C100 Service Training Manual :

Engine Repair (2.0L Diesel)

Instructor Guide
 1-3-2
Table Of Contents C100 (2.0L-Diesel) :
Engine Repair

Instructor Guide

Engine General …………..….…....………………………………….…… 3

Engine Mechanical ..……..….…....…………………………….………...… 6
Engine Lubrication …………….…………………………………………… 20
Engine Timing system …..……….……………...………………………… 21
Accessory Belt …………………………………...………………………… 24
Engine Intake & Exhaust system ..……………………………………..… 25
Engine Vacuum System ………….……………………………..………… 27
PCV System ………………………….…………………………..………… 28
DPF system ……………………………………………………..……….… 29
Engine Cooling system………………….…………………………….…… 35
Turbo-Charger system………………………………………………..…… 37
Fuel Supply system …………………..……………………………...……. 44
2.0L Diesel Engine : Engine general

Engine number
1-3-3

C100 (2.0L-Diesel) :
Engine Repair

Instructor Guide

1. Engine Type (Z : Diesel)

2. Engine Size (20 : 2.0L)
3. Cam Mechanism (DOHC or SOHC)
4. Sequence Number
5. Manufacturer’s country (K : Korea)
6. Bar–code Check
2.0L Diesel Engine : Engine general

Engine specifications
1-3-4
APPLICATION 2.0L Diesel
C100 (2.0L-Diesel) :
Vehicle Max Speed (MT/AT) kph/ kph
Engine Repair
Performance Min Turning Ratio (m) 5.75 m
Engine type
Instructor Guide
4 Cylinder(In-Line)
Bore x Stroke (mm) 83 x 92

Engine Displacement (cc) 1,991

General Compression Ratio 17.5 : 1
Max Power (hp/RPM) 110kw(147.5) / at 4,000
Max Torque (Nm/RPM) 320 N.m (236.0) / at 2,000
Type Compression ignition system
Ignition
Ignition sequence 1-3-4-2
Type Forced feed
Oil Type and Grade MB 229.31 5W 40
Lubrication Filter Cartridge
Oil Capacity (w/filter) 6.2 L
Oil Pump type Gerotor

Type Pressurized
Coolant Capacity (L) 9
Water Pump Centrifugal
Type Cross-flow
673 mm (Width)
Radiator
Core 511 mm (Height)
27 mm (Thickness)
Pressure Valve open 137.3 Kpa
Cooling Surge Tank
Vaccum Valve open 9.81 Kpa
Type WAX Pellet
Star to open (℃ ) 80 ± 2
Thermostat
Completely open (℃ ) 95
Completely close (℃ ) MIN 75
Type Electric
Fan Blades Main:5EA / Aux: 7EA
Fan Diameter 340mm + 320 mm
2.0L Diesel Engine : Engine general

Engine specifications
1-3-5
APPLICATION 2.0L diesel
C100 (2.0L-Diesel) :
Pump type Electric motor in fuel tank
Engine Repair
Low Filter type Depth Media
pressure
Displacement (ℓ/H) 165 ~215(at 4.5 bar) Instructor Guide
pump
Fuel pressure (bar) 4.15 ~5.35
Pump type Common rail
Fuel
Filter type 3 cylinder radial plunger
Delivery High
pressure Displacement (㎣ ) 695 ㎣ / rev
pump
Fuel pressure (bar) Max 1600 bar
Injector pressure (bar) Max 1600 bar
Filter Type Cartridge
Fuel Tank Capacity 65 L
Type Planetary Gear Reduction
Starter
Power 1.8KW
Alternator Power 125A
Type MF
Battery Capacity 12V- 90AH
Cold Cranking Ampere 912 CCA
2.0L Diesel Engine : Engine mechanical

Engine over view

1-3-6

C100 (2.0L-Diesel) :
Engine Repair

Instructor Guide
2.0L Diesel Engine : Engine mechanical

Exploded view (Upper end)

1-3-7

C100 (2.0L-Diesel) :
Engine Repair

Instructor Guide

1. Camshaft Cover 18. Camshaft Cap Bolt

2. Camshaft Cover Gasket 19. Camshaft Cap
3. PCV adapter Gasket 20. Injector Bracket Bolt
4. PCV adapter 21. Injector Bracket
5. PCV Valve 22. Camshaft
6. Injector Seal 23. Camshaft Cap
7. Oil Cap 24. Plug
8. Injector bracket plug 25. Valve Lash Adjuster
9. Engine beauty cover bracket 26. Camshaft Seal Ring
10. Camshaft Position Sensor 27. Cylinder Head
11. Exhaust Roller Finger–Follower 28. Exhaust Valve
12. Intake Roller Finger–Follower 29. Intake Valve
13. Valve Bridge 30. Cylinder Head Gasket
14. Valve Key 31. Glow Plug
15. Valve Spring Retainer 32. Glow Plug Wiring
16. Valve Spring 33. Glow Plug Heat Shield
17. Valve Stem Oil Seal
2.0L Diesel Engine : Engine mechanical

Exploded view (Lower end)

1-3-8

C100 (2.0L-Diesel) :
Engine Repair

Instructor Guide
2.0L Diesel Engine : Engine mechanical

Exploded view (Lower end)

1-3-9

C100 (2.0L-Diesel) :
Engine Repair

Instructor Guide
2.0L Diesel Engine : Engine mechanical

Exploded view (Lower end)

