R-engine

(Common Rail)

Copyright ⓒ 2009 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
 R - Engine 2

Engine Application
Engine
Type T/M EU GEN USA/Canada Aust.
Fuel Model Vol. Power/Torque
(’09. 5) (’09. 5) (’09. 12) (’09. 5)
M6GF2 ● ● ●
2WD
A6MF2 ● ● ● ●
Theta II 2.4 172 / 23.0
M6GF2 ● ● ●
GSL 4WD
A6MF2 ● ● ● ●
(China,09.7)

2WD A6LF2 ● ● ●
Lambda II 3.5 275 / 33.8
4WD A6LF2 ● ●
M6LF1 ● ●
2WD
A6LF3 ● ●
R 2.2 200 / 44.5
M6LF1 ● ● ●
4WD
A6LF3 ● ● ●
DSL (China, ‘09.12)

2WD M6LF1 ●
(March, ’10)
R 2.0 150 / 38.0
4WD M6LF1 ●
(Feb. ’10)

R 2.0 184 / 40.0 2WD A6LF2 Domestic Market

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 R - Engine 3

Specification

Items R-2.0 / 2,2(EURO-Ⅴ) Items R-2.0 / 2,2(EURO-Ⅴ)

1,995 / 2,199
Displacement (cc) Catalytic Converter WCC+DPF
(In-line 4 cylinders)

Bore X Stroke 84 X 90 / 85.4 x 96 Engine Oil 6.2ℓ (5W-30)

Firing Order 1-3-4-2 Relief Valve Pressure 5.0± 0.5bar

TCI (Electrical VGT)

Intake System Injector Piezo type (8Holes)
/ ACV / SCV

Idle (RPM) 720 / 790 Max. Fuel Pressure 1,800 bar

Max. Power 2.0 : 184 / 4,000 Inlet & Outlet

Fuel Pressure Control
(Ps/RPM) 2.2 : 200 / 3,800 (FPCV & RPCV)

2.0 : 40 / 1,800~2,500 DC Motor 45 l/h,

Max. Torque (kgf·m/RPM) Low Pressure Pump
2.2 : 44.5 / 1,800~2,500 4.5bar13V

Max. (RPM) 4,800 Fuel Tank(ℓ) 75ℓ

Quick Glow Plug

Pre-Heating EMS Bosch (EDC17CP)
(1000℃ / 2sec.)

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 R - Engine 4

Lay out
Piezo Injector
1800bar Oil Separator Electrical VGT
4 Valve DOHC
Plastic
Head Cover
Vacuum Pump
(operated by camshaft)

Timing Chain Electrical

EGR Valve

Plastic Intake
Manifold

Water Pump
EGR COOLER
(By-pass type)

Isolation Oil Filter

Damper Pulley with Oil cooler

Close-Coupled DPF
Balance Shaft Module Serpentine driving belt
with Oil pump

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 R - Engine 5

Main Features - Comparison

D (Eruo-4) R (Eruo-5)
Items
2.0 2.2 2.0 STD 2.2 STD
Displacement (cc) 1,991 2,188 1,995 2,199
Bore×Stroke (mm) 83 x 92 87 x 92 84 x 90 85.4 x 96
Type / Valve Train In-line 4 SOHC-16V In-line 4 DOHC-16V
Injector Solenoid Injector (1600bar) Piezo Injector (1800bar)
Catalytic Converter DPF (UCC) DPF (Close-Coupled)
EGR System EGR with cooler By-pass type EGR with cooler
Timing System Timing Belt Timing Chain

DOHC Piezo Injector Close-Coupled By-pass type

16 Valve EGR with cooler Timing Chain
(1800bar) DPF

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 R - Engine 6

Main Features – Cylinder Block

21122-2F000 Oil jet

Oil jet cap

4
2

5
3
1 21123-2F000

• Main bearing cap : Watch out direction and sequence • Oil jet cap color :
• Main bearing cap bolt tightening torque : 5kgf.m + 120˚ - Standard engine: Colorless CAP
• Deep skirt iron block + separated bearing cap - Low power engine : Orange color CAP
• Thrust bearing is located on 4th journal bearing
• Oil level sensor (Only Europe) → ECM → Warning on Cluster

