Hyundai D6ga Fuel System
Hyundai D6ga Fuel System
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ENGINE CONTROL
Tr o u b l e Po s s i b l e c au s es Remed y
Engine will not turn off. Injector wiring short Check injector wiring.
Starti
Starting
ng switch
switch harn
harnes
ess
s is dama
damage
ged.
d. Repla
Replace
ce..
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TROUBLESHOOTING PROCEDURE
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SERVICE PROCEDURE
Sheet Music
Communication with diagnosis equipment is not possible
(Impossilbe
(Impossilbe communication
communication with all systems
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If the
there is fre free play,
lay, check for
for outpu
tput of rail
rail
pres
pressu
sure
re/r
/rai
aill pres
pressu
sure
re sens
sensor
or usin
using
g Hi-s
Hi-sca
can
n or
oscilloscope.
6. Check
Check for wiring
wiring related
related to the
the output
output of rail press
pressure
ure
sensor.
Master
Chec
Checkk your
for
for volt semester
voltag
age
e betw
betwee
een with
n each
each term
termin Scribd
inal
al of rail
rail
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pressure sensor in the ECM side and terminal (-) of
battery. Useful Not useful
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Check
Check wire between
between rail pressu
pressure
re sensor
sensor and ECM
for continuity(resistance).
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SDGFL9014L
Sheet Music
Rail
Rail pressure sensor Check
Check wiring betwee
Voltage check
terminal sure sensor and
Measured
ECM
ECM terminal side re - value noise Reference
Reference value/me
It em
em Pi n No . Ch ec k c o n d i t io
io n
ference value or ausred condition
not
no t
Vc E68 Key On 4.9~5.1 Below 2[ohm]/Key O
Key On/EngineOff 0.9~1.1 Below 2[ohm]/Key O
Vout E32
Engine On/at Accel. Refer to ill
illustratio
tion 3 Below 2[ohm]/Ke
/Key O
Key On/Engine Off 0.9~1.1 Below 2[ohm]/Key O
Vout E13
Engine On/at Accel. Refer to ill
illustratio
tion 3 Below 2[ohm]/Ke
/Key O
GND E25 Key On 0±0.1 Below 2[ohm]/Key O
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Voltage 5V ± 1%
Current Max. 10
Fuel pressure sensor Type Piezo elect
Actuator
Actuator Injector Type Electromagne
Electromagne
Resistance 0.45Ω
Supply control valve SCV Current Active : Below
When stopped :Belo
Master
Fuel tank
your semester with Scribd Capacity
100L
Fuel pressure of high pressure side Max. pRead
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INSPECTION
Sheet Music
It ems Ref er en c e
Idle speed(rpm) N-Range A/Con OFF 600rpm
A/Con ON (A/Con switch ON) 700rpm
700rpm
D-Range A/Con OFF 600rpm
A/Con ON (A/Con compressor
compressor relay ON) 700rpm
700rpm
TIGHTENING TORQUE
It ems K g f .m N.m
ECM mounting bolt 1.9 ~ 2.8 18.6 ~ 27.4 13
Mass air flow sensor mounting bolt 0.8 ~ 1.2 7.8 ~ 11.8 5
Crankshaft positi
ition sensor mounting bolt 0.8 ~ 1.2 7.8 ~ 11.8 5
TDC sensor mounting bolt 0.8 ~ 1.2 7.8 ~ 11.8 5
EGR valve mounting bolt(Inlet pipe) 2.2 ~ 3.3 21.6 ~ 32.3 1
EGR valve mounting bolt(EGR cooler) 2.2 ~ 3.3 21.6 ~ 32.3 1
High
igh pressure pipe
ipe(rail
rail--inje
inject
cto
or 1,2,3
,2,3,4
,4,,5,6)
,6) 4 ~5 39 ~ 49 2
Common rail assembly mounting bolt 1.9 ~ 2.8 18.6 ~ 27.4 13
Fuel filler pipe assembly mounting bolt 0.8 ~ 1.2 7.8 ~ 11.8 5
Fuel return pipe mounting bolt 0.8 ~ 1.2 7.8 ~ 11.8 5
Fuel supply pump flange mounting bolt 10 ~ 13 98.6 ~ 128 72
Fuel supply pump mounting bolt 1.9 ~ 2.8 18.6 ~ 27.4 13
Injector clamp bolt 2.9 ~ 3.1 28.42 ~ 29.4 21
Injector wire nut 0.18 ~ 0.22 1.76 ~ 2.15 1
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INSPECT
INSPECTION
ION PROCEDU
PROCEDURE
RE (Usi ng Hi-sc an) DIES
DIESEL
EL CONT
CONTRO
ROL
L SYST
SYSTEM
EM CO
Sheet Music
1. Turn off the ignition
ignition switch.
switch. LOCATION
2. Connec
Connectt the Hi-scan connecto
connectorr to the connector
connector of 1. Intake air temperatu
temperature
re sensor
sensor and intake
DLC (Data Link Connector) for the trouble diagnosis sensor
as shown in the figure.
