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C100 Service Training Manual :

Engine Mechanical (HFV-3.2L DOHC)


Participants Handout

01.2-3
C100 (3.2 L) Engine Mechanical Participants Handout

Table Of Contents
Engine General ....... 5 Engine Mechanical ......... 8 Engine Lubrication 21 Engine Timing System . 22 Accessory Belt ... 43 Air Intake System .. 44 Exhaust System .... 45 Engine Cooling System ... 46 Fuel Supply system .. 48 Evaporative Emission Control System ...... 54

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01.2-4
C100 (3.2 L) Engine Mechanical Participants Handout

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3.2L Engine : Engine general


Engine number (HFV6 3.2D)

01.2-5
C100 (3.2 L) Engine Mechanical Participants Handout

1. Component ID 2. Engine Broadcast Code 3. Plant Code (H=Holden) 4. Build Year (06 = 2006) 5. Julian Date (070 = built on day 70) 6. Build Sequence Number

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01.2-6
C100 (3.2 L) Engine Mechanical Participants Handout

3.2L Engine : Engine general


Specifications
APPLICATION Max Speed (MT/AT) Vehicle Performance Min Turning Ratio (m) 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 Type Coil Ignition Plug Ignition sequence Maker Type Clearance mm 3.2L DOHC kph/ kph

5.75 m 6 Cylinder(HFV6) 89 x 85.6 3.195 10.2 : 1 TBD TBD 690 8 1-2-3-4-5-6 Direct Ignition System 1-2-3-4-5-6 TBD TBD TBD

Type Oil Type and Grade Filter Lubrication Oil Capacity (w/filter) Type Oil Engine run Pump Pressure Relief

Forced feed API SJ grade, SAE 0W 30 Synthetic Spin-on (Full Flow) 7.4 L Gerotor TBD TBD

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3.2L Engine : Engine general


Specifications
APPLICATION Type Coolant Capacity (L) W ater Pump Type Radiator W idth Core Height Thickness Surge Tank Pressure Valve open Vaccum Valve open Type Thermostat Start to open ( ) Completely open ( ) Completely close ( ) Type Fan Blades Fan Diameter 3.2L DOHC Pressurized 9 Centrifugal Cross 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

01.2-7
C100 (3.2 L) Engine Mechanical Participants Handout

Cooling

Type Type Fuel Delivery Fuel Pump Displacement Fuel pressure Filter Type Fuel Tank Capacity Type Starter Alternator Power Power Type Battery Capacity Cold Cranking Ampere

MPI Electric Motor TBD TBD Cartridge 65 L Planetary Gear Reduction 1.4KW 120A MF 12V- 60AH 650 CCA
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01.2-8
C100 (3.2 L) Engine Mechanical Participants Handout

3.2L Engine : Engine mechanical


General description The V6 engine features a closed V, deep skirt die cast aluminium cylinder block with cast iron cylinder liners, internally balanced crankcase, full length water jackets and six bolt main bearing caps. The cylinders are arranged in two banks of three with a 60 degree included angle between the two banks. The rear bank of cylinders consists of number 135 cylinders (BANK 1) and the front bank of cylinders consists of number 246 (BANK 2). The engine firing order is 123456. Each aluminium cylinder head is fitted with hardened valve seats and four valves per cylinder: two intake and two exhaust. The valves are operated by two camshafts (DOHC) per cylinder bank, one each for intake and exhaust valves. Variable camshaft timing is provided via four actuators fitted at the front of each camshaft. The crankshaft is manufactured from forged steel. A reluctor wheel is pressed in place onto the rear of the crankshaft for the crankshaft position sensor.The connecting rods are manufactured from powdered metal and the rod cap is separated during the manufacturing process using the fractured method. This creates a stronger, visually seamless rod to cap union. Features and Benefits Dual Continuously Variable Cam Phasing (Reduced fuel consumption, increased performance) 24-Valve Cylinder Head (Improved performance due to increased air flow) Closed Coupled Catalytic Converter (Achieve Euro 4 limits) Electronic Throttle Control (Improved drive ability comfort) Roller finger follower and hydraulic valve lash adjuster (Low friction, maintenance-free valve train) Chain Drive Timing System (life-time maintenance free) Poly-V-Belt Accessory Drive with automatic Belt Tensioner

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3.2L Engine : Engine mechanical


Engine over view

01.2-9
C100 (3.2 L) Engine Mechanical Participants Handout

Bank 2

Bank 1

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01.2-10
C100 (3.2 L) Engine Mechanical Participants Handout

3.2L Engine : Engine mechanical


Exploded view (Cylinder head cover assembly)

1. 2. 3. 4. 5. 6. 7. 8. 9.

