Page 1

DI0A-1

SECTION 00 DI0A

GENERAL INFORMATION

Table of Contents CLEANNESS ....................................... DI0A-3

FUEL SYSTEM ................................. DI0A-21

STRUCTURE ...................................... DI0A-8

Fuel supply system ...................... DI0A-22

ENGINE CONTROLS ....................... DI0A-11 ECU related components .............. DI0A-11 Engine and sensors ..................... DI0A-12 Electrical components and pre heating system ...................... DI0A-13 INTAKE SYSTEM ............................. DI0A-14 Intake air flow chart ...................... DI0A-15 INTAKE SYSTEM ............................. DI0A-16 Exhaust air flow chart ................... DI0A-17 LUBRICATION SYSTEM .................. DI0A-18 COOLING SYSTEM ......................... DI0A-19 Coolant flow chart ........................ DI0A-20

GENERAL INFORMATION DI ENG SM - 2004.4

GENERAL SPECIFICATIONS ........... DI0A-23 Vehicle specifications ................... DI0A-23 Maintenance ................................ DI0A-26 VEHICLE IDENTIFICATION .............. DI0A-28 HOW TO USE AND MAINTAIN WORKSHOP MANUAL ........................................... DI0A-30 Consists of workshop manual ...... DI0A-30 Manual description ...................... DI0A-30 Guidelines for service work safety ........................................... DI0A-31 Lifting points ................................. DI0A-36 Tightening torque of standard bolts .............................................. DI0A-37

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DI0A-3

CLEANNESS Cleanness of DI Engine Fuel System and Service Procedures 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 Âľm 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.

Valve actuator lift: 0.028 mm Hair

Diameter: 0.40 mm

Nozzle hole

Operating clearance: 0.002 mm Diameter: 2.0 mm

Y220_0A035

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.

GENERAL INFORMATION DI ENG SM - 2004.4

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DI0A-4

Job procedures 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.

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-i (refer to “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. Notice

Clean the engine compartment before starting service works.

Tool kit for high pressure line

CHANGED BY EFFECTIVE DATE AFFECTED VIN

Took kit for low pressure line

Removal tool box and cap kits

GENERAL INFORMATION DI ENG SM - 2004.4


DI0A-5

6. Follow the job procedures. If you find a defective component, replace it with new one.

Disconnect the negative battery cable.

For safety reasons: check pressure is low before opening the HP systems (pipes)

Use special tools and torque wrench to perform the correct works. 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.

Plug the disconnected parts with sealing caps, and remove the caps immediately before replacing the components.

Fuel pressure sensor

High pressure pump

Common rail

IMV valve Injection pipe

Transfer pump and high pressure pump Fuel temperature sensor

Water separator Water detection sensor Priming pump

Fuel filter

Injector

Cap position Supply line Return line Fuel tank Y220_0A039

GENERAL INFORMATION DI ENG SM - 2004.4

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DI0A-6

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.

Y220_0A040

9. To supply the fuel to transfer line of HP pump press the priming pump until it becomes hard. Warning

Do not crank engine before having filled pump. Priming pump

Y220_0A041

10. Check the installed components again and connect the negative battery cable. Start the engine and check the operating status. 11. With Scan-i, check if there are current faults and erase the history faults. Note

For details, refer to “DI10 Diagnosis teable�.

Y220_0A042

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GENERAL INFORMATION DI ENG SM - 2004.4


DI0A-7

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. Y220_0A041

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 light ( ) 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. (See fuel system for details.)

