Hyundai D6GA Fuel System

General TROUBLESHOOTING It em s Engine does not crank.

Po s s i b l e c au s es Low cranking speed

Remed y Repair Repair the starter or charge charge or replace battery.

Low Low volt voltag age e to glow glow plug plug syst system em

If the the test test light light turn turns s on indi indica catin ting g low low vovoltage when it turns “ON”, check relay and wiring.

Defective glow plug

Replace the glow plug.

Air in the fuel system

Air bleeding bleeding of fuel system

Injection pipe pipe is connected connected incomple incompletely. tely. Connect Connect the pipe pipe correctly correctly Improper injection timing

Check ECM.

Poor injection

Check, replace injector.

Mecha echan nica ical defec efectt of engin ngine e

Test Test com compres pressi sion on,, repa repair ir engi engine ne..

Simultaneous failures of TDC sensor and Check and tighten correctly. CKP sensor Idle is improper or idle speed is u- Loose fuel hose connection between filtTighten or repair. nstable or irregular. irregular. er and supply pump. Air in the fuel system


Fuel filter is clogged. Or fuel supply is no Check hose or fuel line. Replace fuel filtgood because fuel line or injection pipe l- er if necessary. eaks, pinched or pressed.

Exhaus Exhaustt gas (Black, (Black, blue, blue, white) white)

Poor injection

Check, replace injector.

Improper injection timing

Check ECM.



Defective supply pump

Let the engine engine at idle after after replaci replacing ng pump.

Engi Engine ne defe defect ct at high high gear gear rang range e

Obse Observ rve e corr correc ectt shift shift spee speed. d.

Defective EGR valve

Check or replace EGR valve.

Engine Engine tempera temperature ture stays stays below below engine engine Check cooling system. Replace thermosoperating temperature. tat. Abnormal Abnormal at max. RPM

Check and replace replace supply pump.

Defec fectiv tive Inje Injec ctio tion nozzle zzle

Check and repair or replac lace.


Check ECM.

Exh Exhaust aust syst system em malfu alfunc ncti tion on

Chec Check k for for defo deform rme ed or clog clogge ged d.




Replace supply pump.

Defective EGR valve

Check or replace EGR valve.

It em s

Po s s i b l e c au s es

Engine lacks power, acceleration i- Abnormal Abnormal at max. RPM s delayed(Speedometer is normal, Con Contam tamina inated ted air air clea cleane nerr filt filter er no clutch slip) Fuel filter is clogged. Or fuel supply is no good because fuel line or injection pipe leaks, pinched or pressed.Or fuel filter leaks.

Exce Excess ssiv ive e fue fuel con consum sumptio ption n

Remed y Check, replace supply pump. Clea Clean n or rep replace lace.. Check hose or fuel line. Replace fuel filter if necessary.

Air in fuel system


Defective supply nozzle

Check, repair or replace.


Check ECM.



Defective injection ion pump

Check after replacing pump.

Abnormal Abnormal EGR valve

Check, replace EGR valve.

Con Contam tamina inated ted air air clea cleane nerr filt filte er

Clea Clean n, repl replac ace e air air clea cleane nerr filt filte er.

Fuel leaks

Check all pipes, hoses and connection. Replace or tighten as required.

Clog logged ged retu return rn pipe pipe and and hose hose..

Che Check and and rep replace lace the the retu return rn line line,, blow low air if clogged and drain the fuel.

Defective ive injection ion nozzle

Check. Repair or replace.


Com Compres pressi sio on test test,, repl repla ace engin ngine e.


Replace pump.

Defective EGR valve

Check or replce EGR valve.

ENGINE CONTROL Tr o u b l e Engine will not turn off.


Remed y

Injector wiring short

Check injector wiring.

Starti Starting ng switch switch harn harnes ess s is dama damage ged. d.

Repla Replace ce..

ENGINE STARTING SYSTEM Tr o u b l es Engine does not crank

Po s s i b l e c au s es Low battery voltage

Remed y Recharge or replace the battery.

Battery cable connection is loose, corroRepalce or retighten. retighten. ded or worn.

Cranking speed is low

Fusible link is swelled.

Replace the fusible link.

Defective starter motor.

Repair.

Defective injector

Repalce.

Low battery voltage

Recharge or replace the battery.

Battery cable connection is loose, corroRepair or replace. ded or worn

Starter motor continues to run.

Defective starter motor

Repair

Defective starter motor

Repair

Defective ive igniti ition switch tch

Replac lace the the ignitio tion switch.

Starter motor runs but engine is n- Defective wiring ot cranking. Starte Starterr motor motor,, pinio pinion n gear gear dama damage ged d Ring gear damaged

Repair wiring. Repa Repair ir starte starterr moto motor. r. Replace flywheel flywheel or torque converter converter gear.

FUEL TANK AND FUEL LINE Tr o u b l es


Poor engine performance due to i- Fuel pipe ipe is twis twiste ted d or broken nsufficient fuel supply Fuel pipe or hose is clogged

Remed y Repair or replac lace. Clean or replac lace.

Fuel filter is clogged

Replace.

Entry try of water ter to fue fuel filt filte er

Replace lace fue fuel filt filte er or clea lean fue fuel tan tank or fuel line.

Foreign materials intrude in fuel tank. FClean or replace. replace. uel tank rusts. Defective supply pump operation (Clogged filter in pump)

Replace.

Fuel Fuel filte filterr warn warnin ing g lam lamp blin blinks ks..

Exce Excess ssiv ive e wate waterr is in fuel fuel filte filter. r.

Drai Drain n the the wate waterr colle collect cted ed in the the fuel fuel filte filter r (Loosen the drain plug at the bottom of fuel filter..)

Engine check lamps blinks.

Clogged fuel filter.

Replace fuel filter.

TROUBLESHOOTING PROCEDURE

SDGFL9001L

SDGFL9002L

SDGFL9003L

SDGFL9004L

SERVICE PROCEDURE Communication with diagnosis equipment is not possible (Impossilbe (Impossilbe communication communication with all systems

SDGFL9005L

When communication between diagnosis equipment and ECM is not possible Tr o u b l e s y mp t o ms It shows at least one of the following symptoms. When power is not supplied to ECM . ECM ground circuit is defective ECM Defective ECM Wrong communication line between ECU and Hi-scan

Pr o b abl e c au s es Power supply circuit to ECM is defective.ECM Defective ECM Circuit between ECU and DLC is open.

