ENGINE CONTROL SYSTEM

1491-01/1990-01

CONFIGURATION AND FUNCTIONS

1491-01 ENGINE ECU................................ 3

1990-01 SWITCHABLE ENGINE MOUNT
(ELECTRONIC CONTROL TYPE). 17

REMOVAL AND INSTALLATION

1491-01 ENGINE ECU................................ 20

1990-01 SWITCHABLE ENGINE MOUNT... 49
 0000-00 09-3

1) OVERVIEW OF ENGINE ECU

The engine ECUs are various according to the engine model (D27DT engine, D27DT (EU IV),
D27DTP engine with CDPF and D27DTP (POWER UP) engine). For the D27DT engine with
CDPF, the CDPF's function is controlled by the engine ECU with its extra pin. For the D27DTP
(POWER UP) engine, one connector is added to the engine ECU (2 connectors total) to control
the additional sensor, actuator and exhause gas control function.
09-4

For the D27DTP (POWER UP) engine, the connector pin is added and DTC is changed as the
following components are added. the functions of engine ECU pin for D27DTP (POWER UP)
engine and D27DTP engine are not same. For more details, refer to the respective section.

1. E-EGR (Electric-Exhaust Gas Recirculation) Valve

It is electrically controlled by the ECU for precise control. Old version was controlled by the
vacuum modulator.

2. Throttle Body
It is electrically controlled by ECU as E-EGR valve.

3. AQGS (Advanced Quick Glow System) Unit

The glow control relay (K-line communication with engine ECU) is deleted. The unit
communicates via CAN communication with engine ECU. Also, the number of pins is
increased as glow plug's performance has been improved (1000¡ÆC increase in approx. 2
seconds).
 0000-00 09-5

2) TERMINAL (PIN) ARRANGEMENT OF ECU

▶ Description of ECU Terminals for D27DTP (POWER UP) & D27DT (EU IV) Engine
09-6
0000-00 09-7
09-8

¢ºDescription of ECU Terminals for D27DT Engine

0000-00 09-9
09-10
 0000-00 09-11

3) ECU (ENGINE CONTROL UNIT - D27DT (EU IV), D27DTP

¢ºENG Main Relay, Pedal Module, HFM Sensor, Valve, ENG Mount
09-12

▶ Fuel Filter Warning Lamp, Immobilizer, Sensor, preheating Unit, A/Cruise sw,
Diagnosis
 0000-00 09-13

¢ºInjector, Stop Lamp SW, Sensor(A/Con, E-Gas), Clutch SW

09-14

4) ECU (ENGINE CONTROL UNIT - D27DT)

¢ºENG Main Relay, Pedal Module, HFM Sensor, Valve, Cruise Control SW
 0000-00 09-15

¢ºFuel Filter Warning Lamp, Immobilizer, Sensor

09-16

¢ºInjector, CAN LINE

 0000-00 09-17

SWITCHABLE ENGINE MOUNT (ELECTRONIC

CONTROL TYPE)
1) OVERVIEW AND SYSTEM LAYOUT
For the vehicle equipped with D27DTP (POWER UP) engine, the switchable engine mount
system lets the engine ECU electronically control the shock absorber's characteristics in the
engine mount.
This system can control the vacuum in two modes (soft and hard) through the engine ECU to
minimize the noise and vibration and improve driving comfort and stability.

-The components of vacuum solenoid

valves are the same in various types
of engines. However,
their functions are different from
each other. The vacuum solenoid
valve for D27DTP (POWER UP)
engine controls the vacuum in the
engine mount. The vacuum solenoid
valve for D27DT engine controls the
vacuum in IWE (Integrated Wheel
End) of 4WD system.
09-18

2) FUNCTIONS
The switchable engine mount not only supports the engine on the vehicle body, but also has
the following functions:

1. It insulates the vibration during engine running and minimizes the noise and vibration of
the engine transferred to the vehicle.
2. It controls the displacement during shifting, sudden acceleration, abrupt braking or
cornering to keep the engine stable.

