Fuel System

General Information

Fuel System
 2009 > D 2.9 VGT >

SPECIAL SERVICE TOOLS

Tool (Number and name) Illustration Application

Torque Wrench Socket (17mm)

Installing the high pressure pipe
09314-27120

Torque Wrench Socket (19mm)

Installing the high pressure pipe
09314-27130

High pressure pump pulley puller Removaling the high pressure pump
(OK552-131-003) pulley
 2009 > D 2.9 VGT >

SPECIFICATION
FUEL DELIVERY SYSTEM
Items Specification
Fuel tank Capacity 80!
Fuel pump Type High Pressure Pump(Volume metric-blade type)
Fuel Filter Type High Pressure Type
Regulated Fuel
Fuel Pressure 1,600 bar (1,631.5 kgf/cm")
Pressure

SENSOR
MASS AIR FLOW SENSOR (MAFS)
▷ Type: Hot-film type
▷ Specification

Air Flow (kg/h) Voltage (V)

10.0 1.23
15.0 1.37
30.0 1.70
60.0 2.18
120.0 2.75
250.0 3.47
370.0 3.92
480.0 4.23
640.0 4.61

INTAKE AIR TEMPERATURE SENSOR (IATS)

▷ Type: Thermistor type
▷ Specification
Temperature
Resistance (k!)
°C °F
-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

ENGINE COOLANT TEMPERATURE SENSOR (ECTS)

▷ Type: Thermistor type
▷ Specification
Temperature
Resistance (k!)
°C °F
 -40 -40 44.4
-20 -4 13.44 ~ 16.83
0 2 5.74
20 68 2.27 ~ 2.64
40 104 1.15
60 140 0.58
80 176 0.31 ~ 0.33

ACCELERATOR POSITION SENSOR (APS)

▷ Type: Variable resistor type
▷ Specification
Output Voltage (V) [Vref = 5.0V]
Accelerator Position
APS1 APS2
C.T 0.64 ~ 0.86V 0.275 ~ 0.475V
W.O.T 3.8 ~ 4.4V 1.75 ~ 2.35V

Item Sensor Resistance (k!)

APS1 0.7 ~ 1.3k# [20°C(68°F)]
APS2 0.7 ~ 1.3k# [20°C(68°F)]

CAMSHAFT POSITION SENSOR (CMPS)

▷ Type: Hall effect type
CRANKSHAFT POSITION SENSOR (CKPS)
▷ Type: Magnetic field sensitive type
▷ Specification
Item
Coil Resistance (!) 774 ~ 946# [20°C(68°F)]
Air Gap (mm) 0.5 ~ 1.5

KNOCK SENSOR (KS)

▷ Type: Piezo-electricity type
▷ Specification
Item Specification
Capacitance (pF) 800 ~ 1,600pF

Rail Pressure Sensor (RPS)

▷ Specification

Rail Pressure (bar) Output Voltage (V)

0 0.46 ~ 0.54
230 1.00 ~ 1.01
400 1.37 ~ 1.40
600 1.81 ~ 1.85
800 2.25 ~ 2.3
1,000 2.69 ~ 2.75
 1,200 3.12 ~ 3.22
1,400 3.55 ~ 3.67
1,600 3.93 ~ 4.18

FuelTemperature Sensor (FTS)

▷ Type: Thermistor type
▷ Specification

Temperature
Resistance (k!)
°C °F
-40 -40 82.78 ~ 68.78
-20 -4 24.03 ~ 19.71
0 32 7.97 ~ 6.74
20 68 2.98 ~ 2.65
40 104 1.26 ~ 1.14
60 140 0.59 ~ 0.54
80 176 0.29 ~ 0.28

ACTUATORS
INJECTOR
▷ Number: 4
▷ Specification

Item Specification
Minimum Operation Pressure 100 bar

Inlet Metering Valve (IMV)

▷ Specification

Item Specification
Coil Resistance (!) 5.5# [20°C(68°F)]

EGR Solenoid Valve

▷ Specification

Item Specification
Coil Resistance (!) 14.7 ~ 16.1#[20°C(68°F)]

Throttle Control Solenoid Valve

▷ Specification
Item Specification
Coil Resistance (!) 28.3 ~ 31.1# [20°C(68°F)]

SERVICE STANDARD
Idle Speed 800±100 rpm

TIGHTENING TORQUES
Engine Control System

Items Kgf"m N"m lbf"ft

ECM installation bolts (On bracket) 0.7 ~ 1.0 5.9 ~ 9.8 4.3 ~ 7.2
ECM installation nuts (On bracket) 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
ECM Bracket installation nuts 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
Knock sensor installation 0.15 ~ 0.25 1.5 ~ 2.5 1.1 ~ 1.8
Solenoid assembly bracket installation bolts 0.7 ~ 0.9 6.9 ~ 8.8 5.1 ~ 6.5
Crankshaft Position Sensor (CKPS) installation bolts 0.9 ~ 1.0 8.8 ~ 9.8 6.5 ~ 7.2
Mass Air Flow Sensor (MAFS) clamp installation bolts 0.3 ~ 0.5 2.9 ~ 4.9 2.2 ~ 3.6

Fuel Delivery System

Items Kgf"m N"m lbf"ft

High Pressure Pipe (Injector $ Common Rail) installation flange
3.65 ~ 4.35 35.8 ~ 42.7 26.4 ~ 31.5
nuts
High Pressure Pipe (Common Rail $ High pressure pump)
3.65 ~ 4.35 35.8 ~ 42.7 26.4 ~ 31.5
installation flange nuts
Common Rail installation nuts 1.9 ~ 2.3 18.6 ~ 22.6 13.7 ~ 16.6
High Pressure Pipe (Common Rail $ High pressure pump)
0.3 2.9 2.2
clamp installation bolts
High pressure pump installation bolts (Timing case) 2.2 ~ 2.6 21.6 ~ 25.5 15.9 ~ 18.8
High pressure pump installation bolts (Bracket) 2.2 ~ 2.6 21.6 ~ 25.5 15.9 ~ 18.8
High pressure pump bracket installation bolts (Cylinder block) 3.5 ~ 4.1 34.3 ~ 40.2 25.3 ~ 29.7
Injector clamp installation bolts 2 ~ 2.2 19.6 ~ 21.6 14.5 ~ 15.9
Fuel tank band installation bolts 4.5 ~ 6 44.1 ~ 58.9 32.6 ~ 43.4
Fuel filter bracket installation bolts 1.9 ~ 2.8 18.6 ~ 27.5 13.7 ~ 20.3
Fuel Sender installation bolts 0.2 ~ 0.3 2 ~ 2.9 1.4 ~ 2.2
Accelerator Pedal Module installation bolts 0.8 ~ 1.0 7.8 ~ 9.8 5.8 ~ 7.2
 2009 > D 2.9 VGT >

BASIC TROUBLESHOOTING
BASIC TROUBLESHOOTING GUIDE

CUSTOMER PROBLEM ANALYSIS SHEET

1. VEHICLE INFORMATION

(I) VIN:
(II) Production Date:
 (III) Odometer Reading: (mile/㎞)

