Fuel System

GENERAL VGT CONTROL SOLENOID VALVE

LAMBDA SENSOR
DIESEL CONTROL SYSTEM EXHAUST GAS TEMPERATURE SENSOR
ENGINE CONTROL MODULE (ECM) (EGTS) FOR VGT
INJECTOR EXHAUST GAS TEMPERATURE SENSOR
MASS AIR FLOW SENSOR (MAFS) (EGTS) FOR CPF
BOOST PRESSURE SENSOR (BPS) DIFFERENTIAL PRESSURE SENSOR (DPS)
INTAKE AIR TEMPERATURE SENSOR (IATS) THROTTLE FLAP CONTROL SOLENOID VALVE
ENGINE COOLANT TEMPERATURE SENSOR CATALYZED PARTICULATE FILTER (CPF)
(ECTS)
CAMSHAFT POSITION SENSOR (CMPS) DTC TROUBLESHOOTING PROCEDURES
CRANKSHAFT POSITION SENSOR (CKPS)
ACCELERATOR POSITION SENSOR (APS)
RAIL PRESSURE SENSOR (RPS) FUEL DELIVERY SYSTEM-DIESEL
FUEL TEMPERATURE SENSOR (FTS) FUEL TANK
FUEL PRESSURE REGULATOR VALVE FUEL SENDER
RAIL PRESSURE REGULATOR VALVE FUEL FILTER
ELECTRIC EGR CONTROL VALVE FILLER-NECK ASSEMBLY
THROTTLE CONTROL ACTUATOR ACCELERATION PEDAL
VARIABLE SWIRL CONTROL ACTUATOR HIGH PRESSURE FUEL PUMP
WATER SENSOR COMMON RAIL
FLB -2 FUEL SYSTEM
GENERAL FLB -3

GENERAL
SPECIFICATIONS ECF59350

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 53 lit. (56.0 U.S qt., 46.6 lmp qt.)
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 INTAKE AIR TEMPERATURE SENSOR (IATS) #1 [BUILT

IN MAFS]
MASS AIR FLOW SENSOR (MAFS) ▷ Type: Thermistor type
▷ Type: Hot-Film Type ▷ Specification
▷ Specification
* At intake air temperature = 20℃(68℉) Temperature [℃(℉)] Resistance(㏀)
Air Flow (kg/h) Frequency (kHz) -40(-40) 35.14 ~ 43.76
8 1.96 ~ 1.97 -20(-4) 12.66 ~ 15.12
10 2.01 ~ 2.02 0(32) 5.12 ~ 5.89
40 2.50 ~ 2.52 20(68) 2.29 ~ 2.55
105 3.18 ~ 3.23 40(104) 1.10 ~ 1.24
220 4.26 ~ 4.35 60(140) 0.57 ~ 0.65
480 7.59 ~ 7.94 80(176) 0.31 ~ 0.37
560 9.08 ~ 9.89
BOOST PRESSURE SENSOR (BPS)
▷ Type: Piezo-resistive pressure sensor type
* At intake air temperature = -15℃(5℉) or 80℃(176℉)
▷ Specification
Air Flow (kg/h) Frequency (kHz)
Pressure (kPa) Output Voltage (V)
10 2.00 ~ 2.02
32.5 0.5
40 2.49 ~ 2.53
70 1.02 ~ 1.17
105 3.16 ~ 3.25
140 2.13 ~ 2.28
480 7.42 ~ 8.12
210 3.25 ~ 3.40
270 4.20 ~ 4.35
284 4.5
FLB -4 FUEL SYSTEM

INTAKE AIR TEMPERATURE SENSOR (IATS) #2 [BUILT ▷ Specification

IN BPS]
▷ Type: Thermistor type Output Voltage(V)
▷ Specification Test Condition
APS 1 APS 2

Temperature [℃(℉)] Resistance(㏀) Idle 0.7 ~ 0.8 0.275 ~ 0.475

-40(-40) 40.93 ~ 48.35 Fully

3.8 ~ 4.4 1.75 ~ 2.35
depressed
-20(-4) 13.89 ~ 16.03
0(32) 5.38 ~ 6.09 Specification
Items
20(68) 2.31 ~ 2.57 APS 1 APS 2
40(104) 1.08 ~ 1.21 Potentiometer
0.7 ~ 1.3 1.4 ~ 2.6
60(140) 0.54 ~ 0.62 Resistance (㏀)

80(176) 0.29 ~ 0.34

FUEL TEMPERATURE SENSOR (FTS)
▷ Type: Thermistor type
ENGINE COOLANT TEMPERATURE SENSOR (ECTS) ▷ Specification
▷ Type: Thermistor type
▷ Specification
Temperature [℃(℉)] Resistance(㏀)

Temperature [℃(℉)] Resistance(㏀) -30(-22) 27.00

-40(-40) 48.14 -20(-4) 15.00

-20(-4) 14.13 ~ 16.83 -10(14) 9.45

0(32) 5.79 0(32) 5.89

20(68) 2.31 ~ 2.59 20(68) 2.27 ~ 2.73

40(104) 1.15 40(104) 1.17

60(140) 0.59 50(122) 0.83

80(176) 0.32 60(140) 0.60

70(158) 0.43
CAMSHAFT POSITION SENSOR (CMPS) 80(176) 0.30 ~ 0.32
▷ Type: Hall effect type
▷ Specification
RAIL PRESSURE SENSOR (RPS)
Level Output Pulse (V) ▷ Type: Piezo-electricity type
▷ Specification
High 12V
Low 0V Rail pressure Output
Test Condition
(bar) Voltage(V)

Items Specification Idle 220 ~ 320 Below 1.7

Air Gap 1.0 ± 0.5 mm Fully

1,600 Approx. 4.5
depressed

CRANKSHAFT POSITION SENSOR (CKPS)

▷ Type: Variable reluctance type
▷ Output Voltage (V): 0 ~ 5V

Items Specification
Coil Resistance ( )) 774 ~ 946 [20℃(68℉)]

ACCELERATOR POSITION SENSOR (APS)

▷ Type: Potentiometer type
GENERAL FLB -5

LAMBDA SENSOR 0 1.00

▷ Type: Zirconia (ZrO2) Type
▷ Specification 10 1.35
20 1.70
λ Value (A/F Ratio) Pumping Current(A) 30 2.05
0.65 -2.22 40 2.40
0.70 -1.82 50 2.75
0.80 -1.11 60 3.10
0.90 -0.50 70 3.45
1.01 0.00 80 3.80
1.18 0.33 90 4.15
1.43 0.67 100 4.50
1.70 0.94
2.42 1.38 WATER SENSOR
▷ Specification
Air (Atmosphere) 2.54
Item Specification
Item Specification Warning Level (cc) 40 ~ 60
Heater Resistance ( ) 2.4 ~ 4.0 [20℃(68℉)]
VEHICLE SPEED SENSOR (VSS)
EXHAUST GAS TEMPERATURE SENSOR (EGTS) #1 ▷ Type: Inductive type
FOR VGT
▷ Type: Thermistor type
▷ Specification

Temperature [℃(℉)] Resistance(㏀)

100(212) 289.0 ~ 481.0
300(572) 5.30 ~ 6.61
600(1,112) 0.35 ~ 0.38
900(1,652) 0.08 ~ 0.09

EXHAUST GAS TEMPERATURE SENSOR (EGTS) #2

FOR CPF
▷ Type: Thermistor type
▷ Specification

Temperature [℃(℉)] Resistance(㏀)

100(212) 289.0 ~ 481.0
300(572) 5.30 ~ 6.61
600(1,112) 0.35 ~ 0.38
900(1,652) 0.08 ~ 0.09

DIFFERENTIAL PRESSURE SENSOR (DPS)

▷ Type: Piezo-electricity type
▷ Specification: Vout = (4.5 - 1.0) / 100 * △P + 1.0 (V)

Differential Pressure
Output Voltage (V)
[△P] (kPa)
FLB -6 FUEL SYSTEM

ACTUATORS THROTTLE FLAP CONTROL SOLENOID VALVE [WITH-

OUT CPF]
INJECTOR ▷ Specification
▷ Number: 4
▷ Specification Items Specification

Items Specification Coil Resistance (Ω ) 14.7 ~ 16.1Ω [20℃(68℉)]

0.215 ~ 0.295Ω
Coil Resistance (Ω ) VARIABLE SWIRL CONTROL ACTUATOR
[20℃(68℉)]
▷ Type: Motor Driven (including Position Sensor)
▷ Specification
FUEL PRESSURE REGULATOR VALVE Motor
▷ Specification
Items Specification
Items Specification
Coil Resistance (Ω ) 3.4 ~ 4.4Ω [20℃(68℉)]
Coil Resistance (Ω ) 2.6 ~ 3.15Ω [20℃(68℉)]
Position Sensor
RAIL PRESSURE REGULATOR VALVE
▷ Specification Items Specification

Items Specification Coil Resistance (kΩ ) 3.44 ~ 5.16㏀ [20℃(68℉)]

Coil Resistance (Ω ) 3.42 ~ 3.78 [20℃(68℉)]

THROTTLE CONTROL ACTUATOR [WITH CPF]

▷ Type : Duty control motor type
▷ Specification

Duty (%) Throttle Valve Position

5 Open
Normal operation (Partially open
5 ~ 94
in proportion to duty value)
94 Closed
94 ~ 95 Maintaining the last valid position
95 ~ 97 Fully closed

ELECTRIC EGR CONTROL VALVE

▷ Type: Linear solenoid type
▷ Specification

Items Specification

Coil Resistance (Ω ) 7.3 ~ 8.3Ω [20℃(68℉)]

VGT CONTROL SOLENOID VALVE

▷ Specification

Items Specification

Coil Resistance (Ω ) 28.3 ~ 31.1Ω [20℃(68℉)]

GENERAL FLB -7

SERVICE STANDARD E462F09F

Neutral,N,P-range 780 ± 100 rpm

A/C OFF
Basic Idle rpm(After D-range 780 ± 100 rpm
warm up) Neutral,N,P-range 780 ± 100 rpm
A/C ON
D-range 780 ± 100 rpm

TIGHTENING TORQUES E61ACE2A

ENGINE CONTROL SYSTEM

Item Kgf·m N·m lbf·ft

ECM installation bolts 0.8 ~ 1.2 7.8 ~ 11.8 5.8 ~ 8.7
Mass air flow sensor clamp installation bolts 0.3 ~ 0.5 2.9 ~ 4.9 2.2 ~ 3.6
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 47.9 ~ 55.3
Lambda sensor installation 4.0 ~ 6.0 39.2 ~ 58.9 28.9 ~ 43.4
Rail pressure regulator valve installation 8.1 ~ 9.1 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
Variable swirl control actuator installation bolts 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
Exhaust gas temperature sensor (For CPF) installation 4.0 ~ 5.0 39.2 ~ 49.1 28.9 ~ 36.2
Exhaust gas temperature sensor (For VGT) installation 4.0 ~ 5.0 39.2 ~ 49.1 28.9 ~ 36.2
Differential pressure sensor bracket installation nuts 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
Throttle control actuator [With CPF] installation nuts 0.7 ~ 1.1 6.9 ~ 10.8 5.1 ~ 8.0
Throttle body [Without CPF] installation nuts 0.7 ~ 1.1 6.9 ~ 10.8 5.1 ~ 8.0
VGT control solenoid valve bracket installation bolt 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

Pipe (DPS ↔ CPF) installation (CPF side) 3.5 ~ 5.1 34.3 ~ 50.0 25.3 ~ 36.9
FLB -8 FUEL SYSTEM

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 2.5 ~ 2.9 24.5 ~ 28.4 18.1 ~ 21.0
Rail) installation nuts

High pressure fuel pipe (Common RaiI ↔ High Pressure 2.5 ~ 2.9 24.5 ~ 28.4 18.1 ~ 21.0
Fuel Pump) installation nuts
Fuel tank band installation bolts 4.0 ~ 5.5 39.2 ~ 54.0 28.9 ~ 39.8
Fuel Sender installation bolts 0.2 ~ 0.3 2.0 ~ 2.9 1.4 ~ 2.2
Accelerator pedal module installation bolts 1.3 ~ 1.6 12.8 ~ 15.7 9.4 ~ 11.6
GENERAL FLB -9

SPECIAL SERVICE TOOLS E801DD4D

Tool (Number and name) Illustration Application

09351-4A300 Removing the injector
Injector Remover

SVQFL6499D

09314-27110(14mm) Installing the high pressure fuel pipe

09314-27120(17mm)
Torque Wrench Socket

AFAF201B

09331-2A000
High Pressure Fuel Pump Removing the high pressure fuel pump
Sprocket Remover

LXGF021A
FLB -10 FUEL SYSTEM

BASIC TROUBLESHOOTING E0D4B851

BASIC TROUBLESHOOTING GUIDE

1 Bring Vehicle to Workshop

2 Analyze Customer’s Problem

Ask the customer about the conditions and environment relative to the issue
(Use CUSTOMER PROBLEM ANALYSIS SHEET).

3 Verify Symptom, and then Check DTC and Freeze Frame Data
Connect Hi-Scan (Pro) to Diagnostic Link Connector (DLC).
Record the DTC and freeze frame data.

NOTE
To erase DTC and freeze frame data, refer to Step 5.

4 Confirm the Inspection Procedure for the System or Part

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

5 Erase the DTC and Freeze Frame Data

WARNING
NEVER erase DTC and freeze frame data before completing Step 2 MIL/DTC in "CUSTOMER PROBLEM
ANALYSIS SHEET".

6 Inspect Vehicle Visually

Go to Step 11, if you recognize the problem.

7 Recreate (Simulate) Symptoms of the DTC

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

8 Confirm Symptoms of Problem

If DTC(s) is/are not displayed, go to Step 9.
If DTC(s) is/are displayed, go to Step 11.

9 Recreate (Simulate) Symptom

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

10 Check the DTC

If DTC(s) does(do) not occur, refer to INTERMITTENT PROBLEM PROCEDURE in BASIC INSPECTION PROCEDURE.
If DTC(s) occur(s), go to Step 11.

11 Perform troubleshooting procedure for DTC

12 Adjust or repair the vehicle

13 Confirmation test

14 END
LW8F1001
GENERAL FLB -11

CUSTOMER PROBLEM ANALYSIS SHEET

1. VEHICLEINFORMAITON
VIN No. Transmission M/T A/T CVT etc.
Production date Driving type 2WD (FF) 2WD (FR) 4WD
Odometer CPF
km/mile With CPF Without CPF
Reading (Diesel Engine)

2. SYMPTOMS
Engine does not turn over Incomplete combustion
Unable to start
Initial combustion does not occur

Difficult to start Engine turns over slowly Other

Rough idling Incorrect idling

Poor idling Unstable idling (High: rpm, Low: rpm )
Other

Soon after starting After accelerator pedal depressed

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

Poor driving (Surge) Knocking Poor fuel economy

Others
Back fire After fire Other

3. ENVIRONMENT

Problem frequency Constant Sometimes ( ) Once only

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

Place Highway Suburbs Inner City Uphill Downhill

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

Starting Just after starting ( min) Idling Racing

Engine operation Driving Constant speed Acceleration Deceleration
A/C switch ON/OFF Other

4. MIL/DTC
MIL (Malfunction Indicator
Lamp) Remains ON Sometimes lights up Does not light

Normal check Normal DTC ( )

(Pre-check) Freeze Frame Data
DTC
Check mode Normal DTC ( )
Freeze Frame Data

5. ECM/PCM INFORMATION
ECM/PCM Part No.
ROM ID

SFDF28233L
FLB -12 FUEL SYSTEM

BASIC INSPECTION PROCEDURE 4. Repair or replace the component that has a problem.

MEASURING CONDITION OF ELECTRONIC PARTS’ 5. Verify that the problem has disappeared with the road
RESISTANCE test.
The measured resistance at high temperature after vehi- ● SIMULATING VIBRATION
cle running may be high or low. So all resistance must a. Sensors and Actuators
be measured at ambient temperature (20℃, 68℉), unless : Slightly vibrate sensors, actuators or relays with fin-
stated otherwise. ger.

NOTE
WARNING
The measured resistance in except for ambient tem-
Strong vibration may break sensors, actuators or
perature (20℃, 68℉) is reference value.
relays
INTERMITTENT PROBLEM INSPECTION
PROCEDURE b. Connectors and Harness
: Lightly shake the connector and wiring harness ver-
Sometimes the most difficult case in troubleshooting is tically and then horizontally.
when a problem symptom occurs but does not occur again
during testing. An example would be if a problem appears ● SIMULATING HEAT
only when the vehicle is cold but has not appeared when a. Heat components suspected of causing the malfunc-
warm. In this case, the technician should thoroughly make tion with a hair dryer or other heat source.
out a "CUSTOMER PROBLEM ANALYSIS SHEET" and
recreate (simulate) the environment and condition which WARNING
occurred when the vehicle was having the issue.
• DO NOT heat components to the point where
1. Clear Diagnostic Trouble Code (DTC). they may be damaged.
• DO NOT heat the ECM directly.
2. Inspect connector connection, and check terminal for
poor connections, loose wires, bent, broken or cor- ● SIMULATING WATER SPRINKLING
roded pins, and then verify that the connectors are a. Sprinkle water onto vehicle to simulate a rainy day or
always securely fastened. a high humidity condition.

WARNING
DO NOT sprinkle water directly into the engine
compartment or electronic components.

● SIMULATING ELECTRICAL LOAD

a. Turn on all electrical systems to simulate excessive
electrical loads (Radios, fans, lights, rear window de-
fogger, etc.).

BFGE321A

3. Slightly shake the connector and wiring harness ver-

tically and horizontally.
GENERAL FLB -13

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

measure voltage, always insert tester probe from
1. Handling of Connector wire harness side.
a. Never pull on the wiring harness when discon-
necting connectors.

BFGE015I

BFGE015F e. Check waterproof connector terminals from the

connector side. Waterproof connectors cannot
b. When removing the connector with a lock, press be accessed from harness side.
or pull locking lever.

BFGE015J

BFGE015G

NOTE
c. Listen for a click when locking connectors. This
sound indicates that they are securely locked. • Use a fine wire to prevent damage to the terminal.
• Do not damage the terminal when inserting the
tester lead.

"CLICK"
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 bro-
ken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deforma-
tion and bend.
c. Check terminal tightening condition:
Insert a spare male terminal into a female ter-
minal, and then check terminal tightening condi-
BFGE015H tions.
FLB -14 FUEL SYSTEM

d. Pull lightly on individual wires to ensure that each ELECTRICAL CIRCUIT INSPECTION PROCEDURE
wire is secured in the terminal.
● CHECK OPEN CIRCUIT

1. Procedures for Open Circuit

• Continuity Check
• 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.

FIG 1

ECM
BFGE015K SENSOR
1 1 1 1

3. Repair Method of Connector Terminal 2 2 2 2

a. Clean the contact points using air gun and/or (C) (B) (A)

shop rag.

NOTE
Never use sand paper when polishing the contact
points, otherwise the contact point may be damaged.
BFGE501A

b. In case of abnormal contact pressure, replace

the female terminal. 2. Continuity Check Method

WIRE HARNESS INSPECTION PROCEDURE NOTE

1. Before removing the wire harness, check the wire har- When measuring for resistance, lightly shake the wire
ness position and crimping in order to restore it cor- harness above and below or from side to side.
rectly.
Specification (Resistance)
2. Check whether the wire harness is twisted, pulled or 1Ω or less → Normal Circuit
loosened. 1㏁ or Higher → Open Circuit

3. Check whether the temperature of the wire harness is

a. Disconnect connectors (A), (C) and measure
abnormally high.
resistance between connector (A) and (C) as
4. Check whether the wire harness is rotating, moving shown in [FIG. 2].
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.
GENERAL FLB -15

In [FIG.2.] the measured resistance of line 1 and

2 is higher than 1㏁ and below 1 Ω respectively. FIG 4
Specifically the open circuit is line 1 (Line 2 is
normal). To find exact break point, check sub line
V
of line 1 as described in next step.
ECM

FIG 2 SENSOR
1 1 1 1

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

1 1 1 1

2 2 2 2 ECM
(C) (B) (A)
SENSOR
BFGE501D

● CHECK SHORT CIRCUIT

1. Test Method for Short to Ground Circuit

• Continuity Check with Chassis Ground
BFGE501B
If short to ground circuit occurs as shown in [FIG. 5],
b. Disconnect connector (B), and measure for resis- the broken point can be found by performing Step 2
tance between connector (C) and (B1) and be- (Continuity Check Method with Chassis Ground) as
tween (B2) and (A) as shown in [FIG. 3]. shown below.

In this case the measured resistance between

connector (C) and (B1) is higher than 1㏁ and the FIG 5
open circuit is between terminal 1 of connector
(C) and terminal 1 of connector (B1).
ECM

SENSOR
FIG 3 1 1 1 1

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

1 1 1 1

2 2 2 2 ECM
(C) (B1) (B2) (A)
SENSOR
BFGE501E

BFGE501C

3. Voltage Check Method

a. With each connector still connected, measure the
voltage between the chassis ground and terminal
1 of each connectors (A), (B) and (C) as shown
in [FIG. 4].

The measured voltage of each connector is 5V,

5V and 0V respectively. So the open circuit is
between connector (C) and (B).
FLB -16 FUEL SYSTEM

2. Continuity Check Method (with Chassis Ground) b. Disconnect connector (B), and measure the
resistance between connector (A) and chassis
NOTE ground, and between (B1) and chassis ground
as shown in [FIG. 7].
Lightly shake the wire harness above and below, or
from side to side when measuring the resistance. The measured resistance between connector
(B1) and chassis ground is 1Ω or less. The
Specification (Resistance)
short to ground circuit is between terminal 1 of
1Ω or less → Short to Ground Circuit
connector (C) and terminal 1 of connector (B1).
1MΩ or Higher → Normal Circuit

a. Disconnect connectors (A), (C) and measure for FIG 7

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

The measured resistance of line 1 and 2 in this 1 1 1 1

example is below 1 Ω and higher than 1MΩ re- 2 2 2 2 ECM

spectively. Specifically the short to ground circuit (C) (B1) (B2) (A)
is line 1 (Line 2 is normal). To find exact broken SENSOR
point, check the sub line of line 1 as described in
the following step.

FIG 6
BFGE501G

1 1 1 1

2 2 2 2 ECM
(C) (B) (A)
SENSOR

BFGE501F
GENERAL FLB -17

SYMPTOM TROUBLESHOOTING GUIDE TABLE

(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, • Faulty low pressure fuel pump
stuck, jammed • Faulty high pressure fuel pump
• Rail pressure regulator valve contaminated, • Injector jammed open
stuck, 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,
• Carbon deposit on the injector (sealed holes)
stuck, jammed
• Injector needle stuck (injection possible over
• Rail pressure regulator valve contaminated,
a certain pressure)
stuck, 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
• Compensation of individual injector not adapted
• Clogged return line of high pressure fuel pump
• No rail pressure sensor signal
• Clogged fuel filter
• Electric EGR control valve blocked open
• Low compression pressure
• Fuel pressure regulator valve contaminated,
• Intermittent faulty fuel line connection
stuck, jammed
• Carbon deposit on the injector (sealed holes)
• Rail pressure regulator valve contaminated,
• Injector needle stuck (injection possible over
stuck, jammed
a certain pressure)
• Clogged air filter
• Gasoline in fuel
• Air ingress in the low pressure fuel circuit
• ECM program error or hardware fault
• Bad fuel quality or water ingress in fuel
FLB -18 FUEL SYSTEM

(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
• Clogged air filter a certain 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
• No engine coolant temperature sensor signal
• Incorrect state of the electrical pack devices • Electric EGR control valve blocked open
• Faulty alternator or voltage regulator • Faulty accelerator pedal
• ECM program error or hardware fault

(SYMPTOM 6) BLUE, WHITE, OR BLACK SMOKES

Possible Cause
• Compensation of individual injector not adapted
• Clogged air filter
• No engine coolant temperature sensor signal
• Oil suction (engine racing)
• No rail pressure sensor signal
• Faulty glow system
• Electric EGR control valve blocked open
• Low compression pressure
• Fuel pressure regulator valve contaminated,
• Poor tightening of injector clamp
stuck, jammed
• Poor injector O-ring, no O-ring or two O-ring installed
• Rail pressure regulator valve contaminated,
• Injector not adapted
stuck, jammed
• Carbon deposit on the injector (sealed holes)
• Oil level too high or too low
• Injector jammed open
• Bad fuel quality or water ingress in fuel
• Gasoline in fuel
• Sealed or damaged catalytic converter

(SYMPTOM 7) ENGINE RATTLING, NOISY ENGINE

Possible Cause
• Compensation of individual injector not adapted
• Poor injector O-ring, no O-ring or two O-ring installed
• Electric EGR control valve blocked open
• Injector not adapted
• Electric EGR control valve blocked open
• Carbon deposit on the injector (sealed holes)
• No engine coolant temperature sensor signal
• Injector needle stuck (injection possible over
• Faulty glow system
a certain pressure)
• Low compression pressure
• Injector jammed open
• Clogged injector return line
• No engine coolant temperature sensor signal
• No rail pressure sensor signal
GENERAL FLB -19

(SYMPTOM 8) NURST NOISE

Possible Cause
• Fuel pressure regulator valve contaminated,
• Compensation of individual injector not adapted
stuck, jammed
• Intermittent faulty fuel line connection
• Rail pressure regulator valve contaminated,
• Clogged exhaust system
stuck, jammed
• No rail pressure sensor signal
• ECM program error or hardware fault

(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
• Fuel pressure regulator valve contaminated,
• Incorrect state of the electrical pack devices
stuck, jammed
• Blocked accelerator pedal position sensor
• Rail pressure regulator valve contaminated,
• Electric EGR control valve blocked open
stuck, jammed
• Damaged turbocharger or leakage in vacuum line
• Injector needle stuck (injection possible over
• Clogged fuel filter
a certain pressure)
• Low compression pressure
• ECM program error or hardware fault
• Leakage in high pressure fuel circuit

(SYMPTOM 11) ENGINE STOP

Possible Cause
• Run out of fuel
• Not connected fuel feed line • Rail pressure regulator valve contaminated,
• Leakage in high pressure fuel circuit stuck, 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, • ECM program error or hardware fault
stuck, jammed
FLB -20 FUEL SYSTEM

(SYMPTOM 12) ENGINE JUDDER

Possible Cause
• Run out of fuel
• Low compression pressure
• Not connected fuel return line at injector
• Clogged injector return line
• Incorrect state of the electrical pack devices
• Poor valve clearance
• Compensation of individual injector not adapted
• Faulty low pressure fuel pump
• Electric EGR control valve blocked open
• Poor injector O-ring, no O-ring or two O-ring installed
• Faulty fuel filter
• Carbon deposit on the injector (sealed holes)
• Air ingress in the low pressure fuel circuit
• Injector needle stuck (injection possible over
• Bad fuel quality or water ingress in fuel
a certain pressure)
• Clogged fuel filter
• Injector jammed open
• Intermittent faulty fuel line connection
• Gasoline in fuel
• Wiring harness open or poor connection
• ECM program error or hardware fault
• Faulty glow system

(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
• Compensation of individual injector not adapted
• ECM program error or hardware fault
• 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
• 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
GENERAL FLB -21

(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
• Compensation of individual injector not adapted a certain 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
• Sealed or damaged catalytic converter a certain 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
• Not connected fuel return line at injector
• Leakage in high pressure fuel circuit
• 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,
• Inversion of fuel connections (feed ＆ return) stuck, jammed
• Faulty fuel filter • Rail pressure regulator valve contaminated,
• Bad fuel quality or water ingress in fuel stuck, jammed
• 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
FLB -22 FUEL SYSTEM

(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
DIESEL CONTROL SYSTEM FLB -23

DIESEL CONTROL SYSTEM CHECKING PROCEDURE (SELF-DIAGNOSIS)

NOTE
DESCRIPTION E8D782EE
• When attery voltage is excessively low, diagnos-
If the disel control system components (sensors, ECM, in- tic trouble codes can not be read. Be sure to
jector, etc.) fail, interruption to the fuel supply or failure to check the battery for voltage and the charging
supply the proper amount of fuel for variousengine operat- system before starting the test
ing conditions will result. The following situations may be • Diagnosis memory is erased if the battery or
encountered the ECM connector is disconnected. Do not
disconnect the battery before the diagnostic
1. Engine is hard to start or does not start at all. trouble codes are completely read and recorded.
2. Nstable idle.
3. Poor driveability. INSPECTION PROCEDURE (USING GENERIC SCAN
TOOL)
If any of the above conditions are noted, first perform
1. Turn OFF the ignition switch.
a routine diagnosis that includes basic engine checks
(ignition system malfunction, incorrectengine adjustment, 2. Connect the scan tool to the data link connector on
etc.). Then, inspect the disel contorl system components the lower crash pad.
with a scan tool.

NOTE
• Before removing or installing any part, read the
diagnostic trouble codesand then disconnect the
battery negative (-) terminal.
• Before disconnecting the cable from battery ter-
minal, 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 pre-
vent the ECM from damage due to the voltage.
• Wcharging the battery with the external charger,
disconnect the vehicleside battery terminals to AWJF300D

prevent damage to the ECM.

3. Turn ON the ignition switch.
SELF-DIAGNOSIS
4. Use the scan tool to check the diagnostic trouble
The ECM monitors the input/output signals (some signals code.
at all times and theothers under specified conditions).
When the ECM detects an irregularity, it records the 5. Repair the faulty part from the diagnosis chart.
diagnostic trouble code, and outputs the signal to the
6. Erase the diagnostic trouble code.
Data Link connector. The diagnosis results can be read
with the MIL or scan tool. Diagnostic Trouble Code(DTC) 7. Disconnect the scan tool.
will remain in the ECM and may be deleted by the scan
tool.
NOTE
NOTE When deleting diagnostic trouble code, use scan tool
as possible.
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 neg-
ative terminal (-) for 15 seconds or more, and the di-
agnosis memory will be erased.
FLB -24 FUEL SYSTEM

COMPONENT LOCATION E67B2F81

18 30 21 12 19 10 13 7 22 15 8 2 3 32 1 27

28 29 26 11 20 23 25 9 24 6 17 4 5

31 16

1. ECM (Engine Control Module) 11. Fuel Temperature Sensor (FTS) 21. Rail Pressure Regulator Valve
2. Mass Air Flow Sensor (MAFS) 12. Differential Pressure Sensor (DPS) 22. Electric EGR Control Valve
3. Intake Air Temperature Sensor [With CPF] 23. VGT Control Solenoid Valve
(IATS) #1 built in MAFS 13. Exhaust Gas Temperature Sensor 24. Throttle Control Actuator [With CPF]
4. Boost Pressure Sensor (BPS) (EGTS) #1 for VGT [With CPF] 25. Throttle Flap Control
5. Intake Air Temperature Sensor 14. Exhaust Gas Temperature Sensor Solenoid Valve [Without CPF]
(IATS) #2 built in BPS (EGTS) #2 for CPF [With CPF] 26. Variable Swirl Control Actuator
6. Crankshaft Position Sensor (CKPS) 15. Water Sensor (included in Fuel Filter) 27. Main Relay
7. Camshaft Position Sensor (CMPS) 16. Accelerator Pedal Position Sensor (APS) 28. Glow Relay
8. Engine Coolant Temperature Sensor 17. Vehicle Speed Sensor (VSS) 29. PTC Heater Relay (Optional)
(ECTS) 18. A/C Pressure Transducer (APT) 30. Air Heater Relay
9. Rail Pressure Sensor (RPS) 19. Injector 31. Data Link Connector (DLC)
10. Lambda Sensor 20. Fuel Pressure Regulator Valve 32. Multi-Purpose Check Connector
SFDF28200L
DIESEL CONTROL SYSTEM FLB -25

2. Mass Air Flow Sensor (MAFS)

1. ECM (Engine Control Module)
3. Intake Air Temperature Sensor (IATS) #1 built in MAFS

MAFS & IATS #1

ECM

SHDF26014D SFDF28231L

4. Boost Pressure Sensor (BPS) 6. Crankshaft Position Sensor (CKPS)

5. Intake Air Temperature Sensor (IATS) #2 built in BPS2 17. Vehicle Speed Sensor (VSS)

BPS & IATS #2 CKPS

VSS

SHDF26003D SHDF26006D

7. Camshaft Position Sensor (CMPS)

8. Engine Coolant Temperature Sensor (ECTS)
22. Electric EGR Control Valve

EEGR ECTS

CMPS

SLDFL6105L SFDF28201L
FLB -26 FUEL SYSTEM

9. Rail Pressure Sensor (RPS)

19. Injector 10. Lambda Sensor
21. Rail Pressure Regulator Valve

Injector

RPS

Lambda Sensor

Rail Pressure
Regulator Valve

SFDF28202L SHDF26005L

11. Fuel Temperature Sensor (FTS)

12. Differential Pressure Sensor (DPS) [With CPF]
21. Fuel Pressure Regulator Valve

FTS

Fuel Pressure Regulator Valve DPS

SFDF28203L
SHDF26008L

13. Exhaust Gas Temperature Sensor (EGTS) 14. Exhaust Gas Temperature Sensor (EGTS)
#1 for VGT [With CPF] #2 for CPF [With CPF]

EGTS #1

EGTS #2

SEDF27002L SFDF28204L
DIESEL CONTROL SYSTEM FLB -27

15. Water Sensor (included in Fuel Filter) 16. Accelerator Pedal Position Sensor (APS)

Fuel Filter APS

Water Sensor

SFDF28205L SHDF26007D

23. VGT Control Solenoid Valve

18. A/C Pressure Transducer (APT)
25. Throttle Flap Control Solenoid Vlave [Without CPF]

Throttle Flap Control Solenoid

Valve

VGT Control Solenoid Valve

APT

SHDF26009D SFDF28206L

24. Throttle Control Actuator [With CPF] 26. Variable Swirl Control Actuator

Throttle Control Actuator

Variable Swirl Control Actuator

SEDF27005L SLDFL6114L
FLB -28 FUEL SYSTEM

28. Glow Relay

27. Main Relay
29. PTC Heater Relay (Optional)

PTC
Heater Relay

Main Relay Glow Relay

SFDF28207L SFDF38265L

30. Air Heater Relay

Air Heater Relay

SFDF28234L
DIESEL CONTROL SYSTEM FLB -29

ENGINE CONTROL MODULE

(ECM)

ECM (ENGINE CONTROL MODULE) E65E0911

1. ECM HARNESS CONNECTOR

60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 6 5
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51
4 3
30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29
2 1
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7

CUD-A CUD-K

SFDF28225L

2. ECM TERMINAL FUNCTION

CONNECTOR [CUD-A]

Pin Description Connected to

Injector (Cylinder #3) [HIGH] control output Injector (Cylinder #3) [With Immobilizer]
1
Injector (Cylinder #2) [HIGH] control output Injector (Cylinder #2) [Without Immobilizer]
Injector (Cylinder #2) [HIGH] control output Injector (Cylinder #2) [With Immobilizer]
2
Injector (Cylinder #3) [HIGH] control output njector (Cylinder #3) [Without Immobilizer]
3 -
4 Battery power Rail Pressure Regulator Valve
5 -
6 Sensor ground Position Sensor in Variable Swirl Control Actuator
7 Sensor shield Crankshaft Position Sensor (CKPS)
8 Sensor ground Rail Pressure Sensor (RPS)
9 -
10 -
11 -
Crankshaft Position Sensor (CKPS) [-] signal input Crankshaft Position Sensor (CKPS) [A/T]
12
Crankshaft Position Sensor (CKPS) [+] signal input Crankshaft Position Sensor (CKPS) [M/T]
13 Sensor power (+5V) Boost Pressure Sensor (BPS)
14 -
15 -
Injector (Cylinder #1) [HIGH] control output Injector (Cylinder #1) [With Immobilizer]
16
Injector (Cylinder #4) [HIGH] control output Injector (Cylinder #4) [Without Immobilizer]
Injector (Cylinder #4) [HIGH] control output Injector (Cylinder #4) [With Immobilizer]
17
Injector (Cylinder #1) [HIGH] control output Injector (Cylinder #1) [Without Immobilizer]
FLB -30 FUEL SYSTEM

Pin Description Connected to

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 Sensor power (+5V) Position Sensor in Variable Swirl Control Actuator
Crankshaft Position Sensor (CKPS) [+] signal input Crankshaft Position Sensor (CKPS) [A/T]
27
Crankshaft Position Sensor (CKPS) [-] signal input Crankshaft Position Sensor (CKPS) [M/T]
28 Sensor power (+5V) Rail Pressure Sensor (RPS)
29 -
30 Motor [-] control output Variable Swirl Control Actuator
Injector (Cylinder #2) [LOW] control output Injector (Cylinder #2) [With Immobilizer]
31
Injector (Cylinder #3) [LOW] control output Injector (Cylinder #3) [Without Immobilizer]
32 -
Injector (Cylinder #4) [LOW] control output Injector (Cylinder #4) [With Immobilizer]
33
Injector (Cylinder #1) [LOW] control output Injector (Cylinder #1) [Without Immobilizer]
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 MAFS ＆ IATS #1
45 -
Injector (Cylinder #3) [LOW] control output Injector (Cylinder #3) [With Immobilizer]
46
Injector (Cylinder #2) [LOW] control output Injector (Cylinder #2) [Without Immobilizer]
Injector (Cylinder #1) [LOW] control output Injector (Cylinder #1) [With Immobilizer]
47
Injector (Cylinder #4) [LOW] control output Injector (Cylinder #4) [Without Immobilizer]
48 -
49 Fuel Pressure Regulator Valve control output Fuel Pressure Regulator Valve
50 Camshaft Position Sensor (CMPS) signal input Camshaft Position Sensor (CMPS)
51 -
DIESEL CONTROL SYSTEM FLB -31

Pin Description Connected to

52 -
53 Intake Air Temperature Sensor (IATS) #2 signal input Intake Air Temperature Sensor (IATS) #2 built in BPS
54 -
55 -
56 Position Sensor signal input Position Sensor in Variable Swirl Control Actuator
57 -
Engine Coolant Temperature Sensor
58 Engine Coolant Temperature Sensor (ECTS)
(ECTS) signal input
59 Electric EGR Control Valve control output Electric EGR Control Valve
60 Motor [+] control output Variable Swirl Control Actuator

CONNECTOR [CUD-K]

Pin Description Connected to

1 Battery power Main Relay
2 Power ground Chassis Ground
3 Battery power Main Relay
4 Power ground Chassis Ground
5 Battery power Main Relay
6 Power ground Chassis Ground
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 Ground Cruise Control Switch
15 Cruise Control "ACTIVATOR" signal input Cruise Control Switch
16 Ground Immobilizer Control Module
17 -
18 -
19 ESP auto recognition signal input With ESP : Ground, Without ESP : Open
20 -
21 -
22 Sensor power (+5V) A/C Pressure Transducer (APT)
23 -
24 Sensor power (+5V) Cruise Control Switch
25 Diagnosis Data Line (K-Line) Data Link Connector (DLC)
26 -
FLB -32 FUEL SYSTEM

Pin Description Connected to

27 Fuel consumption signal output Trip computer
28 Battery power 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
Exhaust Gas Temperature Sensor (EGTS) Exhaust Gas Temperature Sensor (EGTS)
32
#2 signal input #2 for CPF [With CPF]
Exhaust Gas Temperature Sensor (EGTS)
33 Sensor ground
#2 for CPF [With CPF]
Exhaust Gas Temperature Sensor (EGTS) Exhaust Gas Temperature Sensor (EGTS)
34
#1 signal input #1 [VGT] [With CPF]
Exhaust Gas Temperature Sensor (EGTS)
35 Sensor ground
#1 [VGT] [With CPF]
36 Differential Pressure Sensor (DPS) signal input Differential Pressure Sensor (DPS) [With CPF]
37 Sensor ground Differential Pressure Sensor (DPS) [With CPF]
38 Brake Switch "1" signal input Brake Switch
39 -
40 Water Sensor siganl input Water Sensor in Fuel Filter
41 -
42 A/C Pressure Switch Signal input Blower Switch
43 -
44 Sensor power (+5V) Differential Pressure Sensor (DPS) [With CPF]
45 Sensor power (+5V) Accelerator Position Sensor (APS) #1
46 Sensor power (+5V) Accelerator Position Sensor (APS) #2
47 Immobilizer Communication Line Immobilizer Control Module
48 Engine speed signal output Tachometer (Cluster)
49 Cruise Control "SET" Lamp control output Cruise Control "SET" Lamp (Cluster)
50 -
51 Lambda Sensor Heater control output Lambed Sesnor
52 - -
53 -
54 A/C Switch "ON" signal input A/C Switch
55 -
56 Thermo Switch signal input A/C Switch
57 Neutral Switch signal input (M/T Only) Neutral Switch
58 -
59 -
60 -
61 -
62 -
DIESEL CONTROL SYSTEM FLB -33

Pin Description Connected to

63 -
64 VS+ (NERNST Cell Voltage) Lambda Sensor
65 Rc/Rp (Pumping Cell Voltage) Lambda Sensor
66 -
67 Air Heater Relay control output Air Heater Relay
68 Malfunction Indicator Lamp (MIL) control output Malfunction Indicator Lamp (MIL)
69 Glow Time Lamp contorl 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 Feedback signal input Throttle Control Actuator [With CPF]
78 -
79 Clutch Switch signal input (M/T Only) Clutch Switch
80 Brake Switch "2" signal input Brake Switch
81 MT/AT auto recognition signal input M/T: Open, A/T: Ground
82 -
83 CAN [LOW] Other Control Modules
84 CAN [HIGH] Other Control Modules
85 -
86 VS-/IP- (Virtual Ground) Lambda Sensor
87 Rc (Compensative Resistance) Lambda Sensor
88 -
89 Intake Air Temperature Sensor (IATS) #1 signal input Intake Air Temperature Sensor (IATS) #1 in MAFS
Throttle Control Actuator control output Throttle Control Actuator [With CPF]
90
Throttle Flap Control Solenoid Valve control output Throttle Flap Control Solenoid Valve [Without CPF]
91 Cruise Control "MAIN" Lamp control output Cruise Control "MAIN" Lamp (Cluster)
92 Immobilizer Lamp control output Immobilizer Lamp (Cluster)
93 Glow Relay control output Glow Relay
94 PTC Heater Relay control output PTC Heater Relay
FLB -34 FUEL SYSTEM

3. ECM TERMINAL INPUT/OUTPUT SIGNAL

CONNECTOR [CUD-A]

Test
Pin Description Vehicle State Type Level
Result
Injector (Cylinder #3) [HIGH] control
Battery Voltage ~ 80V 46.4V
output [With Immobilizer]
1 Idle Pulse
Injector (Cylinder #2) [HIGH] control
7.418Hz
output [Without Immobilizer]
Injector (Cylinder #2) [HIGH] control
output [With Immobilizer] Battery Voltage ~ 80V　 46.4V　
2 Idle Pulse
Injector (Cylinder #3) [HIGH] control
7.418Hz
output [Without Immobilizer]
3 -
4 Battery power Idle DC Battery Voltage 13.96V
5 -
6 Sensor ground Idle DC Max. 50mV -1.7mV
-
7 Sensor shield Idle DC Max. 50mV
2.858mV
-
8 Sensor ground Idle DC Max. 50mV
2.702mV
9 -
10 -
11 -
Crankshaft Position Sensor (CKPS)
[-] signal input [A/T] Sine
12 Idle Vpeak_to_peak: Min.1.0V 52.8V
Crankshaft Position Sensor (CKPS) Wave
[+] signal input [M/T]
IG OFF Max. 0.5V -50mV
13 Sensor Power (+5V) DC
IG ON 4.9 ~ 5.1V 4.95V
14 -
15 -
Injector (Cylinder #1) [HIGH] control
Battery Voltage ~ 80V 46.6V
output [With Immobilizer]
16 Idle Pulse
Injector (Cylinder #4) [HIGH] control
7.44Hz
output [Without Immobilizer]
Injector (Cylinder #4) [HIGH] control
Battery Voltage ~ 80V 46.2V
output [With Immobilizer]
17 Idle Pulse
Injector (Cylinder #1) [HIGH] control
7.44Hz
output [Without Immobilizer]
18 -
IG OFF Max. 0.5V 175mV
19 Battery power DC
IG ON Battery Voltage 12.57V
-
20 Sensor ground Idle DC Max. 50mV
3.031mV
DIESEL CONTROL SYSTEM FLB -35

Test
Pin Description Vehicle State Type Level
Result
21 -
22 -
-
23 Sensor ground Idle DC Max. 50mV
2.857mV
24 -
25 -
IG OFF Max. 0.5V -50mV　
26 Sensor Power (+5V) DC
IG ON 4.9 ~ 5.1V 4.91V
Crankshaft Position Sensor (CKPS)
[+] signal input [A/T] Sine
27 Idle Vpeak_to_peak: Min.1.0V 52.8V
Crankshaft Position Sensor (CKPS) Wave
[-] signal input [M/T]
IG OFF Max. 0.5V -50mV
28 Sensor Power (+5V) DC
IG ON 4.9 ~ 5.1V 4.91V
29 -
Hi: Battery Voltage
30 Motor [-] control output Active Pulse Low: Max. 1.0V
Frequency: 1,000Hz
Injector (Cylinder #2) [LOW] control Peak Current: 19 ~ 21 A Peak
output [With Immobilizer] Hold Current: 11~ 13 A Current:
19 ~ 21A 19.7 A
31 Idle Pulse
Injector (Cylinder #3) [LOW] control 11 ~ 13A Hold
output [Without Immobilizer] Current:
EFQG102A
13.4 A

32 -
Injector (Cylinder #4) [LOW] control Peak Current: 19 ~ 21 A Peak
output [With Immobilizer] Hold Current: 11~ 13 A Current:
19 ~ 21A 19.7 A
33 Idle Pulse
Injector (Cylinder #1) [LOW] control 11 ~ 13A Hold
output [Without Immobilizer] Current:
EFQG102A
13.4 A

Hi: Battery Voltage 14.78V

Lo: Max. 1.0V 60mV
Rail Pressure Regulator Valve
34 Idle Pulse Frequency: 1kHz±2% 1.098KHz
control output
Duty (+):
74.37%
35 -
36 -
Hi: Vcc 4.94V
37 Reference frequency Idle Pulse
Lo: Max. 1.0V 340mV
38 -
39 -
FLB -36 FUEL SYSTEM

Test
Pin Description Vehicle State Type Level
Result
Boost Pressure Sensor (BPS)
40 IG ON Analog 0.5 ~ 4.5V 1.602mV
signal input
-
41 Sensor ground Idle DC Max. 50mV
3.301mV

Mass Air Flow Sensor (MAFS) Hi: Vcc 4.95V

42 Idle Pulse
signal input Lo: Max. 1.0V 350mV
IG ON Max. 1.0V 512mV
43 Rail Pressure Sensor (RPS) signal input Idle Analog 1.0 ~ 1.5V 1.089V
3000 RPM 1.5 ~ 3.0V 1.886V
-
44 Sensor ground Idle DC Max. 50mV
1.845mV
45 -
Injector (Cylinder #3) [LOW] control Peak Current: 19 ~ 21 A Peak
output [With Immobilizer] Hold Current: 11~ 13 A Current:
19 ~ 21A 19.8A
46 Idle Pulse
Injector (Cylinder #2) [LOW] control 11 ~ 13A Hold
output [Without Immobilizer] Current:
EFQG102A
13.5A

Injector (Cylinder #1) [LOW] control Peak Current: 19 ~ 21 A Peak

output [With Immobilizer] Hold Current: 11~ 13 A Current:
19 ~ 21A 19.6A
47 Idle Pulse
Injector (Cylinder #4) [LOW] control 11 ~ 13A Hold
output [Without Immobilizer] Current:
EFQG102A
13.4A

48 -
Hi: Battery Voltage 15.02V
Fuel Pressure Regulator Valve
49 Idle Pulse Lo: Max. 1.0V 540mV
control output
203Hz
Hi: Vcc or Battery Voltage 4.95V
Idle Lo: Max. 1.0V -10mV

Camshaft Position Sensor (CMPS) 17.44Hz

50 Pulse
signal input Hi: Vcc or Battery Voltage 4.95V
3000rpm Lo: Max. 1.0V -10mV
52.33Hz
51 -
52 -
Intake Air Temperature Sensor
53 Idle Analog 0.5 ~ 4.5V 1.954V
(IATS) #2 signal input
54 -
55 -
56 Position Sensor signal input IG ON Analog 0.5 ~ 4.5V
57 -
DIESEL CONTROL SYSTEM FLB -37

Test
Pin Description Vehicle State Type Level
Result
Engine Coolant Temperature Sensor
58 Idle Analog 0.5 ~ 4.5V 804.6mV
(ECTS) signal input
Hi: Battery Voltage 14.7V
Lo: Max. 1.0V -20mV
Electric EGR Control Valve
59 Idle Pulse 154.7Hz
control output
Duty(+):
91.79%
Hi: Battery Voltage
60 Motor [+] control output Active Pulse Low: Max. 1.0V
Frequency: 1,000Hz

CONNECTOR [CUD-K]

Test
Pin Description Vehicle State Type Level
Result
IG OFF Max. 1.0V 175mV
1 Battery power DC
IG ON Battery Voltage 12.77V
2 Power ground Idle DC Max. 50mV
IG OFF Max. 1.0V -25mV
3 Battery power DC
IG ON Battery Voltage 12.57V
4 Power ground Idle DC Max. 50mV
IG OFF Max. 1.0V -25mV
5 Battery power DC
IG ON Battery Voltage 12.57V
6 Power ground Idle DC Max. 50mV
Relay OFF Battery Voltage 13.98V
7 Cooling Fan Relay [HIGH] control output DC
Relay ON Max. 1.0V -25mV
-
8 Sensor ground Idle DC Max. 50mV
3.145mV

Accelerator Position Sensor (APS) C.T 0.3 ~ 0.9V 682.8mV

9 Analog
#1 signal input W.O.T 4.0 ~ 4.8V 4.029V
-
10 Sensor ground Idle DC Max. 50mV
3.586mV
Fuel Temperature Sensor (FTS)
11 IG ON Analog 0.5 ~ 4.5V 2.311V
signal input
12 Sensor ground Idle DC Max. 50mV -3.38mV
A/C OFF Max. 4.8V 1.327V
13 A/C Pressure Transducer signal input Analog
A/C ON 2.426V
14 Ground Idle DC Max. 50mV -1.7mV　
Cruise Control "ACTIVATOR"
15
signal input
16 Ground Idle DC Max. 50mV -3.8mV
FLB -38 FUEL SYSTEM

Test
Pin Description Vehicle State Type Level
Result
17 -
18 -
19 ESP auto recognition signal input Idle DC Max. 50mV With ESP
20 -
21 -
IG OFF Max. 0.5V -50mV
22 Sensor Power (+5V) DC
IG ON 4.9 ~ 5.1V 4.91V
23 -
IG OFF Max. 0.5V
24 Sensor Power (+5V) DC
IG ON 4.9 ~ 5.1V

When Hi: Min. Vbatt X 80% 12.78V

transmitting Lo: Max. Vbatt X 20% 140mV
25 Diagnostic K-Line Pulse
Hi: Min. Vbatt X 70% 12.78V
When receiving
Lo: Max. Vbatt X 30% 700mV
26 -
Hi: Battery Voltage or Vcc 3.435V
27 Fuel consumption signal output Idle Pulse Lo: Max. 0.5V -5mV
1.25Hz
IG OFF Max. 1.0V -25mV
28 Battery power DC
IG ON Battery Voltage 12.57V
Hi: Battery Voltage 14.97V
Lo: Max. 0.5V 175mV
Idle
Duty (+):
VGT Control Solenoid Valve 19.87%
29 Pulse
control output Hi: Battery Voltage 14.97V
Lo: Max. 0.5V 175mV
3000rpm
Duty(+):
53.48%
-
30 Sensor ground Idle DC Max. 50mV
3.201mV

Accelerator Position Sensor (APS) C.T 0.3 ~ 0.9V 333.8mV

31 Analog
#2 signal input W.O.T 1.5 ~ 3.0V 1.989V
Exhaust Gas Temperature Sensor
32 Idle Analog 0.5 ~ 4.5V 4.5V　
(EGTS) #2 signal input [With CPF]
33 Sensor ground [With CPF] Idle DC Max. 50mV 11.38mV
Exhaust Gas Temperature Sensor 3.595 ~
34 Idle Analog 0.5 ~ 4.5V
(EGTS) #1 signal input [With CPF] 4.835V　
35 Sensor ground [With CPF] Idle DC Max. 50mV 10.64mV
DIESEL CONTROL SYSTEM FLB -39

Test
Pin Description Vehicle State Type Level
Result
1.039V
(Idle)
Differential Pressure Sensor (DPS)
36 Idle Analog 0.5 ~ 4.5V 1.319V
signal input [with CPF]
(acceler-
ation)
37 Sensor ground [with CPF] Idle DC Max. 50mV 6.498mV
Release Max. 0.5V -20mV
38 Brake Switch "1" signal input DC
Push Battery Voltage 12.06V
39 -
Full of Water Battery Voltage 11.26V
40 Water Sensor siganl input Analog
No Water Max. 1.0V -20mV
41 -
Blower OFF Battery Voltage 12.17V
42 A/C Pressure Switch signal input DC
Blower ON Max. 2.0V 175mV
43 -
IG OFF Max. 0.5V -10mV　
44 Sensor Power (+5V) [With CPF] DC
IG ON 4.9 ~ 5.1V 4.95V
IG OFF Max. 0.5V -10mV
45 Sensor Power (+5V) DC
IG ON 4.9 ~ 5.1V 4.99V
IG OFF Max. 0.5V -10mV
46 Sensor Power (+5V) DC
IG ON 4.9 ~ 5.1V 4.99V
When Hi: Min. 8.5V 12.54V
47 Immobilizer Communication Line communicating Pulse
after IG ON Lo: Max. 3.5V 1.1V

Hi: Battery Voltage 13.18V

48 Engine speed signal output Idle Pulse Lo: Max. 0.5V 140mV
Frequency: 50~60Hz 59.53Hz
Cruise Control "SET" Lamp
49
control output
50 -
Hi: Battery Voltage 14.3V
51 Lambda Sensor Heater control output Vehicle Run Pulse Lo: Max. 1.0V 220mV
109.8Hz
52 -
53 -
A/C S/W OFF Max. 1.0V 140mV
54 A/C Switch "ON" signal input DC
A/C S/W 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
FLB -40 FUEL SYSTEM

Test
Pin Description Vehicle State Type Level
Result
S/W OFF (1st) Battery Voltage 12.54V
57 Neutral Switch signal input (M/T Only) S/W ON DC
Max. 0.5V -20mV
(neutral)
58 -
59 -
60 -
61 -
62 -
63 -
Normal: 450 ± 50mV 452mV
Engine Rich: Max. Normal +
64 VS+ (NERNST Cell Voltage) Analog 452.9V
Running 150mV
Lean: Min. Normal - 150mV 351mV
Normal: 0 ± 500mV 608mV
Engine
65 Rc/Rp (Pumping Cell Voltage) Analog Rich: Min. Normal - 1.5V 447.7mV
Running
Lean: Max. Normal + 1.5V 816.4mV
66 -
67 Air Heater Relay control output

Malfunction Indicator Lamp (MIL) Lamp OFF Battery Voltage 12.3V

68 DC
control output Lamp ON Max. 1.0V -20mV
Glow OFF Battery Voltage 12.06V
69 Glow Time Lamp control output DC
Glow ON Max. 1.0V -20mV
A/C OFF Battery Voltage 13.9V
70 A/C Compressor Relay control output DC
A/C ON Max. 1.0V 60mV
Relay OFF Battery Voltage 13.97V
71 Cooling Fan Relay [LOW] control output DC
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 -
Normal Battery Voltage
77 Feedback signal input DC　
Abnomal Max. 0.5V
78 -
DIESEL CONTROL SYSTEM FLB -41

Test
Pin Description Vehicle State Type Level
Result
Release Max. 0.5V -20mV
79 Clutch Switch signal input (M/T Only) DC
Push Battery Voltage 13.74V
Release Battery Voltage 14.14V
80 Brake Switch "2" signal input DC
Push Max. 0.5V -20mV
M/T Battery Vaoltage
81 MT/AT Auto recognition signal input DC
A/T Max. 0.5V
82 -
RECESSIVE 2.0 ~ 3.0V
83 CAN [LOW] Pulse
DOMINANT 0.5 ~ 2.25V
RECESSIVE 2.0 ~ 3.0V
84 CAN [HIGH] Pulse
DOMINANT 2.75 ~ 4.5V
85 -
Engine
86 Lambda Sensor Virtual Ground Analog 2.4 ~ 2.6V 2.462V
Running
Engine |Current Pump - Current
87 Lambda Sensor Current Adjust Analog 86.86mV
Running Adjust| ＜ 0.2V
88 -
Intake Air Temperature Sensor
89 Idle Analog 0.5 ~ 4.5V 2.129V
(IATS) #1 signal input
Throttle Flap Control Solenoid Valve
IG ON PWM 300Hz
control output [Without CPF]
90
Throttle Control Actuator control Key ON/ Hi: Battery Voltage 11.97V
Pulse
output [With CPF] Key OFF Lo: Max. 1.0V -25mV
Cruise Control "MAIN" Lamp
91 -
control output
Lamp OFF Battery Voltage 12.54V
92 Immobilizer Lamp control output DC
Lamp ON Max. 1.0V 65mV
Relay OFF Battery Voltage 12.46V
93 Glow Relay control output DC
Relay ON Max. 1.0V 60mV
Relay OFF Battery Voltage 13.18V
94 PTC Heater Relay control output DC
Relay ON Max. 1.0V -20mV
FLB -42 FUEL SYSTEM

CIRCUIT DIAGRAM ECB0DD81

CUD-K (28) Battery power

BATTERY
IGNITION SWITCH

CUD-K (2) Power ground

CUD-K (4) Power ground
CHASSIS CUD-K (6) Power ground
GROUND
CUD-K (1) Batter power
MAIN RELAY
CUD-K (3) Batter power
CUD-K (5) Batter power
CUD-K (72) Main Relay control output

AIR HEATER RELAY

AIR
HEATER
CUD-K (67) Air Heater Relay control output

GLOW RELAY

GLOW
PLUG
CUD-K (93) Glow Relay control output

BRAKE SWITCH

CUD-K (80) Brake Switch 2 signal input

CUD-K (38) Brake Switch 1 signal input

STOP
LAMP

MIL

CUD-K (68) Malfunction Indicator Lamp (MIL) control output

GLOW
LAMP

CUD-K (69) Glow Time Lamp contorl output

IMMOBILIZER
LAMP
CUD-K (92) Immobilizer Lamp control output

IMMOBILIZER

CUD-K (47) Immobilizer Communication Line

CUD-K (16) Ground

M/T
NEUTRAL SWITCH

CUD-K (57) Neutral Switch signal input

CLUTCH SWITCH

CUD-K (79) Clutch Switch signal input

SFDF28226L
DIESEL CONTROL SYSTEM FLB -43

MAFS & IATS #1

CUD-K (89) Intake Air Temperature Sensor (IATS) #1 signal input

CUD-A (44) Sensor ground

5
CUD-A (42) Mass Air Flow Sensor (MAFS) signal input

CUD-A (37) Reference frequency

MAIN RELAY
BPS & IATS #2

CUD-A (23) Sensor ground

CUD-A (53) Intake Air Temperature Sensor (IATS) #2 signal input

CUD-A (13) Sensor power (+5V)

CUD-A (40) Boost Pressure Sensor (BPS) signal input

CUD-A (41) Sensor ground

CLUSTER

CUD-A (58) Engine Coolant Temperature Sensor (ECTS) signal input

CMPS

MAIN RELAY

CUD-A (50) Camshaft Position Sensor (CMPS) signal input

CUD-A (20) Sensor ground

CKPS
A /T

CUD-A (12) Crankshaft Position Sensor (CKPS) [-] signal input

CUD-A (27) Crankshaft Position Sensor (CKPS) [+] signal input

CUD-A (7) Sensor shield

CKPS
M /T

CUD-A (27) Crankshaft Position Sensor (CKPS) [-] signal input

CUD-A (12) Crankshaft Position Sensor (CKPS) [+] signal input

CUD-A (7) Sensor shield

RPS
CUD-A (28) Sensor power (+5V)

CUD-A (43) Rail Pressure Sensor (RPS) signal input

CUD-A (8) Sensor ground

CUD-K (11) Fuel Temperature Sensor (FTS) signal input

CUD-K (10) Sensor ground

LAMBDA SENSOR
2
MAIN RELAY
5
CUD-K (51) Lambda Sensor Heater control output
1
CUD-K (64) VS+ (NERNST Cell Voltage)

3
CUD-K (86) VS-/IP- (Virtual Ground)

6
CUD-K (65) Rc/Rp (Pumping Cell Voltage)

4
CUD-K (87) Rc (Compensative Resistance)

CUD-K (45) Sensor power (+5V)

CUD-K (9) Accelerator Position Sensor (APS) #1 signal input

CUD-K (30) Sensor ground

CUD-K (46) Sensor power (+5V)

CUD-K (31) Accelerator Position Sensor (APS) #2 signal input

CUD-K (8) Sensor ground

SFDF28227L
FLB -44 FUEL SYSTEM

WITH CPF
DPS
CUD-K (44) Sensor power (+5V)

CUD-K (36) Differential Pressure Sensor (DPS) signal input

CUD-K (37) Sensor ground

EGTS #1 (VGT)
CUD-K (34) Exhaust Gas Temperature Sensor (EGTS) #1 signal input

CUD-K (35) Sensor ground

EGTS #2 (CPF)
CUD-K (32) Exhaust Gas Temperature Sensor (EGTS) #2 signal input

CUD-K (33) Sensor ground

APT
3
CUD-K (22) Sensor power (+5V)
2
CUD-K (13) A/C Pressure Transducer signal input
1
CUD-K (12) Sensor ground

SFDF28228L
DIESEL CONTROL SYSTEM FLB -45

INEJCTOR #1 WITH IMMO.

CUD-A (16) Injector (Cylinder #1) [HIGH] control output
WITHOUT IMMO.
CUD-A (17) Injector (Cylinder #1) [HIGH] control output
WITH IMMO.
CUD-A (47) Injector (Cylinder #1) [LOW] control output
WITHOUT IMMO.
INEJCTOR #2 CUD-A (33) Injector (Cylinder #1) [LOW] control output
WITH IMMO.
CUD-A (2) Injector (Cylinder #2) [HIGH] control output
WITHOUT IMMO.
CUD-A (1) Injector (Cylinder #2) [HIGH] control output
WITH IMMO.
CUD-A (31) Injector (Cylinder #2) [LOW] control output
WITHOUT IMMO.
INEJCTOR #3 CUD-A (46) Injector (Cylinder #2) [LOW] control output
WITH IMMO.
CUD-A (1) Injector (Cylinder #3) [HIGH] control output
WITHOUT IMMO.
CUD-A (2) Injector (Cylinder #3) [HIGH] control output
WITH IMMO.
CUD-A (46) Injector (Cylinder #3) [LOW] control output
WITHOUT IMMO.
INEJCTOR #4 CUD-A (31) Injector (Cylinder #3) [LOW] control output
WITH IMMO.
CUD-A (17) Injector (Cylinder #4) [HIGH] control output
WITHOUT IMMO.
CUD-A (16) Injector (Cylinder #4) [HIGH] control output
WITH IMMO.
CUD-A (33) Injector (Cylinder #4) [LOW] control output
WITHOUT IMMO.
FUEL PRESSURE CUD-A (47) Injector (Cylinder #4) [LOW] control output
REGULATOR VALVE
CUD-A (19) Battery power

CUD-A (49) Fuel Pressure Regulator Valve control output

RAIL PRESSURE
REGULATOR VALVE
CUD-A (4) Battery power

CUD-A (34) Rail Pressure Regulator Valve control output

ELECTRIC EGR
CONTROL VALVE
CUD-A (59) Electric EGR Control Valve control output

MAIN RELAY
VGT CONTROL
SOLENOID VALVE

CUD-K (29) VGT Control Solenoid Valve control output

MAIN RELAY
THROTTLE CONTROL WITH CPF
ACTUATOR
3

2
CUD-K (90) Throttle Control Actuator control output
1
CUD-K (77) Feedback signal input
4

THROTTLE FLAP CONTROL WITHOUT CPF

SOLENOID VALVE

CUD-K (90) Throttle Flap Control

MAIN RELAY

VARIABLE SWIRL
CONTROL ACTUATOR
3
CUD-A (26) Sensor power (+5V)
P 4
CUD-A (56) Position Sensor signal input

5
CUD-A (6) Sensor ground
1
CUD-A (60) Motor [+] control output

2
CUD-A (30) Motor [-] control output

SFDF28229L
FLB -46 FUEL SYSTEM

VEHICLE SPEED SIGNAL CUD-K (75) Vehicle speed signal input

WATER SENSOR (IN FUEL FILTER) CUD-K (40) Water Sensor siganl input

CUD-K (84) CAN [HIGH]

* OTHER CONTROL MODULE
CUD-K (83) CAN [LOW]

* DATA LINK CONNECTOR (DLC)

CUD-K (25) Diagnosis Data Line (K-Line)
* MULTI PURPOSE CHECK CONNECTOR

TACHOMETER (CLUSTER) CUD-K (48) Engine speed signal output

TRIP COMPUTER CUD-K (27) Fuel consumption signal output

A/T: GROUND, M/T: OPEN CUD-K (81) MT/AT auto recognition signal input

WITH ESP : GROUND, WITHOUT ESP : OPEN CUD-K (19) ESP auto recognition signal input

PTC HEATER RELAY CUD-K (94) PTC Heater Relay control output

COOLING FAN RELAY [HIGH] CUD-K (7) Cooling Fan Relay [HIGH] control output

COOLING FAN RELAY [LOW] CUD-K (71) Cooling Fan Relay [LOW] control output

CUD-K (54) A/C Switch "ON" signal input

CUD-K (56) Thermo Switch signal input

* REFER TO ELECTRICAL TROUBLESHOOTING MANUAL
CUD-K (42) A/C Pressure Switch Signal input

CUD-K (70) A/C Compressor Relay control output

CUD-K (24) Sensor power (+5V)

CUD-K (15) Cruise Control "ACTIVATOR" signal input

* REFER TO ELECTRICAL TROUBLESHOOTING MANUAL CUD-K (14) Ground

CUD-K (91) Cruise Control "MAIN" Lamp control output

CUD-K (49) Cruise Control "SET" Lamp control output

SFDF28230L
DIESEL CONTROL SYSTEM FLB -47

REPLACEMENT E0F4A337 4) Select "COMPONENT CHANGE ROUTINE".

CAUTION
• 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 im-
mobilizer, perform "KEY TEACHING" proce-
dure together (Refer to "IMMOBILIZER" in BE
group).

1. Turn ignition switch OFF and disconnect the negative

(-) battery cable.

2. Disconnect the ECM connector (A).

SFDF28235L

5) Select "ECU CHANGE".

A
B

SFDF38208L

3. Unscrew the ECM mounting bolts (B) and remove the

ECM.
SFDF28236L

4. Install a new ECM.

6) Input the mileage in odometer.
ECM installation bolts: 7.8 ~ 11.8 N·m (0.8 ~
1.2 kgf·m, 5.8 ~ 8.7 lbf·ft)

5. Connect the negative(-) battery cable.

6. Perform "ECM Change" procedure [With CPF].

1) Turn ignition switch OFF.

2) Connect a scan tool to Data Link Connector

(DLC).

3) Turn ignition switch ON.

LFIG108A
FLB -48 FUEL SYSTEM

7) Confirm the "Complete" message, and then turn

ignition switch OFF.

SFDF28237L

8) Wait for more than 10 seconds, and then turn

ignition switch ON.

7. Perform "Injector Specific Data Input" procedure (Re-

fer to "INJECTOR" in this group).

8. Perform "Key Teaching" procedure (Refer to "IMMO-

BILIZER" in BE group).
DIESEL CONTROL SYSTEM FLB -49

ECM PROBLEM INSPECTION

PROCEDURE E9939C3F

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 con-

nector and visually check the ground terminals on
ECM side and harness side for bent pins or poor con-
tact 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, re-
place 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)
FLB -50 FUEL SYSTEM

INJECTOR 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
DESCRIPTION E9888141
cylinder head. This means that the Common Rail injectors
can be installed in already existing DI diesel engines with-
The start of injection and the injected fuel quantity are out major modifications to the cylinder head.
adjusted by electrically triggered injectors. These injec-
tors supersede the nozzle-and-holder assembly (nozzle

COMPONENTS

1. Injector
2. Fuel Inlet
3. Connector
4. O-ring
5. Clamp
6. Clamp Bolt
SFDF28208L
DIESEL CONTROL SYSTEM FLB -51

SPECIFICATION E0CDCDA1

Items Specification

Coil Resistance (Ω ) 0.215 ~ 0.295Ω [20℃(68℉)]

CIRCUIT DIAGRAM E188AA1C

[CIRCUIT DIAGRAM] [CONNECTION INFORMATION]

ECM (CUD-A) INJECTOR #1 (CUD24-1)

INJECTOR #1 (CUD24-1)
1 Terminal Connected to Function
16(17) - Injector (cyl. #1) [High] control
1 ECM CUD-A (16)[17] Injector (cyl. #1) [HIGH]

2 2 ECM CUD-A (47)[33] Injector (cyl. #1) [LOW]

47(33) - Injector (cyl. #1) [Low] control
INJECTOR #2 (CUD24-2)
INJECTOR #2 (CUD24-2)
1 Terminal Connected to Function
2(1) - Injector (cyl. #2) [High] control
1 ECM CUD-A (2)[1] Injector (cyl. #2) [HIGH]
2 2 ECM CUD-A (31)[46] Injector (cyl. #2) [LOW]
31(46) - Injector (cyl. #2) [Low] control
INJECTOR #3 (CUD24-3)
INJECTOR #3 (CUD24-3)
1 Terminal Connected to Function
1(2) - Injector (cyl. #3) [High] control
1 ECM CUD-A (1)[2] Injector (cyl. #3) [HIGH]
2 2 ECM CUD-A (46)[31] Injector (cyl. #3) [LOW]
46(31) - Injector (cyl. #3) [Low] control
INJECTOR #4 (CUD24-4)
INJECTOR #4 (CUD24-4)
1 Terminal Connected to Function
17(16) - Injector (cyl. #4) [High] control
1 ECM CUD-A (17)[16] Injector (cyl. #4) [HIGH]
2 2 ECM CUD-A (33)[47] Injector (cyl. #4) [LOW]
33(47) - Injector (cyl. #4) [Low] control
*[ ] : Without Immobilizer
*( ) : Without Immobilizer

[HARNESS CONNECTOR]

60 59 58 57 56 55 54 53 52 51 50 49 48 47 46
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

2 1
30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

CUD24-1,2,3,4 CUD-A
INJECTOR #1,2,3,4 ECM

SFDF28238L
FLB -52 FUEL SYSTEM

REMOVAL E6ED6176 INSTALLATION EFDF8282

CAUTION 1. Installation is reverse of removal.

• Common Rail Fuel Injection System operates NOTE

with extremely high pressure (approximately
1,600bar), so never perform any work on in- When installing the injector, MUST REPLACE the
jection system with engine running or within O-ring (A) and apply a grease to that.
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, verti-
cally insert the injector into the cylinder head.
• When installing High Pressure Fuel Pipe A
- Do not use again the used high pressure fuel
pipe. SFDF28210L

- Install the flange nut correctly.

NOTE
1. Turn ignition switch OFF and disconnect the negative When installing the high pressure fuel pipe, apply the
(-) battery cable. specified tightening torques with the special service
tool (Refer to below table).
2. Disconnect the injector connector (A).
Item Dimension SST No.
Flange Nut
14 mm (0.551 in) 09314-27110
A (Injector Side)
Flange Nut
(Common Rail 17 mm (0.669 in) 09314-27120
Side)

· Injector clamp installation bolt: 28.4 ~ 30.4 N·m

(2.9 ~ 3.1 kgf·m, 21.0 ~ 22.4 lbf·ft)
B · High pressure fuel pipe installation nut: 24.5 ~ 28.4
C N·m (2.5 ~ 2.9 kgf·m, 18.1 ~ 20.1 lbf·ft)
D

E
SFDF28209L

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.

NOTE
If the injector adheres to the cylinder head, use the
special Service Tool (SST No. : 09351-4A300)
DIESEL CONTROL SYSTEM FLB -53

REPLACEMENT E124D8EE

CAUTION
• Common Rail Fuel Injection System operates
with extremely high pressure (approximately
1,600bar), so never perform any work on in-
jection 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, verti-
cally 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.

CAUTION
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" proce-

dure).

2. Install the injector (Refer to "INSTALLATION" proce-

dure).

3. Perform "Injector Specific Data Input" procedure (Re-

fer to "INJECTOR SPECIFIC DATA INPUT" proce-
dure).
FLB -54 FUEL SYSTEM

INJECTOR SPECIFIC DATA INPUT E0702308 5. Confirm the message, and then press "ENTER" key.

CAUTION
After replacing injector, MUST input the injector
specific data (7 digit) of each cylinder into ECM
with scan tool.

NOTE

Injector Specific Data

(7 digits)

LFIG111A

6. Input the injector data (7 digit), and then press "EN-

TER" key.

SFDF28211L

1. Turn ignition switch OFF.

2. Connect a scan tool to Data Link Connector (DLC).

3. Turn ignition switch ON.

4. Select "INJECTOR SPECIFIC DATA".

SFDF28240L

7. After comfirming the "Complete" message, turn igni-

tion switch OFF.

SFDF28239L

SFDF28241L
DIESEL CONTROL SYSTEM FLB -55

8. In about 10 seconds, turn ignition switch ON and

check the injector specific data memorized in the
ECM.

NOTE
In case of failure, input the injector specific data (7
digits) into ECM again.

SFDF28242L
FLB -56 FUEL SYSTEM

INSPECTION E4443FE0 6. Select "COMPRESSION TEST".

[COMPRESSION TEST]

1. Turn ignition switch OFF.

2. Connect a scan tool to Data Link Connector (DLC).

3. Turn ignition switch ON.

4. Select "ENGINE TEST FUNCTION".

SFDF28245L

7. Perform the test in accordance with the message.

SFDF28243L

5. Confirm the message, and then press "ENTER" key.

SFDF28246L

SFDF28244L

SFDF28247L
DIESEL CONTROL SYSTEM FLB -57

SFDF28248L

SFDF28249L

SFDF28250L

NOTE
If a cylinder’s engine speed is higher than the other
cylinders, the cylinder’s compression pressure is low.
FLB -58 FUEL SYSTEM

[IDLE SPEED COMPARISON] 6. Select "IDLE SPEED COMPARISON".

1. Turn ignition switch OFF.

2. Connect a scan tool to Data Link Connector (DLC).

3. Turn ignition switch ON.

4. Select "ENGINE TEST FUNCTION".

SFDF28251L

7. Perform the test in accordance with the message.

SFDF28243L

5. Confirm the message, and then press "ENTER" key.

SFDF28252L

SFDF28244L

SFDF28253L
DIESEL CONTROL SYSTEM FLB -59

SFDF28254L

SFDF28255L

SFDF28256L

NOTE
The injector in cylinder with significantly high (low) idle
speed injects more (less) quantity than the other injec-
tors.
FLB -60 FUEL SYSTEM

[INJECTION QUANTITY COMPARISON] 6. Select "INJECTION QUANTITY COMPARISON".

1. Turn ignition switch OFF.

2. Connect a scan tool to Data Link Connector (DLC).

3. Turn ignition switch ON.

4. Select "ENGINE TEST FUNCTION".

SFDF28257L

7. Perform the test in accordance with the message.

SFDF28243L

5. Confirm the message, and then press "ENTER" key.

SFDF28258L

SFDF28244L

SFDF28259L
DIESEL CONTROL SYSTEM FLB -61

SFDF28260L

SFDF28261L

SFDF28262L

NOTE
* (+) correction value: Injection quantity is less than
the others.
* (-) correction value: Injection quantity is more than
the others.
* Very high correction value: The injector may have
any fault. At this time, replace the injector with a new
one and perform these tests again.
FLB -62 FUEL SYSTEM

MASS AIR FLOW SENSOR

(MAFS)

INSPECTION E970E4C7

MAFS & IATS #1

FUNCTION AND OPERATION PRINCIPLE

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 rep-
resents deceleration or idle.
The ECM uses this information to control the EGR sole-
SFDF28231L
noid valve and correct the fuel amount.

SPECIFICATION

*At intake air temperature = 20 (68 ) *At intake air temperature = -15 (5 ) or 80 (176 )

Air Flow (kg/h) Frequency (kHz) Air Flow (kg/h) Frequency (kHz)

8 1.96 ~ 1.97 10 2.00 ~ 2.02

10 2.01 ~ 2.02 40 2.49 ~ 2.53

40 2.50 ~ 2.52 105 3.16 ~ 3.25
105 3.18 ~ 3.23 480 7.42 ~ 8.12
220 4.26 ~ 4.35

480 7.59 ~ 7.94

560 9.08 ~ 9.89

SFDF28263L
DIESEL CONTROL SYSTEM FLB -63

CIRCUIT DIAGRAM

[CIRCUIT DIAGRAM] [CONNECTION INFORMATION]

MAFS & IATS #1 (CUD27) ECM (CUD-K)
Terminal Connected to Function
IATS
3 1 IG S/W Power Supply (B+)
89 - IATS #1 Signal
2 ECM CUD-A (44) Sensor Ground

ECM (CUD-A) 3 ECM CUD-K (89) IATS #1 Signal

2 4 ECM CUD-A (37) Reference Frequency
44 - Sensor Ground
5 ECM CUD-A (42) MAFS Signal
5
42 - MAFS Signal

4
37 - Reference Frequency

IG S/W

[HARNESS CONNECTORS]
CUD-A

60 59 58 57 56 55 54 53 52 51 50 49 48 47 46
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

5 4 3 2 1
CUD-K

CUD27
94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
6 5
MAFS & IATS #1 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51
4 3
50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29
2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7

ECM

SFDF28264L
FLB -64 FUEL SYSTEM

SIGNAL WAVEFORM

Fig.1 Fig.2
Fig.1) AFS signal waveform at IG KEY "ON". It shows digital signal of 50% duty, 1.8KHz.
Fig.2) AFS signal waveform at idle(790RPM, EGR actuator duty 5%, air flow for each cylinder 410mg/st).
It shows digital signal of 50% duty, 2.2~2.7KHz.
LFIG222A

COMPONENT INSPECTION

1. Check the MAFS visually.

- Mounting direction correct.
- Any contamination, corrosion or damage on con-
nector.
- Air cleaner’s clogging or wet.
- MAFS cylinder’s deforming or blocking by any for-
eign material.

2. Check any leakage on intake system and intercooler

system.
DIESEL CONTROL SYSTEM FLB -65

REPLACEMENT E4B60742 6. Confirm the message, and then press "ENTER" key.

CAUTION
After replacing the Mass Air Flow Sensor (MAFS),
MUST perform the "COMPONENT CHANGE ROU-
TINE" procedure. Otherwise trouble related with
engine performance or emission control may oc-
cur until ECM learning about the component is
over.

1. Turn ignition switch OFF.

2. Connect a scan tool to Data Link Connector (DLC).

3. Turn ignition switch ON.

4. Select "COMPONET CHANGE ROUTINE". SFDF28266L

7. Confirm the "Complete" message, and then turn igni-

tion switch OFF.

SFDF28235L

5. Select "AIR FLOW SENSOR CHANGE".

SFDF28267L

8. Wait for more than 10 seconds, and then turn ignition

switch ON.

SFDF28265L
FLB -66 FUEL SYSTEM

BOOST PRESSURE SENSOR

(BPS)

INSPECTION E6A48344 BPS & IATS #2

FUNCTION AND OPERATION PRINCIPLE

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.

SHDF26003D

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

4.5
Output Voltage (V)

0.5

0 284
32.5
Pressure (kPa abs.)

LFIG038A
DIESEL CONTROL SYSTEM FLB -67

CIRCUIT DIAGRAM

[CIRCUIT DIAGRAM] [CONNECTION INFORMATION]

BPS & IATS #2 (CUD39) ECM (CUD-A)
3 53 - IATS #2 Signal Terminal Connected to Function
1 ECM CUD-A (40) BPS Signal
4 23 - Sensor Ground
2 ECM CUD-A (13) Sensor Power
2 13 - Sensor Power (+5V) IATS #2 Signal
3 ECM CUD-A (53)
P
1 40 - BPS Signal 4 ECM CUD-A (23) Sensor ground

[HARNESS CONNECTORS] CUD-A

60 59 58 57 56 55 54 53 52 51 50 49 48 47 46
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

4 3 2 1
CUD-K

94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
CUD39 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51
6 5
4 3
BPS & IATS #2 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29
2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7

ECM

SFDF28268L

SIGNAL WAVEFORAM

This illustration represents waveform of BPS when

accelerating and decelerating.

Boost Pressure Sensor Signal

LFIG040A
FLB -68 FUEL SYSTEM

INTAKE AIR TEMPERATURE IATS #1 in Mass Air Flow Sensor (MAFS) and IATS #2
SENSOR (IATS) in Boost Pressure Sensor (BPS) are located in front of
and behind turbo-charger respectively. IATS #1 senses
air temperature entering turbo-charger and the other
INSPECTION E96A79DF (IATS #2) does air temperature coming out from the
turbo-charger.
FUNCTION AND OPERATION PRINCIPLE Comparing these air temperature values from both sen-
sors, more accurate sensing of intake air temperature is
Intake Air Temperature Sensor (IATS) uses a Negative
possible. ECM uses these air temperature signals to per-
Temperature Characteristics (NTC) thermistor and senses
form EGR control correction and fuel injection quantity cor-
intake air temperature. Two intake air temperature sensors
rection.
are installed in this engine.

BPS & IATS #2

MAFS & IATS #1

SFDF28212L

SPECIFICATION

IATS #1 in MAFS IATS #2 in BPS

Temperature [ ( )] Resistance (k ) Temperature [ ( )] Resistance (k )

-40(-40) 35.14 ~ 43.76 -40(-40) 40.93 ~ 48.35

-20(-4) 12.66 ~ 15.12 -20(-4) 13.89 ~ 16.03

0(32) 5.12 ~ 5.89 0(32) 5.38 ~ 6.09

20(68) 2.29 ~ 2.55 20(68) 2.31 ~ 2.57

40(104) 1.10 ~ 1.24 40(104) 1.08 ~ 1.21

60(140) 0.57 ~ 0.65 60(140) 0.54 ~ 0.62

80(176) 0.31 ~ 0.37 80(176) 0.29 ~ 0.34

LFIG042A
DIESEL CONTROL SYSTEM FLB -69

CIRCUIT DIAGRAM

[CIRCUIT DIAGRAM] [CONNECTION INFORMATION]

MAFS & IATS #1 (CUD27) ECM (CUD-K)
Terminal Connected to Function
IATS
3 1 IG S/W Power Supply (B+)
89 - IATS #1 Signal
2 ECM CUD-A (44) Sensor Ground

ECM (CUD-A) 3 ECM CUD-K (89) IATS #1 Signal

2 4 ECM CUD-A (37) Reference Frequency
44 - Sensor Ground
5 ECM CUD-A (42) MAFS Signal
5
42 - MAFS Signal

4
37 - Reference Frequency

IG S/W

[HARNESS CONNECTORS]
CUD-A

60 59 58 57 56 55 54 53 52 51 50 49 48 47 46
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

5 4 3 2 1
CUD-K

CUD27
94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
6 5
MAFS & IATS #1 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51
4 3
50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29
2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7

ECM

SFDF28264L
FLB -70 FUEL SYSTEM

[CIRCUIT DIAGRAM] [CONNECTION INFORMATION]

BPS & IATS #2 (CUD39) ECM (CUD-A)
3 53 - IATS #2 Signal Terminal Connected to Function
1 ECM CUD-A (40) BPS Signal
4 23 - Sensor Ground
2 ECM CUD-A (13) Sensor Power
2 13 - Sensor Power (+5V) IATS #2 Signal
3 ECM CUD-A (53)
P
1 40 - BPS Signal 4 ECM CUD-A (23) Sensor ground

[HARNESS CONNECTORS] CUD-A

60 59 58 57 56 55 54 53 52 51 50 49 48 47 46
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

4 3 2 1
CUD-K

94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
CUD39 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51
6 5
4 3
BPS & IATS #2 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29
2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7

ECM

SFDF28268L

SIGNAL WAVEFORM

IATS signal should be smooth and continuous without any

sudden changes.
After warmed-up, the IATS signal should not change
significantly while ECTS signal drops.

LFIG043A

COMPONENT INSPECTION 4. Check that the resistance is within the specification.

1. Turn ignition switch OFF. Specification: Refer to "SPECIFICATION".

2. Disconnect the MAFS (for IATS #1) or BPS (for IATS

#2) connector.

3. Measure resistance between IATS signal terminal and

sensor ground terminal.
DIESEL CONTROL SYSTEM FLB -71

REPLACEMENT E1CC6951 6. Confirm the message, and then press "ENTER" key.

CAUTION
After replacing the Intake Air Temperature Sen-
sor (IATS) #1, MUST perform the "COMPONENT
CHANGE ROUTINE" procedure. Otherwise trou-
ble related with engine performance or emission
control may occur until ECM learning about the
component is over.

1. Turn ignition switch OFF.

2. Connect a scan tool to Data Link Connector (DLC).

3. Turn ignition switch ON.

4. Select "COMPONET CHANGE ROUTINE". SFDF28266L

7. Confirm the "Complete" message, and then turn igni-

tion switch OFF.

SFDF28235L

5. Select "AIR FLOW SENSOR CHANGE".

SFDF28267L

8. Wait for more than 10 seconds, and then turn ignition

switch ON.

SFDF28265L
FLB -72 FUEL SYSTEM

ENGINE COOLANT
TEMPERATURE SENSOR (ECTS)

INSPECTION EFAAE15E

FUNCTION AND OPERATION PRINCIPLE

Engine Coolant Temperature Sensor (ECTS) is located in

the engine coolant passage of the cylinder head for de-
tecting the engine coolant temperature. The ECTS uses ECTS
a thermistor whose resistance changes with the tempera-
ture. The electrical resistance of the ECTS decreases as
the temperature increases, and increases as the tempera-
ture decreases. The reference 5V in the ECM is supplied
SFDF28201L
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 Terminal
of the thermistor in the ECTS changes according to the en-
gine 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
Packing (Rubber)
information of engine coolant temperature to avoid engine
stalling and improve drivability.
Body

Thermister

EGRF241A

SPECIFICATION

Temperature [℃(℉)] Resistance( ㏀ )

-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
DIESEL CONTROL SYSTEM FLB -73

CIRCUIT DIAGRAM

[CIRCUIT DIAGRAM] [CONNECTION INFORMATION]

ECTS (CUD11) ECM (CUD-A)
1 Terminal Connected to Function
58 - ECTS Signal
1 ECM CUD-A (58) ECTS Signal
2
Cluster Cluster
2 -
3 3 ECM CUD-A (41) Sensor ground
41 - Sensor Ground

[HARNESS CONNECTORS] CUD-A

60 59 58 57 56 55 54 53 52 51 50 49 48 47 46
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

3 2 1
CUD-K

94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
6 5
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51
4 3
CUD11 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29
2 1
ECTS 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7

ECM

SFDF28269L

COMPONENT INSPECTION

1. Turn ignition switch OFF.

2. Disconnect the engine coolant temperature sensor

connector.

3. Remove the sensor.

4. After immersing the thermistor of the sensor into en-

gine coolant, measure resistance between ECTS sig-
nal terminal and ground terminal.

EFNF541A

5. Check that the resistance is within the specification.

Specification: Refer to "SPECIFICATION".

FLB -74 FUEL SYSTEM

CAMSHAFT POSITION SENSOR

(CMPS)

INSPECTION E24544C2

FUNCTION AND OPERATION PRINCIPLE

Camshaft Position Sensor (CMPS) 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 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 4
cylinders is impossible without CMPS signal.

EEGR

CMPS

SLDFL6105L
DIESEL CONTROL SYSTEM FLB -75

SPECIFICATION

Level Output Pulse (V)

High 12V
Low 0V

Items Specification
Air Gap 1.5 ± 0.1 mm

CIRCUIT DIAGRAM

[CIRCUIT DIAGRAM] [CONNECTION INFORMATION]

ECM (CUD-A)
CMPS (CUD13)
Terminal Connected to Function
3 20 - Sensor Ground 1 Main Relay Power Supply (B+)

2 2 ECM CUD-A (50) CMPS Signal

50 - CMPS Signal
3 ECM CUD-A (20) Sensor Ground
1

Main Relay

[HARNESS CONNECTORS] CUD-A

60 59 58 57 56 55 54 53 52 51 50 49 48 47 46
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

CUD-K

CUD13
94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
6 5
CMPS 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51
4 3
50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29
2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7

ECM

SFDF28270L
FLB -76 FUEL SYSTEM

SIGNAL WAVEFORM

Fig.1 Fig.2
Fig.1) This shows waveform of Crank Shaft Position Sensor and Cam Shaft Position Sensor simulatneously. The middle area
indicates reference points of Crank Shaft Position Sensor and Cam Shaft Position Sensor.

Fig.2) Crank Shaft Position Sensor and Cam Shaft Position Sensor signal are measured simultaneously.
Cam Shaft Position Sensor
signal is outputted once when Crank Shaft Position sensor signal is outputted twice. LOW and HIGH output of Cam Shaft
Position sensor reference point is detected at Crank Shaft Position sensor reference point.
( Injection sequence is determined based on LOW and HIGH signal of Cam Shaft Position Sensor reference point as
detecting cylinder position.)
LFIG299A

COMPONENT INSPECTION

1. Check signal waveform of CMPS and CKPS using a

scan tool.

