Dtc Trouble Shooting Procedures D4dd Engine Hyundai Truck

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D4DD ENGINE
DTC
DTC TROUBLE SHOOTING P0502 ............................................................ FL-435
BASIC TROUBLESHOOTING ...................... FL- 2 P0503 ............................................................ FL-446
SCHEMATIC CIRCUIT ................................. FL- 10 P0562 ............................................................ FL-457
DTC LIST ...................................................... FL- 20 P0563 ............................................................ FL-463
P0088 ............................................................ FL- 22 P0601 ............................................................ FL-469
P0093 ............................................................ FL- 36 P0602 ............................................................ FL-471
P0107 ............................................................ FL- 50 P0606 ............................................................ FL-473
P0108 ............................................................ FL- 53 P0607 ............................................................ FL-475
P0112 ............................................................ FL- 57 P0615 ............................................................ FL-477
P0113 ............................................................ FL- 68 P0627 ............................................................ FL-481
P0117 ............................................................ FL- 78 P0629 ............................................................ FL-491
P0118 ............................................................ FL- 85 P0704 ............................................................ FL-501
P0120 ............................................................ FL- 91 P0850 ............................................................ FL-508
P0121 ............................................................ FL-106 P1091 ............................................................ FL-515
P0122 ............................................................ FL-121 P1092 ............................................................ FL-525
P0123 ............................................................ FL-134 P1093 ............................................................ FL-535
P0182 ............................................................ FL-145 P1094 ............................................................ FL-545
P0183 ............................................................ FL-152 P1120 ............................................................ FL-555
P0192 ............................................................ FL-159 P1190 ............................................................ FL-570
P0193 ............................................................ FL-172 P1217 ............................................................ FL-579
P0194 ............................................................ FL-183 P1218 ............................................................ FL-589
P0201 ............................................................ FL-197 P1219 ............................................................ FL-599
P0202 ............................................................ FL-207 P1231 ............................................................ FL-605
P0203 ............................................................ FL-217 P1232 ............................................................ FL-612
P0204 ............................................................ FL-227 P1384 ............................................................ FL-618
P0217 ............................................................ FL-237 P1383 ............................................................ FL-624
P0219 ............................................................ FL-241 P1616 ............................................................ FL-631
P0220 ............................................................ FL-252 P2146 ............................................................ FL-642
P0221 ............................................................ FL-267 P2147 ............................................................ FL-651
P0222 ............................................................ FL-282 P2148 ............................................................ FL-660
P0223 ............................................................ FL-295 P2149 ............................................................ FL-669
P0225 ............................................................ FL-306 P2150 ............................................................ FL-678
P0226 ............................................................ FL-315 P2151 ............................................................ FL-687
P0236 ............................................................ FL-324 P2293 ............................................................ FL-696
P0237 ............................................................ FL-336 P2503 ............................................................ FL-701
P0238 ............................................................ FL-346 P2504 ............................................................ FL-703
P0301 ............................................................ FL-356
P0302 ............................................................ FL-366
P0303 ............................................................ FL-376
P0304 ............................................................ FL-386
P0335 ............................................................ FL-396
P0340 ............................................................ FL-407
P0385 ............................................................ FL-419
P0501 ............................................................ FL-424

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FL -2 FUEL SYSTEM

DTC TROUBLESHOOTING
PROCEDURES
BASIC TROUBLESHOOTING E557CB8D

BASIC TROUBLESHOOTING GUIDE

1 Bring Vehicle to Workshop

2 Analyze Customer’s Complaint.

• Ask the customer about the conditions and environment relative to the issue (Use CUS-
TOMER PROBLEM ANALYSIS SHEET).

3 Verify Symptom, and then Check DTC and Freeze Frame Data
• Connect scan tool to Diagnostic Link Connector (DLC).
• Record the DTC and freeze frame data.

NOTE
To erase DTC and freeze frame data, refer to Step 4.

Confirm the Inspection Procedure for the System or Part

Using the SYMPTOM TROUBLESHOOTING GUIDE CHART, choose the correct inspection
procedure for the system or part to be checked.

4 Erase the DTC and Freeze Frame Data

(WARNING)
NEVER erase DTC and freeze frme data before completing Step 2 MIL/DTC in "CUS-
TOMER PROBLEM ANALYSIS SHEET".

5 Inspect Vehicle Visually

• Go to Step 10, if you recognize the problem.

6 Recreate (Simulate) Symptoms the DTC

• Try to recreate or simulate the symptoms and conditions of the malfunction as described by customer.
• If DTC(s) is/are displayed, simulate the condition according to troubleshooting procedure for the DTC.

7 Confirm Symptoms of Problem

• If DTC(s) is/are not displayed, go to Step 8.
• If DTC(s) is/are displayed, go to Step 10.

8 Recreate (Simulate) Symptom

• Try to recreate or simulate the condition of the malfunction as described by the customer.

