change wheel SSANGYONG NEW ACTYON SPORTS 2012 Service Manual

02-90000-00
1336-01 Timing gear case cover
Added the belt tension mounting boss
1130-01 Crankshaft assembly
- Reduced weight
- Deleted ring gear
1130-18 Drive plate assembly (A/T)
Changed the location of torque converter
mounting hole1130-13 Dual mass flywheel
Deleted centering sleeve
1115-02 Engine mounting bracket
D20DTR (Actyon Sports)
OldNew
OldNew
OldNew
Old
New
OldNew
with center bearingwithout center
bearing

02-36
Torque change curve of engine and drive shaft
Compression stroke Combustion stroke
Small changes from engine (k):
Damper increases the torque changes to clutchLarge changes from engine (j):
Damper decreases the torque changes to
transaxle by absorbing the impact
3) Operation
Compensating the irregular operation of engine: The secondary flywheel operates almost
evenly so does not cause gear noises
The mass of the primary flywheel is less than conventional flywheel so the engine irregularity
increases more (less pulsation absorbing effect).
Transaxle protection function: Reduces the torsional vibration to powertrain (transaxle) by
reducing the irregularity of engine. -
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02-370000-00
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 ▶

06-111914-01
3. TROUBLESHOOTING
The followings are cautions to take in handling defects of turbocharger, which must be fully aware
of.
1) Cautions
After stopping the engine, check whether the bolts on pipe connecting section are loose as
well as the connecting condition of vacuum port and modulator, which is connected to the
actuator.
During idling of the engine, check for leakage in the connecting section of pipe (hoses and
pipes, duct connections, after the turbocharger) by applying soap water. The leakage
condition in the engine block and turbine housing opening can be determined by the
occurrence of abnormal noise of exhaust.
By running the engine at idle speed, abnormal vibration and noise can be checked.
Immediately stop the engine when abnormal vibration and noise is detected and make
thorough inspection whether the turbocharger shaft wheel has any damages as well as
checking the condition of connections between pipes.
In case where the noise of engine is louder than usual, there is possibility of dampness in the
areas related with air cleaner and engine or engine block and turbocharger. And it could affect
the smooth supply of engine oil and discharge.
Check for damp condition in exhaust gas when there is sign of thermal discoloration or
discharge of carbon in connecting area of the duct.
When the engine rotates or in case where there is change in noise level, check for clogging of
air cleaner or air cleaner duct or if there is any significant amount of dust in the compressor
housing.
During the inspection of center housing, inspect inside of the housing by removing the oil
drain pipe to check for sludge generation and its attachment condition at shaft area or turbine
side.
Inspect or replace the air cleaner when the compressor wheel is damaged by inflow of foreign
materials.
Inspect both side of the turbocharger wheel after removing inlet and outlet pipe of the
turbocharger. 1.
2.
3.
4.
5.
6.
7.
8.
9.

15-150000-00
A fourth correction is made according to the pressure error.
This correction is used to reduce the injection timing advance when the pressure in the rail is
higher than the pressure demand.
A fifth correction is made according to the rate of EGR.
This correction is used to correct the injection timing advance as a function of the rate of
exhaust gas recirculation. -
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When the EGR rate increases, the injection timing advance must in fact be increased in order to
compensate for the fall in termperature in the cylinder.
A. Main Flow Control
The main flow represents the amount of fuel injected into the cylinder during the main injection.
The pilot flow represents the amount of fuel injected during the pilot injection.
The total fuel injected during 1 cycle (main flow + pilot flow) is determined in the following manner.
When the driver depress the pedal, it is his demand which is taken into account by the system
in order to determine the fuel injected.
When the driver release the pedal, the idle speed controller takes over to determine the
minimum fuel which must be injected into the cylinder to prevent the enigne from stalling. -
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It is therefore the greater of these 2 values which is retained by the system. This value is then
compared with the lower flow limit determined by the ESP system.
As soon as the injected fuel becomes lower than the flow limit determined by the ESP system, the
antagonistic torque (engine brake) transmitted to the drive wheels exceeds the adherence
capacity of the vehicle and there is therefore a risk of the drive wheels locking.
The system thus chooses the greater of these 2 values (main flow & pilot flow) in order to prevent
any loss of control of the vehicle during a sharp deceleration.
As soon as the injected fuel becomes higher than the fuel limit determined by the ASR trajectory
control system, the engine torque transmitted to the wheels exceeds the adhesion capacity of the
vehicle and there is a risk of the drive wheels skidding. The system therefore chooses the smaller
of the two values in order to avoid any loss of control of the vehicle during accelerations.
The anti-oscillation strategy makes it possible to compensate for fluctuations in engine speed
during transient conditions. This strategy leads to a fuel correction which is added to the total fuel
of each cylinder.
A switch makes it possible to change over from the supercharge fuel to the total fuel according to
the state of the engine.
Until the stating phase has finished, the system uses the supercharged fuel.
Once the engine changes to normal operation, the system uses the total fuel. -
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(5) Fuel Control
The main fuel is obtained by subtracting the pilot injection fuel from the total fuel.
A mapping determines the minimum fuel which can control an injector as a function of the rail
pressure. As soon as the main fuel falls below this value, the fuel demand changes to 0 because
in any case the injector is not capable of injecting the quantity demand.

