DEALER TRAINING MATERIAL

<DI ENGINE>

SSANGYONG MOTOR COMPANY

OVERSEAS SERVICE TEAM
NOV. 2007
 NOTIFICATION OF CHANGING DRIVE PLATE FOR DI ENGINE

Class BEFORE AFTER

■ MODEL
DRIVE
: DI ENGINE PLATE
■ ISB-2007017
; issued Jul. 2007 Photo

plate 2 pcs plate 1 pcs

Remark Drive plate has 2 plates Drive plate has 1 plate

Part No. 665 030 03 12 665 030 05 12

PLATE

Photo

Thickness : 2.6t Thickness : 2.4t

Part No. 161 032 30 76 161 032 31 76

Quantity Need 1 plate / veh. Neet 2 plates / veh.
Effective date All RV DI engine after Apr. 25th, 2007
Applied Engine Engine No. Model
Engine No. D27DT(P) 512751 ~ Rexton / Rexton II / Kyron (5 cyl)/Rodius
per model D20D 530732 ~ Kyron (4 cyl)
D20Q 544106 ~ Actyon, Actyon Sports Page 1/2
NOTIFICATION OF CHANGING DRIVE PLATE FOR DI ENGINE
Work Procedure BEFORE AFTER

Before
Installation

Step 1
1st plate
Install the drive plate Install the 1st plate to crankshaft

Step 2

Install the plate Install the drive plate

Step 3 -
2nd plate

Install the 2nd plate Page 2/2

＊Bolt (8EA) tightening torque : 1st - 45 Nm. 2nd - 90º
 TROUBLESHOOTING FOR FUEL TEMP. SENSOR

♠ SYMPTOMS
- Engine stop at low speed driving, Check engine lamp ON
(P0183 Fuel Temp. Sensor – Short to B+ and many other DTC related
fuel pressure)
- Normally, vehicle has long mileage (30K km ▲)

※ ECU memorized DTC “Fuel Temp. Sensor – Short to B+",

If the DTCs were set like right photo, check abnormal fuel temp. ※ In case of many DTC code,
on freeze frame of each DTC code lower lank was set first

FAULT CODE IN ECU

C-P1148 Accelerator Learning Fault
H-P1252 Too High IMV Pressure
H-P1254 Maximum Rail Pressure Control Malfunction
H-P1259 Too Large High Pressure Fuel in Rail Pressure System
H-P0183 Fuel Temp. Sensor – Short to B+
H-P1253 Minimum Rail Pressure Control Malfunction

Freeze Frame of DTC P1259

 TROUBLESHOOTING FOR FUEL TEMP. SENSOR

♠ CHECK PROCEDURE
- If it happens intermittently, fuel temp. will be abnormal
when the problem happens
(Fuel temp. at normal condition : 20 ℃ ~ 60℃)
- Check fuel temp. value on freeze frame of DTC
- If DTC is set as a current code, check the fuel temp. value on
ECU data list

※ Characteristic of Fuel Temp. Sensor of HP Pump

Freeze Frame of DTC P1259
NTC resistance, negative temp. coefficient.
Lower resistance at high fuel temperature
So, in case of connection problem, fuel temp is less than 0 ℃
due to resistance increasing
But, in case of short circuit or open circuit, fuel temp is 90 ℃

♠ TROUBLESHOOTING
- Spray anti-fretting grease
- Replace engine main wiring if necessary
 TROUBLESHOOTING FOR ACCEL. PEDAL MODULE
■ ISI-07EN011
♠ CASE 1
; issued Aug. 2007
SYMPTOMS
- Suddenly accel. pedal doesn't response at driving
- Engine check lamp ON (DTC in ECU : P1124 - Accel. Pedal Sensor Malfunction)
- Accel. pedal works normally after 2 ~ 3 accel pedal operations (Fail Safe Mode)

FIELD ACTION
- Check driving habit (someone drive A/T using both feet)
- Check brake switch contact stroke and replace it if necessary
- Check short-circuit of parking & brake lamp bulb
(check bulb double filament)
- Check lamp tuning (LED brake lamp)
▶ In this case, don't replace accel. pedal module
Replace brake switch if necessary
TROUBLESHOOTING FOR ACCEL. PEDAL MODULE

♠ CASE 2
SYMPTOMS
- Accel. pedal doesn't response, engine is pegged at 1,200 RPM (LHM mode)
- Engine check lamp ON
DTC in ECU (P1123 - Accel. Pedal Sensor Malfunction,
P1120 - Accel. Pedal Sensor#1 Malfunction)