2. SYMPTOMS
! Engine does not turn over ! Incomplete combustion
! Unable to start
! Initial combustion does not occur
! Difficult to start ! Engine turns over slowly ! Other_________________
! Rough idling ! Incorrect idling
! Poor idling ! Unstable idling (High: ______ rpm, Low: ______rpm)
! Other __________________________________
! Soon after starting ! After accelerator pedal depressed
! After accelerator pedal released ! During A/C ON
! Engine stall
! Shifting from N to D-range
! Other _______________________________________________
! Poor driving (Surge) ! Knocking ! Poor fuel economy
! Others
! Back fire ! After fire ! Other ____________________________

3. ENVIRONMENT

! Constant ! Sometimes (_________________) ! Once only

Problem frequency
! Other ___________________________________________
Weather ! Fine ! Cloudy ! Rainy ! Snowy ! Other __________________
Outdoor temperature Approx. _____ °C/°F
! Highway ! Suburbs ! Inner City ! Uphill ! Downhill
Place
! Rough road ! Other ___________________________________
Engine temperature ! Cold ! Warming up ! After warming up ! Any temperature
! Starting ! Just after starting (____ min) ! Idling ! Racing
Engine operation ! Driving ! Constant speed ! Acceleration ! Deceleration
! A/C switch ON/OFF ! Other _____________________________

4. MIL/DTC

MIL (Malfunction Indicator Lamp) ! Remains ON ! Sometimes lights up ! Does not light
Normal Check ! Normal ! DTC (_______________________________________)
(Pre-check) ! Freeze Frame Data
DTC
! Normal ! DTC (_______________________________________)
Check mode
! Freeze Frame Data

BASIC INSPECTION PROCEDURE

The measured resistance at high temperature after vehicle running may be high or low. So all resistance must be
measured at ambient temperature (20°C, 68°F), unless there is any notice.

The measured resistance in except for ambient temperature (20°C, 68°F) is reference value.

Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does not occur again
during testing. An example would be if a problem appears only when the vehicle is cold but has not appeared when
warm. In this case, technician should thoroughly make out a "CUSTOMER PROBLEM ANALYSIS SHEET" and
recreate (simulate) the environment and condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent, broken or corroded pins,
and then verify that the connectors are always securely fastened.
 and then verify that the connectors are always securely fastened.

3. Slightly shake the connector and wiring harness vertically and horizontally.
4. Repair or replace the component that has a problem.
5. Verify that the problem has disappeared with the road test.
" SIMULATING VIBRATION
1) Sensors and Actuators
: Slightly vibrate sensors, actuators or relays with finger.

Strong vibration may break sensors, actuators or relays

2) Connectors and Harness

: Lightly shake the connector and wiring harness vertically and then horizontally.
" SIMULATING HEAT
1) Heat components suspected of causing the malfunction with a hair dryer or other heat sourre.

• DO NOT heat components to the point where they may be damaged.

• DO NOT heat the ECM directly.

" SIMULATING WATER SPRINKLING

1) Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.

DO NOT sprinkle water directly into the engine compartment or electronic components.

" SIMULATING ELECTRICAL LOAD

1) Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).

CONNECTOR INSPECTION PROCEDURE

1. Handling of Connector
A. Never pull on the wiring harness when disconnecting connectors.
B. When removing the connector with a lock, press or pull locking lever.

C. Listen for a click when locking connectors. This sound indicates that they are securely locked.

D. When a tester is used to check for continuity, or to measure voltage, always insert tester probe from wire
harness side.

E. Check waterproof connector terminals from the connector side. Waterproof connectors cannot be accessed from
harness side.
 • Use a fine wire to prevent damage to the terminal.
• Do not damage the terminal when inserting the tester lead.

2. Checking Point for Connector

A. While the connector is connected:
Hold the connector, check connecting condition and locking efficiency.
B. When the connector is disconnected:
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
C. Check terminal tightening condition:
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
D. Pull lightly on individual wires to ensure that each wire is secured in the terminal.

3. Repair Method of Connector Terminal

A. Clean the contact points using air gun and/or shop rag.

Never use sand paper when polishing the contact points, otherwise the contact point may be damaged.

B. In case of abnormal contact pressure, replace the female terminal.

WIRE HARNESS INSPECTION PROCEDURE

1. Before removing the wire harness, check the wire harness position and crimping in order to restore it correctly.
2. Check whether the wire harness is twisted, pulled or loosened.
3. Check whether the temperature of the wire harness is abnormally high.
4. Check whether the wire harness is rotating, moving or vibrating against the sharp edge of a part.
5. Check the connection between the wire harness and any installed part.
6. If the covering of wire harness is damaged; secure, repair or replace the harness.
ELECTRICAL CIRCUIT INSPECTION PROCEDURE
" CHECK OPEN CIRCUIT
1. Procedures for Open Circuit
A. Continuity Check
B. Voltage Check
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity Check Method) or
Step 3 (Voltage Check Method) as shown below.

2. Continuity Check Method

When measuring for resistance, lightly shake the wire harness above and below or from side to side.

Specification (Resistance)
1# or less $ Normal Circuit
1 M# or Higher $ Open Circuit

A. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1# M# and below 1 # respectively.
Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point, check sub line of line 1 as
described in next step.

B. Disconnect connector (B), and measure for resistance between connector (C) and (B1) and between (B2) and
(A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1M# and the open circuit
is between terminal 1 of connector (C) and terminal 1 of connector (B1).
3. Voltage Check Method
A. With each connector still connected, measure the voltage between the chassis ground and terminal 1 of each
connectors (A), (B) and (C) as shown in [FIG. 4].
The measured voltage of each connector is 5V, 5V and 0V respectively. So the open circuit is between
connector (C) and (B).

" CHECK SHORT CIRCUIT

1. Test Method for Short to Ground Circuit
• Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing below Step 2
(Continuity Check Method with Chassis Ground) as shown below.

2. Continuity Check Method (with Chassis Ground)

Lightly shake the wire harness above and below, or from side to side when measuring the resistance.

Specification (Resistance)
1# or less $ Short to Ground Circuit
1M# or Higher $ Normal Circuit
1) Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis Ground as shown
in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 # and higher than 1M# respectively.
Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken point, check the sub line of
line 1 as described in the folowing step.

2) Disconnect connector (B), and measure the resistance between connector (A) and chassis ground, and between
(B1) and chassis ground as shown in [FIG. 7].
The measured resistance between connector (B1) and chassis ground is 1# or less. The short to ground circuit is
between terminal 1 of connector (C) and terminal 1 of connector (B1).