9 Check the DTC

• If DTC(s) does(do) not occur, refer to BASIC INSPECTION in INTERMITTENT PROBLEM PROCEDURE.
• If DTC(s) occur(s), go to Step 10.
DTC TROUBLESHOOTING PROCEDURES FL -3

10 Perform troubleshooting procedure for DTC

11 Adjust or repair the vehicle

12 Confirmation test

13 END

CUSTOMER PROBLEM ANALYSIS SHEET

1. VEHICLE INFORMATION

(I) VIN:
(II) Production Date:
(III) Odometer Reading: (km)

2. SYMPTOMS

□ Engine does not turn over □ Incomplete combustion

□ Unable to start
□ Initial combustion does not occur

□ Difficult to start □ Engine turns over slowly □ Other_________________

□ Rough idle □ Incorrect idle

□ Poor idle □ Unstable idle(High: ______ rpm, Low: ______rpm)
□ Other __________________________________

□ Soon after starting □ After acceleration pedal depressed

□ After acceleration pedal released □ During A/C ON
□ Engine stall
□ Shifting from N to D-range
□ Other _______________________________________________

□ Poor driving (Surge) □ Knocking □ Poor fuel economy

□ Others
□ Back fire □ After fire □ Other ____________________________

3. ENVIRONMENT

Problem frequency □ Constant □ Sometimes (_________________) □ Once only

□ Other ___________________________________________
Weather □ Fine □ Cloudy □ Rainy □ Snowy □ Other __________________
Outdoor temperature Approx. _____ C/ F

Place □ Highway □ Suburbs □ Inner City □ Uphill □ Downhill

□ Rough road □ Other ___________________________________
Engine temperature □ Cold □ Warming up □ After warming up □ Any temperature

□ Starting □ Just after starting (____ min) □ Idle □ Racing

Engine operation □ Driving □ Constant speed □ Acceleration □ Deceleration
□ A/C switch ON/OFF □ Other _____________________________
FL -4 FUEL SYSTEM

4. MIL/DTC

MIL (Malfunction Indicator Lamp) □ Remains ON □ Sometimes lights up □ Does not light

DTC □ Normal □ DTC (_______________________________________)

□ Freeze Frame Data

BASIC INSPECTION PROCEDURE

MEASURING CONDITION OF ELECTRONIC PARTS’

RESISTANCE

The measured resistance at high temperature after vehi-

cle running may be high or low. So all resistance must
be measured at ambient temperature (20℃, 68℉), unless
there is any notice.

NOTE
The measured resistance in except for ambient tem-
perature (20℃, 68℉) is reference value.

INTERMITTENT PROBLEM INSPECTION

PROCEDURE

Sometimes the most difficult case in troubleshooting is

when a problem symptom occurs but does not occur again
during testing. An example would be if a problem appears
only when the vehicle is cold but has not appeared when
warm. In this case, technician should thoroughly make
out a "CUSTOMER PROBLEM ANALYSIS SHEET" and
recreate (simulate) the environment and condition which BFGE321A
occurred when the vehicle was having the issue.
3. Slightly shake the connector and wiring harness ver-
1. Clear Diagnostic Trouble Code (DTC). tically and horizontally.
2. Inspect connector connection, and check terminal for 4. Repair or replace the component that has a problem.
poor connections, loose wires, bent, broken or cor-
roded pins, and then verify that the connectors are 5. Verify that the problem has disappeared with the road
always securely fastened. test.

● SIMULATING VIBRATION
a. Sensors and Actuators
: Slightly vibrate sensors, actuators or relays with fin-
ger.

WARNING
Strong vibration may break sensors, actuators or
relays

b. Connectors and Harness

: Lightly shake the connector and wiring harness ver-
tically and then horizontally.
DTC TROUBLESHOOTING PROCEDURES FL -5

● SIMULATING HEAT
a. Heat components suspected of causing the malfunc-
tion with a hair dryer or other heat sourre.

WARNING
• DO NOT heat components to the point where
they may be damaged.
• DO NOT heat the ECM directly.

● SIMULATING WATER SPRINKLING

a. Sprinkle water onto vehicle to simulate a rainy day or
a high humidity condition.

WARNING BFGE015G

DO NOT sprinkle water directly into the engine

compartment or electronic components. c. Listen for a click when locking connectors. This
sound indicates that they are securely locked.
● SIMULATING ELECTRICAL LOAD
a. Turn on all electrical systems to simulate excessive
electrical loads (Radios, fans, lights, etc.).

CONNECTOR INSPECTION PROCEDURE

"CLICK"
1. Handling of Connector
a. Never pull on the wiring harness when discon-
necting connectors.

BFGE015H

d. When a tester is used to check for continuity, or to

measure voltage, always insert tester probe from
BFGE015F wire harness side.

b. When removing the connector with a lock, press

or pull locking lever.

