ESP SSANGYONG RODIUS 2012 Service Manual

01-18
The diagnostic connector is located at bottom of instrument panel. It consists of 16 pins.
The REKES key should be coded by the scan tool.
Connector Pin â–¶
Diagnostic connector
Pin No. Function
1 -
2 -
3 STICS "A2"(Coding)
4 Ground
5 Ground
6 CAN HI S205 "12"
7 GSL ECU "58"
8 ABS/ESP unit “2”
9 Air bag unit “9”
10 -
11 TCU "A18"
12 -
13 TCCU "21"
14 CAN LO S205 "5"
15 STICS "B16" (Diagnosis)
16 B+
7. PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR

01-150000-00
7. CODING AND INITIALIZATION
1) Engine Variant Coding
Unit Selection Description
PTC auxiliary heater NO For PTC auxiliary heaterequipped
vehicle, select"YES".
YES
Glow plug Relay (K-line) Select "AQGS".
AQGS (CAN)
Transmission MT 5-speed Select the appropriate system.
MT 6-speed
AT 5-speed (DC 5AT)
AT 6-speed (DSI 6AT)
AT 7-speed (DC 7AT)
Pressure sensor
forA/C refrigerantNOSelect “Refrigerant pressure sensor”.
Refrigerant Pressure Sensor
Immobilizer NO Select "YES" if the vehicle has
immobilizer.
YES
Vehicle speed input
typeCAN Select "CAN" if the vehicle has ABS or
ESP
WIRE
Cooling fan Relay Select "PWM".
PWM
Auto cruise NO Select "YES" if the vehicle hascruise
control.
YES
Engine level control NO Select "NO".
YES
G-sensor NOABS: Select “NO”.
4WD ABS or ESP: Select “YES”.
YES
SMART key NO Select "NO".
YES

01-16
2) Chassis Variant Coding
Unit Selection Description
Region GENERAL Select the region.
EUROPE
EAS NO Select "NO".
ECS
EAS 2-corner
EAS 4-corner
EPB NO Select "NO".
YES
Telematics NO Select "NO".
YES
T/M shift lever DC lever (CAN)A/T: Select “DURA lever (CAN)”.
M/T: Select “M/T”.
DURA lever (CAN)
M/T
DSI lever (NO-CAN)
Brake system NOSelect “ABS” or “ESP”.
ABS
TCS
ESP
EPS NO Select "NO".
YES
4WD 2WDSelect “2WD” or “P/T 4WD”.
TOD
P/T 4WD
AWD
Transmission M/TSelect “M/T” or “DC AT”.
DC AT
DSI AT

01-170000-00
Unit Selection Description
Sedan/Limousine Sedan (RV) Select "Sedan (RV)".
Limousine
Vehicle code
(Flatform)Rodius Select "Rodius".
Rexton
Korando C
Kyron
Korando Sport
Vehicle code
(Engine)D32DTA/T: Select “DURA lever (CAN)”.
M/T: Select “M/T”.
D27DT
D27DTP
D20DT
D20DTR
D20DT-LOW
Brake system NOSelect “D20DTR”.
ABS
TCS
ESP
Coding process Coding uncompletedSelect “Coding completed”.
Coding completed
Coding error
Not defined

02-350000-00
Oil pan sassembly
8. OIL PAN
The oil pan in D20DTR engine improves the NVH. Especially, the oil draining is much easier than
before.
Components â–¶

02-38
4) Features
Reduced vibration noise from the powertrain by blocking the torsional vibrations
Enhanced vehicle silence and riding comforts: reduced engine torque fluctuation
Reduced shifting shocks
Smooth acceleration and deceleration -
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5) Advantages
Improved torque response by using 3-stage type spring: Strengthens the torque response in all
ranges (low, medium, and high speed) by applying respective spring constant at each range.
Stable revolution of the primary and secondary wheel by using planetary gear: Works as
auxiliary damper against spring changes
Less heat generation due to no direct friction against spring surface: Plastic material is covered
on the spring outer surface
Increased durability by using plastic bushing (extends the lifetime of grease) -
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6) Drive Plate
Drive plate receives the power from the start motor when starting the engine. With this, the drive
plate initially drives the power train system. And, it is connected to the torque converter to transfer
the engine torque to the power train system.
Trigger ring
Drive plate
Components â–¶

