General

TROUBLESHOOTING
Items
Engine does not crank.

Possible causes
Low cranking speed

Remedy
Repair the starter or charge or replace battery.

Low voltage to glow plug system

If the test light turns on indicating low voltage when it turns ON, check relay and
wiring.

Defective glow plug

Replace the glow plug.

Air in the fuel system

Air bleeding of fuel system

Injection pipe is connected incompletely. Connect the pipe correctly

Improper injection timing

Check ECM.

Poor injection

Check, replace injector.

Mechanical defect of engine

Test compression, repair engine.

Simultaneous failures of TDC sensor and

Check and tighten correctly.
CKP sensor
Idle is improper or idle speed is u- Loose fuel hose connection between filtTighten or repair.
nstable or irregular.
er and supply pump.
Air in the fuel system

Air bleeding of fuel system

Fuel filter is clogged. Or fuel supply is no Check hose or fuel line. Replace fuel filtgood because fuel line or injection pipe l- er if necessary.
eaks, pinched or pressed.

Exhaust gas (Black, blue, white)

Poor injection

Check, replace injector.

Improper injection timing

Check ECM.

Mechanical defect of engine

Test compression, repair engine.

Defective supply pump

Let the engine at idle after replacing pump.

Engine defect at high gear range

Observe correct shift speed.

Defective EGR valve

Check or replace EGR valve.

Engine temperature stays below engine Check cooling system. Replace thermosoperating temperature.
tat.
Abnormal at max. RPM

Check and replace supply pump.

Defective Injection nozzle

Check and repair or replace.

Improper injection timing

Check ECM.

Exhaust system malfunction

Check for deformed or clogged.

Mechanical defect of engine

Test compression, repair engine.

Defective supply pump

Replace supply pump.

Defective EGR valve

Check or replace EGR valve.

Items

Possible causes

Engine lacks power, acceleration i- Abnormal at max. RPM

s delayed(Speedometer is normal,
Contaminated air cleaner filter
no clutch slip)
Fuel filter is clogged. Or fuel supply is no
good because fuel line or injection pipe leaks, pinched or pressed.Or fuel filter leaks.

Excessive fuel consumption

Remedy
Check, replace supply pump.
Clean or replace.
Check hose or fuel line. Replace fuel filter if necessary.

Air in fuel system

Air bleeding of fuel system

Defective supply nozzle

Check, repair or replace.

Improper injection timing

Check ECM.

Mechanical defect of engine

Test compression, repair engine.

Defective injection pump

Check after replacing pump.

Abnormal EGR valve

Check, replace EGR valve.

Contaminated air cleaner filter

Clean, replace air cleaner filter.

Fuel leaks

Check all pipes, hoses and connection.

Replace or tighten as required.

Clogged return pipe and hose.

Check and replace the return line, blow

air if clogged and drain the fuel.

Defective injection nozzle

Check. Repair or replace.

Mechanical defect of engine

Compression test, replace engine.

Defective supply pump

Replace pump.

Defective EGR valve

Check or replce EGR valve.

ENGINE CONTROL
Trouble
Engine will not turn off.

Possible causes

Remedy

Injector wiring short

Check injector wiring.

Starting switch harness is damaged.

Replace.

ENGINE STARTING SYSTEM

Troubles
Engine does not crank

Possible causes
Low battery voltage

Remedy
Recharge or replace the battery.

Battery cable connection is loose, corroRepalce or retighten.

ded or worn.

Cranking speed is low

Fusible link is swelled.

Replace the fusible link.

Defective starter motor.

Repair.

Defective injector

Repalce.

Low battery voltage

Recharge or replace the battery.

Battery cable connection is loose, corroRepair or replace.

ded or worn

Starter motor continues to run.

Defective starter motor

Repair

Defective starter motor

Repair

Defective ignition switch

Replace the ignition switch.

Starter motor runs but engine is n- Defective wiring

ot cranking.
Starter motor, pinion gear damaged
Ring gear damaged

Repair wiring.
Repair starter motor.
Replace flywheel or torque converter gear.

FUEL TANK AND FUEL LINE

Troubles

Possible causes

Poor engine performance due to i- Fuel pipe is twisted or broken

nsufficient fuel supply
Fuel pipe or hose is clogged

Remedy
Repair or replace.
Clean or replace.

Fuel filter is clogged

Replace.

Entry of water to fuel filter

Replace fuel filter or clean fuel tank or fuel line.

Foreign materials intrude in fuel tank. FClean or replace.

uel tank rusts.
Defective supply pump operation
(Clogged filter in pump)

Replace.

Fuel filter warning lamp blinks.

Excessive water is in fuel filter.

Drain the water collected in the fuel filter

(Loosen the drain plug at the bottom of fuel filter..)

Engine check lamps blinks.

Clogged fuel filter.

Replace fuel filter.

TROUBLESHOOTING PROCEDURE

SDGFL9001L

SDGFL9002L

SDGFL9003L

SDGFL9004L

SERVICE PROCEDURE
Communication with diagnosis equipment is not possible
(Impossilbe communication with all systems

SDGFL9005L

When communication between diagnosis equipment and

ECM is not possible
Trouble symptoms
It shows at least one of the following symptoms.
When power is not supplied to ECM .
ECM ground circuit is defective ECM
Defective ECM
Wrong communication line between ECU and Hi-scan

Probable causes
Power supply circuit to ECM is defective.ECM
Defective ECM
Circuit between ECU and DLC is open.

