3.3 l fuel

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3.3 l fuel

  1. 1. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe GENERAL SPECIFICATION FUEL DELIVERY SYSTEM FUEL DELIVERY SYSTEM - SPECIFICATION Items Fuel Tank Capacity Fuel Filter (built in Fuel Pump assembly) Type Fuel Pressure Regulator (built in Fuel Regulated Fuel Pump assembly) Pressure Type Fuel Pump Driven by Specification 80 lit. (21.1 U.S.gal., 17.6 lmp. gal.) High pressure type 375 ~ 385 kPa (3.82 ~ 3.92 kgf/cm2 , 54.3 ~ 55.8 psi) Electrical, in-tank type Electric motor SENSOR MASS AIR FLOW SENSOR (MAFS) Type: Hot-film type Specification MASS AIR FLOW SENSOR - SPECIFICATION Air Flow (kg/h) 12.6 kg/h 18.0 kg/h 23.4 kg/h 32.4 kg/h 43.2 kg/h 57.6 kg/h 72.0 kg/h 108.0 kg/h 144.0 kg/h 198.0 kg/h 270.0 kg/h 360.0 kg/h 486.0 kg/h 666.0 kg/h Frequency (Hz) 2,617Hz 2,958Hz 3,241 Hz 3,653Hz 4,024Hz 4,399Hz 4,704Hz 5,329Hz 5,897Hz 6.553HZ 7,240Hz 7,957Hz 8,738Hz 9,644Hz Microsoft Saturday, September 26, 2009 12:14:00 PM 12:14:31 Page 1 © 2005 Mitchell Repair Information Company, LLC.
  2. 2. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe 900.0 kg/h 10,590Hz INTAKE AIR TEMPERATURE SENSOR (IATS) Type: Thermistor type Specification INTAKE AIR TEMPERATURE SENSOR - SPECIFICATION Temperature Resistance (kohms) °C °F -40 -40 100.87 kohms -20 -4 28.58 kohms 0 32 9.40 kohms 10 50 5.66 kohms 20 68 3.51 kohms 40 104 1.47kohms 60 140 0.67 kohms 80 176 0.33 kohms MANIFOLD ABSOLUTE PRESSURE SENSOR (MAPS) Type: Piezo-resistive pressure type Specification MANIFOLD ABSOLUTE PRESSURE SENSOR - SPECIFICATION Pressure (kPa) Output Voltage (V) 20.0kPa 0.79V 46.66kPa 1.84V 101.32kPa 4.00V ENGINE COOLANT TEMPERATURE SENSOR (ECTS) Type: Thermistor type Specification ENGINE COOLANT TEMPERATURE SENSOR - SPECIFICATION Temperature Resistance (kohms) °C °F -40 -40 48.14kohms -20 -4 14.13- 16.83kohms Microsoft Saturday, September 26, 2009 12:14:01 PM Page 2 © 2005 Mitchell Repair Information Company, LLC.
  3. 3. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe 0 20 40 60 80 32 68 104 140 176 5.79 kohms 2.31 ~ 2.59kohms 1.15kohms 0.59 kohms 0.32 kohms THROTTLE POSITION SENSOR (TPS) Type: Variable resistor type Specification (When reference voltage = 5.0V) THROTTLE POSITION SENSOR - SPECIFICATION Output Voltage (V) Throttle Angle (°) TPS1 0V 0.5V 0.9V 1.4V 1.8V 2.3V 2.7V 3.2V 3.6V 4.1V 4.5V 5.0V 0° 10° 20° 30° 40° 50° 60° 70° 80° 90° 100° 110° TPS2 5.0V 4.5V 4.1V 3.6V 3.2V 2.7V 2.3V 1.8V 1.4V 0.9V 0.5V 0V THROTTLE POSITION SENSOR - SPECIFICATION Item Sensor Resistance (kohms) TPS1 4.0 ~ 6.0kohms at 20°C (68°F) TPS2 2.72 ~ 4.08kohms at 20°C (68°F) ACCELERATOR POSITION SENSOR (APS) Type: Variable resistor type Specification (When reference voltage = 5.0V) ACCELERATOR POSITION SENSOR - SPECIFICATION Accelerator Position Output Voltage (V) APS1 APS2 Microsoft Saturday, September 26, 2009 12:14:01 PM Page 3 © 2005 Mitchell Repair Information Company, LLC.
  4. 4. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe C.T W.O.T 0.7 ~ 0.8V 3.85 ~ 4.35V 0.29 ~ 0.46V 1.93 ~ 2.18V ACCELERATOR POSITION SENSOR - SPECIFICATION Item Sensor Resistance (kohms) APS1 0.7 ~ 1.3kohms at 20°C (68°F) APS2 1.4 ~ 2.6kohms at 20°C (68°F) HEATED OXYGEN SENSOR (HO2S) Type: Zirconia (ZrO2) type Specification HEATED OXYGEN SENSOR - SPECIFICATION A/F Ratio RICH LEAN Output Voltage (V) 0.75 ~ 1.00V 0 ~ 0.12V HEATED OXYGEN SENSOR - SPECIFICATION Item Resistance (ohms) Sensor Heater 8.1 ~ 11.1ohms at 21°C (69.8°F) CAMSHAFT POSITION SENSOR (CMPS) Type: Hall effect type Specification CAMSHAFT POSITION SENSOR - SPECIFICATION Item Output Voltage (V) Air Gap (mm) Specification High: 5.0V Low: 0.7V 0.5 ~ 1.5mm CRANKSHAFT POSITION SENSOR (CKPS) Type: Magnetic field sensitive type Specification CAMSHAFT POSITION SENSOR - SPECIFICATION Item Specification Microsoft Saturday, September 26, 2009 12:14:01 PM Page 4 © 2005 Mitchell Repair Information Company, LLC.
  5. 5. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Coil Resistance (ohms) Air Gap (mm) 630 ~ 770ohms at 20°C (68°F) 0.5 ~ 1.5mm KNOCK SENSOR (KS) Type: Piezo-electricity type Specification KNOCK SENSOR - SPECIFICATION Item Capacitance (pF) Specification 1,480 ~ 2,220pF CVVT OIL TEMPERATURE SENSOR (OTS) Type: Thermistor type Specification CVVT OIL TEMPERATURE SENSOR - SPECIFICATION Temperature Resistance (kohms) °C °F -20 -4 16.52kohms 20 68 2.45 kohms 80 176 0.29 kohms FUEL TANK PRESSURE SENSOR (FTPS) Type : Piezo-Resistivity type Specification FUEL TANK PRESSURE SENSOR - SPECIFICATION Pressure (kPa) -3.75 kPa 0 kPa +1.25 kPa Output Voltage (V) 4.4 ~ 4.6V 1.4-1.6V 0.4 ~ 0.6V ACTUATORS INJECTOR Number: 6 Microsoft Saturday, September 26, 2009 12:14:01 PM Page 5 © 2005 Mitchell Repair Information Company, LLC.
  6. 6. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Specification INJECTOR - SPECIFICATION Item Coil Resistance (ohms) Specification 11.4 ~ 12.6ohms at 20°C (68°F) PURGE CONTROL SOLENOID VALVE (PCSV) Type: Duty control type Specification PURGE CONTROL SOLENOID VALVE - SPECIFICATION Item Specification Coil Resistance (ohms) 19.0- 22.0ohms at 20°C (68°F) VARIABLE INTAKE SOLENOID (VIS) VALVE Specification VARIABLE INTAKE SOLENOID VALVE - SPECIFICATION Item Specification Coil Resistance (ohms) 30.0 ~ 35.00 [22°C (71.6°F)] CVVT OIL CONTROL VALVE (OCV) Specification CVVT OIL CONTROL VALVE - SPECIFICATION Item Coil Resistance (ohms) Specification 6.7 ~ 7.7ohms at 20°C (68°F) ETC MOTOR Specification ETC MOTOR - SPECIFICATION Item Coil Resistance (ohms) Specification 1.275 ~ 1.725 ohms at 20°C (68°F) IGNITION COIL Type: Stick type Microsoft Saturday, September 26, 2009 12:14:01 PM Page 6 © 2005 Mitchell Repair Information Company, LLC.
  7. 7. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Specification IGNITION COIL - SPECIFICATION Item Primary Coil Resistance (ohms) Secondary Coil Resistance (kohms) Specification 0.62ohms±10% at 20°C (68°F) 7.0kohms±15%at 20°C (68°F) CANISTER CLOSE VALVE (CCV) Type: ON/OFF control type Specification CANISTER CLOSE VALVE - SPECIFICATION Item Coil Resistance (ohms) Specification 19.9 ~ 22.9 at 20°C (68°F) SERVICE STANDARD SERVICE STANDARD Ignition Timing A/CON OFF Idle Speed A/CON ON BTDC 10°±5° Neutral,N,P-range D-range Neutral,N,P-range D-range 680 ± 100 rpm 630 ± 100 rpm 680 ± 100 rpm 630 ± 100 rpm TIGHTENING TORQUES ENGINE CONTROL SYSTEM ENGINE CONTROL SYSTEM - TIGHTENING TORQUES Item PCM installation bolts (on upper bracket) PCM upper bracket installation bolts (on lower bracket) PCM upper bracket installation nuts (on chassis) PCM lower bracket installation bolts (on chassis) Mass air flow sensor installation bolts (on air cleaner assembly) Mass air flow sensor clamp tightening screw Heated oxygen sensor (Bank 1 / Sensor 1) installation Heated oxygen sensor (Bank 1 / Sensor 2) installation Heated oxygen sensor (Bank 2 / Sensor 1) installation Heated oxygen sensor (Bank 2 / Sensor 2) installation Kgf-m 1.0 ~ 1.2 1.0 ~ 1.2 1.9 ~ 2.4 1.9 ~ 2.4 0.4 ~ 0.6 0.3 ~ 0.5 5.0 ~ 6.0 5.0 ~ 6.0 5.0 ~ 6.0 5.0 ~ 6.0 N.m 9.8 ~ 11.8 9.8 ~ 11.8 18.6 ~ 23.5 18.6 ~ 23.5 3.9 ~ 5.9 2.9 ~ 4.9 49.1 ~ 58.9 49.1 ~ 58.9 49.1 ~ 58.9 49.1 ~ 58.9 lbf.ft 7.2 ~ 8.7 7.2 ~ 8.7 13.7 ~ 17.4 13.7 ~ 17.4 2.9 ~ 4.3 2.2 ~ 3.6 36.2 ~ 43.4 36.2 ~ 43.4 36.2 ~ 43.4 36.2 ~ 43.4 Microsoft Saturday, September 26, 2009 12:14:01 PM Page 7 © 2005 Mitchell Repair Information Company, LLC.
  8. 8. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Engine coolant temperature sensor installation Manifold absolute pressure sensor installation bolt Camshaft position sensor [Bank 1] installation bolt Camshaft position sensor [Bank 2] installation bolt Crankshaft position sensor installation Knock sensor #1,2 installation ETC module installation bolt (on throttle body) ETC module installation bolt (on ETC stay) CVVT Oil temperature sensor installation CVVT Oil control valve [Bank 1] installation bolt CVVT Oil control valve [Bank 2] installation bolt Vacuum valve (Variable intake actuator) installation bolts Ignition coil condenser installation bolt Ignition coil installation bolt 2.0 ~ 4.0 0.9 ~ 1.2 0.7 ~ 1.0 0.7 ~ 1.0 0.8 ~ 1.2 1.6 ~ 2.4 0.7 ~ 1.1 1.6 ~ 2.6 2.0 ~ 4.0 1.0 ~ 1.2 1.0 ~ 1.2 0.9 ~ 1.2 0.7 ~ 1.1 0.4 ~ 0.6 19.6 ~ 39.2 8.8 ~ 11.8 6.9 ~ 9.8 6.9 ~ 9.8 7.8 ~ 11.8 15.7 ~ 23.5 6.9 ~ 10.8 15.7 ~ 25.5 19.6 ~ 39.2 9.8 ~ 11.8 9.8 ~ 11.8 8.8 ~ 11.8 6.9 ~ 10.8 3.9 ~ 5.9 14.5 ~ 28.9 6.5 ~ 8.7 5.1 ~ 7.2 5.1 ~ 7.2 5.8 ~ 8.7 11.6 ~ 17.4 5.1 ~ 8.0 11.6 ~ 18.8 14.5 ~ 28.9 7.2 ~ 8.7 7.2 ~ 8.7 6.5 ~ 8.7 5.1 ~ 8.0 2.9 ~ 4.3 FUEL DELIVERY SYSTEM FUEL DELIVERY SYSTEM - TIGHTENING TORQUES Item Kgf.m Fuel Tank band mounting nuts 4.0 ~ 5.5 Accelerator pedal module installation bolts 1.7 ~ 2.6 Delivery pipe installation bolts 0.9 ~ 1.2 N.m 39.2 ~ 53.9 16.7 ~ 25.5 8.8 ~ 11.8 lbf.ft 28.9 ~ 39.8 12.3 ~ 18.8 6.5 ~ 8.7 SPECIAL SERVICE TOOLS SPECIAL SERVICE TOOLS REFERENCE CHART Tool (Number Illustration and name) 09353-24100 Fuel Pressure Gauge Application Measuring the fuel line pressure Microsoft Saturday, September 26, 2009 12:14:01 PM Page 8 © 2005 Mitchell Repair Information Company, LLC.