GENERAL INFORMATION DI ENG SM - 2004.4

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DI0A-8

STRUCTURE Front view

Rear view

Y220_0A001

1. TVD (Torsional Vibration Damper)

7. Cooling fan pulley & viscos clutch 13. Oil filter housing

2. Air conditioner compressor

8. Aut tensioner pulley

14. Vacuum pump

3. Power steering pump pulley

9. Auto tensioner

15. Crank position sensor

10. Poly-groove belt

16. EGR valve

5. Water pump pulley

11. Cam position sensor

17. Power steering pump

6. Alternator

12. Drive plate (M/T: DMF)

18. EGR center pipe

4. Idle pulley

CHANGED BY EFFECTIVE DATE AFFECTED VIN

GENERAL INFORMATION DI ENG SM - 2004.4


DI0A-9 Top view

Y220_0A002

19. Cylinder head cover

24. Fuel pipe

29. Booster pressure sensor

20. Intake manifold

25. Injector

30. Oil separator

21. Water outlet port

26. Fuel return line

31. Oil dipstic

22. Common rail

27. Oil filler cap

32. EGR center pipe

23. Fuel pressure sensor

28. Glow plug

GENERAL INFORMATION DI ENG SM - 2004.4

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DI0A-10 Left side view

Right side view

Y220_0A003

33. Cylinder head

38. EGR - RH pipe

42. Turbocharger vacuum modulator

34. Cylinder block

39. Oil separator

43. EGR valve vacuum modulator

35. Oil pan

40. Oil dipstic

44. EGR valve

36. Drain plug

41. HP pump

45. Exhaust manifold

37. Turbocharger

CHANGED BY EFFECTIVE DATE AFFECTED VIN

GENERAL INFORMATION DI ENG SM - 2004.4


DI0A-11

ENGINE CONTROLS ECU RELATED COMPONENTS ECU/barometric sensor

Cam position sensor

HFM sensor/intake air temperature sensor

Fuel filter (water detection sensor)

Pre heating time relay

Accelerator pedal sensor

Main relay

Y220_0A004

GENERAL INFORMATION DI ENG SM - 2004.4

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DI0A-12

ENGINE AND SENSORS Injector

Common rail

Crankshaft position sensor

Glow plug

Fuel pressure sensor

Camshaft position sensor

Booster pressure sensor

HP pump

Coolant temperature sensor

Knock sensor (2)

Y220_0A005

CHANGED BY EFFECTIVE DATE AFFECTED VIN

GENERAL INFORMATION DI ENG SM - 2004.4


DI0A-13

ELECTRICAL COMPONENTS AND PRE HEATING SYSTEM Glow plug

Pre heating time relay

Fuse box

Starter motor

Battery

Alternator

Y220_0A006

GENERAL INFORMATION DI ENG SM - 2004.4

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DI0A-14

INTAKE SYSTEM

Air cleaner assembly

HFM sensor

Intake duct hose

Intake manifold

Intake outlet hose

Turbocharger

Intercooler

Inlet hose

Y220_0A007

CHANGED BY EFFECTIVE DATE AFFECTED VIN

GENERAL INFORMATION DI ENG SM - 2004.4


DI0A-15

INTAKE AIR FLOW CHART

Intake valve (in combustion chamber)

Intake manifold

Air cleaner side

Turbocharger (compressor)

Engine

HFM sensor

Intake hose (outlet)

Intercooler

Intake hose (inner)

Y220_0A008

GENERAL INFORMATION DI ENG SM - 2004.4

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DI0A-16

INTAKE SYSTEM

Muffler

Turbocharger

Exhaust manifold

Catalytic converter

EGR pipe

EGR valve

Vacuum modulator

Y220_0A009

CHANGED BY EFFECTIVE DATE AFFECTED VIN

GENERAL INFORMATION DI ENG SM - 2004.4


DI0A-17

EXHAUST AIR FLOW CHART

Catalytic converter

Exhaust pipe

Muffler

Ambient air

Exhaust gas

Turbocharger (turbine side) EGR vacuum modulator To turbocharger booster Turbocharger booster vacuum modulator Turbocharger booster

