HYUNDAI HEAVY INDUSTRIES

EUROPE
Training:
Mitsubishi TIER3, D04FD-TAA
Common-rail diesel engine

Compiled 03/2010 by: Jean Joris/Service Dep.

Updated 12/2012 by: Pieter Everaerts/Service Dep.
Engine specifications:
•D04FD-TAA  72 kW in: R110LC-7A
•D04FD-TAA  91kW in: R140LC & W-7A/, R140LC-9 & R145CR-9
•D04FD-TAA  98 kW in: R160LC-7A/-9, R170W-7A & R180LC-7A/-9

Engine features:
- 4 valves per cylinder
- ECM mounted remote on cabin
- Diagnosis by “DR” tool (CAT “ET” design)

2
Maintenance intervals & data:
- Check engine oil level daily!
- Change oil & filter every 500 Hrs.
- Contents: 18.5L

CH-4

4
Engine s/n on rocker cover and
stamped in the block:

5
New features in Common rail engines:

6
ECM Voltages/Current:
• Nominal battery supply voltage 18-32 volts
- Expected voltage range/current draw…
• 24V system / 18-32 volts / Max 15 Amps (10mA ‘Sleep’)

On ECM connectors:
• Do Use the proper tools to tighten the ECM Connector Screws
– 6 Nm (4.4 lb-ft)

Grounding:
• Grounding
– Always ensure that the ground strap is on the ECM.
– Prevent EMI, Electro Magnetic Interference

8
Sensors:
Temperature sensors:
- Air intake temperature sensor, located adjacent to the
air intake boost sensor in the inlet manifold.
- Water temperature sensor, located near the thermostat.
(Both sensors are identical and interchangable)
Pressure sensors:
- Air intake boost sensor, located adjasent to the air
intake temperature sensor in the inlet manifold.
- Engine oil pressure switch located in the engine block at
the rear end from the transfer (fuel) pump.
- Common rail pressure sensor, located on the bottom
side of the common rail.

9
Sensors:
Speed/Timing sensors:

- Crankshaft speed/timing sensor, located in the flywheel

housing.

- Camshaft speed/timing sensor, located in the rear part

of the HP fuel pump.
(Both these sensors are identical and interchangable,
only camshaft sensor needs O-ring)

Note for the electrical connectors

In order to remove the connectors from the sensors:
- Slide red connector-lock back carefully (red arrow)
- Push the lever down (blue arrow) and pull the connector.

To put the connectors on the sensors, push them in

place and lock by sliding the red connector lock back in
place.

10
Fuel Rail Pressure Sensors:

- Determines Fuel Rail Pressure

- Continuous Operating Pressure 200 Mp
- Maximum without damage, 260 MPa burst at 320 MPa)
- Temperature Range, -40º to +160ºC
- Sensor has M12 x 1.5 Thread
- Requires Special ‘Crush’ Washer for Sealing
- Ensure there is no Rail Pressure before removal

I.M.A. Pressure Sensors:

(Intake Manifold Air)

- Measures Manifold Air Pressure

- Used to calculate air/fuel ratio
- Used for smoke limiting strategy
- Measures atmospheric pressure on “key-on”

14
 Pressure Sensors:
- Integrated circuit
- Capacitive sensor
- Voltage output varies with pressure
- Sensor conditions the signal voltage output to the ECM
- Active Sensor (Needs a external power supply)

Speed/Position Sensors:
• Two speed/position sensors

- Crankshaft - Primary
- High Pressure Fuel Pump – Secondary

• Two Wire ‘Hall Effect’

- Produce Conditioned Square Wave

• Engine will Run if the Primary sensor fails

- ‘Limp Home Mode’ derate (50%) Power of the engine

- Engine will Not Shutdown if Secondary sensor fails
- Cannot be re-started if the engine is stopped.

15
Crank Speed/Timing:

Blank

Hole

- 59 holes / 1 blank
- 6º between hole
- The hole next blank “tells” ECM crank position

17
HP Pump Speed/Position Sensor:

Speed / Timing
Sensor
Speed / Timing Sensor
‘Target’ 36 Teeth

18
 Fuel System Handling:

IMPORTANT
work clean! !

• Thoroughly clean equipment before disassembling

• Cap all fuel passages immediately after removal with (clean) protective cap and plug Kit
• Do Not “Blow Out” or “Wash Out” any fuel passages
• Place removed parts in clean area
• Do not pre-fill filters
• Remove packaging and protective caps only prior to installation

19
Fuel system:

green & orange lines:

Cranking: +/- 150–200kPa (1.5-2 Bar)
Idling: +/- 300-400 kPa (3-4 Bar)
red line:
+/- 30  +/- 120 MPa, (300- +/-1200
Bar)
pink line:
+/- 35 kPa (+/- 0.35 Bar)

21
HP Fuel pump:
HP fuel pump is not servicable ! ! !

3 main components:
High Pressure block with:
- “Metering solenoid” valve
- 2 plunjers

Transfer pump:
- Gear pump

Camshaft housing:
- Camshaft with 2 double cams

22
HP block: Schematic drawing (function)

24
Common rail:

1. Pressure sensor
2. Fuel pressure safety
relief valve
3. HP fuel supply from HP
pump
4. HP fuel supply to
injectors
5. Low pressure relief valve
6. Fuel return to tank

