SsangYong: Engine Euro 4. Manual — part 32
LUBRICATION SYSTEM
1222 / 1533
TABLE OF CONTENTS
PCV OIL SEPARATOR . . . . . . . . . . ... 2
1. Overview . . . . . . . . . . . . . . . . . . . . 2
2. Removal and installation of oil separator . . . . . . .. 5
IOP: INTEGRATED OIL PAN . . . . . . . . . 6
1. Overview . . . . . . . . . . . . . . . . . . . . 6
2. Removal and installation of IOP . . . . . . . . . . 9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2
1222
LUBRICATION SYSTEM
D27DTP/D27DT (EU4) SM - 2006.08
D27DTP/D27DT (EU4)
Blow-by gas
(To air duct hose)
Cylinder head
cover
(Oil + Gas)
Oil (To oil dipstick
gauge pipe)
PCV Oil Separator for D27DTP (POWER UP) Engine
PCV valve
Oil separator
1. OVERVIEW
For the D27DTP (POWER UP) engine, the PCV oil separator’s capacity has been increased by 10% compared to
the conventional PCV oil separator for D27DT and D20DT engine to separate the oil and the gas more efficiently.
Oil Separators (Compared to D27DT)
PCV OIL SEPARATOR
Components of Oil Separator for D27DTP (POWER UP) Engine
PCV Oil Separator for D27DT
The first separation will happen
when blowby gas passes through
baffle plates in cylinder head cover.
Then oil and gas will be separated
due to cyclone effect after entering
the oil separator inlet port. Sepa-
rated oil returns to oil pan via oil
drain port and the gas will be burnt
again after entering the combustion
chamber through air duct hose via
PCV valve that opens/closes due to
pressure differences between the
intake side and crankcase.
Blow-by gas
(To air duct hose)
Cylinder
head cover
(Oil + Gas)
Oil (To oil dipstick
gauge pipe)
PCV valve
Oil separator
Operating Procedures
Cylinder head cover (Oil + Gas)
OIl (Oil dipstick gauge pipe)
Blow-by gas
(Air duct hose)
Oil dipstick gauge
Intake air duct
Oil separator
* PCV: Positive Crankcase Ventilation
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
3
1222
LUBRICATION SYSTEM
D27DTP/D27DT (EU4) SM - 2006.08
D27DTP/D27DT (EU4)
ENGINE
FUEL
I
N
T
AKE
EXHAUST
PRE-HEA
TING
LUB
COOLING
SWITCHABLE
ECU
DIAGNOSIS
Performance of PCV Separator and Oil/Carbon Accumulation in Intake Manifold
It is not possible to separate the blowby gas (oil and unburned gas) completely from the crankcase.
This problem is related to the engine control and the PCV oil separator is designed to recirculate
approx. 70% of blowby gas.
When servicing the intake system, you can find that oil and carbon is accumulated in the intake pipe.
It is normal for the vehicle that is normally used in city. Because of the engine control problem, the
100% of blowby gas cannot be recirculated and EGR and PCV oil separator's operating ranges are
overlapped in normal driving mode. These are the cause of oil and carbon accumulated in the intake
pipe.
When the EGR system is operated, the particulate material in the exhaust gas is drawn into the
intake pipe and the oil not filtered in the PCV oil separator is also drawn into the intake pipe.
However, unless the particulate material or oil are accumulated excessively in the pipe, they do not
affect the intake/exhaust valve or related components.
On the contrary, if they are removed using carbon cleaner or chemicals, the engine system may not
function properly.
