Common rail direct injection [CRDI] - ENGINE TABLE OF CONTENTS 1. SAFETY FIRST............................................4
4. Operating principle...........................29
1.1 For Safety................................................... 4
4.1 CRDI (Common Rail Direct Injection) system... 29
1.1.1 Alert symbols.................................... 4 1.2 Safety tips.................................................. 5
4.1.1 ECU (Electronic Control Unit)......... 31 4.1.2 High pressure fuel pump (for injection)... 43 4.1.3 Fuel rail(Common rail).................... 44 4.1.4 Injector [C3I]................................... 44 4.2 Body and power train system................... 49
1.2.1 Safety gear....................................... 5 1.2.2 Work place ...................................... 5 1.2.3 Avoid fires......................................... 6 1.2.4 Cautions when handling the battery (optional)... 7 1.2.5 Cautions for high pressure hoses........ 7 1.2.6 Use of appropriate tools and equipment... 8 1.2.7 Handling of hazardous materials.........8 1.2.8 Handling of rotating driving section.. 9 1.2.9 Prevention of scald........................... 9 1.2.10 Disposal of environmental waste..........10
2. Engine identification.........................11 2.1 Engine decal............................................ 11 2.2 Engine number (B)......................................12 2.3 Assignment standard for engine model code... 13
3. Specifications......................................14 3.1 General specifications.............................. 14 3.2 Engine dImension.................................... 15 3.3 Components............................................. 17 3.4 Engine performance curve....................... 19 3.5 Engine performance curve analysis......... 22 3.6.1 Torque............................................. 22 3.6.3. Brake horse power (HP)................. 22 3.6.3 S.F.C (Specific Fuel Consumption) 23 3.6 Servicing specifications............................ 24 3.6.1 Engine body.................................... 24 3.6.2 Lubricating system.......................... 27 3.6.3 Cooling system............................... 27 3.6.4 Tightening torques for engine......... 28
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4.3.1 Cylinder head................................. 49 4.3.2 Cylinder Block................................. 49 4.3.3 Cylinder honing............................... 49 4.3.4 Crankshaft...................................... 50 4.3.5 Piston and piston ring..................... 50 4.3.6 Connecting Rod.............................. 50 4.3.7 Camshaft........................................ 50 4.3.8 Rocker arm assembly..................... 51 4.3.9 Intake and exhaust valves.............. 51 4.3.10 Timing Gear................................... 52 4.3.11 Flywheel........................................ 52 4.3.12 MLS cylinder head gasket............. 52 4.3 Lubricating system................................... 53 4.4.1 Engine oil flow................................ 53 4.4.2 Engine oil flow chart....................... 54 4.4.3 Function of lubricating system........ 55 4.4 Cooling system......................................... 57 4.4.1 Coolant flow route........................... 57 4.4.2 Water pump.................................... 58 4.4.3 Thermostat..................................... 58 4.4.4 Radiator.......................................... 59 4.4.5 Radiator cap................................... 59 4.5 Fuel system.............................................. 60 4.6.1 Overview for fuel supply................. 60 4.6.2 Fuel flow route................................ 60 4.6.3 Fuel filter......................................... 62 4.6.4 Bleeding the fuel system................ 63 4.6.5 High pressure fuel pump................ 64 4.6.6 Common rail (fuel rail).................... 66
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TABLE OF CONTENTS 4.6.7 INJECTOR [C3I (Calibration improved individual injector)].......... 67 4.6.8 Fuel heater and fuel cooler............. 68 4.6 Intake & exhaust system.......................... 69
7.22 G270A Electric part (1)........................... 132
4.6.1 Overview......................................... 69 4.6.2 EGR cooler..................................... 73 4.6.3 EGR valve...................................... 73 4.6.4 Air control vavle (Tier4 model)........ 74 4.6.5 CCRT (Catalyzed Continuously.......... Regenerating Trap) (Tier4 model).. 75 4.6.5 Turbo charger................................. 78 4.7 Sensor...................................................... 80
8. Disassembly, service and assembly....137
4.8.1 Sensors as input/output for ECU.... 86
5. TROUBLESHOOTING...............................88 6. Measurement and adjustment......91 6.1 Fan belt.................................................... 91 6.2 Piston compression pressure measurement... 91 6.3 Valve clearance........................................ 92 6.4.1 clearance adjustment..................... 92 6.4 Valve lift (Deflection and worn condition of valve cam, tappet, push rod, rocker arm, etc.)... 93 6.5 Oil pressure measurement....................... 93 6.6 Bubble test for radiator............................. 94 6.7 Turbo charger wastegate pressure check... 94
7. Exploded view......................................96 7.1 G010A Cylinder block............................... 96 7.2 G020A Oilpan........................................... 99 7.3 G030A Cylinder head............................. 101 7.4 G040A Gear case................................... 103 7.5 G050A Oil filter....................................... 105 7.6 G060A Crank shaft................................. 107 7.7 G070A Piston & Connecting rod............ 108 7.8 G090A Cam shaft................................... 109 7.9 G100A Idle gear..................................... 110 7.10 G110A Rocker Arm & Valve.................... 112 7.11 G120A Fuel Equipment.......................... 113
7.23 G280A Electric part (2)........................... 134 7.24 T0580A Electric part (3) (tier4 model).... 136
8.1 Engine component removal................... 137 8.2 Engine disassembly............................... 147 8.3.1 Head cover................................... 147 8.3.2 Glow plug and injector.................. 148 8.3.3 Rocker arm assembly................... 149 8.3.4 Cylinder head............................... 151 8.3.5 Intake and exhaust valves............ 153 8.3.6 High pressure fuel pump.............. 155 8.3.7 Gear case..................................... 157 8.3.8 Gears in gear case....................... 159 8.3.9 Piston and connecting rod............ 168 8.3.10 Flywheel and crankshaft............. 172 8.3.11 Oil filter........................................ 182 8.3.12 Oil pump...................................... 183 8.3.13 Thermostat.................................. 185 8.3.14 Water pump................................. 186 8.3.15 Fuel filter..................................... 188 8.3.16 Turbo charger.............................. 189
9. Engine Electric components......191 9.1 Main components Specification............. 191 9.2 Circuit and wiring diagram...................... 193 9.2.1 ECU circuit.................................... 193 9.2.2 Engine wiring diagram.................. 195 9.3 Electric components............................... 197 9.4.1 Start motor.................................... 197 9.4.2 Alternator...................................... 197 9.4.3 Engine oil pressure switch............ 199 9.4.4 ECU.............................................. 199 9.4.5 Sensors and relays....................... 200
10. DIAGNOSTIC..........................................213 10.1 Diagnostic program................................ 213
7.12 G130A Water flange............................... 114
11. General service..............................240
7.13 G150A Cylinder head cover................... 116
11.1 Driving inspection................................... 240
7.14 G160A Fuel Filter & Pipe........................ 118
7.17 G200A EGR cooler................................. 124
11.1.1 Engine startability inspection....... 240 11.1.2 Inspection during driving............. 241 11.1.3 Engine warming up...................... 242 11.2 Daily inspection...................................... 242
7.18 G240A Turbo Charger............................ 125
11.3 Periodic inspection................................. 243
7.19 G245A Turbo pipe.................................. 127
11.3.1 Fuel system................................. 244 11.3.2 Engine oil..................................... 246 11.3.3 Coolant........................................ 247 11.3.4 Others.......................................... 248
7.15 G170A Inlet manifold (Tier4).................. 120 7.16 G175A EGR........................................... 122
7.20 G250A After treatment (Tier4)................ 129 7.21 G260A ECU & sensor............................ 131
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PREFACE This manual is to provide servicing personnel with information on the general specifications, service, operating principle, troubleshooting, exploded view including part name, removing and installing procedures for Common Rail Direct Injection (CRDI) Engine with high-end technology. All information in this manual is based on the latest product information available at the time of publication. Therefore, some of the information in this manual may differ from the machine you have. DAEDONG has a principle to apply update to the next edition of the manual if there is any. However, DAEDONG has no obligation to modify the contents in this manual, especially the contents in the manual which is already distributed or published. The modified information is available in DAEDONG's online electronic manual system (DEMSS). This manual is ultimately to satisfy customers with best performance of tractor. If there is any typo, wrong information or question for this manual, feel free to contact DAEDONG.
2014. 09 service division DAEDONG INDUSTRIAL Co., Ltd.
Important • Using unspecified parts, fuel and lubricants other than DAEDONG's genuine parts can damage the tractor and such damage will not be covered by warranty.
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Remark • We reserve the right to make changes throughout the entire manual at any time without notice.
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CRDI
SAFETY FIRST 1. SAFETY FIRST 1.1 for SAFETY •
Most accidents can be avoided if basic safety instructions and regulations are followed. Always follow the safety regulations and avoid any dangerous situation to prevent an accident.
•
You can be unexpectedly injured if inspecting or servicing the tractor without full knowledge of it. Read the service manual carefully before starting servicing and follow the instructions for servicing, maintenance and inspection to prevent any injury.
reaD manual! 매뉴얼 숙지 ! T46W001A
1.1.1 Alert symbols In this manual, the following safety-alert symbols are used. Their meanings are as follows:
▶ Remark
▶ CAUTION
ⱇ#⪣
Remark
CAUTION T46W002A
•
Broaden your knowledge with additionally supplied service information for optimal service.
▶ Important
T46W004A
•
This mark indicates potentially hazardous situation which, if not observed, may result in serious injury.
▶ WARNING
WARNING T46W003A
•
This mark indicates emphasis on information which can be confused when servicing. If this information is not carefully read and observed, the tractor cannot fully function or may be damaged.
T46W005A
•
This mark indicates hazardous situation which, if not observed, may result in death or injury.
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CRDI
SAFETY FIRST
1.2 Safety TIPS 1.2.1 Safety gear
1.2.2 Work place
T46W006A
When working on the tractor, wear safety gloves, safety shoes, ear plugs, safety goggles, safety helmet, working clothes, etc. appropriate for your working environment. Never wear loose fitting clothing or a tie which can be caught to the rotating part. According to the statistics, most accidents that occurred with rotating parts are due to this inappropriate manner of wearing clothes.
T46W007A
vENTILATINg SYSTEM The service should be performed in well-ventilated area. If the engine should be started in an enclosed place, the exhaust gas pipe should be installed.
WARNING • California Proposition 65 Warning Inhaling exhaust gas can cause cancer or damage the generative function leading to infertility.
SAFE wORkINg pLACE
T46W008A
The work should be done in a wide, level and safe place to prevent slip and fall accident.
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SAFETY FIRST
CRDI
1.2.3 Avoid fires ILLUMINATION The work place should be well illuminated. If working in a dark place or under the tractor, use the work lamp. The work lamp should be covered by the safety cover. The bulb can cause fire due to leaked fuel if it is broken.
T46W011A
SAFETY EqUIpMENT Be sure to keep a first aid kit and fire extinguisher handy at all times.
•
Never smoke or allow flames in your work area when servicing the fuel system.
CLEAN wORkINg AREA Keep the working area clean before and during work. If any oil or fuel is spilled, it should be cleaned up immediately.
T46W012A
•
Keep flames or sparks away from the spray paint or fuel containers and be careful of leak.
T46W013A
•
Always disconnect the battery cable before servicing.
•
Be extra cautious of fire when welding.
T46W014A
•
Always keep a fire extinguisher in workshop.
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CRDI
SAFETY FIRST
1.2.4 C autions w hen han d lin g the battery (optional)
1.2.5 Cautions for high pressure hoses
T46W015A
•
Always disconnect the negative battery cable first and reconnect it last to avoid sparks from an accidental short circuit. You can get injured or fire may break out.
T46W019A
•
The hydraulic fluid leaked from high pressure hoses or pipes can penetrate your skin.
T46W020A T46W016A
•
Do not charge the frozen battery. Charging the frozen battery can cause explosion. Let the battery warmed up to ambient temperature (16°C, 60°F) before charging.
•
Before connecting a high pressure hose or pipe, stop the engine and depressurize it by valve.
•
Check the bolts for tightness before starting the engine after servicing the hydraulic system.
•
Use a cardboard or plank when checking leakage.
T46W021A T46W018A
•
The battery contains the acid that can burn you. When it contacts with your eyes, you may lose your sight.
•
Never weld the high pressure pipe or the surrounding area. The pipe or hose can be heated and explode which can lead to fire or burn.
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SAFETY FIRST
CRDI
1.2.6 Use of appropriate tools and equipment
1.2.7 Handling of hazardous materials
•
Use the appropriate tools in proper size. If an inappropriate tool is used, it can be slipped which can damage parts or injure you.
•
•
Do not confuse units (mm, inch, etc.).
Do not use pressurized air to blow out hazardous materials, such as industrial wasted dust, with compressed air. Inhaling such hazardous materials can damage your health.
•
Use the air impact wrench only when unscrewing the bolts or nuts. Such wrench should not be used when assembly precisely machined parts which its tightening torque should be strictly observed. It can cause malfunction.
•
These materials should be rinsed or wiped away after spraying oil.
•
Be careful of a socket popped out due to the turning force when using the air impact wrench. Especially, be extra cautious when working on connection or socket with joint.
T46W022A
•
When lifting the vehicle with a hydraulic jack or a hoist, fix it firmly and install the auxiliary support. Never work under the tractor if the support and the hydraulic jack (hoist) are not installed.
•
When using a hydraulic jack or a hoist, do not use it over the limit of the equipment and the conveying belt.
•
Make sure that the hydraulic lock operates properly before using the hydraulic jack. Improper use of lock can cause a serious accident.
•
Check the buttons and operating direction of the hoist before using it. Improper operation can cause a serious accident.
•
Do not use wooden blocks or bricks as support under the vehicle. As the tractor's weight is continuously applied to them, they can be broken or collapsed.
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CRDI
SAFETY FIRST
1.2.8 Handling of rotating driving section
1.2.9 Prevention of scald
T46W025A
•
Be careful not to get caught by the rotating engine cooling fan.
T46W027A
•
T46W026A
•
You can be seriously injured if your hand or clothes is caught by the rotating fan belt or A/C belt.
Do not open the radiator cap when the radiator is hot. Hot coolant or steam can be surged leading to a serious scald.
T46W028A
•
Check the surface temperature of the container before draining the engine oil, transmission fluid, coolant, etc. If it is hot, let it cool down before draining it. There is danger of burning.
•
Perform any service on the engine parts (muffler, exhaust manifold, turbocharger, etc.) only when they are not hot.
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SAFETY FIRST
CRDI
1.2.10 Disposal of environmental waste
T46W029A
•
Observe all relevant environmental protection regulations when disposing used oil, transmission fluid, coolant, oil filter, etc. Otherwise, they can pollute the environment seriously and you can be charged in violation of regulations.
10
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CRDI
ENGINE IDENTIFICATION
4A220/4B243 2. Engine identification 2.1 Engine decal
3F183T
MANUFACTURE dECAL (A)
Q53W302A
3FT-HI4
Q53W303A
This aluminum decal is riveted on the engine cylinder head cover. This provides the information such as model number, displacement, rated output, valve clearance, injection timing, etc.
EpA dECAL
HI4W101A
HI4W102A
This provides the information such as exhaust gas (Engine type, Injection timing, Displacement, ect.).
11
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CRDI
ENGINE IDENTIFICATION 2.2 Engine number (B).
ENgINE NUMBER ASSIgNMENT STANdARd Nk7900001
pM9300001
Serial number
Serial number Engine model
Engine model
U89W203A
The engine number is stamped near the fuel injection pump on the cylinder block, in case the bar code is not available due to damage
Important • The engine number is necessary information that is requested on the warranty registration form. This number should be on the form as well as the tractor number and the amount of time used.
Year of manufacturing
K77
3F183T-TMC4
K95
3F183T-TMR4
K74
3F183T-THC4
K96
3F183T-THR4
K79
3F183T-TMC3
K97
3F183T-TMR3
K78
3F183T-THC3
K98
3F183T-THR3
M93
3FT-HI4
Year of manufacturing � �
� �
H
2008
J
2009
K
2010
L
2011
M
2012
N
2013
P � �
2014 � �
For example, NK7900001 means that this engine is the first manufactured unit, 3F183T-TMC3, in 2013.
Remark • I and O are excluded in the identification table above to eliminate possible confusion with 0 and 1.
12
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CRDI
ENGINE IDENTIFICATION
2.3 Assignment standard for engine model code 3 F T - H I 4
3 F 183 T - T M C 3 Emission control category 3
Tier 3
4
Tier 4
CABIN or ROPS C
Cabin
R
ROPS
Customer Code
Power shuttle or Mechanical P
Power shuttle
M
Mechanical
Vehicle type T
Tractor
C
Combine
Engine type -
N/A type
T
Turbo charger type
Displacement 139
Approx. 1,390 cc
150
Approx. 1,500 cc
165
Approx. 1,650 cc
183
Approx. 1,830 cc
200
Approx. 2,000 cc
220
Approx. 2,200 cc
243
Approx. 2,430 cc
Stroke A
92.4 mm (3.638 in.)
B
102.4 mm (4.031 in.)
F
102.4 mm (4.031 in.), CRDI
Number of cylinders 3
3 cylinders
4
4 cylinders
13
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CRDI
SPECIFICATIONS 3. Specifications 3.1 General specifications 3F183T-TMR3 3F183T-TMC3 3F183T-TMR4 3F183T-TMR4
Engine model Bore I.D. X Stroke
mm (in.)
Ø 87 × 102.4 (3.4 x 4.0)
Honing
Plateau honing 3
Number of cylinders
1-2-3
Ignition sequence Displacement
ℓ(cu in.)
Max./Min. speed
(rpm)
Max. gross output kw(HP)/rpm.
1,826 (111.4)
55 / 2,600
60 / 2,600
Direct injection type Turbo charged
High pressure fuel pump type
Delphi DFP 4.4
Injection pressure bar
Max. 1,800
ℓ (u.s.gal.)
Engine oil specification
Anti-freeze
50 / 2,300
17.4 : 1
Combustion chamber type
Coolant capacity
2,450 / 900
2,800 / 850
Compression ratio
Engine oil capacity (with fuel filter)
3FT-HI4
6.0 (1.58) CH or higher of API grade
ℓ (u.s.gal.)
CJ or higher of API grade
7.7 (2.0)
3.4 (0.9) (only engine)
Ethylene glycol 50% with anti-corrosive agent
•
The engine gross output is measured with the cooling fan removed.
•
The cylinder number for ignition sequence is given from the cylinder on the engine cooling fan side.
•
If the coolant level drops due to its evaporation, add only water. If the coolant lever drops due to the leakage, add coolant mixed with anti-freeze.
•
The freezing point of the 50% coolant mixture is -37°C (-34°F) in a normal condition.
•
When replacing the coolant with a different type of coolant, flush the cooling system thoroughly beforehand.
•
The engines for the mechanical and power shuttle models are the same, except for their flywheels. Therefore, they are interchangeable as long as their flywheels are replaced.
14
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CRDI
SPECIFICATIONS
3.2 engine dImension 3F183T 588 (298)
(268)
280
969
(701)
(290)
685
Q53W3E3A
15
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SPECIFICATIONS
CRDI
3FT-HI4
HI4W103A
16
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CRDI
SPECIFICATIONS
3.3 components
Q53W304A
(1) Water pump (2) Turbocharger (3) Starter
(4) Alternator (A) Coolant out (to radiator) (B) Coolant in (from radiator)
Q53W305A
(1) Common rail (2) Oil filter (3) Injector
(4) Oil gauge (5) HP Pump (6) Oil cooler
(7) Fuel filler
17
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CRDI
SPECIFICATIONS 3FT-HI4
HI4W104A
(1) Water pump (2) Turbocharger (3) Starter
(4) Alternator (A) Coolant out (to radiator) (B) Coolant in (from radiator)
HI4W105A
(1) Common rail (2) Oil filter
(3) Injector (4) HP Pump
(5) Fuel filler
18
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CRDI
SPECIFICATIONS
3.4 Engine performance curve 3F183T-TMR3, TMR4, TMC3
N·m
Torque
200 180 160 140 120 100 80 60 40 20 0 850 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 RPM
Kw
Power
45 40 35 30 25 20 15 10 5 0 850 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 RPM Q53W306A
19
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CRDI
SPECIFICATIONS
3F183T-TMR4
Torque [Nm]
200 180 160 140
45
40
30
25
POWER [kW]
35
20
15
10
BSFC [g/kWh]
200
180
140
800
1000
1200
1400
1600
1800
2000
2200
2400
2600
Engine speed [rpm] Q53W3F2A
20
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CRDI
SPECIFICATIONS
3FT-HI4
170 160
Torque [Nm]
150 140 130 120 110
40 35
25 20
Power [kW]
30
15 10
235
BSFC [g/kwh]
230 225 220 215 210
1000
1200
1400
1600
1800
2000
2200
Engine speed [RPM] HI4W106A
21
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CRDI
SPECIFICATIONS 3.5 Engine performance curve analysis 3.6.1 Torque
3.6.3. Brake horse power (HP)
When applying the rotating resistance to the flywheel, the engine speed drops and the rotating force of flywheel increases. Torque curve shows this force as a graph.
Torque 㓫⥯㎷ (kgf -f-m) (kg m)
1800
2200
Power (HP)
=
Torque (Kgf - m) × rpm 725.7
1kw
=
1.341 HP
If substituting the torque and rpm in the left figure for the above formula and getting the power value, the below curve is provided. As shown in the below figure, when the power reaches the maximum point at 2,600 rpm, the power starts to drop. This is because the rpm drops sharply even the torque increases gradually.
Max. point ェᙋtorque 㓫㎷⭛
1400
The power is proportional to the rotating force (torque) and the rotating speed (rpm). Its formula is as follows:
2600
3000
rpm
Power 출력 (HP) (HP)
Max. point 최대power 출력점
T46W207A
When running the engine at full speed without load, the engine rotates at approx. 2,800 rpm as shown in the figure. When the resistance is applied to the flywheel by braking with some kind of dynomometer, the rotating force of the dynomometer increases (arrow direction) as shown in the figure. In this case, the engine speed gradually decreases. When the engine speed reaches approx. 1,700 rpm, the torque starts to decrease. In other words, this point (1,700 rpm) is the maximum torque point.
1400
1800
2200
2600
3000
rpm
T46W208A
22
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CRDI
SPECIFICATIONS
NOTE Work
= Force X Distance
Power
=
Power [kW]
=
Work Time
Force X Distance = Time
=
F[N] X V[m/s] 1000
=
Force X Velocity
F[kgf] X V[m/s] 102
F[kgf] X V[m/s] 76 • 1 horse power [HP] = The power necessary to lift up 76kgf of weight with 1m/s of velocity. Power [HP]
=
• 1 horse power [PS] = The power necessary to lift up 75kgf of weight with 1m/s of velocity. ( ※ kW =
102 x HP = 1.34 · HP ) 76 F·V 76
Power [HP] =
=
T R
·
2πR · rpm 60 76
F R
(Where, T = F · R)
=
T · 2π · rpm = 76 X 60
T · rpm 76 X 60 2π
=
T · rpm 725.7
Where, T[kgf-m] = Torque rpm = Revolution per minute
V[m/s] = 76kgf
F[kgf]
=
2πR · rpm 60 T [kg-m] R[m] 379W201A
3.6.3 S.F.C (Specific Fuel Consumption)
The unit used here is "g/kW-hr".
For example, 225g/kW-hr means that 225g of fuel is consumed by 1kW when running the engine for 1 hour. This can be converted as follows:
Since the fuel consumption at full power in the power curve (3F183T) is 225g/kW-hr, the fuel consumption for 41.0kW(55HP) is 225g x 41.0/hr = 9.23kg/hr.
When converting this value to volume value, 9.23 ÷ 0.835 ℓ/hr = 11.05 ℓ/hr
Because: Diesel fuel 1 ℓ = 0.835 kg
However,the actual fuel consumption will be much less than this maximum fuel consumption in accordance with load factor of job. In general,the load factor could be 30~70% of maximum power.
Therefore the actual fuel consumption will also be 30~70% of this maximum fuel consumption.
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CRDI
SPECIFICATIONS 3.6 Servicing specifications 3.6.1 Engine body Item
Specification
Cylinder head surface flatness
0.05 mm / 100 mm
-
(0.002 in. / 3.94 in.)
0.32 ~ 0.7 mm
T.D.C clearance
Allowable limit
(0.01250 ~ 0.02755 in.)
-
Tightened A. Cylinder Head
Gasket Thickness
(0.040 in.) Compression Pressure (When cranking with starter motor)
Valve Clearance (Cold) Valve Seat Angle
Valve Face Angle
470 ~ 541 psi
370 psi
IN.
0.20 mm (0.0079 in.)
-
EX.
0.20 mm (0.0079 in.)
-
IN.
60° (1.047 rad.)
-
EX.
45° (0.785 rad.)
-
IN.
60° (1.047 rad.)
-
EX.
45° (0.785 rad.)
-
Valve recess EX. Clearance Between Valve Stem and Valve Guide
D. Cylinder
0.2 ~ 0.6 mm
0.8 mm
(0.0079 ~ 0.0236 in.)
(0.0315 in.)
0.040 ~ 0.043 mm
0.1 mm
(0.0016 ~ 0.0017 in.)
(0.0039 in.)
8.015 ~ 8.030 mm (0.3156 ~ 0.3161 in.) Open
0.14 rad (8°) before T.D.C
Close
0.611 rad (35°) after B.D.C
Open
0.785 rad (45°) before B.D.C
Close
0.140 rad (8°) after T.D.C
Bore I.D. Free length
E. Valve spring
1.0 mm (0.0393 in.)
(0.31339 ~ 0.31398 in.)
Valve Stem I.D.
Exhaust Valve
0.4 ~ 0.8 mm (0.0157 ~ 0.0314 in.)
7.960 ~ 7.975 mm
Valve Stem O.D.
C. Valve Timing
2
2.55 MPa 26 kgf/cm2
IN.
Intake Valve
3.24 ~ 3.73 MPa 33 ~ 38 kgf/cm
Variance of compression pressure among cylinders should be 10% or less.
B. Valves
-
1.02 mm
-
-
87.000 ~ 87.022 mm
0.15 mm
(3.425 ~ 3.426 in.)
(0.0059 in.)
46.1 ~ 46.9 mm
45.6 mm
(1.8150 ~ 1.8465 in.)
(1.7955 in.)
Load after assembled / Length after assembled
19.8 kgf / 35.15 mm
16.8 kgf / 35.15 mm
(43.6 lbs / 1.3839 in.)
(37.0 lbs / 1.3839 in.)
Squareness
-
1.0 mm (0.0394 in.)
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CRDI
SPECIFICATIONS
Item
Specification
Rocker arm shaft O.D. F. Rocker Arm Rocker arm bushing I.D. Clearance between tappet and guide G. Tappet
(0.7480 ~ 0.7490 in.)
-
0.020 ~ 0.062 mm
0.07 mm
(0.00079 ~ 0.00244 in.)
(0.0028 in.)
24.000 ~ 24.021 mm (0.94488 ~ 0.94571 in.)
Camshaft deflection
-
0.01 mm (0.0004 in.)
0.05 mm (0.0020 in.)
IN.
33.59 mm (1.3224 in.)
33.54 mm (1.3205 in.)
EX.
33.69 mm (1.3264 in.)
33.64 mm (1.3244 in.)
0.050 ~ 0.091 mm
0.15 mm
(0.00197 ~ 0.00358 in.)
(0.0059 in.)
39.934 ~ 39.950 mm
39.88 mm
(1.57220 ~ 1.57283 in.)
(1.5701 in.)
Journal oil clearance Camshaft journal O.D. Camshaft counter bore I.D. Timing gear backlash Idle gear side clearance Clearance between Idle gear 1 shaft and idle gear 1 bushing Idle gear 1 shaft O.D. Idle gear 1 bushing I.D.
I. Timing Gear
19.000 ~ 19.025 mm
(0.94327 ~ 0.94410 in.)
Tappet guide I.D.
H. Camshaft
(0.7463 ~ 0.7472 in.)
23.959 ~ 23.980 mm
Tappet O.D.
Cam height
18.955 ~ 18.980 mm
Allowable limit
Clearance between Idle gear 3 shaft and idle gear 3 bushing Idle gear 3 shaft O.D Idle gear 3 bushing I.D. Clearance between Idle gear 4 shaft and idle gear 4 bushing Idle gear 4 shaft O.D Idle gear 4 bushing I.D.
40.000 ~ 40.025 mm (1.57480 ~ 1.57579 in.)
-
0.04 ~ 0.10 mm
0.14 mm
(0.0016 ~ 0.0039 in.)
(0.0055 in.)
0.050 ~ 0.250 mm
0.5 mm
(0.00196 ~ 0.00984 in.)
(0.0197 in.)
0.025 ~ 0.066 mm
0.1 mm
(0.00098 ~ 0.00260 in.)
(0.0039 in.)
42.959 ~ 42.975 mm (1.69130 ~ 1.69193 in.) 43.000 ~ 43.025 mm (1.69291 ~ 1.69390 in.)
-
0.025 ~ 0.066 mm
0.1
(0.00098 ~ 0.00260 in.)
(0.0039 in.)
31.959 ~ 31.975 mm (1.25823 ~ 1.25886 in.) 32.000 ~ 32.025 mm (1.25984 ~ 1.26083 in.)
-
0.025 ~ 0.066 mm
0.1
(0.00098 ~ 0.00260 in.)
(0.0039 in.)
27.967 ~ 27.980 mm (1.10106 ~ 1.10157 in.) 28.005 ~ 28.033 mm (1.10256 ~ 1.10366 in.)
-
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CRDI
SPECIFICATIONS
Item
J. Piston Ring
K. Connecting Rod
L. Crankshaft
Specification
Allowable limit
Piston pin bore I.D.
30.006 ~ 30.014 mm (1.18134 ~ 1.18165 in.)
-
Clearance between Oil ring and ring groove
0.020 ~ 0.060 mm (0.00079 ~ 0.00236 in.)
0.15 mm (0.0059 in.)
Oil ring groove width
3.01 ~ 3.03 mm (0.11850 ~ 0.11929 in.)
-
Oil ring width
2.97 ~ 2.99 mm (0.11693 ~ 0.11772 in.)
-
Clearance between 2nd ring and ring groove
0.04 ~ 0.08 mm (0.00157 ~ 0.00315 in.)
0.15 mm (0.0059 in.)
2nd ring groove width
2.03 ~ 2.05 mm (0.07992 ~ 0.08071 in.)
-
2nd ring width
1.97 ~ 1.99 mm (0.07756 ~ 0.07834 in.)
-
Top ring, oil ring end gap
0.25 ~ 0.40 mm (0.00984 ~ 0.01575 in.)
1.25 mm (0.0492 in.)
2nd ring end gap
0.40 ~ 0.55 mm (0.01575 ~ 0.02165 in.)
1.25 mm (0.0492 in.)
Connecting rod deflection limit
-
0.05 mm (0.0020 in.)
Clearance between piston and small end bushing
0.025 ~ 0.045 mm (0.00098 ~ 0.00177 in.)
-
Piston pin O.D.
29.995 ~ 30.000 mm (1.18090 ~ 1.18110 in.)
-
Piston pin bushing I.D.
30.025 ~ 30.040 mm (1.18209 ~ 1.18268 in.)
-
Crankshaft deflection limit
-
0.08 mm (0.0031 in.)
Clearance between Crankshaft and crankshaft bearing 1
0.040 ~ 0.104 mm (0.00157 ~ 0.00400 in.)
0.20 mm (0.0079 in.)
Crankshaft O.D.
59.921 ~ 59.940 mm (2.35909 ~ 2.35984 in.)
-
Crankshaft bearing 1 I.D.
59.980 ~ 60.025 mm (2.36142 ~ 2.36319 in.)
-
Clearance between crank pin and crank pin bearing
0.017 ~ 0.073 mm (0.00067 ~ 0.00287 in.)
0.20 mm (0.0079 in.)
Crankshaft pin O.D.
51.959 ~ 51.975 mm (2.04563 ~ 2.04626 in.)
-
Crankshaft pin bearing I.D.
51.992 ~ 52.032 mm (2.04693 ~ 2.04850 in.)
-
Crankshaft side clearance
0.15 ~ 0.31 mm (0.0059 ~ 0.0122 in.)
0.5 mm (0.020 in.)
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CRDI
SPECIFICATIONS
3.6.2 Lubricating system Item
Specification over 68.6 kPa
At idle speed Engine oil pressure (oil temp. 85 ~ 95 °C)
A. Oil Pump
0.7 kgf/cm2
(1,000 rpm)
Clearance between inner rotor and outer rotor Clearance between outer rotor and pump Clearance between inner rotor and cover
-
9.95 psi
At rated speed (2,600 rpm)
Allowable limit
245.1 ~ 441.2 kPa
294.2 kPa
2
2.5 ~ 4.5 kgf/cm
3.0 kgf/cm2
35.5 ~ 64.0 psi
42.7 psi
0.10 ~ 0.16 mm
0.2 mm
(0.0039 ~ 0.0063 in.)
(0.0079 in.)
0.11 ~ 0.19 mm
0.25 mm
(0.00433 ~ 0.00748 in.)
(0.0098 in.)
