DI0A-1
SECTION 00 DI0A
GENERAL INFORMATION
Table of Contents CLEANNESS ....................................... DI0A-3
FUEL SYSTEM ................................. DI0A-21
STRUCTURE ...................................... DI0A-8
Fuel supply system ...................... DI0A-22
ENGINE CONTROLS ....................... DI0A-11 ECU related components .............. DI0A-11 Engine and sensors ..................... DI0A-12 Electrical components and pre heating system ...................... DI0A-13 INTAKE SYSTEM ............................. DI0A-14 Intake air flow chart ...................... DI0A-15 INTAKE SYSTEM ............................. DI0A-16 Exhaust air flow chart ................... DI0A-17 LUBRICATION SYSTEM .................. DI0A-18 COOLING SYSTEM ......................... DI0A-19 Coolant flow chart ........................ DI0A-20
GENERAL INFORMATION DI ENG SM - 2004.4
GENERAL SPECIFICATIONS ........... DI0A-23 Vehicle specifications ................... DI0A-23 Maintenance ................................ DI0A-26 VEHICLE IDENTIFICATION .............. DI0A-28 HOW TO USE AND MAINTAIN WORKSHOP MANUAL ........................................... DI0A-30 Consists of workshop manual ...... DI0A-30 Manual description ...................... DI0A-30 Guidelines for service work safety ........................................... DI0A-31 Lifting points ................................. DI0A-36 Tightening torque of standard bolts .............................................. DI0A-37
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DI0A-3
CLEANNESS Cleanness of DI Engine Fuel System and Service Procedures The fuel system for DI engine consists of transfer (low pressure) line and high pressure line. Its highest pressure reaches over 1600 bar. Some components in injector and HP pump are machined at the micrometer 100 Âľm of preciseness. The pressure regulation and injector operation are done by electric source from engine ECU. Accordingly, if the internal valve is stucked due to foreign materials, injector remains open. Even in this case, the HP pump still operates to supply high pressurized fuel. This increases the pressure to combustion chamber (over 250 bar) and may cause fatal damage to engine. You can compare the thickness of injector nozzle hole and hair as shown in below figure (left side). The right side figure shows the clearance between internal operating elements.
Valve actuator lift: 0.028 mm Hair
Diameter: 0.40 mm
Nozzle hole
Operating clearance: 0.002 mm Diameter: 2.0 mm
Y220_0A035
The core elements of fuel system has very high preciseness that is easily affected by dust or very small foreign material. Therefore, make sure to keep the preliminary works and job procedures in next pages. If not, lots of system problems and claims may arise.
GENERAL INFORMATION DI ENG SM - 2004.4
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DI0A-4
Job procedures 1. Always keep the workshop and lift clean (especially, from dust). 2. Always keep the tools clean (from oil or foreign materials). 3. 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. 4. Follow the below procedures before starting service works for fuel system.
Carefully listen the symptoms and problems from customer.
Visually check the leaks and vehicle appearance on the wiring harnesses and connectors in engine compartment.
Perform the diagnosis proceee with Scan-i (refer to “DIAGNOSIS” section in this manual).
Locate the fault. If the cause is from fuel system (from priming pump to injector, including return line), follow the step 1 through step 3 above.
5. 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 “DIAGNOSIS” section in this manual. At this point, thoroughly clean the related area in engine compartment. Notice
Clean the engine compartment before starting service works.
Tool kit for high pressure line
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Took kit for low pressure line
Removal tool box and cap kits
GENERAL INFORMATION DI ENG SM - 2004.4
DI0A-5
6. Follow the job procedures. If you find a defective component, replace it with new one.
Disconnect the negative battery cable.
For safety reasons: check pressure is low before opening the HP systems (pipes)
Use special tools and torque wrench to perform the correct works. Once disconnected, the fuel pipes between HP pump and fuel rail and between fuel rail and each injector should be replaced with new ones. The pipes should be tightened to specified tightening torques during installation. Over or under torques out of specified range may cause damages and leaks at connections. Once installed, the pipes have been deformed according to the force during installtion, therefore they are not reusable. The copper washer on injector should be replaced with new one. The injector holder bolt should be tightened to specified tightening torque as well. If not, the injection point may be deviated from correct position, and it may cause engine disorder.
Plug the disconnected parts with sealing caps, and remove the caps immediately before replacing the components.
