ECD SYSTEM(w/ DPF) SYSTEM DESCRIPTION


  1. ENGINE CONTROL SYSTEM

    A01WTV3E01
    Text in Illustration
    *1 ECM *2 Atmospheric Pressure Sensor (built into ECM)
    *3 Accelerator Pedal Position Sensor *4 Generator
    *5 Engine Switch *6 Starter Signal
    *7 Vehicle Speed Signal *8 Battery Voltage
    *9 DLC3 *10 Other Signals
    *11 Stop Light Switch *12 No. 2 Glow Relay
    *13 No. 1 Glow Relay *14 EDU 2 Relay
    *15 No. 2 Injector Driver *16 EDU 1 Relay
    *17 No. 1 Injector Driver - -
    A01WRFGE03
    Text in Illustration
    *1 Fuel Supply Pump Assembly *2 Suction Control Valve
    *3 Fuel Temperature Sensor *4 Common Rail Assembly (for Bank 1)
    *5 Fuel Pressure Sensor *6 Common Rail Assembly (for Bank 2)
    *7 Pressure Discharge Valve *8 Mass Air Flow Meter
    *9 Intake Air Temperature Sensor (Built Into Mass Air Flow Meter) *10 Intake Air Temperature Sensor (Turbo)
    *11 Diesel Throttle Body Assembly (for Bank 1) *12 Diesel Throttle Body Assembly (for Bank 2)
    *13 Manifold Absolute Pressure Sensor *14 No. 1 EGR Valve
    *15 No. 2 EGR Valve *16 EGR Cooler
    *17 Glow Plug *18 Injector Assembly
    *19 Camshaft Position Sensor *20 Crankshaft Position Sensor
    *21 Engine Coolant Temperature Sensor *22 DC motor, Nozzle Vane Position Sensor (for Bank 1)
    *23 DC motor, Nozzle Vane Position Sensor (for Bank 2) *24 Exhaust Gas Temperature Sensor (B1S1)
    *25 Exhaust Gas Temperature Sensor (B2S1) *26 No. 2 Exhaust Gas Temperature Sensor (B1S2)
    *27 No. 3 Exhaust Gas Temperature Sensor (B2S2) *28 No. 4 Exhaust Gas Temperature Sensor (B1S3)
    *29 No. 4 Exhaust Gas Temperature Sensor (B2S3) *30 Air Fuel Ratio Sensor (for Bank 1)
    *31 Air Fuel Ratio Sensor (for Bank 2) *32 Differential Pressure Sensor Assembly (for Bank 1)
    *33 Differential Pressure Sensor Assembly (for Bank 2) *34 Exhaust Fuel Addition Injector Assembly (for Bank 1)
    *35 Exhaust Fuel Addition Injector Assembly (for Bank 2) *36 Monolithic Converter Assembly RH (for Bank 1 CCo catalytic converter)
    *37 Monolithic Converter Assembly LH (for Bank 2 CCo catalytic converter) *38 Front Exhaust Pipe Assembly (for Bank 1 DPF catalytic converter)
    *39 Front No. 2 Exhaust Pipe Assembly (for Bank 2 DPF catalytic converter) - -

  2. DIESEL PARTICULATE FILTER SYSTEM DESCRIPTION


    1. The diesel particulate filter System comprehensively regulates engine control (consists of a catalytic system and a fuel injection system) and purifies the particulate matter (PM) of diesel engines. The catalytic system purifies hydrocarbons (HC) and carbon monoxides (CO), and reduces PM with a catalytic converter using the Diesel Particulate Filter (DPF). The fuel injection system adds fuel into the exhaust port using the exhaust fuel addition injector to maintain a proper catalyst temperature for PM forced regeneration.

