ENGINE FUEL SYSTEM

1881-09/1881-23/1881-08/1881-23

ENGINE FUEL SYSTEM

GENERAL REMOVAL AND INSTALLATION

1. MAJOR CHANGES IN FUEL 1881-08 INJECTOR CODING(C2I/C3I)........ 12

SYSTEM OF ENGINE............................ 3 1881-23 COMMON RAIL AND FUEL
SUPPLY PIPE.............................. 15

OVERVIEW AND OPERATION

PROCESS
1. COMPONENTS OF FUEL SYSTEM....... 6
2. FUEL FLOW OF D20DT (EURO 4)
ENGINE.................................................. 8

CONFIGURATION AND FUNCTIONS

1881-09 INJECTOR................................... 9
1881-23 COMMON RAIL & FUEL SUPPLY
PIPE............................................. 11
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ENGINE FUEL SYSTEM 1881-09

1. MAJOR CHANGES IN FUEL SYSTEM OF ENGINE

There are some changes in the parts related to the fuel system due to the newly adopted
D20DT (EURO 4) engine.
The major changes are as follows. Refer to the next pages for further details.

1) Injector
- Two nozzle holes are added (currently 7)
to the tip of the injector to increase the
amount of fuel injection and to improve
injection efficiency according to the
increased engine power.
- The existing C2I coding (16 digits) is
changed to C3I coding (20 digits) to
monitor fuel injection and follow the
target value.
- For the D20DT engine, the injector MDP
(minimum current for the solenoid in the
injector to lift the nozzle) is leaned only
when the engine is running. However, for
the D20DT (EURO 4) engine, it is learned
when the vehicle is in motion and the
engine is at idle speed.

2) Common Rail
- The orifice is added to the connection to
the fuel pipe of the HP pump to prevent
the fuel pulsation by the fuel supply and
fuel cut according to the increase of
injected fuel volume. (It is also installed
on the connection of the high pressure
fuel supply line of the HP pump.)

ENGINE FUEL SYSTEM

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3) Fuel Rail - Chrome Color

Fuel pipe (Common rail → Injector)
Fuel high pressure pipe (HP pump →
Common rail)
- The I.D and O.D of the fuel rail between
HP pump and common rail are increased
according to the increased amount of fuel
injection.
Also, the engine ECU, HFM sensor and
EGR system are changed to control the
fuel injection volume and engine more
precisely.

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1. COMPONENTS OF FUEL SYSTEM

Injector (7-way Injection and C3I Coding)

C3I

Fuel nozzle
holes (7)

Common Rail (Orifice for Preventing

Fuel Pulsation Added)

Orifice

Orifice for HP pump fuel outlet

Fuel Supply Rail (Increase in I.D)

Fuel pipe Common rail

Fuel rail
High pressure pressure
fuel pipe sensor

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Fuel filter Priming Pump

Priming Fuel filter

pump

Connector
Fuel from Fuel filter
HP pump
Fuel
tank

HP pump

Fuel tank

HP Pump
Fuel return Fuel temperature
Fuel return port
port sensor

IMV valve

Venturi
High pressure
Low pressure fuel supply port
IMV
fuel supply port (orifice included)
connector

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2. FUEL FLOW OF D20DT (EURO 4) ENGINE

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1) Structure and Overview Of Injector

The injector for the D20DT (EURO 4) engine is different from the injector for the D20DT engine.
Also, the injectors for each engine are not compatible with each other.
The amount of fuel injection is increased according to the increased engine power and the
number of nozzle holes on tip are increased (from 5 to 7).
Also, the C2I label is replaced to C3I label for the better control of the fuel injection volume.
With C3I coding, the MDP learning is performed when the vehicle is in motion and the engine is
at idle speed.
Major changes in injector are as follows:

Common rail Fuel high

Injector pressure pipe

C3I label

Fuel filter

Injection
nozzle Fuel pipe

Fuel pressure
sensor

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2) Injector Label
Comparison Between Fuel Injection and Closeness to Target Value
C3I and C2I (Controllability) of C2I and C3I

Injector C3I Label for D20DT

(EURO 4) Engine

C3I value
(20 digits)

Injector C2I Label for D20DT
Engine
The closeness to the target
value is superb so that the
volume is precisely controlled
(decrease in irregular injection
in each injector).
The amount of injected fuel is
close to the target value which
is better than the case of C2I
coding overridden.

C2I value
(16 digits)

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&
1) Components and Overview of Common Rail & Fuel Supply Pipe
The diameter of fuel supply pipe between HP pump and the common rail and the diameter of
fuel pipe between the common rail and the injector have been increased to provide the
increased volume of fuel injection for the higher output of D20DT (EURO 4) engine.
Also, the orifice has been added to prevent the fuel pulsation in the common rail and the HP
pump fuel supply line.
To control the amount of injected fuel to each cylinder precisely and evenly, it is important to
prevent the fuel pulsation occurred during the fuel supply and fuel cut.

Fuel Supply Pipe Fuel High Pressure Pipe

(Common rail → Injector) (HP pump → Common rail)

Common Rail

Green
Damping
orifice

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Perform the "Entering Diagnosis Procedures".

- If the injector/ECU has been replaced or the injector system defective is suspected, go to
C2I Coding item and check the injector and coded injector C2I value.

1. Select "6] INJECTOR (C2I) CORRECTIONS" and press in "FUNCTION SELECTION"

screen.

2. The "INJECTOR (C2I) CORRECTIONS" screen that shows current C2I or C3I coding values
of #1 to #5 injector is displayed. Press and enter the coding value.

3. If you replaced the ECU, enter the C2I or C3I value of the relevant injector.

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3. If you replaced the ECU, enter the C2I or C3I value of the relevant injector.

- The C2I or C31 value of replacing injector is recorded in the label.

- C2I coding number: 16 characters (ex, C0 2D 835....)
- C3I coding number: 20 characters (ex, 8D87E03R....)

D20DTP (EURO 4) Engine D20DT Engine

C3I label C2I label

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3-1. If you want to enter a new code press [ENTER].

For the C3I coding, select the number with numeric key pads and select the alphabet with
PgUp and PgDn keys.

- When selecting an alphabet, A through Z and then 0 to 9 come in order.

3-2. If you enter the invalid C2I or C3I value

of the relevant injector, the message as
shown in figure appears with alarm
sound.

- If you want to go back to previous screen,

press key. You can see the
previous C2I value.

3-3. If you enter the valid C2I or C3I value of

the relevant injector, the message as
shown in figure appears with alarm
sound.

- If you want to go back to previous screen,

press ESC. The new C2I or C3I value is
displayed.

- For C2I or C3I coding, select the engine.

Then, the corresponding injector coding
screen appears.

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1. Remove the engine cover.

1. Disconnect the fuel pressure sensor connector and remove the clamps.

2. Unscrew the mounting bolts of the fuel high pressure pipe and common rail to remove the
fuel supply pipe, fuel high pressure pipe and common rail from the engine.

Fuel Supply Pipe Fuel High Pressure Pipe

- When installing, replace the fuel supply pipes with new ones.
- Plug the fuel hole to the common rail with a protective cap.

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Common Rail

Pulsation orifice

- Plug the fuel hole to the common rail with a protective cap.

ENGINE FUEL SYSTEM

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