2012 SSANGYONG NEW ACTYON SPORTS engine

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3. G23D ENGINE STRUCTURE
Front View
Side View

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Front View ▶
NO. FUNCTION NO. FUNCTION
1 HFM Sensor 12 Intake Manifold
2 Intake Air Duct 13 Cylinder Head
3 Cylinder Head Cover 14 Exhaust Manifold
4 Ignition Coi 15 Dipstick Guide Tube and Gauge
5 Spark Plug Connector 16 Connecting Rod
6 Fuel Distributor 17 Crankshaft
7 Injector 18 Engine Mounting Bracket
8 Exhaust Camshaft 19 Starter
9 Intake Camshaft 20 Crankcase
10 Valve Tappet 21 Oil Pump Sprocket
11 Intake Valve 22 Oil Pan
NO. FUNCTION NO. FUNCTION
23 Camshaft Adjuster 29 Oil Pump Drive Chain
24 Oil Filler Cap 30 Oil Strainer
25 Engine Hanger Bracket 31 Oil Pump
26 Cooling Fan and Viscous Clutch 32 Ring Gear and Flywheel of Drive Plate
27 Oil Filter 33 Piston
28 Timing Chain
Side View ▶

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4. DIAGNOSTIC INFORMATION AND PROCEDURE
1) Oil Leak Diagnosis
Most fluid oil leaks are easily located and repaired by visually finding the leak and replacing or
repairing the necessary parts. On some occasions a fluid leak may be difficult to locate or repair.
The following procedures may help you in locating and repairing most leaks.
Finding the Leak ▶
Identify the fluid. Determine whether it is engine oil, automatic transmission fluid, power
steering fluid, etc.
Identify where the fluid is leaking from. -
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After running the vehicle at normal operating temperature, park the vehicle over a large
sheet of paper.
Wait a few minutes.
You should be able to find the approximate location of the leak by the drippings on the
paper. ·
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Visually check around the suspected component.
Check around all the gasket mating surfaces for leaks. A mirror is useful for finding leaks
in areas that are hard to reach.
If the leak still cannot be found, it may be necessary to clean the suspected area with a
degreaser, steam or spray solvent. -
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Clean the area well.
Dry the area.
Operate the vehicle for several miles at normal operating temperature and varying
speeds.
After operating the vehicle, visually check the suspected component.
If you still cannot locate the leak, try using the powder or black light and dye method. ·
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Clean the suspected area.
Apply an aerosol-type powder (such as foot powder) to the suspected area.
Operate the vehicle under normal operating conditoins.
Visually inspect the suspected component. You should be able to trace the leak path over
the white powder surface to the source. -
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- Powder Method ▶

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Black Light and Dye Method ▶
A dye and light kit is available for finding leaks, Refer to the manufacturer's directions when using
the kit.
Pour the specified amount of dye into the engine oil fill tube.
Operate the vehicle normal operating conditions as directed in the kit.
Direct the light toward the suspected area. The dyed fluid will appear as a yellow path
leading to the source. -
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Once the origin of the leak has been pinpointed and traced back to its source, the cause of the
leak must be determined in order for it to be repaired properly.
If a gasket is replaced, but the sealing flange is bent, the new gasket will not repair the leak. The
bent flange must be repaired also. Before attempting to repair a leak, check for the following
conditions and correct them as they may cause a leak.Repairing the Leak ▶
Gaskets ▶
The fluid level/pressure is too high.
The crankcase ventilation system is malfunctioning.
The seal bore is damaged (scratched, burred or nicked).
The seal is damaged or worn.
Improper installation is evident.
There are cracks in the components.
The shaft surface is scratched, nicked or damaged.
A loose or worn bearing is causing excess seal wear. -
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2) Compression Pressure Test
Standard Service Data ▶
A9912 0012B (001 589 76 21 00) Compression Pressure Tester -
Measuring Procedure ▶
Warm the engine up to normal operating temperature.
Remove the spark plugs using the spark plug wrench.
Place the diagram sheet to compression pressure tester A9912 0012B (001 589 76 21 00).
Connect the adaptor to compression pressure tester A9912 0012B (001 589 76 21 00)
and install it into the spark plug hole.
Crank the engine approx. eight revolutions by using the start motor.
Compare the measurements of compression pressure tester A9912 0012B (001 589 76 21
00) with the specifications.
Measure the compression pressure of the other cylinders in the same way.
If measured value is not within the specifications, perform the cylinder pressure leakage
test. -
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Discharge the combustion residues in the cylinders before testing the compression
pressure.
Apply the parking brake before cranking the engine. -
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3) Cylinder Pressure LeakageTest
Permissible Pressure Leakage ▶
At Whole EngineMax. 25 %
At Valve and Cylinder Head GasketMax. 10 %
At Piston and Piston RingMax. 20 %
OT (TDC)1, 4
UT (BDC 180 °)2, 3
Cylinder Number ▶
Cylinder Number ▶
Cylinder Pressure
Leakage TesterBosch, EFAW210A
Sun, CLT 228

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Leakage Test ▶
Warm the engine up to normal operating temperature.
Disconnect the negative battery cable.
Remove the spark plugs.
Check the coolant level by opening the coolant reservoir cap and replenish if insufficient.
Open the engine oil filler cap.
Connect the tester to air pressure line and adjust the scale of tester.
Install the connecting hose to spark plug hole.
Position the piston of No.1 cylinder at TDC by rotating the crankshaft.
Connect the connecting hose to tester and measure the leakage volume after blowing up
5 bar of compressed air. -
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Measure the leakage volume in the completely opening condition of throttle valve by pulling
the acceleration cable. -
Perform the pressure test according to the firing order. -
Firing Order: 1 - 3 - 4 - 2 -
Compare the leakage pressure with the specifications. -

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6. SPECIFICATIONS
1) Engine Specifications
MSE : Engine Control Module
3.53D : 4 Cylinder Version