Fuel System
Fuel System
Fuel System
OUTLINE
4 1 5 2 3 6
Fuel feed
Fuel line
1. Control unit(ECU)
5. Priming pump
2. Fuel filter
6. Fuel hose (Feed)
3. Fuel pump
7. Return hose
4. Overflow valve
SOLA400A
Fuel tank
Return to fuel tank
GENERAL RESOURCE 31-3
GENERAL RESOURCE
Item Resource
Connector 54 pin x 2
Unit injector Voltage 90V
(Solenoid valve) Resistance 1.0 ~ 2.0
Connector 4 pin
Crank shaft & Resistance 850 ± 10%
Cam shaft location sensor Running range 40 ~ 2500 r/min
Connector 3 pin
Sensor interval 1.0 ~ 2.0 mm
Fuel pressure temperature Voltage 5V
STANDARD REPAIR
Item Standard value Remark
Electric injector Fuel injection time BTDC 16° ~ ATDC 2°
Injection pressure Max. 1500 bar
Idle rotation speed(RPM) 500 ± 10 rpm
Overflow valve opening pressure 3.0kgf/cm2 more
Cam shaft location sensor air gap 1.0 ~ 2.0 mm
Crank shaft location sensor air gap 1.0 ~ 2.0 mm
Fuel pump discharge amount 500rpm Slot arm 4 bar
1900rpm Slot arm 7 bar
JOINT TORQUE
Item Joint torque
Overflow valve 3.4 ~ 4.0 kg·m
Fuel pipe plunge bolt(M6 x 1.0) 0.8 ~ 1.2 kg·m
Fuel filter eyebolt 2.8 ~ 3.0 kg·m
Cylinder head fuel inlet pipe eyebolt 3.0 ~ 3.5 kg·m
ECU side fuel pipe eyebolt 2.8 ~ 3.0 kg·m
Wiring mounting rail 0.5 ~ 0.6 kg·m
EUI captive nut terminal 0.15 ~ 0.2 kg·m
Priming pump bolt 2.8 ~ 3.0 kg·m
Mounting bracket 3.5 ~ 5.5 kg·m
ECU mounting plunge bolt 1.9 ~ 2.8 kg·m
Intake pressure temperature sensor 0.5 ~ 0.6 kg·m
Cam shaft location sensor 0.8 ~ 1.0 kg·m
Crank shaft location sensor 0.8 ~ 1.0 kg·m
Fuel pump fixing bolt 0.8 ~ 1.2 kg·m
EUI COMPOSING ELEMENT 31-5
SOLA705A
1. Spill valve
2. Plunger
3. Vent port
4. Fuel line
SOLA402A
Actuator
Fill
2) Fuel discharge
When rocker arm begins to press plunger, fuel begins to be 1
compressed in pump tank. However, because spill valve is
2
opened, remarkable ascent of pressure doesn’t take place 3
and fuel flows through spill valve.
SOLA402B
Actuator
Spill
SILA002A
SOLA402C
Actuator
SILA003A
EUI COMPOSING ELEMENT 31-7
SOLA402A
Actuator
Spill
SILA004A
31-8 FUEL SYSTEM
5 4 1 6
1) Control unit
Control unit controls unit injector to eject fuel into cylinder.
Mounted in cylinder block, it receives information from ac-
celerator pedal and several sensors and determines the
amount of fuel to inject into cylinder and injection time.
The amount of ejected fuel is calculated by control unit and
decided by the time when spill valve in injector is closed.
The amount of fuel injected into combustion room is adjusted
or restricted by the following conditions.
- Demanded fuel amount (Control fuel amount according
to driver’s operation)
- Limit of fuel amount (Control fuel amount according to
engine condition)
Atmosphere pressure
Pedal angle Fuel amount de-
manded by pedal Minimum
Engine speed Demanded Amount of fuel injection
fuel amount value
PTO fuel
Cruise fuel
START
KEY S/W ON
OFF
Indicator lamp Light up
Light off
Engine rotations > Limit value
Engine RPM
ON
Heating
OFF
Preheating Postheating
(2) Adjustment of unstable idle: Adjust idle by value programmed Idle 500rpm
rotation
in ECU when idle state is unstable speed
- Increase or decrease as much as rotations specified by
driver within prearranged range
Time
- Continue to be remembered before adjusted idle value is Idle adjustment SILA007A
set again.
(3) Idle adjustment
- Idle adjustment at cooling: Increase idle rotating speed Engine
speed
after cooling starting to make engine warming fast.
Idle
- Increase idle to prevent battery discharge in operating air rotation
500rpm
conditioner. speed
Engine speed
800 RPM
500 RPM
-10°C
20°C
T1 T2 Coolant temperature
SILA009A
31-12 FUEL SYSTEM
800 RPM
Increase
8) Cylinder balancing
Cylinder balancing minimizes variation of rotation speed by cyl-
inder at idle rotation, senses speed change connected between
cylinders and compensates the amount of fuel transferred to
cylinders.