0.105 ~ 0.150 mm
0.2 mm
(0.00413 ~ 0.00591 in.)
(0.00787 in.)
3.6.3 Cooling system Item A. Thermostat
Valve opening temperature at beginning Opened completely (height: 8 mm)
Allowable limit
69.5 ~ 72.5°
-
(157.1 ~ 162.5°F)
-
85°C (185°F) 2
Radiator hose tightness
No leak at 1.4 kgf/cm (137 kpa, 20 psi)
-
Radiator cap tightness
10 seconds or more for pressure drop from 0.9 → 0.6 kgf/cm2 (88 → 59 kpa, 13 → 9 psi)
-
7 ~ 9 mm (0.28 ~ 0.35 in.)
-
B. Radiator
C. Fan cooler
Specification
Fan belt tension [deflection at 78 N (8 kgf, 18 lbs) of force]
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CRDI
SPECIFICATIONS 3.6.4 Tightening torques for engine Item
Tightening torque
Size x Pitch
N-m
kgf-m
lb-ft
Cylinder head bolt
M11×1.25
39.22+90˚+70˚
4+90˚+70˚
28.8+90˚+70˚
Head cover bolt
M6×1.0
8.8
11.8
0.9
1.2
6.5
8.7
Main bearing bolt
M12×1.25
90.2
93.2
9.2
9.5
66.5
68.7
Ladder frame bolt
M10×1.25
47.1
52.0
4.8
5.3
34.7
38.3
Piston cooling jet bolt
M12×1.25
29.4
34.3
3.0
3.5
21.7
25.3
*Flywheel bolt
M12×1.25
98.1
107.9
10.0
11.0
72.3
79.6
*Connecting rod bolt
M8×1.0
44.1
49.0
4.5
5.0
32.5
36.2
Rocker arm support bolt
M10×1.25
60.8
70.6
6.2
7.2
44.8
52.1
Injector clamp bolt
M8×1.25
27.5
31.4
2.8
3.2
20.3
23.1
Hi-pressure pipe nut (pump side)
M14×1.5
24.5
29.4
2.5
3.0
18.1
21.7
Hi-pressure pipe nut (rail side)
M14×1.5
27.5
31.4
2.8
3.2
20.3
23.1
Crank shaft bolt
M16×1.5
320.7
343.2
32.7
35.0
236.5
253.2
Glow plug
M10×1.25
19.6
24.5
2.0
2.5
14.5
18.1
Eye-bolt (turbo side)
M10×1.25
27.5
31.4
2.8
3.2
20.3
23.1
Eye-bolt (nut side)
M12×1.5
32.4
37.3
3.3
3.8
23.9
27.5
Coolant temp sensor
PT3/8
34.3
44.1
3.5
4.5
25.3
32.5
Oil pressure switch
PT1/8
14.7
19.6
1.5
2.0
10.8
14.5
CAUTION • For * marked screw, bolts and nuts on the table, apply engine oil to their threads and seats before tightening. • The letter “M” in Size × Pitch means that the screw, bolt or nut dimension stands for metric. The size is the nominal outside diameter in mm of the threads. The pitch is the nominal distance in mm between two threads.
Remark • Tightening torque for cylinder head bolts •
Tightening order (using the angle controlled tightening method)
•
1st step: Tighten the bolts to 4.0 kgf-m (39.2 Nm, 28.8 lb-ft)
•
2nd step: Rotate the bolts additional 90°
•
3rd step: Rotate the bolts additional 70°
• For more details, refer to 7.3.4 “Cylinder head removal.”
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CRDI
OPERATING PRINCIPLE
4. Operating principle 4.1 CRDI (Common Rail Direct Injection) system The CRDI (Common Rail Direct Injection) engine is a high performance engine, featuring superior emission, acceleration, vibration and noise functions. The old version of diesel engines simply delivers fuel into the combustion chamber through its mechanical structure. On the other hand, in the CRDI engine, fuel sent from the fuel tank is pressurized to the necessary level by the highpressure fuel pump and it is stored in the common rail for use. Then, the ECU controls the injector according to the detected engine RPM, load and other factors to inject fuel into the combustion chamber in the optimum injection condition. It is hard to meet the optimum injection condition and achieve precise control on injection timing in a normal diesel engine of the cam injection type. On the other hand, the common rail type engine stores highly pressurized fuel in the common rail to inject the necessary amount of fuel at the correct timing for optimal combustion, resulting in emission reduction and engine power increase. The atomization level, injection timing and injection pressure of fuel have a huge impact on combustion performance. Therefore, in the CRDI engine, as the injector injects highly pressurized fuel (under 1,800 bars) into the combustion chamber according to control from the ECU, it injects fuel as fast as possible to make fuel almost gaseous condition (atomization) at a high pressure. Also, as it is still possible to inject fuel at a high pressure while the engine is running at a low speed with high load, up to torque increase and power improvement can be achieved at a low speed. The CRDI engine mainly consists of the high-pressure pump, pressure control valve, common rail, pressure sensor, injector, ECU and other sensors and actuators. Pressure sensor ② Calculation
ECU
③ Control
HP PUMP (IMV)
④ Pressure build up
COMMON RAIL
⑤ Pressure feed back ⑥ Control and injecting ① Input
Pedal or Lever
Injector U89W338c
•
The position information of the pedal intended by the driver (the amount of movement of the pedal or hand lever) is sent to the ECU as a signal.
•
The ECU determines the required RPM according to this position information and calculates the correct injection pressure and injection timing (fuel injection amount) to achieve this target RPM.
•
It controls the IMV of the HP pump to increase pressure in the common rail.
•
It supplies high-pressure fuel to the common rail to increase the rail pressure to the pressure level demanded by the ECU.
•
The pressure sensor in the common rail sends pressure information to the ECU to confirm whether the actual pressure matches the demanded pressure.
•
When pressure in the rail is sufficiently built, the ECU controls the injector to inject fuel for a proper amount of time.
* The fundamental injection map is set by positions of the pedal or hand lever, and the rail pressure and injection timing are corrected, considering other several external factors, including the intake air temperature, coolant temperature and barometric pressure.
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CRDI
OPERATING PRINCIPLE
structure & fuel line
High pressure ါ⢠⤻ᰗ㛗㡏 fuel pump
᭓⫇ Rail
Fuel cooler ⤻ᰗ㌳ᬷ
Main filter ⤻ᰗ㢏㑻
Fuel pressure ⤻ᰗ⢠᭰⒇⑧ sensor
Fuel tank ⤻ᰗ㐼㎷ Injector
Actuator ⢬㗧⤛⪿㑻 ⒇⑧ Sensor
ECU
Airᬔ Boost ᐔཌ ╣ ၀ ᅻ ⩫ Accelator Crank Air ⒇sensor ᅻ ㎷ ㎷sensor ⒇ ⑧ Cam ⑧ ⢐⒋ ၀ flow teperature ⥳ᜏ 㛣 ᘷ pressure ⥳ᜏ pedal U89W338d
FUEL TANK
FUEL(COMMON) RAIL
FUEL FILTER
HIGH PRESSURE FUEL PUMP
(Pre-filter, MAIN FILTER)
INJECTORs
combustion chamber (cylinder)
COMPONENTs •
HIGH PRESSURE FUEL PUMP : Supplies highly pressurized fuel to fuel rail
•
FUEL(COMMON) RAIL : Stores fuel pressurized down to 1,800 bars before injection
•
INJECTOR : Performs pilot and post injections into each cylinder
•
ECU(Electronic Control Unit) : Controls injection condition, such as injection timing, injection amount and injection pressure
•
SENSOR & ACTUATOR : Detects fuel temperature, fuel pressure, intake air amount, coolant temperature, engine RPM, etc.
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CRDI
OPERATING PRINCIPLE
4.1.1 ECU (ELECTRONIC CONTROL UNIT) OVERVIEW The MAF (Mass Air Flow) sensor detects the amount of intake air and sends this information to the engine ECU which then determines the instant air volume change to control the air-fuel ratio for reduction of exhaust gas (EGR valve control). Also, the ECU receives signals from the coolant temperature sensor, air temperature sensor and booster pressure sensor and uses them for calibration to manage setting values, various variables and operating conditions for main injection and pilot injection.
U89WB12A
The ECU (Electronic Control Unit) is the most important information processor in the engine as it analyzes information sent from various sensors and takes an appropriate action for optimum engine performance. The ECU is integrated with I/O devices, ROM and RAM. Various sensors, including the coolant temperature sensor, intake air temperature sensor, crank angle sensor, cam position sensor, throttle position sensor, air mass flow sensor and rail pressure sensor, check the engine condition and send the corresponding signals to the ECU. Then, the ECU receives signals from these sensors, analyzes them and changes voltage to the permissible level based on these information to activate various actuators. The ECU stores certain map values as standard. Its micro-processor calculates the injection duration and timing according to the piston speed and crankshaft angle to control the engine power and exhaust gas. Also, the output signal from the ECU micro-processor is used to drive the IMV in order to control the pressure in the fuel rail suitable for the engine load condition for optimum performance without any power loss.
function ▶ Engine control 1. Control for each operating phase The ECU needs to calculate the proper fuel injection amount at each phase for optimum combustion. In this process, it takes numerous variables into consideration. 2. Fuel injection amount control for engine start Fuel is injected from the moment that the ignition switch is turned to the START position until the permissible lower speed limit is achieved. The fuel injection amount is calculated by the specified function based on various temperature information and engine cranking speed. 3. Driving mode control The fuel injection amount is calculated based on the position of the accelerator pedal and engine RPM and the ECU uses the drive map to obtain optimum engine power according to the driver's intention (accelerator pedal position).
The engine ECU calculates the command from the driver (accelerator pedal position) and controls overall operating performance of the engine and vehicle instantly. The engine speed is detected by the crankshaft speed (position) sensor while the injection order is determined by the camshaft speed (position) sensor.
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OPERATING PRINCIPLE
CRDI
▶ Fuel system control 1. Fuel pressure control •
It determines the fuel rail pressure according to the engine operating condition and adjusts the IMV accordingly to achieve necessary rail pressure.
•
Pressure in the fuel rail is determined based on the engine RPM and engine load.
•
The fuel pressure is calibrated based on the barometric pressure, coolant temperature and intake air temperature. When starting the engine in cold weather or at a high altitude, the added ignition time is additionally considered for calibration of the fuel pressure. When starting the engine, additional fuel injection is needed so pressure is consumed for this moment. Therefore, the fuel pressure is calibrated based on the temperature of the injected fuel or coolant.
2. Fuel injection control •
In the fuel injection control process, the ECU determines the characteristics of the current pulses to be sent to the injectors. It converts the fuel injection duration, injection amount and injection timing into values which can be recognized by the injector driver.
•
The pulse required for the main injection is determined based on the engine RPM and pilot injection amount.
- The first calibration is determined by the temperature of intake air and coolant. The fuel injection timing is adjusted according to the operating temperature of the engine. When the engine temperature is high, the fuel injection timing is retarded to reduce high combustion temperature and hazardous emissions (NOx). When the engine temperature is low, the fuel injection timing is advanced to achieve optimum combustion performance.
T he second calibration is determined by the barometric pressure. This information is used to advance the injection timing in order to respond to the barometr ic pressure changes with altitudes.
T he third calibration is determined by the coolant temperature and time after the engine is started. When the engine is started, the fuel injection timing is advanced in the engine warmup period (30 seconds) to increase the amount of fuel injected and eliminate any possible misfire or unstable combustion.
T he fourth calibration is determined by the pressure error. This calibration is to retard the injection timing to prevent diesel knocking when the fuel rail pressure is higher than the necessary level.
The fifth calibration is determined by the EGR ratio. When the EGR ratio increases, the fuel injection timing is retarded to compensate the combustion (cylinder) temperature drop.
T h e i n j e c t i o n t i m i n g s h o u l d b e a d j u s te d according to each factor to achieve combustion near at the TDC when the engine is started. The ECU is mapped to obtain optimal injection timing.
•
The pilot injection timing is determined based on the engine RPM and overall fuel flow.
- T he f irst c alibration is determined by the temperature of intake air and coolant. This calibration is to set the pilot timing according to the operating temperature of the engine.
T he second calibration is determined by the barometric pressure. This calibration is to adjust the timing according to the barometric pressure changes with altitudes. The pilot injection timing is determined by the engine RPM and coolant temperature when the engine is started.
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CRDI
OPERATING PRINCIPLE
3. MDP(Minimum Dirve Pulse) LEARNING CONTROL
4. Fuel control •
The ECU controls the amount of fuel injected to the cylinder for the main injection process.
•
The fuel demand amount is determined based on the driver's demand, i.e. displacement of the hand throttle lever or accelerator pedal.
•
It controls the idle speed.
•
It limits the fuel amount based on the engine speed and intake air amount.
•
It controls the amount of fuel injected into the cylinder during the pilot injection process
MDP learning Injection pulse Time
Fuel injection
Initial setting H89W329B
The MDP is the pulse value when the injector starts injecting fuel, and it is actually the period that power is supplied until the needle in the injector moves to the tip. The MDP is controlled to correct the pilot injection timing for aged injectors with relatively low precision. As shown in the figure, fuel injection is initiated at the learned MDP point based on the initial setting. Therefore, the fuel injection timing is retarded or advanced depending on the condition of the nozzle.
▶ Actuator control [injector and EGR valve] •
It receives signals from various sensors to control the actuator for optimum combustion.
The MDP refers to the minimum pulse where power is supplied for fuel injection. When the MDP value is learned precisely, it is possible to control the precise amount of fuel injected by each injector. The knock sensor detects vibration generated from the engine after a small amount of fuel is injected by the injectors. The the MDP is learned by calculating the period from fuel injection to vibration detected from the engine. The MDP is to correct the injection timing for aged injectors in order to reduce engine vibration and emissions and prevent power reduction.
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CRDI
OPERATING PRINCIPLE operation (TIER3 MODEL) ▶ Input/Output of ECU engine control system
INPUT IG "ON" B+
Camshaft wheel sensor
START signal
Fuel rail pressure sensor
Knock sensor #1 & 2
Exhaust gas temperature sensor
Coolant temperature sensor
Fuel temperature sensor
Crankshaft wheel sensor
Water-in-fuel sensor
Accelerator pedal position sensor # 1 & 2
Intake temp, pressure sensor
Hand throttle position sensor #1 & 2
Other CAN information
OUTPUT Start motor control (SKM) Injector control
Self-diagnosis Other CAN information supply
IMV control
U89W3T8C
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CRDI
OPERATING PRINCIPLE
Input/Output of fuel supply system
INPUT Engine RPM (engine load) [Crankshaft wheel sensor]
Measured rail pressure [Fuel rail pressure sensor]
Injection order (engine speed) [Camshaft wheel sensor]
Measured fuel temperature [Fuel temperature sensor]
Driver's acceleration demand Required rail pressure [Accelerator pedal, Hand throttle lever]
Compensation based on coolant temperature [Coolant temperature sensor]
OUTPUT Fuel amount feedback control [IMV (Inlet Metering Valve)]
Air-fuel ratio & fuel injection amount control [Injector]
U89W3T9C
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CRDI
OPERATING PRINCIPLE Input/Output of intake system
INPUT
Driving condition (acceleration demand) [Accelerator pedal, Hand throttle lever]
Engine warming-up condition [Coolant temperature sensor]
Engine RPM (engine load) [Crankshaft wheel sensor]
OUTPUT Fuel injection pressure control [Injector]
U89W3u0B
Input/Output of plug relay driver
INPUT
CONTROL
ENGINE RPM
COOLANT TEMP.
OUTPUT
PWM SIGNAL GLOW PLUG RELAY DRIVER
GLOW PLUG PRE-HEAT GLOW PLUG AFTER-HEAT
LOAD CAPACITY
U89W3u4A
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CRDI
OPERATING PRINCIPLE
operation (TIER4 MODEL) ▶ Input/Output of ECU engine control system
INPUT IG "ON" B+
Camshaft wheel sensor
START signal
EGR position
Knock sensor #1 & 2
Air control throttle position sensor #1 & 2
Intake temp, pressure sensor
Fuel rail pressure sensor
MAF sensor
Differential pressure sensor
Coolant temperature sensor
Exhaust gas temperature sensor
Crankshaft wheel sensor
Fuel temperature sensor
Accelerator pedal position sensor # 1 & 2
Water-in-fuel sensor
Hand throttle position sensor #1 & 2
Other CAN information
OUTPUT Start motor control (SKM)
EGR valve control
A/C Compressor control
Air control throttle valve control
Injector control
Self-diagnosis
IMV control
Other CAN information supply
Turbochager actuator control U89W3T8E
37
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OPERATING PRINCIPLE
CRDI
▶ Input/Output of fuel supply system
INPUT Engine RPM (engine load) [Crankshaft wheel sensor]
Driver's acceleration demand Required rail pressure [Accelerator pedal, Hand throttle lever]
Injection order (engine speed) [Camshaft wheel sensor]
Measured rail pressure [Fuel rail pressure sensor]
Required fuel amount, Required rail pressure [MAF sensor (intake air)
Measured fuel temperature [Fuel temperature sensor]
Compensation based on coolant temperature [Coolant temperature sensor]
OUTPUT Fuel amount feedback control [IMV (Inlet Metering Valve)]
Air-fuel ratio & fuel injection amount control [Injector]
U89W3T9D
38
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CRDI
OPERATING PRINCIPLE
▶ Input/Output of intake system
INPUT Intake air amount [MAF sensor (intake air)
Engine RPM (engine load) [Crankshaft wheel sensor]
Driving condition (acceleration demand) [Accelerator pedal, Hand throttle lever]
Engine RPM (engine load) [MAF sensor (intake air)
Engine warming-up condition [Coolant temperature sensor]
OUTPUT Fuel injection pressure control [Injector]
Throttle body for intake air amount control [Air control throttle body]
U89W3u0D
39
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OPERATING PRINCIPLE
CRDI
▶ Input/Output of EGR valve (exhaust gas control)
INPUT Accelerator pedal sensor/hand throttle lever sensor Coolant temperature sensor MAF sensor Air control throttle sensor Crankshaft wheel sensor Exhaust gas temperature sensor
OUTPUT EGR valve
U89W3u1B
40
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CRDI
OPERATING PRINCIPLE
▶ Input/Output of CCRT control
INPUT Detection of pressure difference between inlet and outlet of CDPF [Differential pressure sensor
CCRT temperature value (to protect CCRT) [Rear exhaust gas temperature sensor
Engine combustion temperature value (to prevent combustion at excessive temperature) [Front exhaust gas temperature sensor]
Intake air amount [MAF sensor]
OUTPUT Injection amount control (post injection control) [Injector]
Air intake ratio control [Air control throttle body] CO/HC -> CO2/H2O Collected PM -> Combusted [FFUW]
U89W3u2B
•
Front exhaust gas temperature sensor: it is installed to the exhaust manifold to determine whether the DOC can burn (oxidize) injected fuel during the post-injection process.
•
Rear exhaust gas temperature sensor: it is installed to the inlet of the DPF to monitor whether the temperature of exhaust gas is maintained at 600℃.
- Excessive temperature (over 600℃), leading to reduction of CCRT life → Decrease in fuel injection amount in post injection process
- Insufficient temperature (below 600℃), leading to low efficiency of CCRT regeneration → Increase in fuel injection amount in post injection process
•
Differential pressure sensor: it detects the pressure difference between the inlet and outlet of the CCRT to calculate the PM amount.
•
Air control throttle valve: it reduces the intake air amount to increase the exhaust gas temperature when the CCRT is activated with the engine idling.
•
MAF sensor (intake air amount): since the value from the differential pressure sensor is used as primary information to calculate the PM amount, the intake air amount and EGR ratio are also used for calculation.
41
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CRDI
OPERATING PRINCIPLE ▶ Input/Output of turbochager
INPUT Driver's acceleration demand Required rail pressure [Accelerator pedal, Hand throttle lever]
exhaust gas temp. value exhaust temp. feedback (Front exhaust temp. sensor) Compensation based on coolant temperature [Coolant temperature sensor]
Engine RPM (engine load) [Crankshaft wheel sensor] Intake air amount prediction EGR amount indirect prediction [MAF sensor - intake air)
Compensation based on height (atmospheric pressure)
OUTPUT Turbochager actuator feedback control, Turbochager actuator control - reaction speed research reaction speed function control, Turbochager operation control, Turbochager actuator PWM control groups of engine rpm (Turbochager actuator) Q53W3E7B
▶ Input/Output of plug relay driver
INPUT
CONTROL
ENGINE RPM
COOLANT TEMP.
OUTPUT
PWM SIGNAL GLOW PLUG RELAY DRIVER
GLOW PLUG PRE-HEAT GLOW PLUG AFTER-HEAT
LOAD CAPACITY
U89W3u4A
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CRDI
OPERATING PRINCIPLE
4.1.2 high pressure fuel pump (for injection) The high-pressure fuel pump is connected to and run by the idle gear which is driven by the crankshaft. It is also equipped with the pressure control valve and fuel temperature sensor, apart from the components mentioned above. The pressure control valve opens the oil passage to decrease pressure in the pump when pressure in the common rail rises excessively.
3F183T
Q53WBE9A
Also, the fuel temperature sensor detects the temperature at the inlet of the high-pressure fuel pump and sends this information to the ECU. Since excessively hot fuel can damage the high-pressure fuel pump, the ECU limits the amount of injected fuel to prevent the engine RPM from rising over a certain level when the fuel temperature rises over the specified value. This high-pressure fuel pump is the high-pressure pump for the Delphi DFP 4.4 common rail and features compact and lightweight design.
Remark
AdjUSTMENT OF HIgH-pRESSURE pUMp TIMINg U89W324A
3FT-HI4
• The conventional fuel injection pump pressurized and distributed fuel to each injector. In this case, the pump timing should be set as fuel is injected to the necessary position in a cycle. However, the high-pressure pump of the common-rail engine is not used for fuel injection, so it is not necessary to set its timing for the engine. However, it should be set and adjusted to synchronize the pressure drop by each injection with the peak pressure occurred by the pump in order to enhance pressure control performance. This phase setting enhances pressure stability and reduces fuel flow difference between the cylinders.
HI4W107A
(1) Fuel temperature sensor (2) IMV
(A) From fuel filter (entrance) (B) To fuel rail (exit) (C) To fuel cooler (return)
The high-pressure fuel pump consists of the lowpressure pump (vane pump) which sucks fuel from the fuel tank, high-pressure pump which supplies fuel at a high pressure to the common rail, and IMV (Inlet Metering Valve) which controls the amount of fuel supplied to the high-pressure pump.
43
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OPERATING PRINCIPLE 4.1.3 fuel rail(common rail)
CRDI
4.1.4 INJECTOR [C3I]
3F183T
U89W327A
U89W329A U89W328A
3FT-HI4
(1) Injector assembly (A) Supplied fuel (from high-pressure pipe) (B) Surplus fuel (to overflow pipe)
The injector injects fuel into the combustion chamber according to the signal from the ECU.
HI4W108A
The Delphi DFR 3.3/3.4 fuel rail stores fuel which is pressurized and sent by the high-pressure fuel pump. This device is controlled by the ECU to help fuel rail pressurized fuel to be injected to the engine combustion chamber at a high pressure through all injectors in order to increase engine efficiency and decrease noise and emission.
The injector is supplied with fuel from the high-pressure fuel pump through the high-pressure pipe and fuel rail. This fuel under high pressure is directly injected into the combustion chamber (on the top of the piston) through the multi-hole injector nozzle by activation of the solenoid valve of the nozzle (through a control signal from the engine ECU). The remainder of fuel after injection (back-leak fuel) is returned to the high-pressure pump through the fuel return line for reuse. Some of fuel supplied to the high-pressure pump is used as lubricant for the pump while fuel returned through the IMV (Inlet Metering Valve) flows back to the fuel tank through the return line.
44
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CRDI
OPERATING PRINCIPLE
Internal view
6 11
5
2
3 14 7
13
12
12 15
7
4
16
4
1
18 17
1
19
16
H89W331A
(1) Cap nut (2) Nozzle holder body (3) Filter (4) Nozzle body (5) Blocking cap (6) Back-leak cap
(7) Actuator bobbin (11) Name plate (12) Control valve body (13) Control valve step (14) Control valve amateur (15) Dowel pin
(16) Needle (nozzle valve) (17) Actuator spring (18) Adjust pin (19) Injector spring
45
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CRDI
OPERATING PRINCIPLE
OPERATING PRINCIPLE
H89W347A
(A) Needle (nozzle valve)
(B) Control valve
1
2
3
4
5
Valve closed
Valve open
Valve open
Valve closed
Valve closed
Nozzle closed
Nozzle closed
Nozzle open
Nozzle open
Nozzle closed
No injection
No injection
Starting injection
Completing injection
No injection
Basically, when the ignition switch is turned to the ON position, the solenoid actuator is energized and the solenoid is compressed, opening the control valve which is connected to the solenoid actuator. Then, fuel at a high pressure is continuously drawn into the combustion chamber through the injector and fuel rail.
(1) W hen the control valve (B) is closed in the initial state, the pressure of fuel (C) drawn into the combustion chamber and pressure of fuel (D) drawn into the valve are the same, keeping the nozzle closed.
(2) When the control valve is opened to start the engine, fuel drawn into the valve is drained to the control valve (B) so pressure of fuel drawn into the combustion chamber increases further.
(3) As pressure on the valve side becomes lower than pressure in the combustion chamber, the needle (nozzle valve) is pushed up by pressure in the combustion chamber, opening the nozzle tip to initiate fuel injection.
(4) When the ignition switch is turned to the OFF position, the valve is closed by force of the spring so pressure of fuel drawn to the valve rises gradually.
(5) The control valve is completely closed and the needle (nozzle valve) is lowered due to increase in pressure of fuel on the valve side. When the needle reaches the bottom, pressure of fuel in the control valve and pressure of fuel in the combustion chamber become equal, completing the fuel injection operation.
After fuel is compressed under up to 1,800 bars by the fuel system of the CRDI (Common Rail Direct Injection) engine and is sent to the injector, the electrically controlled solenoid runs the valve to ensure the correct amount of fuel to be injected according to calculation by the ECU.
46
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CRDI
OPERATING PRINCIPLE
injection
Pilot
Pre
Main After
Noise↓ NOx↓ PM↑
PM↓
Post
PM Trap
CAUTION • As the injector is very sensitive to cleanness, make sure to seal any disconnected hose or pipe with the cap to prevent introduction of foreign materials. • When removing the injector, make sure to replace the copper washer on its bottom with a new one. • Ti g h t e n t h e m o u n t i n g b o l t o f t h e i n j e c t o r mounting clamp to the specified torque.
NOx↓ U89W330A
Also, fuel injection is performed in several steps, such as pilot, pre-, main, after- and post-injections, to generate explosive power in steps in order to decrease combustion noise at a low speed dramatically.
• Be careful not to drop the injector. It is very sensitive to shock.
▶ Pilot injection A very small amount of fuel is injected before main injection to facilitate combustion in the combustion chamber. This injection enables pressure in the combustion chamber to rise smoothly during combustion process to decrease NOx(Nitrogen Oxide) engine noise and vibration. The default amount of fuel injected in the pilot injection process is adjusted according to the coolant temperature and intake air pressure.
▶ Main injection This injection process determines the actual engine power. The amount of injected fuel in this process is calculated based on the accelerator sensor information, engine RPM, coolant temperature, intake air temperature and barometric pressure.
▶ Post injection This injection is performed after the main injection and does not produce actual power. This injection is to reduce PMs and smoke (fuel activation) by injecting fuel into unburned gas after the main injection.
47
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CRDI
OPERATING PRINCIPLE
CHARACTERISTICS The injector of the common rail system is a highly precise part. The characteristics of injectors can vary by minute differences from their machining. Therefore, it is necessar y to calibrate the fuel injection amount for each injector according to their initial characteristics. The initial characteristics of injectors are coded as C3I. The ECU calibrates current applied to the injector according to this value, C3I.
U89W3V1A
Also, the injector is controlled according to the fuel feed curve which is set according to various fuelrelated parameters for precise characterization of injection in order to reduce deviation.
▶ Injector characteristic curve FUEL FLOw CURvE (BEFORE AppLYINg C3I)
FUEL FLOw CURvE (AFTER AppLYINg C3I)
70
60
60
50
50
40
40 30 30 20
20
10
10 0
200
•
400
600
800
1000 1200 1400
1600
Excessive deviation of fuel injection amount among injectors
0
•
200
400
600
800
1000 1200 1400
1600
Minimizing deviation of fuel injection amount among injectors with calibration of each injector
H89W346A
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CRDI
OPERATING PRINCIPLE
4.2 Body and power train system 4.3.1 Cylinder head
1
1
2
4.3.2 Cylinder Block
1
1
2
2
2
U89W308A
(1) Intake port
U89W310A
(2) Exhaust port
The cylinder head is made of special alloy cast iron which can resist high temperature and pressure caused by combustion. The intake and exhaust ports are arranged cross-flow type to get high combustion efficiency by protecting the suction air from being heated and expanded by heated exhaust air.
The cylinder block is a ladder frame type and it features superior serviceability and low vibration and noise compared to the conventional tunnel type.
4.3.3 Cylinder honing ⫇ὣ#㦃ᘨ Standard honing
{8333
㡗㓫#㦃ᘨ Plateau honing
{83
2 3
4
1
U89W309A
(1) Combustion chamber (2) Injection
(3) Glow plug (4) Cylinder head
The Daedong reentry type combustion chamber is designed for high combustion efficiency and reducing fuel consumption. The glow plug helps to start the engine even at -20°C (4°F).
T46W212A
The DAEDONG engine has adopted the plateau honing in manufacturing to enhance the oil tightness of the cylinder bore and the durability of the cylinder for the longer engine life time.
49
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CRDI
OPERATING PRINCIPLE 4.3.4 Crankshaft
4.3.6 Connecting Rod
h89W351A
(1) Crankshaft (2) Spacer
(3) Crankshaft bearing 2 (4) Thrust bearing (side metal)
h89W353A
(1) Small end bushing (2) Connecting rod
(3) Crank pin bearing
The crankshaft is made of forged steel and the journals, the crankpins and the bearing surface for the oil seal are induction-hardened to increase wear resistance. Each crankshaft journal is supported by the cylinder block. The crankshaft, crankshaft bearings 2 (3) have oil holes for lubricant.
The connecting rod (2), which converts the reciprocating motion of the pistons caused by the fuel combustion into the rotating motion of the crankshaft, is made of hard forged steel. The connecting rod has bearings at both ends. The small end has a cylinder type bearing (small end bushing (2)) and the big end has a split type bearing (crank pin bearing (3)).
4.3.5 Piston and piston ring
4.3.7 Camshaft
h89W352A
(1) Top ring (2) 2nd ring
(3) Oil ring
The piston is made of an aluminum alloy that is temperature and pressure resistant. Three rings are installed in the grooves of the piston. The top ring (1) is a keystone type, which can withstand heavy loads, and the barrel face on the ring fits well to the cylinder wall. The second ring (2) is an undercut type, which prevents the oil from being carried up. The oil ring (3) has chamfered faces and an expander ring, which increase the pressure of the oil ring against the cylinder wall to scrape the oil. The top ring is plated with hard chrome to increase wear resistance.
h89W354A
(1) Camshaft gear (2) Camshaft stopper
(3) Camshaft
The camshaft (3) is made of forged steel and its journal and cams are hardened to increase wear resistance. The cams on the camshaft open and close the intake and exhaust valves with the push rods and rocker arms. The journals and their bearings are force-lubricated.
50
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CRDI
OPERATING PRINCIPLE
4.3.8 Rocker arm assembly
4.3.9 Intake and exhaust valves
4
1
2
1 3
4
3 2 5
6
h89W355A
(1) Rocker arm (2) Lock nut (3) Adjusting screw
(4) Rocker arm bracket (5) Rocker arm shaft
The rocker arm assembly includes the rocker arms (1) and an adjusting screw (3), which is at the end of rocker arm and rests on the push rod, rocker arm brackets (4) and rocker arm shaft (5). The rocker arms are activated by the reciprocating movement of the push rods and open or close the intake and exhaust valves. The rocker arm and other parts are lubricated through the drilled holes of the brackets and the rocker arm shaft.
5
h89W356A
(1) Valve spring collet (2) Valve spring retainer (3) Valve spring
(4) Valve stem seal (5) Exhaust valve (6) Intake valve
The valve and its guide of the intake are different from those for the exhaust. Other parts, such as the spring, spring retainers, valve spring collets, valve stem seals are the same for both the intake and the exhaust. The diameter of the intake valve is always larger than the that of the exhaust valve. The intake valve is located prior to exhaust valve when seeing them from the cooling fan side.
51
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OPERATING PRINCIPLE
4.3.10 Timing Gear 6
CRDI
4.3.12 MLS cylinder head gasket
5
4 3
1
2 U89W313A
(1) Idle gear 1 (2) Crankshaft gear (3) Idle gear 3 (4) Idle gear 4
(5) Camshaft gear (6) High pressure fuel pump gear
The crankshaft drives the camshaft, idle gear, hydraulic pump drive gear and high pressure fuel pump gear. The timings for opening and closing the valves is extremely important to achieve the effective air intake and sufficient gas exhaust. When assembling, the appropriate timing can be obtained by aligning the mark on the crankshaft gear (2) with idle gear 1 (1), idle gear 1 with camshaft gear (5). Valve can be opened and closed at the correct timing when the idle gear 1 is aligned with the idle gear 3 (3), the idle gear 3 is aligned with the idle gear 4 (4) and the idle gear 4 is aligned with the high-pressure fuel pump gear (6) properly.
