GENERAL 1. STRUCTURE... 3 OVERVIEW AND OPERATION PROCESS 1. ENGINE CONTROLS COMPONENTS... 2. INTAKE SYSTEM COMPONENTS... 3. EXHAUST SYSTEM COMPONENTS... 4. LUBRICATION SYSTEM COMPONENTS... 5. COOLING SYSTEM COMPONENTS... 6. FUEL SYSTEM COMPONENTS... 6 9 11 13 15 17
01-3 GENERAL 1. STRUCTURE Front view Rear view 1. TVD (Torsional Vibration 2. Damper) 3. Air conditioner compressor 4. Power steering pump pulley 5. Idle pulley 6. Water pump pulley Alternator 7. Cooling fan pulley 8. Aut tensioner pulley 9. Auto tensioner 10. Poly-groove belt 11. Cam position sensor 12. Drive plate (M/T: DMF) 13. Oil filter 14. Vacuum pump 15. Crank position sensor 16. EGR valve 17. Power steering pump 18. EGR center pipe
01-4 Top view 19. Cylinder head cover 20. Intake manifold 21. Water outlet port 22. Common rail 23. Fuel pressure sensor 24. Fuel pipe 25. Injector 26. Fuel return line 27. Oil filler cap 28. Glow plug 29. Booster pressure sensor 30. Oil separator 31. Oil dipstic 32. EGR center pipe
01-5 Left side view Right side view 33. Cylinder head 34. Cylinder block 35. pan 36. Drain plug 37. Turbocharger 38. EGR - RH (#3) pipe 39. Oil separator 40. Oil dipstic 41. HP pump 42. Turbocharger vacuum modulator 43. EGR valve vacuum modulator 44. EGR valve 45. Exhaust manifold
01-6 OVERVIEW AND OPERATION PROCESS 1. ENGINE CONTROLS COMPONENTS 1) ECU Related Components
01-7 2) Engine And Sensors
01-8 3) Electrical Components And Pre Heating System
01-9 2. INTAKE SYSTEM COMPONENTS
01-10 Intake Air Flow Chart
01-11 3. EXHAUST SYSTEM COMPONENTS
01-12 Exhaust Air Flow Chart
01-13 4. LUBRICATION SYSTEM COMPONENTS
01-14 Lubrication Flow Chart 1. Oil pump 2. Oil gallery (to oil filter) 3. Oil filter 4. Oil pressure switch 5. Main oil gallery 7. Oil gallery (chain tensioner side) 9. Chain tensioner 10. Vent (chain tensioner) 11. Front closing cover (φ 17 mm) 12. Oil gallery (at a right angle to axial direction) 13. Ball (φ 6 mm) 14. Oil spray nozzle (timing chain) 15. Oil gallery (cylinder head side) 16. Ball (φ 15 mm) 17. Oil restriction (inner - φ 4 mm) 18. Oil supply (to exhaust camshaft) 19. Oil supply (to intake camshaft) 20. Oil supply (to exhaust camshaft bearing) 21. Oil supply (to intake camshaft bearing) 22. Oil gallery (to exhaust valve tappet) 23. Oil gallery (to intake valve tappet) 24. Oil gallery (to chain tensioner) 25. Expansion plug 26. Ball 30. Valve tappet a. Oil gallery (between oil pump and oil filter) b. Main oil gallery c. Oil return line (the oil is returned to oil pan side when replacing filter element)
01-15 5. COOLING SYSTEM COMPONENTS
01-16 Coolant Flow Chart
01-17 6. FUEL SYSTEM COMPONENTS
01-18 Fuel Supply System According to input signals from various sensors, engine ECU calculates driver's demand (position of the accelerator pedal) and then controls overall operating performance of engine and vehicle on that time. ECU receives signals from sensors via data line and then performs effective engine air-fuel ratio controls based on those signals. Engine speed is measured by crankshaft speed (position) sensor and camshaft speed (position) sensor determines injection order and ECU detects driver's pedal position (driver's demand) through electrical signal that is generated by variable resistance changes in accelerator pedal sensor. Air flow (hot film) sensor detects intake air volume and sends the signals to ECU. Especially, the engine ECU controls the air-fuel ratio by recognizing instant air volume changes from air flow sensor to decrease the emissions (EGR valve control). Furthermore, ECU uses signals from coolant temperature sensor and air temperature sensor, booster pressure sensor and barometric sensor as compensation signal to respond to injection starting, pilot injection set values, various operations and variables.