BFGE015I
FL -6 FUEL SYSTEM

e. Check waterproof connector terminals from the 3. Repair Method of Connector Terminal
connector side. Waterproof connectors cannot a. Clean the contact points using air gun and/or
be accessed from harness side. shop rag.

NOTE
Never use sand paper when polishing the contact
points, otherwise the contact point may be damaged.

b. In case of abnormal contact pressure, replace

the female terminal.

WIRE HARNESS INSPECTION PROCEDURE

1. Before removing the wire harness, check the wire har-

ness position and crimping in order to restore it cor-
rectly.

2. Check whether the wire harness is twisted, pulled or

BFGE015J loosened.

NOTE 3. Check whether the temperature of the wire harness is

abnormally high.
• Use a fine wire to prevent damage to the terminal.
• Do not damage the terminal when inserting the 4. Check whether the wire harness is rotating, moving
tester lead. or vibrating against the sharp edge of a part.

2. Checking Point for Connector 5. Check the connection between the wire harness and
a. While the connector is connected: any installed part.
Hold the connector, check connecting condition
and locking efficiency. 6. If the covering of wire harness is damaged; secure,
b. When the connector is disconnected: repair or replace the harness.
Check missed terminal, crimped terminal or bro- ELECTRICAL CIRCUIT INSPECTION PROCEDURE
ken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deforma- ● CHECK OPEN CIRCUIT
tion and bend.
c. Check terminal tightening condition: 1. Procedures for Open Circuit
Insert a spare male terminal into a female ter- • Continuity Check
minal, and then check terminal tightening condi- • Voltage Check
tions.
d. Pull lightly on individual wires to ensure that each If an open circuit occurs (as seen in [FIG. 1]), it can
wire is secured in the terminal. be found by performing Step 2 (Continuity Check
Method) or Step 3 (Voltage Check Method) as shown
below.

FIG 1

ECM
SENSOR
1 1 1 1

2 2 2 2
(C) (B) (A)

BFGE015K

BFGE501A
DTC TROUBLESHOOTING PROCEDURES FL -7

2. Continuity Check Method

FIG 3
NOTE
When measuring for resistance, lightly shake the wire
harness above and below or from side to side.
1 1 1 1

Specification (Resistance) 2 2 2 2 ECM

1 or less → Normal Circuit (C) (B1) (B2) (A)

1M or Higher → Open Circuit SENSOR

a. Disconnect connectors (A), (C) and measure

resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and
2 is higher than 1 M and below 1 respec-
tively. Specifically the open circuit is line 1 (Line
2 is normal). To find exact break point, check sub
line of line 1 as described in next step.
FIG 2
BFGE501C
3. Voltage Check Method
a. With each connector still connected, measure the
voltage between the chassis ground and terminal
1 of each connectors (A), (B) and (C) as shown
in [FIG. 4].
The measured voltage of each connector is 5V,
5V and 0V respectively. So the open circuit is
between connector (C) and (B).

1 1 1 1

FIG 4
2 2 2 2 ECM
(C) (B) (A)
SENSOR
V

ECM

SENSOR
1 1 1 1

2 2 2 2
BFGE501B
(C) (B) (A)

b. Disconnect connector (B), and measure for resis-

tance between connector (C) and (B1) and be-
tween (B2) and (A) as shown in [FIG. 3].
BFGE501D
In this case the measured resistance between
connector (C) and (B1) is higher than 1M and
the open circuit is between terminal 1 of connec-
tor (C) and terminal 1 of connector (B1).
FL -8 FUEL SYSTEM

● CHECK SHORT CIRCUIT

FIG 6
1. Test Method for Short to Ground Circuit
• Continuity Check with Chassis Ground

If short to ground circuit occurs as shown in [FIG. 5], the 1 1 1 1

broken point can be found by performing below Step 2

(Continuity Check Method with Chassis Ground) as shown 2 2 2 2 ECM
(C) (B) (A)
below. SENSOR

FIG 5

ECM
BFGE501F
SENSOR
1 1 1 1
b. Disconnect connector (B), and measure the resis-
2 2 2 2 tance between connector (A) and chassis ground, and
(C) (B) (A)
between (B1) and chassis ground as shown in [FIG.
7].

The measured resistance between connector (B1)

and chassis ground is 1Ω or less. The short to
BFGE501E ground circuit is between terminal 1 of connector (C)
and terminal 1 of connector (B1).
2. Continuity Check Method (with Chassis Ground)

NOTE FIG 7

Lightly shake the wire harness above and below, or

from side to side when measuring the resistance.

Specification (Resistance) 1 1 1 1

1Ω or less → Short to Ground Circuit 2 2 2 2 ECM

1㏁ or Higher → Normal Circuit (C) (B1) (B2) (A)
SENSOR

a. Disconnect connectors (A), (C) and measure for re-

sistance between connector (A) and Chassis Ground
as shown in [FIG. 6].

