2010 KIA Picanto TCI-U Supplement

General Information
General Information
General Information
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2010 > D 1.1 TCI-U >
Identification Number Locations
Identification Number Description

Vehicle Identification Number
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1. World Manufacturer Identifier (WMI)
- KNA : Passenger vehicle, MPV(Multipurpose Passenger Vehicle)/SUV(Sports Utility Vehicle)/RV(Recreational
Vehicle)
- KNC : Commercial vehicle (Van)
- KND: MPV/SUV/RV (For U.S.A, Canada, Mexico)
- KNH: Van
2. Vehicle line
- B : PICANTO
3. Model & Series
- F : Low grade (L)
- J : Middle-Low grade (GL)
- K : Middle grade (GLS, JSL, TAX)
- L : Middle-High grade (HGS)
- M : High grade (TOP)
4. Body/Cabin type, Gross Vehicle Weight Rating
KNA
- 1 : Limousine
- 2 : Sedan - 2 door
- 6 : Coupe
- 7 : Convertible
- 8 : Wagon
- 9 : Commercial Van
- 0 : Pick-Up
KNC (Commercial vehicle / Van)
Except U.S.A, Canada, Mexico, Gulf Cooperation Council, China
- X : Standard Cabin / Semi-Bonnet
- Y : Double Cabin / Bonnet
- Z : Super Cabin / Box
For U.S.A, Canada, Mexico, Gulf Cooperation Council, China
- 2 : Standard Cabin Class-H 4!2
- 3 : Standard Cabin Class-E 4!2 / Semi-Bonnet Class-E 4!2
- 4 : Standard Cabin Class-E 4!4 / Semi-Bonnet Class-E 4!4
- 5 : Standard Cabin Class-F 4!2 / Semi-Bonnet Class-F 4!2
- 6 : Standard Cabin Class-F 4!4 / Semi-Bonnet Class-F 4!4
- 7 : Double Cabin Class-E 4!2 / Bonnet Class-E 4!2
- 8 : Double Cabin Class-E 4!4 / Bonnet Class-E 4!4
- 9 : Double Cabin Class-F 4!2 / Bonnet Class-F 4!2
- 0 : Double Cabin Class-F 4!4 / Bonnet Class-F 4!4
- A : Super Cabin Class-E 4!2 / Box Class-E 4!2
- B : Super Cabin Class-E 4!4 / Box Class-E 4!4
- C : Super Cabin Class-F 4!2 / Box Class-F 4!2
- D : Super Cabin Class-F 4!4 / Box Class-F 4!4
KND
- 1 : Wagon 4!2 Class-A
- 2 : Wagon 4!2 Class-B
- 3 : Wagon 4!2 Class-C
- 4 : Wagon 4!2 Class-D
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- 5 : Wagon 4!2 Class-E
- 6 : Wagon 4!2 Class-F
- 7 : Wagon 4!2 Class-G
- A : Wagon 4!4 Class-A
- B : Wagon 4!4 Class-B
- C : Wagon 4!4 Class-C
- D : Wagon 4!4 Class-D
- E : Wagon 4!4 Class-E
- F : Wagon 4!4 Class-F
- G : Wagon 4!4 Class-G
KNH
- 1 : Box
- 2 : Bonnet
- 3 : Semi-Bonnet
5. Restraint system, Brake system
KNA, KND
Except U.S.A, Canada, Mexico
- 0 : Both side - None
- 1 : Both side - Active belt
- 2 : Both side - Passive belt
For U.S.A, Canada, Mexico
Front air bag Knee air bag Side air bag Curtain air bag
Seat
Code 3rd
belt Driver's Passenger's Driver's Passenger's 1st row 2nd row 1st row 2nd row 3rd row
row
A " " " ! ! " ! ! " " !
B " " " ! ! ! ! ! ! ! !
C " " " ! ! " ! ! " " "
D " " " ! ! " " ! " " !
E " " ! ! ! ! ! ! ! ! !
F " " " ! ! " ! ! ! ! !
N " ! ! ! ! ! ! ! ! ! !
H " " " " ! " ! ! " " "
KNC, KNH
Except U.S.A, Canada, Mexico
- 7 : Hydraulic brake system
- 8 : Pneumatic brake system
- 9 : Mixed brake system
For U.S.A, Canada, Mexico
- X : Hydraulic brake system
- Y : Pneumatic brake system
- Z : Mixed brake system
6. Engine type
- 3 : Gasoline engine 1.1
- 4 : Gasoline engine 1.0
- 5 : Diesel engine 1.1
7. Check digit or Driver’s side & Transmission
Except U.S.A, Canada, Mexico, Gulf Cooperation Council, China, Yemen
- A : LHD & MT
- B : LHD & AT
- C : LHD & MT+Transfer
- D : LHD & AT+Transfer
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- E : LHD & CVT
- L : RHD & MT
- M : RHD & AT
- N : RHD & MT+Transfer
- S : RHD & AT+Transfer
- T : RHD & CVT
For U.S.A, Canada, Mexico, Gulf Cooperation Council, China, Yemen
- Check digit : 0 ~ 9, !
8. Production year
- A : 2010, B : 2011, C : 2012, D : 2013...
9. Plant of production
- 6 : Sohari (Korea)
- 5 : Hwasung (Korea)
- 7 : Kwangju (Korea)
- T : Seosan (Korea)
10. Vehicle production sequence number
- 000001 ~ 999999
Paint Code
Code Color
3D Bright Silver
IZ Soda Orange
II Fresh Yellow
C0 Cool Blue
IM Titanium Silver
UD Clear White
Z1 Galaxy Black
P9 Scarlet Red
L6 Blue Diamond
Engine Number
1. Engine fuel
- G : Gasoline
- D : Diesel
2. Engine range
- 4 : 4 cycle 4 cylinder
- 6 : 4 cycle 6 cylinder
3 - 4. Engine development order and capacity
- HE : # engine, 999cc (Gasoline)
- HG : # engine, 1086cc (Gasoline)
- FA : U engine, 1120cc (Diesel)
5. Production year
- 9 : 2009, A : 2010, B : 2011, C : 2012, D : 2013...
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Engine production sequence number
- 000001 ~ 999999
Transaxle Number
Manual
1. Model
- M : M5EF2
- R : M5CF1
2. Production year
- 9 : 2009, A : 2010, B : 2011, C : 2012, D : 2013...
3. Gear ratio
- 1671 : 4.437
- 2073 : 3.650
4. Transaxle production sequence number
- 000001 ~ 999999
Automatic
1. Model
- E : A4CF0
2. Production year
- 9 : 2009, A : 2010, B : 2011, C : 2012, D : 2013...
3. Gear ratio
- 5 = 4.587
4. Detailed chassification
- BD : # - 1.1
5. Spare
6. Transaxle production sequence number
- 000001 ~ 999999
Warning / Caution Label Locations
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1. Coolant level caution 4. Battery caution
2. Fan caution 5. Air cleaner caution
3. Radiator cap caution
Battery Caution Label Describtion
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Warning / Caution Label (Cont'd)
A.
Keep lighted cigarettes and all other flames or sparks away from the battery.
B.
Wear eye protection when charging or working near a battery. Always provide ventilation when working in an
enclosed space.
• When lifting a plastic-cased battery, excesive pressure on acid to leak resulting in personal injury. Lift with a
battery carrier or with your hands on opposite corners.
• Never attempt to change the battery when the battery cables are connected.
• The electrical ignition system works with high voltage.
Never touch these components with the engine running or the ignition switched on.
C.
Keep batteries out of the reach of children because batteries contain highly corrosive SULFURIC ACID. Do not allow
battery acid to contact your skin, eyes, clothing or paint finish.
D.
If any electrolyte gets into your eyes, flush your eyes with clean water for at least 15 minutes and get immediate
medical attention. If possible, continue to apply water with a sponge or cloth until medical attention is received.
If electrolyte gets on your skin, throughly wash the contacted area. If you feel a pain or a burning sensation, get
medical attention immediately.
E.
Always read the following instructions carefully when handing a battery.
F.
Hydrogen, which is a highly combustible gas, is always presents in battery cells and may explode if ignited.
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G.
An improperly disposed battery can be harmful to the environment and human health.
Always confirm local regurations for battery disposal.
Handling And Storage The Battery

Battery Itself • Batteries should be stored in cool, dry (27 degrees Celsius) places and out of
direct sunlight.
• MF batteries are tightly sealed to prevent acid leakage.
However, tilting the battery to an angle of 45 degrees can cause acid to leak
through the vents on the sides. Therefore, batteries should always be stored
in their upright positions. Prevent placing any aqueous or solid (i.e.
conductors) bodies on top of the battery.
• It is extremely dangerous to use tools, such as hammers, on the battery
terminals when connecting cables to the mounted battery.
Battery on Vehicle • When storing the vehicle for long periods of time, make sure to remove the
memory fuse at junction box to prevent natural discharging.
• Also, run the engine for battery charging within 1 month if the memory fuse
wasn't removed from the start of vehicle storing.
If the memory fuse was removed, run the engine for battery charging within 3
months from the start of vehicle storing.
After reconnecting or recharging a discharged battery, the ESP OFF indicator may illuminate.
In this case, turn the handle half way to the left and right whilst the ignition switch is in the ON position.
Then, restart the engine after the ignition is OFF.
The ESP OFF indicator may turn OFF.
If the ESP OFF indicator does not turn OFF, have the system checked refering to DTC. (Refer to the BR group.)
Lift And Support Points
When heavy rear components such as suspension, fuel tank, spare tire, tailgate and trunk lid are to be removed,
place additional weight in the luggage area before hoisting. When substatial weight is removed from the rear of
the vehicle, the center of gravity may change and can cause the vehicle to tip forward on the hoist.
• Since each tire/wheel assembly weights approximately 30lbs (14kg), placing the front wheels in the luggage
area can assist with the weight distribution.
• Use the same support points to support the vehicle on safety stands.
1. Place the lift blocks under the support points as shown in the illustration.
2. Raise the hoist a few inches (centimeters) and rock the vehicle to be sure it is firmly supported.
3. Raise the hoist to full height to inspect the lift points for secure support.
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Towing
If the vehicle needs to be towed, call a professional towing service. Never tow vehicle with just a rope or chain. It is
very dangerous.
Emergency Towing
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There are three popular methods of towing a vehicle :
- The operator loads the vehicle on the back of truck. This is best way of transporting the vehicle.
- The tow truck uses two pivoting arms that go under the tires of the driving axle and lift them off the ground. The
other two wheels remain on the ground.
- The tow truck uses metal cables with hooks on the ends. These hooks go around parts of the frame or
suspension, and the cables lift that end of the vehicle off the ground. The vehicle's suspension and body can be
seriously damaged if this method of towing is attempted.
If the vehicle cannot be transported by flat-bed, should be towed with the wheels of the drivig axle off the ground
and do the following :
Manual Transaxle
• Release the parking brake.
• Shift the Transaxle to neutral
Automatic Transaxle
• Release the parking brake.
• Start the engine.
• Shift to [D] position, then [N] position.
• Turn off the engine.
• The vehicle equipped with full-time 4WD should be only transported on a flat-bed.
• Improper towing preparation will damage the transaxle. follow the above procedure exactly. If you cannot shift
the transaxle or start the engine(automatic transaxle), your vehicle must be transported on a flatbed.
• It is the best to tow vehicle no farther than 30km (19miles), and keep the speed below 50km/h (30mph). (For
the full-time 4WD vehicle, limit the towing to 1.5km (1mile) and 15km/h (10mph)
• Trying to lift or tow your vehicle by the bumpers will cause serious damage. The bumpers are not designed to
support the vehicle's weight.
Tightening Torque Table Of Standartd Parts

Bolt niminal diameter Torque Nm (kg.cm, lb.ft)
Pich (mm)
(mm) Head Mark 4 Head Mark 7
M5 0.8 3 ~ 4 (30 ~ 40, 2.2 ~ 2.9) 5 ~ 6 (50 ~ 60, 3.6 ~ 4.3)

M6 1.0 5 ~ 6 (50 ~ 50, 3.6 ~ 4.3) 9 ~ 11 (90 ~ 110, 6.5 ~ 8.0)
20 ~ 25 (200 ~ 250, 14.5 ~
M8 1.25 12 ~ 15 (120 ~ 150, 9 ~ 11)
18.0 )
M10 1.25 25 ~ 30 (250 ~ 300, 18 ~ 22) 30 ~ 50 (300 ~ 500, 22 ~ 36)
M12 1.25 35 ~ 45 (350 ~ 450, 25 ~ 33) 60 ~ 80 (600 ~ 800, 43 ~ 58)
120 ~ 140 (1,200 ~ 1,400, 85
M14 1.5 75 ~ 85 (750 ~ 850, 54 ~ 61)
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M14 1.5 75 ~ 85 (750 ~ 850, 54 ~ 61)
~ 100)
110 ~ 130 (1,100 ~ 1,300, 80 180 ~ 210 (1,800 ~ 2,100, 130
M16 1.5
~ 94) ~ 150)
160 ~ 180 (1,600 ~ 1,800, 116 260 ~ 300 (2,600 ~ 3,000, 190
M18 1.5
~ 130) ~ 215)
220 ~ 250 (2,200 ~ 2,500, 160 360 ~ 420 (3,600 ~ 4,200, 260
M20 1.5
~ 180) ~ 300)
290 ~ 330 (2,900 ~ 3,300, 210 480 ~ 550 (4,800 ~ 5,500, 350
M22 1.5
~ 240) ~ 400)
360 ~ 420 (3,600 ~ 4,200, 260 610 ~ 700 (6,100 ~ 7,000, 440
M24 1.5
~ 300) ~ 505)
1. The torques shown in the table are standard values under the following conditions.
• Nuts and bolts are made of galvanized steel bar.
• Galvanized plain steel washers are inserted.
• All nuts, bolts and plain washers are dry.
2. The torques shown in the table are not applicable.
• When spring washers, toothed washers and the like are inserted.
• If plastic parts are fastened.
• If self-tapping screws or self-locking nuts are used.
• If threads and surfaces are coated with oil.
3. Reduce the torque values to the indicated percentage of the standard value under the following conditions.
• If spring washers are used : 85%
• If threads and bearing surfaces are stained with oil : 85%
General Service Information

Protection Of The Vehicle
Always be sure to cover fenders, seats, and floor areas before starting work.
The support rod must be inserted into the hole near the edge of the hood whenever you inspect the engine
compartment to prevent the hood from falling and causing possible injury.
Make sure that the support rod has been released prior to closing the hood. Always check to be sure the hood is
firmly latched before driving the vehicle.
Preparation Of Tools And Mesuring Equipment

Be sure that all necessary tools and measuring equipment are available starting work.
Special Tools
Use special tools when they are required.
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Removal Of Parts
First find the cause of the problem and then determine whether removal or disassembly before starting the job.
Disassembly
If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be disassembled
in a way that will not affect their performance or external appearance.
1. Inspection of parts
Each part, when removed, should be carefully on suspected for malfunction, deformation, damage, and other
problems.
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2. Arrangement of parts
All disassembled parts should be carefully arranged for effective reassembly.
Be sure to separate and correctly identify the parts to be replaced from those that will be used again.
3. Cleaning parts for reuse

All parts to be used again should be carefully and thoroughly cleaned by an appropriate method.
Parts
When replacing parts, use KIA genuine parts.
Replacement
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Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts.
If removed, the following parts should always be replaced with new ones.
1. Oil seals
2. Gaskets
3. O-rings
4. Lock washers
5. Cotter pins (split pins)
6. Plastic nuts
Depending on their location.

7. Sealant should be applied to gaskets.
8. Oil should be applied to the moving components of parts.
9. Specified oil or grease should be applied to the prescribed locations (oil seals, etc) before assembly.
Adjustment
Use gauges and testers to adjust correctly the parts to standard values correctly.
Electrical System
1. Be sure to disconnect the battery cable from the negative (-) terminal of the battery.
2. Never pull on the wires when disconnecting connectors.
3. Locking connectors will click when the connector is secure.
4. Handle sensors and relays carefully. Be careful not to drop them against other parts.
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Ruber Parts And Tubes
Always prevent gasoline or from touching rubber parts or tubing.
Measuring Body Dimensiongs

1. Basically, all measurements in this manual are taken with a tracking gauge.
2. When a measuring tape is used, check to be sure there is no elongation, twisting or bending.
3. For measuring dimensions, both projected dimensions and actual - measurement dimensions are used in this
manual.
Dimensions Projected
1. These are the dimensions measured when the measurement points are projected from the vehicle's surface, and
are the reference dimensions used for used for body alterations.
2. If the length of the tracking gauge probes is adjustable, measure it by lengthening one of two probes as long as the
different value in height of the two surface.
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Measuring Actual Dimensions
1. These dimensions indicate the actual linear distance between mesaurement points, and are used as the reference
dimensions when a tracking gauge is used for measurement.
2. First adjust both probes to the same length (A=A') before measurement.
Check the probes and gauge itself to make sure there is no free play.
Measurement Point
Measurements should be taken at the center of the hole.
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Checking Cables And Wires
1. Check the terminal for tightness.
2. Check terminals and wires for corrosion from battery electrolyte, etc.
3. Check terminals and wires for open circuits.
4. Check wire insulation and coating for damage, cracks and degrading.
5. Check the conductive parts of terminals for contact with other metallic parts (vehicle body and other parts).
6. Check grounded parts to verify that there is complete continuity between their attaching bolt(s) and the vehicle's
body.
7. Check for incorrect wiring.
8. Check that the wiring is so clamped to the prevent contact with sharp corners of the vehicle body, etc. or hot parts
(exhaust manifold, etc.)
9. Check that the wiring is clamped firmly to provide enough clearance from the fan pulley, fan belt and other rotating
or moving parts.
10. Check that the wiring has a little space so that it can vibrate between fixed and moving parts such as the vehicle
body and the engine.
Check Fuses
A blade type fuse test taps provided to allow checking the fuse itself without removing if from the fuse box. The fuse is
good if the test lamp lights up when one lead is connected to the test taps (one at a time) and the other lead is
grounded. (Turn the ignition switch so that the fuse circuit becomes operative)
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Serivicing The Electrical System
1. Prior to servicing the electrical system, be sure to turn off the ignition switch and disconnect the battery ground
cable.
In the course of MFI or ELC system diagnosis, when the battery cable is removed, any diagnostic trouble code
retained by the computer will be cleared. There fore, if necessary, record the diagnostic data before removing
the battery cable.
2. Attach the wiring harnesses with clamps so that there is no slack. However, for any harness which passes the
engine or other vibrating parts of the vehicle, allow some slack within a range that does not allow the engine
vibrations to cause the harness to come into contact with any of the surrounding parts and then secure the harness
by using a clamp.
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3. If any section of a wiring harness interferes with the edge of a parts, or a corner, wrap the section of the harness
with tape or something similar in order to protect if from damage.
4. When installing any parts, be careful not to pinch or damage any of the wiring harness.
5. Never throw relays, sensors or electrical parts, or expose them to strong shock.
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6. The electronic parts used in the computer, relays, etc. are readily damaged by heat. If there is a need for service
operations that may cause the temperature to exceed 80°C (176°F), remove the electronic parts before hand.
7. Loose connectors cause problems. Make sure that the connectors are always securely fastened.
8. When disconnecting a connector, be sure to grip only the connector, not the wires.
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9. Disconnect connector which have catches by pressing in the direction of the arrows shown the illustration.
10. Connect connectors which have catches by inserting the connectors until they make a clicking sound.
11. When using a circuit tester to check continuity or voltage on connector terminals, insert the test probe into the
harness side. If the connector is a sealed connector, insert the test probe through the hole in the rubber cap until
contacts the terminal, being careful not to damage the insulation of the wires.
12. To avoid overloading the wiring, take the electrical current load of the optional equipment into consideration, and
determine the appropriate wire size.
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Permissible current
Noeminal size SAE gauge No.
In engine compartment Other areas
0.3mm$ AWG 22 - 5A
0.5mm$ AWG 20 7A 13A
0.85mm$ AWG 18 9A 17A
1.25mm$ AWG 16 12A 22A
2.0mm$ AWG 14 16A 30A
3.0mm$ AWG 12 21A 40A
5.0mm$ AWG 10 31A 54A
Precautions For Catalytic Converter
If a large amount of unburned gasoline flows into the converter, it may overheat and create a fire hazard. To
prevent this observe the following precations and explain them to your customer.
1. Use only unleaded gasoline.

2. Do not run the engine while the car is at rest for a long time. Avoid running the engine at fast idle for more than
10minutes and idle speed for more than 20 minutes.
3. Do not measure engine compression for an extended time. Engine compression tests must be made as rapidly as
possible. Remove the fuel pump relay before performing a compression test.
4. Do not dispose of used catalytic converter together with parts contaminated with gasoline or oil.
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Engine Mechanical System
General Information
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2010 > D 1.1 TCI-U >
SPECIFICATION
Description Specifications Limit
General
Type I-type, DOHC
Number of cylinder 3
Bore 75mm(2.9528in.)
Stroke 84.5mm(3.3268in.)
Total displacement 1,120cc
Compression ratio 17.8
Firing order 1-2-3
Valve timing
Intake valve Opens (ATDC) 13°5' ~ 21°5'
Closes (ABDC) 10°6' ~ 18°6' When valve lift is
Exhaust valve Opens (BBDC) 19°25' ~ 27°25' 1mm
Closes (BTDC) 16° ~ 24°

Cylinder head
Flatness of gasket surface Less than 0.05mm (0.0020in)
Less than 0.03mm (0.0012in) for each cylinder
Less than 0.012mm (0.0005in) for 50 ! 50 mm
Flatness of Intake Less than 0.025mm (0.0010in) for width
manifold mounting
Less than 0.160mm (0.0063in) for length
Camshaft
Cam height LH Camshaft Intake 35.452 ~ 35.652mm (1.3957 ~ 1.4036in)
Exhaust 35.700 ~ 35.900mm (1.4055 ~ 1.4134in)
RH Camshaft Intake 35.537 ~ 35.737mm (1.3991 ~ 1.4070in)
Exhaust 35.452 ~ 35.652mm (1.3957 ~ 1.4036in)
Journal outer LH Camshaft
diameter 20.944 ~ 20.960mm(0.8246 ~ 0.8252in.)
RH Camshaft
Bearing oil clearance 0.040 ~ 0.077mm (0.0016 ~ 0.0030in)
End play 0.10 ~ 0.20mm (0.0039-0.0079in)
Valve
Valve length Intake 93.0mm (3.6614in)
Exhaust 93.7mm (3.6890in)
Stem outer Intake 5.455 ~ 5.470mm (0.2148 ~ 0.2154in)
diameter
Exhaust 5.435 ~ 5.450mm (0.2140 ~ 0.2146in)
Face angle 45.58° ~ 45.75°
Thickness of Intake 1.1mm (0.0433in)
valvehead(margin)
Exhaust 1.2mm (0.0472in)
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Valve stem to Intake 0.030 ~ 0.057mm (0.0012 ~ 0.0022in)
valve guide
clearance Exhaust 0.050 ~ 0.077mm (0.0020 ~ 0.0030in)
Valve guide
Inner diameter Intake 5.500 ~ 5.512mm(0.2165 ~ 0.2170in.)
Exhaust 5.500 ~ 5.512mm(0.2165 ~ 0.2170in.)
Length Intake
31.3 ~ 31.7mm(1.2323 ~ 1.2480in.)
Exhaust
Valve spring
Free length 44.9mm (1.7677in)
Load 17.5±0.9kg/32.0mm(38.6±2.0 lb/1.2598in)
31.0±1.6kg/23.5mm(68.3±3.5 lb/0.9252in)
Out of squareness Less than 1.5°
Valve seat
Width of seat Intake 0.8 ~ 1.4(0.0315 ~ 0.0551in.)
contact
Exhaust 1.2 ~ 1.8mm(0.0472 ~ 0.0709in.)
Seat angle Intake
45° ~ 45.5°
Exhaust
Cylinder block
Cylinder bore 75.00 ~ 75.03mm (2.9528 ~ 2.9539in)
Less than 0.05mm (0.0020in)
Flatness of gasket surface
0.012mm/50mm!50mm
Piston
Piston outer diameter 74.93 ~ 74.96mm (2.9500 ~ 2.9512in)
Piston to cylinder clearance 0.060 ~ 0.080mm (0.0024 ~ 0.0031in)
Ring groove width No. 1 ring groove 1.83 ~ 1.85mm(0.0720 ~ 0.0728in.)
No. 2 ring groove 1.82 ~ 1.84mm(0.0717 ~ 0.0724in.)
Oil ring groove 3.02 ~ 3.04mm(0.1189 ~ 0.1197in.)
Piston ring
Side clearance No. 1 ring 0.09 ~ 0.13mm (0.0035 ~ 0.0051in)
No. 2 ring 0.08 ~ 0.12mm (0.0031 ~ 0.0047in)
Oil ring 0.03 ~ 0.07mm (0.0012 ~ 0.0028in)
End gap No. 1 ring 0.20 ~ 0.35mm (0.0079 ~ 0.0138in)
No. 2 ring 0.35 ~ 0.50mm (0.0138 ~ 0.0197in)
Oil ring 0.20 ~ 0.40mm (0.0079 ~ 0.0157in)
Piston pin
Piston pin outer diameter 27.995 ~ 28.000mm (1.1022 ~ 1.1024in)
Piston pin hole inner diameter 28.004 ~ 28.010mm(1.1025 ~ 1.1028in.)
Piston pin hole clearance 0.004 ~ 0.015mm (0.0002 ~ 0.0006in)
Connecting rod small end inner diameter 28.022 ~ 28.034mm(1.1032 ~ 1.1037in.)
Connecting rod small end hole clearance 0.022 ~ 0.039mm (0.0009 ~ 0.0015in)
Connecting rod
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Connecting rod big end inner diameter 49.000 ~ 49.018mm (1.9291 ~ 1.9298in)
Connecting rod bearing oil clearance 0.025 ~ 0.043mm(0.0010 ~ 0.0017in.)
Side clearance 0.050 ~ 0.302mm (0.0020 ~ 0.0119in.)
Crankshaft
Main journal outer diameter 53.972 ~ 53.990mm(2.1249 ~ 2.1256in.)
Pin journal outer diameter 45.997 ~ 46.015mm(1.8109 ~ 1.8116in.)
Main bearing oil clearance 0.024 ~ 0.042mm(0.0009 ~ 0.0017in.)
End play 0.08 ~ 0.28mm (0.0031 ~ 0.110in) 0.30mm (0.0118in)
Oil pump
Side clearance Inner rotor 0.040 ~ 0.085mm(0.0016 ~ 0.0033in.)
Outer rotor 0.040 ~ 0.090mm(0.0016 ~ 0.0035in.)
441.30 ~ 539.36kPa
Relief valve opening pressure
(4.5 ~ 5.5kgf/cm", 64.0 ~ 78.23 psi)
Engine oil
Oil quantity When replacing a
Total 5.7 L (6.02 US qt, 5.01 lmp qt) short engine or a
block assembly
Oil pan 4.8 L (5.07 US qt, 4.22 lmp qt)
Drain and refill 5.3 L (5.60 US qt, 4.66 lmp qt) Including oil filter
Oil grade Classification ACEA B4
Refer to the
SAE viscosity grade Recommended SAE viscosity number
"Lubrication System"
Oil temperature in oil
Oil pressure (at idle) 78.45kPa (0.8kg/cm", 11.38psi) or above
pan : 80°C (176°F)
Cooling system
Cooling method Forced circulation with electrical fan
Coolant quantity 5.3 liters(5.60US qt, 4.66lmp qt)
Thermostat Type Wax pellet type
Opening temperature 85 ± 1.5°C (185.0 ± 2.7°F)
Fully opened
100°C (212°F)
temperature
Full lift 8mm (0.3150in.) or more
Engine coolant temperature sensor
Type Thermister type
Resistance 20°C (68°F) 2.31 ~ 2.59 k#
80°C(176°F) 0.3222 k#
TIGHTENING TORQUE
Item N.m kgf.m lb-ft

Engine mounting
Engine mounting bolt & nut 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
Engine mounting insulator and Engine
88.3 ~ 107.9 9.0 ~ 11.0 65.1 ~ 79.6
mounting bracket fixing nut
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Transaxle mounting bolt & nut 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
Transaxle mounting insulator and transaxle
78.4 ~ 98.0 8.0 ~ 10.0 57.9 ~ 72.3
mounting bracket fixing bolt
Rear roll stopper mountiong bolt 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
Main moving system
Crank shaft pully bolt 225.6 ~ 245.2 23.0 ~ 25.0 166.4 ~ 180.8
Connecting rod bearing cap bolt 12.7 + (87~93°) 1.3 + (87~93°) 9.4 + (87~93°)
(22.6~26.5) + (16.6~19.5) +
Bed plate bolt (long) (2.3~2.7) + (90~94°)
(90~94°) (90~94°)
Bed plate bolt (short) 32.4 ~ 36.3 3.3 ~ 3.7 23.9 ~ 26.8
Flywheel bolt (M/T) 68.6 ~ 78.5 7.0 ~ 8.0 50.6 ~ 57.9
Drive plate bolt (A/T) 68.6 ~ 78.5 7.0 ~ 8.0 50.6 ~ 57.9
Cylinder block
Engine support bracket bolt 42.2 ~ 53.9 4.3 ~ 5.5 31.1 ~ 39.8
Piston cooling oil jet bolt 6.9 ~ 9.8 0.7 ~ 1.0 5.1 ~ 7.2
High pressure pump mounting bolt 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
Timing chain
Timing chain case assembly bolt(B) 24.5 ~ 30.4 2.5 ~ 3.1 18.1 ~ 22.4
Timing chain case assembly bolt(C) 18.6 ~ 27.5 1.9 ~ 2.8 13.7 ~ 20.3
Timing chain case assembly bolt(D) 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Timing chain case assembly bolt(E) 25.5 ~ 34.3 2.6 ~ 3.5 18.8 ~ 25.3
Timing chain cover bolt (M8) 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Timing chain cover bolt (M6) 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain auto tensioner bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Camshaft sprocket bolt 68.6 ~ 73.5 7.0 ~ 7.5 50.6 ~ 54.2
Timing chain guide (1) 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain guide (2) 9.8 ~ 13.7 1.0 ~ 1.4 7.2 ~ 10.1
Drive belt auto-tensioner 25.5 ~ 30.4 2.6 ~ 3.1 18.8 ~ 22.4
Drive belt idler 24.5 ~ 34.3 2.5 ~ 3.5 18.1 ~ 25.3
Water pump pulley 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
High pressure pump sprocket nut 64.7 ~ 74.5 6.6 ~ 7.6 47.7 ~ 55.0
Cylinder head
Camshaft bearing cap bolt 12.7 ~ 14.7 1.3 ~ 1.5 9.4 ~ 10.8
(47.1~51.0) + (4.8~5.2) + (88~92°) + (34.7~37.6) +
Cylinder head bolt
(88~92°) + (118~122°) (118~122°) (88~92°) + (118~122°)
Cylinder head cover bolt (step I) 1.9 ~ 2.9 0.2 ~ 0.3 1.4 ~ 2.2
Cylinder head cover bolt (step II) 4.9 ~ 6.9 0.5 ~ 0.7 3.6 ~ 5.1
Vacuum pump mounting bolt 10.8 ~ 14.7 1.1 ~ 1.5 8.0 ~ 10.8
Engine hanger (front) 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
Engine hanger (rear) 47.1 ~ 51.0 4.8 ~ 5.2 34.7 ~ 37.6
Common rail 14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~ 15.9
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Injector holder mounting bolts 28.4 ~ 30.4 2.9 ~ 3.1 21.0 ~ 22.4
Cooling system
Water pump pulley bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Water pump bolt 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
Thermostat housing 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Lubrication system
Oil screen assembly mounting bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil level gauge bolt 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Oil pump cover 5.9 ~ 8.8 0.6 ~ 0.9 4.3 ~ 6.5
Oil pump relief plunger 25.5 ~ 34.3 2.6 ~ 3.5 18.8 ~ 25.3
Oil filter 24.5 2.5 18.1
Oil drain plug 34.3 ~ 44.1 3.5 ~ 4.5 25.3 ~ 32.5
Balance shaft assembly mounting bolt 26.5 ~ 30.4 2.7 ~ 3.1 19.5 ~ 22.4
Oil pan bolt (M6) 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pan bolt (M10) 34.3 ~ 49.0 3.5 ~ 5.0 25.3 ~ 36.1
Intake and exhaust system
EGR cooler mounting bolt 21.6 ~ 27.5 2.2 ~ 2.8 15.9 ~ 20.3
EGR pipe nut 29.4 ~ 34.3 3.0 ~ 3.5 21.7 ~ 25.3
EGR pipe bolt 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.4
Intake manifold and cylinder head fixing nut 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.4
Intake manifold and cylinder head fixing bolt 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.4
Exhaust manifold and cylinder head fixing nut 29.4 ~ 34.3 3.0 ~ 3.5 21.7 ~ 25.3
Muffler mounting nut 44.1 ~ 53.9 4.5 ~ 5.5 32.5 ~ 39.8
Heat protector bolt 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.4
Intercooler cooler mounting bolt 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.4
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2010 > D 1.1 TCI-U >
Compression pressure inspection
If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure.
1. Warm up the engine until the normal operating temperature becoming 80~95°C(176~203°F).
2. Disconnect the fuel hose(A) from the fuel filter(B).
3. Start the engine until the engine stops.

