Doosan D50SC 5 EngineMaintenanceManual SB4323E00 PDF

SB4323E00
Nov. 2008
Service Manual
D439E Diesel Engine
D35S-5, D40S-5, D40SC-5, D45SC-5

D45S-5, D50C-5, D55C-5, D50SC-5, D55SC-5
D60S-5, D70S-5
D80S-5, D90S-5
Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic
safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations
before an accident occurs. A person must be alert to potential hazards. This person should also have the
necessary training, skills and tools to perform these functions properly.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual. Additional safety
precautions are listed in the “Safety” section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific
hazards. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons.
Warnings in this publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read
and understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings
in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or
operating technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is
safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the
operation, lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product. Obtain the complete and
most current information before starting any job. DOOSAN dealers have the most current information available.
1
Index
1. General Information Turbocharger ......................................................89

Components ..................................................89
General ................................................................. 7 Removal ........................................................91
General........................................................... 7 Inspection......................................................92
General Precautions for Servicing ................. 11 Installation .....................................................93
Intake Manifold ...................................................95

Components ..................................................95
2. Engine Mechanical System (D439E) Removal ........................................................96
Installation .....................................................97
General ............................................................... 16
Description.................................................... 16 Exhaust Manifold................................................98
Specification ................................................. 20 Components ..................................................98
Tightening Torque......................................... 24 Removal ........................................................99
Special Tool.................................................. 28 Installation ...................................................100
Diagnosis...................................................... 30
Adjustment.................................................... 32 Lubrication System ..........................................101
Description ..................................................101
Timing System ................................................... 33 Specification ................................................105
Timing Gear Assembly.................................. 33 Troubleshooting...........................................107
Removal ....................................................... 35 Adjustment ..................................................109
Inspection ..................................................... 39
Replacement................................................. 42 Oil Pump ...........................................................111
Installation .................................................... 43 Components ................................................111
Disassembly ................................................113
Cylinder head Assembly.................................... 49
Components ................................................. 49 Oil Cooler..........................................................114
Removal ....................................................... 51 Components ................................................114
Disassembly ................................................. 54 Disassembly ................................................115
Inspection ..................................................... 55 Inspection....................................................115
Replacement................................................. 59 Reassembly.................................................116
Reassembly.................................................. 61
Installation .................................................... 63 Cooling System ................................................117
Description ..................................................117
Crankcase .......................................................... 65 Specification ................................................118
Flywheel ....................................................... 65 Trouble Shooting .........................................120
Removal ....................................................... 66
Inspection ..................................................... 66 Water pump ......................................................122
Installation .................................................... 67 Components ................................................122
Removal ......................................................123
Cylinder Block Assembly .................................. 69 Inspection....................................................124
Components ................................................. 69 Installation ...................................................125
Removal ....................................................... 71
Disassembly ................................................. 74
Inspection ..................................................... 75
Reassembly.................................................. 81
Installation .................................................... 82
Intake and Exhaust System............................... 86

Specifications................................................ 86
Troubleshooting ............................................ 87
D439E Service Manual 3 Index

3. Engine Electrical System (D439E) Coolant Temperature Sensor...........................186
Inspection....................................................186
General ............................................................. 126 Installation ...................................................187
Specification ............................................... 126
Service Standards....................................... 128 Camshaft Position Sensor ...............................188
Troubleshooting .......................................... 129 Inspection....................................................188
Charging System ............................................. 131 Crankshaft Position Sensor .............................189

Description.................................................. 131 Inspection....................................................189
Adjustment.................................................. 132
Rail Pressure Sensor........................................190
Alternator ......................................................... 136 Inspection....................................................190
Components ............................................... 136
Disassembly ............................................... 137 Supply Control Valve........................................191
Inspection ................................................... 139 Inspection....................................................191
Reassembly................................................ 140
Fuel Delivery System-Electronic......................192
Starting System ............................................... 141 Components ................................................192
Description.................................................. 141
Inspection ................................................... 142 Fuel Filter..........................................................193
Replacement ...............................................193
Preheating System........................................... 144 Inspection....................................................193
Preheating Plug .......................................... 144 Assembly.....................................................193
Injector ..............................................................194
Components ................................................194
4. Fuel System Cleaning ......................................................195
Removal ......................................................195
General ............................................................. 145 Replacement ...............................................196
Specification ............................................... 145 Injector Replacement...................................197
Sealant ....................................................... 146 ECU Replacement .......................................197
Tightening Torque....................................... 146 Installation ...................................................198
Troubleshooting .......................................... 146
Engine control............................................. 148 Common Rail Assembly...................................199
Engine Starting System............................... 148 Removal ......................................................199
Fuel Tank and Fuel Line.............................. 149 Installation ...................................................199
Troubleshooting Procedure ......................... 150
Troubleshooting Procedure ......................... 154 Injection Pump-Electronic................................200
Supply pump ...............................................200
Engine Control System-Electronic.................. 167
Description.................................................. 167
Engine Control Unit (ECU)............................... 170

ECU Pin Connector..................................... 170
ECU Circuit Diagram........................................ 175

Removal ..................................................... 177
Inspection ................................................... 178
Intake Air Temperature Sensor ....................... 184

Inspection ................................................... 184
Intake Air Pressure Sensor ............................. 185

Inspection ................................................... 185

5. Service Tool
Check before use............................................. 203
Read me first .............................................. 203
Safety Warning and Caution before Use...... 204
Hardware .......................................................... 208

Specification ............................................... 208
Introduction of Components ........................ 211
Basic Usage of G-scan .................................... 212

Power supply .............................................. 212
Power ON/OFF ........................................... 215
Description for Main Components of H/W.... 217
Description for layout of S/W screen............ 222
Connecting the DLC cable .......................... 226
Self Test Adapter ........................................ 229
Configuration ................................................... 230

Setup.......................................................... 230
User Information ......................................... 238
Version ....................................................... 241
Self Test ..................................................... 243
STEP-B Test............................................... 247
Vehicle Communication Function................... 250

Vehicle Selection ........................................ 250
Fault Code Searching ................................. 257
DTC Analysis.............................................. 260
Data Analysis.............................................. 268
Actuation Test............................................. 280
Vehicle S/W Management........................... 282
ECU Upgrade ............................................. 286
CARB OBD-II.............................................. 299
Flight Record .............................................. 305
PC Utility .......................................................... 325

PC Utility Installation ................................... 325
How to use PC Utility .................................. 334
Appendix .......................................................... 352

Optional Item Installation and Expenditure
Exchange.................................................... 352
O/S Update................................................. 356

1. General Information Unit
The SI unit is used. Metric notation is also presented

General in parentheses.
General
How to Read Disassembly and Reassembly Note, Warning and Caution
Drawings
NOTE : This refers to a piece of useful information
to the customers.
1. The part names and numbers in the drawings
match the ones in the text. The parts are CAUTION
numbered in the order of disassembly.
This refers to Information about activities that
2. The items to be inspected during disassembly are may cause damage to the vehicle.
shown in the disassembly drawings.
3. All torque specifications for the tightening in the

reassembly drawings may be regarded as "dry" WARNING
unless "wet" is specified.
This refers to Information about activities that
may cause injury or damage to the driver,
passengers or other personnel.
Definition of Terminologies
Unless otherwise specified, all dimensions for the

following values in the illustration represent mm
even if the unit is not explicitly expressed.
1. Nominal Value (Abbr.: NV)

It shows dimension of an individual part, relative
clearance between parts of standard performance.
This value, however, does not necessarily
coincide with design value as it is rounded off to
fall within limits necessary for inspection.
2. Repair Limit (Abbr.: RL)

It shows the specified value, in which repair is
needed. Repair means adjustment, grinding or
replacement such as bushings, metals and others,
selection of oversize, selection of shim thickness,
etc.
3. Service Limit (Abbr.: SL)

It shows the specified value, in which parts
replacement with new ones is needed.
4. Basic Diameter (Abbr.: BD)

It shows nominal diameter of part to be measured.
5. Tightening Torque (Abbr.: T)

It shows tightening torque of bolts or nuts.
D439E Service Manual 7 1. General Information

Conversion Table for Foot-Pound Units Into is units
Unit Unit symbol of foot-pound unit Conversion rate

kg lbs 1 kg = 2.2046 lbs
Weight
g oz 1 g = 0.035274 oz
m ft. 1 mm = 3.2808 ft.
Length
mm in. 1 mm = 0.03937 in
1 lit. = 0.2642 gal. (U.S.)
0.220 gal. (lmp.)
lit. gal.
Volume 1 cc = 0.033814 oz
cc oz
(U.S.)
0.035195 oz (lmp.).
Force N (Newton) lbf 1 N = 0.2248 lbf
1 kPa = 0.145 lbf/in.²
Pressure kPa (kilopascal) lbf/in.²
1 kPa = 0.2953 in.Hg
Stress N/cm² lbf/in.² 1 N/cm²= 1.45 lbf/in.²
Moment of force Nm lbf.ft 1 Nm = 0.7375 lbf.ft
Output kW (kilowatt) HP 1 kW = 1.34 HP
Temperature C F T C = (1.8 t C + 32)  F

Tightening Torque Table of Standard Parts
Torque Nm (kg.cm, lb.ft)

Bolt nominal diameter Pitch (mm)
Head Mark 4 Head Mark 7
M5 0.8 3~4 (30~40, 2.2~2.9) 5~6 (50~60, 3.6~4.3)
M6 1.0 5~6 (50~60, 3.6~4.3) 9~11 (90~110, 6.5~8.0)

20~25 (200~250,
M8 1.25 12~15 (120~150, 9~11)
14.5~18.0)
25~30 (250~300, 30~50 (300~500,
M10 1.25
18~22) 22~36)
35~45 (350~450, 60~80 (600~800,
M12 1.25
25~33) 43~58)
M14 75~85 (750~850, 120~140 (1,200~1,400,
1.5
54~61) 85~100)
110~130 (1,100~1,300, 180~210(1,800~2,100,
M16 1.5
54~61) 130~150)
160~180 (1,600~1,800, 260~300(2,600~3,000,
M18 1.5
116~130) 190~215)
220~250 (2,200~2,500, 360~420 (3,600~4,200,
M20 1.5
160~180) 260~300)
290~330 (2,900~3,300, 480~550(4,800~5,500,
M22 1.5
210~240) 350~400)
360~420 (3,600~4,200,
M24 1.5 610~700 (6,100~7,000,
260~300)
3. If you reduce the torques in the table to the

NOTE percentage indicated below-under the following
conditions, it will be the standard value.
1. The torques shown in the table are standard • If spring washers are used : 85%
values under the following conditions : • If threads and bearing surfaces are stained
• Nuts and bolts are made of galvanized steel bar. with oil : 85%
• Galvanized plain steel washers are inserted.
• All nuts, bolts and plain washers are dry.
2. The torques in the table are not applicable under

following conditions:
• When spring washers, toothed washers and
other similar parts are inserted.
• If plastic parts are fastened.
• If self-tapping screws or self-locking nuts are
used.
• If threads and surfaces are coated with oil.

Engine Identification Number Example :
1) D : DIESEL ENGINE
G : GASOLINE ENGINE
C : CNG ENGINE
2) 4 : 4 CYCLE 4 CYLINDER
6 : 4 CYCLE 6 CYLINDER
8 : 4 CYCLE 8 CYLINDER
3) Engine development order
4) Engine version
5) Model year
X : 1999 Y : 2000 1 : 2001 2 : 2002 3 : 2003
4 : 2004 5 : 2005 6 : 2006 7 : 2007 8 : 2008
6) Product serial number.

000001 ~ 999999

General Precautions for Servicing Removal of Parts
Protection of the vehicle
Always make sure to cover fenders, seats, and floor

areas before commencing service works.
CAUTION
The support rod must be inserted into the hole
near the edge of the hood whenever you inspect
the engine compartment to prevent the hood
from falling and possible resulting injury.
Make sure that the support rod has been
released before closing the hood. Always check First find the cause of the problem and then
to make sure the hood is firmly latched before determine to remove or disassemble before starting
driving the vehicle. the servicing works.
Disassembly
Preparation of Tools and Measuring Equipment
If the disassembly procedure is complex, requiring
Be sure that all necessary tools and measuring many parts to be disassembled, all parts should be
equipment are available before starting work. disassembled in a right way so that the performance
or external appearances are not affected.
Special Tools
1. Inspection of parts
Each part, when removed, should be carefully
inspected for malfunction, deformation, damage,
Use special tools when they are required. or any other problems.

Replacement
Standard values such as torques and adjustments

must be strictly observed in the all parts reassembly.
If removed, some of the following parts must be
replaced with new ones depending on their installing
positions.
2. Arrangement of parts
All parts disassembled should be arranged
deliberately for the purpose of effective
reassembly.
1. Oil seals
2. Gaskets
3. O-rings
4. Lock washers
5. Cotter pins (split pins)
6. Plastic nuts
3. Cleaning parts for reuse
Be sure to separate the parts to be reused for
easy indetification.
Parts
7. Sealant should be applied to gaskets.
8. Oil should be applied to the moving components

of parts.
9. Specified oil or grease should be applied to the

prescribed locations (oil seals, etc.) before
When replacing parts, be sure to use Doosan assembly.
genuine parts.

Adjustment 4. Check wire insulation and coating for any damage,
cracks or degrading.
Use gauges and testers to adjust the parts correctly
to the specification. 5. Check to see if the conductive parts of terminals
contact other metallic parts (vehicle body and
other parts).
Electrical System
6. Check the grounding of parts to ensure the
complete continuity between their installing bolt(s)
and the vehicle’s body.
7. Check to see if the wiring is correct.
8. Check to see if the wiring is clamped to prevent

contact with sharp corners of the vehicle body or
heat exposed parts (exhaust manifold, etc.)
9. Check to see if the wiring is clamped firmly to

provide enough clearance to the fan from pulley,
fan belt and other revolving or moving parts.
1. Be sure to disconnect the battery cable from the 10. Check to see if the wiring has some space so
negative (-) terminal of the battery. that it can vibrate between fixed and moving
parts such as the vehicle body and the engine.
2. Never pull on the wires when disconnecting
connectors.
3. Connectors will sound click when the connector is Checking Fuses

securely locked.
4. Carefully handle sensors and relays. Be careful Fuse box

not to drop them or touch other parts.
Checking Cables and Wires
Test leads
A blade type fuse test leads are provided to allow

fuse check without removing it from the fuse box.
The fuse is good if the test lamp lights up when one
lead is connected to the test leads (one at a time)
and the other lead is grounded. (Turn on the ignition
switch so that the fuse circuit becomes operative)
1. Check to see if the terminal is tightened correctly.
2. Check to see if terminals and wires are corroded

by battery electrolyte, etc.
3. Check terminals and wires for any short circuits.

Servicing the Electrical System
1. Prior to servicing the electrical system, be sure to 3. If any section of a wiring harness interferes with
turn off the ignition switch and disconnect the the edge of parts, or corners, wrap the section of
battery ground cable. the harness with tape or something similar in
order to protect if from damage.
NOTE : When performing MFI or ELC system
diagnosis, if the battery cable is removed, then, any
diagnostic trouble code retained by the computer will
be cleared. There fore, if necessary, read the
diagnostic trouble code before removing the battery
cable.
4. When installing any parts, be careful not to pinch

or damage any of the wiring harness.
2. Secure the wiring harnesses with clamps so that

there is no slack. However, allow some slack or
distance for the wiring harness from vibrating
parts, which crosses the engine or other vibrating
parts of the vehicle. Allow wiring harness some
slack or distance so that it does not contact with
any of the adjacent parts, and then, secure the
harness by using a clamp.
5. Never throw relays, sensors or electrical parts, or

expose them to strong shock.

6. The electronic parts used in the computer, relays, 9. Disconnect the connectors by pressing the
etc. are subject to thermal damage easily. If any catches in the arrow direction as shown in the
service work is needed that may cause the illustration.
temperature to exceed 80 C (176 F), remove the
electronic parts beforehand.
10. Connect connectors by inserting the catches,

until they make a clicking sound.
7. Loose connectors may cause problems. Make

sure that the connectors are always securely
fastened.
11. When using a circuit tester to check continuity or

voltage on connector terminals, insert the test
probe into the harness side. If the connector is a
sealed connector, insert the test probe through
the hole in the rubber cap until contacts the
terminal, taking care not to damage the
insulation of the wires.
8. When disconnecting a connector, be sure to grip

only the connector, not the wires.

2. Engine Mechanical 4. For better I efficient cooling of combustion
chamber, water director is press-fit under cylinder
System (D439E) head floor, which induces the coolant flow.
General
Valve Mechanism
Description
Combustion
1. Heat resistant steel with surface treatment is used

for intake and exhaust valve. The valve seat angle
1. Combustion chamber consists of cylinder head, is 45.
piston Injector installed to the cylinder head and
valve. 2. Valve stem seal, Installed to the stem, adjusts the
lubricant amount on the sliding surface of valve
and valve guide.
NOTE : Valve guide with carbon cutter is used for

exhaust valve.
3. Valve spring consists of two valve springs having

Irregular pitches. The coil directions of inner and
outer springs are opposite each other.
4. Rocker shaft is hollow cylindrical rod, whose each

end are sealed with sealing cap. Inner space of
the shaft is an engine oil passage.
5. Steel ball is installed to the lower end of push rod

and rocker assembly is installed to upper end.
6. Tappet has a cylindrical shape. As enlarging the

2. Fuel is supplied to supply pump through the fuel contacting surface contacted with camshaft, it
filter installed to the frame. Fuel is also supplied to helps to prevent partial wear and to increase Its
injectors throuqh injection pipe No. 1,2,3 and 4 in durability.
common rail assembly.
3. Combustion is accomplished when fuel is Injected

directly Into combustion chamber, at that time
explosion pressure applies to the piston directly.
D439E Service Manual 16 2. Engine Mechanical System (D439E)

7. Camshaft assembly (1) consists of cam sensor 3. Cylinder sleeve made of special cast iron is
plate, thrust plate, cam and journal. Camshaft pressed fit into the crankcase.
gear is coupled with the idler gear A (2).
Piston
Crankcase and Cylinder Sleeve
1. Crankcase is manufactured firmly with cast iron to 1. Piston pin type is full float type and piston pin is
prevent stress concentration and deformation. offset from thrust.
2. The 5 camshaft bushes are installed to the 2. Marks on the piston indicate weight, part number
camshaft bore of the crankcase. and oversize. The front mark indicates the front
To facilitate the removal and installation of direction of the engine.
camshaft, inner diameter of bush is tapered to the
rear side. NOTE : When assembling a piston, let the arrow
mark (→) faced to the center of cylinder head bolt
hole.

Piston Ring 4. Crankshaft pulley and crankshaft gear are
installed at the front end of crankshaft. The
crankshaft pulley drives alternator and water
pump using V-belt.
5. Crankshaft damper pulley absorbs the distorting

vibration of crankshaft.
Piston has two compression rings and one oil ring.

All sliding surfaces of rings are coated with
hardened chrome.
Crankshaft
6. Crankshaft gear (1) drives camshaft gear (2), idler
gear A (3), idler gear B (4), supply pump gear (5)
and oil pump gear (6).
Crankshaft Main Bearing
1. Crankshaft is forged with high-strength alloy built

in with balance weight.
2. Pin, journal and oil seal sliding-surface are

hardened with high frequency heat treatment to
raise the resistance against frictional wear.
3. Through oil passage at the pin and journal, oil Upper main bearing has oil groove and oil hole
lubricates main bearing. Oil flows to the pin for the which matches with oil hole of the crankshaft.
lubrication of connecting rod bearing. Divided type thrust plate is Installed to the both ends
of the last bearing (N0.5).

Timing Gear Flywheel
1. Timing gear is installed in the timing gear case at 1. Flywheel is made of forged iron. Pilot bearing of
the front of engine. transmission drive pinion is disposed at the center
portion. Ring gear which can be geared with
2. Each gear is helical gear manufactured with high starter pinion is pressed fit at the circumferential
precision and Its surface is treated by heat to of tile flywheel.
enhance the durability.
2. Processed is formed at the outer diameter of the
3. Timing marks are marked on the gear. When flywheel to measure the engine rpm.
assernblinq, by aligning the timing marks, gears
can be engaged correctly.
4. Bushes are press-fit into idler gear, which rotates

idler shaft A (1) and idler shaft B (2). Idler shaft
and gear oil hole provides oil passage to lubricate
bush and gear.

Specification
Standard
Corrective
Items ([] indicates standard Limit
action
diameter)
Serial 4-cylinder 4stroke
General lyre
common rail system
104mm
Cylinder inner diameter
115mm
Cylinder stroke
3,907cc
Displacernent
17.5 : 1
Compression ratio
1-3-4-2
Firing order
100ps/2300rpm Adjustment
Maximum output
92ps/2300rpm (As the
38kgf.m/1600rpm difference
Maximum torque
33kgf.m/1600rpm between
cylinder in
within 4kg/cm²)
Compression pressure (at 200rpm) 20kg/cm²
26kg/cm²
Valve timing
lntake valve open (BTDC) 19
lntake valve close (ABDC) 53
Exhaust valve open (BBDC) 60
Exhaust valve close (ATDC) 16
Valve
Intake valve length 137mm
Exhaust valve length 137mm
Outer diameter of Intake valve stern 8.960~8.975mm
8.85mm
Outer diameter of exhaust valve stem 8.925~8.940mm
8.85mm
Valve face angle 45
Thickness (rnargin) of Intake/exhaust valve 1.5mm
1.2mm
head Valve clearance (when engine is cold) 0.4mm
Gap between valve stem and valve guide

Intake [9] 0.04~0.06mm 0.15mm
Replace
Exhaust [9] 0.07~0.10mm 0.2mm
Valve guide length
lntake 64mm
Exhaust 71.5mm
Valve sinkage
Intake 0.75~1.25mm 1.5mm Valve seat
Exhaust 0.75~1.25mm 1.5mm Replace insert
Push rod run out - 0.4mm Replace
Valve seat width
Intake 2.6~3.0mm 3.6mm
Replace
Exhaust 1.8~2.2mm 2.8mm

Standard
Corrective
action
diameter)
Outer side valve Spring

Free height 66.1mm 63mm
Load installed 26.5~29.3kg 23.7kg
Winding direction To the right
Out of squareness 1.5mm 2.1mm
Replace
Inner side valve spring
Free lenqth 60.0mm 57mm
Load Installed 11.5~12.7kg 10.3kg
Winding direction Left side
Out of squareness 1.5mm 2.1mm
Cylinder block
Cylinder bore
104.00~104.03mm
Torsion of upper crankcase
Below 0.07mm
Flatness of qasket surface 0.2mm Replace
0.07mm
Out of squareness of gasket surface
0.05mm
Clearance between tappet and crankcase 0.2mm
[28] 0.045~0.096mm
tappet hole
Clearance between piston ring and piston

ring groove
Replace the
No. 1 ring 0.106~0.170mm 0.2mm
piston ring
No. 2 rlng 0.07~0.11mm 0.15mm
Oil ring 0.03~0.07mm 0.15mm
Piston ring end gap

No.1 ring 0.25~0.40mm 1.0mm
Replace
No.2 ring 0.50~0.65mm 1.5mm
Oil ring 0.20~0.40mm 1.0mm
Measure the
average
Average protrusion of piston
protrusion and
Gasket qrade A. 0.466~0.526mm
replace the
Gasket grade B 0.526~0.588mm
gasket with the
Gasket grade C 0.588~0.648mm
corresponding
grade gasket
Piston
Repair with
Piston outer diameter
103.91~103.92mm oversize or
Clearance between piston and cylinder
0.080~0.130mm replace
sleeve
Piston pin
Outer diameter of piston pin
Clearance between piston pin and piston pin 0.05mm Replace
37.994~38.00mm
hole 0.1mm Replace bush
0.007~0.021mm
Clearance between piston pin and
[38] 0.025~0.046mm
connecting rod end bush

Standard
Corrective
action
diameter)
Cylinder sleeve
lnner diameter 104.00~104.03mm 100.25mm
Repair with
Below
oversize or
Out of roundness 0.005mm 0.01mm
replace
Below
Out of cylinderness 0.015mm 0.03mm
Cylinder head
Repair or
Flatness of cylinder head bottom Below 0.1mm 0.2mm
replace
Length from cylinder head top to bottom 94.9~95.1mm 94.6mm
Connecting rod
Connecting rod twist and distortion - 0.05mm
Oil clearance 0.04~0.099mm 0.2mm
Connecting rod bearing Repair or
Free length of connecting rod bearing - Min. replace
69.5mm
Bearing crush (measured load 600kg) 34.53~34.57mm -
Connecting rod endplay 0.15~0.45mm 0.6mm
Camshaft
Intake cam max. length 47.105mm
Intake cam min. length 39.910mm
Intake cam lilt 7.195mm
Exhaust cam max. length 46.979mm
Exhaust cam min. length 39.658mm
Exhaust cam lift 7.321mm
Camshaft endplay 0.05~0.22mm 0.3mm
Clearance between camshaft journal and Stamp mark #1,2,3,4
bushing ([54.5] 0.04~0.09mm)
Stamp mark #5 0.15mm Replace thrust
([53] 0.04~0.09mm) plate
Crankshaft
Below 0.01mm 0.03mm
Out of roundness of pin and Journal
Below 0.006mm 0.03mm
Out of cylindricity of pin and Journal
Below 0.02mm 0.05mm
Crankshaft distortion
(measured at journal f\~o 1 and No 5)
0.10~0.26mm 0.4mm Replace thrust
Crankshaft endplay
Plate
Crankshaft main bearing

Oil clearance (#1, 2, 4, 5) 0.036~0.098mm 0.15mm
Oil clearance (#3) 0.056~0.118mm 0.15mm
Replace
Free length -
Bearing crush (measured load 500kgf) 41.061~41.101mm Min69.5mm

Standard
Corrective
action
diameter)
Timing gear backlash
Crankshaft gear and idler gear A 0.062~0.159mm
Idler gear A and cam shaft gear 0.068~0.175mm
Idler gear A and idler gear B 0.062~0.160mm
Repair or
Idler gear B and supply pump gear 0.073~0.169mm
replace
Camshaft gear and power steering pump 0.075~0.160mm
gear Crankshaft gear and oil pump gear 0.049~0.169mm
Power steering pump gear and vacuum 0.075~0.160mm
pump gear
Replace thrust
Idler gear endplay 0.05~0.22mm 0.3mm
plate
Clearance between idler businq and idler
[45] 0.025~0.06mm 0.1mm Replace busing
shaft
Flywheel
Distortion of frictional surface Below 0.05mm 0.2mm
Repair or
Height of frictional surface 24.5mm 23.5mm
replace
Run-out of frictional surface (while Below 0.1mm 0.2mm
installed)

Tightening Torque
Screw size
Items (diameter x length) O.D x Nm Kgf.m lb•ft
pitch(mm)
Main bearing cap bolt M14x2.0 49+90° 5.0+90° 36.4+90°
Front plate flange bolt(8 x16) - 18.6~27.4 1.9~2.8 13.8~20.4

Rear oil seal slinger flange bolt(6
- 7.8~11.8 0.8~1.2 5.8~8.7
X12)
Supply pump side timing gear case
- 18.6~27.4 1.9~2.8 13.8~20.4
mounting bolt
Supply pump flange bolt - 16.7~25.5 1.7~2.6 12.4~18.9
Cylinder Oil jet check valve M12X1.25 29.4 3.0 21.8
block
Rear plate flange bolt(10 X22) M10X1.5 63.7 6.5 47.3
Rear stiffener bracket flange bolt(8
- 18.6~27.4 1.9~2.8 13.8~20.4
X55)
Rear stiffener bracket flange bolt
- 38.2~58.8 3.9~6.0 28.4~43.6
(10X90)
Engine mounting bracket mounting
- 32.3~49 3.3~5.0 24~36.4
bolt
Crankcase oil line set screw M10X1.5 24.5 2.5 18.2
Oil strainer flange bolt(8 X16) - 18.6~27.4 1.9~2.8 13.8~20.4
Oil strainer flange bolt (8 X40) - 18.6~27.4 1.9~2.8 13.8~20.4

Oil pan mounting flange bolt (8
M8X1.2 18.6~27.4 1.9~2.8 13.8~20.4
x12)
Oil level gauge mounting flange
- 18.6~27.4 1.9~2.8 13.8~20.4
bolt(8 x16)
Oil pan drain plug M14X1.5 34.3~39.2 3.5~4.0 25.4~29.1
Oil filter element M26X1.5 19.6 2.0 14.5
Oil cooler by-pass M16X1.5 19.6 2.0 14.5

Lubrication
system Oil cooler relief valve M16X1.5 19.6 2.0 14.5
Oil cooler drain plug M14X1.5 34.3 3.5 25.4
Oil cooler mounting flange bolt - 18.6~27.4 1.9~2.8 13.8~20.4
Oil line flange bolt - 7.8~11.8 0.8~1.2 5.8~8.7
Oil line eyebolt - 18.6~22.5 1.9~2.3 13.8~16.7
Idler gear oil supply pipe - 18.6~22.5 1.9~2.3 13.8~16.7
Turbo charger oil pipe eyebolt - 18.6~22.5 1.9~2.3 13.8~16.7

Turbo charger oil pipe flange bolt(8
- 18.6~27.4 1.9~2.8 13.8~20.4
x16)
Oil pump mounting flange bolt(8
Oil pump - 18.6~27.4 1.9~2.8 13.8~20.4
X55)

Screw size
pitch(mm)
Cylinder head mounting bolt M14X2.0 147+90° 15.0+90° 109+90°
Cylinder
Cylinder head stud (10 X25) - 34.3 3.5 25.4
head
Cylinder head stud (10 X48) - 34.3 3.5 25.4
Fan clutch mounting flange bolt (8) - 21.6~32.3 2.2~3.3 16~24
Fan and Fan clutch spring washer bolt

- 16.7~25.5 1.7~2.6 12.4~18.9
pulley (8x25)
Fan flange nut (6) - 3.9~5.9 0.4~0.6 2.9~3.6
Thermostat cover case flange bolt - 21.6~32.3 2.2~3.3 16~24
Thermostat Engine coolant temperature sensor

- 29.4~39.2 3.0~4.0 21.8~29.1
housing and gauge
Thermostat case flange bolt
- 35.3~52.9 3.6~5.4 26.2~39.3
(10x25)
Timing gear case flange bolt M8X1.25 18.6~27.4 1.9~2.8 13.8~20.4
Rocker cover mounting flange bolt M8X1.25 12.7~15.7 1.3~1.6 9.5~11.6

Cam plate and thrust plate flange
- 18.6~27.4 1.9~2.8 13.8~20.4
bolt
Timing
system Cam plate and oil drain plug 58.8~78.4 6.0~8.0 43.6~58.2
Camshaft gear flange bolt - 18.6~27.4 1.9~2.8 13.8~20.4
Idler gear A, B mounting bolt M8X1.25 18.6~27.4 1.9~2.8 13.8~20.4
Supply pump of flower valve - 7.8~12.7 0.8~1.3 5.8~9.5

Blow-by return pipe and blow-by
hose - 9.8~14.7 1.0~1.5 7.3~10.9
Protect clip flange nut
Bleeder Oil separate mounting flange bolt - 18.6~27.4 1.9~2.8 13.8~20.4

system
PCV blow-by return coating clip
- 7.8~11.8 0.8~1.2 5.8~8.7
flange bolt
Blow-by return pipe mounting
- 35.3~52.9 3.6~5.4 26.2~39.3
flange bolt
Alternator adjust plate mounting
- 35.3~52.9 3.6~5.4 26.2~39.3
bolt(10X20)
Alternator adjust shaft mounting
- 18.6~27.4 1.9~2.8 13.8~20.4
nut (10)
Alternator
and
Alternator assembly mounting bolt M12X134 78.4~107.8 8.0~11 58.2~80
vacuum
pump
Vacuum pump pipe tightening bolt M6X14 3.9~5.9 0.4~0.6 2.9~3.6
Vacuum pump mounting flange

