CDPF (EURO IV)

1725-12/2412-02/2412-20/2412-42/

GENERAL INFORMATION CONFIGURATION AND FUNCTIONS

1. OVERVIEW FOR CDPF (EURO IV)......... 3 1725-12 FRONT EXHAUST GAS

2. CDPF (EURO IV) SYSTEM..................... 4 TEMPERATURE SENSOR -
CDPF (EURO IV)..........................
15
2412-42 REAR EXHAUST GAS
TEMPERATURE SENSOR...........
OVERVIEW AND OPERATION 17
2412-20 DIFFERENTIAL PRESSURE
PROCESS SENSOR - CDPF (EURO IV) ........
19

1. OVERVIEW............................................ 6
2. CDPF (EURO IV) SYSTEM CONTROL... 7
3. SOOT FILTERING AND BURNING REMOVAL AND INSTALLATION
PROCEDURES....................................... 10
4. COMPONENTS OF CDPF SYSTEM ...... 14
1725-12 FRONT EXHAUST GAS
TEMPERATURE SENSOR -
CDPF (EURO IV) ......................... 23
2412-42 REAR EXHAUST GAS
TEMPERATURE SENSOR -
CDPF (EURO IV).......................... 25
2412-20 DIFFERENTIAL PRESSURE
SENSOR - CDPF (EURO IV)......... 26
2412-02 CDPF ASSEMBLY -
CDPF (EURO IV)........................... 28
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1. OVERVIEW FOR CDPF (EURO IV)

1) General Description
The CDPF (Catalyst & Diesel Particulate Filter) was installed to the Rexton II D27DTP engine
previously. However, it is now installed to the all 2009 DI engine models, except the Actyon
Sports. The DI engine types installed to Rexton are D27DTP, D27DT and D20DT, and their
CDPF, related sensor and operation logic are the same.
This section describes the CDPF system (based on Euro IV) which is installed to the Rexton II
D27DTP engine (older model).

2) Compatibility of CDPF System by Vehicle Model

Rexton II: Same CDPF system for D27DTP and D27DT engines (including its components)
Kyron & Actyon: Same CDPF system for D27DT and D20DT engines (including its components)

- The CDPF assemblies installed to the Euro IV D27DTP Rexton II and 2009 Rexton II are
different in their mounting layout, but their front/rear exhaust temperature sensors and
differential pressure sensors are same.

3) System Met with Euro IV Regulations

- E-EGR valve
- EGR cooler
- Engine ECU (Ver. 3.2)
- HFM sensor
- C3I injector
- Electronic throttle valve (body)
- Other engine mounting components

For details about the modified components and system related to the Euro IV regulations, refer
to the 2008 Rodius engine service manual.
06-4

2. CDPF(EURO IV) SYSTEM

The CDPF system is only installed to the D27DT engine, and the major changes comparing to
the previous D27DT engine is as follows:

CDPF (Catalyst & Diesel Particulate Filter) and sensors

Differential pressure sensor (¡âP sensor)

Under air cleaner in

right side of engine
compartment

As the soot is filtered in the CDPF, the pressure between the front side and the rear side of
the filter is different from each other. If the amount of soot is over 28 g, the soot is burnt in
the CDPF. The combustion is determined depending on the pressure difference,
temperature of exhaust gas and EGR ratio. According to these, the soot filtered by post
injection of injector is burnt at 600¡ÆC.

Front exhaust gas

temperature sensor

CDPF Exhaust Gas Temperature Sensor

Front Exhaust Gas Rear Exhaust Gas

Temperature Sensor:
The two temperature
sensors inside the CDPF
are installed in exhaust
manifold (front exhaust
gas temperature sensor)
and in DOC (rear exhaust
gas temperature sensor),
and perform the following
functions.
Measures the exhaust gas
temperature of the exhaust manifold.
As it is installed in front of the VGT
turbocharger, it also monitors the
exhaust gas temperature coming to
the turbocharger. If the temperature
of the exhaust gas flowing to the
turbocharger is higher than the
specification, the engine lowers the
exhaust gas temperature.
Temperature Sensor:
Measures the increased
exhaust gas temperature
after the oxidation process
of DOC. If the temperature
is below 600¡ÆC, the post
injection amount is
increased to increase the
temperature.
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Throttle Body

CDPF system controls the amount of intake air by

controlling the electronic throttle body. The electronic
throttle body has the following main functions.

