GENERAL INFORMATION CONFIGURATION AND FUNCTION

1. SPECIFICATIONS.................................. 3 2610-10 EBS (ELECTRONIC BATTERY

2. COMPARISON....................................... 4 SENSOR)..................................... 21
3. BASIC INSPECTION.............................. 5 1491-01 ECU (D20DTF).............................. 23
4. INSPECTION - CHARGING CURRENT... 8 1451-01 ALTERNATOR............................. 29
5. INSPECTION - REGULATING 2610-01 BATTERY.................................... 31
VOLTAGE.............................................. 10
6. INSPECTION - DARK CURRENT............ 11
7. INSPECTION - BATTERY...................... 13 REMOVAL AND INSTALLATION
8. DTC SETTING CONDITIONS................. 15
1491-01 ECU (D20DTF).............................. 34
2610-10 EBS (Electronic Battery Sensor)... 36
OVERVIEW AND OPERATING 1451-01 ALTERNATOR............................. 39
PROCESS 2610-01 BATTERY.................................... 44

1. LAYOUT................................................. 16
2. OPERATING PROCESS......................... 17
3. CAN COMMUNICATION
(Charge Warning Lamp)......................... 19
4. CIRCUIT DIAGRAM................................ 20
 0000-00 14-3

1. SPECIFICATIONS
Unit Description Specification
Alternator Rated output 140A (25℃, 6500rpm)
76A/1800rpm, 140A/6500rpm, 25℃, 13.5V
Battery Capacity 90Ah(20hr)
Reserve capacity 180 minutes
Starting current (when 710A
engine cooed)
Weight 23kg
EBS Resolving power 1mA
(Electronic Battery
Operating voltage 7~18V
Sensor)
Operating temperature -40~105℃
Communication LIN 2.0
14-4

2. COMPARISON
Description
Item
D20DTF D20DTF (Low CO2)
Effective date From March, 2012
Applied engine D20DTF
Battery capacity 12V 90Ah
Alternator capacity Delphi 120A Delphi 140A
Changed the diameter of belt pulley (Front view)

Alternator
Changed the regulator and control logic (Rear view)

ECU Without EEM logic With EEM logic

EBS None Monitoring the battery conditions (voltage,

current, temperature and SOC)
 0000-00 14-5

3. BASIC INSPECTION
1) Battery Terminal
- Make sure the terminal connections are
securely tightened. If the terminals are
corroded, clean them or replace the battery.

* Cleaning
Remove the corrosion or dirt with a wire
brush or sand paper, and then wash out
with lukewarm soapy water.

2) Measuring the Voltage Drop

▶ Measuring at battery terminal

Terminal (+) - Measure the voltage between battery

terminal (+. -) and wiring clamp.

Specified value below 0.3V

If the terminals are corroded, clean and

retightening them. If the specified tightening
torque cannot be kept, replace the clamp.

Terminal (+): 4 ~ 5 Nm
Terminal (-) Terminal (-): 6 ± 1Nm
14-6

▶ Measuring at (-) wiring

- Measure the voltage between battery wiring

and body ground.

Specified value below 0.3V

If the voltage is out of the specified value,

check the wiring mounting bolt for
corrosion and looseness. If there is a poor
contact due to corrosion or paint, wipe out
the contact area and retighten it.

Wiring mounting bolt to body

ground (-): 17 Nm

▶ Measuring the battery voltage

- Stop the engine and wait for 20 minutes.

Measure the voltage between terminal (+)
and terminal (-) with the ignition switch
OFF and all electric devices OFF.

Specified value over 12V

 0000-00 14-7

▶ Measuring the voltage drop between lines

- Measure the voltage drop between alternator B+ and battery B+.

Specified value below 0.3V

If the value is out of the specified value, check the terminal and clamp for looseness.

▶ Checking the charge warning lamp

1. Turn off all electric devices and put the ignition switch “ON” (Pre-warning).
2. Check if the charge warning lamp goes out.
- If the charge warning lamp does not go off, inspect the electric circuit.
3. Start the engine and check if the charge warning lamp keeps off.
14-8

4. INSPECTION - CHARGING CURRENT

- Perform the basic inspection.

