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22MY / L200/L200 SPORTERO / Europe/Russia (Eastern Europe countries) - Workshop Manual

13 -FUEL > 13A-DIESEL FUEL > > GENERAL INFORMATION

GENERAL INFORMATION

The common rail fuel injection system consists of sensors which detect the condition of the
diesel engine, an engine electronic control unit (engine-ECU) which controls the system based on
signals from these sensors, and actuators which operate according to control commands from
the engine-ECU. The engine-ECU carries out activities such as fuel injection control and idle
speed control. In addition, the engine-ECU is equipped with several self-diagnosis functions
which make troubleshooting easier in the event that a problem develops.

FUEL INJECTION CONTROL

The injector drive time, the injection timing and the fuel pressure are controlled so that the
appropriate quantities of fuel are supplied to the engine in response to engine conditions which
can change frequently. A single injector is mounted at each cylinder. The supply pump increases
the fuel pressure to the pressure which is required for high-pressure injection, and then send the
fuel each injector.

IDLE SPEED CONTROL

The idle speed is kept at the optimum speed by controlling the fuel injection quantity in
accordance with changes in idling conditions and engine load during idling.
The engine-ECU drives the fuel injector to keep the engine running at the pre-set idle target speed
in accordance with the engine coolant temperature and A/C and other electrical load.

SELF-DIAGNOSIS FUNCTION

When an abnormality is detected in any of the sensors or actuators, the engine warning
lamp illuminates to warn the driver.
 When an abnormality is detected in any of the sensors or actuators, a diagnosis code
number corresponding to the problem which occurred is stored.
The RAM data relating to the sensors and actuators which is stored in the engine-ECU can
be read using the M.U.T.-III. In addition, the actuator can be force-driven under certain
conditions.

OTHER CONTROL FUNCTIONS

1. Power Supply Control

When the ignition switch "ON" signal is input by the ignition switch, the engine-ECU turns
ON the power transistor for controlling the engine control relay. As a result, current flows
through the coil in the engine control relay, causing the relay switch to turn ON and supply
power to the sensors and actuators.

2. Glow Control

(Refer to GROUP 16 - Glow System, General Information ).

3. EGR Control
[Refer to GROUP 17 - Emission Control <DIESEL>, Exhaust Gas Recirculation (EGR) System,

General Information (EGR system) <4N14> or <4N15>].

4. A/C compressor Relay Control

Turns the compressor clutch of the A/C ON and OFF.

5. Condenser Fan Motor Relay Control

Controls the condenser fan motor relay based on the A/C switch, A/C load signal, engine
coolant temperature and vehicle speed input signals.

6. PTC Heater Relay Control <Vehicle with PTC heater>

The PTC heater is turned ON is accordance with the A/C operation at the engine cold state.
 7. DPF System Control
[Refer to GROUP 17 - Emission Control <DIESEL>, Diesel Particulate Filter (DPF) System,

General Information (DPF system) ].

8. Variable Geometry Turbocharger Control

Performing the duty control over the variable geometry control solenoid valve, the engine-
ECU opens and closes the nozzle vane located in the turbocharger assembly. This allows
the boost pressure to be obtained in accordance with the engine operation.

9. Alternator Output Current Control

Prevents the alternator output current from increasing suddenly and the idle speed from
varying such as when the headlamp is turned on.

10. AS&G system control <Vehicles with AS&G system>

The AS&G-ECU mostly controls the AS&G system [Refer to GROUP 17 - Auto Stop and Go (AS&G)

System, General Information ]. The engine-ECU makes a judgement about the following and
sends a signal to the AS&G-ECU.

Auto Stop Prohibition Control

When one or more of following conditions are satisfied during idling, the engine-ECU should
send the auto stop prohibition signal to the AS&G-ECU.
a. The engine coolant temperature is lower than approximately 55°C or is higher than
approximately 90°C.
b. The intake air temperature is higher than approximately 50°C.
c. When one or more of the following conditions are satisfied, the vehicle is in "auto stop
prohibition status" by electrical load.
The amount of the vehicle current consumption is more than the specified
value.
The power generation control is in the forcible full charge mode.
d. When the battery is determined as being deteriorated.
e. Diagnosis code No. P0622, diagnosis code No. P1608 or diagnosis code No. U1004
is detected.
f. The diagnosis code causing the MIL to illuminate is detected.
g. Approximately 30 seconds have not been taken since the engine started.
h. When the small injection quantity learning is requested.

