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SsangYong: Engine Euro 4. Manual - part 32

LUBRICATION SYSTEM

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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

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

1222

LUBRICATION SYSTEM

D27DTP/D27DT (EU4) SM - 2006.08

D27DTP/D27DT (EU4)

ENGINE

FUEL

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

1222

LUBRICATION SYSTEM

D27DTP/D27DT (EU4) SM - 2006.08

D27DTP/D27DT (EU4)

ڭڠڳگڪکٻڠڞڰٻڟگګٻڍڒڋڃڞڎڤڄ

ڜڞگڰڜگڪڭٻڮڠڧڠڞگڤڪک

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

Inlet port

Outlet port

Drain port

Scan-100 Check

ڭڠڳگڪکٻڠڞڰٻڟگګٻڍڒڋڃڞڎڤڄ

ڜڞگڰڜگڪڭٻڮڠڧڠڞگڤڪک

ڋڌڸٻڠڢڭٻڱڜڧڱڠ

ڋڌڸٻڠڢڭٻڱڜڧڱڠ
ڋڍڸٻگڈڝڪڟڴڃڡڧڜګڄ

ڋڍڸٻگڈڝڪڟڴڃڡڧڜګڄ
ڋڎڸٻڢڧڪڲٻڰکڤگ

ڋڎڸٻڢڧڪڲٻڰکڤگ
ڋڏڸٻڤڨڱٻڱڜڧڱڠ

ڋڏڸٻڤڨڱٻڱڜڧڱڠ

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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