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 Type Maximum supply pressure Driving Control unit Voltage Connector Unit injector(Solenoid Voltage valve) Resistance(at 20C) Coolant temperature Voltage sensor and Gauge unit Operating range Connector Intake pressure temp- Voltage erature sensor Operating range Specifications Inner contact gear type 7kgf.cm Air compressor shaft driving 24V 62 pin x 3 90V 1.665%(5V), 1.405%(NCV) 5V -40C~130C 3 pin 5V Temperature Pressure (Absolute) Connector Crank shaft and Cam- Resistance shaft position sensor Operating range Connector Air gap Fuel pressure temper- Voltage ature sensor Operating range -40C~125C 32.5~284 kPa(0.33~2.9kgf.cm) 4 pin 860 10% 40~3,000 r/min 2 pin 1.0~2.0 mm 5V Temperature Pressure Connector -40C~130C 0~1000 kPa(0~10kgf.cm) 4 pin

SERVICE STANDARDS
Item Electric injector Opening pressure Injection pressure Idle rotation speed(RPM) Overflow valve opening pressure Cam shaft position sensor air gap Crank shaft position sensor air gap Fuel pump discharge amount 500rpm 1900rpm Standard value Min. 260 bar Max. 2,000 bar 500 20 rpm 4.0 bar or higher 1.0~2.0 mm 1.0~2.0 mm 4 bar(1 /min or more) 7 bar(7 /min or more)

TIGHTENING TORQUE
Tightening torque Item N.m Overflow valve Pipe quick connector Eye bolt(Overflow valve side) Fuel filter mounting bolt LH-Cover mounting bolt(ECU side) ECU wiring cover mounting bolt Fuel return hose mounting bolt(M6) Fuel return hose mounting bolt(M10) ECU mounting bracket attaching bolt ECU mounting flange bolt Intake pressure temperature sensor Camshaft position sensor Crankshaft position sensor Fuel pump mounting bolt 33 ~ 39 27.4 ~ 29.4 29.4 ~ 34.3 34.3 ~ 44.1 4.9 ~ 7.8 7.8 ~ 9.8 6.9 ~ 10.8 14.7 ~ 19.6 34 ~ 54 19 ~ 27 5~6 8 ~ 10 8 ~ 10 10 ~ 12 kgf.m 3.4 ~ 4.0 2.8 ~ 3 3 ~ 3.5 3.5 ~ 4.5 0.5 ~ 0.8 0.8 ~ 1 0.7 ~ 1.1 1.5 ~ 2 3.5 ~ 4.5 2 ~ 2.5 0.5 ~ 0.6 0.8 ~ 1.0 0.8 ~ 1.0 1.0 ~ 1.2 lb-ft 24.7 ~ 29.1 20.2 ~ 21.6 21.6 ~ 25.2 25.2 ~ 32.4 3.6 ~ 5.8 5.8 ~ 7.2 5 ~ 7.9 10.8 ~ 14.4 25.5 ~ 40.0 13.8 ~ 20.4 3.6 ~ 4.4 5.8 ~ 7.3 5.8 ~ 7.3 5.8 ~ 8.7

SPECIAL SERVICE TOOL

Tool Rocker arm shaft setting 09245-84100 Shape Use 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

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.

Operating Theory of Unit Injector

1. Fuel intake 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 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.

SGZFL9003L

CONTROL UNIT AND SENSOR

SGZFL9027L

1. 2. 3. 4. 5.

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

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

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)

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 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.

3. Vehicle control function 1) Cruise vehicle speed control 1. Function: Drives specified speed. 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. e. When vehicle speed is 40 km/h or higher. 3. Releasing condition a. Releasing of cruise control switch b. Brake and clutch pedal are pressed 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. 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

the

vehicle

within

the

4. Idle adjustment at cold start 7) Manual adjustment of idle Idle adjustment can be manually using self-diagnostic switch mounted to driver seat. For the manual adjustment of the idle, following conditions should be met. a. Vehicle should be stopped securely. 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

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 1. Pedal sensor 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 When fuel amount is more than the setup value When engine rotations are higher than the setup value When coolant temperature is higher than the setup value

