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This paper presents a 2.5L V6 aluminum cylinder block engine that has been developed for use in the next HYUNDAI SONATA vehicle. The major objective in developing this new engine was to achieve high power,especially high torque at low to mid speed range, quiet engine operation, reliability and good fuel economy. The basic construction of the engine is characterized by its 60-degree V6 configuration, compact combustion chamber and simple variable intake systems. The new engine has been designed to comply with the tougher TLEV emission standard, OBD-II requirements and California's new evaporative emission standards. This paper will introduce various technologies used in this engine that increased engine performance while reducing emission and improving fuel economy and NVH characteristics, and will discuss the engine construction, principal component parts, major development objects and test results.

The weight reduction and noise refinement of powertrain has been major concern in automotive industry although they are known as self trade-off. This paper presents various methods to deal with those problems for new Hyundai 1.5 liter powertrain. It was possible to reduce the weight of powertrain by using plastic for both headcover and intake manifold, aluminum for crankshaft damper pulley and stainless steel for exhaust manifold and by reducing the general thickness of cylinder block On the other hand, the noise refinement of vibration in the powertrain was made by optimizing the engine structure and by adapting the hydraulic lash adjuster valve train system, which was proved to be effective in mechanical noise of engine.