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1. SPECIFICATION Emission Regulation Euro-V

Front Area 182.41cm

SizeDOC 124 X 158 X 78L

DPF 124 X 158 X 194L

CDPF CanisterShell SUS430J1L X 1.5t

End Cone SUS430J1L X 2.0t (Single)

CDPFCatalyst Capacity 4.2L

Material of Filter AT (Aluminum-Titanium Alloy)

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2. CAUTIONSStandard pattern of soot accumulation▶

(1) Abnormal Soot Accumulation (2) Normal Soot Combustion

Cautions to protect the catalyst filter▶

Use the designated fuel only. Observe the recommended service intervals of engine oil.Check the engine oil level frequently and add if necessary. Do not idle the vehicle unnecessarily.Do not turn off the engine while the vehicle is running. Do not shift the gear selector lever to neutral when going downhill.Do not use improper engine oil or fuel additives.Do not drive for a long time when the warning lamp is illuminated.Make sure no flammable material, such as dry grass or tissue paper, contacts with the catalyst filter while the vehicle is parked.For the vehicles used in urban traffic, driving on the expressways for more than 1 hour at least once per week is needed so that the PM inside CDPF isn't collected to one side only.

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(3) Warning Lamp Related to CDPF

CDPF regeneration process (warning lamp NOT illuminated)▶

Overload of CDPF (warning lamp blinking)▶

The CDPF system enters the regeneration mode when the driving distance becomes approx. 600 to 1,200 km (may differ by the driving condition and driving style). Then, the engine ECU performs the CDPF regeneration operation. However, the driver is not informed with this operation by any engine warning lamp or vehicle signal, so he/she may not detect this operation. The control logic at the post-injection dur-ing the regeneration process is to increase the fuel injection volume and control the intake air volume (by the throttle body) in order to increase the temperature of the exhaust gas. The driver may not feel any particular difference from the vehicle.

If the CDPF cannot reach the regeneration temperature due to low speed driving or other reason during the regeneration process, the soot is continuously accumulated in the CDPF. When this condition continues and the CDPF is overloaded with soot, the engine warning lamp blinks to inform this situation to the driver.In order to solve this problem, drive the vehicle at a speed of approx. 80 km/h for 15 to 20 minutes to perform the CDPF regeneration process.If the engine warning lamp on the instrument cluster blinks, the CDPF is overloaded. In this case, perform the step 2.

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Excessive overload of CDPF (warning lamp illuminated)▶

If the vehicle is driven at a speed of 5 to 10 km/h for an extended period of time, the soot accumulated in the CDPF cannot be burned as the CDPF cannot reach the regeneration temperature. Then, an excessive amount of soot can be accumulated in the CDPF.This case is much worse than the simple over-load of the CDPF. To inform this to the driver, the engine warning lamp comes on and the engine power is decreased to protect the system.To solve this problem, blow soot between the engine and exhaust system several times and erase the related DTC. Then, check if the same DTC is regenerated again. If so, check the DTC related to the differential pressure sensor.

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1. OVERVIEWThe DOC (Diesel Oxidation Catalyst) generates CO2 and H2O which are harmless through the oxidation process of CO and HC. And the DPF (Diesel Particulate Filter) collects PM (Particle Matter) and is regenerated to reduce the quantity of particulates, HC and CO. But there is a limitation in reducing the emission of exhaust gas for each system, so the CDPF which combines these two system is applied.

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Engine ECU (D20DTF)

Post-injection

Differential pressure sensor

Calculates the amount of PM collected by reading the pressure difference between before and after the CDPF.

Electric throttle body

Regulates the rate of air intake.

CDPF(DOC + DPF)

Front temperature sensor

Protects the turbocharger.

Rear temperature sensor

Measures the temperature of fuel

combustion.

2. COMPONENT

Oxygen sensor

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3. INPUT/OUTPUT DEVICES

Front temperature sensor: This sensor is installed at the inlet of DOC and detects whether the DOC can burn (oxidize) the post-injected fuel or not.Rear temperature sensor: This sensor is installed at the inlet of DPF and monitors that the temperature of the exhaust gas is kept at 600℃.

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2.

