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Specification General System Layout Control Logic Components Description Engine Control Module Troubleshooting Injection Timing Adjustment
Specification
Item Engine Model No. of Cylinders Valve Mechanism Total Displacement Bore X Stroke Compression Ratio Compression Pressure Valve Clearance D4BH (TCI) 4, In-Line OHC 2,467 cc 91.1 X 95 mm 21 19.2 kg/ Intake : 0.15 mm Exhaust : 0.15 mm 94 ps 22.3 kg.m ATDC 9 Description
General
Features
Improved Torque Performance
COVEC-F
50
100
General
Decreased Smoke at Acceleration
General
Increased Comfort
Conventional type Control sleeve position Fixed
System Layout
Fuel System
Return Pipe Fuel Tank Over Flow Valve
Nozzle
Glow Plug
Injection Pump
System Layout
Components Connection
Add. Vehicle Control Vehicle Sensors Vehicle Switches Battery Voltage
Np Sensor
Np Sensor
CSP Sensor
TCV
TPS
System Layout
Input
Injection Pump Np Sensor CSP Sensor Fuel Temp. Sensor Compensation Resister TPS ECU Vehicle Vehicle Sensors EGR Valve Switches Glow Plugs Diagnostic Lamp Battery Voltage EGR Control Glow Control Self Diagnosis Timer Control Valve Injection Timing GE Actuator Fuel Quantity
Control
Output
Injection Pump
Control Item
Control Logic
Injection Amount Controls
Example
Np Sensor when CPS is failed CPS Eng. speed 3,000 RPM Pump speed ECM Injection Quantity 37mg/stroke APS Accel. Position 50% Feedback CSP Control Sleeve Position Check GE Actuator Fuel Injection 2.8 Volt
10
Control Logic
Injection Timing Controls
11
Np Sensor when CPS is failed Pump speed Eng. speed CPS ECM Injection Timing TCV Duty(%) Control
Components Description
Injection Pump(Mechanical)
Governor Spring Flyweight Control Lever Control Lever Shaft Idle Spring Full Load Adjusting Screw Tension Lever Governor Leve Assembly Fuel Cut Solenoid Plunger Outlet Hole
12
Regulating Valve
Components Description
Injection Pump(Electronic)
Fuel Cut Solenoid Governor Electronic
13
Np Sensor
Components Description
GE(Governor Electric) Actuator
14
Magnet Filter
Components Description
TCV (Timer Control Valve)
15
Duty Ratio = to/T X 100 (%) Duty Ratio = 100% 0% (Advanced) (Retarded)
Components Description
TPS (Timer Position Sensor)
16
Retarded
Advanced
Components Description
Np Sensor
17
Np Sensor
18
Connected to
Neutral Switch (P, N) Idle Switch Immobilizer Switch 01 A/C Load Detection Ground (Power) TCV Signal
Inhibitor Switch(for A/T), Neutral Switch (for M/T) Accelerator Pedal IG 1 (with immobilizer), Open(without immobilizer) A/C Compressor Relay TCV
19
Connected to
Water Temperature and Gauge Unit Fuel Temperature Sensor Boost Pressure and Temperature Sensor Qadj. Resistance Ignition Switch Glow Plug and Glow Relay Open(with immobilizer), IG 1 (without immobilizer) -
Qadj Resistance Signal Ignition Switch Glow Check Immobilizer Switch 02 GND (Power)
20
Signal Fuel Cut Solenoid Valve Camshaft Sensor Np Sensor TCU (A/T Only)
Connected to
Torque Control (PWM) Vref Vref Boost Pressure Signal Intercooler Fan Relay Tach Out (PWM) GND GND
Accelerator Pedal Sensor Boost Pressure and Temperature Sensor Boost Pressure and Temperature Sensor Intercooler Fan Relay TCU (A/T Only) Camshaft Sensor Np Sensor
21
Terminal 39 40 41 42 43 44 45 46 47 49 50 GND
Signal Accelerator Pedal Sensor Signal GND (Analog) GND (Analog) OSC + MDL OSC TPS (OSC +) AT/MT Switch OSC + MDL
Connected to Accelerator Pedal Sensor Accelerator Pedal Sensor Water Temperature and Gauge Unit Water Temperature and Gauge Unit Control Sleeve Position Sensor Control Sleeve Position Sensor Control Sleeve Position Sensor Timer Position Sensor Open (for AT), IG 1 (for MT) Control Sleeve Position Sensor Control Sleeve Position Sensor
22
Terminal 51 52 53 54 55 57 58 59 61 62 63 OSC TPS (MDL) TPS (OSC -) L Line Glow Relay TW Out EGR 1 A/C Fan Relay K Line Diagnosis Lamp Glow Lamp
Signal Control Sleeve Sensor Timer Position Sensor Timer Position Sensor
Connected to
Diagnostic Tool (Scan Tool) Glow Relay TCU (AT only) EGR 1 (Duty) A/C Fan Relay Diagnostic Tool (Scan Tool) Engine Check Lamp Glow Lamp
23
Signal Power Relay A/C Compressor Relay TCU (AT only) Vehicle Speed Sensor EGR 2 (On-Off) Power Relay Power Relay -
Connected to
A/C Compressor Relay Accel. Out (PWM) VSP Signal EGR 2 Main Relay Signal GND (Signal)
Troubleshooting
TCV (Timer Control Valve)
F.I.P Connector
24
No.9 TCVTCV
No.5 TCV+
Specification
No.5 ~ No.9: 110.7
Troubleshooting
TPS (Timer Position Sensor)
F.I.P Connector No.3 MDL
25
TCV
Specification
No.2 ~ No.3, No.1 ~ No.3: 825.7
Troubleshooting
Np Sensor
F.I.P Connector No.2 ECM GND
26
No.3 Signal
Specification
No.2 ~ No.3: 1.650.15 k
Troubleshooting
Q Compensation Resistance
Q Adjustment Resistance
27
Q Comp. Resistance (k) No.1(0.18) No.2(0.30) No.3(0.43) No.4(0.62) No.5(0.82) No.6(1.10) No.7(1.50) No.8 (2.0) No.9(2.70) No.10(3.9) No.11(5.6) No.12(8.2) No.13(150.)