      A01WT1CE06
      Text in Illustration
      *1 ECM *2 Accelerator Pedal Sensor
      *3 Air cleaner *4 Mass Air Flow Meter
      *5 Intercooler *6 Diesel Throttle Body (for Bank 1)
      *7 Intake Air Temperature Sensor (Turbo) *8 Diesel Throttle Body (for Bank 2)
      *9 No. 1 EGR Valve *10 No. 2 EGR Valve
      *11 EGR Cooler *12 Exhaust Fuel Addition Injector Assembly (for Bank 2)
      *13 Exhaust Fuel Addition Injector Assembly (for Bank 1) *14 Turbocharger (for Bank 1)
      *15 Turbocharger (for Bank 2) *16 Exhaust Gas Temperature Sensor (B2S1)
      *17 Exhaust Gas Temperature Sensor (B1S1) *18 No. 3 Exhaust Gas Temperature Sensor (B2S2)
      *19 No. 2 Exhaust Gas Temperature Sensor (B1S2) *20 No. 4 Exhaust Gas Temperature Sensor (B2S3)
      *21 No. 4 Exhaust Gas Temperature Sensor (B1S3) *22 Differential Pressure Sensor (for Bank 1)
      *23 Differential Pressure Sensor (for Bank 2) *24 Air Fuel Ratio Sensor (for Bank 2)
      *25 Air Fuel Ratio Sensor (for Bank 1) *26 Monolithic Converter Assembly RH (for Bank 1 CCo catalytic converter)
      *27 Monolithic Converter Assembly LH (for Bank 2 CCo catalytic converter) *28 Front Exhaust Pipe Assembly (for Bank 1 DPF catalytic converter)
      *29 Front No. 2 Exhaust Pipe Assembly (for Bank 2 DPF catalytic converter) - -

    2. DPF components:

      Component Description

      Monolithic converter assembly

      (CCo catalytic converter)

      		 Reduces HC and CO.

      Front exhaust pipe assembly

      (DPF catalytic converter)

      		 Reduces PM.
      Exhaust Fuel Addition Injector Assembly Adds fuel into the exhaust port in order to raise catalyst temperature for PM forced regeneration.
      Exhaust gas temperature sensor Used for estimating the DPF catalytic converter temperature and adjusting fuel addition by ECM while PM forced regeneration is performed. Also detects the DPF catalytic converter temperature to prevent the catalytic converter temperature from rising too high.
      Differential Pressure Sensor Assembly Detects the volume of PM deposits and any incorrect vacuum hose arrangement on the DPF catalytic converter.
      Air fuel ratio sensor Used for controlling the air-fuel ratio. By controlling the air-fuel ratio, combustion control and PM forced regeneration are properly regulated.

    3. Diagnostic Trouble Codes (DTCs) table for DPF:

      Tech Tips

      This table indicates typical DTC combinations for each malfunction occurrence.

      Trouble Area Malfunction DTC No.

      Front exhaust pipe assembly

      (DPF catalytic converter)

      		 Deteriorated or clogged P062F, P200C*, P200D*, P200E*, P200F*, P2428*, P2429*, P244B*, P244C*, P244E*, P2458*, P2463*, P2465
      Exhaust Fuel Addition Injector Assembly Stuck open P20CF, P20D5
      Stuck closed P244C, P244E, P2458*
      Low fuel addition volume P244B*, P244C*, P244E*, P2458*, P2463 P2465,
      Open in exhaust fuel addition injector circuit P20CD, P20D3, P244C, P244E, P2458*
      Short in exhaust fuel addition injector circuit P20CF, P20D5, P20CD, P20D3, P244C, P244E*, P2458*
      Open or short in exhaust fuel addition injector circuit P200C*, P200D*, P200E*, P200F*, P20CF*, P20D5*, P20CD, P20D3, P2428*, P244C*, P244E*, P2458*
      Exhaust gas temperature sensor Open in exhaust gas temperature sensor circuit P0545, P0546, P0548, P0549, P200C*, P200D*, P200E*, P200F*, P2428*, P2032, P2033, P2035, P2036, P2084, P2086, P242B, P242C, P242D, P2467, P2468, P244C*, P244E*, P2458*, P2469
      Short in exhaust gas temperature sensor circuit P0545, P0546, P0548, P0549, P200C*, P200D*, P200E*, P200F*, P2428*, P2032, P2033, P2035, P2036, P2084, P2086, P242B, P242C, P242D, P2467, P2468, P244C*, P244E*, P2458*, P2469
      Exhaust gas temperature sensor P0545, P0546, P0548, P0549, P200C*, P200D*, P200E*, P200F*, P2428*, P2032, P2033, P2035, P2036, P2084, P2086, P242B, P242C, P242D, P2467, P2468, P244C*, P244E*, P2458*, P2469
      Differential Pressure Sensor Assembly Open in differential pressure sensor circuit P244C* P2454, P2455, P2458*, P2460, P2461, P2463*
      Short in differential pressure sensor circuit P244C*, P244E*, P2454, P2455, P2458*, P2460, P2461, P2463*
      Differential pressure sensor P244C*, P244E*, P2454, P2455, P2458*, P2460, P2461, P2463*
      Differential pressure sensor clogged P244C*, P244E*, P2453, P2458*, P245F, P2463*
      Incorrect vacuum hose arrangement of the differential pressure sensor P244C*, P244E*, P2453, P2458*, P245F, P2463*
      Air fuel ratio sensor Open or short in air fuel ratio sensor or heater circuit P0031, P0032, P0051, P0052, P2238, P2239, P2240, P2241, P2252, P2253, P2255, P2256, P244B*, P2463*, P2465
      Air fuel ratio sensor P0031, P0032, P0051, P0052, P2195, P2197, P2238, P2239, P2240, P2241, P2252, P2253, P2255, P2256, P244B*, P2463*, P2465
      Exhaust gas leaks Exhaust gas leaks P244C*, P2458*
      Fuel leaks Fuel leaks in fuel addition injector P200C*, P200D*, P200E*, P200F*, P20CF*, P20D5*, P2428*, P244B*, P2458*, P244C*, P244E*, P2463*, P2465
      Fuel supply pump assembly Correct fuel pressure cannot be fed to the exhaust fuel addition injector P244B*, P244C*, P244E*, P2458*, P2463*, P2465

