engine SSANGYONG NEW ACTYON SPORTS 2012 Service Manual

04-8
3. DUAL MASS FLYWHEEL (DMF)
The dual mass flywheel (DMF) is of having a mass divided into two halves.
While one mass is connected to the engine crankshaft, which is affected by the mass moment of
inertia of the engine, the other mass is affected by one of the transmission.
The divided dual masses are connected to the coil spring and damping system internally.
The DMF has the following benefits: ▶
Reducing fuel consumption by lowering engine speed
Reducing rattling noise and vehicle vibration in all driving ranges
Reducing synchronization wear
Facilitating gear change
Protecting power train parts by preventing excessive load from being delivered -
-
-
-
-
Primary flywheel
Secondary flywheel
Arc damper spring
Torque limiter
Ring gear 1.
2.
3.
4.
5.

08-10
2. FRONT SUSPENSION (DOUBLE WISHBONE)
Advantage ▶
The advantage of a double wishbone suspension is that it is fairly easy to work out the effect
of moving each joint, so the kinematics of the suspension can be tuned easily and wheel
motion can be optimized.
It is also easy to work out the loads that different parts will be subjected to which allows more
optimized lightweight parts to be designed.
They also provide increasing negative camber gain all the way to full jounce travel unlike the
MacPherson strut which provides negative camber gain only at the beginning of jounce travel
and then reverses into positive camber gain at high jounce amounts. 1.
2.
3.
Disadvantage ▶
The disadvantage is that it is slightly more complex than other systems like a MacPherson strut.
Due to the increased number of components within the suspension setup it takes much longer to
service and is heavier than an equivalent MacPherson design. 1.
2. Double wishbone suspension is an independent suspension design using two (occasionally parallel)
wishbone-shaped arms to locate the wheel. Each wishbone or arm has two mounting points to the
chassis and one joint at the knuckle. The shock absorber and coil spring mount to the wishbones to
control vertical movement. Double wishbone designs allow the engineer to carefully control the
motion of the wheel throughout suspension travel, controlling such parameters as camber angle,
caster angle, toe pattern, roll center height, scrub radius, scuff and more.
Lower arm Upper arm Shock absorber Stabilizer

09-94850-01
Problem Cause Action
Burning smell
around tireToo frequent braking in high driving speed Reduce the use of
foot brake/use
engine brake
properly Used only foot brake during downhill driving
Driving with foot on brake pedal Get off the foot
from pedal
Foreign materials such as dirt or sand in brake system Replace: caliper,
wheel cylinder,
master cylinder,
return spring
Broken return spring in shoe assembly Replace
Incorrectly adjusted parking brake cable Adjust
Incorrect wheel or wheel cover
(generating the heat)Replace

09-10
This section describes the noise phenomena occurred possibly in the brake system operation.
Distinguish between the information given below and the actual problems and then, inspect the
vehicle and take appropriate measures.
Noise symptoms and Causes -
Symptom 1. If depressing the brake pedal when the engine is cold, "screeching" sound always
occurs and, after driving for a while, the sound disappears..
This usually occurs in the morning. When the temperature goes down, the dew condensation
phenomenon sets moisture on the brake disc as the window frost forms. Due to this moisture, the
iron within the brake disc and pad oxidizes, forming undetectable micro-rusts on the disc
surface. When starting the engine under this condition, noise may sound due to the friction of
micro-rusts. When operating the brake several times, the disc temperature goes up and the
micro-rusts come off and the noise goes away. Depending on the driving conditions, noise gets
louder when slightly depressing the brake pedal and oppositely, noise is smaller when deeply
depressing the brake pedal. This is simply a physical phenomenon, called "morning effect" in
professional terms, and does not imply any problems with the brake system.
Symptom 2. Slip or screech after the brake pad replacement.
This usually occurs when the bed-in is not made between the disc and the pad's friction material.
The bed-in is a state that the brake system normally works and gives no noise out, when, after
about 300 km city driving, the contact area of the pad friction material is enlarged and the disk is
in complete contact with the pad's friction material. Therefore, for some time after the brake
disk/pad replacement, the brake system poorly operates or noise (abnormal sound) occurs due
to the partial contact.
Symptom 3. "Groaning" sound occurs in the automatic transmission vehicle when slightly taking
the foot off the brake pedal to slowly start after waiting for the signal, or slightly depressing the
brake pedal.
This is the noise "Creep groan" that occurs when, in both the automatic and manual transmission,
slightly releasing the brake pedal in the neutral gear at downhill roads.
It frequently occurs at the low braking power and low speed, through the following process. When
operating the brake system at low speed and low pressure, adhesion and slip repeatedly take
place between the brake disk and the friction material, and this makes the braking power
inconstant, instantly increasing or decreasing, and gives out the brake noise.
It is also a physical phenomenon and has no relation with the brake performance.BRAKE OPERATION AND NOISE ▶

