CRDi Engine System

Copyright by KIA Motors. All rights reserved.

 CRDi Engine Line-up 2

Engine
D - ENGINE A - ENGINE J3 - ENGINE U - ENGINE
Item

Shape

Available Vehicle RS, MG,KM, UN BL GQ-II, VQ, PU JB/LD/SA/ED

Displacement 1.5 ~ 2.2L 2.5L 2.9L 1.1 ~ 1.6L

EMS BOSCH BOSCH Delphi BOSCH

Timing Timing belt Timing chain Timing belt Timing chain

Fuel Pressure
Outlet control Inlet control Inlet control Inlet control
Control

Grade/Classified
Injector Grade (X,Y,Z) C2I (16 digit code) Classified (C1,C2,C3)
(X,Y,Z / C1,C2,C3)
CRDI Fuel System
 Fuel Flow (D-Eng) 4

Rail Pressure
Control Valve
(RPCV)

High Pressure Common Rail Injector

Pump

Fuel Tank

Low Pressure
Pump
Fuel Filter
Fuel Flow (A,U-Eng) 5

High Pressure Common Rail

Pump Injector

MPROP

Fuel Filter Fuel Tank

Low Pressure
Pump
 Fuel Flow (J-Eng) 6

High Pressure
Pump Common Rail Injector

IMV

Fuel Tank

Fuel Filter
Low Pressure Pump
 Fuel System - Low Pressure Pump 7

Electric motor type

▷ Feed fuel to high pressure pump

▷ Electrical motor + Vane pump

▷ Output pressure : 4 ~ 5 bar

 Fuel System - Low Pressure Pump 8

Electric motor type ※ Main relay : On when ignition is on

※ Fuel pump relay : On for 2 sec when

ignition on and then
Relay is on again after engine rpm is input
Fuel
pump
relay
Fuel pump relay Fuel pump diagnosis connector
Main
relay
 Fuel System - Low Pressure Pump 9

Electric motor type (Low pressure check)

* Low pressure check (Low pressure pump  Fuel filter)

IGN. On (2 sec) Fuel pump operation when cranking

(Increasing until 2.8bar)

* Euro-3 : 1.5 ~ 3 bar

 Fuel System - Low Pressure Pump 10

Field case
Case Poor acceleration and shut off when sudden acceleration
Vehicle KM D-2.0 A/T (2003MY) Mileage 30558Km

1. Shut off engine when driving WOT

Symptom
2. Shut off when idle WOT

1. P1181 Fuel pressure monitoring

2. Poor acceleration
Checking

Cause Contaminated fuel pump

 Fuel System - Fuel Filter 11

Fuel filter (filtering, separator, heating, A/U/D Engine )

Fuse blink box Heating relay

80A 60A 30A 30A Fuel Heater

Heating relay

Fuel temp. S/W

IG B +

Fuel heater
Fuel temp. S/W
(On below -5℃)

* There is another Fuel Temp Sensor.

 Fuel System - High Pressure Pump 12

CP1 type

▶ Max. pressure : 1,350 bar Parts No. Engine type Pump Type
33100 - 27000 D 2.0 WGT
▶ Application : Bosch CRDi Engine with Euro-3
33100 - 27500 D 1.5 WGT CP 1
33100 - 27900 D 2.0 VGT

TO C.R

Damaged Connection seals

Fuel Leak
Fuel return
FROM L.P
Engine stall and Hard starting

[CP1H]
 Fuel System - High Pressure Pump 13

• Max. pressure 1,350 bar • Max. pressure : 1,800~ 2,100 bar

• Operated by timing chain (MPROP* integrated) • Operated by timing belt (IMV* integrated)

[CP3]

Fuel temperature sensor

Fuel return

Cam

MPROP
IMV
Fuel Inlet
Fuel inlet
Low pressure pump

* MPROP : Magnetic Proportioning valve

* IMV : Inlet Metering Valve
 Fuel System - Pressure Control 14

Rail pressure control valve (RPCV)

☞ 4000 rpm (W/O load) :

Spring control duty 30 % (803bar)
Electromagnet

Armature Pressure increase

Valve ball
☞ 750rpm (Idle) : control
duty 16 % (260bar)