Engine does not start.

SDGFL9006L

It is difficult to start the engine. (Possible cranking)

SDGFL9007L

Unstable idle or engine stall.

SDGFL9008L

Engine hesitation or poor acceleration

SDGFL9009L

Troubleshoo Troubleshooting ting flow chart when HUNTING(fluctua HUNTING(fluctuation) tion) occurs

SDGFL9010L

Trou Trouble blesh shoo ootin ting g flow flow char chartt when when FCCB FCCB(F (Fue uell contr control ol cylinder balance) fails.

SDGFL9011L

Troubleshooting flow chart when engine is lack of power

SDGFL9012L

Trouble Troublesho shootin oting g flow chart chart in systems systems of sensor sensors s and wirings

SDGFL9013L

CRS RAIL PRESSURE CHECK ■Items

to check in the vehicle

7. Visual check of connector connector

1. Check for customer customer complaint complaint and trouble trouble symptoms. symptoms.

Chec Check k each each term termin inal al contac contactt part part of rail rail pres pressu sure re sensor for wear.

2. Check Check reoccur reoccurren rence ce or not for custom customer er compla complaint int and trouble symptoms mentioned above.

Check connector housing of rail pressure sensor for wear.

3. Record Record DTC codes codes or record the detailed detailed DTC codes codes by using Hi-scan.

Check locking part/ guide part of rail pressure sensor connector for damage or deformation.

Inspect and repair causes due to DTC codes. 4. Chec Check k rail rail pres pressu sure re when when turn turnin ing g igni igniti tion on key key to NO(Engine OFF). If the rail pressure is displayed, check it according to inspection procedure of remaining pressure. 5. Check for connecto connectorr of rail pressure pressure sensor. sensor. Chec Check k for for wiri wiring ng tens tensio ion n betw betwee een n rail rail pres pressu sure re sensor and connector of vehicle side. Check Check that that wiring wiring between between rail pressu pressure re sensor sensor and con connect nector or of veh vehicle icle side side is tigh tightt or not not due to vibration(under driving) with interference in bracket of engine/vehicle etc. Check rail pressure sensor wire for clamp conditoin. Chec Check k that that wire wire of rail rail pres pressu sure re senor senor is clamp clamped ed securely or not. Check rail pressure sensor and connector of vehicle side for connection conditon. With With conn connec ector tor conn connect ected ed,, chec check k conn connec ector tor for shaking(with right and left/ back and forth). If the there is fre free play, lay, check for for outpu tput of rail rail pres pressu sure re/r /rai aill pres pressu sure re sens sensor or usin using g Hi-s Hi-sca can n or oscilloscope. 6. Check Check for wiring wiring related related to the the output output of rail press pressure ure sensor. Chec Check k for for volt voltag age e betw betwee een n each each term termin inal al of rail rail pressure sensor in the ECM side and terminal (-) of battery. Check Check wire between between rail pressu pressure re sensor sensor and ECM for continuity(resistance).

Check the inside of rail pressure sensor connector for fore foreign ign mater material ials(s s(suc uch h signs signs as wate water, r, oil, oil, spar spark, k, tracking etc.). Check Check the opposite opposite connec connector tor for foreign foreign materia materials, ls, wear wear,, dama damage ge,, exist existen ence ce or not not of rubb rubber er seal seal or shrinkage of rubber seal etc..

SDGFL9014L

Rail Rail pressure sensor terminal

It em em

Pi n No .

Vc

E68

Vout

E32

Vout

E13

GND

E25

Ch ec k c o n d i t io io n

Voltage check

Check Check wiring between between rail pres sure sensor and ECM ECM

Measured ECM ECM terminal side re - value noise ference value or not no t

Reference Reference value/me - Measured ausred condition value

Key On

4.9~5.1

Below 2[ohm]/Key Off

Key On/EngineOff

0.9~1.1


Engine On/at Accel.

Refer to ill illustratio tion 3

Below 2[ohm]/Ke /Key Off

Key On/Engine Off

0.9~1.1


Engine On/at Accel.

Refer to ill illustratio tion 3

Below 2[ohm]/Ke /Key Off

Key On

0±0.1


CRS RAIL PRESSURE CHECK FLOW CHART

SDGFL9015L

Fuel system check processor

SDGFL9016L

Troubleshooting flow chart when the engine stops

SDGFL9017L

SDGFL9018L

SDGFL9019L

SDGFL9020L

SPECIFICATIONS It ems Sensors

BPS(Booster pressure sensor)

Sp ec i f i c at i o n Supply voltage

5V

Operating voltage

0.5~4.5V

Operating temperature

IAT(Intake air temperature)

-40~125°C

Operating pressure

50 ~500kpa

Current

Below 10mA

Type

Thermistor

Resistance

2.31~2.56kΩ [At 20°C(68°F)] 0.30~0.34kΩ [At 80°C(176°F]

WTS(Water temperature sensor)

Type

Thermistor

Resistance

2.31~2.59kΩ [At 20°C(68°F)] 0.314~0.331kΩ [At 80°C(176°F)]

TDC(Top dead center) sensor

Type

Hall sensor

CKP(Crankshaft positon sensor)

Type

Magnetic

APS(Accel APS(Accel positon sensor) sensor)

Actuator Actuator

Supply control valve

Variable resistance(Potentiometer)

Type Voltage

5V ± 1%

Current

Max. 10 mA

Fuel pressure sensor

Type

Piezo electricity

Injector

Type

Electromagne Electromagnetic tic

Resistance

0.45Ω

Current

Active : Below 1.29A

SCV

When stopped :Below 1.16A Fuel tank Fuel pressure of high pressure side Supply pump

Fuel filter

Capacity

100L

Max. pressure

1,800bar

Type

Included Included into high pressure pressure pump mechanical type

Power

Mechanical gear type

Type

Filter

EGR VALVE SPECIFICATION It ems

Sp ec i f i c at i o n

Valve type

Flap type

Control type

Electric DC motor

SEALANT Water temperature temperature sensor(Coola sensor(Coolant nt temperature temperature sensor) sensor)

Loctite 200 or equivalent equivalent

INSPECTION It ems Idle speed(rpm)

