Electric Devices and Sensors PDF

DI09-1
SECTION
00 DI09
ELECTRIC DEVICES
AND SENSORS
Table of Contents
ELECTRIC DEVICES AND SENSORS ........................ DI09-3

Sensors in engine compartment ............................. DI09-3
Electric devices in engine compartment ................. DI09-4
Specifications .......................................................... DI09-5
Circuit diagram of preheating system ..................... DI09-6
Circuit diagram of starting and alternator .............. DI09-7
TROUBLE DIAGNOSIS ............................................... DI09-8
General ................................................................... DI09-8
Alternator .............................................................. DI09-10
Starter ................................................................... DI09-12
Preheating system ................................................ DI09-14
Preheating time relay ............................................ DI09-16
Glow plug .............................................................. DI09-17
SPECIAL TOOLS AND EQUIPMENT ........................ DI09-19
ELECTRIC DEVICES AND SENSORS CHANGED BY

DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI09-3
ELECTRIC DEVICES AND SENSORS
SENSORS IN ENGINE COMPARTMENT
Fuel pressure sensor Booster pressure

sensor
Camshaft position Oil pressure switch

sensor
Coolant temperature Crankshaft position

sensor sensor
Fuel temperature
Knock sensor
sensor
Y220_09001

AFFECTED VIN
DI09-4
ELECTRIC DEVICES IN ENGINE COMPARTMENT
Alternator Glow plug

Capacity
PTC equipped vehicle
: 12V - 140A
FFH equipped vehicle
: 12V - 115A
Air conditioner compressor Starter
Y220_09002
CHANGED BY ELECTRIC DEVICES AND SENSORS

EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
DI09-5
SPECIFICATIONS
Description Unit Specification
Starter Type - WP220
Output power Kw 2.2
No load test @ 12 volts A 160
Drive pinion speed at no load rpm 4500
Drive pinion speed at load rpm/A 1700/430
Brush length mm 18
Armature diameter mm 55
Armature run-out mm 0.1
Segment groove depth mm 21.7
Alternator Type - CS128D
Output voltage / current V/A PTC equipped vehicle: 12V-140A
FFH equipped vehicle: 12V-115A
Regulator type - ←
Regulating voltage V 14.6
Brush Length mm 12.5
Quantity - 2
Wear limit mm 7
Battery Type - MF
Capacity AH 12V - 90AH
Rupture capatity RC 160
Glow plug Type - Seized type
Rated voltage - 11.5
Circuit connection - Parallel
Preheating time sec Max. 60 ~ 90

AFFECTED VIN
DI09-6
CIRCUIT DIAGRAM OF PREHEATING SYSTEM
Y220_09003

AFFECTED VIN
DI09-7
CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR
Y220_09004

AFFECTED VIN
DI09-8
TROUBLE DIAGNOSIS
GENERAL
Condition Probable Cause Correction
No crank • Low battery voltage. • Charging the battery or replace
the battery.
• Battery cable is loose, • Repair or replace the battery
corroded, or damaged. cable.
• Faulty starter motor or starter • Repair or replace the starter
motor circuit is open. motor/starter motor circuit.
• Faulty ignition switch. • Replace the ignition switch.
• Ground short. • Repair the ground short.
Crank ok, but too slow • Low battery voltage. • Charging the battery or replace
the battery.
• Battery. • Repair or replace the battery
• Battery cables are loose, cable.
corroded, or damaged.
• Faulty starter motor. • Repair or replace the starter
motor.
Starter motor does not stop • Faulty starter motor. • Repair or replace the starter
motor.
• Faulty ignition switch. • Replace the ignition switch.
Starter motor running, but not • Broken the clutch pinion gear or • Replace the starter motor.
cranking faulty starter motor.
• Broken the flywheel ring gear. • Replace the flywheel.
• Connected circuit is open. • Repair the open circuit.
Battery discharge • Loosen the generator drive belt. • Adjust the belt tension or replace
the belt.
• The circuit is open or a short. • Repair the open or a short circuit.
• Battery run down. • Replace the battery.
• Open ground circuit. • Repair the open ground circuit.
Charging indicator lamp does not • Charging indicator lamp is blown • Repair or replace the charging
work when the ignition switch on or fuse is blown. indicator lamp/fuse.
(engine does not work) • Faulty ignition switch. • Replace the ignition switch.
• Generator ground circuit is open • Repair the circuit.
or a short.
Charging indicator lamp does not • Battery cable is corroded or • Repair or replace the battery
put out lights after starting the damaged. cable.
engine • Loosen the generator drive belt. • Adjust the belt tension or replace
the belt.
• Faulty wiring harness. • Repair the wiring harness.
Battery over charging • Generator voltage regulator faulty • Replace generator
• Voltage detecfing wiring faulty • Repair wiring

AFFECTED VIN
DI09-9
Symptom Cause Action

Hard engine starting • Ignition coil faulty • Replace ignition coil
• Distributor (including optical • Replace distribator (or sensor)
sensor) faulty
• Spark plug malfuntion • Replace spark plug or adjust
clearance
• Ignition timing faulty (spark plug • Resetting valve timing
light is normal)
Unstable engine idling • Spark plug malfunction • Replace spark plug or adjust
clearance
• Ignition coil faulty • Replace ignition coil
• Ignition timing faulty • Resetting valve timing
Enging acceralation malfunction • Ignition timing faulty • Resetting valve timing

AFFECTED VIN
DI09-10
ALTERNATOR
Y220_09005
1. Cooling fan 3. Alternator

2. Bolt ............................................................. 45 Nm 4. Plug connection

AFFECTED VIN
DI09-11
Removal and Installation

1. Disconnect the negative battery cable.
2. Remove the plug connection.
Y220_09006
3. Unscrew the bolts and remove the alternator.

