D4BH (2.

5 TCI) Diesel Engine

(COVEC F)

Contents
 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

Maximum Power Maximum Torque Basic Injection Timing

General
Features
Improved Torque Performance

COVEC-F

Torque Conventional injection pump

50

100

Accelerator position (%)

General
Decreased Smoke at Acceleration

Conventional injection pump Injection quantity Excess fuel at acceleration

COVEC-F Accelerator position

General
Increased Comfort
Conventional type Control sleeve position Fixed

COVEC-F Control sleeve position Individual control

System Layout
Fuel System
Return Pipe Fuel Tank Over Flow Valve

Nozzle

Fuel Filter & Sedimenter

Glow Plug

Injection Pump

System Layout
Components Connection
Add. Vehicle Control Vehicle Sensors Vehicle Switches Battery Voltage

Np Sensor

GE Actuator Fuel Temp. Sensor Compensation Resister

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

ECM Injection Quantity Feedback

TPS Injection Timing Check

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

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

13

Np Sensor

Timer Control Valve.

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

Engine Control Module

ECM Terminal Layout

18

Terminal 1 2 3 4 5 6 8 10 11 12 13 GE + GE Power Start Switch A/C Switch

Signal GE GE Power Relay Ignition Switch A/C Switch

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

Engine Control Module

ECM Terminal Layout

19

Terminal 14 15 16 17 18 19 20 21 23 24 25 GE + GE Power TW Signal TF Signal TA Signal

Signal GE GE Power Relay

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)

Engine Control Module

ECM Terminal Layout

20

Terminal 26 29 30 31 32 33 34 35 36 37 38 FCV Signal TDC Signal Np Signal

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

Engine Control Module

ECM Terminal Layout

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

Engine Control Module

ECM Terminal Layout

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

Engine Control Module

ECM Terminal Layout

23

Terminal 64 65 68 69 71 72 73 75 76 Signal GND (Signal)

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

Connection with Others

No.5 No.9 IG. Key(B+) ECM Pin No. 13 At idle At acceleration

Troubleshooting
TPS (Timer Position Sensor)
F.I.P Connector No.3 MDL

25

No.2 OSC+ No.1 OSC-

TCV

Specification
No.2 ~ No.3, No.1 ~ No.3: 825.7

Connection with Others

No.1 No.2 No.3 ECM Pin No. 53 ECM Pin No. 46 ECM Pin No. 52 ECM Pin No. 52, 46 at idle ECM Pin No. 52, 53 at idle

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

26

No.3 Signal

Specification
No.2 ~ No.3: 1.650.15 k

Connection with Others

No.2 No.3 ECM Pin No. 38 GND ECM Pin No. 30 Signal Np Signal at idle Np Signal with CKP Sensor at idle

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

F.I.P Connector No.2 GND

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

Connection with ECM

No.4 No.8 No.12 No. 1 ECM Pin No. 43, 49 ECM Pin No. 44, 50 ECM Pin No.45 ECM Pin Nol 51 ECM Pin No. 43, 44 at idle ECM Pin No. 43, 45 at idle

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

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

ECM Pin No. 19 TA Sensor Signal

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

APS Side Connector

ECM Pin No. 8 at acceleration

ECM Pin No. 40 from idle to Max.

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

35

Good condition (Max. Throttle)

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

No.3 Np Signal FC Valve

Connection with ECM

No.1 ECM Pin No.26 Signal

Troubleshooting
EGR (Exhausted Gas Recirculation) Control Valve

38

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 Pin No. 2 of EGR Sol. Valve No.2 Pin No. 1 of EGR Sol. Valve No.2 ECM Pin No.58 Signal Main Relay B+ ECM Pin No.72 Signal Main Relay B+

EGR Control Solenoid Valve 2 (On-OFF Control)

Troubleshooting
EGR (Exhausted Gas Recirculation) Control Valve

39

Waveform

ECM Pin No. 58 at idle

ECM Pin No.58 at acceleration

ECM Pin No. 72 at acceleration

Troubleshooting
Intercooler Fan Motor

40

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 Engine speed : 550 rpm or more

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

Connection with ECM

Main Relay No.4 Engine check lamp Glow lamp ECM Pin No.73 ECM Pin No.62 ECM Pin No.63 ECM Pin No.59 ECM Pin No.68

A/C Fan Motor Relay A/C Comp. Relay

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

Idle mode driving, Limp Home

1. Abnormal output value

Normal operation is possible

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

Normal operation is possible

P0110

Itake Air Temperature

OFF

Normal operation is possible

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

Boost Pressure Sensor

ON

No acceleration (Low speed operation)

P1122

Over Boost

ON

P1123

TPS

OFF

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

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

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

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

Barometric Pressure Sensor

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

Accel Sensor Ref. Voltage

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

1.Open or short wire 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 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