Common Rail System (CRS) Service Manual - Service
Contents
1. 720 CA Q006879E Operation Section 2 17 2 Coolant Temperature Sensor The coolant temperature sensor is attached to the engine cylinder block to detect engine coolant temperature The coolant temperature sensor makes use of a thermistor Thermistors display a characteristic in which the resistance value of the element changes in accordance with temperature As such the thermistor de tects temperature by converting changes in coolant temperature into changes in resistance As temper ature increases the thermistor resistance value decreases lt Resistance Value Characteristics gt Thermistor Q004975E 3 Fuel Temperature Sensor The fuel temperature sensor detects the fuel temperature and sends corresponding signals to the engine ECU The ECU then calculates an injection correction suited to the fuel temperature based on the signal information The SKY ACTIV D engine CRS has a fuel return path from the supply pump built into the engine compartment lower case lt Reference Temperature Resistance Characteristics gt Temperature C Resistance Value kQ 30 25 40 20 15 04 10 9 16 0 5 74 10 3 70 2 45 1 66 1 15 0 811 0 584 0 428 0 318 0 240 0 1836 0 1417 0 1108 Fuel Temperature Sensor Q006891E Operation Section 2 18 4 A F Sensor The A F sensor detects the air fuel ratio in the engine across al2. 2 20 7 3 Injector Temperature Characteristic Correction Control 2 23 74 Interval Dependence Correction 2 25 7 5 Exhaust Gas Recirculation EGR Control 2 26 7 6 i stop Control eI eae nah SuPer ina Sede dra RAD AW bea ehh bre hela bua 2 27 8 Other Controls 8 1 Jet Pump WRIOnly yz seuicnso deprer an geiergert eelere Ak eeler stan dee cece 2 29 9 Exhaust Gas Treatment System 9 1 Diesel Particulate Filter DPF System 2 30 10 Diagnostic Trouble Codes DTC 104 DIC Mig cio ee De e tee see 2 32 11 Wiring Diagrams 11 1 Engine ECU External WiringDiagrams 2 52 11 2 Connector Diagrams 2 58 Operation Section 1 Introduction 1 1 SKYACTIV The name SKYACTIV was chosen for several innovative next generation MAZDA technologies to evoke an image of vehicles that are not only fun to drive but achieve superior environmental friendliness and safe ty This manual introduces the following six key SKYACTIV technologies Engine SKYACTIVG G A next generation high efficiency Direct Fuel Injection DFI engine that suppresses knocking and achieves a high compression ratio 14 0 SKYACTIV D A next generation clean diesel engine that A achieves a low compressio
3. Q006886E 2 59 Operation Section 2 MT i stop only I S a Aale Jm yn SD i maafa Z aTn i Ja mala aaa tte el on elei leed ffl a YY wa Jm Q006922E Service Division DENSO CORPORATION MWA 1 1 Showa cho Kariya shi Aichi ken 448 8661 Japan
4. P0102 ES MAF meter low Sensor output voltage lt 0 289 V P0103 MAF meter high Sensor output voltage gt 4 624 V k e Diagnosis Item _ lntake air temperature sensor air temperature sensor intake manifold high pressure relief valve coil short abnormality pressure relief valve actuation line abnormality pressure relief valve MOS short abnormality ECU pressure relief valve pressure reduction function abnormality Abnormal Mass Air Flow MAF meter characteristics Manifold Pressure MAP sensor Abnormal Absolute characteristics Judgment Conditions Sensor output voltage gt 4 900 V Number of MOS switch actuation the reduction valve actuation circuit gt 190 times energization time 10 msec detections for pressure threshold level ex Number of MOS switch actuation the reduction valve circuit lt 4 detections for pressure Downstream voltage for the actu ation circuit when the pressure reduction valve is not actuated high Pressure reduction flow volume calculated value from change in rail pressure lt threshold level ex 40 mm st Air flow volume lt threshold level ex 210 mg cyl engine rota tional speed 2 000 rpm Difference between MAP sensor compressor outlet atmo spheric pressure sensor built into ECU and exhaust gas pres sure sensor gt 50 kPa MAP sensor intake manifold P0107 Sensor output voltage lt 0 136 V ow
5. 11 Wiring Diagrams 11 1 Engine ECU External Wiring Diagrams 1 AT Blow By Heater Ka 7 8 pa Rey een EXT Ha Seck Di WW e Ee 46 E01 POWER HS To see eee EE CCOO m IH ma cylinder SE Main Relay Fuel Heater deeg ES Ecg eee ylinder No Mass Air Flow D H ES pa MAF Meter HSH SI CANNONI m Injector 1 Wi mH Cylinder No eee aint ES ew SH E mg with Cooler Brake Switch 1 i zen Eert Tu iaa EE ONNAN mm HE Injector 2 mg Tel Cylinder No EGR Valve 2 with Cooler Starter Relay A C Relay Se E Se O006883E O Accelerator Pedal EA Position Sensor 858 E APS2 tia Ambient Temperature Sensor A C Compressor Sensor Master Vacuum Cylinder Pressure Sensor DC DC Converter FL nic Brake Switch 2 Kick Open a Water Level Switch B40 WL SU fa Ne Operation Section 2 53 Electric Shooter Valve Intake Air Temperature Sensor Manifold Absolute Pressure MAP Sensor Exhaust Gas Temperature Sensor MIDDLE Exhaust Gas Temperature Sensor UPPER Differential Pressure Sensor Rail Pressure Sensor Q006884E Operation Section 2 54 850 THRCSL Intake Air Temperature Sensor 2 gt 824 E THRCBL mp Coolant Temperature Sensor Fre See B25 GRU ST eo mU JL Dou Glow Unit ENG EIRTH Ou Glow 1 E TUAG mar Zeng Valve Lit lu
6. der no 1 injector circuit P0201 Short in ECU internal cylinder Cylinder switch 1 short selection switch for cylinder no 1 injector Open circuit downstream of cylin Injector 4 open circuit der no 2 injector circuit P0202 Short in ECU internal cylinder Cylinder switch 4 short selection switch for cylinder no 2 injector Open circuit downstream of cylin Injector 2 open circuit der no 3 injector circuit P0203 Short in ECU internal cylinder Cylinder switch 2 short selection switch for cylinder no 3 injector Operation Section 2 37 DTC Fail Safe Check Diagnosis Item Judgment Conditions Light Open circuit downstream of cylin Target Rail Pressure Limit EGR Valve Control Prohibition Intake Throttle Control Prohibition i stop Prohibition Output Limit Injector 3 open circuit der no 3 injector circuit Short in ECU internal cylinder Cylinder switch 3 short selection switch for cylinder no 3 injector ji Engine rotational speed gt 5 670 Engine overrun abnormality rpm Accelerator pedal position sensor Sensor output voltage lt 0 217 V 2 low Accelerator pedal position sensor Scho Sensor output voltage gt 4 147 V hig The difference between the tar get manifold pressure and actual P0234 Excessive supercharging com manifold pressure in the compact pact turbocharger region turbocharger range is below the specified value continuously for seven seconds P0219 P0222 P0223 Diff
7. enol ce len Oil Control Valve EH wg Wastegate Valve mE ig Compressor Solenoid A Im Te Fuel Temperature Sensor tm mH SES m m et E PINCHA Wu ATADO E E eon Ju N VREF G me Ma Pressure Relief Valve Combination Oil Temperature Oil Pressure Sensor Cylinder Recognition Sensor Crankshaft Position Sensor Regulator Valve Position Sensor Exhaust Gas Pressure Sensor Exhaust Gas Temperature Sensor Q006885E Operation Section 2 55 2 MT Blow By Heater Blow B LU OLCH Heater Relay 7 ge EZ BH ges e Wm eem M6 EO PIER Cal EDI PONER HSH Battery CIO E Injector 3 HH u ya Im Io ESPA Cylinder No 4 aw ja CONNAN p Injector 2 II Cylinder No 3 Main Relay Um Jo Cylinder No 3 Fuel Heater LEI mn Ji l mae mi L b Cylinder No 2 MAF Meter men lt O incor y oytinder No 1 A Ga Duell tevinderNo 1 II E Na w w BEER Ee E WE SSC EGR Valve with Cooler EEGR Valve 2 with Cooler Starter Relay laun Brake Switch 1 Kick Cruise FEIS DH A C Relay Reverse Switch Reverse Cruise HE id Q006919E Operation Section 2 56 Clutch Switch Kick Cruise Neutral Switch Neutral Cruise Electric Clutch Cut Switch Shooter Valve Kick Cruise ooo e Intake Ai a SZ B57 ensor Accelerator Pedal u ii Position Sensor mir 1828 VREF 1P52 Exhaust Gas Temperat