3) CHARACTERISTICS AND PERFORMANCE

1. The engine mounting can be set to the soft mode to minimize the noise and vibration of
engine transferred to the vehicle when the engine is at idle or low speed while driving.
2. The engine mounting can be set to the hard mode to keep the engine stable from the
displacement occurred by poor road condition, shifting, acceleration and braking under
normal driving conditions.
3. The common engine mounting cannot satisfy both of the above characteristics. Therefore,
it is set to compromise both characteristics and its performance is decreased. However, the
electrically controlled switchable engine mounting can switch the operating mode of the
engine mounting between soft and hard mode according to the vehicle speed and engine
rpm so that both characteristics are satisfied.
4. The engine mounting is switched between the soft mode and the hard mode to change the
damping condition and spring characteristics.

Soft Mode: The orifice is opened to apply the atmospheric pressure so that the
shoft rubber mounting's characteristic is performed for lowering the
damping and spring characteristics.

Hard Mode: The orifice is closed to block the atmospheric pressure and
generate the vacuum state so that the shoft rubber mounting is
damped greatly. In this mode, the rattling of the engine is minimized
so that the vehicle's stability is ensured during driving, cornering
and braking.

4) OPERATING CONDITION
Soft Mode: Vacuum blocked ¡æ OFF mode
Engine rpm < 1,000 rpm, vehicle speed < 5 km/h

Hard Mode: Vacuum connected ¡æ ON mode

Engine rpm > 1,200 rpm, vehicle speed > 10 km/h
 0000-00 09-19

· The engine mounting fixes the engine on the vehicle body. It minimizes the noise and
vibration of the engine transferred to the vehicle and keep the engine stable during shifting,
sudden acceleration, abrupt braking or cornering.
· When the vehicle is rolling, the engine and the vehicle body may be rattled separately and
the vehicle's stability and handling get poor.
· The engine mounting can be designed as a hard structure to prevent this, but it may cause
the noise and vibration because it cannot insulate its vibration.
· When the vibration with large amplitude is transferred to the vehicle body due to the road
conditions (ex: driving on rough road), the vibration from the vehicle is transferred to the
engine.
· This phenomenon is similiar to the case when you run carrying a back pack on your
shoulder. If the back pack is sticked to your back, your running gets stable. However, if the
back pack moves from side to side, your running gets unstable.
· The suspension system uses the spring and shock absorber. If the spring is soft, the
vehicle is stable, but the vibration from the road surface is directly transferred to the
vehicle's occupants. If there is no shock absorber, the vehicle continues to rattle once the
vehicle crosses over a bump on the road. With the shock absorber, the vehicle returns to
its stable condition after the impact from the road surface. These are why the spring and
shock absorber are used.
· The hydraulic engine mounting is designed based on these principles. When the vibration
with small amplitude is occurred to the engine, it insulates the vibration smoothly. When the
vibration with large amplitude is occurred, it holds the engine to keep it stable.
· Simply, the small vibration should be insulated softly and the large vibration should be
insulated hardly for the optimal performance. The rubber mounting has its own limit, but the
hydraulic mounting can satisfy both conditions. To separate these distinct conditions, the
modes should be switched depending on the situation.
· The switchable engine mounting system can be switched between two modes by the
engine ECU depending on the situation to cope with both conditions.
09-20

Disconnect the battery negative cable.

1. Open the passenger's door and remove the carpet (B) and door scarf panel (A). lift the front
side of the floor mat and cover mounting nuts on the ECU unit and remove the ECU unit
cover.

2. Remove the LH/RH connectors of the

ECU unit.

Push the fixing lever on

the connector to the
front to disconnect the
connector.

3. Unscrew four ECU unit mounting nuts and remove the ECU unit.
 0000-00 09-21

1) ENTERING DIAGNOSIS PROCEDURES

1. Select "1] DIAGNOSIS" and press

on "MAIN MENU" screen.

2. Select the desired model (REXTON) and

press on "VEHICLE SELECTION"
screen.