EGR valve

Exhaust manifold

EGR pipe

Y220_0A010

GENERAL INFORMATION DI ENG SM - 2004.4

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DI0A-18

LUBRICATION SYSTEM

Cylinder head cover

Oil dipstic

PCV valve

Engine oil filter housing

Engine oil pump

Oil pan

Engine oil cooler

Engine oil pressure switch

Y220_0A011

CHANGED BY EFFECTIVE DATE AFFECTED VIN

GENERAL INFORMATION DI ENG SM - 2004.4


DI0A-19

COOLING SYSTEM

Coolant reservoir

Water pump

Radiator assembly

Cooling fan and fan clutch

Y220_0A013

GENERAL INFORMATION DI ENG SM - 2004.4

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DI0A-20

COOLANT FLOW CHART Heater

Oil cooler Coolant reservoir

Intake manifold

Thermostat Coolant outlet port

Water pump

Inner hose

Outlet hose

Cooling fan

Radiator

Y220_0A014

CHANGED BY EFFECTIVE DATE AFFECTED VIN

GENERAL INFORMATION DI ENG SM - 2004.4


DI0A-21

FUEL SYSTEM

Fuel return hose

Injector

Fuel pressure pipe

HP pump

Common rail

Fuel filter

Priming pump

Y220_0A015

GENERAL INFORMATION DI ENG SM - 2004.4

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DI0A-22

FUEL SUPPLY SYSTEM Fuel pressure sensor High pressure pump

Common rail

IMV valve High pressure pipe

Low and high pressure pump Fuel temperature sensor

Water separator Fuel filter

Label (C21)

Prining pump

Water detection sensor

Injector

Sensors HFM sensor Cam position sensor

ECU

Fuel tank

Crank position sensor Knock sensor etc.

Components: - High pressure fuel pump

- Fuel rails

- Fuel pressure sensor

- Fuel injectors

- Electroc control unit (ECU)

- Various sensors and actuators

Supply line Return line ECU communication line

Y220_0A016

According to input signals from various sensors, engine ECU calculates driver’s demand (position of the accelerator pedal) and then controls overall operating performance of engine and vehicle on that time. ECU receives signals from sensors via data line and then performs effective engine air-fuel ratio controls based on those signals. Engine speed is measured by crankshaft speed (position) sensor and camshaft speed (position) sensor determines injection order and ECU detects driver’s pedal position (driver’s demand) through electrical signal that is generated by variable resistance changes in accelerator pedal sensor. Air flow (hot film) sensor detects intake air volume and sends the signals to ECU. Especially, the engine ECU controls the air-fuel ratio by recognizing instant air volume changes from air flow sensor to decrease the emissions (EGR valve control). Furthermore, ECU uses signals from coolant temperature sensor and air temperature sensor, booster pressure sensor and barometric sensor as compensation signal to respond to injection starting, pilot injection set values, various operations and variables.

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GENERAL INFORMATION DI ENG SM - 2004.4


DI0A-23

GENERAL SPECIFICATIONS VEHICLE SPECIFICATIONS Vehicle Dimension

(mm)

Y220_0A017

GENERAL INFORMATION DI ENG SM - 2004.4

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DI0A-24

Specifications Systems General

Engine

Items

Diesel

Remark

Overall length (mm)

4,720 (4,785)

Overall width (mm)

1,870

( ): optional item

Overall height (mm)

1,760 (1,830)

Gross vehicle weight (kg)

AT: 2450 (2510), MT: 2405 (2465)

Curb weight (kg)

AT: 1995 (2055), MT: 1950 (2010)

Min. turning radius (m)

5.6

Ground clearance (mm)

200

Fuel

Diesel

Fuel tank capacity

80

Model

D27DT

No. of cyl./Compression ratio

5/18:1 2,696 cc

Total displacement

DOHC

Camshaft arrangement Max. power

170 ps/4,000 rpm

Max. torque

34.7 kg•m/1,800 rpm

Injection timing

ATDC 4° ± 1°(at idle) 760 ± 50 rpm

Idle speed

Water-cooled/forced circulation

Cooling system

Approx. 11.5

Coolant capacity

Gear pump, forced circulation

Lubrication

9.3

Max. oil capacity

Turbo charger, air-cooled

Turbo charger and cooling type Manual transmission

Remote control, floor change type

Type 1st

IDI Engine

2.367

2.475

1.473

1.536

th

4

1.000

1.000

5th

0.872

0.807

Rev.