▶ Setting up the testers

▶ Preparation

1. Set up the ammeter and voltmeter as

shown in the figure.

Make sure to set up the tester while keeping

its polarity.
 0000-00 14-9

▶ Inspection

1. Start the engine and turns on the headlamp, blower and heated wire at their full load. Then,
measure the maximum output current (MSM measurement value) when racing the engine to
2,700 rpm.

Specified value 60% of rated current (limit)

The output current may not reach the limit value due to various parameters (high temperature or
electric load etc.). Thus, do not perform the inspection with fully charged battery.

2. Turn the ignition OFF after inspection.

3. Disconnect the negative cable from the battery and remove the testers (ammeter
and voltmeter).

▶ Characteristic curve (output from alternator)

14-10

5. INSPECTION - REGULATING VOLTAGE

- Perform the basic inspection.

▶ Setting up the testers

▶ Preparation

1. Set up the ammeter and voltmeter as

shown in the figure.

Make sure to set up the tester while keeping

its polarity.

▶ Inspection

1. Turn the ignition ON and measure the voltage on the voltmeter.

Specified value over 12V

2. Start the engine and turn all electric devices OFF.

3. Increase the engine speed to 2,700 rpm and maintain the speed. Measure the voltage when the
output current from alternator decrease below 30A.

Specified value 11.5 ~ 15.5V

 0000-00 14-11

6. INSPECTION - DARK CURRENT

- Perform the basic inspection.

1) When Using Multi-tester

▶ Setting up the tester

▶ Preparation
1. Disconnect the negative cable from the battery.
2. Set up the ammeter as shown in the figure above.

Connect the “+” probe to ground wiring and “-“probe to “-“terminal of battery.

▶ Inspection
1. Measure the current while removing the fuses one by one. If the current drops sharply when a
certain fuse is removed, inspect the affected circuit.

Specified value below 0.05A

14-12

2) When Using MSM

▶ Setting up the tester

▶ Preparation

1. Disconnect the negative cable from the

battery.
2. Set up the ammeter and MSM as shown in
the figure above.

Make sure to set up the tester while

keeping its polarity.

3. Connect the negative cable to the

battery.

Specified value below 0.05A

Measure the current while removing the

fuses one by one. If the current drops
sharply when a certain fuse is removed,
inspect the affected circuit.
 0000-00 14-13

7. INSPECTION - BATTERY
- Perform the basic inspection (all electric devices OFF).

Battery tester

1) Voltage Check (without load)

1. Connect one measuring clamp to “+”
terminal of battery first, then connect the
other one to “-“terminal. (Disconnect the
clamps in the reverse order).

2. Read the measurement.

over 11V: Normal

Specified 9 ~ 11V: Charging required
value below: 9V: Over discharged,
battery replacement required
14-14

2) Voltage Check (with load)

1 1. Push the load switch to ON (to arrow

direction) direction for less than 5 seconds.

To identify the battery capacity with the

voltage drop (V) value, discharge the
fixed load capacity (120A) for a certain
period (5 seconds).

2. Read the measurement.

7 ~ 9V (Red): Over discharged

Specified or faulty
value 9 ~ 11V (Yellow): Charging
required
11 ~ 13V: Normal
 0000-00 14-15

8. DTC SETTING CONDITIONS

▶ Charge warning lamp ON condition

1. Turn the ignition ON (Engine stopped)

2. Open or short circuit of L terminal wiring, open or short internal circuit of alternator (fixed
control of 13.8V)
3. Open or short circuit of F terminal wiring, no feedback output signal
14-16