3. Turn the
the ignition switch
switch ON.
ON.
4. Check the diagnostic
diagnostic code using
using Hi-scan.
Hi-scan.
5. Repair the parts
parts having faults shown
shown in the diagnosis
diagnosis
chart.
6. Erase the diagnostic
diagnostic trouble
trouble codes.
codes.
7. Disconnect
Disconnect the Hi-scan.
Hi-scan.
SDG
2. Crankshaft
Crankshaft position sensor
KDDFL5019A
NOTICE
When usin
sing a testteste
er manuf
anufaactu
ctured
red by othe ther
comp
compan
any,
y, oper
operat
ate
e the
the teste
testerr by refe
referr
rrin
ing
g to the
the
manual of the company.
When
When eras
erasin
ing
g the
the diag
diagno
nosti
stic
c troub
trouble
le code
codes,
s, use
use
Hi-scan if possible. Though DTC can be erased by
discon
disconne
nectin
cting
g the batter
battery
y termin
terminal,
al, doing
doing so, the
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SDG
SDGFL7503D 7. Supply
Supply control
control valve(SCV
valve(SCV))
4. TDC sensor(C
sensor(Camsh
amshaft
aft sensor)
sensor)
SDG
SDGFL7504D 8. ECM and EDV
5. Injector
Injector
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SDGFL9021L
10.DLC connector
SDGFL8113D
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ECU(Engine Control Unit)
COMPONENTS
ECM PIN CONNECTOR
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Vehicl
Vehicl e si de(80
de(80pin
pin connector) - ECM connector(C01)
connector(C01)
Sheet Music
Termi
Termi - Termi
Termi -
Ab
A bbr . Ter mi n al n am e Ab
A bb r . Ter mi n al
nal nal
1 +BF +B (For fly back) 41 SWV25 Bleeder #2 switch
2 PWR-ACT1 - 42 SWV23 Stop lamp switch
3 OUTV1 Ma
Main relay 43 SWV21 Se
Self-diagnosis switch
4 OUTV2 Exhaust brake relay 44 SWV19 Cruis main ON/OFF
5 OUTV3 Starter relay 45 A-ground 10 Sensor ground10
Check engine
engine lamp and fuel press-
6 SOUT6 46 A-gr
A-grou
ound
nd 12 Sens
Sensor
or grou
ground
nd 12
ure flashing
7 SOUT4 Glow lamp 47 ADV1 Accelerator position
8 SOUT2 PTO lamp 48 ADV3 -
9 SOUT1 MIL lamp 49 ADV5 Exhaust temperature
10 SWV6 PTO emergency switch 50 A-VCC10 Sensor power supply
11 SWV4 Neutral switch 51 A-VCC11 Sensor power supply
Remote
Remote PTO idle up
12 SWV2 Starter switch 52 SWV17
vice start switch
Idle down
down & PTO idle
13 SWV1 Ig
Ignition switch 53 SWV15
se resume switch
14 VS Vehicle speed sensor 54 SWV13 A/C switch
15 POUT1 A/C control 55 SWV11 Cl
Clutch switch
16 CAN1L CAN1L 56 SWV9 Exhaust brake & ble
17 CAN2L CA
C AN2L 57 CAN-SLD CAN1 shield ground
18 +B +B 58 +B +B
19 BATT Ba
Battery 59 P-ground Power ground
20 CASE-GND Case ground 60 ground Signal ground
Master
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+B (for fly bac k) Scribd 61 SWV26
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22 OUTV4 arning lamp relay 62 SWV24 Starter relay monitor
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ain relay 63 SWV22 Idel warm up switch
24 OUTV5 H t l 64 SWV20 B ilt i d t t
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Engine si de(80
de(80 pin connector) - ECM connector(E01)
connector(E01)
Termi
Termi - Termi
Termi -
Ab
A bbr . Ter mi n al n am e Ab
A bb r . Ter mi n al
nal nal
80 OUTE5 - 40 SWE1 Heater monitor switc
79 OUTE1 Fan clutch PWM 39 SWE3 -
78 OUTE3 Bleeder solenoid #2 38 ADE9 -
77 PWR-ACT2 Power ACT2 37 ADE7 Ambient temperature
76 AUX2 - 36 ADE13 -
75 PWR-PCV Not in use 35 ADE6 -
74 PCV1 Not in use 34 ADE4 Intake temperature s
73 PCV2 Not in use 33 ADE2 Fuel temperature se
72 SCV-HI HP-4 high 32 ADE1 Rail pressure sensor
71 SCV-LO HP-4 low 31 PIN2+ -
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70
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No
Not in use
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F MA F power supply 29 Useful
NE+ Engine
Not useful
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RPM sensor +
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A-VCC1Only S
$4.99/month.
