heater SSANGYONG NEW ACTYON SPORTS 2012 Service Manual

6) F52 ~ F55, BURGLAR HORN RELAY, FUEL HEATER RELAY 5) F50 ~ F51, HEAD LAMP RELAY (HI), RR FOG LAMP RELAY

3
4
5
8
11
1461-00/2820-00/1491-00/8210-00/3110-00/3410-00/4892-00/8810-00/8010-00/7410-100/8510-00/8710-00/8510-00/8610-00/
8730-00/7340-00/7632-00/8310-00/8610-00/8510-00/8320-00/8410-00/8210-00/8310-00/4810-00/7770-00/8910-00/8790-00/6810-00
ENGINE1461-00 STARTING / CHARGING.................
1413-00 GLOW CONTROL UNIT...................
1491-00 ECU (ENGINE CONTROL
UNIT - D20DTR EU-V).....................
1490-00 ECU (ENGINE CONTROL
UNIT - GSL G23)............................
8210-00 DIAGNOSIS CIRCUIT.....................CHASSIS3110-00 TCU (6-A/T)...................................
3410-00 TCCU............................................
4892-00 ABS/ESP........................................8730-00 IMMOBILIZER CIRCUIT................
7340-00 SUNROOF CIRCUIT.......................
7632-00 CIGAR LIGHTER / POWER
OUTLET CIRCUIT........................
8310-00 HEAD LAMP CIRCUIT..................
8610-00 DRL (DAY TIME RUNNING
LIGHT) UNIT CIRCUIT.................
8510-00 HLLD (HEAD LAMP LEVEL G
DEVICE) CIRCUIT.........................
8320-00 TAIL LAMP CIRCUIT....................
8410-00 TURN SIGNAL / HAZARD
LAMP CIRCUIT.............................
8210-00 TRAILER LAMP CIRCUIT.............
8310-00 FOG LAMP CIRCUIT.....................
4810-00 STOP / BACK-UP
LAMP CIRCUIT.............................
7770-00 INTERIOR LAMP CIRCUIT............
7770-00 AUTO DIMMING ROOM
MIRROR CIRCUT.........................
8910-00 AUDIO / CLOCK CIRCUIT..............
8790-00 PARKING AID CIRCUIT..................
6810-00 PTC HEATER (POSITIVE
TEMPERATURE COEFFICIENT).....
6810-00 FATC (FULL AUTO TEMP.
CONTROL) CIRCUIT....................
6810-00 AIR-CON (MANUAL) CIRCUIT......... 12
14
1533
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
52
'
ELECTRIC8810-00 AIR-BAG.......................................
8010-00 CLUSTER......................................
7410-00 POWER SEAT - DRIVER................
7410-00 POWER SEAT - PASSENGER.......
8510-00 ELECTRIC OUTSIDE MIRROR........
8510-00 SEAT WARMER.............................
8710-00 STICS.............................................
8510-00 POWER WINDOW CIRCUIT...........
8610-00 HORN............................................17
18
20
21
22
23
24
31
32

01-110000-00
6. CODING AND INITIALIZATION
1) Engine Variant Coding
Unit Selection Description Remarks
PTC auxilary heater NO For PTC auxilary heater
equipped vehicle, select
"YES".-
YES YES
Glow plug Relay (K-line) Select "AQGS". -
AQGS (CAN) AQGS (CAN)
Transmission 6-speed M/T "DSI 6 AT" is selected
automatically.Select
5-speed A/T (DC 5 AT) -
6-speed A/T (DSI 6 AT) Select
Pressure sensor for
A/C refrigerantNO Select the appropriate
system.-
Type Pressure
sensor for A/C
refrigerant
Immobilizer NO Select "YES" if the vehicle
has immobilizer.-
YES YES
Vehicle speed input
typeCAN Select "CAN" if the vehicle
has ABS or ESPCAN
WIRE -
Fan 2 relays Select "PWM". -
PWM fan PWM fan
Auto cruise NO Select "YES" if the vehicle
has cruise contro.-
YES YES
G-sensor NO 2WD ABS & Non-ABS: NO
4WD ABS & ESP: YESSelect
YES Select

03-32210-01
1. SPECIFICATION
Description Specification
Fuel Diesel
Fuel filterType Fuel heater + priming pump + water
separator integrated type
Filter type Changeable filter element type
Change interval every 50,000 km
Water separation interval every 15,000 km
Water accumulating capacity 200 cc
Heater capacity 250W 13.5V
Injector System pressure 1800 bar
High pressure fuel
pumpType Eccentric cam/Plunger type
Operating type Gear driven type
Normal operating temperature-40 ~ 125˚C
Operating pressure 1800 bar
Operating temperature-30 ~ 120˚C
Low pressure fuel
pumpType Vane type
Gear ratio (pump/engine) 0.5 : 1
Pressure 6 bar
Fuel tankCapacity 75 L
Material Steel
Fuel sender Single sender type

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.

