Common Rail Diesel Injection Hyundai Tucson

2011 Automobile Maintenance
Advanced Course for the

Industrial Technical
Instructors
Cotntnon Rail
Direct Inj ection
D esel Engine
In
Hyundai Tucson
Class No.:
Instructor:
f\()"
~~-----
Lin, Jin-jih
eEl:>
Practice: Fuel System Analysis
HVUnORI
Topic : Oil Pressure Test for Low-pressuse pipe

Time : 20 minutes
1. The fuel system of CRDi D-2.0
Common rail
. Pressure Pu
mp
Injector
II
Fuel Case
Fuel Filter
Low Pressure Pum

p
2. Test of low-pressure area for CRDi D-2.0 engine fuel syst

- Please
connect the pressure gauge according to t
(~)Low-pressure
gauge
@)Low-preSSl.lre gauge so
It pipe
@connect.or
(e)conn~ctor (connect to t
he pipe)
~
pin~
. l:b
IIIIICJll=
CD ~
r:B>
HYUnORI
3. Measurement Method
1. Start the engine first and then close the engine after 5 minutes.
2. Connect the measurement gauge and then select checking, fuel pump starting,
then push the bottom of "start".
3. Read the figure on the pressure gauge and fill the blank.
Pressure of low pressure
(measurement)
Unit
Standard Value
Judgement and Analysis
kg/cm2
"'-\. L
OK
4. Symptons Research
Pressure of low pressure
(measurement)
Unit
o ~ 1.5
kg/cm2
1.5
4~6
Reasons Analysis
\ Qftj{-X
kg/cm2
kg/cm2
\;\;oI[I/Y',
\ocv
0 1 it'
.~A~.\
I "(S
tj'_
A-~
61
-'.( .!'l-(
(I
()
K (}',
riA:,
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Oil Pressure Measurement of Low Pressure Pipe (D-2.0)

Using electrical pump
Pressure
Measurement
Judgement
1.5-3kg/cm'
Normal
4-6kg/cm'
Block in Fuel Filter or low pressure pipe
0-1.5kg/cm'
Leakage of low pressure pipe or

breakdown of electrical pump
Attention:
1. There is some pressure difference between WGT and VGT in Euro-3o
WGT: Standard value is between 2.1'"""2.6 bar
VGT : Standard value is between 2.3'"""2.8 bar
2. All cars in Euro-4 are VGT
VGT : Standard value is 4bar v'
3. The overflow valve in Euro-3 is installed in fuel filter
4. The overflow valve in Euro-4 is installed in the face side of high pressu
re pump, by using 16mm bolts set
3
HYUnORI
- 'fopic . Measm enrent the quantity of fuel i etm n by using Cft'f' 1000 spedf
ic tools Mobile check
Time : 20 minutes
1. The quantity of fuel return check for injector (engine can be starte
d)
1. Separate the fuel return hose according to picture 1

2. Install plunger A according to picture 2
3. Connect injector fuel return hose connector B , clear hose, test
cup and mount
according to picture 3 .
Picture 1
Picture 2
Picture 3
4. After starting the engine, do the following steps

- one second in idle speed ~ 30 seconds in 3,000rpm
he engine ~
Result observation (Picture 4)
- Do the above steps twice in order to
2. Results judgement
Results,.-. :.:_ _ _ _ _ _ _ _ _ _ _ _ _
-!.
Stop t
HYUnORI
- IOPIC: Measurement of the quantIty of fuel return by uSIng CR I 1000 spe
cific tools Static check
Time : 20 minutes
High Pressu
re Gauge
Fuel Pressure
.....
..,.,
Adjust Valve Connec

tor
. mG
Pressure Sensor Connector

Parts for checking the quantity of fuel return
1. Engine can not be started

1. Separate the fuel return hose according to picture 1
3. Connect injector fuel return hose connector B , clear hose, test
cup and mount
according to picture 3
4. Separate each connector in injectors
Picture 1
Picture 2
5
Picture 3
CB;>
HYUnCRI
Picture 4
Picture 5
Picture 6
4. After separating the fuel pressure sensor connectors according to pic1

connect the battery and pressure sensor by using pressure gauge.
5. Separate the pressure adjust valve in the input of fuel pump accrodinf
-Euro-3 (output control )7 one control way
-Euro-4 (input and output contro1)72 control ways
6. After separate the connector of fuel pressure adjust valve according
connect fuel pressure adjust valve to the battery,
- to prevent from the damage of fuel pressure adjust valve.
Hope to connect to the battery only in the measurement. (within 5 rr.
(8)
HVUnORI
Picture 7
Picture 8
Picture 9
7. Connect the connector of separated fuel adjust valve by using fake res i~
- only for Euro-4 (if it is for Euro-3, the way for fuel pressure adju~
input and output, then the fake resistance needs to be set.
- If fake resistance is not set yet, the electrical fuel pump could not v
test of high pressure pump.
8. Turn on the power switch of high pressure gauge
9. Start the engine - 5 seconds
- not more than 5 seconds, the rpm has to over 200 rpm when the en
The battery must be good for a good test result.
10. Read the highest figure in high pressure gauge according to picture 8.
11. After observing the fuel quantity of fuel return clear hose according to
fill the blank and analysis the result.
r:B;>
HYUnoRI
2. Judgement for the quantity of fuel return in high pressure pump and injectors
Pressure of
High Pressure pump
Quantity of fuel return for

injectors
Judgement
CASE
Pressure of high pressure
Quantity of
fuel return for
injectors
1000-1800
(above1000)
0-200mm
Normal
0-1000
(under 1000)
200-400mm
(above 200mm)
Breakdown of
injector
Change the injector

that over 200mm
0-200mm
(under 200)
Breakdown of
high pressure
pump
(not enough
pressue)
Checking the line of

high pressure pipe
0-1000
(under 1000)
Judgement
Checking Item
c:BY
HYUnORI
- Topic: Pressure measurement of high pressure pump by using CRT-I000

specific tools
Time : ~~~'~~---------------------------------------------.
Connector for Fuel pre

ssure adjust valve
......-L......
Connector for
Pressure sensor
(!)
\%112:1:1
~t'l' i?'jOlE~ r ,~
ID :fI &'J ;;:: ~,
m?t, it~~ :1:~~ ~ ~Ol ~
Parts for checking high pressure pump
1. Engine can not be started

