D4BH (2.5 TCI) Diesel Engine.pdf

D4BH (2.5 TCI) Diesel Engine (COVEC – F)

Contents 

Specification



General



System Layout



Control Logic



Components Componen ts Description



Engine Control Module



Troubleshooting



Injection Timing Adjustment

2

Contents 

Specification



General



System Layout



Control Logic



Components Componen ts Description



Engine Control Module



Troubleshooting



Injection Timing Adjustment

2

Specification

3

Item

Description

Engine Model

D4BH (TCI)

No. of Cylinders

4, In-Line

Valve Mechanism

OHC

Total Displacement Displacement

2,467 cc

Bore X Stroke

91.1 X 95 mm

Compression Ratio

21

Compression Pressure

19.2 kg/§ ²

Valve Clearance

Intake : 0.15 mm Exhaust : 0.15 mm

Maximum Power 

94 ps

Maximum Torque

22.3 kg.m

Basic Injection Timing

 ATDC 9º

General

4

Features Improved Torque Performance

COVEC-F

Torque Conventional injection pump

50

100

Accelerator position (%)

General

5

Decreased Smoke at Acceleration

Conventional injection pump Injection quantity Excess fuel at acceleration

COVEC-F Accelerator position

General

6

Increased Comfort Conventional type Fixed

Control sleeve position

COVEC-F Control sleeve position

Individual control

System Layout

7

Fuel System Return Pipe Fuel Tank Over  Flow Valve

Nozzle

Fuel Filter & Sedimenter 

Glow Plug

Injection Pump

System Layout Components Connection

8

Battery Voltage

 Add. Vehicle Control Vehicle Sensors Vehicle Switches

Np Sensor 

GE Actuator  Fuel Temp. Sensor  Compensation Resister 

CSP Sensor 

Np Sensor 

TCV

TPS

System Layout Input

9

Control

Output

Control Item

Injection Pump

Injection Pump Np Sensor  CSP Sensor 

GE Actuator 

Fuel Quantity

Timer Control Valve

Injection Timing

Fuel Temp. Sensor  Compensation Resister  TPS ECU Vehicle Vehicle Sensors

Switches

Battery Voltage

EGR Valve

EGR Control

Glow Plugs

Glow Control

Diagnostic Lamp

Self Diagnosis

Control Logic

10

Injection Amount Controls Example Np Sensor when CPS is failed CPS Eng. speed 3,000 RPM

Pump speed ECM

GE Actuator 

Injection Quantity

Fuel Injection

37mg/stroke

2.8 Volt

APS Accel. Position

CSP

50% Feedback

Control Sleeve Position Check

Control Logic

11

Injection Timing Controls

Np Sensor when CPS is failed Pump speed Eng. speed CPS

ECM

TCV

Injection Timing

Duty(%) Control

TPS

ECM Injection Quantity Feedback

Injection Timing Check

Components Description

12

Injection Pump(Mechanical) Governor Spring Flyweight

Idle Spring Full Load Adjusting Screw

Control Lever 

Tension Lever  Governor Leve Assembly

Control Lever Shaft

Fuel Cut Solenoid

Regulating Valve

Plunger  Outlet Hole

Drive Shaft Delivery Valve

Feed Pump Driving Gear  Cross Coupling

Control Sleeve Timer 

Plunger Spring Cam Disc

Components Description Injection Pump(Electronic) Fuel Cut Solenoid

Governor Electronic

Np Sensor 

Timer Control Valve.

13

Components Description GE(Governor Electric) Actuator 

Magnet Filter 

14

Components Description

15

TCV (Timer Control Valve)

Duty Ratio = to/T X 100 (%) Duty Ratio = 100% T

(Advanced)



0% (Retarded)

Components Description

16

TPS (Timer Position Sensor)

Retarded

 Advanced

Components Description Np Sensor 

Np Sensor 

17

Engine Control Module

18

ECM Terminal Layout

Terminal

Signal

Connected to

1

GE +

GE

2

GE -

GE

3

Power 

Power Relay

4

Start Switch

Ignition Switch

5

 A/C Switch

 A/C Switch

6

Neutral Switch (P, N)

Inhibitor Switch(for A/T), Neutral Switch (for M/T)

8

Idle Switch

 Accelerator Pedal

10

Immobilizer Switch 01

IG 1 (with immobilizer), Open(without immobilizer)

11

 A/C Load Detection

 A/C Compressor Relay

12

Ground (Power)

