Motor 3,2 v6 Captiva

C100 Service Training Manual : Engine Mechanical (HFV-3.2L DOHC)

Participant’s Handout

01.2-3

C100 (3.2 L)Engine Mechanical


rev 01

Table Of Contents

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

01.2-4

C100 (3.2 L) Engine Mechanical


rev 01

01.2-5



rev 01

3.2L Engine : Engine general

1. Component ID2. Engine Broadcast Code3. Plant Code (’H’=Holden)4. Build Year (’06’ = 2006)5. Julian Date (’070’ = built on day 70)6. Build Sequence Number

Engine number (HFV6 3.2D)

01.2-6



rev 01

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

Clearance mm TBD

Ignition

Coil

Plug

Maker

Type

Ignition sequence

Initial Spark Timing (BTDC)

Type

Max Torque (Nm/RPM)

Firing Order

Idle RPM

Bore x Stroke (mm)

APPLICATION

Max Speed (MT/AT)

Min Turning Ratio (m)

VehiclePerformance

EngineGeneral

Engine type

Displacement (cc)

Compression Ratio

Max Power (hp/RPM)

Forced feed

API SJ grade, SAE 0W30 Synthetic

Spin-on (Full Flow)

7.4 L

Gerotor

Engine run TBD

Relief TBD

Lubrication

Type

Oil Type and Grade

Filter

Oil Pump

Type

Pressure

Oil Capacity (w/filter)


Specifications

01.2-7



rev 01

3.2L DOHC

Pressurized

9

Centrifugal

Cross Flow

Width 673 mm

Height 511 mm

Thickness 27 mm

140 Kpa

10 Kpa

Pellet

Start to open () 87 ± 2

Completely open ( ) 102

Completely close ( ) MIN 82

Electric

Main:5EA / Aux: 7EA

Fan Diameter 340mm + 320 mm

APPLICATION

Type

Coolant Capacity (L)

Cooling

Radiator

Type

Thermostat

Type

Fan

Type

Blades

Core

Water Pump

Surge TankPressure Valve open

Vaccum Valve open

MPI

Electric Motor

TBD

TBD

Cartridge

65 L

Planetary Gear Reduction

1.4KW

Alternator 120A

MF

12V- 60AH

650 CCA

Fuel Delivery

Starter

Capacity

Fuel Tank Capacity

Type

Power

Cold Cranking Ampere

Power

Battery

Type

Fuel Pump

Type

Displacement

Fuel pressure

Filter Type

Type


Specifications

01.2-8



rev 01

3.2L Engine : Engine mechanical

The V6 engine features a closed V, deep skirt die cast aluminiumcylinder 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 cylindersconsists of number 1–3–5 cylinders (BANK 1) and the front bank of cylinders consists of number 2–4–6 (BANK 2).The engine firing order is 1–2–3–4–5–6. 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 thefront 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 seamlessrod 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

General description

01.2-9



rev 01


Engine over view

Bank 1Bank 2

01.2-10



rev 01

1. Camshaft Cover, Bank 22. Camshaft Cover Gasket, Bank 23. Camshaft Cover, Bank 14. Camshaft Cover Gasket, Bank 15. Camshaft Cover Spark Plug Port Seal6. Camshaft Cover Bolt7. Camshaft Cover Bolt Insulator8. Ignition Coil Bolt Thread Insert9. Oil Fill Cap10. Oil Fill O–Ring11. Camshaft Cover PCV Fitting, Bank 212. Camshaft Cover PCV Fitting Orifice, Bank 113. Camshaft Cover PCV Fitting O–Ring, Bank 214. Ignition Coil15. Ignition Coil Bolt16. Spark Plug

Exploded view (Cylinder head cover assembly)


01.2-11



rev 01

1. Cylinder Head, Bank 22. Cylinder Head, Bank 13. Cylinder Head Gasket, Bank 24. Cylinder Head Gasket, Bank 15. Cylinder Head Bolt6. Cylinder Head Front Bolt7. Cylinder Head Coolant Hole

Threaded Plug8. Spark Plug Sleeve9. Cylinder Head Oil Gallery

Expansion Plug10. Exhaust Valve11. Intake Valve12. Valve Rocker Arm Assembly13. Hydraulic Valve Lash

