Alpha II engine introduction

Alpha II Engine Introduction Alpha engine is already used in LC 1.6 liter without CVVT.. In case of 1.4 liter dowel pin type target wheel is still used... Using engine room side PCM loca

Published by Hyundai Motor company , september 2005

Engine

Alpha II Engine

Alpha II Engine Introduction

Alpha engine is already used in LC 1.6 liter without CVVT

Main differences form 1.6 liter are

- Using CVVT system

- Individual Ignition System

- Surge tank Volume

- Intake runner length and size

- Throttle bode size (48 to 52mm)

- Cylinder Block Strength

- Can communication for DTC

- PCM (ECM with TCM) with 2 chips inside

- PCM Location

Engine Line Up

MC has 3 types of engine 2 for gasoline 1 for Diesel CRDI As already mentioned, MC’s gasoline is not for the first used in HMC

It is alredy adopted in LC 1.6 with non CVVT model

In case of Alpha 1.6 and 1.4 DOHC, it is designed by HMC and now producing both HMC and KMC The assembly line of this engine is in Ulsan plant

This engine has been quite widely used in HMC side Available model of this engine is Matrix, Gets, Accent, XD Elantra and so

on from 1993 That’s why it has a lot of reliability in quality Now

we are developing 3th generation of this engine Project name is Gamma You can see this Gamma engine from 2006

In case of MC 2nd generation of Alpha engine is used Basic mode of Alpha is 1.5 but it has three more 1.3, 1.4 and 1.6 liter Except 1.3 & 1.4 liter both 1.5 and 1.6 liter have CVVT system But only 1.6 liter with CVVT engine is used for MC export 1.5 liter with CVVT is only for domestic

U 1.5 liter CRDI engine is quite new one Main target area of this

is for European and domestic Amazingly it can produce 110 ps target horse power with 1.5 liter New technology with this is VGT turbo charger with CRDI CP3 system It has 3 line-up by engine displacement 1.1, 1.5 and 1.6 liter Later we will introduce euro 4 emission engine with this

Alpha 2 1.6 liter with CVVT

U 1.5 liter CRDI with VGT

be shared together between 1.4 and 1.6The reason why those can not be inter changeable is mainly from adopting CVVT system and enlarged cylinder bore size in 1.6 liter

Only Intake and exhaust valve mechanism related items can be shared

Graphite coated piston is used so as to increase lubrication and decrease slapping noise since there was some noise and oil consumption problems before with alpha engine without any graphite coated piston

Camshaft target wheel in 1.6 liter has 4 target wheel Each duration from low to high, high to low has 180 degree

increasing more control accuracy with CVVT control In case of 1.4 liter dowel pin type target wheel is still used

Changed Items-2

One big change from 1.6 liter Alpha is PCM location PCM is located just after air cleaner housing Also water proof PCM is used because of the location position Using engine room side PCM location can have advantages such as reducing wire harness length so as to decrease production cost and wire harness electrical problem and maintenance easy,

In case of Alpah 1.6, Bosch M7.9.1 version of software is used but MC uses Bosch M7.9.8 version with CVVT system Main features of M7.9.8 are 2 chips CPU, 400MHz internal clock, waterproof, 154 pin connector, wheel speed sensor interface integrated, 768K flash memory and so on

To make communication to PCM with hi-scan pro, you must use can interface module since CAN communication protocol

is used instead of KWP2000 for DTC only in Gasoline engine Using can protocol communication speed is increased from 10kbps to 38.4kbps There are two terminals for CAN

communication in 16 OBD 2 connector So when you try communication, you must use this

CVVT System is quite similar to Beta 2.0’s Exhaust cam shaft

is driven by crankshaft Between intake and exhaust, chain is used with CVVT actuation

Individual ignition system is applied to 1.6 liter only so as to increase efficiency and accuracy in control TR is in ECM side

•Direction :

Describe PCM location with

advantages and CAN protocol

for DTC.

Full Retard Full Advance

Intake Valve Exhaust Valve

When it comes to MAF sensor, sensor supplier is changed from Bosch to Siemens In case of previous Bosch HFM 5 type revere flow detection MAF sensor, even though it has more accuracy but sensor tip can

be easily damaged by foreign materials resulting in fuel system problems Sensor reliability is increased using Siemens MAF sensor but accuracy can be lower than Bosch’s When you install MAF sensor you must

be careful to installation direction

Other sensors or actuators are no differences except individual ignition system which is newly adopted

•Direction :

Explain CKP sensor and MAF sensor here Others don’t have any change.

