AIR FLOW SENSOR (AFS)

CIRCUIT DIAGRAM

HOT FILM AFS OUTPUT FEATURES

Mass air flow (kg/h) Output voltage (V)

10 1.2226 - 1.2398

15 1.3552 - 1.3778

30 1.6783 - 1.7146

60 2.1619 - 2.2057
 120 2.7215 - 2.7762

250 3.4388 - 3.5037

370 3.8796 - 3.9511

480 4.1945 - 4.2683

640 4.5667 - 4.6469

TEST PROCEDURE

TROUBLESHOOTING HINTS
1.When Ignition switch is turned on, if AFS output voltage is not "0" (engine stops), inspect the
malfunction of AFS and ECU.
2.Even though AFS output voltage is abnormal, if engine is at idle ,inspect the following conditions.
(1)Chect the poor attachment of airflow, cut air duct, and air cleaner filter branched from AFS.
(2)Bad combustion in the cylinder or fault injector.

3.Even it no AFS malfunction occurs, check the mounting direction of AFS.

a. Use correct digital voltmeter.

b. Before inspection, warming up the engine till the engine coolant temperature is up to 80~90°C.

AFS HARNESS INSPECTION PROCEDURES

ATS (INTAKE AIR TEMPERATURE SENSOR) HARNESS INSPECTION
PROCEDURE
TEST PROCEDURE (ATS)

SENSOR INSPECTION
1.Inspect the resistance of sensor using a multi-tester.
2.Measure the resistance between ATS and terminal.
CONDITION TEMPERATURE (°C) RESISTANCE (kΩ)

Ignition switch ON -40 39.260

-30 22.960

-20 13.850

-10 8.609
 0 5.499

+10 3.604

+20 2.420

+30 1.662

+40 1.166

+50 0.835

+60 0.609

+70 0.452

+80 0.340

+90 0.261

+100 0.202

+110 0.159

+120 0.127

+130 0.102

3.If resistance value is out of standard, replace the intake air temperature sensor assembly.

Intake air temperature sensor is integrated in AFS.

WTS (WATER TEMPERATURE SENSOR)

CIRCUIT DIAGRAM
TROUBLESHOOTING HINTS
When idling speed is not appropriate or blacksmoke arises it is likely to be a defect of water temperature
sensor.
HARNESS INSPECTION PROCEDURES
SENSOR INSPECTION
USING HI-SCAN
Set value
Check item Data display Check conditions Coolant temp.
(HI-SCAN)

Water Sensor Ignition switch : ON or engine running -20°C -20°C

temperature temperature
sensor 0°C 0°C

20°C 20°C

40°C 40°C

80°C 80°C

USING MULTITESTER
1.Remove the water temperature sensor from the engine coolant passage of the cylinder head.
2.With the temperature sensing portion of the engine coolant temperature sensor immersed in hot water,
check resistance.
(1)WTS sensor
Temperature (°C) Resistance (kΩ)

-40 48.14

-20 14.13 ~ 16.83

0 5.790

20 2.31 ~ 2.59

40 1.148

60 0.5865

80 0.3222

100 0.1884

110 0.1451 ~ 0.1491

120 0.1163
 (2)Gauge unit
Temperature (°C) Resistance (Ω)

60 125

85 42.6 ~ 54.2

110 22.1 ~ 26.2

125 15.2

3.If the resistance deviates from the standard value greatly, replace the sensor.
INSTALLATION
1.Apply sealant LOCTITE 962T or equivalent to threaded portion.
2.Install water temperature sensor and tighten it to specified torque.

Tightening torque :2.0 ~ 4.0kg·m

3.Connect the harness connector securely.

CAMSHAFT POSITION SENSOR (TDC)

CIRCUIT DIAGRAM
HARNESS INSPECTION PROCEDURES
CRANSHAFT POSITION SENSOR (CKP)

CIRCUIT DIAGRAM
HARNESS INSPECTION PROCEDURES
INJECTOR

CIRCUIT DIAGRAM
 HARNESS INSPECTION PROCEDURES

INJECTOR OPERATION INSPECTION

1.Using a clip-on ammeter of motor tester, check actuation of injector. Clip-on ammeter must satisty the
following conditions.

