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D20DT ENGINE
Contents
Chapter 4. Diagnosis
1. ECU Connector ----------------------------------------------------------------------- 47
2. Diagnostic Trouble Code ---------------------------------------------------------- 53
3. Wiring Diagram ---------------------------------------------------------------------- 60
4. Data List Analysis --------------------------------------------------------------------- 64
Chapter 1
1 2 3 4 5
6 7 8 9 10 11 12 13 14
6
Engine Structure
2. Engine Structure
※ Left View
EGR Valve
Intake Manifold
Vacuum Pump
Vacuum Modulator
HP Pump for VGT & EGR
A/C Compressor
Cyl. Block
Oil Pan
※ Right View
Oil Separator
Cyl. Head Cover
Cyl. Head
VGT
Exhaust Manifold
Water Pump
Alternator
Fly Wheel &
Drive Plate
7
Engine Structure
※ Front View
EGR Pipe
Idle Pulley
Water Pump Pulley
P/Steering Pulley
Cooling Fan Pulley
Auto Tensioner
Pulley
※ Top View
Oil Separator
Injector
Glow Plug
Oil Filler
Common Rail
Intake Manifold
EGR Valve
8
Location of Sensors & Actuators
Accelerator Pedal
Engine ECU Water Sensor Sensor
9
Location of Sensors & Actuators
Knock Sensor
Engine Coolant
Temp’ Sensor
Vacuum Modulator
Fuel Temp’
Sensor IMV
Turbo Charger
Injector
Glow Plug
Rail Pressure
Sensor
10
Engine Specifications
4. Engine Specifications
11
Engine Performance Curve
12
Engine Performance Curve
13
Tightening Torque
6. Tightening Torque
14
Tightening Torque
15
Tightening Torque
16
Tightening Torque
Glow Plug
: 15+3 Nm
HP Pipe
: 40±10 Nm
17
Tightening Torque
HP Pump Center
Nut : 65±5 Nm
Tightening Tightening
Part Name Part Name
Torque Torque
18
19
Chapter 2
22
Components and Special Tools
23
Components and Special Tools
A9910 0150B
6 Engine Lock Fixture D20/D27
(602 589 004000)
24
HP Pump Removal & Installation
1) Removal
Preceding Works:
1. Disconnect the negative battery cable.
2. Apply the parking brake and place the chocks under the tires.
(transmission “N” position)
② ①
25
HP Pump Removal & Installation
26
HP Pump Removal and Installation
27
HP Pump Removal and Installation
2) Installation
Caution)
Be sure to align the notch on the shaft to the
sprocket groove when inserting the HP pump
Caution)
Center nut cannot be reused.
Caution)
Be sure that the 2 modulator connectors
are not to be changed.
28
HP Pump removal and installation
29
Timing Setting
Chain Tensioner
Tightening Toque
60Nm
The number of
teeth of HP Pump
sprocket 40EA
① When installing/removing of chain or sprocket, must align the timing mark “▶”
and copper mark on crank, HP pump and IN/EX manifold sprocket.
② It is necessary to align the HP pump sprocket.
③ Major difference
D27DT D20DT
30
Glow Plug Distinction
When replacing one or more plugs, must use the same type by distinguishing the color of
insulator.
▶ Vendor : BERU φ 4
31
Major Difference
D27DT
D20DT(Actyon/Kyron)
New Rexton Rodius(Stavic)
Photo
Oil Pump
D20DT:148 links
Photo
D27DT: 144 links
Timing Chain
40 teeth 32 teeth
Photo
HP pump sprocket
32
Major Difference
D27DT
D20DT
New Rexton / Rodius
Photo
Chain Tensioner
Photo
D20DT D27DT
Injector
Distinguished by color
- D20DT : Green / D27DT : Yellow
Feature
No of injector hole
- D20DT : 6 holes / D27DT : 5 holes
#1 #2 #3 #4 D20DT #1 #2 #3 #4 #5
Photo D27DT
33
Major Difference
D27DT
D20DT
New Rexton Rodius
7
Photo
P/N 664 010 0772 665 010 0872 665 010 1272
Max
Max 8.0L
7.5L
Max
8.5L
Min
Level
6.0L
Min
5.0L Min
6.0L
34
35
Chapter 3
36
37
Turbo Charger
Features
·High load /high efficient · Bypass valve for preventing · Variable control of inlet
driving excessive exhaust pressure port dimension with a
·Non-supercharged torque · Improved performance by movable vane installed at
in low speed optimizing the turbine exhaust turbine nozzle
·Excessively high efficiency in low & mid · Increases turbo charging
supercharged pressure speed range pressure by suffocating the
and high rotation in high · Reduced pumping loss in nozzle when the amount of
speed range high speed range gas flow is not sufficient in
low speed range.