4. Using the SST(09351-4A200), remove the injectors. (Refer to FL group.)
5. Using the SST(09351-27000/09351-2A000), check the cylinder compression pressure.
(1) Insert a compression gauge into the injector hole.
(2) Crank the engine for 10~15 seconds with opening the throttle fully.
(3) Measure the compression pressure.
Always use a fully charged battery to get the engine speed of 260 rpm or more.
(4) Repeat steps 1) through 3) for each cylinder.
This measurement must be done in as short a time as possible.
Compression pressure(Standard) : 2,353kPa (24.0kg/cm!, 341psi) (260 rpm)

Minimum pressure : 2,059kPa (21.0kg/cm!, 298psi)
Difference between each cylinder : 294.20kPa (3.0kg/cm!, 42.67psi) or less
A. If the pressure doesn't increase, a valve may be sticking or seating may be improper, or there may be leakage
from the gasket.
6. Reinstall the injectors.
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2010 > D 1.1 TCI-U >
TROUBLESHOOTING
Symptom Suspect area Remedy
Engine misfire with Loose or improperly installed engine flywheel. Repair or replace the flywheel as
abnormal internal required.
lower engine noises.
Worn piston rings. Inspect the cylinder for a loss of
(Oil consumption may or may not cause the engine compression.
to misfire.) Repair or replace as required.
Worn crankshaft thrust bearings. Replace the crankshaft and bearings as
required.
Engine misfire with Stuck valves. Repair or replace as required.
abnormal valve train (Carbon buildup on the valve stem can cause the
noise. valve not to close properly.)
Excessive worn or mis-aligned timing chain. Replace the timing chain and sprocket
as required.
Worn camshaft lobes. Replace the camshaft and valve lifters.
Engine misfire with • Faulty cylinder head gasket and/or cracking or • Inspect the cylinder head and
coolant consumption other damage to the cylinder head and engine engine block for damage to the
block cooling system. coolant passages and/or a faulty
• Coolant consumption may or may not cause the head gasket.
engine to overheat. • Repair or replace as required.
Engine misfire with Worn valves, valve guides and/or valve stem oil Repair or replace as required.
excessive oil seals.
consumption
Worn piston rings. Inspect the cylinder for a loss of
(Oil consumption may or may not cause the engine compression
to misfire) Repair or replace as required.
Engine noise on start- Low oil pressure. Repair or replace as required.
up, but only lasting a
Broken valve spring. Replace the valve spring.
few seconds.
Worn or dirty valve lifters. Replace the valve lifters.
Stretched or broken timing chain and/or damaged Replace the timing chain and sprockets.
sprocket teeth.
Worn timing chain tensioner, if applicable. Replace the timing chain tensioner as
required.
Worn camshaft lobes. Inspect the camshaft lobes.
Replace the camshaft and valve lifters
as required.
Worn valve guides or valve stems. Inspect the valves and valve guides,
then repair as required.
Stuck valves. (Carbon on the valve stem or valve Inspect the valves and valve guides,
seat may cause the valve to stay open.) then repair as required.
Lower engine noise, Low oil pressure. Repair or replace damaged components
regardless of engine as required.
speed.
Loose or damaged flywheel. Repair or replace the flywheel.
Damaged oil pan, contacting the oil pump screen. Inspect the oil pan.
Inspect the oil pump screen.
Repair or replace as required.
Oil pump screen loose, damaged or restricted. Inspect the oil pump screen.
Excessive piston-to-cylinder bore clearance. Inspect the piston and cylinder bore.
Repair as required.
Excessive piston pin-to-bore clearance. Inspect the piston, piston pin and the
connecting rod.
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Excessive connecting rod bearing clearance. Inspect the following components and
repair as required.
• The connecting rod bearings.
• The connecting rods.
• The crankshaft.
• The crankshaft journal.
Excessive crankshaft bearing clearance. Inspect the following components and
repair as required.
• The crankshaft bearings.
• The crankshaft journals.
Incorrect piston, piston pin and connecting rod Verify the piston pins and connecting
installation. rods are installed correctly.
Repair as required.
Engine noise under Low oil pressure. Repair or replace as required.
load.
Excessive connecting rod bearing clearance. Inspect the following components and
repair as required.
• The connecting rod bearings.
• The connecting rods.
• The crankshaft.
Excessive crankshaft bearing clearance. Inspect the following components and
repair as required.
• The crankshaft bearings.
• The crankshaft journals.
• The cylinder block crankshaft
bearing bore.
Engine will not crank. Hydraulically locked cylinder. Remove injectors and check for fluid.
(crankshaft will not • Coolant/antifreeze in cylinder. Inspect for broken head gasket.
rotate) • Oil in cylinder. Inspect for cracked engine block or
• Fuel in cylinder. cylinder head.
Inspect for a sticking fuel injector and/or
leaking fuel regulator.
Broken timing chain and/or timing chain gears. Inspect timing chain and gears.
Repair as required.
Foreign material in cylinder. Inspect cylinder for damaged
• Broken valve. components and/or foreign materials.
• Piston material. Repair or replace as required.
• Foreign material.
Seized crankshaft or connecting rod bearings. Inspect crankshaft and connecting rod
bearing.
Bent or broken connecting rod. Inspect connecting rods.
Broken crankshaft. Inspect crankshaft.
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2010 > D 1.1 TCI-U >
SPECIAL TOOLS
Tool (Number and name) Illustration Use
Torque angle adapter Installation of bolts & nuts needing an angular
(09221-4A000) method.
Valve spring compressor Removal and installation of intake and

(09222-3K000) exhaust valves
Valve spring compressor
adapter
(09222-2A100)
Compression gauge Checking engine compression pressure

(09351-27000)
Compression gauge adapter Checking engine compression pressure

(09351-2A000)
Valve stem oil seal installer Installation of valve stem oil seals
(09222-2A000)
Injector remover Removal of injectors

(09351-4A200)
Injector remover adapter Removal of injectors
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Injector remover adapter Removal of injectors
(09351-2A100)
High pressure pump Removal of high pressure pump sprocket

sprocket remover
(09331-2A000)
Crankshaft rear oil seal Installation of crankshaft rear oil seal

installer
(09231-33000)
Front cover oil seal installer Installation of front cover oil seal
(09231-2A000)
Handle
(09231-H1100)
Flywheel stopper Removal and installation of crankshaft pulley

(09231-2A100) bolt.
Oil pan remover Removal of oil pan

(09215-3C000)
Engine support fixture & Support of engine

adapter
(09200-38001, 09200-
1C000)
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Timing System
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2010 > D 1.1 TCI-U >
COMPONENTS
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2010 > D 1.1 TCI-U >
REMOVAL
Engine removal is not required for this procedure.
1. Remove the drive belt(A) by turning the autotensioner(B) counterclockwise.
2. Remove the air compressor.(Refer to Air compressor in HA group.)

3. Remove the oil pan.(Refer to Lubrication system in this group.)
4. Remove the cylinder head cover.(Refer to Cylinder head in this group.)
5. Using the SST(09200-38001, 09200-1C000), support the engine assembly.
6. Remove the engine mounting bracket(A).
7. Remove the alternator(A). (Refer to Alternator in EE group.)
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8. Remove the water pump pulley(A).
9. Remove the engine support bracket(A).
10. Remove the two idlers(A).
11. Remove the drive belt tensioner.
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12. Turn the crankshaft pulley to align its groove with the timing mark on the timing chain cover.
13. Remove the crankshaft pulley bolt(B) and crankshaft pulley(A).
Use the SST(flywheel stopper, 09231-2A110) to remove the crankshaft pulley bolt, after remove the starter.
14. Remove the high pressure pump sprocket nut(B) after removing the timing chain cover plug(A).
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• Use the SST(flywheel stopper, 09231-2A110) to remove the high pressure pump sprocket nut, after
remove the starter.
• Replace O-ring of the plug(A) with a new one when reinstalling the plug.
15. Remove the high pressure pump pipe. (Refer to FL group.)

16. Remove the high pressure pump(A) fixing bolts and fuel hoses(B,C).
17. Install the SST(09331-2A000)(A) to the sprocket by rotating it clockwise.

18. Remove the three timing chain cover bolts(B) illustrated below.
19. Install the SST(09331-2A000) to the timing chain cover with the three long bolts(B).
20. Fix the SST(09331-2A000) and sprocket stopper(C) with two fixing bolts(D).
21. Rotate the bolt(E) clockwise till the high pressure pump is pushed out.
22. Remove the SST(09331-2A000) after removing the high pressure pump assembly.
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23. Remove the timing chain cover(A).
Remove thoroughly sealant, oil and etc on the sealing surface after removing the timing chain cover. (If any
impurities are left at the sealing face, oil may leak after reassembly even with sealant applying.)
24. Remove the timing chain auto tensioner(A).
Before removing the auto-tensioner, install a set pin(B) (a ø2.5 mm steel wire) with compressing the
tensioner.
25. Remove the timing chain lever(A) and the two timing chain guides(B, C).
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26. Remove the timing chain(A).
27. Remove the timing chain auto tensioner(A).
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Before removing the auto-tensioner, install a set pin(B) (ø2.5 mm steel wire) with compressing the tensioner.
28. Remove the timing chain lever(A) and the timing chain guide(B).
29. Remove the timing chain(A)with the high pressure pump sprocket(B) and the crankshaft sprocket(C).
30. Remove the water pump(A).
31. Remove the timing chain case(A).(Engine removal is required for this procedure).
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32. Remove the camshaft sprocket. Holding the portion(A) of the camshaft with a hexagonal wrench, remove the
bolt(C) with a wrench(B) and remove the camshaft sprocket.
Be careful not to damage the cylinder head and valve lifter with the wrench.
INSTALLATION
1. Install the camshaft sprocket and tighten the bolt to the specified torque.
(1) Temporarily install the camshaft sprocket bolt(C).
(2) Holding the portion(A) of the camshaft with a hexagonal wrench, tighten the bolt(C) with a wrench(B).
Tightening torque :
68.6 ~ 73.5N.m (7.0 ~ 7.5kgf.m, 50.6 ~ 54.2lb-ft)
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The timing marks on the camshaft sprockets should face upright.
2. Install the timing chain case(A) with new gasket. (Engine removal is required for this procedure)
Tightening torque :
Bolt(B) :24.5 ~ 30.4N.m (2.5 ~ 3.1kgf.m, 18.1 ~ 22.4lb-ft)
Bolt(C) :18.6 ~ 27.5N.m (1.9 ~ 2.8kgf.m, 13.7 ~ 20.3lb-ft)
Bolt(D) : 7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
Bolt(E) : 25.5 ~ 34.3N.m (2.6 ~ 3.5kgf.m, 18.8 ~ 25.3lb-ft)
3. Install the water pump(A).
Tightening torque :
19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1lb-ft)
• Apply coolant to the o-ring before installing the water pump.

• Do not apply oil or something to the o-ring before installing the water pump.
4. Install the high pressure pump.
Tightening torque :
14.7 ~ 19.6N.m (1.5 ~ 2.0kgf.m, 10.8 ~ 14.5lb-ft)
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5. Set the key of crankshaft sprocket to be aligned with the timing mark of the timing chain case. As a result of this,
place the piston of No.1 cylinder at the top dead center on compression stroke.
6. After installing the timing chain(A) with the high pressure pump sprocket(B) and the crankshaft sprocket(C), insert
the high pressure pump shaft in the sprocket.
The timing marks of the high pressure pump sprocket should be aligned with the timing marks on the timing
chain case.
7. Pretighten the high pressure pump sprocket nut.

8. Install the timing chain lever(A) and the timing chain guide(B).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
9. Install the timing chain auto tensioner(A) and then remove the set pin(B).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
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10. Install the timing chain(A) as following procedure.
High pressure pump sprocket ! LH camshaft sprocket ! RH camshaft sprocket.
The timing mark of each sprockets should be matched with the timing mark(color link) of the timing chain.
11. Install the timing chain lever(A) and the two timing chain guides(B, C).
Tightening torque :
B : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
C : 9.8 ~ 13.7N.m (1.0 ~ 1.4kgf.m, 7.2 ~ 10.1lb-ft)
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12. Install the timing chain auto tensioner(A) and then remove the set pin(B).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
13. Tighten the high pressure pump sprocket nut (A).
Tightening torque :
64.7 ~ 74.5N.m (6.6 ~ 7.6kgf.m, 47.7 ~ 55.0lb-ft)
Use the SST(flywheel stopper, 09231-2A110)(A) to tighten the high pressure pump sprocket nut, after
remove the starter.
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14. Apply liquid gasket evenly to the mating surface of timing chain cover.
• Standard liquid gasket : LOCTITE 5900

• Check that the mating surfaces are clean and dry before applying liquid gasket.
• Assemble the timing chain cover within five minutes after applying liquid gasket.
• Apply liquid gasket in a 3mm wide bead without stopping.
15. Install the timing chain cover(A).
Tightening torque :
M8 BOLT : 19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft)
16. Install the front oil seal by using SST(09231-2A000, 09231-H1100)(A).
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17. Install the crankshaft pulley bolt(B) and crankshaft pulley(A).
Tightening torque :
225.6 ~ 245.2N.m (23.0 ~ 25.0kgf.m, 166.4 ~ 180.8lb-ft)
Use the SST(flywheel stopper, 09231-2A110)(A) to tighten the crankshaft pulley bolt, after remove the starter.
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19. Install the drive belt tensioner.
Tightening torque :
25.5 ~ 30.4N.m (2.6 ~ 3.1kgf.m, 18.8 ~ 22.4lb-ft)
20. Install the two idlers(A).
Tightening torque :
24.5 ~ 34.3N.m (2.5 ~ 3.5kgf.m, 18.1 ~ 25.3lb-ft)
21. Install the engine support bracket(A).
Tightening torque :
42.2 ~ 53.9N.m (4.3 ~ 5.5kgf.m, 31.1 ~ 39.8lb-ft)
22. Install the water pump pulley(A).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
GETtheMANUALS.org
23. Install the alternator(A). (Refer to Alternator in EE group.)
Tightening torque :
38.2 ~ 58.8N.m (3.9 ~ 6.0kgf.m, 28.2 ~ 43.4lb-ft)
24. Install the oil pan.(Refer to Lubrication system in this group.)

25. Install the air compressor.(Refer to Air compressor in HA group.)
26. Install the drive belt.
27. Install the engine mounting bracket(A).
Tightening torque :
Nuts(B), Bolt(C) : 49.0 ~ 63.7N.m(5.0 ~ 6.5kgf.m, 36.1 ~ 47.0lb-ft)
Nut(D) : 88.3 ~ 107.4N.m(9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft)
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28. Remove the SST(09200-38001, 09200-1C000).
29. Install the cylinder head cover.(Refer to Cylinder head in this group.)
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Cylinder Head Assembly
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2010 > D 1.1 TCI-U >
COMPONENTS
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2010 > D 1.1 TCI-U >
REMOVAL
Engine removal is required for this procedure.
• To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal
temperature before removing it.
• When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.
• Mark all wiring and hoses to avoid misconnection.

• Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
1. Remove the intake and exhaust manifold assemblies. (Refer to Intake and exhaust system in this group.)
3. Remove the oil pan(A).
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4. Disconnect the fuel return hose(A) after removing the clips(B).
5. Remove the vacuum pipe assembly(A).
6. Remove the injector holders(A) with the bolts(B).
7. Using the SST(09351-4A200), remove the injectors(A).
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8. Remove the cylinder head cover(A) with the gasket.
9. Disconnect the water hose(A) from thermostat housing.
10. Remove the EGR cooler assembly(A).
11. Remove the thermostat housing(A).
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12. Remove the common rail(A).
13. Remove the timing chain.(Refer to Timing system in this group.)

14. Remove the vacuum pump(A).
15. Remove the camshaft bearing caps(A).
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16. Remove the camshafts(A).
17. Remove the cam followers (A) with the HLA(Hydraulic Lash Adjuster)s(B).
18. Remove the cylinder head bolts(A), and then the cylinder head assembly.
(1) Uniformly loosen and remove the 8 cylinder head bolts, in several passes, in the sequence shown.
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(2) Lift the cylinder head from the cylinder block and place it on wooden blocks.
Be careful not to damage the contact surface of the cylinder head and the cylinder block.
DISASSEMBLY
1. Remove the valves.
(1) Using the SST (09222-3K000, 09222-2A100)(A), compress the valve spring and remove the retainer lock.
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(2) Remove the spring retainer.
(3) Remove the valve spring.
(4) Remove the valve.
(5) Using a needle-nose pliers, remove the stem oil seal.
2. Remove the glow plug and the glow plug plate.
INSPECTION
CYLINDER HEAD
1. Inspect for flatness.
Using a precision straight edge and feeler gauge, measure the surface the contacting the cylinder block and the
manifolds for warpage.
Flatness of cylinder head gasket surface :

Less than 0.03mm (0.0012in) for each cylinder
Flatness of manifold mating surface :
Less than 0.025mm (0.0010in) for width
Less than 0.160mm (0.0063in) for length
2. Inspect for cracks.

Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked,
replace the cylinder head.
VALVE AND VALVE SPRING
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1. Inspect the valve stems and valve guides.
(1) Using a caliper gauge, measure the inner diameter of valve guide.
Valve guide inner diameter :

Intake : 5.500 ~ 5.512mm (0.2165 ~ 0.2170in)
Exhaust : 5.500 ~ 5.512mm (0.2165 ~ 0.2170in)
(2) Using a micrometer, measure the outer diameter of valve stem.
Valve stem outer diameter :

Intake : 5.455 ~ 5.470mm (0.2148 ~ 0.2154in)
Exhaust : 5.435 ~ 5.450mm (0.2140 ~ 0.2146in)
(3) Subtract the valve stem outer diameter measurement from the valve guide inner diameter measurement.
Valve stem- to-guide clearance

Intake : 0.030 ~ 0.057mm (0.0012 ~ 0.0022in)
Exhaust : 0.050 ~ 0.077mm (0.0020 ~ 0.0030in)
If the clearance is greater than specification, replace the valve and valve guide.
2. Inspect the valves.

(1) Check the valve is ground to the correct valve face angle.
(2) Check that the surface of valve for wear.
If the valve face is worn, replace the valve.
(3) Check the valve head margin thickness. If the margin thickness is less than specification, replace the valve.
Margin
Intake : 1.1mm (0.0433in)
Exhaust : 1.2mm (0.0472in)
(4) Check the valve length.
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Length
Intake : 93.0mm (3.6614in)
Exhaust : 93.7mm (3.6890in)
(5) Check the surface of valve stem tip for wear.

If the valve stem tip is worn, replace the valve.
3. Inspect the valve seats.

(1) Check the valve seat for evidence of overheating and improper contact with the valve face.
Replace the seat if necessary.
(2) Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace it, then
recondition the seat.
(3) Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width should be within
specifications and centered on the valve face.
4. Inspect the valve springs.

(1) Using a steel square, measure the out-of-square of valve spring.
(2) Using a vernier calipers, measure the free length of valve spring.
Valve spring
Standard
Free height : 44.9mm (1.7677in)
Load : 17.5±0.9kg/32.0mm (38.6±2.0lb/1.2598in)
31.0±1.6kg/23.5mm (68.3±3.5lb/0.9252in)
Out of square : Less than 1.5°
If the loads is not as specified, replace the valve spring.
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CAMSHAFT
1. Inspect the cam lobes.
Using a micrometer, measure the cam lobe height.
CAM HEIGHT
LH Camshaft
Intake : 35.452 ~ 35.652mm (1.3957 ~ 1.4036in)
Exhaust : 35.700 ~ 35.900mm (1.4055 ~ 1.4134in)
RH Camshaft
Intake : 35.537 ~ 35.737mm (1.3991 ~ 1.4070in)
Exhaust : 35.452 ~ 35.652mm (1.3957 ~ 1.4036in)
If the cam lobe height is less than specification, replace the camshaft.
2. Inspect the camshaft journal clearance.
(1) Clean the bearing caps and camshaft journals.
(2) Place the camshafts on the cylinder head.
(3) Lay a strip of plastigage across each of the camshaft journal.
(4) Install the bearing caps and tighten the bolts with specified torque.
Tightening torque :
11.8 ~ 13.7N.m (1.2 ~ 1.4kgf.m, 8.7 ~ 10.1lbf.ft)
Do not turn the camshaft.
(5) Remove the bearing caps.

(6) Measure the plastigage at its widest point.
Bearing oil clearance

0.040 ~ 0.077mm (0.0016 ~ 0.0030in)
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If the oil clearance is greater than specificaiton, replace the camshaft. If necessary, replace the bearing caps
and cylinder head as a set.
(7) Completely remove the plastigage.
(8) Remove the camshafts.
3. Inspect the camshaft end play.

(1) Install the camshafts.
(2) Using a dial indicator, measure the end play while moving the camshaft back and forth.
Camshaft end play

Standard : 0.1 ~ 0.2mm (0.0039 ~ 0.0079in)
If the end play is greater than specification, replace the camshaft. If necessary, replace the bearing caps and
cylinder head as a set.
(3) Remove the camshafts.
HLA (HYDRAULIC LASH ADJUSTER)

With the HLA filled with engine oil, hold A and press B by hand.
If B moves, replace the HLA.
Problem Possible cause Action

1. Temporary noise when starting a Normal This noise will disappear after the oil
cold engine in the engine reaches the normal
pressure.
2. Continuous noise when the engine Oil leakage of the high ressure Noise will disapapear within 15
is started after parking more than 48 chamber on the HLA, allowing air to minutes when engine runs at 2000-
hours. get in. 3000 rpm.
If it doesn’t disappear, refer to step 7
below.
3. Continuous noise when the engine Insufficient oil in cylinder head oil
is first started after rebuilding cylinder gallery.
head.
Do not run engine at a speed
4. Continuous noise when the engine Oil leakage of the high-pressure higher than 3000 rpm, as this may
is started after excessively cranking chamber in the HLA, allowing air to damage the HLA.
the engine by the starter or band. get in.
Insufficient oil in the HLA.
5. Continuous noise when the engine
is running after changing the HLA.
6. Continuous noise during idle after Engine oil level too high or too low. Check oil level.
high engine speed.
Excessive amount of air in the oil at
Check oil supply system.
high engine speed.
Deteriorated oil. Check oil quality.
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If deteriorated, replace with specified
type.
7. Noise continues for more than 15 Low oil pressure. Check oil pressure and oil supply
minutes. system of each part of engine.
Faulty HLA. Remove the cylinder head cover and
press HLA down by hand.
If it moves, replace the HLA
REASSEMBLY
• Thoroughly clean all parts to be assembled.

• Before installing the parts, apply fresh engine oil to all sliding and rotating surface.
• Replace oil seals with new ones.
1. Install the valves.

(1) Using the SST (09222-2A000)(A), push in a new stem oil seal.
Do not reuse old valve stem oil seals.

Incorrect installation of the seal could result in oil leakage
(2) Install the valve, valve spring and spring retainer.
Place the valve springs so that the side coated with enamel faces toward the valve spring retainer. Installs
the retainer.
(3) Using the SST(09222-2A100, 09222-3K000)(A), compress the spring and install the retainer locks.
After installing the valves, ensure that the retainer locks are correctly in place before releasing the SST.
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(4) Lightly tap the end of each valve stem two or three times with the wooden handle of a hammer to ensure
proper seating of the valve and the retainer locks.
2. Install the glow plug and the glow plug plate.
Tightening torque :
Glow plug: 15 ~ 20N.m (1.5 ~ 2.0kgf.m, 11 ~ 14lb-ft)
Plate nut : 0.8~1.5N.m (0.08 ~ 0.15kgf.m, 0.6 ~ 1.1lb-ft)
INSTALLATION
• Thoroughly clean all parts to be assembled.

• Always use a new cylinder head and manifold gasket.
• Always use a new cylinder head bolt.
• The cylinder head gasket is a metal gasket. Take care not to bend it.
• Rotate the crankshaft, set the No.1 piston at TDC.
1. Cylinder head dowel pins must be aligned.