The measured resistance of line 1 and 2 in this ex- BFGE501G

ample is below 1 Ω and higher than 1㏁ respectively.
Specifically the short to ground circuit is line 1 (Line 2
is normal). To find exact broken point, check the sub
line of line 1 as described in the folowing step.
DTC TROUBLESHOOTING PROCEDURES FL -9

ECM(TICS) PROBLEM INSPECTION PROCEDURE

1. Test ECM(TICS) connector: Disconnect the

ECM(TICS) connector and visually check the ground
terminals on ECM(TICS) side and harness side for
bent pins or poor contact pressure. If the problem is
found, repair it.

2. If problem is not found step 1, the ECM(TICS) could

be faulty. If so, replace the ECM(TICS) with a new
one, and then check the vehicle again. If the vehicle
operates normally then the problem was likely with the
ECM(TICS).

3. Re-test the original ECM(TICS): Install the original

ECM(TICS)(may be broken) into a known-good vehi-
cle and check the vehicle. If the problem occurs again,
replace the original ECM(TICS) with a new one. If
problem does not occur, this is intermittent problem
(Refer to Intermittent Problem Procedure in Basic In-
spection Procedure.)

ABBREVIATION

ABS: Anti-lock brake system

APS: Accelerator pedal sensor
A/C: Air conditioning
B: Battery
BATT: Battery
Comp: Compressor
DTC : Diagnostic trouble code
ECTS: Engine coolant temperature sensor
ECU: Electronic control unit
ETCM: Electronic time control module
EUI: Electronic unit injection
IATS : Intake air temperature sensor
IG: Ignition
MIL: Malfunction indicator lamp(Check engine lamp)
NTC: Negative Temperature Coefficient
PTO: Power take-off
NC: Normal close
NO: Normal open
RPM: Revolution per minute
Sw: Switch
Sig: Signal
 FL -10
HOT AT ALL TIMES HOT AT ALL TIMES
ABS MAIN FUSE
CONTROL ECM BOX
MODULE PHOTO
PHOTO 4 FUSE 19 FUSE 14
26 10A 10A
16 A01 34 M99-2 19 M99-1
DATA LINK DETAILS (1)
SCHEMATIC CIRCUIT

0.85W 0.5Y 0.5W/R 0.85Y 0.85Y

8 MA01
D4DD D4AF/D4AL
PHOTO 21
13 M78
0.5W
E6AD73F3

See Passenger JOINT

Compartment CONNECTOR
0.5W 0.5Y Fuse Details PHOTO
(SD120-3)(SD120-4) 19
D4AF/D4AL D4DD D4DD 12 M78

0.5Y
M72
DATA LINK
CONNECTOR
8 7 6 5 4 3 2 1 PHOTO
Ground Ground L-Line ECM 2

0.5B 0.5B
16
Ground
15 14 13 12 11
K-Line
10 9
Memory
Power

D4DD D4AF/D4AL D4AF/D4AL D4DD

0.5B
0.5Y/O 0.5Y/O
0.5B
0.5B

0.5Y/O 0.5Y/O
6 M38
See Ground JOINT
Distribution CONNECTOR
(SD130-3) PHOTO 17

13 M38 3 MA01 9 MM06

PHOTO 21 PHOTO 20
1.25B
0.5Y/O
46 A01 Not Used
1.25B ABS
CONTROL
MODULE
PHOTO 26
G01 PHOTO 15
FUEL SYSTEM

SUDFL8600L
 A01 M72(D4AF/D4AL) M72(D4DD)

28 26 25
** * * * * 19 * * 16 * 14 13 12 11 10 9 * 7 6 5 * * * 1 3 3 2
55 54 53 * * * * * * * * * * 5 4 *
* * * 49 48 * 46 45 * * * * 40 39 * 37 * 35 34 33 * 31 30 29 16 11 16 11 9
* * * * * 9 * * * * *
* ***** ***** ***** **** * **** **
DATA LINK DETAILS (2)

CR55F005 CR16F007 CR16F044

M99-1 M99-2

7 6 5 7 6 5
* * * * * * 2 1 BLANK BLANK
19
******** 9* * 17 16 15 14 13 12 11 10 9 *
27 23 22 21 23 22 21 20
*** * 19 * * * 25 24
31
* * 32 * * * 28 * 34 * 32 * **
CR34F003 CR35F009
DTC TROUBLESHOOTING PROCEDURES
FL -11