Specification: Refer ro "SIGNAL WAVEFORM"

DIESEL CONTROL SYSTEM FLB -77

CRANKSHAFT POSITION SENSOR

(CKPS)

INSPECTION E6A4864B CKPS

FUNCTION AND OPERATION PRINCIPLE

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 VSS
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
SHDF26006D
sensor.

SPECIFICATION

Items Specification

Coil Resistance (Ω ) 774 ~ 946Ω [20℃(68℉)]

CIRCUIT DIAGRAM

[CIRCUIT DIAGRAM] [CONNECTION INFORMATION]

CKPS (CUD14) ECM (CUD-A)

2 Terminal Connected to Function

12(27) - CKPS [-] signal
1 ECM CUD-A (7) Sensor Shield

3 2 ECM CUD-A (12)[27] CKPS [-] Signal

27(12) - CKPS [+] signal
N S 3 ECM CUD-A (27)[12] CKPS [+] Signal
*[ ] : M/T

1
7 - Shield

*( ) : M/T

[HARNESS CONNECTORS]
CUD-A

60 59 58 57 56 55 54 53 52 51 50 49 48 47 46
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

CUD-K

CUD14
94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
6 5
CKPS 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51
4 3
50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29
2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7

ECM

SFDF28271L
FLB -78 FUEL SYSTEM

SIGNAL WAVEFORM

Fig.1 Fig.2
Fig.1) This shows waveform of Crank Shaft Position Sensor and Cam Shaft Position Sensor simulatneously. The middle area
indicates reference points of Crank Shaft Position Sensor and Cam Shaft Position Sensor.

Fig.2) Crank Shaft Position Sensor and Cam Shaft Position Sensor signal are measured simultaneously.
Cam Shaft Position Sensor
signal is outputted once when Crank Shaft Position sensor signal is outputted twice. LOW and HIGH output of Cam Shaft
Position sensor reference point is detected at Crank Shaft Position sensor reference point.
( Injection sequence is determined based on LOW and HIGH signal of Cam Shaft Position Sensor reference point as
detecting cylinder position.)
LFIG299A

COMPONENT INSPECTION

1. Check signal waveform of CMPS and CKPS using a

scan tool.

Specification: Refer ro "SIGNAL WAVEFORM"

DIESEL CONTROL SYSTEM FLB -79

ACCELERATOR POSITION Using a peogrammed characteristic curve, the pedal’s po-

SENSOR (APS) sition is then calculated from this voltage.

INSPECTION E3B6DA7C

FUNCTION AND OPERATION PRINCIPLE

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 param-
eters, including pedal position, which is measured using APS
a potentiometer. The pedal sensor has two potentio-me-
ters whoses slides are mechanically solid. The two po-
tentiometers are supplied from distinct and different power
sources so there is built in redundancy of information giv-
ing reliable driver’s request information. A voltage is gen-
erated across the potentiometer in the acceleration posi-
SHDF26007D
tion sensor as a function of the accelerator-pedal setting.

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 (㏀) 0.7 ~ 1.3 1.4 ~ 2.6

5.0
Output Voltage (V)

3.8 ~ 4.4
APS 1

2.5
APS 2
1.75 ~ 2.35

0.7 ~ 0.8
0.275 ~ 0.475 Pedal Stroke

C.T W.O.T
Stroke (mm)

LFIG092A
FLB -80 FUEL SYSTEM

CIRCUIT DIAGRAM

[CIRCUIT DIAGRAM] [CONNECTION INFORMATION]

APS (E37) ECM (CUD-K)
Terminal Connected to Function
APS 1 5
45 - Sensor Power (+5V) 1 ECM CUD-K (31) APS 2 Signal

3 2 ECM CUD-K (8) APS 2 Ground

9 - APS 1 Signal
3 ECM CUD-K (9) APS 1 Signal
4 ECM CUD-K (30) APS 1 Ground
4
30 - Sensor Ground
5 ECM CUD-K (45) APS 1 Sensor Power (+5V)
APS 2 6 ECM CUD-K (46)
46 - Sensor Power (+5V) 6 APS 2 Sensor Power (+5V)

1
31 - APS 2 Signal

2
8 - Sensor Ground

[HARNESS CONNECTORS] CUD-A

60 59 58 57 56 55 54 53 52 51 50 49 48 47 46
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

6 5 4 3 2 1
CUD-K

E37
94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
APS 6 5
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51
4 3
50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29
2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7

ECM

SFDF28272L

SIGNAL WAVEFORM

APS 1

APS 2

APS 2 ground check

signal

Fig.1
Fig.1) APS 1 and APS 2 signals are measured simultaneously, Check if output value is rising and APS 2 is 1/2 of APS 1 signal.
LFIG541A
DIESEL CONTROL SYSTEM FLB -81

COMPONENT INSPECTION

1. Turn ignition switch OFF.

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.

5. Check that the resistance is within the specification.

Specification: Refer to "SPECIFICATION".

FLB -82 FUEL SYSTEM

RAIL PRESSURE SENSOR (RPS)

Injector

INSPECTION E38DBBFF

FUNCTION AND OPERATION PRINCIPLE

Rail Pressure Sensor (RPS) is installed at the end of the

common rail and measures the instantaneous fuel pres- RPS
sure in the common rail by using its diaphragm. Its sens-
ing element (semiconductor device) mounted on the di-
aphragm converts the fuel pressure to an electric signal.

Rail Pressure
Regulator Valve
SFDF28202L

SPECIFICATION

Test Condition Rail pressure (bar) Output Voltage (V)

Idle 220 ~ 320 Below 1.7
Fully depressed 1,600 Approx. 4.5

CIRCUIT DIAGRAM

[CIRCUIT DIAGRAM] [CONNECTION INFORMATION]

RPS (CUD33) ECM (CUD-A)
3 Terminal Connected to Function
8 - Sensor Ground
1 ECM CUD-A (28) Sensor Power (+5V)
1
28 - Sensor Power (+5V) 2 ECM CUD-A (43) RPS Signal
P
2 3 ECM CUD-A (8) Sensor Signal
43 - RPS Signal

[HARNESS CONNECTORS]
CUD-A

60 59 58 57 56 55 54 53 52 51 50 49 48 47 46
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

CUD-K

CUD33
94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
6 5
RPS 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51
4 3
50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29
2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7

ECM

SFDF28273L
DIESEL CONTROL SYSTEM FLB -83

SIGNAL WAVEFORM

Rail Pressure Sensor (RPS) is to provide to the ECM the

voltage signal corresponding to rail pressure.
The change in resistance is preportional to the rail pressure
acting upon the diaphragm and rail pressure increases
as load increases.
APS 1 signal

RPS signal

EFNF550A
FLB -84 FUEL SYSTEM

REPLACEMENT E9DC573C 6. Confirm the message, and then press "ENTER" key.

CAUTION
After replacing the Rail Pressure Sensor (RPS),
MUST perform the "COMPONENT CHANGE ROU-
TINE" procedure. Otherwise trouble related with
engine performance or emission control may oc-
cur until ECM learning about the component is
over.

1. Turn ignition switch OFF.

2. Connect a scan tool to Data Link Connector (DLC).

3. Turn ignition switch ON.

4. Select "COMPONET CHANGE ROUTINE". SFDF28275L

7. Confirm the "Complete" message, and then turn igni-

tion switch OFF.

SFDF28235L

5. Select "RAIL PRESSURE SENSOR CHANGE".

SFDF28276L

8. Wait for more than 10 seconds, and then turn ignition

switch ON.

SFDF28274L
DIESEL CONTROL SYSTEM FLB -85

FUEL TEMPERATURE SENSOR

(FTS) FTS

INSPECTION E0A76D4C

FUNCTION AND OPERATION PRINCIPLE

Fuel Temperature Sensor(FTS) is installed in fuel supply-

ing line and senses the termperature of fuel supplied to
high pressure pump. Fuel temperature is limmited to pro-
tect 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 mem-
brance. Fuel Pressure Regulator Valve

SHDF26008L

SPECIFICATION

Temperature [ ( )] Resistance (k ) Temperature [ ( )] Resistance (k )

-30 (-22) 27.00 40 (104) 1.17

-20 (-4) 15.67 50 (122) 0.83

-10 (14) 9.45 60 (140) 0.60

0 (32) 5.89 70 (158) 0.43

20 (68) 2.27 ~ 2.73 80 (176) 0.30 ~ 0.32

LFIG052A
FLB -86 FUEL SYSTEM

CIRCUIT DIAGRAM

[CIRCUIT DIAGRAM] [CONNECTION INFORMATION]

FTS (CUD32) ECM (CUD-K)

1 Terminal Connected to Function

10 - Sensor Ground
1 ECM CUD-K (10) Sensor ground

2 2 ECM CUD-K (11) FTS Signal

11 - FTS Signal

[HARNESS CONNECTORS] CUD-A

60 59 58 57 56 55 54 53 52 51 50 49 48 47 46
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
2 1

CUD-K

CUD32
94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
6 5
FTS 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51
4 3
50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29
2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7

ECM

SFDF28277L

SIGNAL WAVEFORM

This illustration shows the waveform of fuel

temperature sensor at 50 .
The higher fuel temperature rises, the lower signal
voltage becomes.

LGJF502I

COMPONENT INSPECTION Specification: Refer to "SPECIFICATION".

1. Turn ignition switch OFF.

2. Disconnect the fuel temperature sensor connector.

3. Measure resistance between sensor signal terminal

and ground terminal.

4. Check that the resistance is within the specification.

DIESEL CONTROL SYSTEM FLB -87

FUEL PRESSURE REGULATOR common rail respectively. These valves control fuel inlet
VALVE (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"
INSPECTION E38A4B9E and can precisely and quickly control the fuel pressure in
accordance with various engine conditions by controlling
FUNCTION AND OPERATION PRINCIPLE the fuel inlet and outlet simultaneously.
The Fuel Pressure Regulator Valve and the Rail Pressure
Regulator Valve are installed on high pressure pump and

FTS
Injector

RPS

Rail Pressure
Fuel Pressure Regulator Valve
Regulator Valve

SFDF28232L

SPECIFICATION

Items Specification

Coil Resistance (Ω ) 2.6 ~ 3.15Ω [20℃(68℉)]

FLB -88 FUEL SYSTEM

CIRCUIT DIAGRAM

[CIRCUIT DIAGRAM] [CONNECTION INFORMATION]

FUEL PRESSURE ECM (CUD-A)
REGULATOR VALVE(CUD38)
Terminal Connected to Function
2
49 - Valve Control 1 ECM CUD-A (19) Power Supply (B+)
2 ECM CUD-A (49) Valve Control
1
19 - Power Supply (B+)

[HARNESS CONNECTORS]
CUD-A

60 59 58 57 56 55 54 53 52 51 50 49 48 47 46
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

CUD-K

CUD38
94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
6 5
FUEL PRESSURE REGULATOR VALVE 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51
4 3
50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29
2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7

ECM

SFDF28278L

SIGNAL WAVEFORM

Fig.1 Fig.2
Fig.1) Waveform of fuel pressure regulator valve at idle. It shows approx. 34% duty( (-)duty ).
Fig.2) Waveform of fuel pressure regulator valve as accelerating. approx. 38% duty( (-)duty ) is outputted as engine load increases.
LFIG396A

COMPONENT INSPECTION 3. Measure resistance between terminal 1 and 2 of the

valve.
1. Turn ignition switch OFF.
4. Check that the resistance is within the specification.
2. Disconnect the fuel pressure regulator valve connec-
Specification: Refer to "SPECIFICATION".
tor.
DIESEL CONTROL SYSTEM FLB -89

RAIL PRESSURE REGULATOR common rail respectively. These valves control fuel inlet
VALVE (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"
INSPECTION E81FCF31 and can precisely and quickly control the fuel pressure in
accordance with various engine conditions by controlling
FUNCTION AND OPERATION PRINCIPLE the fuel inlet and outlet simultaneously.
The Fuel Pressure Regulator Valve and the Rail Pressure
Regulator Valve are installed on high pressure pump and

FTS
Injector

RPS

Rail Pressure
Fuel Pressure Regulator Valve
Regulator Valve

SFDF28232L

SPECIFICATION

Items Specification

Coil Resistance (Ω ) 3.42 ~ 3.78Ω [20℃(68℉)]

FLB -90 FUEL SYSTEM

CIRCUIT DIAGRAM

[CIRCUIT DIAGRAM] [CONNECTION INFORMATION]

RAIL PRESSURE ECM (CUD-A)
REGULATOR VALVE(CUD34)
Terminal Connected to Function
2
34 - Valve Control 1 ECM CUD-A (4) Power Supply (B+)
2 ECM CUD-A (34) Valve Control
1
4 - Power Supply (B+)

[HARNESS CONNECTORS]
CUD-A

60 59 58 57 56 55 54 53 52 51 50 49 48 47 46
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

CUD-K
CUD34
94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
RAIL PRESSURE REGULATOR VALVE 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51
6 5
4 3
50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29
2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7

ECM

SFDF28279L

SIGNAL WAVEFORM

Fig.1 Fig.2
Fig.1) Waveform of rail pressure regulator valve at idle. It shows approx. 17% duty( (-) duty.
Fig.2) Waveform of rail pressure regulator valve as accelerating. Approx. 50% duty is outputted as engine load increases.
( When rail pressure increases as accelerating, rail pressure regulator valve duty(current) rises.)
LFIG377A

COMPONENT INSPECTION 3. Measure resistance between terminal 1 and 2 of the

valve.
1. Turn ignition switch OFF.
4. Check that the resistance is within the specification.
2. Disconnect the rail pressure regulator valve connec-
Specification: Refer to "SPECIFICATION".
tor.
DIESEL CONTROL SYSTEM FLB -91

ELECTRIC EGR CONTROL VALVE

INSPECTION E9864254

FUNCTION AND OPERATION PRINCIPLE

The Exhaust Gas Recirculation (EGR) system is used to

add the exhaust gas to intake air in order to reduce an ex-
cess of air and the temperature in the combustion cham-
ber. The Electric EGR valve is controlled by ECM’ s duty
control signal depending on engine load and the need of EEGR
intake air and is operated by solenoid valve not vacuum
valve. CMPS

SLDFL6105L

SPECIFICATION

Items Specification

Coil Resistance (Ω ) 7.3 ~ 8.3Ω [20℃(68℉)]

CIRCUIT DIAGRAM

[CIRCUIT DIAGRAM] [CONNECTION INFORMATION]

ECM (CUD-A)
EEGR(CUD31)
Terminal Connected to Function
1
59 - EEGR Control 1 ECM CUD-A (59) EEGR Control

2 2 Main Relay Power Supply (B+)

Main Relay

[HARNESS CONNECTORS]
CUD-A

60 59 58 57 56 55 54 53 52 51 50 49 48 47 46
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

CUD-K
CUD31
94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
6 5
EEGR 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51
4 3
50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29
2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7

ECM

SFDF28280L
FLB -92 FUEL SYSTEM

SIGNAL WAVEFORM

Fig.1 Fig.2
Fig.1) Approx. 10% duty( (-)duty ) signal waveform of EEGR actuator (with EEGR valve closed)
Fig.2) Approx. 40% duty( (-)duty ) signal waveform of EEGR actuator(with EEGR valve opened)
LFIG414A

COMPONENT INSPECTION

1. Turn ignition switch OFF.

2. Disconnect the electric EGR control valve connector.

3. Measure resistance between terminal 1 and 2 of the

valve.

4. Check that the resistance is within the specification.

Specification: Refer to "SPECIFICATION".

DIESEL CONTROL SYSTEM FLB -93

THROTTLE CONTROL ACTUATOR

Throttle Control Actuator
INSPECTION EE8C4FA3

FUNCTION AND OPERATION PRINCIPLE

The Throttle Control Actuator is mounted on throttle body

of diesel engine and controls throttle valve according to
PWM (Pulse With Modulation) signal from ECM.
It consists of;
- a DC motor which actuates the throttle valve,
- a 2-step gear (transmission ratio = 1:40) which is lo-
cated in between the DC motor and the throttle valve
and increases torque of the DC motor,
- a position sensor which is a hall-effect sensor and SEDF27005L

detects status of the throttle valve,

SPECIFICATION
- an electric control unit which is a micro-controller and
drives the DC motor by the PWM (Pulse With Modu-
Duty (%) Throttle Valve Position
lation) signal from the ECM,
- and a reset spring which resets the de-energized 5 Open
throttle valve to its open position. Normal operation (Partially open
5 ~ 94
in proportion to duty value)
Its function is described below:
94 Closed
1. Anti-judder function: When engine is shut off, the 94 ~ 95 Maintaining the last valid position
ECM can prevent intake air from entering to intake
manifold by fully closing the throttle valve for 1.5 sec- 95 ~ 97 Fully closed
onds (95% ＜ Duty ＜ 97%) to reduce engine vibra-
tion.
2. Intake air control for EGR: When exhaust gas pres-
sure 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.
3. Exhaust gas temperature control for CPF regenera-
tion: When the Catalyzed Particulate Filter (CPF) is
need to regenerate, the ECM partially closes the throt-
tle valve (5% ＜ Duty ＜ 94%) to reduce the intake air
quantity. At this time, the air-fuel ratio would become
rich and the exhaust gas temperature would be high
enough to burn the soot inside the CPF.
FLB -94 FUEL SYSTEM

CIRCUIT DIAGRAM

[CIRCUIT DIAGRAM] [CONNECTION INFORMATION]

THROTTLE CONTROL
ACTUATOR(CUD61)
ECM (CUD-K) Terminal Connected to Function

Main 1 ECM CUD-K (77) Feedback Signal

2
Relay Controller 90 - Actuator Control
2 ECM CUD-K (90) Actuator Control

3 1 3 Main Relay Power Supply (B+)

M 77 - Feedback Signal
4 Chassis Ground Ground

Chassis Ground
CUD-A
[HARNESS CONNECTORS]
60 59 58 57 56 55 54 53 52 51 50 49 48 47 46
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

CUD-K
CUD61

THROTTLE CONTROL ACTUATOR 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

6 5
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51
4 3
50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29
2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7

ECM

SFDF28281L

SIGNAL WAVEFORM

Fig.1 Fig.2
Fig.1) Waveform of Throttle control actuator at wide open(at idle) : At IG KEY "ON", ENGINE "ON",
5% duty is outputted continuously.
Fig.2) Waveform of Throttle control actuator at closed position : At IG KEY "OFF",
93% duty is outputted for about 1 sec.
LFIG529A
DIESEL CONTROL SYSTEM FLB -95

COMPONENT INSPECTION

1. Turn ignition switch OFF.

2. Disconnect the electric throttle control actuator con-

nector.

3. Measure resistance between terminal 1 and 2 of the

valve.

4. Check that the resistance is within the specification.

Specification: Refer to "SPECIFICATION".

FLB -96 FUEL SYSTEM

VARIABLE SWIRL CONTROL

ACTUATOR

INSPECTION E78A619C

FUNCTION AND OPERATION PRINCIPLE

Variable Swirl Control Actuator consists of DC motor and

position sensor which detects the position of the swirl
valve.
At idle or below 2,500rpm, the swirl valve is closed. This
swirl effect increases air flow rate. Variable Swirl Control Actuator

SLDFL6114L

Low and Middle Load High Load

Engine speed Below 2,500rpm Above 2,500rpm
Valve operation CLOSE OPEN

Description
illustration

KGNF302A KGNF302B

Fail-safe Fully opened

NOTE and closes the valve twice when engine is being

stopped.
To prevent the swirl valve and the shaft from being
stuck by foreign material and to learn max opening
and closing position of the valve, the ECM fully opens

SPECIFICATION

Motor Position Sensor

Items Specification Items Specification

Coil Resistance ( ) 3.4 ~ 4.4 [20 (68 )] Coil Resistance ( ) 3.44 ~ 5.16 [20 (68 )]

LFIG058A
DIESEL CONTROL SYSTEM FLB -97

CIRCUIT DIAGRAM

[CIRCUIT DIAGRAM] [CONNECTION INFORMATION]

VARIABLE SWIRL
CONTROL ACTUATOR (CUD40) ECM (CUD-A)
Terminal Connected to Function
SENSOR 3 1 ECM CUD-A (60) Motor [+] Control
26 - Sensor Power (+5V)
2 ECM CUD-A (30) Motor [-] Control
4
56 - Position Sensor Signal 3 ECM CUD-A (26) Sensor Power (+5V)
5 4 ECM CUD-A (56) Position Sensor Signal
6 - Sensor Ground
5 ECM CUD-A (6) Sensor Ground

MOTOR 1
60 - Motor [+] Control

M
2
30 - Motor [-] Control

CUD-A
[HARNESS CONNECTORS]

60 59 58 57 56 55 54 53 52 51 50 49 48 47 46
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

5 4 3 2 1
CUD-K

CUD40
94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
6 5
VARIABLE SWIRL CONTROL ACTUATOR 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51
4 3
50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29
2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7

ECM

SFDF28282L
FLB -98 FUEL SYSTEM

SIGNAL WAVEFORM

Fig.1 Fig.2

Fig.3

Fig.1) Waveform when variable swirl valve closed at idle. Terminal 1 is (+) and 2 is (-).
Fig. 2) Waveform when variable swirl valve opened at above 3000RPM. Terminal 1 is (-) and 2 is (+).
Fig. 3) Waveform of variable swirl control actuator motor position sensor at the point of turning engine OFF.
4.3V at swirl valve closed and 0.3V at swirl valve opened. Swirl valve is opened and closed twice at engine "OFF".
LFIG512A

COMPONENT INSPECTION Specification: Refer to "SPECIFICATION".

1. Turn ignition switch OFF.

2. Disconnect the variable swirl control actuator connec-

tor.

3. Check that swirl valve is stuck by foreign material.

4. Measure resistance between motor (+) and (-) control

terminals.

Specification: Refer to "SPECIFICATION".

5. Measure resistance between voltage supply terminal

and ground terminal of position sensor.

6. Check that the resistance is within the specification.

DIESEL CONTROL SYSTEM FLB -99

REPLACEMENT E3DD063B 6. Confirm the message, and then press "ENTER" key.

CAUTION
After replacing the Variable Swirl Control Actu-
ator, 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.

1. Turn ignition switch OFF.

2. Connect a scan tool to Data Link Connector (DLC).

3. Turn ignition switch ON.

4. Select "COMPONET CHANGE ROUTINE". SFDF28284L

7. Confirm the "Complete" message, and then turn igni-

tion switch OFF.

SFDF28235L

5. Select "SWIRL CONTROL VALVE CHANGE".

SFDF28285L

8. Wait for more than 10 seconds, and then turn ignition

switch ON.

SFDF28283L
FLB -100 FUEL SYSTEM

WATER SENSOR

INSPECTION E4BAE882

FUNCTION AND OPERATION PRINCIPLE

Water Sensor is installed on bottom end of fuel filter and

detects presence of water in fuel. When the water level Fuel Filter
reaches the lower level of the upper electrode, the "WA-
TER" lamp in cluster should flash. If the water level de-
creases below the lower electrode, the lamp should turn
off.
Water Sensor
NOTE
SFDF28205L
Without presence of water, the lamp should flash for
2 seconds and turn off afterward in order that this
system has normal condition.

SPECIFICATION

Item Specification
Warning Level (cc) 40 ~ 60

CIRCUIT DIAGRAM

[CIRCUIT DIAGRAM] [CONNECTION INFORMATION]

WATER SENSOR B+ Terminal Connected to Function

ECM(CUD-K)
(E32) 1 IG S/W Power Supply (B+)
1 Sensor Signal
2 ECM CUD-K (40)
2 3 Chassis ground Sensor Ground
40-Water Sensor Signal
3

[HARNESS CONNECTOR]
CUD-A

60 59 58 57 56 55 54 53 52 51 50 49 48 47 46
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

3 2 1
CUD-K

E32
WATER SENSOR 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
6 5
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51
4 3
50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29
2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7

ECM

SFDF28286L
DIESEL CONTROL SYSTEM FLB -101

VGT CONTROL SOLENOID VALVE Throttle Flap Control Solenoid

Valve

INSPECTION E7B4DB7B

FUNCTION AND OPERATION PRINCIPLE

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.
VGT Control Solenoid Valve

SFDF28206L

SPECIFICATION

Items Specification

Coil Resistance (Ω ) 14.7 ~ 16.1Ω [20℃(68℉)]

CIRCUIT DIAGRAM

[CIRCUIT DIAGRAM] [CONNECTION INFORMATION]

ECM (CUD-K)
VGT (CUD37) Terminal Connected to Function
1
29 - Valve Control 1 ECM CUD-K (29) Valve Control

2 2 Main Relay Power Supply (B+)

Main Relay

[HARNESS CONNECTORS]
CUD-A

60 59 58 57 56 55 54 53 52 51 50 49 48 47 46
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

CUD-K

CUD37
94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
6 5
VGT CONTROL SOLENOID VALVE 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51
4 3
50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29
2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7

ECM

SFDF28287L
FLB -102 FUEL SYSTEM

SIGNAL WAVEFORM

Fig.1 Fig.2
Fig.1) VGT actuator output waveform at 76% duty( (-)duty. Duty decreases as boost pressure increases.
Fig.2) VGT actuator duty( (-)duty ) decreases as accelerating.
LFIG369A

COMPONENT INSPECTION

1. Turn ignition switch OFF.

2. Disconnect the VGT control solenoid valve connector.

3. Measure resistance between terminal 1 and 2 of the

valve.

4. Check that the resistance is within the specification.

Specification: Refer to "SPECIFICATION".

DIESEL CONTROL SYSTEM FLB -103

LAMBDA SENSOR 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
INSPECTION E986C77B
(PWM). The resistance of heater coil is low when coil is
cold thus, current through it increases while resistance is
FUNCTION AND OPERATION PRINCIPLE
high when coil is hot thus, current decreases. With this
Lambda Sensor is installed on exhaust manifold and is a principle, temperature of lambda sensor is measured and
linear oxygen sensor. It senses oxygen density of exhaust lambda sensor heater operation varies based on the data.
gas in order to control EGR acculately through fuel cor-
rection and also limits smoke which is generated by reach
air-fuel mixture at high engine load condition. ECM con-
trols pumping current in order to fit λ -value from linear
lambda sensor to 1.0.
Lean air-fuel mixture(1.0 ＜ λ ＜ 1.1): ECM supplies
pumping current to lambda sensor (+pumping current)
and activates it for lambda sensor to have the character-
istic at λ =1.0 (0.0 pumping current). With the value of
pumping current supplied to lambda sensor, ECM detects Lambda Sensor
lambda density of exhaust gas.

Rich air-fuel mixture(0.9 ＜ λ ＜ 1.0): ECM takes away

pumping current from lambda sensor (-pumping current)
and deactivates it for lambda sensor to have the charac-
teristic at λ =1.0 (0.0 pumping current). With the value SHDF26005L

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 op-
erating temperature (450℃ ~ 600℃) thus, in order to reach

SPECIFICATION

Sensor Heater

Value (A/F Ratio) Pumping Current (A) Temperature [ ( )] Heater Resistance( )

0.65 -2.22 20 (68) 9.2

0.70 -1.82 100 (212) 10.7

0.80 -1.11 200 (392) 13.1
0.90 -0.50 300 (572) 14.6
1.01 0.00 400 (752) 17.7

1.18 0.33 500 (932) 19.2

1.43 0.67 600 (1,112) 20.7

1.70 0.94 700 (1,292) 22.5

2.42 1.38

Air (Atmosphere) 2.54

LFIG062A
FLB -104 FUEL SYSTEM

CIRCUIT DIAGRAM

LAMBDA SENSOR
(CUD36) ECM (CUD-K)
2 Terminal Connected to Function
Main Relay
5 1 ECM CUD-K (64) VS+ (NERNST Cell Voltage)
51 - Heater Control
1 2 Main Relay Power Supply (B+)
64 - VS+ (NERNST Cell Voltage)
3 ECM CUD-K (86) VS-/IP- (Virtual Ground)
3
86 - VS-/IP- (Virtual Ground) 4 ECM CUD-K (87) Rc (Compensative Resistance)
6 5 ECM CUD-K (51) Heater Control
65 - Rc/Rp (Pumping Cell Voltage)
6 ECM CUD-K (65) Rc/Rp (Pumping Cell Voltage)
4
87 - Rc (Compensative Resistance)

CUD-A

60 59 58 57 56 55 54 53 52 51 50 49 48 47 46
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

CUD-K

CUD36
94 93 92 91 90 89 88 85 84 83 82 81 80 79 78 77 76 75 74 73
6 5
LAMBDA SENSOR 72 71 70 69 68 67 64 63 62 61 60 59 58 57 56 55 54 53 52 51
4 3
50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29
2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7

87 86
66 65
ECM

SFDF28288L

SIGNAL WAVEFORM

Fig.1 Fig.2
Fig.1) Waveform of Lambda sensor heater power. It is battery voltage.
Fig.2) Waveform of Lambda sensor heater control at cold idle.(duty increases to approx. 40% at heater operation.)

LFIG200A
DIESEL CONTROL SYSTEM FLB -105

REPLACEMENT E97BD6E6 6. Confirm the message, and then press "ENTER" key.

CAUTION
After replacing the Lambda Sensor, MUST per-
form the "COMPONENT CHANGE ROUTINE"
procedure. Otherwise trouble related with engine
performance or emission control may occur until
ECM learning about the component is over.

1. Turn ignition switch OFF.

2. Connect a scan tool to Data Link Connector (DLC).

3. Turn ignition switch ON.

4. Select "COMPONET CHANGE ROUTINE".

SFDF28290L

7. Confirm the "Complete" message, and then turn igni-

tion switch OFF.

SFDF28235L

5. Select "LAMBDA SENSOR CHANGE".

SFDF28291L

8. Wait for more than 10 seconds, and then turn ignition

switch ON.

SFDF28289L
FLB -106 FUEL SYSTEM

EXHAUST GAS TEMPERATURE

SENSOR (EGTS) FOR VGT

INSPECTION EADA2614

FUNCTION AND OPERATION PRINCIPLE

Exhaust Gas Temperature Sensor (EGTS) #1 for VGT is

installed on exhaust manifold and senses the termperature EGTS #1
of exhaust gas flowing into the VGT.

SEDF27002L

SPECIFICATION

Temperature [℃(℉)] Resistance( ㏀ )

100(212) 289.0 ~ 481.0
300(572) 5.30 ~ 6.61
600(1,112) 0.35 ~ 0.38
900(1,652) 0.08 ~ 0.09

CIRCUIT DIAGRAM

[CIRCUIT DIAGRAM] [CONNECTION INFORMATION]

EGTS #1 (CUD62) ECM (CUD-K)

2 Terminal Connected to Function

35 - Sensor Ground
1 ECM CUD-K (34) EGTS #1 Signal

1 2 ECM CUD-K (35) Sensor Ground

34 - EGTS #1 Signal

[HARNESS CONNECTORS]
CUD-A

60 59 58 57 56 55 54 53 52 51 50 49 48 47 46
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

CUD-K

CUD62
94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
6 5
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51
EGTS #1 4 3
50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29
2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7

ECM

SFDF28292L
DIESEL CONTROL SYSTEM FLB -107

SIGNAL WAVEFORM

Fig.1
Fig.1) 4.8V is outputted at EGTS output signal circuit, when exhaust gas temp. is approx.150 .
when exhaust gas temp. is 550~600 at CPF regeneration, output voltage drops to 0.3~0.4V.
LFIG448A

COMPONENT INSPECTION

1. Turn ignition switch OFF.

2. Disconnect the exhaust gas temperature sensor #1

connector.

3. Measure resistance between sensor signal terminal

and ground terminal.

4. Check that the resistance is within the specification.

Specification: Refer to "SPECIFICATION".

FLB -108 FUEL SYSTEM

EXHAUST GAS TEMPERATURE

SENSOR (EGTS) FOR CPF

INSPECTION E7771383

FUNCTION AND OPERATION PRINCIPLE

Exhaust Gas Temperature Sensor (EGTS) #2 for CPF is

installed on Catalyzed Particulate Filter (CPF) assembly
and senses the temperature of exhaust gas flowing into
the CPF.
When pre-determined engine condition is set, ECM burns EGTS #2
soot gathered in CPF with exhaust gas. At this time, the
exhaust gas temperature is an important factor of engine
SFDF28204L
condition.

SPECIFICATION

Temperature [℃(℉)] Resistance( ㏀ )

100(212) 289.0 ~ 481.0
300(572) 5.30 ~ 6.61
600(1,112) 0.35 ~ 0.38
900(1,652) 0.08 ~ 0.09

CIRCUIT DIAGRAM

[CIRCUIT DIAGRAM] [CONNECTION INFORMATION]

EGTS #2 (M37) ECM (CUD-K)

1 Terminal Connected to Function

33 - Sensor Ground
1 ECM CUD-K (33) Sensor Ground

2 2 ECM CUD-K (32) EGTS #2 Signal

32 - EGTS #2 Signal

[HARNESS CONNECTORS]
CUD-A

60 59 58 57 56 55 54 53 52 51 50 49 48 47 46
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

1 2
CUD-K

M37
94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
6 5
EGTS #2 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51
4 3
50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29
2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7

ECM

SFDF28293L
DIESEL CONTROL SYSTEM FLB -109

SIGNAL WAVEFORM

Fig.1
Fig.1) 4.8V is outputted at EGTS output signal circuit, when exhaust gas temp. is approx.150 .
when exhaust gas temp. is 550~600 at CPF regeneration, output voltage drops to 0.3~0.4V.
LFIG448A

COMPONENT INSPECTION

1. Turn ignition switch OFF.

2. Disconnect the exhaust gas temperature sensor #2

connector.

3. Measure resistance between sensor signal terminal

and ground terminal.

4. Check that the resistance is within the specification.

Specification: Refer to "SPECIFICATION".

FLB -110 FUEL SYSTEM

DIFFERENTIAL PRESSURE
SENSOR (DPS)

INSPECTION E176ECBD

FUNCTION AND OPERATION PRINCIPLE

Differential Pressure Sensor (DPS) measures difference

pressure between upstream and downstream exhaust gas
of CPF. The ECM can calculate quantity of soot deposited
in CPF with value from this sensor.

DPS

SFDF28203L

SPECIFICATION

Differential Pressure[ P] (kPa) Output Voltage (V) Differential Pressure[ P] (kPa) Output Voltage (V)

0 1.00 60 3.10

10 1.35 70 3.45
20 1.70 80 3.80
30 2.05 90 4.15
40 2.40 100 4.50
50 2.75

LFIG068A
DIESEL CONTROL SYSTEM FLB -111

CIRCUIT DIAGRAM

[CIRCUIT DIAGRAM] [CONNECTION INFORMATION]

DPS (E07) ECM (CUD-K)
3 Terminal Connected to Function
37 - Sensor Ground
1 ECM CUD-K (44) Sensor Power (+5V)
1
44 - Sensor Power (+5V)
P 2 ECM CUD-K (36) DPS Signal
2
36 - DPS Signal 3 ECM CUD-K (37) Sensor Ground

[HARNESS CONNECTORS] CUD-A

60 59 58 57 56 55 54 53 52 51 50 49 48 47 46
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
3 2 1

CUD-K

E07
94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
6 5
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51
DPS 4 3
50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29
2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7

ECM

SFDF28294L

SIGNAL WAVEFORM

Fig.1 Fig.2
Fig1). This is the signal waveform of DPS at idle state. When CPF is new, 1.0~1.2V is outputted normally.
Fig2). This is the waveform of DPS as accelerating.
LFIG423A
FLB -112 FUEL SYSTEM

REPLACEMENT EAB67059 6. Confirm the message, and then press "ENTER" key.

CAUTION
After replacing the Differential Pressure Sen-
sor (DPS), MUST perform the "COMPONENT
CHANGE ROUTINE" procedure. Otherwise trou-
ble related with engine performance or emission
control may occur until ECM learning about the
component is over.

1. Turn ignition switch OFF.

2. Connect a scan tool to Data Link Connector (DLC).

3. Turn ignition switch ON.

4. Select "COMPONET CHANGE ROUTINE". SFDF28296L

7. Confirm the "Complete" message, and then turn igni-

tion switch OFF.

SFDF28235L

5. Select "D/PRESSURE SENSOR CHANGE".

SFDF28297L

8. Wait for more than 10 seconds, and then turn ignition

switch ON.

SFDF28295L
DIESEL CONTROL SYSTEM FLB -113

THROTTLE FLAP CONTROL closes the throttle valve (5% ＜ Duty ＜ 94%) to reduce the
SOLENOID VALVE intake air quantity. The intake air pressure thus is lower
than the exhaust gas pressure.

INSPECTION ECCF24F4
Throttle Flap Control Solenoid
Valve
FUNCTION AND OPERATION PRINCIPLE

The Throttle Flap Control Solenoid Valve controls the throt-

tle flap vacuum valve which activates the throttle flap in-
stalled inside the throttle body. This throttle flap control
system functions "Anti-judder function" and "Intake air con-
trol 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
VGT Control Solenoid Valve
＜ 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,
SFDF28206L
when low engine speed), the exhaust gas would not en-
ter to the intake manifold. At this time, the ECM partially

SPECIFICATION

Items Specification

Coil Resistance (Ω ) 28.3 ~ 31.1Ω [20℃ (68℉)]

CIRCUIT DIAGRAM

[CIRCUIT DIAGRAM] [CONNECTION INFORMATION]

THROTTLE FLAP CONTROL ECM (CUD-K)
SOLENOID VALVE(CUD35) Terminal Connected to Function
1
90 - Valve Control 1 ECM CUD-K (90) Valve Control
2 Main Relay Power Supply (B+)
2
Main Relay

[HARNESS CONNECTORS]
CUD-A

60 59 58 57 56 55 54 53 52 51 50 49 48 47 46
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

CUD-K

CUD35
94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
THROTTLE FLAP CONTROL 6 5
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51
SOLENOID VALVE 4 3
50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29
2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7

ECM

SFDF28213L
FLB -114 FUEL SYSTEM

SIGNAL WAVEFORM

Fig.1 Fig.2
Fig.1) Waveform of throttle flap actuator without throttle flap operation : 38% duty is always outputted at ignition switch "ON" and with
engine running.
Fig.2) Waveform of throttle flap actuator without throttle flap operation : 90% duty is outputted for about 1 sec. at ignition switch
"OFF".
LGJF501Y

COMPONENT INSPECTION

1. Turn ignition switch OFF.

2. Disconnect the throttle flap control solenoid valve con-

nector.

3. Measure resistance between terminal 1 and 2 of the

valve.

4. Check that the resistance is within the specification.

Specification: Refer to "SPECIFICATION".

DIESEL CONTROL SYSTEM FLB -115

CATALYZED PARTICULATE
FILTER (CPF)

DESCRIPTION E6EAE02F

The Catalyzed Particulate Filter (CPF) system prevents

Particulate Matter (PM) from being discharged to the
atmosphere and consists of a filter assembly, two Exhaust
Gas Temperature Sensor (EGTS) and a Differential Pres-
sure Sensor (DPS).The filter is integrated in the catalytic
converter assembly and has honeycomb cell structure
which can filter the PM in the exhaust gas. While the
exhaust gas passes the CPF, the PM is gathered in the
CPF and the others (CO2, NO, etc.) are discharged to
the atmosphere via muffler. This gathered PM in CPF is
called "soot".

[CPF REGENERATION]

If there are much soot in the CPF, the CPF must be regen-
erated. ECM can calculate amount of the soot by using the
DPS signal, vehicle mileage or simulation data. If the ECM
determines the CPF is need to regenerate, it will perform
"Regeneration Procedure" when the vehicle condition is
corresponded with the predetermined one (Regeneration
Mode).
To burn the soot, the ECM injects additional fuel in the
cylinders during exhaust stroke (two Post Injection) and
increases the exhaust gas temperature to burning temper-
ature of the soot (above 600℃). At this time, the soot are
burn and its ash remains in the CPF as a result of the com-
bustion.

[REGENERATION MODE]

1. Mileage ＞ 1,000km

2. Engine Speed: 1,000 ~ 4,000rpm

3. Engine Load = About 0.7bar [8mg/st]

4. Vehicle Speed ＞ 5km/h

5. Engine Coolant Temperature ＞ 40℃

FLB -116 FUEL SYSTEM

EGTS #1

EGTS #2 DPS

CPF

SFDF28214L

SCHEMATIC DIAGRAM E5F7A143

* CPF: Catalyzed Particulate Filter

Pilot 2 Pilot 1 Main Post 2 Post 1
* EGTS: Exhaust Gas Temperature Sensor
* DPS: Differential Pressure Sensor
* DOC: Diesel Oxidation Catalyst

EGTS #1

DPS

DOC CPF
Common Rail Fuel
Injection System

EGTS #2 CPF

ECM

SFDF28298L
DIESEL CONTROL SYSTEM FLB -117

* CPF: Catalyzed Particulate Filter CPF

* EGTS: Exhaust Gas Temperature Sensor
* DPS: Differential Pressure Sensor DOC
* DOC: Diesel Oxidation Catalyst

Exhaust
Gas

Pipes for DPS EGTS #2

CO2
NO
Cell Plug
Soot
HC
CO

CO2
NO
Cell Plug

Gathered Soot

LFIG117A
FLB -118 FUEL SYSTEM

CPF REGENERATION E1045389 6. Confirm the message, and then press "ENTER" key.

This procedures is to forcibly regenerate the CPF with

scan tool when the CPF doesn’t have been regenerated
during driving. For example, if the vehicle has repeated
"Low speed driving" or "Short distance driving", the CPF
regeneration procedure cannot be proceeded because
"Regeneration Mode" doesn’t made.

FORCIBLY REGENERATION CONDITION

• Engine coolant temperature: about 70℃

• Engine at idle
• P-range (A/T) or Neutral (M/T)
• Normal battery voltage
• Electrical fully load ON (A/C ON if equipped, Blower
ON with maximum speed, Head Lamp ON, Wiper ON,
Other Lamps ON, etc.) SFDF28300L

7. Confirm the data memorized in ECM, and then "EN-

NOTE TER" key.
The air conditioner’s electrical load is very high. Ac-
cordingly, to make regeneration mode more quickly,
turn it ON (If eqquipped).

1. Turn ignition switch OFF.

2. Connect a scan tool to Data Link Connector (DLC).

3. Start engine at idle and P-range (A/T) or neutral (M/T).

4. Apply electrical fully load to the vehicle (A/C ON,

Blower ON with maximum speed, Head Lamp ON,
Wiper ON, and Other Lamps ON, etc.)

5. Select "CPF SERVICE REGENERATION".

SFDF28301L

8. Perform CPF regeneration (Press "STRT" key).

SFDF28299L

SFDF28302L
DIESEL CONTROL SYSTEM FLB -119

REMOVAL E7B181A7

1. Turn ignition switch OFF and disconnect the negative

(-) battery cable.

2. Lift the vehicle and support the CPF assembly with a

jack.

3. Disconnect the hoses (A) connected with the differen-

tial pressure sensor from the CPF assembly.

SUNFL6012D

4. Disconnect the exhaust gas temperature sensor #2

connector (B).

D
C
SFDF28215L

5. Unscrew the mounting nuts (C) and remove the CPF

assembly (D) from the vehicle.

INSTALLATION EFC25B37

1. Installation is reverse of removal.

CPF mounting nuts: 39.2 ~ 58.9N·m (4.0 ~

6.0 kgf·m, 28.9 ~ 43.4lbf·ft)
FLB -120 FUEL SYSTEM

REPLACEMENT E89A9144 6. Confirm the message, and then press "ENTER" key.

NOTE
After replacing the CPF assembly, 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.

1. Turn ignition switch OFF.

2. Connect a scan tool to Data Link Connector (DLC).

3. Turn ignition switch ON.

4. Select "COMPONET CHANGE ROUTINE"

SFDF28304L

7. Confirm the "Complete" message, and then turn igni-

tion switch OFF.

SFDF28235L

5. Select "CPF CHANGE".

SFDF28305L

8. Wait for more than 10 seconds, and then turn ignition

switch ON.

SFDF28303L
DTC TROUBLESHOOTING PROCEDURES FLB -121

DTC TROUBLESHOOTING
PROCEDURES
INSPECTION CHART FOR DIAGNOSTIC
TROUBLE CODES (DTC) EF7B7896

MIL
DTC Description Page
CPF Non-CPF
P0031 HO2S Heater Control Circuit Low (Bank 1 / Sensor 1) ▲ ▲ FLB-125

P0032 HO2S Heater Control Circuit High (Bank 1 / Sensor 1) ▲ ▲ FLB-131

P0047 Turbocharger/Supercharger Boost Control Solenoid "A" Circuit Low ● ▲ FLB-135

P0048 Turbocharger/Supercharger Boost Control Solenoid "A" Circuit High ● ▲ FLB-141

P0069 Manifold Absolute Pressure - Barometric Pressure Correlation ● ▲ FLB-145

P0087 Fuel Rail/System Pressure - Too Low ● ● FLB-150

P0088 Fuel Rail/System Pressure - Too High ● ● FLB-154

P0089 Fuel Pressure Regulator 1 Performance ● ● FLB-157

P0091 Fuel Pressure Regulator 1 Control Circuit Low ● ● FLB-163

P0092 Fuel Pressure Regulator 1 Control Circuit High ● ● FLB-166

P0097 Intake Air Temperature Sensor 2 Circuit Low Input ▲ ▲ FLB-169

P0098 Intake Air Temperature Sensor 2 Circuit High Input ▲ ▲ FLB-174

P0101 Mass or Volume Air Flow Circuit Range / Performance ●/▲ ●/▲ FLB-178

P0102 Mass or Volume Air Flow Circuit Low Input ▲ ▲ FLB-186

P0103 Mass or Volume Air Flow Circuit High Input ▲ ▲ FLB-190

P0107 Manifold Absolute Pressure/Barometric Pressure Circuit Low Input ● ▲ FLB-194

P0108 Manifold Absolute Pressure/Barometric Pressure Circuit High Input ● ▲ FLB-197

P0112 Intake Air Temperature Sensor 1 Circuit Low Input ▲ ▲ FLB-199

P0113 Intake Air Temperature Sensor 1 Circuit High Input ▲ ▲ FLB-204

P0117 Engine Coolant Temperature Circuit Low Input ▲ ▲ FLB-207

P0118 Engine Coolant Temperature Circuit High Input ▲ ▲ FLB-212

P0182 Fuel Temperature Sensor "A" Circuit Low Input ▲ ▲ FLB-216

P0183 Fuel Temperature Sensor "A" Circuit High Input ▲ ▲ FLB-221

P0192 Fuel Rail Pressure Sensor "A" Circuit Low ● ● FLB-225

P0193 Fuel Rail Pressure Sensor "A" Circuit High ● ● FLB-232

P0201 Injector Circuit/Open-Cylinder 1 ● ● FLB-236

P0202 Injector Circuit/Open-Cylinder 2 ● ● FLB-236

P0203 Injector Circuit/Open-Cylinder 3 ● ● FLB-236

FLB -122 FUEL SYSTEM

MIL
DTC Description Page
CPF Non-CPF
P0204 Injector Circuit/Open-Cylinder 4 ● ● FLB-236

P0237 Turbocharger/Supercharger Boost Sensor "A" Circuit Low ● ▲ FLB-242

P0238 Turbocharger/Supercharger Boost Sensor "A" Circuit High ● ▲ FLB-249

Injection Pump Fuel Metering Control "A" Range/Perfor-
P0252 ● ● FLB-253
mance (Cam/Rotor/Injector)
P0253 Injection Pump Fuel Metering Control "A" Low (Cam/Rotor/Injector) ● ● FLB-260

P0254 Injection Pump Fuel Metering Control "A" High (Cam/Rotor/Injector) ● ● FLB-263

P0262 Cylinder 1 Injector Circuit High ● ● FLB-266

P0265 Cylinder 2 Injector Circuit High ● ● FLB-266

P0268 Cylinder 3 Injector Circuit High ● ● FLB-266

P0271 Cylinder 4 Injector Circuit High ● ● FLB-266

P0335 Crankshaft Position Sensor "A" Circuit ● ● FLB-273

P0336 Crankshaft Position Sensor "A" Circuit Range/Performance ● ● FLB-281

P0340 Camshaft Position Sensor "A" Circuit (Single Sensor) ● ● FLB-286

Camshaft Position Sensor A Circuit Range/Performance
P0341 ● ● FLB-293
(Bank 1 or Single Sensor)
P0381 Glow Plug/Heater Indicator Circuit ▲ ▲ FLB-297

P0401 Exhaust Gas Recirculation Flow Insufficient Detected ● ● FLB-302

P0402 Exhaust Gas Recirculation Flow Excessive Detected ● ● FLB-309

P0471 Exhaust Pressure Sensor "A" Circuit Range/Performance ■ - FLB-313

P0472 Exhaust Pressure Sensor "A" Circuit Low ■ - FLB-322

P0473 Exhaust Pressure Sensor "A" Circuit High ■ - FLB-326

P0489 Exhaust Gas Recirculation Control Circuit Low ● ▲ FLB-331

P0490 Exhaust Gas Recirculation Control Circuit High ● ▲ FLB-338

P0501 Vehicle Speed Sensor A Range/Performance ▲ ▲ FLB-341

P0504 Brake Switch "A" / "B" Correlation ▲ ▲ FLB-347

P0532 A/C Refrigerant Pressure Sensor "A" Circuit Low Input ▲ ▲ FLB-353

P0533 A/C Refrigerant Pressure Sensor "A" Circuit High Input ▲ ▲ FLB-359

P0541 Intake Air Heater "A" Circuit Low ▲ ▲ FLB-363

P0542 Intake Air Heater "A" Circuit High ▲ ▲ FLB-369

P0545 Exhaust Gas Temperature Sensor Circuit Low (Bank 1 Sensor 1) ▲ - FLB-373

P0546 Exhaust Gas Temperature Sensor Circuit High (Bank 1 Sensor 1) ▲ - FLB-380

P0562 System Voltage Low ▲ ▲ FLB-384

P0563 System Voltage High ▲ ▲ FLB-389

DTC TROUBLESHOOTING PROCEDURES FLB -123

MIL
DTC Description Page
CPF Non-CPF
P0602 Control Module Programming Error ▲ ▲ FLB-392

P0605 Internal Control Module Read Only Memory(ROM) Error ▲ ▲ FLB-395

P0606 ECM/PCM Processor ● ● FLB-396

P0611 Fuel Injector Control Module Performance ● ● FLB-398

P062D Fuel Injector Driver Circuit Performance (Bank 1) ● ● FLB-404

P062E Fuel Injector Driver Circuit Performance (Bank 2) ● ● FLB-406

P0642 Sensor Reference Voltage "A" Circuit Low ▲ ▲ FLB-408

P0643 Sensor Reference Voltage "A" Circuit High ▲ ▲ FLB-413

P0646 A/C Clutch Relay Control Circuit Low ▲ ▲ FLB-416

P0647 A/C Clutch Relay Control Circuit High ▲ ▲ FLB-422

P0650 Malfunction Indicator Lamp(MIL) Control Circuit ▲ ▲ FLB-426

P0652 Sensor Reference Voltage "B" Circuit Low ▲ ▲ FLB-430

P0653 Sensor Reference Voltage "B" Circuit High ▲ ▲ FLB-436

P0670 Glow Plug Control Module Control Circuit / Open ▲ ▲ FLB-439

P0685 ECM/PCM Power Relay Control Circuit /Open ▲ ▲ FLB-445

P0698 Sensor Reference Voltage C Circuit Low ▲ ▲ FLB-452

P0699 Sensor Reference Voltage C Circuit High ▲ ▲ FLB-458

P0820 Gear Lever X-Y Position Sensor Circuit ▲ ▲ FLB-461

P0830 Clutch Pedal Switch "A" Circuit ▲ ▲ FLB-466

P1145 Overrun monitoring error ▲ ▲ FLB-472

P1185 Maximum Pressure Exceeded ● ● FLB-474

P1186 Minimum Pressure at Engine Speed Too Low ● ● FLB-478

P1403 Differential Pressure not plausible (Hose Line Frozen) ▲ - FLB-481

P1405 CPF-Permanent Regeneration ■ - FLB-490

Exhaust Gas Temperature Not Plausible Between Cal-
P1406 ▲ - FLB-498
culated And Simulated
Plausibility Of Temperature Calculated And Simulated
P1407 ■ - FLB-506
Upstream Of Particulate Filter
P1586 MT/AT Encoding Signal Malfunction ◆ ◆ FLB-510

P1587 MT/AT Recognition (CAN Line) Error ◆ ◆ FLB-512

P1588 MT/AT Auto Recognition Line Error ◆ ◆ FLB-513

P1634 Auxiliary Heater Relay Short/Open circuit ▲ ▲ FLB-516

P1652 Ignition Switch Circuit Malfunction ▲ ▲ FLB-524

P1670 Invalid Injector IQA/C2I ■ ■ FLB-528

FLB -124 FUEL SYSTEM

MIL
DTC Description Page
CPF Non-CPF
P1671 Injector IQA checksum error ■ ■ FLB-531

P1815 ESP Auto Recognition Fail ▲ ▲ FLB-533

P2002 Particulate Trap Efficiency Below Threshold ■ ■ FLB-537

P2009 Intake Manifold Runner Control Circuit Low (Bank 1) ▲ ▲ FLB-546

P2010 Intake Manifold Runner Control Circuit High (Bank 1) ▲ ▲ FLB-553

Intake Manifold Runner Position Sensor/Switch Circuit
P2015 ● ▲ FLB-556
Range/Performance (Bank 1)
P2016 Intake Manifold Runner Position Sensor/Switch Circuit Low (Bank 1) ▲ ▲ FLB-562

P2017 Intake Manifold Runner Position Sensor/Switch Circuit High (Bank 1) ▲ ▲ FLB-566

P2030 Exhaust Temperture Value Not Plausible With Sensor 1 And 2 ▲ - FLB-570

P2032 Exhaust Gas Temperature Sensor Circuit Low (Bank 1 / Sensor 2) ■ - FLB-576

P2033 Exhaust Gas Temperature Sensor Circuit High (Bank 1 / Sensor 2) ■ - FLB-584

P2034 Exhaust Gas Temperature Sensor Performance (Sensor 2)-CPF ■ - FLB-588

P2080 Exhaust Gas Temperature Sensor Performance (Sensor 1)-VGT ▲ - FLB-592

P2111 Throttle Actuator Control System - Stuck Open ● ▲ FLB-599

P2112 Throttle Actuator Control System - Stuck Closed ● ▲ FLB-611

P2113 Throttle Control Actuator Circuit Malfunction - Range/Performance ● - FLB-618

P2123 Throttle/Pedal Position Sensor /Switch "D" Circuit High Input ● ● FLB-625

P2128 Throttle / Pedal Position Sensor/Switch "E" Circuit-High Input ● ● FLB-633

P2138 Throttle/Pedal Position Sensor/Switch D/E Voltage Correlation ● ● FLB-637

P2238 O2 Sensor Pumping Current Circuit Low (Bank 1 Sensor 1) ▲ ▲ FLB-646

P2239 O2 Sensor Pumping Current Circuit High (Bank 1 Sensor 1) ▲ ▲ FLB-656

P2251 O2 Sensor Reference Ground Circuit/Open (Bank 1 Sensor 1) ▲ ▲ FLB-662

P2264 Water in Fuel Sensor Circuit ▲ ▲ FLB-668

P2299 Brake Pedal Position / Accelerator Pedal Position Incompatible ▲ ▲ FLB-674

U0001 High Speed CAN Communication Bus ▲ ▲ FLB-683

U0101 Lost Communication With TCM ▲ ▲ FLB-690

U0122 Lost Communication With Vehicle Dynamics Control Module ▲ ▲ FLB-694

U0416 Invalid Data Received From Vehicle Dynamics Control Module ▲ ▲ FLB-698

NOTE
●: MIL ON ＆ Memory
▲: MIL OFF ＆ Memory
■: MIL Blinking ＆ Memory
◆: Glow Lamp Blinking ＆ Memory
DTC TROUBLESHOOTING PROCEDURES FLB -125

DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 / SENSOR 1)

COMPONENT LOCATION E8A8128B

Lambda Sensor

SFDF28314L

GENERAL DESCRIPTION E2DB0904

Lambda sensor installed at exhaust manifold is linear Lambda sensor and it senses O2 density of exhaust gas for accurate
EGR control through fuel correction. It also limits smoke which is generated by reach air-fuel mixture at engine maximum
loading condition. ECM controls pumping current in order to fit λ -value from linear Lambda sensor to 1.0.
Lean air-fuel mixture(1.0〈λ 〈1.1) : ECM supplies pumping current to Lambda sensor (+pumping current) and activates
it for Lambda sensor to have the characteristic at λ =1.0 (0.0 pumping current). With the value of pumping current supplied
to Lambda sensor, ECM detects O2 density of exhaust gas.F
Rich air-fuel mixture(0.9〈λ 〈1.0) : ECM takes away pumping current from Lambda sensor (-pumping current) and
deactivates it for Lambda sensor to have the characteristic at λ =1.0 (0.0 pumping current). With the value of pumping
current taken away from Lambda sensor, ECM detects O2 density of exhaust gas.
This performance is the most active and fast at normal operating temp.(450 C~600 C) thus, in order to reach normal
operating temp. and last at that temp., heater(heating coil) is integrated with Lambda sensor.
Heater coil is controlled by ECM as 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, Lambda sensor temp. is
measured and Lambda sensor heater operation varies based on the data.

DTC DESCRIPTION EBCACDAB

P0031 is set when open or short to ground in Lambda sensor control circuit is detected for more than 5.0 sec. at Lambda
sensor heater control condition. This code is due to 1)open or short to ground in heater control circuit or 2)Lambda sensor
heater internal short.
FLB -126 FUEL SYSTEM

DTC DETECTING CONDITION E6C6579F

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● Engine running

● Short to GND in Lambda sensor heater

Threshold Value control circuit
● Open in Lambda sensor heater control circuit
● Lambda sensor heater circuit
Diagnostic Time ● 5.0 sec. ● Lambda sensor component
Fuel Cut NO
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp

SPECIFICATION EAA2EF80

Temperature Lambda sensor heater Lambda sensor heater Lambda sensor

Temperature ( C)
( C) resistance(Ω ) resistance(Ω ) heater control Hz
20 9.2 400 17.7
100 10.7 500 19.2
100 Hz
200 13.1 600 20.7
300 14.6 700 22.5
DTC TROUBLESHOOTING PROCEDURES FLB -127

DIAGNOSTIC CIRCUIT DIAGRAM E35BE04D

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.
Main Relay
"ON" Input

<LAMBDA SENSOR> E/R JUNCTION BOX

3 2 1
6 5 4 Sensor Heater
"NERNST" Power

1. 'NERNST' Power Virtual Ground

2. Power
Current Adjust
3. Virtual Ground Current Pump
4. Current Adjust
5. Heater LAMBDA SENSOR
6. Current Pump

<ECM>

94 93 92 90 89
51. Heater
*
72 71 70 69 68 * 87 86 * 84 83 * 81 80 79 * 77 * 75 * * 6 5 64. 'NERNST' Power
* * 65 64 * * * * * * 57 56 * 54 * * 51 4 3 65. Current Pump
* 27* 48 47
28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1 86. Virtual Ground
* 25 * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7 87. Current Adjst

SFDF27592L
FLB -128 FUEL SYSTEM

SIGNAL WAVEFORM AND DATA E35C6483

Fig.1 Fig.2
SFDF27500L

Fig.1) Waveform of Lambda sensor heater power. It is battery voltage.

Fig.2) Waveform of Lambda sensor heater control at idle.

TERMINAL AND CONNECTOR INSPECTION EA9BBFCD

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power Circuit Inspection".

POWER CIRCUIT INSPECTION E9FB3A52

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect Lambda sensor connector.

3. IG KEY "ON".
DTC TROUBLESHOOTING PROCEDURES FLB -129

4. Measure the voltage between heater power terminal of Lambda sensor harness connector and chassis ground.

Specification : 11.0V~13.0V ( Main relay ON power )

5. Is the measured voltage within the specification?

YES

▶ Go to "Control Circuit Inspection".

NO

▶ Repair open in Main relay power circuit and FUSE in E/R JUNCTION BOX and go to "Verification of Vehicle Repair".

CONTROL CIRCUIT INSPECTION EC3DFE69

1. Check Lambda sensor heater control circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Lambda sensor connector.

3) IG KEY "ON".

4) Measure the voltage between heater control terminal of Lambda sensor harness connector and chassis ground.

Specification : 2.0V~2.5V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ No voltage is detected : Go to "2. Check open in Lambda sensor heater control circuit" as follows.
▶ High voltage is detected : Repair short to battery in control circuit and go to "Verification of Vehicle Repair".

2. Check open in Lambda sensor heater control circuit

1) IG KEY "OFF", EFNGINE "OFF".

2) Disconnect Lambda sensor connector and ECM connector.

3) Check continuity between heater control terminal of Lambda sensor harness connector and ECM harness con-
nector.

Specification : Continuity (below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground in control circuit and go to "Verification of Vehicle Repair".

NO
FLB -130 FUEL SYSTEM

▶ Repair open in Lambda sensor heater control circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E9EDA54A

1. Check Lambda sensor component heater coil resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Lambda sensor connector.

3) Check continuity between heater power terminal and heater control of Lambda sensor connector (component
side).

Specification : Refer to "Specification" of "General Information"

4) Is the measured resistance within the specification?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace Lambda sensor and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E5C01044

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

DTC TROUBLESHOOTING PROCEDURES FLB -131

DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 / SENSOR

1)

COMPONENT LOCATION E87A0E15

Refer to DTC P0031.

GENERAL DESCRIPTION E9CEA1D9

Refer to DTC P0031.

DTC DESCRIPTION E4FBD785

P0032 is set when short to battery in Lambda sensor control circuit is detected for more than 5.0 sec. at Lambda sensor
heater control condition. This code is due to 1)short to battery in heater control circuit or 2)Lambda sensor heater internal
open.

DTC DETECTING CONDITION EE500E9C

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● Engine running

Threshold Value ● Short to battery in Lambda sensor

heater control circuit
Diagnostic Time ● 5.0 sec. ● Lambda sensor heater circuit
● Lambda sensor component
Fuel Cut NO
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp

SPECIFICATION EB95D436

Refer to DTC P0031.

DIAGNOSTIC CIRCUIT DIAGRAM EA620D04

Refer to DTC P0031.

FLB -132 FUEL SYSTEM

SIGNAL WAVEFORM AND DATA E1EF050C

Fig.1 Fig.2
SFDF27500L

Fig.1) Waveform of Lambda sensor heater power. It is battery voltage.

Fig.2) Waveform of Lambda sensor heater control at idle.

TERMINAL AND CONNECTOR INSPECTION ED793BDE

Refer to DTC P0031.

POWER CIRCUIT INSPECTION E5C04DEA

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect Lambda sensor connector.

3. IG KEY "ON".

4. Measure the voltage between heater power terminal of Lambda sensor harness connector and chassis ground.

Specification : 11.0V~13.0V ( Main relay ON power )

5. Is the measured voltage within the specification?

YES

▶ Go to "Control Circuit Inspection".

NO

▶ Repair open in Main relay power circuit and FUSE in E/R JUNCTION BOX and go to "Verification of Vehicle Repair".

CONTROL CIRCUIT INSPECTION E3AF3F22

1. Check Lambda sensor heater control circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Lambda sensor connector.

DTC TROUBLESHOOTING PROCEDURES FLB -133

3) IG KEY "ON".

4) Measure the voltage between heater control terminal of Lambda sensor harness connector and chassis ground.

Specification : 2.0V~2.5V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ No voltage is detected : Go to "2. Check open in Lambda sensor heater control circuit" as follows.
▶ High voltage is detected : Repair short to battery in control circuit and go to "Verification of Vehicle Repair".

2. Check open in Lambda sensor heater control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Lambda sensor connector and ECM connector.

3) Check continuity between heater control terminal of Lambda sensor harness connector and ECM harness con-
nector.

Specification : Continuity (below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground in control circuit and go to "Verification of Vehicle Repair".

NO

▶ Repair open in Lambda sensor heater control circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION EFBED5E4

1. Check Lambda sensor component heater coil resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Lambda sensor connector.

3) Check continuity between heater power terminal and heater control of Lambda sensor connector (component
side).

Specification : Refer to "Specification" of "General Information"

4) Is the measured resistance within the specification?

YES

▶ Go to "Verification of Vehicle Repair".

FLB -134 FUEL SYSTEM

NO

▶ Replace Lambda sensor and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E30D46CC

Refer to DTC P0031.

DTC TROUBLESHOOTING PROCEDURES FLB -135

DTC P0047 TURBOCHARGER/SUPERCHARGER BOOST CONTROL

SOLENOID "A" CIRCUIT LOW

COMPONENT LOCATION E14BBB3B

Throttle Flap Control Solenoid

Valve

VGT Control Solenoid Valve

SFDF28322L

GENERAL DESCRIPTION E93D7033

VGT(Variable Geometric Turbocharger) is the device which increases the efficiency of turbocharger at low rpm and lasts
optimum turbo efficiency at high rpm as varying the cross sectional area through which exhaust gas passes turbocharger
impeller. It relieves turbo lag at low speed and increse engine power genetation.
Engine speed, APS signal, MAFS and Boost pressure sensor information is inputted to ECM.
ECM actuates vacuum diafragm which controls exhaust gas line as contrFolling VGT Control solenoid valve duty to main-
tain optimum state of air compression.

DTC DESCRIPTION E02AF686

P0047 is set when "0"A is detected in VGT Control solenoid valve control circuit for more than 1 sec.. This code is due to
open or short to ground in VGT Control solenoid valve circuit, or open in VGT Control solenoid valve component.

DTC DETECTING CONDITION EBADA9A9

Item Detecting Condition Possible Cause

DTC Strategy ● Signal monitoring
Enable Conditions ● IG KEY ON
Threshold Value ● Short to GND, wiring open
Diagnostic Time ● 1000ms ● VGT Control solenoid valve circuit
● VGT Control solenoid valve
Fuel Cut NO
component
EGR Off YES
Fail Safe Fuel Limit YES
Check
NO
Lamp
FLB -136 FUEL SYSTEM

SPECIFICATION E9966A4F

VGT Control solenoid valve VGT Control solenoid valve VGT Control solenoid valve
component resistance operating Hz operating duty
75% at idle, decreases as
14.7 ~ 16.1Ω (20 C) 300Hz
accelerating

DIAGNOSTIC CIRCUIT DIAGRAM E9072791

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.
Main Relay
"ON" Input

<VGT> E/R JUNCTION BOX

2 1

VGT Actuator
1. VGT Actuator
2. Power VGT

<ECM>

94 93 92 90 89
*
72 71 70 69 68 * 87 86 * 84 83 * 81 80 79 * 77 * 75 * * 6 5
* * 65 64 * * * * * * 57 56 * 54 * * 51 4 3

* 27* 48 47
28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1
* 25 * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7
29. VGT Actuator

SFDF27593L
DTC TROUBLESHOOTING PROCEDURES FLB -137

SIGNAL WAVEFORM AND DATA E3CF5EB1

Fig.1 Fig.2
SFDF27503L

Fig.1) VGT Control solenoid valve output waveform at 75% duty. Duty decreases as boost pressure increases.
Fig.2) VGT Control solenoid valve duty decreased at acceleration.

MONITOR SCANTOOL DATA E1B3B468

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Monitor "BOOST PRESSURE SENSOR" parameter on the Scantool.

Specification : 1000hpa ± 100hpa(VGT Control solenoid valve : 75%) at idle

Fig.1 Fig.2
SFDF27522L

Fig1) Monitor "BOOST PRESSURE SENSOR" parameter on the Scantool at idle after warming engine up.
1000hpa ± 100hpa(approx. 1 atm) is correct value.
FLB -138 FUEL SYSTEM

Fig.2) VGT Control solenoid valve duty decreases and boost pressure increases as accelerating. If boost pressure
rises and reaches certain value VGT Control solenoid valve duty stops to drop and keeps steady. Releasing accel-
erator pedal at this moment, VGT Control solenoid valve duty drops to 9.8% then if RPM drops to idle range, duty
returns to 75%.

TERMINAL AND CONNECTOR INSPECTION E71569BD

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power Circuit Inspection".

POWER CIRCUIT INSPECTION EC3DA2A4

1. Check power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect VGT Control solenoid valve connector

3) IG KEY "ON"

4) Measure the voltage between power terminal of VGT actuator harness connector and chassis ground.

Specification : 11.5V~13.0V

5) Is the measured voltage within the specification?

YES

▶ Go to "Control Circuit Inspection".

NO

▶ Repair INJ FUSE in E/R JUNCTION BOX and related circuit and go to "Verification of Vehicle Repair".
DTC TROUBLESHOOTING PROCEDURES FLB -139

CONTROL CIRCUIT INSPECTION E507B6C9

1. Check monitoring voltage in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect VGT Control solenoid valve connector

3) IG KEY "ON".

4) Measure the voltage between control terminal of VGT actuator hanress connector and chassis ground.

Specification : 3.2V~3.7V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ When voltage is not detected : Go to "2. Check open in control circuit" as follows.
▶ When high voltage is detected : Repair short to battery and go to "Verification of Vehicle Repair".

2. Check open in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect VGT Control solenoid valve connector and ECM connector.

3) Check continuity between control terminal of VGT actuator harness connector and ECM harness connector.

Specification : Continuity (below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground and go to "Verification of Vehicle Repair".

NO

▶ Repair open in control circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E871AFC7

1. Check VGT Control solenoid valve component resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect VGT Control solenoid valve connector.

3) Measure the resistance between control terminal and power terminal of VGT actuator connector (component
side).

Specification : 14.7 ~ 16.1Ω (20 C)

FLB -140 FUEL SYSTEM

4) Is VGT Control solenoid valve component resistance within the specification?

YES

▶ Go to "2.Check VGT Control solenoid valve operation" as follows.

NO

▶ Replace VGT Control solenoid valve and go to "Verification of Vehicle Repair".

2. Check VGT Control solenoid valve operation

1) IG KEY "ON", ENGINE "ON".

2) Check that VGT Control solenoid valve operating duty is 75% after warming engine up.

3) Check if vacuum generates after disconnecting VGT valve vacuum hose.

4) Check if vacuum generates when decelerating after rapid acceleration (VGT Control solenoid valve operating
duty 9.8%).

Specification : VGT Control solenoid valve duty 75% : vacuum generates

VGT Control solenoid valve duty 9.8% : vacuum does not generate

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace VGT Control solenoid valve and go to "Verification of Vehicle Repair".

※ Repeat this process 2~3 times.

VERIFICATION OF VEHICLE REPAIR E9FDFC33

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

DTC TROUBLESHOOTING PROCEDURES FLB -141

DTC P0048 TURBOCHARGER/SUPERCHARGER BOOST CONTROL

SOLENOID "A" CIRCUIT HIGH

COMPONENT LOCATION E8FF3936

Refer to DTC P0047.

GENERAL DESCRIPTION EEDE39B1

VGT(Variable Geometric Turbocharger) is the device which increases the efficiency of turbocharger at low rpm and lasts
optimum turbo efficiency at high rpm as varying the cross sectional area through which exhaust gas passes turbocharger
impeller. It relieves turbo lag at low speed and increse engine power genetation.
Engine speed, APS signal, MAFS and Boost pressure sensor information is inputted to ECM.
ECM actuates vacuum diafragm which controls exhaust gas line as controlling VGT Control solenoid valve duty to maintain
optimum state of air compression.

DTC DESCRIPTION E8E426D8

P0048 is set when excessive current is detected in VGT Control solenoid valve control circuit for more than 1 sec.. This
code is due to short to battery in control circuit or internal short of VGT Control solenoid valve component.

DTC DETECTING CONDITION E44A7E58

Item Detecting Condition Possible Cause

DTC Strategy ● Signal monitoring
Enable Conditions ● IG KEY ON
Threshold Value ● Short to battery
Diagnostic Time ● 1000ms ● VGT Control solenoid valve circuit
● VGT Control solenoid valve
Fuel Cut NO
component
EGR Off YES
Fail Safe Fuel Limit YES
Check
NO
Lamp

SPECIFICATION E9A7D294

Refer to DTC P0047.

DIAGNOSTIC CIRCUIT DIAGRAM E504D851

Refer to DTC P0047.

SIGNAL WAVEFORM AND DATA E758332A

Refer to DTC P0047.

MONITOR SCANTOOL DATA E7B82365

Refer to DTC P0047.

FLB -142 FUEL SYSTEM

TERMINAL AND CONNECTOR INSPECTION EDC2CFAA

Refer to DTC P0047.

POWER CIRCUIT INSPECTION E6815238

1. Check power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect VGT Control solenoid valve connector

3) IG KEY "ON"

4) Measure the voltage between power terminal of VGT actuator harness connector and chassis ground.

Specification : 11.5V~13.0V

5) Is the measured voltage within the specification?

YES

▶ Go to "Control Circuit Inspection".

NO

▶ Repair INJ FUSE in E/R JUNCTION BOX and related circuit and go to "Verification of Vehicle Repair".

CONTROL CIRCUIT INSPECTION E4F97D53

1. Check monitoring voltage in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect VGT Control solenoid valve connector

3) IG KEY "ON".

4) Measure the voltage between control terminal of VGT actuator hanress connector and chassis ground.

Specification : 3.2V~3.7V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ When voltage is not detected : Go to "2. Check open in control circuit" as follows.
▶ When high voltage is detected : Repair short to battery and go to "Verification of Vehicle Repair".

2. Check open in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect VGT Control solenoid valve connector and ECM connector.

DTC TROUBLESHOOTING PROCEDURES FLB -143

3) Check continuity between control terminal of VGT actuator harness connector and ECM harness connector.

Specification : Continuity (below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground and go to "Verification of Vehicle Repair".

NO

▶ Repair open in control circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E7CBCD9B

1. Check VGT Control solenoid valve component resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect VGT Control solenoid valve connector.

3) Measure the resistance between control terminal and power terminal of VGT actuator connector (component
side).

Specification : 14.7 ~ 16.1Ω (20 C)

4) Is VGT Control solenoid valve component resistance within the specification?

YES

▶ Go to "2.Check VGT Control solenoid valve operation" as follows.

NO

▶ Replace VGT Control solenoid valve and go to "Verification of Vehicle Repair".

2. Check VGT Control solenoid valve operation

1) IG KEY "ON", ENGINE "ON".

2) Check that VGT Control solenoid valve operating duty is 75% after warming engine up.

3) Check if vacuum generates after disconnecting VGT valve vacuum hose.

4) Check if vacuum generates when decelerating after rapid acceleration (VGT Control solenoid valve operating
duty 9.8%).

Specification : VGT Control solenoid valve duty 75% : vacuum generates

VGT Control solenoid valve duty 9.8% : vacuum does not generate

YES

▶ Go to "Verification of Vehicle Repair".

NO
FLB -144 FUEL SYSTEM

▶ Replace VGT Control solenoid valve and go to "Verification of Vehicle Repair".

※ Repeat this process 2~3 times.

VERIFICATION OF VEHICLE REPAIR E903C32C

Refer to DTC P0047.

DTC TROUBLESHOOTING PROCEDURES FLB -145

DTC P0069 MANIFOLD ABSOLUTE PRESSURE - BAROMETRIC PRESSURE

CORRELATION

COMPONENT LOCATION E2F6A589

BPS & IATS #2

SFDF28309L

GENERAL DESCRIPTION E13D6981

Boost Pressure Sensor(BPS) is installed in intake manifold and senses the pressure of air inside of intake manifold which
is compressed by turbo charager.
Measuring mass air flow accurately with the information of intake mainfold pressure, mass air flow and intake air temper-
ature, ECM performs actuating correction of EGR and VGT.
When excessive intake manifold pressure is detected, engine power generation is limited to protect engine because too
highly compressed pressure due to turbo charger may harm engine.

DTC DESCRIPTION E7DC630A

P0069 is set when the difference between BPS output voltage and atmospheric pressure sensor output voltage is above
300hpa at below 100RPM(in other word, IG KEY ON condition) for more than 3.0 sec. This code is due to abnormal
output characteristic of BPS component.

DTC DETECTING CONDITION EB906305

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON" (below 100RPM)

Threshold Value ● |Boost pressure - Barometric pressure|

is above 300hpa.
Diagnostic Time ● 3.0 sec. ● BPS circuit
● BPS component
Fuel Cut NO
EGR Off YES
Fail Safe ● Boost pressure is fixed
Fuel Limit YES at 900 hpa.
Check
NO
Lamp
FLB -146 FUEL SYSTEM

SPECIFICATION E3142B7E

Pressure [Kpa] 20 100 190 250

Outpur voltage [V] 0.4±0.077 1.878±0.063 3.541±0.063 4.650±0.077

DIAGNOSTIC CIRCUIT DIAGRAM E1F0C902

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.

Main Relay
"ON" Input

E/R JUNCTION BOX

<BOOST PRESSURE SENSOR>

BPS Signal
4 3 2 1
U P Power
1. BPS Signal
2. Power BPS Temp. Signal
3. BPS Temp. Signal
4. Ground Ground

BOOST PRESSURE SENSOR

<ECM>

60 59 58
* * * 53 37* * 50 4934 33* 47 3146
56
44 43 42 41 40
13. Power
* ** * * * 23. Ground
30 28 27 26 23 20 19 17 16 40. BPS Signal
* ** ** * 53. BPS Temp. Signal
* * 13 12 * * * 8 7 6 * 4 * 2 1

SFDF27594L
DTC TROUBLESHOOTING PROCEDURES FLB -147

SIGNAL WAVEFORM AND DATA E1E1EDE9

BPS signal

Fig.1
SFDF27521L

Fig1). This is the waveform of BPS as accelerating from idle state. Signal voltage rises as accelerating.

MONITOR SCANTOOL DATA EC97C882

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Monitor "BOOST PRESSURE SENSOR" parameter on the Scantool.

Specification : 1000hpa ± 100hpa(VGT actuator : 75%) at idle

Fig.1 Fig.2
SFDF27522L

Fig1) Monitor "BOOST PRESSURE SENSOR" parameter on the Scantool at idle after warming engine up.
1000hpa ± 100hpa(approx. 1 atm) is correct value.
FLB -148 FUEL SYSTEM

Fig.2) VGT Control solenoid valve duty decreases and boost pressure increases as accelerating. If boost pressure
rises and reaches certain value, VGT Control solenoid valve duty stops to drop and keeps steady. Releasing accel-
erator pedal at this moment, VGT Control solenoid valve duty drops to 9.8% then if RPM drops to idle range, duty
returns to 75%.

TERMINAL AND CONNECTOR INSPECTION E729D704

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Component Inspection ".

COMPONENT INSPECTION EE4D54D9

1. BPS visual iInspection

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect BPS connector.

3) Check if corrosion and damage in BPS terminal is detected.

4) Check BPS mounting state, leakage at O′ ring, clogged carbon at pressure detecting hall.

5) Are the problems relevant to BPS found?

YES

▶ Replace BPS if necessary and go to "Verification of Vehicle Repair".

NO

▶ Go to "2. Check BPS output voltage at IG KEY ON" as follows.

2. Check BPS output voltage at IG KEY ON

1) IG KEY "ON", ENGINE "ON".

2) Connect Scantool to Data Link Connector (DLC).

DTC TROUBLESHOOTING PROCEDURES FLB -149

3) IG KEY "ON"

4) Monitor "ATMOSPHERIC PRESSURE" and "BOOST PRESSURE SENSOR" parameters on scantool.

5) Check if both "ATMOSPHERIC PRESSURE" and "BOOST PRESSURE SENSOR" indicates similar value at IG
KEY "ON".

Specification : Refer to "Monitor Scantool Data" of Scantool diagnostics parameters.

6) Is any BPS related problem is detedcted?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace BPS and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E5327A73

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -150 FUEL SYSTEM

DTC P0087 FUEL RAIL/SYSTEM PRESSURE - TOO LOW

COMPONENT LOCATION E0A89E67

FTS
Injector

RPS

Rail Pressure
Regulator Valve Fuel Pressure Regulator Valve

SFDF28328L

GENERAL DESCRIPTION E45E4CC8

As inputted rail pressure sensor signal, ECM of Commom rail diesel engine controls Fuel pressure regulator valve(inter-
grated with high press. pump) and rail pressure regulator valve(ntegrated with common rail) in order to maintain optimum
rail pressure according to current engine rpm and load.
However when the problem that leads rail pressure to out of target value intended by ECM occurs due to mechanical or
electronical reason, ECM shuts engine down and sets DTC by limiting fuel (stops injector operation) in order to prevent
engine from being controlled abnormally. "rail pressure monitoring error" is the DTC which diagnose 1).supplying state
of low pressure fuel and 2).mechanical operating conditions of high pressure pump and 3). rail pressure regulator valve
indirectly based on RPS output voltage and RPS duty. thus, repair relavant to this DTC requires mechanics the total
understand of fuel system.

DTC DESCRIPTION E3048876

P0087 is set when rail pressure is lower than target rail pressure by more than 200~150bar for more than 1.0 sec. in
condition that rail press. is controlled by rail pressure control valve(PCV) or rail pressure is below the minimum limiting
value(50~280bar). This code is due to 1)fuel less than target value supplied to common rail or 2)excessive return of fuel
supplied to common rail or 3)short to low voltage line in fuel press. sensor.
DTC TROUBLESHOOTING PROCEDURES FLB -151

DTC DETECTING CONDITION E9FA8A19

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● Engine running

● Rail pressure is below target rail pressure by

more than 200~150bar at rail pressure control
Threshold Value valve(PCV) operating condition.-1.0sec.
● Rail pressure is below minimum limiting ● Fuel metering unit(close stuck)
value(50~280bar) at rail pressure control ● Rail pressure control valve(open
valve(PCV) operating condition.-0.3sec. stuck)
● Rail pressure sensor(Output fixed
Diagnostic Time ● Refer to threshold Value. at low voltage line)
Fuel Cut NO
EGR Off NO
Fail Safe Fuel Limit YES
Check
YES
Lamp

MONITOR SCANTOOL DATA E15CA6A8

1. Monitoring rail pressure data

1) Connect Scantool to Data Link Connector (DLC).

2) Warm engine up to normal operating temperature.

3) Turn "OFF" electrical devices and A/C.

4) Monitor "FUEL PRESSURE MEASURED", "FUEL PRESSURE-TARGET", "RAIL PRESS. REGULATOR1", "INJ.
PUMP REGULATOR" parameter on the Scantool.

Specification : FUEL PRESSURE MEASURED : similar to "FUEL PRESSURE-TARGET"

FUEL PRESSURE-TARGET : 28 ± 5 Mpa
RAIL PRESS. REGULATOR1 : 20 ± 5%
INJ. PUMP REGULATOR : 40 ± 5%
FLB -152 FUEL SYSTEM

Fig.1
SFDF27559L

Fig.1) Monitor "FUEL PRESSURE MEASURED" at idle after warming engine up.

Check if "FUEL PRESSURE MEASURED"data is similar to "FUEL PRESSURE-TARGET". Not only former
two data but also "RAIL PRESS. REGULATOR1" and "INJ. PUMP REGULATOR"shoult be monitored carefully.
Although "FUEL PRESSURE MEASURED" is similar to "FUEL PRESSURE-TARGET", if "RAIL PRESS. REG-
ULATOR1" and "INJ. PUMP REGULATOR" is out of specification, it means wear, leakage, stuck of fuel system.

2. Monitoring rail pressure data at acceleration(loading condition).

1) Connect Scantool to Data Link Connector (DLC).

2) Warm engine up to normal operating temperature.

3) Turn "OFF" electrical devices and A/C.

4) Monitor "FUEL PRESSURE MEASURED", "RAIL PRESS. REGULATOR1", "INJ. PUMP REGULATOR" param-
eter on the Scantool.

SPECIFICATION :

Idle(without load) Accelerating(stall test) Diagnosis

INJ. PUMP REGULATOR 38 ± 5% 32 ± 5% Duty decreases
FUEL PRESSURE
28.5 ± 5 Mpa 145 ± 10 Mpa Press. increases
MEASURED
RAIL PRESS.
19 ± 5% 48 ± 5% Duty increases
REGULATOR1
DTC TROUBLESHOOTING PROCEDURES FLB -153

Fig.2 Fig.3
SFDF27560L

Fig.2) The position of curser on the graph represents idle data.

Fig.3) Data during acceleration(stall test).

NOTE
The waveform of fuel pressure regulator valve installed at high pressure pump(fuel detecting MPROP) shows 38%
duty at idle, duty drops to approx. 32% at acceleration to raise rail pressure. Duty drop means the decrease of
current.
▶ Fuel delivered to common rail increases as current drops.

The waveform of rail pressure regulator valve installed at common rail shows 19% duty at idle, duty rises to approx.
48% at acceleration to raise rail pressure. Duty rise means the increase of current.
▶ If current rises, the returning quantity of fuel deliverd to common rail decreases and common rail pressure rises.

VERIFICATION OF VEHICLE REPAIR E17CB3CB

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -154 FUEL SYSTEM

DTC P0088 FUEL RAIL/SYSTEM PRESSURE - TOO HIGH

COMPONENT LOCATION EDE3BD14

Refer to DTC P0087.

GENERAL DESCRIPTION EB5CDB86

Refer to DTC P0087.

DTC DESCRIPTION E9E4793B

P0088 is set if measured rail pressure is higher than target rail pressure by more than 250bar when rail pressure is
regulated by Rail pressure regulator valve or rail pressure is above the max limiting value. This code is due to 1)fuel more
than target value supplied to common rail or 2)poor return of fuel supplied to common rail or 3)short to high voltage line
in fuel press. sensor.

DTC DETECTING CONDITION E04E46E9

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● Engine running

● Rail pressure is above target rail pressure

by more than 250bar at Rail pressure regulator
Threshold Value valve operating condition.- 2000ms
● Rail pressure is above maximum limiting ● Fuel metering unit(open stuck)
value(1750bar) at Rail pressure regulator valve ● Rail pressure regulator
operating condition. - 240 ms valve(close stuck)
● Rail pressure sensor(Output fixed
Diagnostic Time ● Refer to threshold Value. at high voltage line)
Fuel Cut NO
EGR Off NO
Fail Safe Fuel Limit YES
Check
YES
LamFp

MONITOR SCANTOOL DATA E03C9C7E

1. Monitoring rail pressure data

1) Connect Scantool to Data Link Connector (DLC).

2) Warm engine up to normal operating temperature.

3) Turn "OFF" electrical devices and A/C.

4) Monitor "FUEL PRESSURE MEASURED", "FUEL PRESSURE-TARGET", "RAIL PRESS. REGULATOR1", "INJ.
PUMP REGULATOR" parameter on the Scantool.
DTC TROUBLESHOOTING PROCEDURES FLB -155

Specification : FUEL PRESSURE MEASURED : similar to "FUEL PRESSURE-TARGET"

FUEL PRESSURE-TARGET : 28 ± 5 Mpa
RAIL PRESS. REGULATOR1 : 20 ± 5%
INJ. PUMP REGULATOR : 40 ± 5%

Fig.1
SFDF27559L

Fig.1) Monitor "FUEL PRESSURE MEASURED" at idle after warming engine up.

Check if "FUEL PRESSURE MEASURED"data is similar to "FUEL PRESSURE-TARGET". Not only former
two data but also "RAIL PRESS. REGULATOR1" and "INJ. PUMP REGULATOR"shoult be monitored carefully.
Although "FUEL PRESSURE MEASURED" is similar to "FUEL PRESSURE-TARGET", if "RAIL PRESS. REG-
ULATOR1" and "INJ. PUMP REGULATOR" is out of specification, it means wear, leakage, stuck of fuel system.

2. Monitoring rail pressure data at acceleration(loading condition).

1) Connect Scantool to Data Link Connector (DLC).

2) Warm engine up to normal operating temperature.

3) Turn "OFF" electrical devices and A/C.

4) Monitor "FUEL PRESSURE MEASURED", "RAIL PRESS. REGULATOR1", "INJ. PUMP REGULATOR" param-
eter on the Scantool.

SPECIFICATION :

Idle(without load) Accelerating(stall test) Diagnosis

INJ. PUMP REGULATOR 38 ± 5% 32 ± 5% Duty decreases
FUEL PRESSURE
28.5 ± 5 Mpa 145 ± 10 Mpa Press. increases
MEASURED
RAIL PRESS.
19 ± 5% 48 ± 5% Duty increases
REGULATOR1
FLB -156 FUEL SYSTEM

Fig.2 Fig.3
SFDF27560L

Fig.2) The position of curser on the graph represents idle data.

Fig.3) Data during acceleration(stall test).

NOTE
The waveform of fuel pressure regulator valve installed at high pressure pump(fuel detecting MPROP) shows 38%
duty at idle, duty drops to approx. 32% at acceleration to raise rail pressure. Duty drop means the decrease of
current.
▶ Fuel delivered to common rail increases as current drops.

The waveform of rail pressure regulator valve installed at common rail shows 19% duty at idle, duty rises to approx.
48% at acceleration to raise rail pressure. Duty rise means the increase of current.
▶ If current rises, the returning quantity of fuel deliverd to common rail decreases and common rail pressure rises.

VERIFICATION OF VEHICLE REPAIR EA1C635A

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

DTC TROUBLESHOOTING PROCEDURES FLB -157

DTC P0089 FUEL PRESSURE REGULATOR 1 PERFORMANCE

COMPONENT LOCATION E4A5C8ED

Injector

RPS

Rail Pressure
Regulator Valve

SFDF28313L

GENERAL DESCRIPTION E11B41E1

Rail pressure regulator valve is installed in common rail and controls common rail pressure fast as regulating returning
quantity of fuel which is delivered to common rail when fast rise of rail pressure is required like the moment of turning
engine ON or when fast relief of pressure is required like at the point of deceleration.
The lower Rail pressure regulator valve current is, the more fuel is supplied to common rail. Thus it leads rail pressure to
be high. On the contrary, the higher Rail pressure regulator valve current is, the less fuel is supplied to common rail.

