FUEL SYSTEM

GENERAL FUEL DELIVERY SYSTEM-ELECTRONIC

SPECIFICATION ............................................ FL - 2
TIGHTENING TORQUE .................................. FL - 3
DESCRIPTION ................................................ FL - 4
WIRING DIAGRAM ........................................ FL -15
SELF-DIAGNOSIS ......................................... FL -16
TROUBLESHOOTING ................................... FL -21
FUEL SYSTEM DRAINING ............................ FL -25
ACCELERATOR PEDAL
REPLACEMENT ....................................... FL -35
FUEL TANK
COMPONENTS ........................................ FL -36
REPLACEMENT ....................................... FL -38

ENGINE CONTROL SYSTEM-ELECTRONIC

ENGINE CONTROL UNIT(ECU)
REPLACEMENT ....................................... FL -28
ELECTRONIC UNIT INJECTOR(EUI)
INSPECTION ............................................. FL -29
REPAIR AND ADJUSTMENT .................. FL -30
PRIMING PUMP
REPLACEMENT ........................................ FL -33
OVERFLOW VALVE
REPLACEMENT ........................................ FL -34
FL -2 FUEL SYSTEM

GENERAL
SPECIFICATIONS EAB8C0B5

Item Specifications
Fuel pump Type Inner contact gear type
Maximum supply pressure 7kgf.cm²
Driving Air compressor shaft driving
Control unit Voltage 24V
Connector 54 pin x 2
Unit injector(Solenoid Voltage 90V
valve)
Resistance(at 20 C) 3.9~4.1
Coolant temperature Voltage 5V
sensor and Gauge
Operating range -40 C~125 C
unit
Connector 3 pin
Intake pressure Voltage 5V
temperature sensor
Operating range Temperature -40 C~125 C
Pressure (Absolute) 32.5~284 kPa(0.33~2.9kgf.cm²)
Connector 4 pin
Crank shaft and Resistance 860 ± 10%
Camshaft position
Operating range 40~2500 r/min
sensor
Connector 2 pin
Air gap 1.0~2.0 mm
Fuel pressure Voltage 5V
temperature sensor
Operating range Temperature -40 C~130 C
Pressure 0~1000 kPa(0~10kgf.cm²)
Connector 4 pin
GENERAL FL -3

SERVICE STANDARDS

Item Standard value

Electric injector Opening pressure 342bar
Injection pressure Max. 2000bar
Idle rotation speed(RPM) 500 ± 20 rpm
Overflow valve opening pressure 3.0kgf/cm² more
Cam shaft position sensor air gap 1.0~2.0 mm
Crank shaft position sensor air gap 1.0~2.0 mm
Fuel pump discharge amount 500rpm 4 bar(1ℓ /min or more)
1900rpm 7 bar(7ℓ /min or more)

TIGHTENING TORQUE

Tightening torque Nm(kgf.m)

Item
Nm kgf.m lb-ft
Overflow valve 33 ~ 39 3.4 ~ 4.0 24.7~29.1
Fuel pipe plunge bolt(M6 x 1.0) 8 ~ 12 0.8 ~ 1.2 5.8~8.7
Fuel filter eyebolt 27 ~ 29 2.8 ~ 3.0 20.4~21.8
Cylinder head fuel inlet pipe eyebolt 29 ~ 34 3.0 ~ 3.5 21.8~25.5
ECU side fuel pipe eyebolt 27 ~ 29 2.8 ~ 3.0 20.4~21.8
Wiring mounting rail 5 ~ 6 0.5 ~ 0.6 3.6~4.4
EUI captive nut terminal 2 ~ 2 0.15 ~ 0.2 1.1~1.5
Priming pump bolt 27 ~ 29 2.8 ~ 3.0 20.4~21.8
ECU mounting bracket attaching bolt 34 ~ 54 3.5 ~ 5.5 25.5~40.0
ECU mounting flange bolt 19 ~ 27 1.9 ~ 2.8 13.8~20.4
Intake pressure temperature sensor 5 ~ 6 0.5 ~ 0.6 3.6~4.4
Camshaft position sensor 8 ~ 10 0.8 ~ 1.0 5.8~7.3
Crankshaft position sensor 8 ~ 10 0.8 ~ 1.0 5.8~7.3
Fuel pump mounting bolt 10 ~ 12 0.8 ~ 1.2 5.8~8.7
FL -4 FUEL SYSTEM

DESCRIPTION ED926CA4

Cam position sensor

Fuel pressure
temperature sensor

Intake pressure Crank position sensor

Coolant temperature sensor
temperature sensor
Priming pump
Overflow valve
Fuel filter

ECU

ECBFL5001A

BLOCK DIAGRAM OF FUEL SUPPLY SYSTEM

Fuel rail Filter
Fuel system consists of control unit, unit injector, fuel
pump, fuel line, fuel filter, overflow valve and fuel tank.
Fuel pump, connected to air compressor, supplies fuel
from fuel tank. Injector ECU cooler
Fuel flows into fuel filter via control unit cooling line from
pump.
Fuel from fuel filter is supplied to fuel path in cylinder head. Overflow Fuel pump
When 6 injectors inject fuel it passes through overflow
valve, which is connected to fuel path exit. Fuel returned
from cylinder head goes back into fuel tank again. Fuel tank
Accordingly, fuel system continues to supply and return Return to fuel tank
proper amount of fuel used in engine by control unit.
ECBFL5002A
GENERAL FL -5

EUI COMPONENTS 2. Fuel discharge

UNIT INJECTOR
As shown in the figure, unit injector consists of pumping
element, controlling component and nozzle. Pumping el-
ement generates the fuel pressure as the force from the
cam drives the plunger by way of rocker arm. The control-
ling component controls the open and close timing of spill
valve by driving the solenoid according to the commands
from ECU. Nozzle element finally injects the fuel into the
cylinder by the fuel pressure delivered.
When rocker arm begins to press plunger, fuel begins
to be compressed in pump tank. However, because
spill valve is open, pressure does not drop seriously
and fuel flows through spill valve.
3. Fuel injection start
When solenoid receives signal from ECU, spill valve is
closed, fuel circuit is closed, fuel is kept in pump tank
and fuel pressure increases rapidly. When pressure
exceeds NZ opening pressure, fuel is injected.
4. End of fuel injection
When ECU opens spill valve to end the injection, fuel
pressure in pump tank drops below varying pressure
rapidly together with spill, nozzle is closed and injec-
tion ends.

Plunger

ECBFL5003A

OPERATING THEORY OF UNIT INJECTOR

1. Fuel intake
Fuel circuit is open when spill valve is opened and fuel Spill valve CLOSE
comes into pump tank as the return spring lifts up the (Fuel injection)
plunger.
At this time, spring closes the nozzle.