N-Range

D-Range

Ref er en c e v al u e

A/Con OFF

600rpm

A/Con ON (A/Con switch ON)

700rpm 700rpm

A/Con OFF

600rpm

A/Con ON (A/Con compressor compressor relay ON)

700rpm 700rpm

TIGHTENING TORQUE It ems

K g f .m

N.m

l b f .f t

ECM mounting bolt

1.9 ~ 2.8

18.6 ~ 27.4

13.8 ~ 20.4

Mass air flow sensor mounting bolt

0.8 ~ 1.2

7.8 ~ 11.8

5.8 ~ 8.7

Crankshaft positi ition sensor mounting bolt

0.8 ~ 1.2

7.8 ~ 11.8

5.8 ~ 8.7

TDC sensor mounting bolt

0.8 ~ 1.2

7.8 ~ 11.8

5.8 ~ 8.7

EGR valve mounting bolt(Inlet pipe)

2.2 ~ 3.3

21.6 ~ 32.3

16 ~ 24

EGR valve mounting bolt(EGR cooler)

2.2 ~ 3.3

21.6 ~ 32.3

16 ~ 24

4 ~5

39 ~ 49

29 ~ 36

Common rail assembly mounting bolt

1.9 ~ 2.8

18.6 ~ 27.4

13.8 ~ 20.4

Fuel filler pipe assembly mounting bolt

0.8 ~ 1.2

7.8 ~ 11.8

5.8 ~ 8.7

Fuel return pipe mounting bolt

0.8 ~ 1.2

7.8 ~ 11.8

5.8 ~ 8.7

Fuel supply pump flange mounting bolt

10 ~ 13

98.6 ~ 128

72.3 ~ 94

Fuel supply pump mounting bolt

1.9 ~ 2.8

18.6 ~ 27.4

13.8 ~ 20.4

Injector clamp bolt

2.9 ~ 3.1

28.42 ~ 29.4

21 ~ 22.4

0.18 ~ 0.22

1.76 ~ 2.15

1.3 ~ 1.6

High igh pressure pipe ipe(rail rail--inje inject cto or 1,2,3 ,2,3,4 ,4,,5,6) ,6)

Injector wire nut

Engine Control System-Electronic DESCRIPTION

SELF-DIAGNOSIS

DIESEL CONTROL SYSTEM

The ECM sends the input/output signals to various parts of engine(some signals at all times and the others under specified conditions). conditions).

INS INSPECTION ION SYSTEM

OF

THE

DIES IESEL

CONTROL

If the components of the diesel control system (sensor, ECM, injector etc.) have a problem, the proper amount of fuel for variou various s engineengine-ope operati rating ng conditio conditions ns can not be supplied and also the following situations can occur. 1. It is hard hard to star startt the the engi engine ne or does does not star startt the the engine at all. 2. Idling Idling is unstab unstable. le. 3. Engine Engine driving performa performance nce is bad. bad. If any of the above conditions are met, first perform a routine diagnosis diagnosis that includes basic engine engine checks (ign (igniti ition on syst system em malfu malfunc nctio tion, n, inco incorr rrec ectt engi engine ne adjustment etc). Then, inspect the components of the diesel diesel control control system system with multi-p multi-purp urpose ose tester tester or digital multi-meter. CAUTION Before removing or installing any part, read the diagno diagnostic stic trouble trouble codes codes and then, then, disconne disconnect ct the battery negative negative (-) (-) terminal. Befor Before e discon disconne nectin cting g the cable cable from batte battery ry terminal, turn the ignition switch to OFF. If the batte battery ry cable cable is remov removed ed or conne connected cted during during engine ngine opera operation or the situation situation in which the i g ni t i on s wi t c h is ON, t h en t h e ECU semico semicondu nductor ctor could be dama damage ged d resulting resulting in inaccurate operation.

After the specific time elapses elapses the first detection of irregula irregularr signal, signal, the ECU judges judges this as an irregul irregularit arity y and it record records s the diagnosti diagnostic c trouble trouble code. And then it sends sends the signal signal to the self-dia self-diagno gnosis sis output output termina terminal. l. The diagnosis diagnosis results results can be checked checked by the Hi-scan. In addition, Diagnostic Trouble Codes (DTC) will be directly backed up by the battery so that it will remain in the ECM even if the ignition switch is turned off. The diagnostic troub trouble le codes codes will, will, howe howeve ver, r, be eras erased ed when when batte battery ry terminal or ECM connector is disconnected. CAUTION If, in most of diese diesell control control system, system, the conne connector ctor of a sensor is disconnected with the ignition switch turned turned ON, the diagno diagnostic stic trouble trouble code (DT (DTC) is recor recorde ded d in the EC ECM. In this case case,, if the batte battery ry negative terminal (-) is disconnected for 15 seconds or more, then the diagnosis memory will be erased.

SELF-DIAGNOSIS CHECK CHECK PROCEDURE PROCEDURE CAUTION As DTC code co de may not no t be det ect ed due du e to lo w batter bat ter y voltage voltage,, the batte battery ry condition condition should should be checke checked d prior to inspection. Since DTC code is erased if the battery or the ECM conne connector is disconne disconnecte cted, d, don't don't disconne disconnect ct the batte battery ry until until the the dia diagnos gnostic tic troub trouble le code codes s are completely read and recorded safely. It is most desirable to erase the diagnostic trouble codes codes using Hi-s Hi-sca can n after fter comple completing ting check check and repa repair. ir. After After disconne disconnecting cting ground cable cable from the battery negative (-) terminal for 15 seconds or more, reconnect the cable and check if the trouble codes have been erased. (At this time, ignition switch must be turned off).

INSPECT INSPECTION ION PROCEDU PROCEDURE RE (Usi ng Hi-sc an) 1. Turn off the ignition ignition switch. switch. 2. Connec Connectt the Hi-scan connecto connectorr to the connector connector of DLC (Data Link Connector) for the trouble diagnosis as shown in the figure.