Camshaft Cover, Bank 2 Camshaft Cover Gasket, Bank 2 Camshaft Cover, Bank 1 Camshaft Cover Gasket, Bank 1 Camshaft Cover Spark Plug Port Seal Camshaft Cover Bolt Camshaft Cover Bolt Insulator Ignition Coil Bolt Thread Insert Oil Fill Cap

10. Oil Fill ORing 11. Camshaft Cover PCV Fitting, Bank 2 12. Camshaft Cover PCV Fitting Orifice, Bank 1 13. Camshaft Cover PCV Fitting ORing, Bank 2 14. Ignition Coil 15. Ignition Coil Bolt 16. Spark Plug

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3.2L Engine : Engine mechanical


Exploded view (Cylinder head assembly)

01.2-11
C100 (3.2 L) Engine Mechanical Participants Handout

1. 2. 3. 4. 5. 6. 7. 8. 9.

Cylinder Head, Bank 2 Cylinder Head, Bank 1 Cylinder Head Gasket, Bank 2 Cylinder Head Gasket, Bank 1 Cylinder Head Bolt Cylinder Head Front Bolt Cylinder Head Coolant Hole Threaded Plug Spark Plug Sleeve Cylinder Head Oil Gallery Expansion Plug

15. Valve Spring 16. Valve Spring Cap 17. Valve Stem Key 18. Cylinder Head Camshaft Front Thrust Bearing Cap 19. Camshaft Oil Seal Ring 20. Exhaust Camshaft, Bank 2 21. Intake Camshaft, Bank 2 22. Intake Camshaft, Bank 1 23. Exhaust Camshaft, Bank 1 24. Cylinder Head Camshaft Cap Intermediate 25. Cylinder Head Camshaft Cap Bolt 26. Cylinder Head Oil Galley Check Valve 27. Engine Coolant Temperature Sensor

10. Exhaust Valve 11. Intake Valve 12. Valve Rocker Arm Assembly 13. Hydraulic Valve Lash Adjuster Assembly 14. Valve Stem Oil Seal

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01.2-12
C100 (3.2 L) Engine Mechanical Participants Handout

3.2L Engine : Engine mechanical


Exploded view (Intake manifold assembly)

1. 2. 3. 4. 5. 6. 7. 8. 9.

Upper Intake Manifold Throttle Body Assembly Upper Intake Manifold - to - Lower Intake Manifold Gasket Fuel Injector Wiring Harness Fuel Rail Fuel Injector Lower Intake Manifold Lower Intake Manifold - to - Cylinder Head Gasket Variable Intake Manifold (VIM) Control Valve

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3.2L Engine : Engine mechanical


Exploded view (Front cover)

01.2-13
C100 (3.2 L) Engine Mechanical Participants Handout

1. 2. 3. 4. 5. 6. 7. 8. 9.

Engine Front Cover Locating Pin Engine Front Cover Bolt, M10 Engine Front Cover Engine Front Cover Gasket Engine Front Cover Bolt, M8 Engine Front Cover Seal Coolant Pump Assembly Coolant Pump Bolt Coolant Pump Gasket

10. Coolant Pump Pulley 11. Coolant Pump Pulley Bolt 12. Crankshaft Balancer 13. Crankshaft Balancer Bolt 14. Camshaft Position Sensor 15. Camshaft Position Sensor Oring 16. Camshaft Position Sensor Bolt 17. Camshaft Position Actuator Solenoid Valve 18. Camshaft Position Actuator Solenoid Valve Bolt 19. Camshaft Position Actuator Solenoid Valve Seal
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01.2-14
C100 (3.2 L) Engine Mechanical Participants Handout

3.2L Engine : Engine mechanical


Exploded view (Timing chain components)

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 13. 14. 15. 16. 17.


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18.

Crankshaft Sprocket Lower Primary Timing Chain Guide Primary Timing Chain Tensioner Primary Timing Chain Tensioner Bolt Lower Primary Timing Chain Guide Bolt Primary Timing Chain Upper Primary Timing Chain Guide Upper Primary Timing Chain Guide Bolt Camshaft Intermediate Driveshaft Sprocket Bolt Camshaft Intermediate Driveshaft Sprocket, Bank 2 Camshaft Intermediate Driveshaft Sprocket, Bank 1 Secondary Timing Chain, Bank 2 Secondary Timing Chain Guide Bolt, Bank 2 Secondary Timing Chain Shoe, Bank 2 Secondary Timing Chain Shoe Bolt, Bank 2 Secondary Timing Chain Tensioner, Bank 2 Secondary Timing Chain Tensioner Bolt, Bank 2

19. Secondary Timing Chain Tensioner Gasket, Bank 2 20. Secondary Timing Chain, Bank 1 21. Secondary Timing Chain Guide, Bank 1 22. Secondary Timing Chain Guide Bolt, Bank 1 23. Secondary Timing Chain Shoe, Bank 1 24. Secondary Timing Chain Shoe Bolt, Bank 1 25. Secondary Timing Chain Tensioner, Bank 1 26. Secondary Timing Chain Tensioner Bolt, Bank 1 27. Secondary Timing Chain Tensioner Gasket, Bank 1 28. Exhaust Camshaft Position Actuator, Bank 2 29. Intake Camshaft Position Actuator, Bank 2 30. Camshaft Position Actuator Bolt 31. Exhaust Camshaft Position Actuator, Bank 1 32. Intake Camshaft Position Actuator, Bank 1

3.2L Engine : Engine mechanical


Exploded view (Engine block assembly)

01.2-15
C100 (3.2 L) Engine Mechanical Participants Handout

1. 2. 3. 4. 5. 6.

