check engine SSANGYONG NEW ACTYON SPORTS 2012 Service Manual

3) CIRCUIT IDENTIFICATION SYMBOL
Identification Symbol Meaning
C Connector
D Diode
Ef Fuse in engine room fuse & relay box
F Fuse in passenger room fuse box
G Ground
S Splice pack (Junction connector)
5) WIRING HARNESS COLOR IDENTIFICATION
Abbreviation Color Abbreviation Color
Br Brown Sb Sky Blue
G Green R Red
V Violet L Blue
P Pink Y Yellow
W White Gr Gray
Gr Orange B Black
Lg Light Green
6) HOW TO CHECK TERMINAL NUMBER OF CONNECTOR
Terminal number is given based on Female Terminal Male Connector ▶
ex) Terminal Number 4 of C901 connection -
Power supply No. Power supply condition
15Battery Voltage (B+) supply in Ignition Switch “ON” and “ST” (IGN 1)
15ABattery Voltage (B+) supply in Ignition Switch “ON” (IGN 2)
15C<00690088009b009b008c009900a00047007d00960093009b0088008e008c0047004f0069005200500047009a009c00970097009300a000470090009500470070008e00950090009b0090009600950047007a009e0090009b008a008f004702c80076007502
c9004700880095008b004702c80068006a006a02c9>
30 Battery Voltage (B+) supply directly regardless of Ignition Switch
31 Ground connected to battery (-)
58Battery Voltage (B+) supply in Head Lamp Switch 1st and 2nd step
(Illumination circuit)
4) FUNCTION OF POWER SUPPLY LINE (NUMBER)

01-6
3. ENGINE COMPARTMENT LAYOUT
Do not work on the engine compartment while the engine, radiator, exhaust manifold, muffler
or catalytic converter is hot. Always turn the engine off and allow it to cool before starting the
maintenance.
Regularly check the engine oil level and add Ssangyong genuine engine oil if necessary.
Clean the dipstick with clean cloth so that any foreign materials cannot get into the engine. -
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Power steering fluid
reservoirBrake fluid reservoir
Fuse & relay
Engine oil
dipstick gaugeWasher fluid
reservoir cap Engine oil filler cap
Air cleaner
Operating vehicle with insuffi cient amount of oil can damage the engine. Make sure the
engine oil level is correct and add oil if necessary.
Coolant reservoir

02-70000-00
3. CHECK AND INSPECTION
1) Cylinder
(1) Compression pressure test
Specified value ▶
Compression ratio16.5 : 1
Test conditionat normal operating temperature (80˚C)
Compression pressureStandard32 bar
Minimum18 bar
Differential limit between cylindersMaximum 3 bar
The compression pressure test is to check the conditions of internal components (piston, piston
ring, intake and exhaust vale, cylinder head gasket). This test provides current engine operating
status.
Before cranking the engine, make sure that the test wiring, tools and persons are keeping
away from moving components of engine (e.g., belt and cooling fan).
Park the vehicle on the level ground and apply the parking brake.
Do not allow anybody to be in front of the vehicle. -
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Measurement ▶
<007e0088009900940047009b008f008c0047008c0095008e00900095008c0047009c00970047009b00960047009500960099009400880093004700960097008c00990088009b00900095008e0047009b008c00940097008c00990088009b009c0099008c00
47004f005f005700b6006a00500055>
Disconnect the fuel rail pressure sensor connector to cut off the fuel injection.
Remove the air cleaner duct and glow plugs. -
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Place the diagram sheet to compression
pressure tester and install it into the plug
hole. 1.

02-110000-00
4. GUIDELINES ON ENGINE SERVICE
To prevent personal injuries and vehicle damages that can be caused by mistakes during engine
and unit inspection/repair and to secure optimum engine performance and safety after service
works, basic cautions and service work guidelines that can be easily forgotten during engine
service works are described in.
Cautions before service works
For safe and correct works, you must observe the working procedures and instructions in this
manual. And, use the designated tools as follow:
Engine stand / Heavy duty engine jack
To prevent the engine from starting abruptly, do not allow anybody to get in the vehicle while
servicing in engine compartment.
Before work on engine and each electrical equipment, be sure to disconnect battery negative
(-) terminal.
Before service works, be sure to prepare the works by cleaning and aligning work areas.
Do not allow the foreign material get into the fuel injection system.
When removing the engine, use only the safety hook on engine and engine hanger. Do not
support the bottom of oil pan with a jack.
Engine and accessories ▶
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▶
Completely drain the engine oil, coolant and fuel from engine before removal.
Before disassembling/assembling the engine components, carefully read the working
procedures in this manual.
Make sure to keep the specified tightening torques during installation.
Clean and properly lubricate the parts before reassembly.
Carefully check that there are not any interference while servicing. -
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02-12
Electrical equipment ▶
Electric devices should be handled more carefully.
Currently, the engine has a lot of electric devices. there could be poor engine performance,
incomplete combustion and other abnormal symptoms due to short circuit or poor contact.
Before work on engine and each electrical equipment, be sure to disconnect battery negative
(-) terminal.
When replacing the electric device, use only genuine part and check the conditions of
connections and grounds. Loosened connection or ground make cause a fire and personal
injury. -
-Fuel and lubrication system ▶
Do not allow the fluid and engine oil to make contact with the body paintwork and hoses.
If work on the fluid system such as fuel and oil, working area should be well ventilated and
smoking should be prohibited.
Gasket or seal on the fuel/lubrication system should be replaced with new ones and bolts and
nuts should be tightened as specified.
After removal/installation works, be sure to check whether there is leak on the connecting
section. -
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If fine dust or foreign material enters into DI engine's fuel system, there can be serious damages
in HP pump and injectors. Thus, be sure to plug the inlets of removed fuel line components with
cap and protect removed parts not to be contaminated with dirt. (Refer to cleanness in this
manual while working on DI engine fuel system)