  9. 9. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe 09353-38000 Fuel Pressure Gauge Adapter Connection between the delivery pipe and fuel feed line 09353-24000 Fuel Pressure Gauge Connector Connection between Fuel Pressure Gauge (09353-24100) and Fuel Pressure Gauge Adapter (09353-38000) BASIC TROUBLESHOOTING BASIC TROUBLESHOOTING GUIDE 1. Bring Vehicle to Workshop 2. Analyze Customer's Problem Ask the customer about the conditions and environment relative to the issue (Use CUSTOMER PROBLEM ANALYSIS SHEET). 3. Verify Symptom, and then Check DTC and Freeze Frame Data Connect Hi-Scan (Pro) to Diagnostic Link Connector (DLC). Record the DTC and freeze frame data. NOTE: To erase DTC and freeze frame data, refer to Step 5. 4. Confirm the Inspection Procedure for the System or Part Using the SYMPTOM TROUBLESHOOTING GUIDE CHART, choose the correct inspection procedure for the system or part to be checked. Microsoft Saturday, September 26, 2009 12:14:01 PM Page 9 © 2005 Mitchell Repair Information Company, LLC.
  10. 10. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe 5. Erase the DTC and Freeze Frame Data WARNING: NEVER erase DTC and freeze frame data before completing Step 2 MIL/DTC in "CUSTOMER PROBLEM ANALYSIS SHEET". 6. Inspect Vehicle Visually Go to Step 11, if you recognize the problem. 7. Recreate (Simulate) Symptoms of the DTC Try to recreate or simulate the symptoms and conditions of the malfunction as described by customer. If DTC(s) is/are displayed, simulate the condition according to troubleshooting procedure for the DTC. 8. Confirm Symptoms of Problem If DTC(s) is/are not displayed, go to Step 9. If DTC(s) is/are displayed, go to Step 11. 9. Recreate (Simulate) Symptom Try to recreate or simulate the condition of the malfunction as described by the customer. 10. Check the DTC If DTC(s) does (do) not occur, refer to INTERMITTENT PROBLEM PROCEDURE in BASIC INSPECTION PROCEDURE. If DTC(s) occur(s), go to Step 11. 11. 12. 13. 14. Perform troubleshooting procedure for DTC Adjust or repair the vehicle Confirmation test END CUSTOMER PROBLEM ANALYSIS SHEET Microsoft Saturday, September 26, 2009 12:14:01 PM Page 10 © 2005 Mitchell Repair Information Company, LLC.
  11. 11. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 1: Customer Problem Analysis Sheet Courtesy of HYUNDAI MOTOR CO. BASIC INSPECTION PROCEDURE MEASURING CONDITION OF ELECTRONIC PARTS' RESISTANCE The measured resistance at high temperature after vehicle running may be high or low. So all resistance must be measured at ambient temperature (20°C, 68°F), unless stated otherwise. Microsoft Saturday, September 26, 2009 12:14:01 PM Page 11 © 2005 Mitchell Repair Information Company, LLC.
  12. 12. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe NOTE: The measured resistance in except for ambient temperature (20°C, 68°F) is reference value. INTERMITTENT PROBLEM INSPECTION PROCEDURE Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does not occur again during testing. An example would be if a problem appears only when the vehicle is cold but has not appeared when warm. In this case, the technician should thoroughly make out a "CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and condition which occurred when the vehicle was having the issue. 1. Clear Diagnostic Trouble Code (DTC). 2. Inspect connector connection, and check terminal for poor connections, loose wires, bent, broken or corroded pins, and then verify that the connectors are always securely fastened. Fig. 2: Inspecting Connector Connection Courtesy of HYUNDAI MOTOR CO. 3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace the component that has a problem. 5. Verify that the problem has disappeared with the road test. • SIMULATING VIBRATION a. Sensors and Actuators Microsoft Saturday, September 26, 2009 12:14:01 PM Page 12 © 2005 Mitchell Repair Information Company, LLC.
  13. 13. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe : Slightly vibrate sensors, actuators or relays with finger. WARNING: Strong vibration may break sensors, actuators or relays b. Connectors and Harness : Lightly shake the connector and wiring harness vertically and then horizontally. • SIMULATING HEAT a. Heat components suspected of causing the malfunction with a hair dryer or other heat source. WARNING:   DO NOT heat components to the point where they may be damaged. DO NOT heat the ECM directly. • SIMULATING WATER SPRINKLING a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition. WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components. • SIMULATING ELECTRICAL LOAD a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, rear window de-fogger, etc.). CONNECTOR INSPECTION PROCEDURE 1. Handling of Connector a. Never pull on the wiring harness when disconnecting connectors. Microsoft Saturday, September 26, 2009 12:14:01 PM Page 13 © 2005 Mitchell Repair Information Company, LLC.
  14. 14. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 3: Identifying Handling Of Connector - Never Pull On Wiring Harness When Disconnecting Connectors Courtesy of HYUNDAI MOTOR CO. b. When removing the connector with a lock, press or pull locking lever. Fig. 4: Identifying Handling Of Connector - Removing Connector With Lock, Press Or Pull Locking Lever Courtesy of HYUNDAI MOTOR CO. c. Listen for a click when locking connectors. This sound indicates that they are securely locked. Microsoft Saturday, September 26, 2009 12:14:01 PM Page 14 © 2005 Mitchell Repair Information Company, LLC.
  15. 15. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 5: Identifying Handling Of Connector - Listen For Click When Locking Connectors Courtesy of HYUNDAI MOTOR CO. d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe from wire harness side. Fig. 6: Identifying Handling Of Connector - Tester Is Used To Check For Continuity, Or To Measure Voltage, Always Insert Tester Probe From Wire Harness Side Courtesy of HYUNDAI MOTOR CO. e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot be accessed from harness side. Microsoft Saturday, September 26, 2009 12:14:01 PM Page 15 © 2005 Mitchell Repair Information Company, LLC.
  16. 16. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 7: Identifying Handling Of Connector - Check Waterproof Connector Terminals From Connector Side Courtesy of HYUNDAI MOTOR CO. NOTE:   Use a fine wire to prevent damage to the terminal. Do not damage the terminal when inserting the tester lead. 2. Checking Point for Connector a. While the connector is connected: Hold the connector, check connecting condition and locking efficiency. b. When the connector is disconnected: Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness. Visually check for rust, contamination, deformation and bend. c. Check terminal tightening condition: Insert a spare male terminal into a female terminal, and then check terminal tightening conditions. d. Pull lightly on individual wires to ensure that each wire is secured in the terminal. Microsoft Saturday, September 26, 2009 12:14:01 PM Page 16 © 2005 Mitchell Repair Information Company, LLC.
  17. 17. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 8: Pulling Lightly On Individual Wires To Ensure That Each Wire Is Secured In Terminal Courtesy of HYUNDAI MOTOR CO. 3. Repair Method of Connector Terminal a. Clean the contact points using air gun and/or shop rag. NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may be damaged. b. In case of abnormal contact pressure, replace the female terminal. WIRE HARNESS INSPECTION PROCEDURE 1. Before removing the wire harness, check the wire harness position and crimping in order to restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between the wire harness and any installed part. 6. If the covering of wire harness is damaged; secure, repair or replace the harness. ELECTRICAL CIRCUIT INSPECTION PROCEDURE • CHECK OPEN CIRCUIT 1. Procedures for Open Circuit  Continuity Check  Voltage Check If an open circuit occurs (as seen in [Fig. 9]), it can be found by performing Step 2 (Continuity Check Method) or Step 3 (Voltage Check Method) as shown below. Microsoft Saturday, September 26, 2009 12:14:01 PM Page 17 © 2005 Mitchell Repair Information Company, LLC.
  18. 18. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 9: Checking Open Circuit Courtesy of HYUNDAI MOTOR CO. 2. Continuity Check Method NOTE: When measuring for resistance, lightly shake the wire harness above and below or from side to side. Specification (Resistance) 1ohms or less --> Normal Circuit 1 Mohms or Higher --> Open Circuit a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as shown in [Fig. 10]. In [Fig. 10.] the measured resistance of line 1 and 2 is higher than 1Mohms and below 1 ohms respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point, check sub line of line 1 as described in next step. Fig. 10: Measuring Resistance Between Connector (A) And (C) Courtesy of HYUNDAI MOTOR CO. Microsoft Saturday, September 26, 2009 12:14:01 PM Page 18 © 2005 Mitchell Repair Information Company, LLC.
  19. 19. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe b. Disconnect connector (B), and measure for resistance between connector (C) and (B1) and between (B2) and (A) as shown in [Fig. 11]. In this case the measured resistance between connector (C) and (B1) is higher than 1 MS and the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1). Fig. 11: Measuring For Resistance Between Connector (C) And (B1) And Between (B2) And (A) Courtesy of HYUNDAI MOTOR CO. 3. Voltage Check Method a. With each connector still connected, measure the voltage between the chassis ground and terminal 1 of each connectors (A), (B) and (C) as shown in [Fig. 12]. The measured voltage of each connector is 5V, 5V and 0V respectively. So the open circuit is between connector (C) and (B). Fig. 12: Measuring Voltage Between Chassis Ground And Terminal 1 Of Each Connectors (A), (B) And (C) Courtesy of HYUNDAI MOTOR CO. • CHECK SHORT CIRCUIT Microsoft Saturday, September 26, 2009 12:14:01 PM Page 19 © 2005 Mitchell Repair Information Company, LLC.
  20. 20. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe 1. Test Method for Short to Ground Circuit  Continuity Check with Chassis Ground If short to ground circuit occurs as shown in [Fig. 13], the broken point can be found by performing Step 2 (Continuity Check Method with Chassis Ground) as shown below. Fig. 13: Testing Method For Short To Ground Circuit Courtesy of HYUNDAI MOTOR CO. 2. Continuity Check Method (with Chassis Ground) NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the resistance. Specification (Resistance) 1ohms or less --> Short to Ground Circuit 1Mohms or Higher --> Normal Circuit a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis Ground as shown in [Fig. 14]. The measured resistance of line 1 and 2 in this example is below 1 ohms and higher than 1Mohms respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken point, check the sub line of line 1 as described in the following step. Microsoft Saturday, September 26, 2009 12:14:01 PM Page 20 © 2005 Mitchell Repair Information Company, LLC.
  21. 21. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 14: Measuring For Resistance Between Connector (A) And Chassis Ground Courtesy of HYUNDAI MOTOR CO. b. Disconnect connector (B), and measure the resistance between connector (A) and chassis ground, and between (B1) and chassis ground as shown in [Fig. 15]. The measured resistance between connector (B1) and chassis ground is 1 ohms or less. The short to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1). Fig. 15: Measuring Resistance Between Connector (A) And Chassis Ground, And Between (B1) And Chassis Ground Courtesy of HYUNDAI MOTOR CO. SYMPTOM TROUBLESHOOTING GUIDE CHART SYMPTOM TROUBLESHOOTING GUIDE CHART MAIN DIAGNOSTIC PROCEDURE SYMPTOM Unable to start (Engine does not ALSO CHECK FOR 1. Test the battery 2. Test the starter Microsoft Saturday, September 26, 2009 12:14:01 PM Page 21 © 2005 Mitchell Repair Information Company, LLC.
  22. 22. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe turn over) Unable to start (Incomplete combustion) Difficult to start Poor idling (Rough, unstable or incorrect Idle) Engine stall Poor driving (Surge) 3. Inhibitor switch (A/T) or clutch start switch (M/T) 1. 2. 3. 4. Test the battery Check the fuel pressure Check the ignition circuit Troubleshooting the immobilizer system (In case of immobilizer lamp flashing) 1. Test the battery 2. Check the fuel pressure 3. Check the ECT sensor and circuit (Check DTC) 4. Check the ignition circuit 1. Check the fuel pressure 2. Check the Injector 3. Check the long term fuel trim and short term fuel trim (Refer to CUSTOMER DATASTREAM ) 4. Check the idle speed control circuit (Check DTC) 5. Inspect and test the Throttle Body 6. Check the ECT sensor and circuit (Check DTC) 1. Test the Battery 2. Check the fuel pressure 3. Check the idle speed control circuit (Check DTC) 4. Check the ignition circuit 5. Check the CKPS Circuit (Check DTC) 1. 2. 3. 4. Check the fuel pressure Inspect and test Throttle Body Check the ignition circuit Check the ECT Sensor and Circuit (Check DTC) 5. Test the exhaust system for a possible restriction 6. Check the long term fuel trim and short term fuel trim (Refer to                         DTC Low compression Intake air leaks Slipped or broken timing belt Contaminated fuel DTC Low compression Intake air leaks Contaminated fuel Weak ignition spark DTC Low compression Intake air leaks Contaminated fuel Weak ignition spark DTC Intake air leaks Contaminated fuel Weak ignition spark DTC Low compression Intake air leaks Contaminated fuel Weak ignition spark Microsoft Saturday, September 26, 2009 12:14:01 PM Page 22 © 2005 Mitchell Repair Information Company, LLC.
