SsangYong Rexton Service Manual

ENGINE

SERVICE MANUAL

PYUNGTAEK, KOREA

SECTION INDEX

SERVICE

MANUAL

(vol. 1 of 2)

REXTON

FOREWORD

This manual includes procedure for maintenance, adjustment, service operation and removal and installation of components.

VOLUME 1 OF 2

GENERAL INFORMATION

ENGINE ASSEMBLY

ENGINE HOUSING

INTAKE SYSTEM

EXHAUST SYSTEM

DI0A

DI01

DI02

DI03

DI04

All information, illustrations and specifications contained in this manual are based on the latest

product information available at the time of manual approval.

The right is reserved to make changes at any time without notice.

SSANGYONG MOTOR CO., LTD.

PYUNGTAEK, KOREA

LUBRICATION SYSTEM

COOLING SYSTEM

FUEL SYSTEM

ENGINE CONTROL SYSTEM

ELECTRIC DEVICES AND SENSORS

DIAGNOSIS

DI05

DI06

DI07

DI08

DI09

DI10

DI ENGINE

CONTENTS

GENERAL INFORMATION....................DI0A

ENGINE ASSEMBLY ............................. DI01

ENGINE HOUSING ................................ DI02

INTAKE SYSTEM................................... DI03

EXHAUST SYSTEM............................... DI04

LUBRICATION SYSTEM ....................... DI05

COOLING SYSTEM ............................... DI06

FUEL SYSTEM ...................................... DI07

ENGINE CONTROL SYSTEM ............... DI08

ELECTRIC DEVICES AND SENSORS . DI09

DIAGNOSIS ........................................... DI10

SECTION DI0A

GENERAL INFORMATION

DI0A-1

00SECTION DI0A

GENERAL INFORMATION

Table of Contents

CLEANNESS ....................................... DI0A-3

STRUCTURE ...................................... DI0A-8

ENGINE CONTROLS ....................... DI0A-11

ECU related components ..............DI0A-11

Engine and sensors ..................... DI0A-12

Electrical components and

pre heating system ...................... DI0A-13

INTAKE SYSTEM ............................. DI0A-14

Intake air flow chart ...................... DI0A-15

INTAKE SYSTEM ............................. DI0A-16

Exhaust air flow chart ................... DI0A-17

LUBRICATION SYSTEM .................. DI0A-18

COOLING SYSTEM ......................... DI0A-19

Coolant flow chart ........................ DI0A-20

FUEL SYSTEM ................................. DI0A-21

Fuel supply system ...................... DI0A-22

GENERAL SPECIFICATIONS........... DI0A-23

Vehicle specifications................... DI0A-23

Maintenance ................................ DI0A-26

VEHICLE IDENTIFICATION .............. DI0A-28

HOW TO USE AND MAINTAIN WORKSHOP

MANUAL ........................................... DI0A-30

Consists of workshop manual ...... DI0A-30

Manual description ...................... DI0A-30

Guidelines for service work

safety ........................................... DI0A-31

Lifting points................................. DI0A-36

Tightening torque of standard

bolts.............................................. DI0A-37

GENERAL INFORMATION

DI ENG SM - 2004.4

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DI0A-3

CLEANNESS

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 µm of preciseness. The pressure regulation and injector operation are done by electric source from engine ECU. Accordingly, if the internal valve is stucked due to foreign materials, injector remains open. Even in this case, the HP pump still operates to supply high pressurized fuel. This increases the pressure to combustion chamber (over 250 bar) and may cause fatal damage to engine.

You can compare the thickness of injector nozzle hole and hair as shown in below figure (left side). The right side figure shows the clearance between internal operating elements.

Valve actuator lift: 0.028 mm

Hair

The core elements of fuel system has very high preciseness that is easily affected by dust or very small foreign material. Therefore, make sure to keep the preliminary works and job procedures in next pages. If not, lots of system problems and claims may arise.

Diameter: 0.40 mm

Nozzle hole

Operating clearance:

0.002 mm

Diameter:

2.0 mm

Y220_0A035

GENERAL INFORMATION

DI ENG SM - 2004.4

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DI0A-4

Job procedures

1. Always keep the workshop and lift clean (especially, from dust).

2. Always keep the tools clean (from oil or foreign materials).

3. Wear a clean vinyl apron to prevent the fuzz, dust and foreign materials from getting into fuel system. Wash your hands and do not wear working gloves.

4. Follow the below procedures before starting service works for fuel system.

Carefully listen the symptoms and problems from customer.

Visually check the leaks and vehicle appearance on the wiring harnesses

and connectors in engine compartment.

Locate the fault. If the cause is from fuel system (from priming pump to

injector, including return line), follow the step 1 through step 3 above.

