1

TERRACAN
D4BH (2.5 TCI) Diesel Engine
Fuel System (COVEC-F)

Engine Specification

ITEMS
DISPLACEMENT(cc)
BORE STROKE(mm)
FIRING ORDER

2.5 T/C
2476
91.1 95
1-3-4-2

COMPRESSION RATIO

21

INJECTION TIMING( )

CAM Lift 10.03mm

INJECTION TYPE
NUMBER OF CYLINDER
IDLE RPM
PREHEATING DEVICE
INTAKE SYSTEM

INDIRECTION
4
750
GLOW PLUG
TURBO

Outline

Electronic fuel injection pump (Covec-F) has the same fuel intake and
compression system as mechanical injection pump has.
However, it uses an electronic governor(GE Actuator) instead of a fly-weight
and uses control unit cable instead of a control lever. In checking engine cycle,
mechanical pump uses gear of fly weight holder, but electronic pump uses
sensing gear plate with 4 projections, installed on the driveshaft. A timing
control valve(TCV), which adjust pressure to moot optimal injection timing,
installed between high and low pressure chambers of the timer at lower part of
the main pump body, in mechanical injection pumps, check valves are installed
in part of the inside of the overflow valves. In electronic injection pumps,
however, check valve are installed at all valves, enabling to hold over-flows
until the pressure is stabilized. A timer position sensor(TPS), which senses
location of timer piston is also installed in electric injection.

GE Actuator
Fuel Cut Sol.

Np Sensor

Timer Control Valve.

ECM Input/ Output

GE(Governor Electric) Actuator

GE actuator is attached to the governor chamber at the upper part of the

injection pump. Governor chamber and pump chamber are connected with a
magnetic filter in between. Coil is cooled by the fuel coming into the governor
chamber. A magnetic filter prevents foreign material(ferrous ingredients) from
entering the chambers. Eccentric ball pin that are inserted into control sleeve
holes are placed at the end of the shaft forced into the rotor.
The electronic governor actuator is a magnetic field type. Once the coil
receives electric current, it generates a magnetic field and rotates the rotor until
it reaches the designated range.
The strength of magnetic field at coil is proportional to the strength of input
current and rotates the rotor to the relative position of the return spring ,
enabling the control sleeve to make linear movements.

ECM Input/ Output

GE (Governor Electric) Actuator

F.I.P
Connector
No.10 GE-

Specification

No.6 GE+

No.6 ~ No.10: 0.6

Connection with ECM
No.6

ECM Pin No. 1, 14

No.10

ECM Pin No. 2, 15

Waveform

ECM Pin No. 1, 14

ECM Pin No. 2, 15

ECM Input/ Output

TCV (Timing Control Valve)
The TCV is located at the lower part of the injection pump. Two holes ( A and
B ) in the pump housing connect to the TCV. Hole A connects the timer piston's
high pressure chamber to the fuel inlet side of the TCV. A filter is installed at
this inlet to exclude foreign mater Hole B connects the timer piston's low
pressure chamber to the outlet at the tip of he TCV.
Installed between the timer piston's high and low pressure chambers, the TCV
adjusts high pressure chamber pressure by opening and closing the needle.
When current is not flowing to the TCV, the tip of the needle completely
separates the high and low pressure chambers. Then current is supplied,
needle tip seat is opened, the high and low pressure chamber are connected,
and the high pressure chamber pressure decreases. The timer piston is then
moved by timer spring to a piston that balances the high pressure chamber
pressure. Accompanying this roller holder rotates to vary the injection timing.
Injection timing can therefore be varied by utilizing the ON-OFF duty ratio of
the current flowing to the TCV. Injection timing is controlled by duty. All
characteristics and TCV drive signal duty ratios. Also, he frequency of the TCV
drive signal can be varied to correspond to the frequency of injection pump
speed.
Duty ratio is the ratio the time that the timing control valve is closed per unit of
time (i. e. per cycle).
Duty ratio = to / T x 100 (%)
Injection timing is related when the duty ratio decreases from 100%.
When electric current flows at Timing Control Valve, the needle is pulled lift by
magnet, and seat part of the hall is opened. TCV is located between high
pressure and low pressure chambers and adjusts pressure by opening and
closing of the needle.

