FUEL SYSTEM

OUTLINE ..................................................................... 31-2

GENERAL RESOURCE ............................................... 31-3
STANDARD REPAIR.................................................... 31-4
JOINT TORQUE ........................................................... 31-4
EUI COMPOSING ELEMENT ...................................... 31-5
DIAGNOSTICS AND MEASURES ............................. 31-19
REPAIR AND ADJUSTMENT PROCEDURE ............. 31-31
FUEL FILTER ............................................................ 31-35
31-2 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

Block diagram of fuel feed system

Fuel system consists of control unit, unit injector, fuel pump, fuel
Fuel rail Filter
line, fuel filter, overflow valve and fuel tank. Fuel pump is connected
to air compressor and supplies fuel from fuel tank.
Fuel enters fuel filter via control unit cooling line from pump.
Fuel from fuel filter is fed to fuel gallery in cylinder head. After fuel is Injector ECU cooler
injected by 6 unit injectors, it passes through overflow valve connected
to fuel gallery exit. Fuel returned from cylinder head goes back into
fuel tank again.
Accordingly, fuel system continues to supply and return proper Overflow Fuel pump
amount of fuel used in engine by control unit.

Fuel tank
Return to fuel tank
GENERAL RESOURCE 31-3

GENERAL RESOURCE
Item Resource

Fuel tank Capacity

Fuel pump Type Inner contact gear type

Maximum supply pressure 7kgf.cm2

Driving Air compressor shaft driving
Control unit Voltage 24V

Connector 54 pin x 2
Unit injector Voltage 90V
(Solenoid valve) Resistance 1.0 ~ 2.0

Coolant temperature sensor Voltage 5V

& Gauge unit Running range -40°C ~ 130°C
Connector 3 pin

Intake pressure temperature Voltage 5V

sensor Running range Temperature -40°C ~ 125°C
Pressure (Absolute) 50 ~ 300 kPa(0.5 ~ 3kgf.cm2)

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

sensor Running range Temperature -40°C ~ 130°C

Pressure (Relative) 0 ~ 1000 kPa(0 ~ 10kgf.cm2)
Connector 4 pin
31-4 FUEL SYSTEM

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

EUI COMPOSING ELEMENT

1. Unit injector
Unit injector consists of control part to control opening/closing
time of spill value by operating solenoid according to direction of 1
control unit and pumping element which generates fuel pressure
1. Pumping element
when power transferred from cam operates plunger through locker 3
2. Nozzle part 2
arm as shown in figure, and nozzle part to inject fuel into cylinder 3. Control part SOLA401A
by pressure of finally transferred fuel.

SOLA705A

2. Operational theory of unit injector

1) Fuel intake
Fuel circuit is open when spill valve is opened and fuel comes
into pump tank through rising operation of plunger by return
spring.
At this time, needles of nozzle are closed by spring.

1. Spill valve
2. Plunger
3. Vent port
4. Fuel line
SOLA402A

Actuator

Fill

Spill valve SILA001A

31-6 FUEL SYSTEM

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

3) Fuel injection start

When solenoid receiving signal from ECU closes spill valve, 1
fuel circuit is closed, fuel is kept in pump tank and fuel pres-
sure ascends rapidly. When rising pressure is beyond NZ 2
3
variable pressure, fuel begins to be injected.

SOLA402C

Actuator

SILA003A
EUI COMPOSING ELEMENT 31-7

4) End of fuel injection

When spill valve opens according to ECU’s judgement for
injection end, fuel in pump tank drops below variable pres-
sure rapidly together with spill, nozzle is closed and injection 1
is ended.

SOLA402A

Actuator

Spill

SILA004A
31-8 FUEL SYSTEM

3. Control unit and sensor

5 4 1 6

1. Control unit 4. Intake pressure temperature sensor

2. Crank shaft location sensor 5. Coolant temperature sensor
3. Cam shaft location sensor 6. Fuel pressure temperature sensor
SOLA403A

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)

As control unit is mounted on engine block, it requires cool-

ing unit to keep appropriate operational temperature and fuel
line flowing over control unit acts as cooling unit.
EUI COMPOSING ELEMENT 31-9

(2) Engine control

1) Control of fuel amount
The amount of fuel is calculated by demanded fuel amount set
according to engine load and speed and fuel amount compen-
sated in engine state inputted from all kinds of sensors.

