C100 Service Training Manual :

Engine Repair (2.4L DOHC)

Instructor Guide
 1-1-2
Table Of Contents C100 (2.4L) :
Engine Repair

Instructor Guide

Engine Number …………..….…..………………………….………….…… 3

Engine Specification ……..….…..………………………….………….…… 4
Engine Side View …………..………………………………………………. 6
Engine Lubrication …………….…………………………………………… 7
Engine Exploded View ………….………………………………………….. 8
Timing Belt …………………………………………………………………. 13
Timing Belt Adjustment …………………………………………………… 14
Accessory Belt ……………………………………………………..………. 16
Piston Rings Installation …………………………………………..…….… 17
Engine Cylinder Head ………………………………………………..….… 18
Engine Intake System ………………………………………………..…… 19
Engine Exhaust System ……………………………………………..…… 21
Engine Cooling System …………………………………………………… 22
Fuel Supply system …………………………………………………..…… 24
Fuel Tank ………………………………….…………………………..…… 25
Fuel Pump ………………………………………………………………… 26
Injector & Rail ………………………………………………………………. 29
Evaporative Emission Canister ……………………………………..….… 30
2.4L Engine : Engine number

1. FAM II
1-1-3
T 24 S E D 012345 C100 (2.4L) :
Engine Serial Number
000001~999999 Engine Repair
Design specifics
D : Daewoo, H : High performance Instructor Guide
L : Low end torque, R : Raised performance
Fuel mixture system
E : Fuel injection Z : TBI
V : Carburetor L : LPG
Compression Ratio
G : ＜8.5, L : 8.5~9.0, N : 9.0~9.5
S : 9.5~10.0, X : 10.5~11.5, Y : ＞11.5
Displacement
18 : 1.8 L, 24 : 2.4 L
Exhaust Emission limits
C : Domestic, Others
X : Europe, Euro stage II
T : North America,OBD II, Euro stage III
Z : EURO IV
2.4L Engine : Specification

APPLICATION 2.4 DOHC 1-1-4

Vehicle Max Speed (MT/AT) kph/ kph C100 (2.4L) :

Performance Min Turning Ratio (m) 5.75 m Engine Repair
Engine type 4 Cylinder(In-Line)
Instructor Guide
Bore x Stroke (mm) 87.5 x 100
Displacement (cc) 2,405
Compression Ratio 9.6 : 1
Engine
Max Power (hp/RPM) 100KW(131.1 hp) / at 5,000
General
Max Torque (Nm/RPM) 220 N.m(162.3Ib-ft) / at 2,200
Idle RPM 690
Initial Spark Timing (BTDC) 8˚
Firing Order 1-3-4-2
Type Direct Ignition System
Coil
Ignition sequence 1-3-4-2
Ignition Maker Bosch
Plug Type FLR8LDCU
Clearance mm 0.9 ~ 1.1

Type Forced feed

Oil Type and Grade 5W30 SL
Filter Spin-on (Full Flow)
Lubrication Oil Capacity (w/filter) 4.5 L
Type Rotary (Trochoid)
Oil
Engine run Min 0.6 kg/cm2
Pump Pressure
Relief 4.0 kg/cm2
2.4L Engine : Specification

APPLICATION 2.4 DOHC 1-1-5

Type Forced feed C100 (2.4L) :
Coolant Capacity (L) 9
Engine Repair
Water Pump Centrifugal
Type Down Flow
Instructor Guide

Width 673 mm
Radiator
Core Height 511 mm
Thickness 27 mm
Pressure Valve open 140 Kpa
Surge Tank
Cooling Vaccum Valve open 10 Kpa
Type Pellet
Star to open (℃ ) 87 ± 2
Thermostat
Completely open (℃ ) 102
Completely close (℃ ) MIN 82
Type Electric
Blades Main:5EA / Aux: 7EA
Fan
Fan Diameter 340mm + 320 mm

Type MPI
Type Electric Motor

Fuel Fuel Pump Displacement 100 L/h

Delivery Fuel pressure 410 Kpa
Filter Type Cartridge
Fuel Tank Capacity 65 L
Type Planetary Gear Reduction
Starter
Power 1.4KW
Alternator Power 120A
Type MF
Battery Capacity 12V- 60AH
Cold Cranking Ampere 650 CCA
2.4L Engine Mechanical : Engine side view

