Fuel System D4CB

General
Specifications
Fuel Delivery System
Items Specification
Fuel Injection System Type Common Rail Direct Injection (CRDI)
Fuel Return System Type Return type
Fuel Pressure Max. Pressure 2,000 bar (200 MPa / 29,007 psi)
Fuel Tank Capacity 65 lit. (17.2 U.S.gal., 68.7 U.S.qt., 57.2 Imp.qt.)
Fuel Filter Type High pressure type (Built in under body)
High Pressure Fuel Pump Type Mechanical, Plunger Pumping Type
Driven by Drive Chain
Low Pressure Fuel Pump Type Electrical, in tank type
Driven by Electric motor
Sensors
Mass Air Flow Sensor (MAFS)
▷ Type: Hot-Film Type
▷ Specification
* Air mass characteristic curve at ambient temperature
(20°C±10K)
Air mass m Characteristic Tm Tolerance
[Kg/h] [μsec] ∆m/m in [%] Tm. min [μsec] Tm. max [μsec]
10 504.27 ±3 503.03 505.53
15 484.34 ±2 483.22 485.47
75 365.46 ±2 363.75 367.20
160 295.19 ±2 293.19 297.22
310 223.01 ±2 220.66 225.41
640 127.68 ±2 124.81 130.59
800 94.07 ±3 89.49 98.75
* Air mass characteristic curve at 80°C

10 504.27 ±5 502.20 506.36
75 365.46 ±4 362.07 368.97
160 295.19 ±4 291.22 299.28
310 223.01 ±4 218.33 227.83
Intake Air Temperature Sensor (IATS) #1 [BUILT IN Engine Coolant Temperature Sensor (ECTS)
MAFS] ▷ Type: Thermistor type
▷ Type: Thermistor type ▷ Specification
▷ Specification
Temperature [°C(°F)] Resistance(kΩ)
Temperature [°C(°F)] Resistance(㏀)
-40(-40) 48.14
-40(-40) 35.14 ~ 43.76
-20(-4) 14.13 ~ 16.83
-20(-4) 12.66 ~ 15.12
0(32) 5.79
0(32) 5.12 ~ 5.89
20(68) 2.31 ~ 2.59
20(68) 2.29 ~ 2.55
40(104) 1.15
40(104) 1.10 ~ 1.24
60(140) 0.59
60(140) 0.57 ~ 0.65
80(176) 0.32
80(176) 0.31 ~ 0.37
100(212) 0.19
Boost Pressure Sensor (BPS)

Camshaft Position Sensor (CMPS)
▷ Type: Piezo-resistive pressure sensor type
▷ Type: Hall effect type
▷ Specification
▷ Specification
Pressure[kPa (kg/cm² / psi)] Output Voltage (V)
Level Output Pulse (V)
50 (0.51 / 7.25) 0.5
High 5
100 (1.02 / 14.50) 1.00 ~ 1.14
Low 0
300 (3.06 / 43.51) 3.29 ~ 3.43
Items Specification
400 (4.08 / 58.02) 4.41 ~ 4.59
Air Gap [mm (in.)] 0.2 ~ 2.0 (0.008 ~ 0.079)
Intake Air Temperature Sensor (IATS) #2

▷ Type: Thermistor type Crankshaft Position Sensor (CKPS)
▷ Specification ▷ Type: Variable reluctance type
Temperature [°C(°F)] Resistance(kΩ) Items Specification
-40(-40) 40.93 ~ 48.35 Coil Resistance (Ω) 774 ~ 946 [20°C(68°F)]
-20(-4) 13.89 ~ 16.03 Output Voltage (V) 0~5
0(32) 5.38 ~ 6.09

20(68) 2.31 ~ 2.57 Accelerator Position Sensor (APS)
▷ Type: Potentiometer type
40(104) 1.08 ~ 1.21
▷ Specification
60(140) 0.54 ~ 0.62
Output Voltage (V) [Vref=5V]
80(176) 0.29 ~ 0.34 Test Condition
APS 1 APS 2
Idle 0.7 ~ 0.8 0.325 ~ 0.425
Fully depressed 3.95 ~ 4.25 1.9 ~ 2.2
Fuel Temperature Sensor (FTS) Actuators
▷ Type: Thermistor type Injector
▷ Specification ▷ Number: 4
Temperature [°C(°F)] Resistance(kΩ) ▷ Specification
-30(-22) 25.4 Items Specification
-20(-4) 15.04 Coil Resistance (Ω) 0.42 ~ 0.52 [20°C(68°F)]
-10(14) 9.16
0(32) 5.74 Rail Pressure Regulator Valve
▷ Specification
20(68) 2.45
Items Specification
40(104) 1.15
Coil Resistance (Ω) 0.42 ~ 0.52 [20°C(68°F)]
50(122) 0.811
60(140) 0.584 Suction Control Valve
▷ Specification
70(158) 0.428
Items Specification
80(176) 0.318
Coil Resistance (Ω) 1.9 ~ 2.3 [20°C(68°F)]
Rail Pressure Sensor (RPS) Air Control Valve

▷ Type: Piezo-electricity type ▷ Type : Duty control motor type
▷ Specification ▷ Specification
Rail pressure [ Output Output (V) Throttle Valve Position

Test Condition
bar (MPa / psi)] Voltage(V) 0.5 Full close
Idle 322(32.2 / 4,670) Approx. 0.82 4.5 Full open
Fully depressed 2000(200 / 29,007) Approx. 2.81
Electric EGR Control Valve

Water Sensor ▷ Type: DC Motor / Position Sensor
▷ Specification ▷ Specification
Item Specification Position sensor
Warning Level (cc) 40 ~ 60 Output Vol -

Operating length tate (V) [Po -
Step Valve state
(mm) wer Supply
Vehicle Speed Sensor (VSS) = 5.0V]
▷ Type: Inductive type 1 Closed 0.4 ~ 0.9 4.67
2 0.7 ~ 2.3 4
3 Open 3.4 ~ 4.0 3.17
4 5.7 ~ 6.3 2
Service Standard
Item Specification
Basic Idle rpm
780 rpm
(After warm up)
Tightening Torques
Engine Control System
Item Kgf.m N.m lb-ft
ECU installation bolt/nut 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
Mass air flow sensor clamp installation bolt 0.8 ~ 1.2 7.8 ~ 11.8 5.8 ~ 8.7
Mass air flow sensor installation bolt 0.4 ~ 0.6 2.9 ~ 4.9 2.9 ~ 4.3
Boost pressure sensor installation bolts 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
Intake Air Temperature Sensor #1 installation 0.4 ~ 0.6 3.9 ~ 5.9 2.9 ~ 4.3
Intake Air Temperature Sensor #2 installation 2.0 ~ 3.0 19.6 ~ 29.4 14.5 ~ 21.7
Engine coolant temperature sensor installation 2.0 ~ 4.0 19.6 ~ 39.2 14.5 ~ 28.9
Crankshaft position sensor installation bolt 0.8 ~ 1.2 7.5 ~ 11.8 5.8 ~ 11.7
Camshaft position sensor installation bolt 0.8 ~ 0.9 7.5 ~ 8.5 5.8 ~ 6.5
Electric EGR control valve assembly installation bolt 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
Exhaust gas temperature sensor #1 installation [with Turbocharger] 4.0 ~ 5.0 39.2 ~ 49.1 28.9 ~ 36.2
Exhaust gas temperature sensor #2 installation [with DPF] 4.0 ~ 5.0 39.2 ~ 49.1 28.9 ~ 36.2
Differential pressure sensor bracket installation bolt 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
Air control valve installation bolts 0.8 ~ 1.2 7.8 ~ 11.8 5.8 ~ 8.7
Fuel Delivery System

Item Kgf.m N.m lb-ft
Injector clamp installation bolt 2.0 ~ Loosen 19.6 ~ Loose- 14.5 ~ Loose-
~0.8+60° n ~ 7.8+60° n ~ 5.8+60°
Fuel sender plate cover installation screw 0.13 ~ 0.19 1.3 ~ 1.9 0.9 ~ 1.4
Accelerator pedal module installation bolt 0.8 ~ 1.2 7.8 ~ 11.8 5.8 ~ 8.7
High pressure fuel pump installation bolt 2.0 ~ 2.6 19.6 ~ 25.5 14.5 ~ 18.8
High pressure fuel pipe (Injector ↔ Common Rail) flange nut installation 2.5 ~ 2.9 24.5 ~ 28.4 18.1 ~ 21.0
High pressure fuel pipe bracket installation bolt 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
High pressure fuel pipe (Common RaiI ↔ High Pressure Fuel Pump) fla-
2.5 ~ 2.9 24.5 ~ 28.4 18.1 ~ 21.0
nge nut installation
Common rail installation bolt 1.5 ~ 2.2 14.7 ~ 21.6 10.9 ~ 15.9
Fuel tank band installation nut 4.4 ~ 5.3 42.7 ~ 52.1 31.5 ~ 38.4
Fuel pump cover installation 13.8 ~ 41.4 135 ~ 406 99.5 ~ 299.2
Fuel filter installation bolt 1.1 ~ 1.4 11.2 ~ 13.8 8.0 ~ 10.1
Special Service Tools
Tool (Number and name) Illustration Application
Injector Remover Removing the injector
(09351-4A300)
SVQFL6499D
Injector Remover Adaptor Removing the stuck injector