1-3-10
1. Piston Ring Set 29. Oil Filter Housing Fitting Bolt C100 (2.0L-Diesel) :
2. Piston Pin Retainer 30. Engine Oil Cooler
Engine Repair
3. Piston 31. O–Ring
4. Piston Pin 32. Oil Cooler Outlet Hose
Instructor Guide
5. Connecting Rod and Cap 33. Oil Cooler Inlet Hose
34. Oil Pump Assembly
6. Connecting Rod Journal Bearing Set
35. Oil Pressure Relief Valve
7. Engine Block
36. Oil Pressure Relief Valve Spring
8. Coolant Adapter
37. Oil Pressure Relief Valve Gasket
9. Coolant Adapter
38. Oil Pressure Relief Valve Plug
10. Plug 39. Crankshaft Front Seal Ring
11. Crankshaft Journal Bearing Set 40. Oil Pressure Switch
12. Crankshaft 41. Oil Pump Seal
13. CKP Sensor Target Wheel 42. Oil Pump Outer Rotor
14. Crankshaft Rear Seal Ring 43. Oil Pump Inner Rotor
15. Crankshaft Gear 44. Oil Pump Cover
16. Crankshaft Gear Key 45. Oil Pump Drive Gear
17. Engine Bed Plate 46. Oil Level Indicator
47. Oil Level Indicator Tube
18. Crankshaft Bolt
48. Crankshaft Position Sensor
19. Bed Plate Bolt
49. Oil Pan Bolt
20. Oil Nozzle Tube Bolt
50. Oil Pan Bolt
21. Oil Nozzle Tube 51. Oil Pan
22. Oil Filter Cap 52. Oil Drain Plug
23. O–Ring 53. Oil Drain Plug Washer
24. Oil Filter 54. Crankshaft Balancer
25. Oil Filter Housing 55. Oil Strainer Pipe
26. O–Ring 56. Oil Strainer Pipe Seal
27. Oil Filter Housing Drain Bolt Washer
28. Oil Filter Housing Drain Bolt
2.0L Diesel Engine : Engine mechanical

Exploded view (Intake & Exhaust system)

1-3-11

C100 (2.0L-Diesel) :
Engine Repair

Instructor Guide

1. Wheel Bearing Oil Inlet Pipe Bolt 9. Exhaust Manifold

2. Wheel Bearing Oil Inlet Pipe 10. Thermostat Housing
3. Turbocharger 11. Thermostat Housing Gasket
4. Wheel Bearing Oil Outlet Pipe Gasket 12. Thermostat
5. Wheel Bearing Oil Outlet Pipe 13. Boost Pressure Sensor
6. Wheel Bearing Oil Outlet Hose (T–MAP Sensor)
7. Exhaust Manifold Gasket 14. Intake Manifold
8. Turbocharger Gasket 15. Coolant Temperature Sensor
16. Intake Manifold Gasket
2.0L Diesel Engine : Engine mechanical

Exploded view (Mount system)

1-3-12

C100 (2.0L-Diesel) :
Engine Repair

Instructor Guide

1. Engine Mount Damper (RH Side)

2. Engine Mount Bracket
3. Transaxle Front Mount Damper
4. Transaxle Mount Damper (LH Side)
5. Transaxle Rear Mount Bracket (AWD/FWD)
6. Transaxle Rear Mount Damper
7. Cradle
2.0L Diesel Engine : Engine mechanical

Exploded view (Timing belt system)

1-3-13

C100 (2.0L-Diesel) :
Engine Repair

Instructor Guide

1. Camshaft Sprocket 9. Timing Belt Upper Cover

2. Timing Belt Idler 10. Timing Belt Lower Cover
3. Injection Pump Sprocket 11. Engine Mount Bracket
4. Timing Belt Tensioner 12. Crankshaft Pulley
5. Water Pump Pulley 13. Water Pump Gasket
6. Crankshaft Sprocket 14. Injection Pump
7. Timing Belt 15. A/C compressor & Alternator
8. Timing Belt Rear Cover Bracket
2.0L Diesel Engine : Engine mechanical

Cylinder head
1-3-14
This cylinder head is SOHC(Single Over Head Camshaft) type and has
C100 (2.0L-Diesel) :
only one camshaft that open 4 valves per cylinder with the finger
followers of roller type and the valve bridges. It is similar to that of Engine Repair
DOHC(Double Over Head Camshaft) cylinder head.
Instructor Guide
The camshaft gear is installed in front of camshaft and the vacuum
pump is coupled in the rear of that. Because of the cam follower of the
hydraulic type, it doesn't need to adjust of valve clearance.

The cylinder head is made of cast aluminum ally for better strength in
hardness with light weight.

The combustion chamber of plate type of the cylinder head is designed

for increasing of squish and swirl efficiency and then this is maximized
to diesel combustion efficiency.

** Cylinder head bolt tightening sequence :

Tighten the cylinder head bolts to 65 Nm(47.9 lb–ft).
Using the angular torque gauge KM–470–B, tightening the cylinder
head bolts another 120 degrees plus 120 degrees.
2.0L Diesel Engine : Engine mechanical

Cylinder block
1-3-15
As the largest part of the engine components, the engine block is made
C100 (2.0L-Diesel) :
of cast iron. There are engine oil and coolant passages for lubricating
Engine Repair
and cooling in the inside of engine block. On the upper side of engine
block, there is the cylinder head which has combustion chamber. Also, Instructor Guide
the engine block has the bed plate to support the crankshaft and
decrease the engine vibration on the lower side.

On the inside surface of the engine block, there are bore surfaces
whose the pistons of reciprocating motion assemble in it and 4 oil jets to
lubricate on the each bore surface.
2.0L Diesel Engine : Engine mechanical

Piston & Rings

1-3-16
The pistons are cast aluminum with a flat top design. Piston skirts are
C100 (2.0L-Diesel) :
coated to reduce friction. Each piston uses 2 compression rings and 1
Engine Repair
3-piece oil control ring assembly. The piston pin is a full-floating design
and is retained to the connecting rod by clips located in each end of Instructor Guide
the piston pin bore. The connecting rod and rod cap are positioned
and aligned by a dowel pin and retained by bolts.
2.0L Diesel Engine : Engine mechanical

Crankshaft
1-3-17
The crankshaft is made of better strength forging works design than iron
C100 (2.0L-Diesel) :
cast. It is located between the engine block and the bed plate at 5 main
Engine Repair
journals with main bearings which have oil clearance for lubricating. The
3rd bearing of the 5 main bearings is thrust bearing whose the
Instructor Guide
crankshaft has properly axial end play.

