full bộ tài liệu động cơ kappa MPI engine

3.1 Những cải tiến phần cơ khí: – Intake / Exhaust Manifold※ MAP : Manifold Absolute Pressure ※ PCV : Positive Crankcase Ventilation ※ WCC : Warm-up Catalytic Converter Location for Oxyg

Kappa MPI Engine

-<1.2L / 1.25L> <1.4L>

Công suất cực đại (ps/rpm) 83PS / 6000rpm 87PS / 6000rpm 100PS / 6000rpm

Mô men soắn (kgf·m/rpm) 11.6kgf.m / 4000rpm 12.2kgf.m / 4000rpm 13.6kgf.m / 4000rpm

Bố trí trục cam DOHC, Dual-CVVT DOHC, Dual-CVVT DOHC, Dual-CVVT

Số lượng van 16 VALVE SWING ARM HLA 16 VALVE SWING ARM HLA 16 VALVE SWING ARM HLA

(Tuned Intake System)

TIS (Tuned Intake System)

VIS (Variable Intake System)

Dung tích nước mát (Liter) 1.9ℓ(Eng Only) 1.9ℓ(Eng Only) 1.9ℓ(Eng Only)

Dung tích dầu máy (liter) MAX : 3.3ℓ, MIN : 2.3ℓ MAX : 3.3ℓ, MIN : 2.3ℓ MAX : 3.3ℓ, MIN : 2.3ℓ

※ Các thông số của động cơ Kappa:

2 Bố trí – Kappa 1.4L (Bộ phận được thiết kế mới)

Piston Cooling Jet

Sử dụng tay con lăn điều khiển xu páp

Tăng hiệu quả thoát khí xả SUS

VIS Điều khiển thông minh độ dài đường ống nạp.

3.1 Những cải tiến phần cơ khí:

[Damper Pulley]

[Water Pump Ass’y]

3.1 Những cải tiến phần cơ khí: – Thép cacbon trung bình

[Khối lượng của Thanh truyền]

Bore diameter of Cylinder (mm)

[Khối lượng riêng của thép cacbon]

High Carbon Steel

Medium Carbon Steel

Improvement Ratio

3.1 Những cải tiến phần cơ khí: – Hệ thống biến thiên đường ống nạp

Đường dài

Đường ngắn

Van Đ/K

Long section

Short section

Short section

Long Short

3.1Những cải tiến phần cơ khí: – SUS Tăng hiệu quả lưu thông khí xả và

trung hòa khí xả.

Bố trí đơn giảnỐng SUS

< Catalyst >

- For Euro 6 : WCC + UCC

- For Euro 3, 4 : WCC

UCC (for Euro-6)

HC, CO NOx

CO 2 , N 2

H 2 O

3.1 Những cải tiến phần cơ khí: – Xích ma sát thấp

[Ma sát ][Hệ thống xích cam] [trước]

General product Roughness improvement

RPM

3.1 Những cải tiến phần cơ khí: – Vòng trên trục cam

Sự khác nhau

IN

3.1 Những cải tiến phần cơ khí: – Lốc máy

Lốc máy (1.20/1.25 same)

Các te Bơm dầu nắp trên lốc máy

Nửa dưới hộp trục khuỷu

Nắp bạc chính, căn dọc trục tại vị trí trung tâm.

Outer rotor

Inner rotor + Shaft

3.1 Những cải tiến phần cơ khí: – Sơ mi xy lanh / Áo nước nhựa/ Nắp bạc

chính

Sơ mi

Thép hợp kim, căn dọc trục trung tâm

Áo nước nhựa

Lốc máy

3.1 Mechanical Parts – Moving Part

1.20L : 4-B/W

1.25L & 1.40L : 8-B/W

Độ lệch tâm là:

11mmMax Fuel Efficiency Offset:

15mm (but NVH is not good)

Ma sát ↓

Độ lệch tâm

Center of Crank

3.1 Những cải tiến phần cơ khí: - Nắp máy

Water Pipe

〈 Nắp máy kiểu áp lực thấp〉 〈 Quy trình siết bu lông lắp máy〉

10

〈 Lực siết bu lông nắp máy〉

Head Bolt ,Washer (Separate Type)

