ACTYON

D20DT ENGINE
 Contents

Chapter 1. D20DT Engine General

1. Engine Room Description --------------------------------------------------------- 7
2. Engine Structure ------------------------------------------------------------------------ 8
3. Location of Sensor & Actuator -------------------------------------------------- 10
4. Engine Specifications --------------------------------------------------------------- 12
5. Engine Performance Curve ------------------------------------------------------ 13
6. Tightening Torque -------------------------------------------------------------------- 15

Chapter 2. Removal & Installation

1. Components and Special Tools ---------------------------------------------- 23
2. D20DT HP Pump Removal & Installation ------------------------------- 25
3. D20DT HP Pump Timing Setting -------------------------------------------- 30
4. Glow Plug Distinction -------------------------------------------------------------- 31
5. D20DT/D27DT Parts Major Difference ------------------------------------
32

Chapter 3. Turbo Charger (VGT)

1. Types of Turbo Charger ---------------------------------------------------------- 37
2. VGT Principle -------------------------------------------------------------------------- 38
3. VGT Non-Operating Conditions ------------------------------------------------- 39
4. VGT related Data List of Scan-100 -------------------------------------------- 39
5. Cautions when dealing with VGT ----------------------------------------------- 41
6. Turbo Charger Troubleshooting ------------------------------------------------- 43

Chapter 4. Diagnosis
1. ECU Connector ----------------------------------------------------------------------- 47
2. Diagnostic Trouble Code ---------------------------------------------------------- 53
3. Wiring Diagram ---------------------------------------------------------------------- 60
4. Data List Analysis --------------------------------------------------------------------- 64
 Chapter 1

D20DT Engine General

 Engine Room

1. Engine Room Description

1 2 3 4 5

6 7 8 9 10 11 12 13 14

1. Reservoir Tank 2. FFH(Fuel Fired Heater)

3. Vacuum Pump 4. Brake Booster
5. ABS/ESP Unit 6. Air Cleaner
7. Turbo Charger(VGT) 8. Dipstick Gauge
9. Oil filler 10. Common Rail
11. EGR Valve 12. Fuel Filter
13. Battery 14. Engine Room Fuse Box

7
Engine Structure

2. Engine Structure

※ Left View
EGR Valve

Intake Manifold
Vacuum Pump

P/Steering Pump Oil Filter & Cooler

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

8
 Engine Structure

※ Front View

EGR Pipe

Idle Pulley
Water Pump Pulley
P/Steering Pulley
Cooling Fan Pulley
Auto Tensioner
Pulley

Crank Shaft Pulley

Auto Tensioner

※ Top View

Oil Separator

Cyl. Head Cover

Injector
Glow Plug
Oil Filler

Common Rail

Intake Manifold
EGR Valve

9
 Location of Sensors & Actuators

3. Location of Sensors & Actuators

Accelerator Pedal
Engine ECU Water Sensor Sensor

HFM Sensor Cam Position Preheating Unit

Sensor

10
 Location of Sensors & Actuators

Knock Sensor

Engine Coolant
Temp’ Sensor

Vacuum Modulator

HP Pump Crank Position

Sensor

Fuel Temp’
Sensor IMV
Turbo Charger

Injector

Glow Plug

Rail Pressure
Sensor

EGR Valve Boost Pressure Sensor

11
Engine Specifications

4. Engine Specifications

Item D27DT D20DT

Cylinder Arrangement L – 5(In-line 5 Cylinder) L-4(In-line 4 Cylinder)

Displacement (cc) 2696 cc 1998cc

Max Power (PS/RPM) 165/4,000 141/4,000

Max Torque (Nm) 347/1,800~2,750 310/1,800~2,750

Fuel Consumption (ℓ/km) 10.4 C100 4WD A/T : 11.7

Compression Ratio 18 : 1 17.5 : 1

Firing Order 1–2–4–5–3 1-3-4-2

Bore (mm) 86.2 86.2

Cylinder Stroke (mm) 92.4 85.6

Bore Pitch (mm) 97.0 97.0

Camshaft Type DOHC DOHC

Valve Adjustment HLA HLA

Idle RPM AT/MT 750±50rpm 780±50

Thermostat Opening (℃) 80 85

Bowl on Piston Crown Bowl on Piston Crown

Combustion Chamber
(Direct Injection) (Direct Injection)
Engine Oil Capacity (ℓ)
(SAE 10W-40, 5W-40 / 8.5 ℓ 7.5 ℓ
API CG or Above)

Coolant Capacity(ℓ) Approx. 11.5 ℓ Approx. 10.5 ~ 11.0ℓ

12
 Engine Performance Curve

5. Engine Performance Curve

1) Horse Power & Torque

13
Engine Performance Curve

2) Oil Pressure and Temperature & Boost Pressure

14
 Tightening Torque

6. Tightening Torque

15
Tightening Torque

16
 Tightening Torque

17
Tightening Torque

1) Fuel System Tightening Torque ( D27DT / D20DT )

