C100 Service Training Manual: Engine Mechanical (2.

4L DOHC)
Participants Handout

01.1-3 C100 (2.4L DOHC) Engine Mechanical

Table Of Contents
Engine Number .......5 Engine Specification ....... 6 Engine Side View ... 8 Engine Lubrication . 9 Engine Exploded View ... 10 Timing Belt . 15 Timing Belt Adjustment 16 Accessory Belt ... 18 Piston Rings Installation ... 19 Engine Cylinder Head ... 20 Engine Intake System 21 Engine Exhaust System .. 23 Engine Cooling System . 24 Fuel Supply system .. 26 Fuel Tank ... 27 Fuel Pump 28 Injector & Rail ... 31 Evaporative Emission Canister ... 32

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01.1-4 C100 (2.4L DOHC) Engine Mechanical

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Engine number
1. FAM II

01.1-5 C100 (2.4L DOHC)

24 S E D

012345
Engine Serial Number 000001~999999 Design specifics D : Daewoo, H : High performance L : Low end torque, R : Raised performance Fuel mixture system E : Fuel injection Z : TBI V : Carburetor L : LPG Compression Ratio G :<8.5, L : 8.5~9.0, N : 9.0~9.5 S : 9.5~10.0, X : 10.5~11.5, Y : 11.5 Displacement 18 : 1.8 L, 24 : 2.4 L Exhaust Emission limits C : Domestic, Others X : Europe, Euro stage II T : North America,OBD II, Euro stage III Z : EURO IV

Engine Mechanical

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01.1-6 C100 (2.4L DOHC) Engine Mechanical

Engine Specifications
APPLICATION Engine type Bore x Stroke (mm) Displacement (cc) Compression Ratio Engine General Max Power (hp/RPM) Max Torque (Nm/RPM) Idle RPM Initial Spark Timing (BTDC) Firing Order Coil Ignition Plug Type Ignition sequence Maker Type Clearance mm 2.4 DOHC 4 Cylinder(In-Line) 87.5 x 100 2,405 9.6 : 1 TBD TBD 690 8 1-3-4-2 Direct Ignition System 1-3-4-2 Bosch FLR8LDCU 0.9 ~ 1.1

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Specifications
APPLICATION Type Coolant Capacity (L) Water Pump Type Radiator Width Core Height Thickness Cooling Surge Tank Pressure Valve open Vaccum Valve open Type Thermostat
Start to open (C) Completely open (C) Completely close (C)

01.1-7

2.4 DOHC Forced feed 9 Centrifugal Down Flow 673 mm 511 mm 27 mm 140 Kpa 10 Kpa Pellet 87 2 102 MIN 82 Electric Main:5EA / Aux: 7EA 340mm + 320 mm

C100 (2.4L DOHC) Engine Mechanical

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Type Fan Blades Fan Diameter

Type

Type Fuel Pump Displacement Fuel Delivery Fuel pressure Filter Type Fuel Tank Capacity Planetary Gear Reduction Type Starter Power 1.4KW 120A Alternator Power Type MF Battery Capacity 12V- 60AH Cold Cranking Ampere 650 CCA

MPI Electric Motor TBD TBD Cartridge 65 L

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01.1-8 C100 (2.4L DOHC) Engine Mechanical

Engine side view

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Engine Lubrication

01.1-9 C100 (2.4L DOHC) Engine Mechanical

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ITEMS Lub. Type Engine Oil Oil Replacement with filter Oil Capacity (w/filter) Oil Pump Pressure Oil Pump Relief Pressure Forced feed 5W30 SL

2.4L DOHC

Normal condition : 10,000 km / 6 mths Severe condition : 5,000 km / 3 mths 4.5L 30 Kpa at Idle 4.0 0.5 kg/cm2

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01.1-10 C100 (2.4L DOHC) Engine Mechanical

