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Fuel System General Specifications ................................................... FL - 2 Special Tools ..................................................... FL - 3 Description ........................................................ FL - 4 External Wiring Diagram Of Unit Injector (ECU) ................................................................ FL -16 Troubleshooting ................................................ FL -17

Engine Control System-Eletronic Engine Control Unit(ECU) Replacement ............................................... FL -25 Electronic Unit Injector(EUI) Components ................................................ FL -26 Inspection .................................................... FL -31 Replacement ............................................... FL -31 Priming Pump Replacement ............................................... FL -34 Overflow Valve Replacement ............................................... FL -35 Mass Air Flow Sensor(MAFS) Inspection .................................................... FL -36

Fuel Delivery System-Eletronic Accelerator Pedal Replacement ............................................... FL -39 Fuel Tank Components ................................................ FL -40 Replacement ............................................... FL -41

DTC Troubleshooting Diagnostic Trouble Codes ................................ FL -42

General SPECIFICATIONS Item Fuel pump

Specifications

Type

Inner contact gear type

Maximum supply pressure

Control unit

7kgf.cm²

Driving

Air compressor shaft driving

Voltage

24V

Connector

62 pin x 3

Unit injector(Solenoid Voltage valve) Resistance(at 20°C)

90V 1.66Ω±5%(5V), 1.40Ω±5%(NCV)

Coolant temperature Voltage sensor and Gauge unit Operating range

5V -40°C~130°C

Connector Intake pressure temp- Voltage erature sensor Operating range

3 pin 5V Temperature Pressure (Absolute)

Connector

860Ω ± 10% 40~3,000 r/min

Connector

2 pin

Air gap

1.0~2.0 mm 5V Temperature Pressure

Connector

32.5~284 kPa(0.33~2.9kgf.cm²) 4 pin

Crank shaft and Cam- Resistance shaft position sensor Operating range

Fuel pressure temper- Voltage ature sensor Operating range

-40°C~125°C

-40°C~130°C 0~1000 kPa(0~10kgf.cm²) 4 pin

SERVICE STANDARDS Item Electric injector

Standard value

Opening pressure

Min. 260 bar

Injection pressure

Max. 2,000 bar 500 ± 20 rpm

Idle rotation speed(RPM) Overflow valve opening pressure

4.0 bar or higher

Cam shaft position sensor air gap

1.0~2.0 mm

Crank shaft position sensor air gap

1.0~2.0 mm

Fuel pump discharge amount

500rpm

4 bar(1ℓ /min or more)

1900rpm

7 bar(7ℓ /min or more)

TIGHTENING TORQUE Tightening torque Item N.m

kgf.m

lb-ft

33 ~ 39

3.4 ~ 4.0

24.7 ~ 29.1

Pipe quick connector

27.4 ~ 29.4

2.8 ~ 3

20.2 ~ 21.6

Eye bolt(Overflow valve side)

29.4 ~ 34.3

3 ~ 3.5

21.6 ~ 25.2

Fuel filter mounting bolt

34.3 ~ 44.1

3.5 ~ 4.5

25.2 ~ 32.4

LH-Cover mounting bolt(ECU side)

4.9 ~ 7.8

0.5 ~ 0.8

3.6 ~ 5.8

ECU wiring cover mounting bolt

7.8 ~ 9.8

0.8 ~ 1

5.8 ~ 7.2

Fuel return hose mounting bolt(M6)

6.9 ~ 10.8

0.7 ~ 1.1

5 ~ 7.9

Fuel return hose mounting bolt(M10)

14.7 ~ 19.6

1.5 ~ 2

10.8 ~ 14.4

ECU mounting bracket attaching bolt

34 ~ 54

3.5 ~ 4.5

25.5 ~ 40.0

ECU mounting flange bolt

19 ~ 27

2 ~ 2.5

13.8 ~ 20.4

Intake pressure temperature sensor

5~6

0.5 ~ 0.6

3.6 ~ 4.4

Camshaft position sensor

8 ~ 10

0.8 ~ 1.0

5.8 ~ 7.3

Crankshaft position sensor

8 ~ 10

0.8 ~ 1.0

5.8 ~ 7.3

Fuel pump mounting bolt

10 ~ 12

1.0 ~ 1.2

5.8 ~ 8.7

Overflow valve

SPECIAL SERVICE TOOL Tool

Shape

Use

Rocker arm shaft setting 09245-84100

Installation and removal of rocker arm shaft

SDHEM7022D

DESCRIPTION

SGZFL9001L

1. 2. 3. 4. 5.

MAF sensor Coolant temperature sensor Intake pressure temperature sensor ECU Fuel pressure temperature sensor

6. Fuel filter 7. Priming pump 8. Crank position sensor 9. Cam position sensor 10. Injector wiring connector

BLOCK DIAGRAM OF FUEL SUPPLY SYSTEM Fuel system consists of control unit, unit injector, fuel pump, fuel line, fuel filter, overflow valve and fuel tank. Fuel pump, connected to air compressor, supplies fuel from fuel tank. Fuel flows into fuel filter from pump. Fuel from fuel filter is supplied to fuel path in cylinder head. When 6 injectors inject fuel it passes through overflow valve, which is connected to fuel path exit. Fuel returned from cylinder head goes back into fuel tank again. Accordingly, fuel system continues to supply and return proper amount of fuel used in engine by control unit. SGZFL9002L

EUI (Electronic Unit Injector) Unit Injector

Operating Theory of Unit Injector 1. Fuel intake

The unit injector consists of pumping element(A), controlling component(B), and nozzle(C) as shown in the illustration. The pumping element(A) generates the fuel pressure as the force from the cam drives the plunger by way of the rocker arm. The controlling component(B) controls the operation of the spill valve and needle control valve by driving the solenoid according to the commands from ECU. The nozzle element(C) finally injects fuel into the cylinder by the fuel pressure delivered.

