fuel SSANGYONG NEW REXTON 2012 User Guide

1533-01
2.CDPF (EURO IV) SYSTEM CONTROL
1) General Description
As the soot is filtered in the CDPF, it is burnt and removed, and the CDPF is returned to the initial state to
collect the soot. Therefore, the burning procedures in the CDPF can be called as regeneration.
The CDPF assembly is integrated with DOC (at front side) and DPF (at rear side).
The DPF burns the soot with high-temperature exhaust gas (over
The rear exhaust gas
temperature sensor monitors the temperature of DPF section. If this temperature is below the
regeneration temperature, the ECU increases the post injection period to increase the fuel injection
amount, and consequently to increase the exhaust gas temperature.
Front exhaust gas temperature sensor
(Measuring temperature of exhaust gas in
exhaust manifold)
Rear exhaust gas temperature sensor
(Measuring temperature of exhaust gas
escaping DOC)
Normally, when the vehicle is driven for 600 ~ 1,200 km, the enough amount of soot to be burnt is
filtered and accumulated in the CDPF. The ECU increase the amount of post injection to increase
the tempeature of exhaust gas up to
so that the soot is burnt. The soot is burnt for
15 ~ 20 minutes. -

2) System Composition for Soot Combustion
When the engine is running in low load range, the temperature of exhaust gas is decreased as the
amount of fuel supplied is decreased. To burn the soot filtered in the CDPF, the control system should
be installed to check the operating range and increase the temperature of exhaust gas by controlling the
amount of fuel supplied and intake air.
Two temperature sensors and one differential pressure sensor monitor the CDPF's operating range.
According to these sensors' information, the throttle flap decreases the intake air entered to the throttle
body. Also, the fuel injection pattern is added to increase the temperature of exhaust gas for soot
combustion.
There are three fuel injection patterns (pilot injection, pre-injection and main injection). As the CDPF is
installed, the post injection pattern is added.
3) Post Injection and Air Mass Control
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 acumulated 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
the amount of fuel injected is increased to raise the temperature. If the temperature is over
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 ai
r
are controlled. It is to raise the temperature by increasing the amount of fuel while decreasing the
amount of intake air.

1533-01
Throttle bodies by engine type
The throttle valve is controlled by electric signals sent from the engine ECU for optimal fuel
injection volume, engine load and effective combustion of EGR gas according to the Euro 4
regulations. It has following functions by the engine type. -

2) Fuel Injection During CDPF Regeneration
3) Warning Lamp Related To CDPF
CDPF regeneration process (warning lamp NOT illuminated)
The CDPF system enters the regeneration mode when the
driving distance becomes approx. 600 to 1,200 km (may
differ by the driving condition and driving style). Then, the
engine ECU performs the CDPF regeneration operation.
However, the driver is not in-formed with this operation by an
y
engine warning lamp or vehicle signal, so he/she may not
detect this operation. The control logic at the post-injection
dur-ing the regeneration process is to increase the fuel
injection volume and control the intake air volume (by the
throttle body) in order to increase the tem-perature of the
exhaust gas. The driver may not feel any particular difference
from the vehicle.
No illumination

2. MAJOR COMPONENTS
Front view
Vacuum pump
Camshaft position sensor
Oil filter assembly
Power steering pump pulley
Oil pressure switch
Idler pulley No. 2
Water pump pulley
Alternator pulley
Auto tensioner
Idler pulley No. 1
A/C compressor pulley
Rear view
E-EGR valve
Fuel temperature sensor
Fuel HP pump assembly
Coolant temperature sensor
IMV valve Crankshaft position sensor
Isolation damper

0000-00
1) Service Interval
DescriptionDaily
inspectionWeekly
inspectionService interval
Engine oil & oil
filterInspection - EU Change every 20,000 km or 12 months
(The service interval should be
shortened under severe conditions)
General Change every 15,000 km or 12 months
(The service interval should be
shortened under severe conditions)
Coolant Inspection - Change every 200,000 km or 5 years
Air cleaner
element- Inspection Diesel EU Change every 20,000 km
(The service interval should
be shortened under severe
conditions)
General Clean every 7,500 km,
change every 15,000 km
(The service interval should
be shortened under severe
conditions)
Gasoline Clean every 15,000 km, replace every
60,000 km (The service interval should
be shortened under severe conditions)
Fuel filter - - EU Change every 40,000 km (Draining
water from fuel filter: whenever replacing
the engine oil)
General Change every 45,000 km (Draining
water from fuel filter: whenever replacing
the engine oil)

(3) Cautions before service
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. -
-
-
(5) Tightening the fastener
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. 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.
(4) Lubrication system
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. -
-Clean the mating surfaces before tightening.
Place the marks with paint to tighten by angle if the angle wrench is not available. -
-

Name SizeNumbers of
fastenerTightening
torque (Nm)Note (total
tightening
torque)
Idler pulley/tensioner
pulley1
-
Glow plug M5 4
-
Vacuum pump
3 -
Timing gear case cover
7 -
1 -
3 -
Cylinder head cover
21 -
Oil dipstick gauge cover
1 -
Oil filter cap 1
-
Fuel rail
2 -
Injector clamp bolt
2 -
High pressure pipe
(between high pressure
pump and fuel rail
assembly)M17 1
-
High pressure pipe
(between fuel rail
assembly and injector)M17 4
-
Crankshaft position
sensor
1 -
Main wiring
5 -
Intake duct
3 -
Power steering pump
3 -
Cylinder head front cover
5 -

Component SizeBolt
QuantitySpecified torque
(Nm)Remark
(Total torque)
Glow plug M5 4
-
Vacuum pump
3 -
Timing gear case cover
3 -
7 -
1 -
3 -
Cylinder head cover
21 -
Oil gauge tube
1 -
Oil filter cap 1
-
Fuel rail
2 -
Injector clamp bolt
2 -
High pressure pipe
(between HP pump and
fuel rail)M17 1
-
High pressure pipe
(between fuel rail and
injector)M17 4
-
Crank position sensor
1 -
Main wiring
5 -
Intake duct M8x25 4
-
Power steering pump
3 -
Cylinder head front cover
5 -
Ladder frame
5 -
Oil pump
3 -

0000-00
3. CHECK AND INSPECTION
1) Cylinder
(1) Compression pressure test
Specified value
Compression ratio16.5 : 1
Test condition
Compression pressureStandard32 bar
Minimum18 bar
Differential limit between cylindersMaximum 3 bar
The compression pressure test is to check the conditions of internal components (piston, piston ring,
intake and exhaust vale, cylinder head gasket). This test provides current engine operating status.
Before cranking the engine, make sure that the test wiring, tools and persons are keeping away
from moving components of engine (e.g., belt and cooling fan).
Park the vehicle on the level ground and apply the parking brake.
Do not allow anybody to be in front of the vehicle. -
-
-
Measurement
Disconnect the fuel rail pressure sensor connector to cut off the fuel injection.
Remove the air cleaner duct and glow plugs. -
-
-
Place the diagram sheet to compression
pressure tester and install it into the plug hole. 1.