(09331-59100)
SUBF42010L
High Pressure Fuel Pump Removing the high pressure fuel pump
Sprocket Remover sprocket
(09331-4A000)
C314A000
Torque Wrench Socket (17mm) Installing the high pressure fuel pipe
(09314-3V100)
AFAF201B
Flywheel Stopper Removing the high pressure fuel pump

(09231-2B100)
SHDEM6201D
Tool (Number and name) Illustration Application
Injector hole brush Remove the carbon in the injector hole
(09351-27300)
SYNF20500L
Basic Troubleshooting
Basic Troubleshooting Guide
STDFL0001N
Customer Problem Analysis Sheet
SCMF10001L
Basic Inspection Procedure 3. Slightly shake the connector and wiring harness
Measuring Condition Of Electronic Parts' vertically and horizontally.
Resistance 4. Repair or replace the component that has a problem.
The measured resistance at high temperature after 5. Verify that the problem has disappeared with the road
vehicle running may be high or low. So all resistance test.
must be measured at ambient temperature (20℃, 68℉), ● SIMULATING VIBRATION
unless stated otherwise.
a. Sensors and Actuators
: Slightly vibrate sensors, actuators or relays with
finger.
The measured resistance in except for ambient
temperature (20℃, 68℉) is reference value.
Intermittent Problem Inspection Procedure Strong vibration may break sensors, actuators or
Sometimes the most difficult case in troubleshooting is relays
when a problem symptom occurs but does not occur
b. Connectors and Harness
again during testing. An example would be if a problem
appears only when the vehicle is cold but has not : Lightly shake the connector and wiring harness
appeared when warm. In this case, the technician should vertically and then horizontally.
thoroughly make out a "CUSTOMER PROBLEM ● SIMULATING HEAT
ANALYSIS SHEET" and recreate (simulate) the a. Heat components suspected of causing the
environment and condition which occurred when the malfunction with a hair dryer or other heat source.
vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for • DO NOT heat components to the point where they
poor connections, loose wires, bent, broken or may be damaged.
corroded pins, and then verify that the connectors are
• DO NOT heat the ECM directly.
always securely fastened.
● SIMULATING WATER SPRINKLING
a. Sprinkle water onto vehicle to simulate a rainy day or
a high humidity condition.
DO NOT sprinkle water directly into the engine

compartment or electronic components.
● SIMULATING ELECTRICAL LOAD
a. Turn on all electrical systems to simulate excessive
electrical loads (Radios, fans, lights, rear window
defogger, etc.).
BFGE321A
Connector Inspection Procedure c. Listen for a click when locking connectors. This
1. Handling of Connector sound indicates that they are securely locked.
a. Never pull on the wiring harness when
disconnecting connectors.
BFGE015H
d. When a tester is used to check for continuity, or

BFGE015F to measure voltage, always insert tester probe
from wire harness side.
b. When removing the connector with a lock, press
or pull locking lever.
BFGE015I
BFGE015G
e. Check waterproof connector terminals from the d. Pull lightly on individual wires to ensure that each
connector side. Waterproof connectors cannot be wire is secured in the terminal.
accessed from harness side.
BFGE015K
BFGE015J 3. Repair Method of Connector Terminal
a. Clean the contact points using air gun and/or
shop rag.
• Use a fine wire to prevent damage to the terminal.
• Do not damage the terminal when inserting the
tester lead. Never use sand paper when polishing the contact
2. Checking Point for Connector points, otherwise the contact point may be
a. While the connector is connected: damaged.
Hold the connector, check connecting condition b. In case of abnormal contact pressure, replace the
and locking efficiency. female terminal.
b. When the connector is disconnected:
Check missed terminal, crimped terminal or Wire Harness Inspection Procedure
broken core wire by slightly pulling the wire 1. Before removing the wire harness, check the wire
harness. harness position and crimping in order to restore it
Visually check for rust, contamination, correctly.
deformation and bend. 2. Check whether the wire harness is twisted, pulled or
c. Check terminal tightening condition: loosened.
Insert a spare male terminal into a female 3. Check whether the temperature of the wire harness is
terminal, and then check terminal tightening abnormally high.
conditions. 4. Check whether the wire harness is rotating, moving
or vibrating against the sharp edge of a part.
5. Check the connection between the wire harness and
any installed part.
6. If the covering of wire harness is damaged; secure,
repair or replace the harness.
Electrical Circuit Inspection Procedure
● 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.
BFGE501B
b. Disconnect connector (B), and measure for

resistance between connector (C) and (B1) and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between

connector (C) and (B1) is higher than 1㏁ and the
open circuit is between terminal 1 of connector
(C) and terminal 1 of connector (B1).
BFGE501A
2. Continuity Check Method
When measuring for resistance, lightly shake the wire

harness above and below or from side to side.
Specification (Resistance)
1Ω or less → Normal Circuit
1㏁ or Higher → Open Circuit
a. Disconnect connectors (A), (C) and measure
resistance between connector (A) and (C) as
shown in [FIG. 2].
BFGE501C
In [FIG.2.] the measured resistance of line 1 and 3. Voltage Check Method

2 is higher than 1㏁ and below 1 Ω respectively. a. With each connector still connected, measure the
Specifically the open circuit is line 1 (Line 2 is voltage between the chassis ground and terminal
normal). To find exact break point, check sub line 1 of each connectors (A), (B) and (C) as shown in
of line 1 as described in next step. [FIG. 4].
The measured voltage of each connector is 5V, a. Disconnect connectors (A), (C) and measure for
5V and 0V respectively. So the open circuit is resistance between connector (A) and Chassis
between connector (C) and (B). Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this

example is below 1 Ω and higher than 1MΩ
respectively. Specifically the short to ground
circuit is line 1 (Line 2 is normal). To find exact
broken point, check the sub line of line 1 as
described in the following step.
BFGE501D
● Check Short Circuit

1. Test Method for Short to Ground Circuit
• Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5],
the broken point can be found by performing Step 2
(Continuity Check Method with Chassis Ground) as
BFGE501F
shown below.
b. Disconnect connector (B), and measure the
resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
shown in [FIG. 7].
The measured resistance between connector (B1)

and chassis ground is 1Ω or less. The short to
ground circuit is between terminal 1 of connector
(C) and terminal 1 of connector (B1).
BFGE501E
2. Continuity Check Method (with Chassis Ground)
Lightly shake the wire harness above and below, or

from side to side when measuring the resistance.
Specification (Resistance)
1Ω or less → Short to Ground Circuit
1MΩ or Higher → Normal Circuit BFGE501G
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, stuck, jam- • Faulty low pressure fuel pump
med • Faulty high pressure fuel pump
• Rail pressure regulator valve contaminated, stuck, jam- • Injector jammed open
med • ECM program error or hardware fault
• Bad fuel quality or water ingress in fuel • Faulty glow system
(Symptom 2) Engine Starts With Difficulty Or Starts And Stalls

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

Possible Cause
• Clogged return line of high pressure fuel pump
med
med
pressure)
(Symptom 4) Unstable Idling
Possible Cause
• Not connected fuel return line at injector • Faulty glow system
• Compensation of individual injector not adapted • Low compression pressure
• No rail pressure sensor signal • Poor tightening of injector clamp
• Wiring harness open or poor connection • Faulty high pressure fuel pump
• Air ingress in the low pressure fuel circuit • Injector not adapted
• Bad fuel quality or water ingress in fuel • Carbon deposit on the injector (sealed holes)
• Clogged fuel filter • Injector needle stuck (injection possible over a certain
• Clogged air filter pressure)
• Clogged injector return line • Injector jammed open
• Leakage in high pressure fuel circuit • Electric EGR control valve blocked open
(Symptom 5) Idle Speed Too High Or Too Low

Possible Cause
• Incorrect state of the electrical pack devices • Electric EGR control valve blocked open
• Faulty alternator or voltage regulator • Faulty accelerator pedal
(Symptom 6) Blue, White, Or Black Smokes

Possible Cause
• Oil suction (engine racing)
• Poor tightening of injector clamp
med
• Poor injector O-ring, no O-ring or two O-ring installed
• Injector not adapted
med
• Oil level too high or too low
• Injector jammed open
• Sealed or damaged catalytic converter
(Symptom 7) Engine Rattling, Noisy Engine

Possible Cause
• Injector not adapted
pressure)
(Symptom 8) Nurst Noise
Possible Cause
med
• Clogged exhaust system
med
(Symptom 9) Untimely Acceleration/deceleration And Engine Racing

Possible Cause
• Blocked accelerator pedal position sensor • Oil suction (engine racing)
• Electric EGR control valve blocked open • No rail pressure sensor signal
• Intermittent faulty fuel line connection • ECM program error or hardware fault
(Symptom 10) Gap When Accelerating And At Re-coupling (Response Time)

Possible Cause
• Leakage in intake system
• Incorrect state of the electrical pack devices
med
• Blocked accelerator pedal position sensor
med
• Damaged turbocharger or leakage in vacuum line
pressure)
(Symptom 11) Engine Stop

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

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

Possible Cause
• Oil suction (engine racing)
(Symptom 15) Excessive Fuel Consumption

Possible Cause
• Not connected fuel return line at injector • Incorrect state of the electrical pack devices
• Leakage at the Fuel pressure regulator valve • Oil level too high or too low
• Leakage at fuel temperature sensor • Bad fuel quality or water ingress in fuel
• Leakage in high pressure fuel circuit • Sealed or damaged catalytic converter
• Leakage in intake system • Damaged turbocharger
• Clogged air filter • Low compression pressure
• Compensation of individual injector not adapted • Injector not adapted
• Electric EGR control valve blocked open • ECM program error or hardware fault
(Symptom 16) Over Speed Engine When Changing The Gear Box Ratio
Possible Cause
• Blocked accelerator pedal position sensor • Oil suction (engine racing)
• Compensation of individual injector not adapted • Damaged turbocharger
• Intermittent faulty fuel line connection • Injector not adapted
• Clutch not well set (optional) • ECM program error or hardware fault
(Symptom 17) Exhaust Smells