1. LAYOUT
D20DTF(Low CO2) D20DTF Meter cluster (charge warning Battery sensor (EBS)
ECU lamp)

Alternator (ALT)
 0000-00 14-17

2. OPERATING PROCESS
▶ System diagram

▶ Operation
- EEM monitors the electric loads and battery conditions and controls the voltage to improve the
fuel economy and battery charging efficiency.
- EBS on “-“ terminal of battery sends the battery information (voltage, current, temperature and
SOC) to engine ECU with LIN communication.
- Engine ECU outputs the information from EBS and regulating control signal (PWM) according
to the engine load conditions to “L” terminal on alternator.
- Engine ECU controls the magnetic resistance between stator coil and rotor coil by controlling
the current in rotor coil according to PWM duty value.
- The alternating voltage induced to stator coil is converted to direct voltage by rectifier. And,
EBS outputs the charging voltage to “B” terminal on alternator.
14-18

▶ Basic control logic according to the driving conditions

Engine ECU determines the engine loads according to the fuel injection volume and engine speed.
It charges the battery by increasing the generating voltage during deceleration. To improve the fuel
economy by reducing the alternator load during acceleration, engine ECU decreases the
generating voltage and consumes the battery voltage.

▶ Operation of charge warning lamp

ECU checks the generating voltage from alternator and circuit conditions and sends the warning
lamp ON signal to meter cluster through CAN line.
 0000-00 14-19

3. CAN COMMUNICATION (Charge Warning Lamp)

▶ Overview

Meter cluster
(charge warning lamp)

The meter cluster receives the charge warning lamp ON signal from ECU through CAN line.

Charge warning lamp ON conditions

- Pre-warning
- When DTC related EEM set
- Open or short circuit in alternator

▶ Circuit diagram
14-20

4. CIRCUIT DIAGRAM
 2610-10 14-21

▶ Overview

Battery (EBS)

- EBS sends the battery information (voltage, current, temperature and SOC) to engine ECU
through LIN line.

▶ SOC (State Of Charge)

EBS outputs “0” when the initial SOC value is

over 84% and outputs “1” when it is below
80% (after 10 hours of sleep mode).
If the EEM approval signal is “1”, EEM
controls the SOC and charging capacity. If it
is “0”, EEM stops the controlling. (The control
function may vary according to the battery
conditions and driving conditions)
14-22

▶ Circuit diagram

▶ Connector

Pin No. Function

1 B+
2 LIN communication
 1491-01 14-23

▶ Overview

Engine ECU

Engine ECU receives the battery information (voltage, current, temperature and SOC) from EBS
and outputs the PWM signal to “L” terminal on alternator based on control logic.
Engine ECU determines the engine loads according to the fuel injection volume and engine speed.
It charges the battery by increasing the generating voltage during deceleration. To improve the fuel
economy by reducing the alternator load during acceleration, engine ECU decreases the
generating voltage and consumes the battery voltage.
14-24

▶ Voltage control

Voltage regulation in alternato

Load conditions Status

Headlamp (LO/HI) Fixed control Fixed at 14.3V

Blower Max. speed Fixed control Fixed at 14.3V
Rear heated glass Fixed control Fixed at 14.3V
Wiper Low speed Normal control
High speed Fixed control Fixed at 14.3V

Engine ECU controls the voltage at 14.3V when the headlamp (LO/HI) is ON, blower switch is in
maximum speed, rear heated glass is operating or wiper is operating in high speed. The
conditions of fixed control may vary according to engine loads and conditions.

▶ Circuit diagram
 1491-01 14-25

▶ Connector

Pin No. Function Pin No. Function

01 - 16 EGR valve position sensor
signal
02 - 17 -
03 Power, #4 injector 18 A/C control
04 Intake air temperature signal 19 Ground, fuel rail pressure
(analog) sensor
05 Rear exhaust gas temperature 20 Ground, crankshaft position
sensor signal sensor
06 Front exhaust gas temperature 21 -
sensor signal
07 - 22 Rear exhaust gas temperature
A A
sensor signal
08 Differential pressure sensor 23 Front exhaust gas temperature
signal sensor signal
09 Coolant temperature signal 24 -
10 Fuel temperature sensor signal 25 Ground, #4 injector