DIES DIESEL EL CONT CONTRO ROL L LOCATION

SYST SYSTEM EM

COMP COMPON ONEN ENTS TS

1. Intake air temperatu temperature re sensor sensor and intake air pressure pressure sensor

3. Turn the the ignition switch switch ON. ON. 4. Check the diagnostic diagnostic code using using Hi-scan. Hi-scan. 5. Repair the parts parts having faults shown shown in the diagnosis diagnosis chart. 6. Erase the diagnostic diagnostic trouble trouble codes. codes. 7. Disconnect Disconnect the Hi-scan. Hi-scan.

SDGFL7501D

2. Crankshaft Crankshaft position sensor

KDDFL5019A

NOTICE When usin sing a test teste er manuf anufa actu ctured red by othe ther comp compan any, y, oper operat ate e the the teste testerr by refe referr rrin ing g to the the manual of the company. When When eras erasin ing g the the diag diagno nosti stic c troub trouble le code codes, s, use use Hi-scan if possible. Though DTC can be erased by discon disconne nectin cting g the batter battery y termin terminal, al, doing doing so, the data for learning control in ECM would be erased at the same time.

SDGFL7502D

3. Wat Water er temp temper eratu ature re sensor)

sens sensor or(C (Coo oolan lantt

tempe tempera ratu ture re

6. Rail pressure pressure sensor

SDGFL7002D SDGFL7503D

7. Supply Supply control control valve(SCV valve(SCV))

4. TDC sensor(C sensor(Camsh amshaft aft sensor) sensor)


8. ECM and EDV

5. Injector Injector


9. Accelerator Accelerator position position sensor

SDGFL9021L

10.DLC connector

SDGFL8113D

ECU(Engine Control Unit) COMPONENTS ECM PIN CONNECTOR

SDGFL9022L

Vehicl Vehicl e si de(80 de(80pin pin connector) - ECM connector(C01) connector(C01) Termi Termi nal

Ab A bbr .

1

+BF

2

PWR-ACT1

3

Ter mi n al n am e +B

(For fly back)

Termi Termi nal

Ab A bb r .

Ter mi n al n ame

41

SWV25

Bleeder #2 switch

-

42

SWV23

Stop lamp switch

OUTV1

Ma Main relay

43

SWV21

Se Self-diagnosis switch

4

OUTV2

Exhaust brake relay

44

SWV19

Cruis main ON/OFF switch

5

OUTV3

Starter relay

45

A-ground 10

Sensor ground10

6

ＳOUT6

Check engine engine lamp and fuel pressure flashing

46

A-gr A-grou ound nd 12

Sens Sensor or grou ground nd 12

7

SOUT4

Glow lamp

47

ADV1

Accelerator position sensor 1

8

SOUT2

PTO lamp

48

ADV3

-

9

SOUT1

MIL lamp

49

ADV5

Exhaust temperature sensor 1

10

SWV6

PTO emergency switch

50

A-VCC10

Sensor power supply 10

11

SWV4

Neutral switch

51

A-VCC11


12

SWV2

Starter switch

52

SWV17

Remote Remote PTO idle up & engine engine service start switch

13

SWV1

Ig Ignition switch

53

SWV15

Idle down down & PTO idle down down & cruise resume switch

14

VS

Vehicle speed sensor

54

SWV13

A/C switch

15

POUT1

A/C control

55

SWV11

Cl Clutch switch

16

CAN1L

CAN1L

56

SWV9

Exhaust brake & bleeder #1 switch

17

CAN2L

CA C AN2L

57

CAN-SLD

18

+B

+B

58

+B

19

BATT

Ba Battery

59

P-ground

Power ground

20

CASE-GND

Case ground

60

ground

Signal ground

21

+BF

+B

(for fly back)

61

SWV26

PTO switch(Cap outside)

22

OUTV4

Warning lamp relay

62

SWV24

Starter relay monitor switch

23

OUTV1

Main relay

63

SWV22

Idel warm up switch

24

OUTV5

Heater relay

64

SWV20

Built-in data capture switch

25

SOUT8

Alternator control cut

65

A-ground 11

Sensor ground 11

26

SOUT7

Cruise lamp

66

A-ground 13

-

27

SOUT5

Overheat lamp

67

ADV2

Accel position sensor 2

28

SOUT3

Exhaust brake lamp

68

ADV4

PTO accel position sensor

29

SWV8

Door open switch

69

ADV6

Exhaust temperature sensor 2

30

SWV7

Bus rear flap switch

70

ADV7

Differential pressure sensor

31

SWV5

PTO switch

71

A-VCC12

CAN1 shield ground +B

Se Sensor power supply 12

Termi Termi nal

Ab A bbr .

Ter mi n al n am e

Termi Termi nal

Ab A bb r .

Ter mi n al n ame

32

SWV3

Engine stop switch

72

SWV18

Remote Remote PTO idle down & enginesengineservice stop switch

33

SWV1

Key switch

73

SWV16

QT cut switch

34

TAC1

Tachometer

74

SW SWV14

Idle up & PTO PTO idle idle up up & cruise cruise set set switch

35

PIN5

-

75

SWV12

Brake switch

36

CAN1H

CAN1H

76

SWV10

Idle switch

37

CAN2H

CAN2H

77

KWP

38

+B

+B

78

+B

39

P-ground

Power ground

79

P-ground

Power ground

40

Ground

Signal ground

80

P-ground

Power ground

+B

Engine si de(80 de(80 pin connector) - ECM connector(E01) connector(E01) Termi Termi nal

Ab A bbr .

Ter mi n al n am e

Termi Termi nal

Ab A bb r .

Ter mi n al n ame

80

OUTE5

-

40

SWE1

Heater monitor switch

79

OUTE1

Fan clutch PWM

39

SWE3

-

78

OUTE3

Bleeder solenoid #2

38

ADE9

-

77

PWR-ACT2

Power ACT2

37

ADE7

Ambient temperature sensor

76

AUX2

-

36

ADE13

-

75

PWR-PCV

Not in use

35

ADE6

-

74

PCV1

Not in use

34

ADE4

Intake temperature sensor

73

PCV2

Not in use

33

ADE2

Fuel temperature sensor

72

SCV-HI

HP-4 high

32

ADE1

Rail pressure sensor

71

SCV-LO

HP-4 low

31

PIN2+

-

70

AUX1

No Not in use

30

PIN1+

-

69

A-VAF

MAF power supply

29

NE+

68

A-VCC1


28

G-VCC

Cam angle sensor power

67

COM1

Injection power 1

27

G-ground

Cam angle sensor ground

66

TWV1

Injection #1

26

INJ-SLD

Injection shield ground

65

TWV3

Injection #3

25

A-ground1

Sensor ground 1

64

TWV5

Injection #5

24

A-ground3

Sensor ground 3

63

COM2

Injection power2

23

A-ground5

Sensor ground 5

62

TWV2

In Injection #2

22

CAN3H

61

TWV4

Injection #4

21

TWV6

Injection #6

60

OUTE6

-

20

SWE2

Fuel inlet pressure switch

Engine RPM sensor +

CAN3H

Termi Termi nal

Ab A bbr .

