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TERRA C A N D4BH (2.5 TCI) Diesel Engine Fuel System (COVEC-F)
Engine Specification Specification
I TEMS DI SPLACEMENT(cc) BORE¿ ¡ STROKE(mm) FI RI NG ORDER
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2.5 T/C 2476 91.1 ¿ ¡ 95 1-3 -4-2
COMPRESSI ON RATI O
21
INJECTION INJECTI ON TIMING( TIMING(Æ ¡)
CAM Lif t 1¾ ¡ 0.03mm
I NJECTI ON TYPE NUMBER OF CYLI NDER I DL E R PM PREHEATI NG DEVI CE I NTAKE SYSTEM
I NDI RECTI ON 4 750 GLOW PL UG TURBO
Engine Specification Specification
I TEMS DI SPLACEMENT(cc) BORE¿ ¡ STROKE(mm) FI RI NG ORDER
2
2.5 T/C 2476 91.1 ¿ ¡ 95 1-3 -4-2
COMPRESSI ON RATI O
21
INJECTION INJECTI ON TIMING( TIMING(Æ ¡)
CAM Lif t 1¾ ¡ 0.03mm
I NJECTI ON TYPE NUMBER OF CYLI NDER I DL E R PM PREHEATI NG DEVI CE I NTAKE SYSTEM
I NDI RECTI ON 4 750 GLOW PL UG TURBO
Outline
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Electronic fuel injection pump (Covec-F) has the same fuel intake and compression system as mechanical injection pump has. However, it uses an electronic governor(GE Actuator) instead of a fly-weight and uses control unit cable instead of a control lever. In checking engine cycle, mechanical pump uses gear of fly weight holder, but electronic pump uses sensing gear plate with 4 projections, installed on the driveshaft. A t iming control valve(TCV), which adjust pressure to moot optimal opt imal injection timing, installed between high and low pressure chambers of the timer timer at lower part of the main pump body, in mechanical injection pumps, check valves are installed in part of the inside of the t he overflow valves. In electronic injection pumps, however, check valve are installed at all valves, enabling to hold over-flows until the pressure is stabilized. A timer position sensor(TPS), which senses location of timer piston is also installed in electric injection.
GE Actuator Fuel Cut Sol.
Np Sen Sensor
Timer Control Valve.
ECM Input/ Output GE(Governor Electric) Actuator
GE actuator is attached to the governor chamber at the upper part of the injection pump. Governor chamber and pump chamber are connected with a magnetic filter in between. Coil is cooled by the fuel coming into the governor chamber. A magnetic filter prevents foreign material(ferrous ingredients) from entering the chambers. Eccentric ball pin that are inserted into control sleeve holes are placed at the end of the shaft forced into the rotor. The electronic governor actuator is a magnetic field type. Once the coil receives electric current, it generates a magnetic field and rotates the rotor until it reaches the designated range. The strength of magnetic field at coil is proportional to the strength of input current and rotates the rotor to the relative position of the return spring , enabling the control sleeve to make linear movements.