Measuring range >25A

Bandwidth > 100kHz

2.Attach the plug to the injector. Fasten clip-on ammeter around lead to pin.2 of corresponding injector.
Allow engine to be at idle.
Refer to the set value(current) as following figure.

a. Length of holding current phase (max.12A) is governed by engine speed, injection time and
changes on velocity.
b. The first current curve shows the pre-injection.
3.Check the injector for injecting of fuel. As checking procedure, detach the injector plug from each boxes
and connect to replaced injector.
If change to enine running results, injector is injecting. If no change to engine running results, injector is
not injecting.
This test cannot however establish whether an injector is injecting an correct quantity.
If necessary, all injectors have to be replaced.
AFTER RUN TEST
1.Measure the supply voltage at ECU pin 114(Clinder #1 Injector), pin 119 (Clinder #4 Injector) to pin 117
and pin 120(Cylinder #3 Injector), pin 121(Cylinder #2 Injector) to pin 118 with ignition OFF.

Set value : 0V

2.Check wiring if set value is not attained. If wiring is OK, replace the ECU.
MEASURE THE RESISTANCE BETWEEN TERMINALS
1.Detach the connector from injector.
2.Measure the resistance between terminals.

Specified value :
0.3 ~ 0.6Ω (at 20°C)

3.Connect the connector to the injector.

RAIL PRESSURE SENSOR (RPS)

CIRCUIT DIAGRAM
SENSOR INSPECTION
USING HI-SCAN
Set value
Check item Data display Check conditions Rail pressure
(HI-SCAN)

Rail pressure sensor Rail pressure Engine at idle 220 - 300bar 260bar

HARNESS INSPECTION PROCEDURES

SENSOR REPLACEMENT
1.Replace the RPS if signal voltage exceeds the set value.
2.Note the followings.
(1)Always renew the sealing washer (soft iron sealing ring) even if old sensor is re-used.
(2)When removing seal, take care not to damage sealing surface.
(3)When installing RPS, provide the sealing washer with grease if necessary.
(4)Tightening torque is 35±2 N·m (25.8±1.5 Ib·ft)

Replace the faulty fuel rail assembly in case of new model vehicle within a year, or replace the
faulty parts of vehicle of which model year is more than a year.

EGR SOLENOID VALVE

CIRCUIT DIAGRAM

HARNESS INSPECTION PROCEDURES

EGR SOLENOID VALVE INSPECTION
USING HI-SCAN
Check item Check condition Engine condition Standard value

EGR solenoid valve solenoid valve Ignition switch : ON Check the sound for
OFF →ON proper operation

USING VOLTMETER
Check item Specified value

EGR solenoid valve resistance 14 ~ 17Ω

RAIL PRESSURE REGULATOR (MPROP)

CIRCUIT DIAGRAM
TROUBLESHOOTING HINTS
At after run test mode or fuel cut mode, if within set time engine rpm is not dropped below the lower set
value, error is detected. The reasons are short circuit, connecting resistance, faulty rail pressure sensor,
continuity of fuel pump relay, faulty rail pressure control valve, defective high pressure pump, ECU fault,
etc.
HARNESS INSPECTION PROCEDURES
RAIL RPRESSURE REGULATOR INSPECTION
USING VOLTMETER
Check item Set value (Ω)

Rail pressure control valve resistance 2.9~3.15Ω

Replace the faulty fuel rail assembly in case of new model vehicle within a year, or replace the faulty
parts of vehicle of which model year is more than a year. DON'T DISASSEMBLE OR DISASSEMBLE
Rail Pressure Regulator, because it is NOT SERVICE ITEM.

ACCELERATION PEDAL POSITION SENSOR (APS)

CIRCUIT DIAGRAM
HARNESS INSPECTION PROCEDURES