Engine Exploded View

Upper End

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Engine Exploded View

Upper End
1 . Nut 2 . Engine Beautification Cover 3 . Bolt 4 . Oil Filler Cap 5 . Bolt 6 . Cylinder Head Cover 7 . Cylinder Head Cover Gasket 8 . Tappet Adjuster 9 . Valve Key . 10 . Valve Spring Cap 11 . Valve Spring 12 . Valve Stem Seal 13. Valve Spring Seat 14. Valve Guide 15. Intake Valve Seat Ring 16. Exhaust Valve Seat Ring 17. Intake Valve 18. Exhaust Valve 19. Bolt 20. Front Camshaft Cap 21. Head Bolt 22. Bolt 23. Intermediate Camshaft Cap 24. Exhaust Gas Recirculation Adapter 25. Exhaust Gas Recirculation Adapter Gasket 26. Bolt 27. Exhaust Gas Recirculation Valve 28. Exhaust Gas Recirculation Valve Gasket 29. Cylinder Head 30. Exhaust Manifold Gasket 31. Exhaust Manifold 32. Nut 33. Exhaust Manifold Heat Shield 34. Cylinder Head Gasket 35. Bolt 36. Thermostat Housing 37. Thermostat Housing Gasket 38. Stud 39. Sleeve 40. Plug 41. Bolt 42. Camshaft Position Sensor 43. Oil Gallery Plug 44. Exhaust Camshaft 45. Seal Ring 46. Camshaft Gear 47. Washer 48. Camshaft Gear Bolt 49. Intake Camshaft 50. Intake Manifold Gasket 51. Intake Manifold 52. Throttle Body Gasket 53. Throttle Body 54. Nut 55. Evaporative Emission Canister Purge Solenoid

01.1-11 C100 (2.4L DOHC) Engine Mechanical

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01.1-12 C100 (2.4L DOHC) Engine Mechanical

Engine Exploded View

Lower End

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Engine Exploded View

Lower End
1. Connecting Rod Cap 2. Bearing Set 3. Connecting Rod Bolt 4. Piston Ring Set 5. Piston Pin 6. Piston 7. Engine Block 8. Sleeve 9. Water Jacket Cap 10. Bolt (Manual Transaxle) 11. Flywheel (Manual Transaxle) 12. Flexible Plate (Automatic Transaxle) 13. Bolt (Automatic Transaxle) 14. Seal Ring 15. Crankshaft 16. Reluctor Ring 17. Screw 18. Crankshaft Balancer Unit Assembly 19. Bolt 20. Oil Pan Scraper 21. Bolt 22. Oil Suction Pipe 23. Oil Pan 24. Oil Pan Drain Plug 25. Sleeve 26. Gasket 27. Bolt 28. Oil Pump Cover 29. Ring Gear 30. Gear 31. Oil Pressure Switch 32. Washer 33. Washer 34. Oil Duct Outlet Plug 35. Connecting Piece 36. Seal Ring 37. Oil Filter 38. Bypass Valve 39. Pressure Relief Valve Plunger 40. Pressure Relief Valve Spring 41. Seal Ring 42. Pressure Relief Valve Plug 43. Rear Timing Belt Cover 44. Bolt 45. Special Bolt 46. Idler Pulley 47. Stud 48. Nut 49. Bolt 50. Tensioner 51. Bolt 52. Thrust Inner Washer 53. Woodruff Key 54. Crankshaft Gear 55. Thrust Outer Washer 56. Bolt 57. Camshaft Drive Belt 58. Gasket 59. Front Timing Belt Cover 60. Bolt 61. Bushing Plug 62. Bushing 63. Oil Gallery Plug 64. Bolt 65. Water Pump 66. Seal Ring 67. Crankshaft Position Sensor 68. Bolt 69. Knock Sensor 70. Bolt 71. Oil Filter Adapter

01.1-13 C100 (2.4L DOHC) Engine Mechanical

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01.1-14 C100 (2.4L DOHC) Engine Mechanical

Engine Exploded View

Engine Mount system

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1. Transaxle Front Mount Assembly 2. Engine Mount Adapter Support Bracket 3. Engine Mount Assembly 4. Cradle Assembly 5. Transaxle Mount Assembly 6. Transaxle Rear Mount Bracket 7. Transaxle Rear Mount

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Timing Belt

01.1-15 C100 (2.4L DOHC) Engine Mechanical

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Specification

Model C100

ID

Length TBD

Maintenance I : 30,000 km R : 120,000 km

Remarks

* I : Inspection R : Replacement

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01.1-16 C100 (2.4L DOHC) Engine Mechanical

Timing Belt Adjustment (1)

a. Remove the front cover b. Rotate the crankshaft clockwise one full turn and align the timing mark of the crankshaft sprocket to the rear cover notch.