      *: There may be no DTC output depending on the condition of the malfunction.

    4. Diagnostic trouble code description for DPF:

      DTC No. Description
      P0031 Open in air fuel ratio sensor heater (for bank 1) control circuit (Low output)
      P0032 Short in air fuel ratio sensor heater (for bank 1) circuit (High output)
      P0051 Open in air fuel ratio sensor heater (for bank 2) control circuit (Low output)
      P0052 Short in air fuel ratio sensor heater (for bank 2) circuit (High output)
      P0545 Open or short in exhaust gas temperature sensor circuit (B1S1) (Low output)
      P0546 Open or short in exhaust gas temperature sensor circuit (B1S1) (High output)
      P0548 Open or short in exhaust gas temperature sensor circuit (B2S1) (Low output)
      P0549 Open or short in exhaust gas temperature sensor circuit (B2S1) (High output)
      P200C DPF catalytic converter abnormally high exhaust gas temperature (bank 1 sensor 3)
      P200D DPF catalytic converter abnormally high exhaust gas temperature (bank 2 sensor 3)
      P200E DPF catalytic converter abnormally high exhaust gas temperature (bank 1 sensor 2)
      P200F DPF catalytic converter abnormally high exhaust gas temperature (bank 2 sensor 2)
      P2032 Open or short in exhaust gas temperature sensor circuit (B1S2) (Low output)
      P2033 Open or short in exhaust gas temperature sensor circuit (B1S2) (High output)
      P2035 Open or short in exhaust gas temperature sensor circuit (B2S2) (Low output)
      P2036 Open or short in exhaust gas temperature sensor circuit (B2S2) (High output)
      P2084 Exhaust Gas Temperature Sensor Circuit Range/Performance (B1S2)
      P2086 Exhaust Gas Temperature Sensor Circuit Range/Performance (B2S2)
      P20CD Open in exhaust fuel addition injector (for bank 1) circuit
      P20CF Exhaust fuel addition injector assembly (for bank 1) stuck open
      P20D3 Open in exhaust fuel addition injector (for bank 2) circuit
      P20D5 Exhaust fuel addition injector assembly (for bank 2) stuck open
      P2195 Air fuel ratio sensor (for bank 1) stuck lean
      P2197 Air fuel ratio sensor (for bank 2) stuck lean
      P2238 Open or short in air fuel ratio sensor (for bank 1) circuit (Low output)
      P2239 Open or short in air fuel ratio sensor (for bank 1) circuit (High output)
      P2241 Open or short in air fuel ratio sensor (for bank 2) circuit (Low output)
      P2242 Open or short in air fuel ratio sensor (for bank 2) circuit (High output)
      P2252 Open or short in air fuel ratio sensor (for bank 1) circuit (Low output)
      P2253 Open or short in air fuel ratio sensor (for bank 1) circuit (High output)
      P2255 Open or short in air fuel ratio sensor (for bank 2) circuit (Low output)
      P2256 Open or short in air fuel ratio sensor (for bank 2) circuit (High output)
      P2428 DPF catalytic converter abnormally high exhaust gas temperature (bank 1 sensor 1)
      P2429 DPF catalytic converter abnormally high exhaust gas temperature (bank 2 sensor 1)
      P242B Exhaust Gas Temperature Sensor Circuit Range / Performance (B1S3)
      P242C Open or short in exhaust gas temperature sensor circuit (B1S3) (Low output)
      P242D Open or short in exhaust gas temperature sensor circuit (B1S3) (High output)
      P2467 Exhaust Gas Temperature Sensor Circuit Range/Performance (B2S3)
      P2468 Open or short in exhaust gas temperature sensor circuit (B2S3) (Low output)
      P2469 Open or short in exhaust gas temperature sensor circuit (B2S3) (High output)
      P244B DPF catalytic converter (for bank 1) excessive differential pressure (High input)
      P244C DPF catalytic converter (for bank 1) insufficient temperature increase
      P244E DPF catalytic converter (for bank 2) insufficient temperature increase
      P2453 Differential pressure sensor (for bank 1) is clogged or has incorrect vacuum hose arrangement
      P2454 Open or short in differential pressure sensor (for bank 1) circuit (Low output)
      P2455 Open or short in differential pressure sensor (for bank 1) circuit (High output)
      P2458 Diesel Particulate Filter Regeneration Duration
      P245F Differential pressure sensor (for bank 2) is clogged or has incorrect vacuum hose arrangement
      P2460 Open or short in differential pressure sensor (for bank 2) circuit (Low output)
      P2461 Open or short in differential pressure sensor (for bank 2) circuit (High output)
      P2463 DPF catalytic converter soot deposition
      P2465 DPF catalytic converter (for bank 2) excessive differential pressure (High input)

