water pump 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

01-90000-00
(3) Cautions before service
Prolonged exposure to the engine oil make cause a skin cancer or an irritation.
Used engine cotains the hazardous material that may cause the skin cancer. Do not allow the used
engine to make contact with your skin.
Make sure to wear the protection gloves and goggle when handling the engine oil. If contact happens,
rinse affected areas immediately with plenty of water. Do not wash it with gasoline or solvent. If
irritation persists, consult a doctor.
Improperly disposed engine oil can pollute the environment. Dispose used engine oil in accordance
with local environmental regulations. -
-
-
(5) Tightening the fastener
If fine dust or foreign material enters into DI engine's fuel system, there can be serious damages
between HP pump and injectors. So, be sure to cover removed fuel system components with cap
and protect removed parts not to be contaminated with dirt. (Refer to cleanness in this manual
while working on DI engine fuel system)
When working on the fuel line between priming pump and injector (including return line), always
plug the openings with caps to prevent foreign materials or dust from entering to the openings and
connections.
The HP fuel supply pipe (HP pump to fuel rail) and HP fuel pipe (Fuel rail to injector)
should be replaced with new ones when removed. 1.
2.
3. Scalding hot coolant and steam could be blown out under pressure, which could cause serious injury.
Never remove the coolant reservoir cap when the engine and radiator are hot.
(4) Lubrication system
3) Fuel and Oil System
If work on the fluid system such as fuel and oil, working area should be well ventilated and smoking
should be prohibited.
Gasket or seal on the fuel/lubrication system should be replaced with new ones and bolts and nuts
should be tightened as specified. -
-Clean the mating surfaces before tightening.
Place the marks with paint to tighten by angle if the angle wrench is not available. -
-

01-110000-00
6. TIGHTENING TORQUE
NameSizeNumbers of
fastener Tightening
torque (Nm) Note (total
tightening torque)
Main bearing cap M12×82 10 55±5Nm,
180˚ Not-reusable
Connecting rod cap M9×52 8 40±5Nm,
90˚+10˚ 50 ~80Nm
Crankshaft rear seal M6×20 6 10±1Nm -
Oil pump M8×35 3 25±2.5Nm -
Drive plate M10×22 8 45±5Nm,
90˚+10˚ Not-reusable
Isolation damper center bolt M18×50
1 200±20Nm,
180˚+20˚ 660 ~ 720Nm
Not-reusable
Oil pan M6×20 18 10±1Nm -
M6×35 2 10±1Nm -
M6×85 2 10±1Nm -
M6×120 2 10±1Nm -
M8×40 2 25±2.5Nm -
Mounting nut for high pressure pump M14×1.5-8-1
1 65±5Nm -
Mounting bolt for high pressure pump M8×30
3 25±2.5Nm -
Cylinder head M13×150 12 85Nm
270°±10° -
Camshaft cap M6×30 16 10±1Nm -
M8×60 4 25±2.5Nm -
Exhaust stud bolt 10 15±1.5Nm -
Exhaust sprocket M8x16.5 1 25±2.5Nm -
Chain tensioner screw plug M8x1.5
1 25±2.5Nm -
Coolant temperature sensor 1
20±2.0Nm -
Belt auto tensioner M8×30(LOW) 1 25±2.5Nm -
M10×75(U
pper) 1 55±5.5Nm -
Water pump M6×25 7 10±1.0Nm -

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

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)
▶

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

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.

03-232210-01
Accelerator pedal position
sensor
Detecting driver's intention
for speed up/down
Fuel rail assembly
Relieving the pulsation.
Measuring the fuel pressure.
Distributing the fuel to injectors.
Fuel filter assembly
Supplying clean fuel/fuel
heating/water separation by
priming pump
Plunger type HP pump (1,800 bar)
Vane type LP pump (6 bar)
T-MAP sensor
Measuring booster pressure
and temperature
High pressure pump
Generating high pressurized fuel and
supplying it according to engine rpm,
required volume, required pressure

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