ECBFL5005A

Return spring
Plunger

Cylinder head

Spill valve OPEN

(Fuel intake/ex)

ECBFL5004A
FL -6 FUEL SYSTEM

CONTROL UNIT AND SENSOR

Cam position sensor

Fuel pressure
temperature sensor

Intake pressure Crank position sensor

Coolant temperature sensor
temperature sensor
Priming pump
Overflow valve
Fuel filter

ECU

ECBFL5001A

1. Control unit(ECU)
Control unit(ECU) controls unit injector to inject a fuel
into the cylinder.
Mounted to the cylinder block, it receives information
from accelerator pedal and several sensors and sets
the fuel injection time and amount into cylinder.
The control unit calculates the injection fuel amount
and time when spill valve of injector is closed.
The fuel injection amount into combustion chamber is
adjusted or limited by the following conditions.
- Fuel amount needed (Fuel injection amount is set
by the driver’s operation)
- Fuel injection limit (Fuel injection amount is set
by engine condition)

As control unit is mounted on engine block, it requires

cooling unit to maintain appropriate operational tem-
perature and fuel line flowing over control unit plays
as a cooling unit.
GENERAL FL -7

2. Engine control

1) Control of fuel injection amount

The fuel injection amount is calculated and set by
the engine load, speed and fuel injection amount
is compensated in through the input of various
sensors about the engine condition.

Cranking fuel Max. fuel amount

Vehicle speed

Intake air temperature/pressure

Idle speed Idle fuel
Coolant temperature
Compensation
Fuel temperature pressure
Pedal angle Atmosphere pressure
Fuel amount
requested by pedal
Engine speed
Fuel amount
Minimum value Amount of fuel injection
requested

PTO fuel

Cruise fuel

ECBFL5006A

2) Limit of fuel amount

Control unit limits fuel amount requested by the
driver for safety and engine protection under the
following conditions if necessary.
- In case of excessive smoke
- When engine overheats
- In case of excessively high speed
- When fuel requested exceeds the maximum
injection quantity
- When engine speed is excessively high
- When engine speed limit is needed in cold
state

3) Limit of maximum engine speed

When coolant temperature is lower than set value
or vehicle speed sensor is zero, maximum speed
of engine is limited to protect engine from high
temperature and mechanical damage.
FL -8 FUEL SYSTEM

4) Control of fuel injection timing

Fuel injection time is set depending on engine
speed and requested fuel amount and is com-
pensated based on the engine state from sen-
sors.

Intake temperature compensation

Coolant temperature compensation

Crank injection time

PTO injection time Final fuel injection time

Engine speed
General fuel
Fuel injecting injection time
amount

Intake temperature compensation

Coolant temperature compensation

ECBFL5007A

5) Cold starting control 1. Air heating control

Engine control unit minimizes white smoke gen- a. Intake air heating at cold start
erating at cold start by injecting optimum fuel - Reducing the smokes due to incomplete
amount into engine at cold start and increases combustion
engine temperature to normal running tempera- - Early warming of engine
ture in a short time. - Start improvement
And it controls heater to heat up air flowing into
engine, which is divided into preheating before
starting and post-heating after starting.

START
KEY S/W ON

OFF
Indicator Light up
lamp
Light off
Engine rotations > Limit value
Engine RPM

ON
Heating

OFF
Preheating Post-heating
A. Preheat/post-heat when engine is not running B. Normal preheat/post-heat running

ECBFL5008A
GENERAL FL -9

6) Control of idle speed 3. Idle adjustment

1. Idle adjustment: Keep the specified rpm re-
gardless of load.
2. Adjustment of unstable idling: Adjust idle
speed to the programmed value in ECU
when idling is unstable
- Increase or decrease rotations to the
preset ranges specified by driver
- Store the idle value before adjustment.
4.
- Idle adjustment at cold: Increase idle
speed after cold starting to expedite the
warming up.
- Increase idle to prevent battery dis-
charging when the air conditioner is on.
- Increase idle to quicken the charging
rate if battery voltage is low.
Idle adjustment at cold start

Engine
speed

500rpm
Idle
speed

Times
Idle adjustment

ECBFL5009A

Engine speed

800 RPM

Cold engine speed

500 RPM

Normal idle speed

-10 C
20 C

T1 T2 Coolant temperature

ECBFL5010A
FL -10 FUEL SYSTEM

7) Manual adjustment of idle 3. Vehicle control function

Idle adjustment can be manually using self-diag-
nostic switch mounted to driver seat.
For the manual adjustment of the idle, following
conditions should be met.
a. Vehicle should be stopped securely.
b. There should be no acceleration pedal sig-
nal.
c. Foot brake should be applied securely.
d. It should be at idle state and PTOshould not
be in running state
800 RPM
Increase
Decrease
+25 RPM
Reference idle speed 500 RPM
ECBFL5011A
Driver can set desirable idle speed as mentioned
above. (500 to 800 rpm)
8) Output limit by the fuel pressure
Function: When fuel pressure drops lower than
the value set during regular engine operation, it
reduces the fuel amount requested to protect the
engine and gives driver a warning signal at the
same time.
1) Cruise vehicle speed control
1. Function: Drives the vehicle within the spec-
ified speed.
2. Operating condition
a) Operation of cruise control switch
b) Brake and clutch pedal are not pressed.
c) Safety switch is turned off.
d) Brake is in normal condition.
3. Releasing condition
a) Releasing of cruise control switch
b) Brake and clutch pedal are pressed
c) If the vehicle speed is lower than the
minimum speed by cruise control func-
tion, cruise is released automatically if
one of the above conditions is met.
d) Transmission retarder is operated
4. If the vehicle speed exceeds the specifica-
tion, exhaust brake and engine brake oper-
ate in sequence. In addition, fuel amount is
limited by the smallest value among maxi-
mumengine speed, torque performance and
smoke restriction.
2) Limit of maximum vehicle speed
1. Function: Limit maximum vehicle speed by
restriction of fuel supply
2. Control method
a) Operated by set program in sequence.
b) If the fuel is not applied and the vehicle
speed is higher than specified one on
the downhill, the exhaust brake and the
jake brake work successively. This con-
dition prevents the vehicle speed from
increasing excessively.
GENERAL FL -11

3) Door safety switch

1. Function: While the safety switch installed
on the bus door is operating, ECU keeps the
engine idle by ignoring the accelerator pedal
signal to prevent the risk of vehicle moving.
2. Circuit operation diagram

Engine speed

EUI

Center door switch

ECU
Battery

Acceleration pedal

ECBFL5012A

4) FAIL SAFE function 9. Use crank sensor at breakdown of cam sen-

1. Pedal sensor sor and signal value of cam sensor at break-
a) Condition: Error occurrence at accel- down of crank sensor
eration pedal sensor and idle rotation
switch
b) Limit of pedal function