11 - 26 Ground, #1 injector
12 Boost pressure sensor 27 Power, #1 injector
(T-MAP sensor)
13 - 28 -
14 Swirl valve motor (-) 29 -
15 Throttle valve position sensor 30 Ground, #1 knock sensor
signal
14-26

Pin No. Function Pin No. Function

31 #1 knock sensor signal 51 Power, #3 injector
32 #2 knock sensor signal 52 -
33 Ground, #2 knock sensor 53 Intake air temperature sensor
signal (digital)
34 Intake temperature sensor (T- 54 Oxygen sensor (IA: Current
MAP sensor) Adjust)
35 Fuel rail pressure sensor 55 Oxygen sensor (IP: Current
Adjust)
36 - 56 Oxygen sensor (UN: Current
Adjust)
37 - 57 Oxygen sensor (VM: Current
Adjust)
38 Power, fuel rail pressure sensor 58 Intake air volume sensor signal
(REF1)
39 Power, crankshaft position 59 Camshaft position sensor
A sensor A signal
40 Power, camshaft position 60 Crankshaft position sensor
sensor (REF1) signal
41 Power, T-MAP sensor (REF2) 61 -

42 - 62 Power, swirl valve position

sensor (REF3)
43 - 63 Power, throttle valve position
sensor (REF3)
44 Ground, differential pressure 64 Power, EGR valve position
sensor sensor (REF3)
45 Ground, coolant temperature 65 -
sensor
46 Ground, fuel temperature 66 Power, differential pressure
sensor sensor (REF2)
47 Ground, camshaft position 67 Ground, T-MAP sensor
sensor
48 - 68 -
49 - 69 Swirl valve motor (+)
50 Power, #2 injector 70 Ground, throttle valve position
sensor
 1491-01 14-27

Pin No. Function Pin No. Function

71 Ground, intake air 91 Swirl valve position sensor
volume/temperature sensor signal
72 Ground, EGR position sensor 92 EGR valve motor (+)
A
73 - 93 EGR valve motor (-)
74 Ground, #2 injector 94 -
75 Ground, #3 injector 95 -
76 - 96 -
77 Ground, IMV valve PWM 01 Power, ECU
control
78 - 02 Ground, ECU
79 - 03 Power, ECU
80 Alternator PWM signal 04 Ground, ECU
A
81 VGT PWM signal (with low 05 Power, ECU
CO2)
82 Ground, oxygen sensor heating 06 Ground, ECU

83 Throttle valve motor (-) 07 -

B
84 Throttle valve motor (+) 08 A/C refrigerant pressure sensor
signal
85 - 09 Water detection sensor signal

86 Ground, EGR cooler bypass 10 -

solenoid
87 - 11 Ground, start relay
88 Ground, VGT actuator PWM 12 -
control
89 - 13 #2 accelerator pedal sensor
signal
90 Ground, swirl valve position 14 Ground, #2 accelerator pedal
sensor sensor
14-28

Pin No. Function Pin No. Function

15 Cruise control switch signal 37 #1 cooling fan (low speed)
relay
16 Blower switch signal 38 -
17 Clutch switch (Bottom: NO) 39 -
18 Clutch switch (Top: NC) 40 Alternator feedback signal
19 Key switch signal 41 -
20 Ground, A/C refrigerant 42 -
pressure sensor
21 Ground, vehicle speed sensor 43 #2 cooling fan (high speed)
(w/o ABS) relay
22 Power, A/C refrigerant pressure 44 -
sensor (REF2)

B 23 Power, cruise control switch B 45 Ground, main relay

(REF3)
24 Power, #1 accelerator pedal 46 -
sensor (REF1)
25 #1 accelerator pedal sensor 47 CAN Low (P-CAN)
signal
26 Ground, #1 accelerator pedal 48 CAN High (P-CAN)
sensor
27 Vehicle speed sensor signal 49 -
(w/o ABS)
28 - 50 -
29 Power, #2 accelerator pedal 51 Ground, A/C compressor relay
sensor (REF2)
30 Stop lamp switch signal (NO) 52 EBS (LIN communication)
signal
31 - 53 -
32 Brake pedal switch signal (NC) 54 -