Fuel pressure sensor
High pressure pump
Common rail
IMV valve Injection pipe
Transfer pump and high pressure pump Fuel temperature sensor
Water separator Water detection sensor Priming pump
Fuel filter
Injector
Cap position Supply line Return line Fuel tank Y220_0A039
GENERAL INFORMATION DI ENG SM - 2004.4
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DI0A-6
7. Plug the removed components with clean and undamaged sealing caps and store it into the box to keep the conditions when it was installed. 8. Clear the high pressure offset value by Scan-100 after replacing the high pressure pump.
Y220_0A040
9. To supply the fuel to transfer line of HP pump press the priming pump until it becomes hard. Warning
Do not crank engine before having filled pump. Priming pump
Y220_0A041
10. Check the installed components again and connect the negative battery cable. Start the engine and check the operating status. 11. With Scan-i, check if there are current faults and erase the history faults. Note
For details, refer to “DI10 Diagnosis teable�.
Y220_0A042
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GENERAL INFORMATION DI ENG SM - 2004.4
DI0A-7
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. Y220_0A041
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 light ( ) 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. (See fuel system for details.)
GENERAL INFORMATION DI ENG SM - 2004.4
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DI0A-8
STRUCTURE Front view
Rear view
Y220_0A001
1. TVD (Torsional Vibration Damper)
7. Cooling fan pulley & viscos clutch 13. Oil filter housing
2. Air conditioner compressor
8. Aut tensioner pulley
14. Vacuum pump
3. Power steering pump pulley
9. Auto tensioner
15. Crank position sensor
10. Poly-groove belt
16. EGR valve
5. Water pump pulley
11. Cam position sensor
17. Power steering pump
6. Alternator
12. Drive plate (M/T: DMF)
18. EGR center pipe
4. Idle pulley
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GENERAL INFORMATION DI ENG SM - 2004.4
DI0A-9 Top view
Y220_0A002
19. Cylinder head cover
24. Fuel pipe
29. Booster pressure sensor
20. Intake manifold
25. Injector
30. Oil separator
21. Water outlet port
26. Fuel return line
31. Oil dipstic
22. Common rail
27. Oil filler cap
32. EGR center pipe
23. Fuel pressure sensor
28. Glow plug
GENERAL INFORMATION DI ENG SM - 2004.4
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DI0A-10 Left side view
Right side view
Y220_0A003
33. Cylinder head
38. EGR - RH pipe
42. Turbocharger vacuum modulator
34. Cylinder block
39. Oil separator
43. EGR valve vacuum modulator
35. Oil pan
40. Oil dipstic
44. EGR valve
36. Drain plug
41. HP pump
45. Exhaust manifold
37. Turbocharger
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GENERAL INFORMATION DI ENG SM - 2004.4
DI0A-11
ENGINE CONTROLS ECU RELATED COMPONENTS ECU/barometric sensor
Cam position sensor
HFM sensor/intake air temperature sensor
Fuel filter (water detection sensor)
Pre heating time relay
Accelerator pedal sensor
Main relay
Y220_0A004
GENERAL INFORMATION DI ENG SM - 2004.4
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DI0A-12
ENGINE AND SENSORS Injector
Common rail
Crankshaft position sensor
Glow plug
Fuel pressure sensor
Camshaft position sensor
Booster pressure sensor
HP pump
Coolant temperature sensor
Knock sensor (2)
Y220_0A005
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GENERAL INFORMATION DI ENG SM - 2004.4
DI0A-13
ELECTRICAL COMPONENTS AND PRE HEATING SYSTEM Glow plug
Pre heating time relay
Fuse box
Starter motor
Battery
Alternator
Y220_0A006
GENERAL INFORMATION DI ENG SM - 2004.4
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DI0A-14
INTAKE SYSTEM
Air cleaner assembly
HFM sensor
Intake duct hose
Intake manifold
Intake outlet hose
Turbocharger
Intercooler
Inlet hose
Y220_0A007
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GENERAL INFORMATION DI ENG SM - 2004.4
DI0A-15
INTAKE AIR FLOW CHART
Intake valve (in combustion chamber)
Intake manifold
Air cleaner side
Turbocharger (compressor)
Engine
HFM sensor
Intake hose (outlet)
Intercooler
Intake hose (inner)
Y220_0A008
GENERAL INFORMATION DI ENG SM - 2004.4
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DI0A-16
INTAKE SYSTEM
Muffler
Turbocharger
Exhaust manifold
Catalytic converter
EGR pipe
EGR valve