Q53W309A
The MLS (Multi Layer Steel) cylinder head gasket has a 4-layered steel structure complemented with nonasbestos gasket features. The top clearance variation is minimized and the thermal load is reduced while increasing durability.
CAUTION • When disassembling the cylinder head, its gasket should be replaced with a new one. • Be sure that there is no scratch or foreign material between the cylinder head and the surface of the block.
4.3.11 Flywheel 2
3
1 U89W314A
(1) Ring gear (2) Flywheel
(3) Crankshaft
The ring gear (1) for connecting the start motor is compressed in the flywheel. Therefore, it cannot be replaced separately.
52
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CRDI
OPERATING PRINCIPLE
4.3 Lubricating system 4.4.1 Engine oil flow
17
16
U89W315A
(1) Piston (2) Idle gear (3) Oil pump (4) Relief valve (5) Oil strainer (6) Oil filter
(7) Bypass valve (8) Oil pan (9) Rocker arm shaft (10) Rocker arm (11) Push rod (12) Tappet
(13) Oil pressure gauge (14) Camshaft (15) Crankshaft (16) Oil cooler (3F183T) (17) Oil jet
53
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CRDI
OPERATING PRINCIPLE
(3F183T)
No.2 main bearing No.1 main bearing Journal bearing
c
Oil jet
Oil jet
Oil jet
No.3 main bearing
4.4.2 Engine oil flow chart
U89W316D
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CRDI
OPERATING PRINCIPLE
4.4.3 Function of lubricating system
U89W317A
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CRDI
OPERATING PRINCIPLE Oil strainer (refer to figure (a) on 3.3.3)
Rocker arm shaft (refer to figure (E) on 3.3.3) The oil from the valve camshaft comes through the hole in the support bracket of rocker arm, supplied to each rocker arm through the hole in the center of rocker arm shaft. The oil drained from the hole on top of the rocker arm is used in lubrication on the contact surface of the valve and the rocker arm. Then, it flows along the push rod to lubricate the contact surface between the push rod and the tappet and between the tappet and the valve cam.
Oil pump (refer to figure (b) on 3.3.3)
Type: Gerotor type
Oil: Tier3 - CH grade or higher Tier4 - CJ grade or higher SAE 10W30/10W40/15W40
Standard oil temperature: 80°C
Discharge pressure: 4.5 kg/cm2
Displacement: Over 10.0 ℓ/min (1,000 rpm) Over 24.3 ℓ/min (2,000 rpm)
Drive gear speed ratio (oil pump drive gear/oil pump gear) = 46/41 = 1.121
oil flow (refer to figure (F) on 3.3.3)
Oil filter and relIEF valve
The oil in the oil gallery flows to the main bearing and then to the connecting rod big end journal bearing. Oil is sprayed to the connecting rod (small end), piston interior and cylinder bore by the oil jet that is installed to the oil gallery.
Oil pressure switch (refer to figure (G) on 3.3.3
: ON
3
(C)
1
: OFF
1
u89w3q3a
(1) Bypass valve (2) Filter element
(3) Oil cooler (3F183T)
(A) Oil filter outlet (to idle gear, camshaft and lock arm shaft) (B) Oil filter outlet (to oil gallery, oil jet, crankshaft journal) (C) Oil filter inlet (D) Coolant (Inlet - Outlet) 2
- Relief valve opening pressure: 4.0 ~ 4.5 kgf/cm (57 ~ 64 psi) - Oil filter Filter paper fineness: Max.: 99 ± 5 microns, Average: 75 ± 5 microns Filtered area: 1680 cm2 Bypass valve opening pressure (pressure difference between inner and outer side of filter paper): 1 ± 0.2 kgf/cm2
T46W226A
The oil pressure switch is installed on the cylinder block at the end of the valve camshaft and leads to the oil passage which is passing through the valve camshaft. A: When the oil pressure falls below the specified value, the circuit is connected by the diaphragm in the switch to turn on the warning lamp (1) on the instrument panel. B: When the key switch is turned to the "ON" position with the engine stopped, the warning lamp comes on. When the oil pressure rises, this lamp goes off. Oil switch operating pressure(min.): 0.5 ± 0.1 kgf/cm2 7.1 ± 1.4 psi 49 ± 9.8 kPa
Valve camshaft (refer to figure (D) on 3.3.3) The oil enters the first journal bearing of the valve camshaft and is sent to each journal through the oil holes in the center of the camshaft. Then, it is sent to the oil pressure sensor through the last journal.
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CRDI
OPERATING PRINCIPLE
4.4 Cooling system 4.4.1 Coolant flow route
7 4 2 1
3
6
5
8
9
Q53W311A
When the centrifugal water pump (1) connected to the cooling fan shaft rotates, the coolant in the cylinder block flows from the No. 1 cylinder to the No. 3 cylinder through the No. 2 cylinder, and also flows to the cylinder head (from lower to upper side). In the cylinder head, the coolant flows from the No. 3 cylinder to the No. 1 cylinder through the No. 2 cylinder (from rear to front side). The coolant collected in the coolant flange (2) flows to the inlet of the water pump impeller through the return hose (3), and then returns to the cylinder block through the outlet of the impeller. When the coolant temperature rises over 71°C (160° F), the thermostat (4) opens and most coolant flows to the radiator through the thermostat. The coolant flowed to the top of the radiator through the top hose (7) is cooled down by the cooling air and sinks. Then, it flows to the inlet of the water pump impeller through the radiator lower hose (8) to return to the cylinder block.
The drain hose (5) is to completely drain the coolant in the cylinder block when opening the radiator lower cock (6). On the other hand, the vehicle equipped with the cabin heater has the cooling circuit that draws in hot water from the coolant flange (2) to heat the heater and drains it through the lower hose of the radiator. Also, for the engine equipped with the engine oil cooler cools down the engine oil by connecting the water pump(1) drain line to the engine oil cooler.
Also, for the CRDI (Common Rail Direct Injection) engine, part of coolant escapes the impeller inlet passage of the water pump through the lower hose of the radiator and flows to the ERG cooler (9) to cool down some exhaust gas flowing to the intake manifold.
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CRDI
OPERATING PRINCIPLE 4.4.2 Water pump
a
4.4.3 Thermostat (A): Low temp
3
1
2
(B): High temp
4 5 8
4
2
7
3
9
6 T46W229A
1 Location홀(A)위치 of hole (A)
b c U89W318A
(a) From thermostat (b) To cylinder block
(c) From radiator
(1) Bearing (2) Pump body
(3) Mechanical seal (4) Pump impeller
The water pump sucks the cooled water, forces it into the cylinder block and draws out the hot water to the radiator repeatedly. The mechanical seal (3) prevents the water from entering into the bearing (1).
Remark • If the coolant is leaked from hole (A), it means that the mechanical seal is damaged. Therefore, the water pump assembly should be replaced.
(1) Seat (2) Valve (3) Pellet (4) Spindle (5) Synthetic rubber
(6) Wax (Solid) (7) Spring (8) Leak hole (9) Wax (Liquid)
The thermostat is wax pellet type, which controls the flow of the cooling water to the radiator to keep the proper temperature. The case has a seat (1) and the pellet has a valve (2). The spindle attached to the case is inserted into the synthetic rubber in the pellet. The pellet is charged with wax.
At low temperature: below 71°C (160°F) The valve (2) is seated by the spring (7) and the cooling water circulates in the engine through the water return pipe but does not enter the radiator.
At high temperature: over 71°C (160°F) As the water temperature rises, the wax in the pellet (3) becomes liquid and it pushes out the spindle. The pellet lowers and the valve (2) opens to send the cooling water to the radiator.
By-pass valve T46W230
The bypass valve is equipped in the bottom of thermostat. Therefore, the cooling efficiency is enhanced as all coolant passes through the radiator since the internal circulation circuit is blocked as soon as the thermostat opens.
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CRDI
OPERATING PRINCIPLE
4.4.4 Radiator
4.4.5 Radiator cap
2
(A): High pressure
1 1
(B): Low pressure 3 T46W231A
(1) Cooling air (2) Tube
2
(3) Pin
The radiator core consists of water tubes (2) with fin (3) at a right angle to it. The water in the radiator is cooled down by the air flowing between the tube wall and the fin.
T46W232A
(1) Pressure valve
(2) Vacuum valve
The radiator cap is equipped with the pressure valve (1) and vacuum valve (2).
(A) AT HIGH PRESSURE - OVER 88 kPa (0.9 kgf/cm², 13 psi) When the water temperature rises and the pressure in the radiator increases above the specified value, the pressure valve (1) opens to drain the coolant to the reservoir tank to reduce the internal pressure.
(B) At Low Pressure When the water temperature drops down and a vacuum is generated in the radiator, the vacuum valve (2) opens to allow the coolant in the reservoir tank to enter into the radiator.
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CRDI
OPERATING PRINCIPLE 4.5 Fuel system 4.6.1 Overview for fuel supply
The common rail fuel injection system is comprised of the fuel tank, fuel line, fuel filter, high-pressure fuel pump equipped with high/low pressure pumps for fuel supply, common rail to distribute/store highpressure fuel, injector to inject high-pressure fuel precisely, and ECU (Engine Control Unit) which calculates acceleration (position of the accelerator pedal) desired by the driver based on information from various sensors and controls instant performance of the engine and vehicle in general.
4.6.2 Fuel flow route
④ Injector (C3I) ●
Controls pre-injection, main injection and post-injection according to signals from the ECU.
⑥ Common rail
⑧ High-pressure fuel pump
Dampens pulsation. ● Stores fuel pressure. ● Distributes fuel to injectors.
●
●
3
⑦ Fuel cooler
High pressure(1,800 bar): plunger pump Low pressure (6 bar): Vane pump * Supplies fuel from the fuel tank through the vane pump and high-pressure fuel to the common rail through the plunger p ump. ●
5
Cools down returned hot fuel.
●
② Fuel filter
① Fuel tank
Filters particles at 10 μm. Separates water. ● Heats fuel. ● ●
Q53W312C
(1) Fuel tank (2) Fuel filter (3) Injection pipe
(4) Injector (5) Fuel return hose (6) Fuel Rail
(7) Fuel cooler (8) High pressure fuel pump
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CRDI
OPERATING PRINCIPLE
FUEL SYSTEM FLOW DIaGRaM
FUEL-FILTER
FILTER ELEMENT
FUEL RETURN
PRIMING PUMP WATER SENSOR
FUEL TANK
FUEL COOLER
HIGH-PRESSURE RETURN
High-pressure PUMP
FUEL RAIL
INJECTOR
FUEL SUPPLY
Low-pressure PUMP
FUEL HEATER (250W)
FUEL-TEMP. SENSOR PRESSURE CONTROL VALVE
RETURN
Lub & venturi
FUEL HIGH-PRESSURE PUMP
H89W326c
Fuel sucked from the fuel tank passes the fuel filter and flows into the high-pressure pump from the lowpressure pump in the high-pressure fuel pump. After it is pressurized in the high-pressure pump, it is flowed to the fuel rail and is injected through the injectors according to the fuel injection signal for each injector. The EcU controls the IMV to control the fuel flow according to the pressure needed for the fuel rail. Fuel in the injector is returned to the high-pressure pump and then is drawn into the fuel cooler through the return line to cool down and send this fuel back to the fuel tank. If pressure between the high-pressure pump and fuel rail rises abnormally, the pressure control valve of the high-pressure pump opens to release pressure. Remark • For air bleeding, see the 3.5.4 or 11.3.1 BLEEDING THE FUEL SYSTEM.
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OPERATING PRINCIPLE
CRDI
4.6.3 fUEL FILTER ▶ Water-in-fuel sensor If a certain amount of water (45 cc or more) is accumulated in the filter, this sensor sends a signal to the ECU to turn on the corresponding warning lamp in order to inform the driver to drain water from the filter.
▶ Fuel heater (Option) When the ambient temperature is below 5℉ (-15℃), some ingredients of diesel fuel start to gel, leading to engine stall. Therefore, the fuel heater is operated HI4W109A
If water is mixed in fuel, fuel can be frozen in winter, making the engine hart to start or occurring wear, damage and corrosion across the fuel supply system, resulting in breakdown. Therefore, water and foreign materials should be filtered thoroughly from fuel with the fuel filter.
continuously to prevent engine stopping once the engine is started.. ▶ Priming pump After the fuel tank becomes empty, removing water from the fuel filter or replacing the fuel filter, air remains in the fuel system. To remove this air, press the priming pump repeatedly with the bleeding bolt open until fuel is drained from the tank.
CAUTION • Fuel in the fuel tank should be sent to the filter by using the priming pump after replacing the fuel filter. Never crank the engine to operate the highpressure pump in order to send fuel in the fuel tank to the filter after replacement.
Important
U89W321A
(1) Priming pump (2) Bleeding bolt (3) Pre-filter ass’y (4) Moisture sensor
(5) Fuel heater (option) (A) from fuel tank (B) to HP fuel pump
• If water is collected in the fuel more than the specified, the corresponding warning lamp on the instrument cluster is illuminated. In this case, drain water from the filter. • When replacing the fuel filter, replace it with the priming pump if possible.
As fuel from the fuel tank enters the fuel filter through its port (A), it flows through the filter element and then is supplied to the HP fuel pump through the port (B). The element in the pre-filter filters foreign materials over 10 microns in thickness at differential pressure of 10 kPa (0.1 kgf/cm2, 1.45 psi). This pre-filter is not only to filter water and foreign materials from fuel, but also to preheat fuel. As diesel fuel tends to freeze on a low temperature condition, making the engine hard to start, this pre-filter is equipped with the fuel heater (5) to avoid this situation.
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CRDI
OPERATING PRINCIPLE
4.6.4 Bleeding the fuel system 1. Make sure that the amount of fuel in the fuel tank is sufficient. 2. If air is mixed in the fuel filter, unscrew its bleeding bolt (2), shown in the figure for the fuel filter, and press continuously the priming pump (1). Then, air in the fuel filter is bled through the bleeding bolt.
Remark • If filling the port with fuel before installing the fuel port, it is not necessary to bleed the filter.
3. If fuel is visible from the bleeding bolt, tighten it and start the engine.
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CRDI
OPERATING PRINCIPLE 4.6.5 high pressure fuel pump component
2
3
1
4
5
7
6 8 21 9 14
10
16
12
11 20
13 15
17
18
19
U89W325A
(1) Front plate (2) IMV(Inlet Matering Valve) (3) Fuel inlet vavle (4) High pressure head (5) Bolt (6) Temperature sensor (7) High pressure outlet valve
(8) Gasket (9) plunger (10) Spring seat (11) Tappet (12) Bearing (13) Drive shaft (14) Rider
(15) Pressure control vavle (16) High pressure fuel connector (17) Body (18) Plug (19) Low pressure regulator (20) Low pressure pump (21) Spring
Major component specifications item Low pressure pump
Pressure control valve (IMV)
function Supplying fuel from fuel tank to high-pressure fuel pump Driven by shaft of high-pressure fuel pump
specification Pumping capacity: 5.6 cc/rev
Controlling amount of fuel sent from low-pressure side to highpressure fuel pump to match ECU-commanded pressure and actual fuel rail pressure
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CRDI
OPERATING PRINCIPLE
IMV (Inlet METERING vALVE)
U89W3T0A
1
⭋⢠㛗㡏 Low-pressure pump
2 high-pressure ါ⢠
2
Low-pressure ⭋⢠㛗㡏pump
3
4 H89W327A
(1) Cylinder filter (2) Radial hole
(3) Solenoid coil (4) Piston
The IMV (Inlet Metering Valve) is installed on the front of the high-pressure fuel pump and it is supplied with fuel from the transfer low-pressure pump through 2 radial orifices. This valve is also called as low-pressure actuator and is used to control the rail pressure by adjusting fuel amount sent to the pumping section of the high-pressure pump. It adjusts the fuel amount to keep pressure in the fuel rail constant for more effective injection system. It also limits the amount of fuel returned to the high-pressure pump to prevent excessively high temperature of fuel in the fuel tank due to excessively hot fuel sent from the injectors. •
Components: : piston, piston filter, O-ring, body and coil
•
Function Engine speed
Required rail pressure
Required fuel amount
Measure rail pressure
ECU
IMV (Inlet Metering Valve)
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CRDI
OPERATING PRINCIPLE 4.6.6 common rail (fuel rail) FUEL pRESSURE SENSOR
5
4
3
2
1 H89W328A
U89W327B U89W326A
(1) Fuel rail pressure sensor
T h e D e l p h i D F R 3.3/3.4 f u e l r a i l s t o r e s a n d distributes high-pressure fuel to the injectors for fuel injection. Therefore, it is commonly used by all cylinders, and it maintains its internal pressure continuously by itself even when the injectors open and pressure drops.
(1) Connector (2) Measuring circuit (3) Sensor element (diaphragm) (4) Fuel rail pressure sensor assembly (5) Fuel rail
The fuel pressure sensor (1) with the capacity of 0 to 2,200 bars is installed to the side of the fuel rail. It detects the instant change in the fuel pressure, converts this information to a voltage signal and sends this to the ECU which then controls pressure of the fuel rail precisely. The pressure in the fuel rail is determined by the engine RPM, engine torque, barometric pressure, coolant temperature and intake temperature. Also, the ECU receives and uses this information to adjust the fuel injection amount and injection timing for the injector of each cylinder.
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CRDI
OPERATING PRINCIPLE
4.6.7 injector [C3I (CALIBRATION IMPROVED INDIVIDUAL INJECTOR)] INjECTOR CORdIFICATION
h89W348A
This Delphi DFI 2.5 solenoid type injector is capable of multiple injections for each injection timing within a short period of time with the maximum nozzle opening pressure of 1,800 bar (1,835 kgf/cm2, 26,106 psi) and features low noise, low vibration and low fuel consumption through electronic control by the ECU.
U89W3V4A
The code C3I is marked on the side of the injector and cylinder head cover. This code consists of 20 digits including numbers from 1 to 9 and alphabetic characters excluding I, O, Q and V.
The injector starts fuel injection at least at 300 bars and up to 1,800 bar.
EJDRØ1151Z
DELPHI
A6612345678
1385MV18W09
U89W3V5A
* 20 digits with combination of alphabetic characters and numbers - Alphabetic characters: A , B, C, D, E, F, G, H, J, K, L, M, N, P, R, S, T, U, W, X, Y ,Z - Numbers: 0, 1, 2, 3, 4, 5, 6, 7, 8, 9
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OPERATING PRINCIPLE
CRDI
4.6.8 Fuel heater and fuel cooler Fuel heater (option) IMPORTANT • When installing the injector (new) to the cylinder block, connect the ECU to the scan tool and enter the injector code (20 digits) specified on the top of the injector into the scan tool.
REMARK •
• Mdp (MINIMUM dRIvE pULSE) LEARNINg • When the injector starts injecting fuel, this initial pulse value is measured to correct the pilot injection efficiently through the MDP control. Since the amount of fuel for pilot injection is very small (1 to 2 mm/st), it is hard to control the injectors precisely as they get aged. Therefore, injection amount and condition of the injectors are learned for consistent precise control over the injectors so that the ECU can adjust the pilot injection effectively. The MDP is learned by the knock sensor.
CAUTION • To prevent damage to the fuel system: • Use only genuine Diesel fuel. Low-quality fuel can clog (caulk) the nozzle. • Drain water from the fuel filter when the water-infuel warning lamp comes on.
U89W334A
The fuel heater is installed between the priming pump and filter body of the fuel filter. Diesel fuel contains paraffin, so it tends to solidify in a cold weather. In this case, fuel can block fuel passages, resulting in difficulty to start the engine or engine stall. To prevent this, the filter is equipped with the heater which is operated to melt paraffin in fuel at temperatures below freezing.
It is the method of heating the fuel the fuel heater is operated when operating the heater relay by ECU detects the temperature at a temperature below the freezing point.
• Keep the fuel filter replacement schedule. • Prevent introduction of any foreign material during disassembly and assembly.
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CRDI
OPERATING PRINCIPLE
4.6 INTAKE & EXHAUST SYSTEM 4.6.1 OVERVIEW TIER3 MOdEL: 3F183T
A
INTAKE 㪬ᅻ EXHAUST ύᅻ
B 1
3
2
A
Q53W3E8A
(1) Turbo charger (2) EGR cooler (3) EGR valve
(A) From air cleaner (B) To muffler
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CRDI
OPERATING PRINCIPLE TIER4 MOdEL: 3F183T INTAKE 㪬ᅻ
A
EXHAUST ύᅻ
5 4
B
3
1
2
A
Q53W3E8A
(1) Turbo charger (2) EGR cooler (3) EGR valve (4) Air control valve (5) CCRT
(A) From air cleaner (B) To CCRT(Catalized Continuously Regenrating Trap)
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CRDI
OPERATING PRINCIPLE
3FT-HI4 INTAKE 㪬ᅻ EXHAUST ύᅻ
A
1
B 2
HI4W110A
(1) Turbo charger (2) EGR cooler
(A) From air cleaner (B) To CCRT(Catalized Continuously Regenrating Trap)
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CRDI
OPERATING PRINCIPLE
As fresh air is drawn in to the system through the air cleaner, it flows to the compressor wheel side of the turbocharger (1) through the suction pipe to go through the compression process. Then, it is supplied to the intake manifold flange through the connecting pipe (TIER3 MODEL) and air control valve (TIER4 MODEL). On the other side, exhaust gas discharged from the exhaust manifold enters the turbocharger to turn the turbine and it is discharged to the air through the CCRT (Catalyzed Continuously Regenerating Trap) (5)(TIER4 MODEL) (or Muffler(TIER3 MODEL)). Its remainder is drawn into the EGR cooler (2) as illustrated. This exhaust gas in the EGR cooler is moved to the passage in the cylinder head through the bellows, and it passes through the EGR valve (3) on the other side to enter the intake manifold flange through the connecting pipe. Finally, fresh air, which was compressed by the turbocharger, and exhaust gas are mixed together, flowing into the cylinder of the engine.
▶ INTAKE (TIER3 MODEL) Air cleaner
Turbo charger
Intake manifold
Engine combustion chamber
▶ EXHAUST (TIER3 MODEL) Exhaust manifold
Turbo charger EGR cooler
Muffler EGR valve
Released to air Intake manifold
Engine combustion chamber
▶ INTAKE (TIER4 MODEL) Air cleaner Intake manifold
MAF sensor
Turbo charger
Air control valve
Engine combustion chamber
▶ EXHAUST (TIER4 MODEL) Exhaust manifold
Turbo charger EGR cooler
CCRT (Catalyzed Continuously Regenerating Trap), Muffler EGR valve
Intake manifold
Released to air
Engine combustion chamber
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CRDI
OPERATING PRINCIPLE
4.6.2 EGR COOLER
4.6.3 EGR VALVE
3F183T
3F183T
H89W308A
3FT-HI4
(1) EGR Cooler
U89W345A
3FT-HI4
HI4W111A
•
•
Normally, when the combustion temperature in the combustion chamber is high, a lot of NOx (Nitrogen Oxide) is generated. To decrease this amount, some of exhaust gas is recirculated to decrease the oxygen density so the combustion temperature, and this method is called EGR (Exhaust Gas Recirculation).This EGR type supplies some of exhaust gas to the cylinder so the amount of intake air and fuel consumption are decreased, resulting in improvement of fuel efficiency. The EGR cooler (1) is a pipe type cooler as illustrated and is connected to the coolant flange and cylinder block. It is also connected to the exhaust manifold to flow coolant along the duct line of exhaust gas from the exhaust manifold through the cylinder head passage to the EGR valve to decrease the temperature of exhaust gas.
(1) EGR Valve
HI4W112A
•
The EGR valve (1) supplies exhaust gas to the cylinder so the amount of recirculation intake air and fuel consumption are decreased, resulting in improvement of fuel efficiency. The EGR valve adjust the amount of exhaust gas supplied to the cylinder. It supplies a proper amount of exhaust gas through control of the ECU based on signals from the position sensor.
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OPERATING PRINCIPLE
CRDI
4.6.4 air control vavle (TIER4 MODEL) EGR valve characteristics
3F183T
1. Enhanced responsiveness and accuracy by control from engine ECU:
Solenoid in EGR valve activated by receiving signal directly from engine ECU
2. Feedback function added:
Feedback for exact position of EGR valve to ECU
3. Chattering elimination and durability enhancement:
Reinforced with 2 valve seats
4. EGR valve cleaning:
Chattering with valve seat and solenoid in housing to remove foreign materials
U89W349A
3FT-HI4
HI4W113A
The air control valve is installed right before the intake manifold flange to control the amount of air before this air is drawn into the intake manifold after it is sucked through the air cleaner and is compressed in the turbocharger. The inlet of the air control valve is equipped with a fan(throttle valve) to control the amount of intake air. This fan opens and closes according to the operation of the accelerator pedal to adjust the amount of air supplied into the cylinder. Also, the air control valve has the throttle position sensor (1). This sensor detects the opening angle of the fan and sends this information to the ECU which then determines and controls the amount of injected fuel according to this value.
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CRDI
OPERATING PRINCIPLE
▶ Air control valve characteristics
4.6.5 CCRT (Catalyzed Continuously Regenerating Trap) (TIER4 MODEL)
•
Prevention of dieseling and engine vibration by cutting off intake air with engine stopped
SYSTEM OVERVIEW
•
Intake air amount control synchronized with CCRT system
3F183T
•
Effective EGR control synchronized with EGR system
Remark • When the ignition switch is turned to the OFF position, the throttle valve is completely closed and the output voltage (5 V) is activated for approx. 1.2 seconds.
U89W350A
3FT-HI4
2
1
HI4W114A
( 1) DOC (Diesel Oxidation Catalyst) (2) DPF (Diesel Particulate Filter) (3) Differential pressure sensor
The conventional DOC (Diesel Oxidation Catalyst) equipped in a diesel engine features high purification performance for HC and CO but low reduction rate of PMs. To enhance the performance, the conventional DOC has been combined with the DPF. The DOC discharges harmless CO2 and H2O through oxidation of CO and HC while the DPF regenerates collected PMs (Particulate Materials). This system is called CCRT (Catalyzed Continuously Regenerating Trap). Sulfur in diesel fuel combines with oxygen gas during combustion, promoting creation of PMs. If an excessive amount of PMs is accumulated in the DPF (Diesel Particulate Filter), pressure difference between the front and rear sections of the DPF is detected by the differential pressure sensor (3), resulting in activation of regeneration process. PMs are naturally combusted when the temperature of exhaust gas is high or there is a sufficient amount of NOx (Nitrogen Oxides). Therefore, if regeneration is necessary, the ECU automatically controls the temperature of exhaust gas to activate the regeneration process. Alternatively, the driver can press the regeneration button until the corresponding indicator on the instrument cluster comes ON.
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CRDI
OPERATING PRINCIPLE
Exhaust gas
CO
+1/2 O2
CO2
HC
+O2
PM
Re-combustion
NO
Generation control
DOC
H2O+CO2
H2O+CO2
DPF
CCRT (Catalyzed Continuously Regenerating Trap)
EGR system
System operating principle
Oxidation (DOC)
After exhaust gas is passed through the exhaust manifold, it is led into the CCRT assembly. (Approx. 250℃)
U89W3T2A
PM collection → Re-combustion (regeneration) function
After exhaust gas is drawn into the CCRT assembly, its CO, HC and PMs are reduced by oxidation and reduction in the DOC firstly. The remainder of PMs is collected in the CCRT by its filtering operation. Also, the temperature of exhaust gas after oxidation and reduction rises. (Approx. 450 - 500 ℃)
The engine ECU detects the condition of PM collection through values sent from the temperature sensor and differential pressure sensor. When some PMs are collected in the filter, pressure difference between the front and rear of the filter occurs.
U89W3T3A
U89W3T4A
Then, the engine ECU performs post injection to increase the exhaust gas temperature in order to burn collected PMs. (Approx. 600℃)
U89W3T1A
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CRDI
OPERATING PRINCIPLE
PM regeneration of DPF The DPF is equipped with the differential pressure sensor to detect the pressure at the inlet and outlet of the CCRT. The amount of PMs (Particulate Materials) in the filter of the CCRT is calculated based on the exhaust gas temperature, intake air amount, booster pressure, etc. When the weight of PMs in the filter becomes 28 g or higher, regenerating process is activated. The ECU commands post injection to increase the temperature in the CCRT up to 600℃ during regeneration.
▶ Specified PM amount not detected: The DPF performs only its filtering function Differential pressure sensor
Collecting PMs Exhaust gas
Engine
Pilot/main injection
Exhaust gas temperature sensor
Intake air amount Value from differential pressure sensor U89W3T5C
▶ Specified PM amount detected: The ECU commands the injectors to post-inject fuel in order to increase the exhaust gas temperature for regeneration (re-combustion). Differential pressure sensor
Collecting PMs Exhaust gas
Engine
Pilot/main injection
Exhaust gas temperature sensor
Intake air amount Detecting PM amount over limit
Value from differential pressure sensor U89W3T6C
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OPERATING PRINCIPLE
CRDI
4.6.5 TURBO CHARGER CAUTION •
Precautions for maintenance of • catalytic filter •
• Make sure to use the genuine fuel. • Keep the engine oil change schedule. • Check and service the engine oil amount frequently. • Avoid unnecessary idling of the engine. • Never stop the engine during driving. • Never place the shift lever in the neutral position on a a downhill. • Do not use any kind of additive for engine oil and fuel. • Avoid prolonged driving with the warning lamp illuminated.
System overview The turbocharger is equipped with the turbine and compressor at a different angle at each end of one shaft. The compressor housing is connected to the intake manifold while the turbine housing is connected to the exhaust manifold. When the turbine starts to rotate by pressure of exhaust gas, the impeller on the intake side rotates as well. Then, air around the center of the impeller is applied with centrifugal force, accelerated outwards, and is drawn into the intake manifold through the intake connecting pipe. As the passage is large in volume, kinetic energy of supplied air is converted to pressure energy and this energy is supplied to the cylinder for superior volume efficiency. Also, exhaust efficiency is enhanced by rotation of the exhaust turbine.
TIER3 MOdEL: 3F183T
• Make sure that any flammable material, such as dry grass or paper, gets to the catalytic filter while parked.
HI4W184A
3FT-HI4
HI4W115A
The turbocharger is installed between the exhaust manifold and intake manifold and it is driven by exhaust gas. Its wheel on the turbine side is rotated at a high speed by exhaust gas while the compressor wheel on the other side is rotated by the connecting shaft. As fresh air is drawn through the air cleaner, it is compressed by the compressor wheel of the turbocharger under high pressure, higher than barometric pressure, and it flows to the intake valve. The bearing in the turbocharger is lubricated by the engine oil from the engine cylinder block.
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CRDI
OPERATING PRINCIPLE
Turbocharger structure
Intake valve (CCRT ass’y)
Muffler Actuator
Air cleaner Exhaust valve Oil
Return
A86W306B
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CRDI
OPERATING PRINCIPLE 4.7 sensor TIER3 MOdEL: 3F183T 1
2 8
3
5
4 6 7
Q53W321A
(1) Water temp sensor (2) Knock sensor (3) Fuel temp. sensor
(4) Exhaust temp. sensor (5) Rail pressure sensor (6) Cam position sensor
(7) Oil pressure switch (8) WIF(Water In Fuel) sensor
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CRDI
OPERATING PRINCIPLE
TIER4 MOdEL: 3F183T
1
2
5
4 3 6
8
7
10 9 13
11 12
14
15
U89W352A
(1) ACV( Air Control Valve) (2) MAF(Mass Air Flow) sensor (3) Intake pressure sensor (4) Water temp sensor (5) EGR valve
(6) Knock sensor (1 for 3 Cyl, 2 for 4 Cyl) (7) Fuel temp. sensor (8) Intake temp. sensor (9) Exhaust temp. sensor(FRT) (10) Rail pressure sensor
(11) Cam position sensor (12) Oil pressure switch (13) WIF(Water In Fuel) sensor (14) Differential pressure sensor (15) Exhaust temp sensor(RR)
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CRDI
OPERATING PRINCIPLE 3FT-HI4 2
10
1
4
5 3 8
7
6 13
9
12
11
HI4W116A
(1) ACV( Air Control Valve) (2) MAF(Mass Air Flow) sensor (3) Intake pressure sensor (4) Water temp sensor (5) EGR valve
(6) Crankshaft wheel sensor (7) Fuel temp. sensor (8) Intake temp. sensor (9) Exhaust temp. sensor(FRT) (10) Rail pressure sensor
(11) Cam position sensor (12) Oil pressure switch (13) WIF(Water In Fuel) sensor
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CRDI
OPERATING PRINCIPLE
Sensor and actuator components TIER3 MOdEL
AIR FILTER
* Before turbine (exhaust gas temp. sensor) · Measures combustion temperature to prevent overheating of the exhaust system
Temperature Pressure Others
MUFFLER
EGR cooler
Coolant temperature sensor
Cam position sensor · Air gap: 1.0mm ± 0.4 · Detects the camshaft rotation
(Intake air temp. sensor)
(Intake air press. sensor)
Crank position sensor · Air gap: 0.7mm ± 0.3 · Detects position and speed of the crankshaft Oil pressure switch
Knock sensor · 3-cylinder : 1EA · 4-cylinder : 2EA · Detects knocking of Engine abnormal combustion
· Detects temperature and pressure of air drawn into the intake manifold so that the ECU can determine the optimum injection timing and fuel injection amount IMV (Inlet Metering Valve)
Barometric pressure sensor (In ECU) WIF (Water-In-Fuel) sensor · Detects water mixed in fuel
Rail pressure sensor · Detects pressure of the fuel rail to determine the amount of opening of the IMV.
