CH3 Engine Troubleshooting
CH3 Engine Troubleshooting
CH3 Engine Troubleshooting
<DI ENGINE>
PLATE
Photo
Before
Installation
Step 1
1st plate
Install the drive plate Install the 1st plate to crankshaft
Step 2
Step 3 -
2nd plate
♠ SYMPTOMS
- Engine stop at low speed driving, Check engine lamp ON
(P0183 Fuel Temp. Sensor – Short to B+ and many other DTC related
fuel pressure)
- Normally, vehicle has long mileage (30K km ▲)
♠ CHECK PROCEDURE
- If it happens intermittently, fuel temp. will be abnormal
when the problem happens
(Fuel temp. at normal condition : 20 ℃ ~ 60℃)
- Check fuel temp. value on freeze frame of DTC
- If DTC is set as a current code, check the fuel temp. value on
ECU data list
♠ TROUBLESHOOTING
- Spray anti-fretting grease
- Replace engine main wiring if necessary
TROUBLESHOOTING FOR ACCEL. PEDAL MODULE
■ ISI-07EN011
♠ CASE 1
; issued Aug. 2007
SYMPTOMS
- Suddenly accel. pedal doesn't response at driving
- Engine check lamp ON (DTC in ECU : P1124 - Accel. Pedal Sensor Malfunction)
- Accel. pedal works normally after 2 ~ 3 accel pedal operations (Fail Safe Mode)
FIELD ACTION
- Check driving habit (someone drive A/T using both feet)
- Check brake switch contact stroke and replace it if necessary
- Check short-circuit of parking & brake lamp bulb
(check bulb double filament)
- Check lamp tuning (LED brake lamp)
▶ In this case, don't replace accel. pedal module
Replace brake switch if necessary
TROUBLESHOOTING FOR ACCEL. PEDAL MODULE
♠ CASE 2
SYMPTOMS
- Accel. pedal doesn't response, engine is pegged at 1,200 RPM (LHM mode)
- Engine check lamp ON
DTC in ECU (P1123 - Accel. Pedal Sensor Malfunction,
P1120 - Accel. Pedal Sensor#1 Malfunction)
FIELD ACTION
- Check the poor connection of Accel. Pedal Module
; Please be sure to check this point if the vehicle is new one
▶ This DTC codes happen if the difference of Accel. Pedal Sensor
#1 & #2 signal is more than 15%
Check the signal value of Accel. Pedal Sensor #1 and #2
with SCAN-100 after checking wiring and connector of
Accel. Pedal Module
TROUBLESHOOTING FOR ACCEL. PEDAL MODULE
♠ CASE 3
SYMPTOMS
- Suddenly accel. pedal doesn't response and vehicle speed and torque drop
- No DTC in ECU, TCU and ABS
- Vehicle poor start-off performance
FIELD ACTION
▶ In this case, please inform us by FTR or E-mail before replacing
accel. Pedal module or other parts
ENGINE POOR STARTING AT HOT CONDITION
♠ SYMPTOMS
Engine poor starting after engine warm-up (No DTC in ECU)
Cranking but engine no starting
♠ FIELD ACTION
ECU REPROGRAMMING
- ACTYON SPORTS / EURO III D20DT : HCD38A03
- KYRON EURO III D20DT : HCD38A06
FIELD CASE – ENGINE ABNORMAL NOISE
♠ SYMPTOMS
Engine tapping noise at idle or accelerating
♠ FIELD ACTION
Replace chain tensioner (Tightening Torque : 65Nm)
♠ REMARK
Engine abnormal noise can be happened
by deformation of chain tension inner piston Check
due to chain tensioner damages
Check the damage of guide rail
Check the sliding rail additionally if engin
e noise comes again after replacing chain
tensioner
FIELD CASE – CLOGGED INJECTOR NOZZLE
♠ SYMPTOMS
Engine poor starting performance
No engine vibration, hesitation, noise and No DTC in ECU
♠ POSSIBLE CAUSE : Partly clogged injector nozzle
Injector Nozzle
(5~7EA)
♠ RECOMMENDATION
Hard to diagnose clogged injector nozzle ; can’t detect through injector back leak test
Replace all injector in case of water entering to cylinder inside or in case of vehicle rollover
; if the engine was submerged by water, replace vacuum modulator together
QUALITY PROBLEM OF HP PUMP PLV O-RING
♠ SYMPTOMS
: Intermittent engine stop (at vehicle stop condition)
: Pressure leak by damaged PLV O-Ring
Poor engine starting or no rail pressure at cranking – clogged flange by damaged O-Ring particle
Clogged flange
Damaged O-Ring
TROUBLESHOOTING FOR #3 FUEL PIPE CRACK
■ ISI-07EN010
♠ REWORK PROCEDURE
; issued Jul. 2007
- Disconnect the vacuum hose passing engine front and cut about 40 cm on turbo charger side
- Fix the vacuum hose to injector pipe using pipe holder (2 points)
- Remove the vacuum hose mounting bracket on intake manifold
Remove the
bracket
Holder (2 pieces)
P/No. : 6650733010
NOTICE
■ The rework should be done in case of engine cover related job is made or
complaint of pipe vibration of Injector #2 or #3 pipe