  3. COMMON RAIL SYSTEM DESCRIPTION


    1. Common rail system:

      The common rail system uses high-pressure fuel for improved fuel economy. This system also provides robust engine power while suppressing engine vibration and noise.

      This system stores fuel in the common rail assembly, which has been pressurized and supplied by the fuel supply pump assembly. By storing fuel at high-pressure, the common rail system can provide fuel at stable fuel injection pressures, regardless of engine speed or engine load.

      The ECM, using the injector driver, provides an electric current to the piezo actuator in each injector to regulate the fuel injection timing and volume. The ECM also monitors the internal fuel pressure of the common rail assembly using the fuel pressure sensor. The ECM causes the fuel supply pump assembly to supply the fuel necessary to obtain the target fuel pressure.

      In addition, this system uses a piezo actuator inside each injector to open and close the fuel passages. Therefore, both fuel injection time and fuel injection volume can be precisely regulated by the ECM.

      The common rail system allows a multi-stage fuel injection process. In order to soften combustion shock, this system performs "pilot-injection" prior to the main fuel injection. This helps to reduce engine vibration and noise.

      A01WTDKE02
      Text in Illustration
      *1 Sensors *2 ECM
      *3 No. 1 Injector Driver *4 No. 2 Injector Driver
      *5 Common Rail (for Bank 1) *6 Fuel Pressure Sensor
      *7 Fuel Temperature Sensor *8 Suction Control Valve
      *9 Fuel Supply Pump *10 Exhaust Fuel Addition Injector
      *11 Injector Assembly *12 Pressure Limiter
      *13 Common Rail (for Bank 2) *14 Pressure Discharge Valve
      *15 Fuel Filter *16 Fuel Tank
      *17 Fuel Heater *18 High Pressure Fuel
      *19 Return Fuel *20 Suction Fuel

      Tech Tips

      If there is a problem with a fuel return pipe, as bleeding air from the fuel system may not be able to be performed properly in certain instances, such as after replacing an injector assembly, etc., the engine startability may deteriorate.