  23. 23. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe CUSTOMER DATASTREAM) Knocking Poor fuel economy Hard to refuel (Overflow during refueling) 1. Check the fuel pressure 2. Inspect the engine coolant 3. Inspect the radiator and the electric cooling fan 4. Check the spark plugs 1. Check customer's driving habits  Is A/C on full time or the defroster mode on?  Are tires at correct pressure?  Is excessively heavy load being carried?  Is acceleration too much, too often? 2. Check the fuel pressure 3. Check the injector 4. Test the exhaust system for a possible restriction 5. Check the ECT sensor and circuit 1. Test the canister close valve 2. Inspect the fuel filler hose/pipe  Pinched, kinked or blocked?  Filler hose is torn 3. Inspect the fuel tank vapor vent hose between the EVAP. canister and air filter 4. Check the EVAP. canister         DTC Contaminated fuel DTC Low compression Intake air leaks Contaminated fuel Weak ignition spark Malfunctioning gas station filling nozzle (If this problem occurs at a specific gas station during refueling) GASOLINE ENGINE CONTROL SYSTEM OBD-II REVIEW 1. OVERVIEW The California Air Resources Board (CARB) began regulation of On Board Diagnostics (OBD) for vehicles sold in California beginning with the 1988 model year. The first phase, OBD-I, required monitoring of the fuel metering system, Exhust Gas Recirculation (EGR) system and additional emission related components. The Malfunction Indicator Lamp (MIL) was required to light and alert the driver of the fault and the need for repair of the emission control system. Associated with the MIL was a fault code or Diagnostic Trouble Code (DTC) idenfying the specific area of the fault. Microsoft Saturday, September 26, 2009 12:14:01 PM Page 23 © 2005 Mitchell Repair Information Company, LLC.
  24. 24. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe The OBD system was proposed by CARB to improve air quality by identifying vehicle exceeding emission standards. Passage of the Federal Clean Air Act Amendments in 1990 has also prompted the Environmental Protection Agency (EPA) to develop On Board Diagnostic requirements. CARB OBD-II regulations were followed until 1999 when the federal regulations were used. The OBD-II system meets government regulations by monitoring the emission control system. When a system or component exceeds emission threshold or a component operates outside tolerance, a DTC will be stored and the MIL illuminated. The diagnostic executive is a computer program in the Engine Control Module (ECM) or Powertrain Control Module (PCM) that coordinates the OBD-II self-monitoring system. This program controls all the monitors and interactions, DTC and MIL operation, freeze frame data and scan tool interface. Freeze frame data describes stored engine conditions, such as state of the engine, state of fuel control, spark, RPM, load and warm status at the point the first fault is detected. Previously stored conditions will be replaced only if a fuel or misfire fault is detected. This data is accessible with the scan tool to assist in repairing the vehicle. The center of the OBD-II system is a microprocessor called the Engine Control Module (ECM) or Powertrain Control Module (PCM). The ECM or PCM receives input from sensors and other electronic components (switches, relays, and others) based on information received and programmed into its memory (keep alive random access memory, and others), the ECM or PCM generates output signals to control various relays, solenoids and actuators. 2. CONFIGURATION OF HARDWARE AND RELATED TERMS 1. GST (GENERIC SCAN TOOL) Microsoft Saturday, September 26, 2009 12:14:01 PM Page 24 © 2005 Mitchell Repair Information Company, LLC.
  25. 25. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 16: Generic Scan Tool Circuit Diagram Courtesy of HYUNDAI MOTOR CO. 2. MIL (MALFUNCTION INDICATION LAMP) - MIL ACTIVITY BY TRANSISTOR Fig. 17: Malfunction Indication Lamp Circuit Diagram Courtesy of HYUNDAI MOTOR CO. The Malfunction Indicator Lamp (MIL) is connected between ECM or PCM-terminal Malfunction Indicator Lamp and battery supply (open collector amplifier). In most cars, the MIL will be installed in the instrument panel. The lamp amplifier can not be damaged by a short circuit. Microsoft Saturday, September 26, 2009 12:14:01 PM Page 25 © 2005 Mitchell Repair Information Company, LLC.
  26. 26. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Lamps with a power dissipation much greater than total dissipation of the MIL and lamp in the tester may cause a fault indication. At ignition ON and engine revolution (RPM) < MIN. RPM, the MIL is switched ON for an optical check by the driver. 3. MIL ILLUMINATION When the ECM or PCM detects a malfunction related emission during the first driving cycle, the DTC and engine data are stored in the freeze frame memory. The MIL is illuminated only when the ECM or PCM detects the same malfunction related to the DTC in two consecutive driving cycles. 4. MIL ELIMINATION • Misfire and Fuel System Malfunctions: For misfire or fuel system malfunctions, the MIL may be eliminated if the same fault does not reoccur during monitoring in three subsequent sequential driving cycles in which conditions are similar to those under which the malfunction was first detected. • All Other Malfunctions: For all other faults, the MIL may be extinguished after three subsequent sequential driving cycles during which the monitoring system responsible for illuminating the MIL functions without detecting the malfunction and if no other malfunction has been identified that would independently illuminate the MIL according to the requirements outlined above. 5. ERASING A FAULT CODE The diagnostic system may erase a fault code if the same fault is not re-registered in at least 40 engine warm-up cycles, and the MIL is not illuminated for that fault code. 6. K-LINE  Bidirectional line  K-Line is defined as the line which provides information in a serial digital form from ECM or PCM to the diagnostic tester. K-Line is used bidirectionally, in which case it may carry commands or data from the diagnostic tester to the ECM or PCM. K-Line is also used to initialize the serial communication. 7. DRIVING CYCLE A driving cycle consists of engine start up, and engine shut off. 8. WARM-UP CYCLE A warm-up cycle means sufficient vehicle operation such that the engine coolant temperature has risen by at least 40 degrees Fahrenheit from engine starting and reaches a minimum temperature of at least 160 Microsoft Saturday, September 26, 2009 12:14:01 PM Page 26 © 2005 Mitchell Repair Information Company, LLC.
  27. 27. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe degrees Fahrenheit. 9. TRIP CYCLE A trip means vehicle operation (following an engine-off period) of duration and driving mode such that all components and systems are monitored at least once by the diagnostic system except catalyst efficiency or evaporative system monitoring when a steady-speed check is used, subject to the limitation that the manufacturer-defined trip monitoring conditions shall all be encountered at least once during the first engine start portion of the applicable FTP cycle. 10. DTC FORMAT  Diagnostic Trouble Code (SAE J2012)  DTCs used in OBD-II vehicles will begin with a letter and are followed by four numbers. The letter of the beginning of the DTC identifies the function of the monitored device that has failed. A "P" indicates a powertrain device, "C" indicates a chassis device. "B" is for body device and "U" indicates a network or data link code. The first number indicates if the code is generic (common to all manufacturers) or if it is manufacturer specific. A "0" & "2" indicates generic, "1" indicates manufacturer-specific. The second number indicates the system that is affected with a number between 1 and 7. The following is a list showing what numbers are assigned to each system. 1. 2. 3. 4. 5. 6. 7. Fuel and air metering Fuel and air metering (injector circuit malfunction only) Ignition system or misfire Auxiliary emission controls Vehicle speed controls and idle control system Computer output circuits Transmission The last two numbers of the DTC indicates the component or section of the system where the fault is located. 11. FREEZE FRAME DATA When a freeze frame event is triggered by an emission related DTC, the ECM or PCM stores various vehicle information as it existed the moment the fault occurred. The DTC number along with the engine data can be useful in aiding a technician in locating the cause of the fault. Once the data from the 1st driving cycle DTC occurrence is stored in the freeze frame memory, it will remain there even when the fault occurs again (2nd driving cycle) and the MIL is illuminated.  Freeze Frame List a. Calculated Load Value Microsoft Saturday, September 26, 2009 12:14:01 PM Page 27 © 2005 Mitchell Repair Information Company, LLC.
  28. 28. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe b. c. d. e. f. g. h. i. Engine RPM Fuel Trim Fuel Pressure (if available) Vehicle Speed (if available) Coolant Temperature Intake Manifold Pressure (if available) Closed-or Open-loop operation Fault code 3. OBD-II SYSTEM READINESS TESTS 1. CATALYST MONITORING The catalyst efficiency monitor is a self-test strategy within the ECM or PCM that uses the downstream Heated Oxygen Sensor (HO2S) to determine when a catalyst has fallen below the minimum level of effectiveness in its ability to control exhaust emission. 2. MISFIRE MONITORING Misfire is defined as the lack of proper combustion in the cylinder due to the absence of spark, poor fuel metering, or poor compression. Any combustion that does not occur within the cylinder at the proper time is also a misfire. The misfire detection monitor detects fuel, ignition or mechanically induced misfires. The intent is to protect the catalyst from permanent damage and to alert the customer of an emission failure or an inspection maintenance failure by illuminating the MIL. When a misfire is detected, special software called freeze frame data is enabled. The freeze frame data captures the operational state of the vehicle when a fault is detected from misfire detection monitor strategy. 3. FUEL SYSTEM MONITORING The fuel system monitor is a self-test strategy within the ECM or PCM that monitors the adaptive fuel table The fuel control system uses the adaptive fuel table to compensate for normal variability of the fuel system components caused by wear or aging. During normal vehicle operation, if the fuel system appears biased lean or rich, the adaptive value table will shift the fuel delivery calculations to remove bias. 4. ENGINE COOLING SYSTEM MONITORING The cooling system monitoring is a self-test strategy within the ECM or PCM that monitors ECTS (Engine Coolant Temperature Sensor) and thermostat about circuit continuity, output range, rationality faults. 5. 02 SENSOR MONITORING OBD-II regulations require monitoring of the upstream Heated 02 Sensor (H2OS) to detect if the deterioration of the sensor has exceeded thresholds. An additional HO2S is located downstream of the Warm-Up Three Way Catalytic Converter (WU-TWC) to determine the efficiency of the catalyst. Microsoft Saturday, September 26, 2009 12:14:01 PM Page 28 © 2005 Mitchell Repair Information Company, LLC.
  29. 29. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Although the downstream H2OS is similar to the type used for fuel control, it functions differently. The downstream HO2S is monitored to determine if a voltage is generated. That voltage is compared to a calibrated acceptable range. 6. EVAPORATIVE EMISSION SYSTEM MONITORING The EVAP. monitoring is a self-test strategy within the ECM or PCM that tests the integrity of the EVAP. system. The complete evaporative system detects a leak or leaks that cumulatively are greater than or equal to a leak caused by a 0.040 inch and 0.020 inch diameter orifice. 7. AIR CONDITIONING SYSTEM MONITORING The A/C system monitoring is a self-test strategy within the ECM or PCM that monitors malfunction of all A/C system components at A/C ON. 8. COMPREHENSIVE COMPONENTS MONITORING The comprehensive components monitoring is a self-test strategy within the ECM or PCM that detects fault of any electronic powertrain components or system that provides input to the ECM or PCM and is not exclusively an input to any other OBD-II monitor. 9. A/C SYSTEM COMPONENT MONITORING Requirement: If a vehicle incorporates an engine control strategy that alters off idle fuel and/or spark control when the A/C system is on, the OBDII system shall monitor all electronic air conditioning system components for malfunctions that cause the system to fail to invoke the alternate control while the A/C system is on or cause the system to invoke the alternate control while the A/C system is off. Additionally, the OBD II system shall monitor for malfunction all electronic air conditioning system components that are used as part of the diagnostic strategy for any other monitored system or component. Implementation plan: No engine control strategy incorporated that alters off idle fuel and/or spark control when A/C system is on. Malfunction of A/C system components is not used as a part of the diagnostic strategy for other monitored system or component. COMPONENT LOCATION Microsoft Saturday, September 26, 2009 12:14:01 PM Page 29 © 2005 Mitchell Repair Information Company, LLC.
  30. 30. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 18: Gasoline Engine Control System Component Location (1 Of 5) Courtesy of HYUNDAI MOTOR CO. Microsoft Saturday, September 26, 2009 12:14:01 PM Page 30 © 2005 Mitchell Repair Information Company, LLC.
  31. 31. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 19: Gasoline Engine Control System Component Location (2 Of 5) Courtesy of HYUNDAI MOTOR CO. Microsoft Saturday, September 26, 2009 12:14:01 PM Page 31 © 2005 Mitchell Repair Information Company, LLC.