2. Fuel temperature sensor

3. Intake temperature sensor: Use setup value
4. Fuel pressure sensor: Use setup value
5. Outdoor temperature sensor: Use setup
value
6. Intake pressure sensor: Use setup value
7. Atmosphere pressure sensor: Use setup
value
8. Vehicle speed sensor
a. Fail judgment conditions
- When fuel amount is more than the
setup value
- When engine rotations are higher than
the setup value
- When coolant temperature is higher
than the setup value
- When PTO is not operating
- When vehicle speed is zero
- When clutch is not operating
FL -12
5) PTO
1. Function: Keeps engine rotation speed reg-
ular regardless of load to operate the auxil-
iary unit.
2. Operating condition
a) When cruise / PTO operating switch is
ON
b) When the vehicle speed is lower than
selective setup value (10km/h in general
and engine running state)
c) When PTO is adjustable from the driver
seat or outside of the vehicle
3. Operation: When setup time (approximately
1 sec.) has passed, PTO governor controls
rotation speed of engine into initial engine
rotations of PTO. At this time, PTO indication
lamp turns on to inform driver.
4. Release: When cruise / PTO operating
switch is OFF, ECU slows down the engine
rotations to be at idle speed.
5. When PTO is adjustable from the driver’s
seat or outside of the vehicle
6. PTO engine rotations increase when accel-
eration pedal is applied and return to stan-
dard PTO rotations when it is released.
7. PTO engine rotations decrease to the initial
PTO speed in operating one or both of clutch
and brake at the same time and return to
standard PTO rotations when it is released.
6) Cruise Control / PTO Enable Switch
Set Cruise Control or PTO operation of special
vehicle to ON/OFF.
7) Cruise Control / PTO / Idle Control Switch
Used as control switch at operation of Cruise
Control or PTO of special vehicle, idle control
switch at idle and error code checkup switch at
engine halt.
8) Exhaust brake and jake brake solenoid valve
Control unit controls solenoid valve based on the
switch operation of driver or engine state to oper-
ate exhaust brake or jake brake.
4. Coolant temperature sensor
Engine coolant temperature sensor is a resistance
type, mounted to thermostat housing.
ECU judges damage state of engine on the basis of
output voltage of this sensor and controls fuel amount
properly based on the engine coolant temperature.
FUEL SYSTEM
5. Intake pressure temperature sensor
Intake pressure temperature sensor measures pres-
sure and temperature of air supplied for engine and
sends voltage signal to ECU, mounted to intake man-
ifold.
ECU adjusts the injection timing and fuel amount ac-
cording to the air pressure and temperature informed
by the sensor.
6. Crankshaft position sensor
Crankshaft position sensor generates pulse signal by
projection of the fly-wheel when fly-wheel rotates and
sends it to ECU, mounted to the left side of fly-wheel
housing.
ECU calculates the location and speed of engine, us-
ing generated pulse signal and controls fuel injection
time and amount on the basis of them.
7. Camshaft position sensor
Camshaft position sensor generates pulse signal from
sensor wheel installed at the end of camshaft and
sends it to ECU, mounted to the left side of timing gear
cover of cam shaft.
A pulse signal is generated each cylinder and be-
comes standard of TDC by cylinder. Another pulse
signal is generated to have cylinder No.1 recognized
at the location of cylinder No.1.
ECU recognizes cylinder No. and TDC then, deter-
mines injection order and time.
8. Fan clutch control
ECU measures engine coolant temperature and con-
trols fan clutch electrically to maintain coolant temper-
ature constant. Electronic fan clutch control helps im-
prove fuel consumption ratio by minimizing the oper-
ation of cooling fan and reducing power loss.
1) Fan revolution control type(Truck): This is the
type to control cooling fan at an optimum speed
according to coolant temperature with PWM sig-
nal.
2) Two steps control type(Bus): This is the type to
control cooling fan one step or two steps accord-
ing to coolant temperature.
GENERAL FL -13

ARRANGEMENT OF CRANK SENSOR WHEEL AND

CAM SENSOR WHEEL IN TDC

1st cylinder TDC

NO.1 teeth
TDC "A"
11th teeth
15 CAM
Gap : 1.5–0.5 mm
6
34.5

"A" +1 teeth
69 CA

NO.6 teeth
60

Missing tooth
Crank sensor wheel
Cam sensor wheel
Agreeing point between "A" cam and crank shaft

ECBFL5013A

- Crank sensor wheel is used to recognize the engine CONTROL RELAY

speed and status of engine cylinder and cam sensor
wheel is used to recognize position of cylinder No.1 When the start switch is ON, battery voltage flows from
together with crank signal. starting switch to control unit. At this time, power transistor
- Crank sensor wheel teeth are composed at inter- is switched on to control relay coil.
vals of 6 and 2 teeth are missed at interval of Then, control relay switch is ON and main power is
120 Camshaft is composed of 60 as a standard. supplied from battery to control unit through control relay
- Camshaft has total 7 teeth and a tooth is added at switch.
No.1 to recognize standard of cylinder No.1.
- Cylinder No.1 of camshaft is located after 15 from the
added tooth and TDC of cylinder No.1 is located after
34.5 from tooth No.1.

Starting switch

B+
Control unit
(ECU)

Main power supply in ON

Control relay

ECBFL5014A
FL -14 FUEL SYSTEM

PRIMING PUMP OVERFLOW VALVE

Priming pump is mounted on the fuel filter head and used Overflow valve is mounted on the cylinder head fuel injec-
to discharge fuel and air in fuel system manually at initial tion port.
engine starting or after fuel filter replacement. It controls fuel pressure in fuel gallery.

Priming pump mounting torque: Opening pressure of overflow valve:

27~29Nm(2.8~3kgf.m, 20.4~21.8lb-ft) 3.0bar and more
Joint torque of overflow valve:
Air vent hole 34 ~ 39Nm(3.4 ~ 4.0kgf.m, 24.7~29.1lb-ft)
Priming pump

Overflow valve

Fuel filter

ECBFL5015A

FUEL FILTER ECBFL5017A

Fuel filter is spin-on type so that the element replacement

is easy.
It removes impurities in fuel supplied from fuel supply
pump.