Pressure decrease

RPCV

Sample Waveform: Wide Open Throttle (no load)

Note:
In case the Pressure Control Valve is Rail Pressure Sensor
defective, the whole Rail needs to be
replaced! * IGN OFF : Drop below 100 bar (by spring force)
 Fuel System - Pressure Control 15

Case Starting delayed sometimes

Vehicle KM 2.0 D A/T Mileage 21,621Km

1. Starting is delayed for 1~2 seconds sometimes.
2. Common rail pressure drops immediately abnormally.
3. High pressure test with a CRT-1000. The rail pressure is low.

Off
Symptom &
Checking
Run Run
Off

[Fuel pressure drop]

Ball worn out

Cause Fuel leak from RPCV

(Ball worn-out) Filter
 Fuel System - Pressure Control 16

Magnetic proportioning valve (MPROP)

MPROP

Pressure
Armature relief valve
Spring Fuel supply
Electromagnet

Open position Closed position Gear pump

MPROP
Fuel return

High pressure
Fuel supply

Fuel return 1. 2.
High pressure

[A,U-Engine] 3. Pressure limiter valve

4.
 Fuel System - Pressure Control 17

Rail pressure control

Inlet Metering
Valve (IMV)
Inlet Metering Valve (IMV)
FTS Spring (upper)
Pressure Limiter Valve
Return Sleeve
Solenoid (coil)
IMV

Piston
Filter
Spring (lower)

LP inlet
(suction)
[J-Engine] Flow (l/hr)
250
to Rail 200
150
100
50
0
Pressure Limiter Valve 200 400 600 800 1000 1200 Current (mA)
 Fuel System - Injector 18

Injector (Bosch)

Injector
voltage

Injector
current Pilot Main
 Fuel System - Injector 19

Injector (Bosch)

Pressure
A : start of injection

Combustion Process B : start of ignition

C
D
D : end of injection
E : end of ignition
A ~ B : Ignition lag A ↔ D : Injection
B ↔ E : Combustion B
B ~ C : Premixed flame E
A
C ~ D : Diffusion flame
D ~ E : Post flame

Ignition lag (A~B) TDC Crank Angle

The start of injection and the start of ignition are separated by a certain period of time.

Premixed flame (B~C)

The fuel that is injected prior to the start of ignition and mixed with the air combusts.

Diffusion flame (C~D)

That portion of the combusted fuel which burns as a very rapid premixed flame is primarily responsible for the pressure rise, and thus
is the primary cause of both combustion noise and NOx

Post flame (D~E)

The soot formed primarily during the diffusion flame is oxidized in the post flame phase.
 Fuel System - Injector 20

Injection quantity Service operation

Maker Type Application
compensation after replacement
D-2.0
No marked By ECU None
A-2.5

D-2.0 • Choose the injector type on

Grade X, Y, Z the basis of the combination
Injector A-2.5 table (see the next slide)

Bosch • Use the same class of injector

Classified
A-2.5 C1, C2, C3 • Write on the ECU with a scan
Injector tool (GDS, Hi-scan)

U-1.5 • Write the IQA code on the

IQA Injector IQA Code
D-2.0 ECU with a scan tool (GDS, Hi-
(Euro-Ⅳ) scan)
D-2.2

• Write the C2I code on the ECU

Delphi C2I Injector J-2.9 C2I Code with a scan tool (GDS, Hi-scan)
 Fuel System - Injector 21

* Combination of Grade Injector [A-Engine ]

Application Combination X Y Z
Case 1 0 4 0
Case 2 1 3 0
Case 3 0 3 1
Sorento
Case 4 1 2 1
Case 5 2 2 0
Case 6 0 2 2

* Combination of Grade Injector [D-Engine]

Application Combination X Y Z
Case 1 0 4 0
Case 2 1 3 0
Carens,
Case 3 0 3 1
Sportage
Case 4 2 2 0
Case 5 0 2 2
 Fuel System - Injector 22

Injectors (Bosch) * NTF : No Trouble Found

Injector Defect area Defect Rate Estimated cause

*NTF 40% Wrong diagnosis

Nozzle Deposition of foreign

20%
Contamination material (Carbon etc)