FIELD ACTION
- Check the poor connection of Accel. Pedal Module
; Please be sure to check this point if the vehicle is new one
▶ This DTC codes happen if the difference of Accel. Pedal Sensor
#1 & #2 signal is more than 15%
Check the signal value of Accel. Pedal Sensor #1 and #2
with SCAN-100 after checking wiring and connector of
Accel. Pedal Module
TROUBLESHOOTING FOR ACCEL. PEDAL MODULE

♠ CASE 3
SYMPTOMS
- Suddenly accel. pedal doesn't response and vehicle speed and torque drop
- No DTC in ECU, TCU and ABS
- Vehicle poor start-off performance

FIELD ACTION
▶ In this case, please inform us by FTR or E-mail before replacing
accel. Pedal module or other parts
 ENGINE POOR STARTING AT HOT CONDITION

■ MODEL : KYRON/ACTYON SPORTS (D20DT M/T - DMF)

♠ SYMPTOMS
 Engine poor starting after engine warm-up (No DTC in ECU)
 Cranking but engine no starting

♠ FIELD ACTION
 ECU REPROGRAMMING
- ACTYON SPORTS / EURO III D20DT : HCD38A03
- KYRON EURO III D20DT : HCD38A06
 FIELD CASE – ENGINE ABNORMAL NOISE

■ MODEL : NEW REXTON (D27DT) and DI ALL

♠ SYMPTOMS
 Engine tapping noise at idle or accelerating

♠ FIELD ACTION
 Replace chain tensioner (Tightening Torque : 65Nm)

♠ REMARK
 Engine abnormal noise can be happened
by deformation of chain tension inner piston Check
due to chain tensioner damages
 Check the damage of guide rail
Check the sliding rail additionally if engin
e noise comes again after replacing chain
tensioner
 FIELD CASE – CLOGGED INJECTOR NOZZLE
♠ SYMPTOMS
 Engine poor starting performance
 No engine vibration, hesitation, noise and No DTC in ECU
♠ POSSIBLE CAUSE : Partly clogged injector nozzle

Injector Nozzle
(5~7EA)

♠ RECOMMENDATION
 Hard to diagnose clogged injector nozzle ; can’t detect through injector back leak test
 Replace all injector in case of water entering to cylinder inside or in case of vehicle rollover
; if the engine was submerged by water, replace vacuum modulator together
 QUALITY PROBLEM OF HP PUMP PLV O-RING
♠ SYMPTOMS
: Intermittent engine stop (at vehicle stop condition)
: Pressure leak by damaged PLV O-Ring
Poor engine starting or no rail pressure at cranking – clogged flange by damaged O-Ring particle

♠ RECOMMENDATION : Do not remove the PLV (60% of total HP Pump Failure)

Clogged flange

Damaged O-Ring
 TROUBLESHOOTING FOR #3 FUEL PIPE CRACK
■ ISI-07EN010
♠ REWORK PROCEDURE
; issued Jul. 2007
- Disconnect the vacuum hose passing engine front and cut about 40 cm on turbo charger side
- Fix the vacuum hose to injector pipe using pipe holder (2 points)
- Remove the vacuum hose mounting bracket on intake manifold

Remove the
bracket

Holder (2 pieces)
P/No. : 6650733010

NOTICE
■ The rework should be done in case of engine cover related job is made or
complaint of pipe vibration of Injector #2 or #3 pipe
 RUBBER DAMPER OF HP PIPE BRACKET REPLACEMENT

■ MODEL : DI ENGINE ALL (D27DT/ D20DT ENGINE) ■ ISB-2006036 ; issued Jul. 07

■ ISI-07EN003 ; issued Jan. 07
♠ SYMPTOMS

Injector High Broken HP Pump HP Pipe Leak D20DT #3 Injector

Resistance Flange Bolt Pipe Leak
♠ FIELD ACTION
 Replace Rubber Damper of HP Pipe Bracket
 Vibration caused by fuel pulsation reduce 64%
Rubber Damper of HP Pipe Bracket
; 6650780086
Increase rubber hardness &
decrease rubber inside diameter
; From Apr. 10th, 2006

Color marks after rubber

replacement
 INSTALLATION OF HP PIPE (C2R PIPE)
■ ISI-07EN003
♠ PURPOSE ; issued Jan. 2007
In order to minimize the flection stress in the HP pipes and injectors,
HP pipe should be assembled in a suitable sequence

♠ PROCEDURE
1. Remove the broken HP Pipe (C2P Pipe)
2. Loosen the Common Rail bracket bolts (3EA)
3. HP pipe fitted, with its nut screwed by hand Rail to Injector HP
4. Tighten the Common Rail bracket bolts Pipe