The fuel circuit is open when the spill valve is opened and fuel comes into pump chamber as the return spring lifts up the plunger. At this time, the needle of nozzle is closed by the spring.

SGZFL9004L

2. Fuel discharge

SGZFL9003L

When the rocker arm begins to press plunger, fuel begins to be compressed in pump chamber. However, the sudden pressure rise does not occur as the spill valve is opened. That is, fuel flows through the spill valve. 3. Fuel compression start The fuel in the pump chamber is compressed when the spill valve(SV) is closed by the signal of ECU. The fuel pressure starts to rise according to plunger down. 4. Fuel injection start When the fuel pressure in the pump chamber reaches at appropriate level, the needle control valve is activated by the signal of ECU. At this time, the fuel injection starts to inject according as the nozzle is opened by the pressure difference between before and after needle when the pressure of rear of needle is released. 5. Fuel injection end The pressure between before and after needle is equal when the operation of needle control valve is deactivated by the signal of ECU. And the fuel injection is terminated as the nozzle is closed by the spring.

CONTROL UNIT AND SENSOR

SGZFL9027L

1. 2. 3. 4. 5.

MAF sensor Coolant temperature sensor Intake temperature pressure sensor ECU Fuel temperature/ pressure sensor

1. Control unit(ECU) Control unit(ECU) controls unit injector to inject a fuel into the cylinder. Mounted to the cylinder block, it receives information from accelerator pedal and several sensors and sets the fuel injection time and amount into cylinder. The control unit calculates the injection fuel amount and time when spill valve of injector is closed. The fuel injection amount into combustion chamber is adjusted or limited by the following conditions. -

Fuel amount needed (Fuel injection amount is set by the driver's operation)

-

Fuel injection limit (Fuel injection amount is set by engine condition)

6. Fuel filter 7. Priming pump 8. Crank position sensor 9. Cam position sensor 10. Injector wiring connector

2. Engine control 1) Control of fuel injection amount The fuel injection amount is calculated and set by the engine load, speed and fuel injection amount is compensated in through the input of various sensors about the engine condition.

SGZFL9005L

2) Limit of fuel amount Control unit limits fuel amount requested by the driver for safety and engine protection under the following conditions if necessary. -

In case of excessive smoke

-

When engine overheats

-

In case of excessively high speed

-

When fuel requested exceeds the maximum injection quantity

-

When engine speed is excessively high

-

When engine speed limit is needed in cold state

-

When EGR is defective

3) Limit of maximum engine speed When coolant temperature is lower than set value or vehicle speed sensor is zero, maximum speed of engine is limited to protect engine from high temperature and mechanical damage.

4) Control of fuel injection timing Fuel injection time is set depending on engine speed and requested fuel amount and is compensated based on the engine state from sensors.

SGZFL9006L

5) Cold starting control Engine control unit minimizes white smoke generating at cold start by injecting optimum fuel amount into engine at cold start and increases engine temperature to normal running temperature in a short time. And it controls heater to heat up air flowing into engine, which is divided into preheating before starting and post-heating after starting. 1. Air heating control a. Intake air heating at cold start -

Reducing the smokes due to incomplete combustion

-

Early warming of engine

-

Startability improvement

ECBFL5008A

6) Control of idle speed 1. Idle adjustment: Keep the specified rpm regardless of load. 2. Adjustment of unstable idling: Adjust idle speed to the programmed value in ECU when idling is unstable -

Increase or decrease rotations to the preset ranges specified by driver

-

Store the idle value before adjustment.

SGZFL9007L

3. Idle adjustment -

3. Vehicle control function

Idle adjustment at cold: Increase idle speed after cold starting to expedite the warming up.

-

Increase idle to prevent battery discharging when the air conditioner is on.

-

Increase idle to quicken the charging rate if battery voltage is low.

4. Idle adjustment at cold start

1) Cruise vehicle speed control 1. Function: Drives specified speed.

the

vehicle

within

the

2. Operating condition a. Operation of cruise control switch b. Brake and clutch pedal are not pressed. c. Safety switch is turned off. d. Brake is in normal condition.

7) Manual adjustment of idle Idle adjustment can be manually using self-diagnostic switch mounted to driver seat.

e. When vehicle speed is 40 km/h or higher. 3. Releasing condition

For the manual adjustment of the idle, following conditions should be met.

a. Releasing of cruise control switch

a. Vehicle should be stopped securely.

c. If the vehicle speed is lower than the minimum speed by cruise control function, cruise is released automatically if one of the above conditions is met.

b. There should be no acceleration pedal signal. c. Foot brake should be applied securely. d. It should be at idle state and PTOshould not be in running state

b. Brake and clutch pedal are pressed

d. Transmission retarder is operated The cruise control will be released if one of above conditions is met. 4. If the vehicle speed exceeds the specification, exhaust brake and engine brake operate in sequence. In addition, fuel amount is limited by the smallest value among maximumengine speed, torque performance and smoke restriction. 2) Limit of maximum vehicle speed 1. Function: Limit maximum vehicle speed by restriction of fuel supply 2. Control method a. Operated by set program in sequence.

ECBFL5011A

Driver can set desirable idle speed as mentioned above. (500 to 800 rpm) 8) Output limit by the fuel pressure Function: When fuel pressure drops lower than the value set during regular engine operation, it reduces the fuel amount requested to protect the engine and gives driver a warning signal at the same time.

b. If the fuel is not applied and the vehicle speed is higher than specified one on the downhill, the exhaust brake and the jake brake work successively. This condition prevents the vehicle speed from increasing excessively.

