ECD SYSTEM SYSTEM DESCRIPTION

  1. ENGINE CONTROL SYSTEM

    A299061C02

    *1

    ECM

    *2

    Supply Pump Assembly

    *3

    Suction Control Valve

    *4

    Fuel Temperature Sensor

    *5

    Common Rail Assembly

    *6

    Fuel Pressure Sensor

    *7

    Pressure Discharge Valve

    *8

    Injector Driver (EDU)

    *9

    EDU Relay

    *10

    Injector Assembly

    *11

    Diesel Throttle Body Assembly

    *12

    Manifold Absolute Pressure Sensor

    *13

    Electric EGR Control Valve Assembly

    *14

    Glow Plug Relay Assembly

    *15

    Glow Plug Controller

    *16

    Glow Plug Assembly

    *17

    Engine Coolant Temperature Sensor

    *18

    Intake Air Temperature Sensor (Turbo)

    *19

    Intercooler Assembly

    *20

    Camshaft Position Sensor

    *21

    Crankshaft Position Sensor

    *22

    Mass Air Flow Meter Assembly

    *23

    Intake Air Temperature Sensor (Built into Mass Air Flow Meter Assembly)

    *24

    Turbocharger Sub-assembly

    *25

    DC motor, Nozzle Vane Position Sensor

    *26

    Differential Pressure Sensor Assembly

    *27

    Exhaust Gas Temperature Sensor (B1S1)

    *28

    No. 2 Exhaust Gas Temperature Sensor (B1S2)

    *29

    No. 3 Exhaust Gas Temperature Sensor (B1S3)

    *30

    Air Fuel Ratio Sensor

    *31

    Exhaust Fuel Addition Injector Assembly

    *32

    No. 1 Vacuum Switching Valve Assembly (for EGR Cooler)

    *33

    EGR Pipe with Cooler Sub-assembly

    *34

    Accelerator Pedal Sensor Assembly

    *35

    Generator Assembly

    *36

    Cooling Fan Relay

    *37

    Oil Pressure Switching Valve Assembly

    *38

    Oil Pressure Sender Gauge Assembly

    *39

    Battery

    *40

    Speed Signal

  2. DIESEL PARTICULATE FILTER SYSTEM DESCRIPTION

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

      A264731C01

      *1

      ECM

      *2

      Injector Driver (EDU)

      *3

      Common Rail Assembly

      *4

      Fuel Pressure Sensor

      *5

      Pressure Discharge Valve

      *6

      Supply Pump Assembly

      *7

      No. 1 Vacuum Switching Valve Assembly (for EGR Cooler)

      *8

      EGR Pipe with Cooler Sub-assembly

      *9

      Injector Assembly

      *10

      Electric EGR Control Valve Assembly

      *11

      Diesel Throttle Body Assembly

      *12

      Turbocharger Sub-assembly

      *13

      Exhaust Fuel Addition Injector Assembly

      *14

      Exhaust Manifold Converter Sub-assembly (DPF Catalyst)

      *15

      Differential Pressure Sensor Assembly

      *16

      Exhaust Gas Temperature Sensor (B1S1)

      *17

      No. 2 Exhaust Gas Temperature Sensor (B1S2)

      *18

      No. 3 Exhaust Gas Temperature Sensor (B1S3)

      *19

      Air Fuel Ratio Sensor

      *20

      Fuel Tank Assembly

    2. DPF components:

      Component

      Description

      Exhaust manifold converter sub-assembly (DPF catalyst)

      Reduces HC, CO and PM.

      Exhaust fuel addition injector assembly

      Adds fuel into the exhaust port in order to raise the catalyst temperature for PM forced regeneration.

      Exhaust gas temperature sensor

      Used for estimating the DPF catalyst temperature and adjusting fuel addition by the ECM while PM forced regeneration is performed. Also detects the DPF catalyst temperature to prevent the catalyst 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 Code (DTC) table for DPF:

      Tip:

      This table indicates typical DTC combinations for each malfunction occurrence.

      Trouble Area

      Malfunction

      DTC No.

      Exhaust manifold converter sub-assembly (DPF catalyst)