8. 2 Applicable Vehicles and Parts Information 2 1 Outline The SKYACTIV D engine is equipped with the MAZDA CX 5 released in March 2012 As a result a Common Rail System CRS for the SKYACTIV D engine has been newly designated This manual describes items specific to the parts used in the CRS for the SKYACTIV D engine For CRS basics refer to the COMMON RAIL SYSTEM SERVICE MANUAL OPERATION Doc ID 00400534EA amp The SKYACTIV D engine CRS has undergone the following improvements to comply with exhaust gas reg ulations for 2014 Euro 6 System pressure 200 MPa Supply pump HP3 Complies with pressures up to 200 MPa newly designated injector return system discharge port Rail Complies with pressures up to 200 MPa use of pressure relief valve Injectors G3P use of piezo injectors Use of DPF system Use of injector return system PM g km 0 03 Euro4 2005 Euro5 2008 gt 0 3 NOx g km Q006918E Operation Section 2 2 Applicable Vehicles LDA KE2FW LDA KE2FW 2WD March 2012 LDA KE2AW 4WD 2 3 List of Primary Parts DENSO Customer Part Name Remarks Part Number Part Number Supply Pump 294000 166 SHO1 13800 Injector 295900 295900 0268f SHO1 13H50 13H50 2 ese 2WD 275700 507 SHO2 18881 Low power AT 4WD 275700 511 SH04 18881 High power MT 2WD 275700 508 SHO1 18881 Low power MT 4WD 275700 506 SH1A 18881 Low power AT 4WD 275700 509
9. Judgment Conditions Code Light i stop Prohibition P0672 No 2 cylinder glow plug circuit Abnormality due to diagnosis sig DR No 3 cylinder glow plug circuit Abnormality due to diagnosis sig AE ANED mn a O emi abnormality nal from glow unit DI signal between ECU and glow Glow unit diagnosis signal O E a DI signal between ECU and glow Glow unit diagnosis signal O a men O feunga ess ECU and glow not received Data flash read write abnormality PO6B8 Data flash abnormality Data flash writing counts gt 325 000 times lol ee Io ground short battery voltage elo laws Jeer fo PO6DC Actuation circuit current gt 5 9 A B short ol fama Wn abnormality hPa re Sema y d abnormality 250 hPa No brake switch input even though the vehicle has been P0703 Brake switch diagnosis stopped several times at or above a constant vehicle speed value No clutch switch input even though the vehicle has been P0704 Clutch switch diagnosis stopped several times at or above a constant vehicle speed value ji i Inconsistency between neutral PO7BE Neutral switch malfunction E switch neutral sub switch P0673 P0683 Operation Section 2 44 SAE Check Diagnosis Item Judgment Conditions Code Light Target Rail Pressure Limit EGR Valve Control Prohibition Intake Throttle Control Prohibition i stop Prohibition Output Limit No neutral switch input even i ji ji though there have been several N
10. SH1B 18881 Low power MT 4WD 275700 504 SH1J 18881 High power AT 4WD 275700 502 SH1K 18881 High power AT 2WD 275700 510 SH1M 18881 Ge power Serge rena aer O 265600 327 SH01 187G0 Oxidation catalyst Exhaust Gas Temperature Sensor inlet 265600 265600 328H SH02 187G0 DPF catalyst inlet ETB l 197920 010 SHO1 136BO Diesel Air Control Valve Exhaust Gas Recirculation EGR Valve 150100 020 SHO1 20300 L O Operation Section DENSO Customer Part Name Remarks Fen Numer AA Number Pen Numer Number With heater heater 186300 898 SH01 13480 left hand driver vehi cles Without heater Fuel Filter 186000 707 SHO2 13480 left hand driver vehi cles Without heater 186300 706 SHO3 13480 right hand driver vehicles Electric Water Pump 113730 059 KD 612FX For the EU Operation Section 2 4 System Configuration 1 Engine System Configuration The SKYACTIV D engine system is configured as shown in the figure below Exhaust Gas Recirculation EGR Cooler Bypass Valve Fr EGR Cooler 0 al Differential Pressure Sensor H EGR Valve Turbocharger Pressure Relief Valve Injector Two Stage A g i Exhaust Gas H Wa Temperature Sensors lt Feed Valve 9 an B Fuel Temperature Sensor a Crankshaft Position Sensor NE Sensor Supply Pump Fuel Filter ETB Diesel Air Control Valve lus a Q006872E 2 6 Operation Section 2 Mounting Figure for P
11. and air enters the displacement expansion chamber inside the injector the ability to transmit piezo stack displacement is lost and injection is no longer possible To pre vent the aforementioned circumstances fuel is sent to the injector return side from the supply pump via the feed valve to apply back pressure The air is therefore compressed and eliminated to improve startability The injector return system is built into the lower case of the engine compartment Injector return system con struction and operation are detailed below Retum Back Pressure Pb 1100 kPa GSP Injectors Open Mane eg kPa Large Diameter Piston Displacement Expansion Chamber a H Feed wa Pump Back Pressure Valve Open Valve Pressure 1100 kPa Q006876E 1 Construction Injector return system construction is shown in the figure below Lower Case Feed Valve Back Pressure Valve O006913E Operation Section 2 14 2 Operation When the Feed Valve Operates When the pressure in the lower case drops below a constant value a ball inside the valve presses on a spring and fuel flows into the lower case injector side from the supply pump from Supply Pump Feed Valve Q006914E When the Back Pressure Valve Operates When the fuel returning from the injectors exceeds a constant value a ball inside the valve presses on a spring and a fuel path is opened to the fuel tank side to Fuel Tank Ba
12. of the nozzle needle Therefore injection is not performed Injection When voltage is applied to the piezo stack the stack expands The transmission of actuation power from the large diameter piston to the small diameter piston expands the displacement of the piezo stack and pushes the control valve down thereby opening the upper seat and closing the lower seat As a result fuel is discharged from the control chamber to the leak path via orifice A and control chamber pressure decreas es Since pressure on the bottom of the nozzle needle becomes greater than that of the control chamber the nozzle needle is pushed up and injection begins Injection Complete When the voltage applied to the piezo stack is removed the stack shrinks and both the large and small diameter pistons as well as the control valve rise Additionally the lower seat opens and the upper seat closes As a result a fuel path to the control chamber opens and fuel pressure in the control chamber quickly returns to the same pressure as the rail Therefore the nozzle needle is pushed downward and fuel injection stops Piezo Stack DE Large Diameter Orifice A Orifice A Piston i e Small Diameter Piston Control Valve TE Control Chamber Pressure Nozzle Needle Orifice B Orifice B Non Injection Injection Complete Q006910E Operation Section 2 13 5 3 Injector Return Back Pressure System O When the injector return side is dry no fuel
13. 5 Sensor output voltage lt 0 134 V ow Abnormal exhaust gas tempera P0546 a Sensor output voltage gt 4 96 V ture sensor characteristics Master vacuum pressure sensor lo Sensor output voltage lt 0 133 V w P0555 Master vacuum pressure sensor Kok Sensor output voltage gt 4 906 V IO P053C After a determined amount of time has elapsed since engine start up the engine oil pressure ji is at or below the specified value P055F Low oil pressure abnormality ji Ex engine oil pressure is 80 kPa or less when engine rota tional speed is 2 000 rpm or lower P0571 Brake switch signal abnormality Inconsistency between brake 1 and 2 correlation abnormality switch 1 and brake switch 2 Battery deterioration overall Battery charge discharge abnor PO57F energy mality BMS_SOHCBF Current sensor internal abnor mality battery voltage abnormal PO58A Current sensor malfunction ity battery fluid temperature abnormality P0601 Diesel Particulate Filter DPF Data flash related EEPROM abnormality data corruption abnormality m Data flash P0602 VID writing abnormality writing value abnormal Data flash P0605 ECU flash ROM abnormality checksum abnormal Operation Section 2 42 DTC Fail Safe SAE Check Diagnosis Item Judgment Conditions Code Light ECU abnormality main IC abnor P0606 Main IC run pulse input failure mality ECU abnormality monitoring IC Monitoring IC run pulse input