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 R - Engine 7

Main Features – Engine Oil Filter

Oil filter and Oil cooler

Coolant Inlet

Element

Coolant outlet
Oil Filter
Cap O-ring

Oil Cooler Cap

Drain bolt O-ring

• Installed on front side of engine
• Plastic oil filter housing
Pre-drain bolt
• Aluminum oil cooler
• ECO-friendly oil filter (replace element and O-ring)

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 R - Engine 8

Main Features – Cylinder Head

17 18 19 20
Grade
(A)
1 2 3 4 5 6 7 8
(B) 9 10 11 12
(C)
Gasket sealant apply

1 2 3 4

8 7 6 5
Gasket grade

• Aluminum cylinder head (common use for 2L & 2.2L) 16 15 14 13

• Cam carrier applied

• Tightening torque Installation sequence of camshaft cap bolt

- Head cylinder bolt : 8.0kgf.m + 120° + 120°

• 3 Kinds head gasket (according to thickness of gasket)

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 R - Engine 9

Main Features – Cylinder Head Assemble on

cam carrier

Oil Separator

BOLT (19EA)
Assemble on
cylinder head

Yellow Making

• Plastic head cover

• Oil separator is Combined with cylinder head
• When installing breather hose, watch out direction and location
• When assembling vacuum pump, watch out O-ring
Caution) O-Ring

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 R - Engine 10

Main Features – Valve Train

Spread engine oil Spread engine oil

on surface on surface

• Perpendicular style valve (DOHC 16 Valve)

• End Pivot Roller Follower
• When assembling valve, spread engine oil on surface.

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 R - Engine 11

Jiggle valve
Main Features – Cooling

EGR & Thermostat

Housing
To heater
From heater EGR valve
Water inlet
fitting
T/C inlet
From radiator

EGR cooler
Oil cooler
EGR cooler hose
hose
Oil cooler
return
hose Water
Outlet
pipe
Oil cooler &
Filter module To
Radiator
• EGR valve and Turbocharger is cooled by coolant
• Inlet control (opening temp. : 82℃, fully open 95℃)
Water pump
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 R - Engine 12

Main Features – Crankshaft and Piston

Isolation damper
pulley Connecting rod

• Applied isolation damper pulley Damper Pulley

TDC Mark
- Reduced fluctuation of crankshaft angular speed.
- Reduced noise of driving belt and increased durability.
- Crank bolt tightening torque : 20kg·fm + 60 ˚
Timing Chain Cover
• Connecting rod bolt tightening torque : 3.0 kgf·m + 90˚ TDC Mark

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 R - Engine 13

Main Features – Balance Shaft Module

Gear Teeth
Oil Strainer Inspection
Plastic Pin

Oil Pump

• Applied balance shaft module, which is combined with oil pump and oil strainer.
• Installation procedure
- Install BSM → Remove the plastic pin on the BSM assembly → Confirm BSM rotation smoothly

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 R - Engine 14

Main Features – Timing

Timing Mark

• Scissors gear (intake and exhaust cam sprocket)

• 2 Timing chains are used (Crankshaft and HP pump, HP pump and Camshaft)
• Timing chain type : bush chain (pitch 9.525mm)
• 2 Hydraulic auto-tensioners with an oil jet for timing chain
• Do not re-use chain guide bolts

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 R - Engine 15

Main Features – Timing Cover Sealant

Bolt side

Sealant Plug

Sealant

Cupper washer

: Do not re-use plug and washer

Oil seal

Confirm
different

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 R - Engine 16

Main Features – Intake and Exhaust System

<Electrical Actuator>

<Turbocharger>

• DC motor type VGT actuator <System Diagram>

- Improved accurate VGT control

- Possible to self diagnosis (feedback signal)
- R 2.0 : Spur Gear, R2.2 : Worm Gear (Hella)
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 R - Engine 17

Main Features – Intake and Exhaust System

Intercooler

Electrical VGT

Electrical ACV (Air Control Valve)