RUBBER DAMPER OF HP PIPE BRACKET REPLACEMENT
♠ PROCEDURE
1. Remove the broken HP Pipe (C2P Pipe)
2. Loosen the Common Rail bracket bolts (3EA)
3. HP pipe fitted, with its nut screwed by hand Rail to Injector HP
4. Tighten the Common Rail bracket bolts Pipe
Tightening Torque : 25 Nm
5. Tighten the HP Pipe to HP Pump
C/Rail to Pump
Tightening Torque : 40 Nm (C2R) HP Pipe
2nd Step
- Spray anti anti fretting corrosion oil to the pin of injector connector and wiring terminal
- As a preventive action, spray this oil to all other injector connectors and wiring terminals
- Change the rubber damper of HP Pipe bracket at the same time
- Idle the engine about 5 minutes
TROUBLESHOOTING FOR INJECTOR HIGH RESISTANCE
♠ RECOMMENDATION
- In case of problem again, replace engine wiring or exchange the injector with
other good one
♠ SYMPTOMS
Engine starting problem in the field at around 600 - 650m altitude and
associated with immobilizer-ECU communication on EURO IV models
♠ FIELD
ACTYON ACTION
SUT D20DT : REFER
664 540 4432 NCA33A02
TO RELATED NCA35A01 ISB-2007002
S/BULLETIN 012727 NCA36A04
EURO IV IMMOBILIZER ISSUE AT HIGH ALTITUDE
NOTICE
- Do SCAN-100 update for EURO IV model and then input needed R-Card file
; check the release data (after Dec. 11, 2006)
- Take care not to disconnect SCAN-100 connector during ECU reprogramming
- Perform the Immo. Key coding for all key
- Input EURO IV R-Card file to correct position
; you should choose 0] D27DT/D20DT (C3I) ECU
on SCAN-100 menu
- Do not MISUSE of ECU data of
REXTON II D27DT and D27DTP
- When ECU has variant coding error with DTC P1170 in HECU
; Sometimes ECU has problem after updating the ECU
a. Check the variant coding on ECU and adapted if necessary
b. HECU variant coding clear
c. Clear all DTCs in every control units
d. Ignition OFF (wait more than 10 seconds)
e. Clear again all DTCs in every control units
f. Ignition ON
g. Ignition OFF
→ if there is no result, repeat above action 2-3 times
FIELD CASE - INJECTOR NOISE
■ MODEL : REXTON II (D27DTP ENGINE)
♠ SYMPTOMS
Abnormal noise at accelerating over 2,000 RPM (with black smoke)
It just happens at driving condition after fully warm-up, no problem at idling
No DTC in ECU
; Intermittently ECU set Rail Pressure Control (High or Low) Error
♠ FIELD ACTION
When same symptom happens again after engine warm-up, perform
Injector Dynamic Test : Too much back leak from problematic Injector
Movie Clip
Clattering Noise
“Karararar ~ Black
Smok
e
♠ APPLICATION
Vacuum Modulator (D20DT Engine)
- DI Engine EGR Valve Control
- Turbo Charger (VGT, WGT)
- Huber EGR
- Throttle Body (Euro IV Engine)
♠ CHARACTERISTIC
- Plunger Operation Frequency : 300 ㎐
- Plunger Operation Amplitude : about 1mm
- Max. Vacuum Consumption : 35L / hr
- Automatic Temp. Compensation
OPERATION PRINCIPLE – VACUUM MODULATOR
♠ INTERNAL COMPONENT
Vacuum
Input
Screen Filter
(internal) Vacuum
Output
Filter
(external)
OPERATION PRINCIPLE – VACUUM MODULATOR
♠ FIELD CASE
CASE 1 – Poor starting performance caused by clogged filter of V/Modulator
; Slow response at quick accelerating between 50~80 km/h (Feeling a tug from back side)
; At quick acceleration mode, EGR should be closed immediately but clogged filter could be
a reason of slow response
CASE 2 – DTC “Booster Pressure Sensor Open” set caused by clogged filter
; Waste gate of turbo charge should be opened quickly when high speed is required
but clogged filter delays vacuum release
(If the booster pressure is more than threshold value, ECU recognize sensor is opened)
CASE 3 – Abnormal noised caused by water entering into V/Modulator
; Unbalanced lubrication inside V/Modulator could be a reason of abnormal noise
CASE 4 – Huber EGR Valve broken
; Continuously vacuum entering due to plunger stuck or valve slow response due to
clogged filter
NOTICE
- At engine room cleaning, engine should be OFF and dry the water of filter
- There is high risky on submerged vehicle / high mileage vehicle / running
off-road vehicle
OPERATION PRINCIPLE – VACUUM MODULATOR
■ How to check clogged filter of Vacuum Modulator
Joint with
T-connector
Vacuum Gauge
EGR
V/Modulator Movie Clip
- Check the EGR Valve open at idling (EGR is opened during first 50 second after idle start)
- At “P” condtion, press accel. pedal quickly and check the gauge dropping speed.