14. A I Injection Pulse Width Q006900E REFERENCE In addition to the learning performed automatically at three different pressure levels the learning performed by a dealer with diagnostic tools when an injector or the engine ECU is replaced adds learning at 140 MPa and 197 MPa for a total of five different levels However learning at 140 MPa and 197 MPa is performed while the engine is in an idle up state with an eye towards supply pump reliability Operation Section 2 23 7 3 Injector Temperature Characteristic Correction Control Outline Injectors possess a characteristic under which the injection quantity changes according to the fuel temper ature As a result of fluctuations in this characteristic a disparity occurs between the injection quantity com mand value and the actual injection quantity Injector temperature characteristic correction control corrects any discrepancies due to temperature Goal e To achieve the combustion target and to stabilize engine performance emissions output by minimizing in jection quantity discrepancies caused by fuel temperature fluctuations Control e Control takes place as follows 1 fuel temperature inside the injector is estimated 2 the difference is cal culated between the command injection quantity and the actual injection quantity at the estimated fuel tem perature 3 the calculated difference is passed along to injector control as the correction quantity 1 Estima
15. MAP sensor intake manifold P0108 high Sensor output voltage gt 4 910 V IO Fail Safe i stop Prohibition Operation Section Check Diagnosis Item Judgment Conditions Light Difference between intake air 2 35 Fail Safe Target Rail Pressure Limit EGR Valve Control Prohibition Intake Throttle Control Prohibition i stop Prohibition Output Limit temperature sensor intake mani Intake air temperature sensor fold and intake air temperature with MAF meter CCM diagnosis sensor downstream of I C gt 50 C Intake air temperature sensor Sensor output voltage lt 0 336 V with MAF meter low Intake air temperature sensor Sensor output voltage gt 4 511 V with MAF meter high Difference between maximum P0112 P0113 P0116 Abnormal coolant temperature and minimum coolant tempera sensor characteristics 2 tures recorded in history lt 0 004 C Coolant temperature sensor low Sensor output voltage lt 0 090 V Coolant temperature sensor high Sensor output voltage gt 4 826 V Abnormal accelerator pedal posi Voltage difference between P0121 tion sensor 1 accelerator pedal position sen characteristics sor systems 1 and 2 gt 0 5 V P0117 P0118 P0122 Accelerator pedal position sensor ielo Sensor output voltage lt 0 277 V W Accelerator pedal position sensor 4 high Sensor output voltage gt 4 828 V Ig A F sensor resistance value lt P0123 P0131 P0132 P0133
16. MAZDA SKYACTIV D Engine EURO 6 Common Rail System CRS Service Manual Issued April 2012 Applicable Vehicle Vehicle Name Release Date CCS DENSO CORPORATION 50000061E 2012 by DENSO CORPORATION All rights reserved This material may not be reproduced or copied in whole or in part without the written permission of DENSO Corporation Table of Contents Operation Section 1 Introduction HAs A A A A er eat 2 1 1 2 SKYACTIV D Features o a iS a ee O O OI R2 HR HR 2 1 2 Applicable Vehicles and Parts Information 2 EIA A EE NO Ng dd WL SR MD DO NN 2 2 22 Applicable Vehicles se 2 2 A dd gd aed RA Y de IA a GE Wr Ee FAN GE AG 2 3 2 3 List of Primary PartSic src tra ar a A a ANI SIR a CF 2 3 2 4 System Configuration sers sese eee EEN A A E 2 5 3 Supply Pump 3 1 WA acen oi See ee sok tee AL a ee e Y dyo 2 8 3 2 Suction Control Valve SCH 2 9 4 Rail 4 1 OUNEN Pe ENEE 2 10 5 Injectors 5 1 Outline ee ag di A he Pe eee Ad 2 11 5 2 Operation eo Saag ce dE alee Saat A A Bi eae ee SO BO wae theta th EE Fer 2 12 5 3 Injector Return Back Pressure System 2 13 6 Control System Parts 6 1 Engin E CU se 2n go s ais arar ant rt alee A At E E 2 15 A EE 2 15 7 Fuel Injection Control 7 1 Injection Pattern iis tia NE eo YU ee DYN eed 2 19 7 2 Microinjection Quantity Correction Control
17. Poor A F sensor activation 1000 after heater activation less than or equal to 409 Difference between sensor out A F sensor terminal short put terminal voltages lt 0 1 V Deviation from atmospheric O2 Atmospheric learning abnormality concentration gt 36 5 P0134 P0154 Operation Section 2 36 DTC Fail Safe SAE Check Diagnosis Item Judgment Conditions Code Light Difference between maximum Abnormal fuel temperature sen Target Rail Pressure Limit EGR Valve Control Prohibition Intake Throttle Control Prohibition i stop Prohibition Output Limit P0181 and minimum fuel temperatures sor characteristics recorded in history lt 1 C Fuel temperature sensor low Sensor output voltage lt 0 118 V Fuel temperature sensor high Sensor output voltage gt 4 833 V Amount of change in sensor out Abnormal rail pressure sensor P0182 P0183 P0191 put voltage compared to previ ous value lt 0 00245 V Rail pressure sensor low Sensor output voltage lt 0 514 V Rail pressure sensor high Sensor output voltage gt 4 808 V Abnormal oil temperature sensor Difference with coolant tempera characteristics ture sensor gt 50 C Oil temperature sensor low Sensor output voltage lt 0 211 V characteristics P0192 P0193 P0196 P0197 P0198 ES Oil temperature sensor high Sensor output voltage gt 4 929 V a Open circuit downstream of cylin Injector 1 open circuit W
18. as to decrease combustion noise and vibration After injection is performed to re combust PM and CO and to activate the oxidation catalyst at an early stage Post injection is performed to raise the DPF temperature to the necessary value required to combust the PM accumulated within the DPF Near Top Dead Center TDC 4 Pre1 Pre2 Main After 1 After 2 Posti Post2 Post3 Post4 Post5 Pilot Injection Group Main Injection Group Post Injection Group Maximum of Three Injections Maximum of Five Injections Maximum of Five Injections bind Operation Section 2 20 7 2 Microinjection Quantity Correction Control Outline Under microinjection quantity correction control multiple injections are performed under stable idle condi tions The difference between the injection command value at the time of injection and the actual injection quantity standard injection quantity necessary to achieve equilibrium with the target idle rotational speed is learned by the system The learning results are then used to correct the actual injection quantity Goal To reduce injection quantity disparity and to suppress engine noise and smoke generation Control Outline amp Learning is automatically performed every 2 000 km with the engine in an idle state Rail pressure is raised in order from 35 MPa to 65 MPa and finally to 95 MPa with learning being performed at each of the three pressure levels Actual learning takes place under the fol
19. ck Pressure Valve Q006915E Operation Section 2 15 6 Control System Parts 6 1 Engine ECU The engine ECU regulates the fuel injection system and performs overall engine control 4 A ee DD 0000 000000 CEE Es 6 2 Sensors 1 Crankshaft Position Sensor NE Sensor and Cylinder Recognition Sensor G Sensor The crankshaft position sensor and cylinder recognition sensor used with the SKYACTIV D engine CRS are Magnetic Resistance Element MRE type devices OUT VCC Se Ya ono ET VOUT wee Crankshaft Position Sensor Cylinder Recognition Sensor NE Sensor G Sensor O006889E 2 16 Operation Section Crankshaft Position Sensor NE Sensor The crankshaft position sensor detects the crankshaft angle The pulsar has 56 teeth separated at 6 CA intervals with four missing teeth to detect Top Dead Center TDC for cylinders no 1 and no 4 lt Circuit Diagram gt Engine ECU Sensor Air Gap Direction of Rotation lt Pulse Chart Reference gt Engine Speed Pulse 720 CA Q006878E Cylinder Recognition Sensor G Sensor The cylinder recognition sensor identifies the engine cylinders The pulsar has five teeth recognition of TDC for each cylinder recognition of cylinder no 1 Pulsar lt Circuit Diagram gt Air Gap Pulse Chart Reference Engine ECU Sensor Direction of Rotation 360 CA 360 CA MRE Type e OV