Engine does not start.

SDGFL9006L

It is difficult to start the engine. (Possible cranking)

SDGFL9007L

Unstable idle or engine stall.

SDGFL9008L

Engine hesitation or poor acceleration

SDGFL9009L

Troubleshooting flow chart when HUNTING(fluctuation)

occurs

SDGFL9010L

Troubleshooting flow chart when FCCB(Fuel control

cylinder balance) fails.

SDGFL9011L

Troubleshooting flow chart when engine is lack of power

SDGFL9012L

Troubleshooting flow chart in systems of sensors and

wirings

SDGFL9013L

CRS RAIL PRESSURE CHECK

Items to check in the vehicle

7. Visual check of connector

1. Check for customer complaint and trouble symptoms.

Check each terminal contact part of rail pressure

sensor for wear.

2. Check reoccurrence or not for customer complaint

and trouble symptoms mentioned above.

Check connector housing of rail pressure sensor for

wear.

3. Record DTC codes or record the detailed DTC codes

by using Hi-scan.

Check locking part/ guide part of rail pressure sensor

connector for damage or deformation.

Inspect and repair causes due to DTC codes.

4. Check rail pressure when turning ignition key to
NO(Engine OFF).
If the rail pressure is displayed, check it according to
inspection procedure of remaining pressure.
5. Check for connector of rail pressure sensor.
Check for wiring tension between rail pressure
sensor and connector of vehicle side.
Check that wiring between rail pressure sensor and
connector of vehicle side is tight or not due to
vibration(under driving) with interference in bracket of
engine/vehicle etc.
Check rail pressure sensor wire for clamp conditoin.
Check that wire of rail pressure senor is clamped
securely or not.
Check rail pressure sensor and connector of vehicle
side for connection conditon.
With connector connected, check connector for
shaking(with right and left/ back and forth).
If there is free play, check for output of rail
pressure/rail pressure sensor using Hi-scan or
oscilloscope.
6. Check for wiring related to the output of rail pressure
sensor.
Check for voltage between each terminal of rail
pressure sensor in the ECM side and terminal (-) of
battery.
Check wire between rail pressure sensor and ECM
for continuity(resistance).

Check the inside of rail pressure sensor connector for

foreign materials(such signs as water, oil, spark,
tracking etc.).
Check the opposite connector for foreign materials,
wear, damage, existence or not of rubber seal or
shrinkage of rubber seal etc..

SDGFL9014L

Rail pressure sensor

terminal

Item

Pin No.

Vc

E68

Vout

E32

Vout

E13

GND

E25

Voltage check

Check condition

Check wiring between rail pres sure sensor and ECM

Measured
ECM terminal side re - value noise Reference value/me - Measured
or
ference value
ausred condition
value
not

Key On

4.9~5.1

Below 2[ohm]/Key Off

Key On/EngineOff

0.9~1.1

Below 2[ohm]/Key Off

Engine On/at Accel.

Refer to illustration 3

Below 2[ohm]/Key Off

Key On/Engine Off

0.9~1.1

Below 2[ohm]/Key Off

Engine On/at Accel.

Refer to illustration 3

Below 2[ohm]/Key Off

Key On

00.1

Below 2[ohm]/Key Off

CRS RAIL PRESSURE CHECK FLOW CHART

SDGFL9015L

Fuel system check processor

SDGFL9016L

Troubleshooting flow chart when the engine stops

SDGFL9017L

SDGFL9018L

SDGFL9019L

SDGFL9020L

SPECIFICATIONS
Items
Sensors

BPS(Booster pressure sensor)

Specification
Supply voltage

5V

Operating voltage

0.5~4.5V

Operating temperature

IAT(Intake air temperature)

-40~125C

Operating pressure

50~500kpa

Current

Below 10mA

Type

Thermistor

Resistance

2.31~2.56k [At 20C(68F)]

0.30~0.34k [At 80C(176F]

WTS(Water temperature sensor)

Type

Thermistor

Resistance

2.31~2.59k [At 20C(68F)]

0.314~0.331k [At 80C(176F)]

TDC(Top dead center) sensor

Type

Hall sensor

CKP(Crankshaft positon sensor)

Type

Magnetic

APS(Accel positon sensor)

Actuator

Supply control valve

Type

Variable resistance(Potentiometer)

Voltage

5V 1%

Current

Max. 10 mA

Fuel pressure sensor

Type

Piezo electricity

Injector

Type

Electromagnetic

Resistance

0.45

Current

Active : Below 1.29A

SCV

When stopped :Below 1.16A

Fuel tank
Fuel pressure of high pressure side
Supply pump

Fuel filter

Capacity

100L

Max. pressure

1,800bar

Type

Included into high pressure pump

mechanical type

Power

Mechanical gear type

Type

Filter

EGR VALVE SPECIFICATION

Items

Specification

Valve type

Flap type

Control type

Electric DC motor

SEALANT
Water temperature sensor(Coolant temperature sensor)

