Engine System

Captiva MY 16
Engine Mechanical (2.0L LNP - DOHC - Diesel)
2.0L Diesel Engine : Engine general
Engine number Z 20 xx xxxxxx K
1 2 3 4 5
1. Engine Type (Z : Diesel)
2. Engine Size (20 : 2.0L, 22: 2.0L)
3. Cam Mechanism
4. Sequence Number
5. Manufacturer’s country (K : Korea)
2.0L Diesel Engine : Engine general
Engine specifications
Engine Mechanical Specifications
Specification
Application Metric English
General Data
•RPO LNP
•Engine Type 4 Cylinder Inline
•Displacement 1998 ccm 121.92 cu in
•Bore Diameter 86 mm 3.3858 in
•Stroke 86 mm 3.3858 in
•Compression Ratio 16.3:1
•Output @ Engine Speed 120 KW / 3800 RPM

•Torque @ Engine Speed 400 Y / 1750–2250 RPM 295 lb ft / 1750–2250 RPM

•Idle Speed 725 RPM
•No-Load max. Speed 5000 RPM
•Injection Pressure of Common Rail System 1800 bar 26106.8 PSI
Engine Management
•ECM Type Delphi E20
•Injection Pressure Pump Type Delphi DFP 3.2
•Injector Type Delphi DFI 1,5
•Firing Order 1-3-4-2
•Glow Plug Type Metallic, Low Voltage
•Glow Plug Voltage 4.4 Volt
Drive Belt

•Drive Belt Length

2220 mm 87.4 in
•with Air Conditioning, Generator, Power Steering Pump

Oil Circulation System

Engine Oil Quality (European Countries) Dexos2
•Engine Oil Viscosity 5W–30
2.0L Diesel Engine : Engine mechanical
Engine over view
2.0L Diesel Engine : Engine mechanical
Cylinder head
This cylinder head is DOHC(Double Over Head Camshaft) type and has Rear Side
Intake side
two camshaft that open 4 valves per cylinder with the finger followers of
roller type (end pivot type). (Transmisson side)

The cylinder head is made of aluminum alloy, A356 with T7 air quench
for better strength with light weight.
The intake port shape of the cylinder head is designed for increasing of
high performance and swirl efficiency using swirl control valves and then
this is maximized to diesel combustion efficiency.

** Cylinder head bolt tightening sequence :

Front side
Tighten the cylinder head bolts to 30 Nm plus 100 Nm. Exhaust side
(Timing Chain side)
Using the angular torque gauge KM–470–B, tightening the
cylinder head bolts another 90 degrees plus 90 degrees.
2.0L Diesel Engine : Engine mechanical
Cylinder block
The engine block is made of grey iron with sand casting process. The functions of the engine block can be categorized as support,
locate, seal, transport, and provide clearance
2.0L Diesel Engine : Engine mechanical
Piston & Road assembly
The piston is cast aluminum included combustion chamber of a bowl type. Skirt of piston is coated with polymer to reduce friction
and to enhance anti-scuffing. The piston assembly have 2 compression rings and 1 oil ring of 2-piece type loaded with coil spring.
There is a piston pin of full-floating type between piston pin bore and rod pin bore and it is fixed by retainer located in both ends.
The connecting rod is used fracture method to split rod and rod cap. The connecting rod and rod cap with bearings is positioned
and fastened by bolts.
2.0L Diesel Engine : Engine mechanical
Crankshaft
The crankshaft is made of high strength forged steel Crankshaft axial end play is maintained with thrust bearing placed in the 3rd
crank bore. At the 6th of crankshaft arm, a crankshaft gear is hot press fitted to drive a balance shaft module which runs by gears
meshed. And at the 8th of crankshaft arm, target wheel is assembled with 3 bolts tightened to make a CPS(Crankshaft Position
Sensor) read position signal of crankshaft.
2.0L Diesel Engine : Engine mechanical
Oil Pump & Balance shaft module
The balance shaft module is a type of oil pump integration with suction pipe, running inside of oil pan. A drive gear of balance shaft is driven
by crankshaft gear and drives a driven gear in balance shaft . A driven gear, connected to rotor of oil pump, offers power source to oil pump.
2 unbalance shafts are rotating to eliminate the vibration(2nd order shaking force) from reciprocating mass. And oil in the oil pan is delivered
to oil path by oil pump.
2.0L Diesel Engine : Engine mechanical
Valve train system
DOHC 2 valves for intake and exhaust system is employed with the roller finger follower, hydraulic lash adjuster and assembled cam
shafts. Intake cam shaft that has chain sprocket with integrated spur gear is driven by chain and exhaust cam shaft is driven by
scissors gear. High pressure fuel pump and mechanical vacuum pump are driven by intake and exhaust cam shaft respectively.

