2006-2009 SSANGYONG ACTYON FACTORY Service Repair Manual

ENGINE GENERAL INFORMATION 0A CLEANNESS ............................................. 2 ENGINE ASSEMBLY ................................. 7 LH side view .............................................................. 7 RH side view ............................................................. 7 Front view ................................................................. 8 Fan belt ..................................................................... 8 ENGINE CONTROLS ................................ 9 ECU related components .......................................... 9 Engine control system ............................................ 10 Electrical components and pre heating system ...... 12 INTAKE SYSTEM .................................... 13 EXHAUST SYSTEM ................................ 14 LUBRICATION SYSTEM ......................... 15 TABLE OF CONTENTS COOLING SYSTEM ................................. 16 FUEL SYSTEM ........................................ 17 Fuel supply system ................................................ 18 MAINTENANCE AND REPAIR ................ 19 Maintenance and lubrication ................................... 19 Guidelines for service work safety ........................... 20 OWNER INSPECTIONS AND SERVICES 25 While operating the vehicle ..................................... 25 At each fuel fill ........................................................ 25 At least twice a month ............................................ 25 At least monthly ..................................................... 25 At least twice a year ............................................... 26 Each time the oil is changed .................................. 26 At least annually ..................................................... 26 STANDARD BOLTS SPECIFICATIONS .27

ENGINE GENERAL INFORMATION ACTYON SM - 2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN 2 0A The fuel system for DI engine consists of transfer (low pressure) line and high pressure line. Its highest pressure reaches over 1600 bar. Some components in injector and HP pump are machined at the micrometer 100 µm of preciseness. The pressure regulation and injector operation are done by electric source from engine ECU. Accordingly, if the internal valve is stucked due to foreign materials, injector remains open. Even in this case, the HP pump still operates to supply high pressurized fuel. This increases the pressure to combustion chamber (over 250 bar) and may cause fatal damage to engine. You can compare the thickness of injector nozzle hole and hair as shown in below figure (left side). The right side figure shows the clearance between internal operating elements. Cleanness of DI Engine Fuel System and Service Procedures The core elements of fuel system has very high preciseness that is easily affected by dust or very small foreign material. Therefore, make sure to keep the preliminary works and job procedures in next pages. If not, lots of system problems and claims may arise. CLEANNESS Hair Nozzle hole Valve actuator lift: 0.028 mm Diameter: 0.40 mm Operating clearance: 0.002 mm Diameter: 2.0 mm

CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE GENERAL INFORMATION ACTYON SM - 2006.03 3 0A GENERAL SENSOR ASSY HOUSING INTAKE LUB COOLING FUEL CONTROL EXHAUST 1. Always keep the workshop and lift clean (especially, from dust). 2. Always keep the tools clean (from oil or foreign materials). 3. 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. 4. Follow the below procedures before starting service works for fuel system. Job Procedures Carefully listen the symptoms and problems from customer. Visually check the leaks and vehicle appearance on the wiring harnesses and connectors in engine compartment. Perform the diagnosis proceee with SCAN-100 (refer to “DI10 DIAGNOSIS” section in this manual). Locate the fault. If the cause is from fuel system (from priming pump to injector, including return line), follow the step 1 through step 3 above. 5. 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 “DIAGNOSIS” section in this manual. At this point, thoroughly clean the related area in engine compartment. Tool kit for high pressure line Took kit for low pressure line Removal tool box and cap kits • Clean the engine compartment before starting service works. NOTICE

ENGINE GENERAL INFORMATION ACTYON SM - 2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN 4 0A 6. Follow the job procedures. If you find a defective component, replace it with new one. Disconnect the negative battery cable. Plug the disconnected parts with sealing caps, and remove the caps immediately before replacing the components. Once disconnected, the fuel pipes between HP pump and fuel rail and between fuel rail and each injector should be replaced with new ones. The pipes should be tightened to specified tightening torques during installation. Over or under torques out of specified range may cause damages and leaks at connections. Once installed, the pipes have been deformed according to the force during installtion, therefore they are not reusable. The copper washer on injector should be replaced with new one. The injector holder bolt should be tightened to specified tightening torque as well. If not, the injection point may be deviated from correct position, and it may cause engine disorder. Use special tools and torque wrench to perform the correct works. For safety reasons: check pressure is low before opening the HP systems (pipes) Fuel Pressure Sensor Common Rail High Pressure Pipe Injector Sensors HFM sensor Cam position sensor Crank position sensor Knock sensor etc. Water separator High pressure pump IMV valve Low and high pressure pump Fuel temperature sensor Components: - High pressure fuel pump - Fuel injectors - Fuel rail - Electroc control unit (ECU) Supply line - Fuel pressure sensor - Various sensors and actuators Return line ECU communication line Water detection sensor Fuel tank Priming pump Fuel Filter ECU Label (C2I)

CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE GENERAL INFORMATION ACTYON SM - 2006.03 5 0A GENERAL SENSOR ASSY HOUSING INTAKE LUB COOLING FUEL CONTROL EXHAUST 7. Plug the removed components with clean and undamaged sealing caps and store it into the box to keep the conditions when it was installed. 8. Clear the high pressure offset value by SCAN- 100 after replacing the high pressure pump. 9. To supply the fuel to transfer line of HP pump press the priming pump until it becomes hard. 10. Check the installed components again and connect the negative battery cable. Start the engine and check the operating status. 11. With SCAN-100, check if there are current faults and erase the history faults. Priming pump • Do not crank engine before having filled pump. NOTICE • For details, refer to “Diagnosis table”. NOTE

2006-2009 SSANGYONG ACTYON FACTORY Service Repair Manual

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