      Deteriorated or clogged

      P062F, P2002, P200C*, P200E*, P2428*, P244A*, P244B*, P244C*, P2463*

      Exhaust Fuel Addition Injector Assembly

      Stuck open

      P20CF

      Stuck closed

      P244A*, P244C

      Low fuel addition volume

      P244A*, P244B*, P244C*, P2463

      Open in exhaust fuel addition injector circuit

      P20CD, P244A*, P244C

      Short in exhaust fuel addition injector circuit

      P20CF, P20CD, P244A*, P244C

      Open or short in exhaust fuel addition injector circuit

      P200C*, P200E*, P2428*, P20CF*, P20CD, P244A*, P244C*

      Exhaust gas temperature sensor

      Open in exhaust gas temperature sensor circuit

      P0545, P0546, P200C*, P200E*, P2428*, P2032, P2033, P2084, P242B, P242C, P242D, P244A*, P244C*

      Short in exhaust gas temperature sensor circuit

      P0545, P0546, P200C*, P200E*, P2428*, P2002*, P2032, P2033, P2084, P242B, P242C, P242D, P244A*, P244C*

      Exhaust gas temperature sensor

      P0545, P0546, P200C*, P200E*, P2428*, P2032, P2033, P2084, P242B, P242C, P242D, P244A*, P244C*

      Differential Pressure Sensor Assembly

      Open in differential pressure sensor assembly circuit

      P244A*, P244C* P2454, P2455, P2463*

      Short in differential pressure sensor assembly circuit

      P244A*, P244C*, P2454, P2455, P2463*

      Differential pressure sensor assembly

      P244A*, P244C*, P2454, P2455, P2463*

      Differential pressure sensor assembly clogged

      P244A*, P244C*, P2453, P2463*

      Incorrect vacuum hose arrangement of the differential pressure sensor assembly

      P244A*, P244C*, P2453, P2463*

      Air fuel ratio sensor

      Open or short in air fuel ratio sensor or heater circuit

      P0031, P0032, P2238, P2239, P2252, P2253, P244B*, P2463*

      Air fuel ratio sensor

      P0031, P0032, P2195, P2238, P2239, P2252, P2253, P244B*, P2463*

      Exhaust gas leaks

      Exhaust gas leaks

      P244A*, P244C*

      Fuel leaks

      Fuel leaks in exhaust fuel addition injector assembly

      P2002*, P200C*, P200E*, P2428*, P20CF*, P244A*, P244B*, P244C*, P2463*

      Supply pump assembly

      Correct fuel pressure cannot be fed to the exhaust fuel addition injector assembly

      P244A*, P244B*, P244C*, P2463*

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

    4. Diagnostics trouble code description for DPF:

      DTC No.

      Description

      P0031

      Open in air fuel ratio sensor heater control circuit (Low output)

      P0032

      Short in air fuel ratio sensor or heater 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)

      P2002

      DPF catalytic converter thermal deterioration

      P200C

      DPF catalytic converter abnormally high exhaust gas temperature (B1S3)

      P200E

      DPF catalytic converter abnormally high exhaust gas temperature (B1S2)

      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)

      P2084

      Exhaust Gas Temperature Sensor Circuit Range/Performance (B1S2)

      P20CD

      Open in exhaust fuel addition injector assembly circuit

      P20CF

      Exhaust fuel addition injector assembly stuck open

      P2195

      Air fuel ratio sensor stuck lean

      P2238

      Open or short in air fuel ratio sensor or heater circuit (Low output)

      P2239

      Open or short in air fuel ratio sensor or heater circuit (High output)

      P2252

      Open or short in air fuel ratio sensor or heater ground circuit (Low output)

      P2253

      Open or short in air fuel ratio sensor or heater ground circuit (High output)

      P2428

      DPF catalytic converter abnormally high exhaust gas temperature (B1S1)

      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)

      P244A

      DPF catalytic converter excessive differential pressure (Low input)

      P244B

      DPF catalytic converter excessive differential pressure (High input)

      P244C

      DPF catalytic converter insufficient temperature increase

      P2453

      Differential pressure sensor assembly is clogged or has incorrect vacuum hose arrangement

      P2454

      Open or short in differential pressure sensor assembly circuit (Low output)

      P2455

      Open or short in differential pressure sensor assembly circuit (High output)

      P2463

      DPF catalytic converter soot deposition

  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 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 (EDU), provides an electric current to the piezo actuator in each injector assembly to regulate the fuel injection timing and volume. The ECM also monitors the internal fuel pressure of the common rail using the fuel pressure sensor. The ECM causes the 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 assembly 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 two 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.

      A203846C01

      *1

      Fuel Pressure Sensor

      *2

      Common Rail Assembly

      *3

      Pressure Discharge Valve

      *4

      Supply Pump Assembly

      *5

      Fuel Temperature Sensor

      *6

      Suction Control Valve

      *7

      Fuel Filter Element Assembly

      *8

      Fuel Tank Assembly

      *9

      Injector Driver (EDU)

      *10

      Exhaust Fuel Addition Injector Assembly

      *11

      Injector Assembly

      *12

      ECM

      *a

      Common Rail System Diagram (Fuel System)

      *b

      High Pressure Fuel

      *c

      Return Fuel

      *d

      Suction Fuel
      Tip:

      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 a injector assembly, etc., the engine startability may deteriorate.

