Motor 2,0 Diesel

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    C100 Service Training Manual :

    Engine Mechanical (2.0L Diesel)

    Participants Handout

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    01.3-3

    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout

    rev 01

    Table Of Contents

    Engine General ........ 5

    Engine Mechanical ............. 8

    Engine Lubrication . 22

    Engine Timing system ....... 23

    Accessory Belt ... 26

    Engine Intake & Exhaust system .... 27

    Engine Vacuum System .............. 29

    PCV System ... 30

    DPF system ... 31

    Engine Cooling system.. 31

    Turbo-Charger system.. 39

    Fuel Supply system ...... 33

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    01.3-4

    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout

    rev 01

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    01.3-5

    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout

    rev 01

    Engine general

    1. Engine Type (Z : Diesel)

    2. Engine Size (20 : 2.0L)

    3. Cam Mechanism (DOHC or SOHC)

    4. Sequence Number

    5. Manufacturers country (K : Korea)

    6. Barcode Check

    Engine number

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    01.3-6

    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout

    rev 01

    Engine general

    2.0L Diesel

    186 kph/ 180 kph

    5.75 m

    4 Cy linder(In-Line)

    83 x 92

    1.991

    17.5 : 1

    110/4000

    320/2000

    Compression ignition system

    1-3-4-2

    Forced feed

    MB 229.31 5W 40

    Cartridge

    6.2 L

    Gerotor

    Bore x Stroke (mm)

    APPL ICATION

    Max Speed (MT/AT)

    Min Turning Ratio (m)

    Vehicle

    Performance

    Engine

    General

    Engine type

    Displacement (cc)

    Compression Ratio

    Max Power (kW/RPM)

    IgnitionIgnition sequence

    Max Torque (Nm/RPM)

    Type

    Lubrication

    Type

    Oil Type and Grade

    Filter

    Oil Capacity (w/filter)

    Oil Pump type

    Pressurized

    9

    Centrifugal

    Cross-flow

    673 mm (Width)

    511 mm (Height)

    27 mm (Thickness)

    137.3 Kpa

    9.81 Kpa

    WAX Pellet

    Starts to open () 80 2

    Completely open ( ) 95

    Completely close ( ) MIN 75

    Electric

    Main:5EA / Aux: 7EA

    Fan Diameter 340mm + 320 mm

    Type

    Coolant Capacity (L)

    Cooling

    Radiator

    Type

    Thermostat

    Type

    Fan

    Type

    Core

    Blades

    Water Pump

    Surge TankPressure Valve open

    Vaccum Valve open

    Engine specifications

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    01.3-7

    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout

    rev 01

    Engine general

    2.0L diesel

    Electric motor in fuel tank

    Depth Media

    165 ~215(at 4.5 bar)

    4.15 ~5.35

    Common rail

    3 cylinder radial plunger

    695(mm) / rev

    Max 1600 bar

    Max 1600 bar

    Cartridge

    65 L

    Planetary Gear Reduction

    1.8KW

    Alternator 125A

    MF

    12V- 90AH

    912 CCA

    Fuel

    Delivery

    Filter type

    Displacement (/H)

    Fuel pressure (bar)

    Low

    pressure

    pump

    Pump type

    High

    pressure

    pump

    Pump type

    Fuel pressure

    Capacity

    Fuel Tank Capacity

    Type

    Power

    APPLICATION

    Cold Cranking Ampere

    Power

    Battery

    Filter type

    Displacement

    Injector pressure

    Filter Type

    Type

    Starter

    Engine specifications

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    01.3-8

    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout

    rev 01

    Engine General

    Engine overview

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    01.3-10

    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout

    rev 01

    Exploded view (Lower end)

    Engine mechanical parts

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    01.3-11

    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout

    rev 01

    Exploded view (Lower end)