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

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

Possible Cause
• Not connected fuel feed line
• Leakage at fuel temperature sensor
• Leakage at the Fuel pressure regulator valve
(Symptom 20) The Engine Collapses At Take Off

Possible Cause
• Blocked accelerator pedal position sensor • Intermittent faulty fuel line connection
• Incorrect state of the electrical pack devices • No rail pressure sensor signal
• Clogged air filter • Fuel pressure regulator valve contaminated, stuck, jam-
• Inversion of fuel connections (feed ＆ return) med
• Faulty fuel filter • Rail pressure regulator valve contaminated, stuck, jam-
• Bad fuel quality or water ingress in fuel med
• Air ingress in the low pressure fuel circuit • Gasoline in fuel
• Clogged fuel filter • ECM program error or hardware fault
• Sealed or damaged catalytic converter • Faulty accelerator pedal position sensor
(Symptom 21) Engine Does Not Stop
Possible Cause
• Stuck or worn lubrication circuit of turbocharger • Leakage at vacuum hose
• Too much engine oil • ECM program error or hardware fault
(Symptom 22) Different Mechanical Noises

Possible Cause
• Buzzer noise (discharge by the injectors) • Leakage in intake system
• Broken clip (vibrations, resonance, noises) • Poor tightening of injector clamp
• Incorrect state of the electrical pack devices • Damaged turbocharger
• Sealed or damaged catalytic converter • Poor valve clearance
Engine Control System-Electronic
General Information Checking Procedure (Self-Diagnosis)
If the disel control system components (sensors, ECM,
injector, etc.) fail, interruption to the fuel supply or failure
to supply the proper amount of fuel for variousengine • When attery voltage is excessively low, diagnostic
operating conditions will result. The following situations trouble codes can not be read. Be sure to check the
may be encountered battery for voltage and the charging system before
1. Engine is hard to start or does not start at all. starting the test
2. Nstable idle. • Diagnosis memory is erased if the battery or the ECM
3. Poor driveability. connector is disconnected. Do not disconnect the
If any of the above conditions are noted, first perform a battery before the diagnostic trouble codes are
routine diagnosis that includes basic engine checks completely read and recorded.
(ignition system malfunction, incorrectengine adjustment, Inspection Procedure (Using Generic Scan
etc.). Then, inspect the disel contorl system components Tool)
with a scan tool. 1. Turn OFF the ignition switch.
2. Connect the scan tool to the data link connector on
the lower crash pad.
• Before removing or installing any part, read the
diagnostic trouble codesand then disconnect the
battery negative (-) terminal.
• Before disconnecting the cable from battery terminal,
turn the ignition switch to OFF. Removal or
connection of the battery cable during engine
operationor while the ignition switch is ON could
cause damage to the ECM.
• Wchecking the generator for the charging state, do
not disconnect the battery '+' terminal to prevent the
ECM from damage due to the voltage.
• Wcharging the battery with the external charger,
disconnect the vehicleside battery terminals to
prevent damage to the ECM. AWJF300D
Self-Diagnosis 3. Turn ON the ignition switch.
The ECM monitors the input/output signals (some signals 4. Use the scan tool to check the diagnostic trouble
at all times and theothers under specified conditions). code.
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
Data Link connector. The diagnosis results can be read 6. Erase the diagnostic trouble code.
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.
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 negative
terminal (-) for 15 seconds or more, and the diagnosis
memory will be erased.
Components
1. ECM (Engine Control Module) 2. Mass Air Flow Sensor (MAFS)
SUDFL15-0001D SUDFL15-0002D
3. Boost Pressure Sensor (BPS) 5. Intake Air Temperature Sensor (IATS) #2

4. Rail Pressure Sensor (RPS)
SUDFL15-0003D
SEUFL15-0071E
6. Crankshaft Position Sensor (CKPS) 7. Camshaft Position Sensor (CMPS)
8. Engine Coolant Temperature
SEUFL15-0073E SEUFL15-0074E
9. Exhaust Gas Temperature Sensor #3 10. Differential Pressure Sensor (DPS) [with DPF]
11. Exhaust Gas Temperature Sensor #4, 5, 6
SEUFL15-0003D SEUFL15-0076E
12. Fuel Temperature Sensor (FTS) 13. Rail Pressure Regulator Valve
14. Injector 15. Electric EGR Control Valve (EEGR)
16. Electric VGT Actuator 17. Air Cotrol Valve (ACV)
18. Glow Unit
SUDFL15-0004D
Engine Control Unit(ECU)
Terminal function
1. ECM Harness connector
SEUFL15-0002E
2. ECM Terminal function

Pin Pin description Vehicle state Signal type Reference level Test result
A1 Injector high side CYL.NO.2 Idle Pulse Battery Voltage~52.5V 2.58V
High:Battery Voltage~52.5V
A2 Injector low side CYL.NO.2 Idle Pulse 2.58V
Low:Max. 1.0V
A3 Water in fuel sensor IG-ON V <5.4 0.3
A4 - - - - -
Vp_p:Min 1.0 V
A5 Crank position sensor signal Idle Sine Wave -
Max. ５V
High:Battery voltage-0.8V(M-
A6 TDC Sensor signal Idle Pulse ax. 24V) -
Low:Max 0.5V
A7 Oil level switch IG-ON V <4.6 0
Neutral Vbatt 12.3
A8 Neutral switch V
Gear engaged Max 0.3V 0
A9 - - - - -
A10 - - - - -
A11 Glow plug output signal IG-ON Duty 6.11%
A12 - - - - -
IG-ON Vbatt 12.22
A13 Electrical fuel pump relay V
Idle Max 0.3V 0.16
IG-ON 0.45
A14 Electric VGT actuator V
Idle 2.61
A15 Chip heating IG-ON ㎲ 535.36
IG-ON V - 3.12
A16 A/con comp relay #2
Idle 3.61
A17 - - - - -
A18 Non-smart ACV motor - IG-ON Duty Idle : 2.24V
A19 Non-smart ACV motor + IG-ON Duty idle : 0.1V
A20 - - - - -
A21 - - - - -
A22 Injector high side CYL.NO.3 Idle Pulse Battery Voltage~52.5V 2.58V
A23 Injector low side CYL.NO.3 Idle Pulse 2.58V
Low:Max. 1.0V
A24 - - - - -
IG-ON 11.89
A25 Head lamp dim input V
Idle 13.93
Vp_p:Min 1.0 V
A26 Crank position sensor ground Idle Sine Wave -
Max. 360V
A27 TDC sensor ground IG-ON V <0.25 0
A28 - - - - -
Exhaust gas temp. sensor grou-
A29 IG-ON V <0.25 0
nd ･･･ t3
A30 IG-ON V <0.25 0
nd ･･･ t6
A31 IG-ON V <0.25 0
nd ･･･ t5
A32 IG-ON V <0.25 0
nd ･･･ t4
A33 EGR gas temp. sensor ground IG-ON V <0.25 0
16.7~25Hz
A34 Reference frequency Idle Pulse High:Vcc 19.08Hz/52ms
Low:Max0.7
1.2~14kHz
A35 Air flow sensor signal IG-ON Pulse High:Vcc -
Low:Max0.7V
IG-ON 11.99
A36 Electric VGT feedback signal V
Idle 14.2
A37 Glow time feedback IG-ON V 4.9~5.1 4.99
A38 Start switch input signal IG-ON V <2.9 0
A/T or M/T auto recognition inp- IG-ON 11.87