    2. Common rail system components:

      Component Description
      Common rail assembly Stores high-pressure fuel produced by fuel supply pump assembly
      Fuel supply pump assembly

      • Operated by crankshaft via gear

      • Supplies high-pressure fuel to common rail assembly
      Injector assembly Injects fuel to combustion chamber based on signals from ECM
      Fuel pressure sensor Monitors internal fuel pressure of common rail and sends signals to ECM
      Pressure discharge valve Based on signals from ECM, opens valve when sudden deceleration occurs, or when engine switch is off to prevent fuel pressure from becoming too high.
      Suction control valve Based on signals from ECM, adjusts fuel volume supplied to common rail and regulates internal fuel pressure
      Check valve Keeps pressure that discharges from injector

    3. Diagnostic trouble code (DTC) table for the common rail system:

      Tech Tips

      This table indicates typical DTC combinations for each malfunction occurrence.

      Trouble Area Malfunction DTC No.
      Injector assembly Open or short in injector circuit P0093*, P0201, P0202, P0203, P0204, P0205, P0206, P0207, P0208, P062D, P062E
      Stuck open P0093
      Stuck closed P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308
      Fuel pressure sensor Open or short in fuel pressure sensor circuit or pressure sensor output fixed P0087, P0190, P0192, P0193
      Pressure discharge valve Open or short in pressure discharge valve circuit P0088*, P0093*, P1229*, P1271, P1272
      Stuck open P0093
      Stuck closed P0088*, P1272
      Suction control valve Open or short in suction control valve circuit P0627, P1229, P0088*
      Stuck open P0088*, P1229
      Injector driver Faulty injector driver P0093*, P0201*, P0202*, P0203*, P0204*, P0205*, P0206*, P0207*, P0208*, P062D*, P062E*, P1271*, P1272*
      Common rail system (Fuel system) Fuel leaks in high-pressure area P0093

      *: There may be no DTC output depending on the condition of the malfunction.

    4. Diagnostic trouble code description for the common rail system:

      DTC No. Description
      P0087 Fuel pressure sensor output does not change
      P0088

      Internal fuel pressure too high (250000 kPa [2550 kgf/cm2, 36250 psi] or more)
      P0093 Fuel leaks in high-pressure areas
      P0190 Open or short in fuel pressure sensor circuit (output voltage is too low or too high)
      P0192 Open or short in fuel pressure sensor circuit (output voltage is too low)
      P0193 Open or short in fuel pressure sensor circuit (output voltage is too high)
      P0201 to P0208 Open or short in No. 1 to No. 8 injector circuit
      P0301 to P0308 Cylinder 1 to 8 misfire detected
      P0627 Open or short in suction control valve circuit
      P062D Open or short in No. 1 injector driver
      P062E Open or short in No. 2 injector driver
      P1229 Fuel over-feed
      P1271 Open or short in pressure discharge valve circuit
      P1272 Pressure discharge valve stuck close

  4. FUEL SUPPLY PUMP OPERATION SYSTEM DESCRIPTION

    Due to the rotation of the inner cam (eccentric cam), the outer cam pushes plunger A upward as illustrated below. The force of the spring pulls plunger B and C. As a result, plunger B and C draw fuel in, and plunger A pumps fuel at the same time.

    A01WT7WE03

  5. SUCTION CONTROL VALVE OPERATION SYSTEM DESCRIPTION

    Tech Tips

    The ECM controls the suction control valve operation to regulate the fuel volume that is produced by the fuel supply pump assembly for the common rail. This control is performed to regulate the internal fuel pressure of the common rail to the target injection pressure.


    1. Small opening of the suction control valve:


      1. When the opening of the suction control valve is small, the volume of supplied fuel is small.

      2. The suction volume becomes small due to the narrow path despite the plunger stroke being full. The difference between the geometrical volume and suction volume creates a vacuum.

      3. Pump output will start when the fuel pressure at (A) becomes higher than the common rail pressure (B).

        A01WVJOE23

    2. Large opening of the suction control valve:


      1. When the opening of the suction control valve is large, the volume of supplied fuel is large.

      2. If the plunger stroke is full, the suction volume becomes large because of the wide path.

      3. Pump output will start when the fuel pressure at (A) becomes higher than the common rail pressure (B).

        A01WPAVE21