check engine SSANGYONG NEW ACTYON SPORTS 2012 User Guide

03-10
(3) DI Engine Fuel System Check Procedure
If several DTCs are output simultaneously, check the electric wiring for open or short circuit.
Check the low pressure fuel system and fuel filter and confirm that there are no abnormalities.
Carry out the high pressure fuel system check.

03-12
(5) High Pressure System Pressure Test
Fuel rail pressure test ▶
Disconnect the fuel rail pressure sensor
connector and then IMV connector. 1.
Connect the pressure tester to the fuel rail
pressure sensor connector. 2.
Crank the engine 2 times for 5 seconds. 3.
Read the highest pressure value
displayed on the tester display.
If the highest pressure value is 1,050 bar
or less, refer to the section "Fuel System
Check Process". -
-

03-132210-01
How To Use Pressure Tester ▶
Press the "TEST" button on the tester to
check if the message "TEST?" is
displayed.
If the button is pressed again at 4 seconds
after starting engine cranking, the highest
pressure is displayed on the tester. 1.
2.
The fuel rail pressure value can be checked using a diagnostic device.

03-14
(6) Low Pressure System Pressure Test
Inspection procedure ▶
All wirings/connectors and fuel lines should
be connected and the engine should work
properly.
Prepare a special tool for low pressure test
and clean it thoroughly to prevent foreign
materials from entering. 1.
2.
Disconnect the key connector for fuel filter connection, and connect both connectors to the
fuel filter and hose. 3.
Start the engine and check visually for clogged low pressure fuel system, excessive air or air
entry.
If the fuel flow is not sufficient or air is in the fuel, repair the leak area. 4.
5.

03-152210-01
Static test for backleak of injector ▶
Disconnect the injector return hose and cover
the openings with caps shaped screw
(included in the special tool). 1.
Connect the hose of the container for
measuring backleak to the return nipple of
the injector.
(prevent air entry to the low pressure line) 2.
Disconnect the IMV connector of the
high pressure pump and then fuel
pressure sensor connector. 3.
The connector of the injector can be easily
contaminated. Always keep it clean.
Crank the engine 2 times for 5 seconds.
Check the time for flow if injector backleak
and confirm that it is within the specified
range. 4.
5.
If the value is out of the specified range,
replace the injector.
SpecificationBelow 20 sec.

03-16
Dynamic test for backleak of injector ▶
Warm up the engine so that the engine
coolant temperature be over 80℃ and star
the engine again.
Disconnect the injector return hose and
cover the openings with caps shaped
screw (included in the special tool).. 1.
2.
Connect the hose of the container for
measuring backleak to the return nipple of
the injector.
Start the engine again and let the engine
idle for 30 seconds.
Perform backleak test of fuel system with a
diagnostic device after 30 seconds. 3.
4.
5.
This test consists of 4 cycles, and the engine
rpm reaches 3,500 rpm for 18 seconds in each
cycle.
Check the amount of backleak collected
into the container and confirm that it is
within the specified range. 6.
Specification38 ml or less

03-18
3. CAUTIONS FOR DI ENGINE
1) Cautions for DI Engine
This chapter describes the cautions for DI engine equipped vehicle. This includes the water
separation from engine, warning lights, symptoms when engine malfunctioning, causes and
actions.
DI Engine 1.
Comparatively conventional diesel engines, DI engine controls the fuel injection and timing
electrically, delivers high power and reduces less emission..
System Safety Mode 2.
When a severe failure has been occurred in a vehicle, the system safety mode is activated to
protect the system. It reduces the driving force, restricts the engine speed (rpm) and stops
engine operation. Refer to "Diagnosis" section in this manual.
Engine CHECK Warning Lamp 3.
The Engine CHECK warning lamp on the instrument cluster comes on when the
fuel or major electronic systems of the engine are not working properly. As a result,
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Water Separator Warning Lamp 4.
When the water level inside water separator in fuel filter exceeds a certain level
(approx. 45 cc), this warning light comes on and buzzer sounds.
Also, the driving force of the vehicle decreases (torque reduction). If these
conditions occur, immediately drain the water from fuel filter.

