gas type SSANGYONG NEW ACTYON SPORTS 2012 Service Manual

02-8
(2) Cylinder pressure leakage test
If the measured value of the compression pressure test is not within the specifications, perform
the cylinder pressure leakage test.Specified value ▶
Perform this test in the sequence of firing order.
Do not test the cylinder pressure leakage with wet type test procedure. (do not inject the
engine oil into the combustion chamber) -
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Test condition: normal engine operating
temperature (80˚C)Specified value
Whole engine below 25%
at valve and cylinder head gasket below 10%
at piston ring below 20%
Crank the engine for approx. 10 seconds
by using the start motor. 2.
Record the test result and measure the
compression pressure of other cylinders
with same manner. 3.
If the measured value is out of specified
value, perform the cylinder pressure
leakage test. 4.

02-170000-00
Brake booster and naster
cylinderVacuum pump
Pump capacity: 210 cc/rev
Camshaft speed: 375 to 3,000 rpm
Lubrication temperature: -40 to
155°C
Oil: 5W30
Drive type: Driven by exhaust
Camshaft sprocket
2. VACUUM PUMP
Vacuum pump generates the vacuum pressure and supplies it to EGR cooler bypass solenoid.
This pump is single vane type and displacement is 210 cc/rev. The lubrication oil is supplied
through the hole in hollow shaft.
Components ▶
EGR cooler bypass valve
This valve is controlled by ECU.
When the engine is cooled, the
exhaust gas goes to combustion
chamber without passing
through EGR cooler because the
valve is closed by vacuum
pressure.

02-28
Thickness marking
Ex: 1.3t
4) Cylinder Head Gasket
(1) Features
Sealing the cylinder gas pressure - Peak pressure: 190 bar
Minimizing the distortion of engine structure (cylinder head, block): profile stopper, backland
stopper
Material: MLS (Multi Layer Steel), Gasket (3 layers)
Thickness of gasket: 3 types (1.2 /1.3 /1.4 mm) 1.
2.
3.
4.
(2) Thickness of cylinder head gasket
There are three types of gasket to managing the compression ratio.
Piston protrusion ▶
Piston protrusion Thickness
0.475 to 0.540 mm 1.2t
0.541 to 0.649 mm 1.3t
0.650 to 0.745 mm 1.4t

06-171914-01
1. SYSTEM DESCRIPTION OF E-VGT
(Electric-Variable Geometry Turbine)
The E-VGT turbocharger has one shaft where at each ends are installed with two turbines having
different angles to connect one end of housing to the intake manifold and the other end to the
exhaust manifold. As the turbine, at exhaust end, is rotated by exhaust gas pressure the impeller,
at intake end, gets rotated to send air around center of the impeller, being circumferentially
accelerated by the centrifugal force, into the diffuser. The air, which has been introduced to the
diffuser having a passage with big surface, transforms its speed energy into the pressure energy
while being supplied to the cylinder improving the volume efficiency. Also, the exhaust efficiency
improves as the exhaust turbine rotates. The turbocharger is often referred to as the exhaust
turbine turbocharger.
1) Overview
Diffuser: With the meaning of spreading out it is a device that transforms fluid's speed energy into
the pressure energy by enlarging the fluid's passage to slow down the flow.
The E-VGT system installed to the D20DTR engine variably controls the passages of the turbine
housing to regulate the flow rate of the exhaust gas. The actuator of E-VGT is a DC motor
actuator (E-Actuator) which controls more quickly and precisely than the previous vacuum type
actuator.
The engine ECU controls the E-Actuator electronically as follows:
At low speed: Narrows the flow passage for the exhaust gas, resulting in increasing the
flow speed of the exhaust gas and running the turbine quickly and powerfully.
At high speed: Expands the flow passage for the exhaust gas, resulting in increasing the
mass flow of the exhaust gas and running the turbine more powerfully. -
-

13-31793-00
1. SPECIFICATION
Item Specification
E-EGR valveMotorEGR response time 50 ms
Driven by DC motor
Valve EGR gas flow rate 120 kg/h
Cooling capacity 8.3 kW or more
Cooling fin type Wavy fin
Cooler type U-shaped
E-EGR bypass valve Solenoid valve Drivien byVacuum
(Solenoid valve)
E-EGR cooler

15-12
c. Main Injection
The power of the vehicle is determined by the main fuel injection volume.
Main injection calculates the fuel volume based on pilot injection. The calculation uses the value
for accelerator pedal position, engine rpm, coolant temperature, intake air temperature, boost
pressure, boost temperature and atmospheric pressure etc.
d. Post Injection
Injection after main injection. Consists of After injection, Post 1, Post 2 injection.
Post injection reduces PM and smoke from exhaust gas. No actual output is generated during
these injections, instead, fuel is injected to the unburned gas after main injection to enable fuel
activation. The PM amount in the emission and smoke can be reduced through these processes.
Only up to 5 types of injections can be performed within 1 cycle. If these 7 injections are all
performed, fuel economy and emission performance becomes poor.