Fuel temperature sensor · Detects fuel temperature
H89W330B
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CRDI
OPERATING PRINCIPLE
TIER4 MOdEL
AIR FILTER
* Before turbine (exhaust gas temp. sensor) · Measures combustion temperature to prevent overheating of the exhaust system
Temperature Pressure Others
Differential pressure sensor · Detects pressure difference between CCRT inlet&oulet Collecting PMs
MUFFLER CCRT CCRT [US/EU]
Exhaust gas temperature sensor
EGR r EGRcoole cooler
Coolant temperature sensor
Cam position sensor · Air gap: 1.0mm ± 0.4 · Detects the camshaft rotation
(Intake air temp. sensor)
(Intake air press. sensor)
· Detects temperature and pressure of air drawn into the intake manifold so that the ECU can determine the optimum injection timing and fuel injection amount
MUFFLER [AU]
Crank position sensor · Air gap: 0.7mm ± 0.3 · Detects position and speed of the crankshaft Oil pressure switch
Knock sensor · 3-cylinder : 1EA · 4-cylinder : 2EA · Detects knocking of Engine abnormal combustion
IMV (Inlet Metering Valve)
Barometric pressure sensor (In ECU) WIF (Water-In-Fuel) sensor · Detects water mixed in fuel
Rail pressure sensor · Detects pressure of the fuel rail to determine the amount of opening of the IMV.
Fuel temperature sensor · Detects fuel temperature
u89w3v7D
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CRDI
OPERATING PRINCIPLE
MAF (MASS AIR FLOW) SENSOR (2)
Differential pressure sensor (14)
The MAF sensor is installed on the connection of the suction hose to detect mass air flow. This information is used for determination of fuel injection amount as well as feedback control for EGR (Exhaust Gas Recirculation).
INTAKE AIR TEMPERATURE SENSOR (8) This sensor is installed on the intake manifold and its information is used as correction information for adjustment of the fuel amount, injection timing and fuel amount control at starting.
Front exhaust gas temperature sensor (9)
U89W3u6A
This sensor is to measure the pressure difference between the inlet and outlet of the CCRT.
3F183T
(If the pressure difference between the inlet and outlet is over the specification due to collected PMs, postinjection is performed to regenerate PMs forcibly.)
Rear exhaust gas temperature sensor (15)
U89W3u5A
3FT-HI4
U89W3u7A
It is installed to the rear section of the DOC to determine overheating condition of the CCRT and fuel amount of the post-injection process. HI4W117A
It is installed to the back of the exhaust manifold to measure the combustion temperature in order to prevent overheating of the exhaust system. If t he system is over heate d, t he c ombust i on temperature is decreased by the EGR control.
The fuel amount for the post-injection process is adjusted by the exhaust gas temperature detected by this sensor. If the temperature is below 600℃, the fuel amount is increased to increase the regeneration temperature. If the temperature is over 600℃, the fuel amount is decreased or not adjusted. When the engine is running in the low load range, the intake air amount is also adjusted to increase the regeneration temperature. This process is used to add more fuel and reduce intake air amount simultaneously within the set control logic range in order to increase the combustion temperature during the post-injection process.
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CRDI
OPERATING PRINCIPLE 4.8.1 Sensors as input/output for ECU TIER3 MOdEL
SENSORS AS INPUT E/G oil pressure switch ͑
Crankshaft wheel ͑sensor
Accelerator pedal sensor ͑
Hand throttle lever ͑sensor
Exhaust gas temp. ͑sensor
Coolant temp. sensor ͑
Camshaft wheel sensor ͑
Acceleration (knock)͑ sensor
Fuel rail pressure ͑sensor
Water-in-fuel sensor ͑
Intake temp. pressure͑ sensor
0#Refrigerant
pressure sensor
0#Clutch pedal signal 0#Brake pedal signal
SENSORS AS OUTPUT Start motor ͑
Relay box in engine compartment ͑
LPY#Ydoyh͑
Injector ͑
FDQ͑ 0#Glow plug relay driver
0#Instrument cluster
0#Self-diagnosis
Q53W322B
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CRDI
OPERATING PRINCIPLE
TIER4 MOdEL
SENSORS AS INPUT MAF sensor ͑
Crankshaft wheel ͑sensor
Accelerator pedal ͑sensor
Hand throttle lever͑sensor
Intake air pressure͑sensor
Exhaust gas temp.͑sensor
EGR V/V position sensor ͑
Camshaft wheel sensor ͑
Air control throttle position ͑ sensor
Fuel rail pressure ͑sensor
Differential pressure͑ sensor
Coolant temp. sensor ͑
Water-in-fuel sensor ͑
Acceleration (knock)͑ sensor
Intake air temp. sensor ͑
E/G oil pressure ͑switch
0# Clutch pedal signal 0# Brake pedal signal
SENSORS AS OUTPUT Start motor͑
Relay box in engine compartment ͑
Air control throttle position ͑ sensor
Injector ͑
LPY#Ydoyh ͑
EGR valve position͑sensor
FDQ͑ 0#Glow plug relay driver
0#Instrument cluster
0#Self-diagnosis
U89W3U8d
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CRDI
TROUBLE SHOOTING 5. TROUBLESHOOTING Symptom
Causes • • • • • •
Remedy
•
No fuel Air in fuel system Water in fuel system Clogged fuel pipe Clogged fuel filter Excessively high viscosity of fuel or engine oil at low temperature Fuel with low cetane number Fuel leak due to loose injection pipe mounting nut Incorrect injection timing Defective fuel injection pump Defective fuel transfer pump Seizure of transfer pump, defective piston, cylinder bore or bearing Compression leak from cylinder
• • • •
Improper valve timing Worn piston ring and bore Excessive valve clearance Engine system error (fault)
Replace head gasket, tighten cylinder head screws, glow plug and nozzle holder Correct or replace timing gear Repair or replace Adjust Check the engine check lamp ON (contact your local dealer) Repair or check for error codes
Start motor Does Not Run
• • • •
Discharged battery Defective start motor Defective key switch Disconnected wiring
Charge Repair or replace Repair or replace Connect
Engine Running is Not Smooth
• • • • • •
Clogged or dirty fuel filter Clogged Air cleaner Fuel leak due to loose injection pipe mounting nut Defective fuel injection pump Seized or clogged nozzle Clogged fuel overflow pipe
Clean or replace Clean or replace Tighten nut Repair or replace Repair or replace Clean or replace
Either White or Blue Exhaust Smoke is Produced
• Excessive engine oil • Worn piston ring and bore or seized piston ring • Insufficient compression pressure
Reduce to the specified level Repair or replace Adjust valve clearance
Either Black or Dark Gray Exhaust Smoke is Produced
• • • •
Overheat or overload Low grade fuel used Clogged fuel filter Clogged Air cleaner
Reduce load Use the specified fuel Clean or replace Clean or replace
Insufficient Output
• • • •
Seized engine components Uneven fuel injection Insufficient nozzle injection Compression pressure leak
Repair or replace Repair or replace the fuel injection pump Repair or replace the nozzle Replace cylinder head gasket, check tightness of cylinder head screws and nuts, glow plug and nozzle holder Check the instrument - regen waring lamp ON (contact your local dealer) Activate CCRT Regen operation
Engine Does Not Start
• • • • • •
• C logged CCRT (Catalized Continuously Regenrating Trap)
Add fuel Bleed air Change fuel and repair or flush fuel system Clean Clean or replace Use the specified fuel or engine oil Use the specified fuel Tighten nut Adjust Repair or replace Repair or replace Repair or replace
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CRDI
TROUBLE SHOOTING
Symptom
Causes Aligned gaps of piston rings Worn or seized oil ring Worn piston ring groove Worn valve stem and guide Worn crankshaft bearings and crank pin bearings
Remedy
Excessive Engine Oil Consumption
• • • • •
Hydraulic Oil in Engine Oil (Increased oil amount)
• Damaged hydraulic pump seal
Replace or repair
Water in Engine Oil
• Defective cylinder head gasket • Cracked cylinder block or cylinder head
Replace Replace
Low Oil Pressure
• • • • • • • • • • •
Add Clean Replace Clean Replace Replace Replace Replace Clean Use the specified type of oil Repair or replace
High Oil Pressure
• Improper type of oil • Defective relief valve
Use the specified type of oil Replace
Engine Overheating
• • • • • • • • • • • •
Add Replace or adjust Add Clean or replace Clean or replace Replace Replace Replace Replace Reduce load Replace Use the specified fuel
Coolant leakage
• Damaged mechanical seal on water pump
Replace water pump
Frequently Discharged Battery
• • • • •
Add distilled water and charge Adjust fan belt tension or replace it Connect Replace Replace
Insufficient engine oil Clogged oil strainer Clogged oil filter cartridge Relief valve stuck with dirt Weak or broken relief valve spring Excessive oil clearance of crankshaft bearings Excessive oil clearance of crank pin bearings Excessive oil clearance of rocker arm bushings Clogged oil passage Improper type of oil Defective oil pump
Insufficient engine oil Damaged fan belt or improper tension Insufficient coolant Corroded radiator Corroded coolant flow line Defective radiator cap Damaged coolant pipe Defective thermostat Defective coolant pipe Overload running Defective cylinder head gasket Improper fuel used
Insufficient battery electrolyte Fan belt slip Disconnected wiring Defective regulator or alternator Defective battery
Change the ring gap direction Replace Replace piston Replace Replace
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CRDI
TROUBLE SHOOTING REMARK
Turbocharger troubleshooting The chart below is given to assist in the correct diagnosis of turbocharger faults.
Problems
Possible causes code numbers
Not enough power
1,4,5,6,7,8,9,10,11,18,20,21,22,25,27,28,34,35,36
Black smoke
1,4,5,6,7,8,9,10,11,18,20,21,22,25,27,28,34,35,36
Blue smoke
1,2,4,7,8,9,17,19,20,21,22,30,31,32,34
High lubricating oil consumption
2,8,15,17,19,20,28,29,31,32,34
Too much lubricating oil at turbine end
2,7,8,17,19,20,22,28,30,31,32
Too much lubricating oil at compressor end
1,2,4,5,6,8,19,20,21,28,31,32
Not enough lubrication
8,12,14,15,16,23,24,29,32,33,37,38
Lubricating oil in exhaust manifold
2,7,17,18,19,20,22,28,31,32
Lubricating oil in intake manifold
1,2,4,5,6,8,10,11,17,18,19,20,21,28,32,34
Damaged compressor impeller
3,4,6,8,12,15,16,20,21,23,24,29,32,33,37,38
Damaged turbine rotor
7,8,12,13,14,15,16,18,20,22,23,24,25,27,29,32,33,37,38
Rotating assembly does not turn freely
3,6,7,8,12,13,14,15,16,18,20,21,22,23,24,29,32,33,37,38
Worn bearings, bearing bores, journals
6,7,8,12,13,14,15,16,23,24,29,33,37,38
Noisy turbocharger
1,3,4,5,6,7,8,9,10,11,12,13,14,15,16,18,20,21,22,23,24,29,32,33,34,37,38
Sludge or carbon deposit in bearing housing
2,11,13,14,15,17,18,24,29,33,37,38
1. Element of air filter dirty 2. Restricted crankcase breather 3. Element of air filter not fitted, improper sealing or loose connection to turbocharger 4. Internal distortion or restriction in pipe from air filter to turbocharger 5. Damaged/restricted crossover pipe, turbocharger to intake manifold 6. Clogged air filter and turbocharger 7. Restriction in exhaust system 8. Loose turbocharger or clamps/ setscrews 9. loose or cracked intake manifold or distorted flange 10. Cracked or loose exhaust manifold or distorted flange 11. Restricted exhaust system 12. Delayed lubrication to turbocharger during engine starting
13. Insufficient lubrication 14. Dirty engine oil 15. Incorrect engine oil 16. Restricted lubricating oil supply pipe 17. Restricted lubricating oil drain pipe 18. Turbine housing damaged or restricted 19. Leakage from turbocharger seals 20. Worn turbocharger bearings 21. Excessive dirt in compressor housing 22. Excessive carbon behind turbine rotor 23. Engine speed raised too rapidly at initial start 24. Insufficient engine idle period 25. Defective high pressure fuel pump 27. Valves burned
28. Worn piston rings 29. Lubricating oil leakage from supply pipe 30. Excessive preservation fluid (on initial engine start) 31. Excessive engine idle period 32. Restriction in turbocharger bearing housing 33. Clogged oil filter 34. Air cleaner: Restricted, dirty element 35. Waste-gate actuator faulty or damaged 36. Waste-gate valve not free 37. Engine stopped too soon from high load 38. Insufficient lubricating oil
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CRDI
MEASUREMENT AND ADJUSTMENT
6. Measurement and adjustment 6.1 Fan belt
6.2 piston compression pressure measurement
T46W250A
T46W251A
Measure the deflection by depressing the center of the belt between the fan drive pulley and the alternator pulley at 98 N (10 kgf, 22 lbs) of force.
1. Run the engine until it is warmed up.
If the deflection is out of the specified value, loosen the bolts and nuts and adjust the location of the alternator.
3. Connect a compression tester to the nozzle holder hole.
If the belt is damaged or worn (see figure), replace the belt. Fan belt deflection........... 7 ~ 9 mm (0.28 ~ 0.35 in.)
2. Stop the engine and remove the air cleaner, the muffler and all nozzle holders. 4. Pull the stop lever or close the fuel filter with the cock to cut the fuel and crank the engine with the starter motor for 5 to 10 seconds. 5. Measure the maximum pressure several times while engine running. 6. If the pressure does not reach the allowable limit, apply few drops of oil to the cylinder wall through the nozzle holder hole and check the pressure again. 7. If the pressure rises after applying the oil, check the cylinder wall and piston ring for wear. 8. If the pressure is still low, check the top clearance, valve clearance and cylinder head. Specified value
3.24 ~ 3.73 MPa 33 ~ 38 kgf/cm² 469 ~ 540 psi
Allowable lower limit
2.55 MPa 26 kgf/cm² 370 psi
Compression pressure
Pressure difference Allowable limit between two cylinders
10 %
CAUTION • Check the compression pressure and adjust the valve clearance to the specified value.
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CRDI
MEASUREMENT AND ADJUSTMENT
6.3 Valve clearance 6.4.1 clearance adjustment 1. The valve clearance should be measured only when the engine temperature is same to the ambient temperature. 2. Disconnect the battery cables.
6. If the clearance is not within the factory specifications, turn the adjusting screw to adjust. After adjusting valve clearance, be sure to tighten the lock nut of each valve securely. 7. Turn the flywheel just one turn to position the 1st cylinder piston at top dead center. (At this time, two valves are in their over lap position without any gab between rocker arms and valves.)
3. Remove the cylinder head cover.
8. Measure the clearance at the valves marked with in the table below with a feeler gauge. When the No. 4 cylinder is overlapped 2
1
IN
EX
IN
EX
IN
EX
Cooling fan
Flywheel
3
: closed, : open 196W253B
9. If the clearance is not within the factory specifications, adjust. After adjusting valve clearance, be sure to tighten the lock nut of each valve securely.
Important A
vALvE CLEARANCE IN
EX
0.25 mm
0.20 mm
(0.00984 in.)
(0.00787 in.)
196W254B
4. Turn the flywheel and align the 1TC mark with the timing mark of the rear end plate to position the 1st cylinder piston at the top dead center of its compression cycle. (At this time, both valves of 1st cylinder are closed to allow the gap between rocker arms and valves and Ex. valve of 2nd cylinder and IN. valve of 3rd cylinder are open, and moving at the same time.) 5. Measure the clearance at the valves marked with in the table below with a feeler gauge. When the No. 4 cylinder is overlapped 2
1
IN
EX
IN
EX
IN
EX
Cooling fan
Flywheel
3
: closed, : open
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CRDI
MEASUREMENT AND ADJUSTMENT
6.4 Valve lift (deflection and worn condition of valve cam, tappet, push rod, rocker arm, etc.)
6.5 oil pressure measurement
1. Remove the cylinder head cover. 2. Adjust the valve clearance according to the section 5.3. 3. Set the dial gauge so that its pointer is on the valve. The valve should be closed and the rocker arm should move as much as the free play. 4. Measure the max. valve movement while turning the crankshaft. 5. Measure the max. vertical movement of other valves according to the above process. 6. The vertical movement for all valves should be in the tolerance range of 0.5 mm (0.02 in.). If the measured value is out of the tolerance, check the corresponding valve for the deflection of the pushrod, worn condition, engagement with the tappet, worn tappet and worn valve cam.
T46W262A
1. Remove the oil pressure switch and install the adapter and the pressure tester. 2. Start and warm up the engine. Then, measure the oil pressure at idle and rated speed. 3. If the oil pressure is less than the allowable limit, check the oil level, oil filter, oil pump relief valve, oil passages and oil clearance.
At idle speed
Engine oil pressure
At rated speed
Specified value
Specified value Allowable limit (lower limit)
over 49 kPa 0.5 kgf/cm² 7.11 psi 245 ~ 441 kPa 2.5 ~ 4.5 kgf/cm² 35.6 ~ 64.0 psi 245 kPa 2.5 kgf/cm² 35.6 psi
Oil pressure switch Tightening torque............ 14.7 ~ 19.6 Nm 1.5 ~ 2.0 kgf-m 10.8 ~ 14.5 lb-ft
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MEASUREMENT AND ADJUSTMENT 6.6 Bubble test for radiator
CRDI
6.7 TURBO CHARGER WASTEGATE PRESSURE CHECK
REMARK • Checking if air is leaked through the crack on the cylinder wall
1. Check the coolant level of the radiator and the reservoir tank. Add the coolant if necessary. 2. Start the engine with the radiator cap closed and the reservoir tank cap open. 3. Check if any bubble can be seen in the overflow hose on the bottom of the reservoir tank around 5 minutes later. 4. If any bubble can be seen, remove the engine cylinder head to check the head gasket for damage, the cylinder bore for crack and the cylinder head for crack. Replace the components if necessary.
A86W338A
The wastegate is a valve that automatically opens at a preset level of boost pressure in order to allow excess exhaust gas to bypass the turbine at high engine speeds. The wastegate allows the design of the turbocharger toA be more effective at lower engine speeds. The wastegate is controlled by a diaphragm. One side of this diaphragm is open to the atmosphere. The other side of this diaphragm is open to intake manifold boost pressure.
PRESSURE CHECKING METHOD 1. Remove the boost line(6) from the wastegate actuator(5). Connect an air supply to the wastegate actuator that can be Aadjusted accurately. 2. Install Tooling(A) to the turbocharger so that the end of the actuator rod(1) is in contact with Tooling(A). This will measure axial movement of the actuator rod(4). 3. Slowly apply air pressure to the wastegate so that the actuator rod(4) moves 1.0 mm(0.039 in.). The air pressure should be within 61±3 kPa(8.89 psi) for 4B243T.
REMARK • Ensure that the dial indicator returns to zero when the air pressure is released.
4. Repeat the test several times. This will ensure that an accurate reading is obtained.
If the operation of the wastegate is not correct,the actuator rod(4) can not be adjusted. The turbocharger must be renewed.
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CRDI
MEASUREMENT AND ADJUSTMENT
REMARK
ACTUATOR FUNCTION • When pressure of intake air drawn by the turbocharger rises, so does its temperature, and high temperature of intake air can lead to incomplete combustion. To prevent this situation, the turbocharger is equipped with the actuator. There is a pipe connected between the actuator and intake manifold and this pipe detects intake air pressure continuously. When the intake air pressure is over the setting value of the diaphragm of the actuator, the wastegate is opened to release exhaust gas on the compressor side of the turbocharger Therefore, the turbine of the compressor is slowed down and so is the pressure of intake air. As a result, a proper amount of intake air is flowed into the cylinder through the intake manifold.
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CRDI
EXPLODED VIEW 7. Exploded view REMARK
• The manufacturing parts are subject to change without notice. Therefore, check the parts catalog or electronic manual for latest information.
7.1 G010A CYLINDER BLOCK 3F183T 5
20
14 2
3 3 15
12 7
19
4
11
4
1
15
3 4
18
16
11
17
7 6
11
15
4
2
~
14
3
~
3
15 15
8
13 9 9
10
N60W305A
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CRDI
EXPLODED VIEW
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
F5800-01001
Assy Block,cylinder
10
F6800-90121
Bolt, Ladder Frame
2
06311-75045
Plug
11
05012-01018
Pin, Parallel
3
15221-0338-3
Cap
12
F6800-33651
Pin
4
E5900-96021
Plug
13
F6800-90121
Bolt, Ladder Frame
5
E6301-33812
Tube Pin
14
15221-0339-2
Cap
6
F5800-01101
Cylinder Block Sub Assy
15
05012-01018
Pin, Parallel
6
F5800-01102
Cylinder Block Sub Assy
16
F6800-01311
Body, Piston Cooling Jet
7
F5800-01111
Cylinder Block
17
F6800-01321
Valve, Piston Cooling Jet
7
F5800-01112
Cylinder Block
18
E6500-33062
Tube 3, Oil
8
F5800-01121
Ladder Frame
19
F6800-20702
Coolant Connector Assy
9
F6800-90111
Bolt, Main Bearing
20
F6800-73341
Joint, Hose
97
수출향_커먼레일 직분식 엔진(CRDI).indd 97
2014-09-04 오전 9:02:29
CRDI
EXPLODED VIEW
3FT-HI4
10
20
14 12 13
15
1 3
19
9
7 2
14
9
13 9
16 17 15
7
18
1 15 3 2 7
9 15 15
14
8 5 5
6
HI4W118A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
F5850-A1001
Cylinder block assy
11
F6800-33651
Pin, pipe
2
F5850-01101
Cylinder block sub assy
12
06311-75045
Plug, expansion
3
F5850-01111
Cylinder block
13
15221-0338-3
Cap, sealing
4
F6800-01121
Ladder frame
14
15221-0339-2
Cap, sealing
5
F6800-90111
Bolt, main bearing
15
05012-01018
Pin, parallel
6
F6800-90121
Bolt, ladder frame
16
F6800-01311
Body, piston cooling jet
7
05012-01018
Pin, parallel
17
F6800-01321
Valve, piston cooling jet
8
F6800-90121
Bolt, ladder frame
18
E6500-33062
Pipe 3, oil
9
E5900-96021
Plug
19
F6800-20702
Coolant connector assy
10
E6301-33812
Pin, pipe
20
F6800-73341
Pipe, coolant return
98
수출향_커먼레일 직분식 엔진(CRDI).indd 98
2014-09-04 오전 9:02:30
CRDI
EXPLODED VIEW
7.2 G020A OILPAN 3F183T
7 6
8
2 1 4
3
5 2 4 2 4
N60W306A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
F5800-01601
Assy fan,oil
5
01654-50835
Bolt
2
E6303-33661
Gasket
6
F5800-32111
Oil strainer assy
3
F5800-01611
Fan,oil
7
04811-00150
O ring
4
E6303-33751
Plug
8
01754-50610
Flange bolt
99
수출향_커먼레일 직분식 엔진(CRDI).indd 99
2014-09-04 오전 9:02:30
CRDI
EXPLODED VIEW
3FT-HI4
7 8 6
8
1 2
4
2
5 3
4
HI4W119A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
F5820-01601
Oil pan assy
5
01654-50816
Bolt, flange with pin
2
F5820-01611
Oil pan
6
F5820-32111
Oil strainer assy
3
E6303-33751
Plug
7
04811-00150
O ring
4
E6303-33661
Gasket
8
01754-50610
Bolt, flange
100
수출향_커먼레일 직분식 엔진(CRDI).indd 100
2014-09-04 오전 9:02:31
CRDI
EXPLODED VIEW
7.3 G030A CYLINDER HEAD 3F183T
14
15 9
13 8
6 12
11
5
8 *
7 2
3 4
~
2 9 3 ~
1
7
6
10
N60W307A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
F5800-03041
Assy Head,cylinder
9
15221-0349-3
Cap
2
F5800-03051
Cylinder Head Sub Assy
10
F5800-03311
Gasket,head
3
E6700-13622
Seat,exhaust Valve
11
F6800-03451
Bolt,cylinder Head
4
E6700-13611
Seat,inlet Valve
12
F6800-03501
Hinge, Injector Clamp
5
E6810-13581
Guide, Intake Valve
13
F6800-73341
Joint, Hose
6
E6810-13561
Guide, Valve
14
15221-0175-1
Engine Hook
7
E5900-96021
Plug
15
01754-50816
Bolt, Flange
8
15221-0337-3
Cap
101
수출향_커먼레일 직분식 엔진(CRDI).indd 101
2014-09-04 오전 9:02:31
CRDI
EXPLODED VIEW
3FT-HI4
8
7
6
4 10
13
12
11
6
2
6
2 1 7
5 5 9
HI4W120A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
F5800-03042
Cylinder head sub assy
8
F6800-03501
Hinge, injector clamp
2
F5800-03112
Cylinder head
9
F5800-03311
Gasket, cylinder head
3
E6810-13581
Valve guide, intake
10
F6800-03451
Bolt, cylinder head
4
E6810-13561
Valve guide, exhaust
11
F6800-73341
Pipe, coolant return
5
E5900-96021
Plug
12
15221-0175-1
Engine hook
6
15221-0337-3
Plug, expansion
13
01754-50816
Bolt, flange
7
15221-0349-3
Plug, expansion
102
수출향_커먼레일 직분식 엔진(CRDI).indd 102
2014-09-04 오전 9:02:32
CRDI
EXPLODED VIEW
7.4 G040A GEAR CASE 3F183T 19 20 18
14
4 3
2
17
1 11
17
15 13
17 17 16
6
5
3
7 12
3
3 16 16
8 9 10
2
11 N60W308A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
F6800-04101
Assy Case,gear
11
F6800-04731
Plug, Relief Valve
2
01754-50625
Bolt, Flange
12
05712-00410
Key
3
05012-00510
Pin, Dowel
13
F6800-04501
Bush, Pto Shaft
4
E5800-96031
Plug
14
08101-06205
Ball Bearing
5
F6800-04111
Gear Case
15
01754-50816
Bolt, Flange
6
F6800-04301
Cover, Oil Pump
16
01754-50835
Bolt, Flange
7
F6800-04401
Oil Pump Rotor Shaft Assy
17
04811-00150
O Ring
8
F6800-04711
Plunger, Relief Valve
18
04811-00220
O Ring
9
F6800-04721
Spring/relief Valve
19
E5500-33142
Plug, Oil Filler
10
04811-00160
O Ring
20
04811-50300
O Ring
103
수출향_커먼레일 직분식 엔진(CRDI).indd 103
2014-09-04 오전 9:02:32
CRDI
EXPLODED VIEW
3FT-HI4
23
21
24
22 24
20
16
11 10
2
19
1 11
19
17 15
19 19 18
7
2
10
8 12
10
10
13
3 18
18
14
4 5 6
9
HI4W121A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
F6800-04101
Gearcase assy
13
F6800-35661
Gear, oil pump
2
F6800-04111
Gearcase
14
E6300-35681
Nut, flange
3
F6800-04711
Plunger, relief valve
15
F5820-04501
Bush, pto shaft
4
F6800-04721
Spring, relief valve
16
08101-06205
Ball bearing
5
04811-00160
O ring
17
01754-50816
Bolt, flange
6
F6800-04731
Plug, relief valve
18
01754-50835
Bolt, flange
7
F6800-04301
Cover, oil pump
19
04811-00150
O ring
8
F6800-04401
Oil pump rotor shaft assy
20
04811-00220
O ring
9
01754-50625
Bolt, flange
21
E5500-33142
Cap, oil
10
05012-00510
Pin, parallel
22
04811-00150
O ring
11
E5800-96031
Plug
23
F5820-27021
Bracket 2 ,sensor
12
05712-00410
Key
24
01754-50812
Bolt, flange
104
수출향_커먼레일 직분식 엔진(CRDI).indd 104
2014-09-04 오전 9:02:32
CRDI
EXPLODED VIEW
7.5 G050A oil filter 3F183T
7
8
8 6 10
9
9
4 5 2 2 3
1
N60W309A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
E5850-32614
Support, Oil Filter
6
F6800-16161
Hose 1, Oil Cooler
2
04811-00150
O Ring
7
F6800-16171
Hose 2, Oil Cooler
3
01754-50830
Bolt, Flange
8
09318-88180
Clmap, Hose
4
E6810-32292
Tube, Connecting
9
09318-88220
Clmap, Hose
5
E6820-32451
Cooler, Oil
10
E6201-32443
Filter
105
수출향_커먼레일 직분식 엔진(CRDI).indd 105
2014-09-04 오전 9:02:33
CRDI
EXPLODED VIEW
3FT-HI4
7
8
8
7 4
5
2 2
1
3 3 3
HI4W122A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
E5850-32616
Support, oil filter
5
04011-50180
Plane washer
2
04811-00150
O ring
6
F5820-16161
Hose , oil cooler
3
01754-50830
Bolt, flange
7
09318-88180
Clmap
4
15521-3229-1
Connecting tube
8
E6201-32443
Oil filter
106
수출향_커먼레일 직분식 엔진(CRDI).indd 106
2014-09-04 오전 9:02:33
CRDI
EXPLODED VIEW
7.6 G060A crank shaft
14
11 3 15
16
13
9 2
8
4 10 1 12
5 7
6
N60W310A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
F5800-23111
Shaft,crank
9
F6800-23481
Bearing, Crankshaft Upr
2
F5800-06201
Wheel, Crank Position Sensor
10
F6800-23491
Bearing, Crankshaft Lwr
3
03016-50616
Screw
11
F6800-23531
Bearing, Crankshaft Thrust Upr
4
05712-00730
Key
12
F6800-23541
Bearing, Crankshaft Thrust Lwr
5
F6800-24111
Crankshaft Gear
13
F6800-04811
Case,oil Seal
6
F6800-35631
Gear Oil Pump Drive
14
01654-50830
Bolt, Flange With Pin
7
F6800-23251
Spacer
15
E5500-04464
Seal, Oil
8
05712-00720
Key
16
05012-00408
Pin, Parallel
107
수출향_커먼레일 직분식 엔진(CRDI).indd 107
2014-09-04 오전 9:02:33
CRDI
EXPLODED VIEW 7.7 G070A Piston & Connecting rod
10 11
9
12 3
1 2 3 6 8
4
5
~
5 7
8
7 7 N60W311A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
F6800-21111
Piston
7
F6800-22141
Bolt
2
F6800-21311
Pin, Piston
8
F6800-22311
Bearing, Connecting Rod
3
F6800-21331
Ring, Snap
9
E6302-21051
Piston Ring Assy
4
F6800-22011
Connecting Rod
10
E6302-21151
Ring 1, Piston
5
F6800-22111
Connectingrod
11
E6302-21161
Ring 2, Piston
6
F6800-21351
Bush,piston Pin
12
E6301-21202
Oil Ring Assy
108
수출향_커먼레일 직분식 엔진(CRDI).indd 108
2014-09-04 오전 9:02:33
CRDI
EXPLODED VIEW
7.8 G090A cam shaft
5
7
8
~
6
8 4 3
10 2
11
7
9
1
N60W312A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
01754-50612
Bolt, Flange
7
F5800-16151
Camshaft
2
01754-50830
Bolt, Flange
8
06350-00607
Plug
3
05712-00720
Key
9
F6800-09051
Wheel, Camshaft Sensor
4
E5500-15553
Tappet
10
F6800-16271
Stop, Cam Shaft