Fuel contamination
Nozzle wear 10% misalignment of the
intermediate pin

Seal ring damaged Quality problem

25%
Fuel contamination
A Hole erosion

Others
Fuel contamination
Wear 5%
Breakage
coil damaged
 Fuel System - Injector 23

Field case

Case Shut off the engine when a high speed driving or sudden acceleration

Vehicle KM D-2.0 (VGT) A/T - 2004MY Mileage 1120 km

1. Engine shut off when over 90km/H driving - 5 times during 30 min
Symptom
2. Detonation noise is occurred when shut off time. Unable to re-start.

1. HP pump, common rail, low pressure pump, fuel filter were replaced already.
2. DTC : P1181 Fuel pressure monitoring.
Inspection 3. Idle condition is good. (no vibration)
4. Test driving with Hi scanner and fuel pressure gauge.
5. Fuel pressure is dropped immediately when symptom is occurred.

Injector nozzle worn out.

Cause
: Excessive injection amount of No. 4 injector  Rail pressure drops immediately.
 System Output 24

Injector (Delphi)

Edge filter

Calibration
Return channel mark (C2I)

Connector Shim
Control Valve
Return Spring Valve body

Coil
Valve
Calibration dowel
Valve spring
Nut Spacer
Injector spring

Nozzle
[Injector code registration]
 Fuel System - Injector 25

Diagnosis of injector
Engine Management System
 Diesel Engine System 27

Bosch CRDI, inputs and outputs

Battery + MIL
Accelerator Pedal Sensor Injector
Crankshaft Position Sensor
RPCV
Camshaft Position Sensor
MPROP
Engine Coolant/Fuel Temperature

Mass Air Flow Sensor EGR

Rail Pressure Sensor

Glow plugs
Engine Control Module
Vehicle Speed Sensor
PTC Heater
Blower switch
Fan Control
Boost Pressure Sensor only VGT
Fuel pump
Brake, Clutch switch

Automotive PressureTransducer Fuel Filter Heater

Oxygen Sensor A/C Compressor Relay

Differential Pressure Sensor Variable Swirl Actuator

only CPF
Exhaust Gas Temperature Sensor
Air Control Valve
 Accelerator pedal sensor (APS) 28

Module assembly
Sensor assembly

APS1

APS2

Sample Waveform Idle

Reference Voltage
APS1 signal APS1
Ground

ECM Reference Voltage APS2

APS2 signal
Ground

Sample Waveform Wide Open Throttle

 Dual brake switch 29

ST If brake s/w is pushed while acceleration

10A
KEY
IG pedal is pushed APS fault is fixed.
(vehicle speed is over 5km/h)
Main
30A
relay

ECU Brake Brake

Pin No ON OFF

15A
59 12V 0V
54 0V 12V
Dual brake
switch

STOP LAMP
ECU 5 13 58 59 54
 CKP & CMP 30

Crankshaft position sensor (CKP)

CKP Sample Waveform: CKP signal

Camshaft position sensor (CMP)

CMP Sample Waveform: CMP signal

 Temperature Sensor 31

Engine coolant temperature (ECT)

ECT Sensor
■ NTC (negative temperature coefficient thermistor)

■ Detect coolant temperature (fuel, cooling control)

Fuel temperature (FT) sensor

■ HP pump inlet side (D)

: NTC (negative temperature coefficient thermistor)

■ Limit the fuel pressure : HP pump protection (lubrication)

FT Sensor
 Mass air flow (MAF) sensor 32

Electrical
connections

Internal connections
V Hz
Evaluation
electronics

Housing

HFM5 HFM6 Sensor element

Intake Air Mass

Sample Waveform:
Intake Air
Temperature signal

Replacement = Reset
 Rail pressure sensor (RPS) 33

Euro 4
Replacement = Reset

Electric connections
V
Evaluation circuit

Diaphragm with Sensor element upper fault area

4.65

High pressure connection

0.50
0.30

Note: 0.20
In case the Pressure Control Valve is defective, the whole lower fault area
Rail needs to be replaced! 100bar 1600bar
Solenoid valves 34

