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Service Manual
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Hyundai HD78 Service Manual

Fuel System
General Information
Specifications .................................................. FL - 3
Troubleshooting...............................................FL - 5
Electronic Engine Control System
Description.......................................................FL -28
ECU
Components............................................... FL -31
Mass Air Flow Sensor
Inspection ................................................... FL -36
Differential Pressure Sensor(DPS)
Components............................................... FL -39
Description ................................................. FL -39
Specifications ............................................. FL -40
Part Circuit Diagram .................................. FL -40
Replacement .............................................. FL -41
Electronic Fuel Supply System
Components ....................................................FL -42
Injector
Components............................................... FL -43
Installation .................................................. FL -45
Replacement .............................................. FL -45
Common Rail Assembly
Components............................................... FL -46
Installation .................................................. FL -47
Accelerator Pedal
Description ................................................. FL -48
Inspection ................................................... FL -48
Fuel Tank And Fuel Filter
Replacement .............................................. FL -49
Inspection ................................................... FL -50
Electronic Injection Pump
Supply Pump
Components............................................... FL -51
Installation .................................................. FL -53
DTC Troubleshooting Procedures
Basic Troubleshooting ..................................... FL -55
Schematic Circuit ............................................ FL -63
DTC List ........................................................... FL -80
P0072............................................................... FL -84
P0073............................................................... FL -88
P0088............................................................... FL -92
P0101............................................................... FL -98
P0102............................................................... FL -102
P0103............................................................... FL -106
P0107............................................................... FL -110
P0108............................................................... FL -112
P010A .............................................................. FL -114
P0112............................................................... FL -118
P0113............................................................... FL -122
P0116............................................................... FL -126
P0117............................................................... FL -129
P0118............................................................... FL -132
P0120............................................................... FL -135
P0121............................................................... FL -140
P0122............................................................... FL -145
P0123............................................................... FL -149
P0182............................................................... FL -153
P0183............................................................... FL -156
P0192............................................................... FL -159
P0193............................................................... FL -165
P0194............................................................... FL -171
P0195............................................................... FL -177
P0196............................................................... FL -183
P0201............................................................... FL -189
P0202............................................................... FL -195
P0203............................................................... FL -200
P0204............................................................... FL -205
P0217............................................................... FL -210
P0219............................................................... FL -212
P0220............................................................... FL -217
............................................................... FL -222
P0221
P0222............................................................... FL -227
P0223............................................................... FL -232
P0225............................................................... FL -236
P0226............................................................... FL -240
P0237............................................................... FL -244
P0238............................................................... FL -249
P0335............................................................... FL -254
P0336............................................................... FL -259
P0340............................................................... FL -264
P0341............................................................... FL -269
P0401............................................................... FL -274
P0403............................................................... FL -277
P0404............................................................... FL -280
P0405............................................................... FL -284
P0406............................................................... FL -288
P0501 ............................................................... FL -292
P0502 ............................................................... FL -297
P0503 ............................................................... FL -302
P0541 ............................................................... FL -307
P0542 ............................................................... FL -309
P0562 ............................................................... FL -312