• Control type : DC Motor
• Purpose :
- For reducing dieseling at IG OFF (Valve is closed)
- For controlling intake air for DPF regeneration
Electrical SCV • Size : Φ57 mm

By-pass type EGR cooler

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 R - Engine 18

Main Features – Intake and Exhaust System

Coolant
inlet/outlet
● EGR Valve

CAM Position Sensor DC Motor

EGR Gas
Coupling (Outlet)

EGR Gas
(inlet)
Return Spring Valve shaft
• Purpose : Exhaust gas recirculation for reducing NOx
Valve Disc • Control type : DC Motor (Position sensor is applied)
- Precise EGR control
● EGR Cooler - By-pass valve applied (EGR cooler, under 55℃) )
High Temp.
Exhaust Gas • Size : Φ30 mm
• Motor power : 300N (30N for D engine VGT actuator)
• Increased efficiency of EGR cooler

Cooled Exhaust Gas

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 R - Engine 19

Main Features – Intake and Exhaust System

Swirl control valve

Coupling

• Swirl control valve : DC Motor type

• Motor and flap are connected by coupling
• Initialization : 3 times after IG OFF (Mechanical end point learning)
• Symptom if stuck
- More PM
- Frequent DPF regeneration
- Poor fuel economy
- DPF defective with DTC

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 R - Engine 20

Main Features – Intake and Exhaust System

Tightening Torque : 4.0~4.5kgf.m (10 pcs)

Watch out direction

of bush (4 pcs)

When assembling,
Don’t miss O-ring

EGR Pipe bolt : 1.0~1.2kgf.m

6 3 10 8 5 Inlet port
9 11 4 7 2 1
1,2 : Tightening torque(2.0~2.7kgf.m)
3~11 : Tightening torque(1.9~2.4kgf.m)
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 R - Engine 21

Main Features – Intake and Exhaust System

Intercooler hose clamp
Clamp Cap Information (Torque control cap)

• A : Clamp cap,
• B : Torque control cap Before torque After torque After removing the cap

Service procedure
1) Plier out the intake 2) Loosen the clamp
manifold clamp cap. using a flat head
screwdriver.

• After disassembling clamp of intercooler hose, replace new one

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 R - Engine 22

Main Features – DPF (Diesel Particulate Filter)

Lambda Sensor
DOC

Exhaust Gas
Temperature Sensor

DPF

Euro-4 Euro-5
Differential Pressure
Sensor

Close-Coupled DPF

• Euro 5 : with DPF, Euro 4 : without DPF

• Different spec for MT and AT (more loaded for MT due to lower exhaust gas temperature)
• Close-Coupled Diesel Particulate Filter applied : Increases passive regeneration
→ Increased durability and reduced fuel consumption, because of reducing active regeneration
• Exhaust gas temperature sensor on turbo charger eliminated (due to modeling technology)
• DOC (Diesel Oxidation Catalyst) : CO, HC control

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 R - Engine 23

Main Features – DPF (Diesel Particulate Filter)

Post injection
Exhaust gas

DOC

Pressure /temp sensor PM accumulated & burning

Catalytic filter

Regeneration mode condition

ECM
• Driving distance: every 1,000km
• Engine RPM: 1,000RPM ~ 4,000RPM
• Vehicle speed : over 5km/h
• Coolant temperature : over 40℃
Notice) shock or noise may occurred by changing torque during regeneration

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 R - Engine 24

Main Features – DPF (Diesel Particulate Filter)

1. DPF melting 3. Soot Leak
- Abnormal regeneration (DPF melting) - DPF crack or HC excess

2. DPF white smoke 4. Soot excess

- Abnormal regeneration (DPF melting) - Soot, oil and fuel excess

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 R - Engine 25

Main Features – Fuel Tank ENGINE

Regulator
ⓐ

Main filter Sub. filter

ⓑ From Sub. filter

ⓐ Pump
Return

Main Sender and

Fuel Pump(140L/h)

Sub. Sender
Jet pump(44L/h)