Cranking fuel Max. fuel amount Car speed

Intake air temperature/pressure

Idle speed Coolant temperature

Idle fuel
Compensation Fuel temperature pressure

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

2) Limit of fuel amount

Control unit restricts fuel amount for safety and engine protection
in the below conditions about fuel amount demanded from driver
if necessary.
- When smoke occurs excessively
- When engine overheats
- When car speed is excessive
- When maximum fuel amount is exceeded
- When engine speed is excessive
- When engine speed limit is needed in cooling state

3) Limit of maximum engine speed

When coolant temperature is lower than set value or car speed
sensor is zero, maximum speed of engine is restricted to protect
engine from temperature and mechanical damage.
31-10 FUEL SYSTEM

4) Control of fuel injecting time

Fuel injecting time is set depending on engine speed and de-
manded fuel amount and compensated according to engine state
sensed from sensors.

Intake temperature compensation

Coolant temperature compensation

Crank injecting time

PTO injecting time Final fuel injecting time

Engine speed General fuel

Fuel injecting injecting time
amount

Intake temperature compensation

Coolant temperature compensation

5) Cooling starting control

Engine control unit minimizes white smoke generated at cooling
by ejecting optimum fuel into engine at cooling start and raises
engine temperature to normal running temperature in a short time.
And it controls heater to heat air flowing into engine, which is
divided into preheat operated before starting and postheat oper-
ated after starting.
(1) Air heating control
a. Intake air heating at cooling starting
- Reduction of smoke due to incomplete combustion
- Early warming of engine

START
KEY S/W ON
OFF
Indicator lamp Light up
Light off
Engine rotations > Limit value
Engine RPM

ON
Heating
OFF
Preheating Postheating

A. Preheat/postheat not running B. Normal preheat/postheat running

SILA015A SILA016A
EUI COMPOSING ELEMENT 31-11

6) Control of idle rotating speed

(1) Idle adjustment: Keep specified rpm regardless of load varia- Engine
tion speed

(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

- Increase idle to ascend charging rate if battery voltage is

low
Adjustment of unstable idle
SILA008A

(4) Idle adjustment at cooling starting

Engine speed
800 RPM

Cooling engine speed

500 RPM

Normal idle rotation speed

-10°C
20°C

T1 T2 Coolant temperature

SILA009A
31-12 FUEL SYSTEM

7) Manual adjustment of idle

Manual adjustment of idle is possible using self-diagnostic switch
mounted to driver seat.
The below conditions shall be satisfied for manual adjustment of
idle.
a. Vehicle is in halt state for sure.
b. There is no acceleration pedal signal.
c. The 1st brake is running.(Foot brake is running)
d. Idle state and PTO not running state

800 RPM

Increase

+25 RPM Decrease

Reference idle rotation speed 500 RPM

Driver can set desirable idle rotation speed as mentioned above.

(500 to 800 rpm)

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

9) Output limit according to fuel pressure

Function: When fuel pressure gets lower than set value during
regular engine rotation, it protects engine by reducing the amount
of fuel demanded by engine and gives driver warning signal at
the same time.
EUI COMPOSING ELEMENT 31-13

(3) Vehicle control function

1) Cruise car speed control
(1) Function: Drive vehicle within specified speed.
(2) Operational condition
a. Operation of cruise control switch
b. Brake and clutch pedal not running
c. Safety switch input not running
d. Brake state is normal
(3) Release condition
a. Release of cruise control switch
b. Brake and clutch pedal running
c. If car speed is lower than minimum setup speed by cruise
control function
Cruise is released automatically if even one of the above
conditions is satisfied.
(4) In the case of exceeding a specified car speed, exhaust brake
and engine brake works in sequence. In additions, and fuel
amount is limited by the smallest value among maximum
engine speed, torque performance and smoke restriction.
2) Limit of maximum car speed
(1) Function: Limit maximum car speed by restriction of fuel
supply
(2) Control method
a. Operated by set program in sequence.
b. If car speed is higher than specified one on descending
path, exhaust brake works first and then when speed
increases, jake brake works successively.
(3) Exception: Car speed is kept over maximum speed instantly
when driver steps acceleration pedal at alternation from de-
scending to ascending path.
3) Door safety switch
(1) Function: Idle governor controls engine and other fuel isn’t
supplied when safety switch mounted at bus door works.
(2) Running circuit drawing