3) Door safety switch 1. Function: While the safety switch installed on the bus door is operating, ECU keeps the engine idle by ignoring the accelerator pedal signal to prevent the risk of vehicle moving. 2. Circuit operation diagram

ECBFL5012A

4) FAIL SAFE function

-

When PTO is not operating

1. Pedal sensor

-

When vehicle speed is zero

-

When clutch is not operating

a. Condition: Error occurrence at acceleration pedal sensor and idle rotation switch b. Limit of pedal function 2. Fuel temperature sensor : Use setup value 3. Intake temperature sensor: Use setup value 4. Fuel pressure sensor: Use setup value 5. Outdoor temperature sensor: Use setup value 6. Intake pressure sensor: Use setup value 7. Atmosphere pressure sensor: Use setup value 8. Vehicle speed sensor a. Fail judgment conditions

9. Use crank sensor at breakdown of cam sensor and signal value of cam sensor at breakdown of crank sensor 10. Engine coolant temperature sensor : Use setup value 5) PTO 1. Function: Keeps engine rotation speed regular regardless of load to operate the auxiliary unit. 2. Operating condition a. When cruise / PTO operating switch is ON

-

When fuel amount is more than the setup value

b. When the vehicle speed is lower than selective setup value (10km/h in general and engine running state)

-

When engine rotations are higher than the setup value

c. When PTO is adjustable from the driver seat or outside of the vehicle

-

When coolant temperature is higher than the setup value

3. Operation: When setup time (approximately 1 sec.) has passed, PTO governor controls rotation speed of engine into initial engine rotations of PTO. At this time, PTO indication lamp turns on to inform driver. 4. Release: When cruise / PTO operating switch is OFF, ECU slows down the engine rotations to be at idle speed. 5. When PTO is adjustable from the driver's seat or outside of the vehicle

5. Intake pressure temperature sensor Intake pressure temperature sensor measures pressure and temperature of air supplied for engine and sends voltage signal to ECU, mounted to intake manifold. ECU adjusts the injection timing and fuel amount according to the air pressure and temperature informed by the sensor. 6. Crankshaft position sensor

6. PTO engine rotations increase when acceleration pedal is applied and return to standard PTO rotations when it is released.

Crankshaft position sensor generates pulse signal by projection of the fly-wheel when fly-wheel rotates and sends it to ECU, mounted to the left side of fly-wheel housing.

7. PTO engine rotations decrease to the initial PTO speed in operating one or both of clutch and brake at the same time and return to standard PTO rotations when it is released.

ECU calculates the location and speed of engine, using generated pulse signal and controls fuel injection time and amount on the basis of them.

6) Cruise Control / PTO Enable Switch Set Cruise Control or PTO operation of special vehicle to ON/OFF. 7) Cruise Control / PTO / Idle Control Switch Used as control switch at operation of Cruise Control or PTO of special vehicle, idle control switch at idle and error code checkup switch at engine halt. 8) Exhaust brake and jake brake solenoid valve Control unit controls solenoid valve based on the switch operation of driver or engine state to operate exhaust brake or jake brake. 9) Power mode switch The driver can select fuel economy mode and power mode by operating the switch. The economy mode is to optimize fuel ratio but the power mode is to maximize output under engine operation condition. 4. Coolant temperature sensor Engine coolant temperature sensor is a resistance type, mounted to thermostat housing. ECU judges damage state of engine on the basis of output voltage of this sensor and controls fuel amount properly based on the engine coolant temperature.

7. Camshaft position sensor Camshaft position sensor generates pulse signal from sensor wheel installed at the end of camshaft and sends it to ECU, mounted to the left side of timing gear cover of cam shaft. A pulse signal is generated each cylinder and becomes standard of TDC by cylinder. Another pulse signal is generated to have cylinder No.1 recognized at the location of cylinder No.1. ECU recognizes cylinder No. and TDC then, determines injection order and time. 8. Fuel pressure/ temperature sensor Measure the fuel temperature and the pressure. Output is corrected according to the change of fuel temperature as the fuel varies depending on temperature. 9. Mass air flow sensor(MAF sensor) The intake air voluem sensor is used to control the EGR after measuring the intake air volume and temperature coming from the engine 10.Fan clutch control ECU measures engine coolant temperature and controls fan clutch electrically to maintain coolant temperature constant. Electronic fan clutch control helps improve fuel consumption ratio by minimizing the operation of cooling fan and reducing power loss. -

Two steps control type: This is the type to control cooling fan one step or two steps according to coolant temperature.

-

The electronic fan clutch helps to improve fuel ratio by reducing power loss due to fan operation.

ARRANGEMENT OF CRANK SENSOR WHEEL AND CAM SENSOR WHEEL IN TDC

ECBFL5013A

-

Crank sensor wheel is used to recognize the engine speed and status of engine cylinder and cam sensor wheel is used to recognize position of cylinder No.1 together with crank signal.

-

Crank sensor wheel teeth are composed at intervals of 6° and 2 teeth are missed at interval of 120°Camshaft is composed of 60° as a standard.

-

Camshaft has total 7 teeth and a tooth is added at No.1 to recognize standard of cylinder No.1.

-

Cylinder No.1 of camshaft is located after 15° from the added tooth and TDC of cylinder No.1 is located after 34.5° from tooth No.1.

CONTROL RELAY When the start switch is ON, battery voltage flows from starting switch to control unit. At this time, power transistor is switched on to control relay coil. Then, control relay switch is ON and main power is supplied from battery to control unit through control relay switch.

ECBFL5014A

PRIMING PUMP

FUEL FILTER

Priming pump is mounted on the fuel filter head and used to discharge fuel and air in fuel system manually at initial engine starting or after fuel filter replacement.

