34

06

PREHEATING SYSTEM

ECU

Glow Indicator (Meter Cluster)

Glow plug
Preheat relay

Battery

Tightening torque
when installing
15 3 Nm

No G5 for
4 cylinders
(Without D20DT)

IG1 power supply

terminal

Glow plug control

signal (ECU113)

Ground
terminal
Battery main
wire
Glow plug terminal
(#1 ~ #4)

COOLING SYSTEM
ACTYON SM - 2006.03

K-line
(ECU 34)

Preheat completion transmit

terminal : No use for vehicle
without remote engine start

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OVERVIEW
Glow plug is installed on the cylinder head (combustion chamber) in the D20DT preheating control unit system. Cold
starting performance has improved and exhaust gas during cold starting has reduced.
ECU receives coolant temperature and engine speed to control; after monitoring the engine preheating/post heating
and glow plug diagnosis function, the fault contents will be delivered to ECU.

HOUSING

1. Engine preheating/post heating functions

GENERAL

35

ASSY

06

2. Preheating relay activation by ECU controls

1) Senses engine temperature and controls the preheating/after heating time

EXHAUST I N T A K E

2) Glow indicator
3. K-LINE for information exchanges between preheating unit and ECU
1) Transmits preheating unit self-diagnosis results to ECU
2) Transmits glow plug diagnosis results and operating status to ECU

LUB

PREHEATING RELAY

CONTROL

IG1
Power terminal

Glow plug
control signal
(ECU 113)
Ground
terminal

B+main wire
(12V)
Glow plug
terminal

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COOLING SYSTEM
ACTYON SM - 2006.03

SENSOR

K-LINE #1
(ECU 34)

FUEL

COOLING

Structure

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06

PREHEATING SYSTEM DIAGRAM

Coolant
temperature
sensor

113

Specifications
Description

Specification

Rated voltage

DC 12 V

Operating voltage range

DC 8 ~ 15 V

Operating range

- 40 ~ + 100C

Relay operating voltage

Over 6.5 V

Relay releasing voltage

Over 1.5 V

Relay coil resistance

11.3

Voltage drop

Below 150 mV at each glow plug (at 16A of current)

Parasitic current

MAX 1 mA

COOLING SYSTEM
ACTYON SM - 2006.03

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1. The power will be supplied to the glow plugs by ECU controls when the power is supplied to the IG terminal from the
battery and there are normal communications with ECU within 2 seconds. The surface of glow plug will be heated
up to 850C very quickly to aid combustion by vaporizing air-fuel mixture during compression stroke.
2. Preheating time is controlled by ECU.
Post-heating
1. When the engine is started, post-heating starts by ECU controls. The idle rpm will be increased to reduce toxic
smoke, pollutants and noises.
2. Post-heating time is controlled by ECU.
Checking glow plugs
1. Check each glow plug for short in circuit
2. Check each glow plug for open in circuit due to overvoltage
3. Check glow plug for short to ground

LUB

Forceful relay shut-down

HOUSING

Pre-Heating

EXHAUST I N T A K E

Preheating system controls and checks following functions and operating conditions.

ASSY

GENERAL

Function

1. When glow plug is shorted to ground

1. ECU sends the results to preheating time control relay through K-Line to start communication.
2. Preheating time control relay sends messages including self-diagnosis data for glow plugs to ECU.
3. Glow plug makes communication only as response to demand.

FUEL

4. When power is supplied, ECU starts self-diagnosis within 2 seconds.

5. Under the following conditions, communication error occurs.

CONTROL

1) When there is no response from glow plug module within 2 seconds

2) When an error is detected in checksum
3) Less byte is received

Defective

SENSOR

DTC
DTC

Detailed description

P1678

Glow plug open

Preheat control driver open

P1679

Glow plug short

Preheat control driver short

P1680

Glow plug - short to ground

Preheat control driver is short to ground

P1676

Glow plug communication fault

Communication fault between ECU and preheat controller

P1677

Defective glow plug controller

Communication fault between ECU and preheat controller

P0671

Defective No. 3 glow plug

No. 3 glow plug open

P0672

Defective No. 4 glow plug

No. 4 glow plug open

P0673

Defective No. 5 glow plug

No. 5 glow plug open (N/A for D20DT engine)

P0674

Defective No. 1 glow plug

No. 1 glow plug open

P0675

Defective No. 2 glow plug

No. 2 glow plug open

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COOLING

K-Line communication

COOLING SYSTEM
ACTYON SM - 2006.03

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06

Operating time
Coolant Temp.

