Idea Transcript
2011 Automobile Maintenance Advanced Course for the Industrial Technical Instructors
Cotntnon Rail Direct Inj ection D· esel Engine •
In
Hyundai Tucson Class No.:
Instructor:
f\()"
~~-----
Lin, Jin-jih
eEl:>
Practice: Fuel System Analysis
HVUnORI
Topic : Oil Pressure Test for Low-pressuse pipe Time : 20 minutes 1. The fuel system of CRDi D-2.0
Common rail
. Pressure Pu mp
I
Injector
1
II
Fuel Case
Fuel Filter
Low Pressure Pum p
2. Test of low-pressure area for CRDi D-2.0 engine fuel syst - Please connect the pressure gauge according to t (~)Low-pressure
gauge @)Low-preSSl.lre gauge so It pipe @connect.or (e)conn~ctor (connect to t he pipe) ~ pin~ . ·l:b
©
® IIIIICJll=
CD ~
2
r:B>
Practice: Fuel System Analysis
HYUnORI
3. Measurement Method 1. Start the engine first and then close the engine after 5 minutes. 2. Connect the measurement gauge and then select checking, fuel pump starting, then push the bottom of "start". 3. Read the figure on the pressure gauge and fill the blank. Pressure of low pressure (measurement)
Unit
Standard Value
Judgement and Analysis
kg/cm2
"'-\. L
OK
4. Symptons Research Pressure of low pressure (measurement)
Unit
o ~ 1.5
kg/cm2
1.5
~
3
4~6
Reasons Analysis
\ Qftj{-X
kg/cm2 kg/cm2
\;\;oI[I/Y',
C
\ocv
0 1 it'
.~A~.\
I "(S
I
I
tj'_
,
,
A-~ 61
-'.( .!'l-( (I
()
K (}', riA:,
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Oil Pressure Measurement of Low Pressure Pipe (D-2.0) Using electrical pump Pressure
Measurement
Judgement
1
1.5-3kg/cm'
Normal
2
4-6kg/cm'
Block in Fuel Filter or low pressure pipe
3
0-1.5kg/cm'
Leakage of low pressure pipe or breakdown of electrical pump
Attention: 1. There is some pressure difference between WGT and VGT in Euro-3o WGT: Standard value is between 2.1'"""2.6 bar VGT : Standard value is between 2.3'"""2.8 bar 2. All cars in Euro-4 are VGT VGT : Standard value is 4bar v' 3. The overflow valve in Euro-3 is installed in fuel filter 4. The overflow valve in Euro-4 is installed in the face side of high pressu re pump, by using 16mm bolts set 3
HYUnORI
Practice: Fuel System Analysis
- 'fopic . Measm enrent the quantity of fuel i etm n by using Cft'f' 1000 spedf ic tools Mobile check Time : 20 minutes
1. The quantity of fuel return check for injector (engine can be starte d)
1. Separate the fuel return hose according to picture 1 2. Install plunger A according to picture 2 3. Connect injector fuel return hose connector B , clear hose, test cup and mount according to picture 3 .
Picture 1
Picture 2
Picture 3
4. After starting the engine, do the following steps - one second in idle speed ~ 30 seconds in 3,000rpm he engine ~ Result observation (Picture 4) - Do the above steps twice in order to 2. Results judgement Results,.-. :.:_ _ _ _ _ _ _ _ _ _ _ _ _
-!.
4
~
Stop t
~
Practice: Fuel System Analysis
HYUnORI - IOPIC: Measurement of the quantIty of fuel return by uSIng CR I 1000 spe cific tools Static check Time : 20 minutes High Pressu re Gauge
Fuel Pressure
•..... ..,.,
•
•
Adjust Valve Connec tor
. mG
•
Pressure Sensor Connector Parts for checking the quantity of fuel return
1. Engine can not be started 1. Separate the fuel return hose according to picture 1 2. Install plunger A according to picture 2 3. Connect injector fuel return hose connector B , clear hose, test cup and mount according to picture 3 4. Separate each connector in injectors
Picture 1
Picture 2 5
Picture 3
CB;> HYUnCRI
Practice: Fuel System Analysis
-
Picture 4
Picture 5
Picture 6
4. After separating the fuel pressure sensor connectors according to pic1 connect the battery and pressure sensor by using pressure gauge. 5. Separate the pressure adjust valve in the input of fuel pump accrodinf -Euro-3 (output control )7 one control way -Euro-4 (input and output contro1)72 control ways 6. After separate the connector of fuel pressure adjust valve according connect fuel pressure adjust valve to the battery, - to prevent from the damage of fuel pressure adjust valve. Hope to connect to the battery only in the measurement. (within 5 rr.
