GENERAL INFORMATION REMOVAL AND INSTALLATION

1. SPECIFICATIONS.................................. 3 2313-03 AIR CLEANER ELEMENT............ 21

2330-01 INTERCOOLER............................ 23
1719-01 INTAKE MANIFOLD ASSEMBLY.
OVERVIEW AND OPERATING 1914-01 TURBOCHARGER ASSEMBLY.... 26
1546-13 OIL COOLER ASSEMBLY............ 32
PROCESS
1525-21 COOLANT OUTLET PORT.......... 41
1. MAJOR COMPONENTS 2412-01 CDPF ASSEMBLY........................ 43
(D20DTF(Low CO2))............................... 5 1432-01 T-MAP SENSOR.......................... 48
2. COOLANT FLOWS IN COOLING 53
SYSTEM................................................ 6
3. LAYOUT OF INTAKE SYSTEM.............. 8

CONFIGURATION AND FUNCTION

2313-01 CONFIGURATION AND 10

FUNCTION...................................
2330-01 INTERCOOLER ASSEMBLY........ 11
1719-01 INTAKE MANIFOLD..................... 12
1914-01 TURBOCHARGWE ASSEMBLY... 13
1543-13 OIL COOLER ASSEMBLY............ 16
1525-21 COOLANT OUTLET PORT.......... 17
2412-01 CDPF ASSEMBLY........................ 18
1491-01 ECU (D20DTF(Low CO2))............. 20
 0000-00 02-3

1. SPECIFICATIONS
System Unit Description Specification
Filtering type Dry, filter element
Filtering area 0.208m²
EU: Change every 20,000 km
(But, shorten the service
Air cleaner element interval under severe
conditions)
Service interval GEN: Clean every 7,500 km,
change every 15,000 km
(But, shorten the service
Intake interval under severe
system conditions)
Weight 1.5kg

Air cleaner assembly Operating temperature -30 ~ 100℃

Capacity 8L
Core material Aluminum
Size 510X122X67(WxHxT)
Intercooler
Tank material Plastic (Molding)
Efficiency 80%
Max. temperature of
780 ℃
turbine housing
Diameter of turbine
Exhaust Turbocharger ø40.0
housing
system assembly
Diameter of compressor
ø46.8
housing
Cooling type Air cooled type
 0000-00 02-5

1. MAJOR COMPONENTS (D20DTF(Low CO2))

CDPF Turbocharger ECU

T-MAP sensor Intercooler assembly Air cleaner assembly

02-6

2. COOLANT FLOWS IN COOLING SYSTEM

0000-00 02-7
02-8

3. LAYOUT OF INTAKE SYSTEM

1) Overview
The intake system for D20DTF(Low CO2) engine is equipped with a throttle body which includes a
flap. This flap is controlled by an electrical signal to cut off the intake air entering to the engine
when the ignition switch is turned off. The intake manifold contains the swirl control valve and
dual port system to make the optimum turbulence. The T-MAP sensor is located on the left top of
the intake manifold and the HFM sensor for precise control is located at the rear side of air
cleaner. To reduce the intake noise and to improve the intake efficiency, the volume of air cleaner
has been increased.

2) Components
Intake manifold

It is the passage for intake air when the

swirl vale is operating. The T-MAP sensor
for measuring the pressure and
temperature of pressurized air in
turbocharger is installed on the left top of
intake manifold.

Swirl control valve Electric throttle body

It operates variably in accordance with the

engine load and rpm.
Refer to Chapter “Engine Control”. Refer to Chapter “Engine Control”.
 0000-00 02-9

HFM (Hot Film Air-Mass Sensor)

HFM sensor, version 6

Refer to Chapter “Engine Control”.

Air cleaner assembly Intercooler assembly

Its volume is increased and air flowing Its volume is increased and cooling
efficiency is improved. efficiency is improved.
02-10

1) Overview
The volume of air cleaner has been increased to 8 L (D20DTF Low CO2) from 6.5 L (D20DTF).
The air cleaner uses the dry type element. It filters the foreign material from the intake air to
prevent the engine from damaging.

2) Location

Shorten the service interval under excessive use or severe conditions such as driving on a dusty
road or off-road, or driving in the rain.

