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 Specifications
Fuel pump Type Inner contact gear type
Maximum supply pressure 7kgf.cm²
Driving Air compressor shaft driving
Control unit Voltage 24V
Connector 62 pin x 3
Unit injector(Solenoid Voltage 90V
valve)
Resistance(at 20°C) 1.66Ω±5%(5V), 1.40Ω±5%(NCV)
Coolant temperature Voltage 5V
sensor and Gauge unit
Operating range -40°C~130°C
Connector 3 pin
Intake pressure temp- Voltage 5V
erature sensor
Operating range Temperature -40°C~125°C
Pressure (Absolute) 32.5~284 kPa(0.33~2.9kgf.cm²)
Connector 4 pin
Crank shaft and Cam- Resistance 860Ω ± 10%
shaft position sensor
Operating range 40~3,000 r/min
Connector 2 pin
Air gap 1.0~2.0 mm
Fuel pressure temper- Voltage 5V
ature sensor
Operating range Temperature -40°C~130°C
Pressure 0~1000 kPa(0~10kgf.cm²)
Connector 4 pin
SERVICE STANDARDS
Item Standard value
Electric injector Opening pressure Min. 260 bar
Injection pressure Max. 2,000 bar
Idle rotation speed(RPM) 500 ± 20 rpm
Overflow valve opening pressure 4.0 bar or higher
Cam shaft position sensor air gap 1.0~2.0 mm
Crank shaft position sensor air gap 1.0~2.0 mm
Fuel pump discharge amount 500rpm 4 bar(1ℓ /min or more)
1900rpm 7 bar(7ℓ /min or more)

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

SPECIAL SERVICE TOOL

Tool Shape Use
Rocker arm shaft setting Installation and removal of rocker arm
09245-84100 shaft

SDHEM7022D
DESCRIPTION

SGZFL9001L

1. MAF sensor 6. Fuel filter

2. Coolant temperature sensor 7. Priming pump
3. Intake pressure temperature sensor 8. Crank position sensor
4. ECU 9. Cam position sensor
5. Fuel pressure temperature 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) Operating Theory of Unit Injector
Unit Injector 1. Fuel intake
The unit injector consists of pumping element(A), The fuel circuit is open when the spill valve is opened
controlling component(B), and nozzle(C) as shown in the and fuel comes into pump chamber as the return
illustration. The pumping element(A) generates the fuel spring lifts up the plunger.
pressure as the force from the cam drives the plunger by At this time, the needle of nozzle is closed by the
way of the rocker arm. The controlling component(B) spring.
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.

SGZFL9004L

2. Fuel discharge
When the rocker arm begins to press plunger, fuel
begins to be compressed in pump chamber.
SGZFL9003L
However, the sudden pressure rise does not occur as
the spill valve is opened. That is, fuel flows through
the spill valve.
3. Fuel compression start
The fuel in the pump chamber is compressed when
the spill valve(SV) is closed by the signal of ECU.
The fuel pressure starts to rise according to plunger
down.
4. Fuel injection start
When the fuel pressure in the pump chamber
reaches at appropriate level, the needle control valve
is activated by the signal of ECU. At this time, the
fuel injection starts to inject according as the nozzle
is opened by the pressure difference between before
and after needle when the pressure of rear of needle
is released.
5. Fuel injection end
The pressure between before and after needle is
equal when the operation of needle control valve is
deactivated by the signal of ECU. And the fuel
injection is terminated as the nozzle is closed by the
spring.
CONTROL UNIT AND SENSOR

SGZFL9027L

1. MAF sensor 6. Fuel filter

2. Coolant temperature sensor 7. Priming pump
3. Intake temperature pressure sensor 8. Crank position sensor
4. ECU 9. Cam position sensor
5. Fuel temperature/ pressure 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 3. Vehicle control function
- Idle adjustment at cold: Increase idle 1) Cruise vehicle speed control
speed after cold starting to expedite the 1. Function: Drives the vehicle within the
warming up. specified speed.
- Increase idle to prevent battery 2. Operating condition
discharging when the air conditioner is on.
a. Operation of cruise control switch
- Increase idle to quicken the charging rate
b. Brake and clutch pedal are not pressed.
if battery voltage is low.
c. Safety switch is turned off.
4. Idle adjustment at cold start
d. Brake is in normal condition.
7) Manual adjustment of idle
e. When vehicle speed is 40 km/h or higher.
Idle adjustment can be manually using
self-diagnostic switch mounted to driver seat. 3. Releasing condition

