engine SSANGYONG NEW REXTON 2012 User Guide

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Turbocharger intercooler
4. LAYOUT OF INTAKE SYSTEM
HFM sensor (HFM 6.0)
Turbocharger
Supplying the compressed air by turbocharger
Air cleaner
Turbocharger
Turbocharger
Plug in sensor
Air
cleanerTurbochargerProtension graph
Temperature
sensor
Air cleaner
Intake manifold
Coolant port To respective cylinder
From
intercoolerVGT control
actuator
Exhaust gas
Throttle body
Engine operating: Flap
openEngine stopped:
Flap closed
Intake duct
Intake duct
Boost pressure
sensor
Power
Voltage outputGround

2) Engine Performance Curve
Output and Torque

Injector washer puller
2. SPECIAL SERVICE TOOLS
1) Using the Special Service Tools on Engine
Injector pullerGlow plug socket
HP remover/installerHigh pressure pipe
remover/installerCylinder head bolt wrench
Sealing caps
(fuel line)

4. CAUTION WHEN SERVICING THE ENGINE
1) Cleaness
Engine has a lot of precisely machined (grinding, polishing, lapping) surfaces. Thus, there should be
great cautions for cleaness when servicing the engine components. Apply the engine oil on the sliding
surfaces when assemblying the components. Every component should be disassembled and
reassembled in accordance with the correct sequences. Before servicing the engine, the negative cable
should be diconnected from the battery. Otherwise, some electric or electronic components could be
damaged.
2) Servicing
Before service work, be sure to disconnect battery negative (-) terminal to prevent damages by bad
wire and short.
To prevent the foreign material from getting into engine cylinder, cover the inlet of air cleaner if the
air cleaner has been removed.
(1) Lifting up the vehicle
Always keep the safety precautions.
To prevent the vehicle from rolling down, put the chocks under the tires (when using a 4-post lift).
Make sure to support the correct lifting points (when using a 2-post lift) -
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(2) Exhaust system
Wear the safety glove when removing the exhaust pipe.
Make sure that the exhaust pipe is cooled before removing it. -
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(3) Cautions before service
Scalding hot coolant and steam could be blown out under pressure, which could cause serious injury.
Never remove the coolant reservoir cap when the engine and radiator are hot.

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(4) Lubrication system
Prolonged exposure to the engine oil make cause a skin cancer or an irritation.
Used engine cotains the hazardous material that may cause the skin cancer. Do not allow the used
engine to make contact with your skin.
Make sure to wear the protection gloves and goggle when handling the engine oil. If contact happens,
rinse affected areas immediately with plenty of water. Do not wash it with gasoline or solvent. If
irritation persists, consult a doctor.
Improperly disposed engine oil can pollute the environment. Dispose used engine oil in accordance
with local environmental regulations. -
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(5) Tightening the fastener
Clean the mating surfaces before tightening.
Place the marks with paint to tighten by angle if the angle wrench is not available. -
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3) Fuel and Oil System
If work on the fluid system such as fuel and oil, working area should be well ventilated and smoking
should be prohibited.
Gasket or seal on the fuel/lubrication system should be replaced with new ones and bolts and nuts
should be tightened as specified. -
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If fine dust or foreign material enters into DI engine's fuel system, there can be serious damages
between HP pump and injectors. So, be sure to cover removed fuel system components with cap
and protect removed parts not to be contaminated with dirt. (Refer to cleanness in this manual
while working on DI engine fuel system)
When working on the fuel line between priming pump and injector (including return line), always
plug the openings with caps to prevent foreign materials or dust from entering to the openings and
connections.
The HP fuel supply pipe (HP pump to fuel rail) and HP fuel pipe (Fuel rail to injector)
should be replaced with new ones when removed. 1.
2.
3.

D20DT Engine EU IV D27DTP Engine
5. MAJOR CHANGES IN D20DT (EU-IV) ENGINE
(COMPARED TO D20DT)
Front view
1) Engine Assembly
Left side view
Right side view

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2) Major Changes and Summary
D20DT Engine Remarks
Engine ECU - Version 3.2
ECU ECU version 3.2 in D20DT engine has
two connectors.
1. E-EGR valve system
2. Throttle body system
3. C3I injector system
Injector
C3I label
Layout of E-EGR system
Throttle body
E-EGR valve
EGR cooler
* Injection nozzle (hole): 7
* Injector label and coding
- D27DTP, D20DT
(20 digits: C3I coding)
* To meet the emission regulation,
especially for reducing NOx, same E-EGR
valve and EGR cooler in power-up engine
(Rexton II) have been introduced.

D20DT Engine Remarks
HFM 6.0 HFM 6-ID
(Added digital signal function) -
Electrically controlled E-EGR valveECU controls the EGR valve directly.
It provides precise EGR control by
transmitting the electric signal of EGR
valve operating position. *
Vacuum modulator
Vacuum modulator for
turbocharger control
The vacuum modulator for controlling
EGR valve has been deleted. *
Throttle body is used to prevent the
engine from turning off with fluttering
noise at the moment the air to intake
manifold is blocked by closed flap
when the engine is switched off. *
Throttle body

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D20DT Engine Remarks
To enhance the EGR performance by
making the temperature of exhaust
gas into the intake manifold down, the
EGR cooler has been introduced. *EGR cooler
EGR GasCoolant
The throttle body and boost pressure
sensor have been installed on the
intake manifold. *
Intake manifold
Throttle
bodyBoost pressure sensor
Cylinder head
Coolant portTo enhance the cooling performance,
the coolant port has been introduced. *
To enhance the cooling performance,
the coolant passage has been made
in the cylinder block. *
Cylinder head gasket
Coolant passage

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Injector (7-way Injection and C3I Coding)
1. FUEL SYSTEM - K2006
The C3I injector system is used in D20DT engine.
Injector
C3I Label
Two nozzle holes are added (currently 7) to the tip of the injector to increase the amount of fuel
injection and to improve injection efficiency according to the increased engine power.
The existing C2I coding (16 digits) is changed to C3I coding (20 digits) to monitor fuel injection and
follow the target value.
For the D20DT engine, the injector MDP (minimum current for the solenoid in the injector to lift the
nozzle) is leaned only when the engine is running. However, for the D20DT (EURO 4) engine, it is
learned when the vehicle is in motion and the engine is at idle speed. -
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C3I Label
C3I Code
Fuel nozzle
holes (7)
C3I
Fuel nozzle
holes (7)
C3I Code (20 digits)