Tightening Torque : 25 Nm
5. Tighten the HP Pipe to HP Pump
C/Rail to Pump
Tightening Torque : 40 Nm (C2R) HP Pipe
2nd Step

6. Tighten the HP Pipe to Common Rail

Last Step
Tightening Torque : 40 Nm
7. Tighten the HP Pipe bracket on engine
Tightening Torque : 10 Nm
1st Step
 TROUBLESHOOTING FOR INJECTOR HIGH RESISTANCE

■ MODEL : ALL D27DT ENGINE ■ ISI-06EN005 ; issued Jul. 06

■ ISI-07EN003 ; issued Jan. 07
♠ SYMPTOMS
- Intermittent engine check lamp ON and engine low power, engine hesitation
- DTC codes (1 or more DTC is set)
(Injector #X Balancing Fault / Injector #X Circuit Open /
High Resistance for Injector #X wiring harness)
- Mainly, It happens at No. 2 or No.4 Injector
♠ REWORK PROCEDURE

Spray anti fretting Change Rubber Damper of HP

corrosion oil Pipe Bracket: 6650780086

- Spray anti anti fretting corrosion oil to the pin of injector connector and wiring terminal
- As a preventive action, spray this oil to all other injector connectors and wiring terminals
- Change the rubber damper of HP Pipe bracket at the same time
- Idle the engine about 5 minutes
 TROUBLESHOOTING FOR INJECTOR HIGH RESISTANCE

♠ RECOMMENDATION
- In case of problem again, replace engine wiring or exchange the injector with
other good one

Effect of Anti-fretting corrosion oil

It can recover the condition of contact between Pin of Injector connector and terminal of wiring connector

Anti Fretting Corrosion Oil Sample 1

- Supplier : SANTOVAC FLUIDS INC.
- Model Name : ACCL-52T (Directly solved) Or
0S124 or OS138 (use 10% conc.)

Anti Fretting Corrosion Oil Sample 2

- Supplier : NYE
- Model Name : NYOGEL 760G
- SYMC P/No. : 09886AS000
 EURO IV IMMOBILIZER ISSUE AT HIGH ALTITUDE
■ ISB-2007002
■ MODEL : ALL EURO IV MODELS
; issued Jan. 2007

♠ SYMPTOMS
Engine starting problem in the field at around 600 - 650m altitude and
associated with immobilizer-ECU communication on EURO IV models

♠ FIELD ACTION : ECU REPROGRAMMING

MODEL ECU P/No. Old ECU Ve New ECU Ve First VIN Current ECU Ve
r r r
REXTON II D27DTP 665 540 0632 NCD08A02 NCD12A01 239150 NCD14A01 CDPF
REXTON D27DT 665 540 0532 NCD08A02 NCD12A01 239198 NCD12A03 K2008
RODIUS D27DT 665 540 4432 NCD09A01 NCD12A01 041766 NCD13A01 K2006
KYRON D27DT 665 540 8432 NCD08A02 NCD12A01 NCA13A01
KYRON D20DT 664 540 8432 NCA31A01 NCA35A01 052605 NCA36A01
ACTYON D20DT 664 540 6532 NCA31A01 NCA35A01 028235 NCA36A01

♠ FIELD
ACTYON ACTION
SUT D20DT : REFER
664 540 4432 NCA33A02
TO RELATED NCA35A01 ISB-2007002
S/BULLETIN 012727 NCA36A04
EURO IV IMMOBILIZER ISSUE AT HIGH ALTITUDE

NOTICE
- Do SCAN-100 update for EURO IV model and then input needed R-Card file
; check the release data (after Dec. 11, 2006)
- Take care not to disconnect SCAN-100 connector during ECU reprogramming
- Perform the Immo. Key coding for all key
- Input EURO IV R-Card file to correct position
; you should choose 0] D27DT/D20DT (C3I) ECU
on SCAN-100 menu
- Do not MISUSE of ECU data of
REXTON II D27DT and D27DTP

REXTON II EURO IV D27DT REXTON II EURO IV D27DTP

EURO IV IMMOBILIZER ISSUE AT HIGH ALTITUDE
IN CASE OF PROBLEM
- When ECU reprogram is done unsuccessfully during Multi-Calibration
; At this result, ECU lost coding data
a. Perform Engine and Chassis Variant coding
b. Perform Injector coding (double check C3I no. on Cyl. Head cover)
c. Perform Immobilizer coding
d. Erase the DTC
→ if there is no result, Perform the ECU replace function of SCAN-100