Injector Clamp Bolt

: step 1 :10Nm±1Nm
step 2: 180˚±10˚

Glow Plug
: 15+3 Nm

HP Pipe (Common Rail 

Injector) : 40±4 Nm

HP Pipe (HP Pump 

Common Rail ) : 40±4 Nm

Common Rail fixing

Bolt : 24±2.4 Nm

HP Pipe
: 40±10 Nm

18
 Tightening Torque

2) HP Pump System Tightening Torque (D20DT )

HP Pump Fixing Bolt :

25+2.5 Nm

HP Pump Center
Nut : 65±5 Nm

Tightening Tightening
Part Name Part Name
Torque Torque

Fuel Pipe : Fuel Pipe :

40±4.0Nm 40±4.0Nm
Common Rail  Injector HP Pump  Common Rail

1st step :
1st step :
10Nm Sprocket Fixing Bolt :
Injector Fixing Bolt 20±2Nm
2nd step : (Only for D27DT)
2nd step : 90±10˚
190±10˚

HP Pipe Fixing Bracket 8.6±0.9Nm HP Pump Center Nut 65±5Nm

HP Pump Fixing Bolt 25±2.5Nm

19
20
 Chapter 2

Removal & Installation

22
 Components and Special Tools

1. Components and Special Tools

23
Components and Special Tools

24
 Components and Special Tools

1. List for Special Tools

No SST Name SST P/Number Application

1 Common Rail Tester Y9922 0012B D20/D27

2 Injector Puller Y9922 0072B D20/D27

3 Glow Plug Wrench Y9922 0132B D20/D27

4 Sealing Caps 665 995 5844 D20/D27

5 Copper Washer Puller Y9922 0022B D20/D27

A9910 0150B
6 Engine Lock Fixture D20/D27
(602 589 004000)

Cylinder Head Bolt

7 W9912 0035B D20/D27
Wrench (14mm)

8 HP Bearing Puller Y9922 0302B D20/D27

9 HP Pump Lock Y9922 0102B D27

25
HP Pump Removal & Installation

2. D20DT 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)

1. Turn the auto tensioner counterclockwise

and remove the fan belt.

2. Remove the engine belt pulleys.

1) Cooling fan pulley
2) Coolant pump pulley
③

② ①

3. Unscrew lower bolt (13 mm) and upper bolt

(24 mm) and remove the auto tensioner.

• To prevent oil leaks, place the removed

auto tensioner in upright position.
• Pump the auto tensioner several times
before installing it.

26
 HP Pump Removal & Installation

4. Remove the high pressure pump housing

cover.

5. Align the OT mark by rotating the

crankshaft.
1) Open the oil filler cap and check if the OT
mark on crankshaft is aligned to the notch on
the camshaft.

6. Remove the vacuum modulator bracket,

and HP pipe (Pump to Common Rail)

7. Rotate the crankshaft clockwise so that the

HP pump sprocket holes are aligned to the
bolt holes.

27
HP Pump Removal and Installation

8. Hold the HP pump sprocket and slacken

the center nut.

9. Slacken three HP pump mounting bolts

until they contact with the sprocket.

10. Loosen the HP pump center nut by

tapping it with a hammer.

• Tap the center bolt with a hammer after

tightening.
• Make sure that the center bolt is securely
tightened.

11. Loosen the remaining bolts with the

same manner and remove the high
pressure pump.

28
 HP Pump Removal and Installation

2) Installation

1. Replace the HP pump gasket with new one.

(cannot be reused)

2. Tighten the HP pump bolts.

Tightening Torque 25Nm

Caution)
Be sure to align the notch on the shaft to the
sprocket groove when inserting the HP pump

3. Tighten the center nut after fixing the

sprocket.

Tightening Torque 65Nm

Caution)
Center nut cannot be reused.

4. Install HP pipe and vacuum modulator

bracket.

Caution)
Be sure that the 2 modulator connectors
are not to be changed.

29
HP Pump removal and installation

5. Install the HP pump housing cover after

applying sealant.

Note) · Sealant(DB2210) : 661 989 56 A0

6. Install auto tensioner and belt pulley.

7. See if timing marks are aligned after

rotating
crank shaft 2 turns.

30
 Timing Setting

3. D20DT HP Pump Timing Setting

The teeth number

of Ex. Cam
The teeth number sprocket 40EA
of Ex. cam
sprocket 40EA

Chain Tensioner
Tightening Toque
60Nm

The number of
teeth of HP Pump
sprocket 40EA

The number of teeth

of crank sprocket
20EA

The number of teeth

of oil pump sprocket
26EA

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

Teeth number of HP pump

32 teeth 40 teeth
sprocket

Number of Chain link 144 links 148 links

Crank rotations to coincide

144 turns 74 turns
chain & sprocket timing marks

31
Glow Plug Distinction

4. Glow plug distinction

When replacing one or more plugs, must use the same type by distinguishing the color of
insulator.