Installation Notice
Tightening torque
4. Install in the reverse order of removal.
Y220_09007

AFFECTED VIN
DI09-12
STARTER
Y220_09A008
1. Starter 3. Nut .................................................................... 15 Nm

2. Washer 4. Bolt ................................................................... 48 Nm

AFFECTED VIN
DI09-13

1. Disconnect the negative battery cable.
2. Disconnect the starter terminal.
Y220_09009
3. Lift up the vehicle and remove the front propeller shaft

mounting bolts.
Y220_09010
4. Remove the upper and lower mounting bolts.
5. Install in the reverse order of removal. Y220_09011

AFFECTED VIN
DI09-14
PREHEATING SYSTEM
General
Glow plug is installed on the cylinder head (combustion chamber) in the D27DT 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/after heating and
glow plug diagnosis function, the fault contents will be delivered to ECU.
• Engine preheating/after heating functions
• Preheating relay activation by ECU controls
- Senses engine temperature and controls the preheating/after heating time
- Preheating warning light
• K-LINE for information exchanges between preheating unit and ECU
- Transmits preheating unit self-diagnosis results to ECU
- Transmits glow plug diagnosis results and operating status to ECU
STICS (remote start)
Coolant
temperature
sensor
Y220_09012

AFFECTED VIN
DI09-15
Function
Preheating system controls and checks following functions and operating conditions.
• Pre-Heating
: 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 850°C very quickly to aid combustion by vaporizing air-fuel mixture during compression stroke.
Preheating time is controlled by ECU.
• While engine starting

: Help to warm up engine
• After-heating
: When the engine is started, after-heating starts by ECU controls. The idle rpm will be increased to reduce toxic
smoke, pollutants and noises.
After-heating time is controlled by ECU.
• Checking glow plugs

- Check each glow plug for short in circuit
- Check each glow plug for open in circuit due to overvoltage
- Check glow plug for short to ground
• Forceful relay shut-down

- When glow plug is shorted to ground
• K-Line communication
- ECU sends the results to preheating time control relay through K-Line to start communication.
- Preheating time control relay sends messages including self-diagnosis data for glow plugs to ECU.
- Glow plug makes communication only as response to demand.
- When power is supplied, ECU starts self-diagnosis within 2 seconds.
- Under the following conditions, communication error occurs.
When there is no response from glow plug module within 2 seconds
When an error is detected in checksum
Less byte is received
Error code of “Pre heating control communication fail” will be reported.

AFFECTED VIN
DI09-16
PREHEATING TIME RELAY

Structure
K-LINE #1 IG1 power

(ECU 34) terminal
Glow plug control

signal
(ECU 113)
Ground
terminal
B+ main
wire (12V)
Relay signal output (5V)
Glow plug terminal to RESTICS
#1~ #4 , #5
Y220_09013
Specifications
Description Specification
Rated voltage DC 12 V
Operating voltage range DC 8 ~ 15 V
Operating range - 40 ~ + 100°C
Relay operating voltage Over 6.5 V
Relay releasing voltage Over 1.5 V
Relay coil resistance 11.3 Ω
Voltage drop Below 150 mV at each glow plug (at 16A of current)
Parasitic current Max. 1mA

AFFECTED VIN
DI09-17
GLOW PLUG
Cylinder type glow plug is inserted into the cylinder and com-
posed of heating pin and housing.
There are heating coil and control coil in the heating pin and
those coils located inside of ceramic cover turn ON or OFF
the internal switch.
Purposes of use
- Preheating before engine starting
- During engine starting
- After-heating after engine starting Y220_09014
Conditions for glow plugs

- Prompt heating and secured temperature stabilities (temperature changes) in low operating voltage
- Should not exceed permissible max. temperature under max. operating voltage
- Heating pin should have good heat-resisting properties against combustion gas and durability
- Material of the glow plug should meet high stressing conditions (e.g., temperature, vibration and environmental
factors)
Specifications
Description Specification
Rated voltage 11 ± 0.1 V
Current consumption Initial current I intial < 30.0 A
Preheating time T 850°C = 5 ± 1.5 sec.
(From ambient temperature up to 85°C)
Operating temperature 900 °C
Tightening torque 15 + 3 Nm
Trouble Code
Refer to “Diagnosis” section in this manual.

AFFECTED VIN
DI09-18

1. Turn the ignition switch to “OFF” position and disconnect
the negative battery cable.
2. Set aside the harnesses on the cylinder head.
Y220_09015
3. Disconnect the glow plug connectors and loosen the glow

plugs.
Installation Notice
Tightening torque
Y220_09016
4. Remove the glow plugs from the cylinder head with a

special tool. Plug the openings of the glow plugs with
sealing caps.
Y220_09017

AFFECTED VIN
DI09-19
SPECIAL TOOLS AND EQUIPMENT
Name and Part Number Application
Glow plug remover Removal of glow plug
Y220_09018 Y220_09019

AFFECTED VIN

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DI09-1

ELECTRIC DEVICES AND SENSORS ........................ DI09-3

ELECTRIC DEVICES AND SENSORS CHANGED BY