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Engine
D - ENGINE A - ENGINE J3 - ENGINE U - ENGINE
Item
Shape
Fuel Pressure
Outlet control Inlet control Inlet control Inlet control
Control
Grade/Classified
Injector Grade (X,Y,Z) C2I (16 digit code) Classified (C1,C2,C3)
(X,Y,Z / C1,C2,C3)
CRDI Fuel System
Fuel Flow (D-Eng) 4
Rail Pressure
Control Valve
(RPCV)
Fuel Tank
Low Pressure
Pump
Fuel Filter
Fuel Flow (A,U-Eng) 5
MPROP
High Pressure
Pump Common Rail Injector
IMV
Fuel Tank
Fuel Filter
Low Pressure Pump
Fuel System - Low Pressure Pump 7
Field case
Case Poor acceleration and shut off when sudden acceleration
Vehicle KM D-2.0 A/T (2003MY) Mileage 30558Km
Heating relay
IG B +
Fuel heater
Fuel temp. S/W
(On below -5℃)
CP1 type
▶ Max. pressure : 1,350 bar Parts No. Engine type Pump Type
33100 - 27000 D 2.0 WGT
▶ Application : Bosch CRDi Engine with Euro-3
33100 - 27500 D 1.5 WGT CP 1
33100 - 27900 D 2.0 VGT
TO C.R
Fuel Leak
Fuel return
FROM L.P
Engine stall and Hard starting
[CP1H]
Fuel System - High Pressure Pump 13
[CP3]
Fuel return
Cam
MPROP
IMV
Fuel Inlet
Fuel inlet
Low pressure pump
Valve ball
☞ 750rpm (Idle) : control
duty 16 % (260bar)
Pressure decrease
RPCV
Note:
In case the Pressure Control Valve is Rail Pressure Sensor
defective, the whole Rail needs to be
replaced! * IGN OFF : Drop below 100 bar (by spring force)
Fuel System - Pressure Control 15
Off
Symptom &
Checking
Run Run
Off
MPROP
Pressure
Armature relief valve
Spring Fuel supply
Electromagnet
MPROP
Fuel return
High pressure
Fuel supply
Fuel return 1. 2.
High pressure
Piston
Filter
Spring (lower)
LP inlet
(suction)
[J-Engine] Flow (l/hr)
250
to Rail 200
150
100
50
0
Pressure Limiter Valve 200 400 600 800 1000 1200 Current (mA)
Fuel System - Injector 18
Injector (Bosch)
Injector
voltage
Injector
current Pilot Main
Fuel System - Injector 19
Injector (Bosch)
Pressure
A : start of injection
The start of injection and the start of ignition are separated by a certain period of time.
Application Combination X Y Z
Case 1 0 4 0
Case 2 1 3 0
Case 3 0 3 1
Sorento
Case 4 1 2 1
Case 5 2 2 0
Case 6 0 2 2
Application Combination X Y Z
Case 1 0 4 0
Case 2 1 3 0
Carens,
Case 3 0 3 1
Sportage
Case 4 2 2 0
Case 5 0 2 2
Fuel System - Injector 22
Fuel contamination
Nozzle wear 10% misalignment of the
intermediate pin
25%
Fuel contamination
A Hole erosion
Others
Fuel contamination
Wear 5%
Breakage
coil damaged
Fuel System - Injector 23
Field case
Case Shut off the engine when a high speed driving or sudden acceleration
1. Engine shut off when over 90km/H driving - 5 times during 30 min
Symptom
2. Detonation noise is occurred when shut off time. Unable to re-start.
1. HP pump, common rail, low pressure pump, fuel filter were replaced already.
2. DTC : P1181 Fuel pressure monitoring.
Inspection 3. Idle condition is good. (no vibration)
