low oil pressure SSANGYONG RODIUS 2012 Service Manual

01-10
(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. 1.
2.

01-12
6. TIGHTENING TORQUE
Name SizeNumbers of
fastenerTightening
torque (Nm)Note (total
tightening
torque)
Main bearing capM12×82 10 55±5Nm,
180˚ Not-reusable
Connecting rod capM9×52 8 40±5Nm,
90˚+10˚ 50 ~80Nm
Crankshaft rear sealM6×20 6 10±1Nm -
Oil pumpM8×35 3 25±2.5Nm -
Drive plateM10×22 8 45±5Nm,
90˚+10˚ Not-reusable
Isolation damper center
boltM18×50 1 200±20Nm,
180˚+20˚660 ~ 720Nm
Not-reusable
Oil panM6×20 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 pumpM14×1.5-8-1 1 65±5Nm -
Mounting bolt for high
pressure pumpM8×30 3 25±2.5Nm -
Cylinder headM13×150 12 85Nm
270°±10° -
Camshaft capM6×30 16 10±1Nm -
M8×60 4 25±2.5Nm -
Exhaust stud bolt 10 15±1.5Nm -
Exhaust sprocketM11×40 1 30±3Nm -
Chain tensioner screw
plug
M38×1.5 1 25±2.5Nm -
Coolant temperature
sensor1 20±2.0Nm -
Belt auto tensionerM8×30(LOW) 1 25±2.5Nm -
M10×75(U
pper) 1 55±5.5Nm -
Water pumpM6×50 7 10±1.0Nm -

01-14
Name SizeNumbers of
fastenerTightening
torque (Nm)Note (total
tightening
torque)
Idler pulley/tensioner
pulley1 45±4.5Nm -
Glow plug M5 4 20±2Nm -
Vacuum pumpM8×25 3 10±1Nm -
Timing gear case coverM6×40 7 10±1Nm -
M6×45 1 10±1Nm -
M6×50 3 10±1Nm -
Cylinder head coverM6×35 21 10±1Nm -
Oil dipstick gauge coverM6×16 1 10±1Nm -
Oil filter cap 1 25±2.5Nm -
Fuel railM8×25 2 25±2.5Nm -
Injector clamp boltM6×44 2 9±1.0Nm
130˚±10˚ -
High pressure pipe
(between high pressure
pump and fuel rail
assembly)M17 1 30±3Nm -
High pressure pipe
(between fuel rail
assembly and injector)M17 4 30±3Nm -
Crankshaft position sensorM5×14 1 8±0.4Nm -
Main wiringM6×16 5 10±1Nm -
Intake ductM8×25 3 25±2.5Nm -
Power steering pumpM8×100 3 25±2.5Nm -
Cylinder head front coverM6×10 5 10±1Nm -
Ladder frameM8×16 5 30±3Nm -

02-50000-00
Component SizeBolt
QuantitySpecified torque
(Nm)Remark
(Total torque)
Hot water inlet pipeM6×12210±1Nm-
AlternatorM10×901(lower) 25±2.5Nm-
M10×1161(upper) 46±4.6Nm-
A/C compressorM8×85425±2.5Nm-
A/C 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-
Cam position sensorM8×141 10~14Nm -
T-MAP pressure
sensorM6×20110±1Nm-
Exhaust manifold M8 1040±4Nm-
Turbocharger M8 325±2.5Nm-
T/C support bolt 125±2.5Nm-
T/C support nut M8 125±2.5Nm-
T/C oil supply pipe M6(block side) 110±1.0Nm-
M6(turbo side) 117±2.0Nm-
T/C oil return pipeM6×16
(turbo side)210±1Nm-
M6×16
(block side)210±1Nm-
EGR valveM8×22325±2.5Nm-
EGR pipe bolt
(Intake side)M8×16210±1.0Nm-
EGR pipe bolt
(EGR cooler side)M8×16225±2.5Nm-
Idle pulley/Tensioner
pulley145±4.5Nm -

02-6
Cylinder head coverM6×352110±1Nm-
Oil gauge tubeM6×16110±1Nm-
Oil filter cap 125±2.5Nm-
Fuel railM8×25225±2.5Nm-
Injector clamp boltM6×4429±1.0Nm
130˚±10˚-
High pressure pipe
(between HP pump and
fuel rail)M17 130±3Nm-
High pressure pipe
(between fuel rail and
injector)M17 430±3Nm-
Crank position sensorM5×1418±0.4Nm-
Main wiringM6×16510±1Nm-
Intake ductM8×25325±2.5Nm-
Power steering pumpM8×100325±2.5Nm-
Cylinder head front
coverM6×10510±1Nm-
Ladder frame M8x16 530±3Nm-
Component SizeBolt
QuantitySpecified torque
(Nm)Remark
(Total torque)
Glow plug M5 420±2Nm-
Vacuum pumpM8×25310±1Nm-
Timing gear case coverM6×40710±1Nm-
M6×45110±1Nm-
M6×50310±1Nm-

02-8
(2) Cylinder pressure leakage test
If the measured value of the compression pressure test is not within the specifications, perform
the cylinder pressure leakage test.Specified value ▶
Perform this test in the sequence of firing order.
Do not test the cylinder pressure leakage with wet type test procedure. (do not inject the
engine oil into the combustion chamber) -
-
Test condition: normal engine operating
temperature (80˚C)Specified value
Whole engine below 25%
at valve and cylinder head gasket below 10%
at piston ring below 20%
Crank the engine for approx. 10 seconds
by using the start motor. 2.
Record the test result and measure the
compression pressure of other cylinders
with same manner. 3.
If the measured value is out of specified
value, perform the cylinder pressure
leakage test. 4.

02-170000-00
Vacuum pump
Pump capacity: 210 cc/rev
Camshaft speed:
375 to 3,000 rpm
Lubrication temperature:
-40 to 155°C
Oil: 5W30
Drive type: Driven by exhaust
Camshaft sprocket
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.
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 ▶
Brake booster and naster
cylinder

02-30
(2) Layout
Chain upper bush
Type: single bush
Chains:112 EA
Tensioner rail
Installed between exhaust
Camshaft sprocket and
crankshaft sprocket
Hydraulic tensioner
Contains tensioner housing
plug, spring and check valve,
and operated by hydraulic
pressure
Crankshaft sprocket
Teeth: 21 EA
Oil pump sprocket
Teeth: 33 EA
Chain lower bush
Chain type: single bush
Chains: 60 EA
Mechanical type tensioner
Operated by internal spring
Clamping rail
Installed between exhaust
Camshaft sprocket and
crankshaft sprocket
Exhaust camshaft
sprocket
Teeth: 42 EA
The brass links on timing chain are aligned with the timing marks on crankshaft sprocket and
camshaft sprocket by eight turns of crankshaft.

03-4
Took kit for low pressure lineTool kit for high pressure line
2. MAINTENANCE AND INSPECTION
1) Maintenance Procedures for DI Engine Fuel System
Always keep the workshop and lift clean (especially, from dust).
Always keep the tools clean (from oil or foreign materials).
Wear a clean vinyl apron to prevent the fuzz, dust and foreign materials from getting into fuel
system. Wash your hands and do not wear working gloves. 1.
2.
3.
Follow the below procedures before starting service works for fuel system.
If the problem is from HP pump, fuel supply line or injector, prepare the clean special tools and
sealing caps to perform the diagnosis for DI engine fuel system in this manual. At this point,
thoroughly clean the related area in engine compartment. 4.
Clean the engine compartment before starting service works.

03-20
Water
separator
(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.
To separate the water from the fuel filter,
remove the fuel filter assembly first.