5. If the problem is from HP pump, fuel supply line or injector, prepare the clean special tools and sealing caps to perform the diagnosis for DI engine fuel system in “DIAGNOSIS” section in this manual. At this point, thoroughly clean the related area in engine compartment.

Notice

Clean the engine compartment before starting service works.

Perform the diagnosis proceee with Scan-i

(refer to “DIAGNOSIS” section in this manual).

Tool kit for high pressure line Took kit for low pressure line Removal tool box and cap kits

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GENERAL INFORMATION

DI ENG SM - 2004.4

6. 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. The pipes should be tightened to specified tightening torques during installation. Over or under torques out of specified range may cause damages and leaks at connections. Once installed, the pipes have been deformed according to the force during installtion, therefore they are not reusable.

The copper washer on injector should be replaced with new one. The injector holder bolt should be tightened to specified tightening torque as well. If not, the injection point may be deviated from correct position, and it may cause engine disorder.

DI0A-5

Plug the disconnected parts with sealing caps, and remove the caps immediately

High pressure pump

IMV valve

Transfer pump and high

pressure pump

Fuel temperature sensor

Water separator

Water detection sensor

Fuel filter

before replacing the components.

Priming pump

Fuel pressure sensor

Injection pipe

Common rail

GENERAL INFORMATION

DI ENG SM - 2004.4

Fuel tank

Injector

Cap position Supply line Return line

Y220_0A039

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DI0A-6

7. Plug the removed components with clean and undamaged sealing caps and store it into the box to keep the conditions when it was installed.

8. Clear the high pressure offset value by Scan-100 after replacing the high pressure pump.

Y220_0A040

9. To supply the fuel to transfer line of HP pump press the priming pump until it becomes hard.

Warning

Do not crank engine before having filled pump.

Priming pump

Y220_0A041

10. Check the installed components again and connect the negative battery cable. Start the engine and check the operating status.

11. With Scan-i, check if there are current faults and erase the history faults.

Note

For details, refer to “DI10 Diagnosis teable”.

Y220_0A042

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GENERAL INFORMATION

DI ENG SM - 2004.4

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. However, above phenomenon can be happened if stations have poor facilities or sell improper fuel for the season. In case of DI engine, purity of fuel is very important factor to keep internal preciseness of HP pump and injector. Accordingly, more dense mesh than conventional fuel filter is used. To prevent fuel filter internal clogging due to paraffin separation, SYMC is using fuel line that high pressure and temperature fuel injected by injector returns through fuel filter to have an effect of built-in heater (see fuel system).

SYSTEM SUPPLEMENT AND REMEDY AGAINST WATER IN FUEL

As mentioned above, some gas stations supply fuel with excessive than specified water. In the conventional IDI engine, excessive water in the fuel only causes dropping engine power or engine hunting. However, fuel system in the DI engine consists of precise components so water in the fuel can cause malfunctions of HP pump due to poor lubrication of pump caused by poor coating film during high speed pumping and bacterization (under long period parking). To prevent problems can be caused by excessive water in fuel, water separator is installed inside of fuel filter. When fuel is passing filter, water that has relatively bigger specific

gravity is accumulated on the bottom of the filter.

DI0A-7

Y220_0A041

If water in the separator on the fuel filter exceeds a certain level, it will be supplied to HP pump with fuel, so the engine ECU turns on warning light ( ) on the meter cluster and buzzer if water level is higher than a certain level.

Due to engine layout, a customer cannot easily drain water from fuel filter directly, so if a customer checks in to change engine oil, be sure to perform water drain from fuel filter. (See fuel system for details.)

GENERAL INFORMATION

DI ENG SM - 2004.4

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DI0A-8

STRUCTURE

Front view

Rear view

1. TVD (Torsional Vibration Damper)

2. Air conditioner compressor

3. Power steering pump pulley

4. Idle pulley

5. Water pump pulley

6. Alternator

7. Cooling fan pulley & viscos clutch

8. Aut tensioner pulley

9. Auto tensioner

10. Poly-groove belt

11. Cam position sensor

12. Drive plate (M/T: DMF)

Y220_0A001

13. Oil filter housing

14. Vacuum pump

15. Crank position sensor

16. EGR valve

17. Power steering pump

18. EGR center pipe

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GENERAL INFORMATION

DI ENG SM - 2004.4

Top view

DI0A-9

19. Cylinder head cover

20. Intake manifold

21. Water outlet port

22. Common rail

23. Fuel pressure sensor

24. Fuel pipe

25. Injector

26. Fuel return line

27. Oil filler cap

28. Glow plug

Y220_0A002

29. Booster pressure sensor

30. Oil separator

31. Oil dipstic

32. EGR center pipe

GENERAL INFORMATION

DI ENG SM - 2004.4

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DI0A-10

Left side view

33. Cylinder head

34. Cylinder block

35. Oil pan

36. Drain plug

37. Turbocharger

Right side view

38. EGR - RH pipe

39. Oil separator

40. Oil dipstic

41. HP pump

Y220_0A003

42. Turbocharger vacuum modulator

43. EGR valve vacuum modulator

44. EGR valve

45. Exhaust manifold

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GENERAL INFORMATION

DI ENG SM - 2004.4

ENGINE CONTROLS

ECU RELATED COMPONENTS

DI0A-11

ECU/barometric sensor Cam position sensor

(water detection sensor)

