D4BH Engine[1]

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

Contents Specification General System Layout Control Logic Components 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

2,467 cc

Bore X Stroke

91.1 X 95 mm

Compression Ratio

21

Compression Pressure

19.2 kg/㎠

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 Feed Pump Driving Gear Cross Coupling

Timer

Delivery Valve Control Sleeve 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 TCV (Timer Control Valve)

Duty Ratio = to/T X 100 (%)

T

Duty Ratio = 100% Æ 0% (Advanced) (Retarded)

15

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


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)

-


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


34

Boost Pressure Signal


35

Intercooler Fan Relay

Intercooler Fan Relay

36

Tach Out (PWM)

TCU (A/T Only)

37

GND

Camshaft Sensor

38

GND

Np Sensor


21

ECM Terminal Layout

Terminal

Signal

Connected to

39

GND


40

Accelerator Pedal Sensor Signal


41

GND (Analog)


42

GND (Analog)


43

OSC +

Control Sleeve Position Sensor

44

MDL


45

OSC -


46

TPS (OSC +)

Timer Position Sensor

47

AT/MT Switch

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

49

OSC +


50

MDL



22

ECM Terminal Layout

Terminal

Signal

Connected to

51

OSC -

Control Sleeve Sensor

52

TPS (MDL)


53

TPS (OSC -)


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


23

ECM Terminal Layout

Terminal

Signal

Connected to

64

Signal

Power Relay

65

GND (Signal)

-

68



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 Ω

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 Ω


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 kΩ


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) No.13(150.)

945 946 947 948 949 950 951 952 953 954 955 956 957

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

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 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



Troubleshooting

30

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 Temperature

Troubleshooting

31

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

3

2

1


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.(℃) 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


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


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


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 Pin No. 2 of EGR Sol. Valve No.1


Pin No. 1 of EGR Sol. Valve No.1

Main Relay B+




Main Relay B+

1

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℃ 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 ℃

2

60 ℃

3

- 15 ℃

8

0℃

3

- 20 ℃

10

- 10 ℃

3

- 25 ℃

15

- 20 ℃

5

- 40 ℃

24

- 40 ℃

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

Symptom

OFF

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.

Idle mode driving, Limp Home

Normal operation is possible

Np Sensor

P0335

TDC Sensor

P0121

Acceleration Pedal Positon Sensor

ON

P0120

Accel Sensor Output

OFF

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

P0120

Accel Sensor Learning

OFF

1. Abnormal output value

Troubleshooting

44

Case Study DTC

Item

P0115

Water Temperature Sensor

-

Water Temperature Sensor

P0180

P0110

Fuel Temperature Sensor

Itake Air Temperature

Diag. Lamp

Cause of Trouble

Symptom

ON


1. Smoke may comes out 2. Idle rpm increase

ON

1. Lack of coolant 2. Malfunction of thermostat 3. Defective cooling system

Vehicle speed is decreased by overheating

OFF



OFF



Troubleshooting

45

Case Study DTC

P1116

P1122

P1123

P1123

Item

Boost Pressure Sensor

Over Boost

TPS

TPS Learning

Diag. Lamp

ON

Cause of Trouble 1. Open or short sensor harness 2. Bad connection 3. Open or short wire 4. Abnormal output value

Symptom

No acceleration (Low speed operation)

ON

1. Too much fuel injection 2. Retarded injection timing 3. Disabled wastgate actuator 4. Disabled turbocharger

OFF


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

OFF

1. Bad adjustment of timer piston position 2. EEPROM Error 3. TCV Error

-

Troubleshooting

46

Case Study DTC

P1127

P1120

P1135

Item

CSP Rareshort

GE Servo

IT Servo

Diag. Lamp

Cause of Trouble

Symptom

ON

1.Open or short sensor coil (Abnormal Sensor Output) 2.Bad connection of connector 3.Open or short wire

Engine stops

ON

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

Engine stops

OFF

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

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

Troubleshooting

47

Case Study DTC

P0605

P0105

P1131

Item

EEPROM

Barometric Pressure Sensor

Q Adjustment Resistance

Diag. Lamp

Cause of Trouble

Symptom

OFF

1.ECU ERROR

1.SMOKE increases 2.Abnormal acceleration 3.Starting in impossible for IMMOBI. Vehicle

OFF

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

1.Power and acceleration is bad in low zone from sealevel 2.Too much smoke in high zone from sealevel

OFF

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

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

P1324

P0600

P1621

P1525

Item

Glow Relay

Immobilizer

FCV Short

Accel Sensor Ref. Voltage

Diag. Lamp

Cause of Trouble

Symptom

1.Abnormal GLOW RELAY 2.Bad connection of connector 3.Open or short wire 4.Voltage overflow

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

OFF

1.Communication error 2.Bad connection of connector 3.Open or short wire

Starting is impossible

ON

1.Open of short FCV wire 2.Bad connection of connector

1.Engine stops 2.Starting is impossible

OFF

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

Abnormal sensor output / Power with ACCEL SENSOR ERROR

Blink (75times/min)

Troubleshooting

49

Case Study DTC

Item

Diag. Lamp

Cause of Trouble

Symptom Abnormal sensor output / Power with BOOST SENSOR ERROR -

P1525

Boost Sensor Ref. Voltage

OFF

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

P1613

A/D Conversion

OFF

1.ECU circuit ERROR

OFF

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

ON

1.Open or short wire 2.Abnormal BATTERY charging

P0500

VSP Sensor

P1522

Battery Voltage

SHOCK occurs at acceleration or deceleration.

-

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.

50

Injection Timing Adjustment Basic Injection 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 7 ° ATDC. 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

51

D4BH Engine[1]

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