  32. 32. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 20: Gasoline Engine Control System Component Location (3 Of 5) Courtesy of HYUNDAI MOTOR CO. Microsoft Saturday, September 26, 2009 12:14:01 PM Page 32 © 2005 Mitchell Repair Information Company, LLC.
  33. 33. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 21: Gasoline Engine Control System Component Location (4 Of 5) Courtesy of HYUNDAI MOTOR CO. Microsoft Saturday, September 26, 2009 12:14:01 PM Page 33 © 2005 Mitchell Repair Information Company, LLC.
  34. 34. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 22: Gasoline Engine Control System Component Location (5 Of 5) Courtesy of HYUNDAI MOTOR CO. ETC (ELECTRONIC THROTTLE CONTROL) SYSTEM INSPECTION FUNCTION AND OPERATION PRINCIPLE ETC (Electronic Throttle Control) system is electronically controlled throttle device which controls the throttle Microsoft Saturday, September 26, 2009 12:14:01 PM Page 34 © 2005 Mitchell Repair Information Company, LLC.
  35. 35. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe valve. It consists of ETC motor, throttle body and throttle position sensor (TPS). A mechanical throttle control system receives a driver's intention via a wire cable between the accelerator and the throttle valve, while this ETC system uses the signal from the Accelerator Position Sensor (APS) installed on the accelerator pedal. After the PCM receives the APS signal and calculates the throttle opening angle, it activates the throttle valve by using the ETC motor. Additionally, it can handle cruise control function without any special devices. Fig. 23: Identifying Electronic Throttle Control Courtesy of HYUNDAI MOTOR CO. Fig. 24: Exploded View Of Electronic Throttle Control Courtesy of HYUNDAI MOTOR CO. Microsoft Saturday, September 26, 2009 12:14:01 PM Page 35 © 2005 Mitchell Repair Information Company, LLC.
  36. 36. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe COMPONENTS Fig. 25: Electronic Throttle Control System Diagram Courtesy of HYUNDAI MOTOR CO. SPECIFICATION [THROTTLE POSITION SENSOR] THROTTLE POSITION SENSOR - SPECIFICATION Output Voltage (V) [Vref = 5.0V] Throttle Angle (°) TPS1 TPS2 0° 0V 5.0V 10° 0.5V 4.5V 20° 0.9V 4.1V 30° 1.4V 3.6V 40° 1.8V 3.2V 50° 2.3V 2.7V 60° 2.7V 2.3V 70° 3.2V 1.8V 80° 3.6V 1.4V 90° 4.1V 0.9V 100° 4.5V 0.5V 110° 5.0V 0V THROTTLE POSITION SENSOR - SPECIFICATION Item Sensor Resistance Microsoft Saturday, September 26, 2009 12:14:01 PM Page 36 © 2005 Mitchell Repair Information Company, LLC.
  37. 37. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe TPS1 TPS2 4.0 ~ 6.0kohms at 20°C (68°F) 2.72 ~ 4.08kohms at 20°C (68°F) Fig. 26: Throttle Position Sensor Graph Courtesy of HYUNDAI MOTOR CO. [ETC MOTOR] ETC MOTOR - SPECIFICATION Item Coil Resistance (ohms) Sensor Resistance 1.275 ~ 1.725ohms at 20°C (68°F) SCHEMATIC DIAGRAM Microsoft Saturday, September 26, 2009 12:14:01 PM Page 37 © 2005 Mitchell Repair Information Company, LLC.
  38. 38. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 27: ECT System Schematic Diagram Courtesy of HYUNDAI MOTOR CO. FAIL-SAFE MODE FAIL-SAFE MODE CHART Mode Description Symptom Possible Cause   MODE 1 MODE 2 FORCED ENGINE SHUTDOWN FORCED IDLE & POWER MANAGEMENT ETC system can't proceed reliable algorithm procedure  Fatal PCM internal programming error  Faulty intake system or throttle body ETC system can't control engine power via throttle device Disabled throttle control or broken throttle position information Engine stop Forced idle state controlled by fuel quantity regulation and ignition timing adjustment  Microsoft Saturday, September 26, 2009 12:14:01 PM Page 38 © 2005 Mitchell Repair Information Company, LLC.
  39. 39. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe  MODE 3 FORCED IDLE MODE 4 LIMIT PERFORMANCE & POWER MANAGEMENT MODE 5 LIMIT PERFORMANCE MODE 6 NORMAL No information about the accelerator position  Malfuctioning APS 1 and 2, faulty A/D converter or internal controller  ETC system can't securely control engine power  Not reliable accelerator position signal or bad maximum power generation  Faulty APS, ignition voltage or internal controller Forced idle state and no response for accelerator activation Engine power is determined by accelerator position and idle power requirement (Limited vehicle running) 1. Engine power varies with accelerator position, but driver perceives lack of engine power. 2. MIL ON (Normal vehicle running) Normal MASS AIR FLOW SENSOR (MAFS) INSPECTION FUNCTION AND OPERATION PRINCIPLE Mass Air Flow Sensor (MAFS) is a hot-film type sensor and is located in between the air cleaner and the throttle body. It consists of a tube, a sensor assembly and honeycomb cell and detects intake air quantity flowing into the intake manifold. Air flows from the air cleaner assembly through the honeycomb cell and over the hot film element. At this time, heat transfer is generated by convection and this sensor loses its energy. This sensor detects the mass air flow by using the energy loss and transfers the information to the PCM by frequency. The PCM calculates fuel quantity and ignition timing. Microsoft Saturday, September 26, 2009 12:14:01 PM Page 39 © 2005 Mitchell Repair Information Company, LLC.
  40. 40. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 28: Identifying Mass Air Flow Sensor Courtesy of HYUNDAI MOTOR CO. SPECIFICATION MASS AIR FLOW SENSOR - SPECIFICATION Air Flow (kg/h) 12.6 kg/h 18.0 kg/h 23.4 kg/h 32.4 kg/h 43.2 kg/h 57.6 kg/h 72.0 kg/h 108.0 kg/h 144.0 kg/h 198.0 kg/h 270.0 kg/h 360.0 kg/h 486.0 kg/h 666.0 kg/h 900.0 kg/h Output Frequency (Hz) 2,617Hz 2,958Hz 3,241 Hz 3,653Hz 4,024Hz 4,399Hz 4,704Hz 5,329Hz 5,897Hz 6,553Hz 7,240Hz 7,957Hz 8,738Hz 9,644Hz 10,590Hz SCHEMATIC DIAGRAM Fig. 29: Mass Air Flow Sensor Schematic Diagram Microsoft Saturday, September 26, 2009 12:14:01 PM Page 40 © 2005 Mitchell Repair Information Company, LLC.
  41. 41. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Courtesy of HYUNDAI MOTOR CO. INTAKE AIR TEMPERATURE SENSOR (IATS) INSPECTION FUNCTION AND OPERATION PRINCIPLE Fig. 30: Intake Air Temperature Sensor Function And Operation Principle Chart Courtesy of HYUNDAI MOTOR CO. Intake Air Temperature Sensor (IATS) is installed inside the Mass Air Flow Sensor (MAFS) and detects the intake air temperature. To calculate precise air quantity, correction of the air temperature is needed because air density varies according to the temperature. So the PCM uses not only MAFS signal but also IATS signal. This sensor has a Negative Temperature Coefficient (NTC) and its resistance is in inverse proportion to the temperature. SPECIFICATION INTAKE AIR TEMPERATURE SENSOR - SPECIFICATION Temperature Resistance (kohms) °C °F -40 -40 100.87 kohms -20 -4 28.58 kohms 0 32 9.40 kohms 10 50 5.66 kohms 20 68 3.51 kohms 40 104 1.47kohms 60 140 0.67 kohms 80 176 0.33 kohms SCHEMATIC DIAGRAM Microsoft Saturday, September 26, 2009 12:14:01 PM Page 41 © 2005 Mitchell Repair Information Company, LLC.
  42. 42. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 31: Intake Air Temperature Sensor - Schematic Diagram Courtesy of HYUNDAI MOTOR CO. MANIFOLD ABSOLUTE PRESSURE SENSOR (MAPS) INSPECTION FUNCTION AND OPERATION PRINCIPLE Fig. 32: Manifold Absolute Pressure Sensor Function And Operation Principle Chart Courtesy of HYUNDAI MOTOR CO. Manifold Absolute Pressure Sensor (MAPS) is speed-density type sensor and is installed on the surge tank. This MAPS senses absolute pressure in surge tank and transfers this analog signal proportional to the pressure to the PCM. The PCM calculates the intake air quantity and engine speed based on this signal. This MAPS consists of piezo-electric element and hybrid IC that amplifies the element output signal. The element is silicon diaphragm Microsoft Saturday, September 26, 2009 12:14:01 PM Page 42 © 2005 Mitchell Repair Information Company, LLC.
  43. 43. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe type and adapts pressure sensitive variable resistor effect of semi-conductor. 100% vacuum and the manifold pressure applies to both sides of it respectively. That is, this sensor outputs the silicon variation proportional to pressure change by voltage. SPECIFICATION MANIFOLD ABSOLUTE PRESSURE SENSOR - SPECIFICATION Pressure (kPa) Output Voltage (V) 20.0kPa 0.79V 46.66kPa 1.84V 101.32kPa 4.00V SCHEMATIC DIAGRAM Fig. 33: Manifold Absolute Pressure Sensor - Schematic Diagram Courtesy of HYUNDAI MOTOR CO. ENGINE COOLANT TEMPERATURE SENSOR (ECTS) INSPECTION FUNCTION AND OPERATION PRINCIPLE Engine Coolant Temperature Sensor (ECTS) is located in the engine coolant passage of the cylinder head for detecting the engine coolant temperature. The ECTS uses a thermistor whose resistance changes with the temperature. The electrical resistance of the ECTS decreases as the temperature increases, and increases as the temperature decreases. The reference 5 V in the PCM is supplied to the ECTS via a resistor in the PCM That is, the resistor in the PCM and the thermistor in the ECTS are connected in series. When the resistance value of the thermistor in the ECTS changes according to the engine coolant temperature, the output voltage also changes. Microsoft Saturday, September 26, 2009 12:14:01 PM Page 43 © 2005 Mitchell Repair Information Company, LLC.
  44. 44. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe During cold engine operation the PCM increases the fuel injection duration and controls the ignition timing using the information of engine coolant temperature to avoid engine stalling and improve drivability. Fig. 34: Identifying Engine Coolant Temperature Sensor Courtesy of HYUNDAI MOTOR CO. SPECIFICATION ENGINE COOLANT TEMPERATURE SENSOR - SPECIFICATION Temperature Resistance (ohms) °C °F -40 -40 48.14kohms -20 -4 14.13- 16.83kohms 0 32 5.79 kohms 20 68 2.31 ~ 2.59 kohms 40 104 1.15 kohms 60 140 0.59 kohms 80 176 0.32 kohms SCHEMATIC DIAGRAM Microsoft Saturday, September 26, 2009 12:14:01 PM Page 44 © 2005 Mitchell Repair Information Company, LLC.
  45. 45. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 35: Engine Coolant Temperature Sensor - Schematic Diagram Courtesy of HYUNDAI MOTOR CO. CAMSHAFT POSITION SENSOR (CMPS) INSPECTION FUNCTION AND OPERATION PRINCIPLE Camshaft Position Sensor (CMPS) is a hall sensor and detects the camshaft position by using a hall element. It is related with Crankshaft Position Sensor (CKPS) and detects the piston position of each cylinder which the CKPS can't detect. The two CMPS are installed on engine head cover of bank 1 and 2 and uses a target wheel installed on the camshaft. This sensor has a hall-effect IC which output voltage changes when magnetic field is made on the IC with current flow. Fig. 36: Identifying Camshaft Position Sensor Microsoft Saturday, September 26, 2009 12:14:01 PM Page 45 © 2005 Mitchell Repair Information Company, LLC.
  46. 46. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Courtesy of HYUNDAI MOTOR CO. Fig. 37: Identifying Camshaft Position Sensor Components Courtesy of HYUNDAI MOTOR CO. WAVEFORM Fig. 38: Identifying Camshaft Position Sensor Waveform Courtesy of HYUNDAI MOTOR CO. SCHEMATIC DIAGRAM Microsoft Saturday, September 26, 2009 12:14:01 PM Page 46 © 2005 Mitchell Repair Information Company, LLC.
  47. 47. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 39: Camshaft Position Sensor Schematic Diagram Courtesy of HYUNDAI MOTOR CO. CRANKSHAFT POSITION SENSOR (CKPS) INSPECTION FUNCTION AND OPERATION PRINCIPLE Crankshaft Position Sensor (CKPS) detects the crankshaft position and is one of the most important sensors of the engine control system. If there is no CKPS signal input, fuel is not supplied and the main relay does not operate. That is, vehicle can't run without CKPS signal. This sensor is installed on transaxle housing and generates alternating current by magnetic flux field which is made by the sensor and the target wheel when engine runs. The target wheel consists of 58 slots and 2 missing slots on 360 CA (Crank Angle). Microsoft Saturday, September 26, 2009 12:14:01 PM Page 47 © 2005 Mitchell Repair Information Company, LLC.