(Slow reaction in case of clogged filter / see the movie clip)
- Compare this drop speed with normal good working vehicle
; check the T/Charger V/Modulator same way
EURO IV ENGINE MDP LEARNING MODE
If the Initial MDP learning is not done successfully, engine makea small vibration
at the engine is cold
TROUBLESHOOTING FOR TURBO CHARGER NOISE
2) Operation Principle
Engine Status Modulator Duty (%) Vane Control Actuator Vane Passage
Low load & low rpm 75% Pulling Narrow
(Duty Increases) (Vacuum Applies)
High load & high rpm 45% Return Wide
(Duty Decrease) (Vacuum Release)
FIELD CASE – TURBO CHARGER NOISE
♠ SYMPTOMS
Whistle noise (Beep sound) from engine front side at accelerating at the vehicle
speed of 40~50 Km/h (between 1,000 ~ 2,000 RPM) like turbo charger noise
Noise can be heard at engine stall test (around 1,800rpm)
Noise is severe at cold engine that hot engine
Normal (no noise) at engine idling
Noise is gone when fan belt is removed
♠ FIELD ACTION
Noise comes from idle pulley bearing
♠ FIELD ACTION
NOTICE
When air clear housing bolts are over tightened
beyond specification, it could damage the nut of
housing lower part and air leakage
In case of mis-installation or installation of wrong part
(ex, Rodius air clear element) ; housing will be get
loose due to thickness difference
FIELD CASE – TURBO CHARGER NOISE
Carbon deposit
25 Nm
Residue of
40 Nm
gas leakage
♠ FIELD ACTION
Retightened #5 Ex. Manifold and clean the carbon deposit of turbo charger
FIELD CASE – ENGINE STALL / POOR STARTING
2 REXTON - No start at engine cold - ECU Main Relay problem -Replace Main Relay
RODIUS - P1193 rail pressure signal high - Vehicle sign off before P/No. : 844108100
Mar. 2005
3 DI All - Engine stall at low speed - HP pump IMV fault - Replace HP Pump
braking - Too much variation - Check the fuel quality
- P1253 rail pressure low control on rail pressure & RPM Bad fuel could be a
malfunction at driving reason of malfunction
IMV
4 REXTON - Intermittent engine starting - ECU S/W issue - ECU reprogram Vehicle sign off
RODIUS problem ; ECU BANK 1 Fault ; Higher than HCC73A02 Before Nov. 16th,
- Engine hesitation at cranking * Bank 1 : 1, 3, 4 Inj. 2004
; no start
- No DTC in ECU
5 REXTON - Engine stall while driving low - ECU S/W issue - ECU reprogram Vehicle sign off
RODIUS speed, do restart ; Sudden engine RPM ; Higher than HCC73A02 Before Nov. 16th,
drop 2004
FIELD CASE – ENGINE STALL / POOR STARTING
8 RODIUS - Intermittent engine stall or lack - Foreign material in fuel - Clean the fuel tank
KYRON of engine power tank - Fuel sender can be easily
ACTYON - P1254 max. rail pressure (Plastic seal comes form clogged by foreign
control malfunction fuel additive) material
Clogged area
9 RODIUS - Engine stall and Engine Check - Air incoming due to - Replace fuel sender
KYRON lamp On at quarter full of fuel poor sealing of fuel
ACTYON tank sender
- P1254 max. rail pressure
Air incoming by poor
control malfunction
sealing
FIELD CASE – ENGINE STALL / POOR STARTING
11 DI All - Engine check lamp - Fuel pressure control - Check fuel temp sensor
Fuel Temp.