- When ECU has variant coding error with DTC P1170 in HECU
; Sometimes ECU has problem after updating the ECU
a. Check the variant coding on ECU and adapted if necessary
b. HECU variant coding clear
c. Clear all DTCs in every control units
d. Ignition OFF (wait more than 10 seconds)
e. Clear again all DTCs in every control units
f. Ignition ON
g. Ignition OFF
→ if there is no result, repeat above action 2-3 times
 FIELD CASE - INJECTOR NOISE
■ MODEL : REXTON II (D27DTP ENGINE)

♠ SYMPTOMS
 Abnormal noise at accelerating over 2,000 RPM (with black smoke)
 It just happens at driving condition after fully warm-up, no problem at idling
 No DTC in ECU
; Intermittently ECU set Rail Pressure Control (High or Low) Error

♠ FIELD ACTION
When same symptom happens again after engine warm-up, perform
Injector Dynamic Test : Too much back leak from problematic Injector
Movie Clip
Clattering Noise
“Karararar ~ Black
Smok
e

Bad Injector Normal Injector

 OPERATION PRINCIPLE – VACUUM MODULATOR
♠ OPERATION PRINCIPLE
- Because of their characteristically vacuum controlling and quick response,
vacuum modulate is used extensively than normal ON/OFF type solenoid valve
- Generate magnetic force through ECU PWM signal and it controls vacuum
level through controlling the amplitude of plunger which makes up/down
movement (repeatedly vacuum ON/OFF)

♠ APPLICATION
Vacuum Modulator (D20DT Engine)
- DI Engine EGR Valve Control
- Turbo Charger (VGT, WGT)
- Huber EGR
- Throttle Body (Euro IV Engine)

♠ CHARACTERISTIC
- Plunger Operation Frequency : 300 ㎐
- Plunger Operation Amplitude : about 1mm
- Max. Vacuum Consumption : 35L / hr
- Automatic Temp. Compensation
OPERATION PRINCIPLE – VACUUM MODULATOR
♠ INTERNAL COMPONENT

Plunger Valve Seat

Vacuum
Input
Screen Filter
(internal) Vacuum
Output

Filter
(external)
 OPERATION PRINCIPLE – VACUUM MODULATOR
♠ FIELD CASE
CASE 1 – Poor starting performance caused by clogged filter of V/Modulator
; Slow response at quick accelerating between 50~80 km/h (Feeling a tug from back side)
; At quick acceleration mode, EGR should be closed immediately but clogged filter could be
a reason of slow response
CASE 2 – DTC “Booster Pressure Sensor Open” set caused by clogged filter
; Waste gate of turbo charge should be opened quickly when high speed is required
but clogged filter delays vacuum release
(If the booster pressure is more than threshold value, ECU recognize sensor is opened)
CASE 3 – Abnormal noised caused by water entering into V/Modulator
; Unbalanced lubrication inside V/Modulator could be a reason of abnormal noise
CASE 4 – Huber EGR Valve broken
; Continuously vacuum entering due to plunger stuck or valve slow response due to
clogged filter

NOTICE
- At engine room cleaning, engine should be OFF and dry the water of filter
- There is high risky on submerged vehicle / high mileage vehicle / running
off-road vehicle
 OPERATION PRINCIPLE – VACUUM MODULATOR
■ How to check clogged filter of Vacuum Modulator

Joint with
T-connector

Vacuum Gauge
EGR
V/Modulator Movie Clip

- Check the EGR Valve open at idling (EGR is opened during first 50 second after idle start)
- At “P” condtion, press accel. pedal quickly and check the gauge dropping speed.
(Slow reaction in case of clogged filter / see the movie clip)
- Compare this drop speed with normal good working vehicle
; check the T/Charger V/Modulator same way
 EURO IV ENGINE MDP LEARNING MODE

■ MODEL : ALL EURO IV MODEL

♠ SYMPTOMS
 Engine small hunting & noise after engine warn-up (cracking noise x 4 times)
 Engine small vibration at “D” drive idle condition
♠ MDP LEARNING CONDITION AT IDLE
EURO IV engine has a characteristic of idle MDP learning, it can be recognized
as a problem by driver sometimes
; it could be easily heard at underground parking lot while re-start engine after
10 seconds (ECU power Off) from ignition Off
- Rail Pressure : 250BAR, @ Idle, - Coolant Temp : 75 ~100 ℃
- Vehicle Speed : Less than 5 kph, - Engine Speed : 725 ~ 775 RPM
- First ECU ON cycle
- Every 3,600 seconds per one Injector : Sequence 1 →2 →4 →5 →3 Cyl.
(There is minor difference of noise level between cylinders)