SYMPTOM TROUBLESHOOTING GUIDE TABLE

(SYMPTOM 1) ENGINE DOES NOT START
Possible Cause
• Run out of fuel • Inversion of low pressure fuel connections
• Starter faulty • Fuel filter not adapted
• Fuel pump hose supply cut • Low pressure fuel circuit sealed
• High pressure leakage • Sealed fuel filter
• Fuse out of order • Intermittent fault connection
• The compensation of individual injector not adapted • Air ingress in the low pressure fuel circuit
• Drift of the rail pressure sensor not detected • Fuel return circuit of the pump sealed
• Cam and Crank signals missing simultaneously • Engine compression too low
• Battery voltage too low • Leakage at the injector
• Faulty immobilizer • Low pressure fuel pump faulty
• EGR valve blocked open • High pressure fuel pump faulty
• Inlet metering valve contaminated, stuck, jammed • Injector jammed open
• Fuel quality / presence of water • Bug software or hardware fault not detected

(SYMPTOM 2) ENGINE STARTS WITH DIFFICULTY OR STARTS AND STALLS

Possible Cause
 • Run out of fuel • Low pressure fuel circuit sealed
• Fuel return hose of injector cut • Sealed fuel filter
• High pressure leakage • Oil level too high/too low
• Fuse faulty • Catalytic converter sealed or damaged
• Air filter sealed • Intermittent fault connection
• Alternator or voltage regulator faulty • Air ingress in the low pressure fuel circuit
• The compensation of individual injector not adapted • Fuel return circuit of the pump sealed
• Drift of the engine coolant temperature sensor not • Glow system faulty
detected • Engine compression too low
• Drift of the rail pressure sensor not detected • Fuel return hose of injector sealed
• Battery voltage too low • Carbon deposit on the injector (sealed holes)
• EGR valve blocked open • Needle stuck (injection possible over a certain
• Inlet metering valve contaminated, stuck, jammed pressure)
• Fuel quality / presence of water • Gasoline in fuel
• Inversion of low pressure fuel connections • Bug software or hardware fault not detected

(SYMPTOM 3) POOR STARTING WHEN HOT

Possible Cause
• The compensation of individual injector not adapted • Fuel return circuit of the pump sealed
• Drift of the rail pressure sensor not detected • Sealed fuel filter
• EGR valve blocked open • Engine compression too low
• Inlet metering valve contaminated, stuck, jammed • Intermittent fault connection
• Air filter sealed • Carbon deposit on the injector (sealed holes)
• Air ingress in the low pressure fuel circuit • Needle stuck (injection possible over a certain
• Fuel quality / presence of water pressure)
• Bug software or hardware fault not detected • Gasoline in fuel

(SYMPTOM 4) UNSTABLE IDLING

Possible Cause
• High pressure leakage
• Fuel return hose of injector cut
• Glow system faulty
• The compensation of individual injector not adapted
• Engine compression too low
• Drift of the rail pressure sensor not detected
• Bad flanging of the injector
• Harness resistance increased
• High pressure pump out of order
• Air ingress in the low pressure fuel circuit
• Injector not adapted
• Fuel quality / presence of water
• Carbon deposit on the injector (sealed holes)
• Sealed fuel filter
• Needle stuck (injection possible over a certain
• Air filter sealed
pressure)
• Fuel return hose of injector sealed
• Injector jammed open

(SYMPTOM 5) IDLE SPEED TOO HIGH OR TOO LOW

Possible Cause
• Drift of the engine coolant temperature sensor not • Clutch not well set
detected • Bug software or hardware fault not detected
• Incorrect state of the electrical pack devices
• Alternator or voltage regulator faulty

(SYMPTOM 6) BLUE, WHITE, OR BLACK SMOKES

Possible Cause
 • The compensation of individual injector not adapted • Oil suction (engine racing)
• Drift of the engine coolant temperature sensor not • Glow system faulty
detected • Engine compression too low
• Drift of the rail pressure sensor not detected • Bad flanging of the injector
• EGR valve blocked open • Injector washer not adapted, forgotten, doubled
• Inlet metering valve contaminated, stuck, jammed • Injector not adapted
• Oil level too high/too low • Carbon deposit on the injector (sealed holes)
• Fuel quality / presence of water • Injector jammed open
• Catalytic converter sealed or damaged • Gasoline in fuel
• Air filter sealed

(SYMPTOM 7) ENGINE RATTLING, NOISY ENGINE

Possible Cause
• The compensation of individual injector not adapted • Drift of the rail pressure sensor not detected
• EGR valve blocked closed (noisy engine) • Injector washer not adapted, forgotten, doubled
• EGR valve blocked open • Injector not adapted
• Drift of the engine coolant temperature sensor not • Carbon deposit on the injector (sealed holes)
detected • Needle stuck (injection possible over a certain
• Glow system faulty pressure)
• Engine compression too low • Injector jammed open
• Fuel return hose of injector sealed

(SYMPTOM 8) BURST NOISE

Possible Cause
• The compensation of individual injector not adapted • Drift of the rail pressure sensor not detected
• Intermittent fault connection • Inlet metering valve contaminated, stuck, jammed
• Exhaust system sealed • Bug software or hardware fault not detected

(SYMPTOM 9) UNTIMELY ACCELERATION/DECELERATION AND ENGINE RACING

Possible Cause
• Accelerator position sensor blocked • Oil suction (engine racing)
• EGR valve blocked open • Drift of the rail pressure sensor not detected
• Intermittent fault connection • Bug software or hardware fault not detected

(SYMPTOM 10) GAP WHEN ACCELERATING AND AT RE-COUPLING (RESPONSE TIME)

Possible Cause
• Air inlet circuit open • Engine compression too low
• Incorrect state of the electrical pack devices • High pressure leakage
• Accelerator position sensor blocked • Inlet metering valve contaminated, stuck, jammed
• EGR valve blocked open • Needle stuck (injection possible over a certain
• Turbo charger damaged pressure)
• Sealed fuel filter • Bug software or hardware fault not detected

(SYMPTOM 11) ENGINE STOP OR STALLING

Possible Cause
• Run out of fuel • Inlet metering valve contaminated, stuck, jammed
• Fuel pump hose supply cut • Alternator or voltage regulator faulty
 • High pressure leakage • Intermittent fault connection
• Fuse faulty • Catalytic converter sealed or damaged
• Fuel quality / presence of water • Oil suction (engine racing)
• Low pressure fuel circuit sealed • Low pressure fuel pump faulty
• Sealed fuel filter • High pressure pump faulty
• Cam and Crank signals missing simultaneously • Faulty ignition key
• EGR valve blocked open • Gasoline in fuel
• Bug software or hardware fault not detected

(SYMPTOM 12) ENGINE JUDDER

Possible Cause
• Glow system faulty
• Run out of fuel
• Engine compression too low
• Fuel return hose of injector cut
• Fuel return hose of injector sealed
• Incorrect state of the electrical pack devices
• Valve clearance
• The compensation of individual injector not adapted
• Low pressure fuel pump faulty
• EGR valve blocked open
• Injector washer not adapted, forgotten, doubled
• Fuel filter not adapted
• Carbon deposit on the injector (sealed holes)
• Air ingress in the low pressure fuel circuit
• Needle stuck (injection possible over a certain
• Fuel quality / presence of water
pressure)
• Sealed fuel filter
• Injector jammed open
• Intermittent fault connection
• Gasoline in fuel
• Harness resistance increased
• Bug software or hardware fault not detected

(SYMPTOM 13) LACK OF POWER

Possible Cause
• The compensation of individual injector not adapted • Sealed fuel filter
• Accelerator position sensor blocked • Leakage at the injector
• Incorrect state of the electrical pack devices • Fuel return circuit of the pump sealed
• EGR valve blocked open • Fuel return hose of injector sealed
• Air inlet circuit open • Engine compression too low
• Air filter sealed • Injector not adapted
• Oil level too high/too low • Carbon deposit on the injector (sealed holes)
• Catalytic converter sealed or damaged • Valve clearance
• Turbo charger damaged