1. After separating the high pressure pipe according to picture 1, please put
the cover to prevent
from the impurities go inside the injector (mark A). Install fuel adjust valv
e in common rail
(mark B) and 3 common rail plunger (mark C).
After '-''''' . .
JL...... '
001
002
9
(DSeparate all injector pipe

-Torque in installing: 250-290kg.m
@put the cover to prevent from the impuriti
es go
inside the injector (mark A).
@Install fuel adjust valve in common rail
(mark B) and 3 plunger adjust valve (rna
rk C).
Judgemen
Picture 5
Picture 4
4. Separate the pressure adjust valve in the input of fuel pump accroding
-Euro-3 (output control )~ one control way
-Euro-4 (input and output control)~2 control ways
5. After separate the connector of fuel pressure adjust valve according 1
connect fuel pressure adjust valve to the battery,
-- to prevent from the damage of fuel pressure adjust valve.
Hope to connect to the battery only in the measurement. (within 5 r
10
c:B;>
HVUnORI
Picture 7
Picture 6
6. Connect the connector of separated fuel adjust valve by using fake re:
- only for Euro-4 (if it is for Euro-3, the way for fuel pressure adju~
input and output, then the fake resistance needs to be set.
- If fake resistance is not set yet, the electrical fuel pump could not v
test of high pressure pump.
7. Turn on the power switch of high pressure gauge
8. Start the engine - 5 seconds
- not more than 5 seconds, the rpm has to over 200 rpm when the en
The battery must be good for a good test result.
9. Read the highest figure in high pressure gauge according to picture 7
and analysis the result.
11
cB:>.
HYUnORI
2. Judgement for the quantity of fuel returnj for high pressure pump and injector
Pressure of High
pressure pump
Judgement
Remarks
Judgement
Remarks
3. Trouble Analysis
NO
Pressure of
High pressure p
ump
1000-1500bar
0-1000bar
Obar
Attention:
-The situation of fuel filter needs to check before changing high pressure Pl
and to judge if the impurities exists inside
-If the impurities exists inside the fuel filter, necessary parts need to be ch(
including fuel tank, after clean them.
12
Course: HYUNDAI D-2.0 CRDi

Common Rail Direct Injection Diesel Engine
Instructor: Lin, Jin-jih

(8) HYUnORI Service Training
CRDi - Common Rail Direct Injection Diesel Engine
Outline
The introduction to CRDi and general engine
.. Turbocharger
;I
Fuel System
.. The electronic diesel control system

d The control of Exhaust Gas Discharge
EURO-III ~ EURO-IV
Cautions of repair
(8) HYUnORI nurvica Training
CROi - outline
Types
Engine
Displacement
CC(L)
( Engine Management System)
D-2.0
2000 cc
Bosch
Starex
A-2.5
2500 cc
Bosch
Terracan
J3-2.9
2900 cc
Delphi
Models
JM Tucson
CPI
FO Trajet
HI
CP3
Delphi
HP
EMS
CRDi : Common Rail Direct Injection

CPt : Common Rail Pump 1
CP3: Common Rail Pump 3
(Ii/) HYUnDRJ Service Training
--------------------------CROi - outline
CP1 0-2.0 CRDi Engine on two models

.. FOTrajet, ......
(Ii/) HYUnORI !iHrvice Training
JM . Tucson . . 1
0.
CRDi - outline
Delphi J3-2.9 CRDi

Engine on :
CP3 A-2.S CRDi

Engine on :
. HP Terracan
. Ht Starex
CRDi - outline
The Difference betweenCPl,CP3ahd . Delphi

CPt
CP3
Delphi
The control of fuel

quantity
Outlet
Inlet
Inlet
Fuel Temperature
Sensor
Pressure Limit
Valve
0
0
Fuel Temperature
Easy to go
up
Not Easy to
go up
Not Easy to
go up
Low Pressure
Pump
Electric
Type
Gear Type
Vanes Type
(8) HYUnCRJ !l..,rvice Training
"
0-2.0 CRDi - High Speed Direct Injection
Power UP and the Economy of Fuel Consumption

- SOHC 4 valves and swing rocker arms
- Turbocharger with inter cooler
- Bosch common rail electronic diesel control (EDC)
- Electronic controlled and high precision Injectors
are Installed in the center of the combustion chamber.
- Injection pressure reaches to 1,350 bar
Low Emission and Low NVH

- There is pilot Injection before main Injection
- Balance Shaft
- EGR System and Catalytic Converter
(E:/) HYUnDRI Service Training
The Development of Diesel Engine
The Development of Diesel Engine
90
92
94
96
98 200Q
Year
02
(E:/) HYUnDRI n,1rvice Training
04
06
0 -2.0 - High Speed Direct Injection

HTI D-2.0f Engine
Items
D-Engine
EMS
Bosch
Model
FC,LC,SM
Displacement (cc)
1.se & 2.0e
The Driven Way of

