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Hyundai D6CC ECU MANUAL PDF
Hyundai D6CC ECU MANUAL PDF
General
Specifications ................................................... FL - 2
Special Tools ..................................................... FL - 3
Description ........................................................ FL - 4
External Wiring Diagram Of Unit Injector
(ECU) ................................................................ FL -16
Troubleshooting ................................................ FL -17
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
SDHEM7022D
DESCRIPTION
SGZFL9001L
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. 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
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
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
ECBFL5012A
ECBFL5013A
ECBFL5014A
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.
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 ANALYSIS OF THE TEST RESULT
• With the engine installed to the vehicle, the injector - If the figure or the graph displayed on the screen of
and the combustion performance can be inspected the Hi-Scan is low relatively, a performance
using a Scan tool and the ECU. deterioration of injector and a poor combustion are
• Description for Acceleration Test Mode suspected.
- Comparison of the engine power variation for - If the result value is much low than them of the other
each cylinder cylinders, inspect the EUI of each cylinder or replace
the cylinder with a new one.
- Measurement of the acceleration time by
accelerating the engine with the injectors stopped - If necessary, collect information of the overhaul
one by one. history and a compressive force test and then
analysis and judge the test result.
(Check if any cylinder affects the engine
acceleration.) NOTICE
- At the engine idle, with one cylinder stopped the • Be sure to check the coolant temperature is 60 C
EUI injection, accelerate the engine with five over because engine warm-up can affect the
cylinders. Then measure the acceleration time result of test.
until the 60th times of fuel injection. • After performing the test, the pedal is not
- For each cylinder, repeat the above procedure operated properly, however, this is normal
and measure the each acceleration time. condition.If the engine is turned off and on
repeatedly, the pedal operates properly.
- Compare the measured value relatively and print
the data. • Judge the test result by the relative comparison
and the total average for each cylinder.
Then evaluate the engine power effect for each
cylinder by the compared result. The average of the absolute value is affected by
the engine condition(Load, coolant temperature
- All the above procedures are performed in the
etc.).
acceleration test mode automatically and the
result is displayed on the Hi-Scan with the figure Therefore, judge the test result by the relative
and the graph. comparison in priority.
• Condition of the Acceleration Test • Use this as reference material to inspect the
injector and the combustion performance of the
- When engine is idling(500 rpm)
related cylinder.
- Engine warm-up(Coolant temperature 60°C over)
After overhauling the engine, be sure to perform
- No engine load(Air-conditioning, Electrical this test to inspect cylinders operate properly.
mechanism etc.)
COMPRESSION TEST
• How to use the Scan tool
Inspection for the state of compressive force of the
1. When the engine is idling(500 rpm), release the engine each cylinder using a Hi-scan and ECU on the
engine load such as air-conditioning. vehicle.
2. Connect the Scan tool and check the control unit. EXPLANATION FOR COMPRESSION TEST
Then select the acceleration test mode. MODE
3. Check the message on the screen and if it is - Characteristic comparison of compressive force for
correct, press the enter key. each cylinder
4. As indicated on the screen, press the accel pedal - During engine cranking, measure the engine speed
fully and press the enter key. rate by the compressive resistance from the cylinder.
5. Engine will perform the acceleration test (With the compressive force test mode, no fuel
automatically 6 times. During the test, keep the injection)
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.
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
ECBFL5026A
FUEL SYSTEM DRAINING 4) Close bolt when air has been eliminated
1. Clean around air vent of cylinder head side and fuel completely in fuel discharged to fuel filter air vent
filter side. 5) Unscrew air vent bolt at cylinder head front.
ECBFL5028A ECBFL5028A
FUEL CHARGE AND AIR BLEEDING 6) Close cock after pumping until air is eliminated in
1. After engine assembly/disassembly or fuel bleeding fuel in the same way as described in the Clause
(If fuel is eliminated completely in fuel line) 3).
1) Clean around the air vent of fuel filter and 7) Execute the cranking when the above works are
cylinder head. all done.
2) Unscrew air vent bolt on fuel filter head a little. Crank it for the time for enough (10 to 15 sec.)
and several times until engine starts.(about 3 to 5
times, if fuel has been eliminated fuel line,
especially if fuel in injector is eliminated
thoroughly, sufficient cranking is necessary from
air discharge to start the engine)
Cranking time should not exceed 15 sec. because
cranking for a long time influences badly on
starter motor. Keep the interval of approx. 30 sec.
until the next cranking to prevent starter motor
from overheating.
8) When engine starts, wait until engine becomes
stable, pedaling accelerator (Approx. 1000rpm).
SGZFL9012L
SDCFL8032D
SGZFL9012L
Engine Control System-Electronic
Engine Control Unit(ECU)
REPLACEMENT OF CONTROL ECU
1. Remove the control ECU(A).
SGZFL9013L
SGZFL9014L
Electronic Unit Injector(EUI)
Components
SGZFL9015L
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
SGZFL9014L
SGZFL9018L
Priming Pump
Replacement REPLACEMENT OF FUEL PUMP
REPLACEMENT OF FUEL FILTER 1. Unscrew air vent bolt loosely to eliminate remaining
1. Unscrew the air vent bolt to eliminate remaining pressure in fuel pump.
pressure in fuel filter.
2. Clean the fuel filter around.
SGZFL9021L
ECBFL5053A
ECBFL5028A
SGZFL9028L
SGZFL9029L
CAUTION 3. To dry the sensor element
1. To remove the O-ring of MAF sensor - Using the air gun : Below 5 bar, within 30
- Remove the O-ring of MAF sensor to prevent seconds.
it from damage by cleaning spray and clean - After atomizing the spray, dry the sensor like
the sensor element. below picture for 20 minutes.
SGZFL9030L
SGZFL9030L
SGZFL9031L
Fuel Delivery System-Electronic
Accelerator Pedal
Replacement
Accelerator pedal(Bus)
1. Turn the ignition key off and disconnect battery
negative(-) cable.
2. Remove the accelerator sensor connector.
3. Remove the accelerator pedal assembly(A) after
removing accelerator pedal mounting bolt.
ECBFL5062A
SGZFL9022L