05 - Fuel System

Fuel System
Fuel System
General Information
2009 > D 1.6 TCI-U >
SPECIAL SERVICE TOOLS
Tool (Number and name) Illustration Application
09351-2A100
Removing the injector
Injector Remover Adapter
09351-4A300
Removing the injector
Injector Remover
09314-27110(14mm)
09314-27120(17mm) Installing the high pressure pipe
Torque Wrench Socket
09331-2A000
High Pressure Pump Removing the high pressure fuel pump
Sprocket Remover
09310-2B100 Removing and installing the fuel sender

Fuel Pump Plate Cover Wrench plate cover
REFERENCE SERVICE TOOL - COMMON RAIL TESTER
Tool Number Tool Name

CRT-1000 Common Rail Tester (Standard Kit)
CRT-1010 Tool Case
CRT-1020 Regulator Valve
CRT-1021 Plug (for Delphi) M14mm
CRT-1022 Plug (for Bosch) M12mm
CRT-1023 Adapter (for Bosch)
CRT-1030 Flask & Holder
CRT-1031 Visible Tube
CRT-1032 Injector Return Hose Adapter
CRT-1033 Injector Return Hose Plug
CRT-1034 Flushing Tube
CRT-1035 Dust Cap
CRT-1040 High Pressure Meter
CRT-1041 Adapter Connector (for Delphi Old)
CRT-1042 Adapter Connector (for Delphi New)
CRT-1043 Adapter Connector (for Bosch)
CRT-1044 IMV Control Valve
CRT-1050 Vacuum Gauge
CRT-1051 Pressure Gauge
CRT-1052 Gauge Connection Tube
CRT-1053 Connection Adapter
CRT-1054 Connection Adapter with Hose
CRT-1055 Hose Clamp
CRT-1060 User's Guide
* To use this Common Rail Tester, refer to the user's guide included in this kit.
2009 > D 1.6 TCI-U >
SPECIFICATION
FUEL DELIVERY SYSTEM
Items Specification
55 lit. (14.5 Imp.gal., 12.1
Fuel Tank Capacity
U.S.gal.)
Fuel Return System Type Return Type
High pressure type (Built in
Fuel Filter Type
engine room)
Mechanical, Plunger Pumping
Type
High Pressure Fuel Pump Type
Driven by Drive Belt
1,600 bar (160 MPa, 23,206
Fuel Pressure (Maximum) Pressure
psi)
INPUT SENSORS
MASS AIR FLOW SENSOR (MAFS)
▷ Type: Hot-Film Type
▷ Specification
* At intake air temperature = 20°C(68°F)
Air Flow (kg/h) Frequency (kHz)

8 1.94 ~ 1.96
10 1.98 ~ 1.99
15 2.06 ~ 2.07
75 2.72 ~ 2.75
160 3.36 ~ 3.41
310 4.44 ~ 4.53
640 7.66 ~ 8.01
800 10.13 ~ 11.17
* At intake air temperature = -15°C(5°F) or 80°C(176°F)
Air Flow (kg/h) Frequency (kHz)

10 1.97 ~ 1.99
75 2.71 ~ 2.76
160 3.34 ~ 3.43
310 4.39 ~ 4.58
INTAKE AIR TEMPERATURE SENSOR (IATS) #1 [BUILT IN MAFS]

▷ Type: Thermistor type
▷ Specification
Temperature [°C(°F)] Resistance(k)

-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
BOOST PRESSURE SENSOR (BPS)

▷ Type: Piezo-resistive pressure sensor type
▷ Specification
Pressure (kPa) Output Voltage (V)

32.5 0.5
70.0 1.02 ~ 1.17
100.0 1.53 ~ 1.68
150.0 2.33 ~ 2.48
200.0 3.12 ~ 3.27
250.0 3.92 ~ 4.07
270.0 4.20 ~ 4.35
284.0 4.5
INTAKE AIR TEMPERATURE SENSOR (IATS) #2 [BUILT IN BPS]

▷ Specification

-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
ENGINE COOLANT TEMPERATURE SENSOR (ECTS)

▷ Specification

-40(-40) 48.14
-20(-4) 14.13 ~ 16.83
0(32) 5.79
20(68) 2.31 ~ 2.59
40(104) 1.15
60(140) 0.59
80(176) 0.32
CAMSHAFT POSITION SENSOR (CMPS)

▷ Type: Hall effect type
▷ Specification
Level Output Pulse (V)

High 12V
Low 0V
CRANKSHAFT POSITION SENSOR (CKPS)

▷ Type: Variable reluctance type
▷ Output Voltage (V): 0 ~ 5V
Items Specification
Coil Resistance() 774 ~ 946 [°C(°F)]
ACCELERATOR POSITION SENSOR (APS)

▷ Type: Potentiometer type
▷ Specification
Output Voltage(V)
Test Condition
APS 1 APS 2
Idle 0.7 ~ 0.8 0.275 ~ 0.475
Fully depressed 3.8 ~ 4.4 1.75 ~ 2.35
Specification
Items
APS 1 APS 2
Potentiometer Resistance (k) 0.7 ~ 1.3 1.4 ~ 2.6
FUEL TEMPERATURE SENSOR (FTS)

▷ Specification

-30(-22) 27.0
-20(-4) 15.67
-10(14) 9.45
0(32) 5.89
20(68) 2.27 ~ 2.73
40(104) 1.17
50(122) 0.83
60(140) 0.60
70(158) 0.43
80(176) 0.30 ~ 0.32
RAIL PRESSURE SENSOR (RPS)
▷ Type: Piezo-electricity type
▷ Specification
Test Condition Rail pressure (bar) Output Voltage (V)

Idle 220 ~ 320 Below 1.7
Fully depressed 1800 Approx. 4.5
LAMBDA SENSOR
▷ Type: Zirconia (ZrO2) Type
▷ Specification
Value (A/F Ratio) Pumping Current(A)

0.65 -2.22
0.70 -1.82
0.80 -1.11
0.90 -0.50
1.01 0.00
1.18 0.33
1.43 0.67
1.70 0.94
2.42 1.38
Air (Atmosphere) 2.54
Temperature [°C(°F)] Heater Resistance()

20(68) 9.2
100(212) 10.7
200(392) 13.0
300(572) 14.6
400(752) 17.7
500(932) 19.2
600(1,112) 20.7
700(1,292) 22.5
VEHICLE SPEED SENSOR (VSS)

▷ Type: Inductive type
OUTPUT ACTUATORS
INJECTOR
▷ Number: 4
▷ Specification
Items Specification
Coil Resistance () 0.215 ~ 0.295 [20~70°C(68~158°F)]
FUEL PRESSURE REGULATOR VALVE
▷ Type: Duty control type
▷ Specification
Items Specification
Coil Resistance () 2.6 ~ 3.15 [20°C(68°F)]
RAIL PRESSURE REGULATOR VALVE

▷ Specification
Items Specification
ELECTRIC EGR CONTROL VALVE

▷ Type: Linear solenoid type
▷ Specification
Items Specification
VGT CONTROL SOLENOID VALVE

▷ Specification
Items Specification
VARIALBE SWIRL CONTROL ACTUATOR

▷ Type : Motor driven (including Position Sensor )
▷ Specification
Motor
Items Specification
Coil Resistance () 3.4 ~ 4.4 [20°C (68°F)]
Position Sensor
Items Specification
Coil Resistance () 3.44 ~ 5.16k [20°C (68°F)]
SERVICE STANDARD
Neutral,N,P-range 830 ± 100 rpm

