СИСТЕМА ECD ОПИСАНИЕ СИСТЕМЫ

  1. ENGINE CONTROL SYSTEM

    A012G33C02
    *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.

      A012GKMC01
      *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.

      A012LINC01
      *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 Sub-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.

    A012IHWC01
    *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.

    A012HWOC01
    *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].

        A012KLBC01
        *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].

        A012HAMC01
        *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 - -