Ter mi n al n am e

Termi Termi nal

Ab A bb r .

Ter mi n al n ame

59

OUTE2

-

19

ADE10

-

58

OUTE4

Bleeder solenoid #1

18

ADE8

-

57

PW PWR-ACT2

Power ACT2

17

ADE14

-

56

PW PWR-ACT2

Power ACT2

16

ADE12

-

55

PWR-PCV

Not in use

15

ADE5

Water temperature sensor

54

PCV1

Not in use

14

ADE3

Boost sensor

53

PCV2

Not in use

13

ADE1

Rail pressure sensor

52

SCV-HI

HP-4 high

12

ADE11

Air MAS flow sensor

51

SCV-LO

HP-4 low

11

PIN2-

-

50

NE(MRE)

-

10

PI PIN1-

-

49

PRD+

Not in use

9

NE-

48

A-VCC2


8

G

47

COM1

In Injection power1

7

PIN3

46

TWV1

-

6

NE-SLD

NE Shield ground

45

TWV3

-

5

A-ground 2

Sensor ground 2

44

TWV5

-

4

A-ground 4

Sensor ground 4

43

COM2

Injection power 2

3

A-ground 6

-

42

TWV2

-

2

CAN3L

CAN3L

41

TWV4

-

1

TWV6

-

Engine RPM sensor Cam angle sensor signal -

REMOVAL 1. After the engine engine stops, stops, wait for about about 30 seconds. seconds. 2. Disconnect Disconnect the battery battery ground ground line. line. 3. Remove Remove ECU connector connector wiring sequen sequentially. tially. 4. Loos Loosen en ECM ECM brac bracke kett moun mountin ting g bolt bolt and and remo remove ve ECM(A).

ADJUSTME ADJ USTMENT NT REPLACING ECM

PROCEDURE PROCEDURE

AFTER

1. Perform Perform work proced procedure ure using diagnostic diagnostic tool when replacing with a new ECM. 2. Input Input injector injector QR correc correction tion value using diagnos diagnostic tic tool with the ignition key ON. Follow Follow the instruct instruction ions s on the diagnostic diagnostic tool as to how to input injector QR correction value. If the the inpu inputt of inje inject ctor or QR corr correc ectio tion n valu value e was was comple completed, ted, start the engine engine in 10 sec. after after turning turning the ignition key OFF. CAUTION In case case QR correction correction value value describe described d on the injector is not input in the ECM, there may cause engine performance and and exhaust exhaust gas probl em. 3. Select Select learnin learning g initializat initialization ion instruct instructed ed by diagnos diagnostic tic tool tool and and perfo perform rm pump pump learni learning ng initia initializ lizati ation on and and accelerator sensor learning.

SDGFL7003D

5. Installation is in the reverse reverse of of removal. removal.

4. Acco Accord rdin ing g to the the inst instru ruct ctio ions ns on diag diagno nost stic ic tool tool,, sele select ct param arame eter ter sett settin ing g and perf perfor orm m work ork in sequence.

Mass Air Flow Sensor INSPECTION DESCRIPTION MAF MAF sens sensor or is built built into into the vehic vehicle le for contr controll ollin ing g the the EGR system precisely. precisely. The air flow, flow, supplie supplied d to an engine engine,, is measu measured red lower than actual air flow due to contamination of MAF sensor. Then EGR system can't be controlled precisely. To prev preven entt it in adva advanc nce, e, you you have have to clean clean the MAF sensor periodically. Clean Clean the the MAF MAF sens sensor or ever every y 6 month months s or 60,00 60,000 0 km using "Carb and Choke Cleaner".

VISUAL INSPECTION

SGZFL9028L

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

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

Procedure and caution when cleaning the sensor

SGZFL9029L

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

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

3. To dry the sensor element element -

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

-

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

SGZFL9030L

2. Procedure of atomizing the spray -

Atomiz Atomize e the spra spray to the end end part part of sensor sensor housing.

-

Don't use the noz nozz zle of spray spray to preve prevent nt the sensor element from damage.

-

Atom Atomiz ize e the spra spray y with with 2 ~3 t im imes f or or 2~3 seconds.

SGZFL9032L

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

Insta Install ll the O-ring O-ring afte afterr completing completing to dry the sensor.

SUDFL9500L

SGZFL9031L

Differential Pressure Sensor(DPS) Components

SUDFLDTC9109L

Description The differential pressure sensor is installed upper side of PMC PMC and and measu measures res the pressur pressure e differen difference ce betwee between n before and after PMC. It also has a purpose to monitor that PMC is arbitrarily removed by a user.

SUDFLDTC9110L

Specifications Differential Pressure (kPa)

Output Voltage (V)

0

1

10

1.35

20

1.7

30

2.05

40

2.4

50

2.75

60

3.1

70

3.45

80

3.8

90

4.15

100

4.5

Part Circuit Diagram

SUDFLDTC9112L

Replacement

The differential pressure sensor pipe

The differential pressure sensor

1. Turn Turn the the igni ignitio tion n switc switch h OFF OFF and and disc discon onne nect ct the the battery (-) cable.

1. Turn Turn the the igni ignitio tion n switc switch h OFF OFF and and disc discon onne nect ct the the battery (-) cable. 2. Disco iscon nnect the connector(A).

diffe ifferrentia tial

press ressu ure

sensor

2. Rem Remove the the clip clip con connect necte ed to the the diffe iffere rent ntia iall pressure sensor pipe.

SUDFLDTC9111L

3. Remove Remove the bracket bracket bolt(B). bolt(B).

SUDFLDTC9111L

3. Rem Remov ove e the the clip clip con connect nected ed to the the diff differ eren enti tial al pressure sensor pipe. 4. Remove Remove the mountin mounting g bolt(D). bolt(D).

tigh tighte ten ning ing

torq torqu ue,

refe referr

5. The installation installation is the reverse reverse order order of removal. removal. NOTICE Regardin rding g as "Components".

