wiring SSANGYONG RODIUS 2012 Service Manual

01-190000-00
8. ELECTRIC COMPONENTS AND LAYOUT
1) Wiring Harness Arrangement

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 -

02-6
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-

02-70000-00
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. -
-
-

03-10
(3) DI Engine Fuel System Check Procedure
If several DTCs are output simultaneously, check the electric wiring for open or short circuit.
Check the low pressure fuel system and fuel filter and confirm that there are no abnormalities.
Carry out the high pressure fuel system check.

03-14
(6) Low Pressure System Pressure Test
Inspection procedure ▶
All wirings/connectors and fuel lines should
be connected and the engine should work
properly.
Prepare a special tool for low pressure test
and clean it thoroughly to prevent foreign
materials from entering. 1.
2.
Disconnect the key connector for fuel filter connection, and connect both connectors to the
fuel filter and hose. 3.
Start the engine and check visually for clogged low pressure fuel system, excessive air or air
entry.
If the fuel flow is not sufficient or air is in the fuel, repair the leak area. 4.
5.

08-4
2. INSPECTION
Possible Cause Action
Coolant level
is
too low- Leak from the radiator
- Leak from the coolant auxiliary tank
- Leak from the heater core- Change the radiator
- Change the coolant auxiliary tank
- Change the heater
- Leak from the coolant hose
connections
- Damaged coolant hose - Reconnect the hose or replace
the clamp
- Change the hose
- Leak from the water pump gasket
- Leak from the water pump internal
seal- Change the gasket
- Change the water pump
- Leak from the water inlet cap
- Leak from the thermostat housing- Change the water inlet cap
gasket
- Change the thermostat sealing
- Incorrect tightening torque of the
cylinder head bolts
- Damaged cylinder head gasket- Tighten the bolts to the specified
torque
- Change the cylinder head gasket
Coolant
temperature is
too high- Coolant leakage (Coolant level is low)
- Improper coolant mixture ratio
- Kinked coolant hose- Add coolant
- Check the coolant concentration
(Anti-freeze)
- Repair or replace the hose
- Defective thermostat
- Defective water pump
- Defective radiator
- Defective coolant auxiliary tank or tank
cap- Change the thermostat
- Change the water pump
- Change the radiator
- Change the coolant auxiliary tank
or tank cap
- Cracks on the cylinder block or
cylinder head
- Clogged coolant passages in the
cylinder block or cylinder head- Change cylinder block or cylinder
head
- Clean the coolant passage
- Clogged radiator core - Clean the radiator core
- Improper operation of cooling fan - Replace the cooling fan or repair
the related circuit
- Defective temperature sensor or
faulty wiring- Replace the sensor or repair the
related wiring
Coolant
temperature is
too low- Thermostat is stuck open - Change the thermostat
- Improper operation of cooling fan - Replace the cooling fan or repair
the related circuit
- Defective temperature sensor or faulty
wiring- Replace the sensor or repair the
related wiring

09-4
2. INSPECTION
1) Alternator Output Test
Item How to check DTC set value / Action
Output
current
B terminal
current
Rotor
coil
resistance
D terminal
voltage
Disconnect the cable connected to the
B terminal on the alternator. Connect
one end of the ammeter to the B
terminal and the other end to the cable
connected to the B terminal.
Measure the maximum output value.
(Maintain the engine speed between
2,500 and 3,000 rpm.)
(Turn the headlamp and all the electrical
switches on.) 1.
2.Pass: If the measured current is
45 A or higher.
Fail: If the measured current is
less than 45 A.
Check the current of the B
terminal. -
-
-
Move the gear selector lever to the
neutral position.
Maintain the engine speed at 2,500 rpm
with the vehicle unloaded.
(Turn all the electrical switches off.) 1.
2.Open circuit: If the measured
current is 5 A or higher. -
Disconnect the negative cable from the
battery.
Remove the B terminal and turn off the
ignition switch.
Measure the resistance between the L
and F terminals with an ohmmeter. 1.
2.
3.Pass: If the measured resistance
is between 3 and 6 Ω.
Faulty rotor coil or slip ring: If the
measured resistance is less than
3 Ω or greater than 6 Ω. -
-
Connect the B terminal wiring.
Measure the voltage with the engine
running. 1.
2.Specification: 12.5 V to 14.5 V
Faulty IC regulator or field coil: If
the measured voltage is 14.5 V
or higher. -
-
Disconnect the negative battery cable.
Connect the negative cable again after connecting the ammeter. -
-

09-51451-01
2) Troubleshooting for Alternator
Item Cause Action
Overcharged
batteryDefective alternator voltage regulator Replace the alternator
Defective voltage detection wiring Replace the alternator
Defective voltage detection wiring Repair or replace
Discharged battery Loose alternator drive belt Adjust the belt tension or replace
Poor connection of related circuit or
open circuitRetighten the loose connection or
repair open circuit
Defective alternator voltage regulator Replace the alternator
Terminated battery Replace the battery
Defective ground Repair
Charge warning
lamp does not
come on when
turning on ignition
switch with engine
stoppedDefective alternator voltage regulator Replace the alternator
Open circuit in charge warning lamp,
fuse or wiringReplace or repair the charge
warning lamp or fuse
Defective ignition switch Replace the ignition switch
Defective ground of alternator circuit Repair
Charge warning
lamp is not turned
off after starting
engineDefective alternator voltage regulator Replace the alternator
Corroded or worn battery cable Repair or replace the battery cable
Loose alternator drive bel Replace the batteryAdjust the belt
tension or replace the belt
Defective wiring harness Repair or replace
Warning lamp
does not go off
even after starting
the engineCorrosion or damage of
battery cableRepair or replace the
battery cable
Loose alternator drive belt Adjust the belt tension or
replace the belt
Defective wiring harness Repair or replace
Overcharged
batteryDefective voltage regulator of
alternatorReplace the alternator
Defective voltage detecting wiring Repair or replace

15-230000-00
This is done periodically under certain operating conditions. When the resetting is finished, the new
minimum pulse value replaces the value obtained during the previous resetting. The first MDP value is
provided by the C3I. Each resetting then allows the closed loop of the MDP to be updated according to
the deviation of the injector.
B. Detection of leaks in the cylinders
The accelerometer is also used to detect any injector which may have stuck open. The detection
principle is based on monitoring the ratio. If there is a leak in the cylinder, the accumulated fuel self-
ignites as soon as the temperature and pressure conditions are favorable (high engine speed, high load
and small leak).
This combustion is set off at about 20 degrees before TDC and before main injection.
The ratio therefore increases considerably in the detection window. It is this increase which allows the
leaks to be detected. The threshold beyond which a fault is signaled is a percentage of the maximum
possible value of the ratio.
Because of the severity of the recovery process (engine shut-down), the etection must be extremely
robust.
An increase in the ratio can be the consequence of various causes:
Pilot injection too much
Main combustion offset
Fuel leak in the cylinder -
-
-
If the ratio becomes too high, the strategy initially restricts the pilot injection flow and retards the main
injection. If the ratio remains high despite these interventions, this shows that a real leak is present, a
fault is signaled and the engine is shut down.
C. Detection of an accelerometer fault
This strategy permits the detection of a fault in the sensor or in the wiring loom connecting the sensor to
the ECU.
It is based on detection of the combustion. When the engine is idling, the detection window is set too low
for the combustion caused by the main injection. If the ratio increases, this shows that the knock sensor
is working properly, but otherwise a fault is signaled to indicate a sensor failure. The recovery modes
associated with this fault consist of inhibition of the pilot injection and discharge through the injectors.