Engine speed

EUI

Center door switch

ECU
Battery

Acceleration pedal
SILA011A
31-14 FUEL SYSTEM

4) FAIL SAFE function

(1) Pedal sensor
a. Condition: Error occurrence at acceleration pedal sensor
and idle rotation S/W
b. Limit of pedal function
(2) Fuel temperature sensor’s value is used at failure of coolant
temperature sensor and coolant temperature sensor’s value
at failure of fuel temperature sensor.
(3) Buster temperature sensor: Use setup value
(4) Fuel pressure sensor: Use setup value
(5) Outdoor temperature sensor: Use setup value
(6) Buster pressure sensor: Use setup value
(7) Atmosphere pressure sensor: Use setup value
(8) Car speed sensor
a. Condition of fault judgement
- Fuel amount is more than setup value
- Engine rotations are higher than setup value
- Coolant temperature is higher than setup value
- PTO doesn’t work
- Car speed is zero
- Clutch doesn’t work
(9) Use crank sensor at breakdown of cam sensor and signal
value of cam sensor at breakdown of crank sensor
5) PTO
(1) Function: Keep regular rotation speed of engine regardless
of load to operate auxiliary unit.
(2) Running condition
a. Cruise / PTO running switch is ON
b. Car speed is lower than selectable setup value (10km/h in
general and engine running state)
c. PTO is adjustable in driver seat or out of vehicle
(3) Operation: When setup time (about 1 sec.) have passed, PTO
governor controls rotation speed of engine into initial engine
rotations of PTO. At this time, PTO indication lamp lights up
to inform driver.
(4) Release: When Cruise / PTO running switch is OFF, ECU
slows down rotations of engine to be idle rotation speed.
(5) PTO is adjustable in driver seat or out of vehicle
(6) PTO engine rotations increase in operating acceleration pedal
and return to standard PTO rotations in releasing it.
(7) PTO engine rotations decrease to be initial PTO speed in
operating one or both of clutch and brake at the same time
and return to standard PTO rotations in releasing it.
6) Cruise Control / PTO Enable Switch
Set Cruise Control or PTO operation of special vehicle to ON/
OFF.
EUI COMPOSING ELEMENT 31-15

7) Cruise Control / PTO / Idle Control Switch

Used as control switch at operation of Cruise Control or PTO of
special vehicle, idle control switch at idle and error code checkup
switch at engine halt.
Exhaust brake and jake brake solenoid valve
Control unit controls solenoid valve according to switch opera-
tion of driver or engine state to operate exhaust brake or jake
brake.

(4) Coolant temperature sensor

Engine coolant temperature sensor is a resistance type of sensor,
mounted to thermo starter housing.
ECU judges damage state of engine on the basis of output volt-
age of this sensor and controls proper fuel amount according to
engine coolant temperature.

(5) Intake pressure temperature sensor

Intake pressure temperature sensor measures pressure and tem-
perature of air supplied for engine and sends voltage signal to
ECU, mounted to intake manifold.
ECU adjusts the injecting timing and fuel amount according to
the air pressure and temperature informed by the sensor.

(6) Crank shaft location sensor

Crank shaft location sensor generates pulse signal by projection
formed on fly wheel when fly wheel rotates and sends it to ECU,
mounted to the left side of fly wheel housing.
ECU calculates location and speed of engine, using generated
pulse signal and controls fuel injecting time and amount on the
basis of them.