Fuel filter

Accelerator pedal sensor

HFM sensor/intake air

temperature sensor

Pre heating time relay Main relay

Y220_0A004

GENERAL INFORMATION

DI ENG SM - 2004.4

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DI0A-12

ENGINE AND SENSORS

Injector

Glow plug

Common rail

Crankshaft position

sensor

Fuel pressure sensor

Camshaft position

sensor

HP pump

Coolant temperature

sensor

Booster pressure sensor

Knock sensor (2)

Y220_0A005

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GENERAL INFORMATION

DI ENG SM - 2004.4

ELECTRICAL COMPONENTS AND PRE HEATING SYSTEM

Glow plug Pre heating time relay

DI0A-13

Starter motor

BatteryFuse box

Alternator

Y220_0A006

GENERAL INFORMATION

DI ENG SM - 2004.4

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DI0A-14

INTAKE SYSTEM

Air cleaner assembly Intake duct hoseHFM sensor Intake manifold

Intake outlet hose Turbocharger Intercooler Inlet hose

Y220_0A007

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GENERAL INFORMATION

DI ENG SM - 2004.4

INTAKE AIR FLOW CHART

Air cleaner side

DI0A-15

Intake valve (in combustion chamber)

Intake manifold

HFM sensor

Turbocharger (compressor)

Engine

Intake hose (inner)Intake hose (outlet) Intercooler

Y220_0A008

GENERAL INFORMATION

DI ENG SM - 2004.4

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DI0A-16

INTAKE SYSTEM

Muffler Exhaust manifold EGR valve

Vacuum modulatorTurbocharger Catalytic converter EGR pipe

Y220_0A009

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GENERAL INFORMATION

DI ENG SM - 2004.4

EXHAUST AIR FLOW CHART

Exhaust gas

DI0A-17

Exhaust pipeCatalytic converter Muffler

Ambient

air

Turbocharger

(turbine side)

Turbocharger booster

Exhaust manifold

EGR vacuum modulator

To turbocharger booster

Turbocharger booster vacuum modulator

EGR valve

EGR pipe

Y220_0A010

GENERAL INFORMATION

DI ENG SM - 2004.4

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DI0A-18

LUBRICATION SYSTEM

Cylinder head cover

Oil dipstic PCV valve

Engine oil filter

housing

Engine oil pump Oil pan Engine oil cooler

Engine oil pressure

switch

Y220_0A011

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GENERAL INFORMATION

DI ENG SM - 2004.4

COOLING SYSTEM

DI0A-19

Coolant reservoir

Water pump

Radiator assembly

Cooling fan and fan

clutch

Y220_0A013

GENERAL INFORMATION

DI ENG SM - 2004.4

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DI0A-20

COOLANT FLOW CHART

Coolant reservoir

Heater

Oil cooler

Intake manifold

Thermostat

Water pump

Inner hose

Coolant outlet port

Outlet hose

Cooling fan

Radiator

Y220_0A014

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GENERAL INFORMATION

DI ENG SM - 2004.4

FUEL SYSTEM

Fuel return hose Fuel pressure pipe Common rail Fuel filter

DI0A-21

Injector HP pump Priming pump

Y220_0A015

GENERAL INFORMATION

DI ENG SM - 2004.4

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DI0A-22

FUEL SUPPLY SYSTEM

Fuel pressure sensor

High pressure pump

IMV valve

Low and high

pressure pump

Fuel temperature

sensor

Water separator

Fuel filter

Water detection

sensor

Prining pump

Common rail

High pressure pipe

Label (C21)

Injector

Sensors

Fuel tank

Components:

- High pressure fuel pump

- Fuel injectors

ECU

- Fuel rails

- Electroc control unit (ECU)

- Fuel pressure sensor

- Various sensors and actuators

HFM sensor

Cam position sensor

Crank position sensor

Knock sensor etc.

Supply line Return line ECU communication line

Y220_0A016

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. Engine speed is measured by crankshaft speed (position) sensor and camshaft speed (position) sensor determines injection order and ECU detects driver’s pedal position (driver’s demand) through electrical signal that is generated by variable resistance changes in accelerator pedal sensor. Air flow (hot film) sensor detects intake air volume and sends the signals to ECU. Especially, the engine ECU controls the air-fuel ratio by recognizing instant air volume changes from air flow sensor to decrease the emissions (EGR valve control). Furthermore, ECU uses signals from coolant temperature sensor and air temperature sensor, booster pressure sensor and barometric sensor as compensation signal to respond to injection starting, pilot injection set values, various operations and variables.