ECM Input/ Output

TCV (Timer Control Valve)

ECM Input/ Output

TCV (Timer Control Valve)

F.I.P
Connector

No.9 TCV-

Specification

No.5 TCV+

TCV

No.5 ~ No.9: 111.1

Connection with Others
No.5

IG. Key(B+)

No.9

ECM Pin No. 13

Waveform

At idle

At acceleration

ECM Input/ Output

TPS (Timer Position Sensor)

TPS is attached on the low-pressure side of the timer and is consisted of core
rod and bobbin. It checks position of the timer piston electrically. TPS checks
inductance changes with the core rod and measures position of the timer
piston.

TPS
Connector
TPS

ECM Input/ Output

10

TPS (Timer Position Sensor)

No.1 TPS -

F.I.P
Connector

No.2 TPS +
No.3 TPS
MDL
Specification
No.2 ~ No.3, No.1 ~ No.3: 822

TCV

Connection with Others

No.1

ECM Pin No. 53

No.2

ECM Pin No. 46

No.3

ECM Pin No. 52

Waveform

ECM Pin No. 52, 46 at idle

ECM Pin No. 52, 53 at idle

ECM Input/ Output

Np (Pump Speed) Sensor
NP Sensor checks pump rpm and relays signal to PCM. NP sensor is
consisted of permanent magnets, steel core and coils. It detects electric
voltage generated by the changes in the machine going through the sensing
gear, through rotation signal.
When the 4 projections of the sensing gear plate go through the magnetic field,
while the drive-shaft is rotating, alternating current is generated, which is then
changed into a pulse signal and used as a rotation signal.

Np Sensor

11

ECM Input/ Output

12

Np (Pump Speed) Sensor

No.1 Shield GND
F.I.P
Connector
No.2
ECM GND

No.3
Specification

Signal

No.2 ~ No.3: 1.020.16k

Connection with Others
No.1

Wiring harness Shield GND

No.2

ECM Pin No. 38 GND

No.3

ECM Pin No. 30 Signal

Waveform

Np Signal at idle

Np Signal with CKP Sensor at idle

ECM Input/ Output

13

Q Compensation Resistance
Q Compensation Resistance is to prevent the different injection amount due to
the different characteristic resistance of fuel injection pump affecting to
injection amount controlled by ECM.
The resistance of Q Compensation is decided by below table. The
compensation resistance number is related to the resistance measured
between terminal D & G.

Q Adjustment
Resistance

Q Comp.
Measured
Number
Resistance
Resistance
No.1
No.2
No.3
No.4
No.5
No.6
No.7
No.8
No.9
No.10
No.11
No.12
No.13

945
946
947
948
949
950
951
952
953
954
955
956
957

0.18(k)
0.3(k)
0.43(k)
0.62(k)
0.82(k)
1.1(k)
1.15(k)
2(k)
2.7(k)
3.9(k)
5.6(k)
8.2(k)
15(k)

F.I.P
Connector
No.2

No.3

ECM Input/ Output

CSP (Control Sleeve Position) Sensor
The control Sleeve Position Sensor(CSP) at upper part of GE actuator detects
the position of control sleeve and feeds it back to ECU.
The fixed plate compensates changes of inductance caused by temperature.
The CSP sensor calculates the difference of the inductance at the two sensor
coils(upper and lower sensor coils) into angles and feeds them back to ECU,
and ECU compares its target angle with the actual one, if there is a difference
between the two angles, the ECU adjusts electric currents until the actual angle
equals the target angle.

14

ECM Input/ Output

15

CSP (Control Sleeve Position) Sensor

F.I.P
Connector
No.8 CSP
MDL

No.12 CSP -

Specification

No.4 CDP +

No.4 ~ No.8, No.12 ~ No. 8: 5.8k

Connection with ECM
No.4

ECM Pin No. 43, 49

No.8

ECM Pin No. 44, 50

No.12

ECM Pin No.45, 51

Waveform

ECM Pin No. 43, 44 at idle

ECM Pin No. 43, 45 at idle

ECM Input/ Output

TF (Temperature Fuel) Sensor
This sensor detects the temperature of fuel.
If TF Sensor value is beyond 0.1V~4.6V for 5 second, ECM regards TF Sensor
as failed and sets fuel temperature to 50

F.I.P
Connector
No.7 Signal

No.11 GND
Specification
No.7 ~ No.11: 20.1k at 25
Connection with ECM
No.7

ECM Pin No. 18

No.11

Wiring harness GND

Waveform
ECM Pin No. 18 at
normal operating
Temperature

16

ECM Input/ Output

17

WTS (Water Temperature Sensor) Sensor

If Sensor value is beyond 0.1V~4.6V for 5 second, ECM regards WTS Sensor
as failed and sets coolant temperature from TF Sensor at starting. When TF
Sensor is failed, sets the temperature to 20.