A/C OFF
Basic Idle rpm(After warm D-range 830 ± 100 rpm
up) Neutral,N,P-range 830 ± 100 rpm
A/C ON
D-range 830 ± 100 rpm
TIGHTENING TORQUES
ENGINE CONTROL SYSTEM
Item N·m Kgf·m lbf·ft
ECM installation bolts/nuts (on bracket) 8.8 ~ 13.7 0.9 ~ 1.4 6.5 ~ 10.1
ECM bracket installation bolts/nuts 3.9 ~ 5.9 0.4 ~ 0.6 2.9 ~ 4.3
Mass air flow sensor clamp tightening 2.9 ~ 4.9 0.3 ~ 0.5 2.2 ~ 3.6
Mass air flow sensor mounting bolts (on air cleaner
2.9 ~ 4.9 0.3 ~ 0.5 2.2 ~ 3.6
assembly)
Boost pressure sensor installation bolts 6.9 ~ 10.8 0.7 ~ 1.1 5.1 ~ 8
Engine coolant temperature sensor installation 24.5 ~ 34.3 2.5 ~ 3.5 18.1 ~ 25.3
Crankshaft position sensor installation bolt 5.9 ~ 9.8 0.6 ~ 1.0 4.3 ~ 7.2
Camshaft position sensor installation bolt 6.9 ~ 9.8 0.7 ~ 1.0 5.1 ~ 7.2
Lambda sensor installation 39.2 ~ 58.9 4.0 ~ 6.0 28.9 ~ 43.4
Electric EGR control valve installation bolts 21.6 ~ 27.5 2.2 ~ 2.8 15.9 ~ 20.0
VGT control solenoid valve bracket installation nuts 6.9 ~ 10.8 0.7 ~ 1.1 5.1 ~ 8
Throttle body installation nuts 6.9 ~ 10.8 0.7 ~ 1.1 5.1 ~ 8
Glow plug installation 14.7 ~ 19.6 1.5 ~ 2.0 10.9 ~ 14.5
Glow plug plate installation nuts 0.8 ~ 1.5 0.08 ~ 0.15 0.6 ~ 1.1
FUEL DELIVERY SYSTEM
Item N·m Kgf·m lbf·ft

Injector clamp installation bolt 28.4 ~ 30.4 2.9 ~ 3.1 21 ~ 22.4
Common rail installation bolts 14.7 ~ 21.6 1.5 ~ 2.2 10.9 ~ 15.9
High pressure fuel pump installation bolts 14.7 ~ 19.6 1.5 ~ 2.0 10.9 ~ 14.5
High pressure pipe (Injector Common Rail) installation
24.5 ~ 28.4 2.5 ~ 2.9 18.1 ~ 21
nuts
High pressure pipe (Common RaiI High Pressure Fuel
24.5 ~ 28.4 2.5 ~ 2.9 18.1 ~ 21
Pump) installation nuts
Fuel sender plate cover tightening 60.0 ~ 70.0 6.1 ~ 7.1 44.3 ~ 51.6
Accelerator pedal installation bolts 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Fuel System
Fuel System
Engine Control System
2009 > D 1.6 TCI-U >
DESCRIPTION
1. Engine is hard to start or does not start at all.
2. Nstable idle.
3. Poor driveability.
• 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.
SELF-DIAGNOSIS
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.
CHECKING PROCEDURE (SELF-DIAGNOSIS)
• When attery voltage is excessively low, diagnostic trouble codes can not be read. Be sure to check the
battery for voltage and the charging system before starting the test
• Diagnosis memory is erased if the battery or the ECM connector is disconnected. Do not disconnect
the battery before the diagnostic trouble codes are completely read and recorded.
INSPECTION PROCEDURE (USING GENERIC SCAN TOOL)

1. Turn OFF the ignition switch.
2. Connect the scan tool to the data link connector on the lower crash pad.
3. Turn ON the ignition switch.
4. Use the scan tool to check the diagnostic trouble code.
5. Repair the faulty part from the diagnosis chart.
6. Erase the diagnostic trouble code.
7. Disconnect the GST.
When deleting diagnostic trouble code, use scan tool as possible. When deleting diagnostic trouble
code by disconnecting battery terminal(-), data for ECM control may delete simultaneously.
2009 > D 1.6 TCI-U >
COMPONENT LOCATION
1. Mass Air Flow Sensor (MAFS) 3. Boost Pressure Sensor (BPS)

2. Intake Air Temperature Sensor (IATS) #1 built in MAFS 4. Intake Air Temperature Sensor (IATS) #2 built in BPS
5. Engine Coolant Temperature Sensor (ECTS) 6. Lambda Sensor
7. Camshaft Position Sensor (CMPS)

8. Crankshaft Position Sensor (CKPS)
18. Electric EGR Control Valve
10. Fuel Temperature Sensor (FTS)

9. Accelerator Pedal Position Sensor (APS)
19. Fuel Pressure Regulator Valve
12. Rail Pressure Sensor (RPS)

11.A/C Pressure Transducer (APT) 15. Injector
20. Rail Pressure Regulator Valve
13. Vehicle Speed Sensor (VSS) 14. Water Sensor (included in Fuel Filter)
16. Variable Swirl Control Actuator 17. VGT Control Solenoid Valve
21. Main Relay 24. ECM (Engine Control Module)

Fuel System
Fuel System
Engine Control System,UNPUL*VU[YVS4VK\SL
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2009 > D 1.6 TCI-U >
CIRCUIT DIAGRAM
2009 > D 1.6 TCI-U >
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)
REPLACEMENT
After replacing an ECM, MUST input the injector data (7 digit) of each cylinder into a new ECM.
1. Turn ignition switch OFF.

2. Disconnect the battery negative (-) cable from the battery.
3. Disconnect the ECM connector (A) and unfasten the mounting bolts (B) under the instrument panel (RH
side).
4. Install a new ECM according to the reverse order of steps 1, 2, and 3.
ECM mounting bolts/nuts : 0.4 ~ 0.6kgf·m (3.9 ~ 5.9 N·m, 2.9 ~ 4.3lbf·ft)
5. Connect a scan tool to Data Link Connector (DLC) and turn ignition switch on.
6. Proceed "INJECTOR CORRECTION" procedure.
(1) Select "ENGINE CONTROL".
(2) Select "AUTO SELECTION MODE" or "MANUAL SELECTION MODE".
(3) Select "1.6L VGT DIESEL" in case of "MANUAL SELECTION MODE".

(4) Select "INJECTOR CORRECTION".
(5) Press "ENTER" key.

(6) Input the injector data (7 digit) written on the top of each inejctor with function keys ([F1] ~ [F6]) and
number keys.
When "WRITING FAIL" is displayed on the scan tool, input injector data (7 digits) of each cylinder
into a new ECM again as prior procedure.
2009 > D 1.6 TCI-U >
ECM (ENGINE CONTROL MODULE)