(7) Cam shaft location sensor

Cam shaft location sensor generates pulse signal from sensor
wheel installed at the end of cam shaft and sends it to ECU,
mounted to the left side of timing gear cover of cam axis.
A pulse signal is generated each cylinder and becomes standard
of TDC by cylinder. Another pulse signal is generated to have
cylinder No.1 recognized at the location of cylinder No.1.
ECU recognizes cylinder No. and TDC and determines injecting
order and time.
31-16 FUEL SYSTEM

Arrangement of crank sensor wheel and cam sensor wheel in TDC

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”

6th wheel teech

6teeth spaced at 60° CAM

Crank sensor wheel Cam sensor wheel

Agreeing point between “A” cam and crank shaft

SILA012A

- Crank sensor wheel is used to recognize location of engine cyl-

inder stroke of engine speed and cam sensor wheel to recognize
location of cylinder No.1 together with crank signal.
- Crank shaft teeth are composed at intervals of 60° on the basis
of cam shaft, where 2 teeth decrease every 60° and at intervals
of 120° on the basis of crank shaft.
- Cam shaft has total 7 teeth and a tooth is added at No.1 to
recognize standard of cylinder No.1.
- Cylinder No.1 of cam shaft is located after 15° from added tooth
and TDC of cylinder No.1 is located after 34.5° from tooth No.1.
EUI COMPOSING ELEMENT 31-17

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)

Main power supply in ON Control relay

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

Priming pump SOLA405A

31-18 FUEL SYSTEM

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

Fuel filter SOLA406A

8. Overflow valve Overflow valve

Overflow valve is mounted to cylinder head fuel line exit.
It controls fuel pressure in fuel cylinder.
Opening pressure of overflow valve: 3.0bar and more
Joint torque of overflow valve: 3.4 to 4.0kg.m

SOLA407A

Disassembly

6 7 5
3

4
2

1. Cartridge 5. Air vent

2. Head 6. Plug
3. Eyebolt 7. Priming pump
4. Washer 8. Head plug
SOLA444A
DIAGNOSTICS AND MEASURES 31-19

DIAGNOSTICS AND MEASURES

1. General item
Engine control system has self-diagnostic system to detect fault oc-
curring in system and inform driver of the result.
2. Fault check by self-diagnostic unit
At occurrence of error in parts, engine system stores the correspond-
ing error code and engine state like engine speed at failure, engine load
(fuel amount) and engine temperature and lights up check ENG lamp
on instrument panel if necessary.
1) Set starting switch to OFF
2) Connect self-diagnostic cable with self-diagnostic unit and self-di-
agnostic connector of vehicle.
3) Connect power terminal of self-diagnostic to cigarette socket or
battery power.
4) Set starting switch to ON
5) Switch on power of self-diagnostic unit, perform engine check and
repair according to procedure shown on the screen. Self-diagnostic
unit can display an error code and more. In this case, check in a
series of order shown by self-diagnostic unit.
6) Switch off self-diagnostic unit at completion of engine check.
7) Set starting switch to OFF.
8) Separate self-diagnostic unit from vehicle.
Self-diagnostic unit offers the below additional functions except checkup
of engine fault.
1) Display of engine speed and sensor signal
2) Information on vehicle covering (Covering distance and time)
3) Injector driving
4) Check and test of combustion room pressure and fuel system
(1) Compression test: Check compressed pressure of combustion
room by cylinder of engine
(2) Acceleration test: Check error of fuel injecting system includ-
ing injector
3. Check by check ENG lamp of instrument panel
Engine system offers error code to know content of engine fault di-
rectly without self-diagnostic unit.
Check content of fault by error code as follows.
1) Stop engine
2) Set starting switch to ON
3) Set normal speed switch to ON and check if “CHECK ENG” lamp of
instrument panel lights up.
4) Error code is displayed in turn as follows whenever DEC switch is
ON.
5) Previous error code is displayed when INC switch is ON.
6) Refer to error code table and check content and cause of fault for
troubleshooting.

Next error code

self-diagnostic code 1 sec.
ON

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

Occurrence of D6CA engine fault and condition of lamp

Error Fault diagnostic “CHECK Release
No ITEM Causes of fault Vehicle state
code condition ENG” lamp condition
1 4121 BOOSTER IG “ON” and - Ground short OFF Normal signal - Instant change of output
PRESS. ENG.RUNNING - Power short input - Normal operation possible
5VSUPPLY - ECU inferiority

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

1233 - Power short

- Power supplied for sensor faulty

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

1113 - Power short

- Wire disconnection

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

6 2111 DETECT ENG.RUNNING - Sensor air gap faulty ON Normal signal

SNESOR - Sensor coil short, disconnection input
of the cylinder - Noise
Top dead center - Contact state of connector poor
- Noise - Operation impossible
2112
- Phase difference between cam
and cramp excessive (±6 grade)
2113 ENG.RUNNING - Noise OFF Normal pulse input - Normal operation possible
- Abnormal signal input within 60 sec.