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ECM Input/ Output
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GE (Governor Electric) Actuator F.I.P Connector No.10 GE-
Specification
No.6 GE+
No.6 ~ No.10: 0.6¥ Ø
Connection with ECM No.6
ECM Pin No. 1, 14
No.10
ECM Pin No. 2, 15
Waveform
ECM Pin No. 1, 14
ECM Pin No. 2, 15
ECM Input/ Output TCV (Timing Control Valve) The TCV is located at the lower part of the injection pump. Two holes ( A and B ) in the pump housing connect to the TCV. Hole A connects the timer piston's high pressure chamber to the fuel inlet side of the TCV. A filter is installed at this inlet to exclude foreign mater Hole B connects the timer piston's low pressure chamber to the outlet at the tip of he TCV. Installed between the timer piston's high and low pressure chambers, the TCV adjusts high pressure chamber pressure by opening and closing the needle. When current is not flowing to the TCV, the tip of the needle completely separates the high and low pressure chambers. Then current is supplied, needle tip seat is opened, the high and low pressure chamber are connected, and the high pressure chamber pressure decreases. The timer piston is then moved by timer spring to a piston that balances the high pressure chamber pressure. Accompanying this roller holder rotates to vary the injection timing. Injection timing can therefore be varied by utilizing the ON-OFF duty ratio of the current flowing to the TCV. Injection timing is controlled by duty. All characteristics and TCV drive signal duty ratios. Also, he frequency of the TCV drive signal can be varied to correspond to the frequency of injection pump speed. Duty ratio is the ratio the time that the timing control valve is closed per unit of time (i. e. per cycle). Duty ratio = to / T x 100 (%) Injection timing is related when the duty ratio decreases from 100%. When electric current flows at Timing Control Valve, the needle is pulled lift by magnet, and seat part of the hall is opened. TCV is located between high pressure and low pressure chambers and adjusts pressure by opening and closing of the needle.
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ECM Input/ Output TCV (Timer Control Valve)
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ECM Input/ Output
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TCV (Timer Control Valve) F.I.P Connector
No.9 TCV-
Specification
No.5 TCV+
TCV
No.5 ~ No.9: 11¡¾1.1¥ Ø
Connection with Others No.5
IG. Key(B+)
No.9
ECM Pin No. 13
Waveform
At idle
At acceleration
ECM Input/ Output
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TPS (Timer Position Sensor) TPS is attached on the low-pressure side of the timer and is consisted of core rod and bobbin. It checks position of the timer piston electrically. TPS checks inductance changes with the core rod and measures position of the timer piston.
TPS Connector TPS
ECM Input/ Output
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TPS (Timer Position Sensor) No.1 TPS -
F.I.P Connector
No.2 TPS + No.3 TPS MDL
Specification No.2 ~ No.3, No.1 ~ No.3: 82¡¾2¥ Ø
TCV
Connection with Others No.1
ECM Pin No. 53
No.2
ECM Pin No. 46
No.3
ECM Pin No. 52
Waveform
ECM Pin No. 52, 46 at idle
ECM Pin No. 52, 53 at idle
ECM Input/ Output
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Np (Pump Speed) Sensor NP Sensor checks pump rpm and relays signal to PCM. NP sensor is consisted of permanent magnets, steel core and coils. It detects electric voltage generated by the changes in the machine going through the sensing gear, through rotation signal. When the 4 projections of the sensing gear plate go through the magnetic field, while the drive-shaft is rotating, alternating current is generated, which is then changed into a pulse signal and used as a rotation signal.
Np Sensor
ECM Input/ Output
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Np (Pump Speed) Sensor No.1 Shield GND
F.I.P Connector No.2 ECM GND
No.3
Specification
Signal
No.2 ~ No.3: 1.02¡¾0.16k¥ Ø
Connection with Others No.1
Wiring harness Shield GND
No.2
ECM Pin No. 38 GND
No.3
ECM Pin No. 30 Signal
Waveform
Np Signal at idle
Np Signal with CKP Sensor at idle
ECM Input/ Output
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Q Compensation Resistance Q Compensation Resistance is to prevent the different injection amount due to the different characteristic resistance of fuel injection pump affecting to injection amount controlled by ECM. The resistance of Q Compensation is decided by below table. The compensation resistance number is related to the resistance measured between terminal D & G.
