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Diagnosis Procedures
Read DTC
YES
Sensor Voltage Fault? Sensor problem caused by supply voltage
to sensor. Locate the problem while dis-
connecting the sensor connectors one by
one. If not sensor problem, check sensor
supply voltage circuit for open and short.
NO
YES
Wiring Problem? Repair or Replace rail and sensor
replace
NO YES
Trouble Continues? Replace ECU
YES
Wiring Problem? Repair or Check fuel system
replace
NO
YES
Wiring Problem? Repair wiring
DIAGNOSIS CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI10-150
CHANGED BY DIAGNOSIS
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
DI10-151
Diagnosis Procedures
YES
Wiring Problem? Repair or Reinstall connect and wiring
replace
NO
YES
Trouble Continues? Replace rail
and sensor
Check ECU wiring
NO
YES
Wiring Problem? Repair or Repair completed
replace
NO
YES
Wiring Problem? Repair wiring
DIAGNOSIS CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI10-152
Diagnosis Procedures
NO
YES
Wiring Problem? Repair or
replace Perform forced operation
and replace relay
NO
YES
Check ECU wiring Not available forced Replace ECU
operation?
YES
Wiring Problem? Repair or NO
replace
NO Repair completed
YES
Wiring Problem? Repair wiring
CHANGED BY DIAGNOSIS
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
DI10-153
Diagnosis Procedures
NO
YES
Automatic Transmission Recognize
Equipped? vehicle speed Check gear box target
through CAN.
Check CAN
NO and
YES
transmission. Gear Box Target Problem? Replace gear
box target
Check sensor and wiring NO
NO YES
Trouble Continues? Replace ECU
YES
Wiring Problem? Repair or Repair completed
replace
NO
YES
Wiring Problem? Repair or
replace
DIAGNOSIS CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI10-154
P0643 High
Diagnosis Procedures
YES
All DTCs for sensors Sensor problem caused by supply voltage to
connected to sensor supply sensor. Locate the problem while discon-
voltage? necting the sensor one by one. If not sensor
problem, check wiring.
NO
Check wiring
YES
Trouble Continues? Replace ECU
NO
Repair completed
CHANGED BY DIAGNOSIS
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
DI10-155
P0652 Low
P0653 High
Diagnosis Procedures
YES
All DTCs for sensors Sensor problem caused by supply voltage
connected to sensor supply to sensor. Locate the problem while dis-
voltage? connecting the sensor one by one. If not
sensor problem, check wiring.
NO
Check wiring
YES
Trouble Continues? Replace ECU
NO
Repair completed
DIAGNOSIS CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI10-156
P0699 High
Diagnosis Procedures
YES
All DTCs for sensors Sensor problem caused by supply voltage
connected to sensor supply to sensor. Locate the problem while dis-
voltage? connecting the sensor one by one. If not
sensor problem, check wiring.
NO
Check wiring
YES
Trouble Continues? Replace ECU
NO
Repair completed
CHANGED BY DIAGNOSIS
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
DI10-157
Diagnosis Procedures
NO
YES
Wiring Problem? Repair or
replace Replace actuator
NO
YES
Trouble Continues? Replace ECU
Check resistance of actuator
NO
YES
Resistance Problem? Replace Repair completed
actuator
NO
YES
Wiring Problem? Repair or
replace
NO
YES
Wiring Problem? Repair wiring
NO
DIAGNOSIS CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI10-158
Diagnosis Procedures
Read DTC
YES
ECU Related DTC? Check body
ground wiring
NO
Check wiring
YES
Trouble Continues? Replace ECU
NO
Repair completed
CHANGED BY DIAGNOSIS
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
DI10-159
Diagnosis Procedures
Read DTC
YES
ECU Related DTC? Check body
ground wiring
NO
Check wiring
YES
Trouble Continues? Replace ECU
NO
Repair completed
DIAGNOSIS CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI10-160
Diagnosis Procedures
Read DTC
YES
ECU Related DTC? Check body
ground wiring
NO
Check wiring
YES
Trouble Continues? Replace ECU
NO
Repair completed
CHANGED BY DIAGNOSIS
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
DI10-161
Diagnosis Procedures
Read DTC
YES
ECU Related DTC? Check body
ground wiring
NO
Check wiring
YES
Trouble Continues? Replace ECU
NO
Repair completed
DIAGNOSIS CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI10-162
Diagnosis Procedures
Read DTC
YES
ECU Related DTC? Check body
ground wiring
NO
Check wiring
YES
Trouble Continues? Replace ECU
NO
Repair completed
CHANGED BY DIAGNOSIS
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
DI10-163
Diagnosis Procedures
Read DTC
YES
Knock Sensor Related DTC? Refer to
“Accelerom-
eter (Knock
NO Sensor)
Diagnosis”
DIAGNOSIS CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI10-164
Diagnosis Procedures
Read DTC
YES
EGR valve and HFM sensor Check
related DTC? sensors and
EGR system
NO
Repair completed
CHANGED BY DIAGNOSIS
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
DI10-165
Diagnosis Procedures
1. Diagnosis Procedures(Boost Pressure)
Read DTC
YES
Boost Pressure Problem? Refer to
Diagnosis
Tree “Check
NO sensor(1)”
Repair completed
DIAGNOSIS CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI10-166
Read DTC
YES
Sensor Supply Voltage Sensor problem caused by supply voltage
Problem? to sensor. Locate the problem while dis-
connecting the sensor connectors one by
one. If not sensor problem, check sensor
supply voltage circuit for open and short.