1. ECM HARNESS CONNECTOR
2. ECM TERMINAL FUNCTION

CONNECTOR [CUD-M]
Pin Description Connected to
1 Injector (Cylinder #3) [HIGH] control output Injector (Cylinder #3)
3 -
4 Battery power Rail Pressure Regulator Valve
5 -
6 Sensor ground Position Sensor (in Variable Swirl Control Actuator)
7 Sensor shield Crankshaft Position Sensor (CKPS)
8 Sensor ground Rail Pressure Sensor (RPS)
9 -
10 -
11 -
12 Crankshaft Position Sensor (CKPS) [+] signal input Crankshaft Position Sensor (CKPS)
13 Sensor Power (+5V) Boost Pressure Sensor (BPS)
14 -
15 -
18 -
19 Battery power Fuel Pressure Regulator Valve
20 Sensor ground Camshaft Position Sensor (CMPS)
21 -
22 -
23 Sensor ground Boost Pressure Sensor (BPS)
24 -
25 -
26 Sensor Power (+5V) Position Sensor (in Variable Swirl Control Actuator)
27 Crankshaft Position Sensor (CKPS) [-] signal input Crankshaft Position Sensor (CKPS)
28 Sensor Power (+5V) Rail Pressure Sensor (RPS)
29 -
30 Variable Swirl Control Actuator [-] control output Variable Swirl Control Actuator
31 Injector (Cylinder #2) [LOW] control output Injector (Cylinder #2)
32 -
34 Rail Pressure Regulator Valve control output Rail Pressure Regulator Valve
35 -
36 -
37 Reference frequency Mass Air Flow Sensor (MAFS)
38 -
39 -
40 Boost Pressure Sensor (BPS) signal input Boost Pressure Sensor (BPS)
41 Sensor ground Engine Coolant Temperature Sensor (ECTS)
42 Mass Air Flow Sensor (MAFS) signal input Mass Air Flow Sensor (MAFS)
43 Rail Pressure Sensor (RPS) signal input Rail Pressure Sensor (RPS)
44 Sensor ground MAFS & IATS #1
45 -
48 -
49 Fuel Pressure Regulator Valve control output Fuel Pressure Regulator Valve
50 Camshaft Position Sensor (CMPS) signal input Camshaft Position Sensor (CMPS)
51 -
52 -
53 Intake Air Temperature Sensor (IATS) #2 signal input Intake Air Temperature Sensor (IATS) #2 built in BPS
54 -
55 -
56 Position Sensor signal input Position Sensor (in Variable Swirl Control Actuator)
57 -
Engine Coolant Temperature Sensor (ECTS) signal
58 Engine Coolant Temperature Sensor (ECTS)
input
59 Electric EGR Control Valve control output Electric EGR Control Valve
60 Variable Swirl Control Actuator [+] control output Variable Swirl Control Actuator
CONNECTOR [CUD-K]
Pin Description Connected to
1 Battery voltage supply after main relay Main Relay
2 Power ground Chassis Ground
7 Cooling Fan Relay [HIGH] control output Cooling Fan Relay [HIGH]
8 Sensor ground Accelerator Position Sensor (APS) #2
9 Accelerator Position Sensor (APS) #1 signal input Accelerator Position Sensor (APS) #1
10 Sensor ground Fuel Temperature Sensor (FTS)
11 Fuel Temperature Sensor (FTS) signal input Fuel Temperature Sensor (FTS)
12 Sensor ground A/C Pressure Transducer
13 A/C Pressure Transducer signal input A/C Pressure Transducer
14 Ground Cruise Control Switch
15 Cruise Control "ACTUATOR" signal input Cruise Control Switch
16 Ground Immobilizer Control Module
17 -
18 -
19 -
20 -
21 -
22 Sensor Power (+5V) A/C Pressure Transducer
23 -
24 Power Supply Cruise Control Switch
25 Diagnostic K-Line Data Link Connector (DLC)
26 -
27 Fuel consumption signal output Trip computer
28 Ignition switch signal input Ignition Switch
29 VGT Control Solenoid Valve control output VGT Control Solenoid Valve
30 Sensor ground Accelerator Position Sensor (APS) #1
31 Accelerator Position Sensor (APS) #2 signal input Accelerator Position Sensor (APS) #2
32 -
33 -
34 -
35 -
36 -
37 -
38 Brake Switch "Lamp" signal input Brake Switch
39 -
40 Water Sensor siganl input Water Sensor in Fuel Filter
41 -
42 Blower Switch Signal input Blower Switch
43 -
44 -
45 Sensor Power (+5V) Accelerator Position Sensor (APS) #1
46 Sensor Power (+5V) Accelerator Position Sensor (APS) #2
47 Immobilizer Communication Line Immobilizer Control Module
48 Engine speed signal output Tachometer (Cluster)
49 Cruise Control "SET" Lamp control output Cruise Control "SET" Lamp (Cluster)
50 -
51 Lambda Sensor Heater control output Lambda Sensor
52 "Idle Up" signal input EPS control module
53 -
54 A/C Switch "ON" signal input A/C Switch
55 -
56 Thermo Switch signal input A/C Switch
57 Gear Neutral Switch signal input (MT Only) Gear Neutral Switch
58 -
59 -
60 -
61 -
62 -
63 -
64 Lambda Sensor Voltage "NERNST" Lambda Sensor
65 Lambda Sensor Current Pump Lambda Sensor
66 -
67 -
68 Malfunction Indicator Lamp (MIL) control output Malfunction Indicator Lamp (MIL)
69 Glow Time Indicator Lamp control output Glow Time Indicator Lamp (Cluster)
70 A/C Compressor Relay control output A/C Compressor Relay
71 Cooling Fan Relay [LOW] control output Cooling Fan Relay
72 Main Relay control output Main Relay
73 -
74 -
75 Vehicle speed signal input Vehicle Speed Sensor (VSS)
76 -
77 -
78 -
79 Clutch Switch signal input Clutch Switch
80 Brake Switch "Redundant" signal input Brake Switch
81 MT/AT Auto recognition signal input M/T : Open, A/T : Ground
82 -
83 CAN [LOW] Other Control Modules
84 CAN [HIGH] Other Control Modules
85 -
86 Lambda Sensor Virtual Ground Lambda Sensor
87 Lambda Sensor Current Adjust Lambda Sensor
88 -
89 Intake Air Temperature Sensor (IATS) #1 signal input Intake Air Temperature Sensor (IATS) #1 in MAFS
90 -
91 Cruise Control "MAIN" Lamp control output Cruise Control "MAIN" Lamp (Cluster)
92 Immobilizer Lamp control output Immobilizer Lamp (Cluster)
93 Glow Relay control output Glow Relay
94 PTC Heater Relay control output PTC Heater Relay
3. ECM TERMINAL INPUT/OUTPUT SIGNAL

CONNECTOR [CUD-M]
Pin Description Vehicle State Type Level Test Result
Battery Voltage ~
Injector (Cylinder #3) [HIGH] 46.4V
1 Idle Pulse 80V
control output
7.418Hz
Battery Voltage ~
2 Idle Pulse 80V
control output
7.418Hz
3 -
4 Battery power Idle DC Battery Voltage 13.96V
5 -
6 Sensor ground Idle DC Max. 50mV -1.7mV
7 Sensor shield Idle DC Max. 50mV -2.858mV
9 -
10 -
11 -
Crankshaft Position Sensor Vpeak_to_peak:
12 Idle Sine Wave 52.8V
(CKPS) [+] signal input Min.1.0V
IG OFF Max. 0.5V -50mV
13 Sensor Power (+5V) DC
IG ON 4.9 ~ 5.1V 4.95V
14 -
15 -
Battery Voltage ~
16 Idle Pulse 80V
control output
7.44Hz
Battery Voltage ~
17 Idle Pulse 80V
control output
7.44Hz
18 -
IG OFF Max. 0.5 V 175mV
19 Battery power DC
IG ON Battery Voltage 12.57V
21 -
22 -
24 -
25 -
IG ON 4.9 ~ 5.1V 4.91V
Crankshaft Position Sensor Vpeak_to_peak:
27 Idle Sine Wave 52.8V
(CKPS) [-] signal input Min.1.0V
IG ON 4.9 ~ 5.1V 4.91V
29 -
30 Variable Swirl Control Actuator Active Pulse Hi: Battery Voltage
Low: Max. 1.0V
[-] control output
Frequency: 1,000Hz
Peak Current: 19 ~
21 A
Peak Current: 19.7
Hold Current: 11~ 13
Injector (Cylinder #2) [LOW] A
31 Idle Pulse A
control output Hold Current: 13.4
A
32 -
Peak Current: 19 ~
21 A
Peak Current: 19.7
Injector (Cylinder #4) [LOW] A
33 Idle Pulse A
control output Hold Current: 13.4
A
Hi: Battery Voltage 14.78V

Lo: Max. 1.0V 60mV
Rail Pressure Regulator Valve
34 Idle Pulse Frequency:
control output 1.098KHz
1kHz±2%
Duty (+): 74.37%
35 -
36 -
Hi: Vcc 4.94V
37 Reference frequency Idle Pulse
Lo: Max. 1.0V 340mV
38 -
39 -
Boost Pressure Sensor (BPS)
40 IG ON Analog 0.5 ~ 4.5V 1.602mV
signal input
Mass Air Flow Sensor (MAFS) Hi: Vcc 4.95V