ensor power supply 1 28 G-VCC Cam angle sensor po
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ADJUSTME
ADJ USTMENT
NT PROCEDURE
PROCEDURE
Sheet Music REMOVAL
1. After the engine
engine stops,
stops, wait for about
about 30 seconds.
seconds. REPLACING ECM
2. Disconnect
Disconnect the battery
battery ground
ground line.
line. 1. Perform
Perform work proced
procedure
ure using diagno
replacing with a new ECM.
3. Remove
Remove ECU connector
connector wiring sequen
sequentially.
tially.
2. Input
Input injector
injector QR correc
correction
tion value usin
4. Loos
Loosen
en ECM
ECM brac
bracke
kett moun
mountin
ting
g bolt
bolt and
and remo
remove
ve
tool with the ignition key ON.
ECM(A).
Follow
Follow the instruct
instruction
ions
s on the diagnost
diagnost
how to input injector QR correction value.
If the
the inpu
inputt of inje
inject
ctor
or QR corr
correc
ectio
tio
comple
completed,
ted, start the engine
engine in 10 sec.
the ignition key OFF.
CAUTION
In case
case QR correction
correction value
value descr
injector is not input in the ECM, there
engine performance and and exhaust
exhaust gas p
3. Select
Select learnin
learning
g initializat
initialization
ion instruct
instructed
ed
tool
tool and
and perfo
perform
rm pump
pump learni
learning
ng in
accelerator sensor learning.
4. Acco
Accord
rdin
ing
g to the
the inst
instru
ruct
ctio
ions
ns on di
sele
select
ct param
arame
eter
ter sett
settin
ing
g and perf
perf
SDGFL7003D
sequence.
5. Installation is in the reverse
reverse of
of removal.
removal.
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Mass Air Flow Sensor
INSPECTION
DESCRIPTION
MAF
MAF sens
sensor
or is built
built into
into the vehic
vehicle
le for contr
controll
ollin
ing
g the
the
EGR system precisely.
precisely.
The air flow,
flow, supplie
suppliedd to an engine
engine,, is measu
measured
red lower
than actual air flow due to contamination of MAF sensor.
Then EGR system can't be controlled precisely.
To prev
preven
entt it in adva
advanc
nce,
e, you
you have
have to clean
clean the MAF
sensor periodically.
Clean
Clean the
the MAF
MAF sens
sensor
or ever
every
y 6 month
months
s or 60,00
60,000
0 km
using "Carb and Choke Cleaner".
VISUAL INSPECTION
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SGZFL9030L
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Differential Pressure Sensor(DPS)
Components
Description
The differential pressure sensor is installed upper side of
PMC
PMC and
and measu
measuresres the pressur
pressuree differen
difference
ce betwee
between n
before and after PMC.
It also has a purpose to monitor that PMC is arbitrarily
removed by a user.
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SUDFLD
SUDFLDTC9111L 3. Remove
Remove the bracket
bracket bolt(B).
bolt(B).
3. Rem
Remov
ove
e the
the clip
clip con
connect
nected
ed to the
the diff
differ
eren
enti
tial
al 4. Remove
Remove the differential
differential pressure sensor
sensor p
pressure sensor pipe. 5. The installation
installation is the reverse
reverse order
order of rem
4. Remove
Remove the mountin
mounting
g bolt(D).
bolt(D). NOTICE
5. The installation
installation is the reverse
reverse order
order of removal.
removal. Regardin
rding
g as the
the tig
tighte
htening
ning torq
torq
NOTICE "Components".
