SSANGYONG NEW ACTYON SPORTS 2013 Manual PDF

02-40
(3) Functions
Piston transfers the combustion energy from engine to connecting rod. Es\
pecially in the direct injection
engine such as D20DTR, it provides the combustion space and largely effects to the engine performance
and exhaust gas.
Piston ring
#1 ring (Top ring) : Prevents the high pressurized combustion gas from leaking into crank chamber,
and prevents the engine oil getting into combustion chamber.
#2 ring: Scrapes the engine oil on the cylinder bore, and prevents the leaked combustion gas from #1
ring from leaking into the crank chamber.
Oil ring: Scrapes the engine oil on the cylinder bore.
Piston pin
Connects the piston the connecting rod, and transfers the linear movemen\
t of piston to connecting rod
to convert it to rotating energy
Snap ring
Locks the piston pin.
▶
-
-
-
▶ -
▶ -
(4) Assembling the piston
Install the piston rings with the "Y" mark on the
ring facing upwards.
Position the end gap of #1 ring at 180˚
away from the end gap of #1 ring.
Position the end gap of oil ring at 180˚
away from the end gap of coil spring, and
position the end gap of oil ring at 90˚ away
from the end gap of #2 ring.
1.
2.
3.

02-410000-00
EnginePiston Cylinder bore
Part NO Marking NO. -
D20DTR 671 030 06 17
- -
671 037 07 01 A A
671 037 08 01 X X
671 037 09 01 B B
671 037 10 01 +5 -
671 037 11 01 +10 -
Selecting piston oversize
Top of piston Top of cylinder block

02-42
2) Connecting Rod
(1) Overview
Connecting rod converts the reciprocating movement of piston to the rotating movement of crankshaft.
The big end is connected to connecting rod bearing and the crank pin journal, and the small end is
connected to the piston pin.
(2) Components
Piston pin bush
Connecting rod
Connecting lower bearing
Connecting rod cap
Connecting rod cap bolt
Connecting rod upper bearing

02-430000-00
NoConnecting
rod/ Bore
diameter in
big endUpper bearing Lower bearing
Journal
diameter of
crank pinOil
clearance of
bearing
GradeBearing
thicknessGradeBearing
thickness
1
54.600 R 1.804
B 1.812
50.935 0.017
1.808 1.815 0.063
2
Y 1.808
Y 1.809 0.016
54.614 1.812 1.812
50.960 0.062
3
B 1.812
R 1.806 0.015
1.816 1.809 0.061
Min. 0.015
Max. 0.063
(3) Selection of crankshaft pin journal bearing
The connecting rod bearing contains 3 sets of 3 grades in upper and lower sections.
Three sets in the table below have nearly same oil clearance (0.015~0.063 mm) of bearing.
Identification: Coloe mark on bearing side surface -
-
-
Oil clearance of connecting rod bearing

02-44
3) Crankshaft
(1) Overview
Crankshaft is installed on the cylinder block.
(2) Arrangement
Crankshaft main bearing upperCrankshaft main bearing upper
Upper thrust bearing
Crankshaft main bearing lowerCrankshaft main bearing lower
Lower thrust bearing
Crank pin journalMain journal

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Selection of bearing according to pin punch &
color
Mark Color Thickness of main
bearing
* Blue 66.500~66.506
** Yellow 66.506~66.513
*** Red 66.513~66.519
(3) Selection of crankshaft main bearing
Mark Color Thickness of main
bearing (mm)
V Violet +0.030
+0.025
W White +0.025
+0.020
R Red +0.020
+0.015
Y Yellow +0.015
+0.010
B Blue +0.010
+0.005
2.25
2.25
2.25
2.25
2.25
Bottom of cylinder block
Selection of upper main bearing
Mating surface of crankshaft sprocket
Selection of lower main bearing

02-46
4) Cylinder Block
(1) Overview
The major dimensions in D20DTR are similar to
D20DTR engine. It has two mounting
bosses for knock sensor and meets the
requirements for EURO5 regulation.
(2) Layout
Right sideSpring pin
Expansion plug
Screw plug

02-470000-00
Left sideExpansion plug
(3) Features
For simple manufacturing, the crankcase blow-
by gas passage and the oil return hole are made
by casting on the cylinder block.

02-48
The bottom side of water jacket is desgined as sine wave to strengthen the structure of crankcase. The
main flow of coolant starts from outlet port of water pump and goes along the longitudinal direction of
engine. The coolant passage from cylinder head to inlet port of water pump is integrated in cylinder head.
The engine oil from oil pump is supplied to the main oil gallery through oil channel, oil filter module and
cross bore in cylinder block without using external pipes. This oil is supplied to main bearing, cylinder
head and MBU. And, it is sprayed to the chain through the chain tensioner connected to cross bore.
Crankcase cross bore for oil supply
Water jacket core

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
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
Change interval EU every 40,000 km
GEN every 45,000 km
Water separation
intervalEU every 20,000 km
GEN every 15,000 km