- Engine stall malfunction due to connector or replace HP
Sensor
- P0183 Fuel Temp. Sensor – fuel temp. sensor fault Pump
Short to B+
12 DI All - Engine doesn’t start at cold - Air incoming through - Replace fuel filter
condition fuel filter bending area - Retighten the water
- Fuel leak caused by sensor Poor bending
Poor tightening of water
sensor Poor connection
13 DI All - Delay engine start at cold - Poor Injector pressure - Replace Injector
condition control - Check fuel quality if
- Engine stall while decelerating - Too much backleak at necessary
- P1254 Max. rail pressure Dynamic leak test
control malfunction (Spec : 38 ml) Dynamic leak test
DI ENGINE ECU VERSION
TROUBLESHOOTING FOR DI FAN BELT NOISE
■ ISI-07EN012
♠ INSPECTION Check belt
; issued Aug. 2007 projecting part
Check the fan belt abnormal noise as showing
right photo and check fan belt alignment from
a side view
Cooling
Check fan belt noise after removing fan belt fan
if necessary
Check fan belt alignment if there is belt
movement back and forth
♠ MEASUREMENT
If the fan belt noise is caused by poor belt alignment
replace water pump pulley with improved new one
Water Pump
and check belt noise again Pulley
Special attention
CAUTION to interference
Take care not to damage the rubber bellow of belt tensioner using the wrench
while removing or installation of fan belt using wrench
REFERENCE
Fan belt should rotate evenly without movement back and forth left before the end of pulley
about 2~3 mm if you check tensioner pulley with the naked eye
2~3mm clearance
Fan Belt
Tensioner
Pulley
INSTRUCTION OF BELT TENSIONER REPLACE
VENTILATION HOLE
Belt tensionor has ventilation hole to discharge the hot and pressed e
vaporative oil gas which is generated during operation
This oil gas can misjudge as oil leakage if its mixed with dust around
INSTRUCTION OF BELT TENSIONER REPLACE
♠ BELT TENSIONER OPERATION PRINCIPLE
DOWN UP
Oil Reservoir
Expansion Stage (UP) : Oil flow into the Piston through check valve
Compression Stage (DOWN) : Oil flow out though oil gap of piston upper to
oil reservoir
NOTICE
There is no functional problem if belt tension has more than 50% oil inside
In case of fan belt noise, check the symptom with released technical information
ISI-07EN012 before replace fan belt
OIL LEAK FROM EGR COOLER MOUNTING BOLT
♠ FIELD ACTION
Spray sealant (DOBO 233 ) on the
mounting bolt for EGR cooler lower
♠ RECOMMENDATION
Keep the tighten spec. of intake duct
clamp while the related job is doing
at service station
Tightening Torque : 6 ~7 NM
(0.6 ~ 0.7 Kgf.m)
NOTICE
If necessary, clean the blow-by oil inside intake hose and intake
manifold duct area before clamp installation
INSTRUCTION OF ACOUSTIC COVER REMOVEAL
♠ FIELD ACTION
Spray loctite at the pitch of stud bolt before installation
Spray loctite a lit Spray at the pitch and
tle at the pitch contact surface a little
♠ FIELD ACTION
- Clean the EGR gasket and then spray
sealant on both side
Leakage
♠ SYMPTOMS
- Oil leakage between exhaust manifold and
cylinder head
♠ CAUSES
- incomplete combustion blow-up gas which is Ex. Manifold Gasket Leak
condensed by heat leaks through side part of
exhaust manifold gasket
It could decrease gasket sealing by loosen
the tightening torque of mounting
nuts if the driving mileage is creased
Case 1 Cylinder head replace due to misjudgment of poor position of steel ball
Remark 1) Poor Position of steel ball normally happen at low mileage vehicle
Remark 2) Steel for engine oil line located at engine front side (near chain
tension), the other steel balls located lower side of cylinder head
is for coolant line
Case 2 Cylinder head replace due to misjudgment of processing defects of
cylinder head
♠ RECOMMENDATION
Do not replace cylinder head by field misjudgment
In case of oil leak of cylinder head, do a color marking at leak point
TROUBLESHOOTING FOR IDI ENG BIG SHAKING
■ REMARK
- SYMC are supplying Magnetic Side Cover for 5 cylinder and 4 cylinder engine
from July, 2007 according to field request
Poor Ground
Gap
TROUBLESHOOTING FOR ELEC. T/BODY (EUROIV)
■ Case B – REXTON/RODIUS/KYRON
D27DT EURO 4
DTC : P213B / P213C
A. poor electric connection
A B C
Troubleshooting
problem was gone after T/Body connection
cleaning and repairing
every connector’s female
and male pin
A
C112 CONNECTOR
Location : Under glow
plug control unit