For the manual adjustment of the idle, following a. Releasing of cruise control switch
conditions should be met. b. Brake and clutch pedal are pressed
a. Vehicle should be stopped securely. c. If the vehicle speed is lower than the
b. There should be no acceleration pedal signal. minimum speed by cruise control function,
cruise is released automatically if one of
c. Foot brake should be applied securely.
the above conditions is met.
d. It should be at idle state and PTOshould not
d. Transmission retarder is operated
be in running state
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
b. If the fuel is not applied and the vehicle
speed is higher than specified one on the
Driver can set desirable idle speed as mentioned
downhill, the exhaust brake and the jake
above. (500 to 800 rpm)
brake work successively. This condition
8) Output limit by the fuel pressure prevents the vehicle speed from
Function: When fuel pressure drops lower than increasing excessively.
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.
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
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
ECBFL5012A
- 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
120°Camshaft is composed of 60° as a standard.
- Camshaft has total 7 teeth and a tooth is added at
No.1 to recognize standard of cylinder No.1.
- Cylinder No.1 of camshaft is located after 15° from
the added tooth and TDC of cylinder No.1 is located
after 34.5° from tooth No.1.
CONTROL RELAY
When the start switch is ON, battery voltage flows from
starting switch to control unit. At this time, power
transistor is switched on to control relay coil.
Then, control relay switch is ON and main power is
supplied from battery to control unit through control relay
switch.

ECBFL5014A

PRIMING PUMP FUEL FILTER

Priming pump is mounted on the fuel filter head and used
to discharge fuel and air in fuel system manually at initial
engine starting or after fuel filter replacement.
Priming pump mounting torque:
27~29Nm(2.8~3kgf.m, 20.4~21.8lb-ft)
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:
40±2 Nm(4±0.2 kgf.m, 28.9±1.5 lb-ft)

SGZFL9010L
EXTERNAL WIRING DIAGRAM OF UNIT INJECTOR (ECU)