42 Idle Pulse
signal input Lo: Max. 1.0V 350mV
IG ON Max. 1.0V 512mV
Rail Pressure Sensor (RPS)
43 Idle Analog 1.0 ~ 1.5 V 1.089V
signal input
3000 RPM 1.5 ~ 3.0 V 1.886V
45 -
Peak Current: 19 ~
21 A
Peak Current:
Injector (Cylinder #3) [LOW] 19.8A
46 Idle Pulse A
control output Hold Current:
13.5A
Peak Current: 19 ~
21 A Peak Current:
Injector (Cylinder #1) [LOW] Hold Current: 11~ 13 19.6A
47 Idle Pulse
control output A Hold Current:
13.4A
48 -
Fuel Pressure Regulator Valve
49 Idle Pulse Lo: Max. 1.0V 540mV
control output
203Hz
Hi: Vcc or Battery
4.95V
Voltage
Idle
Lo: Max. 1.0V -10mV
Camshaft Position Sensor 17.44Hz

50 Pulse
(CMPS) signal input Hi: Vcc or Battery
4.95V
Voltage
3000rpm
Lo: Max. 1.0V -10mV
52.33Hz
51 -
52 -
Intake Air Temperature Sensor
53 Idle Analog 0.5 ~ 4.5V 1.954V
(IATS) #2 signal input
54 -
55 -
56 Position Sensor signal input IG ON Analog 0.5 ~ 4.5V
57 -
Engine Coolant Temperature
58 Idle Analog 0.5 ~ 4.5V 804.6mV
Sensor (ECTS) signal input
Electric EGR Control Valve Lo: Max. 1.0V -20mV

59 Idle Pulse
control output 154.7Hz
Duty(+): 91.79%
Hi: Battery Voltage
Variable Swirl Control Actuator
60 Active Pulse Low: Max. 1.0V
[+] control output
Frequency: 1,000Hz
CONNECTOR [CUD-K]
Pin Description Vehicle State Type Level Test Result
Battery voltage supply after IG OFF Max. 1.0 V 175mV

1 DC
main relay IG ON Battery Voltage 12.77V
2 Power ground Idle DC Max. 50mV
Battery voltage supply after IG OFF Max. 1.0 V -25mV

3 DC
Battery voltage supply after IG OFF Max. 1.0 V -25mV

5 DC
7 Cooling Fan Relay [HIGH] Relay OFF DC Battery Voltage 13.98V
control output Relay ON Max. 1.0V -25mV
Accelerator Position Sensor C.T 0.3 ~ 0.9V 682.8mV

9 Analog
(APS) #1 signal input W.O.T 4.0 ~ 4.8V 4.029V
Fuel Temperature Sensor
11 IG ON Analog 0.5 ~ 4.5V 2.311V
(FTS) signal input
A/C Pressure Transducer A/C OFF Max. 4.8V 1.327V

13 Analog
signal input A/C ON 2.426V
14 Ground Idle DC Max. 50mV -1.7mV
Cruise Control
15
"ACTIVATOR" signal input
16 Ground Idle DC Max. 50mV -3.801mV
17 -
18 -
19 -
20 -
21 -
IG ON 4.9 ~ 5.1V 4.91V
23 -
IG OFF Max. 0.5V
24 Power Supply DC
IG ON 4.9 ~ 5.1V
Hi: Min. Battery
12.78V
When Voltage×80%
transmitting Lo: Max. Battery
140mV
Voltage×20%
25 Diagnostic K-Line Pulse
Hi: Min. Battery
12.78V
Voltage×70%
When receiving
Lo: Max. Battery
700mV
Voltage×30%
26 -
Hi: Battery Voltage or Vcc 3.435V
Fuel consumption signal
27 Idle Pulse Lo: Max. 0.5V -5mV
output
1.25Hz
IG OFF Max. 1.0 V -25mV
28 Ignition switch signal input DC
IG ON Battery Voltage 12.57V
Lo: Max. 0.5V 175mV
Idle
Duty (+):
VGT Control Solenoid Valve 19.87%
29 Pulse
control output
3000rpm Lo: Max. 0.5V 175mV
Duty(+): 53.48%
Accelerator Position Sensor C.T 0.3 ~ 0.9V 333.8mV

31 Analog
(APS) #2 signal input W.O.T 1.5 ~ 3.0V 1.989V
32 -
33 -
34 -
35 -
36 -
37 -
Brake Switch "Lamp" signal Release Max. 0.5V -20mV

38 DC
input Push Battery Voltage 12.06V
39 -
Full of Water Battery Voltage 11.26V
40 Water Sensor siganl input Analog
No Water Max. 1V -20mV
41 -
Blower OFF Battery Voltage 12.17V
42 Blower Switch Signal input DC
Blower ON Max. 2V 175mV
43 -
44 -
IG ON 4.9 ~ 5.1V 4.99V
IG ON 4.9 ~ 5.1V 4.99V
When Hi: Min. 8.5V 12.54V
Immobilizer Communication
47 communicating Pulse
Line Lo: Max. 3.5V 1.1V
after IG ON
48 Engine speed signal output Idle Pulse Lo: Max. 0.5V 140mV
Frequency: 50~60Hz 59.53Hz
Cruise Control "SET" Lamp
49
control output
50 -
Lambda Sensor Heater
51 Vehicle Run Pulse Lo: Max. 1.0V 220mV
control output
109.8Hz
SW OFF Hi: Vcc 4.99V
52 Idle Up signal input DC
SW ON Lo: Max. 1.0V 70mV
53 -
A/C SW OFF Max. 1.0V 140mV
54 A/C Switch "ON" signal input DC
A/C SW ON Battery Voltage 14.06V
55 -
A/C OFF Max. 0.5V -20mV
56 Thermo Switch signal input DC
A/C ON Battery Voltage 13.1V
57 Gear Neutral Switch signal SW OFF (1st) DC Battery Voltage 12.54V
input (MT ONly) SW ON (neutral) Max. 0.5V -20mV
58 -
59 -
60 -
61 -
62 -
63 -
Normal: 450 ± 50mV 452mV
Lambda Sensor Voltage
64 Engine Running Analog Rich: Max. Normal + 150mV 452.9V
"NERNST"
Lean: Min. Normal - 150mV 351mV
Normal: 0 ± 500mV 608mV
Lambda Sensor Current
65 Engine Running Analog Rich: Min. Normal - 1.5V 447.7mV
Pump
Lean: Max. Normal + 1.5V 816.4mV
66 -
67 -
Malfunction Indicator Lamp Lamp OFF Battery Voltage 12.3V

68 DC
(MIL) control output Lamp ON Max. 1.0V -20mV
Glow Time Indicator Lamp Glow OFF Battery Voltage 12.06V

69 DC
control output Glow ON Max. 1.0V -20mV
A/C Compressor Relay A/Con OFF Battery Voltage 13.9V

70 DC
control output A/Con ON Max. 1.0V 60mV
Cooling Fan Relay [LOW] Relay OFF Battery Voltage 13.97V

71 DC
control output Relay ON Max. 1.0V 175mV
Relay OFF Battery Voltage 12.94V
72 Main Relay control output DC
Relay ON Max. 1.0V 940mV
73 -
74 -
Hi: Min. 5.0V 13.18V
Lo: Max. 1.0V 60mV
75 Vehicle speed signal input Vehicle Run Pulse
12.52Hz at
20kph
76 -
77 -
78 -
Release Max. 0.5V -20mV
79 Clutch Switch signal input DC
Push Battery Voltage 13.74V
Brake Switch "Redundant" Release Battery Voltage 14.14V