If the temperature exceeds 600℃, the life of CDPF can be reduced. So the amount of fuel

post-injection is decreased.If the temperature drops under 600℃, the rate of regeneration can be decreased. So the

amount of fuel post-injection is increased.

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Differential pressure sensor: This sensor checks the amount of PM collected by calculating the pressure difference between before and after the CDPF.Electric throttle valve: This valve reduces the intake air flow to raise the temperature of the exhaust gas when the CDPF is operating during idling.

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A DPS (Differential Pressure Sensor) measures the pressure difference between before and after the CDPF and detects whether the soot is collected in the CDPF or not. If PM is collected in the CDPF (In this case the pressure difference between before and after the CDPF exceeds the specified value. Normally, the system sends the signal when the driving distance becomes approx. 600 to 1,200 km), the temperature of exhaust gas is increased and the post-injection is started for regeneration. The amount of fuel post-injection is controlled by the exhaust gas temperature measured by the rear temperature sensor. If the temperature is less than 600℃, the amount of post-injection is increased to

increase the regeneration temperature. Otherwise, the fuel injection amount is decreased or the fuel is not injected.When the engine is running with low load, the intake air amount is also controlled as well as fuel injection amount. This function is used to increaser the combustion temperature by increasing the amount of fuel post-injection with the lowest air amount within the specified control logic.

4. POST-INJECTION AND AIR MASS CONTROL

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ECU (DCM 3.7)

T-MAP sensor

Intake air volume

Detecting excess of PM amount limit

Boost pressure/

temperature

Front EGT sensor

Measures the temperature of DOC.

The DOC performs the redox reaction at between 300 and 500℃ and the front EGT sensor monitors the temperature of DOC.

Differential pressure sensor

Measures the pressure values of before and after the CDPF.

The pressure difference between before and after the CDPF is measured by the differential pressure sensor (If PM is collected in the CDPF, the pressure difference between before and after the CDPF exceeds the specified value).

Rear EGT sensor

Measures the temperature of DPF.

The DPF burns the soot with hot exhaust gases (regeneration) at around 600℃ and the rear EGT sensor monitors the temperature of DPF.

Injector (C3I)

Controls the post-injection.

Electric throttle body

Controls the intake air volume.

HFM sensor

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Collecting PM→ Regeneration

The engine ECU detects the amount of PM collected by the information from the temperature sensors and differential pressure sensor. When the soot is accumulated, the engine ECU performs post-injection to increase the exhaust gas temperature and burns the collected PM at approx. 600°C.

Oxidation (DOC)

When the exhaust gas enters into the CDPF assembly, its CO, HC and PM are reduced by the redox reaction of the DOC. The remaining PM is filtered and collected in CDPF, and the temperature of the exhaust gas is increased to between 450 and 500°C.

5. OPERATING PROCESS

[Configuration and principle of operation]

The exhaust gas passed through the exhaust manifold enters into the CDPF assembly (at approx 250℃).

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6. OPERATING TEMPERATURE

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7. ELECTRIC CIRCUIT DIAGRAM

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8. CAUTIONS1) Designated Engine Oil for CDPF (Low Ash Oil)

Need to use the designated engine oil for CDPF1.The smoke from the vehicle may generate the particle material in the ambient air. CDPF is the device to reduce the smoke by collecting and recycling it. To ensure the performance of CDPF, the designated engine oil should be used.The smoke including combusted sulfur in fuel cannot be recycled in CDPF. This smoke generates the ash, resulting in clogging the filter.

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Advantages when using the designated engine oil for CDPF2.Reduces the amount of ashImproves the fuel economy and reduces the CO2Increases the life span of engine oilAvailable for all engines (diesel and gasoline)

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Problems when using non-designated engine oil for CDPF3.Decreases the life span of engine oil due to accumulated ash in DPF (around 30%)Decreases the fuel economy due to friction resistance, exhaust gas resistance and frequent recycling process of DPF

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The fule containing high sulfur may cause the same problems.

2) Do Not Use the Fuel Containing High SulfurProducing white smoke during recycling1.

The sulfur in exhaust gas is changed to sulfate gas during exhaust process. This sulfate gas is shown as white smoke.

