air condition SSANGYONG RODIUS 2012 Service Manual

01-70000-00
1) Service Interval
DescriptionDaily
inspectionWeekly
inspectionService interval
Engine oil & oil
filterInspection - EU Change every 20,000 km or 12
months (The service interval should
be shortened under severe
conditions)
General Change every 15,000 km or 12
months (The service interval should
be shortened under severe
conditions)
Coolant Inspection - Change every 200,000 km or 5 years
Air cleaner
element- Inspection Diesel EU Change every 20,000 km
(The service interval should
be shortened under severe
conditions)
General Change every 15,000 km
(The service interval should
be shortened under severe
conditions)
Gasoline Clean every 15,000 km, replace every
60,000 km (The service interval should
be shortened under severe
conditions)
Fuel filter - - EU Change every 40,000 km (Draining
water from fuel filter: whenever
replacing the engine oil)
General Change every 45,000 km (Draining
water from fuel filter: whenever
replacing the engine oil)

01-130000-00
T/C oil supply pipe M6(to block) 1 10±1.0Nm -
M6
(to turbocharger)1 17±2.0Nm-
T/C oil return pipeM6×16(to block)2 10±1Nm -
M6×16
(to turbocharger)210±1Nm -
EGR valveM8×223 25±2.5Nm -
EGR pipe bolt
(to exhaust manifold)M8×16 2 10±1Nm -
EGR pipe bolt
(to EGR cooler)M8×16 2 25±2.5Nm -
Name SizeNumbers of
fastenerTightening torque
(Nm)Note (total
tightening
torque)
Hot water inlet pipeM6×12210±1Nm-
AlternatorM10×901(LO) 25±2.5Nm -
M10×1161(HI) 46±4.6Nm -
Air conditioner
compressorM8×854 25~2.5Nm -
Air conditioner bracketM6×25410±1Nm-
Intake manifoldM8×35225±2.5Nm-
M8×110625±2.5Nm-
Oil filter moduleM8×40625±2.5Nm-
M8×20125±2.5Nm-
M8×140225±2.5Nm-
Knock sensorM8×28220±5Nm-
Camshaft position
sensorM8×141 10~14Nm -
T-T-MAP pressure
sensorM6×20110±1Nm-
Exhaust manifold M8 1040±4Nm-
Turbocharger M8 325±2.5Nm-
T/C support bolt M8 125±2.5Nm-

02-70000-00
3. CHECK AND INSPECTION
1) Cylinder
(1) Compression pressure test
Specified value ▶
Compression ratio16.5 : 1
Test conditionat normal operating temperature (80˚C)
Compression pressur
eStandard32 bar
Minimum18 bar
Differential limit between cylindersMaximum 3 bar
The compression pressure test is to check the conditions of internal components (piston, piston
ring, intake and exhaust vale, cylinder head gasket). This test provides current engine operating
status.
Measurement ▶
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Disconnect the fuel rail pressure sensor connector to cut off the fuel injection.
Remove the air cleaner duct and glow plugs. -
-
-
Place the diagram sheet to compression
pressure tester and install it into the plug
hole. 1. Before cranking the engine, make sure that the test wiring, tools and persons are keeping
away from moving components of engine (e.g., belt and cooling fan).
Park the vehicle on the level ground and apply the parking brake.
Do not allow anybody to be in front of the vehicle. -
-
-

03-26
The engine ECU calculates the accelerator pedal based on the input signals from various sensors,
and controls the overall operation of the vehicle.
The ECU receives the signals from various sensor through data line, and performs effective air-fuel
ratio control based on these signals.
The crankshaft speed (position) sensor measures the engine speed, and the camshaft speed
(position) sensor determines the order of injections, and the ECU detects the amount of the
accelerator pedal depressed (driver's will) by receiving the electrical signals from the accelerator
pedal sensor.
The mass air flow sensor detects the volume of intake air and sends the value to the ECU.
The major function of the ECU is controlling air-fuel ratio to reduce the emission level (EGR valve
control) by detecting instantaneous air flow change with the signals from the mass air flow sensor.
Also, the ECU uses the signals from the coolant temperature & air temperature sensors, booster
pressure sensor, atmospheric pressure sensor to: a) determine injection starting point and set
value for pilot injection, and b) deal with various operations and variable conditions.