Q Adjustment Resistance
Q Comp. Measured Number Resistance Resistance No.1 No.2 No.3 No.4 No.5 No.6 No.7 No.8 No.9 No.10 No.11 No.12 No.13
945 946 947 948 949 950 951 952 953 954 955 956 957
0.18(kΩ) 0.3(kΩ) 0.43(kΩ) 0.62(kΩ) 0.82(kΩ) 1.1(kΩ) 1.15(kΩ) 2(kΩ) 2.7(kΩ) 3.9(kΩ) 5.6(kΩ) 8.2(kΩ) 15(kΩ)
F.I.P Connector No.2
No.3
ECM Input/ Output CSP (Control Sleeve Position) Sensor The control Sleeve Position Sensor(CSP) at upper part of GE actuator detects the position of control sleeve and feeds it back to ECU. The fixed plate compensates changes of inductance caused by temperature. The CSP sensor calculates the difference of the inductance at the two sensor coils(upper and lower sensor coils) into angles and feeds them back to ECU, and ECU compares its target angle with the actual one, if there is a difference between the two angles, the ECU adjusts electric currents until the actual angle equals the target angle.
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ECM Input/ Output
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CSP (Control Sleeve Position) Sensor F.I.P Connector No.8 CSP MDL
No.12 CSP -
Specification
No.4 CDP +
No.4 ~ No.8, No.12 ~ No. 8: 5.8k¥ Ø
Connection with ECM No.4
ECM Pin No. 43, 49
No.8
ECM Pin No. 44, 50
No.12
ECM Pin No.45, 51
Waveform
ECM Pin No. 43, 44 at idle
ECM Pin No. 43, 45 at idle
ECM Input/ Output TF (Temperature Fuel) Sensor This sensor detects the temperature of fuel. If TF Sensor value is beyond 0.1V~4.6V for 5 second, ECM regards TF Sensor as failed and sets fuel temperature to 50¡ É
F.I.P Connector No.7 Signal
No.11 GND
Specification No.7 ~ No.11: 2¡¾0.1k¥ Ø at 25¡É
Connection with ECM No.7
ECM Pin No. 18
No.11
Wiring harness GND
Waveform ECM Pin No. 18 at normal operating Temperature
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ECM Input/ Output
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WTS (Water Temperature Sensor) Sensor If Sensor value is beyond 0.1V~4.6V for 5 second, ECM regards WTS Sensor as failed and sets coolant temperature from TF Sensor at starting. When TF Sensor is failed, sets the temperature to –20¡ É.
Specification Temp.(É ¡ ) 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
Connection with ECM No.2
ECM Pin No. 17
No.1
Wiring harness GND
Waveform
ECM Pin No. 17 at normal operating Temperature
ECM Input/ Output
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BPS (Booster Pressure Sensor) / TA (Intake-Air-Temperature) Sensor These two sensors are integrated into one. Located after the intercooler. BPS detects the intake air pressure and TA sensor detects the temperature of intake air. If BPS value is beyond 0.2V~4.8V for 1. second, ECM regards BPS as failed and fixes boost pressure to 760mmHg and prohibits EGR operation. If TA sensor value is beyond 0.1V~4.6V for 5 second, ECM regards TA Sensor as failed and fixes air temperature to 60¡ É.
TA Sensor Specification
No.2 TA Sig. No.1 GND
Temp.(É ¡ ) 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 No.4 BPS Sig.
No.3 Ref. Voltage 5V
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
ECM Input/ Output
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BPS (Booster Pressure Sensor) / TA (Intake-Air-Temperature Sensor Waveform
ECM Pin No. 34 BPS Signal at idle
ECM Pin No. 34 BPS Signal at acceleration from idle to 4200rpm
ECM Pin No. 34 BPS Signal at 4200rpm
ECM Pin No. 19 TA Sensor Signal
ECM Input/ Output APS (Accelerator Pedal Sensor) This sensor detects the angle of accelerator pedal. If sensor value is beyond 0.2V~4.93V for 1. second, ECM regards APS as failed. If ECM detects APS malfunction, ECM fix accelerator opening to 0% and prohibit EGR operation. When only idle SW. is good, ECM can increase the accelerator opening to 30% slowly. (equal to approx 1.5V) In the event of complete failure, No throttle response
Connection with ECM No.1
ECM Pin No. 32 V ref
No.2
ECM Pin No.40 APS Sig.