It is assembled the 4 con–rod journals with the metal bearings into the
crankshaft whose bearing caps are cross–bolted to enhance structural
rigidity.

On the front side of the crankshaft, there is a crankshaft gear which

drives oil pump and crankshaft balancer. On the back of the crankshaft,
there is a target wheel to sent the signal to CKP (Crankshaft Position
Sensor).

Crankshaft gear for Balancer

EN-48246
Timing belt adjuster- CKP sensor target wheel
Crankshaft holder
2.0L Diesel Engine : Engine mechanical

Crankshaft balancer
1-3-18
The crankshaft gear drives the balancer 2 shafts that revolve on the C100 (2.0L-Diesel) :
opposite direction. So, the balancer is counterbalance the vibration that
Engine Repair
comes from the crank train.
Instructor Guide
It is located between the bed plate and the oil pan with the engine oil.

Balancer gear
2.0L Diesel Engine : Engine mechanical

Valve train system

1-3-19
The engine utilizes a valve finger–follower and hydraulic lash adjuster C100 (2.0L-Diesel) :
for valve operation. The roller is located at the middle of valve finger–
Engine Repair
follower and delivers the cam movement to valve bridge in correspond
to cam profile continuously. Instructor Guide

b
g

c f

d e

Mark Name Function

a Camshaft Drive valve system
b Roller Finger Follower Deliver the rotating to valve bridge
Pivot and compensate activating
c Hydraulic Lash Adjuster
and de-activating movement
d Intake-Valve Make the fresh gas flow
e Exhaust-Valve Make the exhaust gas flow
f Valve-Spring Keep the valve closed
g Valve-Bridge Activate two valve's movement

Roller finger follower Valve bridge

2.0L Diesel Engine : Engine lubrication

Oil pump and Oil filter

1-3-20
The oil pump draws engine oil from the oil pan and feeds it under
C100 (2.0L-Diesel) :
pressure to the various parts of the engine. An oil strainer is mounted
Engine Repair
before the inlet of the oil pump to remove impurities which could clog or
damage the oil pump or other engine components. When the crankshaft Instructor Guide
rotates,the oil pump driven gear rotates. This causes the space between
the gears to constantly open and narrow, pulling oil in from the oil pan
when the space opens and pumping the oil out to the engine as it
narrows.

Oil pump

Oil filter

Oil drain plug

CAUTION : Check the engine oil maintenance interval and replace the
engine oil filter according to the interval. Also, you have to reset
maintenance interval and check the engine oil remaining life in the scan
tool.
ITEMS 2.0L Diesel
Type Forced feed
Oil Type and Grade MB 229.31 5W 40

Filter Cartridge
Oil Capacity (w/filter) 6.2 L
Oil Pump type Gerotor
2.0L Diesel Engine : Engine timing system

Descriptions
1-3-21
The crankshaft pulley assembled the crankshaft drives the camshaft C100 (2.0L-Diesel) :
sprocket, the water pump pulley and the high pressure pump sprocket
Engine Repair
using by timing belt. Also, the auto timing belt tensioner of double
eccentric type assist the belt tension. Instructor Guide
Timing belt idler which is applied the double low bearing type to endure
big load enlarges the wrap angle between the camshaft sprocket and
the high pressure pump sprocket to enhance the delivery power.

Cam Camshaft
sprocket

Timing belt
idler
High pressure
Timing belt pump sprocket
tensioner

Water pump
Timing belt pulley

Crankshaft
sprocket Crankshaft

Model Maintenance Remarks

C100 I : 30,000 km(20,000 miles) or 2 years

(2.0L Diesel) R : 90,000 km(60,000 miles) or 5 years

* I : Inspection
R : Replacement
2.0L Diesel Engine : Engine timing system

Timing belt adjustment - 1

1-3-22
1. Remove the vacuum pump
C100 (2.0L-Diesel) :
Engine Repair

Instructor Guide

2. Rotate the camshaft and align

the hole on the top point.
3. Rotate the crankshaft and
align the mark on the
crankshaft sprocket.

4. Remove the crankshaft holder

hole cap bolt(a).
5. Insert the crankshaft holder
EN–48246 into the crankshaft
holder hole.(b)
Notice :
Rotate the crankshaft sprocket a
little and simultaneously insert the
crankshaft holder.
6. Install the camshaft holder
EN–48245 onto the camshaft
rear side.(c)

7. Align the high pressure pump

sprocket mark on the timing
belt rear cover mark.
2.0L Diesel Engine : Engine timing system

Timing belt adjustment - 2

1-3-23
8. Install the camshaft sprocket
C100 (2.0L-Diesel) :
with the tightening bolt
Engine Repair
manually.
9. Install the timing belt. Instructor Guide
10. Install the timing belt
tensioner with the tightening
bolt manually.

11. Turn the hex–key(a) tab in a

count–clockwise direction to
tension the belt. Turn until the
point aligns with the notch(b).
12. Aligning with notch, install
the timing belt tensioner bolt.
13. Install the camshaft sprocket
bolt.
Tighten
Tighten the timing belt tensioner
bolt to 25 Nm (18.4 lb–in).
Tighten the camshaft sprocket
bolt to 133 Nm (98.1 lb–in).
14. Remove the camshaft holder
EN–48245 and crankshaft
holder EN–48246.
15. Turn the crankshaft in a
clockwise direction more 2
cycles and check the mark on
the crankshaft sprocket.
16. After alignment of the timing
belt, install the crankshaft
holder hole cap bolt.
Tighten
Tighten the crankshaft holder
hole cap bolt to 30 Nm.