Number 945 946 947 948 949 950 951 952 953 954 955 956 957
Part No. 146649-4500 146649-4600 146649-4700 146649-4800 146649-4900 146649-5000 146649-5100 146649--5200 146649-5300 146649-5400 146649-5500 146649-5600 146649-5700
No.3 Sig
Troubleshooting
CSP (Control Sleeve Position) Sensor
28
Troubleshooting
CSP (Control Sleeve Position) Sensor
No.1 OSC F.I.P Connector No.8 OSC MDL
29
No.12 OSC -
No.4 OSC +
Specification
No.4 ~ No.8, No.12 ~ No. 8: 5.9 0.3
Troubleshooting
TF (Temperature Fuel) Sensor
F.I.P Connector No.7 Signal
30
No.11 GND
Specification No.7 ~ No.11: 20.1k at 25 Connection with ECM No.7 No.11 ECM Pin No. 18 Wiring harness GND ECM Pin No. 18 at normal operating Temperature
Troubleshooting
WTS (Water Temperature Sensor)
Specification
31
Temp.() Resistance(k) Voltage(V) -20 16 4.3 0 5.9 3.4 20 2.5 2.4 40 1.2 1.5 60 0.6 0.9 80 0.3 0.5 100 0.2 0.3
1
ECM Pin No. 17 at normal operating Temperature
Connection with ECM No.2 No.1 No.3 to Cluster ECM Pin No. 17 ECM Pin No. 42 (GND)
Troubleshooting
BPS (Booster Pressure Sensor) / TA (Intake Air Temperature) Sensor
TA Sensor Specification
32
Temp.() Resistance(k) Voltage(V) -20 16 4.3 0 5.9 3.4 20 2.5 2.4 40 1.2 1.5 60 0.6 0.9 80 0.3 0.5 100 0.2 0.3
Connection with ECM No.1 No.2 No.3 No.4 ECM Pin No. 41 GND ECM Pin No. 19 TA Signal ECM Pin No. 33 Reference Voltage 5V ECM Pin No. 34 BPS Signal
Troubleshooting
BPS (Booster Pressure Sensor) / TA (Intake Air Temperature) Sensor
33
Troubleshooting
APS (Accelerator Pedal Sensor)
Connection with ECM
No.1 No.2 No.3 No.4 No.5 No.6 ECM Pin No.39 GND ECM Pin No.40 APS Sig. ECM Pin No.32 (Power Supply) ECM Pin No.32 Idle Switch None Ground Idle Switch ON Accelerator Pedal Sensor
34
6 3
5 2
4 1
Troubleshooting
APS (Accelerator Pedal Sensor)
APS output signal failed, Idle Switch good, At Max. Throttle ECM increases RPM slowly to 30% (4000rpm)
35
Troubleshooting
CPS (Crankshaft Position Sensor)
CPS 1mm
36
Connection with ECM No.1 No.2 No.3 Shield GND ECM Pin No. 37 GND ECM Pin No. 29 Signal ECM Pin No. 29 at idle CPS signal with Np signal at idle
Troubleshooting
Fuel Cut valve
No.1 FCV F.I.P Connector No.2 ECM GND
37
Troubleshooting
EGR (Exhausted Gas Recirculation) Control Valve
38
1 2
EGR Control Solenoid Valve 1 (Duty Control)
Troubleshooting
EGR (Exhausted Gas Recirculation) Control Valve
39
Waveform
Troubleshooting
Intercooler Fan Motor
40
Troubleshooting
Glow System
Preheating
Coolant Temperature 60 - 15 - 20 - 25 - 40 Heating Time (sec) 2 8 10 15 24
41
Post heating
Coolant Temperature 60 0 - 10 - 20 - 40 Heating Time (sec) 3 3 3 5 5
Troubleshooting
Others
Main relay control
ECM controls Main relay to provide the B+ voltage to actuators like EGR Sol. Valves, Grow Plug and A/C fan relay etc.