Specification

Temp.() Resistance(k) Voltage(V)

-20
16
4.3
0
5.9
3.4
20
2.5
2.4
40
1.2
1.5
60
0.6
0.9
80
0.3
0.5
100
0.2
0.3
Connection with ECM
No.2

ECM Pin No. 17

No.1

Wiring harness GND

Waveform

ECM Pin No. 17 at

normal operating
Temperature

ECM Input/ Output

18

BPS (Booster Pressure Sensor) / TA (Intake-Air-Temperature)

Sensor
These two sensors are integrated into one. Located after the intercooler. BPS
detects the intake air pressure and TA sensor detects the temperature of intake
air.
If BPS value is beyond 0.2V~4.8V for 1. second, ECM regards BPS as failed and
fixes boost pressure to 760mmHg and prohibits EGR operation.
If TA sensor value is beyond 0.1V~4.6V for 5 second, ECM regards TA Sensor as
failed and fixes air temperature to 60.
No.2 TA Sig. No.1 GND

TA Sensor Specification

Temp.() Resistance(k) Voltage(V)

-20
16
4.3
0
5.9
3.4
20
2.5
2.4
40
1.2
1.5
60
0.6
0.9
80
0.3
0.5
100
0.2
0.3
No.4 BPS Sig.

No.3 Ref. Voltage 5V

Connection with ECM

No.1

ECM Pin No. 41 GND

No.2

ECM Pin No. 19 TA Signal

No.3

ECM Pin No. 33 Reference Voltage 5V

No.4

ECM Pin No. 34 BPS Signal

ECM Input/ Output

19

BPS (Booster Pressure Sensor) / TA (Intake-Air-Temperature

Sensor
Waveform

ECM Pin No. 34

BPS Signal at idle

ECM Pin No. 34 BPS

Signal at acceleration
from idle to 4200rpm

ECM Pin No. 34 BPS

Signal at 4200rpm

ECM Pin No. 19

TA Sensor Signal

ECM Input/ Output

APS (Accelerator Pedal Sensor)
This sensor detects the angle of accelerator pedal.
If sensor value is beyond 0.2V~4.93V for 1. second, ECM regards APS as
failed. If ECM detects APS malfunction, ECM fix accelerator opening to 0%
and prohibit EGR operation.
When only idle SW. is good, ECM can increase the accelerator opening to 30%
slowly. (equal to approx 1.5V)
In the event of complete failure, No throttle response

Connection with ECM

No.1

ECM Pin No. 32 V ref

No.2

ECM Pin No.40 APS Sig.

No.3

ECM Pin No.8 Idle SW Sig.

No.4

Wiring harness GND Idle SW. GND

No.5

ECM Pin No.39 GND

20

ECM Input/ Output

21

APS (Accelerator Pedal Sensor)

Idle Switch ON

ECM Pin No. 8 at acceleration

Good condition

Accelerator Pedal Sensor

ECM Pin No. 40 from idle to Max.

APS (Accelerator Pedal Sensor)

Good condition (Max. Throttle)

APS output signal failed, Idle Switch good, At Max. Throttle

ECM increases RPM slowly to 30% (4000rp)m

22

ECM Input/ Output

23

CPS (Crankshaft Position Sensor)

This sensor detects the position of crankshaft.
If there is no signal from sensor for 20 consecutive times of Np Sensor, ECM
regards CPS as failed and controls engine with Np (inj pump) Sensor signal.
Note: In this condition Twice ignition applies to start engine
DTC P0335 will be set