6
(8) HVUnORI
Practice: Fuel System Analysis
-
Picture 7
Picture 8
Picture 9
7. Connect the connector of separated fuel adjust valve by using fake res i~ according to picture 7 - only for Euro-4 (if it is for Euro-3, the way for fuel pressure adju~ input and output, then the fake resistance needs to be set. - If fake resistance is not set yet, the electrical fuel pump could not v test of high pressure pump. 8. Turn on the power switch of high pressure gauge 9. Start the engine - 5 seconds - not more than 5 seconds, the rpm has to over 200 rpm when the en The battery must be good for a good test result. 10. Read the highest figure in high pressure gauge according to picture 8. 11. After observing the fuel quantity of fuel return clear hose according to fill the blank and analysis the result.
7
r:B;> HYUnoRI
Practice: Fuel System Analysis
-
2. Judgement for the quantity of fuel return in high pressure pump and injectors Pressure of High Pressure pump
Quantity of fuel return for injectors
Judgement
CASE
Pressure of high pressure
Quantity of fuel return for injectors
1
1000-1800 (above1000)
0-200mm
Normal
2
0-1000 (under 1000)
200-400mm (above 200mm)
Breakdown of injector
Change the injector that over 200mm
0-200mm (under 200)
Breakdown of high pressure pump (not enough pressue)
Checking the line of high pressure pipe
3
0-1000 (under 1000)
8
Judgement
Checking Item
c:BY
Practice: Fuel System Analysis
HYUnORI
- Topic: Pressure measurement of high pressure pump by using CRT-I000 specific tools Time : ~~~'~~---------------------------------------------.
Connector for Fuel pre ssure adjust valve
......-L......
Connector for Pressure sensor (!)
\%112:1:1 ~t'l' i?'jOlE~ r ,~
ID :fI &'J ;;:: ~,
m?t, it~~ :1:~~ ~ ~Ol ~
Parts for checking high pressure pump
1. Engine can not be started 1. After separating the high pressure pipe according to picture 1, please put the cover to prevent from the impurities go inside the injector (mark A). Install fuel adjust valv e in common rail (mark B) and 3 common rail plunger (mark C). 2. Install plunger A according to picture 2 After '-''''' . . JL...... '
001
002 9
Practice: Fuel System Analysis
(DSeparate all injector pipe -Torque in installing: 250-290kg.m @put the cover to prevent from the impuriti es go inside the injector (mark A). @Install fuel adjust valve in common rail (mark B) and 3 plunger adjust valve (rna rk C). Judgemen
Picture 5
Picture 4
4. Separate the pressure adjust valve in the input of fuel pump accroding -Euro-3 (output control )~ one control way -Euro-4 (input and output control)~2 control ways 5. After separate the connector of fuel pressure adjust valve according 1 connect fuel pressure adjust valve to the battery, -- to prevent from the damage of fuel pressure adjust valve. Hope to connect to the battery only in the measurement. (within 5 r
10
c:B;> HVUnORI
Practice: Fuel System Analysis
-
Picture 7
Picture 6
6. Connect the connector of separated fuel adjust valve by using fake re: according to picture 6 - only for Euro-4 (if it is for Euro-3, the way for fuel pressure adju~ input and output, then the fake resistance needs to be set. - If fake resistance is not set yet, the electrical fuel pump could not v test of high pressure pump. 7. Turn on the power switch of high pressure gauge 8. Start the engine - 5 seconds - not more than 5 seconds, the rpm has to over 200 rpm when the en The battery must be good for a good test result. 9. Read the highest figure in high pressure gauge according to picture 7 and analysis the result.
11
cB:>. HYUnORI
Practice: Fuel System Analysis
-
2. Judgement for the quantity of fuel returnj for high pressure pump and injector Pressure of High pressure pump
Judgement
Remarks
Judgement
Remarks
3. Trouble Analysis
NO
Pressure of High pressure p ump
1
1000-1500bar
2
0-1000bar
4
Obar
Attention: -The situation of fuel filter needs to check before changing high pressure Pl and to judge if the impurities exists inside -If the impurities exists inside the fuel filter, necessary parts need to be ch( including fuel tank, after clean them.
12
Course: HYUNDAI D-2.0 CRDi Common Rail Direct Injection Diesel Engine
Instructor: Lin, Jin-jih (8) HYUnORI Service Training
.
