D4GA Engine EURO 4

Copyright by Hyundai Motor Company. All rights reserved

 Engine General D4GA Engine EURO4

▶ D4GA Euro 4 Engine General

Electronic Control Plastic Rocker Cover

Water-Cooled EGR
Head-Integrated IN-MANI
WGT Turbo
2nd Generation Common
Serpentine Belt Rail

Cylinder Block

Double-Weight Gallery Piston

PMC

4-Valve OHC Struc-

ture
 Engine General D4GA Engine EURO4

▶ Specifications

Items D4GA-engine (Euro V)

Model Mighty County
Displacement ( ㏄ ) 3,933 (103 x 118)
Cylinder type I4
General Compression ratio 17
Maximum power (ps/rpm) 150 / 2,500 150 / 2,500
Maximum torque (kg·m/rpm) 59 / 1,400~1800 59 / 14~1800
Total weight (kg) 440
Material of cylinder head and block CGI (Compacted Graphite Iron)
Valve No / CAM type 4 / OHC
Fuel injection system Common rail
Turbo type WGT
Emission system EGR+PMC+WGT
Firing order 1→3→4→2
Idle speed(rpm) 650±25
Engine oil capacity (ℓ) (Oil pan/ total quantity) 13.5/15, API CI-4(10W-40) or more
 Engine General D4GA Engine EURO4

▶ Accessory Belt System

Water Pump
Idler

Auto-tensioner

Alternator Idler Air Compressor

( D4GA EURO 4 )
 Engine General D4GA Engine EURO4

▶ Valve Train

Valve Train Installation Intake / Exhaust Valve

1) Center pivot SOHC 4 valve

2) Applied roller bearing. Intake Valve Exhaust Valve
3) Applied multiple grooves. Valve
4) Increased valve train rigidity. Clearance
5) Improved durability and reliabil- 0.2mm 0.6mm
ity.
(In cold weather)
 Engine General D4GA Engine EURO4

▶ Timing System

Cam
Idler,D

Fuel Pump
Idler,C
Vac. Pump

Idler,E Step Idler(A,B)

P/S Pump Crank

Oil Pump

( F-Engine )
 Engine General D4GA Engine EURO4

▶ Vacuum Pump

90˚

Exhaust
Outlet
Vacuum Pump Installation
 Engine General D4GA Engine EURO4

▶ Oil Filter & Oil Cooler

Oil filter

Filter ele-
ment

Oil cooler
 Engine General D4GA Engine EURO4

▶ CCV(Closed Crankcase Ventilation)

 Engine General D4GA Engine EURO4

▶ Particulate Matter Catalyst (PMC)

PMC

F-Engine G-Engine
 Engine General D4GA Engine EURO4

▶ Turbocharger

F-Engine

1) Maximum rpm
▶ 181,000 rpm
2) Control Method
▶Air pressure method
(same as in the previous D4 system engine)
3) Manufacturer
▶Keyyang Precision
4) Changes and features compared to previous (W) engine
▶Maximum rpm (160,000 -> 181,000)
▶Actuator pressure (960±35 -> 1800±30)
▶Nozzle opening area (8 ㎠ -> 4 ㎠ )
▶Maximum pressure ratio (2.6 -> 3.0)
 Fuel System D4GA Engine EURO4

▶ Fuel Injection System

Injection timing and amount

Injectors
④
③ HP Line
LP Line (vehicle)
RPS
⑤ ① ~ ⑥ Fuel flow
Rail

Pressure Limit Valve

②
Supply pump

⑥
Return line

Actuator Sensor Feed line

①
Fuel temp. sensor
Fuel pressure control (scv)
Tank
ECM Fuel filter
 Fuel System D4GA Engine EURO4

▶ Supply Pump

D4GA D6GA
 Fuel System D4GA Engine EURO4

▶ Supply Pump

Suction Pressure
Discharge Valve Suction Valve Feed Pressure
Injector Rail
High Pressure
Plunger
Return Pressure