  48. 48. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 40: Identifying Crankshaft Position Sensor Courtesy of HYUNDAI MOTOR CO. WAVEFORM Fig. 41: Identifying Crankshaft Position Sensor Waveform Courtesy of HYUNDAI MOTOR CO. SCHEMATIC DIAGRAM Microsoft Saturday, September 26, 2009 12:14:01 PM Page 48 © 2005 Mitchell Repair Information Company, LLC.
  49. 49. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 42: Crankshaft Position Sensor - Schematic Diagram Courtesy of HYUNDAI MOTOR CO. HEATED OXYGEN SENSOR (HO2S) INSPECTION FUNCTION AND OPERATION PRINCIPLE Heated Oxygen Sensor (HO2S) consists of zirconium and alumina and is installed on upstream and downstream of the Manifold Catalyst Converter (MCC). After it compares oxygen consistency of the atmosphere with the exhaust gas, it transfers the oxygen consistency of the exhaust gas to the PCM. When A/F ratio is rich or lean, it generates approximately 1V or 0V respectively. In order that this sensor normally operates, the temperature of the sensor tip is higher than 370"C (698°F). So it has a heater which is controlled by the PCM duty signal. When the exhaust gas temperature is lower than the specified value, the heater warms the sensor tip. Microsoft Saturday, September 26, 2009 12:14:01 PM Page 49 © 2005 Mitchell Repair Information Company, LLC.
  50. 50. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 43: Identifying Heated Oxygen Sensor Courtesy of HYUNDAI MOTOR CO. Fig. 44: Exploded View Of Heated Oxygen Sensor Courtesy of HYUNDAI MOTOR CO. SPECIFICATION HEATED OXYGEN SENSOR - SPECIFICATION A/F Ratio RICH LEAN HEATED OXYGEN SENSOR - SPECIFICATION Item Heater Resistance (ohms) Output Voltage (V) 0.75 ~ 1.00V 0 ~ 0.12V Specification 8.1 ~ 11.1 ohms at 21°C (69.8°F) WAVEFORM Microsoft Saturday, September 26, 2009 12:14:01 PM Page 50 © 2005 Mitchell Repair Information Company, LLC.
  51. 51. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 45: Identifying Heated Oxygen Sensor Waveform Courtesy of HYUNDAI MOTOR CO. SCHEMATIC DIAGRAM Microsoft Saturday, September 26, 2009 12:14:02 PM Page 51 © 2005 Mitchell Repair Information Company, LLC.
  52. 52. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 46: Heated Oxygen Sensor Schematic Diagram Courtesy of HYUNDAI MOTOR CO. KNOCK SENSOR (KS) INSPECTION FUNCTION AND OPERATION PRINCIPLE Knocking is a phenomenon characterized by undesirable vibration and noise and can cause engine damage. Knock Sensor (KS) senses engine knocking and the two sensors are installed inside the V-valley of the cylinder block. When knocking occurs, the vibration from the cylinder block is applied as pressure to the piezoelectric element. At this time, this sensor transfers the voltage signal higher than the specified value to the PCM and the Microsoft Saturday, September 26, 2009 12:14:02 PM Page 52 © 2005 Mitchell Repair Information Company, LLC.
  53. 53. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe PCM retards the ignition timing. If the knocking disappears after retarding the ignition timing, the PCM will advance the ignition timing. This sequential control can improve engine power, torque and fuel economy. Fig. 47: Identifying Knock Sensor Courtesy of HYUNDAI MOTOR CO. Fig. 48: Exploded View Of Knock Sensor Courtesy of HYUNDAI MOTOR CO. SPECIFICATION KNOCK SENSOR - SPECIFICATION Item Specification Microsoft Saturday, September 26, 2009 12:14:02 PM Page 53 © 2005 Mitchell Repair Information Company, LLC.
  54. 54. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Capacitance (pF) 1,480 ~ 2,220pF SCHEMATIC DIAGRAM Fig. 49: Identifying Knock Sensor Schematic Diagram Courtesy of HYUNDAI MOTOR CO. INJECTOR INSPECTION FUNCTION AND OPERATION PRINCIPLE Based on information from various sensors, the PCM measures the fuel injection amount. The fuel injector is a solenoid-operated valve and the fuel injection amount is controlled by length of time that the fuel injector is held open. The PCM controls each injector by grounding the control circuit. When the PCM energizes the injector by grounding the control circuit, the circuit voltage should be low (theoretically 0V) and the fuel is injected. When the PCM de-energizes the injector by opening control circuit, the fuel injector is closed and circuit voltage should momentarily peak. WARNING: If an injector connector is disconnected for more than 46 seconds while the engine runs, the PCM will determine that the cylinder is misfiring and cut fuel supply. So be careful not to exceed 46 seconds. But the engine runs normally in 10 seconds after turning the ignition key off. Microsoft Saturday, September 26, 2009 12:14:02 PM Page 54 © 2005 Mitchell Repair Information Company, LLC.
  55. 55. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 50: Identifying Injector Courtesy of HYUNDAI MOTOR CO. SPECIFICATION INJECTOR - SPECIFICATION Item Coil Resistance (ohms) Specification 11.4 ~ 12.6ohms at 20°C (68°F) SCHEMATIC DIAGRAM Microsoft Saturday, September 26, 2009 12:14:02 PM Page 55 © 2005 Mitchell Repair Information Company, LLC.
  56. 56. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 51: Injector Schematic Diagram Courtesy of HYUNDAI MOTOR CO. CVVT OIL CONTROL VALVE (OCV) INSPECTION FUNCTION AND OPERATION PRINCIPLE The Continuously Variable Valve Timing (CVVT) system controls the amount of valve overlap by varying the amount of oil flow into an assembly mounted on each intake camshaft through PCM control of an oil control valve. This system uses two oil control valves, one on each bank. An Oil Temperature Sensor (OTS) is used to Microsoft Saturday, September 26, 2009 12:14:02 PM Page 56 © 2005 Mitchell Repair Information Company, LLC.
  57. 57. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe allow PCM monitoring of engine oil temperature. As oil is directed into the chambers of the CVVT assembly, the cam phase is changed to suit various performance and emissions requirements. 1. When camshaft rotates engine rotation-wise: Intake-Advance / Exhaust-Retard 2. When camshaft rotates counter engine rotation-wise: Intake- Retard / Exhaust- Advance Fig. 52: Identifying CVVT Oil Control Valve Courtesy of HYUNDAI MOTOR CO. SPECIFICATION CVVT OIL CONTROL VALVE - SPECIFICATION Item Coil Resistance (ohms) Specification 6.7 ~ 7.7ohms at 20°C (68°F) SCHEMATIC DIAGRAM Microsoft Saturday, September 26, 2009 12:14:02 PM Page 57 © 2005 Mitchell Repair Information Company, LLC.
  58. 58. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 53: CVVT Oil Control Valve - Schematic Diagram Courtesy of HYUNDAI MOTOR CO. INSTALLATION CAUTION: If the OCVs are installed incorrectly, the vehicle may be damaged. So when installing them, ensure the OCV and harness connector colors match (Components and harness side). [BANK AND ITS COLOR] OCV AND HARNESS CONNECTOR COLORS REFERENCE Bank Component side Bank 1 (RH) Grey Bank 2 (LH) Black Harness side Grey Black CVVT OIL TEMPERATURE SENSOR (OTS) INSPECTION FUNCTION AND OPERATION PRINCIPLE The CVVT Oil Temperature Sensor (OTS) is a negative coefficient thermistor used by the PCM tl measure engine oil temperature for the purpose of adjusting CVVT calculations. Microsoft Saturday, September 26, 2009 12:14:02 PM Page 58 © 2005 Mitchell Repair Information Company, LLC.
  59. 59. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe SPECIFICATION CVVT OIL TEMPERATURE SENSOR - SPECIFICATION Temperature °C °F -20 -4 20 32 80 176 16.52 kohms 2.45 kohms 0.29 kohms SCHEMATIC DIAGRAM Fig. 54: Identifying CVVT Oil Temperature Sensor Courtesy of HYUNDAI MOTOR CO. Fig. 55: CVVT Oil Temperature Sensor - Schematic Diagram Microsoft Saturday, September 26, 2009 12:14:02 PM Page 59 © 2005 Mitchell Repair Information Company, LLC.
  60. 60. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Courtesy of HYUNDAI MOTOR CO. PURGE CONTROL SOLENOID VALVE (PCSV) INSPECTION FUNCTION AND OPERATION PRINCIPLE Purge Control Solenoid Valve (PCSV) is installed on the surge tank and controls the passage between the canister and the intake manifold. It is a solenoid valve and is open when the PCM grounds the valve control line. When the passage is open (PCSV ON), fuel vapors stored in the canister is transferred to the intake manifold. Fig. 56: Identifying Purge Control Solenoid Valve Courtesy of HYUNDAI MOTOR CO. SPECIFICATION PURGE CONTROL SOLENOID VALVE - SPECIFICATION Item Specification Coil Resistance (ohms) 19.0 ~ 22.0 ohms at 20°C (68°F) SCHEMATIC DIAGRAM Microsoft Saturday, September 26, 2009 12:14:02 PM Page 60 © 2005 Mitchell Repair Information Company, LLC.
  61. 61. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 57: Purge Control Solenoid Valve - Schematic Diagram Courtesy of HYUNDAI MOTOR CO. VARIABLE INTAKE SOLENOID (VIS) VALVE INSPECTION FUNCTION AND OPERATION PRINCIPLE Variable Intake Solenoid (VIS) Valve is installed on the intake manifold and changes the effective length of the intake passenger to improve intake efficiency under varying engine conditions. 1. Low/Middle Speed: VIS Valve Close --> Resonation Effect --> Improving Intake Efficiency 2. High Speed: VIS Valve Open --> Improving Intake Inertia Effect -->Improving Intake Efficiency Fig. 58: Locating Variable Intake Solenoid Valve Courtesy of HYUNDAI MOTOR CO. Microsoft Saturday, September 26, 2009 12:14:02 PM Page 61 © 2005 Mitchell Repair Information Company, LLC.
  62. 62. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 59: Identifying Variable Intake Solenoid Valve (Open And Close) Courtesy of HYUNDAI MOTOR CO. SPECIFICATION VARIABLE INTAKE SOLENOID VALVE - SPECIFICATION Item Specification Coil Resistance (ohms) 30.0 ~ 35.0 ohms at 22°C (71.6°F) SCHEMATIC DIAGRAM Fig. 60: Variable Intake Solenoid Valve - Schematic Diagram Courtesy of HYUNDAI MOTOR CO. ACCELERATOR POSITION SENSOR (APS) INSPECTION FUNCTION AND OPERATION PRINCIPLE Microsoft Saturday, September 26, 2009 12:14:02 PM Page 62 © 2005 Mitchell Repair Information Company, LLC.
  63. 63. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 61: Identifying Accelerator Position Sensor Courtesy of HYUNDAI MOTOR CO. Accelerator Position Sensor (APS) is installed on the accelerator pedal module and detects the rotation angle of the accelerator pedal. The APS is one of the most important sensors in engine control system, so it consists of the two sensors which adapt individual sensor power and ground line. The second sensor monitors the first sensor and its output voltage is half of the first one. If the ratio of the sensor 1 and 2 is out of the range (approximately 1/2), the diagnostic system judges that a malfunction has occurred. SPECIFICATION ACCELERATOR POSITION SENSOR - SPECIFICATION Output Voltage (V) [Vref = 5.0V] Pedal Position APS1 APS2 C.T 0.7 ~ 0.8V 0.29 ~ 0.46V W.O.T 3.85 ~ 4.35V 1.93 ~ 2.18V ACCELERATOR POSITION SENSOR - SPECIFICATION Item Sensor Resistance APS1 0.7 ~ 1.3kohms at 20°C (68°F) APS2 1.4 ~ 2.6 kohms at 20°C (68°F) SCHEMATIC DIAGRAM Microsoft Saturday, September 26, 2009 12:14:02 PM Page 63 © 2005 Mitchell Repair Information Company, LLC.
  64. 64. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 62: Accelerator Position Sensor - Schematic Diagram Courtesy of HYUNDAI MOTOR CO. FUEL TANK PRESSURE SENSOR (FTPS) INSPECTION FUNCTION AND OPERATION PRINCIPLE Fig. 63: Identifying Fuel Tank Pressure Sensor Courtesy of HYUNDAI MOTOR CO. Microsoft Saturday, September 26, 2009 12:14:02 PM Page 64 © 2005 Mitchell Repair Information Company, LLC.
