fuel SSANGYONG KORANDO 2012 Repair Manual

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HFM sensor
(air mass)
CDPF
(7) Wide band oxygen sensor
a. Overview
For diesel engine, combustion is not performed at the optimum (theoretically correct) air-fuel ratio and
the oxygen concentration is thin in most cases. So the wide-band oxygen sensor is used for this kind of
engine, and this sensor is a little different from the one that used for gasoline engine. The combustion in
diesel engine is controlled by fuel injection volume. Therefore, the wide band oxygen sensor should be
used in diesel engine. This sensor measures the air-fuel ratio in very wide range, and is also called full
range oxygen sensor.
The wide band oxygen sensor measures the oxygen density in exhaust gas and sends it to ECU to
control the EGR more precisely. -
b. Components
D20DTF
ECU
EGR valveElectronic
throttle bodyCoolant temp.
sensor
Oxygen
sensorInjector (C3I)

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Rear temp. sensor:
Measure DPF
temp.DPF performs
recycling
(combustion)
process at 600C,
and rear
temperature sensor
monitors the
temperature of DPF.
Differential pressure
sensor measures the
pressure difference
between pre-CDPF
and post-CDPF (If
PM has been
accumulated, the
measured value is
over the specified
value).Diff. pres. sensor:
Measure
pressure between
front side and
rear side of CDPF
Injector: Control
post injection
Front temp.
sensor: Measure
DOC temp.DOC performs
oxidation and
reduction process at
300~500˚C, and
front temperature
sensor monitors the
temperature of
DOC.
Electronic
throttle body:
Control intake ai
r
mass
ECU (DCM 3.7)
d. Operation process
When the differential pressure sensor detects the pressure difference between the front and the rear
side of CDPF, the sensor sends signal indicating the soot is accumulated and the post injection is
performed to raise the temperature of exhaust gas. The amount of fuel injected is determined according
to the temperature of exhaust gas detected by the rear temperature sensor. If the temperature is below
600°C, the amount of fuel injected is increased to raise the tem
perature. If the temperature is over
600°C, the amount of fuel injected is decreased or not controlled. When the engine is running in
low load range, the amount of post injection and the amount of intake air are controlled. It is to raise the
temperature by increasing the amount of fuel while decreasing the amount of intake air.
T-MAP sensor
Intake air
mass
Exceed PM
limitBooster
pressure/
temperaturePost injection
Control intake air
mass

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e. Cautions
Use only specified Engine Oil (approved by MB Sheet 229.51) for CDPF. -
1. Use only specified engine oil (Low Ash Oil)
The vehicle equipped with CDPF should use specific engine oil to improve the engine performance
and fuel economy, and ensure the service life of CDPF. -
2. Issue with normal engine oil
Sulfur, one of the contents of engine oil is burned and generates soot that is not regenerated by the
DPF. This remains on the filter as ashes and keeps accumulating. Eventually, this ashes will block the
filter. -
3. Benefit for specified engine oil
Minimized the sulfur content of engine oil which reduces the service life.
Improved fuel economy and emission level of CO2 with high performance and low viscosity.
Increased service life of engine oil with high resistance to temperature. -
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4. Problems when using unspecified engine oil
The service life of filter may be reduced by 30% or more by the ashes accumulated on the filter.
The fuel economy may be reduced because of engine rolling resistance, frequent regeneration of
DPF. -
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These problems are also caused by oil with high sulfur content, such as tax exemption oil and
heating oil, etc. *

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Right side view ▶
Left side view ▶
Rear oxygen sensor connector
Front oxygen sensor connector
Exhaust manifoldHeat protector
Front oxygen sensor
WCC complete
Crankshaft pulley
Oil pan drain plug
Rear oxygen sensor
Coolant outlet port
Injector assembly
Fuel rail
T-MAP sensor Purge control solenoid valve
Electronic throttle body
VIS solenoid valve
Oil dipstick gauge
Oil filter assembly
Thermostat assembly
Oil pressure sensor