-

13

TCV Signal

TCV

Engine Control Module

19

ECM Terminal Layout

Terminal

Signal

Connected to

14

GE +

GE

15

GE -

GE

16

Power 

Power Relay

17

TW Signal

Water Temperature and Gauge Unit

18

TF Signal

Fuel Temperature Sensor 

19

TA Signal

Boost Pressure and Temperature Sensor 

20

Qadj Resistance Signal

Qadj. Resistance

21

Ignition Switch

Ignition Switch

23

Glow Check

Glow Plug and Glow Relay

24

Immobilizer Switch 02

Open(with immobilizer), IG 1 (without immobilizer)

25

GND (Power)

-

Engine Control Module

20

ECM Terminal Layout

Terminal

Signal

Connected to

26

FCV Signal

Fuel Cut Solenoid Valve

29

TDC Signal

Camshaft Sensor 

30

Np Signal

Np Sensor 

31

Torque Control (PWM)

TCU (A/T Only)

32

Vref 

 Accelerator Pedal Sensor 

33

Vref 

Boost Pressure and Temperature Sensor

34

Boost Pressure Signal

Boost Pressure and Temperature Sensor 

35

Intercooler Fan Relay

Intercooler Fan Relay

36

Tach Out (PWM)

TCU (A/T Only)

37

GND

Camshaft Sensor 

38

GND

Np Sensor 

Engine Control Module

21

ECM Terminal Layout

Terminal

Signal

Connected to

39

GND

 Accelerator Pedal Sensor 

40

 Accelerator Pedal Sensor Signal

 Accelerator Pedal Sensor 

41

GND (Analog)

Water Temperature and Gauge Unit

42

GND (Analog)

Water Temperature and Gauge Unit

43

OSC +

Control Sleeve Position Sensor 

44

MDL

Control Sleeve Position Sensor 

45

OSC -

Control Sleeve Position Sensor 

46

TPS (OSC +)

Timer Position Sensor 

47

 AT/MT Switch

Open (for AT), IG 1 (for MT)

49

OSC +

Control Sleeve Position Sensor 

50

MDL

Control Sleeve Position Sensor 

Engine Control Module

22

ECM Terminal Layout

Terminal

Signal

Connected to

51

OSC -

Control Sleeve Sensor 

52

TPS (MDL)

Timer Position Sensor 

53

TPS (OSC -)

Timer Position Sensor 

54

L – Line

Diagnostic Tool (Scan Tool)

55

Glow Relay

Glow Relay

57

TW Out

TCU (AT only)

58

EGR 1

EGR 1 (Duty)

59

 A/C Fan Relay

 A/C Fan Relay

61

K – Line

Diagnostic Tool (Scan Tool)

62

Diagnosis Lamp

Engine Check Lamp

63

Glow Lamp

Glow Lamp

Engine Control Module

23

ECM Terminal Layout

Terminal

Signal

Connected to

64

Signal

Power Relay

65

GND (Signal)

-

68

 A/C Compressor Relay

 A/C Compressor Relay

69

 Accel. Out (PWM)

TCU (AT only)

71

VSP Signal

Vehicle Speed Sensor 

72

EGR 2

EGR 2 (On-Off)

73

Main Relay

Power Relay

75

Signal

Power Relay

76

GND (Signal)

-

Troubleshooting

24

TCV (Timer Control Valve) F.I.P Connector 

No.9 TCVTCV

No.5 TCV+

Specification No.5 ~ No.9: 11 0.7

Connection with Others No.5

IG. Key(B+)

No.9

ECM Pin No. 13  At idle

 At acceleration

Troubleshooting

25

TPS (Timer Position Sensor) F.I.P

No.3 MDL

Connector 

No.2 OSC+ No.1 OSC-

TCV

Specification No.2 ~ No.3, No.1 ~ No.3: 82 5.7

Connection with Others No.1

ECM Pin No. 53

No.2

ECM Pin No. 46

No.3

ECM Pin No. 52 ECM Pin No. 52, 46 at idle

ECM Pin No. 52, 53 at idle

Troubleshooting

26

Np Sensor  F.I.P Connector  No.2 ECM GND

No.3 Signal

Specification No.2 ~ No.3: 1.65 0.15 k

Connection with Others No.2

ECM Pin No. 38 GND

No.3

ECM Pin No. 30 Signal Np Signal at idle

Np Signal with CKP Sensor at idle

Troubleshooting

27

Q Compensation Resistance Q Adjustment Resistance

F.I.P Connector  No.2 GND

No.3 Sig

Q Comp. Resistance (kΩ)

Number

Part No.

