2012 SSANGYONG NEW ACTYON SPORTS alternator

01-4
2. MAJOR COMPONENTS
Front view ▶
Vacuum pump
Oil filter assembly
Camshaft position sensor
Power steering pump pulley
Water pump pulley
Alternator pulley
Idler pulley No. 2
A/C compressor pulley
Auto tensioner
Idler pulley No. 1
Isolation damper
Rear view ▶
E-EGR valve
Fuel temperature sensor
Fuel HP pump assembly
Coolant temperature sensor
IMV valve Crankshaft position sensor
Oil pressure switch

02-50000-00
Component SizeBolt
QuantitySpecified torque
(Nm)Remark
(Total torque)
Hot water inlet pipeM6×16 2 10±1Nm -
AlternatorM10×90 1 25±2.5Nm -
M10×116 1 46±4.6Nm -
A/C bracketM8×25 4 7.8~11.8Nm -
A/C sub bracketM6×25 4 10±1Nm -
Intake manifoldM8×35 2 25±2.5Nm -
M8×110 6 25±2.5Nm -
Oil filter moduleM8×40 6 25±2.5Nm -
M8×20 1 25±2.5Nm -
M8×140 2 25±2.5Nm -
Knock sensorM8×28 2 20±5Nm -
Cam position sensorM8×14 1 10~14Nm -
Booster pressure
sensorM6×20 2 10±1Nm -
Exhaust manifold M8 10 40±4Nm -
Turbocharger M8 3 25±2.5Nm -
Support bolt 1 25±2.5Nm -
Support nut M8 1 25±2.5Nm -
T/C oil supply pipe M6(block side) 1 10±1.0Nm -
M6(turbo side) 1 17±2.0Nm -
T/C oil return pipeM6×16(turbo side)2 10±1Nm -
M6×16(block side)2 10±1Nm -
EGR valveM8×22 2 25±2.5Nm -
EGR pipe bolt
(Intake side)M8×16 2
25±2.5Nm -
EGR pipe bolt
(EGR cooler side)M8×16 2 25±2.5Nm -
EGR combination boltM6×16 4 10±1Nm -
M8×16 16 25±2.5Nm -
Idle pulley/Tensioner
pulley1 45±4.5Nm -

02-130000-00
D20DTR Engine
1. BELT LAYOUT
It is single drive type and uses FEAD (Front End Accessories Drive) design to make a compact
layout.
Components ▶
HPS (Hydraulic Power Steering)
1 Crankshaft pulley (DDU)
2 Auto tensioner
3 Tensioner pulley
4 Vacuum pump
5 A/C compressor pulley
6 Alternator pulley
7 Water pump pulley
8 Idle pulley #1
9 Idle pulley #2
10 Power steering pump pulley

09-31451-01
1. SPECIFICATION
AlternatorCrankshaft pulley : Alternator pulley 1 : 2.94
Normal output (idling/2200 rpm) 70/120 A
Regulator voltage 14.6 V
BrushLength 12.5 mm
Wear limit 7 mm
BatteryType MF
Capacity 90 AH
Unit Description Specification

09-4
2. INSPECTION
1) Alternator Output Test
Item How to check DTC set value / Action
Output
current
B terminal
current
Rotor
coil
resistance
L terminal
voltage
Disconnect the cable connected to the
B terminal on the alternator. Connect
one end of the ammeter to the B
terminal and the other end to the cable
connected to the B terminal.
Measure the maximum output value.
(Maintain the engine speed between
2,500 and 3,000 rpm.)
(Turn the headlamp and all the electrical
switches on.) 1.
2.Pass: If the measured current is
45 A or higher.
Fail: If the measured current is
less than 45 A.
Check the current of the B
terminal. -
-
-
Move the gear selector lever to the
neutral position.
Maintain the engine speed at 2,500 rpm
with the vehicle unloaded.
(Turn all the electrical switches off.) 1.
2.Open circuit: If the measured
current is 5 A or higher. -
Disconnect the negative cable from the
battery.
Remove the B terminal and turn off the
ignition switch.
Measure the resistance between the L
and F terminals with an ohmmeter. 1.
2.
3.Pass: If the measured resistance
is between 3 and 6 Ω.
Faulty rotor coil or slip ring: If the
measured resistance is less than
3 Ω or greater than 6 Ω. -
-
Connect the B terminal wiring.
Measure the voltage with the engine
running. 1.
2.Specification: 12.5 V to 14.5 V
Faulty IC regulator or field coil: If
the measured voltage is 14.5 V
or higher. -
-
Disconnect the negative battery cable.
Connect the negative cable again after connecting the ammeter. -
-

09-51451-01
2) Troubleshooting for Alternator
Item Cause Action
Overcharged
batteryDefective alternator voltage regulator
Replace the alternator
Defective voltage detection wiring Repair or replace
Loose alternator drive belt Adjust the belt tension or replace
Discharged batteryPoor connection of related circuit or
open circuitRetighten the loose connection or
repair open circuit
Defective alternator voltage regulator
Replace the alternator
Defective alternator voltage regulator
Replace the alternator
Terminated battery Replace the battery
Defective ground Repair
Charge warning
lamp does not
come on when
turning on ignition
switch with engine
stoppedDefective alternator voltage regulator
Replace the alternator
Open circuit in charge warning lamp,
fuse or wiringReplace or repair the charge
warning lamp or fuse
Defective ignition switch Replace the ignition switch
Defective ground of alternator circuit Repair
Charge warning
lamp is not turned
off after starting
engineDefective alternator voltage regulator
Replace the alternator
Corroded or worn battery cableRepair or replace the battery cable
Loose alternator drive belReplace the batteryAdjust the belt
tension or replace the belt
Defective wiring harness Repair or replace

09-71451-01
(1) Checking
Using battery tester ▶
PASS (11.0 V or more): Explain to the customer that the battery is reusable.
Need to be charged (9.0 to 11.0 V): Charge the battery with a charger and reinstall it. Explain it
to the customer.
Need to be replaced (9.0 V or more): The battery should be replaced due to overdischarging. -
-
-
(2) How to use battery tester
How it works and How to use it ▶
Determine battery capacity by fixing current
(load capacity) and time and varying
voltage.
Determine battery capacity based on the
amount of voltage drop when discharging a
fixed load capacity (120 A) for 5 seconds.
Connect the tester to the battery and read
the display while applying a load for 5
seconds. -
-
-
How to read display ▶
Red area (①): overdischarge or faulty
battery
Yellow area (②): Need to be charged (using
a vehicle alternator and a battery charger)
Green area (③): Normal
Red area on the left-hand side of OK (④):
Impossible to charge with an alternator
Green area with OK (⑤): Normally charged
Red area on the right-hand side of OK (⑥):
Overcharged by an alternator태 -
-
-
-
-
-

09-10
Alternator
The alternator charges the battery and
supplies power to each electric unit by
converting the mechanical energy to the
electrical energy.
1. SYSTEM DESCRIPTION
1) Overview
The charge system is designed to supply electrical energy to the vehicle while driving, and
supplies a constant direct current voltage by converting mechanical rotational movement to
electrical energy.
The voltage regulator on the back of the alternator controls the generated voltage in all rotating
ranges and adjusts the system voltage according to the electric load and ambient temperature
change.
2) System Layout (Locations)
Battery
It converts the chemical energy to the
electrical energy and supplies power to
the corresponding electric units when
starting the engine.