80 DC
signal input Push Max. 0.5V -20mV
MT/AT Auto recognition M/T Battery Vaoltage

81 DC
signal input A/T Max. 0.5V
82 -
Recessive 2.0 ~ 3.0 V
83 CAN [LOW] Pulse
Dominant 0.5 ~ 2.25 V
Recessive 2.0 ~ 3.0 V
84 CAN [HIGH] Pulse
Dominant 2.75 ~ 4.5 V
85 -
Lambda Sensor Virtual
86 Engine Running Analog 2.4 ~ 2.6V 2.462V
Ground
Lambda Sensor Current |Current Pump - Current
87 Engine Running Analog 86.86mV
Adjust Adjust| < 0.2V
88 -
Intake Air Temperature
89 Sensor (IATS) #1 signal Idle Analog 0.5 ~ 4.5V 2.129V
input
90 -
Cruise Control "MAIN" Lamp
91
control output
Immobilizer Lamp control Lamp OFF Battery Voltage 12.54V

92 DC
output Lamp ON Max. 1.0V 65mV
Relay OFF Battery Voltage 12.46V
93 Glow Relay control output DC
Relay ON Max. 1.0V 60mV
PTC Heater Relay control Relay OFF Battery Voltage 13.18V

94 DC
output Relay ON Max. 1.0V -20mV
Fuel System
Fuel System
Engine Control S`Z[LT4HZZ(PY-SV^:LUZVY
4(-:

2009 > D 1.6 TCI-U >
INSPECTION
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.
SPECIFICATION
CIRCUIT DIAGRAM
SIGNAL WAVEFORM
COMPONENT INSPECTION
1. Check the MAFS visually.
A. Mounting direction correct.
B. Any contamination, corrosion or damage on connector.
C. Air cleaner's clogging or wet.
D. MAFS cylinder's deforming or blocking by any foreign material.
2. Check any leakage on intake system and intercooler system.
Fuel System
Fuel System
Engine Control System - Intake Air Temperature
Sensor (IATS)
2009 > D 1.6 TCI-U >
INSPECTION
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 in Boost Pressure Sensor (BPS) are located in front of and behind
turbo-charger respectively. IATS #1 senses air temperature entering turbo-charger and the other (IATS #2) does air
temperature coming out from the turbo-charger.
Comparing these air temperature values from both sensors, more accurate sensing of intake air temperature is possible.
ECM uses these air temperature signals to perform EGR control correction and fuel injection quantity correction.
SPECIFICATION
CIRCUIT DIAGRAM
SIGNAL WAVEFORM
2. Disconnect the MAFS (for IATS #1) or BPS (for IATS #2) connector.
3. Measure resistance between IATS signal terminal and sensor ground terminal.
4. Check that the resistance is within the specification.
Specification: Refer to "SPECIFICATION".

Fuel System
Fuel System
Engine Control System - Engine Coolant Tem-
perature Sensor (ECTS)
2009 > D 1.6 TCI-U >
INSPECTION
Engine Coolant Temperature Sensor (ECTS) is located in the engine coolant passage of the cylinder head for detecting
the engine coolant temperature. The ECTS uses a thermistor whose resistance changes with the temperature. The
electrical resistance of the ECTS decreases as the temperature increases, and increases as the temperature decreases.
The reference 5V in the ECM is supplied to the ECTS via a resistor in the ECM.
That is, the resistor in the ECM and the thermistor in the ECTS are connected in series. When the resistance value of the
thermistor in the ECTS changes according to the engine coolant temperature, the output voltage also changes. During
cold engine operation the ECM increases the fuel injection duration and controls the ignition timing using the information
of engine coolant temperature to avoid engine stalling and improve drivability.
SPECIFICATION

-40(-40) 48.14
-20(-4) 14.13 ~ 16.83
0(32) 5.79
20(68) 2.31 ~ 2.59
40(104) 1.15
60(140) 0.59
80(176) 0.32
CIRCUIT DIAGRAM
SIGNAL WAVEFORM
2. Disconnect the engine coolant temperature sensor connector.
3. Remove the sensor.
4. After immersing the thermistor of the sensor into engine coolant, measure resistance between ECTS signal terminal
and ground terminal.
5. Check that the resistance is within the specification.

Fuel System
Fuel System
Engine Control System - Accelerator Position
Sensor (APS)
2009 > D 1.6 TCI-U >
INSPECTION
On electronic injection systems, there is no longer a load lever that mechanically controls the fuelling. The flow is
caculated by the ECM depending on a number of parameters, including pedal position, which is measured using a
potentiometer. The pedal sensor has two 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.
SPECIFICATION
Output Voltage(V)
Test Condition
APS 1 APS 2
Idle 0.7 ~ 0.8 0.275 ~ 0.475
Fully depressed 3.8 ~ 4.4 1.75 ~ 2.35
Specification
Items
APS 1 APS 2
Potentiometer Resistance (k) 0.7 ~ 1.3 1.4 ~ 2.6
CIRCUIT DIAGRAM
SIGNAL WAVEFORM
2. Disconnect the accelerator position sensor connector.
3. Measure resistance between voltage supply terminal and ground terminal of APS1.
4. Measure resistance between voltage supply terminal and ground terminal of APS2.

Fuel System
Fuel System
Engine Control System - Heated Oxygen Sensor
(HO2S)
2009 > D 1.6 TCI-U >
INSPECTION
Lambda Sensor is installed on exhaust manifold and is a linear oxygen sensor. It senses oxygen density of exhaust gas
in order to control EGR acculately through fuel correction and also limits smoke which is generated by rich air-fuel
mixture at high engine load condition. ECM controls pumping current in order to fit -value from linear lambda sensor to
1.0.
Lean air-fuel mixture(1.0 < < 1.1): ECM supplies pumping current to lambda sensor (+pumping current) and activates it
for lambda sensor to have the characteristic at =1.0 (0.0 pumping current). With the value of pumping current supplied
to lambda sensor, ECM detects lambda density of exhaust gas.
Rich air-fuel mixture(0.9 < < 1.0): ECM takes away pumping current from lambda sensor (-pumping current) and
deactivates it for lambda sensor to have the characteristic at =1.0 (0.0 pumping current). With the value of pumping
current taken away from lambda sensor, ECM detects lambda density of exhaust gas.
This performance is the most active and fast at normal operating temperature (450°C ~ 600°C) thus, in order to reach
normal operating temp. and last at that temperature, a heater (heating coil) is integrated with lambda sensor. The heater
coil is controlled by ECM as Pulse Width Modulation (PWM). The resistance of heater coil is low when coil is cold thus,
current through it increases while resistance is high when coil is hot thus, current decreases. With this principle,
temperature of lambda sensor is measured and lambda sensor heater operation varies based on the data.
SPECIFICATION
CIRCUIT DIAGRAM
SIGNAL WAVEFORM
Fuel System
Fuel System
Engine Control System - Crankshaft Position Sen-
sor (CKPS)
2009 > D 1.6 TCI-U >
INSPECTION
Piston position on combustion chamber is the substantial to define the starting of injection timing. All engine pistons are
connected to crankshaft by connecting rod. Sensor on crankshaft can supply the informations 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.
SPECIFICATION
Items Specification
Coil Resistance () 774 ~ 946 [20°C(68°F)]
CIRCUIT DIAGRAM
SIGNAL WAVEFORM
Fuel System
Fuel System
Engine Control System - Camshaft Position Sen-
sor (CMPS)
2009 > D 1.6 TCI-U >
INSPECTION
Camshaft Position Sensor (CMPS) is a hall sensor and detects the camshaft position by using a hall element. It is related
with Crankshaft Position Sensor (CKPS) and detects the piston position of the each cylinder which the CKPS can't
detect. This sensor is installed on engine head cover and uses a target wheel installed on the camshaft. It has a
hall-effect IC which output 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.
SPECIFICATION
Level Output Pulse (V)
High 12V
Low 0V
CIRCUIT DIAGRAM
SIGNAL WAVEFORM
Fuel System
Fuel System
Engine Control System - Injector
2009 > D 1.6 TCI-U >
DESCRIPTION
COMPONENTS
2009 > D 1.6 TCI-U >
REMOVAL
• Common Rail Fuel Injection System is subject to extremely high pressure (Approximately 1,600 bar)
• Never perform any work on injection system with engine running or within 30 seconds after the engine
stops.
• Always pay attention to safety precaution.
• Ensure the absolute cleanliness.
• It is not recommended to remove the injectors without any notice.
1. Turn ignition switch to OFF position.

