SSANGYONG Kyron D100 2005 Manual
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SSANGYONG Kyron D100 2005 Manual

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Summary of Contents for SSANGYONG Kyron D100 2005

  • Page 106: Table Of Contents

    ENGINE GENERAL 0000-00 ENGINE GENERAL GENERAL 1. ENGINE ASSEMBLY LAYOUT....2. ENGINE CONTROLS LAYOUT....3. ELECTRICAL COMPONENTS AND PREHEATING SYSTEM....4. INTAKE SYSTEM LAYOUT....5. EXHAUST SYSTEM LAYOUT....6. LUBRICATION SYSTEM LAYOUT..7. COOLING SYSTEM LAYOUT....8. FUEL SYSTEM LAYOUT....... 9.

  • Page 108: General

    0000-00 0000-00 ENGINE GENERAL GENERAL 1. ENGINE ASSEMBLY LAYOUT 1) LH SIDE VIEW 2) RH SIDE VIEW ENGINE GENERAL KYRON 2005.10...
  • Page 109 0000-00 3) FRONT VIEW 4) FAN BELT ENGINE GENERAL KYRON 2005.10...

  • Page 110: Engine Controls Layout

    0000-00 2. ENGINE CONTROLS LAYOUT 1) ECU Related Componets FUNCTION FUNCTION Coolant reservoir HFM sensor VGT turbo charger Engine oil dipstick Engine Oil separator(PCV valve ) Engine oil filler cap Vacuum pump PWM electric fan & fan shroud EGR valve Power steering oil reservoir Vacuum modulator Fuel filter &...
  • Page 111 0000-00 2) Engine And Sensors Camshaft Position Sensor Injector Glow Plug Fuel Pressure Sensor Booster Pressure Sensor Common Rail (Common Rail) ENGINE GENERAL KYRON 2005.10...
  • Page 112 0000-00 HP Pump Knock Sensor (1 EA) & Crankshaft Vacuum Modulator Water Temperature Sensor Position Sensor Water temp. sensor Knock sensor ENGINE GENERAL KYRON 2005.10...
  • Page 113 0000-00 3) Engine Accessories Related to ECU IP Interior Fuse Box (Passenger Side) Installed Engine ECU main relay Hazard warning lamp VGT & EGR vacuum modulators, HFM HP pumpIMV Engine ECU Mounting Location ENGINE GENERAL KYRON 2005.10...
  • Page 114 0000-00 HFM Sensor Accelerator Pedal Module Fuel Filter Sensor Integrated with 2 PPSs Priming Fuel Pump Filter Service Interval (Fuel Filter) Replace every 30,000 km (Draining water from fuel filter: Only whenever replacing the engine oil) Replace every 25,000 km General (Draining water from fuel filter: whenever replacing the engine oil)

  • Page 115: Electrical Components And Preheating System

    0000-00 3. ELECTRICAL COMPONENTS AND PRE HEATING SYSTEM Battery Preheat Warning Lamp Glow Plug (Cluster) Engine compartment Alternator Starter motor fuse box PTC / FFH: 12V - 2.2kw 12V - 115A ENGINE GENERAL KYRON 2005.10...
  • Page 116 0000-00 Preheat Control Unit FUNCTION Glow plug terminal (#1 ~ #4) No G5 for 4 cylinders (Without D20DT) IG1 power supply terminal Glow plug control signal (ECU113) Ground terminal Battery main wire Preheat completion transmit terminal : No use for vehicle without remote engine start K-line (ECU 34) ENGINE GENERAL...

  • Page 117: Intake System Layout

    0000-00 4. INTAKE SYSTEM Intake outlet hose Air cleaner Front air duct Terbocharger intercooler Supplying Compressed Air with Intake Manifold Turbocharger's Operation To corresponding cylinders Coolant port Air cleaner Inter cooler Turbo charger From intercooler ENGINE GENERAL KYRON 2005.10...
  • Page 118 0000-00 Recirculation of Exhaust Gas when Turbocharger Intercooler EGR Valve Operates EGR valve Intake com pressed air Exhaust gas HFM Sensor Plug-in sensor Temperature Pretension Air cleaner Turbo - charger - Sensor graph ENGINE GENERAL KYRON 2005.10...

