service SSANGYONG RODIUS 2007 Service Manual

01-7
ENGINE INFORMATION
RODIUS 2006.09
0000-00
2. DESCRIPTION AND OPERATION
1) Cleanliness And Care
An automobile engine is a combination of many machined, honed, polished and lapped
surfaces with tolerances that are measured in the ten-thousanths of an inch. When any internal
engine parts are serviced, care and cleanliness are important. A liberal coating of enigne oil
should be applied to friction areas during assembly, to protect and lubricate the surfaces on
initial operation.
Proper cleaning and protection of machined surfaces and friction areas is part of the repai
r
procedure. This is considered standard shop practice even if not specifically stated.
Whenever valve train components are removed for service, they should be kept in order.
They should be installed in the same locations, and with the same mating surfaces, as when
they were removed. Battery cables should be disconnected before any major work is performed
on the engine. Failure to disconnect cables may result in damage to wire harness or othe
r
electrical parts.
2) On-Engine Service
Disconnect the negative battery cable before removing or installing any electrical unit, or
when a tool or equipment could easily come in contact with exposed electrical terminals.
Disconnecting this cable will help prevent personal injury and damage to the vehicle.
The ignition must also be in LOCK unless otherwise noted.
Notice Any time the air cleaner is removed, the intake opening -
Any time the air cleaner is removed, the intake opening should be covered. This will
protect against accidental entrance of foreign material, which could follow the intake
passage into the cylinder and cause extensive damage when the engine is started.g -

08-5
ENGINE ELECTRIC DEVICES
RODIUS 2006.09
0000-00
1. CHARGING SYSTEM OPERATION
Alternators use a new type of regulator that incorpo-rates a diode trio. A Delta stator, a rectifier
bridge, and a rotor with slip rings and brushes are electrically similar to earlier alternators.
A conventional pulley and fan are used. There is no test hole.
1) CHARGING TIME REQUIRED
The time required to charge a battery will vary depending upon the following factors:
▶ Size of Battery
A Completely discharged large heavy-duty battery required more than twice the
recharging time as a completely discharged small passenger car battery. -
▶ Temperature
A longer time will be needed to charge any battery at -18°C (0°F) than at 27°C
(80°F). When a fast charger is connected to a cold battery, the current accepted
by the battery will be very low at first. The battery will accept a higher current rate as the
battery warms. -
▶ Charger Capacity
A charger which can supply only 5 amperes will require a much longer charging period
than a charger that can supply 30 amperes or more. -
▶ State-of-Charge
A completely discharged battery requires more than twice as much charge as a onehal
f
charged battery. Because the electrolyte is nearly pure water and a poor conductor in a
completely discharged battery, the current accepted by the battery is very low at first.
Later, as the charging current causes the electrolyte acid content to increase, the
charging current will likewise increase. -
2. STARTING SYSTEM OPERATION
The engine electrical system includes the battery, the ignition, the starter, the alternator, and all
the related wiring. Diagnostic tables will aid in troubleshooting system faults. When a fault is
traced to a particular component, refer to that component section of the service manual. The
starting system circuit consists of the battery, the starter motor, the ignition switch, and all the
related electrical wiring. All of these components are connected electrically.

08-6
RODIUS 2006.09
0000-00
ENGINE ELECTRIC DEVICES
3. IGNITION SYSTEM OPERATION
This ignition system does not use a conventional distributor and coil. It uses a crankshaft
position sensor input to the Engine Control Module (ECM).
The ECM then determines Electronic Spark Timing (EST) and triggers the electronic ignition
system ignition coil.
This type of distributorless ignition system uses a “waste spark” method of spark
distribution. Each cylinder is paired with the cylinder that is opposite it (2.3L DOHC: 2 - 3 or 1 -
4, 3.2L DOHC: 1 - 6 or 2 - 5 or 3 - 4).
The spark occurs simultaneously in the cylinder coming up on the compression stroke and in
the cylinder coming up on the exhaust stroke.
The cylinder on the exhaust stroke requires very little of the available energy to fire the spark
plug.
The remaining energy is available to the spark plug in the cylinder on the compression stroke.
These systems use the EST signal from the ECM to control the EST.
The ECM uses the following information: Engine load (mass air flow sensor, manifold ai
r
pressure sensor).
Engine coolant temperature.
Intake air temperature.
Crankshaft position.
Engine speed (rpm).
1) Electronic Ignition System Ignition Coil
The Electronic Ignition (EI) system ignition coil is located on the cylinder head cover.
The double ended coils re ceive the signal for the ECM which controls the spark advance.
Each EI system ignition coil provides the high voltage to two spark plugs simultaneously;
3.2L DOHC
T1/1: cylinder 2 and 5
T1/2: cylinder 3 and 4
T1/3: cylinder 1 and 6
The EI system ignition coil is not serviceable and must be replaced as an assembly.

SPECIAL SERVICE TOOLS
0000-00
SPECIAL SERVICE TOOLS
GENERAL
1. ENGINE ASSEMBLY .............................
2. ENGINE INTAKE SYSTEM ...................
3. ENGINE LUBRICATION SYSTEM .........
4. ENGINE COOLING SYSTEM ................3
8
9
10

0-3
SPECIAL SERVICE TOOLS
RODIUS 2006.09
0000-00
0000-00SPECIAL SERVICE TOOLS
1. ENGINE ASSEMBLY
Injector Puller
Y99220072BGlow Plug Wrench
Y99220132BFuel Pipe WrenchSealing Caps
665 995 5844
Valve
Remover/Installer
Y99220082BPulley Lock/Wrench
Y99220052BEngine Lock
602 589 00 40 00
Injector Copper
Washer Puller
Y99220022B
(1) D20DT Engine
1) COMPONENTS AND SPECIAL TOOLS

0-4
RODIUS 2006.09
0000-00
SPECIAL SERVICE TOOLS
Injector Puller Y99220072B Glow Plug Wrench
Y99220132B Fuel Pipe Wrench Sealing Caps
665 995 5844
Injector Copper Washer Puller
Y99220022B
Valve
Remover/Installer
Y99220082B Pulley Lock/Wrench
Y99220052B HP Pump Lock
Y99220102B
Engine Lock
602 589 00 40 00
HP Pump Bearing Puller
Y99220032B
(2) D27DT Engine

0-5
SPECIAL SERVICE TOOLS
RODIUS 2006.09
0000-00
Name and Part Number Application
Y99220092B
Compression pressure measuring
adapter and gauge
Y99220082B
Supporting bar and lever
Y99220162B
Guide pin extractor
Y99220112B
Intake manifold guide pin
2) Special Tools and Equipment

0-6
RODIUS 2006.09
0000-00
SPECIAL SERVICE TOOLS
Name and Part Number Application
Y99220152B
HLA remover
Y99220142B
Stem seal installer

0-7
SPECIAL SERVICE TOOLS
RODIUS 2006.09
0000-00
Name and Part Number Application
Y99220122B
Piston protrusion measuring jig
Y99220172B
Piston insertion jig

0-8
RODIUS 2006.09
0000-00
SPECIAL SERVICE TOOLS
Name and Part Number Application
Y99220112B
Intake manifold guide pinInstallation of intake manifold
2. ENGINE INTAKE SYSTEM