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)

945 946 947 948 949 950 951 952 953 954 955 956

146649-4500 146649-4600 146649-4700 146649-4800 146649-4900 146649-5000 146649-5100 146649--5200 146649-5300 146649-5400 146649-5500 146649-5600

No.13(150.)

957

146649-5700

Troubleshooting CSP (Control Sleeve Position) Sensor 

28

Troubleshooting

29

CSP (Control Sleeve Position) Sensor  No.1 OSC -

F.I.P Connector  No.8 OSC MDL

No.12 OSC -

No.4 OSC +

Specification No.4 ~ No.8, No.12 ~ No. 8: 5.9

0.3

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

ECM Pin No. 43, 45 at idle

Troubleshooting

30

TF (Temperature Fuel) Sensor  F.I.P Connector  No.7 Signal

No.11 GND

Specification No.7 ~ No.11: 2 0.1k

at 25

Connection with ECM No.7

ECM Pin No. 18

No.11

Wiring harness GND

ECM Pin No. 18 at normal operating Temperature

Troubleshooting

31

WTS (Water Temperature Sensor) 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

3

2

1

Connection with ECM No.2

to Cluster 

No.1

ECM Pin No. 17

No.3

ECM Pin No. 42 (GND)

ECM Pin No. 17 at normal operating Temperature

Troubleshooting

32

BPS (Booster Pressure Sensor) / TA (Intake Air Temperature) Sensor  TA Sensor 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.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

4

3

2

1

Troubleshooting

33

BPS (Booster Pressure Sensor) / TA (Intake Air Temperature) Sensor 

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

Troubleshooting

34

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

ECM Pin No. 8 at acceleration

6

5

4

3

2

1

 APS Side Connector   Accelerator Pedal Sensor 

ECM Pin No. 40 from idle to Max.

Troubleshooting

35

APS (Accelerator Pedal Sensor)

Good condition (Max. Throttle)

 APS output signal failed, Idle Switch good, At Max. Throttle ECM increases RPM slowly to 30% (4000rpm)

Troubleshooting

36

CPS (Crankshaft Position Sensor) CPS 1mm

3

2

1

Connection with ECM No.1

Shield GND

No.2

ECM Pin No. 37 GND

No.3

ECM Pin No. 29 Signal

ECM Pin No. 29 at idle

CPS signal with Np signal at idle

Troubleshooting

37

Fuel Cut valve No.1 FCV F.I.P Connector  No.2 ECM GND

No.3 Np Signal FC Valve

Connection with ECM No.1

ECM Pin No.26 Signal

Troubleshooting

38

EGR (Exhausted Gas Recirculation) Control Valve

1 2 EGR Control Solenoid Valve 1 (Duty Control)

Connection with ECM

1

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+

2

EGR Control Solenoid Valve 2 (On-OFF Control)

Troubleshooting

39

EGR (Exhausted Gas Recirculation) Control Valve

Waveform

ECM Pin No. 58 at idle

ECM Pin No.58 at acceleration

ECM Pin No. 72 at acceleration

Troubleshooting

40

Intercooler Fan Motor 

Connection with ECM I/C Fan Motor Relay No.2

Operational Condition (AND) ♦

Vehicle speed : 60km/h or less

♦

Intake air temperature : 58¡ É or higher 

♦

Engine speed : 550 rpm or more

ECM Pin No.35

Troubleshooting

41

Glow System Post heating

Preheating Coolant Temperature

Heating Time (sec)

Coolant Temperature

Heating Time (sec)

60 É ¡

2

60 É ¡

3

- 15 É ¡

8

0É ¡

3

- 20 É ¡

10

- 10 É ¡

3

- 25 É ¡

15

- 20 É ¡

5

- 40 É ¡

24

- 40 É ¡

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.

Lamps ECM controls Engine check lamp and Glow lamp

Connection with ECM Main Relay No.4

ECM Pin No.73

Engine check lamp Glow lamp

ECM Pin No.62 ECM Pin No.63

 A/C Fan Motor Relay  A/C Comp. Relay

ECM Pin No.59 ECM Pin No.68

42

Troubleshooting

43

Case Study DTC P0320

Item

Diag. Lamp

Cause of Trouble

Np Sensor  1. Np/TDC output is lower than threshold level 2. Open or short sensor coil OFF

P0335

TDC Sensor 

3. Noise 4. Bad connection 5. Open or short wire 6. Clearance is too big

P0121

 Acceleration Pedal Positon Sensor 

ON

P0120

 Accel Sensor Output  Accel Sensor  Learning

If one of sensor has failed, normal operation is possible If both sensors are problem, engine will stop.