Vacuum modulator
Y220_0A009
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GENERAL INFORMATION DI ENG SM - 2004.4
DI0A-17
EXHAUST AIR FLOW CHART
Catalytic converter
Exhaust pipe
Muffler
Ambient air
Exhaust gas
Turbocharger (turbine side) EGR vacuum modulator To turbocharger booster Turbocharger booster vacuum modulator Turbocharger booster
EGR valve
Exhaust manifold
EGR pipe
Y220_0A010
GENERAL INFORMATION DI ENG SM - 2004.4
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DI0A-18
LUBRICATION SYSTEM
Cylinder head cover
Oil dipstic
PCV valve
Engine oil filter housing
Engine oil pump
Oil pan
Engine oil cooler
Engine oil pressure switch
Y220_0A011
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GENERAL INFORMATION DI ENG SM - 2004.4
DI0A-19
COOLING SYSTEM
Coolant reservoir
Water pump
Radiator assembly
Cooling fan and fan clutch
Y220_0A013
GENERAL INFORMATION DI ENG SM - 2004.4
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DI0A-20
COOLANT FLOW CHART Heater
Oil cooler Coolant reservoir
Intake manifold
Thermostat Coolant outlet port
Water pump
Inner hose
Outlet hose
Cooling fan
Radiator
Y220_0A014
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GENERAL INFORMATION DI ENG SM - 2004.4
DI0A-21
FUEL SYSTEM
Fuel return hose
Injector
Fuel pressure pipe
HP pump
Common rail
Fuel filter
Priming pump
Y220_0A015
GENERAL INFORMATION DI ENG SM - 2004.4
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DI0A-22
FUEL SUPPLY SYSTEM Fuel pressure sensor High pressure pump
Common rail
IMV valve High pressure pipe
Low and high pressure pump Fuel temperature sensor
Water separator Fuel filter
Label (C21)
Prining pump
Water detection sensor
Injector
Sensors HFM sensor Cam position sensor
ECU
Fuel tank
Crank position sensor Knock sensor etc.
Components: - High pressure fuel pump
- Fuel rails
- Fuel pressure sensor
- Fuel injectors
- Electroc control unit (ECU)
- Various sensors and actuators
Supply line Return line ECU communication line
Y220_0A016
According to input signals from various sensors, engine ECU calculates driver’s demand (position of the accelerator pedal) and then controls overall operating performance of engine and vehicle on that time. ECU receives signals from sensors via data line and then performs effective engine air-fuel ratio controls based on those signals. Engine speed is measured by crankshaft speed (position) sensor and camshaft speed (position) sensor determines injection order and ECU detects driver’s pedal position (driver’s demand) through electrical signal that is generated by variable resistance changes in accelerator pedal sensor. Air flow (hot film) sensor detects intake air volume and sends the signals to ECU. Especially, the engine ECU controls the air-fuel ratio by recognizing instant air volume changes from air flow sensor to decrease the emissions (EGR valve control). Furthermore, ECU uses signals from coolant temperature sensor and air temperature sensor, booster pressure sensor and barometric sensor as compensation signal to respond to injection starting, pilot injection set values, various operations and variables.
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GENERAL INFORMATION DI ENG SM - 2004.4
DI0A-23
GENERAL SPECIFICATIONS VEHICLE SPECIFICATIONS Vehicle Dimension
(mm)
Y220_0A017
GENERAL INFORMATION DI ENG SM - 2004.4
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DI0A-24
Specifications Systems General
Engine
Items
Diesel
Remark
Overall length (mm)
4,720 (4,785)
Overall width (mm)
1,870
( ): optional item
Overall height (mm)
1,760 (1,830)
Gross vehicle weight (kg)
AT: 2450 (2510), MT: 2405 (2465)
Curb weight (kg)
AT: 1995 (2055), MT: 1950 (2010)
Min. turning radius (m)
5.6
Ground clearance (mm)
200
Fuel
Diesel
Fuel tank capacity
80
Model
D27DT
No. of cyl./Compression ratio
5/18:1 2,696 cc
Total displacement
DOHC
Camshaft arrangement Max. power
170 ps/4,000 rpm
Max. torque
34.7 kg•m/1,800 rpm
Injection timing
ATDC 4° ± 1°(at idle) 760 ± 50 rpm
Idle speed
Water-cooled/forced circulation
Cooling system
Approx. 11.5
Coolant capacity
Gear pump, forced circulation
Lubrication
9.3
Max. oil capacity
Turbo charger, air-cooled
Turbo charger and cooling type Manual transmission
Remote control, floor change type
Type 1st
IDI Engine
2.367
2.475
1.473
1.536
th
4
1.000
1.000
5th
0.872
0.807
Rev.