03-24
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.

08-4
2. INSPECTION
Problem Possible Cause Action
Coolant level is
too low- Leak from the radiator
- Leak from the coolant auxiliary tank
- Leak from the heater core- Change the radiator
- Change the coolant auxiliary tank
- Change the heater
- Leak from the coolant hose
connections
- Damaged coolant hose- Reconnect the hose or replace
the clamp
- Change the hose
- Leak from the water pump gasket
- Leak from the water pump internal
seal- Change the gasket
- Change the water pump
- Leak from the water inlet cap
- Leak from the thermostat housing- Change the water inlet cap
gasket
- Change the thermostat sealing
- Incorrect tightening torque of the
cylinder head bolts
- Damaged cylinder head gasket- Tighten the bolts to the specified
torque
- Change the cylinder head gasket
Coolant
temperature is
too high- Coolant leakage (Coolant level is low)
- Improper coolant mixture ratio
- Kinked coolant hose- Add coolant
- Check the coolant concentration
(Anti-freeze)
- Repair or replace the hose
- Defective thermostat
- Defective water pump
- Defective radiator
- Defective coolant auxiliary tank or
tank cap- Change the thermostat
- Change the water pump
- Change the radiator
- Change the coolant auxiliary tank
or tank cap
- Cracks on the cylinder block or
cylinder head
- Clogged coolant passages in the
cylinder block or cylinder head- Change cylinder block or cylinder
head
- Clean the coolant passage
- Clogged radiator core - Clean the radiator core
- Improper operation of cooling fan - Replace the cooling fan or repair
the related circuit
- Defective temperature sensor or
faulty wiring- Replace the sensor or repair the
related wiring
Coolant
temperature is
too low- Thermostat is stuck open - Change the thermostat
- Improper operation of cooling fan - Replace the cooling fan or repair
the related circuit
- Defective temperature sensor or
faulty wiring- Replace the sensor or repair the
related wiring

10-4
Glow plug control unit
(GCU)
1. OVERVIEW
The pre-heating system for D20DTR engine has the glow plug to the cylinder head (combustion
chamber), and improves the cold start performance and reduces the emission level.
The pre-heating resistor (air heater) is used to heat the intake air.
This enables the diesel fuel to be ignited in low temperature condition.
The ECU receives the information such as, engine rpm, coolant temperature, engine torque, etc.,
through CAN communication during pre-heating process; and the pre-heating control unit
controls the pre-heating, heating during cranking and post-heating by the PWM control.
Glow plug
Glow indicatorEngine ECU (D20DTR)

15-8
(3) Components for ECU Output
CAN
E-EGR cooler
bypass valve
- Instrument cluster
- TCU
- Self diagnosis
PTC heaterCooling fan
E-EGR valve
Variable swirl valveE-VGT actuatorIMV valve
A/C compressorInjectorThrottle position
sensor
- Glow plug unit
- ABS & ESP unit
- GCU

15-40
Relay box in engine compartment
(13) High speed
A. Overview
The supplementary electrical heater is installed in DI engine equipped vehicle as a basic
equipment. The PTC system is operated according to two temperature values measured at the
coolant temperature sensor and HFM sensor. This device is mounted in the heater air outlet and
increase the temperature of air to the passenger compartment. Because PTC system is heated by
electrical power, high capacity alternator is required. PTC does not operate during engine
cranking, while the battery voltage is lower than 11 V or during preheating process of glow plugs.
B. Components
HFM (intake air
temperature)
Coolant temperature
sensorPTC heater
PTC 2 relay (PTC
heater 2, 3)
PTC heater
3 (40A)
PTC heater
2 (40A)
PTC heater
1 (40A)
D20DTR ECU
PTC 1 relay
(PTC heater 1)