03-20
(2) Di engine and its expected problems and remedies can be caused by
water in fuel
System supplement against paraffin separation ▶
In case of Diesel fuel, paraffin, one of the elements, can be separated from fuel during winter and
then can stick on the fuel filter blocking fuel flow and causing difficult starting finally. Oil
companies supply summer fuel and winter fuel by differentiating mixing ratio of kerosene and
other elements by region and season. However, above phenomenon can be happened if stations
have poor facilities or sell improper fuel for the season. In case of DI engine, purity of fuel is very
important factor to keep internal preciseness of HP pump and injector.
Accordingly, more dense mesh than conventional fuel filter is used. To prevent fuel filter internal
clogging due to paraffin separation, SYMC is using fuel line that high pressure and temperature
fuel injected by injector returns through fuel filter to have an effect of built-in heater (see fuel
system).
System supplement and remedy against water in fuel ▶
As mentioned above, some gas stations supply fuel with excessive than specified water. In the
conventional IDI engine, excessive water in the fuel only causes dropping engine power or engine
hunting. However, fuel system in the DI engine consists of precise components so water in the
fuel can cause malfunctions of HP pump due to poor lubrication of pump caused by poor coating
film during high speed pumping and bacterization (under long period parking). To prevent
problems can be caused by excessive water in fuel, water separator is installed inside of fuel
filter. When fuel is passing filter, water that has relatively bigger specific gravity is accumulated on
the bottom of the filter.
Water drain from water separator ▶
If water in the separator on the fuel filter exceeds a certain level, it will be supplied to HP pump
with fuel, so the engine ECU turns on warning lamp on the meter cluster and buzzer if water level
is higher than a certain level.
Due to engine layout, a customer cannot easily drain water from fuel filter directly, so if a
customer checks in to change engine oil, be sure to perform water drain from fuel filter.
Water
separator
To separate the water from the fuel filter,
remove the fuel filter assembly first.

04-4
2. INSPECTION
1) Troubleshooting
When Abnormal Noises are Heard from the Engine Room ▶
For the vehicle equipped with DI engine, if a learning noise occurs in each range or other
noises occur, the major cause of it is a faulty turbocharger assembly. But an interference issue,
poor tightness or loose in the intake and exhaust system also can cause those noises. This is
mainly because the operator didn't follow the instruction exactly when reconnecting the intake
hoses and pipes which were disconnected to check the system or replace the air cleaner. If the
intake system is free of any faults, check the EGR and PCV oil separator connected to the
intake system.
The figure may be different from the actual engine. Therefore, read thoroughly below before
replacing the parts.
2) Abnormal Noise Caused by Poor Tightness of Intake System
When the DI engine is running, the air entered into the engine flows in the sequence as shown
above. If high intake pressure is applied to the loose or damaged part, a whistling noise may
occur, the intake air volume is measured incorrectly or the engine power is derated.

04-51719-00
3) Troubleshooting Sequence
The basic checks for intake system are as follows:
Basic Checks for Intake System ▶
Make sure to replace or clean the air
cleaner element periodically. Otherwise,
engine will be derated or work abnormally
because of low intake air volume.
Unlike the fuel system, which is a closed
circuit, the intake system is an open circuit
system. Therefore any malfunction may
occur due to dust and dirt.
Most of the connections consist of hoses
so the system cannot withstand high
temperature and pressure. Also it can be
deformed or loosened easily because it is a
clamp mounting system. Thus, when
checking the engine, basic inspections,
such as tightened status check and visual
inspection for hose, etc., should be carried
out in advance.
Other Checks for Intake System ▶
If the intake system is free of any faults,
check for EGR and PCV oil separator.