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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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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
rev 01
01.2-6
C100 (3.2 L) Engine Mechanical Participants Handout
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
rev 01
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
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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
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
rev 01
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
rev 01
01.2-12
C100 (3.2 L) Engine Mechanical Participants Handout
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
rev 01
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
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
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.
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
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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01.2-17
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
rev 01
01.2-18
C100 (3.2 L) Engine Mechanical Participants Handout
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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01.2-19
C100 (3.2 L) Engine Mechanical Participants Handout
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01.2-20
C100 (3.2 L) Engine Mechanical Participants Handout
rev 01
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
rev 01
01.2-22
C100 (3.2 L) Engine Mechanical Participants Handout
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.
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
rev 01
01.2-23
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
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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01.2-25
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).
rev 01
01.2-26
C100 (3.2 L) Engine Mechanical Participants Handout
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
rev 01
Tighten the camshaft ntermediate driveshaft sprocket attaching bolt to 66 Nm (49 lbft).
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.
rev 01
01.2-28
C100 (3.2 L) Engine Mechanical Participants Handout
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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C100 (3.2 L) Engine Mechanical Participants Handout
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C100 (3.2 L) Engine Mechanical Participants Handout
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01.2-31
C100 (3.2 L) Engine Mechanical Participants Handout
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01.2-32
C100 (3.2 L) Engine Mechanical Participants Handout
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).
rev 01
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
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).
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01.2-35
C100 (3.2 L) Engine Mechanical Participants Handout
rev 01
01.2-36
C100 (3.2 L) Engine Mechanical Participants Handout
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.
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01.2-37
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
01.2-38
C100 (3.2 L) Engine Mechanical Participants Handout
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
01.2-39
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
01.2-40
C100 (3.2 L) Engine Mechanical Participants Handout
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
01.2-41
C100 (3.2 L) Engine Mechanical Participants Handout
rev 01
01.2-42
C100 (3.2 L) Engine Mechanical Participants Handout
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
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
rev 01
01.2-44
C100 (3.2 L) Engine Mechanical Participants Handout
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.
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
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
PART NAME Pup Converter Underbody Converter Exhaust Front Muffler Exhaust Rear Muffler
rev 01
01.2-46
C100 (3.2 L) Engine Mechanical Participants Handout
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
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
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01.2-48
C100 (3.2 L) Engine Mechanical Participants Handout
2 1
rev 01
01.2-49
C100 (3.2 L) Engine Mechanical Participants Handout
4 . Ring-Adaptor
Remarks
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01.2-50
C100 (3.2 L) Engine Mechanical Participants Handout
rev 01
01.2-51
C100 (3.2 L) Engine Mechanical Participants Handout
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
rev 01
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
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01.2-54
C100 (3.2 L) Engine Mechanical Participants Handout
[ Canister ]
rev 01