SSANGYONG NEW ACTYON SPORTS 2013 Workshop Manual

02-20
1) Functions
Appearance Type and function
Front mounting insulator (Right side) Type: Rubber mounting
Function: Supports the torque reaction
Front mounting insulator (Left side) Type: Rubber mounting
Function: Supports the torque reaction
Rear mounting insulato Type: Rubber mounting
Function: Supports the powertrain rod

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Intake manifold
4. INTAKE/EXHAUST MANIFOLD
1) Intake Manifold
Intake manifold is installed on the cylinder head with 8 bolts. The variable swirl valve is introduced to
improve the EGR gas mixture and turbulence in combustion chamber and to decrease the exhaust gas.
2) Exhaust Manifold
Exhaust manifold is installed on the cylinder head with 10 stud bolts and nuts. EGR port is integrated in
cylinder head.Components ▶
Components ▶For detailes, refer to Chapter "Intake System". *
Exhaust manifold
For detailes, refer to Chapter "Exhaust System". *

02-22
Rear view
5. CYLINDER HEAD COVER AND OIL SEPARATOR
The cylinder head cover is made by high strength plastic to reduce the weight. The multi twist type oil
separator improves the oil consumption.
Components ▶
1) Cylinder Head Cover
Front view
Cylinder head cover

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2) Oil Separator
Oil separator separates the particle in blow-by gas to minimize the engine oil consumption and reduces
the inflow oil from intake system into the combustion chamber. The separated oil returns to oil pan
through cylinder head.
Oil separator
Blow-by outlet hose
(1) Overview
(2) Layout

02-24
Intake/exhaust CamshaftsFinger follower & HLACamshaft sprocket
Cylinder head gasket
Vacuum pump driveHP pump drive gearCamshaft position sensor
Components ▶
Cylinder head
Cylinder head contains cam position sensor, vacuum pump, intake manifold, exhaust manifold and valve
assembly. Vacuum pump and the high pressure (HP) pump are driven by Camshaft and valves are install
in vertical direction. This enables the compact layout in cylinder head assembly.
6. CYLINDER HEAD

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Location of Expansion Plugs
1) Cylinder Head
(1) Overview
The cylinder is made by gravity casting and the water jacket is integrated type.
The cylinder oil passage is drilled and sealed by cap.
The Camshaft bearing cap is also made by casting and installed on the cylinder head.
(2) Features
FrontRear
Coolant expansion plug (M21)
Oil gallery expansion plug (M10)
Intake side

02-26
Intake/Exhaust Camshafts
2) Camshaft
(1) Overview
Hollow type camshaft contains cam, octagon cam, HP pump gear and intake/\
exhaust gears.
Camshaft operates the intake/exhaust valves, vacuum pump and HP pump, an\
d transfers the engine
oil to vacuum pump through the internal oil passage.
(2) Location
Exhaust CamshaftHP Pump Gear
Octagon cam
(for tooling)
Thrust journal
Connected to
vacuum pumpIntake Camshaft
Cross flow type water jacket (improving cooling performance)
▶

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3) Valve Assembly (Installed in Cylinder Head)
(1) Features
Automatic valve clearance adjuster by hydraulic pressure (Maintenance Free) - Hydraulic lash
Optimized adjustment of valve clearance reduces the valve noise.
Roller type finger follower reduces the friction loss.
Vertical installation.
Simple and compact design reduces the moving operation (improving valve following and fuel
consumption at high speed) 1.
2.
3.
4.
5.
(2) Arrangement
Hydraulic lash adjuster
Upper valve spring retainer
Lower valve spring retainer
Valve spring
Exhaust valveIntake valve
Finger follower

02-28
Thickness markingEx: 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

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(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 f\
or better NVH.
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 ty pe. Upper chain drives HP pump connected to intake
Camshaft by driving exhaust camshaft sprocket, and lowe r chain drives oil pump to lubricate the engine.
25±2.5Nm