33 Ground, cruise control switch 55 -

34 Ground, water detection 56 PTC relay #1

sensor
35 - 57 PTC relay #2, 3
36 - 58 A/C switch signal
 1451-01 14-29

▶ Overview

Alternator

D20DTF alternator variably controls the charging voltage in the range of 11V to 15.5V by using
engine ECU. It charges the battery with the fixed voltage of 14.3V when the headlamp is ON,
blower motor is operating, rear heated glass is operating or wiper is operating. To prevent under
charging and over charging, it charges the battery with 13.6V in the duty range of 1% to 9% and
91% to 99%. And, it charges the battery with the fixed voltage of 13.8V in fail-safe mode when the
“L” terminal circuit is open or short.

▶ Initial Generation
14-30

▶ PWM duty value according to charging voltage

The graph above shows the output characteristics of generating voltage according to the
increment of ECU duty value. The battery is charged with 13.8V, with duty control, in under
charging range of 1% to 9% and in over charging range of 91% to 99%.
ECU controls the charging voltage in the range of 11V to 15.5V with 5% to 95% PWM duty signal
through “L” terminal. It controls the charging voltage at fixed value of 14.3V when electric load is
applied (headlamp is ON, blower motor is operating, rear heated glass is operating or wiper is
operating).
And, it charges the battery with the fixed voltage of 13.8V (0~5% and 95~100% of duty range) in
fail-safe mode when the “L” terminal circuit is open or short.
▶ Connector

Pin No. Function

1 L (PWM signal)
2 F (Feedback)
 2610-01 14-31

▶ Overview

Battery

The battery charges and discharges the electric charge by receiving the charging voltage from
alternator.

▶ Determination of SOC (State Of Charge)

The charging capacity of battery is decreased as the time goes over.

SOC value is not the calculated value based on charging capacity as shown in the [Figure 1] but
the absolute value according to the battery condition as shown in the [Figure 2].
14-32

▶ SOC management
The battery must be deteriorated as the time goes over.
EEM controls the charging capacity over 80% to provide initial starting. However, if the charging
capacity goes below 80%, EEM does not control the voltage generation.

▶ Charging mode

1. Mode 1 (Constant current control)

If the battery charging level is low, the system provides the high constant current to charge the
battery rapidly. The system controls the charging current according to the electric load
conditions. If the battery temperature increases over 40°C, the charging current is limited by
20A.
2. Mode 2 (Constant voltage control)
If the battery charging level is in middle range, the battery could be charged slowly when the
control voltage is low and the electrolyte could be deteriorated when the control voltage is
high. If the electric load increases very rapidly, the battery charging efficiency could be
decreased.
To improve the charging/discharging efficiency and the fuel economy, do not maintain the
constant voltage control mode for a long time.

Description SOC
Initial status Mode 1 82%
Mode 2 82~92%
Mode 3 82~92%
Target value 94%
 2610-01 14-33

3. Mode 3 (Voltage maintaining control)

If the battery is fully charged, the system tries to keep the current status. In this condition, the
system maintains the charging status with low charging voltage.
If the vehicle is accelerating, the system requires the discharging. The discharging is permitted
only when the SOC is over 80%. If the SOC is low (below 80%), the discharge control is not
available.

▶ Limitation of charging current according to the temperature

Charging Discharging
Temperature
Current Time Current Time
Below OC 45 45
0~40℃ 35 No limitation 35 No limitation

Over 40C 20 20
14-34

- Disconnect the negative cable from the battery.

ECU(D20DTF)

1. Disconnect the engine ECU connectors

(A, B).

Be careful not to bend the pin or let foreign

material enter between the pins when
connecting the engine ECU connectors.

2. Remove the ECU/GCU (Glow plug Control

Unit) assembly.
- Separate the fuel hose (A).
- Unscrew two nuts (B, 12 mm) from the
bracket.
 1491-01 14-35

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

GCU remove the ECU assembly.

The GCU connector (B) has locking tabs

on both sides.