5
E6300-15113
Rod, Push
11
F6800-16511
Camshaft Gear
6
F5800-16011
Assy Camshaft
109
수출향_커먼레일 직분식 엔진(CRDI).indd 109
2014-09-04 오전 9:02:34
CRDI
EXPLODED VIEW 7.9 G100A idle gear 3F183T
15 5
4 3
12
13 10
14 17
11
16 9 2
7 3
1
8
6
N60W313A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
01133-51018
Bolt, Washer
10
F6800-10301
Idle Gear Assy, 3
2
01133-51090
Bolt
11
F6800-10351
Shaft, Idle Gear 3
3
01754-50822
Bolt, Flange
12
F6800-10401
Idle Gear Assy, 4
4
02176-50140
Nut
13
F6800-10451
Shaft, Idle Gear 4
5
15471-9536-1
Snap Ring
14
F6800-10461
Stopper, Idle Gear 4
6
F6800-10101
Idle Gear Assy, 1
15
F6800-10501
Gear, Hp Fuel Pump
7
F6800-10151
Shaft, Idle Gear 1
16
F6800-10611
Gear, Hydraulic Pump Drive
8
F6800-10161
Stopper, Idle Gear 1
17
01123-50816
Bolt, Washer
9
F6800-10261
Stopper, Idle Gear 2
110
수출향_커먼레일 직분식 엔진(CRDI).indd 110
2014-09-04 오전 9:02:34
CRDI
EXPLODED VIEW
3FT-HI4
20 21 14
5 15
18
17
16
19
9
11
22 10 12 13 4 5
2 3 7
6
1
HI4W123A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
F6800-10101
Idle gear assy, 1
12
F6800-10261
Stopper, idle gear 2
2
F6800-10111
Idle gear, 1
13
01133-51090
Bolt, washer
3
F6800-10121
Bush, idle gear 1
14
F6800-10401
Idle gear assy, 4
4
F6800-10151
Shaft, idle gear 1
15
F6800-10411
Idle gear, 4
5
01123-50825
Bolt, washer
16
F6800-10421
Bush, idle gear 4
6
F6800-10161
Stopper, idle gear 1
17
F6800-10451
Shaft, idle gear 4
7
01133-51018
Bolt, washer
18
F6800-10461
Stopper, idle gear 4
8
F6800-10301
Idle gear assy, 3
19
01123-50816
Bolt, washer
9
F6800-10311
Idle gear, 3
20
F6800-10501
Gear, hp fuel pump
10
F6800-10321
Bush, idle gear 3
21
02176-50140
Nut
11
F6800-10351
Shaft, idle gear 3
111
수출향_커먼레일 직분식 엔진(CRDI).indd 111
2014-09-04 오전 9:02:35
CRDI
EXPLODED VIEW 7.10 G110A Rocker Arm & Valve
14 11 5 12
14
12 12
13
9 8
8
4
15
16
7
1
~
10
16
3 2
17
6
N60W314A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
E5500-13332
Retainer, Valve Spring
10
E5500-14232
Screw, Adjusting
2
E6301-13151
Seal, Valve Stem
11
E5800-14261
Shaft, Rocker Arm
3
E6400-13241
Spring, Valve
12
E6301-14111
Arm, Rocker
4
E6403-13361
Collet,valve Spring
13
E6301-14311
Spring, Rocker Arm
5
E6510-91502
Bolt, Rocker Arm Support
14
E6301-14331
Sealing Cap
6
E6700-13121
Exhaust Valve
15
E6301-14431
Washer, Plain
7
F5800-14001
Assy Arm,rocker
16
F6800-14351
Bracket, Rocker Arm
8
04612-00190
Snap Ring
17
E6700-13111
Valve, Intake
9
15021-1424-1
Nut, Adjusting
112
수출향_커먼레일 직분식 엔진(CRDI).indd 112
2014-09-04 오전 9:02:35
CRDI
EXPLODED VIEW
7.11 G120A Fuel Equipment
15 17
12 1
1
11
10
14 16
9 4 2 5 13
A 6
7
A 3
8
15
N60W315A
14 REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
01754-50830
Bolt, Flange
9
F6800-53452
Clmap, Injector
2
01754-50835
Bolt, Flange
10
F6800-53471
Bolt, Injector Clmap
3
04811-50500
O Ring
11
F6800-53722
Pipe 2, Injection
4
F5800-12203
Fuel Rail Assy
12
F6800-53732
Pipe 3, Injection
5
F5800-42501
Injector Return Tube Assy
13
F6800-12103
Hp Fuel Pump Assy
6
F6800-42511
Connector
14
F5800-12252
Pipe, Rail
7
F6800-53003
Injector Ass’y
15
F6800-53742
Pipe 4, Injection
8
F6800-53181
Seat, Injector
113
수출향_커먼레일 직분식 엔진(CRDI).indd 113
2014-09-04 오전 9:02:35
CRDI
EXPLODED VIEW 7.12 G130A Water flange 3F183T
16 16
14
15 10
11
13
2
8
9
5
1
10
7 7
12 6 4
3
N60W316A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
F6800-72912
Plange, Water
9
F6800-13501
Hose, Coolant Return
2
F6800-72921
Gasket, Cooling Water Flange
10
09318-88180
Clmap, Hose
3
01123-50865
Bolt, Washer
11
F6800-13411
Connector, Coolant
4
F6800-64421
Support, Alternator
12
F6800-13311
Connector, Coolant
5
01513-50822
Stud
13
E5853-73011
Thermostat Assy
6
02763-50080
Flange Nut
14
F5800-73261
Cover,thermostat
7
01754-50822
Bolt, Flange
15
E5500-73272
Gasket
8
E5500-73342
Hose, Cooling Water Return
16
01754-50825
Bolt, Flange
114
수출향_커먼레일 직분식 엔진(CRDI).indd 114
2014-09-04 오전 9:02:36
CRDI
EXPLODED VIEW
3FT-HI4
17 17 15 15 16
13
14
12 11 2
10
8
4
1
5
9
3 7
6
7 10 HI4W124A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
F6820-72913
Flange, coolant
10
09318-88180
Clamp
2
F6800-72921
Gasket, coolant flange
11
F6800-13311
Connector, coolant
3
01123-50890
Bolt, washer
12
E5500-73272
Gasket, thermostat cover
4
F5800-64422
Stay, alternator
13
E6308-73261
Cover, thermostat
5
01513-50822
Stud
14
E5853-73011
Thermostat assy
6
02763-50080
Nut, flange
15
01754-50830
Bolt, flange
7
01754-50822
Bolt, flange
16
F5820-27031
Bracket 3 , sensor
8
E5500-73342
Pipe, coolant return
17
01754-50812
Bolt, flange
9
F6800-13501
Hose, coolant return
115
수출향_커먼레일 직분식 엔진(CRDI).indd 115
2014-09-04 오전 9:02:36
CRDI
EXPLODED VIEW 7.13 G150A CYLINDER HEAD COVER 3F183T
11 13 6 2
4
12
1
8
5 13
~
10
8
9
2 7
3
N60W318A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
F5850-14501
Cylinder Head Cover Assembly
8
E6510-05552
Connector, Air Breather Hose
2
F5850-14511
Cover,cylinder Head
9
E6510-33661
Bolt, Cylinder Head Cover
3
F5800-14521
Gasket, Cylinder Head Cover
10
F6800-15121
Clamp, Hose
4
E6510-14532
Cover, Valve
11
01754-50612
Bolt, Flange
5
E6510-14671
O Ring
12
F5800-05512
Hose, Blow By
6
03024-50510
Screw, Washer
13
09318-88180
Clmap, Hose
7
F5800-14561
Protect Plate Of Oil
116
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CRDI
EXPLODED VIEW
3FT-HI4
13 11 12
6
10
4 5 13 9
2 1
8
8
2 7
3
HI4W125A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
F5850-14501
Cylinder head cover assy
8
E6510-05552
Pipe, air breather
2
F5850-14511
Cover, cylinder head
9
E6510-33661
Bolt, cylinder head cover
3
F5800-14521
Gasket, cylinder head cover
10
F6800-15121
Clamp, hose
4
E6510-14532
Cover, valve
11
01754-50610
Bolt, flange
5
E6510-14671
O ring
12
F5820-05511
Hose, blow by
6
03024-50510
Screw, washer
13
09318-88180
Clmap, hose
7
E6510-14561
Plate, oil protecting
117
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CRDI
EXPLODED VIEW 7.14 G160A Fuel Filter & Pipe 3F183T 9
9 2
FUEL TANK FUEL COOLER
4 7
3
7
~
2
4
8 7
3
10
10
6 5
1
7 6
N60W319A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
F5800-16141
Bracket
6
F6800-16131
Quick Connector
2
F5805-16402
Assy Filter,fuel
7
14911-4275-1
Clip, Tube
3
F6800-16121
Sensor, Fuel Water
8
09661-80300
Hose, Fuel
4
F6800-16411
Filter(Fuel
9
01125-50830
Bolt, Washer
5
09661-80450
Hose, Fuel
10
01123-50816
Bolt, Washer
118
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CRDI
EXPLODED VIEW
3FT-HI4 FUEL COOLER ⤻ᰗ㌳ᬷ
6
7 4 6
B
7
6
8
4
7
1
5
B A
2 FUEL COOLER ⤻ᰗ㌳ᬷ
1 2
7
9
3
5
3
A HI4W126b
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
F5805-16401
Main filter assy
6
F6800-16131
Quick connector
2
F5800-16411
Main fuel filter
7
14911-4275-1
Clip, tube
3
F6800-16121
Sensor, fuel water
8
01125-50830
Bolt, washer
4
09661-80450
Hose, fuel
9
02751-50080
Nut , flange
5
09661-80300
Hose, fuel
119
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2014-09-04 오전 9:02:38
CRDI
EXPLODED VIEW 7.15 G170A INLET MANIFOLD (tier4) 3F183T
17
7
4
17 11
15
13
16 13 12 9 8 10 14
1
5
2 6
4 3 N60W320A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
F5800-11761
Manifold, Intake
10
01513-50835
Stud
1
F5800-11762
Manifold, Intake
11
F6800-17701
Air Control Valve Assy
2
F5800-11821
Gasket, Intake Manifold
12
01023-50645
Bolt, Washer
3
01513-50822
Stud
13
01123-50802
Bolt
4
02763-50080
Flange Nut
13
01123-50803
Bolt, Washer
5
01125-50870
Bolt
14
F5800-17311
Support
6
01754-50830
Bolt, Flange
14
F5800-17313
Support
7
F6800-17201
Flange, Intake Manifold
15
01170-51016
Bolt
7
F6800-17202
Flange, Intake Manifold
16
04011-50100
Washer, Plain
8
F6800-17211
Gasket, Intake Manifold Flange
17
32240-3446-1
Clamp,cord
9
01754-50822
Bolt, Flange
120
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CRDI
EXPLODED VIEW
3FT-HI4
10
7
2
1 5
3
6
5
4
8 9
9
11
HI4W127A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
F5820-11761
Intake manifold
7
F6800-17701
Air control valve assy
2
F5800-11821
Gasket, intake manifold
8
F5820-16141
Bracket , fuel filter
3
01513-50822
Stud
9
01754-50835
Bolt, flange
4
02763-50080
Nut, flange
10
01023-50645
Bolt, washer
5
01125-50870
Bolt, washer
11
01125-50820
Bolt, washer
6
01754-50830
Bolt, flange
121
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CRDI
EXPLODED VIEW 7.16 G175A egr 3F183T
6 5 2 4 3
1
8 CYLINDER HEAD
7 8 CYLINDER BLOCK
h89w315a
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
F6800-17551
이지알하우징가스켓
5
01513-50822
심음볼트
2
F6820-17801
이지알파이프조합
6
02763-50080
플랜지너트
3
01754-50820
플랜지볼트
7
F6803-17561
냉각호스
4
F6800-20301
이지알가스켓
8
09318-88130
호스클램프
122
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CRDI
EXPLODED VIEW
3FT-HI4
2 10 3 4
1
3
9
5 9
8
5
4
7 7
4
4
4
6
6
3
3
7
7
☯⅟ᮨ⤛⑧ FROM CYLINDER BLOCK
TO CYLINDER HEAD ☯㤯ᠧᮧ HI4W128B
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
F5800-17501
EGR valve and housing assy
6
F6800-17561
Hose, cooling
2
F6800-17551
Gasket, EGR housing
7
09318-88130
Band
3
01513-50822
Stud
8
F5820-17801
EGR pipe assy
4
02763-50080
Nut, flange
9
F6800-20301
gasket, EGR
5
01754-50825
Bolt, flange
10
01513-50828
Stud
123
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CRDI
EXPLODED VIEW 7.17 G200A EGR COOLER
8 8 3 6
2
8
9 7 8 2 1
5
4
4
q53w334a
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
F5800-20101
EGR cooler assy
6
01123-50816
Bolt, washer
2
F6800-20301
gasket, EGR
7
F6800-20401
Hose 1, EGR cooler
3
01513-50835
Stud
8
F6800-20501
Hose 2, EGR cooler
4
F6800-91911
U-nut
9
09318-88260
Clamp
5
01123-50822
Bolt, washer
124
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CRDI
EXPLODED VIEW
7.18 G240A Turbo Charger 3F183T 10 10
1
5
9 2 5
1
1
5 10 7
8
3 4 2
6 6
N60W323A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
F6800-92411
Flangebolt
6
F6800-92421
Flangebolt
2
F6800-92441
Bolt, Stud
7
F6800-17111
Gasket 2, Turbocharger
3
F5800-17011
Turbocharger Assy
8
F6800-11951
Flange, Turbocharger
4
F6800-17101
Gasket 1, Turbocharger
9
F6800-25501
Support, Turbocharger Flange
5
F6800-91911
U-nut
10
01123-50822
Bolt
125
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CRDI
EXPLODED VIEW
3FT-HI4 4
4
1
3
3 2
3
3
5
5
HI4W129A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
F5820-17011
Turbocharger assy
4
F6800-91911
U-nut
2
F6800-17101
Gasket 1, turbocharger
5
F6800-92421
Bolt, flange
3
F6800-92441
Stud
126
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CRDI
EXPLODED VIEW
7.19 G245A TURBO PIPE 3F183T 11 12 12
8
14 13 1
3
4 10
4
2
10 9
7
~
6 5
7
6 7
N60W324A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
01202-50625
Bolt, Washer
8
F5800-33041
Oil Feeding Pipe Assy
2
F5800-33051
Oil Drain Pipe Assy
9
E5629-24401
Eye Bolt
3
F6800-33671
Gasket
10
04724-00120
Packing
4
01023-50618
Bolt, Washer
11
E6500-95802
Connector 2
5
E6500-33201
Oil Hose Assy
12
E6301-33661
Gasket
6
E6500-33242
Oil Hose
13
E6520-34011
Clamp 1, Tube
7
E6500-33251
Clip
14
E6520-34021
Clamp 2, Tube
127
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CRDI
EXPLODED VIEW
3FT-HI4 10 11
11
7 13 12 14 9
2
9
8 1
3 3
5 4
6 5
5
6 HI4W130A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
F5820-33051
Oil drain pipe assy
8
E5629-24401
Bolt, eye
2
F6800-33671
Gasket 3, turbocharger
9
04724-00120
Gasket, copper
3
01023-50618
Bolt, washer
10
E6500-95802
Bolt, eye
4
E6500-33201
Oil hose assy
11
E6301-33661
Gasket, copper
5
E6500-33251
Clip
12
E6520-34011
Clamp 1, pipe
6
E6500-33242
Hose, oil
13
E6520-34021
Clamp 2, pipe
7
F5820-33041
Oil feeding pipe assy
14
01202-50625
Bolt, washer
128
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CRDI
EXPLODED VIEW
7.20 G250A After treatment (tier4) 3F183T 9 9
11 2
3
1
10
10
8 5
6 4
7
N60W325A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
F5800-25101
CCRT Assy
7
01123-50822
Bolt
2
F6800-26661
Tube, 1
8
F6800-12371
Gasket, Turbocharger Flange
3
F6800-26671
Tube, 2
9
F6800-92411
Flangebolt
4
01774-51030
Flange Bolt
10
F6800-92431
Bolt, Stud
5
02783-50100
Flange Nut
11
F6800-91911
U-nut
6
F5800-25421
Braket
129
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CRDI
EXPLODED VIEW
3FT-HI4
5
3
6
2
1
4
7
8
8
7
HI4W131A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
F5820-25101
CCRT assy
5
F6800-26651
Sensor, DPF differential pressure
2
F6800-26661
Tube, 1
6
H5800-26501
Sensor, exhaust gas temperature
3
F6800-26671
Tube, 2
7
F6800-92411
Bolt, flange
4
F6800-17111
Gasket 2, turbocharger
8
F6800-91911
U-nut
130
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2014-09-04 오전 9:02:42
CRDI
EXPLODED VIEW
7.21 G260A ECU & SENSOR
1
2
2
2
2
U89W3S6A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
F6800-26101
Controller ,engine
2
01754-50625
Bolt, flange
131
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2014-09-04 오전 9:02:43
CRDI
EXPLODED VIEW 7.22 G270A ELECTRIC PART (1) 3F183T
2 3
1
q53w337a
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
E6700-65511
Glow plug
3
02761-50040
Nut, flange
2
F6800-65561
Cord, glow plug
132
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CRDI
EXPLODED VIEW
3FT-HI4
HI4W132A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
E6700-65511
Glow plug
10
F6800-26501
Sensor, exhaust gas temperature
2
F5800-65561
Cord, glow plug
11
F6800-26701
Sensor, intake air pressure
3
02761-50040
Nut, flange
12
F6800-26751
Sensor, intake air temperature
4
F6800-26201
Sensor, camshaft wheel
13
E7240-32731
Sensor, coolant temperature
5
01754-50616
Bolt, flange
14
E5500-39013
Switch, oil pressure
6
F6800-26301
Sensor, crankshaft wheel
15
37150-3447-1
Clamp, cord
7
01754-50610
Bolt, flange
16
01754-50812
Bolt, flange
8
F6800-26401
Sensor, accelerometer
17
T5525-69311
Injector connection wire haness assy
9
01754-50830
Bolt, flange
133
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CRDI
EXPLODED VIEW 7.23 G280A ELECTRIC PART (2) 3F183T
6 6
2
2
5
4 3
8
5 10 9
12
11 13
7
1
2
h89W316A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
F6800-26201
Sensor, camshaft wheel
8
F6800-26701
Sensor, intake air pressure
2
01754-50616
Bolt, flange
9
F6800-26751
Sensor, intake air temperature
3
F6800-26301
Sensor, crankshaft wheel
10
E7240-32731
Temperature sensor assy
4
01754-50610
Flange bolt
11
E5500-39013
Oil rressure switch
5
F6800-26401
Sensor, knock
12
E5900-96021
Plug
6
01754-50830
Bolt, flange
13
F6800-26801
Sensor, exhaust pressure temp.
7
F6800-26501
Sensor, exhaust gas temp.
134
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CRDI
EXPLODED VIEW
3FT-HI4
HI4W133A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
18
E7250-64013
Alternator
25
E6850-63011
Gasket, start motor
19
01153-50804
Bolt
26
E7103-04621
Nut, flange
20
F6800-64101
Washer, plain
27
02763-50080
Bolt, washer
21
04013-50080
Washer, spring
28
01133-51028
Bolt, washer
22
04512-50080
Nut
29
02783-50100
Sensor, air mass flow
23
02156-50080
Bolt, washer
30
F6800-26801
MAF sensor
24
01127-50825
Start motor assy
135
수출향_커먼레일 직분식 엔진(CRDI).indd 135
2014-09-04 오전 9:02:44
CRDI
EXPLODED VIEW 7.24 T0580A ELECTRIC PART (3) (TIER4 model)
14 12
13
4
6
5
3
7
10
1 8
2 11
9 h89W3v6A
REF. NO.
PART. NO.
DESCRIPTION
REF. NO.
PART. NO.
DESCRIPTION
1
E7250-64013
ALternator assy, 75A
8
E7103-04621
Gasket
2
01153-50802
Bolt
9
02763-50080
Flange nut
3
F6800-64101
Bushing
10
01133-51090
Bolt
4
04512-50080
Washer, spring
11
02783-50100
Flange nut
5
02156-50080
Nut
12
F6800-26801
MAF sensor
6
01127-50825
Bolt
13
F6800-26502
Thermocouple K type sensor
7
E6850-63011
Start motor assy
14
F6800-26651
Sensor, DPF differential pressure
136
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CRDI
DISASSEMBLY, SERVICE AND ASSEMBLY
8. dISASSEMBLY, SERvICE ANd ASSEMBLY 8.1 Engine component removal 3F183T 4. Remove sensors as necessary.
U89W3A6A
1. Unscrew the cooling fan mounting bolts (1) to remove the cooling fan, fan collar, fan pulley and fan belt together.
U89W3B1A
•
Coolant temperature sensor
U89W3A7A
2. Remove the alternator (1).
U89W3B4A
•
Crankshaft wheel sensor
Q53W3A1A
3. Disconnect the fuel hose (1) of the fuel filter and remove the fuel filter (2).
U89W3B5A
•
Acceleration sensor (knock sensor)
137
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DISASSEMBLY, SERVICE AND ASSEMBLY
U89W3B6A
•
Fuel (common) rail pressure sensor
U89W3C0A
•
Camshaft wheel sensor
U89W3B7A
•
Engine oil pressure sensor
U89W3C1A
5. Disconnect the EGR pipe (1) on the intake manifold side.
U89W3B9A
•
Exhaust gas temperature sensor
CRDI
U89W3C2A
6. Remove the EGR valve assembly (1).
138
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CRDI
DISASSEMBLY, SERVICE AND ASSEMBLY
U89W3C3A
7. Undo the band (1) and disconnect the intake hose (2) from the turbocharger.
U89W3C7A
10. Disconnect the turbocharger oil supply pipe (1) and drain pipe (2).
U89W3C5A
8. Remove the intake manifold flange (1).
U89W3C8A
11. Remove the turbocharger flange (1).
U89W3C6A
9. Disconnect injector solenoid connector (1).
U89W3C9A
12. Remove the turbocharger assembly (1)..
CAUTION • When connecting the injector solenoid connector, make sure to connect it to the correct position.
139
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DISASSEMBLY, SERVICE AND ASSEMBLY
U89W3D0A
13. Disconnect the EGR cooler hoses 1 (1) and 2 (2).
CRDI
U89W3D3b
16. Disconnect the fuel rail pipe (1) and injection pipes 1, 2 & 3 (2, 3 & 4). Pipe mounting nut tightening torque ............…..…. 27.4 ± 31.4 Nm ..................................................... 2.8 ± 3.2 kgf.m 20.2 ± 23.0 lb.ft
U89W3D1A
14. Remove the EGR cooler assembly (1).
U89W3D4A
17. Unscrew the fuel rail mounting bolts (1) to remove the fuel rail assembly (2). Mounting bolt tightening torque ............…..…. 23.5 ± 27.4 Nm ..................................................... 2.4 ± 2.8 kgf.m 17.3 ± 20.2 lb.ft
CAUTION U89W3D2A
15. Remove the shield plate (1) on the exhaust manifold side.
• When it is necessary to replace the fuel rail pressure sensor, the whole fuel rail assembly should be replaced.
140
수출향_커먼레일 직분식 엔진(CRDI).indd 140
2014-09-04 오전 9:03:02
CRDI
DISASSEMBLY, SERVICE AND ASSEMBLY
U89W3D5A
18. Unscrew the intake manifold mounting bolts (1) to remove the intake manifold (2).
U89W3D8A
20. Disconnect the oil cooler connecting hose (1) and remove the oil cooler (2) with the oil filter.
U89W3D6A
19. Remove the injector return tube assembly (1).
REMARK
U89W3D9A
21. Disconnect the coolant return hose (1) and remove the water pump pipe (2) and water pump assembly (3).
CAUTION • If foreign materials are introduced into the fuel system in the direct injection type engine, major defect can occur between the high-pressure fuel pump and injector. When replacing or servicing any fuel connecting pipe or fuel system part, seal it to prevent introduction of any foreign material. • Replace the fuel pipes between the high-pressure fuel pump, fuel rail and injectors with new ones during reassembly. U89W3D7A
• Disconnect the return tube connector by pulling out its protrusion (A) forward. When connecting it, pull it forward, insert it to the hole and then slide in the connector.
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DISASSEMBLY, SERVICE AND ASSEMBLY
CRDI
3FT-HI4 4. Remove sensors as necessary.
HI4W143A
1. Unscrew the cooling fan mounting bolts (1) to remove the cooling fan.
HI4W146A
•
Coolant temperature sensor
HI4W144A
2. Remove the fan belt (1), alternator (2) and start motor (3).
HI4W147A
•
Crankshaft wheel sensor
HI4W145A
3. Disconnect the fuel hose of the fuel filter and remove the fuel filter (1).
HI4W148A
•
Acceleration sensor (knock sensor)
142
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CRDI
DISASSEMBLY, SERVICE AND ASSEMBLY
HI4W149A
•
Fuel (common) rail pressure sensor
HI4W152A
•
Camshaft wheel sensor
HI4W150A
•
HI4W153A
5. Disconnect the EGR pipe (1) on the intake manifold side.
Engine oil pressure sensor
HI4W151A
•
Exhaust gas temperature sensor
HI4W154A
6. Remove the EGR valve assembly (1).
143
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DISASSEMBLY, SERVICE AND ASSEMBLY
HI4W155A
7. Undo the band (1) and disconnect the intake hose (2) from the turbocharger.
HI4W158A
10. Disconnect the turbocharger oil supply pipe (1).
HI4W156A
8. Remove the ACV valve (1).
CRDI
HI4W159A
11. Remove the air cleaner intake pipe (1).
HI4W157A
9. Disconnect injector solenoid connector.
CAUTION
HI4W160A
12. Remove the oil drain pipe and turbocharger assembly (2).
• When connecting the injector solenoid connector, make sure to connect it to the correct position.
144
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CRDI
DISASSEMBLY, SERVICE AND ASSEMBLY
HI4W161A
13. Disconnect the EGR cooler hoses 1 (1), 2 (2) and EGR cooler assembly (3).
HI4W164A
16. Unscrew the fuel rail mounting bolts (1) to remove the fuel rail assembly (2). Mounting bolt tightening torque ............…..…. 23.5 ± 27.4 Nm ..................................................... 2.4 ± 2.8 kgf.m 17.3 ± 20.2 lb.ft
CAUTION • When it is necessary to replace the fuel rail pressure sensor, the whole fuel rail assembly should be replaced.
HI4W162A
14. Remove the shield plate (1) on the exhaust manifold side.
HI4W165A
17. Unscrew the intake manifold mounting bolts (1) to remove the intake manifold (2).
HI4W163A
15. Disconnect the fuel rail pipe (1) and injection pipes 1, 2, 3 & 4 (2, 3, 4 & 5). Pipe mounting nut tightening torque ............…..…. 27.4 ± 31.4 Nm ..................................................... 2.8 ± 3.2 kgf.m 20.2 ± 23.0 lb.ft
145
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DISASSEMBLY, SERVICE AND ASSEMBLY
HI4W166A
18. Remove the injector return tube assembly (1).
REMARK
CRDI
HI4W168A
20. Disconnect the coolant return hose (1) and remove the water pump pipe (2) and water pump assembly (3).
CAUTION
U89W3D7A
• Disconnect the return tube connector by pulling out its protrusion (A) forward. When connecting it, pull it forward, insert it to the hole and then slide in the connector.
HI4W169A
HI4W170A
• If foreign materials are introduced into the fuel system in the direct injection type engine, major defect can occur between the high-pressure fuel pump and injector. When replacing or servicing any fuel connecting pipe or fuel system part, seal it to prevent introduction of any foreign material. HI4W167A
19. Remove the fan pulley (1) and disconnect the coolant hose (2) to remove the oil filter (3).
• Replace the fuel pipes between the high-pressure fuel pump, fuel rail and injectors with new ones during reassembly.
146
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CRDI
DISASSEMBLY, SERVICE AND ASSEMBLY
8.2 Engine disassembly 8.3.1 HEAD COVER removal
INSTALLATION
U89W3E0A
U89W3E2A
1. Make sure that the head cover gasket is well seated on the groove of the cylinder head cover. 2. When installing the head cover, keep the specified tightening torque and tighten the bolts (2) gradually into 3 ~ 4 steps.
2
3. Ensure that the cylinder head cover gasket (1) is not defective. 1
3
Cylinder head cover bolt (M8) tightening torque....................... 8.8 ~ 11.8 Nm 0.9 ~ 1.2 kgf-m 6.5 ~ 8.7 lb-ft
4
Q53W3A3A
1. Remove the cylinder head cover bolts (1). 2. Remove the head cover (2) and gasket (3). 3. Remove the oil baffle plate (4) if necessary.
147
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DISASSEMBLY, SERVICE AND ASSEMBLY
CRDI
8.3.2 GLOW PLUG AND INJECTOR
U89W3E3A
(1) Glow plug
U89W3E5A
(2) Injector
U89W3E6A U89W3E4A
1. Screw out the glow plug (1) from the intake side of the cylinder head. Glow plug tightening torque....................... 19.6 ± 24.5 Nm 2 ± 2.5 kgf-m 14.4 ± 18.0 lb-ft
2. Unscrew the clamp mounting bolt (1) to remove the clamp (2) and injector (3). Mounting bolt tightening torque .......... 27.4 ± 31.4 Nm 2.8 ± 3.2 kgf-m 20.2 ± 23.0 lb-ft
CAUTION • When the injector is removed, it should be installed to the original position afterwards. When replacing the injector with a new one, connect the scan tool to the ECU and enter the injector code to the scan tool. (Refer to the instructions for injector code management in the Section 3.4.7.)
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CRDI
DISASSEMBLY, SERVICE AND ASSEMBLY
8.3.3 Rocker arm assembly
5 4
3
2
Q53W3A4A
(1) Rocker arm shaft (2) Rocker arm
(3) Rocker arm support (4) Rocker arm support bolt
removal
INSTALLATION
Push rod 㟃☧#ᮧᠧ
Tappet 㐧㢚
U89W3E7A
1. Remove the rocker arm mounting bolts (4) by loosening them in several steps.
T46W281A
1. Make sure that the push rod is seated on the concaved area of the tappet.
2. Remove the rocker arm assembly and the push rod.
149
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CRDI
DISASSEMBLY, SERVICE AND ASSEMBLY
rocker arm assembly check
Installation order 9
10
11
A86W327C
T46W282A
2. Tighten the rocker arm support bolts to the specified torque in several steps with the specified sequence as shown in the figure.
1. Measure the rocker arm I.D. with an inside micrometer.
3. Adjust the valve clearance after assembling the rocker arm assembly.
3. If the clearance exceeds the allowable limit, replace the rocker arm.
2. Measure the rocker arm shaft O.D. with an outside micrometer.
4. If the clearance still exceeds the allowable limit after replacing the rocker arm, replace the rocker arm shaft.
Important Bolt
Clearance Rocker arm shaft T46W2J0A
• To tighten the rocker arm support bolt, the groove on the rocker arm shaft should face the bolt.
Specified size Allowable limit
Rocker arm shaft O.D.
Specified size
Rocker arm I.D.
Specified size
0.020 ~ 0.070 mm (0.00079 ~ 0.00276 in.) 0.15 mm (0.0059 in.) 18.955 ~ 18.980 mm (0.74626 ~ 0.74724 in.) 19.000 ~ 19.025 mm (0.74803 ~ 0.74902 in.)
Rocker arm mounting bolt (M10)................................. 60.8 ~ 73.5 Nm 6.2 ~ 7.2 kgf-m 44.8 ~ 54.2 lb-ft
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CRDI
DISASSEMBLY, SERVICE AND ASSEMBLY
8.3.4 cylinder head Cylinder head removal Important
cylinder head bolt tightening method
U89W3E8A
Flywheel side
Cooling fan side
U89W3F0A
UUVW261c
(1) Cylinder head
(2) Coolant flange
1. Loosen the head bolts in the reverse sequence as shown in the figure. (Follow the sequence in the figure when tightening them.) 2. Lift it slightly with a hoist by using the hook. 3. Remove the coolant flange (2) if necessary. 4. Remove the tappets from the cylinder block.
CAUTION • Mark the cylinder number to the tappets to prevent them from interchanging.
REMARK
U89W3F1A
• Add a little engine oil to the thread and bottom face of bolt head. • Tighten the head bolt to 4 kgf-m in accordance with head bolt tightening order. • Tighten every bolts 90° with angle torque wrench in accordance with tightening order. • Tighten bolts 70° more in accordance with tightening order. • Do not re-use old head bolts.
REMARK • A, B seires engine: 4 kgf-m + 90° + 80° • F seires engine : 4 kgf-m + 90° + 70°
• Before installing the tappets, apply engine oil around them. • Always replace the head gasket with a new one. Pay particular attention to its direction and orientation.
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DISASSEMBLY, SERVICE AND ASSEMBLY
cylinder head installation
CRDI
Cylinder head surface flatness check
1. Apply the liquid gasket (Three bond 1215 or equivalent) on both sides of coolant flange gasket. 2. Always replace the head gasket with a new one. Pay particular attention to its direction and orientation. 3. Remove any gasket residue out of mating surfaces of the cylinder head and cylinder block before installing the new cylinder head gasket. Be careful not to get the residue enter into the block or the head. (Use a vacuum cleaner to clean the residue.) 4. Before installing the tappets, apply engine oil around them.
T46W285A
1. Thoroughly clean the cylinder head surface.
Important • Check the torque after 30 minutes operation of the assembled engine, and adjust valve clearance. • Tightening torgue and angle.
1st Round
2nd Round
3rd Round
4 kgf-m
90°
70°
2. Place a straight edge on the cylinder head and measure the clearance with a feeler gage as shown in the figure. 3. If the measured value exceeds the allowable limit, replace the cylinder head.
Important • Do not place the straight edge on the combustion chamber.
Allowable limit................. 0.05 mm 0.0019 in.