-35 C

Pre31 sec
Operating Time
heating
IG: ON
Operating
Conditions

Postheating

-25 C

-20 C

-10 C

0 C

10 C

20 C

22 sec

19 sec

17 sec

14 sec

0 sec

0 sec

After operating time elapsed

Release
Conditions IG: OFF When engine cranking

B+ : below 15.2V

Coolant Temp.

-30 C

-20 C

-10 C

0 C

10 C

20 C

35 C

Operating Time

115 sec

80 sec

30 sec

19 sec

11 sec

11 sec

0 sec

After engine starting

After operating time elapsed

Release
Torque : 190/170 Nm
Conditions
Speed: 2100/2050 rpm

Operating
Conditions
Coolant Temp.

-30 C

-25 C

-20 C

-10 C

0 C

10 C

20 C

Glow Operating Time

Indicator
Operating

18 sec

16 sec

10 sec

5 sec

2 sec

0 sec

0 sec

Conditions

COOLING SYSTEM
ACTYON SM - 2006.03

IG: ON

Release
When engine cranking
Conditions

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GENERAL

06

Removal and Installation

ASSY

1. Turn the ignition switch to OFF position and disconnect the negative battery cable.

EXHAUST I N T A K E

HOUSING

2. Set aside the harnesses on the cylinder head.

3. Disconnect the glow plug connectors and loosen the

glow plugs.
Installation Notice

COOLING

LUB

Tightening torque

SENSOR

CONTROL

FUEL

4. Remove the glow plugs from the cylinder head with a

special tool. Plug the openings of the glow plugs with
sealing caps.

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COOLING SYSTEM
ACTYON SM - 2006.03

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06

PREGLOW PLUG
Two versions of preglow plugs are used in this vehicle.
Always use only the designated version with correct color mark on insulator surface.

Specifications
BERU version

NGK version

Color mark on insulator surface: Green

Color mark on insulator surface: Yellow

Tip diameter: 4

Tip diameter: 3.5

Resistance: 680 110 m at 20 2C

Resistance: 1400 300 m at 20 2C

Green

Yellow

The color mark on insulator surface may be invisible due to the carbon contamination. To check the color easily,
disconnect the harness connector and clean the preglow plug mounting area with carbon cleaner.
Wait for a while and blow out the area with a compressed air.
Clean and Blow Out

Check the Color Mark

Air gun

COOLING SYSTEM
ACTYON SM - 2006.03

Check the color mark

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Preparations for Replacing Preglow Plug

Preceding Work: Disconnect the negative battery cable.

1. Disconnect the wiring harness with long nose pliers and clean the preglow mounting area with the compressed
air (using air gun).

FUEL
SENSOR

CONTROL

2. Spray the carbon cleaner into the gap between preglow plug and cylinder head and wait for 10 minutes. Remove
the dirt and foreign materials completely with the compressed air (using air gun)..

COOLING

LUB

Air gun

EXHAUST I N T A K E

Removal and Installation of Preglow Plug

HOUSING

ASSY

Torque wrench, Air gun (small), Carbon cleaner (Product name: IPO CHOKE & CARBURATOR CLEANER, Model
name: PRO NO 5007, Manufacturer: Sunbo), Engine oil, Preglow plug wrench (special service tool), Long nose
pliers

GENERAL

06

NOTICE
At this moment, check the color mark on insulator surface and bring the same version of preglow plug for
replacement. (BERU: Green, NGK: Yellow)

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COOLING SYSTEM
ACTYON SM - 2006.03

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06

3. To avoid damage, apply the engine oil into the gap between preglow plug and cylinder head and wait for 5
minutes.

4. Remove the preglow plug with torque wrench. (tightening torque: 15 3 Nm)
NOTICE
To prevent the preglow plug from breaking, carefully turn the wrench with the torque below 20 Nm.
Never use the air impact tool or other tools.

5. Thoroughly remove the foreign materials from the preglow plug hole. If needed, use the carbon cleaner or air gun.

COOLING SYSTEM
ACTYON SM - 2006.03

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43
GENERAL

Remarks

Torque Wrench (max. 25 Nm)

Preglow plug wrench - Special Service Tool (10 mm)

2) SCAN-100 can display only one trouble code. Check whether each preglow plug circuit is open with multitester.

Color mark on
insulator surface

Tip diameter

BERU: Green
NGK: Yellow

BERU: 4 mm
NGK: 3.5 mm

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COOLING SYSTEM
ACTYON SM - 2006.03

CONTROL

1) Check the preglow plug trouble code with SCAN-100.

SENSOR

2. Preglow plug circuit check

FUEL

COOLING

LUB

Part number: Y99220132B

EXHAUST I N T A K E

HOUSING

Carbon Cleaner

ASSY

1. Required tools