4. Test driving with Hi scanner and fuel pressure gauge.
5. Fuel pressure is dropped immediately when symptom is occurred.
Injector (Delphi)
Edge filter
Calibration
Return channel mark (C2I)
Connector Shim
Control Valve
Return Spring Valve body
Coil
Valve
Calibration dowel
Valve spring
Nut Spacer
Injector spring
Nozzle
[Injector code registration]
Fuel System - Injector 25
Diagnosis of injector
Engine Management System
Diesel Engine System 27
Module assembly
Sensor assembly
APS1
APS2
Reference Voltage
APS1 signal APS1
Ground
15A
59 12V 0V
54 0V 12V
Dual brake
switch
STOP LAMP
ECU 5 13 58 59 54
CKP & CMP 30
FT Sensor
Mass air flow (MAF) sensor 32
Electrical
connections
Internal connections
V Hz
Evaluation
electronics
Housing
Sample Waveform:
Intake Air
Temperature signal
Replacement = Reset
Rail pressure sensor (RPS) 33
Euro 4
Replacement = Reset
Electric connections
V
Evaluation circuit
Note: 0.20
In case the Pressure Control Valve is defective, the whole lower fault area
Rail needs to be replaced! 100bar 1600bar
Solenoid valves 34
EGR Actuator
EGR solenoid
Turbocharger
EGR System 35
Benefit
- Increasing EGR volume by cooling (density up)
APS RPM
Filed case
3) Engine test result : OK (Compression test, Idle speed comparison, Injection quantity test)
- MAF sensor data is lower than normal when symptom was occurred EGR suspected
7) Conclusion : EGR open stuck intake air volume decreased unstable combustion
EGR System 37
Diagnosis
1. Coolant temp.:over 60 ℃, idle rpm: below 1000 rpm/maintain 60sec EGR valve off (duty approx. 5%)
2. After confirm E-EGR valve off checked air flow volume per cylinder check (Normal : approx. 400~500mg/st)
3. If air volume is normal then check E-EGR valve moving (after removing upper part)
4. After checking above things then check other parts Check valve moving
and stuck
Current data analysis
Current Data
Mass Air Flow 39.2 kg/h Check cylinder air volume
Air Flow Per Cylinder 449.6 mg/st
Intake Air Temp. xxx ℃
EEGR valve off check
EGR Actuator 4.7 % Upper part
Coolant Temp xxx ℃
Fuel Temp xxx ℃
Push the valve and check moving and stuck
after removing EGR upper bolt. If valve is
moved below approx. 5mm or stuck change EGR valve.
VGT 38
Benefits
- Decrease exhaust emissions, smoke and noise
- Increase output power and
- Maintain nearly constant power at high altitudes
- Better fuel economy
VGT 39
Operation
VGT
Engine Vane control
solenoid Vane path
condition actuator
duty
Caution
ACTUATOR ASSY
UNISON RING
EXTERNAL CRANK
ROLLER
INTERNAL ARM
Field case
Battery +
MIL
Accelerator Pedal Sensor
Accelerometer
Cylinder pressure
Major pilot injection
Needle lift
Accelerometer
Ratio
No injection
Diesel Engine Symptom Diagnosis
Diesel Engine System 45
Basic inspection :
-Connector connection check
-Fuel quality check (Mixing with other fuel )
-DTC ,Current Data check
Claim -etc, repair history
Symptom
check
1. Shut off during driving 1. Hesitation
2. Hard starting 2. Smoke occur
3. Jerking during acceleration 3. Bad acceleration
4. DTC related to fuel pressure
Hi-scan
Diagnosis with CRT OK
OK *2) High OK NG
*1) Injector Low pressure
pressure
back leak test line check
check
NG NG NG
Hard starting
Possible cranking
Compression
Starting system Battery Timing system
pressure
Timing system
Diagnostic Procedure
Caution : First of all check damage of harness and terminals : Check terminals for contact resistance,
corrosion and deformation.
Main relay contact inspection
Check point 1
Continuity or discontinuity?
Fuel system 48
Diagnostic Procedure
Diagnostic Procedure
4. Install pressure gauge of low pressure fuel between the fuel hose quick-connectors.
: Make sure of using low pressure gauge, gauge connection tube, connection adapter.
Low Fuel Pressure Line Check 51
7. Inspect change of the fuel pressure while accelerating engine or stall test.
: The more engine rpm is higher, the more pointer shaking is bigger.
A. Specification : Approx. 3.0 bar at accelerating engine or stall test of engine.
Fuel Filter Inspection 53
B. Case 2 : In case that there is a lot of metallic substances in the fuel filter.
What is possible cause ? How to treat this. ( )
Fuel Pump Circuit Inspection 54
Diagnostic Procedure
Check point 3
Check point 4
Check point 5
Check point 2
Pre-heating System Inspection 55
Diagnostic Procedure
Check point 1
Check point 3
Check point 4
M
1) Status check point 1 ( normal or blown )
Check point 5
2) Status check point 2 ( ) V at IG ON.
(Glow plug operating time)
3) Status check point 3 ( normal or abnormal )
Check point 2 4) Status check point 4 ( normal or blown )
5) Status check point 5 ( normal or abnormal )
Glow Plug Internal Resistance Inspection 56
Diagnostic Procedure
M Measured resistances
( ) Ω (20°C)
M
1) Status check point 1 ( normal or blown )
Check point 3
Check point 4
Check point 5
Fuel Heater Thermo Switch Circuit Inspection 58
Diagnostic Procedure
? ?
Diagnostic Procedure
1. IG KEY "ON"
2. Measure the voltage of CKPS connector terminals.
1) Status check point 1 ( ) V at IG ON.
