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

2Contents

Specification

General

System Layout

Control Logic

Components Description

Engine Control Module

Troubleshooting

Injection Timing Adjustment

3Specification

ATDC 9ºBasic Injection Timing22.3 kg.mMaximum Torque

94 psMaximum Power

Intake : 0.15 mmExhaust : 0.15 mm

Valve Clearance

19.2 kg/Compression Pressure

21Compression Ratio

91.1 X 95 mmBore X Stroke

2,467 ccTotal Displacement

OHCValve Mechanism

4, In-LineNo. of Cylinders

D4BH (TCI)

Description

Engine Model

Item

4GeneralFeaturesImproved Torque Performance

COVEC-F

Conventional injection pump

Torque

50 100

Accelerator position (%)

5General

Decreased Smoke at Acceleration

Injection

quantity

Accelerator position

Conventional injection pump

COVEC-F

Excess fuel at acceleration

6GeneralIncreased Comfort

Control sleeve position

Control sleeve position

Conventional type

COVEC-F

Fixed

Individual control

7System Layout

Fuel Tank

Fuel Filter &Sedimenter

Injection Pump

Return Pipe

Nozzle

GlowPlug

OverFlowValve

Fuel System

8System LayoutComponentsConnection

Battery Voltage

Add. Vehicle Control

Vehicle Sensors

Vehicle Switches

Np Sensor

Compensation Resister

GE Actuator Fuel Temp. Sensor

CSP SensorNp Sensor

TCV

TPS

9System Layout

Input Control Output Control Item

Injection PumpInjection Pump

Np Sensor

CSP Sensor

Fuel Temp. Sensor

Compensation Resister

TPS

GE Actuator

Timer Control Valve

Fuel Quantity

Injection Timing

ECUVehicle

VehicleSensors

Switches

Battery Voltage

EGR Control

Glow Control

Self Diagnosis

EGR Valve

Glow Plugs

Diagnostic Lamp

10Control LogicInjection Amount Controls

Example

Np Sensor when CPS is failedCPS

Pump speedEng. speed3,000 RPM GE ActuatorECM

Injection Quantity

37mg/stroke

Accel. Position50%

Fuel Injection

2.8 Volt

APS

CSPControl Sleeve Position CheckFeedback

11Control LogicInjection Timing Controls

Injection Timing

Pump speed

Eng. speed ECM

Injection Quantity

Duty(%) ControlTCV

Injection Timing Check

TPS

Feedback

CPS

ECM

Np Sensor when CPS is failed

12Components DescriptionInjection Pump(Mechanical)

Governor Spring

Flyweight

Control Lever

Control Lever Shaft

Regulating Valve

Idle Spring

Full Load Adjusting Screw

Tension Lever

Fuel Cut Solenoid

Plunger

Outlet Hole

Delivery ValveControl Sleeve

Plunger SpringCam DiscCross Coupling

Driving GearFeed Pump

Drive Shaft

Governor Leve Assembly

Timer

13Components DescriptionInjection Pump(Electronic)

Fuel Cut Solenoid

Governor Electronic

Np Sensor

Timer Control Valve.

14Components DescriptionGE(Governor Electric) Actuator

Magnet Filter

15Components DescriptionTCV (Timer Control Valve)

T

Duty Ratio = to/T X 100 (%)

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

16Components DescriptionTPS (Timer Position Sensor)