· Outstanding low & mid · Improved torque
· Simple structure speed range characteristics in low
· Outstanding high speed · Improved torque speed range
Strengths
efficiency characteristics in low speed · Improved accelerating
· Outstanding durability range performance
· Simple control mechanism · Excellent control effects
38
Turbo Charger
Power
component appearing by insufficient air,
such as smoke/PM. Such a reduction of WGT Turbo
the PM elements guarantees the exhaust
gas (NOx / PM Trade-Off) margin.
In addition, with the engine output
improvement, we can expect the
increase of the spare driving force in
vehicle
and relatively better fuel consumption 1000 4500
under the same loading condition. Engine Speed, RPM
▷ This is the method to improve the torque in low & mid speed range and to control
variably the size of the exhaust turbine inlet size for lowering the exhaust gas
(smoke/PM) and enlarging the maximum output
Low RPM
High RPM
39
Turbo Charger
Vane Control
Engine Status Modulator Duty(%) Vane Passage
Actuator
This indicates that the pressure generated in the event of air compression by turbo
charging.
- Output value : varies in between 1000 ~ 2,700mbar
40
Turbo Charger
Check if the VGT operates in normal condition by looking into engine rpm/fuel injection
amount/boost pressure sensor values simultaneously.
At high rpm/high injection amount, the boost pressure value is also increased up to
2,700mbar its maximum pressure. If boost pressure sensor value is not as high as it’s
requested, must check the boost pressure sensor or VGT system.
41
Turbo Charger
② Keep horizontal stance that the control actuator places upward when storing, if a lot of
oil supply is made in turbo charger with actuator downward, the oil may inflow
into the vane mechanism.
③ It’s important not to drastically increase the engine rpm right after starting the engine. It
could make rotation at excessive speed even before the journal bearing is lubricated and
when the turbo charger rotates in poor oil supply condition, it could cause damage of
bearing seizure within a few seconds.
42
Turbo Charger
⑤ Do n ’t g r ip t he a ct uat or shaf t wh i l e
transferring or removing.
43
Turbo Charger
① Check procedure
- Check if there is any problem in other engine systems.
- Check the condition of turbo charger
· whether turbine or pump blades are damaged by foreign matters.
· whether turbine or pump blades runs smoothly.
· whether lubricating system and cooling system are in good condition.
44
45
Chapter 4
Diagnosis
ECU Connector
1. ECU Connector
48
ECU Connector
Pin
D27DT D20DT Remarks
Number
7 - -
8 - -
10 - -
11 - -
13 - -
15 - -
16 - -
20 - -
21 - -
22 - -
23 - -
24 - -
49
ECU Connector
Pin
D27DT D20DT Remarks
Number
27 - -
29 - -
30 - -
33 - -
37 IG 1 IG 1
39
41 - -
42 - -
43 - -
47 - -
48 - -
49 - -
50
ECU Connector
Pin
D27DT D20DT
Number
51 - -
52 - -
54 CAN - HI CAN - HI
55 - -
56 - -
59 - -
60 - -
65 - -
68 - -
69 - -
70 - -
74 - -
75 - -
51
ECU Connector
Pin
D27DT D20DT
Number
78 - -
80 - -
81 - -
85 - -
87 IMV IMV
89 - -
91 - -
92 - -
93 - -
94 - -
97 - -
98 - -
52
ECU Connector
Pin
D27DT D20DT Remarks
Number
106 - -
116 Injector # 3
119 - -
53
Diagnostic Trouble Code
