D4BH (2.5 TCI) Diesel Engine
2
Contents
Specification
General
System Layout
Control Logic
Components Description
Engine Control Module
Troubleshooting
3
Specification
ATDC 9º
Basic Injection Timing
22.3 kg.m
Maximum Torque
94 ps
Maximum Power
Intake : 0.15 mm
Exhaust : 0.15 mm
Valve Clearance
19.2 kg/㎠
Compression Pressure
21
Compression Ratio
91.1 X 95 mm
Bore X Stroke
2,467 cc
Total Displacement
OHC
Valve Mechanism
4, In-Line
No. of Cylinders
D4BH (TCI)
Description
Engine Model
Item
4
General
Features
Improved Torque Performance
COVEC-F
Conventional injection pump
Torque
50 100
5
General
Decreased Smoke at Acceleration
Injection quantity
Accelerator position Conventional injection pump
COVEC-F
Excess fuel at acceleration
6
General
Increased Comfort
Control sleeve
position
Control sleeve
position
Conventional type
COVEC-F
Fixed
Individual control
7
System Layout
Fuel Tank
Fuel Filter &
Sedimenter
Injection Pump
Return Pipe
Nozzle
Glow
Plug
Over
Flow
Valve
Fuel System
8
System Layout
Components
Connection
Battery Voltage Add. Vehicle Control
Vehicle Sensors Vehicle Switches
Np Sensor
Compensation Resister
GE Actuator Fuel Temp. Sensor
CSP Sensor Np Sensor
TCV TPS
9
System Layout
Input Control Output Control Item
Injection Pump Injection Pump
Np Sensor CSP Sensor Fuel Temp. Sensor Compensation Resister
TPS
GE Actuator
Timer Control Valve
Fuel Quantity Injection Timing ECU Vehicle Vehicle Sensors Switches Battery Voltage EGR Control Glow Control Self Diagnosis EGR Valve Glow Plugs Diagnostic Lamp
10
Control Logic
Injection Amount Controls
Example
Np Sensor when CPS is failed CPS Pump speed Eng. speed 3,000 RPM GE Actuator ECM Injection Quantity 37mg/stroke Accel. Position 50% Fuel Injection 2.8 Volt APS CSP Control Sleeve Position Check Feedback
11
Control Logic
Injection Timing Controls
Injection Timing Pump speed Eng. speed ECM Injection Quantity Duty(%) Control TCV Injection Timing Check TPS Feedback CPS ECM
12
Components Description
Injection Pump(Mechanical)
Governor Spring Flyweight Control Lever Control Lever Shaft Regulating ValveIdle Spring
Full Load Adjusting Screw Tension Lever
Fuel Cut Solenoid Plunger Outlet Hole Delivery Valve Control Sleeve Plunger Spring Cam Disc Cross Coupling Driving Gear Feed Pump Drive Shaft
Governor Leve Assembly
13
Components Description
Injection Pump(Electronic)
Fuel Cut Solenoid Governor Electronic Np Sensor14
Components Description
GE(Governor Electric) Actuator
15
Components Description
TCV (Timer Control Valve)
T
Duty Ratio = to/T X 100 (%)
Duty Ratio = 100% Æ
0%
16
Components Description
TPS (Timer Position Sensor)
17
Components Description
Np Sensor
18
Engine Control Module
ECM Terminal Layout
TCV TCV Signal 13 -Ground (Power) 12
A/C Compressor Relay A/C Load Detection
11
IG 1 (with immobilizer), Open(without immobilizer) Immobilizer Switch 01
10
Accelerator Pedal Idle Switch
8
Inhibitor Switch(for A/T), Neutral Switch (for M/T) Neutral Switch (P, N) 6 A/C Switch A/C Switch 5 Ignition Switch Start Switch 4 Power Relay Power 3 GE GE -2 GE Connected to GE + Signal 1 Terminal
19
Engine Control Module
ECM Terminal Layout
-GND (Power)
25
Open(with immobilizer), IG 1 (without immobilizer) Immobilizer Switch 02
24
Glow Plug and Glow Relay Glow Check 23 Ignition Switch Ignition Switch 21 Qadj. Resistance Qadj Resistance Signal
20
Boost Pressure and Temperature Sensor TA Signal
19
Fuel Temperature Sensor TF Signal
18
Water Temperature and Gauge Unit TW Signal 17 Power Relay Power 16 GE GE -15 GE Connected to GE + Signal 14 Terminal
20
Engine Control Module
ECM Terminal Layout
Np Sensor GND 38 Camshaft Sensor GND 37
TCU (A/T Only) Tach Out (PWM)
36
Intercooler Fan Relay Intercooler Fan Relay
35
Boost Pressure and Temperature Sensor Boost Pressure Signal
34
Boost Pressure and Temperature Sensor Vref
33
Accelerator Pedal Sensor Vref
32
TCU (A/T Only) Torque Control (PWM) 31 Np Sensor Np Signal 30 Camshaft Sensor TDC Signal 29