CAUTION : Because the setting of these service special tools is aligns

No.1 cylinder TDC point, if not exactly aligns, it has influence on engine
performance and emission.
2.0L Diesel Engine : Accessory belt

Accessory belt
1-3-24
After checking the alternator belt , air conditioning ,power steering belt C100 (2.0L-Diesel) :
, for looseness, crack, wear or tension, replace the belt if necessary.
Engine Repair

Instructor Guide

** Relieve method :
1) Install the accessory belt remover/installer EN–48253 onto the
tensioner lever guide and rotate the tensioner at clockwise.
2) Rotate the tensioner fully and simultaneously insert tensioner spring
holding pin EN–48301 to the tensioner pin hole.
3) Remove the accessory belt.
2.0L Diesel Engine : Engine Intake & Exhaust system

Intake manifold 1-3-25

The intake manifold is air flow passage to the cylinder combustion
C100 (2.0L-Diesel) :
chamber through the throttle body and has an effect on engine torque,
power, noise, drivability, emission, fuel economy and performance. Engine Repair

It is made of cast aluminum alloy for better strength in hardness with Instructor Guide
light weight and is one body with the coolant passage.

Boost pressure
Water Inlet & temp’ sensor

Coolant
temp. sensor
Air Inlet

Thermostat & cover

Exhaust manifold
The exhaust manifold is located to the cylinder head and send the
turbocharger the exhaust gas out of the combustion chamber. It is
designed to endure on high pressure and high temperature and made of
HiSiMo material.
2.0L Diesel Engine : Engine Intake & Exhaust system

Exhaust system 1-3-26

The function of the muffler is to reduce engine noise. It is made up of a
C100 (2.0L-Diesel) :
series of perforated tubes and baffles to break up the sound waves and
Engine Repair
reflect them. It is made of Stainless Steel to protect the front muffler
from corrosion.
Instructor Guide
The rear muffler is to reduce broad band engine exhaust noise. It is
comprised of a series of perforated tubes and baffles to break up the
sound waves and reflect them.The adopted dual muffler for C100
improves the efficiency to reduce flow noise. It is made of Stainless
Steel to protect the front muffler from corrosion.

1. Exhaust Manifold Heat Shield 10. Exhaust Gas Temperature

2. Pre–Catalyst Sensor 1
3. Seal Ring 11. Exhaust Front Pipe Assembly
4. Clamp 12. DPF(Diesel Particulate Filter)
5. DPF Pressure Sensor Assembly
6. DPF Pressure Sensor Hose 13. DPF Heat Shield
7. Exhaust Gas Temperature 14. Front Muffler Heat Shield
Sensor 2 15. Front Muffler Assembly
8. Gasket 16. Rear Muffler Assembly
9. Rubber Hanger (Right–Side)
17. Rear Muffler Assembly(Left–Side)
2.0L Diesel Engine : Engine vacuum system

Vacuum pump 1-3-27

Vacuum pump provides the vacuum to the brake booster and C100 (2.0L-Diesel) :
EGR(exhaust gas recirculation system) valve at diesel engine and
Engine Repair
installed at left upper side of engine for coupling with camshaft and
driven by camshaft. Instructor Guide

To brake
booster

To EGR
Solenoid valve

Part Item Specification

Type Single vane type

When the block of brake side port

Vacuum pump
at idle : - 0.9 bar
Vacuum
When the block of EGR side port
at idle : - 0.7 bar
2.0L Diesel Engine : PCV system

PCV valve 1-3-28

The PCV valve carries the blow–by gas to the turbocharger inlet of the C100 (2.0L-Diesel) :
intake system. According to the engine conditions, driving conditions
Engine Repair
and the pressure of turbocharger, it is different from the amount of
blow–by gas. So, the PCV valve controls the amount of blow–by gas. Instructor Guide

To Turbo
charger

From blow-by gas

2.0L Diesel Engine : DPF system

Description of DPF system 1-3-29

The diesel after-treatment system consists of an under hood pre- C100 (2.0L-Diesel) :
catalytic converter and an underbody catalytic converter (Main Diesel
Engine Repair
Oxidation Catalyst + Coated Diesel Particulate Filter).

Engine control technology and diesel after-treatment system are Instructor Guide
designed to reduce exhaust emissions such as hydrocarbons (HC),
carbon monoxide (CO) and particulates to meet the EURO-4 emission
regulation.

Main Catalytic converter

Pre-catalytic converter

DPF

DPF rear pressure port

DPF front pressure port

Exhaust gas
temperature sensor #1 Exhaust gas
temperature sensor #2
2.0L Diesel Engine : DPF system

Diesel Particulate Filter(DPF)

1-3-30
The diesel particulate filter is made from Silicon Carbide and is coated C100 (2.0L-Diesel) :
with noble metal. It is designed to reduce hydrocarbons (HC) and
Engine Repair
carbon monoxide (CO) emissions and to collect particulates from the
engine exhaust to minimize discharge of soot to the atmosphere. Instructor Guide
The soot particles accumulate in the channels of the coated diesel filter
and are burned off at regular interval (through a process called
“regeneration”) to prevent filter clogging. Excess soot in filter can cause
drop in engine performance and crack the filter during regeneration.

During regeneration, additional fuel is injected via multiple post

injections to increase the exhaust gas temperature. During this period,
the DPF temperature is raised to approximately 600 ℃ and the
deposited soot is oxidized or burned off to carbon-dioxide (CO2).