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CRDI
DISASSEMBLY, SERVICE AND ASSEMBLY
8.3.5 intake and exhaust valves valve Removal
Valve recess check
3 1 2 4
5 T46W286A
(1) Valve (2) Collet (3) Retainer
(4) Valve spring (5) Valve stem seal
1. Compress the valve spring with the replacer and remove the collet (2). 2. Remove the retainer (3), valve spring (4), valve stem seal (5) and the valve (1).
Important • Be careful not to interchange the valves and related components.
S76W270A
1. Clean the cylinder head, the valve face and the valve seat. 2. Insert the valve into the valve guide. 3. Measure the valve recess with a depth gauge. 4. If the recess value exceeds the allowable limit, replace the valve and check the valve seat.
Valve recess
0.2 ~ 0.5 mm
Specified value
0.0078 ~ 0.0197 in.
Allowable limit
0.0315 in.
0.8 mm
• Mark the cylinder number on the valve and the parts to prevent interchanging.
valve Installation 1. Apply oil to the stem of valve and install it into the cylinder head. 2. Lubricate the valve and its related parts after installation.
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DISASSEMBLY, SERVICE AND ASSEMBLY
Valve seat check
CRDI
Valve spring check
T46W288A
1. Coat the valve face lightly with red lead and put the valve on its seat to check the contact. 2. If the valve does not seat all the way around the valve seat or the valve contact is less than 70%, correct the valve seating as follows. 3. Apply compound on the valve face evenly. 4. Put the valve on its seat and hold it with the valve flapper. 5. Turn the valve back and forth on the valve seat to lap. 6. Remove the compound and clean the valve and the seat. 7. Apply oil on the valve face and finish to complete fitting. 8. Repeat lapping until the valve seats correctly.
T46W289A
1. Measure the free length of the spring with vernier calipers. 2. Place the spring on a spring compression tester and compress to the specified length to measure the tension. 3. If the measured value is less than the allowable limit, replace the valve spring. Specified value
117 N / 35.15 mm 12.0 kgf / 35.15 mm 26.5 lbs / 1.3839 in.
Allowable limit
100 N / 35.15 mm 10.2 kgf / 35.15 mm 22.5 lbs / 1.3839 in.
Specified value
41.7 ~ 42.2 mm 1.6417 ~ 1.6614 in.
Allowable limit
41.2 mm 1.622 in
Tension
Free length
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CRDI
DISASSEMBLY, SERVICE AND ASSEMBLY 8.3.6 HIGH PRESSURE FUEL pump
Valve spring squareness (Tilt)
pump Removal 3F183T
T46W290A
1. Place the spring on the flat plate and then put a square at its side. 2. Measure the maximum distance "A" while rotating the spring.
U89W3F3A
3FT-HI4
3. If the measurement exceeds the allowable limit, replace the spring. Valve spring squareness
Allowable limit
1.0 mm 0.039 in.
HI4W171A
1. Disconnect the high-pressure pipe (1) and injector return hose (2) between the high-pressure fuel pump and fuel rail. Pipe-pressure nut tightening torque ............…..…. 24.5 ± 29.4 Nm 2.5 ± 3.0 kgf.m 18.0 ± 21.6 lb.ft
155
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DISASSEMBLY, SERVICE AND ASSEMBLY
CRDI
3F183T
U89W3F6A
U89W3F4A
3FT-HI4
U89W3F7A HI4W172A
2. Remove the cover (3) of the gear case on the highpressure fuel pump gear side.
4. Unscrew the high-pressure fuel pump mounting bolts (5) to remove the high-pressure fuel pump assembly. Mounting nut tightening torque............. 23.5 ± 27.4 Nm 2.4 ± 2.8 kgf-m 17.3 ± 20.2 lb-ft
U89W3F5A
3. Remove the high-pressure fuel pump gear (4) from the gear case. Mounting nut tightening torque......................... 68.6 ~ 78.4 Nm 7 ~ 8 kgf-m 50.4 ` 57.6 lb-ft
156
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CRDI
DISASSEMBLY, SERVICE AND ASSEMBLY
8.3.7 Gear case removal: 3F183T
U89W3F8A
U89W3G1A
4. Unscrew the gear case cover mounting bolts (7) to remove the gear case cover (8). Mounting bolt tightening torque............. 23.5 ~ 27.4 Nm 2.4 ~ 2.8 kgf-m 17.3 ~ 20.2 lb-ft
REMARK
U89W3F9A
1. Disconnect the engine oil cooler connecting hose (1) and remove the oil cooler assembly (2) with the oil filter. 2. Disconnect the coolant return hose (3) as well as the water pump pipe (4).
U89W3G2A
• Depending on the type of work, it is okay to unscrew the water pump case mounting bolts (1) and remove the water pump assembly (2) before removing the gear case cover.
U89W3G0A
3. Unscrew the crankshaft mounting bolt (5) to remove the fan drive pulley (6). Crankshaft bolt tightening torque............. 320.5 ~ 343.0 Nm 32.7 ~ 35.0 kgf-m 235.4 ~ 252.0 lb-ft
157
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DISASSEMBLY, SERVICE AND ASSEMBLY
CRDI
3FT-HI4
HI4W167A
1. Remove the fan pulley (1), coolant hose (2) and engine oil filter (3).
HI4W175A
4. Unscrew the gear case cover mounting bolts (9) to remove the gear case cover (10).
INSTALLATION
HI4W173A
2. Disconnect the coolant return hose (4) and remoce the water pump pipe (5) and water pump assembly (6).
U89W3G3A
1. Apply the grease to the crankshaft oil seal (1) lip on the gear case cover and take care not to damage it when installing. 2. Make sure that the gear case cover mounting bolts are installed at correct locations.
Important • In general, the bolt should be screwed as 1.5 times as the diameter of the bolt in length.
3. Install all bolts and increase the tightening torque gradually (in 2 to 3 steps). HI4W174A
3. Unscrew the crank shaft mounting bolt (7) to remove the fan drive pulley (8).
M8 tightening torque....... 23.5 ~ 27.4 Nm 2.4 ~ 2.8 kgf-m 17.3 ~ 20.2 lb-ft
158
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CRDI
DISASSEMBLY, SERVICE AND ASSEMBLY
8.3.8 Gears in gear case removal REMARK • The crankshaft gear (3) should be removed with a special puller when necessary. When installing the crankshaft gear, heat it to approx. 80℃ (176℉) and insert it into the crankshaft.
U89W3G4A
1. Pull out the crankshaft key (1) and remove the spacer (2) and oil pump drive gear (3).
REMARK U89W3G7A
3. Unscrew the oil pump cover mounting bolts (1) to remove the oil pump cover (2) and oil pump rotor shaft (3) together.
U89W3G5A
• When installing the oil pump drive gear, have its boss set toward the inside.
U89W3G8A
4. Unscrew the camshaft sensor wheel mounting bolts (1) to remove the camshaft sensor wheel (2).
U89W3G6A
2. Unscrew the oil pump gear mounting nut (1) to remove the oil pump gear (2).
159
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DISASSEMBLY, SERVICE AND ASSEMBLY
CRDI
Important
Alignment of gears in gear case
U89W3G9A
U89W3H1A
(1) Crankshaft gear (2) Idle gear 1 (3) Camshaft gear (4) Idle gear 3
(5) Idle gear 4 (6) High-pressure fuel pump gear
• There is a mark on a tooth of each gear in the gear case for alignment. If these marks are not aligned during gear installation, the engine can malfunction. Make sure to align all marks on the gears as illustrated when installing the idle gear.
U89W3H0A
5. Unscrew the idle gear 1 mounting bolts (1) to remove the stopper (2) and idle gear assembly 1 (3) in order.
160
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CRDI
DISASSEMBLY, SERVICE AND ASSEMBLY
U89W3H2A
U89W3H4A
U89W3H3A
U89W3H5A
6. Unscrew the camshaft stopper mounting bolts (1) to remove the camshaft gear (2) and camshaft (3) together.
7. Unscrew the idle gear 3 stopper mounting bolt (1) to remove the idle gear 3 (2) and idle gear 3 shaft (3).
REMARK • When necessary, remove the camshaft gear (2) with a special puller. When installing it, heat it to approx. 80℃ (176℉) and insert it into the crankshaft.
161
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DISASSEMBLY, SERVICE AND ASSEMBLY
CRDI
U89W3H6A
U89W3H8A
U89W3H7A
U89W3H9A
8. Unscrew the idle gear 4 stopper mounting bolt (1) to remove the idle gear 4 (2) and idle gear 4 shaft (3).
U89W3I0A
9. Unscrew the high-pressure fuel pump gear mounting nut (1) and remove the high-pressure fuel pump gear (2) with a special puller.
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CRDI
DISASSEMBLY, SERVICE AND ASSEMBLY 3F183T
U89W3I1A
U89W3I3A
3F183T
U89W3I2A
10. Unscrew the high-pressure fuel pump mounting bolts (1) to remove the high-pressure fuel pump assembly (2).
U89W3I4A
11. Pull out the hydraulic pump drive gear mounting snap ring (1) to remove the hydraulic pump drive gear (2).
U89W3I5A
12. Remove the idle gear 1 shaft (1).
163
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DISASSEMBLY, SERVICE AND ASSEMBLY
CRDI
REMARK
U89W3I6A
U89W3I9A
• Apply liquid gasket (LOCTITE #5902, #5900 or equivalent) to the mating surface of the gear case on the cylinder block side before installing the gear case. • Make sure that the O-ring is installed (sections with dotted circles) before installing the gear case. If any faulty O-ring is detected, install a new one and apply a proper amount of gear or engine oil on it.
U89W3I7A
13. Unscrew the gear case mounting bolts (1) (14 EA) to remove the gear case assembly (2).
U89W3I8A
14. If necessary, remove the relief valve.
164
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CRDI
DISASSEMBLY, SERVICE AND ASSEMBLY
crank gears and shafts check ▶ IDLE gear & cam shaft gear backlash
▶ Idle gear side clearance 1. Install the dial gauge to be in contact with the gear surface. Then, measure the clearance while pushing and pulling the gear. (Refer to the measurement method of the valve camshaft gear side clearance below.) 2. If the clearance exceeds the allowable limit, replace the idle gear. Side clearance
Specified value
0.20 ~ 0.51 mm 0.0079 ~ 0.0201 in.
Allowable limit
0.9 mm 0.0035 in.
U89W3J0A
▶ Valve camshaft gear side clearance
U89W3J1A
1. Set a dial indicator (lever type) with its tip on the gear tooth. 2. Move the idle gear and camshaft gear to measure its backlash while holding the engaged gear to it. 3. If the backlash exceeds the allowable limit, check the oil clearance of the shafts and the gear. (See next page) 4. If the oil clearance is OK but the backlash is over the allowable limit, replace the gear. Specified value
0.04 ~ 0.11mm 0.0016 ~ 0.0043 in.
Allowable limit
0.15 mm 0.0059 in.
Backlash
U89W3J2A
1. Install the dial gauge so that its sensor tip is in contact with the camshaft gear surface slightly. 2. Pull the camshaft gear to measure the side clearance. 3. If the clearance exceeds the allowable limit, replace the camshaft stopper. Side clearance
Specified value
0.07 ~ 0.22 mm 0.0028 ~ 0.0087 in.
Allowable limit
0.3 mm 0.0118 in.
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DISASSEMBLY, SERVICE AND ASSEMBLY ▶ Idle gear oil clearance measurement
CRDI
▶ Valve camshaft oil clearance measurement
9
10
11
U89W3J3A
T46W2B6A
1. Measure the idle gear shaft O.D. with an outside micrometer.
1. Measure the I.D. of the camshaft bore on the crankcase with an inside micrometer.
2. Measure the idle gear bushings I.D. with an inside micrometer.
2. Measure the O.D. of the camshaft journal with an outside micrometer.
3. If the clearance exceeds the allowable limit, replace the bushing.
3. If the clearance exceeds the allowable limit, replace the shaft.
Specified value
0.025 ~ 0.066 mm 0.00098 ~ 0.00259 in.
Allowable limit
0.1 mm 0.004 in.
Shaft O.D.
Specified value
42.959 ~ 42.975 mm 1.69130 ~ 1.69193 in.
Bushing I.D.
Specified value
43.000 ~ 43.025 mm 1.69291 ~ 1.69390 in.
Oil clearance
Specified value
0.050 ~ 0.091 mm 0.00197 ~ 0.00358 in.
Allowable limit
0.15 mm 0.0059 in.
Journal O.D.
Specified value
39.934 ~ 39.950 mm 1.57221 ~ 1.57284 in.
Bore I.D.
Specified value
40.000 ~ 40.025 mm 1.57480 ~ 1.57579 in.
Oil clearance
▶ idle gear bushing replacement
U89W3J4A
1. Press out the bushing using replacing tool. 2. Clean the bore, and apply the oil on it. 3. Press in the new bushing using the replacing tool.
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CRDI
DISASSEMBLY, SERVICE AND ASSEMBLY
▶ valve Camshaft deflection check
▶ valve Cam height measurement
U89W3J5A
1. Place the camshaft on V blocks with its journals supported and set a dial indicator with its tip on the intermediate journal. 2. Measure the eccentricity (half of the measured value) while turning the camshaft on the V blocks.
U89W3J6A
1. Measure the height of the camshaft lobe at largest O.D. with an outside micrometer. 2. If the measured value is below the allowable limit, replace the camshaft.
3. If the eccentricity exceeds the allowable limit, replace the camshaft. Eccentricity
Allowable limit
0.05 mm 0.002 in.
Specification
33.59 mm 1.322 in.
Allowable limit
33.54 mm 1.320 in.
Specification
33.69 mm 1.326 in.
Allowable limit
33.64 mm 1.324 in.
IN. Cam height EX.
167
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DISASSEMBLY, SERVICE AND ASSEMBLY
CRDI
8.3.9 piston and connecting rod removal
U89W3J7A
1. With the engine block body supported, unscrew the oil pan mounting bolts (1) (26 EA) and remove the oil pan (2).
U89W3J8A
2. Remove the oil strainer assembly (1).
CAUTION • When installing the oil strainer to the cylinder block, make sure to check the O-ring (2) on the mounting section.
U89W3J9A
3. Turn the crankshaft (1) to set the connecting rod cap to the lower side. Then, unscrew the connecting rod bolts (2) of each cylinder to remove the connecting rod cap (3).
U89W3K0A
4. Turn the crankshaft again to set the piston to the top of the engine block. Then, tap the connecting rod with a rubber hammer to remove the piston out of the cylinder block.
168
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CRDI
DISASSEMBLY, SERVICE AND ASSEMBLY
INSTALLATION Important • When removing the pistons, mark their installing positions by each cylinder so that they can be installed to their original positions later.
Top ring 톱링 end 엔드gap 갭
Exhaust side 배기 manifold 매니폴드측
Side 각인측 mark
2차 ring 링 2nd end 엔드gap 갭
HP고압연료 fuel pump side 펌프측
표시(Y Mark (Y또는 or R)R)
Oil ring 오일 링 end gap 엔드 갭
U89W3K3A
1
U89W3K1A
• When installing the piston and connecting rod, the combustion chamber groove of the piston head and the mark on the connecting rod should be set symmetrically. • When installing the piston and connecting rod assembly to the cylinder block, set the mark on the connecting rod toward the high-pressure pump.
2
3
T46W2C4A
1. Clean all the parts before installation. 1 2
2. Warm up the piston by soaking it in hot oil (approx. 80 °C) for 10 to 15 minutes before inserting the piston pin into the piston. 3. With the casting marks on the connecting rods aligned vertically, set them toward the high-pressure pump and install the piston and connecting rod so that they are 180 degrees away from the combustion chamber groove on the piston head.
1
U89W3K2A
5. Remove the piston rings with a piston ring replacing tool. 6. Remove the piston pin snap ring (1) and then remove the piston pin (2).
4. The manufacturer mark (Y or R) (3) on the top ring should face the top of the piston. 5. The cutout of expander (1) should face the opposite side of the oil ring (2) end gap. 6. The top ring end gap ring should be on the opposite side of the combustion chamber on piston. 7. The 2nd ring end gap and the oil ring end gap should be 120° far from the top ring end gap.
169
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DISASSEMBLY, SERVICE AND ASSEMBLY
CRDI
piston and connecting rod check ▶ Piston pin bore
Undercut ⥯⫇#㦓
T46W2C5A
(1) Top ring
(2) 2nd ring
(3) Ring
8. Make sure that the undercut of the 2nd ring faces downward. 9. Apply the oil on the crankpin bearing, cylinder wall and connecting rod cap screw.
T46W2C7A
1. Measure the I.D. of piston pin bore (lengthwise and widthwise of the piston) with a cylinder gauge. 2. If the measured value exceeds the allowable limit, replace the piston.
U89W3K4A
1
Piston pin bore I.D.
Specified value
25.000 ~ 25.006 mm (0.9843 ~ 0.9845 in.)
Allowable limit
25.03 mm (0.9854 in.)
U89W3K5A
10. Insert the connecting rod and piston assembly with the stamped number (1) on the connecting rod facing the high pressure fuel pump using a piston ring compressor. 11. Apply the engine oil to the connecting rod cover bolts and hand tighten them all the way down. Then, tighten them with a torque wrench. If they would not be tightened to the specified torque, replace the bolts. The both stamped numbers should be seen from one side. Connecting rod cover bolt tightening torque............. 44.1 ~ 49.0 Nm 4.5 ~ 5.0 kgf-m 32.5 ~ 36.1 lb-ft
Important • Mark the cylinder number on the piston and connecting rod to prevent them from interchanging. • Be careful not to damage the chrome-plate area on the piston ring when pressing the piston and ring assembly into the cylinder.
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CRDI
DISASSEMBLY, SERVICE AND ASSEMBLY piston ring measurement
▶ piston pin and bushing Clearance
▶ Piston ring end gap
9 10
11
T46W2C8A
1. Measure the piston pin O.D. with an outside micrometer. 2. Measure the piston pin busing I.D. with an inside micrometer. 3. If the clearance still exceeds the allowable limit after replacing the bushing with new one, replace the piston pin. Clearance between piston pin and bushing
Specified value
0.025 ~ 0.045 mm (0.00098 ~ 0.00177 in.)
Allowable limit
0.05 mm (0.0020 in.)
Piston pin O.D.
Specified value
29.995 ~ 30.000 mm (1.18090 ~ 1.18110 in.)
Bushing I.D.
Specified value
30.025 ~ 30.040 mm (1.18209 ~ 1.18268 in.)
▶ piston pin bushing replacement
T46W2D0A
1. Place the piston ring to be measured on the top face of piston in cylinder block and slightly push in the piston and piston ring. (Do not put the piston ring on the carbon layer.) 2. Measure the ring end gap with a feeler gauge. 3. If the gap exceed the allowable limit, replace the piston ring.
2nd ring Piston ring end gap
0.40 ~ 0.55 mm Specified value (0.01575 ~ 0.02165 in.) Allowable limit
1.25 mm (0.0492 in.)
0.25 ~ 0.40 mm Specified value (0.00984 ~ 0.01575 in.)
Top ring, oil ring Allowable limit
1.25 mm (0.0492 in.)
4. If the gap is still over the allowable limit with even new ring, measure the diameter of bore (Refer to "7.3.10 - cylinder bore check".).
1
Removal 제거
Press 압입in
T46W2C9A
1. Press out the bushing using a bushing replacing tool. 2. Clean the new bushing and the bore and apply the oil to them. 3. Press in the bushing using the replacing tool.
Important • Align the oil holes (1) of the connecting rod and the bushing.
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DISASSEMBLY, SERVICE AND ASSEMBLY
CRDI
8.3.10 flywheel and crankshaft removal
▶ Piston ring clearance
3F183T
U89W3K6A
1. Clean the ring and ring grooves, and install each ring in its groove.
U89W3K9A
3FT-HI4
2. Measure the clearance between the ring and the ring groove with a feeler gauge. 3. If the clearance exceeds the allowable limit, replace the piston ring. 4. If the clearance still exceeds the allowable limit after removing the ring with new one, replace the piston.
2nd ring Piston ring clearance Oil ring
Specified value
0.04 ~ 0.08 mm (0.00157 ~ 0.00314 in.)
Allowable limit
0.15 mm (0.0059 in.)
Specified value
0.02 ~ 0.06 mm (0.00079 ~ 0.00236 in.)
Allowable limit
0.15 mm (0.0059 in.)
HI4W134A
1. Unscrew the spline hub mounting bolts (1) to remove the spline hub (2) and flywheel (3).
REMARK • Use a crankshaft wrench or flywheel ring gear as a stopper to prevent the flywheel from rotating.
U89W3L0A
2. Unscrew the flywheel housing mounting bolts (1) (13 EA) to remove the flywheel housing (2).
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CRDI
DISASSEMBLY, SERVICE AND ASSEMBLY
U89W3L1A
U89W3L3A
3. Unscrew the oil seal case mounting bolts (1) to remove the oil seal case (2).
U89W3L4A
U89W3L2A
5. Unscrew the ladder frame mounting bolts (1) (16 EA) to remove the cylinder block (2) and ladder frame (3).
4. Unscrew the main bearing bolts (1) (10 EA) from the bottom of the cylinder block.
173
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DISASSEMBLY, SERVICE AND ASSEMBLY
H89W313A
U89W3L7A
6. Remove the crankshaft assembly (1).
CRDI
U89W3L8A
U89W3L9A
7. Remove the piston cooling jet valve (1) from the cylinder block as necessary.
174
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CRDI
DISASSEMBLY, SERVICE AND ASSEMBLY
INSTALLATION REMARK
U89W3M0A
1. Install the piston cooling jet valve (1) to the cylinder block. Then, install the crankshaft bearing (upper) (2).
U89W3q2A
• The crankshaft thrust bearing (upper) does not have any protruded section.
REMARK
U89W3M1A U89W3M4A
• The crankshaft bearing (upper) has an oil groove and hole on its center.
3. Apply engine oil to the crankshaft bearings (upper) of the cylinder block. Then, put the crankshaft (1) on it.
REMARK
U89W3M2A
2. Install the crankshaft thrust bearing (upper) (1). Make sure to set its oil groove toward the outside.
U89W3M5A
• Be careful not to lose the crankshaft thrust bearings (upper) (1) during installation of the crankshaft.
175
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DISASSEMBLY, SERVICE AND ASSEMBLY
CRDI
REMARK •
U89W3M6A
4. Install the crankshaft bearing (lower) (1) to the ladder frame..
REMARK
U89W3M3A
• The crankshaft thrust bearing (lower) has protruded sections.
6. Apply liquid gasket (LOCTITE #518 or equivalent) to the cylinder block face evenly and install the ladder frame.
U89W3M7A
• The crankshaft bearing (lower) does not have any oil groove and hole on its center. U89W3M9A
U89W3M8A
5. Install the crankshaft thrust bearing (lower) (1). Make sure to set its oil groove toward the outside.
U89W3N0A
7. Insert the piston into the cylinder using a piston inserting jig (1) and tighten the connecting rod cap mounting bolts (2).
176
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CRDI
DISASSEMBLY, SERVICE AND ASSEMBLY
3F183T
U89W3N1A
8. Apply liquid gasket (LOCTITE #5902, #5900 or equivalent) to the mating surface of the oil pan evenly and tighten the oil pan mounting bolts (1) to install the oil pan (2) to the ladder frame.
U89W3N2A
9. Apply liquid gasket (LOCTITE #5902, #5900 or equivalent) to the oil seal case mating surface and install the oil seal case (1) to the cylinder block.
U89W3N3A
10. Apply liquid gasket (LOCTITE #5902, #5900 or equivalent) to the flywheel housing mating surface and install the flywheel housing (1) to the cylinder block.
U89W3N4A
11. Install the flywheel. When installing the flywheel bolts (1), apply a small amount of oil to their threads, tighten them with a hand as far as possible and tighten them to the specified torque. Make sure to tighten the bolts diagonally in turn in several steps. Flywheel bolt tightening torque............. 98.1 ~ 107.9 Nm 10.0 ~ 11.0 kgf-m 72.3 ~ 79.6 lb-ft
177
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DISASSEMBLY, SERVICE AND ASSEMBLY
Important
CRDI
REMARK
U89W3N5A T46W2D2A
• It is recommended to insert a long bolt (M8, pitch 1.25) into the flywheel for easier installation.
U89W3N6A
U89W3N7A
• There are installation alignment holes (A) on the mounting surfaces of the crankshaft and flywheel. Make sure to align them during installation.
178
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CRDI
DISASSEMBLY, SERVICE AND ASSEMBLY
metal journal bearings installation
2
Mating notch 홈
5 3
1 6 4
U89W3N8A
1. The connecting rod bearing (1) should be aligned with the mating notch of the connecting rod (2) or connecting rod cap (3) before installation. • Apply sufficient amount of oil to the bearing before and after the installation. 2. The crankshaft bearing (4) should be aligned with the notch of the cylinder block and radder frame. • Apply sufficient amount of oil to the bearing before and after the installation. 3. The crankshaft thrust bearing (upper) (5) and lower (6) can only be installed to the cylinder block and radder frame, which are right next to the flywheel.
Important • The oil groove of the thrust bearing (upper), (lower) should face outward. In other words, the oil groove should be seen after the thrust bearings are installed to the cylinder block and radder frame. • If it is installed backwards, it can cause engine stall. • The protrusion part of the thrust bearing (lower) (6) should face downward.
• Apply sufficient amount of oil before and after the installation.
179
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DISASSEMBLY, SERVICE AND ASSEMBLY
CRDI
flywheel and crankshaft check ▶ Flywheel deflection and crankshaft end play
▶ Crankshaft deflection
T46W2D8A
1. Set a dial indicator with its tip on the rear friction face of the flywheel near the edge. 2. Turn the flywheel to measure the deflection or the uneven wear. 3. If the measured value exceeds the allowable limit, remove the flywheel and check the mating faces of the crankshaft and flywheel. 4. If it is scored or worn excessively, regrind the surface of the flywheel or replace the flywheel. 5. Measure the end play while moving the crankshaft with flywheel back and forth to each end. 6. If the end play exceeds the allowable limit, replace the side bearing. Deflection
End play
Allowable limit
0.05 mm (0.0020 in.)
Specified value
0.15 ~ 0.31 mm (0.0059 ~ 0.0122 in.)
Allowable limit
0.5 mm (0.020 in.)
U89W3N9A
1. Place the crankshaft on V blocks with its journals supported and set a dial indicator with its tip on the intermediate journal. 2. Measure the eccentricity (half of the measured value) while turning the crankshaft on the V blocks. 3. If the eccentricity exceeds the allowable limit, replace the crankshaft. Eccentricity
Allowable limit
0.08 mm (0.0031 in.)
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CRDI
DISASSEMBLY, SERVICE AND ASSEMBLY
▶ crankshaft journal and bearing 1 Oil clearance
▶ crank pin and connecting rod bearing Oil clearance
9 10
11
T46W2E0A
T46W2E3A
1. Measure the I.D. of the crankshaft bearing 1 with an inside micrometer.
1. Place a plastigauge in lengthwise on the center of the crankpin.
2. Measure the O.D. of the crankshaft journal with an outside micrometer.
2. Install the connecting rod, tighten the bolts to the specified torque once and remove the cap again.
3. If the clearance exceeds the allowable limit, replace the crankshaft metal bearing.
3. Measure the amount of the flatness with the scale and get the oil clearance.
Specified value
0.040 ~ 0.104 mm (0.00157 ~ 0.00400 in.)
Allowable limit
0.20 mm (0.0079 in.)
Journal O.D.
Specified value
59.921 ~ 59.940 mm (2.35909 ~ 2.35984 in.)
Bearing 1 I.D.
Specified value
59.980 ~ 60.025 mm (2.36142 ~ 2.36319 in.)
Oil clearance
4. If the clearance exceeds the allowable limit, replace the bearing. Specified value
0.017 ~ 0.073 mm (0.00067 ~ 0.00287 in.)
Allowable limit
0.20 mm (0.0079 in.)
Crankshaft pin O.D.
Specified value
51.959 ~ 51.975 mm (2.04563 ~ 2.04626 in.)
Crankshaft pin Bearing I.D.
Specified value
51.992 ~ 52.032 mm (2.04693 ~ 2.04850 in.)
Oil clearance
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CRDI
DISASSEMBLY, SERVICE AND ASSEMBLY 8.3.11 oil filter 3F183T
cylinder bore check 1. Check the worn condition of the honing groove on the bore. 2. Check the bore for scuffing or scoring.
U89W3O0A
3FT-HI4
S76W271A
HI4W135A
(1) Oil filter
(2) Oil cooler
1. Drain engine oil and remove the engine oil filter (1) and engine oil cooler (2) for inspection. T46W2E5A
(1,2,3) Measuring Points (A) Axial direction (B) Transverse direction
3. Measure the cylinder liner I.D. at six locations as shown in the figure to find the largest worn area. Cylinder liner I.D.
Specified value
87.000 ~ 87.022 mm (3.425 ~ 3.426 in.)
182
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CRDI
DISASSEMBLY, SERVICE AND ASSEMBLY 8.3.12 oil pump
U89W3O3A
U89W3O1A
2. Remove the relief valve from the side of the gear case and check the plunger (1) and spring (2) for deformation. If damaged, replace it with a new one. 3. Measure the free length of the spring. If the measurement is over the allowable limit, replace it with a new one Spring Free length
Specified value Allowable limit
43.8 mm (1.7244 in.) 39.0 mm (1.5354 in.)
REMARK
U89W3O4A
(1) Oil pump gear
Oil filter flow and oil cooler coolant flow
(2) Oil pump ass’y
1. Remove the oil pump gear (1) from the lower section of the gear case. Then, remove the oil pump assembly (2).
Coolant 냉각수 Engine oil 엔진오일
U89W3O2A
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DISASSEMBLY, SERVICE AND ASSEMBLY
CRDI
oil pump check ▶ clearance between rotor and lobe clearance of oil pump
▶ End clearance of rotor in oil pump
T46W2E8A
T46W2F0A
1. Place a plastigauge on the rotor and assemble the pump. 2. Disassemble the pump and measure the amount of the flatness with a scale to get the clearance. 3. If the clearance exceeds the allowable limit, replace the pump.
End clearance
Specified value
0.105 ~ 0.150 mm (0.00423 ~ 0.00591 in.)
Allowable limit
0.20 mm (0.0079 in.)
T46W2E9A
1. Measure the clearance between the outer rotor and inner rotor with a feeler gauge. 2. Measure the clearance between the outer rotor and the housing with a feeler gauge. 3. If the clearance exceeds the allowable limit, replace the pump. Specified Clearance value between outer rotor and inner Allowable limit rotor
0.10 ~ 0.16 mm (0.0039 ~ 0.0063 in.)
Specified Clearance value between outer rotor and Allowable limit housing
0.11 ~ 0.19 mm (0.0043 ~ 0.0075 in.)
0.20 mm (0.0079 in.)
0.25 mm (0.0098 in.)
184
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CRDI
DISASSEMBLY, SERVICE AND ASSEMBLY
8.3.13 thermostat
U89W3O5A
(1) Thermostat cover (2) Thermostat
U89W3O7A
(3) Thermostat cover gasket (4) Coolant flange
removal
U89W3O8A
2. Pull out the thermostat (2).
REMARK U89W3O6A
1. Remove the thermostat cover (1).
U89W3O9A
• When reinstalling the thermostat, the coolant flange and groove alignment holes (A) should be aligned.
185
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DISASSEMBLY, SERVICE AND ASSEMBLY
CRDI
8.3.14 water pump 3F183T
INSTALLATION •
Apply the liquid gasket (Three Bond 1215 or equivalent) on the gasket(3).
Opening temperature of thermostat valve
U89W3P0A
3FT-HI4
T46W2F2A
1. Suspend the thermostat in the water by a string with its end inserted between valve and seat. 2. While heating the water slowly, read the temperatures when the valve starts to open and when the valve opens for approx. 8 mm. 3. If the measured values are not within the specified value, replace the thermostat.
Opening temperature
Specified value
Initial opening temperature: 71 ± 1.5 °C (160 ± 3 °F)
HI4W176A
1. Disconnect the water pump pipe (1) and coolant hoses (2) on the face of the gear case from the water pump side.
Below 85 °C (185 °F) at opening by 8 mm (0.315 in.)
186
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CRDI
DISASSEMBLY, SERVICE AND ASSEMBLY
3F183T
U89W3P1A
U89W3P2A
HI4W177A
U89W3P3A
3FT-HI4
2. Disconnect the coolant return hose (1) and unscrew the water pump case mounting bolts (2) to remove the water pump case assembly (3).
3. Unscrew the main case mounting bolts (1) from the removed water pump assembly to separate the case and cover.
187
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DISASSEMBLY, SERVICE AND ASSEMBLY
CRDI
8.3.15 fuel filter
U89W3P6A
2 3
1
4 U89W3P5A U89W3P4A
(1) Water pump flange (2) Water pump shaft bearing
(3) Mechnical seal (4) Impeller
4. Remove the water pump flange (1) from the main case. 5. Remove the impeller (4) and mechanical seal (3) from the water pump shaft bearing (2).
U89W3P7A
1. Rotate the water-in-fuel sensor (1) and fuel filter (2) to remove them from the removed fuel filter assembly. Then, remove the fuel heater (3) (Option) and priming pump (4).