3. Select "1] ECU" and press on

"CONTROL UNIT SELECTION" screen.
09-22

4. Select the desired engine on [MODEL

SELECTION] screen and press

5. The [FUNCTION SELECTION] screen is

displayed. Select the item to be checked.
 0000-00 09-23

2) SELECTION OF CHECKING ITEMS FOR ENGINE D27DT/

D27DTP (POWER UP)

¢ºCheck the Trouble Code

Perform the "Entering Diagnosis Procedures"

1. Select "1] TROUBLE CODE" and press

on "FUNCTION SELECTION" screen.

2. The [TROUBLE CODE] screen is

displayed. It contains the information for
the trouble.

If there is not any fault, "No Diagnostic

Trouble Codes" message appears.
09-24

3. When selecting a trouble code, then

if you press :

Displays the sensor data for the detected

trouble (Freeze Frame Mode).

if you press :

Displays the help tips for the detected

trouble.
 0000-00 09-25

¢ºSensor Data Check

Perform the "Entering
Diagnosis Procedures"

2. Select "2] DATA LIST" and press

on "FUNCTION SELECTION" screen.

2. The screen shows all the sensor data.

3. Select the items you want to see and

press key to freeze them.

You can freeze up to 5 items (*: selected

items).
09-26

¢ºActuator Check
Perform the "Entering
Diagnosis Procedures"

This section is subject to change or update

from time to time so it is mainly described
for the diagnostic progress. For actual
display items, refer to SCAN-100 screens.

1. Select "3] ACTUATOR CHECK" and press

on "FUNCTION SELECTION" screen.

2. The screen shows 21 items. Select the

item you want to see and press

3. For example, if you select "03] GLOW

UNIT" item and press , the screen
as shown in figure is displayed.
 0000-00 09-27

4. If you want to operate the glow plug relay,

press " " key. The "CHECKING THE
CIRCUIT (WAIT...)" message appears and
the glow plug warning light in the instrument
cluster comes on.

5. If the system operates properly, Scan-

100 displays "GOOD".

6. If you want to stop the operation, press

" " key.
09-28

¢ºTrouble Code Clearing

Perform the "Entering
Diagnosis Procedures"

1. Select "4] TROUBLE CODE CLEAR" and

press on "FUNCTION
SELECTION" screen.

2. The "DIAGNOSTIC TROUBLE CODES"

screen is displayed.
If you press key, the trouble code
is cleared.
But, the active trouble code (C) cannot be
cleared.

3. When the procedure is completed, return

to "1] TROUBLE CODE" screen and
check if the trouble codes have been
completely cleared. But, the active
trouble code (C) cannot be cleared.
 0000-00 09-29

¢ºECU Identification
Perform the "Entering
Diagnosis Procedures"

1. Select "5] ECU IDENTIFICATION" and press

on "FUNCTION SELECTION" screen.

2. The "ECU IDENTIFICATION" screen

showing the VIN, ECU software number,
ECU software version and programming
date is displayed.

3. If you have replaced the ECU, press

to enter the vehicle identification
number.
09-30

¢ºInjector Coding (C2I/C3I)

Perform the "Entering Diagnosis Procedures"

1. Select "6] INJECTOR (C2I) CODING" and

press on "FUNCTION SELECTION"
screen. If the injector/ECU has been replaced or
the injector system failure is suspected,
· Coding of D27DTP (POWER UP) go to C2I or C3I Coding item and check
· Engine Injector: C3I (20 digits) the injector and coded injector C2I or C3I
* Coding of D27DT Engine Injector: C2I value.
(16 digits: samp with current version)

2. The "INJECTOR (C2I or C3I) CODING" screen showing the current C2I or C3I coding values of
#1 to #5 injector is displayed. If necessary, press key and enter the value.

D27DT Engine: C2I Coding D27DTP Engine: C3I Coding

 0000-00 09-31

3. If you have replaced the ECU, enter the C2I or C3I value for the relevant injector.

· The C2I value of injector is on the label.

· C2I coding number: 16 digits (ex, C0 2D 835....)
· C3I coding number: 20 digits (ex, ZD87E03R....)