Regardin
rding
g as the
the tigh
tighte
ten
ning
ing torq
torqu
ue, refe
referr to
"Components".
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Ac cel erato
er ato r Pedal
DESCRIPTION 2. Connec
Connectt DC 5 V to terminal
terminal No.
No. 3.
APS (Accelerator
(Accelerator Position Sensor)
Sensor) senses
senses the 3. Chec
Check k to see
see if the meas
measur
urem
emen
entt vo
acceleration pressure of the driver and delivers it to the term
termin
inal
al No.
No. 1 and
and No.
No. 2 sati
satisf
sfie
ies
s
ECM. Output
Output voltage of accelerator
accelerator position sensor
sensor has voltage.
a functional relation with the accelerator pedal position. At idle : 0.65V
This function
functional
al relation
relation comes
comes from the Potenti
Potentiom
ometer
eter At full stroke : 3.85V
built-in the sensor.
4. Connect
Connect DC 5V
5V to terminal
terminal No.4.
In other words, the positon of pedal is calculated from the
1) Che
Check to see if the the measur
sure
output voltage of the sensor.
betwe
between
en termi
termina
nall No.
No. 1 and
and No.
No.
REMOVAL specified voltage.
voltage.
1. Disconnect
Disconnect accelerator pedal
pedal connector and remove
remove At idle : 5V
mounting bolt, accelerator pedal. At full stroke : 0V
2. Installation is the reverse order
order of removal.
removal.
2) Che
Check to see if the the measur
sure
INSPECTION betwe
between
en termi
termina
nall No.
No. 1 and
and No.
No.
1. Connec
Connectt the voltmeter
voltmeter to the terminal
terminals
s No. 1 and 2 of specified voltage.
voltage.
accelerator position sensor.
At idle : 0V
At full stroke : 5V
SDGFL9026L
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Fuel Tank And Fuel Filter
REMOVAL FUEL TANK AND FUEL FILTER (AERO
FUEL TANK AND FUEL FILTER (HD120) 1. Park
Park the vehicl
vehicle
e on a flat
flat surfa
surface,
ce, stop
1. Park
Park the vehicl
vehicle
e on a flat
flat surfa
surface,
ce, stop the engi
engine
ne and disconnect the terminal (-) of battery.
and disconnect the terminal (-) of battery. 2. Disconn
Disconnect
ect the sender
sender connecto
connectorr on the
2. Disconn
Disconnect
ect the sender
sender connec
connector
tor on the top of fuel
fuel tank.
tank. 3. Remove
Remove return hose
hose (A) and supply
supply hose
3. Remove
Remove return hose
hose (A) and supply
supply hose (B).
SDG
SDGFL7100D 4. Support
Support fuel tank assembly
assembly with the jack.
4. Support
Support fuel tank assembly
assembly with the jack. Loosen
Loosen fuel tank
tank band
band moun
mounti
ting
ng nut
nut and
and rem
remov
tank
tank band
band moun
mounti
ting
ng nut
nut and
and remo
remove
ve fuel
fuel tank
tank assembly by removing mounting bolt.
assembly
assembly by removing
removing mounting bolt. 5. Disconnect
Disconnect connector
connector and hose
hose and rem
5. Disconnect
Disconnect connector
connector and hose and
and remove
remove fuel filter (A).
(C).
6. Installation is the reverse order
order of removal.
removal.
Tighten lower nut to the
8.5~11kgf.m(83.4 ~107.9
107.9N.m 61.5~79.6I
N.m,, 61.5 79.6Ib-
b-ft)
ft) and
and
upper nut to the the 1.3~1.5kg
1.5kgf.m (12.7~14.7N.m,
f.m (12.7
Master your semester with Scribd
9.4~10.8Ib-ft) and install fuel tank band to bracket.
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Master
Tigh
ightening your
tening torque semester
torqu : 1.7~1.9kgf.mwith
1.9kgf.m (16.7~
(16.7 Scribd
18.6N.m,
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Injector
COMPONENTS
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• Ensure
nsure working
working area rea clea
cleans all the time,time, and 5. Disconnect
Disconnect injector
injector ground
ground (A).
place
place the remove
removed d injector
injector on the cleanclean cloth.
An d pay att ent io n to in jec to r nozzle
no zzle so th at it is
not contaminated by foreign materials.
• Remove
move the
the prot
proteective
ctive caps
caps which
which pre
prevent
vents
s
foreign material inflow for injector and fuel hose
immediately just before installation.