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c. Align the timing mark of the intake cam sprocket and the exhaust cam sprocket .

d. Loosen the automatic tensioner fixing bolt (1). e. Rotate the tensioner hex-key tab (2) counterclockwise to give the highest tension. 2 1

f. Rotate the hex-key tab clockwise until the adjust arm pointer is aligned with the notch of the tensioner bracket

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Timing Belt Adjustment (2)

g. Tighten the tensioner bolt

01.1-17 C100 (2.4L DOHC) Engine Mechanical

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h. Rotate the crankshaft two turns clockwise

i. Check the tensioner pointer for the right position

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01.1-18 C100 (2.4L DOHC) Engine Mechanical

Accessory Belt
After checking the alternator belt , air conditioning / steering belt , air conditioning belt , power steering belt , for looseness, crack, wear or tension, replace the belt if necessary.

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** Relieve method : Rotate the drive belt tensioner clockwise.

PART NAME V-belt inspection V-belt replacement

2.4 DOHC 30,000km / 18 months 70,000km / 42 months

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Piston Rings Installation

01.1-19 C100 (2.4L DOHC) Engine Mechanical

Oil Ring Rail Gap

Piston Mark

Piston Oil Ring And Top Compression Ring

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Second Compression Ring Oil Ring Rail Gap

[ Piston Ring Installation ]

Top Compression Ring Second Compression Ring Oil Ring Set

[ Piston Ring Cut-away ]

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01.1-20 C100 (2.4L DOHC) Engine Mechanical

Engine Cylinder Head

New adopted engine has dual outlet exhaust and low restriction induction/ exhaust.

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** Cylinder head bolt tightening sequence : Tighten the cylinder head bolts to 25 Nm (18 lbft) and turn the bolts another 3 turns of 90 using the angular torque gauge KM470B.

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Engine Intake System

Air Intake system

01.1-21 C100 (2.4L DOHC) Engine Mechanical

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PART NAME Air Cleaner Element Effective Area Element Replacement Element material Main Resonator Volume

2.4 DOHC Remote type / 12L 4000 cm2 40,000km / 24 months Non-woven Fabric 3.8L

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01.1-22 C100 (2.4L DOHC) Engine Mechanical

Engine Intake System(2)

Intake manifold EGR passage revised to clear throttle body.

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Runner ends blended to larger cylinder head inlet ports

PCV port added which satisfies OBD2 diagnostics if required. (Throttle body has no PCV port.)

Intake manifold and Throttle body

Revised throttle body mounting pattern. Throttle body size increased.

Support brace mounting position changed to facilitate power take-off unit clearance.

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Engine Exhaust System

01.1-23 C100 (2.4L DOHC) Engine Mechanical

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1. Pup Converter 2. Exhaust Front Pipe Mounting Bracket 3. Exhaust Front Pipe Assembly 4. Underbody Catalytic Converter (UCC)

5. UCC Heat Shield 6. Front Muffler Assembly 7. Front Muffler Heat Shield 8. Rear Muffler Heat Shields 9. Rear Muffler Assembly

PART NAME Pup Converter Underbody Converter Exhaust Front Muffler Exhaust Rear Muffler

2.4 DOHC 1.14 L 0.90 L 10 L 2 x 11.5 L

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01.1-24 C100 (2.4L DOHC) Engine Mechanical

Engine Cooling System - 1

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1. Radiator Upper Bracket 2. Lower Radiator Bumper 3. Radiator 4. Main Cooling Fan 5. Auxiliary Cooling Fan

6. Main Cooling Fan Motor 7. Auxiliary Cooling Fan Motor 8. Cooling Fan Shroud Assembly 9. Coolant Drain Cock

FAN SPEED Low

APPLICATION ECT ( Degr. C) A/C switch ECT ( Degr. C)

ON 96 ON 100 18.98 Malfunction

OFF 93

97 14.76

High

ACP ( kg/) ECT

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Engine Cooling System - 1

Water pump and Thermostat

01.1-25 C100 (2.4L DOHC) Engine Mechanical

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1. Seal Ring 2. Thermostat 3. Thermostat Housing 4. Thermostat Housing Mounting Bolt 5. Water Pump Mounting Bolt 6. Water Pump 7. Seal Ring

PART NAME Radiator Type Radiator Size Coolant Capacity Thermostat start to open Cooling Fans

2.4 DOHC Cross Flow 673 511 27 9L 87 2 degr. C Diameter 340 + Diameter 320

REMARK

W HxT

Complete open : 102 Degr. C Main + Aux

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01.1-26 C100 (2.4L DOHC) Engine Mechanical

Fuel Supply system

The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the main fuel pump module. An electric turbine style fuel pump attaches to the main fuel pump module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter, past the fuel pressure regulator, and through the fuel feed pipe to the fuel injection system. The fuel pressure regulator has a T-joint that diverts the needed fuel to the fuel rail with the unused fuel dropping back into the reservoir of the main fuel tank module. The main fuel pump module contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times.

