Chapter 2.
Gamma Engine
1. Preface
2. Application
3. Gamma engine
4. Overview
5. Changed parts
6. Driving Belt – Serpentine type
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7. Timing Chain
8. Cylinder Head
9. Crankshaft Offset
10. MLA (Mechanical Lash Adjuster)
11. Coolant Passage
12. Changed item – Cylinder Block / Cylinder Head
13. Changed item – Exhaust Manifold / Delivery Pipe
14. Changed item – Others
Copyright by Hyundai Motor Company. All rights reserved.
Chapter 2. Gamma Engine
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24 Technical Training Team 1
Chapter 2. Gamma Engine
1. Preface
To learn the characteristics of the gamma Engine.
To learn the new technology and changed systems in
Learning Goals gamma engine for PB.
To learn the diagnostic procedures for the gamma
Engine.
The gamma engine (1.4L) & 1.6L) is applied for PB (i20). The Gamma engine is already applied for
HD ELANTRA. But, several items are changed for improving performance and reducing emission.
The changed items are cylinder block, LRSP, exhaust manifold, thermostat, piston, and crankshaft
and so on. In this training manual, changed items and new items will be mentioned. For more detail
information or specifications, please refer to the relevant workshop manual and electrical
troubleshooting manual. We hope that this chapter will be of optimal use with the diagnosis and on-
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site servicing of the system.
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Chapter 2. Gamma Engine
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26 Technical Training Team 1
Chapter 2. Gamma Engine
2. Application
Transmission Area
Engine
M/T A/T Europe General India
Kappa 1.2L
- - ○
(1,197cc)
M5EF2 -
Kappa 1.25L
○ ○ -
(1,248cc)
Gasoline
Gamma 1.4 ● ● -
M5CF1-1 A4CF1
Gamma 1.6 ● ● -
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U 1.4 M5CF2-1 - ○ ○ -
Diesel
U-II 1.6 M6CF3-1 - ○ - -
●: A/T, M/T ○: M/T ONLY
PB has 6 types of engine. Those are 4 variants for gasoline (Kappa 1.2 and 1.25, Gamma 1.4 and 1.6) and
2 variants for Diesel CRDI (U-I 1.4 and U-II1.6) respectively. The Kappa engine is being used for PA (i10)
and it matches only M/T, gamma gasoline engine is being used for ELANTRA (HD) and i30 (FD). The U-II
engine is enhanced from U-I engine and it is applied in HMC model for the first time. Gamma engine has a
CVVT system but kappa engine does not. U- I 1.4 WGT and U-II 1.6 VGT engine have 2 variants; low
power and high power model.
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Chapter 2. Gamma Engine
3. Gamma engine
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γ - 1.4 CVVT
Engine γ - 1.6 CVVT (Europe / General)
(Europe / General)
Displacement (cc) 1396 1591
Bore ×Stroke 77 ×74.99 77 ×85.44
Max. Power (PS / RPM) 100 / 5500 126 / 6300
Max. Torque (kgf·m / RPM) 14.0 / 4200 16.0 / 4200
Thermostat 82℃/95℃ 88℃/103℃
◆ Timing Chain
◆ Individual Ignition (Stick coil type)
◆ Shim-less MLA (Solid tappet)
◆ CVVT standard
Feature ◆ Plastic Intake manifold (Reversed intake and exhaust manifold)
◆ BOSCH PCM
◆ Crankshaft offset : 10mm
◆ Serpentine belt
◆ Integrated CCC
The Gamma engine is a successor model of Alpha II. Many mechanical components are changed but EMS
is same as alpha II. The gamma engine uses BOSCH EMS. Mainly the Gamma engine is similar to the
Theta engine. Following is the main features of gamma engine;
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Chapter 2. Gamma Engine
1) Reverse position for intake, exhaust manifold
- Similar as the theta engine intake manifold is located in forward to improve cooling efficiency and repair
ability.
2) Offset crank shaft applied by 10mm
- To increase inertia moment offset crank shaft is used.
3) High pressure casting aluminum block and ladder frame
- To increase coherence add more ribs and cylinder block is made from aluminum.
4) Serpentine belt
- One belt type driving belt is applied.
5) Timing chain
- Timing chain rotate intake and exhaust camshaft at the same time same as theta.
6) CVVT
- Denso CVVT is applied. (Beta, gamma, theta CVVT are same mechanically but operating range is
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different.
7) Direct driven valve train [solid tappet]
- MLA (Mechanical Lash Adjuster) type valve train is applied.