Fuel filter is spin-on type so that the element replacement is easy.

Priming pump mounting torque: 27~29Nm(2.8~3kgf.m, 20.4~21.8lb-ft)

It removes impurities in fuel supplied from fuel supply pump. Joint torque of cartridge : 32 ~ 34Nm(1.2 ~ 1.6kgf.m, 8.7~11.6lb-ft)

SGZFL9008L SGZFL9009L

OVERFLOW VALVE Overflow valve is mounted on the cylinder head fuel injection port. It controls fuel pressure in fuel gallery. Opening pressure of overflow valve: 3.0bar and more Joint torque of overflow valve: 40±2 Nm(4±0.2 kgf.m, 28.9±1.5 lb-ft)

SGZFL9010L

EXTERNAL WIRING DIAGRAM OF UNIT INJECTOR (ECU)

SGZFL9011L

Troubleshooting

USING HI-SCAN TOOL

SELF-DIAGNOSIS

1. Turn OFF the ignition switch.

The ECM monitors the input/output signals (some signals at all times and the others under specified conditions). When the ECM detects an irregularity, it records the diagnostic trouble code, and outputs the signal to the Data Link connector. The diagnosis results can be read with the scan tool or Flash code. Diagnostic Trouble Codes(DTC) will remain in the ECM as long as battery power is maintained.

2. Connect the Scan Tool to the data link connector. 3. Turn ON the ignition switch. 4. Use the scan tool to check the diagnostic trouble codes. 5. Repair the fail parts from the diagnosis chart. 6. Erase the diagnostic trouble code. 7. Disconnect the scan tool.

NOTICE The scan tool can erase the diagnostic trouble codesin the memory only.

•

INSPECTION PROCEDURE(SELF-DIAGNOSIS)

•

NOTICE 1. When battery voltage is low, diagnostic trouble codes can not be read. Be sure to check the battery for voltage and other conditions before starting the test. 2. Diagnosis memory is erased if the battery or the ECM connector is disconnected. Do not disconnect the battery before the diagnostic trouble codes are completely read. You can erase the DTC codes by using Hi-SCAN after completing inspection or repair.

NOTICE The scan tool can erase the diagnostic trouble codes in memory only. It is possible to erase the DTC codes only with key ON without starting the engine.

USING FLASH CODE Check by "Check ENG" lamp on the instrument panel Engine system provides error code inform engine failure directly without scan tool. Check the trouble of the error code as follows. 1. Stop the engine 2. Turn the starter to ON position 3. Check that the "CHECK ENGINE" lamp in the cluster is turned on after pressing SET/INC or REC/DEC switch approx. 3 sec. or more. 4. Error code is displayed in turn as follows whenever DEC switch is ON. 5. Previous error code is displayed when INC switch is ON. 6. Refer to error code table and check the trouble and cause of failure for troubleshooting.

ECBFL5019A

TROUBLESHOOTING Symptom

Probable cause

Remedy

Engine Control sys- ECU main relay does not operate Check the ECU relay and the power circuit does not tem Poor contact of the ECU or the engine Check the circuit start Disconnection of the ECU or the injector connCheck the connector connection ector ECU malfunction

Check the ECU using the Hi-Scan/ Injector compulsory test/ If necessary, replace the ECU

Starter operation malfunction

• •

Fuel system

Others

Malfunction of over flow valve

Check the opening pressure of the over flow/ If necessary, replace the over flow valve

Lack of fuel

Check the amount of fuel in the fuel tank

Fail of the fuel supply pump

Check the fuel supply pump check valve and the shaft for damage/ If necessary, replace them

Poor supply due to the fuel supply hose kink

Check the fuel intake system

Malfunction of the air heater

Check the air heater relay and the ECU

Air in fuel system

Bleed the fuel system

Malfunction of injector

Check the injector variation by acceleration test/ If necessary, replace the injector

Air in fuel system

Check the fuel line

Fail of the accelerator input signal

Check and replace the pedal sensor

Fuel leak to the combustion chamber

Check the injector tube and leak If necessary, replace the injector.

Air heater malfunction

Check the heater relay and ECU

Incorrect injection timing due to ECU damage

Check the ECU If necessary, replace the ECU

Malfunction of injector

Check the injector by acceleration test

Fail of intake pressure sensor

Check the sensor using a Hi-Scan/ Check the sensor output data

Incorrect injection timing due to ECU damage

Check the ECU If necessary, replace the ECU

Poor idle

White smoke

Black smoke

Starter switch, neutral switch, service switch circuit and operation check Immobilizer system check

Symptom

Probable cause

Low engine power outMalfunction of accel pedal put (Poor acceleration)

Remedy Check the accel pedal output data if necessary , replace the accel pedal

Check the water temperature sensor using a Hi Malfunction of water temperature sensor or en- -Scan/ Check the engine cooling system, fan and thergine overheated mostat

Low fuel pressure

Check the fuel pressure sensor using a Hi-Scan/ Check the fuel system(fuel pump, filter, over flow valve etc.)

Check the intake pressure sensor using a HiFail intake pressure sensor or abnormal intake Scan/ Check the intake system(Intercooler, intake hopressure se etc.) Freezing fuel in winter time

Check the fuel for wax and fuel condition

Electronic fan clutch inoperative

Check the fan clutch circuit Check the engine overheat using a Hi-scan

Malfunction of EGR system

Check the EGR system using a Hi-scan

Malfunction of the intake mass air flow sensor

Check the intake mass air flow sensor using a Hi-scan Check the air filter

ACCELERATION TEST

ANALYSIS OF THE TEST RESULT

•

With the engine installed to the vehicle, the injector and the combustion performance can be inspected using a Scan tool and the ECU.

