DP20~35N3

Engine Overview

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 Engine
Overview
Engine
Specification
Stage V

Type Ｄ０４ＥＧ - NA

Displacement ３．３ Litres

Rated output ３６ kW / ２２５０ min-1

Maximum torque １７７ Nm / １８００ min-1

Fuel system Bosch common rail type

Injector 5 - 0.12 - 145

Nox reduction
Engine coolant cooled E ＧＲ
system
Exhaust gas
DOC + DPF + Exhaust throttle
after treatment

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 Engine
Overview
Engine
Appearance

Left side Right side

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 Engine
Overview
D04EG-NA EU Stage V system

ECU Ex.Temp. sensor

Blow by
gas Press. &
Temp. temp.
sensor(A) sensors(A) CRS
DOC DPF
Exhaust Pressure sensor
Valve

EGR
Valve

EGR Cooler
AIR
CLEANE
R
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 Engine
Overview
ECM Control

ECM
Crank sensor Engine control
Cam sensor Injector
Rail press. Sensor Target Current speed EGR valve
Accel. pedal sensor speed calculation
Coolant temp. sensor
Oil press. SW Injection control
Fail safe control
Air flow sensor Output + ECU has a self-
Intake temp. sensor request Injection timing control diagnosis function,
Intake press. Sensor and outputs alarm
Intake temp. sensor Rail pressure control
Injection and performs
DOC inlet temp.
DPF inlet temp. amount Multi. injection control backup control
DPF outlet temp. calculation when failure
DPF differential press. occurs.

After treatment control Engine control

After treatment control + Generate output for engine load.
+ Estimate the amount of DPF soot load calc.
+ Follow the target speed
soot load in the DPF. DPF regen. cont.
+ Burn the soot properly
determined by the accelerator
ETV cont. operation, control the injectors.
and regenerate the DPF.

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 Engine
Overview
Fuel System
PRESSURE
LIMITING VALVE COMMON RAIL

HIGH
PRESSURE
PUMP
： Fuel feed line
： High press. line
： Fuel return line

FUEL FILTER NON-

RETURN
VALVE

FUEL INJECTOR
FUEL TANK

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 Engine
Overview
High-pressure fuel pump assembly
The high-pressure fuel pump assembly FROM FUEL
consists of the following parts: FILTER (FUEL IN)
FUEL INLET
• Feed pump METERING TO FUEL TANK
• Fuel inlet metering valve (MPROP) VALVE (MPROP) (FUEL OUT)
• Supply pump

Feed pump
The feed pump pumps fuel up from
the fuel tank and supplies the fuel to TO COMMON
the fuel inlet metering valve. RAIL (FUEL OUT)
DRIVE SHAFT

Fuel inlet metering valve (MPROP)

The fuel inlet metering valve adjusts the flow
of the fuel supplied by the feed pump, and
delivers the fuel to the supply pump plunger.
This solenoid valve receives a current from ECU,
and adjusts the fuel quantity to make the fuel pressure
which the engine requires

Supply pump
The supply pump utilizes the plunger to pressurize the fuel that is delivered by the fuel inlet
metering valve.

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 Engine
Overview
Common Rail

The common rail assembly accumulates

the high-pressure fuel delivered from the
high-pressure fuel pump assembly and
distributes it to the injectors.

Pressure limiting valve

When an abnormal pressure is developed in the common rail, the pressure
limiting valve returns the fuel to the fuel tank to prevent an abnormal
pressure increase.
Rail pressure sensor
ECU utilizes this feed-back signal to the fuel inlet metering valve in the high-pressure
fuel pump assembly.

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 Engine
Overview
Fuel Injector

Injector assembly
The injector assembly injects pressurized fuel supplied from the common rail into the
combustion chamber.
Each injector has a solenoid. This solenoid receives a current from ECU and actuates
the injector.
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 Engine
Overview
Fuel Injector

No-injection
When the magnet is not energized, the armature plate is pushed down
by the valve spring and the ball seat is closed.
High pressure fuel is acting on the control chamber, and the same
pressure also acts on the nozzle needle side.

Injection
When the magnet is energized, the armature plate is attracted upward
by the electromagnetic force and the ball seat is opened.
The high-pressure fuel in the control chamber flows out through the ball
seat to the fuel tank.
As result, the force of high-pressure fuel acting on the nozzle needle
overcomes the force of valve piston and the nozzle spring set force, the
nozzle needle is pushed up, and the fuel injection begins.