M8X16 18.6~27.4 1.9~2.8 13.8~20.4
bolt

Screw size
pitch(mm)
Piston and
Connecting rod and connecting rod
connecting M12.5X1.25 29.4+90° 3.0+90° 21.8+90°
bearing cap mounting bolt
rod
Flywheel Flywheel mounting bolt M14X1.5 39.2+40° 4.0+40° 29.1+90°

and damper Crankshaft damper pulley
pulley M24X1.5 588 60 436
mounting nut
Mounting flange bolt (12X25) - 78.4~107.8 8.0~11.0 58.2~80
Starter
Mounting flange bolt (12X25) - 37.2~53.9 3.8~5.5 27.6~40
motor
Mounting flange bolt (12) 37.2~53.9 3.8~5.5 27.6~40
Glow plug harness flange nut - 3.9~5.9 0.4~0.6 2.9~3.6

Glow plug
Plain washer nut - 1~1.5 0.1~0.15 0.7~1.1
Actuator mounting flange bolt - 7.8~11.8 0.8~1.2 5.8~8.7

Butterfly valve shaft mounting nut
- 16.7~27.4 1.7~2.8 12.4~20.4
(8)
Intake
manifold Intake manifold front hanger
- 32.3~49 3.3~5.0 24~36.4
mounting flange bolt (10x20)
Intake manifold mounting flange
- 18.6~27.4 1.9~2.8 13.8~20.4
bolt (8 X20)
Exhaust manifold heater protector
M8x1.25 11.8 1.2 8.7
cover mounting bolt
Exhaust
manifold Exhaust manifold assembly self
lock M10X1.25 41.2 4.2 30.5
Flange nut
Engine
Top shield bolt screw - 7.8~11.8 0.8~1.2 5.8~8.7
cover
Turbo charger and Intake pipe
Turbo M9X2.5 3.9 0.4 2.9
clamp band
charger
Turbo charger oil pipe eyebolt M8X1.25 11.8 1.2 8.7
Fuel suction hose - 14.7~19.6 1.5~2.0 10.9~14.5

Common rail fuel return B
- 16.7~22.5 1.7~2.3 12.4~16.7
mounting screw
Fuel return A and fuel supply hose
- 9.8~19.6 1.0~2.0 7.3~14.5
protect clip flange bolt
Fuel return A and rear plate clamp
Fuel - 3.9~5.9 0.4~0.6 2.9~3.6
plate bolt
system
Injector pipe (No. 1, 2, 3, 4) - 39.2~49 4.0~5.0 29.1~36.4
Injector nozzle bridge bolt - 30.4~34.3 3.1~3.5 22.5~25.4
Common rail bracket Flange bolt - 21.6~32.3 2.2~3.3 16~24

Pipe (between supply pump and
- 39.2~49 4.0~5.0 29.1~36.4
common rail)

Screw size
pitch(mm)
Engine speed sensor mounting
- 7.8~11.8 0.8~1.2 5.8~8.7
bolt
Sensor Cam speed sensor mounting bolt - 7.8~11.8 0.8~1.2 5.8~8.7
Booster pressure sensor (M. A. P)

- 7.8~11.8 0.8~1.2 5.8~8.7
mounting bolt

Special Tool
Tool (part no. and part name) Shape Usage
09212-41200
Installation and removal of
Camshaft bushing remover and
camshaft bushing
installer
09246-41000 Installation and removal of

Idler gear bushing puller connecting rod bushing
09222-83200
Installation of piston
Piston guide clamp
09222-83300 Installation and removal of valve

Valve spring compressor cotter
09221 -41100
Removal of valve guide
Valve guide remover
09221-41150 Installation of valve guide

Valve guide Installer (Use together with 09211-41100)

Tool (part no. and part name) Shape Usage
09222-45100
Installation of valve stem seal
Valve stem seal Installer
09353-45100 Measurement of compression

Air compressor adapter pressure
0922283200 Installation and removal of piston

Piston ring tool ring
09222-45000 Installation and removal of rocker

Rocker bush puller bush
09211-41000 Installation and removal of

Oil seal slinger Installer crankshaft rear oil seal slinger

Diagnosis
Symptom Possible cause Maintenance
Cylinder head Gasket is melt Replace gasket (check the status of

head surface, block head)
Compression
Piston ring is worn or damaged Piston Replace the ring
pressure is
or cylinder is damaged Repair or replace piston or cylinder
excessively low
block
Valve seat worn or damaged Repair or replace valve or seat ring
Engine oil depleted Add engine oil

Oil pressure switch fail Replace oil pressure switch Replace
Oil filter clogged the filter with new one Replace the gear
Oil pressure is
Oil pump gear or case is worn Engine or case
excessively low
oil viscosity is low Replace engine oil
Oil relief valve stuck (open) Excessive Repair valve
bearing clearance Replace the bearing
Oil pressure is
Oil relief valve stuck (close) Repair the relief valve
excessively noise
Improper oil supply Check the engine oil level

Low oil pressure Refer to ‘oil pressure is excessively
Connecting rod noise
low’
or main bearing noise
Low engine oil viscosity Replace engine oil
Excessive bearing clearance Replace the bearing
Engine mounting bolt is loose Retighten

Transmission mounting bolt is loose Retighten
Excessive engine Cross member bolt is loose Retighten
vibration Engine mounting rubber is damaged Replace
Transmission mounting rubber is Replace
damaged
Engine coolant leak

Radiator core Joint is damaged
Radiator and heater hose corroded and
Engine coolant level cracked
Replace
is low Radiator cap valve or spring setting is
defective
Thermostat defect
Water pump defect
Foreign substance intrusion into engine
Radiator is clogged Replace
coolant
Thermostat in defective Replace

Radiator cap is defective Replace
Cooling system flow is defective Drive Replace
Engine coolant
belt is loose Adjust or Replace
temperature is
Water pump is defective Temperature Replace
abnormally high
wiring is defective Radiator fan is Repair or replace
defective Repair or replace
Engine coolant is low Add coolant
Engine coolant
Thermostat is defective Temperature Replace
temperature is
wiring is defective Repair or replace
abnormally low

Symptom Possible cause Maintenance
Oil cooling system Hose or pipe connection is loose Hose Retighten
leaks and pipe is cracked or damaged Replace
Radiator fan is
Damage Repair or replace
inoperative
Connection is loose Retighten
Exhaust gas leaks
Pipe or muffler is damaged Repair or replace
Baffle plate inside the muffler fell off Replace
Rubber hanger is damaged Replace
Unusual noise
Pipe or muffler interferes with the body Repair
Pipe or muffler is damaged Repair or replace

Adjustment
CAUTION
Compression Pressure
a. Take care that fuel is not injected.
b. Since compression pressure varies
depending on the engine speed, be careful in
measuring.
c. Since worn amounts of each cylinder are
different, measure the pressure at all cylinders.
8. Measure the compression pressure of all

cylinders to see if all compression pressures are
within the limit.
Corre
Standar
Items Limit ctive
d
action
Each
cylinder
26kg/cm2 20kg/cm2 Check
Compress
ion
pressure Difference
(200rpm) between - 4kg/cm2 Check
1. Before performing on-vehicle inspection, check to cylinders
see whether engine oil, starter motor and battery
are in normal condition.
9. If the compression pressure difference of any
2. Start the engine and warm up until the coolant cylinder exceeds the limit, fill some engine oil
temperature reaches 80~90℃ through injector hole and measure the
compression pressure of the cylinder again.
3. Stop the engine and remove the ECM fuse.
1) If the compression pressure increases, it
4. Remove all injectors from cylinder head. indicates that the piston, piston, piston ring or
cylinder wall is worn or damaged.
CAUTION 2) If the compression pressure does not increase,

it indicates that valve is stuck, valve contact is
Be careful that foreign materials do not intrude poor or pressure is leaking through the cylinder
through the injector installation hole. head gasket.
5. Crank the engine to remove the foreign materials

from cylinders.
6. Install compression gauge adaptor (09353-45100)

together with gasket and then, connect the
compression gauge.
7. Crank the engine and measure the compression

pressure.

Timing System
Timing Gear Assembly
Components
Tightening Torque : Nm (kgf.m, Ib-ft)
1. Crankshaft damper pulley nut

2. Crankshaft damper pulley 16. Cam sensor plate
3. Front oil slinger 17. Camshaft gear
4. Front oil seal 18. Idler gear A mounting bolt
5. Timing gear case 19. Camshaft
6. Idler gear B mounting bolt 20. Thrust plate
7. Thrust plate 21. Idler gear A
8. Idler gear B 22. Idler shaft
9. Idler shaft 23. Oil pump gear
10. Supply pump gear 24. Crankshaft gear
11. Crankcase 25. O-ring
14. Camshaft sensor 26. Power steering oil pump
15. Oil drain plug

1. Thrust plate
2. Semicircular key
3. No.1 camshaft bush
8. Sealing cap

Removal
1. Loosen the alternator (1) tensioner screw (2) and 3. Remove the power steering pump (1).
remove the V-belt (3).
2. Remove the water pump pulley (1) and water 4. Align the timing mark "0" of crankshaft damper
pump assembly (2). pulley (1) with the indicator (2) of the timing gear
case. Then, cylinder No. 1 is positioned at TDC of
compression stroke.

5. Remove the crank shaft damper pulley nut (2) 7. Remove the cam speed sensor (1) from the
and remove the crankshaft damper pulley (1). timing gear case and then remove the timing gear
case (2).
6. Remove the engine coolant temperature sensor

(1) connector and remove the thermostat housing NOTE : Check the front oil seal (1) state. If it is
(2) from the cylinder head. normal, do not remove it.

9. Remove the oil pump gear (1).
CAUTION
Before removing the timing gear case, remove
timing gear case mounting bolt (1) at the supply
pump first.
If the mounting bolt at the supply pump is not
removed, timing gear case will not be removed.
10. Remove the idler gear A (1).
8. Remove the front oil seal slinger (1).

13. Remove the camshaft assembly.
11. Remove the idler gear B (1).
1) Remove the thrust plate-mounting bolt (4)

through cam sensor plate (2) hole (3) of
camshaft gear (1).
12. Remove the supply pump gear (1).
NOTE : Do not remove the cam sensor plate (2), if it

is not damaged.
2) When removing the camshaft assembly (1),

handle cam bush carefully not to be damaged.

Inspection
1. Measure inner diameter of idler gear (1) and outer

14. Remove the front plate (1). diameter of idler shaft (2). If the gap exceeds the
limit, replace the idler gear bush.
Reference gap between idler bush and idler shaft

([]indicates reference diameter) : [45] 0.025 ~ 0.06
mm Limit : 0.1 mm.
2. Measure cam max (1) and min diameter (2).

Replace the camshaft assembly, if it exceeds the
limit.
NOTE : The difference between the max and min

diameter is the lift of the com
CAUTION
When removing the front plate (1), do not
remove the bolts (2) processed with spacers.
If they were removed, assemble them based on
the dowel pin and then sealant must be applied
between front plate and spacers.

Unit : mm
Min cam Max cam Cam 3. Measure the outer diameter of camshaft journal
Items and the inner diameter of camshaft bush in the
diameter (2) diameter (1) lift
crankcase. If the gap exceeds the limit, repair the
Intake camshaft bushing with oversize.
39.910 47.105 7.195
cam
Exhaust
39.658 46.979 7.321
cam
Outer diameter of camshaft journal
Journal No. # 1, 2, 3 and 4 : 54.44 ~ 54.46 mm
Journal No. # 5 : 52.94 ~ 52.96 mm
CAUTION Inner diameter of camshaft bushing
Journal # 1, 2, 3 and 4 : 54.5 mm
Since taper cam is used, measure it as shown in Journal # 5 : 53 mm
the figure. Gap between camshaft journal and bushing
Reference : [54.5] 0.04 ~ 0.09 mm
[53] 0.04 ~ 0.09 mm
Limit : 0.15 mm
Measuring A B
position 6.5 mm 6.5 mm

6. Measure the backlash of each gear and replace it
if necessary.
4. Measure the distortion of camshaft. If it exceeds
the limit, replace or repair it with press. NOTE : When measuring the backlash, fix the gear
contacting the corresponding gear and move the
gear to the left and right to measure the backlash.
Distortion of camshaft : 0.02 mm
a. Crankshaft gear (1) and idler gear A (2)
NOTE : Place the camshaft on the precision block

and turn the camshaft in 1 revolution. And read the Reference : 0.062 ~ 0.159 mm
dial indicator. The distortion of the camshaft is a half
of the measurement.
5. Measure the camshaft (1) endplay. If it exceeds

the limit, repair or replace it. b. Idler gear A (1) and camshaft gear (2)
Camshaft endplay Reference : 0.068 ~ 0.175 mm

Reference : 0.05 mm ~ 0.22 mm
Limit : 0.3 mm

e. Oil pump gear (1) and crankshaft gear (2)
c. Idler gear A (1) and idler gear B (2)

Reference : 0.049 ~ 0.169 mm
Reference : 0.062 ~ 0.160 mm
Replacement
d. Idler gear B (1) and supply pump gear (2)

1. Replacement of idler gear bush
Replace idler gear bush using the special tool
Reference : 0.073 ~ 0.169 mm (0924641000).
CAUTION
a. When assembling the bush, align the bush oil
hole with gear oil hole
b. Check to see whether the clearance between
bush and idler gear shaft satisfies the
reference.

2. Replacement of camshaft bush
a. Remove the sealing cap from the crankcase

camshaft hole.
b. Remove the camshaft bush using the special d. Press fit the bush using the special tool
tool (09212-41200). (0921241200) so that the camshaft bush end
aligns crankcase end.
NOTE : When installing the camshaft bushing, align

the oil hole of bush with crankcase oil hole (2).
Installation
c. Install the camshaft bush (1).
NOTE : When assembling camshaft bush,

distinguish the bush by the number marked outside,
which tells the installing position. If the marked
numbers are illegible, measure the inner diameter
and width of the bush.
Unit : mm
Bush No.
(From the Carved Outer Inner Wid
front of mark diameter diameter th
engine)
1. Install the front plate (1).
No. 1 1 58.519 54.5 33
No. 2 2 58.269 54.5 22
No. 3 3 58.019 54.5 22
No. 4 4 57.769 54.5 22
No. 5 5 57.019 53.0 22

4. Install idler A and B.
2. Install the crankshaft gear (1).
3. Install the idler shaft A (1) and idler shaft B (2).

CAUTION
CAUTION
a. When installing, align the timing mark “1” of
a. When installing the idler shaft A and B, do not idler gear A (1) with the timing mark “1” of
tighten the mounting bolts at once. crankshaft gear (2).
b. After installing the idler shaft A and B, check b. When installing, align the timing mark “4” of
to see whether the shaft rotates smoothly. idler gear B (1) with the timing mark “4” of
idler gear A (2).

5. Install the camshaft gear assembly.
c. Measure the endplay between camshaft gear

(1) and thrust plate (2) and install them as the
a. Install the thrust plate (1) so that the “F” mark of clearance to be within the reference.
its oil hole faces to the camshaft gear (2).
Reference : 0.05 ~ 0.22 mm
b. Press fit the camshaft gear assembly (1) of the

cam plate (2) so that it faces outward.
d. Install the camshaft assembly (1) to the

crankcase.

CAUTION 6. Install the supply pump gear.
When installing, align the timing mark “2” of
camshaft gear A (1) with the timing mark “2” of CAUTION
idler gear A (2).
When installing, align the timing mark “5” of
supply pump (1) with the timing mark “5” of idler
gear B (2).
e. Install the thrust plate (2) mounting bolt (3)

through the hole of camshaft cam plate hole (1). 7. Install the oil pump gear (1).

8. Install the front oil seal slinger (1). 10. Install the power steering pump (1).
9. Install the front timing gear case (1).
11. Install the water pump pulley (1) and water pump
Tightening torque : 21.6 ~ 32.3 Nm assembly (2).
(2.2 ~ 3.3 kgf.m, 16 ~ 24 Ib-ft)
CAUTION
a. Apply the Loctite #5699 or equivalent on the
assembly surface of timing gear case (1), and
then assemble it within 3 minutes.
b. Do not start the engine within 1 hour after
installing the timing gear case.

12. Install the crankshaft damper pulley (1) and
damper pulley mounting nut (2).
14. Install the V-belt (1). Adjust the belt tension

Tightening torque : 588 Nm using the tension adjusting screw (2) of
(60 kgf.m, 436 Ib-ft) alternator.
13. Install the alternator assembly (2).

Cylinder head Assembly
Components
3. Cylinder head cover

4. Cylinder head cover gasket
5. Rocker and bracket assembly
6. Cylinder head bolt
7. Cylinder head assembly
8. Cylinder head gasket
9. Crank case
10. Push rod
11. Oil filler cap

1. Valve cap
2. Valve cotter
3. Valve retainer
4. Outer side spring
5. Inner side spring
6. Valve stem seal
7. Push rod
8. Cylinder head
9. Water director
10. Intake valve
11. Exhaust valve
12. Cylinder head gasket
13. Tappet
14. Crankcase

Removal
1.2. Remove the glow plug and glow plug plate (1). 4. Loosen the hexa-bolt (2) of injector nozzle bridge
(1) and remove the injector (3).
3. Remove the injection pipe (1) No 1, 2, 3 and 4

running from the common rail assembly to the
injector.
5. Remove the oil separator (1) and blow-by hose
(2)

9. Remove the turbocharger heater protector cover
(1) and exhaust manifold heater protector cover
6. Remove the oil level gauge (1). (2).
7. Remove the intake manifold assembly (1). 10. Remover the turbocharger assembly (1) from the
cylinder head.
NOTE : Do not remove the actuator (2) of the intake
manifold if its operation is normal.
11. Loosen the exhaust manifold mounting nut (1)

8. Remove the thermostat housing (1). and then remove exhaust manifold (2).

NOTE
a. Since push rod is pressing the rocker, loosen the

rocker adjusting screws (1) toremove the cylinder
head bolts (2).
b. When removing the cylinder head bolts, remove
them according to the sequence as shown in the
following figure.
12. Remove the cylinder head cover (1).
14. Remove the rocker arm and rocker bracket

assembly (1).
15. Remove the cylinder head assembly (1).

13. Remove the cylinder head bolts.

Disassembly
Rocker and Rocker Shaft bracket Assembly
16. Remove the cylinder head gasket (1).
CAUTION 1. Remove the set bolt from the front rocker shaft
bracket.
When removing the cylinder head gasket, be
careful not to damage the cylinder head and 2. Remove the front and rear rocker shaft bracket.
crankcase.
3. Remove the rocker assembly.
4. Remove the rocker shaft spring from the rocker

shaft.
5. Remove the rocker shaft bracket No.2, 3 and 4

and then, remove the rocker shaft.
Valve and Cylinder Head Assembly
17. Remove the valve tappet (1).
1. Remove the valve cotter (2) with pushing the

valve spring (1) evenly using the special tool
(09222-83300).

2. Remove the retainer (1), valve spring (2), valve 4. Remove the cylinder gasket (1).
stem seal (3) and intake and exhaust valve from
the cylinder head.
CAUTION
CAUTION When removing the cylinder head gasket, check
the cylinder head and crankcase for any damage.
Valve stem seal should be replaced with new
one.
Inspection
3. Remove the water director (1) from the cylinder

head.
NOTE : If water director is corroded, remove it. If not, 1. Check to see whether valve cap (1) and retainer
leave it. (2) have any irregular wear.
2. Check the intake and exhaust valve (3) for any

stuck, crack or damage.

3. Check the valve tappet (1) for any damage or 5. Inspect the out of squareness (A), free length (B),
wear. load installed (C) of valve spring, replace it if any
of them exceeds the limit.
Items Standard Limit
Free length 66.1 mm 63 mm

Outer
side Load
27.9 ± 1.4 kg 23.7 kg
Valve installed
spring Out of
1.5 mm 2.1 mm
squareness
Free length 60 mm 57 mm
Inner
side Load
12.1 ± 0.6 kg 10.3 kg
Valve installed
spring Out of
1.5 mm 2.1 mm
squareness
4. Measure the rocker inner diameter and rocker

shaft outer diameter. Replace the bush of rocker,
if the gap exceeds the limit
Items Standard Limit

Inner diameter
18.980 ~ 18.993 mm -
of rocker bush
Outer diameter
19.05 ~ 19.09 mm -
of rocker shaft
Gap 0.06 ~ 0.11 mm 0.2 mm

7. Measure the run-out of push rod (1). Replace it if
it exceeds the limit.
Limit of pushrod run-out : 0.4 mm
6. Measure the outer diameter of tappet (1) and

inner diameter of crankcase tappet hole (2).
Replace the tappet if the gap exceeds the limit.
Reference : 0.045 ~ 0.096 mm

Limit : 0.2 mm
8. Measure the deformation of cylinder head bottom

face. If the measurement exceeds the limit, repair
it with surface grinder or replace it.
Flatness of cylinder head

Reference : 0.05 mm
Limit : 0.2 mm

9. Measure the outer diameter of valve stem. If the 10. Measure the inner diameter of valve guide and
measurement is below the limit, replace the valve outer diameter of valve stem. If the clearance
stem. exceeds the limit, replace the valve guide.
Outer diameter of valve stem Clearance between valve stem and valve guide
- Intake valve - Intake

Reference : 8.96 ~ 8.97 mm Reference : 0.04 ~ 0.06 mm
Limit : 8.85 mm Limit : 0.15 mm
- Exhaust valve - Exhaust

Reference : 8.93 ~ 8.94 mm Reference : 0.07 ~ 0.10 mm

11. Check the contacting state of valve seat and Replacement
valve.
Replacement of Rocker Bush
a. Apply light blue coating on the valve surface.
b. Check the valve contacting state by pressing

the valve to the valve seat.
CAUTION 1. Remove the bush from rocker using the special

tool (09222-45000).
Be careful that valve does not turn, when valve
seat is pressed by valve. 2. Press fit the bush into rocker using the special
tool (09222-45000).
NOTE : When pressing fit bush into rocker, let the

chamber side of the rocker be inserted first.
CAUTION
When pressing fit, align the bush oil hole with
rocker oil hole.
Repalcement of valve guide
c. Measure the seat contact area (A).
Area of the valve seat contact
- Intake
Reference : 2.8 ± 0.2 mm
Limit : 3.6 mm
- Exhaust
Reference : 2.0 ± 0.2 mm
Limit : 2.8 mm
Remove the valve guide using the special tool
(09221-41100). Install the valve guide using the
special tool (09221-41150, 09221-41100).

Valve Seat Repair
1. Repair the valve face using valve refacer (1). 3. Install the valve seat using the caulking tool body
(1) and locking ring (2).
CAUTION
CAUTION
Valve seat angle is 45°.
Press the valve seat (3) with the chamfered side
of the locking ring. And then, caulk it to the
cylinder head as the ring faces the other side.
4. Grind the seat width (A) and valve sinkage (B) to

be with in the standard.
Valve and valve seat should touch evenly all over
2. To repair the valve seat, use the valve seat cutter the surface.
or valve seat grinder (1). After grinding, insert the
#400 or equivalent sand paper between cutter and
valve seat and grind lightly. Valve seat width (A)
Reference : 2.6 ~ 3.0 mm (Intake)
CAUTION 1.8 ~ 2.2 mm (Exhaust)
Limit : 3.6 mm (Intake)
Repair the valve seat width and valve sinkage to 2.8 mm (Exhaust)
satisfy the specified limit.
Valve sinkage (B)
Reference : 1.5 m
Limit : 1.2 mm

Reassembly
Rocker and rocker shaft assembly
5. Apply the compound evenly over the valve seat

surface (1).
CAUTION
1. Install rocker shaft bracket No. 1, 2, 3 and 4 to the
a. Valve stem (2) should be free from any rocker shaft.
compound. Use the medium mesh (mesh
between 120 and 150) compound at first and 2. Install the rocker shaft spring.
finish the grinding with the fine mesh
compound (above 200 mesh) 3. Apply engine oil on the rocker bush, and then
install the bush to the rocker.
b. Mix the compound with some engine oil to
apply evenly. 4. Install the rocker assembly.
5. Install the front and rear rocker shaft bracket.
6. Install the front and rear rocker shaft bracket set

bolts.
Tightening torque : 7.8 ~ 11.8 Nm

(0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 Ib-ft)
6. Place the valve on the valve seat using the valve

lapper (1). Tap the valve with turning the valve
slightly. Clean the compound with diesel or
equivalent. Apply the engine oil and check
whether the contact surface is securely positioned.

Valve and cylinder head Assembly
1. Install the water director to the cylinder head. 3. Apply the engine oil on the valve stem seal lip and
install the valve stem seal using the special tool
(09222-45100).
NOTE : Tap the seal until the special tool (09222-

45100) contacts the cylinder head.
2. Install the intake and exhaust valve.
CAUTION
When installing the valve stem seal (1), use the
new one.

4. Install the retainer, valve spring and valve cotter
using the special tool (09222-83300).
CAUTION
When installing the cylinder head gasket (1),
cylinder head installing surface should be free
from any impurities or foreign materials such as
Installation oil.
a. Assemble the cylinder head so that “UP” mark
of the cylinder head gasket faces to the
cylinder head.
b. Selection and assembly of cylinder head
gasket.
Select the cylinder head gasket according to
the piston protrusion amount.
Unit : mm
Average piston Gasket
Gasket size
protrusion thickness
0.466 ~ 0.526 A 1.35±0.03
0.526 ~ 0.588 B 1.40±0.03
0.588 ~ 0.648 C 1.45±0.03
1. Assembly is performed in the reverse order of

disassembly.
2. Installation of cylinder head gasket.

NOTE : If the max protrusion of the piston is 0.05 2) At the TDC of compression stroke of cylinder
mm more than average protrusion, then use the No. 1, check and adjust the clearance of the
grade up (A→B) gasket. valve with “O” mark at the following table. And
then, turn the crankshaft in one turn to check
3. Checking and adjusting of valve clearance and adjust the valve clearance of remaining
valves with “X” mark.
NOTE : Check and adjust valve clearance while the
engine is cold. Cylin
der 1 2 3 4
No.
Int Ex Int Ex Int Ex Int Ex
Valve ak ha ak ha ak ha ak ha
e ust e ust e ust e ust
TDC
of O O O O
No.1
TDC
of X X X X
No.4
3) Measure the clearance between rocker and

valve cap using the thickness gauge.
a. If the valve clearance exceeds the reference

value, loosen the lock nut (2) and adjust the
clearance with thickness gauge by turning the
adjusting screws.
b. After the valve clearance adjustment, fix the

1) Crank the engine with the cranking handle and adjusting screw using the screw drive (3) and
align the needle to “0” position of crankshaft fasten the loc아 nut securely.
damper pulley (side marked with No. 1 through
4). Or align it to the “0” position of crankshaft NOTE : Make sure to check whether the valve
damper pulley (side marked No. 2 to 3). (This is clearance satisfies the reference after valve
at the TDC of comopression stroke of cylinder clearance adjustment.
No.1).

Crankcase
Flywheel
Components
Tightening Torque : Nm(kgf.m, Ib-ft)
1. Front plate
2. Gasket
3. Crankcase
4. Rear plate
5. Rear oil seal
6. Pilot bearing
7. Flywheel
8. Flywheel mounting bolt

Removal
1. Remove the flywheel mounting bolt (1), and then 4. Remove the rear oil seal slinger (1).
remove the flywheel (2).
Inspection
2. Remove the rear plate mounting bolt (1), and then

remove the rear plate (2).
1. Distorsion check of frictional surface
a. Put the flywheel (2) on the precision table (1)

and set up the dial indicator (3).
b. Move the dial indicator on the flywheel frictional

surface to measure the distortion.
c. If the distortion of the frictional surface exceeds

the limit, regrind the frictional surface.
Distortion of the frictional surface

Reference : Below 0.05 mm
Limit : 0.2 mm
3. Remove the rear oil seal mounting bolt (1), and

then remove the rear oil seal (2).

Installation
2. Replacement of flywheel ring gear
a. When removing the ring gear (1), hear the ring

gear evenly using acetylene torch or equivalent
tools and then remove the ring gear by tapping
the circumference with rod or hammer.
b. When installing, heat the ring gear with piston

heater for 3 minutes (about 100℃). And then,
insert the ring gear so that the un-chamfered
gear faces to flywheel.
1. Install the rear oil seal slinger using the special

tool (09211-41000).

3. Install the rear plate (1).
Tightening torque : 63.7 Nm

(6.5 kgf.m, 47.3 Ib-ft)
2. Apply the sealant (Loctite #5699) to the rear oil

seal (1), and then install the rear oil seal.

(0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 Ib-ft)
4. Install the flywheel (1).
Tightening torque : 39.2Nm + 40°

(4.0 kgf.m + 40°, 29.1 Ib-ft + 40°)

Cylinder Block Assembly
Components
1. Compression ring No.1

2. Compression ring No.2
3. Oil ring No.3
4. Snap ring
5. Piston
6. Piston pin
7. Connecting rod
8. Connecting rod upper bearing
9. Crankcase
10. Connecting rod lower bearing
11. Connecting rod cap
12. Oil pan

1. Oil jet
2. Oil jet mounting bolt
3. Upper main bearing
4. Thrust plate
5. Rear oil seal singer
6. Lower main bearing
7. Main bearing cap
8. Crankshaft assembly
9. Semicircular key
10. Crankshaft gear
11. Front oil seal slinger
12. Crankshaft pulley

Removal
1. Remove the engine and transaxle.

7. Align the timing mark (2 ~ 3 side) of crankshaft
2. Remove the flywheel and rear plate. damper pulley to the compression TDC of cylinder
No.1.
3. Remove the intake and exhaust manifold.
NOTE : As for the removal of cooling fan pulley,
4. Remove the cylinder head assembly. crankshaft damper pulley and timing gear case,
refer to the removal procedure of timing system.
5. Remove the supply pump (1) and common rail
assembly (2).
8. Remove oil cooler assembly.
6. Remove the V-belt (1) and remove the alternator

assembly (2).

9. Remove timing gear train [(oil pump gear (6), 12. Remove the oil pan (1).
camshaft assembly (2), idler gear A (3), idler
supply pump gear (5)), and then remove front
plate.
13. Remove the oil strainer (1).
10. Remove the power steering pump (1).
11. Remove the starter motor assembly (1).

15. Remove the connecting rod bearing cap (1).
NOTE : Make marks at the connecting rod and cap

to be reassembled correctly.
14. Remove rear oil seal (1) and oil seal slinger (2).
16. Remove the piston and connecting rod assembly

(1) from cylinder block.

17. Remove the front, rear and main bearing caps. 19. Remove the oil jet (1) from the cylinder block.
a. Remove the front bearing cap and rear end

bearing cap. Remove the thrust plate (2) from
the rear-bearing cap (1).
Disassembly
b. Remove the main bearing cap (1) and bearing
(3). Piston and Connecting Rod Assembly
18. Remove the crankshaft (1) from the cylinder 1. Remove the piston ring using the special tool
block. (09222-83200).
CAUTION
Handle the crankshaft carefully so that the
joumal is not damaged.

Inspection
Cylinder Block
2. Remove the piston pin snap ring (2) using the

snap ring pliers (1).
NOTE
a. Before repairing, clean each part to remove dust,

oil, carbon and fur.
b. Before cleaning the cylinder block, check water

leakage or damages.
c. Remove the adhesives at each oil hole using air

brush and check whether any hole is clogged.
1. In addition to the visual check about scratch, rust

and corrosion, inspect the slight scratches with
precipitant. Repair or replace it if needed.
2. Measure the twist of cylinder block using straight

3. Remove the piston pin (1) from the piston. edge (1) and thickness gauge (2). Measure them
by placing the straight edge as shown in the
following figure.
NOTE : When measuring, cylinder upper block

should be free from foreign materials such as gasket
piece.
CAUTION
When grinding the cylinder block, grind it as the
piston protrusion does not exceed the reference.
Flatness figure of cylinder block

Reference : Below 0.07 mm
Limit : 0.2 mm
4. Remove the connecting rod (1) from the piston.

