ActyonA0A06005

COOLING SYSTEMACTYON SM - 2006.03

CHANGED BYEFFECTIVE DATE

AFFECTED VIN

34 06

PREHEATING SYSTEM

Preheat relay

Battery

Glow plug

Groundterminal

Glow plug controlsignal (ECU113)

Battery mainwire

K-line(ECU 34)

Preheat completion transmitterminal : No use for vehiclewithout remote engine start

Glow plug terminal(#1 ~ #4)

No G5 for4 cylinders

(Without D20DT)

IG1 power supplyterminal

Tightening torquewhen installing

15 3 Nm

ECU Glow Indicator (Meter Cluster)


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3506

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OVERVIEWGlow plug is installed on the cylinder head (combustion chamber) in the D20DT preheating control unit system. Coldstarting performance has improved and exhaust gas during cold starting has reduced.ECU receives coolant temperature and engine speed to control; after monitoring the engine preheating/post heatingand glow plug diagnosis function, the fault contents will be delivered to ECU.

1. Engine preheating/post heating functions2. Preheating relay activation by ECU controls

1) Senses engine temperature and controls the preheating/after heating time2) Glow indicator

3. K-LINE for information exchanges between preheating unit and ECU1) Transmits preheating unit self-diagnosis results to ECU2) Transmits glow plug diagnosis results and operating status to ECU

PREHEATING RELAY

Structure

K-LINE #1(ECU 34)

IG1Power terminal

Groundterminal

B+main wire(12V)

Glow plugterminal

Glow plugcontrol signal

(ECU 113)



AFFECTED VIN

36 06

PREHEATING SYSTEM DIAGRAM

SpecificationsDescription

Rated voltageOperating voltage rangeOperating rangeRelay operating voltageRelay releasing voltageRelay coil resistanceVoltage dropParasitic current

SpecificationDC 12 VDC 8 ~ 15 V- 40 ~ + 100COver 6.5 VOver 1.5 V11.3 Below 150 mV at each glow plug (at 16A of current)MAX 1 mA

Coolanttemperature

sensor 113


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3706

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FunctionPreheating system controls and checks following functions and operating conditions.Pre-Heating1. The power will be supplied to the glow plugs by ECU controls when the power is supplied to the IG terminal from the

battery and there are normal communications with ECU within 2 seconds. The surface of glow plug will be heatedup to 850C very quickly to aid combustion by vaporizing air-fuel mixture during compression stroke.

2. Preheating time is controlled by ECU.Post-heating1. When the engine is started, post-heating starts by ECU controls. The idle rpm will be increased to reduce toxic

smoke, pollutants and noises.2. Post-heating time is controlled by ECU.Checking glow plugs1. Check each glow plug for short in circuit2. Check each glow plug for open in circuit due to overvoltage3. Check glow plug for short to groundForceful relay shut-down1. When glow plug is shorted to groundK-Line communication1. ECU sends the results to preheating time control relay through K-Line to start communication.2. Preheating time control relay sends messages including self-diagnosis data for glow plugs to ECU.3. Glow plug makes communication only as response to demand.4. When power is supplied, ECU starts self-diagnosis within 2 seconds.5. Under the following conditions, communication error occurs.

1) When there is no response from glow plug module within 2 seconds2) When an error is detected in checksum3) Less byte is received

Glow plug openGlow plug shortGlow plug - short to groundGlow plug communication faultDefective glow plug controllerDefective No. 3 glow plugDefective No. 4 glow plugDefective No. 5 glow plugDefective No. 1 glow plugDefective No. 2 glow plug

Preheat control driver openPreheat control driver shortPreheat control driver is short to groundCommunication fault between ECU and preheat controllerCommunication fault between ECU and preheat controllerNo. 3 glow plug openNo. 4 glow plug openNo. 5 glow plug open (N/A for D20DT engine)No. 1 glow plug openNo. 2 glow plug open

