Copyright by Hyundai Motor Company. All rights reserved. Engine

2 TQ - ENGINE Power train Application EngineTransmission Power/Torque (PS/kgf m) EU (LHD/RHD) GEN (LHD/RHD) AUST. (RHD) WGN (8P) VAN (2/5P) WGN (9/12P) VAN (2/5P) WGN (8P) VAN (2/5P) Diesel A-2.5 VGT M5SR1 170 / 40.0 (WGT : 136/35.0) (VGT/ WGT) (VGT/ WGT A5SR2-- D4BH TCI-2.5 M5TR1 100 / AW GasolineΘ-2.4 FR M5TR1 175 / AW (9P ONLY) - - VGT (Variable Geometry Turbo charger) onlyNote 1) Note 2) WGT: Europe only (for lower engine power)

3 TQ - ENGINE C/Rail A - engine EngineA – 2.5 VGTA – 2.5 WGT Displacement (cc) 2497 Max. Power (PS / RPM) 170 / / 3800 Max. Torque (kgf·m / RPM) 40.0 / / 2000 Feature Timing Chain 2 nd generation C/Rail (1600bar) Increased power 30 PS (vs A1) – VGT Electrical EGR Duty control Turbocharger - WGT BOSCH C/Rail Serpentine belt Air dam type intercooler EGR cooler Lambda sensor is Installed

4 TQ - ENGINE D4BH TCI – 2.5 EngineD4BH TCI – 2.5 Displacement (cc) 2476 Max. Power (PS / RPM) 100 / 3800 Max. Torque (kgf·m / RPM) 23.0 / 2000 Feature Air dam type intercooler Balance-shaft for improving NVH Covec – F EGR and Cooler Satisfied Euro 3 emission

5 TQ - ENGINE Theta 2.4 engine EngineTheta – 2.4 CVVT Displacement (cc) 2359 Max. Power (PS / RPM) 175 / 6000 Max. Torque (kgf·m / RPM) 23.2 / 4250 Feature Reduced engine weight 22Kg (vs A1) Increased power 39 PS (vs A1) Timing Chain CVVT FF type theta engine

Copyright by Hyundai Motor Company. All rights reserved. A- 2.5 Engine

7 TQ - ENGINE SystemItemA1-WGT EURO – 3TQ VGT EURO – 4Remarks Fuel system / EMS Injector CRIP1 / 6-HOLECRIP2.2 / 8-HOLE (IQA) Max. Rail pressure 1350bar 1600bar +PRV ECM 16 bit 32 bit H/P Pump CP3.2 CP1H λ – Sensor × Added λ – Sensor λ – Sensor is used for compensating amount of injection Comparison (TQ vs A1)

8 TQ - ENGINE SystemItemA1-WGT EURO – 3TQ VGT EURO – 4Remarks Intake / Exhaust system EGR cooler and Valve EGR valve location is changed Turbocharger Changed turbocharger (WGT VGT) improved torque at low rpm Reduced emission Improved performance Intercooler Air dam type improved efficiency Increased capacity ( ) EGR Valve EGR COOLER EGR cooler intercooler Compressor outlet Compressor inlet Comparison (TQ vs A1)

9 TQ - ENGINE SystemItemA1-WGT EURO – 3TQ VGT EURO – 4Remarks Intake / Exhaust system Catalytic Converter Added Warm up Catalytic Converter ( WCC ) MT only Euro 4 : WCC+UCC (M/T only) Euro 3 : UCC only Euro 2 : without catalytic converter Exhaust layout VGT EX FITTING(WCC) H/PROTECTOR UCC WCC UCC WCC VGT H/PROTECTOR Comparison (TQ vs A1)

10 TQ - ENGINE SystemItemA1-WGT EURO – 3TQ VGT EURO – 4Remarks Head / cooling Head Vacuum pump is moved to alternator Water inlet fitting Vacuum pump cap Changed shape of EGR Cooler nipple & hose Comparison (TQ vs A1)

11 TQ - ENGINE SystemItemA1-WGT EURO – 3TQ VGT EURO – 4Remarks Head / cooling Head cover Changed material (Aluminum Plastic) Oil separator is removed Moving Piston Changed combustion chamber for satisfying emission regulation Adopted piston bushing - improved stiffness Comparison (TQ vs A1)

12 TQ - ENGINE contents Model A1 [A-WGT]TQ [A-VGT(EURO-4)] High Pump Max. Fuel pressure1350 bar1600 bar Max. Supplied capacity677mm3/rev843mm3/rev typeCP3.2CP1H Injector typeClassified injectorIQA injector Max. No of Injection2~3 times3~4 times Max. pressure of injection1350 bar1600 bar Min. amount of injection1.5 mm3/st1.0 mm3/st Min. interval of injection1.8 ms0.8 ms Common rail Max. pressure1350 bar1600 bar Pressure controlInlet controlInlet / Outlet control ECM CPU16 bit32 bit No of PIN121 PIN154 PIN Comparison (TQ vs A1)

13 TQ - ENGINE - Maintenance free timing chain and chain guide adapted - Composed by 3 chains : A, B and C - Shorten engine length Timing Chain Tensioner Chain guide Timing Chain A Timing Chain C Timing Chain B Timing Chain

14 TQ - ENGINE - Drive crankshaft pulley, high pressure pump and RH balance shaft Timing Chain A

15 TQ - ENGINE - Drive Crankshaft pulley, oil pump and LH balance shaft pulley - Aligned all timing mark together in initial installation - Proper lubrication for timing chain and chain guide Tensioner 15 teeth 12 teeth 13 teeth Timing Chain B

