Fuel System
Fuel System
Fuel System
Tightening Torques
Engine Control System
Item kgf.m N.m lb-ft
ECM installation bolt 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
Mass air flow sensor installation bolt 0.4 ~ 0.6 3.9 ~ 5.9 2.9 ~ 4.3
Engine coolant temperature sensor installation 2.0 ~ 4.0 19.6 ~ 39.2 14.5 ~ 28.9
Manifold absolute pressure sensor installation bolt 0.9 ~ 1.2 8.8 ~ 11.8 6.5 ~ 8.7
Crankshaft position sensor installation bolt 0.7 ~ 1.0 6.9 ~ 9.8 5.1 ~ 7.2
Camshaft position sensor (Bank 1/Intake) installation bolt 0.7 ~ 1.0 6.9 ~ 9.8 5.1 ~ 7.2
Camshaft position sensor (Bank 1/Exhaust) installation bolt 0.7 ~ 1.0 6.9 ~ 9.8 5.1 ~ 7.2
Camshaft position sensor (Bank 2/Intake) installation bolt 0.7 ~ 1.0 6.9 ~ 9.8 5.1 ~ 7.2
Camshaft position sensor (Bank 2/Exhaust) installation bolt 0.7 ~ 1.0 6.9 ~ 9.8 5.1 ~ 7.2
Knock sensor #1 (Bank 1) installation bolt 1.6 ~ 2.4 15.7 ~ 23.5 11.6 ~ 17.4
Knock sensor #2 (Bank 2) installation bolt 1.6 ~ 2.4 15.7 ~ 23.5 11.6 ~ 17.4
Heated oxygen sensor (Bank 1 / sensor 1) installation 4.0 ~ 5.0 39.2 ~ 49.1 28.9 ~ 36.2
Heated oxygen sensor (Bank 1 / sensor 2) installation 4.0 ~ 5.0 39.2 ~ 49.1 28.9 ~ 36.2
Heated oxygen sensor (Bank 2 / sensor 1) installation 4.0 ~ 5.0 39.2 ~ 49.1 28.9 ~ 36.2
Heated oxygen sensor (Bank 2 / sensor 2) installation 4.0 ~ 5.0 39.2 ~ 49.1 28.9 ~ 36.2
CVVT oil temperature sensor installation 2.0 ~ 4.0 19.6 ~ 39.2 14.5 ~ 28.9
Electronic throttle body installation bolt 0.9 ~ 1.2 8.8 ~ 11.8 6.5 ~ 8.7
Purge control solenoid valve bracket installation bolt 0.9 ~ 1.2 8.8 ~ 11.8 6.5 ~ 8.7
CVVT oil control valve (Bank 1 / Intake) installation bolt 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
CVVT oil control valve (Bank 1 / Exhaust) installation bolt 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
CVVT oil control valve (Bank 2 / Intake) installation bolt 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
CVVT oil control valve (Bank 2 / Exhaust) installation bolt 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
Variable intake solenoid valve installation nut 0.9 ~ 1.2 8.8 ~ 11.8 6.5 ~ 8.7
Ignition coil installation bolt 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
Ignition coil condenser installation bolt 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
Fuel tank pressure snesor installation bolt 0.4 ~ 0.6 3.9 ~ 5.9 2.9 ~ 4.3
Canister close valve installation bolt 0.4 ~ 0.6 3.9 ~ 5.9 2.9 ~ 4.3
Fuel pump installation bolt 0.2 ~ 0.3 2.0 ~ 2.9 1.4 ~ 2.2
Sub fuel sender installation bolt 0.2 ~ 0.3 2.0 ~ 2.9 1.4 ~ 2.2
Filler-neck assembly installation bolt 0.8 ~ 1.2 7.8 ~ 11.8 5.8 ~ 8.7
Filler-neck assembly installation nut 0.4 ~ 0.6 3.9 ~ 5.9 2.9 ~ 4.3
Accelerator pedal module installation bolt 0.9 ~ 1.4 8.8 ~ 13.7 6.5 ~ 10.1
Fuel System
Fuel Pressure Gauge Adapter Connection between the delivery pipe and the fuel feed
(09353-38000) line
Fuel Pressure Gauge Connector Connection between the Fuel Pressure Gauge (09353-
(09353-24000) 24100) and the Fuel Pressure Gauge Adapter (09353-
38000)
Fuel System
Basic Troubleshooting
Basic Troubleshooting Guide
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The measured resistance in except for ambient temperature (20°C, 68°F) is reference value.