MAF for 1.6 liter

MAP for 1.4 liter

Fuel Pump Module Disassembling

Procedure :

F/Pump Relay

PCM

Fuel Cut Switch Fuel Pump

Drive Belt Installation & Adjustment

There are 3 belts in drive belt A is for power steering B is for A/Con

compressor and C is for alternator Belt B and C can be confused when

you reinstall so make your own mark to distinguish Belt C is a little

longer than belt B

Above pictures show each mechanical adjuster which are similar to beta

2.0 liter engine

Timing Belt Installation

Procedure : In case of timing chain side, each one has unique mark on

that Every 4 times of crankshaft rotation can align timing chain to timing

mark on CVVT module because of the different gear ratio between

crankshaft and camshaft timing chain sprocket

Timing Belt Inspection

Belt Tension

TIMING BELT INCREASED IN THICKENESS

24312-22612 24312-22613

To reduce timing belt noise problem in Alpha series engine, thickness of

this is changed as shown in the picture Even MC is already installed

with new one, when you have the same noise problem in timing belt,

check the thickness for your reference

One belt tension method in Alpha series engine is using the bolt position shown in the picture If you give 4.5kg-m of force to timing belt to tensioner side, timing belt will reach

to the near half of bolt center if it is in good condition

.

Compression test result can be different by tools and conditions

Rationality check for 4 cylinder is useful

Test is done after removing No.1 spark plug Amp meter setting is 10mV/A

so 1.5 V means 150A current consumption by start motor for that cylinder.

□ Main Bearing

Main bearing oil clearance is 0.018 ~ 0.036mm Bearing color is divided with 5 Actual measuring shows 0.025mm in plastic gauge scale.

□ Cylinder Bore

Cylinder bore size is stamped

on the bottom face of cylinder block to no.4 cylinder side It has 3 size mark a, b and C by its size In case of 1.6 liter b type size becomes 76.51 ~

76.52mm

Sudden Deceleration +6 to -45 then -35

(Full Vacuum)

Using PV350 which is one of hi-scan pro optional items, you can measure

vacuum pressure

Current Measuring

Dark Current (Ig Off) 0

Starter Motor (Cranking) 150 ~ 170

Charging Current (Alternator)

In 5 minutes after starting 28~32

key Pad Function

The Micro 570 button on the key pad provides the following functions :

Use the arrow buttons

to scroll to main menu.

Press the Enter button to make selection

Press Menu button to view the last test result and set the time

The tester will ask if the battery is connected “IN VEHICLE”

or “ OUT OF VEHICLE” Make your selection by pressing the arrow buttons: then press “ENTER” button.

Battery Test

Battery Test Result

Good battery No action is required.

Good recharge Battery is in a good state.

Recharge the battery and use.

Charge & Retest

Battery is not charged properly Charge and test the battery again (Failure to charge the battery fully may read incorrect measurement value)

Replace battery

Replace battery and recheck the charging system.(Improper connection between battery and vehicle cables may cause “REPLACE BATTERY”, retest the battery after removing cable and connecting the tester to the battery terminal directly prior to replacing the battery)

Bad cell-replace

Charge and retest the battery And than, test results may cause

“REPLACE BATTERY”, replace battery and recheck the charging system.

Cranking voltage is lower than normal level.

Check the battery and retest

Charge battery The state of battery charge is too low to test.

Check the battery and retest.

If the engine does crank, check fuel system.

As soon as you finish battery, move on to charging system following the

direction shown on the screen

battery Tester Utilization

Items Result(on the Screen)

Cooling Fan Control Logic

APT sensor is used instead of triple switch In case of 1.4 liter engine, it has only one cooling fan unlike 1.6 liter which has 2 cooling fans.

Alpha II Engine Management System

In case of Alpha 2 engine’s ECM, it is mounted in engine room compartment as

mentioned before To measure barometric pressure, small ventilation hole which is

shown on top of the PCM is used For perfect waterproof, never disassemble or make

any damage to this CCV which is for evap monitoring checking for NAS is located near

canister

M7.9.8 ECU

M7.9.1 ECU

ECM Comparison

There are several differences between M7.9.1 used

in alpha engine and M7.9.8 for MC

Except something which are already described before, there are some more in connectors

In case of M7.9.1 which has 121 pins, only 81 pins

is used for engine control Left 40 pins are for transmission control purpose But in M7.9.8 with

151 pins, there isn’t any assignment for ECM or TCM purpose Like M7.9.1, M7.9.8 is also divided with two but pin designation is totally different

Can high signal moves from 2.5 to 3.5 voltage after ignition on but Can low signal shows from 2.5 to 1.5 volt

Input and Output

With OBD-II

Vehicle sensor signal recognition is a little different When ABS or OBD system are applied

to the vehicle, wheel speed sensor is used for vehicle speed instead of VSS

ECM Pin Assignment

(V)

Idling (V)