Retarded Advanced

17Components DescriptionNp Sensor

Np Sensor

18Engine Control ModuleECM Terminal Layout

TCVTCV Signal13

-Ground (Power)12

A/C Compressor RelayA/C Load Detection11

IG 1 (with immobilizer), Open(without immobilizer)Immobilizer Switch 0110

Accelerator PedalIdle Switch8

Inhibitor Switch(for A/T), Neutral Switch (for M/T)Neutral Switch (P, N)6

A/C SwitchA/C Switch5

Ignition SwitchStart Switch4

Power RelayPower3

GEGE -2

GE

Connected to

GE +

Signal

1

Terminal

19Engine Control ModuleECM Terminal Layout

-GND (Power)25

Open(with immobilizer), IG 1 (without immobilizer)Immobilizer Switch 0224

Glow Plug and Glow RelayGlow Check23

Ignition SwitchIgnition Switch21

Qadj. ResistanceQadj Resistance Signal20

Boost Pressure and Temperature SensorTA Signal19

Fuel Temperature SensorTF Signal18

Water Temperature and Gauge UnitTW Signal17

Power RelayPower16

GEGE -15

GE

Connected to

GE +

Signal

14

Terminal

20Engine Control ModuleECM Terminal Layout

Np SensorGND38

Camshaft SensorGND37

TCU (A/T Only)Tach Out (PWM)36

Intercooler Fan RelayIntercooler Fan Relay35

Boost Pressure and Temperature SensorBoost Pressure Signal34

Boost Pressure and Temperature Sensor Vref33

Accelerator Pedal SensorVref32

TCU (A/T Only)Torque Control (PWM)31

Np SensorNp Signal30

Camshaft SensorTDC Signal29

Fuel Cut Solenoid Valve

Connected to

FCV Signal

Signal

26

Terminal

21Engine Control ModuleECM Terminal Layout

Control Sleeve Position SensorMDL50

Control Sleeve Position SensorOSC +49

Open (for AT), IG 1 (for MT)AT/MT Switch47

Timer Position SensorTPS (OSC +)46

Control Sleeve Position SensorOSC -45

Control Sleeve Position SensorMDL44

Control Sleeve Position SensorOSC +43

Water Temperature and Gauge UnitGND (Analog)42

Water Temperature and Gauge UnitGND (Analog)41

Accelerator Pedal SensorAccelerator Pedal Sensor Signal40

Accelerator Pedal Sensor

Connected to

GND

Signal

39

Terminal

22Engine Control ModuleECM Terminal Layout

Glow LampGlow Lamp63

Engine Check LampDiagnosis Lamp62

Diagnostic Tool (Scan Tool)K – Line61

A/C Fan RelayA/C Fan Relay59

EGR 1 (Duty)EGR 158

TCU (AT only)TW Out57

Glow RelayGlow Relay55

Diagnostic Tool (Scan Tool)L – Line54

Timer Position SensorTPS (OSC -)53

Timer Position SensorTPS (MDL)52

Control Sleeve Sensor

Connected to

OSC -

Signal

51

Terminal

23Engine Control ModuleECM Terminal Layout

-GND (Signal)76

Power RelaySignal75

Power RelayMain Relay73

EGR 2 (On-Off)EGR 272

Vehicle Speed SensorVSP Signal71

TCU (AT only)Accel. Out (PWM)69

A/C Compressor RelayA/C Compressor Relay68

-GND (Signal)65

Power Relay

Connected to

Signal

Signal

64

Terminal

24TroubleshootingTCV (Timer Control Valve)

F.I.P

Connector

No.9 TCV-TCV

No.5 TCV+

SpecificationNo.5 ~ No.9: 11±0.7 Ω

Connection with OthersNo.5 IG. Key(B+)

No.9 ECM Pin No. 13

At accelerationAt idle

25TroubleshootingTPS (Timer Position Sensor)

No.3 MDLF.I.P

Connector

No.2 OSC+

No.1 OSC-

TCV

SpecificationNo.2 ~ No.3, No.1 ~ No.3: 82±5.7 Ω

Connection with OthersNo.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

26TroubleshootingNp Sensor

F.I.P

Connector

No.2

ECM GND

No.3 Signal

SpecificationNo.2 ~ No.3: 1.65±0.15 kΩ

Connection with OthersNo.2 ECM Pin No. 38 GND

No.3 ECM Pin No. 30 Signal

Np Signal at idle Np Signal with CKP Sensor at idle

27TroubleshootingQ Compensation Resistance

F.I.P

ConnectorNo.2 GND

No.1(0.18) 945 146649-4500No.2(0.30) 946 146649-4600No.3(0.43) 947 146649-4700No.4(0.62) 948 146649-4800No.5(0.82) 949 146649-4900No.6(1.10) 950 146649-5000No.7(1.50) 951 146649-5100No.8 (2.0) 952 146649--5200No.9(2.70) 953 146649-5300No.10(3.9) 954 146649-5400No.11(5.6) 955 146649-5500No.12(8.2) 956 146649-5600

No.13(150.) 957 146649-5700

Number Part No.Q Comp.