▶ Vendor : BERU φ 4

▶ Application : D20DT & D27DT

Green ▶ Resistance : 680±110mΩ( at 20℃)

▶ Vendor : NGK φ 3.5

▶ Application : D20DT & D27DT

Yellow ▶ Resistance : 140±30mΩ( at 20℃)

▶ Vendor : NGK AQGS φ 3.5

▶ Application : D27DT Euro-IV

Red ▶ Resistance : 140±30mΩ( at 20℃)

Diameter of Tip Color of Insulator

- BERU : 4.0mm - Green : BERU
- NGK : 3.5mm - Yellow : NGK

32
 Major Difference

5. D20DT/D27DT Parts major difference

D27DT
D20DT(Actyon/Kyron)
New Rexton Rodius(Stavic)

D20DT D27DT D27DT(RD)

Photo

Oil Pump

P/N 664 180 03 01 665 180 05 01 665 180 06 01

Basket hole 7 Basket hole 9

Higher basket
Feature o’clock o’clock
than others
direction direction

D20DT:148 links
Photo
D27DT: 144 links

Timing Chain

P/N 664 997 01 94 665 997 00 94

Feature D20DT is 4 links longer than D27DT

40 teeth 32 teeth
Photo 

HP pump sprocket

P/N 664 075 02 29 665 075 01 29

D20DT is bigger than D27DT

Feature D20DT sprocket incorporates bearing shaft.
D27DT sprocket separates bearing shaft.

33
Major Difference

D27DT
D20DT
New Rexton / Rodius

Photo

Chain Tensioner

P/N 664 050 00 11 665 050 00 11

D20DT is blue painting cap on the top

Feature
Spring constant for D20DT is greater than D27DT

Photo 

D20DT D27DT
Injector

665 017 01
P/N 664 017 00 21  
21

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 

Fuel Pipe ( Common Rail  Injector )

664 070 00 33(No.1)

665 070 06 33(1&3)
664 070 01 33(No.2)
P/N 665 070 07 33(2&4)
664 070 03 33(No.3)
665 070 08 33(5)
664 070 04 33(No.4)

Different color
Feature
- D20DT : Silver / D27DT : Bronze

34
 Major Difference

D27DT
D20DT
New Rexton Rodius
7

Photo

Oil dipstick gauge

P/N 664 010 0772 665 010 0872 665 010 1272

D20DT : 66407 on the hand rail

Feature
D27DT : 66508 on the hand rail for New Rexton
66512 on the hand rail for Rodius

Max
Max 8.0L
7.5L
Max
8.5L
Min
Level
6.0L
Min
5.0L Min
6.0L

35
36
 Chapter 3

Turbo Charger (VGT)

37
38
 Turbo Charger
1. Types of Turbo Charger
Turbo charger increases the amount of inflowing air into engine by compressing the air
with exhaust energy. It influences on intake and exhaust. The capability of the turbo
charger mainly depends on the exhaust energy and the specifications of turbo charger
such as turbine inlet size, radius of housing, and diameter of the compressor.
The exhaust energy is normally to be high at high speed and to be low at low speed. If
the turbine inlet size is reduced to compensate the low exhaust energy at low speed
range, the intake air pressure becomes excessively high at high speed, which causes the
adverse effect of high-speed performance with the change of injection timing and the
growth of pumping loss. Conversely, if the turbine inlet size is extended for the
improvement of performance at high speed range, sufficient air flow and booster pressure
are not taken at a low speed range, which may cause the adverse effect of low-speed
performance.

▷ Types according to the supercharging method

· Turbo supercharge, intercooler turbo charger
· Waste gate, variable turbo charger
· Ceramic turbo, turbo compound, mechanical type, inertia supercharge,
sequential, complex, etc.
Classification STD WGT VGT

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

· Relatively low efficiency in · Relatively low efficiency in · Complicated control

Weakness low & mid speed range high speed range mechanism
· Slow response · High price

39
Turbo Charger

2. VGT Principle (Variable Geometry Turbocharger)

The vane is installed between the compr
essor and the turbine, the housing .
VGT helps to control the section size of t
he turbine inlet, maximize the exhaust en
ergy efficiency, increase the intake air vo
lume without the increase of the exhaust
volume, and obtain more output.
It also intakes much more air volume VGT Turbo
under the same load, prevents the occurr
ence of incomplete combustion compone

Power
nt appearing by insufficient air, such as
smoke/PM. Such a reduction of the PM WGT Turbo
elements guarantees the exhaust gas (N
Ox / PM Trade-Off) margin.
In addition, with the engine output improv
ement, we can expect the increase of the
spare driving force in vehicle
and relatively better fuel consumption un
der the same loading condition. 1000 4500
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

. Vane opening/
. Improved torque/output in
electronic control
low speed range
. Easy to secure low-
. Reduced exhaust gas
Features speed air volume Expectations
. Improved fuel consumption
. Improved accelerating
. Improved response
performance
. Electric operation

Low RPM

■ Exhaust gas passage becomes narrow

 Gas speed increases
 Turbine blade runs fast

High RPM

■ Exhaust gas passage becomes wide

 Gas amount increases
 Turbine blade runs fast

40
 Turbo Charger

3. VGT Non-Operating Conditions

In case of the following conditions, ECU stops VGT control.