P0563 ............................................................... FL -315
P0601 ............................................................... FL -318
P0602 ............................................................... FL -320
P0603 ............................................................... FL -322
P0604 ............................................................... FL -324
P0606 ............................................................... FL -326
P0607 ............................................................... FL -328
P0615 ............................................................... FL -330
P0627 ............................................................... FL -333
P0629 ............................................................... FL -337
P0642 ............................................................... FL -341
P0643 ............................................................... FL -344
P0652 ............................................................... FL -347
P0653 ............................................................... FL -349
P0698 ............................................................... FL -351
P0699 ............................................................... FL -354
P069E .............................................................. FL -357
P069F ............................................................... FL -360
P0704 ............................................................... FL -363
P0850 ............................................................... FL -366
P1120 ............................................................... FL -369
P1132 ............................................................... FL -374
P1133 ............................................................... FL -377
P1190 ............................................................... FL -380
P1218 ............................................................... FL -384
P1219 ............................................................... FL -388
P1221 ............................................................... FL -391
P1222 ............................................................... FL -397
P1223 ............................................................... FL -400
P1231 ............................................................... FL -403
P1232 ............................................................... FL -406
P1383 ............................................................... FL -409
P1384 ............................................................... FL -411
P1616 ............................................................... FL -414
P1642 ............................................................... FL -419
P1643 ............................................................... FL -422
P2002 ............................................................... FL -425
P2146 ............................................................... FL -427
P2147 ............................................................... FL -432
P2148 ............................................................... FL -437
P2149 ............................................................... FL -442
P2150 ............................................................... FL -448
P2151 ............................................................... FL -453
P2293 ............................................................... FL -458
P2413 ............................................................... FL -462
P2454 ............................................................... FL -466
P2455 ............................................................... FL -471
P2503 ............................................................... FL -476
P2504 ............................................................... FL -478
U0001 .............................................................. FL -480
U0010 .............................................................. FL -483
General Information
SPECIFICATIONS
Items Specification
Sensors BPS(Booster pressure sensor) Supply voltage 5V
Operating voltage 0.5~4.5 V
Operating temperature -40~125°C
Operating pressure 50~500 kpa
Current MAX. 10 mA
IAT(Intake air temperature) Type Thermistor
Resistance 2.31~2.56 k[At 20°C(68°F)]
0.30~0.34 k[At 80°C(176°F)]
WTS(Water temperature sensor) Type Thermistor
Resistance 2.31~2.59 k[At 20°C(68°F)]
0.314~0.331 k[At 80°C(176°F)]
TDC(Topdeadcenter)sensor Type Hall sensor
CKP(Crankshaft positon sensor) Type Magnetic
APS(Accel positon sensor) Type Variable resistance(Potentiometer)
Voltage 5V±1%
Current Max. 10 mA
Fuel pressure sensor Type Piezo electricity
Actuator Injector Type Electromagnetic
Resistance 0.45
Supply control valve SCV Current Active : Below 1.29 A
When stopped :Below 1.16 A
Fuel tank Capacity 100 L
Fuel pressure of high pressure side Max. pressure 1,800 bar
Supply pump Type Included into high pressure pump
mechanical type
Power Mechanical gear type
Fuel filter Type Filter
EGR Valve specification
Items Specification
Valve type Flap type
Control type Electric DC motor
Sealant
Water temperature sensor(Coolant temperature sensor) Loctite 200 or equivalent
Inspection
Item Reference value
Idle speed(rpm) 650±25
Tightening torque
Items Kgf.m N.m lb-ft
ECM mounting bolt 1.9~2.8 18.6~27.4 13.8~20.4
Mass air flow sensor mounting bolt 0.8~1.2 7.8~11.8 5.8~8.7
Crankshaft position sensor mounting bolt 0.8~1.2 7.8~11.8 5.8~8.7
TDC sensor mounting bolt 0.8~1.2 7.8~11.8 5.8~8.7
EGR valve mounting bolt(Inlet pipe) 1.0~1.4 9.8~13.7 7.2~10.1
EGR valve mounting bolt(EGR cooler) 1.0~1.4 9.8~13.7 7.2~10.1
High pressure pipe(rail-injector 1,2,3,4,5,6) 4~5 39~49 29~36
Common rail assembly mounting bolt 1.9~2.8 18.6~27.4 13.8~20.4
Fuel filler pipe assembly mounting bolt 0.8~1.2 7.8~11.8 5.8~8.7
Fuel return pipe mounting bolt 0.8~1.2 7.8~11.8 5.8~8.7
Fuel supply pump flange mounting bolt 10~13 98.6~128 72.3~94
Fuel supply pump mounting bolt 1.9~2.8 18.6~27.4 13.8~20.4
Injector clamp bolt 2.9~3.1 28.42~29.4 21~22.4
TROUBLESHOOTING
Symptom Possible causes Remedy
Engine does not crank.
Idle is improper or idle speed is u­nstable or irregular.
Low cranking speed
Low voltage to glow plug system If the test light turns on indicating low vo-
Defective glow plug Replace the glow plug.