04-4
1. OVERVIEW
The hydraulic clutch transmits the force required to operate the clutch pedal to the concentric
slave cylinder fitted to the clutch housing as a hydraulic pressure.
(The hydraulic pressure is transmitted in the following order: Clutch pedal - Clutch master
cylinder - Clutch pipe - Clutch damper - Clutch pipe and hose - Concentric slave cylinder -
Pressure plate - Flywheel.)
If a driver depress the clutch pedal, the hydraulic pressure is generated in the master cylinder. It
is transmitted to the concentric slave cylinder through the pipe, resulting in the cylinder being
forced out. At this time, the clutch disc is forced against the cylinder by pushing the cover. This,
in turn, remove the flywheel from the pressure plate. As a consequence, the power from the
engine will be cut off and the gear change can be carried out.

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 -
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Primary flywheel
Secondary flywheel
Arc damper spring
Torque limiter
Ring gear 1.
2.
3.
4.
5.

07-53240-01
Operation ▶
Description Mode Conditions
Driving
mode2H 2 Wheel drive
(rear wheel)Rear-wheel drive mode. This is used under
normal or high-speed driving conditions on
public roads or highways.
4H 4 Wheel drive
(high speed)This is used under sandy, muddy or snow-
covered road conditions
4L 4 Wheel drive
(low speed)This is used for maximum traction.
When cornering with low speed in 4WD
condition, there could be tire dragging, some
mechanical shocks and resistances in
vehicle’s drive train. These are normal
conditions due to internal resistance in the
drive train when the 4WD system is properly
working
Mode change2H←4H2 Wheel drive
↔4 Wheel driveShifting is possible while driving at the speed
of 70 km/h or less
2H,
4H↔4L2 Wheel drive,
4 Wheel drive (high
speed)
↔4 Wheel drive
(low speed)For Automatic Transmission:
For Manual Transmission:
Stop the vehicle on level ground and
move the gear selector lever into the
“N” position. Turn the switch to the
desired position. ·
Stop the vehicle on level ground and
move the gear selector lever into the
“N” position. Then turn the switch to
the desired position while depressing
the clutch pedal. ·
To make the mode change easily, stop
the vehicle on level ground and turn the
mode switch to the desired position and
move the shift lever to "N"-"R"-"N" while
depressing the brake pedal.

10-18
4) ABS Control Pattern
The ABS control is performed by comparing the reference speed with each wheel speed. Firstly,
it is determined whether the vehicle is in the deceleration or acceleration state using the wheel
speed change ratio. Then, a signal is transmitted to the valve.
Finally, the brake pressure is adjusted via the signal.
△V: Vehicle speed
Vref: Vehicle speed reference
Vw: Wheel speed

11-94890-10
3. PRECAUTIONS
The warning lamp flashes and warning beep sounds when the ESP is operating
When the ESP operates during vehicle movement, the ESP warning lamp on the instrument
panel flashes and beep comes on every 0.1 second. The ESP system is only a
supplementary device for comfortable driving. When the vehicle exceeds its physical limits, it
cannot be controlled.
Do not rely on the system. Keep on the safe driving.
Feeling when ESP is working
When the ESP system activates, the feeling can be different depending on vehicle driving
conditions.
For example, you will feel differently when the ESP system is activated during the ABS is
operating with the brakes applied and when the brakes are not applied on a curve.
If the ESP system operates when the brake is applied, the brake pressure will be increased on
the corresponding wheel which already has braking pressure for the ESP controls.
ARP Operation
During the ARP operation, vehicle safety (rollover prevention) takes the first priority and thus,
stronger engine control is in effect. Consequently, the vehicle speed decreases rapidly, so the
driver must take caution for the vehicle may drift away from the lane.
Noise and vibration that driver feels when ESP system is operating
The ESP system may transfer noise and vibration to the driver due to the pressure changes
caused by the motor and valve operations in a very short period of time. And, keep in mind
that the output and vehicle speed could be decreased without rpm increase due to the ASR
function that controls the engine power.