Vehicle symptoms if service interval is not kept

- Insufficient engine power
- Excessive emissions
- Prematurely worn engine cylinder wall, piston, piston ring and intake valve
 2330-01 02-11

1) Overview
The turbocharger is designed to improve the engine power by introducing more air (oxygen) into
the cylinder with rotational power of the turbine generated from the exhaust pressure. However,
the intake air is heated during the compression process in the turbocharger compressor and this
leads to a lower air density.
In other words, the intercooler is needed to minimize the loss of turbocharger efficiency due to
heat expansion. The intercooler is a device which cools down the hot air entering the engine to
improve the turbocharging efficiency. Thus, more air is entered into the cylinder and more power
is produced than the engine with turbocharger only.
The volume of intercooler in D20DTF(Low CO2) is larger than that of D20DTF. It reduces the
intake resistance and improves the cooling efficiency.

2) Location

Intercooler assembly
02-12

1) Overview
The T-MAP sensor for measuring the pressure and temperature of pressurized air in turbocharger
is installed on the left top of intake manifold. The intake manifold assembly is designed to
optimize the mixture of the EGR gas in the intake chamber when the compressed air in the
turbocharger is sent to the intake port. The intake port is a dual-type port (tangential and helical
port) which increases the swirl ratio in mid/low operating range (below 3,000 rpm) to improve the
acceleration/fuel economy and to decrease the particle matters. In high operating range (over
3,000 rpm), it gets enough air volume to reduce the EGR gas and emission.

Always replace the gasket with new one and tighten the bolts to the specified tightening torque
(25 ±2.5 Nm).

The intake manifold gasket is coated with NBR elastomeric on the SUS to maximize the sealing
effect.

2) Location

Intake manifold assembly

 1914-01 02-13

1) Overview
The E-VGT turbocharger system installed to the D20DTF(Low CO2) engine variably controls the
passages of the turbine housing to regulate the flow rate of the exhaust gas. The actuator of E-
VGT is a DC motor actuator (E-Actuator) which controls more quickly and precisely than the
previous vacuum type actuator.
The engine ECU controls the E-Actuator electronically as follows:
- At low speed: Narrows the flow passage for the exhaust gas, resulting in increasing the flow
speed of the exhaust gas and running the turbine quickly and powerfully.
- At high speed: Expands the flow passage for the exhaust gas, resulting in increasing the mass
flow of the exhaust gas and running the turbine more powerfully.

2) Location

Turbocharger assembly
02-14

3) System Layout
Center housing
Compressor housing Turbine housing

E-actuator
Oil return tube

Oil supply line

Turbocharger support bar

4) Components

A. Oil supply Center housing Turbine housing Metal gasket

Compressor housing

Oil supply and return

B. Oil return

E-actuator Metal gasket A. Supply B. Return

 1914-01 02-15

5) Circuit Diagram
02-16

1) Overview
The stack plates in the oil cooler (for D20DTF(Low CO2)) have been reduced to minimize the oil
flow interference. It improves the fuel economy by enhanced cooling efficiency.
The oil cooler forms a unit together with the engine oil filter assembly. The oil cooler cools down
the hot engine oil with the engine coolant. It offers the following features:
- Improved cooling performance by increasing the cooling capacity.
- Integrated with oil filter module with coolant inlet and outlet pipes in one piece.
- Enhanced engine durability.

2) Location
In vehicle Oil cooler assembly

Coolant inlet
From heater To E-EGR cooler Oil outlet Oil cooler sealing

Coolant outlet
Oil inlet
 1525-21 02-17

1) Overview
The coolant outlet port is installed on the cylinder head. It is the passage to send the hot coolant
to radiator. The coolant temperature sensor is integrated in the coolant outlet port.

2) Location

Coolant outlet port

02-18

1) Overview
The CDPF has three major functions: Oxidation, PM trapping and Regeneration. The oxidation is
performed by the DOC, and collecting PM and regeneration are performed by the DPF. The DOC
has a built-in catalyst but the DPF needs extra system which controls the regeneration and
collecting PM.