Appropriate conditions
- Engine rotations of idle fuel control state.
- No error in injector
- Not stepping pedal
- Coolant temperature is within specified value
- No error in crank sensor
Engine speed
EUI
Acceleration pedal
SILA011A
31-14 FUEL SYSTEM
TDC
CAM
CPS 1st wheel “A”
11th teech teech
15° CAM
6° Gap:1.5+/-0.5
34.5°
2nd wheel teech
+1 teech
69°CA “A”
4. Control relay
When starting switch is ON, battery voltage flows from starting
switch to control unit. At this time, power transistor is switched
on to filter control relay coil.
Then, control relay switch is ON and main power is supplied from
battery to control unit through control relay switch.
Starting switch
B+
Control unit
(ECU)
SILA013A
5. Fuel pump
Fuel pump of inner contact gear type is driven by air compressor
side.
It supplies cylinder fuel line with fuel of pressure and amount
needed for smooth fuel injection of injector Fuel pump
SOLA404A
6. Priming pump
Priming pump is mounted to fuel filter head and used to take out
fuel and air in fuel system manually at initial engine starting or
after replacement of fuel filter.
Joint torque of priming pump bolt: 2.8 to 3.0kg.m
7. Fuel filter
Fuel filter is cartridge type that replacement of element is easy.
It gets rid of impurities in fuel provided from fuel supply pump.
Joint torque of cartridge: 1.2 to 1.6kgf.m
SOLA407A
Disassembly
6 7 5
3
4
2
OFF
0.5sec. 1 sec.
1.5sec.
DEC S/W ON
DEC S/W ON
key ON Normal speed switch ON
SOLA022A
31-20 FUEL SYSTEM
2 1232 INTAKE PRESS. IG “ON” and - Ground short ON Normal signal - Normal operation possible
SENSOR ENG.RUNNING - Contact state of connector poor input
- Wire disconnection
3 1112 AIR TEMP. IG “ON” and - Ground short OFF Normal signal - Normal operation possible
SENSOR ENG.RUNNING - Contact state of connector poor input - Smoke increase
4 1121 AMBIENTAIR IG “ON” and - Sensor harness short, disconnection OFF Normal signal Normal operation possible
PRESS.SENSOR ENG.RUNNING - Sensor output value faulty input
BATTERY ENG. RUNNING - Battery voltage reduction OFF Normal signal - Idle rotation speed
5 5234
SUPPLY input increase (650rpm)
5233 - Battery voltage excessive - Normal operation possible
- Regulator faulty
7 1312 ENG. COOLANT IG “ON” and - Ground short ON Normal signal - Normal operation possible
TEMP. ENG.RUNNING - Contact state of connector poor input - Engine overheating ON
SENSOR (Ground short)
1313 - Power short
- Wire disconnection
8 2121 ENG. ROTATE ENG.RUNNING - Sensor air gap faulty ON Normal signal - Normal operation possible
SENSOR - Sensor coil short, disconnection input
- Noise
- Contact state of connector poor
- Noise - Operation impossible
2122
- Phase difference between cam
and cramp excessive (6 grade)
2123 ENG.RUNNING - Noise ON Normal pulse input - Normal operation possible
- Abnormal signal input within 60 sec.