2. Select the cylinder head gasket.
(1) Measure the piston protrusion from the upper cylinder block face on 6 places (A ~ F) at the top dead center.
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(2) Measure them along the crankshaft center line.
(3) Select the gasket in the table below using the average value of piston protrusions. Although even the only 1
point is over than the each rank limit, use 1 rank upper gasket than specified in the table below.
Displacement 1.1 L
Average of piston 0.035 ~ 0.105mm 0.105 ~ 0.175mm 0.175 ~ 0.245mm
protrusion (0.0014 ~ 0.0041in) (0.0041 ~ 0.0069in) (0.0069 ~ 0.0096in)
Gasket thickness of 1.00 ~ 1.15mm 1.05 ~ 1.20mm 1.10 ~ 1.25mm
uncompressed (0.0394 ~ 0.0453in) (0.0413 ~ 0.0472in) (0.0433 ~ 0.0492in)
Limit of each rank extent 0.14mm (0.0055 in) 0.21mm (0.0083in) -
Identification code
Gasket grade A B C
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(4) Install the gasket so that the identification mark faces toward the timing chain side.
3. Place the cylinder head quietly in order not to damage the gasket with the bottom part of the end.
4. Install the cylinder head bolts.
(1) Apply a light coat if engine oil on the threads(A) and under the heads of the cylinder head bolts.
(2) Using the SST(09221-4A000), tighten the eight cylinder head bolts(A), in several passes as shown below.
Tightening torque :
47.1~51.0Nm (4.8~5.2kgf.m, 34.7~37.6lb-ft) + (88~92°) + (118~122°)
Always use new cylinder head bolts.
5. Install the HLA(Hydraulic Lash Adjuster) and cam follower assembly(A).
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(1) Until installing HLA shall be held upright so that diesel oil in HLA should not spill and assured that dust does
not adhere to HLA.
(2) HLA shall be inserted tenderly to the cylinder head not to spill diesel oil from HLA. In case of spilling, air bent
shall be done in accordance with the air bent procedure.
• In case of lash adjuster alone
• After installed on engine(reference)
6. Apply oil on the cam bore of head before camshaft assembly(A) in assemblying camshaft bearing cap. All pistons
should be in the middle position between top dead center and bottom dead center not to interfere with valves.
7. Confirm that cam followers are located on lash adjusters and their rollers are in touch with camshaft.
8. Install the camshaft bearing caps(A).
Tightening torque :
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12.7 ~ 14.7N.m (1.3 ~ 1.5kgf.m, 9.4 ~ 10.8lb-ft)
9. Install the vacuum pump(A) with new gasket(B).
Tightening torque :
10.8 ~ 14.7N.m (1.1 ~ 1.5kgf.m, 8.0 ~ 10.8lb-ft)
LOCTITE 5900 or TB 1217H

Tightening torque :
10.8 ~ 14.7N.m (1.1 ~ 1.5kgf.m, 8.0 ~ 10.8lb-ft)
A. Apply liquid gasket in a wide head : 3 ± 0.5 mm

B. Assemble the vacuum pump within 5 minutes after applying.
• Apply the sealant between the camshaft bearing cap and the cylinder head for sealing.
• Apply engine oil to the O-ring(A) of vacuum pump shaft before assembling vacuum pump.
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10. Install the timing chain.(Refer to Timing system in this group.)
11. Install the EGR cooler assembly(A).
Tightening torque :
B : 21.6 ~ 27.5N.m (2.2 ~ 2.8kgf.m, 15.9 ~ 20.3lb-ft)
C : 14.7 ~ 10.8N.m (1.5 ~ 2.0kgf.m, 10.8 ~ 14.5lb-ft)
12. Install the thermostat housing (A).
Tightening torque :
10.8 ~ 14.7N.m (1.0 ~ 1.2kgf.m, 8.0 ~ 10.8lb-ft)
13. Connect the water hose (A).
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14. Install the common rail(A).
Tightening torque :
14.7 ~ 21.6N.m (1.5 ~ 2.2kgf.m, 10.8 ~ 15.9lb-ft)
15. Apply liquid gasket to the mating surface of timing chain case and cylinder block (A), rear cam cap (B).
• Standard liquid gasket: LOCTITE 5900 or TB1217H

• Assemble the cylinder head cover within five minutes after applying liquid gasket.
16. Install the cylinder head cover (A) with the gasket.
Tighten the bolts in two steps with sequence.
Tightening torque
STEP 1: 3.9~5.9Nm (0.4~0.6kgf.m, 2.9~4.3lb.ft)
STEP 2: 8.8~10.8Nm (0.9~1.1kgf.m, 6.5~8.0lb.ft)
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• Do not crank or start the engine until 30 minutes passed after assembling.
17. Insert the injectors(A).
18. Install the injector holders(A) with the bolts(B).
Tightening torque :
28.4 ~ 30.4N.m (2.9 ~ 3.1kgf.m, 21.0 ~ 22.4lb-ft)
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19. Install the vacuum pipe assembly (A).
Tightening torque :
6.8 ~ 10.8N.m (0.7 ~ 1.1kgf.m, 5.1 ~ 7.9lb-ft)
20. Connect the fuel return hose(A) and the clips(B).
21. Install the oil pan.(Refer to Lubrication system in this group.)

22. Install the intake and exhaust manifold assemblies. (Refer to Intake and exhaust system in this group.)
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Engine & Transaxle Assembly
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2010 > D 1.1 TCI-U >
COMPONENT
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2010 > D 1.1 TCI-U >
REMOVAL
• Use fender covers to avoid damaging painted surfaces.

• To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
1. Remove the engine cover.

2. Remove the battery(A) and the intake air hose and air cleaner assembly(C).
(1) Disconnect the AFS(Air Flow Sensor) connector(B).
(2) Remove the air cleaner assembly.
3. Remove the battery tray(A).
Tightening torque :
9.8 ~ 11.7N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
4. Recover the refrigerant and remove the high & low pressure pipe. (Refer to Air conditioning system in HA group)
5. Remove the under covers(A).
Tightening torque :
6.9 ~ 10.8N.m (0.7 ~ 1.1kgf.m, 5.1 ~ 7.9lb-ft)
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6. Drain engine coolant and remove the radiator cap to speed draining.
7. Remove the upper radiator hose(A), the lower radiator hose(B) and reservior hose.
8. Remove the intercooler outlet hose(A).
9. Disconnect the fuel hoses(A).
10. Remove the brake booster vacuum hose(A).
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11. Disconnect the eletronic EGR control valve vacuum hose(A), the throttle flap actuator vacuum hose(B) and the
VGT solenoid valve vacuum hose(C).
12. Remove the engine wire harness connectors and wire harness clamps from cylinder head and the intake manifold.
(1) Disconnect the injector connectors(A).

(2) Disconnect the camshaft positon sensor connector(B).
(3) Disconnect the EGR actuator connector(C).
(4) Disconnect the ECT sensor connector(D) and the rail pressure sensor connector(E).
(5) Disconnect the booster pressure sensor connector(F).
(6) Disconnect the rail pressure regulating valve connector(G).
(7) Disconnect the lambda sensor connector(H) and the glow plug connector(I).
(8) Disconnect the altornator terminal and the connector.
(9) Disconnect the ground lines.
(10) Disconnect the fuel pressure regulating valve connector(A) and the fuel temperature sensor connector(B).
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(11) Disconnect the starter terminal(A), connector(B), the ground line(C) and the compressor connector(D).
(12) Disconnect the fuse & relay box connector(A) and the ground line(B).
(13) Disconnect the crankshaft position sensor(A).
13. Remove the cables and tubes related to the transaxle.(Refer to MT or AT group).
14. Remove the front muffler(A).
Tightening torque :
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44.1 ~ 53.9N.m (4.5 ~ 5.5kgf.m, 32.5 ~ 39.8lb-ft)
15. Remove the rear roll stopper (A).
Tightening torque :
49.0 ~ 63.7N.m (5.0 ~ 6.5kgf.m, 36.1 ~ 47.0lb-ft)
Mark the rear roll stopper direction for proper installation.
16. Remove the inter cooler inlet hose(A).
17. Remove the heater hose.

18. Remove the front wheels.
19. Disconnect the front strut assembly, the wheel speed sensor and the steering tie rod from the front axles.(Refer to
DS and SS groups).
20. Remove the calipers from the discs and fix them to the coil spring of the struts with a wire or a strap.(Refer to DS
group).
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21. Disconnect the stabilizer bar links.(Refer to SS group).
22. Support the engine and transaxle assembly with a jack.
Tightening torque :
Nuts (B). Bolt (C) :
49.0 ~ 63.7N.m (5.0 ~ 6.5kgf.m, 36.1 ~ 47.0lb-ft)
Nut (D) :
88.3 ~ 107.4N.m (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft)
24. Remove the transaxle mounting bracket.(Refer to MT group).

25. Remove the engine and transaxle assembly by lifting vehicle.
When remove the engine and transaxle assembly, be careful not to damage any surrounding parts or body
components.
INSTALLATION
Installation is in the reverse order of removal.
Perform the following :
• Adjust the shift cable.
• Refill the engine with engine oil.
• Refill the transaxle with fluid.
• Refill the radiator and reservoir tank with engine coolant.
• Place the heater control knob on “HOT” position.
• Bleed air from the cooling system.
- Start engine and let it run until it warms up. (until the radiator fan operates 3 or 4 times.)
- Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be
removed from the cooling system.
- Put the radiator cap on tightly, then run the engine again and check for leaks.
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• Clean the battery posts and cable terminals with sandpaper assemble them, then apply grease to prevent
corrosion.
• Inspect for fuel leakage.
- After assemble the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs
for approximately two seconds and fuel line pressurizes.
- Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
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Cylinder Block
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2010 > D 1.1 TCI-U >
COMPONENTS
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2010 > D 1.1 TCI-U >
DISASSEMBLY
1. Remove the fly wheel.
2. Install the engine to engine stand for disassembly.
3. Remove the intake manifold and exhaust manifold assembly. (Refer to Intake and exhaust system in this group.)
4. Remove the cylinder head assembly and the timing chain. (Refer to Cylinder head & Timing system in this group.)
5. Disconnect the hose(A) from the engine oil cooler and remove the water pipe(B).
6. Remove the oil filter and oil cooler assembly(A).
7. Remove the bed plate(A).
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8. Remove the rear oil seal(A).
9. Remove the connecting rod bearing cap(A).
Mark the connecting rod caps to be able to reassemble in the original position and direction.
10. Lift the crankshaft(A) out of the engine block, being careful not to damage journals.
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Arrange the main bearings and thrust bearings in the correct order.
11. Remove the piston and connecting rod assemblies.

(1) Using a ridge reamer, remove all the carbon from the top of the cylinder.
(2) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
• Keep the bearings, connecting rod and cap together.

• Arrange the piston and connecting rod assemblies in the correct order.
12. Remove the oil jet(A).
13. Remove the piston rings.

14. Remove the connecting rod from the piston. Using a press, remove the piston pin from the piston.
INSPECTION
CONNECTING ROD
1. Check the connecting rod bearing oil clearance.
(1) Check the match marks on the connecting rod and the cap to ensure correct reassembly.
(2) Remove the 2 connecting rod cap bolts.
(3) Remove the connecting rod cap and lower bearing.
(4) Clean the crankshaft pin journal and bearing.
(5) Place a plastigage across the crankshaft pin journal.
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(6) Reinstall the lower bearing and cap, and tighten the nuts.
Tightening torque :
12.7Nm (1.3kgf.m, 9.4lb-ft) + (87~93°)
Do not turn the crankshaft.

Do not reuse the connection rod cap bolts.
(7) Remove the connecting rod cap and lower bearing.

(8) Measure the plastigage at its widest point.
Standard oil clearance

0.025 ~ 0.043mm (0.0010 ~ 0.0017in)
(9) If the plastigage measurement is too wide or too narrow, remove the upper and lower bearing and then install
a new bearings with the same color mark.
Recheck the oil clearance.
Do not file, shim, or scrape the bearings or the caps to adjust clearance.
(10) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing.
If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace
the crankshaft.
If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a
wire brush or scraper. Clean them only with solvent or detergent.
Connecting rod mark location
Discrimination of connecting rod

Mark Connecting rod big-end inner diameter
A 49.000 ~ 49.006mm (1.9291 ~ 1.9294in)
B 49.006 ~ 49.012mm (1.9294 ~ 1.9296in)
C 49.012 ~ 49.018mm (1.9296 ~ 1.9298in)
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Crankshaft pin journal mark location
Discrimination of crankshaft pin journal

Mark Connecting rod big-end outer diameter
A 46.009 ~ 46.015mm (1.8114 ~ 1.8116in)
B 46.003 ~ 46.009mm (1.8111 ~ 1.8114in)
C 45.997 ~ 46.003mm (1.8109 ~ 1.8111in)
Connecting rod bearing mark location
Discrimination of connecting rod bearing

Color Connecting rod bearing thickness
Blue 1.477 ~ 1.480mm (0.0581 ~ 0.0583in)
Black 1.480 ~ 1.483mm (0.0583 ~ 0.0584in)
None 1.483 ~ 1.486mm (0.0584 ~ 0.0585in)
Green 1.486 ~ 1.489mm (0.0585 ~ 0.0586in)
Yellow 1.489 ~ 1.492mm (0.0586 ~ 0.0587in)
(11) Select the bearing by using selection table.

Connecting rod bearing selection table
Connecting rod mark

Connecting rod bearing
A B C
Crank shaft pin journal mark A Blue Black None
B Black None Green
C None Green Yellow
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2. Check the connecting rods.
(1) When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at disassembly match.
When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the
same side.
(2) Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a severely
rough surface of the inside diameter of the small end is apparent, the rod must be replaced as well.
CRANKSHAFT
1. Check the crankshaft bearing oil clearance.
(1) To check main bearing-to-journal oil clearance, remove the bed plate and lower bearings.
(2) Clean each main journal and lower bearing with a clean shop towel.
(3) Place one strip of plastigage across each main journal.
(4) Reinstall the lower bearings and bed plate, then tighten the bolts.
Tightening torque :
Long bolts : 22.6~26.5Nm (2.3~2.7kgf.m, 16.6~19.5lb-ft) + 90~94°
Short bolts : 32.4~36.3N.m(3.3~3.7kgf.m, 23.9~26.8lb-ft)
Do not turn the crankshaft.
(5) Remove the bed plate and lower bearing again, and measure the widest part of the plastigage.
Standard oil clearance :

0.024 ~ 0.042mm (0.0009 ~ 0.0017in)
(6) If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then install a new
bearings with the same color mark.
Do not file, shim, or scrape the bearings or the cap to adjust clearance.
(7) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing.
If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the
crankshaft and start over.
If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire
brush or scraper. Clean them only with solvent or detergent.
CRANKSHAFT JOURNAL BORE MARK LOCATION

Letters have been stamped on the front face of block as a mark for the size of each of the 5 main journal
bores.
Use them, and the numbers or letters stamped on the crank (marks for main journal size), to choose the correct
bearings.
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Discrimination of cylinder block crankshaft journal bore
Mark Cylinder block crankshaft journal bore inner diameter
A 58.000 ~ 58.006mm (2.2835 ~ 2.2837in)
B 88.006 ~ 58.012mm (2.2837 ~ 2.2839in)
C 58.012 ~ 58.018mm (2.2839 ~ 2.2842in)
Crankshaft main journal mark location
Discrimination of crankshaft main journal
Mark Crankshaft main journal outer diameter

A 53.984 ~ 53.990mm (2.1254 ~ 2.1256in)
B 53.978 ~ 53.984mm (2.1251 ~ 2.1254in)
C 53.972 ~ 53.978mm (2.1249 ~ 2.1251in)
Crankshaft main bearing mark location
Discrimination of crankshaft main bearing
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Color Crankshaft main bearing thickness
Blue 1.990 ~ 1.993mm (0.0783 ~ 0.0785in)
Black 1.993 ~ 1.996mm (0.0785 ~ 0.0786in)
None 1.996 ~ 1.999mm (0.0786 ~ 0.0787in)
Green 1.999 ~ 2.002mm (0.0787 ~ 0.0788in)
Yellow 2.002 ~ 2.005mm (0.0788 ~ 0.0789in)
(8) Select the bearing by using the selection table below.

Crankshaft main bearing selection table
Cylinder block crankshaft journal bore mark
Crankshaft main bearing
A B C
Crank shaft main journal A Blue Black None
mark
B Black None Green
C None Green Yelllow
2. Check the crankshaft end play.

Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
End play
Standard : 0.08 ~ 0.28mm (0.0031 ~ 0.110in)
Limit : 0.30mm (0.0118in)
If the end play is greater than the maximum, replace the center main bearing as a set.
Thrust washer thickness of center main beaing :

2.335 ~ 2.385mm (0.0919 ~ 0.0939in)
End play
Standard : 0.08 ~ 0.28mm (0.0031 ~ 0.110in)
Limit : 0.30mm (0.0118in)
3. Inspect the crankshaft main journals and pin journals.

Using a micrometer, measure the diameter of each main journal and pin journal.
Main journal diameter :

53.972 ~ 53.990mm (2.1249 ~ 2.1256in)
Pin journal diameter :
45.997 ~ 46.015mm (1.8109 ~ 1.8116in)
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ENGINE BLOCK
1. Remove the gasket material.
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean the cylinder block.
Using a soft brush and solvent, thoroughly clean the cylinder block.
3. Inspect the top surface of cylinder block for flatness.
Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for
warpage.
Flatness of cylinder block gasket surface

Less than 0.012mm (0.0005in)/50mm!50mm
4. Inspect the cylinder bore.

Visually check the cylinder for vertical scratchs.
If deep scratchs are present, replace the cylinder block.
5. Inspect the cylinder bore diameter.
Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial direction.
Standard diameter :
75.00 ~ 75.03mm (2.9528 ~ 2.9539in)
6. Check the cylinder bore size code on the cylinder block front face.
Discrimination of cylinder bore size

Mark Cylinder bore inner diameter
A 75.000 ~ 75.010mm (2.9528 ~ 2.9531in)
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B 75.010 ~ 75.020mm (2.9531 ~ 2.9535in)
C 75.020 ~ 75.030mm (2.9535 ~ 2.9539in)
7. Check the piston size mark(A) on the piston top face.
Discrimination of piston outer diameter

Mark Piston outer diameter
A 74.930 ~ 74.940mm (2.9500 ~ 2.9504in)
B 74.940 ~ 74.950mm (2.9504 ~ 2.9508in)
C 74.950 ~ 74.960mm (2.9508 ~ 2.9512in)
8. Select the piston related to cylinder bore class.
Piston-to-cylinder clearance :
0.060 ~ 0.080mm (0.0024 ~ 0.0031in)
BORING CYLINDER
1. Oversize pistons should be selected according to the largest bore cylinder.
The size of piston is stamped on top of the piston.
2. Measure the outside diameter of the piston to be used.

3. According to the measured O.D(Outer Diameter), calculate the new bore size.
New bore size = piston O.D + 0.060 ~ 0.080mm (0.0024 ~ 0.0031in) (clearance between piston and
cylinder) - 0.01mm (0.0004in) (honing margin.)
4. Bore each of the cylinders to the calculated size.
To prevent distortion that may result from temperature rise during honing, bore the cylinder holes in the firing
order.
5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with cylinder).
6. Check the clearance between the piston and cylinder.
Standard : 0.060 ~ 0.080mm (0.0024 ~ 0.0031in)
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When boring the cylinders, finish all of the cylinders to the same oversize. Do not bore only one cylinder to the
oversize.
PISTON AND PISTON RINGS

1. Clean the piston.
(1) Using a gasket scraper, remove the carbon from the piston top.
(2) Using a groove cleaning tool or broken ring, clean the piston ring grooves.
(3) Using solvent and a brush, thoroughly clean the piston.
Do not use a wire brush.
2. The standard measurement of the piston outside diameter is taken 10mm (0.39in) from bottom land of the piston.
Standard diameter :
74.93 ~ 74.96mm (2.9500 ~ 2.9512in)
3. Calculate the difference between the cylinder bore inner diameter and the piston outer diameter.
Piston-to-cylinder clearance :
0.060 ~ 0.080mm (0.0024 ~ 0.0031in)
4. Inspect the piston ring side clearance.

Using a feeler gauge, measure the clearance between new piston ring and the wall of ring groove.
Piston ring side clearance

No.1 : 0.09 ~ 0.13mm (0.0035 ~ 0.0051in)
No.2 : 0.08 ~ 0.12mm (0.0031 ~ 0.0047in)
Oil ring : 0.03 ~ 0.07mm (0.0012 ~ 0.0028in)
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If the clearance is greater than maximum, replace the piston.
5. Inspect the piston ring end gap.
To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles to
the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge. If the gap exceeds
the service limit, replace the piston rings. If the gap is too large, recheck the cylinder bore inner diameter. If the
bore is over the service limit, the cylinder block must be rebored.
Piston ring end gap

No.1 : 0.20 ~ 0.35mm (0.0079 ~ 0.0138in)
No.2 : 0.35 ~ 0.50mm (0.0138 ~ 0.0197in)
Oil ring : 0.20 ~ 0.40mm(0.0079 ~ 0.0157in)
PISTON PINS
1. Measure the outer diameter of piston pin.
Piston pin diameter :

27.995 ~ 28.000mm (1.1022 ~ 1.1024in)
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2. Measure the piston pin-to-piston clearance.
Piston pin-to-piston clearance :

0.004 ~ 0.015mm (0.0002 ~ 0.0006in)
3. Check the difference between the piston pin outer diameter and the connecting rod small end inner diameter.
Piston pin-to-connecting rod interference :

0.022 ~ 0.039mm (0.0009 ~ 0.0015in)
REASSEMBLY
• Thoroughly clean all parts to assembled.

• Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
• Replace all gaskets, O-rings and oil seals with new parts.
1. Assemble the piston and connecting rod.

(1) Use a hydraulic press for installation
(2) The piston front mark and the connecting rod front mark must face the timing belt side of the engine.
2. Install the piston rings.

(1) Install the oil ring expander and 2 side rails by hand.
(2) Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
(3) Position the piston rings so that the ring ends are as shown.
3. Install the connecting rod bearings.

(1) Align the bearing claw with the groove of the connecting rod and connecting rod cap.
(2) Install the bearings(A) in the connecting rod and connecting rod cap(B).
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4. Install the crankshaft main bearings(A).
Upper 1, 3, 4 bearings have an oil groove of oil holes ; Lower bearings do not.
(1) Align the bearing claw with the claw groove of the cylinder block, push in the four upper bearings(A).
(2) Align the bearing claw with the claw groove of the main bearing cap, and push in the four lower bearings.
5. Install the oil jet(A).
Tightening torque :
6.9 ~ 9.8N.m (0.7 ~ 1.0kgf.m, 5.1 ~ 7.2lb-ft)
6. Place the crankshaft (A) on the cylinder block.
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7. Place the bed plate (A) on the cylinder block.
• Standard liquid gasket : FD20, HYLOMAR3000, DRIBOND 5105

• Apply liquid gasket in a 3mm wide bead without stopping.
• After assembly, wait at least 30 minutes before filling the engine with oil.
8. Install the bed plate bolts.
• The bed plate bolts are tightened in 2 progressive steps.

• If any of the bed plate bolts in broken or deformed, replace it.
(1) Apply a light coat of engine oil on the threads and under the bed plate bolts.
(2) Install and uniformly tighten the bed plate bolts, in several passes, in the sequence shown.
A. Tighten the 9,14,15 bolts.
B. Tighten the 1 ~ 8 bolts in the sequence shown by the specified torque.
C. Loosen the 9, 14, 15 bolts.
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D. Tighten the 9 ~ 16 bolts in the sequence shown by the specified torque.
Tightening torque :
Long bolts(1~8) : 22.6~26.5Nm (2.3~2.7kgf.m, 16.6~19.5lb-ft) + 90~94°
Short bolts(9~16) : 32.4~36.3N.m (3.3~3.7kgf.m, 23.9~26.8lb-ft)
Always use new main bearing cap bolts.
(3) Check that the crankshaft turns smoothly.
9. Check the crankshaft end play.
End play
Standard : 0.08 ~ 0.28mm (0.0031 ~ 0.110in)
Limit : 0.30mm (0.0118in)
10. Install the piston and connecting rod assemblies.
Before installing the piston, apply a coat of engine oil to the ring grooves and cylinder bores.
(1) Remove the connecting rod caps, and slip short sections of rubber hose over the threaded ends of the
connecting rod bolts.
(2) Install the ring compressor, check that the rings are securely in place, then position the piston in the cylinder,
and tap it in using the wooden handle of a hammer.
(3) Stop after the ring compressor pops free, and check the connecting rod-to-crank journal alignment before
pushing the piston into place.
(4) Apply engine oil to the bolt threads. install the rod caps with bearings, and tighten the bolts.
Tightening torque :
12.7Nm (1.3kgf.m, 9.4lb-ft) + (87~93°)
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• Always use new connecting rod bearing cap bolts.
• Maintain downward force on the ring compressor to prevent the rings from expending before entering
the cylinder bore.
11. Install the rear oil seal.

(1) Apply engine oil to a new oil seal lip.
(2) Using the SST(09231-33000) and a hammer, tap in the oil seal until its surface is flush with the rear oil seal
retainer edge.
12. Install the oil filter and oil cooler assembly(A).
Tightening torque :
19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft)
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13. Install the water pipe(B) and connect the hose(A).
Tightening torque :
19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1lb-ft)
14. Install the cylinder head. (Refer to Cyliner head in this group.)
15. Install the intake manifold and exhaust manifold. (Refer to Intake manifold and exhaust manifold in this group.)
16. Install the timing chain. (Refer to Timing system in this group.)
17. Remove the engine stand.
18. Install the fly wheel.
Tightening torque :
68.6 ~ 78.5N.m (7.0 ~ 8.0kgf.m, 50.6 ~ 57.9lb-ft)
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Cooling System
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2010 > D 1.1 TCI-U >
COMPONENTS(1)
COMPONENTS(2)
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2010 > D 1.1 TCI-U >
TROUBLESHOOTING
WATER PUMP
SYMPTOMS POSSIBLE CAUSES REMEDY

▷If coolant still leaks, replace a
▷ From the bleed water pump.
▷Check leaks after about ten-
hole of the water
minute warming up. ▷If leakage stops, reuse the
pump water pump(Do not replace the
pump with a new one).
Coolant Naked eye ▷Check the tightening of the
▷Retighten the mounting bolts.
leakage ▷ From gaskets or observation water pump mounting bolts.
bolts ▷Check damage of gaskets or ▷Replace the gasket and clean
inflow of dust. dust off.
▷ From outer
▷Check the material or any ▷Poor material. If any crack
surface of water
cracks of the water pump. found, replace the water pump.
pump
▷If there is no noise, reuse the
Inspection water pump(do not replace it).
▷After starting the engine, check
with a
noise with a stethoscope. ▷If there is any noise from the
stethoscope water pump, remove the drive
▷ From bearings belt and recheck.
▷If there is noise, reuse the
▷ From mechanical Inspection
Noise seals ▷After removing a water pump water pump. Check other drive
after line parts.
and a drive belt, check noise
removing a
▷ Impeller again. If there is no noise, replace the
drive belt
interference water pump with a new one.
Inspection
▷After removing a water pump ▷If there is any interference
after
and a drive belt, check noise between them, replace the water
removing a
again. pump with a new one.
water pump
▷Check engine coolant.
- Poor coolant quality /
Maintenance check
▷Corrosion of the impeller wing - Poor coolant quality /
▷ Damaged impeller Loosened Maintenance check
Overheating
▷ Loosened impeller impeller
▷Poor coolant quality /
Maintenance check
▷Impeller seperation from the
▷Replace the water pump.
shaft
THERMOSTAT
SYMPTOMS POSSIBLE CAUSES REMEDY
Check the
▷Check the torque of the ▷Retighten the bolts and check
mounting
mounting bolts leakage again.
Coolant ▷ From the bolts
leakage thermostat gasket Check the
▷Check gasket or seal for ▷Replace gaskets and reuse the
gasket for
damage thermostat.
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damage thermostat.
damage
Naked
eyes
observation
after ▷Insufficient coolant or leakage. ▷After refilling coolant, recheck.
removing
the radiator
cap.
▷ Low hearer
▷Check DTCs
performance (cool air
Cooled HI-scan ▷Check connection of the fan
blowed-out) ▷Check the enging coolant
excessively check& clutch or the fan motor.
▷ Thermogauge sensor, wiring and connectors.
Starting ※ If the fan clutch is always
indicates 'LOW' ▷Replace the componants.
engine connected, there will be a noise
at idle.
Remove
▷Check if there are dusts or ▷Clean the thermostat valve and
the
chips in the thermostat valve. reuse the thermostat.
thermostat
▷Check adherence of the ▷Replace the thermostat, if it
and
thermostat. doesn't work properly.
inspection
Naked
eyes ▷Insufficient coolant or leakage. ▷After refilling coolant, recheck.
observation ※Be careful when removing a ▷Check the cylinder head
after radiator cap of the overheated gaskets for damage and the
removing vehicle.※ tightening torque of the mounting
the radiator ▷Check air in cooling system. bolts.
cap.
▷Check the enging coolant
▷Check DTCs
sensor, wiring and connectors.
▷Check the fan motor
▷Engine overheated HI-scan ▷Check the fan motor, the relay
Heated performance as temperature
▷Thermogauge check& and the connector.
excessively varies.
indicates 'HI' Starting ▷Replace the fan clutch, if it
▷Check if the fan clutch slips.
engine doesn't work properly.
▷Check the water pump
▷Replace the water pump, if it
adherence or impeller damaged.
doesn't work properly.
Immerse
the ▷After removing the thermostat,
thermostat check it works properly. ▷Replace the thermostat, if it
in boiling ※ Check the thermostat opens at doesn't work properly.
water and the valve opening temperature.
inspection.
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2010 > D 1.1 TCI-U >
INSPECTION
ENGINE COOLANT REFILLING AND BLEEDING
Never remove the radiator cap when the engine is hot.

Serious scalding could be caused by hot fluid under high pressure escaping from the radiator.
When pouring engine coolant, be sure to shut the relay box lid and not to let coolant spill on the electrical parts of
the paint. If any coolant spills, rinse it off immediately.
1. Make sure the engine and radiator are cool enough to touch.
2. Remove the radiator cap(A).
3. Loosen the drain plug, and drain coolant.

4. Tighten the radiator drain plug securely.
5. Remove the coolant reservoir tank(A). Drain coolant and clean the coolant reservoir tank. After reinstalling the tank,
refill fluid mixture with coolant and water(4:6) through the radiator cap slowly. Gently squeeze the upper and lower
hoses of the radiator to bleed air easily in this step.
• Use only genuine antifreeze/coolant.

• Coolant concentrations greater than 60% impair cooling efficiency and are not recommended.
• Do not mix different brands of antifreeze/coolants.
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• Do not use additional rust inhibitors or antirust products; they may not be compatible with the coolant.
6. Start the engine and allow coolant to circulate. When the cooling fan operates and coolant circulates, refill coolant
through the radiator cap.
7. Bleed air sufficiently out of the cooling system by repeating the step 5 until the cooling fan operates 3 ~ 5 times.
Recheck the coolant level in the reservoir tank for 2 ~ 3 days after replacing coolant.
Coolant capacity : 5.3 liters(5.60US qt, 4.66lmp qt)
RADIATOR CAP TESTING

1. Remove the radiator cap, wet its seal with engine coolant, then install it on pressure tester.
2. Apply a pressure of 93.16 ~ 122.58kpa (0.95 ~ 1.25kg/cm!, 13.51 ~ 17.78psi).

