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Hyundai: Engine D4FA. Manual - part 34

GENERAL

FLA -7

SPECIAL SERVICE TOOLS

E758BEE7

Tool (Number and name)

Illustration

Application

09351-2A100
Injector Remover Adapter

LCGF062A

Removing the injector

09351-4A200
Injector Remover

LXGF022A

Removing the injector

09314-27110(14mm)
09314-27120(17mm)
Torque Wrench Socket

AFAF201B

Installing the high pressure pipe

09331-2A000
High Pressure Pump
Sprocket Remover

LXGF021A

Removing the high pressure
fuel pump

FLA -8

FUEL SYSTEM

BASIC TROUBLESHOOTING

EFAE5C7F

BASIC TROUBLESHOOTING GUIDE

Bring Vehicle to Workshop

Perform troubleshooting procedure for DTC

Adjust or repair the vehicle

Confirmation test

END

Analyze Customer's Problem

•

Ask the customer about the conditions and environment relative to the issue
(Use CUSTOMER PROBLEM ANALYSIS SHEET).

Confirm the Inspection Procedure for the System or Part

•

Using the SYMPTOM TROUBLESHOOTING GUIDE CHART, choose the correct inspection procedure for the system
or part to be checked.

Inspect Vehicle Visually

•

Go to Step 11, if you recognize the problem.

Recreate (Simulate) Symptoms the DTC

•

Try to recreate or simulate the symptoms and conditions of the malfunction as described by customer.

•

If DTC(s) is/are displayed, simulate the condition according to troubleshooting procedure for the DTC.

Recreate (Simulate) Symptom

•

Try to recreate or simulate the condition of the malfunction as described by the customer.

Check the DTC

•

If DTC(s) does(do) not occur, refer to INTERMITTENT PROBLEM PROCEDURE in BASIC INSPECTION PROCEDURE.

•

If DTC(s) occur(s), go to Step 11.

Confirm Symptoms of Problem

•

If DTC(s) is/are not displayed, go to Step 9.

•

If DTC(s) is/are displayed, go to Step 11.

Verify Symptom, and then Check DTC and Freeze Frame Data

•

Connect Hi-Scan (Pro) to Diagnostic Link Connector (DLC).

•

Record the DTC and freeze frame data.

To erase DTC and freeze frame data, refer to Step 5.

Erase the DTC and Freeze Frame Data

NEVER erase DTC and freeze frame data before completing Step 2 MIL/DTC in "CUSTOMER PROBLEM
ANALYSIS SHEET".

NOTE

WARNING

LXGF500A

GENERAL

FLA -9

CUSTOMER PROBLEM ANALYSIS SHEET

VEHICLE INFORMATION

(I) VIN:

(II) Production Date:

(III) Odometer Reading: (mile/ ㎞ )

SYMPTOMS

□ Unable to start

□ Engine does not turn over □ Incomplete combustion
□ Initial combustion does not occur

□ Difficult to start

□ Engine turns over slowly □ Other_________________

□ Poor idling

□ Rough idling □ Incorrect idling
□ Unstable idling (High: ______ rpm, Low: ______rpm)
□ Other __________________________________

□ Engine stall

□ Soon after starting □ After accelerator pedal depressed
□ After accelerator pedal released □ During A/C ON
□ Shifting from N to D-range
□ Other _______________________________________________

□ Others

□ Poor driving (Surge) □ Knocking □ Poor fuel economy
□ Back fire □ After fire □ Other ____________________________

ENVIRONMENT

Problem frequency

□ Constant □ Sometimes (_________________) □ Once only
□ Other ___________________________________________

Weather

□ Fine □ Cloudy □ Rainy □ Snowy □ Other __________________

Outdoor temperature

Approx. _____ C/ F

Place

□ Highway □ Suburbs □ Inner City □ Uphill □ Downhill
□ Rough road □ Other ___________________________________

Engine temperature

□ Cold □ Warming up □ After warming up □ Any temperature

Engine operation

□ Starting □ Just after starting (____ min) □ Idling □ Racing
□ Driving □ Constant speed □ Acceleration □ Deceleration
□ A/C switch ON/OFF □ Other _____________________________

MIL/DTC

MIL (Malfunction Indicator Lamp)

□ Remains ON □ Sometimes lights up □ Does not light

Normal Check
(Pre-check)

□ Normal □ DTC (_______________________________________)
□ Freeze Frame Data

DTC

Check mode

□ Normal □ DTC (_______________________________________)
□ Freeze Frame Data

FLA -10

FUEL SYSTEM

BASIC INSPECTION PROCEDURE

MEASURING CONDITION OF ELECTRONIC PARTS’
RESISTANCE

The measured resistance at high temperature after vehi-
cle running may be high or low. So all resistance must
be measured at ambient temperature (20℃, 68℉), unless
there is any notice.

NOTE

The measured resistance in except for ambient tem-
perature (20℃, 68℉) 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, 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.

Clear Diagnostic Trouble Code (DTC).

Inspect connector connection, and check terminal for
poor connections, loose wires, bent, broken or cor-
roded pins, and then verify that the connectors are
always securely fastened.

BFGE321A

Slightly shake the connector and wiring harness ver-
tically and horizontally.

Repair or replace the component that has a problem.

Verify that the problem has disappeared with the road
test.

● SIMULATING VIBRATION
a.

Sensors and Actuators
: Slightly vibrate sensors, actuators or relays with fin-
ger.

WARNING

Strong vibration may break sensors, actuators or
relays

Connectors and Harness
: Lightly shake the connector and wiring harness ver-
tically and then horizontally.

● SIMULATING HEAT
a.

Heat components suspected of causing the malfunc-
tion with a hair dryer or other heat sourre.

WARNING

• DO NOT heat components to the point where

they may be damaged.

• DO NOT heat the ECM directly.

● SIMULATING WATER SPRINKLING
a.

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

WARNING

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

● SIMULATING ELECTRICAL LOAD
a.

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

CONNECTOR INSPECTION PROCEDURE

Handling of Connector
a.

Never pull on the wiring harness when discon-
necting connectors.

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