-

•

Description for Acceleration Test Mode

If the figure or the graph displayed on the screen of the Hi-Scan is low relatively, a performance deterioration of injector and a poor combustion are suspected.

-

If the result value is much low than them of the other cylinders, inspect the EUI of each cylinder or replace the cylinder with a new one.

-

If necessary, collect information of the overhaul history and a compressive force test and then analysis and judge the test result.

-

Comparison of the engine power variation for each cylinder

-

Measurement of the acceleration time by accelerating the engine with the injectors stopped one by one. (Check if any acceleration.)

-

cylinder

affects

the

engine

•

At the engine idle, with one cylinder stopped the EUI injection, accelerate the engine with five cylinders. Then measure the acceleration time until the 60th times of fuel injection.

-

For each cylinder, repeat the above procedure and measure the each acceleration time.

-

Compare the measured value relatively and print the data.

•

After performing the test, the pedal is not operated properly, however, this is normal condition.If the engine is turned off and on repeatedly, the pedal operates properly.

•

Judge the test result by the relative comparison and the total average for each cylinder.

Then evaluate the engine power effect for each cylinder by the compared result. -

•

•

The average of the absolute value is affected by the engine condition(Load, coolant temperature etc.).

All the above procedures are performed in the acceleration test mode automatically and the result is displayed on the Hi-Scan with the figure and the graph.

Therefore, judge the test result by the relative comparison in priority. •

Condition of the Acceleration Test -

When engine is idling(500 rpm)

-

Engine warm-up(Coolant temperature 60°C over)

-

No engine load(Air-conditioning, mechanism etc.)

1. When the engine is idling(500 rpm), release the engine load such as air-conditioning. 2. Connect the Scan tool and check the control unit. Then select the acceleration test mode. 3. Check the message on the screen and if it is correct, press the enter key. 4. As indicated on the screen, press the accel pedal fully and press the enter key. 5. Engine will perform the acceleration test automatically 6 times. During the test, keep the accel pedal pressed fully. 6. After completing the test, the result will be displayed on the screen automatically. - After checking the result, turn off the engine.

Use this as reference material to inspect the injector and the combustion performance of the related cylinder. After overhauling the engine, be sure to perform this test to inspect cylinders operate properly.

Electrical

How to use the Scan tool

NOTICE Be sure to check the coolant temperature is 60 C over because engine warm-up can affect the result of test.

COMPRESSION TEST Inspection for the state of compressive force of the engine each cylinder using a Hi-scan and ECU on the vehicle.

EXPLANATION MODE

FOR

COMPRESSION

TEST

-

Characteristic comparison of compressive force for each cylinder

-

During engine cranking, measure the engine speed rate by the compressive resistance from the cylinder. (With the compressive force test mode, no fuel injection)

HOW TO USE HI-SCAN 1. With the engine key turned on, connect the Hi-Scan and check the control unit.

4. After completing the test, compare the engine speed rate for each cylinder by pressing the keys(F1, F2, F3..) in sequence.

Then select the compression test mode. 2. Check the message displayed on the screen, if it is correct press the enter key.

ECBFL5027A

ANALYSIS OF TEST RESULT -

After completing the test, the graph of the engine speed rate for each cylinder will be displayed on the screen of the Hi-Scan.

-

When the engine is in the normal condition, the graph tendency is almost identical.

ECBFL5025A

3. As indicated on the screen, press the key and crank the engine.

However, when a certain cylinder exhibits abnormal compressive force characteristic, the graph tendency is quite different from normal compressive force characteristic. -

ECBFL5026A

If the graph tendency is abnormal, inspect the compressive system including the piston ring and the valve to prevent a malfunction of the compressive system.

FUEL SYSTEM DRAINING 1. Clean around air vent of cylinder head side and fuel filter side.

ECBFL5028A

4) Close bolt when air has been eliminated completely in fuel discharged to fuel filter air vent 5) Unscrew air vent bolt at cylinder head front.

ECBFL5028A

1. After engine assembly/disassembly or fuel bleeding (If fuel is eliminated completely in fuel line)

6) Close cock after pumping until air is eliminated in fuel in the same way as described in the Clause 3).

1) Clean around the air vent of fuel filter and cylinder head.

7) Execute the cranking when the above works are all done.

FUEL CHARGE AND AIR BLEEDING

2) Unscrew air vent bolt on fuel filter head a little.

Crank it for the time for enough (10 to 15 sec.) and several times until engine starts.(about 3 to 5 times, if fuel has been eliminated fuel line, especially if fuel in injector is eliminated thoroughly, sufficient cranking is necessary from air discharge to start the engine) Cranking time should not exceed 15 sec. because cranking for a long time influences badly on starter motor. Keep the interval of approx. 30 sec. until the next cranking to prevent starter motor from overheating. 8) When engine starts, wait until engine becomes stable, pedaling accelerator (Approx. 1000rpm).

SGZFL9012L

3) Perform pumping works, using priming pump on fuel filter until fuel begins to drain from air vent cock.

2. When replacing a fuel filter element (If fuel is filled in cylinder head) 1) Clean the fuel filter. 2) Unscrew air vent in fuel filter and remove the pressure from fuel line. 3) Replace the filter element. •

NOTICE Check if the gasket is placed on element when replacing.

•

Apply oil to gasket and tighten it sufficiently by hand.

•

Tightening torque : 4.4±0.2 kgf.m

SDCFL8032D

4) Perform pumping until fuel drains from air vent, using priming pump.(In case of filling fuel in new cartridge before mounting, pumping time can be reduced.) 5) Close air vent bolt

SGZFL9012L

6) Perform cranking and start the engine (Air discharge of cylinder head is not necessary when replacing a filter and engine starts with just cranking once in general)

Engine Control System-Electronic Engine Control Unit(ECU) REPLACEMENT OF CONTROL ECU 1. Remove the control ECU(A).