3.1 Những cải tiến phần cơ khí: – Gioăng nắp máy

3.1 Những cải tiến phần cơ khí: – Xu páp và con đội thủy lực (HLA)

Roller Swing Arm

HLA

Valve

Camshaft

HLA Roller Swing Arm

Valve

OCV-IN/EX CVVT-IN/EX

※ HLA : Hydraulic Lash Adjust

※ CVVT : Continuous Variable Valve Timing

※ OCV : Oil Control Valve

3.1 Những cải tiến phần cơ khí: – Giảm tiếng ồn xích cam

In CVVT

Ex CVVT

Chain Tensioner

Chain Guide Chain

Tensioner Arm

Chain Guide (Crank)

Chain Guide (Cam)

Oil Pump

Crankshaft

3.1 Những cải tiến phần cơ khí: – Intake / Exhaust Manifold

※ MAP : Manifold Absolute Pressure

※ PCV : Positive Crankcase Ventilation

※ WCC : Warm-up Catalytic Converter

Location for Oxygen Sensor

WCC Stay

Heat protector

Clip for fixing Oxygen sensor wiring

〈Cổ xả〉

Cylinder Block Water Pump

3.1 Những cải tiến phần cơ khí: – Hệ thống làm mát

Radiator

Heater & Bypass

Cylinder Head T/BODY

At 88℃ ↑, Thermostat Open

At 88℃ ↓

〈Coolant Flow  Entrance Control〉

• Thermostat Open Temp.: 88℃

• Parallel Flow

TO HTR

FROM HTR

TO RAD.

TO T/BODY

FROM T/BODY

3.1 Những cải tiến phần cơ khí: – Hệ thống bôi trơn

〈Dầu bôi trơn trong đông cơ〉

Oil Pump Cover

Outer Rotor Inner

Rotor

Oil Inlet

Oil Outlet

〈Oil Pump〉

3.1 Những cải tiến phần cơ khí: – Phun dầu lên piston

Vòi phun dầu

3.1 Những cải tiến phần cơ khí: – Dầu động cơ

〈lắp ghép ống của thức thăm dầu

với lốc máy〉

Head / Head Cover: 300cc

Drain & Refill (with Oil Filter) :3,600cc

(Initial Oil Quantity from Plant :3,550cc)

(If not available, refer to below…)

* SAE viscosity grade : 5W-30, 10W-30…

* API classification : SM or above

* ILSAC classification : GF4 or above

Oil replacement period

- Europe/General (except India & Middle East) : 15,000km/year

- India & Middle East : 10,000km/year

300 cc

Oil Level Gauge

Bolt 1 EA(Assembled

at In-mani)

O-RING

< 1.2/1.25L >

3.1 Những cải tiến phần cơ khí: – PCV (Positive Crankcase Ventilation) System

〈FuelPump & Gauge Pin〉

Fuel Tank Capacity IB(45ℓ),GB(45ℓ)

Fuel Pump Type Electrical, in-tank type

Driven by Electric motor

3.2 EMS Input & 3.3 EMS Output

ECTS Knock sensor

O2Sensor D-CVVT

CKP

Canister

IG Coil

Injectors

Main relay Fuel Pump Relay Cooling fan Relay

Check Engine Lamp

Oil Control Valve (CVVT Control)

A/C Compressor Relay

Electronic Throttle Control

Oxygen Sensor Heater Circuit Ignition Coils

C terminal (For AMS) Purge Control Solenoid Valve

MAP / Intake Air temp

Battery sensor / FR terminal (for AMS)

Engine Coolant Temperature Sensor

Accelerator Position Sensor 1,2

Crankshaft Position Sensor

Ignition switch on / Crank signal / Battery voltage

Knock sensor

Vehicle Speed- / Wheel Speed- / Sensor

AC switch / APT

Brake switch

Oxygen Sensor Front / Rear

Throttle Position Sensor 1,2

Camshaft Position Sensor

3.2 EMS Input & 3.3 EMS Output

3.2 Input – MAP Sensor (Manifold Absolute Pressure Sensor)

3.2 Input – IATS (Intake Air Temperature Sensor)

Included inside MAP Sensor (Manifold

Absolute Pressure Sensor)