Piston and Connecting Rod Assembly Crankshaft Bearing Cap Crankshaft Bearing Thrust Cap Crankshaft Bearing Cap Inboard Bolt Crankshaft Bearing Cap Outboard Bolt Crankshaft Bearing Cap Side Bolt, Short Crankshaft Bearing Cap Side Bolt, Long Engine Block Oil Gallery Expansion Plug, 10 mm Crankshaft Crankshaft Sprocket Locating Pin

13. Crankshaft Upper Thrust Bearing #3 14. Engine Block Oil Gallery Expansion Plug, 14 mm 15. Engine Block Oil Gallery Threaded Plug, 14 mm 16. Engine Block Coolant Drain Threaded Plug, 14 mm 17. Engine Block Oil Gallery Threaded Plug, 20 mm 18. Engine Block Core Coolant Expansion Plug, 34.3mm 19. Transaxle Locating Pin 20. Crankshaft Rear Oil Seal Housing Assembly 21. Crankshaft Rear Oil Seal Housing Assembly Bolt 22. Oil Pan Locating Pin 23. Cylinder Head Locating Pin 24. Piston Oil Nozzle

7.

8. 9. 10. 11. 12.

Crankshaft Upper Bearing 25. Piston Oil Nozzle Bolt Crankshaft Lower Bearing
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01.2-16
C100 (3.2 L) Engine Mechanical Participants Handout

3.2L Engine : Engine mechanical


Exploded view Piston & connecting rod)

1. 2. 3. 4. 5. 6. 7. 8. 9.

Connecting Rod Connecting Rod Bolt Connecting Rod Bush Lower Connecting Rod Bearing Higher Connecting Rod Bearing Piston Piston Pin Piston Pin Retainer Piston Upper Compression Ring

10. Piston Lower Compression Ring 11. Piston Oil Control Rail Ring
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12. Piston Oil Control Ring Spacer

3.2L Engine : Engine mechanical


Exploded view (Oil pan assembly)

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C100 (3.2 L) Engine Mechanical Participants Handout

1. 2. 3. 4. 5.

Oil Deflector Oil Pump Suction Pipe Oil Pan Oil Pan Drain Plug Engine Oil Level Sensor

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01.2-18
C100 (3.2 L) Engine Mechanical Participants Handout

3.2L Engine : Engine mechanical


Exploded view (Engine mount system)

1. 2. 3. 4. 5. 6. 7.

Transaxle Front Mount Assembly Engine Mount Adapter Support Bracket Engine Mount Assembly Cradle Assembly Transaxle Mount Assembly Transaxle Rear Mount Bracket Transaxle Rear Mount

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3.2L Engine : Engine mechanical


Camshaft and Bearings Three timing chains are fitted (primary, righthand secondary and left hand secondary). The primary timing chain connects the crankshaft sprocket with the lefthand and righthand intermediate drive shaft sprockets. ** Camshaft bolt tightening sequence : 1. Tighten the camshaft bearing cap attaching bolt to 10 Nm (89 lb in) as below sequence . 2 Loosen the center intake camshaft bearing cap bolts 1 and 2, and the center exhaust camshaft bearing cap bolts 3 and 4. 3. Retighten the center camshaft bearing cap bolts 1, 2, 3 and 4 as below sequence

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C100 (3.2 L) Engine Mechanical Participants Handout

[ Bank 1 camshaft bearing direction ]

[ Bank 2 camshaft bearing direction ]

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01.2-20
C100 (3.2 L) Engine Mechanical Participants Handout

3.2L Engine : Engine mechanical


Piston and Rings The piston assembly is fitted with two low tension compression rings and one multi-piece oil control ring. The top compression ring is plasma sprayed, while the second compression ring is cast iron Napier. The oil control ring incorporates a steel expander and two Chrome plated steel rails. The cast aluminium pistons incorporate a polymer coated skirt to reduce friction.

[ Piston and Rings ]


1. 2. 3. 4. 5. Lower oil control ring position Upper oil control ring position Top ring position Oil control ring expander position Second ring position

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[ Piston rings installation ]

3.2L Engine : Engine lubrication


Oil pump

01.2-21
C100 (3.2 L) Engine Mechanical Participants Handout

1. 2. 3. 4. 5. 6. 7. 8. 9.