DTC DESCRIPTION E5E1B42A

P0089 is set when excessive current in control circuit of Rail pressure regulator valve(integrated with high common rail)
is detected for more than 0.22 sec.. This code is due to short to battery in control circuit or Rail pressure regulator valve
internal short.

DTC DETECTING CONDITION EF11493A

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● Short to battery (control circuit of Rail

pressure regulator valve)
● Rail pressure regulator valve circuit
Diagnostic Time ● 220ms ● Rail pressure regulator valve
Fuel Cut YES component
EGR Off NO
Fail Safe Fuel Limit NO
Check
YES
Lamp
FLB -158 FUEL SYSTEM

SPECIFICATION E804C766

Rail pressure regulator valve resistance Operating frequancy

3.42 ~ 3.78Ω (20 C) 1000Hz(1KHz)

DIAGNOSTIC CIRCUIT DIAGRAM EFC5BC29

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.

Main Relay
"ON" Input

<RAIL PRESSURE E/R JUNCTION BOX

REGULATOR>

Power
2 1

Ground
1. Power
2.Ground RAIL PRESSURE
REGULATOR

<ECM>

60 59 58
* * * 53 37* * 50 4934 33* 47 3146
56
44 43 42 41 40
* ** * * *
30 28 27 26 23 20 19 17 16
* ** ** *
* * 13 12 * * * 8 7 6 * 4 * 2 1
4. Power
34. Ground

SFDF27595L
DTC TROUBLESHOOTING PROCEDURES FLB -159

SIGNAL WAVEFORM AND DATA EE53E604

Fig.1 Fig.2
SFDF27504L

Fig.1) Waveform of rail pressure regulator valve at idle. It shows approx. 20% duty.
Fig.2) Waveform of rail pressure regulator valve as accelerating. Approx. 50% duty is outputted as engine load increases.
( When rail pressure increases as accelerating, rail pressure regulator valve duty(current) rises.)

MONITOR SCANTOOL DATA E5856A93

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Monitor "FUEL PRESSURE MEASURED", "RAIL PRESS. REGULATOR1", "INJ. PUMP REGULATOR" parameter
on the Scantool.

SPECIFICATION :

Idle(without load) Accelerating(stall test) Diagnosis

INJ. PUMP REGULATOR 38 ± 5% 32 ± 5% Duty decreases
FUEL PRESSURE
28.5 ± 5 Mpa 145 ± 10 Mpa Press. increases
MEASURED
RAIL PRESS.
19 ± 5% 48 ± 5% Duty increases
REGULATOR1
FLB -160 FUEL SYSTEM

Fig.2 Fig.3
SFDF27560L

Fig.1) The position of curser on the graph represents idle data.

Fig.2) Data during acceleration(stall test).

NOTE
The waveform of Fuel pressure regulator valve installed at high pressure pump(fuel detecting MPROP) shows 38%
duty at idle, duty drops to approx. 32% at acceleration to raise rail pressure. Duty drop means the decrease of
current.
▶ Fuel delivered to common rail increases as current drops.

The waveform of rail pressure regulator valve installed at common rail shows 19% duty at idle, duty rises to approx.
48% at acceleration to raise rail pressure. Duty rise means the increase of current.
▶ If current rises, the returning quantity of fuel deliverd to common rail decreases and common rail pressure rises.

TERMINAL AND CONNECTOR INSPECTION E5B20A47

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power Circuit Inspection".

DTC TROUBLESHOOTING PROCEDURES FLB -161

POWER CIRCUIT INSPECTION EB2DCB5A

1. Check power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Rail pressure regulator valve connector.

3) IG KEY "ON".

4) Measure the voltage between control terminal of RPRV harness connector and chassis ground.

Secification : 11.5V~13.0V

5) Is the measured voltage within the specification?

YES

▶ Go to "Control Circuit Inspection".

NO

▶ Repair open between rail pressure regulator valve power terminal of RPRV harness connector and ECM
harness connector and go to "Verification of Vehicle Repair".

CONTROL CIRCUIT INSPECTION ECAF2663

1. Check monitoring voltage in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Rail pressure regulator valve connector.

3) IG KEY "ON".

4) Measure the voltage between control terminal of RPRV harness connector and chassis ground.

Specification : 3.2V~3.7V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection"

NO

▶ When voltage is not detected : Go to "2. Check open in control circuit" as follows.
▶ When high voltage is detected : Repair short to battery and go to "Verification of Vehicle Repair".

2. Check open in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Rail pressure regulator valve connector and ECM connector.

3) Check continuity between control terminal of RPRV harness connector and ECM harness connector.
FLB -162 FUEL SYSTEM

Specification : Continuity (below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground in Rail pressure regulator valve control circuit and go to "Verification of Vehicle Repair".

NO

▶ Repair open in Rail pressure regulator valve control circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION EFC4FFC8

1. Check Rail pressure regulator valve component resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Rail pressure regulator valve connector.

3) Measure resistance between power terminal and control terminal of RPRV connector (component side).

Specification : 3.42 ~ 3.78Ω (20 C)

4) Is the measured resistance within the specification?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace common rail assy’ and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E706E466

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

DTC TROUBLESHOOTING PROCEDURES FLB -163

DTC P0091 FUEL PRESSURE REGULATOR 1 CONTROL CIRCUIT LOW

COMPONENT LOCATION E47F9B9C

Refer to DTC P0089.

GENERAL DESCRIPTION EA410267

Refer to DTC P0089.

DTC DESCRIPTION E4D4F02B

P0091 is set when Short to GRD is sensed in control circuit of Rail pressure regulator valve (integrated with common rail)
for more than 0.22 sec or Wiring open is sensed for more than 0.28 sec. This code is due to open or short to ground in
control circuit or Rail pressure regulator valve internal open.

DTC DETECTING CONDITION EB303CCA

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"
Threshold Value ● Short to GND - 220ms, Wiring open - 280ms
Diagnostic Time ● 220ms, 280ms ● Rail pressure regulator valve circuit
● Rail pressure regulator valve
Fuel Cut YES
component
EGR Off NO
Fail Safe Fuel Limit NO
Check
YES
Lamp

SPECIFICATION E577DD40

Refer to DTC P0089.

DIAGNOSTIC CIRCUIT DIAGRAM E3364F3E

Refer to DTC P0089.

SIGNAL WAVEFORM AND DATA EA010BF1

Refer to DTC P0089.

MONITOR SCANTOOL DATA E7CD4A44

Refer to DTC P0089.

TERMINAL AND CONNECTOR INSPECTION E9549C08

Refer to DTC P0089.

FLB -164 FUEL SYSTEM

POWER CIRCUIT INSPECTION EBD4E65F

1. Check power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Rail pressure regulator valve connector.

3) IG KEY "ON".

4) Measure the voltage between control terminal of RPRV harness connector and chassis ground.

Secification : 11.5V~13.0V

5) Is the measured voltage within the specification?

YES

▶ Go to "Control Circuit Inspection".

NO

▶ Repair open between rail pressure regulator valve power terminal of RPRV harness connector and ECM
harness connector and go to "Verification of Vehicle Repair".

CONTROL CIRCUIT INSPECTION E62B6DA6

1. Check monitoring voltage in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Rail pressure regulator valve connector.

3) IG KEY "ON".

4) Measure the voltage between control terminal of RPRV harness connector and chassis ground.

Specification : 3.2V~3.7V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection"

NO

▶ When voltage is not detected : Go to "2. Check open in control circuit" as follows.
▶ When high voltage is detected : Repair short to battery and go to "Verification of Vehicle Repair".

2. Check open in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Rail pressure regulator valve connector and ECM connector.

3) Check continuity between control terminal of RPRV harness connector and ECM harness connector.
DTC TROUBLESHOOTING PROCEDURES FLB -165

Specification : Continuity (below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground in Rail pressure regulator valve control circuit and go to "Verification of Vehicle Repair".

NO

▶ Repair open in Rail pressure regulator valve control circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION EF70FAA4

1. Check Rail pressure regulator valve component resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Rail pressure regulator valve connector.

3) Measure resistance between power terminal and control terminal of RPRV connector (component side).

Specification : 3.42 ~ 3.78Ω (20 C)

4) Is the measured resistance within the specification?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace common rail assy’ and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR EFEA414E

Refer to DTC P0089.

FLB -166 FUEL SYSTEM

DTC P0092 FUEL PRESSURE REGULATOR 1 CONTROL CIRCUIT HIGH

COMPONENT LOCATION E753F24F

Refer to DTC P0089.

GENERAL DESCRIPTION E026AEB2

Refer to DTC P0089.

DTC DESCRIPTION E6008260

P0092 is set when Short to battery is sensed in control circuit of Rail pressure regulator valve (integrated with common
rail) for more than 0.28 sec. This code is due to short to battery in power circuit or Rail pressure regulator valve internal
short.

DTC DETECTING CONDITION E7B87E9B

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● Short to battery (power circuit in rail

pressure regulator valve)
● Rail pressure regulator valve circuit
Diagnostic Time ● 280ms ● Rail pressure regulator valve
Fuel Cut NO component
EGR Off NO
Fail Safe Fuel Limit YES
Check
YES
Lamp

SPECIFICATION E75A05D6

Refer to DTC P0089.

DIAGNOSTIC CIRCUIT DIAGRAM EAF72CBA

Refer to DTC P0089.

SIGNAL WAVEFORM AND DATA E4EB0FCB

Refer to DTC P0089.

MONITOR SCANTOOL DATA E9D4F092

Refer to DTC P0089.

DTC TROUBLESHOOTING PROCEDURES FLB -167

TERMINAL AND CONNECTOR INSPECTION E8BC5174

Refer to DTC P0089.

POWER CIRCUIT INSPECTION E2AFF1AD

1. Check power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Rail pressure regulator valve connector.

3) IG KEY "ON".

4) Measure the voltage between control terminal of RPRV harness connector and chassis ground.

Secification : 11.5V~13.0V

5) Is the measured voltage within the specification?

YES

▶ Go to "Control Circuit Inspection".

NO

▶ Repair open between rail pressure regulator valve power terminal of RPRV harness connector and ECM
harness connector and go to "Verification of Vehicle Repair".

CONTROL CIRCUIT INSPECTION E889A59D

1. Check monitoring voltage in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Rail pressure regulator valve connector.

3) IG KEY "ON".

4) Measure the voltage between control terminal of RPRV harness connector and chassis ground.

Specification : 3.2V~3.7V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection"

NO

▶ When voltage is not detected : Go to "2. Check open in control circuit" as follows.
▶ When high voltage is detected : Repair short to battery and go to "Verification of Vehicle Repair".

2. Check open in control circuit

1) IG KEY "OFF", ENGINE "OFF".

FLB -168 FUEL SYSTEM

2) Disconnect Rail pressure regulator valve connector and ECM connector.

3) Check continuity between control terminal of RPRV harness connector and ECM harness connector.

Specification : Continuity (below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground in Rail pressure regulator valve control circuit and go to "Verification of Vehicle Repair".

NO

▶ Repair open in Rail pressure regulator valve control circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E245DD3E

1. Check Rail pressure regulator valve component resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Rail pressure regulator valve connector.

3) Measure resistance between power terminal and control terminal of RPRV connector (component side).

Specification : 3.42 ~ 3.78Ω (20 C)

4) Is the measured resistance within the specification?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace common rail assy’ and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E295F1AC

Refer to DTC P0089.

DTC TROUBLESHOOTING PROCEDURES FLB -169

DTC P0097 INTAKE AIR TEMPERATURE SENSOR 2 CIRCUIT LOW INPUT

COMPONENT LOCATION E56796FB

MAFS & IATS #1

SFDF28308L

GENERAL DESCRIPTION E00DA305

Intake Air Temperature Sensor(IATS) is NTC thermistor. Installed inside of both MAFS and BPS, it senses intake air
temperature.
In case of EURO-4 diesel engine, IATS is installed in front of turbocharger(inside of MAFS) and behind it(inside of BPS).
Comparing air temperature from both sensors(one is intake air temperature, the other is air temperature passing through
turbo charger), more accurate sensing of intake air temperature is possible.
With intake air temperature signal, ECM performs EGR control correction and fuel injection quantity correction.(MAFS is
needed for EGR FEED BACK control in electronically controlled diesel engine. The calculation of air density at certain
temperture is required to perform EGR FEED BACK control correctly.)

DTC DESCRIPTION E7D9479B

P0097 is set when the voltage below 73mV(0.11V) - minimum output voltage of IATS(integrated with BPS) - is detected
for more than 2.0 sec. This code is due to short to ground in IATS signal circuit.

DTC DETECTING CONDITION E245CE77

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● Output signal below minimum value(

below 73mV )
Diagnostic Time ● 2.0 sec. ● IATS circuit
● IATS component
Fuel Cut NO
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp
FLB -170 FUEL SYSTEM

SPECIFICATION E259913D

Temp. - 40 C - 20 C 0C 20 C
Resistance 35.14~43.76KΩ 12.66~15.12KΩ 5.12~5.89KΩ 2.29~2.55KΩ
Temp. 40 C 60 C 80 C
Resistance 1.10~1.24KΩ 0.57~0.65KΩ 0.31~0.37KΩ

DIAGNOSTIC CIRCUIT DIAGRAM E0269A96

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.

Main Relay
"ON" Input

E/R JUNCTION BOX

<BOOST PRESSURE SENSOR>

BPS Signal
4 3 2 1
U P Power
1. BPS Signal
2. Power BPS Temp. Signal
3. BPS Temp. Signal
4. Ground Ground

BOOST PRESSURE SENSOR

<ECM>

60 59 58
* * * 53 37* * 50 4934 33* 47 3146
56
44 43 42 41 40
13. Power
* ** * * * 23. Ground
30 28 27 26 23 20 19 17 16 40. BPS Signal
* ** ** * 53. BPS Temp. Signal
* * 13 12 * * * 8 7 6 * 4 * 2 1

SFDF27594L
DTC TROUBLESHOOTING PROCEDURES FLB -171

SIGNAL WAVEFORM AND DATA E4287DFC

Fig.1
SFDF27505L

Fig.1) IATS output waveform at 25 C. The higher temperature is, the lower voltage becomes.

MONITOR SCANTOOL DATA E9013B67

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Monitor "AIR TERMPERATURE SENSOR" parameter on the Scantool.

Specification : Current intake air temperture is displayed.

Fig.1
SFDF27506L

Fig.1) Check if current temperature is same as the value displayed on the Scantool.
FLB -172 FUEL SYSTEM

TERMINAL AND CONNECTOR INSPECTION E96941C9

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Signal Circuit Inspection".

SIGNAL CIRCUIT INSPECTION E29D7D1F

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect BPS connector.

3) IG KEY "ON".

4) Check the voltage between signal terminal of IAT in BPS harness connector and chassis ground.

Secification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ Repair "2. Check short to ground in signal circuit" as follows.

2. Check short to ground in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect BPS connector and ECM connector.

3) Check continuity between signal terminal of IAT in BPS harness connector and and chassis ground.
DTC TROUBLESHOOTING PROCEDURES FLB -173

Specification : Discontinuity(Infinite Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to"Component Inspection".

NO

▶ Repair short to ground in signal circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION EB0EAD95

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect BPS connector.

3. Measure resistance between signal terminal of IAT in BPS connector and ground terminal of BPS connector (com-
ponent side)

Specification : Refer to Specification of General Information

4. Is the measured resistance at certain temperature within the specified resisance range at the temperature?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace BPS assy’ and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E4C3BC7D

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -174 FUEL SYSTEM

DTC P0098 INTAKE AIR TEMPERATURE SENSOR 2 CIRCUIT HIGH INPUT

COMPONENT LOCATION E73C2171

Refer to DTC P0097.

GENERAL DESCRIPTION E354E5F9

Refer to DTC P0097.

DTC DESCRIPTION EFAD5A87

P0098 is set when the voltage above 4965mV - maximum output voltage of IATS(integrated with BPS) - is detected for
more than 2.0 sec.. This code is due to 1) open or 2) short to ground or 3) short to battery in IATS signal circuit.

DTC DETECTING CONDITION E11C51E3

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● Output signal above maximum value(

above 4965mV )
Diagnostic Time ● 2.0 sec. ● IATS circuit
● IATS component
Fuel Cut NO
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp

SPECIFICATION E92439F5

Refer to DTC P0097.

DIAGNOSTIC CIRCUIT DIAGRAM EA660594

Refer to DTC P0097.

SIGNAL WAVEFORM AND DATA E2940F95

Refer to DTC P0097.

MONITOR SCANTOOL DATA EE2A6828

Refer to DTC P0097.

TERMINAL AND CONNECTOR INSPECTION E0437F01

Refer to DTC P0097.

DTC TROUBLESHOOTING PROCEDURES FLB -175

SIGNAL CIRCUIT INSPECTION E304AD4D

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect BPS connector.

3) IG KEY "ON".F

4) Check the voltage between signal terminal of IAT in BPS harness connector and chassis ground.

Secification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Go to "2.Check open in signal circuit" as follows.

2. Check open in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect BPS connector and ECM connector.

3) Check continuity between signal terminal of IAT 2 in BPS harness connector and signal terminal of IAT 2 in ECM
harness connector

Specification : Continuity (below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "3. Check short to battery in signal circuit" as follows.

NO

▶ Repair open in signal circuit and go to "Verification of Vehicle Repair".

3. Check short to battery in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect BPS connector and ECM connector.

3) IG KEY "ON"

4) Check the voltage between signal terminal of IAT in BPS harness connector and chassis ground.

Specification : 0.0V~0.1V

5) Is the measured voltage within the specification?(with both connector disconnected)

FLB -176 FUEL SYSTEM

YES

▶ Repair short to battery in signal circuit and go to "Verification of Vehicle Repair".

NO

▶ Go to "Ground Circuit Inspection".

GROUND CIRCUIT INSPECTION ED2097F0

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect BPS connector.

3. IG KEY "ON".

4. Measure the voltage between signal terminal of IAT in BPS harness connector and chassis ground.. [ TEST "A" ]

5. Measure the voltage between signal terminal of IAT and ground terminal of BPS harness connector.[ TEST "B" ]
( Signal terminal : Check + prove , Ground terminal 4 : Check - prove )

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6. Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION EDBFB372

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect BPS connector.

3. Measure resistance between signal terminal of IAT in BPS connector and ground terminal of BPS connector (com-
ponent side)

Specification : Refer to Specification of General Information

4. Is the measured resistance at certain temperature within the specified resisance range at the temperature?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace BPS assy’ and go to "Verification of Vehicle Repair".

DTC TROUBLESHOOTING PROCEDURES FLB -177

VERIFICATION OF VEHICLE REPAIR E71FF90A

Refer to DTC P0097.

FLB -178 FUEL SYSTEM

DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE /

PERFORMANCE

COMPONENT LOCATION EE127694

MAFS & IATS #1

SFDF28308L

GENERAL DESCRIPTION E45B376A

Air Flow Sensor(MAFS) is digital sensor. Measuring mass of air flow, signal is outputted as frequency(Hz).
ECM performs EGR system feed back control with the information of measured mass air flow. (The role of MAFS in diesel
engine is different from gasoline engine. Fuel injection quantity is decided by MAFS signal in gasoline engine.)
When EGR gas(contains no oxygen) flowing into combustion chamber increases, the air passing through MAFS(contains
oxygen) decreases. Thus, with the output signal change of MAFS accompanied by EGR actuator actuation, ECM deter-
mines the amount of recirculated EGR gas quantity.

NOTE
NOx is produced from the reaction of nitrogen and oxygen.
If least intake air required for complete combustion flows into combustion chamber by controlling EGR gas(contains
no oxygen) which is recirculated to combustion chamber, NOx decreases because there is no supplementary oxygen
to react with nitrogen.

DTC DESCRIPTION E1F292D9

P0101 is set 1) when Air mass ratio(real/threshold) above 1.5 or below 0.85 is detected for more than 7 sec.. or 2) short
to battery or ground in MAFS or IATS signal circuit is detected for more than 0.58 sec. or 3) short to low or high voltage
line in IATS signal circuit is detected for more than 0.6 sec.
DTC TROUBLESHOOTING PROCEDURES FLB -179

DTC DETECTING CONDITION E48EAD7F

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● Engine running

● Air mass ratio(real/threshold) above 1.5

or below 0.85 - 7 sec.
Threshold Value ● Short to low or high voltage line in IATS
signal circuit - 0.6 sec.
● Shrot to battery or ground in MAFS or
● MAFS circuit
IATS circuit - 0.58 sec.
● MAFS component
Diagnostic Time ● Refer to threshold Value.
Fuel Cut NO
EGR Off YES
Fail Safe Fuel Limit YES
Check
YES
Lamp

SPECIFICATION E9D77313

Output frequency ( KHz ) Deviation [ % ]

Intake air quantity (Kg/h)
20 C 80 C ± 3
8 1.97 ± 2
10 2.01 2.01 ± 2
40 2.50 2.50 ± 2
105 3.20 3.20 ± 2
220 4.30 ± 2
480 7.80 7.80 ± 2
560 9.50 ± 3
FLB -180 FUEL SYSTEM

DIAGNOSTIC CIRCUIT DIAGRAM E7C74B8D

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.

Main Relay
"ON" Input

E/R JUNCTION BOX

<AIR FLOW SENSOR>

Reference Freqency
5 4 3 2 1
AFS Signal
1. Power from IG SW
Temperature Output
2. Ground
3. Temperature Output Ground
4. Reference Frequency
5. AFS Signal AIR FLOW SENSOR

<ECM>

<ECM> 60 59 58
* * * 53 37* * 50 4934 33* 47 3146
56
44 43 42 41 40
* ** * * *
94 93 92 90 89
* * 87 86 * 84 83 * 81 80 79 * 77 * 75 * * 6 5
30
* 28 27 26 23
** ** 20 19
* 17 16
72 71 70 69 68
* * 65 64 * * * * * * 57 56 * 54 * * 51 4 3 * * 13 12 * * * 8 7 6 * 4 * 2 1
* 27* 48 47
28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1
* 25 * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7 37. Reference Frequency
42. AFS Signal
89. Temperature Output 44. Ground

SFDF27596L
DTC TROUBLESHOOTING PROCEDURES FLB -181

SIGNAL WAVEFORM AND DATA E3E2570C

Fig.1 Fig.2
SFDF27507L

Fig.1) MAFS signal waveform at IG KEY "ON". It shows digital signal of 50% duty, 1.8KHz.
Fig.2) MAFS signal waveform at idle(830RPM, Electric EGR control valve duty 9.4%, air flow for each cylinder 340mg/st).
It shows digital signal of 50% duty, 2.0~2.5KHz.

NOTE
Signal frequency increases as RPM rises.

MONITOR SCANTOOL DATA EB10BD4F

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Monitor "AIR MASS PERCYLINDER" parameter on the Scantool.

Specification :
When Electric EGR control valve does not operate 6% duty) at idle : 340mg/st ± 50 mg/st
When Electric EGR control valve operates(Approx. 50% duty) at idle : 200ms/st ± 50 mg/st
FLB -182 FUEL SYSTEM

Fig.1 Fig.2
SFDF27508L

Fig.1) Check if "AIR MASS PERCYLINDER"l is 340mg/st ± 50mg/st without EEGR operation at warm idle (Electric
EGR control valve 6% duty)
Fig.2) Check if "AIR MASS PERCYLINDER"l is 200mg/st ± 50mg/st with EEGR operation at warm idle (Electric EGR
control valve approx. 50% duty)
※ Electric EGR control valve operates as decelerating after rapid acceleration when idle EEGR does not operate,
Electric EGR control valve operating duty decreases as time goes by. This controlling process lasts for about 1 min.
and EElectric EGR control valve turns "OFF" (duty 6% ) after 1 min..

TERMINAL AND CONNECTOR INSPECTION E2F6CD26

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power Circuit Inspection".

POWER CIRCUIT INSPECTION EF756B10

1. Check power circuit voltage

DTC TROUBLESHOOTING PROCEDURES FLB -183

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect MAFS connector.

3) IG KEY "ON".

4) Measure the voltage between IG power terminal of MAFS harness connector and chassis ground.

5) Measure the voltage between power terminal of MAFS harness connector and chassis ground.

Specification : 4.8V~5.1V ( Sensor power )

11.5V~13.0V ( IG Power )

6) Is the measured voltage within the specification?

YES

▶ Go to "Signal Circuit Inspection".

NO

▶ When output voltage is not detected at IG power terminal :

▶ Repair open in ‘ SNSR.2 FUSE 10A’ in E/R junction box and related circuit and go to "Verification of Vehicle
Repair".
▶ When output voltage is not detected at power terminal :
▶ Repair open between power terminal of MAFS connector and sensor power terminal of ECM connector
(CUD-A), and go to "Verification of Vehicle Repair".

SIGNAL CIRCUIT INSPECTION EA7779AF

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect MAFS connector and ECM connector.

3) IG KEY "ON".

4) Measure the voltage between signal terminal of IATS harness connector and chassis ground.

5) Measure the voltage between signal terminal of MAFS harenss connector and chassis ground

Specification :
Terminal 3 : 4.8V~5.1V (IATS signal )
Terminal 5 : 4.8V~5.1V (MAFS signal )

6) Is the measured voltage within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Repair short to battery in signal circuit and go to "Verification of Vehicle Repair".

FLB -184 FUEL SYSTEM

GROUND CIRCUIT INSPECTION E2307C9C

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect MAFS connector.

3. IG KEY "ON".

4. Measure the voltage between power terminal of MAFS harness connector and chassis ground. [ TEST "A" ]

5. Measure the voltage between power terminal of MAFS harness connector and and signal terminal of MAFS harness
connectorter. [ TEST "B" ]

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6. Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E1C1D4B3

1. IG KEY "OFF", ENGINE "OFF".

2. Check that MAFS is installed in correctly according to the direction of arrow on MAFS assy’ .

3. Check contamination of air cleaner filter.

4. IG KEY "ON", ENGINE "ON".

5. Let IDLE RPM last after warming engine up.

6. Check the leakage of intake system(the leakage or damage of intercooler).

7. Check that VGT operates correctly.(Check if vacuum operating state of VGT Control solenoid valve is appropriate, if
VGT diaphragm and unison ring are stuck.)

8. Check that Electric EGR control valve does not operate.

( Electric EGR control valve turns "OFF" and 6% duty is outputted 1 min after rapid acceleration. Disconnect EElectric
EGR control valve connector if needed. )

9. Monitor signal voltage of MAFS when engine speed lasts at approx. 800RPM using Scantool.

10. Check MAFS output signal at idle after rapid acceleration.(Electric EGR control valve duty 50%)

Specification : When Electric EGR control valve does not operate (6%) at idle : 340mg/st ± 50 mg/st
EEGR When EElectric EGR control valve operates(50%) at idle : 200ms/st ± 50 mg/st

11. Is output signal within the specification?

YES
DTC TROUBLESHOOTING PROCEDURES FLB -185

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace MAFS assy’ and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR EDE6DE0F

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -186 FUEL SYSTEM

DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT

COMPONENT LOCATION E01BE289

Refer to DTC P0101.

GENERAL DESCRIPTION EE3F5488

Refer to DTC P0101.

DTC DESCRIPTION E45A5965

P0102 is set when MAFS output voltage is below lower limit for more than 0.58 sec. This code is due to 1)open in power
circuit 2) open or short to ground in signal circuit.

DTC DETECTING CONDITION EEA07FA8

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● Engine running
Threshold Value ● Abnormal minimum output signal
Diagnostic Time ● 0.58 sec. ● MAFS circuit
Fuel Cut NO ● MAFS component
EGR Off YES
Fail Safe Fuel Limit YES
Check
YES
Lamp

SPECIFICATION EC84A1CC

Refer to DTC P0101.

DIAGNOSTIC CIRCUIT DIAGRAM E102C61F

Refer to DTC P0101.

SIGNAL WAVEFORM AND DATA EA128097

Refer to DTC P0101.

MONITOR SCANTOOL DATA E9E42CE8

Refer to DTC P0101.

TERMINAL AND CONNECTOR INSPECTION E58EF0C2

Refer to DTC P0101.

DTC TROUBLESHOOTING PROCEDURES FLB -187

POWER CIRCUIT INSPECTION ED839F7E

1. Check power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect MAFS connector.

3) IG KEY "ON".

4) Measure the voltage between IG power terminal of MAFS harness connector and chassis ground

5) Measure the voltage between power terminal of MAFS harness connector and chassis ground

Specification : 4.8V~5.1V ( Sensor power )

11.5V~13.0V ( IG Power )

6) Is the measured voltage within the specification?

YES

▶ Go to "Signal Circuit Inspection".

NO

▶ When output voltage is not detected at IG power terminal :

▶ Repair open in ‘ SNSR.2 FUSE (10A)’ in E/R junction box and related circuit and go to "Verification of
Vehicle Repair".
▶ When output voltage is not detected at power terminal :
▶ Repair open between power terminal of MAFS connector and sensor power terminal of ECM connector
(CUD-A), and go to "Verification of Vehicle Repair".

SIGNAL CIRCUIT INSPECTION E496DDB5

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect MAFS connector.

3) IG KEY "ON".

4) Measure the voltage between signal terminal of MAFS connector and chassis ground.

Specification : 4.8~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Go to "2. Check open in signal circuit" as follows.

2. Check open in signal circuit

FLB -188 FUEL SYSTEM

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect MAFS sensor connector and ECM connector.

3) Check continuity between siganl terminal of MAFS harness connector and signal terminal of ECM harness con-
nector.

Specification : Continuity ( below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "3. Check short to ground in signal circuit" as follows.

NO

▶ Repair open in signal circuit and go to "Verification of Vehicle Repair".

3. Check short to ground in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect MAFS sensor connector and ECM connector.

3) Check continuity between siganl terminal of MAFS harness connector and chassis ground.

Specification : Discontinuity(Infinite Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Repair short to ground in signal circuit and go to "Verification of Vehicle Repair".

GROUND CIRCUIT INSPECTION EE4143DD

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect MAFS connector.

3. IG KEY "ON".

4. Measure the voltage between power terminal of MAFS harness connector. [ TEST "A" ]

5. Measure the voltage between power terminal of MAFS harness connector and ground terminal of MAFS harness
connector. [ TEST "B" ]
( MAFS power terminal : Check + prove , MAFS ground terminal : Check - prove )

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6. Is the measured voltage within the specification?

DTC TROUBLESHOOTING PROCEDURES FLB -189

YES

▶ Go to "Component Inspection".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E5818477

1. IG KEY "OFF", ENGINE "OFF".

2. Check that MAFS is installed in correctly according to the direction of arrow on MAFS assy’ .

3. Check contamination of air cleaner filter.

4. IG KEY "ON", ENGINE "ON".

5. Let IDLE RPM last after warming engine up.

6. Check the leakage of intake system(the leakage or damage of intercooler).

7. Check that VGT operates correctly.(Check if vacuum operating state of VGT Control solenoid valve is appropriate, if
VGT diaphragm and unison ring are stuck.)

8. Check that Electric EGR control valve does not operate.

( Electric EGR control valve turns "OFF" and 6% duty is outputted 1 min after rapid acceleration. Disconnect EElectric
EGR control valve connector if needed. )

9. Monitor signal voltage of MAFS when engine speed lasts at approx. 800RPM using Scantool.

10. Check MAFS output signal at idle after rapid acceleration.(Electric EGR control valve duty 50%)

Specification : When Electric EGR control valve does not operate (6%) at idle : 340mg/st ± 50 mg/st
EEGR When EElectric EGR control valve operates(50%) at idle : 200ms/st ± 50 mg/st

11. Is output signal within the specification?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace MAFS assy’ and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR EB29BC1C

Refer to DTC P0101.

FLB -190 FUEL SYSTEM

DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT

COMPONENT LOCATION E61800F8

Refer to DTC P0101.

GENERAL DESCRIPTION E1DF47E3

Refer to DTC P0101.

DTC DESCRIPTION EECA0C3B

P0103 is set when MAFS output voltage above 1200Hz is detected for more than 0.58 sec. This code is due to excessive
output voltage from sensor component or poor connection in sensor circuit.

DTC DETECTING CONDITION E3D3D46E

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● Engine running
Threshold Value ● Abnormal maximum output signal
Diagnostic Time ● 0.58 sec. ● MAFS circuit
Fuel Cut NO ● MAFS component
EGR Off YES
Fail Safe Fuel Limit YES
Check
YES
Lamp

SPECIFICATION EB1A5657

Refer to DTC P0101.

DIAGNOSTIC CIRCUIT DIAGRAM EC58A985

Refer to DTC P0101.

SIGNAL WAVEFORM AND DATA E1A50DA9

Refer to DTC P0101.

MONITOR SCANTOOL DATA ECF5D979

Refer to DTC P0101.

TERMINAL AND CONNECTOR INSPECTION E0036C53

Refer to DTC P0101.

DTC TROUBLESHOOTING PROCEDURES FLB -191

POWER CIRCUIT INSPECTION E91E0F06

1. Check power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect MAFS connector.

3) IG KEY "ON".

4) Measure the voltage between IG power terminal of MAFS harness connector and chassis ground

5) Measure the voltage between power terminal of MAFS harness connector and chassis ground

Specification : 4.8V~5.1V ( Sensor power )

11.5V~13.0V ( IG Power )

6) Is the measured voltage within the specification?

YES

▶ Go to "Signal Circuit Inspection".

NO

▶ When output voltage is not detected at IG power terminal :

▶ Repair open in ‘ SNSR.2 FUSE (10A)’ in E/R junction box and related circuit and go to "Verification of
Vehicle Repair".
▶ When output voltage is not detected at power terminal :
▶ Repair open between power terminal of MAFS connector and sensor power terminal of ECM connector
(CUD-A), and go to "Verification of Vehicle Repair".

SIGNAL CIRCUIT INSPECTION EEDBC71D

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect MAFS connector.

3) IG KEY "ON".

4) Measure the voltage between signal terminal of MAFS connector and chassis ground.

Specification : 4.8~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Go to "2. Check open in signal circuit" as follows.

2. Check open in signal circuit

FLB -192 FUEL SYSTEM

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect MAFS sensor connector and ECM connector.

3) Check continuity between siganl terminal of MAFS harness connector and signal terminal of ECM harness con-
nector.

Specification : Continuity ( below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "3. Check short to ground in signal circuit" as follows.

NO

▶ Repair open in signal circuit and go to "Verification of Vehicle Repair".

3. Check short to ground in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect MAFS sensor connector and ECM connector.

3) Check continuity between siganl terminal of MAFS harness connector and chassis ground.

Specification : Discontinuity(Infinite Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Repair short to ground in signal circuit and go to "Verification of Vehicle Repair".

GROUND CIRCUIT INSPECTION EF3C69EA

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect MAFS connector.

3. IG KEY "ON".

4. Measure the voltage between power terminal of MAFS harness connector. [ TEST "A" ]

5. Measure the voltage between power terminal of MAFS harness connector and ground terminal of MAFS harness
connector. [ TEST "B" ]
( MAFS power terminal : Check + prove , MAFS ground terminal : Check - prove )

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6. Is the measured voltage within the specification?

DTC TROUBLESHOOTING PROCEDURES FLB -193

YES

▶ Go to "Component Inspection".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION EE2191ED

1. IG KEY "OFF", ENGINE "OFF".

2. Check that MAFS is installed in correctly according to the direction of arrow on MAFS assy’ .

3. Check contamination of air cleaner filter.

4. IG KEY "ON", ENGINE "ON".

5. Let IDLE RPM last after warming engine up.

6. Check the leakage of intake system(the leakage or damage of intercooler).

7. Check that VGT operates correctly.(Check if vacuum operating state of VGT Control solenoid valve is appropriate, if
VGT diaphragm and unison ring are stuck.)

8. Check that Electric EGR control valve does not operate.

( Electric EGR control valve turns "OFF" and 6% duty is outputted 1 min after rapid acceleration. Disconnect EElectric
EGR control valve connector if needed. )

9. Monitor signal voltage of MAFS when engine speed lasts at approx. 800RPM using Scantool.

10. Check MAFS output signal at idle after rapid acceleration.(Electric EGR control valve duty 50%)

Specification : When Electric EGR control valve does not operate (6%) at idle : 340mg/st ± 50 mg/st
EEGR When EElectric EGR control valve operates(50%) at idle : 200ms/st ± 50 mg/st

11. Is output signal within the specification?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace MAFS assy’ and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR ED3450C8

Refer to DTC P0101.

FLB -194 FUEL SYSTEM

DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE

CIRCUIT LOW INPUT

COMPONENT LOCATION E513A65E

ECM

SFDF28307L

GENERAL DESCRIPTION E9BBC057

Atmospheric sensor is installed in ECM and senses atmospheric pressure where the vehicle is.
Based on singal of atmospheric sensor, air density is calculated. And atmospheric sensor is used to detect mass air flow
with MAFS, IATS.
This sensor is required to perform 1) fuel injection quantity correction in high altitude and 2) EGR control.
Atmospheric pressure is fixed at 900hpa when atmospheric sensor fails.

DTC DESCRIPTION EE7CE80F

P0107 is set when the voltage below 250mV - minimum output voltage of Atmospheric pressure sensor - is detected for
more than 5 sec. This code is due to fhe failure of the sensor inside of ECM.

DTC DETECTING CONDITION E64A8F5A

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● When output voltage is below the minimum

value.(below 250mV )
Diagnostic Time ● 5.0 sec. ● Atmospheric pressure sensor(ECM
component)
Fuel Cut NOF
EGR Off YES
Fail Safe ● Atmospheric pressure
Fuel Limit YES is fixed at 1000hpa.
Check
NO
Lamp
DTC TROUBLESHOOTING PROCEDURES FLB -195

SPECIFICATION EC1FEF98

1ATM IS SAME AS

hpa (hecto pascal) mb mmHg

1013 1013 760

MONITOR SCANTOOL DATA E163D945

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Monitor "ATMOSPHERIC PRESS. SNSR " parameter on the scantool.

Specification : Approx. 1 atm is displayed

Fig.1
SFDF27509L

Fig.1) The atmospheric pressure where the vehicle is displayed. Atmospheric pressure decreases as vehicle going
up to higher altitude. The pressure at average level of sea surface is regarded as 1atm and, check if the pressure
different from 1 atm is displayed. ( 1 atm is correct pressure)

COMPONENT INSPECTION E2CB5C2A

1. ECM Component Inspection

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECM.

3) Replace ECM, check if abnormal operations disappear.

4) If problems are corrected, replace ECM.

NOTE
Input injector IQA data(7 letters) using scantool at replacing ECM.
Enter the driving distance - how many km the CPF is used- into New ECM with scanner.
FLB -196 FUEL SYSTEM

For immobilizer applied vehicle, input pin code.

VERIFICATION OF VEHICLE REPAIR EC8893B0

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

DTC TROUBLESHOOTING PROCEDURES FLB -197

DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE

CIRCUIT HIGH INPUT

COMPONENT LOCATION E09FCBC3

Refer to DTC P0107.

GENERAL DESCRIPTION E84373AE

Refer to DTC P0107.

DTC DESCRIPTION EE20FDAC

P0108 is set when the voltage above 4.85V - maximum output voltage of Barometric pressure sensor - is detected for
more than 5sec.. This code is due to fhe failure of the sensor inside of ECM.

DTC DETECTING CONDITION ED8A080F

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● When output voltage is above the maximum

value. (above 4.85V)
Diagnostic Time ● 5.0 sec. ● Atmospheric pressure sensor
(ECM component)
Fuel Cut NO
EGR Off YES
Fail Safe ● Barometric pressure is
Fuel Limit YES fixed at 1000hpa.
Check
NO
Lamp

SPECIFICATION EF824DF9

Refer to DTC P0107.

MONITOR SCANTOOL DATA E573B53C

Refer to DTC P0107.

COMPONENT INSPECTION E89D5427

1. ECM Component Inspection

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECM.

3) Replace ECM, check if abnormal operations disappear.

4) If problems are corrected, replace ECM.

FLB -198 FUEL SYSTEM

NOTE
Input injector IQA data(7 letters) using scantool at replacing ECM.
Enter the driving distance - how many km the CPF is used- into New ECM with scanner.
For immobilizer applied vehicle, input pin code.

VERIFICATION OF VEHICLE REPAIR E38D00EB

Refer to DTC P0107.

DTC TROUBLESHOOTING PROCEDURES FLB -199

DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW INPUT

COMPONENT LOCATION EE15D0B7

MAFS & IATS #1

SFDF28308L

GENERAL DESCRIPTION E400341A

Intake Air Temperature Sensor(IATS) is NTC thermistor. Installed inside of both MAFS and BPS, it senses intake air
temperature.
In case of EURO-4 diesel engine, IATS is installed in front of turbocharger(inside of MAFS) and behind it(inside of BPS).
Comparing air temperature from both sensors(one is intake air temperature, the other is air temperature passing through
turbo charger), more accurate sensing of intake air temperature is possible.
With intake air temperature signal, ECM performs EGR control correction and fuel injection quantity correction.(MAFS is
needed for EGR FEED BACK control in electronically controlled diesel engine. The calculation of air density at certain
temperture is required to perform EGR FEED BACK control correctly.)

DTC DESCRIPTION E482F7FC

P0112 is set when the voltage below 73mV - minimum output voltage of IATS(inside of AFS) - is detected for more than
1.0 sec. This code is due to short to ground in IATS signal circuit.

DTC DETECTING CONDITION E97BC02B

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● When output signal is below the minimum

value ( below 73mV )
Diagnostic Time ● 1.0 sec. ● IATS circuit
● IATS component
Fuel Cut NO
EGR Off NO
Fail Safe ● Intake air temperature
Fuel Limit NO is regarded as 50 C
Check
NO
Lamp
FLB -200 FUEL SYSTEM

SPECIFICATION E255AE8F

Temp. - 40 C - 20 C 0C 20 C
Resistance 35.14~43.76KΩ 12.66~15.12KΩ 5.12~5.89KΩ 2.29~2.55KΩ
Temp. 40 C 60 C 80 C
Resistance 1.10~1.24KΩ 0.57~0.65KΩ 0.31~0.37KΩ

DIAGNOSTIC CIRCUIT DIAGRAM E9C027D2

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.

Main Relay
"ON" Input

E/R JUNCTION BOX

<AIR FLOW SENSOR>

Reference Freqency
5 4 3 2 1
AFS Signal
1. Power from IG SW
Temperature Output
2. Ground
3. Temperature Output Ground
4. Reference Frequency
5. AFS Signal AIR FLOW SENSOR

<ECM>

<ECM> 60 59 58
* * * 53 37* * 50 4934 33* 47 3146
56
44 43 42 41 40
* ** * * *
94 93 92 90 89
* * 87 86 * 84 83 * 81 80 79 * 77 * 75 * * 6 5
30
* 28 27 26 23
** ** 20 19
* 17 16
72 71 70 69 68
* * 65 64 * * * * * * 57 56 * 54 * * 51 4 3 * * 13 12 * * * 8 7 6 * 4 * 2 1
* 27* 48 47
28 25
46 45 44
22 *
42
* 40 * 1638 1537 1436 35
19
34 33 32 31 30 29
13 12 11 10 9 8 7
2 1
* ** ** ** 37. Reference Frequency
42. AFS Signal
89. Temperature Output 44. Ground

SFDF27596L
DTC TROUBLESHOOTING PROCEDURES FLB -201

SIGNAL WAVEFORM AND DATA E15976E9

Fig.1
SFDF27510L

Fig.1) IATS output signal at 25 C.The higher temperature rises, the lower signal voltage becomes.

TERMINAL AND CONNECTOR INSPECTION E6FDE7A9

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Signal Circuit Inspection ".

SIGNAL CIRCUIT INSPECTION ED8FB5B5

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect AFS connector

3) IG KEY "ON".
FLB -202 FUEL SYSTEM

4) Measure the voltage between signal terminal of MAFS harness connector and chassis ground.

Secification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection"

NO

▶ Go to "2.Check short to ground in signal circuit" as follows.

2. Check short to ground in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect MAFS connector and ECM connector

3) Check continuity between signal terminal of MAFS harness connector and chassis ground.

Specification : Discontinuity ( Infinite Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ Repair short to ground in signal circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E1EB648D

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect MAFS connector.

3. Measure resistance between signal terminal and ground terminal of MAFS component.

Specification : Refer to Specification of General Information.

4. Is the measured resistance at certain temperature within the specified resisance range at the temperature?

YES

▶ Go to "Verification of Vehicle Rapair"

NO

▶ Replace MAFS ASSY’ and go to "Verification of Vehicle Repair".

DTC TROUBLESHOOTING PROCEDURES FLB -203

VERIFICATION OF VEHICLE REPAIR EE3B1BDD

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -204 FUEL SYSTEM

DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH INPUT

COMPONENT LOCATION E354D8FB

Refer to DTC P0112.

GENERAL DESCRIPTION E5E83449

Refer to DTC P0112.

DTC DESCRIPTION EAAA9418

P0113 is set when the voltage above 4886mV - maximum output voltage of IATS - is detected for more than 1.0 sec. This
code is due to 1) open or 2) short to ground or 3) short to battery in IATS signal circuit.

DTC DETECTING CONDITION ED0BF420

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● When output signal is above the maximum

value ( above 4.886mV )
Diagnostic Time ● 1 sec. ● IATS circuit
● IATS component
Fuel Cut NO
EGR Off NO
Fail Safe ● Intake air temperature
Fuel Limit NO is regarded as 50 C
Check
NO
Lamp

SPECIFICATION EF9AD2D1

Refer to DTC P0112.

DIAGNOSTIC CIRCUIT DIAGRAM E1A8667B

Refer to DTC P0112.

SIGNAL WAVEFORM AND DATA E61CB3F0

Refer to DTC P0112.

TERMINAL AND CONNECTOR INSPECTION EEFD2A30

Refer to DTC P0112.

SIGNAL CIRCUIT INSPECTION E238513A

1. Check signal circuit voltage

DTC TROUBLESHOOTING PROCEDURES FLB -205

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect MAFS connector

3) IG KEY "ON".

4) Measure the voltage between signal terminal of MAFS harness connector and chassis ground.

Secification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection"

NO

▶ Go to "2.Check open in signal circuit" as follows.

2. Check open in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect MAFS connector and ECM connector.

3) Check continuity between signal terminal of MAFS harness connector and ECM harness connector.

Specification : Continuity (below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "3.Check short to battery in signal circuit " as follows

NO

▶ Repair open spots in signal circuit and go to "Verification of Vehicle Repair".

3. Check short to battery in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect MAFS connector and ECM connector

3) IG KEY "ON"

4) Measure the voltage between signal terminal of MAFS harness connector and chassis ground.

Specification : 0.0V~0.1V

5) Is abnormal voltage detected in the circuit with both connector disconnected?

YES

▶ Repair short to battery and go to "Verification of Vehicle Repair".

FLB -206 FUEL SYSTEM

NO

▶ Go to "Ground Circuit Inspection".

GROUND CIRCUIT INSPECTION E292406A

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect MAFS connector and ECM connector

3. IG KEY "ON"

4. Measure the voltage between signal terminal of MAFS harness connector and chassis ground. [ TEST "A" ]

5. Measure the voltage between signal terminal and groud terminal of MAFS harness connector. [ TEST "B" ]
( Signal terminal : Check + prove , Ground terminal 2 : Check - prove )

Specification : the voltage difference between TEST "A" and TEST "B" is within 200mV

6. Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection"

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E6B079F1

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect MAFS connector.

3. Measure resistance between signal terminal and ground terminal of MAFS component.

Specification : Refer to Specification of General Information.

4. Is the measured resistance at certain temperature within the specified resisance range at the temperature?

YES

▶ Go to "Verification of Vehicle Rapair"

NO

▶ Replace MAFS ASSY’ and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E58C8A29

Refer to DTC P0112.

DTC TROUBLESHOOTING PROCEDURES FLB -207

DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW INPUT

COMPONENT LOCATION E8FA8E14

ECTS

SFDF28312L

GENERAL DESCRIPTION EB5590F5

Engine Coolant Temperature Sensor(ECTS), installed in coolant line, senses engine coolant temperature.
With the information about engine coolant temperature, ECM performs fuel injection quantity correction, cooling fan control
and glow relay operating duration control.
Especially, because ECTS signal is main variable of fuel injection quantity correction when engine is cold, sensor trouble
makes starting engine difficult when engine is cold.
If engine is running when ECTS is out of order, ECM regards engine coolant temperature as 80 C. And during cranking,
ECM considers engine coolant temperature as -10 C. Besides, cooling fan, which is controlled based on ECTS signal,
operates at HIGH-MODE to prevent engine overheat and supplementary heater is deactivated.

DTC DESCRIPTION E270BB5F

P0117 is set when the voltage below 83mV - minimum output voltage of ECTS - is detected for more than 2.0 sec. This
code is due to short to ground in signal circuit.

DTC DETECTING CONDITION E5E79833

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● Output signal below the minimum value.(

below 83mV )
Diagnostic Time ● 2.0 sec. ● ECTS circuit
● ECTS component
Fuel Cut NO
EGR Off YES ● during engine operation :
Fail Safe temperature is fixed at 80 C
Fuel Limit NO at cranking : temperature
Check is fixed at -10 C
NO
Lamp
FLB -208 FUEL SYSTEM

SPECIFICATION EA2424DF

Temperature - 40 C - 20 C 0C 20 C 40 C
Resistance 48.14kΩ 15.48±1.35kΩ 5.790kΩ 2.45±0.14kΩ 1.148kΩ
Temperature 60 C 80 C 100 C 110 C 120 C
Resistance 0.586kΩ 0.322kΩ 0.188kΩ 0.147±0.002kΩ 0.116kΩ

DIAGNOSTIC CIRCUIT DIAGRAM EAD75676

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.
Main Relay
"ON" Input

E/R JUNCTION BOX

<ECTS & SENDER>

Instrument
Cluster

3 2 1
SENDER
Signal
1. Signal
2. Instrument Cluster
3. Ground
Ground

ECTS & SENDER

<ECM>

60 59 58
* * * 53 37* * 50 4934 33* 47 3146
56
44 43 42 41 40
* ** * * *
30 28 27 26 23 20 19 17 16
* ** ** *
* * 13 12 * * * 8 7 6 * 4 * 2 1
41. Ground
58. Signal

SFDF27597L
DTC TROUBLESHOOTING PROCEDURES FLB -209

SIGNAL WAVEFORM AND DATA E724F2BE

Fig.1
SFDF27511L

Fig.1) ECTS output signal at 80 C.The higher temperature rises, the lower signal voltage becomes.

MONITOR SCANTOOL DATA EDD7F4ED

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Monitor "ECTS" parameter on the Scantool.

Specification : Current enigne coolant temperature is displayed.

Fig.1
SFDF27512L

Fig.1) Check if 1) incorrect value is displayed 2) coolant temperature is fixed at 80 C suddenly during driving 3)coolant
temperature is fixed at -10 C when turning IG KEY "ON". That coolant temperature is fixed at -10 C or 80 C means
failure of ECTS.
To prevent overheat of engine due to ECTS , if ECTS fails, cooling fan operates continuously.
FLB -210 FUEL SYSTEM

TERMINAL AND CONNECTOR INSPECTION EC6BBDEA

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Signal Circuit Inspection ".

SIGNAL CIRCUIT INSPECTION EBE2B3DE

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECTS connector.

3) IG KEY "ON".

4) Measure the voltage between signal terminal of ECTS harness connector and chassis ground.

Secification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ Go to "2.Check short to ground in signal circuit" as follows.

2. Check short to ground in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECTS connector and ECM connector.

3) Check continuity between signal terminal of ECTS harness connector and chassis ground.
DTC TROUBLESHOOTING PROCEDURES FLB -211

Specification : Discontinuity ( Infinite Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ Repair short to ground in signal circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION EB9E0077

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect ECTS connector.

3. Measure resistance between signal terminal and ground terminal of ECTS.

Specification : Refer to Specification of General Information

4. Is the measured resistance at certain temperature within the specified resisance range at the temperature?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace ECTS and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E60F5CEE

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -212 FUEL SYSTEM

DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH INPUT

COMPONENT LOCATION E074C22B

Refer to DTC P0117.

GENERAL DESCRIPTION E43816E2

Refer to DTC P0117.

DTC DESCRIPTION E979D946

P0118 is set when the voltage above 4965mV - maximum output voltage of ECTS - is detected for more than 2.0 sec.
This code is due to open or short to battery in signal circuit or open in ground circuit.

DTC DETECTING CONDITION EC052964

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● Output signal above the maximum value(

above 4965mV )
Diagnostic Time ● 2.0 sec. ● ECTS circuit
● ECTS component
Fuel Cut NO
EGR Off YES ● during engine operation :
Fail Safe temperature is fixed at 80 C
Fuel Limit NO at cranking : temperature
Check is fixed at -10 C
NO
Lamp

SPECIFICATION E62861A8

Refer to DTC P0117.

DIAGNOSTIC CIRCUIT DIAGRAM EB229600

Refer to DTC P0117.

SIGNAL WAVEFORM AND DATA E4ACDC84

Refer to DTC P0117.

MONITOR SCANTOOL DATA E0ECB337

Refer to DTC P0117.

TERMINAL AND CONNECTOR INSPECTION E888A590

Refer to DTC P0117.

DTC TROUBLESHOOTING PROCEDURES FLB -213

SIGNAL CIRCUIT INSPECTION EBFAB02F

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECTS connector.

3) IG KEY "ON".

4) Measure the voltage between signal terminal of ECTS harness connector and chassis ground.

Secification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ Go to "2.Check open in signal circuit" as follows.

2. Check open in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECTS connector and ECM connector.

3) Check continuity between signal terminal of ECTS harness connector and ECM harness connector.

Specification : Continuity ( below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "3.Check short to battery in signal circuit" as follows.

NO

▶ Repair open in signal circuit and go to "Verification of Vehicle Repair".

3. Check short to battery in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECTS connector and ECM connector.

3) IG KEY "ON".

4) Measure the voltage between signal terminal of ECTS harness connector and chassis ground.

Specification : 0.0V~0.1V

5) Is the measured voltage within the specification?

FLB -214 FUEL SYSTEM

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Repair short to battery in signal circuit and go to "Verification of Vehicle Repair".

GROUND CIRCUIT INSPECTION EAB619C1

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect ECTS connector.

3. IG KEY "ON".

4. Measure the voltage between signal terminal of ECTS harness connector and chassis ground. [ TEST "A" ]

5. Measure the voltage between signal terminal and ground terminal of ECTS harness connector. [ TEST "B" ]
( Signal terminal : Check + prove , Ground trminal : Check - prove )

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6. Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION ED8B1805

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect ECTS connector.

3. Measure resistance between signal terminal and ground terminal of ECTS.

Specification : Refer to Specification of General Information

4. Is the measured resistance at certain temperature within the specified resisance range at the temperature?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace ECTS and go to "Verification of Vehicle Repair".

DTC TROUBLESHOOTING PROCEDURES FLB -215

VERIFICATION OF VEHICLE REPAIR E8D1BCB4

Refer to DTC P0117.

FLB -216 FUEL SYSTEM

DTC P0182 FUEL TEMPERATURE SENSOR "A" CIRCUIT LOW INPUT

COMPONENT LOCATION EED09427

FTS

Fuel Pressure Regulator Valve

SFDF28315L

GENERAL DESCRIPTION EE389154

Fuel Temperature Sensor is NTC thermistor installed in fuel supplying line. It senses the temperature of fuel supplied to
high pressure pump.
Fuel temperature is limited (engine power is limited) to keep fuel temperature from reaching at 120 C.
This limit is to protect fuel line such as high pressure pump and injectors from damages due to rapid deterioration by
vapor-lock phenomenon which can occur at high temperature or destruction of oil membrane.

DTC DESCRIPTION EABC5828

P0182 is set when the voltage below 53mV(0.053V) - minimum voltage of FTS output - is detected for more than 2.0 sec..
This code is due to short to ground in FTS signal circuit.

DTC DETECTING CONDITION E87BEF88

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● When output signal is below the minimum

value.(below 53mV)
Diagnostic Time ● 2.0 sec. ● FTS circuit
● FTS component
Fuel Cut NO
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp
DTC TROUBLESHOOTING PROCEDURES FLB -217

SPECIFICATION E7570AC0

Temperature - 30 C - 20 C -10 C 0C 20 C
Resistance 22.22~31.78kΩ 13.24~18.10kΩ 8.16~10.74kΩ 5.18~6.60kΩ 2.27~2.73kΩ
Temperature 40 C 50 C 60 C 70 C
Resistance 1.059~1.281kΩ 0.748~0.904kΩ 0.538~0.650kΩ 0.392~0.476kΩ

DIAGNOSTIC CIRCUIT DIAGRAM ED29000A

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.
Main Relay
"ON" Input

E/R JUNCTION BOX

<Fuel Temperature Sensor>

Signal

2 1
Ground

1. Ground Fuel Temperature Sensor

2. Signal

<ECM>

94 93 92 90 89
*
72 71 70 69 68 * 87 86 * 84 83 * 81 80 79 * 77 * 75 * * 6 5
* * 65 64 * * * * * * 57 56 * 54 * * 51 4 3

* 27* 48 47
28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1
* 25 * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7
10. Ground
11. Signal

SFDF27598L
FLB -218 FUEL SYSTEM

SIGNAL WAVEFORM AND DATA E5AF64D7

Fig.1
SFDF27513L

Fig.1) FTS output signal at 50 C.The higher temperature rises, the lower signal voltage becomes.

MONITOR SCANTOOL DATA E04899FC

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Monitor "FUEL TEMPERATURE " parameter on the scantool.

Specification : Fuel temperature is displayed

Fig.1
SFDF27514L

Fig.1) Check if too high or low temperature is displayed.(too high or low temperature is abnormal value.)
DTC TROUBLESHOOTING PROCEDURES FLB -219

TERMINAL AND CONNECTOR INSPECTION ECB493A8

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Signal Circuit Inspection "

SIGNAL CIRCUIT INSPECTION EB1145EA

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect FTS connector.

3) IG KEY "ON".

4) Measure the voltage between signal terminal of FTS harness connector and chassis ground.

Secification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection"

NO

▶ Go to "2.Check short to ground in signal circuit" as follows.

2. Check short to ground in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect FTS connector and ECM connector.

3) Check continuity between signal terminal of FTS harenss connector and chassis ground.
FLB -220 FUEL SYSTEM

Specification : Discontinuity ( Infinite Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ Repair short to ground in signal circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION EB08A14E

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect FTS connector.

3. Measure resistance of signal terminal and ground terminal of FTS connector. (component side)

Specification : Refer to Specification of General Information.

4. Is the measured resistance at certain temperature within the specified resisance range at the temperature?

YES

▶ Go to "Verification of Vehicle Rapair".

NO

▶ Replace FTS and go to "Verification of Vehicle Rapair".

VERIFICATION OF VEHICLE REPAIR E2302979

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

DTC TROUBLESHOOTING PROCEDURES FLB -221

DTC P0183 FUEL TEMPERATURE SENSOR "A" CIRCUIT HIGH INPUT

COMPONENT LOCATION EE43FA0C

Refer to DTC P0182.

GENERAL DESCRIPTION E7F79F55

Refer to DTC P0182.

DTC DESCRIPTION EA03A86F

P0183 is set when the voltage above 4912mV - maximum voltage of FTS output - is detected for more than 2.0 sec.. This
code is due to 1)open or short to battery in FTS signal circuit or 2)open in ground circuit.

DTC DETECTING CONDITION E8E96BF4

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● When output signal is below the minimum

value.(below 53mV)
Diagnostic Time ● 2.0 sec. ● FTS circuit
● FTS component
Fuel Cut NO
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp

SPECIFICATION E828CCB5

Refer to DTC P0182.

DIAGNOSTIC CIRCUIT DIAGRAM E20A8C9F

Refer to DTC P0182.

SIGNAL WAVEFORM AND DATA EA7F71EB

Refer to DTC P0182.

MONITOR SCANTOOL DATA E5B02438

Refer to DTC P0182.

TERMINAL AND CONNECTOR INSPECTION EC47CA72

Refer to DTC P0182.

FLB -222 FUEL SYSTEM

SIGNAL CIRCUIT INSPECTION E99EFBFD

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect FTS connector.

3) IG KEY "ON".

4) Measure the voltage between signal terminal of FTS harness connector and chassis ground.

Secification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Go to "2.Check open in signal circuit" as follows.

2. Check open in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect FTS connector and ECM connector.

3) Check continuity between signal terminal of FTS harness connector and ECM harness connector.

Specification : Continuity (below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "3. Check short to battery in signal circuit" as follows.

NO

▶ Repair open in signal circuit and go to "Verification of Vehicle Repair".

3. Check short to battery in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect FTS connector and ECM connector

3) IG KEY "ON"

4) Measure the voltage between signal terminalof FTS harness connector and chassis ground.

Specification : 0.0V~0.1V

5) Is abnormal voltage detected in the circuit with both connector is disconnected?

DTC TROUBLESHOOTING PROCEDURES FLB -223

YES

▶ Repair short to battery and go to "Verification of Vehicle Repair".

NO

▶ Go to "Ground Circuit Inspection".

GROUND CIRCUIT INSPECTION E99B574E

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect FTS connector and ECM connector

3. IG KEY "ON"

4. Measure the voltage between signal terminal of FTS harness connector and chassis ground.[ TEST "A" ]

5. Measure the voltage between signal terminal and ground terminal of FTS harness connector. [ TEST "B" ]
( Signal terminal : Check + prove , Ground terminal : Check - prove )

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6. Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E5F21329

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect FTS connector.

3. Measure resistance of signal terminal and ground terminal of FTS connector. (component side)

Specification : Refer to Specification of General Information.

4. Is the measured resistance at certain temperature within the specified resisance range at the temperature?

YES

▶ Go to "Verification of Vehicle Rapair".

NO

▶ Replace FTS and go to "Verification of Vehicle Rapair".

FLB -224 FUEL SYSTEM

VERIFICATION OF VEHICLE REPAIR E0CFAC9C

Refer to DTC P0182.

DTC TROUBLESHOOTING PROCEDURES FLB -225

DTC P0192 FUEL RAIL PRESSURE SENSOR "A" CIRCUIT LOW

COMPONENT LOCATION E204558A

Injector

RPS

Rail Pressure
Regulator Valve

SFDF28313L

GENERAL DESCRIPTION EF7EE5DA

RPS(Rail Pressure Sensor), consists of piezzo electric element, measures rail pressure inside of common rail.
ECM determines optimum fuel injection quantity at specific engine condition based on RPS signal. RPS signal is also
used as rail pressure regualtor feed back signal in order to achieve optimum rail pressure at certain engine condition.

DTC DESCRIPTION E1DFC116

P0192 is set when RPS output voltage is below the minimum value of 254mV for more than 0.2 sec.. This code is due to
the open in power circuit or the short to ground in signal circuit.

DTC DETECTING CONDITION E6381A05

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● Engine running
Threshold Value ● Output sinal below minimum value (below 254mV)
Diagnostic Time ● 200ms ● RPS circuit
Fuel Cut NO ● RPS component
EGR Off NO
Fail Safe ● Rail press. Sensor value
Fuel Limit YES fixed at 330bar
Check
YES
Lamp
FLB -226 FUEL SYSTEM

SPECIFICATION EB337FEE

4.8V

4.5V

Output
voltage

at idle : 1.3V (260bar)

0.5V

0.2V

0bar Pressure 1800bar

SENFL7238L
DTC TROUBLESHOOTING PROCEDURES FLB -227

DIAGNOSTIC CIRCUIT DIAGRAM E1B530F0

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.

Main Relay
"ON" Input

E/R JUNCTION BOX

<RAIL PRESSURE SENSOR>

Signal

3 2 1 P Power

1. Power Ground
2. Signal
3. Ground RAIL PRESSURE SENSOR

<ECM>

60 59 58 8. Ground
* * * 53 37* * 50 4934 33* 47 3146
56
44 43 42 41 40
* ** * * * 28. Power
30 28 27 26 23 20 19 17 16
* ** ** *
* * 13 12 * * * 8 7 6 * 4 * 2 1 43. Signal

SFDF27599L
FLB -228 FUEL SYSTEM

SIGNAL WAVEFORM AND DATA E1E98681

APS1

RPS

Fig.1
SFDF27517L

Fig.1) APS 1 and RPS signals are measured simultaneously. This waveform shows the rise of RPS output voltage at
rapid acceleration.

MONITOR SCANTOOL DATA EFA2F6FD

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Monitor "FUEL PRESSURE MEASURED", "RAIL PRESS. REGULATOR1", "INJ. PUMP REGULATOR" parameter
on the Scantool.

SPECIFICATION :

Idle(without load) Accelerating(stall test) Diagnosis

INJ. PUMP REGULATOR 38 ± 5% 32 ± 5% Duty decreases
FUEL PRESSURE
28.5 ± 5 Mpa 145 ± 10 Mpa Press. increases
MEASURED
RAIL PRESS.
19 ± 5% 48 ± 5% Duty increases
REGULATOR1
DTC TROUBLESHOOTING PROCEDURES FLB -229

Fig.1 Fig.2
SFDF27524L

Fig.1) The position of curser on the graph represents idle data.

Fig.2) Data during acceleration(stall test).

NOTE
The waveform of Fuel pressure regulator valve installed at high pressure pump(fuel detecting MPROP) shows 38%
duty at idle, Duty drop means the decrease of current.
▶ Fuel delivered to common rail increases as current drops.

The waveform of rail pressure regulator valve installed at common rail shows 19% duty at idle, duty rises to approx.
48% at acceleration to raise rail pressure. Duty rise means the increase of current.
▶ If current rises, the returning quantity of fuel deliverd to common rail decreases and common rail pressure rises.

TERMINAL AND CONNECTOR INSPECTION EF49A27C

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power Circuit Inspection".

FLB -230 FUEL SYSTEM

POWER CIRCUIT INSPECTION E6CCA350

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect RPS connector.

3. IG KEY "ON".

4. Measure the voltage between power terminal of RPS harness connector and chassis ground.

Specification : 4.8V~5.1V

5. Is the measured voltage within the specification?

YES

▶ Go to "Signal Circuit Inspection".

NO

▶ Repair open in RPS power circuit and go to "Verification of Vehicle Repair".

[ Check between power terminal of RPS harness connector and ECM harness connector. ]

SIGNAL CIRCUIT INSPECTION E551A872

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect RPS connector.

3) IG KEY "ON".

4) Measure the voltage between signal terminal of RPS harness connector and chassis ground.

Secification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ Repair short to ground in signal circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E88A31F3

1. Visual Inspection of RPS

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect RPS connector.

3) Check if corrosion and damage in RPS terminal is detected.

4) Check RPS mounting torque and oil leakage.

DTC TROUBLESHOOTING PROCEDURES FLB -231

5) Are the problems relevant to RPS found?

YES

▶ Replace RPS if necessary and go to "Verification of Vehicle Repair".

NO

▶ Go to "RPS waveform Inspection".

2. RPS Waveform Inspection

1) IG KEY "OFF", ENGINE "OFF".

2) Connect RPS connector.

3) Connect an Oscilloscope to signal teminal of RPS connector.

4) After turning engine "ON", Check waveform at idle and during acceleration.

Specification : Refer to "Signal Waveform ＆ Data" of "General Information".

5) Does RPS waveform look similar to standard "Signal Waveform ＆ Data"?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace RPS and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E5054DFB

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -232 FUEL SYSTEM

DTC P0193 FUEL RAIL PRESSURE SENSOR "A" CIRCUIT HIGH

COMPONENT LOCATION E4C166A6

Refer to DTC P0192.

GENERAL DESCRIPTION E3F3358B

Refer to DTC P0192.

DTC DESCRIPTION E198BAFA

P0193 is set when RPS output voltage is above the maximum value of 4830mV(4.8V) for more than 0.2 sec.. This code
is due to the open or short in 1) RPS signal circuit 2) RPS ground circuit.

DTC DETECTING CONDITION EF5FEEA9

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● Engine running

Threshold Value ● Output signal above the maximum

value(above 4750mV)
Diagnostic Time ● 200ms ● RPS circuit
● RPS component
Fuel Cut NO
EGR Off NO
Fail Safe ● Rail press. Sensor value
Fuel Limit YES fixed at 330bar
Check
YES
Lamp

SPECIFICATION E6037A34

Refer to DTC P0192.

DIAGNOSTIC CIRCUIT DIAGRAM EED7BB17

Refer to DTC P0192.

SIGNAL WAVEFORM AND DATA EB1C1447

Refer to DTC P0192.

MONITOR SCANTOOL DATA E9CEBD9F

Refer to DTC P0192.

TERMINAL AND CONNECTOR INSPECTION ED744CE5

Refer to DTC P0192.

DTC TROUBLESHOOTING PROCEDURES FLB -233

POWER CIRCUIT INSPECTION E61CFB5F

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect RPS connector.

3. IG KEY "ON".

4. Measure the voltage between power terminal of RPS harness connector and chassis ground.

Specification : 4.8V~5.1V

5. Is the measured voltage within the specification?

YES

▶ Go to "Signal Circuit Inspection".

NO

▶ Repair open in power circuit and go to "Verification of Vehicle Repair".

[ Check between power terminal of RPS harness connector and ECM harness connector. ]

SIGNAL CIRCUIT INSPECTION E73DF91F

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect RPS connector.

3) IG KEY "ON".

4) Measure the voltage between signal terminal of RPS harness connector and chassis ground.

Secification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Go to "2. Check open in signal circuit" as follows.

2. Check open in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect RPS connector and ECM connector.

3) Check continuity between signal terminal of RPS harness connector and signal terminal of ECM harness con-
nector.

Specification : continuity ( below 1.0Ω )

FLB -234 FUEL SYSTEM

4) Is the measured resistance within the specification?

YES

▶ Go to "3. Check short to battery in signal circuit" as follows.

NO

▶ Repair open in RPS signal circuit and go to "Verification of Vehicle Repair".

[ Check the circuit between signal terminal of RPS harness connector and ECM harness connector. ]

3. Check short to battery in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect RPS connector and ECM connector.

3) IG KEY "ON".

4) Measure the voltage between signal terminal of RPS harness connector and chassis ground.

Specification : 0.0V~0.1V

5) Is abnormal voltage measured in signal circuit(with both connectors disconnected)?

YES

▶ Repair short to battery in signal circuit and go to "Verification of Vehicle Repair".

NO

▶ Go to "Component Inspection".

GROUND CIRCUIT INSPECTION EF6693C1

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect RPS connector.

3. IG KEY "ON".

4. Measure the voltage between signal terminal of RPS harness connector and chassis ground. [ TEST "A" ]

5. Measure the voltage between signal terminal and ground terminal of RPS harness connector. [ TEST "B" ]
( Signal terminal : Check + prove , Ground terminal : Check - prove )

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6. Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
DTC TROUBLESHOOTING PROCEDURES FLB -235

▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION EEA213CF

1. Visual Inspection of RPS

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect RPS connector.

3) Check if corrosion and damage in RPS terminal is detected.

4) Check RPS mounting torque and oil leakage.

5) Are the problems relevant to RPS found?

YES

▶ Replace RPS if necessary and go to "Verification of Vehicle Repair".

NO

▶ Go to "RPS waveform Inspection".

2. RPS Waveform Inspection

1) IG KEY "OFF", ENGINE "OFF".

2) Connect RPS connector.

3) Connect an Oscilloscope to signal teminal of RPS connector.

4) After turning engine "ON", Check waveform at idle and during acceleration.

Specification : Refer to "Signal Waveform ＆ Data" of "General Information".

5) Does RPS waveform look similar to standard "Signal Waveform ＆ Data"?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace RPS and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E7A24BEF

Refer to DTC P0192.

FLB -236 FUEL SYSTEM

DTC P0201 INJECTOR CIRCUIT/OPEN-CYLINDER 1

DTC P0202 INJECTOR CIRCUIT/OPEN-CYLINDER 2
DTC P0203 INJECTOR CIRCUIT/OPEN-CYLINDER 3
DTC P0204 INJECTOR CIRCUIT/OPEN-CYLINDER 4

COMPONENT LOCATION ED470F9D

Injector

RPS

Rail Pressure
Regulator Valve

SFDF28313L

GENERAL DESCRIPTION EB6E8774

Injectors spray fuel in the highly compressed combustion chamber, and power generates through combustion process.
Fuel pressure is raised to 1600bar in common rail diesel engine for the purpose of making fuel into minute particles. And
fuel devided into minute particles leads smoke reduction, high power generation, and improved fuel efficiency. To control
pressure of 1600bar with solenoid, oil pressure surbo is applied. And injector solenoids is actuated by solenoid operating
voltage raised to 80V with the method of current control.
Niddle valve inside of injector is located between A and B chamber. If applied pressure to B chamber is relived by injector
solenoid, niddle valve is raised by the pressure of A chamber then, fuel is injected. If same pressure is applied to A and
B chamber, niddle valve closes by the elasticity then, fuel injection stops.
As electronically controlled injector is applied instead of mechanical injector, pilot and post injection, injeciton duration
and quantity control are achieved. And engine performance is improved by these control.

DTC DESCRIPTION E2C9CDFE

P0201/P0202/P0203/P0204 is set when no current is detected in injector power and control circuit at injector #1/2/3/4
operating condition. This code is due to open in injector circuit or open in injector component coil.
DTC TROUBLESHOOTING PROCEDURES FLB -237

DTC DETECTING CONDITION E1DED7E7

Item Detecting Condition Possible Cause

DTC Strategy ● Current monitoring
Enable Conditions ● IG KEY "ON"
Threshold Value ● Open in injector circuit
Diagnostic Time ● Immediately ● Open in injector circuit
Fuel Cut NO ● Injector component
EGR Off NO
Fail Safe Fuel Limit YES
Check
YES
Lamp

SPECIFICATION E2956C76

Injector Component Injector Operating

Injector Operating Voltage Injector Control Type
Resistance Current
Peak current : 18±1A
0.255Ω ±0.04 (20 C). 80V Hold in current : 12±1A Current control
Recharging current : 7A
FLB -238 FUEL SYSTEM

DIAGNOSTIC CIRCUIT DIAGRAM EA3D1435

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.

Main Relay
"ON" Input

E/R JUNCTION BOX

<Injector>

Low side
2 1

1. Injector Low Side High side

2. Injector High Side
Injector

<W/O IMMO> <With IMMO>

<ECM>
1. Injector #2 Control 1. Injector #3 Control
2. Injector #3 Control 2. Injector #2 Control
60 59 58
* * * 53 37* * 50 4934 33* 47 3146
56
44 43 42 41 40
16. Injector #4 Control 16. Injector #1 Control
* ** * * * 17. Injector #1 Control 17. Injector #4 Control
30 28 27 26 23 20 19 17 16
31. Injector #3 Control 31. Injector #2 Control
* ** ** * 33. Injector #1 Control 33. Injector #4 Control
* * 13 12 * * * 8 7 6 * 4 * 2 1 46. Injector #2 Control 46. Injector #3 Control
47. Injector #4 Control 47. Injector #1 Control

SFDF27600L
DTC TROUBLESHOOTING PROCEDURES FLB -239

SIGNAL WAVEFORM AND DATA E76F1E95

Pilot Injection1 Pilot Injection2 Main injection

Fig.1 Fig.2
SFDF27519L

Injector current waveform

Fig.3 Fig.4
SFDF27520L

Fig.1) Injector operating waveform at Low side, It shows 2 pilot and 1 main injection.
Fig.2) Magnified waveform of main injection at Fig.1)
Fig.3) Injector voltage and current waveforms are measured at the same time using current prove of scope meter.
Fig.4) Magnified waveform of pilot injection at Fig.3)

TERMINAL AND CONNECTOR INSPECTION E9B41DD7

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.
FLB -240 FUEL SYSTEM

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power Circuit Inspection".

POWER CIRCUIT INSPECTION EEC482C0

1. Check open in power circuit(High side)

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect injector connector and ECM connector.

3) Check continuity between high side terminal of injector harness connector and ECM harness connector.

Secification : Continuity (below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "Control Circuit Inspection".

NO

▶ Repair open in injector power circuit and go to "Verification of Vehicle Repair".

CONTROL CIRCUIT INSPECTION E9BEDEC8

1. Check open in control circuit(Low side)

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect injector connector and ECM connector.

3) Check continuity between low side terminal of injector harness connector and low side terminal of ECM harness
connector.

Specification : Continuity (below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "Component Inspection".
DTC TROUBLESHOOTING PROCEDURES FLB -241

NO

▶ Repair open in injector control circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION EFD2CF18

1. Check injector component resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect injector connector.

3) Measure the resistance between high side terminal and low side terminal of injector connector. (component
side).

Specification : 0.255Ω ±0.04 (20 C).

4) Is the measured resistance(of injector solenoid) within the specification?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace injector and go to "Verification of Vehicle Repair".

NOTE
Replacing injectors, peculiar IQA code of each injector should be inputted to ECM Perform this process using "Injector
data input" function on scantool, Refer to P1670, P1671 for more detailed information.

VERIFICATION OF VEHICLE REPAIR E3758355

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -242 FUEL SYSTEM

DTC P0237 TURBOCHARGER/SUPERCHARGER BOOST SENSOR "A"

CIRCUIT LOW

COMPONENT LOCATION E2A234EC

BPS & IATS #2

SFDF28309L

GENERAL DESCRIPTION E5648DD3

Boost Pressure Sensor(BPS) is installed in intake manifold and senses the pressure of air inside of intake manifold which
is compressed by turbo charager.
Measuring mass air flow accurately with the information of intake mainfold pressure, mass air flow and intake air temper-
ature, ECM performs actuating correction of EGR and VGT.
When excessive intake manifold pressure is detected, engine power generation is limited to protect engine because too
highly compressed pressure due to turbo charger may harm engine.

DTC DESCRIPTION E77C31D7

P0237 is set when the voltage below 200mV - mimimum output voltage of BPS - is detected for more than 2.0 sec.. This
code is due to short to ground in signal circuit.

DTC DETECTING CONDITION E55F6F2F

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● Output signal below minimum value(be-

low 200mV)
Diagnostic Time ● 2.0 sec. ● BPS circuit
● BPS component
Fuel Cut NO
EGR Off YES
Fail Safe ● Boost pressure is fixed
Fuel Limit YES at 900 hpa.
Check
NO
Lamp
DTC TROUBLESHOOTING PROCEDURES FLB -243

SPECIFICATION ED68BE75

Pressure [Kpa] 20 100 190 250

Outpur voltage [V] 0.4±0.077 1.878±0.063 3.541±0.063 4.650±0.077

DIAGNOSTIC CIRCUIT DIAGRAM EE8E1B45

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.

Main Relay
"ON" Input

E/R JUNCTION BOX

<BOOST PRESSURE SENSOR>

BPS Signal
4 3 2 1
U P Power
1. BPS Signal
2. Power BPS Temp. Signal
3. BPS Temp. Signal
4. Ground Ground

BOOST PRESSURE SENSOR

<ECM>

60 59 58
* * * 53 37* * 50 4934 33* 47 3146
56
44 43 42 41 40
13. Power
* ** * * * 23. Ground
30 28 27 26 23 20 19 17 16 40. BPS Signal
* ** ** * 53. BPS Temp. Signal
* * 13 12 * * * 8 7 6 * 4 * 2 1

SFDF27594L
FLB -244 FUEL SYSTEM

SIGNAL WAVEFORM AND DATA EC0608F0

BPS signal

Fig.1
SFDF27521L

Fig1). This is the waveform of BPS as accelerating from idle state. Signal voltage rises as accelerating.

MONITOR SCANTOOL DATA E08BEB97

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Monitor "BOOST PRESSURE SENSOR" parameter on the Scantool.

Specification : 1000hpa ± 100hpa(VGT actuator : 75%) at idle

Fig.1 Fig.2
SFDF27522L

Fig1) Monitor "BOOST PRESSURE SENSOR" parameter on the Scantool at idle after warming engine up.
1000hpa ± 100hpa(approx. 1 atm) is correct value.
DTC TROUBLESHOOTING PROCEDURES FLB -245

Fig.2) VGT Control solenoid valve duty decreases and boost pressure increases as accelerating. If boost pressure
rises and reaches certain value, VGT Control solenoid valve duty stops to drop and keeps steady. Releasing accel-
erator pedal at this moment, VGT Control solenoid valve duty drops to 9.8% then if RPM drops to idle range, duty
returns to 75%.

TERMINAL AND CONNECTOR INSPECTION E11129D1

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power Circuit Inspection".

POWER CIRCUIT INSPECTION E5EAE2C0

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect BPS connector.

3. IG KEY "ON".

4. Measure the voltage between power terminal of BPS harness connector and chassis ground.

Specification : 4.8V~5.1V

5. Is the measured voltage within the specification?

YES

▶ Go to "Signal Circuit Inspection".

NO

▶ Repair open in power circuit and go to "Verification of Vehicle Repair".

SIGNAL CIRCUIT INSPECTION ED826CCD

1. Check signal circuit voltage

FLB -246 FUEL SYSTEM

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect BPS connector.

3) IG KEY "ON"

4) Measure the voltage between signal terminal of BPS harness connector and chassis ground.

Specification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ Go to "2. Check short to ground in signal circuit" as follows.

2. Check short to ground in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect BPS connector and ECM connector.

3) Check continuity between signal terminal of BPS harness connector and chassis ground.

Specification : Discontinuity (Infinite Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ Repair short to ground in signal circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION EBB92EED

1. BPS visual inspection

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect BPS connector.

3) Check if corrosion and damage in BPS terminal is detected.

4) Check BPS mounting state, leakage at O′ ring, clogged carbon at pressure detecting hall.

5) Are the problems relevant to BPS found?

YES

▶ Replace BPS if necessary and go to "Verification of Vehicle Repair".

DTC TROUBLESHOOTING PROCEDURES FLB -247

NO

▶ Go to "2. Check VGT Turbo charger and leakage in intake system".

2. Check VGT turbo charger and leakage in intake system

1) IG KEY "OFF", ENGINE "OFF".

2) Check if VGT actuating rod which is connected to diaphragm of VGT turbo charger assy’ is at the bottom
position.

3) IG KEY "ON"., ENGINE "ON".

4) Check if VGT actuating rod is pulled upward Approx. 10mm when engine is about to start.

5) As accelerating and decelerating, Check if VGT actuating rod moves upward and downward.

6) Check if intake air leak is detected at intake hose at acceleration.(Check if intake hose inflates properly.)

7) Are the problems relevant to VGT turbo charger and intake hose found?

YES

▶ VGT actuating rod does not work.

▶ If any problem is not detected after checking connecting condition of VGT Control solenoid valve vacuum
hose and VGT Control solenoid valve operating states(refer to "Component Inspection" of P0048 ), VGT Control
solenoid valve variable controlling part is considered as stuck. Replace VGT turbo charger in this case.
▶ Intake air leak is detected.
▶ Checking intake hose is not damaged and band clamp is fastened well, repair trouble causing parts.
If trouble causing parts are repaired, go to "Verification of Vehicle Repair".

NO

▶ Go to "3. BPS Waveform inspection".

3. BPS Waveform inspection

1) IG KEY "ON", ENGINE "OFF".

2) Connect BPS.

3) Connect Oscilloscope to BPS connector terminal 1.

4) Monitor the waveform at idle and acceleration after ENGINE "ON".

Specification : Refer to "Signal Waveform ＆ Data" of "General Information".

5) Is BPS waveform displayed correctly?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace BPS and go to "Verification of Vehicle Repair".

FLB -248 FUEL SYSTEM

VERIFICATION OF VEHICLE REPAIR E192C11D

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

DTC TROUBLESHOOTING PROCEDURES FLB -249

DTC P0238 TURBOCHARGER/SUPERCHARGER BOOST SENSOR "A"

CIRCUIT HIGH

COMPONENT LOCATION E7B788A7

Refer to DTC P0237.

GENERAL DESCRIPTION E550D745

Refer to DTC P0237.

DTC DESCRIPTION E449DB53

P0238 is set when the voltage above 4900mV - maximum output voltage of BPS - is detected for more than 2.0 sec.. This
code is due to short to battery in BPS signal circuit or open in ground circuit.

DTC DETECTING CONDITION EFFF0C97

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● Output signal above maximum value(above

4900mV)
Diagnostic Time ● 2.0 sec. ● BPS circuit
● BPS component
Fuel Cut NO
EGR Off YES
Fail Safe ● Boost pressure is fixed
Fuel Limit YES at 900 hpa.
Check
NO
Lamp

SPECIFICATION E68CCA9C

Refer to DTC P0237.

DIAGNOSTIC CIRCUIT DIAGRAM E1855A82

Refer to DTC P0237.

SIGNAL WAVEFORM AND DATA E2DB8144

Refer to DTC P0237.

MONITOR SCANTOOL DATA E88D958A

Refer to DTC P0237.

FLB -250 FUEL SYSTEM

TERMINAL AND CONNECTOR INSPECTION E46B8D67

Refer to DTC P0237.

POWER CIRCUIT INSPECTION EB30F241

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect BPS connector.

3. IG KEY "ON".

4. Measure the voltage between power terminal of BPS harness connector and chassis ground.

Specification : 4.8V~5.1V

5. Is the measured voltage within the specification?

YES

▶ Go to "Signal Circuit Inspection".

NO

▶ Sensor power too high : Refer to circuit inspection of P0653

SIGNAL CIRCUIT INSPECTION E4154AA9

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect BPS connector.

3) IG KEY "ON".

4) Measure the voltage between signal terminal of BPS harness connector and chassis ground.

Specification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Repair short to battery in signal circuit and go to "Verification of Vehicle Repair".

GROUND CIRCUIT INSPECTION EE80AAF1

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect BPS connector.

3. IG KEY "ON".
DTC TROUBLESHOOTING PROCEDURES FLB -251

4. Measure the voltage between power terminal of BPS harness connector and chassis ground. [ TEST "A" ]

5. Measure the voltage between power terminal and ground terminal of BPS harness connector. [ TEST "B" ]
( Power terminal : Check + prove , Ground terminal : Check - prove )

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6. Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E2A288D4

1. BPS visual inspection

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect BPS connector.

3) Check if corrosion and damage in BPS terminal is detected.

4) Check BPS mounting state, leakage at O′ ring, clogged carbon at pressure detecting hall.

5) Are the problems relevant to BPS found?

YES

▶ Replace BPS if necessary and go to "Verification of Vehicle Repair".

NO

▶ Go to "2. Check VGT Turbo charger and leakage in intake system".

2. Check VGT turbo charger and leakage in intake system

1) IG KEY "OFF", ENGINE "OFF".

2) Check if VGT actuating rod which is connected to diaphragm of VGT turbo charger assy’ is at the bottom
position.

3) IG KEY "ON"., ENGINE "ON".

4) Check if VGT actuating rod is pulled upward Approx. 10mm when engine is about to start.

5) As accelerating and decelerating, Check if VGT actuating rod moves upward and downward.

6) Check if intake air leak is detected at intake hose at acceleration.(Check if intake hose inflates properly.)

7) Are the problems relevant to VGT turbo charger and intake hose found?

YES
FLB -252 FUEL SYSTEM

▶ VGT actuating rod does not work.

▶ If any problem is not detected after checking connecting condition of VGT Control solenoid valve vacuum
hose and VGT Control solenoid valve operating states(refer to "Component Inspection" of P0048 ), VGT Control
solenoid valve variable controlling part is considered as stuck. Replace VGT turbo charger in this case.
▶ Intake air leak is detected.
▶ Checking intake hose is not damaged and band clamp is fastened well, repair trouble causing parts.
If trouble causing parts are repaired, go to "Verification of Vehicle Repair".

NO

▶ Go to "3. BPS Waveform inspection".

3. BPS Waveform inspection

1) IG KEY "ON", ENGINE "OFF".

2) Connect BPS.

3) Connect Oscilloscope to BPS connector terminal 1.

4) Monitor the waveform at idle and acceleration after ENGINE "ON".

Specification : Refer to "Signal Waveform ＆ Data" of "General Information".

5) Is BPS waveform displayed correctly?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace BPS and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR EB73E3A4

Refer to DTC P0237.

DTC TROUBLESHOOTING PROCEDURES FLB -253

DTC P0252 INJECTION PUMP FUEL METERING CONTROL "A"

RANGE/PERFORMANCE (CAM/ROTOR/INJECTOR)

COMPONENT LOCATION E83A50E7

FTS

Fuel Pressure Regulator Valve

SFDF28315L

GENERAL DESCRIPTION E76A7C8C

Fuel pressure regulator valve is integrated with high pressure pump and controls common rail pressure as regulating
the quantity of fuel which is delivered to common rail. In order to control rail pressure to be optimum to current driving
condition, ECM controls fuel pressure regulator operating current(with the method of duty-control) using Rail pressure
regulator valve signal, RPM and APS signal.
The lower Fuel pressure regulator valve current is, the more fuel is supplied to common rail. Thus it leads rail pressure to
be high. On the contrary, the higher Fuel pressure regulator valve current is, the less fuel is supplied to common rail. Thus
it leads rail pressure to be low. Therefore, when Fuel pressure regulator valve current becomes "0", as if there is open
spot in Fuel pressure regulator valve circuit or connector is disconnected, maximum fuel quantity is supplied to common
rail, so the pressure of common rail rise to maximum value.