Fuel Cut Solenoid Valve
Connected to FCV Signal
Signal 26
21
Engine Control Module
ECM Terminal Layout
Control Sleeve Position Sensor MDL
50
Control Sleeve Position Sensor OSC +
49
Open (for AT), IG 1 (for MT) AT/MT Switch
47
Timer Position Sensor TPS (OSC +)
46
Control Sleeve Position Sensor OSC
-45
Control Sleeve Position Sensor MDL
44
Control Sleeve Position Sensor OSC +
43
Water Temperature and Gauge Unit GND (Analog)
42
Water Temperature and Gauge Unit GND (Analog)
41
Accelerator Pedal Sensor Accelerator Pedal Sensor Signal
40
Accelerator Pedal Sensor
Connected to GND
Signal 39
22
Engine Control Module
ECM Terminal Layout
Glow Lamp Glow Lamp
63
Engine Check Lamp Diagnosis Lamp
62
Diagnostic Tool (Scan Tool) K – Line
61
A/C Fan Relay A/C Fan Relay
59
EGR 1 (Duty) EGR 1
58
TCU (AT only) TW Out
57
Glow Relay Glow Relay
55
Diagnostic Tool (Scan Tool) L – Line
54
Timer Position Sensor TPS (OSC -)
53
Timer Position Sensor TPS (MDL)
52
Control Sleeve Sensor
Connected to OSC
-Signal 51
23
Engine Control Module
ECM Terminal Layout
-GND (Signal) 76 Power Relay Signal 75 Power Relay Main Relay 73 EGR 2 (On-Off) EGR 2 72
Vehicle Speed Sensor VSP Signal
71
TCU (AT only) Accel. Out (PWM)
69
A/C Compressor Relay A/C Compressor Relay
68 -GND (Signal) 65 Power Relay Connected to Signal Signal 64 Terminal
24
Troubleshooting
TCV (Timer Control Valve)
F.I.P Connector No.9 TCV-TCV No.5 TCV+Specification
No.5 ~ No.9: 11±0.7 ΩConnection with Others
No.5 IG. Key(B+) No.9 ECM Pin No. 13
At acceleration At idle
25
Troubleshooting
TPS (Timer Position Sensor)
No.3 MDL F.I.P Connector No.2 OSC+ No.1 OSC-TCV
Specification
No.2 ~ No.3, No.1 ~ No.3: 82±5.7 Ω
Connection with Others
No.1 ECM Pin No. 53 No.2 ECM Pin No. 46 No.3 ECM Pin No. 52
26
Troubleshooting
Np Sensor
F.I.P Connector No.2 ECM GND No.3 SignalSpecification
No.2 ~ No.3: 1.65±0.15 kΩConnection with Others
No.2 ECM Pin No. 38 GND No.3 ECM Pin No. 30 Signal
27
Troubleshooting
Q Compensation Resistance
F.I.P Connector No.2 GND No.1(0.18) 945 146649-4500 No.2(0.30) 946 146649-4600 No.3(0.43) 947 146649-4700 No.4(0.62) 948 146649-4800 No.5(0.82) 949 146649-4900 No.6(1.10) 950 146649-5000 No.7(1.50) 951 146649-5100 No.8 (2.0) 952 146649--5200 No.9(2.70) 953 146649-5300 No.10(3.9) 954 146649-5400 No.11(5.6) 955 146649-5500 No.12(8.2) 956 146649-5600 No.13(150.) 957 146649-5700Number Part No. Q Comp. Resistance (kΩ) Q Adjustment Resistance No.3 Sig
28
Troubleshooting
29
Troubleshooting
CSP (Control Sleeve Position) Sensor
F.I.P Connector No.4 OSC + No.8 OSC MDL No.12 OSC
-Specification
No.4 ~ No.8, No.12 ~ No. 8: 5.9 ±0.3 Ω
Connection with ECM
No.4 ECM Pin No. 43, 49 No.8 ECM Pin No. 44, 50 No.12 ECM Pin No.45
No. 1 ECM Pin Nol 51 ECM Pin No. 43, 44 at idle No.1 OSC
30
Troubleshooting
TF (Temperature Fuel) Sensor
F.I.P Connector No.7 Signal No.11 GND Specification No.7 ~ No.11: 2±0.1kΩ at 25℃Connection with ECM
No.7 ECM Pin No. 18 No.11 Wiring harness GND
ECM Pin No. 18 at normal operating
31
Troubleshooting
WTS (Water Temperature Sensor)
Specification
Temp.(℃) Resistance(kΩ) 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
2
3
ECM Pin No. 17 at normal operating Temperature
Connection with ECM
No.2 to Cluster
No.1 ECM Pin No. 17
32
Troubleshooting
BPS (Booster Pressure Sensor) / TA (Intake Air Temperature)
Sensor
TA Sensor Specification
Temp.(℃) Resistance(kΩ) 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
2
3
4
Connection with ECM
No.1 ECM Pin No. 41 GND No.2 ECM Pin No. 19 TA Signal
No.3 ECM Pin No. 33 Reference Voltage 5V No.4 ECM Pin No. 34 BPS Signal
33
Troubleshooting
BPS (Booster Pressure Sensor) / TA (Intake Air Temperature)
Sensor
ECM Pin No. 34 BPS Signal at idle ECM Pin No. 34 BPS Signal at 4200rpm
ECM Pin No. 34 BPS Signal at acceleration from idle to 4200rpm
34
Troubleshooting
APS (Accelerator Pedal Sensor)
Connection with ECM
No.1 ECM Pin No.39 GND No.2 ECM Pin No.40 APS Sig.
