ECU SSANGYONG RODIUS 2012 Service Manual

01-18
The diagnostic connector is located at bottom of instrument panel. It consists of 16 pins.
The REKES key should be coded by the scan tool.
Connector Pin ▶
Diagnostic connector
Pin No. Function
1 -
2 -
3 STICS "A2"(Coding)
4 Ground
5 Ground
6 CAN HI S205 "12"
7 GSL ECU "58"
8 ABS/ESP unit “2”
9 Air bag unit “9”
10 -
11 TCU "A18"
12 -
13 TCCU "21"
14 CAN LO S205 "5"
15 STICS "B16" (Diagnosis)
16 B+
7. PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR

02-110000-00
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
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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02-170000-00
Vacuum pump
Pump capacity: 210 cc/rev
Camshaft speed:
375 to 3,000 rpm
Lubrication temperature:
-40 to 155°C
Oil: 5W30
Drive type: Driven by exhaust
Camshaft sprocket
EGR cooler bypass valve
This valve is controlled by ECU. When the
engine is cooled, the exhaust gas goes to
combustion chamber without passing through
EGR cooler because the valve is closed by
vacuum pressure.
2. VACUUM PUMP
Vacuum pump generates the vacuum pressure and supplies it to EGR cooler bypass solenoid.
This pump is single vane type and displacement is 210 cc/rev. The lubrication oil is supplied
through the hole in hollow shaft.
Components ▶
Brake booster and naster
cylinder

03-192210-01
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 1,800 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

03-20
Water
separator
(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.
To separate the water from the fuel filter,
remove the fuel filter assembly first.

03-212210-01
1. OVERVIEW
The components in fuel system supply the fuel and generate the high pressure to inject the 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 low pressure fuel to the low pressure pump (including high pressure pump), common rail
which distributes and accumulates the high pressurized fuel from the fuel 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.
1) Fuel Flow Diagram

03-22
Camshaft position sensor
Determining injection orderFuel tank
Fuel metering by sender
2. SYSTEM LAYOUT AND OPERATION
1) Layout
For sensor and actuator control logic, refer to Chapter "Engine Control".
Engine ECU (D20DTR)
Engine control by various
signalsInjector (C3I)
Pre-injection, main injection,
after-injection by signals from
ECU
HFM sensor
Measuring intake air mass
and temperature
Crankshaft position sensor
Measuring engine rpm

03-26
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.

06-191914-01
2. COMPONENTS
Atmospheric pressure, RPM
signal <00510047006d009600990047008b008c009b008800900093009a0047008800890096009c009b0047008a00960095009b009900960093004700930096008e0090008a005300470099008c008d008c00990047009b00960047006a008f00880097009b008c00
99004702c8006c0095008e00900095008c0047006a00960095>trol”.
E-VGT turbocharger
Improves engine powerAccelerator pedal position
sensor
Transfers driver's will to
accelerate to ECUEngine ECU (D20DTR)
E-VGT duty control
Coolant temperature sensor
Operates the VGT according
to engine warm-upHFM sensor
Improves the engine powerT-MAP sensor
Booster pressure and
temperature

07-51543-00
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) Components
Oil coolerOil dipstick gaugeOil pump
Oil filter moduleOil pressure switchOil pan