2) Location

CDPF assembly

DOC Broad band oxygen sensor

Pre-DPF pressure Rear exhaust

temperature sensor
DPF

Post-DPF pressure
 2412-01 02-19

3) PM regeneration of DPF
The differential pressure sensor installed in the DPF measures the pressure values of inlet and
outlet of CDPF. And the amount of the PM collected in the filter is calculated based on the
exhaust temperature, intake air mass flow, booster pressure, etc.
The regeneration is started when the amount of the collected PM is 28 g or more.
The ECU commands post-injection to increase the temperature of CDPF to 600℃.

(1) When the amount of the collected PM is not enough:

The DPF works as a filter.

(2) When enough amount of PM is collected: The ECU commands

post-injection and increase the exhaust gas temperature to start
regeneration.
02-20

1) Overview
The D20DTF(Low CO2) ECU is proper to meet the EURO V regulations. It uses a certain map to
improve the fuel economy.
Existing components: swirl valve, EGR bypass valve
New or revised components: oil pump, E-EGR valve, CDPF
ECU receives and analyzes signals from various sensors and then modifies those signals into
permissible voltage levels and analyzes to control respective actuators.
ECU 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 drives IMV valve to control the rail pressure according to the engine
load. It makes the control optimized and minimizes the output loss.

2) Location

D20DTF ECU
 2313-03 02-21

- Disconnect the negative cable from the battery.

Air cleaner element

1. Disconnect the HFM sensor connector (A),

release the clamp (B), and separate the air
cleaner hose.

2. Release the clamps (A) and unscrew two

bolts (B, 10 mm) from the air cleaner upper
housing.
02-22

3. Remove the air cleaner upper housing by

lifting to the arrow direction as shown in the
figure.

4. Remove the air cleaner element from the

air cleaner housing.

5. Install the air cleaner element in the reverse

order of removal.

Make sure to replace the air cleaner

element with a genuine part.

- Check that the air cleaner element is

clogged, contaminated or damaged. If
- the element is clogged a little bit, remove
the foreign material using compressed air
from the back side of the element.
Replace the element if it is excessively
contaminated. Do not allow any foreign
material to enter into the system when
replacing the element.
 2330-01 02-23

- Disconnect the negative cable from the battery.

- Remove the engine acoustic cover.

Intercooler

1. Remove the air cleaner upper housing and

element.

Refer to Chapter “Intake System”.

2. Unscrew the bolt (A, 12 mm) and release

the lower lock (B) to remove the air cleaner
lower housing.
02-24

3 3. Release the clamps and separate the inlet

hose (A) and outlet hose (B) from the
intercooler.

4. Unscrew three bolts (A, 10 mm) and

remove the intercooler assembly.

Pull the intercooler to arrow Pull it up to arrow direction (B). Remove it to arrow direction
direction. (C).
 2330-01 02-25

5. Install the intercooler in the reverse

order of removal.
02-26

- Disconnect the negative cable from the battery.

- Remove the acoustic cover.
- Remove the electric throttle cover.

Intake manifold

1. Remove the drain plug at the bottom of

radiator and drain the coolant in radiator
completely.

- Scalding hot coolant and steam could be

blown out under pressure, which could
cause serious injury. Never remove the
coolant reservoir cap when the engine
and radiator are still hot.
- Drain the coolant into a suitable container
and do not spill it on the floor.
- Avoid the coolant to come in contact with
your skin or the vehicle body as anti-
freeze is included. In case of skin
contact, wash thoroughly with plenty of
clean water immediately.
- Use only the genuine coolant.
 1719-01 02-27

2 2. Disconnect the engine wiring harness

connectors.

A. Variable swirl actuator connector

B. EGR valve connector
C. EGR bypass valve connector
D. A/C compressor connector
E. T-MAP sensor connector
F. Knock sensor connector

3. Release the clamps (A, B) and separate

the hoses.

4. Disconnect the electric throttle body

connector (A) and the oil level switch
connector (B).
02-28

5. Unscrew the bolt (10 mm) on the intake

duct and remove the wiring bracket with
engine wiring.

6. Unscrew three bolts (10 mm) from the

electric throttle body.

7. Remove the electric throttle body.

Make sure not to

damage the O-
ring.

8. Unscrew the bolts A (10 mm-2) and the

bolts B (13 mm-2) and remove the EGR
pipe.
 1719-01 02-29

9. Unscrew the bolt (19 mm) from the

intake duct lower bracket.