A39 V
ut Idle 14.19
A40 - - - - -
A41 EGR cooling bypass Idle V Battery Voltage 14.83
EGR motor plus Engine High:Battery Voltage
A42 Running Pulse Low:Max. 1.0V -
Frequency:1,000Hz
A43 Injector high side CYL.NO.1 Idle Pulse Battery Voltage~52.5V 2.58
A44 Injector low side CYL.NO.1 Idle Pulse 2.58
Low:Max. 1.0V
A45 - - - - -
A46 - - - - -
A47 Crank position sensor supply IG-ON V 4.9~5.1 5
A48 TDC Sensors supply IG-ON V 4.9~5.1 5
A49 - - - - -
Exhaust gas temp. sensor sign-
A50 IG-ON V 0.36~5.0 5
al ･･･ t3
A51 IG-ON V 0.672~2.29 0.90(25.3℃)
al ･･･ t6
A52 IG-ON V 0.672~2.29 0.91(28.2℃)
al ･･･ t5
A53 IG-ON V 0.672~2.29 0.91(26.9℃)
al ･･･ t4
A54 EGR gas temp. sensor signal IG-ON V 0.63~2.39 0.9(24.2℃)
A55 Rail press. sensor supply IG-ON V 4.9~5.1 5
A56 - - - - -
A57 Differential press. sensor supply IG-ON V 4.9~5.1 5
A58 Boost pressure sensor supply IG-ON V 4.9~5.1 5
A59 - - - - -
A60 EGR position feedback supply IG-ON V 4.9~5.1 5
Non-smart acv position feedbac-
A61 IG-ON V 4.9~5.1 5
k supply
A62 - - - - -
EGR motor (-) High:Battery Voltage
A63 Active Pulse Low:Max. 1.0V -
Frequency:1,000Hz
A64 Injector high side CYL.NO.4 Idle Pulse Battery Voltage~52.5V 2.58
A65 Injector low side CYL.NO.4 Idle Pulse 2.58
Low:Max. 1.0V
A66 Pressure regulator valve(+) Idle Pulse Battery Voltage~52.5V 2.58
A67 Pressure regulator valve(-) Idle Pulse 2.58
Low:Max. 1.0V
A68 Lambda sensor virtual ground - - - -
A69 Lambda sensor voltage nernst - - - -
A70 Lambda sensor current adjust - - - -
A71 Lambda sensor current pump - - - -
A72 Water temperature signal IG-ON V 0.3~4.88 2.59(31℃)
A73 Air temperature sensor signal IG-ON V 0.16~4.81 2.25(28℃)
A74 Fuel temp. sensor signal IG-ON V 0.16~4.81 2.0(27℃)
A75 Intake temp sensor signal IG-ON V 0.16~4.81 2.6(21℃)
A76 Rail press. sensor signal IG-ON V 0.5~4.5 0.5(0.7MPa)
A77 Air temp. signal(NTC) Idle V 0.17~4.79 2.0(32℃)
A78 Differential press. sensor signal Idle V 0.95~4.725 1.04
1.09(101.62k-
A79 Boost pressure sensor signal IG-ON V 0.5~4.5
Pa)
A80 - - - - -
A81 EGR position feedback signal IG-ON V 0.6~4.3 3.88/-0.04mm
A82 IG-ON V 0.4~4.6 4.28
k signal
A83 - - - - -
A84 - - - - -
A85 Inlet metering valve(-) (PWM) IG-ON V <0.1 0
A86 Inlet metering valve(+) (PWM) IG-ON V <0.1 0
A87 Lambda sensor heating 1 - - - -
A88 - - - - -
A89 - - - - -
A90 - - - - -
A91 - - - - -
A92 - - - - -
A93 Coolant temp. sensor ground IG-ON V <0.25 0
A94 - - - - -
A95 Fuel temp. sensor ground IG-ON V <0.25 0
A96 Intake temp sensor ground IG-ON V <0.25 0
A97 Rail press. sensor ground IG-ON V <0.25 0
A98 Air flow sensor ground IG-ON V <0.25 0
Differential press. sensor groun-
A99 IG-ON V <0.25 0
d
A100 Boost pressure sensor ground IG-ON V <0.25 0
A101 - - - - -
A102 EGR position feedback ground IG-ON V <0.25 0
A103 IG-ON V <0.25 0
k ground
A104 - - - - -
A105 - - - - -
BB BTBT I-NGO V >.>. 0
B2 BAT- IG-ON V >0.2 0
B3 BAT+ IG-ON V 10~16 12.44
B4 BAT- IG-ON V >0.2 0
B5 BAT+ IG-ON V 10~16 12.44
B6 BAT+ IG-ON V 10~16 12.44
on Vbatt
B7 Remote PTO idle up switch IG-ON V
off 0.01
on Vbatt
B8 PTO switch IG-ON V
off 0.01
B9 - - - - -
B10 - - - - -
B11 - - - - -
0.7/0%, 4.0/10
B12 Accel. pedal signal 1 IG-ON V 0.7~4.4
0%
B13 Cruise/speed limit control signal - - - -
B14 PTO accel sensor signal - - - -
0.3/0%, 2.0/10
B15 Accel. pedal signal 2 IG-ON V 0.475~2.35
0%
B16 - - - - -
A/con pressure transducer sign-
B17 IG-ON V 0.375~4.6 1.1/0.4MPa
al
B18 Break press. sensor signal IG-ON V 0.24~4.86 -
B19 Immobilizer interface Idle V 13.29
Open Vbatt 13.05
B20 Middle door switch V
Close <0.25 0
B21 Start relay low side IG-ON V 3.07
IG-ON V <0.25 0
B22 Malfunction indication lamp
Idle Vbatt 13.61
B23 Start relay high side IG-ON V 8.2~14.2 12.2
B24 - - - - -
B25 - - - - -
Active
B26 Wiper motor input V - 0.01
Stop
B27 Vehicle speed signal IG-ON V 0.02
Vbatt
A/C On 12
B28 A/CON on signal V <0.25
A/C Off <0.25 0.02
B29 Accel. pedal ground 1 IG-ON V >0.25 0
Cruise/speed limit control grou-
B30 IG-ON V >0.25 0
nd
B31 PTO accel sensor ground IG-ON V >0.25 0
B32 Accel. pedal ground 2 IG-ON V >0.25 0
B33 - - - - -
A/con pressure transducer grou-
B34 IG-ON V >0.25 0
nd
B35 Break press. sensor ground IG-ON V >0.25 0
B36 Immobilizer ecu smatra ground IG-ON V >0.25 0
B37 Engine speed signal - - - -
B38 - - - - -
B39 - - - - -
B40 Cruise set lamp IG-ON V 2.62
B41 Terminal 15 IG-ON/OFF V 10~16/<1.3 12/0
B42 Brake switch signal IG-ON(on/off) V 10~16/<1.1 12/0
B43 Out cab PTO IG-ON V 0
B44 - - - - -
B45 Max blower switch input - - - -
B46 Accel. sensor supply 1 IG-ON V 4.9~5.1 5
Cruise/speed limit control suppl-
B47 - - - -
y
B48 PTO accel sensor supply - - - -
B49 Accel. sensor supply 2 IG-ON V 4.9~5.1 5
B50 - - - - -
A/CON pressure transducer su-
B51 IG-ON V 4.9~5.1 5
pply
B52 Break press. sensor supply IG-ON V 4.9~5.1 5
B53 - - - - -
B54 Fan low relay IG-ON V 10~16 12.3
B55 - - - - -
B56 Glow time ind. lamp - - - -
B57 ISG inhibit lamp - - - -
termination resistor for high spe-
B58 - - - -
ed CAN2 low
RECESSIVE 2.0~3.0V
B59 High speed CAN2 low Pulse
DOMINANT 0.5~2.25V -
RECESSIVE 2.0~3.0V
B60 High speed CAN1 low Pulse
B61 - - - - -
Lin communication(battery level, RECESSIVE 2.0~3.0V

B62 Pulse
alternator) DOMINANT 0.5~2.25V -
RECESSIVE 2.0~3.0V
B63 Low speed can low Pulse
B64 PTO idle up sw IG-ON(on/off) V <2.9/10~16 0.3/12.2
B65 Thermo switch - - - -
B66 Redundant brake switch IG-ON(on/off) V <2.9/10~16 0.3/12.2
B67 PTO idle down switch IG-ON(on/off) V <2.9/10~16 0.3/12.2
B68 Clutch switch IG-ON(on/off) V 10~16/<4.6 12.3/0
B69 Body type detection switch - - - -
B70 System power relay
B71 - - - - -
B72 Fuel consumption signal IG-ON V - 2.64
B73 Fan high relay IG-ON V 10~16 12.3
B74 Auxiliary heating relay IG-ON V 10~16 12.15
Termination resistor for high sp-
B75 - - - -
eed CAN2 high
RECESSIVE 2.0~3.0V
B76 High speed CAN2 high Pulse
RECESSIVE 2.0~3.0V
B77 High speed CAN1 high Pulse
B78 - - - - -
B79 - - - - -
RECESSIVE Pulse 2.0~3.0V
B80 Low speed can high
B81 PTO emergency IG-ON(on/off) V 10~16/<2.9 12.2/0.3
B82 Blower switch input IG-ON(on/off) V <2.9/10~16 0.3/12.2
B83 ISG inhibit switch
B84 Remote pto idle down switch IG-ON(on/off) V 10~16/<2.9 12.1/0.3
B85 Active ECO switch IG-ON(on/off) V <2.9/10~16 0.3/11.96
B86 - - - - -
B87 System power relay IG-ON V <1.25 0.93
B88 Permanent BAT+ IG-OFF DC 10~16 12.44
B89 Immobilizer ind. lamp IG-ON V 12.3
B90 A/CON comp relay IG-ON V 10~16 12.23
B91 Cruise main lamp - - - -
Replacement
After replacing ECM, MUST input the injector specific

data (20 digits) of each cylinder into a new ECM with
scan tool.
1. Turn ignition switch OFF and disconnect the negative

(-) battery cable.
2. Remove the harness mounting bolt (C) and
disconnect the ECM connector (A).
3. Unscrew the ECM mounting bolt (B).
4. Remove the ECM.
SUDFL15-0005D
5. Install a new ECM.