√ Lower than 700RPM
√ Below 0℃
√ EGR related trouble stored in ECU
√ VGT Actuator faulty
√ Boost Pressure Sensor faulty
√ Air Flow Sensor faulty
√ Accelerator Pedal Sensor faulty

4. VGT related Data List of Scan-100

① VGT vacuum modulator operating status

Vane Control
Engine Status Modulator Duty(%) Vane Passage
Actuator

Low load & low 85% Pulling

Narrow
rpm (Duty Increases) (Vacuum Applies)

Return
High load & high 5%
(Vacuum Wide
rpm (Duty Decreases)
Releases)

② VGT vacuum modulator valve duty (%)

This represents that how much the ECU opens and closes the VGT vacuum modulator,
Duty value increases to 85% so that the VGT control actuator pulls the vane and the
gas passage becomes narrow when low load/low speed. When high load/speed, Duty
value decreases to 5% so that the VGT control actuator releases and gas passage
becomes wide by the return spring force.

③ Boost Pressure Sensor Value (mbar)

This indicates that the pressure generated in the event of air compression by turbo
charging.
- Output value : varies in between 1000 ~ 2,700mbar

41
Turbo Charger

[ Low rpm/low load ]

[ High load/Stall test ]

[ VGT Actuator Duty Value

(%) ]

③ VGT control analysis

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.

42
 Turbo Charger

5. Cautions when dealing with VGT

① Be sure not to transmit external impact on

turbo charger to prevent internal damage.

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.

43
Turbo Charger

④ The screw for adjusting of actuator shaft

should not be adjusted, since it’s already
adjusted precisely in assembly line.

⑤ Don’t grip the actuator shaft while

transferring or removing.

⑥ Before installing a new VGT, fill a little of

oil on the inlet pipe connecting hold.

⑦ Be sure not to be inserted any metallic

matters when installing.

44
 Turbo Charger

6. Turbo Charger Troubleshooting

Turbo charger trouble will hardly happen as long as it runs in normal condition.
Therefore, it is not necessary to check regularly upon mileage or running time, however,
it is strongly recommended to check according to the maintenance schedule.

The following symptoms may happen when it’s faulty.

· Deterioration of engine power.
· Engine noises
· Excessive engine oil consumption
· Excessive exhaust gas
The cause of these symptoms may result from engine itself and no trouble in turbo
system. It is possible to foresee the trouble of turbo charger before removing it by
checking the turbine.

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.

② Causes of turbo charger damage

- Problem of lubricant
· Insufficient lubricant
· Deteriorated lubricant
· Oil become sludge in center housing
- Inflow of foreign matters
· to compressor from air cleaner
· to turbine blade from exhaust manifold
- Excessively high temperature of exhaust gas
- Material or workers fault

