Turbo SSANGYONG NEW REXTON 2012 Service Manual

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Knock sensor (one) and
water temperature sensor
Fuel rail sensor (common
rail)
1. LOCATION OF MAJOR SENSORS ON ENGINE
Major sensors and devices
InjectorGlow plugCommon rail
Camshaft position sensorBoost pressure sensor
Crankshaft position
sensor
HP pumpCommon rail
Injector
Turbocharger vacuum
modulator

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Turbocharger intercooler
4. LAYOUT OF INTAKE SYSTEM
HFM sensor (HFM 6.0)
Turbocharger
Supplying the compressed air by turbocharger
Air cleaner
Turbocharger
Turbocharger
Plug in sensor
Air
cleanerTurbochargerProtension graph
Temperature
sensor
Air cleaner
Intake manifold
Coolant port To respective cylinder
From
intercoolerVGT control
actuator
Exhaust gas
Throttle body
Engine operating: Flap
openEngine stopped:
Flap closed
Intake duct
Intake duct
Boost pressure
sensor
Power
Voltage outputGround

E-EGR Valve
EGR cooler
PCV oil separator
The first separation will happen when blow-by
gas passes through baffle plates in cylinde
r
head cover. Then oil and gas will be separated
due to cyclone effect after entering the oil
separator inlet port. Separated oil returns to oil
pan via oil drain port and the gas will be burnt
again after entering the combustion chambe
r
through air duct hose via PCV valve that
opens/closes due to pressure differences
between the intake side and crankcase.Blow-by gas (air
duct hose)
Oil (oil gauge pipe) Cylinder head cover (oil + gas)
Inlet port
5. LAYOUT OF EXHAUST SYSTEM
VGT Turbocharger
Vacuum
modulator
To exhaust
pipe (DOC)
From exhaust manifold

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CDPF
Throttle body
Turbocharger vacuum modulator
EGR cooler
EGR pipe: Exhaust gas passage for recirculating
the exhaust gas
Intercooler
Intake manifold
DOCDPF
Coolant
port
Intake
manifold Exhaust
gas
To water
pump

D20DT Engine Remarks
HFM 6.0 HFM 6-ID
(Added digital signal function) -
Electrically controlled E-EGR valveECU controls the EGR valve directly.
It provides precise EGR control by
transmitting the electric signal of EGR
valve operating position. *
Vacuum modulator
Vacuum modulator for
turbocharger control
The vacuum modulator for controlling
EGR valve has been deleted. *
Throttle body is used to prevent the
engine from turning off with fluttering
noise at the moment the air to intake
manifold is blocked by closed flap
when the engine is switched off. *
Throttle body

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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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