Intermittent Problem Inspection Procedure
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, the 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.
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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.
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, rear window defogger, etc.).
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.
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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.
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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.
When measuring for resistance, lightly shake the wire harness above and below or side to side.
Specification (Resistance)
1Ω or less → Normal Circuit
1MΩ 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 1MΩ and below 1 Ω 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.
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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 1MΩ and the open circuit is between terminal 1 of connector (C) and terminal 1
of connector (B1).
Lightly shake the wire harness above and below, or from side to side when measuring the resistance.
Specification (Resistance)
1Ω or less → Short to Ground Circuit
1MΩ or Higher → Normal Circuit
A. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis Ground as shown in [FIG. 6].
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The measured resistance of line 1 and 2 in this example is below 1 Ω and higher than 1MΩ 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 following step.
B. 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 1Ω or less. The short to ground circuit is between terminal 1 of connector (C) and terminal
1 of connector (B1).
Hard to refuel 1. Test the canister close valve • Malfunctioning gas station filling nozzle
(Overflow during refueling) 2. Inspect the fuel filler hose/pipe (If this problem occurs at a specific gas
· Pinched, kinked or blocked? station during refueling)
· Filler hose is torn
3. Inspect the fuel tank vapor vent hose between the EVAP. canister and air filter
4. Check the EVAP. canister
Fuel System
OBD-II review
1. Overview
The California Air Resources Board (CARB) began regulation of On Board Diagnostics (OBD) for vehicles sold in california beginning with the 1988 model year. The first
phase, OBD-I, required monitoring of the fuel metering system, Exhust Gas Recirculation (EGR) system and additional emission related components. The Malfunction
Indicator Lamp (MIL) was required to light and alert the driver of the fault and the need for repair of the emission control system. Associated with the MIL was a fault code or
Diagnostic Trouble Code (DTC) idenfying the specific area of the fault.
The OBD system was proposed by CARB to improve air quality by identifying vehicle exceeding emission standards. Passage of the Federal Clean Air Act Amendments in
1990 has also prompted the Environmental Protection Agency (EPA) to develop On Board Diagnostic requirements. CARB OBD-II regulations were followed until 1999
when the federal regulations were used.
The OBD-II system meets government regulations by monitoring the emission control system. When a system or component exceeds emission threshold or a component
operates outside tolerance, a DTC will be stored and the MIL illuminated.
The diagnostic executive is a computer program in the Engine Control Module (ECM) or PowertrainControl Module (PCM) that coordinates the OBD-II self-monitoring
system. This program controls all the monitors and interactions, DTC and MIL operation, freeze frame data and scan tool interface.
Freeze frame data describes stored engine conditions, such as state of the engine, state of fuel control, spark, RPM, load and warm status at the point the first fault is
detected. Previously stored conditions will be replaced only if a fuel or misfire fault is detected. This data is accessible with the scan tool to assist in repairing the vehicle.
The center of the OBD-II system is a microprocessor called the Engine Control Module (ECM) or Powertrain Control Module(PCM).
The ECM or PCM receives input from sensors and other electronic components (switches, relays, and others) based on information received and programmed into its
memory (keep alive random access memory, and others), the ECM or PCM generates output signals to control various relays, solenoids and actuators.
The Malfunction Indicator Lamp (MIL) is connected between ECM or PCM-terminal Malfunction Indicator Lamp and battery supply (open collector amplifier).
In most cars, the MIL will be installed in the instrument panel. The lamp amplifier can not be damaged by a short circuit.
Lamps with a power dissipation much greater than total dissipation of the MIL and lamp in the tester may cause a fault indication.
▷ At ignition ON and engine revolution (RPM)< MIN. RPM, the MIL is switched ON for an optical check by the driver.
3) MIL illumination
When the ECM or PCM detects a malfunction related emission during the first driving cycle, the DTC and engine data are stored in the freeze frame memory. The MIL is
illuminated only when the ECM or PCM detects the same malfunction related to the DTC in two consecutive driving cycles.
4) MIL elimination
● Misfire and Fuel System Malfunctions:
For misfire or fuel system malfunctions, the MIL may be eliminated if the same fault does not reoccur during monitoring in three subsequent sequential driving cycles in
which conditions are similar to those under which the malfunction was first detected.