54
Diagnostic Trouble Code
O
36 P0251 IMV Driving Circuit Short O
2000bar
O
37 P0253 IMV Driving Circuit Short to ground O
2000bar
O
38 P0255 IMV Driving Circuit Open O
2000bar
60 sec
68 P0652 #2 ECU Power Supply Low (5V) O O later
60 sec
69 P0653 #2 ECU Power Supply High (5V) O O later
Glow
70 P0671 #3 Glow Plug Open lamp
Glow
71 P0672 #4 Glow Plug Open lamp
Glow
72 P0673 #5 Glow Plug Open lamp
Glow
73 P0674 #1 Glow Plug Open lamp
Glow
74 P0675 #2 Glow Plug Open lamp
57
Diagnostic Trouble Code
58
Diagnostic Trouble Code
59
Diagnostic Trouble Code
60
Wiring Diagram
61
Wiring Diagram
62
Wiring Diagram
63
Wiring Diagram
64
Data List Analysis
D20DT
D27DT
65
Data List Analysis
D20DT
D27DT
66
Data List Analysis
D20DT
D27DT
67
Data List Analysis
N Uni
Item Description Idle Remark
o t
Boost Pressure
(MAP) Calculated absolute 1.01 ~ 1.06 bar(D20) Must same as actual
4 Bar
: combination pressure by ECU 0.98 ~ 1.01bar(D27) boost pressure
with #2
74.8%(D20) / %(D27)
Turbo Valve VGT modulator operating
Drive Duty duty, as rpm increases, D20 : 45 %
Max VGT for D20DT
5 : combination % the duty decreases. D27 : %
with #2 WGT for D27DT
Compare with Boost D20 :
- stall test Pressure. 50~65 %
at 1500 rpm
D27 : %
EGR Cut Conditions:
0%
EGR Valve 1. Above 2950rpm
Duty EGR modulator operating D20: 50 % 2. Above 105km/h
6 % duty, as rpm increases, 3. Above 1000m
: combination the duty increases. At 1500 rpm 4. Above 100 ℃ ,below
with #3 D27 : % 10
5. Idle 50sec continues
EGR Demand
(MAP) Target EGR volume. Air
mg/ Almost same as #3
7 Meter value determines 576 (D20) / 329 (D27)
: combination strk when EGR is operating
EGR volume.
with #3
68
Data List Analysis
N
Item Unit Description Idle Remark
o
250 bar
Rail Pressure
: combination with
9 Bar Rail pressure sensor signal At IMV 32%
#21,28,8 - stall Cranking :
test 250 ~290 bar
Check if ABS/ESP
Vehicle speed from
14 Vehicle Speed Km/h Variable unit displays
ABS/ESP unit via CAN line
normal speed.
MT : Neutral signal
Current gear position, data P/N or D , 1 ~ 4 by
15 Gear Ratio - from cluster via
from TCU via CAN speed
CAN
Num
17 Engine Block Noise 2 Calculated knock signal 30 ~ 50, Stall : 144 Only for D27DT
eric
69
Data List Analysis
BTDC 24.4(D20) /
Pilot Advance (MAP) Pilot injection timing 14.5(D27)
24 : combination with ° advance depending on
#12,19 engine load CKP & CMP
Racing : BTDC 39 sensor are
basic to
calculate
ATDC 1(D20) / 2.4(D27) timing.
Main injection timing
25 Main Advance (MAP) ° advance depending on
engine load
Racing : BTDC 7.5
70
Data List Analysis
Clutch Switch
To increase rpm when clutch
32 - Check if rpm increases On/Off release with neutral S/W off. M/T only
when releasing clutch ON when depressed.
engaging gear.
99.9% at
39 Pedal #2 Sensor Position % Monitoring signal opening % 0%
W.O.T
71
Data List Analysis
On/
45 Cruise Off Switch
Off
On/
46 Cruise Safety Switch
Off
On/
47 Cruise Accel Switch Auto Cruise S/W signal
Off
On/
48 Cruise Decel Switch
Off
On/
49 Cruise Resume Switch
Off
New Rexton
On/
50 Rear Blower Input Rear Blower S/W signal input (dual A/C) /
Off
Rodius only
Operating
On/ On when IG ON, blinks when
51 Glow Plug Lamp signal from
Off preheating system is faulty
ECU via CAN
72