5. The installation installation is the reverse reverse order order of removal. removal. NOTICE Regardin rding g as the the "Components".

4. Remove Remove the differential differential pressure sensor sensor pipe(C). pipe(C).

to

the the

tig tighte htening ning torq torqu ue,

refe referr

to

Fuel Fuel Delivery System-Electro ystem-Electro nic COMPONENTS

SDGFL9023L

1. 2. 3. 4. 5. 6. 7. 8.

ECM ECM Injector assembly assembly Injectio Injection n pipe pipe Common Common rail assemb assembly ly Fuel supply supply pump pump High pressure(co pressure(commo mmon n rail ~injector) High pressure pressure pipe(comm pipe(common on rail ~supply pump) Injector clamp bolt

9. Injector Injector clam clamp p 10. Injector assembly assembly 11. Nozzle gasket gasket 12. Fuel return pipe 13. Fuel supply pipe 14. Fuel pump pump flange 15. Overflow Overflow screw screw 16. Fuel temperatu temperature re sensor sensor

Ac cel erato er ato r Pedal DESCRIPTION

2. Connec Connectt DC 5 V to terminal terminal No. No. 3.

APS (Accelerator (Accelerator Position Sensor) Sensor) senses senses the acceleration pressure of the driver and delivers it to the ECM. Output Output voltage of accelerator accelerator position sensor sensor has a functional relation with the accelerator pedal position.

3. Chec Check k to see see if the meas measur urem emen entt volta voltage ge betwe between en term termin inal al No. No. 1 and and No. No. 2 sati satisf sfie ies s the the spec specifi ified ed voltage.

This function functional al relation relation comes comes from the Potenti Potentiom ometer eter built-in the sensor. In other words, the positon of pedal is calculated from the output voltage of the sensor.

REMOVAL 1. Disconnect Disconnect accelerator pedal pedal connector and remove remove mounting bolt, accelerator pedal. 2. Installation is the reverse order order of removal. removal.

INSPECTION 1. Connec Connectt the voltmeter voltmeter to the terminal terminals s No. 1 and 2 of accelerator position sensor.

SDGFL9026L

SDGFL9027L

At idle : 0.65V At full stroke : 3.85V 4. Connect Connect DC 5V 5V to terminal terminal No.4. 1) Che Check to see if the the measur surement volta ltage betwe between en termi termina nall No. No. 1 and and No. No. 6 satis satisfie fies s the the specified voltage. voltage. At idle : 5V At full stroke : 0V 2) Che Check to see if the the measur surement volta ltage betwe between en termi termina nall No. No. 1 and and No. No. 5 satis satisfie fies s the the specified voltage. voltage. At idle : 0V At full stroke : 5V

Fuel Tank And Fuel Filter REMOVAL

FUEL TANK AND FUEL FILTER (AEROTOWN)

FUEL TANK AND FUEL FILTER (HD120)

1. Park Park the vehicl vehicle e on a flat flat surfa surface, ce, stop the engin engine e and disconnect the terminal (-) of battery.

1. Park Park the vehicl vehicle e on a flat flat surfa surface, ce, stop the engi engine ne and disconnect the terminal (-) of battery. 2. Disconn Disconnect ect the sender sender connec connector tor on the top of fuel fuel tank.

2. Disconn Disconnect ect the sender sender connecto connectorr on the top of fuel tank. 3. Remove Remove return hose hose (A) and supply supply hose (B).

3. Remove Remove return hose hose (A) and supply supply hose (B).


4. Support Support fuel tank assembly assembly with the jack. Loosen Loosen fuel tank tank band band moun mounti ting ng nut nut and and remo remove ve fuel fuel tank tank assembly assembly by removing removing mounting bolt. 5. Disconnect Disconnect connector connector and hose and and remove remove fuel filter (C).

4. Support Support fuel tank assembly assembly with the jack. Loosen fuel fuel tank tank band band moun mounti ting ng nut nut and and rem remove ove fuel fuel tank tank assembly by removing mounting bolt. 5. Disconnect Disconnect connector connector and hose hose and remove remove fuel filter (A).

6. Installation is the reverse order order of removal. removal. Tighten lower nut to the 8.5~11kgf.m(83.4 ~107.9 107.9N.m N.m,, 61.5 61.5~79.6I 79.6Ibb-ft) ft) and and upper nut to the the 1.3~1.5kg 1.5kgf.m f.m (12.7 (12.7~14.7N.m, 9.4~10.8Ib-ft) and install fuel tank band to bracket.

SDGFL7102D

6. Installation is the reverse order order of removal removal.. Tighten lower nut to the 3.3~4.0kgf.m (32.4~39.2N.m, 23.9~28.9Ib-ft) and upper nut to the 8~11kg 11kgf.m f.m (78.4 (78.4~107.9N 107.9N.m, .m, 57.9~79.6I 79.6Ibb-ft) ft) and and install fuel tank band to bracket.

INSPECTION 1. General General check a. Crack, Crack, bending bending,, deform deformatio ation, n, deterio deteriorati ration on and clogging of hose or pipe b. Clogging Clogging or damage damage of fuel fuel filter 2. When When the filter filter has to be checked checked a. When When the fuel in the tank is drained drained out and then then replenished again for maintenance b. When When fuel fuel filter is replace replaced d c. When fuel main hose (pipe) (pipe) is remove removed d Loosen the air plug of fuel filter. Cove Coverr air plug plug hole hole with with cotto cotton n cloth cloth and and keep keep pumping until it stops bubble. When When bubble bubbles s are remove removed d complet completely, ely, fasten fasten the the air air plug plug and and conti continu nue e to pump pump until pump pump operation effort feels heavy. 3. Water drain from the the fuel filter filter Check for the water level of transparent bowl and if water is filled with one-third, be sure to drain water by the following sequence. CAUTION If the the vehi vehicle cle is drive driven n with withou outt dra draining ining the the wate water, r, it may may cause cause fatal fatal trouble trouble to the supply pump and injector. a. Drain the the water by by turning about about half way. CAUTION Since water is drained even if the plug is not fully loosened, be careful not to loosen drain plug fully. b. If diesel diesel fuel drains drains after after water water has been drained drained completely, fasten the drain plug by hand. Tigh ighten tening ing torq torqu ue 12.3~13.7Ib-ft)

:

1.7~1.9kg 1.9kgf.m f.m

(16.7 (16.7~18.6N.m,

Injector COMPONENTS

SDGFL9024L

1. 2. 3. 4.

