Table Of Contents - SSANGYONG Actyon Sports II 2012.01 Manual

Table of Contents

General Information3
Dimensions3
Vehicle Identification6
Specifications7
Recommended Fluids And Lubricants9
Scheduled Maintenance Services - Diesel Engine10
Scheduled Maintenance Services (General) - Diesel Engine13
Scheduled Maintenance Services - Gasoline Engine16
Modified Items19
Table Of Contents19
Exterior20
Interior22
Major Changes In Engine (Rh)24
Major Changes In Engine (Lh)26
Major Changes In Chassis28
Engine - General Information31
Engine Layout33
Engine Components34
Major Components34
Engine Compartment Layout36
Engine Service Interval37
Engine Specification And Capacity37
Caution When Servicing The Engine38
Standard Bolts Specifications40
Coding And Initialization41
Engine Variant Coding41
Special Service Tools42
Normal Equipment47
Engine Specification49
Cylinder Inspection53
Compression Pressure Test53
Cylinder Pressure Leakage Test54
Piston Protrusion Check55
Cylinder Head Mating Surface Check56
Cylinder Head Pressure Leak Test56
Guidelines On Engine Service57
Belt Layout59
Crankshaft Pulley (Isolation Damper)60
Belt Tensioner62
Vacuum Pump63
Engine Mounting65
Intake Manifold67
Exhaust Manifold67
Cylinder Head Cover68
Oil Separator69
Cylinder Head70
Camshaft72
Valve Assembly (Installed In Cylinder Head)73
Cylinder Head Gasket74
Chain And Gear Drive System75
Chain Drive75
Timing Chain And Gear76
Tensioner76
Mechanical Tensioner Assembly77
Guide Rail77
Timing Gear Case Cover78
Oil Pan80
Dual Mass Flywheel (Dmf) And Drive Plate81
Piston/Crankshaft/Cylinder Block84
Piston Overview85
Assembling The Piston86
Selecting Piston Oversize87
Connecting Rod88
Selection Of Crankshaft Pin Journal Bearing89
Crankshaft90
Selection Of Crankshaft Main Bearing91
Cylinder Block92
Water Jacket Core94
Crankcase Cross Bore For Oil Supply94
Fuel System Specification95
Maintenance Procedures For Di Engine Fuel System96
Fuel Filter Assembly97
Priming Pump Cap97
Diagnostic Test For Engine Fuel System98
Hydraulic System98
Excessive Backleak Of Injector99
Loss Of Pump Pressure/Flow100
Di Engine Fuel System Pressure Test101
Di Engine Fuel System Check Procedure102
Fuel System Check Procedure103
High Pressure System Pressure Test104
How To Use Pressure Tester105
Low Pressure System Pressure Test106
Static Test For Backleak Of Injector107
Dynamic Test For Backleak Of Injector108
Hp Pump Pressure Test109
Cautions For Di Engine110
Cleanness Of Di Engine Fuel System111
Di Engine And Its Expected Problems And Remedies112
Fuel System Overview And Operating Process113
Fuel Flow Diagram113
Fuel System Layout114
Fuel System Flow Diagram116
Input/Output Devices117
Intake System Specification119
Intake System Troubleshooting120
When Abnormal Noises Are Heard From The Engine Room120
Abnormal Noise Caused By Poor Tightness Of Intake System120
The Basic Checks For Intake System121
Intake System Overview122
Input/Output Of Intake System124
Intake System Operating Process125
Types Of Swirl126
Swirl Control126
Relationship Between Swirl And Fuel Injection Pressure127
Exhaust System Troubleshooting128
Cautions On Exhaust System129
Exhaust System Overview And Operating Process130
Exhaust Gas Flow131
Input & Output Devices131
Turbocharger Specification132
Turbocharger Inspection133
Inspection Of Turbine135
Possible Causes Of Defect136
Defects Caused By Reasons Other Than That Of The Turbocharger139
Turbocharger Troubleshooting140
E-Vgt (Electric-Variable Geometry Turbine) System Description146
E-Vgt Actuator (Electric-Actuator)147
E-Vgt Components148
E-Vgt Operating Principles150
Lubrication System Specification152
Lubrication System Maintenance153
Level Check (Lubrication System)153
Replenishment (Lubrication System)153
Lubrication System Overview And Operating Process154
Cooling System Specification155
Cooling System Inspection156
Coolant Level Check157
Leak Test (Cooling System)158
Thermostat158
Cautions On Cooling System159
Cooling System Overview And Operating Process160
Charging System Specification162
Charging System Inspection163
Alternator Output Test163
Troubleshooting For Alternator164