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

1323 - Power short

- Power supplied for sensor faulty
DIAGNOSTICS AND MEASURES 31-21

Error Fault diagnostic “CHECK Release

No ITEM Causes of fault ENG” lamp Vehicle state
code condition condition
11 1332 FUEL TEMP. IG “ON” and - Ground short OFF Normal signal - Normal operation possible
SENSOR ENG.RUNNING - Contact state of connector poor input
- Wire disconnection

1333 - Power short

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

1213 - Power short

- High impedance of pin
- Pedal sensor 5V power faulty

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

Error Fault diagnostic “CHECK Release

No Causes of fault ENG” lamp Vehicle state
code condition condition
25 3214 ENG. CHECK IG “ON” and - ECU output terminal short to battery OFF - Error release
LAMP ENG.RUNNING

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

32 5611 DIAGNOSTIC IG “ON” and - Ground short OFF - Error release

PORT ENG.RUNNING - Wire disconnection
- ECU faulty

33 5612 CAN IG “ON” and - Ground short OFF - Error release

COMMUNICA- ENG.RUNNING - Wire disconnection
TION - ECU faulty

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

External wiring view of unit injector (ECU)

SOLA408A
31-24 FUEL SYSTEM

Inspection of injector (EUI) components

<Test condition>
1. Switch off starting key.
2. Operate parking brake
3. Separate ECU connector and connect tester with cable harness
4. Perform test using multimeter

EU1 NO1

(Connector of ECU harness side)

E29

E43
SOLA408A

Test item Data display Possible causes of fault Normal value

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

Crank shaft location sensor

<Test condition>
1. Switch off starting key.
2. Operate parking brake
3. Separate ECU connector and connect tester with cable harness
4. Perform test using multimeter

(Connector of ECU harness side) (Connector of sensor side)

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

Test item Data display Possible causes of fault Normal value

Crank shaft location Resistance Sensor faulty 850 ± 10%

sensor Cable harness faulty

[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

Cam shaft location sensor

<Test condition>
1. Switch off starting key.
2. Operate parking brake
3. Separate ECU connector and connect tester with cable harness
4. Perform test using multimeter

(Connector of ECU harness side) (Connector of sensor side)

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

Test item Data display Possible causes of fault Normal value

Crank shaft location Resistance Sensor faulty 850 ± 10%

sensor Cable harness faulty

[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

Coolant temperature sensor

<Test condition>
1. Switch off starting key.
2. Operate parking brake
3. Separate ECU connector and connect tester with cable harness
4. Perform test using multimeter

(Connector of ECU harness side) (Connector of sensor side)

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

Test item Data display Possible causes of fault Normal value

Coolant Resistance Sensor faulty Refer to table
temperature sensor Cable harness faulty
and cable harness

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

3. If resistance exceeds specified value, replace sensor.

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

Intake pressure temperature sensor

<Test condition>
1. Switch off starting key.
2. Operate parking brake
3. Separate ECU connector and connect tester with cable harness
4. Perform test using multimeter

(Connector of ECU harness side) (Connector of sensor side)

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

1. Pressure sensor output

2. Power (5V)
3. Temperature sensor output

(Pressure characteristic grwph) 4. Ground

(Temperature characteristic graph)

kpa.abs[mmHg abs]
SOLA725A

Test item Data display Possible causes of fault Normal value

Intake pressure Resistance and Sensor faulty Refer to graph

temperature sensor voltage Cable harness faulty
and cable harness
DIAGNOSTICS AND MEASURES 31-29

Sensor test
1. Separate intake pressure temperature sensor connector
2. Measure resistance between terminal (3) and (4).