If too much oil or particulate material is accumulated, check the followings:
1. Engine oil level
2. EGR valve (exhast gas leak and operating condition)
3. Turbocharger (oil/gas leak and operating condition)
4. PCV oil separator (installation condition and leak)
5. PCV oil separator (some functions)
NOTICE
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4
1222
LUBRICATION SYSTEM
D27DTP/D27DT (EU4) SM - 2006.08
D27DTP/D27DT (EU4)
ڭڠڳگڪکٻڠڞڰٻڟگګٻڍڒڋڃڞڎڤڄ
ڭڠڳگڪکٻڠڞڰٻڟگګٻڍڒڋڃڞڎڤڄ
ڜڞگڰڜگڪڭٻڮڠڧڠڞگڤڪک
ڜڞگڰڜگڪڭٻڮڠڧڠڞگڤڪک
ڋڌڸٻڠڢڭٻڱڜڧڱڠ
ڋڌڸٻڠڢڭٻڱڜڧڱڠ
ڋڍڸٻگڈڝڪڟڴڃڡڧڜګڄ
ڋڍڸٻگڈڝڪڟڴڃڡڧڜګڄ
ڋڎڸٻڢڧڪڲٻڰکڤگ
ڋڎڸٻڢڧڪڲٻڰکڤگ
ڋڏڸٻڤڨڱٻڱڜڧڱڠ
ڋڏڸٻڤڨڱٻڱڜڧڱڠ
ڋڐڸٻگڰڭڝڪٻڨڪڟڰڧډ
ڋڐڸٻگڰڭڝڪٻڨڪڟڰڧډ
ڋڑڸٻڡڜکٻپڌ
ڋڑڸٻڡڜکٻپڌ
ڋڒڸٻڡڜکٻپڌڊپڍ
ڋڒڸٻڡڜکٻپڌڊپڍ
ڋړڸٻڡڜکڃګڲڨڄ
ڋړڸٻڡڜکڃګڲڨڄ
ڋڔڸٻګڪڲڠڭٻڭڠڧڜڴ
ڋڔڸٻګڪڲڠڭٻڭڠڧڜڴ
ڌڋڸٻڠکڢٻڞڣڠڞڦٻڧڜڨګ
ڌڋڸٻڠکڢٻڞڣڠڞڦٻڧڜڨګ
ڌڌڸٻڢڧڪڲٻګڧڰڢٻڧڜڨګ
ڌڌڸٻڢڧڪڲٻګڧڰڢٻڧڜڨګ
ڌڍڸٻڤڨڨڪډڧڜڨګ
ڌڍڸٻڤڨڨڪډڧڜڨګ
ڌڎڸٻڜڊڞٻڭڠڧڜڴ
ڌڎڸٻڜڊڞٻڭڠڧڜڴ
ڌڏڸٻګگڞٻڭڠڧڜڴڃپڍڄ
ڌڏڸٻګگڞٻڭڠڧڜڴڃپڍڄ
ڌڐڸٻګگڞٻڭڠڧڜڴڃپڌڄ
ڌڐڸٻګگڞٻڭڠڧڜڴڃپڌڄ
ڌڑڸٻڡڰڠڧٻڡڤڧڧگڠڭ
ڌڑڸٻڡڰڠڧٻڡڤڧڧگڠڭ
ڌڒڸٻڤکڥڠڞگڪڭٻپڌ
ڌڒڸٻڤکڥڠڞگڪڭٻپڌ
ڌړڸٻڤکڥڠڞگڪڭٻپڍ
ڌړڸٻڤکڥڠڞگڪڭٻپڍ
ڌڔڸٻڤکڥڠڞگڪڭٻپڎ
ڌڔڸٻڤکڥڠڞگڪڭٻپڎ
ڍڋڸٻڤکڥڠڞگڪڭٻپڏ
ڍڋڸٻڤکڥڠڞگڪڭٻپڏ
ڍڌڸٻڤکڥڠڞگڪڭٻپڐ
ڍڌڸٻڤکڥڠڞگڪڭٻپڐ
1. Engine oil level
5. PCV oil separator
When the PCV oil separator is malfunctioning, remove the unit and check the following:
Block the inlet port connected to the cylinder head
cover and the drain port connected to the oil drain
pipe with hands and apply vacuum to the outlet port
(if the unit is clean, you can suck it with your mouth
to apply vacuum).
The membrane and the spring are normal if you
feel the PCV oil separator is blocked with noise.
(This is similar to the situation that the blowby gas
coming into the outlet port is blocked by negative
vacuum pressure when accelerating.)