REMARK
6. If the mechanical seal is to be removed, replace it with a new one.
CAUTION • The components of the water pump is firmly assembled together and they cannot be easily disassembled or assembled without a special equipement. Therefore, it is recommended to
U89W3P8A
• When installing a new fuel filter for replacement, apply a thin film of oil onto the O-ring surface (A) and tighten the filter firmly with a hand.
188
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CRDI
DISASSEMBLY, SERVICE AND ASSEMBLY
8.3.16 TURBO CHARGER WARNING
3F183T
• As the turbocharger operates at a high speed and high temperature, there should be no tool or foreign materials around its inlet and outlet. Especially, be careful not to touch them with a finger or body.
removal 3F183T Q53W3A7A
3FT-HI4
Q53W3A6A
3FT-HI4 HI4W137A
2. Unscrew the turbocharger mounting bolts (1) and oil pipe mounting bolts (2) to remove the turbocharger assembly. Turbocharger mounting bolt tightening torque............. 47.0 Nm 4.8 kgf-m 34.0 lb-ft HI4W136A
HI4W178A
1. Disconnect the air cleaner suction hose (1) and intake valve connecting hose (2).
189
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CRDI
DISASSEMBLY, SERVICE AND ASSEMBLY
REMARK
3F183T
Turbocharger component tightening torque
A86W334A
A86W336A
(1) 2.3 ~ 4.5 Nm (2) 6.0 ~ 8.0 Nm
(3) 11.1 ~ 12.3 Nm (4) 5.6 ~ 6.8 Nm
A86W335A
3FT-HI4
HI4W179A
3. If necessary, remove the turbocharger assembly.
190
수출향_커먼레일 직분식 엔진(CRDI).indd 190
2014-09-04 오전 9:05:16
CRDI
Engine Electric components
9. Engine Electric components 9.1 main components Specification Item
Specification
Starter motor
12V 50A
Alternator
12V 50A
Glow plug
12V
Coolant temperature sensor Engine oil pressure switch
Temperature gauge: Approx. 2.45 KΩ at 20˚C Preheating: Approx. 125 KΩ at 60˚C Operational at 0.5 ± 0.1 kgf/cm² or below
191
수출향_커먼레일 직분식 엔진(CRDI).indd 191
2014-09-04 오전 9:05:16
수출향_커먼레일 직분식 엔진(CRDI).indd 192
2014-09-04 오전 9:05:16
CRDI
CIRCUIT AND WIRING DIAGRAM
9.2 CIRCUIT AND WIRING DIAGRAM
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9.2.1 ECU CIRCUIT
229 213 214
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HOUSING : PB621-10020 RETAINER : PB871-10880 COVER : HV011-10020 CLIP : KPP022-13020 14
13
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212 113 219 237
245 247 248 256
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193
수출향_커먼레일 직분식 엔진(CRDI)_A3.indd 193
2014-09-04 오전 8:57:57
CRDI
CIRCUIT AND WIRING DIAGRAM
(&8$ ZD\ (QJLQH &RQQHFWRU -
-
-
-
147 146 145 144
-
123 122
-
193 192
-
-
172 171 170 169 168 167 166
-
-
-
-
-
-
164 163
141 -
-
-
184 183
-
-
-
14
-
177
-
175
-
-
-
-
160 159
-
-
-
-
-
-
-
151
-
-
-
-
-
128
127
126
125
-
103
-
-
-
139 138 -
119 118 117 116 115
-
135 134
113 112 111 110 109
-
131 130 -
106 105
(&8% ZD\ 9HKLFOH &RQQHFWRU
201
202
-
203
PIN NO,
DESCRIPTION
PIN NO,
103
Cylinder 3 signal
105
Exhaust temp. sensor (T5) signal
106
Exhaust temp. sensor (T3) signal
109
Coolant dual temp. sensor signal(Preheat)
110 111 112
Intake pressure (P2) sensor signal
113
A/C S/W signal(+)
115
205
-
-
-
221 -
-
224 225 226
-
237
-
-
-
-
-
-
212 213 214 215 -
-
-
-
219
-
-
-
-
-
-
245
-
256
-
-
228 229
204
-
206
-
-
-
247 248 -
-
-
253 254
DESCRIPTION
PIN NO,
DESCRIPTION
139
Crank sensor power (5V)
201
ECU power1
141
Intake pressure (P2) sensor power (5V)
202
ECU GND1
144
Diff pressure sensor (DPS) GND
203
ECU power2
145
Coolant dual temp. sensor GND
204
ECU GND2
Fuel temp. sensor signal
146
Fuel temp. sensor GND
205
ECU power3
Engine oil pressure S/W signal
147
Cam sensor GND
206
ECU GND3
151
Cylinder 2 signal
212
Start S/W (ST)
159
Cam sensor signal
213
H-FOOT pedal sensor 2 signal
ACV sensor signal
160
Crank sensor signal
214
H-FOOT pedal sensor 2 GND
116
EGR valve sensor signal
163
ACV sensor power (5V)
215
MAF sensor temp. signal
117
Diff pressure sensor (DPS) signal
164
EGR valve sensor power (5V)
219
Start S/W (ON)
118
WATER sensor signal
166
DPS sensor power (5V)
221
MAF sensor GND
119
Rail pressure sensor GND
167
Intake pressure (P2) sensor GND
224
H-FOOT pedal sensor 1 power (5V)
122
Exhaust temp. sensor (T5) GND
168
Intake temp. (T2) sensor GND
225
H-FOOT pedal sensor 1 signal
123
Exhaust temp. sensor (T3) GND
169
WATER sensor GND
226
H-FOOT pedal sensor 1 GND
125
Cylinder 3 GND
170
ACV sensor GND
228
MAF sensor ďŹ&#x201A;ow rate(FREQ) signal
126
Cylinder 1 GND
171
Crank sensor GND
229
H-FOOT pedal sensor 2 power (5V)
127
Cylinder 1 signal
172
EGR valve GND
237
Start relay coil signal(-)
128
Knock sensor 1 shield
175
Cylinder 2 GND
245
Main relay coil signal
130
Knock sensor 1 GND
177
IMV PWM output
247
CAN1 LO
131
Knock sensor 1 signal
183
ACV motor(-)
248
CAN1 HI
134
Intake temp. (T2) sensor signal
184
ACV motor(+)
253
CAN2(DEV) HI
135
Rail pressure sensor signal
192
EGR valve motor(+)
254
CAN2(DEV) LO
138
Rail pressure sensor power (5V)
193
EGR valve motor(-)
256
Preheatrelay coil signal HI4W191B
194
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2014-09-04 ě&#x2DC;¤ě &#x201E; 8:57:57
CRDI
CIRCUIT AND WIRING DIAGRAM
9.2.2 ENGINE WIRING DIAGRAM OBD. OBD II
14 - 247 -
-
- 254
- 248 999 999 -
- 253
-
30
HOUSING:MG 610761-5 COVER:T5520-69111006
WTS. Engine temp. sensor KPB016-03427(HOUSING) KPB026-03520(HOLDER)
150
C1. Cylinder 1 HOUSING : FCI 240PC024S8014 TERMINAL : FCI 60001534 SEALS : FCI 60993928
90
20
109 - 145
MAF. Air Mass Flow & Temp Sensor HOUSING : FCI 211PC042S8021 TERMINAL : TYCO(AMP) 929027-1 (Gold plate)
127126
P2. P2(Inlet Manifold Press) Sensor
100
40
20
193 - 192 164172116
141 112
167 -
EGR. EGR Valve TYCO 284716-3
30
80
20
14 221 215 228 30
180
151175
HOUSING:TYCO 368162-1 TERMINAL:TYCO 927770-3 SEAL:TYCO 828904-1 or 368932-1
180
20
C2. Cylinder 2 HOUSING : FCI 240PC024S8014 TERMINAL : FCI 60001534 SEALS : FCI 60993928
TYCO 284716-3
14 212 113 219 237 245 247 248 256
-
183
999
184
130
120
80
-
163 170 115
130
OPS. Engine oil pressure S/W
ACV. Air Control Valve
30
13
HOUSING : SUMITOMO F(6180-2451) WIER SEAL : SUMITOMO (7160-8234) TERMINAL : SUMITOMO F(1500-0106)
HOUSING : PB621-10020 RETAINER : PB871-10880 COVER : HV011-10020 CLIP : KPP022-13020 WIRE SEAL : RS220-01100
20
150
100
HOUSING : PB621-06020 138 119 135 HOLDER : PB871-06880 COVER : HV011-06020 CLIP : KPP022-13020 RPS. Rail Press Sensor WIRE SEAL : RS220-01100 HOUSING : KOSTAL 09 4413 91 TERMINAL : KOSTAL 2 21 24 49206 0 224 225 226 HOUSING : MG 652934-5 COVER : MG 632946 SEAL : KOSTAL 1 08 00 44452 2 229 213 214 CLIP : MG 632278
170
P. VEHICLE SECTION 140
T3. Exhaust Gas Temp Sensor
MG630063
20
190
50
100
111
50
220
320
60
160
50
T2. T2(Inlet Manifold Temp) Sensor
ECUA. DCM3.7
HOUSING : AMP 368356-1 COVER : AMP 936138-1
CAM. Cam Shaft Sensor
-
-
-
-
193 192
-
172 171 170 169 168 167 166
-
-
-
-
164 163
-
-
184 183 160 159
-
-
-
-
-
-
14
-
-
177 -
-
-
-
175
-
151
FTS. Fuel Temp Sensor
100 30
-
123 122
-
-
141 -
139 138
119 118 117 116 115
-
-
-
135 134
-
-
113 112 111 110 109
131 130 -
-
-
106 105
128
127
126
125
-
103
-
-
171 160 139
CPS. Crank Position Sensor
HOUSING : SUMITOMO F(6180-3451) WIER SEAL : SUMITOMO (7160-8234) TERMINAL : SUMITOMO F(1500-0106)
160
-
-
ECUB. DCM3.7
HOUSING : TYCO 9-1452415-9 LOCKING : TYCO 1452408-1, 1452409-1 COVER : TYCO 0-1452416-1 (180°) TERMINAL : TYCO 1394897-1(0.5~0.85SQ), 1-968857-1(1.25~2.0SQ) SEAL : TYCO 828905-1
201
202
-
203
-
-
221 -
-
-
212 213 214 215
224 225 226
-
-
228 229
-
-
219
-
-
-
206
169 80
204
BLIND PLUG : 1-1452424-1(BROWN) or 0-1452424-1(GREY) 205
-
-
-
-
247 248 -
-
237
-
-
-
-
-
-
-
253 254
60
HOUSING : FCI 211PC022S5081 (Green) TERMINAL : TYCO(AMP) 929027-1 (Gold plate)
50
147 146 145 144
134 168
HOUSING : AMP 368215 COVER : AMP 936138-1
60
131 128130
-
80
-
20
K1. Knock Sensor 1
90
159 147 14
70
750
HOUSING : TYCO 9-1452380-9 LOCKING : TYCO 1452388-1 COVER : TYCO 0-1452389-1 (90°) TERMINAL : TYCO 1394897-1(0.5~0.85SQ) BLIND PLUG : 1-1452424-1(BROWN) or 0-1452424-1(GREY)
70
30
150
HOUSING:TYCO 282762-1 TERMINAL:TYCO 929939-3 SEAL:TYCO 828904-1
-
110 146
14 177
20
20
170
105 117 122 144 166 -
80
106 123
210
C3. Cylinder 3
HOUSING : FCI 240PC024S8014 TERMINAL : FCI 60001534 SEALS : FCI 60993928 80 20 103125
170
IMV. Inlet Matering Valve
DPF. DPF CONNECTIN SECTION HOUSING : PB621-06020 HOLDER : PB871-06880 COVER : HV011-06020 CLIP : KPP022-13020 WIRE SEAL : RS220-01100
HOUSING : FCI 211PC022S1081 (Brown) TERMINAL : TYCO(AMP) 929027-1 (Gold plate)
118
50
WIF. Water In Fuel sensor
-
-
-
245
-
256
-
-
HOUSING:TYCO 936251-2 TERMINAL:TYCO 927770-3 SEAL:TYCO 828905-1 COVER:TYCO 936312
HI4W183B
195
수출향_커먼레일 직분식 엔진(CRDI)_A3.indd 195
2014-09-04 오전 8:57:58
CRDI
CIRCUIT AND WIRING DIAGRAM
No.
SIZE
COLOR
13
UL 1015 AWG 12
R
CIRCUIT P
UL 1569 AWG 18 14
R
P
UL 1569 AWG 20
REMARK
No.
SIZE
COLOR
ECU power
166
UL 1569 AWG 20
R
ECUA
DPF
DPS sensor power (5V)
IMV
167
UL 1569 AWG 20
Br
ECUA
P2
Intake pressure (P2) sensor GND
MAF
168
UL 1569 AWG 20
Gr
ECUA
T2
Intake temp. (T2) sensor GND
169
UL 1569 AWG 20
B
ECUA
WIF
Water sensor GND
CAM
170
UL 1569 AWG 20
Br
ECUA
ACV
A CV sensor GND
ECUA
171
UL 1569 AWG 20
Gr twist_C
ECUA
CPS
Crank sensor GND
J4
OBD
ECU power
CIRCUIT
REMARK
103
UL 1569 AWG 18
Y twist_C3
ECUA
C3
Cylinder 3 signal
172
UL 1569 AWG 20
B
ECUA
EGR
EGR valve GND
105
UL 1569 AWG 20
G
ECUA
DPF
Exhaust temp. sensor (T5) signal
175
UL 1569 AWG 18
Br twist_C2
ECUA
C2
Cylinder 2 GND
106
UL 1569 AWG 20
L
ECUA
T3
Exhaust temp. sensor (T3) signal
177
UL 1569 AWG 18
G
ECUA
IMV
IMV PWM output
109
UL 1569 AWG 20
V
ECUA
WTS
Coolant dual temp. sensor signal(Preheat)
183
UL 1569 AWG 18
Gr twist_A
ECUA
ACV
A CV motor(-)
110
UL 1569 AWG 18
Y
ECUA
FTS
Fuel temp. sensor signal
184
UL 1569 AWG 18
O twist_A
ECUA
ACV
A CV motor(+)
111
UL 1569 AWG 20
G
ECUA
OPS
Engine oil pressure S/W signal
192
UL 1569 AWG 18
W twist_E
ECUA
EGR
EGR valve motor(+)
112
UL 1569 AWG 20
L
ECUA
P2
Intake pressure (P2) sensor signal
193
UL 1569 AWG 18
B twist_E
ECUA
EGR
EGR valve motor(-)
113
UL 1569 AWG 20
V
ECUA
P
A /C S/W signal(+)
201
UL 1569 AWG 16
R
ECUB
J4
ECU power1
115
UL 1569 AWG 20
Y
ECUA
ACV
A CV sensor signal
202
UL 1569 AWG 16
B
ECUB
J3
ECU GND1
116
UL 1569 AWG 20
G
ECUA
EGR
EGR valve sensor signal
203
UL 1569 AWG 16
R
ECUB
J4
ECU power2
117
UL 1569 AWG 20
L
ECUA
DPF
Diff pressure sensor (DPS) signal
204
UL 1569 AWG 16
B
ECUB
J3
ECU GND2
118
UL 1569 AWG 20
V
ECUA
WIF
Water sensor signal
205
UL 1569 AWG 16
R
ECUB
J4
ECU power3
119
UL 1569 AWG 20
Br twist_R
ECUA
RPS
Rail pressure sensor GND
206
UL 1569 AWG 16
B
ECUB
J3
ECU GND3
122
UL 1569 AWG 20
Gr
ECUA
DPF
Exhaust temp. sensor (T5) GND
212
UL 1569 AWG 20
Y
ECUB
P
Start S/W (ST)
123
UL 1569 AWG 20
B
ECUA
T3
Exhaust temp. sensor (T3) GND
213
UL 1569 AWG 20
G
ECUB
P
H-FOOT pedal sensor 2 signal
125
UL 1569 AWG 18
Gr twist_C3
ECUA
C3
Cylinder 3 GND
214
UL 1569 AWG 20
Br
ECUB
P
H-FOOT pedal sensor 2 GND
126
UL 1569 AWG 18
B twist_C1
ECUA
C1
Cylinder 1 GND
215
UL 1569 AWG 18
L
ECUB
MAF
MA F sensor temp. signal
127
UL 1569 AWG 18
Y twist_C1
ECUA
C1
Cylinder 1 signal
219
UL 1569 AWG 20
V
ECUB
P
Start S/W (O N)
128
UL 2464 AWG 18
shield_K1
ECUA
K1
Knock sensor 1 shield
221
UL 1569 AWG 18
Gr
ECUB
MAF
MA F sensor GND
130
UL 2464 AWG 18
B shield_K1
ECUA
K1
Knock sensor 1 GND
224
UL 1569 AWG 20
O
ECUB
P
H-FOOT pedal sensor 1 power (5V)
131
UL 2464 AWG 18
R shield_K1
ECUA
K1
Knock sensor 1 signal
225
UL 1569 AWG 20
Y
ECUB
P
H-FOOT pedal sensor 1 signal
134
UL 1569 AWG 20
Y
ECUA
T2
Intake temp. (T2) sensor signal
226
UL 1569 AWG 20
B
ECUB
P
H-FOOT pedal sensor 1 GND
135
UL 1569 AWG 20
G twist_R
ECUA
RPS
Rail pressure sensor signal
228
UL 1569 AWG 18
G
ECUB
MAF
MA F sensor flow rate(FREQ) signal
138
UL 1569 AWG 20
O twist_R
ECUA
RPS
Rail pressure sensor power (5V)
229
UL 1569 AWG 20
W
ECUB
P
H-FOOT pedal sensor 2 power (5V)
139
UL 1569 AWG 20
W twist_C
ECUA
CPS
Crank sensor power (5V)
237
UL 1569 AWG 20
L
ECUB
P
Start relay coil signal(-)
141
UL 1569 AWG 20
R
ECUA
P2
Intake pressure (P2) sensor power (5V)
245
UL 1569 AWG 20
V
ECUB
P
Main relay coil signal
144
UL 1569 AWG 20
B
ECUA
DPF
Diff pressure sensor (DPS) GND
145
UL 1569 AWG 20
Br
ECUA
WTS
Coolant dual temp. sensor GND
247
UL 1569 AWG 18
Br twist_CV
ECUB
146
UL 1569 AWG 18
Gr
ECUA
FTS
Fuel temp. sensor GND
147
UL 1569 AWG 20
B
ECUA
CAM
Cam sensor GND
248
UL 1569 AWG 18
Y twist_CV
ECUB
151
UL 1569 AWG 18
L twist_C2
ECUA
C2
Cylinder 2 signal
253
UL 1569 AWG 18
G twist_CD
ECUB
OBD
CAN2(DEV) HI
159
UL 1569 AWG 20
V
ECUA
CAM
Cam sensor signal
254
UL 1569 AWG 18
Gr twist_CD
ECUB
OBD
CAN2(DEV) LO
160
UL 1569 AWG 20
Y twist_C
ECUA
CPS
Crank sensor signal
256
UL 1569 AWG 20
L
ECUB
P
Preheatrelay coil signal
163
UL 1569 AWG 20
O
ECUA
ACV
A CV sensor power (5V)
164
UL 1569 AWG 20
W
ECUA
EGR
EGR valve sensor power (5V )
B
P
999
UL 1015 AWG 12 UL 1569 AWG 20
P OBD P OBD
J3 OBD
CAN1 LO CAN1 HI
(2EA) BatteryGND HI4W192B
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CRDI
Engine Electric components
9.3 ELECTRIC COMPONENTS 9.4.1 Start motor
9.4.2 Alternator There are some components, such as headlamp, start motor, engine stop solenoid and glow plug, which need a lot of electricity. The alternator supplies power to such components and charges the battery which stores electricity for the tractor. Therefore, the alternator correlates with the battery and electric loads and it is an original source of electricity for the entire tractor.
Test 3F183T
T85WBA9A q53wb33a
ᴓᅃᑯ㘃#◯⩏ㆣ Magnet switch
T46WBA4B A53WB18A
ᷳ㑻 Motor
(1) 2P No. 1 connector (2) 2P No. 2 connector
⥯῏ᬻ#㎿ᬷㆣ Overrun clutch
(3) Battery power
T85WBJ1C
The start motor is divided by three sections: •
Motor - Generates torque for cranking the engine.
•
Magnet switch - Engages the ring gear with the pinion gear and turns current ON and OFF.
•
Overrun clutch - Transfers torque from the start motor to the engine, and blocks engine turning torque to the start motor if the engine rotates faster than the start motor, i.e. the engine is started, for protection of the start motor.
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Engine Electric components
CRDI
Performance curve of alternator
ョ᭰#⭏Უ Output current
3FT-HI4
Alternator ὧ⭏ᅻ#ⓘᜏspeed T46WBA5A
As shown in the performance curve in the above figure, the alternator does not generate power until its speed reaches 1,200 rpm. This minimum revolution speed is called "Cut In Speed". 2
If the alternator's speed is below the cut in speed, the alternator does not generate power and the charge warning lamp does not go off.
1
U89WB06A HI4W138A
DC Voltage
Item
(1) 2P No. 1 connector (2) 2P No. 2 connector
(3) Battery power
Also, the output performance changes as the output current (A) changes according to the coil's temperature (cold and hot). Therefore, the average curve for the cold and hot conditions is presented as guaranteed performance. In general, the alternator's pulley ratio is determined to maximize the alternator output in the rated maximum output of the engine.
Tester Connection Location
Result
Chassis (GND)
Ignition switch ON
DC 12V
2P No. 2 connector
Chassis (GND)
Ignition switch in ST
DC12 ~ 14.7 V
2P No. 1 connector
2P No. 2 connector
Ignition switch ON
DC 12 V
Red
Black
Lead
Lead
2P No. 1 connector
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CRDI
Engine Electric components
9.4.3 Engine oil pressure switch
9.4.4 ECU
3F183T
u98wb10a
U89WB12A
The ECU (Electronic Control Unit) is installed on the rear right side of the engine. The ECU receives information from various sensors installed in the engine to optimize combustion in order to enhance engine performance and fuel consumption.
3FT-HI4
HI4W139A
The engine oil pressure switch is installed to the top of the start motor on the left rear section of the engine. When 0.5 ± 0.1 kg/cm2 (7 psi ± 1.4 psi) or less of pressure is built in the engine oil system, this switch's contact point is connected to send a warning signal to the instrument cluster. Test Tester Connection Item
Resistance
Red Lead
Oil switch contact
Black
Position
Result
Oil lamp ON on instrument cluster
Continuity (0Ω)
Lead Chassis (GND)
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CRDI
Engine Electric components 9.4.5 Sensors and relays TIER3 MOdEL: 3F183T 8
2
3FT-HI4 4
9
2
3
8
10
5
3 1
11
4
1 HI4W185A
TIER3 MOdEL: 3F183T
5
6
HI4W140A
3FT-HI4 6 7
HI4W186A
TIER4 MOdEL: 3F183T 9 7
12
HI4W141A
HI4W187A
(1) Crankshaft wheel sensor (2) Fuel rail pressure sensor (3) Accelator(Knock) sensor (4) High-pressure fuel pump temperature sensor
(5) Water in fuel sensor (6) Exhaust gas Temp. sensor (7) Camshaft wheel sensor (8) EGR valve sensor
(9) Air MF sensor (10) Intake pressure sensor (11) Intake gas Temp. sensor (12) DPF diff sensor
200
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CRDI
Engine Electric components
CRANkSHAFT wHEEL SENSOR •
Connector and circuit diagram
COMMON(BW) OUTPUT(GW) POWER(RW)
POWER(RW)
HALL IC
OUTPUT(GW) COMMON(BW)
U89WB16A
U89WB17A
U89WB15A
The crankshaft wheel sensor is installed to the edge on the lower right side of the engine next to the transmission. •
Supplied power: 4 ~ 24 VDC
•
Supplied current: 6 mA
•
Output current: 30 mA
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Engine Electric components
CRDI
FUEL RAIL pRESSURE SENSOR
U89WBD1A
(1) Crankshaft sensitive wheel (2) Crankshaft wheel sensor
The crankshaft wheel sensor is a magnetic pick-up type and it is supplied with 5 V power. It outputs sine waveform according to the change in magnetic field occurred by rotation of the crankshaft. Then, the position/speed of the crankshaft can be determined by the current value through the changed resistance value. The crankshaft wheel sensor detects the position of each piston and sends this information to the ECU which then uses this information to set the injection timing and amount.
U89WB23A U89WB22A
The fuel rail pressure sensor is installed to the side of the fuel rail. The fuel rail is a device to convert the fuel pressure signal into a electric signal, amplify it and supply it to the ECU. The fuel rail pressure is determined based on the engine RPM, engine torque, barometric pressure, coolant temperature, intake air temperature, etc. Once the fuel rail pressure is determined, it is controlled by the IMV. Then, the fuel rail pressure sensor is used to detect the fuel rail pressure and set the opening amount of the IMV. The fuel rail pressure sensor can measure the fuel pressure from 0 up to 2,200 bars. Q53WBH5A
The crankshaft wheel sensor is a magnetic pick-up type and it is supplied with 5 V power. It outputs sine waveform according to the change in magnetic field occurred by rotation of the crankshaft. Then, the position/speed of the crankshaft can be determined by the current value through the changed resistance value. The crankshaft wheel sensor detects the position of each piston to determine the injection timing and amount. This sensor is a magnetic pickup type so its N polar and S polar intersect during rotation of the crankshaft to send 60 signals in total. It detects the position of each cylinder by detecting the position without a tooth on the gear.
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CRDI
Engine Electric components ACCELERATION (kNOCk) SENSORS
▶ Fuel rail pressure sensor characteristics SENSOR OUTpUT vOLTAgE
Upper limit range
Output voltage Lower limit range Pressure U89WBD3A
Sensor supply voltage
5 ± 0.1 V
Sensor out-
At 2,200 bars
4.5 ± 0.125 V
put voltage
At 0 bar
0.5 ± 0.04 V
Faulty
At 0 - 1,000 bars
± 1.0% or more
range
U89WB27A
At 1,000 - 1,800 bars ± 1.6% or more
U89WB26A
Two acceleration (knock) sensors are installed to the engine cylinder block (intake manifold side). When engine knocking occurs, the piston or connecting rod is vibrated and, in a severe condition, hitting a metallic object is heard. The knock sensor is to detect this knocking condition due to abnormal combustion. This sensor has a piezo-electric element fixed to the diaphragm to detect vibration of the engine occurred by abnormal combustion, and the diaphragm is fixed to the base. Also, it is also used to control idle stability and detect injector's faulty condition to illuminate the engine warning lamp and adjust the pilot injection amount precisely. If the acceleration (knock) sensor malfunctions, the ECU calibrates the injection timing based on the engine RPM, intake air amount and coolant temperature. Operation temperature: -40 ~ 150℃
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Engine Electric components
CRDI
HIgH-pRESSURE FUEL pUMp TEMpERATURE SENSOR •
Connector
Signal 1 U89WB30B
Signal 2 GND U89WB28A
▶ Knock sensor characteristics When the engine temperature is low, it outputs a high value due to a large fuel injection amount and vibration. However, after the engine is warmed up, its signal value is decreased. The 1st knock sensor outputs signals for the 1st and 2nd cylinders while the 2nd knock sensor outputs signals for the 3rd and 4th cylinders. Insulation resistance
Min. 1 MΩ
Resonance frequency
25 kHz
Operating temperature range
-40 ~ 150℃ 26 ± 8 mV/g (at 5 kHz)
Output voltage
The high-pressure fuel pump temperature sensor is installed right below the IMV (Inlet Metering Valve) of the high-pressure fuel pump. This temperature sensor detects the inlet temperature of the high-pressure fuel pump and sends this information to the ECU. Generally, the temperature of returning fuel rises quite a lot in the common rail diesel engine. In this case, lubrication film of fuel is destroyed so its lubricating performance is deteriorated, resulting in possible damage of the high-pressure fuel pump. Therefore, when the fuel temperature rises over the specified level, this information is sent from the temperature sensor to the ECU which then adjusts the fuel injection amount to control the engine RPM in order to prevent further fuel temperature increase. It also measures the fuel temperature to decrease the opening amount of the IMV in case of overheating condition in order to decrease the amount of compressed fuel and prevent a further rise of the fuel temperature. The fuel temperature sensor is a NTC resistor type and is installed between the low-pressure line and highpressure line in the high-pressure pump. It uses 5 V power to generate its output voltage.
22 ~ 37 mV/g (3~10kHz) 22 ~ 57 mV/g (10~20kHz)
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CRDI
Engine Electric components wATER-IN-FUEL SENSOR
▶ Fuel temperature sensor characteristics
3F183T
Resistance(Ω) Voltage(V) Resistance(Ω) HI4W188A
3FT-HI4
Temperature(˚C) U89WBD4A
Temperature (˚C) Resistance (Ω)
Voltage (V)
-40
75,789
4.903
-10
12,462
4.463
0
7,355
4.153
10
4,481
3.746
20
2,812
3.261
40
1,199
2.221
70
394
1.040
90
206
0.604
120
87
0.276
140
52
0.171
HI4W142A
The water-in-fuel sensor is installed under the fuel-filter. When water enters the engine fuel system, it can damage the high-pressure fuel pump, filter and injector and cause poor engine starting performance and malfunction. Therefore, when water is collected (45cc or more) on the bottom of the fuel-filter, this water-in-fuel sensor sends a signal to the instrument cluster which then turns on the water-in-fuel warning lamp. Make sure to drain water from the fuel-filter in this case.
205
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Engine Electric components
CRDI
ExHAUST gAS TEMp. SENSOR Therefore, when the exhaust gas temperature rises over a certain level, the exhaust gas temperature sensor sends a signal to the ECU which then controls the EGR operation to decrease the temperature in the combustion chamber in order to prevent overheating of the catalyst and decrease the exhaust gas temperature. •
Input data - Min. operating temperature of probe tip: 1000℃
Supplied power: 5 ± 0.1 VDC •
Output data - Type: passive
Max. current: 2.5 mA U89WB32A
•
Front exhaust temperature sensor
The front exhaust temperature sensor is installed in the exhaust manifold. It uses the change in resistance occurred by the exhaust gas temperature change, coverts it to the voltage value, and send this information to the engine ECU.
TIER4 MOdEL
To prevent tur bocharger damage in the postinjection process, it is used to limit the fuel injection amount at a high exhaust gas temperature. • U89WB33A
Rear exhaust temperature sensor
The rear exhaust temperature sensor measures the temperature of exhaust gas passing through the DPF. If this temperature in the DPF regenerating section is low (below approx. 600℃), the engine ECU decreases the amount of intake air and increases the post-injection duration based on this information to increase the temperature of exhaust gas. In other words, this sensor determines whether the CCRT is at a proper temperature for regeneration and sets the post-injection amount accordingly.
U89WB34A
The exhaust gas temperature sensors are installed to the side of the exhaust manifold (front exhaust temperature sensor) and to the CCRT (Catalyzed Continuously Regenerating Trap) (rear exhaust temperature sensor). It is also installed to the outlet of the DOC (Diesel Oxidation Catalyst) to detect the temperature in the DOC for determination of overheating condition. When the engine is overheated (over 900℃ to 950℃), the DOC is melted, increasing soot in exhaust gas.
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CRDI
Engine Electric components CAMSHAFT wHEEL SENSOR
▶ Resistance by measured temperature Temperature (˚C)
Resistance (Ω)
-40
169.7
-20
185.1
0
200.5
25
219.6
50
238.5
100
275.9
150
312.7
200
349.0
250
384.6
300
419.7
350
454.2
400
488.1
450
521.4
500
554.1
600
617.8
700
679.2
800
738.2
900
794.9
1000
849.2 U89WB37A
•
HI4W189A
Connector
The camshaft wheel sensor is installed to the side of the gear case in the front section of the engine. This sensor is aligned with the operating trajectory of the camshaft wheel to detect the rotating condition of the camshaft. It supplies information about cylinder stroke or position to the ECU to control the fuel injection timing.
G
R U89WB35A
The camshaft rotates at a half speed of the crankshaft. When the piston moves toward TDC while controlling the intake and exhaust valves of the engine, this sensor detects the position of the camshaft to check whether a particular cylinder is at the compression stroke or exhaust stroke. Especially, when the engine is initially started, it is hard to identify the stroke condition of a particular cylinder only with information from the crankshaft wheel sensor. Therefore, information from the camshaft wheel sensor is necessary to identify the accurate stroke condition of cylinders after the engine is initially started. On the other hand, after the engine is started, information from the crankshaft wheel sensor is fed to the ECU which then learns conditions of every cylinder in the engine. Therefore, afterwards the engine can keep running even when the camshaft wheel sensor is malfunctioning.