CRDi - Common Rail Direct Injection Diesel Engine
Outline • The introduction to CRDi and general engine .. Turbocharger ;I
Fuel System
.. The electronic diesel control system d The control of Exhaust Gas Discharge
EURO-III ~ EURO-IV • Cautions of repair (8) HYUnORI nurvica Training
2
CROi - outline
Types
3
Engine
Displacement CC(L)
( Engine Management System)
D-2.0
2000 cc
Bosch
Starex
A-2.5
2500 cc
Bosch
Terracan
J3-2.9
2900 cc
Delphi
Models JM Tucson
CPI
FO Trajet
HI
CP3 Delphi
HP
EMS
CRDi : Common Rail Direct Injection CPt : Common Rail Pump 1 CP3: Common Rail Pump 3 (Ii/) HYUnDRJ Service Training
--------------------------CROi - outline
4
CP1 0-2.0 CRDi Engine on two models .. FOTrajet, ......•
•
·° 1
(Ii/) HYUnORI !iHrvice Training
JM . Tucson . . 1 0.
CRDi - outline
5
Delphi J3-2.9 CRDi Engine on :
CP3 A-2.S CRDi Engine on :
. HP Terracan
. Ht Starex
CRDi - outline
6
The Difference betweenCPl,CP3ahd .· Delphi · CPt
CP3
Delphi
The control of fuel quantity
Outlet
Inlet
Inlet
Fuel Temperature Sensor
0
Pressure Limit Valve
.
0 0
Fuel Temperature
Easy to go up
Not Easy to go up
Not Easy to go up
Low Pressure Pump
Electric Type
Gear Type
Vanes Type
(8) HYUnCRJ !l..,rvice Training
"
0-2.0 CRDi - High Speed Direct Injection
7
• Power UP and the Economy of Fuel Consumption - SOHC 4 valves and swing rocker arms - Turbocharger with inter cooler - Bosch common rail electronic diesel control (EDC) - Electronic controlled and high precision Injectors are Installed in the center of the combustion chamber. - Injection pressure reaches to 1,350 bar
• Low Emission and Low NVH - There is pilot Injection before main Injection - Balance Shaft - EGR System and Catalytic Converter
(E:/) HYUnDRI Service Training
.
The Development of Diesel Engine
8
• The Development of Diesel Engine
90
92
94
96
98 200Q Year
02
(E:/) HYUnDRI n,1rvice Training
04
06
0 -2.0 - High Speed Direct Injection • HTI D-2.0f Engine
Items
9
D-Engine
EMS
Bosch
Model
FC,LC,SM
Displacement (cc)
1.se & 2.0e
The Driven Way of High Pressure Pump The Control of Injectors
Camshaft Gear Inductive Current ( 20A ) Controlled by EMS
Pre-Injection Main Injection
Fuel Injection The Max. Fuel Pressure
1350 bar
The Control of Fuel Pressure
Outlet Control
Heating Device
Glow Plug Fuel Heater Coolant Heater
Valve Lash
HLA
(8) HYUnDRI Service Training
•
Timing Belt
10
Valve Driven System - SOHC 4 valves and swing rocker anns - Blacksmithing camshaft and hardening intake cams. - Low friction roller and minimized slipping component. . Hydraulic Lash Adjuster maintain no or low noise . . Camshaft drives CR pump
• •
- Timing Driving System - Belts drive camshaft and auto tensioner
(8) HYUnDRI f'lfJrvice Training
Driving Belt
11
cross-section
driving belt
(8) HYUnORI Service Training 12
Main Engine Parts
Main Characteristics - Peak of ignition pressure: 150 bar - Forging crankshaft and 5 flat rolling main bearing - Full balanced crankshaft and 8 reverse balanced weight - 2 balanced shaft are in the oil pan. (Lancaster Type) - Completely reliable moving components (piston/bearing)
- Oil pump is installed in the oil pan. - Driven by crankshaft small gear - Oil used: CE 10W30
Balanced shaft module
•----
(8) HYUnORI 5arvice Training --- - --
--- - - - - --
- --
--
-
-
- --
13
Turbocharger WGT ( Waste-gate Turbocharger)
(
) ".
"
VGT ( Variable Geometry Turbocharger) (Ii/) HYUnDRI Service Training
.
Turbocharger
14
WGT (Waste-gate Turbocharger)
VGT (Variable Geometry Turboch
.
_1T1lo_
(Ii/) HYUnDRI n!)rvice Training
CRDi- WGT (Waste-gate Turbocharger)
15
• System Chart
• Inter Cooling Inter cooling is the process that the air passes the inter cooler to reduce the temperature of compressed air intake, and increases the density of oxygen in the intake air. It is combined with the turbocharger, and obtain high level and equal combustion, so the engine power is increased 15%. (1i/) HYUnORI Service Training
CRDi - WGT (Waste-gate Turbocharger)
16
• Waste-gate Passage valve (Waste-gate I Regulation Valve) will reduce the exceed manifold pressure (over boost) during high speed, and make turbocharger system reach the peak of intake pressure to obtain highest boost reaction. After accurate metering, waste-gate intakes the exhaust emission to the turbocharger, and limits the speed of the turbocharger shaft to control the boost pressure.
wastegate Boost Pressure Turbocharger Boost
Without wastegate
Desired boost
Turbine In1et
Engine
-+------------------~~Speed
(1i/) HYUnORI
~!)rvice
Training
CRDi - VGT ( Variable Geometry Turbocharger)
17
VGT ( Variable Geometry Turbocharger) ECM control the solenoid valve (duty ratio) to change the vacuum above the actuator. The actuator is connected with the connecting I ever that pulls the rotation base. On the base, a cam is used to c onnect with vanes and decides the angle of vanes.
