2012 SSANGYONG NEW ACTYON SPORTS engine oil

02-390000-00
1) Piston
(1) Overview
Piston assembly contains piston, #1 ring, #2
ring, oil ring, piston pin and snap ring. The
expansion energy from engine is transferred
to the crankshaft through connecting rod to
convert the linear movement to rotating
energy.
(2) Layout
#1 ring
Oil ring
Snap ring
#2 ringMaterial: B2+
Skirt coating:
MoS2
Piston cooling gallery
for connecting rod
Wide bawl type (CR 16.5)
Cooling jet

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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(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.

02-48
The bottom side of water jacket is desgined as sine wave to strengthen the structure of crankcase.
The main flow of coolant starts from outlet port of water pump and goes along the longitudinal
direction of engine. The coolant passage from cylinder head to inlet port of water pump is
integrated in cylinder head.
The engine oil from oil pump is supplied to the main oil gallery through oil channel, oil filter
module and cross bore in cylinder block without using external pipes. This oil is supplied to main
bearing, cylinder head and MBU. And, it is sprayed to the chain through the chain tensioner
connected to cross bore.
Crankcase cross bore for oil supply
Water jacket core

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

03-20
(2) 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.
Water drain from water separator ▶
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 lamp 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.
Water
separator
To separate the water from the fuel filter,
remove the fuel filter assembly first.

04-4
2. INSPECTION
1) Troubleshooting
When Abnormal Noises are Heard from the Engine Room ▶
For the vehicle equipped with DI engine, if a learning noise occurs in each range or other
noises occur, the major cause of it is a faulty turbocharger assembly. But an interference issue,
poor tightness or loose in the intake and exhaust system also can cause those noises. This is
mainly because the operator didn't follow the instruction exactly when reconnecting the intake
hoses and pipes which were disconnected to check the system or replace the air cleaner. If the
intake system is free of any faults, check the EGR and PCV oil separator connected to the
intake system.
The figure may be different from the actual engine. Therefore, read thoroughly below before
replacing the parts.
2) Abnormal Noise Caused by Poor Tightness of Intake System
When the DI engine is running, the air entered into the engine flows in the sequence as shown
above. If high intake pressure is applied to the loose or damaged part, a whistling noise may
occur, the intake air volume is measured incorrectly or the engine power is derated.

04-51719-00
3) Troubleshooting Sequence
The basic checks for intake system are as follows:
Basic Checks for Intake System ▶
Make sure to replace or clean the air
cleaner element periodically. Otherwise,
engine will be derated or work abnormally
because of low intake air volume.
Unlike the fuel system, which is a closed
circuit, the intake system is an open circuit
system. Therefore any malfunction may
occur due to dust and dirt.
Most of the connections consist of hoses
so the system cannot withstand high
temperature and pressure. Also it can be
deformed or loosened easily because it is a
clamp mounting system. Thus, when
checking the engine, basic inspections,
such as tightened status check and visual
inspection for hose, etc., should be carried
out in advance.
Other Checks for Intake System ▶
If the intake system is free of any faults,
check for EGR and PCV oil separator.

06-4
2. INSPECTION
1) Cautions During Driving
The following lists cautions to take during test drive and on the turbocharger vehicle, which must
be considered during the operation.
It's important not to drastically increase the engine rpm starting the engine. It could make
rotation at excessive speed even before the journal bearing is lubricated and when the
turbocharger rotates in poor oil supply condition, it could cause damage of bearing seizure
within few seconds.
If the engine is running radically after replacing the engine oil or oil filter brings poor oil supply
condition. To avoid this, it's necessary to start off after idling the engine for about 1 minute
allowing oil to circulate to the turbocharger after the replacement.
When the engine is stopped abruptly after driving at high speed, the turbocharger continues to
rotate in condition where the oil pressure is at '0'. In such condition, an oil film between the
journal bearing and the housing shaft journal section gets broken and this causes abrasion of
the journal bearing due to the rapid contact. The repeat of such condition significantly reduces
life of the turbocharger. Therefore, the engine should be stopped possibly in the idle condition. 1.
2.
3.
After string for long period of time during winter season or in the low temperature condition
where the fluidity of engine oil declines, the engine, before being started, should be cranked to
circulate oil and must drive after checking the oil pressure is in normal condition by idling the
engine for few minutes.