When PTO is not operating When vehicle speed is zero When clutch is not operating

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 b. When the vehicle speed is lower than selective setup value (10km/h in general and engine running state) c. When PTO is adjustable from the driver seat or outside of the vehicle

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

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 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. ECU calculates the location and speed of engine, using generated pulse signal and controls fuel injection time and amount on the basis of them. 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 120Camshaft 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
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. Priming pump mounting torque: 27~29Nm(2.8~3kgf.m, 20.4~21.8lb-ft)

FUEL FILTER
Fuel filter is spin-on type so that the element replacement is easy. 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: 402 Nm(40.2 kgf.m, 28.91.5 lb-ft)

SGZFL9010L

EXTERNAL WIRING DIAGRAM OF UNIT INJECTOR (ECU)

SGZFL9011L

Troubleshooting
SELF-DIAGNOSIS
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. NOTICE The scan tool can erase the diagnostic trouble codesin the memory only.

USING HI-SCAN TOOL

1. Turn OFF the ignition switch. 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 codes in memory only. It is possible to erase the DTC codes only with key ON without starting the engine.

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.

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 Starter operation malfunction Check the ECU using the Hi-Scan/ Injector compulsory test/ If necessary, replace the ECU Fuel system Malfunction of over flow valve Lack of fuel Fail of the fuel supply pump Poor supply due to the fuel supply hose kink Others Malfunction of the air heater Air in fuel system Poor idle Malfunction of injector Air in fuel system Fail of the accelerator input signal White smoke Fuel leak to the combustion chamber Air heater malfunction Incorrect injection timing due to ECU damage Black smoke Malfunction of injector Fail of intake pressure sensor Incorrect injection timing due to ECU damage Starter switch, neutral switch, service switch circuit and operation check Immobilizer system check

Check the opening pressure of the over flow/ If necessary, replace the over flow valve Check the amount of fuel in the fuel tank Check the fuel supply pump check valve and the shaft for damage/ If necessary, replace them Check the fuel intake system Check the air heater relay and the ECU Bleed the fuel system Check the injector variation by acceleration test/ If necessary, replace the injector Check the fuel line Check and replace the pedal sensor Check the injector tube and leak If necessary, replace the injector. Check the heater relay and ECU Check the ECU If necessary, replace the ECU Check the injector by acceleration test Check the sensor using a Hi-Scan/ Check the sensor output data Check the ECU If necessary, replace the ECU

Symptom

Probable cause

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

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

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

Low fuel pressure

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 Electronic fan clutch inoperative Malfunction of EGR system Malfunction of the intake mass air flow sensor Check the fuel for wax and fuel condition Check the fan clutch circuit Check the engine overheat using a Hi-scan Check the EGR system using a Hi-scan Check the intake mass air flow sensor using a Hi-scan Check the air filter

ACCELERATION TEST
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 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

ANALYSIS OF THE TEST RESULT

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. NOTICE Be sure to check the coolant temperature is 60 C over because engine warm-up can affect the result of test. 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. The average of the absolute value is affected by the engine condition(Load, coolant temperature etc.). Therefore, judge the test result by the relative comparison in priority. 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.

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

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. When engine is idling(500 rpm) Engine warm-up(Coolant temperature 60C over) No engine load(Air-conditioning, mechanism etc.) Electrical

Condition of the Acceleration Test -

How to use the Scan tool 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.

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

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

ECBFL5027A

ANALYSIS OF TEST RESULT

ECBFL5025A

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

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

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.

ECBFL5026A

FUEL SYSTEM DRAINING

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

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

ECBFL5028A

FUEL CHARGE AND AIR BLEEDING

1. After engine assembly/disassembly or fuel bleeding (If fuel is eliminated completely in fuel line) 1) Clean around the air vent of fuel filter and cylinder head. 2) Unscrew air vent bolt on fuel filter head a little.

6) Close cock after pumping until air is eliminated in fuel in the same way as described in the Clause 3). 7) Execute the cranking when the above works are all done. 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 : 4.40.2 kgf.m

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)

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

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

Inspection
INSPECTION COMPONENTS
[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.