Valve opening pressure:

35 +/- 15 kPa
( 0.35 +/- 0.015 Bar)

27
Fuel pressure relief valves:

High pressure safety relief valve:

- Protects System from over-pressure

- Opens at Constant Pressure of 160
MPa (1600 Bar / 23,200 PSI)
- Withstands Spikes to 190 MPa
(1900 Bar / 27,500 PSI)
- Returns fuel to Tank

Low pressure relief valve:

-Keeps the low pressure system around the

35 +/- 15 kPa (+/- 0.35 Bar / 50 PSI)

28
Injector: Manufactured by: Caterpillar

- Electrical connection
(5  105 V signal from ECM)

- HP fuel supply from rail

- Excessive fuel drain

When one or more

new injectors are
installed, a new
“E-trim file” has te
be uploaded into
the ECM.
29
Multiple Injection:
The common rail “system” can control fuel injection pressure, injection quantity and injection timing independently
without depending on the engine speed because of the electronic control of high pressure fuel pump and injectors. For
this reason, multiple injection per cycle is made possible. This reduces nitrogen oxide (NOx), particular matter (PM),
and engine noise.

Each injection period is designated as follows.

• Pilot injection
• Pre injection
• Main injection
• Post injection Pilot injection

The pilot injection, which is injected early

aids in pre-mixing thus reducing particul
matter (PM).

Pre injection

The pre injection raises the temperature

of gases in the cylinder by injecting small
amount of fuel right before the main
injection, and decreases ignition delay at
main injection. This reduces nitrogen
oxide (NOx) and engine noise.

Post injection

The post injection actuates the diffusive

combustion by
injecting fuel after the main injection,
and reduces particul matter (PM).

31
Replacing the injector:

- Remove bold bracket dipstick, common rail cover, and

valve cover.
- Remove HP fuel pipe.
- Remove electrical connection.
- Pull out sleeve carefully with screwdriver.

33
Replacing the injector:
- Remove injector wiring, pay attention to the position of + (red) and – (black).
- Remove with Allen key the 6mm bolt & washer.

- Remove injector with puller

ref. No.: 900.832
(SB2009-037 page 7)

34
 Installing the injector:

- Write down the injector s/n prior to

installation (after installation is not always
possible). This s/n is required to download
the E-trim file.
- Always install a new O-ring in required
location and apply grease to the O-ring.
- Always install a new copper seal, and check
that the old washer came out with old
injector (See SB2009-037 page 7).

35
 Installing the injector:

- Slowly tighten the hexagon socket bold from

the nozzle gland by hand & when injector is
fully inserted apply 29,4 Nm +/- 2,9 Nm of
torque.
- Re-connect electrical wire, make sure it is
correctly routed.
-Re-install the sleeve.
-Re-connect the HP fuel line (torque: +/- 41 Nm).
- Re-install valve cover, cover common rail and
dipstick.
- E-trim files need to be downloaded from the
MHI Service Web (best before installation).
- Then up-load required E-trim file in ECM with
DR-tool.

36
 Removing the HP fuel pump:
The full procedure has been published in “Service Bulletin”: HHIE-SB-2009-037 page 8  11
& SB2008-025

Most important points:

- Loosen the HP fuel pump gear nut first,
this nut has to be re-used.
- Make sure the engine is at TDC / OT on cylinder 1
(cylinder 1 = timing side)
- Mark tooth clearly from idler gear between “3 3”

37
Installing the HP fuel pump:
Proceed in reverse order to removal.

- When fitting the new pump, start

by lifting the rear end of the pump
and slide it back in its location while
lowering the rear end at the same
time.

Important:
- Make sure the pump flange is correctly positioned.
-The tooth with the marking needs to be put back in it’s
position between both “3”, as in the picture adjacent.

38
Check & adjust valve clearance:

Inspect & adjust only when engine is cold

Long rocker lever is intake, short lever is exhaust

Adjusting procedure:

- Make sure the valve & rocker is fully loose.

- Loosen valve adjustment
- Loosen valve bridge
- Push on the rocker arm to equalize bridge
- Fix valve bridge with adjusting screw
- Turn in adjusting screw with 10°
- Tighten lock nut
- Then only adjust valve clearance

Clearance: inlet 0,25 mm & outlet 0,40 mm

39
Electrical wiring diagram:

40
Lubrication system:
Schematic overview:

42
Lubrication system:
In case of low oil pressure check:
- Oil pressure relief valve
Oil pressure:
Max: 400 kPa
Min: 154 kPa  Fault code in ECM
Min: 104 kPa  derate power 50%
- Oil pump safety valve

Oil pump
43
In order to troubleshoot this
engine you require the:
“DR” diagnostic tool

50
Overhaul instructions: (extract from Mitsubishi D04FD Service Manual)

Compiled by: Jean Joris 51

Service Department
Overhaul instructions: (extract from Mitsubishi D04FD Service Manual)

52
 The end!
Thank you for
your attention.
Compiled by: Jean Joris 53
Service Department