20. d dur ing an open command DTC Diagnosis Item Check Light Regulator valve lift feedback diagnosis Temperature upstream of DPF Abnormal temperature character DPF PM accumulation abnormal DPF PM accumulation abnormal P242C P242D P242F DPF PM accumulation abnormal ity 5 Differential pressure sensor upstream piping abnormality P244A Differential pressure sensor upstream piping abnormality Differential pressure sensor off set abnormality Differential pressure sensor gain P2452 P2453 abnormality Differential pressure sensors P2454 upstream downstream of DPF low sensors of DPF Differential pressure upstream downstream high u D D Differential pressure sensor inter mediate abnormality Operation Section 2 47 Fail Safe Judgment Conditions Target Rail Pressure Limit Output Limit Difference between the target regulating valve position and the actual regulating valve position is 10 mm or more continuously for three seconds Sensor output voltage lt 0 107 Sensor output voltage gt 4 960 PM volume gt 17 g L PM volume gt 17 g L PM volume gt 100 g L Differential pressure lt 0 2 kPa Differential pressure lt 0 2 kPa Differential pressure lt 5 kPa 5 kPa lt differential pressure Differential pressure gt threshold level ex 100 kPa exhaust gas flow rate 10 m min Sensor output voltage lt 0 217 V Sensor output volta
21. ectors Mechanical Configuration Non DENSO Products DPF Oxidation catalyst Differential Pressure Sensor A F Sensor IIIT AAD IRA LAN DPF Catalyst AGS Exhaust Gas Temperature Sensor Oxidation Catalyst Inlet Exhaust Gas Temperature Sensor No 2 Diesel Particulate Filter DPF Catalyst Inlet Q006881E Operation Section 2 31 2 Sensors Exhaust Gas Temperature Sensors Exhaust gas temperature sensors are installed before and after the oxidation catalyst to detect the ex haust gas temperature across the DPF Temperature increase control signals are sent by the sensors to the engine ECU for use in NOx reduction and PM regeneration The exhaust gas temperature sensor is a thermistor element in which the resistance value changes according to temperature variations Resistance Value Specifications 13 20 Q006882E 3 Operation Outline Fuel injection patterns are optimized by using the common rail type fuel injection system so that after injection increases the exhaust gas temperature to approximately 250 C even from low exhaust gas tem peratures Post injection adds HC to the catalyst to further increase the DPF temperature to 650 C or the PM self combustion temperature thereby enabling the PM trapped in the DPF to be regenerated in a short time period After Injection Post Injection Q006893E Operation Section 2 32 10 Diagnostic Trouble Codes DTC 10 1 DTC Lis
22. ed to the SV1 type due to a smaller solenoid Improved valve sliding performance lt External View gt Plunger Valve Body Valve Spring Solenoid Needle Valve lt Cross Sectional Diagram gt O006786E Needle Valve Ne lt Short Duty ON Duration gt Large Valve Opening Large Suction Quantity Large Valve Cylinder Opening Operation Concept Diagram a Te LL Long Duty ON Duration gt Small Valve Opening gt Small Suction Quantity Small Valve Cylinder Opening Q006787E Operation Section 2 10 4 Rail 4 1 Outline O The rail used with the SKYACTIV D engine CRS is compliant with pressures up to 200 MPa The rail uses a new model pressure relief valve Rail Pressure Sensor Pressure Relief Valve Q006873E 1 Pressure Relief Valve The pressure relief valve controls rail fuel pressure If rail pressure reaches or exceeds a specified value a solenoid coil is energized to open a path in the valve and return fuel to the fuel tank thereby reducing pressure to the specified value Q004958E 2 Rail Pressure Sensor The rail pressure sensor is compliant with pressures up to 200 MPa Vout V 200 Rail Pressure MPa Q006906E Operation Section 2 11 5 Injectors 5 1 Outline e The G3P type piezo injectors equipped with the SKYACTIV D engine CRS can inject fuel at extremely high pressure 200 MPa As a result the atomizatio
23. erence between MAP sensor Abnormal MAP sensor compres intake manifold pressure sen P0236 am FR sor outlet characteristics sor built into ECU exhaust gas pressure sensor gt 50 kPa MAP sensor Sensor output voltage lt 0 127 V compressor outlet low MAP sensor Sensor output voltage gt 4 092 V compressor outlet high The difference between the tar P0237 P0238 get manifold pressure and actual P0299 Insufficient supercharging com manifold pressure in the compact pact turbocharger region turbocharger range exceeds the specified value continuously for seven seconds Operation Section 2 38 Check Light u nn u e Code le S S S P0313 RDP control status 2 Remaining fuel quantity lt 4 L lol lo P0336 Crankshaft position sensor NE pulse count between missing pulse count abnormality teeth does not equal 56 Diagnosis Item Excessive supercharging heavy duty turbocharger region Insufficient supercharging heavy duty turbocharger region Injector function non injection 1 Injector function non injection 2 Injector function non injection 3 Injector function non injection 4 Judgment Conditions The difference between the tar get manifold pressure and actual manifold pressure in the heavy duty turbocharger range is below the specified value continuously for seven seconds The difference between the tar get manifold pressure and actual manifold
24. eutral switch diagnosis i ji clutch switch inputs ator above a constant vehicle speed value IR run failure ISS_IRFAIL POAOF i i stop restart fault i stop When the battery voltage ECU control voltage or DC DC con POA8D Decreased battery voltage verter control voltage is low at engine start up E Abnormality received in commu DC DC malfunction POA94 nications from the DC DC con DCDC_FAIL1 verter ji When the water level switch with P1140 Water level switch diagnosis fuel filter is ON P115A RDP control status 1 Remaining fuel quantity lt 5 L P115B RDP control status 3 Remaining fuel quantity lt 3 9 L lol lol Main relay stuck high P1196 Main relay abnormality during main relay OFF command P1200 Learning incomplete failure to Incomplete injector microinjection finish learning Q learning P1260 Immobilizer abnormality Immobilizer verification failure 142 Actual rail pressure gt threshold P1282 Pump protective fail plug level ex 123 MPa 750 rpm EE Failure to learn EGR valve fully P1303 EGR valve initialize abnormality u closed position Actual rail pressure gt threshold P1329 Pump replacement fail flag level ex 200 MPa 750 rpm Wastegate valve is open when P132E Wastegate valve function diagno there is a wastegate valve close i command in the compact turbo charger region Operation Section Check Diagnosis Item Judgment Conditions Code Light Cyl
25. fail abnormality ure Data flash VID checksum abnormality checksum abnormality Engine start up speed exceeds the guaranteed performance speed for the starter or starter i stop Prohibition P0607 P0610 P0615 Starter malfunction ISS_STA relay SCV B short Diagnosis signal fixed at high SCV actuation system abnormal _ a it Diagnosis signal fixed at low ity Communication abnormal PO62A Injector actuation circuit D3P P062B between injector actuation IC and ECU P0642 EN Sensor voltage 1 low Sensor output voltage gt 3 894 V communication abnormality P0643 Sensor voltage 1 high Sensor output voltage gt 4 115 V A C magnetic clutch relay Actuation circuit voltage lt 0 35 V open circuit ground short battery voltage A C magnetic clutch relay ji SSC Actuation circuit current gt 1 5 A B short P0646 P0647 P0652 Sensor voltage 2 low Sensor output voltage gt 3 894 V Sensor voltage 2 high Sensor output voltage gt 4 115 V ECU internal temperature sen Sensor output voltage lt 0 100 V sor low ECU internal temperature sen A Sensor output voltage gt 4 900 V sor high Glow unit control Abnormality due to diagnosis sig circuit abnormality nal from glow unit No 1 cylinder glow plug circuit Abnormality due to diagnosis sig abnormality nal from glow unit P0653 P0668 P0669 P0670 P0671 Operation Section 2 43 Fail Safe SAE Check Diagnosis Item