NO
YES
Wiring Problem? Repair or
replace Check wiring and insulation
NO
YES
Wiring Problem? Repair or
Visually check sensor replace
NO
YES
Sensor Problem? Replace
sensor Replace sensor
NO
YES
Trouble Continues? Replace ECU
Check ECU wiring
NO
YES
Wiring Problem? Repair or
replace Check fuel system
CHANGED BY DIAGNOSIS
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
DI10-167
TBD
Diagnosis Procedures
Read DTC
YES
ECU Related DTC? Check body
ground wiring
NO
Check wiring
YES
Trouble Continues? Replace ECU
NO
Repair completed
DIAGNOSIS CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI10-168
No Crank Signal
Diagnosis Procedures
YES
Wiring Problem? Repair or
YES
replace Trouble Continues? Replace APS
wheel
NO
NO
YES
Wiring Problem? Repair or
YES
replace Trouble Continues? Replace ECU
NO
NO
YES
Wiring Problem? Repair wiring
NO
YES
Trouble Continues? Replace VR
sensor
NO
CHANGED BY DIAGNOSIS
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
DI10-169
Diagnosis Procedures
Read DTC
YES
IMV Related DTC? Refer to IMV
diagnosis
NO
Read DTC
NO
YES
Rail Pressure Sensor Repair or Check high pressure fuel
Problem? replace system
NO
YES
High pressure fuel system Repair or
Problem? replace
Check transfer pressure fuel
system
NO
YES
Transfer pressure fuel Repair or Replace ECU
system Problem? replace
DIAGNOSIS CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI10-170
P1676 Communication
P1677 Controller
Diagnosis Procedures
Read DTC
NO
YES
Poor Glow Plug Communica-
Communication? tion problem Check wiring and insulation
between ECU
and glow plug
NO box. Check
YES
related wirings. Wiring Problem? Repair wiring
Check glow plug box wiring
NO
YES
Wiring Problem? Repair or Replace glow plug box
replace
NO
YES
Trouble Continues? Replace ECU
Check glow plug and wiring
(Resistance: below 1 Ω) NO
YES
Wiring Problem? Repair or
replace
CHANGED BY DIAGNOSIS
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
DI10-171
Diagnosis Procedures
Read DTC
NO
YES
Poor Glow Plug Communica-
Communication? tion problem Check wiring and insulation
between ECU
and glow plug
NO
box. Check YES
related wirings. Wiring Problem? Repair wiring
Check glow plug box wiring
NO
Repair completed
YES
Problems? Repair or
replace glow
NO
plug
YES
Wiring Problem? Repair or
replace
DIAGNOSIS CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI10-172
Diagnosis Procedures
Read DTC
NO
YES
Poor Glow Plug Communica-
Communication? tion problem Check wiring and insulation
between ECU
and glow plug
NO
box. Check YES
related wirings. Wiring Problem? Repair wiring
Check glow plug box wiring
NO
Repair completed
YES
Problems? Repair or
replace glow
NO
plug
YES
Wiring Problem? Repair or
replace
CHANGED BY DIAGNOSIS
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
DI10-173
Diagnosis Procedures
YES
Wiring Problem? Repair or
replace
NO
YES
Wiring Problem? Repair wiring
NO
YES
Communication problem Repair or
continues replace
(Replace TCU)
NO
Repair completed
DIAGNOSIS CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI10-174
Diagnosis Procedures
NO YES
Wiring Problem? Repair wiring
NO
YES
A/C Problem? Repair or
replace
Check sensor
NO
YES
Sensor Problem? Replace Replace sensor
sensor
NO
YES
Trouble Continues? Replace ECU
Check ECU wiring
NO
YES
Wiring Problem? Repair or Repair completed
replace
CHANGED BY DIAGNOSIS
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
DI10-175
Diagnosis Procedures
NO
YES
Water in fuel filter? Repair
completed Check ECU wiring
NO
YES
Wiring Problem? Repair or
Check water detection sensor
replace
NO
YES
Wiring Problem? Repair or
replace Check wiring and insulation
NO
YES
Wiring Problem? Repair wiring
Check water detection
sensor wiring
NO
YES
Wiring Problem? Repair or Replace ECU
replace
NO
YES
Resistance Problem? Replace
coolant
temperature
sensor
DIAGNOSIS CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI10-176
Immobilizer Malfunction
P1630
P1631
P1632
P1633
P0633
P1636
Diagnosis Procedures
YES
Wiring Problem? Repair or
replace
NO
YES
Perform immobilizer coding Repair
again completed
NO
CHANGED BY DIAGNOSIS
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
DI10-177
DIAGNOSIS CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI10-178
High pressure
Transfer pump pump
Supply
valve
Suction
valve
Below 2 bar
Injectors
Priming pump
Fuel filter
CHANGED BY DIAGNOSIS
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
DI10-179
Fuel injection
volume
Y220_10063
DIAGNOSIS CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI10-180
Pressure/volume loss
Fuel injection
volume
Pressure/volume Pressure/volume
consumption build up
Y220_10064
Ex.:
• Foreign materials in fuel
• Burnt out or worn high pressure pump
• Mechanical damage in inside of injector
CHANGED BY DIAGNOSIS
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
DI10-181
Pressure/volume loss
Injector back
leak volume
Pump capacity
Fuel injection
volume
Pressure/volume Pressure/volume
consumption build up
Y220_10065
Ex.:
• Air in fuel supply line
• Excessive vacuum pressure in fuel supply line (-300 mbar)
• Burnt out or mechanically damaged pump
• Supply fuel with increased temperature ( > 65°C)
