Hyundai J3 Install guide

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<ElJ HYUnDAI
DIESEL ENGINE
J3
(DELPHICOMMONRAIL)
Shop Manual
ISUPPLEMENT I
FOREWORD
This shop manual is intended lor use by service techni-
cians
01 authorized Hyundai dealersto help them provide
efficientand correct service and maintenance on Hyundai
vehicle.
To ensure customer satislaction with Hyundai producls,
properserviceandmaintenance
by Hyundaitechniciansis
essential. Consequently, His important that service per-
sonnel lullyunderstand
the contents 01 this manual, which
should
be kept in a handy place lor quick and easy
relerence.
All the contents 01 this manual, including photographs,
drawings, and specilications,arethe latestavailable atthe
time
01 printing. As modilications affecting service occur,
dealers will
be provided technical service bulletins or
supplementaryvolumes. Thismanualshould
be keptcare-
lully up-to date upon receipt 01 the new inlormation.
HyundaiMotor
Company reserves !herighttomakechanges
in design or to make additions to or improvements in its
products without imposing any obligations upon itseH to
install !hem on its products previously manufactured.
Thisbook
may not be reproduced orcopied, as awhole or
as apart, without the written permission 01 the publisher.
II
you don't use HYUNDAI Genuine Parts (Engine oil,
Transaxle
oil, etc.) or use bad luel, it can cause damage
to
the vehicle.
JUL. 2001,
Printed in Korea
CONTENTS
TITLE GROUP
Engine Mechanical System
EM
Engine Electrical System EE
Fuel System FL
Schematlc Oiagrams
SO
This is the supplement shop manual of the J3 Engine
equipped with luel injection system
01 DELPHI Common
Rail.
This Diesel Engine, named J3 lor4 cylinders, is applied
to the vehicle 01 Terracan.
For any inlormation not covered in this supplement,
please relerto
the related shop manual published earlier.

11
I
111
I
AND SB EIes IIII!IB l!lI m IlII!iI g mllllllsa mm IISmEl sam IlIIIiIEi emSElmililm III uom m m SO~2
CHARGING SYSTEM ...........................................................m..... SDm8
MFI
CONTROl SYSTEM......................................8 ..................... SO .. 10
AUTOMATICTRANSAXlE
CONTROl SYSTEMms ..................... 50 ... 18
BlOWER &AlC CONTROlS (AUTO) .......................................SD .. 24
BlOWER & AlC CONTROlS (MANUAL).......... se ...................... 50-30
FUEl HEATING SYSTEM .......................................................... SO ... 36
WATER SEPARATOR SYSTEM..................................................
SO ... 38
COMPONENT lOCATION ..........................................................SD-40
CONNECTOR CONFIGURATION ..............................................SD
... 47

SD-2
FUSE AND RElAY INFORMATION
PASSENGER COMPARTMENT FUSE BOX
LAYOUT
11 30A I
I2 10A I
I3
iSA f
14 20A I
I5
i0A I
I6
iSA I
I7 30A I
I8 20A I
I9
i0A I
110
i0A I
1
11
iSA I
112
i0A I
113
114
SCHEMATIC DIAGRAMS
115 10A I
I16
i0A I
117
118 10A I
119
i0A I
I
20
i0A I
I
21
i0A I
122
i0A I
I23 10A I
I24
125 10A I
I26
iSA I
I
27
i0A I
128 10A I
E2MB001A-A

FUSE AND RELAY INFORMATION SD-3
CIRCUIT
NO Amperages(A) Circuit protected
1 30A Defogger
2 10A Hazard relay, Hazard switch
3 15A Stop lamps
4 20A Transfer
5 10A SMATRA
6 15A Sunroof
7 30A Blower motor
8 20A Power door locks
9 10A Rear fog lamp relay
10 10A Audio, Overhead console lamp
11 15A Cigarette lighter, Accessory socket
12 10A Outside mirror & folding
13 -
14 -
15 10A
NC switch
16 10A Rear window & outside mirror defogger
17 -
18 10A TCM, TCCM(EST), Transaxle range switch
19 10A Back-up lamp, Inside mirror
20 10A Hazard switch
21 10A Instrument cluster, ETACM, Vehicle speed sensor, DRL control module
22 10A Air bag
23 10A Air bag ind., ABS control module
24 -
25 10A Blower &
NC, ETACM, Defogger relay
26 15A Seat warmer
27 10A Sunroof, Rear wiper & washer, Rain sensor
28 10A Start relay, Burglar alarm relay
E2MB001A-B