SGZFL9013L

2. When replacing the unit injector of the control ECU, be sure to re-input the compensation value using a scan tool. CAUTION Be sure to match the compensation value indicated on the injector connector and the input data of the control ECU for the engine performance and the exhaust gas.

SGZFL9014L

Electronic Unit Injector(EUI) Components

SGZFL9015L

1. MAF sensor 2. Coolant temperature sensor 3. Intake temperature pressure sensor 4. ECU 5. Fuel temperature/ pressure sensor 6. Fuel filter 7. Priming pump 8. Crank position sensor

9. Cam position sensor 10. Injector wiring connector 11. ECU engine side connector(E65-1) 12. ECU engine side connector(E65-2) 13. ECU chassis side connector(C121) 14. EDU 15. EDU connector(E59)

Connector(E65-1)

SGZFL9023L

Connector(E65-2)

SGZFL9024L

Connector(C121)

SGZFL9025L

EDU connector(E59)

SGZFL9026L

2. Remove the injector cable.

Inspection INSPECTION COMPONENTS

OF

INJECTOR

(EUI)

[Checking condition] 1. Turn off the ignition switch. 2. Apply the parking brake. 3. Separate ECU connector and connect tester to the cable harness 4. Perform a test using a multi-meter.

Replacement REPLACEMENT OF UNIT INJECTOR CAUTION 1. Be sure to replace the injector at the service center designated by Hmc. 1. Do not operate the injector while running the engine because the injector generates the high voltage over than 50 volts. However, when the injector should be operated inevitably, be careful with an electric shock.

SGZFL9016L

3. Remove cam cap bolts. NOTICE Separate bolts in turn to prevent rocker arm shaft from bending.

2. When removing the used injector, be sure to wear the protective gloves. At the high temperature over than 315°C, the surface of the injector can be carbonized or sticky, which cause hydrofluoric acid. When removing the injector from the engine, be sure to wear protective gloves to protect the skin. 1. Remove rocker cover CAUTION Be careful for unit injector cable harness not to be damaged. ECBFL5034A

SGZFL9017L

4. Remove rocker arm tool(09245-84100).

shaft

using

the

special

8. Fix protecting sleeve after removing unit injector. 9. Insert sealing clamp into cylinder head fuel gallery. NOTICE Check if sealing clamp is inserted properly at its place. 10.Remove the sealing clamp, and then clean unit injector hole in cylinder head. 11.Replace O-ring with the new one in the unit injector and apply engine oil. Check if it is installed properly in between valve spring and tighten the unit injector mounting bolt to the specific torque.

ECBFL5035A

5. Drain fuel in cylinder head according to fuel draining procedure. CAUTION Be sure to drain the fuel in the cylinder head before removing the unit injector to prevent the fuel in the combustion chamber from inflowing. 6. Clean around the unit injector to replace. 7. Unscrew the injector clamp bolt, remove clamp and then remove the injector carefully.

CAUTION When replacing the injector, be sure to replace the O-ring with a new one. [Specific torque] When replacing other than nozzle tube (when replacing injector only) : 18 N.m(1.8 kgf.m) + 60° When replacing nozzle tube: First : 18 Nm(1.8 kgf.m) + 60° + 60° Loosen completely in 2 min. Second : 18 Nm(1.8 kgf.m) + 60° 12.Apply engine oil to the cam-shaft rob and the valve bridge and install the rocker arm shaft using the special tool(09245-84100).

CAUTION When removing the used injector, be sure to wear protective gloves.

ECBFL5035A

ECBFL5037A

13.Install the unit injector CAUTION When replacing the unit injector with a new one, be sure to consider the compensation value of trim setting code indicated on the top surface of the injector connector using a scan tool. Be sure to match the compensation value indicated on the injector connector and the input data of the control ECU for the engine performance and the exhaust gas.

SGZFL9019L

16.Install the rocker cover. 17.Perform fuel bleeding following the procedure. 18.Run the engine for about 10min at idle to bleed the air in the system.

SGZFL9014L

14.Connect cable to the unit injector. Injector pre-stroke : 0.75±0.15 mm 15.Check if rocker arm shaft is properly mounted after tightening the cam cap bolts. Adjust the clearance of the valve and the injector after tightening the cam cap bolt to the specific torque.

SGZFL9018L

Priming Pump Replacement

REPLACEMENT OF FUEL PUMP

REPLACEMENT OF FUEL FILTER

1. Unscrew air vent bolt loosely to eliminate remaining pressure in fuel pump.

1. Unscrew the air vent bolt to eliminate remaining pressure in fuel filter. 2. Clean the fuel filter around.

SGZFL9021L

2. Clean the fuel pump around. SGZFL9020L

3. Disconnect fuel line.

3. After disconnecting the fuel line, remove the mounting bolt and then detach the fuel filter.

4. Loosen fuel pump bolt and remove fuel pump.

4. Perform the fuel charge and air bleeding.

Tightening torque of fuel pump bolt: 10~12Nm(1.0~1.2kgf.m, 7.3~8.7lb-ft)

5. Start engine and run the engine at idle for about 10min to bleed air remaining in the system.

5. Apply oil to O-ring of new fuel pump and install it.

6. Install fuel line. 7. Perform fuel charge and air bleeding (up to fuel filter). 8. Start engine and run the engine at idle for about 10min to bleed air remaining in system.

Overflow Valve 4. Remove overflow valve.

Replacement 1. Clean the overflow valve around.