3. Check the cylinder wall to see if it is cracked or
damaged. If it is abnormal, repair (oversize) or
replace the cylinder sleeve.
4. Measure the cylinder sleeve ID using the cylinder

gauge. If it is excessively worn, repair it with
oversize and replace the piston and piston ring.
Clearance between piston and cylinder sleeve :

0.080 ~ 0.130 mm
CAUTION
1. When replacing piston, piston ring should be b. Measure the outer diameter of piston skirt at
replaced together. the position, which is 85 mm down from the
2. Even if only one cylinder needs boring, all upper piston.
cylinder walls should be grinded with over
size at the same time
Outer diameter of piston : 103.91 ~ 103.92 mm
3. Measure the most seriously worn cylinder wall
and select the oversize based on the
measurement.
4. Available over sizes are +0.25, +0.50, +0.75
and +1.00.
Piston
5. Piston and connection rod should be replaced
with the new one which has identical weight
and grade with the old one.
1. Check each piston to see whether it is damaged.
a. Measure the inner diameter of cylinder sleeve 2. Check whether the piston pin (1) is installed
using the cylinder gauge (1). correctly in the piston hole.
If any defect is found, replace the piston and
piston pin as an assembly.
Piston pin should slide into the piston hole
Inner diameter of cylinder sleeve : 104.00 ~
smoothly when it is pushed y hand.
104.03mm

Piston Ring
3. Measure the clearance between piston pin and

piston hole by measuring the inner diameter of 1. Check the piston ring for any damage, unusual
piston pin (1) and piston boss. wear or breakage. If damaged, replace the ring.
2. When replacing the piston, replace the piston pin

Inner diameter of piston boss : 38 mm together.
Outer diameter of piston pin : 38 mm
Clearance Reference : 0.007 ~ 0.021 mm 3. Measure the clearance between piston ring and
Clearance Limit : 0.05 mm the wall of the ring groove, using a feeler gauge.
Piston ring Standard Limit
Ring No.1 0.106 ~ 0.170 mm 0.2 mm
Ring No.2 0.07 ~ 0.11 mm 0.15 mm
Oil ring 0.03 ~ 0.07 mm 0.15 mm
4. Measure the clearance between piston pin and

connecting rod end.
Outer diameter of piston pin : 38 mm

Inner diameter of connecting rod end : 38 mm
Clearance Reference : 0.025 ~ 0.046 mm
Clearance Limit : 0.1 mm

Crankshaft
1. Measure the endplay of crankshaft.
Crankshaft endplay
Limit : 0.4 mm
a. If the endplay exceeds the limit, replace the

4. After installing the piston ring to the cylinder bore, thrust plate with the oversize.
push the piston ring to the vertical direction with
the piston. b. Over sizes of the thrust plate are +0.15, +0.30,
and +0.45.
Piston ring end gap 2. Measure the oil gap of crankshaft main bearing.
Ring No.1 : 0.25 ~ 0.40 mm
Ring No.2 : 0.50 ~ 0.65 mm a. Remove the man bearing cap.
Oil ring : 0.20 ~ 0.40 mm
b. Measure the oil gap of man bearing.
1) Remove the oil or other foreign materials

from main journal and main bearing surface.
2) Place the plastic gauge along with the shaft

direction of the journal.

3) Install the main bearing cap and fasten the 3. Measure roundness and cylindricity of crankshaft
bolt. journal and pin. If the measurement exceeds the
limit, repair it with under size.
Tightening torque : 49.0 Nm + 90°

(5.0 kgf.m + 90°, 36.4 Ib-ft + 90°) Roundness of crankshaft
Reference : less than 0.01 mm
Limit : 0.03 mm
Cylindricity of crankshaft
Reference : less than 0.006 mm
Limit : 0.03 mm
4) Remove the main bearing cap and measure

oil gap at each journal.
4. Check to see if the crankshaft is bent.
Install the dial gauge of crankshaft center journal,
Oil gap of journal #1, 2, 4 and 5 and check the bending of the crankshaft.
Reference : 0.036 ~ 0.098 mm
Limit : 0.15 mm
Oil gap of journal #3 Bending of the crankshaft
Reference : 0.056 ~ 0.118 mm Standard : Below 0.02 mm
5) If the oil gap of the main bearing is NOTE : Actual bending is a half of the measurement.
excessively large, replace the main bearing.

Connecting Rod Bearing
d. Remove the connecting rod bearing cap and

measure the oil gap at each pin journal.
1. Before removing the connecting rod cap, measure
the connecting rod endplay. If the gap exceeds
the reference, replace the connecting rod. Connecting rod oil gap
Reference : 0.040 ~ 0.099 mm
Limit : 0.2 mm
Connecting rod endplay
Limit : 0.6 mm e. If the oil gap is excessively large, replace the
connecting rod bearing.
2. Measure the oil gap of the connecting rod bearing.
1) Remove the connecting rod cap.

3. Length of the connecting rod bearing.
2) Measure the oil gap of the connecting rod Length of the connecting rod bearing (1) is
bearing. measured at the free state. If the measurement is
below the limit, replace the upper and lower
a. Remove the oil or foreign materials from pin bearing.
journal and connecting rod bearing surface.
b. Place the plastic gauge on the shaft of pin Length of the connecting rod bearing
journal along with its direction. Limit : above 69.5 mm
c. Install the connecting rod bearing cap and

fasten the bolt.
CAUTION
Tightening torque : 29.4 Nm + 90° Bearing should not be artificially expanded to
(3.0kgf.m + 90°, Ib-ft + 90°) reuse.

Reassembly
Riston and connecting Rod Assembly
1. Install the piston ring using the special tool 2. Apply engine oil at the piston rod end and piston
(09222-83200). pin hole, and then install the piston pin (1).
3. Install the piston pin snap ring (2) using snap ring
NOTE pliers (1).
a. Install the piston ring so that open end of the

piston ring faces to the direction shown in the
figure.
b. Install the oil ring expander spring to be

positioned at 180° direction with the oil ring end.
Otherwise, expander spring may be loosened.

Installation
1. Install oil jet (1) to the cylinder block. 3. Install the crankshaft (1) to the cylinder block.
CAUTION
Handle crankshaft care fully not to be damaged.
2. Install thrust plate (1) and upper main bearing (2)

to the crankcase.
CAUTION
a. Install the thrust plate with the oil groove less 4. Install the front, rear and main bearing caps.
side toward the crankcase.
a. Insert the lower main bearing (1) into bearing
b. Align the lug groove of crankcase with the lug cap (2).
of main bearing.
c. Since there is oil hole at upper bearing, take NOTE : Check to see whether the main bearing lug
care not to be interchanged with lower bearing. matches main bearing cap lug groove.
d. Apply engine oil on the all over the sliding b. Install thrust plate (3) to the rear-bearing cap.
surface.

c. Install the main bearing cap with the specified
torque.
CAUTION
When installing connecting rod cap, align mark
(1) on connecting rod big end cap with mark (2)
Tightening torque : 49.0 Nm + 90° on connecting rod cap.
(5.0kgf.m + 90°, 36.4 Ib-ft + 90°)
5. Install piston and connecting rod assembly.
CAUTION
CAUTION When installing piston, assemble it so that front
Install piston and connecting rod to the mark (1) of the piston face to the front side.
crankshaft pin journal using the special tool Assemble so that the arrow mark (→) of piston
(09222-83200). head faces to the center of cylinder head bolt
hole.

e. Tighten the connecting rod cap with specified 7. Apply the sealant (Loctite #5699) to the rear oil
torque. seal, and then install the rear oil seal (1).
Tightening torque : 29.4 Nm + 90°

(3.0 kgf.m + 90°, 21.8 Ib-ft + 90°)
8. Install the oil strainer (1).
6. Install rear oil seal slinger using the special tool

(09211-41000).
9. Install the oil pan (1).

10. After installing the cylinder block assembly,
measure the piston protrusion, Install the right
cylinder head gasket.
NOTE : As for the cylinder head gasket selection

and assembly, refer to the cylinder head assembly
procedure.
11. Install the timing system.
12. Install the flywheel and rear plate.
13. Install the cylinder head assembly.
14. Install intake and exhaust manifold.
15. Install engine accessories.

Intake and Exhaust System
Specifications
Items Specifications
Air cleaner type Dry type
Element type Paper type
Type Turbocharger (TD04HL-11T-6)
Length 168 mm
Width 154 mm
Turbocharger
Height 165 mm
Max rpm allowed 170,000 rpm
Maximum exhaust gas temperature 760℃
Tightening Torque
Screw size
Items (diameter x Length) O,D x pitch Nm Kgf.m Ib-ft
(mm)
Turbocharger and intake pipe clamp
Turboch M9 x 2.5 3.9 0.4 2.9
band
arger
Turbocharger oil pipe eyebolt M8 x 1.25 16.7 1.7 12.4
Actuator mounting flange bolt M6 x 1.0 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Butterfly valve shaft mounting nut (8) M8 x 1.25 16.7 ~ 25.5 1.7 ~ 2.6 12.4 ~ 18.9
Intake
Intake manifold front hanger mounting
manifold M10 x 1.5 32.3 ~ 49 3.3 ~ 5.0 24 ~ 36.4
flange bolt (10 x 20)
Intake manifold mounting flange bolt
M8 x 1.25 18.6 ~ 27.4 1.9 ~ 2.8 13.8 ~ 20.4
(8 x 20)
Heater protector cover mounting bolt M8 x 1.25 11.8 1.2 8.7
Exhaust
manifold Exhaust manifold assembly self lock
M10 x 1.25 41.2 4.2 30.5
flange nut

Troubleshooting
Output drop
Yes
Intake system Is air cleaner clogged? Replace the element
No
Yes
Does air leak at the connection of intake Repair
system?
Exhaust system
Yes
• Is muffler or exhaust pipe deformed? Repair or replace
• Is carbon accumulated?
No
Yes
Does gas leak at exhaust system? Repair
No
Yes
Is exhaust brake opened? Repair or replace
Turbocharger
(TD05H-12G)
If the turbocharger is defective, Yes

Any leakage at the connection of Tighten the clamp
replace it in the assembly unit.
compressor cover and intake pipe?
No
Yes
Are compressor inside, compressor Cleaning
cover and compressor wheel polluted?
No
No
Does turbine wheel rotate smoothly if Clean the carbon
turned by hands? deposit and

Unusual noise and
vibration
Are fixing bolts and nuts of intake system No

Intake system fastened securely? Tighten
Yes
No
Exhaust system Are fixing bolts and nuts of exhaust Repair or replace
system fastened securely
Yes
Yes
Is exhaust pipe or muffler damaged? Repair or replace
Turbocharger
No
Are bearing and rotating parts Inspect the following.
OK? • Deterioration of engine oil
• Oil filter element clogging
• Foreign materials in oil
supply pipe.
Yes • Bearing damage due to
repeated sudden
departures and stops.
No
Do rotating parts rotate smoothly? • Defective bearing
Isn’t turbine wheel shaft bent? • Compressor wheel or
turbine wheel damage due
to the foreign materials
Yes inside.
Yes
Are there any foreign materials in Check the intake and
turbocharger ? exhaust piper care fully for
the chip of compressor or
turbine wheel

Turbocharger
Components

2. Exhaust manifold assembly
2. Plain washer
4. Distance piece
5. Exhaust manifold self lock flange nut (M10 x 1.25)
6. Oil pipe
7. Turbocharger oil pipe eye bolt (M8 x 1.25)
8. Oil return pipe
9. Turbocharger assembly
10. Self lock flange nut

2. Compressor cover
3. O-ring
4. Cartridge assembly
5. Snap ring
6. Coupling
7. Turbine housing

Removal
1. Remove the turbocharger heater protector cover 3. Make an aligning mark on the coupling (1),
(1). turbine housing (2), compressor cover (3), and
cartridge assembly (4).
2. Remove the turbocharger assembly (1). 4. Remove the turbine housing (1).
CAUTION
a. Lightly tap the housing circumference with
rubber hammer so that turbine housing is not
damaged.
b. Since turbine wheel blade is easily bent,
exercise care when removing the housing.

2. Check the shaft directional clearance of shaft and
turbine wheel assembly.
5. Remove the compressor cover (1).
a. Check the clearance of shaft and turbine wheel

CAUTION assembly.
a. Lightly tap the compressor cover
circumference with rubber hammer so that
compressor cover is not damaged.
b. Since compressor wheel blade is easily bent,
exercise care when removing the compressor
cover.
Inspection
b. Inspect the clearance of compressor wheel side.

If the measurement exceeds the limit, replace
the cartridge assembly (1).
1. Measure the shaft directional clearance of shaft

and turbine wheel assembly, If the measurement
exceeds the limit, replace the cartridge assembly
(1).

Installation
3. After assembling the turbocharger assembly (1),

turn each wheel (2) to see if it rotates smoothly. 1. When assembling the snap ring (1) to compressor
cover (2), assemble it so that the snap ring taper
side (3) faces up.
CAUTION
When installing the snap ring, install it to the
compressor cover by holding the snap with one
hand.
4. When assembling turbocharger assembly (1), fill

with the engine oil through the oil hole (2) so that
each part operates smoothly.
2. Install the turbocharger assembly (1).

(4.2 kgf.m, 30.5 Ib-ft)

3. Install the turbocharger heater protector cover (1).

(1.2 kgf.m, 8.7 Ib-ft)

Intake Manifold
Components
1. Intake manifold gasket

2. Intake manifold assembly
3. Actuator
4. Intake manifold front hanger

Removal
1. Remove the injection pipe (1) No. 1,2,3 and 4

from common rail assembly to the injector.
2. Remove the intake manifold assembly (1).

Installation
1. Install the intake manifold (1).

(1.9 ~ 2.8 kgf.m, 13.8 ~ 20.4 Ib-ft)
2. Install the injection pipe (1) No. 1, 2, 3 and 4.
Tightening torque : 39.2 ~ 49 Nm

(4.0 ~ 5.0 kgf.m, 29.1 ~ 36.4 Ib-ft)

Exhaust Manifold
Components
Tightening Torque : Nm (kgf.m, lb-ft)

2. Exhaust manifold gasket
3. Exhaust manifold assembly
4. Plain washer
5. Distance piece
6. Exhaust manifold self lock flange nut (M10 x 1.25)

Removal
1. Remove the turbocharger assembly. 3. Remove the exhaust manifold assembly (1).
2. Remove the exhaust manifold heater protector

cover (1).

Installation
1. Install the exhaust manifold assembly (1).

(4.2 kgf.m, 30.5 Lb-ft) 3. Install the turbocharger assembly.

(4.2 kgf.m, 30.5 lb-ft)
2. Install the exhaust manifold heater protector cover

(1).

(1.2 kgf.m, 8.7 lb-ft)

Lubrication System
Description
Flow Chart of Lubrication System
Engine is lubricated by a gear-type oil pump that

forces engine oil through the oil cooler and oil filter
into the engine for lubrication of various engine parts.
Oil Pump
The oil pump, of a gear type, is driven by the

crankshaft rotation engaged with oil pump gear. And
the relief valve is in stalled to the oil pump so that it
prevents the excessive pressure by bypassing the
engine oil to oil pan when the oil pressure exceeds
the specification.

Oil Cooler Regulator Valve
Oil cooler is equipment for heat exchange between When oil pressure in main oil gallery exceeds the
the coolant and oil fed from the crankcase water specification, regulator valve (1) opens and some
jacket and oil pump, respectively. The oil cooler has engine oil drains to the oil pan to adjust the oil
a bypass valve that opens when the element (1) pressure.
becomes clogged.
Bypass Valve Oil Pressure Switch
When the oil viscosity is high (in cold) or oil path If the pressure of engine oil which is sent to the main
shows high resistance depending on the element oil gallery is below the specification, the built-in relay
load, the bypass valve (1) opens and oil goes in the oil pressure switch (1) is closed, then the
directly to oil filter without passing oil cooler. warning lamp in the instrument panel is on to inform
the driver of abnormal pressure.

Oil Filter Lubrication of Parts
The engine oil routed from the oil filter to oil main
gallery lubricates all engine parts as detailed below
before returning to the oil pan.
1. Main bearing and connecting rod bearing
a. There is an oil passage (1) provided from the oil

1. Out packing main gallery to each main bearing. The oil flows
2. Seaming cap
3. Bypass element assembly
through the oil hole (2) to lubricate the main
4. Full-flow element assembly bearing and passes through the oil passage
5. Housing drilled into the crankshaft to lubricate the
connecting rod bearings.
Oil filter uses a spin-on type paper element, in which
full flow filter and bypass filter are integrated.
Bypass valve is assembled to the bottom of the filter.
If the element is loaded, valve opens so that engine
oil goes to oil main gallery without passing through
the element to prevent engine overload.
b. The Oil jet (1), installed at each cylinder oil

main passage, injects engine oil into the piston
(2) to cool the piston. This oil jet has a check
valve which is opened/closed by the specified
oil pressure, it prevents oil flow and oil pressure
from decreasing at low pressure.

2. Camshaft
Camshaft bushings are lubricated by the oil
flowing through the oil passages leading from the
oil main gallery to each bushing.
3. Valve mechanism
The engine oil that has lubricated No. 1 camshaft
bushing passes through the oil hole and pipe
provided at the top portion of crankcase to the
cylinder head. The engine oil then goes through
the front rocker shaft bracket into the rocker shaft,
lubricating each rocker bushing. At the same time,
it lubricates valve cap and valve stem of the
rocker. The oil then passes through the push rod
holes in the cylinder head and crankcase to
lubricate the tappets and camshaft cams before
returning to the oil pan.

Specification
Oil Cooler
Item Specification
2
Bypass valve open 3.5~4.5kg/cm (361~419kpa)
Regulator oil pump valve open 5~7kg/cm2(490~686kpa)
Oil Pump
Item Specification
Module 2.0
Pressure angle 20°
Head gear No. of gear teeth 36
Distortion angle 19.5°
Backlash (mm) 0.049~0.151
Pump rotation (rpm) 550~3100
Oil Temperature (℃) -25~130
Oil in use SAE 10W~30W
Injection pressure MPa (kgf/cm2) 0.4(4)
Injection amount (ℓ/min) 25
Relief valve operating pressure MPa (kgf/cm2) 1.1±0.1 (11±1)
Oil Filter
Item Specification
3
Full-flow : above 1700cm
Filtration capacity 3
By-pass : above 2400 cm
Pressure loss Below 0.5 kgf/cm2
Bypass opening pressure MPa (kgf/cm2) 98±20 (1.0±0.2)

Bypass pressure loss MPa (kgf/cm2) 157±20 (1.6±0.2)
Lubricant
Oil viscosity
Item Types Oil grade Oil capacity
(temperature applied)
1) 0~40℃ : SAE 30
API classification 2) above -10℃ : SAE 20W-40
grade CF-4 or Grade CF-4 or Oil pan : 8ℓ
Engine oil 3) above -15℃ : SAE 15W-40
more SAE 10W- more Total capacity : 9ℓ
30 4) -20~40℃ : SAE 10W-30
5) below 10℃ : SAE 15W-30

Service Standard
Nominal value([] Corrective

Item indicates base Limit action and
diameter) remarks
Oil pressure At idle 1~5 kg/cm2 0.5 kg/cm2 Adjust
(oil temperature
2
70~90℃) At max speed 3~5 kg/cm 2 kg/cm2 Adjust
Oil pump case and gear teeth
0.10~0.9 0.2 Replace
end clearance
Difference between oil pump
case depth and gear height 0.01~0.07 0.18 Replace
(sinkage)
Oil pump Driven gear to driven shaft
[20]0.04~0.07 0.15 Replace
clearance
Drive gear end play 0.03
Relief valve opening pressure 10~12 kg/cm2 Replace
Bypass valve pressure 3.5~4.5 kg/cm2 Replace

Oil cooler Opening pressure of regulator 2
5.0~7.0 kg/cm Replace
valve
Unit : mm
Tightening Torque
Size
Item (Diameter x length) Nm Kgf.m lb·ft
OD x pitch (mm)
Oil strainer flange bolt (8x16) - 18.6~27.4 1.9~2.8 13.8~20.4
Oil strainer flange bolt (8x40) - 18.6~27.4 1.9~2.8 13.8~20.4

Oil pan mounting flange bolt (8x12) M8x1.2 18.6~27.4 1.9~2.8 13.8~20.4
Oil level gauge mounting flange bolt
- 18.6~27.4 1.9~2.8 13.8~20.4
(8x16)
Oil pan drain plug M14x1.5 34.3~39.2 3.5~4.0 25.4~29.1
Oil filter element M26x1.5 19.6 2.0 14.5
Oil cooler bypass M16x1.5 19.6 2.0 14.5
Oil cooler relief valve M16x1.5 19.6 2.0 14.5
Oil cooler drain plug M14x1.5 34.3~44.1 3.5~4.5 25.4~32.7
Oil cooler mounting flange bolt - 18.6~27.4 1.9~2.8 13.8~20.4
Oil line flange bolt - 7.8~11.8 0.8~1.2 5.8~8.7
Oil line eye bolt - 18.6~22.5 1.9~2.3 13.8~16.7
Idler gear oil supply pipe - 58.8~83.3 6.0~8.5 43.6~61.8
Turbo oil pipe eye bolt - 18.6~22.5 1.9~2.3 13.8~16.7
Turbo oil pipe flange bolt (8x16) - 18.6~27.4 1.9~2.8 13.8~20.4
Oil pump mounting flange bolt (8x55) - 18.6~27.4 1.9~2.8 13.8~20.4

Troubleshooting
Is oil pressure decreasing?
Yes
Check for oil leaks or mixture with
No coolant.
Is oil level proper?
Repair the damaged parts and replenish
it with oil to the proper level.
Yes
No Replace the oil with the proper viscosity.

Is the oil viscosity normal? Check fuel supply.
Yes
Do the oil pressure switch and gauge unit No

work? Replace.
Yes
Yes
Is the filter element clogged? Replace the element.
No
Is the oil strainer clogged? Yes

Is oil pump locked? Repair or replace the faulty parts.
Is pipe cracked?
No
Do the relief valve and regulator valve No

work? Repair or replace.
Yes
Is there any damage or wear at the oil Yes

pump body? Replace the faulty parts
No
Yes
Is connecting rod or main bearing worn? Repair or replace the faulty parts

Excessive oil consumption
Check the following items for a leakage

• Oil filter
• Oil cooler Yes
Repair the leaking parts.
• Oil pan
• Oil pipe
• Oil cover
No
Is oil leaking from the oil seals of front No

and rear crankshaft? Repair or replace the faulty parts.
Yes
No Repair the damage of oil cooler and

Is any damage in cooling system? water jacket etc.
Yes
Check the abrasion of the engine bearing No

which causes a leakage of oil. Repair or replace.

Adjustment Engine oil Change
Engine Oil Inspection
1. Park the vehicle on the flat surface.
2. Stop the engine.
NOTE
a. Warm up the engine for minutes if the vehicle has

not been inspected.
b. Stop the engine and wait for 5 minutes at least to

measure the oil level.
1. Stop the engine after warming up and remove the

oil filler cap (2) on the cylinder head cover (1).
3. If the oil level is below L mark of the gauge, refill

the oil up to mark F
NOTE : When refilling, oil should be same kind with 2. Loosen the drain plug (1) of oil pan to drain
the one in the pan. engine oil.
4. Check the oil for pollution, mixture with coolant 3. Tighten the drain plug with the specified torque.
and viscosity.
Tightening torque : 34.3~44.1 Nm

(3.5~4.5kgf.m, 25.4~32.7 lb-ft)
CAUTION
If oil drain plug is not tightened to the specified
torque or gasket is reused, it may cause oil
leakage or thread wear. Be sure to replace the
gasket with new one at every oil change.

4. Fill in the new engine oil into the oil filler. Oil Pressure check
NOTE : Overfilling may cause oil saturation or

pressure drop.
Oil capacity
Oil pan : 8ℓ
Total capacity : 9ℓ
5. Close oil filler cap.
6. Start the engine.
7. Stop the engine and check the oil level. Refill the
engine oil if necessary.
Oil Filter replacement Remove regulator valve assembly and install

pressure gauge (1). Warm up the engine until the
temperature reaches 70~90℃. Measure the oil
pressure at idle speed and max speed. If the
readings are below the limit, disassemble and check
the lubrication system.
Item Standard Limit
No load min rpm 1.5 kg/cm2 0.5 kg/cm2
No load max rpm 3~5 kg/cm2 2 kg/cm2
1. Remove the oil filter (1) using oil filter wrench.
2. Apply engine oil on the gasket surface before

installing oil filter.
3. Install the oil filter with the specified torque.
Tightening torque : 17.6~21.6 Nm (1.8~202 kgf.m,

13.1~16.0 lb-ft)
4. Start the engine and check the oil leakage.
5. Stop the engine and check oil level. Refill engine

oil as needed.

Oil Pump
Components
1. Crankcase
2. Oil strainer
3. O-ring
4. Oil pan drain plug
5. Oil pan
6. Stiffener

1. Oil pump assembly 2. O-ring

3. Crankshaft gear 4. O-ring
5. Oil pump case assembly 6. Snap ring
7. Relief valve 8. Spring
9. Seat 10. Oil pump cover
11. O-ring 12. Drive gear
13. Driven gear

Disassembly 3. Measure the clearance between driven gear and
driven shaft. If the clearance exceeds the limit,
replace the parts.
Clearance between driven gear and driven shaft

Standard : 0.04~0.07 mm
Limit : 0.15 mm
1. If the clearance between the end of the drive (1)

and driven gear (2) and oil pump case exceeds
the limit, replace those parts.
Clearance between oil pump case and gear tooth

end
Limit : 0.2 mm 4. Measure the play of drive gear end, if the
measurement exceeds the limit, replace the parts.
Standard play of drive gear end : 0.03 mm
5. Check the opening pressure of relief valve,

replace the parts if they exceeds the limit.
Standard of relief valve opening pressure : 10~12

2
kg/cm
2. Measure the difference between the drive and

driven gears tooth end height and the oil pump
case depth. If the measurement exceeds the limit,
replace the parts.
Difference between oil pump case and gear tooth

end height.
(Sinkage)
Limit : 0.18 mm

Oil Cooler
Components
1. Oil cooler element 2. Oil cooler body assembly

3. Plug 4. Spring
5. Bypass valve 6. Plug
7. Spring 8. Regulator valve
9. Out packing 10. Seaming cap assembly
11. Bypass element assembly 12. Full flow assembly
13. Housing

Disassembly Inspection
1. Remove the exhaust manifold. 1. Cover oil cooler element (1) and connect hose to
the engine oil filler. And immerse it into the water
tank.
2
2. Apply air pressure of 3 kg/cm to hose side and
check the oil cooler element.
3. Check air leakage. If air leaks, replace the oil

cooler element.
4. Check the pressure of oil cooler bypass valve and

regulator valve opening. Replace them if
necessary.
2
Bypass valve pressure : 3.5~4.5 kg/cm
2
Regulator valve opening pressure : 5.0~7.0 kg/cm
2. Remove the oil filter (1) and oil cooler assembly 5. Oil pressure switch inspection
(2).
3. Disassemble oil cooler element (1) from oil cooler. a. Remove oil pressure switch from oil cooler.

b. Check the continuity between oil pressure
switch terminal (2) and body (3) using a tester
(1).
If there is no continuity, replace the switch.
c. lnsert the slim rod (1) Into oil hole of all

pressure switch and check the continuity.
If there is continuity, replace the parts because
it is faulty.
Cleaning
1. Check the oil path and bypass valve of the oil

cooler element for carbon deposits and sludge
formation. If contaminated, wash it in cleaning oil.
2. If much scale is evident on the element and cover,

clean It.
Reassembly
Assembly is made in the reverse order of
disassembly. When installing oil cooler, align oil
cooler with the oil pump installation surface.

Cooling System Thermostat
Description
Cooling System
A : form cylinder head B : to radiator

C : to water pump
1. The thermostat. of a bottom bypass configuration

has a valve controlled by a special wax enclosed
In a pellet
Water pump cools down the engine by circulating 2. Tile wax changes from solid to liquid as it is
the coolant forcibly as shown In the illustration below. heated involving volumetric change for regulation
the flow of coolant.
Water Pump Tile valve position changes depending on the
coolant temperatures regulate the flow rate of
coolant into the radiator and water pump (bypass
side), thus controlling coolant temperature.
A : from the radiator

B : from the thermostat
C : to the crank case A : air B : water
Water pump, a centrifugal type, is driven by the V- 3. A Jiggle valve is installed in the air plug hole of
belt from tile crankshaft pulley. A unit seal is thermostat, which heats up the coolant
installed between impeller and water pump that temperature rapidly to put the engine temperature
prevents leakage of coolant. There is a drain hole to the normal one. When engine stops, and
provided at the bottom of the water pump case, coolant flows as jiggle valve falls down by its
which ensures that water should leak from the unit weight so that air in the engine is led to radiator
seal does not enter bearings. The water pump is through the clearance between the jiggle valve
mounted on the timing gear case provided with a and the breather hole.
suction pipe and swirl chamber. When the engine starts coolant flow into the
An Impeller pressed fit into the one end of water radiator and Jiggle valve is pushed up by the
pump shaft, has tile combination blade, which feeds water pressure As a result. valve covers tile air
coolant under pressure into the engine. plug hole to prevent the coolant from leaking
through the hole

Specification
Item Specification
Cooling method Water cooling, forced circulation
Coolant capacity 20ℓ (includes engine, radiator and heater)
Type Volute pump

Water pump
Drive V-belt
V-belt Quantity 2EA
Type Wax-pellet, bottom bypass (installed with jiggle valve)

Thermostat
Valve opening temperature 82℃
Service Standards
Nominal value
Correction
Item ( [] indicates base Limit
and remarks
diameter)
Fan rotation (Auto cool fan coupling) - More than 2~3 revs. Replace
Interference between pump
[17] 0.08~0.10 mm Up to 2 times Replace
shaft and flange
Gap between pump shaft
Water pump [13] 0.03~0.06 mm Replace
and impeller
Pump case to impeller
20.8~21.7 mm Replace
installed dimension
Valve opening temperature 80~84℃ Replace
Thermostat
Valve lift / temperature Above 10 / 95℃ Replace
Pressure cap nominal 0.83~1.10 kg/cm2 Replace
opening
2
Radiator pressure negative Below 0.05 kg/ cm Replace
Radiator check pressure 1.4 kg/cm2 Replace
Reservoir tank inner pressure 0.5 kg/mm2 Replace

Between alternator and
12~16 mm adjust
water pump
V-belt Between power steering
4~6 mm adjust
deflection pump and crankshaft pulley
Air-con compressor and
16~20 mm adjust
tension pulley

Tightening torque
Screw size
Description (diameter x length) Nm kgf.m Ib-ft
ODxPitch (mm)
Thermostat cover case flange bolt M8x1.25 21.6~32.3 2.2~3.3 16~24
Coolant temperature sensor and gauge PT 3/8 29.4~39.2 3.0~4.0 21.8~29.1
Thermostat case flange bolt(10x25) M10x1.5 35.3~52.9 3.6~5.4 26.2~39.3

Alternator adjusting plate mounting
- 35.3~52.9 3.6~5.4 26.2~39.3
bolt( 10x20)
Alternator adjusting shaft mounting nut (10) - 18.6~27.4 1.9~2.8 13.8~20.4

Trouble Shooting
Overheat
Yes
No Adjust the tension of the belt and after
Is the tension of V-belt normal?
checking the belt, replace it if necessary.
Yes
No Add the coolant, and if there is a leak,

Is coolant level proper? check the cooling system.
Yes
Yes Clean the radiator core and adjust the

Is there any clogged radiator fan?
deformation of core if necessary.
No
Yes
Is coolant polluted or rusted? Clean the cooling system
No
Yes
Is thermostat operating? Replace the thermostat
No
Yes
Does water pump work properly? Replace the water pump
No
Is there any leak in the auto cooling fan No

coupling? Replace the fan coupling
No
Check the all possible causes of

overheating.