Lower Primary Timing Chain Guide Lower Primary Timing Chain Guide Bolt Oil Pump Housing Oil Pump Cover Oil Pump Gerotor Outer Ring Oil Pump Gerotor Inner Ring Oil Pump Cover Bolt Oil Pressure Relief Valve Bore Plug Oil Pressure Relief Valve Spring

10. Oil Pressure Relief Valve 11. Oil Pressure Relief Valve Bore Plug Retainer Clip 12. Oil Pump Bolt
ITEMS Lub. Type Engine Oil Oil Replacement with filter Oil Capacity (w/filter) Oil Pump Pressure Forced feed API SJ grade SAE 0W -30 Synthetic oil . Normal condition : 30,000 km / 12 months . Severe condition : 15,000 km / 6 months 7.4L 69 Kpa at Idle (138 Kpa at 2000 rpm) 3.2L DOHC

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01.2-22
C100 (3.2 L) Engine Mechanical Participants Handout

3.2L Engine : Engine timing system


Timing chains

1. 2. 3. 4. 5. 6. 7. 8.

Intake Camshaft Position (CMP) Actuator Timing Mark Bank 2 Secondary Timing Chain Bright Plated Link Bank 2 Exhaust Camshaft Position (CMP) Actuator Timing Mark Bank 2 Secondary Timing Chain Bank 2 Primary Timing chain Camshaft Intermediate Drive Chain Sprocket Timing Mark Bank 2 Primary Camshaft Intermediate Drive Chain Sprocket Bank 2 Primary Timing Chain Bright Plated Link

9.

Camshaft Intermediate Drive Chain Sprocket Timing Mark Bank 2

10. Camshaft Intermediate Drive Chain Sprocket Bank 1 11. Crankshaft Sprocket 12. Crankshaft Sprocket Timing Mark 13. Secondary Timing chain Bright Plated Link Bank1 14. Camshaft Intermediate Drive Chain Bank 1 15. Exhaust Camshaft Position (CMP) Actuator Timing Mark Bank 1 16. Inlet Camshaft Position (CMP) Actuator Timing Mark Bank 1

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3.2L Engine : Engine timing system


Primary and Bank 2 secondary timing chains

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C100 (3.2 L) Engine Mechanical Participants Handout

1. 2. 3. 4. 5. 6. 7. 8. 9.

Intake Camshaft Position (CMP) Actuator Timing Mark Bank 2 Secondary Timing Chain Bright Plated Link Bank2 Exhaust Camshaft Position (CMP) Actuator Timing Mark Bank 2 Secondary Timing Chain Bank 2 Primary Timing Chain Camshaft Intermediate Driveshaft Sprocket Timing Mark Bank 2 Camshaft Intermediate Driveshaft Sprocket Bank2 Primary Timing Chain Bright Plated Link Camshaft Intermediate Driveshaft Sprocket Timing Mark Bank 2

10. Camshaft Intermediate Drive shaft Sprocket Bank1 11. Crankshaft Sprocket 12. Crankshaft Sprocket Timing Mark
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01.2-24
C100 (3.2 L) Engine Mechanical Participants Handout

3.2L Engine : Engine timing system


Bank 2 secondary timing chain installation procedure - 1 1. Install the crankshaft sprocket (1) onto the crankshaft (2) by aligning the keyway to the key on the crankshaft. 2. Slide the crankshaft sprocket on the crankshaft until the crankshaft sprocket contacts the step in the crankshaft. Note : Ensure that the crankshaft sprocket is installed with the timing mark (1) visible. CAUTION : In order to install Tool No. EN 46105 onto the camshafts, rotate the camshafts in an anticlockwise direction. There should be no need to rotate the camshaft more than 45 degrees.3. Install Tool No. EN 461051 (1) onto the rear of the bank 2 cylinder head camshafts (2), and Tool No. EN 461052 onto the rear of the bank 1 cylinder head camshafts.

CAUTION : All camshafts must be locked in place before installation of any timing chains. 4. Ensure that Tool No. EN 46105 is fully seated onto the camshafts.
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3.2L Engine : Engine timing system


Bank 2 secondary timing chain installation procedure - 2 5. Using Tool No. EN46111 (1), rotate the crankshaft in a clockwise direction until the crankshaft sprocket timing mark (2) is aligned with the indexing mark (3) on the oil pump housing. 6. Install the bank 2 secondary timing chain (1) aligning the chain in the following manner:

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C100 (3.2 L) Engine Mechanical Participants Handout

A. Wrap the secondary timing chain around both bank 2 actuator drive sprockets. B. Ensure there are two bright links located on top of each of the camshaft actuator sprockets.

CAUTION : When aligning the bank 2 secondary timing chain to the camshaft actuator sprockets, ensure the circular timing marks on the sprocket are used, NOT the triangular mark. C. Align the bright plated timing chain link (1) with the bank 2 exhaust camshaft position actuator sprocket alignment circle mark (2).
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01.2-26
C100 (3.2 L) Engine Mechanical Participants Handout

3.2L Engine : Engine timing system


Bank 2 secondary timing chain installation procedure - 3 D. Align the bright plated timing chain link (1) with the intake camshaft position actuator sprocket alignment circle mark(2).