(SYMPTOM 14) TOO MUCH POWER

Possible Cause
• EGR valve blocked closed (noisy engine) • Oil suction (engine racing)
• The compensation of individual injector not adapted • Bug software or hardware fault not detected

(SYMPTOM 15) EXCESSIVE FUEL CONSUMPTION

Possible Cause
• Fuel return hose of injector cut • Incorrect state of the electrical pack devices
• Leakage at the Inlet metering valve • Oil level too high/too low
• Leakage at fuel temperature sensor • Fuel quality / presence of water
• Leakage at the spacers • Catalytic converter sealed or damaged
• High pressure leakage • Turbo charger damaged
 • Air inlet circuit open • Engine compression too low
• Air filter sealed • Injector not adapted
• The compensation of individual injector not adapted • Bug software or hardware fault not detected
• EGR valve blocked open

(SYMPTOM 16) OVER SPEED ENGINE WHEN CHANGING THE GEAR BOX RATIO

Possible Cause
• Accelerator position sensor blocked • Oil suction (engine racing)
• The compensation of individual injector not adapted • Turbo charger damaged
• Intermittent fault connection • Injector not adapted
• Clutch not well set • Bug software or hardware fault not detected

(SYMPTOM 17) EXHAUST SMELLS

Possible Cause
• EGR valve blocked open • Injector washer not adapted, forgotten, doubled
• Oil suction (engine racing) • Injector not adapted
• Turbo charger damaged • Carbon deposit on the injector (sealed holes)
• Oil level too high/too low • Needle stuck (injection possible over a certain
• The compensation of individual injector not adapted pressure)
• Catalytic converter sealed or damaged • Injector jammed open
• Bad flanging of the injector • Bug software or hardware fault not detected

(SYMPTOM 18) SMOKES (BLACK, WHITE, BLUE) WHEN ACCELERATING

Possible Cause
• High pressure leakage
• The compensation of individual injector not adapted
• Intermittent fault connection
• EGR valve blocked open
• Bad flanging of the injector
• Air filter sealed
• Injector washer not adapted, forgotten, doubled
• Fuel quality / presence of water
• Injector not adapted
• Oil level too high/too low
• Carbon deposit on the injector (sealed holes)
• Turbo charger damaged
• Needle stuck (injection possible over a certain
• Catalytic converter sealed or damaged
pressure)
• Oil suction (engine racing)
• Injector jammed open
• Air heaters out of order
• Gasoline in fuel
• Engine compression too low
• Bug software or hardware fault not detected

(SYMPTOM 19) FUEL SMELLS

Possible Cause
• Fuel pump hose supply cut • Leakage at fuel temperature sensor
• Fuel return hose of injector cut • Leakage at the spacers
• Leakage at the Inlet metering valve • High pressure leakage

(SYMPTOM 20) THE ENGINE COLLAPSES AT TAKE OFF

Possible Cause
• Accelerator position sensor blocked • Catalytic converter sealed or damaged
• Incorrect state of the electrical pack devices • Clutch not well set
• Air filter sealed • Intermittent fault connection
 • Inversion of low pressure fuel connections • Drift of the rail pressure sensor not detected
• Fuel filter not adapted • Inlet metering valve contaminated, stuck, jammed
• Fuel quality/presence of water • Gasoline in fuel
• Air ingress in the low pressure fuel circuit • Bug software or hardware fault not detected
• Sealed fuel filter

(SYMPTOM 21) THE ENGINE DOES NOT STOP

Possible Cause
• Faulty ignition key
• Oil suction (engine racing)
• Bug software or hardware fault not detected

(SYMPTOM 22) DIFFERENT MECHANICAL NOISES

Possible Cause
• Buzzer noise (discharge by the injectors) • Bad flanging of the injector
• Clip broken (vibrations, resonance, noises) • Clutch not well set
• Incorrect state of the electrical pack devices • Turbo charger damaged
• Catalytic converter sealed or damaged • Valve clearance
• Air inlet circuit open
 Fuel System

Engine Control System

Fuel System
 2009 > D 2.9 VGT >

COMPONENT LOCATION

2. Mass Air Flow Sensor (MAFS)

1. ECM (Engine Control Module)
3. Intake Air Temperature Sensor (IATS)
4. Engine Coolant Temperature Sensor (ECTS) 5. Camshaft Position Sensor (CMPS)

7. Rail Pressure Sensor (RPS)

6. Crankshaft Position Sensor (CKPS)
13. Injector

8. Fuel Temperature Sensor (FTS)

9. Knock Sensor(KS)
16. Inlet Metering Valve (IMV)
10. Vehicle Speed Sensor (VSS) 11. Accelerator Position Sensor (APS)

14. Throttle Control Solenoid valve

12. Water Sensor (WS)
15. EGR Solenoid valve

18. Air Heater relay #1

19. Air Heater relay #2
20. PTC Heater relay #1
21. PTC Heater relay #2
17. Mail relay
22. PTC Heater relay #3
23. Cooling Fan relay (High) #1
24. Cooling Fan relay (High) #2
25. Cooling Fan relay (Low)
 Fuel System

Engine Control System - Engine Control

Module (ECM)

Fuel System
 2009 > D 2.9 VGT >

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.

Specification (Resistance): 1! or less

2. TEST ECM CONNECTOR: Disconnect the ECM connector and visually check the ground terminal on ECM side
and harness side for bent pins or poor 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 agaon. 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 dose not occur, this is
intermittent problem (Refer to INTERMITTENT PROBLEM PROCEDURE in BASIC INSPECTION PROCEDURE).
 2009 > D 2.9 VGT >

ECM (ENGINE CONTROL MODULE)

1. ECM HARNESS CONNECTOR

2. ECM TERMINAL FUNCTION

CONNECTOR [C06-1]

Pin Description Connected to

1 -  
2 Accelerator Position Sensor (APS) 1 signal input Accelerator Position Sensor (APS) 1
3 Sensor ground Accelerator Position Sensor (APS) 1
4 Power ground Chassis Ground
5 Battery power Main Relay
6 Reference voltage (+5V) Accelerator Position Sensor (APS) 1
7 -  
8 Power ground Chassis Ground
9 Malfunction Indicator Lamp (MIL) control output Malfunction Indicator Lamp (MIL) in Cluster
10 Reference voltage (+5V) Accelerator Position Sensor (APS) 2
11 Accelerator Position Sensor (APS) 2 signal input Accelerator Position Sensor (APS) 2
12 Sensor ground Accelerator Position Sensor (APS) 2
13 -
14 Immobilizer Lamp control output Immobilizer Lamp (Cluster)
15 -  
16 Brake Switch 1 signal input Brake Switch
17 Battery power
18 -  
19 -  
20 Fuel consumption signal output Trip computer
21 Cruise control "MAIN" lamp control output Cruise control "MAIN" lamp (Cluster)
22 -  
23 Water Sensor siganl input Water Sensor in Fuel Filter
24 [M/T only] Clutch Switch signal input Clutch Switch
25 -  
26 Engine speed signal output Tachometer (Cluster)
 27 Immobilizer Communication Line Immobilizer Control Module
28 Diagnostic K-Line Data Link Connector (DLC)
29 Glow Time Indicator Lamp contorl output Glow Time Indicator Lamp (Cluster)
[A/T only] P/N switch signal input Inhibitor Switch
30
[M/T Only] Gear Neutral Switch signal input Gear Neutral Switch
31 CAN [LOW] TCM, ESP Control Module
32 CAN [HIGH] TCM, ESP Control Module