CPS
1mm

Connection with ECM

No.1

Shield GND

No.3

ECM Pin No.37 GND

Waveform

No.2

ECM Pin No.29 Signal

ECM Input/ Output

ECM Pin No. 29 at idle

24

CPS signal with Np signal at idle

ECM Input/ Output

25

FC (Fuel Cut) Valve

When the IG. Key is On, ECM supplies B+ Voltage to open fuel line.
When Immobilizer is on ECM inhibits the connection, (vale remains closed)
F.I.P
Connector

No.1 FC
Valve

FC Valve

Connection with ECM

No.1

ECM Pin No.26 Signal

Waveform

FC Valve signal at idle

Diagnosis Reference chart

26

(Checking Pump Components, Ignition off plug disconnected)

Terminal Component
Remarks
1
FCV
Fuel Cut Valve
2
Adj (-)
Adjustment resistor (-)
3
Adj (+)
Adjustment resistor (+)
4
CSP
Oscillate (+)
5
TCV (+) Timer Control Valve (+)
6
GE (+)
GE (+)
7
TF (+)
Fuel temperature (+)
8
CSP
MDL
9
TCV (-) Timer Control Valve (-)
10
GEGE (-)
11
TF (-)
Fuel Temperature (-)
12
CSP
Oscillate (-)

12

Note: Pin arrangement is different to H-1

Pumps are not interchangeable

Diagnosis Reference chart

27

(Checking Pump Components)

Component Plug (No of pins) Terminal

Resistance
Fuel Cut
12 pin black 1--Ground
7 ~ 9 Ohms
Actuator
12 pin black
6 ~ 10 0.71 0.13 Ohms
TCV
12 pin black
5~9
11 1.1 Ohms
TPS
3 pin black
2~3
82 2 Ohms
1 ~3
82 2 Ohms
Speed Sensor 3 pin grey
2 ~ 3 1.02 0.16 KOhms
Trim Resistor 12 pin black
3 ~2
same as resistor
CSP
3 pin
4~8
5.9 0.3 Ohms
8 ~ 12
5.9 0.3 Ohms
Fuel Temp
12 pin black
11 ~ 7
0.1 Kohms

Temp
23 +- 5
23 +- 5
23 +- 5
23 +- 5
23 +- 5
23 +- 5
23 +- 5
23 +- 5
23 +- 5
25

ECM Input/ Output

28

EGR (Emission Gas Re-circulation) Solenoid Valve

There are two EGR Solenoid Valves. One is controlled by duty signal from
ECM and connected from vacuum tank or atmosphere to the other EGR
Solenoid Valves. The other is controlled by On/Off signal from ECM and
connected to EGR Control valve.

EGR Vacuum Sol.

Valve Out port

EGR Sol. Valve

To EGR
Control Valve

From Vacuum
Pump

Atmosphere
Port

EGR Vacuum
Sol. Valve

Connection with ECM

EGR Vacuum Sol. Valve No.1

ECM Pin No.58 Signal

EGR Vacuum Sol. Valve No.2

Main Relay B+

EGR Sol. Valve No. 1

ECM Pin No.68 Signal

EGR Sol. Valve No. 2

Main Relay B+

ECM Input/ Output

29

EGR (Exhuast Gas Re-circulation) Solenoid Valve

Waveform

ECM Pin No. 58 at idle

ECM Pin No. 68 at acceleration

ECM Pin No.58 at acceleration

ECM Input/ Output

30

I/C (Inter Cooler) Fan Motor Relay

Terracan has a intercooler fan motor controlled by ECM. Intercooler fan motor
is operated when vehicle speed is under 60Km/h and intake air temperature is
over 58 and engine speed is over 550rpm.

Connection with ECM

I/C Fan Motor Relay No.85

ECM Pin No.35

Grow Plug Relay

ECM controls the glow plug to heat the intake air through glow plug relay.
According to the condition, the heating time is as below.
Preheating
Post heating
Coolant Temp. Heating time
2Sec.
60
8Sec.
-15
10Sec.
-20
15Sec.
-25
24.5Sec.
-40

Coolant Temp. Heating time

3Sec.
60
3Sec.
0
3Sec.
-10
5Sec.
-20
5Sec.
-40

Connection with ECM

Glow Plug Relay No.85

ECM Pin No.55

ECM Input/ Output

31

Others
Main relay control
ECM controls Main relay to provide the B+ voltage to actuators like EGR Sol.
Valves, Grow Plug and A/C fan relay etc.
Lamps
ECM controls Engine check lamp and Glow lamp
A/C Fan Motor Relay & A/C Comp. Relay
Connection with ECM
Main Relay No.85