ECBFL5053A ECBFL5053A

2. Place container under hose of air vent hole at fuel filter head and loosen air vent bolt.

5. Clean the contact points of cylinder head and mount new overflow valve. Tightening torque of overflow valve : 40±2 Nm(4±0.2 kgf.m, 28.9±1.5 lb-ft) 6. Install fuel line and perform fuel charge and air bleeding (Refer to method if the fuel is completely eliminated from fuel line). 7. Start the engine and run the engine at idle about 10 minutes to bleed air remaining in system.

ECBFL5028A

3. Disconnect fuel line from overflow valve.

Mass Air Flow Sensor Inspection Description MAF sensor is built into the vehicle for controlling the EGR system precisely. The air flow, supplied to an engine, is measured lower than actual air flow due to contamination of MAF sensor. Then EGR system can't be controlled precisely. To prevent it in advance, you have to clean the MAF sensor periodically. Clean the MAF sensor every 6 months or 60,000 km using "Carb and Choke Cleaner".

Visual inspection

SGZFL9028L

CAUTION 1. Don't impact or drop the sensor when replacing it.

2. Don't use the sharp tool at removing the sensor, otherwise the O-ring may be damaged.

Procedure and caution when cleaning the sensor

SGZFL9029L

CAUTION 1. To remove the O-ring of MAF sensor -

Remove the O-ring of MAF sensor to prevent it from damage by cleaning spray and clean the sensor element.

3. To dry the sensor element -

Using the air gun : Below 5 bar, within 30 seconds.

-

After atomizing the spray, dry the sensor like below picture for 20 minutes.

SGZFL9030L

2. Procedure of atomizing the spray -

Atomize the spray to the end part of sensor housing.

-

Don't use the nozzle of spray to prevent the sensor element from damage.

-

Atomize the spray with 2~3 times for 2~3 seconds.

SGZFL9032L

4. To install the O-ring of MAF sensor -

Install the O-ring after completing to dry the sensor.

SGZFL9030L

SGZFL9031L

Fuel Delivery System-Electronic Accelerator Pedal Replacement Accelerator pedal(Bus) 1. Turn the ignition key off and disconnect battery negative(-) cable. 2. Remove the accelerator sensor connector. 3. Remove the accelerator pedal assembly(A) after removing accelerator pedal mounting bolt.

ECBFL5062A

4. Installation is in the reverse of removal. Tightening torque: 18.6~ 27.5 Nm (1.9~2.8 kgf.m, 13.7~20.3 Ib-ft)

Fuel Tank Components

SGZFL9022L

1. Fuel tank 2. Air compressor

3. Fuel pre-filter 4. Fuel pump

Replacement Fuel tank 1. Park the vehicle on a flat road surface and stop the engine. Disconnect battery negative(-) cable. 2. Remove the sender connector on the upper of the fuel tank. 3. Remove return hose and feed hose. 4. Remove the fuel hose connecting to the fuel tank. 5. Support the fuel tank assembly with a jack and loosen the fuel tank bracket of lower part and the band mounting nut. And remove the fuel tank. 6. Installation is in the reverse of removal. NOTICE When installing fuel cap rotor to fuel cap holder, turn the ignition key clockwise 15˚ or so with it pressed after inserting the ignition key into fuel cap rotor(A). After installed, repeat to lock and unlock the ignition key five times so that grease is spread evenly.