04-31719-00
1. SPECIFICATIONS
Shorten the service interval under severe conditions such as driving on a dusty road or off-
road. *
Unit Description Specification
Air cleaner elementFilter type Dry, filter element
Initial resistance Max. 300 mmAq
Service interval EU: Change every 20,000 km
GEN: Change every 15,000 km
Air cleaner assemblyWeight 2.36kg
Operating temperature-30 ~ 100℃
IntercoolerRadiation over 13,000 Kcal
Pressure loss at turbocharger below 90 mmHg
Cooling type Air cooled type
Core size 450W*130H*70T
Core type C/FIN

04-111719-00
LoadEngine
speedSwirl valve Amount of
swirlRemarks
Low speed,
Low loadbelow
3,000 rpmClosed HeavyIncreased EGR ratio, better air-fuel
mixture (reduce exhaust gas)
High speed,
High loadover 3,000
rpmOpen LightIncrease charge efficiency, higher
engine power
The variable swirl valve actuator operates
when turning the ignition switch ON/OFF
position to open/close the swirl valve. In this
period, the soot will be removed and the
learning for swirl valve position is performed.
Swirl: This is the twisted (radial) air flow along the cylinder wall during the intake stroke. This
stabilizes the combustion even in lean air-fuel mixture condition.
Swirl valve
3) Features
Swirl and air intake efficiency
To generate the swirl, the intake port should be serpentine design. This makes the resistance
in air flow. The resistance in air flow in engine high speed decreases the intake efficiency.
Eventually, the engine power is also decreased, Thus, the swirl operation is deactivated in high
speed range to increase the intake efficiency.
Relationship between swirl and EGR
To reduce Nox, it is essential to increase EGR ratio. However, if EGR ratio is too high, the PM
also could be very higher. And, the exhaust gas should be evenly mixed with newly aspired air.
Otherwise, PM and CO are dramatically increased in highly concentrated exhaust gas range
and EGR ratio could not be increased beyond a certain limit. If the swirl valve operates in this
moment, the limit of EGR ratio will be higher. -
-
4) Relationship Between Swirl and Fuel Injection Pressure
The injector for DI engine uses the multi hole design. For this vehicle, there are 8 holes in injector.
If the swirl is too strong, the injection angles might be overlapped and may cause the increased
PM and insufficient engine power. Also, if the injection pressure is too high during strong swirl, the
injection angles might be overlapped. Therefore, the system may decreases the fuel injection
pressure when the swirl is too strong.

06-6
3) Inspection of Turbine
Thoroughly check the followings.
Must absolutely not operate the turbocharger with the compressor outlet and inlet opened as it
could damage the turbocharger or be hazardous during inspection.
Interference: In case where is trace of interference or smallest damage on the compressor
wheel means, most of times, that abrasion has occurred on the journal bearing. Must inspect
after the overhaul.
Oil Leakage: The reason for oil leakage at the compressor section is the air cleaner, clogged
by substances such as dust, causes the compressor inlet negative pressure. -
-
Rotating in high speed at no-load for extended period of time can cause oil leakage to the
compressor section as oil pressure within the center housing gets higher than pressure
within the compressor housing.
Overuse of engine break (especially in low gear) in down hill makes significantly low
exhaust gas energy compared to the time where great amount of air is required during
idling conditions of the engine. Therefore, amount of air in the compressor inlet increases
but the turbocharge pressure is not high, which makes negative a.
b.
No problem will occur with the turbocharger if above conditions are found in early stage but oil
leaked over long period of time will solidify at each section causing to breakout secondary
defects.
Damages by foreign materials: In case where the compressor wheel is damaged by foreign
materials requires having an overhaul. At this time, it's necessary to check whether the foreign
materials have contaminated intake/exhaust manifold or inside of engine.