2. Disconnect the negative battery (-) terminal and wait for about 30 seconds.
3. Disconnect the injector connector (A).
• Plugs must be installed and/or uninstalled only with the ignition switch turned OFF.
• Do not extremely bend or squeeze the cable, do not bring them in contact with sharp edges, and
also secure cables against vibrations.
4. Disconnect the high pressure pipe (A) connecting the injectors with the common rail.
5. After removing the clip (B), disconnect the retun hose (C) from the injectors and unscrew the clamp
tightening bolt (D).
6. Pull the injector assembly.
When pulling the injector, pull the injector upright so that the nozzle needle cannot be scratched or
damaged.
When the injector is stuck on cylinder head, pull it out with SST (SST No.: 09351-4A300).
INSTALLATION
1. Install the injector according to the reverse order of REMOVAL procedure.
When installing the injector, MUST REPLACE the O-ring (A) and apply a grease to that.
When installing the high pressure pipe, apply the specified tightening torques to the flange nuts of the
injectors and the common rail side with SST (Refer to below table).
Item Dimension SST No.

Flange Nut
14 mm (0.551 in) 09314-27110
(Injector Side)
Flange Nut
17 mm (0.669 in) 09314-27120
(Common Rail Side)
· Injector clamp installation bolts: 28.4 ~ 30.4 N·m
(2.9 ~ 3.1 kgf·m, 21 ~ 22.4 lbf·ft)
· High pressure pipe flange nuts (Injectors Common Rail):
24.5 ~ 28.4 N·m(2.5 ~ 2.9 kgf·m, 18.1 ~ 20.1 lbf·ft)
REPLACEMENT
After replacing an ECM, MUST input the injector data (7 digit) of each cylinder into a new ECM.
1. Replace the injector with a new one according to the "REMOVAL" and "INSTALLATION" procedures.
2. Connect a scan tool to Data Link Connector (DLC) and turn ignition switch on.
3. Select "ENGINE CONTROL".
4. Select "AUTO SELECTION MODE" or "MANUAL SELECTION MODE".
5. Select "1.6L VGT DIESEL" in case of "MANUAL SELECTION MODE".

6. Select "INJECTOR CORRECTION".
7. Press "ENTER" key.
8. Input the injector data (7 digit) written on the top of each inejctor with function keys ([F1] ~ [F6]) and number
keys.
When "WRITING FAIL" is displayed on the scan tool, input injector data (7 digits) of each cylinder into a
new ECM again as prior procedure.
INSPECTION
• COMPRESSION TEST
• IDLE SPEED COMPARISON
• INJECT QUANTITY COMPARISON
TEST PROCEDURE
1. Connect Hi-Scan(Pro) and select "Vehicle" and "Engine Test Function".
2. Information for ECM version is displayed as below.
3. After pressing "[ENTER]", select "COMPRESSION TEST" mode and press "[ENTER]".
4. Set the test condition described as below screen and then, crank engine. When engine stop message being
appeared, stop cranking.
5. Press "ANAL" and the test result is appeared.
During cranking engine does not start.

6. Press "AVG" and the data average of each cylinder is appeared.
Press "HELP" and description of the data is appeared.
7. After pressing "ESC", select "IDLE SPEED COMPARISON" and press "[ENTER]".
8. Set the test condition described as below screen and press "[ENTER]".
9. The rpm data of each cylinder is appeared.
10. Press "AVG" and the data average of each cylinder is appeared.
Press "HELP" and description of the data is appeared.
11. After pressing "ESC", select "INJECTOR QUANTITY COMPARISON" and press "[ENTER]".
12. Set the test condition described as below screen and press "[ENTER]".
13. The data od each cylinder about RPM and compensating injection quantity is appeared.
14. Press "HELP" and description of the data is displayed as below.
15. Replace the default injector, and then repeat previous test modes to check if the injector is normal.
1. Turn ignition switch "OFF".
2. Disconnect injector connector.
3. Measure resistance between the terminals 1 and 2 of injector connector.
Resistance : 0.215 ~ 0.295 [20 ~ 70°C(68 ~ 158°F)]

Fuel System
Fuel System
Engine Control System - Rail Pressure Sensor
(RPS)
2009 > D 1.6 TCI-U >
INSPECTION
Rail Pressure Sensor (RPS) is installed at the end of the common rail and measures the instantaneous fuel pressure in
the common rail by using its diaphragm. Its sensing element (semiconductor device) mounted on the diaphragm converts
the fuel pressure to an electric signal.
SPECIFICATION
Test Condition Rail pressure (bar) Output Voltage (V)

Idle 220 ~ 320 Below 1.7
Fully depressed Approx. 1,800 Approx. 4.5
CIRCUIT DIAGRAM
SIGNAL WAVEFORM
Fuel System
Fuel System
Engine Control System - Boost Pressure Sensor
(BPS)
2009 > D 1.6 TCI-U >
INSPECTION
Boost pressure sensor (BPS) is installed on surge tank to measure the absolute intake manifold pressure. BPS input
voltage is changed in proportion with absolute pressure in manifold. This information is used to control Variable
Geometery Turbocharger (VGT) by ECM.
SPECIFICATION
Pressure (kPa) Output Voltage (V)

32.5 0.5
70.0 1.02 ~ 1.17
100.0 1.53 ~ 1.68
150.0 2.33 ~ 2.48
200.0 3.12 ~ 3.27
250.0 3.92 ~ 4.07
270.0 4.20 ~ 4.35
284.0 4.5
CIRCUIT DIAGRAM
SIGNAL WAVEFORM
Fuel System
Fuel System
Engine Control System - Rail Pressure Regulator
Valve
2009 > D 1.6 TCI-U >
INSPECTION
The Fuel Pressure Regulator Valve and the Rail Pressure Regulator Valve are installed on high pressure pump and
common rail respectively. These valves control fuel inlet (feed) from fuel tank via fuel filter and outlet (return) to fuel tank
of high pressure fuel circuit.
This system is called "Dual Fuel Pressure Control System" and can precisely and quickly control the fuel pressure in
accordance with various engine conditions by controlling the fuel inlet and outlet simultaneously.
SPECIFICATION
Items Specification
CIRCUIT DIAGRAM
SIGNAL WAVEFORM
2. Disconnect the rail pressure regulator valve connector.
3. Measure resistance between terminal 1 and 2 of the valve.

Fuel System
Fuel System
Engine Control System - VGT Control Solenoid
Valve
2009 > D 1.6 TCI-U >
INSPECTION
Variable Geometry Turbo-charger (VGT) is used to charge additional air into combustion chamber for improvement of
combustion efficiency.
ECM controls the VGT with controlling duty of the VGT control solenoid valve according to engine load.
SPECIFICATION
Items Specification
CIRCUIT DIAGRAM
SIGNAL WAVEFORM
2. Disconnect the VGT control solenoid valve connector.