High Pressure Pump
The Control of Injectors
Camshaft Gear
Inductive Current ( 20A )
Controlled by EMS
Pre-Injection
Main Injection
Fuel Injection
The Max. Fuel Pressure
1350 bar
The Control of Fuel Pressure
Outlet Control
Heating Device
Glow Plug
Fuel Heater
Coolant Heater
Valve Lash
HLA
(8) HYUnDRI Service Training
Timing Belt
10
Valve Driven System

- SOHC 4 valves and swing rocker anns
- Blacksmithing camshaft and hardening intake cams.
- Low friction roller and
minimized slipping component.
. Hydraulic Lash Adjuster maintain no or low noise .
. Camshaft drives CR pump
- Timing Driving System

- Belts drive camshaft and auto tensioner
(8) HYUnDRI f'lfJrvice Training
Driving Belt
11
cross-section
driving belt

12
Main Engine Parts
Main Characteristics
- Peak of ignition pressure: 150 bar
- Forging crankshaft and
5 flat rolling main bearing
- Full balanced crankshaft and 8 reverse balanced
weight
- 2 balanced shaft are in the oil pan.
(Lancaster Type)
- Completely reliable moving components
(piston/bearing)
- Oil pump is installed in the oil pan.

- Driven by crankshaft small gear
- Oil used: CE 10W30
Balanced shaft module
----
(8) HYUnORI 5arvice Training

--- - --
--- - - - - --
- --
--
- --
13
Turbocharger
WGT
( Waste-gate Turbocharger)
)
".
"
VGT
( Variable Geometry Turbocharger)
(Ii/) HYUnDRI Service Training
Turbocharger
14
WGT (Waste-gate Turbocharger)
VGT (Variable Geometry Turboch
_1T1lo_
(Ii/) HYUnDRI n!)rvice Training
CRDi- WGT (Waste-gate Turbocharger)
15
System Chart
Inter Cooling
Inter cooling is the process that the air passes the inter cooler to reduce the
temperature of compressed air intake, and increases the density of oxygen
in the intake air. It is combined with the turbocharger, and obtain high level
and equal combustion, so the engine power is increased 15%.
(1i/) HYUnORI Service Training
CRDi - WGT (Waste-gate Turbocharger)
16
Waste-gate
Passage valve (Waste-gate I Regulation Valve) will reduce the exceed
manifold pressure (over boost) during high speed, and make turbocharger
system reach the peak of intake pressure to obtain highest boost reaction.
After accurate metering, waste-gate intakes the exhaust emission to the
turbocharger, and limits the speed of the turbocharger shaft to control the
boost pressure.
wastegate
Boost Pressure
Turbocharger
Boost
Without
wastegate
Desired boost
Turbine
In1et
Engine
-+------------------~~Speed
(1i/) HYUnORI
~!)rvice
Training
CRDi - VGT ( Variable Geometry Turbocharger)
17
VGT ( Variable Geometry Turbocharger)

ECM control the solenoid valve (duty ratio) to change the vacuum
above the actuator. The actuator is connected with the connecting I
ever that pulls the rotation base. On the base, a cam is used to
c
onnect with vanes and decides the angle of vanes.
Vacuum Pump
1
1---------.
I Vans COlltrolactuator I
1
Vans control
---actuator
18
Regulating Ring
Compressor
Housing
Turbocharger
Housing
(8) ~YUnDRI ~~rvice Training

~High
Speed and high load:
The exhaust gas has large contact area, and the

turbocharger's reaction and speed goes up
(Max horse power is increased to 10-15%)
High Speed : Vanes Open
~Low
19
Speed and low load:
Because of narrow flow quantity area,

the motion is reached to highest.
(Max torque is increased to 5 -15%)
Low Speed : Vanes Closed

20
Main Advantages of CRDi - VGT

.Improve the horse power (10 -15% ) :
High efficiency during low speed, and reduces the horse power loss of exhaust
during high speed
Improve the acceleration ability(10-15 %
Improve the instant reaction
Improve the fuel consumption(5-10 0/0) :

Effective engine output
.Fast warm-up :
Higher boost temperature, boost pressure, and exhaust back pressure .
Match the emission regulations easily:

Reduce the emission of smoke, control the air intake, lower the emission during
idle speed.
--=::: - -- - ~-----
Turbocharger
21
Cautions:
1. Never using air guns to blow vanes.
2.When the engine is just starting'
the oil isn't lubricated to the turbocharger,
please do not accelerate.
3.Never stop the engine suddenly.
4.Never depress the acceleration pedal heavily.
5.Replace the oil periodically.
6.Never make the vehicle coast after ignition switch is
off during it is running.
(E/) HYUnORI Service Training
CRDi- Clean
22
Clean
Common Rail system needs higher pressure, so it needs smaller injector holes and
more accurate adjustment compared to conventional injection system. Therefore,
when repairing common rail system ,you have to remain it absolutely clean.
~~ ;,
',..,
Hair
The hole of
injectors
(E/) HYUnORI
~i,(~rvice
Training
enRi
23
Fuel System
(Ii/) HYUnORI Service Training
CDRi
24
Fuel Using Information:

@
@
Super diesel has to be used. (The sulphur contentis lower than 50ppm)
Normal diesel content inspection:
-
Impurities (inspected by eyes)

Metals (inspected by magnet)
Water (Diesel and water separation inspection)
Lubrication (inspected by hands)
The color of the diesel
(inspected by eyes)
-.
-
$-
-,
(Ii/) HYUnORI Snrvice Training
0-2.0 Introduction
25
,1
CRDI-D ENG FUEL SYSTEM