EGR Actuator

Air Control Valve Actuator

Air Control Valve

(Throttle flap)

EGR solenoid

Turbocharger
 EGR System 35

Benefit
- Increasing EGR volume by cooling (density up)

- Reducing NOx , PM (a little)

Compress Intake air

Turbine
or
Vacuum
EGR EGR valve EGR valve
cooler Intake air amount
(EGR feedback)
Coolant OUT
Coolant
IN
Vacuum
Engine
pump ECU

Inter cooler EGR solenoid

APS RPM

Cooled exhaust Hot exhaust gas

gas
Exhaust mani.
 EGR System 36

Filed case

EGR Malfunction (KM)

1. Symptom : Poor acceleration, hesitation, shut off sometimes

2. Check and cause

1) No DTC

2) Fuel system check

- low pressure line OK : fuel motor, filter
- high pressure line OK : H/P pump, injector, pressure regulator

3) Engine test result : OK (Compression test, Idle speed comparison, Injection quantity test)

4) as above result  not related to fuel system  inspect intake system

5) Current data analysis : MAFS signal, EGR control duty

- MAF sensor data is lower than normal when symptom was occurred  EGR suspected

6) Actuation test for EGR : EGR valve open stuck intermittently

7) Conclusion : EGR open stuck  intake air volume decreased  unstable combustion
 EGR System 37

Symptom Unnecessary replacement of E-EGR valve

Vehicle KM (CRDi D-eng)

Diagnosis

1. Coolant temp.:over 60 ℃, idle rpm: below 1000 rpm/maintain 60sec  EGR valve off (duty approx. 5%)
2. After confirm E-EGR valve off checked air flow volume per cylinder check (Normal : approx. 400~500mg/st)
3. If air volume is normal then check E-EGR valve moving (after removing upper part)
4. After checking above things then check other parts Check valve moving
and stuck
Current data analysis

Current Data
Mass Air Flow 39.2 kg/h Check cylinder air volume
Air Flow Per Cylinder 449.6 mg/st
Intake Air Temp. xxx ℃
EEGR valve off check
EGR Actuator 4.7 % Upper part
Coolant Temp xxx ℃
Fuel Temp xxx ℃
Push the valve and check moving and stuck
after removing EGR upper bolt. If valve is
moved below approx. 5mm or stuck change EGR valve.
 VGT 38

Benefits
- Decrease exhaust emissions, smoke and noise
- Increase output power and
- Maintain nearly constant power at high altitudes
- Better fuel economy
 VGT 39

Operation

VGT
Engine Vane control
solenoid Vane path
condition actuator
duty

Low load Pull Vane

85 %
Low speed (vacuum:large) Narrow

High load Release Vane

5%
High speed (vacuum:small) wide
 VGT 40

Caution

ACTUATOR ASSY

UNISON RING
EXTERNAL CRANK
ROLLER
INTERNAL ARM

Both yellow painting marks, actuator

NOZZLE RING
rod and minimum flow setting screw
VANE ARM
can not be adjustable. From the VANE
factory side all VGT is adjusted with
high accuracy.
 VGT 41

Field case

Turbine wheel damage Foreign material suction

Turbine housing deformed

Bearing wear out
 Diesel Engine System 42

Delphi CRDI, inputs and outputs

Battery +
MIL
Accelerator Pedal Sensor

Crankshaft Position Sensor

Injector

Camshaft Position Sensor

IMV
Engine Coolant Temperature Sensor
EGR
Mass Air Flow Sensor /
Intake Air Temperature Engine Control Module
Air Intake Heater
Vehicle Speed Sensor

A/C switch Fan Control

Rail Pressure Sensor

Fuel Filter Heater
Brake, Clutch switch

Accelerometer A/C Compressor Relay

 System Output 43

Accelerometer

Cylinder pressure
Major pilot injection
Needle lift
Accelerometer
Ratio

Minor pilot injection

ECM No pilot injection

No injection
Diesel Engine Symptom Diagnosis
 Diesel Engine System 45
Basic inspection :
-Connector connection check
-Fuel quality check (Mixing with other fuel )
-DTC ,Current Data check
Claim -etc, repair history

