Enging_SM(2).pdf

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SECTION INDEX

EURO 4

D27DTP / D27DT

1

SERVICE

ENGINE

D20DT ENGINE

2

MANUAL

G32D ENGINE

3

G23D ENGINE

4

KYRON SUPPLEMENT

FOREWORD

5

SERVICE MANUAL

This manual includes procedure for maintenance,

adjustment, service operation and removal and

installation of components.

DIAGNOSIS

6

All information, illustrations and specifications

contained in this manual are based on the

latest product information available at the time

of manual approval.

The right is reserved to make changes at any

time without notice.

PYUNGTAEK, KOREA

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Section 1

D27DTP / D27DT

ENGINE

SYSTEM

GENERAL INFORMATION

D27DTP ENGINE

FUEL SYSTEM

INTAKE SYSTEM

EXHAUST SYSTEM

PRE - HEATING SYSTEM

LUBRICATION SYSTEM

COOLING SYSTEM

SWITCHABLE ENGINE MOUNT

ENGINE ECU

DIAGNOSIS

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SYSTEM

0000

TABLE OF CONTENTS

SYSTEM .................................................................. 3

1. Major changes in D27DTP (POWERUP) engine

(for more information, refer to engine service manual) ...... 3

2. Major changes in interior electric components ................. 4

3. Major changes in electric components and units ............. 5

4. Major changes in chassis.................................................. 6

5. Major changes in vehicle exterior ...................................... 7

6. Frame dimension ............................................................... 8

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D27DTP/D27DT (EU4)

0000

3

1. MAJOR CHANGES IN D27DTP (POWERUP) ENGINE (FOR MORE INFORMATION, REFER TO ENGINE SERVICE MANUAL)

1913

VGT TURBOCHARGER

2433

VGT TURBO VACUUM MODULATOR

1490

ENGINE ECU - VERSION 3.2

COMMON RAIL & FUEL PIPE

Common Rail

1881

1881

INJECTOR (C3I LABEL)

C3I

Fuel Pipe

Air cleaner

(intake air)

Intercooler

(compressed air)

Exhaust pipe

(exhaust gas)

Connector A

Connector B

Orifice

This enhances the output power and torque, re-

duces the fuel consumption, and decreases the

exhaust gas by changing the exhaust gas flow by

controlling the vane in low and high speed range.

The diameter of fuel supply rail (including high pres-

sure rail) is increased due to the increase of engine

power and torque, and the orifice is installed in

common rail and HP pump to prevent fuel pulsation.

Only the vacuum modulator that controls VGT turbo

charger actuator is adopted in accordance with the

electrically controlled E-EGR.

E-EGR valve, throttle body and AQGS are

adopted to D27DTP engine, along with two

connectors to control the exhaust gas.

Two injection holes are added (currently 7 holes) to the injector

and C3I coding is adopted to control the amount of injected fuel

more precisely.

1222

PCV OIL SEPARATOR

1431 BOOST PRESSURE SENSOR

Mounting location and specification are changed

due to the newly added throttle body.

Blow-by gas

(to air duct hose)

Cylinder head

cover (oil + gas)

1412

2820

AQGS

GLOW PLUG

Oil (to oil dipstick

gauge pipe)

PCV oil separator with large capacity has been

adopted to improve the separation efficiency for

the oil and gas from crankcase.

8410

FUSE AND RELAY BOX

Red

2330

HFM SENSOR - VERSION 6.0

The glow plug for quick preheat-

ing function and CAN communi-

cation with ECU

The glow plug for quick preheating

is used with AQGS (Incompatible).

To control the engine more precisely, the digital

signal for inlet air mass is newly adopted and the

arrangement of connector pin is changed.

ELECTRONIC THROTTLE BODY

Normal: Open

1715

1792

E-EGR VALVE

1792

EGR COOLER PIPE

During engine stopping: Close

Intake

Coolant

EGR

gas

To EGR

cooler

Intake

Coolant

From exhaust

manifold

When the engine is not running, the flap in the throttle body is closed to

block the intake air to prevent the engine turning off with abnormal noise.

This is directly controlled by ECU.

The E-EGR valve electrically controls EGR valve,

and transmits the location signal of EGR valve to

ECU (Vacuum modulator for control eliminated).

This reduces the content of NOx in EGR gas by

decreasing the temperature.

1520

HIGH-CAPACITY WATER PUMP

6820

REFRIGERANT PRESSURE SENSOR

1990

SWITCHABLE ENGINE MOUNT & VACUUM SOLENOID VALVE

1533

IOP (OIL PAN)

2411

* CDPF SYSTEM (D27DT)

Connector

CDPF Assembly

EGR cooler and connecting port

Receiver Drier

LH/RH

Switchable

Engine Mount

Refrigerant

Pressure Sensor

Vacuum Pump

This is integrated in the front axle so that the

center of gravity of the vehicle can be low-

ered and NVH performance and power trans-

fer can be improved.

The EGR cooler and the coolant port (inside the

cylinder block) are adopted to improve the cool-

ing performance in high power engine.

With the continuous monitoring of refrigerant

pressure, the engine ECU controls the air condi-

tioner compressor precisely.

This engine mounting system can be elec-

tronically controlled in two stages (soft/hard)

depending on the vehicle’s condition.

Solenoid valve to draw or block the vacuum

to the switchable engine mounting system by

ECU control.

In pursuit of the exhaust gas reduction policy,

this system drastically reduces polluted material.

This consists of CDPF assembly and sensors.

SYSTEM

D27DTP/D27DT (EU4) SM - 2006.08

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

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