4. Unscrew the nut (A) and remove the ECU.

5. Install the ECU in the reverse order of

removal.

ECU (D20DTF)

Back-up the following items with scan tool

before replacing the engine ECU with new
one.
- Existing ECU data
- C3I code
- Vehicle identification number
- Variant coding data
Download the back-up data to new engine
ECU. The vehicle with immobilizer system
needs to additional coding.

- Refer to Chapter “Engine Control”.

14-36

- Disconnect the negative cable from the battery.

EBS

1. Remove the positive terminal from the

battery.

2. Disconnect the engine ECU connectors

(A, B).

Be careful not to bend the pin or let foreign

material enter between the pins when
connecting the engine ECU connectors.
 2610-10 14-37

3. Remove the ECU/GCU (Glow plug Control

Unit) assembly.
- Separate the fuel hose (A).
- Unscrew two nuts (B, 12 mm) from the
bracket.

4. Disconnect the GCU connectors (A, B) and

GCU remove the ECU assembly.

The GCU connector

(B) has locking tabs
on both sides.

5. Unscrew two bolts from the bracket and

remove the battery.

6. Unscrew four bolts (A, 12 mm) from the

bracket, unscrew bolt (B, 12 mm) from the
air cleaner lower housing, pull out the lock
pin, and remove the battery bracket.
14-38

7. Unscrew the bolt (12 mm) on the ground

cable and remove the EBS.

8. Install the EBS in the reverse order of

removal.

Pole clamp

EBS Body ground terminal

 1451-01 14-39

- Disconnect the negative cable from the battery.

- Remove the engine acoustic cover.
- Remove the under cover.
- Collect the refrigerant from A/C system.

Alternator assembly

1. Remove the coolant reservoir (A).

- Separate the coolant hose (B).
- Unscrew the bolts (C).

Make sure not to spill over the coolant on

the engine and vehicle body.
14-40

2. Set up the engine support hanger on the

engine hanger bracket. (Refer to Chapter
“Engine General”.)

3. Unscrew three nuts (A, 17 mm) and bolt (B,

17 mm) and remove the RH insulator
mounting bracket.

4. Remove the belt.

- Raise the support hanger to get the
working space for belt.
- To release the tension of the belt
tensioner assembly (A), turn the belt
tensioner adjusting bolt (B) clockwise
with a special service tool (C). And,
remove the fan belt.
 1451-01 14-41

5. Remove the intake hose.

6. Disconnect the magnetic switch

connector from the A/C compressor.

7. Unscrew the nut (A, 12 mm) and separate

the discharge and suction hoses from the
A/C compressor.
11.7 ~ 16.6Nm
(1.2 ~ 1.7kgf.m)

8. Unscrew four bolts (A, 13 mm) from the

A/C compressor.
19.6 ~ 24.5Nm
(2 ~ 2.5kgf.m)
14-42

9 9. Disconnect the battery “L” and “F”

connector (B) and separate the “B+”
cable.

Make sure to secure the ground

connection. Otherwise, the voltage could
be generated between “B+” terminal and
ground.

10.Unscrew the lower bolt (15 mm) from the

alternator.

11.Unscrew the upper bolt (17 mm) from the

alternator.
 1451-01 14-43

12.Remove the alternator.

13. Install the alternator in the reverse order of

removal.

To make the reassembly easy, slide the

bushing in bracket to arrow direction (A).
14-44

- Disconnect the negative cable from the battery.

Battery

1. Disconnect the engine ECU connectors (A,

B).

Be careful not to bend the pin or let foreign

material enter between the pins when
connecting the engine ECU connectors.

2. Remove the ECU/GCU (Glow plug Control

Unit) assembly.
- Separate the fuel hose (A).
- Unscrew two nuts (B, 12 mm) from the
bracket.
 2610-01 14-45

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

GCU remove the ECU assembly.

The GCU connector

(B) has locking tabs on
both sides.

4. Unscrew two bolts (12 mm) from the

bracket and remove the battery.

5. Install the battery in the reverse order of

removal.