    Engine mechanical parts

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    01.3-12

    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout

    rev 01

    1. Piston Ring Set

    2. Piston Pin Retainer3. Piston

    4. Piston Pin

    5. Connecting Rod and Cap

    6. Connecting RodJournal Bearing Set

    7. Engine Block

    8. Coolant Adapter

    9. Coolant Adapter

    10. Plug11. Crankshaft Journal

    Bearing Set

    12. Crankshaft

    13. CKP Sensor Target Wheel

    14. Crankshaft Rear Seal Ring

    15. Crankshaft Gear

    16. Crankshaft Gear Key

    17. Engine Bed Plate

    18. Crankshaft Bolt19. Bed Plate Bolt

    20. Oil Nozzle Tube Bolt

    21. Oil Nozzle Tube

    22. Oil Filter Cap

    23. ORing

    24. Oil Filter

    25. Oil Filter Housing

    26. ORing

    27. Oil Filter Housing Drain

    Bolt Washer

    28. Oil Filter Housing Drain Bolt

    29. Oil Filter Housing Fitting Bolt

    30. Engine Oil Cooler

    31. ORing

    32. Oil Cooler Outlet Hose

    33. Oil Cooler Inlet Hose

    34. Oil Pump Assembly

    35. Oil Pressure Relief Valve

    36. Oil Pressure Relief Valve Spring

    37. Oil Pressure Relief Valve Gasket38. Oil Pressure Relief Valve Plug

    39. Crankshaft Front Seal Ring

    40. Oil Pressure Switch

    41. Oil Pump Seal

    42. Oil Pump Outer Rotor

    43. Oil Pump Inner Rotor

    44. Oil Pump Cover

    45. Oil Pump Drive Gear

    46. Oil Level Indicator

    47. Oil Level Indicator Tube

    48. Crankshaft Position Sensor

    49. Oil Pan Bolt

    50. Oil Pan Bolt

    51. Oil Pan

    52. Oil Drain Plug

    53. Oil Drain Plug Washer

    54. Crankshaft Balancer

    55. Oil Strainer Pipe

    56. Oil Strainer Pipe Seal

    Exploded view (Lower end)

    Engine mechanical parts

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    01.3-13

    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout

    rev 01

    1. Wheel Bearing Oil Inlet Pipe Bolt

    2. Wheel Bearing Oil Inlet Pipe

    3. Turbocharger

    4. Wheel Bearing Oil OutletPipe Gasket

    5. Wheel Bearing Oil Outlet Pipe

    6. Wheel Bearing Oil Outlet Hose

    7. Exhaust Manifold Gasket

    8. Turbocharger Gasket

    9. Exhaust Manifold

    10. Thermostat Housing

    11. Thermostat Housing Gasket

    12. Thermostat

    13. Boost Pressure Sensor

    (TMAP Sensor)

    14. Intake Manifold

    15. Coolant Temperature Sensor16. Intake Manifold Gasket

    Exploded view (Intake & Exhaust system)

    Engine mechanical parts

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    01.3-14

    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout

    rev 01

    1. Engine Mount Damper (RH Side)

    2. Engine Mount Bracket3. Transaxle Front Mount Damper

    4. Transaxle Mount Damper (LH Side)

    5. Transaxle Rear Mount Bracket (AWD/FWD)

    6. Transaxle Rear Mount Damper

    7. Cradle

    Exploded view (Mount system)

    Engine mechanical parts

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    01.3-15

    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout

    rev 01

    1. Camshaft Sprocket

    2. Timing Belt Idler

    3. Injection Pump Sprocket

    4. Timing Belt Tensioner

    5. Water Pump Pulley

    6. Crankshaft Sprocket

    7. Timing Belt

    8. Timing Belt Rear Cover

    9. Timing Belt Upper Cover

    10. Timing Belt Lower Cover

    11. Engine Mount Bracket

    12. Crankshaft Pulley

    13. Water Pump Gasket

    14. Injection Pump

    15. A/C compressor & AlternatorBracket

    Exploded view (Timing belt system)

    Engine mechanical parts

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    01.3-16

    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout

    rev 01

    This cylinder head is SOHC(Single Over Head Camshaft) type

    and has only one camshaft that open 4 valves per cylinder with

    the finger followers of roller type and the valve bridges. It is

    similar to that of DOHC(Double Over Head Camshaft) cylinder

    head.

    The camshaft gear is installed in front of camshaft and the

    vacuum pump is coupled in the rear of that. Because the cam

    followers are of the hydraulic type, valve clearance adjustments

    is not necessary.

    The cylinder head is made of cast aluminum alloy for better

    strength in hardness with light weight.

    The combustion chamber of plate type of the cylinder head is

    designed for increasing of squish and swirl efficiency and then

    this is maximized to diesel combustion efficiency.

    ** Cylinder head bolt tightening sequence :

    Tighten the cylinder head bolts to 65 Nm(47.9 lbft).