  • Page 119: Exhaust System Layout

    0000-00 5. EXHAUST SYSTEM LAYOUT EEGR Pipe Passage for recirculation of exhaust gas DOC (Diesel Catalytic Converter) Exhaust Manifold To turbo - To EGR charger pipe From cylinders ENGINE GENERAL KYRON 2005.10...
  • Page 120 0000-00 VGT Turbocharger EGR Valved Vacuum modulator To exhaust Intake com - pipe (DOC) pressed air Exhaust Exhaust gas manifold PCV Oil Separator Turbocharger Vacuum Modulator Cylinder head cover (oil + gas) Blow-by gas Vacuum (air duct hose) pump Inlet port Turbo - charger (oil gauge pipe)

  • Page 121: Lubrication System Layout

    0000-00 6. LUBRICATION SYSTEM LAYOUT Oil dipstick gauge Cylinder Head Cover Oil Pressure Warning Lamp (Cluster) Oil Pan and Baffle Plate (Integrated Type) Oil Strainer ENGINE GENERAL KYRON 2005.10...
  • Page 122 0000-00 Oil Filter & Oil Cooler PCV Oil Separator Cylinder head cover (oil + gas) Blow-by gas cooler filter (air duct hose) Inlet port (oil gauge pipe) The first separation will happen when blow- by gas passes through baffle plates in cylinder head cover.

  • Page 123: Cooling System Layout

    0000-00 7. COOLING SYSTEM LAYOUT Coolant reservoir Coolant inlet hose Return hose Coolant outlet hose PWM electric Radiator Coolant Port Water Pump & Pipe Thermostat (inside) Coolant - Cylinder outlet port Radiator block Reservoir (Coolant inlet hose) Radiator Assembly Cooling Fan and Fan Clutch ENGINE GENERAL KYRON 2005.10...
  • Page 124 0000-00 Engine Oil Filter & Cooler Oil filter cap Oil cooler cooler filter Oil pressure switch ENGINE GENERAL KYRON 2005.10...

  • Page 125: Fuel System Layout

    0000-00 8. FUEL SYSTEM LAYOUT HP Pump Injector Fuel Filter & Priming Pump Priming pump Fuel filter Connector HP Pump Fuel return port Fuel return port Fuel tempera - ture sensor Venturi IMV connector IMV valve High pres - sure fuel supply port Low pres - sure fuel supply port ENGINE GENERAL KYRON 2005.10...
  • Page 126 0000-00 Cylinder Head Fuel return hose Fuel pipe Common rail High pressure fuel pipe Fuel rail pressure sensor ENGINE GENERAL KYRON 2005.10...

  • Page 127: Fuel Supply System

    0000-00 9. FUEL SUPPLY SYSTEM 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.

  • Page 128: Cleanness

    0000-00 10. CLEANNESS 1) 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 of preciseness.
  • Page 129 0000-00 2) Job Procedures 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.
  • Page 130 0000-00 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.
  • Page 131 0000-00 Plug the removed components with clean and undamaged sealing caps and store it into the box to keep the conditions when it was installed. Clear the high pressure offset value by SCAN-100 after replacing high pressure pump. To supply the fuel to transfer line of HP pump press the priming pump until it becomes hard.
  • Page 132 0000-00 3) 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.

  • Page 133: Maintenance And Repair

    0000-00 11. MAINTENANCE AND REPAIR 1) Maintenance And Lubrication Normal Vehicle Use The maintenance instructions contained in the maintenance schedule are based on the assumption that the vehicle will be used for the following reasons: To carry passengers and cargo within the limitation of the tire inflation prassure. Refer to "Wheels and Tire"...
  • Page 134 0000-00 Spark Plug Wire Replacement Clean wires and inspect them for burns, cracks or other damage. Check the wire boot fit at the Distributor and at the spark plugs. Replace the wires as needed. Brake System Service Check the disc brake pads or the drum brake linings. Check the pad and the lining thickness carefully.