45
46
Chapter 4

Diagnosis
 ECU Connector

1. ECU Connector

49
ECU Connector

Pin
D27DT D20DT Remarks
Number

1 Engine Ground Engine Ground

2 Engine Ground Engine Ground

3 Main Power (B+) Main Power (B+)

4 Main Power (B+) Main Power (B+)

5 Main Power (B+) Main Power (B+)

6 RPS power supply RPS power supply

7 - -

8 - -

9 Engine Main Relay Engine Main Relay

10 - -

11 - -

12 Neutral s/w(only for New Rexton) -

13 - -

14 Accel Pedal Sensor 2 ground Accel Pedal Sensor 2 ground

15 - -

16 - -

17 Auto Cruise OFF Auto Cruise OFF

18 Auto Cruise Safety S/W Auto Cruise Safety S/W

19 A/C Pressure Signal (Hi/Low) A/C Pressure Signal (Hi/Low)

20 - -

21 - -

22 - -

23 - -

24 - -

25 RPS Signal RPS Signal

50
 ECU Connector

Pin
D27DT D20DT Remarks
Number

26 RPS Ground RPS Ground

27 - -

28 ECU Ground ECU Ground

29 - -

30 - -

31 Auto Cruise + Auto Cruise +

32 Accel Pedal Sensor 2 Signal Accel Pedal Sensor 2 Signal

33 - -

34 K-LINE (for Preheating/Immo) K-LINE (for Preheating/Immo)

35 K-LINE (Diagnosis) K-LINE (Diagnosis)

36 VSS (Non ABS/ESP) VSS (Non ABS/ESP)

37 IG 1 IG 1

38 Clutch Pedal S/W (M/T) Clutch Pedal S/W (M/T)

39

40 Water Sensor signal Water Sensor signal

41 - -

42 - -

43 - -

44 Knock Sensor Signal (#2)

45 Knock Sensor Signal (#1) Knock Sensor Signal (#1)

46 Knock Sensor Ground (#1) Knock Sensor Ground (#1)

47 - -

48 - -

49 - -

50 Auto Cruise Result Signal Auto Cruise Result Signal

51
ECU Connector

Pin
D27DT D20DT
Number

51 - -

52 - -

53 Accel Pedal Sensor 1 Ground Accel Pedal Sensor 1 Ground

54 CAN - HI CAN - HI

55 - -

56 - -

57 Accel Pedal Sensor 2 Power Accel Pedal Sensor 2 Power

58 Brake Lamp S/W Brake Lamp S/W

59 - -

60 - -

61 PTC #1 Relay PTC #1 Relay

62 PTC #2 Relay PTC #2 Relay

63 Knock Sensor 2 Ground -

64 HFM Sensor (Ambient signal) HFM Sensor (Ambient signal)

65 - -

66 ECU Ground ECU Ground

67 Auto Cruise - Auto Cruise -

68 - -

69 - -

70 - -

71 Accel Pedal Sensor 1 signal Accel Pedal Sensor 1 signal

Accel Pedal Sensor 1 power Accel Pedal Sensor 1 power

72
supply supply

73 CAN -LO CAN -LO

74 - -

75 - -

52
 ECU Connector

Pin
D27DT D20DT
Number

76 A/Con Middle Pressure S/W A/Con Middle Pressure S/W

77 Brake S/W Brake S/W

78 - -

79 A/Con Compressor Relay A/Con Compressor Relay

80 - -

81 - -

82 Crank Position Sensor Ground Crank Position Sensor Ground

83 HFM Sensor Signal HFM Sensor Signal

84 HFM Sensor Ground HFM Sensor Ground

85 - -

86 HFM Sensor Power Supply HFM Sensor Power Supply

87 IMV IMV

88 ECU Ground ECU Ground

89 - -

90 Crank Position Sensor Signal Crank Position Sensor Signal

91 - -

92 - -

93 - -

94 - -

95 WGT Actuator Modulator VGT Actuator Modulator

96 EGR Vacuum Modulator EGR Vacuum Modulator

97 - -

98 - -

99 Boost Pressure Signal Boost Pressure Signal

100 Boost Pressure Sensor Ground Boost Pressure Sensor Ground

53
ECU Connector

Pin
D27DT D20DT Remarks
Number

101 Engine Coolant Temp Signal Engine Coolant Temp Signal

102 Engine Coolant Temp Ground Engine Coolant Temp Ground

103 Cam Position Sensor Signal Cam Position Sensor Signal

104 Cam Position Sensor Ground Cam Position Sensor Ground

105 Engine Warning Lamp Engine Warning Lamp

106 - -

107 A/Con S/W A/Con S/W

Boost Pressure Sensor Power Boost Pressure Sensor Power

108
Supply Supply

109 Fuel Temp Sensor Signal Fuel Temp Sensor Signal

110 Fuel Temp Sensor Ground Fuel Temp Sensor Ground

Cam Position Sensor Power Cam Position Sensor Power

111
Supply Supply

112 Immo Lamp (Old Model) -

113 Preheating Control Signal Preheating Control Signal

114 Injector # 1 Injector # 1

115 Injector # 4 Injector # 4

116 Injector # 3

117 Injector Power (#1.3.4) Injector Power (#1.4)

118 Injector Power (#2.5) Injector Power (#2.3)

119 - -

120 Injector # 5 Injector # 2

121 Injector # 2 Injector # 3

54
 Diagnostic Trouble Code

2. Diagnostic Trouble Code

Torque Limp Delay
No DTC Description MIL Stop
Reduction home

1 P0102 Low HFM Sensor Signal (Circuit Open) O

2 P0103 High HFM Sensor Signal O

3 P0105 Boost Pressure Sensor Power Supply Error

4 P0106 Boost Pressure Sensor Signal High

5 P0107 Boost Pressure Sensor Open

6 P0108 Boost Pressure Sensor Short

7 P0109 Boost Pressure Sensor Signal Low