Joint torque of cartridge :

32 ~ 34Nm(1.2 ~ 1.6kgf.m, 8.7~11.6lb-ft)

Fuel filter
ECBFL5016A
GENERAL FL -15

EXTERNAL WIRING DIAGRAM OF UNIT

INJECTOR (ECU) EDC850BB

<D6CB>
Truck Bus
52 Torque mode lamp Fan clutch 1 step
53 Fan clutch output Fan clutch 2 steps

53
52
51

ECBFL5018A
FL -16 FUEL SYSTEM

SELF-DIAGNOSIS E52056DF USING HI-SCAN TOOL

The ECM monitors the input/output signals (some signals 1. Turn OFF the ignition switch.
at all times and the others under specified conditions).
When the ECM detects an irregularity, it records the di- 2. Connect the Scan Tool to the data link connector.
agnostic trouble code, and outputs the signal to the Data
3. Turn ON the ignition switch.
Link connector. The diagnosis results can be read with the
scan tool or Flash code. Diagnostic Trouble Codes(DTC) 4. Use the scan tool to check the diagnostic trouble
will remain in the ECM as long as battery power is main- codes.
tained.
5. Repair the fail parts from the diagnosis chart.
NOTE
6. Erase the diagnostic trouble code.
The scan tool can erase the diagnostic trouble
codesin the memory only. 7. Disconnect the scan tool.
INSPECTION PROCEDURE(SELF-DIAGNOSIS)
NOTE
NOTE The scan tool can erase the diagnostic trouble codes
in memory only.
1. When battery voltage is low, diagnostic trouble
codes can not be read. Be sure to check the USING FLASH CODE
battery for voltage and other conditions before
starting the test. Check by "Check ENG" lamp on the instrument panel
2. Diagnosis memory is erased if the battery or Engine system provides error code inform engine failure
the ECM connector is disconnected. Do not directly without scan tool.
disconnect the battery before the diagnostic
trouble codes are completely read. Check the trouble of the error code as follows.

1. Stop the engine

2. Turn the starter to ON position

3. Check if "CHECK ENG" lamp of instrument panel

blinks.

4. Error code is displayed in turn as follows whenever

DEC switch is ON.

5. Previous error code is displayed when INC switch is

ON.

6. Refer to error code table and check the trouble and

cause of failure for troubleshooting.

Example : ERROR Code 2231

Next error code

1ST error code
1 sec.
ON
OFF

0.5sec. 1 sec. 1.5sec.

key ON DEC S/W ON
DEC S/W ON

ECBFL5019A
 Error code
Faulty diagnostic "CHECK
GENERAL

No ITEM Causes of failure Release condition Vehicle state

condition ENG" lamp
DTC FLASH
code code

1 P1619 4121 Booster IG "ON" and - Ground short OFF Normal signal input - Instant change of output
PRESS. ENG.RUNNING - Power short - Normal operation possible
SELF-DIAGNOSIS TABLE

5V SUPPLY - ECU inferiority

2 P0196 1232 INTAKE PRESS. IG "ON" and - Ground short ON Normal signal input - Normal operation possible
SENSOR ENG.RUNNING - Contact state of connector poor
- Wire open

P0197 1233 - Power short

- Power supplied for sensor fault

3 P0112 1112 AIR TEMP. IG "ON" and - Ground short OFF Normal signal input - Normal operation possible
SENSOR ENG.RUNNING - Contact state of connector poor - Smoke increase

P0113 1113 - Power short

- Wire open

4 P0105 1121 AMBIENT AIR IG "ON" and - Sensor harness short, disconnected OFF Normal signal input Normal operation possible
PRESS. SENSOR ENG.RUNNING - Sensor output value failure
- Idle speed increase
5 P1524 5234 BATTERY ENG. RUNNING - Low battery voltage reduction OFF Normal signal input
(650rpm)
SUPPLY
P1523 5233 - Excessively high battery voltage - Normal operation possible
- Regulator fault

6 P0340 2111 CAM SENSOR ENG.RUNNING - Sensor air gap fault ON Normal signal input - Normal operation possible
- Sensor coil short, disconnection
- Noise
- Poor connection of the connector

P0341 2112 - Noise - Operation impossible

- Phase difference between cam
and crank excessive (–6 )

P0342 2113 CAM SENSOR ENG.RUNNING - Noise OFF Normal pulse input - Normal operation possible
HIGH FREQUENCY - Abnormal signal input within 60 sec.
- Normal operation possible
7 P0117 1312 ENG. COOLANT IG "ON" and - Ground short ON Normal signal input
- Engine overheating ON
TEMP.SENSOR ENG.RUNNING - Contact state of connector poor
(Ground short)
- Normal operation possible
P0118 1313 - Power short
- Wire open
FL -17

ECBFL5054A
 FL -18
Error code
Faulty diagnostic "CHECK
No ITEM Causes of failure Release condition Vehicle state
condition ENG" lamp
DTC FLASH
code code

8 P0335 2121 CRANK ENG.RUNNING - Sensor air gap fail ON Normal signal input - Normal operation possible
POSITION - Sensor coil short, open
SENSOR - Noise
- Poor connector connection
- Noise
P0336 2122 - Phase difference between cam and - Operation impossible
crank excessive ( 6 )
CRANK POSITION - Noise
P0337 2123 ENG.RUNNING - Abnormal signal input ON Normal pulse input - Normal operation possible
SENSOR HIGH
within 60 sec.
FREQUENCY
- Deflection of No. n cylinder fuel - Delete fault by
9 P13n1 33n1 CYLINDER ENG.RUNNING injecting amount excessive OFF - Normal operation possible
Hi-scanner
BALANCING - No. n injector fail (Delete Memory) - Idle unstable

10 P0192 1322 IG "ON" and - Ground short ON Normal signal input - Normal operation possible
FUEL PRESS.
ENG.RUNNING - Poor connector connection
SENSOR
- Wire open
P0193 1323 - Power short
- Power supplied for sensor fault
11 P0182 1332 FUEL TEMP. IG "ON" and - Ground short OFF Normal signal input - Normal operation possible
SENSOR ENG.RUNNING - Poor connector
- Wire opne
P0183 1333 - Power short
12 P0198 2222 INTERNAL. ECU IG "ON" and - ECU built-in temperature sensor fail OFF Normal signal input - Normal operation possible
TEMP. SENSOR ENG.RUNNING
13 P1618 4112 PEDAL SENSOR IG "ON" and - Ground short Normal signal input - Running in idle mode
OFF
5V POWER SUPPLY ENG.RUNNING - Power short - LIMP HOME execution
- ECU fault - Engine speed limit
14 P1149 1212 ACCEL. PEDAL - Ground short ON Normal signal input - LIMP HOME realization
IG "ON" and
SENSOR - Poor connector connection (0 to 75%)
ENG.RUNNING
- Wire open - Engine speed limit
P1150 1213 - Power short
- High impedance of pin
- Pedal sensor 5V power fault
15 P0511 5111 IDLE IG "ON" and - Ground short
OFF Normal signal input - Normal operation possible
VALIDATION SW1 ENG.RUNNING - Wire open
(at pedal sensor normal)
- Power short
16 P0513 5113 IDLE IG "ON" and - Ground short OFF Normal signal input - Normal operation possible
VALIDATION SW2 ENG.RUNNING - Wire open (at pedal sensor normal)
- Power short
17 P2149 2212 REMOTE ACCEL. IG "ON" and - Ground short OFF - Remote pedal PTO
PEDAL SENSOR ENG.RUNNING - Wire open operation impossible
(PTO) - Power short
P2150 2213
FUEL SYSTEM