Checking Battery165
How To Use Battery Tester166
Starting With Jumper Cable167
Charging System Maintenance168
Charging System Overview And Operating Process169
Charging Flow170
Charging171
Output Characteristics (Charging System)171
Charging System Circuit Diagram172
Pre-Heating Specification173
Pre-Heating System Overview And Operating Process174
Input/Output Diagram Of Glow Plug Control Unit175
Pre-Heating System Diagram175
Pre-Heating System Circuit Diagram176
Pre-Heating System Operation177
Starting System Specification179
Starting System Troubleshooting180
Starting System Overview And Operating Process181
Starting System Circuit Diagram182
Cruise Control Overview And Operating Process183
Traffic Conditions For Using Cruise Control184
Cruise Control System Circuit Diagram185
Cruise Control System Configuration186
Cruise Control Operation187
Setting A Desired Speed187
Accelerating With The Cruise Control System188
Tap-Up While The Cruise Control System Is Running188
Decelerating With The Cruise Control System189
Tap-Down While The Cruise Control System Is Running189
Recovery Of Set Speed (Resume)190
Normal Cancellation Of The Cruise Control191
Abnormal Cancellation Of The Cruise Control192
E-Egr System Specification193
E-Egr System Overview And Operating Process194
E-Egr System Schematic Diagram196
Input/Output Devices (E-Egr System)197
Egr System Control Logic198
Cdpf System Specification200
Cautions On Cdpf System201
Cautions To Protect The Catalyst Filter201
Standard Pattern Of Soot Accumulation201
Warning Lamp Related To Cdpf202
Cdpf System Overview And Operating Process204
Cdpf System Components View205
Cdpf System Input/Output Devices206
Post-Injection And Air Mass Control207
Cdpf System Operating Process209
Oxidation Of Doc210
Collecting Pm Of Dpf211
Pm Regeneration Of Dpf212
Fuel Injection During Cdpf Regeneration213
Cdpf System Electric Circuit Diagram214
Engine Control215
Engine Data List215
Engine Control Overview And Operating Process216
Engine Control System Operation218
Input/Output Of Ecu218
Components For Ecu Input219
Components For Ecu Output220
Ecu Control221
Fuel Injection Control222
Pilot Injection223
Main Injection224
Post Injection224
Fuel Pressure Control225
Injection Timing Control226
Fuel Control227
Main Flow Control227
Driver Demand228
Idle Speed Controller229
Flow Limitation229
Superchager Flow Demand229
Pilot Flow Control230
Cylinder Balancing Strategy230
Mdp Learning231
Injector Characteristic Curve For Rail Pressure232
Knocking Control233
Resetting The Pilot Injection233
Detection Of Leaks In The Cylinders234
Detection Of An Accelerometer Fault234
Input/Output For Variable Swirl Valve236
Egr Control239
Input/Output Of E-Egr System240
Bypass Control For Egr Cooler241
Control Elements For Egr System241
E-Vgt Control243
Input/Output For E-Vgt System244
E-Vgt System Control245
Wide Band Oxygen Sensor Control246
Input/Output For Oxygen Sensor247
Oxygen Sensor Control248
Cooling Fan Control249
Overview Of Cooling Fan And A/C Compressor249
Input/Output For Cooling Fan And A/C Compressor250
Cooling Fan And A/C Compressor Control251
High Speed252
Immobilizer Control255
Cdpf Control257
Input/Output For Cdpf Control258
Cautions On Cdpf260
Input/Output For Can Communication261
Engine Assembly Description And Operation262
On-Engine Service263
Engine Assembly View And Parts Identification264
Engine Structure266
Oil Leak Diagnosis268
Cylinder Pressure Leakagetest271
Engine - General Diagnosis273
Engine Specifications278
Engine Performance Curve281
Engine Intake System Specifications283
Engine Exhaust System Specifications284
Exhaust System Description And Operation285
Catalytic Converter (Gasoline Engine)285
Engine Cooling System Specifications288
Engine Cooling System Overview And Operation Process290
Pwm (Pulse Width Modulation) Electric Fan Operation294
Pwm Electric Fan295
Pwm (Pulse Width Modulation) Unit295
Shutting-Off Condition Of The A/C Compressor296
Engine Electric Devices297
Engine Electric Devices Diagnostic Information And Procedure299
Engine Electric Devices Overview And Operation Process301