16 TQ - ENGINE - Drive high pressure pump intake and exhaust cam sprocket 5teeth High Pressure Pump sprocket Auto Tensioner Timing Chain C

17 TQ - ENGINE - Replacing work for timing chain A and B is not possible in condition of engine installation while timing chain C is possible. - Alignment between each sprocket and timing belt should be in spec. especially in timing chain C. - There are 3 types of high pressure pump sprocket supplied related to high pressure pump. Every time when you are in replacing work, you have to check the clearance between high pressure pump end and pump sprocket end and choose the right size of sprocket for proper installation. Color Thickness (mm) Sprocket Blue A White B Red C HP Pump Cylinder Block Sprocket Caution for timing chain

18 TQ - ENGINE Data Analysis (Idling Condition)

19 TQ - ENGINE Data AnalysisActuation Test

20 TQ - ENGINE Burner Type Heating System Layout ECU Coolant Outlet Air feeding Combustion air fan Oil feeding Water pump Heat exchanger Coolant inlet Exhaust pipe Intake pipe Coolant outlet Coolant inlet Fuel feeding Burner

21 TQ - ENGINE Burner ECU Fuel inlet by dosing pump Evaporator Air-inlet Water-inlet Burning chamber Heat-exchanger Exhaust gas out Combustion air fan Warm water outlet Glow plug Internal temp. sensor

22 TQ - ENGINE Burner Type Heating System Location - Burner

23 TQ - ENGINE Burner Type Heating System Location – Dosing Pump (Fuel Motor)

24 TQ - ENGINE ECUECU Ambient temp. by ambient S/W Coolant Temp. by internal temp sensor Dosing pump Combustion air fan B+ Voltage Glow plug Heater Control Logic Operating Condition 1. Operating condition : below coolant temp. 78 o C & ambient temp. 2 o C 2. Working procedure Cleaning : combustion air fan & glow plug on (for 30sec) Pre-filling : dosing pump on (for 3sec) Combustion : glow plug, combustion air fan, dosing pump on (for 121sec) Full load : combustion air fan, dosing pump 100% on SpecificationFull modeHalf mode Heater capacity5.0kW2.5kW Power consumption0.63l/h0.32l/h Fuel consumption37W13W

25 TQ - ENGINE Off Condition 1. When engine off Dosing pump stop Cleaning operating : burn out remain fuel inside burner 100%, combustion air fan & water pump on Other parts are stopped 2. When coolant temp. over 78 o C Dosing pump stop Cleaning operating : burn out remain fuel inside burner 100%, combustion air fan & water pump on Water pump working but other parts are stopped What is cleaning ** Purpose of cleaning : Burning out remain fuel and foreign material after combustion then emit exhaust gas When engine off burner operating noise can be occurred but that is normal sound (cleaning sound) - Engine off during full load operation : cleaning time – 175 sec - Engine off during half load operation : cleaning time – 100sec

26 TQ - ENGINE Wiring Diagram

27 TQ - ENGINE Actuation Test DTC & Data Analysis

Copyright by Hyundai Motor Company. All rights reserved. D4BH TCI Engine

29 TQ - ENGINE LH Balance Shaft RH Balance Shaft Timing Belt

30 TQ - ENGINE Standard Value : 0.25mm Valve Clearance

31 TQ - ENGINE Injection Timing Adjustment

32 TQ - ENGINE System Overview (Covec – F)

33 TQ - ENGINE System components GE Actuator Timing Control Valve (TCV) with Timer Position Sensor (TPS) Control Sleeve Position (CSP) Sensor Pump Speed Sensor (Np) Injection pump GE Actuator Timing Control Valve (TCV) Additional Control EGR valve Glowplugs MIL Engine Control Module Fuel injection quantity Injection timing EGR control Glow control Diagnosis Injection system Pump speed Sensor (Np) Control Sleeve Position Sensor (CSP) Fuel Temp. Sensor Compensation Resistor Timing Position Sensor Vehicle Sensors Switches Battery voltage

34 TQ - ENGINE GE - Actuator, TCV and TPS Sensor yoke Shaft Movable plate Fixed plate Sensor coil Current (A) Rotor´s rotational angle (°) A B TCV TPS Magnet Return spring Rotor and Core Shaft Ball pin Control sleeve

35 TQ - ENGINE NP sensor, CSP

36 TQ - ENGINE Fuel Temperature Sensor, Fuel Cut Valve No. 7 Fuel temperature sensor signal No. 11 Ground Fuel Cut Valve

Copyright by Hyundai Motor Company. All rights reserved. Theta 2.4L Engine

38 TQ - ENGINE SYSTEMMain FeaturesFigure Aluminum Block Main Feature - light weight : Aluminum cylinder block - High Stiffness : Added rib and adopted cone-shaped type cohesion face with T/M Reduced vibration and noise - FR type theta engine is adopted firstly Cone-shaped type Added rib Changing Items

39 TQ - ENGINE SYSTEMMain FeaturesFigure Driving Belt Main Features - Intake manifold is changed (Plastic Aluminum) - Throttle body with ISA instead of ETC - MAP is used instead of MAF - Exhaust manifold is changed (Stainless steel Cast iron) - Location of Oil filter is changed - Alternator and steering pump are moved - Reduce tension of driving belt Water Pump Alternator A/C compressor Auto-tensioner Steering Pump Changing Items