2012 SSANGYONG NEW ACTYON SPORTS ESP

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1461-00/2820-00/1491-00/8210-00/3110-00/3410-00/4892-00/8810-00/8010-00/7410-100/8510-00/8710-00/8510-00/8610-00/
8730-00/7340-00/7632-00/8310-00/8610-00/8510-00/8320-00/8410-00/8210-00/8310-00/4810-00/7770-00/8910-00/8790-00/6810-00
ENGINE1461-00 STARTING / CHARGING.................
1413-00 GLOW CONTROL UNIT...................
1491-00 ECU (ENGINE CONTROL
UNIT - D20DTR EU-V).....................
1490-00 ECU (ENGINE CONTROL
UNIT - GSL G23)............................
8210-00 DIAGNOSIS CIRCUIT.....................CHASSIS3110-00 TCU (6-A/T)...................................
3410-00 TCCU............................................
4892-00 ABS/ESP........................................8730-00 IMMOBILIZER CIRCUIT................
7340-00 SUNROOF CIRCUIT.......................
7632-00 CIGAR LIGHTER / POWER
OUTLET CIRCUIT........................
8310-00 HEAD LAMP CIRCUIT..................
8610-00 DRL (DAY TIME RUNNING
LIGHT) UNIT CIRCUIT.................
8510-00 HLLD (HEAD LAMP LEVEL G
DEVICE) CIRCUIT.........................
8320-00 TAIL LAMP CIRCUIT....................
8410-00 TURN SIGNAL / HAZARD
LAMP CIRCUIT.............................
8210-00 TRAILER LAMP CIRCUIT.............
8310-00 FOG LAMP CIRCUIT.....................
4810-00 STOP / BACK-UP
LAMP CIRCUIT.............................
7770-00 INTERIOR LAMP CIRCUIT............
7770-00 AUTO DIMMING ROOM
MIRROR CIRCUT.........................
8910-00 AUDIO / CLOCK CIRCUIT..............
8790-00 PARKING AID CIRCUIT..................
6810-00 PTC HEATER (POSITIVE
TEMPERATURE COEFFICIENT).....
6810-00 FATC (FULL AUTO TEMP.
CONTROL) CIRCUIT....................
6810-00 AIR-CON (MANUAL) CIRCUIT......... 12
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ELECTRIC8810-00 AIR-BAG.......................................
8010-00 CLUSTER......................................
7410-00 POWER SEAT - DRIVER................
7410-00 POWER SEAT - PASSENGER.......
8510-00 ELECTRIC OUTSIDE MIRROR........
8510-00 SEAT WARMER.............................
8710-00 STICS.............................................
8510-00 POWER WINDOW CIRCUIT...........
8610-00 HORN............................................17
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(2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION (1) CONNECTOR INFORMATION
1) ESP OFF SW, STOP LAMP SW, G-SENSOR

02-10
4892-01 ABS/ESP module
Introduced ESP system
4420-01 Stabilizer bar
Introduced dual peak bush
4411-01 Shock absorber spring
Spring height and rate changed
Height: 345.7 (4WD), 341.7 (2WD)
5. MAJOR CHANGES IN CHASSIS
OldNew
OldNew
Dual peak bush

01-110000-00
6. CODING AND INITIALIZATION
1) Engine Variant Coding
Unit Selection Description Remarks
PTC auxilary heater NO For PTC auxilary heater
equipped vehicle, select
"YES".-
YES YES
Glow plug Relay (K-line) Select "AQGS". -
AQGS (CAN) AQGS (CAN)
Transmission 6-speed M/T "DSI 6 AT" is selected
automatically.Select
5-speed A/T (DC 5 AT) -
6-speed A/T (DSI 6 AT) Select
Pressure sensor for
A/C refrigerantNO Select the appropriate
system.-
Type Pressure
sensor for A/C
refrigerant
Immobilizer NO Select "YES" if the vehicle
has immobilizer.-
YES YES
Vehicle speed input
typeCAN Select "CAN" if the vehicle
has ABS or ESPCAN
WIRE -
Fan 2 relays Select "PWM". -
PWM fan PWM fan
Auto cruise NO Select "YES" if the vehicle
has cruise contro.-
YES YES
G-sensor NO 2WD ABS & Non-ABS: NO
4WD ABS & ESP: YESSelect
YES Select

02-34
Oil pan sassembly
8. OIL PAN
The oil pan in D20DTR engine improves the NVH. Especially, the oil draining is much easier than
before.
Components ▶

02-370000-00
4) Features
Reduced vibration noise from the powertrain by blocking the torsional vibrations
Enhanced vehicle silence and riding comforts: reduced engine torque fluctuation
Reduced shifting shocks
Smooth acceleration and deceleration -
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5) Advantages
Improved torque response by using 3-stage type spring: Strengthens the torque response in
all ranges (low, medium, and high speed) by applying respective spring constant at each
range.
Stable revolution of the primary and secondary wheel by using planetary gear: Works as
auxiliary damper against spring changes
Less heat generation due to no direct friction against spring surface: Plastic material is
covered on the spring outer surface
Increased durability by using plastic bushing (extends the lifetime of grease) -
-
-
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6) Drive Plate
Drive plate receives the power from the start motor when starting the engine. With this, the drive
plate initially drives the power train system. And, it is connected to the torque converter to transfer
the engine torque to the power train system.
Trigger ring
Drive plate
Components ▶

02-40
(3) Functions
Piston transfers the combustion energy from engine to connecting rod. Especially in the direct
injection engine such as D20DTF, it provides the combustion space and largely effects to the
engine performance and exhaust gas.
Piston ring
#1 ring (Top ring) : Prevents the high pressurized combustion gas from leaking into crank
chamber, and prevents the engine oil getting into combustion chamber.
#2 ring: Scrapes the engine oil on the cylinder bore, and prevents the leaked combustion gas
from #1 ring from leaking into the crank chamber.
Oil ring: Scrapes the engine oil on the cylinder bore.
Piston pin
Connects the piston the connecting rod, and transfers the linear movement of piston to
connecting rod to convert it to rotating energy
Snap pin
Locks the piston pin. ▶
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▶
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▶
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(4) Assembling the piston
Install the piston rings with the "Y" mark on
the ring facing upwards.
Position the end gap of #1 ring at 180˚
away from the end gap of #1 ring.
Position the end gap of oil ring at 180˚
away from the end gap of coil spring, and
position the end gap of oil ring at 90˚ away
from the end gap of #2 ring. 1.
2.
3.

03-4
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.
Tool kit for high pressure lineTook kit for low pressure line