DTC DESCRIPTION E35F1F14

P0252 is set when excessive current in control circuit of Fuel pressure regulator valve(integrated with high pressure pump)
is detected for more than 0.22 sec.. This code is due to short to battery in control circuit or Fuel pressure regulator valve
internal short.
FLB -254 FUEL SYSTEM

DTC DETECTING CONDITION E5D01157

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● Short to battery (control circuit in Fuel

pressure regulator valve)
● Fuel pressure regulator valve circuit
Diagnostic Time ● 220ms ● Fuel pressure regulator valve
Fuel Cut NO component
EGR Off NO
Fail Safe Fuel Limit YES
Check
YES
Lamp

SPECIFICATION EB531316

Fuel pressure regulator valve resistance Operating frequancy

2.9 ~ 3.15Ω (20 C) 185 Hz

DTC TROUBLESHOOTING PROCEDURES FLB -255

DIAGNOSTIC CIRCUIT DIAGRAM E12D79F0

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.

Main Relay
"ON" Input

<FUEL PRESSURE E/R JUNCTION BOX

REGULATING VALVE>

Power
2 1

Ground(control)
1. Power
2.Ground FUEL PRESSURE
REGULATING VALVE

<ECM>

60 59 58
* * * 53 37* * 50 4934 33* 47 3146
56
44 43 42 41 40
* ** * * *
30 28 27 26 23 20 19 17 16
* ** ** *
* * 13 12 * * * 8 7 6 * 4 * 2 1
19. Power
49. Ground

SFDF27601L

SIGNAL WAVEFORM AND DATA E644A9FC

Fig.1 Fig.2
SFDF27523L
FLB -256 FUEL SYSTEM

Fig.1) Waveform of Fuel pressure regulator valve at idle. It shows approx. 38% duty.
Fig.2) Waveform of Fuel pressure regulator valve as accelerating. Approx. 32% duty is outputted as engine load in-
creases.
( When rail pressure increases as accelerating, rail pressure regulator valve duty(current) drops.)

MONITOR SCANTOOL DATA EF1B4867

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Monitor "FUEL PRESSURE MEASURED", "RAIL PRESS. REGULATOR1", "INJ. PUMP REGULATOR" parameter
on the Scantool.

SPECIFICATION :

Idle(without load) Accelerating(stall test) Diagnosis

INJ. PUMP REGULATOR 38 ± 5% 32 ± 5% Duty decreases
FUEL PRESSURE
28.5 ± 5 Mpa 145 ± 10 Mpa Press. increases
MEASURED
RAIL PRESS.
19 ± 5% 48 ± 5% Duty increases
REGULATOR1

Fig.1 Fig.2
SFDF27524L

Fig.1) The position of curser on the graph represents idle data.

Fig.2) Data during acceleration(stall test).

NOTE
The waveform of Fuel pressure regulator valve installed at high pressure pump(fuel detecting MPROP) shows 38%
duty at idle, duty drops to approx. 32% at acceleration to raise rail pressure. Duty drop means the decrease of
current.
▶ Fuel delivered to common rail increases as current drops.

The waveform of rail pressure regulator valve installed at common rail shows 19% duty at idle, duty rises to approx.
48% at acceleration to raise rail pressure. Duty rise means the increase of current.
▶ If current rises, the returning quantity of fuel deliverd to common rail decreases and common rail pressure rises.
DTC TROUBLESHOOTING PROCEDURES FLB -257

TERMINAL AND CONNECTOR INSPECTION E36B3335

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power Circuit Inspection".

POWER CIRCUIT INSPECTION E0F4B733

1. Check power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Fuel pressure regulator valve connector.

3) IG KEY "ON".

4) Measure the voltage between power terminal of FPRV harness connector and chassis ground.

Specification : 11.5V~13.0V

5) Is the measured voltage within the specification?

YES

▶ Go to "Control Circuit Inspection".

NO

▶ Repair open between power terminal of FPRV harness connector and ECM harness connector and go to
"Verification of Vehicle Repair".

CONTROL CIRCUIT INSPECTION E4690345

1. Check monitoring voltage in control circuit

1) IG KEY "OFF", ENGINE "OFF".

FLB -258 FUEL SYSTEM

2) Disconnect Fuel pressure regulator valve connector.

3) IG KEY "ON".

4) Measure the voltage between control terminal of FPRV harness connector and chassis groud.

Specification : 3.2V~3.7V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection"

NO

▶ When voltage is not detected : Go to "2. Check open in control circuit" as follows.
▶ When high voltage is detected : Repair short to battery and go to "Verification of Vehicle Repair".

2. Check open in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Fuel pressure regulator valve and ECM connector.

3) Check continuity between control terminal of FPRV harness connector and ECM harness connector.

Specification : Continuity ( below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground in Fuel pressure regulator valve control circuit and go to "Verification of Vehicle Repair".

NO

▶ Repair open in Fuel pressure regulator valve control circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E32B380A

1. Check Fuel pressure regulator valve component resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect rail pressure control valve connector.

3) Measure the resistance between signal terminal and power terminal of FPRV connector. (component side).

Specification : 2.9 ~ 3.15Ω (20 C)

4) Is Fuel pressure regulator valve component resistance within the specification?

YES

▶ Go to "Verification of Vehicle Repair".

DTC TROUBLESHOOTING PROCEDURES FLB -259

NO

▶ Replace High pressure pump ass’ y and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E9BE1D81

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -260 FUEL SYSTEM

DTC P0253 INJECTION PUMP FUEL METERING CONTROL "A" LOW

(CAM/ROTOR/INJECTOR)

COMPONENT LOCATION E14AF594

Refer to DTC P0252.

GENERAL DESCRIPTION E193C6A1

Refer to DTC P0252.

DTC DESCRIPTION E16E3FD7

P0253 is set when "0"A in control circuit of Fuel pressure regulator valve(integrated with high pressure pump) is detected
for more than 0.22 sec.. This code is due to open of short to ground in control circuit or Fuel pressure regulator valve
internal open.

DTC DETECTING CONDITION EED85CEE

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"
Threshold Value ● Short to GND, Wiring open
Diagnostic Time ● 220ms ● Fuel pressure regulator valve circuit
● Fuel pressure regulator valve
Fuel Cut NO
component
EGR Off NO
Fail Safe Fuel Limit YES
Check
YES
Lamp

SPECIFICATION E3F83C59

Refer to DTC P0252.

DIAGNOSTIC CIRCUIT DIAGRAM E2F92561

Refer to DTC P0252.

SIGNAL WAVEFORM AND DATA E6B3AFA8

Refer to DTC P0252.

MONITOR SCANTOOL DATA EAED056F

Refer to DTC P0252.

DTC TROUBLESHOOTING PROCEDURES FLB -261

TERMINAL AND CONNECTOR INSPECTION EE7ABB12

Refer to DTC P0252.

POWER CIRCUIT INSPECTION EAD4D421

1. Check power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Fuel pressure regulator valve connector.

3) IG KEY "ON".

4) Measure the voltage between power terminal of FPRV harness connector and chassis ground.

Specification : 11.5V~13.0V

5) Is the measured voltage within the specification?

YES

▶ Go to "Control Circuit Inspection".

NO

▶ Repair open between power terminal of FPRV harness connector and ECM harness connector and go to
"Verification of Vehicle Repair".

CONTROL CIRCUIT INSPECTION EE74C83D

1. Check monitoring voltage in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Fuel pressure regulator valve connector.

3) IG KEY "ON".

4) Measure the voltage between control terminal of FPRV harness connector and chassis groud.

Specification : 3.2V~3.7V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection"

NO

▶ When voltage is not detected : Go to "2. Check open in control circuit" as follows.
▶ When high voltage is detected : Repair short to battery and go to "Verification of Vehicle Repair".

2. Check open in control circuit

1) IG KEY "OFF", ENGINE "OFF".

FLB -262 FUEL SYSTEM

2) Disconnect Fuel pressure regulator valve and ECM connector.

3) Check continuity between control terminal of FPRV harness connector and ECM harness connector.

Specification : Continuity ( below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground in Fuel pressure regulator valve control circuit and go to "Verification of Vehicle Repair".

NO

▶ Repair open in Fuel pressure regulator valve control circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E82388DD

1. Check Fuel pressure regulator valve component resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect rail pressure control valve connector.

3) Measure the resistance between signal terminal and power terminal of FPRV connector. (component side).

Specification : 2.9 ~ 3.15Ω (20 C)

4) Is Fuel pressure regulator valve component resistance within the specification?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace High pressure pump ass’ y and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E5688B67

Refer to DTC P0252.

DTC TROUBLESHOOTING PROCEDURES FLB -263

DTC P0254 INJECTION PUMP FUEL METERING CONTROL "A" HIGH

(CAM/ROTOR/INJECTOR)

COMPONENT LOCATION E39D067B

Refer to DTC P0252.

GENERAL DESCRIPTION E8C69DF0

Refer to DTC P0252.

DTC DESCRIPTION EBC7CBC2

P0254 is set when excessive current in power circuit of Fuel pressure regulator valve(integrated with high pressure pump)
is detected for more than 0.22 sec.. This code is due to short to battery in power circuit or Fuel pressure regulator valve
internal short.

DTC DETECTING CONDITION E5B63BE8

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● Short to battery (power circuit in Fuel

pressure regulator valve)
● Fuel pressure regulator valve circuit
Diagnostic Time ● 220ms ● Fuel pressure regulator valve
Fuel Cut NO component
EGR Off NO
Fail Safe Fuel Limit YES
Check
YES
Lamp

SPECIFICATION E19F1F7F

Refer to DTC P0252.

DIAGNOSTIC CIRCUIT DIAGRAM E328E211

Refer to DTC P0252.

SIGNAL WAVEFORM AND DATA E4383F3C

Refer to DTC P0252.

MONITOR SCANTOOL DATA E52E5609

Refer to DTC P0252.

FLB -264 FUEL SYSTEM

TERMINAL AND CONNECTOR INSPECTION E4474A41

Refer to DTC P0252.

POWER CIRCUIT INSPECTION E563BCF9

1. Check power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Fuel pressure regulator valve connector.

3) IG KEY "ON".

4) Measure the voltage between power terminal of FPRV harness connector and chassis ground.

Specification : 11.5V~13.0V

5) Is the measured voltage within the specification?

YES

▶ Go to "Control Circuit Inspection".

NO

▶ Repair open between power terminal of FPRV harness connector and ECM harness connector and go to
"Verification of Vehicle Repair".

CONTROL CIRCUIT INSPECTION E4601CC6

1. Check monitoring voltage in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Fuel pressure regulator valve connector.

3) IG KEY "ON".

4) Measure the voltage between control terminal of FPRV harness connector and chassis groud.

Specification : 3.2V~3.7V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection"

NO

▶ When voltage is not detected : Go to "2. Check open in control circuit" as follows.
▶ When high voltage is detected : Repair short to battery and go to "Verification of Vehicle Repair".

2. Check open in control circuit

1) IG KEY "OFF", ENGINE "OFF".

DTC TROUBLESHOOTING PROCEDURES FLB -265

2) Disconnect Fuel pressure regulator valve and ECM connector.

3) Check continuity between control terminal of FPRV harness connector and ECM harness connector.

Specification : Continuity ( below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground in Fuel pressure regulator valve control circuit and go to "Verification of Vehicle Repair".

NO

▶ Repair open in Fuel pressure regulator valve control circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E68985F1

1. Check Fuel pressure regulator valve component resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect rail pressure control valve connector.

3) Measure the resistance between signal terminal and power terminal of FPRV connector. (component side).

Specification : 2.9 ~ 3.15Ω (20 C)

4) Is Fuel pressure regulator valve component resistance within the specification?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace High pressure pump ass’y and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E807D868

Refer to DTC P0252.

FLB -266 FUEL SYSTEM

DTC P0262 CYLINDER 1 INJECTOR CIRCUIT HIGH

DTC P0265 CYLINDER 2 INJECTOR CIRCUIT HIGH
DTC P0268 CYLINDER 3 INJECTOR CIRCUIT HIGH
DTC P0271 CYLINDER 4 INJECTOR CIRCUIT HIGH

COMPONENT LOCATION E931A059

Injector

RPS

Rail Pressure
Regulator Valve

SFDF28313L

GENERAL DESCRIPTION E621BF58

Injectors spray fuel in the highly compressed combustion chamber, and power generates through combustion process.
Fuel pressure is raised to 1600bar in common rail diesel engine for the purpose of making fuel into minute particles. And
fuel devided into minute particles leads smoke reduction, high power generation, and improved fuel efficiency. To control
pressure of 1600bar with solenoid, oil pressure surbo is applied. And injector solenoids is actuated by solenoid operating
voltage raised to 80V with the method of current control.
Niddle valve inside of injector is located between A and B chamber. If applied pressure to B chamber is relived by injector
solenoid, niddle valve is raised by the pressure of A chamber then, fuel is injected. If same pressure is applied to A and
B chamber, niddle valve closes by the elasticity then, fuel injection stops.
As electronically controlled injector is applied instead of mechanical injector, pilot and post injection, injeciton duration
and quantity control are achieved. And engine performance is improved by these control.

DTC DESCRIPTION E29ADF2C

P0262/P0265/P0268/P0271 is set when 1)short between injector power circuit(High side) and control circuit(Low side) or
2)short between control circuit(Low side) and battery occurs at injector #1/2/3/4 operating condition. This code is due to
over current in opened injector or open in coil inside of injector.
DTC TROUBLESHOOTING PROCEDURES FLB -267

DTC DETECTING CONDITION E9C00FA3

Item Detecting Condition Possible Cause

DTC Strategy ● Current monitoring
Enable Conditions ● IG KEY "ON"
Threshold Value ● Short in injector circuit
Diagnostic Time ● Immediately ● Short in injector circuit
Fuel Cut YES ● Injector component
EGR Off NO
Fail Safe Fuel Limit NO
Check
YES
Lamp

SPECIFICATION E342BE8B

Injector Component Injector Operating

Injector Operating Voltage Injector Control Type
Resistance Current
Peak current : 18±1A
0.255Ω ±0.04 (20 C). 80V Hold in current : 12±1A Current control
Recharging current : 7A
FLB -268 FUEL SYSTEM

DIAGNOSTIC CIRCUIT DIAGRAM EA3AC581

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.

Main Relay
"ON" Input

E/R JUNCTION BOX

<Injector>

Low side
2 1

1. Injector Low Side High side

2. Injector High Side
Injector

<W/O IMMO> <With IMMO>

<ECM>
1. Injector #2 Control 1. Injector #3 Control
2. Injector #3 Control 2. Injector #2 Control
60 59 58
* * * 53 37* * 50 4934 33* 47 3146
56
44 43 42 41 40
16. Injector #4 Control 16. Injector #1 Control
* ** * * * 17. Injector #1 Control 17. Injector #4 Control
30 28 27 26 23 20 19 17 16
31. Injector #3 Control 31. Injector #2 Control
* ** ** * 33. Injector #1 Control 33. Injector #4 Control
* * 13 12 * * * 8 7 6 * 4 * 2 1 46. Injector #2 Control 46. Injector #3 Control
47. Injector #4 Control 47. Injector #1 Control

SFDF27600L
DTC TROUBLESHOOTING PROCEDURES FLB -269

SIGNAL WAVEFORM AND DATA E64F301E

Pilot Injection1 Pilot Injection2 Main injection

Fig.1 Fig.2
SFDF27519L

Injector current waveform

Fig.3 Fig.4
SFDF27520L

Fig.1) Injector operating waveform at Low side, It shows 2 pilot and 1 main injection.
Fig.2) Magnified waveform of main injection at Fig.1)
Fig.3) Injector voltage and current waveforms are measured at the same time using current prove of scope meter.
Fig.4) Magnified waveform of pilot injection at Fig.3)

TERMINAL AND CONNECTOR INSPECTION EBCC56A1

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.
FLB -270 FUEL SYSTEM

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power Circuit Inspection".

POWER CIRCUIT INSPECTION EAE52155

1. Check short to ground in power circuit(High side)

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect injector connector and ECM connector.

3) Check continuity between high side terminal of injector harness connector and chassis ground.

Secification : Discontinuity (Infinite Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "2. Check short between power circuit and control circuit".

NO

▶ Repair short to ground in injector power circuit and go to "Verification of Vehicle Repair".

2. Check short between power circuit and control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect injector connector and ECM connector.

3) Check continuity between low side terminal and high side terminal of injector harness connector.

Specification : Discontinuity (Infinite Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "Control Circuit Inspection".

NO

▶ Repair short between injector power circuit and control circuit and go to "Verification of Vehicle Repair".
DTC TROUBLESHOOTING PROCEDURES FLB -271

CONTROL CIRCUIT INSPECTION EBE877D2

1. Check short to battery in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect injector connector.

3) IG KEY "ON"

4) Measure the voltage between low side terminal of injector harness connector and chassis ground.

Secification : 0.4V~0.5V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ Repair short to battery in injector control circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E2A39B84

1. Check injector component resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect injector connector.

3) Measure the resistance between high side terminal and low side terminal of injector connector. (component
side).

Specification : 0.255Ω ±0.04 (20 C).

4) Is the measured resistance(of injector solenoid) within the specification?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace injector and go to "Verification of Vehicle Repair".

NOTE
Replacing injectors, peculiar IQA code of each injector should be inputted to ECM Perform this process using "Injector
data input" function on scantool, Refer to P1670, P1671 for more detailed information.

VERIFICATION OF VEHICLE REPAIR E77DDA06

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.
FLB -272 FUEL SYSTEM

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

DTC TROUBLESHOOTING PROCEDURES FLB -273

DTC P0335 CRANKSHAFT POSITION SENSOR "A" CIRCUIT

COMPONENT LOCATION E7D98946

CKPS

VSS

SFDF28310L

GENERAL DESCRIPTION E4E87327

Crank Shaft Position Sensor(CKPS) is magnetic inductive type. Mounted on transaxle hausing, it senses tone wheel
position of fly wheel.
As tone wheel is devided with 58 teeth and 2 missing teeth (referrence point), 1 tooth corresponds to 6 degree.
CKPS which calculates RPM and crank angle is important to determine fuel injection quantity and injection timing with
APS.
Crank shaft position is closely related to engine starting.

DTC DESCRIPTION E8CD2117

P0335 is set when CMPS signal is outputted while CKPS signal does not generate. This code is due to CKPS circuit or
component failure. If CKPS signal is not inputted during driving, RPM is calculated based on CMPS signal.

DTC DETECTING CONDITION E760AAD5

Item Detecting Condition Possible Cause

DTC Strategy ● Signal monitoring
Enable Conditions ● Engine running

Threshold Value ● CMPS signal is outputted while CKPS

signal does not generate.
● CKPS circuit
Diagnostic Time ● - ● CKPS component
● Abnormal deformation of Crank
Fuel Cut YES
Shaft tone wheel
EGR Off NO
Fail Safe Fuel Limit NO
Check
YES
Lamp
FLB -274 FUEL SYSTEM

SPECIFICATION EDCF48A7

Output Signal Low RPM Minimum High RPM Minimum

Sensor Type Air Gab
Characteristic Detecting Voltage Detecting Voltage
Magnetic inductive A/C waveform 1.8mm 230mV 2769 mV

DIAGNOSTIC CIRCUIT DIAGRAM E6AC248C

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.
Main Relay
"ON" Input

E/R JUNCTION BOX

<CRANKSHAFT POSITION SENSOR>

Sensor Signal
3 2 1

1. Sensor Shield N S CKP Shield

2.3. Sensor Signal
CRANKSHAFT POSITION SENSOR

<ECM>

60 59 58
* * * 53 37* * 50 4934 33* 47 3146
56
44 43 42 41 40
* ** * * *
30 28 27 26 23 20 19 17 16
* ** ** *
* * 13 12 * * * 8 7 6 * 4 * 2 1
7. Sensor Shield
12.27. Sensor Signal

SFDF27602L
DTC TROUBLESHOOTING PROCEDURES FLB -275

SIGNAL WAVEFORM AND DATA EC0206CE

CMPS reference point

reference point : HIGH

reference point : LOW

CKPS reference point

Fig.1 Fig.2
SFDF27525L

Fig.1) This shows waveform of Crank Shaft Position Sensor and Cam Shaft Position Sensor simulatneously. The middle
area indicates reference points of Crank Shaft Position Sensor and Cam Shaft Position Sensor.
Fig.2) Crank Shaft Position Sensor and Cam Shaft Position Sensor signal are measured simultaneously. Cam Shaft
Position Sensor signal is outputted once when Crank Shaft Position sensor signal is outputted twice. LOW and HIGH
output of Cam Shaft Position sensor reference point is detected at Crank Shaft Position sensor reference point. ( Injection
sequence is determined based on LOW and HIGH signal of Cam Shaft Position Sensor reference point as detecting
cylinder position.)
※ Signal Analysis

CKPS signal recognition below 1000RPM

SFDF27526L
FLB -276 FUEL SYSTEM

CKPS signal recognition above 1000RPM

SFDF27527L

1) The output voltage of CKPS signal varies according to rpm(the speed of tone wheel passing by sensor)
( low voltage is inducted for low speed and high voltage is inducted for high speed. )
2) CKPS should detect from low rpm at cranking to above 5000rpm. If minimum detecting voltage is set low for the ease
of signal detection at low rpm, 1) the abnormal signal at high rpm from which high voltage generates or 2) electrical NOise
through circuit can be recognized as Crank signal. Thus minimum detecting voltages at low rpm and high rpm are set
differently.
3) ECM convert analog signal like the waveform illustrated above into digital signal with A/D converter.The voltage above
minimum detecting voltage of crank signal and "-"voltage below 0.0V is meaningless at converting process. RPM is de-
tected as Hz.(signal detecting period)

MONITOR SCANTOOL DATA EAEE4CCC

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Monitor "ENGINE SPEED SENSOR" parameter on the Scantool.

Specification : 800±50RPM at idle

Fig.1
SFDF27529L
DTC TROUBLESHOOTING PROCEDURES FLB -277

Fig.1) Check "ENGINE SPEED SENSOR" parameter carefully after warming engine up, also check engine stall and
rpm instability or engine shut down.

TERMINAL AND CONNECTOR INSPECTION EA2D36E5

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Signal Circuit Inspection ".

SIGNAL CIRCUIT INSPECTION E967B2CE

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect CKPS connector.

3) IG KEY "ON".

4) Measure the voltage between signal (-) terminal of CKPS harness connector and chassis ground.

5) Measure the voltage between signal (+) terminal of CKPS harness connector and chassis ground.

Specification : 2.4V~2.6V

6) Is the measured voltage within the specification?

YES

▶ Go to "3.Check short between signal circuits."

NO

▶ Go to "2.Check open in signal circuit" as follows.

2. Check open in signal circuit

FLB -278 FUEL SYSTEM

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect CKPS connector and ECM connector.

3) Check continuity between CKPS connector terminal 2 and ECM connector(CUD-A) terminal 27.

4) Check continuity between CKPS connector terminal 3 and ECM connector(CUD-A) terminal 12.

Specification : Continuity ( below 1.0Ω )

5) Is the measured resistance within the specification?

YES

▶ Go to "3. Check short between signal circuits".

NO

▶ Repair open in signal circuit and go to "Verification of Vehicle Repair".

3. Check short between signal circuits

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect CKPS connector and ECM connector.

3) Check continuity between signal (+) and (-) terminal of CKPS harness connector.

Specification : Discontinuity ( Infinite Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "4. Check short to ground in signal circuit" as follows.

NO

▶ Repair short between signal circuits and go to "Verification of Vehicle Repair".

4. Check short to ground in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect CKPS connector and ECM connector.

3) Check continuity between signal (-) terminal of CKPS harness connector and shield ground terminal of CKPS
harness connector. (crank signal)

4) Check continuity between signal (+) terminal of CKPS harness connector and shield ground terminal of CKPS
harenss connector.(crank signal)

Specification : Discontinuity ( Infinite Ω )

5) Is the measured resistance within the specification?

YES
DTC TROUBLESHOOTING PROCEDURES FLB -279

▶ Go to "Ground Circuit Inspection".

NO

▶ Repair the short between signal circuit and shield ground and go to "Verification of Vehicle Repair".

GROUND CIRCUIT INSPECTION E659BD74

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect CKPS connector.

3. Check continuity between shield ground terminal of CKPS harness connector and chassis ground.

Specification : Continuity ( below 1.0Ω )

4. Is the measured resistance within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ Repair open or poor connection in ground circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E332B70B

1. Check Resistance of CKPS component

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect CKPS connector.

3) Check resistance between signal (-) and signal (+) terminal of CKPS connector (component side.)

Specification : 860Ω ±10% (20 C)

4) Is the measured resistance within the specification?

YES

▶ Go to "Check short to ground in CKPS component" as follows.

NO

▶ Replace CKPS and go to "Verification of Vehicle Repair".

2. Check short to ground in CKPS component

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect CKPS connector.

3) Check resistance between shield ground terminal and signal (+) terminal of CKPS connector. ( component side.)
FLB -280 FUEL SYSTEM

Specification : Discontinuity (Infinite Ω )

4) Is the measured resistance within the specification? (Is the inside of component insulated correctly?)

YES

▶ Go to "Check CKPS waveform".

NO

▶ Replace CKPS and go to "Verification of Vehicle Repair".

3. Check CKPS waveform

1) IG KEY "OFF", ENGINE "OFF".

2) Connect CKPS connector.

3) Connect Oscilloscope to CKPS connector terminal 2.

4) Check if CKPS waveform is outputted correctly as cranking or turning engine on.

Specification : Refer to "Signal waveform ＆ data" of "General Information".

5) Is CKPS waveform outputted correctly?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace CKPS and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR EB7CD7EE

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

DTC TROUBLESHOOTING PROCEDURES FLB -281

DTC P0336 CRANKSHAFT POSITION SENSOR "A" CIRCUIT

RANGE/PERFORMANCE

COMPONENT LOCATION E3E52AB7

Refer to DTC P0335.

GENERAL DESCRIPTION E9843AF9

Refer to DTC P0335.

DTC DESCRIPTION E8EA9AF1

P0336 is set when 1). engine speed detected by CKPS is above 6000RPM, or 2). CKPS signal pulse is abnormal. For
repair, check temporary poor connection in CKPS circuit, component failure or deformation of tone wheel.

DTC DETECTING CONDITION E2F31040

Item Detecting Condition Possible Cause

DTC Strategy ● Signal monitoring
Enable Conditions ● Engine running

Threshold Value ● Engine speed sensed at CKPS above 6000RPM

● Abnormal crank signal pulse
● CKPS circuit
Diagnostic Time ● Immediately ● CKPS component
● Abnormal deformation of Crank
Fuel Cut YES
Shaft tone wheel
EGR Off NO
Fail Safe Fuel Limit NO
Check
YES
Lamp

SPECIFICATION EA993D86

Refer to DTC P0335.

DIAGNOSTIC CIRCUIT DIAGRAM EB2A8576

Refer to DTC P0335.

SIGNAL WAVEFORM AND DATA E25DC7A9

Refer to DTC P0335.

MONITOR SCANTOOL DATA EC5EF988

Refer to DTC P0335.

FLB -282 FUEL SYSTEM

TERMINAL AND CONNECTOR INSPECTION EB5D81E2

Refer to DTC P0335.

SIGNAL CIRCUIT INSPECTION E3C25710

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect CKPS connector.

3) IG KEY "ON".

4) Measure the voltage between signal (-) terminal of CKPS harness connector and chassis ground.

5) Measure the voltage between signal (+) terminal of CKPS harness connector and chassis ground.

Specification : 2.4V~2.6V

6) Is the measured voltage within the specification?

YES

▶ Go to "3.Check short between signal circuits."

NO

▶ Go to "2.Check open in signal circuit" as follows.

2. Check open in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect CKPS connector and ECM connector.

3) Check continuity between CKPS connector terminal 2 and ECM connector(CUD-A) terminal 27.

4) Check continuity between CKPS connector terminal 3 and ECM connector(CUD-A) terminal 12.

Specification : Continuity ( below 1.0Ω )

5) Is the measured resistance within the specification?

YES

▶ Go to "3. Check short between signal circuits".

NO

▶ Repair open in signal circuit and go to "Verification of Vehicle Repair".

3. Check short between signal circuits

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect CKPS connector and ECM connector.

3) Check continuity between signal (+) and (-) terminal of CKPS harness connector.
DTC TROUBLESHOOTING PROCEDURES FLB -283

Specification : Discontinuity ( Infinite Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "4. Check short to ground in signal circuit" as follows.

NO

▶ Repair short between signal circuits and go to "Verification of Vehicle Repair".

4. Check short to ground in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect CKPS connector and ECM connector.

3) Check continuity between signal (-) terminal of CKPS harness connector and shield ground terminal of CKPS
harness connector. (crank signal)

4) Check continuity between signal (+) terminal of CKPS harness connector and shield ground terminal of CKPS
harenss connector.(crank signal)

Specification : Discontinuity ( Infinite Ω )

5) Is the measured resistance within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Repair the short between signal circuit and shield ground and go to "Verification of Vehicle Repair".

GROUND CIRCUIT INSPECTION E0B77802

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect CKPS connector.

3. Check continuity between shield ground terminal of CKPS harness connector and chassis ground.

Specification : Continuity ( below 1.0Ω )

4. Is the measured resistance within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ Repair open or poor connection in ground circuit and go to "Verification of Vehicle Repair".
FLB -284 FUEL SYSTEM

COMPONENT INSPECTION E1CE44A3

1. Check Resistance of CKPS component

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect CKPS connector.

3) Check resistance between signal (-) and signal (+) terminal of CKPS connector (component side.)

Specification : 860Ω ±10% (20 C)

4) Is the measured resistance within the specification?

YES

▶ Go to "Check short to ground in CKPS component" as follows.

NO

▶ Replace CKPS and go to "Verification of Vehicle Repair".

2. Check short to ground in CKPS component

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect CKPS connector.

3) Check resistance between shield ground terminal and signal (+) terminal of CKPS connector. ( component side.)

Specification : Discontinuity (Infinite Ω )

4) Is the measured resistance within the specification? (Is the inside of component insulated correctly?)

YES

▶ Go to "Check CKPS waveform".

NO

▶ Replace CKPS and go to "Verification of Vehicle Repair".

3. Check CKPS waveform

1) IG KEY "OFF", ENGINE "OFF".

2) Connect CKPS connector.

3) Connect Oscilloscope to CKPS connector terminal 2.

4) Check if CKPS waveform is outputted correctly as cranking or turning engine on.

Specification : Refer to "Signal waveform ＆ data" of "General Information".

5) Is CKPS waveform outputted correctly?

YES
DTC TROUBLESHOOTING PROCEDURES FLB -285

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace CKPS and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E2EE4123

Refer to DTC P0335.

FLB -286 FUEL SYSTEM

DTC P0340 CAMSHAFT POSITION SENSOR "A" CIRCUIT (SINGLE

SENSOR)

COMPONENT LOCATION E64AAC36

EEGR

CMPS

SFDF28311L

GENERAL DESCRIPTION EF1DFAD0

Cam Shaft Position Sensor(CMPS) is hall sensor type. Sensing the teeth attatch at the end of exhaust cam shaft, CMPS
detects rotation of Cam shaft (1 signal per 1 lotation).
As Cam shaft rotates once while Crank shaft does twice, CMPS referrence point generates once while CKPS′ do twice.
As this signal inputted to ECM, it distinguishes crank angle and the cylinder which requires fuel injection in order to de-
termine injection sequence and duration.

DTC DESCRIPTION EFFC5866

P0340 is set when CKPS signal is outputted while CMPS signal does not generate. This code is due to the failure relevant
to CMPS related circuit and sensor component.

DTC DETECTING CONDITION E2A949C5

Item Detecting Condition Possible Cause

DTC Strategy ● Signal monitoring
Enable Conditions ● Engine running(during accelerating)

Threshold Value ● CKPS signal is outputted while CMPS

signal does not generate.
Diagnostic Time ● CMPS circuit
● CMPS component
Fuel Cut NO
EGR Off NO
Fail Safe Fuel Limit YES
Check
YES
Lamp
DTC TROUBLESHOOTING PROCEDURES FLB -287

SPECIFICATION EE388C43

Output Signal LOW Signal HIGH Signal

Sensor Type Air Gab
Characteristic Detecting Voltage Detecting Voltage
0V~5V Digital signal
Hall effect type 1.25mm Below 2.0V Above 3.8V
output

DIAGNOSTIC CIRCUIT DIAGRAM E05F2276

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.

Main Relay
"ON" Input

E/R JUNCTION BOX

<CAMSHAFT POSITION SENSOR>

3 2 1
Signal
TR
1. Power
2. Sensor Signal Ground
3. Sensor Ground
CAMSHAFT POSITION SENSOR

<ECM>

60 59 58
* * * 53 37* * 50 4934 33* 47 3146
56
44 43 42 41 40 20. Sensor Ground
* ** * * *
30 28 27 26 23 20 19 17 16 50. Sensor Signal
* ** ** *
* * 13 12 * * * 8 7 6 * 4 * 2 1

SFDF27603L
FLB -288 FUEL SYSTEM

SIGNAL WAVEFORM AND DATA E4D30EB3

CMPS reference point

reference point : HIGH

reference point : LOW

CKPS reference point

Fig.1 Fig.2
SFDF27525L

Fig.1) This shows waveform of Crank Shaft Position Sensor and Cam Shaft Position Sensor simulatneously. The middle
area indicates reference points of Crank Shaft Position Sensor and Cam Shaft Position Sensor.
Fig.2) Crank Shaft Position Sensor and Cam Shaft Position Sensor signal are measured simultaneously. Cam Shaft
Position Sensor signal is outputted once when Crank Shaft Position sensor signal is outputted twice. LOW and HIGH
output of Cam Shaft Position sensor reference point is detected at Crank Shaft Position sensor reference point. ( Injection
sequence is determined based on LOW and HIGH signal of Cam Shaft Position Sensor reference point as detecting
cylinder position.)
※ Signal Analysis

Falling edge

High-signal detecting range

Hysteresis range

Rising edge

V0 Low-signal detecting range

SFDF27528L

1. 1) ECM recognizes HIGH signal as LOW signal when CMPS signal drops below 2.0V and LOW signal as HIGH signal
when CMPS signal rises above 3.8V.

2. 2) V0 - the Minimum voltage of LOW signal does not drop below 0.0V due to the hall sensor inside resistance. When
the Minimum voltage of LOW signal is above 0.6V during signal waveform inspection, check excessive resistance
inside of CMPS component or in ground circuit.

MONITOR SCANTOOL DATA E1F76F4E

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

DTC TROUBLESHOOTING PROCEDURES FLB -289

3. Turn "OFF" electrical devices and A/C.

4. Monitor "ENGINE SPEED SENSOR" parameter on the Scantool.

Specification : 800±50RPM at idle

Fig.1
SFDF27529L

Fig.1) Check "ENGINE SPEED SENSOR" parameter carefully after warming engine up, also check engine stall and
rpm instability or engine shut down.

TERMINAL AND CONNECTOR INSPECTION EE90B6DC

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power Circuit Inspection".

POWER CIRCUIT INSPECTION E7F23101

1. IG KEY "OFF", ENGINE "OFF".

FLB -290 FUEL SYSTEM

2. Disconnect CMPS connector.

3. IG KEY "ON".

4. Measure the voltage between IG Power terminal of CMPS harness connector and chassis ground.

Specification : 11.0V~13.0V ( Main relay "ON" power )

5. Is the measured voltage within the specification?

YES

▶ Go to "Signal Circuit Inspection".

NO

▶ Repair open in Main relay power circuit and fuse, and go to "Verification of Vehicle Repair".
[Check open in E/R JUNCTION BOX INJ FUSE and related circuit.]
※ If the fuse is damaged again after replacing the damaged fuse, repair short to ground in Main relay power circuit.

SIGNAL CIRCUIT INSPECTION EA59BCE8

1. Check CMPS signal voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect CMPS connector.

3) IG KEY "ON".

4) Measure the voltage between signal terminal of CMPS harness connector and chassis ground.

Specification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Go to "Check open in signal circuit" as follows.

2. Check open in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect CMPS connector and ECM connector.

3) Check continuity between signal terminal of CMPS harness connector and ECM harness connector.

Specification : Continuity ( below 1.0Ω )

4) Is the measured resistance within the specification? (Is continuity confirmed?)

YES
DTC TROUBLESHOOTING PROCEDURES FLB -291

▶ Go to "Check short to ground in signal circuit" as follows.

NO

▶ Repair open in the circuit between CMPS connector terminal 2 and ECM connector terminal 50 and go to
"Verification of Vehicle Repair".

3. Check short to ground in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect CMPS connector and ECM connector.

3) Check continuity between signal terminal of CMPS harness connector and ECM harness connector.

Specification : Discontinuity ( Infinite Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ Repair short to ground in signal circuit and go to "Verification of Vehicle Repair".

GROUND CIRCUIT INSPECTION E4F86EF9

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect CMPS connector.

3. IG KEY "ON".

4. Check the voltage between signal terminal of CMPS harness connetor and chassis ground. [ TEST "A" ]

5. Check the voltage between signal terminal and ground terminal of CMPS harness connetor. [ TEST "B" ]
( Signal terminal : Check + prove , Ground terminal : Check - prove )

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6. Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION EF443253

1. Cam shaft detecting teeth inspection

FLB -292 FUEL SYSTEM

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect CMPS connector.

3) Disconnect CMPS.

4) Check the condition of Cam shaft detecting teeth through CMPS mounting hall.

5) Is abnormal deformation of Cam shaft detecting teeth found?

YES

▶ Replace Cam shaft assy’ or Cylinder head assy’ and go to "Verification of Vehicle Repair".

NO

▶ Go to "CMPS waveform Inspection" as follows.

2. CMPS waveform inspection

1) IG KEY "OFF", ENGINE "OFF".

2) Connect CMPS connector.

3) Connect Oscilloscope to CMPS connector terminal 2.

4) Monitor if CMPS waveform is outputted normally as cranking or turning engine "ON".

Specification : Refer to "Signal waveform ＆ Data" of "General Information".

5) Is CMPS waveform displayed correctly?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace CMPS and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR EC40CB90

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

DTC TROUBLESHOOTING PROCEDURES FLB -293

DTC P0341 CAMSHAFT POSITION SENSOR A CIRCUIT

RANGE/PERFORMANCE (BANK 1)

COMPONENT LOCATION E5E1291B

Refer to DTC P0341.

GENERAL DESCRIPTION E8CBBC12

Refer to DTC P0341.

DTC DESCRIPTION E23B0DCC

P0341 is set when CMPS reference point is detected more or less than twice while CKPS reference point is recognized
4 times. This code is due to temporary poor connection or short to ground in CMPS circuit. CMPS component failure.

DTC DETECTING CONDITION EA509AE7

Item Detecting Condition Possible Cause

DTC Strategy ● Signal monitoring
Enable Conditions ● Engine running(during accelerating)
Threshold Value ● When the signal from CMPS is abnormal.
Diagnostic Time ● - ● CMPS circuit
Fuel Cut YES ● CMPS component
EGR Off YES
Fail Safe Fuel Limit NO
Check
NO
Lamp

SPECIFICATION E92CA01D

Refer to DTC P0341.

DIAGNOSTIC CIRCUIT DIAGRAM EC3DDC57

Refer to DTC P0341.

SIGNAL WAVEFORM AND DATA EDE09408

Refer to DTC P0341.

MONITOR SCANTOOL DATA E88FE85F

Refer to DTC P0341.

TERMINAL AND CONNECTOR INSPECTION E65B69D2

Refer to DTC P0341.

FLB -294 FUEL SYSTEM

POWER CIRCUIT INSPECTION E58513A4

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect CMPS connector.

3. IG KEY "ON".

4. Measure the voltage between IG Power terminal of CMPS harness connector and chassis ground.

Specification : 11.0V~13.0V ( Main relay "ON" power )

5. Is the measured voltage within the specification?

YES

▶ Go to "Signal Circuit Inspection".

NO

▶ Repair open in Main relay power circuit and fuse, and go to "Verification of Vehicle Repair".
[Check open in E/R JUNCTION BOX INJ FUSE and related circuit.]
※ If the fuse is damaged again after replacing the damaged fuse, repair short to ground in Main relay power circuit.

SIGNAL CIRCUIT INSPECTION E9686947

1. Check CMPS signal voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect CMPS connector.

3) IG KEY "ON".

4) Measure the voltage between signal terminal of CMPS harness connector and chassis ground.

Specification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Go to "Check open in signal circuit" as follows.

2. Check open in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect CMPS connector and ECM connector.

3) Check continuity between signal terminal of CMPS harness connector and ECM harness connector.

Specification : Continuity ( below 1.0Ω )

DTC TROUBLESHOOTING PROCEDURES FLB -295

4) Is the measured resistance within the specification? (Is continuity confirmed?)

YES

▶ Go to "Check short to ground in signal circuit" as follows.

NO

▶ Repair open in the circuit between CMPS connector terminal 2 and ECM connector terminal 50 and go to
"Verification of Vehicle Repair".

3. Check short to ground in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect CMPS connector and ECM connector.

3) Check continuity between signal terminal of CMPS harness connector and ECM harness connector.

Specification : Discontinuity ( Infinite Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ Repair short to ground in signal circuit and go to "Verification of Vehicle Repair".

GROUND CIRCUIT INSPECTION E330FB08

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect CMPS connector.

3. IG KEY "ON".

4. Check the voltage between signal terminal of CMPS harness connetor and chassis ground. [ TEST "A" ]

5. Check the voltage between signal terminal and ground terminal of CMPS harness connetor. [ TEST "B" ]
( Signal terminal : Check + prove , Ground terminal : Check - prove )

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6. Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".
FLB -296 FUEL SYSTEM

COMPONENT INSPECTION EE7AF850

1. Cam shaft detecting teeth inspection

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect CMPS connector.

3) Disconnect CMPS.

4) Check the condition of Cam shaft detecting teeth through CMPS mounting hall.

5) Is abnormal deformation of Cam shaft detecting teeth found?

YES

▶ Replace Cam shaft assy’ or Cylinder head assy’ and go to "Verification of Vehicle Repair".

NO

▶ Go to "CMPS waveform Inspection" as follows.

2. CMPS waveform inspection

1) IG KEY "OFF", ENGINE "OFF".

2) Connect CMPS connector.

3) Connect Oscilloscope to CMPS connector terminal 2.

4) Monitor if CMPS waveform is outputted normally as cranking or turning engine "ON".

Specification : Refer to "Signal waveform ＆ Data" of "General Information".

5) Is CMPS waveform displayed correctly?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace CMPS and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E8C42483

Refer to DTC P0341.

DTC TROUBLESHOOTING PROCEDURES FLB -297

DTC P0381 GLOW PLUG/HEATER INDICATOR CIRCUIT

GENERAL DESCRIPTION E8E75D6F

Heating combustion chamber, glow plug increases fuel ignitibility and makes fuel in the foggy state easily when engine
is cold. Thus, glow plug makes engine starting easily and decreases exhaust gas produced just after turning engine on
when engine is cold.
ECM controls operation and operating duration of glow plug relay which supplies power to glow plug with ECTS signal,
battery voltage and IG KEY ON signal.
Through glow lamp in cluster, ECM let drivers know if glow plug is ON.

DTC DESCRIPTION EA52C000

P0381 is set when 1)excessive voltage is detected or 2)no current is detected like open or short to ground in glow lamp
control circuit for more than 1 sec. at glow lamp ON condition. This code is due to open in glow lamp control circuit or
internal open in filament of glow lamp component.

DTC DETECTING CONDITION EF79F164

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring

Enable Conditions ● IG KEY "ON" (monitoring only performed

within lamp operating condition)

Threshold Value ● Short to battery

● Short to GND, Wiring open
● Open in glow lamp
Diagnostic Time ● 1.0 sec. ● Glow lamp circuit
Fuel Cut NO
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp
FLB -298 FUEL SYSTEM

DIAGNOSTIC CIRCUIT DIAGRAM EB32ABBD

ECM

ON/START Input
- +
BATT.
INSTRUMENT CLUSTER
GLOW

Glow Indicator
GLOW

<ECM> <INSTRUMENT CLUSTER>

94 93 92 90 89
*
72 71 70 69 68 * 87 86 * 84 83 * 81 80 79 * 77 * 75 * * 6 5
* * 65 64 * * * * * * 57 56 * 54 * * 51 4 3
8
* * 5 4 3 2 1
* 27* 48 47
28 25
46 45 44
22 *
42
* 40 * 1638 1537 1436 35
19
34 33 32 31 30 29
13 12 11 10 9 8 7
2 1 16 15 14 13 12 11 10 9
* ** ** **
9. Glow Time Ind. Lamp
69. Glow Time Ind. Lamp

SFDF27604L

MONITOR SCANTOOL DATA E6B3A9C8

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Select "ACTUATION TEST" parameter on the scantool.

Specification : Lamp turns ON at ACTUATION TEST of Glow lamp

DTC TROUBLESHOOTING PROCEDURES FLB -299

Fig.1
SFDF27530L

Fig.1) Diagnosing problem is convenient through ACTUATION TEST of glow lamp.

TERMINAL AND CONNECTOR INSPECTION EAA7BC46

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Control Circuit Inspection".

CONTROL CIRCUIT INSPECTION EFBAECB8

1. Check voltage in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECM connector

3) IG KEY "ON".

4) Measure the voltage between glow lamp terminal of ECM harness connector and chassis ground.
FLB -300 FUEL SYSTEM

Specification : 10.8V~13.0V

5) Is the measured voltage within the specification?

YES

▶ Go to "2. Grounding test of glow lamp control circuit".

NO

▶ Check filament of glow lamp. ( ReferF to Component Inspection)

2. Grounding test of glow lamp control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECM connector

3) IG KEY "ON"

4) Ground glow lamp terminal of ECM harness connector to chassis ground.

Specification : Glow lamp turns ON.

5) Does glow lamp turn ON?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Repair short to battery in glow lamp control circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION EA33A336

1. IG KEY "OFF", ENGINE "OFF".

2. Dismount cluster and disconnect glow lamp.

3. Check filament of glow lamp.

4. Supply 12V to glow lamp to turn lamp ON.

Specification : Lamp turns ON when 12V is supplied.

5. Does glow lamp turn ON?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace glow lamp and go to "Verification of Vehicle Repair".

DTC TROUBLESHOOTING PROCEDURES FLB -301

VERIFICATION OF VEHICLE REPAIR E2FDB4D5

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -302 FUEL SYSTEM

DTC P0401 EXHAUST GAS RECIRCULATION FLOW INSUFFICIENT

DETECTED

COMPONENT LOCATION E89572FE

EEGR

CMPS

SFDF28311L

GENERAL DESCRIPTION E84BF553

Receiving ECM signal, linear solenoid type electronic EGR actuator operates Electric EGR control valve directly.
ECM performs EGR system feed back control with the information of measured mass air flow (The role of MAFS in diesel
engine is different from gasoline engine. Fuel injection quantity is decided by MAFS signal in gasoline engine.)
When EGR gas(contains no oxygen) flowing into combustion chamber increases, the air passing through AFS(contains
oxygen) decreases. Thus, with the output signal change of AFS accompanied by Electric EGR control valve actuation,
ECM determine the amount of recirculated EGR gas quantity.

NOTE
NOx is produced from the reaction of nitrogen and oxygen.
Controlling EGR gas(contains no oxygen) which is recirculated to combustion chamber, if least intake air required for
complete combustion flows into combustion chamber, NOx decreases because there is no supplementary oxygen to
react with nitrogen.

DTC DESCRIPTION E5F20401

P401 is set when ECM detects that duty amount of EEGR actuator contol valve, ENG speed or amount of EGR is ex-
ceeded to minimum set point last to more than 15sec. In this case, check that stuck of EEGR actuator, air leakage of
intake line.
DTC TROUBLESHOOTING PROCEDURES FLB -303

DTC DETECTING CONDITION E6E06D76

Item Detecting Condition Possible Cause

DTC Strategy ● Signal monitoring
Enable Conditions ● Engine running

Threshold Value ● Real value - Target value ＞ upper

specified air amout value
● EGR actuator stuck
Diagnostic Time ● 15 sec. ● EGR actuator component
Fuel Cut NO ● Air leakage of intake line
EGR Off YES
Fail Safe Fuel Limit NO
Check
YES
Lamp

SPECIFICATION E64B82C6

Electric EGR control valve Electric EGR control valve Electric EGR control valve
component resistance operating Hz operating duty

14.7 ~ 16.1Ω (20 C) 142Hz 5%(closed)~39%(opened)

FLB -304 FUEL SYSTEM

DIAGNOSTIC CIRCUIT DIAGRAM E9931A13

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.

Main Relay
"ON" Input

E/R JUNCTION BOX

<EGR>

2 1

EGR Actuator
1. EGR Actuator
2. Power EGR

<ECM>

60 59 58
* * * 53 37* * 50 4934 33* 47 3146
56
44 43 42 41 40
* ** * * *
30 28 27 26 23 20 19 17 16
* ** ** *
* * 13 12 * * * 8 7 6 * 4 * 2 1

59. EGR Actuator

SFDF27605L

SIGNAL WAVEFORM AND DATA EF181CA1

Fig.1 Fig.2
SFDF27537L
DTC TROUBLESHOOTING PROCEDURES FLB -305

Fig.1) Approx. 6% duty signal waveform of Electric EGR control valve (with EEGR valve closed)
Fig.2) Approx. 40% duty signal waveform of Electric EGR control valve(with EEGR valve opened)

NOTE
The output of approx. 6% duty is mainly for the diagnosis of Electric EGR control valve circuit than actuating EEGR.

MONITOR SCANTOOL DATA E406106D

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Monitor "AIR MASS PERCYLINDER" parameter on the Scantool.

Specification : When Electric EGR control valve does not operate 6% duty) at idle : 340mg/st ± 50 mg/st
When Electric EGR control valve operates(Approx. 50% duty) at idle : 200ms/st ± 50 mg/st

Fig.1 Fig.2
SFDF27532L

Fig.1) Check if "AIR MASS PERCYLINDER"l is 340mg/st ± 50mg/st without EEGR operation at warm idle (Electric
EGR control valve 6% duty)
Fig.2) Check if "AIR MASS PERCYLINDER"l is 200mg/st ± 50mg/st with EEGR operation at warm idle (Electric EGR
control valve approx. 50% duty)

NOTE
※ Electric EGR control valve operates as decelerating after rapid acceleration when idle EEGR does not operate,
Electric EGR control valve operating duty decreases as time goes by. This controlling process lasts for about 1 min.
and EElectric EGR control valve turns "OFF" (duty 6% ) after 1 min.

TERMINAL AND CONNECTOR INSPECTION E86F4553

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.
FLB -306 FUEL SYSTEM

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power Circuit Inspection".

POWER CIRCUIT INSPECTION EF0471B3

1. Check power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Electric EGR control valve connector

3) IG KEY "ON".

4) Measure the voltage between power terminal of EGR actuator harness connector and chassis ground.

Secification : 11.5V~13.0V

5) Is the measured voltage within the specification?

YES

▶ Go to "Control Circuit Inspection".

NO

▶ Repair INJ FUSE in E/R FUSE ＆ RELAY BOX and related circuit and go to "Verification of Vehicle Repair".

CONTROL CIRCUIT INSPECTION EB6A5E70

1. Check control circuit monitoring voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Electric EGR control valve connector.

3) IG KEY "ON".

4) Measure the voltage between control terminal of EGR actuator harness connector and chassis ground.

Specification : 3.2V~3.7V

5) Is the measured voltage within the specification?

DTC TROUBLESHOOTING PROCEDURES FLB -307

YES

▶ Go to "Component Inspection".

NO

▶ When voltage is not detected : Go to "2. Check open in control circuit" as follows.
▶ When high voltage is detected : Repair short to battery and go to "Verification of Vehicle Repair".

2. Check open in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Electric EGR control valve connector and ECM connector

3) Check continuity between control terminal of EGR actuator harness connector and ECM harness connector.

Specification : Continuity ( below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground and go to "Verification of Vehicle Repair".

NO

▶ Repair open in control circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION EC057019

1. Check EGR actuator component resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect EGR actuator.

3) Measure the resistance between power terminal and control terminal of EGR actuator (component side).

Secification : 7.3~ 8.8Ω (30 C)

4) Is EEGR actuator component resistance within the specification?

YES

▶ Go to "2. Check EEGR actuator operation condition"as follows.

NO

▶ Replace EEGR actuator and go to "Verification of Vehicle Repair".

2. Check EEGR actuator operation condition

1) IG KEY "OFF", ENGINE "OFF"

2) Check that MAFS is installed in correctly according to the direction of arrow on MAFS assy’ .
FLB -308 FUEL SYSTEM

3) Check contamination of air cleaner filter.

4) IG KEY "ON", ENGINE "ON".

5) Let IDLE RPM last after warming engine up.

6) Check the leakage of intake system(the leakage or damage of intercooler).

7) Check that VGT operates correctly.( Check if vacuum operating state of VGT actuator is appropriate, if VGT
diaphragm and unison ring are stuck.)

8) Check that EEGR actuator does not operate.

( EEGR actuator turns "OFF" and 6% duty is outputted 1 min. after rapid acceleration. )

9) Monitor signal voltage of MAFS when engine speed lasts at approx. 800RPM using Scantool.

10) Check MAFS output signal at idle after rapid acceleration.(EEGR actuator duty 50%)

Specification : When EEGR actuator does not operate (6%) at idle : 340mg/st ± 50 mg/st
When EEGR actuator operates(50%) at idle : 200mg/st ± 50 mg/st

11) Is output signal within the specification?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Check that EEGR actuator is stuck. If it is, replace EEGR actuator assembly then, go to "Verification of Vehicle
Repair".

VERIFICATION OF VEHICLE REPAIR E6D57033

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

DTC TROUBLESHOOTING PROCEDURES FLB -309

DTC P0402 EXHAUST GAS RECIRCULATION FLOW EXCESSIVE DETECTED

COMPONENT LOCATION E5B62028

Refer to DTC P0401.

GENERAL DESCRIPTION ED551E5D

Refer to DTC P0401.

DTC DESCRIPTION EDB75771

P0402 is set when EGR governer deviaton is above the upper limit value for more than 5 sec. This code is due to open
or short to battery in EEGR actuator circuit or internal open in EEGR component.

DTC DETECTING CONDITION E46110C7

Item Detecting Condition Possible Cause

DTC Strategy ● Signal monitoring
Enable Conditions ● Engine running

Threshold Value ● Real value - Target value ＜ lower

specified air amount value
● EGR actuator stuck
Diagnostic Time ● 5 sec. ● EGR actuator component
Fuel Cut NO ● Air leakage of intake line
EGR Off YES
Fail Safe Fuel Limit NO
Check
YES
Lamp

SPECIFICATION E331A27A

Refer to DTC P0401.

DIAGNOSTIC CIRCUIT DIAGRAM E30EC6AC

Refer to DTC P0401.

SIGNAL WAVEFORM AND DATA E26D53D7

Refer to DTC P0401.

MONITOR SCANTOOL DATA E1000953

Refer to DTC P0401.

TERMINAL AND CONNECTOR INSPECTION EDEE1F2E

Refer to DTC P0401.

FLB -310 FUEL SYSTEM

POWER CIRCUIT INSPECTION E5D462C5

1. Check power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Electric EGR control valve connector

3) IG KEY "ON".

4) Measure the voltage between power terminal of EGR actuator harness connector and chassis ground.

Secification : 11.5V~13.0V

5) Is the measured voltage within the specification?

YES

▶ Go to "Control Circuit Inspection".

NO

▶ Repair INJ FUSE in E/R FUSE ＆ RELAY BOX and related circuit and go to "Verification of Vehicle Repair".

CONTROL CIRCUIT INSPECTION EB0295A8

1. Check control circuit monitoring voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Electric EGR control valve connector.

3) IG KEY "ON".

4) Measure the voltage between control terminal of EGR actuator harness connector and chassis ground.

Specification : 3.2V~3.7V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ When voltage is not detected : Go to "2. Check open in control circuit" as follows.
▶ When high voltage is detected : Repair short to battery and go to "Verification of Vehicle Repair".

2. Check open in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Electric EGR control valve connector and ECM connector

3) Check continuity between control terminal of EGR actuator harness connector and ECM harness connector.

Specification : Continuity ( below 1.0Ω )

DTC TROUBLESHOOTING PROCEDURES FLB -311

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground and go to "Verification of Vehicle Repair".

NO

▶ Repair open in control circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E2EA4DF6

1. Check EGR actuator component resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect EGR actuator.

3) Measure the resistance between power terminal and control terminal of EGR actuator (component side).

Secification : 7.3~ 8.8Ω (30 C)

4) Is EEGR actuator component resistance within the specification?

YES

▶ Go to "2. Check EEGR actuator operation condition"as follows.

NO

▶ Replace EEGR actuator and go to "Verification of Vehicle Repair".

2. Check EEGR actuator operation condition

1) IG KEY "OFF", ENGINE "OFF"

2) Check that MAFS is installed in correctly according to the direction of arrow on MAFS assy’ .

3) Check contamination of air cleaner filter.

4) IG KEY "ON", ENGINE "ON".

5) Let IDLE RPM last after warming engine up.

6) Check the leakage of intake system(the leakage or damage of intercooler).

7) Check that VGT operates correctly.( Check if vacuum operating state of VGT actuator is appropriate, if VGT
diaphragm and unison ring are stuck.)

8) Check that EEGR actuator does not operate.

( EEGR actuator turns "OFF" and 6% duty is outputted 1 min. after rapid acceleration. )

9) Monitor signal voltage of MAFS when engine speed lasts at approx. 800RPM using Scantool.

10) Check MAFS output signal at idle after rapid acceleration.(EEGR actuator duty 50%)

Specification : When EEGR actuator does not operate (6%) at idle : 340mg/st ± 50 mg/st
When EEGR actuator operates(50%) at idle : 200mg/st ± 50 mg/st
FLB -312 FUEL SYSTEM

11) Is output signal within the specification?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Check that EEGR actuator is stuck. If it is, replace EEGR actuator assembly then, go to "Verification of Vehicle
Repair".

VERIFICATION OF VEHICLE REPAIR E960A9CE

Refer to DTC P0401.

DTC TROUBLESHOOTING PROCEDURES FLB -313

DTC P0471 EXHAUST PRESSURE SENSOR "A" CIRCUIT

RANGE/PERFORMANCE

COMPONENT LOCATION E9747716

DPS

SFDF28316L

GENERAL DESCRIPTION E9EFDC22

Differential pressure sensor(DPS) is piezzo electric type sensor. Sensing the differential pressure between in front of
CPF and in the back of CPF, DPS outputs linear signal from 0~5V. Using output signal, DPS detects the amount of soot,
sulfide, SOF(soluble organic fraction) to determine if CPF regeneration is needed.
【CPF regeneration】When vehicle is in steady speed condition and above normal engine loading condition, if differential
pressure between before and after CPF is above the specified pressure, ECM considers that stored soot inside of CPF is
excessive. In this condition, exhaust gas tempt. is raised by post injection 1 and 2 to warm CPF up to 550 C~650 C. In
this high tempt, soot inside of CPF burns up naturally and this mechanism is called as "CPF regeneration". Most of soot is
burned up during regeneration process but a little amount of soot is not burned up and stored inside of CPF continuously.
The stored soot decreases the efficiency of CPF slowly. DPS corrects CPF regeneration period and duration as comparing
and calculating the differential pressure due to stored soot with the total distance covered.

DTC DESCRIPTION E9BB737C

P0471 is set when the measured Differential pressure is above 100 hPa - the upper limiting value - for more than 1 sec.
This code is due to 1) short beween power and signal circuit or 2) short to battery in signal circuit or 3) short to ground in
ground circuit.
FLB -314 FUEL SYSTEM

DTC DETECTING CONDITION E6824A50

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"
Threshold Value ● When differential pressure is above 100 hPa ● DPS Wiring
● DPS component
Diagnostic Time ● 1.0 sec ● Reversly connected DPS hose line
Fuel Cut NO ● Clogged DPS
● Clogged CPF inlet section
EGR Off NO
● Engine check lamp ● Clogged CPF
Fail Safe Fuel Limit NO blinks.
Check
BLINK
Lamp

SPECIFICATION E139E15D

Differential Pressure Characteristic

Abnormall output (Reversely connected) Normal output

4.5

Output Output
voltage voltage
(V) (V)

1 1
0.5

0 15 100 0 15 100
Differential Pressure (kPa) Differential Pressure (kPa)

SEDF27325L
DTC TROUBLESHOOTING PROCEDURES FLB -315

DIAGNOSTIC CIRCUIT DIAGRAM E652AF3A

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.
Main Relay
"ON" Input

E/R JUNCTION BOX

<Differential Pressure Sensor>

3 2 1 Power

P Ground

1. Power Signal
2. Signal
3. Ground Differential Pressure Sensor

<ECM>

94 93 92 90 89 36. Signal
72 71 70 69 68* * 87 86 * 84 83 * 81 80 79 * 77 * 75 * * 6 5
* * 65 64 * * * * * * 57 56 * 54 * * 51 4 3 37. Ground
* 27* 48 47
28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1
* 25 * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7 44. Power

SFDF27606L
FLB -316 FUEL SYSTEM

SIGNAL WAVEFORM AND DATA ED39BA6A

Fig.1 Fig.2
SFDF27534L

Fig1). This is the signal waveform of DPS at idle state. When CPF is new, 1.0~1.2V is outputted normally.
Fig2). This is the waveform of DPS as accelerating.

NOTE
As accelerating, DPS signal output voltage does not vary too much. Even when accelerator pedal is fully depressed,
the signal voltage fluctuates just a little bit like "Fig. 2". However, the more CPF is used, the more waveform fluctuates.

MONITOR SCANTOOL DATA E1377B4A

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Monitor "DIFFERENTIAL PRESSURE" and "PRESSURE PRE CPF" parameter on the scantool.

Specification : "DIFFERENTIAL PRESSURE" and "PRESSURE PRE CPF" data must not be too high or low.

Fig.1
SFDF27535L
DTC TROUBLESHOOTING PROCEDURES FLB -317

Fig. 1) Check if "DIFFERENTIAL PRESSURE" and "PRESSURE PRE CPF" data is abnormally too high or low.
▶ When "DIFFERENTIAL PRESSURE" is too high : Check if excessive soot is accumulated inside of CPF before
inspecting DPS related problem. If needed, perform "CPF SERVICE REGENERATION" to burn the soot inside of
CPF and monitor data change.
▶ When "DIFFERENTIAL PRESSURE" is too low : "DIFFERENTIAL PRESSURE" and "PRESSURE PRE CPF"
data rises depending on engine load increase and the amount of soot inside of CPF. If differential pressure is not
generated or soot is emitted without the rise of "PRESSURE PRE CPF" during excceleration, check CPF component
failure.

NOTE
※ The "Scantool Data" shown above is measured at the vehicle with new CPF component. Therfore, data varies
depending on CPF used duration

TERMINAL AND CONNECTOR INSPECTION ECB6171A

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power Circuit Inspection".

POWER CIRCUIT INSPECTION E76F97F3

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect DPS connector.

3. IG KEY "ON"

4. Measure the voltage between power supply terminal of DPS harness connector and chassis ground.

Specification : 4.8V~5.1V

5. Is the measured voltage within the specification?

YES

▶ Go to "Signal Circuit Inspection".

FLB -318 FUEL SYSTEM

NO

▶ Repair open in power circuit and go to "Verification of Vehicle Repair".

SIGNAL CIRCUIT INSPECTION E2D04267

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect DPS connector.

3) IG KEY "ON"

4) Measure the voltage between signal terminal of DPS harness connector and chassis ground.

Specification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Go to "2. Check open in signal circuit" as follows.

2. Check open in signal circuit

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect DPS connector and ECM connector.

3) Measure the resistance between signal terminal of DPS harness connector and DPS signal terminal of ECM
harness connector.

Specification : Continuity ( below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "3. Check short to battery in signal circuit" as follows.

NO

▶ Repair open in DPS signal circuit and go to "Verification of Vehicle Repair".

3. Check short to battery in signal circuit

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect DPS connector and ECM connector.

3) IG KEY "ON"

4) Measure the voltage between signal terminal of DPS harness connector and chassis ground.
DTC TROUBLESHOOTING PROCEDURES FLB -319

Specification : 0.0V~0.1V

5) Is abnormal voltage detected in the circuit with both connector disconnected?

YES

▶ Repair short to battery in signal circuit and go to "Verification of Vehicle Repair".

NO

▶ Go to "Ground Circuit Inspectiont".

GROUND CIRCUIT INSPECTION E28500DF

1. IG KEY "OFF", ENGINE "OFF"

2. Disconnect DPS connector.

3. IG KEY "ON"

4. Measure the voltage between signal terminal of DPS harness connector and chassis ground. [ TEST "A" ]

5. Measure the voltage between signal terminal and ground terminal of DPS harness connector. [ TEST "B" ]
( Signal terminal : Check + prove , Ground terminal : Check - prove )

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6. Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION EFC333B4

1. DPS visual inspection

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect DPS connector.

3) Check DPS terminals for corrosion and contamination.

4) Check (1)connecting condition of DPS and pressure sensing hose, (2)exhaust gas pressure leakate, (3)miss
connection of pressure sensing hose (reverse connection) is detected.

5) Is DPS related problem detected?

YES

▶ If needed, replace DPS or pressure sensing hose and go to "Verification of Vehicle Repair".
FLB -320 FUEL SYSTEM

NO

▶ Go to "2. Monitor DPS signal waveform" as follows.

2. Monitor DPS signal waveform

1) IG KEY "ON", ENGINE "OFF"

2) Connect DPS connector.

3) Connect oscilloscope to DPS connector terminal 2.

4) After warming engine up, monitor the waveform at idle and during acceleration.

Specification : Refer to "Signal Waveform ＆ Data" of "General Information".

Fig.1 Fig.2
SFDF27534L

Fig1). This is the signal waveform of DPS at idle state. When CPF is new, 1.0~1.2V is outputted normally.
Fig2). This is the waveform of DPS as accelerating.

NOTE
As accelerating, DPS signal output voltage does not vary too much. Even when accelerator pedal is fully depressed,
the signal voltage fluctuates just a little bit like "Fig. 2". However, the more CPF is used, the more waveform fluctuates.

5) Is DPS signal waveform is similar to the waveform of "Signal Waveform ＆ Data"?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace DPS and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E93D7E36

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.
DTC TROUBLESHOOTING PROCEDURES FLB -321

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -322 FUEL SYSTEM

DTC P0472 EXHAUST PRESSURE SENSOR "A" CIRCUIT LOW

COMPONENT LOCATION E2ABB385

Refer to DTC P0471.

GENERAL DESCRIPTION E7193D23

Refer to DTC P0471.

DTC DESCRIPTION E7D41B40

P0472 is set when the voltage below 0.85V - mimimum output voltage of DPS - is detected for more than 0.6 sec.. This
code is due to open in power circuit or short to ground in signal circuit.

DTC DETECTING CONDITION EC8D987C

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● When output voltage is below the minimum

value (below 0.85V) ● DPS Wiring
● DPS component
Diagnostic Time ● 0.6 sec. ● Reversly connected DPS hose line
Fuel Cut NO ● Clogged DPS
● Clogged CPF inlet section
EGR Off NO
Fail Safe ● Engine check lamp
Fuel Limit NO blinks.
Check
BLINK
Lamp

SPECIFICATION E8448980

Refer to DTC P0471.

DIAGNOSTIC CIRCUIT DIAGRAM E5E5C4E0

Refer to DTC P0471.

SIGNAL WAVEFORM AND DATA E158A02D

Refer to DTC P0471.

MONITOR SCANTOOL DATA E7228DDC

Refer to DTC P0471.

TERMINAL AND CONNECTOR INSPECTION E0A962AB

Refer to DTC P0471.

DTC TROUBLESHOOTING PROCEDURES FLB -323

POWER CIRCUIT INSPECTION E87630F2

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect DPS connector.

3. IG KEY "ON"

4. Measure the voltage between power supply terminal of DPS harness connector and chassis ground.

Specification : 4.8V~5.1V

5. Is the measured voltage within the specification?

YES

▶ Go to "Signal Circuit Inspection".

NO

▶ Repair open in power circuit and go to "Verification of Vehicle Repair".

SIGNAL CIRCUIT INSPECTION EA8D1CCF

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect DPS connector.

3) IG KEY "ON".

4) Measure the voltage between signal terminal of DPS harness connector and chassis ground.

Specification : 4.8V~5.1V

5) the measured voltage within the specification?

YES

▶ Go to "Component Inspectiont".

NO

▶ Repair short to ground in signal circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION EDF11A0B

1. DPS visual inspection

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect DPS connector.

3) Check DPS terminals for corrosion and contamination.

4) Check (1)connecting condition of DPS and pressure sensing hose, (2)exhaust gas pressure leakate, (3)miss
connection of pressure sensing hose (reverse connection) is detected.
FLB -324 FUEL SYSTEM

5) Is DPS related problem detected?

YES

▶ If needed, replace DPS or pressure sensing hose and go to "Verification of Vehicle Repair".

NO

▶ Go to "2. Monitor DPS signal waveform" as follows.

2. Monitor DPS signal waveform

1) IG KEY "ON", ENGINE "OFF"

2) Connect DPS connector.

3) Connect oscilloscope to DPS connector terminal 2.

4) After warming engine up, monitor the waveform at idle and during acceleration.

Specification : Refer to "Signal Waveform ＆ Data" of "General Information".

Fig.1 Fig.2
SFDF27534L

Fig1). This is the signal waveform of DPS at idle state. When CPF is new, 1.0~1.2V is outputted normally.
Fig2). This is the waveform of DPS as accelerating.

NOTE
As accelerating, DPS signal output voltage does not vary too much. Even when accelerator pedal is fully depressed,
the signal voltage fluctuates just a little bit like "Fig. 2". However, the more CPF is used, the more waveform fluctuates.

5) Is DPS signal waveform is similar to the waveform of "Signal Waveform ＆ Data"?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace DPS and go to "Verification of Vehicle Repair".

DTC TROUBLESHOOTING PROCEDURES FLB -325

VERIFICATION OF VEHICLE REPAIR E92B6DFC

Refer to DTC P0471.

FLB -326 FUEL SYSTEM

DTC P0473 EXHAUST PRESSURE SENSOR "A" CIRCUIT HIGH

COMPONENT LOCATION ECC6CF79

Refer to DTC P0471.

GENERAL DESCRIPTION E44AC283

Refer to DTC P0471.

DTC DESCRIPTION E2ED2C87

P0473 is set when the voltage above 4.72V - maximum output voltage of DPS - is detected for more than 0.6 sec.. or
measured Differential pressure is above 500 hPa - the upper limiting value - for more than 1 sec.. This code is due to 1)
short beween power and signal circuit or 2) short to battery in signal circuit or 3) short to ground in ground circuit.

DTC DETECTING CONDITION EB142489

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

● When output signal is above the maximum

Threshold Value value( above 4.72V ) - 0.6sec
● DPS Wiring
● When differential pressure is above
● DPS component
500 hPa - 1.0 sec
● Reversly connected DPS hose line
Diagnostic Time ● Refer to Threshold Value ● Clogged DPS
● Clogged CPF inlet section
Fuel Cut NO
● Clogged CPF
EGR Off NO
Fail Safe ● Engine check lamp
Fuel Limit NO blinks.
Check
BLINK
Lamp

SPECIFICATION ED4FC7E2

Refer to DTC P0471.

DIAGNOSTIC CIRCUIT DIAGRAM EFCEEDD0

Refer to DTC P0471.

SIGNAL WAVEFORM AND DATA EB627E63

Refer to DTC P0471.

MONITOR SCANTOOL DATA E4D0E168

Refer to DTC P0471.

DTC TROUBLESHOOTING PROCEDURES FLB -327

TERMINAL AND CONNECTOR INSPECTION EB5CF778

Refer to DTC P0471.

POWER CIRCUIT INSPECTION EE249414

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect DPS connector.

3. IG KEY "ON"

4. Measure the voltage between power supply terminal of DPS harness connector and chassis ground.

Specification : 4.8V~5.1V

5. Is the measured voltage within the specification?

YES

▶ Go to "Signal Circuit Inspection".

NO

▶ Repair open in power circuit and go to "Verification of Vehicle Repair".

SIGNAL CIRCUIT INSPECTION EB20DF72

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect DPS connector.

3) IG KEY "ON"

4) Measure the voltage between signal terminal of DPS harness connector and chassis ground.

Specification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Go to "2. Check open in signal circuit" as follows.

2. Check open in signal circuit

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect DPS connector and ECM connector.

3) Measure the resistance between signal terminal of DPS harness connector and DPS signal terminal of ECM
harness connector.
FLB -328 FUEL SYSTEM

Specification : Continuity ( below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "3. Check short to battery in signal circuit" as follows.

NO

▶ Repair open in DPS signal circuit and go to "Verification of Vehicle Repair".

3. Check short to battery in signal circuit

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect DPS connector and ECM connector.

3) IG KEY "ON"

4) Measure the voltage between signal terminal of DPS harness connector and chassis ground.

Specification : 0.0V~0.1V

5) Is abnormal voltage detected in the circuit with both connector disconnected?

YES

▶ Repair short to battery in signal circuit and go to "Verification of Vehicle Repair".

NO

▶ Go to "Ground Circuit Inspectiont".

GROUND CIRCUIT INSPECTION E18C31F6

1. IG KEY "OFF", ENGINE "OFF"

2. Disconnect DPS connector.

3. IG KEY "ON"

4. Measure the voltage between signal terminal of DPS harness connector and chassis ground. [ TEST "A" ]

5. Measure the voltage between signal terminal and ground terminal of DPS harness connector. [ TEST "B" ]
( Signal terminal : Check + prove , Ground terminal : Check - prove )

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6. Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO
DTC TROUBLESHOOTING PROCEDURES FLB -329

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION ED9219F5

1. DPS visual inspection

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect DPS connector.

3) Check DPS terminals for corrosion and contamination.

4) Check (1)connecting condition of DPS and pressure sensing hose, (2)exhaust gas pressure leakate, (3)miss
connection of pressure sensing hose (reverse connection) is detected.

5) Is DPS related problem detected?

YES

▶ If needed, replace DPS or pressure sensing hose and go to "Verification of Vehicle Repair".

NO

▶ Go to "2. Monitor DPS signal waveform" as follows.

2. Monitor DPS signal waveform

1) IG KEY "ON", ENGINE "OFF"

2) Connect DPS connector.

3) Connect oscilloscope to DPS connector terminal 2.

4) After warming engine up, monitor the waveform at idle and during acceleration.

Specification : Refer to "Signal Waveform ＆ Data" of "General Information".

Fig.1 Fig.2
SFDF27534L

Fig1). This is the signal waveform of DPS at idle state. When CPF is new, 1.0~1.2V is outputted normally.
FLB -330 FUEL SYSTEM

Fig2). This is the waveform of DPS as accelerating.

NOTE
As accelerating, DPS signal output voltage does not vary too much. Even when accelerator pedal is fully depressed,
the signal voltage fluctuates just a little bit like "Fig. 2". However, the more CPF is used, the more waveform fluctuates.

5) Is DPS signal waveform is similar to the waveform of "Signal Waveform ＆ Data"?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace DPS and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E26E7E1C

Refer to DTC P0471.

DTC TROUBLESHOOTING PROCEDURES FLB -331

DTC P0489 EXHAUST GAS RECIRCULATION CONTROL CIRCUIT LOW

COMPONENT LOCATION E001431F

EEGR

CMPS

SFDF28311L

GENERAL DESCRIPTION EE04F5CA

Receiving ECM signal, linear solenoid type electronic EGR actuator operates Electric EGR control valve directly. ECM
performs EGR system feed back control with the information of measured mass air flow (The role of MAFS in diesel engine
is different from gasoline engine. Fuel injection quantity is decided by MAFS signal in gasoline engine.)
When EGR gas(contains no oxygen) flowing into combustion chamber increases, the air passing through AFS(contains
oxygen) decreases. Thus, with the output signal change of AFS accompanied by Electric EGR control valve actuation,
ECM determine the amount of recirculated EGR gas quantity.

NOTE
NOx is produced from the reaction of nitrogen and oxygen.
Controlling EGR gas(contains no oxyger) which is recirculated to combustion chamber, if least intake air required for
complete combustion flows into combustion chamber, NOx decreases because there is no supplementary oxygen to
react with nitrogen.

DTC DESCRIPTION E690C699

P0489 is set when ‘ 0’ A is detected in Electric EGR control valve circuit for more than 0.5 sec.. This code is due to
open or short to ground in Electric EGR control valve circuit or internal open in Electric EGR control valve component.
FLB -332 FUEL SYSTEM

DTC DETECTING CONDITION E9922559

Item Detecting Condition Possible Cause

DTC Strategy ● Signal monitoring
Enable Conditions ● Engine run
Threshold Value ● short to GND, wiring open
Diagnostic Time ● 500ms ● Electric EGR control valve circuit
● Electric EGR control valve
Fuel Cut NO
component
EGR Off YES
Fail Safe Fuel Limit NO
Check
NO
Lamp

SPECIFICATION E25E5E6B

Electric EGR control valve Electric EGR control valve Electric EGR control valve
component resistance operating Hz operating duty

14.7 ~ 16.1Ω (20 C) 142Hz 5%(closed)~39%(opened)

DTC TROUBLESHOOTING PROCEDURES FLB -333

DIAGNOSTIC CIRCUIT DIAGRAM EF65A409

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.

Main Relay
"ON" Input

E/R JUNCTION BOX

<EGR>

2 1

EGR Actuator
1. EGR Actuator
2. Power EGR

<ECM>

60 59 58
* * * 53 37* * 50 4934 33* 47 3146
56
44 43 42 41 40
* ** * * *
30 28 27 26 23 20 19 17 16
* ** ** *
* * 13 12 * * * 8 7 6 * 4 * 2 1

59. EGR Actuator

SFDF27605L

SIGNAL WAVEFORM AND DATA EA054392

Fig.1 Fig.2
SFDF27537L
FLB -334 FUEL SYSTEM

Fig.1) Approx. 6% duty signal waveform of Electric EGR control valve (with EEGR valve closed)
Fig.2) Approx. 40% duty signal waveform of Electric EGR control valve(with EEGR valve opened)

NOTE
The output of approx. 6% duty is mainly for the diagnosis of Electric EGR control valve circuit than actuating EEGR.

MONITOR SCANTOOL DATA EB82E558

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Monitor "AIR MASS PERCYLINDER" parameter on the Scantool.

Specification :
When Electric EGR control valve does not operate 6% duty) at idle : 340mg/st ± 50 mg/st
When Electric EGR control valve operates(Approx. 50% duty) at idle : 200ms/st ± 50 mg/st

Fig.1 Fig.2
SFDF27508L

Fig.1) Check if "AIR MASS PERCYLINDER"l is 340mg/st ± 50mg/st without EEGR operation at warm idle (Electric
EGR control valve 6% duty)
Fig.2) Check if "AIR MASS PERCYLINDER"l is 200mg/st ± 50mg/st with EEGR operation at warm idle (Electric EGR
control valve approx. 50% duty)
※ Electric EGR control valve operates as decelerating after rapid acceleration when idle EEGR does not operate,
Electric EGR control valve operating duty decreases as time goes by. This controlling process lasts for about 1 min.
and EElectric EGR control valve turns "OFF" (duty 6% ) after 1 min..

TERMINAL AND CONNECTOR INSPECTION E4DF5E02

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.
DTC TROUBLESHOOTING PROCEDURES FLB -335

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power Circuit Inspection".

POWER CIRCUIT INSPECTION EDCC91BC

1. Check power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Electric EGR control valve connector

3) IG KEY "ON".

4) Measure the voltage between power terminal of EGR actuator harness connector and chassis ground.

Secification : 11.5V~13.0V

5) Is the measured voltage within the specification?

YES

▶ Go to "Control Circuit Inspection".

NO

▶ Repair INJ FUSE in E/R FUSE ＆ RELAY BOX and related circuit and go to "Verification of Vehicle Repair".

CONTROL CIRCUIT INSPECTION EE0BAFCC

1. Check control circuit monitoring voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Electric EGR control valve connector.

3) IG KEY "ON".

4) Measure the voltage between control terminal of EGR actuator harness connector and chassis ground.

Specification : 3.2V~3.7V

5) Is the measured voltage within the specification?

FLB -336 FUEL SYSTEM

YES

▶ Go to "Component Inspection".

NO

▶ When voltage is not detected : Go to "2. Check open in control circuit" as follows.
▶ When high voltage is detected : Repair short to battery and go to "Verification of Vehicle Repair".

2. Check open in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Electric EGR control valve connector and ECM connector

3) Check continuity between control terminal of EGR actuator harness connector and ECM harness connector.

Specification : Continuity ( below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground and go to "Verification of Vehicle Repair".

NO

▶ Repair open in control circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E00E7876

1. Check Electric EGR control valve component resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Electric EGR control valve.

3) Measure the resistance between power and control terminal of EGR actuator connector (component side).

Secification : 14.7 ~ 16.1Ω (20 C)

4) Is EElectric EGR control valve component resistance within the specification?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace EElectric EGR control valve and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E46AF98D

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.
DTC TROUBLESHOOTING PROCEDURES FLB -337

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -338 FUEL SYSTEM

DTC P0490 EXHAUST GAS RECIRCULATION CONTROL CIRCUIT HIGH

COMPONENT LOCATION E4D738AF

Refer to DTC P0489.

GENERAL DESCRIPTION E1E01DF8

Refer to DTC P0489.

DTC DESCRIPTION EFF87EC0

P0490 is set when excessive current is detected in Electric EGR control valve circuit for more than 0.5 sec.. This code is
due to short to battery in Electric EGR control valve control circuit or internal short in Electric EGR control valve compo-
nent.

DTC DETECTING CONDITION E810FF52

Item Detecting Condition Possible Cause

DTC Strategy ● Signal monitoring
Enable Conditions ● Engine run
Threshold Value ● Short to battery
Diagnostic Time ● 500ms ● Electric EGR control valve circuit
● Electric EGR control valve
Fuel Cut NO
component
EGR Off YES
Fail Safe Fuel Limit NO
Check
NO
Lamp

SPECIFICATION EF26B460

Refer to DTC P0489.

DIAGNOSTIC CIRCUIT DIAGRAM E714B7CB

Refer to DTC P0489.

SIGNAL WAVEFORM AND DATA E47388E4

Refer to DTC P0489.

MONITOR SCANTOOL DATA E31561F7

Refer to DTC P0489.

TERMINAL AND CONNECTOR INSPECTION ECFF81D8

Refer to DTC P0489.

DTC TROUBLESHOOTING PROCEDURES FLB -339

POWER CIRCUIT INSPECTION E3EE4197

1. Check power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Electric EGR control valve connector

3) IG KEY "ON".

4) Measure the voltage between power terminal of EGR actuator harness connector and chassis ground.

Secification : 11.5V~13.0V

5) Is the measured voltage within the specification?

YES

▶ Go to "Control Circuit Inspection".

NO

▶ Repair INJ FUSE in E/R FUSE ＆ RELAY BOX and related circuit and go to "Verification of Vehicle Repair".

CONTROL CIRCUIT INSPECTION E211AD47

1. Check control circuit monitoring voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Electric EGR control valve connector.

3) IG KEY "ON".

4) Measure the voltage between control terminal of EGR actuator harness connector and chassis ground.

Specification : 3.2V~3.7V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ When voltage is not detected : Go to "2. Check open in control circuit" as follows.
▶ When high voltage is detected : Repair short to battery and go to "Verification of Vehicle Repair".

2. Check open in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Electric EGR control valve connector and ECM connector

3) Check continuity between control terminal of EGR actuator harness connector and ECM harness connector.

Specification : Continuity ( below 1.0Ω )

FLB -340 FUEL SYSTEM

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground and go to "Verification of Vehicle Repair".

NO

▶ Repair open in control circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E449359A

1. Check Electric EGR control valve component resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Electric EGR control valve.

3) Measure the resistance between power and control terminal of EGR actuator connector (component side).

Secification : 14.7 ~ 16.1Ω (20 C)

4) Is EElectric EGR control valve component resistance within the specification?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace EElectric EGR control valve and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E32ECE27

Refer to DTC P0489.

DTC TROUBLESHOOTING PROCEDURES FLB -341

DTC P0501 VEHICLE SPEED SENSOR A RANGE/PERFORMANCE

GENERAL DESCRIPTION E36E5243

Vehicle Speed Sensor(VSS) is hall sensor type and senses the rotating speed of differential gear mounted on transaxle.
Comparing engine speed with vehicle speed calculated based on vehicle speed sensor signal, ECM recognizes engaged
gear. And based on the information about engaged gear, ECM performs optimum fuel injection quantity correction.
VSS signal is also used in speed meter of cluster, aircon control module, BCM, etc.

DTC DESCRIPTION E63CB605

P0501 is set when 1)vehicle speed below 13.8Km/h is detected for more than 1 sec. at above 4000RPM and above 38.5
cc of fuel injection quantity or 2)above 240Kph is detected for more than 0.5 sec.

DTC DETECTING CONDITION E9F6DDB6

Item Detecting Condition Possible Cause

DTC Strategy ● Signal monitoring
Enable Conditions ● During driving

● Vehicle speed calculated by ECM is above

240Kph for more than 0.5 sec.
Threshold Value ● When vehicle speed below 13.8Km/h is detected
for more than 1.0 sec. at above 4000RPM and
above 38.5mcc of fuel injection quantity.
Diagnostic Time ● Refer to threshold Value ● Vehicle speed sensor circuit
● Vehicle speed sensor component
Fuel Cut NO ● Clutch error monitoring
EGR Off NO inhibited
● Cruise control
Fuel Limit NO deactivated (for Cruise
Fail Safe control option applied
vehicle)
Check
NO ● Idle correction
Lamp
deactivated at low battery
voltage

SPECIFICATION E2675806

Sensing Type LOW Signal Voltage HIGH Signal Voltage Signal Duty
Hall sensor type Below 1.5V Above 3.5V 50±5%
FLB -342 FUEL SYSTEM

DIAGNOSTIC CIRCUIT DIAGRAM EC962DE2

I/P JUNCTION BOX ECM

IG SW
ON/START Input
- +
BATT.

Vehicle Speed Input

<VSS>
HALL IC
INSTRUMENT CLUSTER

3 2 1

VEHICLE SPEED SENSOR

Vehicle Speed Input

1. VSS ground
2. VSS power
3. Vehicle Speed Output

<ECM>
<INSTRUMENT CLUSTER>

94 93 92 90 89
*
72 71 70 69 68 * 87 86 * 84 83 * 81 80 79 * 77 * 75 * * 6 5
* * 65 64 * * * * * * 57 56 * 54 * * 51 4 3 12 11
* 9 8 7 6 5 4 3
**
* 27* 48 47
28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1 24 23 22 21 20 19 18 17
* 15 * 13
* 25 * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7
19. Vehicle Speed Input
75. Vehicle Speed Input

SFDF27607L

SIGNAL WAVEFORM AND DATA EE3652F5

Fig.1
SFDF27538L
DTC TROUBLESHOOTING PROCEDURES FLB -343

Fig.1) This is the signal waveform of vehicle speed sensor. Digital waveform, LOW 0.8V, HIGH : 10V with 50% duty is
outputted.
ECM detects vehicle speed, sensing this ON-OFF period (Hz).

MONITOR SCANTOOL DATA E90A0232

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Monitor "VEHICLE SPEED SENSOR " parameter on the Scantool.

Specification : Current vehicle speed is displayed.

Fig.1
SFDF27539L

Fig.1) Check if current vehicle speed is same as vehicle speed displayed on the Scantool.

TERMINAL AND CONNECTOR INSPECTION E05822B6

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES
FLB -344 FUEL SYSTEM

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ with M/T : Go to "Power Circuit Inspection".

with A/T : Go to "Signal Circuit Inspection".

POWER CIRCUIT INSPECTION EF78D91C

1. Check power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Vehicle Speed Sensor connector.

3) IG KEY "ON".

4) Measure the voltage between signla terminal of VSS harness connector and chassis ground.

Secification : 11.5V~13.0V

5) Is the measured voltage within the specification?

YES

▶ Go to "Signal Circuit Inspection".

NO

▶ Repair poor connection or open in joint connector and go to "Verification of Vehicle Repair".

SIGNAL CIRCUIT INSPECTION E4A8BDEB

1. Check signal circuit voltage at sensor side

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect VSS connector.

3) IG KEY "ON".

4) Measure the voltage between signal terminal of ECM harness connector and chassis ground.

Specification : 8.0V~11.5V

5) Is the measured voltage within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Repair poor connection or open in signal terminal of ECM harness connector and go to "Verification of Vehicle
Repair".
DTC TROUBLESHOOTING PROCEDURES FLB -345

GROUND CIRCUIT INSPECTION E861FD8E

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect VSS connector.

3. IG KEY "ON".

4. Measure the voltage between signal terminal of VSS harness connector and chassis ground. [ TEST "A" ]

5. Measure the voltage between signal terminal and ground terminal of VSS harness connector. [ TEST "B" ]
( Signal terminal : Check + prove , Ground terminal : Check - prove )

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6. Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION EA87AEF4

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect VSS connector.

3. Disconnect VSS and Driven gear assy′ .

4. Check rotating state of VSS driven gear.

5. Connect VSS connector and IG KEY "ON".

6. Rotate Driven gear with hand.

Specification : Vehicle Speed Signal generates.

7. Does vehicle speed signal generate?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace vehicle speed sensor and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E250400B

After a repair, it is essential to verify that the fault is corrected.

FLB -346 FUEL SYSTEM

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

DTC TROUBLESHOOTING PROCEDURES FLB -347

DTC P0504 BRAKE SWITCH "A" / "B" CORRELATION

GENERAL DESCRIPTION EE13CCFB

Brake switch is connected to brake pedal and transmits brake operating state to ECM.
When the output signal of APS is higher than what driver intended during driving (e.g. short to high voltage line in APS
circuit, false signal ), driver depresses brake pedal.
Like this, if driver′ s decelerating intension is transmitted to ECM (break pedal depressed)when APS output voltage is
high, ECM recognizes APS trouble and Limp Home mode is activated.
At Limp Home mode, engine speed is fixed at 1200RPM and engine power generation is limitted.
Even at Limp home mode, if correct APS signal is detected, Limp Home mode is deactivated.
Brake switch, which monitors proper operation of APS, is devided 1 and 2 for the fidelity of brake switch.