2. Remove the injector cable.

OF

INJECTOR

(EUI)

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. 2. When removing the used injector, be sure to wear the protective gloves. At the high temperature over than 315C, 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

SGZFL9016L

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

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. 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).

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

REPLACEMENT OF FUEL PUMP

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

SGZFL9021L

2. Clean the fuel pump around.

SGZFL9020L

3. Disconnect fuel line. 4. Loosen fuel pump bolt and remove fuel pump. 5. Apply oil to O-ring of new fuel pump and install it. Tightening torque of fuel pump bolt: 10~12Nm(1.0~1.2kgf.m, 7.3~8.7lb-ft) 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.

3. After disconnecting the fuel line, remove the mounting bolt and then detach the fuel filter. 4. Perform the fuel charge and air bleeding. 5. Start engine and run the engine at idle for about 10min to bleed air remaining in the system.

Overflow Valve
Replacement
1. Clean the overflow valve around. 4. Remove overflow valve.

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 : 402 Nm(40.2 kgf.m, 28.91.5 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 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 DTC P0016 P0017 P0072 P0073 P0102 P0103 P0107 P0108 P0112 P0113 P0117 P0118 P0182 P0183 P0217 P0335 P0340 P0401 P0402 P0475 P0480 P0481 P0500 P0541 P0542 P0543 P0562 P0563 P0601 P0611 P0615 P0616 P0617 Description Camshaft - Crankshaft position Correlation Crankshaft - Camshaft Position Correlation Ambient Air Temperature Sensor Circuit Low Ambient Air Temperature Sensor Circuit High Mass or Volume Air Flow Circuit Low Input Mass or Volume Air Flow Circuit High Input Manifold Absolute Pressure Circuit Low Input Manifold Absolute Pressure Circuit High Input Intake Air Temperature Sensor Circuit Low Intake Air Temperature Sensor Circuit High Engine Coolant Temperature Sensor Circuit Low Engine Coolant Temperature Sensor Circuit High Fuel Temperature Sensor Circuit Low Fuel Temperature Sensor Circuit High Engine Coolant Over Temperature Condition Crankshaft Position Sensor Circuit Camshaft Position Sensor Circuit Exhaust Gas Recirculation Flow Insufficient Detected Exhaust Gas Recirculation Flow Excessive Detected Exhaust Brake, Open Circuit Fan 1 Control Circuit Fan 2 Control Circuit Vehicle Speed Sensor Intake Air Heater Circuit Low Intake Air Heater Circuit High Intake Air Heater Circuit Open System Voltage Low System Voltage High Internal Control Module Memory Check Sum Error Fuel Injector Control Module Performance Starter Relay Circuit Open Starter Relay Circuit Low Starter Relay Circuit High

No 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68

DTC P0642 P0643 P0652 P0653 P0668 P0669 P0685 P0691 P0692 P0693 P0694 P1087 P1088 P1089 P1106 P1201 P1202 P1203 P1204 P1205 P1206 P1207 P1208 P1209 P1210 P1211 P1212 P1213 P1214 P1215 P1216 P1217 P1218 P1219 P1220 Sensor 5V Reference Under Range Sensor 5V Reference Over Range

Description

Pedal Sensor Reference Voltage Circuit Low Pedal Sensor Reference Voltage Circuit High ECU Internal Temperature Sensor Circuit Low ECU Internal Temperature Sensor Circuit High ECU Power Relay Control Circuit /Open Fan 1 Control Circuit Low Fan 1 Control Circuit High Fan 2 Control Circuit Low Fan 2 Control Circuit High Fuel Pressure Derate Level 1 Fuel Pressure Derate Level 2 Fuel Pressure Derate Level 3 Air Plausibility Fault Injector 1 needle valve open circuit Injector 1 needle valve short circuit across injector Injector 1 needle valve low side short circuit to ground Injector 1 needle valve low side short circuit to battery voltage Injector 2 needle valve open circuit Injector 2 needle valve short circuit across injector Injector 2 needle valve low side short circuit to ground Injector 2 needle valve low side short circuit to battery voltage Injector 3 needle valve open circuit Injector 3 needle valve short circuit across injector Injector 3 needle valve low side short circuit to ground Injector 3 needle valve low side short circuit to battery voltage Injector 4 needle valve open circuit Injector 4 needle valve short circuit across injector Injector 4 needle valve low side short circuit to ground Injector 4 needle valve low side short circuit to battery voltage Injector 5 needle valve open circuit Injector 5 needle valve short circuit across injector Injector 5 needle valve low side short circuit to ground Injector 5 needle valve low side short circuit to battery voltage