8) Plastic intake manifold
- Length/Cross-sectional shape is optimized for enhancing torque at all rpm zone.
- As the material is changed (aluminum plastic), the air flowing resistance is enhanced so the output
and torque is increased.
9) Stainless steel exhaust manifold
- Stainless steel exhaust manifold is applied to prevent from cooling down the exhaust gas temperature
quickly.
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Chapter 2. Gamma Engine
4. Overview
Effect
Item
Performance Emission NVH Weight Cost Endurance
Al cylinder block ●
Reverse In/Ex
● ● ● ●
Manifold
CVVT ● ●
Solid Tappet ● ●
Timing Chain ●
Serpentine belt ● ● ●
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SUS Ex/Manifold ● ● ●
Ladder Frame ● ●
Offset crank ●
Serpentine belt Timing chain CVVT MLA (Shimless type)
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Chapter 2. Gamma Engine
5. Changed parts
Fuel
Parts Performance Durability Compatibility Remark
economy
Cylinder block O X Water jacket wall removed
Cylinder head O X Water jacket size increased
Piston O O X ‘EA’ marked on the top
Cylinder head gasket O X Water hole changed
Combustion chamber O X Shape changed
Spark plug O X LRSP (M12)
Thermostat O X Opening: 82°C 88 °C
CKP target wheel O X Thickness reduced by 1mm
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Delivery pipe X Rectangular type, no damper
Thermostat cover X Shape changed
Catalytic converter O X Integrated (WCC+UCC)
Exhaust manifold O X Shape changed
◆ Crank shaft, Timing chain, CVVT, MLA, Intake manifold and Ladder frame are not changed.
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Chapter 2. Gamma Engine
6. Driving Belt – Serpentine type
Idler
◆ Driving belt
- Serpentine type (One-Belt type)
- With MDPS
- Weight and size is reduced
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Alternator
A/C compressor
Water Pump
Driving belt
- By driving all auxiliary machineries using one serpentine belt, the alignment of the auxiliary machinery
is optimized and the vibration by rotating is reduced so that vibrating amplitude is reduced.
- As auto tensioner is employed, the belt endurance is enhanced
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Chapter 2. Gamma Engine
7. Timing Chain
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For Gamma For Theta
Aligning is same as theta timing aligning. In theta and gamma engine timing system ratchet type auto
tensioner is used. Right is for theta and left is for gamma. Mounting position is same but length of piston is
different.
Timing chain system
- By employing low noise chain, the chain meshing noise and crashing noise are reduced.
- Reinforcing timing chain cover strength and enhancing the sounds
- The endurance is enhanced by changing the timing chain.
- By employing variable valve timing system, the torque for low or middle speed is optimized and fuel
efficiency is enhanced.
Installing method for timing chain and auto tensioner
1) Dispose the crank axis sprocket half-circle key to the horizontal line of the cylinder block assembling
surface to align with 1st cylinder top dead center.
2) Meet the TDC mark of the intake·/ exhaust cam shaft sprocket to the upper surface of the cylinder
head. (There are two marks on the cam shaft sprocket surface. Between them, align to the ‘━’ TDC
mark. Note: ‘●’: Timing Chain Mark)
3) Turn the timing chain to meet the crank axis sprocket timing mark (‘●’) to the middle position of the
colored link of the chain.
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Chapter 2. Gamma Engine
4) Meet the intake·/ exhaust cam shaft sprocket timing mark (‘●’) to the middle position of the colored
link of the chain.
5) Install the timing chain guide (A).
6) Install the timing chain guide (B).
7) Install the auto tensioner after fixing it with a fixing pin by pushing the rod of the auto tensioner
thoroughly.
8) After the fixing pin is removed, check the timing chain whether it is properly installed or not.
9) After turn the crank axis shaft with two rotations, check the timing chain mark.
[Remark]
When the timing chain is installed, do not apply excessive force. (to prevent the timing chain link being
distorted)
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Chapter 2. Gamma Engine
8. Cylinder Head
Gamma 10mm double Theta 12mm double
hexagon hexagon
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◆ Cylinder Head
- Aluminum block
- Tightening Torque
→ 2.0kgf-m + 90˚ + 100˚
→ Use 10mm double hexagon wrench
- Cap marking
Cylinder head
- AC2B-T7 aluminum
- Weight : 9.5kg
- Tightening torque: 2.0kgf-m + 90˚ + 100˚
Cylinder head bolt
For gamma: 10mm double hexagon
For theta : 12mm double hexagon
Above picture shows cylinder head bolt of gamma (left) and theta (right) engine. When assembling or
disassembling, use 10mm double hexagon socket. If use hexagon socket then head bolt screw thread is
damaged. For reference in case of theta use 12mm double hexagon socket.