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5) Guidelines on Engine Service
(1) Cautions before service works
Make sure to disconnect the negative (-) cable from the battery to prevent any damage to electric
systems.
Make sure to clean the working area and to prepare the necessary tools before service works.
Always place the ignition switch to OFF position if not required. Otherwise, there could be unexpected
damage to electric devices or personal injuries due to short-circuit.
To prevent the foreign material from entering into the fuel injection system, completely seal the inlets o
f
HP pump, fuel hoses and high pressure pipes.
To remoev the engine, use the dedicated equipments such as engine jack, transmission jack, engine
stand and engine crane. -
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(2) Engine and accessories
When disassembling the engine, related parts (bolts, gaskets, etc.) should be stored as a set.
Clean the components completely with engine oil before assembling if needed.
Fully drain the engine oil, coolant and fuel from the vehicle and seal the inlets with the plugs before
removing the engine.
All the interference should be eliminated before removing the engine. -
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- To prevent the personal injuries and vehicle damages that can be caused by mistakes during service
and to provide the optimized performance and safety after service works, the service technicials must
keep the basic cautions and service guidelines below. These could be easily forgotten during service
works.
Engine has a lot of precise components. The specified tightening torque and correct procedures should
be kept during service works. And, the working area is always clean and well prepared.
To prevent any damage to electric systems, make sure to disconnect the negative (-) cable from the
battery and place the ignition switch to OFF position before servicing.
Use only the specified parts with same ratings when replacing the electric devices. Check the
grounds and connections for looseness. -
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(3) Electric devices
Extraordinary care should be taken when servicing the electric systems. Currently, the engine uses a lot
of electric devices. Short circuit and poor contact may cause the low engine performance, incomplete
combustion and other abnormalities.
When working with the fuel or oil systems in enclosed area, always keep the working area well-
ventilated and never allow anybody to smoke.
Gaskets and seals on the fuel and oil systems should be replaced with new ones. All bolts and nuts
should be tightened as specified.
Make sure to check the connections for leak after installation. -
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(4) Fuel and lubrication system

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1. ENGINE COMPARTMENT
Coolant reservoir
OCV
Ignition coil
Rear oxygen sensor connector
Front oxygen sensor connector
Coolant temperature sensor
Purge control solenoid valve
Engine ECU
Battery
Fuse box 1.
2.
3.
4.
5.
6.
7.
8
9.
10.HECU assembly
Alternator
Fuel rail assembly
Injector
Intake manifold
Oil dipstick gauge
VIS solenoid valve
T-MAP sensor
Electronic throttle body
Air cleaner assembly 11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

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Engine ECU
2. FUEL SYSTEM
Engine compartment
Purge control solenoid
valveFuel railInjector

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Fuel tank assembly
CanisterFuel filter
Fuel pump & fuel sender assembly

02-6
3. GUIDELINES ON ENGINE SERVICE
G20DF engine is for FF (Front Engine Front Drive) type vehicle. Therefore, there are some deferent
maintenance and repair works compared to the engine for FR (Front Engine Rear Drive) type vehicle.
For safe and correct works, you must observe the working procedures and instructions in this manual.
And, use the designated tools as follow:
: Power train mounting stand / Engine hanger / Engine stand / Heavy duty engine jack.
Cautions before service works ▶
G20DF engine is FF (Front Engine Front Drive) type engine, and the engine and transmission are
integrated in a same module. Remember that there are many differences compared to
conventional engine in FR (Front Engine Rear Drive) type SUV vehicle.
To remove the engine, use the dedicated equipments such as engine jack, transmission jack,
engine stand and engine crane (1 ton).
To prevent the engine from abruptly starting during service in engine compartment, never allow
anybody to stay in the vehicle.
Make sure to disconnect the negative (-) cable from the battery to prevent any damage to electric
systems.
Make sure to clean the working area and to prepare the necessary tools before service works.
Always place the ignition switch to OFF position if not required. Otherwise, there could be
unexpected damage to electric devices or personal injuries due to short-circuit..
To prevent the foreign material from entering into the fuel injection system, completely seal the
inlets of HP pump, fuel hoses and high pressure pipes.
Do not remove the engine while supporting the oil pan with a jack. -
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Lifting up the vehicle ▶
Before lifting up the vehicle with a lift, correctly support the lifting points.
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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Engine and accessories ▶
Engine has a lot of precise components. The specified tightening torque and correct procedures should
be kept during service works. And, the working area is always clean and well prepared.
When disassembling the engine, related parts (bolts, gaskets, etc.) should be stored as a set.
Carefully read the disassembly and reassembly procedures in this manual before starting the
works.
Clean the components completely with engine oil before assembling if needed.
Fully drain the engine oil, coolant and fuel from the vehicle and seal the inlets with the plugs before
removing the engine.
All the interference should be eliminated before removing the engine. -
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Tightening the fastener ▶
When reassembling the parts to G20DF, use the angle tightening as a final step.
1. Clean the mating surfaces before tightening.
2. Place the marks with paint to tighten by angle if the angle wrench is not available.Exhaust system ▶
Wear the protective gloves before removing the exhaust pipe.
The exhaust pipe is very hot immediately after stopping th engine. Check if the exhaust pipe is fully
cooled down before servicing the exhaust system. -
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Cooling system ▶
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 the radiator are hot. -
The position and direction of the componets is based on the rear view.
Do not tighten the fasteners with excessive force. Especially, the threads of cylinder block could be
damaged.
The self screw bolt makes the thread itself when tightening it. Do not apply excessive force.
Do not reuse the bolt that has been tightened with angle tightening method.