ECBFL5055A
 Error code
Faulty diagnostic "CHECK
GENERAL

No ITEM Causes of failure Release condition Vehicle state

condition ENG" lamp
DTC FLASH
code code

18 P0501 5211 VEHICEL ENG.RUNNING - Vehicle speed sensor fault OFF Normal signal input - Contact running impossible
SPEED SENSOR - Wire open, short - Maximum speed limit
- Poor connector connection impossible
- Vehicle speed sensing cable fail - PTO operation impossible
19 P12n6 31n6 INJECTOR IG "ON" and - No. n injector driving power cable short to BAT ON Normal signal input
P12n5 31n5 NO.N ENG.RUNNING - No. n injector driving power cable short to GND - Engine discord
P12n4 31n4 - No. n injector driving signal cable short to BAT
P12n3 31n3 - No. n injector driving signal cable short to GND
P12n2 31n2 - No. n injector driving power cable and signal
cable short
P12n1 31n1 - No. n injector driving power cable and signal
cable short
20 P0191 1321 FUEL PRESS. IG "ON" and - Fuel pressure keeps 2bar(idle) to 3.5bar(rated) ON Normal signal input - Maximum output limit
IN RAIL ENG.RUNNING for 20 hour.
- Fuel filter clogging
- Fuel pressure is less than 1.5 bar(idle)to
3.5bar(rated)
- Fuel filter clogging
21 P0119 1314 HIGH COOLANT IG "ON" and - Coolant temperature sensor short to ground Over - Coolant temperature: - Maximum output limit
TEMP. ENG.RUNNING - Engine temperature overheating heating 98˚C and less
OVERHEATING warning
light on
22 P1999 1266 Air Heater ENG.RUNNING - Air heater relay melting Air heater - Error release - Air Heater lamp flashing
MONITORING - Air heater line short to battery lamp on
- Heater fail (Flashing)

23 P1658 3222 AIR HEATER IG "ON" and - ECU output terminal short to ground OFF - Error release - Air Heater lamp flashing
SUB-RELAY ENG.RUNNING

24 P1659 3223 CRUISE/PTO/RSG IG "ON" and - ECU output terminal short to ground OFF - Error release
LAMP ENG.RUNNING
25 P1651 3211 ENG. CHECK LAMP IG "ON" and - ECU output terminal short to ground OFF - Error release
ENG.RUNNING
26 P1652 3212 PREHEATER IG "ON" and - ECU output terminal short to ground OFF - Error release
LAMP ENG.RUNNING
27 P1653 3213 ENG. BRAKE IG "ON" and - ECU output terminal short to ground OFF - Error release
IND. LAMP ENG.RUNNING
28 P1654 3214 EXHAUST IG "ON" and - ECU output terminal short to battery OFF - Error release
BRAKE ENG.RUNNING
29 P1655 3215 ENG. BRAKE IG "ON" and - Exhaust brake output terminal short to OFF - Error release
LO/HI ENG.RUNNING battery
FL -19

ECBFL5056A
 FL -20
Error code
Faulty diagnostic "CHECK
No ITEM Causes of failure Release condition Vehicle state
condition ENG" lamp
DTC FLASH
code code

30 P1656 3216 ENG. BRAKE IG "ON" and - ECU output terminal short to battery OFF - Error release
MED/HI ENG.RUNNING

31 P1600 5611 DIAGNOSTIC IG "ON" and - Ground short OFF

PORT ENG.RUNNING - Wire open - Error release
- ECU fault

32 P1640 5612 OPEN CIRCUIT IN IG "ON" and - Ground short OFF - Error release
CAN ENG.RUNNING - Wire open
COMMUNICATION - ECU fail
Line
33 P1616 3224 MAIN POWER IG "ON" and - Relay melting OFF - Error release - Starting impossible
RELAY FAULT ENG.RUNNING - Relay fail
34 P1613 4449 ENGINE IG "ON" and - Relay fuse melted ON (solid) - Error release - Starting impossible
CONTROL UNIT ENG.RUNNING - Memory fail
FAULT - S/W & H/W fail
- Input / Output terminal fail
35 P0500 510 INTAKE IG "ON" and - Central processing unit fail ON (solid) - Error release
PRESSURE ERROR ENG.RUNNING - Intake system fail
- Intake pressor sensor fail
36 P1525 5235 BATTERY OVER IG "ON" and - Battery voltage excessive ON (flash) - After key OFF/ON, - Engine speed limit
SUPPLY ENG.RUNNING - regulator fail error release
FUEL SYSTEM

ECBFL5057A
GENERAL FL -21

TROUBLESHOOTING

Symptom Probable cause Remedy

Engine Control ECU main relay does not operate Check the ECU relay and the power circuit
doe snot system
Poor contact of the ECU or the engine Check the circuit
start
Disconnection of the ECU or the
Check the connector connection
injector connector
Check the ECU using the Hi-Scan/
ECU malfunction Injector compulsory test/
If necessary, replace the ECU
Fuelsys- Check the opening pressure of the over flow/
Malfunction of over flow valve
tem If necessary, replace the over flow valve
Lack of fuel Check the amount of fuel in the fuel tank
Check the fuel supply pump check valve
Fail of the fuel supply pump and the shaft for damage/
If necessary, replace them
Poor supply due to the fuel supply hose kink Check the fuel intake system
Others Malfunction of the air heater Check the air heater relay and the ECU
Air in fuel system Bleed the fuel system
Poor idle Check the injector variation by
Malfunction of injector acceleration test/
If necessary, replace the injector
Air in fuel system Check the fuel line
Fail of the accelerator input signal Check and replace the pedal sensor
White smoke Check the injector tube and leak
Fuel leak to the combustion chamber
If necessary, replace the injector.
Air heater malfunction Check the heater relay and ECU
Check the ECU
Incorrect injection timing due to ECU damage
If necessary, replace the ECU
Black smoke Malfunction of injector Check the injector by acceleration test
Check the sensor using a Hi-Scan/
Fail of intake pressure sensor
Check the sensor output data
Check the ECU
Incorrect injection timing due to ECU damage
If necessary, replace the ECU
FL -22 FUEL SYSTEM