DTC DESCRIPTION EAD92FB0

When brake switch operates correctly, switch 1 is OFF and switch 2 is ON when releasing brake pedal, while switch 1 is
ON and switch 2 is OFF when depressing brake pedal. thus when the signal from a switch is different from the other′ s,
brake switch is in good condition. When the signal from a switch is same as the other′ s, brake switch is fault.

DTC DETECTING CONDITION EC4B92E4

Item Detecting Condition Possible Cause

DTC Strategy ● Signal monitoring
Enable Conditions ● IG KEY "ON"
Threshold Value ● Wiring open
Diagnostic Time ● 100 sec. ● Brake switch component
● Abnormal brake pedal height
Fuel Cut NO
● Brake switch circuit
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp

SPECIFICATION EF13BCDA

Sensing Type LOW Signal Voltage HIGH Signal Voltage Signal Duty
Hall sensor type Below 1.5V Above 3.5V 50±5%
FLB -348 FUEL SYSTEM

DIAGNOSTIC CIRCUIT DIAGRAM E9CA91E1

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.
Main Relay
"ON" Input

E/R JUNCTION BOX

Redundant Brake
Switch
Brake Switch Signal

STOP LAMP SWITCH

<STOP LAMP SWITCH>

<ECM>

94 93 92 90 89
2 1 *
72 71 70 69 68 * 87 86 * 84 83 * 81 80 79 * 77 * 75 * * 6 5

4 3
* * 65 64 * * * * * * 57 56 * 54 * * 51 4 3

* 27* 48 47
28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1
1. Brake Switch Signal * 25 * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7
2. Power from Battery
3. Power from Main Relay 38. Brake Switch Signal
4. Redundant Brake Switch 80. Redundant Brake Switch

SFDF27608L
DTC TROUBLESHOOTING PROCEDURES FLB -349

SIGNAL WAVEFORM AND DATA E4EA3BA4

brake signal 2

brake pedal depressed range

brake signal 1

Fig.1
SFDF27540L

Fig.1) The waveform of brake signal 1 and 2 are measured simultaneously. Both waveforms are symmetrical.

MONITOR SCANTOOL DATA E8313B0A

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Monitor "BRAKE SWITCH" and "REDUNDANT BRAKE SWITCH" parameter on the Scantool.

Specification : When brake pedal is released : "BRAKE SWITCH" and "REDUNDANT BRAKE SWITCH" : OFF
When brake pedal is depressed : "BRAKE SWITCH" and "REDUNDANT BRAKE SWITCH" : ON

Fig.1 Fig.2
SFDF27541L

Fig.1) Data when brake switch(brake pedal) is deactivated(released) : "BRAKE SWITCH" and "REDUNDANT BRAKE
SWITCH" : OFF
FLB -350 FUEL SYSTEM

Fig.2) Data when brake switch(brake pedal) is activated(depressed) : "BRAKE SWITCH" and "REDUNDANT BRAKE
SWITCH" : ON

TERMINAL AND CONNECTOR INSPECTION E5E8F283

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power Circuit Inspection".

POWER CIRCUIT INSPECTION EE2C22B5

1. Check brake switch 1 "HOT AT ALL TIMES"

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect brake switch connector.

3) Measure the voltage between power input terminal of brake switch 1 harness connector and chassis ground.

Secification : 11.5V~13.0V

4) Is the measured voltage within the specification?

YES

▶ Go to "2.Check brake switch 2 main relay power" as follows.

NO

▶ Repair STOP FUSE in I/P JUNCTION BOX and related circuit and go to "Verification of Vehicle Repair".

2. Check brake switch 2 main relay power

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect brake switch connector.

DTC TROUBLESHOOTING PROCEDURES FLB -351

3) IG KEY "ON".

4) Measure the voltage between power terminal of brake switch 2 harness connector and chassis ground.

Specification : 11.5V~13.0V

5) Is the measured voltage within the specification?

YES

▶ Go to "Signal Circuit Inspection".

NO

▶ Repair SNSR1 FUSE in E/R JUNCTION BOX and related circuit and go to "Verification of Vehicle Repair".

SIGNAL CIRCUIT INSPECTION EB10E65F

1. Check brake switch signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECM connector with brake switch connector connected.

3) Measure the voltage of ECM connector terminal 38 and 80 as depressing brake pedal.

SPECIFICATION :

Brake Pedal Released Brake Pedal Depressed

Brake Switch Signal 0.0V~0.1V 11.5V~13.0V
Redundant Brake Switch 11.5V~13.0V 0.0V~0.1V

4) Is the measured voltage within the specification?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ If component has no problem after performing "Component Inspection" and go to "2. Check open in signal
circuit".

2. Check open in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect brake switch connector and ECM connector.

3) Check continuity between brake switch connector terminal 1 and ECM connector(CUD-K) terminal 38. (brake
switch 1 circuit)

4) Check continuity between brake switch connector terminal 4 and ECM connector(CUD-K) terminal 80. (brake
switch 2 circuit)

Secification : Continuity ( below 1.0Ω )

FLB -352 FUEL SYSTEM

5) Is the measured resistance within the specification?

YES

▶ Repair short in signal circuit and go to "Verification of Vehicle Repair".

NO

▶ Repair open in signal circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION EED6B4B8

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect brake switch connector.

3. Check continuity between brake switch component terminal 1and 2 as depressing brake pedal. (brake switch 1)

4. Check continuity between brake switch component terminal 3and 4 as depressing brake pedal. (brake switch 2)

SPECIFICATION :

Brake Pedal Released Brake Pedal Depressed

Brake Switch Signal Redundant Brake Switch Brake Switch Signal Redundant Brake Switch
Discontinuity Continuity Continuity Discontinuity

5. Does brake switch operate correctly?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Unless any problem is detected after checking height of brake pedal, replace brake switch component and go to
"Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR EC8409B0

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

DTC TROUBLESHOOTING PROCEDURES FLB -353

DTC P0532 A/C REFRIGERANT PRESSURE SENSOR "A" CIRCUIT LOW

INPUT

COMPONENT LOCATION E537744A

APT

SFDF28321L

GENERAL DESCRIPTION EDEDCF87

A/C pressure transducer consists of piezoelectric element and it detects aircon refrigerant pressure. Piezoeletric type is
more advantageous to obtain linear data of pressure than existing switch type. Thus, optimum control of aircon compres-
sor and fan is realized and improved fuel efficiency follows with it.

DTC DESCRIPTION E836F542

P0532 is set when the voltage below 190mV - minimum voltage of A/C pressure transducer signal - is detected for more
than 0.6 sec.. This code is due to open in power circuit or short to ground in signal circuit of A/C pressure transducer.

DTC DETECTING CONDITION EC3A5589

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● When output voltage is below the minimum

value (below 190mV)
Diagnostic Time ● 600ms ● A/C pressure transducer circuit
● A/C pressure transducer component
Fuel Cut NO
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp
FLB -354 FUEL SYSTEM

SPECIFICATION EFC29078

SFDF27542L

DIAGNOSTIC CIRCUIT DIAGRAM E6FB7267

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.
Main Relay
"ON" Input

E/R JUNCTION BOX

<A/C PRESSURE TRANSDUCER>

Ground

3 2 1 P Signal

Power
1. Ground
2. Signal A/C PRESSURE TRANSDUCER
3. Power

<ECM>

94 93 92 90 89 12. Ground
*
72 71 70 69 68 * 87 86 * 84 83 * 81 80 79 * 77 * 75 * * 6 5
* * 65 64 * * * * * * 57 56 * 54 * * 51 4 3 13. Signal
* 27* 48 47
28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1
* 25 * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7 22. Power

SFDF27609L
DTC TROUBLESHOOTING PROCEDURES FLB -355

SIGNAL WAVEFORM AND DATA E9AF23A6

A/C "ON" A/C "OFF"

Fig.1
SFDF27543L

Fig.1) Waveform of A/C pressure transducer in accordance with aircon operation.(aircon compressor operation)

NOTE
Output signal(voltage) changes in accordance with the amount of refrigerant and the change of weather. Check if
normal pressure change occurs in accordance with aircon compressor operation at normal pressure range shown in
"Specification".

MONITOR SCANTOOL DATA EB261398

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Monitor " A/C PRESSURE SENSOR " parameter on the scantool.

Specification : A/C "OFF" : 1200mV~1500mV

A/C " ON" : 1500mV~ 2400mV
FLB -356 FUEL SYSTEM

Fig.1 Fig.2
SFDF27544L

Fig.1) Data at idle and aircon "OFF", Aircon pressure sensor output voltage is 1300mV.
Fig.2) Data at idle and aircon "ON". Aircon pressure sensor output voltage increases as aircon compressor operates.

TERMINAL AND CONNECTOR INSPECTION E74BB907

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power Circuit Inspection".

POWER CIRCUIT INSPECTION E803BF42

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect A/C pressure transducer connector.

3. IG KEY "ON".

4. Measure the voltage between power terminal of A/C pressure transducer harness connetor and chassis ground.
DTC TROUBLESHOOTING PROCEDURES FLB -357

Specification : 4.8V~5.1V

5. Is the measured voltage within the specification ?

YES

▶ Go to "Signal Circuit Inspection".

NO

▶ Repair open in power circuit of A/C pressure transducer and go to "Verification of Vehicle Repair".

SIGNAL CIRCUIT INSPECTION EDBD2103

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect A/C pressure transducer connector.

3) IG KEY "ON".

4) Measure the voltage between signal terminal of A/C pressure transducer harness connetor and chassis ground.

Secification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ Repair short to ground in signal circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E8E3DC45

1. Aircon pressure sensor visual inspection

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect A/C pressure transducer connector.

3) Check if corrosion and contamination at aircon pressure sensor terminal is detected.

4) Check aircon pressure sensor connecting torque and aircon refrigerant leakage.

5) Does any problem is detected at aircon pressure sensor?

YES

▶ Replace aircon pressure sensor and go to "Verification of Vehicle Repair".

NO

▶ Go to "2. Check A/C pressure transducer waveform " as follows.

FLB -358 FUEL SYSTEM

2. Check A/C pressure transducer waveform

1) IG KEY "OFF", ENGINE "OFF".

2) Connect A/C pressure transducer connector.

3) Connect oscilloscope to A/C pressure transducer connector terminal 2.

4) Monitor aircon pressure sensor waveform at idle as turning Aircon "ON".

Specification : Refer to "Siganl waveform ＆ data"

5) Is A/C pressure transducer waveform outputted correctly?

YES

▶ Go to "Verification of Vehicle Rapair".

NO

▶ Replace A/C pressure transducer and go to "Verification of Vehicle Rapair".

VERIFICATION OF VEHICLE REPAIR EC110A08

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

DTC TROUBLESHOOTING PROCEDURES FLB -359

DTC P0533 A/C REFRIGERANT PRESSURE SENSOR "A" CIRCUIT HIGH

INPUT

COMPONENT LOCATION E0A6053A

Refer to DTC P0532.

GENERAL DESCRIPTION E0653905

Refer to DTC P0532.

DTC DESCRIPTION EF35CD87

P0533 is set when the voltage above 4700mV - maximum voltage of A/C pressure transducer signal - is detected for more
than 0.6 sec.. This code is due to open or short in signal or ground circuit of A/C pressure transducer.

DTC DETECTING CONDITION E5FAF30C

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● When output signal is above the maximum

value ( above 4700mV )
Diagnostic Time ● 600ms ● A/C pressure transducer circuit
● A/C pressure transducer component
Fuel Cut NO
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp

SPECIFICATION ED4F77D4

Refer to DTC P0532.

DIAGNOSTIC CIRCUIT DIAGRAM E3C8A600

Refer to DTC P0532.

SIGNAL WAVEFORM AND DATA EFC63731

Refer to DTC P0532.

MONITOR SCANTOOL DATA E59A22C8

Refer to DTC P0532.

FLB -360 FUEL SYSTEM

TERMINAL AND CONNECTOR INSPECTION E302314B

Refer to DTC P0532.

POWER CIRCUIT INSPECTION E9834FE8

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect A/C pressure transducer connector.

3. IG KEY "ON".

4. Measure the voltage between power terminal of A/C pressure transducer harness connetor and chassis ground.

Specification : 4.8V~5.1V

5. Is the measured voltage within the specification ?

YES

▶ Go to "Signal Circuit Inspection".

NO

▶ Repair open in power circuit of A/C pressure transducer and go to "Verification of Vehicle Repair".

SIGNAL CIRCUIT INSPECTION E60FFC3A

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect A/C pressure transducer connector.

3) IG KEY "ON".

4) Measure the voltage between signal terminal of A/C pressure transducer harness connetor and chassis ground.

Secification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Repair short to battery and go to "Verification of Vehicle Repair".

GROUND CIRCUIT INSPECTION E206C03B

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect A/C pressure transducer connector.

3. IG KEY "ON".
DTC TROUBLESHOOTING PROCEDURES FLB -361

4. Measure the voltage between power terminal of A/C pressure transducer harness connetor and chassis ground. [
TEST "A" ]

5. Measure the voltage between power terminal of A/C pressure transducer harness connector and ground terminal of
A/C pressure transducer harness connector. [ TEST "B" ]
( Power terminal : Check + prove , Ground terminal : Check - prove )

Specification : the voltage difference between TEST "A" and TEST "B" is within 200mV

6. Is the measured voltage within the specification ?

YES

▶ Go to "Component Inspection"

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E22130A5

1. Aircon pressure sensor visual inspection

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect A/C pressure transducer connector.

3) Check if corrosion and contamination at aircon pressure sensor terminal is detected.

4) Check aircon pressure sensor connecting torque and aircon refrigerant leakage.

5) Does any problem is detected at aircon pressure sensor?

YES

▶ Replace aircon pressure sensor and go to "Verification of Vehicle Repair".

NO

▶ Go to "2. Check A/C pressure transducer waveform " as follows.

2. Check A/C pressure transducer waveform

1) IG KEY "OFF", ENGINE "OFF".

2) Connect A/C pressure transducer connector.

3) Connect oscilloscope to A/C pressure transducer connector terminal 2.

4) Monitor aircon pressure sensor waveform at idle as turning Aircon "ON".

Specification : Refer to "Siganl waveform ＆ data"

5) Is A/C pressure transducer waveform outputted correctly?

YES
FLB -362 FUEL SYSTEM

▶ Go to "Verification of Vehicle Rapair".

NO

▶ Replace A/C pressure transducer and go to "Verification of Vehicle Rapair".

VERIFICATION OF VEHICLE REPAIR EDEED2CC

Refer to DTC P0532.

DTC TROUBLESHOOTING PROCEDURES FLB -363

DTC P0541 INTAKE AIR HEATER “ A” CIRCUIT LOW

COMPONENT LOCATION E7BB8D1B

Air Heater Relay

SFDF28327L

GENERAL DESCRIPTION EAD88099

Heating combustion chamber, glow plug increases fuel ignitibility and makes fuel in the foggy state easily when engine
is cold. Thus, glow plug makes engine starting easily and decreases exhaust gas produced just after turning engine on
when engine is cold.
ECM controls operation and operating duration of glow plug relay which supplies power to glow plug with ECTS signal,
battery voltage and IG KEY ON signal.
Through glow lamp in cluster, ECM let drivers know if glow plug is ON.

DTC DESCRIPTION EBE6F210

P0541 is set when ‘ 0A’ is detected in Air Heater relay control circuit for more than 1 sec.. This code is due to open or
short to ground in Air Heater relay control circuit or internal open in relay component.

DTC DETECTING CONDITION EA90908B

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"
Threshold Value ● Short to GND, Wiring open
Diagnostic Time ● 1.0 sec. ● Air Heater relay circuit
Fuel Cut NO ● Air Heater relay component
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp
FLB -364 FUEL SYSTEM

DIAGNOSTIC CIRCUIT DIAGRAM E9E81C39

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.
Main Relay
"ON" Input

E/R JUNCTION BOX

Air Heater Relay

Control

AIR HEATER RELAY

AIR HEATER

<AIR HEATER RELAY>

1 <ECM>

3 2
94 93 92 90 89
4 *
72 71 70 69 68 67 * 87 86 * 84 83 * 81 80 79 * 77 * 75 * * 6 5
* 65 64 * * * * * * 57 56 * 54 * * 51 4 3

1. Air Heater relay power * 27* 48 47

28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1
2. Air Heater power(Output) * 25 * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7
3. Air Heater power(Input)
4. Air Heater Relay Control 67. Air Heater Relay Control

SFDF27610L

MONITOR SCANTOOL DATA E2B66EB1

1. Connect scantool to Data Link Cable (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Select "ACTUATION TEST" parameter on the scantool.

Specification : Air Heater relay operate by turns per 1 sec. repeatedly.

DTC TROUBLESHOOTING PROCEDURES FLB -365

Fig.1
SFDF27591L

Fig.1) Checking Air Heater relay operation and power supply to Air Heater using "ACTUATION TEST" on Scantool is
convenient.

TERMINAL AND CONNECTOR INSPECTION E5F6FA85

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power Circuit Inspection".

POWER CIRCUIT INSPECTION E1D05F41

1. Check power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Air Heater relay.

3) Measure the voltage between power terminal of Air Heater relay and chassis ground.
FLB -366 FUEL SYSTEM

Secification : 11.5V~13.0V

4) Is the measured voltage within the specification?

YES

▶ Go to "2. Check IG KEY "ON" power circuit" .

NO

▶ Repair problems of A/C FUSE in E/R JUNCTION BOX and related circuit and go to "Verification of Vehicle
Repair".

2. Check IG KEY "ON" power circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Air Heater relay

3) IG KEY "ON".

4) Measure the voltage between coil power terminal of Air Heater relay and chassis ground.

specification : 11.5V~13.0V

5) Is the measured voltage within the specification?

YES

▶ Go to "Control Circuit Inspection".

NO

▶ Repair problems of INJ fuse in E/R JUNCTION BOX and related circuit and go to "Verification of Vehicle
Repair".

CONTROL CIRCUIT INSPECTION EC1E27E1

1. Check monitoring voltage in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Air Heater relay

3) IG KEY "ON".

4) Measure the voltage between coil control terminal of Air Heater relay and chassis ground.

Specification : 3.2V~3.7V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO
DTC TROUBLESHOOTING PROCEDURES FLB -367

▶ When voltage is not detected : Go to "2. Check open in control circuit" as follows.
▶ When high voltage is detected : Repair short to battery and go to "Verification of Vehicle Repair".

2. Check open in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Air Heater relay and ECM connector .

3) Check continuity between coil control terminal of Air Heater relay and ECM harness connector.

Specification : Continuity ( below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground and go to "Verification of Vehicle Repair".

NO

▶ Repair open in control circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION EA426B88

1. Check A/C relay component resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Air Heater relay.

3) Measure the resistance between coil power terminal and coil control terminal of Air Heater relay coil.

Secification : 85±5 Ω (20 C)

4) Is the measured resistance within the specification?

YES

▶ Go to "2. Check Air Heater relay component operation" as follows.

NO

▶ ReplaceAir Heater relay and go to "Verification of Vehicle Repair".

2. Check A/C relay component operation

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Air Heater relay.

3) Supplies random B+ and ground to coil sides of Air Heater relay.

4) Check continuity between power input terminal and power output terminal of Air Heater relay.

specification : When power is supplied : Continuity ( below 1.0Ω )

When power is not supplied : Discontinuity ( Infinite Ω )
FLB -368 FUEL SYSTEM

5) Is the continuity test within the specification?

YES

▶ go to "Verification of Vehicle Repair".

NO

▶ Replace Air Heater relay and go to "Verification of Vehicle Repair".

※ Repeat this process 2~3 times.

VERIFICATION OF VEHICLE REPAIR E0945D86

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

DTC TROUBLESHOOTING PROCEDURES FLB -369

DTC P0542 INTAKE AIR HEATER “ A” CIRCUIT HIGH

COMPONENT LOCATION E9E30BA1

Refer to DTC P0541.

GENERAL DESCRIPTION EA85F3AF

Refer to DTC P0541.

DTC DESCRIPTION E3453F93

P0542 is set when excessive current is detected in Air Heater relay control circuit for more than 1 sec.. This code is due
to short to battery in Air Heater relay control circuit or internal short in relay component.

DTC DETECTING CONDITION E54BD3A2

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"
Threshold Value ● Short to battery
Diagnostic Time ● 1.0 sec. ● Air Heater relay circuit
Fuel Cut NO ● Air Heater relay component
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp

DIAGNOSTIC CIRCUIT DIAGRAM E0529F09

Refer to DTC P0541.

MONITOR SCANTOOL DATA E47E3DE9

Refer to DTC P0541.

TERMINAL AND CONNECTOR INSPECTION E6FB5463

Refer to DTC P0541.

POWER CIRCUIT INSPECTION ED50D76E

1. Check power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Air Heater relay.

3) Measure the voltage between power terminal of Air Heater relay and chassis ground.
FLB -370 FUEL SYSTEM

Secification : 11.5V~13.0V

4) Is the measured voltage within the specification?

YES

▶ Go to "2. Check IG KEY "ON" power circuit" .

NO

▶ Repair problems of A/C FUSE in E/R JUNCTION BOX and related circuit and go to "Verification of Vehicle
Repair".

2. Check IG KEY "ON" power circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Air Heater relay

3) IG KEY "ON".

4) Measure the voltage between coil power terminal of Air Heater relay and chassis ground.

specification : 11.5V~13.0V

5) Is the measured voltage within the specification?

YES

▶ Go to "Control Circuit Inspection".

NO

▶ Repair problems of INJ fuse in E/R JUNCTION BOX and related circuit and go to "Verification of Vehicle
Repair".

CONTROL CIRCUIT INSPECTION E9E14638

1. Check monitoring voltage in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Air Heater relay

3) IG KEY "ON".

4) Measure the voltage between coil control terminal of Air Heater relay and chassis ground.

Specification : 3.2V~3.7V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO
DTC TROUBLESHOOTING PROCEDURES FLB -371

▶ When voltage is not detected : Go to "2. Check open in control circuit" as follows.
▶ When high voltage is detected : Repair short to battery and go to "Verification of Vehicle Repair".

2. Check open in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Air Heater relay and ECM connector .

3) Check continuity between coil control terminal of Air Heater relay and ECM harness connector.

Specification : Continuity ( below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground and go to "Verification of Vehicle Repair".

NO

▶ Repair open in control circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION EDCEEFD9

1. Check A/C relay component resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Air Heater relay.

3) Measure the resistance between coil power terminal and coil control terminal of Air Heater relay coil.

Secification : 85±5 Ω (20 C)

4) Is the measured resistance within the specification?

YES

▶ Go to "2. Check Air Heater relay component operation" as follows.

NO

▶ ReplaceAir Heater relay and go to "Verification of Vehicle Repair".

2. Check A/C relay component operation

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Air Heater relay.

3) Supplies random B+ and ground to coil sides of Air Heater relay.

4) Check continuity between power input terminal and power output terminal of Air Heater relay.

specification : When power is supplied : Continuity ( below 1.0Ω )

When power is not supplied : Discontinuity ( Infinite Ω )
FLB -372 FUEL SYSTEM

5) Is the continuity test within the specification?

YES

▶ go to "Verification of Vehicle Repair".

NO

▶ Replace Air Heater relay and go to "Verification of Vehicle Repair".

※ Repeat this process 2~3 times.

VERIFICATION OF VEHICLE REPAIR EA02C217

Refer to DTC P0541.

DTC TROUBLESHOOTING PROCEDURES FLB -373

DTC P0545 EXHAUST GAS TEMPERATURE SENSOR CIRCUIT LOW (BANK

1 SENSOR 1)

COMPONENT LOCATION E180D275

EGTS #1

SFDF28317L

GENERAL DESCRIPTION E8BC59DA

In EURO4 diesel engine with CPF, injection is devided into 2 pilot, 1 main, 2 post injections. Among these injections, pilot
and main injections are for the operation of engine, however post injections are for CPF regeneration. Only in activating
condition of CPF regeneration during driving, post injection starts. 1st post injection happens at the end of combustion
cycle then, injected fuel is used to raise exhaust temperature. that temp. is sensed at T3 exhaust tempt. sensor which
is ahead of Turbo charger. 2nd post injection happens at exhaust cycle then, injected fuel is also used to raise exhaust
temperature. that temp. is sensed T5 exhaust tempt. sensor which is between Oxydation catalyst and CPF. The reason
of raising exhaust tempt. is because exhaust tempt. in diesel engine is too low for CPF regeneration. The optimum
tempt. for CPF regeneration is 550~600 C thus, the goal of post injection is raise exhaust tempt. to that range of tempt..
However if exhaust tempt. is too high, turbo charger or CPF are likely to be damaged. Therefore if tempt. measured at
each sensor is out of permittable value(specification), ECM deactivates CPF regeneration.

DTC DESCRIPTION EC28BBA6

P0545 is set when front exhaust gas temp. sensor(T3-VGT) signal voltage is below 0.2V - the lower limit value - for more
than 0.6 sec.
FLB -374 FUEL SYSTEM

DTC DETECTING CONDITION EEB6C140

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● Signal voltage below 0.2V(Short to

ground in signal circuit)
● Exhaust gas temp. sensor(T3-VGT)
Diagnostic Time ● 0.6 sec. wiring● Exhaust gas temp.
Fuel Cut NO sensor(T3-VGT) component
EGR Off NO
Fail Safe ● Exhaust gas temp.
Fuel Limit NO fixed at 400 C
Check
OFF
Lamp

SPECIFICATION E7C5F314

RESISTANCE/TEMPERATURE CHARACTERISTICS

NEW AGED
Temp.(℃) Nominal (kΩ )
Min(kΩ ) Max(kΩ ) Min(kΩ ) Max(kΩ )
100 371 289 481 272 515
300 5.92 5.3 6.61 5.15 6.79
600 0.363 0.347 0.379 0.341 0.386
900 0.0893 0.0842 0.0949 0.0833 0.096
DTC TROUBLESHOOTING PROCEDURES FLB -375

DIAGNOSTIC CIRCUIT DIAGRAM E350F647

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.
Main Relay
"ON" Input

E/R JUNCTION BOX

<Exhaust Gas Temperature

Sensor #1>

Signal
2 1

Ground
1. Signal
2. Ground Exhaust Gas Temperature Sensor #1

<ECM>

94 93 92 90 89
*
72 71 70 69 68 * 87 86 * 84 83 * 81 80 79 * 77 * 75 * * 6 5
* * 65 64 * * * * * * 57 56 * 54 * * 51 4 3

* 27* 48 47
28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1
* 25 * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7
34. Signal
35. Ground

SFDF27611L
FLB -376 FUEL SYSTEM

SIGNAL WAVEFORM AND DATA E0DF1735

Fig.1
SFDF27545L

Fig.1) 4.8V is outputted at EGTS output signal circuit, when exhaust gas temp. is approx.150 C.
When exhaust gas temp. is 550~600 C at CPF regeneration, output voltage drops to 0.3~0.4V.

MONITOR SCANTOOL DATA EF3EEF1D

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Monitor "E/GAS TEMP. PRE VGT","E/GAS TEMP. PRE CPF" parameter on the Scantool.

Specification : Current "E/GAS TEMP." is displayed.

Fig.1 Fig.2
SFDF27546L

Fig.1) "EXHAUST GAS TEMP." at idle is shown. Monitor if abnormall difference between "Fig. 1) data" and the data
from the vehicle to test.
DTC TROUBLESHOOTING PROCEDURES FLB -377

Fig.2) The display during performing CPF regeneration after selecting "CPF SERVICE REGENERATION" mode is
shown.
Monitor if "EXHAUST GAS TEMP." varies correctly.

TERMINAL AND CONNECTOR INSPECTION EE1550AC

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Signal Circuit Inspection ".

SIGNAL CIRCUIT INSPECTION ECBDF10C

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect EGTS(T3-VGT) connector.

3) IG KEY "ON"

4) Measure the voltage between signal terminal of EGTS(T3-VGT) harness connector.

Specification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Go to "2.Check open in signal circuit" as follows.

2. Check open in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

FLB -378 FUEL SYSTEM

2) Disconnect EGTS(T3-VGT) connector and ECM connector.

3) Check the resistance between signal terminal of EGTS(T3-VGT) harness connector and EGTS signal terminal
of ECM harness connector.

Secification : Continuity (below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "3. Check short to ground in signal circuit"as follows.

NO

▶ Repair open in signal circuit and go to "Verification of Vehicle Repair".

3. Check short to ground in signal circuit

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect EGTS(T3-VGT) connector and ECM connector.

3) Check the resistance between signal terminal of EGTS(T3-VGT) harness connector and chassis ground.

Specification : Discontinuity ( Infinite Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Repair short to ground in signal circuit and go to "Verification of Vehicle Repair".

GROUND CIRCUIT INSPECTION E79FA6E6

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect EGTS(T3-VGT) connector.

3. IG KEY "ON".

4. Measure the voltage between signal terminal of EGTS(T3-VGT) harness connector and chassis ground. [ TEST "A" ]

5. Measure the voltage between signal terminal and ground terminal of EGTS(T3-VGT) harness connector. [ TEST "B"
]
( Signal terminal : Check + prove , Ground terminal : Check - prove )

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6. Is the measured voltage within the specification ?

YES
DTC TROUBLESHOOTING PROCEDURES FLB -379

▶ Go to "Component Inspection".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E28B910B

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect EGTS(T3-VGT) connector.

3. Measure the resistance between signal terminal and ground terminal of EGTS(T3-VGT) connector. (Component
side)

SPECIFICATION :

NEW AGED
Temp.(℃) Nominal (kΩ )
Min(kΩ ) Max(kΩ ) Min(kΩ ) Max(kΩ )
100 371 289 481 272 515
300 5.92 5.3 6.61 5.15 6.79
600 0.363 0.347 0.379 0.341 0.386
900 0.0893 0.0842 0.0949 0.0833 0.096

4. Is the measured resistance at certain temperature within the specified resisance range at the temperature?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace EGTS(T3-VGT) and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E0A58D80

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -380 FUEL SYSTEM

DTC P0546 EXHAUST GAS TEMPERATURE SENSOR CIRCUIT HIGH (BANK

1 SENSOR 1)

COMPONENT LOCATION EB707E0D

Refer to DTC P0545.

GENERAL DESCRIPTION EB65C4D9

Refer to DTC P0545.

DTC DESCRIPTION E6647125

P0546 is set when the Exhaust gas temperature sensor(EGTS) - VST signal is detected over maximum set tempera-
ture(890 C),- In case that exhaust gas temperature on the front side of VGT is abnormally increased -, for more than
1sec. Therefore, check component or vehicle is driven in severe driving condition.

NOTE
※ In case that real exhaust gas temperature reaches up to 890 C, engine and exhaust line(Turbo charger), CPF can
be damaged.

DTC DETECTING CONDITION E91B02CF

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"
Threshold Value ● Exhaust gas temp. exceeds 890℃(EGTS-VGT) ● Abnormal over-load (driving)
condition
Diagnostic Time ● 1.0 sec. ● Exhaust gas temp. sensor(T3-VGT)
Fuel Cut NO wiring
● Exhaust gas temp. sensor(T3-VGT)
EGR Off NO
component
Fail Safe Fuel Limit NO
Check
OFF
Lamp

SPECIFICATION E24447E5

Refer to DTC P0545.

DIAGNOSTIC CIRCUIT DIAGRAM E3E523F5

Refer to DTC P0545.

SIGNAL WAVEFORM AND DATA E3E973ED

Refer to DTC P0545.

DTC TROUBLESHOOTING PROCEDURES FLB -381

MONITOR SCANTOOL DATA E8A00FAB

Refer to DTC P0545.

TERMINAL AND CONNECTOR INSPECTION E3CEC78A

Refer to DTC P0545.

SIGNAL CIRCUIT INSPECTION ED212D4C

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect EGTS(T3-VGT) connector.

3) IG KEY "ON"

4) Measure the voltage between signal terminal of EGTS(T3-VGT) harness connector.

Specification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Go to "2.Check open in signal circuit" as follows.

2. Check open in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect EGTS(T3-VGT) connector and ECM connector.

3) Check the resistance between signal terminal of EGTS(T3-VGT) harness connector and EGTS signal terminal
of ECM harness connector.

Secification : Continuity (below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "3. Check short to ground in signal circuit"as follows.

NO

▶ Repair open in signal circuit and go to "Verification of Vehicle Repair".

3. Check short to ground in signal circuit

1) IG KEY "OFF", ENGINE "OFF"

FLB -382 FUEL SYSTEM

2) Disconnect EGTS(T3-VGT) connector and ECM connector.

3) Check the resistance between signal terminal of EGTS(T3-VGT) harness connector and chassis ground.

Specification : Discontinuity ( Infinite Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Repair short to ground in signal circuit and go to "Verification of Vehicle Repair".

GROUND CIRCUIT INSPECTION E8E3B0DC

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect EGTS(T3-VGT) connector.

3. IG KEY "ON".

4. Measure the voltage between signal terminal of EGTS(T3-VGT) harness connector and chassis ground. [ TEST "A" ]

5. Measure the voltage between signal terminal and ground terminal of EGTS(T3-VGT) harness connector. [ TEST "B"
]
( Signal terminal : Check + prove , Ground terminal : Check - prove )

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6. Is the measured voltage within the specification ?

YES

▶ Go to "Component Inspection".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION EA0B343E

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect EGTS(T3-VGT) connector.

3. Measure the resistance between signal terminal and ground terminal of EGTS(T3-VGT) connector. (Component
side)
DTC TROUBLESHOOTING PROCEDURES FLB -383

SPECIFICATION :

NEW AGED
Temp.(℃) Nominal (kΩ )
Min(kΩ ) Max(kΩ ) Min(kΩ ) Max(kΩ )
100 371 289 481 272 515
300 5.92 5.3 6.61 5.15 6.79
600 0.363 0.347 0.379 0.341 0.386
900 0.0893 0.0842 0.0949 0.0833 0.096

4. Is the measured resistance at certain temperature within the specified resisance range at the temperature?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace EGTS(T3-VGT) and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR ED7D67D0

Refer to DTC P0545.

FLB -384 FUEL SYSTEM

DTC P0562 SYSTEM VOLTAGE LOW

GENERAL DESCRIPTION E7A6F814

Normally, battery voltage fluctuates from 11.5V to 14.5V. Especially at cranking, voltage can drop to 9.8V. Therefore,
actuators which require 12V power supply meet fluctuation of power by 5V.
A little change of voltage supply can shift controlling characteristic of actuators, such as injectors, Rail pressure regulator
valve and EGR actuator, which should be controlled delicately. To correct controlling characteristic change arrised from
voltage fluctuation, ECM performs actuator operating correction according to voltage change as detecting battery voltage
change.

DTC DESCRIPTION E667F888

P0562 is set when battery voltage below 6V is detected for more than 5 sec. Check charging system.(charging circuit,
alternator component)
▶ ECM senses battery voltage as monitoring the voltages in ECM(CUD-K) connector terminal 1,3,5 which are transmitted
from main relay.

DTC DETECTING CONDITION E9B30101

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"
Threshold Value ● when battery voltage is below 6V
Diagnostic Time ● 5 sec. ● Charging circuit
Fuel Cut NO ● Alternator component
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp
DTC TROUBLESHOOTING PROCEDURES FLB -385

DIAGNOSTIC CIRCUIT DIAGRAM EC89115B

E/R JUNCTION BOX ECM

IG SW
ON/START Input

MAIN RELAY
- +
BATT. Main Relay Control

Main Relay 'ON'

Power

INSTRUMENT CLUSTER

CHARGE

I.C

GENERATOR
<GENERATOR>

2
*
2. Charge Lamp

SFDF27612L

SIGNAL WAVEFORM AND DATA EA03FECF

Fig.1
SFDF27547L
FLB -386 FUEL SYSTEM

Fig.1) This is alternator charging waveform during engine running. Check if battery voltage drops dramatically as turning
on the electrical device such as head lamp, defogger and A/C.

MONITOR SCANTOOL DATA E5F9F2E4

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Monitor "BATTERY VOLTAGE" parameter on the Scantool.

Specification : 12.5V~14.5V at idle without any load(800RPM)

Fig.1
SFDF27548L

Fig 1) "BATTERY VOLTAGE" data at idle after warming engine up.

Check if the symptoms listed below occur as checking if battery voltage drops dramatically when turning on the
electrical devices.

NOTE
※ The vehicles with the alternator of poor charging efficiency
1. Lamps are dim at idle, while lamps are bright at acceleration.
2. Intermitently RPM drops excessively or engine shut down at low RPM close to idle state at times.
3. Smooth cranking happens rarely. (Warning lamps in cluster turn dimmer excessively at cranking and poor cranking
happen.)
4. Charging lamp turns on during driving.

TERMINAL AND CONNECTOR INSPECTION EC87CB60

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.
DTC TROUBLESHOOTING PROCEDURES FLB -387

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power Circuit Inspection".

POWER CIRCUIT INSPECTION E3B87ADA

1. Check charging lamp operation

1) IG KEY "ON", ENGINE "OFF".

2) Disconnect alternator connector.

3) Measure the voltage between charging terminal of alternator harness connector and chassis ground.

Secification : Charging lamp "ON" when grounded to chassis ground.

4) Does charging lamp turn ON?

YES

▶ Go to "3.Check voltage drop of aternator B+ cable".

NO

▶ Replace lamp and go to "Verification of Vehicle Repair".

2. Check voltage drop of aternator B+ cable

1) IG KEY "ON", Turn engine "ON".

2) Measure the voltage difference between alternator B+ terminal and battery + terminal.
(connect + terminal of multimeter to alternator B+ and connect - terminal of multimeter to battery +terminal. )

Specification : Below 0.2V (below 200mV)

3) Is the measured voltage within the specification? (Is the voltage drop in alternator B+ cable normal? )

YES

▶ Go to "Component Inspection".

NO

▶ After checking corrosion and deformation of alternator B+ cable and replace it if needed and go to "Verification
of Vehicle Repair".
FLB -388 FUEL SYSTEM

COMPONENT INSPECTION E4326019

1. IG KEY "OFF", ENGINE "OFF".

2. Check belt tension which operates alternator .

3. Check battery terminal and fusible link, poor connection or corrosion of alternator B+ terminal.

4. Turn Engien "ON.

5. Operate the electrical device such as head lamp,defroster and blower motor.

6. Check battery voltage at above 2000 RPM.

Specification : 12.5V~14.5V

7. Is the measured voltage within the specification?

YES

▶ Alternator is performing within the specification.

NO

▶ Replace alternator and go to "Verification of Vehicle Repair" .

VERIFICATION OF VEHICLE REPAIR E3594150

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

DTC TROUBLESHOOTING PROCEDURES FLB -389

DTC P0563 SYSTEM VOLTAGE HIGH

GENERAL DESCRIPTION E5EBBE1C

Refer to DTC P0562.

DTC DESCRIPTION EEEABE6E

P0563 is set when battery voltage above 17.5V is detected for more than 5 sec.. Check alternator component. (over-
charging of alternator)
▶ ECM senses battery voltage as monitoring the voltages in ECM(CDD-K)connector terminal 1,3,5 which are transmitted
from main.

DTC DETECTING CONDITION E01D6A77

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"
Threshold Value ● when battery voltage is above 17.5V
Diagnostic Time ● 5 sec. ● Charging circuit
Fuel Cut NO ● Alternator component
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp

DIAGNOSTIC CIRCUIT DIAGRAM E81BB12A

Refer to DTC P0562.

SIGNAL WAVEFORM AND DATA E4E800CE

Refer to DTC P0562.

MONITOR SCANTOOL DATA E4473EFF

Refer to DTC P0562.

TERMINAL AND CONNECTOR INSPECTION E8A6C66B

Refer to DTC P0562.

POWER CIRCUIT INSPECTION EA48790E

1. Check charging lamp operation

1) IG KEY "ON", ENGINE "OFF".

2) Disconnect alternator connector.

FLB -390 FUEL SYSTEM

3) Measure the voltage between charging terminal of alternator harness connector and chassis ground.

Secification : Charging lamp "ON" when grounded to chassis ground.

4) Does charging lamp turn ON?

YES

▶ Go to "3.Check voltage drop of aternator B+ cable".

NO

▶ Replace lamp and go to "Verification of Vehicle Repair".

2. Check voltage drop of aternator B+ cable

1) IG KEY "ON", Turn engine "ON".

2) Measure the voltage difference between alternator B+ terminal and battery + terminal.
(connect + terminal of multimeter to alternator B+ and connect - terminal of multimeter to battery +terminal. )

Specification : Below 0.2V (below 200mV)

3) Is the measured voltage within the specification? (Is the voltage drop in alternator B+ cable normal? )

YES

▶ Go to "Component Inspection".

NO

▶ After checking corrosion and deformation of alternator B+ cable and replace it if needed and go to "Verification
of Vehicle Repair".

COMPONENT INSPECTION E220AEC6

1. IG KEY "OFF", ENGINE "OFF".

2. Check belt tension which operates alternator .

3. Check battery terminal and fusible link, poor connection or corrosion of alternator B+ terminal.

4. Turn Engien "ON.

5. Operate the electrical device such as head lamp,defroster and blower motor.

6. Check battery voltage at above 2000 RPM.

Specification : 12.5V~14.5V

7. Is the measured voltage within the specification?

YES

▶ Alternator is performing within the specification.

NO
DTC TROUBLESHOOTING PROCEDURES FLB -391

▶ Replace alternator and go to "Verification of Vehicle Repair" .

VERIFICATION OF VEHICLE REPAIR EC8BE5CB

Refer to DTC P0562.

FLB -392 FUEL SYSTEM

DTC P0602 CONTROL MODULE PROGRAMMING ERROR

COMPONENT LOCATION EE527EDF

ECM

SFDF28307L

GENERAL DESCRIPTION E739A83F

ECM is activated by power supply. Signals from several sensors, such as CKPS and APS, is inputted to ECM. Comparing
inputted siganals with control LOGIC saved at micro controller and EEPROM, ECM controlls engine as actuating injectors,
solenoids and relays.
To guarantee accurate control, ECM performs SELF TEST, DIAGNOSIS of several sensors and actuators. And if serious
trouble which affects vehicle performance occurrs, ECM sets DTCs.
At certain cases, ECM shuts down whole systems in order to prevent dangerous situation due to incorrect control.

DTC DESCRIPTION E12AF07C

P0602 is set when 1)communication error between micro controller inside of ECM and EEP ROM is detected or 2)a
different vesion of ECM is installed.
DTC TROUBLESHOOTING PROCEDURES FLB -393

DTC DETECTING CONDITION ECD4F530

Item Detecting Condition Possible Cause

DTC Strategy ● EEPROM monitorting
Enable Conditions ● IG KEY "ON"

● (EEPROM communication error): communication

failure between micro controller inside of
Threshold Value ECM and EEPROM
● Each data range is activated abnormally.
● self test about optional devices(A/C, ● Version difference between ECM
immobilizer, cruise control) and ECM communication module
● ECM component failure
Diagnostic Time ● Immediately
Fuel Cut YES
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp

COMPONENT INSPECTION EAF84D8C

1. ECM Component Inspection

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECM.

3) Replace ECM, check if abnormal operations disappear.

4) If problems are corrected, replace ECM.

NOTE
Input injector IQA data(7 letters) using scantool at replacing ECM.
Enter the driving distance - how many km the CPF is used- into New ECM with scanner.
For immobilizer applied vehicle, input pin code.

VERIFICATION OF VEHICLE REPAIR E45C1C50

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO
FLB -394 FUEL SYSTEM

▶ System operates within specification.

DTC TROUBLESHOOTING PROCEDURES FLB -395

DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY(ROM)

ERROR

COMPONENT LOCATION E7D5DAFA

Refer to DTC P0602.

GENERAL DESCRIPTION ED30F1F9

Refer to DTC P0602.

DTC DESCRIPTION E068EEFD

P0605 is set when data writing on EEPROM inside of ECM is impossible.This code is due to the failure of ECM(ECM
hardware failure).

DTC DETECTING CONDITION E21AC8F7

Item Detecting Condition Possible Cause

DTC Strategy ● EEPROM monitorting
Enable Conditions ● IG KEY "ON"

Threshold Value ● when data writing on EEPROM inside

of ECM is impossible
Diagnostic Time ● Immediately ● ECM component failure
Fuel Cut YES
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp

COMPONENT INSPECTION EB25440A

1. ECM Component Inspection

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECM.

3) Replace ECM, check if abnormal operations disappear.

4) If problems are corrected, replace ECM.

NOTE
Input injector IQA data(7 letters) using scantool at replacing ECM.
Enter the driving distance - how many km the CPF is used- into New ECM with scanner.
For immobilizer applied vehicle, input pin code.

VERIFICATION OF VEHICLE REPAIR EA271AD2

Refer to DTC P0602.

FLB -396 FUEL SYSTEM

DTC P0606 ECM/PCM PROCESSOR

COMPONENT LOCATION EE8A0A4A

Refer to DTC P0602.

GENERAL DESCRIPTION E8CA5F8F

Refer to DTC P0602.

DTC DESCRIPTION EB6722DB

P0606 is set when 1) writing/reading error inside of ECM occur. 2) error of APS 2 ground checking which is repeated
every 0.2 sec. or 3) the voltage of sensor power supply 1 and 2 ( the standard voltage of A/D converter) are below 4.7V
or above 5.1V. This code is due to ECM internal failure.

DTC DETECTING CONDITION EC2EF720

Item Detecting Condition Possible Cause

DTC Strategy ● Signal monitoring
Enable Conditions ● IG KEY "ON"

● writing/reading error inside of ECM

Threshold Value ● APS 2 ground checking error
● APS 2 ground checking error
Diagnostic Time ● Immediately ● ECM component failure
Fuel Cut YES
EGR Off NO
Fail Safe Fuel Limit NO
Check
YES
Lamp
DTC TROUBLESHOOTING PROCEDURES FLB -397

SIGNAL WAVEFORM AND DATA E955ACC3

APS 1 Signal

APS1 Power

APS 2 Signal
APS 2 Power

APS 2 Ground check signal

Fig.1 Fig.2
SFDF27549L

Fig.1) Ground checking signal of APS 2 signal is for ECM to monitor APS 2. This signal drops APS 2 output voltage to
below 200.39mV every 200msec. If APS 2 output voltage does not drop to below 200.39mV, ECM sets DTC as recognizing
ground circuit error of APS 2 .

NOTE
※ The waveform below 200.39mV is not detectable in ground checking signal waveform of APS 2 signal. Instead,
the waveform which drops a little is detected. If APS 2 data of "SERVICE DATA" on the Scantool varies from 350mV
to 0mV periodically, it means it works normally.

Fig.2) APS 1 and APS 2 signals are measured simultaneously, Check if 5V sensor voltage(the standard voltage of A/D
converter inside of ECM) is from 4.8V to 5.16V.

COMPONENT INSPECTION E20538D7

1. ECM Component Inspection

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECM.

3) Replace ECM, check if abnormal operations disappear.

4) If problems are corrected, replace ECM.

NOTE
Input injector IQA data(7 letters) using scantool at replacing ECM.
Enter the driving distance - how many km the CPF is used- into New ECM with scanner.
For immobilizer applied vehicle, input pin code.

VERIFICATION OF VEHICLE REPAIR E034C74A

Refer to DTC P0602.

FLB -398 FUEL SYSTEM

DTC P0611 FUEL INJECTOR CONTROL MODULE PERFORMANCE

COMPONENT LOCATION E5B98123

Injector

RPS

Rail Pressure
Regulator Valve

SFDF28313L

GENERAL DESCRIPTION E240CD22

Injectors spray fuel in the highly compressed combustion chamber, and power generates through combustion process.
Fuel pressure is raised to 1600bar in common rail diesel engine for the purpose of making fuel into minute particles. And
fuel devided into minute particles leads smoke reduction, high power generation, and improved fuel efficiency. To control
pressure of 1600bar with solenoid, oil pressure surbo is applied. And injector solenoids is actuated by solenoid operating
voltage raised to 80V with the method of current control.
Niddle valve inside of injector is located between A and B chamber. If applied pressure to B chamber is relived by injector
solenoid, niddle valve is raised by the pressure of A chamber then, fuel is injected. If same pressure is applied to A and
B chamber, niddle valve closes by the elasticity then, fuel injection stops.
As electronically controlled injector is applied instead of mechanical injector, pilot and post injection, injeciton duration
and quantity control are achieved. And engine performance is improved by these control.

DTC DESCRIPTION E784D362

P0611 is set when the problems of more than 2 injector circuits are detected thus, it is difficult to find abnormal injector.
Check "Circuit Inspection" of all injectors
DTC TROUBLESHOOTING PROCEDURES FLB -399

DTC DETECTING CONDITION EE619CE6

Item Detecting Condition Possible Cause

DTC Strategy ● Current monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● Cylinder recognition is impossible due to

the failure more than 2 injectors.
Diagnostic Time ● Immediately ● Short in Injector circuit
● Injector component
Fuel Cut YES
EGR Off NO
Fail Safe Fuel Limit NO
Check
YES
Lamp

SPECIFICATION E09E58A3

Injector Component Injector Operating

Injector Operating Voltage Injector Control Type
Resistance Current
Peak current : 18±1A
0.255Ω ±0.04 (20 C). 80V Hold in current : 12±1A Current control
Recharging current : 7A
FLB -400 FUEL SYSTEM

DIAGNOSTIC CIRCUIT DIAGRAM E80694D0

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.

Main Relay
"ON" Input

E/R JUNCTION BOX

<Injector>

Low side
2 1

1. Injector Low Side High side

2. Injector High Side
Injector

<W/O IMMO> <With IMMO>

<ECM>
1. Injector #2 Control 1. Injector #3 Control
2. Injector #3 Control 2. Injector #2 Control
60 59 58
* * * 53 37* * 50 4934 33* 47 3146
56
44 43 42 41 40
16. Injector #4 Control 16. Injector #1 Control
* ** * * * 17. Injector #1 Control 17. Injector #4 Control
30 28 27 26 23 20 19 17 16
31. Injector #3 Control 31. Injector #2 Control
* ** ** * 33. Injector #1 Control 33. Injector #4 Control
* * 13 12 * * * 8 7 6 * 4 * 2 1 46. Injector #2 Control 46. Injector #3 Control
47. Injector #4 Control 47. Injector #1 Control

SFDF27600L
DTC TROUBLESHOOTING PROCEDURES FLB -401

SIGNAL WAVEFORM AND DATA E5972C93

Pilot Injection1 Pilot Injection2 Main injection

Fig.1 Fig.2
SFDF27519L

Injector current waveform

Fig.3 Fig.4
SFDF27520L

Fig.1) Injector operating waveform at Low side, It shows 2 pilot and 1 main injection.
Fig.2) Magnified waveform of main injection at Fig.1)
Fig.3) Injector voltage and current waveforms are measured at the same time using current prove of scope meter.
Fig.4) Magnified waveform of pilot injection at Fig.3)

TERMINAL AND CONNECTOR INSPECTION ED0AC6C8

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.
FLB -402 FUEL SYSTEM

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power Circuit Inspection".

POWER CIRCUIT INSPECTION E819344D

1. Check injector connector terminal voltage (failed injector analysis)

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect all injectors.

3) IG KEY "ON".

4) Check the voltage of all injector connector terminal 1 and 2.

Secification : Terminal 1 : 0.4V~0.5V

Terminal 2 : 2.0V~2.5V

5) Is the measured voltage within the specification?.

YES

▶ Go to "Component Inspection".

NO

▶ Refer to "DTC" guide corresponding to each problem occurred injector.

Injector #1 related problem : Refer to P0201for open in injector circuit.
Refer to P0262 for short in injectoer circuit.
Injector #2 related problem : Refer to P0202 for open in injector circuit.
Refer to P0265 for short in injectoer circuit.
Injector #3 related problem : Refer to P0203 for open in injector circuit.
Refer to P0268 for short in injectoer circuit.
Injector #4 related problem : Refer to P0204 for open in injector circuit.
Refer to P0271 for short in injectoer circuit.

COMPONENT INSPECTION EDD29552

1. Check injector component resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect injector connector.

3) Measure the resistance between high side terminal and low side terminal of injector connector. (component
side).
DTC TROUBLESHOOTING PROCEDURES FLB -403

Specification : 0.255Ω ±0.04 (20 C).

4) Is the measured resistance(of injector solenoid) within the specification?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace injector and go to "Verification of Vehicle Repair".

NOTE
Replacing injectors, peculiar IQA code of each injector should be inputted to ECM Perform this process using "Injector
data input" function on scantool, Refer to P1670, P1671 for more detailed information.

VERIFICATION OF VEHICLE REPAIR E03B9427

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -404 FUEL SYSTEM

DTC P062D FUEL INJECTOR DRIVER CIRCUIT PERFORMANCE (BANK 1)

COMPONENT LOCATION EA592D84

ECM

SFDF28307L

GENERAL DESCRIPTION E5478234

There are two transformer for injector operation in side of ECM. 1 pilot and 1 main injection are operated by ECM in EURO
3 diesel engine therefore one transformer device is sufficient to control injector however, 2 pilot and if CPF is applied, 2
post injection are performed additionally by ECM in EURO 4 diesel engine thus, two transformer is required.

DTC DESCRIPTION EC19BCBA

P062D is set when the problem of transforming system 1 for injector contol occurs. This code is due to the failure of
transforming system inside of ECM.

NOTE
※ If battery voltage is low, this code can be set. Therefore, beforehand, check DTC code relevant to battery voltage
and charging system.

DTC DETECTING CONDITION E815B16E

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● Engine running

Threshold Value ● Power stage error for injector voltage

control, CPU circuit failure
Diagnostic Time ● Immediately ● ECM internal error
Fuel Cut YES
EGR Off NO
Fail Safe Fuel Limit NO
Check
YES
Lamp
DTC TROUBLESHOOTING PROCEDURES FLB -405

COMPONENT INSPECTION EBD1ED39

1. ECM Component Inspection

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECM.

3) Replace ECM, check if abnormal operations disappear.

4) If problems are corrected, replace ECM.

NOTE
Input injector IQA data(7 letters) using scantool at replacing ECM.
Enter the driving distance - how many km the CPF is used- into New ECM with scanner.
For immobilizer applied vehicle, input pin code.

VERIFICATION OF VEHICLE REPAIR EDD7806B

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -406 FUEL SYSTEM

DTC P062E FUEL INJECTOR DRIVER CIRCUIT PERFORMANCE (BANK 2)

COMPONENT LOCATION EFB1453A

Refer to DTC P062D.

GENERAL DESCRIPTION E63C9330

Refer to DTC P062D.

DTC DESCRIPTION E6718D07

P062E is set when the problem of transforming system 2 for injector contol occurs. This code is due to the failure of
transforming system inside of ECM.

NOTE
※ If battery voltage is low, this code can be set. Therefore, beforehand, check DTC code relevant to battery voltage
and charging system.

DTC DETECTING CONDITION E6615FE2

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● Engine running

Threshold Value ● Power stage error for injectoer voltage

control, CPU circuit failure
Diagnostic Time ● Immediately ● ECM internal error
Fuel Cut YES
EGR Off NO
Fail Safe Fuel Limit NO
Check
YES
Lamp

COMPONENT INSPECTION ECE6314F

1. ECM Component Inspection

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECM.

3) Replace ECM, check if abnormal operations disappear.

4) If problems are corrected, replace ECM.

NOTE
Input injector IQA data(7 letters) using scantool at replacing ECM.
Enter the driving distance - how many km the CPF is used- into New ECM with scanner.
For immobilizer applied vehicle, input pin code.
DTC TROUBLESHOOTING PROCEDURES FLB -407

VERIFICATION OF VEHICLE REPAIR E3C624C8

Refer to DTC P062D.

FLB -408 FUEL SYSTEM

DTC P0642 SENSOR REFERENCE VOLTAGE "A" CIRCUIT LOW

COMPONENT LOCATION EBA0F6BC

ECM

SFDF28307L

GENERAL DESCRIPTION EC69A719

ECM is activated by power supply. Signals from several sensors, such as CKPS and APS, is inputted to ECM. Comparing
inputted siganals with control LOGIC saved at micro controller and EEPROM, ECM controlls engine as actuating injectors,
solenoids and relays.
To guarantee accurate control, ECM performs SELF TEST, DIAGNOSIS of several sensors and actuators. And if serious
trouble which affects vehicle performance occurrs, ECM sets DTCs.
At certain cases, ECM shuts down whole systems in order to prevent dangerous situation due to incorrect control.

DTC DESCRIPTION E1ADAB23

P0642 is set when the voltage in ‘ Power #1’ circuit is below lower limit for more than 0.1 sec.. This code is due to the
short to ground in sensor power circuit or the voltage problem inside of ECM.

DTC DETECTING CONDITION E85660CE

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● when the voltage is below the minimum

voltage of sensor power supply.
Diagnostic Time ● 100ms ●APS 1 power supply circuit
● ECM component
Fuel Cut NO
EGR Off NO ● Limp home mode
Fail Safe is activated.
Fuel Limit YES (engine speed is fixed
Check at 1200RPM. )
NO
Lamp
DTC TROUBLESHOOTING PROCEDURES FLB -409

SPECIFICATION EF382BF5

Sensor power 1 Sensor power 2 Sensor power 3

A/C pressure transducer,
APS 1 RPS, APS 2,BPS Differntil pressure sensor,
VSA position Sensor
4830mV~5158mV 4830mV~5158mV 4830mV~5158mV

DIAGNOSTIC CIRCUIT DIAGRAM E20B3608

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.
Main Relay
"ON" Input

E/R JUNCTION BOX

<Accelerator Pedal Sensor>

APS1
Power
6 5 4 3 2 1
Signal APS #1
Ground
1. Signal #2
2. Ground #2 APS2
Power
3. Signal #1
4. Ground #1 Signal APS #2
5. Power #1
6. Power #2 Ground

Accelerator Pedal Sensor

<ECM>
8. APS2 Ground
94 93 92 90 89 87 86 84 83 81 80 79 77 75 9. APS1 Signal
*
72 71 70 69 68 * * *
65 64 * * ** 6 5
** * * * * * * * * * 51 57 56 54
4 3
30. APS1 Ground
31. APS2 Signal
* 27* 48 47
28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1
* 25 * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7 45. APS1 Power
46. APS2 Power

SFDF27613L
FLB -410 FUEL SYSTEM

SIGNAL WAVEFORM AND DATA ECBB4749

APS1 Power

APS2 Power

Fig.1
SFDF27550L

Fig.1) APS 1 power supply is measured simultaneously , check if this waveform is within the specification (4.8~5.1V )
when turning ignition "ON".

TERMINAL AND CONNECTOR INSPECTION E3B9D778

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power circuit Inspection "

POWER CIRCUIT INSPECTION E4C22399

1. Check power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnector APS connector.

DTC TROUBLESHOOTING PROCEDURES FLB -411

3) IG KEY "ON".

4) Measure the voltage between power terminal of APS1 harness connector and chassis ground.

Secification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ Go to "2. Check short to ground in power circuit" as follows.

2. Check short to ground in power circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect APS connector, ECM connectors.

3) Check continuity between APS connector terminal 5 and chassis ground.

Secification : Discontinuity ( Infinite Ω )

4) Is the measured resistance within the specification?

YES

▶ If the circuit is insulated well and the sensor power supply from ECM is low, replace ECM and go to "Verification
of Vehicle Repair".

NO

▶ Repair short to ground and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E2E761C3

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect APS connector.

3. Check that sensor connector power supply is within the specification after turning IG KEY "ON".

4. Connect APS connector in turn.

5. Measure the voltage of power circuit of each sensor with all connector connected.

Specification : sensor power supply should not change as connecting APS connector.
( If the change of sensor power supply occur as connecting sensor connector, this means
the occurrence of short inside of sensor.)

6. Does change of sensor power supply occur as connecting sensor connector?

YES
FLB -412 FUEL SYSTEM

▶ Replace APS.

NO

▶ go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E151C46B

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

DTC TROUBLESHOOTING PROCEDURES FLB -413

DTC P0643 SENSOR REFERENCE VOLTAGE "A" CIRCUIT HIGH

COMPONENT LOCATION E0D52ECC

Refer to DTC P0642.

GENERAL DESCRIPTION E878C230

Refer to DTC P0642.

DTC DESCRIPTION E7FCE25B

P0643 is set when the voltage in ‘ Power #1’ circuit is above upper limit for more than 0.1 sec.. This code is due to the
short to battery in sensor power circuit or the voltage problem inside of ECM.

DTC DETECTING CONDITION E1CBF686

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● when the voltage is above the maximum

voltage of sensor power supply.
Diagnostic Time ● 100ms ● APS 1 power supply circuit
● ECM component
Fuel Cut NO
EGR Off NO ● Limp home mode
Fail Safe is activated.
Fuel Limit YES (engine speed is fixed
Check at 1200RPM. )
NO
Lamp

SPECIFICATION EA2646E7

Refer to DTC P0642.

DIAGNOSTIC CIRCUIT DIAGRAM E293063C

Refer to DTC P0642.

SIGNAL WAVEFORM AND DATA E15EF985

Refer to DTC P0642.

TERMINAL AND CONNECTOR INSPECTION E3450332

Refer to DTC P0642.

POWER CIRCUIT INSPECTION ED5946BC

1. Check power circuit voltage

FLB -414 FUEL SYSTEM

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnector APS connector.

3) IG KEY "ON".

4) Measure the voltage between power terminal of APS1 harness connector and chassis ground.

Secification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ Go to "2. Check short to battery in power circuit" as follows.

2. Check short to battery in power circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnector APS connector and ECM connector.

3) IG KEY "ON".

4) Measure the voltage between power #1 terminal of APS harness connector and chassis ground.

Specification : 0.0V~0.1V

5) Is abnormal voltate measured in this test?

YES

▶ Repair short to battery and go to "Verification of Vehicle Repair".

NO

▶ If the circuit is insulated well and the sensor power supply from ECM is high, replace ECM and go to "Verifi-
cation of Vehicle Repair".

COMPONENT INSPECTION EC282D89

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect APS connector.

3. Check that sensor connector power supply is within the specification after turning IG KEY "ON".

4. Connect APS connector in turn.

5. Measure the voltage of power circuit of each sensor with all connector connected.

Specification : sensor power supply should not change as connecting APS connector.
( If the change of sensor power supply occur as connecting sensor connector, this means
the occurrence of short inside of sensor.)
DTC TROUBLESHOOTING PROCEDURES FLB -415

6. Does change of sensor power supply occur as connecting sensor connector?

YES

▶ Replace APS.

NO

▶ go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR EB4CCECB

Refer to DTC P0642.

FLB -416 FUEL SYSTEM

DTC P0646 A/C CLUTCH RELAY CONTROL CIRCUIT LOW

GENERAL DESCRIPTION EA7393FF

Aircon Relay which is controled by ECM supplies and cut electrical power to Aircon compressor. ECM activates or deac-
tivates Aircon Relay based on inputted signal such as aircon switch siganl and Aircon switch signal.
As controlling Aircon Relay, ECM 1)turns OFF aircon compressor at rapid acceleration to retain suffiecient capacity for
acceleration, 2)actively performs idle-up function to cope with the change of engine load which happens at aircom com-
pressor operation.

DTC DESCRIPTION EF44C77B

P0646 is set when ‘ 0A’ is detected in Aircon relay control circuit for more than 1 sec.. This code is due to open or
short to ground in Aircon relay control circuit or internal open in relay component.

DTC DETECTING CONDITION E00539CE

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"
Threshold Value ● Short to GND, Wiring open
Diagnostic Time ● 1.0 sec. ● A/C relay circuit
Fuel Cut NO ● A/C relay component
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp
DTC TROUBLESHOOTING PROCEDURES FLB -417

DIAGNOSTIC CIRCUIT DIAGRAM E989D917

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.
Main Relay
"ON" Input

E/R JUNCTION BOX

A/Con Relay Control

A/CON Relay
A/C Compressor

<A/CON Relay terminal>

<ECM>
85 87

94 93 92 90 89
30 86 *
72 71 70 69 68 * 87 86 * 84 83 * 81 80 79 * 77 * 75 * * 6 5
* * 65 64 * * * * * * 57 56 * 54 * * 51 4 3

30. Relay power (Input) * 27* 48 47

28 25
46 45 44
22 *
42
* 40 * 1638 1537 1436 35
19
34 33 32 31 30 29
13 12 11 10 9 8 7
2 1
85. Relay coil power * ** ** **
86. Relay coil control
87. Relay power (Output) 70. A/CON Relay Control

SFDF27614L

MONITOR SCANTOOL DATA E7E31647

1. Connect scantool to Data Link Cable (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Monitor "A/C COMPRESSOR CONTROL" parameter on the scantool.

Specification : A/C switch "ON" : A/C RELAY "ON" (Aircon compressor turns ON and OFF
periodically by Aircon pressure S/W. )
A/C switch "OFF" : A/C RELAY "OFF"
FLB -418 FUEL SYSTEM

Fig.1 Fig.2
SFDF27551L

Fig.1) The operating condition of aircon relay is shown. Check if aircon compressor works properly when aircon
switch is turning ON.
Fig.2) Diagnosing problem of "A/C RELAY" and "AIRCON COMPRESSOR" is convenient through ACTUATION TEST
on the Scantool.

TERMINAL AND CONNECTOR INSPECTION E9AB8105

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power Circuit Inspection".

POWER CIRCUIT INSPECTION E5E9DECB

1. Check power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect A/C relay.

DTC TROUBLESHOOTING PROCEDURES FLB -419

3) Measure the voltage between power terminal of A/C relay and chassis ground.

specification : 11.5V~13.0V

4) Is the measured voltage within the specification?

YES

▶ Go to "2. Check IG KEY "ON" power circuit" .

NO

▶ Repair problems of A/C FUSE in E/R JUNCTION BOX and related circuit and go to "Verification of Vehicle
Repair".

2. Check IG KEY "ON" power circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect A/C relay

3) IG KEY "ON".

4) Measure the voltage between coil power terminal ofA/C relay and chassis ground.

specification : 11.5V~13.0V

5) Is the measured voltage within the specification?

YES

▶ Go to "Control Circuit Inspection".

NO

▶ Repair problems of INJ fuse in E/R JUNCTION BOX and related circuit and go to "Verification of Vehicle
Repair".

CONTROL CIRCUIT INSPECTION E538249D

1. Check monitoring voltage in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect A/C relay

3) IG KEY "ON".

4) Measure the voltage between coil control terminal of A/C relay and chassis ground.

Secification : 3.2V~3.7V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".
FLB -420 FUEL SYSTEM

NO

▶ When voltage is not detected : Go to "2. Check open in control circuit" as follows.
▶ When high voltage is detected : Repair short to battery and go to "Verification of Vehicle Repair".

2. Check open in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect A/C relay and ECM connector .

3) Check continuity between coil control terminal of A/C relay and ECM harness connector.

Secification : Continuity ( below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground and go to "Verification of Vehicle Repair".

NO

▶ Repair open in control circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E38EBF9E

1. Check A/C relay component resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect A/C relay.

3) Measure the resistance between coil power terminal and coil control terminal of A/C relay coil.

Secification : 85±5 Ω (20 C)

4) Is the measured resistance within the specification?

YES

▶ Go to "2. Check A/C relay component operation" as follows.

NO

▶ Replace A/C relay and go to "Verification of Vehicle Repair".

2. Check A/C relay component operation

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect A/C relay.

3) Supplies random B+ and ground to coil sides of A/C relay. ( Coil power terminal, Coil control terminal)

4) Check continuity between power input terminal and power output terminal of A/C relay.
DTC TROUBLESHOOTING PROCEDURES FLB -421

Secification : When power is supplied : Continuity ( below 1.0Ω )

When power is not supplied : Discontinuity ( Infinite Ω )

5) Is the continuity test within the specification?

YES

▶ go to "Verification of Vehicle Repair".

NO

▶ Replace A/C relay and go to "Verification of Vehicle Repair".

※ Repeat this process 2~3 times.

VERIFICATION OF VEHICLE REPAIR E4DCB99A

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -422 FUEL SYSTEM

DTC P0647 A/C CLUTCH RELAY CONTROL CIRCUIT HIGH

GENERAL DESCRIPTION EDE4A7DB

Refer to DTC P0646.

DTC DESCRIPTION E3C11586

P0647 is set when excessive current is detected in Aircon relay control circuit for more than 1 sec.. This code is due to
short to battery in Aircon relay control circuit or internal short in relay component.

DTC DETECTING CONDITION EAAA56BD

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"
Threshold Value ● Short to battery
Diagnostic Time ● 1.0 sec. ● A/C relay circuit
Fuel Cut NO ● A/C relay component
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp

DIAGNOSTIC CIRCUIT DIAGRAM E13FAB8C

Refer to DTC P0646.

MONITOR SCANTOOL DATA E129186B

Refer to DTC P0646.

TERMINAL AND CONNECTOR INSPECTION E13DD022

Refer to DTC P0646.

POWER CIRCUIT INSPECTION EBC1416B

1. Check power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect A/C relay.

3) Measure the voltage between power terminal of A/C relay and chassis ground.

specification : 11.5V~13.0V

4) Is the measured voltage within the specification?

DTC TROUBLESHOOTING PROCEDURES FLB -423

YES

▶ Go to "2. Check IG KEY "ON" power circuit" .

NO

▶ Repair problems of A/C FUSE in E/R JUNCTION BOX and related circuit and go to "Verification of Vehicle
Repair".

2. Check IG KEY "ON" power circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect A/C relay

3) IG KEY "ON".

4) Measure the voltage between coil power terminal ofA/C relay and chassis ground.

specification : 11.5V~13.0V

5) Is the measured voltage within the specification?

YES

▶ Go to "Control Circuit Inspection".

NO

▶ Repair problems of INJ fuse in E/R JUNCTION BOX and related circuit and go to "Verification of Vehicle
Repair".

CONTROL CIRCUIT INSPECTION EEC0D198

1. Check monitoring voltage in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect A/C relay

3) IG KEY "ON".

4) Measure the voltage between coil control terminal of A/C relay and chassis ground.

Secification : 3.2V~3.7V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ When voltage is not detected : Go to "2. Check open in control circuit" as follows.
▶ When high voltage is detected : Repair short to battery and go to "Verification of Vehicle Repair".

2. Check open in control circuit

FLB -424 FUEL SYSTEM

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect A/C relay and ECM connector .

3) Check continuity between coil control terminal of A/C relay and ECM harness connector.

Secification : Continuity ( below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground and go to "Verification of Vehicle Repair".

NO

▶ Repair open in control circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E3EDDFB8

1. Check A/C relay component resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect A/C relay.

3) Measure the resistance between coil power terminal and coil control terminal of A/C relay coil.

Secification : 85±5 Ω (20 C)

4) Is the measured resistance within the specification?

YES

▶ Go to "2. Check A/C relay component operation" as follows.

NO

▶ Replace A/C relay and go to "Verification of Vehicle Repair".

2. Check A/C relay component operation

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect A/C relay.

3) Supplies random B+ and ground to coil sides of A/C relay. ( Coil power terminal, Coil control terminal)

4) Check continuity between power input terminal and power output terminal of A/C relay.

Secification : When power is supplied : Continuity ( below 1.0Ω )

When power is not supplied : Discontinuity ( Infinite Ω )

5) Is the continuity test within the specification?

YES
DTC TROUBLESHOOTING PROCEDURES FLB -425

▶ go to "Verification of Vehicle Repair".

NO

▶ Replace A/C relay and go to "Verification of Vehicle Repair".

※ Repeat this process 2~3 times.

VERIFICATION OF VEHICLE REPAIR E057464A

Refer to DTC P0646.

FLB -426 FUEL SYSTEM

DTC P0650 MALFUNCTION INDICATOR LAMP(MIL) CONTROL CIRCUIT

GENERAL DESCRIPTION E0AE6A21

As monitoring the errors of several sensors and actuator circuit, TCM related problem and ECM error, if any problem
occurs, ECM turns Engine Check Lamp ON at cluster to notify driver the occurence of a problem.
Generally, Engine Check Lamp turns ON at Ignition ON and turns OFF within couple of seconds after turning engine ON.
If engine check lamp turns on during driving, perform diagnosis of engine system and auto-transaxle system.

DTC DESCRIPTION E6ECFA32

P0650 is set when 1)excessive current is detected in engine check lamp control circuit for more than 2.0 sec. at engine
check lamp ON condition or 2)like open or short to ground, no current is detected. This code is due to open in control
circuit or opened filament of lamp component.

DTC DETECTING CONDITION EDB11166

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring

Enable Conditions ● IG KEY "ON" (Monitoring only performed

within lamp operating condition)

Threshold Value ● Short to battery

● Short to GND, Wiring open
● Open in engine check lamp
Diagnostic Time ● 2.0 sec. ● Engine check lamp circuit.
Fuel Cut NO
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp
DTC TROUBLESHOOTING PROCEDURES FLB -427

DIAGNOSTIC CIRCUIT DIAGRAM E4779D97

ECM
IG SW
ON/START Input
- +
BATT.
INSTRUMENT CLUSTER

CHECK

MIL Indicator

MIL.

<ECM>
<INSTRUMENT CLUSTER>

94 93 92 90 89
*
72 71 70 69 68 * 87 86 * 84 83 * 81 80 79 * 77 * 75 * * 6 5
* * 65 64 * * * * * * 57 56 * 54 * * 51 4 3
12 11 9 8 7 6 5 4 3
* 27* 48 47 46 45 44
22 *
42
* 40 * 1638 1537 1436 35 34 33 32 31 30 29
2 1 *
24 23 22 21 20 19 18 17
**
28 25
* ** ** ** 19 13 12 11 10 9 8 7
* 15 * 13
11. MIL. Ind. Control
68. MIL. Ind. Control 15. Power

SFDF27615L

TERMINAL AND CONNECTOR INSPECTION E69C509D

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Control Circuit Inspection".

FLB -428 FUEL SYSTEM

CONTROL CIRCUIT INSPECTION EE59435B

1. Check control circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECM connector.

3) IG KEY "ON".

4) Measure the voltage between engine MIL terminal of ECM harness connector and chassis ground.

Secification : 10.8V~13.0V

5) Is the measured voltage within the specification?

YES

▶ Go to "2. Grounding test of check lamp control circuit" as follows.

NO

▶ Check open in filament of check lamp. ( Refer to Component Inspection)

▶ Repair open between power terminal of cluster and ECM harness connector and go to "Verification of Vehicle
Repair",

2. Grounding test of check lamp control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECM connector.

3) IG KEY "ON".

4) Ground MIL terminal of ECM harness connector to chassis ground.

Secification : Check lamp turns ON.

5) Does check lamp turn ON?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Repair short to battery in check lamp control circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E3D6428D

1. IG KEY "OFF", ENGINE "OFF".

2. Dismount cluster and disconnect check lamp.

3. Check filament of check lamp.

4. Supply 12V to "check lamp" to turn lamp ON

DTC TROUBLESHOOTING PROCEDURES FLB -429

Specification : Lamp turns ON when 12V is supplied.

5. Does check lamp turn ON?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace check lamp and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E167954D

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -430 FUEL SYSTEM

DTC P0652 SENSOR REFERENCE VOLTAGE "B" CIRCUIT LOW

COMPONENT LOCATION EED4E4FB

ECM

SFDF28307L

GENERAL DESCRIPTION ED0F6F32

ECM is activated by power supply. Signals from several sensors, such as CKPS and APS, is inputted to ECM. Comparing
inputted siganals with control LOGIC saved at micro controller and EEPROM, ECM controlls engine as actuating injectors,
solenoids and relays.
To guarantee accurate control, ECM performs SELF TEST, DIAGNOSIS of several sensors and actuators. And if serious
trouble which affects vehicle performance occurrs, ECM sets DTCs.
At certain cases, ECM shuts down whole systems in order to prevent dangerous situation due to incorrect control.

DTC DESCRIPTION E0F7B047

P0652 is set when the voltage in ‘ Power #2’ circuit is below lower limit for more than 0.1 sec.. This code is due to the
short to ground in sensor power circuit or the voltage problem inside of ECM.

DTC DETECTING CONDITION EF9B271C

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● when the voltage is below the minimum

voltage of sensor power supply
●RPS power supply circuit
Diagnostic Time ● 100ms ●APS 2 power supply circuit
●BPS power supply circuit
Fuel Cut NO
● ECM component
EGR Off NO ● Limp home mode is
Fail Safe Fuel Limit YES activated.(engine speed is
fixed at 1200RPM.)
Check
NO
Lamp
DTC TROUBLESHOOTING PROCEDURES FLB -431

SPECIFICATION E46C440D

Sensor power 1 Sensor power 2 Sensor power 3

A/C pressure transducer,
APS 1 RPS, APS 2,BPS Differntil pressure sensor,
VSA position Sensor
4830mV~5158mV 4830mV~5158mV 4830mV~5158mV

DIAGNOSTIC CIRCUIT DIAGRAM E714B07E

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.

Main Relay "ON" Input

E/R JUNCTION BOX APS1

Power

APS #1 Signal

Ground
Signal
APS2
Power
U P Power
APS #2 Signal
Ground
Ground
Rail Pressure Sensor
ACCELERATOR
PEDAL SENSOR

Signal
U P Power

Signal
Ground

Booster Pressure Sensor

SFDF27616L
FLB -432 FUEL SYSTEM

<Accelerator Pedal Sensor>

<Rail Pressure Sensor> <Booster Pressure Sensor>

6 5 4 3 2 1 4 3 2 1
3 2 1

1. Signal #2 1. BPS Signal

1. Power 2. Ground #2 2. Power
2. Signal 3. Signal #1 3. BPS Temp. Signal
3. Ground 4. Ground #1 4. Ground
5. Power #1
6. Power #2

<ECM>
8. Ground
13. Power
60 59 58
* * * 53 37* * 50 4934 33* 47 3146
56
44 43 42 41 40
23. Ground
* ** * * * 28. Power
30 28 27 26 23 20 19 17 16
40. BPS Signal
* ** ** * 43. Signal
* * 13 12 * * * 8 7 6 * 4 * 2 1 53. BPS Temp.Signal

<ECM>
8. Ground #2
94 93 92 90 89 87 86 84 83 81 80 79 77 75
9. Signal #1
*
72 71 70 69 68 * * *
65 64 * * ** 6 5
** * * * * * * * * * 51
57 56 54
4 3
30. Ground #1
48 47 46 45 44 42 40 38 37 36 35 34 33 32 31 30 29 31. Signal #2
* 27* 25 22 * 19* * 16 15 14 13 12 11 10 9 8 7
28
2 1
* ** ** ** 45. Power #1
46. Power #2

SFDF27617L

SIGNAL WAVEFORM AND DATA E972B66F

APS 2 power BPS power

RPS power RPS power

Fig.1 Fig.2
SFDF27552L
DTC TROUBLESHOOTING PROCEDURES FLB -433

Fig.1) APS2 and RPS power supply signals are measured simultaneously. Check if the voltages are within the specifica-
tion ( 4.8~5.1V) at IG KEY "ON".
Fig.2) BPS and RPS power supply signals are measured simultaneously. Check if the voltages are within the specification
( 4.8~5.1V) at IG KEY "ON".

TERMINAL AND CONNECTOR INSPECTION EC1A66A8

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power Circuit Inspection".

POWER CIRCUIT INSPECTION E17CCFA5

1. Check power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnector RPS connector, APS connector and BPS connector.

3) IG KEY "ON".

4) Measure the voltage between power terminal of RPS harness connector and chassis ground.

5) Measure the voltage between power terminal of APS harness connector and chassis ground.

6) Measure the voltage between power terminal of BPS harness connector and chassis ground.

Secification : 4.8V~5.1V

7) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection

NO
FLB -434 FUEL SYSTEM

▶ Go to "2. Check short to ground in power circuit" as follows.

2. Check short to ground in power circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect RPS connector, APS connector, BPS connector, ECM connectors.

3) Measure the continuity between power terminal of RPS harness connector and chassis ground.

4) Measure the continuity between power terminal of APS harness connector and chassis ground.

5) Measure the continuity between power terminal of BPS harness connector and chassis ground.

Secification : Discontinuity ( Infinite Ω )

6) Is the measured resistance within the specification?

YES

▶ If the circuit is insulated well and the sensor power supply from ECM is low, replace ECM and go to "Verification
of Vehicle Repair".

NO

▶ Repair short to ground and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E813D5CE

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect RPS connector, APS connector, BPS connector.

3. Check that sensor connector power supply is within the specification after turning IG KEY "ON".

4. Connect RPS connector and APS connector in turn.

5. Measure the voltage of power circuit of each sensor with all connector connected.

Specification : Sensor power supply should not change as connecting RPS connector, APS connector, BPS connector.
( If the change of sensor power supply occur as connecting sensor connector, this means
the occurrence of short inside of sensor.)

6. Does change of sensor power supply occur as connecting sensor connector?

YES

▶ Replace related sensors. (rail pressure sensor, accel pedal sensor, boost pressure sensor)

NO

▶ Go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR EFC6984C

After a repair, it is essential to verify that the fault is corrected.

DTC TROUBLESHOOTING PROCEDURES FLB -435

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -436 FUEL SYSTEM

DTC P0653 SENSOR REFERENCE VOLTAGE "B" CIRCUIT HIGH

COMPONENT LOCATION E6FFD3E2

Refer to DTC P0652.

GENERAL DESCRIPTION EE078F84

Refer to DTC P0652.

DTC DESCRIPTION EBEE0B05

P0653 is set when the voltage in ‘ Power #1’ circuit is above upper limit for more than 0.1 sec.. This code is due to the
short to battery in sensor power circuit or the voltage problem inside of ECM.

DTC DETECTING CONDITION EFD62032

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● when the voltage is above the maximum

voltage of sensor power supply.
●RPS power supply circuit
Diagnostic Time ● 100ms ●APS 2 power supply circuit
●BPS power supply circuit
Fuel Cut NO
● ECM component
EGR Off NO ● Limp home mode is
Fail Safe Fuel Limit YES activated.(engine speed is
fixed at 1200RPM.)
Check
NO
Lamp

SPECIFICATION ED6EAD52

Refer to DTC P0652.

DIAGNOSTIC CIRCUIT DIAGRAM EF96ACA3

Refer to DTC P0652.

SIGNAL WAVEFORM AND DATA EC74DD25

Refer to DTC P0652.

TERMINAL AND CONNECTOR INSPECTION EB949F2A

Refer to DTC P0652.

POWER CIRCUIT INSPECTION E2F0FF43

1. Check power circuit voltage

DTC TROUBLESHOOTING PROCEDURES FLB -437

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnector RPS connector, APS connector and BPS connector.

3) IG KEY "ON".

4) Measure the voltage between power terminal of RPS harness connector and chassis ground.

5) Measure the voltage between power terminal of APS harness connector and chassis ground.

6) Measure the voltage between power terminal of BPS harness connector and chassis ground.

Secification : 4.8V~5.1V

7) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection"

NO

▶ Go to "2. Check short to battery in power circuit" as follows

2. Check short to battery in power circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnector RPS connector, APS connector ,BPS connector, ECM connector

3) IG KEY "ON"

4) Measure the voltage between power terminal of RPS harness connector and chassis ground.

5) Measure the voltage between power terminal of APS harness connector and chassis ground.

6) Measure the voltage between power terminal of BPS harness connector and chassis ground.

Secification : 0.0V~0.1V

7) Is abnormal voltate measured in this test?

YES

▶ Repair short to battery and go to "Verification of Vehicle Repair".

NO

▶ If the circuit is insulated well and the sensor power supply from ECM is high, replace ECM and go to "Verifi-
cation of Vehicle Repair".

COMPONENT INSPECTION E77F9A25

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect RPS connector, APS connector, BPS connector.

3. Check that sensor connector power supply is within the specification after turning IG KEY "ON".
FLB -438 FUEL SYSTEM

4. Connect RPS connector and APS connector in turn.

5. Measure the voltage of power circuit of each sensor with all connector connected.

Specification : Sensor power supply should not change as connecting RPS connector, APS connector, BPS connector.
( If the change of sensor power supply occur as connecting sensor connector, this means
the occurrence of short inside of sensor.)

6. Does change of sensor power supply occur as connecting sensor connector?

YES

▶ Replace related sensors. (rail pressure sensor, accel pedal sensor, boost pressure sensor)

NO

▶ Go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E3B21897

Refer to DTC P0652.

DTC TROUBLESHOOTING PROCEDURES FLB -439

DTC P0670 GLOW PLUG CONTROL MODULE CONTROL CIRCUIT / OPEN

GENERAL DESCRIPTION EC4B9A20

Heating combustion chamber, glow plug increases fuel ignitibility and makes fuel in the foggy state easily when engine
is cold. Thus, glow plug makes engine starting easily and decreases exhaust gas produced just after turning engine on
when engine is cold.
ECM controls operation and operating duration of glow plug relay which supplies power to glow plug with ECTS signal,
battery voltage and IG KEY ON signal.
Through glow lamp in cluster, ECM let drivers know if glow plug is ON.

DTC DESCRIPTION EB58C51A

P0670 is set when 1)excessive voltage is detected or 2)no current is detected like open or short to ground in glow relay
control circuit for more than 1 sec. at glow relay ON condition. This code is due to open in glow relay control circuit or
internal open in glow relay component.

DTC DETECTING CONDITION E14EDBB4

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring

Enable Conditions ● IG KEY "ON" (monitoring only performed

within relay operating condition)

Threshold Value ● short to battery

● Short to GND, Wiring open
● Glow relay control circuit
Diagnostic Time ● 1.0 sec. ● Glow relay component
Fuel Cut NO
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp

SPECIFICATION EF38FF56

※ RELAY OPERATING TIME

- 20 C - 10 C 10 C 50 C
10V 16sec 10sec 4sec 2.0sec
14.9V 16sec 10sec 4sec 2.0sec
FLB -440 FUEL SYSTEM

DIAGNOSTIC CIRCUIT DIAGRAM E4693BA0

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.
Main Relay
"ON" Input

E/R JUNCTION BOX

GLOW PLUG RELAY

Glow Plug Relay

DIESEL BOX

<GLOW PLUG RELAY>

1 <ECM>

4 2
* 94 93 92
* 90 89
* 87 86 * 84 83 * 81 80 79 * 77 * 75 * * 6 5
5 72 71 70 69 68 67
* 65 64 * * * * * * 57 56 * 54 * * 51 4 3
1. Power from battery * 27* 48 47
28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1
2. Glow Plug Relay Control * 25 * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7
4. Power from Main Relay
5. To Glow plug 93. GLOW PLUG Relay Control

SFDF27618L

MONITOR SCANTOOL DATA EA245E4A

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Monitor "GLOW RELAY" parameter on the Scantool.

Specification : After operating according to engine coolant temperature and battery voltage, Glow relay turns "OFF".
At IG KEY "ON". (Refer to Specification)
DTC TROUBLESHOOTING PROCEDURES FLB -441

Fig.1 Fig.2
SFDF27553L

Fig 1) Operating state of Glow relay is shown. However, it is difficult to check operating state because Glow relay
turns OFF 2~3 sec. after operation at normal temp.
Fig.2) Checking glow relay operation and power supply to glow plug using "ACTUATION TEST" on Scantool is con-
venient.

TERMINAL AND CONNECTOR INSPECTION E7E2F0C7

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power Circuit Inspection".

POWER CIRCUIT INSPECTION E5B44D5D

1. Check HOT AT ALL TIMES power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect glow relay.

FLB -442 FUEL SYSTEM

3) Measure the voltage between power input terminal of glow relay harness connector and chassis ground.

Secification : 11.5V~13.0V

4) Is the measured voltage within the specification?

YES

▶ Go to "2. Check IG KEY "ON" power circuit voltage" as follows.

NO

▶ Repair GLOW PLUG FUSIBLE LINK in E/R FUSIBLE LINK BOX and related circuit and go to "Verification of
Vehicle Repair".

2. Check IG KEY "ON" power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect glow relay.

3) IG KEY "ON"

4) Measure the voltage between power terminal of glow relay harness connector and chassis ground.

Secification : 11.5V~13.0V

5) Is the measured voltage within the specification?

YES

▶ Go to "Control Circuit Inspection".

NO

▶ Repair INJ fuse in E/R JUNCTION BOX and related circuit and go to "Verification of Vehicle Repair".

CONTROL CIRCUIT INSPECTION EA843EAF

1. Check control circuit monitoring voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect glow relay.

3) IG KEY "ON".

4) Measure the voltage between coil control terminal of glow relay harness connector and chassis ground.

Secification : 3.2V~3.7V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".
DTC TROUBLESHOOTING PROCEDURES FLB -443

NO

▶ When no value is detected : Go to "2. Check open in control circuit".

▶ When high voltage is detected : Repair short to battery in signal circuit and go to "Verification of Vehicle
Repair".

2. Check open in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect glow relay and ECM connector.

3) Check continuity between coil control terminal of glow relay harness connector and ECM harness connector.

Secification : Continuity ( below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground and go to "Verification of Vehicle Repair".

NO

▶ Repair open in control circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION ECA8A3FE

1. Check golw relay component coil resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect glow relay.

3) Measure the resistance of glow relay component coil.

Secification : 55±5 Ω (20 C)

4) Is the measured resistance within the specification?

YES

▶ Go to "2. Check glow relay component operation" as follows.

NO

▶ Replace glow relay and go to "Verification of Vehicle Repair".

2. Check glow relay component operation

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect glow relay.

3) Supplies random B+ and ground to coil sides of glow relay ( terminal 85, terminal 86).