Forcible Auto Start Request Control

When one or more of following conditions are satisfied during the auto stop, the engine-
ECU should send the engine start request signal to the AS&G-ECU.
a. The engine coolant temperature is lower than approximately 40°C.
b. The amount of the vehicle current consumption is more than the specified value.
c. Diagnosis code No. P1608 is detected.
d. When the DPF regeneration is requested.
GENERAL SPECIFICATIONS

Item Specification
Engine-ECU Identification No. (Part No.) <4N14 M/T (without fuel filter 1860D380
(Vehicles with 18 inch tyre)> pressure switch)
M/T (with fuel filter 1860D383
pressure switch)
A/T (without fuel filter 1860D381
pressure switch)
A/T (with fuel filter 1860D384
pressure switch)
Identification No. (Part No.) <4N14 M/T (without fuel filter 1860D687
(Vehicles with 16 inch tyre)> pressure switch)
M/T (with fuel filter 1860D689
pressure switch)
A/T (with fuel filter 1860D688
pressure switch)
Identification No. (Part No.) <4N15> M/T (Except MIVEC) 1860D283
A/T (Except MIVEC) 1860D284
A/T [MIVEC (High power 1860D282
engine)]
Sensors Air flow sensor Heat sensitizing type
Engine oil pressure and temperature Contact switch type
sensor (engine oil pressure switch)
<4N14>
Engine oil pressure and temperature Thermistor type
sensor (engine oil temperature sensor)
<4N14>
Engine oil pressure switch <4N15> Contact switch type
Barometric pressure sensor Semiconductor type
Intake air temperature sensor Thermistor type
Engine coolant temperature sensor No. 1 Thermistor type
<4N14>
Engine coolant temperature sensor No. 2 Thermistor type
<4N14>
Engine coolant temperature sensor Thermistor type
<4N15>
Accelerator pedal position sensor Hall element type
Camshaft position sensor Magneto resistance element type
Crank angle sensor Magneto resistance element type
Manifold absolute pressure sensor Piezo resistive semiconductor type
Throttle position sensor Hall element type
Battery temperature sensor <4N14> Thermistor type
Item Specification
Battery current sensor <4N14> Magneto resistance element type
Fuel temperature sensor Thermistor type
Exhaust differential pressure sensor Piezo resistive semiconductor type
EGR gas temperature sensor Thermistor type
EGR valve position sensor Hall element type
No. 1 exhaust gas temperature sensor Thermistor type
No. 2 exhaust gas temperature sensor Thermistor type
No. 3 exhaust gas temperature sensor Thermistor type
Rail pressure sensor Piezo resistive semiconductor type
Water level switch Contact switch type
Variable geometry position sensor Hall element type
Actuators Engine control relay Contact switch type
EGR valve DC motor type, having brushes
Suction control valve Duty cycle type solenoid valve
Fuel pump relay Contact switch type
Injector type and number Solenoid control type, 4
Injector identification mark <4N14> G4S022
Injector identification mark <4N15> G3S77
Throttle valve control servo DC motor type, having brushes
Variable geometry control solenoid valve Linear type solenoid valve
EGR cooler bypass control solenoid valve ON/OFF type solenoid valve
A/C compressor relay Contact switch type
Starter relay Contact switch type
Starter cut relay <4N14-M/T> Contact switch type
Fuel pressure relief control valve <4N14> ON/OFF type solenoid valve