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 R - Engine 26

Main Features – Fuel Tank

Warnin
Gauge Full 7/8 6/8 5/8 2/1 3/8 2/8 1/8 Empty
g Lamp
Fuel
Amount (ℓ) 62.5 55.6 48.6 41.7 34.8 27.8 20.9 13.9 9 7

Main 6.3 28.4 46.8 66.7 73.9 88.1

Resistance of
Sub 11.6 34.1 55.9 77.6 100
Sender (Ω)
Total 17.9 40.4 62.2 83.9 106.3 128.4 146.8 166.7 173.9 188.1

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 R - Engine 27

Main Features – Glow Plug

ST
ON
Key Switch OFF

PWM Signal
From ECM
VB > 11.5
Duty control

FET Relay
output

VB ≦ 11.5
Duty 100%

Duty control
STEP 1 STEP 2 STEP 3 STEP 4 STEP 5

ECM FET RELAY

Glow Plug
Temp.
Ceramic Glow Plug
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 R - Engine 28

Main Features – EPMS (Electrical Power Management System)

▶ Battery Sensor : Measure Temperature, Voltage, Current

▶ SOC (State Of Charge)

ECM

B+ Supply Battery Sensor Decide charging voltage C Terminal

Monitoring Vehicle
LIN
SOC conditions
Alternator

FR Terminal
TPS VSS RPM

※C - Terminal : Communication with alternator

FR - Terminal : Field Coil Reflector.

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 R - Engine 29

System Component
▶ Alternator : 3 Pins ▶ Calculate SOC
FR Terminal
▶ Wake-up Mode (each 8 hours)

L Terminal

C Terminal
Send SOC Request
information SOC information
Decel.
Accel.
Accel.
Vehicle Speed

Voltage

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 R - Engine 30

Comparison – 2.2L Euro 5 and Euro 4

Items XM 2.2 Euro-5 XM 2.2 Euro-4 Remarks

6 Floors 4 Floors

- Different capacity
EGR Cooler
EGR cooler

28416-2F000 28416-2F320

Ceramic Metal

Glow Plug

36710-2F000 36710-2F100

Catalytic - Different catalytic

Converter converter (DPF, WCC)

DPF WCC

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 R - Engine 31

Comparison (2.0/2.2)
Items Parts No. ( 2.2L) Parts No. ( 2.0L) Figure Remarks

Cylinder - Bore size is difference

21111-2F050 21111-2F100
Block (2.0L: Φ84, 2.2L: Φ85.4)

Cylinder Head - Gasket bore size is difference

22311-2F100 22311-2F000
Gasket (2.0L: Φ85, 2.2L: Φ86.2)

- Crank pin diameter is difference

(2.0L: Φ48 2.2L: Φ52)
Crankshaft 23110-2F110 23110-2F010
- Stroke is difference
(2.0L: Φ90 2.2L: Φ96)

- Bore size is difference

Piston 23400-2F101 23400-2F001
(2.0L: Φ84, 2.2L: Φ85.4)

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 R - Engine 32

Comparison (2.0/2.2)
Items Parts No. ( 2.2L) Parts No. ( 2.0L) Figure Remarks

- Crank side diameter is difference

Connecting (2.0L: Φ51, 2.2L: Φ55)
23510-2F100 23510-2F000
Rod - Connecting Rod length is difference
(2.0L: 149, 2.2L: 145)

- Turbine and compressor wheel size

is difference
Turbocharger 28231-2F100 28231-2F000
-Actuator supplier is different
(2.2L hella-4pins, 2.0L seohan-5pins)

Catalytic - 2.2L: CPF (EU-5)

28990-2F020 28940-2F110
Converter - 2.0L: WCC (EU-4)

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 R - Engine 33

Fuel System – Overview

Common Rail Injector
Rail Pressure
Sensor

FPCV
(Fuel Pressure
Control Valve)

High Pressure Pump

RPCV
(Rail Pressure Control Valve)

