10.

Trouble shooting

0
Check sensors

1. PREPARATION
- Circuit Tester (Multi-meter)
Note : The Circuit tester is used during inspection procedure to check the continuity and
resistance of each electrical components.

2. CRICYIT TESTER USE

- Turn the engine key switch OFF when checking continuity or resistance.
CAUTION : If the key switch is ON when checking continuity or resistance,
Then electrical components may be damaged.

- Do not damage connector terminals when checking continuity or resistance.

- Do not push the tester pins into the female terminals.
CAUTION : New faults may arise if the connector terminals are damaged.

3. AFTER INSPECTION
- Always reconnect connector in their original position after checking continuity or resistance
CAUTION : New faults or improper operation may arise if the connectors are not reinstalled
in the original position.

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Check sensors

1-1. Injector Inspection

※ Remark
Injector Inspection
Key switch (ECU Power) OFF
Visual Check

Check Injector tightness

No
Results OK?

Yes Connector Fixing

Resistance Check

No
Resistance OK?

Yes

Mechanically and
Electronically OK Replace Injector

Injector Function check

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1-2. Injector Resistance Measurement

¾ Injector Coil resistance

Terminal NO Engine Resistance (mΩ) Temperature (˚C)

No Polarity DL06 220~290mΩ 20 ˚C
DL08, 310~420mΩ
DV11

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1-3. Electrical characteristic of Injector for DL08, DV11

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1-4. Electrical characteristic of Injector for DL06

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Check sensors

2-1. Metering Unit Inspection

※ Remark
CP3.x Inspection
Key switch (ECU Power) OFF
Visual Check

Check tightness

No
Results OK?

Yes Connector Fixing

MPROP Resistance Check

No
Resistance OK?

Yes

CP3.x Function Check Replace

CP3.x Pump
or lese MPROP

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Check sensors

2-2. MPROP Resistance Measurement

¾ MROP Resistance

Terminal NO Resistance (mΩ) Temperature (˚C)

No Polarity 2.6±3.15mΩ 20 ˚C

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3-1. RDS Inspection

※ Remark
Common Rail Inspection
Need a power supply
Visual Check to provide 5 Voltage

Check tightness

No
Results OK?

Yes Connector Fixing

RDS Check

No
Output OK?

Yes

Faulty Vehicle Wire Harness Replace RDS

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Check sensors

3-2. RDS Failure Check

1. RDS terminals / ECU PIN Description

RDS Pin No / ECU PIN Components wiring

Pin No 1 / 2.20 Ground(-)
Pin No 2 / 2.27 Output
Pin No 3 / 2.12 Supply Voltage

2. Power Supply connection

RDS Pin No Input Voltage (V) Remark

1-3 DC 5 volt Need power supply

3. Check RDS output signal

RDS Pin No Output signal (V) Ambient pressure

1-2 0.48 ~ 0.59 1 bar

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Check sensors

4-1. Cam & Crank Sensor Inspection

※ Remark
Cam & Crank Sensor Inspection
Key switch (ECU Power) OFF
Visual Check

Check tightness

No
Results OK?

Yes
Cam & Crank Sensor Resistance
Check

No
Resistance OK?

Yes

Faulty Vehicle Wire Harness Replace Sensor

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Check sensors

4-2. Cam & Crank sensor Check

¾ Sensor Type

Sensor DL06 DL08 DV11

Crank SIEMENS VDO(3 BOSCH(2 Pin) BOSCH(2
Pin) Pin)
Cam SIEMENS VDO(3 SIEMENS VDO(3 Pin) BOSCH(2
Pin) Pin)

¾ Sensor Resistance

Terminal NO Resistance (Ω) Temperature (˚C) Remark

1-2 860Ω±10% 20 ˚C No Polarity

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Check sensors

5-1. Temperature Sensor Inspection

※ Remark
Temperature Sensor Inspection
Key switch (ECU Power) OFF

Visual Check

No
Results OK?

Yes
Temperature Sensor Resistance
Check

No
Resistance OK?

Yes

Faulty Vehicle Wire Harness Replace Sensor

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Check sensors

5-2. Temperature sensor Check

¾ Sensor Resistance

Resistance(KΩ)
Terminal NO Temperature (˚C) Remark
Min Normal Max
1-2 2.35 2.50 2.65 20 ˚C No Polarity

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Check sensors

6-1. Air Pressure & Temperature Sensor Inspection

※ Remark
Air Pres. & Tem. Sensor Inspection
Key switch (ECU Power) OFF
Visual Check Need a power supply to
provide 5 Voltage
No
Results OK?

Yes
Tem. Sensor Resistance Check

No
Resistance OK?