DTC Troubleshooting Diagnostic Trouble Codes [DTCs] No

DTC

Description

1

P0016

Camshaft - Crankshaft position Correlation

2

P0017

Crankshaft - Camshaft Position Correlation

3

P0072

Ambient Air Temperature Sensor Circuit Low

4

P0073

Ambient Air Temperature Sensor Circuit High

5

P0102

Mass or Volume Air Flow Circuit Low Input

6

P0103

Mass or Volume Air Flow Circuit High Input

7

P0107

Manifold Absolute Pressure Circuit Low Input

8

P0108

Manifold Absolute Pressure Circuit High Input

9

P0112

Intake Air Temperature Sensor Circuit Low

10

P0113

Intake Air Temperature Sensor Circuit High

11

P0117

Engine Coolant Temperature Sensor Circuit Low

12

P0118

Engine Coolant Temperature Sensor Circuit High

13

P0182

Fuel Temperature Sensor Circuit Low

14

P0183

Fuel Temperature Sensor Circuit High

15

P0217

Engine Coolant Over Temperature Condition

16

P0335

Crankshaft Position Sensor Circuit

17

P0340

Camshaft Position Sensor Circuit

18

P0401

Exhaust Gas Recirculation Flow Insufficient Detected

19

P0402

Exhaust Gas Recirculation Flow Excessive Detected

20

P0475

Exhaust Brake, Open Circuit

21

P0480

Fan 1 Control Circuit

22

P0481

Fan 2 Control Circuit

23

P0500

Vehicle Speed Sensor

24

P0541

Intake Air Heater Circuit Low

25

P0542

Intake Air Heater Circuit High

26

P0543

Intake Air Heater Circuit Open

27

P0562

System Voltage Low

28

P0563

System Voltage High

29

P0601

Internal Control Module Memory Check Sum Error

30

P0611

Fuel Injector Control Module Performance

31

P0615

Starter Relay Circuit Open

32

P0616

Starter Relay Circuit Low

33

P0617

Starter Relay Circuit High

No

DTC

Description

34

P0642

Sensor 5V Reference Under Range

35

P0643

Sensor 5V Reference Over Range

36

P0652

Pedal Sensor Reference Voltage Circuit Low

37

P0653

Pedal Sensor Reference Voltage Circuit High

38

P0668

ECU Internal Temperature Sensor Circuit Low

39

P0669

ECU Internal Temperature Sensor Circuit High

40

P0685

ECU Power Relay Control Circuit /Open

41

P0691

Fan 1 Control Circuit Low

42

P0692

Fan 1 Control Circuit High

43

P0693

Fan 2 Control Circuit Low

44

P0694

Fan 2 Control Circuit High

45

P1087

Fuel Pressure Derate Level 1

46

P1088

Fuel Pressure Derate Level 2

47

P1089

Fuel Pressure Derate Level 3

48

P1106

Air Plausibility Fault

49

P1201

Injector 1 needle valve open circuit

50

P1202

Injector 1 needle valve short circuit across injector

51

P1203

Injector 1 needle valve low side short circuit to ground

52

P1204

Injector 1 needle valve low side short circuit to battery voltage

53

P1205

Injector 2 needle valve open circuit

54

P1206

Injector 2 needle valve short circuit across injector

55

P1207

Injector 2 needle valve low side short circuit to ground

56

P1208

Injector 2 needle valve low side short circuit to battery voltage

57

P1209

Injector 3 needle valve open circuit

58

P1210

Injector 3 needle valve short circuit across injector

59

P1211

Injector 3 needle valve low side short circuit to ground

60

P1212

Injector 3 needle valve low side short circuit to battery voltage

61

P1213

Injector 4 needle valve open circuit

62

P1214

Injector 4 needle valve short circuit across injector

63

P1215

Injector 4 needle valve low side short circuit to ground

64

P1216

Injector 4 needle valve low side short circuit to battery voltage

65

P1217

Injector 5 needle valve open circuit

66

P1218

Injector 5 needle valve short circuit across injector

67

P1219

Injector 5 needle valve low side short circuit to ground

68

P1220

Injector 5 needle valve low side short circuit to battery voltage

No

DTC

Description

69

P1221

Injector 6 needle valve open circuit

70

P1222

Injector 6 needle valve short circuit across injector

71

P1223

Injector 6 needle valve low side short circuit to ground

72

P1224

Injector 6 needle valve low side short circuit to battery voltage

73

P1225

Injector 1, 3, or 5 needle valve high side short circuit to ground

74

P1226

Injector 1, 3, or 5 needle valve high side short circuit to battery voltage

75

P1227

Injector 2, 4, or 6 needle valve high side short circuit to ground

76

P1228

Injector 2, 4, or 6 needle valve high side short circuit to battery voltage

77

P1229

Injector 1 spill valve open circuit

78

P1230

Injector 1 spill valve short circuit across injector

79

P1231

Injector 1 spill valve low side short circuit to ground

80

P1232

Injector 1 spill valve low side short circuit to battery voltage

81

P1233

Injector 2 spill valve open circuit

82

P1234

Injector 2 spill valve short circuit across injector

83

P1235

Injector 2 spill valve low side short circuit to ground

84

P1236

Injector 2 spill valve low side short circuit to battery voltage

85

P1237

Injector 3 spill valve open circuit

86

P1238

Injector 3 spill valve short circuit across injector

87

P1239

Injector 3 spill valve low side short circuit to ground

88

P1240

Injector 3 spill valve low side short circuit to battery voltage

89

P1241

Injector 4 spill valve open circuit

90

P1242

Injector 4 spill valve short circuit across injector

91

P1243

Injector 4 spill valve low side short circuit to ground

92

P1244

Injector 4 spill valve low side short circuit to battery voltage

93

P1245

Injector 5 spill valve open circuit

94

P1246

Injector 5 spill valve short circuit across injector

95

P1247

Injector 5 spill valve low side short circuit to ground

96

P1248

Injector 5 spill valve low side short circuit to battery voltage

97

P1249

Injector 6 spill valve open circuit

98

P1250

Injector 6 spill valve short circuit across injector

99

P1251

Injector 6 spill valve low side short circuit to ground

100

P1252

Injector 6 spill valve low side short circuit to battery voltage

101

P1253

Injector 1, 3, or 5 spill valve high side short circuit to ground

102

P1254

Injector 1, 3, or 5 spill valve high side short circuit to battery voltage

103

P1255

Injector 2, 4, or 6 spill valve high side short circuit to ground

No

DTC

Description

104

P1256

Injector 2, 4, or 6 spill valve high side short circuit to battery voltage

105

P1403

EGR EDU power-up sequence.

106

P1562

The battery voltage is too high

107

P1653

Check Engine/Diagnostics Lamp, open circuit

108

P1654

Check Engine/Diagnostics Lamp, shortcut to ground

109

P1655

Check Engine/Diagnostics Lamp, shortcut to battery

110

P1656

Engine Hot Lamp Output Control Circuit

111

P1657

Engine Hot Lamp, shortcut to battery

112

P1658

Engine Hot Lamp, shortcut to ground

113

P1666

Fault on the hardware watchdog

114

P1680

Memory fault with customer data checksum

115

P1681

Memory fault with calibration data checksum

116

P1700

Engine brake 1, open circuit

117

P1701

Engine brake 2, open circuit

118

P1702

Engine brake 3, open circuit

119

P2109

Pedal Position Sensor Minimum Stop Performance

120

P2110

Pedal Position Sensor Maximum Stop Performance

121

P2147

Injector boost voltage under range

122

P2148

Injector boost voltage over range

123

P2228

Barometric pressure circuit low

124

P2229

Barometric pressure circuit high

125

P2541

Low Pressure Fuel System Sensor circuit Low

126

P2542

Low Pressure Fuel System Sensor circuit High

127

P2609

Intake Air Heater System Performance

128

U1169

EGR Valve Stick Fault

129

U1170

EGR Actuator Terminal Coil Open Circuit

130

U1171

EGR Actuator Over Current

131

U1180

EGR Actuator Battery Supply Error

132

U1182

EGR Valve Position Error

133

U1183

EGR Message Transmit Fault Error