SSANGYONG 0000-00 User manual

ENGINE GENERAL
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ENGINE GENERAL
GENERAL
1. ENGINE ASSEMBLY LAYOUT...............
2. ENGINE CONTROLS LAYOUT...............
3. ELECTRICAL COMPONENTS
AND PREHEATING SYSTEM.................
4. INTAKE SYSTEM LAYOUT...................
5. EXHAUST SYSTEM LAYOUT................
6. LUBRICATION SYSTEM LAYOUT.........
7. COOLING SYSTEM LAYOUT................
8. FUEL SYSTEM LAYOUT.......................
9. FUEL SUPPLY SYSTEM......................
10. CLEANNESS........................................
11. MAINTENANCE AND REPAIR..............
12. GUIDELINES FOR SERVICE
WORK SAFETY....................................
13. DURING SERVICE WORK
FOR INSPECTION................................
14. DURING SERVICE WORK
FOR ELECTRIC DEVICES....................
15. OWNER INSPECTIONS
AND SERVICES...................................
16. STANDARD BOLTS SPECIFICATIONS
3
5
10
12
14
16
18
20
22
23
28
30
34
36
37
41

01-3
ENGINE GENERAL
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ENGINE GENERAL
GENERAL
1. ENGINE ASSEMBLY LAYOUT
1) LH SIDE VIEW
2) RH SIDE VIEW

01-4
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ENGINE GENERAL
3) FRONT VIEW
4) FAN BELT

01-5
ENGINE GENERAL
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1) ECU Related Componets
2. ENGINE CONTROLS LAYOUT
NO. FUNCTION NO. FUNCTION
A Coolant reservoir K HFM sensor
B FFH L VGT turbo charger
C Engine oil dipstick M Engine
D Oil separator(PCV valve ) N Engine oil filler cap
E Vacuum pump O PWM electric fan & fan shroud
F EGR valve P Power steering oil reservoir
G Vacuum modulator Q Fuel filter & priming pump
H Brake fluid reservoir R Battery
I ABS/ESP modulator S Fuse box
J Air cleaner assembly T Washer fluid reservoir

01-6
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ENGINE GENERAL
2) Engine And Sensors
Camshaft Position Sensor Injector Glow Plug
Common Rail Fuel Pressure Sensor
(Common Rail)
Booster Pressure Sensor

01-7
ENGINE GENERAL
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Knock Sensor (1 EA) &
Water Temperature Sensor Vacuum Modulator Crankshaft
Position Sensor
Water temp.
sensor
Knock sensor
HP Pump

01-8
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ENGINE GENERAL
3) Engine Accessories Related to ECU
IP Interior Fuse Box (Passenger Side)
Engine ECU Mounting Location
Engine ECU main relay
Hazard warning lamp
VGT & EGR vacuum
modulators, HFM
HP pumpIMV
1.
2.
3.
4.
Installed

01-9
ENGINE GENERAL
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HFM Sensor
Accelerator Pedal Module Fuel Filter Sensor
Service Interval (Fuel Filter)
EU
Only
Replace every 30,000 km
(Draining water from fuel filter:
whenever replacing the engine oil)
General
Replace every 25,000 km
(Draining water from fuel filter:
whenever replacing the engine oil)
Integrated
with 2
PPSs
Priming
Pump
Fuel
Filter

01-10
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ENGINE GENERAL
3. ELECTRICAL COMPONENTS AND PREHEATING SYSTEM
Glow Plug Preheat Warning Lamp
(Cluster)
Alternator Starter motor Engine compartment
fuse box
PTC / FFH:
12V - 115A 12V - 2.2kw
Battery

01-11
ENGINE GENERAL
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Preheat Control Unit
NO. FUNCTION
1 Glow plug terminal (#1 ~ #4)
2No G5 for 4 cylinders
(Without D20DT)
3 IG1 power supply terminal
4 Glow plug control signal (ECU113)
5 Ground terminal
6 Battery main wire
7
Preheat completion transmit
terminal : No use for vehicle
without remote engine start
8 K-line (ECU 34)