There is heavy loss of coolant.
Yes
Is the radiator hose leaking?
No
Does the hose clamp tighten No
Tighten the clamp.
properly?
Yes
Cracked or damaged hose? Replace the hose.
Yes Repair or replace the

Is the radiator core leaking? radiator.
No
Yes
Is the water pump leaking? Replace the O-ring
No
Is the radiator pressure pump leaking?
No Yes
• Is the pressure range correct in
No
the pressure valve? Replace the pressure valve.
• Is gasket in good condition?
Any gas in the coolant leaked from No Replace the cylinder head
cylinder head gasket? gasket.
Yes
Is the oil cooler leaking?
No
No
Are bolts tightened properly? Tighten the bolts.
Yes
Yes
Defective or damaged O-ring? Replace.
Check the possible leaking spots of the

engine.

Water pump
Components
Tightening Torque : Nm(kgf.m, lb-ft)
4. Water pump pulley

5. V-belt
6. Water pump assembly
7. O-ring
8. Crankshaft damper pulley
9. Thermostat housing

Removal
1. Remove the coolant drain plug and drain the 4. Remove water pump pulley (1) and water pump
coolant. assembly (2).
2. Loosen the alternator (1) tension adjusting screw

(2) and remove V-belt (3).
5. Disassemble the coolant temperature sensor

connector and remove the thermostat housing (1)
from the cylinder head.
a. Remove the thermostat cover.
b. Remove the thermostat.

3. Remove the cooling fan
c. Disassemble the bypass pipe from the
thermostat case.
d. Remove the coolant temperature sensor.

Inspection V-Belt Tension Check
Water Pump
1. Inspect the crack, damage, and wear of the parts,

and replace the water pump if necessary.
2. Inspect the bearing to see any damage, unusual

noise, and poor revolution and replace it, if
necessary.
3. Check the leakage of the seal unit and replace

the water pump, if necessary.
Thermostat
Adjust the belt tension to obtain the specified belt

deflection when the center of each belt is pressed
hard with a force of 10 kgf.
Deflection between the alternator ( 1) and water

Pump (2) : 12~16mm
CAUTION
a. Since a slack belt may cause overheating or
undercharge, adjust the tension to the
specification.
1. Heat the water to see if the thermostat valve b. An excessively tight belt may result in
operates properly. possible damages of the belt or bearing.
c. All of two V-belts should be replaced as a
2. Measure the temperature when the valve starts complete set.
opening and is fully open.
Item Specification
Valve opening
80~84°C
temperature
Valve lift / temperature more than 10 / 95°C

Installation
1. Install thermostat housing (1) to the cylinder head.
3. Install the \/-belt (1) and adjust the tension using

the alternator mounting nuts and adjusting bolts(2).
V-belt tension : 12~16mm deflection

(with a force of 10kg)
2. Install the water pump (1) and water pump pulley

(2) to the timing gear case.
Tightening torque : 16.7~25.5 Nm (1.7~2.6 kgf.m,

12.4~18.9 lb-ft)

3. Engine Electrical System (D439E)
General
Specification
Starting System
Item Specification
Type Pro-engaged drive (Assistance drive)
Rated output 24V-5.0 KW
No. of pinion teeth 9
Rotation direction Clockwise from pinion side
No of ring gear teeth 114
Input angle of pinion 20°
Center distance between ring gear and pinion 187.2 mm
Terminal voltage 23 V
Starter Max. Current 95A, MAX

No load test
Min. RPM 3,300 rpm, MIN
Magnetic switch
Below 16 V
operating voltage
Terminal voltage 18.5 V
Load test Terminal current 400 A
Min RPM 2.6kgf.m / 1,250rpm, MIN
Terminal voltage 9V
Characteristic of
Max. Current 1,400 A
assurance output
Max rotation force 7.0 kgf.m, MIN
Charging System
Item Specification
Type 3 phase alternate current commutator type
Rated output 24 V-50 A
Rated RPM 5,000rpm

Alternator
RPM in use 8,000rpm
Regulator type IC regulator

Adjusted regulator voltage [at 20℃] 28~29 V
D439E Service Manual 126 3. Engine Electrical System (D439E)

NOTE
• Cold Cranking Ampere : It refers to the current that the battery can supply for 30 seconds with maintaining
the 7.2 V terminal voltage at a specific temperature.
• Reserve Capacity : It refers to the total time duration in which the battery can supply 25A current at a
temperature of 26.7°C with maintaining the min. terminal voltage of 10.5 V.
Pre-Heating System
Item Specification
Rated voltage 23 V
Resistance 4Ω
Preheating plug It takes 8±1.5 sec to reach 800℃ when DC 23 V is applied.

Temperature increase The temperature should be 1050±80℃ at 30 seconds after
DC 23V is applied.
Heater relay fuse 127 A

Service Standards
Corrective
Item Nominal value (Base diameter in [ ]) Limit
action
Commutator OD 32 mm 31 mm Replace
Commutator run Correct or

- Above 0.5 mm
out replace
Starter Motor Brush length - 7.5 mm Replace
Brush spring
- 2.0~3.8 kgf Replace
pressure
Adjust with
Pinion gap 3.0 mm -
packing
Output current (A)

Revolution
At cold At hot (rpm)
cranking cranking
Output
Alternator
characteristics (27) Above 22 1500 - -
(24V~50A)
(27V)
(48) Above 38 2500
(55) Above 45 5000
Tightening torque
Item Nm kgf.m Ib-ft
Alternator adjusting shaft mounting nut 18.6~27.4 1.9~2.8 13.8~20.4
Alternator adjusting plate mounting bolt 35.3~52.3 3.6~5.4 26.2~39.3
Alternator assembly mounting bolt 78.4~107.8 8.0~11 58.2~80
Starter motor mounting bolt (upper) 78.4~107.8 8.0~11 58.2~80

Starter motor mounting bolt (lower) 37.2~53.9 3.8~5.5 27.6~40
Vacuum pump mounting bolt 18.6~27.4 1.9~2.8 13.8~20.4
Vacuum pump pipe and oil cooler flange bolt 3.9~5.9 0.4~0.6 2.9~4.4
Pre-heater plug mounting nut 1~1.5 0.1~0.15 0.7~1.1

Troubleshooting
Alternator
Troubles Possible causes Corrective action
Fuse is broken. Replace the fuse

Charge warning lamp is Bulb is broken. Replace the bulb
not turned on when
ignition switch is ON Loose wiring connection Retighten the loose connection
state.
Check and replace wiring or
Wrong connection of L-S terminals
replace the voltage regulator.
Drive belt is loose or worn. Replace the drive belt
Charge warning lamp Fuse is broken. Replace the fuse

does not turn off even
after the engine is Fusible link is broken. Replace the fusible link
started. (When battery Voltage regulator or alternator is defective. Replace the alternator
needs to be charged
frequently). Wiring is defective. Repair or replace the wiring
Battery cable is corroded or worn. Repair or replace the battery cable

Voltage regulator is defective (charge
Replace the voltage regulator
Battery is overcharged. warning lamp is on)
Defective of voltage sensing wiring Replace the wiring
Drive belt is loose or worn. Replace the drive belt

Wiring connector is loose or circuit is Retighten the loose connection or
short. Repair the wiring.
Fusible link is short. Replace the fusible link
Battery is discharged.
Poor grounding Repair
Voltage regulator is defective (charge
Check the alternator
warning lamp is on)
Battery is exhausted. Check the battery

Starter
Battery voltage is low Charge or replace the battery
Battery cable is loose corroded or worn Repair or replace the cable

Engine does not crank Fusible link is short Replace the fusible link
Starter is defective Replace the starter
Ignition switch is defective Replace the Ignition switch
Battery voltage is low Charge or replace tile battery

Cranking is slow Battery cable is loose corroded or worn Repair or replace the cable

Starter keeps rotating
Ignition switch is defective Replace the ignition switch
Wiring is short Repair or replace the wire

Starter motor operates Pinion gear teeth are worn or damaged or
but engine does not Replace the starter
motor is defective
crank
Replace the flywheel gear or
Ring gear teeth are worn 01 damaged
torque converter
Pre-Heater

Wiring connection is loose or Repair the Wiring or tighten the
wiring is defective connection
Engine does not start when the
Coolant sensor is defective Replace the coolant temperature
coolant temperature is below 0℃
sensor
Pre-heater plug is defective Replace the pre-heater plug
Pre-heater control unit is defective Replace the unit
If engine stops after 1st Connection is loose or wiring is Correct or tighten the wiring or
explosion or Idle is unstable defective connection
when the coolant temperature is Pre-heating plug is defective Replace tile pre-heater plug
below 0℃ Pre-heating plug relay is defective Replace the relay
Lamp is short Replace the lamp
Connection is loose or wiring is Replace tile wiring or tighten the
Pre-heating indicator remains off cracked connection
Wiring is short Replace tile wiring
Pre-heater control unit is defective Replace the unit

Charging System
Description
Alternator Stator
Alternator is of a built-In type with an IC regulator. A Stator core forms the magnetic flux path together
brush holder is installed in the rear bracket. with rotor core. The magnetic flux in the stator core
When IC regulator falls, regulator assembly should is affected by the passage of the rotor core field so
be replaced because the voltage cannot be that electricity is generated as each rotor core
controlled. rotates.
Rotor
Commutator
Commutator comprises of 3 pails of diodes (6 in

total) and 2 heat sinks. It converts AC output of the
stator to DC power.
When the rotor is driven by the rotation of the pulley, Regulator

the current flows from the brush to rotor coil through
slip ring. Then, rotor core becomes an electro- Regulator assembly comprises of IC regulator,
magnetic. brush and brush spring. It stabilizes the output
varying according to the engine rpm.

Adjustment 2. Test
Voltage Drop Test of Alternator Output Wire 1) Start the engine.
This is a test to check the wiring between" B" 2) With turning ON/OFF the headlight adjust the
terminal of alternator and (+) terminal of battery. engine speed as the ammeter indicator points
20A. At that time, measure the voltage.
1. Preparation works
3. Result
1) Turn tile Ignition switch off.
1) It is normal If the measured voltage is Within
2) Remove the ground cable of the battery. the specification.
3) Disconnect the alternator output wire from the

“B" terminal of alternator. Test Reference voltage : Max 0.2V.
4) Connect a DC ammeter (O~150A) between “B"

terminal and the disconnected output Wile 2) If the measured voltage exceeds the reference
Connect the (+) and (-) lead wires of the wiring may be defective Therefore check the
ammeter to" B" terminal and the disconnected wiring between" B" terminal of the alternator
output wire, respectively. and fusible link and between alternator and
terminal of the battery.
CAUTION 3) In addition, before the secondary test, check

the looseness at the connection and the
If clamp type ammeter is used, current can be discoloration of harness due to the overheating
measured without disconnecting the harness. Repair them.
4) Turn the light and Ignition switch "OFF" after

the test.
5) Disconnect the battery ground cable.
6) Disconnect the ammeter and voltmeter used for

the test.
7) Connect the alternator output lead wire to the

“B" terminal of the alternator.
8) Connect the battery ground cable.
5) Connect a digital voltmeter between alternator

“B" terminal and (+) terminal of the battery.
Connect tile (+) and (-) lead wires of the
voltmeter to “B" terminal and (-) terminal of the
battery, respectively.

Output Current Test 2. Test
This test is to check whether the alternator output 1) Check to see If the voltmeter Indicates the
current coincides with the rated current. same voltage value with battery voltage.
If voltmeter Indicates OV It means wiring
1. Preparation works between "B" terminal of alternator and (-)
terminal of battery may be disconnected.
Otherwise, It means fusible link is short or
CAUTION ground is poor.
When the output current is measured, use the
2) Start the engine and turn the headlight switch
battery discharged a little bit. It is difficult to
"ON”.
perform the accurate test with the fully charged
battery because of insufficient load.
3) Set the headlight on "High" and place the
heater blower switch at " HIGH” Measure the
a. Turn tile Ignition switch “OFF". max output current by accelerating the engine
speed up to 2500rpm.
b. Disconnect the battery ground cable.
NOTE : Since charging current drops down rapidly
after engine is started, perform this test quickly to
c. Disconnect the alternator output wire from “B”
get accurate max current.
terminal of the alternator.
3. Result
d. Connect a DC ammeter (0~150A) to "B" terminal
and the disconnected output wire.
1) Measured value from the ammeter should be
Connect (+) lead wire and (-) lead wire to "B"
greater than the limit value. Despite that the
terminal and output Wire, respectively.
alternator output wire is normal. If the
measured-value is low, remove the alternator
CAUTION and check it.
Since it has high voltage, make sure to tighten

the connection completely using bolts and nuts Output current : 70% of the rated current
not clips.
CAUTION
• Rated output current is shown on the
identification plate attached on the alternator
body.
• Since output current varies depending on the
electric load of the alternator and ambient
temperature, it is difficult to get the rated
output current if the electric load of the vehicle
is low. In that case, turn the headlight on to
result in the battery discharging or increase
the electric load by using additional light from
other vehicle.
• Since rated output current cannot be measured
when the temperature of alternator and ambient
e. Connect the voltmeter (0~20V) between “B" temperatures are too high, you should lower
terminal and ground terminal Connect (+) lead the temperature before the secondary test.
wire to "B” terminal and (-) lead wire to ground
terminal at the proper position.
2) After completing the output current test, lower
f. Connect engine tachometer And then connect the engine speed down to the idle rpm and turn
battery ground cable. the Ignition switch "OFF".

3) Disconnect the battery ground cable. 7) Install engine tachometer. Connect battery
ground cable.
4) Remove ammeter, voltmeter and tachometer.
2. Test
5) Connect alternator output wire to "B" terminal of
the alternator. 1) Turn the Ignition switch "ON” and check to see
whether voltmeter indicates the reference value.
6) Connect the battery ground cable. If voltmeter Indicates 0V, it means wire between
"B” terminal of alternator and (+) terminal of
battery is disconnected. Otherwise, it means
fusible link is burned out.
Adjusting Voltage and LRC Function Test,
Trouble-Diagnosis Function Test 2) Start the engine. Turn the light and all other
accessory switches "ON".
This test is to check to see whether the voltage
regulator controls the voltage properly. 3) Increasing the engine speed up to 2500rpm,
read the voltmeter when alternator output
1. Preparation current drops to 10A.
4) Keep the engine speed at Idle rpm and turn off

the externally applied load (various electric
instruments).
5) Then, apply the externally applied load

momentarily. (load current of 15A or more)
6) Read the voltmeter before the externally

applied load is applied Measure the time taken
until the voltage after the external load is
applied is equal to the voltage before the
external load is applied.
7) In addition charging lamp turns on if "S"

terminal wire is opened with the idle load only. If
the charging lam p does not turn on It means
that voltage regulator is defective.
1) Check the battery Installed on the vehicle 3. Result

whether : it is fully charged.
1) If the voltmeter reading agrees with the table of
2) Turn the Ignition switch "OFF". the adjusting voltage, the voltage regulator is
normally operating. If the voltage value is larger
3) Disconnect the battery ground cable. than the reference value, the voltage regulator
or alternator is defective.
4) Connect a digital voltmeter between the ground
cable and “L" or "S" terminal of alternator. NOTE : Maximum ambient temperature should be
Connect (+) lead wire to "L" or "S" terminal lower than 90℃. (However 100℃ is acceptable
using special tool “wire-harness connector." within 10 minutes.)
Connect (-) lead wire to proper ground wire or (-
) terminal of the battery. Ambient temperature of
Adjust voltage (V)
voltage regulator (℃)
5) Disconnect alternator output wire from "B"
terminal of the alternator. 20 28~29 V
6) Connect the DC ammeter (0~150A) In serial
between "B” terminal and the disconnected 2) It is normally operating if it is 2~7 seconds to
output wire. take until the voltage after the external load is
Connect (-) lead wire of ammeter to the applied is equal to the voltage before the
disconnected output wire. external load is applied.

3) After the test, adjust the engine speed to idle
rpm, and turn the Ignition switch "OFF”.
4) Disconnect the battery ground cable.
5) Remove ammeter, voltmeter and engine

tachometer.
6) Connect alternator output wire to "B" terminal of

alternator.

Alternator
Components
Tightening Torque : Nm(kgf.m, lb-ft)
1. Rear cover
2. Commutator assembly
3. Rear bracket mounting bolt
4. Rear bracket
5. Stator
6. Rotor
7. Front bracket
8. Alternator pulley
9. Alternator pulley nut

Disassembly
1. Remove rear cover (2) using a drive (1) 3. Remove the commutator mounting screws using
a drive (1) so as to disassemble the commutator
(2).
2. Remove the end portions of the 4 stator coils

soldered to the commutator main diodes using a
soldering tool. 4. Remove 4 rear-bracket-through-bolts.
NOTE : When removing rear bracket, insert (-) drive

CAUTION (1) into the groove of the through bolt and then
separate the rear bracket.
a. Do not overheat the diodes for a long time
when soldering or unsoldering.
b. Be careful not to apply excessive force to
stator coils soldered to diodes.

5. Remove the pulley (1) using air tool and
CAUTION disassemble the rotor (2) and the front bracket (3).
Be careful not to damage the parts when
removing rear bracket. CAUTION
Be careful not to be injured from the rotor
rotation when removing the pulley.
6. Remove the stator (1) from the rear bracket.

Inspection
Rotor Inspection Brush Inspection
1. Check for continuity between slip rings (1). 1. Replace the brush If It is worn exceeding to the
Replace tile rotor If there is no continuity. limit (A).
2. Check for the continuity between slip ring (1) and 2. Unsolder the lead wire of the brush to separate
rotor (2) and between slip ring (1) and shaft (3). the brush and spring. When assembling new parts,
Replace the rotor If there is continuity each other. push the lead wire and solder it so that it fits in the
brush holder.
Stator Inspection Regulator Inspection
1. Check for continuity between lead wires (1). 1. When continuity is tested between (+) regulator
Replace tile stator if there is no continuity. and stator call lead connector rheostat must show
that the electric current flows In one way If the
2. Check for continuity between lead wire (1) and electric current flows In both ways replace the
call core (2) Replace the stator if there is regulator assembly because It means that the
continuity diode is short.

Reassembly
Assembly is performed In the reverse order of
disassembly.
NOTE : When assembling commutator, fix the brush

with wire. Assemble the commutator after fixing the
brush with wires through small hole of the
commutator. Then, remove the wire before
assembling the rear cover.
2. When continuity is tested between (-) regulator

and stator coil lead connector rheostat must show
that the electric current flows In one way If the
electric current flows in both ways replace the
regulator assembly because It means that the
diode is short.
3. When continuity is tested among 4 diodes with

rheostat it must show that the electric current
flows in one way if the electric current flows in
both ways, replace the heat Sink assembly
because it means that the diode is short.

Starting System a. Check solenoid plunger and switch for any
troubles.
Description b. Check pinion gear or overrunning clutch for any
damage.
3. Check the connection state of each battery,

terminals, the connection state between battery (-)
cable and the body, the engine ground cable, the
connection state of the starter "B" terminal and
any corroded portion. And, then crank the engine
again.
NOTE : If the starter cranks the engine, poor

connection is the cause for the trouble. Then, the
starting system is now normal. If it fails to crank
again, go to next step to continue the checking.
4. After disconnect the connector from "S" terminal

of starter solenoid connect the "B" terminal of
solenoid to the "S" terminal of solenoid using jump
wire.
The starting system includes battery, starter motor,
solenoid switch, Ignition switch, inhibitor switch,
NOTE : If starter cranks the engine go to next step
ignition lock switch, connection wires and battery
to continue checking. Otherwise, remove the starter
cable. When the ignition key is turned to the
to repair or replace If necessary.
"START" position, electric current flows so that an
electric power is supplied to the starter motor's
5. Check the following items until an open circuit is
solenoid coil. After that, solenoid plunger and clutch
found.
shift lever are activated.
Then the clutch pinion engages to the ring gear so
a. Check the connectors and wires between the
that the engine is cranked. In order to prevent
damage caused by excessive rotation of the starter interior fuse box and the ignition switch, and
armature when the engine starts, the clutch pinion connectors and wires between the interior fuse
box and the starter.
gear overruns.
b. Check the ignition switch.
Starter Circuit Trouble Diagnosis
c. Check the shift range switch and connector and
NOTE : Battery should be fully charged and In good the ignition lock switch and connector.
condition.
d. Check the starter relay.
1. Remove supply pump relay from fuse box.
2. For A/T with the shift lever at N or P position (A/T),

and for M/T, with tile clutch pedal being depressed
(M/T), turn the ignition switch to START.
NOTE
1. If the starter cranks the engine successfully,

starting system is normal. If the starter falls to
crank the engine go to next step to check.
2. When the ignition switch returns to "ON" position

from" START" after the switch is released, if the
pinion gear is not disengaged from ring gear,
check the following items.

Inspection Pull-in Coil Test in The Magnetic Switch
Pinion GAP
Pull-in coil is normal if the plunger is inserted and

then the pinion pops out when the battery is
connected between “S" and "M" terminals of
magnetic switch. If it does not pop out, replace the
1. Remove field coil from “M" terminal of magnetic magnetic switch.
switch.
CAUTION
2. Connect the battery between "S" and "M" terminal
of magnetic switch. • When this test is performed, remove the
connector from "M" terminal.
• Do not try continually the connection longer
CAUTION than 1 0 seconds.
Do not try continually the connection longer
than 10 seconds to prevent coil from being
burned out. Holding Coil Support Test In The Magnetic
Switch
3. Slightly push the protruded pinion with hand and

measure the returns (moving distance). This
distance is the pinion gap.
4. If the pinion gap exceeds the reference value,

increase or decrease the number of fiber washers
between the magnetic switch and the front bracket
to adjust the gap to the reference value. Pinion
gap decreases as the number of washer is
increased.
Reference value : 3.0mm
Pull out the pinion to the stopper position by hand as

battery is connected between "S" terminal of
magnetic switch and body. If pinion returns when It
is released, holding coil is normally functioning.

Unloading Test
CAUTION
Do not try continually the connection longer
than 10 seconds.
Magnetic Switch Return Test
1. Connect starter motor (A), battery (B),

ammeter(C), voltmeter (D) and rheostat (E) as
shown in the following figure.
2. Turn the switch ON with setting the rheostat at

max. If starter motor rotates smoothly, then the
starter motor is normal.
CAUTION
a. The wires should be thick as possible and all
terminals should be tightened securely.
Pull out the pinion to the stopper position by hand as b. If the starter motor operates for a long time,
battery is connected between "M" terminal of then the rotation speed drops down because
magnetic switch and body. If pinion returns the battery may be discharged.
immediately when it is released, both coils are Do not operate it longer than 10~15 seconds at
normally functioning. once.
CAUTION 3. If the current and rpm are not in accordance with

Do not try continually the connection longer the standards, perform troubleshooting as to the
than 10 seconds. following table.
Troubles Possible cause

Metal portion is damaged or oil is polluted
High current and low rpm.
Armature core and pole piece are worn
Torque is not enough strong.
Armature coil is short
Armature switch is connected to the ground
High current and no rotation. Armature coil or field coil is connected to the ground
Metal portion is melted
Armature coil or field coil is broken
Brush and pigtail are broken
No current and no rotation.
Poor contact between brush and commutator
Due to the stain or biotite etc.
Poor contact at field coil connection (However, if only
Low current and rotation.
shunt coil is short or poorly connected, rotation will
(Torque is not so strong.)
be high.)
High current and high rotation.
Feed coil is short
(Torque is not so strong.)

Preheating System Glow Plug Inspection
Preheating Plug
Inspection
Pre-Heating System Operating Inspection
1. Conditions before inspection : battery voltage is

24 V coolant temperature is below 30°C ( or
perform the test as the coolant temperature
sensor is disconnected)
2. Connect the voltmeter between glow plug plate

and plug body (earth)
3. Turn the Ignition switch ON and read the

voltmeter value.
4. If the pre-heating indication lamp lights for about 6

seconds and indicates battery voltage for about
36 seconds after ignition switch is turned ON, the 1. Check glow plug plate for rust.
system is normal. (When coolant temperature is
20°C) 2. Check glow plug for any damage.
CAUTION CAUTION
Time for electric current varies depending on the Do not use the plug if it has been dropped from
coolant temperature. the height of 10em or more.
5. After checking No 3 set the Ignition switch to 3. Check the resistance between terminal of each
START position. glow plug (NO.1~NO.4) and body.
6. If the battery voltage is generated during engine

cranking and for about 6 seconds after start, the Reference value : 4Ω
system is normal. (When coolant temperature is
20°C)
Relation Between Glow pug Temperature CAUTION

(Resistance) and Time For Electric Current.
As glow plug resistance is very small, remove
1. It takes approximately 8 ±1.5 seconds to heat the any oil from plug surface before measuring the
glow plug up to 800°C when glow plug is cold with resistance.
the battery voltage of DC 23V or more.
2. Apply the battery voltage of DC 23V. After 30

seconds, the temperature should be less than
1050±80°C.

4. Fuel System
General
Specification
Items Specification
Supply
5V
voltage
Operating
4.5~5.5V
voltage
BPS (Booster Operating
Pressure sensor) -40~125℃
temperature
Operating
32.5~284kpa (244~2130mmHg)
pressure
Current MAX, 10mA
Type Thermistor type
IAT (Intake Air
Temperature) 2.31~2.56kΩ [at 20℃(68℉)]
sensor Resistance
0.30~0.34kΩ [at 80℃(176℉)]
Sensors
Type Thermistor type
WTS (Water
2.31~2.59kΩ [at 20℃(68℉)]
temperature sensor) Resistance
0.314~0.331kΩ [at 80℃(176℉)]
TDC sensor Type Hall sensor type
CKP sensor Type Magnetic type
Type Variable resistance type (Potentia meter type)

ASP(Accel position
Voltage 5V±1%
sensor)
Current 10mA MAX.
Fuel pressure sensor Type Piezo electricity type
Type Electromagnetic type

Actuator Injector
Resistance 0.45Ω
Supply When operating : below 1.29A
SCV Current
control valve When stopped : below 1.16A
Max
High-pressure side fuel pressure 1800bar
Pressure
Type Included into high pressure pump, mechanical type
Supply pump
Power Mechanical gear type
Fuel filter Type Filter type
D439E Service Manual 145 4. Fuel system

Sealant
Engine Coolant Temperature Sensor Three Bond 2310 or equivalent
Tightening Torque
Items N.m Kgf.m Ib.ft
Commeom rail installation 21.6~32.4 2.2~2.3 15.9~23.9
Engine Coolant Temperature sensor 29.4~39.2 3.0~4.0 21.6~28.9
Pipe (rall-injector 1/2/3/4) 39.2~49 4.0~5.0 29~36.2

Injector clamping bolt 30.4~34.3 3.1~3.5 22.4~25.3
Supply pump fixing bolt 18.6~27.5 1.9~2.8 13.7~20.3
TDC-bolt 7.9~11.8 0.8~1.2 5.8~8.7
CKP-bolt 7.9~11.8 0.8~1.2 7.9~11.8
Pipe (high pressure pump - rail) 39.2~49 4.0~5.0 29~36.2
Supply pump nut 58.8~68.7 6.0~7.0 43.4~50.6
Troubleshooting
Fuel Injection System
Troubles Possible causes Corrective actions

Remove the supply pump and check
Poor tightening of supply pump nut.
nut tightening.
Defective SCV of supply pump Replace
Repair the starter or charge or replace
Low cranking speed
battery.
If the test light turns on indicating low
Low voltage to glow plug system voltage when it turns “ON”, check
relay and wiring
Defective glow plug Replace the glow plug
Engine does not crank.
Air in the fuel system Air bleeding of fuel system
Injection pipe is connected
Connect the pipe correctly
incompletely.
Improper injection timing Check ECU
Poor injection Check, replace injector

Mechanical defect of engine Compression test, repair engine
Simultaneous failures of TDC sensor
Check and tighten correctly Replace
and CKP sensor

Loose fuel hose connection between
Tighten or repair.
filter and supply pump
Fuel filter is clogged. Or fuel supply is
Check hose or fuel line. Replace fuel
no good because fuel line or injection
filter.
pipe leaks, pinched or pressed.
Idle is improper or idle
speed is unstable or Poor injection Check, replace injector.
irregular
Improper injection timing Check ECU.
Mechanical defect of engine Compression test, repair engine.

Let the engine at idle after replacing
Defective supply pump
pump.
Engine defect at high gear range Observe appropriate shift speed.
Check rail pressure and cooling
Engine temperature stays below
system.
engine operation temperature.
Replace thermostat.
Abnormal at max RPM Check and replace supply pump.
Defective Injection nozzle Check and repair or replace.
Exhaust gas (Black, Improper injection timing Check ECU.

blue, white) Exhaust system malfunction Check if deformed or clogged.
Mechanical defect of the engine Compression test, repair engine.
Defective supply pump Replace pump.

Check the input of QR code value.
Non-input of QR code value Check if it matches the QR value on
the injector.
- Check the history of trouble codes,
check rail pressure. (Target value,
Accel pedal malfunction
Actual value)
- Input the improved ECU data
Defective max. rpm Check and replace supply pump
Air cleaner element polluted Clean or replace.
Engine lacks power, Fuel filter is clogged. Or fuel supply is

acceleration is delayed no good because fuel line or injection Check fuel line and hose, replace fuel
(Speedometer is normal, pipe leaks, pinched or pressed. Or fuel filter.
no clutch slip) filter leaks
Defective injector nozzle Check, repair or replace.
Improper injection timing Check ECU.
Mechanical defect of engine Compression test, repair engine.
Defective supply pump Check after replacing pump.

Air cleaner filter is polluted Clean, replace air cleaner element.

Check, replace or tighten every
Fuel leaks
connection of hose and pipe.
Check and replace the return line,
Excessive fuel Return pipe and hose are clogged
blow air if clogged and drain the fuel.
consumption
Defective injection nozzle Check. Repair or replace.
Mechanical defect of engine Compression test, replace engine.
Defective supply pump Replace pump.
Engine control
Injector wiring short Check injector wiring.

Engine will not turn off Starting switch harness is
Replace.
damaged
Engine Starting System

Defective supply pump/defective
Replace
SCV
Low battery voltage Recharge or replace the battery.
Battery cable connection is loose,
Replace or retighten.
Engine does not crank corroded or worn.
Fusible link is swelled Replace the fusible link.
Defective starter motor Repair
Defective injector Replace

Low battery voltage Recharge or replace the battery.
Battery cable connection is loose,
Cranking speed is low Repair or replace.
corroded or worn
Defective starter motor Replace
Defective starter motor Replace

Starter motor continues to run.
Defective ignition switch Replace the ignition switch.
Defective wiring Repair wiring.
Starter motor runs but engine is Starter motor, pinion gear

Repair starter motor.
not cranking. damaged
Replace flywheel or torque
Ring gear damaged
converter gear.

Fuel Tank and Fuel Line
Fuel pipe is twisted or broken Repair or replace.
Fuel pipe or hose is clogged Clean or replace.
Fuel filter is clogged Replace.

Poor engine performance due to Replace fuel filter or clean fuel
Water intrudes into fuel filter.
insufficient fuel supply tank or fuel line.
Foreign materials intrude in fuel
tank. Clean or replace.
Fuel tank is corroded.
Defective supply pump operation Replace assembly.
Drain the water collected in the
Fuel filter warning lamp blinks. Excessive water is in fuel filter. fuel filter. (Loosen the drain plug
at the bottom of fuel filter.)