SD-4
ENGINE COMPARTMENT FUSE & RELAY BOX #1
ENGINE COMPARTMENT FUSE & RELAY BOX #1
LAYOUT
Zen
:D;!;-I m
,SE>
...L
...L
-<-I:D
e.n
0-1
:D
~:D
m
om
...L
5~
I\)
~-<
c
JJ
~~
~
-'
...L
s'lJ
fD
m
....I. ...A. ...A. ...A.
w
-....I 0> 01
....I.
C-
o ....I.
Z
-i
«::)
»
()
0
z
z
m
~
0
JJ
m
...10
w
0
C-
o
Z
-i
()
0
z
z
m
()
-i
0
JJ
:D
~~
~
_I
.....
giJ
eo
...A. ...A.
.j:::o. (J.)
....I.
«::)
»
[[J
9-
c:
cn
Cl)
0.
E134
E133
E132
...A.
I\:)
....I.
c.n
»
JOINT
'lJ
C-n
,C
'en
g:}m
JJ::i
II
-<iJ
...A.
...A.
....I.
c.n
»
JJO
m
10
...a.
-<s:
~
'lJ
CONNECTOR
JOINT
CONNECTOR
JOINT
CONNECTOR
~
...L
.....
...A.
0
....I.
c.n
»
SCHEMATIC DIAGRAMS
~
~
liGN.2l
~
fAiCONl
~
fAB8.1l
~
[ PNVDW 1
30A
[ ~:: 1
fAB8.2l
~
FUEL PUMP
20A
POWERCONN
'A' 10A
'B' 15A
E2MB001A-C

FUSE AND RELAY INFORMATION SD
.. 5
CIRCUIT
NO Amperages(A) Circuit protected
10
15A
Fuel heater
11
15A
Head lamp relay(Low), ORL control module
12
15A
Head lamp relay(High)
13 --
14
10A
AlC compressor reiay
15
10A
TCI fan relay
16
--
17
15A
-
18 15A
ECM
19 15A
ECM
FUSE
20 15A
ECM, Air heater relay #1
21 10A
Illuminations, Combination lamp
22
10A
License lamp, Combination lamp
23 10A
ABS control module
24 10A
ECM, Radiator fan relay, Condenser fan relay
25
10A
ABS
26 10A
Cruise
27 15A
Front wiper & washer
28 25A
Power seat
29 20A
Accessory relay
BATT.2 50A
Power connector(A, B)
IGN.2 30A
Start relay, Ignition switch
AlCON 40A
AlC compressor relay, Condenser fan relay
FUSIBLE ABS.1
40A
ABS control module
LINK
PIWOW 30A
Power window relay, Head lamp washer motor
LAMP
40A
Taillamp relay
ABS.2
20A
ABS control module
FUEL PUMP 20A
Fuel pump motor
POWER CONNECTOR.A
10A
AlC, TCM, Oata link connector, ETACM, Siren, Mirror folding
POWER CONNECTOR.B 15A
Audio, Courtesy lamps, Overhead console lamp
US E ESI L E2MB001A-D

SD-6 SCHEMATIC DIAGRAMS
ENGIN,E COMPARTMENT FUSE & RELAY BOX #2
LAYOUT
~GJCJCJGJ
[ 8
10A
E139 E131
2 [
HORN RLY 9 i5A
AlHTR RLY
100A
120A
( 10
E138
[
11
10A
FR FOG LP
RLY [ 12
10A
CIRCUIT
NO
Amperages(A)
Circuit protected
1 100A Air heater relay
#1
2 120A Engine compartment fuse & relay box
#1
3 50A Passenger compartment fuse box(1 , 2,
3, 4, 5), Engine compartment
FUSIBLE fuse & relay box
#2(8,9), Fuel heatercontrol module
LINK 4 30A Generator
5 --
6 --
7 20A Engine control relay
8 10A Horn relay
9 15A Front fog lamp
FUSE 10 --
11 10A ECM
12 10A ECM
E2MB001A-E