Symptom
check
1. Shut off during driving 1. Hesitation
2. Hard starting 2. Smoke occur
3. Jerking during acceleration 3. Bad acceleration
4. DTC related to fuel pressure

Hi-scan
Diagnosis with CRT OK

Injector balance test

OK *2) High OK NG
*1) Injector Low pressure
pressure
back leak test line check
check

NG NG NG

Back leak exceed High pressure pump

Filter replace or Over + 4Q injector
(over 3 times) part replace (O-ring
Fuel line repair replace
Injector replace etc)
 Hard Starting Check Flow 46

Hard starting

Impossible cranking Irregular cranking

Possible cranking

Compression
Starting system Battery Timing system
pressure

Main relay Main relay

operated operated

Main relay circuit

Fuel system CKPS, CMPS Immobilizer

Timing system

Low fuel High fuel Preheating Fuel

pressure pressure system heating
 Main Relay Inspection – Contact 47

Diagnostic Procedure

Caution : First of all check damage of harness and terminals : Check terminals for contact resistance,
corrosion and deformation.
Main relay contact inspection

M 1) Status check point 1 ( )

Check point 1

Continuity or discontinuity?
 Fuel system 48

Diagnostic Procedure

Current data of fuel system inspection

1. IG KEY "ON", ENGINE "OFF"
2. Connect scantool to Data Link Connector (DLC).
3. Select "Fuel pressure measured", "rail pressure regulator (rail)",
"injection pump regulator (pump)" parameters on the scantool.
4. Remove all injector connectors (For impossible starting).
5. Monitor current data is selected while engine cranking.

M A. Check parameters at keep cranking. (Normal current

data)
- "Rail pressure measured" : approx. ( ) Mpa
- "Rail pressure regulator (rail)" : approx. ( ) % duty
- "Injection pump regulator (pump)" : approx. ( ) % duty

M B. Check parameters at end of cranking. (Normal current

data)
- "Rail pressure" is lowered gradually.
- "Rail pressure regulator (rail)" is lowered suddenly from
approx. ( ) % duty.
- "Injection pump regulator (pump)" is ( )% duty after few
seconds.
 Low Fuel Pressure Line Check 49

Diagnostic Procedure

Pressure of low pressure fuel system inspection

1. IG KEY "OFF", ENGINE "OFF"

2. Disconnect air cleaner assembly and MAFS connector.
3. Disconnect fuel supply hose quick-connector from function block.
- Make sure of fuel leak after disconnecting fuel hose quick-connector and an inrush of foreign substances.
 Low Fuel Pressure Line Check 50

4. Install pressure gauge of low pressure fuel between the fuel hose quick-connectors.
: Make sure of using low pressure gauge, gauge connection tube, connection adapter.
 Low Fuel Pressure Line Check 51

5. Reassemble air cleaner assembly and MAFS connector.

6. IG KEY "ON", ENGINE "ON“
: Make sure of fuel leak in the quick-connector at ENGINE "ON" after installing pressure gauge.
A. Specification : Approx. 3.5 ~ 3.8 bar at idle.
 Low Fuel Pressure Line Check 52

7. Inspect change of the fuel pressure while accelerating engine or stall test.
: The more engine rpm is higher, the more pointer shaking is bigger.
A. Specification : Approx. 3.0 bar at accelerating engine or stall test of engine.
 Fuel Filter Inspection 53

D A. Case 1 : In case that there is a lot of water in the fuel filter.

What is possible cause ? How to treat this. ( )

B. Case 2 : In case that there is a lot of metallic substances in the fuel filter.
What is possible cause ? How to treat this. ( )
 Fuel Pump Circuit Inspection 54

Diagnostic Procedure

Check point 3

Check point 4

Check point 1 M 1) Status check point 1 ( normal or blown )

2) Status check point 2 ( ) V at IG ON.
3) Status check point 3 ( normal or blown )
4) Status check point 4 ( normal or abnormal )
5) Status check point 5 ( normal or abnormal )

Check point 5

Check point 2
 Pre-heating System Inspection 55

Diagnostic Procedure

Glow relay circuit inspection

Check point 1
Check point 3

Check point 4

M
1) Status check point 1 ( normal or blown )
Check point 5
2) Status check point 2 ( ) V at IG ON.
(Glow plug operating time)
3) Status check point 3 ( normal or abnormal )
Check point 2 4) Status check point 4 ( normal or blown )
5) Status check point 5 ( normal or abnormal )
 Glow Plug Internal Resistance Inspection 56

Diagnostic Procedure

Measure the resistance between the terminal and body as below.

