2012 SSANGYONG NEW ACTYON SPORTS low oil pressure

02-6
1533-31 Oil dipstick gauge
Changed the location
1719-40 Intake manifold
T-MAP sensor installing hole (1), intake duct
mounting flange (2), intake duct mounting
boss (3)
1719-29 Intake duct and bracket
Changed intake duct, air intake direction,
location of T-MAP sensor
D20DTF (Korando C)
3. MAJOR CHANGES IN ENGINE (RH)
OldNew
OldNew
OldNew
T-MAP sensorT-MAP sensor
1533-30 Oil level sensor & oil pressure
switch
OldNew
OldNew
Oil pressure switchOil level sensor
1225-01 Cylinder head cover & PCV valve
Changed the location of blow-by hose and
PCV valve

01-90000-00
(3) Cautions before service
Prolonged exposure to the engine oil make cause a skin cancer or an irritation.
Used engine cotains the hazardous material that may cause the skin cancer. Do not allow the
used engine to make contact with your skin.
Make sure to wear the protection gloves and goggle when handling the engine oil. If contact
happens, rinse affected areas immediately with plenty of water. Do not wash it with gasoline or
solvent. If irritation persists, consult a doctor.
Improperly disposed engine oil can pollute the environment. Dispose used engine oil in
accordance with local environmental regulations. -
-
-
(5) Tightening the fastener
If fine dust or foreign material enters into DI engine's fuel system, there can be serious
damages between HP pump and injectors. So, be sure to cover removed fuel system
components with cap and protect removed parts not to be contaminated with dirt. (Refer to
cleanness in this manual while working on DI engine fuel system)
When working on the fuel line between priming pump and injector (including return line),
always plug the openings with caps to prevent foreign materials or dust from entering to the
openings and connections.
The HP fuel supply pipe (HP pump to fuel rail) and HP fuel pipe (Fuel rail to injector)
should be replaced with new ones when removed. 1.
2.
3. Scalding hot coolant and steam could be blown out under pressure, which could cause serious
injury. Never remove the coolant reservoir cap when the engine and radiator are hot.
(4) Lubrication system
3) Fuel and Oil System
If work on the fluid system such as fuel and oil, working area should be well ventilated and
smoking should be prohibited.
Gasket or seal on the fuel/lubrication system should be replaced with new ones and bolts and
nuts should be tightened as specified. -
-Clean the mating surfaces before tightening.
Place the marks with paint to tighten by angle if the angle wrench is not available. -
-

02-6
Component SizeBolt
QuantitySpecified torque
(Nm)Remark
(Total torque)
Glow plug M5 4 20±2Nm -
Vacuum pumpM8×25 3 10±1Nm -
Timing gear case coverM12×55 3 85±8.5Nm -
M6×25 7 10±1Nm -
M6×45 1 10±1Nm -
M6×50 3 10±1Nm -
Cylinder head coverM6×35 21 10±1Nm -
Oil gauge tubeM6×16 1 10±1Nm -
Oil filter cap 1 25±2.5Nm -
Fuel railM8×35SOC 2 25±2.5Nm -
Injector clamp boltM6×60 2 10±1Nm,
120˚+10˚ -
High pressure pipe
(between HP pump and
fuel rail)M17 1 30±3Nm -
High pressure pipe
(between fuel rail and
injector)M17 4 30±3Nm -
Crank position sensorM5×14 1 8±0.4Nm -
Main wiringM6×16 5 10±1Nm -
Intake duct M8x25 4 25±2.5Nm -
Power steering pumpM8×100 3 25±2.5Nm -
Cylinder head front
coverM6×10 5 10±1Nm -
Ladder frameM8×16 5 30±3Nm -
Oil pumpM8×35 3 25±2.5Nm
-

02-8
(2) Cylinder pressure leakage test
If the measured value of the compression pressure test is not within the specifications, perform
the cylinder pressure leakage test.Specified value ▶
Perform this test in the sequence of firing order.
Do not test the cylinder pressure leakage with wet type test procedure. (do not inject the
engine oil into the combustion chamber) -
-
Test condition: normal engine operating
temperature (80˚C)Specified value
Whole engine below 25%
at valve and cylinder head gasket below 10%
at piston ring below 20%
Crank the engine for approx. 10 seconds
by using the start motor. 2.
Record the test result and measure the
compression pressure of other cylinders
with same manner. 3.
If the measured value is out of specified
value, perform the cylinder pressure
leakage test. 4.

02-170000-00
Brake booster and naster
cylinderVacuum pump
Pump capacity: 210 cc/rev
Camshaft speed: 375 to 3,000 rpm
Lubrication temperature: -40 to
155°C
Oil: 5W30
Drive type: Driven by exhaust
Camshaft sprocket
2. VACUUM PUMP
Vacuum pump generates the vacuum pressure and supplies it to EGR cooler bypass solenoid.
This pump is single vane type and displacement is 210 cc/rev. The lubrication oil is supplied
through the hole in hollow shaft.
Components ▶
EGR cooler bypass valve
This valve is controlled by ECU.
When the engine is cooled, the
exhaust gas goes to combustion
chamber without passing
through EGR cooler because the
valve is closed by vacuum
pressure.

02-290000-00
(2) Layout
Chain upper bush
Type: single bush
Chains:112 EA
Tensioner rail
Installed between exhaust
Camshaft sprocket and
crankshaft sprocket
Hydraulic tensioner
Contains tensioner housing
plug, spring and check valve,
and operated by hydraulic
pressure
Crankshaft sprocket
Teeth: 21 EA
Oil pump sprocket
Teeth: 33 EA
Chain lower bush
Chain type: single bush
Chains: 60 EA
Mechanical type tensioner
Operated by internal spring
Clamping rail
Installed between exhaust
Camshaft sprocket and
crankshaft sprocket
Exhaust camshaft
sprocket
Teeth: 42 EA
1) Chain Drive
(1) Overview
The drive chain is single chain drive system with simple design and variable performance, and it
utilizes the hydraulic tensioner to reduce the wave impact generated by the chain. This chain is light
weight and has high durability through single bush chain. Shoulder bolts are used for better NHV.
7. CHAIN AND GEAR DRIVE SYSTEM
D20DTR engine uses single stage chain drive system. Timing chain drives the exhaust side and
gear drive the intake side. Timing chain is single bush type. Upper chain drives HP pump
connected to intake Camshaft by driving exhaust cam shift sprocke, and lower chain drives oil
pump to lubricate the engine.

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.