Air in the fuel system Air bleeding of fuel system
Injection pipe is connected incompletely. Connect the pipe correctly
Improper injection timing Check ECM.
Poor injection Check, replace injector.
Mechanical defect of engine Test compression, repair engine.
Simultaneous failures of TDC sensor and CKP sensor
Loose fuel hose connection between filt­er and supply pump.
Air in the fuel system Air bleeding of fuel system
Fuel filter is clogged. Or fuel supply is no good because fuel line or injection pipe l­eaks, pinched or pressed.
Repairthestarterorchargeorreplaceb­attery.
ltage when it turns “ON”, check relay and wiring.
Check and tighten correctly.
Tighten or repair.
Check hose or fuel line. Replace fuel filt­er if necessary.
Poor injection Check, replace injector.
Improper injection timing Check ECM.
Mechanical defect of engine Test compression, repair engine.
Defective supply pump
Engine defect at high gear range Observe correct shift speed.
EGR valve malfunction Check or replace EGR valve.
Exhaust gas (Black, blue, white) Engine temperature stays below engine
operating temperature.
Abnormal at max. RPM Check and replace supply pump.
Defective Injection nozzle Check and repair or replace.
Improper injection timing Check ECM.
Exhaust system malfunction Check for deformed or clogged.
Mechanical defect of engine Test compression, repair engine.
Defective supply pump Replace supply pump.
EGR valve malfunction Check or replace EGR valve.
Let the engine at idle after replacing pu­mp.
Check cooling system. Replace thermos­tat.
Symptom Possible causes Remedy
Engine lacks power, acceleration i­s delayed(Speedometer is normal, no clutch slip)
Excessive fuel consumption Contaminated air cleaner filter Clean, replace air cleaner filter.
Abnormal at max. RPM Check, replace supply pump.
Contaminated air cleaner filter Clean or replace.
Fuel filter is clogged. Or fuel supply is no good because fuel line or injection pipe l­eaks, pinched or pressed.Or fuel filter le­aks.
Air in fuel system Air bleeding of fuel system
Defective supply nozzle Check, repair or replace.
Improper injection timing Check ECM.
Mechanical defect of engine Test compression, repair engine.
Defective injection pump Check after replacing pump.
EGR valve malfunction Check, replace EGR valve.
Fuel leaks Check all pipes, hoses and connection.
Clogged return pipe and hose. Check and replace the return line, blow
Defective injection nozzle Check. Repair or replace.
Check hose or fuel line. Replace fuel filt­er if necessary.
Replace or tighten as required.
air if clogged and drain the fuel.
Mechanical defect of engine Compression test, replace engine.
Defective supply pump Replace pump.
EGR valve malfunction Check or replce EGR valve.
Engine control
Symptom Possible causes Remedy
Engine will not turn off. Injector wiring short Check injector wiring.
Starting switch harness is damaged. Replace.
Engine starting system
Symptom Possible causes Remedy
Engine does not crank Low battery voltage Recharge or replace the battery.
Battery cable connection is loose, corro­ded or worn.
Fusible link is swelled. Replace the fusible link.
Defective starter motor. Repair.
Defective injector Replace.
Cranking speed is low Low battery voltage Recharge or replace the battery.
Battery cable connection is loose, corro­ded or worn
Defective starter motor Repair
Starter motor continues to run. Defective starter motor Repair
Defective ignition switch Replace the ignition switch.
Starter motor runs but engine is n­ot cranking.
Defective wiring Repair wiring.
Starter motor, pinion gear damaged Repair starter motor.
Ring gear damaged Replace flywheel or torque converter ge-
Replace or retighten.
Repairorreplace.
ar.
Fuel tank and fuel line
Symptom Possible causes Remedy
Poor engine performance due to i­nsufficient fuel supply
Fuel filter warning lamp blinks. Excessive water is in fuel filter. Drain the water collected in the fuel filter
Engine check lamps blinks. Clogged fuel filter. Replace fuel filter.
Fuel pipe is twisted or bended Repair or replace.
Fuel pipe or hose is clogged Clean or replace.
Fuel filter is clogged Replace.