FUSE AND RElAY INFORMATION
PASSENGER COMPARTMENT RELAY BOX
LAYOUT
M64
OR LOCK
RLY
M61
RR OEF
RLY
M65
DR UNLOCK
RLY
EM02
M68 JOINT CONNECTOR
EM03
M62
FLASH
UNIT
M66
RRFOG
RLY
M67
RAIN SNSR
RLY
EM01
M63
PIWOW
RLY
M69 JOINT CONNECTOR
M70 JOINT CONNECTOR
SD .. 7
Not used
E2MB001A-F

SD-8
i5R
BATIERY
20B 20B 20W
BATIERY BODY
GROUND GROUND
(1)
2.0Y
0.3UO
SCHEMATIC DIAGRAMS
IHOT AT ALL TIMES I
See Brake
Warning System
o
IGNITION
SWITCH
INSTRUMENT
CLUSTER
5 M13-2 3 M18
ACM DRL
CONTROL
MODULE
E2MB010A-A

CHARGING SYSTEM
COMPONENT lOCATION INDEX
Components
Ei20
Ei3i
Ei32
Ei55
M05
Mi3-2
Connectors
EE02
EMOi
EM02
MIOi
Pre-excitation resistor
Joint connector
Joint connector
Generator
Ignition switch
ETACM
Location reference-Page
8D-42
80-42
80-42
80-42
80-40
8D-40
80-45·
80-45
80-45
80-46
SD-9

SO-10
MFICONTROLSYSTEM
MFI CONTROL SYSTEM (1)
SCHEMATIC OIAGRAMS
AIR
HEATER
#1
E2MB013A-A

MFICONTROLSYSTEM
MFICONTROLSYSTEM~)
5.0W
O.5W/G
E52
AIR
HEATER
RELAY#2
5 - - - - - - - - - - - - - - - - -2 E52
5.0BIY
5.0BIY 2.0BIY
O.5UY
O.5UR
ENGINE
COMPARTMENT
FUSE &RELAY
BOX #2
O.85Y/L
2 E86
1 E86
1.25UB
INLET
METERING
VALVE
1 E34
SD-11
E2MB013A-B

SD .. 12
MFI CONTROL SYSTEM (3)
O.5GN O.5L O.5UB 0.5RN
O.5R
ECT
SENSOR &
SENDER
O.5RN O.5YIW
3 2
0.5B
O.5Br/R
EgO
CAMSHAFT
POSITION
SENSOR
SCHEMATIC DIAGRAMS
0.85R
PASSENGER
COMPARTMENT
FUSE BOX
"--......-I. See
Stop Lamps
84 E03-3
O.5UY
ENGINE
COMPARTMENT
FUSE & RELAY
BOX
#1
E2MB013Ä-C

MFICONTROL SYSTEM
MFI CONTROL SYSTEM (4)
O.5UO O.5G/O
O.5Lg
O.5L
O.5UO O.5G/O
O.5Lg
O.5L
9
--------
3 - - -
--8
O.5LgIW O.5UW
O.5RIY
O.5Y
O.5Y/B O.5P/O
~ _________________ 1
O.3Y/B
6 M22-2
TOD
CONTROL
MODULE
INJECTOR
#2
O.5YIL
O.5GIW
O.5P/B
O.5Y/G
O.5UG
INJECTOR
#3
O.5G/R
O.5Y/R
O.5Y/O
O.5Br/B
O.5BrlW
O.5Y/O O.5Y/O
________ 1 EMOS
INJECTOR
#4
SD-13
E2MB013A-D