Adjuster Assembly14. Valve Stem Oil Seal

15. Valve Spring16. Valve Spring Cap17. Valve Stem Key18. Cylinder Head Camshaft Front

Thrust Bearing Cap19. Camshaft Oil Seal Ring20. Exhaust Camshaft, Bank 221. Intake Camshaft, Bank 222. Intake Camshaft, Bank 123. Exhaust Camshaft, Bank 124. Cylinder Head Camshaft

Cap – Intermediate25. Cylinder Head Camshaft

Cap Bolt26. Cylinder Head Oil Galley

Check Valve27. Engine Coolant Temperature

Sensor

Exploded view (Cylinder head assembly)


01.2-12



rev 01

1. Upper Intake Manifold2. Throttle Body Assembly3. Upper Intake Manifold - to - Lower Intake Manifold Gasket4. Fuel Injector Wiring Harness5. Fuel Rail6. Fuel Injector7. Lower Intake Manifold8. Lower Intake Manifold - to - Cylinder Head Gasket9. Variable Intake Manifold (VIM) Control Valve

Exploded view (Intake manifold assembly)


01.2-13



rev 01

1. Engine Front Cover Locating Pin2. Engine Front Cover Bolt, M103. Engine Front Cover4. Engine Front Cover Gasket5. Engine Front Cover Bolt, M86. Engine Front Cover Seal7. Coolant Pump Assembly8. Coolant Pump Bolt9. Coolant Pump Gasket10. Coolant Pump Pulley11. Coolant Pump Pulley Bolt12. Crankshaft Balancer13. Crankshaft Balancer Bolt14. Camshaft Position Sensor15. Camshaft Position Sensor O–ring16. Camshaft Position Sensor Bolt17. Camshaft Position Actuator Solenoid Valve18. Camshaft Position Actuator Solenoid Valve Bolt19. Camshaft Position Actuator Solenoid Valve Seal

Exploded view (Front cover)


01.2-14



rev 01

Exploded view (Timing chain components)


1. Crankshaft Sprocket 2. Lower Primary Timing Chain Guide3. Primary Timing Chain Tensioner 4. Primary Timing Chain Tensioner

Bolt5. Lower Primary Timing Chain Guide

Bolt6. Primary Timing Chain 7. Upper Primary Timing Chain Guide8. Upper Primary Timing Chain Guide

Bolt9. Camshaft Intermediate Driveshaft

Sprocket Bolt10. Camshaft Intermediate Driveshaft

Sprocket, Bank 211. Camshaft Intermediate Driveshaft

Sprocket, Bank 113. Secondary Timing Chain, Bank 2 14. Secondary Timing Chain Guide

Bolt, Bank 215. Secondary Timing Chain Shoe,

Bank 216. Secondary Timing Chain Shoe

Bolt, Bank 217. Secondary Timing Chain

Tensioner, Bank 218. 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 122. Secondary Timing Chain Guide

Bolt, Bank 123. Secondary Timing Chain Shoe, Bank 124. Secondary Timing Chain Shoe Bolt, Bank 125. Secondary Timing Chain Tensioner,

Bank 126. Secondary Timing Chain Tensioner

Bolt, Bank 127. Secondary Timing Chain Tensioner

Gasket, Bank 128. Exhaust Camshaft Position

Actuator, Bank 229. Intake Camshaft Position Actuator,

Bank 230. Camshaft Position Actuator Bolt31. Exhaust Camshaft Position

Actuator, Bank 132. Intake Camshaft Position Actuator,

Bank 1

01.2-15



rev 01

1. Piston and Connecting Rod Assembly

2. Crankshaft Bearing Cap3. Crankshaft Bearing

Thrust Cap4. Crankshaft Bearing Cap

Inboard Bolt5. Crankshaft Bearing Cap

Outboard Bolt6. Crankshaft Bearing Cap

Side Bolt, Short

7. Crankshaft Bearing Cap SideBolt, Long

8. Engine Block Oil Gallery Expansion Plug, 10 mm

9. Crankshaft10. Crankshaft Sprocket

Locating Pin11. Crankshaft Upper Bearing12. Crankshaft Lower Bearing

Exploded view (Engine block assembly)