FUEL INJECTION SYSTEM DIAGRAM

<4N14>
 1 Air flow sensor Accelerator pedal Engine- 1 Suction control Oil relief control valve
2 Crank angle sensor position sensor ECU valve
(main) Water flow cut valve
3 Camshaft position Barometric 2 Throttle valve
Accelerator pedal pressure Engine control relay
sensor control servo
position sensor sensor (DC motor) A/C compressor relay
4 Engine coolant
temperature sensor (sub) 3 Fuel injector Glow control unit
No. 1 Power supply Alternator
4 EGR valve
5 Engine coolant Ignition switch-IG (DC motor) (LIN communication)
temperature sensor Ignition switch-ST CAN communication
No. 2 5 Variable geometry
Alternator control solenoid (output signal)
6 Rail pressure sensor (LIN communication) valve
7 Intake air temperature Battery current 6 EGR cooler bypass
sensor sensor control solenoid
8 EGR gas temperature (LIN communication) valve
sensor
Engine oil pressure 7 Fuel pressure
9 Manifold absolute and temperature relief valve
pressure sensor sensor
10 Fuel temperature Glow diagnosis
sensor signal
11 Throttle position Water level switch
sensor
12 EGR valve Starter active signal
position sensor switch
13 No. 1 exhaust gas CAN communication
temperature sensor (input signal)
14 No. 2 exhaust gas
temperature sensor
(catalyst 9 Manifold absolute pressure sensor
temperature) 12 EGR valve position sensor
15 No. 3 exhaust gas
temperature sensor 4 EGR valve (DC motor)
(DPF temperature) 3 Camshaft position sensor
16 Exhaust differential 8 EGR gas
pressure sensor temperature To fuel
sensor tank
17 Variable geometry
position sensor 7 Fuel pressure
relief valve Fuel From
filter fuel tank
2 Throttle valve control servo (DC motor)
6 Rail
11 Throttle position sensor pressure 1 Suction
sensor control
1 Air flow sensor valve

3 Fuel
Variable injector Supply
geometry pump
turbocharger 4
Air Engine
coolant
5 temperature
Engine sensor No. 1
7 Intake air coolant
temperature 6 EGR cooler temperature
sensor bypass control sensor No. 2 10
Catalytic solenoid valve Fuel
2 Crank angle sensor temperature
converter
5 Variable geometry control solenoid valve sensor
16 Exhaust
differential 17 Variable geometry position sensor
pressure DPF 13 No. 1 exhaust gas temperature sensor
sensor 14 No. 2 exhaust gas temperature sensor (catalyst temperature)
15 No. 3 exhaust gas temperature sensor (DPF temperature)
No. 1 exhaust muffler NOx sensor
Urea
pump
module No. 2 exhaust muffler NOx sensor
SCR Exhaust muffler PM sensor
Urea tank Mixer
assembly Urea injector assembly ACJ01006 AC

<4N15>
 1 Air flow sensor Accelerator pedal Engine- 1 Suction control Engine control relay
2 Crank angle sensor position sensor ECU valve A/C compressor relay
3 Camshaft position (main) Barometric 2 Throttle valve Glow control unit
sensor Accelerator pedal pressure control servo Alternator G terminal
position sensor sensor (DC motor)
4 Engine coolant CAN communication
temperature sensor (sub) 3 Injector (output signal)
Power supply 4 EGR valve
5 Rail pressure sensor (DC motor)
Ignition switch-IG
6 Intake air temperature
sensor Ignition switch-ST 5 Variable geometry
Alternator L terminal control solenoid
7 EGR gas temperature valve
sensor Alternator FR
terminal 6 EGR cooler bypass
8 Manifold absolute control solenoid
pressure sensor Glow diagnosis valve
9 Fuel temperature signal
sensor Water level switch
10 Throttle position Engine oil pressure
sensor switch
11 EGR valve
position sensor CAN communication
(input signal)
12 No. 1 exhaust gas
temperature sensor Starter active signal
13 No. 2 exhaust gas switch
temperature sensor
(catalyst
temperature)
4 EGR valve (DC motor)
14 No. 3 exhaust gas
temperature sensor
(DPF temperature) 11 EGR valve position sensor
15 Exhaust differential
pressure sensor 8 Manifold absolute pressure sensor
16 Variable geometry
position sensor 7 EGR gas temperature sensor
To fuel
3 Camshaft position sensor tank
2 Throttle valve control servo (DC motor) Fuel From
filter fuel tank
10 Throttle position sensor 5 Rail
pressure 1 Suction
sensor control
1 Air flow sensor valve

3 Injector Supply
Variable pump
geometry
turbocharger
4 Engine
coolant
temperature
sensor 9
Air Fuel
16 Variable geometry temperature
6 Intake air position sensor 2 Crank angle sensor sensor
temperature
sensor
5 Variable geometry 6 EGR cooler bypass control solenoid valve
control solenoid valve
Catalytic
converter 15 Exhaust differential pressure sensor

12 No. 1 exhaust gas

temperature sensor DPF 14 No. 3 exhaust gas temperature sensor
(DPF temperature)
13 No. 2 exhaust gas temperature sensor
(catalyst temperature) ACG00609 AE
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