4) Check continuity between glow relay terminal 30 and terminal 87.

FLB -444 FUEL SYSTEM

Secification : When power is supplied : Continuity ( below 1.0Ω )

When power is not supplied : Discontinuity ( Infinite Ω )

5) Is the measured resistance within the specification?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace glow relay and go to "Verification of Vehicle Repair".

※ Repeat this process 2~3 times.

VERIFICATION OF VEHICLE REPAIR EAB4860A

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

DTC TROUBLESHOOTING PROCEDURES FLB -445

DTC P0685 ECM/PCM POWER RELAY CONTROL CIRCUIT /OPEN

COMPONENT LOCATION E52400B7

Main Relay

SFDF28325L

GENERAL DESCRIPTION E8165136

Main relay operates when Ignition ON signal is inputted to terminal 28 of ECM CUD-K connector and it supplies power to
ECM, fuel pump relay, CMP, EGR actuator, throttle flap actuator, PTC heater relay and brake switch, etc. Especially, the
power supplied to ECM is used as a main power of injectors, rail pressure control valve and ECM operation.
When IG KEY ON signal is shut off during turning engine OFF, ECM stops injector operation then engine turns OFF.
Approx. after 5 sec., ECM shuts OFF main relay and system turns OFF.
Main relay is very important for engine operation, so careful inspection is strongly required.

DTC DESCRIPTION E4CB91FE

When IG KEY OFF signal is imputted to ECM. ECM stops injector operation andn engine turns OFF. Then, After-run(turn-
ing off process of ECM intermal system) is performed in order to shut system down. During this process, if main relay
power supply is cut too late or power supply is cut too early before After-run process completes, ECM detect main relay
error and P0685 is set.
FLB -446 FUEL SYSTEM

DTC DETECTING CONDITION E7D42A57

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

● When main relay respond to IG KEY - ON/OFF

signal too fast or slow (After-run finished and
Threshold Value it requires more than 2 sec. for Main relay to
be deactivated. Main relay deactivated before
After-run finished more than 3 times. ) ● Main relay circuit
● Main relay component
Diagnostic Time ● Immediately
Fuel Cut NO
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp

SPECIFICATION E1E472F3

Main Relay Coil Resistance 73±10 Ω (20 C)

DTC TROUBLESHOOTING PROCEDURES FLB -447

DIAGNOSTIC CIRCUIT DIAGRAM E32FE1D9

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.
Main Relay
"ON" Input

E/R JUNCTION BOX

<ECM>

94 93 92 90 89
*
72 71 70 69 68 * 87 86 * 84 83 * 81 80 79 * 77 * 75 * * 6 5
* * 65 64 * * * * * * 57 56 * 54 * * 51 4 3

* 27* 48 47
28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1
* 25 * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7
1.3.5. Main Relay "ON" Input
72. Main Relay Control

SFDF27619L

SIGNAL WAVEFORM AND DATA E7577198

IG KEY signal

Main relay

Fig.1
SFDF27554L

Fig.1) Main relay operates when IG KEY "ON" (CUD-K terminal 28 ON signal), it turns "OFF" in 12 sec. after IG KEY
"OFF".
FLB -448 FUEL SYSTEM

TERMINAL AND CONNECTOR INSPECTION E3108C9B

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power Circuit Inspection".

POWER CIRCUIT INSPECTION ECF6503E

1. Check power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect main relay.

3) Measure the voltage between power input terminal of main relay connector and chassis ground.

4) Measure the voltage between coil power terminal of main relay connector and chassisg ground.

Secification : 11.5V~13.0V

5) Is the measured voltage within the specification?

YES

▶ Go to "Check power supply line(relay▶actuator)" as follows.

NO

▶ Repair ECU FUSIBLE LINK in E/R JUNCTION BOX and related circuit and go to "Verification of Vehicle
Repair".

2. Check power supply line(relay▶actuator)

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect main relay and ECM connector.

3) Connect ‘ Power from battery to main relay’ terminals(30, 87, and 87a) with power by jump wires.
DTC TROUBLESHOOTING PROCEDURES FLB -449

4) Measure the voltage on ‘ Main relay control’ terminal and ‘ Main relay ON input’ terminals of ECM harness
connector(CUD-K).

Secification : 11.5V~13.0V

5) Is the measured voltage within the specification?

YES

▶ Go to "Control Circuit Inspection".

NO

▶ Check and repair the open circuit where voltage can not be checked and go to "Verification of Vehicle Repair".

CONTROL CIRCUIT INSPECTION E4D391F2

1. Check open in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect main relay and ECM connector.

3) Check the resistance of main relay control circuit between ECM harness connector and Main relay harness side.

Secification : Continuity ( below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "2. Check short to ground in control circuit" as follows.

NO

▶ Repair open in control circuit and go to "Verification of Vehicle Repair".

2. Check short to ground in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect main relay and ECM connector.

3) Check the resistance between main relay control terminal and chassis ground.

Secification : Discontinuity ( Infinite Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "3.Check short to battery in control circuit" as follows.

NO

▶ Repair short to ground in control circuit and go to "Verification of Vehicle Repair".

FLB -450 FUEL SYSTEM

3. Check short to battery in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect main relay and ECM connector.

3) IG KEY "ON".

4) Measure the voltage between main relay control terminal and chassis ground.

Specification : 0.0V~0.1V

5) Is abnormal voltage detected in the circuit with both connectors disconnected?

YES

▶ Repair short to battery in signal circuit and go to "Verification of Vehicle Repair".

NO

▶ Go to "Component Inspection".

COMPONENT INSPECTION EB25B6D3

1. Check main relay component resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect main relay.

3) Measure the resistance between main relay control terminals (Component side).

Secification : 73±10 Ω (20 C)

4) Is the measured resistance within the specification?

YES

▶ Go to "2. Check main relay component operation" as follows.

NO

▶ Replace main relay and go to "Verification of Vehicle Repair".

2. Check main relay component operation

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect main relay.

3) Supplies random B+ and ground to coil sides of main relay. (Component side)

4) Check continuity between main relay power supply terminals - 30 and 87. (Component side)

Secification : When power is supplied : Continuity ( below 1.0Ω )

When power is not supplied : Discontinuity ( Infinite Ω )
DTC TROUBLESHOOTING PROCEDURES FLB -451

5) Is the continuity test within the specification?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace main relay and go to "Verification of Vehicle Repair".

※ Repeat this process 2~3 times.

VERIFICATION OF VEHICLE REPAIR EF3A0961

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -452 FUEL SYSTEM

DTC P0698 SENSOR REFERENCE VOLTAGE C CIRCUIT LOW

COMPONENT LOCATION EF984587

ECM

SFDF28307L

GENERAL DESCRIPTION E0A8F530

ECM is activated by power supply. Signals from several sensors, such as CKPS and APS, is inputted to ECM. Comparing
inputted siganals with control LOGIC saved at micro controller and EEPROM, ECM controlls engine as actuating injectors,
solenoids and relays.
To guarantee accurate control, ECM performs SELF TEST, DIAGNOSIS of several sensors and actuators. And if serious
trouble which affects vehicle performance occurrs, ECM sets DTCs.
At certain cases, ECM shuts down whole systems in order to prevent dangerous situation due to incorrect control.

DTC DESCRIPTION E9B7CE0A

P0698 is set when the voltage is below lower limit for more than 0.1 sec.. This code is due to the short to ground in sensor
power circuit or the voltage problem inside of ECM.

DTC DETECTING CONDITION EC1884C6

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● when the voltage is below the minimum ● A/C pressure transducer power
voltage of sensor power supply supply circuit
● Variable swirl control actuator
Diagnostic Time ● 100ms power supply circuit
Fuel Cut NO ● Differntil pressure sensor power
supply circuit
EGR Off NO
● ECM component
Fail Safe Fuel Limit YES
Check
NO
Lamp
DTC TROUBLESHOOTING PROCEDURES FLB -453

SPECIFICATION E1CFF8B7

Sensor power 1 Sensor power 2 Sensor power 3

A/C pressure transducer,
APS 1 RPS, APS 2,BPS Differntil pressure sensor,
VSA position Sensor
4830mV~5158mV 4830mV~5158mV 4830mV~5158mV

DIAGNOSTIC CIRCUIT DIAGRAM E819601A

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.

Main Relay "ON" Input

E/R JUNCTION BOX

MTR (+)

Power M
MTR (-)
P Ground
Power
Signal
Signal
Differential Pressure sensor
Ground

Variable Swirl
Control Actuator

Ground

P Signal

Power

A/C PRESSURE TRANSDUCER

SFDF27620L
FLB -454 FUEL SYSTEM

<Differential Pressure Sensor> <A/C PRESSURE TRANSDUCER> <Variable Swirl

Control Actuator>

3 2 1
3 2 1 5 4 3 2 1

1.Ground 1. MTR(+)
1. Power
2. Signal 2. MTR(-)
2. Signal
3. Power 3. Power
3. Ground
4. Feed Back Signal
5. Ground

<ECM>

60 59 58 6. Ground
* * * 53 37* * 50 4934 33* 47 3146
56
44 43 42 41 40 26. Power
* ** * * * 30. MTR(-)
30 28 27 26 23 20 19 17 16
* ** ** * 56. Feed Back Signal
* * 13 12 * * * 8 7 6 * 4 * 2 1 60. MTR(+)

<ECM>

12. Ground
94 93 92 90 89
*
72 71 70 69 68 * 87 86 * 84 83 * 81 80 79 * 77 * 75 * * 6 5 13. Signal
* * 65 64 * * * * * * 57 56 * 54 * * 51 4 3 22. Power
36. Signal
* 27* 48 47
28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1
* 25 * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7 37. Ground
44. Power

SFDF27621L

SIGNAL WAVEFORM AND DATA ED1C05E6

Aircon pressure sensor power Aircon pressure sensor power

Variable swirl control actuator position sensor Differntil pressure sensor power

Fig.1 Fig.2
SFDF27555L

Fig.1) A/C pressure transducer and VSA position Sensor power supply signals are measured simultaneously.
DTC TROUBLESHOOTING PROCEDURES FLB -455

Check if the voltages are within the specification ( 4.8~5.1V) at IG KEY "ON"
Fig.2) A/C pressure transducer and Differntil pressure transducer power supply signals are measured simultaneously.
Check if the voltages are within the specification ( 4.8~5.1V) at IG KEY "ON"

TERMINAL AND CONNECTOR INSPECTION EBA45969

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power Circuit Inspection".

POWER CIRCUIT INSPECTION E652C913

1. Check power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect A/C pressure transducer connector, Differntil pressure sensor connector and variable swirl control
actuator connector.

3) IG KEY "ON".

4) Measure the voltage between power terminal of A/C Pressure Transducer harness connector and chassis ground.

5) Measure the voltage between power terminal of Variable Swirl Ccontrol Actuator harness connector and chassis
ground.

6) Measure the voltage between power terminal of Differentil Pressure Sensor harness connector and chassis
ground.

Secification : 4.8V~5.1V

7) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".
FLB -456 FUEL SYSTEM

NO

▶ Go to "2. Check short to ground in power circuit" as follows.

2. Check short to ground in power circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect A/C pressure transducer connector, Differntil pressure sensor connector, variable swirl control actu-
ator connector, ECM connectors.

3) Check continuity between A/C pressure transducer connector , Differntil pressure sensor connector or variable
swirl control actuator connector and chassis ground.

Secification : Discontinuity ( Infinite Ω )

4) Is the measured resistance within the specification?

YES

▶ If the circuit is insulated well and the sensor power supply from ECM is low, replace ECM and go to "Verification
of Vehicle Repair".

NO

▶ Repair short to ground and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E63755E0

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect A/C pressure transducer connector, Differntil pressure sensor connector and variable swirl control actu-
ator connector.

3. Check that sensor connector power supply is within the specification after turning IG KEY "ON".

4. Connect A/C pressure transducer connector, Differntil pressure sensor connector and variable swirl control actuator
connector in turn.

5. Measure the voltage of power circuit of each sensor with all connector connected.

Specification : sensor power supply should not change as connecting A/C pressure transducer connector,
Differntil pressure sensor connector and variable swirl control actuator connector.
( If the change of sensor power supply occur as connecting sensor connector, this means
the occurrence of short inside of sensor.)

6. Does change of sensor power supply occur as connecting sensor connector?

YES

▶ Replace A/C pressure transducer, Differntil pressure sensor or variable swirl control actuator.

NO

▶ Go to "Verification of Vehicle Repair".

DTC TROUBLESHOOTING PROCEDURES FLB -457

VERIFICATION OF VEHICLE REPAIR E1F2715E

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -458 FUEL SYSTEM

DTC P0699 SENSOR REFERENCE VOLTAGE C CIRCUIT HIGH

COMPONENT LOCATION EBBA918B

Refer to DTC P0698.

GENERAL DESCRIPTION EC599FED

Refer to DTC P0698.

DTC DESCRIPTION E8EAFD45

P0699 is set when the voltage is above upper limit for more than 0.1 sec.. This code is due to the short to battery in
sensor power circuit or the voltage problem inside of ECM.

DTC DETECTING CONDITION E0E2A4F2

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● when the voltage is above the maximum ● A/C pressure transducer power
voltage of sensor power supply supply circuit
● Variable swirl control actuator
Diagnostic Time ● 100ms power supply circuit
Fuel Cut NO ● Differntil pressure sensor power
supply circuit
EGR Off NO
● ECM component
Fail Safe Fuel Limit YES
Check
NO
Lamp

SPECIFICATION ECF09891

Refer to DTC P0698.

DIAGNOSTIC CIRCUIT DIAGRAM E7F5CB6D

Refer to DTC P0698.

SIGNAL WAVEFORM AND DATA E7E3F594

Refer to DTC P0698.

TERMINAL AND CONNECTOR INSPECTION EA2215F7

Refer to DTC P0698.

POWER CIRCUIT INSPECTION E7D78572

1. Check power circuit voltage

DTC TROUBLESHOOTING PROCEDURES FLB -459

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect A/C pressure transducer connector, Differntil pressure sensor connector and variable swirl control
actuator connector.

3) IG KEY "ON".

4) Measure the voltage between A/C pressure transducer connector , Differntil pressure sensor connector , variable
swirl control actuator connector and chassis ground.

Secification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ Go to "2. Check short to ground in power circuit" as follows.

2. Check short to battery in power circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect A/C pressure transducer connector, Differntil pressure sensor connector, variable swirl control actu-
ator connector, ECM connectors.

3) IG KEY "ON".

4) Measure the voltage between A/C pressure transducer connector , Differntil pressure sensor connector , variable
swirl control actuator connector and chassis ground.

Secification : 0.0V~0.1V

5) Is abnormal voltate measured in this test?

YES

▶ Repair short to battery and go to "Verification of Vehicle Repair".

NO

▶ If the circuit is insulated well and the sensor power supply from ECM is high, replace ECM and go to "Verifi-
cation of Vehicle Repair".

COMPONENT INSPECTION E34798EB

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect A/C pressure transducer connector, Differntil pressure sensor connector and variable swirl control actu-
ator connector.

3. Check that sensor connector power supply is within the specification after turning IG KEY "ON".

4. Connect A/C pressure transducer connector, Differntil pressure sensor connector and variable swirl control actuator
connector in turn.
FLB -460 FUEL SYSTEM

5. Measure the voltage of power circuit of each sensor with all connector connected.

Specification : sensor power supply should not change as connecting A/C pressure transducer connector,
Differntil pressure sensor connector and variable swirl control actuator connector.
( If the change of sensor power supply occur as connecting sensor connector, this means
the occurrence of short inside of sensor.)

6. Does change of sensor power supply occur as connecting sensor connector?

YES

▶ Replace A/C pressure transducer, Differntil pressure sensor or variable swirl control actuator.

NO

▶ Go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E77547C0

Refer to DTC P0698.

DTC TROUBLESHOOTING PROCEDURES FLB -461

DTC P0820 GEAR LEVER X-Y POSITION SENSOR CIRCUIT

GENERAL DESCRIPTION E3CF9446

Neutral Gear Switch is installed in M/T vehicle and senses driver′ s intension to shift gear(driver′ s intension to drive).
ECM recognizes engaged gear based on vehicle speed sensor signal and engine RPM in M/T vehicle. And Black Smoke
limiting fuel quantity value varies according to engaged gear.(As higher gear shift is engaged, maximum possible fuel
injection quantity increases to raise power generation.)
The recognition of engaged gear is available when vehicle speed reachs to 2Km/h - the minimum speed for ECM to detect.
When vehicle starts to move after standing for a while and vehicle speed does not reach to 2Km/h, fuel quantity mapping
value at neutral gear is adopted to vehicle. Moreover, this phenomenon is more serious when vehicle requires high power
generation such as the situation when vehicle is on the slope.
To cope with this problem, neutral gear switch which senses driver′ s intension of starting to move is applied. And fuel
injection quantity mapping value suitable for 1st gear is adopted immediately.

NOTE
To reduce black smoke produced during rapid acceleration when no load is applied, fuel injection quantity at none
load condition is 70% of that at 1st gear.

DTC DESCRIPTION E25DE9A9

P0820 is set when 1)gear is engaged at non-neutral positon at engine ON, but clutch signal is not detected. or 2)only
neutral signal is detected at above 600RPM or above 80Km/h. for more than 3 sec.. This code is due to open, short to
battery or ground in neutral gear switch circuit.

DTC DETECTING CONDITION E76DE7D1

Item Detecting Condition Possible Cause

DTC Strategy ● Signal monitoring
Enable Conditions ● During driving

Threshold Value ● Short to Battery

● short to GND, wiring open
Diagnostic Time ● 3.0 sec. ● Nertral gear switch component
● Nertral gear switch circuit
Fuel Cut NO
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp

SPECIFICATION E7CDE2A8

Signal Voltage Neutral Position Except Neutral Position

11.0V~13.5V 0.0V~0.2V(LOW) 11.0V~13.5V(HIGH)
FLB -462 FUEL SYSTEM

DIAGNOSTIC CIRCUIT DIAGRAM EA0B7DF6

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.
Main Relay
"ON" Input

E/R JUNCTION BOX

<Neutral Switch>

2 1 Neutral Switch

1. Neutral Switch
2. Ground
NEUTRAL SWITCH

<ECM>

94 93 92 90 89
*
72 71 70 69 68 * 87 86 * 84 83 * 81 80 79 * 77 * 75 * * 6 5
* * 65 64 * * * * * * 57 56 * 54 * * 51 4 3

* 27* 48 47
28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1
* 25 * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7
57. Neutral Switch

SFDF27622L

SIGNAL WAVEFORM AND DATA EF082129

Gear ingaged

Neutral gear

Fig.1
SFDF27556L
DTC TROUBLESHOOTING PROCEDURES FLB -463

Fig 1) 0V at neutral gear position, 12V at any gear position except neutral position.

TERMINAL AND CONNECTOR INSPECTION E800E328

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Signal Circuit Inspection".

SIGNAL CIRCUIT INSPECTION E8E091F9

1. Neutral gear switch Voltage Inspection

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect neutral gear switch connector.

3) IG KEY "ON"

4) Check the voltage between signal terminal of neutral gear switch harness connector and chassis ground.

Secification : 11.5V~13.0V

5) Is the measured voltage within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Go to "2. Check open in neutral gear switch signal cicuit" as follows.

2. Check open in neutral gear switch signal cicuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect neutral gear switch connector and ECM connector.

FLB -464 FUEL SYSTEM

3) Check the continuity between signal terminal of neutral gear switch harness connector and ECM harness con-
nector.

Secification : Approx. below 1Ω

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground in signal circuit and go to "Verification of Vehicle Repair".

NO

▶ Repair open in signal circuit and go to "Verification of Vehicle Repair".

GROUND CIRCUIT INSPECTION E2C152E7

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect neutral gear switch connector and ECM connector.

3. IG KEY "ON".

4. Measure the voltage between signal terminal of neutral gear switch harness connector and chassis ground. [ TEST
"A" ]

5. Measure the voltage between signal terminal and ground terminal of neutral gear switch harness connector. [ TEST
"B" ]
( Signal terminal : Check + prove , Ground terminal : Check - prove )

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6. Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E3343E25

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect neutral gear switch connector and ECM connector.

3. Check the contituity between signal terminal and ground terminal of neutral gear switch connector (component side)
as shifting gear lever 2~3 times.

Specification : At neutral position : Continuity (below 1.0)

At any gear position except neutral position : Discontinuity ( Iinfinite Ω )
DTC TROUBLESHOOTING PROCEDURES FLB -465

4. Is the measured resistance within the specification?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace neutral gear switch and go to Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E662A945

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -466 FUEL SYSTEM

DTC P0830 CLUTCH PEDAL SWITCH "A" CIRCUIT

GENERAL DESCRIPTION E78C668C

Clutch switch is connected to clutch pedal and transmits clutch operating state to ECM.
When clutch pedal is depressed during driving, engine load changes from loaded to none loaded condition. However,
ECM regards vehicle to be loaded becuase VSS signal is still inputted to it. therefore, ECM controls none loaded engine
with the condition suitable for loaded engine.
Accordingly, optimum fuel injection control is not performed then, RPM becomes unstable and smoke is produced.
Clutch operation is detected through clutch switch signal. This signal enables ECM to cope with instant change of load
condition.
Besides, clutch switch signal is used to detect engaged gear with vehicle speed and engine speed.

DTC DESCRIPTION EA0B67D4

P0830 is set when no clutch switch signal change is detected 1). within 2 sec. after shifting gear during driving. 2). while
gear shifts 4 times at above 10Km/h and 1000rpm. This code is due to 1) clutch switch component failure or 2) open or
short in circuit 3) improper height of clutch pedal.
※ ECM recognize ingaged gear with rpm and vehicle speed sensor signal.

DTC DETECTING CONDITION EC7DEC60

Item Detecting Condition Possible Cause

DTC Strategy ● Signal monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● No clutch switch signal change is detected until

gear shifted 4 times at above 10Km/h and 1500rpm
Diagnostic Time ● immediately ● Clutch S/W circuit● Clutch S/W
component● Clutch S/W pedal hight
Fuel Cut NO
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp

SPECIFICATION EE4F96CA

Condition Clutch Pedal Depressed Clutch Pedal Released

Switch Operation Switch ON Switch OFF
DTC TROUBLESHOOTING PROCEDURES FLB -467

DIAGNOSTIC CIRCUIT DIAGRAM E2D08C90

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.

Main Relay
"ON" Input

E/R JUNCTION BOX

<Clutch Switch>

1 Clutch Switch
2
1. Ground
2. Clutch Switch Signal
CLUTCH SWITCH

<ECM>

94 93 92 90 89
*
72 71 70 69 68 * 87 86 * 84 83 * 81 80 79 * 77 * 75 * * 6 5
* * 65 64 * * * * * * 57 56 * 54 * * 51 4 3

* 27* 48 47
28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1
* 25 * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7
79. Clutch Switch Signal

SFDF27623L
FLB -468 FUEL SYSTEM

SIGNAL WAVEFORM AND DATA E5ECDBFC

Clutch pedal OFF

Clutch pedal ON

Fig.1
SFDF27557L

Fig.1) The waveform of clutch switch when clutch pedal is depressed. The output voltage of clutch pedal is 0V when
clutch pedal is depressed and 12V when released.

MONITOR SCANTOOL DATA E9FFBBE9

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Select "CLUTCH SWITCH" parameter on the Scantool.

Specification : When clutch switch released : "CLUTCH SWITCH" : OFF

When clutch switch depressed : "CLUTCH SWITCH" : ON

Fig.1
SFDF27558L

Fig. 1) Check if "CLUTCH SWITCH" parameter changes correctly from "ON" to "OFF" and vice versa as activating
clutch pedal.
DTC TROUBLESHOOTING PROCEDURES FLB -469

TERMINAL AND CONNECTOR INSPECTION E210AC78

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Signal Circuit Inspection".

SIGNAL CIRCUIT INSPECTION EB3DE00F

1. Check clutch switch pull-up voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect clutch switch connector.

3) IG KEY "ON".

4) Measure the voltage between signal terminal of clutch switch harness connector and chassis ground.

Secification : 11.5V~13.0V

5) Is the measured voltage within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Go to "2.Check open in clutch switch signal circuit" as follows.

2. Check open in clutch switch signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect clutch switch connector and ECM connector.

3) Check continuity between signal terminal of clutch switch harness connector and ECM harness connector.
FLB -470 FUEL SYSTEM

Secification : Continuity ( below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground in signal circuit and go to "Verification of Vehicle Repair".

NO

▶ Repair open in signal circuit and go to "Verification of Vehicle Repair".

GROUND CIRCUIT INSPECTION EF3ABF3A

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect clutch switch connector.

3. Check continuity between clutch switch connector ground terminal and chassis ground.

Specification : Continuity ( below 1.0Ω )

4. Is the measured resistance within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ Repair open or poor connection in ground circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E20DF8BC

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect clutch switch connector.

3. Check continuity between signal terminal and ground termimal of clutch switch connector. component side) as de-
pressing clutch pedal.

Specification : Clutch pedal depressed : Continuity ( below 1.0Ω )

Clutch pedal released : Discontinuity ( Infinite Ω )

4. Is the measured resistance within the specification?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ After checking height of clutch pedal, if there is no problem, replace clutch switch and go to "Verification of Vehicle
Repair".
DTC TROUBLESHOOTING PROCEDURES FLB -471

VERIFICATION OF VEHICLE REPAIR EF1EF4BA

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -472 FUEL SYSTEM

DTC P1145 OVERRUN MONITORING ERROR

COMPONENT LOCATION E1B3FFC2

ECM

SFDF28307L

GENERAL DESCRIPTION E20D0B65

ECM is activated by power supply. Signals from several sensors, such as CKPS and APS, is inputted to ECM. Comparing
inputted siganals with control LOGIC saved at micro controller and EEPROM, ECM controlls engine as actuating injectors,
solenoids and relays.
To guarantee accurate control, ECM performs SELF TEST, DIAGNOSIS of several sensors and actuators. And if serious
trouble which affects vehicle performance occurrs, ECM sets DTCs.
At certain cases, ECM shuts down whole systems in order to prevent dangerous situation due to incorrect control.

DTC DESCRIPTION E133A16F

P1145 is set if fuel to injector is not limited(fuel cut disabled) and injector operates when accelerator pedal is released
after acceleraton(when vehicle coasts). This code is due to the case that ECM fails to cut power of injector operating
system inside of ECM.

DTC DETECTING CONDITION E4C99594

Item Detecting Condition Possible Cause

DTC Strategy ● Software monitoring
Enable Conditions ● During driving

Threshold Value ● Overrun lasts for seconds. (fuel injection

performed regardless with driver’s intension)
Diagnostic Time ● Immediately ● ECM internal error
Fuel Cut YES
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp
DTC TROUBLESHOOTING PROCEDURES FLB -473

COMPONENT INSPECTION E3A93B47

1. ECM Component Inspection

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECM.

3) Replace ECM, check if abnormal operations disappear.

4) If problems are corrected, replace ECM.

NOTE
Input injector IQA data(7 letters) using scantool at replacing ECM.
Enter the driving distance - how many km the CPF is used- into New ECM with scanner.
For immobilizer applied vehicle, input pin code.

VERIFICATION OF VEHICLE REPAIR EC876DDA

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -474 FUEL SYSTEM

DTC P1185 MAXIMUM PRESSURE EXCEEDED

COMPONENT LOCATION E35B4486

FTS
Injector

RPS

Rail Pressure
Regulator Valve Fuel Pressure Regulator Valve

SFDF28328L

GENERAL DESCRIPTION E43E1C99

As inputted rail pressure sensor signal, ECM of Commom rail diesel engine controls Fuel pressure regulator valve(inter-
grated with high press. pump) and rail pressure regulator valve(ntegrated with common rail) in order to maintain optimum
rail pressure according to current engine rpm and load.
However when the problem that leads rail pressure to out of target value intended by ECM occurs due to mechanical or
electronical reason, ECM shuts engine down and sets DTC by limiting fuel (stops injector operation) in order to prevent
engine from being controlled abnormally. "rail pressure monitoring error" is the DTC which diagnose 1).supplying state
of low pressure fuel and 2).mechanical operating conditions of high pressure pump and 3). rail pressure regulator valve
indirectly based on RPS output voltage and RPS duty. thus, repair relavant to this DTC requires mechanics the total
understand of fuel system.

DTC DESCRIPTION E7E195CB

P1185 is set when 1)rail press. is higher than target rail press. by 200~350bar in condition that rail press. is controlled by
Fuel pressure regulator valve or 2)rail press. exceeds maximum limiting value. This code is due to 1)more than intended
fuel supply to common rail or 2)poor return of fuel supplied to common rail or 3)short to high voltage line in fuel press.
sensor.
DTC TROUBLESHOOTING PROCEDURES FLB -475

DTC DETECTING CONDITION EB741FE5

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● Engine running

● Rail pressure is above target rail pressure by

more than 200~350bar at Fuel pressure regulator
Threshold Value valve operating condition.- 2000ms
● Fuel pressure regulator valve
● Rail pressure is above maximum limiting
(open stuck)
value(1750bar) at Fuel pressure regulator valve
● rail pressure regulator valve
operating condition. - 240 ms
(close stuck)
Diagnostic Time ● Refer to threshold Value ● Rail pressure sensor (Output
fixed at high voltage line)
Fuel Cut NO
EGR Off NO
Fail Safe Fuel Limit YES
Check
YES
Lamp

MONITOR SCANTOOL DATA E1CD0686

1. Monitoring rail pressure data

1) Connect Scantool to Data Link Connector (DLC).

2) Warm engine up to normal operating temperature.

3) Turn "OFF" electrical devices and A/C.

4) Monitor "FUEL PRESSURE MEASURED", "FUEL PRESSURE-TARGET", "RAIL PRESS. REGULATOR1", "INJ.
PUMP REGULATOR" parameter on the Scantool.

Specification : FUEL PRESSURE MEASURED : similar to "FUEL PRESSURE-TARGET"

FUEL PRESSURE-TARGET : 28 ± 5 Mpa
RAIL PRESS. REGULATOR1 : 20 ± 5%
INJ. PUMP REGULATOR : 40 ± 5%
FLB -476 FUEL SYSTEM

Fig.1
SFDF27559L

Fig.1) Monitor "FUEL PRESSURE MEASURED" at idle after warming engine up.
Check if "FUEL PRESSURE MEASURED"data is similar to "FUEL PRESSURE-TARGET". Not only former
two data but also "RAIL PRESS. REGULATOR1" and "INJ. PUMP REGULATOR"shoult be monitored carefully.
Although "FUEL PRESSURE MEASURED" is similar to "FUEL PRESSURE-TARGET", if "RAIL PRESS. REG-
ULATOR1" and "INJ. PUMP REGULATOR" is out of specification, it means wear, leakage, stuck of fuel system.

2. Monitoring rail pressure data at acceleration(loading condition).

1) Connect Scantool to Data Link Connector (DLC).

2) Warm engine up to normal operating temperature.

3) Turn "OFF" electrical devices and A/C.

4) Monitor "FUEL PRESSURE MEASURED", "RAIL PRESS. REGULATOR1", "INJ. PUMP REGULATOR" param-
eter on the Scantool.

SPECIFICATION :

Idle(without load) Accelerating(stall test) Diagnosis

INJ. PUMP REGULATOR 38 ± 5% 32 ± 5% Duty decreases
FUEL PRESSURE
28.5 ± 5 Mpa 145 ± 10 Mpa Press. increases
MEASURED
RAIL PRESS.
19 ± 5% 48 ± 5% Duty increases
REGULATOR1
DTC TROUBLESHOOTING PROCEDURES FLB -477

Fig.2 Fig.3
SFDF27560L

Fig.1) The position of curser on the graph represents idle data.

Fig.2) Data during acceleration(stall test).

NOTE
The waveform of fuel pressure regulator valve installed at high pressure pump(fuel detecting MPROP) shows 38%
duty at idle, duty drops to approx. 32% at acceleration to raise rail pressure. Duty drop means the decrease of
current.
▶ Fuel delivered to common rail increases as current drops.

The waveform of rail pressure regulator valve installed at common rail shows 19% duty at idle, duty rises to approx.
48% at acceleration to raise rail pressure. Duty rise means the increase of current.
▶ If current rises, the returning quantity of fuel deliverd to common rail decreases and common rail pressure rises.

VERIFICATION OF VEHICLE REPAIR EB7064B1

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -478 FUEL SYSTEM

DTC P1186 MINIMUM PRESSURE AT ENGINE SPEED TOO LOW

COMPONENT LOCATION E47618AF

Refer to DTC P1185.

GENERAL DESCRIPTION EC777AA7

Refer to DTC P1185.

DTC DESCRIPTION E0348C98

P1186 is set when rail press. is lower than target rail press. by 500~150bar for more than 1.0 sec. in condition that rail
press. is controlled by Fuel pressure regulator valve. This code is due to 1)less than intended fuel supply to common rail
or 2)excessive return of fuel supplied to common rail or 3)short to low voltage line in fuel press. sensor.

DTC DETECTING CONDITION E6914A99

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● Engine running

● Rail pressure is below target rail pressure by

more than 500~150bar at Fuel pressure regulator
Threshold Value valve operating condition.- 1.0sec
● Fuel pressure regulator valve
● Rail pressure is below minimum limiting
(close stuck)
value(50~280bar) at rail Fuel pressure regulator
● rail pressure regulator valve
valve operating condition.- 0.3sec
(open stuck)
Diagnostic Time ● Refer to threshold Value ● Rail pressure sensor (Output
fixed at low voltage line)
Fuel Cut NO
EGR Off NO
Fail Safe Fuel Limit YES
Check
YES
Lamp

MONITOR SCANTOOL DATA EFA41263

1. Monitoring rail pressure data

1) Connect Scantool to Data Link Connector (DLC).

2) Warm engine up to normal operating temperature.

3) Turn "OFF" electrical devices and A/C.

4) Monitor "FUEL PRESSURE MEASURED", "FUEL PRESSURE-TARGET", "RAIL PRESS. REGULATOR1", "INJ.
PUMP REGULATOR" parameter on the Scantool.

Specification : FUEL PRESSURE MEASURED : similar to "FUEL PRESSURE-TARGET"

FUEL PRESSURE-TARGET : 28 ± 5 Mpa
RAIL PRESS. REGULATOR1 : 20 ± 5%
INJ. PUMP REGULATOR : 40 ± 5%
DTC TROUBLESHOOTING PROCEDURES FLB -479

Fig.1
SFDF27559L

Fig.1) Monitor "FUEL PRESSURE MEASURED" at idle after warming engine up.
Check if "FUEL PRESSURE MEASURED"data is similar to "FUEL PRESSURE-TARGET". Not only former
two data but also "RAIL PRESS. REGULATOR1" and "INJ. PUMP REGULATOR"shoult be monitored carefully.
Although "FUEL PRESSURE MEASURED" is similar to "FUEL PRESSURE-TARGET", if "RAIL PRESS. REG-
ULATOR1" and "INJ. PUMP REGULATOR" is out of specification, it means wear, leakage, stuck of fuel system.

2. Monitoring rail pressure data at acceleration(loading condition).

1) Connect Scantool to Data Link Connector (DLC).

2) Warm engine up to normal operating temperature.

3) Turn "OFF" electrical devices and A/C.

4) Monitor "FUEL PRESSURE MEASURED", "RAIL PRESS. REGULATOR1", "INJ. PUMP REGULATOR" param-
eter on the Scantool.

SPECIFICATION :

Idle(without load) Accelerating(stall test) Diagnosis

INJ. PUMP REGULATOR 38 ± 5% 32 ± 5% Duty decreases
FUEL PRESSURE
28.5 ± 5 Mpa 145 ± 10 Mpa Press. increases
MEASURED
RAIL PRESS.
19 ± 5% 48 ± 5% Duty increases
REGULATOR1
FLB -480 FUEL SYSTEM

Fig.2 Fig.3
SFDF27560L

Fig.1) The position of curser on the graph represents idle data.

Fig.2) Data during acceleration(stall test).

NOTE
The waveform of fuel pressure regulator valve installed at high pressure pump(fuel detecting MPROP) shows 38%
duty at idle, duty drops to approx. 32% at acceleration to raise rail pressure. Duty drop means the decrease of
current.
▶ Fuel delivered to common rail increases as current drops.

The waveform of rail pressure regulator valve installed at common rail shows 19% duty at idle, duty rises to approx.
48% at acceleration to raise rail pressure. Duty rise means the increase of current.
▶ If current rises, the returning quantity of fuel deliverd to common rail decreases and common rail pressure rises.

VERIFICATION OF VEHICLE REPAIR E348D1B8

Refer to DTC P1185.

DTC TROUBLESHOOTING PROCEDURES FLB -481

DTC P1403 DIFFERENTIAL PRESSURE NOT PLAUSIBLE (HOSE LINE

GROZEN) (DIESEL)

COMPONENT LOCATION E01AE053

DPS

SFDF28329L

GENERAL DESCRIPTION E260EE1A

Differential pressure sensor(DPS) is piezzo electric type sensor. Sensing the differential pressure between in front of
CPF and in the back of CPF, DPS outputs linear signal from 0~5V. Using output signal, DPS detects the amount of soot,
sulfide, SOF(soluble organic fraction) to determine if CPF regeneration is needed.
【CPF regeneration】When vehicle is in steady speed condition and above normal engine loading condition, if differential
pressure between before and after CPF is above the specified pressure, ECM considers that stored soot inside of CPF is
excessive. In this condition, exhaust gas tempt. is raised by post injection 1 and 2 to warm CPF up to 550 C~650 C. In
this high tempt, soot inside of CPF burns up naturally and this mechanism is called as "CPF regeneration". Most of soot is
burned up during regeneration process but a little amount of soot is not burned up and stored inside of CPF continuously.
The stored soot decreases the efficiency of CPF slowly. DPS corrects CPF regeneration period and duration as comparing
and calculating the differential pressure due to stored soot with the total distance covered.

DTC DESCRIPTION EB50C773

P1403 is set when outdoor temp. is -5 C and failure ID signal is outputted as 1. If differncial pressure does not change
or it is extremly low, ECM recognizes hose line to be faulty. This code is likely to be set when vehicle is parked at a slope
with front side of vehicle headed to downward.
FLB -482 FUEL SYSTEM

DTC DETECTING CONDITION ED28C4C4

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● Engine running

Threshold Value ● Abnormal signal outputted at below ● Water freezing

-5℃ of outdoor temp. ● DPS Wiring
● DPS component
Diagnostic Time ● Immediately ● Reversly connected DPS hose line
Fuel Cut NO ● Clogged DPS hose
● Clogged CPF inlet section
EGR Off NO
● Clogged CPF
Fail Safe Fuel Limit NO
Check
OFF
Lamp

SPECIFICATION EDCAC60B

Differential Pressure Characteristic

Abnormall output (Reversely connected) Normal output

4.5

Output Output
voltage voltage
(V) (V)

1 1
0.5

0 15 100 0 15 100
Differential Pressure (kPa) Differential Pressure (kPa)

SEDF27325L
DTC TROUBLESHOOTING PROCEDURES FLB -483

DIAGNOSTIC CIRCUIT DIAGRAM ED63AA74

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.
Main Relay
"ON" Input

E/R JUNCTION BOX

<Differential Pressure Sensor>

3 2 1 Power

P Ground

1. Power Signal
2. Signal
3. Ground Differential Pressure Sensor

<ECM>

94 93 92 90 89 36. Signal
72 71 70 69 68* * 87 86 * 84 83 * 81 80 79 * 77 * 75 * * 6 5
* * 65 64 * * * * * * 57 56 * 54 * * 51 4 3 37. Ground
* 27* 48 47
28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1
* 25 * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7 44. Power

SFDF27606L
FLB -484 FUEL SYSTEM

SIGNAL WAVEFORM AND DATA EE62A6FC

Fig.1 Fig.2
SFDF27534L

Fig1). This is the signal waveform of DPS at idle state. When CPF is new, 1.0~1.2V is outputted normally.
Fig2). This is the waveform of DPS as accelerating.

NOTE
As accelerating, DPS signal output voltage does not vary too much. Even when accelerator pedal is fully depressed,
the signal voltage fluctuates just a little bit like "Fig. 2". However, the more CPF is used, the more waveform fluctuates.

MONITOR SCANTOOL DATA E91DC721

1. Connect Scantool to Data Link Connector (DLC).

2. When atmospheric temp. is below 0 C, monitor data as soon as turning engine ON.

3. Turn "OFF" electrical devices and A/C.

4. Monitor "DIFFERENTIAL PRESSURE" and "PRESSURE PRE CPF" parameter on the scantool.

Specification : "DIFFERENTIAL PRESSURE" and "PRESSURE PRE CPF" data vary normally.
Even at the temperature of below 0 C
DTC TROUBLESHOOTING PROCEDURES FLB -485

Fig.1
SFDF27562L

Fig. 1) When turning enigne ON at below 0 C in which water freezes, monitor if "DIFFERENTIAL PRESSURE"
and "PRESSURE PRE CPF" data vary normally. When a vehicle is in acceleration or driven in that cold condition,
"DIFFERENTIAL PRESSURE" and "PRESSURE PRE CPF" data must vary.

NOTE
※ When data do not vary
▶ Check if diconnected differential pressure sensing hose or pressure leakage is detected. Check if the deforma-
tion(which may disturb water flow) of the steel pipe connecting CPF and DIFFERENTIAL PRESSURE SENSOR as
well.

TERMINAL AND CONNECTOR INSPECTION E0C06F32

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power Circuit Inspection".

FLB -486 FUEL SYSTEM

POWER CIRCUIT INSPECTION E5C27155

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect DPS connector.

3. IG KEY "ON"

4. Measure the voltage between power supply terminal of DPS harness connector and chassis ground.

Specification : 4.8V~5.1V

5. Is the measured voltage within the specification?

YES

▶ Go to "Signal Circuit Inspection".

NO

▶ Repair open in power circuit and go to "Verification of Vehicle Repair".

SIGNAL CIRCUIT INSPECTION E138F712

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect DPS connector.

3) IG KEY "ON".

4) Measure the voltage between signal terminal of DPS harness connector and chassis ground.

Specification : 4.8V~5.1V

5) the measured voltage within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Go to "2. Check open in signal circuit" as follows.

2. Check open in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect DPS connector and ECM connector.

3) Measure the resistance between signal terminal of DPS harness connector and DPS signal terminal of ECM
harness connector.

Specification : Continuity ( below 1.0Ω )

4) Is the measured resistance within the specification?

DTC TROUBLESHOOTING PROCEDURES FLB -487

YES

▶ Go to "3. Check short in signal circuit" as follows.

NO

▶ Repair open in DPS signal circuit and go to "Verification of Vehicle Repair".

3. Check short in signal circuit

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect DPS connector and ECM connector.

3) IG KEY "ON"

4) Measure the resistance between signal terminal of DPS harness connector and chassis ground.

5) Measure the voltage between signal terminal of DPS harness connector and chassis ground.

Specification : Test for short to ground : Discontinuity (Infinite Ω )

Test for short to battery : below 0.1 V

6) Is the isolation of DPS signal circuit normal?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Repair short in signal circuit and go to "Verification of Vehicle Repair".

GROUND CIRCUIT INSPECTION EAF1D47C

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect DPS connector.

3. IG KEY "ON"

4. Measure the voltage between signal terminal of DPS harness connector and chassis ground. [ TEST "A" ]

5. Measure the voltage between signal terminal and ground terminal of DPS harness connector. [ TEST "B" ]
( Signal terminal : Check + prove , Ground terminal : Check - prove )

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6. Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
FLB -488 FUEL SYSTEM

▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION ED7A927E

1. DPS visual inspection

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect DPS connector.

3) Check DPS terminals for corrosion and contamination.

4) Check (1)connecting condition of DPS and pressure sensing hose, (2)exhaust gas pressure leakate, (3)miss
connection of pressure sensing hose (reverse connection) is detected.

5) Is DPS related problem detected?

YES

▶ If needed, replace DPS or pressure sensing hose and go to "Verification of Vehicle Repair".

NO

▶ Go to "2. Monitor DPS signal waveform" as follows.

2. Monitor DPS signal waveform

1) IG KEY "ON", ENGINE "OFF"

2) Connect DPS connector.

3) Connect oscilloscope to DPS connector terminal 2.

4) After warming engine up, monitor the waveform at idle and during acceleration.

Specification : Refer to "Signal Waveform ＆ Data" of "General Information".

Fig.1 Fig.2
SFDF27534L

Fig1). This is the signal waveform of DPS at idle state. When CPF is new, 1.0~1.2V is outputted normally.
Fig2). This is the waveform of DPS as accelerating.
DTC TROUBLESHOOTING PROCEDURES FLB -489

NOTE
As accelerating, DPS signal output voltage does not vary too much. Even when accelerator pedal is fully depressed,
the signal voltage fluctuates just a little bit like "Fig. 2". However, the more CPF is used, the more waveform fluctuates.

5) Is DPS signal waveform is similar to the waveform of "Signal Waveform ＆ Data"?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace DPS and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E4E2AA5C

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -490 FUEL SYSTEM

DTC P1405 CPF-PERMANENT REGENERATION

COMPONENT LOCATION E42950DC

EGTS #1

EGTS #2 DPS

CPF

SFDF28330L

GENERAL DESCRIPTION E656A82F

Comparing with gasoline engine, one of the worst point of diesel engine is that a lot of particle material(PM) are generated
after combustion process. In order to decrease the amount of PM, CPF is equipped in EURO-4 diesel engine. CPF is the
device which gathers PM with installed filter then burns it up as raising the tempt. inside of CPF above the ignition point
of PM. The process which burns up PM is called "CPF regeneration".
※ CPF regeneration : When vehicle is in steady speed condition and above normal engine loading condition, if differential
pressure between before and after CPF is above the specified pressure, ECM considers that stored soot inside of CPF is
excessive. In this condition, exhaust gas tempt. is raised by post injection 1 and 2 to warm CPF up to 550 C~650 C. In
this high tempt, soot inside of CPF burns up naturally and this mechanism is called as "CPF regeneration".
Most of soot is burned up during regeneration process but a little amount of soot is not burned up and stored inside of
CPF continuously. The stored soot decreases the efficiency of CPF slowly. DPS corrects CPF regeneration period and
duration as comparing and calculating the differential pressure due to stored soot with the total distance covered.

DTC DESCRIPTION E2F1096D

P1405 is set when CPF is in generation mode to get rid of piled P.M but generation has not completed for exceeding
designated time (600sec.) or temperature difference between VGT-CPF sensors signal is over set temperature (40 C)
during cold condition.
This DTC will be set by foreign materials in the CPF, Malfunctioning of DPS signal, Faulty EGTS - VGT or CPF or circuit
malfunction.
DTC TROUBLESHOOTING PROCEDURES FLB -491

DTC DETECTING CONDITION EE1A2F3C

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

● Regenerating duration lasts more than the

specified duration - 600sec.
Threshold Value ● Temperature difference between VGT-CPF ● Dropped regeneration efficiency
sensors signal is over set temperature (40℃) ● Clogged CPF
during cold condition. - 1.0sec. ● DPS circuit
● DPS component
Diagnostic Time ● Refer to "Threshold Value" ● EGTS circuit (VGT,CPF)
Fuel Cut NO ● EGTS component (VGT,CPF)
EGR Off NO
Fail Safe ● Engine check lamp
Fuel Limit NO blinks.
Check
BLINK
Lamp

MONITOR SCANTOOL DATA ECE11B52

1. Data analysis about CPF

1) Connect scantool to Data Link Connector (DLC).

2) Warm engine up to normal operating temperature.

3) Turn "OFF" electrical devices and A/C.

4) Monitor "DIFFERENTIAL PRESSURE" and "PRESSURE PRE CPF" parameter on the scantool.

Fig.1
SFDF27570L

Fig. 1) Check if "DIFFERENTIAL PRESSURE" and "PRESSURE PRE CPF" data is abnormally too high or low.

NOTE
※ The "Scantool Data" shown above is measured at the vehicle with new CPF component. Therfore, data varies
depending on CPF used duration and total driven distance.
FLB -492 FUEL SYSTEM

▶ When "DIFFERENTIAL PRESSURE" is too high : Check if excessive soot is accumulated inside of CPF before
inspecting DPS related problem.
If needed, perform "CPF SERVICE REGENERATION" to burn the soot inside of CPF and monitor data change.
▶ When "DIFFERENTIAL PRESSURE" is too low : "DIFFERENTIAL PRESSURE" and "PRESSURE PRE CPF"
data rises depending on engine load increase and the amount of soot inside of CPF. If differential pressure is not
generated or soot is emitted without the rise of "PRESSURE PRE CPF" during excceleration, check CPF component
failure.
▶ When "DIFFERENTIAL PRESSURE" doesn’ t change : If the not only Black smoke is not exhausted but the
pressure difference also is not measred between at the front and rear of CPF, check disconnection, clog or leakage
of DPS pressure hose.

2. CPF SERVICE REGENERATION procedure.

1) Connect scantool to Data Link Connector (DLC).

2) Warm engine up to normal operating temperature.

3) Turn the all the electrocity (Head lamp -HIGH, Blower motor - Max speed, Defroster)and air conditioner "ON".

4) Perform the "CPF SERVICE REGENERATION" procedure with scantool.

Specification : CPF regeneration should be O.K when performing CPF service mode.

Fig.2 Fig.3
SFDF27571L

Fig 2) Check "COVERAGE DRIVEN LENGTH" will be change to "0"km by checking the initial display after per-
forming the CPF Service mode.
Fig 3) Check the temperature both EGTS(CPF) and EGTS(VGT) are within 500 C~700 C after performing CPF
service mode with scantool displaying in the middle of procedure.

TERMINAL AND CONNECTOR INSPECTION EE11C9B0

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.
DTC TROUBLESHOOTING PROCEDURES FLB -493

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power Circuit Inspection".

POWER CIRCUIT INSPECTION E10A469A

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect DPS connector.

3. IG KEY "ON"

4. Measure the voltage between power supply terminal of DPS harness connector and chassis ground.

Specification : 4.8V~5.1V

5. Is the measured voltage within the specification?

YES

▶ Go to "Signal Circuit Inspection".

NO

▶ Repair open in power circuit and go to "Verification of Vehicle Repair".

SIGNAL CIRCUIT INSPECTION E7573445

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect DPS connector.

3) IG KEY "ON".

4) Measure the voltage between signal terminal of DPS harness connector and chassis ground.

Specification : 4.8V~5.1V

5) the measured voltage within the specification?

YES

▶ Go to "Ground Circuit Inspection".

FLB -494 FUEL SYSTEM

NO

▶ Go to "2. Check open in signal circuit" as follows.

2. Check open in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect DPS connector and ECM connector.

3) Measure the resistance between signal terminal of DPS harness connector and DPS signal terminal of ECM
harness connector.

Specification : Continuity ( below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "3. Check short in signal circuit" as follows.

NO

▶ Repair open in DPS signal circuit and go to "Verification of Vehicle Repair".

3. Check short in signal circuit

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect DPS connector and ECM connector.

3) IG KEY "ON"

4) Measure the resistance between signal terminal of DPS harness connector and chassis ground.

5) Measure the voltage between signal terminal of DPS harness connector and chassis ground.

Specification : Test for short to ground : Discontinuity (Infinite Ω )

Test for short to battery : below 0.1 V

6) Is the isolation of DPS signal circuit normal?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Repair short in signal circuit and go to "Verification of Vehicle Repair".

GROUND CIRCUIT INSPECTION E7426C43

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect DPS connector.

3. IG KEY "ON"
DTC TROUBLESHOOTING PROCEDURES FLB -495

4. Measure the voltage between signal terminal of DPS harness connector and chassis ground. [ TEST "A" ]

5. Measure the voltage between signal terminal and ground terminal of DPS harness connector. [ TEST "B" ]
( Signal terminal : Check + prove , Ground terminal : Check - prove )

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6. Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E01BF8A0

1. DPS visual inspection

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect DPS connector.

3) Check DPS terminals for corrosion and contamination.

4) Check (1)connecting condition of DPS and pressure sensing hose, (2)exhaust gas pressure leakate, (3)miss
connection of pressure sensing hose (reverse connection) is detected.

5) Is DPS related problem detected?

YES

▶ If needed, replace DPS or pressure sensing hose and go to "Verification of Vehicle Repair".

NO

▶ Go to "2. Monitor DPS signal waveform" as follows.

2. Monitor DPS signal waveform

1) IG KEY "ON", ENGINE "OFF"

2) Connect DPS connector.

3) Connect oscilloscope to DPS connector terminal 2.

4) After warming engine up, monitor the waveform at idle and during acceleration.
FLB -496 FUEL SYSTEM

SPECIFICATION :

Fig.1 Fig.2
SFDF27534L

Fig1). This is the signal waveform of DPS at idle state. When CPF is new, 1.0~1.2V is outputted normally.
Fig2). This is the waveform of DPS as accelerating.

NOTE
As accelerating, DPS signal output voltage does not vary too much. Even when accelerator pedal is fully depressed,
the signal voltage fluctuates just a little bit like "Fig. 2". However, the more CPF is used, the more waveform fluctuates.

5) Is DPS signal waveform is similar to the waveform of "Signal Waveform ＆ Data"?

YES

▶ Go to "3. CPF component visual inspection" as follows.

NO

▶ Replace DPS and go to "Verification of Vehicle Repair".

3. CPF component visual inspection

1) IG KEY "OFF", ENGINE "OFF"

2) Visually inspect any evidence of exhaust gas leakage on the connection of the exhaust pipe.

3) After removing CPF assembly, check any Inside of CPF is contaminated or Catalyst converter is damaged, dis-
engaged or melted.

Specification : Catalyst Converter and PM filter in the CPF should be normal.

4) Is CPF related problem detected?

YES

▶ Replace CPF and go to "Verification of Vehicle Repair"

NO

▶ Go to "Verification of Vehicle Repair".

DTC TROUBLESHOOTING PROCEDURES FLB -497

※ After replacing CPF, perform the "CPF CHANGE" procedure to reset the ECM with scantool.

VERIFICATION OF VEHICLE REPAIR EC91BF9D

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -498 FUEL SYSTEM

DTC P1406 EXHAUST GAS TEMPERATURE NOT PLAUSIBLE BETWEEN

CALCULATED AND SIMULATED

COMPONENT LOCATION E9EECD7D

EGTS #1

SFDF28317L

GENERAL DESCRIPTION EBB176DB

In EURO4 diesel engine with CPF, injection is devided into 2 pilot, 1 main, 2 post injections. Among these injections, pilot
and main injections are for the operation of engine, however post injections are for CPF regeneration. Only in activating
condition of CPF regeneration during driving, post injection starts. 1st post injection happens at the end of combustion
cycle then, injected fuel is used to raise exhaust temperature. that temp. is sensed at T3 exhaust tempt. sensor which
is ahead of Turbo charger. 2nd post injection happens at exhaust cycle then, injected fuel is also used to raise exhaust
temperature. that temp. is sensed T5 exhaust tempt. sensor which is between Oxydation catalyst and CPF. The reason
of raising exhaust tempt. is because exhaust tempt. in diesel engine is too low for CPF regeneration. The optimum
tempt. for CPF regeneration is 550~600 C thus, the goal of post injection is raise exhaust tempt. to that range of tempt..
However if exhaust tempt. is too high, turbo charger or CPF are likely to be damaged. Therefore if tempt. measured at
each sensor is out of permittable value(specification), ECM deactivates CPF regeneration.

DTC DESCRIPTION E81C516F

P1406 is set when the temperature difference between catalyst converter, its temperature is measured by EGTS-CPF and
model value memorized in ECM is higher than 300 C. This DTC will be set by resulting from faulty exhaust temperature
sensor(EGTS - CPF) circuit malfunction, catalyst converter of CPF or Faulty post injector #2.
DTC TROUBLESHOOTING PROCEDURES FLB -499

DTC DETECTING CONDITION EEE6E6FA

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

● Temperature difference between catalyst

Threshold Value converter, its temperature is measured by
EGTS-CPF and model value memorized in
ECM is higher than 300℃. ● Exhaust gas temp. sensor circuit
● Exhaust gas temp. sensor
Diagnostic Time ● 10 sec. component
Fuel Cut NO
EGR Off NO
Fail Safe Fuel Limit NO
Check
OFF
Lamp

SPECIFICATION E8FEFC8B

RESISTANCE/TEMPERATURE CHARACTERISTICS

NEW AGED
Temp.(℃) Nominal (kΩ )
Min(kΩ ) Max(kΩ ) Min(kΩ ) Max(kΩ )
100 371 289 481 272 515
300 5.92 5.3 6.61 5.15 6.79
600 0.363 0.347 0.379 0.341 0.386
900 0.0893 0.0842 0.0949 0.0833 0.096
FLB -500 FUEL SYSTEM

DIAGNOSTIC CIRCUIT DIAGRAM EA3A65E4

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.
Main Relay
"ON" Input

E/R JUNCTION BOX

<Exhaust Gas Temperature

Sensor #2>

Signal
1 2

1. Ground Ground
2. Signal
Exhaust Gas Temperature Sensor #2

<ECM>

94 93 92 90 89
*
72 71 70 69 68 * 87 86 * 84 83 * 81 80 79 * 77 * 75 * * 6 5
* * 65 64 * * * * * * 57 56 * 54 * * 51 4 3

* 27* 48 47
28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1
* 25 * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7
32. Signal
33. Ground

SFDF27631L
DTC TROUBLESHOOTING PROCEDURES FLB -501

SIGNAL WAVEFORM AND DATA EC26702D

Fig.1
SFDF27576L

Fig. 1) Signal waveform when exhaust gas temperature(T5-CPF) shows the higher temperature increases, the lower
the voltage decreases. If the exhaust gas temperature increases up to approx. 600 C, output voltage will decreases in
0.3~0.4V

MONITOR SCANTOOL DATA E7A00E59

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Monitor "E/GAS TEMP. PRE VGT","E/GAS TEMP. PRE CPF" parameter on the Scantool.

Specification : Current "E/GAS TEMP." is displayed.

Fig.1 Fig.2
SFDF27546L

Fig.1) "EXHAUST GAS TEMP." at idle is shown. Monitor if abnormall difference between "Fig. 1) data" and the data
from the vehicle to test.
FLB -502 FUEL SYSTEM

Fig.2) The display during performing CPF regeneration after selecting "CPF SERVICE REGENERATION" mode is
shown.
Monitor if "EXHAUST GAS TEMP." varies correctly.

TERMINAL AND CONNECTOR INSPECTION E8C30106

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Signal Circuit Inspection".

SIGNAL CIRCUIT INSPECTION E2DFBB0A

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect EGTS(T5-CPF) connector.

3) IG KEY "ON"

4) Measure the voltage between signal terminal of EGTS(T5-CPF) harness connector and chassis ground.

Specification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Go to "2.Check open in signal circuit" as follows.

2. Check open in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

DTC TROUBLESHOOTING PROCEDURES FLB -503

2) Disconnect EGTS(T5-CPF) connector and ECM connector.

3) Measure the resistance between signal terminal of EGTS(T5-CPF) harness connector and EGTS signal terminal
of ECM harness connector(CUD-K).

Secification : Continuity (below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "3. Check short to ground in signal circuit" as follows.

NO

▶ Repair open in signal circuit and go to "Verification of Vehicle Repair".

3. Check short to ground in signal circuit

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect EGTS(T5-CPF) connector and ECM connector.

3) Measure the resistance between signal terminal of EGTS(T5-CPF) harness connector and chassis ground.

Specification : Discontinuity ( Infinite Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Repair short to ground in signal circuit and go to "Verification of Vehicle Repair".

GROUND CIRCUIT INSPECTION E2D5BBD6

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect EGTS(T5-CPF) connector.

3. IG KEY "ON".

4. Measure the voltage between signal terminal of EGTS(T5-CPF) harness connector and chassis ground. [ TEST "A" ]

5. Measure the voltage between signal terminal and ground terminal of EGTS(T5-CPF) harness connector. [ TEST "B"
] ( Signal terminal : Check + prove , Ground terminal : Check - prove )

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6. Is the measured voltage within the specification?

YES
FLB -504 FUEL SYSTEM

▶ Go to "Component Inspection".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION EF603C3D

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect EGTS(T5-CPF) connector.

3. Measure the resistance between signal terminal and ground terminal of EGTS(T5-CPF) connector. (Component
side)

SPECIFICATION :

NEW AGED
Temp.(℃) Nominal (kΩ )
Min(kΩ ) Max(kΩ ) Min(kΩ ) Max(kΩ )
100 371 289 481 272 515
300 5.92 5.3 6.61 5.15 6.79
600 0.363 0.347 0.379 0.341 0.386
900 0.0893 0.0842 0.0949 0.0833 0.096

4. Is the measured resistance at certain temperature within the specified resisance range at the temperature?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace EGTS(T5-CPF) and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR EFADA762

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO
DTC TROUBLESHOOTING PROCEDURES FLB -505

▶ System operates within specification.

FLB -506 FUEL SYSTEM

DTC P1407 PLAUSIBILITY OF TEMPERATURE CALCULATED AND

SIMULATED UPSTREAM OF PARTICULATE FILTER

COMPONENT LOCATION EC6D770C

Refer to DTC P1405.

GENERAL DESCRIPTION EC011802

Refer to DTC P1405.

DTC DESCRIPTION E9632A55

P1407 is set when the temperature difference between exhaust gas temperature measured by exhaust gas temperature
sensor at the front of turbo charger and model temperature memorized in ECM is higher than 200 C for more than 10sec.
This DTC will be turned on in case of the faulty EGTS -VGT itself, circuit malfunction or faulty post injector #1.

DTC DETECTING CONDITION EB392EF0

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"
Threshold Value ● | signal temp. - model temp. | is above 200℃.
● Exhaust gas temp. sensor(T3-VGT)
Diagnostic Time ● 10 sec. wiring
Fuel Cut NO ● Exhaust gas temp. sensor(T3-VGT)
component
EGR Off NO
Fail Safe Fuel Limit NO
Check
BLINK
Lamp

SPECIFICATION E045BCC6

Refer to DTC P1405.

DIAGNOSTIC CIRCUIT DIAGRAM EF08B2D5

Refer to DTC P1405.

SIGNAL WAVEFORM AND DATA E02EFC12

Refer to DTC P1405.

MONITOR SCANTOOL DATA EDDDEC5A

Refer to DTC P1405.

DTC TROUBLESHOOTING PROCEDURES FLB -507

TERMINAL AND CONNECTOR INSPECTION E22FD72D

Refer to DTC P1405.

SIGNAL CIRCUIT INSPECTION E7A2E55B

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect EGTS(T3-VGT) connector.

3) IG KEY "ON"

4) Measure the voltage between signal terminal of EGTS(T3-VGT) harness connector.

Specification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Go to "2.Check open in signal circuit" as follows.

2. Check open in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect EGTS(T3-VGT) connector and ECM connector.

3) Check the resistance between signal terminal of EGTS(T3-VGT) harness connector and EGTS signal terminal
of ECM harness connector.

Secification : Continuity (below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "3. Check short to ground in signal circuit"as follows.

NO

▶ Repair open in signal circuit and go to "Verification of Vehicle Repair".

3. Check short to ground in signal circuit

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect EGTS(T3-VGT) connector and ECM connector.

3) Check the resistance between signal terminal of EGTS(T3-VGT) harness connector and chassis ground.
FLB -508 FUEL SYSTEM

Specification : Discontinuity ( Infinite Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Repair short to ground in signal circuit and go to "Verification of Vehicle Repair".

GROUND CIRCUIT INSPECTION E2213131

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect EGTS(T3-VGT) connector.

3. IG KEY "ON".

4. Measure the voltage between signal terminal of EGTS(T3-VGT) harness connector and chassis ground. [ TEST "A" ]

5. Measure the voltage between signal terminal and ground terminal of EGTS(T3-VGT) harness connector. [ TEST "B"
]
( Signal terminal : Check + prove , Ground terminal : Check - prove )

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6. Is the measured voltage within the specification ?

YES

▶ Go to "Component Inspection".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E49C84AE

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect EGTS(T3-VGT) connector.

3. Measure the resistance between signal terminal and ground terminal of EGTS(T3-VGT) connector. (Component
side)

SPECIFICATION :

NEW AGED
Temp.(℃) Nominal (kΩ )
Min(kΩ ) Max(kΩ ) Min(kΩ ) Max(kΩ )
100 371 289 481 272 515
300 5.92 5.3 6.61 5.15 6.79
DTC TROUBLESHOOTING PROCEDURES FLB -509

600 0.363 0.347 0.379 0.341 0.386

900 0.0893 0.0842 0.0949 0.0833 0.096

4. Is the measured resistance at certain temperature within the specified resisance range at the temperature?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace EGTS(T3-VGT) and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR EE7492C7

Refer to DTC P1405.

FLB -510 FUEL SYSTEM

DTC P1586 MT/AT ENCODING SIGNAL MALFUNCTION

GENERAL DESCRIPTION EDC4E8AD

Because both A/T and M/T fuel control map is inputted in one type of ECM and selecting option is possible, one type is
applied to both A/T and M/T option.
When ECM is installed to vehicle, A/T and M/T recognition is performed by ECM automatically as checking whether ground
line(ECM connector CUD-K terminal 81) is grounded or opened.(A/T and M/T recognition is performed every IG KEY ON
process.)
If A/T, M/T recognition is not fulfilled well or any error occurs during the process, engine power generation is not sufficient
and glow lamp on cluster blinks.

A/T : ECM connector CUD-K terminal 81 is grounded

M/T : ECM connector CUD-K terminal 81 is opened(no wiring exists)

DTC DESCRIPTION E9586715

P1586 is set when recognized A/T, M/T data based on ECM CUD-K terminal 81 state(grounded or opened) is not readable
or writable at EEP ROM. This code is due to ECM failure.

DTC DETECTING CONDITION EF7BF447

Item Detecting Condition Possible Cause

DTC Strategy ● software monitoring
Enable Conditions ● IG KEY "ON"

● A/T, M/T learning error

Threshold Value (when data writing on EEPROM inside of
ECM is impossible)
Diagnostic Time ● 4.0 sec. ● ECM component failure
Fuel Cut NO
EGR Off NO
Fail Safe Fuel Limit NO ● Glow Lamp blinks.
Check
NO
Lamp

COMPONENT INSPECTION EB26EFC9

1. ECM Component Inspection

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECM.

3) Replace ECM, check if abnormal operations disappear.

4) If problems are corrected, replace ECM.

NOTE
Input injector IQA data(7 letters) using scantool at replacing ECM.
Enter the driving distance - how many km the CPF is used- into New ECM with scanner.
For immobilizer applied vehicle, input pin code.
DTC TROUBLESHOOTING PROCEDURES FLB -511

VERIFICATION OF VEHICLE REPAIR EE413E44

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -512 FUEL SYSTEM

DTC P1587 MT/AT RECOGNITION (CAN LINE) ERROR

GENERAL DESCRIPTION E247760D

Refer to DTC P1586.

DTC DESCRIPTION EBCA85A3

P1587 is set when ECM is recognized as 1)A/T but CAN communication signal is not transmitted from TCM 2)M/T but
CAN communication signal is transmitted from TCM. After checking if A/T, M/T auto recognition terminal is normal for each
vehicle option, if no problem is detected, check poor connection in CAN communication circuit or CAN communication
problem of TCM.

DTC DETECTING CONDITION E8CF42C4

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● Engine run

● When TCM signal(through CAN communication)

Threshold Value opposite to recognized data(A/T or M/T)
at ECM is detected. ● A/T, M/T recognition terminal circuit
● CAN communication line circuit
Diagnostic Time ● 1.0 sec. ● TCM component failure
Fuel Cut NO ● ECM component failure
EGR Off NO
Fail Safe Fuel Limit NO ● Glow Lamp blinks.
Check
NO
Lamp

COMPONENT INSPECTION E25B1328

1. ECM Component Inspection

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECM.

3) Replace ECM, check if abnormal operations disappear.

4) If problems are corrected, replace ECM.

NOTE
Input injector IQA data(7 letters) using scantool at replacing ECM.
Enter the driving distance - how many km the CPF is used- into New ECM with scanner.
For immobilizer applied vehicle, input pin code.

VERIFICATION OF VEHICLE REPAIR EFD76C06

Refer to DTC P1586.

DTC TROUBLESHOOTING PROCEDURES FLB -513

DTC P1588 MT/AT AUTO RECOGNITION LINE ERROR

GENERAL DESCRIPTION EC1E0A28

Refer to DTC P1586.

DTC DESCRIPTION E86F2920

P1588 is set when the signal from A/T, M/T auto recognition terminal(ECM CUD-K terminal 81) changes during engine
run. This code is due to open in terminal for A/T option, grounded condition for M/T option. This code is normally arises
from A/T option vehicle. Check the grounding condition of A/T, M/T auto recognition terminal.

DTC DETECTING CONDITION ED0BBAAF

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● Engine run

Threshold Value ● A/T, M/T auto recognition signal changes

at engine ON.
Diagnostic Time ● 1.0 sec. ● A/T, M/T recognition terminal circuit
● ECM component failure
Fuel Cut NO
EGR Off NO
Fail Safe Fuel Limit NO ● Glow Lamp blinks.
Check
NO
Lamp
FLB -514 FUEL SYSTEM

DIAGNOSTIC CIRCUIT DIAGRAM E2CA1A18

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.

Main Relay
"ON" Input

E/R JUNCTION BOX

<ECM>

94 93 92 90 89
*
72 71 70 69 68 * 87 86 * 84 83 * 81 80 79 * 77 * 75 * * 6 5
* * 65 64 * * * * * * 57 56 * 54 * * 51 4 3

* 27* 48 47
28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1
* 25 * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7
6. Ground
19. ESP/FTCS Auto Recognition
81. M/T, A/T Auto Recognition

SFDF27625L

TERMINAL AND CONNECTOR INSPECTION ECE41F75

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Ground Circuit Inspection".

DTC TROUBLESHOOTING PROCEDURES FLB -515

GROUND CIRCUIT INSPECTION E7E7BF75

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect ECM.

3. Check continuity between A/T, M/T auto recognition terminal of ECM harness connector and chassis ground.

Specification : Discontinuity ( Infinite Ω )

4. Is A/T, M/T auto recognition terminal grounded well?

YES

▶ Go to "Component Inspection".

NO

▶ Repair short to ground in controll circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION EBE0E451

1. ECM Component Inspection

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECM.

3) Replace ECM, check if abnormal operations disappear.

4) If problems are corrected, replace ECM.

NOTE
Input injector IQA data(7 letters) using scantool at replacing ECM.
Enter the driving distance - how many km the CPF is used- into New ECM with scanner.
For immobilizer applied vehicle, input pin code.

VERIFICATION OF VEHICLE REPAIR EA2933C4

Refer to DTC P1586.

FLB -516 FUEL SYSTEM

DTC P1634 AUXILIARY HEATER RELAY SHORT/OPEN CIRCUIT

COMPONENT LOCATION E538FA52

PTC
Heater Relay

Glow Relay

SFDF28326L

GENERAL DESCRIPTION E9F0A0C8

Because thermal efficiency of electronically controlled diesel engine is higher than that of gasoline engine, heat loss to
cylinder wall is lower. This enables electronically controlled diesel engine to generate high power and have high fuel
efficiency.
However in other point of view, due to low engine coolant temperature, heating efficiency lowered then, driver is unsatisfied
with the heating. To cope with this situation, PTC heater is installed in coolant line and it raises heating efficiency and
raise coolant temperature.
ECM activates heater relay 1 and 2 when engine coolant temperature is below 70 C and engine speed is above 700RPM.

NOTE
※ Heater relay operation inhibited condition : engine coolant temperature above 70 C, engine speed below
700RPM(to prevent battery discharge)

DTC DESCRIPTION EA9F7592

P1634 is set when excessive current or "0"A is detected in heater relay control circuit for more than 1.0 sec. at heater
relay operating condition. This code is due to 1)open or 2)short to battery or ground in heater relay control circuit or
3)component problem.
DTC TROUBLESHOOTING PROCEDURES FLB -517

DTC DETECTING CONDITION E16ED5A1

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring

Enable Conditions ● IG KEY "ON" (monitoring only performed

at relay operating condition)
Threshold Value ● Short to battery or ground or open.
Diagnostic Time ● 1.0 sec. ● PTC heater relay #1 control circuit
● Heater relay component
Fuel Cut NO
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp

SPECIFICATION E075B1E4

Heater relay coil resistance PTC heater operating temperature PTC heater operating condition
Coolant temp. beolw 70 C Engine speed above 700RPM
52±5Ω (20 C) (Intake air temp.below 5 C) (Battery voltage above 8.9V)
FLB -518 FUEL SYSTEM

DIAGNOSTIC CIRCUIT DIAGRAM EC96F1B1

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.
Main Relay
"ON" Input

E/R JUNCTION BOX

PTC HEATER RELAY

PTC Heater
Relay #1 Control

DIESEL BOX

<PTC HEATER #1 RELAY> <PTC HEATER> PTC HEATER

1 <ECM>
5 4 3 2 1
4 2
* 1. Power 94 93 92
* 90 89 87 86
* 65 84 83 81 80 79
* 57 56* 77 54* 75 * 51*
64 *
6 5
5 2. Ground 72 71 70 69 68
** ****** * ** 4 3
4. Ground
1. To PTC Heater * 27* 48 47
28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1
2. PTC Heater Relay Control * * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7
25

4. Power from Main Relay

5. Power from Battery 94. Auxiliary Electric Heater

SFDF27626L

MONITOR SCANTOOL DATA ED909F52

1. Connect Scantool to Data Link Connector (DLC).

2. ENGINE "ON".(Engine coolant temp. below 70 C,Intake air temp. below 5 C)

3. Blower switch "ON".

4. Monitor "Auxiliary Heater(PTC)" parameter on the Scantool.

( As soon as turning engine ON "Auxiliary Heater(PTC)" parameter turns "ON". Check if the parameter turns "OFF"
after engine is warmed up.)

Specification : Engine coolant temp. below 70 C(Intake air temp. below 5 C) : "Auxiliary Heater(PTC)" "ON"
Engine coolant temp. above 70 C : "Auxiliary Heater(PTC)" "OFF"
DTC TROUBLESHOOTING PROCEDURES FLB -519

Fig.1 Fig.2
SFDF27563L

Fig.3
SFDF27564L

Fig.1) "Auxiliary Heater(PTC)" operates only when Intake air temp. is below 5 C and Engine coolant temp. is below
70 C.
"ON" state of "Auxiliary Heater(PTC)" lasts till Engine coolant temp. reaches 70 C.
Fig.2) "Auxiliary Heater(PTC)" turns "OFF" as soon as engine coolant temp. reaches 70 C.
Fig.3) If it is difficult to cool engine when current condition does not meat "Auxiliary Heater(PTC)" operating condition,
check relay operation using "ACTUATION TEST" function on the Scantool.

TERMINAL AND CONNECTOR INSPECTION E68409D3

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.
FLB -520 FUEL SYSTEM

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power Circuit Inspection".

POWER CIRCUIT INSPECTION E3BD3FC2

1. Check HOT AT ALL TIMES power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect PTC heater relay #1.

3) Measure the voltage between power supply(input) terminal of PTC heater relay #1 harness connector and chas-
sis ground.

specification : 11.5V~13.0V

4) Is the measured voltage within the specification?

YES

▶ Go to "2. Check IG KEY "ON" power circuit voltage" as follows.

NO

▶ Repair PTR HTR #1 FUSIBLE LINK in FUSIBLE LINK BOX and related circuit and go to "Verification of Vehicle
Repair".

2. Check IG KEY "ON" power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect PTC heater relay #1.

3) IG KEY "ON".

4) Measure the voltage between coil power terminal of PTC heater relay #1 harness connector and chassis ground.

specification : 11.5V~13.0V

5) Is the measured voltage within the specification?

YES

▶ Go to "Control Circuit Inspection".

NO
DTC TROUBLESHOOTING PROCEDURES FLB -521

▶ Repair INJ FUSE in E/R JUNCTION BOX and related circuit and go to "Verification of Vehicle Repair".

CONTROL CIRCUIT INSPECTION E0014AA3

1. Check control circuit monitoring voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect PTC heater relay #1.

3) IG KEY "ON".

4) Measure the voltage between relay control terminal of PTC heater relay #1harness connector and chassis
ground.

Secification : 8.0V~10.0V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ When no value is detected : Go to "2. Check open in control circuit".

▶ When high voltage is detected : Repair short to battery in control circuit and go to "Verification of Vehicle
Repair".

2. Check open in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect PTC heater relay #1 and ECM connector.

3) Check continuity between control terminal of PTC heater relay #1 harness connector and ECM harness connec-
tor.

Secification : Continuity ( below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground and go to "Verification of Vehicle Repair".

NO

▶ Repair open in signal circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION ED267F8B

1. Check PTC heater relay #1 component coil resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect PTC heater relay #1.

FLB -522 FUEL SYSTEM

3) Measure the resistance between coil power terminal and control terminal of PTC heater relay #1 connector.
(component side)

Secification : 52±5 Ω (20 C)

4) Is the measured resistance within the specification?

YES

▶ Go to "2. Check PTC heater relay #1 component operation" as follows.

NO

▶ Replace PTC heater relay #1 and go to "Verification of Vehicle Repair".

2. Check PTC heater relay #1 component operation

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect PTC heater relay #1.

3) Supplies random B+ and ground to coil sides of PTC heater relay #1. ( Coil power terminal , coil control terminal)

4) Check continuity between power supply terminal(input) and power supply terminal (output) of PTC heater relay
#1 (component side)

Secification : When power is supplied : Continuity ( below 1.0Ω )

When power is not supplied : Discontinuity ( Infinite Ω )

5) Is the measured resistance within the specification?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace PTC heater relay #1 and go to "Verification of Vehicle Repair".

※ Repeat this process 2~3 times.

VERIFICATION OF VEHICLE REPAIR EEDA0150

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO
DTC TROUBLESHOOTING PROCEDURES FLB -523

▶ System operates within specification.

FLB -524 FUEL SYSTEM

DTC P1652 IGNITION SWITCH MALFUNCTION

GENERAL DESCRIPTION ED302338

When a driver turns on IG KEY, IG KEY ON signal is inputted to ECM CUD-K connector terminal 28 through IG KEY
switch. This signal initializes(boots) ECM accordingly, main relay operates. Main relay supplies powers for ECM, sensors
and actuators in order to enable engine to start.
When IG KEY ON signal is shut off during turning engine OFF, ECM stops injector operation then engine turns OFF.
Approx. after 12 sec., ECM shuts OFF main relay and system turns OFF.

DTC DESCRIPTION E619D108

When the condition that IG KEY ON signal turns OFF while ECM, to which IG signal inputted, is initialized (booting,
Approx. 25ms is required), IG KEY switch error is recognized and P1652 is set (monitored only once every IG KEY ON
initialization process). This code is due to poor connection in IG KEY ON signal circuit.

DTC DETECTING CONDITION EC2561F4

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● Engine run
Threshold Value ● No signal through IG line after IG KEY "ON"
Diagnostic Time ● Immediately ● IG KEY "ON" signal circuit
Fuel Cut NO ● IG KEY switch
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp
DTC TROUBLESHOOTING PROCEDURES FLB -525

DIAGNOSTIC CIRCUIT DIAGRAM EE6EF51D

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.
Main Relay
"ON" Input

E/R JUNCTION BOX

<ECM>

94 93 92 90 89
*
72 71 70 69 68 * 87 86 * 84 83 * 81 80 79 * 77 * 75 * * 6 5
* * 65 64 * * * * * * 57 56 * 54 * * 51 4 3

* 27* 48 47
28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1
* 25 * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7
1.3.5. Main Relay "ON" Input
72. Main Relay Control

SFDF27619L

SIGNAL WAVEFORM AND DATA E2BDE89B

IG KEY signal

Main relay

Fig.1
SFDF27565L

Fig.1) The waveforms of IG KEY "ON" signal and main relay operation are measured simultaneously.
Check poor connection at the point of IG KEY "ON".
FLB -526 FUEL SYSTEM

TERMINAL AND CONNECTOR INSPECTION EC8F0856

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Signal Circuit Inspection".

SIGNAL CIRCUIT INSPECTION EF58F10B

1. IG KEY "OFF", ENGINE "OFF".

2. Connect Oscilloscope to ON/START terminal of ECM connector with ECM connector being connected.

3. Check IG KEY "ON" signal waveform at IG KEY "ON".

Specification : The signals indicate poor connection should not exist at IG KEY "ON" range.

SFDF27566L

4. Does abnormal waveform generate at IG KEY "ON" range?

YES
DTC TROUBLESHOOTING PROCEDURES FLB -527

▶ Repair IG KEY S/W and poor connection of SNSR.2 FUSE in E/R JUNCTION BOX and related circuit and go to
"Verification of Vehicle Repair".

NO

▶ Go to "Verification of Vehicle Repair".

※ Repeat this process 2~3 times.

VERIFICATION OF VEHICLE REPAIR E8377B91

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -528 FUEL SYSTEM

DTC P1670 INVALID INJECTOR IQA/C2I

COMPONENT LOCATION E47F70EC

Injector

RPS

Rail Pressure
Regulator Valve

SFDF28313L

GENERAL DESCRIPTION E652BBB9

IQA (Injector Quantity Adjustment) means adjusting fuel injection quantity difference between injectors which occurs in-
evitably at manufacturing process as allotting serial number consists of 7 letters to each injectors.
Inputting IQA code of injectors installed in each cylinder to ECM, ECM recognizes the fuel injection quantity difference
between each injectors. ECM adjusts every injector to have same fuel injecting characteristic as recognizing specific fuel
injection map which is different for each serial number.

DTC DESCRIPTION E60A925B

P1670 is set when ’IQA input error’ or ’saving error’ occurs in EEP ROM where IQA data is saved. This code is due to
ECM internal error.

DTC DETECTING CONDITION E168619B

Item Detecting Condition Possible Cause

DTC Strategy ● EEP ROM monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● Input error, saving error occurs at injector

IQA code inputting.
Diagnostic Time ● Immediately ● ECM internal error
Fuel Cut NO
EGR Off NO
Fail Safe ● Engine Check Lamp
Fuel Limit NO blinks.
Check
YES
Lamp
DTC TROUBLESHOOTING PROCEDURES FLB -529

COMPONENT INSPECTION EDAB436C

1. Check injector class input state

1) IG KEY "OFF", ENGINE "OFF".

2) Using Scantool, select "ENGINE CONTROL" - "INJECTOR CORRECTION".

3) Check currently inputted "injector class input state".

Specification : IQA data inputted to ECM should be identical with IQA data of injector.

SFDF27568L

4) Are both data identical?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ If error is not corrected after reperforming "INJECTOR CORRECTION" procedure, replace ECM.

NOTE
Input IQA data of injector mounted at cylinder at replacing ECM using scantool.
If this process is not performed, engine check lamp on cluster blinks and normal engine power generation is impos-
sible.

VERIFICATION OF VEHICLE REPAIR E3EBFEB7

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

FLB -530 FUEL SYSTEM

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

DTC TROUBLESHOOTING PROCEDURES FLB -531

DTC P1671 INJECTOR IQA CHECKSUM ERROR

COMPONENT LOCATION E78B939B

Refer to DTC P1670.

GENERAL DESCRIPTION E2EFAFFC

Refer to DTC P1670.

DTC DESCRIPTION E9BEA06E

P1671 is set when IQA data is not inputted to ECM during initialization of ECM.

DTC DETECTING CONDITION E8C44658

Item Detecting Condition Possible Cause

DTC Strategy ● EEP ROM monitoring
Enable Conditions ● IG KEY "ON"
Threshold Value ● IQA code is not inputted to ECM.
Diagnostic Time ● Immediately
● IQA not inputted to ECM
Fuel Cut NO
EGR Off NO
Fail Safe ● Engine Check Lamp
Fuel Limit NO blinks.
Check
YES
Lamp

COMPONENT INSPECTION E45B7292

1. Check injector class input state

1) IG KEY "OFF", ENGINE "OFF".

2) Using Scantool, select "ENGINE CONTROL" - "INJECTOR CORRECTION".

3) Check currently inputted "injector class input state".

Specification : IQA data inputted to ECM should be identical with IQA data of injector.
FLB -532 FUEL SYSTEM

SFDF27568L

4) Are both data identical?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ If error is not corrected after reperforming "INJECTOR CORRECTION" procedure, replace ECM.

NOTE
Input IQA data of injector mounted at cylinder at replacing ECM using scantool.
If this process is not performed, engine check lamp on cluster blinks and normal engine power generation is impos-
sible.

VERIFICATION OF VEHICLE REPAIR E819560D

Refer to DTC P1670.

DTC TROUBLESHOOTING PROCEDURES FLB -533

DTC P1815 ESP AUTO RECOGNITION FAIL

GENERAL DESCRIPTION E5171359

Because both ESP and Non ESP control map is inputted in one type of ECM and selecting option is possible, one type is
applied to both ESP and Non ESP option
When ECM is installed to vehicle, ESP and Non ESP recognition is performed by ECM automatically as checking whether
ground line(ECM connector C244-K terminal 19) is grounded or opened.(ESP and Non ESP recognition is performed
every IG KEY ON process.)
If ESP, Non ESP recognition is not fulfilled well or any error occurs during the process, engine power generation is not
sufficient.
ESP : ECM connector CUD-K terminal 19 is grounded
Non ESP : ECM connector CUD-K terminal 19 is opened(no wiring exists)

DTC DESCRIPTION E006F6A5

P1815 is set when recognized ESP data based on ECM CUD-K terminal 19 state(grounded or opened) is not readable
or writable at EEP ROM. This code is due to ECM failure.

DTC DETECTING CONDITION E844DBB5

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"
Threshold Value ● ESP learning error
Diagnostic Time ● 0.6 sec ● ESP/FTCS Auto recognition
terminal circuit
Fuel Cut NO
● ECM component failure
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp
FLB -534 FUEL SYSTEM

DIAGNOSTIC CIRCUIT DIAGRAM E0766F52

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.
Main Relay
"ON" Input

E/R JUNCTION BOX

ESP/FTCS
Auto Recognition

<ECM>

ESP/FTCS: GND
94 93 92 90 89 87 86 84 83 81 80 79 77 75 NO ESP/FTCS: OPEN
* * *
72 71 70 69 68 * 65 64 * * ** 6 5
* * * * * * * * * 51
** 57 56 54
4 3
48 47 46 45 44
40 38 37 36 35 34 33 32 31 30 29
42
**
28 27 * * * 2 1
* * * * * 19 * * 16 15 14 13 12 11 10 9 8 7
25 22

6. Ground
19. ESP/FTCS Auto Recognition
81. M/T, A/T Auto Recognition

SFDF27627L

TERMINAL AND CONNECTOR INSPECTION EF10E6F8

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO
DTC TROUBLESHOOTING PROCEDURES FLB -535

▶ Go to "Ground Circuit Inspection".

GROUND CIRCUIT INSPECTION E95FDA3C

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect ECM connector.

3. Check continuity between auto recognition terminal at ECM harness connector and chassis ground.

specification : Continuity ( below 1.0 Ω )

4. Is A/T, M/T auto recognition terminal grounded well?

YES

▶ Go to "Component Inspection".

NO

▶ Repair poor connection or open between ECM connector(CUD-K) terminal 19 and ground point GUD21 and go
to "Verification of Vehicle Repair".

COMPONENT INSPECTION E55B477D

1. ECM Component Inspection

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECM.

3) Replace ECM, check if abnormal operations disappear.

4) If problems are corrected, replace ECM.

NOTE
Input injector IQA data(7 letters) using scantool at replacing ECM.
Enter the driving distance - how many km the CPF is used- into New ECM with scanner.
For immobilizer applied vehicle, input pin code.

VERIFICATION OF VEHICLE REPAIR E01C87FE

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

FLB -536 FUEL SYSTEM

NO

▶ System operates within specification.

DTC TROUBLESHOOTING PROCEDURES FLB -537

DTC P2002 DIESEL PARTICULATE FILTER EFFICIENCY BELOW

THRESHOLD

COMPONENT LOCATION EE0970AB

EGTS #1

EGTS #2 DPS

CPF

SFDF28330L

GENERAL DESCRIPTION E9A6397C

Comparing with gasoline engine, one of the worst point of diesel engine is that a lot of particle material(PM) are generated
after combustion process. In order to decrease the amount of PM, CPF is equipped in EURO-4 diesel engine. CPF is the
device which gathers PM with installed filter then burns it up as raising the tempt. inside of CPF above the ignition point
of PM. The process which burns up PM is called "CPF regeneration".
【CPF regeneration】When vehicle is in steady speed condition and above normal engine loading condition, if differential
pressure between before and after CPF is above the specified pressure, ECM considers that stored soot inside of CPF is
excessive. In this condition, exhaust gas tempt. is raised by post injection 1 and 2 to warm CPF up to 550 C~650 C. In
this high tempt, soot inside of CPF burns up naturally and this mechanism is called as "CPF regeneration".
Most of soot is burned up during regeneration process but a little amount of soot is not burned up and stored inside of
CPF continuously. The stored soot decreases the efficiency of CPF slowly. DPS corrects CPF regeneration period and
duration as comparing and calculating the differential pressure due to stored soot with the total distance covered.