06-111914-01
3. TROUBLESHOOTING
The followings are cautions to take in handling defects of turbocharger, which must be fully aware
of.
1) Cautions
After stopping the engine, check whether the bolts on pipe connecting section are loose as
well as the connecting condition of vacuum port and modulator, which is connected to the
actuator.
During idling of the engine, check for leakage in the connecting section of pipe (hoses and
pipes, duct connections, after the turbocharger) by applying soap water. The leakage condition
in the engine block and turbine housing opening can be determined by the occurrence of
abnormal noise of exhaust.
By running the engine at idle speed, abnormal vibration and noise can be checked.
Immediately stop the engine when abnormal vibration and noise is detected and make
thorough inspection whether the turbocharger shaft wheel has any damages as well as
checking the condition of connections between pipes.
In case where the noise of engine is louder than usual, there is possibility of dampness in the
areas related with air cleaner and engine or engine block and turbocharger. And it could affect
the smooth supply of engine oil and discharge.
Check for damp condition in exhaust gas when there is sign of thermal discoloration or
discharge of carbon in connecting area of the duct.
When the engine rotates or in case where there is change in noise level, check for clogging of
air cleaner or air cleaner duct or if there is any significant amount of dust in the compressor
housing.
During the inspection of center housing, inspect inside of the housing by removing the oil drain
pipe to check for sludge generation and its attachment condition at shaft area or turbine side.
Inspect or replace the air cleaner when the compressor wheel is damaged by inflow of foreign
materials.
Inspect both side of the turbocharger wheel after removing inlet and outlet pipe of the
turbocharger. 1.
2.
3.
4.
5.
6.
7.
8.
9.

06-211914-01
Control
rangeTurbocharger
driving
mechanismControl methodEffectImproved
performance
At low
speedNarrows the
flow passage
for the exhaust
gas by folding
the vanesThe flow rate is
increased as the
exhaust gas passes
the narrow passage
→ Increased
turbine & impeller
speed, Increased
compressive forceImproved
low speed
torque
4. OPERATING PRINCIPLES
The E-VGT is designed to get more improved engine power in all ranges by controlling the turbine
as follows:
1) How it Works at Low Speed
Normal turbocharger cannot get the turbo effect because the amount of exhaust gas is not
enough and the flow speed is slow in a low speed zone, but VGT allows the flow passage of
exhaust to narrow, resulting in increasing the flow speed of exhaust gas and running the turbine
quickly and powerfully.
Therefore, as VGT can intake more air than normal turbocharger, it can give the benefit of the
increased output even in a low speed zone.
Turbocharger lag
The turbocharger is at idle speed when there is no load or it is in the normal driving condition.
During this period, the amount of exhaust gas passing through the turbine is not enough to turn
the compressor wheel (impeller) fast. Therefore, the intake air is not compressed as needed.
Because of this, it takes time for turbocharger to supply the additional power after the
accelerator pedal is depressed. This is called "turbocharger lag".Basic principle at low speed
At low speed, it utilizes the principle of
venturi.
For example, when air flows through the
venturi tube, the flow speed is faster and the
pressure is lower at the point "A". In this case,
if the inner
diameter of venturi is more narrowed, the flow
speed is so much faster (refer to the
equation). ※

10-4
1. OVERVIEW
The pre-heating system for D20DTR engine has the glow plug to the cylinder head (combustion
chamber), and improves the cold start performance and reduces the emission level.
The pre-heating resistor (air heater) is used to heat the intake air.
This enables the diesel fuel to be ignited in low temperature condition.
The ECU receives the information such as, engine rpm, coolant temperature, engine torque, etc.,
through CAN communication during pre-heating process; and the pre-heating control unit
controls the pre-heating, heating during cranking and post-heating by the PWM control.
Glow plug
Engine ECU (D20DTR)Glow indicator
Glow plug control unit
(GCU)