ECU SSANGYONG KORANDO 2012 Service Manual

02-14
4. GUIDELINES ON ENGINE SERVICE
To prevent personal injuries and vehicle damages that can be caused by mistakes during engine and
unit inspection/repair and to secure optimum engine performance and safety after service works, basic
cautions and service work guidelines that can be easily forgotten during engine service works are
described in.
Cautions before service works
For safe and correct works, you must observe the working procedures and instructions in this
manual. And, use the designated tools as follow:
Engine stand / Heavy duty engine jack
To prevent the engine from starting abruptly, do not allow anybody to get in the vehicle while
servicing in engine compartment.
Before work on engine and each electrical equipment, be sure to disconnect battery negative (-)
terminal.
Before service works, be sure to prepare the works by cleaning and aligning work areas.
Do not allow the foreign material get into the fuel injection system.
When removing the engine, use only the safety hook on engine and engine hanger. Do not support
the bottom of oil pan with a jack.
Engine and accessories ▶
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Completely drain the engine oil, coolant and fuel from engine before removal.
Before disassembling/assembling the engine components, carefully read the working procedures in
this manual.
Make sure to keep the specified tightening torques during installation.
Clean and properly lubricate the parts before reassembly.
Carefully check that there are not any interference while servicing. -
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- Engine has a lot of precise portions so tightening torque should be correct during disassembly/assembly
and removal/installation and service work should be done in clean ways during disassembly/assembly.
Maintaining working area clean and cautious service administration is essential element of service works
while working on the engine and each section of the vehicle. So the mechanics should well aware of it.

03-210000-00
2) Cleanness
(1) Cleanness of DI engine fuel system
Cleanness of DI engine fuel system and service procedures ▶
The fuel system for DI engine consists of transfer (low pressure) line and high pressure line.
Its highest pressure reaches over 1,600 bar.
<007a00960094008c0047008a00960094009700960095008c0095009b009a0047009000950047009000950091008c008a009b00960099004700880095008b0047006f007700470097009c00940097004700880099008c004700940088008a008f0090009500
8c008b00470088009b0047009b008f008c004700940090008a>rometer 100 μm of
preciseness.
The pressure regulation and injector operation are done by electric source from engine ECU.
Accordingly, if the internal valve is stuck due to foreign materials, injector remains open.
Even in this case, the HP pump still operates to supply high pressurized fuel. This increases the
pressure to combustion chamber (over 250 bar) and may cause fatal damage to engine.
You can compare the thickness of injector nozzle hole and hair as shown in below figure (left side). The
below figure shows the clearance between internal operating elements.
The core elements of fuel system has very high preciseness that is easily affected by dust or very small
foreign material. Therefore, make sure to keep the preliminary works and job procedures in next pages.
If not, lots of system problems and claims may arise.
Hair
Nozzle holeValve actuator lift - 0.028 mm
Diameter
0.04 mm
Operating
clearance
0.002 mm
Diameter
2.0 mm

03-22
(2) Di engine and its expected problems and remedies can be caused by
water in fuel
System supplement against paraffin separation ▶
In case of Diesel fuel, paraffin, one of the elements, can be separated from fuel during winter and then
can stick on the fuel filter blocking fuel flow and causing difficult starting finally. Oil companies supply
summer fuel and winter fuel by differentiating mixing ratio of kerosene and other elements by region and
season. However, above phenomenon can be happened if stations have poor facilities or sell improper
fuel for the season. In case of DI engine, purity of fuel is very important factor to keep internal
preciseness of HP pump and injector.
Accordingly, more dense mesh than conventional fuel filter is used. To prevent fuel filter internal clogging
due to paraffin separation, SYMC is using fuel line that high pressure and temperature fuel injected by
injector returns through fuel filter to have an effect of built-in heater (see fuel system).
System supplement and remedy against water in fuel ▶
As mentioned above, some gas stations supply fuel with excessive than specified water. In the
conventional IDI engine, excessive water in the fuel only causes dropping engine power or engine
hunting. However, fuel system in the DI engine consists of precise components so water in the fuel can
cause malfunctions of HP pump due to poor lubrication of pump caused by poor coating film during high
speed pumping and bacterization (under long period parking). To prevent problems can be caused by
excessive water in fuel, water separator is installed inside of fuel filter. When fuel is passing filter, water
that has relatively bigger specific gravity is accumulated on the bottom of the filter.
Water drain from water separator ▶
If water in the separator on the fuel filter exceeds a certain level, it will be supplied to HP pump with fuel,
so the engine ECU turns on warning lamp on the meter cluster and buzzer if water level is higher than a
certain level.
Due to engine layout, a customer cannot easily drain water from fuel filter directly, so if a customer
checks in to change engine oil, be sure to perform water drain from fuel filter.
Water separator

03-230000-00
ENGINE CONTROL
SYSTEM
Engine ECU (D20DTF)
1. OVERVIEW
The components in the fuel system supply fuel and generate high pressure to inject fuel to each injector.
They are controlled by the engine ECU.
The common rail fuel injection system consists of fuel tank, fuel line, low pressure line which supplies lo
w
pressure fuel to the low pressure pump (includes high pressure pump), high pressure line which
connected to the injector and the engine control unit (ECU) which calculates the accelerator pedal
position and controls the overall performance of vehicle based on the input signals from various sensors.
HP fuel pump
Common rail and
Injector Fuel filter
(Priming pump)
Fuel supply tube
Fuel return tube
Fuel tank Fuel neck
Fuel sender (main)
Fuel sender (sub)
Low pressure line
High pressure line