01-91113-01
4. DIAGNOSTIC INFORMATION AND PROCEDURE
1) Oil Leak Diagnosis
Most fluid oil leaks are easily located and repaired by visually finding the leak and replacing or
repairing the necessary parts. On some occasions a fluid leak may be difficult to locate or repair.
The following procedures may help you in locating and repairing most leaks.
Finding the Leak ▶
Identify the fluid. Determine whether it is engine oil, automatic transmission fluid, power
steering fluid, etc.
Identify where the fluid is leaking from. -
-
After running the vehicle at normal operating temperature, park the vehicle over a large
sheet of paper.
Wait a few minutes.
You should be able to find the approximate location of the leak by the drippings on the
paper. ·
·
·
Visually check around the suspected component.
Check around all the gasket mating surfaces for leaks. A mirror is useful for finding leaks
in areas that are hard to reach.
If the leak still cannot be found, it may be necessary to clean the suspected area with a
degreaser, steam or spray solvent. -
-
Clean the area well.
Dry the area.
Operate the vehicle for several miles at normal operating temperature and varying
speeds.
After operating the vehicle, visually check the suspected component.
If you still cannot locate the leak, try using the powder or black light and dye method. ·
·
·
·
·
Clean the suspected area.
Apply an aerosol-type powder (such as foot powder) to the suspected area.
Operate the vehicle under normal operating conditoins.
Visually inspect the suspected component. You should be able to trace the leak path over
the white powder surface to the source. -
-
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- Powder Method ▶

03-4
1. DESCRIPTION AND OPERATION
1) Exhaust System
When you are inspecting or replacing exhaust system components, make sure there is adequate
clearance from all points on the underbody to avoid possible
overheating of the floor panel and possible damage to the passenger compartment insulation
and trim materials.
Check the complete exhaust system and the nearby body areas and trunk lid for broken,
damaged, missing or mispositioned parts, open seams, holes, loose connections, or other
deterioration which could permit exhaust fumes to seep into the trunk may be an indication of a
problem in one of these areas. Any defects should be corrected immediately.
2) Catalytic Converter (Gasoline Engine)
When jacking or lifting the vehicle from the body side rails, be certain that the lift pads do not
contact the catalytic converter, as this could damage the catalytic converter.
Use of anything other than unleaded fuel will damage the catalyst in the catalytic converter. 1.
2.
Catalytic Converter Structure ▶
The Catalytic converter of monolith type consists
of 2 walled metal bodies which is made of
Cordierite. The principal element of converter
consists of the materials like Alumina or oxidized
Serume in order to apply to Ceramic Monolith.
Washer coat operates first, and catalytic metal
elements (Pt, Pd, Rh) operates to washer coat
next.
Monolith type is lighter than other types, easy to
manufacture and quickly approaches to proper
temperature. Washer coat is used to make a
contact surface with exhaust gas bigger by
adhering closely to small holes
of inner layer. If a lead compound or phosphorus
adheres to the surface and the temperature rises,
its surface is decreased. The total area of general
monolith converter is about 45, 000~500,000ft3.
(10 times of a football field) Generally
Alumina
(AL2 O3) is used as a raw materialand its 7
phases of gamma, delta, theta have big areas and
high stability for the temperature, and nowadays
gamma Alumina is used usually.

08-34411-01
1. SPECIFICATIONS
2. WHEEL ALIGNMENT
Description Specification
Front SuspensionSuspension typeDouble wishbone
Spring typeCoil spring
Shock absorber typeReciprocating cylindrical type (gas type)
Stabilizer bar typeTorsion bar type
Rear SuspensionSuspension type5-link type
Spring typeCoil spring
Shock absorber typeReciprocating cylindrical type (gas type)
Stabilizer bar typeTorsion bar type
Front
Wheel
AlignmentToe-in2 ± 2 mm [0~4mm]
CamberLH-0.19° ± 0.25°
RH-0.29° ± 0.25°
CasterLH4.4° ± 0.4°
RH4.5° ± 0.4°

02-58810-01
3. GENERAL WARNINGS
Do not diagnose the circuit with a circuit tester or attempt to modify any air bag components
including the steering wheel, air bag mounting area and harness.
Incorrect inspection could cause a problem with an air bag and seat belt pretensioner, and
they cannot protect occupants properly. Inspection and repair service should be done only by
a qualified technician.
An infant or a child should not be seated on the front seat alone or on an adult's lap. An infant
or a child could be severely injured by air bag deployed.
A child restraint system should be placed on the rear seat which has the 3-point type seat belt.
Never install a child restraint system on the front seat. Impact by the air bag inflation might
cause severe injury or even death.
When an occupant fastens the seat belt with unstable or inclined posture, the air bag cannot
protect the occupant properly. Moreover, the occupant may be injured by the air bag.
Do not incline toward the steering wheel while driving. If you hit the air bag before it is fully
inflated, brain or neck injury, or even death can occur.
Be careful not to strike the steering wheel, air bag mounting area, any air bag related
component (including wiring) and seat belt pretensioner. You might get severely injured by
sudden deployment of the air bag.
The air bag contains explosive materials, so handle it carefully when disposing or replacing it.
The air bag components will be very hot immediately after deployment. Do not touch them until
they cool down.
Once the air bag/seat belt pretentioner is triggered, it will not deploy again even if an additional
impact is applied to it. Once triggered air bag/seat belt pretensioner related components
cannot be reused, so they should be removed from the vehicle and the whole system should
be replaced with a new one.
Do not place any object or sticker on the air bag mounting area for correct and safe activation
of the air bag.
Do not bang the door. Otherwise, an air bag might operate erroneously.
Hold the outer rim of the steering so that the air bag can inflate without any hindrance.
Do not incline toward the steering wheel or hold the steering wheel with your hands crossed. It
will cause a problem with the air bag activation or severe injury when the air bag inflates.
Never put your hands or feet on the dash board. You can severely injured when the air bag
inflates.
It is normal that a loud noise, dust and smoke occur when the air bag and seat belt
pretensioner operate.
The gas come out of air bag/seat belt pretensioner activation is non-toxic nitrogen gas.
However, if this gas occurs irritation to your skin, eyes, nose, and so on, wash it out with clean
water. Seek medical help if symptoms develop. -
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