Main Catalytic converter

Pre-catalytic converter

DPF

Soot & Ash

Collecting Area

Exhaust gas

Exhaust Gas Flow

2.0L Diesel Engine : DPF system

DPF pressure sensor

1-3-31
The pressure pipes, which are connected to the differential pressure C100 (2.0L-Diesel) :
sensor, measure the level of soot deposit in the coated diesel particulate
filter and protect the engine by triggering regeneration when critical soot Engine Repair
level is detected in the filter.
Instructor Guide

DPF pressure sensor

DPF rear
pressure port

DPF front
pressure port

DPF front
DPF rear
pressure port
pressure port

Part Item Specification

Type Piezo resistor
Operation voltage 5V
Operation current 10mA Max
DPF Pressure
sensor Operation temperature -40 ∼ 125 ℃
Operation pressure 0 ∼ 100 KPa
8.0mm (front)
DPF pressure port size
6.0mm (rear)
2.0L Diesel Engine : DPF system

Exhaust gas temperature sensors 1-3-32

The sensor detects temperature in DPF and exhaust front pipe. Under C100 (2.0L-Diesel) :
hood pre-catalyst and main diesel oxidation catalyst are coated with
Engine Repair
noble metal and have the function of reducing hydrocarbons (HC) and
carbon monoxide (CO) emissions by burning the post injected fuel. Instructor Guide
The in-cylinder post injection allows filter regeneration to occur over the
entire engine operating range as well as under all ambient temperature
and pressure conditions. The regeneration process is smooth and
essentially transparent to the driver of the vehicle.

[ Sensor # 1 - Front] [ Sensor #2 - Rear ]

Front : 264mm, Rear 666mm

Sensor(24 hole & diameter 2.2mm)

Part Item Specification

Exhaust gas Type NTC Thermister

temperature Operation voltage 5V
sensor Sensor tighten torque 45 N.m ±10%
2.0L Diesel Engine : DPF system

Wiring diagram
1-3-33

C100 (2.0L-Diesel) :
ECM Engine Repair

Instructor Guide
J1 44 5V Ref
1

DPF
pressure J1 64 DPF pressure
sensor 3 signal

J1 37
2

Sig
J1 34 5V Ref’
1

Exhaust gas
temperature
sensor #1

2 J1 35

Sig
J1 32 5V Ref’
1

Exhaust gas
temperature
sensor #2

2 J1 33
 2.0L Diesel Engine : DPF system

Re-generation procedure

The regeneration of particulate filter is initiated by raising the

temperature in the exhaust system up to the ignition temperature of the
soot .( > 600°C).
The Post-injection of diesel fuel is used with the current fuel additive
and catalysted systems to raise the temperature in front of the filter.
The catalytic coating promotes the soot combustion and Oxidises CO
and hydrocarbon emissions.
The soot loading on filters used in fuel additive systems is normally quite high (> 600°
C)and the regeneration usually proceeds for 10 minutes.
The ECM enters regeneration mode when the formation of ash deposited
in the particulate filters and displays indicate lamp on the cluster to the
driver.
2.0L Diesel Engine : Engine cooling system - 1

Cooling fans 1-3-35

C100 (2.0L-Diesel) :
Engine Repair

Instructor Guide

1. Radiator 5. Main Cooling Fan Motor

2. Charge Air Cooler 6. Auxiliary Cooling Fan Motor
3. Main Cooling Fan Blade 7. Cooling Fan Shroud
4. Auxiliary Cooling Fan Blade

FAN SPEED APPLICATION ON OFF

ECT ( ℃) 100 97
Low
A/C switch ON
ECT ( ℃) 105 102
High ACP ( kg/㎠) 18.98 14.76
ECT Malfunction
Cooling fans size Φ340 (Main)+ Φ 320(Aux)
2.0L Diesel Engine : Engine cooling system - 2

Water pump and Thermostat 1-3-36

C100 (2.0L-Diesel) :
Engine Repair

Instructor Guide

1. Water Pump 6. Boost pressure & Temperature

2. Water Pump Gasket Sensor
3. Thermostat Housing 7. Intake Manifold
4. Thermostat Gasket 8. Coolant Temperature Sensor
5. Thermostat

Water pump Thermostat

Part Name 2.0L Diesel Remarks

Radiator Type Cross Flow

Radiator Size 673 × 414 × 27 W × HxT

Coolant Capacity 10ℓ

Thermostat start to open 80 ±2℃ Complete open : 95℃

2.0L Diesel Engine : Turbo charger system

General description of Turbocharger

1-3-37
The turbocharger increases engine power by pumping compressed air
C100 (2.0L-Diesel) :
into the combustion chambers, allowing a greater quantity of fuel to
combust at the optimal air/fuel ratio. In a conventional turbo, the Engine Repair
turbine spins as exhaust gas flows out of the engine and over the
Instructor Guide
turbine blades. This spins the compressor wheel at the other end of the
turbine shaft, pumping more air into the intake system.

Inter-cooler

Intake air

Turbo charger Exhaust valve

Intake valve

Piston
2.0L Diesel Engine : Turbo charger system

Description of Variable Geometry Turbocharger(VGT)

1-3-38
The turbocharger for this system has boost pressure actuator control by
C100 (2.0L-Diesel) :
the engine control module (ECM). The vanes can be opened and closed
to vary the amount of boost pressure. Thus, the boost pressure can be Engine Repair
controlled independent of engine speed. There are 11 controllable
Instructor Guide
vanes in this turbocharger. The vanes mount to a drive ring that can be
rotated to change the vane angle. When the engine is not under load,
the vanes are open to minimize boost and exhaust back pressure. To
increase boost when the engine load requires it, the vanes are
commanded closed. The ECM will vary the boost dependent upon the
load requirements of the engine.

Bearing
housing

Noz
z le
ass
emb
Lever plate ly c
artr
Drive ring idge
Mount
Vane
Support Ring

Boost pressure
actuator
Crank

Cr a Lever
nk s
yste
m

Turbine housing
2.0L Diesel Engine : Turbo charger system

Boost pressure actuator -1

1-3-39
The turbocharger vanes are normally open when the engine is not
C100 (2.0L-Diesel) :
under load. However, the ECM will often the turbocharger vanes to
increase engine power and to create back pressure by boost pressure Engine Repair
actuator.
Instructor Guide
At extreme cold temperatures, the ECM may close the vanes at low
load conditions in order to accelerate engine coolant heating. The ECM
may also close the turbocharger vanes under exhaust braking
conditions.