TEMP RESISTANCE[ ] TEMP RESISTANCE[ ]

[°C] MIN. TYP. MAX. [°C] MIN. TYP. MAX.
0±1 5384 5734 6085 80±1 294 315 337
20±1 2311 2438 2565
40±1 1077 1141 1205

3. Measure resistance, heating sensor in use of hair dryer. <Connector of sensor side>
Temperature (°C) Resistance
The higher The lower
1234

SOLA726A

4. If resistance exceeds specified value or doesn’t change, replace

intake pressure temperature sensor assembly.
Joint torque of intake pressure temperature sensor : 0.5~0.6kg.m
31-30 FUEL SYSTEM

Fuel pressure temperature sensor

<Test condition>
1. Switch off starting key.
2. Operate parking brake
3. Separate ECU connector and connect tester with cable harness
4. Perform test using multimeter

(Connector of ECU harness side)

(Connector of sensor side)

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

(Characteristic table of sensor pressure) (Characteristic table of sensor temperature)

Pressure Temperature (°C) Resistance (K )

(KPa) min nom max -40 (48.14)
0 0.0589 0.2000 0.3412 -20 15.48 ± 1.35

100 0.5094 0.6505 0.7917 0 (5.79.0)

200 0.9599 1.1010 1.2422 20 2.45 ± 0.14
300 1.4104 1.5515 1.6927 40 (1.148)

400 1.8609 2.0020 2.1432 60 (0.5865)

500 2.3114 2.4525 2.5937 80 (0.3222)
600 2.7619 2.9030 3.0442 100 (0.1884)

700 3.2124 3.3535 3.4947 110 0.1471 ± 0.002

800 3.6629 3.8040 3.9452 120 (0.1163)
900 4.1134 4.2545 4.3957

1000 4.5639 4.7050 4.8462

*. 1 Bar = 100KPa

Test item Data display Possible causes of fault Normal value

Oil pressure temperature Resistance and voltage Sensor faulty Refer to table
sensor and cable harness Cable harness faulty
REPAIR AND ADJUSTMENT PROCEDURE 31-31

REPAIR AND ADJUSTMENT PROCEDURE

Replacement of unit injector
[NOTE]
Be sure to have injector replacement executed at service center
designated by HMC.
1. Remove locker cover
[NOTE]
SOLA413A
Be careful for unit injector cable harness not to be damaged.
2. Remove cam cap bolt
[NOTE]
Separate bolts in turn to prevent locker arm shaft from
bending.

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

6. Remove cable to be connected with unit injector.

SOLA019A

7. Unscrew injector cramp bolt, remove cramp and then separate

injector carefully.
31-32 FUEL SYSTEM

8. Fix protecting sleeve after separating unit injector.

SOLA023A

9. Insert sealing cramp into cylinder head fuel gallery

Sealing cramp
[NOTE]
Check if sealing cramp is inserted properly at its place.
10. Clean nozzle tube, using hand drill and brush.

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

(Refer to 20 –12 for main engine)

REPAIR AND ADJUSTMENT PROCEDURE 31-33

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

15. Check if locker arm shaft is properly mounted after tightening up

cam cap bolt.
Adjust clearance of valve and injector after tightening up cam
cap bolt to specific torque.
16. Mount locker cover
17. Perform fuel breeding according to procedure.
18. Start engine and execute idle rotation for about 10 min. to elimi-
nate air from system.

Fuel system draining

1. Clean around air vent of cylinder head side and fuel filter side.

Air vent
bolt

SOLA426A

2. Unscrew air vent bolt in cylinder head

Air vent bolt

SLA427A

3. After removing air vent bolt of cylinder head side completely,

blows compressed air, using air gun with air bent hole blocked
by hand to discharge fuel remaining in cylinder head.

SOLA428A
31-34 FUEL SYSTEM

Fuel charge and air discharge

1. After engine assembly/disassembly or fuel exhaustion (If fuel is
eliminated completely in fuel line)
1) Clean around air vent of fuel filer side and cylinder head side. Air vent
2) Unscrew air vent bolt on fuel filter head a little. bolt
3) Perform pumping work, using priming pump on fuel filter until
fuel begins to come out from air vent cock.
4) Close bolt when air is eliminated completely in fuel discharged
to fuel filter air vent SOLA430A

5) Unscrew air vent bolt at cylinder head front side.