3. Check for a drop in pressure.
4. If the pressure drops, replace the cap.
RADIATOR LEAKGE TEST

1. Wait until engine is cool, then carefully remove the radiator cap and fill the radiator with engine coolant.
2. Install a pressure tester to the radiator and apply a pressure of 93.16 ~ 122.58kpa (0.95 ~ 1.25kg/cm!, 13.51 ~
17.78psi).
3. Inspect for engine coolant leaks and a drop in pressure.

4. Remove the tester and reinstall the radiator cap.
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Check for engine oil in the coolant and/or coolant in the engine oil.
REMOVAL
WATER PUMP
1. Drain the engine coolant.
System is under high pressure when the engine is hot. To avoid danger of releasing scalding engine coolant,
remove the cap only when the engine is cool.
2. Remove the drive belt.

4. Remove the water pump(A).
THERMOSTAT
Disassembly of the thermostat would have an adverse effect, causing a lowering of cooling efficiency.
1. Drain the engine coolant so its level is below thermostat.

2. Disconnect the water hose(A) from thermostat housing.
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3. Remove the thermostat housing(A).
RADIATOR
1. Remove the battery (A) and the intake air hose and air cleaner assembly.
(1) Disconnect the AFS (Air Flow Sensor) connector (B).
(2) Remove the air cleaner assembly(C).
2. Remove the battery tray (A).
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3. Remove the under cover (A).
4. Drain engine coolant and remove the radiator cap to speed draining.
5. Remove the upper radiator hose (A), the lower radiator hose (B) and reservior hose.
6. Remove the cooling fan first, then remove the radiator from the vehicle.
(1) Disconnect the fan motor connector (A).
(2) Remove the cooling fan (B) from the radiator.
(3) Remove the radiator mounting bracket (C) after loosen the screw.
(4) Remove the radiator assembly by pulling down.
INSTALLATION
WATER PUMP
1. Install the water pump(A) and a new gasket.
Tightening torque :
19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1lb-ft)
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Apply coolant to the O-ring before installing the water pump.
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
4. Fill with engine coolant.

5. Start engine and check for leaks.
6. Recheck engine coolant level.
THERMOSTAT
1. Place the thermostat in thermostat housing with new gasket.
2. Install the thermostat housing(A).
Tightening torque :
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10.8 ~ 14.7N.m (1.0 ~ 1.2kgf.m, 8.0 ~ 10.8lb-ft)
3. Fill with engine coolant.

4. Start engine and check for leaks.
RADIATOR
1. Install the radiator.
(1) Install the radiator to the vehicle with the mounting bracket (C).
(2) Install the cooling fan (B) to the radiator.
Tightening torque :
6.8 ~ 10.8N.m (0.7 ~ 1.1kgf.m, 5.1 ~ 7.9lb-ft)
(3) Connect the fan motor connector (A).
2. Install the upper radiator hose (A), the lower radiator hose (B) and reservior hose.
3. Install the under cover (A).
Tightening torque : bolts

6.9~10.8Nm (0.7 ~1.1kgf.m, 5.1~7.9lb-ft)
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4. Install the battery tray (A).
Tightening torque : bolts

9.8~11.7 Nm (1.0~1.2kgf.m, 7.2~8.7lb-ft)
5. Install the battery (A) and the intake air hose and air cleaner assembly.
(1) Install the air cleaner assembly(C).
(2) Connect the AFS (Air Flow Sensor) connector (B).
6. Fill engine coolant and start engine to check for leaks.
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Lubrication System
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2010 > D 1.1 TCI-U >
COMPONENTS(1)
COMPONENTS(2)
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2010 > D 1.1 TCI-U >
REPLACEMENT
OIL AND FILTER
• Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading
to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants
which may cause skin cancer.
• Exercise caution in order to minimize the length and frequency of contact of your skin to used oil. Wear
protective clothing and gloves. Wash your skin thoroughly with soap and water, or use water-less hand
cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents.
• In order to preserve the environment, used oil and used oil filter must be disposed of only at designated
disposal sites.
1. Drain the engine oil.

(1) Remove the oil filler cap(A).
(2) Loosen the oil filter cap(B) until the O-ring appears. Be careful for oil not to overflow.
(3) Remove the oil drain plug, and drain oil into a container.
2. Replace the oil filter.

(1) Remove the oil filter upper cap.
(2) Replace the O-rings of the oil filter cap with new ones. Inspect the threads and O-rings. Wipe off the seat on
the oil filter cap, then apply a light coat of oil to the oil filter upper cap O-rings.
(3) Install the new oil filter by hand to the upper cap.
(4) After the rubber seal's seating, tighten the oil filter clockwise.
Tightening torque :
24.5N.m(2.5kgf.m, 18.1lb-ft)
3. Refill with engine oil.

(1) Clean and install the oil drain plug with a new gasket.
Tightening torque :
34.3 ~ 44.1N.m (3.5 ~ 4.5kgf.m, 25.3 ~ 32.5lb-ft)
(2) Fill wih fresh engine oil.
Capacity
Total : 5.5 L (5.81US qt, 4.83 lmp qt)
Oil pan : 4.8 L (5.07 US qt, 4.22 lmp qt)
Drain and refill including oil filter : 5.3 L (5.60 US qt, 4.66 lmp qt)
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When filling engine oil, fill half of full capacity and do the remainings in 1 minutes.
(3) Install the oil filler cap.
4. Start engine and check for oil leaks.

5. Recheck the engine oil level.
REMOVAL
BALANCE SHAFT ASSEMBLY
1. Remove the engine oil level gauge(A) assembly.
2. Remove the oil pan(A).
Using the SST(09215-3C000), remove the oil pan.

Be careful not to damage the contact surface of the oil pan.
3. Remove the oil screen assembly(A).
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4. Remove the balance shaft assembly(A).
OIL PUMP
2. Remove the air compressor.(Refer to Air compressor in HA group.)

3. Remove the oil pan.
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4. Remove the cylinder head cover.
5. Using the SST(09200-38001, 09200-1C000), support the engine assembly.
7. Remove the Alternator(A). (Refer to Alternator EEA group.)
9. Remove the engine support bracket(A).
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10. Remove the two idlers(A).
11. Remove the drive belt tensioner.

13. Remove the crankshaft pulley bolt(B) and crankshaft pulley(A).
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Use the SST(flywheel stopper, 09231-2A110) to remove the crankshaft pulley bolt, after remove the starter.
14. Remove the high pressure pump sprocket nut(B) after removing the timing chain cover plug(A).
• Use the SST(flywheel stopper, 09231-2A110) to remove the high pressure pump sprocket nut, after
remove the starter.
• Replace O-ring of the plug with a new one when reinstalling the plug
15. Remove the high pressure pump pipe. (Refer to FL group.)

16. Remove the high pressure pump(A) fixing bolts and fuel hoses(B,C).
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17. Install the SST(09331-2A000) to the sprocket by rotating it clockwise.
18. Remove the three timing chain cover bolts(B) illustrated below.
19. Install the SST(09331-2A000) to the timing chain cover with the three long bolts(B).
20. Fix the SST(09331-2A000) and sprocket stopper(C) with two fixing bolts(D).
21. Rotate the bolt(E) clockwise till the high pressure pump is pushed out.
22. Remove the SST(09331-2A000) after removing the high pressure pump assembly.
23. Remove the timing chain cover(A).
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Remove thoroughly sealant, oil and etc on the sealing surface after removing the timing chain cover. (If any
impurities are left at the sealing face, oil may leak after reassembly even with sealant applying.)
24. Remove the oil pump cover(A) from the timing chain cover.
25. Remove the inner rotor and outer rotor.
DISASSEMBLY
RELIEF PLUNGER
1. Remove the relief plunger.
Remove the plug(A), spring(B) and relief plunger(C).
INSPECTION
OIL PRESSURE SWITCH
1. Check the continuity between the terminal and the body with an ohmmeter. If there is no continuity, replace the oil
pressure switch.
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2. Check the continuity between the terminal and the body when the fine wire is pushed. If there is continuity even
when the fine wire is pushed, replace the switch.
3. If there is no continuity when a 49.0kpa (0.5kg/cm!, 7.1psi) is applied through the oil hole, the switch is operating
properly.
Check for air leakage. If air leaks, the diaphragm is broken. Replace it.
OIL PUMP
1. Inspect the relief plunger.
Coat the plunger with engine oil and check that it falls smoothly into the plunger hole by its own weight. If it does
not, replace the relief plunger. If necessary, replace the front case.
OIL QUALRITY
1. Check the engine oil quality. Check the oil deterioration, entry of water, discoloring of thinning. If the quality is
visibly poor, replace the oil.
2. Check the engine oil level. After warming up the engine and then 5 minutes after the engine stops, oil level should
be between the “L” and “F” marks in the dipstick. If low, check for leakage and add oil up to the “F” mark.
Do not fill with engine oil above the “F” mark.
SELECTION OF ENGINE OIL

ACEA classificaton : B4
SAE viscosity grades : Refer to the recommended SAE viscosity number
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For best performance and maximum protection of all types of operation, select only those lubricants which :
1. Satisfy the requirement of the ACEA classification.
2. Have proper SAE grade number for expected ambient temperature range.
• Lubricants that do not have both an SAE grade number and ACEA service classification on the container
should not be used.
• The ACEA certified engine oil is required as a service engine oil. Only in case that ACEA certified engine oil
is not available, the API certified engine oil (API CH-4 or above) is allowed restrictively.
• For the vehicle equipped with CPF, the service engine oil quality should meet the ACEA C3 grade. However,
oil refill with small amount of ACEA B4 grade between oil change intervals is possible.
REASSEMBLY
RELIEF PLUNGER
1. Install the relief plunger. Install relief plunger(C) and spring(B) into the front case hole, and install the plug(A).
Tightening torque :
25.5 ~ 34.3N.m (2.6 ~ 3.5kgf.m, 18.8 ~ 25.3lb-ft)
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INSTALLATION
BALANCE SHAFT ASSEMBLY
1. Install the balance shaft assembly(A).
Tightening torque :
26.5 ~ 30.4N.m (2.7 ~ 3.1kgf.m, 19.5 ~ 22.4lb-ft)
2. Install the oil screen assembly(A).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
3. Apply liquid gasket to the mating surface of oil pan, then install it.
Tightening torque :
M6 : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
M10 : 34.3 ~ 49.0N.m (3.5 ~ 5.0kgf.m, 25.3 ~ 36.1lb-ft)
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• Standard liquid gasket : LOCTITE 5900
• Apply liquid gasket in a 3mm wide bead without stopping. Assemble the oil pan in 5 minutes after applying
the liquid gasket.
• After assembly, wait at least 30 minutes before filling the engine with oil.
• Apply liquid gasket to T-joint before assembling oil pan.
4. Install the engine oil level gauge(A) assembly.
Tightening torque :
19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft)
OIL PUMP
1. Install the oil pump.
(1) Place the inner and outer rotors into front case with the marks facing the oil pump cover side.
(2) Install the oil pump cover(A) to timing chain cover with the screws.
Tightening torque :
5.9 ~ 8.8N.m (0.6 ~ 0.9kgf.m, 4.3 ~ 6.5lb-ft)
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2. Check that the oil pump turns freely.
3. Install the timing chain cover(A).
Tightening torque :
4. Install the front oil seal by using SST(09231-2A000, 09231-H1100).
5. Install the crankshaft pulley bolt(B) and crankshaft pulley(A).
Tightening torque :
225.6 ~ 245.2N.m (23.0 ~ 25.0kgf.m, 166.4 ~ 180.8lb-ft)
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Use the SST(flywheel stopper, 09231-2A110) to tighten the crankshaft pulley bolt, after remove the starter.
6. Turn the crankshaft pulley to align its groove with the timing mark(C) on the timing chain cover.
7. Install the drive belt tensioner.
Tightening torque :
25.5 ~ 30.4N.m (2.6 ~ 3.1kgf.m, 18.8 ~ 22.4lb-ft)
8. Install the two idlers(A).
Tightening torque :
24.5 ~ 34.3N.m (2.5 ~ 3.5kgf.m, 18.1 ~ 25.3lb-ft)
9. Install the engine support bracket(A).
Tightening torque :
42.2 ~ 53.9N.m (4.3 ~ 5.5kgf.m, 31.1 ~ 39.8lb-ft)
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Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
11. Install the alternator(A).

(Refer to Alternator in EEA group.)
Tightening torque :
38.2 ~ 58.8N.m (3.9 ~ 6.0kgf.m, 28.2 ~ 43.4lb-ft)
12. Install the oil pan.

13. Install the air compressor. (Refer to Air compressor in HA group)
15. Install the engine mounting support bracket(A).
Tightening torque :
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Nuts (B), Bolt (C) :
49.0 ~ 63.7N.m (5.0 ~ 6.5kgf.m, 36.1 ~ 47.0lb-ft)
Nut (D) :
88.3 ~ 107.4N.m (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft)
16. Remove the SST(09200-38001, 09200-1C000).

17. Install the cylinder head cover.
(Refer to Cylinder head assembly in this group.)
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Intake & Exhaust System
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2010 > D 1.1 TCI-U >
COMPONENTS(1)
COMPONENTS(2)
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COMPONENTS(3)
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COMPONENTS(4)
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COMPONENTS(5)
1. Turbine housing 6. Compressor outlet

2. Turbine inlet 7. Center housing
3. Turbine outlet 8. Actuator
4. Compressor housing 9. Actuator rod
5. Compressor inlet
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2010 > D 1.1 TCI-U >
REPLACEMENT
Intake manifold assembly
1. Remove the engine cover.
2. Disconnect the engine wiring.
3. Remove the high pressure pipe. (Refer to FL group).
4. Remove the intake manifold assembly(A) with a gasket.
Tightening torque :
6.8 ~ 10.8N.m (0.7 ~ 1.1kgf.m, 5.1 ~ 7.9lb-ft)
5. Remove the swirl control device assembly(A) with a gasket.
Tightening torque :
14.7 ~ 19.6N.m (1.5 ~ 2.0kgf.m, 10.8 ~ 14.5lb-ft)
Exhaust manifold assembly

1. Remove the cowl top cover.(Refer to BD group).
2. Remove the heat protector(A).
Tightening torque :
14.7 ~ 19.6N.m (1.5 ~ 2.0kgf.m, 10.8 ~ 14.5lb-ft)
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3. Remove the alternator(A). (Refer to Alternator in EEA group.)
4. Remove the EGR(Exhaust Gas Recirculation) pipe (A).
Tightening torque :
29.4 ~ 34.3N.m (3.0 ~ 3.5kgf.m, 21.7 ~ 25.3lb-ft)
5. Remove the WCC(Warm-up Catalytic Converter) & bracket assembly(A) and intercooler inlet hose & pipe assembly
(B).
Tightening torque :
Nuts : 29.4 ~ 34.3 Nm (3.0 ~ 3.5 kgf.m, 21.7 ~ 25.3lb-ft)
Bolt C : 21.6~27.5 Nm (2.2 ~ 2.8 kgf.m, 15.9 ~ 20.3lb-ft)
Bolt D : 6.9 ~ 10.8Nm (0.7 ~ 1.1kgf.m, 5.1 ~ 7.9lb-ft)
6. Remove the exhaust manifold.

(1) Remove the oil return pipe(A).
Tightening torque :
9.8 ~ 14.7 Nm (1.0 ~ 1.5 kgf.m, 7.2 ~ 10.8lb-ft)
(2) Remove the oil feed pipe mounting eye joint bolt & gasket (B).
Tightening torque :
13.7 ~ 18.6 Nm (1.4 ~ 1.9 kgf.m, 10.1 ~ 13.7lb-ft)
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(3) Remove the exhaust manifold & turbo charger assembly (C).
Tightening torque :
29.4 ~ 34.3 Nm (3.0 ~ 3.5 kgf.m, 21.7 ~ 25.3lb-ft)
7. Remove the exhaust manifold gasket(A) .
8. Remove the EGR cooler assembly(A).
Tightening torque :
B : 21.6 ~ 27.5N.m (2.2 ~ 2.8kgf.m, 15.9 ~ 20.3lb-ft)
C : 14.7 ~ 19.6N.m (1.5 ~ 2.0kgf.m, 10.8 ~ 14.5lb-ft)
EXHAUST PIPE
1. Remove the front muffler(A).
Tightening torque :
39.2 ~ 53.9N.m (4.0 ~ 5.5kgf.m, 28.9 ~ 39.8lb-ft)
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2. Remove the catalytic converter and center muffler assembly(A).
Tightening torque :
39.2 ~ 53.9N.m (4.0 ~ 5.5kgf.m, 28.9 ~ 39.8lb-ft)
3. Remove main muffler(A).
Tightening torque :
39.2 ~ 53.9 Nm(4.0 ~ 5.5 kgf.m, 28.9 ~ 39.8 lb-ft)
4. Installation is in the reverse order of removal with a new gasket.

5. Install the clamp in between the center pipe and main muffler pipe.
(1) Align the marks on the center pipe and main muffler pipe as shown illustration.
(2) The clamp installing position (A) must be upper than the line virtually made by the two marks.
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Tightening torque :
17.7~ 27.5Nm (1.8 ~ 2.8kgf.m, 13.0 ~ 20.3lb-ft)
Do not reuse the clamp.
On-vehicle Inspection
Turbocharger Diagnostic Flow
If any problem related with turbocharger, such as lack of engine power, poor acceleration, abnormal engine
noise or oil leaks, may occur, check the turbocharger according to the procedure as follows.
1. Check for assembling of the turbocharger and the exhaust fitting (or the after treatment).
A. Check if a gasket is installed.
A. Check if mounting bolts (or nuts) are tightened properly.
A. Check if there is a gas leak.
A. Check if there is any damage, such as crack, on the parts.
If a gas leak occur as a gasket was not installed or mounting bolts (or nuts) were tightened inadequately, it may
cause abnormal engine noise.
If the cause of the problem is detected, retighten the mounting bolts (or nuts) as the specified torque or replace the
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gasket or damaged parts with new ones if necessary.
2. Check for assembling of the turbocharger and the exhaust manifold.
B. Check if the mounting bolts (or nuts) are tightened properly.
C. Check if there is a gas leak.
D. Check if there is any damage, such as crack, on the parts.
3. Check for assembling of the exhaust manifold and the cylinder head.
B. Check if the mounting bolts (or nuts) are tightened properly.
C. Check if there is a gas leak.
If the cause of the problem is detected, retighten the mounting bolts (or nuts) as the specified torque or install a
new gasket if necessary.
4. Check the turbocharger oil feed pipe & hose and oil drain pipe & hose.
B. Check if the mounting bolts are tightened properly.
C. Check if the clamps are positioned in place.
D. Check if the oil pipes & hoses are damaged (bent, crushed, torn or cracked).
If a gas leak occur as a gasket was not installed or mounting bolts were tightened inadequately, it may cause oil
leaks.
If the oil feed pipe & hose is damaged, engine oil is not supplied sufficiently to the turbocharger then it may
damage the turbocharger. If the oil drain pipe & hose is damaged and clogged, engine oil is not drained smoothly
then it may cause oil leaks from the turbocharger.
5. Check for oil leaks between center housing and compressor housing.
A. Check if the mounting bolts are tightened properly.
B. Check if there is an oil leak.
If the O-ring (gasket) between the center housing and the compressor housing is damaged, it may cause oil leaks.
If an oil leak is detected, replace the turbocharger with a new one.
6. Check the setting marks of the turbocharger actuator rod.
A. Check if the actuator rod setting mark is aligned in line.
B. Check if the minimum flow setting mark is aligned in line.
If the setting marks are not aligned in line, the engine performance is changed by an arbitrary tune-up of the
turbocharger after delivery.
If the setting marks are not aligned in line, replace the turbocharger with a new one.
7. Check the turbocharger actuator vacuum hoses & pipes.
A. Check if the vacuum hose is connected to the actuator properly.
B. Check if the vacuum hoses & pipes are damaged (bent, detached or torn).
C. Check if there is any damage, such as crack, on the vacuum pipes.
D. Check if the vacuum hoses are connected to inlet or outlet of the solenoid valve correctly.
If the vacuum pipes & hoses are damaged or disconnected, the actuator does not work properly then it may cause
lack of engine power and poor acceleration.
If the vacuum hoses & pipes are damaged, replace them with new ones.
8. Check the turbocharger actuator.
A. Vacuum type actuator: Check for movement of the actuator rod when a vacuum of 60kPa (450mmHg, 8.7psi) is
applied to the actuator or a forced actuator operating mode is performed by GDS. (Refer to DTC guide)
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If the turbocharger actuator is damaged, it may cause lack of engine power and poor acceleration.
If the actuator rod does not move, replace the turbocharger with a new one.
9. Check the turbocharger compressor wheel.
A. Check if the compressor wheel is damaged (bent or deformed).
B. Check if the compressor wheel rotates smoothly.
EX)
If the compressor wheel are damaged, it may cause abnormal noise from the turbocharger and poor acceleration.
If the compressor wheel are damaged or deformed, replace the turbocharger with new ones.
10. Check the turbocharger turbine wheel.
A. Check if the turbine wheel is damaged.
B. Check if the turbine wheel rotates smoothly.
EX)
If the turbine wheel are damaged, it may cause abnormal noise from the turbocharger and poor acceleration.
If the turbine wheel are damaged or deformed, replace the turbocharger with new ones.
If any problem is not detected in the turbocharger, check the turbocharger-related parts according to the
procedure as follows.
1. Check the blow-by hose. (Refer to FL group)
A. Check if the breather hose is damaged (bent, clogged).
B. Check if the positive crankcase ventilation (PCV) valve is clogged.
If the breather hose is bent or clogged, the internal pressure in the engine increases then engine oil is not supplied
smoothly to the turbocharger. So it may cause damage of the turbocharger and oil leaks.
If the cause of the problem is detected, replace the breather hose or the related parts with new ones.
2. Check the air intake hose connected to the turbocharger.
A. Check if the air intake hose is damaged (bent, crushed, detached or torn).
If a cross-section of the hose diminishes as the air intake hose is bent or crushed, intake air to the turbocharger
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reduces and the pressure in front of turbocharger drops. So it may cause damage of the turbocharger and oil leaks.
If the air intake hose is detached or torn, a foreign substance goes into the turbocharger and causes damage of it.
If the air intake hose is damaged, replace it with a new one.
3. Check the air cleaner.
A. Check the air cleaner filter for pollution state.
B. Check the air cleaner filter for water influx.
C. Check the air cleaner cover for dirtiness.
D. Check if the air cleaner filter is a genuine part..
If the air cleaner filter is moistened or polluted excessively or a non-genuine part is used, intake air to the
turbocharger reduces and the pressure in front of turbocharger drops. So it may cause damage of the turbocharger
and oil leaks. .
If the air cleaner filter is moistened or polluted excessively, replace it with a new one.
Replace the air cleaner filter according to the maintenance schedule.
4. Check the intercooler hoses & pipes.

A. Check if the intercooler hoses & pipes are connected properly.
B. Check if the intercooler hoses & pipes are damaged (bent, detached or torn).
C. Check if there is any damage, such as crack, on the intercooler pipes.
D. Check if the clamps are positioned in place.
If the intercooler hoses & pipes are damaged or disconnected, oil leaks may occur from the hoses & pipes and the
turbocharger may exceed the permissible speed then it may cause damage of the turbocharger.
If the intercooler hoses & pipes are damaged, replace them with new ones.
Use new clamps when replacing the hoses & pipes.
5. Check the intercooler.

A. Check if the intercooler tubes and tanks are damaged (oil leak or crack).
If the intercooler is damaged, the turbocharger may exceed the permissible speed then it may cause damage of the
turbocharger.
If the intercooler is damaged, replace them with a new one.
Use new clamps when replacing the intercooler.
6. Check the engine oil.

A. Check the engine oil level.
B. Check the engine oil for discoloration, water influx and viscosity degradation.
C. Check the engine oil grade.
If the engine oil level is low, amount of engine oil fed to turbocharger reduces then the bearings in the
turbocharger may adhere due to insufficient lubrication and cooling.
If the cause of the problem is detected, add or change engine oil.
Change the engine oil according to the maintenance schedule.
7. Check the engine oil pressure.

A. Engine oil pressure: Check the oil pressure using an oil pressure gauge after removing the oil pressure switch
on the cylinder block.
B. Check the engine oil screen in the oil pan if the engine oil level is low. Then check the injectors for gas leaks if
foreign substances are accumulated on the oil screen.
If the engine oil level is low, amount of engine oil fed to turbocharger reduces then the bearings in the
turbocharger may adhere due to insufficient lubrication and cooling.
If the cause of the problem is detected, add or change engine oil. If foreign substances are accumulated on the oil
screen, wash the oil screen and replace the injector’s washer with a new one after checking the injectors for gas
leaks. Check the engine oil-related parts, such as oil pump, if necessary.
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As the turbocharger rotates at high speed of 100,000 rpm or above, deterioration of engine oil can cause
damage of the turbocharger bearings. Check engine oil for discoloration, water influx, viscosity degradation and
oil pressure lowering.
8. Check the solenoid valve of turbocharger. (Refer to DTC guide)

A. Damage of the solenoid valve: Check if vacuum is generated at the disconnected vacuum hose from the
actuator when a forced actuator operating mode is performed by GDS..
B. Clog of the solenoid valve filter: Check if vacuum is released when a forced actuator operating mode is
performed from max. duty (95%) to min. duty (5%) by GDS. (If the solenoid valve filter is clogged, the vacuum
won’t be released or it will take a long time to be released.)
If the solenoid valve is damaged, the actuator does not work properly then it may cause lack of engine power and
poor acceleration. If the solenoid valve filter is clogged, vacuum is not released then it may cause damage of the
turbocharger by overrunning.
If the solenoid valve is damaged, replace it with a new one.
9. Check the injectors, sensors, EGR valve, etc. (Refer to FL group)
A. Check if the injectors operate properly.
B. Check if the sensors, such as the mass air flow sensor (MAFS), intake air temperature sensor (IATS), boost
pressure sensor (BPS), operate properly.
C. Check if the exhaust gas recirculation (EGR) valve operates properly.
If the injectors, sensors, EGR valve and etc. don’t work properly, it may cause lack of engine power.
If the cause of the problem is detected, replace the related parts with new ones.
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Engine Electrical System
General Information
Engine ,SLJ[YPcal System
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2010 > D 1.1 TCI-U >
SPECIFICATION
STARTING SYSTEM
Items Specification
Rated voltage 12 V, 1.7 kW
No. of pinion teeth 8
No-load Test Voltage 11 V

characteristics condition Ampere 90A, MAX
Starter Speed 2,600 rpm, MIN
Test Voltage 7.7V

condition Ampere 400A
Load characteristics
Speed 880rpm MIN
Torque 1.4kgf.m MIN
CHARGING SYSTEM
Items Specification
Norminal output 12V, 90A
Rated voltage 12 V
Speed in use 1,000 ~ 18,000 rpm
Alternator
System Built-in I.C. regulator
Regulator Setting voltage 14.55 ± 0.2 V (at 20°C)
Temperature compensation -7 ± 3 mV / °C
Type 48-23GL
Cold cranking amperage [at -18°C(-0.4°F)] 550A
Battery
Reserve capacity 92min
Specific gravity [at 20°C(68°F)] 1.280 ± 0.01
• COLD CRANKING AMPERAGE is the amperage a battery can deliver for 30 seconds and maintain a terminal
voltage of 7.2V or greater at a specified temperature.
• RESERVE CAPACITY RATING is amount of time a battery can deliver 25A and maintain a minimum terminal
voltage of 10.5V at 26.7°C(80.1°F).
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2010 > D 1.1 TCI-U >
TROUBLE SHOOTING
STARTING SYSTEM
Engine will not crank Battery charge low Charge or replace battery
Battery cables loose, corroded or worn Repair or replace cables
out Refer to AT group
Transaxle range switch (Vehicle with
automatic transaxle only) Replace fuse
Fuse blown Replace
Starter faulty Replace
Ignition switch faulty
Engine cranks slowly Battery charge low Charge or replace battery
Battery cables loose, corroded or worn Repair or replace cables
out Replace
Starter faulty
Starter keeps running Starter Replace
Ignition switch Replace
Starter spins but engine will Short in wiring Repair wiring
not crank Pinion gear teeth broken or starter Replace
Ring gear teeth broken Replace fly wheel or torque converter
CHARGING SYSTEM

Charging warning indicator Fuse blown Check fuses
does not light with ignition Light burned out Replace light
switch "ON" and engine off. Wiring connection loose Tighten loose connection
Electronic voltage regulator Replace voltage regulator
Charging warning indicator Drive belt loose or worn Adjust belt tension or replace belt
does not go out with engine Battery cable loose, corroded or worn Inspect cable connection, repair or replace
running. (Battery requires Fuse blown cable
frequent recharging) Electronic voltage regulator or alternator Check fuses
Wiring Replace voltage regulator or alternator
Repair or replace wiring
Overcharge Electronic voltage regulator Replace voltage regulator
Voltage sensing wire Repair or replace wiring
Discharge Drive belt loose or worn Adjust belt tension or replace belt
Wiring connection loose or short circuit Inspect wiring connection, repair or replace
Fuse blown wiring
Electronic voltage regulator or alternator Check fuses
Poor grounding Replace voltage regulator or alternator
Worn battery Inspect ground or repair
Replace battery
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2010 > D 1.1 TCI-U >
SPECIAL SERVICE TOOL

Tool (Number and name) Illustration Use
Alternator pulley remover wrench Removal and installation of alternator
(09373-27000) pulley
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2010 > D 1.1 TCI-U >
The Micro 570 Analyzer

