engine SSANGYONG RODIUS 2012 Service Manual

07-4
3. MAJOR CHANGES
Front Sub Frame
Old New
The engine mounting insulators (A) have been changed according to newly equipped engine
(D20DTR). It improves the durability and NVH.
Front Knuckle Assembly
Old New
The front knuckle assembly has been changed according to new 4WD system (Part-time T/C).
Hub bearingLocking hub
actuator

08-70000-00
Problem Cause Action
Burning smell
around tireToo frequent braking in high driving speed Reduce the use of
foot brake/use
engine brake
properly sed only foot brake during downhill driving
Driving with foot on brake pedal Get off the foot
from pedal
Foreign materials such as dirt or sand in brake system Replace: caliper,
wheel cylinder,
master cylinder,
return spring
Broken return spring in shoe assembly Replace
Incorrectly adjusted parking brake cable Adjust
Incorrect wheel or wheel cover
(generating the heat)Replace

08-114850-03
Let the engine run for 1 to 2 minutes and
stop it. If the brake pedal stroke is
shortened as pumping the brake pedal,
the system is normal. If not, the system is
defective.
Depress the brake pedal several times with
engine off. If the brake goes down when
starting engine with pedal depressed, the
system is normal. If not, the system is
defective. 1.
2.
Depress the brake pedal when the engine
is running. If the pedal height is not
changed for 30 seconds after stopping the
engine, the system is normal. If not, the
system is defective. 3.
If the above three checks are OK, the system
is normal. If any condition is not met, check
the valve, vacuum hose and brake booster.
3) Brake Booster
OK
NG
Engine stopped
Engine running

09-114891-01
(3) ESP Control
The ESP (Electronic Stability Program) has been developed to help a driver avoid danger of losing
control of the vehicle stability due to understeer or oversteer during cornering. The yaw rate sensor,
lateral sensor and longitudinal sensor in the sensor cluster and the steering wheel angle sensor
under the steering column detect the vehicle conditions when the inner or outer wheels are
spinning during oversteer, understeer or cornering. The ESP ECU controls against oversteer or
understeer during cornering by controlling the vehicle stability using input values from these
sensors and applying the braking force to the corresponding wheels independently. The system
also controls the engine power right before the wheel spin synchronized to decelerate the vehicle
automatically in order to maintain the vehicle stable during cornering.

09-154891-01
4. SCHEMATIC DIAGRAM
When equipped with ABS, the braking force at each wheel will be controlled with 3-channel 4-
sensor method. And when equipped with ESP, 4 wheels will be controlled independently with 4-
channel method. (When controlling ABS system only, it will be operated with 3-channel method.)
When compared to the vehicle equipped with ABS/EBD only, the internal hydraulic circuit has a
normally-open separation valve and a shuttle valve in primary circuit and in secondary circuit.
When the vehicle brakes are not applied during engine running or when applying the non-ABS
operating brakes, the normally-open separation valve and the inlet valve are open, whereas the
normally-closed shuttle valve and the outlet valve are closed. When the ESP system is operating,
the normally-open separation valve will be closed by the solenoid valve operation and the hydraulic
circuit will be established by the shuttle valve. Then, the inlet and outlet valves will be
closed or open depending on the braking pressure increase, decrease or unchanged conditions.
▶The warning lamp comes on and warning beep sounds when the ESP is operating
Driving feeling when the ESP is operating ▶
▶Noise and vibration that driver senses when the ESP is operating
1) Hydraulic Circuit Diagram
When the ESP operates during vehicle movement, the ESP warning lamp on the instrument
panel flickers and beep comes on every 0.1 seconds. The ESP operation shows that the vehicle
stability is extremely unstable and it is used to warn the driver. The ESP system is just a
supplementary system for the vehicle motion and it cannot control the vehicle when it exceeds
the physical limits. Do not solely rely on the system but be advised to drive the vehicle safely.
When the ESP system activates, the driving feeling can be different depending on vehicle
driving conditions. For example, you will feel differently when the ESP system is activated during
when ABS is operating with the brakes applied and when brakes are not applied on a curve.
Thus, the ESP system would make the driver feel more abruptly when the brakes are applied
during the ESP system activation.
The ESP system may transfer noise and vibration to the driver due to the pressure changes
caused by the motor and valve operations in a very short period of time. Extreme cornering will
trigger the ESP operation and this will make the driver feel noise and vibration due to sudden
brake application. Also, the ESP system controls the engine output. So, the driver may notice
the engine output decrease even when the accelerator pedal is being applied.

