Copyright by Hyundai Motor Company. All rights reserved. Engine

2 PA - ENGINE Application Epsilon 1.1L engine is already used for Santro(Atoz) Kappa 1.2L engine, which is newly developed, will be applied in Common Rail U-1.1L engine is only for EU market with manual transaxle. Common Rail U-1.1L engine has 3 cylinders EngineT/MArea Model Volume [cc] Performance [PS/kgf.m] M/TA/TIndiaEuropeGeneral ε-1.11,08664/9.9M5EF2A4CF0 U-1.11,12075/15.5M5CF1-- -

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

4 PA - ENGINE Epsilon engine Engine ε-1.1 Displacement (cc) 1086 Max. Power (PS / RPM) 64 / 5,500 Max. Torque (kgf·m / RPM) 9.8 / 2,800 Feature SOHC In-line 4 cylinders (12 valves) One Timing Belt DLI BOSCH PCM Return-less fuel system ROSA type ISA

5 PA - ENGINE -When cold : 60 ~ 70 Nm -When hot : 70 ~ 75 Nm Traditional torque method is used. To keep proper installation, mentioned torque should be tightened with right procedure. Tightening Torque

6 PA - ENGINE Adjustment Specification Rocker Arm No.1s TDC

7 PA - ENGINE Be sure to remove camshaft from front side to rear side(fly wheel side). Target Wheel Camshaft

8 PA - ENGINE Upside Mark Top ring and second ring have unique up side mark. Be sure to keep this mark when you assemble piston ring to piston. To assemble piston pin to piston SST( ) is needed. Piston

9 PA - ENGINE Timing

10 PA - ENGINE Inlet Cooling System Thermostat opening temperature is 82. When it fully opens, it becomes 95.

11 PA - ENGINE At engine idle condition after warm up, normally oil pressure reaches 147kpa(1.5kg/ ) Oil pressure switch is screwed near engine oil filter. When the oil pressure goes down less than 0.5kg/, oil pressure warning lamp turns on. Oil Pump and Oil Pressure Switch

12 PA - ENGINE Return Less Fuel System (RLFS) 15.9 Resistance measurement Sound inspectionInspection by test lamp D/Pipe Damper Injector

13 PA - ENGINE Fuel Pump

14 PA - ENGINE ItemSpecification Ignition Coil TypeMold Dual Coil Resistance Primary0.82±10% Secondary15.5K±10% Ignition Coil and Spark Plug

15 PA - ENGINE Input & Output 10. WHEEL SPEED SENSOR For General Market For European Market

16 PA - ENGINE Bosch M7.9.8

17 PA - ENGINE Intake air temperature sensor is integrated with T_MAP sensor. It produces 0.3 ~ 4.8 voltage range as signal. At ignition on condition, it shows 3.8 ~ 4.2 V which is converted to atmospheric pressure. T_MAP Sensor

18 PA - ENGINE When IAT fault is detected, current data shows -40 an a default value. IAT Sensor Checking Condition TemperatureCurrent DataRemarks IG On ~ 4.4V NTC type ~ 3.7V ~ 2.9V ~ 1.4V

19 PA - ENGINE TP Sensor (Lever type) MAP TPS Its better check TPS waveform with MAP signals together. Both signals are similar and signal trend has to be compared together.

20 PA - ENGINE This sensor has 4 terminals. 2 are for ECT sensor. These two terminals are gold coated. Another 2 are for engine temperature indicator in cluster. ECT Sensor Checking Condition TemperatureCurrent DataResistance (K) IG On ±0.3V5.18 ~ ±0.3V2.27 ~ ±0.3V1.059 ~ ±0.3V0.298 ~ 0.322

21 PA - ENGINE Hall IC type CKP sensor is used. ECM No. 15 is used for sensor signal. Unlike other general target wheel which is composed with 60 teeth including 2 missing teeth, it has 30 teeth with 2 missing. Except tis tooth unit, all logical processing in ECM is the same CKP Sensor Reference Point Missing Tooth