The Micro 570 Analyzer provides the ability to test the charging and starting systems, including the battery, starter and
alternator.
Because of the possibility of personal injury, always use extreme caution and appropriate eye protection when
working with batteries.
Keypad
The Micro 570 button on the key pad provide the following functions :
Battery Test Procedure

1. Connect the tester to the battery.
A. Red clamp to battery positive (+) terminal.
B. Black clamp to battery negative (-) terminal.
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Connect clamps securely. If "CHECK CONNECTION" message is displayed on the screen, reconnect clamps
securely.
2. The tester will ask if the battery is connected "IN-VEHICLE" or "OUT-OF-VEHICLE". Make your selection by
pressing the arrow buttons; then press ENTER.
3. Select CCA and press the ENTER button.
CCA : Cold cranking amps, is an SAE specification for cranking batteried at -0.4°F (-18°C).
4. Set the CCA value displayed on the screen to the CCA value marked on the battery label by pressing up and
down buttons and press ENTER.
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The battery ratings(CCA) displayed on the tester must be identical to the ratings marked on battery label.
5. The tester will conduct battery test.
6. The tester displays battery test results including voltage and battery ratings.
Refer to the following table and take the appropriate action as recommended by the Micro 570.
Battery Test Results

Result On Printer Remedy
GOOD BATTERY No action is required.
GOOD RECHARGE Battery is in a good state.
Recharge the battery and use.
CHARGE & RETEST Battery is not charged properly.
- Charge and test the battery again. (Failure to charge the battery fully may read
incorrect measurement value.)
REPLACE BATTERY Replace battery and recheck the charging system.
- Improper connection between battery and vehicle cables may cause
"REPLACE BATTERY", retest the battery after removing cables and connecting
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the tester to the battery terminal directly prior to replacing the battery.
BAD CELL-REPLACE Charge and retest the battery.
- If the Micro 570 recommends "REPLACE BATTERY", replace the battery and
recheck the charging system.
Whenever filing a claim for battery, the print out of the battery test results must be attached.
Starter Test Procedure

7. After the battery test, press ENTER immediately for the starter test.
8. Start the engine.
9. Cranking voltage and starter test results will be displayed on the screen.
Refer to the following table and take the appropriate action as recommended by the Micro 570.
Starter Test Results

CRANKING VOLTAGE System shows a normal starter draw.
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NORMAL
CRANKING VOLTAGE LOW Cranking voltage is lower than normal level.
- Check starter.
CHARGE BATTERY The state of battery charge is too low to test.
- Charge the battery and retest.
REPLACE BATTERY Replace battery.
- If the vehicle is not started though the battery condition of "GOOD BATTERY"
is displayed, check wiring for open circuit, battery cable connection, starter and
repair or replace as necessary.
- If the engine does crank, check fuel system.
When testing the vehicle with old diesel engines, the test result will not be favorable if the glow plug is not
heated. Conduct the test after warming up the engine for 5 minutes.
Charging System Test Procedure

10. Press ENTER to begin charging system test.
11. The tester displays the actual voltage of alternator.

Press ENTER to continue.
12. Turn off all electrical load and rev engine for 5 seconds with pressing the accelerator pedal. (Follow the
instructions on the screen)
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13. The message that engine RPM is detected will be displayed on the screen. Press ENTER to continue.
14. If the engine RPM is not detected, press ENTER after revving engine.
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15. The tester will conduct charging system test during loads off.
16. Turn on electrical loads (air conditioner, lamps, audio and etc). Press ENTER to continue.
17. The tester will conduct charging system test during loads on.
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18. Rev engine for 5 seconds with pressing the accelerator pedal. (Follow the instructions on the screen)
19. The message that engine RPM is detected will be displayed on the screen. Press ENTER to continue.
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20. If the engine RPM is not detected, press ENTER after revving engine.
21. Turn off electrical loads (air conditioner, lamps, audio and etc). Turn the engine off.
22. Charging voltage and charging system test results will be displayed on the screen.
Shut off engine end disconnect the tester clamps from the battery. Refer to the following table and take the
appropriate action as recommended by the Micro 570.
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Charging System Test Results
CHARGING SYSTEM Charging system is normal.
NORMAL / DIODE RIPPLE
NORMAL
NO CHARGING VOLTAGE Alternator does not supply charging current to battery.
- Check belts, connection between alternator and battery and replace belts or
cable or alternator as necessary.
LOW CHARGING Alternator does not supply charging current to battery and electrical load to system
VOLTAGE fully.
- Check belts and alternator and replace as necessary.
HIGH CHARGING The voltage from alternator to battery is higher than normal limit during voltage
VOLTAGE regulating.
- Check connection and ground and replace regulator as necessary.
- Check electrolyte level in the battery
EXCESS RIPPLE One or more diodes in the alternator is not functioning properly.
DETECTED - Check alternator mounting and belts and replace as necessary.
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Charging System
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2010 > D 1.1 TCI-U >
DESCRIPTION
The charging system includes a battery, an alternator with a built-in regulator, and the charging indicator light and
wire.
The Alternator six eight built-in diodes, each rectifying AC current to DC current.
Therefore, DC current appears at alternator "B" terminal.
In addition, the charging voltage of this alternator is regulated by the battery voltage detection system.
The main components of the alternator are the rotor, stator, rectifier, capacitor brushes, bearings and V-ribbed belt
pulley. The brush holder contains a built-in electronic voltage regulator.
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2010 > D 1.1 TCI-U >
ON-VEHICLE INPECTION
• Check that the battery cables are connected to the correct terminals.
• Disconnect the battery cables when the battery is given a quick charge.
• Never disconnect the battery while the engine is running.
CHECK THE BATTERY TERMINALS AND FUSES

1. Check that the battery terminals are not loose or corroded.
2. Check the fuses for continuity.
VISUALLY CHECK ALTERNATOR WIRING AND LISTEN FOR ABNORMAL NOISES

1. Check that the wiring is in good condition.
2. Check that there is no abnormal noise from the alternator while the engine is running.
CHECK DISCHARGE WARNING LIGHT CIRCUIT

1. Warm up the engine and then turn it off.
2. Turn off all accessories.
3. Turn the ignition switch "ON". Check that the discharge warning light is lit.
4. Start the engine. Check that the light is lit.
If the light does not go off as specified, troubleshoot the discharge light circuit.
VOLTAGE DROP TEST OF ALTERNATOR OUTPUT WIRE

This test determines whether or not the wiring between the alternator "B" terminal and the battery (+) terminal is good
by the voltage drop method.
PREPARATION
1. Turn the ignition switch to "OFF".
2. Disconnect the output wire from the alternator "B" terminal. Connect the (+) lead wire of ammeter to the "B"
terminal of alternator and the (-) lead wire of ammeter to the output wire. Connect the (+) lead wire of voltmeter to
the "B" terminal of alternator and the (-) lead wire of voltmeter to the (+) terminal of battery.
TEST
1. Start the engine.
2. Turn on the headlamps and blower motor, and set the engine speed until the ammeter indicates 20A.
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And then, read the voltmeter at this time.
RESULT
1. The voltmeter may indicate the standard value.
Standard value : 0.2V max
2. If the value of the voltmeter is higher than expected (above 0.2V max.), poor wiring is suspected. In this case
check th e wiring from the alternator "B" terminal to the battery (+) terminal. Check for loose connections, color
change due to an over-heated harness, etc. Correct them before testing again.
3. Upon completion of the test, set the engine speed at idle.
Turn off the headlamps, blower motor and the ignition switch.
OUTPUT CURRENT TEST

This test determines whether or not the alternator gives an output current that is equivalent to the normal output.
PREPARATION
1. Prior to the test, check the following items and correct as necessary.
Check the battery installed in the vehicle to ensure that it is good condition. The battery checking method is
described in the section "Battery".
The battery that is used to test the output current should be one that has been partially discharged. With a fully
charged battery, the test may not be conducted correctly due to an insufficient load.
Check the tension of the alternator drive belt.
2. Turn off the ignition switch.
3. Disconnect the battery ground cable.
4. Disconnect the alternator output wire from the alternator "B" terminal.
5. Connect a DC ammeter (0 to 200A) in series between the "B" terminal and the disconnected output wire. Be sure
to connect the (-) lead wire of the ammeter to the disconnected output wire.
Tighten each connection securely, as a heavy current will flow. Do not rely on clips.
6. Connect a voltmeter (0 to 20V) between the "B" terminal and ground. Connect the (+) lead wire to the alternator "B"
terminal and (-) lead wire to a good ground.
7. Connect the battery ground cable.
8. Leave the engine hood open.
TEST
1. Check to see that the voltmeter reads as the same value as the battery voltage. If the voltmeter reads 0V, and the
open circuit in the wire between alternator "B" terminal and battery (+) terminal or poor grounding is suspected.
2. Start the engine and turn on the headlamps.
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3. Set the headlamps to high beam, the heater blower switch to 'MAX', the air conditioning switch to ON and the heat
warmer switch to ON, quickly increase the engine speed to 2,500 rpm and read the maximum output current value
indicated by the ammeter.
After the engine start up, the charging current quickly drops. Therefore, the above operation must be done
quickly to read the maximum current value correctly.
RESULT
1. The ammeter reading must be higher than the limit value. If it is lower but the alternator output wire is in good
condition, remove the alternator from the vehicle and test it.
Limit value (90A alternator) : 45A min.
• The nominal output current value is shown on the nameplate affixed to the alternator body.
• The output current value changes with the electrical load and the temperature of the alternator itself.
Therefore, the nominal output current may not be obtained. If such is the case, keep the headlamps on the
cause discharge of the battery, or use the lights of another vehicle to increase the electrical load.
The nominal output current may not be obtained if the temperature of the alternator itself or ambient
temperature is too high. In such a case, reduce the temperature before testing again.
2. Upon completion of the output current test, lower the engine speed to idle and turn off the ignition switch.
4. Remove the ammeter and voltmeter.
5. Connect the alternator output wire to the alternator "B" terminal.
REGULATED VOLTAGE TEST

The purpose of this test is to check that the electronic voltage regulator controls voltage correctly.
PREPARATION
1. Prior to the test, check the following items and correct if necessary.
Check that the battery installed on the vehicle is fully charged. The battery checking method is described in the
section "Battery".
Check the alternator drive belt tension.
2. Turn ignition switch to "OFF".
4. Connect a digital voltmeter between the "B" terminal of the alternator and ground. Connect the (+) lead of the
voltmeter to the "B" terminal of the alternator. Connect the (-) lead to good ground or the battery (-) terminal.
5. Disconnect the alternator output wire from the alternator "B" terminal.
6. Connect a DC ammeter (0 to 200A) in series between the "B" terminal and the disconnected output wire.
Connect the (-) lead wire of the ammeter to the disconnected output wire.
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TEST
1. Turn on the ignition switch and check to see that the voltmeter indicates the following value.
Voltage: Battery voltage
If it reads 0V, there is an open circuit in the wire between the alternator "B" terminal and the battery and the battery
(-) terminal.
2. Start the engine. Keep all lights and accessories off.
3. Run the engine at a speed of about 2,500 rpm and read the voltmeter when the alternator output current drops to
10A or less
RESULT
1. If the voltmeter reading agrees with the value listed in the regulating voltage table below, the voltage regulator is
functioning correctly. If the reading is other than the standard value, the voltage regulator or the alternator is faulty.
REGULATING VOLTAGE TABLE
Voltage regulator ambient temperature °C (°F) Regulating voltage (V)
-20 (-4) 14.2 ~ 15.4
20 (68) 14.0 ~ 15.0
60 (140) 13.7 ~ 14.9
80 (176) 13.5 ~ 14.7
2. Upon completion of the test, reduce the engine speed to idle, and turn off the ignition switch.
4. Remove the voltmeter and ammeter and the engine tachometer.
5. Connect the alternator output wire to the alternator "B" terminal.
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Charging System - Alternator
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2010 > D 1.1 TCI-U >
COMPONENT
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2010 > D 1.1 TCI-U >
REPLACEMENT
1. Disconnect the battery negative terminal first, then the positive terminal.
2. Disconnect the alternator connector(A), and remove the cable(B) from alternator "B" terminal.
3. Remove the alternator(A).
Tightening torque :
38.2 ~ 58.8N.m (3.9 ~ 6.0kgf.m, 28.2 ~ 43.4lbf.ft)
4. Installation is the reverse order of removal.
DISASSEMBLY
1. Remove the B terminal mounting nut(A) and rear cover nut(B).
2. Remove the alternator cover(A) using a screw driver(B).
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3. Loosen the mounting bolts(A) and disconnect the brush holder assembly(B).
4. Remove the slip ring guide(A).
5. Remove the pulley(A) using the SST(09373-27000).
6. Unsolder the 3 stator leads(A).
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7. Loosen the 4 through bolts(A).
8. Disconnect the rotor(A) and the front housing(B).
9. Reassembly is the reverse order of disassembly.
INSPECTION
ROTOR
1. Check that there is continuity between the slip rings(A).
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2. Check that there is no continuity between the slip rings and the rotor(B) or rotor shaft(C).
3. If the rotor fails either continuity check, replace the alternator.
STATOR
1. Check that there is continuity between each pair of leads(A).
2. Check that there is no continuity between each lead and the coil core.
3. If the coil fails either continuity check, replace the alternator.
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Charging System - Battery
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2010 > D 1.1 TCI-U >
DESCRIPTION
1. The maintenance-free battery is, as the name implies, totally maintenance free and has no removable battery cell
caps.
2. Water never needs to be added to the maintenance-free battery.
3. The battery is completely sealed, except for small vent holes in the cover.
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2010 > D 1.1 TCI-U >
Inspection
Battery Diagnostic Flow
Vehicle parasitic current inspection

1. Turn the all electric devices OFF, and then turn the ignition switch OFF.
2. Close all doors except the engine hood, and then lock all doors.
(1) Disconnect the hood switch connector.
(2) Close the trunk lid.
(3) Close the doors or remove the door switches.
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3. Wait a few minutes until the vehicle’s electrical systems go to sleep mode.
For an accurate measurement of a vehicle parasitic current, all electriacl systems should go to sleep mode. (It
takes at least one hour or at most one day.) However, an approximate vehicle parasitic current can be
measured after 10~20 minutes.
4. Connect an ammeter in series between the battery (-) terminal and the ground cable, and then disconnect the
clamp from the battery (-) terminal slowly.
Be careful that the lead wires of an ammeter do not come off from the battery (-) terminal and the ground
cable to prevent the battery from being reset. In case the battery is reset, connect the battery cable again, and
then start the engine or turn the ignition switch ON for more than 10 sec. Repeat the procedure from No. 1.
To prevent the battery from being reset during the inspection,
1) Connect a jump cable between the battery (-) terminal and the ground cable.
2) Disconnect the ground cable from the battery (-) terminal.
3) Connect an ammeter between the battery (-) terminal and the ground cable.
4) After disconnecting the jump cable, read the current value of the ammeter.
5. Read the current value of the ammeter.

A. If the parasitic current is over the limit value, search for abnormal circuit by removing a fuse one by one and
checking the parasitic current.
B. Check the parasitic current again, and search for suspected unit by removing a unit connected with the
abnormal circuit one by one.
Limit value (after 10~20 min.) : Below 50mA
Cleaning
1. Make sure the ignition switch and all accessories are in the OFF position.
2. Disconnect the battery cables (negative first).
3. Remove the battery from the vehicle.
Care should be taken in the event the battery case is cracked or leaking, to protect your skin from the
electrolyte.
Heavy rubber gloves (not the household type) should be wore when removing the battery.
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4. Inspect the battery tray for damage caused by the loss of electrolyte. If acid damage is present, it will be necessary
to clean the area with a solution of clean warm water and baking soda. Scrub the area with a stiff brush and wipe
off with a cloth moistened with baking soda and water.
5. Clean the top of the battery with the same solution as described above.
6. Inspect the battery case and cover for cracks. If cracks are present, the battery must be replaced.
7. Clean the battery posts with a suitable battery post tool.
8. Clean the inside surface of the terminal clamps with a suitable battery cleaning tool. Replace damaged or frayed
cables and broken terminal clamps.
9. Install the battery in the vehicle.
10. Connect the cable terminals to the battery post, making sure tops of the terminals are flush with the tops of the
posts.
11. Tighten the terminal nuts securely.
12. Coat all connections with light mineral grease after tightening.
When batteries are being charged, an explosive gas forms beneath the cover of each cell. Do not smoke
near batteries being charged or which have recently been charged. Do not break live circuit at the terminals
of batteries being charged.
A spark will occur when the circuit is broken. Keep open flames away from battery.
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Starting System
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2010 > D 1.1 TCI-U >
DESCRIPTION
The starting system includes the battery, starter, solenoid switch, ignition switch, inhibitor switch (A/T), ignition lock
switch, connection wires and the battery cable.
When the ignition key is turned to the start position, current flows and energizes the starter motor's solenoid coil.
The solenoid plunger and clutch shift lever are activated, and the clutch pinion engages the ring gear which means
the starter motor cranks. In order to prevent damage caused by excessive rotation of the starter armature when the
engine starts, the clutch pinion gear overruns.
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2010 > D 1.1 TCI-U >
TROUBLESHOOTING
STARTER CIRCUIT
The battery must be in good condition and fully charged.
1. Remove the fuel pump tube(A) from the fuel pump.
2. With the shift lever in N or P (A/T) or clutch pedal pressed (M/T), turn the ignition switch to "START"
If the starter normally cranks the engine, starting system is OK. If the starter will not crank the engine at all, go to
next step.
If it won't disengage from the ring gear when you release key to 'ON' position, check for the following until you find
the cause.
A. Solenoid plunger and switch malfunction.
B. Dirty pinion gear or damaged overrunning clutch.
3. Check the battery condition. Check electrical connections at the battery, battery negative cable connected to the
body, engine ground cables, and the starter for looseness and corrosion. Then try starting the engine again.
If the starter cranks normally the engine, repairing the loose connection repaired the problem. The starting system
is now OK.
If the starter still does not crank the engine, go to next step.
4. Disconnect the connector from the S-terminal of solenoid. Connect a jumper wire from the B-terminal of solenoid to
the S-terminal of solenoid.
If the starter cranks the engine, go to next step.
If the starter still does not crank the engine, remove the starter, and repair or replace as necessary.
5. Check the following items in the order listed until you find the open circuit.
A. Check the wire and connectors between the driver's under-dash fuse/relay box and the ignition switch, and
between the driver's under-dash fuse/relay box and the starter.
B. Check the ignition switch.
C. Check the transaxle range switch connector or ignition lock switch connector.
D. Inspect the starter relay.
STATER SOLENOID TEST

1. Disconnect the field coil wire from the M-terminal of solenoid switch.
2. Connect a 12V battery between S-terminal and the starter body.
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3. Connect the field coil wire to the M-terminal.
This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning.
4. If the pinion moves out, the pull-in coil of solenoid is working properly.
If the pinion does not move, replace the solenoid.
5. Diconnect the field coil wire from the M-terminal.
6. If the pinion has moved out, the hold-in coil of the solenoid is working properly.
If the pinion moves in, replace the solenoid.
FREE RUNNING TEST

1. Place the starter in a vise equipped with soft jaws and connect a fully-charged 12-volt battery to starter as follows.
2. Connect a test ammeter (100-ampere scale) and carbon pile rheostats shown is the illustration.
3. Connect a voltmeter (15-volt scale) across starter motor.
4. Rotate carbon pile to the off position.

5. Connect the battery cable from battery's negative post to the starter body.
6. Adjust until battery voltage shown on the voltmeter reads 11volts.
7. Confirm that the maximum amperage is within the specifications and that the starter turns smoothly and freely.
Current : 90A max

Speed : 2,600 rpm
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Starting System - Starter
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COMPONENT
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2010 > D 1.1 TCI-U >
REPLACEMENT
1. Disconnect the battery negative cable.
2. Disconnect the starter cable(A) from the B terminal on the solenoid then disconnect the connector(B) from the S
terminal.
3. Remove the 2 bolts holding the starter, then remove the starter.
4. Installation is the reverse of removal.
38.2~58.8Nm (3.9~6.0kgf.m, 28.2~43.4 Ib.ft)
5. Connect the battery negative cable to the battery.
DISASSEMBLY
1. Disconnect the M-terminal(A) on the magnet switch assembly(B).
2. After loosening the 2 screws(A), detach the magnet switch assembly(B).
3. Loosen the brush holder mounting screw(A) and through bolts(B).
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4. Remove the rear bracket(A) and brush holder assembly(B).
5. Remove the yoke(A) and amature(B).
6. Reassembly is the reverse of disassembly.
INSPECTION
ARMATURE INSPECTION AND TEST
1. Remove the starter.
2. Disassemble the starter as shown at the beginning of this procedure.
3. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage,
replace the armature.
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4. Check the commutator(A) surface. If the surface is dirty or burnt, resurface with emery cloth or a lathe within the
following specifications, or recondition with #500 or #600 sandpaper(B).
5. Check the commutator diameter. If the diameter is below the service limit, replace the armature.
Commutator diameter
Standard (New) : 29.4 mm (1.1575 in)
Service limit : 28.8 mm (1.1339 in)
6. Measure the commutator(A) runout.

A. If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips
between the segments.
B. If the commutator run out is not within the service limit, replace the armature.
Commutator runout
Standard (New) : 0.02mm (0.0008in.) max
Service limit : 0.05mm (0.0020in.)
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7. Check the mica depth(A). If the mica is too high(B), undercut the mica with a hacksaw blade to the proper depth.
Cut away all the mica(C) between the commutator segments. The undercut should not be too shallow, too narrow,
or v-shaped(D).
Commutator mica depth

Standard (New) : 0.5 mm (0.0197 in.)
Limit : 0.2mm (0.0079 in.)
8. Check for continuity between the segments of the commutator. If an open circuit exists between any segments,
replace the armature.
9. Check with an ohmmeter that no continuity exists between the commutator(A) and armature coil core(B), and
between the commutator and armature shaft(C). If continuity exists, replace the armature.
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STARTER BRUSH
Brushes that are worm out, or oil-soaked, should be replaced.
STARTER BRUSH HOLDER TEST

Check that there is no continuity between the (+) brush holder(A) and (-) brush holder(B). If there is no continuity,
replace the brush holder assembly.
OVERRUNNING CLUTCH
1. Slide the overrunning clutch along the shaft.
Replace it if does not slide smoothly.
2. Rotate the overrunning clutch both ways.
Does it lock in one direction and rotate smoothly in reverse? If it does not lock in either direction of it locks in both
directions, replace it.
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3. If the starter drive gear is worn or damaged, replace the overrunning clutch assembly. (the gear is not available
separately)
Check the condition of the flywheel or torque converter ring gear if the starter drive gear teeth are damaged.
CLEANING
1. Do not immerse parts in cleaning solvent.
Immersing the yoke assembly and/or armature will damage the insulation wipe these parts with a cloth only.
2. Do not immerse the drive unit in cleaning solvent.
The overrun clutch is pre-lubricated at the factory and sol-vent will wash lubrication from the clutch.
3. The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.
CLEANING
1. Do not immerse parts in cleaning solvent.
Immersing the yoke assembly and/or armature will damage the insulation wipe these parts with a cloth only.
2. Do not immerse the drive unit in cleaning solvent.
The overrun clutch is pre-lubricated at the factory and sol-vent will wash lubrication from the clutch.
3. The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.
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Starting System - Starter Relay
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2010 > D 1.1 TCI-U >
INSPECTION
1. Remove the fuse box cover.
2. Remove the starter relay(A).
3. Using an ohmmeter, check that there is continuity between each terminal.

Terminal Continuity
3-4 NO
1-2 YES
4. Apply 12V to terminal 85 and ground to terminal 86.

Check for continuity between terminals 30 and 87.
5. If there is no continuity, replace the starter relay.

6. Install the starter relay.
7. Install the fuse box cover.
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Preheating System
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2010 > D 1.1 TCI-U >
COMPONENT
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2010 > D 1.1 TCI-U >
INSPECT
Conditions before inspection :
Battery voltage : 12V
Cooling water temperature : Below 30°C (86°F)
(Disconnect the water temperature sensor connector).
Reconnect the water temperature sensor connector after inspection.
1. Connect voltmeter between glow plug plate and plug body (ground).
2. Check indicated value on voltmeter with ignition switch ON.
3. Check that preheat indication lamp lights for about 6 seconds and indicates battery voltage (about 9V or over) for
about 36 seconds immediately after ignition switch is turned on. [At cooling water temperature 20°C (68.0°F)]
Continuity time varies depending upon cooling water temperature.
4. After checking 3, set ignition switch at START position.

5. The system is normal if battery voltage (about 9V or over) is generated for about 6 seconds during engine cranking
and after start operation. [at cooling water temperature 20°C (68.0°F)]
6. When the voltage or continuity time is not normal, check the terminal voltage in glow control unit, and single parts.
GLOW PLUG
1. Check the continuity between the terminal and body as illustrated. Replace if discontinuity or with large resistance.
Standard value : 0.25!
Remove oil from plug before measuring as glowplug resistance is very small.
2. Check for rust on glow plug plate.

3. Check glow plug for damage.
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GLOW PLUG RELAY
1. Remove the glow plug relay.
2. Inspect the relay continuity.
A. Using an ohmmeter, check that there is continuity between terminals 2 and 4.
If there is no continuity, replace the relay.
B. Check that there is no continuity between terminals 1 and 5.
If there is continuity, replace the relay.
3. Inspect the relay operation.