1-1-6

C100 (2.4L) :
Engine Repair

Instructor Guide
2.4L Engine Mechanical : Lubrication

1-1-7

C100 (2.4L) :
Engine Repair

Instructor Guide

ITEMS 2.4L DOHC

Lub. Type Forced feed

Engine Oil 5W30 SL

. Normal condition : 15,000 km / 12 months

Oil Replacement with filter
. Severe condition : 7,500 km / 6 months

Oil Capacity (w/filter) 4.5L

Oil Pump Pressure 30 Kpa at Idle

Oil Pump Relief Pressure 4.0 ± 0.5 kg/cm2

2.4L Engine Mechanical : Engine Exploded View

Upper End
1-1-8

C100 (2.4L) :
Engine Repair

Instructor Guide
2.4L Engine Mechanical : Engine Exploded View

Upper End
1-1-9
1. Nut 28. Exhaust Gas Recirculation Valve
2. Engine Beautification Cover Gasket
C100 (2.4L) :
3. Bolt 29. Cylinder Head Engine Repair
4. Oil Filler Cap 30. Exhaust Manifold Gasket
5. Bolt 31. Exhaust Manifold Instructor Guide
6. Cylinder Head Cover 32. Nut
7. Cylinder Head Cover Gasket 33. Exhaust Manifold Heat Shield
8. Tappet Adjuster 34. Cylinder Head Gasket
35. Bolt
9. Valve Key
36. Thermostat Housing
10. Valve Spring Cap
37. Thermostat Housing Gasket
11. Valve Spring
38. Stud
12. Valve Stem Seal 39. Sleeve
13. Valve Spring Seat 40. Plug
14. Valve Guide 41. Bolt
15. Intake Valve Seat Ring 42. Camshaft Position Sensor
16. Exhaust Valve Seat Ring 43. Oil Gallery Plug
17. Intake Valve 44. Exhaust Camshaft
18. Exhaust Valve 45. Seal Ring
19. Bolt 46. Camshaft Gear
47. Washer
20. Front Camshaft Cap
48. Camshaft Gear Bolt
21. Head Bolt
49. Intake Camshaft
22. Bolt
50. Intake Manifold Gasket
23. Intermediate Camshaft Cap
51. Intake Manifold
24. Exhaust Gas Recirculation Adapter 52. Throttle Body Gasket
25. Exhaust Gas Recirculation Adapter 53. Throttle Body
Gasket 54. Nut
26. Bolt 55. Evaporative Emission Canister Purge
27. Exhaust Gas Recirculation Valve Solenoid
2.4L Engine Mechanical : Engine Exploded View

Lower End
1-1-10

C100 (2.4L) :
Engine Repair

Instructor Guide
2.4L Engine Mechanical : Engine Exploded View

Lower End
1-1-11
1. Connecting Rod Cap 37. Oil Filter
2. Bearing Set 38. Bypass Valve C100 (2.4L) :
3. Connecting Rod Bolt 39. Pressure Relief Valve Plunger
Engine Repair
40. Pressure Relief Valve Spring
4. Piston Ring Set
41. Seal Ring
5. Piston Pin Instructor Guide
42. Pressure Relief Valve Plug
6. Piston
43. Rear Timing Belt Cover
7. Engine Block
44. Bolt
8. Sleeve 45. Special Bolt
9. Water Jacket Cap 46. Idler Pulley
10. Bolt (Manual Transaxle) 47. Stud
11. Flywheel (Manual Transaxle) 48. Nut
12. Flexible Plate (Automatic Transaxle) 49. Bolt
13. Bolt (Automatic Transaxle) 50. Tensioner
14. Seal Ring 51. Bolt
15. Crankshaft 52. Thrust Inner Washer
53. Woodruff Key
16. Reluctor Ring
54. Crankshaft Gear
17. Screw
55. Thrust Outer Washer
18. Crankshaft Balancer Unit Assembly
56. Bolt
19. Bolt 57. Camshaft Drive Belt
20. Oil Pan Scraper 58. Gasket
21. Bolt 59. Front Timing Belt Cover
22. Oil Suction Pipe 60. Bolt
23. Oil Pan 61. Bushing Plug
24. Oil Pan Drain Plug 62. Bushing
25. Sleeve 63. Oil Gallery Plug
26. Gasket 64. Bolt
65. Water Pump
27. Bolt
66. Seal Ring
28. Oil Pump Cover
67. Crankshaft Position Sensor
29. Ring Gear
68. Bolt
30. Gear
69. Knock Sensor
31. Oil Pressure Switch 70. Bolt
32. Washer 71. Oil Filter Adapter
33. Washer
34. Oil Duct Outlet Plug
35. Connecting Piece
36. Seal Ring
2.4L Engine Mechanical : Engine Exploded View

Engine Mount system

1-1-12

C100 (2.4L) :
Engine Repair

Instructor Guide

1. Transaxle Front Mount Assembly

2. Engine Mount Adapter Support Bracket
3. Engine Mount Assembly
4. Cradle Assembly
5. Transaxle Mount Assembly
6. Transaxle Rear Mount Bracket
7. Transaxle Rear Mount
2.4L Engine Mechanical : Timing Belt