Troubleshooting Procedure
Poor engine operation, ignition

Troubles
Stay in high rpm (without any
Knocking during acceleration
Bucking (sudden movement)

Restart after engine stop
Hard to crank the engine

Engine does not crank
accel pedal pressing)
(during warm-up)
Lacks of power
Vibrates at idle
fail, knocking
Check items
Self-diagnosis 1 1 1 1 1 1 1 1 1
Vehicle supply voltage 2 2 9 3
Main relay 3 3 3 11 4
Fuse/plug wire harness 4 2 8 2
Terminal 46 (Ignition ON/OFF signal) 5 4 4 10 5
CKP sensor 6 6 15 12
Run out of fuel 7
Wrong fuel 8 5 7 2 3 3
Fuel shortage 2
Air mixture in fuel 9 6 8 3 4
Low pressure circuit (fuel) 10 7 12 4 4 7
High pressure circuit (fuel) 14 8 13 12 14 17
Fuel filter 11 9 5 5 5
Supply pump 16 11 6
Fuel pre-heater 12 10 6 6
Wrong injector connection 13 16 3 11 17 13
Injector 15 9 4 9 13 14
Mechanical components
19 18 16 18 8
(Pressure valve gap, compression etc)
Defective ECU 20
TDC sensor 22 5
Water temperature sensor (WTS) 14 2 15
Coolant loss
Glow plug system 21 16

Poor engine operation, ignition
Troubles
Stay in high rpm (without any
Knocking during acceleration
Bucking (sudden movement)

Restart after engine stop
Hard to crank the engine

Engine does not crank
accel pedal pressing)
(during warm-up)
Lacks of power
Vibrates at idle
fail, knocking
Check items
Self-diagnosis 1 1 1 1 1 1 1 1 1
Rail pressure sensor (RPS) 18 15 10 11 15

Accel position sensor (APS) 2 7
Mechanical defect of accel 3 8
Booster pressure sensor 17 8 12
Air filter is clogged 7 2
Defective turbo charger 9
Waist gate valve connection 10
Check the valve tension 16
Clutch switch 6
Brake switch 7
Vehicle speed signal 7

Check the Oil level
Radiator fan
Radiator is defective or clogged
Defective IG switch
AC pressure SW
Plug adhesion 6
Leaks at the connection of turbo and
6 11
intake manifold

Diagnostic lamp remains on or
Troubles
Engine stop is impossible with

Discharging black smoke
Engine overruns, accel
White/blue smoke
AC is not turn on
Engine overheat
ignition key
blinking
Check items
Self-diagnosis 1 1 1 1 1 1 1
Vehicle voltage supply

Main relay
Fuse/plug wire harness 4 2 2
Terminal 15 (Ignition ON/OFF signal) 3
CKP sensor
Run out of fuel
Wrong fuel 2
Fuel shortage
Air into the fuel 3
Fuel filter 4
Supply pump
Fuel pre-heater 5
Wrong injector connection
Injector
Mechanical components
5 7
(Pressure valve gap, compression etc)
Defective ECU 5
TDC sensor
Water temperature sensor (WTS) 6 2 4 3 5
Coolant loss 6
Glow plug system

Diagnostic lamp remains on or
Troubles
Engine stop is impossible with

Discharging black smoke
Engine overruns, accel
White/blue smoke
AC is not turn on
Engine overheat
ignition key
blinking
Check items
Rail pressure sensor (RPS)
Accel position sensor (APS) 3 6

Mechanical defect of accel 2
Booster pressure sensor 3
Air filter is clogged 2
Defective turbo charger 4
Waist gate valve connection 5
Check the valve tension
Clutch switch
Brake switch
Vehicle speed signal
Check the oil level 6

Radiator fan 4
Radiator is defective or clogged 5
Defective IG switch 2
AC pressure SW 4
AC SW 3
Plug adhesion
Leaks at the connection of turbo and In-
manifold

Troubleshooting Procedure
When communication with diagnosis equipment is not possible (Communication with any system is not
possible)
Measure the data link connector Check and repair wire harness
Voltage when grounded with 16 : between power source and data
battery voltage NG link connector.
OK
Measure the data link connector Check and repair wire harness
• Continuity between 4 and ground between data link connector and
• Continuity between 5 and ground NG ground.
OK
Replace Hi-scan
When communication between diagnosis equipment and ECU is not possible.
Trouble symptoms Probable causes

It shows at least one of the following symptoms.
• When power is not supplied to ECU.
• Power supply circuit to ECU is broken.
• ECU ground circuit is defective
• ECU is out of order.
• Defectives on ECU
• Circuit between ECU and DLC is open.
• Wrong communication line between ECU and
Hi-scan
Engine is not start.
• Battery
1. Connector
2. Specific gravity, charging
Check the power system
NG 3. Drive belt
4. Voltage
• Fusible link
OK
• Start relay
Check starting system • Starter motor
NG • Wiring

Hard to start the engine. (cranking is possible)
Self diagnosis Trouble code

Trouble code • Use Hi-scan
No trouble code
• Leakage
• Fuel line
Check injector
• Fuel filter
NG
• Fuel pump
OK
Check fuel supply to injector • Oil filler cap

• Fuel pressure • Oil level gauge
• Fuel in the tank NG • Vacuum hose connection
OK
• Supply pump
Fuel pressure check (comparison • Fuel filter
between target and actual values) NG • Fuel pressure regulator
OK
• Wiring connection
Engine control system check • Power to ECU
NG 1. Fusible link
2. Fuse
3. Control relay
• Engine coolant temperature
sensor
• Intake air temperature sensor
• Injection signal circuit
1. Injector wiring
2. ECU

Unstable idle or engine stall.
Trouble code
Self diagnosis
NG • Use Hi-scan
OK
• Fuel line (Leakage, deformation)

Check fuel supply to injector • Fuse
• Fuel in the tank • Supply pump
• Fuel pressure NG • Fuel filter
• Fuel pressure
OK
Check air cleaner element Clean or replace element

NG
OK
Check idle speed

Standard : 750rpm (A/C OFF) Check ECU
850rpm (A/C ON) NG
OK
Check injection timing Check fuel system

NG
OK
• Supply pump
Check fuel pressure • Fuel filter
NG • Fuel pressure regulator
OK
Check injector Injection state

NG
OK • Power to ECU
1. Fusible link
2. Fuse
Check engine control system 3. Control relay
NG • Engine coolant temperature
sensor
1. Injector wiring
2. ECU

Engine hesitation or poor acceleration
• Clutch slip
Check clutch or brake
• Brake slip
OK
Check sir cleaner element Clean or replace element

NG
OK
Trouble code
Self diagnosis check
• Use Hi-scan
NG
OK
Check injection timing Check fuel system

NG
OK
• Supply pump
Check fuel pressure • Fuel filter
NG • Fuel pressure regulator
OK
Check injector • Injector state

NG
OK • Power to ECU
1. Fusible link
2. Fuse
Check engine control system 3. Control relay
NG • Engine coolant temperature
sensor
1. Injector wiring
2. ECU

Trouble diagnosis flow when HUNTING is occurred
Ex)
Currently Fix the single fall of sensors,
malfunction ECU, pump SCV and TWV
Idle rotation Currently Check based on system
hunting (change) malfunction each trouble code
CKP (Crankshaft Position)
Sensor system
PC sensor system (rail
pressure sensor)
Accel sensor system
ECU sensor system (CPUI
malfunction)
Pump SCV system
NG TWV system
Defect caused by FCCB (fuel
control for cylinder balance) is
processed by other flow
OK
Hunting
Completed
corrected?
NG
Fuel system check flow
OK
Sensors, wirings check flow
OK
Check SCV resistance value NG

Pump system Replace supply pump
7.9±0.25Ω(24V), 20℃
OK
Check
injector injection (Diagnosis NG
equipment) Check the cylinder Check injector NG Repair or replace
Injector system
with no vibration change at one wiring wiring
cylinder stop mode
OK
OK
Complete
Check poor connection of ECU NG

ECU system Repair or correct the wiring
ground and ECU connector and connection
OK
Erase the
trouble code and previous
pump learned values with the OK
diagnosis equipment. Complete
Perform the learning again at idle
with no load after engine
warm up.
NG Replace ECU

Trouble diagnosis flow when FCCB (Fuel control cylinder balance) fails
Repair or correct
the wiring
NG
(Continue checking Check Flow OK
Check FCCB
with the key on) Damper chamber operation
trouble codes Faulty because OK
and injector injection (with dia gnosis Check injector
P0301, P0302, of FCCB equipment). Check if there is any cylinder
P0303, P0304 malfunction wiring
without any vibration at 1 cylinder
OK injection stop mode.
(check
Flow damper trouble code
previous
- When Flow Damper
fault)
operates actually (when OK
operating mechanically
due to leakage etc)
- When Flow Damper is not
OK Trouble
operating actually (When
Completed code of FCCB
trouble is caused by
malfunction
compensation differences)
Replace ECU
OK
Check FCCB
compensation value of each NG Check other than the
cylinder on the monitor and identify injection system
the cylinder with the greatest
value.
NG
Record each trouble code and

erase previous trouble codes.
Check the
Trouble code again. NG
Trouble judging conditions : water
temperature 75℃, at neutral and
accel 0%
OK
NG
Completed Ex) (Above ECU
Fix the single fail of reading)
Check injector Corret ECU
sensors, ECU, pump QR date reading
Current SCV and TWV system compensation
malfunction CKP(Crankshaft
Malfunction Position)
other than Flow Check basic Sensor system
trouble codes PC sensor system Installed to
Damper
(rail pressure sensor) the system.
operation Replace
Accel sensor system Check injector common
ECU sensor system QR date rail (Flow
(CPU malfunction) compensation Damper)
OK (Current SCV system
malfunction) TWV system When
Installed replacling
Troubleshoot OK to injector injector)
Flow Damper Complete Input QR
operation
compens
trouble code
Replace the injector ation date
into ECU
after
NG
replacing
injector.
Fuel system checking flow Completed Completed

Trouble diagnosis flow when engine is lack of power
Ex)
Currently Fix the single fail of sensor,
Lack of power in malfunction ECU, pump SCV and TWV
Currently Check based on system
engine, Insufficient malfunction each trouble code CKP (Crank shaft Position)
injection quantity
Sensor system
PC sensor system (rail
pressure sensor)
Accel sensor system
ECU sensor system (CPU
malfunction)
TWV system
OK Defect caused by FCCB
(fuel control for cylinder
balance) is processed by other
flow
Is “engine OK
lacks power” Completed
corrected?
NG
OK
Sensors, wirings check flow
OK
Check SCV resistance value NG

Pump system Replace supply pump
at 20℃, 7.9±0.25Ω(24V)
OK
Check injector
injection (Diagnosis equipment NG
Check the cylinder without any Check injector NG Repair or replace
Injector system
vibration change at one cylinder wiring wiring
stop mode
OK
OK
Replace corresponding injector
Check poor connection of ECU NG

ECU system Repair or correct the wiring
ground and ECU connector and connection
OK
Erase the
trouble code and previous
pump learned values with the OK
diagnosis equipment. Perform the Completed
learning again at idle after
engine warm up.
NG
Replace ECU

Trouble diagnosis flow in systems of sensors and wirings
Sensors and wirings check flow
Check connectors
and wires for connection (DCP, TDC, NG Repair or replace connector
PC, Accel sensor) connection and wiring
OK
Check and replace flywheel for any

damage (Check to see if the air
Check rotation NG gap between sensor and flywheel
signals, and active conditions of CKP
tone wheel is proper)
sensor and TDC sensor
CKP sensor
TDC sensor
OK
Check
PC sensor output NG NG
(Diagnosis equipment) at 0 MPa after Check wiring Repair wiring
10 minutes from engine
stop
OK
OK
Replace PC sensor
Check
PC sensor
(diagnosis equipment) Check Pressure
Check to see if pressure NG Hot
limiter leakage (Return pipe at the Replace the rail
increases to the pressureset at leakage pressure limiter is cold,
check mode and check PC warm-up)
movement at the
same time.
Cold
NG
Check wiring Repair wiring
OK OK
Replace PC sensor
Check accel
sensor output (with diagnosis NG
equipment) and voltage value at idle Adjust accel sensor
full (PTO system also must be
checked)
OK
Check main relay NG Check wiring and replace

operating sound and voltage supply relay
(19V)
OK

Trouble diagnosis flow in fuel system
Check fuel tank

(airtightness, dirt, NG Repair or replace fuel tank
moisture, etc.)
OK
Check fuel hose

NG
for damage Repair or replace hose
(both sides)
OK
Clean or replace fuel filter or fuel line.
De-moisturize the element
Check fuel filter NG “After replacing fuel filter, perform air
(foreign substances or oil) Check
bleeding of filter and increase the rpm
moistures in element
(racing several times) to bleed the air in the
fuel line.
OK
Operate the fuel

filter priming pump to eliminate NG
the completely from fuel passage. Bleed air completely
Check any air leak from fuel
tank retum pipe.
Check engine NG
leaks outside of the engine Check repair or correction of pipe etc
OK
Check the leak NG Check fuel line again and replace injector
inside the engine (Check if engine oil (when injector leaks)
in creases)
OK

Trouble diagnosis flow for engine stall
ECU Defective relay

Engine stop Communication Check main relay Replace the relay
error
OK
Defective fuse Replace fuse

Check ECU fuse Key switch : 5A
Main power : 10A
OK
Check
NG
ECU connector for Connect connector
connection
OK
Check ECU Not applied state Check wire

ground (Battery “-“ terminal harness and repair
with ECU ground and Chassis or replae
ECU ground)
OK
Check if +B terminal
of ECU and both ends of key
switch are 24 V.
OK
Check
OK
communication line Replace ECU
harness connector
NG Repair or replace
harness

Check fuel hose NG
Engine stop Oil leak Repair
(for damage etc)
OK
Check the Check locking.

Leak
leakage between supply Replace the pipe if
pump and common leaks.
rail pipe
OK
PC sensor, unusual
Check if fuel line out put Clean the clogged
clogged area and replace
fuel filter
OK
PC sensor, unusual
Check normal output output
Replace common
of PC sensor at 0 Mpa
rail (PC sensor)
OK
Check PC
sensor (Diagnosis
equipment) Check to see
if pressure increases to the NG Check Pressure limiter Hot Replace
pressure set at leakage leakage (Return pipe at the the
check mode and check pressure limiter is cold, commonrail
warm-up)
PC movement at the
same time.
Cold
Replace supply
pump

Measure Below the standard
Injector ground the ground resistance
Engine stop short Replace the
between terminal and injector
body
OK
Check
harness ground short OK
Replace ECU
between ECU and
injector
Short Repair the short

harness
Injector B+ is Check injector harness. It Short

Repair the harness
short shouldn’t be +B short
OK
Stop the
injectors one by one Partial malfunctions Replace the
using diagnosis equipment, corresponding
Then, check any vibration or injector
smoke.
Does it
Internal fail of Yes
happen at test drive
ECU Replace ECU
after engine
restart?

Fuel system Insufficient fuel Check the
Check the fuel filter remaining fuel and
Engine stop No trouble code outiet for the fuel fuel system (for
supply hose damage etc)
OK
Vapor check Rerform air

Check any air in the bleeding until vapor
fuel. removal completes.
OK
Replace the fuel,

air bleeding. If fuel
Check moisture contains any
De-moisturization
in the fuel system. Check carbonized
moisture in the fuel tank and substance, check
filter. and replace
injection parts.
OK
If fuel contained
any impurities Replace injector or
Check the fuel for any
use genuine fuel
impurities
Engine stop
Switches
Turn off the engine Not fixed
stop switch connector Replace switches
and check the
switches
OK
Check engine stop Not applied Check and repair

switch after applying wiring
voltage
OK
Check wiring
short of adjacent wires to Short
check the possibility with
other wirings

Engine Control System- CAUTION
Electronic If a sensor connector is disconnected with being
the ignition switch turned ON, the diagnostic
Description trouble code (DTC) is recorded in most diesel
control unit. In this case, if the battery negative
Inspection of The Diesel Control System terminal (-) is disconnected for 15 seconds or
more, then the diagnosis memory will be erased.
If the components of the diesel control system
(sensor ECM, Injector etc) has a problem, the
proper amount of fuel for various engine-operating Self-Diagnosis Checking Procedure
conditions is not supplied so that the following
situations can occur. • Since diagnosis memory is erased if the battery or
the ECU connector is disconnected, don’t
1. Engine is hard to start or does not start at all. disconnect the battery just until the diagnostic
trouble codes are completely read and recorded
2. Idling is unstable safely.
3. Engine drive performance is bad. • It is most desirable to erase the diagnostic trouble
If any of the above conditions are met first perform a codes using Hi-scan after completing check and
routine diagnosis that includes basic engine checks repair. After disconnecting ground cable from the
(ignition system malfunction, incorrect engine battery negative (-) terminal for 15 seconds or more,
adjustment etc). Then, inspect the components of reconnect the cable and check if the trouble codes
the diesel control system with multi-purpose tester have been erased. (At this time, ignition switch
or digital multi-meter. must be turned off).
Inspection Procedure (With Hi-scan)

CAUTION
1. Turn off the Ignition switch
• Before removing or installing any part, read the
diagnostic trouble codes and then, disconnect 2. Connect the Hi-scan connector to the connector
the battery negative (-) terminal. of DLC (Data Link Connector) of the trouble
diagnosis as shown in the following figure.
• Before disconnecting the cable from battery
terminal, turn the ignition switch to OFF. If the 3. Turn the ignition switch ON.
battery cable is removed or connected during
engine operation or the situation in which the 4. Check the diagnostic code using Hi-scan
ignition switch is ON, then the ECU
semiconductor could be damaged resulting in 5. Repair the parts having faulty shown in the
inaccurate operation. diagnosis chart.
6. Erase the diagnostic trouble codes.

Self-Diagnosis
7. Disconnect the Hi-scan.
The ECU sends the input/output Signals (some
Signals at all times and the others under specified
conditions). When some time elapse after the first CAUTION
detection of unusual signal, the ECU judges an
irregularity and it records the diagnostic trouble code. • When the battery voltage is excessively low,
And then it outputs the signal to the self-diagnosis diagnostic trouble codes cannot be read. Be
output terminal. The diagnosis results can be sure to check the battery for voltage and the
checked by the Hi-scan. In addition, Diagnostic charging system before starting the test.
Trouble Codes (DTC) will be directly backed up by • When using a tester manufactured by other
the battery so that it will remain in the ECU even if company, operate the tester by referring to the
the ignition switch is turned off. The diagnostic manual of the company.
trouble codes will, however, be erased when battery
terminal or ECU connector is disconnected.

CAUTION
• When erasing the diagnostic trouble codes,
use Hi-scan if possible. Though OTC can be
erased by disconnecting the battery terminal,
doing so, the data for learning control in ECU
would be erased at the same time.
Diesel Control Unit
Component Location
3. Engine Coolant Temperature sensor
1. Intake air temperature sensor and Intake air

pressure sensor
4. Crankshaft position sensor
2. Camshaft position sensor
5. injector

6. Rail pressure sensor
7. Supply Control Valve (SCV)

Engine Control Unit (ECU)
ECU Pin Connector

<34 pin connector>
Terminal Terminal name Function Connection part

1 - - -
2 - - -
3 - - -
4 - - -
5 +B Battery (+) via fuse (A) Main relay
8 - - -
Engine speed signal
9 TAC2 Speedometer (TACHOMETER)
(sent to speedometer)
10 - - -
11 - - -
12 - - -
13 - - -
14 - - -
15 - - -
16
17
18 - - -
19 KWP 2000 K-LINE -
20 - - -
Accelerator pedal position sensor 1
21 AD1 Accelerator pedal position sensor
signal
Accelerator pedal position sensor 2
22 AD2 Accelerator pedal position sensor
signal
23 - - -
24 - - -
25 - - -
26 - - -
27 - - -
28 CASE GND ECU CASE grounded ECU CASE
29 - - -
30 - - -
31 - - -
32 AD16 Intake air temperature sensor signal Intake air temperature sensor
33 - - -
34 - - -

<35 pin connector>

35 +BF +B FOR FLYABCK -
36 - - -
37 - - -
38 - - -
39 NE-SLD Sealed ground of engine RPM sensor -
40 NE+ Engine RPM sensor (+) -
41 NE- Engine RPM sensor (-) -
42 - - -
43 OUT2 Overheater warning lamp -
44 - - -
45 OUT4 Glow lamp -
46 SW1 Key switch -
47 - - -
48 SW2 Starter switch -
49 - - -
50 - - -
51 SW5 Idle up switch -
52 - - -
53 - - -
54 A-GND4 Booster pressure sensor GND -
Engine coolant temperature, Fuel
temperature, Intake air temperature,
55 A-GND5 -
PTO(HD65,72,78), Door interlock
(County)
56 SW1 GND -
57 - - -
58 SW8 Key switch Idle switch
59 - Booster pressure sensor power -
60 - Idle switch -
61 - - -
62 - - -
63 - - -
64
65 - - -
66 - - -
67 - Neutral switch -
68 - - -
69 - - -

<32 pin connector>

70 OUT19 Glow relay -
71 OUT20 Glow relay -
72 GND Signal GND -
73 GND Signal GND -
74 OUT17 Main relay -
75 OUT18 Main relay -
76 +BF +B -
77 - - -
78 - - -
79 - - -
80 - - -
81 - - -
82 S-OUT1 Engine check lamp -
83 - - -
84 - - -
85 - - -
86
87 - - -
88 - - -
89 - - -
90 - - -
91 - - -
92 - - -
93 - - -
94 - - -
95 - - -
96 - - -
97 - - -
98 - - -
99 - - -
100 - - -
101 - - -

<35 pin connector>

102 P-GND Power GND -
103 TWV1 Injector 1 -
104 TWV3 Injector 3 -
105 - - -
106 COMMON1 Injector Power 1 -
107 COMMON1 Injector Power 1 -
108 - - -
109 - - -
110 - - -
111 - - -
112 - - -
113 - - -
114 - - -
115 - - -
116
117
118 - - -
119 - - -
120 G Cam speed sensor signal 1 -
121 AD4 Common rail pressure sensor 1 -
122 - - -
123 A-VCC3 Accelerator position sensor 2 power -
124 - - -
125 A-VCC2 Accelerator position sensor 1 power -
126 A-VCC1 Common rail position sensor power -
127 - - -
128 AD3 Booster pressure sensor signal -
129 - - -
130 - - -
131 G-GND Cam speed sensor GND -
132 AD5 Common rail pressure sensor 2 -
133 G-VCC Cam speed sensor power -
134 A-GND1 Common rail pressure sensor GND -
135 A-GND2 Accelerator position sensor 1 GND -
136 A-GND3 Accelerator position sensor 2 GND -

ECU Circuit Diagram

Removal
1. After the engine stops wait for about 30 seconds.
2. Disconnect the battery ground line.
3. Remove ECU connector wiring sequentially.
4. Loosen ECU bracket fixing bolt and remove ECU.
CAUTION
When replacing ECU with new one, ECU data
corresponding to the vehicle should be
reprogrammed and injector QR code value
should be inputted according to the process of
the diagnosis. Otherwise, engine performance
could be deteriorated and there may have
problems in the emission gas.

Inspection
Check Sheet of Engine ECU Pin
Input/output signal
Pin
Check items Condition LEVEL Remarks
NO. Type
(normal → operating)
1 NA
2 NA
3 NA
4 NA
5 Battery (+) via fuse (A) IG. ON DC Battery voltage
8 NA
9 Engine speed signal Engine drive Pulse
10 NA
11 NA
12 NA
13 NA
14 NA
15 NA
16 -
17 -
18 NA
19 Trouble diagnosis K-LINE Analogue Communication signal
20 NA
Accelerator pedal position IG. ON(idle) Analogue 0.6V ~ 0.85V

21
sensor 1 signal IG. ON(WOT) Analogue 3.75V ~ 3.95V
Accelerator pedal position IG. ON(idle) Analogue 0.6V ~ 0.85V
22
sensor 2 signal IG. ON(WOT) Analogue 3.75V ~ 3.95V
23 NA
24 NA
25 NA
26 NA
27 NA
28 ECU CASE ground DC Below 0.5V
29 NA

Input/output signal
Pin
NO. Type
30 NA
31 NA
Intake air temperature IG. ON(20℃) Analogue Above 0.791V 0.116KΩ ~

32
sensor IG. ON(40℃) Analogue Below 0.406V 48.14 KΩ
33 NA
34 NA
35 +B FOR FLYBACK IG ON DC Battery voltage
36 NA
37 NA
38 NA
Engine RPM sensor shield
39 DC Below 0.5V
ground
40 Engine RPM sensor + Engine drive Sine wave
41 Engine RPM sensor - Engine drive Sine wave
42 -
Coolant
Battery voltage > below
43 Overheat warning lamp temperature DC
0.5V
above 115
44 NA
45 Glow lamp IG ON DC
0.5V
below 0.5V > Battery
46 Key switch IG ON DC
voltage
47 NA
below 0.5V > Battery
48 Starter switch At starting DC
voltage
49
50 -
51
52 NA
53
Booster pressure sensor
54 DC Below 0.5V
GND
Coolant temperature, Fuel
55 temperature, Intake air DC Below 0.5V
temperature
Below 0.5V > battery
56 Key switch DC
voltage
Booster pressure sensor
57 IG ON DC 5V
power

Input/output signal
Pin
NO. Type
58 Idle switch IG ON DC
0.5V
59 NA
60 NA
61 NA
62 NA
63 NA
64 -
65
66 Neutral switch IG.ON DC
0.5V
67 NA
68 NA
69 NA
Below 0.5V > Battery
70 Glow relay IG.ON DC
voltage
71 Glow relay IG.ON DC
voltage
72 Signal GND DC Below 0.5V
73 Signal GND DC Below 0.5V
74 Main relay IG.ON DC
0.5V
75 Main relay IG.ON DC
0.5V
76 +B IG.ON DC
voltage
77
78 NA
79 NA
80 NA
81 Air-con idle up switch IG.ON DC
voltage
82 Engine check lamp IG.ON DC
0.5V
83 NA
84 NA
85 NA
86 -
87 NA

Input/output signal
Pin
NO. Type
88 Idle down switch IG.ON DC
voltage
89
90 NA
91 NA
92 NA
93 NA
94 NA
95 NA
96 NA
97 NA
98 -
99 NA DC
voltage
100 NA
101 NA
102 Power GND DC Below 0.5V
engine
103 Injector 1 drive(injector Analogue
operation)
engine
104 Injector 3 drive(injector Analogue
operation)
105 NA
engine
106 Injector COMMON 1 drive(injector Analogue
operation)
engine
107 Injector COMMON 1 drive(injector Analogue
operation)
108 NA
109 NA
110 NA
111 NA
112 NA
113 NA
114 NA
115 NA

Input/output signal
Pin
NO. Type
116 -
117 -
118 NA
119 NA
Spherical
120 Cam speed sensor signal IG ON
wave
Common rail pressure IDLE=1.72V

121 IG ON Analogue
sensor 1 level(45MPa)
122 NA
Accelerator position
123 IG ON DC 5V
sensor 2 Power
124 NA IG ON
Accelerator position
125 IG ON DC 5V
sensor 1 Power
Common rail pressure
126 IG ON DC 5V
sensor power
127 NA
Boost pressure sensor

128 IG ON
signal
129 NA
130 NA
131 CAM speed sensor GND DC Below 0.5V
IDLE=1.72V
Commonrail pressure
132 IG ON Analogue level
sensor 2
(45MPa)
133 CAM speed sensor power IG ON DC 5V

Common rail pressure
134 DC Below 0.5V
sensor GND
Accel position sensor 1
135 DC Below 0.5V
GND
Accel position sensor 2
136 DC Below 0.5V
GND
Engine drive
137 Injector 2 Analogue
(injector)

Input/output signal
Pin
NO. Type
Engine drive
138 Injector 4 Analogue
(injector)
139 NA
Engine drive
142 Injector COMMON 2 Analogue
(injector)
Engine drive
143 Injector COMMON 2 Analogue
(injector)
144 HP3.4 LO Engine drive Analogue
145 HP3.4 LO Engine drive Analogue
146 HP3.4 HI Engine drive Analogue
147 HP3.4 HI Engine drive Analogue
148 -
149 -
150 NA
151 NA
152 NA
153 NA
154 NA
Water temperature sensor IG. ON(20~C) Analogue Above 2.5V 0.12KΩ ~

155
signal IG. ON(20~C) Analogue Below 0.527V 48.14KΩ
156 -
157 NA
158 NA
159 -
160 -
161 NA
162 NA
Fuel temperature sensor IG. ON (20℃) Analogue Above 2.38V 0.11KΩ ~

163
signal IG. ON (40℃) Analogue Below 1.5V 25.4KΩ
164 NA
165 NA
166 -
167 NA

Intake Air Temperature Sensor 3. If the resistance exceeds the normal range,
replace the intake air temperature sensor
assembly.
Inspection
NOTE : Intake air temperature sensor is a built-in
ATS (Air Temperature Sensor) Harness type assembled with the intake air pressure sensor.
Inspection Procedure
Refer to P0113 P0112 DTC inspection procedures.
Sensor Inspection
1. Check the sensor resistance using multi-tester
2. Measure the resistance between Intake air

temperature sensor and terminal.
Temperature Resistance
Condition
(℃) (kΩ)
-40 39.260
-30 22.960
-20 13.850
-10 8.609
0 5.499
+10 3.604
+20 2.420
+30 1.662
Ignition switch +40 1.116
ON +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

Intake Air Pressure Sensor
Inspection
Intake Pressure Sensor Harness Inspection
Procedure
Refer 10 P0236 P0237 and P0238 DTC inspection

procedures.
Sensor Inspection
1. Check tile sensor resistance using multi-tester.
2. Measure the voltage of Intake air pressure sensor.
Intake air
Condition pressure Voltage (V)
[kPa(mmHg)]
32.5 (244) 0.5
50 (375) 0.78±0.095
70 (525) 1.096±0.075
at starting
270 (2025) 4.277±0.075
284 (2130) 4.5
300 (2250) 4.75±0.095
3. If the resistance exceeds the normal range

replace tile Intake air pressure sensor assembly.
NOTE : Intake air pressure sensor is a built-in type

assembled with the intake air temperature sensor.

Coolant Temperature Sensor
Inspection
Engine coolant temperature sensor is a resistance

type sensor, which is installed on the engine coolant
passage of Intake manifold. Based on the output
voltage of this sensor, ECU determines the engine
temperature and supplies the optimal fuel quantity to
Injector when engine is cold.
Troubleshooting Hint
If the idle speed is not proper or the engine causes

smoke at warm up the engine coolant temperature
sensor is defective.
Harness Inspection Procedure
Refer to P0117, P0118, P0217 DTC inspection

procedures.
Sensor Inspection
Checking Coolant Specification

Check items Data display
condition temperature (Hi-scan)
-20℃ -20℃
0℃ 0℃
Coolant
Sensor Ignition switch : ON
temperature 20℃ 20℃
temperature or engine is started
sensor
40℃ 40℃
80℃ 80℃

Inspection Method Using a Multi-Tester Installation
1. Apply locktite 962T or the equivalent around the
bolt.
2. Install coolant temperature sensor and tighten

with specified torque Specification Torque : 3.0 ~
4.0 kgf.m
3. Connect the harness connector correctly.
1. Remove engine coolant temperature sensor from

the coolant passage of the cylinder head.
2. Immerse the temperature sensing part of engine

coolant temperature sensor into the hot water and
check the resistance.
1) Engine coolant temperature sensor
Temperature (℃) Resistance (KΩ)

-40 48.14
-20 14.13~16.83
0 5.790
20 2.31~2.59
40 1.148
60 0.586
80 0.322
100 0.1884
110 0.1451~0.1491
120 0.1163
2) Gauge unit
Temperature (℃) Resistance (KΩ)

60 125
85 42.6~54.2
110 22.1~26.2
125 15.2
3. If the measurement shows great difference from

the specification replace the sensor

Camshaft Position Sensor
Inspection
TDC sensor senses the TDC (Top Dead Center) of

compression strokes of cylinder No 1 and 4, and
then it transforms it to pulse signals and then Inputs
it to ECU. Then, ECU sets the fuel injection
sequence based on the signals Crank angle sensor
senses each crank angle (piston position) and
transforms it to pulse signals and then inputs it to
ECU. Then, ECU calculates the engine speed based
on the signals and adjusts the fuel injection timing
and Ignition timing.
Wiring Harness Inspection
Refer to P0340 DTC Inspection procedure.