02-290000-00
(2) Layout
Chain upper bush
Type: single bush
Chains:112 EA
Tensioner rail
Installed between exhaust
Camshaft sprocket and
crankshaft sprocket
Hydraulic tensioner
Contains tensioner housing
plug, spring and check valve,
and operated by hydraulic
pressure
Crankshaft sprocket
Teeth: 21 EA
Oil pump sprocket
Teeth: 33 EA
Chain lower bush
Chain type: single bush
Chains: 60 EA
Mechanical type tensioner
Operated by internal spring
Clamping rail
Installed between exhaust
Camshaft sprocket and
crankshaft sprocket
Exhaust camshaft
sprocket
Teeth: 42 EA
1) Chain Drive
(1) Overview
The drive chain is single chain drive system with simple design and variable performance, and it
utilizes the hydraulic tensioner to reduce the wave impact generated by the chain. This chain is light
weight and has high durability through single bush chain. Shoulder bolts are used for better NHV.
7. CHAIN AND GEAR DRIVE SYSTEM
D20DTR engine uses single stage chain drive system. Timing chain drives the exhaust side and
gear drive the intake side. Timing chain is single bush type. Upper chain drives HP pump
connected to intake Camshaft by driving exhaust cam shift sprocke, and lower chain drives oil
pump to lubricate the engine.

02-30
2) Timing Chain and Gear
(1) Timing chain
Simple layout: optimized timing, enhanced
NVH
Single stage layout: minimized chain load -
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Chain upper bush
- Single bush type (112 EA)
Chain lower bush
- Single bush type (60 EA)
(2) Tensioner
Tensioner adjusts the chain tension to keep it tight during engine running. This reduces the wear
in guide rail and spoke.
Operating principle
- Use the spring tension in tensioner and hydraulic pressure
Tensioner type
- Compensation and impact absorbing
Static and dynamic force
- Spring + Hydraulic pressure 1.
2.
3.
Plunger
HousingSpring
Check valve
Hydraulic tensioner assembly ▶

03-52210-01
Follow the job procedures. If you find a defective component, replace it with new one. 5.
Once disconnected, the fuel pipes between HP pump and fuel rail and between fuel rail and each
injector should be replaced with new ones. The pipes should be tightened tospecified tightening
torques during installation. Over or under torques out of specified range may cause damages and
leaks at connections. Once installed, the pipes have been deformed according to the force
during installation, therefore they are not reusable. The copper washer on injector should be
replaced with new one. The injector holder bolt should be tightened to specified tightening torque
as well. If not, the injection point may be deviated from correct position, and it may cause engine
disorder.
Plug the removed components with clean and undamaged sealing caps and store it into the
box to keep the conditions when it was installed. 6.
To supply the fuel to transfer line of HP
pump press the priming pump until it
becomes hard. 7.
Priming pump
Priming pump cap
Fuel filter assembly
Check the installed components again and connect the negative battery cable. Start the
engine and check the operating status.
With Scan Tool, check if there are current faults and erase the history faults. 8.
9.

03-6
2) Diagnostic Test for Engine Fuel System
(1) Overview
If a DTC is displayed on the diagnostic device, check the low pressure- and high pressure fuel
systems before removing the components.
To run the system properly, the electric system must be intact but for the DI engine, the fuel
pressure should be measured also when there is a malfunction even after the diagnostic test with
a diagnostic device.
(2) Hydraulic system

03-92210-01
3) DI Engine Fuel System Pressure Test
(1) Test device (Tool kit)
Device for high pressure
Device for low pressure
(2) Pre-check
Check-tighten fuel supply line
Check fuel level in fuel tank
Check air in fuel supply line (bubble in fuel supply line or fuel)
Check fuel supply line for leaks (low pressure and high pressure)
Check that specified fuel is used
Check fuel filter for contamination -
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