1. Open or short sensor harness 2. Bad connection 3. Open or short wire

P0120

Symptom

OFF

4. Abnormal output value

OFF

1. Abnormal output value

Idle mode driving, Limp Home

Normal operation is possible

Troubleshooting

44

Case Study DTC

P0115

-

P0180

Item

Water Temperature Sensor  Water Temperature Sensor  Fuel Temperature Sensor 

Diag. Lamp

Cause of Trouble 1. Open or short sensor harness

ON

2. Bad connection 3. Open or short wire 4. Abnormal output value 1. Lack of coolant

ON

2. Malfunction of thermostat 3. Defective cooling system

Symptom 1. Smoke may comes out 2. Idle rpm increase Vehicle speed is decreased by overheating

1. Open or short sensor harness OFF

2. Bad connection 3. Open or short wire

Normal operation is possible

4. Abnormal output value 1. Open or short sensor harness

P0110

Itake Air Temperature

OFF

2. Bad connection 3. Open or short wire 4. Abnormal output value

Normal operation is possible

Troubleshooting

45

Case Study DTC

Item

Diag. Lamp

Cause of Trouble

Symptom

1. Open or short sensor harness P1116

P1122

Boost Pressure Sensor 

Over Boost

ON

ON

2. Bad connection 3. Open or short wire 4. Abnormal output value

No acceleration

1. Too much fuel injection

(Low speed operation)

2. Retarded injection timing 3. Disabled wastgate actuator  4. Disabled turbocharger  1. Open or short sensor harness

P1123

TPS

OFF

2. Bad connection 3. Open or short wire 4. Abnormal output value

1. Smoke 2. Abnormal acceleration 3. Unstalbe idle RPM 4. Noise

1. Bad adjustment of timer piston position P1123

TPS Learning

OFF

2. EEPROM Error  3. TCV Error 

-

Troubleshooting

46

Case Study DTC

P1127

Item

CSP Rareshort

Diag. Lamp

ON

Cause of Trouble 1.Open or short sensor  coil (Abnormal Sensor Output) 2.Bad connection of connector 

Symptom

Engine stops

3.Open or short wire 1.CSP SENSOR ERROR

P1120

GE Servo

ON

2.Abnormal GE’s Yoke/Rotor  operation 3.Fuel temperature is low and has high viscosity

Engine stops

4.Open or short wire 1.TPS SENSOR ERROR 2.Timer piston’s operation error  P1135

IT Servo

OFF

3.Fuel has high viscosity and in low temperature. 4.TCV ERROR 5.Open or short wire

1.Too much smoke 2.Abnormal acceleration 3.Unstable IDLE RPM

Troubleshooting

47

Case Study DTC

Item

Diag. Lamp

Cause of Trouble

Symptom 1.SMOKE increases

P0605

P0105

EEPROM

Barometric Pressure Sensor 

OFF

1.ECU ERROR

1.Open or short sensor  harness OFF

2.Bad connection of  connector  3.Open or short wire 4.Abnormal sensor output 1.EEPROM ERROR

P1131

Q Adjustment Resistance

OFF

2.Bad connection of  connector  3.Open or short wire 4.Open or short wire in resistor 

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

Troubleshooting

48

Case Study DTC

Item

Diag. Lamp

Cause of Trouble 1.Abnormal GLOW RELAY

P1324

Glow Relay

Blink (75times/min)

2.Bad connection of  connector  3.Open or short wire 4.Voltage overflow

Symptom 1.Starting is not possible in low temperature 2.Increase of starting time

1.Communication error  P0600

Immobilizer 

OFF

2.Bad connection of  connector 

Starting is impossible

3.Open or short wire 1.Open of short FCV wire P1621

FCV Short

ON

2.Bad connection of  connector  1.ECU circuit ERROR

P1525

 Accel Sensor Ref. Voltage

OFF

2.Open or short wire 3.Bad connection of  connector 

1.Engine stops 2.Starting is impossible

 Abnormal sensor output / Power with ACCEL SENSOR ERROR

Troubleshooting

49

Case Study DTC

Item

Diag. Lamp

Cause of Trouble 1.ECU circuit ERROR

P1525

Boost Sensor Ref. Voltage

OFF

P1613

 A/D Conversion

OFF

2.Open or short wire 3.Bad connection of  connector  1.ECU circuit ERROR 1.VSP SENSOR ERROR

P0500

P1522

VSP Sensor 

Battery Voltage

OFF

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.

1.Open or short wire ON

2.Abnormal BATTERY charging

-

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¡ Æ before top dead center. Then , set dial indicator to zero.

50