- The resistance value is very small, Inspect foreign substances on the glow plug meticulously.
A. Specification : 0.2 Ω ± 10% (20°C)

M Measured resistances
( ) Ω (20°C)

B. Case 1 : In case that resistance is high. (Open or over resistance)

 Heating coil in the glow plug open
 Replace the glow plug.

D C. Case 2 : In case that resistance is low. (Short)

 In this condition what happen ? ( )
 Replace the glow plug.
 Fuel Heating System Inspection 57

M
1) Status check point 1 ( normal or blown )

Check point 2 2) Status check point 2 (normal or blown )

Check point 1
3) Status check point 3 ( normal or abnormal )
4) Status check point 4 ( normal or abnormal )
5) Status check point 5 ( normal or abnormal )

Check point 3

Check point 4

Check point 5
 Fuel Heater Thermo Switch Circuit Inspection 58

Diagnostic Procedure

Fuel filter heater switch (Thermo switch) connector inspection

? ?

Check point 1 Check point 2

M 1) Status check point 1 ( ) V at IG On.

2) Status check point 2 ( ) V at IG ON.
 CKP Inspection 59

Diagnostic Procedure

1. IG KEY "ON"
2. Measure the voltage of CKPS connector terminals.
1) Status check point 1 ( ) V at IG ON.
2) Status check point 2 ( ) V at IG ON.
M
3) Status check point 3 ( ) V at IG ON.
Check point 2

? ? ?
Check point 1 Check point 3

A. Case 1 : In case of abnormal voltage at terminal "1", "2", "3".

 "DTC" related with CKPS would be displayed.
 Refer to "DTC" troubleshooting procedures.

B. Case 2 : In case of normal voltage at terminal "1", "2", "3".

 Go to "CKPS inspection" procedure.
 Impossible Cranking –Inhibitor S/W Inspection 60

Diagnostic Procedure

1. IG KEY "OFF", ENGINE "OFF"

2. Remove the battery.
3. Remove the air cleaner assembly.
4. Remove the battery tray.
5. Place the shift lever in "N" position.
6. Inspect shift cable position. (Shift cable would be located near center of the hole of ATA manual control lever.)
- Inspect shift cable whether it is fixed or not. (Check the 12 mm nut and cable bending)
7. Inspect ATA manual control lever position. (8mm hole of the ATA manual control lever is located on the 8mm
hole of the inhibitor switch exactly.)
 Engine Hesitation Check Flow 61

Engine Hesitation

Hesitation at cold start Normally hesitation

Exhaust system (leak,

block)
Preheating
Injector nozzle Poor quality fuel
system Exhaust system

Intake system (leak,

Fuel system
block)

Injector Compression test Fuel pump, filter

MAFS Air filter Intercooler

 Common Rail System Diagnosis 62

Idle hesitation (over 80%)

: Check two items if hesitation during cold condition but disappear warm-up.

▶ Injector carbon cleaning

▶ Glow plug check

* The reason why carbon can affect to injector in cold condition.
: warm-up condition  cylinder internal temperature increased
 fuel vaporization is increased  combustion is OK.
 Injector Nozzle Cleaning 63

Diagnostic Procedure

1. IG KEY "OFF", ENGINE "OFF"

2. Remove injectors.
Injector Nozzle Cleaning 64

3. Prepare the ultrasonic

injector nozzle cleaner.

4. Fill the ultrasonic

injector nozzle cleaner
with a cleaning solvent.
(water : cleaning solvent =
10 : 1)

5. Soak injectors in the

ultrasonic injector nozzle
cleaner and Clean injectors for
2~3 minutes.
 Injector Nozzle Cleaning 65

6. Inspect injector nozzles visually after cleaning.

- Inspect damage of the nozzle, blocked hole of the nozzle and widen hole of the nozzle.