♠ PURPOSE OF MDP LEARNING

Learn and reset the fuel injection characteristic of each injectors according to
aging, fuel condition and many engine variation to maintenance perfect fuel
injection control
 EURO IV ENGINE MDP LEARNING MODE

♠ INITIAL MDP LEARNING (EURO III & EURO IV ONLY)

To adjust fuel injection characteristic of all injectors quickly

♠ INITIAL MDP LEARNING CONDITION

- Coolant Temp : over 60 ℃
- Learning Time : 30 ~ 120 seconds (considering MDP learning failure)
- After ECU or Injector (C3I coding) replace
- Recode C3I code value through SCAN-100
; ECU carry out Initial MDP Learning one time at above condition

If the Initial MDP learning is not done successfully, engine makea small vibration
at the engine is cold
 TROUBLESHOOTING FOR TURBO CHARGER NOISE

♠ CHARACTERISTIAC of REXTON II (D27DTP) TURBO CHARGER

1) Noise Characteristic
: At accelerating over 1,000 RPM, there is whistling sound
It means that turbo charger works normally
Also, at releasing accel. Pedal (Tip-out) suddenly,
there would be exhaust harsh sound such as “shriring ~”
and sound level will be different according vehicle variation,
road condition and engine temp.
(Before engine warm-up, sound level could be bigger than hot
* Vane control actuator
engine condition)
Point : Turbo Charger on D27DTP engine is controlled by ECU PWM signal according to
combustion condition, engine temperature and so on. This lead to a little bit different
sound tone at turbo charger operating

2) Operation Principle
Engine Status Modulator Duty (%) Vane Control Actuator Vane Passage
Low load & low rpm 75% Pulling Narrow
(Duty Increases) (Vacuum Applies)
High load & high rpm 45% Return Wide
(Duty Decrease) (Vacuum Release)
 FIELD CASE – TURBO CHARGER NOISE

■ MODEL : REXTON II D27DTP ENGINE

♠ SYMPTOMS
 Whistle noise (Beep sound) from engine front side at accelerating at the vehicle
speed of 40~50 Km/h (between 1,000 ~ 2,000 RPM) like turbo charger noise
 Noise can be heard at engine stall test (around 1,800rpm)
 Noise is severe at cold engine that hot engine
 Normal (no noise) at engine idling
 Noise is gone when fan belt is removed

♠ FIELD ACTION
Noise comes from idle pulley bearing

Noise is gone when

fan belt is removed
 FIELD CASE – TURBO CHARGER NOISE

■ MODEL : KYRON D20DT ENGINE

♠ SYMPTOMS
 Wind noise from engine front side (intake manifold)
at accelerating at the vehicle speed of 40~80 Km/h
(over 1,500 RPM) continuously Widen contacting
bracket
 Distinguishable noise tone compare to normal operation
sound of D20DT VGT turbo inlet
 This noise looks like EGR valve noise if you seated
at driver seat

♠ FIELD ACTION

Fixed the interference of bracket with screw driver

 FIELD CASE – TURBO CHARGER NOISE

■ MODEL : KYRON D20DT ENGINE

♠ SYMPTOMS
 Wind noise from engine front side (intake manifold)
at accelerating (over 1,500 RPM)
 No result after replacing T/Charger, EGR valve and Vacuum modulator
several times
 Root cause is the unexpected input air caused by air cleaning housing leak
due to poor workmanship while air cleaning replacement
; housing bolt tightening torque : 4.2 ~ 6.2 Nm
♠ FIELD ACTION
Replace air cleaner housing assy with new one

NOTICE
 When air clear housing bolts are over tightened
beyond specification, it could damage the nut of
housing lower part and air leakage
 In case of mis-installation or installation of wrong part
(ex, Rodius air clear element) ; housing will be get
loose due to thickness difference
 FIELD CASE – TURBO CHARGER NOISE

■ MODEL : ACTYON D20DT ENGINE

♠ SYMPTOMS
 Whistle noise (Beep sound) from turbo charger area at accelerating
(over 1,500 RPM)
 Noise is gone while VGT vacuum hose is disconnected by hand
; Because of less turbo pressure generation
 Distinguishable noise tone (like high tone beep sound)
compare to normal operation sound of D20DT VGT turbo inlet