13. Crankshaft Upper Thrust Bearing #314. Engine Block Oil Gallery Expansion

Plug, 14 mm15. Engine Block Oil Gallery Threaded

Plug, 14 mm16. Engine Block Coolant Drain Threaded

Plug, 14 mm17. Engine Block Oil Gallery Threaded

Plug, 20 mm18. Engine Block Core Coolant Expansion

Plug, 34.3mm19. Transaxle Locating Pin20. Crankshaft Rear Oil Seal Housing

Assembly21. Crankshaft Rear Oil Seal Housing

Assembly Bolt22. Oil Pan Locating Pin23. Cylinder Head Locating Pin24. Piston Oil Nozzle25. Piston Oil Nozzle Bolt

01.2-16



rev 01

1. Connecting Rod2. Connecting Rod Bolt3. Connecting Rod Bush4. Lower Connecting Rod Bearing5. Higher Connecting Rod Bearing6. Piston7. Piston Pin8. Piston Pin Retainer9. Piston Upper Compression Ring10. Piston Lower Compression Ring11. Piston Oil Control Rail Ring12. Piston Oil Control Ring Spacer

Exploded view Piston & connecting rod)


01.2-17



rev 01

1. Oil Deflector2. Oil Pump Suction Pipe3. Oil Pan4. Oil Pan Drain Plug5. Engine Oil Level Sensor

Exploded view (Oil pan assembly)


01.2-18



rev 01

1. Transaxle Front Mount Assembly2. Engine Mount Adapter Support Bracket3. Engine Mount Assembly4. Cradle Assembly5. Transaxle Mount Assembly6. Transaxle Rear Mount Bracket7. Transaxle Rear Mount

Exploded view (Engine mount system)


01.2-19



rev 01

Three timing chains are fitted (primary, right–hand secondary and left–

hand secondary). The primary timing chain connects the crankshaft

sprocket with the left–hand and right–hand 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

[ Bank 1 camshaft bearing direction ] [ Bank 2 camshaft bearing direction ]

Camshaft and Bearings


01.2-20



rev 01

[ 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 toreduce friction.

1. Lower oil control ring position

2. Upper oil control ring position

3. Top ring position

4. Oil control ring expander position

5. Second ring position

[ Piston rings installation ]

Piston and Rings


01.2-21



rev 01

ITEMS 3.2L DOHC

Lub. Type Forced feed

Engine Oil API SJ grade SAE 0W-30 Synthetic oil

Oil Replacement with filter. Normal condition : 30,000 km / 12 months. Severe condition : 15,000 km / 6 months

Oil Capacity (w/filter) 7.4L

Oil Pump Pressure 69 Kpa at Idle (138 Kpa at 2000 rpm)

1. Lower Primary Timing Chain Guide2. Lower Primary Timing Chain Guide Bolt3. Oil Pump Housing4. Oil Pump Cover5. Oil Pump Gerotor Outer Ring6. Oil Pump Gerotor Inner Ring7. Oil Pump Cover Bolt8. Oil Pressure Relief Valve Bore Plug9. Oil Pressure Relief Valve Spring10. Oil Pressure Relief Valve11. Oil Pressure Relief Valve Bore Plug Retainer Clip12. Oil Pump Bolt