7. Install injectors, it is essential to verify that the symptom is corrected.

[Caution] Never use steel brush to clean injector  injector hole damaged
: Poor acceleration during full load but it is normal other condition  Injector fault
 Fuel Quality Inspection 66

Caution : In case of common rail diesel engine, Using poor quality diesel fuel can cause the fatal damage in engine
performance and high pressure fuel system.

Poor fuel quality

1. Water or foreign substance is mixed.
2. Solvent or chemical substance is mixed.
3. Gasoline or kerosene is mixed.

D Influence of abnormal fuel

1) If you use poor quality fuel in your car what is the symptom. ( )
2) If you fill up gasoline to diesel vehicle, what happen ? Why ? How to repair that vehicle.
( )
3) Discuss about diesel fuel characters
( )
 Idle Speed Comparison Test 67

Diagnostic Procedure

1. Cylinder engine speed (rpm) is displayed.

2. Press "AVG" key after pressing "ANAL" key.

3. If there is engine hesitation in the vehicle, The symptom would get worse while testing.
Because fuel injection compensation of ECM be stopped while testing.
 Idle Speed Comparison Test 68

4. "03.Injection quantity comparison test" in the "Engine test function" compensates each cylinder equally by
increasing (or decreasing) fuel injection quantity.
A. This result is artificial data when each injector connector is disconnected by turns.

B. Case 1 : In case of engine hesitation at

certain cylinder.
 Go to "Compression test" procedure.
 Compression Test (Hi-scan) 69

Diagnostic Procedure

1. Press "AVG" key after pressing "ANAL" key.

A. Specification : The RPM variation of cylinders < 10 rpm

 Compression Test (Hi-scan) 70

B. This result is artificial data when each glow plug is removed by turns, refer to below data while inspecting.
- RPM of abnormal cylinder is the highest, but real data is not the highest. You must refer to real data as below while
inspecting.
 Compression Test (Pressure gauge)) 71

Diagnostic Procedure

1. IG KEY "OFF", ENGINE "OFF"

2. Remove the intercooler.
3. Remove all injector connectors for impossible starting.
4. Remove the injector.
5. Install the compression pressure gauge (09351-27000) and adapter (09351-27100).
 Injection Quantity Comparison 72
2. Press "AVG" key after pressing "ANAL" key.

A. In case of cylinder that causes engine hesitation, injection quantity(㎣) data is "-6" or "+6". Engine speed would be
balanced by ECM in the specific limit. This result means that compensation of injection quantity controlled by ECM goes
beyond the limit below 1,500 rpm.(Engine hesitation occurs at idle.)

Caution :You can not draw a conclusion that the cause of engine hesitation is "the injector" from first test.
If same data is displayed in the second test after cleaning nozzle of injectors, change the injector position. Inspect the
data on the scantool whether it is same or not in the same cylinder position after changing injector.

B. Case 1 : In case that injection quantity data is displayed "-6" or "+6" and engine speed (rpm) is not similar after
cleaning nozzles and changing injector position.
 Replace the Injector.
C. Case 2 : In case that injection quantity data is displayed within "± 4" and engine speed (rpm) is similar after cleaning
nozzles and changing injector position.
 Reuse the Injector.
 Poor Acceleration / Power Check Flow 74

Poor accel / power

Poor accel / power at

Slight poor accel / power
cold start
Normally poor accel /
power
Preheating Injector Poor quality FTS& Injector
RPS
system nozzle fuel ECTS IQA

Low fuel
Intake system
pressure

Low fuel High fuel

EGR MAFS VGT
pressure pressure

Fuel pump H/P

Fuel filter C/R rail
circuit pump
 Poor Acceleration 75

D A. Case 1 : In case that fuel system data are normal, "Fuel pressure measured" is controlled by ECM to follow
"fuel pressure s/point" normally.
 Which parts (or system) should be checked ? ( )

B. Case 2 :
- In case that "Fuel pressure measured" is unstable or "Rail pressure regulator (rail)" and "INJ. pump regulator
(pump)" data is abnormal.
- In case that "Fuel pressure measured" is not controlled by ECM to follow "fuel pressure s/point" at stall test,
finally poor acceleration occurs or engine stall.
 What is the next step ? ( )
 EGR & MAFS Inspection 76

B. Case 1 : In case that "Air mass flow" data by operating EGR

solenoid valve is normal
1) Go to "VGT inspection" procedure.