Common rail
Pressure
regUlator
valve
High pressure pump
Injector
low Dressure DumD

Fuel filter
Low Pressure Line - Fuel Filter
26
Components Explanation
-Because of several reasons, common rail system needs more pur
ified fuel compared to conventional diesel system.
-Especially in cold climate, water and solid contaminants will ca
use worn, corruption, clog in filter, corruption on the surface of
metal, pressure loss, and less lubrication in high pressure pump.
- In order to reduce these latent problems, there are Bosch fuel f
i1ter and fuel pre-heater with water separation
0
- Main Components:
CD Main Filter
Fuel Temperature Switch
Water Separate Sensor
@ Fuel Pre-heater
Air drain pump (only for A-2.S J -2.9 model)
(8) HYUnDRI ~~'rvice Training
Low Pressure Line - Fuel Heating System
27
System Explanation
- Purpose: To prevent diesel wax occurred
( To stabilize the diesel in cold climate)
- Working Temperature:
On : lower than -5C
Fuel Temperature S
witch
Off : higher than 3C
Wiring Diagram
Fuse Box
Battery
Fuel Temperature
Switch
High Pressure Line - Pressure Control Valve
28
- Main function: According to the engine speed and load, injection pressure will be
controlled.
CD High engine speed and load: The perturbation motion in combustion chamber is
high, so it needs higher pressure fuel to help combustion.
Low engine speed and load: If the injection pressure is too high during low load,
the penetration pressure of injectors will be over, some fuel will directly injected to
the cylinder wall. This will produce smoke and unburned hydrocarbon.
- The process of pressure control:
CD The rail pressure is measured
by rail pressure sensor.
The signal is sent to EDC ( Electronic Diesel Control)

According to the engine speed and load, proper fuel quantity is calculated.
@ PWM (Pulse Width Modulation) controls the pressure control valve, and reaches t
he pressure needed.
(8J HYUnORI
~i)rvice Training
.
- - - - - -- - - --
- - - --
-_.'",
' - '-
29
- Type:
CD Outlet Control: It is located at the end of the accumulator line, increases or
reduces the total quantity of fuel return, and controls the output pressure of
high pressure pump.
Inlet Control: It is combined with high pressure pump and controls the fuel
quantity from supply pump to high pressure pump.
Outlet Control Type :

Advantages : The rail pressure can moved up instantly.
Drawbacks : When the car is decelerated suddenly, the unnecessary rail

pressure will be difficult to release, and it wastes motion of energy.
* Inlet Control Type:
Advantages: When the car is decelerated suddenly, the rail pressure can
be controlled accurately to avoid consuming motion of energy.
Drawbacks: The rail pressure cannot moved up instantly.
(E/) HYUnDRI Service Training
30
- 2006 Tucson uses Outlet" Inlet Control Type p
ressure control valve
- As showed below :
Trajet uses Outlet Control Type
pressure control valve
Control Valve
High Pressure Pump

Supply Pump
(E/) HYUnDRI
f'~Jrvice
Training
High Pressure Line The 0 eration of Pressure Control Valve Outlet Control
31
----------------------------High Pressure Line - High Pressure Pump
32
- Main Components:
CD Driving Shaft
Offset Cam
Pumping Parts and Pump Piston
@ Inlet Valve
Outlet Valve
Inlet Valve
r - I- - - - - - ,
. Outlet Valve
(8) HYUnORI
S:~rvice Training
High Pressure Line - Fuel Common Rail
33
- Main function:
High pressure accumulator is commonly named fuel common rail, it
stores high pressure fuel. Even when large fuel quantity is discharged,
the common rail still can maintain the internal constant pressure.
- Components :
CD Common Rail
From the inlet of high pressure pump .
@ Rail Pressure Sensor
@ Fuel pressure limit valve
To the pipes of the injectors
D-Engine (2.0L)
34
Classification of injectors
These injectors have been produced since March,2003.
3 different type of distinguishing word X, Y;fa Z .
Injectors ofY mark must be installed on more than 2 cylinders.
Table of Injectors
Classification of Injectors Unit
Combination
Situation 1
Situation 2
Situation 3
Situation 4
Situation 5
(8) HYUnORI
~~)rvice Training
High Pressure Line - Injectors
35
.,
- Main function:
<"
,I .
"
"
Vertically installed injectors inject the

proper quantity of fuel into combustion
chamber at the proper time.
How to attend this function:
CD Complete electronic control

In every short circle of injection,
multi-injection will be produced.
,;j
S I
I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,. .
"d " I
L--_o_en_o_l_v_,a_v_e_--I '~
IG
Hydraulic Servo System

Hole Type Nozzle
* Initial operation current: 80V/20A


Closed
36
Open
CD t'
- Components :
CD Fuel Return
Connector
Solenoid Valve
@ Fuel Inlet
Valve Ball
@ Drain Port
(j) Supply Port
@ Valve Control Chamber
@)
Valve Control Plunger

@) Supply Passage
Injector Needle
(8) HYUnDRI Sl)rvice Training
. .
37
Components Explanation:
- Operation :
CD Injectors closed ( no operation) :

Solenoid valve does not operate and drain port is closed.
Valve spring pushes the valve ball to drain port seat.
The pressure in valve control chamber is the same as nozzle chamber.
Injector s open ( Injection starting) :

Solenoid valve is operated by inductive current and the operation force is higher than the valve s
pring force of drain port opening. When drain port opens ' fuel will flow to fuel tank from valve c
ontrol chamber via fuel return pipes. This makes the pressure is not balanced between valve contr
01 chamber and nozzle chamber. The reduced pressure in valve control chamber makes the inject
or needle open and start to inject the fuel.
@ I njectors closed ( Injection finish) :