CDPF control - added a function that increases the

exhaust gas temperature by closing the throttle valve
flap to minimize the intake air amount by the fuel
injection amount during the CDPF regeneration range
with the low engine load range.

ON/OFF control - prevents the engine from turning off

with vibration and noise by closing the throttle body
flap to block the intake air when the engine is stopped.

Duty control - controls the valve inside the throttle body

to burn more EGR gas in the EGR valve operating range.

VGT Turbocharger and Front Exhaust Gas Temperature Sensor

Turbocharger may become weaker if high Front exhaust gas

temperature exhaust gas passes through the temperature sensor
turbocharger for DPF regeneration process.
The front exhaust gas temperature sensor
monitors the temperature of the exhaust gas that
flows into the turbocharger.
If the temperature of the exhaust gas that passes
through the exhaust manifold is higher than the
specification, the ECU decreases the fuel injection
amount and increases the EGR gas intake amount
to decrease the exhaust gas temperature.
06-6

1. OVERVIEW
As the solution for environmental regulations and PM
(Particla Material) of diesel engine, the low emission
vehicle is getting popular. This vehicle is equipped with
an extra filter to collect the soot and burn it again so that
the amount of PM in the exhaust gas passed through
the DOC (Diesel Oxydation Catalyst) is reduced. The
CDPF (Catalyst & Diesel Particulate Filter) is an
integrated filter including DOC (Diesel Oxydation
Catalyst) and DPF (Diesel Particulate Filter).

¢ºComparison of throttle body functions based on exhaust emission regulation

Regulated parts are carbon monoxide (CO), nitrogen oxide (NOx), particular matter (PM) and
soot in the exhaust emission, and the particulars of the regulations are prescribed in the
following table.
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2. CDPF (EURO IV) SYSTEM CONTROL

1) Combustion Temperature and Procedures
As the soot is filtered in the CDPF, it is burnt and removed, and the CDPF is returned to the
initial state to collect the soot. Therefore, the burning procedures in the CDPF can be called as
regeneration.
The CDPF assembly is integrated with DOC (at front side) and DPF (at rear side).
The DPF burns the soot with high-temperature exhaust gas (over 600¡ÆC). The rear exhaust
gas temperature sensor monitors the temperature of DPF section. If this temperature is below
the regeneration temperature, the ECU increases the post injection period to increase the fuel
injection amount, and consequently to increase the exhaust gas temperature.

Front exhaust gas temperature sensor

(Measuring temperature of exhaust gas in
exhaust manifold)

Rear exhaust gas temperature sensor

(Measuring temperature of exhaust gas escaping DOC)

- Normally, when the vehicle is driven for 600 ~ 1,200 km, the enough amount of soot to
be burnt is filtered and accumulated in the CDPF. The ECU increase the amount of post
injection to increase the tempeature of exhaust gas up to 600¡ÆC so that the soot is
burnt. The soot is burnt for 15 ~ 20 minutes.
06-8

2) Sytem Composition for Soot Combustion

When the engine is running in low load range, the temperature of exhaust gas is decreased as
the amount of fuel supplied is decreased. To burn the soot filtered in the CDPF, the control
system should be installed to check the operating range and increase the temperature of
exhaust gas by controlling the amount of fuel supplied and intake air.
Two temperature sensors and one differential pressure sensor monitor the CDPF's operating
range. According to these sensors' information, the throttle flap decreases the intake air
entered to the throttle body. Also, the fuel injection pattern is added to increase the
temperature of exhaust gas for soot combustion.
There are three fuel injection patterns (pilot injection, pre-injection and main injection). As the
CDPF is installed, the post injection pattern is added.

3) Post Injection and Air Mass Control

When the differential pressure sensor detects the pressure difference between the front and
the rear side of CDPF, the sensor sends signal indicating the soot is acumulated and the post
injection is performed to raise the temperature of exhaust gas. The amount of fuel injected is
determined according to the temperature of exhaust gas detected by the rear temperature
sensor. If the temperature is below 600¡ÆC, the amount of fuel injected is increased to raise
the temperature. If the temperature is over 600¡ÆC, the amount of fuel injected is decreased
or not controlled.
When the engine is running in low load range, the amount of post injection and the amount of
intake air are controlled. It is to raise the temperature by increasing the amount of fuel while
decreasing the amount of intake air.
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Throttle bodies by engine type

- The throttle valve is controlled by electric signals sent from the engine ECU for
optimal fuel injection volume, engine load and effective combustion of EGR gas
according to the Euro 4 regulations. It has following functions by the engine type.
06-10

3. SOOT FILTERING AND BURNING PROCEDURES

1) Operating Procedures of CDPF
The most efficient and practical technology for now is adopted to the diesel particulate filter
(DPF).
This system collects the soot from the diesel engine to the filter and burns the soot so that over
than 95% of soot can be removed from the exhaust gas. However, the durability and the cost of
additional system remain as problems.