No.3 ECM Pin No.32 (Power Supply) No.4 ECM Pin No.32 Idle Switch No.5 None
No.6 Ground Idle Switch ON
4
5
6
1
2
3
APS Side Connector
Accelerator Pedal SensorECM Pin No. 40 from idle to Max. ECM Pin No. 8 at acceleration
35
Troubleshooting
APS (Accelerator Pedal Sensor)
APS output signal failed, Idle Switch good, At
Max. Throttle
ECM increases RPM slowly to 30% (4000rpm)
Good condition (Max. Throttle)
36
Troubleshooting
CPS (Crankshaft Position Sensor)
CPS
1mm
1
2
3
Connection with ECM
No.1 Shield GND
No.2 ECM Pin No. 37 GND
37
Troubleshooting
Fuel Cut valve
No.1 FCV F.I.P Connector No.2 ECM GND No.3 Np Signal FC Valve
Connection with ECM
38
Troubleshooting
EGR (Exhausted Gas Recirculation) Control Valve
1
2
EGR Control Solenoid Valve 1
(Duty Control)
1
2
Connection with ECM
Pin No. 2 of EGR Sol. Valve No.1 ECM Pin No.58 Signal Pin No. 1 of EGR Sol. Valve No.1 Main Relay B+
Pin No. 2 of EGR Sol. Valve No.2 ECM Pin No.72 Signal Pin No. 1 of EGR Sol. Valve No.2 Main Relay B+
EGR Control Solenoid Valve 2
(On-OFF Control)
39
Troubleshooting
EGR (Exhausted Gas Recirculation) Control Valve
Waveform
40
Troubleshooting
Intercooler Fan Motor
Connection with ECM
I/C Fan Motor Relay No.2 ECM Pin No.35
Operational Condition (AND)
♦
Vehicle speed : 60km/h or less
♦
Intake air temperature : 58℃ or higher
41
Troubleshooting
Glow System
Post heating
Preheating
24
- 40 ℃
15
- 25 ℃
10
- 20 ℃
8
- 15 ℃
2
Heating Time (sec)
60 ℃
Coolant
Temperature
5
- 40 ℃
5
- 20 ℃
3
- 10 ℃
3
0 ℃
3
Heating Time (sec)
60 ℃
Coolant
Temperature
42
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.
Lamps
ECM controls Engine check lamp and Glow lamp
Connection with ECM
Main Relay No.4 ECM Pin No.73 Engine check lamp ECM Pin No.62 Glow lamp ECM Pin No.63
A/C Fan Motor Relay ECM Pin No.59 A/C Comp. Relay ECM Pin No.68
43
Troubleshooting
Case Study
Normal operation is possible
1. Abnormal output value OFF Accel Sensor Learning P0120 OFF Accel Sensor Output P0120
Idle mode driving, Limp Home
1. Open or short sensor harness 2. Bad connection
3. Open or short wire 4. Abnormal output value ON Acceleration Pedal Positon Sensor P0121 TDC Sensor P0335
If one of sensor has failed, normal
operation is possible If both sensors are problem, engine will stop.