As long as the solenoid valve doesn't operate, valve spring will push down the armature, make
valve ball close the drain port Drain port is closed to build pressure in control room.
This pressure let the pressure between valve control chamber and nozzle chamber obtain balance,
and nozzle is closed.
0
(8) HVUnORI Service Training
-------------------------------------------------------------------------------38
- Pilot Injection:
25'"
15<>
0"
-5"
1-
~.
~r
1)/
,.,
,...
2-'-:'
~~
~
./~
rYJ ~a-p
L /"
-10
il\
."
~~.
r.,..
~.
,\
.A
~ . ~.&."
-"
".. "
,
. .1
1 = Pilot Injection
la = Combustion Pressure with Pilot Injection
2 = Main Injection
2a = Combustion Pressure without Pilot Injection
(8) HVUnORI Snrvice Training
39
Components Explanation :
- The Purpose of Pre-Injection:
Reduce Combustion Noise
CD Combustion Noise
HC Emission
@ Fuel Consumption (Injection beginning delayed)
- Working Condition:
Idle speed and a little engine load
- Principle:
Diesel engine will not combust immediately after fuel into cylinders.
Therefore, it will cause serious combustion noise when the diesel is ignited.
In order to reduce combustion noise and combust during idle speed, it
must increase evaporation and chemistry form to reduce the ignition time.
This effect could be obtained by a little quantity of injection before main
injection. It is called pre-injection
0
--------------------------------EDC
40
Electronic Diesel Control

(EDC)
(E/) HYUnDRI
S.~rvice
Training
EDC - Input I Output
41
I Output>
Input>
1. Mass AirFlow
Sensor
"','
1. Injectors
2~' ECT S~hsor
2. Fuel Rail Control Valve
3. IAT Sensor
3. Relay
"
..
;.,.
...
- Main
- Glow Plug
ECM
- Cooling Fan
- Air Conditioning Fan
4. VAC Regulator of EGR

5. Pre-heater ( Coolant)
6. CAN
------------------------------EDC- ECM
42
- Clear Trouble Code:
When trouble codes occurred and were stored in ECM, only Hi-scan pro
can be used to clear codes in ECM.
- Required Signal of ECM Output:
Maintain the pressure constant in high pressure accumulator (Common
Rail) => P > 150 bar ( Instant pressure should be less than 150 bar)
To start and stop the actual injection sequence => CKP and CMP Signal
are normal.
ECM Connector
PLUG "M"
PLUG "K'
40
CJ S
d3
24:rrILLLLLLLLLILLLlXJ 6
:; :::::::; : : : : : : : : : :
1002 81: I
II I I I I
I, I I I I I I I
(8) HYUnORI
:~
HE
Z(~rvice
Training
........ _
- - - - - -.._
EDC - General Items
43
- Emergency Mode:
When ECM is malfunctioned on important Input/Output Signal, it will switche
d to Emergency Mode It will cause:
0
CD Reduce horse power

Reduce max. rpm
Without EGR (according to equipments)

- Emergency Stop
If the following system components got problem ' ECM will emergently stop t
he engine:
CD Injectors
CKPSensor
Pressure Control Valve
@ Fuel Leak
- Caution: When the engine is running or after the engine is stopped less than
30 seconds, do not repair the engine.
EDe - Heat Film Type Mass Air Flow Sensor ( AFS )
44
- The principle of hot film sensor is to heat the sensor and transfer the air mass.
Compared to gasoline engine, mass air flow sensor of diesel engine is mainly the limit of E
GR. Intake air temperature is built in.
- Functions :
CD EGR Feedback Control

The correction of fuel quantity
when suddenly acceleration or deceleration.
Mass Air Flow Sensor
ECM
AFS Output (V)
89 t--i:------+--++---,
B+(12V)
reference (V)
971 - tl--------- --l--. +-.I -- ~/
86
IAT Output (V)
1-1!----------+---I- I-----I%~~t_-_4to
Ground
88t--ir-----+--++----~
(8) HYUnORI SHrvice Training
EDC
- Intake Air Temperature Sensor ( IAT )

[Characteristic Curve]
-
IAT Sensor is built in AFS
Using NTC to detect the variation of temperature, so the!

ensor's main function is to measure the intake
te
mperature.
When malfunction occur, the temperature of IAT is set to
50C .
LI
....
'.',.,
\,
'~.-......
_-.......,-----
,..
J.
"1XT4' ~/'&
0110
.;..
Symptom
Trouble Codes
Details
CC
DTC
45
C001
Signal is lower than limit