Firstly, the exhaust gas is passed through the DOC and its temperature is increased as it is
oxidized. The ECU detects the temperature change with two temperature sensors. The CO, HC
and partial particulate material are removed from the exhaust gas (this procedures are the
sames as the ones for the conventional DOC and no sensor is required).

After the exhaust gas is passed through the DOC and oxidized, most of the harmful material is
removed from the exhaust gas. However, to meet the environmental regulations in the future,
the soot is filtered and burnt again in DPF to decrease the particulate material further.

Rear exhaust gas temperature sensor

(Measuring temperature of exhaust gas
escaping DOC)

- The filtered soot is burned whenever the vehicle is driven for 600 ~ 1200 km. The driving
distance can be differed depending on the vehicle's driving conditions. The soot is burnt
for 15 ~ 20 minutes.
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Front temperature sensor

(Measuring the temperature Rear temperature sensor
of exhaust gas passed (Measuring the temperature of exhaust gas
through exhaust manifold) passed through DOC)

Differrential pressure sensor Differrential pressure sensor

(Front pressure port) (Rear pressure port)

The exhaust gas enters When the exhaust gas
into CDPF assembly enters into the CDPF
after passing through the assembly, its CO, HC and
exhaust manifold. particulate material are
(Normal temperature of reduced as it is oxidized
exhaust gas: approx. in DOC. The remaining
250¡ÆC) particulate material is
filtered and collected in
DPF and the temperature
of exhaust gas is
increased to approx. 450
~ 500¡ÆC.
The engine ECU detects
the amount of particulate
material colected by the
information from
temperature sensors and
differential pressure
snesor. When the soot is
accumulated, the pressure
difference between the
front and the rear side
occurs. Then, the engine
ECU performs the post
injection to raise the
exhaust gas temperature
and burn the collected
soot at approx. 600¡ÆC.
06-12

2) Fuel Injection During CDPF Regeneration

3) Warning Lamp Related To CDPF

¢ºCDPF regeneration process (warning lamp NOT illuminated)
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 during the regeneration process is to
increase the fuel injection volume and control the
intake air volume (by the throttle body) in order to
No illuminating increase the temperature of the exhaust gas. The
driver may not feel any particular difference from the
vehicle.
 0000-00 06-13

¢ºOverload of CDPF (warning lamp blinking)

1. 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.
2. 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.
3. If the engine warning lamp on the instrument
cluster blinks, the CDPF is overloaded. In this
Blinking case, perform the step 2.

¢ºExcessive overload of CDPF (warning lamp illuminated)

1. 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 burnt as the
CDPF cannot reach the regeneration
temperature. Then, an excessive amount of soot
can be accumulated in the CDPF.
2. This case is much worse than the simple
overload 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.
3. To solve this problem, blow soot between the
engine and exhaust system several times and
Illuminating
erase the related DTC. Then, check if the same
DTC is regenerated again. If so, check the DTC
related to the differential pressure sensor.

Actually, the DTC for the CDPF is generated more often by the component related to the CDPF
system, such as the differential pressure sensor, than by excessive soot in the CDPF.
06-14

4. COMPONENTS OF CDPF SYSTEM

¢ºMounting condition and location

Differential Pressure Sensor

Engine compartment
(RH)

Front Exhaust Gas Throttle Body

Temperature Sensor

Front exhaust gas

temperature
sensor
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FRONT EXHAUST GAS TEMPERATURE

