fuel 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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Accelerator pedal moduleFuse
Relay
Engine main relay 4
PPS (integrated
two pedal position
sensors)
Pre-glow and immobilizer
Engine main relay 4
IMV
Priming pumpFuel filter

InjectorFuel filter and priming pump
8. LAYOUT OF FUEL SYSTEM
Components
IMV connector
Pressure sensor
in fuel rail
High pressure
fuel pipe
Fuel pipe
Common rail IMV connector
HP pump
Priming pumpFuel filter
Connector
Returned fuel
from HP pumpFuel filter
Fuel tank
HP pump
Fuel tank
Fuel return port
Low pressure fuel supply portVenturi
Fuel return portFuel temperature
sensor
IMV valve
IMV connectorHigh pressure fuel
supply port
(with orifice)

Injector washer puller
2. SPECIAL SERVICE TOOLS
1) Using the Special Service Tools on Engine
Injector pullerGlow plug socket
HP remover/installerHigh pressure pipe
remover/installerCylinder head bolt wrench
Sealing caps
(fuel line)

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

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Injector (7-way Injection and C3I Coding)
1. FUEL SYSTEM - K2006
The C3I injector system is used in D20DT engine.
Injector
C3I Label
Two nozzle holes are added (currently 7) to the tip of the injector to increase the amount of fuel
injection and to improve injection efficiency according to the increased engine power.
The existing C2I coding (16 digits) is changed to C3I coding (20 digits) to monitor fuel injection and
follow the target value.
For the D20DT engine, the injector MDP (minimum current for the solenoid in the injector to lift the
nozzle) is leaned only when the engine is running. However, for the D20DT (EURO 4) engine, it is
learned when the vehicle is in motion and the engine is at idle speed. -
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C3I Label
C3I Code
Fuel nozzle
holes (7)
C3I
Fuel nozzle
holes (7)
C3I Code (20 digits)

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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HP PumpFuel Line
Injector (7-way Injection and C3I Coding)Fuel filter Priming Pump
Common Rail
2. COMPONENTS OF FUEL SYSTEM
Fuel nozzle
holes (7)
Injector
Fuel pipe
High pressure fuel pip Fuel rail pressure sensor
Fuel filter
Connector
Priming
pump
Fuel from
HP pumpFuel filter
HP pumpFuel tank
Fuel tank
Common rail
Fuel return
port
Low pressure
fuel supply port
Venturi
High pressure
fuel supply port
(orifice included)
Fuel
temperature
sensor
IMV valve
Fuel return
port
IMV
connector

3. HYDRAULIC CYCLE IN FUEL LINE
(TRANSFER AND HIGH PRESSURE LINE)

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