Inductive and Hall Effect

Inductive type sensor which is generally used

in CKP sensor generates AC voltage and do not need an external power supply As each sensing tooth moves by the sensor, an AC voltage of signal is induced Each tooth produces one pulse signal A sensing tooth rotates faster there more pulses are

generated One critical point with this sensor

is the distance between the sensor and the sensing tooth

□ Hall Effect

CKP & CMP Sensor

Function : ECM calculates engine rpm by using CKP sensor which is

used by inductive type to controls the injection timing, ignition timing ,

misfiring, and variable valve timing with CVVT CMP is a hall IC type

sensor and signals to ECM for determining the TDC point with CKP

CMP 0.09 0~12

□ Signal Output Voltage

Synchronizing 1 Synchronizing 2

VSS Sensor

Function : VSS is one of the essential components which ECM utilizes to

calculate vehicle speed when it is moving especially with A/T It is also

used for shift pattern decision and shift timing controlling Unlike

VSS Waveform

Vehicle speed value which is

shown through hi-scan pro

current data is from WSS

Signal from VSS is the same

as conventional one with hall

IC effect The signal which is shown in this slide is not from VSS It is from WSS used in OBD 2 regulation

Just for your reference, compare with conventional one.

VSS Waveform

VSS Waveform

VSS signal for engine ECM is from WSS which is mounted on front right side When you

make D shifting on circled condition, analog time signal goes to engine ECM and it is

converted there into digital one

P0171 ~P0172 for Fuel Trim failure

P0420 Catalyst System Efficiency failure

P2096, P2097, P2232 Post Catalyst failure (Rear Oxygen Sensor)

Frt O2 Sensor PCM Pin No. Description

1 C01-2 (31) Sensor Gnd

3 C01-2 (34) Heater control

Oxygen Sensor Waveform

Since oxygen sensor related

DTC’s are so various

Understanding its function

and DTC are important

Explain here why rear

oxygen sensor is used What

is different comparing with

front oxygen sensor.

Rear oxygen sensor is the rear side of catalytic converter to check the proper operation of catalyst Oxygen density after the catalytic converter has to

be within specific range around 0.5V when there is no acceleration or deceleration If the oxygen density changes in accordance with front oxygen sensor, it means the poor performance of catalytic converter.

Oxygen Sensor Current Data

□ Heater Resistance

A/F Closed Loop on on on Open or Close loop

Frt O2 Sensor 0.12~0.79 A/F feedback

S/T Fuel Trim -5.7 1.7 -4.5 Fuel correction

Long Term – Idle 1.0 0.4 0.2 Fuel Adaptation

Long Term – P/Load -0.7 -0.7 -0.7 Fuel Adaptation

Injection (ms) 2.8 2.9 2.4 Injection Duration

AFS (kg/h) 8.1 17.1 31.8 AFS volumn

□Current Data Analyzing

Frt :8.6Ω

Rr :9.4Ω

Ignition Coil Inspection

Coil / Connector No.1 No.2 No.3 No.4 Voltage

Goo

Goo d

Goo d

□ Power Balance Test

Spark Plug Inspection

Type BKR5ES-11( ) RC10YC4( )

①

Injector

Function : Electronically controlled fuel injector is a solenoid valve

which supplies exactly calculated amount of fuel to engine for optimum

combustion under various engine load and speed To meet air fuel ratio

required in system ECM regulates fuel injection quantity as controlling

injector solenoid operating duration referring air flow to cylinders and

output signals from oxygen sensor For this precise control, quick

response of solenoid is required.

Injector Test - 1

Injector / Connector No.1 No.2 No.3 No.4 Voltage

CVVT System

CAMSHAFT-SPROCKET CAMSHAFT-EXHAUST

CAMSHAFT-INTAKE

CVVT

BELT-TIMING CHAIN SPROCKET

CHAIN-TIMING

Retard

Advance

Rotating Direction of Engine

Driving condition Intake / Timing Why ?

At high load & high speed Retard Improved performance

At high load & low speed Advance Improved Torque

At middle condition Advance Increase fuel consumption

PIN STOPPER

ROTOR VANE HOUSING

C/Angle C/Angle

EX

Ignition IN

OCV

Function : Different from the existing fixed cam phase angle type, CVVT

is the device which varies cam phase angle continuously to be optimum

It operates by engine oil pressure OCV controls the amount and

direction of oil delivered to CVVT module by oil valve which is

connected to a solenoid If there is 3 more degree differences between

target angle and real then it goes to limphome function and sets DTC of

OCV Control

OCV is controlled by ECM with PWM but the duty is so various depending on engine load

Maximum advance of intake cam timing is set around 1800

~ 2500rpm range It is controlled mainly by engine load.

CVVT Practice-1

□ Air Test □ Oil Filter Clogging Check

□ Auto Tensioner Check

□ Timing Chain Align Check

whether it is recovered or no.

1 Resistance : 7.6Ω

2 Voltage output

- No.1 Pin to GND : 3.2V

- No.2 Pin to GND : 13.2V

CVVT Practice - 4

Advanced in Valve Timing Approximately 30 degree

Since Each CKP tooth becomes 6 degree in CKP angle.