1
Vacuum Pump
1 1---------.·
I Vans COlltrolactuator I
1 (8) HYUnDRI Service Training
CRDi - VGT ( Variable Geometry Turbocharger)
Vans control ---actuator
18
Regulating Ring
Compressor Housing
~
Turbocharger Housing
(8) ~YUnDRI ~~rvice Training
,
CRDi - VGT ( Variable Geometry Turbocharger) ~High
Speed and high load:
The exhaust gas has large contact area, and the turbocharger's reaction and speed goes up (Max horse power is increased to 10-15%)
High Speed : Vanes Open
~Low
19
Speed and low load:
Because of narrow flow quantity area, the motion is reached to highest. (Max torque is increased to 5 -15%)
Low Speed : Vanes Closed
(8) HYUnDRI Service Training 20
Main Advantages of CRDi - VGT .Improve the horse power (10 -15% ) : High efficiency during low speed, and reduces the horse power loss of exhaust during high speed
• Improve the acceleration ability(10-15 %
)
:
Improve the instant reaction
• Improve the fuel consumption(5-10 0/0) : Effective engine output
.Fast warm-up : Higher boost temperature, boost pressure, and exhaust back pressure .
• Match the emission regulations easily: Reduce the emission of smoke, control the air intake, lower the emission during idle speed.
--=::: - -- - ~-----
Turbocharger
21
Cautions: 1. Never using air guns to blow vanes. 2.When the engine is just starting' the oil isn't lubricated to the turbocharger, please do not accelerate. 3.Never stop the engine suddenly. 4.Never depress the acceleration pedal heavily. 5.Replace the oil periodically. 6.Never make the vehicle coast after ignition switch is off during it is running. (E/) HYUnORI Service Training
.
CRDi- Clean
22
• Clean Common Rail system needs higher pressure, so it needs smaller injector holes and more accurate adjustment compared to conventional injection system. Therefore, when repairing common rail system ,you have to remain it absolutely clean. ~~ ;,
',..,
~
,
Hair
The hole of injectors
•
(E/) HYUnORI
~i,(~rvice
Training
enRi
23
Fuel System
(Ii/) HYUnORI Service Training
.
CDRi
24
Fuel Using Information: @ @
Super diesel has to be used. (The sulphur contentis lower than 50ppm) Normal diesel content inspection: -
Impurities (inspected by eyes) Metals (inspected by magnet) Water (Diesel and water separation inspection) Lubrication (inspected by hands) The color of the diesel (inspected by eyes)
-. -
$-
-,
•
(Ii/) HYUnORI Snrvice Training
-
0-2.0 Introduction
25
,1
CRDI-D ENG FUEL SYSTEM Common rail
Pressure regUlator valve
High pressure pump
Injector
low Dressure DumD Fuel filter (8) HYUnDRI Service Training
Low Pressure Line - Fuel Filter
26
• Components Explanation -Because of several reasons, common rail system needs more pur ified fuel compared to conventional diesel system. -Especially in cold climate, water and solid contaminants will ca use worn, corruption, clog in filter, corruption on the surface of metal, pressure loss, and less lubrication in high pressure pump. - In order to reduce these latent problems, there are Bosch fuel f i1ter and fuel pre-heater with water separation 0
- Main Components:
CD Main Filter ® Fuel Temperature Switch ® Water Separate Sensor @ Fuel Pre-heater
® Air drain pump (only for A-2.S J -2.9 model)
(8) HYUnDRI ~~'rvice Training
Low Pressure Line - Fuel Heating System
27
• System Explanation - Purpose: To prevent diesel wax occurred ( To stabilize the diesel in cold climate) - Working Temperature: On : lower than -5°C
Fuel Temperature S witch
Off : higher than 3°C
•
Wiring Diagram
Fuse Box
Battery
Fuel Temperature Switch
.
(8) HYUnORI Service Training
High Pressure Line - Pressure Control Valve
28
• Components Explanation - Main function: According to the engine speed and load, injection pressure will be controlled.
CD High engine speed and load: The perturbation motion in combustion chamber is high, so it needs higher pressure fuel to help combustion.
