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19FPG12
Page2
1. Main specification
Item Specification
Type In-line 4 cyl. Common rail system
Displacement 3,907cc
Compression ratio 17.5:1
Max. output 140ps / 2800rpm
Max. torque 38kgf.m / 1600rpm
Specification 26kg/㎠ (at 200rpm)
Compression pressure Service value 20kg/㎠
ΔP, among cyl. Within 4kg/㎠
Supply voltage 5V
Operating volt. 4.5 ~ 5.5V
Boost Pressure Sensor(BPS) Operating temp. -40 ~ 125℃
Operating pres. 32.5~284 kpa (244~2130mmHg)
Current MAX. 10mA
Type Thermistor type
Intake Air Temp. sensor(IAT) Resistance 2.31~2.56kΩ [at 20℃(68F)]
0.30~0.34kΩ [at 80℃(176F)]
Sensor Type Thermistor type
Water Temp. Sensor(WTS) Resistance 2.31~2.59kΩ [at 20℃(68F)]
0.314~0.331kΩ [at 80℃(176F)]
TDC sensor Type Hall sensor
CKP sensor Type Magnetic
Type Variable resistance type(potentiometer type)
Accel. Position Sensor(APS) Voltage 5V±1%
Current 10mA MAX.
Fuel Pressure Sensor Type Piejo electric type
Page3
Item Specification
Type Electric & Magnetic type
Actuator Injector
Resistance 0.45Ω
Supply Current At operation : below 1.29A
SCV
Control Valve At stop : below 1.16A
Fuel tank Capacity 100 liter
Fuel pressure of high pressure side Max. press. 1600 bar
Type Included in high pres. pump, mechanical
Supply pump Driven Mechanical gear type
Fuel filter Type Element paper
W – Engine
(MODEL: D4DD)
Page4
2. Main Character of System
2-1.W-ENG Control Functions
The control system uses inputs from the operator and its
sensors to determine the fueling and timing required to
operate at the desired engine speed.
ECM is the control center of the system. It processes all
inputs and sends commands to the fuel system, and
Fuel flow control engine control devices.
Multi injection control
Fuel injection
control Injection timing control A/C idle up switch
Pressure control
Pump control Over heat lamp
Lamp/Switch
Pre-heating control
Page5
2-2. Common rail system circuit
· Diagnosis
Hi-Scan
or
HCE-DT
Page6
2-3. W-ENG Fuel Line
Fuel tank
Page7
3. W-ENG Electronic control system
3-1. Electronic control system
OUPUT1 : control
INPUT : Sensor
·GLOW CONTROL
·Cam position sensor
·MAIN RELAY CONTROL
·Crank position sensor
·Injector control
·Accel pedal sensor
·Supply pump control
(SCV)
.K-LINE
·Coolant temp. sensor
·MAP sensor(intake air temp.
/pressure:booster pressure) OUPUT2 : lamp
·Rail pressure sensor
·Fuel temp. sensor ·OVERHEAT LAMP
·GLOW LAMP
·ENGINE CHECK LAMP
INPUT : Switch
·ACIDLE SW OUPUT3 : Tachometer
·NEUTRAL SW
·KEY SW ·TACHO signal
·STARTER SW
When a diagnostic fault code is recorded in
the ECM, the ECM input and output data is
recorded from all sensors and switches.
Page8
3-2. W-ENG Electronic system
Page10
3-4. W-ENG ECU pin disposition & no.