(Signal <224mV)
C002
Signal is higher than the limit

(Signal>4.97V)
Fuel
EGR
=0
Closed
Fuel
Limit
MIL
-- '~"C
Inspection
Condition
on
Ignition
Switch is
ON
(Malfunction : 50C)
v
,"
"
'''~'W~YY''Y' ' ''YY''''''Y''Y'''' ''''Y''Y
"'Y'-""Y "
W"
"
~SY='~"Y "
Y'_Nvv _ ' ~Y"=vw,,~vY,,_yyy=~'.' Y~"
""
'"
,_,"'v='yyyyy
"
""""
yV V Vyy"Nyy y yy=,yyyyyyyy,-yy ,~y" "
"
..
yY~YVN =-',y,.w"
"N ,"" yVy y"N y y
..
v".yyv, "
'.y__ , .", "v. _ ~ ,, v ."N v
__r.wyv ' ' ' y ,.y .. =V ."",WW'_''V_'_"W,,V
(/i/) HYUnDRI Service Training
EDC - Accelerator Position Sensor ( APS )
46
- Accelerator Position Sensor is used to detect driver's acceleration or
deceleration, and sends signal to ECM. ECM decides injection quantity and
proper timing by this signal. There are two sensors in APS
(Accelerator Position Sensor) , APS 1 and APS 2. APS 1 is the main sensor to t
m
ell ECM about driver's motion. APS 2 is the sub sensor to monitor APS 1
alfunctioned or not. The output value of APS 2 is half of APS 1.
ECM
APS1 reference
rp
11111
11M
I
.11 I-~:
...
,.,
..
.. -......
.'"
......
r~
,~
-...t
00
APS1 Signal
,""",':'*':"':::-:'~~:">OOO~.
...
~.
APS1 Ground
{- '-.J
-...I
APS2 reference
r
APS2 Signal
APS2 Ground
L..
(XI
-{- 00
0
(-
(8; HYUnDRI
...
~
~~'rvice Training
EDC - Crank Position Sensor (CKP) :
47
- Crank Position Sensor (CKP):
Crank Position Sensor is named CKP technically. The operation is to detect and
calculate the teeth (60-2) on the pulse gear, sends the position of every piston in
combustion chamber to ECM, and decide the actual injection timing. This important
information is calculated in ECM by using CKP sensor.
ECM
Ground
101
99
Signal (+)
Signal (-)
100
(F:/) HYUnORI Service Training
----------------------------------EDC - Camshaft Position Sensor (CMP)
48
- Camshaft Position Sensor (CMP)
Camshaft position sensor detects the initial position of camshaft by Hall effect.
Magnetic teeth are mounted to the camshaft and rotates with it. When teeth pass the
CMP Sensor, the magnetic field will transform the electron inside of the
semiconductor into current direction that passes through the chips. This causes short
voltage signal (Hall voltage), and let ECM know the location of 1stpiston's
compression stroke_
CAMSHAFT
POSITION
SENSOR
ECM
104
103
Ground
Sensor Signal
N
I-t-- - - - - - - ' - - . . . . . . . : . . . . ;+___;
-<> ~
VM1
(F:/) HYUnORI
~t1rvice
Training
EDC - Rail Pressure Sensor (RPS)
49
- Rail Pressure Sensor (RPS) :
The main function of rail pressure sensor is to measure the instant pressure in the rail,
and sends the output voltage to ECM correspond to the operation voltage. To shorten
the inaccuracy in rail pressure sensor during pressure measurement, RPS must maintain
proper accuracy to operate fast.
RAIL PRESSURE
SENSOR
ECM
Signal
91 ~~~~~------~-r---.
reference
90~~~~~------~-+~
Ground
92 ~-;~~~-------&--r------J
"
EDC - Engine Coolant Temperature Sensor (ECT)
50
- Engine Coolant Temperature Sensor (ECT) :
Engine coolant temperature sensor is located in the passage of engine coolant on the top of cylinder
head. It detects the engine coolant temperature, and send signal to ECM.
It senses the variation of the temperature sensor.
The higher temperature is, the resistance of temperature sensor is lower.
ECM controls the injection timing by this signal, and limit the idle speed of the engine by ECT
output. At the same time, when the ECT value is higher than the value in ECM, ECM will reduce the
fuel quantity.
ECM
Temperature gauge
85 1---------11---
Ground
Signal
(BJ HYUnORI
~1f~rvice Training
EDC - Brake Switch
51
- Brake Switch :
For safety, there are two brake lamp switches. Every time when every driver depresses
the brake pedal, it will send ON! OFF signal of brake system to ECM.
When brake lamp switch 1 is on, brake lamp switch 2 must be off. By using this opposite
signal output, ECM can check the reasonable operation of switches.
To brake lamp
Brake Switch 1
1
54_~~(O_.3~)____-+3
__
VB
VM1
Brake Switch 2
-----------------------------------------------------------------------EDC - Injectors
52
- Injectors :
Sorento Uses hydraulic servo system and electronic start components for
special injectors.
Inductive Current: 20A 1A, Current Maintained: 12A + 1A
E
114
,-+,
o.z
P
1
..
CD
G)
s:::
::::I
No.1 Injection
Injectors
..
..
G)
P
3
..
::::I
No.4 Injection
Injectors
::::I
No.3 Injection
t:f2 .!~
G)
0
s:::
"tJ
p
2 r
::::I
= Injectors
~/
o.z
..
s:::
118
..-h
G)
s:::
121
.-+-..
o.z
"tJ
120
.-+-.
o.z
117
119
..
~
CD
No.2 Injection
Injectors
(E/) HYUnDRI S:,rvice Training
EDC - The Control System of Glow Plug
53
- Glow Plug System:
Glow plug system ensures effective cold start. It can shorten the warm-up time,
and directly affect the exhaust gas emission.
I Glow Plug Relay I
IGlow Plug I
l'
(/ij) HYUnDRI Service Training
EDC - The Control System of Glow Plug
54
- The glow time is decided by the temperature of engine coolant and engine speed.
Engine is
Start
running
! IG ON - - - .
'
/__'::O
_~ ___ l
IPre-glo; IStart-glow'" ~ain-glo~,I
CD
1 Pre-glow:
- Preheat system as three modes of operation__ . :' -:~i
Coolant temperature rC)
-20C
-10C
20C
50 c
Glow time (Sec.)
12
0.7
Start-glow: Pre-glow has completed, but the engine doesn't start yet.
When the engine coolant temperature is lower than 60C, max glow time will maintain 30 seconds.
When the coolant temperature reaches 60C in 30 seconds, glow will be stopped.
Main-glow: After the engine starts, rpm is lower than 2500 and the quantity of fuel
injection is lower than 75cc / min
------
Coolant temperatureCC)
-20C
-10C
20C
40 c
Glow time (Sec.)
40
25
10
(/ij) HYUnDRI
Z~)rvice
Training
EOC - EGR System
55
Solenoid valve
- EGR System:
Equipped with EGR, some exhaust gas will be inducted
into intake system of the engine. When reaching to some
level, increasing the rest exhaust gas will be positively
effective to energy transfer and exhaust gas discharge.
The EGR solenoid valve is controlled by PWM signal
produced by ECM.
ECM
Main Relay
VAOJUM
Ma:xJLATOR
(FOR EGR VALVE)
EGR valve
16
(8) HVUnORI Service Training
------------------------------EOC - 0-2.0 EGR System
56
EGR Cooler
The main purpose of EGR cooler is to reduce the emission temperature