3-1 If you press [ENTER] on C3I (C2I) display, the recoding menu of C3I or C2I appears. C3I
is coded by using alphabet letters up to Z. If you want to change a number in the coding
letters, press the number keypad of SCAN-100. If you press PgUp or PgDn key, you can
enter alphabet letters again.

The alphanumeric letters are from A ~ Z followed by 0 ~ 9.

09-32

3-2 If you enter the invalid C2I or C3I value

of the relevant injector, the message
as shown in figure appears with alarm
sound.

If you want to return to previous screen,

press key. You can see the previous
C2I or C3I value.

3-3 If you enter the valid C2I or C3I value

of the relevant injector, the message
as shown in figure appears with alarm
sound.

· If you return to previous screen, press

key. Then, the new C2I or C3I
values are displayed.
When coding C2I or C3I, if you select
the engine out of the models, the
injector coding items pertaining to the
engine appear.
 0000-00 09-33

¢ºLeak Detection
Perform the "Entering
Diagnosis Procedures"

This item is for checking the high fuel

pressure after the IMV supply line of HP
pump in DI engine fuel system. If you still
suspect that the fuel pressure system is
defective even after no trouble is detected,
perform the fuel pressure test again by
using a fuel pressure tool kit.

1. [Select "1] LEAK DETECTION" and press

on "MISCELLANEOUS SELECTION"
screen.

2. The "LEAK DETECTION" screen

showing the checking conditions as
shown in figure is displayed.

3. The pressure leakage check for fuel

system should be done under idling, and
as the engine RPM is raising during the
self test, the shift lever should be place to
"P" position.
09-34

¢ºVariant Coding
For REXTON II, D27DTP (POWER UP) engine is newly adopted but the coding methods are
almost same as the variant coding items of the previous model. The variant coding items
entering the vehicle information to the engine ECU are changed a little. As the model for
exporting and current model contain the unavailable items, it is necessary to variant code to the
engine ECU if the engine ECU or the ECU of other systems are replaced.
Most of all, you should check the variant coding items if the abnormal operation of any systems
or errors occur.

- Coding Item
1. Engine-related Coding Item
 0000-00 09-35

2. Chassis Related Coding Item

09-36

¢ºCoding Procedures
This descripes how to progress variant
coding.

1. Select "7] VARIANT CODING" and press

on "FUNCTION SELECTION"
screen.

As the pictures are used to help the user to

easily understand, they may be different
from the actual procedures. Please follow
the contents and steps on SCAN-100
screens.

2. When the "VARIANT CODING" screen is

displayed, select "1] READ VARLANT
VALVE" and press

3. Select the variant coding item related to

the engine or chassis.

4. The "VARIANT CODING" screen

showing the currently equipped devices
is displayed.

- Please refer to the remarks (mentioned at

the beginning of the variant coding items)
about the coding items related to engine
and chassis.
 0000-00 09-37

5. If you need to change the variant coding,

press key to return to "VARIANT
CODING" screen. On the screen, select
"2] WRITE VARIANT CODING" and
press

6. When the "VARIANT CODING" screen is

displayed, change the item using arrow
keys.

7. If you press , the message as

shown in figure appears. And, then
"VARIANT CODING" screen is displayed.
09-38

8 If the "ENTER" key is pressed after

turning "OFF" the ignition, the standby
screen will be displayed for 15 seconds.

9. After 15 seconds, if the ignition key is

"ON" and the "ENTER" key is pressed,
then the coding is completed.
 0000-00 09-39

¢ºECU Replace
When replacing the engine ECU, there are two ways to replace the ECU according to the
status of ECU. Firstly, when the ECU is able to communicate with SCAN-100, you can
immediately transfer the vehicle identification number, variant coding value, and C2I/C3I
coding value that the ECU is memorizing to SCAN-100 device, and then update the new ECU
using this information, without manually entering the values. But when the ECU is not able to
communicate with SCAN-100, you should manually enter all the values. For more information,
refer to the below.

