power steering SSANGYONG NEW ACTYON SPORTS 2012 Service Manual

02-70000-00
1719-09 Acoustic cover
Changed the design1543-01 Steering pump assembly
Introduced reservoir integrated tpe steering
pump
D20DTR (Actyon Sports)
OldNew
OldNew
OldNew
Power steering pump
Old
New
1533-30 Coolant outlet pipe
OldNew
Coolant temperature sensor hole
EGR cooler
outlet
Coolant temperature sensor hole
EGR cooler outletCoolant outlet pipe
1520-21 Coolant outlet port
Changed the location of coolant
temperature sensor and deleted the
coolant outlet port from turbocharger
1793-23 EGR cooler & coolant outlet
hose

01-4
2. MAJOR COMPONENTS
Front view ▶
Vacuum pump
Oil filter assembly
Camshaft position sensor
Power steering pump pulley
Water pump pulley
Alternator pulley
Idler pulley No. 2
A/C compressor pulley
Auto tensioner
Idler pulley No. 1
Isolation damper
Rear view ▶
E-EGR valve
Fuel temperature sensor
Fuel HP pump assembly
Coolant temperature sensor
IMV valve Crankshaft position sensor
Oil pressure switch

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. -
-
-
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

02-6
Component SizeBolt
QuantitySpecified torque
(Nm)Remark
(Total torque)
Glow plug M5 4 20±2Nm -
Vacuum pumpM8×25 3 10±1Nm -
Timing gear case coverM12×55 3 85±8.5Nm -
M6×25 7 10±1Nm -
M6×45 1 10±1Nm -
M6×50 3 10±1Nm -
Cylinder head coverM6×35 21 10±1Nm -
Oil gauge tubeM6×16 1 10±1Nm -
Oil filter cap 1 25±2.5Nm -
Fuel railM8×35SOC 2 25±2.5Nm -
Injector clamp boltM6×60 2 10±1Nm,
120˚+10˚ -
High pressure pipe
(between HP pump and
fuel rail)M17 1 30±3Nm -
High pressure pipe
(between fuel rail and
injector)M17 4 30±3Nm -
Crank position sensorM5×14 1 8±0.4Nm -
Main wiringM6×16 5 10±1Nm -
Intake duct M8x25 4 25±2.5Nm -
Power steering pumpM8×100 3 25±2.5Nm -
Cylinder head front
coverM6×10 5 10±1Nm -
Ladder frameM8×16 5 30±3Nm -
Oil pumpM8×35 3 25±2.5Nm
-

02-130000-00
D20DTR Engine
1. BELT LAYOUT
It is single drive type and uses FEAD (Front End Accessories Drive) design to make a compact
layout.
Components ▶
HPS (Hydraulic Power Steering)
1 Crankshaft pulley (DDU)
2 Auto tensioner
3 Tensioner pulley
4 Vacuum pump
5 A/C compressor pulley
6 Alternator pulley
7 Water pump pulley
8 Idle pulley #1
9 Idle pulley #2
10 Power steering pump pulley

15-170000-00
C. Idle Speed Controller
The idle speed controller consists of 2 principal modules:
The first module determines the required idle speed according to:
* The operating conditions of the engine (coolant temperature, gear engaged)
* Any activation of the electrical consumers (power steering, air conditioning, others)
* The battery voltage
* The presence of any faults liable to interface with the rail pressure control or the injection
control. In this case, increase the idle speed to prevent the engine from stalling.
The second module is responsible for providing closed loop control of the engine's idle speed
by adapting the minimum fuel according to the difference between the required idle speed and
the engine speed. -
-
D. Flow Limitation
The flow limitation strategy is based on the following strategies:
The flow limitation depending on the filling of the engine with air is determined according to
the engine speed and the air flow. This limitation allows smoke emissions to be reduced
during stabilized running.
The flow limitation depending on the atmospheric pressure is determined according to the
engine speed and the atmospheric pressure. It allows smoke emissions to be reduced
when driving at altitude.
The full load flow curve is determined according to the gear engaged and the engine
speed. It allows the maximum torque delivered by the engine to be limited.
A performance limitation is introduced if faults liable to upset the rail pressure control or the
injection control are detected by the system. In this case, and depending on the gravity of
the fault, the system activates: -
-
-
-
Reduced fuel logic 1: Guarantees 75 % of the performance without limiting the engine speed.
Reduced fuel logic 2: Guarantees 50 % of the performance with the engine speed limited to
3,000 rpm.
Reduce fuel logic 3: Limits the engine speed to 2,000 rpm.
The system chooses the lowest of all values.
A correction depending on the coolant temperature is added to the flow limitation. This correction
makes it possible to reduce the mechanical stresses while the engine is warming up.
The correction is determined according to the coolant temperature, the engine speed and the
time which has passed since starting.
E. Superchager Flow Demand
The supercharge flow is calculated according to the engine speed and the coolant temperature. A
correction depending on the air temperature and the atmospheric pressure is made in order to
increase the supercharge flow during cold starts. It is possible to alter the supercharge flow value
by adding a flow offset with the aid of the diagnostic tool

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. -
-
-
- Powder Method ▶

08-8
5. TROUBLESHOOTING
Problem Cause Action
Vehicle rollingBroken stabilizer bar Replace
Faulty shock absorber Replace
Abnormal noise.Loosening mounting Retighten
Damaged or worn wheel bearing Replace
Damaged shock absorber Replace
Damaged tire Replace
Poor ridingOver inflated tire Adjust pressure
Faulty shock absorber Replace
Loosened wheel nut Tighten as specified torque
Bent or broken coil spring Replace
Damaged tire Replace
Worn bushing Replace
Vehicle pulls to one sideDeformed arm assembly Replace
Worn bushing Replace
Bent or broken coil spring Replace
Hard steeringExcessive resistance of lower arm
ball jointReplace
Insufficient tire pressure Replace
Faulty power steering Replace
Unstable steering
Worn or loosened lower arm
bushingRetighten or replace
Vehicle bottoming
Worn or broken coil spring Replace
Vehicle height loweredOver loaded on the vehicle -
Defective shock absorber Replace
Defective coil spring Replace

10-6
1. SYSTEM OVERVIEW
1) What is ABS?
When braking suddenly or braking on slippery roads, the vehicle keeps moving forward but the
wheels are locking and not rotating. If these happen, the vehicle may lose stability or rotate
resulting in an accident. ABS helps to maintain directional stability and control of the vehicle. ABS
is designed to secure more safety and increase the control of steering wheel during emergency
braking situation. But, ABS does not guarantee perfect safety beyond its physical limit. ABS in
this vehicle contains EBD function. In normal driving conditions, the brake system operates
without ABS function.
2) What is EBD (Electronic Brake-force Distribution)?
EBD is an automobile brake technology that automatically varies the amount of force applied to
each of a vehicle's brakes, based on road conditions, speed, loading, etc. Always coupled with
anti-lock braking systems, EBD can apply more or less braking pressure to each wheel in order to
maximize stopping power whilst maintaining vehicular control. EBD does not operate when ABS is
working.
ABS effect according to braking conditions ▶
Braking on split road Maneuvering while braking

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.