1-1-13

C100 (2.4L) :
Engine Repair

Instructor Guide

Specification

Model Maintenance Remarks

I : 30,000 km
C100 (2.4D)
R : 120,000 km

* I : Inspection
R : Replacement
Engine Mechanical : Timing Belt Adjustment (1)

a. Remove the front cover 1-1-14

b. Rotate the crankshaft
C100 (2.4L) :
clockwise one full turn and
Engine Repair
align the timing mark of the
crankshaft sprocket to the Instructor Guide
rear cover notch.

c. Align the timing mark of the

intake cam sprocket and the
exhaust cam sprocket .

d. Loosen the automatic

tensioner fixing bolt(①).
①
e. Rotate the tensioner hex-key
tab(②) counterclockwise to
give the highest tension.
②

f. Rotate the hex-key tab

clockwise until the adjust arm
pointer is aligned with the
notch of the tensioner bracket
Engine Mechanical : Timing Belt Adjustment (2)

1-1-15
g. Tighten the tensioner bolt
C100 (2.4L) :
Engine Repair

Instructor Guide

h. Rotate the crankshaft two

turns clockwise

i. Check the tensioner pointer for

the right position
Engine Mechanical : Accessory Belt

After checking the alternator belt , air conditioning / steering belt , air 1-1-16
conditioning belt , power steering belt , for looseness, crack, wear or
C100 (2.4L) :
tension, replace the belt if necessary.
Engine Repair

Instructor Guide

** Relieve method :
Rotate the drive belt tensioner
clockwise.
Engine Mechanical : Piston Rings Installation

1-1-17

C100 (2.4L) :
Engine Repair

Instructor Guide

[ Piston Ring Installation ]

[ Piston Ring Cut-away ]

Engine Mechanical : Engine Cylinder Head

New adopted engine has dual outlet exhaust and low restriction 1-1-18
induction/ exhaust. C100 (2.4L) :
Engine Repair

Instructor Guide

** Cylinder head bolt tightening sequence :

Tighten the cylinder head bolts to 25 Nm (18 lb–ft) and turn the bolts
another 3 turns of 90 using the angular torque gauge KM–470–B.
2.4L Engine Mechanical : Engine Intake System

Air Intake system

1-1-19

C100 (2.4L) :
Engine Repair

Instructor Guide

PART NAME 2.4 DOHC

Air Cleaner Remote type / 12L

Element Effective Area 4000 cm2

Element Replacement 60,000㎞ / 24 months

Element material Non-woven Fabric

Main Resonator Volume 3.8L

Engine Mechanical : Engine Intake System(2)

Intake manifold
1-1-20

EGR passage revised C100 (2.4L) :

Runner ends blended to larger to clear throttle body.
Engine Repair
cylinder head inlet ports
Instructor Guide

PCV port added which satisfies OBD2 diagnostics

if required. (Throttle body has no PCV port.)

Intake manifold and Throttle body

Revised throttle body mounting pattern.

Throttle body size increased.

Support brace mounting position changed to

facilitate power take-off unit clearance.
Engine Mechanical : Engine Exhaust System

1-1-21

C100 (2.4L) :
Engine Repair

Instructor Guide

1. Pup Converter 5. UCC Heat Shield

2. Exhaust Front Pipe Mounting Bracket 6. Front Muffler Assembly
3. Exhaust Front Pipe Assembly 7. Front Muffler Heat Shield
4. Underbody Catalytic Converter 8. Rear Muffler Heat Shields
(UCC) 9. Rear Muffler Assembly

PART NAME 2.4 DOHC

Pup Converter 1.14 ℓ

Underbody Converter 0.90 ℓ

Exhaust Front Muffler 10ℓ

Exhaust Rear Muffler 11.5ℓ X 2EA

Engine Mechanical : Engine Cooling System - 1

1-1-22

C100 (2.4L) :
Engine Repair

Instructor Guide

1. Radiator Upper Bracket 6. Main Cooling Fan Motor

2. Lower Radiator Bumper 7. Auxiliary Cooling Fan Motor
3. Radiator 8. Cooling Fan Shroud Assembly
4. Main Cooling Fan 9. Coolant Drain Cock
5. Auxiliary Cooling Fan

FAN SPEED APPLICATION ON OFF

ECT ( ℃ ) 96 93
Low
A/C switch ON
ECT ( ℃ ) 100 97
High ACP ( kg/㎠ ) 18.98 14.76
ECT Malfunction
Engine Mechanical : Engine Cooling System - 1

Water pump and Thermostat

1-1-23

C100 (2.4L) :
Engine Repair

Instructor Guide

1. Seal Ring
2. Thermostat
3. Thermostat Housing
4. Thermostat Housing Mounting Bolt
5. Water Pump Mounting Bolt
6. Water Pump
7. Seal Ring