SGZFL9011L
Troubleshooting USING HI-SCAN TOOL
SELF-DIAGNOSIS 1. Turn OFF the ignition switch.
The ECM monitors the input/output signals (some signals 2. Connect the Scan Tool to the data link connector.
at all times and the others under specified conditions). 3. Turn ON the ignition switch.
When the ECM detects an irregularity, it records the 4. Use the scan tool to check the diagnostic trouble
diagnostic trouble code, and outputs the signal to the codes.
Data Link connector. The diagnosis results can be read
5. Repair the fail parts from the diagnosis chart.
with the scan tool or Flash code. Diagnostic Trouble
Codes(DTC) will remain in the ECM as long as battery 6. Erase the diagnostic trouble code.
power is maintained. 7. Disconnect the scan tool.
NOTICE NOTICE
The scan tool can erase the diagnostic trouble codesin • The scan tool can erase the diagnostic trouble
the memory only. codes in memory only.
INSPECTION PROCEDURE(SELF-DIAGNOSIS) • It is possible to erase the DTC codes only with
key ON without starting the engine.
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 conn-
Check the connector connection
ector
Check the ECU using the Hi-Scan/
ECU malfunction Injector compulsory test/
If necessary, replace the ECU
Starter operation malfunction • Starter switch, neutral switch, service switc-
h circuit and operation check
• Immobilizer system check
Fuel system Check the opening pressure of the over flow/
Malfunction of over flow valve
If necessary, replace the over flow valve
Lack of fuel Check the amount of fuel in the fuel tank
Check the fuel supply pump check valve and t-
Fail of the fuel supply pump he shaft for damage/
If necessary, replace them
Poor supply due to the fuel supply hose kink Check the fuel intake system
Others Malfunction of the air heater Check the air heater relay and the ECU
Air in fuel system Bleed the fuel system
Poor idle Check the injector variation by acceleration te-
Malfunction of injector st/
If necessary, replace the injector
Air in fuel system Check the fuel line
Fail of the accelerator input signal Check and replace the pedal sensor
White smoke Check the injector tube and leak
Fuel leak to the combustion chamber
If necessary, replace the injector.
Air heater malfunction Check the heater relay and ECU
Check the ECU
Incorrect injection timing due to ECU damage
If necessary, replace the ECU
Black smoke Malfunction of injector Check the injector by acceleration test
Check the sensor using a Hi-Scan/
Fail of intake pressure sensor
Check the sensor output data
Check the ECU
Incorrect injection timing due to ECU damage
If necessary, replace the ECU
 Symptom Probable cause Remedy
Low engine power out- Check the accel pedal output data if necessary
Malfunction of accel pedal
put , replace the accel pedal
(Poor acceleration)
Check the water temperature sensor using a Hi
Malfunction of water temperature sensor or en- -Scan/
gine overheated Check the engine cooling system, fan and ther-
mostat
Check the fuel pressure sensor using a Hi-Sc-
an/
Low fuel pressure
Check the fuel system(fuel pump, filter, over fl-
ow valve etc.)
Check the intake pressure sensor using a Hi-
Fail intake pressure sensor or abnormal intake Scan/
pressure Check the intake system(Intercooler, intake ho-
se etc.)
Freezing fuel in winter time Check the fuel for wax and fuel condition
Electronic fan clutch inoperative Check the fan clutch circuit
Check the engine overheat using a Hi-scan
Malfunction of EGR system Check the EGR system using a Hi-scan
Check the intake mass air flow sensor using a
Malfunction of the intake mass air flow sensor 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 cylinder affects the engine
acceleration.)
- 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.
• Condition of the Acceleration Test
- When engine is idling(500 rpm)
- Engine warm-up(Coolant temperature 60°C over)
- No engine load(Air-conditioning, Electrical
mechanism etc.)
• 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.
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.
COMPRESSION TEST
Inspection for the state of compressive force of the
engine each cylinder using a Hi-scan and ECU on the
vehicle.
EXPLANATION FOR COMPRESSION TEST
MODE
- 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 4. After completing the test, compare the engine speed
1. With the engine key turned on, connect the Hi-Scan rate for each cylinder by pressing the keys(F1, F2,
and check the control unit. F3..) in sequence.
Then select the compression test mode.
2. Check the message displayed on the screen, if it is
correct press the enter key.

ECBFL5027A

ANALYSIS OF TEST RESULT

- After completing the test, the graph of the engine
ECBFL5025A speed rate for each cylinder will be displayed on the
screen of the Hi-Scan.
3. As indicated on the screen, press the key and crank
the engine. - 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.
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.
SGZFL9012L
3) Perform pumping works, using priming pump on
fuel filter until fuel begins to drain from air vent
cock.
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
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).
2. When replacing a fuel filter element (If fuel is filled in 6) Perform cranking and start the engine
cylinder head) (Air discharge of cylinder head is not necessary
1) Clean the fuel filter. when replacing a filter and engine starts with just
2) Unscrew air vent in fuel filter and remove the cranking once in general)
pressure from fuel line.
3) Replace the filter element.
NOTICE
• Check if the gasket is placed on element
when replacing.
• Apply oil to gasket and tighten it sufficiently
by hand.
• Tightening torque : 4.4±0.2 kgf.m

SDCFL8032D

4) Perform pumping until fuel drains from air vent,

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

SGZFL9012L
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 9. Cam position 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
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 2. Remove the injector cable.
INSPECTION OF INJECTOR (EUI)
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.
Replacement
REPLACEMENT OF UNIT INJECTOR
CAUTION
1. Be sure to replace the injector at the service
center designated by Hmc. SGZFL9016L

1. Do not operate the injector while running the 3. Remove cam cap bolts.
engine because the injector generates the
NOTICE
high voltage over than 50 volts. However,
Separate bolts in turn to prevent rocker arm shaft
when the injector should be operated
from bending.
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 315°C, the
surface of the injector can be carbonized or
sticky, which cause hydrofluoric acid.
When removing the injector from the engine,
be sure to wear protective gloves to protect
the skin.
1. Remove rocker cover
CAUTION
Be careful for unit injector cable harness not to
be damaged.
ECBFL5034A

