fuel filter SSANGYONG NEW ACTYON SPORTS 2012 User Guide

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.

03-232210-01
Accelerator pedal position
sensor
Detecting driver's intention
for speed up/down
Fuel rail assembly
Relieving the pulsation.
Measuring the fuel pressure.
Distributing the fuel to injectors.
Fuel filter assembly
Supplying clean fuel/fuel
heating/water separation by
priming pump
Plunger type HP pump (1,800 bar)
Vane type LP pump (6 bar)
T-MAP sensor
Measuring booster pressure
and temperature
High pressure pump
Generating high pressurized fuel
and supplying it according to
engine rpm, required volume,
required pressure

03-24
2) Fuel System Flow Diagram
The fuel from the fuel tank is supplied to the fuel heater of fuel filter/priming pump and then low
pressure generated by the low pressure pump (built into HP pump) is transmitted to the HP pump.
The fuel pressure at the HP pump is controlled by the IMV valve, and the maximum allowed
pressure is 1,800 bar. The compressed fuel at the fuel pump is delivered to the rail, and injected by
the injectors according to the injection signals. The injection method is the same with the
conventional method; Fuel return by backleak which operates the needle valve.
The major difference is that the fuel return line is connected to the fuel filter inlet port, not the HP
pump venturi.
The pressure from the high pressure pump is increased to 1,800 bar from 1,600 bar, and the pump
is now installed to the cylinder head (cylinder block for previous model). The fuel pressure is
generated by the operation of intake camshaft and gears. The specifications for the IMV valve and
the fuel temperature sensor are not changed.

14-4
2. CAUTIONS
Standard pattern of soot accumulation ▶
(1) Abnormal Soot Accumulation (2) Normal Soot Combustion
Cautions to protect the catalyst filter ▶
Use the designated fuel only.
Observe the recommended service intervals of engine oil.
Check the engine oil level frequently and add if necessary.
Do not idle the vehicle unnecessarily.
Do not turn off the engine while the vehicle is running.
Do not shift the gear selector lever to neutral when going downhill.
Do not use improper engine oil or fuel additives.
Do not drive for a long time when the warning lamp is illuminated.
Make sure no flammable material, such as dry grass or tissue paper, contacts with the catalyst
filter while the vehicle is parked.
For the vehicles used in urban traffic, driving on the expressways for more than 1 hour at least
once per week is needed so that the PM inside CDPF isn't collected to one side only. -
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14-14
2) Collecting PM of DPF
There is a filter installed in the DPF and the PM filtered by this filter is burned (regeneration) when
the temperature of exhaust gas is increased due to post-injection. The filter has a honeycomb-
like structure to capture the particulate matter and the inlet and outlet of each channel are closed
alternatively. Once the exhaust gas enters to the inlet of a channel, it is released from the outlet of
the adjacent channel through the porous wall because of the closed outlet of the first channel,
and the PM is collected in the first channel.
[Collecting PM of CDPF]
Normally, when the driving distance becomes approx. 600 to 1,200 km, enough amount of
soot to be burned is filtered and accumulated in the CDPF. The ECU increases the amount of
fuel post-injection to increase the temperature of the exhaust gas up to 600°C, so that the
soot is burned. The soot is burned for 15 to 20 minutes (may differ by conditions).

15-16
B. Driver Demand
The driver demand is the translation of the pedal position into the fuel demand. It is calculated as
a function of the pedal position and of the engine speed. The driver demand is filtered in order to
limit the hesitations caused by rapid changes of the pedal position. A mapping determines the
maximum fuel which can be injected as a function of the driver demand and the rail pressure.
Since the flow is proportional to the injection time and to the square root of the injection pressure,
it is necessary to limit the flow according to the pressure in order to avoid extending the injection
for too long into the engine cycle. The system compares the driver demand with this limit and
chooses the smaller of the 2 values. The driver demand is then corrected according to the
coolant temperature. This correction is added to the driver demand.

15-48
E. Cautions
Use only specified Engine Oil (approved by MB Sheet 229.51) for CDPF. -
Use only specified engine oil (Low Ash Oil) ▶
The vehicle equipped with CDPF should use specific engine oil to improve the engine
performance and fuel economy, and ensure the service life of CDPF. -
Issue with normal engine oil ▶
Sulfur, one of the contents of engine oil is burned and generates soot that is not regenerated
by the DPF. This remains on the filter as ashes and keeps accumulating. Eventually, this
ashes will block the filter. -
Benefit for specified engine oil ▶
Minimized the sulfur content of engine oil which reduces the service life.
Improved fuel economy and emission level of CO2 with high performance and low viscosity.
Increased service life of engine oil with high resistance to temperature. -
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Problems when using unspecified engine oil ▶
The service life of filter may be reduced by 30% or more by the ashes accumulated on the
filter.
The fuel economy may be reduced because of engine rolling resistance, frequent
regeneration of DPF. -
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These problems are also caused by oil with high sulfur content, such as tax exemption oil
and heating oil, etc. *

01-8
Front View ▶
NO. FUNCTION NO. FUNCTION
1 HFM Sensor 12 Intake Manifold
2 Intake Air Duct 13 Cylinder Head
3 Cylinder Head Cover 14 Exhaust Manifold
4 Ignition Coi 15 Dipstick Guide Tube and Gauge
5 Spark Plug Connector 16 Connecting Rod
6 Fuel Distributor 17 Crankshaft
7 Injector 18 Engine Mounting Bracket
8 Exhaust Camshaft 19 Starter
9 Intake Camshaft 20 Crankcase
10 Valve Tappet 21 Oil Pump Sprocket
11 Intake Valve 22 Oil Pan
NO. FUNCTION NO. FUNCTION
23 Camshaft Adjuster 29 Oil Pump Drive Chain
24 Oil Filler Cap 30 Oil Strainer
25 Engine Hanger Bracket 31 Oil Pump
26 Cooling Fan and Viscous Clutch 32 Ring Gear and Flywheel of Drive Plate
27 Oil Filter 33 Piston
28 Timing Chain
Side View ▶