Resistance(kΩ)

Q Adjustment

Resistance

No.3 Sig

28TroubleshootingCSP (Control Sleeve Position) Sensor

29TroubleshootingCSP (Control Sleeve Position) Sensor

F.I.P

Connector

No.4 OSC +

No.8 OSC MDL

No.12 OSC -

SpecificationNo.4 ~ No.8, No.12 ~ No. 8: 5.9 ±0.3 Ω

Connection with ECMNo.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 -

ECM Pin No. 43, 45 at idle

30TroubleshootingTF (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

31TroubleshootingWTS (Water Temperature Sensor)

Specification

Temp.() Resistance(kΩ) Voltage(V)-20 16 4.30 5.9 3.4

20 2.5 2.440 1.2 1.560 0.6 0.980 0.3 0.5100 0.2 0.3

123ECM Pin No. 17 at normal operating Temperature

Connection with ECM

No.2 to Cluster

No.1 ECM Pin No. 17

No.3 ECM Pin No. 42 (GND)

32TroubleshootingBPS (Booster Pressure Sensor) / TA (Intake Air Temperature)Sensor

TA Sensor Specification

Temp.() Resistance(kΩ) Voltage(V)-20 16 4.30 5.9 3.4

20 2.5 2.440 1.2 1.560 0.6 0.980 0.3 0.5100 0.2 0.3

1234

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

33TroubleshootingBPS (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 accelerationfrom idle to 4200rpm

ECM Pin No. 19 TA Sensor Signal

34TroubleshootingAPS (Accelerator Pedal Sensor)

Connection with ECMNo.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

456

123

APS Side Connector

Accelerator Pedal Sensor

ECM Pin No. 40 from idle to Max.ECM Pin No. 8 at acceleration

35TroubleshootingAPS (Accelerator Pedal Sensor)

APS output signal failed, Idle Switch good, At Max. Throttle

ECM increases RPM slowly to 30% (4000rpm)Good condition (Max. Throttle)

36TroubleshootingCPS (Crankshaft Position Sensor)

CPS

1mm

123

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

37TroubleshootingFuel Cut valve

No.1 FCV

F.I.P

Connector

No.2

ECM GND

No.3 Np Signal

FC Valve

Connection with ECMNo.1 ECM Pin No.26 Signal

38TroubleshootingEGR (Exhausted Gas Recirculation) Control Valve

1

2

EGR Control Solenoid Valve 1(Duty Control)

1 2Connection with ECMPin 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)

39TroubleshootingEGR (Exhausted Gas Recirculation) Control Valve

Waveform

ECM Pin No. 58 at idle ECM Pin No.58 at acceleration ECM Pin No. 72 at acceleration

40TroubleshootingIntercooler Fan Motor

Connection with ECMI/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

41TroubleshootingGlow System

Post heatingPreheating

24- 40

15- 25

10- 20

8- 15

2

Heating Time (sec)

60

Coolant Temperature

5- 40

5- 20

3- 10

30

3

Heating Time (sec)

60

Coolant Temperature

42TroubleshootingOthers

Main relay controlECM controls Main relay to provide the B+ voltage to actuators like EGR Sol. Valves, Grow Plug and A/C fan relay etc.

LampsECM controls Engine check lamp and Glow lamp

Connection with ECMMain 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

43TroubleshootingCase Study

Normal operation is possible1. Abnormal output valueOFF

Accel SensorLearning

P0120

OFFAccel Sensor OutputP0120

Idle mode driving, Limp Home

1. Open or short sensor harness2. Bad connection 3. Open or short wire4. Abnormal output value

ONAcceleration Pedal Positon Sensor

P0121

TDC SensorP0335

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

Symptom

1. Np/TDC output is lower than threshold level2. Open or short sensor coil3. Noise4. Bad connection5. Open or short wire6. Clearance is too big