The boost pressure actuator is controlled by ECM.

The engine control module (ECM) uses a pulse width modulation on the
boost pressure actuator. This boost actuator rod rotates the drive ring,
thus controlling the engine boost dependant upon engine load.

Engine
Actuator Operation status Remarks
status

Low speed ** Increase MAX.

Pull
(Low load) torque.(5 ~15%)

High
**Increase MAX.
speed Release
power.(10 ~15%)
(High load)
2.0L Diesel Engine : Turbo charger system

Boost pressure actuator -2

1-3-40

Engine load Boost actuator Boost actuator C100 (2.0L-Diesel) :

Vane passage
status PWM control operation
Engine Repair
Low speed low
85 % Pull Narrow
load
Instructor Guide
High speed high
5% Release Wide
load

<Low speed, low load> <High speed, high load>

2.0L Diesel Engine : Turbo charger system

Boost pressure & Temperature sensor

1-3-41
The boost pressure sensor mounted on intake manifold, measures both
C100 (2.0L-Diesel) :
boost pressure and air temperature. The two output signals are used for
ECM to calculate amount of air. The Pressure Sensor uses Piezo Engine Repair
resistor, which generates a changing resistance with variable absolute
Instructor Guide
pressure in intake manifold.

Sensor Items Specification Remarks

Type Piezo resistor
Operating voltage 5V
Operating current 12.5mA
Operating
Boost -40 ∼ 130℃
temperature
pressure
Operating
sensor 20 ∼ 300 KPa
Pressure
0.65~0.75 V 40 KPa
Output voltage 2.16~2.27 V 140 KPa
3.68~3.79 V 240 KPa
Type NTC Thermistor
Boost 14,785 ∼ 16,443 Ω -20℃
temperature 2,401 ∼ 2,619 Ω 20℃
sensor Resistance
590 ∼ 634 Ω 60℃
180 ∼ 191 Ω 100℃
2.0L Diesel Engine : Turbo charger system

Wiring diagram for VGT

1-3-42

C100 (2.0L-Diesel) :
Ignition
Engine Repair

1 ECM Instructor Guide

Boost pressure
actuator

2 4
A15

3 A13 5V
Ref’

Boost
P 4 A40
pres’
Boost signal
pressure
1 A23
sensor
Boost Temp’ Boost
sensor temp’
signal
2 A53 5V
Ref’
2.0L Diesel Engine : Turbo charger system

Inter-cooler
1-3-43
Turbo charger is the device that supplies hot and compressed air, that
C100 (2.0L-Diesel) :
is from the turbine by sucking exhaust gas or ram air, to the engine to
increase the power. Engine Repair

Quick compressed air from this turbo charger expands with high Instructor Guide
temperature and causes decreasing of charging efficiency into the
cylinder because density of oxygen gets lower.
However Charging efficiency into the cylinder increases as compressed
hot air is cooled and density of air gets higher through the intercooler.
It brings also higher fuel efficiency as well as lower CO2 emissions.
Intercooler which is installed on top of radiator in front of car makes
compressed hot air cool by airflow through the radiator grill.

Air inlet port

Fin & Tube

Air outlet port

Part Item Specification Remarks

Type Air to Air

Inter-cooler Size 570 x 99.6 x 90 WxHxT

Cooling capicity 13,000 kacl/h

2.0L Diesel Engine : Fuel supply system

Fuel tank
1-3-44
The fuel tank stores the fuel and the tank is sealed up leakage of vapor.
C100 (2.0L-Diesel) :
The fuel tank is made from high density polyethylene. The main fuel
Engine Repair
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 Instructor Guide
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.

5. Grade Vent Valve

1. Sub Fuel Pump

2. Main Fuel Pump

3. Roll Over
Valve

4 . Ring-Adaptor

Fuel tank Remarks

Capacity 65 L
2.0L Diesel Engine : Fuel supply system

Main Fuel Pump Module

1-3-45
The main fuel pump module is located inside of the right side of the
C100 (2.0L-Diesel) :
fuel tank. The main fuel pump module consists of the following major
components: Engine Repair
•The fuel level sender assembly
Instructor Guide
•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
2.0L Diesel Engine : Fuel supply system

1. Specification of Fuel pump

1-3-46
System Pressure 450 kpa C100 (2.0L-Diesel) :

Displacement 165 ~215ℓ /h Engine Repair

Relief pressure min 650 kPa - max 900 kPa Instructor Guide

Current 3.0 ~ 11.5 AMP

2. Fuel level gage resistance

Fuel level Resistance(Ω )

Float Height
Status Fuel Height MAX MIN
Full Stop 228.9 40 45.5 37.0

1/2 130.6 106.2 112.8 99.4

Empty Stop 1.3 250.0 253.0 240.4

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 fuel
level 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 Signal Remarks

FULL 3.4V 5V Ref
3/4 3.0V
1/2 2.2 ∼ 2.5V

1/4 2.0V
Empty 1.4 ~ 1.5V
2.0L Diesel Engine : Fuel supply system

Description of Diesel common rail system

1-3-47
The common rail system was developed primarily to cope with exhaust
C100 (2.0L-Diesel) :
gas regulations for diesel engines, and aimed for further improved fuel
economy; noise reduction and high power output. Engine Repair
The common rail system uses a type of accumulation chamber called a
Instructor Guide
Common rail to store pressurized fuel, and injectors that contain
Electronically controlled solenoid valves to spray the pressurized fuel
into the cylinders. Because the ECM controls the injection system
such as injection pressure, injection quantity, and injection timing
1) Injection pressure control
- Enables high-pressure injection even at low engine speeds.
- Optimizes control to minimize particulate matter and NOx emissions.
2) Injection quantity control
- Pilot injection control sprays a small amount of fuel before the main
injection.
3) Injection timing control
- Enables finely tuned optimized control in accordance with driving
conditions.
2.0L Diesel Engine : Fuel supply system
Fuel filter heater & Temperature sensor
1-3-48