3.2 Input – ECTS (Engine Coolant Temperature Sensor)

3.2 Input – APS (Acceleration Pedal Position Sensor)

• Non-Contact Type (Hall IC Type)

• Both APS #1 and #2 exist for safety

• Refer to TPS contents handled with ETC in‘3.4 Output Chapter’

Condition

Output Voltage (V)

Idle 0.7 ~ 0.8 0.29 ~ 0.46 Fully

depressed 3.85 ~ 4.35 1.93 ~ 2.18

〈Specification〉

3.2 Input – CKPS (Crankshaft Position Sensor)

〈Specification〉

〈Image〉

Option Sensor Type Output Signal Remark

Non-ISG (MT, AT) Magnetic Inductive

(2 pin) 0V~5V Analog

Detect crankshaft position

ISG (MT) Hall IC (3 pin) 0V,5V Digital Detect crankshaft

position and direction

CKP

IN CMP

EX CMP

〈Specification〉

Standard Waveform for CKPS and CMPS (When Idle)

Cursor Average Value

3.2 Input – CMPS (CaMshaft Position Sensor)

3.2 Input – Knock Sensor

3.2 Input – Binary Type Oxygen Sensor

A/F Ratio (λ) Output Voltage (V)

3.3 Output – Ignition Coil

〈Ignition Coil Tower for 1.2〉 〈Ignition Coil for 1.2〉 〈Plug Cable for 1.2〉

Condenser

〈Distributer-less Type Ignition Coil〉

Power

Plug Cable Ignition Coil

Ignition Coil Tower

3.3 Output – Spark Plug (M12 Long Reach)

〈Specification〉

Ground Electrode

Central Electrode

M12 Long Reach

Larger Valve Size : Increased the quantity of intake air flow

More stable cooling : Improved Knocking characteristic

 Improved performance and fuel

economy

3.3 Output – ETC (Electronic Throttle Control) & TPS (Throttle Position Sensor)

• ETC is integrated with TPS and Control Motor

• Both TPS #1 and #2 exist for safety

• In Textbook, Table of Fail-Safe for ETC/APS/TPSexists

• Applied ALL engine (Kappa 1.2/1.25/1.4)

〈Location〉 〈Gear & Motor〉

〈Connector〉

〈TPS〉

〈Location〉

〈Specification〉

3.3 Output – CVVT (Continuous Variable Valve Timing)

Engine Valve (Max Ret ~ Angle

Max Adv)

Valve Opening/Closing (˚)

Valve Duration

Valve overlap

in idle

Valve Lift Max Retardation Max Advancement

1.2 K

1.25 K

1.4 K

Idle, Full Load Part Load

Advanced Chamber Retarded Chamber

3.3 Output – OCV (Oil Control Valve)

3.3 Output – OCV (Oil Control Valve)

1

3

2

6.9 - 7.9 Ω (20 ℃)

3.3 Output – PCSV (Purge Control Solenoid Valve)

※ However, the PCSV duty is decreased

at the time of full load (WOT), as the engine injection amount itself is

increased.

• Normal Close Type

• Duty Signal Operation

• Low Duty Close

• High Duty  Open

〈Specification〉

〈Operation〉

4 Control – AMS (Alternator Management System)

FR Battery Charge Voltage Setting

1

BatteryState

of Charge (SOC)Check

VS, RPM, APS, Engine Load

3

Generation Control Prohibition Condition Check

C A N

C A N

C

Constant Speed

Battery sensor

AGM BatteryHigh capacity Alternator Headlamp signal Wiper signal Blow fan signal

Non-Changed Item

Changed Item

1 Genera -tion

1.5~2 Generation

Discharging Discharging Discharging Discharging Discharging

Discharging High charging Low charging Low charging Low charging

Energy

flow

4 Control – ISG (Idle Stop & Go)

Off (Auto Stop) /

On (Auto Start)

AT: Brake pedal MT: Clutch pedal Vehicle Speed After running at 10kps

When entering under 5kph

Stop for standard type, diesel Idle stop is possible when D N Air conditioning conditions Satisfying FATC/MTC Within -2~35 degree outside temperature

(32 degrees in North America)

Battery Sensor Activation Conditions : Dark Current 100mA↓, Kept for 4 hours

-No error related to ISG H/W or EMS error related to the ISG

Pleasantness FATC/MTC request Evaporator temperature/time

Battery

conditions

Voltage Under 12.1V for more than 180 seconds

Different conditions by vehicle model Discharging quantity Over discharging current 2AH

-Only GB has ISG not IB.