SUDFL8601L
 FL -12

HOT AT ALL TIMES HOT IN ON

FUSE
BOX

FUSE 20 FUSE 32 FUSE 8 FUSE 9 FUSE 10 FUSE 12

20A 5A 10A 10A 15A 10A

2.0R/O 0.85L/O 1.25R 0.85O

16 M78
A
JOINT
MFI CONTROL SYSTEM (D4DD) (1)

11 MC06
PHOTO 20 CONNECTOR
To Accelerator PHOTO 19
Pedal Sensor
(SD313-2)
0.85R/O 2.0R/O 0.85L/G 0.5R 1.25Y 0.85R 14 M78

1 C11
RELAY NEUTRAL 0.5O
2 5 M91 BOX SWITCH
PHOTO PHOTO 59
ENGINE 1
ECM 2 M36-3
RELAY
2 C11 INSTRU-
MENT
CLUSTER
4 1 M91 0.85L PHOTO
ENGINE ENGINE EXHAUST OVER
CHECK PTO BRAKE GLOW HEAT 10
TACHO
See METER
Starting System CHECK
(SD360-1) ENG
0.5L 1.25G/O
0.85L
11 M36-3 7 M36-2 8 M36-3 3 M36-1 11 3 M36-4
See Passenger
Compartment
Fuse Details
(SD120-2)
11 MC04
PHOTO
20

0.5L 0.5L 1.25G/O 1.25G/O 1.25G/O 0.5R 0.5R 1.25Y 1.25Y 0.5L 0.5L/G 0.5G/O 0.5G/Y 0.5W/B 0.5L/O 0.5Y

5 6 M99-3 5 6 7 M99-1 22 12 1 M99-2 7 M99-3 32 M99-2 9 M99-1 13 M99-3 13 10 11 9 M99-2

Neutral RPM ENGINE ENGINE EXHAUST GLOW OVERHEAT MAIN
Engine ECM Engine ECM ON Input Switch Signal CHECK PTO BRAKE IND. IND. ECM
Relay Control Relay 'ON' Input IND. IND. IND. PHOTO
4
FUEL SYSTEM

SUDFL8602L
 From FUSE 32 5A
(SD313-1)
A

0.85L/O

See Illuminations See Illuminations

(SD941-1) (SD941-1)

0.5L/O 0.85L/O 0.85L/O 0.5L/O 0.5G/O 0.85L/O 0.5L/O 0.5G/O

MFI CONTROL SYSTEM (D4DD) (2)

3 2 M17 5 2 M39
2 M43-1
See Stop Lamps
(SD927-1) IDLE ENGINE
G MULTIFUN- UP/DOWN PTO CAB
EXHAUST CTION SWITCH IN SWITCH
BRAKE SWITCH DOWN UP ILL.
To PTO PHOTO PHOTO PHOTO
0.5L/O 0.85Y SWITCH 3 15
(SD313-3) 18

5 6 1 M17 4 M32 1 4 6 3 M39

4 2 M41
DTC TROUBLESHOOTING PROCEDURES

2 M49
STOP ACCELE-
3 M43-1 EXHAUST 0.5B RATOR
LAMP BRAKE CLUTCH 0.5B 0.5B
SWITCH PEDAL
PEDAL POSITION SENSOR
PHOTO SWITCH
2 See Illuminations SW2 SW1 PHOTO
PHOTO 2 (SD941-1) 5
With ABS W/O ABS 1 M49
3 1 M41 6 2 3 1 M32

0.85L/O 0.85Y 0.5R 0.5L 0.5P/O 0.85B 0.5Y 0.5G/Y 0.5G 0.5B
9 10 MC04 9 M38
RELAY
1 M15 BOX PHOTO
See Stop Lamps 0.5B 0.5Y See Ground JOINT
ABS 20 Distribution CONNEC-
(SD927-1) PHOTO
RELAY 1 (SD130-3) TOR
See P.T.O B PHOTO
See Exhaust C
Control System 13 M38 17
(SD471-2) Parking Brakes To From
(SD596-2) 1.25B
Engine Engine
4 M15 ECM ECM
1.25B
(SD313-4)

G01 PHOTO 15
0.5L/G 0.5L/O 0.5L 0.5G/O 0.5G/R 0.85W/B 0.5L 0.5P/O 0.5Y
0.5G

19 15 M99-2 8 19 M99-3 17 2 24 M99-2 21 22 M99-1 20 M99-3

Brake Exhaust Clutch Switch DOWN UP Exhaust Idle SNR 1 SNR 2 PTO MAIN
Switch Brake Switch Signal Brake Relay Switch Switch ECM
Signal Control PHOTO
4
FL -13

SUDFL8603L
 FL -14

HOT IN ON HOT IN START

FUSE
BOX

FUSE 4 FUSE 24
10A 15A

0.5L N.E BOOST

6 M78 1.25B/O SENSOR PRESSURE
JOINT PHOTO & AIR
See Passenger TEMPERATURE
Compartment Fuse Details CONNECTOR 54
SENSOR
(SD120-1) PHOTO 19
PHOTO
See Passenger 2 1 E12 4 2 3 1 E14 47
1 M78
Compartment Fuse Details 0.5R 0.5B
MFI CONTROL SYSTEM (D4DD) (3)