• Max. 1800 bar fuel pressure

• Piezo type injector (injection response, timing and amount is improved than solenoid type injector)
• ECM : EDC17CP (32bit)
• Low pressure pump : electrical type (same as D-engine)
• Fuel pressure control : Inlet and outlet control (FPCV and RPCV)

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 R - Engine 34

Fuel System – Injector Pressure valve

Connector

Start injection

Power supplied Piezo

(Charge) expansion

Amplification
Hydraulic
Opened Control valve coupler
Nozzle needle open Piezo-actuator
Nozzle
needle
Pressure
control valve

Stop injection

Power supplied Piezo

IQA Matrix Code (Discharge) contraction

• CRI 3.2
Pressure reduction
• Applied IQA (Injector Quantity Adjustment)
Closed Closed
• Operating Voltage / Ampere : Max. 156V / Max. 17A Nozzle needle control valve
• 8 holes

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 R - Engine 35

Fuel System – Injector

Operating principle (hydraulic coupler)

Voltage
Low pressure line
(1~10bar) time

Piezo Amplifier Pressure

P system
Hydraulic Coupler
(Amplifier) time

time
Rail pressure
Amplifier pre. Leakage Refilling
10 bar (Ps>Psys) (Ps<Psys)
1 bar

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 R - Engine 36

Fuel System – Injector

Operating principle (pressure control part)

Initial position Needle opened Needle closed

Control valve

Control outlet
Volume Outlet Inlet
By-pass By-pass By-pass
Inlet Closed opened
Inlet Inlet

Needle

Rail pressure
Leakage pressure
Control volume pressure

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 R - Engine 37

Fuel System – Injector

Piezo injector (comparison with Solenoid injector)

- Injector response : no delay time between the voltage and the stroke

- Control current : only controls injection starting current and ending current.

[Piezo- Injector]

Injector voltage

Pilot2 Pilot1 Main

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 R - Engine 38

Fuel System – High Pressure Pump

Suction Valve
Cylinder head
High pressure
outlet
By-pass
FPCV piston-check-valve
Plunger

Tappet body

Shaft sealing ring Spring seat

(pump side) Overflow Valve

Shaft sealing ring Roller shoe

(motor side) Roller

Cham shaft

• CP 4.1 (Max. 1800bar)

• Max. revolution speed : 4500rpm
• FPCV (Fuel Pressure Control Valve) : Control fuel pressure from HP pump to common rail.
• Improved passage of shaft lubrication
→ If pressure is increased between shaft sealing ring (Motor and pump side), fuel is returned (by-pass)

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 R - Engine 39

Fuel System – Common Rail

Rail Pressure Sensor Throttle Rail Pressure Control Valve

• Throttle : Installed in common rail connection side with injector pipe

- Purpose : Reduce fluctuation of fuel pressure, which is supplied to injector
• Capacity : 21 ㎤
• Applied RPCV : Control rail pressure (control amount of return fuel)

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 R - Engine 40

Fuel System – Return Line

Back-leak Rail Installation & Removal
• In order to overcome 1~10bar in return line, connector
shape, installation and removal of return linen is difference.
- Double locking structure : It is for preventing leakage.
• For normal operation of the coupler, 1~10bar remains on
the fuel return line (low pressure line).

Injector connection side

Plug Bush

Plug fixing (4EA)

Plug

Connector of fuel return hose

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 R - Engine 41

Fuel System – Return Line

Installation

Before assembling the Push the plug to Confirm installed Install plug bush until
return line, confirm plug vertical direction until condition by moving plug hear click sound
fixing condition and plug make clicker sound
bush is lifted. from injector nipple

Removal Case study

Press both knob and lift Lift up plug vertical -Cause : One plug fixing is broken. Because of
up plug bush direction from injector excessive
nipple at lifted plug bush installation without the plug bush fully up.
- Symptom : Fuel leaks from the injector nipple
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 R - Engine 42

Sensors and Actuators - Overview

RPCV
RPS
FPCV
MAF
BPS ACV IAT Inter- Sensor
Piezo injector cooler

CMP
SCV
Fuel Temp. EGR
Sensor cooler
Glow Plug EGR Valve
ECT
sensor VGT
CKP EGR by-pass Lambda
Valve Sensor
LP pump EGR Solenoid
Valve DOC
EGTS
DPF
Sensors LP line
APS
Actuators HP line

