Alpha II engine introduction

Engine
Alpha II Engine

Published by Hyundai Motor company , september 2005


Alpha II Engine Introduction

2

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

3

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
Alpha 2 1.6 liter with CVVT 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
U 1.5 liter CRDI with VGT emission engine with this.


Changed Items-1

4

In case of main moving parts such as piston, piston ring,

camshaft, crankshaft, connecting rod, cylinder head,
cylinder head gasket and cylinder block, any parts can not
be shared together between 1.4 and 1.6
The 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.
1.6 Intake Camshaft
Target Wheel

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.

1.6 Cylinder Head


Changed Items-2

5

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.
•Direction :
Describe PCM location with
advantages and CAN protocol
for DTC.

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.


Specification

6

Exhaust Valve

Intake Valve
Duration : 228˚

Duration : 236˚
Full Advance

Full Retard

TDC

TDC
ATDC 10˚

TDC

BTDC 32˚

ATDC 8˚

82˚

BBDC 46˚

122˚

ABDC

56˚

ABDC 16˚

BDC
BDC

BDC

Valve timing for 1.6 liter engine is as shown in the table. The half value of 82 degree in full
advance or 122 degree in full retard is used as “CVVT set position”.
Two types of spark plugs are used, NGK and Champion. Using one type of spark plug for
all 4 cylinders is recommended.


Parts List

MAF for 1.6 liter

7
Inductive type CKP sensor is used. Typically when you
use Bosch EMS system, CKP sensor type is from
inductive type contrary to Siemens of hall IC type. Of
course these days there isn’t any board to share both
hall or inductive in CKP sensor. Main reason why
Bosch prefer to use inductive type is it doesn’t need
any power supply for sensor operation. For example a
vehicle is driving on rough road, suddenly micro cut off
happens in power supply to sensor then the vehicle
will stall immediately because of no power to sensor in

hall IC type. On the other hand, since inductive type
doesn’t need any power supply the vehicle will still
move.
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.

MAP for 1.4 liter

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.


RLFS Fuel System

8

Available Vehicle

XD, LC, FC, MC

Filter Interval

60,000 KM (Depends on the region)

Advantage :
Because of the circulation of fuel from fuel tank to heated fuel delivery
pipe, conventional return type fuel system compared to RLFS which fuel
is regulated in fuel pump module inside of fuel tank can produce much
more evaporated high temperature gas.
Reducing circulating fuel line as shown in the picture, RLFS maintains
lower fuel temperature and reduces evaporative gas by 25 ~ 30%.
Main items consist of RLFS are fuel pump module including fuel filter
and fuel pressure regulator submerged in fuel tank.


Fuel Pump Module Disassembling

Procedure :
1.

Descrewed two bolts hidden in rear seat

2.

Disconnect fuel pump connector

3.

Carefully open fuel tank cap and take out the fuel pump module

4.

Disassemble one by one carefully and replace fuel filter

9


Fuel Pump Circuit

10

Battery
Fuel Cut
Switch

F/Pump
Relay
Main
Relay

Fuel Pump

PCM

(V)

①

②

③

④

⑤

Ig. On

0

B+

B+

B+

0 ⇒ B+

Starting

B+ ⇒ 0

B+

B+

B+

B+ ⇒ 0

Running

0

B+

B+

B+

0


Fuel Pressure Measuring

11

Fuel Pressure(kg/㎠)
Ig. On

3.5 ⇒ 3.0

Starting

3.5

Sudden Acceleration

3.5

Fuel Pump Current Consumption

Current (A)
Maximum

11.2

Average

4.5

Minimum

3.5

12


Parts Location

13

1.

PCM

11. Knock Sensor

2.

MAF Sensor

12. Vehicle Speed Sensor

5.

TP Sensor

14. ISA

6.

ECT Sensor

15. PCSV

7.

CMP Sensor

16. OCV

8.

CKP Sensor

17. Ignition Coil

9.

Frt. Oxygen Sensor


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.

14


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.

15


Timing Belt Inspection

16

TIMING BELT INCREASED IN THICKENESS
PART NAME
TIMING BELT

PART NUMBER
PREVIOUS

NEW

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.
.
Belt Tension


Compression-1

17

No.1

No.2

No.3

No.4

Dry
(Kg/㎡)

12.5 ~13

12.5 ~13

12.5 ~13

12.5 ~13

Oil
(Kg/㎠)

13.5~14.2

13.5~14.2

13.5~14.2

13.5~14.2

Good/Bad

Good

Good

Good

Good

Compression test result can be different by tools and conditions.
Rationality check for 4 cylinder is useful.


Compression-2

18

No.1

No.2

No.3

No.4

Voltage

(V)

0.6

1.5

1.5

1.5

Good/Bad

Bad

Good

Good

Good

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.


Bearing Selection & Measuring
□ 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
□ Con-Rod Bearing
Con rod bearing oil clearance
is 0.022 ~0.040mm. Also
bearing has 5 selection with
difference size. Con Rod itself
has 3 type A, B and C by its
size. Size mark is stamped on
the side of con rod cap.
□ 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.

19


Vacuum (Negative) Pressure Measuring

Idle

WOT to Deceleration
(Full Vacuum)

Condition

Pressure (cmHg)

Idling

-35 ~ -37

Sudden Acceleration

-35 to +26

Sudden Deceleration

+6 to -45 then -35

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

20


Current Measuring

21

Items

Current(A)

Dark Current (Ig. Off)

0

Starter Motor (Cranking)

150 ~ 170

Charging Current (Alternator)
In 5 minutes after starting

28~32


Micro 570 Analyzer

22

Function
□ Battery Test
- Out of Vehicle Test
- In Vehicle Test

□ Starter Test

□ Charging Test

The Micro 570 analyzer provides the ability to test the charging and starting, including the
battery, starter and alternator.


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.

23


Battery Test

24


Battery Test Result
Result
Good battery

Good recharge

25

Remedy
No action is required.

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.