Crankshaft Position Sensor
Inspection
Piston position in the combustion chamber is critical

to define the starting of Injection timing. All engine
pistons are connected to crankshaft by connecting
rod. Sensor on crankshaft can supply the
information concerning all piston positions.
Revolution speed is defined by the crankshaft
revolution number per minute. Important input
factors are treated by ECU using the signal from
induction type crankshaft speed sensor.
Refer to P0335 DTC Inspection procedures

Rail Pressure Sensor Harness Inspection Procedure
Refer to P0192, P0193, and P0194 DTC Inspection

Inspection procedure.
Sensor Inspection
1. If the rail pressure sensor falls, replace the

common rail assembly.
2. Tightening torque of common rail bracket flange

bolt is 22~33kgf.m.
In order to output a voltage signal corresponding to

the applied pressure to the ECM, the rail pressure
sensor must measure the instant pressure in the rail.
The fuel flows to the rail pressure sensor through an
inlet of the rail. The end of rail pressure sensor is
sealed off by the sensor diaphragm. Pressurized
fuel reaches the sensors diaphragm through a blind
hole. The sensor element (semiconductor device)
for converting the pressure to an electric signal is
mounted on this diaphragm. The signal generated
by the sensor is inputted to an evaluation circuit
which amplifies the measuring signal and sends It to
the ECU.
Sensor Inspection
Check items Rail pressure value

Data display Rail pressure value
Display condition Engine idle
Rail pressure 35~50MPa
Normal value (Hi-scan) 40MPa
NOTE : Check the rail pressure with diagnosis

equipment after engine has been warmed up
enough.
Coolant temperature : 85 ± 3°C,

Fuel temperature : 35 ± 3°C

Supply Control Valve
Inspection
SCV is solenoid type valve, in which ECU controls

the valve opening and closing time and the pumping
start time. To meet the target rail pressure, pump
fuel amount is controlled by the current supplied to
SCV. When SCV is closed, fuel path is shut so as to
compress the fuel. And then, compressed fuel is
supplied to common rail. If fuel pressure decreases,
SCV opens and fuel is supplied for pumping.
Refer to P0627, P0629, and P1190 DTC procedure

Fuel Delivery System-Electronic
Components
1. Injection Pipe No.1

5. Injector assembly
6. Injection pipe (Pipe from pump to common rail)
7. Common rail assembly
8. Fuel return tube
9. Fuel suction tube
10. Fuel leak off hose
11. Supply pump assembly
12. Fuel filter assembly
13. Air bleeding pump
14. Air bleeding pump
15. Fuel hose in
16. Fuel hose out

Fuel Filter • When bubbles are removed completely fasten
tile air plug and continue to pump until pump
operation effort feels heavy.
Replacement
3. Water drain from the fuel filter
Removal
When water-warning lam p of fuel filter is turned
on It Indicates that fuel filter is filled with water So
that water should be drained by the following
sequence
CAUTION
If the vehicle is driven without draining the water
despite the warning lamp is on, it may cause
fatal trouble to the supply pump and injector.
a. Turn the water drain sensor about half way to

drain the water
CAUTION
1. Remove fuel hose In and out. Since water drains even if the plug is not fully
loosened, water removal sensor should not be
2. Remove thermo switch and heater sensor. fully loosened.
3. Remove two mounting bolts IA) and fuel filter

assembly (B). b. If diesel fuel drains after water has been
drained completely fasten the water drain
Installation sensor by hand.
Installation is the reverse order of removal.
Assembly
Inspection
1. Apply oil to fuel filter cartridge and Install It to the
1. General check fuel filter head.
a. Crack bending, deformation, deterioration and

clogging of hose or pipe. Fuel filter cartridge tightening torque : 1.0~1.5kgf.m
b. Clogging or damage of fuel filter.

2. Perform [pump learning Initialization] with
2. When the filter has to be checked diagnosis equipment after replacing fuel filter.
Refer to [pump learning initialization] procedure
a. When the fuel III the tank is drained out and when replacing ECU.
then replenished again for maintenance
reasons
b. When fuel filter is replaced
c. When fuel main hose (pipe) is removed
• Loosen the air plug of fuel filter.
• Cover air plug hole with cotton cloth and keep

pumping until it stops bubble.

Injector
Components
CAUTION
• Since common rail fuel injection system
operates at high pressure (1600bar), a special
caution should be exercised.
• While engine is running or within 1 minute after
engine stops no works should be made In
relation to common rail fuel injection system.
• In particular, as the Injector solenoid generates
high temperature heat, do not touch it with bare
hands Start the service works only when
engine has been cooled down enough after
engine stops.
• Always keep the safety precautions.
• Ensure working area cleans all the time, and
place the removed injector on the clean cloth
and pay attention to Injector nozzle so that at it
is not polluted by foreign materials.
• Remove the protective caps for Injector and
fuel hose immediately just before performing
the installation.
• When Installing or removing injector, clean the
injector contacting portion and replace O-ring
and nozzle gasket with new one.
• Apply diesel to the O-ring of the Injector before
inserting them into the cylinder head.
• Install injector to the cylinder head vertically
and install It correctly not to cause any damage
such as shock.
• Observe bolts tightening torque when Inserting
and tightening the Injector.
• Never reuse the high-pressure fuel pipe.

Cleaning
CAUTION
Clean the Injector as follows to be reused.
When removing injector, stop the engine and
1. Clean the Injector by setting the Injector vertically wait until the engine cools down enough. Since
to the clean container. solenoid surface has high temperature, cool it
down enough before starting the service work.
2. Remove dust or dirt from the Injector body and
nozzle sealing with clean cloth If necessary.
Removal
1. Stop the engine.
2. Remove negative (-) terminal of the battery.
NOTE : The ignition key should be turned OFF.
3. Pull off the injector connector.
CAUTION
• Connector should be connected and
disconnected after the ignition switch is
turned off.
• When installing connector, be sure to check
clicking sound of connectors.
• Do not extremely bend or squeeze the cable.
4. Remove high-pressure fuel tube (rail Injector).
5. At first, pull off the fixing clip and then remove the
injector return line.
6. Loosen injector clam p fixing bolt and remove the

injector.

Replacement
Injector and ECU
Reference
: Input injector QR code into Hi-scan
: Using Hi-scan, input injector QR adjusting

value into ECU
: Reprogram ECU using Hi-scan when

replacing ECU

Injector Replacement ECU Replacement
1. Remove the Injector according to the removal 1. Key must be turned off before replacing ECU
procedure. Otherwise. ECU may be Inoperative or have
troubles.
2. Install new Injector.
2. When replacing ECU, ECU data of the
3. Before connecting wiring connector to Injector corresponding vehicle must be inputted using a
after Installing Injector record the OR Hi-scan. Refer to the Instruction on the Hi-scan for
compensation value on the top of the Injector the detailed procedure.
connector.
3. When replacing ECU, QR compensation value of
4. Input the OR compensation value into ECU after the currently installed injector should be inputted
connecting Injector connector and turning the key using a Hi-scan.
on And then Input the previously recorded
compensation value In the order of the cylinders. 4. When Inputting Injector QR compensation value
key must be turned on.
CAUTION 5. As for the Input of the Injector QR compensation
When replacing injector, the QR compensation value, refer to the instruction of Hi-scan.
value of injector must be inputted. If
compensation value marked is not inputted into 6. When the Input of injector QR compensation
ECU, the engine performance can be value is completed turn the Ignition key off and
turn it on again after hearing relay clicking sound
deteriorated and there may have problems in the
(about 10 seconds later).
emission gas.
7. Perform [pump learning Initialization] in the
If the Input of OR compensation value is missing or ‘actuator test Items’.
incorrect, check engine warning lamp may turn on or
engine power may decrease. CAUTION
1) If Input is not performed DTC P0602 When replacing injector or ECU, the QR
compensation value of injector must be inputted.
2) If Input is incorrect : DTC P0611 If compensation value is not inputted into ECU,
the engine performance could be deteriorated
3) If OR value is invalid : DTC P0612 and there may have problems in the emission
gas.
If the Input of QR compensation value is missing or

incorrect check engine warning lamp may turn on or
engine power may decrease.
1) If Input is not made DTC P0602
2) If Input is Incorrect DTC P0602

Installation
1. The ignition key must be turned off 5. Install injector and Injection pipe No. 1, 2, 3 and 4
between rails.
2. Install new O-ring to the injector.
3. Install new nozzle gasket to the Injector nozzle. Tightening torque : 4.0~4.5kgf.m
CAUTION
• Fix the injector securely with the injector clamp
and then, install high-pressure fuel pipe.
• When installing high-pressure pipe, assemble
the nut tentatively to both sides of injector and
rail.
• After tentative assembly, tighten the nut in
accordance with the specified torque.
• Do not apply excessive force nor use
unauthorized tools.
6. Fix the fuel return hose. Never fix without fixing

4. lnstall an injector clamp-mounting bolt. clip.
7. Install the Injector connector.

Tightening torque : 3.1~3.5kgf.m
NOTE : Install the connector #1, 2, 3 and 4 naturally
under the high-pressure pipe.
8. Start the engine and check the high-pressure fuel

line for any leakage of oil.
NOTE : If common rail fuel injection system leaks

despite of the correct tightening torque, then
components must be replaced.

Common Rail Assembly
Removal Installation
1. Remove the high-pressure pipe (1~4) connecting 1. Install the mounting bolt of the common rail
fall and Injector. assembly.
2. Fasten high-pressure fuel pipe.
Tightening torque : 4.0—5.0kgf.rn
2. Remove tile injector pipe (1) connecting high-

pressure pipe to common rail.
3. Remove return fuel hose (2).
4. Remove the rail pressure sensor (4).
CAUTION
Take care so that the fuel remaining in the rail
may not leak.
5. Loosen the common r811 pressure sensor

mounting bolt (3) and remove the common rail
assembly.

Injection Pump-Electronic
Supply pump
Component
1. Suppply pump mounting nut

2. Supply pump gear
3. O-ring 2
4. Spacer
5. O-ring 1
6. Supply pump
Removal
2. Remove supply pump mounting bolt (1)

1. Disconnect the high-pressure pipe (1) connected
between supply pump and rail. 3. Remove the pump (2) from timing gear case (3).
NOTE : When removing supply pump, remove pump,

spacer, and supply pump gear from the assembly.

Installation
4. Insert the pump assembly (1) and gear (2) Into

the timing gear case.
1. Rotate the crankshaft to align the engine No 1 At this time, insert It as the *mark of the supply
cylinder at the TDC (Top Dead Center) position. pump gear tooth aligns to ▽ mark of timing gear
case.
2. Before installing the pump assemble the following
parts at first. NOTE : Be sure to align the *mark at the top of gear
tooth to the mark of timing gear case Otherwise, the
a. Place the key groove (1) of the pump at the engine performance could be deteriorated and there
center of the top. may have problems In the emission gas
b. Insert the O-ring into the pump and insert the

spacer (3) into pump shaft.
c. Insert the O-ring 2(4) onto spacer and inset the

supply pump gear.
3. Tighten the nut (5) with tightening torque.
CAUTION
If they are not fastened with the specified torque, 5. Fasten the bolt (1) with the tightening torque after
supply pump and gear may be loosened so that installing pump.
the engine may be damaged or engine may stop.
Tightening torque 1 9~28kgfm
6. When replacing the pump with a new one, delete

the learned value of previous pump Inside the
ECU and be sure to perform [pump learning
Initialization] in the ‘actuator test items’ to Initialize
the learning of the new pump.
NOTE : After 10 seconds from [pump learning

Initialization] is completed, turn the Ignition key off.
(Wait for 10 seconds at key off state).

7. The ignition key should be turned off more than
10sec. later after [pump learning initialization] is
completed.
8. Start the engine and let the vehicle for 10 minutes

at idle.
NOTE : Above mentioned [pump learning

initialization] actuator test should be performed
when the pump is replaced with new one.
CAUTION
If the above mentioned [pump learning
initialization] is not performed with diagnosis
equipment after replacing new pump, the engine
performance could be deteriorated and there
may have problems in the emission gas.

5. Service Tool
Check before use
Read me first
Introduction
Thank you for purchasing G-scan. This manual describes the basic information for using G-scan. Before
operation, please read this manual to be familiar with important information.
Copyright
Global Information Technology Co., Ltd. copyrights this Manual. All rights reserved. No part of this manual
may be reproduced in any form without prior written permission of Global Information Technology Co., Ltd.
No patent liability is assumed with respect to the use of the information contained herein.
G-scan is registered trademark or trademark of Global Information Technology Corporation.
ⓒ2008 Global Information Technology Co., Ltd. All Right Reserved.
Disclaimer
G-scan specifications and manual are subject to change without prior notice. Global Information technology
Co., Ltd. assumes no liability for the products, which GIT do not produce.
Overview
Comparing with the conventional diagnostic tool, the interface of G-scan is designed for easy operation so that
efficiency of service maintenance is maximized.
• Input using the Touch Screen

Without complicated button operation, you can select menu and function on the screen directly for easy
operation.
• 5.6″ Color TFT LCD

Adapting the 5.6″ large size Color TFT LCD, more data can be shown on the screen at the same time.
• USB communication interface

Using the USB communication interface, it can be connected with other options to be developed in the future.
• Possible to search the DTC of all control module installed in vehicle at one time
• Diagnose the vehicle with CARB OBD-II
• Record the current data
• Support Vehicle S/W management functions for diagnosis
• Actuator test
• Comparison analysis through dual mode
• Support general description relating to DTC
D439E Service Manual 203 5. Service Tool

Safety Warning and Caution before Use
This section contains WARNING and CAUTION for safe usage of G-scan.
Before use, user should read the following information carefully.
WARNING
This indicates incorrect handling may result in a major accident involving death or serious injury.
• G-scan should be secured in a safe location when operated in the vehicle to avoid interference with other
vehicle equipment.
• Only use the specified adapters and cables when connecting G-scan module.
• Ensure all cables are properly connected during operation. Do not disconnect communication cable (150109
- 00050) or power cables unless the operation is over.
• Do not disassemble G-scan module.
• When updating G-scan (firmware, O/S, etc.), connect the external power (AC/DC adaptor) to supply stable
power.
• Use only genuine accessory parts supplied by GIT.
• Do not connect the measuring device to other equipments rather than vehicles.
• Products are to be used within the operating temperatures. (Refer to Specifications)
• Products are to be stored within the storage temperatures. (Refer to Specifications)
• Use GIT products for their original purpose only.
• Users have their own responsibility for Product damages and fire hazards caused by users’ operation
without full understanding of the Caution and other information stated in the manual.
• GIT products should never be tested or repaired by anyone rather than authorized service technicians by
GIT.
• When exchanging rechargeable battery, comply with the method described in this manual for sure.
• Use rechargeable battery supplied from GIT only.
• Do not disconnect the rechargeable battery at one’s discretion.
• Be careful that the rechargeable battery is neither wet nor in water.
• Do not put the rechargeable battery near the fire.
• Do not impact or prick the rechargeable battery with sharpen object.
• Do not put the rechargeable battery into the microwave oven or high pressed vessel.
• Do not throw nor impact on rechargeable battery.
• Be careful that the terminals of rechargeable battery are not short.

• If the rechargeable battery shows any abnormal symptoms such as odor, heat, deformation or discolor, do
not use it. And stop operation and remove the battery immediately.
• Do not reverse the positive(+) and negative(-) terminals for the rechargeable battery.
• Do not connect the rechargeable battery directly to wall outlets or car cigar lighter sockets.
• Do not put the rechargeable battery into a fire or apply direct heat to it.
• Do not make a short-circuit of rechargeable battery by connecting wires or other metal objects to the
positive(+) and negative(-) terminals.
• We, GIT are not responsible for products other than products produced by GIT.

CAUTION
This indicates incorrect handling may lead to injury or damage to properties. Under certain conditions
more serious consequences may result.
• Do not drop G-scan.
• Do not place any objects (tools, manuals, etc.) on G-scan module.
• When connecting cables under the hood, secure the cables to avoid damage caused by hot or moving parts.
• When connecting the DLC cable (150109 - 00050), check the locking device.
• Observe correct polarity when connecting the power supply cable.
• Properly store all components when not in use.
• Do not use cables as carrying handle.
• Do not store products in places where
▪ Extremely high or low temperature (Refer to feature of products)
▪ Extremely high or low humidity (Refer to feature of products)
▪ Inside a vehicle during summer season for a long time
▪ Exposed to direct rays
• Avoid a shock or vibrations during carrying.
• Keep products away from moisture.
• Keep products away from flammable substances or places where fierce static electricity may occur.
• Products and accessories are not to be coated or painted with chemical substances or acid that can corrode
the equipment.
• Do not expose the equipment to X-ray or Microwave. This might cause severe damage to the equipment.
• When inserting SD card, check the direction.
• When supplying electric power to G-scan with 220/100V source, use the adapter supplied by GIT only.
• When using touch screen, use the specified stylus pen only. If you use other sharp or keen object on the
touch screen, it can be damaged severely.
• Do not store the battery in the hot area. It may reduce the longevity of battery.
• If G-scan with battery pack has to be stored for a long time(over 3 months), the environmental
condition(Temperature: 23±5℃, Humidity: 65±20%RH, Battery Level Indicator: 2 of 3 levels) should be
observed.
• When your eyes contact battery liquid, do not rub your eyes, but clean out them with fresh water. And
contact doctor immediately.

• Do not expose the LCD to humidity.
• When LCD is broken, the liquid crystal material will be flown out. Do not contact liquid crystal. If you contact
it, clean it out immediately with soap and water.
• When LCD surface is contaminated, clean it using soft clothes with alcohol.
• Do not get volatile material except alcohol to LCD surface.
• Do not lay any heavy object down on LCD panel.
• After using for a long time, conduct zero calibration to the touch screen.

Hardware
Specification
Main Specification
Item Specifications
Micro Controller ARM9 (S3C2440A) @400MHz
NOR Flash Memory 16MB
Memory NAND Flash 64MB
SDRAM Memory 32MB×2
External Memory 2GB
0℃~45℃(32℉~113℉) : Battery Charging
Operating
Temperature 0℃~50℃(32℉~122℉) : Battery Discharging or without Battery
-10℃~70℃(14℉~158℉)
Storage
(Refer to cautions of manual)
Noncondensing @ 0℃~10℃(32℉~50℉)
Operating 90%RH @ 10℃~30℃(50℉~86℉)
Relative
Humidity 70%RH @ 30℃~50℃(86℉~122℉)
Noncondensing @ -10℃~70℃(14℉~158℉)
Storage
(Refer to cautions of manual)
LCD 5.6″ TFT Analog LCD (480 × 234 pixel)
Power ON/OFF Key, Enter Key, ESC Key, Arrow 4 Keys, Functional
Input Devices 6 Keys
Touch Screen 5.6 ″
External Lamps 2 Color LED × 3 (Power, DLC, Option)
Sound Buzzer 1 Tone
Rechargeable Battery Li-Ion Polymer 2100mAh 1cell
Operating Voltage 7~35VDC
Housing PC + ABS & TPE Shroud
Dimension 194×132×59 mm
Weight About 900g(Body weight including battery Pack)
Communication Interface
Item Specifications
External input/output device USB Host, USB Slave (USB 1.1)

Vehicle Communication Interface
Item Specifications
CAN ISO - 11898, ISO - 11519
K-Line/L-Line ISO-9141, ISO-9141-CARB, KWP-2000
Commercial Vehicle SAE-J1708, RS-232C
Data/Control Line Melco Pull-Down UART
Added interface
Item Specifications
VSS Vehicle Speed Simulation
Voltage Output 5~20 VDC
AC/DC Adapter
Item Specifications
Input Voltage 100~240 VAC
Frequency 50/60 Hz
Input Current 0.8 A
Output Voltage 12 VDC
Output Current 3A

FCC ID: TMGG1PDDMN001
NOTE: This equipment has been tested and found to comply with the limits for a Class A digital device,
pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against
harmful interference when the equipment is operated in a commercial environment.
This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in
accordance with the instruction manual, may cause harmful interference to radio communications. Operation
of this equipment in a residential area is likely to cause harmful interference in which case the user will be
required to correct the interference at his own expense.
CAUTION
Changes or modifications not expressly approved by the party responsible for compliance could void
the user's authority to operate the equipment.
This device complies with part 15 of the FCC Rules.
Operation is subject to the following two conditions:
(1) This device may not cause harmful interference.
(2) This device must accept any interference received, including interference that may cause undesired
operation.

Introduction of Components
G-scan Hardware Components
G-SCAN KIT (Parts No. 150109 - 00048)
Part Description Qty.
Part Name: G-scan Main Module

P/No: 150109 - 00049 1
G-scan main module for communication with vehicles.
P/Name: Carrying Case

P/No: 150109 - 00051
Preserving G-scan main module and components. For 1
preventing from being damaged and lost, G-scan should be
stored in this case after using.
P/Name: AC/DC Adapter

Adapter for supplying power to G-scan main module from AC 1
power
P/Name: AC Power Cable

Cable for AC/DC adapter
The socket plug for AC power cable can be different dependent 1
on each country. Please purchase the right plug if it doesn’t
match with your country’s electrics specification.
P/Name: CABLE-DLC
P/No: 150109 - 00050
1
DLC main cable for communication between G-scan module and
(16 pin) OBD-II diagnosis connector on vehicle.
• Please check above items at receiving the product for the first time.
• The optional item is to be sold additionally.

Basic Usage of G-scan
Power supply
1. Supply external power
There are 4 methods for supplying external DC power to G-scan.
• With DLC cable(P/No: 150109 - 00050)
• From the cigar lighter terminal in Center Facia with cable-cigar
• From the battery of vehicle through cable-battery
• From the AC/DC adapter
CAUTION
<Figure 1: Low Voltage Warning for Rechargeable Battery>
<Figure 1> is the message warning the low battery. If you see this message, supply the external power
immediately.
Otherwise, G-scan will be turned OFF automatically.

How to connect the external power
<Figure 2: Connect the External DC power to G-scan>

Description of Power Supplying Method
Power supply with the DLC cable
The vehicle with diagnosis connector terminal of the 20-Pin connector or which is satisfying the OBD-II
communication regulation can get electric power from the DLC cable without any additional power line.
NOTE : The DLC connector, in general, is located on the lower part of the driver’s front panel. This location
may be different somewhat. Please check the correct location before connecting.
From the cigar lighter terminal
Using the Cable-Cigar, the electric power can be supplied.
NOTE : When using the Cable - Cigar, the power will be off during cranking of the engine. If your G-scan does
not have rechargeable battery and you diagnose vehicle relating to the cranking of engine, use other power
supplying method.
From the vehicle battery
When power is supplied from the vehicle battery, the electric power can be supplied without interruption.
Caution at connecting the vehicle battery
• Do not get the battery power line to the driving part in the engine room.
• Do not reverse the positive(+) and negative(-) terminals.
From the AC/DC adapter
Using the AC/DC adapter, the electric power can be supplied to G-scan.
When updating G-scan, use the AC/DC adapter for supplying stable power to G-scan.
WARNING
Use only the AC/DC adapter (GHDM-260001) supplied by G.I.T for G-scan. G.I.T has not responsibility
for the damage by using other AC/DC adapter.
CAUTION
• When communicating with vehicle (for all vehicle diagnosis function with DLC cable), G-scan should
be connected with vehicles battery directly or indirectly (DLC).
• For updating G-scan, connect the AC/DC adapter for supplying the stable power.

Power ON/OFF
<Figure 1: Location of the Power S/W>
Power ON/OFF Method
Power ON
1. Please connect the power before turn on G-scan.
NOTE : For the details of power connection to G-scan, refer to “Power Supply” of the “Basic usage of G-scan”.
2. Press the “Power Switch” shown in <Figure 1> until the DLC LED and OPTION LED located on upper right
of G-scan are turned from yellow to green. (It requires about 0.5 second.)
NOTE : For the lightening color of POWER LED, refer to the “Description for Main Component of H/W” of the
“Basic Usage of G-scan” (Module: A-02-003).
After booting G-scan normally, the main screen of G-scan will be shown as <Figure 2>.

<Figure 2: Main Screen of G-scan>
Power OFF
Press the power switch for 2.5 seconds and G-scan will be turned off.

Description for Main Components of H/W
Even G-scan is operated through the touch screen, for more fluent operation, please be familiar with the
functions and positions of the buttons, connecters and LEDs.
Touch Screen and Hardware Buttons
<Figure 1: Front view of G-scan>

1. Description of front side of main module
Use the specified stylus pen at selecting functions and items on

① TOUCH SCREEN
the touch screen
Buttons for operating functions relative to buttons on the bottom

②
of diagnosis screen.
• Exits from the screen currently executed.
③ • Moves to previous process in vehicle selection screen
• Closes the pop-up window.
• Executes the item or function selected on the current screen

④
• Moves to the next screen in vehicle selection screen
• Moves the cursor to the wanted item or function on the current

screen.
• At diagnosing on dual mode, you can select the diagnosing

⑤
window with , and the items in the diagnosing
window with , .
⑥ POWER BUTTON ON/OFF the power of G-scan.
⑦ POWER LED LED showing the power condition.
⑧ DLC LED LED showing the communication condition with the ECU.
LED showing the communication condition with supplementary

⑨ OPTION LED
optional item connected to G-scan.
NOTE : As the CALIBRATION of the touch screen may be changed by the temperature variation or passing of
the time, reset the CALIBRATION of the touch screen at the “Setup” in the Configuration.
NOTE : For the details relating to the power ON/OFF, refer to the “Power ON/OFF” in the “Basic usage of G-
scan” <Module: A-02-002>.

• POWER LED Lighting Condition
Charging Full Charged

Battery Pack With DC power LED (Green) ON LED (Red) ON
Installation Without DC power LED OFF LED OFF
NOTE : If the battery pack is not installed, when the external power is connected, the Power LED light will be
Green.
NOTE : For the details of the power supply, refer to the “Power Supply” in the “Basic usage of G-scan”
<Module: A-02-001>.
• DLC LED Lighting Condition
LED operating condition

Communicate with Vehicle Control Module LED (Green) Flicker
Communication with Vehicle Control Module is OFF LED OFF
• OPTION LED Lighting Condition
Communication by USB port (Host) of G-scan main module LED (Green) Flicker
Others LED OFF

2. Description for the Communication Connecter and COM port
<Figure 2: G-scan COM port>
Connecter for connecting DLC cable to communicate with vehicle

① DLC
Control Module.
The USB Host port prepared for expanding the function by
② OPTION
connecting to additional equipments in the future.
The USB port for PC to communicate with vehicle through G-scan
PASS-THRU
in the future.
③ PC COMM
DOWNLOAD The USB port for maintenance of G-scan.

3. SD Memory Slot & Reset Button
<Figure 3: SD Memory Slot and Reset Button>
① SD Memory Slot Slot for inserting the SD card restoring the various data for driving G-scan.
When program has errors with the OS or others, press the Reset button to
② RESET Button
initialize G-scan.
NOTE
1. To eject SD card from slot, push the SD card once.
2. To reset G-scan, use stylus pen to push the reset button.

Description for layout of S/W screen
Unlike the conventional diagnostic tool, G-scan is equipped with touch screen. The images on G-scan screen
are not simple pictures but the functional buttons for operation.
This chapter describes the functions and marks commonly applied to the main screen of G-scan and other
diagnosing screen. Please be familiar with these descriptions to operate G-scan freely.
Components of the main screen
<Figure 1: Components of the Main Screen>

Description for the components of the main screen
Configuration and User’s Guide
Configure the “Setup”, “User Information”, “Software version” and

①
“Self-diagnosis”.
② Summarized user’s manual.
Vehicle Selection
Selects the vehicle model and system for diagnosing.

③
* The selected system will be shown in the blank box.
Diagnosis Menu
Shows the Diagnosis Trouble Code(DTC) on the screen by
④ communication with the selected vehicle system. Fault code will be
updated by continuous communication.
⑤ Checks the current data of ECU.
Supports supplementary vehicle S/W function except the basic

⑥
diagnosing functions (DTC, Current Data, Actuation Test).
⑦ Supports the ECU reprogramming.
⑧ Diagnoses the vehicle applied with OBD-II communication protocol.
⑨ Recording the current data for review and analysis.
Searches the DTC of selected systems, more than one system can
⑩
be searched at one time.
Mark for charging battery in connection with external power

(Lightening mark: Red)
Mark for full charged battery in connection with external power

(Lightening mark: Green)
⑪
Mark remained battery capacity in use (as battery is used, the
available battery amount is reduced.)
No rechargeable battery in the battery pack

Diagnosis Screen Layout
<Figure 2: Diagnosis Screen>
Showing the Diagnosing System and Hot Key
<Figure 3. Selected vehicle system and Hot Keys>
The diagnosing item and the model under process are shown. For the icons, refer to the following table.
Description for the Common Icons in Diagnosing Window
Closes the current window and, return to the initial main screen.
Captures the current screen and save.

The captured screen will be saved at the “Storage Card\G-scan Image\Model” folder of
SD card.
Shows the information of the system currently communicating in detail.
Changes the system for diagnosing.
Changes to the dual mode from the overall screen.
Changes to the overall screen from the dual mode.

Window for current data
<Figure 3: Current data>
Screen Function Button
<Figure 4: Screen Function Button>
Function button and corresponding screen function button are same.
NOTE : The screen function button will be changed according to the diagnosis mode (Activated window on the
dual mode).

Connecting the DLC cable
For the communication between the control module installed on the vehicle and G-scan, the DLC cable should
be connected.
<Figure 1: Connecting the DLC cable>
Vehicle with the OBD-II connector
OBD-II standard connector support communication and power.
NOTE : In general, the DLC connector is located on the bottom part of the driver’s front panel. According to
the kinds of vehicle it may be different. Therefore, before connecting, please check the correct position of DLC
Connector.
Vehicle with non OBD-II Connector
• Connecting the power

For some vehicle of which power is not supplied through connector, connect the power line additionally.
• Connecting through additional adapter

For some vehicles, additional adapter is required. After connecting the adapter to the 16 pins connecter of
the DLC cable, connect it to the diagnosis connecter of the vehicle.
NOTE : For the detailed information, refer to “Power Supply”<A-02-001> in the “Basic Usage of G-scan”.

CAUTION
<Figure 2: Disconnecting DLC cable>
Before disconnecting the main DLC cable, release the lock and disconnect.
Do not pull the wire or distort it. It may cause the damages on the cable or connector.

CAUTION
<Figure 3: Connecting the main DLC to G-scan>
Connecting the main DLC connector to G-scan, tighten the 3 clamping screws to the body of G-scan
firmly.
<Figure 4: Caution for carrying G-scan>
Carrying G-scan, do not hold the DLC cable. Hold the main module or hand strap.