C100 (2.0L-Diesel) :
Engine Repair

Instructor Guide

Fuel filter cap

Fuel filter Fuel temp’

heater (PTC) Sensor (NTC)

Part Item Specification Remarks

Type PTC Thermistor
Operating
12V
voltage
Fuel filter Heater resistor 0.4 ∼ 2 Ω
heater Operating
250W -20℃
power
Enable
Less than 3℃ Off (more than 5℃)
condition
Type NTC thermistor
26,116 ± 2,533 Ω -30℃
5,896 ± 430 Ω 0℃
Fuel temp’
2,057 ± 115 Ω 25℃
Sensor Resistance
596 ± 23 Ω 60℃
187 ± 4 Ω 100℃
127 ± 3.3 Ω 115℃
2.0L Diesel Engine : Fuel supply system
Water In Fuel (WIF) sensor
1-3-49

C100 (2.0L-Diesel) :
Engine Repair

Instructor Guide

WIF sensor

Part Item Specification Remarks

Mechanical lead
Type Float
switch
WIF Operating voltage 10 ∼ 16 V
sensor Indicate lamp ON Over 95 CC
Less than 15mA Indicate lamp Off
Consume current
Less than 50mA Indicate lamp ON

Water Draining Procedure

1. Turn the water–in–fuel drain screw counterclockwise.
2. If finished, unscrew the drain screw reverse toward.
3. Do work fuel priming.
2.0L Diesel Engine : Fuel supply system
Fuel filter replacement procedure
1-3-50
1. Remove the air cleaner
C100 (2.0L-Diesel) :
assembly.
2. Disconnect the fuel inlet/outlet Engine Repair
line from the fuel filter.
Instructor Guide
3. Disconnect the fuel heater and
temperature sensor connector.
(a)
4. Disconnect the water in fuel
sensor connector.(b)
5. Remove the fuel filter
assembly from the bracket
upward.

6. Install the filter housing holder

EN–48303(a) and the fuel filter
locker installer/remover EN–
48304(b) to the fuel filter
assembly.
7. Turn the fuel filter locker
installer/remover EN–48304(b)
counterclockwise.

8. Remove the fuel filter

locker(a).
9. Remove the fuel filter cap(b)
with the O–ring(c).
10. Remove the fuel filter(d) in
the fuel filter housing(e).
Notice : The fuel filter cap
includes the fuel heater and
temperature sensor as one
body. Also, the fuel filter
housing includes the water in
fuel sensor as one body.

CAUTION : It is impossible to reuse the fuel filter element if exposed the

element to the air over a minute.
2.0L Diesel Engine : Fuel supply system
Description of Fuel priming
1-3-51
In order for the VM2.0S diesel fuel system to work properly, the fuel lines
C100 (2.0L-Diesel) :
must be full of fuel and contain no air. If air gets into the fuel lines, it will
be necessary to prime the fuel system to eliminate the air before Engine Repair
Operating the vehicle.
Instructor Guide
Air could have entered the system in one of the following ways:
1) The vehicle ran out of fuel.
2) The filter was removed for service or replacement.
3) The fuel lines were removed or disconnected for servicing.
4) The fuel pump was removed for servicing.
5) The fuel filter water drain cock was opened while the engine was
running
Notice :
If one or more of the above occurred, air has entered the fuel system
and you will need to prime the system prior to operating the vehicle.
Priming procedure

1. Turn the ignition key ON at 5–second intervals.

2. Turn the ignition key OFF and wait 3 seconds.
3. Repeat procedure No.1 ~ 2 at 6 or 7 times.
CAUTION : Do not turn the ignition key START. It could be damaged to
injection pump.
Notice : You can do fuel priming work using by SCAN tool.
2.0L Diesel Engine : Fuel supply system
High pressure pump - 1
1-3-52
The high pressure pump creates the system pressure required by the
C100 (2.0L-Diesel) :
Common Rail System for all operating conditions of the engine.
Engine Repair
It is operated by timing belt and has 3-cylinder radial plunger.
The fuel metering valve is controlled by ECM and limits the amount of Instructor Guide
fuel to pump.

High pressure pump solenoid

(fuel metering valve )

Fuel outlet
to rail

Fuel return Fuel inlet

2.0L Diesel Engine : Fuel supply system
High pressure pump - 2
1-3-53
Part Item Specification Remarks
C100 (2.0L-Diesel) :
Type 3-cylinder radial plunger Engine Repair
Pump output
High pressure 695㎣/rev
capacity Instructor Guide
pump
Output 650 bar 500 rpm
pressure 1,600 bar 1860 rpm
PWM
High pressure Type Solenoid
control
pump solenoid
Resistance 2.60 ∼ 3.15 Ω At 20℃
(Fuel metering
valve) Operating
120 ∼ 200 Hz
frequency

①
Injector

② ③

Pressure Overflow valve

control
valve Filter with water
separator

Common rail
400 ∼1600 bar
High pressure
pump

High pressure pump

① Injector return solenoid Tank & Pump
② Rail return (Fuel metering valve)
③ Pump return

Wiring diagram

ECM
1
J2 19 B+

2
J2 49
PWM
High pressure pump
Solenoid
(Fuel metering valve)
2.0L Diesel Engine : Fuel supply system
Common rail
1-3-54
The Common Rail Assembly is used to maintain the high fuel pressure
C100 (2.0L-Diesel) :
provided by high pressure pump, allows the fuel injector to be regulated
Engine Repair
and injected separately for each cylinder by using the management
strategy of ECM. The Common Rail Assembly consists of common rail Instructor Guide
body, rail pressure sensor, rail pressure control valve. The fuel
pressure in the rail is regulated constant pressure by rail pressure
control valve and monitored by rail pressure sensor. In this way, the
Common Rail Assembly controls the fuel pressure to desired point.