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3 4 2

1. Under body pipe line 2. Canister 3. Fuel tank 4. Fuel filter

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Fuel Tank
The fuel tank stores the fuel and the tank is sealed up leakage of vapor. The fuel tank is made from high density polyethylene. The main fuel tank is located in the rear of "Front muffler"and under the body of the vehicle. The fuel tank are each sides held in place by 2 metal straps that is able to hold from two nuts attach to the frame. The fuel in the tank supplies to the engine through the supply line by the pump. The vapor that is produced in the tank is going through the line by Roll over valve and Grade vent valve, vapor pressure in the tank is discharged to the Canister and it doesn't make the tank over.
5. Grade Vent Valve 1. Sub Fuel Pump

01.1-27 C100 (2.4L DOHC) Engine Mechanical

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2. Main Fuel Pump 3. Roll Over Valve

4 . Ring-Adaptor

Fuel tank Capacity 65 L

Remarks

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01.1-28 C100 (2.4L DOHC) Engine Mechanical

Fuel pump - 1
Main Fuel Pump Module The main fuel pump module is located inside of the right side of the fuel tank. The main fuel pump module consists of the following major components: The fuel level sender assembly The fuel pump and reservoir assembly The fuel filter The fuel pressure regulator The suction and return jet assembly Sub Fuel Pump Module The sub fuel pump module is located inside of the left side of the fuel tank. The sub fuel pump module consists of the following major components: The fuel sender assembly The fuel transfer tube
Sub Flange

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Main Level Sender Assy

Main Pump

Support Pole

Level Sender Assy Suction Jet Assy

Check Valve

Sub MRA

Reservoir Body Return Jet

Main MRA

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Fuel pump 2
1. Specifications

01.1-29 C100 (2.4L DOHC)

System Pressure Displacement (12.0V / 410kPa) Relief pressure (12.0V) Current (12.0V / 410kPa) Fuel filter replacement
2. Fuel Level Gage Resistance

410 kpa 100L/h min 600 kPa - max 900 kPa 8 AMP 60,000 km / 36 months

Engine Mechanical

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FUEL LEVEL Status Full Stop 1/2 Empty Stop Fuel Height 228.9 130.6 1.3

Float Height 40 106.2 250.0

Resistance() MAX 45.5 112.8 253.0 MIN 37.0 99.4 240.4

3. Fuel Level Gage Control The fuel level sensor changes resistance in response to the fuel level. The engine control module (ECM) monitors the signal circuit of the fuel level sensor in order to determine the fuel level. When the fuel tank is full, the sensor resistance is low and the ECM senses a low signal voltage. When the fuel tank is empty, the sensor resistance is high and the ECM senses a high signal voltage. The ECM uses the signal circuit of the fue llevel sensor in order to calculate the percentage of remaining fuel in the tank. The fuel level signal is sent to ECM, the ECM sends the message of the fuel level to the BCM and the BCM modulates fuel level gauge in the cluster by single wire CAN.
FUEL LEVEL FULL 3/4 1/2 1/4 EMPTY SIGNAL 3.4V 3.0V 2.2 ~ 2.5V 2.0V 1.4 ~ 1.5V
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REMARK 5V Ref

01.1-30 C100 (2.4L DOHC) Engine Mechanical

Fuel pump 3
4. Fuel Pressure Regulator The fuel pressure regulator is installed inside the fuel pump. It is referenced by the fuel tank pressure instead of the vacuum pressure, which is roughly the same as the atmospheric pressure.
Pressure 410 Kpa 600 ~ 900 Kpa Condition Engine running Relief pressure

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Injector & Rail

01.1-31 C100 (2.4L DOHC) Engine Mechanical

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1. Injector specification
Application Static flow rate Spray type Injection type Color Resistance() 2.4 L DOHC 194 4% (g/min) Dual spray type Sequential Black 12 5%

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01.1-32 C100 (2.4L DOHC) Engine Mechanical

Evaporative Emission Canister - 1

The evaporative emission canister is an emission control device containing activated charcoal granules. The evaporative emission canister is used to store fuel vapors from the fuel tank. Once certain conditions are met, the electronic control module (ECM) activates the controlled canister purge solenoid allowing the fuel vapors to be drawn into the engine cylinders and burned. Capacity : 900cc

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[ Canister ]

[ Purge control solenoid ]

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