26. ge gt 4 843 V Difference between differential pressure maximum and minimum lt 0 1 kPa DPF PM accumulation abnormal P2458 ty 4 PM volume gt 10 g L ity EGR Valve Control Prohibition Intake Throttle Control Prohibition i stop Prohibition Operation Section 2 48 DTC Fail Safe SAE Check Diagnosis Item Judgment Conditions Code Light EGR valve cooler side l DC motor actuation current gt 8 A DC motor status abnormality i stop Prohibition P245A EGR DC motor temperature DC motor actuation current gt 8 A abnormality EGR bypass valve ECU side Energization duty continuously gt high duty abnormality diagnosis 95 P245B DPF PM accumulation abnormal ity 2 PM volume gt 13 g L ity Oil dilution quantity calculated oe ote ae from injection quantity gt thresh Oil dilution 6 i old level Ex 16 751 g intake air temperature 207C EGR lift sensor 2 low Sensor output voltage lt 0 168 V P246C EGR lift sensor 2 high Sensor output voltage gt 4 870 V Energization duty continuously gt EGR feedback abnormality 69 o P24A5 EGR valve position sensor output EGR bypass valve stuck open value is not at fully closed during a fully closed command When the alternator generated B terminal open circuit warning voltage is at least 17 V and the ALC BODEN battery voltage is 11 V or less continuously for five seconds Alternator generated current is between 8 to 5 V or less contin
27. idation cata Sensor output voltage gt 4 960 V lyst DC motor overcurrent abnormal P2101 it DC motor actuation current gt 8 A ty ji ji Engine rotational speed gt 1 000 P2105 Overrun diagnosis rpm when the key is OFF Operation Section 2 46 Fail Safe Check Diagnosis Item Judgment Conditions Code Light mmm O ES mm e energization duty abnormality 90 Open circuit upstream of cylin P2146 COM1 open circuit ders no 1 4 injector circuit Ground short upstream of cylin P2147 COM1 ground short ders no 1 4 injector circuit B short upstream of cylinders P2148 COM1 B short no 1 4 injector circuit i stop Prohibition Open circuit upstream of cylin P2149 COM 2 open circuit ders no 2 3 injector circuit Ground short upstream of cylin P2150 COM 2 ground short ders no 2 3 injector circuit B short upstream of cylinders P2151 COM 2 B short no 2 3 injector circuit Difference between MAP sensor Abnormal atmospheric pressure intake manifold MAP sensor P2227 sensor built into the engine compressor outlet and exhaust ECU characteristics gas pressure sensor gt 50 kPa Atmospheric pressure sensor P2228 eg Sensor output voltage lt 1 151 V built into ECU low Atmospheric pressure sensor P2229 Se f Sensor output voltage gt 4 656 V built into ECU high Turbocharger compressor p2261 Compressor bypass valve bypass valve is open during a function diagnosis close command or close
28. inder recognition sensor recognition sensor installation phase disparity abnor NE G phase deviation gt 4 56 CA 2 45 Fail Safe Target Rail Pressure Limit EGR Valve Control Prohibition Intake Throttle Control Prohibition i stop Prohibition Output Limit P1336 mality Low injector actuation circuit Injector low charge charge voltage High injector actuation circuit P1379 Injector overcharge charge voltage P1378 P1589 Intake throttle valve es opening actual opening gt sticking abnormality QR data write failure abnormality No injector QR correction data P1675 Injector QR correction data QR data abnormality checksum abnormality P1676 QR correction information input Injector QR correction data AA LEO Een e fo to start cannot be executed Clutch stroke sensor low stroke sensor low Sensor output voltage lt 0 202 V output Sensor output voltage lt 0 202 V lt 0 202 V 1 lo UT stroke sensor high Sensor output voltage gt 4 852 V CJ UNS Inconsistency between the clutch Clutch malfunction ISS CLAB switch clutch cut switch clutch stroke sensor P1905 Test terminal short Test terminal ON bb ji Pressure difference across the Differential pressure type DPF ji P2002 DPF is less than the specified diagnosis value Upstream oxidation catalyst tem P2032 Sensor output voltage lt 0 107 V perature low Abnormal temperature character P2033 istics upstream of ox
29. l regions from rich to lean based on the oxygen concentration in the vehicle exhaust gas and the concentration of unburned fuel The air fuel ratio is fed back to the engine ECU to control combustion in a state optimized to the driving conditions Sep Sensor Heater a a Sensor Heater Q006880E 5 ETB Diesel Air Control Valve The ETB operates a DC throttle motor to change the throttle position in accordance with signals from the ECU that correspond to the accelerator position Additionally the ETB is interlocked with the key switch to block intake air when stopping the engine to reduce engine vibration lt Circuit Diagram gt Output Characteristics Output Voltage V Throttle Position Sensor Section Throttle Valve Position 44 14 Operation Section 2 19 7 Fuel Injection Control 7 1 Injection Pattern The fuel injection system allows a maximum of nine separate injections a limit exists for each injection group to be set However injection settings are performed with a guard placed on the number of injections to prevent exceeding the following 1 the charging capacity of the DC DC converter for the piezo injector actuation circuit and 2 the maximum actuation frequency limit due to ECU heat generation Pilot and pre injections are performed in accordance with engine load conditions and the environment to shorten the main injection ignition lag to suppress NOx generation as well
30. lation e e gt j Injection Duration Calculation Injection Duration Correction Quantity Calculation Injection Post Correction Injection Duration Pressure Pulsations in the High Pressure Fuel Path Injection Quantity Injection Quantity Correction Quantity Fluctuations Injection Interval Q006894E Operation Section 2 26 7 5 Exhaust Gas Recirculation EGR Control Outline EGR control decreases the NOx generated in large quantities at high temperatures by recirculating the ex haust gas through the combustion chamber and lowering the combustion temperature Furthermore the EGR cooler path contains an EGR valve with a DC motor to perform control that is opti mized to the engine state The EGR valve has an angle sensor that detects the valve position and outputs corresponding signals to the ECU The ECU sends current through the DC motor so that the valve opens to the appropriate angle External View Figure lt Sensor Terminals gt VIA E2 VC lt Motor Terminals gt Operational Outline Figure EGR Valve Position Sensor Coolant Temperature Fuel Injection Quantity Rotational Speed Vehicle Speed e EGR Valve Valve Opening Q006904E 7 6 i stop Control Outline Operation Section 2 27 amp i stop control is a system that automatically stops and starts the engine when the vehicle is not moving to improve fuel economy reduce exhaust gas and decrease idling noise i stop Operating Conditi