CAUTION : The bank 2 camshaft intermediate driveshaft sprocket (1) is marked with the letters LB and FRONT, and the bank 1 sprocket (2) is marked with the letters RB and FRONT Ensure the correct sprocket is used and the FRONT text is facing forwards when installed. 7. Ensure the bank 2 camshaft intermediate driveshaft sprocket is selected and orientated correctly. 8. Place the bank 2 secondary timing chain around the left hand camshaft intermediate driveshaft inner sprocket, with the bright plated timing chain link (1) aligned with the access hole (2) in the outer sprocket. 9. Install the bank 2 camshaft intermediate driveshaft sprocket to the cylinder block. Tighten
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Tighten the camshaft ntermediate driveshaft sprocket attaching bolt to 66 Nm (49 lbft).

3.2L Engine : Engine timing system


Bank 2 secondary timing chain installation procedure - 4 10. Verify the Bank 2 secondary timing chain timing mark alignments (1 to 6). CAUTION : The bank 2 secondary timing chain guide is marked with the letters LH. Ensure the correct shoe is used when installing to the Bank 2 side in this procedure and that the letters LH are facing the front of the vehicle when installed. 11. Ensure the bank 2 secondary timing chain guide is selected and orientated correctly.

01.2-27
C100 (3.2 L) Engine Mechanical Participants Handout

12. Install the bank 2 secondary timing chain guide (1). Tighten the secondary timing chain guide attaching bolt to 23 Nm (17 lbft).

CAUTION : The bank 2 secondary timing chain shoe (2) is marked with the letters LH on the back face of the timing chain shoe. Ensure the correct shoe is used when installing to the bank 2 side. 13. Ensure the bank 2 secondary timing chain shoe is selected and orientated correctly.
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C100 (3.2 L) Engine Mechanical Participants Handout

3.2L Engine : Engine timing system


Bank 2 secondary timing chain installation procedure - 5

14. Install the bank 2 secondary timing chain shoe (1). Note : Ensure secondary timing chain shoe is clear of the Bank 2 secondary timing chain tensioner mounting pad,before tightening the attaching bolt. Tighten Tighten the bank 2 secondary timing chain shoe bolt to 23 Nm (17 lbft). 15. Ensure the bank 2 secondary timing chain tensioner is selected and orientated correctly.

16. Reset the bank 2 secondary timing chain tensioner. Note : To reset the tensioner, use a suitably sized flat blade screwdriver (1) to wind the plunger in a clockwise direction, into the tensioner shaft (2).

17. Install the tensioner shaft (1) into the bank 2 secondary timing chain tensioner body (2).
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3.2L Engine : Engine timing system


Bank 2 secondary timing chain installation procedure - 6 CAUTION : If Tool No. EN 46112 (1) is not inserted into the tensioner body (2), the tensioner shaft (3) will remain in the locked position and no tension will be placed on the timing chain, this will cause damage to the engine. 18. Compress the tensioner shaft into the body and lock the bank 2 secondary timing chain tensioner by inserting Tool No. EN 46112 into the access hole in the side of the tensioner body. 19. Slowly release pressure on the bank 2 secondary timing chain tensioner. The tensioner should remain compressed. 20. Install a new bank 2 secondary timing chain tensioner gasket (1) to the tensioner (2). 21. Install the bank 2 secondary timing chain tensioner bolts through tensioner and gasket. 22. Ensure the bank 2 secondary timing chain tensioner mounting surface on the Bank 2 cylinder head does not have any burrs or defects that would affect the sealing of the new gasket. 23. Place the bank 2 secondary timing chain tensioner (2) into position and loosely install the bolts (1) to the cylinder head.

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C100 (3.2 L) Engine Mechanical Participants Handout

rev 01

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C100 (3.2 L) Engine Mechanical Participants Handout

3.2L Engine : Engine timing system


Bank 2 secondary timing chain installation procedure - 7 24. Verify the proper placement of the bank 2 secondary timing chain tensioner gasket tab (1). 25. Tighten the bank 2 secondary timing chain tensioner bolts (2). Tighten Tighten the bank 2 secondary timing chain tensioner bolts to 23 Nm (17 lbft). 26. Release the bank 2 secondary timing chain tensioner (1) by pulling out Tools No. EN 46112 (2) and unlocking the tensioner shaft. 27. Verify the bank 2 secondary timing chain timing mark alignments (1 to 6).

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3.2L Engine : Engine timing system


Primary timing chain installation procedure - 1 1. Install the bank 2 secondary timing chain components. CAUTION : The bank 1 camshaft intermediate driveshaft sprocket (2) is marked with the letters RB and FRONT, and the bank 2 sprocket (1) is marked with the letters LB and FRONT Ensure the correct sprocket is used and the FRONT text is facing forwards when installed. 2. Ensure the bank 1 camshaft intermediate driveshaft sprocket is selected and orientated correctly. 3. Install the bank 1 camshaft intermediate driveshaft sprocket(2). Tighten Tighten the bank 1 camshaft intermediate driveshaft sprocket attaching bolt to 65 Nm (48 lbft). 4. Ensure that the crankshaft sprocket timing mark (1) is aligned with the indexing mark (2) on the oil pump housing.