ECM Pin No.73

Engine check lamp

ECM Pin No.62

Glow lamp

ECM Pin No.63

A/C Fan Motor Relay No.85

A/C Comp. Relay

ECM Pin No.59

ECM Pin No.72

ECM Controls

32

Q(Injection amount) Controls

Example)
CPS
Eng. speed

Np Sensor when CPS is failed

Pump speed

3,000 RPM

ECM

GE Actuator

Injection Quantity

Fuel Injection

37mg/stroke

2.8 Volt

APS
Accel. Position

CSP

50%
Feedback

Control Sleeve
Position Check

IT (Injection Timing) Controls

Np Sensor when CPS is failed
Pump speed
Eng. speed
CPS

ECM

TCV

Injection Timing

Duty(%) Control

TPS

ECM
Injection Quantity
Feedback

Injection
Timing Check

Basic Adjustments (Injection pump timing)

1. Engine stop
2. Turn the crankshaft to place in No.1 Cylinder at top dead center on
compression stroke
3. Loosen injection pipe
4. Loosen injection mounting bolts and nuts
5. Remove timing check plug from injection pump head

6. Attach the special tool and a dial gauge

7. Turn crankshaft to such a position that the notch on pulley is at
approximately 30 before top dead center. Then , set dial indicator to
zero.

33

Basic Adjustments (Injection pump timing)

8. Slightly turn crankshaft clockwise and counterclockwise to make sure
that dial indicator pointer does not deviate from zero position.
9. Turn the crankshaft in the normal direction and position the notch of
crankshaft pulley at 5 ATDC. (N/A : 5 T/C : 7 TCI : 7 )

10. If the dial indicator does not indicate the specified value.
Tilt the injection pump body to the right or left until the indicator does
indicate the standard value.
11. Tighten mounting bolt of injection bolts and nuts.
12. Remove special tool and dial gauge
13. Install timing check plug with new copper gasket

34

Basic Adjustments (Valve clearances)

1. Warm up temperature
2. Remove upper timing belt cover and rocker cover
3. Turn the crankshaft clockwise and align the timing mark on the
camshaft sprocket with the timing mark
4. Check the valve clearance indicated in the
diagram(A)
Standard clearance : 0.25mm(0.098in)

5. If not within the standard value, adjust the valve clearance with the
adjusting screw and the thickness gauge
6. Rotate clockwise the crankshaft one complete turn (360 )
7. Check the valve clearance indicated in the diagram(B)
Standard clearance : 0.25mm(0.098in)

35

HI-Scan

36

HI-Scan

37

See Page 39

Current Data

HI-Scan

Actuation Test

38

HI-Scan DTC List

39

No

DTC No

Conents

MIL

P0105

BAROMETRIC SENSOR - MAL

P0110

INT - AIR TEMP CIRCUIT - NAL

P0115

ENG COOLANT TEMP - MAL

P0120

ACCEL P. SENSOR - MAL

P0121

APS. RANGE / PERFORMANCE - MAL

P0180

FUEL TEMP. SENSOR - CIRCUIT-MAL

P0320

ENGINE SPEED INPUT CIRCUIT - MAL

P0335

CRANKSHAFT P. SENSOR - MAL

P0500

VEHICLE SPEED SENSOR - MAL

10

P0600

IMMOBILZER COMMUNICATION - MAL

11

P0605

CONTROL MODULE (EEPROM) - ROM MAL

12

P0613

ECU - MALFUNCTION

13

P1116

BOOST PRESSURE SENSOR - MAL

14

P1120

ELECTRIC GOVERNOR - MAL

15

P1122

BOOST PRESSURE CONTROL VALVE - MAL

16

P1123

TIMER POSITION SENSOR - MAL

17

P1127

CONTOL SLEEVE POSITION SENSOR - MAL

18

P1131

INJECTION QUANTITY ADJUST - MAL

19

P1135

INJECTION TIMING SERVO - MAL

20

P1324

GLOW RELAY - MALFUNCTION

21

P1522

BATTERY VOLTAGE ERROR

22

P1525

5V SOURCE VOLTAGE

23

P1621

FUEL CUT VALVE - MAL