  65. 65. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe The evaporative emission control system prevents hydrocarbon vapors from escaping from the fuel tank into the atmosphere where they could form photochemical smog. Gasoline vapors are collected in the charcoal canister. The Fuel Tank Pressure Sensor (FTPS) is installed on fuel pump assembly and is an integral part of the evaporative monitoring system. The PCM monitors the FTPS signal to detect vacuum decay and excess vacuum. The FTPS measures the difference between the air pressure inside the fuel tank and atmospheric air pressure to check the purge control solenoid valve operation and for leak detection in the evaporative emission control system by monitoring pressure and vacuum levels in the fuel tank during the purge control solenoid valve operating cycles. SPECIFICATION FUEL TANK PRESSURE SENSOR - SPECIFICATION Pressure (kPa) -3.75 kPa 0 kPa +1.25 kPa Output Voltage (V) 4.4 ~ 4.6V 1.4 ~ 1.6V 0.4 ~ 0.6V SCHEMATIC DIAGRAM Fig. 64: Fuel Tank Pressure Sensor - Schematic Diagram Courtesy of HYUNDAI MOTOR CO. CANISTER CLOSE VALVE (CCV) INSPECTION FUNCTION AND OPERATION PRINCIPLE The evaporative emission control system prevents hydrocarbon (HC) vapors from the fuel tank from escaping Microsoft Saturday, September 26, 2009 12:14:02 PM Page 65 © 2005 Mitchell Repair Information Company, LLC.
  66. 66. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe into the atmosphere where they could form photochemical smog. Gasoline vapors are collected in the charcoal canister. The Canister Close Valve (CCV) closes off the air inlet into the canister for leak detection of the evaporative emission system. The CCV also prevents fuel vapors from escaping from the canister. When the engine purges the HC vapors from the canister, the clean air comes into the canister through the canister airfilter and the CCV. Fig. 65: Identifying Canister Close Valve Courtesy of HYUNDAI MOTOR CO. SPECIFICATION CANISTER CLOSE VALVE - SPECIFICATION Item Coil Resistance (ohms) Specification 19.9 ~ 22.9ohms at 20°C (68°F) SCHEMATIC DIAGRAM Microsoft Saturday, September 26, 2009 12:14:02 PM Page 66 © 2005 Mitchell Repair Information Company, LLC.
  67. 67. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 66: Canister Close Valve - Schematic Diagram Courtesy of HYUNDAI MOTOR CO. POWERTRAIN CONTROL MODULE (PCM) POWERTRAIN CONTROL MODULE (PCM) 1. PCM HARNESS CONNECTOR Fig. 67: Identifying PCM Harness Connector Courtesy of HYUNDAI MOTOR CO. 2. PCM TERMINAL FUNCTION CONNECTOR [C130-A] PCM TERMINAL FUNCTION - CONNECTOR (C130-A) Pin Description Connected to No. 1 2nd CAN [High] Multi-Purpose Check Connector 2 2nd CAN [Low] Multi-Purpose Check Connector 3 For Auto transaxle Control 4 For Auto transaxle Control 5 For Auto transaxle Control 6 For Auto transaxle Control 7 For Auto transaxle Control 8 For Auto transaxle Control 9 For Auto transaxle Control 10 Power Steering Switch Signal Input Power Steering Switch 11 For Auto transaxle Control 12 13 For Auto transaxle Control 14 15 Alternator load signal input Alternator 16 Cruise Switch ground Cruise Switch Microsoft Saturday, September 26, 2009 12:14:02 PM Page 67 © 2005 Mitchell Repair Information Company, LLC.
  68. 68. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe 17 18 19 20 21 22 23 24 25 26 Sensor ground Air conditioner switch "ON" signal input For Auto transaxle Control Brake switch signal input Brake lamp signal input Cruise Switch signal input Air conditioner blower switch signal input 27 Diagnostic Data Line (K-Line) 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 Fuel Tank Pressure Sensor signal input Fuel level "A" signal input Fuel level "B" signal input A/C Pressure Transducer signal input Sensor ground Canister Close Valve (CCV) control output Battery voltage supply after main relay Battery voltage supply after main relay Battery voltage supply after main relay CAN [High] CAN [Low] Main Relay control output Intake Air Temperature Sensor signal input Immobilizer communication line For Auto transaxle Control Mass Air Flow Sensor signal input Sensor ground Accelerator Position Sensor #2 signal input For Auto transaxle Control Cruise "SET" lamp control output Vehicle speed signal input Sensor ground Accelerator Position Sensor #1 signal input Sensor ground Sensor power (+5V) Fuel Tank Pressure Sensor (FTPS) Air Conditioner Control Module Brake Switch Brake Switch Cruise Switch Air Conditioner Control Module Data Link Connector (DLC), Multi-Purpose Check Connector Fuel Level Sensor (FLS) in Fuel Pump Fuel Level Sensor (FLS) in Sub Fuel Sender A/C Pressure Transducer (APT) A/C Pressure Transducer (APT) Canister Close Valve (CCV) Main Relay Main Relay Main Relay 4WD Control Module, ESC Control Module 4WD Control Module, ESC Control Module Main Relay Intake Air Temperature Sensor (IATS) Immobilizer Mass Air Flow Sensor (MAFS) Accelerator Position Sensor (APS) #2 Accelerator Position Sensor (APS) #2 Cruise "SET" Lamp (Cluster) ESC Control Module Intake Air Temperature Sensor (IATS) Accelerator Position Sensor (APS) #1 Accelerator Position Sensor (APS) #1 Fuel Tank Pressure Sensor (FTPS) Microsoft Saturday, September 26, 2009 12:14:02 PM Page 68 © 2005 Mitchell Repair Information Company, LLC.
  69. 69. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 Sensor power (+5V) Sensor power (+5V) Sensor power (+5V) For Auto transaxle Control Engine speed signal output Fuel consumption signal output Malfunction Indicator Lamp (MIL) control output Air Conditioner Compressor Relay control output Radiator fan relay control output Condenser fan relay #1 control output For Auto transaxle Control Throttle position signal output Cruise "MAIN" lamp control output Fuel Pump Relay control output Variable Intake Solenoid Valve control output Immobilizer lamp control output For Auto transaxle Control For Auto transaxle Control For Auto transaxle Control For Auto transaxle Control For Auto transaxle Control Purge Control Solenoid Valve control output - Accelerator Position Sensor (APS) #2 A/C Pressure Transducer (APT) Accelerator Position Sensor (APS) #1 Cluster (Tachometer) Trip Computer Cluster (Malfunction Indicator Lamp) Air Conditioner Compressor Relay Radiator fan relay Condenser fan relay #1 ECS Control Module, EPS Control Module Cruise "MAIN" Lamp (Cluster) Fuel Pump Relay Variable Intake Solenoid (VIS) Valve Immobilizer Lamp Purge Control Solenoid Valve (PCSV) - CONNECTOR [C130-B] PCM TERMINAL FUNCTION - CONNECTOR (C130-B) Pin Description Connected to No. 1 ETC Motor [-] control output ETC Motor (in ETC Module) 2 ETC Motor [+] control output ETC Motor (in ETC Module) 3 For Auto transaxle Control 4 CVVT Oil Temperature Sensor signal input CVVT Oil Temperature Sensor (OTS) 5 6 For Autotransaxle Control Engine Coolant Temperature Sensor signal 7 Engine Coolant Temperature Sensor (ECTS) input Microsoft Saturday, September 26, 2009 12:14:02 PM Page 69 © 2005 Mitchell Repair Information Company, LLC.
  70. 70. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Manifold Absolute Pressure Sensor signal input For Auto transaxle Control For Auto transaxle Control Sensor power (+5V) Battery voltage supply after ignition switch Sensor power (+5V) Sensor ground Sensor power (+5V) Sensor power (+5V) Sensor ground Sensor ground Ignition Coil (Cylinder #6) control output Crankshaft Position Sensor [High] signal input For Auto transaxle Control 23 Sensor Shield 24 25 26 27 28 29 30 31 32 33 Camshaft Position Sensor [Bank 2] signal input Camshaft Position Sensor [Bank 1] signal input Sensor ground Sensor ground Sensor ground Sensor ground Sensor power (+5V) Sensor ground 34 Sensor ground 35 36 37 38 39 40 Power ground Power ground Power ground Power ground Power ground Ignition Coil (Cylinder #4) control output Crankshaft Position Sensor [Low] signal 41 input 42 For Auto transaxle Control Manifold Absolute Pressure Sensor (MAPS) Manifold Absolute Pressure Sensor (MAPS) Ignition Switch Throttle Position Sensor (TPS) #2 Throttle Position Sensor (TPS) #1 Camshaft Position Sensor (CMPS) [Bank 2] Throttle Position Sensor (TPS) #1 Camshaft Position Sensor (CMPS) [Bank 2] Camshaft Position Sensor (CMPS) [Bank 1] Ignition Coil (Cylinder #6) Crankshaft Position Sensor (CKPS) Crankshaft Position Sensor (CKPS), Knock Sensor (KS) #1,2 Camshaft Position Sensor (CMPS) [Bank 2] Camshaft Position Sensor (CMPS) [Bank 1] HO2S (B2/S1) HO2S (B2/S2) HO2S (B1/S1) HO2S (B1/S2) Camshaft Position Sensor (CMPS) [Bank 1] Engine Coolant Temperature Sensor (ECTS) Manifold Absolute Pressure Sensor (MAPS), CVVT Oil Temperature Sensor (OTS) Chassis Ground Chassis Ground Chassis Ground Chassis Ground Chassis Ground Ignition Coil (Cylinder #4) Crankshaft Position Sensor (CKPS) Microsoft Saturday, September 26, 2009 12:14:02 PM Page 70 © 2005 Mitchell Repair Information Company, LLC.
  71. 71. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 For Auto transaxle Control For Auto transaxle Control For Auto transaxle Control Throttle Position Sensor #1 signal input Heated Oxygen Sensor [Bank 1 / Sensor 1] signal input Heated Oxygen Sensor [Bank 1 / Sensor 2] signal input Heated Oxygen Sensor [Bank 2 / Sensor 1] signal input Heated Oxygen Sensor [Bank 2 / Sensor 2] signal input Knock Sensor (KS) #2 [High] signal input Knock Sensor (KS) #2 [Low] signal input Knock Sensor (KS) #1 [Low] signal input Knock Sensor (KS) #1 [High] signal input Throttle Position Sensor #2 signal input Sensor ground For Auto transaxle Control Ignition Coil (Cylinder #2) control output CVVT Oil Control Valve [Bank 2] control output CVVT Oil Control Valve [Bank 1] control output Injector (Cylinder #2) control output Injector (Cylinder #3) control output Heated Oxygen Sensor [Bank 2 / Sensor 1] Heater control output Injector (Cylinder #4) control output Injector (Cylinder #5) control output Heated Oxygen Sensor [Bank 1 / Sensor 1] Heater control output Injector (Cylinder #6) control output Injector (Cylinder #1) control output Heated Oxygen Sensor [Bank 2 / Sensor 2] Heater control output Heated Oxygen Sensor [Bank 1 / Sensor 2] Heater control output Throttle Position Sensor (TPS) #1 HO2S (B1/S1) HO2S (B1/S2) HO2S (B2/S1) HO2S (B2/S2) Knock Sensor (KS) #2 [High] Knock Sensor (KS) #2 [Low] Knock Sensor (KS) #1 [Low] Knock Sensor (KS) #1 [High] Throttle Position Sensor (TPS) #2 Throttle Position Sensor (TPS) #2 Ignition Coil (Cylinder #2) CVVT Oil Control Valve (OCV) [Bank 2] CVVT Oil Control Valve (OCV) [Bank 1] Injector (Cylinder #2) Injector (Cylinder #3) HO2S (B2/S1) Injector (Cylinder #4) Injector (Cylinder #5) HO2S (B1/S1) Injector (Cylinder #6) Injector (Cylinder #1) HO2S (B2/S2) HO2S (B1/S2) Microsoft Saturday, September 26, 2009 12:14:02 PM Page 71 © 2005 Mitchell Repair Information Company, LLC.