    2. Common rail system components:

      Component

      Description

      Common rail assembly

      Stores high pressure fuel produced by supply pump

      Supply pump assembly

      Operated by crankshaft

      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 assembly and sends signals to ECM

      Pressure discharge valve

      Based on signals from ECM, opens valve when sudden deceleration occurs, or when ignition 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 assembly and regulates internal fuel pressure

      Check valve

      Keeps pressure that discharges from injector assembly

    3. Diagnostic Trouble Code (DTC) table for the common rail system:

      Tip:

      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, P062D

      Stuck open

      P0093

      Stuck closed

      P0301, P0302, P0303, P0304

      Fuel pressure sensor

      Open or short in fuel pressure sensor circuit or pressure sensor output fixed

      P0087, P0190, P0191, 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

      P0088*, P0627, P1229

      Stuck open

      P0088*, P1229

      Injector driver (EDU)

      Faulty injector driver (EDU)

      P0093*, P0201*, P0202*, P0203*, P0204*, P062D*, 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 (220000 kPa [2243.3 kgf/cm2, 31911 psi] or higher)

      P0093

      Fuel leaks in high pressure areas

      P0190

      Open or short in fuel pressure sensor circuit (output voltage is too low or too high)

      P0191

      Fuel pressure sensor malfunction

      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

      Open or short in No. 1 injector circuit

      P0202

      Open or short in No. 2 injector circuit

      P0203

      Open or short in No. 3 injector circuit

      P0204

      Open or short in No. 4 injector circuit

      P0301

      Cylinder 1 misfire detected

      P0302

      Cylinder 2 misfire detected

      P0303

      Cylinder 3 misfire detected

      P0304

      Cylinder 4 misfire detected

      P0627

      Open or short in suction control valve circuit

      P062D

      Open or short in EDU or injector circuit

      P1229

      Fuel over-feed

      P1271

      Open or short in pressure discharge valve circuit

      P1272

      Pressure discharge valve stuck close

  4. INJECTION CONTROL SYSTEM DESCRIPTION

    The ECM controls the fuel injection system through the injector driver (EDU), injector assemblies and supply pump assembly.

    The ECM determines the injection volume and injection timing based on signals from the accelerator pedal sensor assembly, crankshaft position sensor and camshaft position sensor. Based on the signals from the ECM, the injector driver (EDU) controls the injector assemblies. The injector driver (EDU) also controls the suction control valve installed on the supply pump assembly to help regulate fuel pressure.

    The piezo type injector assembly used in the 1AD-FTV engine makes noise when the engine is idling because this injector assembly operates at high speed. Therefore, the injector driver (EDU) controls the injector assembly to operate at low speed when the engine is idling based on signals from the ECM to achieve noise reduction.

    The feed pump is used to pump fuel from the fuel tank to the supply pump assembly.

    A241887C01

    *1

    Accelerator Pedal Sensor Assembly

    *2

    Camshaft Position Sensor

    *3

    Crankshaft Position Sensor

    *4

    Other Sensors

    *5

    ECM

    *6

    Injector Driver (EDU)

    *7

    Common Rail Assembly

    *8

    Fuel Pressure Sensor

    *9

    Fuel Discharge Valve

    *10

    Supply Pump Assembly

    *11

    Plunger

    *12

    Suction Control Valve

    *13

    Feed Pump

    *14

    Eccentric Cam

    *15

    Check Valve

    *16

    Fuel Tank Assembly

    *17

    Injector Assembly

    -

    -

    *a

    Injection Control Diagram

    -

    -

  5. SUPPLY PUMP OPERATION SYSTEM DESCRIPTION

    The rotation of the eccentric cam in the supply pump assembly causes the ring cam in the supply pump assembly to push plunger A upward as illustrated below. The spring force pulls plunger B (located opposite to plunger A) upward. As a result, plunger B draws fuel in, and plunger A pumps fuel out at the same time.

    A241888C01

    *1

    Check Valve

    *2

    Plunger A

    *3

    Eccentric Cam

    *4

    Ring Cam

    *5

    Plunger B

    *6

    Suction Control Valve

    *a

    Supply Pump Operation Diagram

    *b

    to Common Rail Assembly

    *c

    from Feed Pump

    *d

    Plunger A: Pumping End

    *e

    Plunger B: Suction End

    *f

    Plunger A: Suction End

    *g

    Plunger B: Pumping End

    -

    -

  6. SUCTION CONTROL VALVE OPERATION SYSTEM DESCRIPTION

    Tip:

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

      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 [B].

      3. Pump output will start when the fuel pressure at (1) becomes higher than the common rail pressure (2) [C].

        A208439C01

        *1

        Check Valve

        *2

        Suction Control Valve

        *a

        Suction Control Valve Operation at Small Opening

        *b

        Plunger Top Dead Center

        *c

        Plunger Bottom Dead Center

        *d

        Pump Output Starting Point

        *e

        Cam Stroke

        *f

        Small Opening

        *g

        Fuel Pumping Volume

        -

        -

    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 [A].

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

      3. Pump output will start when the fuel pressure at (1) becomes higher than the common rail pressure (2) [C].

        A208440C01

        *1

        Suction Control Valve

        -

        -

        *a

        Suction Control Valve Operation at Large Opening

        *b

        Pump Output Starting Point

        *c

        Cam Stroke

        *d

        Large Opening

        *e

        Fuel Pumping Volume

        -

        -