engine SSANGYONG NEW REXTON 2012 Owner's Manual

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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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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-

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1. OVERVIEW FOR CDPF (EURO IV)
The CDPF (Catalyst & Diesel Particulate Filter) was installed to the Rexton II D27DTP engine previously.
However, it is now installed to the all 2009 DI engine models, except the Actyon Sports. The DI engine
type sinstalled to Rexton are D27DTP, D27DT and D20DT, and their CDPF, related sensor and
operation logic are the same.This section describes the CDPF system (based on Euro IV) which is
installed to the Rexton II D27DTPengine (older model).
1) General Description
2) Compatibility of CDPF System by Vehicle Model
Rexton II: Same CDPF system for D27DTP and D27DT engines (including its components)
Kyron & Actyon: Same CDPF system for D27DT and D20DT engines (including its components)
The CDPF assemblies installed to the Euro IV D27DTP Rexton II and 2009 Rexton II are
different in their mounting layout, but their front/rear exhaust temperature sensors and
differential pressure sensors are same. -
3) System Met with EURO IV Regulations
The Ssangyong vehicles installed with the D27DT engine manufactured from July 2007 to December
2007 comply with the EURO IV regulations. Modified components from the old engine model are as
follow:
- E-EGR valve
- EGR cooler
- Engine ECU (Ver. 3.2)
- HFM senso
- C3I injector
- Electronic throttle valve (body)
- Other engine mounting components
For details about the modified components and system related to the EURO IV regulations, refer to the
2008 Rodius engine service manual.

Under air cleaner in right side
of engine compartment
2. CDPF (EURO IV) SYSTEM
The CDPF system is only installed to the D27DT engine, and the major changes comparing to the
previous D27DT engine is as follows:
CDPF (Catalyst & Diesel Particulate Filter) and Sensors
Front exhaust gas
temperature sensor
CDPF Exhaust Gas Temperature Sensor
The two temperature sensors
in-side the CDPF are installed
inexhaust manifold (front
exhaustgas temperature
sensor) and inDOC (rear
exhaust gas tempera-ture
sensor), and perform the fol-
lowing functions.Front Exhaust Gas Tempera-ture
Sensor:
Measures the exhaust gas tem-
perature of the exhaust manifold. As it
is installed in front of the VGT
turbocharger, it also monitors the
exhaust gas tempera-ture coming to
the turbocharger. If the temperature of
the exhaust gas flowing to the
turbocharger is higher than the
specification, the engine lowers the
exhaust gas temperature.Rear Exhaust Gas Tempera-
ture Sensor:
Measures the increased ex-
haust gas temperature after
the oxidation process of DOC.
If the temperature is below
amount is increased to
increase the temperature.
As the soot is filtered in the CDPF, the pressure between the front side and the rear side of the filter is
different from each other. If the amount of soot is over 28 g, the soot is burnt in the CDPF. The
combustion is determined depending on the pressure difference, temperature of exhaust gas and

1533-01
Throttle Body
CDPF system controls the amount of intake air by controlling the
electronic throttle body. The electronic throttle body has the
following main functions.
CDPF control - added a function that increases the exhaust gas
temperature by closing the throttle valve flap to minimize the intake
air amount by the fuel injection amount during the CDPF
regeneration range with the low engine load range.
ON/OFF control - prevents the engine from turning off with
vibration and noise by closing the throttle body flap to block the
intake air when the engine is stopped.
Duty control - controls the valve inside the throttle body to burn
more EGR gas in the EGR valve operating range.
VGT Turbocharger and Front Exhaust Gas Temperature Sensor
Turbocharger may become weaker if high tem-
perature exhaust gas passes through the tur-
bocharger for DPF regeneration process.
The front exhaust gas temperature sensor moni-tors
the temperature of the exhaust gas that flows into the
turbocharger.
If the temperature of the exhaust gas that passes
through the exhaust manifold is higher than the
specification, the ECU decreases the fuel injection
amount and increases the EGR gas intake amount to
decrease the exhaust gas temperature.Front exhaust gas
temperature sensor

1. OVERVIEW
As the solution for environmental regulations and PM (Particla
Material) of diesel engine, the low emission vehicle is getting
popular. This vehicle is equipped with an extra filter to collect
the soot and burn it again so that the amount of PM in the
exhaust gas passed through the DOC (Diesel Oxydation
Catalyst) is reduced. The CDPF (Catalyst & Diesel Particulate
Filter) is anintegrated filter including DOC (Diesel Oxydation
Catalyst) and DPF (Diesel Particulate Filter).
Comparison of throttle body functions based on exhaust emission regulation
Regulated parts are carbon monoxide (CO), nitrogen oxide (NOx), particular matter (PM) and soot in the
exhaust emission, and the particulars of the regulations are prescribed in the following table.