● All Other Malfunctions:
For all other faults, the MIL may be extinguished after three subsequent sequential driving cycles during which the monitoring system responsible for illuminating the MIL
functions without detecting the malfunction and if no other malfunction has been identified that would independently illuminate the MIL according to the requirements
outlined above.
5) Erasing a fault code
The diagnostic system may erase a fault code if the same fault is not re-registered in at least 40 engine warm-up cycles, and the MIL is not illuminated for that fault code.
6) Communication Line (CAN)
• Bus Topology : Line (bus) structure
• Wiring : Twisted pair wire
• Off Board DLC Cable Length : Max. 5m
• Data Transfer Rate
-
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Additionally, the OBD II system shall monitor for malfunction all electronic air conditioning system components that are used as part of the diagnostic strategy for any other
monitored system or component.
Implementation plan:
No engine control strategy incorporated that alters offidle fuel and/or spark control when A/C system is on. Malfuction of A/C system components is not used as a part of the
diagnostic strategy for other monitored system or component.
Fuel System
Components Location
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4. Manifold Absolute Pressure Sensor (MAPS) 5. Engine Coolant Temperature Sensor (ECTS)
6. Throttle Position Sensor (TPS) 18. CVVT Oil Temperature Sensor (OTS)
[integrated into ETC Module]
25. ETC Motor [integrated into ETC Module]
7. Crankshaft Position Sensor (CKPS) 8. Camshaft Position Sensor (CMPS) [Bank 1 / Intake]
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9. Camshaft Position Sensor (CMPS) [Bank 1 / Exhaust] 10. Camshaft Position Sensor (CMPS) [Bank 2 / Intake]
11. Camshaft Position Sensor (CMPS) [Bank 2 / Exhaust] 12. Knock Sensor (KS) [Bank 1]
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13. Knock Sensor (KS) [Bank 2] 14. Heated Oxygen Sensor (HO2S) [Bank 1 / Sensor 1]
15. Heated Oxygen Sensor (HO2S) [Bank 1 / Sensor 2] 16. Heated Oxygen Sensor (HO2S) [Bank 2 / Sensor 1]
17. Heated Oxygen Sensor (HO2S) [Bank 2 / Sensor 2] 19. Accelerator Position Sensor (APS)
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20. A/C Pressure Transducer (APT) 21. Power Steering Pressure Sensor (PSPS)
22. Fuel Tank Pressure Sensor (FTPS) 23. Fuel Level Sensor (FLS)
32. Canister Close Valve (CCV)
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27. CVVT Oil Control Valve (OCV) [Bank 1 / Intake] 28. CVVT Oil Control Valve (OCV) [Bank 1 / Exhaust]
29. CVVT Oil Control Valve (OCV) [Bank 2 / Intake]
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30. CVVT Oil Control Valve (OCV) [Bank 2 / Exhaust] 34. Main Relay
35. Fuel Pump Relay
Fuel System
6 -
7 -
8 -
9 -
10 -
11 -
12 -
13 -
14 -
15 Alternator "FR" PWM signal input Alternator
16 Ground Cruise Control Switch
17 Sensor ground Feul Tank Pressure Sensor (FTPS)
18 A/C Switch "ON" signal input A/C Control Module
19 -
20 -
21 Brake Switch 2 signal input Brake Switch
22 -
23 Brake Switch 1 signal input Brake Switch
24 -
25 Cruise Control Switch signal input Cruise Control Switch
26 -
Immobilizer Control Unit
[Without Button Engine Start System]
27 Immobilizer communication line
Instrument Panel Module
[With Button Engine Start System]
28 Feul Tank Pressure Sensor (FTPS) signal input Feul Tank Pressure Sensor (FTPS)
29 Fuel Level Sensor (FLS) [TOTAL] signal input Fuel Level Sensor (FLS)