Carbon deposit

25 Nm

Residue of
40 Nm
gas leakage

Nut loosen on #5 Ex. manifold Turbo charger gas leakage

♠ FIELD ACTION
Retightened #5 Ex. Manifold and clean the carbon deposit of turbo charger
 FIELD CASE – ENGINE STALL / POOR STARTING

No MODEL SYMPTOMS POSSIBLE CAUSES FIELD ACDTION REMARK

1 REXTON - Engine stall & no start - Poor Ground G205 - Retighten G205 bolt
- No SCAN-100 diagnosis with (Passenger foot area) E G205
ECU (other unit all OK) C
U
- No glow plug lamp at Key ON

2 REXTON - No start at engine cold - ECU Main Relay problem -Replace Main Relay
RODIUS - P1193 rail pressure signal high - Vehicle sign off before P/No. : 844108100
Mar. 2005

3 DI All - Engine stall at low speed - HP pump IMV fault - Replace HP Pump
braking - Too much variation - Check the fuel quality
- P1253 rail pressure low control on rail pressure & RPM Bad fuel could be a
malfunction at driving reason of malfunction
IMV
4 REXTON - Intermittent engine starting - ECU S/W issue - ECU reprogram Vehicle sign off
RODIUS problem ; ECU BANK 1 Fault ; Higher than HCC73A02 Before Nov. 16th,
- Engine hesitation at cranking * Bank 1 : 1, 3, 4 Inj. 2004
; no start
- No DTC in ECU
5 REXTON - Engine stall while driving low - ECU S/W issue - ECU reprogram Vehicle sign off
RODIUS speed, do restart ; Sudden engine RPM ; Higher than HCC73A02 Before Nov. 16th,
drop 2004
 FIELD CASE – ENGINE STALL / POOR STARTING

No MODEL SYMPTOMS POSSIBLE CAUSES FIELD ACDTION REMARK

6 DI All - Engine can’t start after - Poor fuel pressure - Start after IMV fuse When IMV fuse is
repairing job related fuel generation due to air in disconnection removed, IMV is
system or timing fuel system (Rexton/Rodius – EF5) fully opened and
(Kyron/Actyon – F64) make fuel pressure
(Injector, Fuel pipe, Rail, over 1,000 bar and
HP Pump, Cylinder head) it can release air
7 D20DT - Engine stall while passing water - Water entering on filter - Refer to Service Bulletin
ENGINE puddle and can’t restart of EGR valve vacuum ; ISB-20070313 For Turbo Charger
- EGR valve control malfunction modulator
For EGR Control

8 RODIUS - Intermittent engine stall or lack - Foreign material in fuel - Clean the fuel tank
KYRON of engine power tank - Fuel sender can be easily
ACTYON - P1254 max. rail pressure (Plastic seal comes form clogged by foreign
control malfunction fuel additive) material

Clogged area

9 RODIUS - Engine stall and Engine Check - Air incoming due to - Replace fuel sender
KYRON lamp On at quarter full of fuel poor sealing of fuel
ACTYON tank sender
- P1254 max. rail pressure
Air incoming by poor
control malfunction
sealing
 FIELD CASE – ENGINE STALL / POOR STARTING

No MODEL SYMPTOMS POSSIBLE CAUSES FIELD ACDTION REMARK

10 DI All - Intermittent lack of engine - Poor contact of HFM - Reconnect HFM sensor
power and black smoke sensor - Check sensor wiring
; engine stall in severe case ; could be happened
while air clear replace

11 DI All - Engine check lamp - Fuel pressure control - Check fuel temp sensor
Fuel Temp.
- Engine stall malfunction due to connector or replace HP
Sensor
- P0183 Fuel Temp. Sensor – fuel temp. sensor fault Pump
Short to B+

12 DI All - Engine doesn’t start at cold - Air incoming through - Replace fuel filter
condition fuel filter bending area - Retighten the water
- Fuel leak caused by sensor Poor bending
Poor tightening of water
sensor Poor connection

13 DI All - Delay engine start at cold - Poor Injector pressure - Replace Injector
condition control - Check fuel quality if
- Engine stall while decelerating - Too much backleak at necessary
- P1254 Max. rail pressure Dynamic leak test
control malfunction (Spec : 38 ml) Dynamic leak test
DI ENGINE ECU VERSION
 TROUBLESHOOTING FOR DI FAN BELT NOISE
■ ISI-07EN012
♠ INSPECTION Check belt
; issued Aug. 2007 projecting part
Check the fan belt abnormal noise as showing
right photo and check fan belt alignment from
a side view
Cooling
 Check fan belt noise after removing fan belt fan
if necessary
 Check fan belt alignment if there is belt
movement back and forth
♠ MEASUREMENT
If the fan belt noise is caused by poor belt alignment
replace water pump pulley with improved new one
Water Pump
and check belt noise again Pulley