  72. 72. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe 75 76 77 78 79 80 For Auto transaxle Control Battery Voltage Ignition Coil (Cylinder #3) control output Ignition Coil (Cylinder #5) control output Ignition Coil (Cylinder #1) control output - Battery Ignition Coil (Cylinder #3) Ignition Coil (Cylinder #5) Ignition Coil (Cylinder #1) 3. PCM TERMINAL INPUT/OUTPUT SIGNAL CONNECTOR [C130-A] PCM TERMINAL INPUT/OUTPUT SIGNAL - CONNECTOR (C130-A) Pin Test Description Condition Type Level No. Result 1 2nd CAN [High] Idle DC 2.0 ~ 3.0V 2.5V 2 2nd CAN [Low] Idle 2.0 ~ 3.0V 2.5V 3 For Auto transaxle Control 4 For Auto transaxle Control 5 For Auto transaxle Control 6 For Auto transaxle Control 7 For Auto transaxle Control 8 For Auto transaxle Control 9 For Auto transaxle Control 10 Power Steering Switch signal input 11 For Auto transaxle Control 12 13 For Auto transaxle Control 14 High: Battery Voltage 13.6V 15 Alternator load signal input Idle PULSE Low: Max. 1.5V 0V 140 ~ 190Hz 160Hz 16 Cruise Switch ground 17 Sensor ground Idle DC Max. 50mV 30mV A/C Relay OFF Battery Voltage 9.1V Air conditioner switch "ON" signal 18 DC input A/C Relay ON Max. 1.0V 0.1V 19 20 For Auto transaxle Control Brake pedal Battery Voltage 12.7V releasing 21 Brake switch signal input DC Brake pedal Max. 0.5V 0.03V pressing 22 Microsoft Saturday, September 26, 2009 12:14:02 PM Page 72 © 2005 Mitchell Repair Information Company, LLC.
  73. 73. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe 23 Brake lamp signal input Brake pedal releasing Brake pedal pressing 24 25 Cruise Switch signal input A/C OFF Air conditioner blower switch signal 26 input A/C ON 27 Diagnostic Data Line (K-Line) Max. 0.5V 0V Battery Voltage 13.0V DC Max. 1.0V Battery Voltage High: Min. Vbatt * 80% When transmitting Low: Max. Vbatt * 20% PULSE High: Min. Vbatt * 70% When receiving Low: Max. Vbatt * 30% DC 0V 11.9V 11.3V 0.14V 11.3V 0.32V Fuel Tank Pressure Sensor signal input 29 Fuel level "A" signal input 30 Fuel level "B" signal input 31 28 A/C OFF 32 A/C Pressure Transducer signal input A/CON 33 Sensor ground Idle 34 35 36 37 Canister Close Valve Control output IG OFF Battery voltage supply after main 38 relay IG ON IG OFF Battery voltage supply after main 39 relay IG ON IG OFF Battery voltage supply after main 40 relay IG ON RECESSIVE 41 CAN [High] DOMINANT RECESSIVE 42 CAN [Low] DOMINANT Relay ON 43 Main Relay control output Relay OFF DC 0 ~ 5.0V DC Max. 50mV 1.85 ~ 2.2V 40mV Max. 1.0V Battery Voltage Max. 1.0V Battery Voltage Max. 1.0V Battery Voltage 2.0 ~ 3.0V 2.75 ~ 4.5V 2.0 ~ 3.0V 2.75-4.5V Battery Voltage Max. 1.0V 0V 12.1V 0V 12.1V 0V 12.1V 3.85V 2.5V 2.55V 1.34V 12.3V 0.87V DC DC DC PULSE PULSE DC Intake Air Temperature Sensor signal Microsoft Saturday, September 26, 2009 12:14:02 PM Page 73 © 2005 Mitchell Repair Information Company, LLC.
  74. 74. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe 44 input 45 Immobilizer communication line 46 For Auto transaxle Control Idle Idle 47 Mass Air Flow Sensor signal input 3,000 rpm 48 Sensor ground Idle C.T Accelerator Position Sensor #2 signal 49 input W.O.T 50 For Auto transaxle Control 51 Cruise "SET" lamp control output 52 Vehicle speed signal input 61 Engine speed signal output Idle 62 Fuel consumption signal output Idle Malfunction Indicator Lamp (MIL) control output Air Conditioner Compressor Relay 64 control output 65 Radiator fan relay control output 0 ~ 5.0V MIL OFF MIL ON A/C OFF A/CON 1.86V High: Vref Low: Max. 0.5V Idle: 3.0KHz PULSE High: Vref Low: Max. 0.5V 3000rpm: 4.5 kHz DC Max. 50mV 0.3 ~ 0.9V Analog 1.5 ~ 3.0V 35mV 0.4V 2.1V High: Min. 5.0V Low: Max. 1.0V DC DC Max. 50mV 0.3 ~ 0.9V Analog 4.0 ~ 4.8V DC DC Max. 50mV Max. 0.5V DC 4.9 ~ 5.1V Max. 0.5V DC 4.9 ~ 5.1V Max. 0.5V 4.9 ~ 5.1V Max. 0.5V DC 4.9 ~ 5.1V 12.6V 0.2V 34mV 0.77V 4.23V 36mV 0V 5.01V 0V 5.08V 0V 5.08V 0V 5.08V High: Battery Voltage PULSE Low: Max. 0.5V 20~26Hz High: Battery Voltage or Vref PULSE Low: Max. 0.5V High: Battery Voltage DC Low: Max. 2.0V Battery Voltage DC Max. 1.0V 13.0V 0V 35Hz Vehicle running PULSE 53 Sensor ground Idle C.T Accelerator Position Sensor #1 signal 54 input W.O.T 55 Sensor ground Idle IG OFF 56 Sensor power (+5V) IG ON IG OFF 57 Sensor power (+5V) IG ON IG OFF 58 Sensor power (+5V) IG ON IG OFF 59 Sensor power (+5V) IG ON 60 For Auto transaxle Control 63 Analog 5.04V 0.27V 5.04V 0.27V 12.8V 0V 4.24V 0V 13.0V 0.14V Condenser fan relay #1 control Microsoft Saturday, September 26, 2009 12:14:02 PM Page 74 © 2005 Mitchell Repair Information Company, LLC.
  75. 75. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe 66 output 67 For Auto transaxle Control 68 Throttle position signal output Cruise "CRUISE" lamp control 69 output 70 Fuel Pump Relay control output 71 72 73 74 75 76 77 Variable Intake Solenoid Valve control output Immobilizer lamp control output For Auto transaxle Control For Auto transaxle Control For Auto transaxle Control For Auto transaxle Control For Auto transaxle Control Purge Control Solenoid Valve 78 control output 79 80 Relay OFF Relay ON Active Inactive DC DC Battery Voltage Max. 1.0V Max. 1.0V Battery Voltage High: Battery Voltage Inactive Active PULSE Low: Max. 1.0V 12.5V 0.09V 0.1V 12.4V 13.2V 0.08V 16Hz - CONNECTOR [C130-B] PCM TERMINAL INPUT/OUTPUT SIGNAL - CONNECTOR (C130-B) Pin Description Condition Type Level No. High: Battery Voltage 1 ETC Motor [-] control output Idle PULSE Low: Max. 1.0V 2 ETC Motor [+] control output 3 For Autotransaxle Control CVVT Oil Temperature Sensor signal input For Auto transaxle Control Engine Coolant Temperature Sensor signal input Manifold Absolute Pressure Sensor signal input For Auto transaxle Control 4 5 6 7 8 9 High: Battery Voltage Low: Max. 1.0V Test Result 13.3 V 0.3V 3.14KHz 13.3V 0.4V 3.14KHz Idle PULSE Idle Analog 0.5 ~ 4.5V 1.68V Idle Analog 0.5 ~ 4.5V 0.47V Analog 3.9 ~ 4.1V 0.8 ~ 1.6V 4.01V 1.59V IG ON Idle Microsoft Saturday, September 26, 2009 12:14:02 PM Page 75 © 2005 Mitchell Repair Information Company, LLC.
  76. 76. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe 10 For Auto transaxle Control 11 Sensor power (+5V) 12 Battery voltage supply after ignition switch 13 Sensor power (+5V) 14 Sensor ground 15 Sensor power (+5V) 16 Sensor power (+5V) 17 Sensor ground 18 Sensor ground 19 Ignition Coil (Cylinder #6) control output 20 Crankshaft Position Sensor [High] 21 signal input 22 For Autotransaxle Control 23 Sensor Shield IG OFF IG ON IG OFF IG ON IG OFF IG ON Idle IG OFF IG ON IG OFF IG ON Idle Idle DC DC DC DC DC DC DC DC Idle PULSE Idle Sine Wave Idle DC Max. 0.5V 4.9 ~ 5.1V Max. 0.5V Battery Voltage Max. 0.5V 4.9 ~ 5.1V Max. 50mV Max. 0.5V 4.9 ~ 5.1V Max. 0.5V 4.9 ~ 5.1V Max. 50mV Max. 50mV 1st: 300~400V ON: Max. 2V 0V 5.08V 0V 12.2V 0V 5.05V 30mV 0V 5.06V 0V 5.06V 30mV 30mV 272V 1.2V 5.8Hz Vp_p: Min.LOV 8V 700Hz 24 Camshaft Position Sensor [Bank 2] signal input Idle PULSE Max. 50mV High: Vref Low: Max. 0.5V 25 Camshaft Position Sensor [Bank 1] signal input Idle PULSE High: Vref Low: Max. 0.5V 26 27 28 29 30 31 Sensor ground Sensor ground Sensor ground Sensor ground 32 Sensor power (+5V) 33 34 35 36 37 32mV 5.08V 0.06V 40Hz 5.08V 0.06V 40Hz Sensor ground Sensor ground Power ground Power ground Power ground Idle Idle Idle Idle IG OFF IG ON Idle Idle Idle Idle Idle DC DC DC DC DC DC DC DC DC DC Max. 50mV Max. 50mV Max. 50mV Max. 50mV Max. 0.5V 4.9 ~ 5.1V Max. 50mV Max. 50mV Max. 50mV Max. 50mV Max. 50mV 27mV 27mV 26V 27mV 0V 5.06V 13mV 13mV 0mV 0mV 0mV Microsoft Saturday, September 26, 2009 12:14:02 PM Page 76 © 2005 Mitchell Repair Information Company, LLC.
  77. 77. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe 38 Power ground 39 Power ground 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 Ignition Coil (Cylinder #4) control output Crankshaft Position Sensor [Low] signal input For Auto transaxle Control For Auto transaxle Control For Auto transaxle Control For Auto transaxle Control Throttle Position Sensor #1 signal input Heated Oxygen Sensor [Bank 1 / Sensor 1] signal input Heated Oxygen Sensor [Bank 1 / Sensor 2] signal input Heated Oxygen Sensor [Bank 2 / Sensor 1] signal input Heated Oxygen Sensor [Bank 2 / Sensor 2] signal input Knock Sensor (KS) #2 [High] signal input Knock Sensor (KS) #2 [Low] signal input Knock Sensor (KS) #1 [Low] signal input Knock Sensor (KS) #1 [High] signal input Throttle Position Sensor #2 signal input Sensor ground For Auto transaxle Control Ignition Coil (Cylinder #2) control 60 output CVVT Oil Control Valve [Bank 2] 61 control output Idle Idle DC DC Idle PULSE Idle Sine Wave C.T W.O.T Engine Running Engine Running Engine Running Engine Running Knocking Normal Knocking Normal Knocking Normal Knocking Normal C.T W.O.T Idle Idle Idle Max. 50mV Max. 50mV 1st: 300-400V ON: Max. 2V Vp_p: Min.LOV DC 0.25 ~ 0.9V Min. 4.0V Rich: 0.6 ~ 1.0V Lean: 0 ~ 0.4V Rich: 0.6 ~ 1.0V Lean: 0 ~ 0.4V Rich: 0.6 ~ 1.0V Lean: 0 ~ 0.4V Rich: 0.6 ~ 1.0V Lean: 0 ~ 0.4V -0.3 ~ 0.3 V 0V -0.3 ~ 0.3 V 0V -0.3 ~ 0.3 V 0V -0.3 ~ 0.3 V 0V Min. 4.0V 0.25 ~ 0.9V Max. 50mV PULSE 1st: 300~400V ON: Max. 2V Analog DC DC DC DC Variable Frequency Variable Frequency Variable Frequency Variable Frequency Analog PULSE Battery Voltage Max. 1.0V Duty variance when 2mV 2mV 263V 1.4V 5.8Hz 8V 700Hz 0.95V 0.13V 0.88V 0.21V 0.91V 0.18V 0.89V 0.22V 1.7V 1.7V 1.7V 1.7V 17mV 266V 1.3V 5.8Hz 14.5V 0.1V Microsoft Saturday, September 26, 2009 12:14:02 PM Page 77 © 2005 Mitchell Repair Information Company, LLC.