3.700

3.591

Model

Electronic

Type

Floor change type 1st

2.742

3.595

2.742

2nd

1.508

2.186

1.508

rd

1.000

1.405

1.000

th

4

0.708

1.000

0.708

5th

-

0.831

-

2.429

3.162

2.429

-

1.926

-

Rev. 1st nd

Rev. 2 CHANGED BY AFFECTED VIN

4.315

rd

3

EFFECTIVE DATE

DI Engine

2nd 3

Automatic transmission

4.007

GENERAL INFORMATION DI ENG SM - 2004.4


DI0A-25

Specifications (Cont’d) Systems Transfercase

Items

Diesel

Model

Part-time

Type Gear ratio

Clutch

Remark ( ): optional item

Planetary gear type High

1.000 : 1

Low

2.483 : 1

Type

Hydraulic [A/T: Torque converter]

Disc type

Dry single diaphragm type [A/T: 3 elements 1 stage 2 phases]

Power steering

Front axle

Rear axle

Brake

Type Steering angle

Rack and pinion Inner

36° 17'

Outer

32° 40'

Drive shaft type

Ball joint type

Axle housing type

Build-up type

Drive shaft type

Semi-floating type

Axle housing type

Build-up type

Master cylinder type

Tandem type

Booster type Type

Vacuum booster Inner

Disc

Outer

Drum (Disc)

Parking brake Suspension

Cable type (internal expansion)

Front

Wishbone + Coil spring

Rear

5-link + Coil spring

Air conditioner

Refrigerant

Electrical

Battery type/Capacity (V-AH)

R134a

Compressor type

Vane type MF / 12 - 90

Starter capacity (V-kW) Alternator capacity (V-A)

GENERAL INFORMATION DI ENG SM - 2004.4

Diesel : 12 - 2.2, Gasoline : 12 - 1.8 IDI

12 - 75 (12 - 90)

DI

12 - 140 (12 - 115)

Gasoline

12 - 115

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DI0A-26

MAINTENANCE Major Components and Service Interval * Use only Ssangyong Genuine Parts. Components

Daily Weekly

Gasoline engine

O

DI diesel engine

O

IDI diesel engine

O

-

Coolant

O

-

Replace at every 60,000 km or 3 years

Brake pipe and hose

-

-

Initial inspection: 1,000 km

Engine oil and oil filter

-

Service Interval Initial change: 10,000 km Replace at every 15,000 km

-

Initial change: 5,000 km Replace at every 10,000 km or 12 months

Remarks More frequent maintenance is required if the vehicle is operated under severe condition. Severe conditions? - Frequent low-speed operation as in stop-and-go traffic - When most trips are less than 6 km (in winter, less than 16 km) - Driving in sandy, dusty, and salty road - Driving in mountainous areas - Extensive idling or high load operation such as towing a trailer

Inspect at every 20,000 km, replace if necessary Brake pad, shoe and disc

-

-

Inspect at every 10,000 km, check or adjust if necessary

Air cleaner element

Gasoline engine

-

O

Clean at every 15,000 km,

DI diesel engine

-

O

Initial clean: 5,000 km,

IDI diesel engine

-

O

Clean at every 10,000 km, replace if necessary,

Fuel filter Gasoline engine

-

-

Replace at every 60,000 km

DI diesel engine

-

-

Replace at every 30,000 km (Drain the water from fuel filter at every 10,000 km)

IDI diesel engine

-

-

Replace at every 40,000 km

Auto4-speed matic transmis- 5-speed sion oil

-

-

-

-

Inspect at every 30,000 km or 1 year, replace if necessary (replace at every 60,000 km if the vehicle is operated under severe conditions)

Manual transmission oil

-

-

Transfer case oil

-

-

Axle oil

-

-

Replace at every 30,000 km

Air conditioner air filter

-

-

Replace at every 10,000 km

Spark plug (gasoline engine)

-

-

Replace at every 60,000 km

Replace at every 60,000 km

If vehicle is operated under dusty or sandy area, frequently clean and inspect the air cleaner system. If necessary, replace the air cleaner element.

Replace at every 30,000 km

More frequent maintenance is required if the vehicle is operated under severe condition. - Driving in unpaved road - Towing a trailer

Inspect at every 10,000 km, Replace at every 60,000 km Inspect at every 10,000 km, Replace at every 60,000 km (but, frequently chexk the leaks)

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More frequent maintenance is required if the vehicle is operated under severe condition. - Driving in sandy, dusty, and unpaved road - Excessive operation of air conditioner or heater

GENERAL INFORMATION DI ENG SM - 2004.4


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