ECM ECM Injector assembly assembly Injector Injector pipe pipe Common Common rail assemb assembly ly

5. 6. 7. 8.

Fuel supply pump Injector clamp bolt Injector Injector clam clamp p Injector assembly assembly

REMOVAL

4. Remove Remove rocker arm arm assembly assembly (A). (A).

CAUTION • Since common rail rail fuel injection operate operates s under under high pressure(1, pressure(1,80 800ba 0bar), r), a s pecial care shoul d be taken. •

While hile engin engine e is runnin running g or within 1 min. min. after after en g i ne ne s t o p s , an y w o r k s s ho u l d n o t b e p er er fo fo rm rm ed ed i n r el el at at io io n t o c om om mo mo n r ai ai l f ue uel injection system.

•

In particula particular, r, as the injector injector solenoid solenoid gene generate rates s high temperature heat, do not touch it with bare hands hands.. Start tart the servic service e works works only only whe when the engine ngine has has bee been coole cooled d down down enough nough after fter engine stops.

•

Always Always keep keep the safety safety precau precautions. tions.

•

Ensure nsure working working area rea clea cleans all the time, time, and place place the remove removed d injector injector on the clean clean cloth. An d pay att ent io n to in jec to r nozzle no zzle so th at it is not contaminated by foreign materials.

•

Remove move the the prot prote ective ctive caps caps which which pre prevent vents s foreign material inflow for injector and fuel hose immediately just before installation.

•

When hen installing installing or remov removing ing injector, injector, clean clean the i nj nj ec ec to to r c on on ta tac ti ti ng ng p or or ti ti on on an d b e s ur ur e t o replace O-ring O-ring and nozzle gasket wit h new ones.

•

Apply Apply diesel diesel to the O-r O-ring ing of injector injector and and insert insert them into the cylinder head.

•

Install Install injector to the cylinder hea head d vertically vertically and and install it correctly not to cause any damage such as shock.

•

Be sure sure to obse observ rve e the the specif specifie ied d tight tighte ening ning torque of bolts when inserting and tightening the injector.

•

Never Never use use the high pressure pressure fuel pipe. pipe.

SDGFL7507D

5. Disconnect Disconnect injector injector ground ground (A).

SDGFL7508D

6. Disconnect Disconnect high pressure pressure pipe (A). (A).

1. Turn the ignition ignition key OFF. OFF. 2. Disconnect Disconnect terminal terminal (-) of battery. battery. 3. Remove Remove rocker rocker cover. cover.

SDGFL7509D

7. Loosen Loosen injector clamp bolt bolt (A) and remove remove injector. injector.

replace O-ring O-ring and nozzle gasket gasket wi th new ones. •

Appl Apply y die diesel sel oil oil to the the O-ring ring of inje injecto ctorr and insert them into the cylinder head.

•


•

Be sure sure to obse observe rve the the specif specifie ied d tight tighte ening ning torque of bolts when inserting and tightening the injector.

•


1. Remove Remove injector. 2. Install Install the the injector injector.. 3. Input Input injector injector QR correc correction tion value using diagnos diagnostic tic tool with the ignition key ON. SDFFL7510D

INSTALLATION 1. Installation is in the reverse reverse of of removal. removal. 2. When When installing, tighten tighten bolts to the specified specified torque. torque. High High press pressur ure e fuel fuel pipe pipe moun mountin ting g bolt bolt : 4 ~ 5kgf.m (39.2 ~ 49N.m, 28.9 ~ 36.2Ib-ft) Injector clamp mounting bolt : 2.9~3.1kgf.m (28.4 ~ 30.4N.m, 21 ~ 22.4Ib-ft) Injec Injector tor wire nut nut : 0.18 0.18 ~ 0.22kgf.m 0.22kgf.m (1.76 ~ 2.15N.m, 1.3 ~ 1.6Ib-ft)

Follow Follow the instruct instruction ions s on the diagnostic diagnostic tool as to how to input injector QR correction value. If the the inpu inputt of inje inject ctor or QR corr correc ectio tion n valu value e was was comple completed, ted, start the engine engine in 10 sec. after after turning turning the ignition key OFF. CAUTION In case case QR correction correction value value describe described d on the injector is not input in the ECM, there may cause engine performance and and exhaust exhaust gas probl em.

CLEANING

REPLACEMENT

Clean the injector as follows to be reused.

CAUTION • Since common rail rail fuel injection operate operates s under under high pressure(1, pressure(1,80 800ba 0bar), r), a s pecial care shoul d be taken.

1. Clean Clean the injector injector by setting setting the injector injector vertical vertically ly to the clean container. container.

•


•


•


•


•


•

When hen installing installing or remov removing ing injector, injector, clean clean the i nj nj ec ec to to r c on on ta tac ti ti ng ng p or or ti ti on on an d b e s ur ur e t o

2. Remove Remove dust or dirt from the injector injector body body and nozzle sealing with clean cloth if necessary.

Common Common Rail Rail Assembly COMPONENTS

SDGFL9025L

1. 2. 3. 4.

ECM ECM Injector assembly assembly Injectio Injection n pipe pipe Common Common rail assemb assembly ly

5. Fuel supply pump 6. High pressure( pressure(comm common on rail~injector) 7. High pressure pressure pipe(comm pipe(common on rail ~supply pump)

REMOVAL CAUTION • Since common rail rail fuel injection operate operates s under under high pressure(1, pressure(1,80 800ba 0bar), r), a s pecial care shoul d be taken. •


•


•


•


4. Disconn Disconnect ect the injector injector pipe leading leading to commo common n rail (A) from the supply pump.

SDGFL7513D

1. Turn the ignition ignition key OFF. OFF.

5. Disconnect Disconnect the return fuel hose. hose.

2. Disconnect Disconnect terminal terminal (-) of battery. battery.

6. Disconnect Disconnect the rail rail pressure pressure sensor. sensor.

3. Disconn Disconnect ect high pressure pressure pipe (A) leadin leading g to injector injector from rail.

CAUTION Be careful not to leak the fuel remaining in the rail. 7. Disconn Disconnect ect the commo common n rail assembly assembly mounting mounting bolt and then disconnect the common rail assembly (A).