Pulley-Water Pump P/No. : 6642050110

Improvement history for Water Pump Pulley
Increase the depth of pulley groove and modified groove
layout to improve belt positioning (prevent movement)
♠ TARGET VEHICLE
Vehicles sign-off before Apr. 1st, 2007
NOTICE
 Replace the water pump pulley in case of fan belt noise only
 Reuse removed fan belt, replace fan belt if there is severe damage
 Please inform us if there is any complaint at the vehicle with water pump pulley(after Apr. 1st, 2007 sign-of
f)
 TROUBLESHOOTING FOR DI FAN BELT NOISE
♠ EFFECTIVE DATE OF WATER PUMP PULLEY
Engine Effective Date Engine Serial No. Model
Actyon/Actyon Sports/
D20DT (4 cyl.) Mar. 22nd, 2007 541695
Kyron
D27DT (5 cyl.) Mar. 22nd, 2007 553950 Rexton 2/Kyron/Rodius

D27DTP (5 cyl.) Mar. 22nd, 2007 511573 Rexton 2

Special attention
CAUTION to interference
Take care not to damage the rubber bellow of belt tensioner using the wrench
while removing or installation of fan belt using wrench

REFERENCE
Fan belt should rotate evenly without movement back and forth left before the end of pulley
about 2~3 mm if you check tensioner pulley with the naked eye
2~3mm clearance

Fan Belt

Tensioner
Pulley
 INSTRUCTION OF BELT TENSIONER REPLACE

■ MODEL : DI ENGINE ALL

♠ RECOMMENDATION
 Clean the belt tensioner when the related job is doing
 Belt tensionor could be replaced due to oil contamination even though it
works well
1. Remove the fan belt
2. Spray WD40 around contaminated area
3. Wait around 5 minutes
4. Blow the contamination away using
compression air Belt Tensioner
; Take care not to direct contact compression Ventilation
hole
air into rubber part of belt tensioner
5. Clean up the rubber part with clean cloth
6. Install the fan belt

VENTILATION HOLE
Belt tensionor has ventilation hole to discharge the hot and pressed e
vaporative oil gas which is generated during operation
This oil gas can misjudge as oil leakage if its mixed with dust around
 INSTRUCTION OF BELT TENSIONER REPLACE
♠ BELT TENSIONER OPERATION PRINCIPLE
DOWN UP

Oil Reservoir

Expansion Stage (UP) : Oil flow into the Piston through check valve
Compression Stage (DOWN) : Oil flow out though oil gap of piston upper to
oil reservoir

NOTICE
 There is no functional problem if belt tension has more than 50% oil inside
 In case of fan belt noise, check the symptom with released technical information
ISI-07EN012 before replace fan belt
 OIL LEAK FROM EGR COOLER MOUNTING BOLT

■ MODEL : DI ENGINE ALL Contaminated by

engine oil at EGR
cooler lower area
♠ SYMPTOMS
Oil leak from EGR Cooler low area

♠ FIELD ACTION
Spray sealant (DOBO 233 ) on the
mounting bolt for EGR cooler lower

Tightening Torque : 25±2.5 Nm

Spray sealant inside

mounting hole

Spray sealant at the

end of mounting bolt
NOTICE
Do not replace cylinder head assy
at this case
 INFORMATION OF INTAKE HOSE TIGHTENING TORQUE

■ MODEL : DI ENGINE ALL

♠ RECOMMENDATION
Keep the tighten spec. of intake duct
clamp while the related job is doing
at service station

Tightening Torque : 6 ~7 NM
(0.6 ~ 0.7 Kgf.m)

NOTICE
If necessary, clean the blow-by oil inside intake hose and intake
manifold duct area before clamp installation
 INSTRUCTION OF ACOUSTIC COVER REMOVEAL

■ MODEL : DI ENGINE ALL

♠ SYMOPTOMS
Loosen stud bolt for DI acoustic cover could be the reason of abnormal
engine noise
Stud bolt can be broken
long mileage after if its not
Loosened tightened correctly
stud bolt

♠ FIELD ACTION
Spray loctite at the pitch of stud bolt before installation
Spray loctite a lit Spray at the pitch and
tle at the pitch contact surface a little

Do not over spray

(Can’t remove stud bolt later)
 TROUBLESHOOTING FOR EGR VALVE LEAK

■ MODEL : MUSSO SPORTS/KORANDO/REXTON (IDI ENGINE)