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 Engine
Overview
Multiple Injection

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 Engine
Overview
Injector
Fuel injector
specification
5 - 0.12 – 145
Number of hole Hole diameter Spray angle

Example of injection holes

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 Engine
Overview
EGR System

EGR
VALVE
EGR COOLER

HIGH
PRESSURE
PUMP

EGR FUEL
VALVE INJECTOR

EGR COOLER The concentration of oxygen in exhaust gas after

combustion is low. The oxygen concentration in the
intake air is decreased by mixing the exhaust gas.
AIR CLEANER As a result, the combustion temperature is lowered,
and the amount of generated nitrogen oxide (NOx)
is reduced.
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 Engine
Overview
EGR Cooler

When the high temperature exhaust gas is mixed with fresh air, the gas density of the
intake air decreases, and the filling efficiency of the intake air and the re-reflux gas
amount deteriorate. Therefore, the EGR cooler is installed to cool the recirculating gas
by EGR. The EGR cooler of this engine is water cooled type.

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 Engine
Overview
EGR Valve

EGR valve controls the flow rate of exhaust gas to

be mixed with the intake air.
The rod, one component of the main structure, is
made of stainless steel on which the carbon
deposition amount is small. A stainless-steel filter,
carbon bushing and teflon seal are installed around
the rod to prevent the valve from sticking.

Valve control
The valve is connected to the ECU by CAN communication.
The valve is equipped with a controller and controls the valve
operation by instructions from the ECU via CAN
communication.
The valve has a built-in potential sensor.

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 Engine
Overview
EGR System

EGR COOLER EXHAUST MANIFOLD

INTAKE MANIFOLD

： INTAKE AIR
： EXHAUST GAS
EGR VALVE

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 Engine
Overview
Exhaust System

Exhaust
manifold

Exhaust
throttle valve

Exhaust flange

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 Engine
Overview
Exhaust Throttle Valve

At DPF activate regeneration, the exhaust flow rate is throttled by the throttle
valve (valve closes) and the pressure is increased to raise the temperature of
the exhaust gas.
Controller

Drive type DC motor 12V

Controller
Integrated type
mount
Valve angle Hall non-contact
sensor type
Motor insulation Water cold type

Iron-based cast iron

Body material
FCD450

Butterfly type
Valve
SUS410

Motor cooling housing

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 Engine
Overview
Exhaust Throttle Valve
Reduction gear

DC motor Controller

Throttle valve

Heat resistant bush

Cooling passage Cooling pipe

Exhaust throttle valve unit is integrated with the controller.

ECU sends control signal by CAN communication
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 Engine
Overview
Engine Control System

Service tool

Exhaust throttle
valve

The ECU continuously monitors the engine operating conditions and provides the best
control fitting every situation.
ECU has a self-diagnostic function.
The service tool is connected to the engine to check the engine operational conditions or
the diagnostic code.

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 Engine
Overview
Sensor Location

Intake pres.
Oil pres. switch sensor

Wiring harness
Coolant temp. sensor

Crankshaft sensor
Camshaft sensor

Fuel temp. sensor

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Overview
Sensor Location

COOLANT TEMP. SENSOR

CAMSHAFT ANGLE SENSOR

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 Engine
Overview
Sensor Location

COMMON RAIL

COMMON RAIL PRESSURE

SENSOR

Relief
Valve

CRANK ANGLE
SENSOR

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 Engine
Overview
Sensor Location
FUEL INJECTOR

INTAKE AIR
PRESSURE
EGR VALVE
SENSOR

COMMON RAIL
PRESSURE SENSOR

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 Engine
Overview
Sensor Location

MPROP

FUEL TEMP.
SENSOR

HIGH PRESSURE
PUMP

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 Engine
Overview
Sensor
List
Sensor D04EG-NA D04EG-T
Injector 32K61-00020 32K61-00030
High pressure pump 32K65-00010 ←
MPROP 32K61-07500 ←
Fuel temp. sensor 32K61-07900 ←
Common rail pressure sensor 32K61-00600 ←
Coolant temp. sensor 32K90-00200 ←
Crankshaft sensor 32G90-00600 ←
Camshaft sensor 32K90-00100 ←
Air pressure & temp.
32K90-00700 X 2 32K90-00700
sensor (A)
Intake manifold temp. sensor
N/A 32K90-01400
(B)
EGR valve 32K32-06600 ←
Air flow meter with temp.
N/A 16E53-00100
sensor
Exhaust throttle valve 32K95-02334 ←
DPF Exhaust temp. sensor 31F90-04111×3 ←
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