Cold Cranking Amperage302
Charging Time Required302
Charging A Completely Discharged Battery (Off The Vehicle)303
Jump Starting Procedure304
Alternator305
Charging System305
Starter305
Starting System306
Cruise Control Configuration309
Setting A Desired Speed (Cruise Control)311
Fuse Relay Overview And Operation Process317
Capacity And Name Of Fuse And Relay In Engine Compartment318
Capacity And Name Of Interior Fuse And Relay319
Operating Process Of Icm Box321
Stics Performance And Specifications326
Rated Load & Input Signals326
Stics Overview And Operating Process329
Wiper And Washer Operations330
Front Auto Washer Switch (Afw)330
Front Wiper And Washer Coupled Operation330
Front Wiping Speed Control Switch330
Rain Sensor Coupled Wiper And Auto Light Control335
Int Switch Auto Position Reminder (Power-Up Reminder Wiper)336
Washer Coupled Wiper In Rain Sensing Mode337
Sensitivity Control338
When The Wiper Parking Signal Is Abnormal339
Defective Rain Sensor340
Wiper And Washer Troubleshooting341
Auto Light Control343
Volume Sensitive Int (Intermittent) Wiper344
Ignition Key Reminder Warning346
Ignition Key Reminder347
All Door Lock Prevention Function When A Door Is Open348
Tail Lamp Left On Warning349
Door Ajar Warning350
Seat Belt Warning351
Parking Brake Warning352
Center Room Lamp Control353
Ignition Key Hole Illumination355
Key Cylinder With Key Hole Illumination355
Stics Circuit For Tail Lamp Auto Cut (Battery Saver)356
Tail Lamp Auto Cut (Battery Saver)356
Stics Circuit For Front/Rear Defogger Timer357
Front Defogger Timer359
Rear Defogger Timer360
Headlamp Control (Escort)361
Door Lock/Unlock Control By Door Lock Switch362
Door Lock/Unlock Control By Central Door Lock Switch363
Door Lock/Unlock Control By Remote Control Key364
Auto Door Lock365
Auto Door Unlock (Crash Unlock: Automatic Door Unlock In Collision)366
Cautions For Door Lock/Unlock Control366
Time Lag Power Window Control367
Stics Control Regarding Theft Warning Alarm368
Description Of Theft Deterrent Function369
Automatic Hazard Warning Lamp Switch (Shp: Safety Hazard Protection)372
Specifications Of Remote Control Key373
Door Unlock And Panic Function373
Door Lock And Escort Function373
Battery Replacement (Key)374
Specification Of Receiver375
Remote Door Lock375
Door Unlock376
Remote Panic377
Remote Escort378
Auto Door Lock In 30 Seconds After Pressing Door Unlock Button378
Outside Rearview Mirror Folding/Unfolding Control379
Stics Outside Rearview Mirror Folding/Unfolding Control Circuit380
Sunroof Open Warning380
Circuit Diagram For Wiper381
Circuit Diagram For Door Lock Control382
Rekes Key Coding383
Transmitter Code Registration383
How To Code Rekes Key384
How To Register Transponder386
Pin Arrangement Of Diagnostic Connector389
Immobilizer And Rechargeable Key Overview And Operating Process390
Functions Of Immobilizer And Rechargeable Key393
Start Function395
Immobilizer Function395
Immobilizer And Warning Lamp396
Rechargeable Key Function (Charging)397
Rekes Operation Logic400
Cluster Specifications403
Cluster Overview And Operating Process404
Descriptions Of Indicator Display404
Indicators On Instrument Cluster407
Rpm Gauge410
Speedometer Gauge411
Fuel Level Gauge413
Coolant Temperature Gauge414
Description For Lcd Display415
Shifting Mode417
Brightness Of Lcd Display When Turning On/Off Tail Lamp418
Illumination Conditions Of Lcd Display When Turning On/Off Tail Lamp418
Warning Lights And Indicators420
Self-Diagnosis Check422
Cluster Circuit Diagram423
Lamps Specifications425
Switch Specifications426
Switch Overview And Operating Process427
Major Functions Of Multifunction Switch (Added Functions)428
Wiper Function Coupled Auto Washer429
Integrated Auto Light Sensor In Rain Sensor Unit429
Fluidic Washer Nozzle430
Auto Washer Switch431
Front Nozzle431
Washer Reservoir Tank431
Rain Sensor Unit431
Wiper And Washer Fluid Switch Operation432
Stics Control Logic Related To Wiper And Washer433
Wiper Mist And Front Washer Coupled Wiper433
Wiper System Circuit Diagram435
Rain Sensing Unit Overview And Operating Process436
Auto Light Sensor And Rain Sensor Coupled Control437