    Using the angular torque gauge KM470B, tightening thecylinder head bolts another 120 degrees plus 120 degrees.

    Cylinder head

    Engine mechanical parts

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    01.3-17

    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout

    rev 01

    As the largest part of the engine components, the engine block

    is made of cast iron. There are engine oil and coolant passages

    for lubricating and cooling in the inside of engine block. On the

    upper side of engine block, there is the cylinder head which has

    combustion chamber. Also, the engine block has the bed plate

    to support the crankshaft and decrease the engine vibration on

    the lower side.

    On the inside surface of the engine block, there are bore

    surfaces whose the pistons of reciprocating motion assemble init and 4 oil jets to lubricate on the each bore surface.

    Cylinder block

    Engine mechanical parts

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    01.3-18

    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout

    rev 01

    The pistons are cast aluminum with a flat top design. Piston skirts are

    coated to reduce friction. Each piston uses 2 compression rings and 1

    3-piece oil control ring assembly. The piston pin is a full-floating design

    and is retained to the connecting rod by clips located in each end of

    the piston pin bore. The connecting rod and rod cap are positioned

    and aligned by a dowel pin and retained by bolts.

    Piston & Rings

    Engine mechanical parts

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    01.3-19

    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout

    rev 01

    The crankshaft is made of better strength forging works design

    than iron cast. It is located between the engine block and the

    bed plate at 5 main journals with main bearings which have oil

    clearance for lubricating. The 3rd bearing of the 5 main bearings

    is thrust bearing whose the crankshaft has properly axial end

    play.

    4 conrod journals with the metal bearings are assembled into

    the crankshaft. The bearing caps are crossbolted to enhance

    structural rigidity.

    On the front side of the crankshaft, there is a crankshaft gear

    which drives oil pump and crankshaft balancer. On the back of

    the crankshaft, there is a CKP target wheel (Crankshaft Position

    Sensor).

    EN-48246Timing belt adjuster-

    Crankshaft holderCKP sensor target wheel

    Crankshaft gear for Balancer

    Crankshaft

    Engine mechanical parts

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    01.3-20

    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout

    rev 01

    The crankshaft gear drives the 2 balancer shafts that revolve on

    the opposite direction. So, the balancer counterbalances the

    vibration that comes from the crank train.

    It is located between the bed plate and the oil pan with the

    engine oil.

    Balancer gear

    Crankshaft balancer

    Engine mechanical parts

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    01.3-21

    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout

    rev 01

    The engine utilizes a valve fingerfollower and hydraulic lash

    adjuster for valve operation. The roller is located at the middle of

    valve fingerfollower and delivers the cam movement to valve

    bridge in correspond to cam profile continuously.

    Mark Nam e Function

    a Camshaft Drive valve system

    b Roller Finger Fol lower Deliver the rotat ing to valve bridge

    c Hydraulic Lash Adjus ter Pivot and compensate activa- ting

    and deactivating movement

    d Intake-Valve Make the fresh gas flow

    e Exhaust-Valve Make the exhaust gas flow

    f Valve-Spring Keep the valve closed

    g Valve-Bridge Activate two valve's movement

    a

    b

    c

    ed

    f

    g

    Valve train system

    Engine mechanical parts

    Valve bridgeRoller finger follower

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    01.3-23

    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout

    rev 01

    Model Maintenance Remarks

    C100

    (2.0L Diesel)

    I : 30,000 km(20,000 miles) or 2 years

    R : 90,000 km(60,000 miles) or 5 years

    * I : Inspection

    R : Replacement

    Crankshaft

    High pressure

    pump sprocket

    CamshaftCamsprocket

    Timing belt

    idler

    Timing belt

    tensioner

    Crankshaft

    sprocket

    Water pump

    pulleyTiming belt

    The crankshaft pulley assembled on the crankshaft drives the

    camshaft sprocket, the water pump pulley and the high pressure

    pump sprocket using a timing belt. Also, the auto timing belt

    tensioner of double eccentric type assists the belt tension.

    The timing belt idler which consists of a double low bearing type,

    to endure big load on the wrap angle between the camshaft

    sprocket and the high pressure pump sprocket.

    Descriptions

    Engine timing system

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    01.3-24

    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout

    rev 01

    1. Remove the vacuum pump

    2. Rotate the camshaft and

    align the hole on the top

    point.

    3. Rotate the crankshaft and

    align the mark on the

    crankshaft sprocket.