2) Status check point 2 ( ) V at IG ON.
M
3) Status check point 3 ( ) V at IG ON.
Check point 2
? ? ?
Check point 1 Check point 3
Diagnostic Procedure
Engine Hesitation
: Check two items if hesitation during cold condition but disappear warm-up.
Diagnostic Procedure
2. Remove injectors.
Injector Nozzle Cleaning 64
[Caution] Never use steel brush to clean injector injector hole damaged
: Poor acceleration during full load but it is normal other condition Injector fault
Fuel Quality Inspection 66
Caution : In case of common rail diesel engine, Using poor quality diesel fuel can cause the fatal damage in engine
performance and high pressure fuel system.
Diagnostic Procedure
3. If there is engine hesitation in the vehicle, The symptom would get worse while testing.
Because fuel injection compensation of ECM be stopped while testing.
Idle Speed Comparison Test 68
4. "03.Injection quantity comparison test" in the "Engine test function" compensates each cylinder equally by
increasing (or decreasing) fuel injection quantity.
A. This result is artificial data when each injector connector is disconnected by turns.
Diagnostic Procedure
B. This result is artificial data when each glow plug is removed by turns, refer to below data while inspecting.
- RPM of abnormal cylinder is the highest, but real data is not the highest. You must refer to real data as below while
inspecting.
Compression Test (Pressure gauge)) 71
Diagnostic Procedure
A. In case of cylinder that causes engine hesitation, injection quantity(㎣) data is "-6" or "+6". Engine speed would be
balanced by ECM in the specific limit. This result means that compensation of injection quantity controlled by ECM goes
beyond the limit below 1,500 rpm.(Engine hesitation occurs at idle.)
Caution :You can not draw a conclusion that the cause of engine hesitation is "the injector" from first test.
If same data is displayed in the second test after cleaning nozzle of injectors, change the injector position. Inspect the
data on the scantool whether it is same or not in the same cylinder position after changing injector.
B. Case 1 : In case that injection quantity data is displayed "-6" or "+6" and engine speed (rpm) is not similar after
cleaning nozzles and changing injector position.
Replace the Injector.
C. Case 2 : In case that injection quantity data is displayed within "± 4" and engine speed (rpm) is similar after cleaning
nozzles and changing injector position.
Reuse the Injector.
Poor Acceleration / Power Check Flow 74
Low fuel
Intake system
pressure
D A. Case 1 : In case that fuel system data are normal, "Fuel pressure measured" is controlled by ECM to follow
"fuel pressure s/point" normally.
Which parts (or system) should be checked ? ( )
B. Case 2 :
- In case that "Fuel pressure measured" is unstable or "Rail pressure regulator (rail)" and "INJ. pump regulator
(pump)" data is abnormal.
- In case that "Fuel pressure measured" is not controlled by ECM to follow "fuel pressure s/point" at stall test,
finally poor acceleration occurs or engine stall.
What is the next step ? ( )
EGR & MAFS Inspection 76
C. Case 2 : In case that "Air mass meter" data is lower than 300
mg/st although "EGR actuator" data is 5.9 %.
D 1) What is possible cause. Which component should be
checked? ( )
MAFS Inspection 77
Diagnostic Procedure
MAFS inspection.
1. IG KEY "OFF", ENGINE "OFF"
2. Inspect contamination of air cleaner filter.
- Terrible contamination of air cleaner filter.
- Wetting of air cleaner filter.
3. Inspect foreign substances (leaves, paper, vinyl) in front of MAFS and damage of the grid of MAFS.
MAFS Inspection 78
Diagnosis
* Symptom
- No smoke (white, black smoke)
- Low stall rpm (approx. 1600~1800 rpm)
* Result Analysis
► Normal stall rpm with no black smoke Defected MAF sensor (less sensitive)
► Normal stall rpm with a lot of black smoke less intake air volume (clogged intake system)
: Because injection volume is increased by simulation but real intake air volume is lack.
► Low stall rpm Defected injector
[Notice] MAF sensor simulation is working well with a EURO 3 engine. (Euro IV: Frequency type MAF sensor)
Intake System Inspection 79
D
C. Case 1 : In case of Intake
system partial leakage.
Diagnostic Procedure
: White color, after emitting disappear. Water vapor can be generated inside muffler because
of engine high efficiency. Steam can be emitted by high temp. exhaust gas.
3) Smoke by excessive engine oil inside combustion chamber (somewhat blue color)
- Incomplete combustion due to excessive engine oil consumption
- Symptom occurs in engine idle
- Symptom gone after engine warm-up
1) Injector
- Excessive injection volume
- 2 cooper washers