CONNECTOR [C06-2]

Pin Description Connected to

1 Sensor shield Knock Sensor (KS)
2 -  
3 Throttle Control Solenoid valve control output Throttle Control Solenoid Valve
4 Inlet Metering Valve (IMV) cotrol output Inlet Metering Valve (IMV)
5 Sensor shield Crankshaft Position Sensor (CKPS)
6 -  
7 EGR Solenoid Valve control output
8 -  
9 -  
10 Intake Air Temperature Sensor (IATS) signal input Intake Air Temperature Sensor (IATS)
11 -  
12 -  
13 -  
14 Air heater Relay 2 diagnosis line Glow Relay
15 -  
16 -  
17 -  
Engine Coolant Temperature Sensor (ECTS)
18 Engine Coolant Temperature Sensor (ECTS)
signal input
19 Sensor ground Engine Coolant Temperature Sensor (ECTS)
20 Injector (Cylinder #4) [LOW] control output Injector (Cylinder #4)
21 Knock Sensor (KS) signal input Knock Sensor (KS)
22 Fuel Temperature Sensor (FTS) signal input Fuel Temperature Sensor (FTS)
23 Sensor ground Fuel Temperature Sensor (FTS)
24 Injector (Cylinder #4) [HIGH] control output Injector (Cylinder #4)
25 Sensor ground Knock sensor (KS)
26 Crankshaft Position Sensor (CKPS) [+] signal input Crankshaft Position Sensor (CKPS)
27 Crankshaft Position Sensor (CKPS) [-] signal input Crankshaft Position Sensor (CKPS)
28 Injector (Cylinder #3) [LOW] control output Injector (Cylinder #3)
29 Reference voltage (+5V) Camshaft Position Sensor (CMPS)
30 Camshaft Position Sensor (CMPS) signal input Camshaft Position Sensor (CMPS)
31 Sensor ground Camshaft Position Sensor (CMPS)
 32 Injector (Cylinder #3) [HIGH] control output Injector (Cylinder #3)
33 Reference voltage (+5V) Rail Pressure Sensor (RPS)
34 Rail Pressure Sensor (RPS) signal input Rail Pressure Sensor (RPS)
35 Sensor ground Rail Pressure Sensor (RPS)
36 Injector (Cylinder #2) [LOW] control output Injector (Cylinder #2)
37 -  
38 -  
39 -  
40 Injector (Cylinder #2) [HIGH] control output Injector (Cylinder #2)
41 -  
42 -  
43 -
44 Injector (Cylinder #1) [LOW] control output Injector (Cylinder #1)
45 Reference voltage (+5V) Mass Air Flow Sensor (MAFS)
46 Mass Air Flow Sensor (MAFS) signal input Mass Air Flow Sensor (MAFS)
Mass Air Flow Sensor (MAFS), Intake Air
47 Sensor ground
Temperature Sensor (IATS)
48 Injector (Cylinder #1) [HIGH] control output Injector (Cylinder #1)

CONNECTOR [C06-3]

Pin Description Connected to

1 -  
2 -  
3 -  
4 A/C Compressor Fan Relay control output A/C Compressor Fan Relay
5 -  
6 Brake Switch 2 signal input Brake Switch
7 Cooling Fan Relay [HIGH] control output Cooling Fan Relay [HIGH]
8 Cooling Fan Relay [LOW] control output Cooling Fan Relay [LOW]
9 Cruise Control "MAIN" signal input Cruise Control Switch
10 PTC Heater Relay diagnosis line PTC Heater Relay
11 Air heater Relay 1 control Glow Relay 1
12 -  
13 Blower Switch signal input Blower Switch
14 Air heater Relay 1 diagnosis line Glow Relay 1
15 Air heater Relay 2 control Glow Relay 2
16 -  
17 M/T, A/T switch signal input A/T: Chassis Ground, M/T: Not used
18 -  
19 A/C Switch "ON" signal input A/C Switch
20 Vehicle speed sensor (VSS) signal input Vehicle speed sensor (VSS)
21 -  
 22 -  
23 -  
24 Main Relay control output Main Relay
25 A/C Relay control output A/C Relay
26 -  
27 Battery power Main Relay
28 Power ground Chassis GroundChassis Ground
29 PTC Heater Relay control output PTC Heater Relay
30 -  
31 Battery power Main Relay
32 Power ground Chassis Ground

3. ECM TERMINAL IN/OUT SIGNAL

CONNECTOR [C06-1]

PinNo. Description Condition Type Level

1 -

Accelerator Position Sensor C.T 0.3 ~ 0.9V

2 Analog
(APS) 1 signal input W.O.T 4.0 ~ 4.8V
3 Sensor ground Idle DC Max. 50mV
4 Power ground Idle DC Max. 50mV
IG OFF Max. 1.0V
5 Battery power DC
IG ON Battery Voltage
IG OFF Max. 0.5V
6 Reference voltage (+5V) DC
IG ON 4.9 ~ 5.1V
7 -
8 Power ground Idle DC Max. 50mV

Malfunction Indicator Lamp (MIL) Lamp OFF Battery Voltage

9 DC
control output Lamp ON Max. 1.0V
IG OFF Max. 0.5V
10 Reference voltage (+5V) DC
IG ON 4.2 ~ 5.2V

Accelerator Position Sensor C.T 0.3 ~ 0.9V

11 Analog
(APS) 2 signal input W.O.T 1.5 ~ 3.0V
12 Sensor ground Idle DC Max. 50mV
13 -
Lamp OFF Battery Voltage
14 Immobilizer Lamp control output DC
Lamp ON Max. 1.0V
15 -
Release Max. 0.5V
16 Brake Switch 1 signal input DC
Push Battery Voltage
IG OFF Max. 0.5V
17 Battery power DC
IG ON Battery Voltage
18 -
 19 -
HI: Battery Voltage
20 Fuel consumption signal output Vehicle Run Pulse
LO: Max. 1.0V
21 -
22 -
Indicator ON Battery Voltage
23 Water Sensor siganl input DC
Indicator OFF Max. 0.5V

[M/T only] Clutch Switch signal Release Max. 0.5V

24 DC
input Push Battery Voltage
25 -
HI: Battery Voltage
26 Engine speed signal output Idle Pulse LO: Max. 0.5V
Idle: 40 ~ 50Hz
[Transmitting]
HI: Min. Vbatt ! 80%
LO: Max. Vbatt ! 20%
27 Immobilizer Communication Line IG ON Pulse
[Receiving]
HI: Min. Vbatt ! 70%
LO: Max. Vbatt ! 30%
[Transmitting]
HI: Min. Vbatt ! 80%
GST LO: Max. Vbatt ! 20%
28 Diagnostic K-Line Pulse
Communication [Receiving]
HI: Min. Vbatt ! 70%
LO: Max. Vbatt ! 30%