03-24
Fuel rail assembly
Relieves the pulsation.
Measures the fuel pressure.
Distributes the fuel to injectors.Camshaft position sensor
Determines the injection order.
Injector (C3I)
Pre-injection, main injection, after-injection by
signals from ECU
Fuel tank
Fuel metering by dual sender. Supply the fuel in
main fuel tank and sub fuel tank through fuel
inlet tube
2. SYSTEM LAYOUT AND OPERATION
1) Layout
Fuel supply line
Fuel return line
For sensor and actuator control logic,
refer to Chapter "ENGINE CONTROL".

03-250000-00
Crankshaft position sensor
Measuring engine rpmT-MAP sensor
Measuring booster pressure
and temperatureHFM
Measuring intake air mass and
temperature
Engine ECU (D20DTF)
Engine control by various
signals
Fuel filter assembly
Supply clean fuel/fuel
heating/water separation by
priming pumpAccelerator pedal
position sensor
Detects driver's intention for
speed up/downHigh pressure pump
Generates the high pressurized fuel
and supply it.
Plunger type HP pump (1,800
bar)
Vane type transfer pump (6bar)

03-28
The engine ECU calculates the accelerator pedal based on the input signals from various sensors, and
controls the overall operation of the vehicle.
The ECU receives the signals from various sensor through data line, and performs effective air-fuel ratio
control based on these signals.
The crankshaft speed (position) sensor measures the engine speed, and the camshaft speed (position)
sensor determines the order of injections, and the ECU detects the amount of the accelerator pedal
depressed (driver's will) by receiving the electrical signals from the accelerator pedal sensor.
The mass air flow sensor detects the volume of intake air and sends the value to the ECU.
The major function of the ECU is controlling air-fuel ratio to reduce the emission level (EGR valve control)
by detecting instantaneous air flow change with the signals from the mass air flow sensor.
Also, the ECU uses the signals from the coolant temperature & air temperature sensors, booster pressure
sensor, atmospheric pressure sensor to: a) determine injection starting point and set value for pilot
injection, and b) deal with various operations and variable conditions.

06-170000-00
1. SYSTEM DESCRIPTION OF E-VGT
(Electric-Variable Geometry Turbine)
A turbocharger is a centrifugal compressor powered by a high speed turbine that is driven by an engine's
exhaust gases. Its benefit lies with the compressor increasing the mass of air entering the engine (forced
induction), thereby resulting in greater performance (for either, or both, power and efficiency). As the
turbine, at exhaust end, is rotated by exhaust gas pressure the impeller, at intake end, gets rotated to
send air around center of the impeller, being circumferentially accelerated by the centrifugal force, into
the diffuser. The air, which has been introduced to the diffuser having a passage with big surface,
transforms its speed energy into the pressure energy while being supplied to the cylinder improving the
volume efficiency. Also, the exhaust efficiency improves as the exhaust turbine rotates. The
turbocharger is often referred to as the exhaust turbine turbocharger.
The E-VGT system installed to the D20DTF engine variably controls the passages of the turbine
housing to regulate the flow rate of the exhaust gas. The actuator of E-VGT is a DC motor actuator (E-
Actuator) which controls more quickly and precisely than the previous vacuum type actuator.
The engine ECU controls the E-Actuator electronically as follows:
Diffuser: With the meaning of spreading out it is a device that transforms fluid's speed energy into the
pressure energy by enlarging the fluid's passage to slow down the flow.
At low speed: Narrows the flow passage for the exhaust gas, resulting in increasing the flow speed
of the exhaust gas and running the turbine quickly and powerfully.
At high speed: Expands the flow passage for the exhaust gas, resulting in increasing the mass flow
of the exhaust gas and running the turbine more powerfully. -
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06-190000-00
T-MAP sensor
Boost pressure and
temperature
E-VGT turbocharger
Improves engine power
2. COMPONENTS
Engine ECU (D20DTF)
E-VGT duty controlAccelerator pedal position
sensor
Transfers accelerating demand
to ECU
Atmospheric pressure, RPM
signal
HFM sensor
Improves the engine powerCoolant temperature sensor
Operates the VGT according to
engine warm-up
For more information about control logic, refer to Chapter "Engine Control".

07-50000-00
1. SYSTEM DESCRIPTION
1) Overview
The lubrication system supplies oil to each lubrication section to prevent friction and wear and to remove
heat from the friction part. As the engine runs, frictional heat is generated on each lubrication section. If
this condition persists, the bearing can be burned and stuck.
In other words, it creates an oil film on each sliding surface to convert solid friction to liquid friction in
order to minimize wear and prevent temperature increasing on the friction part.
For the D20DTF engine with no oil pressure switch, the engine ECU receives the low engine oil level
signal from the oil level sensor and communicates with the instrument cluster through the CAN
communication to turn on the warning lamp.
2) Component
Oil level sensorEngine oil dipstick
Oil panOil pumpOil filter module
Oil cooler