10.Unscrew three bolts (13 mm) and remove

the intake duct (A).

11.Remove the EGR cooler assembly.

Refer to Chapter “Exhaust System”.

12.Remove the E-EGT valve assembly.

Refer to Chapter “Exhaust System”.

02-30

13.Unscrew eight bolts (13 mm) from the

intake manifold.

Tighten the bolts in two or more steps to

the specified tightening torque.

14.Remove the intake manifold assembly.

Replace the gasket with new one.

15.Install the intake manifold in the reverse

order of removal.
 1719-01 02-31

Cautions for installation

Tightening order: 1→2→3→4→5→6→7→8

- Tighten the bolts in two or more steps to the specified tightening torque.

Apply the soapy water around the O-ring to

check for leak from mounting area.
02-32

- Disconnect the negative cable from the battery.

- Remove the engine acoustic cover.
- Remove the engine under cover.

Do not start to perform the service for the exhaust system until it cools down.

Turbocharger assembly

1. Remove the air duct hose (A).

- Release the spring clamp (B) on air duct
hose and the spring clamp (C) on blow-by
hose.

C
 1914-01 02-33

2 2. Release the clamp (A) on the hose

between turbocharger and intercooler and
unscrew the nut (B, 10 mm).

A. Using clamp pliers

B. Duct mounting nut

3. Remove the hose between turbocharger

and intercooler.

4. Disconnect the E-actuator connector.

02-34

5. Disconnect the front and rear exhaust gas

temperature sensor connectors and
remove them from the bracket.

Rear temperature Front temperature

sensor sensor

6. Disconnect the broad band oxygen sensor

connector.

7. Remove the connector from the bracket.

 1914-01 02-35

8. Release the spring clamps on the hoses to

differential sensor with pliers.

A. Hose to front pressure port

B. Hose to rear pressure port

9. Remove the mounting bracket (A) for

differential pressure sensor pipe.

10.Unscrew four bolts (5 mm) from the heat

shield on exhaust manifold with L-
wrench.

11.Remove the heat shield.

02-36

12.Unscrew the hollow bolt (14 mm) on the

turbocharger.

Replace the copper washers on hollow bolt

with new ones.

- Hold the nut (A) with a spanner (17 mm)

when unscrewing the hollow bolt.

13.Release the V-clamp on the pipe between

turbocharger and CDPF with L-wrench and
pull the V-clamp to arrow direction.

14.Unscrew two upper bolts (A, 13 mm) on

CDPF.
 1914-01 02-37

15.Lift up the vehicle and remove No.1 exhaust

pipe.

Refer to Chapter “Exhaust System”.

16.Remove the right drive shaft and

intermediate shaft.

Refer to Chapter “Drive Shaft and Axle”.

17.Unscrew two lower bolts (13 mm) on

CDPF.

18.Remove the CDPF assembly.

Make sure not to damage the differential

pipe during removal.
02-38

19 19.Unscrew the upper bolt/nut (13 mm) and

the lower bolt (13 mm) and remove the
turbocharger support bar.

20.Unscrew the screw fitting (A) and remove

the oil supply tube from turbocharger.

21
21.Unscrew four bolts (5 mm) with L-wrench
and remove the oil return tube from
turbocharger.
 1914-01 02-39

22.Unscrew the upper nut (A, 13 mm).

23.Unscrew two lower nuts (A, 13 mm) and

remove the turbocharger assembly.

24.Install the turbocharger assembly in the

reverse order of removal.
02-40

Cautions for installation

* To prevent the gas leak, securely tighten the V-clamp as below.

1. Temporarily tighten four CDPF mounting bolts.

Upper bolts Lower bolts

2. Temporarily install the V-clamp (A),

install the CDPF assembly and push it to
direction B tight. Then, completely
tighten V-clamp.

The V-clamp is a non-reusable part and

should be replaced with new one.

3. Tighten two upper bolts and two lower

bolts.
 1546-13 02-41

- Disconnect the negative cable from the battery.

- Remove the engine acoustic cover.
- Remove the engine under cover.

Oil cooler assembly

1. Remove the E-EGR cooler assembly.

Refer to Chapter “Lubrication System”.

02-42

2. Release the clamp and separate the water

inlet hose from the oil cooler.