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 R - Engine 43

Sensors and Actuators - RPCV

Valve housing Connector pins
Anchor bolt
Retaining Ring
Backflow
Anchor plate
Adjusting Shin
Spring
Valve body

RPCV (Piezo type) Filter

Ball
: Normal opened type
Bite edge Flange screw Coil

• RPCV (Rail Pressure Control Valve)

- In order to maintain rail pressure, RPCV control valve according
engine condition. (received signal from ECM)
- Operating ampere : 0.15 ~ 1.8 A / Coil resistance : 3.42 ~ 3.78 Ω
• Normal opened type : Valve is opened at engine off
RPCV (Solenoid type) - Fuel is drained in fuel system. It is for improving starting delayed
: Normal Closed type caused by fuel contraction at cold condition
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 R - Engine 44

Sensors and Actuators – Rail Pressure Sensor

• RPS4.2 : Measure pressure in common rail (Max. 2000bar)

• Failsafe

- Rail pressure 360bar (36MPa) fixed

- Engine speed limitation - 3000 rpm

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 R - Engine 45

Sensors and Actuators – CKP and CMP

CMP

CKP

CKP

CMP

• CMP : Hall IC type sensor

• CKP : Hall IC type sensor
• CKP target wheel : magnetic encoder
Magnetic encoder

Copyright ⓒ 2009 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
 R - Engine 46

Sensors and Actuators – Lambda Sensor

λ 0.65 0.70 0.80 0.90 1.016 1.18 1.43 1.70 2.42 Air
Pumping
Ampere -2.22 -1.82 -1.11 -0.50 0.00 0.33 0.67 0.94 1.38 2.54
(mA)

• Measure density of oxygen in emission gas

- Bosch LSU
• Heating and oxygen pumping type
• For set up target EGR and fuel mean adaptation

Copyright ⓒ 2009 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
 R - Engine 47

Sensors and Actuators – Boost Pressure Sensor

Output Voltage (V)

• Measure pressure in intake manifold

• For controlling turbocharger
• Max. 4bar Pressure (kPa)

Copyright ⓒ 2009 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
 R - Engine 48

Sensors and Actuators – DPS and EGTS

Output (V)

4.5

EGTS
1

DPS
0 100
Pressure (kpa)

DPS
• Detect the diff pressure between DPF inlet (upstream) and outlet (downstream) for DPF regeneration
• Output voltage: 1V ~ 4.5
EGTS
• Measure the temperature of DPF for regeneration
• Located between DOC and DPF

Copyright ⓒ 2009 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
 R - Engine 49

Sensors and Actuators – MAF Sensor and IAT 1,2

MAF Sensor

• Type : Hot-film type with IAT 2 (Bosch HFM-7)

• Used for injection amount and EGR amount control
• IAT 1 is installed on intake hose (after intercooler)
• Failsafe : Limp-home (limited injection)

Copyright ⓒ 2009 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
 R - Engine 50

Sensors and Actuators – Fuel Temperature Sensor

Temperature (℃) Resistance (㏀)

-20 13.4 ~ 17.7

-10 8.24 ~ 10.66
0 5.23 ~ 6.62
20 2.26 ~ 2.76
40 1.08 ~ 1.28
Fuel Temp. Sensor 60 0.56 ~ 0.64
80 0.3 ~ 0.34
120 0.11 ~ 0.12

• Detects the fuel inlet temperature at fuel line.

• If the fuel temperature is over 80 ℃, max. engine rpm is limited 3000rpm
• Located on return line

Copyright ⓒ 2009 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
 R - Engine 51

Sensors and Actuators – APS 1,2 and Brake S/W

• Sensor 1

Brake S/W - For injection amount and timing

(torque request signal)
• Sensor 2
- Sensor 1 monitoring,
APS 1, 2 preventing sudden starting
• Failsafe
- 1,250 rpm fix

Copyright ⓒ 2009 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.