09-16
(1) Hydraulic Circuit Diagram
When compared to the vehicle equipped with ABS/EBD only, the internal hydraulic circuit has a
normally-open separation valve and a shuttle valve in primary circuit and in secondary circuit.
When the vehicle brakes are not applied during engine running or when applying the non-ABS
operating brakes, the normally-open separation valve and the inlet valve are open, whereas the
normally-closed shuttle valve and the outlet valve are closed.
When the ESP system is operating, the normally-open separation valve will be closed by the
solenoid valve operation and the hydraulic circuit will be established by the shuttle valve. Then,
the inlet and outlet valves will be closed or open depending on the braking pressure RISE, HOLD
or DUMP conditions.

11-74610-00
Free Play Check ▶
Start the engine and place the wheels at
straight ahead direction.
Turn the steering wheel until the tires starts to
move and measure the distance on the
circumference of the steering wheel. A.
B.
Free play30mm
If the free play is out of the specified value,
check the free play in steering column shaft
connection and steering linkage. Replace or
repair if necessary.
Steering Effort Check ▶
Park the vehicle on a paved and flat ground and
place the front wheels at straight ahead direction.
Start the engine and let it run around 1,000 rpm.
Install the spring scale on the circumference of
the steering wheel and measure the steering
effort in both directions. A.
B.
C.
Steering effort in
standstillbelow 3.0 kg
The difference between both sides should be
within 0.6 kg.
Steering Angle Check ▶
Place the front wheel on a turning radius
measuring tool.
Turn the steering wheel to the both ends and
measure the maximum steering angle. A.
B.
Steering
angleInner36.4°
Outer31.5°
If the steering angle is out of the specified
value, check and adjust the toe-in.

11-8
Oil Level Check ▶
Check the fluid level on a level ground with the
engine turned off. The fluid level should be
between the MIN and MAX marks on the
reservoir cap gauge.
Place the vehicle on a level ground and start
the engine and let it run at idle speed.
Turn the steering wheel several times so that
the oil temperature reaches to normal
operating level (75~85˚C).
Place the steering wheel at straight ahead
direction.
Check the oil level in the power steering oil
reservoir. Adjust the oil level between MAX
and MIN. A.
B.
C.
D.
Oil Change ▶
If the difference between two measurements
is below 5 mm and the level is between MAX
and MIN level, it's normal. If it is over 5 mm,
bleed air from the system.
Open the power fluid reservoir cap and drain
the fluid completely with oil suction device.
To make it easy, turn the steering wheel to its
both ends several times.
Fill up the specified fluid into fluid reservoir
and bleed air from the steering system. A.
B.
Oil typeS-PSF3
Capacityapprox. 1.1ℓ
(including reservoir)
below 5
mm
Engine running Engine idling

11-94610-00
Air Bleeding ▶
The air bleeding should be done after servicing the
power steering system and when the difference
between two measurements (cooled and normal
temperature) is prominent.
Normal AbnormalLift up the vehicle very carefully.
Turn the steering wheel to its both ends
several times and add the oil up to MAX line
in the steering oil reservoir.
Periodically crank the starting motor and turn
the steering wheel to its both ends without
any interruption.
Check the oil level again. If the oil level is
fluctuated, repeat the procedures from step 3
to step 5.
Start the engine.
Turn the steering wheel to its both ends until
any bubble can be found in the steering oil
reservoir.
Perform the test drive and check the steering
wheel for normal operation and noise.
If the oil level abruptly goes up, bleed the air
from the system again. A.
B.
C.
D.
E.
F.
G.
H.
If the air bleeding is not properly performed,
the life span of the power steering pump may
be shortened. -

11-10
Oil Pump Pressure Check ▶
Check the oil pump pressure to locate any defect
in oil pump.
Before checking the pressure, check the oil
level and belt tension. Prepare the empty
container to collect the spilled oil during the
service.
Unscrew the pressure line fitting in power
steering pump.
Install the pressure gauge between the
power steering pump and the power steering
oil pressure line.
Place the shift lever to neutral position. Apply
the parking brake.
Open the valve in pressure gauge. Start the
engine and let it run at idle speed.
Turn the steering wheel several times so that
the oil temperature reaches to normal
operating level. A.
B.
C.
D.
E.
Fully close the valve in pressure gauge and
measure the oil pressure. F.
To prevent internal damage, do not close the
gauge valve over 10 seconds.
Keep the oil temperature at proper range. -
-
Relief pressure90 ± 3 bar