    4. Remove the crankshaft

    holder hole cap bolt(a).

    5. Insert the crankshaft holder

    EN48246 into the

    crankshaft holder hole.(b)

    Notice :

    Rotate the crankshaft

    sprocket a little and

    simultaneously insert the

    crankshaft holder.

    6. Install the camshaft holder

    EN48245 onto the camshaft

    rear side.(c)

    7. Align the high pressure pump

    sprocket mark on the timing

    belt rear cover mark.

    Timing belt adjustment - 1

    Engine timing system

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    01.3-25

    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout

    rev 01

    8. Install the camshaft sprocket with

    the tightening bolt manually.

    9. Install the timing belt.

    10. Install the timing belt

    tensioner with the tightening

    bolt manually.

    11.Turn the hexkey(a) tab in a

    countclockwise direction to

    tension the belt. Turn until thepoint aligns with the notch(b).

    12. Aligning with notch, tighten

    the timing belt tensioner bolt.

    13. Tighten the camshaft sprocket

    bolt.

    Tighten

    Tighten the timing belt tensioner

    bolt to 25 Nm (18.4 lbin).Tighten the camshaft sprocket bolt

    to 133 Nm (98.1 lbin).

    14. Remove the camshaft holder

    EN48245 and crankshaft

    holder EN48246.

    15. Turn the crankshaft in a

    clockwise direction more 2

    cycles and check the mark onthe crankshaft sprocket.

    16. After alignment of the timing

    belt, install the crankshaft

    holder hole cap bolt.

    Tighten

    Tighten the crankshaft holder hole

    cap bolt to 30 Nm.

    CAUTION : The special service tools align the timing at exactlycyl. no. 1 TDC. If these special tools are not used, it will have

    an inluence on engine performance and emissions.

    Timing belt adjustment - 2

    Engine timing system

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    01.3-26

    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout

    rev 01

    Check the accessory belt for looseness, crack, wear or tension,

    replace the belt if necessary.

    ** Relieve method :

    1) Install the accessory belt remover/installer EN48253 onto the

    tensioner lever guide and rotate the tensioner at clockwise.

    2) Rotate the tensioner fully and simultaneously insert tensioner spring

    holding pin EN48301 to the tensioner pin hole.

    3) Remove the accessory belt.

    Accessory belt

    Accessory belt

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    01.3-27

    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout

    rev 01

    Intake manifold

    Coolant

    temp. sensor

    Thermostat & cover

    Boost pressure

    & temp sensor

    Air Inlet

    Water Inlet

    Exhaust manifold

    The intake manifold is used for air flow passage into the cylinder

    combustion chamber and has an effect on engine torque, power,

    noise, drivability, emission, fuel economy and performance.

    It is made of cast aluminum alloy for better strength. A coolant

    passage and thermostat housing is integrated into the intake

    manifold.

    The exhaust manifold is attached to the cylinder head and sends

    the exhaust gas out of the combustion chamber. It is designed

    to endure high pressure and high temperature and made of

    HiSiMo material.

    Engine Intake & Exhaust system

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    01.3-28

    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout

    rev 01

    1. Exhaust Manifold Heat Shield

    2. PreCatalyst3. Seal Ring

    4. Clamp

    5. DPF Pressure Sensor

    6. DPF Pressure Sensor Hose

    7. Exhaust Gas TemperatureSensor 2

    8. Gasket

    9. Rubber Hanger

    10. Exhaust Gas Temperature

    Sensor 111. Exhaust Front Pipe Assembly

    12. DPF(Diesel Particulate Filter)Assembly

    13. DPF Heat Shield

    14. Front Muffler Heat Shield

    15. Front Muffler Assembly

    16. Rear Muffler Assembly(RightSide)

    17. Rear Muffler Assembly(LeftSide)

    The function of the muffler is to reduce engine noise. It is made

    up of a series of perforated tubes and baffles to break up the

    sound waves and reflect them. It is made of Stainless Steel to

    protect the front muffler from corrosion.

    The rear muffler is to reduce broad band engine exhaust noise.

    It is comprised of a series of perforated tubes and baffles to

    break up the sound waves and reflect them.The adopted dual

    muffler for C100 improves the efficiency to reduce flow noise.

    It is made of Stainless Steel to protect the front muffler from

    corrosion.