® Low engine speed and load: If the injection pressure is too high during low load, the penetration pressure of injectors will be over, some fuel will directly injected to the cylinder wall. This will produce smoke and unburned hydrocarbon. - The process of pressure control:
CD The rail pressure is measured
by rail pressure sensor.
® The signal is sent to EDC ( Electronic Diesel Control) ® According to the engine speed and load, proper fuel quantity is calculated. @ PWM (Pulse Width Modulation) controls the pressure control valve, and reaches t he pressure needed.
•
(8J HYUnORI
~i)rvice Training . - - - - - -- - - --
- - - --
-_.'",
' - '-
High Pressure Line - Pressure Control Valve
29
• Components Explanation - Type: CD Outlet Control: It is located at the end of the accumulator line, increases or reduces the total quantity of fuel return, and controls the output pressure of high pressure pump.
® Inlet Control: It is combined with high pressure pump and controls the fuel quantity from supply pump to high pressure pump.
*
Outlet Control Type : Advantages : The rail pressure can moved up instantly.
Drawbacks : When the car is decelerated suddenly, the unnecessary rail pressure will be difficult to release, and it wastes motion of energy.
* Inlet Control Type:
Advantages: When the car is decelerated suddenly, the rail pressure can be controlled accurately to avoid consuming motion of energy. Drawbacks: The rail pressure cannot moved up instantly. (E/) HYUnDRI Service Training
.
High Pressure Line - Pressure Control Valve
30
• Components Explanation - 2006 Tucson uses Outlet" Inlet Control Type p ressure control valve
- As showed below : Trajet uses Outlet Control Type pressure control valve
Control Valve
High Pressure Pump Supply Pump
•
(E/) HYUnDRI
f'~Jrvice
Training
High Pressure Line The 0 eration of Pressure Control Valve Outlet Control
31
t
(8) HYUnORI Service Training
----------------------------High Pressure Line - High Pressure Pump
32
• Components Explanation - Main Components:
CD Driving Shaft ® Offset Cam ® Pumping Parts and Pump Piston @ Inlet Valve
® Outlet Valve
Inlet Valve
I
r - I- - - - - - ,
. Outlet Valve
•
(8) HYUnORI
S:~rvice Training
.
High Pressure Line - Fuel Common Rail
33
• Components Explanation - Main function: High pressure accumulator is commonly named fuel common rail, it stores high pressure fuel. Even when large fuel quantity is discharged, the common rail still can maintain the internal constant pressure. - Components :
CD Common Rail ® From the inlet of high pressure pump . @ Rail Pressure Sensor @ Fuel pressure limit valve
® To the pipes of the injectors
.
(8) HYUnORI Service Training
D-Engine (2.0L)
34
Classification of injectors • These injectors have been produced since March,2003. • 3 different type of distinguishing word X, Y;fa Z . • Injectors ofY mark must be installed on more than 2 cylinders.
© Table of Injectors Classification of Injectors Unit Combination
•
X
y
Z
Situation 1
0
4
0
Situation 2
1
3
0
Situation 3
0
3
1
Situation 4
2
2
0
Situation 5
0
2
2
(8) HYUnORI
~~)rvice Training
High Pressure Line - Injectors
35
• Components Explanation .,
- Main function:
Input> 1. Mass Air·Flow Sensor· "','
1. Injectors
2~' ECT S~hsor
2. Fuel Rail Control Valve
3. IAT Sensor
3. Relay
"
..
;.,.
.
...
- Main - Glow Plug
ECM
- Cooling Fan - Air Conditioning Fan
4. VAC Regulator of EGR 5. Pre-heater ( Coolant) 6. CAN
(8) HYUnORI Service Training
------------------------------EDC- ECM
42
• Components Explanation : - Clear Trouble Code: When trouble codes occurred and were stored in ECM, only Hi-scan pro can be used to clear codes in ECM. - Required Signal of ECM Output: Maintain the pressure constant in high pressure accumulator (Common Rail) => P > 150 bar ( Instant pressure should be less than 150 bar) To start and stop the actual injection sequence => CKP and CMP Signal are normal. ECM Connector PLUG "M"
PLUG "K' 40
CJ S
d3
24:rrILLLLLLLLLILLLlXJ 6
:; :::::::; : : : : : : : : : :
1002 81: I
II I I I I
r
I, ¥ I I I I I I I
(8) HYUnORI
:~
HE
Z(~rvice
Training
........ _
- - - - - -.._
EDC - General Items
-
43
- Emergency Mode: When ECM is malfunctioned on important Input/Output Signal, it will switche d to Emergency Mode It will cause: 0
CD Reduce horse power ® Reduce max. rpm
® Without EGR (according to equipments) - Emergency Stop If the following system components got problem ' ECM will emergently stop t he engine:
CD Injectors ® CKPSensor ® Pressure Control Valve @ Fuel Leak
- Caution: When the engine is running or after the engine is stopped less than 30 seconds, do not repair the engine. (8) HYUnORI Service Training
.