Oil pump

3.2L Engine : Engine lubrication

01.2-22



rev 01

1. Intake Camshaft Position (CMP) Actuator Timing Mark – Bank 2

2. Secondary Timing Chain Bright Plated Link – Bank 2

3. Exhaust Camshaft Position (CMP) Actuator Timing Mark – Bank 2

4. Secondary Timing Chain – Bank 2

5. Primary Timing chain

6. Camshaft Intermediate Drive Chain Sprocket Timing Mark – Bank 2

7. Primary Camshaft Intermediate Drive Chain Sprocket – Bank 2

8. Primary Timing Chain Bright PlatedLink

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

Timing chains

3.2L Engine : Engine timing system

01.2-23



rev 01

1. Intake Camshaft Position (CMP) Actuator Timing Mark – Bank 2

2. Secondary Timing Chain Bright Plated Link – Bank2

3. Exhaust Camshaft Position (CMP) Actuator Timing Mark – Bank 2

4. Secondary Timing Chain – Bank 2

5. Primary Timing Chain

6. Camshaft Intermediate Driveshaft Sprocket Timing Mark – Bank 2

7. Camshaft Intermediate Driveshaft Sprocket – Bank2

8. Primary Timing Chain Bright Plated Link

9. Camshaft Intermediate Driveshaft Sprocket Timing Mark – Bank 2

10. Camshaft Intermediate Drive shaft Sprocket – Bank1

11. Crankshaft Sprocket

12. Crankshaft Sprocket Timing Mark

Primary and Bank 2 secondary timing chains


01.2-24



rev 01

1. Install the crankshaft sprocket (1) onto the crankshaft(2) by aligning the keyway to the key on the crankshaft.

2. Slide the crankshaft sprocketon the crankshaft until thecrankshaft sprocket contactsthe step in the crankshaft.

Note : Ensure that the crankshaftsprocket is installed with the timing mark (1) visible.

CAUTION : In order to installTool No. EN 46105 onto thecamshafts, rotate the camshaftsin an anti–clockwise direction.There should be no need torotate the camshaft more than45 degrees.3. Install Tool No. EN 46105–1

(1) onto the rear of the bank 2cylinder head camshafts (2), and Tool No. EN 46105–2 onto the rear of the bank 1 cylinder head camshafts.

CAUTION : All camshafts must be locked in place before installationof any timing chains.4. Ensure that Tool No. EN 46105

is fully seated onto the camshafts.

Bank 2 secondary timing chain installation procedure - 1


01.2-25



rev 01

5. Using Tool No. EN46111 (1),rotate the crankshaft in aclockwise direction until thecrankshaft sprocket timingmark (2) is aligned with theindexing mark (3) on the oilpump housing.

6. Install the bank 2 secondarytiming chain (1) aligning thechain in the following manner:

A. Wrap the secondary timingchain around both bank 2actuator drive sprockets.

B. Ensure there are two brightlinks located on top of each ofthe camshaft actuator sprockets.

CAUTION : When aligning the bank 2 secondary timing chain tothe camshaft actuator sprockets,ensure the circular timing markson the sprocket are used, NOTthe triangular mark.C. Align the bright plated timing

chain link (1) with the bank 2exhaust camshaft position actuator sprocket alignment circle mark (2).



01.2-26



rev 01

D. Align the bright plated timing chain link (1) with the intakecamshaft position actuatorsprocket alignment circle mark(2).

CAUTION : The bank 2 camshaftintermediate driveshaft sprocket(1) is marked with the letters LBand ’FRONT’, and the bank 1sprocket (2) is marked with theletters RB and ’FRONT’ Ensurethe correct sprocket is used andthe ’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 secondarytiming chain around the left–hand camshaft intermediatedriveshaft 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.

TightenTighten the camshaft ntermediatedriveshaft sprocket attaching bolt

to 66 Nm (49 lb–ft).



01.2-27



rev 01

10. Verify the Bank 2 secondarytiming chain timing markalignments (1 to 6).

CAUTION : The bank 2 secondary timing chain guideis marked with the letters LH. Ensure the correct shoe is usedwhen installing to the Bank 2 sidein this procedure and that theletters ’LH” are facing the front ofthe vehicle when installed.11. Ensure the bank 2 secondary

timing chain guide is selected and orientated correctly.

12. Install the bank 2 secondarytiming chain guide (1).Tighten the secondary timingchain guide attaching bolt to 23 Nm (17 lb–ft).

CAUTION : The bank 2 secondary timing chain shoe(2) is marked with the letters LHon the back face of the timingchain shoe. Ensure the correctshoe is used when installing tothe bank 2 side.

13. Ensure the bank 2 secondarytiming chain shoe is selectedand orientated correctly.



01.2-28



rev 01

14. Install the bank 2 secondary timing chain shoe (1).

Note : Ensure secondary timingchain shoe is clear of the Bank 2secondary timing chain tensionermounting pad,before tightening the attaching bolt.TightenTighten the bank 2 secondary timing chain shoe bolt to 23 Nm (17 lb–ft).

15. Ensure the bank 2 secondarytiming chain tensioner is selected and orientated correctly.

16. Reset the bank 2 secondarytiming 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 secondarytiming chain tensioner body (2).



01.2-29



rev 01

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 inthe side of the tensioner body.

19. Slowly release pressure on the bank 2 secondary timing chain tensioner. The tensionershould remain compressed.

20. Install a new bank 2 secondary timing chain tensioner gasket (1) to the tensioner (2).

21. Install the bank 2 secondarytiming chain tensioner bolts through tensioner and gasket.

22. Ensure the bank 2 secondarytiming chain tensioner mounting surface on the Bank2 cylinder head does not haveany burrs or defects that wouldaffect 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.