    Engine Intake & Exhaust system

    Exhaust system

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    01.3-29

    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout

    rev 01

    The vacuum pump provides the vacuum to the brake booster

    and EGR(exhaust gas recirculation system) valve and is

    installed at left upper side of engine. It is driven by the camshaft.

    To brake

    booster

    To EGR

    Solenoid valve

    Part Item Specification

    Type Single vane type

    When brake side port is blocked

    at idle : - 0.9 bar

    When EGR side port is blockedat idle : - 0.7 bar

    Vacuum

    Vacuum pump

    Engine vacuum system

    Vacuum pump

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    01.3-30

    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout

    rev 01

    The PCV valve carries the blowby gas to the turbocharger inletof the intake system. According to the engine conditions, driving

    conditions and turbocharger pressure, blowby gas flow is

    different. So, the PCV valve controls the amount of blowby gas.

    From blow-by gas

    To Turbo

    charger

    PCV system

    PCV valve

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    01.3-31

    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout

    rev 01

    Engine cooling system

    FAN SPEED APPLICATION ON OFF

    ECT ( ) 100 97

    A/C switch

    ECT ( ) 105 102

    ACP ( kg/cm) 18,98 14,76

    ECT

    Cooling fans size 340 (Main)+ 320(Aux)

    ON

    Malfunction

    High

    Low

    1. Radiator

    2. Charge Air Cooler3. Main Cooling Fan Blade

    4. Auxiliary Cooling Fan Blade

    5. Main Cooling Fan Motor

    6. Auxiliary Cooling Fan Motor7. Cooling Fan Shroud

    Cooling fans

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    01.3-32

    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout

    rev 01

    1. Water Pump

    2. Water Pump Gasket

    3. Thermostat Housing

    4. Thermostat Gasket

    5. Thermostat

    6. Boost pressure & Temperature

    Sensor

    7. Intake Manifold

    8. Coolant Temperature Sensor

    Water pump

    Part Name 2.0L Diesel Remarks

    Radiator Type Cross Flow

    Radiator Size 673 414 27 W H x T

    Coolant Capacity 10

    Thermostat start to open 80 2 Complete open : 95

    Thermostat

    Engine cooling system

    Water pump and Thermostat

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    01.3-33

    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout

    rev 01

    Remarks

    Capacity 65 L

    Fuel tank

    The fuel tank stores the fuel and the tank is sealed up leakage

    of vapor.

    The fuel tank is made from high density polyethylene. The main

    fuel tank is located in the rear of "Front muffler"and under the

    body of the vehicle. The fuel tank are each sides held in place

    by 2 metal straps that is able to hold from two nuts attach to the

    frame. The fuel in the tank supplies to the engine through the

    supply line by the pump.

    The vapor that is produced in the tank is going through the line

    by Roll over valve and Grade vent valve.

    2. Main Fuel Pump

    4 . Ring-Adaptor

    3. Roll Over

    Valve

    1. Sub Fuel Pump5. Grade Vent Valve

    Fuel tank

    Fuel supply system

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    01.3-34

    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout

    rev 01

    The sub fuel pump module is located inside of the left side of thefuel tank. The sub fuel pump module consists of the followingmajor components:

    - The fuel sender assembly

    - The fuel transfer tube

    The main fuel pump module is located inside of the right side ofthe fuel tank. The main fuel pump module consists of the

    following major components:- The fuel level sender assembly

    - The fuel pump and reservoir assembly

    - The fuel filter

    - The fuel pressure regulator

    - The suction and return jet assembly

    Main Fuel Pump Module

    Sub Fuel Pump Module

    Fuel supply system

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    01.3-35

    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout

    rev 01

    3. Fuel level gage control

    The fuel level sensor changes resistance in response to the fuel

    level. The engine control module (ECM) monitors the signal

    circuit of the fuel level sensor in order to determine the fuel level.

    When the fuel tank is full, the sensor resistance is low and the

    ECM senses a low signal voltage. When the fuel tank is empty,

    the sensor resistance is high and the ECM senses a high signal

    voltage. The ECM uses the signal circuit of the fuel level sensor

    in order to calculate the percentage of remaining fuel in the

    tank. The fuel level signal is sent to ECM, the ECM sends the

    message of the fuel level to the BCM and the BCM modulates

    fuel level gauge in the cluster by single wire CAN.