♠ SYMOPTOMS
- Oil leak from EGR valve gasket area
(symptoms return occasionally) Leak

♠ FIELD ACTION
- Clean the EGR gasket and then spray
sealant on both side

Bolt T/Torque : 25NM

Front Rear Bolt Spec. : M8*25

→ Spray loctite 271
NOTICE
(red color) to prevent defor
- DOBO 233 Sealant A/S P/No. mation by heat
: 665 989 50A0
TROUBLESHOOTING FOR EGR VALVE LEAK

Leakage

Bolt Length : 25mm

TROUBLESHOOTING FOR IDI CYLINDER HEAD LEAK

■ MODEL : MUSSO SPORTS/KORANDO/REXTON (IDI ENGINE)

♠ CONDITION
- There is some field cases replacing cylinder head gasket due to misjudgment
as oil leakage

♠ SYMPTOMS
- Oil leakage between exhaust manifold and
cylinder head

♠ CAUSES
- incomplete combustion blow-up gas which is Ex. Manifold Gasket Leak
condensed by heat leaks through side part of
exhaust manifold gasket
It could decrease gasket sealing by loosen
the tightening torque of mounting
nuts if the driving mileage is creased

♠ FIELD ACTION Coolant Line Oil Line

- Replace gasket and nuts with new one
(do not reuse mounting nuts, Tightening Torque : 35 NM)
- Check oil leakage of exhaust valve stem seal at the same time
TROUBLESHOOTING FOR IDI CYLINDER HEAD LEAK

■ MODEL : MUSSO SPORTS/KORANDO/REXTON (IDI ENGINE)

♠ FIELD CASE – MISJUDGMENT

Case 1 Cylinder head replace due to misjudgment of poor position of steel ball
Remark 1) Poor Position of steel ball normally happen at low mileage vehicle

Remark 2) Steel for engine oil line located at engine front side (near chain
tension), the other steel balls located lower side of cylinder head
is for coolant line
Case 2 Cylinder head replace due to misjudgment of processing defects of
cylinder head

♠ RECOMMENDATION
Do not replace cylinder head by field misjudgment
In case of oil leak of cylinder head, do a color marking at leak point
 TROUBLESHOOTING FOR IDI ENG BIG SHAKING

■ FIELD ACTION (BEFORE)

1st Step) Rework with ball adjusting system
2nd Step) In case of no result after 1st step, replace timing device and
injection pump
; Refer to Technical Information ISI-06EN004

■ FIELD ACTION (AFTER)

1st Step) Rework with Ball Adjusting System or Magnetic Side Cover (6t,8t)
2nd Step) In case of no result after 1st step, replace timing device and
injection pump
; Refer to Technical Information ISI-07EN015

■ REMARK
- SYMC are supplying Magnetic Side Cover for 5 cylinder and 4 cylinder engine
from July, 2007 according to field request

* Part No. : 6620703012 (5cylinder – 8t Thickness)

6610703012 (4 cylinder – 8t Thickness)
TROUBLESHOOTING FOR ELEC. T/BODY (EUROIV)
1. SYMPTOMS : Check engine lamp ON & lack of power with following DTC
P213B – Abnormal Throttle Control
P213C – Low Throttle Signal
P1234 – VGT Operation Fault (High)
P0107 - Boost Pressure Sensor Open/GND Short
P0108 – Boost Pressure Sensor Fault
; If Boost Pressure Sensor, V/Modulator or Any vacuum leak could not help for
the case, please check below points one by one
2. POSSIBLE CAUSES
A. Poor electric connection between Throttle Body and ECU
; You should check every connection and make a tight connection
because it could transfer abnormal signal at driving condition by
vehicle (or engine) vibration.
B. Broken Gear teeth in Throttle Body
C. Poor ground connection
; Please check every engine ground, especially hidden points
 TROUBLESHOOTING FOR ELEC. T/BODY (EUROIV)
3. Field Cases
■ Case A - RODIUS D27DT EURO 4
DTC : P2100 / P213B / P213C / P0108 / P0530 / P0698
A. broken gear

B. Poor ground connection BROKEN GEAR

Poor Ground
Gap
TROUBLESHOOTING FOR ELEC. T/BODY (EUROIV)

■ Case B – REXTON/RODIUS/KYRON
D27DT EURO 4
DTC : P213B / P213C
A. poor electric connection
A B C
Troubleshooting
problem was gone after T/Body connection
cleaning and repairing
every connector’s female
and male pin
A

B Female side Male side

C112 CONNECTOR
Location : Under glow
plug control unit