• When
hen installing
installing or remov
removinging injector,
injector, clean
clean the
i nj
nj ec
ec to
to r c on
on ta
tac ti
ti ng
ng p or
or ti
ti on
on an d b e s urur e t o
replace O-ring
O-ring and nozzle gasket wit h new ones.
• Apply
Apply diesel
diesel to the O-r
O-ring
ing of injector
injector and
and insert
insert
them into the cylinder head.
• Install
Install injector to the cylinder hea
head
d vertically
vertically and
and
install it correctly not to cause any damage such
as shock.
SDG
• Be sure
sure to obse
observ
rvee the
the specif
specifie
ied
d tight
tighteening
ning
torque of bolts when inserting and tightening the 6. Disconnect
Disconnect high pressure
pressure pipe (A).
(A).
injector.
Master Never your
• Never use semester
use the high pressure fuelwith
pressure pipe. Scribd
pipe.
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Turn the ignition
ignition key OFF.
OFF.
Disconnect
Disconnect terminal
terminal (-) of battery.
battery.
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3. Remove
Remove rocker
rocker cover.
cover.
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Common
Common Rail
Rail Assembly
COMPONENTS
Master
ECM your semester with Scribd
1. ECM 5. Fuel supply pump
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3. Injectio
Injection
n pipe
pipe
York Times
2. Injector assembly
assembly 6. High pressure(
pressure(comm
common
sureCancel
Useful
7. High pressure
pres
on rail~injector)
pipe(comm
Not useful
pipeanytime.
(common on rail ~supply pum
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4. Common
Comm students: Only ly
rail assemb
assembly$4.99/month.
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SDGFL7514D
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Master
2. Injectoryour semester with Scribd
1. ECM
ECM 6. Fuel return pipe
assembly
assembly 7. Fuel
Fuel supply
supply pipe
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3. Injectio
Injection
n pipe
pipe 8. Fuel pump flange
4. Common
Common rail assemb
assembly
9. Overflo
Overflow Useful
w screw
scre Not useful
w anytime.
Cancel
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5. Fuel students:
supply
supply pumpOnly $4.99/month.
pump 10. Fuel temperatu
temperature re sensor
sensor
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• Appl
Applyy die
diesel
sel oil
oil to the
the O-ring
ring of inje
injector
ctor and 7. Remo
Remove
ve supply
supply pump
pump moun
mountin
ting
g hexa
hexa
insert them into the cylinder head. remove supply pump.
• Install
Install injector to the cylinder hea
head
d vertically
vertically and
and
install it correctly not to cause any damage such
as shock.
• Be sure
sure to obse
observ
rvee the
the specif
specifie
ied
d tight
tighteening
ning
torque of bolts when inserting and tightening the
injector.
Master
Never your
• Never use semester
use the high pressure fuelwith
pressure pipe. Scribd
pipe.
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SDGFL7510D
b. Open
pen rock
rockeer cove
cover,
r, in vie
view from
from the
the rear
rear of
engine, align the mark(or painting) of TDC sensor
gear plate with the head contact surface of block SDG
from the left. b. When
When tightening
tightening flange and pump
so that the mark(1) of flange backsid
upper side of straight line as shown in
Align the part that the number
number of
gear
ear is marked
rked with
ith the
the mark
ark
backs
backside
ide and
and assem
assembleble supp
supply
ly
supply pump.
Supply pump gear mounting nut :
6 ~ 7kgf.m(58.8 ~68.6Nm,43.40~50.6lb.ft)
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SDGFL7512D
d. When installing
installing supply
supply pump assembly
assembly to engine,
engine,
double check above mentioned items and engage
supply pump gear part with counterpart gear and
then tighten it with bolts.
Flange mounting bolt :
10 ~ 13kgf.m(98.1~127.5Nm, 72.3~94.0lb.ft)
3. Tighten
Tighten high pressure
pressure pipe.
pipe.
High pressure pipe mounting bolt :
4 ~ 5kgf.m(39.2 ~49.0Nm, 28.9~36.2lb.ft)
NOTICE
At assembling, assemble those from center to
outside in sequence for convenience's sake.
4. Install low
low pressure
pressure pipe.
5. Install supply
supply pump
pump connector.
connector.
6. Install
Install rocker
rocker cover.
cover.
Master
7. When
your
When replacing
semester
replacing with the new pump,
with
pump, erase
Scribd
erase learnin
learning
value of the previous pump and be sure to perform
g
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ning of new pump
pump newly.
newly.
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