EDe - Heat Film Type Mass Air Flow Sensor ( AFS )
44
• Components Explanation: - The principle of hot film sensor is to heat the sensor and transfer the air mass. Compared to gasoline engine, mass air flow sensor of diesel engine is mainly the limit of E GR. Intake air temperature is built in. - Functions :
CD EGR Feedback Control ® The correction of fuel quantity when suddenly acceleration or deceleration. Mass Air Flow Sensor ECM AFS Output (V)
89 t--i:------+--++---, B+(12V)
reference (V)
971 ···- tl--------··- ·--l--. +-.I ·-- ~/
86
IAT Output (V)
1-1!----·---·--·-+---I-· I-----I%~~t_-_4to Ground
88t--ir-----+--++----~
•
(8) HYUnORI SHrvice Training
EDC
- Intake Air Temperature Sensor ( IAT ) [Characteristic Curve]
• Components Explanation -
IAT Sensor is built in AFS °
.
Using NTC to detect the variation of temperature, so the! ensor's main function is to measure the intake te mperature. When malfunction occur, the temperature of IAT is set to 50°C .
LI ....
'.',.,
\,
'~.-......
j
_-.......,-----
,..
J. "1XT4' ~/'&
0110
.;..
Symptom
Trouble Codes
Details
CC
DTC
45
C001
Signal is lower than limit (Signal 4.97V)
Fuel
EGR
=0
Closed
Fuel Limit
MIL
-- '~"C
Inspection Condition
on
Ignition Switch is ON
y
(Malfunction : 50°C) v
,"
"
'''~'W~YY''Y' ' ''YY''''''Y''Y'''' ''''Y''Y
"'Y'-""Y "
W"
"
~SY='~"Y "
Y'_Nvv _ ' ~Y"=vw,,~vY,,_yyy=~'.' · Y~"
""
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,_,"'v='yyyyy
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y··V V Vy··y·"Nyy·· · ·y y··y=·,yyyyyyyy,-yy· ·· ,~y" "
"
..
· ··· · · yY~YVN ·· =-'·,y,.w"
"N ·,·""¥ yVy y·"N · ·y·· y
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v".yyv·, ·"
'···.y_··_ ·, .·"··, · ·"v·. _ ~ ·,, v · ."N v ·
__r.wyv· ·' ' ' y ,·.y· .. =V · ."",··WW'_'···'··V_'_"W·,,V·
(/i/) HYUnDRI Service Training
.
EDC - Accelerator Position Sensor ( APS )
46
• Components Explanation : - Accelerator Position Sensor is used to detect driver's acceleration or deceleration, and sends signal to ECM. ECM decides injection quantity and proper timing by this signal. There are two sensors in APS (Accelerator Position Sensor) , APS 1 and APS 2. APS 1 is the main sensor to t m ell ECM about driver's motion. APS 2 is the sub sensor to monitor APS 1 alfunctioned or not. The output value of APS 2 is half of APS 1. ECM
APS1 reference
rp
11111
11M I
m
.11 I-~:
•
...
,.,
~
..
.. -......
~
.'"
......
r~
,~
-...t
00
APS1 Signal ,""",':«'*':"':::-:'~~:">OOO««~.
_
...
~.
APS1 Ground
{- '-.J -...I
~
APS2 reference
r APS2 Signal APS2 Ground
L..
(XI
-{- 00 0
(-
(8; HYUnDRI
... ~
~~'rvice Training
EDC - Crank Position Sensor (CKP) :
47
• Components Explanation : - Crank Position Sensor (CKP): Crank Position Sensor is named CKP technically. The operation is to detect and calculate the teeth (60-2) on the pulse gear, sends the position of every piston in combustion chamber to ECM, and decide the actual injection timing. This important information is calculated in ECM by using CKP sensor.
ECM Ground
101
99
Signal (+) Signal (-)
100
(F:/) HYUnORI Service Training
----------------------------------EDC - Camshaft Position Sensor (CMP)
48
• Components Explanation : - Camshaft Position Sensor (CMP) Camshaft position sensor detects the initial position of camshaft by Hall effect. Magnetic teeth are mounted to the camshaft and rotates with it. When teeth pass the CMP Sensor, the magnetic field will transform the electron inside of the semiconductor into current direction that passes through the chips. This causes short voltage signal (Hall voltage), and let ECM know the location of 1stpiston's compression stroke_ CAMSHAFT POSITION SENSOR
ECM
104 103
Ground Sensor Signal N I-t-- - - - - - - ' - - . . . . . . . : . . . . ;+___;
~
- ~
VM1
(F:/) HYUnORI
~t1rvice
Training
EDC - Rail Pressure Sensor (RPS)
49
• Components Explanation - Rail Pressure Sensor (RPS) : The main function of rail pressure sensor is to measure the instant pressure in the rail, and sends the output voltage to ECM correspond to the operation voltage. To shorten the inaccuracy in rail pressure sensor during pressure measurement, RPS must maintain proper accuracy to operate fast.