Ma rk Na me Function
a CAM SHAFT ASM- INT O pen/ close inta ke va lves
b CAM SHAFT ASM- EXH O pen/ close exha ust va lves
Drive Inta ke ca m sha ft a nd exha ust
c GEAR INT- CM/ SHF
gea r
d GEAR EXH- CM/ SHF Drive exha ust ca m sha ft
e VALVE- INT Air inlet pa ssa ge to the cylinder
f VALVE- EXH Ga s outlet pa ssa ge to the exha ust ma nifold
g SPRING- VLV O pen/ close inta ke/ exha ust va lves
h RETAINER- VLV SPR Reta ining the spring
i KEY- VLV STEM Keeping the va lve
j SEAL- VLV STEM O IL Air/ Ga s lea ka ge sea ling on the va lve stem
k ADJUSTER- HYD VLV LASH Va lve la sh a djustment
l ARM ASM- VLV RKR Activa te the va lve
2.0L Diesel Engine : Engine lubrication
Engine oil distribution
Oil distribution circuit is shown in below figure. Oil pump is integrated with balance shaft with 6/7 lobe and it is directly driven by balance
shaft gear. In order to improve NVH, oil pan consists of upper structural and lower laminated oil pan. Oil filter is integrated with oil cooler
and FEAD bracket. The upright no spill design results in the easy replacement of cartridge element. OLM(Oil Life Monitoring) system is
adapted to notice oil change which is decided according to the driving pattern. Oil level switch is mounted on oil pan to check oil level. GM
new developed engine oil “Dexos2” is used for all regions.

ITEMS 2.2L Diesel

Oil Type and Grade Dexos2 5W30

Oil Filter Cartridge

Oil Capacity (w/filter) 5.6 L

Oil Change interval 1 year or oil change lamp-on

2.0L Diesel Engine : Engine lubrication
Engine oil seal(crankshaft rear oil seal)
Currently there are two basic seal designs for radial shaft seals in the field
as garter spring design and laydown lip design .The laydown lip
technology , specially reverse type has been in use for FamZ diesel
engine due to higher life targets .The reverse laydown lip design was
invented to allow for easier installation over the crankshaft. With the
reverse lip design, greater amounts of oil must be pumped away from the
seal. it also reduces oil at the outer edge of the seal which is at the
highest load. ISO View
(PTFE Reverse laydown lip type)
Assembly View

Cyl. Block

Crankshaft

[Section view (After assembly)]

2.0L Diesel Engine : Engine lubrication
Engine Oil Cooler
Additional Engine Oil Cooler installed on the engine block.

Oil pan(two piece)

• Allows increased oil volume
• Acoustic metal lower pan eliminates exterior foam
• Additional oil volume achievable
• Upper part high pressure die cast
• Lower part acoustic sheet metal for best NVH behavior
2.0L Diesel Engine : Engine lubrication
Engine oil pressure switch
The Engine Oil Pressure switch measures engine oil pressure. When the
Engine Oil Pressure switch signal is below a certain value, the ECM
activates the Check Oil warning lamp in the instrument cluster.
2.0L Diesel Engine : Engine lubrication
Engine oil level switch
The Engine Oil Level switch measures engine oil level. When the Engine
Oil Level switch signal is below a certain value, the ECM activates the
Check Oil warning lamp in the instrument cluster.
2.0L Diesel Engine : Engine timing chain system
1. Descriptions
2.0L Diesel Engine : Engine timing chain system
Timing chain component
a) Chain assembly a
b) Crankshaft sprocket
c) Timing chain tensioner
d) Timing chain dampener
e) Timing chain guide
f
f) Bolt
c
g) Bolt
h) Bolt
d e