9 33n1 CYLINDER ENG.RUNNING - Deflection of No. n cylinder fuel OFF - Delete fault by - Normal operation possible
BALANCING injecting amount excessive Hi-scanner
- No. n injector faulty Idle unstable
(Delete Memory)
10 1322 FUEL PRESS. IG “ON” and - Ground short ON Normal signal - Normal operation possible
SENSOR ENG.RUNNING - Contact state of connector poor input
- Wire disconnection
12 222 INTERNAL. ECU IG “ON” and - ECU built-in temperature sensor faulty OFF Normal signal - Normal operation possible
TEMP. SENSOR ENG.RUNNING input - Smoke increase
13 4112 DIAGNOSTIC IG “ON” and - Ground short OFF Normal signal - Running in idle mode
COMMUNICA- ENG.RUNNING - Power short input - LIMP HOME realization
TION - ECU faulty - Engine speed limit
14 1212 ACCEL. PEDAL IG “ON” and - Ground short ON Normal signal - LIMP HOME realization
SENSOR ENG.RUNNING - Contact state of connector poor input - Engine speed limit
- Wire disconnection
15 5111 IDLE IG “ON” and - Ground short OFF Normal signal - Normal operation possible
SW 1 ENG.RUNNING - Wire disconnection input (at pedal sensor normal)
- Power short
16 5113 IDLE IG “ON” and - Ground short OFF Normal signal - Normal operation possible
SW 1 ENG.RUNNING - Wire disconnection input (at pedal sensor normal)
- Power short
17 2212 REMOTE IG “ON” and - Ground short OFF - Remote pedal PTO
ACCEL. PEDAL ENG.RUNNING - Wire disconnection operation impossible
SENSOR(PTO)
2213 - Power short
18 5211 VEHICEL ENG.RUNNING - Car sped sensor faulty OFF - Contact running impossible
SPEEDSENSOR - Wire disconnection, short - Maximum speed limit impossible
- Contact state of connector poor - PTO operation impossible
- Car speed sensing cable faulty
19 31n6 INJECTOR n IG “ON” and - No. n injector driving power cable short to BAT ON Normal signal - Engine discord
31n5 ENG.RUNNING - No. n injector driving power cable short to GND input
31n4 - No. n injector driving signal cable short to BAT
31n3 - No. n injector driving signal cable short to GND
31n2 - No. n injector driving power cable and signal cable short
31n1 - No. n injector driving power cable and signal cable short
20 1321 FUEL PRESS. IG “ON” and - Fuel pressure keeps 2bar(idle) ON Normal signal - Maximum output limit
IN RAIL ENG.RUNNING to 3.5bar(rated) for 20 H. input
- Fuel filter clogging
- Fuel pressure is less than 1.5
bar(idle)to 3.5bar(rated)
- Fuel filter clogging
Over heating - Coolant temperature: - Maximum output limit
21 1314 HIGH COOLANT IG “ON” and - Coolant temperature sensor short to ground
warning light 98°C and less
TEMP. ENG.RUNNING - Engine temperature overheating
On
22 1266 Air Heater ENG.RUNNING - Air heater relay melting Air heater - Error release - Air Heater lamp
- Air heater line short to battery lamp On flashing
- Heater faulty (Flashing)
23 3222 ENG. PRE IG “ON” and - ECU output terminal short to ground OFF - Error release - Air Heater lamp
HEATER SUB- ENG.RUNNING flashing
RELAY
24 3223 CRUISE/PTO IG “ON” and - ECU output terminal short to ground OFF - Error release
M/V DRIVE ENG.RUNNING
31-22 FUEL SYSTEM
26 3215 COOLANT IG “ON” and - ECU output terminal short to battery OFF - Error release
OVERHEAT IND. ENG.RUNNING
LAMP
27 3216 ENG. BRAKE IG “ON” and - ECU output terminal short to battery OFF - Error release
IND. LAMP ENG.RUNNING
28 3211 CYLINDER IG “ON” and - ECU output terminal short to ground OFF - Error release
BALANCING ENG.RUNNING
29 3212 ENG. BRAKE IG “ON” and - Exhaust brake idle output short OFF - Error release
IDLE OUTPUT ENG.RUNNING
30 3213 ENG. BRAKE IG “ON” and - ECU output terminal short to ground OFF - Error release
IDLE OUTPUT ENG.RUNNING
MED/HI
31 3221 ENG. IG “ON” and - ECU output terminal short to ground OFF - Error release
PREHEATER ENG.RUNNING
34 3224 MAIN POWER IG “ON” and - Relay melting OFF - Error release - Starting impossible
RELAY ENG.RUNNING - Relay faulty
- Relay fuse disconnection
35 4444 ENGINE IG “ON” and - Memory faulty ON - Error release - Starting impossible
CONTROL ENG.RUNNING - S/W & H/W faulty (solid)
UNIT - Input / Output terminal faulty
- Central processing unit faulty
DIAGNOSTICS AND MEASURES 31-23
SOLA408A
31-24 FUEL SYSTEM
EU1 NO1
E29
E43
SOLA408A
Unit injector 1
Unit injector faulty
(Connector No.43, 29 terminal of ECU Resistance 1.0~2.0
Cable harness faulty
harness side)
Unit injector 2
Unit injector faulty
(Connector No.43, 45 terminal of ECU Resistance 1.0~2.0
Cable harness faulty
harness side)
Unit injector 3
Unit injector faulty
(Connector No.43, 30 terminal of ECU Resistance 1.0~2.0
Cable harness faulty
harness side)
Unit injector 4
Unit injector faulty
(Connector No.46, 32 terminal of ECU Resistance 1.0~2.0
Cable harness faulty
harness side)
Unit injector 5
Unit injector faulty
(Connector No.46, 31 terminal of Resistance 1.0~2.0
Cable harness faulty
ECU harness side)
Unit injector 6
Unit injector faulty
(Connector No.46, 33 terminal of ECU Resistance 1.0~2.0
Cable harness faulty
harness side)
DIAGNOSTICS AND MEASURES 31-25
E39
1 2 3
14 13 12 11 10 9 8 7 6 5 4 3 2 1
27 26 25 24 23 22 21 20 19 18 17 16 15
41 40 39 38 37 36 35 34 33 32 31 30 29 28
54 53 52 51 50 49 48 47 46 45 44 43 42
E38
1. Sensor input (Cut-off )
2. Sensor output
3. Ground
SOLA722A
[NOTE]
Check if gap between sensor and fly wheel is proper at sensor
replacement.