DTC DESCRIPTION E4A38FAE

P2002 is set when 1) Differncial pressure below lower limit value at exhaust flow above specified value(Case 1) or 2)
Differential pressure above maximum acceptable value(Case 2) or 3) too slight change of differential pressure compared
to exhaust flow(Case 3) is detected.
FLB -538 FUEL SYSTEM

DTC DETECTING CONDITION E9134E31

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"
Threshold Value ● Refer to DTC description
● Differncial pressure sensor wiring
● (Case 1) - 15 sec. ● Differncial pressure sensor
Diagnostic Time ● (Case 2) - 25 sec. component
● (Case 3) - 2 sec. ● Differncial pressure sensor hose line
Misinstallation/Clogging/Freezing/Crack
Fuel Cut NO Case 1,3 ● Failed CPF
EGR Off NO ● Soot simulation ON ● Too much soot loading inside CPF
mode activated
Fail Safe Fuel Limit NO ● Reduced regeneration
Check mileage Case 2
BLINK ● Torque reduction
Lamp

DIAGNOSTIC CIRCUIT DIAGRAM E758CF42

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.
Main Relay
"ON" Input

E/R JUNCTION BOX

<Differential Pressure Sensor>

3 2 1 Power

P Ground

1. Power Signal
2. Signal
3. Ground Differential Pressure Sensor

<ECM>

94 93 92 90 89 36. Signal
72 71 70 69 68* * 87 86 * 84 83 * 81 80 79 * 77 * 75 * * 6 5
* * 65 64 * * * * * * 57 56 * 54 * * 51 4 3 37. Ground
* 27* 48 47
28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1
* 25 * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7 44. Power

SFDF27606L
DTC TROUBLESHOOTING PROCEDURES FLB -539

SIGNAL WAVEFORM AND DATA E76A257E

Fig.1 Fig.2
SFDF27534L

Fig1). This is the signal waveform of DPS at idle state. When CPF is new, 1.0~1.2V is outputted normally.
Fig2). This is the waveform of DPS as accelerating.

NOTE
As accelerating, DPS signal output voltage does not vary too much. Even when accelerator pedal is fully depressed,
the signal voltage fluctuates just a little bit like "Fig. 2". However, the more CPF is used, the more waveform fluctuates.

MONITOR SCANTOOL DATA EA6B5F15

1. Data analysis about CPF

1) Connect scantool to Data Link Connector (DLC).

2) Warm engine up to normal operating temperature.

3) Turn "OFF" electrical devices and A/C.

4) Monitor "DIFFERENTIAL PRESSURE" and "PRESSURE PRE CPF" parameter on the scantool.

Specification : "DIFFERENTIAL PRESSURE" and "PRESSURE PRE CPF" data must not be too high or low.
FLB -540 FUEL SYSTEM

Fig.1
SFDF27535L

Fig. 1) Check if "DIFFERENTIAL PRESSURE" and "PRESSURE PRE CPF" data is abnormally too high or low.
* The "Scantool Data" shown above is measured at the vehicle with new CPF component. Therfore, data varies
depending on CPF used duration and total driven distance.

When "DIFFERENTIAL PRESSURE" is too high : Check if excessive soot is accumulated inside of CPF before
inspecting DPS related problem.
If needed, perform "CPF SERVICE REGENERATION" to burn the soot inside of CPF and monitor data change.

When "DIFFERENTIAL PRESSURE" is too low : "DIFFERENTIAL PRESSURE" and "PRESSURE PRE CPF"
data rises depending on engine load increase and the amount of soot inside of CPF. If differential pressure is
not generated or soot is emitted without the rise of "PRESSURE PRE CPF" during excceleration, check CPF
component failure.

When "DIFFERENTIAL PRESSURE" doesn’ t change : If the not only Black smoke is not exhausted but the
pressure difference also is not measred between at the front and rear of CPF, check disconnection, clog or
leakage of DPS pressure hose.

2. CPF SERVICE REGENERATION procedure.

1) Connect scantool to Data Link Connector (DLC).

2) Warm engine up to normal operating temperature.

3) Turn the all the electrocity (Head lamp -HIGH, Blower motor - Max speed, Defroster)and air conditioner "ON".

4) Perform the "CPF SERVICE REGENERATION" procedure with scantool.

Specification : CPF regeneration should be O.K when performing CPF service mode.
DTC TROUBLESHOOTING PROCEDURES FLB -541

Fig.2 Fig.3
SFDF27571L

Fig 2) Check "COVERAGE DRIVEN LENGTH" will be change to "0"km by checking the initial display after per-
forming the CPF Service mode.
Fig 3) Check the temperature both EGTS(CPF) and EGTS(VGT) are within 500 C~700 C after performing CPF
service mode with scantool displaying in the middle of procedure.

TERMINAL AND CONNECTOR INSPECTION E27D1AE1

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power Circuit Inspection".

POWER CIRCUIT INSPECTION E758623D

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect DPS connector.

3. IG KEY "ON"
FLB -542 FUEL SYSTEM

4. Measure the voltage of DPS connector terminal 1.

Specification : 4.8V~5.1V

5. Is the measured voltage within the specification?

YES

▶ Go to "Signal Circuit Inspection".

NO

▶ Repair open in power circuit and go to "Verification of Vehicle Repair".

SIGNAL CIRCUIT INSPECTION E6670D1A

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect DPS connector.

3) IG KEY "ON".

4) Measure the voltage of DPS connector terminal 2.

Specification : 4.8V~5.1V

5) the measured voltage within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Go to "2. Check open in signal circuit" as follows.

2. Check open in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect DPS connector and ECM connector.

3) Check continuity between DPS connector terminal 2 and ECM connector(CUD-K) terminal 36.

Specification : Continuity ( below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "3. Check short in signal circuit" as follows.

NO

▶ Repair open in DPS signal circuit and go to "Verification of Vehicle Repair".

DTC TROUBLESHOOTING PROCEDURES FLB -543

3. Check short in signal circuit

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect DPS connector and ECM connector.

3) IG KEY "ON"

4) Check continutity between DPS connector terminal 2 and chassis ground. ( Test for short to ground )

5) Check voltage between DPS connector terminal 2 and chassis ground. ( Test for short to battery )

Specification : Test for short to ground : Discontinuity (Infinite Ω )

Test for short to battery : below 0.1 V

6) Is the isolation of DPS signal circuit normal?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Repair short in signal circuit and go to "Verification of Vehicle Repair".

GROUND CIRCUIT INSPECTION E9155402

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect DPS connector.

3. IG KEY "ON"

4. Measure the voltage of DPS connector terminal 1. [ TEST "A" ]

5. Measure the voltage between DPS connector terminal 1 and terminal 3. [ TEST "B" ]
(terminal 1 : Check + prove , terminal 3 : Check - prove)

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6. Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E28C285C

1. DPS visual inspection

1) IG KEY "OFF", ENGINE "OFF".

FLB -544 FUEL SYSTEM

2) Disconnect DPS connector.

3) Check DPS terminals for corrosion and contamination.

4) Check (1)connecting condition of DPS and pressure sensing hose, (2)exhaust gas pressure leakate, (3)miss
connection of pressure sensing hose (reverse connection) is detected.

5) Is DPS related problem detected?

YES

▶ If needed, replace DPS or pressure sensing hose and go to "Verification of Vehicle Repair".

NO

▶ Go to "2. Monitor DPS signal waveform" as follows.

2. Monitor DPS signal waveform

1) IG KEY "ON", ENGINE "OFF"

2) Connect DPS connector.

3) Connect oscilloscope to DPS connector terminal 2.

4) After warming engine up, monitor the waveform at idle and during acceleration.

SPECIFICATION :

Fig.1 Fig.2
SFDF27569L

Fig1). This is the signal waveform of DPS at idle state. When CPF is new, 1.0~1.2V is outputted normally.
Fig2). This is the waveform of DPS as accelerating.

NOTE
As accelerating, DPS signal output voltage does not vary too much. Even when accelerator pedal is fully depressed,
the signal voltage fluctuates just a little bit like "Fig. 2". However, the more CPF is used, the more waveform fluctuates.

5) Is DPS signal waveform is similar to the waveform of "Signal Waveform ＆ Data"?

YES
DTC TROUBLESHOOTING PROCEDURES FLB -545

▶ Go to "3. CPF component visual inspection" as follows.

NO

▶ Replace DPS and go to "Verification of Vehicle Repair".

3. CPF component visual inspection

1) IG KEY "OFF", ENGINE "OFF"

2) Visually inspect any evidence of exhaust gas leakage on the connection of the exhaust pipe.

3) After removing CPF assembly, check any Inside of CPF is contaminated or Catalyst converter is damaged, dis-
engaged or melted.

Specification : Catalyst Converter and PM filter in the CPF should be normal.

4) Is CPF related problem detected?

YES

▶ Replace CPF and go to "Verification of Vehicle Repair".

NO

▶ Go to "Verification of Vehicle Repair".

※ After replacing CPF, perform the "CPF CHANGE" procedure to reset the ECM with scantool.

VERIFICATION OF VEHICLE REPAIR E53F232C

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool

NO

▶ System operates within specification.

FLB -546 FUEL SYSTEM

DTC P2009 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT LOW (BANK

1)

COMPONENT LOCATION EDCB2640

Variable Swirl Control Actuator

SFDF28332L

GENERAL DESCRIPTION E5AEE90D

Variable swirl control actuator consists of DC motor and motor position sensor(potentiometer) which detects the position
of swirl valve.
As closing one intake port out of two at idle and below 3000RPM, swirl effect is taken on intake air. This swirl effect
increases air flow rate.
However, because air flow rate is too high, swirl effect is neglectable thus, swirl valve is opened for efficient intake of air.
To prevent swirl valve and shaft form being stuck by foreign metarial, and to learn max opening and closing position of
swirl valve, it is fully opened and closed twice at turning engine OFF.
※ Swirl
The air flow which indicates Intake air swirls with respect to the axis passing through the centre of piston with length-
direction by intake port which is eccentric from the centre of combustion chamber.

DTC DESCRIPTION ED1C2E22

P2009 is set when open or short to ground in variable swirl actuator driving motor (+) output terminal. The polarity of (+)
and (-) lines shift each other in accordance with the condition of swirl valve(opened or closed) thus, checking both (+) and
(-) circuits is requied
DTC TROUBLESHOOTING PROCEDURES FLB -547

DTC DETECTING CONDITION ED0749D2

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● Engine running

Threshold Value ● Short to ground in motor output terminal

● Open in motor circuit
Diagnostic Time ● 200ms ●Variable swirl valve motor circuit
Fuel Cut NO
EGR Off NO ● Swirl valve opened
Fail Safe Fuel Limit NO at variable swirl control
actuator failure
Check
NO
Lamp

SPECIFICATION E7752B02

SFDF27636L
FLB -548 FUEL SYSTEM

DIAGNOSTIC CIRCUIT DIAGRAM ED5A4BF6

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.
Main Relay
"ON" Input

<Variable Swirl E/R JUNCTION BOX

Control Actuator>

MTR (+)
5 4 3 2 1 M
MTR (-)
1. MTR(+)
Power
2. MTR(-)
3. Power Feed Back Signal
4. Feed Back Signal
5. Ground Ground

Variable Swirl
Control Actuator

<ECM>

60 59 58
6. Ground
* * * 53 37* * 50 4934 33* 47 3146
56
44 43 42 41 40 26. Power
* ** * * * 30. MTR (-)
30 28 27 26 23 20 19 17 16 56. Feed Back Signal
* ** ** *
* * 13 12 * * * 8 7 6 * 4 * 2 1 60. MTR (+)

SFDF27628L
DTC TROUBLESHOOTING PROCEDURES FLB -549

SIGNAL WAVEFORM AND DATA EE976BAA

Fig.1 Fig.2
SFDF28306L

Swirl valve fully closed

Swirl valve fully opened

Fig.3
SFDF27573L

Fig.1) Waveform when variable swirl valve closed at idle. Channel A is (+) and B is (-).
Fig.2) Waveform when variable swirl valve opened at above 3000RPM. Channel A is (-) and B is (+).
Fig. 3) Waveform of variable swirl control actuator motor position sensor at the point of turning engine OFF. 4.3V at swirl
valve closed and 0.3V at swirl valve opened. Swirl valve is opened and closed twice at engine "OFF".(at signal terminal)

TERMINAL AND CONNECTOR INSPECTION EBBF07CA

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.
FLB -550 FUEL SYSTEM

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶Go to "Control Circuit Inspection".

CONTROL CIRCUIT INSPECTION EB34ECC2

1. Check short to ground in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect variable swirl control actuator connector and ECM connector.

3) Check continuity between motor plus terminal of variable swirl control actuator harness connector and chassis
ground.

4) Check continuity between motor minus terminal of variable swirl control actuator harness connector and chassis
ground..

Secification : Discontinuity(Infinite Ω )

5) Is the measured resistance within the specification?

YES

▶ Go to "2.Check open in motor circuit" as follows.

NO

▶ Repair short to ground in variable swirl control actuator motor circuit and go to "Verification of Vehicle Repair".

2. Check open in motor circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect variable swirl control actuator connector and ECM connector.

3) Check continuity between motor plus terminal of variable swirl control actuator harness connector and ECM
harness connecor.

4) Check continuity between motor minus terminal of variable swirl control actuator harness connector and ECM
harness connecor.

Secification : Continuity (below 1.0Ω )

5) Is the measured resistance within the specification?

DTC TROUBLESHOOTING PROCEDURES FLB -551

YES

▶ Go to "Component Inspection".

NO

▶ Repair open in control circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E21E1AB5

1. Check motor coil resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect variable swirl control actuator connector.

3) Measure the resistance between motor plus terminal and motor minus terminal of variable swirl control actuator
connector. (component side).

Specification : 15.0 ± 3 Ω (20 C)

4) Is the measured resistance within the specification?

YES

▶ Go to "2. Check motor operation".

NO

▶ Replace variable swirl control actuator assy.

2. Check motor operation

1) IG KEY "ON" , ENGINE "ON".

2) Keep engine at idle state.

3) Monitor the waveform of variable swirl control actuator at motor plus terminal and motor minus terminal with two
channel oscilloscope.

4) Accelerating engine to above 3000RPM, let variable swirl control actuator be opened(operates).

Specification : Refer to Signal Waveform ＆ Data "Fig.1)", " Fig.2)".

5) Does variable swirl control actuator operate correctly?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace variable swirl control actuator assy and go to "Verification of Vehicle Repair".
FLB -552 FUEL SYSTEM

VERIFICATION OF VEHICLE REPAIR E56FB107

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

DTC TROUBLESHOOTING PROCEDURES FLB -553

DTC P2010 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT HIGH(BANK

1)

COMPONENT LOCATION E216C049

Refer to DTC P2009.

GENERAL DESCRIPTION E9A9927F

Refer to DTC P2009.

DTC DESCRIPTION E099F857

P2010 is set when short to battery in variable swirl control actuator driving motor (+) output terminal. The polarigy of (+)
and (-) lines shift each other in accordance with the condition of swirl valve(opened or closed) thus, checking both (+) and
(-) circuits is required.

DTC DETECTING CONDITION E3EEBE69

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● Engine running
Threshold Value ● Short to battery in motor output terminal
Diagnostic Time ● 200ms
●Variable swirl valve motor circuit
Fuel Cut NO
EGR Off NO ● Swirl valve opened
Fail Safe Fuel Limit NO at variable swirl control
actuator failure
Check
NO
Lamp

SPECIFICATION E1D02A8F

Refer to DTC P2009.

DIAGNOSTIC CIRCUIT DIAGRAM EEF7AD5F

Refer to DTC P2009.

SIGNAL WAVEFORM AND DATA EF3727C5

Refer to DTC P2009.

TERMINAL AND CONNECTOR INSPECTION ECBF5C56

Refer to DTC P2009.

FLB -554 FUEL SYSTEM

CONTROL CIRCUIT INSPECTION E5DD6A47

1. Check control circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect variable swirl control actuator connector.

3) IG KEY "ON"

4) Measure the voltage between motor plus terminal of variable swirl control actuator harness connector and chas-
sis ground.

5) Measure the voltage between motor minus terminal of variable swirl control actuator harness connector and
chassis ground.

Secification : 0.0V~0.1V

6) Is the measured voltage within the specification?

YES

▶ Repair short to battery in variable swirl control actuator motor circuit and go to "Verification of Vehicle Repair"

NO

▶ Check "2. Check open in motor circuit" as follows.

2. Check open in motor circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect variable swirl control actuator connector and ECM connector.

3) Check continuity between variable swirl control actuator connector terminal 1 and ECM connecor(CUD-A) ter-
minal 60.

4) Check continuity between variable swirl control actuator connector terminal 2 and ECM connecor(CUD-A) ter-
minal 30.

Secification : Continuity (below 1.0Ω )

5) Is the measured resistance within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ Repair open in control circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION EDFAABEF

1. Check motor coil resistance

1) IG KEY "OFF", ENGINE "OFF".

DTC TROUBLESHOOTING PROCEDURES FLB -555

2) Disconnect variable swirl control actuator connector.

3) Measure the resistance between motor plus terminal and motor minus terminal of variable swirl control actuator
connector. (component side).

Specification : 15.0 ± 3 Ω (20 C)

4) Is the measured resistance within the specification?

YES

▶ Go to "2. Check motor operation".

NO

▶ Replace variable swirl control actuator assy.

2. Check motor operation

1) IG KEY "ON" , ENGINE "ON".

2) Keep engine at idle state.

3) Monitor the waveform of variable swirl control actuator at motor plus terminal and motor minus terminal with two
channel oscilloscope.

4) Accelerating engine to above 3000RPM, let variable swirl control actuator be opened(operates).

Specification : Refer to Signal Waveform ＆ Data "Fig.1)", " Fig.2)".

5) Does variable swirl control actuator operate correctly?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace variable swirl control actuator assy and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR EFFA72A5

Refer to DTC P2009.

FLB -556 FUEL SYSTEM

DTC P2015 INTAKE MANIFOLD RUNNER POSITION SENSOR/SWITCH

CIRCUIT RANGE/PERFORMANCE(BANK 1)

COMPONENT LOCATION EA755A12

Variable Swirl Control Actuator

SFDF28332L

GENERAL DESCRIPTION E48F9C2C

Variable swirl control actuator consists of DC motor and motor position sensor(potentiometer) which detects the position
of swirl valve.
As closing one intake port out of two at idle and below 3000RPM, swirl effect is taken on intake air. This swirl effect
increases air flow rate.
However, because air flow rate is too high, swirl effect is neglectable thus, swirl valve is opened for efficient intake of air.
To prevent swirl valve and shaft form being stuck by foreign metarial, and to learn max opening and closing position of
swirl valve, it is fully opened and closed twice at turning engine OFF.
※ Swirl
The air flow which indicates Intake air swirls with respect to the axis passing through the centre of piston with length-
direction by intake port which is eccentric from the centre of combustion chamber.

DTC DESCRIPTION E847F1D6

P2015 is set if variable swirl valve position fails to reach target position within 1 sec. while ECM already outputted motor
driving signal(swirl valve fully open or close signal). This code is due to 1)swirl valve shaft stuck or problem of link device
or 2)variable swirl valve position sensor output value stuck.
DTC TROUBLESHOOTING PROCEDURES FLB -557

DTC DETECTING CONDITION E98CFE6E

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● Variable swirl valve operating motor

mechanically stuck ●Variable swirl valve shaft stuck
●Variable swirl valve link device
Diagnostic Time ● 1.0 sec. problem
Fuel Cut NO ●Variable swirl valve position
sensor component
EGR Off YES ● Swirl valve opened
Fail Safe Fuel Limit NO at variable swirl control
actuator failure
Check
NO
Lamp

SPECIFICATION E6DB4E60

SFDF27636L
FLB -558 FUEL SYSTEM

DIAGNOSTIC CIRCUIT DIAGRAM E48DE4B5

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.
Main Relay
"ON" Input

<Variable Swirl E/R JUNCTION BOX

Control Actuator>

MTR (+)
5 4 3 2 1 M
MTR (-)
1. MTR(+)
Power
2. MTR(-)
3. Power Feed Back Signal
4. Feed Back Signal
5. Ground Ground

Variable Swirl
Control Actuator

<ECM>

60 59 58
6. Ground
* * * 53 37* * 50 4934 33* 47 3146
56
44 43 42 41 40 26. Power
* ** * * * 30. MTR (-)
30 28 27 26 23 20 19 17 16 56. Feed Back Signal
* ** ** *
* * 13 12 * * * 8 7 6 * 4 * 2 1 60. MTR (+)

SFDF27628L
DTC TROUBLESHOOTING PROCEDURES FLB -559

SIGNAL WAVEFORM AND DATA EA8A8FD4

Fig.1 Fig.2
SFDF28306L

Swirl valve fully closed

Swirl valve fully opened

Fig.3
SFDF27573L

Fig.1) Waveform when variable swirl valve closed at idle. Channel A is (+) and B is (-).
Fig.2) Waveform when variable swirl valve opened at above 3000RPM. Channel A is (-) and B is (+).
Fig. 3) Waveform of variable swirl control actuator motor position sensor at the point of turning engine OFF. 4.3V at swirl
valve closed and 0.3V at swirl valve opened. Swirl valve is opened and closed twice at engine "OFF".(at signal terminal)

COMPONENT INSPECTION EE64F4A3

1. Check variable swirl control actuator link device operation

1) IG KEY "OFF", ENGINE "OFF".

2) Wait for approx. 20 sec. and check Main relay turns "OFF".

3) Disconnect variable swirl control actuator connector.

4) Pressing variable swirl control actuator link with hands, check if shaft stuck, tightness or problem of link device
is detected.

Secification : Variable swirl control actuator link device should move smoothly.
FLB -560 FUEL SYSTEM

5) Does variable swirl control actuator move slowly?

YES

▶ Go to "2 Check motor coil resistance".

NO

▶ Replace stuck or too tight parts of component(intake manifold assy or swirl actuator) and go to "Verification
of Vehicle Repair".

2. Check motor coil resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect variable swirl control actuator.

3) Measure the resistance between motor plus terminal and motor minus terminal of variable swirl control actuator
connector. (component side).

Secification : 15.0 ± 3 Ω (20 C)

4) Is the measured resistance within the specification?

YES

▶ Go to "3. Check variable swirl control actuator position sensor resistance".

NO

▶ Replace variable swirl control actuator and go to "Verification of Vehicle Repair".

3. Check variable swirl control actuator position sensor resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect variable swirl control actuator.

3) Measure the resistance of variable swirl control actuator component terminal 3,4,5 referring "Terminal resistance
table" as follows.

Specification : Terminal resistance table

4) Is the measured resistance within the specification?

YES

▶ Go to "4. Check motor operation" as follows.

NO

▶ Replace variable swirl control actuator assy and go to "Verification of Vehicle Repair".

4. Check motor operation

1) IG KEY "ON" , ENGINE "ON".

2) Keep engine at idle state.

DTC TROUBLESHOOTING PROCEDURES FLB -561

3) Monitor the waveform of variable swirl control actuator terminal 1and 2 with two channel oscilloscope.

4) Accelerating engine to above 3000RPM, let variable swirl control actuator be opened(operates).

Specification : Refer to Signal Waveform ＆ Data "Fig.1)", " Fig.2)".

5) Does variable swirl control actuator operate correctly?

YES

▶ Go to "5. Check variable swirl control actuator position sensor operation".

NO

▶ Replace variable swirl control actuator assy and go to "Verification of Vehicle Repair".

5. Check variable swirl control actuator position sensor operation

1) IG KEY "ON", ENGINE "ON".

2) Keep engine at idle state.

3) Monitor the waveform of variable swirl control actuator terminal 4 with oscilloscope.

4) Turning off engine, monitor the waveform of variable swirl control actuator at the point of operation stop.

Specification : Refer to Signal Waveform ＆ Data "Fig.3)"

5) Does variable swirl control actuator and position sensor operations are OK?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace variable swirl control actuator assy and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR EC1FFD41

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -562 FUEL SYSTEM

DTC P2016 INTAKE MANIFOLD RUNNER POSITION SENSOR/SWITCH

CIRCUIT LOW(BANK 1)

COMPONENT LOCATION E04BD5F7

Refer to DTC P2015.

GENERAL DESCRIPTION E46EAEB4

Refer to DTC P2015.

DTC DESCRIPTION EEDDB005

P2016 is set when variable swirl valve position sensor output voltage below 0.133V is detected for more than 0.6 sec.
This code is due to open in power circuit or short to ground in signal circuit.

DTC DETECTING CONDITION E59E1800

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● Output voltage below minimum value(

below 133mV )
● Variable swirl valve position
Diagnostic Time ● 2500ms sensor circuit
● Variable swirl valve position
Fuel Cut NO
sensor component
EGR Off NO ● Swirl valve opened
Fail Safe Fuel Limit NO at variable swirl control
actuator failure
Check
NO
Lamp

SPECIFICATION EAE8E53C

Refer to DTC P2015.

DIAGNOSTIC CIRCUIT DIAGRAM E82421D0

Refer to DTC P2015.

SIGNAL WAVEFORM AND DATA EB36F810

Refer to DTC P2015.

TERMINAL AND CONNECTOR INSPECTION EF842325

Refer to DTC P2015.

DTC TROUBLESHOOTING PROCEDURES FLB -563

POWER CIRCUIT INSPECTION EAC5DEE7

1. Check power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect variable swirl control actuator connector.

3) IG KEY "ON"

4) Measure the voltage between power terminal of variable swirl control actuator harness connector and chassis
ground.

Secification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Signal Circuit Inspection".

NO

▶ Repair open in power circuit and go to "Verification of Vehicle Repair".

SIGNAL CIRCUIT INSPECTION E1F9A81E

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect variable swirl control actuator connector.

3) IG KEY "ON".

4) Measure the voltage between signal terminal of variable swirl control actuator harness connector and chassis
ground.

Secification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ Go to "2. Check short to ground in signal circuit" as follows.

2. Check short to ground in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect variable swirl control actuator connector and ECM connector.

3) Check continuity between signal terminal of variable swirl control actuator harness connector and chassis ground.
FLB -564 FUEL SYSTEM

Specification : Discontinuity(Infinite Ω )

4) Is the measured resistance within the specificaiton?

YES

▶ Go to "Component Inspection".

NO

▶ Repair short to ground in signal circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E61B91B4

1. Check variable swirl control actuator position sensor resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect variable swirl control actuator.

3) Measure the resistance of variable swirl control actuator component at each terminal referring "Terminal resis-
tance table" as follows.

Specification : Terminal resistance table

4) Is the measured resistance within the specification?

YES

▶ "2. Check variable swirl control actuator position sensor operation".

NO

▶ Replace variable swirl control actuator assy and go to "Verification of Vehicle Repair".

2. Check variable swirl control actuator position sensor operation

1) IG KEY "ON" , ENGINE "ON".

2) Keep engine at idle state.

3) Monitor the waveform of variable swirl control actuator terminal 4 with oscilloscope.

4) Turning off engine, monitor the waveform of variable swirl control actuator at the point of operation stop.

Specification : Refer to Signal Waveform ＆ Data "Fig.3)"

5) Does variable swirl control actuator and position sensor operations are OK?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace variable swirl control actuator assy and go to "Verification of Vehicle Repair".
DTC TROUBLESHOOTING PROCEDURES FLB -565

VERIFICATION OF VEHICLE REPAIR EB893994

Refer to DTC P2015.

FLB -566 FUEL SYSTEM

DTC P2017 INTAKE MANIFOLD RUNNER POSITION SENSOR/SWITCH

CIRCUIT HIGH(BANK 1)

COMPONENT LOCATION ECE0DCA3

Refer to DTC P2015.

GENERAL DESCRIPTION EFDED354

Refer to DTC P2015.

DTC DESCRIPTION EDA2CEE9

P2017 is set when variable swirl valve position sensor output voltage above 4.8V is detected for more than 0.6 sec. This
code is due to 1)open in signal circuit or ground circuit or 2)short to battery in power circuit or signal circuit.

DTC DETECTING CONDITION E2B5ECA9

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● Output voltage above minimum value(

above 4800mV )
● Variable swirl valve position
Diagnostic Time ● 2500ms sensor circuit
● Variable swirl valve position
Fuel Cut NO
sensor component
EGR Off NO ● Swirl valve opened
Fail Safe Fuel Limit NO at variable swirl control
actuator failure
Check
NO
Lamp

SPECIFICATION E4FD5DCB

Refer to DTC P2015.

DIAGNOSTIC CIRCUIT DIAGRAM E637511C

Refer to DTC P2015.

SIGNAL WAVEFORM AND DATA EE88F66B

Refer to DTC P2015.

TERMINAL AND CONNECTOR INSPECTION E97C30BC

Refer to DTC P2015.

DTC TROUBLESHOOTING PROCEDURES FLB -567

POWER CIRCUIT INSPECTION E945A1FB

1. Check power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect variable swirl control actuator connector.

3) IG KEY "ON"

4) Measure the voltage between power terminal of variable swirl control actuator harness connector and chassis
ground.

Secification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Signal Circuit Inspection".

NO

▶ Repair open in power circuit and go to "Verification of Vehicle Repair".

SIGNAL CIRCUIT INSPECTION E3C10847

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect variable swirl control actuator connector.

3) IG KEY "ON".

4) Measure the voltage between terminal of variable swirl control actuator harness connector and chassis ground.

Secification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Go to "2. Check open in signal circuit" as follows.

2. Check open in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect variable swirl control actuator connector and ECM connector.

3) Check continuity between signal terminal of variable swirl control actuator harness connector and ECM harness
connector.
FLB -568 FUEL SYSTEM

Specification : Discontinuity(Infinite Ω )

4) Is the measured resistance within the specificaiton?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Repair open in signal circuit and go to "Verification of Vehicle Repair".

GROUND CIRCUIT INSPECTION E1C5CBF5

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect variable swirl control actuator connector.

3. IG KEY "ON".

4. Measure the voltage between power terminal of variable swirl control actuator harness connector and chassis ground.
[ TEST "A" ]

5. Measure Measure the voltage between power terminal and ground terminal of variable swirl control actuator connec-
tor. [ TEST "B" ] ( Power terminal : Check + prove , Ground terminal : Check - prove )

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6. Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E03C6399

1. Check variable swirl control actuator position sensor resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect variable swirl control actuator.

3) Measure the resistance of variable swirl control actuator component at each terminal referring "Terminal resis-
tance table" as follows.

Specification : Terminal resistance table

4) Is the measured resistance within the specification?

DTC TROUBLESHOOTING PROCEDURES FLB -569

YES

▶ "2. Check variable swirl control actuator position sensor operation".

NO

▶ Replace variable swirl control actuator assy and go to "Verification of Vehicle Repair".

2. Check variable swirl control actuator position sensor operation

1) IG KEY "ON" , ENGINE "ON".

2) Keep engine at idle state.

3) Monitor the waveform of variable swirl control actuator terminal 4 with oscilloscope.

4) Turning off engine, monitor the waveform of variable swirl control actuator at the point of operation stop.

Specification : Refer to Signal Waveform ＆ Data "Fig.3)"

5) Does variable swirl control actuator and position sensor operations are OK?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace variable swirl control actuator assy and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR EB9EEC15

Refer to DTC P2015.

FLB -570 FUEL SYSTEM

DTC P2030 EXHAUST TEMPERATURE VALUE NOT PLAUSIBLE WITH

SENSOR 1 AND 2

COMPONENT LOCATION E3481AF9

EGTS #1

EGTS #2

SFDF28331L

GENERAL DESCRIPTION E3D62133

In EURO4 diesel engine with CPF, injection is devided into 2 pilot, 1 main, 2 post injections. Among these injections, pilot
and main injections are for the operation of engine, however post injections are for CPF regeneration. Only in activating
condition of CPF regeneration during driving, post injection starts. 1st post injection happens at the end of combustion
cycle then, injected fuel is used to raise exhaust temperature. that temp. is sensed at T3 exhaust tempt. sensor which
is ahead of Turbo charger. 2nd post injection happens at exhaust cycle then, injected fuel is also used to raise exhaust
temperature. that temp. is sensed T5 exhaust tempt. sensor which is between Oxydation catalyst and CPF. The reason
of raising exhaust tempt. is because exhaust tempt. in diesel engine is too low for CPF regeneration. The optimum
tempt. for CPF regeneration is 550~600 C thus, the goal of post injection is raise exhaust tempt. to that range of tempt..
However if exhaust tempt. is too high, turbo charger or CPF are likely to be damaged. Therefore if tempt. measured at
each sensor is out of permittable value(specification), ECM deactivates CPF regeneration.

DTC DESCRIPTION E5E2A27B

P2030 is set when the temperature difference between front Exhaust temp. sensor(T3) and rear Exhaust temp. sen-
sor(T5) is above 40 C at cold idle. This code is set to prevent CPF from damaging due to inaccurate sensing of exhaust
gas temp.
DTC TROUBLESHOOTING PROCEDURES FLB -571

DTC DETECTING CONDITION EDC5014E

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● | front Exhaust temp.- rear Exhaust temp.

| is above 40℃ at cold idle.
● Exhaust Gas temp. sensor circuit
Diagnostic Time ● 1 sec. ● Exhaust Gas temp. sensor
Fuel Cut NO component
EGR Off NO
Fail Safe Fuel Limit NO
Check
OFF
Lamp

SPECIFICATION E0565D5B

RESISTANCE/TEMPERATURE CHARACTERISTICS

NEW AGED
Temp.(℃) Nominal (kΩ )
Min(kΩ ) Max(kΩ ) Min(kΩ ) Max(kΩ )
100 371 289 481 272 515
300 5.92 5.3 6.61 5.15 6.79
600 0.363 0.347 0.379 0.341 0.386
900 0.0893 0.0842 0.0949 0.0833 0.096
FLB -572 FUEL SYSTEM

DIAGNOSTIC CIRCUIT DIAGRAM E60DDD40

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.

Main Relay
"ON" Input

E/R JUNCTION BOX

<Exhaust Gas Temperature

Sensor #1> Signal

2 1 Ground
Exhaust Gas Temperature Sensor #1
1. Signal
2. Ground Signal

Ground
Exhaust Gas Temperature Sensor #2

<ECM> <Exhaust Gas Temperature

Sensor #2>

94 93 92 90 89 87 86 84 83 81 80 79
32. Signal
*
72 71 70 69 68 * 65 64 * * 57 56* 77 54* 75 * 51* 6 5
33. Ground
** ****** * ** 4 3 1 2
34. Signal
* 27* 48 47
28 25
46 45 44
22 *
42
* 40 * 1638 1537 1436 35
19
34 33 32 31 30 29
13 12 11 10 9 8 7
2 1
* ** ** ** 35. Ground 1. Ground
2. Signal

SFDF27630L
DTC TROUBLESHOOTING PROCEDURES FLB -573

SIGNAL WAVEFORM AND DATA E4670F9A

Fig.1 Fig.2
SFDF27574L

Fig.1) 4.8V is outputted at EGTS(T3-VGT) output signal circuit at IG KEY ON.

Fig.2) 4.8V is outputted at EGTS(T5-CPF) output signal circuit at IG KEY ON.

NOTE
At IG KEY ON state and as soon as turning engine ON, the difference of output voltage between EGTS(T3-VGT) and
EGTS(T5-CPF) must be small to be neglectable.

MONITOR SCANTOOL DATA EA7301AC

1. Connect Scantool to Data Link Connector (DLC).

2. Monitoring should be performed at cold idle.

3. Turn "OFF" electrical devices and A/C.

4. IG KEY "ON"

5. Monitor "E/GAS TEMP. PRE VGT","E/GAS TEMP. PRE CPF" parameter on the Scantool.

Specification : Specification : The difference between "E/GAS TEMP. PRE VGT" and
"E/GAS TEMP. PRE CPF" is below 40 C
FLB -574 FUEL SYSTEM

Fig.1
SFDF27575L

※ At IG KEY ON state and as soon as turning engine ON, the difference of output voltage between "E/GAS TEMP.
PRE VGT" and "E/GAS TEMP. PRE CPF" must be small to be neglectable.

TERMINAL AND CONNECTOR INSPECTION E2F1646B

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Signal Circuit Inspection".

SIGNAL CIRCUIT INSPECTION EE1B4B1F

1. EGTS(T3-VGT) circuit inspection

Refer to "Signal Circuit Inspection" of "P0545" DTC guide.

2. EGTS(T5-CPF) circuit inspection

Refer to "Signal Circuit Inspection" of "P2032" DTC guide.

DTC TROUBLESHOOTING PROCEDURES FLB -575

GROUND CIRCUIT INSPECTION E46E3970

1. EGTS(T3-VGT) circuit inspection

Refer to "Ground Circuit Inspection" of "P0545" DTC guide.

2. EGTS(T5-CPF) circuit inspection

Refer to "Ground Circuit Inspection" of "P2032" DTC guide.

COMPONENT INSPECTION EB63BA75

1. EGTS(T3-VGT) circuit inspection

Refer to "Component Inspection" of "P0545" DTC guide.

2. EGTS(T5-CPF) circuit inspection

Refer to "Component Inspection" of "P2032" DTC guide.

VERIFICATION OF VEHICLE REPAIR E9FB2A7D

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -576 FUEL SYSTEM

DTC P2032 EXHAUST GAS TEMPERATURE SENSOR CIRCUIT LOW (BANK

1 / SENSOR 2)

COMPONENT LOCATION EEA4DF6B

EGTS #2

SFDF28318L

GENERAL DESCRIPTION EA2FF5BD

In EURO4 diesel engine with CPF, injection is devided into 2 pilot, 1 main, 2 post injections. Among these injections, pilot
and main injections are for the operation of engine, however post injections are for CPF regeneration. Only in activating
condition of CPF regeneration during driving, post injection starts. 1st post injection happens at the end of combustion
cycle then, injected fuel is used to raise exhaust temperature. that temp. is sensed at T3 exhaust tempt. sensor which
is ahead of Turbo charger. 2nd post injection happens at exhaust cycle then, injected fuel is also used to raise exhaust
temperature. that temp. is sensed T5 exhaust tempt. sensor which is between Oxydation catalyst and CPF. The reason
of raising exhaust tempt. is because exhaust tempt. in diesel engine is too low for CPF regeneration. The optimum
tempt. for CPF regeneration is 550~600 C thus, the goal of post injection is raise exhaust tempt. to that range of tempt..
However if exhaust tempt. is too high, turbo charger or CPF are likely to be damaged. Therefore if tempt. measured at
each sensor is out of permittable value(specification), ECM deactivates CPF regeneration.

DTC DESCRIPTION EC884363

P2032 is set when rear exhaust temp. sensor(T5-CPF) signal is below 0.2V - the lower limiting value - for more than 0.6
sec.
DTC TROUBLESHOOTING PROCEDURES FLB -577

DTC DETECTING CONDITION E476971B

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● Rear exhaust temp. sensor(T5-CPF)

signal voltage below 0.2V
● Exhaust temp. sensor(T5-CPF)
Diagnostic Time ● 0.6 sec. wiring
● Exhaust temp. sensor(T5-CPF)
Fuel Cut NO
component
EGR Off NO ● Exhaust temp. is
Fail Safe considered as 300℃
Fuel Limit NO ● Engine check lamp
Check blinks.
BLINK
Lamp

SPECIFICATION EF31EEF9

RESISTANCE/TEMPERATURE CHARACTERISTICS

NEW AGED
Temp.(℃) Nominal (kΩ )
Min(kΩ ) Max(kΩ ) Min(kΩ ) Max(kΩ )
100 371 289 481 272 515
300 5.92 5.3 6.61 5.15 6.79
600 0.363 0.347 0.379 0.341 0.386
900 0.0893 0.0842 0.0949 0.0833 0.096
FLB -578 FUEL SYSTEM

DIAGNOSTIC CIRCUIT DIAGRAM EA1428C2

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.
Main Relay
"ON" Input

E/R JUNCTION BOX

<Exhaust Gas Temperature

Sensor #2>

Signal
1 2

1. Ground Ground
2. Signal
Exhaust Gas Temperature Sensor #2

<ECM>

94 93 92 90 89
*
72 71 70 69 68 * 87 86 * 84 83 * 81 80 79 * 77 * 75 * * 6 5
* * 65 64 * * * * * * 57 56 * 54 * * 51 4 3

* 27* 48 47
28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1
* 25 * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7
32. Signal
33. Ground

SFDF27631L
DTC TROUBLESHOOTING PROCEDURES FLB -579

SIGNAL WAVEFORM AND DATA E19B5445

Fig.1
SFDF27576L

Fig. 1) Signal waveform when exhaust gas temperature(T5-CPF) shows the higher temperature increases, the lower
the voltage decreases. If the exhaust gas temperature increases up to approx. 600 C, output voltage will decreases in
0.3~0.4V

MONITOR SCANTOOL DATA E287F30F

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Monitor "E/GAS TEMP. PRE VGT","E/GAS TEMP. PRE CPF" parameter on the Scantool.

Specification : Current "E/GAS TEMP." is displayed.

Fig.1 Fig.2
SFDF27578L

Fig.1) "EXHAUST GAS TEMP." at idle is shown. Monitor if abnormall difference between "Fig. 1) data" and the data
from the vehicle to test.
FLB -580 FUEL SYSTEM

Fig.2) The display during performing CPF regeneration after selecting "CPF SERVICE REGENERATION" mode is
shown. Monitor if "EXHAUST GAS TEMP." varies correctly.

TERMINAL AND CONNECTOR INSPECTION E27BA6D3

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Signal Circuit Inspection".

SIGNAL CIRCUIT INSPECTION EA3D72B1

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect EGTS(T5-CPF) connector.

3) IG KEY "ON"

4) Measure the voltage between signal terminal of EGTS(T5-CPF) harness connector and chassis ground.

Specification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Go to "2.Check open in signal circuit" as follows.

2. Check open in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

DTC TROUBLESHOOTING PROCEDURES FLB -581

2) Disconnect EGTS(T5-CPF) connector and ECM connector.

3) Measure the resistance between signal terminal of EGTS(T5-CPF) harness connector and EGTS signal terminal
of ECM harness connector(CUD-K).

Secification : Continuity (below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "3. Check short to ground in signal circuit" as follows.

NO

▶ Repair open in signal circuit and go to "Verification of Vehicle Repair".

3. Check short to ground in signal circuit

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect EGTS(T5-CPF) connector and ECM connector.

3) Measure the resistance between signal terminal of EGTS(T5-CPF) harness connector and chassis ground.

Specification : Discontinuity ( Infinite Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Repair short to ground in signal circuit and go to "Verification of Vehicle Repair".

GROUND CIRCUIT INSPECTION E2B1997F

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect EGTS(T5-CPF) connector.

3. IG KEY "ON".

4. Measure the voltage between signal terminal of EGTS(T5-CPF) harness connector and chassis ground. [ TEST "A" ]

5. Measure the voltage between signal terminal and ground terminal of EGTS(T5-CPF) harness connector. [ TEST "B"
] ( Signal terminal : Check + prove , Ground terminal : Check - prove )

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6. Is the measured voltage within the specification?

YES
FLB -582 FUEL SYSTEM

▶ Go to "Component Inspection".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E188AD25

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect EGTS(T5-CPF) connector.

3. Measure the resistance between signal terminal and ground terminal of EGTS(T5-CPF) connector. (Component
side)

SPECIFICATION :

NEW AGED
Temp.(℃) Nominal (kΩ )
Min(kΩ ) Max(kΩ ) Min(kΩ ) Max(kΩ )
100 371 289 481 272 515
300 5.92 5.3 6.61 5.15 6.79
600 0.363 0.347 0.379 0.341 0.386
900 0.0893 0.0842 0.0949 0.0833 0.096

4. Is the measured resistance at certain temperature within the specified resisance range at the temperature?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace EGTS(T5-CPF) and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E93BE71B

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO
DTC TROUBLESHOOTING PROCEDURES FLB -583

▶ System operates within specification.

FLB -584 FUEL SYSTEM

DTC P2033 EXHAUST GAS TEMPERATURE SENSOR CIRCUIT HIGH (BANK

1 / SENSOR 2)

COMPONENT LOCATION E1AA2ED5

Refer to DTC P2032.

GENERAL DESCRIPTION E03BA19C

Refer to DTC P2032.

DTC DESCRIPTION E73982DB

P2033 is set when the Exhaust gas temperature sensor(EGTS) - CPF signal is detected over maximum set tempera-
ture(890 C),- In case that exhaust gas temperature on the rear side of CPF is abnormally increased -, for more than 1sec.
Therefore, check component or vehicle is driven in severe driving condition. or Check that HC gas is flown to catalyst
converter at front side of CPF which is resulting from low compression ratio and faulty in/exhaust valve or backleak at
injector nozzle.
*. In case that real exhaust gas temperature reaches up to 890 C, engine and exhaust line(Turbo charger), CPF can be
damaged.

DTC DETECTING CONDITION ECE6ED1A

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"
● abnormal over-load (driving)
Threshold Value ● Rear exhaust temperature above 890℃ condition
● Engine misfire
Diagnostic Time ● 1.0 sec. ● Injector nozzle back leak
Fuel Cut NO ● Exhaust temp. sensor(T5-CPF)
circuit
EGR Off NO
● Exhaust temp. sensor(T5-CPF)
Fail Safe Fuel Limit NO component
Check
BLINK
Lamp

SPECIFICATION E27CC3D9

Refer to DTC P2032.

DIAGNOSTIC CIRCUIT DIAGRAM EEBDA26F

Refer to DTC P2032.

SIGNAL WAVEFORM AND DATA E08F11EF

Refer to DTC P2032.

DTC TROUBLESHOOTING PROCEDURES FLB -585

MONITOR SCANTOOL DATA E97B4225

Refer to DTC P2032.

TERMINAL AND CONNECTOR INSPECTION E842C7BE

Refer to DTC P2032.

SIGNAL CIRCUIT INSPECTION E2BDEC4F

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect EGTS(T5-CPF) connector.

3) IG KEY "ON"

4) Measure the voltage between signal terminal of EGTS(T5-CPF) harness connector and chassis ground.

Specification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Go to "2.Check open in signal circuit" as follows.

2. Check open in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect EGTS(T5-CPF) connector and ECM connector.

3) Measure the resistance between signal terminal of EGTS(T5-CPF) harness connector and EGTS signal terminal
of ECM harness connector(CUD-K).

Secification : Continuity (below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "3. Check short to ground in signal circuit" as follows.

NO

▶ Repair open in signal circuit and go to "Verification of Vehicle Repair".

3. Check short to ground in signal circuit

1) IG KEY "OFF", ENGINE "OFF"

FLB -586 FUEL SYSTEM

2) Disconnect EGTS(T5-CPF) connector and ECM connector.

3) Measure the resistance between signal terminal of EGTS(T5-CPF) harness connector and chassis ground.

Specification : Discontinuity ( Infinite Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Repair short to ground in signal circuit and go to "Verification of Vehicle Repair".

GROUND CIRCUIT INSPECTION E3124F18

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect EGTS(T5-CPF) connector.

3. IG KEY "ON".

4. Measure the voltage between signal terminal of EGTS(T5-CPF) harness connector and chassis ground. [ TEST "A" ]

5. Measure the voltage between signal terminal and ground terminal of EGTS(T5-CPF) harness connector. [ TEST "B"
] ( Signal terminal : Check + prove , Ground terminal : Check - prove )

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6. Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION EF0EB22F

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect EGTS(T5-CPF) connector.

3. Measure the resistance between signal terminal and ground terminal of EGTS(T5-CPF) connector. (Component
side)
DTC TROUBLESHOOTING PROCEDURES FLB -587

SPECIFICATION :

NEW AGED
Temp.(℃) Nominal (kΩ )
Min(kΩ ) Max(kΩ ) Min(kΩ ) Max(kΩ )
100 371 289 481 272 515
300 5.92 5.3 6.61 5.15 6.79
600 0.363 0.347 0.379 0.341 0.386
900 0.0893 0.0842 0.0949 0.0833 0.096

4. Is the measured resistance at certain temperature within the specified resisance range at the temperature?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace EGTS(T5-CPF) and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E2867D86

Refer to DTC P2032.

FLB -588 FUEL SYSTEM

DTC P2034 EXHAUST GAS TEMPERATURE SENSOR CIRCUIT (BANK 2 /

SENSOR 2)

COMPONENT LOCATION EAD0DB37

Refer to DTC P2032.

GENERAL DESCRIPTION E23AAE4F

Refer to DTC P2032.

DTC DESCRIPTION E3D20A75

P2034 is set when Exhaust gas temperature sensor(EGTS) - CPF signal is higher than 200 C. Check open or short circuit
and EGTS.
*. In case that real exhaust gas temperature reaches up to 890 C, engine and exhaust line(Turbo charger), CPF can be
damaged.

DTC DETECTING CONDITION E1558D0C

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● In case that Exhaust gas temperature

(CPF) is higher than 200℃
● Exhaust temp. sensor(T5-CPF)
Diagnostic Time ● 1.0 sec. circuit
● Exhaust temp. sensor(T5-CPF)
Fuel Cut NO
component
EGR Off NO
Fail Safe Fuel Limit NO
Check
BLINK
Lamp

SPECIFICATION E0040155

Refer to DTC P2032.

DIAGNOSTIC CIRCUIT DIAGRAM EA872D53

Refer to DTC P2032.

SIGNAL WAVEFORM AND DATA EEDA2F98

Refer to DTC P2032.

MONITOR SCANTOOL DATA E6A51382

Refer to DTC P2032.

DTC TROUBLESHOOTING PROCEDURES FLB -589

TERMINAL AND CONNECTOR INSPECTION E53F12CC

Refer to DTC P2032.

SIGNAL CIRCUIT INSPECTION E04547BF

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect EGTS(T5-CPF) connector.

3) IG KEY "ON"

4) Measure the voltage between signal terminal of EGTS(T5-CPF) harness connector and chassis ground.

Specification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Go to "2.Check open in signal circuit" as follows.

2. Check open in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect EGTS(T5-CPF) connector and ECM connector.

3) Measure the resistance between signal terminal of EGTS(T5-CPF) harness connector and EGTS signal terminal
of ECM harness connector(CUD-K).

Secification : Continuity (below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "3. Check short to ground in signal circuit".

NO

▶ Repair open in signal circuit and go to "Verification of Vehicle Repair".

3. Check short to ground in signal circuit

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect EGTS(T5-CPF) connector and ECM connector.

3) Measure the resistance between signal terminal of EGTS(T5-CPF) harness connector and chassis ground.
FLB -590 FUEL SYSTEM

Specification : Discontinuity ( Infinite Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Repair short to ground in signal circuit and go to "Verification of Vehicle Repair".

GROUND CIRCUIT INSPECTION E0E5B205

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect EGTS(T5-CPF) connector.

3. IG KEY "ON".

4. Measure the voltage between signal terminal of EGTS(T5-CPF) harness connector and chassis ground. [ TEST "A" ]

5. Measure the voltage between signal terminal and ground terminal of EGTS(T5-CPF) harness connector. [ TEST "B"
]
( Signal terminal : Check + prove , Ground terminal : Check - prove )

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6. Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E67C0DBD

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect EGTS(T5-CPF) connector.

3. Measure the resistance between signal terminal and ground terminal of EGTS(T5-CPF) connector. (Component
side)

Specification : Refer to Specification of General Information

4. Is the measured resistance at certain temperature within the specified resisance range at the temperature?

YES
DTC TROUBLESHOOTING PROCEDURES FLB -591

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace EGTS(T5-CPF) and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR ED282784

Refer to DTC P2032.

FLB -592 FUEL SYSTEM

DTC P2080 EXHAUST GAS TEMPERATURE SENSOR CIRCUIT

RANGE/PERFORMANCE (BANK 1 / SENSOR 1)

COMPONENT LOCATION EE5578BB

EGTS #1

SFDF28317L

GENERAL DESCRIPTION EA457C98

In EURO4 diesel engine with CPF, injection is devided into 2 pilot, 1 main, 2 post injections. Among these injections, pilot
and main injections are for the operation of engine, however post injections are for CPF regeneration. Only in activating
condition of CPF regeneration during driving, post injection starts. 1st post injection happens at the end of combustion
cycle then, injected fuel is used to raise exhaust temperature. that temp. is sensed at T3 exhaust tempt. sensor which
is ahead of Turbo charger. 2nd post injection happens at exhaust cycle then, injected fuel is also used to raise exhaust
temperature. that temp. is sensed T5 exhaust tempt. sensor which is between Oxydation catalyst and CPF. The reason
of raising exhaust tempt. is because exhaust tempt. in diesel engine is too low for CPF regeneration. The optimum
tempt. for CPF regeneration is 550~600 C thus, the goal of post injection is raise exhaust tempt. to that range of tempt..
However if exhaust tempt. is too high, turbo charger or CPF are likely to be damaged. Therefore if tempt. measured at
each sensor is out of permittable value(specification), ECM deactivates CPF regeneration.

DTC DESCRIPTION EE069D2A

P2080 is set when Exhaust gas temperature sensor(EGTS) - VGT signal is higher than 200 C. Check open or short circuit
and EGTS.
*. In case that real exhaust gas temperature reaches up to 890 C, engine and exhaust line(Turbo charger), CPF can be
damaged.
DTC TROUBLESHOOTING PROCEDURES FLB -593

DTC DETECTING CONDITION EC95D00A

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON" or Engine running

Threshold Value ● In case that Exhaust gas temperature

(VGT) is higher than 200℃
● Exhaust gas temp. sensor(T3-VGT)
Diagnostic Time ● 1.0 sec. wiring
● Exhaust gas temp. sensor(T3-VGT)
Fuel Cut NO
component
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp

SPECIFICATION EC1F8972

RESISTANCE/TEMPERATURE CHARACTERISTICS

NEW AGED
Temp.(℃) Nominal (kΩ )
Min(kΩ ) Max(kΩ ) Min(kΩ ) Max(kΩ )
100 371 289 481 272 515
300 5.92 5.3 6.61 5.15 6.79
600 0.363 0.347 0.379 0.341 0.386
900 0.0893 0.0842 0.0949 0.0833 0.096
FLB -594 FUEL SYSTEM

DIAGNOSTIC CIRCUIT DIAGRAM EF167F8B

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.
Main Relay
"ON" Input

E/R JUNCTION BOX

<Exhaust Gas Temperature

Sensor #1>

Signal
2 1

Ground
1. Signal
2. Ground Exhaust Gas Temperature Sensor #1

<ECM>

94 93 92 90 89
*
72 71 70 69 68 * 87 86 * 84 83 * 81 80 79 * 77 * 75 * * 6 5
* * 65 64 * * * * * * 57 56 * 54 * * 51 4 3

* 27* 48 47
28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1
* 25 * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7
34. Signal
35. Ground

SFDF27611L
DTC TROUBLESHOOTING PROCEDURES FLB -595

SIGNAL WAVEFORM AND DATA E807F7CA

Fig.1
SFDF27577L

Fig.1) 4.8V is outputted at EGTS output signal circuit, when exhaust gas temp. is approx.150 C.
when exhaust gas temp. is 550~600 C at CPF regeneration, output voltage drops to 0.3~0.4V.

MONITOR SCANTOOL DATA E6455244

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Monitor "E/GAS TEMP. PRE VGT","E/GAS TEMP. PRE CPF" parameter on the Scantool.

Specification : Current "E/GAS TEMP." is displayed.

Fig.1 Fig.2
SFDF27578L

Fig.1) "EXHAUST GAS TEMP." at idle is shown. Monitor if abnormall difference between "Fig. 1) data" and the data
from the vehicle to test.
FLB -596 FUEL SYSTEM

Fig.2) The display during performing CPF regeneration after selecting "CPF SERVICE REGENERATION" mode is
shown.
Monitor if "EXHAUST GAS TEMP." varies correctly.

TERMINAL AND CONNECTOR INSPECTION E1111069

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Signal Circuit Inspection ".

SIGNAL CIRCUIT INSPECTION E34E8A24

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect EGTS(T3-VGT) connector.

3) IG KEY "ON"

4) Measure the voltage between signal terminal of EGTS(T3-VGT) harness connector and chassis ground.

Specification : 4.8V~5.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Go to "2.Check open in signal circuit" as follows.

2. Check open in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

DTC TROUBLESHOOTING PROCEDURES FLB -597

2) Disconnect EGTS(T3-VGT) connector and ECM connector.

3) Measure the resistance between signal terminal of EGTS(T3-VGT) harness connector and EGTS signal terminal
of ECM harness connector(CUD-K).

Secification : Continuity (below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "3. Check short to ground in signal circuit".

NO

▶ Repair open in signal circuit and go to "Verification of Vehicle Repair".

3. Check short to ground in signal circuit

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect EGTS(T3-VGT) connector and ECM connector.

3) Measure the resistance between signal terminal of EGTS(T3-VGT) harness connector and chassis ground.

Specification : Discontinuity ( Infinite Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Repair short to ground in signal circuit and go to "Verification of Vehicle Repair".

GROUND CIRCUIT INSPECTION E576C905

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect EGTS(T3-VGT) connector.

3. IG KEY "ON".

4. Measure the voltage between signal terminal of EGTS(T3-VGT) harness connector and chassis ground. [ TEST "A" ]

5. Measure the voltage between signal terminal and ground terminal of EGTS(T3-VGT) harness connector. [ TEST "B"
]
( Signal terminal : Check + prove , Ground terminal : Check - prove )

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6. Is the measured voltage within the specification?

YES
FLB -598 FUEL SYSTEM

▶ Go to "Component Inspection".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION ED41E282

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect EGTS(T3-VGT) connector.

3. Measure the resistance between signal terminal and ground terminal of EGTS(T5-CPF) connector. (Component
side)

Specification : Refer to Specification of General Information

4. Is the measured resistance at certain temperature within the specified resisance range at the temperature?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace EGTS(T3-VGT) and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E5BB9AD4

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

DTC TROUBLESHOOTING PROCEDURES FLB -599

DTC P2111 THROTTLE ACTUATOR CONTROL SYSTEM - STUCK OPEN

COMPONENT LOCATION E4B952AE

[WITH CPF]

Throttle Control Actuator

SFDF28323L

[WITHOUT CPF]

Throttle Flap Control Solenoid

Valve

VGT Control Solenoid Valve

SFDF28322L

GENERAL DESCRIPTION E78644FB

[WITH CPF]

As closing or opening vacuum line from vacuum pump which is installed at the end of cam shaft, with the method of duty
control, Throttle contor Actuator controls throttle flap valve when engine is turning OFF.
When turning engines OFF, Throttle flap valve cuts intake air to prevent overrun phenomena.(In spite of turning engine
OFF, engine does not stop and runs for a while due to rotating inertia of engine and fuel leakage at injector nozzle. )
To check its operation, watch if it operate when turning engine OFF.

[WITHOUT CPF]

As closing or opening vacuum line from vacuum pump which is installed at the end of cam shaft, with the method of duty
control, Throttle contor Actuator controls throttle flap valve when engine is turning OFF.
When turning engines OFF, Throttle flap valve cuts intake air to prevent overrun phenomena.(In spite of turning engine
OFF, engine does not stop and runs for a while due to rotating inertia of engine and fuel leakage at injector nozzle. )
FLB -600 FUEL SYSTEM

To check its operation, watch if it operate when turning engine OFF.

DTC DESCRIPTION EFD31543

[WITH CPF]

P2111 is set when excessive current in throttle control actuator is detected for more than 1 sec. this code is due to short
to battery in control circuit or internal short of actuator component.

[WITHOUT CPF]

P2111 is set when excessive current in throttle flap actuator is detected for more than 0.11 sec. this code is due to short
to battery in control circuit or internal short of actuator component.

DTC DETECTING CONDITION EF01D5B2

[WITH CPF]

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"
Threshold Value ● Short to battery
Diagnostic Time ● 1 sec. ● TCA circuit
Fuel Cut NO ● TCA component
EGR Off YES
Fail Safe Fuel Limit NO
Check
OFF
Lamp

[WITHOUT CPF]

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"
Threshold Value ● Short to battery
Diagnostic Time ● 110ms ● Throttle contor actuator circuit
Fuel Cut NO ● Throttle contor actuator component
EGR Off YES
Fail Safe Fuel Limit NO
Check
NO
Lamp
DTC TROUBLESHOOTING PROCEDURES FLB -601

SPECIFICATION EB41D0E1

[WITH CPF]

Throttle control actuator fully Throttle control actuator Throttle control actuator
opened fully closed operating Hz
5% 95% 250±7.5 Hz

[WITHOUT CPF]

Throttle control actuator Throttle control actuator Throttle control actuator

component resistance operating Hz operating duty

23.8~31.3Ω (20 C) 300Hz 38%(no vacuum)~90%(vacuum)

DIAGNOSTIC CIRCUIT DIAGRAM EA871566

[WITH CPF]

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.

Main Relay
"ON" Input

E/R JUNCTION BOX

<ELECTICL THROTTLE
CONTROL ACTUATOR>

4 3 2 1
Electicl throttle
Actuator
1. Feedback Status Signal
2. Throttle Valve Actuator Feedback Status
3. Power Signal
4. Ground

ELECTICL THROTTLE
CONTROL ACTUATOR

<ECM>

94 93 92 90 89
*
72 71 70 69 68 * 87 86 * 84 83 * 81 80 79 * 77 * 75 * * 6 5
77. Feedback Status Signal
* * 65 64 * * * * * * 57 56 * 54 * * 51 4 3

* 27* 48 47
28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1 90. Throttle Valve Actuator
* 25 * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7

SFDF27629L
FLB -602 FUEL SYSTEM

[WITHOUT CPF]

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.
Main Relay
"ON" Input

<THROTTLE FLAP ACTURE> E/R JUNCTION BOX

2 1
Throttle Valve
Actuator
1. Throttle Valve Actuator
2. Power THROTTLE FLAP ACTURE

<ECM>

94 93 92 90 89
*
72 71 70 69 68 * 87 86 * 84 83 * 81 80 79 * 77 * 75 * * 6 5
* * 65 64 * * * * * * 57 56 * 54 * * 51 4 3

* 27* 48 47
28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1
* 25 * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7
90. Throttle Valve Actuator

SFDF27624L

SIGNAL WAVEFORM AND DATA E7C7D773

[WITH CPF]

Fig.1 Fig.2
SFDF27579L
DTC TROUBLESHOOTING PROCEDURES FLB -603

Fig.1) Waveform of Throttle control actuator at wide open(at idle) : At IG KEY "ON", ENGINE "ON", 5% duty is outputted
continuously.
Fig.2) Waveform of Throttle control actuator at closed position : At IG KEY "OFF", 93% duty is outputted for about 1 sec.

[WITHOUT CPF]

Fig.1 Fig.2
SFDF27581L

Fig.1) Waveform of Throttle control actuator without throttle flap operation(idle) : At IG KEY "ON", ENGINE "ON", 38%
duty is outputted continuously.
Fig.2) Waveform of Throttle control actuator with throttle flap operation(engine "OFF") : At IG KEY "OFF", 90% duty is
outputted for about 1 sec.

MONITOR SCANTOOL DATA E48ACAF0

[WITH CPF]

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Monitor "INLET THROTTLE ACTU." parameter on the Scantool.

Specification : 94.5% duty outputted except the operation of throttle flap

9.4% duty outputted at the operation of throttle flap
FLB -604 FUEL SYSTEM

Fig.1
SFDF27580L

Fig 1) The duty of "INLET THROTTLE ACTU." is 94.5% at IG KEY "ON" and ENGINE "ON". The duty of "INLET
THROTTLE ACTU." is 9.4% at IG KEY "OFF" and ENGINE "OFF".

[WITHOUT CPF]

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Monitor "INLET THROTTLE ACTU." parameter on the Scantool.

Specification : 94.5% duty outputted except the operation of throttle flap

9.4% duty outputted at the operation of throttle flap

Fig.1
SFDF27582L

Fig 1) The duty of "INLET THROTTLE ACTU." is 94.5% at IG KEY "ON" and ENGINE "ON".
The duty of "INLET THROTTLE ACTU." is 9.4% at IG KEY "OFF" and ENGINE "OFF".
DTC TROUBLESHOOTING PROCEDURES FLB -605

TERMINAL AND CONNECTOR INSPECTION E084ECF0

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power Circuit Inspection".

POWER CIRCUIT INSPECTION EF8C27C3

[WITH CPF]

1. Check power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Throttle control actuator.

3) IG KEY "ON"

4) Measure the voltage between power terminal of Throttle control actuator harness connector and chassis ground.

Secification : 11.5V~13.0V

5) Is the measured voltage within the specification?

YES

▶ Go to "Control Circuit Inspection".

NO

▶ Repair INJ1 FUSE E/R JUNCTION BOX and related circuit and go to "Verification of Vehicle Repair".

[WITHOUT CPF]

1. Check power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

FLB -606 FUEL SYSTEM

2) Disconnect Throttle control actuator.

3) IG KEY "ON".

4) Measure the voltage between power terminal of Throttle control actuator harness connector and chassis ground.

Specification : 11.5V~13.0V

5) Is the measured voltage within the specification?

YES

▶ Go to "Control Circuit Inspection".

NO

▶ Repair INJ FUSE in E/R JUNCTION BOX and related circuit and go to "Verification of Vehicle Repair".

CONTROL CIRCUIT INSPECTION E09092E7

[WITH CPF]

1. Check control circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Throttle control actuator connector.

3) IG KEY "ON".

4) Measure the voltage between control terminal of Throttle control actuator harness connector and chassis ground.

Secification : 0.0V~0.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "2.Check open in control circuit"as follows.

NO

▶ Repair short to battery in control circuit and go to "Verification of Vehicle Repair".

2. Check open in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Throttle control actuator connector and ECM connector.

3) Check continuity between control terminal of throttle control actuator harness connector and ECM harness con-
nector.

Specification : Continuity ( below 1.0Ω )

4) Is the measured resistance within the specificaiton?

DTC TROUBLESHOOTING PROCEDURES FLB -607

YES

▶ Go to "3. Check short to ground in control circuit" as follows.

NO

▶ Repair open in throttle control actuator control circuit and go to "Varification of Vehicle Repair".

3. Check short to ground in control circuit

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect Throttle control actuator connector.

3) Check continuity between control terminal of throttle control actuator harness connector and chassis ground.

Specification : Discontinuity (Infinite Ω )

4) Is the measured resistance within the specification? (Is control circuit insulated with ground?)

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Repair short to ground in control circuit and go to "Verification of Vehicle Repair".

[WITHOUT CPF]

1. Check monitoring voltage in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Throttle control actuator connector.

3) IG KEY "ON".

4) Measure the voltage between control terminal of throttle control actuator hanress connector and chassis ground.

Specification : 3.2V~3.7V

5) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ When voltage is not detected : Go to "2. Check open in control circuit" as follows.
▶ When high voltage is detected : Repair short to battery in control circuit and go to "Verification of Vehicle
Repair".

2. Check open in control circuit

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect throttle control actuator connector and ECM connector.

FLB -608 FUEL SYSTEM

3) Check continuity between control terminal of throttle control actuator harness connector and ECM harness con-
nector.

Specification : Continuity (below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground in control circuit and go to "Verification of Vehicle Repair".

NO

▶ Repair open in control circuit and go to "Verification of Vehicle Repair".

GROUND CIRCUIT INSPECTION E3BB7E11

[WITH CPF]

1. IG KEY "OFF", ENGINE "OFF"

2. Disconnect Throttle control actuator connector.

3. IG KEY "ON"

4. Measure the voltage between power terminal of Throttle control actuator harness connector and chassis ground. [
TEST "A" ]

5. Measure the voltage between power terminal and ground terminal of Throttle control actuator harness connector. [
TEST "B" ]
( Power terminal : Check + prove , Ground terminal : Check - prove )

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6. Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION EDB372B2

[WITH CPF]

1. Throttle control actuator component visual inspection

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect intake hose connected to throttle control actuator.

3) Check if throttle control actuator is contaminated with carbon fraction.

DTC TROUBLESHOOTING PROCEDURES FLB -609

4) Check if throttle flap moves smoothly as touching it with hand (perform this process at IG KEY "OFF" state.)

NOTE
※ Check if abnormal noise, valve shaft stuck, too much wear are detected.

Specification : Flap moves smoothly and carbon fraction, too much wear, abnormal noise are not detected.

5) Is throttle control actuator is OK after performing visual inspection?

YES

▶ Go to "2. Throttle control actuator operating test" as follows.

NO

▶ If same symptom is detected after clear carbon fraction up, replace throttle control actuator and go to "Veri-
fication of Vehicle Repair".

2. Throttle control actuator operating test

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect intake hose connected to throttle control actuator.

3) ENGINE "ON"

4) Check if throttle control actuator is in wide open state during engine running.

5) ENGINE "OFF

6) Check if throttle flap is closed once and opened again at the point of turning engine OFF.

NOTE
※ Check if abnormal noise or irregular moving of flap is detected.

Specification :
Throttle flap moves smoothly.
At engine ON : Throttle control actuator opened.
At the point of turning engine OFF : Throttle flap is closed once and opened again.

7) Is throttle flap moves smoothly?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace throttle control actuator and go to "Verification of Vehicle Repair".

[WITHOUT CPF]

1. Check Throttle control actuator component resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Throttle control actuator.

FLB -610 FUEL SYSTEM

3) Check the resistance of Throttle control actuator.

Specification : 23.8~31.3Ω (20 C)

4) Is the measured resistance within the specification?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace Throttle control actuator and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E718D527

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

DTC TROUBLESHOOTING PROCEDURES FLB -611

DTC P2112 THROTTLE ACTUATOR CONTROL SYSTEM STUCK CLOSED

COMPONENT LOCATION EF971860

Refer to DTC P2111.

GENERAL DESCRIPTION EAD9757C

Refer to DTC P2111.

DTC DESCRIPTION ED4F78A8

[WITH CPF]

P2112 is set when "0"A in throttle flap actuator is detected for more than 1 sec. this code is due to 1)open or short to
ground in control circuit or 2)internal open in actuator component.

[WITHOUT CPF]

P2111-2 is set when "0"A in throttle contor actuator is detected for more than 0.11 sec. this code is due to 1)open or short
to ground in control circuit or 2)internal open in actuator component.

DTC DETECTING CONDITION E7F73C7A

[WITH CPF]

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● Short to GND

● Wiring open
Diagnostic Time ● 1 sec. ● TCA circuit
● TCA component
Fuel Cut NO
EGR Off YES
Fail Safe Fuel Limit NO
Check
OFF
Lamp
FLB -612 FUEL SYSTEM

[WITHOUT CPF]

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"
Threshold Value ● Short to GND, Wiring open
Diagnostic Time ● 110ms ● Throttle control actuator circuit
Fuel Cut NO ● Throttle control actuator component
EGR Off YES
Fail Safe Fuel Limit NO
Check
NO
Lamp

SPECIFICATION E68524CC

Refer to DTC P2111.

DIAGNOSTIC CIRCUIT DIAGRAM E14FD4B7

Refer to DTC P2111.

SIGNAL WAVEFORM AND DATA EA7E2E89

Refer to DTC P2111.

MONITOR SCANTOOL DATA EDD5DE76

Refer to DTC P2111.

TERMINAL AND CONNECTOR INSPECTION E1433CBA

Refer to DTC P2111.

POWER CIRCUIT INSPECTION E7969A0D

[WITH CPF]

1. Check power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Throttle control actuator.

3) IG KEY "ON"

4) Measure the voltage between power terminal of Throttle control actuator harness connector and chassis ground.

Secification : 11.5V~13.0V

5) Is the measured voltage within the specification?

DTC TROUBLESHOOTING PROCEDURES FLB -613

YES

▶ Go to "Control Circuit Inspection".

NO

▶ Repair INJ1 FUSE E/R JUNCTION BOX and related circuit and go to "Verification of Vehicle Repair".

[WITHOUT CPF]

1. Check power circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Throttle control actuator.

3) IG KEY "ON".

4) Measure the voltage between power terminal of Throttle control actuator harness connector and chassis ground.

Specification : 11.5V~13.0V

5) Is the measured voltage within the specification?

YES

▶ Go to "Control Circuit Inspection".

NO

▶ Repair INJ FUSE in E/R JUNCTION BOX and related circuit and go to "Verification of Vehicle Repair".

CONTROL CIRCUIT INSPECTION E3AB56C7

[WITH CPF]

1. Check control circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Throttle control actuator connector.

3) IG KEY "ON".

4) Measure the voltage between control terminal of Throttle control actuator harness connector and chassis ground.

Secification : 0.0V~0.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "2.Check open in control circuit"as follows.

NO

▶ Repair short to battery in control circuit and go to "Verification of Vehicle Repair".

FLB -614 FUEL SYSTEM

2. Check open in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Throttle control actuator connector and ECM connector.

3) Check continuity between control terminal of throttle control actuator harness connector and ECM harness con-
nector.

Specification : Continuity ( below 1.0Ω )

4) Is the measured resistance within the specificaiton?

YES

▶ Go to "3. Check short to ground in control circuit" as follows.

NO

▶ Repair open in throttle control actuator control circuit and go to "Varification of Vehicle Repair".

3. Check short to ground in control circuit

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect Throttle control actuator connector.

3) Check continuity between control terminal of throttle control actuator harness connector and chassis ground.

Specification : Discontinuity (Infinite Ω )

4) Is the measured resistance within the specification? (Is control circuit insulated with ground?)

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Repair short to ground in control circuit and go to "Verification of Vehicle Repair".

[WITHOUT CPF]

1. Check monitoring voltage in control circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Throttle control actuator connector.

3) IG KEY "ON".

4) Measure the voltage between control terminal of throttle control actuator hanress connector and chassis ground.

Specification : 3.2V~3.7V

5) Is the measured voltage within the specification?

YES
DTC TROUBLESHOOTING PROCEDURES FLB -615

▶ Go to "Component Inspection".

NO

▶ When voltage is not detected : Go to "2. Check open in control circuit" as follows.
▶ When high voltage is detected : Repair short to battery in control circuit and go to "Verification of Vehicle
Repair".

2. Check open in control circuit

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect throttle control actuator connector and ECM connector.

3) Check continuity between control terminal of throttle control actuator harness connector and ECM harness con-
nector.

Specification : Continuity (below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground in control circuit and go to "Verification of Vehicle Repair".

NO

▶ Repair open in control circuit and go to "Verification of Vehicle Repair".

GROUND CIRCUIT INSPECTION E498CB86

[WITH CPF]

1. IG KEY "OFF", ENGINE "OFF"

2. Disconnect Throttle control actuator connector.

3. IG KEY "ON"

4. Measure the voltage between power terminal of Throttle control actuator harness connector and chassis ground. [
TEST "A" ]

5. Measure the voltage between power terminal and ground terminal of Throttle control actuator harness connector. [
TEST "B" ]
( Power terminal : Check + prove , Ground terminal : Check - prove )

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6. Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
FLB -616 FUEL SYSTEM

▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E2994A27

[WITH CPF]

1. Throttle control actuator component visual inspection

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect intake hose connected to throttle control actuator.

3) Check if throttle control actuator is contaminated with carbon fraction.

4) Check if throttle flap moves smoothly as touching it with hand (perform this process at IG KEY "OFF" state.)

NOTE
※ Check if abnormal noise, valve shaft stuck, too much wear are detected.

Specification : Flap moves smoothly and carbon fraction, too much wear, abnormal noise are not detected.

5) Is throttle control actuator is OK after performing visual inspection?

YES

▶ Go to "2. Throttle control actuator operating test" as follows.

NO

▶ If same symptom is detected after clear carbon fraction up, replace throttle control actuator and go to "Veri-
fication of Vehicle Repair".

2. Throttle control actuator operating test

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect intake hose connected to throttle control actuator.

3) ENGINE "ON"

4) Check if throttle control actuator is in wide open state during engine running.

5) ENGINE "OFF

6) Check if throttle flap is closed once and opened again at the point of turning engine OFF.

NOTE
※ Check if abnormal noise or irregular moving of flap is detected.

Specification :
Throttle flap moves smoothly.
At engine ON : Throttle control actuator opened.
At the point of turning engine OFF : Throttle flap is closed once and opened again.

7) Is throttle flap moves smoothly?

DTC TROUBLESHOOTING PROCEDURES FLB -617

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace throttle control actuator and go to "Verification of Vehicle Repair".

[WITHOUT CPF]

1. Check Throttle control actuator component resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Throttle control actuator.

3) Check the resistance of Throttle control actuator.

Specification : 23.8~31.3Ω (20 C)

4) Is the measured resistance within the specification?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace Throttle control actuator and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E7343017

Refer to DTC P2111.

FLB -618 FUEL SYSTEM

DTC P2113 THROTTLE/PEDAL POSITION SENSOR "B" MINIMUM STOP

PERFORMANCE

COMPONENT LOCATION E5F6EE61

Throttle Control Actuator

SFDF28323L

GENERAL DESCRIPTION EF5EC99A

Throttle Control actuator(TCA) helps EEGR actuator in EGR control as controlling throttle flap position with the method of
duty control. In EURO 3 diesel engine, precise EGR control is more difficult than in EURO 4 engine. Even though EGR
actuator opens exhaust gas outlet fully, it is difficult for exhaust gas to be inhaled at intake manifold because intake air is
already exist to be inhaled at there in EURO 3 engine. However in EURO 4 engine, controlling throttle flap position, it is
possible to regulate the differential pressure between exhaust and intake air. With the control of the differential pressure,
the amount of exhaust air to be recirculated is regulated. Besides, When turning engines OFF, Throttle control actuator
cuts intake air to prevent dieselling.(In spite of turning engine OFF, engine does not stop and runs for a while due to
rotating inertia of engine and fuel leakage at injector nozzle. )

DTC DESCRIPTION E5B22E2E

P2113 is set when Feed-back signal is not normal for more than 5 sec. this code is due to fault in circuit or actuator
component.

DTC DETECTING CONDITION ECD8DD5D

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"
Threshold Value ● Feed-back signal Failed
Diagnostic Time ● 5 sec. ● TCA signal circuit
● TCA component
Fuel Cut NO
EGR Off YES
Fail Safe
Fuel Limit NO
Check Lamp OFF
DTC TROUBLESHOOTING PROCEDURES FLB -619

SPECIFICATION E8BDD1BE

Throttle control actuator fully Throttle control actuator fully Throttle control actuator
opened closed operating Hz
5% 95% 250±7.5 Hz

DIAGNOSTIC CIRCUIT DIAGRAM E91BFD83

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.

Main Relay
"ON" Input

E/R JUNCTION BOX

<ELECTICL THROTTLE
CONTROL ACTUATOR>

4 3 2 1
Electicl throttle
Actuator
1. Feedback Status Signal
2. Throttle Valve Actuator Feedback Status
3. Power Signal
4. Ground

ELECTICL THROTTLE
CONTROL ACTUATOR

<ECM>

94 93 92 90 89
*
72 71 70 69 68 * 87 86 * 84 83 * 81 80 79 * 77 * 75 * * 6 5
77. Feedback Status Signal
* * 65 64 * * * * * * 57 56 * 54 * * 51 4 3

* 27* 48 47
28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1 90. Throttle Valve Actuator
* 25 * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7

SFDF27629L
FLB -620 FUEL SYSTEM

SIGNAL WAVEFORM AND DATA EB9EE6BA

Fig.1 Fig.2
SFDF27579L

Fig.1) Waveform of Throttle control actuator at wide open(at idle) : At IG KEY "ON", ENGINE "ON", 5% duty is outputted
continuously.
Fig.2) Waveform of Throttle control actuator at closed position : At IG KEY "OFF", 93% duty is outputted for about 1 sec..

MONITOR SCANTOOL DATA E0FEDDF5

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Monitor "INLET THROTTLE ACTU." parameter on the Scantool.

Specification : 94.5% duty outputted except the operation of throttle flap

9.4% duty outputted at the operation of throttle flap

Fig.1
SFDF27580L
DTC TROUBLESHOOTING PROCEDURES FLB -621

Fig 1) The duty of "INLET THROTTLE ACTU." is 94.5% at IG KEY "ON" and ENGINE "ON". The duty of "INLET
THROTTLE ACTU." is 9.4% at IG KEY "OFF" and ENGINE "OFF".

TERMINAL AND CONNECTOR INSPECTION E7E3F519

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power Circuit Inspection".

POWER CIRCUIT INSPECTION ED4FAA35

1. IG KEY "OFF", ENGINE "OFF"

2. Disconnect Throttle control actuator.

3. IG KEY "ON"

4. Measure the voltage between power terminal of Throttle control actuator harness connector and chassis ground.

Secification : 11.5V~13.0V

5. Is the measured voltage within the specification?

YES

▶ Go to "Control Circuit Inspection".

NO

▶ Repair INJ1 FUSE E/R JUNCTION BOX and related circuit and go to "Verification of Vehicle Repair".

CONTROL CIRCUIT INSPECTION EF5CC8EB

1. Check control circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

FLB -622 FUEL SYSTEM

2) Disconnect Throttle control actuator connector.

3) Measure the voltage between signal terminal of Throttle control actuator harness connector and chassis ground.

Secification : 0.0V~0.1V

4) Is the measured voltage within the specification?

YES

▶ Go to "2.Check signal in control circuit"as follows.

NO

▶ Repair short to battery in control circuit and go to "Verification of Vehicle Repair".

2. Check open in siganl circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Throttle control actuator connector and ECM connector.

3) Check continuity between signal terminal of throttle control actuator harness connector and ECM harness con-
nector.

Specification : Continuity ( below 1.0Ω )

4) Is the measured resistance within the specificaiton?

YES

▶ Go to "3. Check short to ground in signal circuit" as follows.

NO

▶ Repair open in throttle control actuator control circuit and go to "Varification of Vehicle Repair".

3. Check short to ground in signal circuit

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect Throttle control actuator connector.

3) Check continuity between signal terminal of throttle control actuator harness connector and chassis ground.

Specification : Discontinuity (Infinite Ω )

4) Is the measured resistance within the specification? (Is control circuit insulated with ground?)

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Repair short to ground in signal circuit and go to "Verification of Vehicle Repair".

DTC TROUBLESHOOTING PROCEDURES FLB -623

GROUND CIRCUIT INSPECTION E0CD34EB

1. IG KEY "OFF", ENGINE "OFF"

2. Disconnect Throttle control actuator connector.

3. IG KEY "ON"

4. Measure the voltage between power terminal of Throttle control actuator harness connector and chassis ground. [
TEST "A" ]

5. Measure the voltage between power terminal and ground terminal of Throttle control actuator harness connector. [
TEST "B" ]
( Power terminal : Check + prove , Ground terminal : Check - prove )

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6. Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E4F3A14E

1. Throttle control actuator component visual inspection

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect intake hose connected to throttle control actuator.

3) Check if throttle control actuator is contaminated with carbon fraction.

4) Check if throttle flap moves smoothly as touching it with hand (perform this process at IG KEY "OFF" state.)

NOTE
※ Check if abnormal noise, valve shaft stuck, too much wear are detected.

Specification : Flap moves smoothly and carbon fraction, too much wear, abnormal noise are not detected.

5) Is throttle control actuator is OK after performing visual inspection?

YES

▶ Go to "2. Throttle control actuator operating test" as follows.

NO

▶ If same symptom is detected after clear carbon fraction up, replace throttle control actuator and go to "Veri-
fication of Vehicle Repair".
FLB -624 FUEL SYSTEM

2. Throttle control actuator operating test

1) IG KEY "OFF", ENGINE "OFF"

2) Disconnect intake hose connected to throttle control actuator.

3) ENGINE "ON"

4) Check if throttle control actuator is in wide open state during engine running.

5) ENGINE "OFF

6) Check if throttle flap is closed once and opened again at the point of turning engine OFF.

NOTE
※ Check if abnormal noise or irregular moving of flap is detected.

Specification :
Throttle flap moves smoothly.
At engine ON : Throttle control actuator opened.
At the point of turning engine OFF : Throttle flap is closed once and opened again.

7) Is throttle flap moves smoothly?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace throttle control actuator and go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR EAAD62EB

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

DTC TROUBLESHOOTING PROCEDURES FLB -625

DTC P2123 THROTTLE/PEDAL POSITION SENSOR /SWITCH "D" CIRCUIT

HIGH INPUT

COMPONENT LOCATION E24E264C

APS

SFDF28320L

GENERAL DESCRIPTION ECFDCA14

Driver′ s intension to accelerate is transmitted to ECM through Accelerator Pedal Sensor(APS) . And APS, whose mech-
anism is same as TPS, is required for ECM to determine optimum fuel injection quantity.
As fidelity of APS is strongly required, APS is devided into two. One is APS1, which outputs main signals and the other
is APS2, which monitors APS1 performance.
APS1 and 2 do not share power supply and ground. Normally, APS2 output voltage is the half of APS1 and if the ratio of
two signal is out of specified value, error is recognized then, Limp Home mode is activated.
When Limp Home mode is activated, engine speed is fixed at 1200RPM and driving performance is limited to prevent
excessive power generation due to APS false signal.

DTC DESCRIPTION E582F8A7

P2123 is set when output voltage of APS 1 is above the maximum value of 4.9V for more than 0.18 sec. This code is due
to the short to battery in APS 1 power circuit and signal circuit or open in sensor ground circuit.
FLB -626 FUEL SYSTEM

DTC DETECTING CONDITION EA0EB6D4

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● When output signal is above the maximum

value (above 4910mV )
Diagnostic Time ● 180ms ● APS 1 Circuit
● APS component
Fuel Cut NO
EGR Off NO ● APS standard value
Fail Safe is 0%.
Fuel Limit YES ● Limp home idle is fixed
Check at (1200RPM)
YES
Lamp

SPECIFICATION EA7839F1

Pedal released Pedal depressed Sensor Type

APS 1 0.7V~0.8V 3.8V~4.4V Variable resistance
APS 2 0.275V~0.475V 1.75V~2.35V type(Potentiometer)
DTC TROUBLESHOOTING PROCEDURES FLB -627

DIAGNOSTIC CIRCUIT DIAGRAM E0EC203C

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.
Main Relay
"ON" Input

E/R JUNCTION BOX

<Accelerator Pedal Sensor>

APS1
Power
6 5 4 3 2 1
Signal APS #1
Ground
1. Signal #2
2. Ground #2 APS2
Power
3. Signal #1
4. Ground #1 Signal APS #2
5. Power #1
6. Power #2 Ground

Accelerator Pedal Sensor

<ECM>
8. APS2 Ground
94 93 92 90 89 87 86 84 83 81 80 79 77 75 9. APS1 Signal
*
72 71 70 69 68 * * *
65 64 * * ** 6 5
** * * * * * * * * * 51 57 56 54
4 3
30. APS1 Ground
31. APS2 Signal
* 27* 48 47
28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1
* 25 * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7 45. APS1 Power
46. APS2 Power

SFDF27613L
FLB -628 FUEL SYSTEM

SIGNAL WAVEFORM AND DATA EA3F026E

APS 1

APS 2

APS 2 ground check

signal

Fig.1
SFDF27583L

Fig.1) APS 1 and APS 2 signals are measured simultaneously, Check if output value is rising and APS 2 is 1/2 of APS 1
signal.

NOTE
APS 2 Ground checking signal is for ECM to monitor APS 2. This signal drops APS 2 output voltage to below
200.39mV per 200msec. If APS 2 output voltage does not drop to below 200.39mV, ECM sets DTC as recognizing
ground circuit error of APS 2 .

※ The waveform below 200.39mV is not detectable in Ground checking signal waveform of APS 2 signal. Instead,
the waveform which drops a little is detected. If APS 2 data of "SERVICE DATA" on the Scantool varies from 350mV
to 0mV periodically, it means it works well.

MONITOR SCANTOOL DATA EE4C75A5

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Monitor "ACCEL PEDAL SENSOR", "ACCEL PEDAL SENSOR 1", "ACCEL PEDAL SENSOR 2 " parameter on the
scantool.

Specification : At idle( 0% ) ACCEL PEDAL SENSOR 1 : 600mV~800mV

ACCEL PEDAL SENSOR 2 : 1/2 of ACCEL PEDAL SENSOR 1
DTC TROUBLESHOOTING PROCEDURES FLB -629

Fig.1
SFDF27584L

Fig.1) APS output data at warm idle. Check if output value is rising and "ACCEL PEDAL SENSOR 2" is 1/2 of "ACCEL
PEDAL SENSOR 1" signal.

TERMINAL AND CONNECTOR INSPECTION E5EEAC59

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power Circuit Inspection" as follows.

POWER CIRCUIT INSPECTION E2C01791

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect APS connector.

3. IG KEY "ON".

4. Measure the voltage between power terminal of APS harness connector and chassis ground.
FLB -630 FUEL SYSTEM

Specification : 4.8V~5.1V

5. Is the measured voltage within the specification?

YES

▶ Go to "Signal Circuit Inspection".

NO

▶ If the measured voltage is not within the specified value, find and repair short to battery in APS 1 power circuit and
go to "Verification of Vehicle Repair".

SIGNAL CIRCUIT INSPECTION E57218DC

1. Check open in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect APS connector and ECM connector.

3) Check continuity between signal terminal of APS harness connector and signal terminal of ECM harness con-
nector.

Secification : Continuity (below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "Check short to battery in signal circuit" as follows.

NO

▶ Repair open in signal circuit and go to "Verification of Vehicle Repair".

2. Check short to battery in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect APS connector and ECM connector.

3) IG KEY "ON".

4) Measure the continuity between signal terminal of APS harness connector and chassis ground .

Secification : 0.0V~0.1V

5) Is abnormal voltage detected in signal circuit with both connector disconnected?

YES

▶ Repair short to battery and go to "Verification of Vehicle Repair".

NO
DTC TROUBLESHOOTING PROCEDURES FLB -631

▶ Go to "Ground Circuit Inspection".

GROUND CIRCUIT INSPECTION E5E4F299

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect APS connector.

3. IG KEY "ON".

4. Measure the voltage between power terminal of APS connector and chassis ground. [ TEST "A" ]

5. Measure the voltage between power terminal of APS harness connector and ground terminal of APS harness con-
nector. [ TEST "B" ]
( Power terminal : Check + prove , Ground Terminal : Check - prove )

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6. Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E242C7C1

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect APS connector .

3. Check resistance for each terminal refering to Resistance characteristic table.

Specification : Resistance characteristic table for each terminal

4. Are resistances for each terminal measured correctly?

YES

▶ Go to "Verification of Vehicle Rapair".