Symptom Probable cause Remedy

Low engine power Check the accel pedal output data if
Malfunction of accel pedal
output necessary, replace the accel pedal
(Poor acceleration)
Check the water temperature sensor
Malfunction of water temperature sensor using a Hi-Scan/
or engine overheated Check the engine cooling system,
fan and thermostat
Check the fuel pressure sensor using
a Hi-Scan/
Low fuel pressure
Check the fuel system(fuel pump, filter,
over flow valve etc.)
Check the intake pressure sensor
Fail intake pressure sensor or abnormal using a Hi-Scan/
intake pressure Check the intake system(Intercooler,
intake hose etc.)
Freezing fuel in winter time Check the fuel for wax and fuel condition
Check the fan clutch circuit
Electronic fan clutch inoperative (D6CB)
Check the engine overheat using a Hi-scan
GENERAL FL -23

ACCELERATION TEST

• With the engine installed to the vehicle, the injector

and the combustion performance can be inspected
using a Scan tool and the ECU.
• Description for Acceleration Test Mode
- Comparison of the engine power variation for
each cylinder
- Measurement of the acceleration time by accel-
erating the engine with the injectors stopped one
by one.
(Check if any cylinder affects the engine acceler-
ation.)
- At the engine idle, with one cylinder stopped
the EUI injection, accelerate the engine with five ECBFL5021A
cylinders. Then measure the acceleration time
until the 60th times of fuel injection. 4) As indicated on the screen, press the accel pedal
- For each cylinder, repeat the above procedure fully and press the enter key.
and measure the each acceleration time.
- Compare the measured value relatively and print
the data.
Then evaluate the engine power effect for each
cylinder by the compared result.
- All the above procedures are performed in the ac-
celeration test mode automatically and the result
is displayed on the Hi-Scan with the figure and
the graph.

• Condition of the Acceleration Test

- When engine is idling(500 rpm)
- Engine warm-up(Coolant temperature 60캜 over)
- No engine load(Air-conditioning, Electrical mech-
anism etc.)
ECBFL5022A
• How to use the Scan tool
1) When the engine is idling(500 rpm), release the 5) Engine will perform the acceleration test auto-
engine load such as air-conditioning. matically 6 times. During the test, keep the accel
2) Connect the Scan tool and check the control unit. pedal pressed fully.
Then select the acceleration test mode below on 6) After completing the test, the result will be dis-
the menu. played on the screen automatically.
- After checking the result, turn off the engine.

ECBFL5020A

ECBFL5023A
3) Check the message on the screen and if it is cor-
rect, press the enter key.
FL -24 FUEL SYSTEM

ANALYSIS OF THE TEST RESULT

- If the figure or the graph displayed on the screen of the

Hi-Scan is low relatively, a performance deterioration
of injector and a poor combustion are suspected.
- If the result value is much low than them of the other
cylinders, inspect the EUI of each cylinder or replace
the cylinder with a new one.
- If necessary, collect information of the overhaul his-
tory and a compressive force test and then analysis
and judge the test result.

NOTE
• Be sure to check the coolant temperature is 60
ECBFL5024A
C over because engine warm-up can affect the
result of test.
2. Check the message displayed on the screen, if it is
• After performing the test, the pedal is not oper-
correct press the enter key.
ated properly, however, this is normal condition.If
the engine is turned off and on repeatedly, the
pedal operates properly.
• Judge the test result by the relative comparison
and the total average for each cylinder.
The average of the absolute value is affected by
the engine condition(Load, coolant temperature
etc.).
Therefore, judge the test result by the relative
comparison in priority.
• Use this as reference material to inspect the in-
jector and the combustion performance of the re-
lated cylinder.
After overhauling the engine, be sure to perform
this test to inspect cylinders operate properly.
ECBFL5025A
COMPRESSION TEST
3. As indicated on the screen, press the key and crank
Inspection for the state of compressive force of the engine
the engine.
each cylinder using a Hi-scan and ECU on the vehicle.

EXPLANATION FOR COMPRESSION TEST MODE

- Characteristic comparison of compressive force for

each cylinder
- During engine cranking, measure the engine speed
rate by the compressive resistance from the cylinder.
(With the compressive force test mode, no fuel injec-
tion)

HOW TO USE HI-SCAN

1. With the engine key turned on, connect the Hi-Scan

and check the control unit.
Then select the compression test mode below on the
menu. ECBFL5026A
GENERAL FL -25

4. After completing the test, compare the engine speed FUEL SYSTEM DRAINING EAAA631C

rate for each cylinder by pressing the keys(F1, F2,

F3..) in sequence. 1. Clean around air vent of cylinder head side and fuel
filter side.
Air vent

ECBFL5027A
ECBFL5028A
ANALYSIS OF TEST RESULT
2. Unscrew air vent bolt in cylinder head.
- After completing the test, the graph of the engine
speed rate for each cylinder will be displayed on the Air vent bolt
screen of the Hi-Scan.
- When the engine is in the normal condition, the graph
tendency is almost identical.
However, when a certain cylinder exhibits abnormal
compressive force characteristic, the graph tendency
is quite different from normal compressive force char-
acteristic.
- If the graph tendency is abnormal, inspect the com-
pressive system including the piston ring and the
valve to prevent a malfunction of the compressive
system.

ECBFL5029A

3. After removing air vent bolt of cylinder head com-

pletely, blow the compressed air, using an air gun with
air bent hole blocked by hand to discharge fuel re-
maining in cylinder head. Engine control system-Me-
chanical ECU.
FL -26 FUEL SYSTEM

FUEL CHARGE AND AIR DISCHARGE 7) Execute the cranking when the above works are
all done.
1. After engine assembly/disassembly or fuel bleeding Crank it for the time for enough (10 to 15 sec.)
(If fuel is eliminated completely in fuel line) and several times until engine starts.(about 3
to 5 times, if fuel has been eliminated fuel line,
1) Clean around the air vent of fuel filter and cylinder especially if fuel in injector is eliminated thor-
head. oughly, sufficient cranking is necessary from air
discharge to start the engine)
2) Unscrew air vent bolt on fuel filter head a little.
Cranking time should not exceed 15 sec. be-
Air vent cause cranking for a long time influences badly
on starter motor. Keep the interval of approx. 30
sec. until the next cranking to prevent starter mo-
tor from overheating.

8) When engine starts, wait until engine becomes

stable, pedaling accelerator (Approx. 1000rpm).

2. When replacing a fuel filter element (If fuel is filled in

cylinder head)

1) Clean the fuel filter.