30 Fuel Level Sensor (FLS) [MIDDLE] signal input Fuel Level Sensor (FLS)
31 Electrical Load signal input Head Lamp Relay
32 A/C Pressure Transducer (APT) signal input A/C Pressure Transducer (APT)
A/C Pressure Transducer (APT)
33 Sensor ground Power Steering Pressure Sensor (PSPS)
[Without EHPS]
34 -
35 -
36 Alternator "C" PWM signal output Alternator
37 Canister Close Valve (CCV) control output Canister Close Valve (CCV)
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Connector [CLG-B]
Pin No. Description Connected to
1 ETC Motor [-] control output ETC Motor
2 ETC Motor [+] control output ETC Motor
3 -
4 CVVT Oil Temperature Sensor (OTS) signal input CVVT Oil Temperature Sensor (OTS)
5 -
6 -
Engine Coolant Temperature Sensor (ECTS)
7 Engine Coolant Temperature Sensor (ECTS)
signal input
Manifold Absolute Pressure Sensor (MAPS)
8 Manifold Absolute Pressure Sensor (MAPS)
signal input
9 -
10 -
11 Sensor power (+5V) Manifold Absolute Pressure Sensor (MAPS)
12 Batterypower (B+) Ignition Switch
13 Sensor power (+5V) Throttle Position Sensor (TPS) 2
14 Sensor ground Throttle Position Sensor (TPS) 1
Camshaft Position Sensor (CMPS) [Bank 2/Intake]
15 Sensor power (+5V)
Camshaft Position Sensor (CMPS) [Bank 2/Exhaust]
16 Sensor power (+5V) Throttle Position Sensor (TPS) 1
Camshaft Position Sensor (CMPS) [Bank 2/Intake]
17 Sensor ground
Camshaft Position Sensor (CMPS) [Bank 2/Exhaust]
Camshaft Position Sensor (CMPS) [Bank 1/Intake]
18 Sensor ground
Camshaft Position Sensor (CMPS) [Bank 1/Exhaust]
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19 Ignition Coil (Cylinder #6) control output Ignition Coil (Cylinder #6)
20 -
21 Crankshaft Position Sensor (CKPS) [High] signal input Crankshaft Position Sensor (CKPS)
22 -
Knock Sensor (KS) #1 [Bank 1]
23 Sensor Shield
Knock Sensor (KS) #2 [Bank 2]
Camshaft Position Sensor (CMPS)[Bank 2/Intake]
24 Camshaft Position Sensor (CMPS) [Bank 2/Intake]
signal input
Camshaft Position Sensor (CMPS)[Bank 1/Intake]
25 Camshaft Position Sensor (CMPS) [Bank 1/Intake]
signal input
26 Camshaft Position Sensor (CMPS)[Bank 2/Exhaust] signal input Camshaft Position Sensor (CMPS) [Bank 2/Exhaust]
27 Camshaft Position Sensor (CMPS)[Bank 1/Exhaust] signal input Camshaft Position Sensor (CMPS) [Bank 1/Exhaust]
28 Sensor ground Heated Oxygen Sensor (HO2S) [Bank 2/Sensor 1]
29 Sensor ground Heated Oxygen Sensor (HO2S) [Bank 2/Sensor 2]
30 Sensor ground Heated Oxygen Sensor (HO2S) [Bank 1/Sensor 1]
31 Sensor ground Heated Oxygen Sensor (HO2S) [Bank 1/Sensor 2]
Camshaft Position Sensor (CMPS) [Bank 1/Intake]
32 Sensor power (+5V)
Camshaft Position Sensor (CMPS) [Bank 1/Exhaust]
33 Sensor ground Engine Coolant Temperature Sensor (ECTS)
Manifold Absolute Pressure Sensor (MAPS)
34 Sensor ground
CVVT Oil Temperature Sensor (OTS)
35 Power ground Chassis Ground
36 Power ground Chassis Ground
37 Power ground Chassis Ground
38 Power ground Chassis Ground
39 Power ground Chassis Ground
40 Ignition Coil (Cylinder #4) control output Ignition Coil (Cylinder #4)
Crankshaft Position Sensor (CKPS) [Low]
41 Crankshaft Position Sensor (CKPS)
signal input
42 -
43 -
44 -
45 -
46 -
47 -
48 Throttle Position Sensor (TPS) 1 signal input Throttle Position Sensor (TPS) 1
49 Heated Oxygen Sensor (HO2S) [Bank 1/Sensor 1]
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75 -
76 Batterypower (B+) Battery
77 Ignition Coil (Cylinder #3) control output Ignition Coil (Cylinder #3)
78 Ignition Coil (Cylinder #5) control output Ignition Coil (Cylinder #5)