Return Spring

Return

Fuel Overflow
Regulator Valve

Feed
Filter Pump
Camshaft Fuel Inlet

Intake

Fuel Tank
Fuel Filter
 Fuel System D4GA Engine EURO4

▶ Supply Control Valve(or Suction Control Valve)

Fuel OUT SCV

VALVE BODY

Fuel IN

Needle valve Return Spring

SCV OFF
SCV ON
- Solenoid valve energize
- Fuel less supply control time
 Fuel System D4GA Engine EURO4

▶ Common rail

Flow Damper

Rail Pressure Sensor

Pressure Limit Valve
 Fuel System D4GA Engine EURO4

▶ Pressure Limit Valve

2,210 bar
Valve Open

Valve Closed 500 bar

Pressure (bar)
 Fuel System D4GA Engine EURO4

▶ Flow damper

Engine stopped.

Repeat

Engine is operating.

High pressure fuel has leaked.

 Fuel System D4GA Engine EURO4

▶ Injector

Solenoid

Operating Operating Operating

Current Current Current
Valve

Outlet Orifice
Common Rail

Inlet Orifice

Pressure Control Pressure Control Pressure Control

Chamber Chamber Chamber
Command Piston

Injection Injection Injection

Nozzle
Amount Amount Amount

Before Injection Injection After Injection

 Fuel System D4GA Engine EURO4

▶ Injector QR compensation
 Fuel System D4GA Engine EURO4

▶ Fuel filter

Fuel pump

Fuel tank

Vacuum pressure switch Filter (5 ㎛ )

- Heater
- Themo switch
. ON : 7℃±4 ℃
. OFF : 24℃±4 ℃
 Engine Management System D4GA Engine EURO4

▶ Input and output

Accelerator Pedal Sensor 1, 2

Break and Clutch S/W

CKPS,CMPS

MAP, Intake Air Temperature Sensor

Injector
(injection amount
Rail Pressure Sensor
/Injection time)
Denso
DensoECM
ECM
MAF
EuroⅣ
Euro Ⅳ
Fuel Temperature Sensor Fuel Pressure Control (SCV)

Coolant Temperature Sensor

EGR Control

Neutral Switch
Communication (CAN Line)
EGR Lift Sensor

Filter Switch Warm Up System

 Engine Management System D4GA Engine EURO4

▶ CKP (Crankshaft Position sensor)

Checking items Descriptions

Resistance (Ω) 125±20 (20℃)
Air gap 1.50±0.5mm
Crank sensor active OFF (At IG ON)
Crank sensor active ON (At idle)
 Engine Management System D4GA Engine EURO4

▶ CMP (Camshaft Position sensor)

Checking items Descriptions

Air gap 1.50±0.5mm
CAM sensor active OFF (At IG ON)
CAM sensor active ON (At idle)
 Engine Management System D4GA Engine EURO4

▶ Boost Air Pressure & Temp. Sensor

1 2 3 4

1 : Intake air pressure signal

2 : Sensor power source
3 : Intake air temp signal
4 : Sensor ground
 Engine Management System D4GA Engine EURO4

▶ Rail pressure sensor

Output(V)

Fuel pressure
 Engine Management System D4GA Engine EURO4

▶ Fuel Temperature Sensor

 Engine Management System D4GA Engine EURO4

▶ Coolant Temperature Sensor

 Engine Management System D4GA Engine EURO4

▶ Accelerator pedal position sensor

 Engine Management System D4GA Engine EURO4

▶ Mass Air Flow sensor

EGR rate (%) = α - ß/α × 100

(α: Intake air amount without EGR operation, ß: Intake air amount with EGR operation)
 EGR System D4GA Engine EURO4

▶ Exhaust Gas Recirculation System

EGR Valve
EGR Cooler

Reed Valve

5 3 6 2
1 Thermostat Intake Manifold

4
EGR Valve Cooling
 EGR System D4GA Engine EURO4

▶ EGR Control

ENGINE
ECU

PWM Duty Control

ECV

H-BRIDGE

(Exhaust Control Valve)

 Engine Control Module D4GA Engine EURO4

▶ ECM(Engine Control Module)