Loctite 200 or equivalent

INSPECTION
Idle speed(rpm)

N-Range

D-Range

Items

Reference value

A/Con OFF

600rpm

A/Con ON (A/Con switch ON)

700rpm

A/Con OFF

600rpm

A/Con ON (A/Con compressor relay ON)

700rpm

TIGHTENING TORQUE
Items

Kgf.m

N.m

lbf.ft

ECM mounting bolt

1.9 ~ 2.8

18.6 ~ 27.4

13.8 ~ 20.4

Mass air flow sensor mounting bolt

0.8 ~ 1.2

7.8 ~ 11.8

5.8 ~ 8.7

Crankshaft position sensor mounting bolt

0.8 ~ 1.2

7.8 ~ 11.8

5.8 ~ 8.7

TDC sensor mounting bolt

0.8 ~ 1.2

7.8 ~ 11.8

5.8 ~ 8.7

EGR valve mounting bolt(Inlet pipe)

2.2 ~ 3.3

21.6 ~ 32.3

16 ~ 24

EGR valve mounting bolt(EGR cooler)

2.2 ~ 3.3

21.6 ~ 32.3

16 ~ 24

4~5

39 ~ 49

29 ~ 36

Common rail assembly mounting bolt

1.9 ~ 2.8

18.6 ~ 27.4

13.8 ~ 20.4

Fuel filler pipe assembly mounting bolt

0.8 ~ 1.2

7.8 ~ 11.8

5.8 ~ 8.7

Fuel return pipe mounting bolt

0.8 ~ 1.2

7.8 ~ 11.8

5.8 ~ 8.7

Fuel supply pump flange mounting bolt

10 ~ 13

98.6 ~ 128

72.3 ~ 94

Fuel supply pump mounting bolt

1.9 ~ 2.8

18.6 ~ 27.4

13.8 ~ 20.4

Injector clamp bolt

2.9 ~ 3.1

28.42 ~ 29.4

21 ~ 22.4

0.18 ~ 0.22

1.76 ~ 2.15

1.3 ~ 1.6

High pressure pipe(rail-injector 1,2,3,4,5,6)

Injector wire nut

Engine Control System-Electronic

DESCRIPTION

SELF-DIAGNOSIS

DIESEL CONTROL SYSTEM

INSPECTION OF THE DIESEL
SYSTEM

The ECM sends the input/output signals to various parts

of engine(some signals at all times and the others under
specified conditions).

CONTROL

If the components of the diesel control system (sensor,

ECM, injector etc.) have a problem, the proper amount of
fuel for various engine-operating conditions can not be
supplied and also the following situations can occur.
1. It is hard to start the engine or does not start the
engine at all.
2. Idling is unstable.
3. Engine driving performance is bad.
If any of the above conditions are met, first perform a
routine diagnosis that includes basic engine checks
(ignition system malfunction, incorrect engine
adjustment etc). Then, inspect the components of the
diesel control system with multi-purpose tester or
digital multi-meter.
CAUTION
Before removing or installing any part, read the
diagnostic trouble codes and then, disconnect
the battery negative (-) terminal.
Before disconnecting the cable from battery
terminal, turn the ignition switch to OFF. If the
battery cable is removed or connected during
engine operation or the situation in which the
ignition switch is ON, then the ECU
semiconductor could be damaged resulting in
inaccurate operation.

After the specific time elapses the first detection of

irregular signal, the ECU judges this as an irregularity
and it records the diagnostic trouble code. And then it
sends the signal to the self-diagnosis output terminal.
The diagnosis results can be checked by the Hi-scan. In
addition, Diagnostic Trouble Codes (DTC) will be directly
backed up by the battery so that it will remain in the ECM
even if the ignition switch is turned off. The diagnostic
trouble codes will, however, be erased when battery
terminal or ECM connector is disconnected.
CAUTION
If, in most of diesel control system, the connector
of a sensor is disconnected with the ignition switch
turned ON, the diagnostic trouble code (DTC) is
recorded in the ECM. In this case, if the battery
negative terminal (-) is disconnected for 15 seconds
or more, then the diagnosis memory will be erased.

SELF-DIAGNOSIS CHECK PROCEDURE

CAUTION
As DTC code may not be detected due to low battery
voltage, the battery condition should be checked
prior to inspection.
Since DTC code is erased if the battery or the ECM
connector is disconnected, don't disconnect the
battery
until the diagnostic trouble codes are
completely read and recorded safely.
It is most desirable to erase the diagnostic trouble
codes using Hi-scan after completing check and
repair. After disconnecting ground cable from the
battery negative (-) terminal for 15 seconds or more,
reconnect the cable and check if the trouble codes
have been erased. (At this time, ignition switch must
be turned off).

INSPECTION PROCEDURE (Using Hi-scan)

1. Turn off the ignition switch.
2. Connect the Hi-scan connector to the connector of
DLC (Data Link Connector) for the trouble diagnosis
as shown in the figure.

DIESEL CONTROL
LOCATION

SYSTEM

COMPONENTS

1. Intake air temperature sensor and intake air pressure

sensor

3. Turn the ignition switch ON.

4. Check the diagnostic code using Hi-scan.
5. Repair the parts having faults shown in the diagnosis
chart.
6. Erase the diagnostic trouble codes.
7. Disconnect the Hi-scan.