Self Test Adapter
The self-test functions are used to check the Main DLC cable (P/No: 150109 - 00050) and specific related
circuits. Not all G-scan circuits are checked through the self-test functions.
Purpose and Scope of Self Test (Semi-Test)
Basic operation of the self-test function is the loop-back theory.
Loop-back theory is verification between sent data from G-scan module and returned data, which passed
through the pins of all the outside connectors during the self-test.
Some communication circuits such as high speed CAN, low speed CAN and SAE-J1708, cannot be checked
with loop-back tests.
There are 2 self-test steps included in the Self Test function on the Configuration menu.
• Step A :
Performs test functions by automatically changing circuit configurations at the inner end of DLC connector of
G-scan module.
• Step B :
Performs test functions on the Main DLC cable using the self-test adapter which will short all the terminals
(except power and ground functions) at the end of Main DLC cable.
This self-test function cannot determine open or short circuits in other adapter cables except Cable-DLC
(P/No: 150109 - 00050).
Connecting the Self-Test Adapter
Before performing the self-test function, connect the Main DLC cable (P/No: 150109 - 00050) between G-scan
module and Self-test adapter. Then, connect the other side of Self-test Adapter to the OBD-∥ Connector on
the vehicle as shown in [Figure1].
<Figure 1: Installation of the Self-test adapter>
After installing the adapter, follow the instructions as indicated on the Self-Test screen located on the
configuration menu.

Configuration
Setup
Selecting in the main screen, “Setup” screen will be shown. In this item, the brightness of touch screen can be
adjusted for the user’s favor, the language can be selected and the operation of key pad and calibration of the
touch screen can be controlled.
Introduction of the Setup Main Screen
<Figure 1: Setup Screen>
The descriptions for the screen function buttons in “Setup” are as follows.
Control the brightness of LCD screen.
Change the language.
Checks the operations ofs the 12 function buttons.
Calibrates touch screen.
Sets the diagnosis data unit and the buzzer ON/OFF.
Moves to the next tab.

Operating Order and References
Screen Brightness Adjustment
1. How to select the “Back Light”
• Select button.
• Select the at the bottom of screen.
• Select the “Back Light (F1)” on screen.
<Figure 2: Back Light Adjustment>
Adjust the brightness using stylus pen or pressing the , on the key pad.
2. It can be adjusted at 5 levels. Screen will be brighter as it is adjusted to (+).
3. Move to another setup
• Using stylus pen, move to another setup if required
• Selecting the , move to the menu and use , buttons to move another
setup if required.

Language Selection
1. How to select the “Language”.
• Select button .
• Select the at the bottom of screen.
• Select the “Language (F2)” on screen.
<Figure 3: Move to Language Selection>

2. Using the stylus pen, select your language or press , and press the . Then language list will
be shown. (ENGLISH, KOREAN)
<Figure 4: Language Selection>
3. Move to another setup
• Using stylus pen, move to another setup if required
• Selecting the , move to the menu and use , buttons to move another
setup if required.

Keypad Test
1. How to select the “Keypad Test”
• Select button.
• Select at the bottom of the screen.
• Select the “Keypad Test (F3)” on screen.
<Figure 5: Keypad Test>
2. Upon pressing the function button , arrow keys, , , the color of

selected item will be changed to orange. You can easily check the operational status of the button by the
color change.
NOTE : Pressing , buttons at the same time allows users to move setup list using
H/W button.

Calibration of Touch Screen
1. How to select the “Touch Screen Calibration (F4)”, the screen will be shown as follows.
• Select button.
• Select the at the bottom of the screen.
• Select the “Touch Screen Calibration (F4)” on screen.
<Figure 6: Calibration of Touch Screen>
2. Select the center of (+) mark on the touch screen as shown in the above figure with the stylus pen.
* Totally 5 points are shown on the screen. Select all center points of the 5 marks.
3. After selecting 5 centers of (+) marks, message is shown as <Figure 7>.
• : Save the new calibration and move to menu.
• : Cancel the new calibration and move to menu.
<Figure 7: Completion of the Touch Screen Calibration >

Setup for Unit and Buzzer ON/OFF
1. Selecting or , following setup window will be shown.
<Figure 8: Unit & Buzzer setup>
2. Setup the Unit and Buzzer operation in the setup window.
• Using stylus pen, setup on the touch screen.
• Setup using the function button
① Select the item of unit
Unit: Move to full down screen

②
Buzzer: Move to On/Off
Unit: Select the unit for display
③
Buzzer: Select ON or OFF
Unit: Move to setup list, after selection of unit.
④
Buzzer: Move to setup list, after selection of ON or OFF.
Repeat ①~④, setting-up the unit
3. After completing all items, select at the bottom of setup window.
NOTE : The selected unit at this Tab is displayed on the diagnosis mode.

Exit from “Setup”
1. After completing “Setup”, move to other Tab.
• Select to move to “User Info”.
• Using stylus pen, select the “Tab” on the upper portion of the touch screen directly to move.
2. Move to the main screen
• Select to move to the main screen.
• Select at the top right of the screen to move to the main screen.
3. Selecting ‘Move to main screen’, following message will be shown.
<Figure 9: Save Message>
Save the setups and exit to the main screen.
Cancel the setups and exit to the main screen.

User Information
This is how to input user’s personal information.
How to input the User Information
How to select the “User Info”
• Selecting the “User Info” on the touch screen using the stylus pen, following screen will be shown.
• Select the or button in the “Setup” to move to “User Info”.
How to move in “User Info” lists
• Select the items on the touch screen using the stylus pen.
• Use , to move and use to select.
<Figure 1: User Info Screen>

Input the personal information
Use the stylus pen on the touch screen to input personal information.
Inputting by using H/W buttons are not supported.
How to input
1. Using stylus pen, at the “User Info” screen, select the blank box or using and then
select the then input panel will be shown.
2. Using the stylus pen, press the input panel on the touch screen to input the personal information.
3. Select or use stylus pen to move to next.
<Figure 2: Input Panel>
How to input the User Info:
1. When the cursor move to blank text to prompt input panel.
2. To input user information in the blank text by the input panel.
NOTE
• To input user information in the blank text by the input panel.

• H/W button does not support to input the user information, please use stylus pen only.

Exit from “User Info”
Move to other Tap after fill-out user information
• Select the to move to “Version”.
• Using stylus pen, select the next “Tab” to move.
Move to main screen
• Select to move to the main screen.
• Select at the top right side of the touch screen to move to the main screen.
Save the setups and move to main screen.
Cancel the setups and move to main screen.

Version
S/W versions and serial number can be checked.
Description of Version Information Screen
<Figure 1: Version Information Screen>
Operating System G-scan OS version

S/W Version S/W version on SD card
Serial Number Serial number of G-scan main module
TPMS VAERSION TPMS Version
How to check Version
How to move to the “Version” item
• Using the stylus pen, select the on the touch screen to move to the “Version”
screen.
• Press the or button in the “User Info” to move to the “Version”.
<Figure 2: Version screen>

Exit from “Version”
Move to other Tab after check the version.
• Select the to move to the “Self Test”.
• Using the stylus pen, select the Tab at the upper side of the touch screen.
Move to the main screen
• Select the to move to the main screen.
• Select the at the top right side of the touch screen to move to the main screen.
Selecting ‘Move to main screen’, the following message will be shown.

Self Test
This is the function for checking if the circuits relating to the communication of G-scan and the DLC cable
have defects or not. If G-scan has problems relating to the vehicle communication function, conduct the test
following the instruction of the screen.
Description of Self Test Screen
<Figure 1: Description of Self Test Screen>
Checks the defects of circuits relating to the vehicle communication of G-scan.
Checks the defects of the DLC cable.
Start the Self Diagnosis Test.

Self Diagnosis Test
How to move “Self Test”
• Selecting the “Self Test” on the touch screen using the stylus pen, the following screen will be shown.
• Press the or button at “Version” to move to the “Self Test”.
<Figure 2: Move to the Self Test>
• Using the stylus pen, select it on the touch screen or press buttons, to select ,
.

STEP-A Test
The purpose of STEP-A test is for diagnosing the specific vehicle communication circuit of G-scan. During
proceeding with this test, the power is supplied by the DLC cable and the Self Test adapter. For the details of
Self Test adapter, refer to the ‘Connecting the Self Test adapter’ in the ‘Basic usage of G-scan’.
<Figure 3: STEP-A Screen>
How to test
1. Connect the DLC cable to G-scan and connect the Self Test adapter to the other end of DLC cable.
Connect the adapter to the OBD-II connector of the vehicle.
2. Turn on the power of G-scan and move to the ‘Self Test’ tab of configuration.
3. After selecting the , select the or button to perform the test.
<Figure 4: STEP-A Proceeding >

4. Check the ‘Test Result’ shown on the test result window.
<Figure 5: STEP-A Result>
No Error Found : Proceed another test of 16-pin DLC cable; begin the “STEP-B” test.
Error Found : G-scan main module may be inoperative. Contact the authorized service provider

STEP-B Test
STEP-B test is to check if the DLC main cable is broken or short on the condition that communication module
of G-scan is normal. During this test, the power is supplied by DLC cable and Self Test adapter. For the
details of Self Test adapter, please refer to the ‘Connecting Self Test adapter’ in the ‘Basic usage of G-scan.’
<Figure 6: STEP-B Screen>
How to test.
1. Connect the DLC cable to G-scan and connect the Self Test adapter to the other end of DLC cable.
Connect the adapter to the OBD-II connector of the vehicle.
2. Turn on G-scan power and move to the ‘Self Test’ tab of the configuration.
3. Select and then select or button to perform the test.
<Figure 7: STEP-B Proceeding>

4. Check the ‘Test Result’ shown on the test result window.
<Figure 8: STEP-B Result>
The test result messages are explained below:
No Error Found:
You may still need to test cable integrity by wiggling to test for intermittent connections.
If the test results indicate “No Error Found” and the vehicle communication continues to fail after the self-test
adaptor is removed, verify that the communication problem is not vehicle related; contact the authorized
service provider if necessary.
Error Found:
When the test result in self-diagnosis STEP-A is “No Error Found” but the result of STEP-B is “Error Found”,
then there is a high possibility that the 16-pin Main DLC cable (P/No: 150109 - 00050) is inoperative. Contact
the authorized service provider.

Exit from the “Self Test”
After setup the “Self Test”, move to other Tab.
• Select the to move to the “Setup”.
• Using stylus pen, select the “Tab” at the upper side of the touch screen to move.
Move to main screen
• Select the to move to main screen.
• Select the on top right side of the touch screen to move to main screen.
Selecting ‘Move to main screen’, the following message will be shown.

Vehicle Communication Function
Vehicle Selection
In order to diagnose the vehicle through G-scan vehicle model and system should be selected before the start.
More than one system can be selected and diagnosed at one time.
Introduction of Vehicle Selection Screen
For the convenience of user, it is categorized into the Model, Year, Engine, System and Option. The control
modules of vehicle selected by user are shown in the “Selected” zone on the right side.
<Figure 1: Vehicle Selection Screen>
After saving the systems selected by user, move to the main screen or the
diagnosis screen selected by user.
Cancels the systems currently selected and returns to the main screen.
Clear all systems currently selected.
Brings systems previously selected and diagnosed.
Deletes the system on which the cursor is located in “Selected” zone.

Vehicle Selection using the H/W Button
Select the on the main screen, then below screen will be displayed.
How to select Vehicle
<Figure 2: Model Selection Screen>
1. Model Selection
On vehicle selection screen, the cursor will be located at the upper portion of the Model Selecting Zone as
follows.
1 , Move and set the cursor on the model.
2 Select the model to be diagnosed. Move to “Year” zone.

,

<Figure 3: Year Selection>
2. Year Selection
1 , Move and set the cursor on the year of model
2 Select the year of model to be diagnosed. Move to “Engine” zone.

,
<Figure 4: Engine Selection>
3. Engine Selection
1 , Move and set the cursor on the year of model
2 Select the year of model to be diagnosed. Move to “Engine” zone.

,

<Figure 5: System Selection>
4. System Selection
1 , Move and set the cursor on the system of model
After selecting the system of model to be diagnosed
① When there is one system option :

2
, The system is registered in the “Selected” zone.
② When there are two or more system options :

Move to the “Option” zone.

<Figure 6: Option Selection>
5. Option Selection
1 , Move and set the cursor on the system option of model
2 Selected option type is registered in “Selected” zone

,
6. Multiple System Selection
When the number of the Systems to be diagnosed is more than one, press or
buttons to move to “system” and select other systems.
→ Repeat 4 ~ 6 for multiple system selection.
NOTE : During selecting system, when it moves to upper zone than “System” zone (“Model”, “Year”, “Engine”
zones), all previously selected systems will be cleared.

<Figure 7: Main Diagnosis System Selection>
7. Main Diagnosis System Selection
Using buttons in the “Selected” zone, locate the cursor on the wanted system and
press button. Then the mark will be shown in front of the system name as following
figure.
Main Diagnosis System : Multiple system communications are supported in “Fault Code Searching” function
only, Only one selected system (.. marked) will be communicated on other diagnosis functions.(eg: DTC
Analysis, Data Analysis, Flight Record and etc.)
8. Completion of vehicle selection
After selecting all systems to be diagnosed, select or button to complete the

vehicle selection.
9. Delete the selected system

For deleting the system registered in the “Selected” zone, select the system to be deleted in the “Selected”
zone and then select or button to be deleted.

System Selection using touch screen
• The vehicle selection process and its caution for using the touch screen are the same for using the H/W
button described.
• When the wanted items are not shown in each zone, move the scroll bar up and down to find the items.
• To delete the registered system in the “Selected” zone, select the system in the “Selected” zone again and
then select or button.
NOTE
The information of latest vehicle selection is always memorized although power is off. Select
button and then previous selection will be available.
DTC search for multi systems is supported only in function. Otherwise only selected
one system will be searched.(in DTC Analysis)
Multiple System Selection
Through more than one system can be diagnosed. Select all control modules which
may have problems in the vehicle. However, multiple systems selection is not supported for the vehicle with
some specific communication protocol type.

Fault Code Searching
In this screen, you can check DTCs of all selected systems at one time and directly move to DTC analysis or
DATA analysis screen.
Introduction for Fault Code Searching Screen
<Figure 1: Fault Code Searching Screen>
Moves to DTC analysis of selected system.
Moves to DATA analysis of selected system.
Searches the fault code of the selected system again.
Closes the current window and moves to the main screen.

Operating Sequence and Reference
Processing of fault Code Searching
Select in the main screen after completing system selection, and it will show fault
codes of selected systems as below.
<Figure 2: processing of fault Code Searching>
Move to DTC Analysis or Data Analysis
1. Using the stylus pen or buttons, select the detected DTC.
2. Select the diagnosis mode.
Move to DTC Analysis of selected system

or
Move to Data Analysis of selected system

or

• When is selected, you can erase DTC or check the data of related DTC.
<Figure 3: When ‘GOTO DTC’ is selected>
• When is selected, you can check the current data of related control module.
<Figure 4: When ‘GOTO DATA’ is selected>

DTC Analysis
In DTC Analysis, it shows detected DTC and provides related information. After item repaired related DTC can
be erased in this function.
There are 3 methods to move to DTC Analysis.
• On the main screen, select the .

→ Move to DTC Analysis of main diagnosis system ( marked in “Selected” zone).
• On “Fault Code Searching” screen, select the .

→ Move to the DTC Analysis of selected DTC.
• Select the DTC among the menu of button on “Data Analysis” screen.
→ Dual mode is supported that DTC Analysis and Data Analysis can be shown on the display at one time.
Introduction of DTC Analysis screen
<Figure 1: DTC Analysis Screen>
General Description for fault code
Freeze Frame function, shows the current data of the control module at the time of
DTC Detected
* Availability of this function is subject to control module.
Erase all fault codes saved in the control module
Erase the fault code selectively among the fault codes.

*Availability of this function is subject to control module
Shows detailed information for DTC.
* Availability of this function is subject to control module
Dual mode and other supplementary function available.

NOTE
• When fault code is many and all are not shown in one screen, move the scroll bar at right side using the
stylus pen or buttons to find.
• If you want to move back to main screen, press the button or on top right side.
Diagnosis Sequence for DTC and References
Check Tips
1. Select the DTC for detailed description.
2. Select or button, and you will see description window.
<Figure 2: Tips>
3. If you want to close the ‘General Description’, select , button again or
button.

Check Freeze Frame
1. Select the DTC for the Freeze Frame you want to see.
Freeze Frame : Specific Current data of control module at the time of DTC detected.
2. Select or button on DTC Analysis screen, you can check Freeze Frame.
<Figure 3: See the Freeze Frame>
3. If you want to close the Freeze Frame screen, select the of “DTC Analysis” on top right side of
screen <Figure 3>.
NOTE : Availability of this function is subject to control module.

Erase DTC
1. Select or button on DTC Analysis screen.
<Figure 4: Erase DTC>
2. As shown in <Figure 4>, pop-up window to ask your confirmation is displayed.
• When is selected:
→All DTCs are erased and the message will be shown.
<Figure 5: DTC erased message>
• When is selected:
→The erase of DTC will be canceled.

Selective erase of DTC
1. Select the DTC to be erased on DTC Analysis Screen.
2. Select the or button.
3. The message for confirming erasion is displayed.
• When is selected :
DTC selected in step 1) is erased and message is displayed.
• When is selected :
DTC erase is cancelled.
Check Detailed Information of DTC
1. Select DTC on DTC Analysis.
2. Select or button.
<Figure 6: DTC information>
3. As shown in <Figure 6>, DTC information window is shown.
NOTE : Availability of this function is subject to control module.

DTC Analysis with Dual Diagnosis Mode
• Check DTC Analysis and Data Analysis at the same time
1. On the DTC Analysis screen <Figure 1>, select or button, and then
Function Menu is shown as in <Figure 7>.
<Figure 7: DTC Analysis “Function Menu”>
2. On the “Function” menu, select the Current Data, and it changes to the Dual mode as shown in <Figure
8>.
• Using stylus pen, select it on the touch screen directly.
• After moving cursor using buttons, press button.
<Figure 8: Dual Diagnosis Mode of DTC Analysis & Data Analysis >

• Check DTC Analysis and Actuation Test at the same time
1. On DTC Analysis screen, select or button, and then Function Menu will be
shown as in <Figure 7>.
2. Select the “Actuation Test” on function menu, then it changes to Dual diagnosis mode as shown in <Figure
9>.
• Select it using stylus pen on the touch screen.
• After moving the cursor using buttons, press button.
<Figure 9: DTC Analysis & Actuation Test on Dual Diagnosis Mode>

• Check the ECU Information
1. On DTC Analysis screen, select or button, then the Function Menu is shown
as in <Figure 7>.
Select the “ECU Info” and then ECU Information is displayed as shown in <Figure 10>.
• Using the stylus pen, select it on the touch screen directly.
<Figure 10: ECU Information>
2. Press button to close the “ECU Information” pop-up window.

• Change to the Vehicle S/W Management
1. On DTC Analysis screen, select the or button, then the Function Menu is
shown as <Figure 7>.
2. Select the “Vehicle S/W Management” in the function menu, and then the screen changes to the Vehicle
S/W Management as <Figure 11>.
<Figure 11: Vehicle S/W Management>
Data Analysis
To check current data of control module, and you can move to data analysis in 3 different ways.
• Select the on the main screen.

→Move to Data Analysis of main diagnosis system ( marked in “Selected” zone).
• Select the at the “Fault Code Searching”

→Move to the Data Analysis of selected DTC.
• On DTC analysis, select and select current data among the menu.
→The “DTC Analysis” and “Data Analysis” of the control module communicated in the “DTC Analysis” are
shown on dual mode at one time.

Introduction of Data Analysis
<Figure 1: Data Analysis Screen>
Fixes the selected item at the top of the screen.
Splits the current data screen into left and right sides and shows maximum 26 data.
Shows the current data in graph mode.
Starts recording the selected items.
Dual mode and other functions available.
NOTE
• If the wanted data is not on display, move the scroll bar with the stylus pen or use ,
buttons to find it.
• If you want to return to initial screen, select the on top right of the screen or button.

Operating Sequence and References
Fix the Data Items
• How to fix the items
1. Select a item to fix.
2. Select at the bottom of the screen, button, or double click the item using the
stylus pen on the touch screen, then the selected item will be fixed at the top of the screen as shown in
<Figure 2>.
<Figure 2: Fix the Data Item>
• How to release the fixed item
1. Select the fixed item again.
2. Select at the bottom of the screen, button or double click the item to be
released using the stylus pen on the touch screen.
NOTE : The speed of updating current data is dependent upon the number of fixed(selected) items.

Full
• Display maximum item number of current data on screen. On the Data Analysis screen, select
or button, then the screen will be divided as shown in <Figure 3> and
maximum 26 data items are shown.
<Figure 3: See in Full>
• Return to Normal screen.
On Full screen mode, press or button.
NOTE
• On the screen in Full mode, FIX and graph functions are not available.
• Find wanted data moving the scroll bar with the stylus pen or use the control navigation.
• If full name of data item is not shown, select the item using the stylus pen, then full name can be shown by
moving to left side.

Graph
1. Select the item to fix in text mode.
2. Select or button, then the selected item will be shown in graph mode as in
<Figure 4>.
<Figure 4: Graph mode>
① Max Maximum value of selected item’s output
② Current Current value of selected item’s output
③ Min Minimum value of selected item’s output
Initialize the Max and Min values output in graph.
Change displayed item in graph mode.

• Add/Delete the graph list using .
<Figure 5: Item List>
① In graph mode, select , then Item List is shown as in <Figure 5>.

(The item having “*” mark among the List is currently displayed in graph mode.)
② Select the item to be deleted among the list in graph mode using , and
buttons or using the stylus pen on the touch screen.
③ Select the item to be displayed in graph mode among the list using , and
buttons or using the stylus pen on the touch screen.
④ If you want to check current data in text mode, press the button or .
NOTE : The number of current data to be displayed in graph mode is 4 at most on single mode, and 2 on dual
mode.

Record
1. Users should fix the data before recording.
Please refer to “Fix” function in the Data Analysis chapter.
<Figure 6: Fixing record items before record>
2. Select button or .
<Figure 7: Select record mode>
Select Record mode and click button as in <Figure 7>. Then it will start recording data
as in <Figure 8-1> or <Figure 8-2> and recording status lamp on top right of the screen will be flickering.

<Figure 8-1: Recording in text mode>
<Figure 8-2: Recording in graph mode>
Finishes recording data
Marks the moment of triggering during recording the data.
Recording check lamp. During recording data, it turns on in red. (Normal:

black, Record: red)
NOTE : Please refer to <A-04-009> for data record and how to use buttons.
NOTE : Record screen can be switched to graph mode by select or buttons in

<Figure 6>.
NOTE : Recording function screen will be changed to full size screen and start recording when
or button is selected on dual diagnosis mode.

Data Analysis on Dual Diagnosis Mode
• Check the Data Analysis and the DTC Analysis at one
1. On Data Analysis screen select or button, and then the Function Menu will
be shown as in <Figure 9>.
<Figure 9: Function menu in Data Analysis>
2. On the function menu, select the “DTC” to change the screen to the Dual mode as shown in <Figure 10>.
• Using the stylus pen, select it directly on the touch screen.
• Moving the cursor using , and press the button.
<Figure 10: Data Analysis & DTC Analysis on Dual Diagnosis Mode>

• Check Data Analysis and the Actuation Test at one time
1. On Data Analysis screen, select or button, and then the Function Menu will
be shown as in <Figure 9>.
2. On the function menu, select “Actuation Test”, and screen will be changed to Dual mode as shown in
<Figure 11>.
• Moving the cursor using , and press button.
<Figure 11: Data Analysis & Actuation Test on Dual Diagnosis Mode>

• Check the ECU Information
1. On Data Analysis screen, select or button, and then Function Menu will be
2. On the function menu, select the “ECU Info”, then the ECU Information popup window as in <Figure 12> is
shown.
<Figure 12: ECU Information>
3. Press button at the bottom of the “ECU Information” to close the window.

• Change to Vehicle S/W Management
1. On Data Analysis screen, select or button and then Function Menu will be
2. On function menu, select the “Vehicle S/W Management”, then screen will be changed to Vehicle S/W
Management as in <Figure 13> is shown.
<Figure 13: Vehicle S/W Management>

Actuation Test
Through the "Actuation Test", you can check whether control module or component is defected or not.
There are two methods of using “Actuation Test”.
z At “DTC Analysis”, select the "Actuation Test" on function menu.

→ “DTC Analysis” and "Actuation Test" will be displayed on dual mode.
z At “Data Analysis”, select "Actuation Test" on function menu.

→ “Data Analysis” and "Actuation Test" will be displayed on dual mode.
Description of Actuation Test screen
<Figure 1: Actuation Test & Data Analysis on dual mode>
<Figure 2: Actuation Test overall screen>
Change to the "Actuation Test" on full screen:
Select on top right of the screen<Figure 1>, and it will be changed to full screen mode as in <Figure 2>.
Change to Dual Mode from full screen:
Select on top of <Figure 2>, then the screen will be changed to dual screen mode as in <Figure 1>.

Left Zone of "Actuation Test" Screen:
You can check the list for actuation test. Move the scroll bar by using the stylus pen or
button to select.
Right Zone of "Actuation Test" Screen:
You can check the Duration, Test Condition and Test Result.
Bottom zone of “Actuation Test” screen
Starts the test for the selected item.
Finishes the test for selected item.
Changes to the Current Data, DTC, ECU Info, or Vehicle S/W management.
How to execute the Actuation Test
1. Select the Actuator for Actuation Test

At the left zone of “Actuation Test” screen, select a item directly using stylus pen on the touch screen or
move the cursor using , buttons.
2. Check Actuation Test condition and set vehicle

After checking the “Duration” and “Condition” at the right zone of “Actuation Test” screen, set the vehicle
accordingly.
3. Start Actuation Test
Select or button to start the test.
4. Check the Actuation Test result

Test result (Failure or Success) will be show at the right zone of the “Actuation Test” screen.
5. Stop the Actuation Test
When duration is fixed Test will be finished when duration is over automatically.
When duration is not fixted After checking the result, select or to finish
the test.
NOTE : Test could be finished when or selected, although duration is fixed

Vehicle S/W Management
It contains all supplementary functions except the DTC Analysis, Data Analysis, Actuation Test. It provides
various supplementary functions according to vehicle control module.
Main Screen of Vehicle S/W Management
<Figure 1: Vehicle S/W Management Screen>
Function for initializing the adaptive value in ECU.
Function for setting the option such as ABS and TCS

configured in ECU.
NOTE : This screen is the item list for specific vehicle. According to the system control module, the item list for
“Vehicle S/W Management” may be different.

Example of Vehicle S/W Management Function
Resetting Adaptive Values
The "Resetting Adaptive Values" function is used to reset adaptive learn data on specific ECUs.
z On the main screen, select , then screen will show the window as in
<Figure 2>. After checking the conditions shown in screen, select or button.
<Figure 2: Resetting Adaptive Values - STEP 1>
z After checking the conditions shown in the message window, select to initialize the
adaptive value.

z Checking the following message, select to complete initialization of adaptive value.
Version Configuration
The “Version Configuration” function is used to configure the functionality of the ECU or to activate or
deactivate additional modules.
On the main screen, select , then following window will be shown. After
checking the sentence on the screen, select the proceeding item.
<Figure 5: Version Configuration - STEP 1>

z After checking the conditions on the message window, select the button.
<Figure 6: Version Configuration – STEP 2>
z After showing the following message, select . Then the ECU option setup is completed.
<Figure 7: Version Configuration - STEP 3>

ECU Upgrade
This is to upgrade the ECU program to enhance the performance of ECU. Please be familiar with the
instruction and caution before ECU upgrade and then perform the ECU upgrade. Incompliant ECU upgrade
may cause serious damages on the ECU.
Introduction of the ECU Upgrade screen
<Figure 1: ECU Upgrade Screen>
Upgrades the ECU for the selected event automatically.
Upgrades ECU manually in case auto upgrade is not possible
Shows the Technical Service Bulletin of selected event.

It should be checked before ECU upgrade.
Shows all events list to upgrade ECU.

Check all list
Select or button on ECU upgrade screen, and you will see all events list to
upgrade ECU.
<Figure 2: List All screen>
Note: Upgrading ECU or checking TSB is not available on “List All” function. Please select
or button to go back to ECU upgrade screen main for further operation.
How to ECU Upgrade
How to use the Auto Upgrade
When the ECU of relating vehicle has event to be upgraded and not upgraded yet, the auto upgrade is
conducted on the Auto Mode.
1. On the main screen, select , then screen will be changed to the event selection
screen as in the following figure, and all events applied to the vehicle are shown. If there is no event applied,
it will not be changed from the main screen to the event selection screen.

<Figure 4: TSB>
Notice: After selecting the event to be upgraded, select at the bottom of the screen and
check Technical Service Bulletin.
2. After selecting the event on the event selection screen, select or button, then
the screen will be changed to prepare ECU upgrade as follows.
<Figure 5: ECU Auto Upgrade – STEP 1>

Error or Information Message:
When the vehicle was upgraded already with selected event
<Figure 6: ECU Auto Upgrade -Information>
Wrong event is selected and applied.
<Figure 7: ECU Auto Upgrade – Error >

3. Select in <Figure 5> at the bottom of ECU upgrade windows, then following message will
be shown.
CAUTION
<Figure 9: Low Voltage>
The pop up screen warns low voltage of battery prompted in the STEP 2 battery voltage check level.
To follow the instruction given before proceeding the ECU upgrade.

4. As it confirms the voltage is normal, select button, and upgrade will be started as shown
in following figure.
5. After completing all ECU upgrade procedure, the following message will be shown.

Error Message:
If an error occurred during upgrade ECU, the following message will be displayed.
<Figure 12: ECU Auto Upgrade – Error>
Caution for processing
The time required to complete an ECU upgrade will vary. Menus and buttons are all disabled during the
upgrade process.
CAUTION
Following instructions should be kept during the upgrade process, otherwise ECU may be damaged.
z Do not start the engine or turn the ignition key OFF.

z Do not operate any vehicle accessories during the upgrade process.
z Do not disconnect G-scan during the upgrade process.
z Review the TSB (Technical Service Bulletin) before upgrade, as upgrade procedures can be different
for each event.

How to conduct the Manual Upgrade
The manual upgrade of ECU is required only when auto upgrade is failed, Unlike the auto upgrade, user
should select the event and enter the password.
1. On the main screen, select , then the screen will be changed as following figure
and all events to the vehicle are shown.
<Figure 14: TSB>
After selecting the event to be upgraded, select at the bottom of the screen to check
before upgrade

2. After selecting the event, select or button, then the screen will be changed to
the system selection screen as shown in following figure.
<Figure 15: ECU Manual Upgrade – STEP 1>
CAUTION
Please make sure to select compliant system of the vehicle specification.
3. Select or button, then the message window requiring password will be

displayed as following figure.

4. After entering the password using the stylus pen as following figure, select at the bottom
of the message window.
How to input the password:

① When the cursor move to blank text to prompt input panel.
② To input password in the blank text by the input panel.
NOTE
• If you’d like to move the input panel, to drag the upper-side of input panel to move input panel by stylus pen.
• H/W button does not support to input the password, please use stylus pen only.
5. If the password is correct, the following preparing screen will be displayed.

6. Select at the bottom of the upgrade proceeding window, then following message will be
shown.
CAUTION
<Figure 20: Low Voltage>
The pop up screen warns low voltage of battery prompted in the STEP 5 battery voltage check level.
To follow the instruction given before proceeding the ECU upgrade.

7. As it confirm the voltage is normal, select to start upgrading as shown in the following
figure.
8. After completing all ECU upgrade, the following message will be displayed.

◈ Error Message:
If any error occurred during ECU upgrade, the following message will be displayed.
<Figure 23: ECU Manual Upgrade- Error>
◈ Error Message: No ROM Data
<Figure 24: ECU Upgrade Data Error Message>
This is the error message appeared when ECU upgrade is tried without ROM data for ECU upgrading. (When
there is no ROM data, the event item is shown in vague.)
< Could not find any corresponding data on G-scan for ECU upgrade. Please run PC-utility program
with connecting internet and update the SD card to download ROM data. >

CARB OBD-II
CARB OBD-II is to diagnose the power train of the vehicle which uses CARB OBD-II protocol.
CARB OBD-II
<Figure 1. CARB OBD-II Function List>
CARB OBD-II Function Menu
On the CARB OBD-II screen, select or button. And then the pop-up menu for
the OBD-II function will be shown as <Figure 1>.
In G-scan CARB OBD-II, the detail function will be changed only using the pop-up menu as <Figure 1>.
NOTE
• When conducting diagnosis in the CARB OBD-II, the location of DTC analysis is fixed on the bottom and
CARB OBD-II Function will be located on upper part.
• According to the ECU specification, the list in the pop-up menu may be different.

