel Oxidation Catalyst) 4 valve DOHC HLA λ sensor E.G.R cooler

28 FD - ENGINE Timing System DOHC 4 Valve VALVE operating type: - END PIVOT ROLLER SWING ARM CAM operating type : 2 Chains Hollow camshaft

29 FD - ENGINE Intake / Exhaust manifold VGT SCV (Swirl Control Valve) Electrical EGR VALVE WCC (Warm-up Catalytic Converter) EGR COOLER High Speed Low Speed Swirl Control Valve

30 FD - ENGINE With A/CWithout A/C Appearance RemarkP/S pump is not applied because of MDPS Serpentine Belt

31 FD - ENGINE Changed items compared with XD U-1.5 (EURO-3) ItemChanged thingRemark Increased displacement Cylinder blockBore increased (Φ75 Φ77.2) Cylinder head gasketChanged shape PistonDiameter increased (Φ75 Φ77.2) EURO-4 (Performance, emission) CRDi Injection pressure increased (1350bar 1600bar) U1.5 EURO-4 Common parts EGR coolerApplied (Φ54) SCV (Swirl Control Valve)Applied Lambda sensorApplied

32 FD - ENGINE Current Data

33 FD - ENGINE Current Data

34 FD - ENGINE Injector correction & ID check

Copyright by Hyundai Motor Company. All rights reserved. Common Rail D-Engine

36 FD - ENGINE SCV SCV (Swirl Control Valve) Fresh Air Intake ManifoldSCV Valve closed Valve opened Middle/Low Speed, Low Load - Valve Closed (Increased Swirl) : Increased fuel/air mixture, EGR ratio Reduced emission gas High Speed, High Load - Valve Opened (Decreased Swirl) : Increased intake efficiency, Reduced pumping loss Improved performance

37 FD - ENGINE Electrical EGR & EGR cooler EGR Cooler Electrical EGR valve EGR Cooler - Coolant cooling type - Reduced intake air temperature and increased intake air Reduced NOx and PM - Diameter : 54mm Electrical EGR valve - Valve type : linear solenoid type - Deviation is reduced 50% EGR is controlled precisely - Max. flux : 88±8 kg/hr (at 85%) - Control voltage : 13.5V - Control Signal : PWM (140Hz)