SSANGYONG Q151 Service Manual

01-3

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Left viewRight view

Rear viewFront view

1. ENGINE LAYOUT

01-4

2. MAJOR COMPONENTS

Front view

▶

Vacuum pump

Oil filter assembly

Camshaft position sensor

Power steering pump pulley

Water pump pulley

Alternator pulley

Idler pulley No. 2

A/C compressor pulley

Auto tensioner
Idler pulley No. 1
Isolation damper

Rear view

▶

E-EGR valve

Fuel temperature sensor

Fuel HP pump assembly

Coolant temperature sensor

IMV valve

Crankshaft position sensor

Oil pressure switch

01-5

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Right view

▶

Front exhaust gas temperature

sensor

Oil dipstick tube &

gauge assembly

E-VGT actuator

E-VGT turbocharger

Coolant screw plug

Oil drain plug

Left view

▶

Thermostat assembly

Variable swirl valve assembly

E-EGR valve

E-EGR solenoid valve

EGR cooler

Electronic throttle body

Oil cooler assembly

01-6

3. ENGINE COMPARTMENT LAYOUT

Do not work on the engine compartment while the engine, radiator, exhaust manifold, muffler or
catalytic converter is hot. Always turn the engine off and allow it to cool before starting the
maintenance.
Regularly check the engine oil level and add Ssangyong genuine engine oil if necessary.
Clean the dipstick with clean cloth so that any foreign materials cannot get into the engine.

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Power steering fluid
reservoir

Brake fluid reservoir

Fuse & relay

Engine oil dipstick
gauge

Washer fluid
reservoir cap

Engine oil filler cap

Air cleaner

Operating vehicle with insuffi cient amount of oil can damage the engine. Make sure the engine oil
level is correct and add oil if necessary.

Coolant reservoir

01-7

0000-00

1) Service Interval

2) Specification and Capacity

Engine oil

Specification Quality class: Ssangyong genuine engine oil (Total Quartz INEO ECS

5W 30, SK ZIC SY 5W 30) or oil Approved by MB Sheet 229.51

Capacity approx. 6.0 litter

Engine
coolant

Specification Ssangyong genuine coolant Anti-Freeze SYC-1025

Capacity approx. 8.5 litter

Severe condition

Frequent stop-and-go traffic, extended idling, short driving distance below 6 km, driving distance below
16 km when the outside temperature remains below freezing
Driving in a hilly or mountainous terrain, sandy, or dusty area
High load driving such as trailer towing
Taxi, patrol service or delivery service (extended idling and excessive driving with low speed)

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Description

Daily

inspection

Weekly

inspection

Service interval

Engine oil & oil
filter

Inspection - EU Change every 20,000 km or 12 months

(The service interval should be shortened
under severe conditions)

General Change every 15,000 km or 12 months

(The service interval should be shortened
under severe conditions)

Coolant Inspection - Change every 200,000 km or 5 years
Air cleaner

element

- Inspection Diesel EU Change every 20,000 km (The
service interval should be
shortened under severe
conditions)

General Clean every 7,500 km, change

every 15,000 km (The service
interval should be shortened
under severe conditions)

Gasoline Clean every 15,000 km, replace every

60,000 km (The service interval should be
shortened under severe conditions)

Fuel filter - - EU Change every 40,000 km (Draining water

from fuel filter: whenever replacing the
engine oil)

General Change every 45,000 km (Draining water

from fuel filter: whenever replacing the
engine oil)

01-8

4. CAUTION WHEN SERVICING THE ENGINE

1) Cleaness

Engine has a lot of precisely machined (grinding, polishing, lapping) surfaces. Thus, there should be great
cautions for cleaness when servicing the engine components. Apply the engine oil on the sliding surfaces
when assemblying the components. Every component should be disassembled and reassembled in
accordance with the correct sequences. Before servicing the engine, the negative cable should be
diconnected from the battery. Otherwise, some electric or electronic components could be damaged.

2) Servicing

(1) Lifting up the vehicle

Always keep the safety precautions.
To prevent the vehicle from rolling down, put the chocks under the tires (when using a 4-post lift).
Make sure to support the correct lifting points (when using a 2-post lift)

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(2) Exhaust system

Wear the safety glove when removing the exhaust pipe.
Make sure that the exhaust pipe is cooled before removing it.