NO

▶ Replace APS and go to "Verification of Vehicle Rapair".

VERIFICATION OF VEHICLE REPAIR E17B0B64

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.
FLB -632 FUEL SYSTEM

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

DTC TROUBLESHOOTING PROCEDURES FLB -633

DTC P2128 THROTTLE / PEDAL POSITION SENSOR/SWITCH "E"

CIRCUIT-HIGH INPUT

COMPONENT LOCATION EBA9438B

Refer to DTC P2123.

GENERAL DESCRIPTION E801C24F

Refer to DTC P2123.

DTC DESCRIPTION EE1B92F6

P2128 is set when output voltage of APS 2 is above the maximum value of 2463 mV for more than 0.18 sec. This code
is due to the short to battery in APS 2 power circuit and signal circuit or open in sensor ground circuit.

DTC DETECTING CONDITION E8DCAC56

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON" or Engine running

Threshold Value ● When output signal is above the maximum

value (above 2464mV)
Diagnostic Time ● 180ms ● APS 2 Circuit
● APS component
Fuel Cut NO
EGR Off NO ● APS standard value
Fail Safe is 0%.
Fuel Limit YES ● Limp home idle is fixed
Check at (1200RPM)
YES
Lamp

SPECIFICATION EB2F2D7B

Refer to DTC P2123.

DIAGNOSTIC CIRCUIT DIAGRAM E08D7257

Refer to DTC P2123.

SIGNAL WAVEFORM AND DATA E38C51BC

Refer to DTC P2123.

MONITOR SCANTOOL DATA E78792B8

Refer to DTC P2123.

FLB -634 FUEL SYSTEM

TERMINAL AND CONNECTOR INSPECTION ECA7DF58

Refer to DTC P2123.

POWER CIRCUIT INSPECTION E35D87D4

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect APS connector.

3. IG KEY "ON".

4. Measure the voltage between power terminal of APS 2 harness connector and chassis ground.

Specification : 4.8V~5.1V

5. Is the measured voltage within the specification?

YES

▶ Go to "Signal Circuit Inspection".

NO

▶ If the measured voltage is above the specified value, find and repair short to battery in APS 2 power circuit and
go to "Verification of Vehicle Repair".

SIGNAL CIRCUIT INSPECTION E165489E

1. Check open in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect APS connector and ECM connector.

3) Check continuity between signal terminal of APS 2 harness connector and signal terminal of ECM harness con-
nector.

Secification : Continuity (below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Go to "Check short to battery in signal circuit" as follows.

NO

▶ Repair open in signal circuit and go to "Verification of Vehicle Repair".

2. Check short to battery in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect APS connector and ECM connector.

3) IG KEY "ON".
DTC TROUBLESHOOTING PROCEDURES FLB -635

4) Measure the voltage between signal terminal of APS harness connector and chassis ground.

Secification : 0.0V~0.1V

5) Is abnormal voltage detected in signal circuit with both connector disconnected?

YES

▶ Repair short to battery and go to "Verification of Vehicle Repair".

NO

▶ Go to "Ground Circuit Inspection".

GROUND CIRCUIT INSPECTION E6E2E045

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect APS connector.

3. IG KEY "ON".

4. Measure the voltage between power terminal of APS harness connector. [ TEST "A" ]

5. Measure the voltage between power terminal of APS2 harness connector and ground terminal of APS2 harness
connector. [ TEST "B" ]
( Power terminal : Check + prove , Ground terminal : Check - prove )

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6. Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resistance
and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E7C7E181

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect APS connector .

3. Check resistance for each terminal refering to Resistance characteristic table.

Specification : Resistance characteristic table for each terminal

4. Are resistances for each terminal measured correctly?

YES
FLB -636 FUEL SYSTEM

▶ Go to "Verification of Vehicle Rapair".

NO

▶ Replace APS and go to "Verification of Vehicle Rapair".

VERIFICATION OF VEHICLE REPAIR E97E791B

Refer to DTC P2123.

DTC TROUBLESHOOTING PROCEDURES FLB -637

DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH D/E VOLTAGE

CORRELATION

COMPONENT LOCATION E157BE32

APS

SFDF28320L

GENERAL DESCRIPTION ED175756

Driver′ s intension to accelerate is transmitted to ECM through Accelerator Pedal Sensor(APS) . And APS, whose mech-
anism is same as TPS, is required for ECM to determine optimum fuel injection quantity.
As fidelity of APS is strongly required, APS is devided into two. One is APS1, which outputs main signals and the other
is APS2, which monitors APS1 performance.
APS1 and 2 do not share power supply and ground. Normally, APS2 output voltage is the half of APS1 and if the ratio of
two signal is out of specified value, error is recognized then, Limp Home mode is activated.
When Limp Home mode is activated, engine speed is fixed at 1200RPM and driving performance is limited to prevent
excessive power generation due to APS false signal.

DTC DESCRIPTION E34630A1

P2138 is set when there is difference above the threshold value between APS1 and (APS2 * 2) for more than 0.24 sec..
Careful inspection of poor connection between APS 1 and APS 2, resistance characteristic of APS component is needed.
FLB -638 FUEL SYSTEM

DTC DETECTING CONDITION E19AC956

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"(APS depressed)

● When APS 1,2 is depressed 0~6%, APS1

Threshold Value - (APS2 * 2) ＞ 347mV
● When APS 1,2 is depressed above 7%,
APS1 - (APS2 * 2) ＞ 405mV ● APS 1 Circuit
● APS 2 Circuit
Diagnostic Time ● 240ms ● APS component
Fuel Cut NO
EGR Off NO ● APS standard value
Fail Safe is 0%.
Fuel Limit YES ● Limp home idle is fixed
Check at (1200RPM)
YES
Lamp

SPECIFICATION E915E772

Pedal released Pedal depressed Sensor Type

APS 1 0.7V~0.8V 3.8V~4.4V Variable resistance
APS 2 0.275V~0.475V 1.75V~2.35V type(Potentiometer)
DTC TROUBLESHOOTING PROCEDURES FLB -639

DIAGNOSTIC CIRCUIT DIAGRAM E3FDB412

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.
Main Relay
"ON" Input

E/R JUNCTION BOX

<Accelerator Pedal Sensor>

APS1
Power
6 5 4 3 2 1
Signal APS #1
Ground
1. Signal #2
2. Ground #2 APS2
Power
3. Signal #1
4. Ground #1 Signal APS #2
5. Power #1
6. Power #2 Ground

Accelerator Pedal Sensor

<ECM>
8. APS2 Ground
94 93 92 90 89 87 86 84 83 81 80 79 77 75 9. APS1 Signal
*
72 71 70 69 68 * * *
65 64 * * ** 6 5
** * * * * * * * * * 51 57 56 54
4 3
30. APS1 Ground
31. APS2 Signal
* 27* 48 47
28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1
* 25 * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7 45. APS1 Power
46. APS2 Power

SFDF27613L
FLB -640 FUEL SYSTEM

SIGNAL WAVEFORM AND DATA EC28F876

APS 1

APS 2

APS 2 ground check

signal

Fig.1
SFDF27583L

Fig.1) APS 1 and APS 2 signals are measured simultaneously, Check if output value is rising and APS 2 is 1/2 of APS 1
signal.

NOTE
APS 2 Ground checking signal is for ECM to monitor APS 2. This signal drops APS 2 output voltage to below
200.39mV per 200msec. If APS 2 output voltage does not drop to below 200.39mV, ECM sets DTC as recognizing
ground circuit error of APS 2 .

※ The waveform below 200.39mV is not detectable in Ground checking signal waveform of APS 2 signal. Instead,
the waveform which drops a little is detected. If APS 2 data of "SERVICE DATA" on the Scantool varies from 350mV
to 0mV periodically, it means it works well.

MONITOR SCANTOOL DATA EEB7DAD9

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Monitor "ACCEL PEDAL SENSOR", "ACCEL PEDAL SENSOR 1", "ACCEL PEDAL SENSOR 2 " parameter on the
scantool.

Specification : At idle( 0% ) ACCEL PEDAL SENSOR 1 : 600mV~800mV

ACCEL PEDAL SENSOR 2 : 1/2 of ACCEL PEDAL SENSOR 1
DTC TROUBLESHOOTING PROCEDURES FLB -641

Fig.1
SFDF27584L

Fig.1) APS output data at warm idle. Check if output value is rising and "ACCEL PEDAL SENSOR 2" is 1/2 of "ACCEL
PEDAL SENSOR 1" signal.

TERMINAL AND CONNECTOR INSPECTION E75BD14B

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

Go to "Power Circuit Inspection" as follows.

POWER CIRCUIT INSPECTION E2D0AB2E

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect APS connector.

3. IG KEY "ON".

4. Measure the voltage between power terminal of APS1 harness connector and chassis ground.
FLB -642 FUEL SYSTEM

5. Measure the voltage between power terminal of APS2 harness connector and chassis ground.

Specification : 4.8V~5.1V

6. Is the measured voltage within the specification?

YES

▶ Go to "Signal Circuit Inspection".

NO

▶ If the measured voltage is not within the specified value, find and repair trouble causing part in circuits and go to
"Verification of Vehicle Repair".
When the measured voltage is higher than the specified value : Refer to P0643 Circuit Inspection. (APS1)
Refer to P0653 Circuit Inspection.(APS2)
When the measured voltage is lower than the specified value : Refer to P0642 Circuit Inspection.(APS1)
Refer to P0652 Circuit Inspection.(APS2)

SIGNAL CIRCUIT INSPECTION EE3DCD34

1. Check open in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect APS connector and ECM connector.

3) Check continuity between signal terminal of APS1 harness connector and signal terminal of ECM harness con-
nector.(APS1)

4) Check continuity between signal terminal of APS2 harness connector and signal terminal of ECM harness con-
nector.(APS2)

Secification : Continuity (below 1.0Ω )

5) Is the measured resistance within the specification?

YES

▶ Go to "Check short in signal circuit".

NO

▶ Repair open in signal circuit and go to "Verification of Vehicle Repair".

2. Check short in signal circuit ( APS 1 )

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect APS connector and ECM connector.

3) IG KEY "ON".

4) Check continuity between signal terminal of APS1 harness connector and chassis ground. (Check short to
ground )
DTC TROUBLESHOOTING PROCEDURES FLB -643

5) Measure the voltage between signal terminal of APS1 harness connector and chassis ground. (Check short to
battery )

Secification : Check short to ground : Discontinuity ( Infinite Ω )

Check short to battery : 0.0V~0.1V

6) Is APS 1 signal circuit insulated normally?

YES

▶ Go to "3.Signal Circuit Inspection (APS 2)" as follows.

NO

▶ Repair short in circuit and go to "Verification of Vehicle Repair".

3. Signal Circuit Inspection (APS 2)

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect APS connector and ECM connector.

3) IG KEY "ON".

4) Check continuity between signal terminal of APS2 harness connector and chassis ground. (Check short to
ground )

5) Measure the voltage between signal terminal of APS2 harness connector and chassis ground. (Check short to
battery )

Specification : Check short to ground : Discontinuity ( Infinite Ω )

Check short to battery : 0.0V~0.1V

6) Is APS 2 signal circuit insulated normally?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Repair short in circuit and go to "Verification of Vehicle Repair".

GROUND CIRCUIT INSPECTION E2734DD1

1. Check ground circuit (APS1)

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect APS connector.

3) IG KEY "ON".

4) Measure the voltage between power terminal of APS1 harness connector and chassis ground. [ TEST "A" ]

5) Measure the voltage between power terminal and ground terminal of APS1 harness connector. [ TEST "B" ]
( Power terminal : Check + prove , Ground terminal 4 : Check - prove )
FLB -644 FUEL SYSTEM

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6) Is the measured voltage within the specification?

YES

▶ Go to "2. Check ground circuit (APS2)".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resis-
tance and go to "Verification of Vehicle Repair".

2. Check ground circuit (APS2)

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect APS connector.

3) IG KEY "ON".

4) Measure the voltage of APS terminal 6. [ TEST "A" ]

5) Measure the voltage of APS terminal 6 and terminal 2. [ TEST "B" ]

( terminal 6: Check + prove , terminal 2 : Check - prove )

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resis-
tance and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E4023DCD

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect APS connector .

3. Check resistance for each terminal refering to Resistance characteristic table.

Specification : Resistance characteristic table for each terminal

4. Are resistances for each terminal measured correctly?

YES

▶ Go to "Verification of Vehicle Rapair".

DTC TROUBLESHOOTING PROCEDURES FLB -645

NO

▶ Replace APS and go to "Verification of Vehicle Rapair".

VERIFICATION OF VEHICLE REPAIR E4AB8CC4

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -646 FUEL SYSTEM

DTC P2238 O2 SENSOR PUMPING CURRENT CIRCUIT LOW (BANK 1

SENSOR 1)

COMPONENT LOCATION ED2348D8

Lambda Sensor

SFDF28314L

GENERAL DESCRIPTION E1C112AE

Lambda sensor installed at exhaust manifold is linear Lambda sensor and it senses O2 density of exhaust gas for accurate
EGR control through fuel correction. It also limits smoke which is generated by reach air-fuel mixture at engine maximum
loading condition. ECM controls pumping current in order to fit λ -value from linear Lambda sensor to 1.0.
Lean air-fuel mixture(1.0〈λ 〈1.1) : ECM supplies pumping current to Lambda sensor (+pumping current) and activates
it for Lambda sensor to have the characteristic at λ =1.0 (0.0 pumping current). With the value of pumping current supplied
to Lambda sensor, ECM detects O2 density of exhaust gas.
Rich air-fuel mixture(0.9〈λ 〈1.0) : ECM takes away pumping current from Lambda sensor (-pumping current) and
deactivates it for Lambda sensor to have the characteristic at λ =1.0 (0.0 pumping current). With the value of pumping
current taken away from Lambda sensor, ECM detects O2 density of exhaust gas.
This performance is the most active and fast at normal operating temp.(450 C~600 C) thus, in order to reach normal
operating temp. and last at that temp., heater(heating coil) is integrated with Lambda sensor.
Heater coil is controlled by ECM as 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, Lambda sensor temp. is
measured and Lambda sensor heater operation varies based on the data.

DTC DESCRIPTION EFF22EE2

P2238 is set when 1) short to ground in signal line(terminal 4), ground line(terminal 3), power line(terminal 1), pumping
current line(terminal 6) or 2) open in ground line is detected. This code is due to the problem of O2 sensor circuit.
DTC TROUBLESHOOTING PROCEDURES FLB -647

DTC DETECTING CONDITION EB3B66D9

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● Engine running

Threshold Value ● Short to GND in Lambda sensor circuit

● Open in Lambda sensor circuit
Diagnostic Time ● 2.0 sec. ● Lambda sensor circuit
● Lambda sensor component
Fuel Cut NO
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp

SPECIFICATION E2CB283C

SFDF27585L

λ value 0.65 0.70 0.80 0.90 1.01 1.18 1.43 1.70 2.42 Air
Pump-
ing cur- -2.22 -1.82 -1.11 -0.50 0.00 0.33 0.37 0.94 1.38 2.54
rent
FLB -648 FUEL SYSTEM

DIAGNOSTIC CIRCUIT DIAGRAM EFAF7A32

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.
Main Relay
"ON" Input

<LAMBDA SENSOR> E/R JUNCTION BOX

3 2 1
6 5 4 Sensor Heater
"NERNST" Power

1. 'NERNST' Power Virtual Ground

2. Power
Current Adjust
3. Virtual Ground Current Pump
4. Current Adjust
5. Heater LAMBDA SENSOR
6. Current Pump

<ECM>

94 93 92 90 89
51. Heater
*
72 71 70 69 68 * 87 86 * 84 83 * 81 80 79 * 77 * 75 * * 6 5 64. 'NERNST' Power
* * 65 64 * * * * * * 57 56 * 54 * * 51 4 3 65. Current Pump
* 27* 48 47
28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1 86. Virtual Ground
* 25 * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7 87. Current Adjst

SFDF27592L
DTC TROUBLESHOOTING PROCEDURES FLB -649

SIGNAL WAVEFORM AND DATA E77BD960

Fig.1 Fig.2
SFDF27586L

Fig.3 Fig.4
SFDF27587L

Fig.1) Waveform of Lambda sensor power(terminal 1) at IG KEY "ON" and Engine running. It fluctuates between 1V and
3V periodically.
Fig.2) Waveform of Lambda sensor ground(terminal 3) at IG KEY "ON" and Engine running. 2.5V is displayed.
Fig.3) Waveform of Lambda sensor signal(terminal 4) at IG KEY "ON" and Engine running. 850mV is displayed. (same
value at idle and acceleration)
Fig.4) Waveform of Lambda sensor pump(terminal 6) at IG KEY "ON" and Engine running. 850mV is displayed. (same
value at idle and acceleration)

TERMINAL AND CONNECTOR INSPECTION E6903F29

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.
FLB -650 FUEL SYSTEM

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power Circuit Inspection".

POWER CIRCUIT INSPECTION E5C9C13A

1. Check voltage ＆ waveform in sensor power circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Lambda sensor connector.

3) IG KEY "ON"

4) Measure the voltage between power terminal of Lambda sensor harness connector and chassis ground.

Secification : Measured voltage : 2.0 V

Waveform : Refer to "Signal Waveform ＆ Data" of "General Information". The waveform similar to Fig.1) is displayed.

5) Monitor the waveform in Lambda sensor connector terminal 1.

Fig.1 Fig.2
SFDF27586L
DTC TROUBLESHOOTING PROCEDURES FLB -651

Fig.3 Fig.4
SFDF27587L

Fig.1) Waveform of Lambda sensor power(terminal 1) at IG KEY "ON" and Engine running. It fluctuates between
1V and 3V periodically.
Fig.2) Waveform of Lambda sensor ground(terminal 3) at IG KEY "ON" and Engine running. 2.5V is displayed.
Fig.3) Waveform of Lambda sensor signal(terminal 4) at IG KEY "ON" and Engine running. 850mV is displayed.
(same value at idle and acceleration)
Fig.4) Waveform of Lambda sensor pump(terminal 6) at IG KEY "ON" and Engine running. 850mV is displayed.
(same value at idle and acceleration)

6) Is the measured voltage within the specification?

YES

▶ Go to "Signal Circuit Inspection".

NO

▶ No voltage detected in Lambda sensor power circuit : Go to "2. Check open in sensor power circuit" as follows.
▶ High voltage detected in Lambda sensor power circuit : Repair short to battery in Lambda sensor power circuit
and go to "Verification of Vehicle Repair".

2. Check open in Lambda sensor power circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Lambda sensor connector and ECM connector.

3) Check continuity between power terminal of Lambda sensor harness connector and ECM harness connector.

Secification : Continuity(below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground in Lambda sensor power circuit and go to "Verification of Vehicle Repair".

NO
FLB -652 FUEL SYSTEM

▶ Reapir open in Lambda sensor power circuit and go to "Verification of Vehicle Repair".

SIGNAL CIRCUIT INSPECTION EF711E23

1. Check voltage in sensor signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Lambda sensor connector.

3) IG KEY "ON".

4) Measure the voltage between signal terminal of Lambda sensor harness connector and chassis ground.

Specification : 0.8V~0.9 V

5) Is the measured voltage within the specification?

YES

▶ Go to "3. Check sensor pump circuit".

NO

▶ No voltage detected in Lambda sensor signal circuit : Go to "2. Check open in sensor signal circuit" as follows.
▶ High voltage detected in Lambda sensor power circuit : Repair short to battery in Lambda sensor signal circuit
and go to "Verification of Vehicle Repair".

2. Check open in Lambda sensor signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Lambda sensor connector and ECM connector.

3) Check continuity between signal terminal of Lambda sensor harness connector and ECM harness connector.

Secification : Continuity (below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground in Lambda sensor signal circuit and go to "Verification of Vehicle Repair".

NO

▶ Repair open in Lambda sensor signal circuit and go to "Verification of Vehicle Repair".

3. Check voltage in sensor pump circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Lambda sensor connector.

3) IG KEY "ON".

4) Measure the voltage between pump terminal of Lambda sensor harness connector and chassis ground.
DTC TROUBLESHOOTING PROCEDURES FLB -653

Secification : 0.8V~0.9 V

5) Is the measured voltage within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ No voltage detected in Lambda sensor pumpl circuit : Go to "4. Check open in sensor pump circuit" as follows.
▶ High voltage detected in Lambda sensor power circuit : Repair short to battery in Lambda sensor pump circuit
and go to "Verification of Vehicle Repair".

4. Check open in sensor pump circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Lambda sensor connector and ECM connector.

3) Check continuity between pump terminal of Lambda sensor harness connector and ECM harness connector.

Specification : Continuity (below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground in Lambda sensor pump circuit and go to "Verification of Vehicle Repair".

NO

▶ Repair open in Lambda sensor pump circuit and go to "Verification of Vehicle Repair".

GROUND CIRCUIT INSPECTION EA34F7B3

1. Check voltage in sensor ground circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Lambda sensor connector.

3) IG KEY "ON"

4) Measure the voltage between ground terminal of Lambda sensor harness connector and chassis ground.

Secification : 2.3V~2.7V

5) Is the measured voltage within the specification?

YES

▶ Go to"Component Inspection"

NO
FLB -654 FUEL SYSTEM

▶ No voltage detected in Lambda sensor ground circuit : Go to "2. Check open in sensor ground circuit" as
follows.
▶ High voltage detected in Lambda sensor ground circuit : Repair short to battery in Lambda sensor ground
circuit and go to "Verification of Vehicle Repair".

2. Check open in sensor ground circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Lambda sensor connector and ECM connector.

3) Check continuity between ground terminal of Lambda sensor harness connector and ECM harness connector.

Secification : Continuity(below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground in Lambda sensor ground circuit and go to "Verification of Vehicle Repair".

NO

▶ Repair open in Lambda sensor ground circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION EDB8CA66

1. Lambda sensor Visual Inspection

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Lambda sensor connector.

3) Perform visual inspection for each checking point as follows.

a. Check corrosion inside of Lambda sensor terminal.
b. Check damaged coverring and open in component wiring.
c. Check connecting torque(poor connection) of Lambda sensor component.
d. Disconnect Lambda sensor and check deformation, clogging, melting of Lambda detecting prove.

Secification : Everyting OK

4) Is any problem of Lambda sensor detected?

YES

▶ Replace Lambda sensor and go to "Verification of Vehicle Repair".

NO

▶ Refer to "NOTE" as follows.

NOTE
In diesel engine, ultra lean combustion generates at normal operating condition. Therefore, Lambda sensor sig-
nal change in accordance with engine acceleration and various loading condition rarely happens, unlikely to linear
DTC TROUBLESHOOTING PROCEDURES FLB -655

Lambda sensor of gasoline engine. Moreover, pumping current is not measurable with normal measuring device(am-
pere meter) because maximum value is 3mA. If DTC code is recorded continuously eventhough circuit inspection is
correctly performed and no problem at visual inspection of component is detected, replace Lambda sensor.

VERIFICATION OF VEHICLE REPAIR E8CEC2E5

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -656 FUEL SYSTEM

DTC P2239 O2 SENSOR PUMPING CURRENT CIRCUIT HIGH (BANK 1

SENSOR 1)

COMPONENT LOCATION EE7D8554

Refer to DTC P2238.

GENERAL DESCRIPTION E530CD62

Refer to DTC P2238.

DTC DESCRIPTION E31A6181

P2239 is set when 1) short to battery in signal line(terminal4), ground line(terminal3), power line(terminal1), pumping
current line(terminal6) or 2) short to ground is detected. This code is due to the problem of Lambda sensor circuit.

DTC DETECTING CONDITION E70B6215

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● Engine running

Threshold Value ● Short to battery in Lambda sensor circuit

● Open in Lambda sensor circuit
Diagnostic Time ● 60 sec. ● Lambda sensor circuit
● Lambda sensor component
Fuel Cut NO
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp

SPECIFICATION EC8DA956

Refer to DTC P2238.

DIAGNOSTIC CIRCUIT DIAGRAM E5BDD48A

Refer to DTC P2238.

SIGNAL WAVEFORM AND DATA EE80D5BD

Refer to DTC P2238.

TERMINAL AND CONNECTOR INSPECTION E7206D36

Refer to DTC P2238.

DTC TROUBLESHOOTING PROCEDURES FLB -657

POWER CIRCUIT INSPECTION EDE5C6ED

1. Check voltage ＆ waveform in sensor power circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Lambda sensor connector.

3) IG KEY "ON"

4) Measure the voltage between power terminal of Lambda sensor harness connector and chassis ground.

Secification : Measured voltage : 2.0 V

Waveform : Refer to "Signal Waveform ＆ Data" of "General Information". The waveform similar to Fig.1) is displayed.

5) Monitor the waveform in Lambda sensor connector terminal 1.

Fig.1 Fig.2
SFDF27586L

Fig.3 Fig.4
SFDF27587L

Fig.1) Waveform of Lambda sensor power(terminal 1) at IG KEY "ON" and Engine running. It fluctuates between
1V and 3V periodically.
Fig.2) Waveform of Lambda sensor ground(terminal 3) at IG KEY "ON" and Engine running. 2.5V is displayed.
Fig.3) Waveform of Lambda sensor signal(terminal 4) at IG KEY "ON" and Engine running. 850mV is displayed.
FLB -658 FUEL SYSTEM

(same value at idle and acceleration)

Fig.4) Waveform of Lambda sensor pump(terminal 6) at IG KEY "ON" and Engine running. 850mV is displayed.
(same value at idle and acceleration)

6) Is the measured voltage within the specification?

YES

▶ Go to "Signal Circuit Inspection".

NO

▶ No voltage detected in Lambda sensor power circuit : Go to "2. Check open in sensor power circuit" as follows.
▶ High voltage detected in Lambda sensor power circuit : Repair short to battery in Lambda sensor power circuit
and go to "Verification of Vehicle Repair".

2. Check open in Lambda sensor power circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Lambda sensor connector and ECM connector.

3) Check continuity between power terminal of Lambda sensor harness connector and ECM harness connector.

Secification : Continuity(below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground in Lambda sensor power circuit and go to "Verification of Vehicle Repair".

NO

▶ Reapir open in Lambda sensor power circuit and go to "Verification of Vehicle Repair".

SIGNAL CIRCUIT INSPECTION E16DAACF

1. Check voltage in sensor signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Lambda sensor connector.

3) IG KEY "ON".

4) Measure the voltage between signal terminal of Lambda sensor harness connector and chassis ground.

Specification : 0.8V~0.9 V

5) Is the measured voltage within the specification?

YES

▶ Go to "3. Check sensor pump circuit".

DTC TROUBLESHOOTING PROCEDURES FLB -659

NO

▶ No voltage detected in Lambda sensor signal circuit : Go to "2. Check open in sensor signal circuit" as follows.
▶ High voltage detected in Lambda sensor power circuit : Repair short to battery in Lambda sensor signal circuit
and go to "Verification of Vehicle Repair".

2. Check open in Lambda sensor signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Lambda sensor connector and ECM connector.

3) Check continuity between signal terminal of Lambda sensor harness connector and ECM harness connector.

Secification : Continuity (below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground in Lambda sensor signal circuit and go to "Verification of Vehicle Repair".

NO

▶ Repair open in Lambda sensor signal circuit and go to "Verification of Vehicle Repair".

3. Check voltage in sensor pump circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Lambda sensor connector.

3) IG KEY "ON".

4) Measure the voltage between pump terminal of Lambda sensor harness connector and chassis ground.

Secification : 0.8V~0.9 V

5) Is the measured voltage within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ No voltage detected in Lambda sensor pumpl circuit : Go to "4. Check open in sensor pump circuit" as follows.
▶ High voltage detected in Lambda sensor power circuit : Repair short to battery in Lambda sensor pump circuit
and go to "Verification of Vehicle Repair".

4. Check open in sensor pump circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Lambda sensor connector and ECM connector.

3) Check continuity between pump terminal of Lambda sensor harness connector and ECM harness connector.
FLB -660 FUEL SYSTEM

Specification : Continuity (below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground in Lambda sensor pump circuit and go to "Verification of Vehicle Repair".

NO

▶ Repair open in Lambda sensor pump circuit and go to "Verification of Vehicle Repair".

GROUND CIRCUIT INSPECTION EC8E08A7

1. Check voltage in sensor ground circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Lambda sensor connector.

3) IG KEY "ON"

4) Measure the voltage between ground terminal of Lambda sensor harness connector and chassis ground.

Secification : 2.3V~2.7V

5) Is the measured voltage within the specification?

YES

▶ Go to"Component Inspection"

NO

▶ No voltage detected in Lambda sensor ground circuit : Go to "2. Check open in sensor ground circuit" as
follows.
▶ High voltage detected in Lambda sensor ground circuit : Repair short to battery in Lambda sensor ground
circuit and go to "Verification of Vehicle Repair".

2. Check open in sensor ground circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Lambda sensor connector and ECM connector.

3) Check continuity between ground terminal of Lambda sensor harness connector and ECM harness connector.

Secification : Continuity(below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground in Lambda sensor ground circuit and go to "Verification of Vehicle Repair".
DTC TROUBLESHOOTING PROCEDURES FLB -661

NO

▶ Repair open in Lambda sensor ground circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION EBB26267

1. Lambda sensor Visual Inspection

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Lambda sensor connector.

3) Perform visual inspection for each checking point as follows.

a. Check corrosion inside of Lambda sensor terminal.
b. Check damaged coverring and open in component wiring.
c. Check connecting torque(poor connection) of Lambda sensor component.
d. Disconnect Lambda sensor and check deformation, clogging, melting of Lambda detecting prove.

Secification : Everyting OK

4) Is any problem of Lambda sensor detected?

YES

▶ Replace Lambda sensor and go to "Verification of Vehicle Repair".

NO

▶ Refer to "NOTE" as follows.

NOTE
In diesel engine, ultra lean combustion generates at normal operating condition. Therefore, Lambda sensor sig-
nal change in accordance with engine acceleration and various loading condition rarely happens, unlikely to linear
Lambda sensor of gasoline engine. Moreover, pumping current is not measurable with normal measuring device(am-
pere meter) because maximum value is 3mA. If DTC code is recorded continuously eventhough circuit inspection is
correctly performed and no problem at visual inspection of component is detected, replace Lambda sensor.

VERIFICATION OF VEHICLE REPAIR E665E4A9

Refer to DTC P2238.

FLB -662 FUEL SYSTEM

DTC P2251 O2 SENSOR REFERENCE GROUND CIRCUIT/OPEN (BANK 1

SENSOR 1)

COMPONENT LOCATION EFF79884

Refer to DTC P2238.

GENERAL DESCRIPTION E0D5C988

Refer to DTC P2238.

DTC DESCRIPTION E1D4B669

P2251 is set when there is short battery or open in circuit (refer to DTC Detecting Condition).

DTC DETECTING CONDITION E8E04506

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● Engine running

● Short to battery on ’Current Pump Line’,

Threshold Value ’Current Adjust Line’, Virtual Ground Line’,
’Voltage Nernst Line’.
● Open on ’Virtual Ground Line’.
● Lambda sensor circuit
Diagnostic Time ● 2.0 sec. ● Lambda sensor component
Fuel Cut NO
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp

SPECIFICATION E900F55E

Refer to DTC P2238.

DIAGNOSTIC CIRCUIT DIAGRAM EE11AB95

Refer to DTC P2238.

SIGNAL WAVEFORM AND DATA E5AB3964

Refer to DTC P2238.

TERMINAL AND CONNECTOR INSPECTION E143D3DA

Refer to DTC P2238.

DTC TROUBLESHOOTING PROCEDURES FLB -663

POWER CIRCUIT INSPECTION E39A4DE7

1. Check voltage ＆ waveform in sensor power circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Lambda sensor connector.

3) IG KEY "ON"

4) Measure the voltage between power terminal of Lambda sensor harness connector and chassis ground.

Secification : Measured voltage : 2.0 V

Waveform : Refer to "Signal Waveform ＆ Data" of "General Information". The waveform similar to Fig.1) is displayed.

5) Monitor the waveform in Lambda sensor connector terminal 1.

Fig.1 Fig.2
SFDF27586L

Fig.3 Fig.4
SFDF27587L

Fig.1) Waveform of Lambda sensor power(terminal 1) at IG KEY "ON" and Engine running. It fluctuates between
1V and 3V periodically.
Fig.2) Waveform of Lambda sensor ground(terminal 3) at IG KEY "ON" and Engine running. 2.5V is displayed.
Fig.3) Waveform of Lambda sensor signal(terminal 4) at IG KEY "ON" and Engine running. 850mV is displayed.
FLB -664 FUEL SYSTEM

(same value at idle and acceleration)

Fig.4) Waveform of Lambda sensor pump(terminal 6) at IG KEY "ON" and Engine running. 850mV is displayed.
(same value at idle and acceleration)

6) Is the measured voltage within the specification?

YES

▶ Go to "Signal Circuit Inspection".

NO

▶ No voltage detected in Lambda sensor power circuit : Go to "2. Check open in sensor power circuit" as follows.
▶ High voltage detected in Lambda sensor power circuit : Repair short to battery in Lambda sensor power circuit
and go to "Verification of Vehicle Repair".

2. Check open in Lambda sensor power circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Lambda sensor connector and ECM connector.

3) Check continuity between power terminal of Lambda sensor harness connector and ECM harness connector.

Secification : Continuity(below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground in Lambda sensor power circuit and go to "Verification of Vehicle Repair".

NO

▶ Reapir open in Lambda sensor power circuit and go to "Verification of Vehicle Repair".

SIGNAL CIRCUIT INSPECTION E033D256

1. Check voltage in sensor signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Lambda sensor connector.

3) IG KEY "ON".

4) Measure the voltage between signal terminal of Lambda sensor harness connector and chassis ground.

Specification : 0.8V~0.9 V

5) Is the measured voltage within the specification?

YES

▶ Go to "3. Check sensor pump circuit".

DTC TROUBLESHOOTING PROCEDURES FLB -665

NO

▶ No voltage detected in Lambda sensor signal circuit : Go to "2. Check open in sensor signal circuit" as follows.
▶ High voltage detected in Lambda sensor power circuit : Repair short to battery in Lambda sensor signal circuit
and go to "Verification of Vehicle Repair".

2. Check open in Lambda sensor signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Lambda sensor connector and ECM connector.

3) Check continuity between signal terminal of Lambda sensor harness connector and ECM harness connector.

Secification : Continuity (below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground in Lambda sensor signal circuit and go to "Verification of Vehicle Repair".

NO

▶ Repair open in Lambda sensor signal circuit and go to "Verification of Vehicle Repair".

3. Check voltage in sensor pump circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Lambda sensor connector.

3) IG KEY "ON".

4) Measure the voltage between pump terminal of Lambda sensor harness connector and chassis ground.

Secification : 0.8V~0.9 V

5) Is the measured voltage within the specification?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ No voltage detected in Lambda sensor pumpl circuit : Go to "4. Check open in sensor pump circuit" as follows.
▶ High voltage detected in Lambda sensor power circuit : Repair short to battery in Lambda sensor pump circuit
and go to "Verification of Vehicle Repair".

4. Check open in sensor pump circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Lambda sensor connector and ECM connector.

3) Check continuity between pump terminal of Lambda sensor harness connector and ECM harness connector.
FLB -666 FUEL SYSTEM

Specification : Continuity (below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground in Lambda sensor pump circuit and go to "Verification of Vehicle Repair".

NO

▶ Repair open in Lambda sensor pump circuit and go to "Verification of Vehicle Repair".

GROUND CIRCUIT INSPECTION E45815C8

1. Check voltage in sensor ground circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Lambda sensor connector.

3) IG KEY "ON"

4) Measure the voltage between ground terminal of Lambda sensor harness connector and chassis ground.

Secification : 2.3V~2.7V

5) Is the measured voltage within the specification?

YES

▶ Go to"Component Inspection"

NO

▶ No voltage detected in Lambda sensor ground circuit : Go to "2. Check open in sensor ground circuit" as
follows.
▶ High voltage detected in Lambda sensor ground circuit : Repair short to battery in Lambda sensor ground
circuit and go to "Verification of Vehicle Repair".

2. Check open in sensor ground circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Lambda sensor connector and ECM connector.

3) Check continuity between ground terminal of Lambda sensor harness connector and ECM harness connector.

Secification : Continuity(below 1.0Ω )

4) Is the measured resistance within the specification?

YES

▶ Repair short to ground in Lambda sensor ground circuit and go to "Verification of Vehicle Repair".
DTC TROUBLESHOOTING PROCEDURES FLB -667

NO

▶ Repair open in Lambda sensor ground circuit and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION EE9C04B7

1. Lambda sensor Visual Inspection

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Lambda sensor connector.

3) Perform visual inspection for each checking point as follows.

a. Check corrosion inside of Lambda sensor terminal.
b. Check damaged coverring and open in component wiring.
c. Check connecting torque(poor connection) of Lambda sensor component.
d. Disconnect Lambda sensor and check deformation, clogging, melting of Lambda detecting prove.

Secification : Everyting OK

4) Is any problem of Lambda sensor detected?

YES

▶ Replace Lambda sensor and go to "Verification of Vehicle Repair".

NO

▶ Refer to "NOTE" as follows.

NOTE
In diesel engine, ultra lean combustion generates at normal operating condition. Therefore, Lambda sensor sig-
nal change in accordance with engine acceleration and various loading condition rarely happens, unlikely to linear
Lambda sensor of gasoline engine. Moreover, pumping current is not measurable with normal measuring device(am-
pere meter) because maximum value is 3mA. If DTC code is recorded continuously eventhough circuit inspection is
correctly performed and no problem at visual inspection of component is detected, replace Lambda sensor.

VERIFICATION OF VEHICLE REPAIR ED9D8245

Refer to DTC P2238.

FLB -668 FUEL SYSTEM

DTC P2264 WATER IN FUEL SENSOR CIRCUIT

COMPONENT LOCATION E067FB82

Fuel Filter

Water Sensor

SFDF28319L

GENERAL DESCRIPTION E824BEA2

Diesel fuel filter can seperate water from fuel. If water more than specified amount is detected by "water sensor" installed
at the bottom of fuel filter, "Fuel warning lamp" on cluster turns ON.
Especially for high pressure pump or injectors of common rail diesel engine is fatal. because water causes poor lubrication
and corrosion in such accurate devices, furthermore, it leads engine hesitation. In order to prevent this harsh condition to
engine, "Water warning lamp" turns ON to let driver relief the gathered water from the filter and engine power generation
is limited.

NOTE
If sensing prove of water sensor contacts with water, impressed voltage on prove is grounded to chassis ground, then
12V is outputted from signal line. With this method, ECM recognizes the amount of water.

DTC DESCRIPTION E0F2241B

P2264 is set when water sensor operates for more than 4 sec. Water warning lamp turns on and engine power generation
is limited in this condition. When this code is set, water in the filter should be removed to prevent engine from water
contained fuel. If same code is set even after removing water, check short to battery in water in fuel sensor signal circuit
or component failure.
DTC TROUBLESHOOTING PROCEDURES FLB -669

DTC DETECTING CONDITION E168A403

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring
Enable Conditions ● IG KEY "ON"
Threshold Value ● Signal voltage detected at Water sensor
● Water stored inside of fuel filter
Diagnostic Time ● 4.0 sec. ( remove water inside of filter)
Fuel Cut NO ● Water sensor circuit(short to battery)
● Water sensor component
EGR Off NO
Fail Safe Fuel Limit YES
Check
NO
Lamp

DIAGNOSTIC CIRCUIT DIAGRAM E5432D1D

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.

Main Relay
"ON" Input

E/R JUNCTION BOX

<Fuel Filter Warning Switch>

Instrument
Cluster
Power

3 2 1
Signal Signal

1. Power
2. Signal Ground
3. Ground
Fuel Filter Warning Switch

<ECM>
<Instrument Cluster>

94 93 92 90 89
*
72 71 70 69 68 * 87 86 * 84 83 * 81 80 79 * 77 * 75 * * 6 5
* * 65 64 * * * * * * 57 56 * 54 * * 51 4 3 8
* * 5 4 3 2 1

* 27* 48 47
28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1 16 15 14 13 12 11 10 9
* 25 * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7 8. Signal
40. Signal

SFDF27632L
FLB -670 FUEL SYSTEM

TERMINAL AND CONNECTOR INSPECTION E9814D29

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶Go to "Power Circuit Inspection".

POWER CIRCUIT INSPECTION ED787321

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect Water sensor connector.

3. IG KEY "ON".

4. Measure the voltage between ON/START power terminal of water sensor harness connector and chassis ground.

Specification : 11.0V~12.5V

5. Is the measured voltage within the specification?

YES

▶ Go to "Signal Circuit Inspection".

NO

▶ Repair open of SNSR.2 FUSE in E/R JUNCTION BOX and related circuit and go to "Verification of Vehicle Repair".

SIGNAL CIRCUIT INSPECTION EF5A9413

1. Check signal circuit voltage

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Water sensor connector.

3) IG KEY "ON"
DTC TROUBLESHOOTING PROCEDURES FLB -671

4) Measure the voltage between signal terminal of water sensor harness connector and chassis ground.

Secification : 0.0V~0.1V

5) Is the measured voltage within the specification?

YES

▶ Go to "2. Water warning lamp operation test" as follows.

NO

▶ Repair short to battery and go to "Verification of Vehicle Repair".

2. Water warning lamp operation test

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect Water sensor connector .

3) IG KEY "ON".

4) Connect ON/START power terminal and signal terminal of water sensor harness connector using jump wire.

Secification : Water warning lamp on cluster turns ON. 12V battery voltage is detected at ECM connector

5) Does water warning lamp turn ON? And is 12V battery voltage detected at ECM connector

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Repair open in water warning lamp filament and related circuit and go to "Verification of Vehicle Repair".

GROUND CIRCUIT INSPECTION EE905AC5

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect Water sensor connector

3. Check continuity between ground terminal of water sensor harness connector and chassis ground.

Specification : Continuity (below 1.0Ω )

4. Is the measured resistance within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ Repair short to ground in signal circuit and go to "Verification of Vehicle Repair".

FLB -672 FUEL SYSTEM

COMPONENT INSPECTION EDF955ED

1. Check water inside of fuel filter

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect fuel filter assy′ from vehicle. (note : fuel filter should be maintained to stand up vertically at discon-
necting.)

3) Set up clean vessel like beaker to collect fuel outflowed from filter.

4) Disconnect Water sensor and collect fuel and water mixed to it.

Secification : Outflowed fuel must not contain much water.

5) Does fuel contains much water?

YES

▶ Checking odometer and filter used duration, replace fuel filter if needed. If too much water flowed to fuel filter,
check if water flowed into fuel tank and clean up inside of fuel tank. After replacing filter and clean up fuel tank
and go to "Verification of Vehicle Repair".

NO

▶ Go to "2.Check Water sensor component" as follows.

2. Check Water sensor component

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect fuel filter assy′ from vehicle. (note : fuel filter should be maintained to stand up vertically at discon-
necting.)

3) Set up clean vessel like beaker to collect fuel outflowed from filter.

4) Disconnect fuel warning sensor from disconnected fuel filter.

5) Connect Water sensor to disconnected wiring connector.

6) IG KEY "ON".

7) Touch water sensing prove of Water sensor to chassis ground.

Specification : Water warning lamp turns ON when touching water sensing prove to chassis ground.

8) Does water warning lamp operate well?

YES

▶ Go to "Verification of Vehicle Repair".

NO

▶ Replace Water sensor and go to "Verification of Vehicle Repair".

DTC TROUBLESHOOTING PROCEDURES FLB -673

VERIFICATION OF VEHICLE REPAIR E04B6CC1

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -674 FUEL SYSTEM

DTC P2299 BRAKE PEDAL POSITION / ACCELERATOR PEDAL POSITION

INCOMPATIBLE

COMPONENT LOCATION E7421819

APS

SFDF28320L

GENERAL DESCRIPTION E638CCFD

Brake switch monitors malfunction of accel pedal sensor(APS).

Drivers depress brake pedal when 1).the voltage higher than driver′ s intension is detected due to APS malfunction(signal
circuit short to high voltage) 2).engine power generates excessively due to fault signal.
Like previous example, if driver′ s intension to decelerate is transmitted to ECM(brake pedal depressed) when APS signal
is high, ECM consider APS to be fault and Limp Home mode is activated.
When Limp Home mode is activated, engine speed is fixed at 1200RPM and driving performance is limited, later, if correct
APS signal is detected, Limp Home mode is deactivated immediately.

DTC DESCRIPTION EE7E5100

P2299 is set when brake signal is inputted to ECM for more than 0.5 sec. while APS is depressed more than 5% at
above 870RPM, 2Km/h. And Limp Home mode is activated with the DTC code occurence. Later, if correct APS signal is
detected, Limp Home mode is deactivated immediately. This code is set when APS signal is a bit higher than the voltage at
accelerator released position and driver′ s pedal manipulation, therfore careful inspection of APS and checking driver′ s
pedal depressing habit is required.
DTC TROUBLESHOOTING PROCEDURES FLB -675

DTC DETECTING CONDITION E0F1088F

Item Detecting Condition Possible Cause

DTC Strategy ● Voltage monitoring

Enable Conditions ● Engine run ( engine speed below 870RPM,

vehicle speed below 2Km/h)

● Brake pedal singal inputted at APS

Threshold Value output voltage above 5%
(Enabled when brake pedal released or accelerator
● APS 1 Circuit
pedal depressed 200% per sec.)
● APS 2 Circuit
Diagnostic Time ● 500ms ● APS component
Fuel Cut NO
EGR Off NO ● APS standard value
Fail Safe is 0%.
Fuel Limit YES ● Limp home idle is fixed
Check at (1200RPM)
NO
Lamp

SPECIFICATION E43CD3E4

Pedal released Pedal depressed Sensor Type

APS 1 0.7V~0.8V 3.8V~4.4V Variable resistance
APS 2 0.275V~0.475V 1.75V~2.35V type(Potentiometer)
FLB -676 FUEL SYSTEM

DIAGNOSTIC CIRCUIT DIAGRAM E28D4F0E

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.
Main Relay
"ON" Input

E/R JUNCTION BOX

<Accelerator Pedal Sensor>

APS1
Power
6 5 4 3 2 1
Signal APS #1
Ground
1. Signal #2
2. Ground #2 APS2
Power
3. Signal #1
4. Ground #1 Signal APS #2
5. Power #1
6. Power #2 Ground

Accelerator Pedal Sensor

<ECM>
8. APS2 Ground
94 93 92 90 89 87 86 84 83 81 80 79 77 75 9. APS1 Signal
*
72 71 70 69 68 * * *
65 64 * * ** 6 5
** * * * * * * * * * 51 57 56 54
4 3
30. APS1 Ground
31. APS2 Signal
* 27* 48 47
28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1
* 25 * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7 45. APS1 Power
46. APS2 Power

SFDF27613L
DTC TROUBLESHOOTING PROCEDURES FLB -677

SIGNAL WAVEFORM AND DATA EDBA99A5

APS 1

APS 2

APS 2 ground check

signal

Fig.1
SFDF27583L

Fig.1) APS 1 and APS 2 signals are measured simultaneously, Check if output value is rising and APS 2 is 1/2 of APS 1
signal.

NOTE
APS 2 Ground checking signal is for ECM to monitor APS 2. This signal drops APS 2 output voltage to below
200.39mV per 200msec. If APS 2 output voltage does not drop to below 200.39mV, ECM sets DTC as recognizing
ground circuit error of APS 2 .

※ The waveform below 200.39mV is not detectable in Ground checking signal waveform of APS 2 signal. Instead,
the waveform which drops a little is detected. If APS 2 data of "SERVICE DATA" on the Scantool varies from 350mV
to 0mV periodically, it means it works well.

MONITOR SCANTOOL DATA E5C60CE6

1. Connect Scantool to Data Link Connector (DLC).

2. Warm engine up to normal operating temperature.

3. Turn "OFF" electrical devices and A/C.

4. Monitor "ACCEL PEDAL SENSOR", "ACCEL PEDAL SENSOR 1", "ACCEL PEDAL SENSOR 2 " parameter on the
scantool.

Specification : At idle( 0% ) ACCEL PEDAL SENSOR 1 : 600mV~800mV

ACCEL PEDAL SENSOR 2 : 1/2 of ACCEL PEDAL SENSOR 1
FLB -678 FUEL SYSTEM

Fig.1
SFDF27584L

Fig.1) APS output data at warm idle. Check if output value is rising and "ACCEL PEDAL SENSOR 2" is 1/2 of "ACCEL
PEDAL SENSOR 1" signal.

TERMINAL AND CONNECTOR INSPECTION EB4F92DA

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Power Circuit Inspection" as follows.

POWER CIRCUIT INSPECTION E7A66167

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect APS connector.

3. IG KEY "ON".

4. Measure the voltage between power terminal of APS1 harness connector and chassis ground.
DTC TROUBLESHOOTING PROCEDURES FLB -679

5. Measure the voltage between power terminal of APS2 harness connector and chassis ground.

Specification : 4.8V~5.1V

6. Is the measured voltage within the specification?

YES

▶ Go to "Signal Circuit Inspection".

NO

▶ If the measured voltage is not within the specified value, find and repair trouble causing part in circuits and go to
"Verification of Vehicle Repair".
When the measured voltage is higher than the specified value : Refer to P0643 Circuit Inspection. (APS1)
Refer to P0653 Circuit Inspection.(APS2)
When the measured voltage is lower than the specified value : Refer to P0642 Circuit Inspection.(APS1)
Refer to P0652 Circuit Inspection.(APS2)

SIGNAL CIRCUIT INSPECTION E2E2FAB0

1. Check open in signal circuit

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect APS connector and ECM connector.

3) Check continuity between signal terminal of APS1 harness connector and signal terminal of ECM harness con-
nector.(APS1)

4) Check continuity between signal terminal of APS2 harness connector and signal terminal of ECM harness con-
nector.(APS2)

Secification : Continuity (below 1.0Ω )

5) Is the measured resistance within the specification?

YES

▶ Go to "Check short in signal circuit".

NO

▶ Repair open in signal circuit and go to "Verification of Vehicle Repair".

2. Check short in signal circuit ( APS 1 )

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect APS connector and ECM connector.

3) IG KEY "ON".

4) Check continuity between signal terminal of APS1 harness connector and chassis ground. (Check short to
ground )
FLB -680 FUEL SYSTEM

5) Measure the voltage between signal terminal of APS1 harness connector and chassis ground. (Check short to
battery )

Secification : Check short to ground : Discontinuity ( Infinite Ω )

Check short to battery : 0.0V~0.1V

6) Is APS 1 signal circuit insulated normally?

YES

▶ Go to "3.Signal Circuit Inspection (APS 2)" as follows.

NO

▶ Repair short in circuit and go to "Verification of Vehicle Repair".

3. Signal Circuit Inspection (APS 2)

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect APS connector and ECM connector.

3) IG KEY "ON".

4) Check continuity between signal terminal of APS2 harness connector and chassis ground. (Check short to
ground )

5) Measure the voltage between signal terminal of APS2 harness connector and chassis ground. (Check short to
battery )

Specification : Check short to ground : Discontinuity ( Infinite Ω )

Check short to battery : 0.0V~0.1V

6) Is APS 2 signal circuit insulated normally?

YES

▶ Go to "Ground Circuit Inspection".

NO

▶ Repair short in circuit and go to "Verification of Vehicle Repair".

GROUND CIRCUIT INSPECTION E2B30773

1. Check ground circuit (APS1)

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect APS connector.

3) IG KEY "ON".

4) Measure the voltage between power terminal of APS1 harness connector and chassis ground. [ TEST "A" ]

5) Measure the voltage between power terminal and ground terminal of APS1 harness connector. [ TEST "B" ]
( Power terminal : Check + prove , Ground terminal 4 : Check - prove )
DTC TROUBLESHOOTING PROCEDURES FLB -681

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6) Is the measured voltage within the specification?

YES

▶ Go to "2. Check ground circuit (APS2)".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resis-
tance and go to "Verification of Vehicle Repair".

2. Check ground circuit (APS2)

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect APS connector.

3) IG KEY "ON".

4) Measure the voltage of APS terminal 6. [ TEST "A" ]

5) Measure the voltage of APS terminal 6 and terminal 2. [ TEST "B" ]

( terminal 6: Check + prove , terminal 2 : Check - prove )

Specification : [TEST "A"] Voltage - [TEST "B"] Voltage = below 200mV

6) Is the measured voltage within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ When "B" voltage is not detected : Repair open in ground circuit and go to "Verification of Vehicle Repair".
▶ When the voltage difference between "A" and "B" is above 200mV : Eliminate the causes of excessive resis-
tance and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E95C5A75

1. IG KEY "OFF", ENGINE "OFF".

2. Disconnect APS connector .

3. Check resistance for each terminal refering to Resistance characteristic table.

Specification : Resistance characteristic table for each terminal

4. Are resistances for each terminal measured correctly?

YES

▶ Go to "Verification of Vehicle Rapair".

FLB -682 FUEL SYSTEM

NO

▶ Replace APS and go to "Verification of Vehicle Rapair".

VERIFICATION OF VEHICLE REPAIR E0A7DEA6

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

DTC TROUBLESHOOTING PROCEDURES FLB -683

DTC U0001 HIGH SPEED CAN COMMUNICATION BUS OFF

GENERAL DESCRIPTION EF98B8BB

Several control units are applied to electronically controlled vehicles. These units perform each control with informations
from various sensors. Thus, sharing signal information from sensors is needed, so CAN communication type whose com-
munication speed is high and insensitive to electrical noise by spark generation is adopted to controlling power-train(en-
gine, atutomatic transaxle, ABS, TCS, ECS)
As sharing signals of engine speed, APS, engaged gear and torque reduction through CAN communication, ECM and
TCM modules control vehicle actively.

DTC DESCRIPTION E3A20F39

U0001 is set when signal transmission through CAN communication line is impossible for more than 0.1 sec. because of
open or short to ground in CAN communication line. Checking CAN communication BUS and signals from ECM, TCM
module is required.

DTC DETECTING CONDITION E5474DEF

Item Detecting Condition Possible Cause

DTC Strategy ● Signal monitoring
Enable Conditions ● IG KEY "ON"
Threshold Value ● CAN BUS error
Diagnostic Time ● 100ms ● CAN BUS
● CAN communication module
Fuel Cut NO
component
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp

SPECIFICATION E4CEB315

CAN Communication Line

DIGITAL "0" DIGITAL "1"( BUS IDLE )
Resistance
Communica-
tion Format Inside of
HIGH LOW HIGH LOW Inside of ECM In-pannel
junction box
CAN 2.0B 3.5V 1.5V 2.5V 2.5V 120Ω (20℃) 120Ω (20℃)
FLB -684 FUEL SYSTEM

DIAGNOSTIC CIRCUIT DIAGRAM E81D3817

ECM
IG SW
ON/START Input

MAIN RELAY

- + Main Relay Control

BATT.

Main Relay
"ON" Input

E/R JUNCTION BOX

CAN HIGH

CAN LOW
6 5 4 3 2 1
13 12 11 10 9
120
DATA LINK CONNECTOR
ESP/ABS ECM

CAN HIGH
I/P JUNCTION BOX

CAN LOW

INSTRUMENT TCM

CAN HIGH CAN HIGH

CAN LOW CAN LOW

YAWRATE SENSOR TPMM

CAN HIGH CAN HIGH

CAN LOW CAN LOW

SFDF27633L
DTC TROUBLESHOOTING PROCEDURES FLB -685

<Yawrate Sensor>
<Instrument Cluster> <TPMM>

1
12 11
2
* 9 8 7 6 5 4 3 2 1
* 9 8 7 6 5
24 23 22 21 20 19 18 17
4 3
* 13
* 3
4 * * 18
* * * * * * *
* 15 *
6. CAN HIGH 5. CAN HIGH
7. CAN LOW 2. CAN LOW 6. CAN LOW
3. CAN HIGH

<TCM> <ABS>

6 7 8 9 10 5 4
* 12 * 14 * * * 18 19 20 21 22 23 24 1 2 3 4
5 6
* 8 9 10 11 12
* 14 15
36. CAN LOW
* * * * * * * * * * * 36 37 38 * * * * * 3
16 17 18 19 20 22
* * * * 26
44
* * * * * * * 52 53 * * * * 58 59 * 61 62 37. CAN HIGH
2 1
* * * * * * * * * * * 74 * * * 78 * * * 15. CAN LOW
26. CAN HIGH

<ESP>

5 6 8 9 10 11 12 13 14 14. CAN LOW

1 2 3 4 *
26 27 28 29 30 31 32 33 35
* * * * * * 21 * * * *
* * * 38 * * * * * * * * 35. CAN HIGH

<ECM>

94 93 92 90 89 87 86 84 83 81 80 79
*
72 71 70 69 68 * 65 64 * * 57 56* 77 54* 75 * 51* 6 5
** ****** * ** 4 3
83. CAN LOW

* 27* 48 47
28
46 45 44
* 42 * 40 * 38 37 36 35 34 33 32 31 30 29 2 1 84. CAN HIGH
* * * 22 * * 19 * * 16 15 14 13 12 11 10 9 8 7
25

SFDF27634L

SIGNAL WAVEFORM AND DATA E2DD70EE

SOF Bit CAN HIGH signal

Digital "1" Digital "0"

BUS IDLE CAN LOW signal

Fig.1
SFDF27590L
FLB -686 FUEL SYSTEM

Fig.1) CAN communication waveform

Monitoring CAN HIGH and LOW simultaneously is important in monitoring CAN communication waveform. When CAN
HIGH signal rise to 3.5V and LOW signal drops to 1.5V - voltage difference between HIGH and LOW signal is 2V - at BUS
IDLE state(DIGITAL "1") whose reference voltage is 2.5V, "0" is recognized. Besides, comparing HIGH and LOW signal
if opposite waveform is detected with the reference voltage of 2.5V, Check if current cam signal transfers correctly.
Continuous "0"signal above 6BIT means the occurence of error in CAN communication. 1BIT is easily distinguished as
calculating the time when "SOF"(START OF FRAME) which notifies the start of frame occurs. Check if "0"signal above
6BIT is detected continuously when monitoring CAN communication waveform.

TERMINAL AND CONNECTOR INSPECTION EC1C3033

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various prob-
lems and damge of component.

2. Perform checking procedure as follows.

1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.

2) Check connecting condition of ECM and component connector : Check terminal seperation, damage of locking
device and connecting condition between terminal and wiring.

NOTE
Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for
checking connecting condition. ( after checking, reconnect the pin at correct position. )

3. Is the problem found?

YES

▶ Repair the trouble causing part and go to "Verification of Vehicle Repair".

NO

▶ Go to "Signal Circuit Inspection".

SIGNAL CIRCUIT INSPECTION E31B4A65

1. Check CAN BUS resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Measure the resistance between diagnostic connector 3 and 11.

3) Disconnect ECM and ABS(ESP) connector.

4) Measure the resistance between diagnostic connector 3 and 11.

Secification : Both ECM connected : 60 ± 3Ω (Test 1)

Both ECM disconnected : 120 ± 3Ω (Test 2)

5) Is CAN BUS resistance within the specification?

YES

▶ Go to "2.Check short to ground in CAN BUS" as follows.

DTC TROUBLESHOOTING PROCEDURES FLB -687

NO

▶ Below 10Ω for both conditions(disconnected, connected) : Repair short between CAN BUS and go to "Veri-
fication of Vehicle Repair".
▶ 120Ω for both conditions(disconnected, connected) : Go to "4. Check CAN BUS continuity".
▶ Infinite Ω for both conditions(disconnected, connected) :Repair open in CAN communication circuit between
DLC terminal and In-pannel junction box.

2. Check short to ground in CAN BUS

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECM and ABS(ESP) connector.

3) Check continuity between DLC terminal 3 and chassis ground. (CAN HIGH)

4) Check continuity between DLC terminal 11 and chassis ground. (CAN LOW)

Secification : Discontinuity ( Infinite Ω )

5) Is measured resistance within the specification?

YES

▶ Go to "3. Check short to battery in CAN BUS".

NO

▶ Repair short to ground in circuit and go to "Verification of Vehicle Repair".

3. Check short to battery in CAN BUS

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECM and ABS(ESP) connector.

3) IG KEY "ON".

4) Measure the voltage of DLC terminal 3. (CAN HIGH)

5) Measure the voltage of DLC terminal 11. (CAN LOW)

Secification : 0.0V~0.1V

6) Is measured voltage within the specification with both connector disconnected?

YES

▶ Go to"4. Check CAN BUS continuity" as follows.

NO

▶ Repair short to battery and go to "Verification of Vehicle Repair".

4. Check CAN BUS continuity

1) IG KEY "OFF", ENGINE "OFF".

FLB -688 FUEL SYSTEM

2) Disconnect ECM and ABS(ESP) connector.

3) Check continuity between DLC terminal 3 and CAN HIGH terminal of each module.

4) Check continuity between DLC terminal 11 and CAN LOW terminal of each module.

Secification : Continuity(below 1.0Ω )

5) Is measured resistance within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ Repair open in CAN BUS and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E8F6F837

1. Check CAN communication waveform generation

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECM, and ABS(ESP) connector.

3) Connect 2 channel scope to DLC terminal 3(CAN HIGH) and 11(CAN LOW).

4) IG KEY "ON" after connecting only "the Control Module(s) to be checked" to CAN BUS.

Secification : At IG KEY "ON", the waveform same as "Signal Waveform ＆ Data" of this code generates.
※ Different from "Signal Waveform ＆ Data", if 1) both CAN HIGH and LOW signal are fixed at 2.5 V or 2) HIGH and
LOW signal are fixed at 3.5 V and 1.5 V, respectively, it is due to communication error between modules.

5) Is there a module which outputs normal waveform after disconnecting module connectors or which outputs ab-
normal waveform after connecting module connectors?

YES

▶ Replace the module which generates poor communication waveform, and go to "Verification of Vehicle Re-
pair".

NO

▶ Go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR ECC5A7AA

After a repair, it is essential to verify that the fault is corrected.

1. After connecting scantool select "Diagnostic Trouble Codes(DTCs)" mode to and then clear DTC.

2. Drive the vehicle within DTC Enable conditions in General information.

3. After selecting "Diagnostic Trouble Codes(DTCs)" mode and check DTC is recorded again.
DTC TROUBLESHOOTING PROCEDURES FLB -689

4. Are any DTCs recorded ?

YES

▶ Go to the DTC guide of recorded NO. in Scantool.

NO

▶ System operates within specification.

FLB -690 FUEL SYSTEM

DTC U0101 LOST COMMUNICATION WITH TCM

GENERAL DESCRIPTION E417AC2C

Refer to DTC U0001.

DTC DESCRIPTION EB2C3800

U0101 is set when ECM send data requiring signal to TCM, but no return signal is transmitted to ECM within 0.5 sec..
This code is due to TCM CAN line related problem or TCM module failure.

DTC DETECTING CONDITION E2F1F4EC

Item Detecting Condition Possible Cause

DTC Strategy ● Signal monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● CAN communication error between

ECM and TCM
● CAN BUS
Diagnostic Time ● 490ms ● CAN communication module
Fuel Cut NO component
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp

SPECIFICATION EC240515

Refer to DTC U0001.

DIAGNOSTIC CIRCUIT DIAGRAM EF5BE68F

Refer to DTC U0001.

SIGNAL WAVEFORM AND DATA E5946940

Refer to DTC U0001.

TERMINAL AND CONNECTOR INSPECTION ED50116E

Refer to DTC U0001.

SIGNAL CIRCUIT INSPECTION E5C86079

1. Check CAN BUS resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Measure the resistance between diagnostic connector 3 and 11.

DTC TROUBLESHOOTING PROCEDURES FLB -691

3) Disconnect ECM and ABS(ESP) connector.

4) Measure the resistance between diagnostic connector 3 and 11.

Secification : Both ECM connected : 60 ± 3Ω (Test 1)

Both ECM disconnected : 120 ± 3Ω (Test 2)

5) Is CAN BUS resistance within the specification?

YES

▶ Go to "2.Check short to ground in CAN BUS" as follows.

NO

▶ Below 10Ω for both conditions(disconnected, connected) : Repair short between CAN BUS and go to "Veri-
fication of Vehicle Repair".
▶ 120Ω for both conditions(disconnected, connected) : Go to "4. Check CAN BUS continuity".
▶ Infinite Ω for both conditions(disconnected, connected) :Repair open in CAN communication circuit between
DLC terminal and In-pannel junction box.

2. Check short to ground in CAN BUS

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECM and ABS(ESP) connector.

3) Check continuity between DLC terminal 3 and chassis ground. (CAN HIGH)

4) Check continuity between DLC terminal 11 and chassis ground. (CAN LOW)

Secification : Discontinuity ( Infinite Ω )

5) Is measured resistance within the specification?

YES

▶ Go to "3. Check short to battery in CAN BUS".

NO

▶ Repair short to ground in circuit and go to "Verification of Vehicle Repair".

3. Check short to battery in CAN BUS

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECM and ABS(ESP) connector.

3) IG KEY "ON".

4) Measure the voltage of DLC terminal 3. (CAN HIGH)

5) Measure the voltage of DLC terminal 11. (CAN LOW)

Secification : 0.0V~0.1V
FLB -692 FUEL SYSTEM

6) Is measured voltage within the specification with both connector disconnected?

YES

▶ Go to"4. Check CAN BUS continuity" as follows.

NO

▶ Repair short to battery and go to "Verification of Vehicle Repair".

4. Check CAN BUS continuity

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECM and ABS(ESP) connector.

3) Check continuity between DLC terminal 3 and CAN HIGH terminal of each module.

4) Check continuity between DLC terminal 11 and CAN LOW terminal of each module.

Secification : Continuity(below 1.0Ω )

5) Is measured resistance within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ Repair open in CAN BUS and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E98AC9FC

1. Check CAN communication waveform generation

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECM, and ABS(ESP) connector.

3) Connect 2 channel scope to DLC terminal 3(CAN HIGH) and 11(CAN LOW).

4) IG KEY "ON" after connecting only "the Control Module(s) to be checked" to CAN BUS.

Secification : At IG KEY "ON", the waveform same as "Signal Waveform ＆ Data" of this code generates.
※ Different from "Signal Waveform ＆ Data", if 1) both CAN HIGH and LOW signal are fixed at 2.5 V or 2) HIGH and
LOW signal are fixed at 3.5 V and 1.5 V, respectively, it is due to communication error between modules.

5) Is there a module which outputs normal waveform after disconnecting module connectors or which outputs ab-
normal waveform after connecting module connectors?

YES

▶ Replace the module which generates poor communication waveform, and go to "Verification of Vehicle Re-
pair".
DTC TROUBLESHOOTING PROCEDURES FLB -693

NO

▶ Go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR EF40BAC0

Refer to DTC U0001.

FLB -694 FUEL SYSTEM

DTC U0122 LOST COMMUNICATION WITH VEHICLE DYNAMICS CONTROL

MODULE

GENERAL DESCRIPTION E3A3B297

Refer to DTC U0001.

DTC DESCRIPTION EEA851C3

U0122 is set when ECM sends data requiring signal to TCS, but no return signal is transmitted to ECM by within 0.5 sec..
This code is due to TCS CAN line related problem or TCS module failure.

DTC DETECTING CONDITION E8F3B9C9

Item Detecting Condition Possible Cause

DTC Strategy ● Signal monitoring
Enable Conditions ● IG KEY "ON"

Threshold Value ● CAN communication error between

ECM and TCS1
● CAN BUS
Diagnostic Time ● 500ms ● CAN communication module
Fuel Cut NO component
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp

SPECIFICATION EF03A174

Refer to DTC U0001.

DIAGNOSTIC CIRCUIT DIAGRAM E5AEB7C5

Refer to DTC U0001.

SIGNAL WAVEFORM AND DATA EF99D247

Refer to DTC U0001.

TERMINAL AND CONNECTOR INSPECTION E8A440DE

Refer to DTC U0001.

SIGNAL CIRCUIT INSPECTION E6A19507

1. Check CAN BUS resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Measure the resistance between diagnostic connector 3 and 11.

DTC TROUBLESHOOTING PROCEDURES FLB -695

3) Disconnect ECM and ABS(ESP) connector.

4) Measure the resistance between diagnostic connector 3 and 11.

Secification : Both ECM connected : 60 ± 3Ω (Test 1)

Both ECM disconnected : 120 ± 3Ω (Test 2)

5) Is CAN BUS resistance within the specification?

YES

▶ Go to "2.Check short to ground in CAN BUS" as follows.

NO

▶ Below 10Ω for both conditions(disconnected, connected) : Repair short between CAN BUS and go to "Veri-
fication of Vehicle Repair".
▶ 120Ω for both conditions(disconnected, connected) : Go to "4. Check CAN BUS continuity".
▶ Infinite Ω for both conditions(disconnected, connected) :Repair open in CAN communication circuit between
DLC terminal and In-pannel junction box.

2. Check short to ground in CAN BUS

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECM and ABS(ESP) connector.

3) Check continuity between DLC terminal 3 and chassis ground. (CAN HIGH)

4) Check continuity between DLC terminal 11 and chassis ground. (CAN LOW)

Secification : Discontinuity ( Infinite Ω )

5) Is measured resistance within the specification?

YES

▶ Go to "3. Check short to battery in CAN BUS".

NO

▶ Repair short to ground in circuit and go to "Verification of Vehicle Repair".

3. Check short to battery in CAN BUS

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECM and ABS(ESP) connector.

3) IG KEY "ON".

4) Measure the voltage of DLC terminal 3. (CAN HIGH)

5) Measure the voltage of DLC terminal 11. (CAN LOW)

Secification : 0.0V~0.1V
FLB -696 FUEL SYSTEM

6) Is measured voltage within the specification with both connector disconnected?

YES

▶ Go to"4. Check CAN BUS continuity" as follows.

NO

▶ Repair short to battery and go to "Verification of Vehicle Repair".

4. Check CAN BUS continuity

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECM and ABS(ESP) connector.

3) Check continuity between DLC terminal 3 and CAN HIGH terminal of each module.

4) Check continuity between DLC terminal 11 and CAN LOW terminal of each module.

Secification : Continuity(below 1.0Ω )

5) Is measured resistance within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ Repair open in CAN BUS and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION E0D1C6D1

1. Check CAN communication waveform generation

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECM, and ABS(ESP) connector.

3) Connect 2 channel scope to DLC terminal 3(CAN HIGH) and 11(CAN LOW).

4) IG KEY "ON" after connecting only "the Control Module(s) to be checked" to CAN BUS.

Secification : At IG KEY "ON", the waveform same as "Signal Waveform ＆ Data" of this code generates.
※ Different from "Signal Waveform ＆ Data", if 1) both CAN HIGH and LOW signal are fixed at 2.5 V or 2) HIGH and
LOW signal are fixed at 3.5 V and 1.5 V, respectively, it is due to communication error between modules.

5) Is there a module which outputs normal waveform after disconnecting module connectors or which outputs ab-
normal waveform after connecting module connectors?

YES

▶ Replace the module which generates poor communication waveform, and go to "Verification of Vehicle Re-
pair".
DTC TROUBLESHOOTING PROCEDURES FLB -697

NO

▶ Go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E9F1F357

Refer to DTC U0001.

FLB -698 FUEL SYSTEM

DTC U0416 INVALID DATA RECEIVED FROM VEHICLE DYNAMICS

CONTROL MODULE

GENERAL DESCRIPTION E1927015

Refer to DTC U0001.

DTC DESCRIPTION E7845F68

U0416 is set when ECM detects the signal requires abnormal torque increase from ECM for more than 0.5 sec. Checking
CAN communication line or TCS module is required.

DTC DETECTING CONDITION E91B9319

Item Detecting Condition Possible Cause

DTC Strategy ● Signal monitoring
Enable Conditions ● IG KEY "ON"
Threshold Value ● Abnormal torque increase request from TCS
Diagnostic Time ● 500ms ● CAN BUS
● CAN communication module
Fuel Cut NO
component
EGR Off NO
Fail Safe Fuel Limit NO
Check
NO
Lamp

SPECIFICATION E2FDCD75

Refer to DTC U0001.

DIAGNOSTIC CIRCUIT DIAGRAM E958ECFC

Refer to DTC U0001.

SIGNAL WAVEFORM AND DATA E77D260C

Refer to DTC U0001.

TERMINAL AND CONNECTOR INSPECTION EBE59A36

Refer to DTC U0001.

SIGNAL CIRCUIT INSPECTION EB5B5C16

1. Check CAN BUS resistance

1) IG KEY "OFF", ENGINE "OFF".

2) Measure the resistance between diagnostic connector 3 and 11.

DTC TROUBLESHOOTING PROCEDURES FLB -699

3) Disconnect ECM and ABS(ESP) connector.

4) Measure the resistance between diagnostic connector 3 and 11.

Secification : Both ECM connected : 60 ± 3Ω (Test 1)

Both ECM disconnected : 120 ± 3Ω (Test 2)

5) Is CAN BUS resistance within the specification?

YES

▶ Go to "2.Check short to ground in CAN BUS" as follows.

NO

▶ Below 10Ω for both conditions(disconnected, connected) : Repair short between CAN BUS and go to "Veri-
fication of Vehicle Repair".
▶ 120Ω for both conditions(disconnected, connected) : Go to "4. Check CAN BUS continuity".
▶ Infinite Ω for both conditions(disconnected, connected) :Repair open in CAN communication circuit between
DLC terminal and In-pannel junction box.

2. Check short to ground in CAN BUS

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECM and ABS(ESP) connector.

3) Check continuity between DLC terminal 3 and chassis ground. (CAN HIGH)

4) Check continuity between DLC terminal 11 and chassis ground. (CAN LOW)

Secification : Discontinuity ( Infinite Ω )

5) Is measured resistance within the specification?

YES

▶ Go to "3. Check short to battery in CAN BUS".

NO

▶ Repair short to ground in circuit and go to "Verification of Vehicle Repair".

3. Check short to battery in CAN BUS

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECM and ABS(ESP) connector.

3) IG KEY "ON".

4) Measure the voltage of DLC terminal 3. (CAN HIGH)

5) Measure the voltage of DLC terminal 11. (CAN LOW)

Secification : 0.0V~0.1V
FLB -700 FUEL SYSTEM

6) Is measured voltage within the specification with both connector disconnected?

YES

▶ Go to"4. Check CAN BUS continuity" as follows.

NO

▶ Repair short to battery and go to "Verification of Vehicle Repair".

4. Check CAN BUS continuity

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECM and ABS(ESP) connector.

3) Check continuity between DLC terminal 3 and CAN HIGH terminal of each module.

4) Check continuity between DLC terminal 11 and CAN LOW terminal of each module.

Secification : Continuity(below 1.0Ω )

5) Is measured resistance within the specification?

YES

▶ Go to "Component Inspection".

NO

▶ Repair open in CAN BUS and go to "Verification of Vehicle Repair".

COMPONENT INSPECTION EDA8B2CA

1. Check CAN communication waveform generation

1) IG KEY "OFF", ENGINE "OFF".

2) Disconnect ECM, and ABS(ESP) connector.

3) Connect 2 channel scope to DLC terminal 3(CAN HIGH) and 11(CAN LOW).

4) IG KEY "ON" after connecting only "the Control Module(s) to be checked" to CAN BUS.

Secification : At IG KEY "ON", the waveform same as "Signal Waveform ＆ Data" of this code generates.
※ Different from "Signal Waveform ＆ Data", if 1) both CAN HIGH and LOW signal are fixed at 2.5 V or 2) HIGH and
LOW signal are fixed at 3.5 V and 1.5 V, respectively, it is due to communication error between modules.

5) Is there a module which outputs normal waveform after disconnecting module connectors or which outputs ab-
normal waveform after connecting module connectors?

YES

▶ Replace the module which generates poor communication waveform, and go to "Verification of Vehicle Re-
pair".
DTC TROUBLESHOOTING PROCEDURES FLB -701

NO

▶ Go to "Verification of Vehicle Repair".

VERIFICATION OF VEHICLE REPAIR E3DA1D2B

Refer to DTC U0001.

FLB -702 FUEL SYSTEM

FUEL DELIVERY
SYSTEM-DIESEL
COMPONENT LOCATION E1795A52

1 6

2 5 4 3

Plate Cover

Seal-Ring

9
10
11

12 7

1. Injector 7. Fuel Tank

2. High Pressure Fuel Pump 8. Fuel Sender
3. Common Rail 9. Separator
4. High Pressure Fuel Pipe (Injector Common Rail) 10. Fuel Filler Hose
5. High Pressure Fuel Pipe (Common Rail High Pressure Fuel Pump) 11. Leveling Hose
6. Fuel Filter 12. Ventilation Hose

SFDF28216L
FUEL DELIVERY SYSTEM-DIESEL FLB -703

CAUTION
• Common Rail Fuel Injection System operates
with extremely high pressure (approximately
1,600bar), so never perform any work on in-
jection 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, verti-
cally 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.
FLB -704 FUEL SYSTEM

COMMON RAIL FUEL INJECTION SYSTEM

(CRDI) E1374AA3

Rail Pressure
Regulator Valve

Common Rail

Rail Pressure
Sensor

High Pressure Injector

Fuel Pump Fuel Pressure
Regulator Valve

Fuel Filter
ECM

Fuel Tank

Fuel Sender or
Low Pressure Fuel Pump

High Pressure Fuel Line

Low Pressure Fuel Line

Fuel Return Line

SFDF38247L
FUEL DELIVERY SYSTEM-DIESEL FLB -705

● LOW PRESSURE FUEL CIRCUIT

LOW PRESSURE FUEL PUMP

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 re-
quired quantity of fuel in the direction of the high pressure
fuel pump (via fuel filter).

FUEL SENDER

The fuel sender is located into the fuel tank and measures
amount of fuel contained in fuel tank.

FUEL FILTER

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

HIGH PRESSURE FUEL PUMP

The high pressure fuel pump compresses fuel up to 1,600

bar and delivers the compressed fuel to the common rail.

COMMON RAIL

The common rail is connected with the high pressure fuel

pump and the injectors by the high pressure fuel pipes.
This rail stores the fuel compressed in the high pressure
fuel pump. The ECM controls the fuel pressure of the com-
mon rail by using the rail pressure sensor and the rail pres-
sure regulator valve installed on the common rail.

INJECTOR

The injector injects the high pressure fuel stored in the

common rail into the cylinder by the ECM control signal.

HIGH PRESSURE FUEL PIPE

The high pressure fuel pipe is a channel in high pressure

fuel circuit consisting of the high pressure fuel pump, com-
mon rails, and injectors. It is a steel tube which can with-
stand 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.
FLB -706 FUEL SYSTEM

BLEEDING AIR IN LOW PRESSURE FUEL

CIRCUIT EC0CB497

1. After disconnecting the fuel outlet quick-connector

(A), press the priming pump (B) several times until
fuel comes out of the fuel outlet.

SFDF28217L

2. Connect the fuel outlet quick-connector (A).

NOTE
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
FUEL DELIVERY SYSTEM-DIESEL FLB -707

FUEL TANK 8. Disconnect the fuel filler hose (A), the leveling hose
(B), and the ventilation hose (C).

REMOVAL EB6E3F0B

1. Turn ignition switch OFF and disconnect the negative

(-) battery cable.

2. Remove or fold the rear seat cushion (Refer to "SEAT" B

in BD group).

3. Remove the service cover (A).

SEDF37007L

9. Unscrew the fuel tank band installation nuts (A), and

then remove the fuel tank (B) from the vehicle.

A
A

SEDF37004L

4. Disconnect the fuel pump connector (A).

SEDF37009L

INSTALLATION E249C299

C B 1. Installation is reverse of removal.

Fuel tank band installation nuts: 39.2 ~ 54.0 N·m

(4.0 ~ 5.5 kgf·m, 28.9 ~ 39.8 lbf·ft)
SFDF38248L

5. Disconnect the fuel feed tube quick-connector (B) and NOTE

the fuel return tube quick-connector (C).
After removing or replacing the part below, bleed air
6. Lift the vehicle. in low pressure fuel circuit (Refer to "BLEEDING AIR
IN LOW PRESSURE FUEL CIRCUIT" in this group).
7. Support the fuel tank with a jack. - Fuel Tank
- Fuel Sender
- Fuel Filter
- High Pressure Fuel Pump
- Low Pressure Fuel Lines
FLB -708 FUEL SYSTEM

FUEL SENDER 6. Unscrew the fuel sender installation bolts (D), and
then remove the fuel sender from the fuel tank.

REMOVAL E64EBE72

Plate Cover
1. Turn ignition switch OFF and disconnect the negative
(-) battery cable.
Seal-Ring
2. Remove or fold the rear seat cushion (Refer to "SEAT"
in BD group).

3. Remove the service cover (A).

Fuel Sender

SFDF38250L

INSTALLATION E9D52CF4

1. Installation is reverse of removal.

A
Fuel sender installation bolts: 2.0 ~ 2.9 N·m
(0.2 ~ 0.3 kgf·m, 1.4 ~ 2.2 lbf·ft)

SEDF37004L
NOTE
4. Disconnect the fuel sender connector (A). 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
A - High Pressure Fuel Pump
- Low Pressure Fuel Lines

C C B

SFDF38249L

5. Disconnect the fuel feed tube quick-connector (B) and

the fuel return tube quick-connector (C).
FUEL DELIVERY SYSTEM-DIESEL FLB -709

FUEL FILTER

COMPONENTS EAC9846F

4 6

2 5

1. Fuel Filter
2. Heater
3. Water Sensor
4. Thermostat
5. Nipple ( Fuel Tank)
6. Nipple ( High Pressure Fuel Pump)
SFDF28218L
FLB -710 FUEL SYSTEM

REPLACEMENT E21F16CF 5. Remove the water sensor (A).

1. Turn ignition switch OFF and disconnect the negative

(-) battery cable.

2. Disconnect the water sensor connector (A), the heater

connector (B), and the thermostat connector (C).

E
C
A
D
B
SFDF28221L

A 6. 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.
SFDF28219L

3. Disconnect the fuel inlet tube quick-connector (D) and

the fuel outlet tube quick-connector (E).

4. Unscrew the fuel filter installation nuts (A), and then

remove the fuel filter (B) from the vehicle.

B
A SFDF38254L

Filter Body
SFDF28220L

O-ring

Fuel Filter

Water Sensor

SFDF38255L

CAUTION
When replacing the fuel filter, must replace the
O-ring.
FUEL DELIVERY SYSTEM-DIESEL FLB -711

7. Bleed air in low pressure fuel circuit (Refer to "BLEED-

ING AIR IN LOW PRESSURE FUEL CIRCUIT").

8. Start the engine and check that there is any leak on

the low pressure fuel circuit including the fuel filter.
FLB -712 FUEL SYSTEM

FILLER-NECK ASSEMBLY 4. Remove the fuel filler neck assembly after unscrewing
the mounting screws (A).

REMOVAL E88D2E07

1. Disconnect the fuel filler hose (A), the leveling hose

(B), and the ventilation hose (C).

A
SFDF38257L

A
NOTE
C
If the filler neck assembly can’t be removed easily,
SEDF37007L remove it again after loosening the rear cross member
mounting bolt partly (Refer ro "REAR LOW ARM" in
2. Remove the left - rear wheel ＆ tire and the wheel SS group).
house.

3. Unscrew the mounting bolt (A). INSTALLATION E0EF3652

1. Installation is reverse of removal.

SFDF38256L
FUEL DELIVERY SYSTEM-DIESEL FLB -713

ACCELERATION PEDAL

REMOVAL E05CDBD8

1. Turn ignition switch OFF and disconnect the negative

(-) battery cable.

2. Disconnect the accelerator pedal position sensor con-

nector (A).

C
B

SFDF38258L

3. Remove the accelerator pedal assembly from the ve-

hicle after unscrewing the mounting bolt (B) and nuts
(C).

INSTALLATION EA2F87CF

1. Installation is reverse of removal.

Fuel pump installation bolts: 12.8 ~ 15.7 N·m

(1.3 ~ 1.6 kgf·m, 9.4 ~ 11.6 lbf·ft)
FLB -714 FUEL SYSTEM

HIGH PRESSURE FUEL PUMP - To protect damage caused by shock, verti-

cally insert the injector into the cylinder head.
• When installing High Pressure Fuel Pipe
DESCRIPTION E49A7453
- Do not use again the used high pressure fuel
pipe.
The high pressure fuel pump is the interface between the - Install the flange nut correctly.
low pressure and the high pressure stages. Under all
operating conditions, it is responsible for providing ade-
1. Turn ignition switch OFF and disconnect the negative
quate high pressure fuel through out the vehicle’s com-
(-) battery cable.
plete service life. This also includes the provision of extra
as needed for rapid starting and for rapid build-up of pres- 2. Remove the intake manifold (Refer to "INTAKE AND
sure in the rail. The high pressure pump continually gen- EXHAUST SYSTEM" in "EM" group).
erates the system pressure as needed in the high-pres-
sure accumulator (common rail). This means therefore, 3. Disconnect the fuel pressure regulator valve connec-
that in contrast to conventional systems, the fuel does not tor (A).
have to be specially compressed for each individual injec-
tion process.

Fuel Pressure
B Regulator Valve

SFDF28223L

A
4. Remove the high pressure fuel pipe (B) connecting
A : Fuel Inlet
(From Fuel Tank via Fuel Filter) the high pressure fuel pump with the common rail.
B : Fuel Outlet (To Common Rail)
C : Fuel Return (To Fuel Tank) 5. Remove the oil gage guide.
SFDF28222L
6. Disconnect the fuel feed tube (A) and the fuel return
tube (B).
REMOVAL E3775D0E

CAUTION
• Common Rail Fuel Injection System operates
B
with extremely high pressure (approximately
1,600bar), so never perform any work on in-
jection 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. A
• Do not remove injector except for special C
case.
• When installing Injector SLDFL6151L
- Wash the contact area of the injector and
replace the O-ring with a new one. 7. Unscrew the three high pressure fuel pump mounting
- Spread oil on the injector O-ring. bolts (C).
FUEL DELIVERY SYSTEM-DIESEL FLB -715

8. Remove the drive belt (Refer to "TIMING SYSTEM" in 12. Install the high pressure fuel pump sprocket stopper
"EM" group). (A) (SST No.: 09331-2A000) with rotating it clockwise.

9. Turn the crankshaft pulley and align its groove with

timing mark "T" of the timing chain cover.
(NO.1 cylinder compression TDC position.)

Mark

SLDFL6157L

13. Install the high pressure fuel pump remover (SST

No.:09331-2A000) (A) with three mounting bolts (B).
SLDFL6152L
B
10. Remove the idler (A) and the timing chain cover plug
(B).
D

A
B
E C

SSAFL6164L
C
14. Fix the high pressure fuel pump remover (SST
No.:09331-2A000) (A) and sprocket stopper (C) with
SSAFL6162L two fixing bolts (D).

11. Remove the high pressure fuel pump sprocket nut (C) 15. Rotate the bolt (E) of the high pressure fuel pump
after fixing the crank shaft. remover (SST No.:09331-2A000) (A) clockwise till the
high pressure fuel pump is pushed out.
FLB -716 FUEL SYSTEM

INSTALLATION EF518F8A

1. Installation is reverse of removal.

NOTE
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 (HP
14 mm (0.551 in) 09314-27110
Pump Side)
Flange Nut
(Common Rail 17 mm (0.669 in) 09314-27120
Side)

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)

NOTE
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
- High Pressure Fuel Pump
- Low Pressure Fuel Lines
FUEL DELIVERY SYSTEM-DIESEL FLB -717

COMMON RAIL - Wash the contact area of the injector and

replace the O-ring with a new one.
- Spread oil on the injector O-ring.
DESCRIPTION E8E8B6DC
- To protect damage caused by shock, verti-
cally insert the injector into the cylinder head.
The common rail stores the fuel at high pressure. At the • When installing High Pressure Fuel Pipe
same time, the pressure oscillations which are generated - Do not use again the used high pressure fuel
due to the high-pressure pump delivery and the injection pipe.
of fuel are damped by the rail volume. This common rail - Install the flange nut correctly.
is common to all cylinders, hence its name "common rail".
Even when large quantities of fuel are extracted, the com- 1. Turn ignition switch OFF and disconnect the regative
mon rail maintains its inner pressure practically constant (-) battery cable.
from the moment the injector opens.
2. Disconnect the rail pressure sensor connector (A) and
In order to comply with the wide variety of engine installa- rail pressure regulator valve connector (B).
tion conditions, the common rail with its flow limiters and
the provistions for attaching rail pressure sensor, fuel pres-
sure 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 re-
sulting from the high pressure is utilized to achieve the ac-
cumulator effect. When fuel leaves the rail for injection, the
pressure variations resulting from the pulsating fuel supply A
from the high-pressure pump are compensated for.

C E
B D

SFDF28224L

Fuel Pressure
Regulator Valve 3. Disconnect the return hose from the common rail.

4. Remove the high pressure fuel pipe (C) connecting

the injectors with the common rail.

Rail Pressure Sensor (RPS) 5. Remove the high pressure fuel pipe (D) connecting
the common rail with the high pressure fuel pump.

SFDF38262L
6. Remove the intake manifold (Refer to "INTAKE AND
EXHAUST MANIFOLD" in EM group).

REMOVAL E71BAF17 7. Unscrew the two mounting bolts (E) and remove the
common rail.
CAUTION
• Common Rail Fuel Injection System operates
with extremely high pressure (approximately
1,600bar), so never perform any work on in-
jection 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
FLB -718 FUEL SYSTEM

INSTALLATION E7A492E9

1. Installation is reverse of removal.

NOTE
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 (HP
Pump Side)
Flange Nut
(Common Rail 17 mm (0.669 in) 09314-27120
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 fuel pipe installation nut: 24.5 ~ 28.4
N·m (2.5 ~ 2.9 kgf·m, 18.1 ~ 20.1 lbf·ft)