RAIL PRESSURE SENSOR
ECM
Signal 91 ~~~~~------~-r---. reference 90~~~~~------~-+~ Ground 92 ~-;~~~-------&--r------J
"
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EDC - Engine Coolant Temperature Sensor (ECT)
50
• Components Explanation: - Engine Coolant Temperature Sensor (ECT) : Engine coolant temperature sensor is located in the passage of engine coolant on the top of cylinder head. It detects the engine coolant temperature, and send signal to ECM. It senses the variation of the temperature sensor. The higher temperature is, the resistance of temperature sensor is lower. ECM controls the injection timing by this signal, and limit the idle speed of the engine by ECT output. At the same time, when the ECT value is higher than the value in ECM, ECM will reduce the fuel quantity.
ECM
Temperature gauge
85 1---------11---
Ground
Signal
•
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EDC - Brake Switch
51
• Components Explanation: - Brake Switch : For safety, there are two brake lamp switches. Every time when every driver depresses the brake pedal, it will send ON! OFF signal of brake system to ECM. When brake lamp switch 1 is on, brake lamp switch 2 must be off. By using this opposite signal output, ECM can check the reasonable operation of switches.
To brake lamp Brake Switch 1 1 54_~~(O_.3~)____-+3 __
2
VB
4
VM1
Brake Switch 2 (E/) HYUnDRI Service Training
-----------------------------------------------------------------------EDC - Injectors
52
• Components Explanation - Injectors : Sorento Uses hydraulic servo system and electronic start components for special injectors. Inductive Current: 20A ± 1A, Current Maintained: 12A + 1A E
114 ,-+,
o.z P 1
..
0
4
CD
G)
0
0
s:::
::::I
No.1 Injection Injectors
..
..
G)
P 3
~
..
::::I
No.4 Injection Injectors
::::I
No.3 Injection
t:f2 .!~
G) 0
s:::
~
"tJ
p 2 r
::::I
= Injectors
~/
o.z
..
s:::
118
..-h
0
G)
s:::
121
.-+-..
o.z
"tJ
P
U
120
.-+-.
~
o.z
G
117
119
•
0
.. ~
CD
!
No.2 Injection Injectors
(E/) HYUnDRI S:,rvice Training
EDC - The Control System of Glow Plug
53
• Components Explanation : - Glow Plug System: Glow plug system ensures effective cold start. It can shorten the warm-up time, and directly affect the exhaust gas emission.
I Glow Plug Relay I
IGlow Plug I
l' •••••
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EDC - The Control System of Glow Plug
54
- The glow time is decided by the temperature of engine coolant and engine speed. Engine is Start running ! IG ON - - - . ' /__'::O _~ ___ l IPre-glo; IStart-glow'" ~ain-glo~,I
CD 1 Pre-glow:
I
I
- Preheat system as three modes of operation__ . :' -:~i
Coolant temperature rC)
-20°C
-10°C
20°C
50 °c
Glow time (Sec.)
12
8
3
0.7
® Start-glow: Pre-glow has completed, but the engine doesn't start yet. When the engine coolant temperature is lower than 60°C, max glow time will maintain 30 seconds. When the coolant temperature reaches 60°C in 30 seconds, glow will be stopped.
® Main-glow: After the engine starts, rpm is lower than 2500 and the quantity of fuel injection is lower than 75cc / min °
------•
Coolant temperatureCC)
-20°C
-10°C
20°C
40 °c
Glow time (Sec.)
40
25
10
0
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Training
EOC - EGR System
55
• Components Explanation :
Solenoid valve
- EGR System: Equipped with EGR, some exhaust gas will be inducted into intake system of the engine. When reaching to some level, increasing the rest exhaust gas will be positively effective to energy transfer and exhaust gas discharge. The EGR solenoid valve is controlled by PWM signal produced by ECM.
ECM
Main Relay
VAOJUM Ma:xJLATOR (FOR EGR VALVE)
EGR valve
16
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------------------------------EOC - 0-2.0 EGR System
56
EGR Cooler
The main purpose of EGR cooler is to reduce the emission temperature of EGR, and promote volume efficiency when EGR is working.
