SSANGYONG NEW REXTON 2012 Service Manual

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

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The strut type tensioner automatically adjusts the belt tension to provide the reliability and durability for
the system. And, the belt tension is decreased to minimize the friction loss and improve the belt
operating noise.
1) Crankshaft Pulley (Isolation Damper)
(1) Overview
(2) Sectional drawing
Axial & radial bearing
Sleeve
Hub
Isolation pulley rubber Pulley
Damper rubber
Inertia ring

(3) Features
Rubber damper: Decrease crankshaft torsion
Improve belt NHV: Reduce unbalance speed to crankshaft due to irregular combustion
Minimize noise: Anti-vibration from crankshaft and belt
Post bonded type rubber damper: Improve durability of rubber damper 1.
2.
3.
4.

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2) Belt Tensioner
(1) Overview
The torque deviation from crankshaft affects the components in belt drive system and the belt
movement. The auto tensioner system is to adjust this deviation automatically.
In D20DTR engine, one of the mechanical tensioner, pivot damped tensioner is used to keep the
damping force, system reliability and durability. The single belt drive system needs to use the automatic
belt tensioning device to transfer the power to pulleys effectively. To get this, the tensioner uses the
spring and damping unit.
(2) Location
Belt tensioner

Brake booster and naster
cylinderVacuum pump
Pump capacity: 210 cc/rev
Camshaft speed: 375 to 3,000 rpm
Lubrication temperature: -40 to
Oil: 5W30
Drive type: Driven by exhaust
Camshaft sprocket
2. VACUUM PUMP
Vacuum pump generates the vacuum pressure and supplies it to EGR cooler bypass solenoid. This
pump is single vane type and displacement is 210 cc/rev. The lubrication oil is supplied through the hole
in hollow shaft.
Components
EGR cooler bypass valve
This valve is controlled by ECU.
When the engine is cooled, the
exhaust gas goes to combustion
chamber without passing through
EGR cooler because the valve is
closed by vacuum pressure.

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1) Location
2) Operation
The vacuum pump is engaged to the exhaust camshaft.
Connection between vacuum
pump and exhaust camshaft
Oil supply and driving
Vacuum pumpExhaust camshaft

Front mounting insulator (Right side)
Location Insulator
3. ENGINE MOUNTING
D20DTR engine uses 3-point mounting type that supports the engine and transmission simultaneously.
Components
Rear mounting insulator
2WD 4WD
A/TM/TA/TM/T
Front mounting insulator (Left side)
Location Insulator

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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

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". *

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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