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TQ - ENGINE
Power train Application
Power/Torque (PS/kgf m)
EU (LHD/RHD)
WGN
(8P)
GEN (LHD/RHD)
WGN
(9/12P)
AUST. (RHD)
WGN
(8P)
Engine
Transmission
VAN
(2/5P)
VAN
(2/5P)
VAN
(2/5P)
A-2.5 VGT M5SR1 A5SR2 M5TR1 100 / 23.0 AW30-43 M5TR1 170 / 40.0
(WGT : 136/35.0) (VGT/ WGT)
(VGT/ WGT
Diesel
D4BH TCI-2.5
Gasoline
-2.4 FR
AW30-40
175 / 23.2
-
(9P ONLY)
Note 1)
TQ - ENGINE
C/Rail A - engine
Engine Displacement (cc) Max. Power (PS / RPM) Max. Torque (kgfm / RPM) A 2.5 VGT 2497 170 / 3800 40.0 / 2000 Timing Chain 2nd generation C/Rail (1600bar) Increased power 30 PS (vs A1) VGT Electrical EGR Feature Duty control Turbocharger - WGT BOSCH C/Rail Serpentine belt Air dam type intercooler EGR cooler Lambda sensor is Installed
3
A 2.5 WGT 2497 136 / 3800 35.0 / 2000
TQ - ENGINE
D4BH TCI 2.5
Engine Displacement (cc) Max. Power (PS / RPM) D4BH TCI 2.5 2476 100 / 3800 23.0 / 2000
Air dam type intercooler Balance-shaft for improving Feature NVH Covec F EGR and Cooler Satisfied Euro 3 emission
TQ - ENGINE
Theta 2.4 engine
Engine Displacement (cc) Max. Power (PS / RPM) Theta 2.4 CVVT 2359 175 / 6000 23.2 / 4250
Reduced engine weight 22Kg (vs A1) Increased power Feature 39 PS (vs A1) Timing Chain CVVT FF type theta engine
A- 2.5 Engine
TQ - ENGINE
Comparison (TQ vs A1)
System Item A1-WGT EURO 3 TQ VGT EURO 4 Remarks
Injector
CRIP1 / 6-HOLE
1350bar
ECM
H/P Pump
16 bit CP3.2
Sensor
Added Sensor
TQ - ENGINE
Comparison (TQ vs A1)
System Item A1-WGT EURO 3 TQ VGT EURO 4 Remarks
EGR COOLER
EGR Valve
EGR Valve
Turbocharger
TQ - ENGINE
Comparison (TQ vs A1)
System Item A1-WGT EURO 3 TQ VGT EURO 4 Remarks
Added Warm up Catalytic Converter ( WCC ) MT only Euro 4 : WCC+UCC (M/T only)
Euro 3 : UCC only Euro 2 : without catalytic converter
UCC
UCC
H/PROTECTOR
Exhaust layout
VGT
WCC
TQ - ENGINE
Comparison (TQ vs A1)
System Item A1-WGT EURO 3 TQ VGT EURO 4
Vacuum pump cap
10
Remarks
Head
Head / cooling
TQ - ENGINE
Comparison (TQ vs A1)
System Item A1-WGT EURO 3 TQ VGT EURO 4 Remarks
11
Head / cooling
Head cover
Moving
Piston
TQ - ENGINE
Comparison (TQ vs A1)
Model
12
contents
A1 [A-WGT] Max. Fuel pressure High Pump Max. Supplied capacity type type Max. No of Injection 1350 bar 677mm3/rev CP3.2 Classified injector 2~3 times TQ [A-VGT(EURO-4)] 1600 bar 843mm3/rev CP1H IQA injector 3~4 times
Injector
1350 bar
1.5 mm3/st 1.8 ms 1350 bar Inlet control 16 bit 121 PIN
1600 bar
1.0 mm3/st 0.8 ms 1600 bar Inlet / Outlet control 32 bit 154 PIN
TQ - ENGINE
Timing Chain
- Maintenance free timing chain and chain guide adapted - Composed by 3 chains : A, B and C - Shorten engine length
Timing Chain Timing Chain C
13
Timing Chain B
Timing Chain A
TQ - ENGINE
Timing Chain A
- Drive crankshaft pulley, high pressure pump and RH balance shaft
14
TQ - ENGINE
Timing Chain B
- Drive Crankshaft pulley, oil pump and LH balance shaft pulley - Aligned all timing mark together in initial installation - Proper lubrication for timing chain and chain guide
15 teeth
15
13 teeth 12 teeth
Tensioner
TQ - ENGINE
Timing Chain C
- Drive high pressure pump intake and exhaust cam sprocket
5teeth
16
Auto Tensioner
TQ - ENGINE
Caution for timing chain
- Replacing work for timing chain A and B is not possible in condition of engine installation while timing chain C is possible. - Alignment between each sprocket and timing belt should be in spec. especially in timing chain C. - There are 3 types of high pressure pump sprocket supplied related to high pressure pump. Every time when you are in replacing work, you have to check the clearance between high pressure pump end and pump sprocket end and choose the right size of sprocket for proper installation.