A. Apply battery positive voltage across terminals 2 and 4.
B. Using an ohmmeter, check that there is continuity between terminals 1 and 5.
If there is no continuity, replace the relay.
4. Install the glow plug relay.
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Fuel System
General Information
Fuel System
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2010 > D 1.1 TCI-U >
SPECIFICATIONS
FUEL DELIVERY SYSTEM
Items Specification
Fuel Injection System Type Common Rail Direct Injection (CRDI)
Fuel Return System Type Return type
Fuel Pressure Max. Pressure 1,600 bar
Fuel Tank Capacity 35 lit. (37.0 Us gt., 30.8 lmp gt.)
Fuel Filter Type High pressure type (Built in engine room)
Type Mechanical, Plunger Pumping Type
High Pressure Fuel Pump
Driven by Drive Belt
Type Mechanical, Gear Pumping Type
Low Pressure Fuel Pump
Driven by Involved in High Pressure Fuel Pump
SENSORS
MASS AIR FLOW SENSOR (MAFS)
▷ Type: Hot-Film Type
▷ Specification
* At intake air temperature = 20°C(68°F)
Air Flow (kg/h) Frequency (kHz)
8 1.96 ~ 1.97
10 2.01 ~ 2.02
40 2.50 ~ 2.52
105 3.18 ~ 3.23
220 4.26 ~ 4.35
480 7.59 ~ 7.94
560 9.08 ~ 9.89
* At intake air temperature = -15°C(5°F) or 80°C(176°F)

Air Flow (kg/h) Frequency (kHz)
10 2.00 ~ 2.02
40 2.49 ~ 2.53
105 3.16 ~ 3.25
480 7.42 ~ 8.12
INTAKE AIR TEMPERATURE SENSOR (IATS) #1 [BUILT IN MAFS]

▷ Type: Thermistor type
▷ Specification
Temperature [°C(°F)] Resistance(k!)
-40(-40) 35.14 ~ 43.76
-20(-4) 12.66 ~ 15.12
0(32) 5.12 ~ 5.89
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20(68) 2.29 ~ 2.55
40(104) 1.10 ~ 1.24
60(140) 0.57 ~ 0.65
80(176) 0.31 ~ 0.37
BOOST PRESSURE SENSOR (BPS)

▷ Type: Piezo-resistive pressure sensor type
▷ Specification
Pressure (kPa) Output Voltage (V)
32.5 0.5
70 1.02 ~ 1.17
140 2.13 ~ 2.28
210 3.25 ~ 3.40
270 4.20 ~ 4.35
284 4.5
INTAKE AIR TEMPERATURE SENSOR (IATS) #2 [BUILT IN BPS]

▷ Specification
-40(-40) 40.93 ~ 48.35
-20(-4) 13.89 ~ 16.03
0(32) 5.38 ~ 6.09
20(68) 2.31 ~ 2.57
40(104) 1.08 ~ 1.21
60(140) 0.54 ~ 0.62
80(176) 0.29 ~ 0.34
ENGINE COOLANT TEMPERATURE SENSOR (ECTS)

▷ Specification
-40(-40) 48.14
-20(-4) 14.13 ~ 16.83
0(32) 5.79
20(68) 2.31 ~ 2.59
40(104) 1.15
60(140) 0.59
80(176) 0.32
CAMSHAFT POSITION SENSOR (CMPS)

▷ Type: Hall effect type
▷ Specification
Level Output Pulse (V)
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High 12V
Low 0V
Items Specification
Air Gap Approx. 1.0 mm
CRANKSHAFT POSITION SENSOR (CKPS)

▷ Type: Variable reluctance type
▷ Output Voltage (V): 0 ~ 5V
Items Specification
Coil Resistance (!)) 774 ~ 946! [20°C(68°F)]
ACCELERATOR POSITION SENSOR (APS)

▷ Type: Potentiometer type
▷ Specification
Output Voltage(V)
Test Condition
APS 1 APS 2
Idle 0.7 ~ 0.8 0.275 ~ 0.475
Fully depressed 3.8 ~ 4.4 1.75 ~ 2.35
Specification
Items
APS 1 APS 2
Potentiometer Resistance (k!) 0.7 ~ 1.3 1.4 ~ 2.6
FUEL TEMPERATURE SENSOR (FTS)

▷ Specification
-30(-22) 27.00
-20(-4) 15.00
-10(14) 9.45
0(32) 5.89
20(68) 2.27 ~ 2.73
40(104) 1.17
50(122) 0.83
60(140) 0.60
70(158) 0.43
80(176) 0.30 ~ 0.32
RAIL PRESSURE SENSOR (RPS)

▷ Type: Piezo-electricity type
▷ Specification
Test Condition Rail pressure (bar) Output Voltage(V)
Idle 220 ~ 320 Below 1.7
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Fully depressed 1,600 Approx. 4.5
LAMBDA SENSOR
▷ Type: Zirconia (ZrO2) Type
▷ Specification
" Value (A/F Ratio) Pumping Current(A)
0.65 -2.22
0.70 -1.82
0.80 -1.11
0.90 -0.50
1.01 0.00
1.18 0.33
1.43 0.67
1.70 0.94
2.42 1.38
Air (Atmosphere) 2.54
Item Specification
Heater Resistance (!) 2.4 ~ 4.0! [20°C(68°F)]
WATER SENSOR
▷ Specification
Item Specification
Warning Level (cc) 40 ~ 60
VEHICLE SPEED SENSOR (VSS)

▷ Type: Inductive type
ACTUATORS
INJECTOR
▷ Number: 3
▷ Specification
Items Specification
Coil Resistance (!) 0.215 ~ 0.295! [20°C(68°F)]
FUEL PRESSURE REGULATOR VALVE

▷ Specification
Items Specification
RAIL PRESSURE REGULATOR VALVE

▷ Specification
Items Specification
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ELECTRIC EGR CONTROL VALVE
▷ Type: Linear solenoid type
▷ Specification
Items Specification
VGT CONTROL SOLENOID VALVE

▷ Specification
Items Specification
THROTTLE FLAP CONTROL SOLENOID VALVE

▷ Specification
Items Specification
VARIABLE SWIRL CONTROL SOLENOID VALVE

▷ Specification
Items Specification
SERVICE STANDARD
Neutral,N,P-range 880 ± 100 rpm
A/C OFF
Basic Idle rpm(After warm D-range 880 ± 100 rpm
up) Neutral,N,P-range 880 ± 100 rpm
A/C ON
D-range 880 ± 100 rpm
TIGHTENING TORQUES
ENGINE CONTROL SYSTEM
Item Kgf#m N#m lbf#ft
ECM installation bolts (on bracket) 0.9 ~ 1.4 8.8 ~ 13.7 6.5 ~ 10.1
ECM bracket installation bolts/nuts 0.4 ~ 0.6 3.9 ~ 5.9 2.9 ~ 4.3
Mass air flow sensor clamp installation bolts 0.3 ~ 0.5 2.9 ~ 4.9 2.2 ~ 3.6
Mass air flower sensor installation bolts (on air cleaner
0.3 ~ 0.5 2.9 ~ 4.9 2.2 ~ 3.6
assembly)
Boost pressure sensor installation bolts 0.7 ~ 1.1 6.9 ~ 10.8 5.1 ~ 8.0
Engine coolant temperature sensor installation 2.5 ~ 3.5 24.5 ~ 34.3 18.1 ~ 25.3
Crankshaft position sensor installation bolt 0.6 ~ 1.0 5.9 ~ 9.8 4.3 ~ 7.2
Camshaft position sensor installation bolt 0.7 ~ 1.0 6.9 ~ 9.8 5.1 ~ 7.2
Rail pressure sensor installation 6.6 ~ 7.6 65.0 ~ 75.0 47.8 ~ 55.0
Lambda sensor installation 4.0 ~ 6.0 39.2 ~ 58.9 28.9 ~ 43.4
Rail pressure regulator valve installation 8.2 ~ 9.2 80.0 ~ 90.0 59.0 ~ 66.4
Electric EGR control valve installation bolts 2.2 ~ 2.8 21.6 ~ 27.5 15.9 ~ 20.3
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Throttle body installation nuts 0.7 ~ 1.1 6.9 ~ 10.8 5.1 ~ 8.0
Solenoid valves bracket installation nuts 0.7 ~ 1.1 6.9 ~ 10.8 5.1 ~ 8.0
Throttle flap control solenoid valve bracket installation bolt 0.7 ~ 1.1 6.9 ~ 10.8 5.1 ~ 8.0
Glow plug installation 1.5 ~ 2.0 14.7 ~ 19.6 10.9 ~ 14.5
Glow plug plate installation nuts 0.08 ~ 0.15 0.8 ~ 1.5 0.6 ~ 1.1
FUEL DELIVERY SYSTEM
Item Kgf#m N#m lbf#ft

Injector clamp installation bolt 2.9 ~ 3.1 28.4 ~ 30.4 21.0 ~ 22.4
Common rail installation bolts 1.5 ~ 2.2 14.7 ~ 21.6 10.9 ~ 15.9
High pressure fuel pump installation bolts 1.5 ~ 2.0 14.7 ~ 19.6 10.9 ~ 14.5
High pressure fuel pipe (Injector " Common Rail) installation
2.5 ~ 2.9 24.5 ~ 28.4 18.1 ~ 21.0
nuts
High pressure fuel pipe (Common RaiI " High Pressure Fuel
2.5 ~ 2.9 24.5 ~ 28.4 18.1 ~ 21.0
Pump) installation nuts
Fuel tank mounting nuts 4.0 ~ 5.5 39.2 ~ 54.0 28.9 ~ 39.8
Fuel sender plate cover tightening 6.1 ~ 7.1 60.0 ~ 70.0 44.3 ~ 51.6
Accelerator pedal module installation bolts 0.8 ~ 1.2 7.8 ~ 11.8 5.8 ~ 8.7
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2010 > D 1.1 TCI-U >
SPECIAL SERVICE TOOLS

Tool (Number and name) Illustration Application
09351-4A300 Removing the injector
Injector Remover
09314-27110(14mm) Installing the high pressure fuel pipe

09314-27120(17mm)
Torque Wrench Socket
09331-2A000 Removing the high pressure fuel

High Pressure Fuel Pump pump
Sprocket Remover
09310-2B100 Removing and installing the fuel

Fuel Pump Plate Cover Wrench sender plate cover
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2010 > D 1.1 TCI-U >
BASIC TROUBLESHOOTING
BASIC TROUBLESHOOTING GUIDE
CUSTOMER PROBLEM ANALYSIS SHEET
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BASIC INSPECTION PROCEDURE
The measured resistance at high temperature after vehicle running may be high or low. So all resistance must be
measured at ambient temperature (20°C, 68°F), unless stated otherwise.
The measured resistance in except for ambient temperature (20°C, 68°F) is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does not occur again
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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, the technician should thoroughly make out a "CUSTOMER PROBLEM ANALYSIS SHEET" and
recreate (simulate) the environment and condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent, broken or corroded pins,
and then verify that the connectors are always securely fastened.
3. Slightly shake the connector and wiring harness vertically and horizontally.
4. Repair or replace the component that has a problem.
5. Verify that the problem has disappeared with the road test.
! SIMULATING VIBRATION
1) Sensors and Actuators
: Slightly vibrate sensors, actuators or relays with finger.
Strong vibration may break sensors, actuators or relays
2) Connectors and Harness

: Lightly shake the connector and wiring harness vertically and then horizontally.
! SIMULATING HEAT
1) Heat components suspected of causing the malfunction with a hair dryer or other heat source.
• DO NOT heat components to the point where they may be damaged.

• DO NOT heat the ECM directly.
! SIMULATING WATER SPRINKLING

1) Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
DO NOT sprinkle water directly into the engine compartment or electronic components.
! SIMULATING ELECTRICAL LOAD

1) Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, rear window defogger,
etc.).
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CONNECTOR INSPECTION PROCEDURE
1. Handling of Connector
A. Never pull on the wiring harness when disconnecting connectors.
B. When removing the connector with a lock, press or pull locking lever.
C. Listen for a click when locking connectors. This sound indicates that they are securely locked.
D. When a tester is used to check for continuity, or to measure voltage, always insert tester probe from wire
harness side.
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E. Check waterproof connector terminals from the connector side. Waterproof connectors cannot be accessed from
harness side.
• Use a fine wire to prevent damage to the terminal.

• Do not damage the terminal when inserting the tester lead.
2. Checking Point for Connector

A. While the connector is connected:
Hold the connector, check connecting condition and locking efficiency.
B. When the connector is disconnected:
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
C. Check terminal tightening condition:
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
D. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
3. Repair Method of Connector Terminal

A. Clean the contact points using air gun and/or shop rag.
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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 harness position and crimping in order to restore it correctly.
2. Check whether the wire harness is twisted, pulled or loosened.
3. Check whether the temperature of the wire harness is abnormally high.
4. Check whether the wire harness is rotating, moving or vibrating against the sharp edge of a part.
5. Check the connection between the wire harness and any installed part.
6. If the covering of wire harness is damaged; secure, repair or replace the harness.
ELECTRICAL CIRCUIT INSPECTION PROCEDURE

1. Procedures for Open Circuit
A. Continuity Check
B. Voltage Check
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity Check Method) or
Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
When measuring for resistance, lightly shake the wire harness above and below or from side to side.
Specification (Resistance)
1" or less # Normal Circuit
1M" or Higher # Open Circuit
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 1M" and below 1 " respectively. 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.
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B. Disconnect connector (B), and measure for resistance between connector (C) and (B1) and between (B2) and
(A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1M" and the open circuit
is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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).
! CHECK SHORT CIRCUIT

1. Test Method for Short to Ground Circuit
A. Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing Step 2
(Continuity Check Method with Chassis Ground) as shown below.
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2. Continuity Check Method (with Chassis Ground)
Lightly shake the wire harness above and below, or from side to side when measuring the resistance.
Specification (Resistance)
1" or less # Short to Ground Circuit
1M" or Higher # Normal Circuit
A. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis Ground as
shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 " and higher than 1M" 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 following step.
B. Disconnect connector (B), and measure the resistance between connector (A) and chassis ground, and
between (B1) and chassis ground as shown in [FIG. 7].
The measured resistance between connector (B1) and chassis ground is 1" or less. The short to ground circuit
is between terminal 1 of connector (C) and terminal 1 of connector (B1).
SYMPTOM TROUBLESHOOTING GUIDE TABLE
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(SYMPTOM 1) ENGINE DOES NOT START
Possible Cause
• Run out of fuel • Inversion of fuel connections (feed & return)

• Faulty starter • Faulty fuel filter
• Not connected fuel feed line • Clogged low pressure fuel circuit
• Leakage in high pressure fuel circuit • Clogged fuel filter
• Fuse out of order • Intermittent faulty fuel line connection
• Drift of the rail pressure sensor • Air ingress in the low pressure fuel circuit
• Cam and crank signals missing simultaneously • Clogged return line of high pressure fuel pump
• Low battery voltage • Low compression pressure
• Faulty immobilizer • Leakage at the injector
• Fuel pressure regulator valve contaminated, stuck, • Faulty low pressure fuel pump
jammed • Faulty high pressure fuel pump
• Rail pressure regulator valve contaminated, stuck, • Injector jammed open
jammed • ECM program error or hardware fault
• Bad fuel quality or water ingress in fuel • Faulty glow system
(SYMPTOM 2) ENGINE STARTS WITH DIFFICULTY OR STARTS AND STALLS
Possible Cause
• Not connected fuel return line at injector

• Clogged low pressure fuel circuit
• Leakage in high pressure fuel circuit
• Clogged fuel filter
• Fuse out of order
• Oil level too high or too low
• Clogged air filter
• Sealed or damaged catalytic converter
• Faulty alternator or voltage regulator
• Intermittent faulty fuel line connection
• Compensation of individual injector not adapted
• Air ingress in the low pressure fuel circuit
• No engine coolant temperature sensor signal
• Clogged return line of high pressure fuel pump
• No rail pressure sensor signal
• Faulty glow system
• Low battery voltage
• Low compression pressure
• Electric EGR control valve blocked open
• Clogged injector return line
• Fuel pressure regulator valve contaminated, stuck,
• Carbon deposit on the injector (sealed holes)
jammed
• Injector needle stuck (injection possible over a certain
• Rail pressure regulator valve contaminated, stuck,
pressure)
jammed
• Gasoline in fuel
• Bad fuel quality or water ingress in fuel
• ECM program error or hardware fault
• Inversion of fuel connections (feed & return)
(SYMPTOM 3) POOR STARTING WHEN HOT
Possible Cause

• Clogged return line of high pressure fuel pump
jammed
jammed
pressure)
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(SYMPTOM 4) UNSTABLE IDLING

Possible Cause
• Not connected fuel return line at injector • Faulty glow system

• Compensation of individual injector not adapted • Low compression pressure
• No rail pressure sensor signal • Poor tightening of injector clamp
• Wiring harness open or poor connection • Faulty high pressure fuel pump
• Air ingress in the low pressure fuel circuit • Injector not adapted
• Bad fuel quality or water ingress in fuel • Carbon deposit on the injector (sealed holes)
• Clogged fuel filter • Injector needle stuck (injection possible over a certain
• Clogged air filter pressure)
• Clogged injector return line • Injector jammed open
• Leakage in high pressure fuel circuit • Electric EGR control valve blocked open
(SYMPTOM 5) IDLE SPEED TOO HIGH OR TOO LOW

Possible Cause

• Incorrect state of the electrical pack devices • Electric EGR control valve blocked open
• Faulty alternator or voltage regulator • Faulty accelerator pedal
(SYMPTOM 6) BLUE, WHITE, OR BLACK SMOKES
Possible Cause

• Oil suction (engine racing)
• Poor tightening of injector clamp
jammed
• Poor injector O-ring, no O-ring or two O-ring installed
• Injector not adapted
jammed
• Oil level too high or too low
• Injector jammed open
• Sealed or damaged catalytic converter
(SYMPTOM 7) ENGINE RATTLING, NOISY ENGINE

Possible Cause

• Injector not adapted
pressure)
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(SYMPTOM 8) NURST NOISE
Possible Cause

jammed
• Clogged exhaust system
jammed
(SYMPTOM 9) UNTIMELY ACCELERATION/DECELERATION AND ENGINE RACING
Possible Cause
• Blocked accelerator pedal position sensor • Oil suction (engine racing)

• Electric EGR control valve blocked open • No rail pressure sensor signal
• Intermittent faulty fuel line connection • ECM program error or hardware fault
(SYMPTOM 10) GAP WHEN ACCELERATING AND AT RE-COUPLING (RESPONSE TIME)
Possible Cause
• Leakage in intake system

• Incorrect state of the electrical pack devices
jammed
• Blocked accelerator pedal position sensor
jammed
• Damaged turbocharger or leakage in vacuum line
• Clogged fuel filter pressure)
• Low compression pressure • ECM program error or hardware fault
(SYMPTOM 11) ENGINE STOP
Possible Cause
• Run out of fuel

• Not connected fuel feed line • Rail pressure regulator valve contaminated, stuck,
• Leakage in high pressure fuel circuit jammed
• Fuse out of order • Faulty alternator or voltage regulator
• Bad fuel quality or water ingress in fuel • Intermittent faulty fuel line connection
• Clogged low pressure fuel circuit • Sealed or damaged catalytic converter
• Clogged fuel filter • Faulty low pressure fuel pump
• Crank signals missing • Faulty high pressure fuel pump
• Electric EGR control valve blocked open • Gasoline in fuel
• Fuel pressure regulator valve contaminated, stuck, • ECM program error or hardware fault
jammed
(SYMPTOM 12) ENGINE JUDDER
Possible Cause
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• Run out of fuel
• Incorrect state of the electrical pack devices
• Poor valve clearance
• Faulty low pressure fuel pump
• Faulty fuel filter
pressure)
• Wiring harness open or poor connection
(SYMPTOM 13) LACK OF POWER

Possible Cause
• Compensation of individual injector not adapted • Clogged fuel filter

• Blocked accelerator pedal position sensor • Leakage at the injector
• Incorrect state of the electrical pack devices • Clogged return line of high pressure fuel pump
• Electric EGR control valve blocked open • Clogged injector return line
• Leakage in intake system • Low compression pressure
• Clogged air filter • Injector not adapted
• Oil level too high or too low • Carbon deposit on the injector (sealed holes)
• Sealed or damaged catalytic converter • Poor valve clearance
• Damaged turbocharger or leakage in vacuum line • Engine coolant temperature too high
• Damaged turbocharger • Fuel temperature too high
(SYMPTOM 14) TOO MUCH POWER
Possible Cause

• Oil suction (engine racing)
(SYMPTOM 15) EXCESSIVE FUEL CONSUMPTION
Possible Cause
• Not connected fuel return line at injector • Incorrect state of the electrical pack devices
• Leakage at the Fuel pressure regulator valve • Oil level too high or too low
• Leakage at fuel temperature sensor • Bad fuel quality or water ingress in fuel
• Leakage in high pressure fuel circuit • Sealed or damaged catalytic converter
• Leakage in intake system • Damaged turbocharger
• Clogged air filter • Low compression pressure
• Compensation of individual injector not adapted • Injector not adapted
• Electric EGR control valve blocked open • ECM program error or hardware fault
(SYMPTOM 16) OVER SPEED ENGINE WHEN CHANGING THE GEAR BOX RATIO
Possible Cause
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• Blocked accelerator pedal position sensor • Oil suction (engine racing)
• Compensation of individual injector not adapted • Damaged turbocharger
• Intermittent faulty fuel line connection • Injector not adapted
• Clutch not well set (optional) • ECM program error or hardware fault
(SYMPTOM 17) EXHAUST SMELLS

Possible Cause
• Leakage at electric EGR control valve • Poor injector O-ring, no O-ring or two O-ring installed
• Oil suction (engine racing) • Injector not adapted
• Damaged turbocharger • Carbon deposit on the injector (sealed holes)
• Oil level too high or too low • Injector needle stuck (injection possible over a certain
• Compensation of individual injector not adapted pressure)
• Sealed or damaged catalytic converter • Injector jammed open
• Poor tightening of injector clamp • ECM program error or hardware fault
(SYMPTOM 18) SMOKES (BLACK, WHITE, BLUE) WHEN ACCELERATING

Possible Cause
• Compensation of individual injector not adapted • Intermittent faulty fuel line connection
• Electric EGR control valve blocked open • Poor tightening of injector clamp
• Clogged air filter • Poor injector O-ring, no O-ring or two O-ring installed
• Bad fuel quality or water ingress in fuel • Injector not adapted
• Oil level too high or too low • Carbon deposit on the injector (sealed holes)
• Damaged turbocharger • Injector needle stuck (injection possible over a certain
• Sealed or damaged catalytic converter pressure)
• Oil suction (engine racing) • Injector jammed open
• Faulty air heater • Gasoline in fuel
• Low compression pressure • ECM program error or hardware fault
• Leakage in high pressure fuel circuit • Catalyzed Particulate Filter (CPF) fail
(SYMPTOM 19) FUEL SMELLS

Possible Cause
• Not connected fuel feed line

• Leakage at fuel temperature sensor
• Leakage at the Fuel pressure regulator valve
(SYMPTOM 20) THE ENGINE COLLAPSES AT TAKE OFF
Possible Cause
• Blocked accelerator pedal position sensor • Intermittent faulty fuel line connection
• Incorrect state of the electrical pack devices • No rail pressure sensor signal
• Clogged air filter • Fuel pressure regulator valve contaminated, stuck,
• Inversion of fuel connections (feed & return) jammed
• Faulty fuel filter • Rail pressure regulator valve contaminated, stuck,
• Bad fuel quality or water ingress in fuel jammed
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• Air ingress in the low pressure fuel circuit • Gasoline in fuel
• Clogged fuel filter • ECM program error or hardware fault
• Sealed or damaged catalytic converter • Faulty accelerator pedal position sensor
(SYMPTOM 21) ENGINE DOES NOT STOP
Possible Cause
• Stuck or worn lubrication circuit of turbocharger • Leakage at vacuum hose

• Too much engine oil • ECM program error or hardware fault
(SYMPTOM 22) DIFFERENT MECHANICAL NOISES

Possible Cause
• Buzzer noise (discharge by the injectors) • Leakage in intake system

• Broken clip (vibrations, resonance, noises) • Poor tightening of injector clamp
• Incorrect state of the electrical pack devices • Damaged turbocharger
• Sealed or damaged catalytic converter • Poor valve clearance
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Fuel System
Engine Control System
Fuel System
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2010 > D 1.1 TCI-U >
DESCRIPTION
1. Engine is hard to start or does not start at all.
2. Nstable idle.
3. Poor driveability.
• Before removing or installing any part, read the diagnostic trouble codesand then disconnect the battery
negative (-) terminal.
• Before disconnecting the cable from battery terminal, turn the ignition switch to OFF. Removal or connection
of the battery cable during engine operationor while the ignition switch is ON could cause damage to the
ECM.
• Wchecking the generator for the charging state, do not disconnect the battery '+' terminal to prevent the ECM
from damage due to the voltage.
• Wcharging the battery with the external charger, disconnect the vehicleside battery terminals to prevent
damage to the ECM.
SELF-DIAGNOSIS
If a sensor connector is disconnected with the ignition switch turned on, the diagnostic trouble code (DTC) is
recorded. In this case, disconnect the battery negative terminal (-) for 15 seconds or more, and the diagnosis
memory will be erased.
CHECKING PROCEDURE (SELF-DIAGNOSIS)
• When attery voltage is excessively low, diagnostic trouble codes can not be read. Be sure to check the battery
for voltage and the charging system before starting the test
• 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 and recorded.
INSPECTION PROCEDURE (USING GENERIC SCAN TOOL)

1. Turn OFF the ignition switch.
2. Connect the scan tool to the data link connector on the lower crash pad.
3. Turn ON the ignition switch.

4. Use the scan tool to check the diagnostic trouble code.
5. Repair the faulty part from the diagnosis chart.
6. Erase the diagnostic trouble code.
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7. Disconnect the scan tool.
When deleting diagnostic trouble code, use scan tool as possible.
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2010 > D 1.1 TCI-U >
COMPONENT LOCATION
1. Engine Control Module (ECM)

2. Mass Air Flow Sensor (MAFS)
23. Main Relay
3. Intake Air Temperature Sensor (IATS) #1 built in MAFS
24. Glow Relay
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4. Boost Pressure Sensor (BPS)
6. Crankshaft Position Sensor (CKPS)
5. Intake Air Temperature Sensor (IATS) #2 built in BPS
7. Camshaft Position Sensor (CMPS)

8. Engine Coolant Temperature Sensor (ECTS)
19. Electric EGR Control Valve
9. Rail Pressure Sensor (RPS) 10. Lambda Sensor
11. Fuel Temperature Sensor (FTS)

12. Water Sensor (included in Fuel Filter)
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12. Water Sensor (included in Fuel Filter)
17. Fuel Pressure Regulator Valve
13. Accelerator Pedal Position Sensor (APS) 14. Vehicle Speed Sensor (VSS)
15.A/C Pressure Transducer (APT) 16. Injector
20. VGT Control Solenoid Valve

18. Rail Pressure Regulator Valve 21. Throttle Flap Control Solenoid Valve
22. Variable Swirl Control Solenoid Valve
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25. Cooling Fan Relay
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Fuel System
Engine Control System - Engine Control

Module (ECM)
Fuel System
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2010 > D 1.1 TCI-U >
ECM (ENGINE CONTROL MODULE)

1. ECM HARNESS CONNECTOR
2. ECM TERMINAL FUNCTION

CONNECTOR [C201-1]
Pin Description Connected to
1 Injector (Cylinder #2) [HIGH] control output Injector (Cylinder #2)
2 -
3 -
4 Battery power Rail Pressure Regulator Valve
5 -
6 -
7 Sensor shield Crankshaft Position Sensor (CKPS)
8 Sensor ground Rail Pressure Sensor (RPS)
9 -
10 -
11 -
12 Crankshaft Position Sensor (CKPS) [+] signal input Crankshaft Position Sensor (CKPS)
13 Reference voltage (+5V) Boost Pressure Sensor (BPS)
14 -
15 -
18 -
19 Battery power Fuel Pressure Regulator Valve
20 Sensor ground Camshaft Position Sensor (CMPS)
21 -
22 -
23 Sensor ground Boost Pressure Sensor (BPS)
24 -
25 -
26 -
27 Crankshaft Position Sensor (CKPS) [-] signal input Crankshaft Position Sensor (CKPS)
28 Reference voltage (+5V) Rail Pressure Sensor (RPS)
29 -
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30 -
31 -
32 -
33 Injector (Cylinder #3) [LOW] control output Injector (Cylinder #3)
34 Rail Pressure Regulator Valve control output Rail Pressure Regulator Valve
35 -
36 -
37 Reference frequency Mass Air Flow Sensor (MAFS)
38 -
39 -
40 Boost Pressure Sensor (BPS) signal input Boost Pressure Sensor (BPS)
41 Sensor ground Engine Coolant Temperature Sensor (ECTS)
42 Mass Air Flow Sensor (MAFS) signal input Mass Air Flow Sensor (MAFS)
43 Rail Pressure Sensor (RPS) signal input Rail Pressure Sensor (RPS)
44 Sensor ground Intake Air Temperature Sensor (IATS) #1
Variable Swirl Control Solenoid Valve control
45 Variable Swirl Control Solenoid Valve
output
48 -
49 Fuel Pressure Regulator Valve control output Fuel Pressure Regulator Valve
50 Camshaft Position Sensor (CMPS) signal input Camshaft Position Sensor (CMPS)
51 -
52 -
Intake Air Temperature Sensor (IATS) #2 signal Intake Air Temperature Sensor (IATS) #2 built in
53
input BPS
54 -
55 -
56 -
57 -
Engine Coolant Temperature Sensor (ECTS)
58 Engine Coolant Temperature Sensor (ECTS)
signal input
59 Electric EGR Control Valve control output Electric EGR Control Valve
60 -
CONNECTOR [C201-2]
Pin Description Connected to
1 Battery voltage supply after main relay Main Relay
2 Power ground Chassis Ground
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7 Cooling Fan Relay [HIGH] control output Cooling Fan Relay [HIGH]
8 Sensor ground Accelerator Position Sensor (APS) #2
9 Accelerator Position Sensor (APS) #1 signal input Accelerator Position Sensor (APS) #1
10 Sensor ground Fuel Temperature Sensor (FTS)
11 Fuel Temperature Sensor (FTS) signal input Fuel Temperature Sensor (FTS)
12 Sensor ground A/C Pressure Transducer
13 A/C Pressure Transducer signal input A/C Pressure Transducer
14 -
15 -
16 Ground Immobilizer Control Module
17 -
18 -
19 -
20 -
21 -
22 Reference voltage (+5V) A/C Pressure Transducer
23 -
24 -
25 Diagnostic K-Line Data Link Connector (DLC)
26 -
27 Fuel consumption signal output Trip computer
28 Ignition switch signal input Ignition Switch
29 VGT Control Solenoid Valve control output VGT Control Solenoid Valve
30 Sensor ground Accelerator Position Sensor (APS) #1
31 Accelerator Position Sensor (APS) #2 signal input Accelerator Position Sensor (APS) #2
32 -
33 -
34 -
35 -
36 -
37 -
38 Brake Switch "Lamp" signal input Brake Switch
39 -
40 Water Sensor siganl input Water Sensor in Fuel Filter
41 -
42 Blower Switch Signal input Blower Switch
43 -
44 -
45 Reference voltage (+5V) Accelerator Position Sensor (APS) #1
46 Reference voltage (+5V) Accelerator Position Sensor (APS) #2
47 Immobilizer Communication Line Immobilizer Control Module
48 Engine speed signal output Tachometer (Cluster)
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49 -
50 -
51 Lambda Sensor Heater control output Lambda Sensor
52 "Idle Up" signal input EPS control module
53 -
54 A/C Switch "ON" signal input A/C Switch
55 -
56 Thermo Switch A/C Switch
57 Gear Neutral Switch signal input (MT Only) Gear Neutral Switch
58 -
59 -
60 -
61 -
62 -
63 -
64 Lambda Sensor Voltage "NERNST" Lambda Sensor
65 Lambda Sensor Current Pump Lambda Sensor
66 -
67 -
68 Malfunction Indicator Lamp (MIL) control output Malfunction Indicator Lamp (MIL)
69 Glow Time Indicator Lamp control output Glow Time Indicator Lamp (Cluster)
70 A/C Compressor Relay control output A/C Compressor Relay
71 Cooling Fan Relay [LOW] control output Cooling Fan Relay
72 Main Relay control output Main Relay
73 -
74 -
75 Vehicle speed signal input Vehicle Speed Sensor (VSS)
76 -
77 -
78 -
79 Clutch Switch signal input Clutch Switch
80 Brake Switch "Redundant" signal input Brake Switch
81 -
82 -
83 CAN [LOW] Other Control Modules
84 CAN [HIGH] Other Control Modules
85 -
86 Lambda Sensor Virtual Ground Lambda Sensor
87 Lambda Sensor Current Adjust Lambda Sensor
88 -
Intake Air Temperature Sensor (IATS) #1 signal
89 Intake Air Temperature Sensor (IATS) #1 in MAFS
input
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90 Throttle Flap Control Solenoid Valve control output Throttle Flap Control Solenoid Valve
91 -
92 Immobilizer Lamp control output Immobilizer Lamp (Cluster)
93 Glow Relay control output Glow Relay
94 PTC Heater Relay control output PTC Heater Relay
3. ECM TERMINAL INPUT/OUTPUT SIGNAL

CONNECTOR [C201-1]
Pin Description Vehicle State Type Level Test Result
Injector (Cylinder #2) Battery Voltage ~ 80V 46.4V