Camshaft cap
There is an arrow mark on camshaft cap. When assembling let that arrow mark face to timing chain side.
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Chapter 2. Gamma Engine
9. Crankshaft Offset
Offset
Center of Cylinder bore
◆ Crankshaft offset
- For reducing fuel consumption
- To increase inertia moment offset
crank shaft is used
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Center of Crankshaft
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Chapter 2. Gamma Engine
10. MLA (Mechanical Lash Adjuster)
◆ Valve Clearance
→ Intake: 0.2 ± 0.03mm (0.17 ~ 0.23 mm)
→ Exhaust: 0.25 ± 0.03 mm (0.22 ~ 0.28 mm)
◆ Tappet
→ 41 kinds tappet are supplied.
→ Thickness: 3.000 ~ 3.600 mm
→ Size and parts number of Tappets for gamma
and Mu engine are same
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When MLA valve clearance is checked, the engine status is basically at room temperature, that is the
coolant temperature is 20℃.
At first, the clearance of γ-Engine is 0.17~0.23mm for intake valve and 0.22~0.28mm for exhaust valve.
If the valve clearance is exceeding the regulated value, at first, noise problem is considered. Further it may
affect to engine performance. For acquiring wanted performance in engine, the clearance deviation of each
cylinder should be minimized and the camshaft should press the valve at exact timing. Therefore, the valve
clearance should be adjusted to standard value
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Chapter 2. Gamma Engine
11. Coolant Passage
HEAD BLOCK R
A
D
I
A
T
O
R
HEATER, T/BODY
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W/PUMP ASSY
EX: Cold Operation
Thermostat
88~103℃
Coolant passage
- Coolant passage is divided cylinder head and cylinder block.
- Inlet control type
- Thermostat is started to open at 88℃ and open fully at 103℃
(conventional gamma: 82 ℃ / 95 ℃)
Cooling Fan logic
A/C ECT(℃)
A/CON Pressure (kg/ cm2) VS(KPH)
S/W
-30 60 95 100 105
P ≥ 15.5 ALL OFF HIGH
＜45 OFF LOW HIGH
15.5＞P ≥ 12 45 ≤ V＜80 OFF LOW HIGH
80＜V OFF HIGH
ON
＜45 OFF LOW HIGH
12＞P ≥ 6 45 ≤ V＜80 OFF LOW HIGH
80＜V OFF HIGH
6 ＞P ALL OFF HIGH
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Chapter 2. Gamma Engine
＜45 OFF LOW HIGH
OFF 45 ≤ V＜80 OFF LOW HIGH
80＜V OFF HIGH
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Chapter 2. Gamma Engine
12. Changed item – Cylinder Block / Cylinder Head
HD PB Remark
Applied LRSP
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- M14 -> M12
LRSP :Long Reach Spark Plug
M12
M14
Side wall is removed from convention gamma engine. It is for enhancing engine cooling. So, Head gasket
is changed. The water jacket is expanded at exhaust side. It can control lean A/F ratio by reducing
temperature of exhaust gas. Also exhaust side water jacket of spark plug circumference is expanded. It is
for improving fuel consumption by controlling spark timing (advanced) by improving knock characteristic.
Spark plug is changed (M12 Long Reach Spark plug)
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Chapter 2. Gamma Engine
13. Changed item – Exhaust Manifold / Delivery Pipe
HD PB Remark
- SUS Exhaust manifold is applied
- Integrated CCC (WCC+UCC) is
applied.
- Reduced weight
- Reduced catalytic heating time
- Rectangular type delivery pipe is
applied.
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- Damper is removed.
- Delivery capacity is increased.
(43cc → 92cc)
Exhaust System
◆ SUS Exhaust manifold is applied
◆ Integrated CCC (WCC+UCC) is applied
◆ Reduced weight
◆ Reduced catalytic heating time
Delivery Pipe
◆ Rectangular type delivery pipe is applied
◆ Damper is removed
◆ Delivery capacity is increased ( 43cc → 92cc)
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Chapter 2. Gamma Engine
14. Changed item – Others
◆ Reduced counter weight
◆ Piston is changed
- Compensated compression ratio
Marked identification : “EA’, “EB”, “EC”
E
A
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Counter Weight
◆ CKP target wheel : reduced thickness (10.5mm →
9.5mm)
◆ Specification of thermostat is changed
- 82℃/95℃ → 88℃/103℃
Thermostat
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