I Feature :

 Common : Dual CVVT, Low Friction Chain, Piston Cooling Jet, Sus Ex-manifold,

Roller Swing Arm

 1.2/1.25L : 2nd Generation Alternator Management System (with a Battery Sensor)

 1.4L : VIS (Variable Intake System)

II Main Input & Output Signal(Sensor and Actuator)

 Input : MAPS, IATS, ECTS, APS, TPS, Brake Switch, CMP, CKP, Knock Sensor,

Lambda Sensor(B1S1), Linear Oxygen Sensor(B1S2)

 Output : Ignition Coil, Injector, Spark Plug, ETC, OCV(Dual CVVT), PCSV

III Other Control

 AMS :Battery Sensor, Alternator, EMS

 MT ISG Only (for - Kappa MPI)

STEERING SYSTEM

-1 Thông tin chung

2 Cụm chi tiết – Cảm biến mô men và góc đánh lái

Gear cover

Sensing gearw/ magnet

2 Cụm chi tiết – MDPS ECU

3P Motor

2P Power Connector

DC Link CapacitorPower

Module

MDPS ECU (GB)

3 Điều khiển – Input and Output

MDPS ECU

Diagnosis (DTC)

GB : BLAC Motor

EPS- Failure MIL

Engine RPM Vehicle Speed

IB : DC Motor

3 Control – Operation Principle

Torque & Steering Angle Sensor

Reduction gear

ECU

Motor operation(Motor assist torque)

Motor

PowerSensor Signals

Rack & Pinion Gear

Vehicle speed (CAN)RPM (CAN)

Steering wheel

Sensor power

Torsion-bar

3 Điều khiển – Main Control

3 Điều khiển – Main Control

assist current demanded currentBảo vệ quá nhiệt

3 Điều khiển – Main Control

4 Chẩn đoán – MDPS Current Data

4 Chẩn đoán – S/W MANAGEMENT

4 Chẩn đoán – Faulty Diagnosis (MDPS normal noise)

Worm Gear

Worm wheel

4 Chẩn đoán – Trouble Case

5 Kết luận

- Steering Wheel, Steering Column, Torque & Angle Sensor MDPS

Motor, MDPS ECU, U-Joint, Steering Gear Box

- ECU receives Power, RPM, Vehicle Speed, torque and steering angle

sensor  ECU calculates motor assist torque  ECU activates the motor

ESC (Electronic Stability Control)

and hill-start assist control (HAC)

1 Giới thiệu tổng quan:

2 Bố trí hệ thống

C-CAN

MDPS SAS (Steering Angle Sensor)

Master cylinder ESC

WSSx4 (Wheel Speed Sensor)

Yaw & 2G sensor

ACU (Airbag Control Unit)

3 System Components – Input and Output

Gear hold request

TCU

Torque reduction request

Battery power

Wheel speed sensor

Stop lamp switch

Clutch switch

Yaw rate / 2G sensor Steering angle sensor

ESC off switch

3 Thành phần trong hệ thống – Input and Output

Gear hold request

TCU

Torque reduction request

Battery power

Wheel speed sensor

Stop lamp switch

Clutch switch

Yaw rate / 2G sensor Steering angle sensor

Local-CAN

ESC off switch

3 Thành phần trong hệ thống – Sensors

1 Active Wheel Speed Sensor 2 Yaw rate & 2G Sensor

ACU

IMU (Inertial Measurement Unit) Yaw & 2G sensor

ESC Sensor cluster

< without ABS >

< with ABS >

< Wheel Slip Tendency >

4 Điều khiển – ABS (Anti-lock Brake System)

λ = - X 100 Vehicle speed - Wheel speed

Vehicle speed

Horizontal friction (μs)Brake force of tire (μB)

Brake intervention Traction Control System (BTCS)