01-12
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ENGINE GENERAL
4. INTAKE SYSTEM LAYOUT
Supplying Compressed Air with
Turbocharger's Operation Intake Manifold
Intake outlet hose
Front air duct
Air cleaner
Terbocharger
intercooler
Turbo charger
Inter cooler
Air cleaner
To corresponding cylinders
From intercooler
Coolant
port

01-13
ENGINE GENERAL
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Recirculation of Exhaust Gas when
EGR Valve Operates Turbocharger Intercooler
EGR valve
Exhaust gas
Intake com
pressed air
HFM Sensor
Plug-in sensor
Air cleaner Turbo - charger
Temperature
- Sensor
Pretension
graph

01-14
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ENGINE GENERAL
5. EXHAUST SYSTEM LAYOUT
DOC (Diesel Catalytic Converter) Exhaust Manifold
To turbo -
charger
To EGR
pipe
From cylinders
EEGR Pipe
Passage for recirculation of exhaust gas

01-15
ENGINE GENERAL
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PCV Oil Separator Turbocharger Vacuum Modulator
VGT Turbocharger EGR Valved
Vacuum
modulator
To exhaust
pipe (DOC)
Exhaust
manifold
Intake com -
pressed air
Exhaust gas
Cylinder head cover (oil + gas)
Inlet port
Blow-by gas
(air duct hose)
Oil
(oil gauge pipe)
The first separation will happen when blow-
by gas passes through baffle plates in
cylinder head cover. Then oil and gas will
be separated due to cyclone effect afte
r
entering the oil separator inlet port.
Separated oil returns to oil pan via oil drain
port and the gas will be burnt again afte
r
entering the combustion chamber through
air duct hose via PCV valve that
opens/closes due to pressure differences
between the intake side and crankcase.
IP interior fuse
box (RH)
No.63(7.5A)
Engine ECU
(No. 95)
Turbo -
charger
actuator
Vacuum
pump

01-16
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ENGINE GENERAL
Cylinder Head Cover Oil Pressure Warning Lamp (Cluster)
6. LUBRICATION SYSTEM LAYOUT
Oil Pan and Baffle Plate (Integrated Type) Oil Strainer
Oil dipstick gauge

01-17
ENGINE GENERAL
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Oil Filter & Oil Cooler PCV Oil Separator
Oil
cooler
Oil
filter
Cylinder head cover (oil + gas)
Inlet port
Blow-by gas
(air duct hose)
Oil
(oil gauge pipe)
The first separation will happen when blow-
by gas passes through baffle plates in
cylinder head cover. Then oil and gas will
be separated due to cyclone effect afte
r
entering the oil separator inlet port.
Separated oil returns to oil pan via oil drain
port and the gas will be burnt again afte
r
entering the combustion chamber through
air duct hose via PCV valve that
opens/closes due to pressure differences
between the intake side and crankcase.

01-18
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ENGINE GENERAL
7. COOLING SYSTEM LAYOUT
Coolant Port Water Pump & Pipe
Radiator Assembly Cooling Fan and Fan Clutch
Coolant -
outlet port
Thermostat (inside)
Cylinder
block
Reservoir
(Coolant inlet hose)
Radiator
Coolant outlet hose
PWM electric
fan
Radiator
Coolant reservoir Coolant inlet hose
Return
hose

01-19
ENGINE GENERAL
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Engine Oil Filter & Cooler
Oil
cooler
Oil
filter
Oil cooler
Oil filter cap
Oil pressure switch

01-20
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ENGINE GENERAL
8. FUEL SYSTEM LAYOUT
Injector Fuel Filter & Priming Pump
Fuel filter
Connector
Priming
pump
HP Pump
Fuel return port
Venturi
Low pres - sure fuel supply port
Fuel return port
Fuel tempera -
ture sensor
IMV connector
IMV valve
High pres -
sure fuel supply port
1.
2.
3.
4.
5.
HP Pump