0.5L (SD120-5)
A/C
0.5L 0.5B 0.5B 0.5W 0.5L 0.5Y PRESSURE
RELAY SWITCH
1 3 M94 BOX 0.5R 0.5B PHOTO 44
0.5B
GLOW PHOTO 23 24 25 6 7 9 8 EC01
RELAY 1 2 M79
PHOTO 1 C21
See Ground JOINT 0.5R 0.5B 0.5Y 48
Distribution CONNECTOR 0.85G/O
(SD130-3) PHOTO 1 D
2 5 M94 0.5B 0.5W 0.5L
From 5 M79 From 0.85G/O 0.85G/O
Battery (+) Engine ECM
0.85B/O 0.5G/R 0.85B 0.5R 0.5B
See Ground (SD313-4)
16 MC05
Distribution 5 13 12 6 14 4 MC04 14 MC06 1 C22
0.85B/O PHOTO 20 (SD130-4) PHOTO PHOTO
2 C42 0.5G/R 0.5Y/O 1.25B 0.5L/R 0.5 0.5R 0.5B A/C
20 20 COMPRE-
AIR SSOR
HEATER 0.5B 0.5W 0.5L 0.5G/O PHOTO
RELAY 50
PHOTO 48 G02 PHOTO 1
0.5 0.5R 0.5B
1 2 M99-3 14 5 6 7 20 23 M99-2 32 M99-1 12 M99-3
MAIN
Start Shield (+) (-) Ground Power Air Temp. A/C ECM
GLOW Glow Relay Input Sensor Pressure
PLUG Control N.E Sensor Boost Sensor Switch PHOTO
Remote PTO 4
From PTO PTO Engine Idle Switch Data Link Vehicle
FUSE 32 5A Accel Accel Stop OUT-CAB Sensor Connector Speed CASE Ground
(SD313-2) Signal Power Switch Up Down PTO Switch Ground Sensor Ground
G 23 M99-1 31 16 25 M99-2 11 24 M99-3 21 34 M99-2 19 27 28 M99-1 4 3 M99-3
0.5B 0.5Y 0.5B 1.25B 1.25B
See Data
0.5L/O 0.5B 0.5R 0.5W/O 0.5R/B 0.5Y 0.5G/O 3 MC04 Link Details
0.5B PHOTO 20 (SD200-1)
8 1 7 MC04 10 12 20 9 MC06
PHOTO PHOTO 0.5B 0.5B 0.5Y 0.5W/R 0.5O 1.25B
20 20 PHOTO 35 EC01 4 EC02
0.85L/O 0.5B 0.5R 0.5W/O 0.5R/B 0.5Y 0.5G/O 0.5B/W 0.5B PHOTO 0.5B PHOTO 2 MC04
71 PHOTO
48 50
1 2 7 6 8 4 5 3 EC04 1.25B 20
F E 3 2 M72
From Fuel From Engine Coolant DATA LINK See Vehicle
PTO Temperature Temperature CONNECTOR Speed Sensor
Sensor Sensor & Sender PHOTO 2 System G05 PHOTO 60
(SD313-4) (SD313-4) (SD436-1)
FUEL SYSTEM

SUDFL8604L
 INJECTOR INJECTOR INJECTOR INJECTOR INSTRUMENT
#4 #2 #1 #3 CLUSTER To Main ECM
PHOTO PHOTO PHOTO PHOTO PHOTO 10 (SD313-3)
47 47 47 47
F
2 1 E11-4 2 1 E11-2 2 1 E11-1 2 1 E11-3 2 M36-1
1.25B 1.25R 1.25B 1.25R 1.25B 1.25R 1.25B 1.25R 0.5Y/O
0.5B
8 MC06
PHOTO 20 2 E16
0.85Y/O
FUEL
3 EC02 TEMPERATURE
0.5P PHOTO 50 SENSOR
1.25B 1.25R 1.25B 1.25R 1.25B 1.25R 1.25B 1.25R PHOTO 49
2 E07
MFI CONTROL SYSTEM (D4DD) (4)

ENGINE 1 E16 To From

28 29 12 10 11 1 2 21 19 20 EC01 SENDER COOLANT Accelerator Accelerator
PHOTO TEMPERATURE Pedal Sensor Pedal Sensor
48 SENSOR SENSOR & (SD313-2) (SD313-2)
SENDER
1.25B 1.25R 1.25B 1.25R 1.25B 1.25R 1.25B 1.25R B
PHOTO 46 C
1 3 E07

0.5B 0.5Y 0.5W 0.5Y 0.5B

DTC TROUBLESHOOTING PROCEDURES

0.5B 0.5B 0.5B 0.5B

0.5B 0.5B E 2 EC02 34 EC01
PHOTO PHOTO
1.25B 1.25R 1.25B 1.25R 1.25B 1.25R 1.25B 1.25R 0.5Y 50 0.5W 48 0.5B 0.5B/O
To Main ECM
G03 PHOTO 48 G03 PHOTO 48 (SD313-3)
6 3 C10-2 7 2 C10-1 5 2 C10-2 6 1 19 27 C10-1 24 34 35 C10-2
Sensor Fuel Power ENGINE
Injector #4 Injector #2 Injector #1 Injector #3 Signal Temp. Ground ECM
Sensor PHOTO
4
CAN S/PUMP S/PUMP
Ground Control High Control Low Sensor Signal CAM CAM Sensor
High Low Ground Power Power Ground Signal Signal