PART NAME 2.4 DOHC REMARK

Radiator Type Cross Flow

Radiator Size 673 × 511 × 27 W ×HxT

Coolant Capacity 9ℓ

Thermostat start to open 87 ±2℃ Complete open : 102℃

Cooling Fans Φ 340 + Φ 320 Main + Aux

Engine Mechanical : Fuel Supply system

The fuel system is a returnless on-demand design. The fuel pressure 1-1-24
regulator is a part of the main fuel pump module.
C100 (2.4L) :
An electric turbine style fuel pump attaches to the main fuel pump
Engine Repair
module inside the fuel tank. The fuel pump supplies high pressure fuel
through the fuel filter, past the fuel pressure regulator, and through the Instructor Guide
fuel feed pipe to the fuel injection system. The fuel pressure regulator
has 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 3. Fuel tank

2. Canister 4. Fuel filter
Engine Mechanical : Fuel Tank

The fuel tank stores the fuel and the tank is sealed up leakage of vapor. 1-1-25
The fuel tank is made from high density polyethylene. The main fuel
C100 (2.4L) :
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 Engine Repair
that is able to hold from two nuts attach to the frame. The fuel in the
Instructor Guide
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

3. Roll Over
Valve

4 . Ring-Adaptor

Fuel tank Remarks

Capacity 65 L
Engine Mechanical : Fuel pump - 1

Main Fuel Pump Module

1-1-26
The main fuel pump module is located inside of the right side of the
C100 (2.4L) :
fuel tank. The main fuel pump module consists of the following major
components: Engine Repair
•The fuel level sender assembly
Instructor Guide
•The fuel pump and reservoir assembly
•The fuel filter
•The fuel pressure regulator
•The suction and return jet assembly

Sub Fuel Pump Module

The sub fuel pump module is located inside of the left side of the fuel
tank. The sub fuel pump module consists of the following major
components:
• The fuel sender assembly
• The fuel transfer tube
Engine Mechanical : Fuel pump – 2

1. Specifications
1-1-27
System Pressure 410 kpa C100 (2.4L) :
Displacement (12.0V / 410kPa) 100ℓ /h Engine Repair

Relief pressure (12.0V) min 600 kPa - max 900 kPa Instructor Guide
Current (12.0V / 410kPa) 8 AMP

135,000 km(Europe)
Fuel filter replacement
140,000 km(General)

2. Fuel Level Gage Resistance

FUEL LEVEL Resistance(Ω )

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

1/2 130.6 106.2 112.8 99.4

Empty Stop 1.3 250.0 253.0 240.4

3. Fuel Level Gage Control

The fuel level sensor changes resistance in response to the fuel level.
The engine control module (ECM) monitors the signal circuit of the fuel
level sensor in order to determine the fuel level. When the fuel tank is
full, the sensor resistance is low and the ECM senses a low signal
voltage.
When the fuel tank is empty, the sensor resistance is high and the ECM
senses a high signal voltage. The ECM uses the signal circuit of the fuel
level sensor in order to calculate the percentage of remaining fuel in the
tank.
The fuel level signal is sent to ECM, the ECM sends the message of
the fuel level to the BCM and the BCM modulates fuel level gauge in
the cluster by single wire CAN.

FUEL LEVEL SIGNAL REMARK

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

1/4 2.0V
EMPTY 1.4 ~ 1.5V
Engine Mechanical : Fuel pump – 3
4. Fuel Pressure Regulator
1-1-28
The fuel pressure regulator is installed inside the fuel pump.
C100 (2.4L) :
It is referenced by the fuel tank pressure instead of the vacuum
pressure, which is roughly the same as the atmospheric pressure. Engine Repair

Instructor Guide
Pressure Condition
410 Kpa Engine running
600 ~ 900 Kpa Relief pressure
Engine Mechanical : Injector & Rail

1-1-29

C100 (2.4L) :
Engine Repair

Instructor Guide

1. Injector specification

Application 2.4 L DOHC

Static flow rate 194 ± 4% (g/min)

Spray type Dual spray type

Injection type Sequential

Color Black

Resistance(Ω) 12 ± 5%
Engine Mechanical : Evaporative Emission Canister - 1

The evaporative emission canister is an emission control device 1-1-30

containing activated charcoal granules. The evaporative emission
C100 (2.4L) :
canister is used to store fuel vapors from the fuel tank.
Engine Repair
Once certain conditions are met, the electronic control module (ECM)
activates the controlled canister purge solenoid allowing the fuel Instructor Guide
vapors to be drawn into the engine cylinders and burned.

※ Capacity : 900cc

[ Canister ]

[ Purge control solenoid ]