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C100 (3.2 L) Engine Mechanical Participants Handout

rev 01

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C100 (3.2 L) Engine Mechanical Participants Handout

3.2L Engine : Engine timing system


Primary timing chain installation procedure - 2 5. Install the primary timing chain(1).

6.

Wrap the primary timing chain around the large sprockets of each camshaft intermediate driveshaft sprocket and the crankshaft sprocket aligning the brightened chain links as follows:

A. The bank 2 camshaft intermediate driveshaft sprocket timing mark (1) will align with a bright plated primary timing chain link (2).

B. The bank 1 camshaft intermediate driveshaft sprocket Timing mark (1) will align with a bright plated primary timing chain link (2).

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3.2L Engine : Engine timing system


Primary timing chain installation procedure - 3 C. The crankshaft sprocket timing mark (1) will align with a bright plated timing chain link (2).

01.2-33
C100 (3.2 L) Engine Mechanical Participants Handout

7.

Ensure all the timing marks (1, 2 and 3) are properly aligned with the bright plated timing chain links (4, 5 and 6).

Note : Do not remove the primary timing chain lower guide (1). The primary timing chain lower guide is not serviced separately. If the primary timing chain lower guide must be replaced, the oil pump assembly (2) must be replaced.

8.

Ensure the primary timing chain upper guide is selected and orientated correctly.

rev 01

01.2-34
C100 (3.2 L) Engine Mechanical Participants Handout

3.2L Engine : Engine timing system


Primary timing chain installation procedure - 4 9. Install the primary timing chain upper guide (1). 10. Install the primary timing chain upper guide bolts (2). Tighten Tighten the primary timing chain upper guide bolts to 23 Nm (17 lbft).

11. Ensure that the primary timing chain tensioner is being installed.

12. Reset the primary timing chain tensioner. Note : To reset the tensioner, use a suitably sized flat blade screwdriver (1) to wind the plunger in a clockwise direction, into the tensioner shaft (2).

13. Install the tensioner shoe assembly (1) into the primary timing chain tensioner body (2).

rev 01

3.2L Engine : Engine timing system


Primary timing chain installation procedure - 5 CAUTION : If Tool No. EN 46112 (1) is not inserted into the tensioner body, the plunger will remain in the locked position and no tension will be placed on the timing chain. 14. Compress the shoe assembly into the body (2) and lock the primary timing chain tensioner by inserting Tool No. EN 46112 into the access hole in the side of the body. 15. Slowly release pressure on the primary timing chain tensioner. The primary timing chain tensioner should remain compressed. 16. Install a new primary timing chain tensioner gasket (1) to the tensioner (2). 17. Install the primary timing chain tensioner bolts (3) through tensioner and gasket. 18. Ensure the primary timing chain tensioner mounting surf ace on the engine block does not have any burrs or defects that would affect the sealing of the new gasket. 19. Place the primary timing chain tensioner (2) into position and loosely install the bolts (1) to the engine block.

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C100 (3.2 L) Engine Mechanical Participants Handout

rev 01

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C100 (3.2 L) Engine Mechanical Participants Handout

3.2L Engine : Engine timing system


Primary timing chain installation procedure - 6 20. Verify the proper placement of the primary timing chain tensioner gasket tab (1). 21. Tighten the primary timing chain tensioner bolts (2). Tighten Tighten the primary timing chain tensioner bolts to 23 Nm (17 lbft). 22. Release the primary timing chain tensioner (1) by pulling out Tool No. EN 46112 (2) and unlocking the tensioner shaft.

23. Verify the primary and bank 2 secondary timing chain timing mark alignments (1 to 12). 24. Remove Tool No. EN 46105 from the bank 2 and bank 1 cylinder head camshafts.

rev 01

3.2L Engine : Engine timing system


Bank 1 secondary timing chain installation procedure - 1 1. 2. Install the primary timing chain components. Using Tool No. EN46111 (1), rotate the crankshaft in a clockwise direction until the crankshaft sprocket timing mark (2) is aligned with the indexing mark (3) on the oil pump housing. CAUTION : In order to install Tool No. EN 46105 onto the camshafts, rotate the camshafts. There should be no need to rotate the camshaft more than 45 degrees.

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C100 (3.2 L) Engine Mechanical Participants Handout

3.

Install Tool No. EN 461051 (1) onto the rear of the bank 1cylinder head camshafts (2).

4.

Install Tool No. EN 461052 (1) onto the rear of the bank 2 cylinder head camshafts (2).

rev 01

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C100 (3.2 L) Engine Mechanical Participants Handout

3.2L Engine : Engine timing system


Bank 1 secondary timing chain installation procedure - 2 5. Install the bank 1 secondary timing chain (1) onto the camshaft actuators (2) and the right hand camshaft intermediate driveshaft sprocket (3) aligning the chain in the following manner:

A. Place the secondary timing chain around the bank 1 camshaft intermediate driveshaft outer sprocket, aligning the bright plated timing chain link (1) with the alignment access hole (2) in the inner sprocket.