•
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_~I
EDC - EGR System
57
- General Concept of EGR System:
.... -.----:;.-====b==::-f~;r--::::;:¢=::::J
Intake
AFS Signal (EGR Feedback Control)
Controlled Vacuum Pressure
rpm ~
•
Intakeair Vacuum Pressure
. . . . Input Signal . . . Exhaust ~ EGR Emission
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EDe - EGR System
58
The Timing of : • • • • • ...
Engine speed is 11 00 ~ 3000 rpm Coolant Temperature : ECT > 60 °C Atmospheric Pressure: Altitude is higher than 1700 meters Mass Air Flow Sensor ( AFS ) is not malfunctioned Injection quantity is less than 42 C.c. EGR is off during normal idle speed, release acceleration pedal and EGR will operate 50 seconds.
EGROFF
Driving Idle Speed (NO APS)
EGRON
•
I(
50 seconds
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)1
EDC - EGR System
57
- General Concept of EGR System:
AFS Signal (EGR Feedback Control)
Controlled Vacuum Pressure
rpm ~
1
Intakeair Vacuum Pressure
..... Input Signal
~ Exhaust EGR Emission
c=::::(E/) HYUnDRI Service Training
.
EDe - EGR System
58
The Timing of : • • • •
Engine speed is 11 00 ~ 3000 rpm Coolant Temperature : ECT > 60 °C Atmospheric Pressure: Altitude is higher than 1700 meters Mass Air Flow Sensor (AFS ) is not malfunctioned
• Injection quantity is less than 42 c.c. EGR is off during normal idle speed, release acceleration pedal and EGR will operate 50 seconds.
'*
EGROFF
Driving Idle Speed (NO APS)
EGRON
•
I( (E/) HYUnDRI
50 seconds
~'4~rvice Training
)1
FO D-2.0L and JM D-2.0L Engine
59
FO D-2.0 CRDi
1M D-2.0 CRDi
Displacement
1,991 cc
1991cc
PS
110.5 PS/4000rpm
136 PS/4000rpm
Torque
26.0 kg·m/2000rpm
31.1 kg·m12000rpm
83x92
83x92
Appearance
Cylinder diameter X str oke
BOSCH 2nd generation • Fuel Pressure Control - Inlet& Outlet Control - 1,600bar • SCV ( Swirl Control Valve) • ACV( Air Control Valve) • CPF - Euro IV
BOSCH 1st generation • Fuel Pressure Control -Outlet Control
characteristics
- 1,350bar
.
C8J HYiJniJFii Service
I
I
raining
EURO III and EURO IV ~ The
60
development goal of Exhaust Gas Emission ~----------------------------~
CD The comparison between EURO 4 and EURO 3 Emission Standard:
PM (g/km)
- PM EURO-3 ( regulation)
- NOx : Reduce 50 %
0.05 0.04
--
0.03
- - EURO-4 ( regulation)
0.02
~) Development Goal
- Ruled 70 %
• ••• •• ••••••
0.01
~
EURO-4 ( ideal)
• • • •
®
•• ••
0.0
0.1
0.2
EURO-4 application - New Model : January,2005
I
•
: Reduce 50 %
0.3
0.4
- Now: January,2006
0.5 HC+ NOx (g/km)
" (E/) HYUnDRI !:"'~rvice Training
I
.~~ __ ~ . . __ J
61
EURO-IV Application
2nd generation CRDi System Injection Pressure: 1350 ---->1600 bar ECU : 16 ---->32 bit
ACV ( Air Control Valve)
G;;I B!!I
(/if) HVUnDRI Service Training
Cautions of Repair
62
> Every system component should be packed by sealed plastic. Every port should use proper plug to prevent dust. > Never use air guns to clean engine room when fuel pipes are removed. Removing and Installing Injectors
y Install Injectors: e Clean the base eCopper washer eTorque T40 Torx (torque: 2.70 9.2 kgm)
•
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~' Effectively control the quantity of fuel injection
Injector (multi-injection) • 2nd Injector Cutaway
Eng ine start and low idle
Se(lllng pli'tc Va!\'o bO Reduce exhaust gas emission 45 - -- - - - - , - - - - - - -
IQA (Injector Quantity Adjustment)
46
Cautions of Repair
63
y When disconnect high pressure pipes, use 2 wrenches to loosen both sides nuts. ~ Please
use bare hands to repair in order to prevent dust.
.
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Cautions of Repair
64
Removing High Pressure Pipe Never release high pressure pipes with running: engine
~"T"""LI""
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.
-------------------------
Cautions of Repair
65
Checking fuel pressure & checking injector operation
High pressure can be checked only via the Raj,1 Pressure Sensor Voltage Reading.
High pressure can be checked only via the Rail Pressure Sensor Voltage Reading.
(8;>
.
(8) HYUnORI Service Training
48
HVUnCRI