Yes

Pressure Sensor Check

No
Output OK?

Yes

Faulty vehicle wire harness Replace Sensor

14
Check sensors

6-2. Air Pressure & Tem. sensor Check

1. Sensor terminals / ECU PIN Description

Pin No / ECU PIN Components wiring Remark

No
1 / 2.21 Ground(-)
2 / 2.29 NTC Temperature Signal Out
3 / 2.10 +5 V Supply Voltage
4 / 2.28 Pressure Out Pressure Signal Out

2. Pressure Sensor Output Signal

Pin No Output Signal (V) Ambient Pressure
1-4 0.98 ~ 1.14 1bar

3. Tem. Sensor Resistance

Resistance (KΩ) Temperature
Terminal NO Remark
Min Normal Max (˚C)

1-2 2.41 2.50 2.62 20 ˚C No Polarity

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Check sensors

7-1. Oil Presure & Temperature Sensor Inspection

※ Remark
Oil pres & tem. Sensor Inspection
Key switch (ECU Power) OFF
Visual Check Need a power supply to
provide 5 Voltage
No
Results OK?

Yes
Tem. Sensor Resistance Check

No
Resistance OK?

Yes

Pressure Sensor Check

No
Output OK?

Yes

Faulty vehicle wire harness Replace Sensor

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Check sensors

7-2. Oil Pressure & Tem. sensor Check

1. Sensor terminals / ECU PIN Description

Pin No / ECU PIN Components wiring Remark

No
1 / 2.19 Ground(-)
2 / 2.35 NTC Temperature Signal Out
3 / 2.09 +5 V Supply Voltage
4 / 2.33 Pressure Out Pressure Signal Out

2. Pressure Sensor Output Signal

Pin No Output Signal (V) Ambient Pressure
1-4 0.98 ~ 1.14 1bar

3. Tem. Sensor Resistance

Resistance (KΩ) Temperature
Terminal NO Remark
Min Normal Max (˚C)

1-2 2.30 2.50 2.70 20 ˚C No Polarity

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Trouble shooting

1. Can not start engine (Even though starter is OK)

• Self diagnosis

• Fuel supply
• Electric power supply

• Electric wire harness (Fuse), Bad Injector connection

• Fuel line leakage (High pressure line, low pressure line)

• Bad fuel
• Air mixing in fuel line
• Fuel filter
Check point • Defect of gear pump on CP pump

• Mechanical defect of engine

• Mechanical defect of injector

• Pressure limiter valve on CP pump is opened

• Bad connection or intermittent connection

• Defect of Camshaft / Crank speed sensor
• Mechanical defect of CP pump
• Defect of metering unit on CP pump
• Defect of ECU

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Trouble shooting

2. Engine stop while running (Can not be started again)

• Self diagnosis

• Fuel supply
• Electric power supply

• Electric wire harness of start circuit

• Fuel line leakage (High pressure line, low pressure line)

• Bad fuel
• Air mixing in fuel line
• Fuel filter
Check point • Defect of gear pump on CP pump

• Mechanical defect of engine

• Mechanical defect of injector

• Pressure limiter valve on CP pump is opened

• Bad connection or intermittent connection

• Defect of Camshaft / Crank speed sensor
• Mechanical defect of CP pump
• Defect of metering unit on CP pump
• Defect of ECU

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Trouble shooting

3. Engine stop while running (can be started again)

• Self diagnosis
• Electric wire harness (Fuse) of start circuit
• Bad fuel
• Air mixing in fuel line
• Fuel filter
Check point
• Fuel line leakage (High pressure line, low pressure line)

• Bad connection or intermittent connection

• Defect of crank speed sensor
• Mechanical defect of high pressure pump or metering unit
• Rail pressure valve is opened

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Trouble shooting

4. Can not start engine

• Self diagnosis
• Electric power supply
• Fuel line leakage (High pressure line, low pressure line)
• Bad fuel
• Air mixing in fuel line
• Fuel filter
• Defect of gear pump on CP pump
• Air filter
• Pressure limiter valve on CP pump is opened
• Bad connection or intermittent connection
• Defect of Camshaft sensor
Check point • Mechanical defect of CP pump
• Defect of metering unit on CP pump
• Defect of coolant sensor
• Defect of rail pressure sensor
• Defect of injector
• Injector closed
• Lots of fuel overflow from injector
• Bad connection or intermittent connection
• Check main relay
• Electric wire harness (Fuse) of start circuit (Start key)
• Mechanical defect of engine
• Defect of crank speed sensor
• Defect of ECU