HMC:39100-48700
DN:112500-1041
Engine side A (80 pin)

No. Items Descriptions

1 EMS DENSO
2 Pin 160
3 CPU Processing speed : 80MHz
4 1 H-Bridge EGR Control
5 ROM Memory 32Kb

Vehicle side B (80 pin)

Precise control of injection amount, injection timing, fuel pressure and intake air amount
 Optimized combustion condition
Satisfaction of EURO IV by EMS control and After treatment of exhaust gas
 Engine Control Module D4GA Engine EURO4

▶ When ECM is Replaced

1. Injector Data Input(QR CODE)

2. Learning Data Initialization
3. Parameter Setting
4. ECM Upgrade-ECU Calibration data
 Engine Control Module D4GA Engine EURO4

▶ Injector Data Input(QR CODE)

 Engine Control Module D4GA Engine EURO4

▶ Learning Data Initialization

 Engine Control Module D4GA Engine EURO4

▶ Parameter setting
Engine Control Module D4GA Engine EURO4
 Engine Control Module D4GA Engine EURO4

▶ ECM Upgrade
 Engine Control Module D4GA Engine EURO4

PTO Governor Option Settings and Wiring for D4GA Engine

Default특Value
장 팀 Requested
요 청 D E F Aby
U L TSpecial
값 Vehicle Team
항No
목 Unit
단 위 Remarks
비 고
한 글Display
DISPLAY "C"TYPE "F"TYPE "H"TYPE "J"TYPE "L"TYPE "M"TYPE

1 Deactivate
PTO 클러치 PTO
해제clutch ENABLE ENABLE ENABLE ENABLE ENABLE ENABLE

2 Deactivate
PTO 브레이크 PTO brake
해제 ENABLE ENABLE ENABLE ENABLE ENABLE ENABLE

3 Operate
PTO 페달 PTO
작동pedal ENABLE ENABLE ENABLE ENABLE ENABLE ENABLE

4 Operate
PTO 리모트 PTO remote
페달 작동 pedal DISABLE DISABLE ENABLE ENABLE DISABLE DISABLE

5 Reset리모트
PTO PTO remote
리셋 ENABLE ENABLE ENABLE ENABLE ENABLE ENABLE

6 PTO
PTO control
제어 모드 mode REMOTE BOTH REMOTE REMOTE BOTH CAB

7 PTO 감소
PTO reducing
RPMrpm RPM 200 200 200 200 200 200

8 PTO 증가
PTO increasing
RPM rpm RPM 200 200 200 200 200 200

9 PTO 최대
PTO maximum
RPM rpm RPM 1100 2500 2200 1200 1000 1800 Change
"W"엔진대비변경 compared
to “\” engine

10 PTO
PTO default
기본 RPM rpm RPM 650 650 650 650 650 650 Change
"W"엔진대비변경 compared
to “\” engine
PTO maximum speed
11 PTO
permit허용 최대 차속 km/h 30 30 30 30 30 30

PTO minimum speed

12 PTO
permit허용 최소 차속 km/h 20 20 20 20 20 20

Vehicle mounted with WRECKER,CRANE FGC,T/LORRY

특장 적
special 용 차종
equipment P/PACK,R/PACK FIRE LADDER W/WAGON
,SAFETY LODDER ,C/PACK
 Engine Control Module D4GA Engine EURO4

PTO Governor Diagram for D4GA Engine (Cab inside / outside)

Middle
Mighty Size Mighty
Mid-sized: engine ECU (F8=20A)

OEM; Factory installed

OEM; Factory installed For reconfiguration;
For reconfiguration; to to be purchased PTO Switch
be purchased separately separately
(93764-5K00* (93764-6B00*)
,93795-5A10*) : When the plug next
Connect to the white 6P to the fog lamp is
connectorabove pulled out,the
the acc. pedal. connector is also
pulled out.

Engine rpm UP/DN Switch

Shared use with

IDLE UP/DOWN
SW; factory installed

PTO Indicator Lamp

Turned on
when IN CAB ENG PTO
SW is activated. Inside cab Outside cab