01.2-30



rev 01

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).

TightenTighten the bank 2 secondarytiming chain tensioner bolts to 23Nm (17 lb–ft).

26. Release the bank 2 secondary timing chaintensioner (1) by pulling outTools No. EN 46112 (2) andunlocking the tensioner shaft.

27. Verify the bank 2 secondarytiming chain timing markalignments (1 to 6).



01.2-31



rev 01

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 wheninstalled.2. Ensure the bank 1 camshaft

intermediate driveshaft sprocket is selected and orientated correctly.

3. Install the bank 1 camshaftintermediate driveshaft sprocket(2).

TightenTighten the bank 1 camshaft intermediate driveshaft sprocket attaching bolt to 65 Nm (48 lb–ft).

4. Ensure that the crankshaft sprocket timing mark (1) isaligned with the indexing mark(2) on the oil pump housing.

Primary timing chain installation procedure - 1


01.2-32



rev 01

5. Install the primary timing chain(1).

6. Wrap the primary timing chainaround the large sprockets ofeach camshaft intermediate driveshaft sprocket and thecrankshaft sprocket aligning thebrightened chain links as follows:

A. The bank 2 camshaft intermediate driveshaft sprocket timing mark (1) willalign with a bright platedprimary timing chain link (2).

B. The bank 1 camshaft intermediate driveshaft sprocketTiming mark (1) will align with abright plated primary timingchain link (2).



01.2-33



rev 01

C. The crankshaft sprocket timing mark (1) will align with a bright plated timing chain link (2).

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 timingchain lower guide is notserviced separately. If theprimary timing chain lowerguide must be replaced, the oilpump assembly (2) must bereplaced.

8. Ensure the primary timing chain upper guide is selectedand orientated correctly.



01.2-34



rev 01

9. Install the primary timing chain upper guide (1).

10. Install the primary timing chain upper guide bolts (2).

TightenTighten the primary timing chainupper guide bolts to 23 Nm (17lb–ft).

11. Ensure that the primarytiming chain tensioner is being installed.

12. Reset the primary timing chain tensioner.

Note : To reset the tensioner,use a suitably sized flat bladescrewdriver (1) to wind theplunger in a clockwise direction,into the tensioner shaft (2).

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



01.2-35



rev 01

CAUTION : If Tool No. EN 46112(1) is not inserted into thetensioner body, the plunger willremain in the locked position andno tension will be placed on thetiming 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 sideof the body.

15. Slowly release pressure onthe primary timing chaintensioner. The primary timingchain tensioner should remain compressed.

16. Install a new primary timingchain tensioner gasket (1) tothe tensioner (2).

17. Install the primary timingchain tensioner bolts (3) through tensioner and gasket.

18. Ensure the primary timingchain tensioner mountingsurf ace on the engine blockdoes not have any burrs ordefects that would affect thesealing of the new gasket.

19. Place the primary timing chain tensioner (2) into position and loosely install the bolts (1) to the engine block.



01.2-36



rev 01

20. Verify the proper placement of the primary timing chaintensioner gasket tab (1).

21. Tighten the primary timingchain tensioner bolts (2).

TightenTighten the primary timing chaintensioner bolts to 23 Nm(17 lb–ft).

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 2secondary timing chain timing mark alignments (1 to 12).

24. Remove Tool No. EN 46105from the bank 2 and bank 1cylinder head camshafts.



01.2-37



rev 01

1. Install the primary timing chain components.

2. Using Tool No. EN46111 (1), rotate the crankshaft in aclockwise direction until thecrankshaft 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 thecamshafts, rotate the camshafts.There should be no need torotate the camshaft more than45 degrees.

3. Install Tool No. EN 46105–1 (1) onto the rear of the bank 1cylinder head camshafts (2).

4. Install Tool No. EN 46105–2(1) onto the rear of the bank 2 cylinder head camshafts (2).



01.2-38



rev 01

5. Install the bank 1 secondarytiming chain (1) onto thecamshaft actuators (2) and the right hand camshaft intermediate driveshaftsprocket (3) aligningthe chain in the followingmanner:

A. Place the secondary timing chain around the bank 1camshaft 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 1actuator drive sprockets.