C. Case 2 : In case that "Air mass meter" data is lower than 300
mg/st although "EGR actuator" data is 5.9 %.
D  1) What is possible cause. Which component should be
checked? ( )
 MAFS Inspection 77

Diagnostic Procedure

MAFS inspection.
1. IG KEY "OFF", ENGINE "OFF"
2. Inspect contamination of air cleaner filter.
- Terrible contamination of air cleaner filter.
- Wetting of air cleaner filter.
3. Inspect foreign substances (leaves, paper, vinyl) in front of MAFS and damage of the grid of MAFS.
 MAFS Inspection 78

Diagnosis

* Symptom
- No smoke (white, black smoke)
- Low stall rpm (approx. 1600~1800 rpm)

* Diagnosis by sensor simulation (defected MAF sensor? or defected injector?)

: Sensor Simulation 4.2V input  when normal stall rpm (approx. 2400rpm) is shown
 Bad MAF or real intake air volume low

* Result Analysis

► Normal stall rpm with no black smoke  Defected MAF sensor (less sensitive)

► Normal stall rpm with a lot of black smoke  less intake air volume (clogged intake system)
: Because injection volume is increased by simulation but real intake air volume is lack.
► Low stall rpm  Defected injector

[Notice] MAF sensor simulation is working well with a EURO 3 engine. (Euro IV: Frequency type MAF sensor)
Intake System Inspection 79

D
C. Case 1 : In case of Intake
system partial leakage.

-What happen to air mass

flow current
data?( )

- "Boost pressure sensor" is

increased normally but
"VGT actuator (54.5%)" is
higher than normal data
(45%) at stall test.
 Intake System Inspection 80

D D. Case 2 : In case of Intake system complete leakage. (intake hose is disconnected)

- "Air mass flow (kg/h)" and "Air mass meter (g/st)" current data is increased a lot compared with normal current
data.
- "Boost pressure sensor" is not increased , then what about VGT actuator duty?
( )
 VGT Inspection 81

Diagnostic Procedure

1. IG KEY "OFF", ENGINE "OFF"

2. Remove the intercooler.
3. Disconnect VGT vacuum actuator hose.
4. Install hand vacuum pump to the VGT vacuum actuator nipple.
5. Inspect rod stroke of VGT while vacuuming with hand vacuum pump to VGT vacuum actuator. (Inspect rod stroke
of VGT visually by using pocket mirror.)
A. When -65 kpa vacuum is supplied by hand vacuum pump, rod of VGT must be moved to up stopper.
B. On the contrary when vacuum is released, rod of VGT must be moved to down stopper softly.(Rod stroke of VGT
stroke is approx. 10 mm.)
 Analysis of Smoke Matter 82

Cause of white smoke

1) Steam (water vapor)

: White color, after emitting disappear. Water vapor can be generated inside muffler because
of engine high efficiency. Steam can be emitted by high temp. exhaust gas.

2) Defected glow plug or carbon deposit around glow plugs

 Visual inspection required.

3) Smoke by excessive engine oil inside combustion chamber (somewhat blue color)
- Incomplete combustion due to excessive engine oil consumption
- Symptom occurs in engine idle
- Symptom gone after engine warm-up

4) Smoke by bad fuel

- Diesel fume
- Symptom occurs in engine idle
- Symptom gone after engine warm-up
 Analysis of Smoke Matter 83

Cause of black smoke

1) Injector
- Excessive injection volume
- 2 cooper washers

2) Intake air leak

- Intake air leak inspection after turbocharger (ex. Turbocharger clamp check)
- Hose condition check (Hose crack)

3) EGR valve leak

- Poor acceleration with black smoke
- Less intake air amount detected through the MAF sensor
- Check if EGR valve stuck open

4) Low cylinder compression

- Measure the cylinder compression (pressure gauge)
- Intake, exhaust valve leak check