ECM installation nut/bolt:
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
6. Connect the negative(-) battery cable.
7. Perform "ECM Change" procedure [With DPF]. 5) Select "Vehicle S/W Management".
1) Turn ignition switch OFF. 6) Select "Component Change Routine".
2) Connect a GDS Data Link Connector (DLC). 7) Select "ECU Change".
3) Turn ignition switch ON. 8) Input the mileage in odometer.
4) Select "Vehicle, Model year, Engine, System".
SYNF10450L
9) Confirm the "Complete" message and then turn
ignition switch OFF.
SYNF10451L
10) Wait for more than 10 seconds, and then turn

ignition switch ON.
8. Perform "Injector Specific Data Input" procedure
(Refer to "Injector" in this group).
ECM Problem Inspection Procedure
1. TEST ECM GROUND CIRCUIT: Measure resistance
between ECM and chassis ground using the backside
of ECM harness connector as ECM side check point.
If the problem is found, repair it.
2. TEST ECM CONNECTOR: Disconnect the ECM
connector and visually check the ground terminals on
ECM side and harness side for bent pins or poor
contact contact pressure. If the problem is found,
repair it.
3. If problem is not found in Step 1 and 2, the ECM
could be faulty. If so, replace the ECM with a new
one, and then check the vehicle again. If the vehicle
operates normally then the problem was likely with
the ECM.
4. RE-TEST THE ORIGINAL ECM : Install the original
ECM (may be broken) into a known-good vehicle and
check the vehicle. If the problem occurs again,
replace the original ECM with a new one. If problem
does not occur, this is intermittent problem (Refer to
INTERMITTENT PROBLEM PROCEDURE in BASIC
INSPECTION PROCEDURE)
Electronic Unit Injector(EUI)
Description Specification
The start of injection and the injected fuel quantity are Items Specification
adjusted by electrically triggered injectors. These
Coil Resistance (kΩ) 0.42 ~ 0.52 [20°C(68°F)]
injectors supersede the nozzle-and-holder assembly
(nozzle and nozzle-holder). Similar to the already
existing nozzle-holder assemblies in direct-injection (DI)
diesel engines, clamps are preferably used for installing
the injectors in the cylinder head. This means that the
Common Rail injectors can be installed in already
existing DI diesel engines without major modifications to
the cylinder head.
SEUFL15-0004E
1. Injector
2. Fuel inlet
3. Return nipple
4. Gasket
5. Clamp
6. Clamp bolt
Removal 4. Remove the high pressure fuel pipe after remove the
flange nut.
• Common Rail Fuel Injection System operates with

extremely high pressure [approximately 2000 bar
(200 MPa / 29.007 psi)], so never perform any work
on injection system with engine running or within 30
seconds after the engine stops.
• Keep clean the parts and the working area.
• Pay attention to a foreign substance.
• Just before installing injector, tube or hose, remove
the protect-cap attached to them.
• Do not remove injector except for special cases.
• When installing Injector
- Wash the contact area of the injector and replace SEUFL15-0005E
gasket with a new one.
5. Unscrew the clamp tightening bolt (A) and pull the
- To prevent damage caused by shock, vertically injector upward.
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.
- Do not grasp the high pressure pipe on high
pressure pump.

(-) battery cable.
2. Disconnect the injector connector.
3. Disconnect the retun hose from the injectors.
STQF11120L
If the injector adheres to the cylinder head, use the

special Service Tool [SST No. : 09351-4A300,
09331-59100]
Installation
1. Installation is reverse of removal.
After removing or replacing fuel system below, must

perform fuel leakage test procedure. (Refer to Fuel
Delivery System - "Fuel Leakage Test")
- Fuel tank
- Fuel sender
- Fuel filter
- High pressure fuel pump
- Injector
SPUFL2310D - Common rail
- Low pressure fuel line
When installing the injector, MUST REPLACE the

gasket
SEUFL15-0050D
SUDFL13-0046E
When installing the high pressure fuel pipe, apply the

specified tightening torques with the special service
tool (SST No.: 09314-3V100).
2. Injector clamp bolt tightening method (angle method).
1) Fasten with19.6Nm (2.0kgf.m, 14.5 ib.ft), and
unfasten completely.
2) Tighten with 7.8N.m (0.8kgf.m, 5.8 ib.ft) + 60˚.
Replacement

extremely high pressure [approximately 1,800 bar
(180 MPa / 26,106 psi)], so never perform any work
on injection system with engine running or within 30
seconds after the engine stops.
• Keep cleanly the parts and the working area.
the protect-cap attached on them.
• Do not remove injector except for special case.
- Wash the contact are of the injector and replace
gasket with a new one.
- To protect damage caused by shock, vertically
After replacing injector, MUST input the injector specific

data (20 digits) of each cylinder into ECM with scan tool.
1. Remove the injector (Refer to "Removal" procedure).
2. Install the injector (Refer to "Installation" procedure).
3. Perform "Injector Specific Data Input" procedure
(Refer to "Injector Specific Data Input" procedure).
Injector Specific Data Input 1. Turn ignition switch OFF.
2. Connect a GDS to Data Link Connector (DLC).
3. Turn ignition switch ON.
After replacing injector, MUST input the injector specific 4. Select "Vehicle, Model year, Engine, System".
data (30 characters) of each cylinder into ECU with scan 5. Select "Vehicle S/W Management".
tool.
6. Select "Injector Data Input".
7. Perform the procedure in accordance with the
message.
SEUFL15-0007E
SEUFL15-0060E
SEUFL15-0061E
SEUFL15-0062E
SEUFL15-0063E
SEUFL15-0064E
SEUFL15-0065E
8. After selecting "OK" on the "Test competed"

message, turn ignition switch OFF.
9. In about 10 seconds, turn ignition switch ON and
recheck the injector specific data memorized in the
ECU.
In case of failure, input the injector specific data (30

characters) into ECU again.
Mass Air Flow Sensor
Description
MAFS uses a hot-film type sensing element to measure
the mass of intake air entering the engine, and send the
signal to ECM.
A large amount of intake air represents acceleration or
high load conditions while a small amount of intake air
represents deceleration or idle.
The ECM uses this information to control the EGR
solenoid valve and correct the fuel amount.
SPBF29117L
Specification
* Air mass characteristic curve at ambient
temperature (20℃±10K)
10 504.27 ±3 503.03 505.53
15 484.34 ±2 483.22 485.47
75 365.46 ±2 363.75 367.20
160 295.19 ±2 293.19 297.22
310 223.01 ±2 220.66 225.41
640 127.68 ±2 124.81 130.59
800 94.07 ±3 89.49 98.75
* Air mass characteristic curve at 80℃

10 504.27 ±5 502.20 506.36
75 365.46 ±4 362.07 368.97
160 295.19 ±4 291.22 299.28
310 223.01 ±4 218.33 227.83
Inspection Installation
1. Check the MAFS visually.
- Mounting direction correct.
- Any contamination, corrosion or damage on • Install the component with the specified torques.
connector. • Note that internal damage may occur when the
- Air cleaner's clogging or wet. component is dropped. In this case, use it after
- MAFS cylinder's deforming or blocking by any inspecting.
foreign material.
2. Check any leakage on intake system and intercooler
system. • Be careful not to damage the sensing element and
Removal the honey cell.
(-) battery cable. 1. Installation is reverse of removal.
2. Disconnect the mass air flow sensor connector (A)
Mass air flow sensor installation bolt: 3.9 ~ 5.9 N.m
and the installation clamp (B). (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
Mass air flow sensor clamp installation bolt: 7.8 ~
11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
SUDFL15-0006D
3. Remove the mass air flow sensor after removing the

installation bolts.
Booster Pressure Sensor
Boost pressure sensor (BPS) is installed on surge tank to Pressure[kPa (kg/cm² / psi)] Output Voltage (V)
measure the absolute intake manifold pressure. BPS
50 (0.51 / 7.25) 0.5
input voltage is changed in proportion with absolute
pressure in manifold. This information is used to control 100 (1.02 / 14.50) 1.00 ~ 1.14
Turbocharger by ECM.
300 (3.06 / 43.51) 3.29 ~ 3.43
400 (4.08 / 58.02) 4.41 ~ 4.59
SBHFL8133D
STQF11410L
Removal Installation
1. Turn the ignition switch OFF and disconnect the
battery (-) cable.
2. Remove the engine room cover. • Install the component with the specified torques.
3. Disconnect the boost pressure sensor connector (A). • Note that internal damage may occur when the
4. Removal the boost pressure sensor (B) after component is dropped. In this case, use it after
removing the installation bolts. inspecting.

Boost pressure sensor installation bolt : 9.8 ~ 11.7
N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
SPUFL2161D
Intake Air Temperature Sensor
Description
Intake Air Temperature Sensor (IATS) uses a Negative
Temperature Characteristics (NTC) thermistor and
senses intake air temperature. Two intake air
temperature sensors are installed in this engine.
IATS #1 in Mass Air Flow Sensor (MAFS) and IATS #2
installed at intercooler pipe are located in front of and
behind turbo-charger respectively. IATS #1 senses air
temperature entering turbo-charger and the other (IATS
#2) senses air temperature coming out from the
turbo-charger.
Comparing these air temperature values from both
sensors, it is possible to sense the intake air temperature
in a more accurate manner. ECU uses these air SUDFL15-0007D
temperature signals to perform EGR control correction
and fuel injection quantity correction. Specification
IATS #1 in MAFS
Temperature [℃(℉)] Resistance(㏀)
-40(-40) 35.14 ~ 43.76
-20(-4) 12.66 ~ 15.12
0(32) 5.12 ~ 5.89
20(68) 2.29 ~ 2.55
40(104) 1.10 ~ 1.24
60(140) 0.57 ~ 0.65
80(176) 0.31 ~ 0.37
IATS #2
STQFL2010D Temperature [℃(℉)] Resistance(㏀)
-40(-40) 40.93 ~ 48.35
-20(-4) 13.89 ~ 16.03
0(32) 5.38 ~ 6.09
20(68) 2.31 ~ 2.57
40(104) 1.08 ~ 1.21
60(140) 0.54 ~ 0.62
80(176) 0.29 ~ 0.34
Inspection [IATS #2]
1. Turn ignition switch OFF. 1. Turn the ignition switch OFF and disconnect the
2. Disconnect the IATS #1 (for MAFS) or IATS #2 battery (-) cable.
connector. 2. Lift the vehicle.
3. Measure resistance between IATS signal terminal 3. Disconnect the intake air temperature sensor #2
and sensor ground terminal. connector (A),
4. Check that the resistance is within the specification. 4. Remove the intake air temperature sensor #2 (B).
Specification: Refer to Specification section.
Removal
[IATS #1]
(-) battery cable.
2. Disconnect the intake air temperature sensor #1
connector (A) and the installation clamp (B).
SUDFL15-0008D
Installation
• Install the component with the specified torques.