31. le valve P2621 Sensor output voltage lt 0 113 V position sensor low Intake throttle valve P2622 Sensor output voltage gt 4 812 V position sensor high U0073 CAN 1 communication bus off When the HS CAN public bus is abnormality off U0074 CAN 2 communication bus off When the HS CAN private bus abnormality is off CAN 1 communication no TCM When the CAN public message dM reception abnormality is not received from TCM CAN 2 communication no TCM When the CAN private mes reception abnormality sage is not received from TCM U0104 CAN 1 communication no PCS When the CAN message is not reception abnormality received from PCS Operation Section 2 50 DTC Fail Safe SAE Check Diagnosis Item Judgment Conditions Code Light U0121 CAN 1 communication no DSC When the CAN message is not reception abnormality received from DSC CAN 1 communication no EPAS When the CAN message is not reception abnormality received from EPAS CAN 1 communication no FBCM When the CAN message is not reception abnormality received from FBCM CAN 1 communication no RCM When the CAN message is not reception abnormality received from RCM i stop Prohibition U0131 U0140 U0151 U0155 CAN 1 communication no HEC When the CAN message is not reception abnormality received from HEC U0214 CAN 1 communication no SSU When the CAN message is not reception abnormality received from SSU U0235 CAN 1 communication no CVM When the CAN message is
32. lowing control flow Learning Condition Determinations Divided Injections Target Rotational Speed Actual Rotational Speed Increase to the Next Pressure Level Leaming Correction Quantity Calculation Command Injection Quantity Value Standard Injection Quantity Completion at all Pressure Levels Learning Correction Value Reflected in the Microinjection Quantity Q006895E Operation Section 2 21 Determinations for Learning Conditions e Learning is performed when the engine is in an idle state and all environmental conditions such as tem perature are satisfied The figure below shows the specific details for each learning determination lt Determination Content gt Stable Idle Determination Environmental Condition Determinations Engine rotational speed stability determination Water temperature within predefined range Rail pressure stability determination Fuel temperature within predefined range Suction temperature within predefined range Atmospheric pressure at predetermined value or higher Performing Multiple Injections e Learning is performed when the engine is in an idle state and all environmental conditions such as tem perature are satisfied The figure below shows the specific details for each setting F 4 mmY st lt Setting Content gt Necessary Injection Setting for number of injection levels divided injections Quantity for Idle Setting for injection quantity co
33. manifold MAP sensor Abnormal exhaust gas pressure aa compressor outlet and atmo sensor characteristics spheric pressure sensor built into ECU gt 50 kPa Exhaust pressure sensor low Sensor output voltage lt 0 117 V Exhaust pressure sensor high Sensor output voltage gt 4 858 V FANPWM1 malfunction Radiator fan 1 actuation duty FANPWM1 stuck in high low FANPWM2 malfunction Radiator fan 2 actuation duty FANPWM2 stuck in high low EGR valve cooler side Energization duty continuously gt energization duty abnormality 90 o detection Vehicle speed signal error mes CAN communication vehicle sage received from ABS DSC or speed malfunction CAN ID217 received from ABS DSC Oil pressure sensor low Sensor output voltage lt 0 135 V Oil pressure sensor high Sensor output voltage gt 4 809 V Engine oil pressure is less than Oil pressure zero abnormality 30 hPa A C compressor sensor low A C compressor sensor high Blow by heater relay open circuit ground short battery voltage Ca e Circuit voltage is low when there BBH circuit low abnormality is a relay ON command Operation Section 2 41 DTC SAE Check Diagnosis Item Judgment Conditions Code Light i stop Prohibition Blow by heater relay ji SEH Actuation circuit current gt 1 5 A B short ee Circuit voltage is high when there BBH circuit high abnormality is a relay OFF command Exhaust gas temperature sensor P054
34. mmand value Injection timing inverter setting Rail pressure setting Divided Injections i Four Divisions 1 1 1 1 mmY st Q006898E Learning Correction Quantity Calculation The learning correction quantity is calculated by detecting the difference between the injection command value setting for multiple injections and the actual injection quantity standard injection quantity neces sary to achieve equilibrium with the target idle rotational speed The figure below shows the processing for the aforementioned corrections Standard Injection Quantity Injection Quantity Command Value lt Processing Content gt Detection of the difference between the command injection quantity value and standard injection quantity e Learning correction quantity calculation Difference Between Command Injection Quantity Value and Standard Injection Quantity Leaming Correction Quantity Q006899E Operation Section 2 22 Reflection of the Learning Correction Quantity In this process the learning correction quantity is reflected in the command injection pulse width TO so that the actual injection quantity becomes the target injection quantity The figure below shows the pro cessing for the aforementioned corrections Map Value 7 Actual Injection Quantity lt Processing Content gt e Learning correction quantity reflected W Learning Correction Quantity in the injection pulse width TQ d P y
35. n of the fuel mist from the nozzle is improved leading to increased combustion efficiency and reduced exhaust gas quantity amp A piezo injector primarily consists of a piezo stack large diameter piston small diameter piston control valve and nozzle needle e The piezo stack is a laminated body consisting of alternating layers of a substance called PZT PbZrTiO3 and thin electrodes By applying voltage the characteristics of a piezo element are used to expand and shrink the stack via the inverse piezoelectric effect Small displacements of the piezo stack are expanded by transmitting actuation from the large diameter piston to the small diameter piston The small diameter piston moves the control valve to regulate the pressure inside the injector The nozzle needle is moved up and down via control valve pressure control QR Code Piezo Stack Large Diameter Piston Small Diameter Piston Control Valve i Nozzle Needle I Q006874E Operation Section 2 12 oO gt E o 5 O c 2 5 Actuation Pulse Width TQ Q006875E Correction Points Using QR Codes 5 2 Operation Non Injection When voltage is not applied to the piezo stack the pressure in the control chamber and at the bottom of the nozzle needle is at the same value as fuel in the rail The nozzle needle remains closed due to the difference in surface area exposed to pressure between the control chamber and bottom
36. n ratio 14 0 Transmission SKYACTIV Drive A next generation high efficiency automatic transmission that achieves a high torque trans mission ratio via lockup in all regions SKYACTIV MT A next generation manual transmission for FF TT ASES Body SKYACTIV Body A next generation lightweight body that achieves ms high rigidity combined with high collision safety Chassis SKYACTIV Chassis A next generation high performance lightweight chassis that creates an effective balance between handling and driving comfort 1 2 SKYACTIV D Features O SKYACTIV D takes the following measures to lower fuel consumption Use of a variable valve lift mechanism to improve ignition stability when the engine is cold Use of two stage supercharging control to generate high levels of supercharging efficiently As such low emissions performance low fuel consumption performance high torque and high response are attained Use of Exhaust Gas Recirculation EGR to clean exhaust gas and improve fuel economy Use of i stop to improve fuel economy as well as to lower the amount of exhaust gas and idling noise Low Compression Ratio Combustion performance is improved via a low compression ratio 14 0 Weight Reductions Aluminum alloy cylinder block Integrated exhaust manifold and cylinder head Weight Reductions and Reduced Mechanical Resistance Losses Optimized piston shape Lightweight crankshaft journals Operation Section