SO-14
MFI
CONTROL SYSTEM (5)
IHOT IN ON OR STARTt
0.50/B
2
0.5R1L 0.5Br/0
O.5P
21
See Blower & AlC Controls 0.5Br/0 0.5P
PASSENGER
COMPARTMENT
FUSE BOX
3
0.5Gr
30
------
0.5Gr
11 10
0.5Gr/0 0.5UB
SCHEMATIC DIAGRAMS
IHOT IN ON OR STARTI
0.5W/G
12 E03-1
0.5B
ENGINE
COMPARTMENT
FUSE & RELAY
BOX #1
4 _____ ~ _____ 3 EMDS
0.5Gr/0 0.5UB 0.5B
E2MB013A-E

MFICONTROLSYSTEM
MFI CONTROL SYSTEM (6)
G14
PASSENGER
COMPARTMENT
FUSE BOX
0.5R1G 0.5Y/B 0.5B/G
I.
0.5R1G 0.5Y/B 0.5B/G
2 3 E89
KNOCK
SENSOR
27 E03-1
0.5B
32 EM05
0.5B
G11
0.5B
IGNITION KEY
ILL& nOOR
WARNING SWITCH
2 E85
0.5R1L 0.5RIW
54 E03-2
2.0B 2.0B 2.0B
G09
SD-15
E2MB013A-F

SD-16
MFI CONTROL SYSTEM (7)
See Vehicle See 810wer &
Speed Sensor AlC Controls
0.5Y/O 0.5Y
100 E03-3
0.58/R
DATA LINK
CONNECTOR
2 M14
0.5UO
0.5UO
28
0.58
0.5W
See Starting
System
0.3UO
E03-1
0.5UO
0.5P/O
0.5G/8 0.5G/R
67
1 M71
CLUTCH
SWITCH
2 M71
0.58
G14
SCHEMATIC DIAGRAMS
0.5G
0.5G/8
17 E51
RAIL
PRESSURE
REGULATOR
SENSOR
ECM
A8S
CONTROL
MODULE
E2M8013A-G

MFICONTROLSYSTEM
COMPONENT LOCATION INDEX
Components
E03-1
E03-2
E03-3
E17
E34
E43
E52
E85
E86
E88
E89
E90
E91
E92
E110
E113
E114
E131
E132
E139
E157-1
E157-2
E157-3
E157-4
M06
M11
M14
M20-1
M22-2
M70
M71
Connectors
EE07
EM02
EM05
MC01
MC02
MI01
Grounds
G09
G11
G14
ECM
ECM
ECM
Mass air flow sensor
EG R solenoid
ECT sensor & sender
Air heater relay #2
Fuel temperature sensor
10M valve
Rail pressure regulator sensor
Knock sensor
Camshaft position sensor
Air heater
#1
Air heater #2
Condenser fan relay #2
Engine control relay
CRI relay
Joint connector
Joint connector
Air heater relay
#1
Injector #1
Injector #2
Injector #3
Injector #4
Ignition key ILL & Ooor warning switch
8top lamp switch
Oata link connector
TCM
TOO control module
Joint connector
Clutch switch
Location reference-Page
80-41
80-41
80-41
80-41
80-41
80-41
80-41
80-41
80-41
80-42
80-41
80-42
80-42
80-42
80-42
80-42
80-42
80-42
80-42
80-42
80-42
80-42
80-42
80-42
80-40
80-40
80-40
80-40
80-40
80-40
80-40
80-40
80-45
80-45
80-45
80-45
80-45
80-46
80-46
80-46
80-46
5D-17

SO .. 18
AUTOMATICTRANSAXlE CONTROl SYSTEM
AUTOMATIC TRANSAXlE CONTROl SYSTEM (1)
See Starting System
,.__--......,A--------.
O.5R
O.5Gr
O.3P/O
O.3L
O.3R
O.3P/O
O.5L O.3R O.3W
SCHEMATIC DIAGRAMS
O.5GIB
E2MB019A-A

AUTOMATICTRANSAXLE CONTROL SYSTEM
AUTOMATIC
TRANSAXLE CONTROL SYSTEM (2)
See Indicators +=---e
om
SWITCH
See Illuminations
IHOT IN ON OR STARTI
0.50/8
0.50/8
PASSENGER
COMPARTMENT
FUSE BOX
See Passenger
..... --. Compartment
Fuse Details
14 103-1
0.5R
2 cos
MOlL
TEMPERATURE
SENSOR
SD-19
E2M8019A-8