SGZFL9017L
4. Remove rocker arm shaft using the special 8. Fix protecting sleeve after removing unit injector.
tool(09245-84100). 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.
ECBFL5035A
[Specific torque]
5. Drain fuel in cylinder head according to fuel draining
When replacing other than nozzle tube (when replacing
procedure.
injector only) : 18 N.m(1.8 kgf.m) + 60°
CAUTION When replacing nozzle tube:
Be sure to drain the fuel in the cylinder head First : 18 Nm(1.8 kgf.m) + 60° + 60° Loosen completely
before removing the unit injector to prevent the in 2 min.
fuel in the combustion chamber from inflowing. Second : 18 Nm(1.8 kgf.m) + 60°
6. Clean around the unit injector to replace. 12.Apply engine oil to the cam-shaft rob and the valve
7. Unscrew the injector clamp bolt, remove clamp and bridge and install the rocker arm shaft using the
then remove the injector carefully. special tool(09245-84100).
CAUTION
When removing the used injector, be sure to
wear protective gloves.

ECBFL5035A

ECBFL5037A
13.Install the unit injector
CAUTION
When replacing the unit injector with a new one,
be sure to consider the compensation value of
trim setting code indicated on the top surface of
the injector connector using a scan tool.
Be sure to match the compensation value
indicated on the injector connector and the input
data of the control ECU for the engine
performance and the exhaust gas.

SGZFL9019L

16.Install the rocker cover.

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

SGZFL9014L

14.Connect cable to the unit injector.

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

SGZFL9018L
Priming Pump
Replacement
REPLACEMENT OF FUEL FILTER
1. Unscrew the air vent bolt to eliminate remaining
pressure in fuel filter.
2. Clean the fuel filter around.
SGZFL9020L
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.
REPLACEMENT OF FUEL PUMP
1. Unscrew air vent bolt loosely to eliminate remaining
pressure in fuel pump.
SGZFL9021L
2. Clean the fuel pump around.
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.
Overflow Valve
Replacement 4. Remove overflow valve.
1. Clean the overflow valve around.

ECBFL5053A

ECBFL5053A 5. Clean the contact points of cylinder head and mount

2. Place container under hose of air vent hole at fuel
filter head and loosen air vent bolt.
new overflow valve.
Tightening torque of overflow valve :
40±2 Nm(4±0.2 kgf.m, 28.9±1.5 lb-ft)
6. Install fuel line and perform fuel charge and air
bleeding (Refer to method if the fuel is completely
eliminated from fuel line).
7. Start the engine and run the engine at idle about 10
minutes to bleed air remaining in system.

ECBFL5028A

3. Disconnect fuel line from overflow valve.

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

SGZFL9028L

CAUTION 2. Don't use the sharp tool at removing the sensor,

1. Don't impact or drop the sensor when replacing otherwise the O-ring may be damaged.
it.
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.
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.
SGZFL9031L
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.
SGZFL9032L
4. To install the O-ring of MAF sensor
- Install the O-ring after completing to dry the
sensor.
SGZFL9030L
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 3. Fuel pre-filter