Entry of water to fuel filter Replace fuel filter or clean fuel tank or f-
uel line.
Foreign materials intrude in fuel tank. Fuel tank rusts.
Defective supply pump operation (Clogged filter in pump)
Clean or replace.
Replace.
(Loosen the drain plug at the bottom of f­uel filter.)
Troubleshooting procedure
SDGFL9001L
SUDFL9001L
SUDFL9002L
SDGFL9004L
SERVICE PROCEDURE
Communication with diagnosis equipment is not possible
(Impossible communication with all systems)
When communication between diagnosis equipment and ECM is not possible
Trouble symptoms
It shows at least one of the following symptoms. When power is not supplied to ECM, ECM ground circuit is defective. Defective ECM Wrong communication line between ECU and Hi-scan
Engine does not start.
SDGFL9005L
Probable causes
Power supply circuit to ECM is defective.ECM
Malfunction ECM Circuit between ECU and DLC is open.
SDGFL9006L
It is difficult to start the engine. (Possible cranking)
SDGFL9007L
Unstable idle or engine stall.
SUDFL9003L
Engine hesitation or poor acceleration
SDGFL9009L
Troubleshooting flow chart when HUNTING(Varying) occurs
SUDFL9004L
Troubleshooting flow chart when FCCB(Fuel control cylinder balance) fails.
SUDFL9005L
Troubleshooting flow chart when engine is lack of power
SUDFL9006L
Troubleshooting flow chart in systems of sensors and wirings
SDGFL9013L
CRS RAIL PRESSURE CHECK
■
Items to check in the vehicle
1. Check for customer complaint and trouble symptoms.
2. Check reoccurrence or not for customer complaint and trouble symptoms mentioned above.
3. Record DTC codes or record the detailed DTC codes by using Hi-scan.
Inspect and repair causes due to DTC codes.
4. Check rail pressure when turning ignition key to NO(Engine OFF).
If the rail pressure is displayed, check it according to inspection procedure of remaining pressure.
5. Check for connector of rail pressure sensor.
Check for wiring tension between rail pressure sensor and connector of vehicle side.
Check that wiring between rail pressure sensor and connector of vehicle side is tight or not due to vibration(under driving) with interference in bracket of engine/vehicle etc.
Check rail pressure sensor wire for clamp conditoin.
Check that wire of rail pressure senor is clamped securely or not.
Check rail pressure sensor and connector of vehicle side for connection conditon.
With connector connected, check connector for shaking(with right and left/ back and forth).
7. Visual check of connector
Check each terminal contact part of rail pressure sensor for wear.
Check connector housing of rail pressure sensor for wear.
Check locking part/ guide part of rail pressure sensor connector for damage or deformation.
Check the inside of rail pressure sensor connector for foreign materials(such signs as water, oil, spark, tracking etc.).
Check the opposite connector for foreign materials, wear, damage, existence or not of rubber seal or shrinkage of rubber seal etc..
If there is free play, check for output of rail pressure/rail pressure sensor using Hi-scan or oscilloscope.
6. Check for wiring related to the output of rail pressure sensor.
Check for voltage between each terminal of rail pressure sensor in the ECM side and terminal (-) of battery.
Check wire between rail pressure sensor and ECM for continuity(resistance).
SDGFL9014L
Rail pressure sensor
terminal
Voltage check
Check wiring between rail pres -
sure sensor and ECM
Measured v-
Item Pin No. Check condition
ECM terminal side r-
eference value
alue noise
or
Reference value/me-
asured condition
not
Vc E68 Key On 4.9~5.1 Below 2[ohm]/Key Off
Measured
value
Vout E32
Key On/EngineOff 0.9~1.1 Below 2[ohm]/Key Off
Engine On/at Accel. Refer to illustration 3 Below 2[ohm]/Key Off
Key On/Engine Off 0.9~1.1 Below 2[ohm]/Key Off
Vout E13
Engine On/at Accel. Refer to illustration 3 Below 2[ohm]/Key Off
GND E25 Key On 0±0.1 Below 2[ohm]/Key Off
CRS Rail pressure check flow chart
SDGFL9015L
Fuel system check processor
SUDFL9007L
Troubleshooting flow chart when the engine stops
SUDFL9008L
SUDFL9009L
SDGFL9019L
SUDFL9010L
Electronic Engine Control System
DESCRIPTION
DIESEL CONTROL SYSTEM Inspection of the diesel control system
If the components of the diesel control system (sensor, ECM, injector etc.) have a problem, the proper amount of fuel for various engine-operating conditions can not be supplied and also the following situations can occur.