h
b
2.0L Diesel Engine : Engine timing chain system
Timing chain adjustment(Removal)
1. Remove the camshaft cover.
2. Remove the engine front
3. Push the timing chain (5) in direction to the timing chain tensioner (4)
and install the EN-49073 pin (3).
4. Install an open end wrench (6) on the flats of the camshaft to prevent
the camshaft from turning.
5. Remove the exhaust camshaft gear bolt (2), gear and thrust washer (1)
6. Remove the timing chain tensioner bolts (1) and tensioner (2).
7. Remove the two timing chain guide right side bolts (1).
8. Remove the timing chain guide right side (2).
2.0L Diesel Engine : Engine timing chain system
Timing chain adjustment(Removal)
9. Remove the timing chain (1).
10. Install an open end wrench (3) on the flats of the camshaft to prevent
the cam shaft from turning.
11. Remove the Intake camshaft sprocket bolt (5) and sprocket (1).
12. Remove the crankshaft sprocket (1).
2.0L Diesel Engine : Engine timing chain system
Timing chain adjustment(Installation)
1. Install the crankshaft sprocket
(1) with the timing chain mark at the 4 o’clock position.
Note: Ensure the crankshaft key (2) is aligned with the
crankshaft timing mark (3).
Note: Ensure the camshaft dowel (4) is at the 12 o’clock position and the
camshaft sprocket timing marks are at the 12 an 3 o’clock positions as shown.
2.0L Diesel Engine : Engine timing chain system
Timing chain adjustment(Installation)
2. Install an open end wrench (3) on the flats of the camshaft
to prevent the camshaft fro turning.
3. Install the intake camshaft sprocket (2) and bolt(1). Tighten
to 25 N·m (18.4 lb ft).

Note: When installing the timing chain, ensure the camshaft marks (2) and
crankshaft marks (3) are aligned.
4. Install the timing chain (1) over he intake camshaft (2)

5. Install the timing chain guide shoe (2).

6. Install the timing chain guide hoe bolts (1) and tighten to 25 N·m (18 lb ft)
2.0L Diesel Engine : Engine timing chain system
Timing chain adjustment(Installation)
7. Install the timing chain tensioner shoe (2).
8. Install the timing chain tensioner shoe side bolts (1) and tighten to
25 N·m(18 lb ft).
9. Install the timing chain tensioner (3).
10. Install the timing chain tensioner bolts (2) and tighten to 10 N·m (89 lb in)
11. Install the exhaust camshaft sprocket and thrust washer (2).
12. Install an open end wrench (1) on the flats of the camshaft to prevent the
camshaft from turning.
13. Install the exhaust camshaft sprocket bolt (3) and tighten to 8 N·m (71 lb in)
14. Remove EN-955-1 pin (4).
15. Install the engine front cover.
16. Install the camshaft cover.
2.0L Diesel Engine : Accessory drive system
Accessory belt
Fam Z Accessory drive system has a serpentine belt layout, belt Pulley_Alternator(OWC) P/S Pump
length 2200mm with Aramid cord for belt vibration control. Idler(Lower)
Idler(Upper)
Mechanical tensioner is used for the constant tension. Double row
bearing and wide width of pulley for Idler(Lower) is applied to
prevent belt jumping off. Alternator with OWC(One Way Clutch)
to prevent belt noise during engine start-up. Crank Isolator to Water Pump
decouple the rigid body torsional motion of chankshaft to stabilize
the accessory drive system.
Rubber material(EPDM) of belt is easily deformed and degraded
by Engine Oil, Engine Coolant, Fuel, P/S Pump Fluid, engine room
washing Fluid ,so need a careful operating not to be
contaminated. Tensioner

A/C Compressor
Crank Pulley (Crankshaft
Isolator)
Belt
2.0L Diesel Engine : Engine Intake system
Description of Plastic Intake Manifold with Variable Swirl System
The intake manifold is air flow passage to the cylinder combustion chamber through the Seal -
Swirl
Actuator
throttle body and has an effect on engine torque, power, noise, drivability, emission, fuel Port Seal -
economy and performance. It is made of plastic(PA66+GF30%) with light weight . Vacuum Throttle
swirl actuator with integrated position sensor Body