2. Air compressor 4. Fuel pump
Replacement
Fuel tank
1. Park the vehicle on a flat road surface and stop the
engine. Disconnect battery negative(-) cable.
2. Remove the sender connector on the upper of the
fuel tank.
3. Remove return hose and feed hose.
4. Remove the fuel hose connecting to the fuel tank.
5. Support the fuel tank assembly with a jack and
loosen the fuel tank bracket of lower part and the
band mounting nut. And remove the fuel tank.
6. Installation is in the reverse of removal.
NOTICE
When installing fuel cap rotor to fuel cap holder, turn
the ignition key clockwise 15˚ or so with it pressed
after inserting the ignition key into fuel cap rotor(A).
After installed, repeat to lock and unlock the ignition
key five times so that grease is spread evenly.
DTC Troubleshooting
Diagnostic Trouble Codes [DTCs]
No DTC Description
1 P0016 Camshaft - Crankshaft position Correlation
2 P0017 Crankshaft - Camshaft Position Correlation
3 P0072 Ambient Air Temperature Sensor Circuit Low
4 P0073 Ambient Air Temperature Sensor Circuit High
5 P0102 Mass or Volume Air Flow Circuit Low Input
6 P0103 Mass or Volume Air Flow Circuit High Input
7 P0107 Manifold Absolute Pressure Circuit Low Input
8 P0108 Manifold Absolute Pressure Circuit High Input
9 P0112 Intake Air Temperature Sensor Circuit Low
10 P0113 Intake Air Temperature Sensor Circuit High
11 P0117 Engine Coolant Temperature Sensor Circuit Low
12 P0118 Engine Coolant Temperature Sensor Circuit High
13 P0182 Fuel Temperature Sensor Circuit Low
14 P0183 Fuel Temperature Sensor Circuit High
15 P0217 Engine Coolant Over Temperature Condition
16 P0335 Crankshaft Position Sensor Circuit
17 P0340 Camshaft Position Sensor Circuit
18 P0401 Exhaust Gas Recirculation Flow Insufficient Detected
19 P0402 Exhaust Gas Recirculation Flow Excessive Detected
20 P0475 Exhaust Brake, Open Circuit
21 P0480 Fan 1 Control Circuit
22 P0481 Fan 2 Control Circuit
23 P0500 Vehicle Speed Sensor
24 P0541 Intake Air Heater Circuit Low
25 P0542 Intake Air Heater Circuit High
26 P0543 Intake Air Heater Circuit Open
27 P0562 System Voltage Low
28 P0563 System Voltage High
29 P0601 Internal Control Module Memory Check Sum Error
30 P0611 Fuel Injector Control Module Performance
31 P0615 Starter Relay Circuit Open
32 P0616 Starter Relay Circuit Low
33 P0617 Starter Relay Circuit High
No DTC Description
34 P0642 Sensor 5V Reference Under Range
35 P0643 Sensor 5V Reference Over Range
36 P0652 Pedal Sensor Reference Voltage Circuit Low
37 P0653 Pedal Sensor Reference Voltage Circuit High
38 P0668 ECU Internal Temperature Sensor Circuit Low
39 P0669 ECU Internal Temperature Sensor Circuit High
40 P0685 ECU Power Relay Control Circuit /Open
41 P0691 Fan 1 Control Circuit Low
42 P0692 Fan 1 Control Circuit High
43 P0693 Fan 2 Control Circuit Low
44 P0694 Fan 2 Control Circuit High
45 P1087 Fuel Pressure Derate Level 1
46 P1088 Fuel Pressure Derate Level 2
47 P1089 Fuel Pressure Derate Level 3
48 P1106 Air Plausibility Fault
49 P1201 Injector 1 needle valve open circuit
50 P1202 Injector 1 needle valve short circuit across injector
51 P1203 Injector 1 needle valve low side short circuit to ground
52 P1204 Injector 1 needle valve low side short circuit to battery voltage
53 P1205 Injector 2 needle valve open circuit
54 P1206 Injector 2 needle valve short circuit across injector
55 P1207 Injector 2 needle valve low side short circuit to ground
56 P1208 Injector 2 needle valve low side short circuit to battery voltage
57 P1209 Injector 3 needle valve open circuit
58 P1210 Injector 3 needle valve short circuit across injector
59 P1211 Injector 3 needle valve low side short circuit to ground
60 P1212 Injector 3 needle valve low side short circuit to battery voltage
61 P1213 Injector 4 needle valve open circuit
62 P1214 Injector 4 needle valve short circuit across injector
63 P1215 Injector 4 needle valve low side short circuit to ground
64 P1216 Injector 4 needle valve low side short circuit to battery voltage