1 Idle Pulse
[HIGH] control output 7.418Hz
2 -
3 -
4 Battery power Idle DC Battery Voltage 13.96V
5 -
6 -
7 Sensor shield Idle DC Max. 50mV -2.858mV
8 Sensor ground Idle DC Max. 50mV -2.702mV
9 -
10 -
11 -
Crankshaft Position Sensor Sine
12 Idle Vpeak_to_peak: Min.1.0V 52.8V
(CKPS) [+] signal input Wave
IG OFF Max. 0.5V -50mV
13 Reference voltage (+5V) DC
IG ON 4.9 ~ 5.1V 4.95V
14 -
15 -

16 Idle Pulse

17 Idle Pulse
18 -
IG OFF Max. 0.5 V 175mV
19 Battery power DC
IG ON Battery Voltage 12.57V
21 -
22 -
24 -
25 -
26 -
Crankshaft Position Sensor Sine
27 Idle Vpeak_to_peak: Min.1.0V 52.8V
(CKPS) [-] signal input Wave
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IG ON 4.9 ~ 5.1V 4.91V
29 -
30 -
31 -
32 -
Peak Current: 19 ~ 21 A
Peak Current:
Hold Current: 11~ 13 A
Injector (Cylinder #3) 19.7 A
33 Idle Pulse
[LOW] control output Hold Current:
13.4 A
Hi: Battery Voltage 14.78V

Lo: Max. 1.0V 60mV
Rail Pressure Regulator
34 Idle Pulse Frequency: 1kHz±2% 1.098KHz
Valve control output
Duty (+):
74.37%
35 -
36 -
Hi: Vcc 4.94V
37 Reference frequency Idle Pulse
Lo: Max. 1.0V 340mV
38 -
39 -
Boost Pressure Sensor
40 IG ON Analog 0.5 ~ 4.5V 1.602mV
(BPS) signal input
Mass Air Flow Sensor Hi: Vcc 4.95V

42 Idle Pulse
(MAFS) signal input Lo: Max. 1.0V 350mV
IG ON Max. 1.0V 512mV
Rail Pressure Sensor
43 Idle Analog 1.0 ~ 1.5 V 1.089V
(RPS) signal input
3000 RPM 1.5 ~ 3.0 V 1.886V
Variable Swirl Control Hi: Battery Voltage 14.94V
45 Solenoid Valve control Idle Pulse
output Lo: Max. 1.0V 60mV
Peak Current:
Injector (Cylinder #2) 19.8A
46 Idle Pulse
13.5A
Peak Current:
Injector (Cylinder #1) 19.6A
47 Idle Pulse
13.4A
48 -
Fuel Pressure Regulator
49 Idle Pulse Lo: Max. 1.0V 540mV
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49 Idle Pulse Lo: Max. 1.0V 540mV
Valve control output
203Hz
Hi: Vcc or Battery Voltage 4.95V
Idle Lo: Max. 1.0V -10mV
Camshaft Position Sensor 17.44Hz

50 Pulse
(CMPS) signal input Hi: Vcc or Battery Voltage 4.95V
3000rpm Lo: Max. 1.0V -10mV
52.33Hz
51 -
52 -
Intake Air Temperature
53 Sensor (IATS) #2 signal Idle Analog 0.5 ~ 4.5V 1.954V
input
54 -
55 -
56 -
57 -
Engine Coolant
58 Temperature Sensor Idle Analog 0.5 ~ 4.5V 804.6mV
(ECTS) signal input
Lo: Max. 1.0V -20mV
Electric EGR Control Valve
59 Idle Pulse 154.7Hz
control output
Duty(+):
91.79%
60 -
CONNECTOR [C201-2]
Pin Description Vehicle State Type Level Test Result
Battery voltage supply after IG OFF Max. 1.0 V 175mV

1 DC
main relay IG ON Battery Voltage 12.77V
2 Power ground Idle DC Max. 50mV
Battery voltage supply after IG OFF Max. 1.0 V -25mV

3 DC
Battery voltage supply after IG OFF Max. 1.0 V -25mV

5 DC
Cooling Fan Relay [HIGH] Relay OFF Battery Voltage 13.98V

7 DC
control output Relay ON Max. 1.0V -25mV
Accelerator Position Sensor C.T 0.3 ~ 0.9V 682.8mV

9 Analog
(APS) #1 signal input W.O.T 4.0 ~ 4.8V 4.029V
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Fuel Temperature Sensor
11 IG ON Analog 0.5 ~ 4.5V 2.311V
(FTS) signal input
A/C Pressure Transducer A/C OFF Max. 4.8V 1.327V

13 Analog
signal input A/C ON 2.426V
14 -
15 -
16 Ground Idle DC Max. 50mV -3.801mV
17 -
18 -
19 -
20 -
21 -
IG ON 4.9 ~ 5.1V 4.91V
23 -
24 -
Hi: Min. Battery
12.78V
When Voltage!80%
transmitting Lo: Max. Battery
140mV
Voltage!20%
25 Diagnostic K-Line Pulse
Hi: Min. Battery
12.78V
Voltage!70%
When receiving
Lo: Max. Battery
700mV
Voltage!30%
26 -
Hi: Battery Voltage or Vcc 3.435V
Fuel consumption signal
27 Idle Pulse Lo: Max. 0.5V -5mV
output
1.25Hz
IG OFF Max. 1.0 V -25mV
28 Ignition switch signal input DC
IG ON Battery Voltage 12.57V
Lo: Max. 0.5V 175mV
Idle
Duty (+):
VGT Control Solenoid 19.87%
29 Pulse
Valve control output Hi: Battery Voltage 14.97V
Lo: Max. 0.5V 175mV
3000rpm
Duty(+):
53.48%
Accelerator Position Sensor C.T 0.3 ~ 0.9V 333.8mV

31 Analog
(APS) #2 signal input W.O.T 1.5 ~ 3.0V 1.989V
32 -
33 -
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34 -
35 -
36 -
37 -
Brake Switch "Lamp" signal Release Max. 0.5V -20mV

38 DC
input Push Battery Voltage 12.06V
39 -
Full of Water Battery Voltage 11.26V
40 Water Sensor siganl input Analog
No Water Max. 1V -20mV
41 -
Blower OFF Battery Voltage 12.17V
42 Blower Switch Signal input DC
Blower ON Max. 2V 175mV
43 -
44 -
IG ON 4.9 ~ 5.1V 4.99V
IG ON 4.9 ~ 5.1V 4.99V
When Hi: Min. 8.5V 12.54V
Immobilizer Communication
47 communicating Pulse
Line Lo: Max. 3.5V 1.1V
after IG ON
48 Engine speed signal output Idle Pulse Lo: Max. 0.5V 140mV
Frequency: 50~60Hz 59.53Hz
49 -
50 -
Lambda Sensor Heater
51 Vehicle Run Pulse Lo: Max. 1.0V 220mV
control output
109.8Hz
SW OFF Hi: Vcc 4.99V
52 Idle Up signal input DC
SW ON Lo: Max. 1.0V 70mV
53 -
A/C Switch "ON" signal A/C SW OFF Max. 1.0V 140mV

54 DC
input A/C SW ON Battery Voltage 14.06V
55 -
A/C OFF Max. 0.5V -20mV
56 Thermo Switch signal input DC
A/C ON Battery Voltage 13.1V
SW OFF (1st) Battery Voltage 12.54V
Gear Neutral Switch signal
57 SW ON DC
input (MT ONly) Max. 0.5V -20mV
(neutral)
58 -
59 -
60 -
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61 -
62 -
63 -
Normal: 450 ± 50mV 452mV
Lambda Sensor Voltage Rich: Max. Normal +
64 Engine Running Analog 452.9V
"NERNST" 150mV
Lean: Min. Normal - 150mV 351mV
Normal: 0 ± 500mV 608mV
Lambda Sensor Current
65 Engine Running Analog Rich: Min. Normal - 1.5V 447.7mV
Pump
Lean: Max. Normal + 1.5V 816.4mV
66 -
67 -
Malfunction Indicator Lamp Lamp OFF Battery Voltage 12.3V

68 DC
(MIL) control output Lamp ON Max. 1.0V -20mV
Glow Time Indicator Lamp Glow OFF Battery Voltage 12.06V

69 DC
control output Glow ON Max. 1.0V -20mV
A/C Compressor Relay A/Con OFF Battery Voltage 13.9V

70 DC
control output A/Con ON Max. 1.0V 60mV
Cooling Fan Relay [LOW] Relay OFF Battery Voltage 13.97V

71 DC
control output Relay ON Max. 1.0V 175mV
Relay OFF Battery Voltage 12.94V
72 Main Relay control output DC
Relay ON Max. 1.0V 940mV
73 -
74 -
Hi: Min. 5.0V 13.18V
Lo: Max. 1.0V 60mV
75 Vehicle speed signal input Vehicle Run Pulse
12.52Hz at
20kph
76 -
77 -
78 -
Release Max. 0.5V -20mV
79 Clutch Switch signal input DC
Push Battery Voltage 13.74V
Brake Switch "Redundant" Release Battery Voltage 14.14V

80 DC
signal input Push Max. 0.5V -20mV
81 -
82 -
Recessive 2.0 ~ 3.0 V
83 CAN [LOW] Pulse
Dominant 0.5 ~ 2.25 V
Recessive 2.0 ~ 3.0 V
84 CAN [HIGH] Pulse
Dominant 2.75 ~ 4.5 V
85 -
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Lambda Sensor Virtual
86 Engine Running Analog 2.4 ~ 2.6V 2.462V
Ground
Lambda Sensor Current |Current Pump - Current
87 Engine Running Analog 86.86mV
Adjust Adjust| < 0.2V
88 -
Intake Air Temperature
89 Sensor (IATS) #1 signal Idle Analog 0.5 ~ 4.5V 2.129V
input
Lo: Max. 1V 60mV
IG OFF
Duty (+):
Throttle Flap Control 9.308%
90 Solenoid Valve control Pulse
output Hi: Battery Voltage 14.22V
Lo: Max. 1V 60mV
Idle
Duty (+):
94.61%
91 -
Immobilizer Lamp control Lamp OFF Battery Voltage 12.54V

92 DC
output Lamp ON Max. 1.0V 65mV
Relay OFF Battery Voltage 12.46V
93 Glow Relay control output DC
Relay ON Max. 1.0V 60mV
PTC Heater Relay control Relay OFF Battery Voltage 13.18V

94 DC
output Relay ON Max. 1.0V -20mV
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2010 > D 1.1 TCI-U >
CIRCUIT DIAGRAM
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2010 > D 1.1 TCI-U >
ECM PROBLEM INSPECTION PROCEDURE

1. TEST ECM GROUND CIRCUIT: Measure resistance between ECM and chassis ground using the backside of ECM
harness connector as ECM side check point. If the problem is found, repair it.
2. TEST ECM CONNECTOR: Disconnect the ECM connector and visually check the ground terminals on ECM side
and harness side for bent pins or poor contact contact pressure. If the problem is found, repair it.
3. If problem is not found in Step 1 and 2, the ECM could be faulty. If so, replace the ECM with a new one, and then
check the vehicle again. If the vehicle operates normally then the problem was likely with the ECM.
4. RE-TEST THE ORIGINAL ECM : Install the original ECM (may be broken) into a known-good vehicle and check
the vehicle. If the problem occurs again, replace the original ECM with a new one. If problem does not occur, this
is intermittent problem (Refer to INTERMITTENT PROBLEM PROCEDURE in BASIC INSPECTION PROCEDURE)
REPLACEMENT (ECM)
• After replacing ECM, MUST input the injector specific data (7 digits) of each cylinder into a new ECM with
scan tool.
• In the case of the vehicle equipped with immobilizer, perform "KEY TEACHING" procedure together (Refer to
"IMMOBILIZER" in BE group).
1. Turn ignition switch OFF.

2. Remove the battery negative (-) cable from the battery.
3. Disconnect the ECM connector (A) and unfasten the mounting bolts (B) under the instrument panel (RH side).
4. Install a new ECM according to the reverse order of steps 1, 2, and 3.
ECM mounting bolts : 0.9 ~ 1.4kgf·m (8.8 ~ 13.7 N·m, 6.5 ~ 10.1lbf·ft)
5. Perform "Injector Specific Input" procedure (Refer to "INJECTOR" in this group).

6. Perform "Key Teaching" procedure (Refer to "IMMOBILIZER" in BE group).
7. Proceed "INJECTOR CORRECTION" procedure.
(1) Select "ENGINE CONTROL".
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(2) Select "AUTO SELECTION MODE" or "MANUAL SELECTION MODE".
(3) Select "1.1L VGT DIESEL" in case of "MANUAL SELECTION MODE".
(4) Select "INJECTOR CORRECTION".
(5) Press "ENTER" key.
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(6) Input the injector data (7 digit) written on the top of each inejctor with function keys ([F1] ~ [F6]) and number
keys.
When "WRITING FAIL" is displayed on the scan tool, input injector data (7 digits) of each cylinder into a
new ECM again as prior procedure.
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Fuel System
Engine Control System - Mass Air Flow

Sensor (MAFS)
Fuel System
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2010 > D 1.1 TCI-U >
INSPECTION
MAFS uses a hot-film type sensing element to measure the mass of intake air entering the engine, and send the
signal to ECM.
A large amount of intake air represents acceleration or high load conditions while a small amount of intake air
represents deceleration or idle.
The ECM uses this information to control the EGR solenoid valve and correct the fuel amount.
SPECIFICATION
CIRCUIT DIAGRAM
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SIGNAL WAVEFORM
COMPONENT INSPECTION
1. Check the MAFS visually.
A. Mounting direction correct.
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B. Any contamination, corrosion or damage on connector.
C. Air cleaner's clogging or wet.
D. MAFS cylinder's deforming or blocking by any foreign material.
2. Check any leakage on intake system and intercooler system.
REPLACEMENT
After replacing the Mass Air Flow Sensor (MAFS), MUST perform the "COMPONENT CHANGE ROUTINE"
procedure. Otherwise trouble related with engine performance or emission control may occur until ECM learning
about the component is over.

2. Connect a scan tool to Data Link Connector (DLC).
3. Turn ignition switch ON.
4. Select "ENGINE (DIESEL)".
5. Select "COMPONET CHANGE ROUTINE".
6. Select "AIR FLOW SENSOR CHANGE".
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7. Confirm the message, and then press "ENTER" key.
8. Confirm the "Complete" message, and then turn ignition switch OFF.
9. Wait for more than 10 seconds, and then turn ignition switch ON.
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Fuel System
Engine Control System - Intake Air

Temperature Sensor (IATS)
Fuel System
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2010 > D 1.1 TCI-U >
INSPECTION
Intake Air Temperature Sensor (IATS) uses a Negative Temperature Characteristics (NTC) thermistor and senses
intake air temperature. Two intake air temperature sensors are installed in this engine.
IATS #1 in Mass Air Flow Sensor (MAFS) and IATS #2 in Boost Pressure Sensor (BPS) are located in front of and
behind turbocharger respectively. IATS #1 senses air temperature entering turbo-charger and the other (IATS #2)
does air temperature coming out from the turbo-charger.
Comparing these air temperature values from both sensors, more accurate sensing of intake air temperature is
possible. ECM uses these air temperature signals to perform EGR control correction and fuel injection quantity
correction.
SPECIFICATION
CIRCUIT DIAGRAM
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SIGNAL WAVEFORM
2. Disconnect the MAFS (for IATS #1) or BPS (for IATS #2) connector.
3. Measure resistance between IATS signal terminal and sensor ground terminal.
4. Check that the resistance is within the specification.
Specification: Refer to "SPECIFICATION".
REPLACEMENT
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After replacing the Intake Air Temperature Sensor (IATS) #1, MUST perform the "COMPONENT CHANGE
ROUTINE" procedure. Otherwise trouble related with engine performance or emission control may occur until
ECM learning about the component is over.

6. Select "AIR FLOW SENSOR CHANGE".
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Fuel System
Engine Control System - Engine Coolant

Temperature Sensor (ECTS)
Fuel System
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2010 > D 1.1 TCI-U >
INSPECTION
Engine Coolant Temperature Sensor (ECTS) is located in the engine coolant passage of the cylinder head for
detecting the engine coolant temperature. The ECTS uses a thermistor whose resistance changes with the
temperature. The electrical resistance of the ECTS decreases as the temperature increases, and increases as the
temperature decreases. The reference 5V in the ECM is supplied to the ECTS via a resistor in the ECM.
That is, the resistor in the ECM and the thermistor in the ECTS are connected in series. When the resistance value of
the thermistor in the ECTS changes according to the engine coolant temperature, the output voltage also changes.
During cold engine operation the ECM increases the fuel injection duration and controls the ignition timing using the
information of engine coolant temperature to avoid engine stalling and improve drivability.
SPECIFICATION
-40(-40) 48.14
-20(-4) 14.13 ~ 16.83
0(32) 5.79
20(68) 2.31 ~ 2.59
40(104) 1.15
60(140) 0.59
80(176) 0.32
CIRCUIT DIAGRAM
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2. Disconnect the engine coolant temperature sensor connector.
3. Remove the sensor.
4. After immersing the thermistor of the sensor into engine coolant, measure resistance between ECTS signal terminal
and ground terminal.
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Fuel System
Engine Control System - Accelerator Position

Sensor (APS)
Fuel System
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2010 > D 1.1 TCI-U >
INSPECTION
On electronic injection systems, there is no longer a load lever that mechanically controls the fuelling. The flow is
caculated by the ECM depending on a number of parameters, including pedal position, which is measured using a
potentiometer. The pedal sensor has two potentio-meters whoses slides are mechanically solid. The two
potentiometers are supplied from distinct and different power sources so there is built in redundancy of information
giving reliable driver's request information. A voltage is generated across the potentiometer in the acceleration position
sensor as a function of the accelerator-pedal setting. Using a peogrammed characteristic curve, the pedal's position is
then calculated from this voltage.
SPECIFICATION
Output Voltage(V)
Test Condition
APS 1 APS 2
Idle 0.7 ~ 0.8 0.275 ~ 0.475
Fully depressed 3.8 ~ 4.4 1.75 ~ 2.35
Specification
Items
APS 1 APS 2
Potentiometer Resistance (k!) 0.7 ~ 1.3 1.4 ~ 2.6
CIRCUIT DIAGRAM
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SIGNAL WAVEFORM
2. Disconnect the accelerator position sensor connector.
3. Measure resistance between voltage supply terminal and ground terminal of APS1.
4. Measure resistance between voltage supply terminal and ground terminal of APS2.
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Fuel System
Engine Control System - Heated Oxygen

Sensor (HO2S)
Fuel System
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2010 > D 1.1 TCI-U >
INSPECTION
Lambda Sensor is installed on exhaust manifold and is a linear oxygen sensor. It senses oxygen density of exhaust
gas in order to control EGR acculately through fuel correction and also limits smoke which is generated by reach air-
fuel mixture at high engine load condition. ECM controls pumping current in order to fit !-value from linear lambda
sensor to 1.0.
Lean air-fuel mixture(1.0 < ! < 1.1): ECM supplies pumping current to lambda sensor (+pumping current) and activates
it for lambda sensor to have the characteristic at ! =1.0 (0.0 pumping current). With the value of pumping current
supplied to lambda sensor, ECM detects lambda density of exhaust gas.
Rich air-fuel mixture(0.9 < ! < 1.0): ECM takes away pumping current from lambda sensor (-pumping current) and
deactivates it for lambda sensor to have the characteristic at ! =1.0 (0.0 pumping current). With the value of pumping
current taken away from lambda sensor, ECM detects lambda density of exhaust gas.
This performance is the most active and fast at normal operating temperature (450°C ~ 600°C) thus, in order to reach
normal operating temp. and last at that temperature, a heater (heating coil) is integrated with lambda sensor. The
heater coil is controlled by ECM as Pulse With Modulator (PWM). The resistance of heater coil is low when coil is cold
thus, current through it increases while resistance is high when coil is hot thus, current decreases. With this principle,
temperature of lambda sensor is measured and lambda sensor heater operation varies based on the data.
SPECIFICATION
CIRCUIT DIAGRAM
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SIGNAL WAVEFORM
REPLACEMENT
After replacing the Lambda Sensor, MUST perform the "COMPONENT CHANGE ROUTINE" procedure.
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Otherwise trouble related with engine performance or emission control may occur until ECM learning about the
component is over.

6. Select "LAMBDA SENSOR CHANGE".
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Fuel System
Engine Control System - Crankshaft Position

Sensor (CPKS)
Fuel System
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2010 > D 1.1 TCI-U >
INSPECTION
Piston position on combustion chamber is the substantial to define the starting of injection timing. All engine pistons
are connected to crankshaft by connecting rod. Sensor on crankshaft can supply the informations concerning all piston
positions, revolution speed is defined by revolution perminute of crankshaft. Prior input variable is determined at ECM
by using signal induced from crankshaft position sensor.
SPECIFICATION
Items Specification
Coil Resistance (!) 774 ~ 946! [20°C(68°F)]
CIRCUIT DIAGRAM
SIGNAL WAVEFORM
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1. Check signal waveform of CMPS and CKPS using a scan tool.
Specification: Refer ro "SIGNAL WAVEFORM"
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Fuel System
Engine Control System - Camshaft Position

Sensor (CMKS)
Fuel System
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2010 > D 1.1 TCI-U >
INSPECTION
Camshaft Position Sensor (CMPS) is a hall sensor and detects the camshaft position by using a hall element. It is
related with Crankshaft Position Sensor (CKPS) and detects the piston position of the each cylinder which the CKPS
can't detect. The one CMPS are installed on engine head cover and uses a target wheel installed on the camshaft.
This sensor has a hall-effect IC which output voltage changes when magnetic field is made on the IC with current
flow. So the sequential injection of the 3 cylinders is impossible without CMPS signal.
SPECIFICATION
Level Output Pulse (V)

High 12V
Low 0V
Items Specification
Air Gap 1.5 ± 0.1 mm
CIRCUIT DIAGRAM
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SIGNAL WAVEFORM
1. Check signal waveform of CMPS and CKPS using a scan tool.
Specification: Refer ro "SIGNAL WAVEFORM"
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Fuel System
Engine Control System - Injector
Fuel System
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2010 > D 1.1 TCI-U >
DESCRIPTION
The start of injection and the injected fuel quantity are adjusted by electrically triggered injectors. These injectors
supersede the nozzle-and-holder assembly (nozzle and nozzle-holder). Similar to the already existing nozzle-holder
assemblies in direct-injection (DI) diesel engines, clamps are preferably used for installing the injectors in the cylinder
head. This means that the Common Rail injectors can be installed in already existing DI diesel engines without major
modifications to the cylinder head.
COMPONENTS
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2010 > D 1.1 TCI-U >
SPECIFICATION
Items Specification
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2010 > D 1.1 TCI-U >
CIRCUIT DIAGRAM
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2010 > D 1.1 TCI-U >
REMOVAL
• Common Rail Fuel Injection System operates with extremely high pressure (approximately 1,600bar), so never
perform any work on injection system with engine running or within 30 seconds after the engine stops.
• Keep cleanly the parts and the working area.
• Pay attention to a foreign substance.
• Just before installing injector, tube or hose, remove the protect-cap attached on them.
• Do not remove injector except for special case.
• When installing Injector
- Wash the contact area of the injector and replace the O-ring with a new one.
- Spread oil on the injector O-ring.
- To protect damage caused by shock, vertically insert the injector into the cylinder head.
• When installing High Pressure Fuel Pipe
- Do not use again the used high pressure fuel pipe.
- Install the flange nut correctly.
1. Turn ignition switch OFF and disconnect the negative (-) battery cable.
2. Disconnect the injector connector (A).
3. After removing the clip (B), disconnect the retun hose (C) from the injectors.
4. Disconnect the high pressure fuel pipe (D) connecting the injectors with the common rail.
5. Unscrew the clamp tightening bolt (E) and pull the injector upward.
If the injector adheres to the cylinder head, use the special Service Tool (SST No. : 09351-4A300)
INSTALLATION
1. Installation is reverse of removal.
When installing the injector, MUST REPLACE the O-ring (A) and apply a grease to that.
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When installing the high pressure fuel pipe, apply the specified tightening torques with the special service tool
(Refer to below table).
Item Dimension SST No.

Flange Nut (Injector Side) 14 mm (0.551 in) 09314-27110
Flange Nut (Common Rail Side) 17 mm (0.669 in) 09314-27120
· Injector clamp installation bolt: 28.4 ~ 30.4 N·m (2.9 ~ 3.1 kgf·m, 21.0 ~ 22.4 lbf·ft)
· High pressure fuel pipe installation nut: 24.5 ~ 28.4 N·m (2.5 ~ 2.9 kgf·m, 18.1 ~ 20.1 lbf·ft)
REPLACEMENT
After replacing injector, MUST input the injector specific data (7 digits) of each cylinder into ECM with scan tool.
1. Remove the injector (Refer to "REMOVAL" procedure).

2. Install the injector (Refer to "INSTALLATION" procedure).
3. Perform "Injetor correction" procedure (Refer to "INJECTOR CORRETION" procedure).
INJECTOR CORRECTION
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After replacing injector, MUST input the injector specific data (7 digit) of each cylinder into ECM with scan tool.

4. Select "ENGINE CONTROL".
5. Select "AUTO SELECTION MODE" or "MANUAL SELECTION MODE".
6. Select "1.1L VGT DIESEL" in case of "MANUAL SELECTION MODE".
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7. Select "INJECTOR CORRECTION".
8. Press "ENTER" key.
9. Input the injector data (7 digit) written on the top of each inejctor with function keys ([F1] ~ [F6]) and number keys.
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When "WRITING FAIL" is displayed on the scan tool, input injector data (7 digits) of each cylinder into a new
ECM again as prior procedure.
INSPECTION
USING HI-SCAN(PRO)
Test mode
• COMPRESSION TEST
• IDLE SPEED COMPARISON
• INJECT QUANTITY COMPARISON
TEST PROCEDURE
1. Connect Scan tool to the DLC and select "Vehicle" and "Engine Test Function".
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2. Information for ECM version is displayed as below.
3. After pressing "[ENTER]" select "COMPRESSION TEST" mode and press "[ENTER]".
4. Set the test condition described as below screen and then, crank engine. When engine stop message being
appeared, stop cranking.
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5. Press "ANAL" and the test result is appeared.
During cranking engine does not start.
6. Press "AVG" and the data average of each cylinder is appeared.

Press "HELP" and description of the data is appeared.
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7. After pressing "ESC", select "IDLE SPEED COMPARISON" and press "[ENTER]".
8. Set the test condition described as below screen and press "[ENTER]".
9. The rpm data of each cylinder is appeared.
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10. Press "AVG" and teh data average of each cylinder is appeared.
Press "HELP" and description of the data is appeared.
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11. After pressing "ESC", select "INJECT QUANTITY COMPARISON" and press "[ENTER]".
12. Set the test condition described as below screen and press "[ENTER]".
13. The data of each cylinder about RPM and compensating injection quantity is appeared.
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14. Press "HELP" and description of the data is displayed as below.
15. Replace the default injector, and then repeat previous test modes to check if the injector is normal.
2. Disconnect the injector connector.
3. Measure resistance between terminal 1 and 2.
Specification : 0.215 ~ 0.295! at 20°C(68°F)
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Fuel System
Engine Control System - Rail Pressure

Sensor (RPS)
Fuel System
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2010 > D 1.1 TCI-U >
INSPECTION
Rail Pressure Sensor (RPS) is installed at the end of the common rail and measures the instantaneous fuel pressure
in the common rail by using its diaphragm. Its sensing element (semiconductor device) mounted on the diaphragm
converts the fuel pressure to an electric signal.
SPECIFICATION
Test Condition Rail pressure (bar) Output Voltage (V)
Idle 220 ~ 320 Below 1.7
Fully depressed 1,800 Approx. 4.5
CIRCUIT DIAGRAM
SIGNAL WAVEFORM
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REPLACEMENT
After replacing the Rail Pressure Sensor (RPS), MUST perform the "COMPONENT CHANGE ROUTINE"
procedure. Otherwise trouble related with engine performance or emission control may occur until ECM learning
about the component is over.