SENSOR-CDPF(EURO IV)
1) Overview
Once CDPF system is installed, the front exhaust gas
temperature sensor is installed in the exhaust manifold and the
rear exhaust gas temperature sensor is installed in the CDPF
assembly. These sensors are similar in appearance, but the
sensing part of the rear exhaust gas temperature sensor is
longer than the one of the front exhaust gas temperature
sensor.
The front exhaust gas temperature sensor measures the
Front exhaust exhaust gas temperature inside the exhaust manifold. High
gas temperature exhaust gas may weaken the turbochager.
temperature Moreover, if the gas passes through DOC, the temperature is
sensor increased further. Therefore, this sensor is to monitor the
exhaust gas temperature and protect the turbocharger.
Rear exhaust If the temperature of the exhaust gas becomes higher than 800
gas temperature ¡ÆC, the bearing inside the turbocharger may be seized.
sensor Therefore, the ECU monitors the front exhaust gas temperature
sensor to adjust the fuel injection amount and intake EGR gas
amount. When the temperature is high, the fuel injection amount
is decreased. When the temperature is low, the EGR gas
amount is increased.

2) Connecting Port and Mounting Location

Mounting Location

Front exhaust
gas temperature
Exhaust manifold sensor

VGT turbocharger
06-16

3) Circuit Connecting ECU and Front Exhaust Gas Temperature

Sensor
The front exhaust gas temperature sensor is installed inside the exhaust manifold and sends
signals to the ECU with voltage values by using the resistance changes as the exhaust gas
temperature changes.

4) Resistance by Temperature
 0000-00 06-17

REAR EXHAUST GAS TEMPERATURE SENSOR

1) Overview
The rear exhaust gas temperature sensor is installed in the DPF
to measure the exhaust gas temperature after the exhaust gas
passes through DOC. Once the exhaust gas escapes DOC, its
temperature is higher than before entering DOC due to
oxidation, etc. The higher the gas temperature is before DOC,
the higher it becomes due to oxidation process.
When the pressure difference is detected by the differential
pressure sensors and the system enters the CDPF generation
mode, the ECU adds post injection process to increase the
Front exhaust exhaust gas temperature. When the engine is running at low
gas load range, the throttle flaps are closed to decrease the intake
temperature air amount, and consequently to increase the combustion
sensor temperature. During post injection process, if the temperature
value from the rear exhaust gas temperature sensor is higher
than 600¡ÆC, the post injection is not performed or the fuel
Rear exhaust injection amount is decreased.If the temperature is lower than
gas temperature 600¡ÆC, the fuel injection amount is increased to control the
sensor soot combustion temperature in CDPF.

2) Connecting Port and Mounting Condition

- Its temperature sensing part's length is longer than the one of the front exhaust gas
temperature sensor.
06-18

3) Circuit Connecting ECU and Rear Exhaust Gas Temperature

Sensor
The rear exhaust temperature sensor measures the temperature of the exhaust gas that
passes through DPF. If the exhaust gas temperature is low (below 600¡ÆC) , the ECU
decreases the intake air amount and increases the post injection period to increase the gas
temperature. The rear exhaust gas temperature sensor is installed inside the exhaust manifold
and sends signals to the ECU with voltage values by using the resistance changes as the
exhaust gas temperature changes.

4) Resistance by Temperature
 0000-00 06-19

DIFFERENTIAL PRESSURE SENSOR

- CDPF(EURO IV)
1) Overview
View From RH Tire Under Air Cleaner In Right Side Of Engine

Rear pressure port Front pressure port

The differential pressure sensor is connected to CDPF through two ports.

It can be found behind the front left tire (on the frame in front of the coil spring).
This sensor detects the pressure difference between the front and the rear side of CDPF.
When the soot is collected in CDPF, the pressure difference is increased and this difference, as
a signal, is sent to ECU to perform the post injection.

The differential pressure sensor monitors the pressure of the opening of DOC and the end of
DPF. When the soot is collected as the exhaust gas is passed through CDPF, the sensor
sends the combustion timing to the ECU. Then, the ECU performs the post injection to
increase the temperature in CDPF up to 600°C. At this time, the temperature is monitored by
rear temperature sensor. According to the temperature monitored, the amount of post injection
is increased or decreased, or the post injection is ceased.