SDGFL7501D

2. Crankshaft position sensor

KDDFL5019A

NOTICE
When using a tester manufactured by other
company, operate the tester by referring to the
manual of the company.
When erasing the diagnostic trouble codes, use
Hi-scan if possible. Though DTC can be erased by
disconnecting the battery terminal, doing so, the
data for learning control in ECM would be erased at
the same time.

SDGFL7502D

3. Water temperature
sensor)

sensor(Coolant

temperature

6. Rail pressure sensor

SDGFL7002D
SDGFL7503D

7. Supply control valve(SCV)

4. TDC sensor(Camshaft sensor)

SDGFL7505D
SDGFL7504D

8. ECM and EDV

5. Injector

SDGFL8001D
SDGFL7001D

9. Accelerator position sensor

SDGFL9021L

10.DLC connector

SDGFL8113D

ECU(Engine Control Unit)

COMPONENTS
ECM PIN CONNECTOR

SDGFL9022L

Vehicle side(80pin connector) - ECM connector(C01)

Termi nal

Abbr.

+BF

PWR-ACT1

Terminal name

Termi nal

Abbr.

Terminal name

+B (For fly back)

41

SWV25

Bleeder #2 switch

42

SWV23

Stop lamp switch

OUTV1

Main relay

43

SWV21

Self-diagnosis switch

OUTV2

Exhaust brake relay

44

SWV19

Cruis main ON/OFF switch

OUTV3

Starter relay

45

A-ground 10

Sensor ground10

OUT6

Check engine lamp and fuel pressure flashing

46

A-ground 12

Sensor ground 12

SOUT4

Glow lamp

47

ADV1

Accelerator position sensor 1

SOUT2

PTO lamp

48

ADV3

SOUT1

MIL lamp

49

ADV5

Exhaust temperature sensor 1

10

SWV6

PTO emergency switch

50

A-VCC10

Sensor power supply 10

11

SWV4

Neutral switch

51

A-VCC11

Sensor power supply 11

12

SWV2

Starter switch

52

SWV17

Remote PTO idle up & engine service start switch

13

SWV1

Ignition switch

53

SWV15

Idle down & PTO idle down & cruise resume switch

14

VS

Vehicle speed sensor

54

SWV13

A/C switch

15

POUT1

A/C control

55

SWV11

Clutch switch

16

CAN1L

CAN1L

56

SWV9

Exhaust brake & bleeder #1 switch

17

CAN2L

CAN2L

57

CAN-SLD

18

+B

+B

58

+B

19

BATT

Battery

59

P-ground

Power ground

20

CASE-GND

Case ground

60

ground

Signal ground

21

+BF

+B (for fly back)

61

SWV26

PTO switch(Cap outside)

22

OUTV4

Warning lamp relay

62

SWV24

Starter relay monitor switch

23

OUTV1

Main relay

63

SWV22

Idel warm up switch

24

OUTV5

Heater relay

64

SWV20

Built-in data capture switch

25

SOUT8

Alternator control cut

65

A-ground 11

Sensor ground 11

26

SOUT7

Cruise lamp

66

A-ground 13

27

SOUT5

Overheat lamp

67

ADV2

Accel position sensor 2

28

SOUT3

Exhaust brake lamp

68

ADV4

PTO accel position sensor

29

SWV8

Door open switch

69

ADV6

Exhaust temperature sensor 2

30

SWV7

Bus rear flap switch

70

ADV7

Differential pressure sensor

31

SWV5

PTO switch

71

A-VCC12

CAN1 shield ground

+B

Sensor power supply 12

Termi nal

Abbr.

Terminal name

Termi nal

Abbr.

Terminal name

32

SWV3

Engine stop switch

72

SWV18

Remote PTO idle down & engineservice stop switch

33

SWV1

Key switch

73

SWV16

QT cut switch

34

TAC1

Tachometer

74

SWV14

Idle up & PTO idle up & cruise set

switch

35

PIN5

75

SWV12

Brake switch

36

CAN1H

CAN1H

76

SWV10

Idle switch

37

CAN2H

CAN2H

77

KWP

38

+B

+B

78

+B

39

P-ground

Power ground

79

P-ground

Power ground

40

Ground

Signal ground

80

P-ground

Power ground

+B

Engine side(80 pin connector) - ECM connector(E01)

Termi nal

Abbr.

Terminal name

Termi nal

Abbr.