1 C10-2 4 5 21 22 11 10 9 8 C10-1 33 25 31 20 32 30 19 27 C10-2

0.5W 0.5W 0.5Br 0.5Br 0.5B 0.5W 0.5Y 0.5Y 0.5W 0.5B 0.5Y/B 0.5Y

0.5W 0.5Br 0.5Y

1.25B 1.25B 1.25B 0.5B 0.5W 32 31 15 16 17 EC01 6 7 8 EC02 D
PHOTO 48 PHOTO 50
To Boost
0.5W 0.5W 0.5Br 0.5Br 0.5B 0.5W 0.5Y 0.5Y 0.5W 0.5B 0.5Y Pressure & Air
Temperature Sensor
(SD313-3)
2 1 C75 2 1 E15 3 1 2 E13 1 2 3 E03
CAN TOOL SCV RAIL CAM
PHOTO PRESSURE SPEED
PHOTO 4 SENSOR SENSOR
49
PHOTO 49 PHOTO 46
G05 PHOTO 60
FL -15

SUDFL8605L
 FL -16
C10-1 C10-2 C11 C21

7 6 5 4 6 5
* 2 1 * 3 2 1 2 1 2 1
27
* * * 22* 21* * 11 10 199 8 * 25* 24* * * * 20* 19* * *
* * * * 27 * 35 34 33
* * * 32* 3130 * *
** ** * **
CR31F002 CR35F008 CR02F040 CR02F025

C22 C42 C75 E03

1 2 2 1 3 2 1
MFI CONTROL SYSTEM (D4DD) (5)

CR01F020 CR02F040 CR02F046 CR03F230

E07 E11-1 E11-2 E11-3

1 2 3 2 1 2 1 2 1

CR03M019 CR02F152 CR02F152 CR02F152

E11-4 E12 E13 E14

2 1 3 2 1 4 3 2 1
2 1

CR02F152 CR02F154 CR03F230 CR04F091

E15 E16 M15 M17

1 3 2 1
2 1 2 1 *
5 4 3 6 5
* *
CR02F152 CR02F175 CR05F011 CR07F002
FUEL SYSTEM

SUDFL8606L
 M32 M36-1 M36-2

3 2 1
10 9 8 7 6 5 4 3 2 1 14 13 11 10 9 8 7 5 4 3 2 1
6
* 4 * *

CR06F043 CR10F005 CR14F007

M36-3 M36-4 M39

2 1
11 8 6 5 4 3 2 12 11 10 9 8 3 2 1
MFI CONTROL SYSTEM (D4DD) (6)

* * * * * * * * * * * 6 5 4 3

CR14F007 CR12F001 CR06F017

M41 M43-1 M49 M72

DTC TROUBLESHOOTING PROCEDURES

2 1 3 2 1 1 3 2
* * * * * * 5 4 *
14 13 12 11 10 9 8 7 16 11 9
4 3 2 * * * * *
CR04F016 CR14F019 CR02F187 CR16F044

M91 M94 M99-1 M99-2

1 1 7 6 5 7 6 5
2 * * * * * * 2 1
19
4 2 ******** 9* * 17 16 15 14 13 12 11 10 9 *
* 27 23 22 21 23 22 21 20
5 5 3 *** * 19 * * * 25 24
* 31
* * 32 * * * 28 * 34 * 32 * **
CR05F019 CR05F011 CR34F003 CR35F009

M99-3

7 6 5 4 3 2 1

* * * * 13 12 11 * * 8 BLANK BLANK BLANK

* * * 24 * * * 20 19 *
** * **
CR32F004
FL -17

SUDFL8607L
 FL -18
FUSIBLE 6 M42
LINK BOX
AM IGNITION
IGN SW SWITCH
FUSIBLE START PHOTO 6 D4AF/D4AL D4DD
LINK LOCK
30A 3.0O
ON ACC See Power
STARTING SYSTEM (1)