Swirl Valve

TMAP Sensor
Hole

Seal – EGR Pipe

EGR Gas
Inlet
2.0L Diesel Engine : Engine Intake system
Electrical circuit

Powertrain
ECM
Swirl actuator relay
solenoid valve
X2 1

X2 2 J1 89

X1 1
J1 69

X1 2 J1 14
Signal

X1 3 J1 43
5V ref
Position sensor
2.0L Diesel Engine : Engine Exhaust system
Exhaust system
The function of the muffler is to reduce engine noise. It is made up of a series
of perforated tubes and baffles to break up the sound waves and reflect them.
It is made of Stainless Steel to protect the front muffler from corrosion.
The rear muffler is to reduce broad band engine exhaust noise. It is comprised
of a series of perforated tubes and baffles to break up the sound waves and
reflect [Link] adopted dual muffler for C-car improves the efficiency to
reduce flow noise. It is made of Stainless Steel to protect the front muffler from
corrosion.

1. Front pipe nuts

2. Rear muffler nuts
3. Gasket
4. Exhaust resonator
2.0L Diesel Engine : Engine vacuum system
Vacuum pump
Vacuum pump provides the vacuum to the brake booster and Turbo, swirl flap, VGT, Swirl, EGR
EGR(exhaust gas recirculation system) valve at diesel engine and installed at
the end of exhaust camshaft

Part Item Specification

Type Single vane type

Vacuum pump
Vacuum - 0.92 bar at idle
2.0L Diesel Engine : Engine vacuum system
PCV valve
PCV system functions as a recirculation of blow by gas from crankcase to 2
combustion chamber as the attached passage of blow by gas. PCV valve is 1
one of the key parts of PCV system. It does not only regulate crankcase
pressure by controlling the flow of blow by gas but also separate oil from blow 4
by gas effectively. 3

1. PCV hose
: Blow by gas 2. PCV valve
: Fresh air + Blow by assembly(W/OIL SEP)
3. Turbo charger
4. Intake manifold

PCV valve
2.0L Diesel Engine : Engine cooling system
Coolant circuit diagram 2. Water pump and Thermostat
Model Year ‘11

Hub
Pulley
2

Model Year ‘12

EM coil
4
3
1
Electric
Pulley and connector
clutch
1. Water pump
2. Water pump gasket
3. Thermostat
4. Thermostat cover

Part name Specification Remark

Pump is OFF and coolant
Water pump Operating voltage : 9V ~ 16V
is not circulated with the
(Since MY ’12) (DC)
electric power input
Opening Temp. : 82±1.5℃ At 0.35mm valve lift
Thermostat
Full opening lift : Min. 8mm At 95℃
2.0L Diesel Engine : Turbo charger system
Description of Variable Geometry Turbocharger(VGT)
The turbocharger for this system has boost pressure actuator control by the engine control module (ECM). The vanes can be
opened and closed to vary the amount of boost pressure. Thus, the boost pressure can be controlled independent of engine
speed. There are 11 controllable vanes in this turbocharger. The vanes mount to a drive ring that can be rotated to change
the vane angle. When the engine is not under load, the vanes are open to minimize boost and exhaust back pressure. To
increase boost when the engine load requires it, the vanes are commanded closed. The ECM will vary the boost dependent
upon the load requirements of the engine.

Compressor
Turbine

Intake air

Exhaust gas

Throttle body
2.0L Diesel Engine : Turbo charger system
Inter-cooler
Turbo charger is the device that supplies hot and compressed air, that is
from the turbine by sucking exhaust gas or ram air, to the engine to
increase the power.
Quick compressed air from this turbo charger expands with high
temperature and causes decreasing of charging efficiency into the
cylinder because density of oxygen gets lower.
However Charging efficiency into the cylinder increases as compressed
hot air is cooled and density of air gets higher through the intercooler.
It brings also higher fuel efficiency as well as lower CO2 emissions.
Intercooler which is installed on top of radiator in front of car makes
compressed hot air cool by airflow through the radiator grill.
2.0L Diesel Engine : Fuel supply system
Fuel tank
The fuel tank is made from high density polyethylene. 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 Rollover valve and Grade vent valve.