DIAGNOSIS CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI10-182
Y220_10066
Y220_10067
CHANGED BY DIAGNOSIS
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
DI10-183
Prerequisite
1. Check the connections in fuel supply lines.
2. Check the fuel level in fuel tank.
3. Check if the air exists in fuel supply lines (air bubbles in fuel supply lines or fuel with air bubbles).
4. Check the fuel supply lines for leaks (transfer and high pressure).
5. Check if the specified fuel is used.
6. Check the fuel filter for contamination and abnormality.
Determine DTC
No Yes
DTC Detected?
no
Check and repair Diagnose and repair
transfer and H/P fuel Check fuel filter and H/P according to the de-
system fuel system tected DTC
Notice
If more than one DTC have been detected, check the wiring
harness for open or short first.
Check the transfer fuel system and fuel filter before
proceeding the high pressure fuel system check in next page.
DIAGNOSIS CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI10-184
No
No Abnormality Check and repair
in Initial Check?
Yes
Method 1 Method 2
Static Test for Injector Back leak Volume Dynamic Test for Injector Back leak Volume (refer to 4-4)
(refer to 4-3)
(with engine running)
(with engine cranking but not running)
1. Warm up engine (coolant temp.: over 60°C), place an
Place an empty plastic container under the return of empty plastic container under the return of injector, and
injector: start engine.
Remove IMV and injector connectors, crank for 5 2. Run the engine for 30 seconds at idle speed, perform :
seconds, and check the injector back leak volume. fuel system pressure leakage test” with Scan-i, and
The fuel length in tube should be over 20 cm. check the fuel level in container. It should be over 38 ml.
No
CHANGED BY DIAGNOSIS
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
DI10-185
Y220_10068
Y220_10069
Y220_10070
DIAGNOSIS CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI10-186
Y220_10071
Note
The fuel rail pressure can be measured through the scan
tool.
Y220_10072
CHANGED BY DIAGNOSIS
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
DI10-187
Test Procedures
1. All wiring harnesses, connectors and fuel lines should
be installed properly and the engine should be ready to
start.
2. Prepare the special tools for transfer fuel system test
and thoroughly clean the system.
Y220_10073
3. Disconnect the key connector for connecting the priming pump to fuel filter and install both connectors of the
special tool to the fuel pump and the priming pump hoses.
Y220_10074
4. Start the engine and visually check the transfer line for clogged and air bubbles while running the engine at idle
speed.
5. If the fuel flows are not smooth or air bubbles are found in fuel lines, locate the leaking area and correct it.
DIAGNOSIS CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI10-188
Y220_10076
Y220_10077
Y220_10078
CHANGED BY DIAGNOSIS
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
DI10-189
Note
If the measured value is out of specified value, replace
the injector.
Y220_10079
DIAGNOSIS CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI10-190
Y220_10080
Y220_10081
4. Start the engine and let it run for 2 minutes at idle speed.
5. Check if the back leak volume meets the specification.
Y220_10082
CHANGED BY DIAGNOSIS
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
DI10-191
2. Test Conditions:
• No defective or faulty sensors and components in fuel system: checked by Scan-i
• Coolant temperature: over 60°C
DIAGNOSIS CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI10-192
CHANGED BY DIAGNOSIS
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
DI10-193
Y220_10083
Specified value 40 Nm
3. Install the opposite end of the closed rail into the fuel rail
for test.
Specified value 40 Nm
Y220_10085
Y220_10086
DIAGNOSIS CHANGED BY
DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI10-194
Y220_10087
Y220_10088
CHANGED BY DIAGNOSIS
EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
REXTON (1 OF 2)
ENGINE SERVICE MANUAL
ISSUED BY
INTERNATIONAL A/S TEAM
SSANGYONG MOTOR CO., LTD.
TELEPHONE : 82-31-610-2740
FACSIMILE : 82-31-610-3762