No.3
ECM Pin No.8 Idle SW Sig.
No.4
Wiring harness GND Idle SW. GND
No.5
ECM Pin No.39 GND
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ECM Input/ Output
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APS (Accelerator Pedal Sensor) Idle Switch ON
ECM Pin No. 8 at acceleration
Good condition
Accelerator Pedal Sensor
ECM Pin No. 40 from idle to Max.
APS (Accelerator Pedal Sensor) Good condition (Max. Throttle)
APS output signal failed, Idle Switch good, At Max. Throttle ECM increases RPM slowly to 30% (4000rp)m
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ECM Input/ Output
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CPS (Crankshaft Position Sensor) This sensor detects the position of crankshaft. If there is no signal from sensor for 20 consecutive times of Np Sensor, ECM regards CPS as failed and controls engine with Np (inj pump) Sensor signal. Note: In this condition ‘Twice ignition’ applies to start engine DTC P0335 will be set
CPS 1mm
Connection with ECM No.1
Shield GND
No.3
ECM Pin No.37 GND
Waveform
No.2
ECM Pin No.29 Signal
ECM Input/ Output
ECM Pin No. 29 at idle
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CPS signal with Np signal at idle
ECM Input/ Output
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FC (Fuel Cut) Valve When the IG. Key is On, ECM supplies B+ Voltage to open fuel line. When Immobilizer is on ECM inhibits the connection, (vale remains closed)
F.I.P Connector
No.1 FC Valve
Connection with ECM No.1
FC Valve
ECM Pin No.26 Signal
Waveform
FC Valve signal at idle
Diagnosis Reference chart
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(Checking Pump Components, Ignition off plug disconnected ) Terminal Component Remarks 1 FCV Fuel Cut Valve 2 Adj (-) Adjustment resistor (-) 3 Adj (+) Adjustment resistor (+) 4 CSP Oscillate (+) 5 TCV (+) Timer Control Valve (+) 6 GE (+) GE (+) 7 TF (+) Fuel temperature (+) 8 CSP MDL 9 TCV (-) Timer Control Valve (-) 10 GEGE (-) 11 TF (-) Fuel Temperature (-) 12 CSP Oscillate (-)
1
6
7
12
Note: Pin arrangement is different to H-1 Pumps are not interchangeable
Diagnosis Reference chart
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(Checking Pump Components)
Component Plug (No of pins) Terminal Resistance Fuel Cut 12 pin black 1--Ground 7 ~ 9 Ohms ¡0.13 Ohms Actuator 12 pin black 6 ~ 10 0.71 à ¡1.1 Ohms TCV 12 pin black 5~9 11 à ¡2 Ohms TPS 3 pin black 2~3 82 à ¡2 Ohms 1 ~3 82 à ¡0.16 KOhms Speed Sensor 3 pin grey 2 ~ 3 1.02à Trim Resistor 12 pin black 3 ~2 same as resistor ¡0.3 Ohms CSP 3 pin 4~8 5.9 à ¡0.3 Ohms 8 ~ 12 5.9 à Fuel Temp 12 pin black 11 ~ 7 0.1 Kohms
C Temp ° 23 +- 5 23 +- 5 23 +- 5 23 +- 5 23 +- 5 23 +- 5 23 +- 5 23 +- 5 23 +- 5 25
ECM Input/ Output
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EGR (Emission Gas Re-circulation) Solenoid Valve There are two EGR Solenoid Valves. One is controlled by duty signal from ECM and connected from vacuum tank or atmosphere to the other EGR Solenoid Valves. The other is controlled by On/Off signal from ECM and connected to EGR Control valve.