37. not reception abnormality received from CVM rc DC DC Converter information DC DC communication error o communication error from FBCM U0302 CAN communication CNTCS When there is a CAN message abnormality diagnosis TCM checksum abnormality from TCM E U0298 U0305 CAN communication NTCS When there is a CAN message abnormality diagnosis PCS checksum abnormality from PCS CAN communication CNTCS When there is a CAN message abnormality diagnosis ABS checksum abnormality from ABS DSC U0315 When there is a CAN message checksum abnormality from EPAS CAN communication CNTCS When there is a CAN message CAN communication CNTCS When there is a CAN message CAN communication NTCS When there is a CAN message ICA updatebit fail determination i Correct data cannot be received CAN communication CNTCS abnormality diagnosis EPAS U0320 U0323 U0336 U0338 U0433 Operation Section Check Diagnosis Item Judgment Conditions Code Light 2 51 Fail Safe Intake Throttle Control Prohibition i stop Prohibition Target Rail Pressure Limit EGR Valve Control Prohibition Output Limit BE not configured or correct U2300 GCC abnormality diagnosis data cannot be received from HEC Data flash three point check U3000 Immens ammeze i abnormality B10A2 History of fuel cut off control Fuel cut off command received operation during a collision from RCM Operation Section 2 52
38. on control to adjust the actuation pulse duration for each injection stage Adjustment due to Temperature Injector Characteristics Correction lt Processing Content gt Actuation Pulse Injector actuation pulse msec Standard pulse Adjustment due to temperature characteristics correction Standard Pulse Standard Pulse The standard pulse is the injector actuation pulse time calculated from the command injection quantity Injector Injection Quantity Q006903E Operation Section 2 25 7 4 Interval Dependence Correction Outline amp The interval dependence correction compensates for fluctuations in the post injection quantity due to pres sure pulsations that occur when an injector nozzle seats Control Outline O The interval dependence correction performs control by calculating the pre adjusted injection quantity cor rection based on the following 1 the length of the high pressure fuel path from the injector nozzle to the rail 2 the pressure pulsation transmission interval calculated from the fuel environmental conditions fuel tem perature and pressure and 3 injection conditions fuel pressure fuel injection quantity injection interval Pressure Pulsations lt Control Flow gt Before Injection Nozzle Seated Injection Quantity Interval Calculation G ge vn Mes Rail Command Value J m y y Nozzle vi Ti H Calculation LE Interval Correction Seating K Timing L y p Quantity Calcu
39. ons O stop operates under the conditions shown below Engine Stop Conditions Engine Stop Conditions Lo ED AA Restart Conditions Brake pedal depressed Shift position in the D or M range Accelerator pedal not depressed Vehicle speed within a predetermined range 0 km h Coolant temperature within a predetermined range 30 C 110 C A C set temperature at a value other than MAX or MIN Battery voltage at least 11 2 V Steering angle 65 or less left to right Altitude 1 500 m or less Brake pedal depressed Shift position in the N range Accelerator pedal not depressed Vehicle speed within a predetermined range 0 km h Coolant temperature within a predetermined range 30 C 110 C A C set temperature at a value other than MAX or MIN Battery voltage at least 11 2 V Steering angle 65 or less left to right Altitude 1 500 m or less When any When any of the following are detected the following are detected Foot released from the brake pedal Shift position in the P or N range Accelerator pedal depressed Accelerator pressed while in the D or M range Shift position changed P or N range D M or R range When A C set temperature is changed to MAX or MIN When any of the following are detected Clutch pedal depressed Accelerator pedal depressed When A C set temperature is changed to MAX or MIN Change in vehicle speed Operation Section 2 28 Im
40. ort 8 Mi Intake air temperature sensor P007C P0079 Abnormal intake air sensor char acteristics Intake air temperature sensor high P0080 EA Exhaust VVL valve B short nm 5 ii o P0093 o Fuel leak H Rail under pressure abnormality Rail over pressure abnormality Abnormal intake manifold tem perature sensor characteristics Intake air temperature sensor intake manifold low Operation Section 2 33 Fail Safe Judgment Conditions i stop Prohibition Sensor output voltage gt 4 886 V Actuation circuit voltage lt 0 35 V battery voltage Difference in temperature between the intake air tempera ture sensor with Mass Air Flow MAF meter and the intake air temperature sensor intake mani fold gt 50 C Sensor output voltage lt 0 041 V lolo Sensor output voltage gt 4 900 V cc Actuation circuit current gt 5 9 A lol lol Rail pressure divergence under shoot side S threshold level ex 30 MPa state continues Rail pressure divergence over shoot side S threshold level ex 30 MPa state continues for high pressure fuel consump tion every 90 CA gt threshold level ex 120 mm3 st Difference in temperature between the intake air temperature sensor with Mass Air Flow MAF meter and the intake air temperature sen sor downstream of I C gt 50 C Sensor output voltage lt 0 044 V oo Operation Section 2 34 Check Code Light 5 o u D
41. pressure in the heavy duty turbocharger range exceeds the specified value continuously for seven seconds Difference in rotational fluctua tions between cylinders gt 0 212 msec MT vehicles target rota tional speed 750 rpm coolant temperature 80 C Difference in rotational fluctua tions between cylinders gt 0 212 msec MT vehicles target rota tional speed 750 rpm coolant temperature 80 C Difference in rotational fluctua tions between cylinders gt 0 212 msec MT vehicles target rota tional speed 750 rpm coolant temperature 80 C Difference in rotational fluctua tions between cylinders gt 0 212 msec MT vehicles target rota tional speed 750 rpm coolant temperature 80 C Target Rail Pressure Limit Fail Safe Output Limit EGR Valve Control Prohibition Intake Throttle Control Prohibition i stop Prohibition Operation Section 2 39 Fail Safe Check Diagnosis Item Judgment Conditions Code Light l Crankshaft position sensor position sensor P0337 No NE pulse input pulse input failure Deviation between recorded Crankshaft position sensor crankshaft position during an reverse pulse output failure engine stall and crankshaft posi abnormality tion during restart cylinder recog P0339 S nition gt 6 CA Crankshaft position sensor ji Reverse rotation pulse input dur forward reverse pulse inversion ing forward rotation abnormality P0341 Cylinder recognition sen
42. proved Engine Restarts When Under i stop Control Smooth startability is required when restarting the engine with i stop control Therefore the crankshaft po sition sensor identifies the cylinder prior to top dead center of compression so that injection to that cylinder can be pinpointed Control Diagram Starter Operation Combustion Engine Start FES Fuel Injection Starter Starter Q006916E Operation Section 2 29 8 Other Controls 8 1 Jet Pump 4WD Only Outline When the fuel tank main side level is low the jet pump feeds fuel from the sub tank side to the main side so that the fuel level inside the tank is always stable Return Fuel e to Engine to Fuel Tank i Transfer Pipe l Sub Side Ki _ Min Side AN NT Jet Pump to Transfer 1 Pipe lt Extemal View Diagram gt lt Cross Sectional Diagram gt Q006905E Operation Section 2 30 9 Exhaust Gas Treatment System 9 1 Diesel Particulate Filter DPF System The DPF system efficiently traps and purifies Particulate Matter PM CO and HC contained in diesel en gine exhaust gas The DPF system comes with PM forced regeneration control that allows exhaust gas to be purified according to driving conditions 1 System Configuration Electronic Control Configuration Sensors Exhaust gas temperature sensor differential pressure sensor non DENSO products ECU Engine ECU Actuators Inj