1. It is hard to start the engine or does not start the engine at all.
2. Idling is unstable.
3. Engine driving performance is bad.
If any of the above conditions are met, first perform a routine diagnosis that includes basic engine checks (ignition system malfunction, incorrect engine adjustment etc). Then, inspect the components of the diesel control system with multi-purpose tester or digital multi-meter.
CAUTION Before removing or installing any part, read t he diagnostic trouble codes and then, disconnect the battery negative (-) terminal.
Before disconnecting the cable from battery terminal, turn the ignition switch to OFF. If the battery cable is removed or connected during engine operation or the situation in which the ignition switch is ON, then the ECU semiconductor could be damaged resulting in inaccurate operation.
Self-diagnosis
The ECM sends the input/output signals to various parts of engine(some signals at all times and the others under specified conditions).
After the specific time elapses the first detection of irregular signal, the ECU judges this as an irregularity and it records the diagnostic trouble code. And then it sends the signal to the self-diagnosis output terminal. The diagnosis results can be checked by the Hi-scan. In addition, Diagnostic Trouble Codes (DTC) will be directly backed up by the battery so that it will remain in the ECM even if the ignition switch is turned off. The diagnostic trouble codes will, however, be erased when battery terminal or ECM connector is disconnected.
negative terminal (-) is disconnected for 15 seconds or more, then the diagnosis memory will be erased.
Self-diagnosis check procedure
CAUTION As DTC code may not be detected due to low battery voltage, the battery condition should be checked prior to inspection.
Since DTC code is erased if the battery or the ECM connector is disconnected, don't disconnect the battery until the diagnostic trouble codes are completely read and recorded safely.
It is most desirable to erase the diagnostic trouble codes using Hi-scan after completing check and repair. After disconnecting ground cable from the battery negative ( -) terminal for 15 seconds or more, reconnect the cable and check if the trouble codes have been erased. (At this time, ignition switch must be turned off).
Inspection procedure (Using Hi-scan)
1. Turn off the ignition switch.
2. Connect the Hi-scan connector to the connector of DLC (Data Link Connector) for the trouble diagnosis as shown in the figure.
3. Turn the ignition switch ON.
4. Check the diagnostic code using Hi-scan.
5. Repair the parts having faults shown in the diagnosis chart.
6. Erase the diagnostic trouble codes.
7. Disconnect the Hi-scan.
CAUTION If, in most of diesel control system, the connector of a sensor is disconnected with the ignition switch turned ON, the diagnostic trouble code (DTC) is recorded in the ECM. In this case, if the battery
KDDFL5019A
NOTICE
When using a tester manufactured by other company, operate the tester by referring to the manual of the company.
When erasing the diagnostic trouble codes, use Hi-scan if possible. Though DTC can be erased by disconnecting the battery terminal, doing so, the data for learning control in ECM would be erased at the same time.
DIESEL CONTROL SYSTEM COMPONENTS LOCATION
1. Intake air temperature sensor and intake air pressure sensor
3. Water temperature sensor(Coolant temperature sensor)
SDFFL7505D
4. Camshaft sensor
2. Crankshaft position sensor
SDFFL7503D
SDFFL7506D
5. Injector(A)
SDFFL7504D
SDFFL7009D
6. Rail pressure sensor(A)
9. Accelerator position sensor
7. Supply control valve(SCV, A)
8. ECM(Engine control module, A)
SDFFL7006D
SDFFL7007D
SUDFL9016L
10. DLC connector
SDFFL7314D
11. DPS(Differential Pressure Sensor)
SDFFL7008D
SUDFLDTC9108L
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