CAUTION : Ensure that when aligning the bank 1 secondarytiming chain to the bank 1camshaft actuator sprockets, thatthe triangular timing marks (1) onthe sprocket are used, NOT thecircular mark.C. Align the bright plated timing

chain link (2) with the exhaust actuator sprocket alignment triangle mark.



01.2-39



rev 01

D. Align the bright plated timingchain link (1) with the intakeactuator sprocket alignmenttriangle mark (2).

CAUTION : Ensure that the bank1 secondary timing chain guideis used when installing to theBank 1 side in this procedure.6. Ensure that the bank 1

secondary timing chain guide is selected and orientated correctly.

7. Position the chain guide (2).8. Ensure the primary timing

chain upper guide is selectedand orientated correctly.

TightenTighten the secondary timingchain guide bolts to 23 Nm (17lb–ft).

CAUTION : The bank 1 secondary camshaft drive shoe ismarked with the letters ’RH’.Ensure that the bank 1 drive shoeis used when installing to thebank 1 side in this procedure andthat the letters ’RH” are facing thefront of the vehicle when installed.9. Ensure the bank 1 secondary

timing chain shoe is selectedand orientated correctly.



01.2-40



rev 01

10. Position the bank 1 secondary timing chain shoe(1).

TightenTighten the bank 1 secondarytiming chain shoe attachingbolt to 23 Nm (17 lb–ft).

11. Ensure the bank 1 secondarytiming chain tensioner isselected and orientated correctly.

12. Reset the bank 1 secondary timing chain tensioner.

Note : To reset the tensioner,use a suitably sized flat bladescrewdriver (1) to wind theplunger 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).



01.2-41



rev 01

CAUTION : If Tool No. EN 46112 (1) is not inserted into thetensioner body (2), the plungerwill remain in the locked positionand no tension will be placed onthe timing chain, this will causedamage 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 onthe bank 1 secondary timingchain tensioner. The tensioner should remain compressed.

16. Install a new bank 1 secondary timing chaintensioner gasket (1) to thetensioner (2).

17. Install the bank 1 secondarytiming chain tensioner bolts (3) through the tensioner andgasket.

18. Ensure the bank 1 secondarytiming chain tensionermounting 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 secondarytiming chain tensioner (2) into position and loosely install the bolts (1) to the engine block.



01.2-42



rev 01

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).

TightenTighten the bank 1 secondarytiming chain tensioner bolts to 23Nm (17 lb–ft).

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 46105and EN 46105–2 from the both cylinder head camshafts.

25. Reinstall the spark plugs.26. Reinstall the engine front

cover assembly.



01.2-43



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.

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

1. Power steering pump2. Water pump3. Belt tensioner4. Crankshaft5. Alternator6. Idler7. Compressor

01.2-44



rev 01

1. Air Cleaner Upper Housing2. Air Cleaner Element Seal3. Air Cleaner Element4. Air Cleaner Snorkel Assembly5. Lower Intake Air Duct6. Air Cleaner Resonator Duct Seal7. Air Cleaner Resonator Duct

Assembly

8. Air cleaner aFront Resonator9. Air Cleaner Resonator Seal10. Air Cleaner Rear Resonator11. Air Cleaner Lower Housing12. Mass Air Flow (MAF) Sensor

