The World Engine: The Truths and Myths - Hyundai Genesis Forum
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post #1 of 19 Old 02-13-2009, 03:11 AM Thread Starter
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The World Engine: The Truths and Myths

FRCDAIR compiled this info on the GEMA world engine into one easy to use thread & I thought would be nice for those who are not familiar with the engine developement.

"I just spent a good 2 hrs looking this up and double and triple checking the info so it should all be good to go. Anything beyond this is speculation unless there is some kind of evidence. This is by no means all the information available on the GEMA project. Nor is it likely that all the information on individual manufacture's specifications is readily available, especially on a new car and engine like the Gen Coupe and Theta II."


Quote:
Originally Posted by GEMA Website
In total, annual production of Global Engines surpasses 1 million units per year and they can be found in over 20 vehicle nameplates worldwide

Quote:
Originally Posted by Mitsubishi Website
Hyundai will have the lead responsibility for implementing the decisions of the joint venture company for design, development and engineering.

Getting sick of seeing bad info and stuff taken as fact that isn't, here are the basics followed by the quoted info, I will focus on the 2.0 as that is what we all care about.

The World Engine is produced by the Global Engine Manufacturing Alliance, a joint venture between Hyundai, Mitsubishi, and Chrysler. The main goal is to produce more efficient components through extreme mass production.

The engine is modular in design and displacement is adaptable through change of stroke and piston sleeves. Comes in three displacements 1.8, 2.0 and 2.4. The engine was in essence designed for boost and has received complaints about vibration and bad low range power in N/A applications.

- Many engine components (accessories) are unique to each company: Intake manifolds, exhaust manifolds, and small modifications to fit any of the companies individual technology. (for example, the standard engine is equipped with a single built in oil pump while Hyundai's Theta II has two)

- The block and initial heads were designed by Hyundai.

- The final head design and CVVT system are based on an advanced Mercedes design from the E-class V6. Development was headed by Chrysler.

- Engine components such as pistons, rods, crankshafts, etc. Are all outsourced and arrive at the assembly factory ready to be installed.

- Engines are assembled at each companies separate GEMA plant (2 US, 1 Japan, 2 S. Korea) Although some cross trading is normal to fill companies individual volume requirements.

- There are some differences in the World Engines between manufacturers when the engine is applied in a more high performance intended application.
> Mitsubishi's claims its Turbo 2.0 4B11 series is using different intake and exhaust manifolds, reconfigured ports, and Mitsu's own CVVT system.
> The current 4B11 is using the modular block construction to create a 'square combustion chamber of 86mm bore x 86mm stroke which Mitsu claims give the engine a 'rev happy" nature.
> However, information on sites like wikipedia stating the 4B11 was reinforced "heavily" for boost are in no way backed up when the quoted source is followed back to Mitsubishi's website. In fact Mitsubishi make no mention whatsoever of reinforced internals beyond the standard for the engine.


Quote:
The initial design of the engine block was handled by Hyundai. It features siamesed bores, meaning that there is no coolant flow between cylinders. The aluminum block has cast iron cylinder liners, and different liners can be fitted to alter the engine's bore.

Quote:
The heads feature electro-hydraulic variable valve timing on both the intake and exhaust side. The system was based on that used by the recent Mercedes-Benz 24-valve V6 and is quite sophisticated and expensive for a low-end engine. A variable tumble control system creates air tumbles in the intake runners at low rpms for better mixture. Valves are directly actuated by solid Bucket tappets.

Quote:
According to GEMA, Chrysler actually took the lead in development of the dual variable valve timing system.

Quote:
While all the engines use essentially the same block, displacement is changed by shortening the stroke or using thicker piston liners. The pistons themselves have short skirts and friction-reducing graphite patches. The crankshaft is forged steel, is located above the balance shaft/oil pump, and draws oil from the oil pan; it includes an integrated pump. The blocks are all automatically measured at the factory and key components such as pistons and bearings are matched to individual engines to reduce machining and noise, while increasing engine efficiency.

Quote:
Originally Posted by executive vice president Product Development, Chrysler Group
Hyundai handled the initial block and cylinder head design and was the short-block lead, but JL French (J.L. French Aluminum Die Casting) will deliver the high-pressure die-cast aluminum block from its Sheboygan, WI, facility in fully machined form to the Dundee plants.The block is stout, has cast-in iron liners, and has been designed to support the naturally aspirated, turbocharged, and supercharged performance variants that inevitably will supplement the base engines.

Quote:
Originally Posted by executive vice president Product Development, Chrysler Group
Ample water jackets surround each siamesed cylinder and leave enough structure to help the block take high boost pressures, resist twisting, and provide a stable sealing surface around the wedge-shape combustion chamber. Displacement is altered by fitting thicker liners or altering the stroke, and the pistons have short skirts and wear graphite patches to reduce friction.

Quote:
The basic engines were designed jointly by Chrysler, Mitsubishi, and Hyundai, and are made and used by all three - in different configurations. Reviewers generally praised the Hyundai version more than the Mitsu, and the Chrysler version, being tuned for peak paper power, comes in last - except when turbocharged. The World Engine is criticized for being rough and noisy, and making poor power at lower engine speeds, but it was reportedly cheaper to build than the old 2.0 / 2.4 liter engines.

Quote:
The cylinder block and other basic structural parts of the engine were jointly developed by the GEMA companies, but the intake and exhaust manifolds, the cylinder headís intake and exhaust ports, and other elements related to engine tuning were independently developed by Mitsubishi.

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post #2 of 19 Old 02-13-2009, 04:18 AM
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Man he must have alot of time to research all that.
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post #3 of 19 Old 02-13-2009, 04:43 AM
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"wow" very good info .
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post #4 of 19 Old 02-13-2009, 04:45 AM Thread Starter
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Originally Posted by Lord Calvert View Post
Man he must have alot of time to research all that.
He's a fanatic, like a lot of us...LoL

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post #5 of 19 Old 02-13-2009, 05:46 AM
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For those who want to here are the links to the GEMA site and a very good read from AllPar regarding the engines:

GEMA Engine - Home

Chrysler World Engines
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post #6 of 19 Old 02-13-2009, 07:47 AM
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im curious how does a service advisor have that much time??lol. it must be a dealership thing

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post #7 of 19 Old 02-13-2009, 10:24 AM
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Wow, very good info!
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post #8 of 19 Old 02-13-2009, 11:21 AM Thread Starter
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Quote:
Originally Posted by OHGENESIS View Post
im curious how does a service advisor have that much time??lol. it must be a dealership thing
Well FRCDAIR is not a svc advisor to my knowledge, although I could be wrong.

I on the other hand, have the forums (esp this one) up constantly in the back ground of my computer. Anytime I get a split second that I'm not helping a customer or working on something, I jump on here & try to get something accomplished. Like, over the past couple of weeks, I've been going through all my post your pics & organizing, reducing post sizes so they will load faster, deleting duplicates, putting pics of the same car together, etc

P.S By the way, this short post took me over an hour because of interuptions from my job, customers, etc
It can be fustrating at times just trying to finish a sentence.

I also spend a fair amount of time at home at night when there's nothing else to do. Remember I don't go out much because all m y money goes to modding my cars...LoL

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post #9 of 19 Old 02-13-2009, 01:15 PM
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that was my point. its the same way around here.
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post #10 of 19 Old 02-13-2009, 01:19 PM
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it wasnt ment to be a jab at you. i was just curious because i know how things can be customers/techs/mngrs. etc.
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