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Producing odor during recycling2.The sulfur after oxidation may produce the odor.-

Accumulation of ash3.The sulfur accumulated in DPF cannot be recycled. It reduces the life span of DPF.-

3) White SmokeThe white smoke can be generated when the exhaust gas is recycled in DPF. There are two reasons as below.

Saturated vaporSulfate

1.2.

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No. Sensor item Data Unit Description

1 Driven distance from last CDPF regeneration

0 km

2 CDPF regeneration history (distance/time) Index

0 -

3 Driven distance between CDPF regenerations[0]

0 km

4 Driven distance between CDPF regenerations[1]

0 km

5 Driven distance between CDPF regenerations[2]

0 km

6 Driven distance between CDPF regenerations[3]

0 km

7 Driven distance between CDPF regenerations[4]

0 km

8 CDPF regeneration time[0] 0.0 S

9 CDPF regeneration time[2] 0.0 S

10 CDPF regeneration time[2] 0.0 S

11 CDPF regeneration time[3] 0.0 S

12 CDPF regeneration time[4] 0.0 S

13 CDPF regeneration history (OK/Fail) Index

0 -

14 CDPF regeneration history[0] OK OK/Fail

15 CDPF regeneration history[1] OK OK/Fail

16 CDPF regeneration history[2] OK OK/Fail

17 CDPF regeneration history[3] OK OK/Fail

18 CDPF regeneration history[4] OK OK/Fail

19 Times of CDPF regeneration start (differential pressure)

0 -

Driven distance from last generation up to now

Display regeneration history (distance/time) stored until now in figure, Index ([0] ~ [4])

The regeneration distance/time is stored up to the last 5 events in sequence and the oldest one will be deleted if the number of events is exceeded 5 times.The currently displayed index value indicates where the regeneration information will be stored in the future and the just previous value shows the last regeneration information.Ex) Index value: 3 (last regeneration information stored at 2)

Display regeneration history (OK/Fail) stored until now in figure, Index ([0]~[4])

The regeneration distance/time is stored up to the last 5 events in sequence and the oldest one will be deleted if the number of events is exceeded 5 times.The currently displayed index value indicates where the regeneration information will be stored in the future and the just previous value shows the last regeneration information.Ex) Index value: 3 (last regeneration information stored at 2)

Times which regeneration is requested using differential pressure sensor signal

9. DESCRIPTION ON CDPF REGENERATION

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No. Sensor item Data Unit Unit

20 Times of CDPF regeneration start (soot mass from engine)

0 - The ECU calculates the soot mass from engine in consideration of the engine RPM, based on the ECU base MAP. The ECU regenerates the CDPF automatically when it determines that the accumulated soot is about 36 g or greater. (The more city driving, the greater value is) The times of regeneration is displayed cumulatively.

21 Times of CDPF regeneration start (collected soot mass)

0 - The ECU calculates the soot mass from engine in consideration of the engine RPM, based on the ECU base MAP. The ECU regenerates the CDPF automatically when it determines that the accumulated soot is about 24 g or greater. (The more city driving, the greater value is) The times of regeneration is displayed cumulatively.

22 Times of CDPF regeneration start (driven distance)

0 - The ECU regenerates the CDPF automatically when the driving distance reaches about 1,000 km or longer. (The more high-speed driving, the greater value is) The times of regeneration is displayed cumulatively.

23 Times which CDPF re-regeneration start is requested

0 - When the regeneration should be stopped and started again according to the exhaust gas temperature, start condition and vehicle speed during CDPF regeneration, the times of re-regeneration is displayed cumulatively.

24 Times which SIW forced CDPF regeneration is requested

0 - The times which the technician carried out the forced regeneration using the SIW program is displayed cumulatively.

25 Times of ECU replacement 1 - The times of ECU initialization is displayed cumulatively.

The ECU calculates the data of 4 items from No. 19 to No. 22 (map value calculated by the ECU) to carry out the CDPF regeneration and the regeneration event map values of 4 items between No. 19 to No. 22 will be reset. (times of regeneration start is stored normally)In the event of ECU initialization, the data of items from No. 1 to No. 24 will be reset.

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