• Note that internal damage may occur when the
component is dropped. In this case, use it after
inspecting.
SUDFL15-0006D
• Be careful not to damage the sensing element and

the honey cell.

Intake air temperature sensor #1 installation bolt:
3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
Intake air temperature sensor #1 clamp installation
bolt: 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
Intake air temperature sensor #2 installation: 19.6 ~
29.4 N.m (2.0 ~ 3.0 kgf.m, 14.5 ~ 21.7 lb-ft)
Coolant Temperature Sensor
Engine Coolant Temperature Sensor (ECTS) is located in Temperature [℃(℉)] Resistance(㏀)
the engine coolant passage of the cylinder head for
-40(-40) 48.14
detecting the engine coolant temperature. The ECTS
uses a thermistor whose resistance changes with the -20(-4) 14.13 ~ 16.83
temperature. The electrical resistance of the ECTS
0(32) 5.79
decreases as the temperature increases, and increases
as the temperature decreases. The reference 5V in the 20(68) 2.31 ~ 2.59
ECM is supplied to the ECTS via a resistor in the ECM. 40(104) 1.15
That is, the resistor in the ECM and the thermistor in the
60(140) 0.59
ECTS are connected in series. When the resistance
value of the thermistor in the ECTS changes according to 80(176) 0.32
the engine coolant temperature, the output voltage also
changes. During cold engine operation the ECM Inspection
increases the fuel injection duration and controls the 1. Turn ignition switch OFF.
ignition timing using the information of engine coolant 2. Disconnect the engine coolant temperature sensor
temperature to avoid engine stalling and improve connector.
drivability. 3. Remove the sensor.
4. After immersing the thermistor of the sensor into
engine coolant, measure resistance between ECTS
signal terminal and ground terminal.
EGRF241A
EFNF541A
5. Check that the resistance is within the specification.

battery negative (-) cable.
2. Disconnect the engine coolant temperature sensor • Install the component with the specified torques.
connector (A).
• Note that internal damage may occur when the
component is dropped. In this case, use it after
inspecting.
• Apply the engine coolant to the O-ring.

• Be careful not to damage the O-ring.
• Insert the sensor in the installation hole and be

careful not to damage when installation.
• Be careful not to damage the sensor housing and the
connector.
SPUFL2033D • Supplement the engine coolant (Refer to "Cooling
3. Remove the engine coolant temperature sensor (A). System" in EM group).

Engine Coolant Temperature Sensor installation
:19.6 ~ 39.2 N.m (2.0 ~ 4.0 kgf.m, 14.4 ~ 28.9 lb-ft)
STQFL2050D
• Note that engine coolant may be flowed out from

the water temperature control assembly when
removing the sensor.
Camshaft Position Sensor
Camshaft Position Sensor (CMPS) a hall sensor and Level Output Pulse (V)
detects the camshaft position by using a hall element. It
High 5
is related with Crankshaft Position Sensor (CKPS) and
detects the piston position of the each cylinder which the Low 0
CKPS can't detect. The CMPS are installed on engine
head cover and uses a target wheel installed on the Items Specification
camshaft. This sensor has a hall-effect IC which output Air Gap [mm (in.)] 0.2 ~ 2.0 (0.008 ~ 0.079)
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.
SUDFL13-0047E
• DON’T remove the camshaft position sensor during • Install the component with the specified torques.
engine running or right after engine stops, or a scald • Note that internal damage may occur when the
by the flowed out engine oil may occur. component is dropped. In this case, use it after
inspecting.
battery (-) cable.
2. Disconnect the camshaft position sensor connector • Apply the engine coolant to the O-ring.
(A).
• Be careful not to damage the O-ring.
• Insert the sensor in the installation hole and be

careful not to damage when installation.
• Be careful not to damage the sensor housing and the
connector.

Camshaft position sensor installation bolt: 7.8 ~ 8.8
N.m (0.8 ~ 0.9 kgf.m, 5.8 ~ 6.5 lb-ft)
SPUFL2151D
3. Remove the camshaft position sensor.

Crankshaft Position Sensor
Piston position on combustion chamber is the substantial Items Specification
to define the starting of injection timing. All engine
Coil Resistance (Ω) 774 ~ 946 [20℃(68℉)]
pistons are connected to crankshaft by connecting rod.
Sensor on crankshaft can supply the informations Output Voltage (V) 0~5
concerning all piston positions, revolution speed is
defined by revolution perminute of crankshaft. Prior input
variable is determined at ECM by using signal induced
from crankshaft position sensor.
SEUFL15-0057E
• DON’T remove the crankshaft position sensor during • Install the component with the specified torques.
engine running or right after engine stops, or a scald • Note that internal damage may occur when the
by the flowed out engine oil may occur. component is dropped. In this case, use it after
inspecting.
battery (-) cable.
2. Disconnect the crankshaft position sensor connector • Insert the sensor in the installation hole and be
(A). careful not to damage when installation.
3. Remove the crankshaft position sensor (C) after • Be careful not to damage the sensor housing and the
removing the installation bolt (B). connector.

Crankshaft position sensor installation bolt: 6.9 ~
10.8 N.m (0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lb-ft)
SPUFL2441D
Acceleration Position Sensor
On electronic injection systems, there is no longer a load Output Voltage (V) [Vref=5V]
lever that mechanically controls the fuelling. The flow is Test Condition
APS 1 APS 2
caculated by the ECM depending on a number of
parameters, including pedal position, which is measured Idle 0.7 ~ 0.8 0.325 ~ 0.425
using a potentiometer. The pedal sensor has two
Fully depressed 3.95 ~ 4.25 1.9 ~ 2.2
potentio-meters whoses slides are mechanically solid.
The two potentiometers are supplied from distinct and
different power sources so there is built in redundancy of
information giving reliable driver's request information. A
voltage is generated across the potentiometer in the
acceleration position sensor as a function of the
accelerator-pedal setting. Using a peogrammed
characteristic curve, the pedal's position is then
calculated from this voltage.
SUDFL68002L
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.
SPUFL2470D 4. Measure resistance between voltage supply terminal
and ground terminal of APS2.
1. Turn ignition switch OFF and disconnect the negative 1. Installation is reverse of removal.
(-) battery cable.
Accelerator pedal module installation bolts (B): 7.8
2. Disconnect the accelerator pedal position sensor ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
connector (A). Accelerator pedal full stroke : 42.6 ~ 48.6 mm (1.67 ~
3. Remove the accelerator pedal assembly from the 1.91 in)
vehicle after unscrewing the mounting bolts (B).
SPUFL2471D
Rail Pressure Sensor
Rail Pressure Sensor (RPS) is installed at the end of the Rail pressure [ Output V -
common rail and measures the instantaneous fuel Test Condition
bar (MPa / psi)] oltage (V)
pressure in the common rail by using its diaphragm. Its
Idle 322 (32.2 / 4,670) Approx. 0.82
sensing element (semiconductor device) mounted on the
diaphragm converts the fuel pressure to an electric Fully depressed 2,000 (200 / 29,007) Approx. 2.81
signal.
SEUFL15-0013E
SEUFL15-0012E
Fuel Temperature Sensor
Fuel Temperature Sensor(FTS) is installed in on the high Temperature [°C(°F)] Resistance(kΩ)
pressure fuel pump and senses the termperature of fuel
-30(-22) 25.4
supplied to high pressure pump. Fuel temperature is
limmited to protect fuel such as high pressure pump and -20(-4) 15.04
injectors from damages due to rapid deterioration by
-10(14) 9.16
vapor-lock which can occur at high temperature or
destruction of oil membrance. 0(32) 5.74
20(68) 2.45
40(104) 1.15
50(122) 0.811
60(140) 0.584
70(158) 0.428
80(176) 0.318
SPUFL2200D
Inspection
2. Disconnect the fuel temperature sensor connector.
3. Measure resistance between sensor signal terminal
and ground terminal.
Electric EGR Control Valve
The Electric EGR Control Valve is installed in between [Position Sensor]
the EGR cooler and the exhaust line and is a solenoid
Output Vol -
valve. This valve controls EGR (Exhaust Gas
Operating length tate (V) [Po -
Recirculation) amount by the ECM's duty control signal Step Valve state
(mm) wer Supply
depending on engine load and the need of intake air.
= 5.0V]
The Exhaust Gas Recirculation (EGR) system is used to
add the exhaust gas to intake air in order to reduce an 1 Closed 0.4 ~ 0.9 4.67
excess of air and the temperature in the combustion 2 1.7 ~ 2.3 4
chamber.
3 Open 3.4 ~ 4.0 3.17
4 5.7 ~ 6.3 2
[Motor]
Item Specifications
Coil Resistance (kΩ) 2.2 ~ 2.6 (20°C)
Input Voltage (V) 13.5 (Battery Voltage)
SPUFL2291L
Inspection
2. Measure voltage between signal (No.4) and ground
(No.5) terminals of the position sensor.
3. Check that the voltage is within the specification.
Specification: Refer to “Specification” section.
Removal 5. Remove the EGR cooler assembly. (Refer to Engine
1. Turn the ignition switch OFF and disconnect the Mechanical System - "Intake Manifold")
battery (-) cable. 6. Remove the installation bolts.
2. Remove the side cover (A). 7. Remove the EEGR valve (A) from EGR cooler
assembly.
SPUFL2360D
3. Disconnect the EEGR valve connector (A). SPUFL2035D
SPUFL2292D
4. Remove the engine room cover.