Glow Time Indicator Lamp Lamp OFF Battery Voltage

29 DC
contorl output Lamp ON Max. 1.0V
Battery Voltage
Neutral DC
[A/T only] P/N switch signal input Max. 1.0V
30 [M/T Only] Gear Neutral Switch
signal input Max. 1.0V
Except Neutral DC
Battery Voltage
RECESSIVE 2.0 ~ 3.0V
31 CAN [LOW] Pulse
DOMINANT 0.5 ~ 2.25V
RECESSIVE 2.0 ~ 3.0V
32 CAN [HIGH] Pulse
DOMINANT 2.75 ~ 4.5V

CONNECTOR [C06-2]
PinNo. Description Condition Type Level
1 Sensor shield Idle DC Max. 50mV
2 -
Throttle Control Solenoid valve HI: Battery Voltage
3 ActiveInactive DC
control output LO: Max. 1.0V
Inlet Metering Valve (IMV) cotrol HI: Battery Voltage
4 Vehicle Run PULSE
output LO: Max. 1.0V
5 Sensor shield Idle DC Max. 50mV
6 -
HI: Battery Voltage
 HI: Battery Voltage
EGR Solenoid Valve control
7 Vehicle Run PULSE LO: Max. 1.0V
output
Vpeak: Max. 70V
8 -
9 -
Intake Air Temperature Sensor
10 Idle Analog 0 ~ 5V
(IATS) signal input
11 -
12 -
13 -
Relay OFF Max. 1.0V
14 Air heater Relay 2 diagnosis line DC
Relay ON Battery Voltage
15 -
16 -
17 - Max. 50mV
Engine Coolant Temperature
18 Idle Analog 0.5 ~ 4.5V
Sensor (ECTS) signal input
19 Sensor ground Idle DC Max. 50mV
[HI]
PULL: 22.0 ~ 26.5A
Injector (Cylinder #4) [LOW] HOLD: 5.9 ~ 8.0A
20 Idle PULSE
control output [LO]
PULL: 6.4~8.8A
HOLD: 4.4 ~ 6.3A
Knocking Variable
21 Knock Sensor (KS) signal input
Normal Frequency

Fuel Temperature Sensor (FTS)

22 IG ON DC 0.5 ~ 4.5V
signal input
23 Sensor ground Idle DC Max. 50mV
[HI]
PULL: 22.0 ~ 26.5A
Injector (Cylinder #4) [HIGH] HOLD: 5.9 ~ 8.0A
24 Idle PULSE
control output [LO]
PULL: 6.4~8.8A
HOLD: 4.4 ~ 6.3A
25 Sensor ground Idle DC Max. 50mV
Crankshaft Position Sensor
26 Idle SINE WAVE Vp-p: Min. 1.0V
(CKPS) [+] signal input
Crankshaft Position Sensor
27 Idle DC Max. 50mV
(CKPS) [-] signal input
[HI]
PULL: 22.0 ~ 26.5A
Injector (Cylinder #3) [LOW] HOLD: 5.9 ~ 8.0A
28 Idle PULSE
control output [LO]
PULL: 6.4~8.8A
HOLD: 4.4 ~ 6.3A
IG OFF Max. 0.5V
29 Reference voltage (+5V) DC
IG ON 4.9 ~ 5.1V
HI: Vcc or B+
 Camshaft Position Sensor HI: Vcc or B+
30 Idle PULSE
(CMPS) signal input LO: Max. 0.6V
31 Sensor ground Idle DC Max. 50mV
[HI]
PULL: 22.0 ~ 26.5A
Injector (Cylinder #3) [HIGH] HOLD: 5.9 ~ 8.0A
32 Idle PULSE
control output [LO]
PULL: 6.4~8.8A
HOLD: 4.4 ~ 6.3A
IG OFF Max. 0.5V
33 Reference voltage (+5V) DC
IG ON 4.9 ~ 5.1V
IG ON Max. 1.0V
Rail Pressure Sensor (RPS)
34 Idle Analog 1.0 ~ 2.0V
signal input
3000 RPM 2.0 ~ 5.0V
35 Sensor ground Idle DC Max. 50mV
[HI]
PULL: 22.0 ~ 26.5A
Injector (Cylinder #2) [LOW] HOLD: 5.9 ~ 8.0A
36 Idle PULSE
control output [LO]
PULL: 6.4~8.8A
HOLD: 4.4 ~ 6.3A
37 -
38 -
39 -
[HI]
PULL: 22.0 ~ 26.5A
Injector (Cylinder #2) [HIGH] HOLD: 5.9 ~ 8.0A
40 Idle PULSE
control output [LO]
PULL: 6.4~8.8A
HOLD: 4.4 ~ 6.3A
41 -
42 -
43 -
[HI]
PULL: 22.0 ~ 26.5A
Injector (Cylinder #1) [LOW] HOLD: 5.9 ~ 8.0A
44 Idle PULSE
control output [LO]
PULL: 6.4~8.8A
HOLD: 4.4 ~ 6.3A
IG OFF Max. 0.5V
45 Reference voltage (+5V) DC
IG ON 4.9 ~ 5.1V

Mass Air Flow Sensor (MAFS) Idle 0 ~ 2.0V

46 Analog
signal input 3000RPM 1.0 ~ 4.5V
47 Sensor ground Idle DC Max. 50mV
[HI]
PULL: 22.0 ~ 26.5A
Injector (Cylinder #1) [HIGH] HOLD: 5.9 ~ 8.0A
48 Idle PULSE
control output [LO]
PULL: 6.4~8.8A
HOLD: 4.4 ~ 6.3A
 HOLD: 4.4 ~ 6.3A

CONNECTOR [C06-3]

PinNo. Description Condition Type Level

1 -
2 -
3 -
Relay OFF Battery Voltage
4 A/C Compressor Fan Relay control output DC
Relay ON Max. 1.0V
5 -
RELEASE Max. 0.5V
6 Brake Switch 2 signal input DC
PUSH Battery Voltage
Relay OFF Battery Voltage
7 Cooling Fan Relay [HIGH] control output DC
Relay ON Max. 1.0V
Relay OFF Battery Voltage
8 Cooling Fan Relay [LOW] control output DC
Relay ON Max. 1.0V
9 -
Relay OFF Max. 1.0V
10 PTC Heater Relay diagnosis line DC
Relay ON Battery Voltage
Relay OFF Battery Voltage
11 Air heater Relay 1 control DC
Relay ON Max. 1.0V
12 -
Blower OFF Battery Voltage
13 Blower Switch signal input DC
Blower ON Max. 1.0V
Relay OFF Max. 1.0V
14 Air heater Relay 1 diagnosis line DC
Relay ON Battery Voltage
Relay OFF Battery Voltage
15 Air heater Relay 2 control DC
Relay ON Max. 1.0V
16 -
M/T: Battery
17 M/T, A/T switch signal input IG ON DC Voltage
A/T: Ground
18 -
A/C SW OFF Battery Voltage
19 A/C Switch "ON" signal input DC
A/C SW ON Max. 1.0V
HI: Min. 5.0V
20 Vehicle speed sensor (VSS) signal input Vehicle Run PULSE
LO: Max. 1.0V
21 -
22 -
23 -
Relay OFF Battery Voltage
24 Main Relay control output DC
Relay ON Max. 1.0V
Relay OFF Battery Voltage
 Relay OFF Battery Voltage
25 A/C Relay control output DC
Relay ON Max. 1.0V
26 -
IG OFF Max. 1.0V
27 Battery power DC
IG ON Battery Voltage
28 Power ground Idle DC Max. 50mV
Relay OFF Battery Voltage
29 PTC Heater Relay control output DC
Relay ON Max. 1.0V
30 -
IG OFF Max. 1.0V
31 Battery power DC
IG ON Battery Voltage
32 Power ground Idle DC Max. 50mV
 Fuel System