42
Lamps
ECM controls Engine check lamp and Glow lamp
Troubleshooting
Case Study
DTC P0320 Item Np Sensor 1. Np/TDC output is lower than threshold level 2. Open or short sensor coil 3. Noise 4. Bad connection 5. Open or short wire 6. Clearance is too big If one of sensor has failed, normal operation is possible If both sensors are problem, engine will stop. Diag. Lamp Cause of Trouble Symptom
43
P0335
TDC Sensor
OFF
P0121
Acceleration Pedal Positon Sensor Accel Sensor Output Accel Sensor Learning
ON
P0120 P0120
OFF OFF
1. Open or short sensor harness 2. Bad connection 3. Open or short wire 4. Abnormal output value
Troubleshooting
Case Study
DTC Item Water Temperature Sensor Water Temperature Sensor Fuel Temperature Sensor Diag. Lamp Cause of Trouble 1. Open or short sensor harness 2. Bad connection 3. Open or short wire 4. Abnormal output value 1. Lack of coolant 2. Malfunction of thermostat 3. Defective cooling system 1. Open or short sensor harness 2. Bad connection 3. Open or short wire 4. Abnormal output value 1. Open or short sensor harness 2. Bad connection 3. Open or short wire 4. Abnormal output value Symptom 1. Smoke may comes out 2. Idle rpm increase Vehicle speed is decreased by overheating
44
P0115
ON
ON
P0180
OFF
P0110
OFF
Troubleshooting
Case Study
DTC Item Diag. Lamp Cause of Trouble 1. Open or short sensor harness 2. Bad connection 3. Open or short wire 4. Abnormal output value 1. Too much fuel injection 2. Retarded injection timing 3. Disabled wastgate actuator 4. Disabled turbocharger 1. Open or short sensor harness 2. Bad connection 3. Open or short wire 4. Abnormal output value 1. Bad adjustment of timer piston position 2. EEPROM Error 3. TCV Error Symptom
45
P1116
ON
P1122
Over Boost
ON
P1123
TPS
OFF
P1123
TPS Learning
OFF
Troubleshooting
Case Study
DTC Item Diag. Lamp Cause of Trouble
1.Open or short sensor coil (Abnormal Sensor Output) 2.Bad connection of connector 3.Open or short wire 1.CSP SENSOR ERROR 2.Abnormal GEs Yoke/Rotor operation 3.Fuel temperature is low and has high viscosity 4.Open or short wire 1.TPS SENSOR ERROR 2.Timer pistons operation error 3.Fuel has high viscosity and in low temperature. 4.TCV ERROR 5.Open or short wire
46
Symptom
P1127
CSP Rareshort
ON
Engine stops
P1120
GE Servo
ON
Engine stops
P1135
IT Servo
OFF
Troubleshooting
Case Study
DTC Item Diag. Lamp Cause of Trouble Symptom
1.SMOKE increases 2.Abnormal acceleration 3.Starting in impossible for IMMOBI. Vehicle 1.Power and acceleration is bad in low zone from sealevel 2.Too much smoke in high zone from sealevel Normal operation is possible when EEPROM is normal condition. Too much smoke /abnormal acceleration happens when EEPROM is not normal condition
47
P0605
EEPROM
OFF
1.ECU ERROR
P0105
OFF
1.Open or short sensor harness 2.Bad connection of connector 3.Open or short wire 4.Abnormal sensor output 1.EEPROM ERROR 2.Bad connection of connector 3.Open or short wire 4.Open or short wire in resistor
P1131
Q Adjustment Resistance
OFF
Troubleshooting
Case Study
DTC Item Diag. Lamp Cause of Trouble
1.Abnormal GLOW RELAY 2.Bad connection of connector 3.Open or short wire 4.Voltage overflow 1.Communication error 2.Bad connection of connector 3.Open or short wire 1.Open of short FCV wire 2.Bad connection of connector 1.ECU circuit ERROR 2.Open or short wire 3.Bad connection of connector
48
Symptom
1.Starting is not possible in low temperature 2.Increase of starting time
P1324
Glow Relay
Blink (75times/min)
P0600
Immobilizer
OFF
Starting is impossible
P1621
FCV Short
ON
1.Engine stops 2.Starting is impossible Abnormal sensor output / Power with ACCEL SENSOR ERROR
P1525
OFF
Troubleshooting
Case Study
DTC Item
Boost Sensor Ref. Voltage A/D Conversion
49
Diag. Lamp
Cause of Trouble
1.ECU circuit ERROR 2.Open or short wire 3.Bad connection of connector 1.ECU circuit ERROR 1.VSP SENSOR ERROR 2.Open or short wire 3.Bad connection of connector
Symptom
Abnormal sensor output / Power with BOOST SENSOR ERROR SHOCK occurs at acceleration or deceleration.
P1525
OFF
P1613
OFF
P0500
VSP Sensor
OFF
P1522
Battery Voltage
ON
50
51