- ECU Replace (if possible to communicate with SCAN-100)

Perform the "Entering

Diagnosis Procedures"

1. Select the desired model and press

after selecting "3] ECU Replace"
on "MISCELLANEOUS SELECTION"
screen.

2. The version of the new ECU should be

same as that of the ECU equipped in
vehicle. If they differ each other, re
program after replacement. Press
ENTER key to record the ECU
information.

Temporarily transfer the data stored in the

ECU equipped in vehicle to SCAN-100
device. At this time, be careful not to turn
off the power of the device. If this happens,
all the data in the device will be lost.

3. Turn the ignition key to "OFF" and

replace the ECU.
09-40

4. ECU Replace
The version of D27DTP (POWER UP)
engine ECU is upgraded from v. 3.1 to v.
3.2 due to adding or modifying of the Be careful not to turn off the power of
sensors or other systems, the number of SCAN-100 when switching the ignition key
connectors is also changed from one to to "OFF". At this time, the data below is
two. stored to SCAN-100 memory:
a. E-EGR valve and related systems
- vehicle identification number
b. Throttle body and related systems
- variant coding value
c. AQGS and related systems
- C2I/C3I coding value.

5. If you turn the ignition key to "ON" and press , the message as shown in the figure
appears (the system is initializing), and then "MULTI CALIBRATION SELECTION" screen is
displayed.
 0000-00 09-41

6. Select the appropriate value on the

"MULTI CALIBRATION SELECTION"
screen.
- A/T: Select "1] EXPORT (EUROPE) A/T".
- M/T: Select "3] EXPORT (EUROPE) M/T".

For REXTON D27DTP (POWER UP)

engine, select the "DOM A/T".

7. When you press "ENTER", ECU

information screen appears for a while,
and then the message (multicalibration
completed) as shown in figure appears.
Turn the ignition key to the "OFF"
position and turn it to the "ON" posigion
again.

8. If the multi-calibration is completed

successfully, ECU REPLACE (STEP 5)
screen is displayed.
Backup data:
- Multi-calibration value
- VIN value
- Variant code value
- Injector (C2I or C3I) value

* D27DTP (POWER UP) Engine: C3I (20

digits)
* D27DT Engine: C2I (16 digits: samp as
the previous version)
09-42

9. For the vehicle eqipped with immobilizer

system, the immobilizer should be coded
by pressing after the multi
calibration is completed.

- For the vehicle without the immobilizer

system, press "ESC".

10.When you press , the sign in screen

is displayed. Enter the user password to
perform the immobilizer coding.

11.When you press , the immobilizer

coding is activated. When the coding is
failed, the failure screen as shown in
figure appears.

12.If the coding is completed successfully,

the completion message as shown in
figure appears, and then key coding
completion screen is displayed.
 0000-00 09-43

13.If you want to code for additional keys,

remove the first key from key switch and
insert the second key. Turn it to "ON"
position and press to proceed.
The second key coding message
appears and then key coding completion
screen is displayed.

14.When the immobilizer coding is

completed, press The completion
message as shown in figure appears.

15.When you turn the ignition key to "OFF"

position and press , the message
screen as shown in figure appears. Wait
for 15 seconds and turn the ignition key
to "ON" position.

16.Press to return to "MAIN MENU"

screen.
09-44

- ECU Replace (Scan-100 Communication is not available)

If the Scan-100 communication is not
available due to ECU failure, replace the
ECU as follows.

1. Replace the ECU with new one.

2. Select "3] ECU REPLACE" and press
on "FUNCTION SELECTION"
screen.

3. If the versions of ECUs are not matched,

program he new ECU after replacement.

2. VIN/Variant Data/Injector Code(C2I or

C3I) Data is not read from ECU. Press
to run the multi calibration.

3. Select the appropriate model on "MULTI

CALIBRATION SELECTION" screen.
- Vehicle with A/T: 1] EXPORT
(EUROPE) A/T
 0000-00 09-45

6. If the MULTI-CALIBRATION is completed

successfully, the message screen shown
in the figure is displayed.

The VIN/Variant Data/Injector Code (C2I

or C3I) Data should be input manually.

