alternator SSANGYONG NEW ACTYON SPORTS 2013 Service Manual

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

01-12
T/C oil supply pipeM161 25±2.5Nm
(Fitting Screw) -
M10 1 17±2.0Nm
(Hollow Bolt) -
T/C oil return pipe M6×16(to block) 2 10±1Nm -
M6×16
(to turbocharger) 2
10±1Nm -
EGR valve M8×303 25±2.5Nm -
Name SizeNumbers of
fastener Tightening
torque (Nm) Note (total
tightening torque)
Hot water inlet pipe M6×12210±1Nm -
Alternator M10×901(LO) 25±2.5Nm -
M10×116 1(HI) 46±4.6Nm -
Air conditioner compressor M8×85
425Nm -
Air conditioner bracket M6×25410±1Nm -
Intake manifold M8×35225±2.5Nm -
M8×110 625±2.5Nm -
Oil filter module M8×40625±2.5Nm -
M8×80 125±2.5Nm -
M8×140 225±2.5Nm -
Knock sensor M8×28220±5Nm -
Camshaft position sensor M8×14
110~14Nm -
T-MAP pressure sensor M6×20
110±1Nm -
Exhaust manifold M81040±4Nm -
Turbocharger M8325±2.5Nm -
T/C support bolt M8 x 35125±2.5Nm
(Turbo Side) -
M8 x 16 125±2.5Nm
(Block Side) -

02-50000-00
ComponentSizeBolt
Quantity Specified torque
(Nm) Remark
(Total torque)
Hot water inlet pipe M6×16 2 10±1Nm -
Alternator M10×90 1 25±2.5Nm -
M10×116 1 46±4.6Nm -
A/C bracket M8×25 4 7.8~11.8Nm -
A/C sub bracket M6×25 4 10±1Nm -
Intake manifold M8×35 2 25±2.5Nm -
M8×110 6 25±2.5Nm -
Oil filter module M8×40 6 25±2.5Nm -
M8×20 1 25±2.5Nm -
M8×140 2 25±2.5Nm -
Knock sensor M8×28 2 20±5Nm -
Cam position sensor M8×14 1 10~14Nm -
Booster pressure sensor M6×20 2 10±1Nm -
Exhaust manifold M810 40±4Nm -
Turbocharger M83 25±2.5Nm -
Support nut M81 25±2.5Nm -
T/C oil supply pipe M161 25±2.5Nm
(Fitting Screw) -
M10 1 17±2Nm
(Hollow Bolt) -
T/C oil return pipe M6×16(turbo side) 2 10±1Nm -
M6×16(block side) 2 10±1Nm -
EGR valve M8×30325±2.5Nm -
EGR pipe bolt (Intake side) M6×16
2 10±1Nm -
EGR pipe bolt
(EGR cooler side) M8×25
2 25±2.5Nm -
Support bolt M8×35125±2.5Nm
(Turbo Side) -
M8×16 125±2.5Nm
(Block Side) -

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

09-31451-01
1. SPECIFICATION
AlternatorCrankshaft pulley : Alternator pulley 1 : 2.94
Normal output (idling/2200 rpm) 70/120 A
Regulator voltage 14.6 V
BrushLength 12.5 mm
Wear limit 7 mm
BatteryType MF
Capacity 90 AH
Unit Description Specification

09-4
2. INSPECTION
1) Alternator Output Test
Item How to check DTC set value / Action
Output
current
B terminal
current
Rotor
coil
resistance
L terminal
voltage
Disconnect the cable connected to the B
terminal on the alternator. Connect one end
of the ammeter to the B terminal and the
other end to the cable connected to the B
terminal.
Measure the maximum output value.
(Maintain the engine speed between 2,500
and 3,000 rpm.)
(Turn the headlamp and all the electrical
switches on.) 1.
2.Pass: If the measured current is 45
A or higher.
Fail: If the measured current is less
than 45 A.
Check the current of the B terminal. -
-
-
Move the gear selector lever to the neutral
position.
Maintain the engine speed at 2,500 rpm
with the vehicle unloaded.
(Turn all the electrical switches off.) 1.
2.Open circuit: If the measured
current is 5 A or higher. -
Disconnect the negative cable from the
battery.
Remove the B terminal and turn off the
ignition switch.
Measure the resistance between the L and
F terminals with an ohmmeter. 1.
2.
3.Pass: If the measured resistance is
between 3 and 6 Ω.
Faulty rotor coil or slip ring: If the
measured resistance is less than
3 Ω or greater than 6 Ω. -
-
Connect the B terminal wiring.
Measure the voltage with the engine running. 1.
2.Specification: 12.5 V to 14.5 V
Faulty IC regulator or field coil: If
the measured voltage is 14.5 V or
higher. -
-
Disconnect the negative battery cable.
Connect the negative cable again after connecting the ammeter. -
-