1. When the engine is running in high load/speed range, the temperature of exhaust
gas passed through DOC can be over 600¡ÆC. If it happens, the collected soot is
burnt without post injection.
The filtered soot is burnt normally after the vehicle is driven for 600 ~ 1,200 km.
06-20

2) Differential Pressure Sensor Connecting Port and Mounting

Condition Connector Section

Sensor Section Connector Section

 0000-00 06-21

3) Output Voltage by Pressure Difference Detected By

Differential

The differential pressure sensor sends output voltage value (0.5 ~ 4.5 V) to the ECU based on
pressure difference before and after the CDPF.
The pressure ports installed before and after the CDPF are not sensors, but the connecting
passages to send the pressure to the differential pressure sensor.
The front and rear ports send the exhaust gas pressure before and after the CDPF to the
differential pressure sensor. Then, the differential pressure sensor compares these values and
sends the pressure difference value to the ECU.
As the soot is collected, the pressure difference gets greater. When the ECU receives the
pressure difference signal indicating that the soot mass exceeds the limit (normally 28 g but
may vary depending on the conditon), it starts the CDF regeneration process. (The ECU also
receives signals for EGR ratio and exhaust gas temperature.) As the CDPF regeneration
process is performed, the post injection occurs even when the engine is idling. It also closes
the flap doors on the throttle body during engine idling to decrease the intake air amount.
As shown on the above graph, the smaller the pressure difference is, the output voltage
(signal) from the differential pressure sensor is lowered. When the pressure difference
increases, the output voltage is increased and maximum 4.5 V is sent to ECU.
06-22

4) Port Mounting Location for Measuring CDPF Pressure

The pressure ports installed to measure pressure difference before and after the CDPF are
mounted similar to the temperature sensors. However, these are simply pipe connecting ports
to send pressure inside CDPF to the differential pressure sensor.

Rear connecting port (After CDPF - Front connecting port (Before CDPF -
connected to differential pressure sensor) connected to differential pressure sensor)

5) Circuit Connecting ECU and Differential Pressure Sensor

The front and rear connecting ports send the pressure values of "before CDPF" and "after
CDPF" to differential pressure sensor. Then, the differential pressure sensor compares these
values and sends the pressure difference value to ECU.
 0000-00 06-23

FRONT EXHAUST GAS TEMPERATURE SENSOR

- CDPF(EURO IV)
Disconnect the battery ground cable.

Mounting View

Front Exhaust Gas

Temperature Sensor

1. Disconnect the front exhaust gas

temperature sensor connector (A) and
remove it from its mounting bracket (B)

2. Remove the front exhaust gas temperature

sensor.
a. Insert a 14 mm spanner (B) between the
turbocharger oil supply pipe (A) and
turbocharger to unscrew the sensor.
06-24

b. Remove the front exhaust gas

temperature sensor by pulling it from the
exhaust manifold.

3. Install in the reverse order of removal.

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REAR EXHAUST GAS TEMPERATURE SENSOR

- CDPF(EURO IV)
1. Disconnect the negative battery cable with the engine off.
2. Make sure that the CDPF and its related exhaust system are sufficiently
cooled down.
3. Lift the vehicle with a lift.

1. Disconnect the rear exhaust gas

temperature sensor connector (A) (wiring
side) and remove the connector on the
sensor side from its mounting holder (B).

Mounting View of Rear Exhaust

Gas Temperature Sensor

2. Unscrew the rear exhaust gas temperature sensor and remove it from the CDPF assembly.
06-26

DIFFERENTIAL PRESSURE SENSOR-

CDPF(EURO IV)
Disconnect the battery ground cable.

Differential Pressure Sensor

1. Remove the air cleaner by lifting it up.

2. Disconnect the differential pressure sensor

connector.
 0000-00 06-27

3. Unscrew the differential pressure sensor

bracket mounting bolt (12 mm).

4. Disconnect the sensor hose using pliers

with the sensor pried off backward.
A. Front pressure port hose
B. Rear pressure port hose

5. Remove the differential pressure sensor

from the vehicle body.

6. Install in the reverse order of removal.

06-28

CDPF ASSEMBLY-CDPF(EURO IV)

Disconnect the battery ground cable and lift the vehicle with a lift.

1. Disconnect the connector (C) to the rear

exhaust gas temperature sensor wiring,
which is located in (A), and remove the
connector on the sensor side from its
mounting holder (D).

2. Disconnect the differential pressure

sensor hoses (FRT/RR) in the section
(B).
 0000-00 06-29

3. Remove the rubber (A) of the CDPF

assembly mounting rubber hanger with a
lever.

4. Unscrew the two mounting nuts (14 mm)

from the front exhaust pipe (B) and CDPF
assembly (C).

5. Unscrew the two mounting nuts (14 mm)

from the rear muffler (D) CDPF assembly
(C).

6. Remove the CDPF assembly by guiding it

over the A/T center member.
06-30

7. Install in the reverse order of removal.