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Before service work, be sure to disconnect battery negative (-) terminal to prevent damages by bad
wire and short.
To prevent the foreign material from getting into engine cylinder, cover the inlet of air cleaner if the
air cleaner has been removed

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01-9

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(3) Cautions before service

Prolonged exposure to the engine oil make cause a skin cancer or an irritation.
Used engine cotains the hazardous material that may cause the skin cancer. Do not allow the used
engine to make contact with your skin.
Make sure to wear the protection gloves and goggle when handling the engine oil. If contact happens,
rinse affected areas immediately with plenty of water. Do not wash it with gasoline or solvent. If
irritation persists, consult a doctor.
Improperly disposed engine oil can pollute the environment. Dispose used engine oil in accordance
with local environmental regulations.

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(5) Tightening the fastener

If fine dust or foreign material enters into DI engine's fuel system, there can be serious damages
between HP pump and injectors. So, be sure to cover removed fuel system components with cap
and protect removed parts not to be contaminated with dirt. (Refer to cleanness in this manual
while working on DI engine fuel system)
When working on the fuel line between priming pump and injector (including return line), always
plug the openings with caps to prevent foreign materials or dust from entering to the openings and
connections.
The HP fuel supply pipe (HP pump to fuel rail) and HP fuel pipe (Fuel rail to injector)
should be replaced with new ones when removed.

1.

2.

3.

Scalding hot coolant and steam could be blown out under pressure, which could cause serious injury.
Never remove the coolant reservoir cap when the engine and radiator are hot.

(4) Lubrication system

3) Fuel and Oil System

If work on the fluid system such as fuel and oil, working area should be well ventilated and smoking
should be prohibited.
Gasket or seal on the fuel/lubrication system should be replaced with new ones and bolts and nuts
should be tightened as specified.

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Clean the mating surfaces before tightening.
Place the marks with paint to tighten by angle if the angle wrench is not available.

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01-10

5. STANDARD BOLTS SPECIFICATIONS

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. Try not to over max. allowable tightening torque if not required to
do so.
Determine extra proper tightening torque if tightens with washer or packing.
If tightens bolts on the below materials, be sure to determine the proper torque.

1)

2)

3)

4)
Aluminum alloy: Tighten to 80 % of above torque table.

Plastics: Tighten to 20 % of above torque table.

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01-11

0000-00

6. TIGHTENING TORQUE

Name Size

Numbers of

fastener

Tightening

torque (Nm)

Note (total
tightening

torque)

Main bearing cap M12×82 10 55±5Nm,

180˚

Not-reusable

Connecting rod cap M9×52 8 40±5Nm,

90˚+10˚

50 ~80Nm

Crankshaft rear seal M6×20 6 10±1Nm -

Oil pump M8×35 3 25±2.5Nm -

Drive plate M10×22 8 45±5Nm,

90˚+10˚

Not-reusable

Isolation damper center

bolt

M18×50 1 200±20Nm,

180˚+20˚

660 ~ 720Nm

Not-reusable

Oil pan M6×20 18 10±1Nm -

M6×35 2 10±1Nm ­M6×85 2 10±1Nm -

M6×120 2 10±1Nm -

M8×40 2 25±2.5Nm -

Mounting nut for high

pressure pump

M14×1.5-8-1 1 65±5Nm -

Mounting bolt for high

pressure pump

M8×30 3 25±2.5Nm -

Cylinder head M13×150 12 85Nm

270°±10°

-

Camshaft cap M6×30 16 10±1Nm -

M8×60 4 25±2.5Nm ­Exhaust stud bolt 10 15±1.5Nm -
Exhaust sprocket M8x16.5 1 25±2.5Nm -

Chain tensioner screw

plug

M8x1.5 1 25±2.5Nm -

Coolant temperature

sensor

1 20±2.0Nm -

Belt auto tensioner M8×30(LOW) 1 25±2.5Nm -

M10×75(U

pp

er) 1 55±5.5Nm -

Water pump M6×25 7 10±1.0Nm -

01-12

T/C oil supply pipe M16 1 25±2.5Nm

(Fitting Screw)

-

M10 1 17±2.0Nm

(Hollow Bolt)

-

T/C oil return pipe M6×16(to block) 2 10±1Nm -

M6×16

(to turbocharger)

2 10±1Nm -

EGR valve M8×30 3 25±2.5Nm -

Name Size

Numbers of

fastener

Tightening

torque (Nm)

Note (total
tightening

torque)