65 P1217 Injector 5 needle valve open circuit
66 P1218 Injector 5 needle valve short circuit across injector
67 P1219 Injector 5 needle valve low side short circuit to ground
68 P1220 Injector 5 needle valve low side short circuit to battery voltage
No DTC Description
69 P1221 Injector 6 needle valve open circuit
70 P1222 Injector 6 needle valve short circuit across injector
71 P1223 Injector 6 needle valve low side short circuit to ground
72 P1224 Injector 6 needle valve low side short circuit to battery voltage
73 P1225 Injector 1, 3, or 5 needle valve high side short circuit to ground
74 P1226 Injector 1, 3, or 5 needle valve high side short circuit to battery voltage
75 P1227 Injector 2, 4, or 6 needle valve high side short circuit to ground
76 P1228 Injector 2, 4, or 6 needle valve high side short circuit to battery voltage
77 P1229 Injector 1 spill valve open circuit
78 P1230 Injector 1 spill valve short circuit across injector
79 P1231 Injector 1 spill valve low side short circuit to ground
80 P1232 Injector 1 spill valve low side short circuit to battery voltage
81 P1233 Injector 2 spill valve open circuit
82 P1234 Injector 2 spill valve short circuit across injector
83 P1235 Injector 2 spill valve low side short circuit to ground
84 P1236 Injector 2 spill valve low side short circuit to battery voltage
85 P1237 Injector 3 spill valve open circuit
86 P1238 Injector 3 spill valve short circuit across injector
87 P1239 Injector 3 spill valve low side short circuit to ground
88 P1240 Injector 3 spill valve low side short circuit to battery voltage
89 P1241 Injector 4 spill valve open circuit
90 P1242 Injector 4 spill valve short circuit across injector
91 P1243 Injector 4 spill valve low side short circuit to ground
92 P1244 Injector 4 spill valve low side short circuit to battery voltage
93 P1245 Injector 5 spill valve open circuit
94 P1246 Injector 5 spill valve short circuit across injector
95 P1247 Injector 5 spill valve low side short circuit to ground
96 P1248 Injector 5 spill valve low side short circuit to battery voltage
97 P1249 Injector 6 spill valve open circuit
98 P1250 Injector 6 spill valve short circuit across injector
99 P1251 Injector 6 spill valve low side short circuit to ground
100 P1252 Injector 6 spill valve low side short circuit to battery voltage
101 P1253 Injector 1, 3, or 5 spill valve high side short circuit to ground
102 P1254 Injector 1, 3, or 5 spill valve high side short circuit to battery voltage
103 P1255 Injector 2, 4, or 6 spill valve high side short circuit to ground
No DTC Description
104 P1256 Injector 2, 4, or 6 spill valve high side short circuit to battery voltage
105 P1403 EGR EDU power-up sequence.
106 P1562 The battery voltage is too high
107 P1653 Check Engine/Diagnostics Lamp, open circuit
108 P1654 Check Engine/Diagnostics Lamp, shortcut to ground
109 P1655 Check Engine/Diagnostics Lamp, shortcut to battery
110 P1656 Engine Hot Lamp Output Control Circuit
111 P1657 Engine Hot Lamp, shortcut to battery
112 P1658 Engine Hot Lamp, shortcut to ground
113 P1666 Fault on the hardware watchdog
114 P1680 Memory fault with customer data checksum
115 P1681 Memory fault with calibration data checksum
116 P1700 Engine brake 1, open circuit
117 P1701 Engine brake 2, open circuit
118 P1702 Engine brake 3, open circuit
119 P2109 Pedal Position Sensor Minimum Stop Performance
120 P2110 Pedal Position Sensor Maximum Stop Performance
121 P2147 Injector boost voltage under range
122 P2148 Injector boost voltage over range
123 P2228 Barometric pressure circuit low
124 P2229 Barometric pressure circuit high
125 P2541 Low Pressure Fuel System Sensor circuit Low
126 P2542 Low Pressure Fuel System Sensor circuit High
127 P2609 Intake Air Heater System Performance
128 U1169 EGR Valve Stick Fault
129 U1170 EGR Actuator Terminal Coil Open Circuit
130 U1171 EGR Actuator Over Current
131 U1180 EGR Actuator Battery Supply Error
132 U1182 EGR Valve Position Error
133 U1183 EGR Message Transmit Fault Error