2012 SSANGYONG NEW REXTON Service Manual

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1. ENGINE DATA LIST
Data Unit Value
Coolant temperature
Intake air temperature
temperature or engine mode)
Idle speed rpm
Engine load % 18~25%
Mass air flow kg/h 16 to 25 kg/h
Throttle position angle
Engine torque Nm varies by engine conditions
Injection time ms 3 to 5ms
Battery voltage V 13.5 V to 14.1 V
Accelerator pedal position 1 V 0.4. to 4.8V
Accelerator pedal position 2 V 0.2 to 2.4 V
Throttle position 1 V 0.3 to 4.6 V
Throttle position 2 V 0.3 to 4.6 V
Oxygen sensor mV 0 to 5 V
A/C compressor switch 1=ON / 0=OFF -
Full load 1=ON / 0=OFF -
Gear selection (A/T) 1=ON / 0=OFF -
Knocking control 1=ON / 0=OFF -
Brake switch 1=ON / 0=OFF -
Cruise control 1=ON / 0=OFF -

Glow plug
Differential pressure
sensor
Camshaft position
sensor
1. MAJOR COMPONENTS
Rear EGT sensorOxygen sensor
Front EGT sensor
HFM (air mass/
temperature)Injector (C3I)Variable swirl valve
actuator
IMV

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Fuel rail pressure
sensorEGR valve
Electric throttle bodyKnock sensor
(2 ea)
Coolant temperature
sensor
T-MAP sensorD20DTR ECU
E-VGT actuator
Water sensorGCU (Preglow control
unit)
E-EGR bypass valve
Fuel temperature
sensor

2. SYSTEM OPERATION
1) Input/Output of ECU
(1) ECU Block diagram

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Fuel rail pressure
sensor
(2) Components for ECU Input
CAN
- ABS & ESP
- GCU
- Instrument
cluster
- TCU
- STICSSwirl valve
position sensor
Differential
pressure sensorE-EGR valve
position sensorCamshaft position
sensorCoolant
temperature
sensor
Exhaust gas
temperature
sensorHFM sensorOxygen sensorT-MAP sensor
Crankshaft
position sensorAccelerator pedal
sensorThrottle position
sensorKnock sensor
-Auto cruise switch
- Rear right wheel
speed (without ABS)
- Refrigerant pressure
sensor
- Clutch pedal signal
- Blower switch signal
- Brake pedal signal
Water sensor

(3) Components for ECU Output
CAN
E-EGR cooler
bypass valve
- Instrument cluster
- TCU
- Self diagnosis
PTC heaterCooling fan
E-EGR valve
Variable swirl
valveE-VGT actuatorIMV valve
A/C compressorInjectorThrottle position
sensor
- Glow plug unit
- ABS & ESP unit
- GCU

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2) ECU Control
(1) Function
a. ECU Function
ECU receives and analyzes signals from various sensors and then modifies those signals into
permissible voltage levels and analyzes to control respective actuators.
ECU microprocessor calculates injection period and injection timing proper for engine piston speed and
crankshaft angle based on input data and stored specific map to control the engine power and emission
gas.
Output signal of the ECU microprocessor drives pressure control valve to control the rail pressure and
activates injector solenoid valve to control the fuel injection period and injection timing; so controls
various actuators in response to engine changes. Auxiliary function of ECU has adopted to reduce
emission gas, improve fuel economy and enhance safety, comforts and conveniences. For example,
there are EGR, booster pressure control, autocruise (export only) and immobilizer and adopted CAN
communication to exchange data among electrical systems (automatic T/M and brake system) in the
vehicle fluently. And Scanner can be used to diagnose vehicle status and defectives.
water and electromagnetism and there should be no mechanical shocks.
To control the fuel volume precisely under repeated injections, high current should be applied instantly
so there is injector drive circuit in the ECU to generate necessary current during injector drive stages.
Current control circuit divides current applying time (injection time) into full-in-current-phase and hold-
current-phase and then the injectors should work very correctly under every working condition.
b. Control Function
Controls by operating stages
To make optimum combustion under every operating stage, ECU should calculate proper injection
volume in each stage by considering various factors.
Starting injection volume control
During initial starting, injecting fuel volume will be calculated by function of temperature and engine
cranking speed. Starting injection continues from when the ignition switch is turned to ignition
position to till the engine reaches to allowable minimum speed.
Driving mode control
If the vehicle runs normally, fuel injection volume will be calculated by accelerator pedal travel and
engine rpm and the drive map will be used to match the drivers inputs with optimum engine power. -
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(2) Fuel injection control
a. Multi injection
Fuel injection process consists of 3 steps: Main Injection, Pilot Injection, Post Injection
InjectionFunction
MainProduces engine power
Pilot 1Reduces PM by injecting before
main injection.AfterPM control
Pilot 2Reduces NOx and noise by
shortening main injection delay
due to flammability Post 1Reduces PM by enabling fuel
activation.
PreControls NOx emission level,
Combustion noise and
Stable idle Post 2Activates CDPF by increasing
exhaust gas temperature and
supplying reduction material
Pilot injectionMulti injection