8 P0110 Ambient Temp Sensor Power Supply Error

9 P0112 Ambient Temp Sensor Open

10 P0113 Ambient Temp Sensor Short

11 P0115 ECT Sensor Power Supply Error

12 P0117 ECT Sensor Open

13 P0118 ECT Sensor Short

14 P0120 APS 1 Power Supply Error O 50%

15 P0122 APS 1 Open O 50%

16 P0123 APS 1 Short O 50%

17 P0180 Fuel Temp Sensor Power Supply Error

18 P0182 Fuel Temp Sensor Short to Ground

19 P0183 Fuel Temp Sensor Open

20 P0190 RPS Power Supply Error 50%

21 P0191 RPS Signal Impossible to measure 50%

22 P0192 RPS Signal Open O 50%

23 P0193 RPS Signal Short O 50%

24 P0201 #1 Injector Open O

25 P0202 #2 Injector Open O

55
Diagnostic Trouble Code

Torque Limp Delay

No DTC Description MIL Stop
Reduction home

26 P0203 #3 Injector Open O

27 P0204 #4 Injector Open O

28 P0205 #5 Injector Open O

29 P0215 Main Relay Stuck for over 3 sec

30 P0219 CKP Sensor Clearance Low O

31 P0220 APS 2 Power Supply Error O 50%

32 P0222 APS 2 Open O 50%

33 P0223 APS 2 Short O 50%

34 P0245 VGT Modulator Circuit Short O 50%

35 P0246 VGT Modulator Circuit Open O 50%

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

39 P0263 #1 Cyl. Balance Error O

40 P0266 #2 Cyl. Balance Error O

41 P0269 #3 Cyl. Balance Error O

42 P0272 #4 Cyl. Balance Error O

43 P0275 #5 Cyl. Balance Error O

44 P0325 #1 Knock Sensor Error O

45 P0330 #2 Knock Sensor Error O

46 P0335 No Crank Signal

47 P0336 CKP Sensor Large Clearance O

CKP Sensor Signal Error (No

48 P0337 Recognition)

49 P0341 Synchronization with CMP Error O

50 P0344 CMP Sensor Signal Error O

CKP Sensor Signal Error (Faulty Drive

51 P0372 Plate)
O

52 P0400 EGR Control Error O

56
 Diagnostic Trouble Code

Torque Limp Delay

No DTC Description MIL Stop
Reduction home

53 P0500 Vehicle Speed Signal Error

54 P0503 Vehicle Speed Signal Error

55 P0530 A/C Pressure Sensor short to B+

56 P0532 A/C Pressure Sensor Signal Low

57 P0533 A/C Pressure Sensor High

58 P0560 Battery Voltage Error : Too Low 50%

59 P0562 Battery Voltage Too Low O 50%

60 P0563 Battery Voltage Too High : over 16v

61 P0606 ECU Watch Dog Error

Immobilizer Error, (key coding

62 P0633 impossible)

63 P0636 Immobilizer Error

64 P0641 #1 ECU Power Supply Error (5V) O

65 P0642 #1 ECU Power Supply Low (5V) O

66 P0643 #1 ECU Power Supply High (5V) O

60 sec
67 P0651 #2 ECU Power Supply Error (5V) O O later

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

75 P0685 Main Relay Faulty O

76 P0697 ECU Power Supply Error (2.5V) O

77 P0698 ECU Power Supply Low O

78 P0699 ECU Power Supply High O

79 P0700 TCU Signal Error O

57
Diagnostic Trouble Code

Torque Limp Delay

No DTC Description MIL Stop
Reduction home

80 P0704 Clutch Switch Faulty

81 P1105 Atmospheric Pressure Sensor (Power Supply)

82 P1106 Atmospheric Pressure Sensor Error

83 P1107 Atmospheric Pressure Sensor open/short

84 P1108 Atmospheric Pressure Sensor short

85 P1109 Boost Pressure Initial Check Error

86 P1115 ECT Sensor short to ground

87 P1116 ECT Sensor Error

88 P1120 APS 1 Error O 50%

89 P1121 APS 2 Error O 50%

90 P1122 APS Error (Emergency) O

91 P1123 APS Error ( Limp-home) 50% O

92 P1148 Accelerometer Adaptation Error 20%

93 P1149 Water detected in fuel filter (over 39cc) 20%

94 P1170 Torque Trim High O

95 P1171 #1 Injector MDP Error O

96 P1172 #2 Injector MDP Error O

97 P1173 #3 Injector MDP Error O

98 P1174 #4 Injector MDP Error O

99 P1175 #5 Injector MDP Error O

100 P1190 RPS Initial Signal Error O

101 P1191 Rail Pressure Creation Too Slow O

102 P1192 RPS Initial Signal Low O 50%

103 P1193 RPS Initial Signal High O 50%

104 P1201 #1 Injector Circuit Short O

105 P1202 #2 Injector Circuit Short O

106 P1203 #3 Injector Circuit Short O

58
 Diagnostic Trouble Code

Torque Limp Delay

No DTC Description MIL Stop
Reduction home

107 P1204 #4 Injector Circuit Short O

108 P1205 #5 Injector Circuit Short O

109 P1235 Boost Pressure Control Error O 50%

110 P1252 IMV Pressure Excessive O

111 P1253 RPS Too Low (pressure difference) O

112 P1254 RPS Too High (pressure difference) O

Insufficient low pressure (IMV current

113 P1256 high)

114 P1257 Excessive low pressure O

115 P1258 Insufficient high pressure O

