SSANGYONG NEW REXTON 2012 Service Manual

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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)

1. FUEL FLOW OF D20DT (EURO 4) ENGINE
According to input signals from various sensors, engine ECU calculates driver's demand (position of the
accelerator pedal) and then controls overall operating performance of engine and vehicle on that time. ECU
receives the signals from sensors via data line and then performs effective engine air-fuel ratio controls
based on those signals. Engine speed is measured by crankshaft speed (position) sensor and camshaft
speed (position) sensor determines injection order and ECU detects driver's pedal position (driver's
demand) through electrical signal that is generated by variable resistance changes in accelerator pedal
sensor. HFM (Hot Film Air Mass) sensor detects intake air volume and sends the signals to ECU.
Especially, the engine ECU controls the air-fuel ratio by recognizing instant air volume changes from air flow
sensor to decrease the emissions (EGR valve control). Furthermore, ECU uses signals from coolant
temperature sensor and air temperature sensor, booster pressure sensor and atmospheric pressure sensor
as compensation signal to respond to injection starting, pilot injection set values, various operations and
variables.

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HP PumpFuel Line
Injector (7-way Injection and C3I Coding)Fuel filter Priming Pump
Common Rail
2. COMPONENTS OF FUEL SYSTEM
Fuel nozzle
holes (7)
Injector
Fuel pipe
High pressure fuel pip Fuel rail pressure sensor
Fuel filter
Connector
Priming
pump
Fuel from
HP pumpFuel filter
HP pumpFuel tank
Fuel tank
Common rail
Fuel return
port
Low pressure
fuel supply port
Venturi
High pressure
fuel supply port
(orifice included)
Fuel
temperature
sensor
IMV valve
Fuel return
port
IMV
connector

3. HYDRAULIC CYCLE IN FUEL LINE
(TRANSFER AND HIGH PRESSURE LINE)

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3. Connection on EGR pipes4. Clamp on inlet hose to intake
manifold and inlet hose to
intercooler
1. TIGHTENINF TORQUE
The hose clamps and fasteners should be tightened to the specified tightening torque when
installing/removing the engine and/or components for intake system.
1. Hose between air cleaner and
turbocharger2. Hose between turbocharger and
intercooler

HFM Sensor (ver. 6.0)VGT Turbo Chargera
Uncompressed air
Air coeaner Turbo
charger
Temperature
sensor
Pretension
graph
Ambient air
Air cleaner
Compressed air
1. INTAKE SYSTEM LAYOUT
The intake system is equipped with an electric throttle body which includes a flap. This flap is controlled
by an electrical signal to cut off the intake air entering to the engine when the ignition switch is turned off.
And, the improved HFM sensor has been adopted to control the intake air volume more precisely.
Exhaust manifold
Air coeaner
Intercooler Exhaust gas
VGT control actuator

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Intercooler
Booster Pressure SensorIntake Manifold
Ground Supply power
Output
voltageTo corresponding
cylinders Coolant
port
Compressed
air
EGR gas
Engine stopped:
flap closed Normal: flap open
Intake duct
Intake duct
Intake manifold
(Throttle body)
Turbo charger
Throttle body

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1. TURBO CHARGER CHECK FOR VGT
The turbocharger is sensitive to excessive
vibration coming from external impact.
When exposed to excessive impact or
vibration, the inside mechanism may be
damaged even though the outside is intact. 1.
The turbocharger should be kept horizontally. If there is much engine oil in the turbocharger and it is
kept vertically with the turbine housing downward, the engine oil may be provided to variable
mechanism assembled towards the turbine housing, which may lead to a malfunction of the variable
mechanism. 2.
Never re-adjust the adjusting screw marked
with yellow paint or the axial end of actuator.
Renew them if you found looseness of the
screw or actuator axle, because they are
shipped after precisely adjusting from the
factory.
Do not move or assemble the actuator axle
by grasping it in hands. The actuator axle
may be deformed, which affects the precisely
adjusted value. 3.
4.

After installing to the engine, replenish a small
amount of clean engine oil to the inlet before
connecting the oil inlet pipe of the
turbocharger.
Do not let any metal debris enter when
installing to the engine.
The engine oil may be provided to the
compressor housing if you rapidly operate the
turbocharger with excessive revolutions
immediately after installing to the engine. 5.
6.
7.
Do not raise the engine rpm rapidly after
starting the engine.
Do not raise the engine rpm rapidly after
renewing the engine oil and filter element.
Do not stop the turbocharger rapidly after
operating at high engine speed. -
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1. COMPONENTS
1. E-EGR valve: Controlling the EGR valve electrically and sends the valve location signal to ECU
(vacuum modulator control has been deleted).
2. EGR cooler:
VGT turbochargerIntake manifold
Turbocharger intercooler
(intake air)
EGR gas (from EG
R
cooler)
E-EGR
valve
Exhaust manifoldE-EGR
valveCoolant
To intake
manifold
EGR cooler
EGR pipe
E-EGR valveDecreasing EGR gas (NOx) efficiently by cooling the EGR gas and let it flow to the
intake manifold. The components of the exhaust system consist of:
Throttle body
Exhaust manifold