  • Page 135: Guidelines For Service Work Safety

    0000-00 12. GUIDELINES FOR SERVICE WORK SAFETY 1) General To maintain and operate the vehicle under optimum state by performing safe service works, the service works should be done by following correct methods and procedures. Accordingly, the purpose of this manual is to prevent differences that can be caused by personal working method, skill, ways and service...
  • Page 136 0000-00 2) Cautions on Inspection/Service During service works, be sure to observe below general items for your safety. For service works, be sure to disconnect battery negative (-) terminal if not starting and inspection. While inspecting vehicle and replacing various consumable parts, be sure to take caution not to damage vehicle and injure people.
  • Page 137 0000-00 3) Guidelines on Engine Service To prevent personal injuries and vehicle damages that can be caused by mistakes during engine and unit inspection/repair and to secure optimum engine performance and safety after service works, basic cautions and service work guidelines that can be easily forgotten during engine service works are described in.
  • Page 138 0000-00 Fuel and lubrication system Painted surface of the body can be damaged or rubber products (hoes) can be corroded if engine oil and fuel are spilled over. If spilled over engine, foreign materials in air can be accumulated on the engine damaging fuel system. If work on the fluid system such as fuel and oil, working area should be well ventilated and mechanic should not smoke.

  • Page 139: During Service Work For Inspection

    0000-00 13. DURING SERVICE WORK FOR INSPECTION Before lifting up the vehicle with lift, correctly support the lifting points and lift When using a jack, park the vehicle on the level ground and block front and rear wheels. Position the jack under the frame and lift up the vehicle and then support with chassis stand before service work.
  • Page 140 0000-00 Never reuse cotter pin, gasket, O-ring, oil seal, lock washer and self-locking nut. Replace them with new. If reused, normal functions cannot be maintained. Align the disassembled parts in clean according to disassembling order and group for easy assembling. According to installing positions, the bolts and nuts have different hardness and design.

  • Page 141: During Service Work For Electric Devices

    0000-00 14. DURING SERVICE WORK FOR ELECTRIC DEVICES Be careful not to modify or alter electrical system and electrical device. Or there can be vehicle fire or serious damage. Be sure to disconnect battery negative (-) terminal during every service work. Before disconnecting battery negative (-) terminal, turn off ignition key.

  • Page 142: Owner Inspections And Services

    0000-00 15. OWNER INSPECTIONS AND SERVICES 1) While Operating The Vehicle Horn Operation Blow the horn occasionally to make sure it works. Check all the button locations. Brake System Operation Be alert for abnormal sounds, increased brake pedal travel or repeated puling to one side when braking.
  • Page 143 0000-00 2) At Each Fuel Fill A fluid loss in any (except windshield washer) system may indicate a problem. Have the system inspected and repaired immediately. Engine Oil Level Check the oil level and add oil if necessary. The best time to check the engine oil level is when the oil is warm.
  • Page 144 0000-00 5) At Least Twice A Year Power Steering System Reservoir Level Check the power steering fluid level. Keep the power steering fluid at the proper level. Refer to Section 4G, Power Steering System. Brake Master Cylinder Reservoir Level Check the fluid and keep it at the proper level. A low fluid level can indicate worn disc brake pads which may need to be serviced.
  • Page 145 0000-00 7) At Least Annually Lap and Shoulder Belts Condition and Operation Inspect the belt system including: the webbing, the buckles, the latch plates, the retractor, the guide loops and the anchors. Movable Head Restraint Operation On vehicles with movable head restraints, the restraints must stay in the desired position. Spare Tire and Jack Storage Be alert to rattles in the rear of the vehicle.

  • Page 146: Standard Bolts Specifications

    0000-00 16. STANDARD BOLTS SPECIFICATIONS ENGINE GENERAL KYRON 2005.10...
  • Page 147 0000-00 Metric bolt strength is embossed on the head of each bolt. The strength of bolt can be classified as 4T, 7T, 8.8T, 10.9T, 11T and 12.9T in general. Observe standard tightening torque during bolt tightening works and can adjust torque to be proper within 15 % if necessary.

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