Assembly13. Air Cleaner Outlet Elbow Hose14. Air Intake Duct15. PCV Hose

PART NAME 3.2 DOHC

Air Cleaner Remote type / 12L

Element Effective Area 4000 cm2

Element Replacement 40,000 / 24 months

Element material Non-woven Fabric

Main Resonator Volume 3.8L

3.2L Engine : Air intake system

01.2-45



rev 01

1. Exhaust Manifold, Bank 1

2. Upper Heated Oxygen Sensor, Bank 1

3. Exhaust Manifold, Bank 2

4. Upper Heated Oxygen Sensor, Bank 2

5. Pup Converter, Bank 2

6. Pup Converter, Bank 1

7. Lower Heated Oxygen Sensor, Bank1

8. Lower Heated Oxygen Sensor, Bank 2

9. Exhaust Front Pipe

10. Exhaust Front Pipe to UCC Gasket

11. Underbody Catalytic Converter (UCC)

12. UCC to Front Muffler Gasket

13. Front Muffler Assembly

14. Front Muffler to Rear MufflerGasket

15. Rear Muffler Assembly

16. UCC Heat Shield

17. Front Muffler Heat Shield

18. Rear Muffler Heat Shields

3.2L Engine : Exhaust system

Pup Converter 1.14 ℓ

Underbody Converter 0.90 ℓ

Exhaust Front Muffler 10ℓ

Exhaust Rear Muffler 11.5ℓX 2EA

PART NAME 3.2L DOHC

01.2-46



rev 01

FAN SPEED APPLICATION ON OFF

ECT ( ) 100 97

A/C switch

ECT ( ) 110 107

ACP ( Kpa) 1760 1347

ECT

ON

Malfunction

High

Low

1. Radiator Upper Bracket2. Lower Radiator Bumper3. Radiator4. Main Cooling Fan5. Auxiliary Cooling Fan

6. Main Cooling Fan Motor7. Auxiliary Cooling Fan Motor8. Cooling Fan Shroud Assembly9. Coolant Drain Cock

3.2L Engine : Engine cooling system

Cooling fans

01.2-47



rev 01

1. Water Pump Pulley Bolt

2. Water Pump Pulley

3. Water Pump Bolt

4. Water Pump

5. Water Pump to Engine Front Cover Gasket

6. Thermostat Housing Bolt

7. Thermostat Housing

8. Thermostat

9. Thermostat Housing to Engine Block Gasket

Water pump and Thermostat

PART NAME 3.2L DOHC REMARK

Radiator Type Cross Flow

Radiator Size 673 × 511 × 27 W × H x T

Coolant Capacity 9ℓ

Thermostat start to open 87 ±2 Complete open : 102

Cooling Fans Φ340 + Φ 320 Main + Aux

3.2L Engine : Engine cooling system

01.2-48



rev 01

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 pumpmodule inside the fuel tank. The fuel pump supplies high pressure fuelthrough the fuel filter, past the fuel pressure regulator, and through thefuel 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.

1. Under body pipe line

2. Canister

3. Fuel tank

4. Fuel filter

21

34

Description of Fuel supply system

3.2L Engine : Fuel supply system

01.2-49



rev 01

Remarks

Capacity 65 L

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 fueltank is located in the rear of "Front muffler"and under the body of thevehicle. The fuel tank are each sides held in place by 2 metal strapsthat 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 Rollover valve and Grade vent valve, vapor pressure in the tank is discharged to the Canister and it doesn't make the tank over.

2. Main Fuel Pump

4 . Ring-Adaptor

3. Roll Over Valve

1. Sub Fuel Pump

5. Grade Vent Valve

Fuel tank


01.2-50



rev 01

The sub fuel pump module is located inside of the left side of the fueltank. The sub fuel pump module consists of the following majorcomponents:

• The fuel sender assembly • The fuel transfer tube

Main Fuel Pump Module

Sub 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 majorcomponents:• The fuel level sender assembly • The fuel pump and reservoir assembly • The fuel filter • The fuel pressure regulator• The suction and return jet assembly

01.2-51



rev 01

Fuel Level Gage ControlThe 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 inthe cluster by single wire CAN.

Fuel Level Gage Resistance

System Pressure 410 kpa

Displacement (12.0V / 410kPa) 100ℓ /h

Relief pressure (12.0V) min 600 kPa - max 900 kPa

Current (12.0V / 410kPa) 8 AMP

Fuel filter replacement 100,000miles / 10 years

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

Resistance(Ω )Float Height

FUEL LEVEL

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

Specification of Fuel pump


01.2-52



rev 01

Pressure Condition

410 Kpa Engine running

600 ~ 900 Kpa Relief pressure

Fuel Pressure RegulatorThe 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.


01.2-53



rev 01

Injector specification

Application 3.2 L DOHC

Static flow rate 193.6 (g/min)

Spray type Single spray type(4 holes)

Injection type Sequential

Injection angle 15 ˚

Resistance(Ω) 11.4 ~12.6


Injector and Rail

01.2-54



rev 01

The evaporative emission canister is an emission control device containing activated charcoal granules. The evaporative emissioncanister 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 ]

3.2L Engine : Evaporative emission control system

Canister

Documents

Motor 3,2 v6 Captiva