Functions Of Rain Sensing Wiper438
Power-Up Reminder Wiper Function438
When Wiper Parking Signal Is Abnormal441
Speed Sensitive Int Wiper443
Pause Time Table Of Vehicle Speed Coupled Int Wiper444
Pause Time Against Vehicle Speed444
Cautions For Wiper Control444
Operation Mode Of Rain Sensing Wiper System445
Parking Aid System Component Specifications446
When Parking Aid System Will Not Work Or Improperly Work447
Pas Overview And Operating Process448
Alarm Interval449
Sensing Distance And Range449
Pas Troubleshooting450
Pas Circuit Diagram451
Audio System Specification452
Audio System Overview And Operating Process453
Audio System Controls455
Dsi 6 A/T General Information456
Tip Switch On Steering Wheel457
Gear Position Display On Instrument Cluster457
Gear Select Lever457
Dsi 6 A/T Features And Specifications458
4Wd Automatic Transmission View459
2Wd Automatic Transmission View460
Dsi 6 A/T Sectional Diagram461
Shift Pattern Diagram463
Dsi 6 A/T Overview And Operating Process464
Dsi 6 A/T Features465
The Transmission Cooling System466
Shift Strategy466
Mode Descriptions467
Mode "M" (Manual Shift Mode)468
Limp Home Mode469
In Case Of Transmission Malfunction469
In Case Of Overheated Transmission469
Towing The Vehicle With A/T469
Electronic Control System470
Transmission Control Unit (Tcu)470
Hard-Wired (Analog) Input/Output470
Can Input/Output471
Can Input/Output Data Between Abs/Esp And Tcu472
Can Input/Output Data Between Tccu And Tcu472
Can Input/Output Data Between Icm And Tcu472
Transmission Control Monitoring System473
Shift Energy Management473
Shift Mode Selection By Tcu474
Power Flow In Gears476
Gear Selection And Engaged Element476
Hydraulic Circuit Diagram477
Power Flow - Manual (M Position)478
Power Flow - 1St Gear (D)480
Power Flow - 2Nd Gear (D)482
Power Flow - 2Nd Gear (D) Lock-Up484
Power Flow - 3Rd Gear (D)486
Power Flow - 4Th Gear (D) & 4Th Gear (D) In Limp Home Mode488
Power Flow - 5Th Gear (D)490
Power Flow - 6Th Gear (D)492
Power Flow - Reverse (R)494
Power Flow - Reverse (R) Limp Home Mode496
Power Flow - Park (P)498
Neutral (N)500
M/T (Manual Transmission) Specification502
Special Service Tools (Manual Transmission)503
Tightening Torque (Manual Transmission)505
Manual Transmission Housing View506
Main Shaft View507
Counter Shaft509
Adapter Assembly510
Rail And Shift Fork511
Extension Housing512
M/T Overview And Operating Process513
Characteristics Of Transmission513
M/T Sectional Diagram514
Gear Ratio514
Power Flow515
Shifting Mechanism519
Manual Transmission Overview And Characteristics520
Specifications And Tightening Torque Of Manual Transmission521
Neutral Switch523
Function Of N Switch524
Clutch Specification527
Clutch Overview And Operating Process528
Satic (Self Adjusting Technology With Integrated Cassette)529
Dual Mass Flywheel (Dmf)532
Propeller Shaft Specifications533
Propeller Shaft Overview And Operating Process534
Axle Specifications535
Transfer Case Specifications536
Transfer Case Overview And Operating Process537
Iwe Locking Hub System542
Vacuum System Related To 4Wd543
2H Mode (2 Wheel Drive)545
4H Mode (4 Wheel Drive - High Speed)546
4L Mode (4 Wheel Drive - Low Speed)547
Suspension Specifications548
Wheel Alignment548
System Layout And Tightening Torque Of Front Suspension549
System Layout And Tightening Torque Of Rear Suspension551
Suspension System Troubleshooting553
Suspension Overview And Operating Process554
Front Suspension (Double Wishbone)555
Rear Suspension (Multi Link Type)556
Wheel Alignment Information557
Toe-In557
Camber558
Caster559
Brake System Specification560
Brake System Overview561
Brake System Parts Arrangement562
Brake System Components562
Indicators And Warning Lamps For Abs/Esp563
Brake System Troubleshooting564
Brake Operation And Noise567
Air Bleeding (Brake System)568
Brake System Check570
Maximum Stroke Of Brake Pedal570
Pedal Height571
Pedal Free Play572
Stop Lamp Switch572
Brake Booster573
Brake Fluid574
Brake Fluid Type574
Brake Fluid Level Check574
Front Brake575
Rear Brake577
Parking Brake578
Brake Pedal, Master Cylinder And Booster View579
Brake Pipe View580