2) Unscrew air vent in fuel filter and remove the

pressure from fuel line.
ECBFL5028A
3) Replace the filter element.
3) Perform pumping works, using priming pump on
fuel filter until fuel begins to drain from air vent NOTE
cock. • Check if the gasket is placed on element when
replacing.
4) Close bolt when air has been eliminated com-
• Apply oil to gasket and tighten it sufficiently by
pletely in fuel discharged to fuel filter air vent
hand.
5) Unscrew air vent bolt at cylinder head front. • Tightening torque : 12~16Nm (1.2~1.6kgf.m,
8.7~11.6lb-ft)
Air vent
Filter cartridge

ECBFL5028A
ECBFL5031A
6) Close cock after pumping until air is eliminated in
fuel in the same way as described in the Clause
2).
GENERAL FL -27

4) Perform pumping until fuel drains from air vent,

using priming pump.(In case of filling fuel in new
cartridge before mounting, pumping time can be
reduced.)

5) Close air vent bolt

Air vent

ECBFL5028A

6) Perform cranking and start the engine

(Air discharge of cylinder head is not necessary
when replacing a filter and engine starts with just
cranking once in general)
FL -28 FUEL SYSTEM

ENGINE CONTROL
SYSTEM-ELECTRONIC
ENGINE CONTROL UNIT(ECU)

REPLACEMENT OF CONTROL ECU EAADF9AE

1. Remove the control ECU.

ECU

ECBFL5058A

2. When replacing the unit injector of the control ECU, be

sure to re-input the compensation value(T3,T4)using
a scan tool.

CAUTION
Be sure to match the compensation value(T3,T4)
indicated on the injector connector and the in-
put data of the control ECU for the engine perfor-
mance and the exhaust gas.

T3 : Injection Timing Compensation

T4 : Fuel Injection Amount Compensation

Top surface of EUI connector

2A003B
T4 T3

ECBFL5030A
ENGINE CONTROL SYSTEM-ELECTRONIC FL -29

ELECTRONIC UNIT 2. Apply the parking brake.

INJECTOR(EUI) 3. Separate ECU connector and connect tester to the
cable harness
INSPECTION OF INJECTOR (EUI)
4. Perform a test using a multi-meter.
COMPONENTS E562B05D

[Checking condition]

1. Turn off the ignition switch.

(ECU harness side connector)

E29

E43

ECBFL5032A

Test item Data display Possible causes of failure Normal value

Unit injector 1
Unit injector fail [D6CA] 1~2Ω
(Connector No.43, 29 terminal Resistance
Cable harness fail [D6CB] 3.9~4.1Ω
of ECU harness side)
Unit injector 2
Unit injector fail
(Connector No.43, 45 terminal Resistance
Cable harness fail ↑
of ECU harness side)
Unit injector 3
Unit injector fail
(Connector No.43, 30 terminal Resistance ↑
Cable harness fail
of ECU harness side)
Unit injector 4
Unit injector fail
(Connector No.46, 32 terminal Resistance
Cable harness fail ↑
of ECU harness side)
Unit injector 5
Unit injector fail
(Connector No.46, 31 terminal Resistance ↑
Cable harness fail
of ECU harness side)
Unit injector 6
Unit injector fail
(Connector No.46, 33 terminal Resistance
Cable harness fail ↑
of ECU harness side)
FL -30 FUEL SYSTEM

REPAIR AND ADJUSTMENT 2. Remove cam cap bolts.

PROCEDURE E31B2377
NOTE
REPLACEMENT OF UNIT INJECTOR
Separate bolts in turn to prevent rocker arm shaft from
bending.
CAUTION
1. Be sure to replace the injector at the service
center designated by Hmc.
1) Do not operate the injector while running
the engine because the injector gener-
ates the high voltage over than 90 volts.
However, when the injector should be op-
erated inevitably, be careful with an elec-
tric shock.
2) When removing the used injector, be sure
to wear the protective gloves.
At the high temperature over than 315 C,
the surface of the injector can be car-
bonized or sticky, which cause hydroflu-
oric acid.
When removing the injector from the en- ECBFL5034A
gine, be sure to wear protective gloves to
protect the skin. 3. Remove rocker arm shaft using the special
tool(09245-84100).
1. Remove rocker cover

09245-84100
CAUTION
Be careful for unit injector cable harness not to be
damaged.

Rocker cover

Gasket

ECBFL5035A

4. Drain fuel in cylinder head according to fuel draining

procedure.

ECBFL5033A 5. Clean around the unit injector to replace.

ENGINE CONTROL SYSTEM-ELECTRONIC FL -31

6. Remove cable to be connected with unit injector. 10. Remove the sealing clamp, and then clean unit injec-
tor hole in cylinder head.
Injector cable

Sealing clamp

ECBFL5036A

ECBFL5038A
7. Unscrew the injector clamp bolt, remove clamp and
then remove the injector carefully.
11. Replace O-ring with the new one in the unit injector
and apply engine oil.
CAUTION Check if it is installed properly in between valve spring
When removing the used injector, be sure to wear and tighten the unit injector mounting bolt to the spe-
protective gloves. cific torque.

CAUTION
Injector
When replacing the injector, be sure to replace the
O-ring with a new one.

[Specific torque]
When replacing other than nozzle tube (when replacing
injector only) : 18Nm(1.8kgf.m) + 60 C
When replacing nozzle tube:
First : 18Nm(1.8kgf.m) + 90 + 90 Loosen
completely in 2 min.
Second : 18Nm(1.8kgf.m) + 60

ECBFL5037A 12. Apply engine oil to the cam-shaft rob and the valve
bridge and install the rocker arm shaft using the spe-
8. Fix protecting sleeve after removing unit injector. cial tool(09245-84100).

9. Insert sealing clamp into cylinder head fuel gallery.

09245-84100

NOTE
Check if sealing clamp is inserted properly at its place.

ECBFL5035A
FL -32 FUEL SYSTEM

13. Adjust the injector pre-stroke. 15. Check if rocker arm shaft is properly mounted after
tightening the cam cap bolts.
Adjust the clearance of the valve and the injector after
tightening the cam cap bolt to the specific torque.

ECBFL5040A

14. Connect cable to the unit injector.

ECBFL5041A

CAUTION
16. Install the rocker cover.
When replacing the unit injector with a new one,
be sure to consider the compensation value(T3, 17. Perform fuel bleeding following the procedure.
T4) of trim setting code indicated on the top sur-
face of the injector connector using a scan tool. 18. Run the engine for about 10min at idle to bleed the air
Be sure to match the compensation value(T3,T4) in the system.
indicated on the injector connector and the in-
put data of the control ECU for the engine perfor-
mance and the exhaust gas.

T3 : Injection Timing Compensation

T4 : Fuel Injection Amount Compensation

Upper of EUI connector

2A003B
T4 T3

ECBFL5039A
ENGINE CONTROL SYSTEM-ELECTRONIC FL -33

PRIMING PUMP REPLACEMENT OF FUEL PUMP

1. Unscrew air vent bolt loosely to eliminate remaining

REPLACEMENT OF PRIMING PUMP E12E2FBC pressure in fuel pump.