SDGFL7509D

SDGFL7514D

INSTALLATION 1. Install common common rail rail assembly assembly (A).

SDGFL7514D

Common rail assembly mounting bolt : 1.9 ~ 2.8kgf.m( 2.8kgf.m( 18.6~27.5Nm,13.7~20.3lb.ft) 2. Tighte Tighten n high high pressure pressure fuel pipe pipe (A) to the specified specified torque. High pressure fuel pipe mounting bolt : 4 ~ 5kgf.m(39.2 ~49.0Nm, 28.9~36.2lb.ft)

SDGFL7509D

Injection Pump-Electronic Supply Pump COMPONENTS

SDGFL9028L

1. 2. 3. 4. 5.

ECM ECM Injector assembly assembly Injectio Injection n pipe pipe Common Common rail assemb assembly ly Fuel supply supply pump pump

6. Fuel return pipe 7. Fuel Fuel supply supply pipe 8. Fuel pump flange 9. Overflo Overflow w screw screw 10. Fuel temperatu temperature re sensor sensor

REMOVAL

1. Turn the ignition ignition key OFF.

CAUTION • Since common rail rail fuel injection operate operates s under under high pressure(1, pressure(1,80 800ba 0bar), r), a s pecial care shoul d be taken.

2. Disconnect Disconnect terminal terminal (-) of battery. battery.

•


•


•


•


•


•

When hen installing installing or remov removing ing injector, injector, clean clean the i nj nj ec ec to to r c on on ta tac ti ti ng ng p or or ti ti on on an d b e s ur ur e t o replace O-ring O-ring and nozzle gasket wit h new ones.

•

Appl Apply y die diesel sel oil oil to the the O-ring ring of inje injector ctor and insert them into the cylinder head.

•


•

Be sure sure to obse observ rve e the the specif specifie ied d tight tighte ening ning torque of bolts when inserting and tightening the injector.

•


3. Disconnect Disconnect supply supply pump pump connector. connector. 4. Disconnect Disconnect low pressure pressure pipe. pipe. 5. Disconnect Disconnect high high pressure pressure pipe. pipe. 6. Remo Remove ve flang flange e moun mountin ting g bolt bolt and and remo remove ve supp supply ly pump assembly from flywheel housing. NOTICE When removing supply pump, remove pump, flange and supply pump gear from assembly.

SDGFL7505D

7. Remo Remove ve supply supply pump pump moun mountin ting g hexa hexago gon n bolt bolt and and remove supply pump.

SDGFL7006D

INSTALLATION 1. Rotat Rotate e the crank cranksh shaft aft to align align the cylind cylinder er No. 1 at the TDC (Top Dead Center) position. a. Alig Align n the the mark mark(o (orr pain paintin ting) g) at damp damper er pull pulley ey circu circumf mfer eren entia tiall surfa surface ce of cran cranksh kshaft aft with with the direction mark on block surface.

2. Engine Engine installation installation after assem assemblin bling g pump pump gear gear and plate a. As Assem semble plate late to pump and tem temporarily ily assem assemble ble gear to pump pump shaft. shaft. Assemb Assemble le to the direction direction of flange flange (d) from pump pump (b) and insert insert O-rin O-ring g betwe between en pump pump (b) (b) and and flang flange e (d), (d), then then tighten bolt (a). Supply Supply pump mountin mounting g bolt : 1.9 ~ 2.8kgf.m(18.6 ~27.5Nm, 13.7~20.3lb.ft)

SDGFL7510D

b. Open pen rock rocke er cove cover, r, in vie view from from the the rear rear of engine, align the mark(or painting) of TDC sensor gear plate with the head contact surface of block from the left.

SDGFL7007D

b. When When tightening tightening flange and pump, pump, tighten tighten those so that the mark(1) of flange backside faces the upper side of straight line as shown in the figure. Align the part that the number number of supply pump pump gear ear is marked rked with ith the the mark ark (1) (1) of flan flang ge backs backside ide and and assem assemble ble supp supply ly pump pump gear gear to supply pump. Supply pump gear mounting nut : 6 ~ 7kgf.m(58.8 ~68.6Nm,43.40~50.6lb.ft)

SDFFL7512D

c. If the the abov above e menti mention oned ed two items items are are satis satisfie fied, d, cylinder #1 is at TDC position.

SDGFL7511D

c. After After assemblin assembling g as above, above, and also insert insert O-ring between pump assembly and block.

SDGFL7512D

d. When installing installing supply supply pump assembly assembly to engine, engine, double check above mentioned items and engage supply pump gear part with counterpart gear and then tighten it with bolts. Flange mounting bolt : 10 ~ 13kgf.m(98.1~127.5Nm, 72.3~94.0lb.ft) 3. Tighten Tighten high pressure pressure pipe. pipe. High pressure pipe mounting bolt : 4 ~ 5kgf.m(39.2 ~49.0Nm, 28.9~36.2lb.ft) NOTICE At assembling, assemble those from center to outside in sequence for convenience's sake. 4. Install low low pressure pressure pipe. 5. Install supply supply pump pump connector. connector. 6. Install Install rocker rocker cover. cover. 7. When When replacing replacing with the new pump, pump, erase erase learnin learning g value of the previous pump and be sure to perform "Pump learning initialization" using the diagnostic tool to start the learning learning of new pump pump newly. newly. CAUTION Be sure to perform the above mentioned "Pump lea learning initializa initialization" tion" when when repla replacing cing with the new pump. If t he he ab o v e m en t io io ne ned " Pu Pu mp l ea ear ni ni ng ng i ni ni ti ti al al iz izat io io n" n" i s n o t p er fo fo r me med w i th th t he he diagno diagnostic stic tool after fter repla replacing cing with new new pump, pump, the engine ngine perform performa ance could be dete deteriora riorate ted d and there there may may have have proble problems ms in the emission emission gas.

Hyundai D6GA Fuel System

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