Engine Control System - Injector

Fuel System
 2009 > D 2.9 VGT >

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.
• Take care that the foreign material does not enter to the components when you remove or install the Fuel
system.
• Clean the connction parts of injector and replace the O-ring when you remove or install the injector.
• Insert the O-ring in the Cylinder head after pasting Diesel oil to the O-ring gasket.
• Avoid damaging the injector when you insert the injector into the cylinder.
• High pressure fuel pipe should not be reused.
• Mount the flare nut and the component vertically when you install the high pressure fuel pipe.

1. Remove the fuel return hose (A).

2. Remove the fixing clip (B) and disconnect the injector connector (C).
3. High pressure pipe (Common rail ! Injector) Removal
(1) Unscrews the flange nut (A) at the common rail.

(2) Unscrews the flange nuts (B) of injectors and remove the high pressure pipe (C).

4. Remove the injector clamp (B) after unscrewing the clamp mounting bolt (A).
5. Remove the injector from the cylinder.

INSTALLATION

• 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.
• Take care that the foreign material does not enter to the components when you remove or install the Fuel
system.
• Clean the connction parts of injector and replace the O-ring when you remove or install the injector.
• Insert the O-ring in the Cylinder head after pasting Diesel oil to the O-ring gasket.
• Avoid damaging the injector when you insert the injector into the cylinder.
• High pressure fuel pipe should not be reused.
• Mount the flare nut and the component vertically when you install the high pressure fuel pipe.

1. Install the Injector according to the reverse order to REMOVAL procedure.

1. Install the flange nut (Injector & Common rail side) with SST as following specification.

Classification SPEC SST No.

Flange nut (Common rail) 19mm (0.74 in.) 09314-27130
Flange nut (Injector) 17mm (0.67 in.) 09314-27120

Tightening torque:
Flange nut (Common rail): 35.8 ~ 42.7 N.m (3.65 ~ 4.35 kgf"m, 26.4 ~ 31.5 lbf.ft)
Flange nut (Injector): 35.8 ~ 42.7 N.m (3.65 ~ 4.35 kgf"m, 26.4 ~ 31.5 lbf.ft)
Injector clamp mounting bolt : 19.6 ~ 21.6 N.m (2.0 ~ 2.2 kgf"m, 14.5 ~ 15.9 lbf.ft)

REPLACEMENT
1. Remove the injector according to the removal procedure.
2. Install new injector according to the installation.
3. Eliminate injector characteristic data in the ECM using the diagnosis tool.
 Refer to "Injector characteristic data elimination" procedure.

4. Input the characteristic data elimination of new injector using diagnosis tool.

Refer to "Injector characteristic data input" procedure.

INSPECTION
INJECTOR CHARACTERISTIC DATA INFORMATION CHECK
1. Select " J2.9 WGT(DIESEL)".

2. Select " ENGINE CONTROL".

3. Select "INDIVIDUAL INJECTOR CORRECTION".

4. Select "INFO" tab using F5 key.

5. Check whether the charateristic data displayed on the diagnosis tool screen (ECM data) and the real injector
charateristic data are same or not. If they are different, eliminate the charateristic data in the ECM data and input
again.

Refer to "Injector charateristic data elimination & input" procedure.

INJECTOR CHARACTERISTIC DATA ELIMINATION

1. Select " J2.9 WGT(DIESEL)".
2. Select " ENGINE CONTROL".

3. Select "INDIVIDUAL INJECTOR CORRECTION".

4. Select "CLR" tab "using" F6 key.

5. Select "ENTER"

If you want to cancel data elimination, select "ESC".

INJECTOR CHARACTERISTIC DATA ELIMINATION
1. Select " J2.9 WGT(DIESEL)".

2. Select " ENGINE CONTROL".

3. Select "INDIVIDUAL INJECTOR CORRECTION".

4. Select the cylinder using F1 ~ F4 (Each cylinder 1,2,3,4) key.

5. Input "Injector charateristic data" 16 unit using the direction key and press "ENTER".
 Fuel System

Fuel Delivery System

Fuel System
2009 > D 2.9 VGT >

COMPONENT LOCATION
 Fuel System

Fuel Delivery System - Fuel Tank

Fuel System
 2009 > D 2.9 VGT >

REMOVAL
1. Remove the second seat (Refer to "BD" group in this WORKSHOP MANUAL).
2. Remove the Service cover (A).

3. Disconnect the Fuel sender connector (A).

4. Disconnect the Fuel supply hose Quick - connector (A) and the Fuel return hose Quick - connector (B).

When you disconnect the Fuel supply & Return hose quick - connector , you should disconnet the connector
from the lower part first before the fuel sender side.

5. Disconnect the fuel feed hose (A), the leveling hose (B).
6. Support the Fuel tank with the jack.
7. Unscrew the fuel tnak mounting nuts (A) and then remove the fuel tnak.

INSTALLATION
1. Install the Fuel Tank according to the reverse order to REMOVAL procedure.

Tightening Torques
Fuel tank installation bolts: 44.1 ~ 58.9 N!m (4.5 ~ 6.0 kg!m, 32.6 ~ 43.4 lb!ft)
 Fuel System

Fuel Delivery System - Fuel Filter

Fuel System
 2009 > D 2.9 VGT >

REMOVAL
1. Disconnect the fuel tube (A,B,C).

2. Disconnect the water sensor connector (B).

3. Remove the fuel filter (D) after unscrewing the mounting bolt (C).

INSTALLATION
1. Install the Fuel filter according to the reverse order to REMOVAL procedure.

Take care that the foreign material does not enter to the hose and the filter when you remove or install the
hose and filter.
 Fuel System

Fuel Delivery System - Common Rail

Fuel System
 2009 > D 2.9 VGT >

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.
• Take care that the foreign material does not enter to the components when you remove or install the Fuel
system.
• Clean the connction parts of injector and replace the O-ring when you remove or install the injector.
• Insert the O-ring in the Cylinder head after pasting Diesel oil to the O-ring gasket.
• Avoid damaging the injector when you insert the injector into the cylinder.
• High pressure fuel pipe should not be reused.
• Mount the flare nut and the component vertically when you install the high pressure fuel pipe.