No 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103

DTC P1221 P1222 P1223 P1224 P1225 P1226 P1227 P1228 P1229 P1230 P1231 P1232 P1233 P1234 P1235 P1236 P1237 P1238 P1239 P1240 P1241 P1242 P1243 P1244 P1245 P1246 P1247 P1248 P1249 P1250 P1251 P1252 P1253 P1254 P1255 Injector 6 needle valve open circuit

Description

Injector 6 needle valve short circuit across injector Injector 6 needle valve low side short circuit to ground Injector 6 needle valve low side short circuit to battery voltage Injector 1, 3, or 5 needle valve high side short circuit to ground Injector 1, 3, or 5 needle valve high side short circuit to battery voltage Injector 2, 4, or 6 needle valve high side short circuit to ground Injector 2, 4, or 6 needle valve high side short circuit to battery voltage Injector 1 spill valve open circuit Injector 1 spill valve short circuit across injector Injector 1 spill valve low side short circuit to ground Injector 1 spill valve low side short circuit to battery voltage Injector 2 spill valve open circuit Injector 2 spill valve short circuit across injector Injector 2 spill valve low side short circuit to ground Injector 2 spill valve low side short circuit to battery voltage Injector 3 spill valve open circuit Injector 3 spill valve short circuit across injector Injector 3 spill valve low side short circuit to ground Injector 3 spill valve low side short circuit to battery voltage Injector 4 spill valve open circuit Injector 4 spill valve short circuit across injector Injector 4 spill valve low side short circuit to ground Injector 4 spill valve low side short circuit to battery voltage Injector 5 spill valve open circuit Injector 5 spill valve short circuit across injector Injector 5 spill valve low side short circuit to ground Injector 5 spill valve low side short circuit to battery voltage Injector 6 spill valve open circuit Injector 6 spill valve short circuit across injector Injector 6 spill valve low side short circuit to ground Injector 6 spill valve low side short circuit to battery voltage Injector 1, 3, or 5 spill valve high side short circuit to ground Injector 1, 3, or 5 spill valve high side short circuit to battery voltage Injector 2, 4, or 6 spill valve high side short circuit to ground

No 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133

DTC P1256 P1403 P1562 P1653 P1654 P1655 P1656 P1657 P1658 P1666 P1680 P1681 P1700 P1701 P1702 P2109 P2110 P2147 P2148 P2228 P2229 P2541 P2542 P2609 U1169 U1170 U1171 U1180 U1182 U1183

Description Injector 2, 4, or 6 spill valve high side short circuit to battery voltage EGR EDU power-up sequence. The battery voltage is too high Check Engine/Diagnostics Lamp, open circuit Check Engine/Diagnostics Lamp, shortcut to ground Check Engine/Diagnostics Lamp, shortcut to battery Engine Hot Lamp Output Control Circuit Engine Hot Lamp, shortcut to battery Engine Hot Lamp, shortcut to ground Fault on the hardware watchdog Memory fault with customer data checksum Memory fault with calibration data checksum Engine brake 1, open circuit Engine brake 2, open circuit Engine brake 3, open circuit Pedal Position Sensor Minimum Stop Performance Pedal Position Sensor Maximum Stop Performance Injector boost voltage under range Injector boost voltage over range Barometric pressure circuit low Barometric pressure circuit high Low Pressure Fuel System Sensor circuit Low Low Pressure Fuel System Sensor circuit High Intake Air Heater System Performance EGR Valve Stick Fault EGR Actuator Terminal Coil Open Circuit EGR Actuator Over Current EGR Actuator Battery Supply Error EGR Valve Position Error EGR Message Transmit Fault Error