Installation 2. Turn ignition switch OFF.
3. Connect the GDS to Data Link Connector (DLC).
• Install the component with the specified torques. 5. Select "Vehicle, Model year, Engine, System".
• Note that internal damage may occur when the 6. Select "Vehicle S/W Management".
component is dropped. In this case, use it after 7. Select "Component Change Routine".
inspecting.
8. Select " EGR Valve Change".
1. Installation is reverse of removal. message.
Electric EGR control valve assembly installation
bolt:
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
After replacing the Electric EGR control valve, 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.
SUDFL13-0050E
SCMFL0254L
Replacement 1. Turn ignition switch OFF.
After replacing the Electric EGR control valve, MUST 4. Select "Vehicle, Model year, Engine, System".
perform the "Component Change Routine" procedure. 5. Select "Vehicle S/W Management".
Otherwise trouble related with engine performance or
6. Select "Component Change Routine".
component is over. 7. Select " EGR Valve Change".
message.
SUDFL13-0050E
SCMFL0254L
Air Control Valve
Description
The air control valve is mounted on throttle body of diesel
engine and controls air control valve according to PWM
(Pulse With Modulation) signal from ECM.
It consists of;
- a DC motor which actuates the air control valve,
- a 2-step gear (transmission ratio = 1:40) which is
located in between the DC motor and the air control
valve and increases torque of the DC motor,
- a position sensor which is a hall-effect sensor and
detects status of the air control valve,
- an electric control unit which is a micro-controller and
drives the DC motor by the PWM (Pulse With
SPUFL2260D
Modulation) signal from the ECM,
- and a reset spring which resets the de-energized air Specification
control valve to its open position. Duty (%) Air Control Valve Position
Its function is described below: 5 Open
Normal operation (Partially open in prop-
1. Anti-judder function: When engine is shut off, the 5 ~ 94
ortion to duty value)
ECM can prevent intake air from entering to intake
manifold by fully closing the air control valve for 1.5 94 Closed
seconds (95% ＜ Duty ＜ 97%) to reduce engine 94 ~ 95 Maintaining the last valid position
vibration.
95 ~ 97 Fully closed
2. Intake air control for EGR: When exhaust gas
pressure is equal to or lower than intake air pressure
(for example, when low engine speed), the exhaust
gas would not enter to the intake manifold. At this
time, the ECM partially closes the air control 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 DPF
regeneration: When the Catalyzed Particulate Filter
(DPF) is need to regenerate, the ECM partially closes
the air control 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
DPF.
Inspection
2. Disconnect the throttle control actuator connector.
3. Check that throttle valve is stuck by foreign material.
4. Measure resistance between motor (+) and (-) control
terminals.
5. Measure resistance between voltage supply terminal
and ground terminal of position sensor.
battery (-) cable.
2. Remove the engine room cover. • Install the component with the specified torques.
3. Disconnect the air intake hose (A) after removing the • Note that internal damage may occur when the
clamp from the air control valve. component is dropped. In this case, use it after
inspecting.

Air control valve installation bolt: 7.8 ~ 11.8 N.m (0.8
~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
SPUFL2140D
4. Disconnect the air control valve connector (A).

Remove the installation bolts (B), and then remove
the air control valve (C).
SPUFL2191D
Replacement 1. Turn ignition switch OFF.
After replacing the Air Contorol Valve, MUST perform the 4. Select "Vehicle, Model year, Engine, System".
"ECU Initialization" procedure. 5. Select "Vehicle S/W Management".
Otherwise trouble related with engine performance or 6. Select "ECU Initialization".
7. Select "Throttle Valve (ACV) Change".
component is over.
message.
SYNF10463L
SYNF10464L
Water Sensor
Water Sensor is installed on bottom end of fuel filter and Item Specification
detects presence of water in fuel. When the water level
Warning Level (cc) 40 ~ 60
reaches the lower level of the upper electrode, the
"WATER" lamp in cluster should flash. If the water level
decreases below the lower electrode, the lamp should
turn off.
Without presence of water, the lamp should flash for 2

seconds and turn off afterward in order that this system
has normal condition.
SPUFL2380L
WGT Control Solenoid Valve
Waste Gate Turbo-charger (WGT) is used to charge Items Specification
additional air into combustion chamber for improvement
Coil Resistance (Ω) 14.7 ~ 16.1 [20℃(68℉)]
of combustion efficiency.
ECM controls the WGT with controlling duty of the WGT
control solenoid valve according to engine load.
SPUFL2170L
Circuit Diagram
SUDFL13-0020E
1. Turn the ignition switch OFF and disconnect the 1. Install is reverse of removal.
battery (-) cable.
2. Disconnect the WGT control solenoid valve (A).
3. Disconnect the vacumm hose (B) from the WGT
control solenoid valve.
4. Remove the WGT control solenoid valve (C).
SPUFL2171D
Fuel Delivery System-Electronic
Component Location
SUDFL13-0024E
1. Injector 7. Fuel tank

2. High pressure fuel pump 8. fuel feed hose
3. Common rail 9. Fuel return hose
4. High pressure fuel pipe (Common rail to injector) 10. Fuel senser
5. High pressure fuel pipe (Hihg pressure fuel pump to common rail) 11. fuel tank band
6. Fuel filter
General Safety Information and Caution

extremely high pressure (approximately 1,800bar), so
never perform any work on injection system with
engine running or within 30 seconds after the engine
stops.
- Wash the contact area of the injector and replace
the O-ring with a new one.
- Spread oil on the injector O-ring.
- Do not use again the used high pressure fuel
pipe.
Common Rail Direct Injection(CRDI) System
SPUFL2041L
● Low Pressure Fuel Circuit Bleeding Air In Low Pressure Fuel Circuit
Low Pressure Fuel Pump 1. After removing the air plug (A), press the priming
The low pressure fuel pump is either an electric fuel pump (B) several times until fuel comes out of the
pump with pre-filter, or a gear-type fuel pump. The pump outlet port.
draws the fuel from the fuel tank and continually delivers
the required quantity of fuel in the direction of the high
pressure fuel pump (via fuel filter).
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
SPUFL2370D
The high pressure fuel pump compresses fuel up to
2. Install the air plug (A).
1,800 bar and delivers the compressed fuel to the
common rail.
Common Rail
The common rail is connected with the high pressure fuel After removing or replacing the part below, bleed air
pump and the injectors by the high pressure fuel pipes. in low pressure fuel circuit.
This rail stores the fuel compressed in the high pressure - Fuel Tank
fuel pump. The ECM controls the fuel pressure of the - Fuel Sender
common rail by using the rail pressure sensor and the rail
- Fuel Filter
pressure regulator valve installed on the common rail.
- High Pressure Fuel Pump
Injector
- Low Pressure Fuel Lines
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,
common rails, and injectors. It is a steel tube which can
withstand high frequency generated when the fuel
pressure reaches the maximum pressure or fuel injection
stops.
The differences in length between the common rail and
the individual injectors are compensated for by using
slight or pronounced bends in the individual lengths of
tubing. Nevertheless, the injection lines should be kept
as short as possible.
Fuel Leakage Test
perform fuel leakage test procedure.
- Fuel tank
- Fuel sender
- Fuel filter
- Injector
- Common rail

2. Connect a GDS to Data Link Connector (DLC).
4. Select "Vehicle, Model year, Engine, System".
5. Select "Vehicle S/W Management".
6. Select "Fuel leakage test".
message.
SYNF10473L
SYNF10474L
Fuel Tank
1. Turn ignition switch OFF and disconnect the negative 1. Installation is reverse of removal.
(-) battery cable.
2. Disconnect the fuel sender connector (A).
When install the strap, tightening the lower nut first
and tightening the upper nut later.
SUDFL15-0010D
3. Disconnect the fuel feed hose (B) and the fuel retuen
hose (C). SUDFL68001L
4. Unscrew the fuel tank band installation bolts (A), and
then remove the fuel tank.
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
- Low pressure fuel lines

SPUFL8148L Delivery System - "Fuel Leakage Test")
- Fuel tank
- Fuel sender
- Fuel filter
- Injector
- Common rail
Fuel Sender Assembly
1. Remove the fuel pump. 1. Install is in the reverse order of removal.
(Refer to Fuel Delivery System - "Fuel Pump")
2. Disconnect the fuel sender connector (A).
3. Remove the fuel sender (C) in the direction of the
arrow after releasing the fixing hook (B) with the
common driver.
SDMFL3521D
Fuel Filter
Description
Fuel filter is composed of the main body with heater, the
cartridge filtering impurities out from the fuel and the
water sensor detecting the water accumulated in the fuel
filter.
Components
SEUFL15-0030E
1. Thermo switch 6. Center bolt