Terminal name

80

OUTE5

40

SWE1

Heater monitor switch

79

OUTE1

Fan clutch PWM

39

SWE3

78

OUTE3

Bleeder solenoid #2

38

ADE9

77

PWR-ACT2

Power ACT2

37

ADE7

Ambient temperature sensor

76

AUX2

36

ADE13

75

PWR-PCV

Not in use

35

ADE6

74

PCV1

Not in use

34

ADE4

Intake temperature sensor

73

PCV2

Not in use

33

ADE2

Fuel temperature sensor

72

SCV-HI

HP-4 high

32

ADE1

Rail pressure sensor

71

SCV-LO

HP-4 low

31

PIN2+

70

AUX1

Not in use

30

PIN1+

69

A-VAF

MAF power supply

29

NE+

68

A-VCC1

Sensor power supply 1

28

G-VCC

Cam angle sensor power

67

COM1

Injection power 1

27

G-ground

Cam angle sensor ground

66

TWV1

Injection #1

26

INJ-SLD

Injection shield ground

65

TWV3

Injection #3

25

A-ground1

Sensor ground 1

64

TWV5

Injection #5

24

A-ground3

Sensor ground 3

63

COM2

Injection power2

23

A-ground5

Sensor ground 5

62

TWV2

Injection #2

22

CAN3H

CAN3H

61

TWV4

Injection #4

21

TWV6

Injection #6

60

OUTE6

20

SWE2

Fuel inlet pressure switch

Engine RPM sensor+

Termi nal

Abbr.

Terminal name

Termi nal

Abbr.

Terminal name

59

OUTE2

19

ADE10

58

OUTE4

Bleeder solenoid #1

18

ADE8

57

PWR-ACT2

Power ACT2

17

ADE14

56

PWR-ACT2

Power ACT2

16

ADE12

55

PWR-PCV

Not in use

15

ADE5

Water temperature sensor

54

PCV1

Not in use

14

ADE3

Boost sensor

53

PCV2

Not in use

13

ADE1

Rail pressure sensor

52

SCV-HI

HP-4 high

12

ADE11

Air MAS flow sensor

51

SCV-LO

HP-4 low

11

PIN2-

50

NE(MRE)

10

PIN1-

49

PRD+

Not in use

NE-

48

A-VCC2

Sensor power supply 2

47

COM1

Injection power1

PIN3

46

TWV1

NE-SLD

NE Shield ground

45

TWV3

A-ground 2

Sensor ground 2

44

TWV5

A-ground 4

Sensor ground 4

43

COM2

Injection power 2

A-ground 6

42

TWV2

CAN3L

CAN3L

41

TWV4

TWV6

Engine RPM sensor Cam angle sensor signal

-

REMOVAL
1. After the engine stops, wait for about 30 seconds.
2. Disconnect the battery ground line.
3. Remove ECU connector wiring sequentially.
4. Loosen ECM bracket mounting bolt and remove
ECM(A).

ADJUSTMENT
REPLACING ECM

PROCEDURE

AFTER

1. Perform work procedure using diagnostic tool when

replacing with a new ECM.
2. Input injector QR correction value using diagnostic
tool with the ignition key ON.
Follow the instructions on the diagnostic tool as to
how to input injector QR correction value.
If the input of injector QR correction value was
completed, start the engine in 10 sec. after turning
the ignition key OFF.
CAUTION
In case QR correction value described on the
injector is not input in the ECM, there may cause
engine performance and exhaust gas problem.
3. Select learning initialization instructed by diagnostic
tool and perform pump learning initialization and
accelerator sensor learning.

SDGFL7003D

5. Installation is in the reverse of removal.

4. According to the instructions on diagnostic tool,

select parameter setting and perform work in
sequence.

Mass Air Flow Sensor

INSPECTION
DESCRIPTION
MAF sensor is built into the vehicle for controlling the
EGR system precisely.
The air flow, supplied to an engine, is measured lower
than actual air flow due to contamination of MAF sensor.
Then EGR system can't be controlled precisely.
To prevent it in advance, you have to clean the MAF
sensor periodically.
Clean the MAF sensor every 6 months or 60,000 km
using "Carb and Choke Cleaner".

VISUAL INSPECTION

SGZFL9028L

CAUTION
1. Don't impact or drop the sensor when replacing
it.

2. Don't use the sharp tool at removing the sensor,

otherwise the O-ring may be damaged.

Procedure and caution when cleaning the sensor

SGZFL9029L

CAUTION
1. To remove the O-ring of MAF sensor
-

Remove the O-ring of MAF sensor to prevent

it from damage by cleaning spray and clean
the sensor element.

3. To dry the sensor element

-

Using the air gun : Below 5 bar, within 30

seconds.

After atomizing the spray, dry the sensor like

below picture for 20 minutes.

SGZFL9030L

2. Procedure of atomizing the spray

-

Atomize the spray to the end part of sensor

housing.

Don't use the nozzle of spray to prevent the

sensor element from damage.

Atomize the spray with 2~3 times for 2~3

seconds.

SGZFL9032L

4. To install the O-ring of MAF sensor

-

Install the O-ring after completing to dry the

sensor.

SUDFL9500L

SGZFL9031L

Differential Pressure Sensor(DPS)

Components

SUDFLDTC9109L

Description
The differential pressure sensor is installed upper side of
PMC and measures the pressure difference between
before and after PMC.
It also has a purpose to monitor that PMC is arbitrarily
removed by a user.

SUDFLDTC9110L

Specifications
Differential Pressure (kPa)

Output Voltage (V)

10

1.35

20

1.7

30

2.05

40

2.4

50

2.75

60

3.1

70

3.45

80

3.8

90

4.15

100

4.5

Part Circuit Diagram

SUDFLDTC9112L

Replacement

The differential pressure sensor pipe

The differential pressure sensor

1. Turn the ignition switch OFF and disconnect the

battery (-) cable.