3. Unscrew seven bolts (5 mm) with L-

wrench and remove the oil cooler assembly
(A).

Make sure not to spill out the oil from the oil
cooler.

4. Install the oil cooler in the reverse order

of removal.

Replace the gasket with new one.

Part number Name

A 6719970645 Oil cooler gasket
B 6719970745 Oil cooler gasket

C 6711840480 Oil filter housing

gasket
D 6719970545 Oil cooler gasket
 1525-21 02-43

- Disconnect the negative cable from the battery.

- Remove the engine acoustic cover.

Coolant outlet port

1. Remove the air duct hose (A).

- Release the clamp (B) on air duct hose
and the clamp (C) on blow-by hose

C
02-44

2. Disconnect the HFM sensor connector (A)

and remove the air cleaner upper cover
(B).

3. Disconnect the ECU connectors (A, B) and

release the wiring locks (arrows)

4. Unscrew two nuts (A, 12 mm) from the

ECU/GCU bracket and separate the fuel
hose (B).

5. Disconnect the GCU connectors (A, B)

The GCU connector

(A) has locking tabs
on both sides.
 1525-21 02-45

6 6. Release the clamps (A) on the hose

between turbocharger and intercooler and
unscrew the nut (B).

A. Using clamp pliers

B. Duct mounting nut

7. Remove the duct and hose between

turbocharger and intercooler.

8. Disconnect the coolant temperature sensor

connector.
02-46

9. Release the clamp (A) on upper hose and

the clamp (B) on cabin heater outlet hose.

10.Unscrew two bolts (10 mm) from the

coolant outlet port.

11.Remove the coolant outlet port.

12.Take out the sealing (A) from the coolant

outlet port.
 1525-21 02-47

13.Install the coolant outlet port in the reverse

order of removal.
02-48

- Disconnect the negative cable from the battery.

- Remove the engine acoustic cover.
- Remove the engine under cover.

Do not start to perform the service for the exhaust system until it cools down.

CDPF installed on engine CDPF assembly

1. Disconnect the rear exhaust gas

temperature sensor connector (A) and the
broad band oxygen sensor connector (B).
 2412-01 02-49

2. Separate the differential pressure sensor

hoses with pliers.
A. Spring clamp on front pressure port hose
B. Spring clamp on rear pressure port hose

3. Remove the mounting bracket (A) for

differential pressure sensor pipe.

4. Unscrew four bolts (5 mm) from the heat

shield on exhaust manifold with L-
wrench.

5. Remove the heat shield.

02-50

6. Release the V-clamp on the pipe between

turbocharger and CDPF with L-wrench and
pull the V-clamp to arrow direction.

7. Unscrew two upper bolts (A, 13 mm) on

CDPF.

8. Lift up the vehicle and remove No.1

exhaust pipe.

Refer to Chapter “Exhaust System”.

9. Remove the right drive shaft and

intermediate shaft.

Refer to Chapter “Drive Shaft and Axle”.

 2412-01 02-51

10.Unscrew two lower bolts (13 mm) on CDPF.

11.Remove the CDPF assembly.

CDPFMake sure not to damage the

differential pipe during removal.

12.Install the CDPF in the reverse order of

removal.
02-52

Cautions for installation

* To prevent the gas leak, securely tighten the V-clamp as below.

1. Temporarily tighten four CDPF mounting bolts.

Upper bolts Lower bolts

2. Temporarily install the V-clamp (A),

install the CDPF assembly and push it to
direction B tight. Then, completely
tighten V-clamp.

The V-clamp is a non-reusable part and

should be replaced with new one.

3. Tighten two upper bolts and two lower

bolts.
 1432-01 02-53

- Disconnect the negative cable from the battery.

- Remove the engine acoustic cover.

T-MAP sensor

1. Disconnect the T-MAP sensor connector.

How to disconnect the T-MAP sensor

Press the point A on Insert the tip of flat Hold both ends (D) of
the connector to get a blade driver into the slit connector and pull it
slit B. B and pry up the out.
connector end to
direction C.
02-54

2. Unscrew the bolt (10 mm) on the T-MAP

sensor.

3. Remove the T-MAP sensor from the intake

manifold.

4. Install the T-MAP sensor in the

reverse order of removal.