  78. 78. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe 62 63 64 CVVT Oil Control Valve [Bank 1 ] control output Injector (Cylinder #2) control output Injector (Cylinder #3) control output 65 66 PULSE Idle PULSE Idle PULSE Injector (Cylinder #4) control output Engine Running Idle Idle Heated Oxygen Sensor [Bank 1 / 70 Sensor 1] Heater control output Engine Running 71 Injector (Cylinder #6) control output PULSE Idle PULSE PULSE Injector (Cylinder #1) control output Idle Heated Oxygen Sensor [Bank 2 / 73 Sensor 2] Heater control output Engine Running 72 PULSE PULSE Injector (Cylinder #5) control output 69 High: Battery Voltage Low: Max. 1.0V Vpeak: Max. 80V 128Hz 14.3V 0.1V 128Hz 13.8V 0.13V 57.5V 5.8Hz 13.8V 0.13V 56.8V 5.8Hz - Heated Oxygen Sensor [Bank 2 / 67 Sensor 1] Heater control output 68 Idle operating the accelerator Battery Voltage Max. 1.0V Duty variance when operating the accelerator High: Battery Voltage Low: Max. 1.0V Vpeak: Max. 80V PULSE PULSE High: Battery Voltage Low: Max. 1.0V High: Battery Voltage Low: Max. 1.0V Vpeak: Max. 80V High: Battery Voltage Low: Max. 1.0V Vpeak: Max. 80V High: Battery Voltage Low: Max. 1.0V High: Battery Voltage Low: Max. 1.0V Vpeak: Max. 80V High: Battery Voltage Low: Max. 1.0V Vpeak: Max. 80V High: Battery Voltage Low: Max. 1.0V High: Battery Voltage 13.8V 0.17V 16Hz 13.8V 0.13V 56.8V 5.8Hz 13.7V 0.13V 56.8V 5.8Hz 13.8V 0.17V 16Hz 13.8V 0.13V 56.8V 5.8Hz 13.8V 0.13V 56.8V 5.8Hz 13.9V 0.19V 16Hz 13.9V Microsoft Saturday, September 26, 2009 12:14:02 PM Page 78 © 2005 Mitchell Repair Information Company, LLC.
  79. 79. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Heated Oxygen Sensor [Bank 1 / Sensor 2] Heater control output 75 For Auto transaxle Control 76 Battery Voltage 74 77 Ignition Coil (Cylinder #3) control output Ignition Coil (Cylinder #5) control 78 output Ignition Coil (Cylinder #1) control 79 output 80 Low: Max. 1.0V 0.18V 16Hz PULSE Battery Voltage 1st: 300~400V ON: Max. 2V PULSE 1st: 300~400V ON: Max. 2V PULSE 1st: 300~400V ON: Max. 2V 13.0V 266V 1.4V 5.8Hz 267V 1.4V 5.8Hz 268V 1.4V 5.8Hz Engine Running PULSE Always DC Idle Idle Idle - CIRCUIT DIAGRAM Microsoft Saturday, September 26, 2009 12:14:02 PM Page 79 © 2005 Mitchell Repair Information Company, LLC.
  80. 80. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 68: Powertrain Control Module - Circuit Diagram (1 Of 5) Microsoft Saturday, September 26, 2009 12:14:02 PM Page 80 © 2005 Mitchell Repair Information Company, LLC.
  81. 81. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Courtesy of HYUNDAI MOTOR CO. Fig. 69: Powertrain Control Module - Circuit Diagram (2 Of 5) Microsoft Saturday, September 26, 2009 12:14:02 PM Page 81 © 2005 Mitchell Repair Information Company, LLC.
  82. 82. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Courtesy of HYUNDAI MOTOR CO. Microsoft Saturday, September 26, 2009 12:14:02 PM Page 82 © 2005 Mitchell Repair Information Company, LLC.
  83. 83. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 70: Powertrain Control Module - Circuit Diagram (3 Of 5) Courtesy of HYUNDAI MOTOR CO. Microsoft Saturday, September 26, 2009 12:14:02 PM Page 83 © 2005 Mitchell Repair Information Company, LLC.
  84. 84. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 71: Powertrain Control Module - Circuit Diagram (4 Of 5) Courtesy of HYUNDAI MOTOR CO. Microsoft Saturday, September 26, 2009 12:14:02 PM Page 84 © 2005 Mitchell Repair Information Company, LLC.
  85. 85. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 72: Powertrain Control Module - Circuit Diagram (5 Of 5) Microsoft Saturday, September 26, 2009 12:14:02 PM Page 85 © 2005 Mitchell Repair Information Company, LLC.
  86. 86. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Courtesy of HYUNDAI MOTOR CO. PCM PROBLEM INSPECTION PROCEDURE 1. TEST PCM GROUND CIRCUIT: Measure resistance between PCM and chassis ground using the backside of PCM harness connector as PCM side check point. If the problem is found, repair it. Specification (Resistance): 1 ohms or less 2. TEST PCM CONNECTOR: Disconnect the PCM connector and visually check the ground terminals on PCM side and harness side for bent pins or poor contact pressure. If the problem is found, repair it. 3. If problem is not found in Step 1 and 2, the PCM could be faulty. If so, replace the PCM with a new one, and then check the vehicle again. If the vehicle operates normally then the problem was likely with the PCM. 4. RE-TEST THE ORIGINAL PCM : Install the original PCM (may be broken) into a known-good vehicle and check the vehicle. If the problem occurs again, replace the original PCM with a new one. If problem does not occur, this is intermittent problem (Refer to INTERMITTENT PROBLEM PROCEDURE in BASIC INSPECTION PROCEDURE). VIN PROGRAMMING PROCEDURE VIN (Vehicle Identification Number) is a number that has the vehicle's information (Maker, Vehicle Type, Vehicle Line/Series, Body Type, Engine Type, Transmission Type, Model Year, Plant Location and so forth. For more information, please refer to the GENERAL INFORMATION in this SERVICE MANUAL). When replacing an PCM, the VIN must be programmed in the PCM. If there is no VIN in PCM memory, the fault code (DTC P0630) is set. CAUTION: The programmed VIN cannot be changed. When writing the VIN, confirm the VIN carefully 1. Select "Vehicle" and "Engine" (For example, TUCSON 2.0L L4). Microsoft Saturday, September 26, 2009 12:14:02 PM Page 86 © 2005 Mitchell Repair Information Company, LLC.
  87. 87. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 73: VIN Programming Procedure - Vehicle And Engine Courtesy of HYUNDAI MOTOR CO. 2. Select "VIN WRITING". Fig. 74: VIN Programming Procedure - VIN WRITING Microsoft Saturday, September 26, 2009 12:14:02 PM Page 87 © 2005 Mitchell Repair Information Company, LLC.
  88. 88. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Courtesy of HYUNDAI MOTOR CO. 3. Check the PCM status. Fig. 75: VIN Programming Procedure - PCM Status Courtesy of HYUNDAI MOTOR CO. NOTE:   VIRGIN: VIN is not programmed LEARNT: VIN has been already programmed Is the PCM status "VIRGIN"? YES  Go to next step 4. NO END 4. Write the VIN with cursor, function and number keys.  WARNING: Before pressing the "ENTER" key, confirm the VIN again because the programmed VIN cannot be changed. Microsoft Saturday, September 26, 2009 12:14:02 PM Page 88 © 2005 Mitchell Repair Information Company, LLC.
  89. 89. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Fig. 76: VIN Programming Procedure - WRITE VIN Courtesy of HYUNDAI MOTOR CO. 5. After verifying the written VIN, press the "ENTER" key. 6. Turn the ignition switch OFF, and then turn ON. Fig. 77: VIN Programming Procedure - ENTER Key Microsoft Saturday, September 26, 2009 12:14:02 PM Page 89 © 2005 Mitchell Repair Information Company, LLC.
  90. 90. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe Courtesy of HYUNDAI MOTOR CO. 7. Verify the programmed VIN in the PCM memory. DTC TROUBLESHOOTING PROCEDURES INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODES (DTC) DIAGNOSTIC TROUBLE CODES CHART DTC Description P0011 "A" Camshaft Position-Timing Over-Advanced or System Performance (Bank 1) P0012 "A" Camshaft Position-Timing Over-Retarded (Bank 1) P0016 Crankshaft Position-Camshaft Position Correlation (Bank 1 Sensor A) P0018 Crankshaft Position-Camshaft Position Correlation (Bank 2 Sensor A) P0021 "A" Camshaft Position-Timing Over-Advanced or System Performance (Bank 2) P0022 "A" Camshaft Position-Timing Over-Retarded (Bank 2) P0026 Intake Valve Control Solenoid Circuit Range/Performance (Bank 1) P0028 Intake Valve Control Solenoid Circuit Range/Performance (Bank 2) P0030 HO2S Heater Control Circuit (Bank 1 / Sensor 1) P0031 HO2S Heater Circuit Low (Bank 1 / Sensor 1) P0032 HO2S Heater Circuit High (Bank 1 / Sensor 1) P0036 HO2S Heater Control Circuit (Bank 1 / Sensor 2) P0037 HO2S Heater Circuit Low (Bank 1 / Sensor 2) P0038 HO2S Heater Circuit High (Bank 1 / Sensor 2) P0050 HO2S Heater Control Circuit (Bank 2 / Sensor 1) P0051 HO2S Heater Circuit Low (Bank 2 / Sensor 1) P0052 HO2S Heater Circuit High (Bank 2 / Sensor 1) P0056 HO2S Heater Control Circuit (Bank 2 / Sensor 2) P0057 HO2S Heater Circuit Low (Bank 2 / Sensor 2) P0058 HO2S Heater Circuit High (Bank 2 / Sensor 2) P0076 Intake Valve Control Solenoid Circuit Low (Bank 1) P0077 Intake Valve Control Solenoid Circuit High (Bank 1) P0082 Intake Valve Control Solenoid Circuit Low (Bank 2) P0083 Intake Valve Control Solenoid Circuit High (Bank 2) P0101 Mass or Volume Air Flow Circuit Range/Performance P0102 Mass or Volume Air Flow Circuit Low Input P0103 Mass or Volume Air Flow Circuit High Input P0105 Manifold Absolute Pressure/Barometric Pressure Circuit P0106 Manifold Absolute Pressure/Barometric Pressure Circuit Range/Performance P0107 Manifold Absolute Pressure/Barometric Pressure Circuit Low Input P0108 Manifold Absolute Pressure/Barometric Pressure Circuit High Input P0110 Intake Air Temperature Sensor1 Circuit MIL Page • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Microsoft Saturday, September 26, 2009 12:14:02 PM Page 90 © 2005 Mitchell Repair Information Company, LLC.
  91. 91. 2007 Hyundai Santa Fe Limited 2007 ENGINE PERFORMANCE Fuel System (G6DA-GSL 3.3) - Santa Fe P0111 Intake Air Temperature Sensor1 Circuit Range/Performance P0112 Intake Air Temperature Sensor1 Circuit Low Input P0113 Intake Air Temperature Sensor1 Circuit High Input P0115 Engine Coolant Temperature Circuit P0116 Engine Coolant Temperature Circuit Range/Performance P0117 Engine Coolant Temperature Circuit Low Input P0118 Engine Coolant Temperature Circuit High Input P0122 Throttle/Pedal Position Sensor/Switch "A" Circuit Low Input P0123 Throttle/Pedal Position Sensor/Switch "A" Circuit High Input P0125 Insufficient Coolant Temperature for Closed Loop Fuel Control P0128 Coolant Thermostat (Coolant Temperature below Thermostat Regulating Temperature) P0131 HO2S Circuit Low Voltage (Bank 1 / Sensor 1) P0132 HO2S Circuit High Voltage (Bank 1 / Sensor 1) P0133 HO2S Circuit Slow Response (Bank 1 / Sensor 1) P0134 HO2S Circuit No Activity Detected (Bank 1 / Sensor 1) P0137 HO2S Circuit Low Voltage (Bank 1 / Sensor 2) P0138 HO2S Circuit High Voltage (Bank 1 / Sensor 2) P0139 HO2S Circuit Slow Response (Bank 1 / Sensor 2) P0140 HO2S Circuit No Activity Detected (Bank 1 / Sensor 2) P0151 HO2S Circuit Low Voltage (Bank 2 / Sensor 1) P0152 HO2S Circuit High Voltage (Bank 2 / Sensor 1) P0153 HO2S Circuit Slow Response (Bank 2 / Sensor 1) P0154 HO2S Circuit No Activity Detected (Bank 2 / Sensor 1) P0157 HO2S Circuit Low Voltage (Bank 2 / Sensor 2) P0158 HO2S Circuit High Voltage (Bank 2 / Sensor 2) P0159 HO2S Circuit Slow Response (Bank 2 / Sensor 2) P0160 HO2S Circuit No Activity Detected (Bank 2 / Sensor 2) P0171 System Too Lean (Bank 1) P0172 System Too Rich (Bank 1) P0174 System Too Lean (Bank 2) P0175 System Too Rich (Bank 2) P0196 Engine Oil Temperature Sensor Range / Performance P0197 Engine Oil Temperature Sensor Low Input P0198 Engine Oil Temperature Sensor High Input P0217 Engine Coolant Over Temperature Condition P0222 Throttle/Pedal Position Sensor/Switch "B" Circuit Low Input P0223 Throttle/Pedal Position Sensor/Switch "B" Circuit High Input P0230 Fuel Pump Primary Circuit P0261 Cylinder 1-Injector Circuit Low P0262 Cylinder 1-Injector Circuit High P0264 Cylinder 2-Injector Circuit Low • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Microsoft Saturday, September 26, 2009 12:14:02 PM Page 91 © 2005 Mitchell Repair Information Company, LLC.

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