Front/Rear Brake Assembly View581
Parking Brake View582
Brake System Overview And Operating Process583
Braking Distance & Stopping Distance584
Brake System Layout585
Parking Brake Diagram587
Hydraulic Circuit589
Stop Lamp Circuit Diagram590
Abs Specification591
Abs Operating Frequency592
Hydraulic And Electronic Control Unit (Hecu)592
Abs System593
What Is Ebd (Electronic Brake-Force Distribution)594
Abs System Components596
Abs Control Logic598
Abs Warning Lamp599
Ebd (Electronic Brake-Force Distribution) Warning Lamp600
Block Diagram Of Abs Hecu601
Basic Theory Of Abs Function602
Basic Abs Control605
Abs Control Pattern606
Ebd (Electronic Brake Force Distribution) System607
Hydraulic Circuit Of Abs608
Normal Brake Operation (Abs Is Not Working) Mode608
Dump (Abs Is Working) Mode609
Hold (Abs Is Working) Mode610
Rise (Abs Is Working) Mode611
Abs Circuit Diagram612
Esp Specification613
Specification Of Active Wheel Sensor613
Specification Of Steering Wheel Angle Sensor614
Specification Of Sensor Cluster614
Esp System Layout615
Hecu (Hydraulic & Electronic Control Unit)616
Esp (Electronic Stability Program) Overview And Operating Process617
Esp (Electronic Stability Program) Components618
Esp (Electronic Stability Program) Precautions619
Esp (Electronic Stability Program) Warning Lamps620
Esp Off Indicator621
Esp Warning Lamp621
Esp Off Switch621
Block Diagram Of Esp Hecu622
Operation Of Esp System623
Understeering623
Esp Controls During Understeer624
Oversteering624
Vehicle Control During Cornering625
Hba (Hydraulic Brake Assist System)626
Arp (Active Roll-Over Protection)627
Hydraulic Circuit Of Esp628
Flashing Warning Lamp And Warning Sound During Esp Operation629
Drive Feeling During Esp Operation629
Noise And Vibration That Driver Senses During Esp Operation629
Idling And Normal Braking Condition630
Dump (Esp Is Working) Mode631
Hold (Esp Is Working) Mode632
Rise (Esp Is Working) Mode633
Hydraulic Circuit Of Hba634
Esp Circuit Diagram636
Steering Specifications638
Steering Wheel And Column View639
Steering Gear Linkage View640
Pipe Lines View641
Steering Troubleshooting642
Steering Inspection And Maintenance644
Steering Free Play Check645
Steering Effort Check645
Steering Angle Check645
Steering Oil Level Check646
Steering Oil Change646
Steering Air Bleeding647
Oil Pump Pressure Check648
Power Steering System Overview And Operating Process650
Power Steering System Layout651
Oil Flows During Right Turn652
Wheel Tire Specifications653
Wheel View653
Wheel - Trouble Diagnosis654
Wheel Inspection655
Tread657
Wear Limit657
Tire Inflation Pressure658
Wheel Runout658
Wheel Balance659
Change Tire Location659
Wheel Components View660
Wheel Overview And Operating Process661
Structure Of Tire663
Tire Unit Indication664
Tire Inflation Pressure (32 Psi)664
Abnormal Tire Symptom665
Standing Wave665
Hydro Planing666
Wheel Static Balance667
Wheel Dynamic Balance667
A/C Assembly Specifications668
A/C Assembly Components669
A/C Assembly Troubleshooting672
When A/C System Is Faulty (Initial Auto-Diagnosis)678
A/C System Trouble Diagnosis679
A/C System Overview And Operating Process681
Ventilation System684
Vent Ports Location - Interior684
Configuration Of Air Duct684
A/C Module Components685
A/C Input/Output Diagram689
A/C Cooling Cycle690
A/C Circuit Diagram692
Air Bag System694
Cautions For Air Bag Operation694
Air Bag System Operating Range695
Air Bag System - General Warnings696
Air Bag System Overview And Operating Process698
Air Bag System Block Diagram701
Air Bag System Deployment (Firing Loop)703
Air Bag Deployment Signal Output (Crash Out)703
Air Bag Warning Lamp Operational Conditions705
Sunroof Specifications707
Sunroof - Cautions For Operations707
Sunroof Overview And Operating Process708
Sunroof Switch709
Sunroof Sliding Opening/Closing710
Body Repair713
Major Dimensions713
Detailed Dimensions714
Lifting Points716
Design For Improving Nvh717
Dual Type Dash Panel And Engine Tunnel With Foaming Pad717
Applied Bpr (Body Panel Reinforcement) Sealer To The Door Outer Panel718
Applying The Asphalt Sheet To The Body Panel (Improved Anti-Vibration)719