Fuel return

Fuel inlet
from pump
Fuel outlet
to injector Rail pressure
control valve

Rail pressure sensor

Part Item Specification Remarks

Common rail Rail pressure Max. 1600bar

Rail pressure Type Solenoid

control valve Resistance 3.42 ∼ 3.78Ω
Type Piezo Resistor
Rail pressure
sensor Operating
4.75 ∼ 5.25 V
pressure
2.0L Diesel Engine : Fuel supply system
Rail pressure sensor & Rail pressure control valve
1-3-55
The Rail Pressure Sensor is located at left side of common rail
C100 (2.0L-Diesel) :
and measures the fuel pressure.
Engine Repair
The fuel metering valve in the high pressure pump and the rail pressure
control valve in the rail controls the fuel pressure to desired point for Instructor Guide
engine combustion.

<Rail pressure Sensor>

<Rail pressure control valve>

2.0L Diesel Engine : Fuel supply system
Wiring diagram
1-3-56
ECM C100 (2.0L-Diesel) :
Engine Repair
2
J2 4 B+
Instructor Guide

1
J2 34
PWM control
Rail pressure control valve

J2 28 5V Ref
3

J2 43 Signal
2

1
J2 8

Rail Pressure Sensor

2.0L Diesel Engine : Fuel supply system
Injector - 1
1-3-57
The injector is a fuel injection equipment and injects the fuel to
C100 (2.0L-Diesel) :
combustion chamber directly. It has seven holes sized for 141
micromet in the nozzle. Engine Repair
The amount of fuel required by the engine is injected by the injectors.
It is controlled by engine control unit(ECM). Instructor Guide
Common Rail Systems is used multiple injections per combustion stroke.
Alignment of pilot and post injection events are required to emission or
after-treatment system requirements. Injection pressure, injection
quantity and injection timing control are independent of engine speed
or position.

Fuel return

IQA code

Fuel inlet

Nozzle
Nozzle

Part Item Specification Remarks

Multi injection
Type Solenoid
type
Injection hole 7 holes
-30 - 115C
Operating temperature
degree
Injector Solenoid coil resistance 0.25 - 0.29 Ohm 20 C degree
Max. Injection pressure 1,600 bar
Min. Injection pressure 120 bar
Normal Injection
250 - 1,600bar
pressure
Return pressure 0.3 - 0.8 bar
2.0L Diesel Engine : Fuel supply system
Injector - 2
1-3-58

Return C100 (2.0L-Diesel) :

Return
Engine Repair

Instructor Guide
Valve spring

Control
chamber Solenoid
valve
Ball valve

Outlet orifice
Nozzle chamber

Control piston

Nozzle spring
Injector needle

Injector Nozzle
2.0L Diesel Engine : Fuel supply system
Injector Quantity Adjustment(IQA)
1-3-59
IQA (Injector Quantity Adjustment) codes have been adopted to
C100 (2.0L-Diesel) :
enhance the injection quantity precision of the injectors.
The adoption of IQA codes enables injection quantity dispersion control Engine Repair
throughout all pressure ranges, contributing to improvement in
Instructor Guide
combustion efficiency, reductions in exhaust gas emissions and so on.
IQA codes displaying various injector characteristics are laser marked in
the injector body
When an injector is newly installed in a vehicle, it is necessary to input
the IQA codes in the ECM by Scan-tool.

IQA code
2.0L Diesel Engine : Fuel supply system
Injection control

1. Fuel Injection Pressure Control

A value that is determined by the final injection quantity, the water
temperature and the engine speed is calculated. During the starting of
the engine, the calculation is based on the water temperature
and the atmospheric pressure.

2. Fuel Injection Timing Control Function

Fuel injection timing is controlled by varying the timing in which current
is applied to the injectors.
1) Pilot Injection Timing
Pilot injection timing is controlled by adding a pilot interval to the
main
injection timing. The pilot interval is calculated based on the final
injection quantity, engine speed, coolant temperature(map
correction).
2) Main Injection Timing
The engine ECM calculates the basic injection timing based on the
engine speed, the final injection quantity, and adds various types of
corrections in order to determine the optimal main injection timing.
3) Post Injection Timing
The regeneration of particulate filters is initiated by raising the
temperature in the exhaust system up to the ignition temperature of the
soot .( > 600°C).
The Post-injection of diesel fuel is used with the current fuel additive
and catalysted systems to raise the temperature in front of the filter.

3. Fuel Injection Quantity Control Function

This control determines the fuel injection quantity by adding coolant
temperature, fuel temperature, intake air temperature, and mass airflow
corrections to the basic injection quantity is calculated by the ECM,
based on the engine operating conditions and driving conditions.
2.0L Diesel Engine : Fuel supply system
Injection control
1-3-61
4. Fuel Injection Rate Control Function
C100 (2.0L-Diesel) :
While the injection rate increases with the adoption of high-pressure fuel
Engine Repair
injection, the ignition lag, which is the delay from the start of injection to
the beginning of combustion, cannot be shortened to less than a Instructor Guide
certain value. As a result, the quantity of fuel that is injected until main
ignition occurs increases, resulting in an explosive combustion at the
time of main ignition. This increases both NOx and noise. For this
reason, pilot injection is provided to minimize the initial injection rate,
prevent the explosive first-stage combustion, and reduce noise and
NOx.

5. Fuel Injection Volume Control according to Fuel Temperature

Detects the fuel temperature and sends a corresponding signal to the
ECM. Based on this information, the ECM calculates the injection
volume correction that is appropriate for the fuel temperature.

Wiring diagram

ECM

1
J2 16

Injector # 1 2
J2 47

1
J2 2

Injector # 2 2
J2 31

1
J2 1

Injector # 3 2
J2 46

1
J2 17

Injector # 4 2
J2 33