1. Turn the ignition switch OFF and disconnect the

battery (-) cable.
2. Disconnect the
connector(A).

differential

pressure

sensor

2. Remove the clip connected to the differential

pressure sensor pipe.

SUDFLDTC9111L

3. Remove the bracket bolt(B).

SUDFLDTC9111L

3. Remove the clip connected to the differential

pressure sensor pipe.
4. Remove the mounting bolt(D).

the

tightening

torque,

refer

5. The installation is the reverse order of removal.

NOTICE
Regarding as
"Components".

5. The installation is the reverse order of removal.

NOTICE
Regarding as
"Components".

4. Remove the differential pressure sensor pipe(C).

to

the

tightening

torque,

refer

to

Fuel Delivery System-Electronic

COMPONENTS

SDGFL9023L

1.
2.
3.
4.
5.
6.
7.
8.

ECM
Injector assembly
Injection pipe
Common rail assembly
Fuel supply pump
High pressure(common rail~injector)
High pressure pipe(common rail~supply pump)
Injector clamp bolt

9. Injector clamp
10. Injector assembly
11. Nozzle gasket
12. Fuel return pipe
13. Fuel supply pipe
14. Fuel pump flange
15. Overflow screw
16. Fuel temperature sensor

Accelerator Pedal
DESCRIPTION

2. Connect DC 5 V to terminal No. 3.

APS (Accelerator Position Sensor) senses the

acceleration pressure of the driver and delivers it to the
ECM. Output voltage of accelerator position sensor has
a functional relation with the accelerator pedal position.

3. Check to see if the measurement voltage between

terminal No. 1 and No. 2 satisfies the specified
voltage.

This functional relation comes from the Potentiometer

built-in the sensor.
In other words, the positon of pedal is calculated from the
output voltage of the sensor.

REMOVAL
1. Disconnect accelerator pedal connector and remove
mounting bolt, accelerator pedal.
2. Installation is the reverse order of removal.

INSPECTION
1. Connect the voltmeter to the terminals No. 1 and 2 of
accelerator position sensor.

SDGFL9026L

SDGFL9027L

At idle : 0.65V
At full stroke : 3.85V
4. Connect DC 5V to terminal No.4.
1) Check to see if the measurement voltage
between terminal No. 1 and No. 6 satisfies the
specified voltage.
At idle : 5V
At full stroke : 0V
2) Check to see if the measurement voltage
between terminal No. 1 and No. 5 satisfies the
specified voltage.
At idle : 0V
At full stroke : 5V

Fuel Tank And Fuel Filter

REMOVAL

FUEL TANK AND FUEL FILTER (AEROTOWN)

FUEL TANK AND FUEL FILTER (HD120)

1. Park the vehicle on a flat surface, stop the engine

and disconnect the terminal (-) of battery.

1. Park the vehicle on a flat surface, stop the engine

and disconnect the terminal (-) of battery.
2. Disconnect the sender connector on the top of fuel
tank.

2. Disconnect the sender connector on the top of fuel

tank.
3. Remove return hose (A) and supply hose (B).

3. Remove return hose (A) and supply hose (B).

SDGFL7101D
SDGFL7100D

4. Support fuel tank assembly with the jack. Loosen fuel

tank band mounting nut and remove fuel tank
assembly by removing mounting bolt.
5. Disconnect connector and hose and remove fuel filter
(C).

4. Support fuel tank assembly with the jack. Loosen fuel

tank band mounting nut and remove fuel tank
assembly by removing mounting bolt.
5. Disconnect connector and hose and remove fuel filter
(A).

6. Installation is the reverse order of removal.

Tighten
lower
nut
to
the
8.5~11kgf.m(83.4~107.9N.m, 61.5~79.6Ib-ft) and
upper nut to the 1.3~1.5kgf.m (12.7~14.7N.m,
9.4~10.8Ib-ft) and install fuel tank band to bracket.

SDGFL7102D

6. Installation is the reverse order of removal.

Tighten
lower
nut
to
the
3.3~4.0kgf.m
(32.4~39.2N.m, 23.9~28.9Ib-ft) and upper nut to the
8~11kgf.m (78.4~107.9N.m, 57.9~79.6Ib-ft) and
install fuel tank band to bracket.

INSPECTION
1. General check
a. Crack, bending, deformation, deterioration and
clogging of hose or pipe
b. Clogging or damage of fuel filter
2. When the filter has to be checked
a. When the fuel in the tank is drained out and then
replenished again for maintenance
b. When fuel filter is replaced
c. When fuel main hose (pipe) is removed
Loosen the air plug of fuel filter.
Cover air plug hole with cotton cloth and keep
pumping until it stops bubble.
When bubbles are removed completely, fasten
the air plug and continue to pump until pump
operation effort feels heavy.
3. Water drain from the fuel filter
Check for the water level of transparent bowl and if
water is filled with one-third, be sure to drain water by
the following sequence.
CAUTION
If the vehicle is driven without draining the
water, it may cause fatal trouble to the supply
pump and injector.
a. Drain the water by turning about half way.
CAUTION
Since water is drained even if the plug is not
fully loosened, be careful not to loosen drain
plug fully.
b. If diesel fuel drains after water has been drained
completely, fasten the drain plug by hand.
Tightening torque
12.3~13.7Ib-ft)

1.7~1.9kgf.m

(16.7~18.6N.m,

Injector
COMPONENTS

SDGFL9024L

1.
2.
3.
4.