EGR Vacuum Sol. Valve Out port
EGR Sol. Valve
To EGR Control Valve
From Vacuum Atmosphere Pump Port
EGR Vacuum Sol. Valve
Connection with ECM EGR Vacuum Sol. Valve No.1
ECM Pin No.58 Signal
EGR Vacuum Sol. Valve No.2
Main Relay B+
EGR Sol. Valve No. 1
ECM Pin No.68 Signal
EGR Sol. Valve No. 2
Main Relay B+
ECM Input/ Output
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EGR (Exhuast Gas Re-circulation) Solenoid Valve Waveform
ECM Pin No. 58 at idle
ECM Pin No. 68 at acceleration
ECM Pin No.58 at acceleration
ECM Input/ Output
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I/C (Inter Cooler) Fan Motor Relay Terracan has a intercooler fan motor controlled by ECM. Intercooler fan motor is operated when vehicle speed is under 60Km/h and intake air temperature is over 58¡ É and engine speed is over 550rpm.
Connection with ECM I/C Fan Motor Relay No.85
ECM Pin No.35
Grow Plug Relay ECM controls the glow plug to heat the intake air through glow plug relay. According to the condition, the heating time is as below.
Preheating
Post heating
Coolant Temp. Heating time 2Sec. 60 É ¡ 8Sec. -15 É ¡ 10Sec. -20 É ¡ 15Sec. -25 É ¡ 24.5Sec. -40 É ¡
Coolant Temp. Heating time 3Sec. 60 É ¡ 3Sec. 0 É ¡ 3Sec. -10 É ¡ 5Sec. -20 É ¡ 5Sec. -40 É ¡
Connection with ECM Glow Plug Relay No.85
ECM Pin No.55
ECM Input/ Output
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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
A/C Fan Motor Relay & A/C Comp. Relay Connection with ECM Main Relay No.85
ECM Pin No.73
Engine check lamp
ECM Pin No.62
Glow lamp
ECM Pin No.63
A/C Fan Motor Relay No.85 A/C Comp. Relay
ECM Pin No.59 ECM Pin No.72
ECM Controls
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Q(Injection amount) Controls Example) CPS Eng. speed 3,000 RPM
Np Sensor when CPS is failed Pump speed GE Actuator
ECM Injection Quantity
Fuel Injection
37mg/stroke
2.8 Volt
APS Accel. Position 50% Feedback
CSP Control Sleeve Position Check
IT (Injection Timing) Controls Np Sensor when CPS is failed Pump speed Eng. speed CPS
ECM Injection Timing
ECM Injection Quantity Feedback
TCV Duty(%) Control
TPS Injection Timing Check
Basic Adjustments (Injection pump 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¡ Æ before top dead center. Then , set dial indicator to zero.
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Basic Adjustments (Injection pump timing) 8. Slightly turn crankshaft clockwise and counterclockwise to make sure that dial indicator pointer does not deviate from zero position. 9. Turn the crankshaft in the normal direction and position the notch of crankshaft pulley at 5 Æ ¡ ATDC. (N/A : 5¡ Æ T/C : 7¡ Æ TCI : 7¡ Æ)
10. If the dial indicator does not indicate the specified value. Tilt the injection pump body to the right or left until the indicator does indicate the standard value. 11. Tighten mounting bolt of injection bolts and nuts. 12. Remove special tool and dial gauge 13. Install timing check plug with new copper gasket
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Basic Adjustments (Valve clearances) 1. Warm up temperature 2. Remove upper timing belt cover and rocker cover 3. Turn the crankshaft clockwise and align the timing mark on the camshaft sprocket with the timing mark 4. Check the valve clearance indicated in the diagram(A) Standard clearance : 0.25mm(0.098in)
5. If not within the standard value, adjust the valve clearance with the adjusting screw and the thickness gauge 6. Rotate clockwise the crankshaft one complete turn (360¡ Æ) 7. Check the valve clearance indicated in the diagram(B) Standard clearance : 0.25mm(0.098in)
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HI-Scan
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HI-Scan
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See Page 39
Current Data
HI-Scan
Actuation Test
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