22 PA - ENGINE CMP sensor is also used from Hall IC. It distinguishes the cylinder No. by comparing with CKP sensor. It is located near ignition coil. Camshaft target wheel shape is as shown on the picture. CMP Sensor [CMP with CKP Sensor Waveform]

23 PA - ENGINE Front or Up Stream Oxygen Sensor Rear or Down Stream Oxygen Sensor Zirconia type oxygen sensor is used. The Zirconia oxygen sensor generates a small voltage depending on the exhaust gas condition. The normal voltage range is 0.2 ~ 0.8 volts. 0.2 volts indicates a lean mixture and a voltage of 0.8v indicates a richer mixture. Oxygen Sensor

24 PA - ENGINE Engine knock control is used to constrain the knocking. Knock sensor detects knocking generated in engine and retard ignition timing. The knock sensor is installed at between No2. and No.3 cylinder. Like other piezo type sensors, this is made by piezo material. Tightening torque is 20±5Nm. Knock Sensor Maximum Retard Limit : 12˚ When knocking is detected : Initially retard 3˚ and increase step by step with 0.75˚

25 PA - ENGINE The main role of wheel speed sensor is detecting the rough load condition which allows misfire monitoring inhibition (EOBD:Euro3/Euro4). When the vehicle is running on rough load condition, the CKP angular speed is affected from this road condition. It can signal to ECM as a misfiring. In this case wheel speed sensor detects this kind of rough load condition and order ECM not to consider this situation as a misfiring. Wheel Speed Sensor M/TInput VariableECU PIN NO. With EOBD With ABSABS SignalK 64 Without ABSWheel Speed Sensor K 79, K 58 (K 64 open) Without EOBD With ABS Vehicle Speed Sensor K 64 Without ABSK 64 ATInput VariablePCM PIN NO. With EOBD With ABSABS SignalK 20 Without ABSWheel Speed SensorA 60, A 45 Without EOBD With ABS From TCM K 20 Without ABSK 20

26 PA - ENGINE T/MTypeVehicle speed fromECU PIN NO. MT With EOBD With ABSABS unitK64 Without ABSWheel Speed Sensor K79, K58 (K 64 open) Without EOBD With ABS Vehicle Speed SensorK64 Without ABS AT With EOBD With ABSABS unitK20 Without ABSWheel Speed SensorK60, K45 Without EOBD With ABS From TCMK20(from A49) Without ABS Vehicle Speed Sensor - Vehicle speed sensor is applied on MT only. - In the case of AT, the vehicle speed sensor is eliminated. Instead, ECM receives a corresponding vehicle speed from others. (refer to the table below)

27 PA - ENGINE Maintaining screw Coil assembly Magnet Drive unit Axis Housing Ball bearing Valve Stopper O-Ring Cushion ring ISA (Idle Speed Actuator) 1. The ISA controls the proper intake air mass in every engine operating conditions. 2. The ECU controls the ISA (double coil of open/close) with frequency of 250Hz. 3. The ISA duty is determined by basic map and compensation of ATS, WTS, altitude and A/CON compressed load etc.

28 PA - ENGINE PCSV For Evaporative gas monitoring. PCSV is installed between the canister and the intake manifold, it delivers or shuts the vapor gas to intake manifold, which is stored in the canister. The ECM controls the purge control solenoid valve.