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
2.0L Diesel 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

3. 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
2.0L Diesel Engine : Fuel supply system
. Specification of Fuel pump
System Pressure 450 kpa

Displacement 165 ~215ℓ/h

Relief pressure min 650 kPa - max 900 kPa

Current 3.0 ~ 11.5 AMP

3-2. 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

Fuel level Signal Remarks

FULL 3.4V 5V Ref

3/4 3.0V

1/2 2.2 ∼ 2.5V

1/4 2.0V

Empty 1.4 ~ 1.5V

2.0L Diesel Engine : Fuel supply system
Fuel heater

Part Item Specification Remarks

Type PTC Thermistor
Operating
12V
voltage
Heater resistor 0.4 ∼ 2 Ω
Fuel heater
Operating
250W -20℃
power
Enable
Less than 3℃ Off (more than 5℃)
condition
2.0L Diesel Engine : Fuel supply system
. Water In Fuel (WIF) sensor
[Link] in fuel sensor Part Item Specification Remarks
Mechanical lead
Type Float
switch
WIF Operating voltage 10 ∼ 16 V
sensor Indicate lamp ON Over 95 CC
Less than 15mA Indicate lamp Off
Consume current
Less than 50mA Indicate lamp ON

Water Draining Procedure

1. Attach a small piece of hose onto the water in fuel drain. Place the
other end of the hose into an approved fuel-resistant container.
2. Open the drain 3 or 4 turns or until the water contaminated fuel seeps
from the drain.
Tighten :10 N·m
2.0L Diesel Engine : Diesel common rail system
Description of Diesel common rail system
The common rail system was developed primarily to cope with exhaust gas
regulations for diesel engines, and aimed for further improved fuel economy; noise
reduction and high power output.
ECM controls the injection system such as injection pressure, injection quantity, and
injection timing
1) Injection pressure control
- Enables high-pressure injection even at low engine speeds.
- Optimizes control to minimize particulate matter and NOx emissions.
2) Injection quantity control
- Pilot injection control sprays a small amount of fuel before the main
injection.
3) Injection timing control
- Enables finely tuned optimized control in accordance with driving
conditions.
2.0L Diesel Engine : Diesel common rail system
High pressure pump Fuel outlet to rail Fuel return to fuel tank

Fuel return from

The high pressure pump creates the system pressure required by the injectors
Common Rail System for all operating conditions of the engine. It is directly
connected by Oldham Coupling to Cam Shaft and operated and has 2
cylinder plungers. The Inlet Metering Valve is controlled by ECM and limits
Inlet metering valve
the amount of fuel to pump.
Fuel inlet

Cylinder

Oldham Coupling

Cylinder
2.0L Diesel Engine : Diesel common rail system
. Common rail 3-1. Electrical circuit

Fuel outlet to injector Rail Pressure Sensor

ECM
3 J1 38
5V Ref

Fuel inlet 2 J1 35
from pump Signal

1 J1 19
Rail pressure sensor

Part Item Specification Remarks

Common rail Rail pressure Max. 1800bar

Type Piezo Resistor
Rail pressure
Supply Voltage 5V
sensor
Output Voltage 0.5 - 4.5 V
2.0L Diesel Engine : Diesel common rail system
Injector
It has seven holes sized for 134㎛ in the nozzle. Common Rail Systems uses multiple injections per combustion stroke. Alignment of pilot and
post injection events are required to emission or after-treatment system requirements. Injection pressure, injection quantity and injection
timing control are independent of engine speed or position.

Part Item Specification Remarks

Fuel Return IQA code
Type Solenoid Multi injection type
Fuel Inlet Injection hole 8 holes
Operating temperature -30 ∼ 120℃
Injector Max. Injection pressure 1800 bar
IQA code
Min. Injection pressure 150 bar
Normal Injection pressure 230 ∼ 1800bar
Return pressure Pabs < 900 mb

Nozzle
2.0L Diesel Engine : Diesel common rail system
Injector Quantity Adjustment(IQA)
IQA (Injector Quantity Adjustment) codes have been adopted to enhance the injection quantity precision of the injectors. The adoption of
IQA codes enables injection quantity dispersion control throughout all pressure ranges, contributing to improvement in combustion
efficiency, reductions in exhaust gas emissions and so on.
IQA codes displaying various injector characteristics are laser marked in the label plate onto the injector. When an injector is newly installed
in a vehicle, it is necessary to input the IQA codes in the ECM by MDI tool.

IQA code
2.0L Diesel Engine : Diesel common rail system
Electrical circuit

ECM

1
J1 27

Injector # 1 2
J1 26

1
J1 50

Injector # 2 2
J1 74

1
J1 51

Injector # 3 2
J1 75

1
J1 3

Injector # 4 2
J1 25