ECM
Injector assembly
Injector pipe
Common rail assembly

5.
6.
7.
8.

Fuel supply pump

Injector clamp bolt
Injector clamp
Injector assembly

REMOVAL

4. Remove rocker arm assembly (A).

CAUTION
Since common rail fuel injection operates under
high pressure(1,800bar), a special care should be
taken.

While engine is running or within 1 min. after

engine stops, any works should not be
performed in relation to common rail fuel
injection system.

In particular, as the injector solenoid generates

high temperature heat, do not touch it with bare
hands. Start the service works only when the
engine has been cooled down enough after
engine stops.

Always keep the safety precautions.

Ensure working area cleans all the time, and

place the removed injector on the clean cloth.
And pay attention to injector nozzle so that it is
not contaminated by foreign materials.

Remove the protective caps which prevents

foreign material inflow for injector and fuel hose
immediately just before installation.

When installing or removing injector, clean the

injector contacting portion and be sure to
replace O-ring and nozzle gasket with new ones.

Apply diesel to the O-ring of injector and insert

them into the cylinder head.

Install injector to the cylinder head vertically and

install it correctly not to cause any damage such
as shock.

Be sure to observe the specified tightening

torque of bolts when inserting and tightening the
injector.

Never use the high pressure fuel pipe.

SDGFL7507D

5. Disconnect injector ground (A).

SDGFL7508D

6. Disconnect high pressure pipe (A).

1. Turn the ignition key OFF.

2. Disconnect terminal (-) of battery.
3. Remove rocker cover.

SDGFL7509D

7. Loosen injector clamp bolt (A) and remove injector.

replace O-ring and nozzle gasket with new ones.

Apply diesel oil to the O-ring of injector and

insert them into the cylinder head.

Install injector to the cylinder head vertically and

install it correctly not to cause any damage such
as shock.

Be sure to observe the specified tightening

torque of bolts when inserting and tightening the
injector.

Never use the high pressure fuel pipe.

1. Remove injector.
2. Install the injector.
3. Input injector QR correction value using diagnostic
tool with the ignition key ON.
SDFFL7510D

INSTALLATION
1. Installation is in the reverse of removal.
2. When installing, tighten bolts to the specified torque.
High pressure fuel pipe mounting bolt : 4 ~ 5kgf.m
(39.2 ~ 49N.m, 28.9 ~ 36.2Ib-ft)
Injector clamp mounting bolt : 2.9~3.1kgf.m
(28.4 ~ 30.4N.m, 21 ~ 22.4Ib-ft)
Injector wire nut : 0.18 ~ 0.22kgf.m (1.76 ~ 2.15N.m,
1.3 ~ 1.6Ib-ft)

Follow the instructions on the diagnostic tool as to

how to input injector QR correction value.
If the input of injector QR correction value was
completed, start the engine in 10 sec. after turning
the ignition key OFF.
CAUTION
In case QR correction value described on the
injector is not input in the ECM, there may cause
engine performance and exhaust gas problem.

CLEANING

REPLACEMENT

Clean the injector as follows to be reused.

CAUTION
Since common rail fuel injection operates under
high pressure(1,800bar), a special care should be
taken.

1. Clean the injector by setting the injector vertically to

the clean container.

While engine is running or within 1 min. after

engine stops, any works should not be
performed in relation to common rail fuel
injection system.

In particular, as the injector solenoid generates

high temperature heat, do not touch it with bare
hands. Start the service works only when the
engine has been cooled down enough after
engine stops.

Always keep the safety precautions.

Ensure working area cleans all the time, and

place the removed injector on the clean cloth.
And pay attention to injector nozzle so that it is
not contaminated by foreign materials.

Remove the protective caps which prevents

foreign material inflow for injector and fuel hose
immediately just before installation.

When installing or removing injector, clean the

injector contacting portion and be sure to

2. Remove dust or dirt from the injector body and nozzle

sealing with clean cloth if necessary.

Common Rail Assembly

COMPONENTS

SDGFL9025L

1.
2.
3.
4.

ECM
Injector assembly
Injection pipe
Common rail assembly

5. Fuel supply pump

6. High pressure(common rail~injector)
7. High pressure pipe(common rail~supply pump)

REMOVAL

CAUTION
Since common rail fuel injection operates under
high pressure(1,800bar), a special care should be
taken.

While engine is running or within 1 min. after

engine stops, any works should not be
performed in relation to common rail fuel
injection system.

In particular, as the injector solenoid generates

high temperature heat, do not touch it with bare
hands. Start the service works only when the
engine has been cooled down enough after
engine stops.

Always keep the safety precautions.

Never use the high pressure fuel pipe.

4. Disconnect the injector pipe leading to common rail

(A) from the supply pump.

SDGFL7513D

1. Turn the ignition key OFF.

5. Disconnect the return fuel hose.

2. Disconnect terminal (-) of battery.

6. Disconnect the rail pressure sensor.

3. Disconnect high pressure pipe (A) leading to injector

from rail.