of EGR, and promote volume efficiency when EGR is working.
(8) HVUnORI r;urvice Training
_~I
EDC - EGR System
57
- General Concept of EGR System:
....
-.----:;.-====b==::-f~;r--::::;:=::::J
Intake
AFS Signal
(EGR Feedback Control)
Controlled
Vacuum
Pressure
rpm
~
Intakeair
Vacuum Pressure
. . . . Input Signal
. . . Exhaust
~ EGR Emission
(8) HYUnDAI Service Training
EDe - EGR System
58
The Timing of :
...
Engine speed is 11 00 ~ 3000 rpm

Coolant Temperature : ECT > 60 C
Atmospheric Pressure: Altitude is higher than 1700 meters
Mass Air Flow Sensor ( AFS ) is not malfunctioned
Injection quantity is less than 42 C.c.
EGR is off during normal idle speed, release acceleration pedal
and EGR will operate 50 seconds.
EGROFF
Driving
Idle Speed (NO APS)
EGRON
I(
50 seconds
(8; HYUnDRI !:.. ~rvice Training
)1
EDC - EGR System
57
- General Concept of EGR System:
AFS Signal
(EGR Feedback Control)
Controlled
Vacuum
Pressure
rpm
~
Intakeair
Vacuum Pressure
..... Input Signal
~ Exhaust
EGR Emission
c=::::(E/) HYUnDRI Service Training
EDe - EGR System
58
The Timing of :
Engine speed is 11 00 ~ 3000 rpm

Coolant Temperature : ECT > 60 C
Atmospheric Pressure: Altitude is higher than 1700 meters
Mass Air Flow Sensor (AFS ) is not malfunctioned
Injection quantity is less than 42 c.c.

EGR is off during normal idle speed, release acceleration pedal
and EGR will operate 50 seconds.
'*
EGROFF
Driving
Idle Speed (NO APS)
EGRON
I(
(E/) HYUnDRI
50 seconds
~'4~rvice Training
)1
FO D-2.0L and JM D-2.0L

Engine
59
FO D-2.0 CRDi
1M D-2.0 CRDi
Displacement
1,991 cc
1991cc
PS
110.5 PS/4000rpm
136 PS/4000rpm
Torque
26.0 kgm/2000rpm
31.1 kgm12000rpm
83x92
83x92
Appearance
Cylinder diameter X str

oke
BOSCH 2nd generation

Fuel Pressure Control
- Inlet& Outlet Control
- 1,600bar
SCV ( Swirl Control Valve)
ACV( Air Control Valve)
CPF - Euro IV
BOSCH 1st generation

Fuel Pressure Control
-Outlet Control
characteristics
- 1,350bar
C8J HYiJniJFii Service
raining
EURO III and EURO IV

~ The
60
development goal of Exhaust Gas Emission

~----------------------------~
CD The comparison between EURO 4 and

EURO 3 Emission Standard:
PM
(g/km)
- PM
EURO-3 ( regulation)
- NOx : Reduce 50 %
0.05
0.04
--
0.03
- - EURO-4 ( regulation)
0.02
~) Development Goal
- Ruled 70 %
0.01
EURO-4
( ideal)
0.0
0.1
0.2
EURO-4 application
- New Model : January,2005
: Reduce 50 %
0.3
0.4
- Now: January,2006
0.5
HC+ NOx
(g/km)
" (E/) HYUnDRI !:"'~rvice Training
.~~ __ ~ . . __ J
61
EURO-IV Application
2nd generation CRDi System

Injection Pressure: 1350 ---->1600 bar
ECU : 16 ---->32 bit
ACV
( Air Control
Valve)
G;;I
B!!I
(/if) HVUnDRI Service Training
Cautions of Repair
62
> Every system component should be packed by sealed plastic.

Every port should use proper plug to prevent dust.
> Never use air guns to clean engine room when fuel pipes are
removed.
Removing and Installing Injectors
y Install Injectors:
e Clean the base
eCopper washer
eTorque
T40 Torx (torque: 2.70 9.2 kgm)
(/if) HVUnORI
~'<~rvice
Training
2 nd Generation CRDi System

CRDi system ( Injection pressure: 1600 bar)
High pressure pump
2nd injector
Rail pressure control valve
Function
1600bar high pressure injection => Effectively control the quantity of fuel injection
Injector (multi-injection)
2nd Injector Cutaway
Eng ine start

and low idle
Se(lllng pli'tc
Va!\'o bO<;Jy
V~)I\i~)
Valve
{lI!::ol 01.
gl\'vp
rpm
area
Characteristic
2nd GEN INJ
l ' tGEN INJ
1600 bar 15
0.8ms
1.0 mm 3/st
0.5 mm3 /st
1.0 mm3 /st
1350 bar/3
1.8 ms
1.5 mm3 /st
0.8 mm 3 /st
1.5 mm3 /st
Multi-injection:
Pilot Injection 2+Pilot Injection l+Main Injection
+ Secondary Injection 2+ Secondary Injection 1
Function
Pressure I Time
Min injection interval
Min fuel injection quantity
Inaccuracy in Pilot Injection
Inaccuracy in Main Injection
Reduce the min quantity of fuel injection and 1/3 inaccuracy of pilot injection I main injection.
Optimal injection in every driving situation.
Gr
Noise I exhaust gas I driving feeling are optimal.