02-410000-00
(3) Functions
Piston transfers the combustion energy from engine to connecting rod. Especially in the direct
injection engine such as D20DTF, it provides the combustion space and largely effects to the
engine performance and exhaust gas.
Piston ring
#1 ring (Top ring) : Prevents the high pressurized combustion gas from leaking into crank
chamber, and prevents the engine oil getting into combustion chamber.
#2 ring: Scrapes the engine oil on the cylinder bore, and prevents the leaked combustion gas
from #1 ring from leaking into the crank chamber.
Oil ring: Scrapes the engine oil on the cylinder bore.
Piston pin
Connects the piston the connecting rod, and transfers the linear movement of piston to
connecting rod to convert it to rotating energy
Snap pin
Locks the piston pin. â–¶
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â–¶
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â–¶
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(4) Assembling the piston
Install the piston rings with the "Y" mark on
the ring facing upwards.
Position the end gap of #1 ring at 180Ëš
away from the end gap of #1 ring.
Position the end gap of oil ring at 180Ëš
away from the end gap of coil spring, and
position the end gap of oil ring at 90Ëš away
from the end gap of #2 ring. 1.
2.
3.

03-4
Took kit for low pressure lineTool kit for high pressure line
2. MAINTENANCE AND INSPECTION
1) Maintenance Procedures for DI Engine Fuel System
Always keep the workshop and lift clean (especially, from dust).
Always keep the tools clean (from oil or foreign materials).
Wear a clean vinyl apron to prevent the fuzz, dust and foreign materials from getting into fuel
system. Wash your hands and do not wear working gloves. 1.
2.
3.
Follow the below procedures before starting service works for fuel system.
If the problem is from HP pump, fuel supply line or injector, prepare the clean special tools and
sealing caps to perform the diagnosis for DI engine fuel system in this manual. At this point,
thoroughly clean the related area in engine compartment. 4.
Clean the engine compartment before starting service works.

06-6
3) Inspection of Turbine
Thoroughly check the followings.
Must absolutely not operate the turbocharger with the compressor outlet and inlet opened as it
could damage the turbocharger or be hazardous during inspection.
Interference: In case where is trace of interference or smallest damage on the compressor
wheel means, most of times, that abrasion has occurred on the journal bearing. Must inspect
after the overhaul.
Oil Leakage: The reason for oil leakage at the compressor section is the air cleaner, clogged
by substances such as dust, causes the compressor inlet negative pressure. -
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Rotating in high speed at no-load for extended period of time can cause oil leakage to the
compressor section as oil pressure within the center housing gets higher than pressure
within the compressor housing.
Overuse of engine break (especially in low gear) in down hill makes significantly low
exhaust gas energy compared to the time where great amount of air is required during
idling conditions of the engine. Therefore, amount of air in the compressor inlet increases
but the turbocharge pressure is not high, which makes negative a.
b.
No problem will occur with the turbocharger if above conditions are found in early stage but oil
leaked over long period of time will solidify at each section causing to breakout secondary
defects.
Damages by foreign materials: In case where the compressor wheel is damaged by foreign
materials requires having an overhaul. At this time, it's necessary to check whether the foreign
materials have contaminated intake/exhaust manifold or inside of engine.

06-18
Maximizes the intake air charging efficiency (Approx. 15%) -Optimizes the exhaust gas flow rate by controlling the vanes inside the turbine housing with
the EActuator. 1.
(2) E-VGT Actuator (Electric-Actuator)
Target temperature and airflow control -Enhanced emmission control: By temperature control with CDPF system 1.
(1) Performance (for EURO V)
Has a faster response time than the conventional vacuum actuator. 2.
Improved low speed torque, high speed power and fuel economy.
Improved acceleration performance with rapid response time of vane. -
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1) Features
Features
Benefits
Folding and unfolding of the vane
is controlled electrically
Easy to get low speed air volume
Rapid response time
Electric control -
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Improved low speed torque and
power
Reduced exhaust gas
Improved fuel consumption
Improved acceleration
performance -
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