CAUTION
Be careful not to leak the fuel remaining in the
rail.
7. Disconnect the common rail assembly mounting bolt
and then disconnect the common rail assembly (A).

SDGFL7509D

SDGFL7514D

INSTALLATION
1. Install common rail assembly (A).

SDGFL7514D

Common rail assembly mounting bolt :

1.9 ~ 2.8kgf.m( 18.6~27.5Nm,13.7~20.3lb.ft)
2. Tighten high pressure fuel pipe (A) to the specified
torque.
High pressure fuel pipe mounting bolt :
4 ~ 5kgf.m(39.2~49.0Nm, 28.9~36.2lb.ft)

SDGFL7509D

Injection Pump-Electronic
Supply Pump
COMPONENTS

SDGFL9028L

1.
2.
3.
4.
5.

ECM
Injector assembly
Injection pipe
Common rail assembly
Fuel supply pump

6. Fuel return pipe

7. Fuel supply pipe
8. Fuel pump flange
9. Overflow screw
10. Fuel temperature sensor

REMOVAL

1. Turn the ignition key OFF.

CAUTION
Since common rail fuel injection operates under
high pressure(1,800bar), a special care should be
taken.

2. Disconnect terminal (-) of battery.

6. Remove flange mounting bolt and remove supply

pump assembly from flywheel housing.

While engine is running or within 1 min. after

engine stops, any works should not be
performed in relation to common rail fuel
injection system.

In particular, as the injector solenoid generates

high temperature heat, do not touch it with bare
hands. Start the service works only when the
engine has been cooled down enough after
engine stops.

Always keep the safety precautions.

Ensure working area cleans all the time, and

place the removed injector on the clean cloth.
And pay attention to injector nozzle so that it is
not contaminated by foreign materials.

Remove the protective caps which prevents

foreign material inflow for injector and fuel hose
immediately just before installation.

When installing or removing injector, clean the

injector contacting portion and be sure to
replace O-ring and nozzle gasket with new ones.

Apply diesel oil to the O-ring of injector and

insert them into the cylinder head.

Install injector to the cylinder head vertically and

install it correctly not to cause any damage such
as shock.

Be sure to observe the specified tightening

torque of bolts when inserting and tightening the
injector.

Never use the high pressure fuel pipe.

3. Disconnect supply pump connector.

4. Disconnect low pressure pipe.
5. Disconnect high pressure pipe.

NOTICE
When removing supply pump, remove pump, flange
and supply pump gear from assembly.

SDGFL7505D

7. Remove supply pump mounting hexagon bolt and

remove supply pump.

SDGFL7006D

INSTALLATION
1. Rotate the crankshaft to align the cylinder No. 1 at
the TDC (Top Dead Center) position.
a. Align the mark(or painting) at damper pulley
circumferential surface of crankshaft with the
direction mark on block surface.

2. Engine installation after assembling pump gear and

plate
a. Assemble plate to pump and temporarily
assemble gear to pump shaft. Assemble to the
direction of flange (d) from pump (b) and insert
O-ring between pump (b) and flange (d), then
tighten bolt (a).
Supply pump mounting bolt :
1.9 ~ 2.8kgf.m(18.6~27.5Nm, 13.7~20.3lb.ft)

SDGFL7510D

b. Open rocker cover, in view from the rear of

engine, align the mark(or painting) of TDC sensor
gear plate with the head contact surface of block
from the left.

SDGFL7007D

b. When tightening flange and pump, tighten those

so that the mark(1) of flange backside faces the
upper side of straight line as shown in the figure.
Align the part that the number of supply pump
gear is marked with the mark (1) of flange
backside and assemble supply pump gear to
supply pump.
Supply pump gear mounting nut :
6 ~ 7kgf.m(58.8~68.6Nm,43.40~50.6lb.ft)

SDFFL7512D

c. If the above mentioned two items are satisfied,

cylinder #1 is at TDC position.

SDGFL7511D

c. After assembling as above, and also insert O-ring

between pump assembly and block.

SDGFL7512D

d. When installing supply pump assembly to engine,

double check above mentioned items and engage
supply pump gear part with counterpart gear and
then tighten it with bolts.
Flange mounting bolt :
10 ~ 13kgf.m(98.1~127.5Nm, 72.3~94.0lb.ft)
3. Tighten high pressure pipe.
High pressure pipe mounting bolt :
4 ~ 5kgf.m(39.2~49.0Nm, 28.9~36.2lb.ft)
NOTICE
At assembling, assemble those from center to
outside in sequence for convenience's sake.
4. Install low pressure pipe.
5. Install supply pump connector.
6. Install rocker cover.
7. When replacing with the new pump, erase learning
value of the previous pump and be sure to perform
"Pump learning initialization" using the diagnostic tool
to start the learning of new pump newly.
CAUTION
Be sure to perform the above mentioned "Pump
learning initialization" when replacing with the
new pump.
If the above mentioned "Pump learning
initialization" is not performed with the
diagnostic tool after replacing with new pump,
the engine performance could be deteriorated
and there may have problems in the emission
gas.