Air gap between sensor and fly wheel: 1.0~2.0mm
Joint torque of crank shaft location sensor: 0.8~1.0kg.m
HEW45-5796
31-26 FUEL SYSTEM
14 13 12 11 10 9 8 7 6 5 4 3 2 1
27 26 25 24 23 22 21 20 19 18 17 16 15
1 2 3
41 40 39 38 37 36 35 34 33 32 31 30 29 28
54 53 52 51 50 49 48 47 46 45 44 43 42
1. Screen
2. Sensor output
3. Ground
SOLA723A
[NOTE]
Check if gap between sensor and fly wheel is proper at sensor
replacement.
Air gap between sensor and fly wheel : 1.0~2.0mm
Joint torque of crank shaft location sensor : 0.8~1.0kg.m
DIAGNOSTICS AND MEASURES 31-27
14 13 12 11 10 9 8 7 6 5 4 3 2 1
27 26 25 24 23 22 21 20 19 18 17 16 15 1 2 3
41 40 39 38 37 36 35 34 33 32 31 30 29 28
54 53 52 51 50 49 48 47 46 45 44 43 42
E6
E19
1. Sensor output
2. Coolant temperature gauge unit
3. Ground
SOLA724A
Sensor test
1. Remove coolant temperature sensor
2. Sink temperature sensing part of coolant temperature sensor
into warm water and check resistance.
Temperature(°C) Resistance( )
0 5.79
20 2.48
40 1.15
80 0.32
Assembly
1. Apply three bond TB2403 or equivalent one to screw.
2. Mount coolant temperature sensor and tighten up to be specific
torque.
SOLA410A
Torque : 2-4kg·m
3. Connect harness connector precisely.
31-28 FUEL SYSTEM
14 13 12 11 10 9 8 7 6 5 4 3 2 1
27 26 25 24 23 22 21 20 19 18 17 16 15 1234
41 40 39 38 37 36 35 34 33 32 31 30 29 28
54 53 52 51 50 49 48 47 46 45 44 43 42
kpa.abs[mmHg abs]
SOLA725A
Sensor test
1. Separate intake pressure temperature sensor connector
2. Measure resistance between terminal (3) and (4).
3. Measure resistance, heating sensor in use of hair dryer. <Connector of sensor side>
Temperature (°C) Resistance
The higher The lower
1234
SOLA726A
14 13 12 11 10 9 8 7 6 5 4 3 2 1
27 26 25 24 23 22 21 20 19 18 17 16 15 1 2
41 40 39 38 37 36 35 34 33 32 31 30 29 28 3 4
54 53 52 51 50 49 48 47 46 45 44 43 42
1. Power (5V)
2. Temperature sensor output
3. Pressure sensor output
4. Ground SOLA727A
*. 1 Bar = 100KPa
Oil pressure temperature Resistance and voltage Sensor faulty Refer to table
sensor and cable harness Cable harness faulty
REPAIR AND ADJUSTMENT PROCEDURE 31-31
SOLA421A
3. Remove locker arm shaft, using locker arm shaft setting tool.
4. Discharge fuel in cylinder head according to fuel draining
procedure.
5. Clean around unit injector to replace.
SOLA020A
SOLA019A
SOLA023A
SOLA019A
11. Clean unit injector hole in cylinder head and remove sealing
cramp.
Sealing
cramp
SOLA418A
12. Replace with new O-ring in unit injector and apply engine oil.
Check if it is held between valve spring and tighten up to specific
torque.
[Specific torque]
In not replacing nozzle tube (in replacing injector only):
1.5kg + 60°
In replacing nozzle tube:
First: 1.5kg + 90° + 90°, Loosen completely in 2 min.
Second: 1.5kg + 60°
13. Connect cable with unit injector and tighten up to specific torque.
[Specific torque]
0.15 ~ 0.2 kgf.m
[NOTE]
If nut is tightened up over specific torque, solenoid valve
may be damaged.
14. Adjustment of injector pre-stroke SILA020A
14. Apply engine oil to cam shaft rob and valve bridge and mount
locker arm shaft in its place, using locker arm shaft using setting
tools.
SOLA020A
Air vent
bolt
SOLA426A
SOLA428A
31-34 FUEL SYSTEM
FUEL FILTER
Fuel filter is cartridge type that replacement of element is easy.
Composition drawing
7 5
6 3
SOLA437A
SOLA439A
2. Place container under hose of air vent hole at fuel filter head and
loosen air vent bolt.
SOLA441A
SOLA442A
SOLA440A