7. To enter the data manually, press "ESC"

on the screen in Step 5 and return to
main screen. To enter the VIN, variant
data, and injector code(C2I or C3I),
select "5] ECU IDENTIFICATION", "6]
INJECTOR (C2I or C3I)
CORRECTIONS" and "7] VARIANT
8. CODING".
To enter the VIN, select "5] ECU
IDENTIFICATION" and press "ENTER".

9. Press "ENTER" and enter the VIN again.

10.Enter the VIN into the number plate on

the screen. To change the number to the
character, use the arrow keys.
09-46

11.Select "6] INJECTOR (C2I or C3I) CORRECTIONS" and press "ENTER". Remove the
engine acoustic cover and enter the 16 or 20 character code on each injector label for all
injectors.
Enter the correct injector code after pressing with the ignition "ON".
(The nearest injector from the radiator is number 1 and the number goes higher as it moves
away.)
* The figure shows that C2I is not coded.

12.Select "7] VARIANT CODING" and press

to change the item.
 0000-00 09-47

¢ºRail Pressure Initialization

- Rail Pressure Reset Procedures

The engine ECU needs a specific amount of fuel according to the fuel supply lines and vehicle
driving conditions.
However, if the fuel supply (pressure) is not achieved due to, for instance, defective fuel
system, ECU designates the offset value to the high pressure pump to compensate it.
The fuel supply pressure varies according to the offset value and the engine output could be
decreased due to this variation. When the engine output decreases, check whether all rail
pressure offset values is set to 0 in the Rail Pressure Reset screen in SCAN-100.
If the setting value is not 0, measure the fuel pressure with a tester. If any defective is found,
repair the affected components and reset the rail pressure offset value to 0.
The rail pressure reset procedures should be done after replacing any high pressure pump and
fuel system related components.

1. Select the vehicle model.

2.. Select "2] RAIL PRESSURE RESET" on

"MISCELLANEOUS SELECTION"
screen.
09-48

3. Enter the current rail pressure value and

press to reset the offset value.

4. The screen returns back to step 3 after

displaying the [RAIL PRESSURE RESET
IS SUCCESSFUL] message.

If the offset value is not set to 0, check

the fuel pressure and other DTC
generations before starting the rail
pressure reset operation.
 0000-00 09-49

¢ºStructure of Switchable Engine Mount

For the vehicle equipped with the D27DTP (POWER UP) engine, the installation/removal
procedures of the switchable engine mount are different.

Location
09-50

1) Switchable Engine Mount (LH)

Perform the EAS ECU LOCK
in the EAS air discharge
mode using SCAN-100.

1. Unscrew the engine bracket mounting

bolts.

2. Disconnect the vacuum hose of the

switchable engine mount under the
vehicle.

3. Lift the vehicle and unscrew two mounting

bolts of the switchable engine mount
bracket.

4. Lift the engine assembly a little with

auxiliary lift so that the engine bracket
and the switchable engine mount are
separated. Remove the engine mounting
adapter and the switchable engine mount
at a time.
 0000-00 09-51

2) Switchable Engine Mount (RH)

1. Disconnect the vacuum hose of the
switchable engine mount under the
vehicle.

2. Unscrew the engine bracket mounting bolt and remove two mounting nuts on the switchable
engine mount.

3. Lift the engine assembly a little and unscrew four engine bracket mounting bolts and remove
the engine bracket.
09-52

4. Remove the RH switchable engine mount assembly.

 0000-00 09-53

3) Vacuum Solenoid Valve

1. Open the engine hood and remove the
battery.

2. Unscrew the vacuum solenoid valve mounting bolt from the battery plate and disconnect the
vacuum hose and connector from the vacuum solenoid to remove the vacuum solenoid.

- The components of vacuum solenoid valves are same in the various types of engines.
However, their functions are different from each other. The vacuum solenoid valve for
D27DTP (POWER UP) engine controls the vacuum in the engine mount. The vacuum
solenoid valve for D27DT engine controls the vacuum in IWE (Integrated Wheel End) of
4WD system.