3.700
3.591
Model
Electronic
Type
Floor change type 1st
2.742
3.595
2.742
2nd
1.508
2.186
1.508
rd
1.000
1.405
1.000
th
4
0.708
1.000
0.708
5th
-
0.831
-
2.429
3.162
2.429
-
1.926
-
Rev. 1st nd
Rev. 2 CHANGED BY AFFECTED VIN
4.315
rd
3
EFFECTIVE DATE
DI Engine
2nd 3
Automatic transmission
4.007
GENERAL INFORMATION DI ENG SM - 2004.4
DI0A-25
Specifications (Cont’d) Systems Transfercase
Items
Diesel
Model
Part-time
Type Gear ratio
Clutch
Remark ( ): optional item
Planetary gear type High
1.000 : 1
Low
2.483 : 1
Type
Hydraulic [A/T: Torque converter]
Disc type
Dry single diaphragm type [A/T: 3 elements 1 stage 2 phases]
Power steering
Front axle
Rear axle
Brake
Type Steering angle
Rack and pinion Inner
36° 17'
Outer
32° 40'
Drive shaft type
Ball joint type
Axle housing type
Build-up type
Drive shaft type
Semi-floating type
Axle housing type
Build-up type
Master cylinder type
Tandem type
Booster type Type
Vacuum booster Inner
Disc
Outer
Drum (Disc)
Parking brake Suspension
Cable type (internal expansion)
Front
Wishbone + Coil spring
Rear
5-link + Coil spring
Air conditioner
Refrigerant
Electrical
Battery type/Capacity (V-AH)
R134a
Compressor type
Vane type MF / 12 - 90
Starter capacity (V-kW) Alternator capacity (V-A)
GENERAL INFORMATION DI ENG SM - 2004.4
Diesel : 12 - 2.2, Gasoline : 12 - 1.8 IDI
12 - 75 (12 - 90)
DI
12 - 140 (12 - 115)
Gasoline
12 - 115
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DI0A-26
MAINTENANCE Major Components and Service Interval * Use only Ssangyong Genuine Parts. Components
Daily Weekly
Gasoline engine
O
DI diesel engine
O
IDI diesel engine
O
-
Coolant
O
-
Replace at every 60,000 km or 3 years
Brake pipe and hose
-
-
Initial inspection: 1,000 km
Engine oil and oil filter
-
Service Interval Initial change: 10,000 km Replace at every 15,000 km
-
Initial change: 5,000 km Replace at every 10,000 km or 12 months
Remarks More frequent maintenance is required if the vehicle is operated under severe condition. Severe conditions? - Frequent low-speed operation as in stop-and-go traffic - When most trips are less than 6 km (in winter, less than 16 km) - Driving in sandy, dusty, and salty road - Driving in mountainous areas - Extensive idling or high load operation such as towing a trailer
Inspect at every 20,000 km, replace if necessary Brake pad, shoe and disc
-
-
Inspect at every 10,000 km, check or adjust if necessary
Air cleaner element
Gasoline engine
-
O
Clean at every 15,000 km,
DI diesel engine
-
O
Initial clean: 5,000 km,
IDI diesel engine
-
O
Clean at every 10,000 km, replace if necessary,
Fuel filter Gasoline engine
-
-
Replace at every 60,000 km
DI diesel engine
-
-
Replace at every 30,000 km (Drain the water from fuel filter at every 10,000 km)
IDI diesel engine
-
-
Replace at every 40,000 km
Auto4-speed matic transmis- 5-speed sion oil
-
-
-
-
Inspect at every 30,000 km or 1 year, replace if necessary (replace at every 60,000 km if the vehicle is operated under severe conditions)
Manual transmission oil
-
-
Transfer case oil
-
-
Axle oil
-
-
Replace at every 30,000 km
Air conditioner air filter
-
-
Replace at every 10,000 km
Spark plug (gasoline engine)
-
-
Replace at every 60,000 km
Replace at every 60,000 km
If vehicle is operated under dusty or sandy area, frequently clean and inspect the air cleaner system. If necessary, replace the air cleaner element.
Replace at every 30,000 km
More frequent maintenance is required if the vehicle is operated under severe condition. - Driving in unpaved road - Towing a trailer
Inspect at every 10,000 km, Replace at every 60,000 km Inspect at every 10,000 km, Replace at every 60,000 km (but, frequently chexk the leaks)
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More frequent maintenance is required if the vehicle is operated under severe condition. - Driving in sandy, dusty, and unpaved road - Excessive operation of air conditioner or heater
GENERAL INFORMATION DI ENG SM - 2004.4
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