Symptom
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
Cause of Trouble OFF Diag. Lamp Np Sensor Item P0320 DTC
44
Troubleshooting
Case Study
Normal operation is possible
1. Open or short sensor harness 2. Bad connection
3. Open or short wire 4. Abnormal output value OFF Itake Air Temperature P0110 Normal operation is possible
1. Open or short sensor harness 2. Bad connection
3. Open or short wire 4. Abnormal output value OFF Fuel Temperature Sensor P0180 Vehicle speed is decreased by overheating 1. Lack of coolant 2. Malfunction of thermostat 3. Defective cooling system ON Water Temperature Sensor -Symptom Cause of Trouble Diag. Lamp Item DTC 1. Smoke may comes out 2. Idle rpm increase 1. Open or short sensor harness
2. Bad connection 3. Open or short wire 4. Abnormal output value ON
Water
Temperature Sensor
45
Troubleshooting
-1. Bad adjustment of timer piston position
2. EEPROM Error 3. TCV Error OFF TPS Learning P1123 1. Smoke 2. Abnormal acceleration 3. Unstalbe idle RPM 4. Noise
1. Open or short sensor harness 2. Bad connection
3. Open or short wire 4. Abnormal output value OFF
TPS P1123
1. Too much fuel injection 2. Retarded injection timing 3. Disabled wastgate actuator 4. Disabled turbocharger ON Over Boost P1122 Symptom Cause of Trouble Diag. Lamp Item DTC No acceleration
(Low speed operation) 1. Open or short sensor harness
2. Bad connection 3. Open or short wire 4. Abnormal output value ON
Boost Pressure Sensor
P1116
46
Troubleshooting
Case Study
Engine stops 1.Open or short sensor
coil
(Abnormal Sensor Output) 2.Bad connection of
connector
3.Open or short wire ON
CSP Rareshort P1127
Engine stops 1.CSP SENSOR ERROR
2.Abnormal GE’s Yoke/Rotor operation
3.Fuel temperature is low and has high viscosity 4.Open or short wire ON
GE Servo P1120
1.Too much smoke 2.Abnormal acceleration 3.Unstable IDLE RPM 1.TPS SENSOR ERROR
2.Timer piston’s operation error
3.Fuel has high viscosity and in low temperature.
4.TCV ERROR 5.Open or short wire OFF IT Servo P1135
Symptom
Cause of Trouble
Diag. Lamp
Item
DTC
47
Troubleshooting
Case Study
1.SMOKE increases 2.Abnormal acceleration 3.Starting in impossiblefor IMMOBI. Vehicle 1.ECU ERROR OFF EEPROM P0605 1.Power and acceleration is bad in low zone from sea-level
2.Too much smoke in high zone from sea-level
1.Open or short sensor harness
2.Bad connection of connector
3.Open or short wire
4.Abnormal sensor output OFF Barometric Pressure Sensor P0105 Normal operation is possible when EEPROM is normal condition.
Too much smoke
/abnormal acceleration happens when EEPROM is not normal condition 1.EEPROM ERROR
2.Bad connection of connector
3.Open or short wire 4.Open or short wire in
resistor OFF Q Adjustment -Resistance P1131
Symptom
Cause of Trouble
Diag. Lamp
Item
DTC
48
Troubleshooting
Case Study
1.Starting is not possible in low temperature 2.Increase of starting
time 1.Abnormal GLOW RELAY
2.Bad connection of connector
3.Open or short wire 4.Voltage overflow Blink (75times/min) Glow Relay P1324 Starting is impossible 1.Communication error 2.Bad connection of connector
3.Open or short wire OFF
Immobilizer P0600
1.Engine stops
2.Starting is impossible 1.Open of short FCV wire
2.Bad connection of connector
ON FCV Short
P1621
Abnormal sensor output / Power with ACCEL SENSOR ERROR 1.ECU circuit ERROR
2.Open or short wire 3.Bad connection of connector OFF Accel Sensor Ref. Voltage P1525
Symptom
Cause of Trouble
Diag. Lamp
Item
DTC
49
Troubleshooting
Case Study
Abnormal sensor output / Power with BOOST SENSOR ERROR 1.ECU circuit ERROR
2.Open or short wire 3.Bad connection of connector OFF Boost Sensor Ref. Voltage P1525 -1.ECU circuit ERROR
OFF A/D Conversion
P1613
-1.Open or short wire
2.Abnormal BATTERY charging ON Battery Voltage P1522 SHOCK occurs at acceleration or deceleration.
Symptom
1.VSP SENSOR ERROR 2.Open or short wire 3.Bad connection of connectorCause of Trouble
OFFDiag. Lamp
VSP SensorItem
P0500DTC
50
Injection Timing Adjustment
Basic Injection Timing
1. Engine stop
2. Turn the crankshaft to place in No.1
Cylinder at top dead center on
compression stroke
3. Loosen injection pipe
4. Loosen injection mounting bolts and nuts
5. Remove timing check plug from injection
pump head
6. Attach the special tool and a dial
gauge
7. Turn crankshaft to such a position
that the notch on pulley is at
approximately 30° before top
dead center. Then , set dial
indicator to zero.
51