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Trouble shooting

5. Drop of engine speed

• Self diagnosis

• Mechanical defect of accelerator pedal

• Mechanical defect of CP pump
• Defect of metering unit on CP pump

• Air mixing in fuel line

• Fuel filter
Check point • Wire harness / Fuse
• Defect of crank speed sensor
• Abnormal signal of accelerator pedal
• Defect of coolant sensor
• Defect of boost sensor
• Fuel leakage of low pressure fuel line
• Pressure limiter valve on CP pump is opened
• Defect of gear pump on CP pump
• Defect of rail pressure sensor on common rail

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Trouble shooting

6. Drop of torque or power (Engine speed can be increased)

• Self diagnosis

• Mechanical defect of accelerator pedal

• Abnormal signal of accelerator pedal

Check point
• Bad connection or intermittent connection
• Defect of coolant sensor
• Defect of boost sensor
• Defect of gear pump on CP pump
• Defect of ECU

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Trouble shooting

7. Engine knocking while accelerating

• Self diagnosis

• Defect of coolant sensor

• Defect of Boost sensor
• Defect of rail pressure sensor on common rail

• Mechanical defect of injector

• Mechanical defect of engine

Check point

• Defect of ECU
• Air mixing in fuel line
• Fuel filter
• Leakage of low pressure fuel line
• Defect of metering unit on CP pump
• Pressure limiter valve on CP pump is opened
• Defect of gear pump on CP pump

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Trouble shooting

8. Vibration of engine with lower engine speed

• Self diagnosis

• Bed fuel
• Air mixing in fuel line
• Fuel filter
• Defect of gear pump on CP pump
• Bad connection of injector connector
Check point
• Air filter

• Mechanical defect of injector

• Bad connection or intermittent connection

• Defect of metering unit on CP pump

• Defect of rail pressure sensor on common rail

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Trouble shooting

9. Low engine power

• Self diagnosis
• Leakage of low pressure fuel line
• Leakage air before intake manifold

• Air filter

• Bad fuel
• Fuel filter
• Defect gear pump on CP pump

• Mechanical defect of accelerator pedal

• Abnormal signal of accelerator pedal
Check point
• Defect turbocharger

• Defect of coolant sensor

• Defect of boost pressure sensor
• Defect of rail pressure sensor on common rail

• Mechanical defect of engine

• Air mixing in fuel line

• Defect of crank speed sensor
• Opened pressure limiter valve of common rail

• Mechanical defect of injector

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Trouble shooting

10. Abnormal engine operation (noise, smoke)

• Self diagnosis

• Bad fuel
• Air mixing in fuel line
• Fuel filter
• Defect of gear pump on CP pump

• Wire harness (Fuse)

• Main relay
• Electric wire harness (Fuse) of start circuit
Check point • Electric power supply

• Mechanical defect of injector

• Defect of metering unit on CP pump

• Bad connection or intermittent connection

• Mechanical defect of engine

• Defect of crank speed sensor

• Opened pressure limiter valve on common rail
• Leakage of high pressure / low pressure fuel line

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Trouble shooting

11. Blue & white smoke

• Self diagnosis

• Defect of coolant sensor

• Defect of intake air temperature sensor

• Bad fuel
• Air mixing in fuel line

• Fuel filter
Check point • Defect of boost pressure sensor
• Defect of turbo charger
• Leakage air before intake manifold
• Mechanical defect of high pressure pump or metering unit
• Opened common rail pressure valve
• Leakage of high pressure & low pressure fuel line
• Defect gear pump on high pressure pump
• Defect of common rail pressure sensor

• Defect ECU

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Trouble shooting

12. Black smoke

• Self diagnosis

• Defect of boost pressure sensor

• Defect of coolant sensor

• Defect of boost temperature sensor
• Defect of rail pressure sensor on common rail

• Mechanical defect of engine

Check point
• Mechanical defect of injector

• Bad fuel
• Air mixing in fuel line
• Fuel filter
• Defect of turbocharger
• Leakage air before intake manifold

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Trouble shooting

13. Overheating of engine coolant

• Self diagnosis

• Bad fuel

• Defect of coolant sensor

Check point
• Mechanical defect of engine

• Defect of rail pressure sensor on common rail

• Fan belt / fan control system

14. Can not stop engine

• Self diagnosis

Check point
• Electric wire harness of start circuit
• Electric wire harness (Fuse)

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Trouble shooting

15. Abnormal engine accelerating

• Self diagnosis

Check point
• Mechanical defect of accelerator pedal
• Abnormal signal of accelerator pedal

16. Can not communicate with diagnosis tool

• Electric power supply

• Electric wire harness (Fuse)

• Main relay
Check point
• Electric wire harness of start circuit

• Defect of ECU
• Bad connection or intermittent connection

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