09-134850-01
Maximum Stroke of Brake Pedal ▶
Check the brake pedal with below
procedures: -
Start the engine.
Pump the brake pedal around 3 times.
Depress the brake pedal with approx. 30
kg and measure the distance (A) between
the upper surface of pedal pad and the
lower dash panel.
If the measured value is out of the
specified value, adjust the length. 1.
2.
3.
4.
Specified value (A)150mm
5. BRAKE SYSTEM CHECK
Over the specified value
Cause Action
Worn brake pad Replace
Worn brake shoe Replace
Improper stroke of hand
brakeAdjust
Air in brake line Air bleeding
Oil leak Repair or replace
Brake booster push rod Replace or adjust
Improperly adjusted
stopper boltAdjust
Below the specified value
Cause Action
Brake booster push rod
Replace or adjust
Air in brake fluid Replace
Improperly adjusted
stopper boltAdjust

09-14
Specified value (B)155mm
Push rod
Stop lamp
switch Pedal Height ▶
Check the pedal height with below
procedures: -
Start the engine and measure the length
(A) between floor mat and pedal.
If the measured value is out of the
specified value, adjust the length. 1.
2.
Adjust the pedal height with below
procedures: -
Disconnect the stop lamp switch connector.
Unscrew the lock nut and remove the stop
lamp switch assembly.
Loosen the lock nut on the pedal push rod.
Turn the pedal push rod to adjust the pedal
height.
Tighten the lock nut.
Install the stop lamp switch assembly.
Connect the stop lamp switch connector.
Check if the stop lamps come on when
pressing the brake pedal around 5 mm.
If the stop lamp dpes not come on, adjust
the stop lamp switch assembly again.
If the stop lamps come on, tighten the lock
nut and measure the pedal height again. 1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

09-154850-01
Specified value (A)3 ~ 10mm
Connect the multimeter to stop lamp
switch connector and check if the
continuity exists when pushing in the
plunger. If the continuity doesn't exist, the
stop lamp switch is normal. - Pedal Free Play ▶
Stop Lamp Switch ▶Check the pedal free play with below
procedures: -
Stop the engine.
Depress the brake pedal several times to
discharge the vacuum pressure of the brake
booster.
Depress the brake pedal until you feel the
resistance, and measure the movement (A). 1.
2.
3.
Below the specified value: Check if the
distance between the outer case of stop
lamp switch and the brake pedal.
Over the specified value: It may be caused
by bigger clearance between the clevis pin
and the brake pedal arm. Replace the
components if necessary. -
-

09-16
Let the engine run for 1 to 2 minutes and
stop it. If the brake pedal stroke is
shortened as pumping the brake pedal,
the system is normal. If not, the system is
defective.
Depress the brake pedal several times
with engine off. If the brake goes down
when starting engine with pedal
depressed, the system is normal. If not,
the system is defective.
Depress the brake pedal when the engine
is running. If the pedal height is not
changed for 30 seconds after stopping
the engine, the system is normal. If not,
the system is defective. 1.
2.
3.
If the above three checks are OK, the system
is normal. If any condition is not met, check
the valve, vacuum hose and brake booster. Brake Booster ▶

10-94892-01
Front wheel speed sensor (4WD)
Located on the hub assembly.
Front discFront caliper assembly (2WD/4WD)
Located on the knuckle.
ABS hydraulic device and control unit
Located near the brake booster in engine compartment.

11-74890-10
1. OVERVIEW
The ESP (Electronic Stability Program) has been developed to help a driver avoid danger of losing
control of the vehicle stability due to understeer or oversteer during cornering. The yaw rate
sensor, lateral sensor and longitudinal sensor in the sensor cluster and the steering wheel angle
sensor under the steering column detect the vehicle conditions when the inner or outer wheels are
spinning during oversteer, understeer or cornering. The ESP ECU controls against oversteer or
understeer during cornering by controlling the vehicle stability using input values from these
sensors and applying the braking force to the corresponding wheels independently. The system
also controls the engine power right before the wheel spin synchronized to decelerate the vehicle
automatically in order to maintain the vehicle stable during cornering.