8.0W 3.0O Distribution

3.0O (SD110-2)
1 CC01 PHOTO 61 2 3 M42
3.0W 2.0G
FUSE
5 MC03 PHOTO 4 BOX

3.0W FUSE 24 FUSE 9 FUSE 10

1 C13 15A 15A 15A
+ BATTERY
PHOTO 60
D4AF/D4AL D4DD
2.0R 1.25R
1.25B/O
2.0B/O 2 MC01 11 MC06
- PHOTO PHOTO
1.25B/O
4 20
0.5L/R 2.0R 0.85R
0.5B/O 10 MC01 1 MC05 14 M99-2
7 M56-2 PHOTO PHOTO MAIN
ETACM 4 20 ECM D4AF/D4AL D4DD
PHOTO 2.0B/O 2.0B/O PHOTO
24 4 (D4AF/D4AL)2
(D4DD)1 C11
32 M99-2 NEUTRAL
SWITCH
FLY WHEEL MAGNETIC (Closed with
+ BATTERY 2.0B/O 2.0B/O
0.5L Transmission
LEVER in netural)
D4AF/D4AL D4DD
2.0B/O 1.25B/O (D4AF/D4AL)1 C11 PHOTO 59
START 11 MC04 (D4DD)2
1 C44 MOTOR
PHOTO
START PHOTO 20
SOLENOID 48/51 D4DD D4AF/D4AL
- 0.85L

2 C01 0.85L
SUB
ENGINE START 2.0R
SWITCH
0.85L
PHOTO
61
1 C01
PINION MOTOR
GEAR

BATTERY OVERRUNNING
GROUND CLUTCH
FUEL SYSTEM

SUDFL8608L
 C01 C11 C13 C44

2 1 2 1 1
STARTING SYSTEM (2)

CR02F040 CR02F040 CR01F002 CR01F035

M42 M56-2(D4AF/D4AL) M99-2

3 2 8 7 6 5 4 7 6 5
* * * 1 * * 2 1 BLANK
19
16 15 14 13 11 10 9 * 17 16 15 14 13 12 11 10 9 *
6 4 * 23 22 21 20
* * * 25 24
31
* 34 * 32 * **
CR06F014 CR16F002 CR35F009
DTC TROUBLESHOOTING PROCEDURES
FL -19

SUDFL8609L
Dtc Trouble Shooting Procedures D4dd Engine Hyundai Truck
Full download: http://manualplace.com/download/dtc-trouble-shooting-procedures-d4dd-engine-hyundai-truck/

FL -20 FUEL SYSTEM

DTC LIST E7D910C2

NO DTC DESCRIPTION Page

1 P0088 COMMON RAIL PRESSURE EXCEEDS LIMIT
2 P0093 FUEL SYSTEM LEAK DETECTED
3 P0107 BAROMETRIC PRESSURE SENSOR -LOW VOLTAGE
4 P0108 BAROMETRIC PRESSURE SENSOR -HIGH VOLTAGE
5 P0112 INTAKE AIR TEMPERATURE SENSOR - LOW VOLTAGE
6 P0113 INTAKE AIR TEMPERATURE SENSOR - HIGH VOLTAGE
7 P0117 ENGINE COOLANT TEMPERATURE SENSOR-LOW VOLTAGE
8 P0118 ENGINE COOLANT TEMPERATURE SENSOR-HIGH VOLTAGE
9 P0120 PEDAL SENSOR NO.1 NOT OPEN
10 P0121 PEDAL SENSOR NO.1 NOT CLOSE
11 P0122 PEDAL SENSOR NO.1 SIGNAL LOW
12 P0123 PEDAL SENSOR NO.1 SIGNAL HIGH
13 P0182 FUEL TEMP. SENSOR LOW INPUT
14 P0183 FUEL TEMP. SENSOR HIGH INPUT
15 P0192 C/RAIL PRESSURE SENSOR SIGNAL LOW
16 P0193 C/RAIL PRESSURE SENSOR SIGNAL HIGH
17 P0194 C/RAIL PRESSURE SENSOR INTERMITTENT
18 P0201 INJECTOR #1 COIL OPEN
19 P0202 INJECTOR #2 COIL OPEN
20 P0203 INJECTOR #3 COIL OPEN
21 P0204 INJECTOR #4 COIL OPEN
22 P0217 ENGINE COOLANT OVER TEMPERATURE
23 P0219 ENGINE OVERSPEED CONDITION
24 P0220 PEDAL SENSOR NO.2 NOT OPEN
25 P0221 PEDAL SENSOR NO.2 NOT CLOSE
26 P0222 PEDAL SENSOR NO.2 SIGNAL LOW
27 P0223 PEDAL SENSOR NO.2 SIGNAL HIGH
28 P0225 IDLE SWITCH STUCK CLOSED
29 P0226 IDLE SWITCH STUCK OPENED
30 P0236 BOOST PRESSURE SENSOR INVALID
31 P0237 BOOST PRESSURE SENSOR SIGNAL LOW
32 P0238 BOOST PRESSURE SENSOR SIGNAL HIGH
33 P0301 CYLINDER 1 MISFIRE DETECTED
34 P0302 CYLINDER 2 MISFIRE DETECTED
35 P0303 CYLINDER 3 MISFIRE DETECTED
36 P0304 CYLINDER 4 MISFIRE DETECTED
37 P0335 CRANK SENSOR NO PULSE

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