79 Ignition Coil (Cylinder #1) control output Ignition Coil (Cylinder #1)
80 -
20 -
Brake ON Max. 0.5V
21 Brake Switch 2 signal input DC
Brake OFF Battery Voltage
22 -
Brake ON Battery Voltage
23 Brake Switch 1 signal input DC
Brake OFF Max. 0.5V
24 -
MAIN 11.1 ~ 12.1V
SET 1.0 ~ 1.8V
25 Cruise Control Switch signal input DC
CANCEL -0.5 ~ 0.5V
RESUME 2.5 ~ 3.5V
26 -
Hi: Min. Vbatt X 80%
When transmitting
Lo: Max. Vbatt X 20%
27 Immobilizer communication line DC
Hi: Min. Vbatt X 70%
When receiving
Lo: Max. Vbatt X 30%
28 Feul Tank Pressure Sensor (FTPS) signal input Idle DC 0.14 ~ 4.86V
29 Fuel Level Sensor (FLS) [TOTAL] signal input Idle DC 0.88 ~ 8.45V
30 Fuel Level Sensor (FLS) [MIDDLE] signal input Idle DC 0.3 ~ 4.9V
31 Electrical Load signal input
32 A/C Pressure Transducer (APT) signal input A/C ON DC 0.5 ~ 4.5V
33 Sensor ground Idle DC Max. 150mV
34 -
35 -
High: Min. 4.0V
36 Alternator "C" PWM control output Idle PWM
Low: Max. 2.0V
Open Battery Voltage
37 Canister Close Valve (CCV) control output DC
Close Max. 1.0V
38 Batterypower (B+) Idle DC Battery Voltage
39 Batterypower (B+) Idle DC Battery Voltage
40 Batterypower (B+) Idle DC Battery Voltage
RECESSIVE 2.0 ~ 3.0V
41 CAN [High] Pulse
DOMINANT 2.75 ~ 4.5V
RECESSIVE 2.0 ~ 3.0V
42 CAN [Low] Pulse
DOMINANT 0.5 ~ 2.25V
Relay ON Max. 1.7V
43 Main Relay control output DC
Relay OFF Battery Voltage
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Connector [CLG-B]
Pin
Description Condition Type Level
No
1 ETC Motor [-] control output Idle PWM Battery Voltage
High: Battery Voltage
Low: Max.1.0V
2 ETC Motor [+] control output Idle Pulse
1,500
0
3 -
4 Idle DC 0.15(150°C) ~ 4.85V(-40°C)
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Normal Variable 0V
Frequency
Knocking Variable -0.3 ~ 0.3V
56 Knock Sensor (KS) [Bank 1] [High] signal input
Normal Frequency 0V
C.T Min. 4.0V
57 Throttle Position Sensor (TPS) 2 signal input DC
W.O.T 0.25 ~ 0.9V
58 Sensor ground Idle DC Max. 150mV
59 -
Vpeak = 400V
60 Ignition Coil (Cylinder #2) control output Idle Pulse
0
High: Battery Voltage
Low: Max. 1.0V
61 CVVT Oil Control Valve (OCV)[Bank 2/Intake] control output Idle PWM
Frequency= 128Hz
0
High: Battery Voltage
Low: Max. 1.0V
62 CVVT Oil Control Valve (OCV)[Bank 1/Intake] control output Idle PWM
Frequency= 128Hz
0
High: Battery Voltage
Low: Max. 1.0V
63 Injector (Cylinder #2) control output Idle PWM
0
47 < Vpeak < 64V
High: Battery Voltage
Low: Max. 1.0V
64 Injector (Cylinder #3) control output Idle PWM
0
47 < Vpeak < 64V
High: Battery Voltage
CVVT Oil Control Valve (OCV) Low: Max. 1.0V
65 Idle PWM
[Bank 1/Exhaust] control output Frequency= 128Hz
0
High: Battery Voltage
CVVT Oil Control Valve (OCV) Low: Max. 1.0V
66 Idle PWM
[Bank 2/Exhaust] control output Frequency= 128Hz
0
High: Battery Voltage
Heated Oxygen Sensor (HO2S)
67 Idle PWM Low: Max. 1.15V
[Bank 2/Sensor 1] Heater control output
0
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Fuel System
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Circuit Diagram
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Fuel System
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The programmed VIN cannot be changed. When writing the VIN, confirm the VIN carefully
1. Select "Vehicle" and "Engine" (For example, TUCSON 2.0L L4).
▶ Go to next step 4.
▶ END
4. Write the VIN with cursor, function and number keys.
Before pressing the "ENTER" key, confirm the VIN again because the programmed VIN cannot be changed.
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