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Engine Electric components
CRDI
EgR vALvE SENSOR •
Operating temperature range: -40℃ ~ 150℃
•
Possible speed range: 15 ~ 4,000 rpm
•
Supplied power (Vs): 6 ~ 24 VDC
•
Supplied current: Max. 10 mA
•
Output (Vout): Max. 24 VDC Max. 20 mA
•
Connector Vs
Ground
Vout
U89WB21A U89WB20A U89WB38A
The EGR (Exhaust Gas Recirculation) valve sends some of exhaust gas back into the cylinder through the intake port to decrease the combustion temperature during ignition in order to decrease NOx (Nitrogen Oxides) in exhaust gas. The EGR valve sensor detects the position of the valve so that the EGR valve can control the air intake amount.
208
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CRDI
Engine Electric components
EgR vALvE SENSOR ▶ Input/Output diagram
MAF 흡입공기량
Intake air amount
Intake air 흡입온도 temperature
Large air volume
Small air volume
가속/고부하
Accelerate/ high load
감속/공회전
Precise fuel amount control
Precise EGR control
Fuel control 연료제어
EGR valve EGR control 밸브제어
공 기 량 많 음
U89WB19A U89WB18A
The MAF sensor consists of the intake air flow sensor and intake air temperature sensor. It measures the amount and temperature of the intake air and sends these information to the ECU which then uses these information to set the injection amount and timing. The intake air amount information is also used as a primary condition for the EGR control. •
It measures the amount and temperature of the air drawn into the engine.
•
Its measurement is used as an important information to determine the fuel injection amount for theoretical air-fuel ratio control.
•
Its measurement is also used as a feedback signal for EGR valve control.
•
Intake air amount - output as digital signal, intake air temperature - output as digital/analogue
정 밀 한 연 료 량 제 어
공 기 량 적 음
Decelerate/ idle
정 밀 한 E G R 제 어
U89WBD2A
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CRDI
Engine Electric components INTAkE AIR pRESSURE SENSOR/TEMpERATURE SENSOR
▶ Intake air temperature sensor Applied temperature
-40℃ ~ 200℃
range (continuous) Supplied power
•
U89WB24A
(1) Intake air pressuresensor (2) Intake air temperature sensor
The intake air pressure sensor and temperature sensor are installed on the intake manifold side by side. The intake air pressure sensor detects the pressure of air drawn in forcibly by the turbocharger precisely for use as important information to determine the optimal fuel injection amount. Also, the intake air temperature sensor detects the temperature of the intake air by its resistor which its resistance value is changed by changes in the air temperature. This information is used to identify the exact air mass and adjust the fuel injection amount accordingly for optimum operation.
5 ± 4% VDC
Probe characteristics
Temperature
Resistance (Ω)
TEMP. TOL.
(˚C)
MINIMUM NORMAL MAXiMUM
( ± ℃)
-40
36,308
39,650
42,992
1.5
-20
12,890
13,844
14,798
1.4
0
5,179
5,489
5,799
1.3
20
2,316
2,419
2,522
1.1
25
1,925
2,000
2,075
1.0
50
805.8
833
860.2
1.0
80
326.7
336.1
345.5
1.0
100
190.7
197.3
203.8
1.3
150
60.93
63.77
66.61
2.2
180
34.45
36.26
38.08
2.8
200
24.49
25.87
27.25
3.3
▶ Intake air pressure sensor Guaranteed pressure range
20 ~ 300 kPa
Guaranteed temperature range
-40℃ ~ 125℃
Guaranteed supplying power
4.75 ~ 5.25 V
Max. current consumption
•
12.5 mA
Pressure sensor output characteristics Vs = 5 V VOLTAGE (V) 4.6500 3.7393
2.2214 0.7036 0.4000 20
40
140
240
300
PRESSURE (kPa) U89WB25A
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CRDI
Engine Electric components
dpF dIFFERENTIAL pRESSURE SENSOR (TIER4 MOdEL) •
Supplied power: 4.75 ~ 5.25 VDC
•
Supplied current: Max. 10 mA
•
Operating temperature range: -40℃ ~ 145℃
•
Operating pressure range (difference between ports): -10 ~ 150 kPa
•
Pressure range in normal mode (each port): 50 ~ 250 kPa
•
Connector GND SUPPLY OUT
U89WB40A U89WB39A
The DPF differential pressure sensor is installed on the top of the CCRT (Catalyzed Continuously Regenerating Trap).
If excessive PM is accumulated, air passage is blocked, resulting in high pressure difference between the front and back of the DPF. The differential pressure sensor detects this pressure difference and sends this information to the ECU. If a certain amount of PMs is detected in the CCRT, the post-injection is performed to increase the temperature of the DOC to 450 to 500℃ in order to regenerate (oxidize) PMs. The post-injection process is activated only when the amount of PMs is over the specification. In a normal condition, the PM amount is monitored.
▶ Differential pressure sensor characteristics
Sensor signal voltage (V)
The CCRT is mainly composed of the DOC (Diesel Oxidation Catalyst) and DPF (Diesel Particulate Filter). When exhaust gas passes through this trap, hydrocarbon soot called PM (Particulate Material) is accumulated in the DPF.
U89WB41A
Pressure difference between inlet and outlet of CCRT CCRT U89WBD5A
The differential pressure sensor detects the pressure difference between the inlet and outlet of the CCRT and sends a signal value of 0.5 to 4.5 V to the ECU. The larger the pressure difference between the inlet port and outlet port is, the closer the signal value gets to 4.5 V. The smaller the pressure difference is, the closer the signal value gets to 0.5 V.
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Engine Electric components
CRDI
AIR CONTROL vALvE SENSOR (TIER4 MOdEL)
U89WB43A HI4W190A
The air control valve sensor is installed to the air control valve between the turbocharger intake hose and intake manifold flange. The air control valve adjusts the amount of air entering the intake manifold. The operating angle of the blade at its inlet is changed according to the depressed amount of the accelerator pedal to control the intake air amount into the engine. Therefore, this sensor detects the opening angle of the blade and sends this information to the ECU which then adjust the fuel injection amount accordingly.
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CRDI
DIAGNOSTIC
10. DIAGNOSTIC 10.1 DIAGNOSTIC PROGRAM uvIM COMMUNICATION MOdULE pARTS
USB Cable Diagnostic Connector uVIM Communication Module h89wb62a
uvIM COMMUNICATION MOdULE CONNECTINg METHOd Connect to notebook
LINk CONNECTOR
14 - 247 Connect to vehicle
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-
- 254
- 248 999 999 -
- 253
-
HI4W192B
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DIAGNOSTIC INSTALL pROgRAM ▶ Install Microsoft Visual C++ 2008 SP1 Redistributable Package
CRDI
uvIM USB dRIvER RECOgNITION ▶ WINDOWS 7 - AUTOMATICALLY INSTALLED
1. Copy vcredist_x64_eng.exe and vcredist_x86_eng. exe on laptop’s wallpaper. 2. If you use 32bit’s OS, Install vcredist_x86_eng.exe. 3. If you use 64bit’s OS, Install vcredist_x64_eng.exe. 4. If you don’t know OS type, Install vcredist_x86_eng. exe. If it doesn’t install, Install vcredist_x64_eng.exe
▶ Install FT4 Diagnostic Program 1. Copy Installation Program on laptop’s wallpaper. 2. Run Installation Program. 3. Install Program. 4. Installation completed.
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5. Icon will be shown on wallpaper.
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CRDI
DIAGNOSTIC
▶ WINDOWS XP 1. After installing the program, please progress as follows. 2. Connect deskuVIM to laptop by USB cable. 3. Progress as follows.
N60WCD4A
N60WCD2A
N60WCD5A
N60WCD3A
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CRDI
DIAGNOSTIC USER AUTHENTICATION ANd LOgIN ▶ Authentication
Hqwhu#wkh#fruuhvsrqglqj# qxpehu#iurp# dgplqlvwudwru
H89WB70D
1. When you run the program, registration screen will be shown. 2. Original Number of installed laptop will be shown. 3. Transfer Original Number to administrator. Receive applicable Key value and enter applicable Key value. 4. Click OK button.
▶ LOGIN
Hqwhu#LG
Hqwhu#Sdvvzrug
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1. If it has been normally registered, Login screen will be shown. 2. Enter ID and PW that received from administrator. 3. Click OK button.
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CRDI
DIAGNOSTIC
pROgRAM MANUAL ▶ Upper Menu
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•
MENU(M)
- Exit : Exit the program.
•
SETTING(S): Set the setting value for program.
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- Language : Korean/English choice
•
HELP(H)
- Communication Port : uVIM USB Port
- Delay : Enter as 500. If reprogram time is over 5 minutes, enter as 0.
- FT4Scan Information : Program version and Release Date will be shown.
- Fault code : f ault code list will be shown on screen.
- Manual : Help will be shown on screen.
- FlowControl Time : Set as 0
- Consecutive Frame : Set as 2
- Temperature : Kelvin, °C, °F
- Pressure : bar, hPa
- Time : s(second), hour
•
VIEW(V)
- Application Shape : Change program screen as various types.
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CRDI
DIAGNOSTIC
Vwduw2Vwrs
Surjudp#Lqir1
Idxow#Frghv
HFX#lqirupdwlrq
Gdwd#Prqlwrulqj
Uhsurjudpplqj
Vkds#Vkrw Hqjlqh#Whvw
Diwhu#Vhuylfh Lqsxw2Rxwsxw#Whvw
h89wbM1B
•
If you click icon, run that function. If you move mouse’s point to icon, display icon’s short name.
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CRDI
DIAGNOSTIC
▶ Main Menu START
STOp
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•
Start Button: Starting communication between FT4Scan Program and Vehicle ECU.
•
Stop Button: Closing communication between FT4Scan Program and vehicle ECU.
FAULT COdES
2
3
1
4
6
7
5
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•
Click the Fault Codes button and failure information will be shown. (1) Erasing Fault Codes. (2) Save Fault Codes as Excel file. (3) Indicating current Fault Codes. (4) Indicating Fault Codes number.
(5) Indicating description of Fault. (6) Indicating Current DTC/History DTC. (7) Checking detailed description of applicable fault
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DIAGNOSTIC
CRDI
h89wb77B
•
Click Description(7) button, checking detailed description of applicable fault is available.
REMARK • •
FAULT COdE INFORMATION - dETAIL
• • • • • • • • • • •
1
• •
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• Click HELP(1) button and Fault code help file will be opened. • • • • • • •
h89wb79A
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CRDI
DIAGNOSTIC
▶ Data Monitoring
2
3
4
5
B
C
1 6 7
8
9
A
D
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• I
Click Data Monitoring, you can check Engine data value. (1) Activate Snapshot function. (2) Start Auto Start function. (3) Save Snapshot Data. (4) Stop Data saving. (5) Indicating saved Snapshot frame. (6) Choose Data Group that will be indicated on screen. (7) ndicating All data of chosen group.
(8) Indicating checked data from D section only. (9) Indicating data indicated from Step 8 as Graph.
(A) Save indicated data as Excel. (B) Save data list indicated from Step 8. (C) Open data saved from B. (D) Select/cancel each item.
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DIAGNOSTIC
A. SAvE SANpSHOT
CRDI
B. gROUp SELECTION
h89wb82B
•
Can select Data by Group. ALL SELECT
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•
Function that saves currently indicated data value.
- Auto Start : S ave data based on Before/After occurrence of Fault Codes.
- Manual Start : Save data based on Before/After click button.
1. Check Snapshot and button will activate. 2. Click Start button and Stop button will activate. h89wb83B
3. Click Stop button and save file. 4. Y ou can check saved Snapshot file by Snapshot function of main menu
AFTER TREATMENT SELECT
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CRDI
DIAGNOSTIC
C. ALL/SELECT C-1. SELECT dATA THAT wILL BE INdICATEd
h89wb85b
C-2. CLICk SELECT BUTTON
h89wb86b
•
Can indicate selected data among displayed data.
C-3. INdICATE SELECTEd ITEM
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C-4. INdICATE ALL ITEM
•
When you select ‘All’ from C-2, No.1 will be shown.
•
Select ‘All’ again, checked item will be released.
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CRDI
DIAGNOSTIC d. gRApH
•
After progress until “C” of C-3, click graph button and selected item value can be seen as Graph
1
2
3
4
9
5
6
7
8 h89wb88B
(1) Indicating min/max standard of sensor value as 0~100%. Sensor will be separated by color.
(5) Delete graph screen.
(2) Indicate sensor value. Click min/max value and can change standard value.
(7) Save graph screen as image file.
(3) When graph stops, move standard line no.(9) as left/right.
(6) Start/Stop : Start or stop indicating graph. (8) Exit graph screen.
(4) Can magnify no.1 screen double/ quadruple to Time axis. INdICATE SENSOR vALUE
h89wb89B
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CRDI
DIAGNOSTIC
E. SELECT ITEM CLICK CLICK
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h89wb92B
h89wb91a
•
If you select/save frequent item, you can check selected data by opening applicable file when you run next program. After select C-3, click Save Selection button. Save selected item as selectable name.
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Selected System Display
Indicate checked item
h89wb94B
h89wb95B
•
When you click Selection button, selected item will be indicated only.
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DIAGNOSTIC
CRDI
▶ SNAP SHOT
3
4
1 2 6
5
h89wb96B
•
When you click Snap Shot button, Snap Shot screen will be displayed. You can check saved data. (1) Select data saving file. (2) Select wanted item from data items. (3) Frame number that is shown on screen. (4) Save Time of applicable frame.
(5) Indicating selected item as graph. (6) Save current screen contents as axel.
A. SELECT FILE CLICK
h89wb97B
•
Click File Selection
h89wb98B
•
Choose File.
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CRDI
DIAGNOSTIC
h89wb99B
•
Indicate saved data.
B. FRAME CHANgE
FOLFN
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•
When you click arrows next to Frame section, Frame will be changed. When Frame is changed, data value of applicable Frame will be indicated. Time of applicable Frame will be indicated on right.
C. gRApH
•
Graph function is the same with Graph function of Data Monitoring.
d. SAvE AS ExCEL
•
Function of saving as excel is the same with Graph function of Data monitoring.
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CRDI
DIAGNOSTIC
▶ ENGINE TEST •
When you click Engine Test, Run-up Test, Shut-off Test, Hydraulic Test, Compression Test and High Pressure Test will be shown at the bottom.
- Run-up Test: Grasp the differences of individual cylinder's power ability.
- Shut-off Test: Check injector efficiency of individual cylinder.
- Hydraulic Test: Check backleak of injectors.
- Compression Test: Check speed of pistons.
- HighPressure Test: Check fuel rail pressure change.
h89wbA2b
A. RUN-Up TEST
4
2
3
1 3
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(1) Click Run-up Test, Test terms will be shown. (2) Click Auto Start button, Test will be started.
- If it doesn’t meet the terms, it will not be started. - I t will be progressed from no.1 cylinder to no.4 cylinder in order. (3) When Test is completed, result value will be shown. (3) Each cylinder’s gradient of rising section and falling section will be indicated.
- In case of normal, rising section should be indicated as the same gradient except Blue. In case of normal, all falling section should be shown as the same gradient. - When gradient is different, you can expect there’s
error in cylinder. 4. Click “Help” button, Test description display.
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CRDI
DIAGNOSTIC
B. SHUT-OFF TEST
3
4
6
2
1 5
h89wbA4b
(1) Click Shut-Off Test, Test terms will be indicated. (2) In case of testing, indicate sensor value. (3) Click Auto Start button, it will progress as NONE, 1, 3,
4, 2 order. - When it doesn’t meet terms, it won’t be started.
(4) You can test individually by each cylinder. (5) Indicate Test Result.
- In case of NONE, indicate Fuel injection quantity as (100%) based on Fuel injection ratio. - Indicate result in case of Auto Start only. (6) Click “Help” button, Test description display.
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CRDI
DIAGNOSTIC C. HYdRAULIC TEST
3
4
7
2
6
5
1
h89wbm2B
(1) Click Hydraulic Test, Test terms will be shown. (2) In case of Testing, indicate related sensor value. (3) Click Auto Start button, Cranking by messages of message box. - When it doesn’t meet terms, it won’t be started.
(4) Click Stop button to stop Test. (5) Indicate Test Result. (6) Explain Test terms. (7) Click “Help” button, Test description display.
230
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CRDI
DIAGNOSTIC
d. COMpRESSION TEST
3
7
4
2
5 6
1
h89wbm3B
(1) Click Compression Test, Test terms will be shown. (2) In case of Testing, indicate related sensor value. (3) Click Auto Start button, Cranking until stop command
appears. - When it doesn’t meet terms, it won’t be started.
(5) Indicate Test Result.
- Indicate comparing value based on the highest Fuel
injection time. (6) Explain Test terms. (7) Click “Help” button, Test description display.
(4) Click Stop button to stop Test.
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CRDI
DIAGNOSTIC E. HIgH pRESSURE TEST
3
4
7
2
6
5
1
h89wbM4B
(1) Click High Pressure Test button, Test terms will be shown. (2) In case of Testing, indicate related sensor value. (3) Click Auto Start button, Cranking. Then, engine will be on and test will be started. - When it doesn’t meet terms, it won’t be started.
(4) Click Stop button to stop Test. (5) Indicate Test Result. (6) Explain Test terms. (7) Click “Help” button, Test description display.
232
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CRDI
DIAGNOSTIC
▶ INPUT/OUTPUT TEST •
Can test Actuator item by Input/Output Test.
•
Test Item
(1) Throttle Actuator
(7) Water In Fuel Lamp
(2) EGR Valve
(8) DPF Underway Lamp
(3) Glow Plug
(9) Regen Warning Lamp
(4) HP Pump/IMV Valve
(10) PTO Cruise Lamp
(5) Check Engine Lamp
(11) RPM Guage
(6) Glow Plug Lamp
(12) Injector
h89wbA5B
A. SCREEN ExpLANATION
5
6
7
1
2
3
4
h89wbA6B
(1) Select Input/Output Test item. (2) Indicate conditions for Test. (3) Indicate Test status. (4) Indicate Data value that needs to be checked for Test.
(5) Start Test. (6) Stop Test. (7) Data value will be shown as Graph.
233
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DIAGNOSTIC
CRDI
▶ AFTER SERVICE •
Click After Service button, lower items will be shown.
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h89wbA8B
- In case of replace Part Replacement item, Click Apply button and apply replacement issue to ECU.
- Progress After Service item in case of need.
- If you want to stop working, click Return button.
234
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CRDI
DIAGNOSTIC
A. ECU CHANgE
CLICK
CLICK
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1. Click ECU Data Download Button.
h89wbB3B
4. After replacing ECU, click ECU Data Upload button.
CLICK
CLICK
h89wbB1B
2. Download ECU Data.
h89wbB4B
5. Select data file.
CLICK
CLICK
h89wbB2B
3. Save Download data as file.
h89wbB5B
6. Upload Complete message will be shown. REMARK • In case of replace ECU, download ECU Data on PC first. After the replacing ECU, please upload downloaded ECU Data.
235
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DIAGNOSTIC
B. INjECTOR COdINg
CRDI
C. CLUSTER
1
3
2 h89wbB6a
(1) Enter replaced injector number. (2) Click Write button. (3) Click Read button, check it.
•
In case of replacing Injector, enter installed injector’ s No. (20 digits).
h89wbB7B
•
In case of replace Cluster, Please check whether Lamp operates normally.
•
Click each item and applicable Lamp or Guage will be operated. At this moment, check the status of applicable Lamp or Guage by Cluster screen.
d. Others
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•
Besides A ~ C items, it will immediately applied when you click Apply button.
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CRDI
DIAGNOSTIC
E. dpF REgENERATION
•
Click DPF Regeneration’s Apply button, it will progress Regeneration.
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2.
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1. Click DPF Regeneration Apply button, ‘Run Engine’ message will be shown.
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4. If it doesn’t meet Test conditions, Error message will be shown.
$SSOLQJ LV DERUWHG
2.
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2. Click ‘Yes’ button to continue.
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5. If it meets Test conditions, it will star t DPF Regeneration. But when appling is aborted, Error message will be shown.
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3. Test conditions will be shown.
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DIAGNOSTIC
CRDI
▶ REPROGRAM •
Reprogram function is entering update file to ECU when software of ECU is updated. Click Reprogram button and it will be shown as below.
h89wbC5B
2
3
1 4
6
5 h89wbC6B
(1) SW version of ECU will be indicated. (2) Select file. (3) Reprogram file route will be indicated.
(4) MAP version of file will be indicated. (5) Start button will be activated. (6) Click Start button and rate of progress will be indicated.
238
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CRDI
DIAGNOSTIC
▶ ECU INFORMATION
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3FT-HI4 Vehicle
h89wbC8d
239
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General service
CRDI
11. General service 11.1 Driving inspection 11.1.1 Engine startability inspection
Key switch → ON
Engine oil pressure warning lamp/charge indicator ON
Coolant temperature 15°C or higher: No need of preheating Coolant temperature below 15°C: Start engine after 15 seconds of preheating
Key switch → START
Engine oil pressure warning lamp/charge indicator OFF
Warm up engine at mid speed
240
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CRDI
General service
11.1.2 Inspection during driving OIL pRESSURE wARNINg LAMp When the engine oil pressure is dropped below the specified limit, this lamp comes on to warn the operator. If this lamp stays illuminated with the engine running or at 1,000 rpm or higher speed, stop the engine immediately and check the engine oil level.
FUEL Make sure that a sufficient amount of fuel is in the tank. If the tank becomes empty, air enters the fuel system. In this case, the system needs to be bled.
EMISSION COLOR Exhaust gas is almost transparent when the engine is running at the rated speed. However, when the engine speed is over the rated speed range, the color of exhaust gas becomes darker. If the engine keeps producing black smoke, it indicates malfunction. In this case, check the system.
ENgINE ROTATINg IN REvERSE dIRECTION If the engine runs in the reverse direction, engine oil is no longer circulated in the system, resulting in a serious problem. Make sure to stop the engine immediately if the engine rotates in the reverse direction. ▶ Symptoms for engine rotating in reverse direction 1. T he lubricant pressure is dropped significantly. If keeping using the machine under this condition, the oil pressure warning lamp comes on. 2. As the intake and exhaust sides are reversed, abnormal sound is produced from the engine and exhaust gas comes out of the air cleaner. 3. I f the engine is rotating in the reverse direction, large knocking sound is heard. ▶ Solution 1. Stop the engine immediately. 2. After stopping the engine, check the air cleaner, intake rubber tube and other parts and replace them as necessary. WARNING Stop the engine immediately under the following conditions: • When the engine speed increases or decreases suddenly • When abnormal noise is heard • When engine exhaust gas becomes black • When the oil pressure warning lamp or coolant temperature warning lamp comes on
CAUTION To avoid accidents: • Opening the radiator cap while the engine is running or right after the engine is stopped can spring out steam to have the operator burned. Make sure to wait for at least 10 minutes after the engine is stopped before opening the cap.
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General service 11.1.3 Engine warming up Warming up the engine is to ensure that each part in the engine is properly lubricated and each hydraulic part is in a perfect condition in order to prevent malfunction in the engine as well as the hydraulic system. Following this instruction can maintain the durability of the engine and secure its service life.
HOw TO wARM Up 1. S tart the engine and run it at a low speed and without a load for approx. 3 to 4 minutes. 2. In cold weather, increase the warm up time to 10 minutes. If it is very cold, warm up the engine for approx. 15 minutes. 3. T he engine is sufficiently warmed up when the temperature gauge on the instrument panel indicates 1/4 of the normal temperature range, regardless of the warming-up time.
CRDI
11.2 Daily inspection 1. Previously troubled part 2. Area around engine •
Oil and coolant for leakage
•
Engine oil level and contamination
•
Fuel amount
•
Coolant amount
•
PM amount in air cleaner
•
Damaged part and loose bolt/nut
3. After starting the engine •
Exhaust gas color
•
Abnormal engine noise
4. D o not increase the work load rapidly af ter starting work. Run the engine without load for approx. 2 to 3 minutes before stopping the engine after work. WARNING • Warming up the engine excessively increases fuel consumption and affects the durability of the machine negatively. Make sure to warm up the engine only for a proper amount of time.
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CRDI
General service
11.3 Periodic inspection No.
Operating year
Operating time
Item
1 2 50 100 150 200 300 400 600 800 year years
After Purchase
1
Engine oil
Change
○
2
Engine oil filter
Replace
○
3
Engine start system
Check
○
Every 50 hrs
4
Tightness on each part (tightening torque)
Check
○
Every 50 hrs
5
Battery condition
Check
○
Every 100 hrs
6
Air cleaner element
Clean
○
Every 100 hrs
7
Fuel filter
8
Fan belt
9
Radiator hose and clamp
10
Fuel line
11
Intake air line
12
Engine valve gap
Adjust
13
Cooling system
Clean
○
Every 2 years
14
Coolant (anti-freeze)
Change
○
Every 2 years
15
Bleeding fuel system
Check
Service as necessary
16
Radiator screen
Clean
Daily
17
CCRT
Check
Service as necessary
Replace Clean
Every 100 hrs
○
Replace Adjust
Every year
○
Every 200 hrs
○
Every 100 hrs
○
Check
Every 600 hrs
○
Replace Check
○
Every 200 hrs
○
Replace Check
○
• ⊙ must be done after the first 50 hours of operation. • Do not try to repair the ECU, high pressure pump, common rail, injector, alternator and start motor by yourself. Have them check by your dealer. • Otherwise, the vehicle's safety cannot be guaranteed any longer due to their abnormal conditions.
Every 2 years Every 200 hrs
○
Replace
Remark
Every 2 years
○
Every 2 years Every 800 hrs
○
Remark
REpLENISHMENT LIST Fuel Coolant Engine oil
-
Use only ultra sulfur diesel (SISD) fuel with a maximum of 15 mg/kg (15 ppm) sulfur content
3.4 ℓ Ethylene glycol 50% + Water 50% 6ℓ
API CJ or or higher grade SAE 10W 30, 10W 40, 15W 40
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General service
CRDI
11.3.1 Fuel system CHECkINg FUEL LEvEL
CHECkINg FUEL pIpE
1. C heck if the fuel level is below the lower limit marked on the dipstick before adding fuel into the fuel tank. CAUTION • Before refueling, make sure to stop the engine and keep any flammable away from the engine. If a different type of fuel, such as gasoline, is added into the fuel tank, it can damage the high pressure pump. Never replenish the tank with a different type of fuel. HI4W193A
Important • Use only ultra sulfur diesel (SISD) fuel with a maximum of 15 mg/kg (15 ppm) sulfur content
1. Check the fuel pipe system for every 200 hours of engine operation. •
If any clamp is loose, apply a small amount of oil to the band bolt and tighten it firmly.
•
Rubber fuel pipes can be worn naturally regardless of operation time of the engine. Therefore, replace them every two years.
•
If any pipe or clamp is worn prematurely, replace it immediately.
Important • Use a strainer when pouring fuel into the tank. Otherwise, foreign materials or sand may enter the fuel system, causing a problem to the high pressure fuel pump and other parts. • Make sure that the fuel tank does not become completely empty. If the fuel tank becomes empty, air enters the fuel system and the system needs to be bled to start the engine again. • When refueling, be careful not to spill fuel. If spilled, wipe it clean to prevent a fire.
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CRDI
General service
REpLACINg FUEL FILTER
BLEEdINg
HI4W194A
HI4W195A
(1) Fuel filter
(1) Bleeding bolt
1. Replace the fuel filter with a new one for every 200 hours of engine operation.
1. Make sure to bleed the fuel system after adding fuel to the completely empty fuel tank, draining water from the fuel filter or replacing the fuel filter.
2. D uring installation, apply a thin coat of engine oil on the sur face of the O-ring, screw in the filter with a hand, and tighten it firmly with a filter wrench. Important • Replace the fuel filter periodically to prevent blockage of the high-pressure fuel pump and injector due to foreign materials in fuel.
(2) Priming pump
2. To bleed the system, unscrew the bleeding bolt (1) on top of the fuel filter and press the priming pump (2) repeatedly until fuel in the fuel tank is delivered to the fuel filter. 3. W hen fuel f lows out from the bleeding bolt, tighten the bleeding bolt. CAUTION • Never crank the engine to run the high pressure pump for bleeding.
WARNING
T11O104A
• High-pressure fluid left in the fuel system can cause a severe injury. Never try to remove or repair the high-pressure fuel pump, common rail and fuel pipes around the injectors. • Have them serviced by well-trained technicians and contact your dealer for service.
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General service
CRDI
11.3.2 Engine oil INSpECTINg OIL LEvEL
CHANgINg OIL
HI4W196A
TE4W505A
1. Change engine oil after 200 hours of initial engine operation. 2. While the engine is warm, unscrew the engine oil drain plug to drain engine oil. 3. Tighten the drain plug and add the specified oil through the oil filler neck up to the upper level limit.
REpLACINg OIL FILTER
HI4W197A
(1) Oil filler neck (2) Dipstick
(A) Proper level
1. Check the level on level ground before starting the engine or in 5 minutes after the engine is stopped. 2. P ull out the dipstick, wipe it out, and insert it again. Then, pull it out and check if the level is within the proper range. 3. If the level is low, add the specified oil through the oil filler neck up to the proper level. Model
Proper oil amount
3F183T
5.8 ℓ
3FT-HI4
6.0 ℓ
4F234T
9.7 ℓ
Oil specification
API CJ or or higher grade SAE 10W 30, 10W 40, 15W 40
HI4W198A
(1) Oil filter
1. Replace the oil filter as well when changing engine oil. 2. D uring installation, apply a thin coat of engine oil to the gasket of a new cartridge, screw in the cartridge with a hand, and tighten it firmly with a filter wrench. 3. A f ter star ting and r unning the engine for a moment, check the engine oil level and add more oil as necessary. (The oil level is decreased a little by replacement of the oil filter.)
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CRDI
General service
11.3.3 Coolant CHECkINg COOLANT LEvEL
CHANgINg COOLANT
1
051W603B
TE4W507A
(1) Pressure cap
1. Open the radiator cap and check that the coolant is filled up to the filler neck.
1
A HI4W199A
(1) Drain Plug
B 051W605B
(1) Reservoir tank
(A) FULL (B) LOW
2. I f the machine is equipped with a reser voir tank, check that its coolant level is between the FULL and LOW marks. If the coolant amount is insufficient, add clean water to the radiator or reservoir tank. WARNING • When starting the engine after adding coolant, the coolant level drops. Then, stop the engine and add more coolant.
(2) Drain cock
1. To drain used coolant in the system completely for new coolant, unscrew the drain plug on the side of the crankcase and unscrew the drain cock on the radiator. Then, open the radiator cap to drain coolant. ▶ Coolant amount (only in engine) Model
Capacity
3F183T
3.5 ℓ
3FT-HI4
3.4 ℓ
4F243T
4.2 ℓ
Coolant Ethylene glycol (50%) + Water (50%)
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CRDI
General service
11.3.4 Others CHECkINg RAdIATOR HOSE
SERvICINg AIR CLEANER
1. Check the hoses for every 600 hours of engine operation. •
If any clamp band is loose or leakage is found around it, tighten it firmly.
•
If any hose is swollen, hardened or cracked, replace it with a new one.
2. Replace hoses and clamps every two years. If any of them has a problem before two years, replace it immediately.
CLEANINg RAdIATOR 1. Clean the radiator for every 500 hours of engine operation. Also, flush the radiator with distilled water thoroughly before and after using antifreeze.
2
2
1 051W110B
(1) Air cleaner body
(2) Element
1. To keep the full service life of the engine, it is necessary to keep the air cleaner clean at all times. 2. Under a normal condition, remove foreign materials from the element every week. In a dusty condition, clean the element every day. 3. R emove dust f rom the element by blowing compressed air (686 kPa, 7 kgf/cm2, 100 psi 이하) from its inside toward the outside. 4. Replace the element with a new one after 6 times of cleaning or every year.
SERvICINg BATTERY 1. Mishandling the battery shortens its service life and adds to maintenance costs. It is important to inspect the battery periodically. 2. Check the battery and cable for damage and corrosion. Keep them clean and securely fixed at all times. 3. Apply grease to the terminals and cable ends in order to prevent corrosion. 4. To slow charge the battery, connect the battery positive terminal to the charger positive terminal and the negative to the negative, then recharge in the standard fashion. 5. W hen the battery is discharged and should be replaced, replace it with a new one with same specification and capacity. 6. T he battery self discharges while it is stored. Recharge it once every three months in hot seasons and once every six months in cold seasons.
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CRDI
General service
SERvICINg FAN BELT 2
1
TE4W511A
(1) Battery
(2) Sight glass
7. Check the battery sight glass frequently to keep the battery in the best charging condition. Sight glass
Battery condition
Blue
Battery normally charged
Black
Battery discharged, immediate charge required
White
Replace the battery
HI4W1A1A
1. Adjust the tension of the fan belt correctly. Check if the fan belt is deflected for 7 to 9 mm when pressing its middle with force of 10 kgf using a finger. 2. Check the fan belt for crack or damage. If any damage is found, replace it with a new one.
WARNING • The battery gas can explode. Do not expose the battery to flames or sparks. It may cause a fire. • The battery fluid contains sulfuric acid that can burn you. Do not allow the battery fluid to contact your eyes, skin, or painted surfaces. If you accidentally get it in your eyes or on your skin, flush with water several times immediately and contact your doctor. • The battery fluid can hurt your eyes. Be sure to wear eye protection while working on the battery. • Use only the battery with the specified voltage to prevent a fire.
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MEMO
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