Fuel System
Fuel System
Engine Control System - Variable Swirl Actuator
2009 > D 1.6 TCI-U >
DESCRIPTION
Variable Swirl Control Actuator consists of DC motor and position sensor which detects the position of the swirl valve.
At idle or below 3000rpm, the swirl valve is closed. This swirl effect increases air flow rate.
Low and Middle Load High Load

Engine speed Below 3000rpm Above 3000rpm
Valve operation CLOSE OPEN
Description
illustration
Fail-safe Fully opened
To prevent the swirl valve and the shaft from being stuck by foreign material and to learn max opening and closing
position of the valve, the ECM fully opens and closes the valve twice when engine is being stopped.
SPECIFICATION
CIRCUIT DIAGRAM
SIGNAL WAVEFORM
2. Disconnect the variable swirl control actuator connector.
3. Check that swirl 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.
REMOVAL
1. Disconnect the battery (-) terminal.
2. Disconnect the variable swirl actuator connector (A).
3. Remove the installation bolt (C) after removing the engine wiring harness part (B).
4. Remove the shaft link assembly (C) after removing the E-ring (A) and the washer (B).
5. Remove the variable swirl actuator.
INSTALLATION
1. Installation is the reverse order of removal.
Variable swirl actuator installation bolt:

9.8 ~ 11.8 Nm (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
2. Confirm normal operation of the actuator more than 3 times when the ignition switch OFF after full warm up (Engine
Coolant Temperature > 70°C).
Fuel System
Fuel System
Engine Control System - Fuel Temperature Sensor
(FTS)
2009 > D 1.6 TCI-U >
INSPECTION
Fuel Temperature Sensor(FTS) is installed in fuel supplying line and senses the termperature of fuel supplied to high
pressure pump. Fuel temperature is limmited to protect fuel such as high pressure pump and injectors from damages due
to rapid deterioration by vapor-lock which can occur at high temperature or destruction of oil membrance.
SPECIFICATION
CIRCUIT DIAGRAM
SIGNAL WAVEFORM
2. Disconnect the fuel temperature sensor connector.
3. Measure resistance between sensor signal terminal and ground terminal.

Fuel System
Fuel System
Engine Control System - EGR (Exhaust Gas Re-
circulation) Solenoid Valve
2009 > D 1.6 TCI-U >
INSPECTION
The Exhaust Gas Recirculation (EGR) system is used to add the exhaust gas to intake air in order to reduce an excess of
air and the temperature in the combustion chamber. The Electric EGR valve is controlled by ECM’s duty control signal
depending on engine load and the need of intake air and is operated by solenoid valve not vacuum valve.
SPECIFICATION
Items Specification
CIRCUIT DIAGRAM
SIGNAL WAVEFORM
2. Disconnect the electric EGR control valve connector.

Fuel System
Fuel System
Fuel Delivery System
2009 > D 1.6 TCI-U >
SCHEMATIC DIAGRAM
LOW PRESSURE FUEL SYSTEM COMPONENTS

FUEL PUMP
The fuel pump is either an electric fuel pump(located in fuel tank) with pre-filter, or a gear-type fuel pump(involved in high
pressure fuel pump). The pump draws the fuel from the fuel tank and continually delivers the required quantity of fuel in
the direction of the high-pressure pump.
FUEL FILTER
Inadequate filtering can lead to damage at the pump components, delivery valves, and injector nozzles. The fuel filter
cleans the fuel before it reaches the high-pressure pump, and thereby prevents premature wear at the pump's sensitive
components.
HIGH PRESSURE FUEL SYSTEM COMPONENTS

HIGH PRESSURE FUEL PUMP
The high-pressure pump pressurizes the fuel to a system pressure of up to 1,600bar. This pressurized fuel then passes
through a high-pressure line and into the tubular common rail.
COMMON RAIL (HIGH PRESSURE ACCUMULATOR)
Even after an injector has taken fuel from the rail in order to inject it, the fuel pressure inside the rail remains practically
constant. This is due to the accumulator effect arising from the fuel's inherent elasticity. Fuel pressure is measured by the
rail pressure sensor and maintained at the desired level by the pressure-control valve.
INJECTORS
The nozzles of these injectors open when the solenoid valve is triggered and permit the flow of fuel. They inject the fuel
directly into the engine's combustion chamber. The excess fuel which was needed for opening the injector nozzles flows
back to the tank through a collector line. The return fuel from the fuel pressure control valve and from the low-pressure
stage is also led into this collector line together with the fuel used to lubricate the high-pressure pump.
HIGH PRESSURE PIPE
These High Pressure Pipes carry the high-pressure fuel. They must therefore be able to permanently withstand the
maximum system pressure and, during the pauses in injection, the sometimes high-frequency pressure fluctuations which
occur. They are therefore manufactured from steel tubing.
Normally, they have an outside diameter of about 6.35mm and an internal diameter of about 3.0mm. The injection lines
between the common rail and the injectors must all be of the same length. 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.
2009 > D 1.6 TCI-U >
COMPONENT LOCATION
• Never perform any work on injection system with engine running or within 30 seconds after the engine stops.
Fuel System
Fuel System
Fuel Delivery System - Fuel Tank
2009 > D 1.6 TCI-U >
REMOVAL
1. Turn ignition switch off.
2. Remove the second seat (Refer to "BD" group in this WORKSHOP MANUAL).
3. Open the service cover (A).
4. Disconnect the fuel sender connector (A), the fuel feed tube quick-connector (B) and the return tube quick -
connector (C).
5. Lift the vehicle and remove the mufflers passing under the fuel tank (Refer to group "EM" in this
WORKSHOP MANUAL).
6. Support the fuel tank with a jack and remove the brake line mounting bolts (LH & RH).
7. Disconnect the fuel filler hose (A) and the leveling hose (B).
8. Remove the fuel tank band mounting bolts (A) and remove the fuel tank from the vehicle.
INSTALLATION
1. Install the fuel tank according to the reverse order of "REMOVAL" procedure.
Fuel System
Fuel System
Fuel Delivery System - Fuel Filter
2009 > D 1.6 TCI-U >
COMPONENTS
2009 > D 1.6 TCI-U >
REMOVAL
2. Disconnect the thermostat connector (A), the water sensor connector (B) and the heater connector (C).
3. Disconnet the outlet hose (A) and the inlet hose (B).
Cover the hose connection with the shop towel to prevent splashing of fuel caused by residual pressure
in the fuel line.
4. Unscrew the two mounting nuts (C) and remove the fuel filter.
INSTALLATION
1. Install the fuel filter according to the reverse order of "REMOVAL" procedure.
Fuel System
Fuel System
Fuel Delivery System - Common Rail
2009 > D 1.6 TCI-U >
DESCRIPTION
In order to comply with the wide variety of engine installation conditions, the common rail with its flow limiters
and the provistions for attaching rail pressure sensor, fuel pressure control valve, and pressure limiter valve is
available in a number of different designs.
The available common rail volume is permanently filled with pressurized fuel. The compressibility of the fuel
resulting from the high pressure is utilized to achieve the 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 for.
2009 > D 1.6 TCI-U >
REMOVAL
stops.
1. Turn ignition switch to OFF position.

3. Disconnect the rail pressure sensor connector (A).
4. Disconnect the rail pressure regulator valve connector (B).

5. Remove the high pressure pipe (C) connecting injectors and the common rail.
6. Remove the high pressure pipe (D) connecting the high pressure fuel pump and and the common rail.
7. Remove the intake manifold (Refer to the group "EM" in this WORKSHOP MANUAL).
8. Unscrew the common rail mounting bolts (A) and the remove the common rail (B).
INSTALLATION
1. Install the common rail according to the reverse order of "REMOVAL" procedure.
injectors, the high pressure pipe, and the common rail side with SST (Refer to below table).

Flange Nut (Injector Side)
14 mm (0.551 in) 09314-27110
Flange Nut (HP Pump Side)
Flange Nut (Common Rail Side) 17 mm (0.669 in) 09314-27120
· Common rail installation bolts: 14.7 ~ 21.6 N·m (1.5 ~ 2.2 kgf·m, 10.9 ~ 15.9 lbf·ft)
· High pressure pipe flange nuts (Injectors Common Rail):
24.5 ~ 28.4 N·m (2.5 ~ 2.9 kgf·m, 18.1 ~ 20.1 lbf·ft)
· High pressure pipe flange nuts (Common Rail HP Pump):
24.5 ~ 28.4 N·m (2.5 ~ 2.9 kgf·m, 18.1 ~ 20.1 lbf·ft)
Fuel System
Fuel System
Fuel Delivery System - Fuel Pressure Control Valve
2009 > D 1.6 TCI-U >
INSPECTION
The Fuel Pressure Regulator Valve and the Rail Pressure Regulator Valve are installed on high pressure pump and
common rail respectively. These valves control fuel inlet (feed) from fuel tank via fuel filter and outlet (return) to fuel tank
of high pressure fuel circuit.
This system is called "Dual Fuel Pressure Control System" and can precisely and quickly control the fuel pressure in
accordance with various engine conditions by controlling the fuel inlet and outlet simultaneously.
SPECIFICATION
Items Specification
CIRCUIT DIAGRAM
SIGNAL WAVEFORM
2. Disconnect the fuel pressure regulator valve connector.