6) Close cock after pumping until air is eliminated in fuel in the
same way as Clause 2).
7) Execute cranking when the above works are all terminated.
Carry out cranking for enough time (10 to 15 sec.) and sev-
eral times until engine starts.(about 3 to 5 times, if fuel is
perfectly eliminated in fuel line, especially if fuel in injector is
eliminated thoroughly, sufficient cranking is necessary from
air discharge to engine starting)
Continuous cranking time should not exceed 15 sec. because SOLA431A
long-term cranking has a bad influence on starter motor. Keep
interval of approx. 30 sec. until the next cranking after crank-
ing once to prevent starter motor from overheating.
8) When engine starts, await until engine grows stable, pedal-
ing accelerator (Approx. 1000rpm).

2. At replacement of fuel filter cartridge (If fuel is filled in cylinder

head)
1) Clean around fuel filter.
2) Unscrew air vent on fuel filter and remove pressure of fuel
line.
3) Replace filter cartridge.
[NOTE]
- Check if gasket is placed on cartridge in replacing
cartridge.
- Apply oil to gasket and tighten up sufficiently by hand.
- Joint torque : 1.2~1.6kg.m
4) Perform pumping until fuel comes out to air vent side, using
priming pump.(In case of filling fuel in new cartridge before
mounting, pumping time can be reduced.)
5) Close air vent bolt SOLA445A
6) Execute cranking and start engine
(Air discharge of cylinder head side isn’t needed at replace-
ment of filter and engine starting is possible by once crank-
ing in general)

3. Air discharge of D6CA engine (Particularity)

D6CA engine makes use of different unit injector system from
existing engine and injector is installed in cylinder. So, even if air
is thoroughly eliminated in filter rail, remaining air exists in injector.
Therefore, sufficient cranking is necessary after air discharge to
SOLA436A
get rid of the remaining air.
Once normal air discharge is completed, there is no trouble in
engine starting through enough cranking.
FUEL FILTER 31-35

FUEL FILTER
Fuel filter is cartridge type that replacement of element is easy.

Composition drawing

7 5
6 3

1. Cartridge 5. Air vent

2. Head 6. Plug
3. Eyebolt 7. Priming pump
4. Washer 8. Head plug
SOLA444A

Fuel filer replacing method is equal to clause 2 of “Fuel charge and

air discharge”.
31-36 FUEL SYSTEM

Replacement of priming pump

1. Unscrew air vent bolt to eliminate remaining pressure in fuel filter.
2. Clean around priming pump

SOLA437A

3. Remove bolt of priming pump

4. Insert sealing washer into new priming pump and mount it.
Joint torque of priming pump bolt: 2.8 to 3.0kg.m
5. Perform fuel charge and air discharge in the same way as at
replacement of fuel filter.
6. Start engine and execute idle rotation to get rid of air remaining
in system.
SOLA438A

Replacement of fuel pump

1. Unscrew air vent bolt to eliminate remaining pressure in fuel pump.
2. Clean around fuel pump
3. Separate fuel line
Fuel pump
4. Loosen fuel pump bolt and separate fuel pump
5. Apply oil to O-ring part of new fuel pump and mount it.
Joint torque of fuel pump bolt: 1.0 to 1.2kg.m
6. Mount fuel line. SOLA443A

7. Perform fuel charge and air discharge (up to fuel filter).

8. Start engine and execute idle rotation to get rid of air remaining
in system.
FUEL FILTER 31-37

Replacement of overflow valve

1. Clean around overflow valve

SOLA439A

2. Place container under hose of air vent hole at fuel filter head and
loosen air vent bolt.

SOLA441A

3. Separate fuel line from overflow valve.

SOLA442A

4. Remove overflow valve

SOLA440A

5. Clean contact side of cylinder head and mount new overflow

valve.
Joint torque of overflow valve : 3.4 to 4.0kg.m
6. Mount fuel line and perform fuel charge and air discharge (Refer
to method if fuel is completely eliminated in fuel line).
7. Start engine and execute idle rotation about 10 minutes to get rid
of air remaining in system.