Cause of Trouble

OFF

Diag. Lamp

Np Sensor

Item

P0320

DTC

44TroubleshootingCase Study

Normal operation is possible

1. Open or short sensor harness2. Bad connection3. Open or short wire4. Abnormal output value

OFFItake Air TemperatureP0110

Normal operation is possible

1. Open or short sensor harness2. Bad connection3. Open or short wire4. Abnormal output value

OFFFuel

Temperature Sensor

P0180

Vehicle speed is decreased by overheating

1. Lack of coolant2. Malfunction of thermostat3. Defective cooling system

ONWater Temperature Sensor

-

SymptomCause of TroubleDiag. LampItemDTC

1. Smoke may comes out

2. Idle rpm increase

1. Open or short sensor harness2. Bad connection3. Open or short wire4. Abnormal output value

ONWater Temperature Sensor

P0115

45Troubleshooting

-1. Bad adjustment of timer piston position2. EEPROM Error3. TCV Error

OFFTPS LearningP1123

1. Smoke2. Abnormal

acceleration3. Unstalbe idle RPM4. Noise

1. Open or short sensor harness2. Bad connection3. Open or short wire4. Abnormal output value

OFFTPS P1123

1. Too much fuel injection2. Retarded injection timing3. Disabled wastgate actuator4. Disabled turbocharger

ONOver BoostP1122

SymptomCause of TroubleDiag. LampItemDTC

No acceleration(Low speed operation)

1. Open or short sensor harness2. Bad connection3. Open or short wire4. Abnormal output value

ONBoost Pressure SensorP1116

Case Study

46TroubleshootingCase Study

Engine stops

1.Open or short sensorcoil(Abnormal Sensor Output)

2.Bad connection of connector

3.Open or short wire

ONCSP RareshortP1127

Engine stops

1.CSP SENSOR ERROR2.Abnormal GE’s Yoke/Rotor

operation3.Fuel temperature is low

and has high viscosity4.Open or short wire

ONGE ServoP1120

1.Too much smoke2.Abnormal acceleration3.Unstable IDLE RPM

1.TPS SENSOR ERROR2.Timer piston’s operation

error3.Fuel has high viscosity and

in low temperature.4.TCV ERROR5.Open or short wire

OFFIT ServoP1135

SymptomCause of TroubleDiag. LampItemDTC

47TroubleshootingCase Study

1.SMOKE increases2.Abnormal acceleration3.Starting in impossible

for IMMOBI. Vehicle

1.ECU ERROROFFEEPROMP0605

1.Power and acceleration is bad inlow zone from sea-level

2.Too much smoke inhigh zone from sea-level

1.Open or short sensorharness

2.Bad connection ofconnector

3.Open or short wire4.Abnormal sensor output

OFFBarometric 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 ERROR2.Bad connection of

connector3.Open or short wire4.Open or short wire in

resistor

OFFQ Adjustment -ResistanceP1131

SymptomCause of TroubleDiag. LampItemDTC

48TroubleshootingCase Study

1.Starting is not possiblein low temperature

2.Increase of startingtime

1.Abnormal GLOW RELAY2.Bad connection of

connector3.Open or short wire4.Voltage overflow

Blink(75times/min)Glow RelayP1324

Starting is impossible

1.Communication error2.Bad connection of

connector3.Open or short wire

OFFImmobilizerP0600

1.Engine stops2.Starting is impossible

1.Open of short FCV wire2.Bad connection of

connectorONFCV ShortP1621

Abnormal sensor output / Power with ACCEL SENSOR ERROR

1.ECU circuit ERROR2.Open or short wire3.Bad connection of

connector

OFFAccel Sensor Ref. VoltageP1525

SymptomCause of TroubleDiag. LampItemDTC

49TroubleshootingCase Study

Abnormal sensor output / Power with BOOST SENSOR ERROR

1.ECU circuit ERROR2.Open or short wire3.Bad connection of

connector

OFFBoost Sensor Ref. VoltageP1525

-1.ECU circuit ERROROFFA/D ConversionP1613

-1.Open or short wire2.Abnormal BATTERY

chargingON

BatteryVoltage

P1522

SHOCK occurs at acceleration or deceleration.

Symptom

1.VSP SENSOR ERROR2.Open or short wire3.Bad connection of

connector

Cause of Trouble

OFF

Diag. Lamp

VSP Sensor

Item

P0500

DTC

50Injection Timing AdjustmentBasic 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 pipe4. Loosen injection mounting bolts and nuts5. 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.

51Injection Timing AdjustmentBasic 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 gauge13. Install timing check plug with new

copper gasket