This is only the test method. Actually, the blowby
gas is passed through the outlet port by overcom-
ing the spring tension while driving.
2. EGR valve (exhast gas leak and operating
condition)
3. Turbocharger (oil leak and operating
condition)
4. PCV oil separator (installation and leak)
Check with Scan-100
Exterior Check
* Check the correct oil level
Exterior Check
Exterior Check
Inlet port
Outlet port
Drain port
Scan-100 Check
ڭڠڳگڪکٻڠڞڰٻڟگګٻڍڒڋڃڞڎڤڄ
ڭڠڳگڪکٻڠڞڰٻڟگګٻڍڒڋڃڞڎڤڄ
ڜڞگڰڜگڪڭٻڮڠڧڠڞگڤڪک
ڜڞگڰڜگڪڭٻڮڠڧڠڞگڤڪک
ڋڌڸٻڠڢڭٻڱڜڧڱڠ
ڋڌڸٻڠڢڭٻڱڜڧڱڠ
ڋڍڸٻگڈڝڪڟڴڃڡڧڜګڄ
ڋڍڸٻگڈڝڪڟڴڃڡڧڜګڄ
ڋڎڸٻڢڧڪڲٻڰکڤگ
ڋڎڸٻڢڧڪڲٻڰکڤگ
ڋڏڸٻڤڨڱٻڱڜڧڱڠ
ڋڏڸٻڤڨڱٻڱڜڧڱڠ
ڋڐڸٻگڰڭڝڪٻڨڪڟڰڧډ
ڋڐڸٻگڰڭڝڪٻڨڪڟڰڧډ
ڋڑڸٻڡڜکٻپڌ
ڋڑڸٻڡڜکٻپڌ
ڋڒڸٻڡڜکٻپڌڊپڍ
ڋڒڸٻڡڜکٻپڌڊپڍ
ڋړڸٻڡڜکڃګڲڨڄ
ڋړڸٻڡڜکڃګڲڨڄ
ڋڔڸٻګڪڲڠڭٻڭڠڧڜڴ
ڋڔڸٻګڪڲڠڭٻڭڠڧڜڴ
ڌڋڸٻڠکڢٻڞڣڠڞڦٻڧڜڨګ
ڌڋڸٻڠکڢٻڞڣڠڞڦٻڧڜڨګ
ڌڌڸٻڢڧڪڲٻګڧڰڢٻڧڜڨګ
ڌڌڸٻڢڧڪڲٻګڧڰڢٻڧڜڨګ
ڌڍڸٻڤڨڨڪډڧڜڨګ
ڌڍڸٻڤڨڨڪډڧڜڨګ
ڌڎڸٻڜڊڞٻڭڠڧڜڴ
ڌڎڸٻڜڊڞٻڭڠڧڜڴ
ڌڏڸٻګگڞٻڭڠڧڜڴڃپڍڄ
ڌڏڸٻګگڞٻڭڠڧڜڴڃپڍڄ
ڌڐڸٻګگڞٻڭڠڧڜڴڃپڌڄ
ڌڐڸٻګگڞٻڭڠڧڜڴڃپڌڄ
ڌڑڸٻڡڰڠڧٻڡڤڧڧگڠڭ
ڌڑڸٻڡڰڠڧٻڡڤڧڧگڠڭ
ڌڒڸٻڤکڥڠڞگڪڭٻپڌ
ڌڒڸٻڤکڥڠڞگڪڭٻپڌ
ڌړڸٻڤکڥڠڞگڪڭٻپڍ
ڌړڸٻڤکڥڠڞگڪڭٻپڍ
ڌڔڸٻڤکڥڠڞگڪڭٻپڎ
ڌڔڸٻڤکڥڠڞگڪڭٻپڎ
ڍڋڸٻڤکڥڠڞگڪڭٻپڏ
ڍڋڸٻڤکڥڠڞگڪڭٻپڏ
ڍڌڸٻڤکڥڠڞگڪڭٻپڐ
ڍڌڸٻڤکڥڠڞگڪڭٻپڐ
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