Readiness Test
The type and result of the READINESS TESTS supported by more than one MODULE within the vehicle will
be displayed. The number of DTCs present and the MIL status will also be displayed.
<Figure 2: DTC & Readiness Test>
Current Data
The CURRENT DATA MODE allows for sensor values and switch states to be displayed, based upon the
concept that one item may be supported by several modules. Supporting module information is displayed in
this mode.
< Figure 3: DTC & Current Data>

Freeze Frame Data
The FREEZE FRAME DATA displays the data values stored in the Engine Control Module at the point when
the first conformed DTC is detected.
< Figure 4: DTC Analysis & Freeze Frame>
Diagnostic Trouble Code
At this level, DIAGNOSTIC TROUBLE CODES (DTC) are Displayed based upon the concept that several
modules may support one DTC. Supporting module information is displayed in this mode.
< Figure 5: DTC Analysis>

O2 Test Result
The results of the on board oxygen sensor monitoring test can be displayed in this mode. Note that only items
related to the oxygen sensor will be displayed.
<Figure 6: O2 Test Result>
Monitoring Test Result
The results of on board monitoring tests conducted during normal driving are displayed this mode.
< Figure 7: DTC Analysis & Monitoring Test Result>

Test or Component Control
<Figure 8: Test or Component Control >
Vehicle Information
<Figure 9: Vehicle Information >

In-USE Performance Tracking
This data is used to support possible regulatory requirements for In-use Performance Tracking. Manufacturers
are required to implement software algorithms that track in-use performance for each of the flowing
component:
z Catalyst bank 1
z Catalyst bank 2
z Primary oxygen sensor bank 1
z Primary oxygen sensor bank 2
z Evaporative 0.020” leak detecting system
z EGR system
z Secondary air system
The numerator for each component or system shall track the number of time that all conditions necessary for
a specific monitor to detect a malfunction have been encountered. The denominator for each component or
system shall track the number of times that the vehicle has been operated in the specified conditions. These
conditions are specified for each monitored component or system.
The ignition counter shall track the number of times that the engine has been started. All data items of the In-
use Performance Tracking record have to be reported in the order as shown.
<Figure 10: In-USE Performance Tracking >

Flight Record
The function of flight record is to save the current data of control module in order to offer valuable data which
can be retrieved at any time for analysis.
Providing the trigger function (marking specific timing) and “DTC Record” mode, the staus of the control
module can be checked at the moment of the DTC occurred or abnormal symptom.
Starting the Flight Record
Select on the main screen, pop-up window as <Figure 1> will be shown.
<Figure 1: Record/Review Selecting Box>
Record Saves the data by Flight Record function
Review Retrieves a Flight Record file saved previously

Starting the Record Mode
1. In the selection box of <Figure 1>, select the Record Mode using the stylus pen or
buttons and press button or , then <Figure 2> screen will be shown.
<Figure 2: Flight Record Main Screen>
Recording check lamp. During recording data, it turns on in red.

(Normal: black, Record: red)
Starts recording selected item.
Selects the item for recording.
Separating the service data screen into two(left & right), 26 data are shown in
the screen at maximum.
* In Full mode, Recording is not supported.
Selected item can be shown in graph.
NOTICE
• When item is not shown, move the right scroll bar using the stylus pen, or pressing
buttons to find.
• If you want to return to main screen, select on top right side or button.

2. On the screen of <Figure 2>, choose the items and select or button to fix.
<Figure 3: Selecting the item for saving>
Note: When the number of selected item is large, the data recording speed would be slower according to the
vehicle communication protocol.
3. After fixing the items, select or button and following selection box will be
shown.
<Figure 4: Record Mode Selection Box>
Manual Record Record data until is pressed manually.
Records data until DTC occurs and pop-up window of termination of record will
DTC Record be displayed, And you can also stop it manually by
selecting .

4. In <Figure 4>, select the Record Mode and select , then it starts recording as shown in
<Figure 5-1> or <Figure 5-2>. The recording lamp will turn on in red.
<Figure 5-1: Text mode recording>
<Figure 5-2: Graph mode recording>
Stop recording data
When user wants to mark a certain moment during recording data, user
selects the Trigger button to mark the time.
Note: Record processing screen of <Figure 5-2> is shown when the data recording is processed in graph
mode after selecting or button in <Figure 3>.
NOTICE
• During recording the Data, it is not possible to switch the graph mode to the text mode (vice versa.)
• At switching from text mode to graph mode, at most 4 items can be selected.

Stop Recording the Data in each Record Mode
Stop Recording the Data and Create the Data file in Manual Record Mode
1. During recording the data, press or button, the data saving confirm window
is shown as in <Figure 6>.
<Figure 6: Data Saving Confirm>
2. Recording data is stopped at selecting and the data saving confirm pop-up window is
: Save the data and another pop-up window will be displayed as in <Figure 9>.
: The pop-up window for re-confirming the cancelling of data saving as in <Figure 7>.
Select button in <Figure 7>, the recorded data will be deleted
(at selecting button, return to <Figure 6>).
<Figure 7: Data Saving Cancel Re-confirm>

NOTE
<Figure 8: Saving Stop Recording Pop-up in 1hr of Data Recording >
When data recording time reaches to 1 hour, the message as in <Figure 8> will be shown and the data
recording is stopped automatically.
If additional Data recording is required, save the currently recorded data and re-start the record mode.
3. Select in the data saving confirm window in <Figure 6>, additionally confirming window
for checking the data saving path and saving file name will be shown as in <Figure 9>.
Select , and the save mode is terminated.
<Figure 9: Data Recording Information Confirm>
Note: To change saved file name, please refer to the ‘How to change the file name’ in rear page.

Stop the Recording Data and Create the Data file in DTC Record Mode
1. When DTC occurs or the user selects as in the manual mode, the window for confirming
the stop recording will be shown as in <Figure 10> or <Figure 6>.
<Figure 10: Saving Stop Message by DTC occurrence>
At occurring DTC, the recording is stopped and the pop-up window for confirming data saving as in <Figure
10> will be shown.
: Save the data using pop-up window as in <Figure 13>.
: The pop-up window for re-confirming the cancelling of data saving as in <Figure 11>.
Select in <Figure 11>, the recorded data will be deleted
(at selecting , return to <Figure 10>.
<Figure 11: Data Saving Cancel Re-confirm>

NOTE
<Figure 12: Saving Stop Pop-up at 1hr of Data Recording >
When for data recording time reaches to 1 hour, the message as in <Figure 12> will be shown and the data
recording is stopped automatically.
If additional data recording is required, save the currently recorded data and re-start the record mode.
2. Select in the recording stop confirming window in <Figure 10>, the saving data
confirming window for checking the data saving path and saving file name will be shown as in <Figure 13>.
Select , and the save mode is terminated.
<Figure 13: Data Recording Information Confirm>
Note: To change saved file name, please refer to the ‘How to change the file name’ in rear page.
Note: When the data recording confirm window is shown as <Figure 9> at saving the Flight Record file, the
saved file name is used as default file name. When user wants to change the file name, select the file
name zone in the saving information window using the stylus pen, then the Input Panel as <Figure 14>
is shown. After changing the file name, select .

How to change file name
<Figure 14: Change the saving file name>
NOTE
How to change the file name
③ On the screen of <Figure 13>, select the region under the file name using stylus pen, then an Input Panel
is shown.
④ Using button in the Input Panel, delete the default file name.
⑤ Input new file name in the file name box using the Input Panel.
⑥ Select in <Figure 13>, the Flight Record file is saved.
NOTICE
• If is covered by the Input Panel, drag the upper side of the Input Panel using the stylus
panel, then you can move the Input Panel.
• H/W button does not support to change the file name. Use stylus pen only.

How to use the function button at analyzing the recording data of flight record
Function Button of Flight Record Data Analyzing Screen
After completing Flight Record, the screen is changed to <Figure 15-1> or <Figure 15-2>, as the recorded
Data can be analyzed.
<Figure 15-1: Data analyzing in graph mode>
<Figure 15-2: Data analyzing in text mode>
Play backward or stop.
Play forward or stop.
Scale up the analyzing Data on time axis.
Scale down the analyzing Data on time axis.
Resets the data recording condition.
Show the Function menu

* For details, refer to the “Function Menu of Flight Record Data Analyzing
Screen” described in next page.

Function Menu of Flight Record Data Analyzing Screen
<Figure 16: Show the Function Menu>
Among the data item recorded in the Flight Record function, change the data
① Item List
item to show in graph mode (Available in graph mode only).
② Text/Graph Switch between text mode / graph mode.
③ Two Cursor A Cursor “A” can be repositioned in the time division by activating Cursor “A”
Cursor “B” can be repositioned in the time division, by selecting cursor “B” in
④ Two Cursor B
item list and activating cursor “B”
⑤ Go To Trigger Move where trigger button is pressed.
Initializes the Max/Min of Data shown on the right zone. (Available in graph
⑥ Reset Min. Max.
mode only.)
Show information of saved Data.
⑦ Recorded Data Info. (File Information, Vehicle Information, Time Information, and Record Mode
Information)

1) Change the data item in graph mode using “Item List”
<Figure 17: Change item to display in graph>
① In graph mode, select and select “Item List” to be seen as <Figure 17>.
(The item having “*” mark in front of item name in the List is currently shown in graph.)
Note: In graph mode, Maximum 4 items can be selected and shown at one time.
② Select the item in the list you want to deselect which is currently shown in graph by using
buttons and pressing button, or using the stylus pen.
③ For the item you want to show in graph mode, select it in the list using
buttons and pressing button, or using the stylus pen to mark “*” in front of item name.
2) Switching Record Data Output mode using “Text/Graph”
<Figure 18: Change to text mode>
Among the function menu after selecting in graph mode, select “Text/Graph”, and then the
graph mode screen will be changed to the text mode as shown in <Figure 18>.

3) Check the Min/Max using “Two Cursor” function
“Maximum” and “Minimum” value can be checked by using “Two cursor function”
<Figure 19: Data analysis using “Two cursor” function>
Cursor “A” Red
Cursor “B” Green
Note: “Two cursor function is only enabled in graph mode. Convert text mode to graph mode
<Repositioning “A” cursor location>
Use Stylus pen or H/W button to reposition cursor “A”.
Touch Screen Use stylus pen to position cursor “A”.
Arrow Key Use , button when cursor “A” is activated
Note: If cursor “B” is activated, select to retrieve list, then select cursor “A” to activate and
position cursor “A”
<Figure 20: Positioning Cursor “A” >

<Repositioning “B” cursor location>
① Select to retrieve list then select “ Two Cursor B”

② Use stylus pen or H/W button to reposition “B” Cursor.
Touch Screen Use stylus pen to position cursor “B”.
Arrow Key Use , button when cursor “B” is activated
<Figure 21: Repositioning Cursor “B” >
<Deactivating two cursor function>
With cursor “B” activated, select , then select “Two cursor B” to deactivate cursor “B”.
Note: The mean of data displayed on the right side section(or screen) under Two Cursor mode.
<Figure 22: Data value at two cursor mode>
① Max Maximum value of Data detected in the region between cursor “A” and cursor “B”
② Current Value Data value detected at Cursor “A” position
③ Min Minimum value of Data detected in the region between cursor “A” and cursor “B”
④ Time The time differences between Cursor “A” and Cursor “B”

4) Check the Data at Trigger timing using “Go To Trigger”
<Select “Go to Trigger” in graph mode>
Select and select “Go To Trigger” then the Cursor “A” is going to be positioned where user
marked using during recording the data by Flight Record function.
<Figure 23: Select “Go To Trigger” in graph mode>
<Select “Go to Trigger” in text mode>
Select the “Go To Trigger” function, then you can check the current data of each recording item when user
marked using .
<Figure 24: Select “Go To Trigger” in text mode>

5) Reset Min/Max
Select and select “Reset Min/Max”, then all the data shown in the right zone are reset.
②
④
③
<Figure 25: Reset Min/Max>
① Max Maximum value among the data detected at Cursor “A” position
② Current Data value detected at Cursor “A” position
③ Min Minimum value among the data detected at Cursor “A” position
④ Time The time from recording Data to Cursor “A”.

6) Recorded Data Info.
In the function menu shown by selecting , select “Recorded Data Info.” function, then the
information regarding the saved data can be checked.
<Figure 26-2: Pop-up window for Record Data Information >
<Figure 26-1: Pop-up window for Record Data Information>
① Check the saving path and size of the recorded file.
② Check the vehicle model and year of the recorded Data.
Time Information of recorded Data

③ • Trigger Time(Marked point of specific timing)
• Recording Time(Duration of saving data)
Record Mode Information of the recorded Data
④ • Stop Condition
• DTC Code

How to use the Data Review function
This is the function to review for analysis of recorded data in Flight Record function.
Retrieving of the recorded data
1. Select on the main screen and select “Review” in the pop-up window as <Figure 27>.
select .
<Figure 27: Record/Review Selection Box>
2. In the pop-up window as <Figure 28>, select the Flight Record data file which you want to see and
select .
<Figure 28: Select the Record File in Pop-up Window>
Note: The Data recorded by Flight Record is saved with the extension of “.GSR”.

Finding data directories for individual vehicle
z Move to upper folder using selecting “••”
After moving the cursor, select “••” using , buttons and press button
or using the stylus pen.
<Figure 29-1: Move to Upper Folder>
z Select the Data

After moving the cursor, select the folder using , buttons and press
button or using the stylus pen.
<Figure 29-2: Data saved in folder of each vehicle model>

How to analyze the recorded data
The method for analyzing the recorded data is the same with the method described in the “How to use the
function for analyzing the recorded data of Flight Record”.
<Figure 30: Data Review in graph mode>
<Figure 31: Data Review in text Mode>
Play backward or stop.
Play forward or stop.
Scale up the analyzing Data on time axis.
Show all the recorded data files of Flight Record and user can open the new
file.
Resets the data recording condition.
Show the Function menu

* For details, refer to the “Function Menu of Flight Record Data Analyzing
Screen”.

PC Utility
PC Utility Installation
NOTE : G-scan PC Utility requires the Microsoft Windows 2000 operating system or later.
1. Insert G-scan PC Utility Software to the CD ROM.
NOTE : You may see the following dialogue box during installation of PC Utility on PC with Windows Vista,
and select "Allow" to start PC Utility Installation.

2. Install Shield will start automatically in a few seconds.
3. Press “Next” button in following dialog.

4. Press “Install” Button in following dialog.
5. Installing PC Utility S/W.

6. Installing G-scan USB driver.
7. After Installing USB driver, Adobe Reader program will be installed automatically.

8. Press "Next" button in following dialog.

11. Press "Install" button in following dialog.

12. Installing "Adobe Reader” S/W.
13. Please press "Finish" button to complete Adobe Reader installation.

14. “G-scan PC utility” installation is completed. Please press “Finish” button to complete the installation.
15. The icon will be displayed after installation is completed.

NOTE : You may see the following dialogue box when you run PC Utility on PC with Windows Vista, and
select "Allow" to start PC Utility.

How to use PC Utility
PC Utility is the specific program for maintaining the Data and S/W of G-scan at the latest version and for
recovering the system.
Before using the PC utility program, you should read the manual carefully.
Description for the PC Utility
<Figure 1: PC Utility Main Screen>

① Updates the Data of G-scan and the O/S saved in SD card.
Checks the version of the S/W installed in the SD card and the
②
version of S/W registered in the server.
Function for recovering this equipment to initial condition when G-

③
scan S/W has error or a new SD card is used (including format).
Function to review the recorded data using the G-scan and analyze
④ data from the Flight Record & Captured image. - Flight Record Data
- Screen Capture Data
⑤ Offer a function to view the User Manual.
⑥ Use the Q&A board of server.
⑦ Select user’s language.

How to use PC Utility
Run the PC Utility
<Figure 2: PC Utility Main Screen>
Double click the PC Utility icon on the desktop to run. The main screen of the PC Utility will be shown as in
<Figure 2>.
NOTE : Your PC should be connected to internet prior to use PC Utility. Otherwise, it is restricted to use full
function of the PC Utility.
NOTE : The button having ⓘ mark on the PC Utility main screen can be used only when the internet is
connected.

Start Update
Performs the update so that G-scan maintains up to its latest version of O/S and data.
Method of G-scan update
<Figure 3: Choosing the method to update>
Select on the main screen of PC utility, pop up windows as <Figure 3> will be shown.
If PC is connected to the internet, G-scan can be updated by

lastest version file that downloaded from update server.
When internet update is not available, you can update it manually

by receiving update file (*.zip) through e-mail or through other
channels.

Internet Update
<Figure 4: Run the Start Update>
If is selected, It will download the update file through the internet to

update the data and O/S files to SD card.
NOTE : Execution of is available when SD card is inserted to PC drive through the

reader.

<Figure 5: Update Reinstall Message>
NOTE : When the latest version registered in G-scan Update server is the same with the version registered in
the SD card, the follow message will be shown. If you want to reinstall with the same version, select
When update file is downloaded, the following message will be shown.
<Figure 6: Upgrade Complete Message>
Press the “Close” button to close the message dialogue.

Insert the SD card into the memory slot of G-scan.

<Figure 7: Update Error Message>
1. Generated errors during updating
This is the message shown when error is occurred during Update.
Check if the drive of SD card is found. Run the Update function again.
<Figure 8: Update Drive Found Message>
2. When the target drive for G-scan Update cannot be found
This is the message shown when the drive installed with G-scan S/W cannot be found.
• When the SD card installed with G-scan is not connected to the PC through the Reader
→ Connect the SD card and retry.
• Even the SD card is connected to the PC through the Reader, G-scan SD card is accidentally formatted or
because it is a new one
→ Using “Recovery” function, recover the Data and retry.

<Figure 9: Disconnecting with Server during update >
3. Disconnected during proceeding of update

This is the message when PC is disconnected from internet. Check the internet connection of PC and retry.

Manual Update
This is the function for updating when internet update from the server is impossible because the PC is not
connected to the internet.
<Figure 10: File search window of Manual update>
On the PC Utility main screen, select button, then the file search
window will be shown as in <Figure 10>.
Select the update file from the drive saving the manual update file using the searching window as
in <Figure 10> and press the “OK” button.
After pressing button, repeat same procedure with the
function.

Recovery
On G-scan PC Utility Main Screen, select , then G-scan Data and O/S files
saved in the SD card will be recovered to the initial state as follows.
<Figure 11: Run G-scan Recovery>
Unknown Error during Recovery function
<Figure 12: Error during Recovery>
This is the message shown when unknown error is occurred during Recovery.
Check if the drive of SD card is found. Retry the Recovery function again.

<Figure 13: Setup Window for selecting SD card drive of Reader>
NOTE : When previous Data of G-scan is not in the SD card by formatting the card or replacing with new one,
message as in <Figure 13> will be shown.
After setting up the drive installed with SD card exactly, press the “OK” button.
CAUTION
When using the Recovery function, the drive installed with SD card should be set exactly. If a wrong
drive is selected, the SD card cannot be recovered.
Data recovered into SD memory is the data version for recovering system suggested in the PC
Utility CD. After using the recovery function, use function to update.

Check Version
<Figure 14: G-scan Version Check Window>
This is the function for checking the latest version of G-scan S/W in the server and the current version (Local
Version) of G-scan S/W installed in SD card.
On G-scan PC Utility main screen, press button.
① The latest version of G-scan S/W registered in the server.
② The version of the S/W installed in SD card of G-scan.

Data Viewer
<Figure 15: Recorded Data selection>
When button is clicked from the PC Utility main screen, following pop up
screen will be displayed as shown in <Figure 15>.
From <Figure.15>, select the recorded data.
Function to review and analyze the recorded data from Flight

Record function.
Function to review the captured image from the Screen Capture

function.

◆ Flight Record Data Review
<Figure 16. Recorded fie list>
Copies the recorded file from SD memory card to PC to directory [C:\g-

scanupdate\BACKUP\Flight Record].
Deletes the selected file from the PC or SD memory card.
Retrieves the selected data from PC or SD memory card.
Closes the selection window.

<Figure 17. Flight Record data viewer>
NOTE : Please refer to the Flight Record <Module : A-04-009> of Vehicle Communication Function for
functions on buttons.

◆ Screen Capture Data Review
<Figure 18. Captured image list>
Copies the captured image from SD memory card to PC to directory [C:\g-

scanupdate\BACKUP\IMAGES].
Deletes the selected file from the PC or SD memory card.
Prints the selected image from the list.
Closes the image list window.

User’s Manual
<Figure 19: List of User’s Guide>
On the PC Utility main screen, select button. The User’s Manual list is
<Figure 20: Show the User’s Guide>
Select the list in <Figure 19>, then the details of list can be shown.

Q&A
<Figure 21: Q&A Page>
On the PC Utility main screen, select button. Through the internet, Q&A page is
connected as shown in <Figure 21>.
<Figure 22: Page for writing the Q&A >
Select in <Figure 21>, then it changes to the window for making comments and
questions of user.

Appendix
Optional Item Installation and Expenditure Exchange
The optional item should be installed to G-scan according to the method described in the manual. Otherwise,
it may cause defects on the product.
Battery Pack Installation
<Figure 1: Position of the Pack Mounting Bolt>
1. Loosen the Package mounting bolts from the 4 points shown in <Figure 1>.
2. Detach the pack from the main module carefully. (If excessive force is applied, the product may be
damaged.)
3. Attach Battery Pack to the main module.
4. Tighten the 4 mounting bolts.

Exchanging the Rechargeable Battery
<Figure 2: Open the battery cover>
1. For installation and removal of the Pack, refer to the Battery Pack Installation.
2. Open the battery cover of Pack disassembled as shown in <Figure 2>.
<Figure 3: Remove the battery>
3. Remove the used battery as shown in <Figure 3>.

<Figure 4: Install the New battery>
4. Check the battery terminal shape of the new rechargeable battery, insert it properly.
5. Locate the new rechargeable battery into the case correctly.
6. Close the battery cover and attach the pack according to the manual.
CAUTION
• Be careful of the connector direction not to change the polarity of the rechargeable battery.
• After installing the connector, be careful that the battery wiring is not damage by the battery cover.
• After the rechargeable battery cover is closed completely, the Pack should be mounted on the body
module.

Exchanging the Cigar-Cable Fuse
<Figure 5: Disassemble the Cable . Cigar>
1. Turning the portion marked in the <Figure 5> to the counter clockwise direction with the 10mm Hexagonal
wrench, it is disassembled as shown in <Figure 5>.
2. After exchanging the fuse (250V, 4A), assemble it in reversed order of disassemble.

O/S Update
This is the chapter for how to update the O/S which are the basic system for operating this equipment.
O/S Update
With SD card installed, press the & buttons at the same time and turn on the
power.
O/S Update Conditions
• Supply the electric power using the AC/DC adapter.
• The version of current G-scan and that of the O/S update file saved in SD card should be different.
• The O/S update file should be included in the data loaded in the SD card.
• Proceed O/S update with all peripherals removed at option port (USB).
◈ Error Massage :
• When the condition is not satisfied.
<Figure 1: Message shown at peripherals attached to USB port while O/S updating>
Dialogue <Figure 1> will be shown if O/S update is prompted with peripherals attached at option port(USB).
Reboot G-scan then try again.

<Figure 2: Message for confirming the O/S update condition >
It is the message when the condition for updating the O/S is not satisfied.
Please check the data upgrade condition of SD card and the connection of the AC/DC power adapter.
• When the O/S version of main module is the same with that of the update file saved in SD card
<Figure 3: When current version is the latest version>
When this message pop-up is shown, press any key to turn OFF the G-scan automatically. As the current
version is the latest one, use the equipment after booting normally.

<Figure 4: Screen for confirming the O/S update>
When the screen as in <Figure 4> is shown, press the “Enter” button. (Pressing “ESC” button, the
power will be OFF automatically.)
<Figure 5: Screen for completing the O/S update>
After completing the O/S update, the pop-up window as in <Figure 5> will be shown.
According to the update completing message as in <Figure 5>, press “Enter” button, and it is
changed to G-scan touch screen calibration screen.

<Figure 6: Touch Screen Calibration Screen>
NOTE
Korean sentence in the box means.

Carefully press and briefly hold stylus on the center of the target.
Repeat as the target moves around the screen.
Since above screen comes right after OS updating it says in Korean as default.
After OS update, language should be configured again.
Select the center of (+) shown on the screen as in above screen using the stylus pen.
NOTE : Totally 5 positions are shown. Select the centers of all 5 (+) marks.

<Figure 7: Completing the Touch Screen Calibration >
After selecting all centers of 5 (+) marks, the message as in <Figure 7> will be shown.
To save the new setup, select button. To keep the previous setup, press .
NOTE
Korean sentence in the box means.

New calibration setting have been measured.
Press the Enter Key to accept the new settings.
Press the Esc Key to keep the old settings.
After OS update, language should be configured again.

Main screen will appear automatically after O/S update is completed.
<Figure 8: Main screen will appear after O/S update >
◈ Error Message:
• When the external power is not connected
<Figure 9: When external power is not connected >
When the error message pop-up is shown, press Any Key, then the power of main module will be turned OFF
automatically.
After connection the external power using AC/DC adapter, retry previous steps.

• When the O/S update file saved in the SD card has an error
<Figure 10: When update file is not stored in SD Card >
1. When this error message pop-up is shown, press any key to turn OFF the power.
2. Using the PC utility, update the O/S data saved in the SD card.
3. Retry the O/S update procedure.
NOTE : When the O/S update is proceeded without inserting the SD card installed into G-scan, the power is
automatically turned OFF.
Providing that this product has been installed and used as instructed in the operation manual, Global
Information Technology (referred to as “GIT”) will repair G-scan module (main body other than software, which
is covered by a separate warranty) with new or rebuilt parts, free of charge for three (3) years from the date of
original purchase in the event of a defect in materials or workmanship. This warranty excludes all other
options and accessories, which are covered for a period of one (1) year from the date of original purchase.
This warranty is extended solely to the original purchaser. A purchase receipt or other proof of evidencing the
date of original purchase will be required before warranty service is provided.
This warranty only covers failures due to defects in materials or workmanship, which may occur during normal
use. It does not cover damage which occurs in shipment or failures which may be caused by products not
supplied by GIT, or failures resulting from alteration, accident, misuse, introduction of liquid material or other
foreign matter into the product, abuse, neglect, installation, maladjustment of consumer controls, improper
maintenance, modification or service by anyone other than GIT, or damage to be attributable to acts of God.
GIT SHALL NOT BE LIABLE FOR LOSS OF DATA OR OTHER INCIDENTAL OR CONSEQUENTIAL
DAMAGES RESULTING FROM THE USE OF THIS PRODUCT, OR ARISING OUT OF ANY BREACH OF
THIS WARRANTY. ALL EXPRESS AND IMPLIED WARRANTIES, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED TO THE APPLICABLE
WARRANTY PERIOD SET FORTH ABOVE.

GIT’s entire liability, and your exclusive remedy under this warranty shall be limited to the replacement, of any
defective parts or functions in the product, which is returned to GIT’s Service Center, together with a copy of
the purchase receipt, during the aforementioned warranty period. Anything in the foregoing to the contrary
notwithstanding, GIT shall have no obligation for any defects in the product resulting from your storage thereof,
or for defects that have been caused by operation of the product other than on the operation manual or in
environmental conditions other than those specified by GIT or by alteration, accident, misuse, abuse, neglect,
mishandling, misapplication, installation, maladjustment of consumer controls, improper maintenance,
modification of damage that is attributable to acts of God.
This limited warranty gives you specific legal rights, and you may also have other rights, which vary from
country to country. The laws of Republic Korea, without regard to its conflict-of-laws rules, will govern this
Limited Warranty.
To obtain help or technical Assistance, please contact your product supplier or distributor.
Disposal of Old Electrical and Electronic Equipment
<Figure 1: WEEE Symbol>
WEEE (Waste Electrical and Electronic Equipment) symbol shown in [Figure 1] is indicated on the back of G-
scan main module
Please follow the regulation guide for disposal of Waste Electrical and Electronic Equipment.
Disposal of Old Electrical & Electronic Equipment (Applicable in the European Union and other European
countries with separate collection systems)
This symbol on the product or on its packaging indicates that this product shall not be treated as household
waste. Instead it shall be handed over to the applicable collection point for the recycling of electrical and
electronic equipment. By ensuring this product is disposed of correctly, you will help prevent potential negative
consequences for the environment and human health, which could otherwise be caused by Inappropriate
waste handling of this product. The recycling of materials will help to conserve natural resources. For more
detailed information about recycling of this product, please contact your local city office, your household waste
disposal service or the shop where you purchased the product.

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SB4323E00

D35S-5, D40S-5, D40SC-5, D45SC-5

1. General Information Turbocharger ......................................................89

Intake Manifold ...................................................95

Intake and Exhaust System............................... 86

D439E Service Manual 3 Index

Charging System ............................................. 131 Crankshaft Position Sensor .............................189

Engine Control Unit (ECU)............................... 170

ECU Circuit Diagram........................................ 175

Intake Air Temperature Sensor ....................... 184

Intake Air Pressure Sensor ............................. 185

D439E Service Manual 4 Index

Hardware .......................................................... 208

Basic Usage of G-scan .................................... 212

Configuration ................................................... 230

Vehicle Communication Function................... 250

PC Utility .......................................................... 325

Appendix .......................................................... 352

D439E Service Manual 5 Index

The SI unit is used. Metric notation is also presented

3. All torque specifications for the tightening in the

Unless otherwise specified, all dimensions for the

1. Nominal Value (Abbr.: NV)

2. Repair Limit (Abbr.: RL)

3. Service Limit (Abbr.: SL)

4. Basic Diameter (Abbr.: BD)

5. Tightening Torque (Abbr.: T)

D439E Service Manual 7 1. General Information

Unit Unit symbol of foot-pound unit Conversion rate

Moment of force Nm lbf.ft 1 Nm = 0.7375 lbf.ft

Output kW (kilowatt) HP 1 kW = 1.34 HP

Temperature C F T C = (1.8 t C + 32)  F

D439E Service Manual 8 1. General Information

Torque Nm (kg.cm, lb.ft)

M5 0.8 3~4 (30~40, 2.2~2.9) 5~6 (50~60, 3.6~4.3)

M6 1.0 5~6 (50~60, 3.6~4.3) 9~11 (90~110, 6.5~8.0)

3. If you reduce the torques in the table to the

2. The torques in the table are not applicable under

D439E Service Manual 9 1. General Information

3) Engine development order

6) Product serial number.

D439E Service Manual 10 1. General Information

Protection of the vehicle

Always make sure to cover fenders, seats, and floor

D439E Service Manual 11 1. General Information

Standard values such as torques and adjustments

5. Cotter pins (split pins)

7. Sealant should be applied to gaskets.

8. Oil should be applied to the moving components

9. Specified oil or grease should be applied to the

D439E Service Manual 12 1. General Information

7. Check to see if the wiring is correct.

8. Check to see if the wiring is clamped to prevent

9. Check to see if the wiring is clamped firmly to

3. Connectors will sound click when the connector is Checking Fuses

4. Carefully handle sensors and relays. Be careful Fuse box

Checking Cables and Wires

A blade type fuse test leads are provided to allow

1. Check to see if the terminal is tightened correctly.

2. Check to see if terminals and wires are corroded

3. Check terminals and wires for any short circuits.

D439E Service Manual 13 1. General Information

4. When installing any parts, be careful not to pinch