1. Unscrew air vent bolt to eliminate remaining pressure 2. Clean the fuel pump around.
in fuel filter.
3. Disconnect fuel line.
2. Clean the priming pump around.
4. Loosen fuel pump bolt and remove fuel pump.
Priming pump Air vent hole
5. Apply oil to O-ring of new fuel pump and install it.

Tightening
torque of fuel pump bolt:
10~12Nm(1.0~1.2kgf.m, 7.3~8.7lb-ft)

6. Install fuel line.

7. Perform fuel charge and air bleeding (up to fuel filter).

8. Start engine and run the engine at idle for about 10min
Fuel filter to bleed air remaining in system.

ECBFL5051A

3. Remove the priming pump bolt. Fuel filter

Air compressor
4. Insert sealing washer into new priming pump and
mount it.

Tightening torque of priming pump bolt:

28~29Nm(2.8~3.0kgf.m, 20.4~21.8lb-ft)

5. Perform the fuel charge and air bleeding in the same

way with the replacement of fuel filter.

6. Start engine and run the engine at idle for about 10min Bypass oil filter Fuel pump
to bleed air remaining in the system. ECBFL5052A
FL -34 FUEL SYSTEM

OVERFLOW VALVE 3. Disconnect fuel line from overflow valve.

4. Remove overflow valve.

REPLACEMENT OF OVERFLOW
Overflow valve
VALVE E6CF89AD

1. Clean the overflow valve around.

Overflow valve

ECBFL5053A

5. Clean the contact points of cylinder head and mount

new overflow valve.
ECBFL5053A
Tightening torque of overflow valve :
2. Place container under hose of air vent hole at fuel filter 34~39Nm(3.4~4.0kgf.m, 24.7~29.1lb-ft)
head and loosen air vent bolt.
Air vent
6. Install fuel line and perform fuel charge and air bleed-
ing (Refer to method if the fuel is completely elimi-
nated from fuel line).

7. Start the engine and run the engine at idle about 10

minutes to bleed air remaining in system.

ECBFL5028A
FUEL DELIVERY SYSTEM-ELECTRONIC FL -35

FUEL DELIVERY ACCELERATOR PEDAL(BUS)

SYSTEM-ELECTRONIC 1. Turn the ignition key off and disconnect battery nega-
tive(-) cable.

ACCELERATOR PEDAL 2. Remove the accelerator sensor connector.

3. Remove the accelerator pedal assembly(A) after re-

REPLACEMENT E1FF42B1
moving accelerator pedal mounting bolt.
ACCELERATOR PEDAL(TRUCK)

1. Turn the ignition key off and disconnect battery nega-

tive(-) cable.

2. Remove the accelerator sensor connector.

A
3. Remove the accelerator pedal assembly after remov-
ing accelerator pedal mounting bolt.

ECBFL5062A

4. Installation is in the reverse of removal.

Tightening torque: 1.9~ 2.8 kgf.m

SGVFL7501D

4. Installation is in the reverse of removal.

Tightening torque: 2.0~ 3.0 kgf.m

FL -36 FUEL SYSTEM

FUEL TANK

COMPONENTS E7DEDD89

[Bus- Except LD model]

1

<Vehicle front> 1

Stick hook on the bracket hole.

0.4-0.8
8.5-11

1. Fuel tank assembly

2. Fuel tank cap Detailed B

Detailed A
Tightening torque : Nm(kgf.m, lb-ft)

ECBFL5059A
FUEL DELIVERY SYSTEM-ELECTRONIC FL -37

[Bus- LD model]

<Vehicle front>

2.5-4.2

0.4-0.8
Detailed A
1. Fuel tank assembly 8.5-11

2. Fuel tank cap

Detailed B

Tightening torque : Nm(kgf.m, lb-ft)

ECBFL5060A
FL -38 FUEL SYSTEM

REPLACEMENT E8AF8CEB 5. Installation is in the reverse of removal.

FUEL TANK(TRUCK) NOTE

1. Park the vehicle on a flat road surface and stop the When installing fuel cap rotor to fuel cap holder, turn
engine. Disconnect battery negative(-) cable. the ignition key clockwise 15˚ or so with it pressed
after inserting the ignition key into fuel cap rotor(A).
2. Remove the sender connector on the upper of the fuel After installed, repeat to lock and unlock the ignition
tank. key five times so that grease is spread evenly.

3. Remove return hose(A) and feed hose(B). FUEL TANK(BUS: LD MODEL)

1. Park the vehicle on a flat road surface and stop the

B engine. Disconnect battery negative(-) cable.
A

2. Remove the sender connector on the upper of the fuel

tank.

3. Remove return hose and feed hose.

4. Support the fuel tank assembly with a jack and loosen

fuel tank band mounting nut. And remove the mount-
SGVFL7012D ing bolt.

4. Support the fuel tank assembly with a jack and loosen

fuel tank band mounting nut. And remove the mount-
ing bolt.

5. Installation is in the reverse of removal.

Strap bolt tightening torque: 2.5~4.5kgf.m

A
FUEL TANK(BUS: EXCEPT LD MODEL)

1. Park the vehicle on a flat road surface and stop the

engine. Disconnect battery negative(-) cable.

2. Remove the sender connector on the upper of the fuel

tank. SGVFL7016D

3. Remove return hose and feed hose. 5. Installation is in the reverse of removal.
4. Support the fuel tank assembly with a jack and loosen
NOTE
fuel tank band mounting nut. And remove the mount-
ing bolt. When installing fuel cap rotor(A) to fuel cap holder,
turn the ignition key clockwise 15˚ or so with it
A pressed after inserting the ignition key into fuel cap
Holder rotor(A). After installed, repeat to lock and unlock the
ignition key five times so that grease is spread evenly.

ECBFL5061A
FUEL DELIVERY SYSTEM-ELECTRONIC FL -39

CAP REPLACEMENT 4. Remove the accessories.

1. Disassemble the cap from the tank.

SPYFL7504D

SPYFL7501D 5. Push the holder inside the rotor.

2. Remove the snap ring.

SPYFL7505D

SPYFL7502D
6. Push the rotor outside by the thumb.

3. Detach the upper part from the lower part of the cap.

SPYFL7506D

SPYFL7503D
FL -40 FUEL SYSTEM

7. Pull out the rotor.

CAUTION
- Be careful not to separate the accessories of
rotor.

SPYFL7510D

10. Push the rotor with rotating the key clockwise.

SPYFL7507D

8. Inject the key into the rotor separated.

SPYFL7511D

11. After installed, repeat to lock and unlock the ignition

key five times so that grease is spread evenly.Then
remove the ignition key.

SPYFL7508D

9. Inject the rotor into the new cap correctly.

SPYFL7512D

SPYFL7509D