116 P1259 Excessive high pressure O

117 P1286 #1 Injector wiring low resistance O

118 P1287 #1 Injector wiring high resistance O

119 P1288 #2 Injector wiring low resistance O

120 P1289 #2 Injector wiring high resistance O

121 P1290 #3 Injector wiring low resistance O

122 P1291 #3 Injector wiring high resistance O

123 P1292 #4 Injector wiring low resistance O

124 P1293 #4 Injector wiring high resistance O

125 P1294 #5 Injector wiring low resistance O

126 P1295 #5 Injector wiring high resistance O

127 P1405 EGR Modulator Circuit Open O

128 P1406 EGR Modulator Circuit Short O

129 P1480 #1 Condenser Fan Circuit Open

130 P1481 #1 Condenser Fan Circuit Short

#1 Condenser Fan Circuit Short to

131 P1482 ground

132 P1500 No Vehicle Speed Signal O

133 P1526 #2 Condenser Fan Circuit Open

59
Diagnostic Trouble Code

Torque Limp Delay

No DTC Description MIL Stop
Reduction home

134 P1527 #2 Condenser Fan Circuit Short

#2 Condenser Fan Circuit Short to

135 P1528 ground

136 P1530 #1 PTC Control Circuit Open O

137 P1531 #1 PTC Control Circuit Short

138 P1532 #1 PTC Control Circuit Short to ground

139 P1534 #2 PTC Control Circuit Open O

140 P1535 #2 PTC Control Circuit Short O

141 P1536 #2 PTC Control Circuit Short to ground O

142 P1540 A/C Comp Control Circuit Open

143 P1541 A/C Comp Control Circuit Short

144 P1542 A/C Comp Control Circuit Short to ground

145 P1571 Brake Lamp Signal Error (ECU #77) O

146 P1572 Brake Lamp Signal Error (ECU #58) O

147 P1600 ECU Shut Down Error (Injector Control) O

148 P1601 ECU Error (Injector Control) O

149 P1602 ECU Error (Injector Control) O

150 P1606 ECU Error (CAN/KWP2000 Error) O O

151 P1607 ECU Injector Cut Error O

152 P1608 ECU Error (Injector Control) O

153 P1614 ECU Error (C2I / MDP) O O

154 P1615 ECU Error (Rail Pressure Calculation) O O

155 P1616 ECU Error (DTC Watchdog) O O

156 P1618 Injector Bank 2 Voltage Low O

157 P1619 Injector Bank 2 Voltage High O

157 P1620 ECU Error (Injection Timing Error) O O

159 P1621 ECU Error (DTC Control) O O

160 P1622 ECU Error (Variant Coding) O O

60
 Diagnostic Trouble Code

Torque Limp Delay

No DTC Description MIL Stop
Reduction home

Immobilizer Response Error

161 P1630 (Transponder)

162 P1631 Immobilizer Error

163 P1632 Immobilizer Error (system invalid)

164 P1633 Immobilizer Error (Key coding is needed)

165 P1634 Immobilizer Response Error

Immobilizer Response Error (Invalid

166 P1635 response)

167 P1636 Immobilizer Error (unidentified failure)

168 P1671 #3 Glow Plug Short

169 P1672 #4 Glow Plug Short

170 P1673 #5 Glow Plug Short

171 P1674 #1 Glow Plug Short

172 P1675 #2 Glow Plug Short

Glow Plug Communication Error

173 P1676 (Preheating Unit and ECU)

Preheating Unit Communication Error

174 P1677 (Preheating Unit and ECU)

175 P1678 Glow Plug Open

176 P1679 Glow Plug Short

177 P1680 Glow Plug Short to ground

61
Wiring Diagram

3. Electrical Wiring Diagram

1) Preheating

62
 Wiring Diagram

2) Power Supply / VGT / EGR / IMV / HFM / APS

63
Wiring Diagram

3) Immobilizer & Sensors

64
 Wiring Diagram

4) Injector / Air-con / Triple Pressure Switch

65
Data List Analysis

1. Scan-100 Screen Capture

At above 82 ℃ of ECT

D20DT

D27DT

66
 Data List Analysis

D20DT

D27DT

67
Data List Analysis

D20DT

D27DT

68
 Data List Analysis

2. Scan-100 Data List : Actyon(D20) / New Rexton(D27)

At above 82 ℃ of ECT

N Uni
o
Item t
Description Idle Remark

Fuel Fuel temperature in HP NTC resistor

1 ℃ Below 75
Temperature pump 95℃ when faulty

1.01 ~ 1.06 bar(D20)

Boost Pressure Absolute pressure in 0.98 ~ 1.01bar(D27) VGT for D20DT
: combination intake manifold, higher
2 Bar D20 2.350 WGT for D27DT
with #4,5 than atmospheric due to bar
turbo charger. Max No EGR when faulty
- stall test (Stall)
D27 2.330
bar

W/EGR
Air Meter (Max 150 When EGR valve stuck
mg/ opening) open, no acceleration,
3 : Combination HFM sensor signal
strk rough idle and black
with #6 smoke occur.
W/O
550
EGR

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 : 50~65
- stall test Pressure. %
at 1500 rpm
D27 : %

0% EGR Cut Conditions:

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 ℃
with #3 D27 : % ,below 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