6. Select "RAIL PRESSURE SENSOR CHANGE".
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Fuel System
Engine Control System - Boost Pressure

Sensor (BPS)
Fuel System
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2010 > D 1.1 TCI-U >
INSPECTION
Boost pressure sensor (BPS) is installed on surge tank to measure the absolute intake manifold pressure. BPS input
voltage is changed in proportion with absolute pressure in manifold. This information is used to control Variable
Geometery Turbocharger (VGT) by ECM.
SPECIFICATION
Pressure (kPa) Output Voltage (V)
32.5 0.5
70 1.02 ~ 1.17
140 2.13 ~ 2.28
210 3.25 ~ 3.40
270 4.20 ~ 4.35
284 4.5
CIRCUIT DIAGRAM
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SIGNAL WAVEFORAM
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Fuel System
Engine Control System - Rail Pressure

Regulator Valve
Fuel System
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2010 > D 1.1 TCI-U >
INSPECTION
The Fuel Pressure Regulator Valve and the Rail Pressure Regulator Valve are installed on high pressure pump and
common rail respectively. These valves control fuel inlet (feed) from fuel tank via fuel filter and outlet (return) to fuel
tank of high pressure fuel circuit.
This system is called "Dual Fuel Pressure Control System" and can precisely and quickly control the fuel pressure in
accordance with various engine conditions by controlling the fuel inlet and outlet simultaneously.
SPECIFICATION
Items Specification
CIRCUIT DIAGRAM
SIGNAL WAVEFORM
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2. Disconnect the rail pressure regulator valve connector.
3. Measure resistance between terminal 1 and 2 of the valve.
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Fuel System
Engine Control System - VGT Control

Solenoid Valve
Fuel System
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2010 > D 1.1 TCI-U >
INSPECTION
Variable Geometry Turbo-charger (VGT) is used to charge additional air into combustion chamber for improvement of
combustion efficiency.
ECM controls the VGT with controlling duty of the VGT control solenoid valve according to engine load.
SPECIFICATION
Items Specification
CIRCUIT DIAGRAM
SIGNAL WAVEFORM
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2. Disconnect the VGT control solenoid valve connector.
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Fuel System
Engine Control System - Throttle Flap

Control Solenoid Valve
Fuel System
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2010 > D 1.1 TCI-U >
INSPECTION
The Throttle Flap Control Solenoid Valve controls the throttle flap vacuum valve which activates the throttle flap
installed inside the throttle body. This throttle flap control system functions "Anti-judder function" and "Intake air control
for EGR".
Ⅰ. Anti-judder function: When engine is shut off, the ECM can prevent intake air from entering to intake manifold by
fully closing the throttle valve for 1.5 seconds (95% < Duty < 97%) to reduce engine vibration.
Ⅱ. Intake air control for EGR: When exhaust gas pressure is equal to or lower than intake air pressure (for example,
when low engine speed), the exhaust gas would not enter to the intake manifold. At this time, the ECM partially closes
the throttle valve (5% < Duty < 94%) to reduce the intake air quantity. The intake air pressure thus is lower than the
exhaust gas pressure.
SPECIFICATION
Items Specification
Coil Resistance (!) 28.3 ~ 31.1! [20°C (68°F)]
CIRCUIT DIAGRAM
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SIGNAL WAVEFORM
2. Disconnect the throttle flap control solenoid valve connector.
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Fuel System
Engine Control System - Variable Swirl

Actuator
Fuel System
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2010 > D 1.1 TCI-U >
DESCRIPTION
The Variable Swirl Control Solenoid Valve controls the vacuum valve which activates the swirl valve inside the intake
manifold.
At idle or below 3000rpm, the swirl valve is closed. This swirl effect increases air flow rate.
Low and Middle Load High Load

Engine speed Below 3000rpm Above 3000rpm
Valve operation CLOSE OPEN
Description
illustration
Fail-safe Fully opened
SPECIFICATION
Items Specification
Coil Resistance (!) 28.3 ~ 31.1! [20°C (68°F)]
CIRCUIT DIAGRAM
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SIGNAL WAVEFORM
2. Disconnect the variable swirl control solenoid valve connector.
3. Check that swirl valve is stuck by foreign material.
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Fuel System
Engine Control System - Fuel Temperature

Sensor (FTS)
Fuel System
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2010 > D 1.1 TCI-U >
INSPECTION
Fuel Temperature Sensor(FTS) is installed in fuel supplying line and senses the termperature of fuel supplied to high
pressure pump. Fuel temperature is limmited to protect fuel such as high pressure pump and injectors from damages
due to rapid deterioration by vapor-lock which can occur at high temperature or destruction of oil membrance.
SPECIFICATION
CIRCUIT DIAGRAM
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SIGNAL WAVEFORM
2. Disconnect the fuel temperature sensor connector.
3. Measure resistance between sensor signal terminal and ground terminal.
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Fuel System
Engine Control System - EGR (Exhaust Gas

Recirculation) Valve
Fuel System
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2010 > D 1.1 TCI-U >
INSPECTION
The Exhaust Gas Recirculation (EGR) system is used to add the exhaust gas to intake air in order to reduce an
excess of air and the temperature in the combustion chamber. The Electric EGR valve is controlled by ECM’s duty
control signal depending on engine load and the need of intake air and is operated by solenoid valve not vacuum
valve.
SPECIFICATION
Items Specification
CIRCUIT DIAGRAM
SIGNAL WAVEFORM
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2. Disconnect the electric EGR control valve connector.
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Fuel System
Engine Control System - Fuel Pressure

Control Valve
Fuel System
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2010 > D 1.1 TCI-U >
INSPECTION
The Fuel Pressure Regulator Valve and the Rail Pressure Regulator Valve are installed on high pressure pump and
common rail respectively. These valves control fuel inlet (feed) from fuel tank via fuel filter and outlet (return) to fuel
tank of high pressure fuel circuit.
This system is called "Dual Fuel Pressure Control System" and can precisely and quickly control the fuel pressure in
accordance with various engine conditions by controlling the fuel inlet and outlet simultaneously.
SPECIFICATION
Items Specification
CIRCUIT DIAGRAM
SIGNAL WAVEFORM
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2. Disconnect the fuel pressure regulator valve connector.
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Fuel System
Engine Control System - Water Sensor
Fuel System
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2010 > D 1.1 TCI-U >
INSPECTION
Water Sensor is installed on bottom end of fuel filter and detects presence of water in fuel. When the water level
reaches the lower level of the upper electrode, the "WATER" lamp in cluster should flash. If the water level decreases
below the lower electrode, the lamp should turn off.
Without presence of water, the lamp should flash for 2 seconds and turn off afterward in order that this system
has normal condition.
SPECIFICATION
Items Specification
Warning Level (cc) 40 ~ 60
CIRCUIT DIAGRAM
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Fuel System
Fuel Delivery System
Fuel System
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2010 > D 1.1 TCI-U >
COMPONENT LOCATION
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2010 > D 1.1 TCI-U >
COMMON RAIL FUEL INJECTION SYSTEM (CRDI)
! LOW PRESSURE FUEL CIRCUIT

The low pressure fuel pump is either an electric fuel pump with pre-filter, or a gear-type fuel pump. The pump draws
the fuel from the fuel tank and continually delivers the required quantity of fuel in the direction of the high pressure fuel
pump (via fuel filter).
The fuel sender is located into the fuel tank and measures amount of fuel contained in fuel tank.
The fuel filter is located in between the low pressure fuel pump and the high pressure fuel pump and filters the fuel
delivered from the fuel tank.
! HIGH PRESSURE FUEL CIRCUIT

The high pressure fuel pump compresses fuel up to 1,600 bar and delivers the compressed fuel to the common rail.
The common rail is connected with the high pressure fuel pump and the injectors by the high pressure fuel pipes. This
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rail stores the fuel compressed in the high pressure fuel pump. The ECM controls the fuel pressure of the common rail
by using the rail pressure sensor and the rail pressure regulator valve installed on the common rail.
The injector injects the high pressure fuel stored in the common rail into the cylinder by the ECM control signal.
The high pressure fuel pipe is a channel in high pressure fuel circuit consisting of the high pressure fuel pump,
common rails, and injectors. It is a steel tube which can withstand high frequency generated when the fuel pressure
reaches the maximum pressure or fuel injection stops.
The differences in length between the common rail and the individual injectors are compensated for by using slight or
pronounced bends in the individual lengths of tubing. Nevertheless, the injection lines should be kept as short as
possible.
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2010 > D 1.1 TCI-U >
BLEEDING AIR IN LOW PRESSURE FUEL CIRCUIT

1. After disconnecting the fuel outlet quick-connector (A), press the priming pump (B) several times until fuel comes
out of the fuel outlet.
2. Connect the fuel outlet quick-connector (A).
After removing or replacing the part below, bleed air in low pressure fuel circuit.
- Fuel Tank
- Fuel Sender
- Fuel Filter
- High Pressure Fuel Pump
- Low Pressure Fuel Lines
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Fuel System
Fuel Delivery System - Fuel Tank
Fuel System
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2010 > D 1.1 TCI-U >
REMOVAL
When lifting up or downing the vehicle, be sure to place blocks between the vehicle and lifter to prevent fuel tank
from being damaged.
2. Turn over the rear seat.
3. Open the service cover (A).
4. Disconnect the fuel sender connector (A), the fuel feed tube quick-connector (B) and the return tube quick -
connector (C).
5. Lift the vehicle and remove the mufflers passing under the fuel tank (Refer to "Intake and Exhaust system" in EM
group).
6. Disconnect the fuel filler hose (A), the fuel leveling hose (B).
7. Unfasten the torsion axle assembly mounting bolts (A) to make working space.
8. Unfasten the torsion axle assembly mounting bolts (A) to make working space.
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Support the torsion axle assembly with a jack in order not to seperate it completely.
9. Unscrew 4 fuel tank mounting nuts (A).
10. Remove the fuel tank from the vehicle with setting down the jack.
INSTALLATION
Fuel tank mounting nuts: 39.2 ~ 54.0 N·m (4.0 ~ 5.5 kgf·m, 28.9 ~ 39.8 lbf·ft)
After removing or replacing the part below, bleed air in low pressure fuel circuit (Refer to "BLEEDING AIR IN
LOW PRESSURE FUEL CIRCUIT" in this group).
- Fuel Tank
- Fuel Sender
- Fuel Filter
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Fuel System
Fuel Delivery System - Fuel Filter
Fuel System
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2010 > D 1.1 TCI-U >
COMPONENTS
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2010 > D 1.1 TCI-U >
REPLACEMENT
1. Turn ignition switch OFF position.
2. Disconnect the negative (-) battery cable.
3. Remove the windshield wiper assembly.
4. Remove the cowl top cover.
5. Disconnect the intake hose.
6. Disconnect the thermoswitch connector (A), the water sensor connector (B) and the heater connector (C).
7. Disconnet the fuel outlet quick-connector (A) connected with high pressure fuel pump and the fuel inlet quick-
connector (B) connected with the fuel tank.
Cover the hose connection with the shop towel to prevent splashing of fuel caused by residual pressure in the
fuel line.
8. Unscrew two mounting nuts (C) and remove the fuel filter assembly (D).
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9. Remove the water sensor (A).
10. After removing the fuel filter (A) from the fuel filter assembly, replace it with a new one, and then install the fuel
filter assembly in accordance with reverse of above steps.
When replacing the fuel filter, must replace the O-ring.
11. Bleed air in low pressure fuel circuit (Refer to "BLEEDING AIR IN LOW PRESSURE FUEL CIRCUIT").
12. Start the engine and check that there is any leak on the low pressure fuel circuit including the fuel filter.
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Fuel System
Engine Control System - Accelerator Pedal
Fuel System
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2010 > D 1.1 TCI-U >
REMOVAL
2. Disconnect the accelerator pedal position sensor connector (A).
3. Remove the accelerator pedal assembly from the vehicle after unscrewing the mounting bolts (B).
INSTALLATION
Accelerator Pedal installation bolts: 7.8 ~ 11.8 N·m (0.8 ~ 1.2 kgf·m, 5.8 ~ 8.7 lbf·ft)
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Fuel System
Engine Control System - Common Rail
Fuel System
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2010 > D 1.1 TCI-U >
DESCRIPTION
In order to comply with the wide variety of engine installation conditions, the common rail with its flow limiters and the
provistions for attaching rail pressure sensor, fuel pressure control valve, and pressure limiter valve is available in a
number of different designs.
The available common rail volume is permanently filled with pressurized fuel. The compressibility of the fuel resulting
from the high pressure is utilized to achieve the accumulator effect. When fuel leaves the rail for injection, the pressure
variations resulting from the pulsating fuel supply from the high-pressure pump are compensated for.
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2010 > D 1.1 TCI-U >
REMOVAL
1. Turn ignition switch to OFF position.

2. Disconnect the negative battery (-) terminal and wait for about 30 seconds.
3. Disconnect the rail pressure sensor connector (A).
4. Disconnect the rail pressure regulator valve connector (B).
5. Remove the high pressure pipe (A) connecting injectors and the common rail.
6. Remove the high pressure pipe (B) connecting the high pressure fuel pump and and the common rail.
7. Disconnect the return line (C) from the common rail.
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8. Remove the common rail by unscrewing two mounting bolts (D).
INSTALLATION
1. Install the common rail according to the reverse order of "REMOVAL" procedure.
When installing the high pressure pipe, apply the specified tightening torques to the flange nuts of the
injectors, the high pressure pipe, and the common rail side with SST (Refer to below table).

Flange Nut (Injector Side)
14 mm (0.551 in) 09314-27110
Flange Nut (HP Pump Side)
· Common rail installation bolts: 14.7 ~ 21.6 N·m (1.5 ~ 2.2 kgf·m, 10.9 ~ 15.9 lbf·ft)
· High pressure pipe flange nuts (Injectors ! Common Rail):
24.5 ~ 28.4 N·m (2.5 ~ 2.9 kgf·m, 18.1 ~ 20.1 lbf·ft)
· High pressure pipe flange nuts (Common Rail ! HP Pump):
24.5 ~ 28.4 N·m (2.5 ~ 2.9 kgf·m, 18.1 ~ 20.1 lbf·ft)
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Fuel System
Fuel Delivery System - High Pressure Pump
Fuel System
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2010 > D 1.1 TCI-U >
DESCRIPTION
The high-pressure pump is the interface between the low pressure and the high-pressure stages. Under all operating
conditions, it is responsible for providing adequate high-pressure fuel through out the vehicle's complete service life.
This also includes the provision of extra as needed for rapid starting and for rapid build-up of pressure in the rail. The
high pressure pump continually generates the system pressure as needed in the high-pressure accumulator (common
rail). This means therefore, that in contrast to conventional systems, the fuel does not have to be specially
compressed for each individual injection process.
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2010 > D 1.1 TCI-U >
REMOVAL
1. Turn ignition switch OFF position.

2. Disconnect the negative battery (-) terminal and wait for about 30 seconds.
3. Remove the intake hose and throttle body. (Refer to the group "EM" in this Shop Manual)
4. Remove the high pressure pipe (A) connecting high pressure fuel pump and common rail after removing the
function block (B).
5. Remove the oil gage.

6. Remove the intake manifold. (Refer to the group "EM" in this Shop Manual)
7. Disconnect the fuel pressure regulator connector (A) and fuel temperature sensor connector (B).
8. Disconnect the return hose (A) and the (B) hose connecting to the fuel filter.
9. Unscrew the three high pressure mounting bolts (C).
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10. Remove the drive belt.(Refer to the group "EM" in this Shop Manual)
11. Remove the idler (A) and the timing chain cover plug (B).
12. Remove the high pressure fuel pump sprocket nut (C) after fixing the crank shaft.
13. Install the high pressure fuel pump sprocket stopper (D) (SST: 09331-2A000) rotating it clockwise.
14. Install the high pressure fuel pump remover (SST:09331-2A000) (A) with three mounting bolts (B).
15. Fix the high pressure fuel pump remover (SST:09331-2A000) (A) and sprocket stopper (C) with two fixing bolts
(D).
16. Rotate the bolt (E) of the high pressure fuel pump remover (SST:09331-2A000) (A) clockwise till the high pressure
fuel pump is pushed out.
17. Remove the SST(09331-2A000) (A) after removing the high pressure fuel pump assembly.
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INSTALLATION
When installing the high pressure fuel pipe, apply the specified tightening torques with the special service tool
(Refer to below table).

Flange Nut (HP Pump Side) 14 mm (0.551 in) 09314-27110
High pressure fuel pump installation bolts: 14.7 ~ 19.6 N·m (1.5 ~ 2.0 kgf·m, 10.9 ~ 14.5 lbf·ft)
High pressure fuel pipe installation nut: 24.5 ~ 28.4 N·m (2.5 ~ 2.9 kgf·m, 18.1 ~ 20.1 lbf·ft)
- Fuel Tank
- Fuel Sender
- Fuel Filter
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Fuel System
Engine Control System - Fuel Sender
Fuel System
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2010 > D 1.1 TCI-U >
REMOVAL
When lifting up or downing the vehicle, be sure to place blocks between the vehicle and lifter to prevent fuel tank
from being damaged.
2. Turn over the rear seat.
3. Open the service cover (A).
4. Disconnect the fuel sender connector (A), the fuel feed tube quick-connector (B) and the return tube quick -
connector (C).
5. Remove the fuel sender assembly (D) after removing the fuel sender plate cover (E) with SST (No.:09310-2B100).
INSTALLATION
Fuel sender plate cover tightening: 60~70 N.m (6.1~7.1 kgf.m, 44.3~51.6 lbf.ft)
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- Fuel Tank
- Fuel Sender
- Fuel Filter
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Fuel System
Engine Control System - Filler-Neck

Assembly
Fuel System
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2010 > D 1.1 TCI-U >
REMOVAL
1. Disconnect the fuel filler hose (A), the leveling hose (B).
2. Remove the left - rear wheel & tire and the wheel house.
3. Unscrew the mounting bolts (A).
4. Remove the fuel filler neck assembly after unscrewing the mounting screws (A).
If the filler neck assembly can't be removed easily, remove it again after loosening the rear cross member
mounting bolt partly (Refer ro "REAR LOW ARM" in SS group).
INSTALLATION
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Manual Transaxle System
General Information
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2010 > D 1.1 TCI-U >
SPECIFICATIONS
Engine type U-1.1
Transaxle type M5CF1
Gear ratio 1st 3.615
2nd 1.950
3rd 1.233
4th 0.886
5th 0.689
Reverse 3.583
Final gear ratio 3.650
TIGHTENING TORQUES
Standard value Nm kgf.m lb-ft
Oil drain plug 60-80 6.0-8.0 43.4-57.8
Oil filler plug 60-80 6.0-8.0 43.4-57.8
Shift control cable bracket 15-22 1.5-2.2 10.8-15.9
Rear roll support bracket bolt 60-80 6.0-8.0 43.4-57.8
Transaxle support bracket bolts 60-80 6.0-8.0 43.4-57.8
Always follow torque tightening levels. Failure to follow such levels can result in parts breaking if over-tightened or
loosening if under-tightened. In either case, serious personal injury or death could result to vehicle occupants.
LUBRICANTS
Items Recommnend lubricant Quantity
SAE 75W/85
API GL-4
TGO-7(MS517-14)
Transaxle gear oil 1.9L(2.0US qt, 1.67lmp qt)
ZIC G-F TOP 75W/85(SK)
HD GEAR OIL XLS
75W/85(H.K.SHELL)
Air breather MS721-38 As requried
Transaxle housing MS721-40 or MS721-38 As requried
Surface of release fork and Grease (CASMOLY L9508) release bearing 0.5~1.0g
bearing release bearing and fork 0.3~0.5g
release fork and fulcram 0.5~10.g
release fork and clutch felease cylinder
0.4~0.8g
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2010 > D 1.1 TCI-U >

TOOL
Illustration Use
(Number and Name)
09452-21200 Installation of differential oil seal
Oil seal installer
09200-38001 Removal and installation of the transaxle

Engine support fixture
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2010 > D 1.1 TCI-U >

TOOL
Illustration Use
(Number and Name)
09452-21200 Installation of differential oil seal
Oil seal installer
09200-38001 Removal and installation of the transaxle

Engine support fixture
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2010 > D 1.1 TCI-U >
SERVICE ADJUSTMENT PROCEDURE

TRANSAXLE GEAR OIL LEVEL
INSPECTION
Inspect each component for evidence of leakage.
Check the gear oil level by removing the filler plug.
If the oil is contaminated, it is necessary to replace it with new oil.
1. Remove oil filler plug (A).
2. Check level with finger.

Oil level must be up to fill the hole, add oil until it runs over.
3. Install the filler plug with new washer.
TORQUE :
60-80 Nm (6.0-8.0 kgf.m, 43.4-57.8 lb-ft)
REPLACEMENT
1. With the vehicle parked on a level surface, remove the drain plug.
2. Drain the transaxle oil after loosening the drain plug (A).
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3. Install the drain plug with new washer.
TORQUE :
60-80 Nm (6.0-8.0 kgf.m, 43.4-57.8 lb-ft)
4. Add new oil through the fille plug hole and, fill it ot just below the plug opening.
Standard oil : SAE 75W/85, API GL-4

Oil capacity: 1.9 liter (2.0 US qt, 1.67 lmp qt)
BACKUP LAMP SWITCH

INSPECTION
1. Disconnect the intergrated connector (A).
2. Check the continuity between no.6 and 7 terminals of backup lamp switch when the shift lever is in reverse. If not,
take the next step.
3. Disconnect the backup lamp switch connector(A).
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4. Check the continuity between no. 1 and 2 terminals of backup lamp switch.
When the shift lever is in reverse, there should be contunuity.
5. If necessary, repair or replace the backup lamp switch.
TORQUE :
30-35 Nm (3.0-3.5 kgf.m, 21.7-25.3 lb-ft)
NEUTRAL SWITCH
INSPECTION
1. Disconnect the integrated connector (A).
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2. Check the continuity between no. 2 and 5 terminals when the shift lever is in neutral position. If not, take the next
step.
3. Disconnect the neutral switch connector (A).
4. Check the continuity between no. 1 and 2 terminals of neutral switch, when the shift lever is in neutral position,
there should be continuity.
5. If necessary, repair or replace the neutral switch.
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TORQUE :
35-42 Nm (3.5-4.2 kgf.m, 25.3-30.3 lb-ft)
DRIVE SHAFT OIL SEAL

REPLACEMENT
1. Remove the drive shaft from the transaxle. (refer to Front Driveshaft in DS group)
2. Using a flat-tip screwdriver, remove the oil seal.
3. Using the special tool(09452-21200), tap the drive shaft oil seal into the transaxle.
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Manual Transaxle System - Manual Transaxle
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2010 > D 1.1 TCI-U >
COMPONENTS
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2010 > D 1.1 TCI-U >
REMOVAL
• Use fender covers to avoid damaging painted surfaces.

• To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
1. Remove the battery after removing the battery (A) terminal.
2. Remove the battery tray (A).
3. Remove the upper cover (B) of the air cleaner by loosening the clamp (A).
4. Remove the lower cover of the air cleaner assembly.
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5. Remove the wire harness bracket bolts.
6. Disconnect the integrated connector (A) and remove the CKP sensor (B).
7. Remove the shift cables.
Move the bending parts to the arrow direction in the illustration before removing the 'one-touch' clips (A) from
the bracket.
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8. Remove the shift cable bracket.
9. Installing the engine supporter(09200-38001), hold the enigne and transaxle assembly safely.
10. Remove the transaxle upper mounting bolts.
11. Remove the transaxle mounting support bracket bolts.
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12. Remove the front tires.
13. Remove the under cover.
14. Remove the drive shaft from transaxle. (Refer to Front Driveshaft in DS group)
15. Remove the clutch release cylinder by removing the two bolts (A).
16. Remove the starter motor mounting bolts.
17. Remove the rear roll stopper bracket (A).
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18. Remove the transaxle mounting bolts (A,B) from the engine side and the other (C) from the transaxle side.
19. Remove the transaxle lower mounting bolts (A,B).
20. Remove the transaxle assembly from the engine assembly.
When removing the transaxle assembly, be careful not to damage any surrounding parts or body components
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INSTALLATION
1. Temporarily install the transaxle assembly to the engine assembly.
Be careful not to damage any surrounding parts or body components.
2. Install the transaxle lower mounting bolts (A,B).
TORQUE :
[A] 43~55Nm(4.3~5.5kgf.m, 31.1~39.7lb-ft)
[B] 35~50Nm(3.5~5.0kgf.m, 25.3~36.1lb-ft)
3. Install the transaxle mounting bolts (A,B) from the engine side and the other (C) from the transaxle side.
TORQUE :
[A] 43~55Nm(4.3~5.5kgf.m, 31.1~39.7lb-ft)
[B,C] 35~50Nm(3.5~5.0kgf.m, 25.3~36.1lb-ft)
4. Install the rear roll stopper bracket (A).
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TORQUE :
60~80Nm(6.0~8.0kgf.m, 43.4~57.8lb-ft)
5. Install the starter motor mounting bolts.
TORQUE :
39~60Nm(3.9~6.0kgf.m, 28.2~43.4lb-ft)
6. Install the clutch release cylinder by installing the two bolts (A).
TORQUE :
15~22Nm(1.5~2.2kgf.m, 10.8~15.9lb-ft)
7. Install the drive shaft to the transaxle assembly. (Refer to Front Driveshaft in DS group)
8. Install the under cover.
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9. Install the front tires.
10. Install the transaxle mounting support bracket bolts.
TORQUE :
60~80Nm(6.0~8.0kgf.m, 43.4~57.8lb-ft)
11. Install the transaxle upper mounting bolts.
TORQUE :
60~80Nm(6.0~8.0kgf.m, 43.4~57.8lb-ft)
12. Remove the engine supporter(09200-38001).
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13. Install the shift cable bracket.
TORQUE :
15~22Nm(1.5~2.2kgf.m, 10.8~15.9lb-ft)
14. Install the shift cable by using new 'one-touch' clips (A).
15. Connect the integrated connector (A) and install the CKP sensor (B).
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16. Install the wire harness bracket bolts.
17. Install the lower cover of the air cleaner assembly.
18. Install the upper cover (B) of the air cleaner assembly by tightening the clamp (A).
19. Install the battery tray (A).
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20. Install the battery and the battery (A) terminal.
Perform the following :

• Adjust the shift cable.
• Refill the transaxle with fluid.
• Clean the battery posts and cable terminals with sandpaper, assemble them, then apply grease to prevent
corrosion.
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Manual Transaxle Control System - Manual

Transaxle Shift Control
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2010 > D 1.1 TCI-U >
COMPONENTS
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2010 > D 1.1 TCI-U >
REMOVAL
1. Remove the floor console switch(A) and connector.
2. Remove the center console(A).(Refer to BD group.)
3. Remove the select cable snap pin(A).
4. Remove the shift cable clip(A).
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5. Remove the shift cable(A) and select cable(B).
6. Remove the shift lever assembly(C).
7. Remove the retainer(A) and nuts(B).
8. Remove the snap pins(2EA).(Transaxle side).
9. Remove the shift cable and select cable.
INSTALLATION
1. Install the shift cable and select cable after locating the shift lever and select lever at the neutral position.
When operating lever of body side, check secure operation of lever of transaxle side after assembly.
2. Install the snap pins(2EA) of transaxle side.
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3. Install the shift lever assembly.
TORQUE:
9-14Nm(90-140kgf.cm, 6-9.5lb.ft)
4. Disconnect the clip (A) and the locking piece (B) from the select cable as shown in the illustration.
Be sure to confirm that the locking piece is movable before adjusting the select cable length in the direction
(C) shown in the illustration.
5. Insert the select lever pin to the select cable and install the snap pin (A) placing the select lever in neutral position
and adjusting free play of the select cable.
GETtheMANUALS.org
6. Install the locking piece (A) in the direction as shown in the illustration.
7. Install the clip (A) in the direction as shown in the illustration.z
Adjust the cable length with select cable adjuster in "N" position before installing the center console.
8. Install the center console.(Refer to BD group.)
INSPECTION
1. Check the select cable for proper operation and for damage.
2. Check the shift cable for proper operation and for damage.
3. Check the boots for damage.
4. Check the boots for wear abrasion sticking, restricted movement or damage.
5. Check for the weak or damaged spring.
GETtheMANUALS.org

2010 KIA Picanto TCI-U Supplement

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2010 KIA Picanto TCI-U Supplement

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General Information

Identification Number Locations

Identification Number Description

Warning / Caution Label Locations

Battery Caution Label Describtion

Handling And Storage The Battery

Lift And Support Points

Tightening Torque Table Of Standartd Parts

M5 0.8 3 ~ 4 (30 ~ 40, 2.2 ~ 2.9) 5 ~ 6 (50 ~ 60, 3.6 ~ 4.3)

General Service Information

Preparation Of Tools And Mesuring Equipment

3. Cleaning parts for reuse

Depending on their location.

Measuring Body Dimensiongs

Precautions For Catalytic Converter

1. Use only unleaded gasoline.

Engine Mechanical System

Closes (BTDC) 16° ~ 24°

Item N.m kgf.m lb-ft

Compression pressure inspection

3. Start the engine until the engine stops.

(4) Repeat steps 1) through 3) for each cylinder.

This measurement must be done in as short a time as possible.

Compression pressure(Standard) : 2,353kPa (24.0kg/cm!, 341psi) (260 rpm)

Valve spring compressor Removal and installation of intake and

Compression gauge Checking engine compression pressure

Compression gauge adapter Checking engine compression pressure

Injector remover Removal of injectors

Injector remover adapter Removal of injectors

High pressure pump Removal of high pressure pump sprocket

Crankshaft rear oil seal Installation of crankshaft rear oil seal

Flywheel stopper Removal and installation of crankshaft pulley

Oil pan remover Removal of oil pan

Engine support fixture & Support of engine

Engine Mechanical System

2. Remove the air compressor.(Refer to Air compressor in HA group.)

7. Remove the alternator(A). (Refer to Alternator in EE group.)

9. Remove the engine support bracket(A).

10. Remove the two idlers(A).

11. Remove the drive belt tensioner.

13. Remove the crankshaft pulley bolt(B) and crankshaft pulley(A).

15. Remove the high pressure pump pipe. (Refer to FL group.)

17. Install the SST(09331-2A000)(A) to the sprocket by rotating it clockwise.

24. Remove the timing chain auto tensioner(A).

27. Remove the timing chain auto tensioner(A).

30. Remove the water pump(A).

3. Install the water pump(A).

• Apply coolant to the o-ring before installing the water pump.

4. Install the high pressure pump.

7. Pretighten the high pressure pump sprocket nut.

13. Tighten the high pressure pump sprocket nut (A).

• Standard liquid gasket : LOCTITE 5900

15. Install the timing chain cover(A).

16. Install the front oil seal by using SST(09231-2A000, 09231-H1100)(A).

20. Install the two idlers(A).

21. Install the engine support bracket(A).

22. Install the water pump pulley(A).

24. Install the oil pan.(Refer to Lubrication system in this group.)

27. Install the engine mounting bracket(A).

Cylinder Head Assembly

Engine Mechanical System

• Mark all wiring and hoses to avoid misconnection.

3. Remove the oil pan(A).

5. Remove the vacuum pipe assembly(A).