    2. Fuel level gage resis tance

    System Pressure 450 kpa

    Displacement 165 ~215/h

    Relief pressu re min 650 kPa - max 900 kPa

    Current 3.0 ~ 11.5 AMP

    Status Fuel Height MAX MIN

    Full Stop 228.9 40 45,5 37,0

    1/2 130.6 106.2 112,8 99,4

    Empty Stop 1.3 250.0 253,0 240,4

    Resistance( )Float Heigh t

    Fuel lev el

    Fuel level Signal Remarks

    FULL 3.4V 5V Ref

    3/4 3.0V

    1/2 2.2 2.5V

    1/4 2.0V

    Empty 1.4 ~ 1.5V

    1. Specification of Fuel pump

    Fuel supply system

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    01.3-36

    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout

    rev 01

    Fuel filter heater & Temperature sensor

    RemarksSpecificationItemPart

    115127 3.3

    0.4 2Heater resistor

    100187 4

    Resistance

    -3026,116 2,533

    05,896 430

    252,057 115

    60596 23

    NTC thermistorType

    Fuel temp

    Sensor

    -20250WOperating

    power

    Off (more than 5)Less than 3Enable

    condition

    12VOperating

    voltage

    PTC ThermistorType

    Fuel filterheater

    Fuel filter cap

    Fuel temp

    Sensor (NTC)Fuel filter

    heater (PTC)

    The fuel filter heater relay is controlled by the ECM. When the

    temperature is less than 3, the fuel filter heater relay is

    commanded. Fuel temperature is measured by the ECM and

    also has an influence on injection timing and quantity.

    Fuel supply system

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    rev 01

    Water In Fuel (WIF) sensor

    WIF sensor

    RemarksSpecificationItemPart

    Over 95 CCIndicate lamp ON

    Indicate lamp ONLess than 50mA

    Indicate lamp OffLess than 15mAConsume current

    10 16 VOperating voltage

    Mechanical lead

    switchFloatType

    WIF

    sensor

    Water Draining Procedure

    1. Turn the waterinfuel drain screw counterclockwise.

    2. If finished, unscrew the drain screw reverse toward.

    3. Do work fuel priming.

    Fuel supply system

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    rev 01

    CAUTION : It is impossible to reuse the fuel filter element if theelement is exposed to the air for over a minute.

    Fuel supply system

    Fuel filter replacement procedure

    1. Remove the air cleaner

    assembly.

    2. Disconnect the fuel inlet/outlet line

    from the fuel filter.

    3. Disconnect the fuel heater and

    temperature sensor connector. (a)

    4. Disconnect the water in fuel

    sensor connector.(b)

    5. Remove the fuel filter

    assembly from the bracket

    upward.

    6. Install the filter housing holder

    EN48303(a) and the fuel filter

    locker installer/remover EN

    48304(b) to the fuel filter

    assembly.

    7. Turn the fuel filter lockerinstaller/remover EN48304(b)

    counterclockwise.

    8. Remove the fuel filter

    locker(a).

    9. Remove the fuel filter cap(b)

    with the Oring(c).

    10. Remove the fuel filter(d) in

    the fuel filter housing(e).

    Notice : The fuel filter cap

    includes the fuel heater and

    temperature sensor as one

    body. Also, the fuel filter

    housing includes the water in

    fuel sensor as one body.

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    rev 01

    In order for the VM2.0S diesel fuel system to work properly, the

    fuel lines must be full of fuel and contain no air. If air gets into

    the fuel lines, it will be necessary to prime the fuel system to

    eliminate the air before operating the vehicle.

    Air could have entered the system in one of the following ways:

    1) The vehicle ran out of fuel.

    2) The filter was removed for service or replacement.

    3) The fuel lines were removed or disconnected for servicing.

    4) The fuel pump was removed for servicing.

    5) The fuel filter water drain cock was opened while the engine

    was running

    Notice :

    If one or more of the above occurred, air has entered the fuel

    system and you will need to prime the system prior to operating

    the vehicle.

    Priming procedure

    1. Turn the ignition key ON at 5second intervals.

    2. Turn the ignition key OFF and wait 3 seconds.3. Repeat procedure No.1 ~ 2 at 6 or 7 times.

    CAUTION : Do not turn the ignition key START. The injection

    pump might get damaged.

    Notice : You can do fuel priming work using by SCAN tool.

    Fuel supply system

    Descript ion of Fuel priming

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    C100 (2.0l Diesel)

    Engine Mechanical

    ParticipantsHandout