Fuel System
Fuel System
Fuel Delivery System - High Pressure Pump
2009 > D 1.6 TCI-U >
DESCRIPTION
The high-pressure pump is the interface between the low pressure and the high-pressure stages. Under all
operating conditions, it is responsible for providing adequate high-pressure fuel through out the vehicle's
complete service life. This also includes the provision of extra as needed for rapid starting and for rapid
build-up 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.
2009 > D 1.6 TCI-U >
REMOVAL
stops.

3. Remove the intake manifold. (Refer to the group "EM" in this WORKSHOP MANUAL).
4. Remove the high pressure pipe (A) connecting high pressure fuel pump and common rail.
5. Disconnect the fuel pressure regulator valve connector (B).

6. Remove the oil gage guide.
7. Disconnect the feed tube (A) and the return tube (B).
8. Unscrew the three high pressure fuel pump mounting bolts (C).
9. Remove the drive belt (Refer to the group "EM" in this WORKSHOP MANUAL).
10. Turn the crankshaft pulley and align its groove with timing mark "T" of the timing chain cover.
(NO.1 cylinder compression TDC position.)
11. Remove the idler (A) and the timing chain cover plug (B).
12. Remove the high pressure fuel pump sprocket nut (C) after fixing the crank shaft.
13. Install the high pressure fuel pump sprocket stopper (A) (SST No.: 09331-2A000) with rotating it clockwise.
14. Install the high pressure fuel pump remover (SST No.:09331-2A000) (A) with three mounting bolts (B).
15. Fix the high pressure fuel pump remover (SST No.:09331-2A000) (A) and sprocket stopper (C) with two
fixing bolts (D).
16. Rotate the bolt (E) of the high pressure fuel pump remover (SST No.:09331-2A000) (A) clockwise till the
high pressure fuel pump is pushed out.
INSTALLATION
1. Install the high pressure fuel pump according to the reverse order of "REMOVAL" procedure.
high pressure pipe side and the common rail side with SST (Refer to below table).

Flange Nut (HP Pump Side) 14 mm (0.551 in) 09314-27110
Flange Nut (Common Rail Side) 17 mm (0.669 in) 09314-27120
· High pressure fuel pump installation bolts: 14.7 ~ 19.6 N·m (1.5 ~ 2.0 kgf·m, 10.9 ~ 14.5 lbf·ft)
· High pressure pipe flange nuts (Common Rail High Pressure Fuel Pump):
24.5 ~ 28.4 N·m (2.5 ~ 2.9 kgf·m, 18.1 ~ 20.1 lbf·ft)
Fuel System
Fuel System
Fuel Delivery System - -\LS:LUKLY
2009 > D 1.6 TCI-U >
REMOVAL
2. Remove the second seat (Refer to "BD" group in this WORKSHOP MANUAL).
3. Open the service cover (A).
4. Disconnect the fuel sender connector (A), the fuel feed tube quick-connector (B), the return tube quick -
connector (C) and the suction hose (D).
5. Remove the fuel sender assembly after removing the fuel sender plate cover (E) with SST
(No.:09310-2B100).
INSTALLATION
1. Install the fuel pump assembly according to the reverse order of "Removal" procedure.
Fuel sender plate cover tightening: 60.0 ~ 70.0N·m (6.1 ~ 7.1kgf·m, 44.3 ~ 51.6lbf·ft)
Fuel System
Fuel System
Fuel Delivery System - >H[LY:LUZVY
2009 > D 1.6 TCI-U >
INSPECTION
Water Sensor is installed on bottom end of fuel filter and detects presence of water in fuel. When the water level 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.
SPECIFICATION
Items Specification
Warning Level of Water Presence (cc) 40 ~ 60
CIRCUIT DIAGRAM

05 - Fuel System

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Fuel System

SPECIAL SERVICE TOOLS

Tool (Number and name) Illustration Application

09310-2B100 Removing and installing the fuel sender

REFERENCE SERVICE TOOL - COMMON RAIL TESTER

Tool Number Tool Name

Air Flow (kg/h) Frequency (kHz)

* At intake air temperature = -15°C(5°F) or 80°C(176°F)

Air Flow (kg/h) Frequency (kHz)

INTAKE AIR TEMPERATURE SENSOR (IATS) #1 [BUILT IN MAFS]

Temperature [°C(°F)] Resistance(k)

BOOST PRESSURE SENSOR (BPS)

Pressure (kPa) Output Voltage (V)

INTAKE AIR TEMPERATURE SENSOR (IATS) #2 [BUILT IN BPS]

Temperature [°C(°F)] Resistance(k)

ENGINE COOLANT TEMPERATURE SENSOR (ECTS)

Temperature [°C(°F)] Resistance(k)

CAMSHAFT POSITION SENSOR (CMPS)

Level Output Pulse (V)

CRANKSHAFT POSITION SENSOR (CKPS)

ACCELERATOR POSITION SENSOR (APS)

FUEL TEMPERATURE SENSOR (FTS)

Temperature [°C(°F)] Resistance(k)

Test Condition Rail pressure (bar) Output Voltage (V)

Value (A/F Ratio) Pumping Current(A)

Temperature [°C(°F)] Heater Resistance()

VEHICLE SPEED SENSOR (VSS)

RAIL PRESSURE REGULATOR VALVE

ELECTRIC EGR CONTROL VALVE

VGT CONTROL SOLENOID VALVE

VARIALBE SWIRL CONTROL ACTUATOR

Neutral,N,P-range 830 ± 100 rpm

FUEL DELIVERY SYSTEM

Item N·m Kgf·m lbf·ft

CHECKING PROCEDURE (SELF-DIAGNOSIS)

INSPECTION PROCEDURE (USING GENERIC SCAN TOOL)

1. Mass Air Flow Sensor (MAFS) 3. Boost Pressure Sensor (BPS)

7. Camshaft Position Sensor (CMPS)

10. Fuel Temperature Sensor (FTS)

12. Rail Pressure Sensor (RPS)

21. Main Relay 24. ECM (Engine Control Module)

ECM PROBLEM INSPECTION PROCEDURE

1. Turn ignition switch OFF.

4. Install a new ECM according to the reverse order of steps 1, 2, and 3.

(3) Select "1.6L VGT DIESEL" in case of "MANUAL SELECTION MODE".

(5) Press "ENTER" key.

ECM (ENGINE CONTROL MODULE)

2. ECM TERMINAL FUNCTION

3. ECM TERMINAL INPUT/OUTPUT SIGNAL

Hi: Battery Voltage 14.78V

Mass Air Flow Sensor (MAFS) Hi: Vcc 4.95V

Camshaft Position Sensor 17.44Hz

Electric EGR Control Valve Lo: Max. 1.0V -20mV

Battery voltage supply after IG OFF Max. 1.0 V 175mV

Battery voltage supply after IG OFF Max. 1.0 V -25mV

Battery voltage supply after IG OFF Max. 1.0 V -25mV

Accelerator Position Sensor C.T 0.3 ~ 0.9V 682.8mV

A/C Pressure Transducer A/C OFF Max. 4.8V 1.327V

Accelerator Position Sensor C.T 0.3 ~ 0.9V 333.8mV

Brake Switch "Lamp" signal Release Max. 0.5V -20mV