B. Wrap the secondary timing chain around both bank 1 actuator drive sprockets.

CAUTION : Ensure that when aligning the bank 1 secondary timing chain to the bank 1 camshaft actuator sprockets, that the triangular timing marks (1) on the sprocket are used, NOT the circular mark. C. Align the bright plated timing chain link (2) with the exhaust actuator sprocket
rev 01

alignment triangle mark.

3.2L Engine : Engine timing system


Bank 1 secondary timing chain installation procedure - 3 D. Align the bright plated timing chain link (1) with the intake actuator sprocket alignment triangle mark (2).

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C100 (3.2 L) Engine Mechanical Participants Handout

CAUTION : Ensure that the bank 1 secondary timing chain guide is used when installing to the Bank 1 side in this procedure. 6. Ensure that the bank 1 secondary timing chain guide is selected and orientated correctly. 7. 8. Position the chain guide (2). Ensure the primary timing chain upper guide is selected and orientated correctly. Tighten Tighten the secondary timing chain guide bolts to 23 Nm (17 lbft). CAUTION : The bank 1 secondary camshaft drive shoe is marked with the letters RH. Ensure that the bank 1 drive shoe is used when installing to the bank 1 side in this procedure and that the letters RH are facing the front of the vehicle when installed. 9. Ensure the bank 1 secondary timing chain shoe is selected and orientated correctly.
rev 01

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C100 (3.2 L) Engine Mechanical Participants Handout

3.2L Engine : Engine timing system


Bank 1 secondary timing chain installation procedure - 4 10. Position the bank 1 secondary timing chain shoe(1). Tighten Tighten the bank 1 secondary timing chain shoe attaching bolt to 23 Nm (17 lbft).

11. Ensure the bank 1 secondary timing chain tensioner is selected and orientated correctly.

12. Reset the bank 1 secondary timing chain tensioner. Note : To reset the tensioner, use a suitably sized flat blade screwdriver (1) to wind the plunger in a clockwise direction, into the tensioner shaft (2).

13. Install the tensioner shaft (1) into the bank 1 secondary timing chain tensioner body (2).

rev 01

3.2L Engine : Engine timing system


Bank 1 secondary timing chain installation procedure - 5 CAUTION : If Tool No. EN 46112 (1) is not inserted into the tensioner body (2), the plunger will remain in the locked position and no tension will be placed on the timing chain, this will cause damage to the engine. 14. Compress the tensioner shaft into the body and lock the tensioner by inserting Tool No. EN 46112 into the access hole in the side of the tensioner body. 15. Slowly release pressure on the bank 1 secondary timing chain tensioner. The tensioner should remain compressed. 16. Install a new bank 1 secondary timing chain tensioner gasket (1) to the tensioner (2). 17. Install the bank 1 secondary timing chain tensioner bolts (3) through the tensioner and gasket. 18. Ensure the bank 1 secondary timing chain tensioner mounting surface on the bank 1 cylinder head does not have any burrs or defects that would affect the sealing of the new tensioner gasket. 19. Place the bank 1 secondary timing chain tensioner (2) into position and loosely install the bolts (1) to the engine block.

01.2-41
C100 (3.2 L) Engine Mechanical Participants Handout

rev 01

01.2-42
C100 (3.2 L) Engine Mechanical Participants Handout

3.2L Engine : Engine timing system


Bank 1 secondary timing chain installation procedure - 6 20. Verify the proper placement of the bank 1 secondary iming chain tensioner gasket tab (1). 21. Tighten the bank 1 secondary timing chain tensioner bolts (2). Tighten Tighten the bank 1 secondary timing chain tensioner bolts to 23 Nm (17 lbft). 22. Release the bank 1 timing chain tensioner (1) by pulling out Tool No. EN 46112 (2) and unlocking the tensioner plunger.

23. Verify all primary and secondary timing chain timing mark alignments (1 to 18). 24. Remove Tool No. EN 46105 and EN 461052 from the both cylinder head camshafts. 25. Reinstall the spark plugs. 26. Reinstall the engine front cover assembly.

rev 01

3.2L Engine : 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.

01.2-43
C100 (3.2 L) Engine Mechanical Participants Handout

1. 2. 3. 4. 5. 6. 7.

Power steering pump Water pump Belt tensioner Crankshaft Alternator Idler Compressor

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

rev 01

01.2-44
C100 (3.2 L) Engine Mechanical Participants Handout

3.2L Engine : Air intake system

1. 2. 3. 4. 5. 6. 7.

Air Cleaner Upper Housing Air Cleaner Element Seal Air Cleaner Element Air Cleaner Snorkel Assembly Lower Intake Air Duct Air Cleaner Resonator Duct Seal Air Cleaner Resonator Duct Assembly

8. 9.