70- 71- 72- 73- 74- 75- 76-
770 770A 772 773 774 774A 735A
1– 2- 3- 4– 5- 6– 7- 77- 78- 79- 80- 81- 82- 83- 84- 85- 86-
N.C N.C N.C N.C 705 705A 705B N.C N.C N.C N.C N.C 782 N.C N.C N.C N.C
8- 9 – 10- 11- 12- 13- 14- 15- 16- 17- 87- 88- 89- 90- 91- 92- 93- 94- 95- 96-
N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C
97- 98- 99- 100- 101-
18- 19- 20- 21- 22- 23- 24- 25- 26- 27- N.C N.C N.C N.C N.C
N.C 719 N.C 721 722 N.C N.C N.C N.C N.C
28– 29- 30- 31- 32- 33- 34-
772A N.C N.C N.C 732 N.C N.C
35- 36- 37- 38- 39- 40- 41- 102– 103- 104- 105- 106- 107-
735 N.C N.C N.C 739 740 741 802 803 804 N.C 806 807
42- 43- 44- 45- 46- 47- 48- 49- 50- 51- 52- 53- 108- 109- 110- 111- 112- 113- 114- 115- 116- 117-
N.C 743 N.C 745 746 N.C 131 N.C N.C N.C N.C 753 N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C
54- 55- 56- 57- 58- 59- 60– 61- 118- 119- 120- 121- 122- 123- 124- 125- 126- 127- 128-
754 755 764A 757 758 N.C N.C N.C N.C N.C 820 821 N.C N.C N.C 825 826 N.C 828
62- 63- 64- 65- 66- 67- 68- 69- 129- 130- 131- 132- 133- 134- 135- 136-
N.C N.C N.C N.C 183 N.C 768 N.C N.C N.C 831 832 833 834 835 836
Page11
3-5. Check sheet of ECU pin (50D7E model)
Input / Output signal
Pin No. Check item Condition Remarks
Type Level(normal → operation)
1~4 N.A - - -
Pulse …Vbat
9 Engine speed signal Engine running
0~0.5 KGSD700C
10~18 N.A - - -
Accel pedal position sensor 1 signal IG. ON(Idle) Analog 0.6V ~ 0.85V
21 IG. ON(WOT)
WOT : Wide-open throttle Analog 3.75V ~ 3.95V
: pedal full position
Page12
Input / Output signal
Pin no. Check item Condition Remarks
Type Level(normal → operation)
39 Eng. rpm sensor shield ground - DC Below 0.5V
40 Engine rpm sensor + Engine running Sign wave
41 Engine rpm sensor - Engine running Sign wave
42 - - - -
43 Over heat warning lamp Coolant T. over 115℃ DC Ba. vol. > below 0.5V
44 - - - -
Page13
Input / Output signal
Pin no. Check item Condition Remarks
Type Level(normal → operation)
67~69 N.A
Page14
Input / Output signal
Pin NO. Check item Condition Remarks
Type Level(normal → operation)
122 N.A
Page15
Input / Output signal
Pin NO. Check item Condition Remarks
Type Level(normal → operation)
Page16
4. Input : Sensors
4-1. Cam Position Sensor (P0340)
IC
IC chip
Permanent
Magnet
magnetic
Connector:
(MRE)
Page17
4-1-1. Cam Position Sensor
AIR GAP :
1±0.5 mm
A Vcc
1 kohm
ECU
Multi-meter measuring 10 kohm
Sensor Out
Check
Power V 1nF
condition
At engine
about 4.5V
running
Page18
4-2. Crank Position Sensor [P0335/385,P0219(4000rpm ↑),P0615(300rpm↓)]
Page19
4-2-1. Wave form of Crank Position Sensor
Multi-meter measuring
Check Power
condition(rpm) (AC)
Wave form with Hi-scanner Idle ~ high about 2.8 V ~
rpm 5.9 V
Page20
4-3. Synchronized wave (20ms) of crank & cam position sensor
Page21
- Synchronized wave (4ms) of crank & cam position sensor
# 1 cylinder # 4 cylinder
Page22
4-4. MAP Sensor [Intake pressure & temperature sensor ]
The intake manifold pressure
sensor(combination sensor with
intake temperature sensor)
monitors intake manifold
pressure and passes the
information to the Electronic
Control Module (ECM) through
the engine harness. ECM
decides fuel injection volume and
timing using the signal of intake
pressure sensor.
The intake manifold air temperature sensor(combination sensor with intake pressure
sensor) monitors intake manifold air temperature and passes the information to the
Electronic Control Module (ECM) through the engine harness.