44
EURO-IV Injection
Recycle
[500C i]
<p I t
' CrS
l.Ist:
'"
,~~_iJial nje0tion1i6@Quen'ce l'contit)14~)[~if;1(S~~i~4i'4'!;;j',k~~
2{l.i"-'>j<'TJ<ffi
f
~
~M{;u
~3.~?~~14~.~~i~tJr_1~~I'lfdt[i~,~!!!t~lgPill9~~~ffi.f~1
nee
,"
Aetara 1\ngte '.)
~ng
'$,"
,, ,'"
Pilot Injection
2
(BTDC) 1000
SOE(PiI1 )+ 150 I..Is + ET(PiI2)
Pilot Injection
1
(BTDC) 1000
SOE(MI) + 150 I..Is + ET(PiI1)
(BTDC) 40
SOE(MI)
(ATDC) 40
Main Injection
Secondary
Injection 2
(ATDC) 40 0
=Start Of Energizing
; ET
J\Jmor4?~s~~tfli. ,
Start
Reduce smoke
NVH
Increase torque
(ATDC) 40 0
Increase the temperature

of CPF
Max Ignition advance angle

for next cylinder
Stimulate catalysis
(Burn the soot)
+ ET(MI) + 150 I..IS
Secondary
Injection 1
SOE
.V;;tf;;."ii
"Z:"J,",
f";''0~~.
~I!~ -i"''f'':<'~#'r'
-ffl>:;.:~
"'1&
=Energizing Time
-----------~----------------------------
IQA (Injector Quantity Adjustment)

PI
U
Pilot Injection
Low tdle
WithlQA
Energizing Time (tis]
Function
Reduce the inaccuracy of every injector's injection quantity = > Reduce exhaust gas emission
45
- -- - - - - , - - - - - - -
IQA (Injector Quantity Adjustment)
46
Cautions of Repair
63
y When disconnect high pressure pipes, use 2

wrenches to loosen both sides nuts.
~ Please
use bare hands to repair

in order to prevent dust.
(E/) HYUnORI Service Training
Cautions of Repair
64
Removing High Pressure Pipe

Never release high pressure pipes with running: engine
~"T"""LI""
(E/) HYUnORI S'Jrvice Training
-------------------------
Cautions of Repair
65
Checking fuel pressure & checking injector operation
High pressure can be checked

only via the Raj,1 Pressure
Sensor Voltage Reading.
High pressure can be checked

only via the Rail Pressure
Sensor Voltage Reading.
(8;>
48
HVUnCRI

Common Rail Diesel Injection Hyundai Tucson

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Common Rail Diesel Injection Hyundai Tucson

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2011 Automobile Maintenance

Advanced Course for the

Practice: Fuel System Analysis

Topic : Oil Pressure Test for Low-pressuse pipe

Low Pressure Pum

2. Test of low-pressure area for CRDi D-2.0 engine fuel syst

Practice: Fuel System Analysis

Judgement and Analysis

Oil Pressure Measurement of Low Pressure Pipe (D-2.0)

Block in Fuel Filter or low pressure pipe

Leakage of low pressure pipe or

Practice: Fuel System Analysis

1. Separate the fuel return hose according to picture 1

4. After starting the engine, do the following steps

Practice: Fuel System Analysis

Adjust Valve Connec

Pressure Sensor Connector

1. Engine can not be started

Practice: Fuel System Analysis

4. After separating the fuel pressure sensor connectors according to pic1

Practice: Fuel System Analysis

Practice: Fuel System Analysis

Quantity of fuel return for

Pressure of high pressure

Change the injector

Checking the line of

Practice: Fuel System Analysis

- Topic: Pressure measurement of high pressure pump by using CRT-I000

Connector for Fuel pre

ID :fI &'J ;;:: ~,

m?t, it~~ :1:~~ ~ ~Ol ~

Parts for checking high pressure pump

1. Engine can not be started

Practice: Fuel System Analysis

(DSeparate all injector pipe

Practice: Fuel System Analysis

Practice: Fuel System Analysis

Course: HYUNDAI D-2.0 CRDi

Instructor: Lin, Jin-jih

CRDi - Common Rail Direct Injection Diesel Engine

.. The electronic diesel control system

( Engine Management System)

CRDi : Common Rail Direct Injection

CP1 0-2.0 CRDi Engine on two models

(Ii/) HYUnORI !iHrvice Training

Delphi J3-2.9 CRDi

CP3 A-2.S CRDi

The Difference betweenCPl,CP3ahd . Delphi

The control of fuel

(8) HYUnCRJ !l..,rvice Training

0-2.0 CRDi - High Speed Direct Injection

Power UP and the Economy of Fuel Consumption

Low Emission and Low NVH

(E:/) HYUnDRI Service Training

The Development of Diesel Engine

The Development of Diesel Engine

(E:/) HYUnDRI n,1rvice Training

0 -2.0 - High Speed Direct Injection

1.se & 2.0e

The Driven Way of

The Control of Fuel Pressure

(8) HYUnDRI Service Training

Valve Driven System

- Timing Driving System

m?t, it :1: ~ ~Ol ~