17
Cylinder Block
Color Blue
HP Pump Sprocket
Sprocket A B C
White Red
TQ - ENGINE
Data Analysis (Idling Condition)
18
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Data Analysis Actuation Test
19
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Burner Type Heating System Layout
20
Exhaust pipe
Burner
Fuel feeding
ECU
Radiator
Thermostat
Air feeding
Engine
Heater
Heater
Water pump
TQ - ENGINE
Burner
Combustion air fan ECU Internal temp. sensor
21
Air-inlet Heat-exchanger
Evaporator
Glow plug
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Burner Type Heating System Location - Burner
22
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Burner Type Heating System Location Dosing Pump (Fuel Motor)
23
TQ - ENGINE
Heater Control Logic
B+ Voltage Ambient temp. by ambient S/W Coolant Temp. by internal temp sensor Combustion air fan
24
E C U
Operating Condition
1. 2. Operating condition : below coolant temp. 78oC & ambient temp. 2oC Working procedure Cleaning : combustion air fan & glow plug on (for 30sec) Pre-filling : dosing pump on (for 3sec) Combustion : glow plug, combustion air fan, dosing pump on (for 121sec) Full load : combustion air fan, dosing pump 100% on Specification Heater capacity Power consumption Full mode 5.0kW 0.63l/h Half mode 2.5kW 0.32l/h
Fuel consumption
37W
13W
TQ - ENGINE
Off Condition
1.
25
When engine off Dosing pump stop Cleaning operating : burn out remain fuel inside burner 100%, combustion air fan & water pump on Other parts are stopped When coolant temp. over 78oC Dosing pump stop Cleaning operating : burn out remain fuel inside burner 100%, combustion air fan & water pump on Water pump working but other parts are stopped
2.
What is cleaning
** Purpose of cleaning : Burning out remain fuel and foreign material after combustion then emit exhaust gas
When engine off burner operating noise can be occurred but that is normal sound (cleaning sound) - Engine off during full load operation : cleaning time 175 sec - Engine off during half load operation : cleaning time 100sec
TQ - ENGINE
Wiring Diagram
Fuse(20A) HMC WIR'G HCC WIR'G
26
1 2
To Heater
Ambient SW 1 1 3 2 3 To Heater
Alternator(+)
2 4
4
Dosing Pump 5 1 5 2 Ambient temp. sensor &dosing pump Burner main connector 6
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DTC & Data Analysis
27
Actuation Test
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Timing Belt
29
RH Balance Shaft
LH Balance Shaft
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Valve Clearance
30
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Injection Timing Adjustment
31
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System Overview (Covec F)
32
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System components
Control Sleeve Position (CSP) Sensor Injection system
33
GE Actuator
Vehicle
Pump speed Sensor (Np) Sensors Control Sleeve Position Switches Sensor (CSP) Battery voltage Fuel Temp. Sensor Compensation Resistor Timing Position Sensor
Additional Control
EGR valve Glowplugs MIL
TQ - ENGINE
GE - Actuator, TCV and TPS
Sensor yoke Fixed plate Return spring
34
Shaft Ball pin Sensor coil Shaft Control sleeve Movable plate Magnet
Current (A)
B TPS
TCV
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NP sensor, CSP
35
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Fuel Temperature Sensor, Fuel Cut Valve
36
No. 11 Ground
TQ - ENGINE
Changing Items
SYSTEM Main Feature - light weight
: Aluminum cylinder block
38
Main Features
Figure
- High Stiffness
: Added rib and adopted cone-shaped type
Aluminum Block
TQ - ENGINE
Changing Items
SYSTEM Main Features Main Features - Intake manifold is changed Figure
39
(Plastic Aluminum)
- Throttle body with ISA instead of ETC - MAP is used instead of MAF Driving Belt - Exhaust manifold is changed (Stainless steel Cast iron) - Location of Oil filter is changed - Alternator and steering pump are moved
Alternator Auto-tensioner A/C compressor Water Pump Steering Pump