Hot water inlet pipe M6×12 2 10±1Nm -

Alternator M10×90 1 (LO) 25±2.5Nm -

M10×116 1 (HI) 46±4.6Nm -

Air conditioner

compressor

M8×85 4 25Nm -

Air conditioner bracket M6×25 4 10±1Nm -

Intake manifold M8×35 2 25±2.5Nm -

M8×110 6 25±2.5Nm -

Oil filter module M8×40 6 25±2.5Nm -

M8×80 1 25±2.5Nm -

M8×140 2 25±2.5Nm -

Knock sensor M8×28 2 20±5Nm -

Camshaft position

sensor

M8×14 1 10~14Nm -

T-MAP pressure

sensor

M6×20 1 10±1Nm -

Exhaust manifold M8 10 40±4Nm -

Turbocharger M8 3 25±2.5Nm -

T/C support bolt M8 x 35 1 25±2.5Nm

(Turbo Side)

-

M8 x 16 1 25±2.5Nm

(Block Side)

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01-13

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Name Size

Numbers of

fastener

Tightening

torque (Nm)

Note (total
tightening

torque)

Idler pulley/tensioner

pulley

1 45±4.5Nm -

Glow plug M5 4 20±2Nm -

Vacuum pump M6×25 3 10±1Nm -

Timing gear case cover M6×40 7 10±1Nm -

M6×45 1 10±1Nm ­M6×50 3 10±1Nm -

Cylinder head cover M6×35 21 10±1Nm -

Oil dipstick gauge cover M6×16 1 10±1Nm -

Oil filter cap 1 25±2.5Nm -

Fuel rail M8×25 2 25±2.5Nm -

Injector clamp bolt M6×44 2 9±1.0Nm

130˚±10˚

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High pressure pipe

(between high pressure

pump and fuel rail

assembly)

M17 1 30±3Nm -

High pressure pipe

(between fuel rail assembly

and injector)

M17 4 30±3Nm -

Crankshaft position

sensor

M5×14 1 8±0.4Nm -

Main wiring M6×16 5 10±1Nm -

Intake duct M8×25 4 25±2.5Nm -

Power steering pump M8×100 3 25±2.5Nm -

Cylinder head front

cover

M6×10 5 10±1Nm -

Ladder frame M8×35 5

30±3Nm -

EGR pipe bolt

(to air duct)

M6×16 2 10±1Nm -

EGR pipe bolt

(to EGR cooler)

M8×25 2 25±2.5Nm -

01-14

7. CODING AND INITIALIZATION

1) Engine Variant Coding

Unit Selection Description Remarks

Additional heater YES For PTC auxiary heater equipped

vehicle, select "YES"

YES

NO -

Gear box 5 MT "DSI 6 AT" is selected

automatically.

-

6 MT Select

5 AT(DC 5 AT) -

6 AT(DSI 6 AT) Select

7 AT(DC 7 AT) -

Immobilizer NO Select "YES" if the vehicle has

immobilizer.

-

YES YES

Fan PWM control Select "PWM" PWM fan

Relay -

Engine level control NO

YES

SKM key NO NO

YES -

Glow plug AQGS (CAN) Select "AQGS" AQGS (CAN)

Relay (K-line) -

A/C Refrigerant pressure

sensor

Select the appropriate system. Pressure sensor

for A/C refrigerant

NO -

Vehicle speed sensor CAN Select "CAN" if the vehicle has

ABS or ESP

CAN

WIRE -

Cruise control YES Select "YES" if the vehicle has

cruise control.

YES

NO -

G-sensor YES 2WD ABS & Non-ABS: NO

4WD ABS & ESP: YES

Select

NO Select

01-15

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2) Chassis Variant Coding

Unit Selection Description

Domestic/Export Domestic Select the region.

GEN. Export

EUROPE

EPB application YES Select "NO".

NO

Shift lever type MT AT: Select "DURA lever (CAN)".

MT: Select "MT".

DC lever (CAN)

DURA lever (CAN)

DSIH (NO-CAN)

Electric power steering
(EPS)

NO NO

YES

Transper case P/T Select "2WD" or "P/T".

4WD
2WD
TOD
AWD

Sedan/Limousine Sedan (RV) Select "Sedan (RV)".

Limousine

Vehicle code (Engine) Undefined Select "D20DTR".

D32DT

D27DT
D27DTP
D20DTR

EAS NO Select "NO".

ECS
EAS2 corner
EAS4 corner

Telematics NO Select "NO".

YES

01-16

Unit Selection Description

Brake system ESP Select "ABS" or "ESP".

ABS
TCS

NO

SSPS NO Select "YES".

YES

TPMS NO Select "NO".

YES

T/M type MT Select "M/T" or "DSIH 6 AT".

DC AT

DSIH 6 AT

Vehicle code Rodius / Stavic Select "Rodius".

Rexton

Korando C

Actyon sports

Kyron

ECU coding status ECU not coded Select "ECU coded".

ECU coded

Signal not valid

Not defind