43. rimary CRS Parts The primary parts for the SKYACTIV D CRS are mounted as shown in the figure below Injectors Lower Case Built into the Injector Return System Supply Pump to Fuel Tank from Fuel Filter Injector Pipes Fuel Temperature Sensor Injector Side Pressure Relief Valve Suction Control Valve Q006912E Operation Section 2 7 3 CRS Configuration The functional parts of the SKYACTIV D CRS are shown in the figure below Supply Pump HP3 Rail Pressure Sensor H Pressure Relief Valve nal Q006890E SKYACTIV D 4 Fuel Flow Fuel flows through the CRS as shown below Injectors Suction Feed Return Fuel Tank Q006907E Conventional Type Operation Section 3 Supply Pump 3 1 Outline The supply pump used with the SKYACTIV D engine CRS HP3 complies with pressures up to 200 MPa In addition a port has been established to feed fuel to the injector return system used with the CRS The fuel temperature sensor is separate from the pump and is now set in the path between the supply pump and the fuel return Fuel Outlet Feed Fuel Outlet to Injector Return Back Pressure System Fuel Inlet Q006837E 3 2 Suction Control Valve SCV O The SCV used with the SKYACTIV D engine CRS is a normally open SV3 type The SV3 type has the fol lowing features Operation Section 2 9 A more compact design compar
44. sor pulse G pulse count between extra count abnormality teeth does not equal five i stop Prohibition Cylinder recognition sensor pulse P0342 f No G pulse input count input failure Actuation signal between ECU ji oo Actuation circuit voltage lt 0 35 V P0383 and glow unit battery voltage open circuit ground short Actuation signal between ECU P0384 and glow unit Actuation circuit current gt 5 9 A B short EGR flow volume at or below a P0401 Low Exhaust Gas Recirculation constant value in relation to the EGR flow volume abnormality target value continuously for eight seconds EGR flow volume at or above a P0402 High EGR flow volume abnormal constant value in relation to the ity target value continuously for eight seconds P0404 Eon EGR DC motor abnormality DC motor actuation current gt 8A Jo lo P0405 EM EGR lift sensor low Sensor output voltage lt 0 241 V o lo P0406 con EGR lift sensor high Sensor output voltage gt 4 856 V lolololo Operation Section 2 40 Fail Safe Diagnosis Item Judgment Conditions Target Rail Pressure Limit EGR Valve Control Prohibition Intake Throttle Control Prohibition i stop Prohibition Output Limit Difference in exhaust gas tem perature before and after passing ji the oxidation catalyst is at or Oxidation catalyst diagnosis u below the specified value contin uously for between 60 and 80 seconds Difference between MAP sensor intake
45. t Check Diagnosis Item Judgment Conditions Code Light IT Crank cam pulse input Fail Safe Intake Throttle Control Prohibition i stop Prohibition Output Limit EGR Valve Control Prohibition Target Rail Pressure Limit relative position abnormality P0016 Speed G phase gap malfunction Crank cam error correction quan tity gt 15 CA A F sensor heater abnormality Actuation circuit voltage high gt 0 25 V battery voltage A F sensor heater abnormality Actuation circuit voltage lt 0 25 V battery voltage Two stage turbocharger ji oo Actuation circuit voltage P0034 compressor bypass valve lt 0 35 V battery voltage open circuit ground short P0030 Two stage turbocharger P0035 compressor bypass valve Actuation circuit current gt 5 9 A B short Two stage turbocharger ji WA Actuation circuit voltage P0047 lt 0 35 V battery voltage regulator valve open circuit ground short Two stage turbocharger regulator valve Actuation circuit current gt 5 9 A B short Two stage turbocharger ji oo Actuation circuit voltage P004C wastegate valve lt 0 35 V battery voltage ground short Two stage turbocharger P004D wastegate valve Actuation circuit current gt 3 5 A B short A C ambient temperature sensor P0072 Sensor output voltage lt 0 182 V ow P0048 SAE Code Check Light Diagnosis Item P0073 TAC ambient temperature sensor high Exhaust VVL valve ground sh
46. ting Fuel Temperature Inside the Injector Injectors are heavily influenced by the engine temperature roughly equivalent to engine coolant temper ature Additionally combustion heat and heat generated by injector leak also act as influencing factors lt Processing Content gt Fuel temperature inside the injector C Engine coolant temperature Influence of combustion heat Heat Generated Influence of heat generated from leak by Injector Leak 1 1 GE Heat Q006901E 2 Calculating the Difference in Injection Quantities To calculate the difference in injection quantities first the actual injection quantity is estimated from the following 1 the fuel temperature estimated in step 1 and 2 the injection conditions rail pressure com mand injection quantity from the pre adjusted injection quantity fluctuation characteristics map Finally the actual quantity is used to calculate the difference with the command quantity Inject tity Dispari lt Processing Content gt eae DEREN Command Injection Injection quantity disparity mm3 Command injection quantity Estimated injection quantity Estimated Injection Quantity Injection Quantity Characteristics mm3 Estimated Temperature Fuel Temperature inside Injector C Q006902E Operation Section 2 24 3 Calculating the Difference in Injection Quantities The calculated difference in injection quantities is passed along to injector actuati
47. u Alternator malfunction ously for five seconds regardless ALC ALTTF of whether or not the alternator target power generation current is 20 A or more Alternator generated voltage is at Excessive voltage warning least 18 5 V or battery voltage is ALC_OVCHG 16 V or more continuously for five seconds Operation Section 2 49 Fail Safe Check Diagnosis Item Judgment Conditions Code Light I Back up memory up memory Back up power supply voltage lt P2507 power supply malfunction deter 1 4 battery voltage mination PBATTF Oil dilution quantity calculated P252F Oil dilution EE from injection quantity gt 1 161 g Oil dilution quantity calculated Oil dilution 2 O from injection quantity gt 2 236 y Oil dilution quantity calculated from injection quantity gt thresh Oil dilution 5 i P253F old level ex 16 751 g intake air temperature 20 C Target Rail Pressure Limit EGR Valve Control Prohibition Intake Throttle Control Prohibition i stop Prohibition Output Limit Engine oil pressure has dropped Oil dilution 50 kPa or more compared to when the oil was changed VNT lift sensor low P2564 Sensor output voltage lt 0 214 V two stage turbocharger VNT lift sensor high P2565 Sensor output voltage gt 4 786 V two stage turbocharger P2610 EN Soak timer abnormality diagnosis HEC internal failure detection failure detection HEC internal failure detection O Intake thrott
48. ure Ambient Temperature pajn Sensor Sensor MIDDLE Exhaust Gas Temperature Sensor UPPER A C Compressor Sensor EHEM NEF Vum Pressure Sensor Clutch Stroke Sensor Rail Pressure Sensor Master Vacuum Cylinder Pressure Sensor DC DC Converter Brake Switch 2 Kick Open gt y MT only Water Level Switch Stop only LC D Q006920E a E 850 THRCBL Intake Air Temperature Sensor 2 B24 JE THRCOL Kaa Coolant Temperature Sensor ma Maa lo ST Nom Glow 1 Glow Unit E mur Variable Valve Lift WL Solenoid een ASS Compressor Solenoid Omp r Solenoi BEE m Regulator Valve 1 ga SCD NE WF CT CIE A F Sensor ek Operation Section 2 57 AN ID um SE Fuel Temperature 4 Sensor Ca GOSS m SCV IM P Rn Roe Vale BRAUN MAP Senso ze b4 Ge ompressors san asi RE GE nano Oil Pressure Sensor Q VEE PAIL TAL MH Im Ju Cylinder C ei Recognition Sensor Crankshaft Position Sensor Regulator Valve Position Sensor Exhaust Gas Pressure Sensor Exhaust Gas Temperature Sensor Q006921E Operation Section 2 58 11 2 Connector Diagrams 1 AT i EEN DA SEN ve paf fa o ar js m un VAC stop only AT only r Be DD N AU AY A DD 1444 41 444 4 4 144444 nn uu m0 OODDIDDZDY A a e al lalala nl Jm A A APRA AAA BEI ZZGL Oe DE MBA VA 220110 fm
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