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

30 PA - ENGINE U engine EngineU VGT Displacement (cc) 1120 Max. Power (PS / RPM) 75 / 4000 Max. Torque (kgf·m / RPM) 15.5 / 2000 Feature VGT Turbo Charger Timing Chain Electrical EGR & EGR cooler Lambda Sensor Throttle flap Serpentine belt Bed Plate In-line 3 cylinders

31 PA - ENGINE Electrical E.G.R Throttle flap CRDi system EURO-4: 1600bar VGT Timing chain Serpentine belt DOC (Diesel Oxidation Catalyst) 4 valve DOHC HLA λ sensor E.G.R cooler System Overview

32 PA - ENGINE Timing System DOHC 4 Valve VALVE operating type: - END PIVOT ROLLER SWING ARM CAM operating type : 2 Chains Hollow camshaft Balance shaft is operated by gear -> for reducing vibration Timing Chain Balance shaft

33 PA - ENGINE Balance Shaft Timing Mark Balance Shaft

34 PA - ENGINE Intake / Exhaust manifold Electrical EGR Valve - Valve type : linear solenoid type - Control voltage : 13.5V (Duty control) - Coil resistance : 7.3 ~ 8.3 (at 20 ) EGR COOLER - Coolant cooling type - Reduced intake air temperature and increased intake air Reduced NOx and PM WCC (Warm-up Catalytic Converter) Lambda sensor High SpeedLow Speed To cylinder From cylinder Exhaust Intake Vane VGT EGR cooler E / EGR Valve

35 PA - ENGINE Cylinder Block Cylinder Head Injector High pressure pump C/ Rail Fuel system – location / component Component - High Pressure Pump - Common Rail - Injector Max. Pressure : 1600 bar Duel pressure control (2 Governor control) : FPV + RPV FRV : Fuel Pressure regulator Valve, RPV : Rail Pressure regulator Valve

36 PA - ENGINE High Pressure Plunger FPV (Fuel Pressure regulator Valve) Fuel system – High Pressure Pump / Common Rail High Pressure Pump - Type : CP1H - Max. Pressure : 1600 bar Common Rail - Allowed pressure : 1,600 bar - Rail Pressure Sensor : Max. Measurement : 1,800 bar - Applied RPV - Throttle : Reduced fluctuation of fuel pressure to injector RPV (Rail Pressure regulator Valve) Rail Pressure Sensor Throttle

37 PA - ENGINE Injector - compensates fuel amount : Applied IQA (Injector Quantity Adjustment) code for compensating fuel amount of each injectors - Type : CRI2.2 - Max. Pressure : 1600 bar Fuel system – Injector Ampere for solenoid control Lift of armature Fuel pressure of injector inside Injection pattern Controlled by ECM H/pressure fuel

38 PA - ENGINE Current Data Idle condition 1500 rpm 3000 rpm Conditions -No Electrical Load -Neutral (Manual Transaxle) -No DTC

39 PA - ENGINE Current Data Idle condition 1500 rpm 3000 rpm Conditions -No Electrical Load -Neutral (Manual Transaxle) -No DTC

40 PA - ENGINE Current Data Idle condition 1500 rpm 3000 rpm Conditions -No Electrical Load -Neutral (Manual Transaxle) -No DTC

41 PA - ENGINE Current Data Idle condition 1500 rpm 3000 rpm Conditions -No Electrical Load -Neutral (Manual Transaxle) -No DTC

42 PA - ENGINE Current Data Idle condition 1500 rpm 3000 rpm Conditions -No Electrical Load -Neutral (Manual Transaxle) -No DTC

43 PA - ENGINE Current Data Idle condition 1500 rpm 3000 rpm Conditions -No Electrical Load -Neutral (Manual Transaxle) -No DTC

44 PA - ENGINE Current Data Idle condition 1500 rpm 3000 rpm Conditions -No Electrical Load -Neutral (Manual Transaxle) -No DTC

45 PA - ENGINE Injector specific data (IQA)

46 PA - ENGINE Engine Test Function Engine Test Function is consist of 3 tests, which are tested by Hi-scan. Those are test for mechanical condition of engine, mechanical condition of injectors and electrical compensated by ECM - Compression test - Idle speed comparison - Injection quantity comparison

47 PA - ENGINE Engine Test Function – compression test

48 PA - ENGINE Engine Test Function – Idle speed comparison

49 PA - ENGINE Engine Test Function – Injection quantity comparison