Full Traction Control System (FTCS)

 Individual Brake Intervention

at the front wheels

 Individual Brake Intervention

 at the front wheels

 Engine Torque reduction

4 Điều khiển – TCS (Traction Control System)

BTCS

Low-μ

ETCS Low-μ

Traction force

Góc đánh lái Cảm biến gia tốc dọc

và soay thân xe

Điều kiện quay vòng và yêu cầu Sự khác biệt nhỏ

Xe hoạt động bình thường không có ESC

Sự khác biệt lớn

Điều khiển phanh bởi HECU

4 Điều khiển – ESC (Electronic Stability Control)

Prevent

under steer

Chủ động của người lái Yêu cầu của điều khiển

4 Điều khiển – Value-added Functions

4 Điều khiển – Value-added Functions

4 SLS – GB only

* SLS : Straight Line Stability

4 Điều khiển – Value-added Functions

* ESS : Emergency Stop Signal

* HAC : Hill start Assist Control

TCS/ESC OFF (stage1)

ESC OFF (stage2) with buzzer

Select ESC OFF switch

Warning lamp Active FunctionEBD

Warning Lamp

ABS Warning Lamp

ESC ON / warning lamp EBD ABS BTCS ETCS ESC Additional

Option treatment Inspection / Test

System identification

HECU air bleeding mode

ID Register Data treatment

Auto detected configuration reset SAS calibration

G sensor calibration

5 Chẩn đoán – GDS

- MEB4 (by MOBIS) applied

- HECU assembly (pressure sensor included), wheel speed sensor, yaw&2G sensor in ACU, steering angle sensor

3) Notable control logics

- ABS, TCS, ESC

- CBC, VSM1, HAC, HBA, SLS, ESS

6 Tổng kết:

- Body Electrical –

BODY CAN

2 Vị trí (LHD)

A

C B

LHD

3 Chức năng của BCM

ATM Shift Lock

Burglar Alarm Auto Relock, Lock Confirmation

Defroster Control by toggle switch, time

Door Lock Unlock

Central Door Lock Unlock by Switch/RKE/SMK/Driver Mechanical Key, Unlocking by Crash, Auto Door Lock by Shift-Lever/Vehicle Speed, Auto Door Unlock by Shift-Lever/Key Off, Key Reminder Unlock in Driver side/Assistant side

Exterior Lamp

Tail Lamp Control by Switch/Auto Light/Autocut, Head Lamp Low by Switch, Head Lamp Low by Auto Light Control, Head Lamp Escort Control, Head Lamp Remote Welcome Control, Head Lamp Low Output, Head Lamp High Control by Switch, Front Fog Lamp, Rear Fog Lamp Control, Auto Light Sensor Monitoring Control, Dedicated DRL Function, Static Bending Lamp, LH/RH

Flasher Hazard, Turn Signal, One Touch Turn Signal

Interior Lamp Autocut Room Lamp Control

Mirror Fold Unfold Folding Unfolding by Switch/SMK

Power Window Safety Power Window

RKE RF Communication Function, RF Receiver Function, RKE Key Teaching Function

Tailgate Release Release Control, Status Indicator, Lamp Control

Warning SBR Function, Driver/Assist/Rear Seatbelt Indicator Control, Key Reminder Warning, Sun Roof Open

Warning, PAS Mode Indicator Control, PAS Sensor Fault Detection, Parking Brake

Wiper Front Wiper Low/High/Mist/Intermittent/Auto Control, Front Washer Control, Rear Wiper Control

4 BCM - Input and Output Signal

4 BCM - Input and Output Signal (Multi Function Switch)

4 BCM - Input and Output Signal (Multi Function Switch)

10 Tổng quan về Đồng hồ táp lô:

10 Tổng quan về Đồng hồ táp lô (USM)

11 Tổng hợp

1) LHD : BCM is behind the center facia RIGHT side.

2) RHD : BCM is behind the center facia LEFT side.

- ATM solenoid, Burglar Alarm, Defroster, Door Lock Unlock, Exterior Lamp,

Flasher, Interior Lamp Autocut, Mirror Fold Unfold, Power Window, RKE,

Tailgate Release, Warning, Wiper