09-51451-01
2) Troubleshooting for Alternator
Item Cause Action
Overcharged batteryDefective alternator voltage regulator
Replace the alternator
Defective voltage detection wiring Repair or replace
Loose alternator drive belt Adjust the belt tension or replace
Discharged batteryPoor connection of related circuit or open
circuitRetighten the loose connection or
repair open circuit
Defective alternator voltage regulator
Replace the alternator
Defective alternator voltage regulator
Replace the alternator
Terminated battery Replace the battery
Defective ground Repair
Charge warning
lamp does not come
on when turning on
ignition switch with
engine stoppedDefective alternator voltage regulator
Replace the alternator
Open circuit in charge warning lamp, fuse
or wiringReplace or repair the charge warning
lamp or fuse
Defective ignition switch Replace the ignition switch
Defective ground of alternator circuit Repair
Charge warning
lamp is not turned
off after starting
engineDefective alternator voltage regulator
Replace the alternator
Corroded or worn battery cableRepair or replace the battery cable
Loose alternator drive belReplace the batteryAdjust the belt
tension or replace the belt
Defective wiring harness Repair or replace

09-71451-01
(1) Checking
Using battery tester ▶
PASS (11.0 V or more): Explain to the customer that the battery is reusable.
Need to be charged (9.0 to 11.0 V): Charge the battery with a charger and reinstall it. Explain it to the
customer.
Need to be replaced (9.0 V or more): The battery should be replaced due to overdischarging. -
-
-
(2) How to use battery tester
How it works and How to use it ▶
Determine battery capacity by fixing current
(load capacity) and time and varying voltage.
Determine battery capacity based on the
amount of voltage drop when discharging a
fixed load capacity (120 A) for 5 seconds.
Connect the tester to the battery and read the
display while applying a load for 5 seconds. -
-
-
How to read display ▶
Red area (①): overdischarge or faulty
battery
Yellow area (②): Need to be charged (using
a vehicle alternator and a battery charger)
Green area (③): Normal
Red area on the left-hand side of OK (④):
Impossible to charge with an alternator
Green area with OK (⑤): Normally charged
Red area on the right-hand side of OK (⑥):
Overcharged by an alternator태 -
-
-
-
-
-

09-10
Alternator
The alternator charges the battery and
supplies power to each electric unit by
converting the mechanical energy to the
electrical energy.
1. SYSTEM DESCRIPTION
1) Overview
The charge system is designed to supply electrical energy to the vehicle while driving, and supplies a
constant direct current voltage by converting mechanical rotational movement to electrical energy.
The voltage regulator on the back of the alternator controls the generated voltage in all rotating ranges
and adjusts the system voltage according to the electric load and ambient temperature change.
2) System Layout (Locations)
Battery
It converts the chemical energy to the
electrical energy and supplies power to the
corresponding electric units when starting the
engine.

09-12
Alternator (140 A)Alternator (120 A)
2) Charging
The alternator uses a new regulator which has three diodes. It consists of the delta stator, rectifier bridge,
slip ring and brush.
Charging time according to vehicle conditions and environment ▶
Specification: Charging a fully depleted high-
capacity battery takes twice or more as long as
charging a fully depleted battery for small
vehicles.
Temperature: The lower the temperature is, the
longer the time taken to charge the battery.
When connecting the battery charger to the cold
battery, the amount of current the battery can
accept initially is very small. As the battery gets
warmer, it can accept more current.
Charging capacity: Charging a battery with a low-capacity charger takes longer time than charging with
a high-capacity charger.
Charging status: Charging a fully depleted battery takes twice or more as long as charging a half-
depleted battery. Since the electrolyte in a fully depleted battery consists of nearly pure water and
conductor, only a very small amount of current can be accepted by the battery initially. The charging
current increases as the amount of acids in the electrolyte is increased by the charging current.
3) Output Characteristics