This sensor has NTC type thermistor.
Page23
4-4-1. MAP SENSOR (Intake pressure & temp. sensor), Checking
1 2 3 4
1 : Ground
2 : Intake temp. signal
3 : Sensor power supply
4 : Intake pressure signal
흡 기 압(Kpa)
Intake air pres(Kpa)
전 압(V)
Voltage(V)
101 Kpa ~ 130 Kpa
32.5 0.5
Idle ~ high rpm
Intake air about 1.6V ~ 2.1V
흡기압 50 0.78
pressure
센서
sensor 70 1.96
Intake 규정값
Specification
270 4.28 air
흡기온도
temp. 0℃ 10℃ 30℃ 50℃
284 4.5
sensor
300 4.75 5.4㏀~6.0㏀ 3.5㏀~3.9㏀ 1.6㏀~1.7㏀ 0.8㏀~0.9㏀
Page24
4-5. Common rail pressure sensor
Flow damper
P1091~4
P0088(2000bar↑)
P2293
221 Mpa
Open (abnormally high)
Dead Volume(internal rail) 11cc
4.2
Voltage
[V]
1.0
0 200 P [ MPa ]
Page26
4-5-2. Wave form of rail pressure sensor(HCE-DT measuring)
Engine
speed
Water
temp.
Battery
voltage
Real C/R
pressure
Target C/R
pressure
SCV drive
current
SCV target
current
SCV duty
value
Page27
4-6. Flow Damper (P1091~4)
At ENGINE STOP
At Damping orifice
At engine running
Piston with orifice damps the
fuel pressure in common rail.
Page28
- Flow Damper
Page29
4-7. Water temperature sensor [(P0117/0118/0217(over 115℃)]
규정값
Specification
냉각수온
Water
temperature -20℃ 20℃ 40℃ 80℃
15.48㏀ 5.79㏀ 1.148㏀ 0.322㏀
Page30
4-8. Fuel temperature sensor (P0182/3)
Fuel temperature sensor measures the
temperature of fuel, sends this signal to ECU.
ECU compensates the injection volume at
cold or hot engine by using the signal.
Fuel temperature sensor is installed on the right
side of fuel pump.
Page31
4-9. Accel. pedal position sensor(APS) (P0122/0123/0222/0223/1120/0225/6)
규정값
Specification
Accel.
악셀페달
Pedal At들idling(0%) At전
full
센서 아이 상 태 (0%) 개stroke(100%)
시 (100%)
sensor
0.6V ∼ 0.85V (0.65V) 3.75V ∼ 3.95V (3.85V)
Page32
5. Output: Control & Drive parts
5-1. Supply Pump control
Inlet
Outlet
(return)
SCV (Suction
Control Valve)
Supply(to rail)
: DTC – P1217~9
Page34
Fuel System: High-Pressure Fuel Pump
SCV
Fuel overflow
Regulator valve
Feed pump
Cam shaft
Fuel tank
Fuel filter
Page35
5-1-2. SCV (Suction Control Valve) duty control
Page36
5-1-3. Control valve of fuel supply pump : SCV (Suction Control Valve) wave
(DTC : P0629/0627/1190)
At idle condition
No. 1 channel : Voltage wave of SCV
operation
No. 1 channel : Current wave of SCV
operation
Page37
5-2. Injector control
Solenoid
Valve spring
Valve
Orifice
Body
Edge filter
Piston
Solenoid
Operation
current
Valve
Common rail
Pressure
control
Piston chamber
Injection
Nozzle volume
Injection
Explosion
Pre-injection :
Page40
5-2-3. Wave check of Injector operating voltage & current
Pre-injection
(ignition injection) Main injection
전압
Injection time Injection time
전류
Influence factor of injection : nozzle dia. X injection time X injection pressure X Injection
times X battery voltage
Page41
5-3. Fuel filter
Air bleeding, pump
Thermo switch
Fuel inlet
Fuel outlet
Heater sensor
Page42
5-4. Engine Wiring