2. Filter body 7. O-ring
3. Nipple (from fuel tank) 8. Filter cartridge
4. Nipple (to high pressure pump) 9. Water sensor
5. Heater
Removal 7. Remove the water sensor (A).
(-) battery cable.
2. Clean the fuel filter around.
3. Disconnect the water sensor connector.
4. Disconnect the heater connector.
5. Disconnect the fuel inlet tube quick-connector and
the fuel outlet tube hose.
SEUFL15-0033E
8. Remove the fuel filter cartridge (A) from the fuel filter
assembly.
SEUFL15-0031E
6. Unscrew the fuel filter bracket installation nuts (A),

and then remove the fuel filter assembly (B) from the
vehicle.
SEUFL15-0034E
SEUFL15-0032E
SEUFL15-0035E
Installation 3. Install the fuel filter assembly to the bracket.
1. Install the water sensor by hand. Tightening torque :
Tightening torque : 11.2 ~ 13.8 N.m (1.1 ~ 1.4 kgf.m, 8.0 ~ 10.1 lb-ft)
2.0 ~ 2.5 N.m (20 ~ 25 kgf.m, 1.5 ~ 1.8 lb-ft) 4. Install the fuel tube and re-connect the connectors.
5. Start the engine and check that there is any leak on
the low pressure fuel circuit including the fuel filter.
SEUFL15-0035E
2. Screw the cartridge until the gasket contacts the body

, and then tighten 2/3 turn of the cartridge.
Tightening torque :
10 ~ 14.7 N.m (1.0 ~ 1.5 kgf.m, 7.2 ~ 10.8 lb-ft)
SEUFL15-0035E
• When replacing the fuel filter, must replace the

O-ring.
• Apply engine oil to the O-ring
High Pressure Fuel Pump
Description 1. Turn ignition switch OFF and disconnect the negative
The high pressure fuel pump is the interface between the (-) battery cable.
low pressure and the high pressure stages. Under all 2. Tilt the cap up.
operating conditions, it is responsible for providing 3. Disconnect the fuel temperature sensor connector
adequate high pressure fuel through out the vehicle's (A).
complete service life. This also includes the provision of 4. Disconnect the fuel feed tube quick-connector (B)
extra as needed for rapid starting and for rapid build-up and the fuel return tube quick-connector (C).
of pressure in the rail. The high pressure pump
continually generates the system pressure as needed in
the high-pressure accumulator (common rail). This
means therefore, that in contrast to conventional
systems, the fuel does not have to be specially
compressed for each individual injection process.
Removal

extremely high pressure (approximately 2,000 bar),
so never perform any work on injection system with
engine running or within 30 seconds after the engine
SPUFL2201D
stops.
5. Disconnect the injector return hose (A).
6. Remove the high pressure fuel pipe bracket
installation bolt (B).
7. Remove the high pressure fuel pipe (D) after
loosening the flange nut (C).
SPUFL2210D
8. Disconnect the fuel pressure regulator valve 11.Install the fixing flywheel stopper (A) [SST No:
connector (A). 09231-2B100] on the flywheel.
SPUFL2270D STQFL2043D
9. Remove the timing chain upper-front cover (A). 12.Install the SST (SST No.:09331-4A000) to the under
(Refer to Engine Mechanical System - "Timing cover of the upper timing chain.
Chain")
SPUFL2180D
13.Remove the mounting bolts (A).
AFAF405A
10.Remove the stater. (Refer to Engine Electrical

System - "Stater")
STQF11180L
14.Rotate the bolt (A) of the high pressure fuel pump
remover (SST No.: 09331-4A000) clockwise till the
high pressure fuel pump is pushed out.
SEUFL15-0053E
High pressure fuel pump installation bolts: 19.6 ~

25.5 N.m (2.0 ~ 2.6 kgf.m, 14.5 ~ 18.8 lb-ft)
SPUFL2181D High pressure fuel pipe flange nut installation: 24.5
Installation ~ 28.4 N.m (2.5 ~ 2.9 kgf.m, 18.1 ~ 21.0 lb-ft)
1. Installation is reverse of removal. High pressure fuel pipe bracket installation bolt: 9.8
~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
When installing the high pressure fuel pipe, apply the

specified tightening torques with the special service After removing or replacing the part below, bleed air
tool (Refer to below table). in low pressure fuel circuit (Refer to "BLEEDING AIR
IN LOW PRESSURE FUEL CIRCUIT" in this group).
Item Dimension SST No.
- Fuel Tank
Flange Nut
- Fuel Sender
(High Pressure 17mm (0.669 in) 09314-3V100
Pump Side) - Fuel Filter
- High Pressure Fuel Pump
Flange Nut
(Common Rail 17mm (0.669 in) 09314-3V100 - Low Pressure Fuel Lines
Side)

perform fuel leakage test procedure.
(Refer to Fuel Delivery System - "Fuel Leakage
Test")
- Fuel tank
- Fuel sender
- Fuel filter
- Injector
- Common rail
SEUFL15-0052E
Common Rail Assembly
Description Removal
In order to comply with the wide variety of engine
installation conditions, the common rail with its flow
limiters and the provisions for attaching rail pressure • Common Rail Fuel Injection System operates with
sensor, fuel pressure control valve, and pressure limiter extremely high pressure (approximately 2,000bar), so
valve is available in a number of different designs never perform any work on injection system with
The available common rail volume is permanently filled engine running or within 30 seconds after the engine
with pressurized fuel. The compressibility of the fuel stops.
resulting from the high pressure is utilized to achieve the • Keep cleanly the parts and the working area.
accumulator effect. When fuel leaves the rail for injection,
the pressure variations resulting from the pulsating fuel
supply from the high-pressure pump are compensated • Just before installing injector, tube or hose, remove
for. the protect-cap attached on them.

SEUFL15-0037E
(-) battery cable.
2. Disconnect the rail pressure sensor connector (A)
and rail pressure regulator valve connector (B).
SEUFL15-0038E
3. Remove the high pressure fuel pipes (A). Installation
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)
Flange Nut
(High Pressure Pum - 17mm (0.669in) 09314-3V100
p Side)
SEUFL15-0039E
Flange Nut
4. Remove the high fuel pipe bracket installation bolt. (Common Rail Side)
5. Remove the high fuel pipe flange installation nut.
6. Remove the high pressure fuel pipe.

Delivery System - "Fuel Leakage Test")
- Fuel tank
- Fuel sender
- Fuel filter
- Injector
- Common rail
Common rail installation bolts: 14.7 ~ 21.6 N.m (1.5
~ 2.2 kgf.m, 10.8 ~ 15.9 lb-ft)
SEUFL15-0041E
High pressure fuel pipe flange nut installation: 24.5
7. Remove the intake manifold (Refer to "INTAKE AND ~ 28.4 N.m (2.5 ~ 2.9 kgf.m, 18.1 ~ 20.1 lb-ft)
EXHAUST SYSTEM" in EM group).
8. Remove the common rail after unscrewing the
mounting bolts (A).
SEUFL15-0040E

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General

* Air mass characteristic curve at 80°C

Boost Pressure Sensor (BPS)

Intake Air Temperature Sensor (IATS) #2

Temperature [°C(°F)] Resistance(kΩ) Items Specification

-40(-40) 40.93 ~ 48.35 Coil Resistance (Ω) 774 ~ 946 [20°C(68°F)]

-20(-4) 13.89 ~ 16.03 Output Voltage (V) 0~5

0(32) 5.38 ~ 6.09

-30(-22) 25.4 Items Specification

-20(-4) 15.04 Coil Resistance (Ω) 0.42 ~ 0.52 [20°C(68°F)]

Rail Pressure Sensor (RPS) Air Control Valve

Rail pressure [ Output Output (V) Throttle Valve Position

Electric EGR Control Valve

Warning Level (cc) 40 ~ 60 Output Vol -

Fuel Delivery System

Injector Remover Adaptor Removing the stuck injector

Flywheel Stopper Removing the high pressure fuel pump

DO NOT sprinkle water directly into the engine

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

b. Disconnect connector (B), and measure for

In this case the measured resistance between

2. Continuity Check Method

When measuring for resistance, lightly shake the wire

In [FIG.2.] the measured resistance of line 1 and 3. Voltage Check Method

The measured resistance of line 1 and 2 in this

● Check Short Circuit

The measured resistance between connector (B1)

2. Continuity Check Method (with Chassis Ground)

Lightly shake the wire harness above and below, or

(Symptom 2) Engine Starts With Difficulty Or Starts And Stalls

(Symptom 3) Poor Starting When Hot

(Symptom 5) Idle Speed Too High Or Too Low

(Symptom 6) Blue, White, Or Black Smokes

(Symptom 7) Engine Rattling, Noisy Engine

(Symptom 9) Untimely Acceleration/deceleration And Engine Racing

(Symptom 10) Gap When Accelerating And At Re-coupling (Response Time)

(Symptom 11) Engine Stop

(Symptom 13) Lack Of Power

(Symptom 14) Too Much Power

(Symptom 15) Excessive Fuel Consumption

(Symptom 17) Exhaust Smells

(Symptom 18) Smokes (Black, White, Blue) When Accelerating

(Symptom 19) Fuel Smells

(Symptom 20) The Engine Collapses At Take Off

(Symptom 22) Different Mechanical Noises

When deleting diagnostic trouble code, use scan tool

3. Boost Pressure Sensor (BPS) 5. Intake Air Temperature Sensor (IATS) #2

14. Injector 15. Electric EGR Control Valve (EEGR)

16. Electric VGT Actuator 17. Air Cotrol Valve (ACV)

2. ECM Terminal function

A/T or M/T auto recognition inp- IG-ON 11.87

Lin communication(battery level, RECESSIVE 2.0~3.0V

After replacing ECM, MUST input the injector specific

1. Turn ignition switch OFF and disconnect the negative

5. Install a new ECM.

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

• Common Rail Fuel Injection System operates with

1. Turn ignition switch OFF and disconnect the negative

If the injector adheres to the cylinder head, use the