P1678P1679P1680P1676P1677P0671P0672P0673P0674P0675

DTC Defective Detailed description

DTC



AFFECTED VIN

38 06

IG: ON B+ : below 15.2V

ReleaseConditions

After operating time elapsed IG: OFF When engine cranking

-35 C -25 C -20 C -10 C 0 C 10 C 20 C31 sec 22 sec 19 sec 17 sec 14 sec 0 sec 0 sec

Operating time

-30 C115 sec

-20 C80 sec

-10 C30 sec

0 C19 sec

10 C11 sec

20 C11 sec

35 C0 sec

After engine starting After operating time elapsed Torque : 190/170 Nm Speed: 2100/2050 rpm

When engine cranking

ReleaseConditions

IG: ON

-30 C18 sec

-25 C16 sec

-20 C10 sec

-10 C5 sec

0 C2 sec

10 C0 sec

20 C0 sec

ReleaseConditions

Pre-heating

Coolant Temp.Operating Time

OperatingConditions

Coolant Temp.Operating TimePost-

heating

GlowIndicator

Coolant Temp.Operating Time

OperatingConditions

OperatingConditions


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3906

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1. Turn the ignition switch to OFF position and discon-nect the negative battery cable.

2. Set aside the harnesses on the cylinder head.

3. Disconnect the glow plug connectors and loosen theglow plugs.

Installation Notice

4. Remove the glow plugs from the cylinder head with aspecial tool. Plug the openings of the glow plugs withsealing caps.

Tightening torque

Removal and Installation



AFFECTED VIN

40 06

PREGLOW PLUGTwo versions of preglow plugs are used in this vehicle.Always use only the designated version with correct color mark on insulator surface.

SpecificationsBERU versionColor mark on insulator surface: GreenTip diameter: 4Resistance: 680 110 m at 20 2C

NGK versionColor mark on insulator surface: YellowTip diameter: 3.5Resistance: 1400 300 m at 20 2C

Green Yellow

The color mark on insulator surface may be invisible due to the carbon contamination. To check the color easily,disconnect the harness connector and clean the preglow plug mounting area with carbon cleaner.Wait for a while and blow out the area with a compressed air.

Clean and Blow Out Check the Color Mark

Air gunCheck the color mark


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4106

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Preparations for Replacing Preglow PlugTorque wrench, Air gun (small), Carbon cleaner (Product name: IPO CHOKE & CARBURATOR CLEANER, Modelname: PRO NO 5007, Manufacturer: Sunbo), Engine oil, Preglow plug wrench (special service tool), Long nosepliers

Removal and Installation of Preglow PlugPreceding Work: Disconnect the negative battery cable.

1. Disconnect the wiring harness with long nose pliers and clean the preglow mounting area with the compressedair (using air gun).

2. Spray the carbon cleaner into the gap between preglow plug and cylinder head and wait for 10 minutes. Removethe dirt and foreign materials completely with the compressed air (using air gun)..

At this moment, check the color mark on insulator surface and bring the same version of preglow plug forreplacement. (BERU: Green, NGK: Yellow)

NOTICE

Air gun



AFFECTED VIN

42 06

3. To avoid damage, apply the engine oil into the gap between preglow plug and cylinder head and wait for 5minutes.

5. Thoroughly remove the foreign materials from the preglow plug hole. If needed, use the carbon cleaner or air gun.

4. Remove the preglow plug with torque wrench. (tightening torque: 15 3 Nm)

To prevent the preglow plug from breaking, carefully turn the wrench with the torque below 20 Nm. Never use the air impact tool or other tools.

NOTICE


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4306

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Remarks1. Required tools

2. Preglow plug circuit check1) Check the preglow plug trouble code with SCAN-100.2) SCAN-100 can display only one trouble code. Check whether each preglow plug circuit is open with multi-

tester.

Carbon Cleaner Torque Wrench (max. 25 Nm)

Preglow plug wrench - Special Service Tool (10 mm)Part number: Y99220132B

Tip diameter BERU: 4 mmNGK: 3.5 mm

Color mark oninsulator surface

BERU: GreenNGK: Yellow

Documents

ActyonA0A06005