Air cleaner aFront Resonator Air Cleaner Resonator Seal

10. Air Cleaner Rear Resonator 11. Air Cleaner Lower Housing 12. Mass Air Flow (MAF) Sensor Assembly 13. Air Cleaner Outlet Elbow Hose 14. Air Intake Duct 15. PCV Hose

PART NAME Air Cleaner Element Effective Area Element Replacement Element material Main Resonator Volume
rev 01

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

3.2L Engine : Exhaust system

01.2-45
C100 (3.2 L) Engine Mechanical Participants Handout

1. 2. 3. 4. 5. 6. 7. 8. 9.

11. Underbody Catalytic Converter (UCC) Upper Heated Oxygen Sensor, Bank 1 12. UCC to Front Muffler Gasket Exhaust Manifold, Bank 2 Exhaust Manifold, Bank 1 Upper Heated Oxygen Sensor, Bank 2 13. Front Muffler Assembly Pup Converter, Bank 2 Pup Converter, Bank 1 Lower Heated Oxygen Sensor, Bank1 14. Front Muffler to Rear Muffler Gasket 15. Rear Muffler Assembly

Lower Heated Oxygen Sensor, Bank 2 16. UCC Heat Shield 17. Front Muffler Heat Shield Exhaust Front Pipe 18. Rear Muffler Heat Shields

10. Exhaust Front Pipe to UCC Gasket

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

3.2L DOHC 1.14 0.90 10 11.5 X 2EA

rev 01

01.2-46
C100 (3.2 L) Engine Mechanical Participants Handout

3.2L Engine : Engine cooling system


Cooling fans

1. Radiator Upper Bracket 2. Lower Radiator Bumper 3. Radiator 4. Main Cooling Fan 5. Auxiliary Cooling Fan
FAN SPEED Low APPLICATION ECT ( ) A/C switch ECT ( ) High ACP ( Kpa) ECT

6. Main Cooling Fan Motor 7. Auxiliary Cooling Fan Motor 8. Cooling Fan Shroud Assembly 9. Coolant Drain Cock
ON 100 ON 110 1760 Malfunction 107 1347 OFF 97

rev 01

3.2L Engine : Engine cooling system


Water pump and Thermostat

01.2-47
C100 (3.2 L) Engine Mechanical Participants Handout

1. 2. 3. 4. 5. 6. 7. 8. 9.

Water Pump Pulley Bolt Water Pump Pulley Water Pump Bolt Water Pump Water Pump to Engine Front Cover Gasket Thermostat Housing Bolt Thermostat Housing Thermostat Thermostat Housing to Engine Block Gasket
PART NAME 3.2L DOHC Cross Flow 673 511 27 9 87 2 340 + 320 Complete open : 102 Main + Aux W HxT REMARK

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

rev 01

01.2-48
C100 (3.2 L) Engine Mechanical Participants Handout

3.2L Engine : Fuel supply system


Description of 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 as 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. 3 4

2 1

1. Under body pipe line 2. Canister

3. Fuel tank 4. Fuel filter

rev 01

3.2L Engine : Fuel supply system


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 2. Main Fuel Pump

01.2-49
C100 (3.2 L) Engine Mechanical Participants Handout

3. Roll Over Valve

4 . Ring-Adaptor

Fuel tank Capacity 65 L

Remarks

rev 01

01.2-50
C100 (3.2 L) Engine Mechanical Participants Handout

3.2L Engine : Fuel supply system


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

rev 01

3.2L Engine : Fuel supply system


Specification of Fuel pump
Syste m Pre ssure Displa ce m e nt (12.0V / 410kPa ) Re lie f pre ssure (12.0V) Curre nt (12.0V / 410kPa ) Fue l filte r re pla ce m e nt 410 kpa 100 /h min 600 kPa - max 900 kPa 8 AMP 100,000miles / 10 years

01.2-51
C100 (3.2 L) Engine Mechanical Participants Handout

Fuel Level Gage Resistance


FUEL LEVEL Float He ight Status Full Stop 1/2 Empty Stop Fuel Height 228.9 130.6 1.3 40 106.2 250.0 MAX 45,5 112,8 253,0 MIN 37,0 99,4 240,4 Resistance( )

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 FULL 3/4 1/2 1/4 EMPTY SIGNAL 3.4V 3.0V 2.2 2.5V 2.0V 1.4 ~ 1.5V
rev 01

REMARK 5V Ref

01.2-52
C100 (3.2 L) Engine Mechanical Participants Handout

3.2L Engine : Fuel supply system


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

rev 01

3.2L Engine : Fuel supply system


Injector and Rail

01.2-53
C100 (3.2 L) Engine Mechanical Participants Handout

Injector specification
Application Static flow rate Spray type Injection type Injection angle Resistance( ) 3.2 L DOHC 193.6 (g/min) Single spray type(4 holes) Sequential 15 11.4 ~12.6

rev 01

01.2-54
C100 (3.2 L) Engine Mechanical Participants Handout

3.2L Engine : Evaporative emission control system


Canister 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

[ Canister ]

[ Purge control solenoid ]

rev 01

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