1. Remove the cooling fan (Refer to "EM" group in this WORKSHOP MANUAL)
2. Remove the high pressure pipe (High pressure pump ! Common rail).
(1) Unscrews the flange nut (A) on the common rail.

(2) Unscrews the flange nut (A) at the side of the high pressure pump.

(3) Remove the high pressure pipe clamp (A) and high pressure pipe (B).
3. High pressure pipe (Common rail ! Injector) Removal
(1) Unscrews the flange nut (A) at the common rail.

(2) Unscrews the flange nuts (B) of injectors and remove the high pressure pipe (C).

4. Disconnect the rail pressure sensor connector (A).

5. Remove the intake manifold. (Refer to "EM" group)
6. Remove the common rail (B) after unscrewing 3 mounting bolts (A).

INSTALLATION

• 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.
• Take care that the foreign material does not enter to the components when you remove or install the Fuel
system.
 • Clean the connction parts of injector and replace the O-ring when you remove or install the injector.
• Insert the O-ring in the Cylinder head after pasting Diesel oil to the O-ring gasket.
• Avoid damaging the injector when you insert the injector into the cylinder.
• High pressure fuel pipe should not be reused.
• Mount the flare nut and the component vertically when you install the high pressure fuel pipe.

1. Install the Common rail according to the reverse order to REMOVAL procedure.

Install the flange nut (High pressure pump & Common rail side) with SST as following specification.
Classification SPEC SST No.
Flange nut (Common rail) 19mm (0.74 in.) 09314-27130
Flange nut (High pressure pump) 19mm (0.74 in.) 09314-27130
Flange nut (Injector) 17mm (0.67 in.) 09314-27120

Tightening torque:
Flange nut (Common rail): 35.8 ~ 42.7 N.m (3.65 ~ 4.35 kgf"m, 26.4 ~ 31.5 lbf.ft)
Flange nut (Common rail): 35.8 ~ 42.7 N.m (3.65 ~ 4.35 kgf"m, 26.4 ~ 31.5 lbf.ft)
Flange nut (Injector): 35.8 ~ 42.7 N.m (3.65 ~ 4.35 kgf"m, 26.4 ~ 31.5 lbf.ft)
High pressure pipe(Common rail !High pressure pump) clamp mounting bolt: 2.9 N.m (0.3 kgf"m, 2.2
lbf.ft)
Common rail mounting bolt : 18.6 ~ 22.6 N.m (1.9 ~ 2.3 kgf"m, 13.7 ~ 16.6 lbf.ft)
 Fuel System

Fuel Delivery System - High Pressure Pump

Fuel System
 2009 > D 2.9 VGT >

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.
• Take care that the foreign material does not enter to the components when you remove or install the Fuel
system.
• Clean the connction parts of injector and replace the O-ring when you remove or install the injector.
• Insert the O-ring in the Cylinder head after pasting Diesel oil to the O-ring gasket.
• Avoid damaging the injector when you insert the injector into the cylinder.
• High pressure fuel pipe should not be reused.
• Mount the flare nut and the component vertically when you install the high pressure fuel pipe.

1. Remove the cooling fan (Refer to "EM" group in this WORKSHOP MANUAL)
2. Remove the high pressure pipe (High pressure pump ! Common rail).
(1) Unscrews the flange nut (A) at the common rail.

(2) Unscrews the flange nut (A) at the side of the high pressure pump.

(3) Remove the high pressure pipe clamp (A) and high pressure pipe (B).
3. Disconnect the fuel temperature sensor connector (A) and the inlet metering valve connector (B).

4. Remove the fuel feed hose (C).

5. Remove the return hose (D) connected with the injector.
6. Remove the return hose (E) connected with the fuel filter.
7. Unscrew 2 mounting bolts (A) at the side of the high pressure pump bracket.

8. Unscrew 2 mounting bolts (B) at the side of the cylinder block .

9. Remove the rubber cover (B) from the high pressure pump sprocket.
10. Rotate the sprocket (C) in order to meet the fixing hole of the sprocket (A) and the fixing hole (B) of the timing
case.
Fix the sprocket (C) to the timing case by using 2 bolts(I) of the SST (No.:OK552 131 003)
11. Unscrews the timing case mounting bolt (E) after unscrewing the high pressure pump mounting nut (D).
12. Install the SST (No.: OK552 131 003) (F) to the hole (G) of the sprocket.
13. Push the high pressure pump from the timing case by using the tightening bolts (H).

INSTALLATION
 • 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.
• Take care that the foreign material does not enter to the components when you remove or install the Fuel
system.
• Clean the connction parts of injector and replace the O-ring when you remove or install the injector.
• Insert the O-ring in the Cylinder head after pasting Diesel oil to the O-ring gasket.
• Avoid damaging the injector when you insert the injector into the cylinder.
• High pressure fuel pipe should not be reused.
• Mount the flare nut and the component vertically when you install the high pressure fuel pipe.

1. Install the High pressure pump according to the reverse order to REMOVAL procedure.

1. When you install the high pressure pump bracket mounting bolt, Install the bracket as following order.
Cylinder block side -> High pressure pump side

2. Remove the sprocket fixing bolt (SST: OK552 131 003) after the high pressure pump set to the timing case
completely.

Install the flange nut (High pressure pump & Common rail side) with SST as following specification.
Classification SPEC SST No.
Flange nut (Common rail) 19mm (0.74 in.) 09314-27130
Flange nut (High pressure pump) 19mm (0.74 in.) 09314-27130

Tightening torque:
Flange nut (Common rail): 35.8 ~ 42.7 N.m (3.65 ~ 4.35 kgf"m, 26.4 ~ 31.5 lbf.ft)
Flange nut (High pressure pump): 35.8 ~ 42.7 N.m (3.65 ~ 4.35 kgf"m, 26.4 ~ 31.5 lbf.ft)
High pressure pipe clamp mounting bolt: 2.9 N.m (0.3 kgf"m, 2.2 lbf.ft)
Bracket mounting bolt (Cylinder block): 34.3 ~ 40.2 N.m (3.5 ~ 4.1 kgf"m, 25.3 ~ 29.7 lbf.ft)
Bracket mounting bolt (High pressure pump): 21.6 ~ 25.5 N.m (2.2 ~ 2.6 kgf"m, 15.9 ~ 18.8 lbf.ft)
High pressure pump mounting bolt (Timing case): 21.6 ~ 25.5 N.m (2.2 ~ 2.6 kgf"m, 15.9 ~ 18.8 lbf.ft)
 Fuel System

Fuel Delivery System - Fuel Sender

Fuel System
 2009 > D 2.9 VGT >

REMOVAL
1. Remove the second seat (Refer to "BD" group in this WORKSHOP MANUAL).
2. Remove the Service cover (A).

3. Disconnect the Fuel sender connector (A), the Fuel supply hose Quick - connector (B) and the Fuel return hose
Quick - connector (C).

4. Unscrew the fuel sender mounting bolt (D) and than remove the fuel sender.

INSTALLATION
1. Install the Fuel Sender according to the reverse order to REMOVAL procedure.

Tightening Torques
Fuel tank installation bolts: 2 ~ 2.9 N!m (0.2 ~ 0.3 kg!m, 1.4 ~ 2.2 lb!ft)