APS 1 is main signal

Calculated accelerator
8 Pedal Position % 0% (99.9% at WOT) Check for its max
pedal sensor
position

69
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

Atmospheric pressure
Atmospheric sensor in ECU (same with
10 Bar 1.010bar Varies by altitude
Pressure boost pressure sensor when
IG ON)

Calculated engine coolant

11 Coolant Temperature ℃ 82 ~ 90 Warm-up condition
temperature sensor signal

Ambient temperature in HFM Consider the

12 Air Temperature ℃ Variable
sensor ambient temp’

Battery voltage for Check if it is

13 Battery Voltage V compensating Injection Charging voltage different from
quantity by voltage level. charging voltage

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

Calculated knock signal into 30 ~ 60 ECU takes certain

Num
16 Engine Block Noise 1 numeric unit, knock sensor period of knock
eric
condition can be checked. signal.
Stall : 144

Num
17 Engine Block Noise 2 Calculated knock signal 30 ~ 50, Stall : 144 Only for D27DT
eric

4.5 (D20) / 5.5

Injected Fuel (D27)
Quantity mg/s Total injection amount for Main is much more
18
trk each cylinder : Pilot + Main than Pilot
- stall test Stall : 30 ~ 50

Engine Speed Calculated crank position 768(D20) /

19 rpm
- stall test sensor signal (D27)

70
 Data List Analysis

No Item Unit Description Idle Remark

44(D20) / 52 (D27)
Calculates using Not actual
20 Engine Torque (MAP) Nm RPM,APS and Injection engine
amount torque
Stall : 310 ~ 340

Rail Pressure (MAP) Check the

Target rail pressure Must same as rail difference
21 :combination with #9 Bar
calculated by APS pressure with Rail
-stall test Pressure

With normal A/C

On/ Condenser Fan Low
22 Fan 1 Output (Low) operation or over 91 ℃
Off speed
of ECT

When middle pressure

On/ Condenser Fan Low
23 Fan 2 Output (High) S/W is ON or over 95 ℃ 19Kg/ ㎠
Off speed
of ECT

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

Pilot Fuel Quantity

Pilot injection quantity 0.7~1.5 Related to
(MAP) mg/
26 calculated with knock MDP
: combination with strk
signal Adaptation
#16,17 Stall : 1.0 / D range : 1.4

2.5 ~ 5.5 Greater

Main Fuel Quantity Main injection quantity value than
(MAP) mg/
27 calculated from APS & normal
strk
: combination with #9 rpm means low
Stall : 34 / D range : 7 pressure.

IMV control duty, as Rail N : 32.1%  Lower value

Inlet Valve Duty (MAP)
Pressure (MAP) 240~250bar than normal
28 : combination with #9 %
increases, duty D : 31.7%  260bar means low
- stall test decreases. pressure
Stall : 27.8%  1070bar

Depending on engine Warm-up

29 Idle Target RPM rpm 730 ~ 780
temperature and load condition

71
Data List Analysis

No Item Unit Description Idle Remark

Running Judges by vehicle speed from

30 Engine State
/Stop ABS/ESP unit via CAN

Result of Immobilizer Immobilizer

31 Engine Start Enable Yes/No
response only

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.

Main brake S/W signal.

33 Brake Light Switch On/Off NO type
ON when depressed.

Monitoring S/W signal for

34 Brake Safety Switch On/Off main S/W , ON when NC type
depressed.

Brake pedal status, ON when

35 Brake Switch On/Off
depressed

12v from A/C S/W to ECU

36 A/C Switch Input On/Off
when A/C S/W is ON.

ON when middle pressure

37 A/C Head Pressure Input On/Off 19Kg/ ㎠
switch is on

Pedal #1 Sensor Position 99.9% at

38 % Main signal opening % 0%
: combination with #39 W.O.T

99.9% at
39 Pedal #2 Sensor Position % Monitoring signal opening % 0%
W.O.T

A/C Control Output A/C Compressor Relay 0V when

40 On/Off
: combination with #36 driving output Comp’ is ON

Main relay driving output, ON

0V when IG
41 Power Relay Output On/Off when IG ON and for 10 sec
ON
after IG OFF.

72
 Data List Analysis

No Item Unit Description Idle Remark

On/ Glow plug output signal to Depends on

42 Glow Plug Output
Off Preheating Unit via K-line. engine temp.

PTC Relay output depending

On/ Supply current
43 PTC Relay #1 on engine temp and ambient
Off for PTC 1
temp.

PTC Relay output depending

On/ Supply current
44 PTC Relay #2 on engine temp and ambient
Off for PTC 2 & 3
temp.

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

On/ Ground control

52 Engine Check Lamp Engine check lamp
Off by ECU

ON when water is detected

On/ more than 39cc, Lamp
53 Fuel Filter Water Inflow
Off operating signal goes to
cluster via CAN

The number of MDP

Num
54 #1 ~ #5 Inj. MDP Count (Minimum Drive Pulse)
eric
Adaptation

73