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GENERAL INFORMATION

DI ENG SM - 2004.4

GENERAL SPECIFICATIONS

VEHICLE SPECIFICATIONS

DI0A-23

Vehicle Dimension

(mm)

Y220_0A017

GENERAL INFORMATION

DI ENG SM - 2004.4

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DI0A-24

Specifications

Systems Items Diesel Remark

General Overall length (mm)

Overall width (mm)

Overall height (mm)

4,720 (4,785)

1,870

1,760 (1,830)

( ): optional

item

Engine

Gross vehicle weight (kg)

Curb weight (kg)

Min. turning radius (m)

Ground clearance (mm)

Fuel

Fuel tank capacity

Model

No. of cyl./Compression ratio

Total displacement

Camshaft arrangement

Max. power

Max. torque

Injection timing

Idle speed

Cooling system

Coolant capacity

Lubrication

Max. oil capacity

AT: 2450 (2510), MT: 2405 (2465)

AT: 1995 (2055), MT: 1950 (2010)

5.6

200

Diesel

D27DT

5/18:1

2,696 cc

DOHC

170 ps/4,000 rpm

34.7 kg•m/1,800 rpm

ATDC 4° ± 1°(at idle)

760 ± 50 rpm

Water-cooled/forced circulation

Approx. 11.5

Gear pump, forced circulation

9.3

Manual

Turbo charger and cooling type

Type

transmission

Automatic transmission

Model

Type

Rev.

Rev. 1

Rev. 2

Turbo charger, air-cooled

Remote control, floor change type

IDI Engine 4.007

2.367

1.473

1.000

0.872

3.700

DI Engine 4.315

2.475

1.536

1.000

0.807

3.591

Electronic

Floor change type

2.742

1.508

1.000

0.708

2.429

3.595

2.186

1.405

1.000

0.831

3.162

1.926

2.742

1.508

1.000

0.708

2.429

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GENERAL INFORMATION

DI ENG SM - 2004.4

Specifications (Cont’d)

DI0A-25

Systems

Transfercase

Model

Type

Gear ratio

Clutch

Type

Disc type

Power steering

Front axle

Type

Steering angle

Drive shaft type

Axle housing type

Rear axle

Drive shaft type

Axle housing type

Brake

Master cylinder type

Booster type

Type

Parking brake

Suspension

Front

Rear

Air conditioner

Electrical

Refrigerant

Compressor type

Battery type/Capacity (V-AH)

Starter capacity (V-kW)

Alternator capacity (V-A)

Items

High

Low

Inner

Outer

Inner

Outer

Diesel

Part-time

Planetary gear type

1.000 : 1

2.483 : 1

Hydraulic [A/T: Torque converter]

Dry single diaphragm type

[A/T: 3 elements 1 stage 2 phases]

Rack and pinion

36° 17

32° 40

Ball joint type

Build-up type

Semi-floating type

Build-up type

Tandem type

Vacuum booster

Disc

Drum (Disc)

Cable type (internal expansion)

Wishbone + Coil spring

5-link + Coil spring

R134a

Vane type

MF / 12 - 90

Diesel : 12 - 2.2, Gasoline : 12 - 1.8

IDI

Gasoline

12 - 75 (12 - 90)

12 - 140 (12 - 115)

12 - 115

Remark

( ): optional item

GENERAL INFORMATION

DI ENG SM - 2004.4

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DI0A-26

MAINTENANCE

Major Components and Service Interval

* Use only Ssangyong Genuine Parts.

Components Service Interval Remarks

Engine oil and oil filter

Gasoline engine

DI diesel

Daily Weekly

O-

engine

IDI diesel

O-

engine

Coolant

Brake pipe and hose

Brake pad, shoe and

O-

disc

Air cleaner element

Gasoline engine

DI diesel

-O

engine

IDI diesel

-O

engine

Fuel filter

Gasoline

engine

DI diesel engine

IDI diesel

engine

Auto-

4-speed

matic transmission oil

5-speed

Manual transmission

oil

Transfer case oil

Axle oil

Air conditioner air

filter

Spark plug (gasoline

engine)

Initial change: 10,000 km

Replace at every 15,000 km

Initial change: 5,000 km

Replace at every 10,000 km or 12 months

More frequent maintenance is required if the vehicle is operated under severe condition.

Severe conditions?

- Frequent low-speed operation as in stop-and-go traffic

- When most trips are less than 6 km (in winter, less than 16 km)

- Driving in sandy, dusty, and salty road

- Driving in mountainous areas

- Extensive idling or high load operation such as towing a trailer

Replace at every 60,000 km or 3 years

Initial inspection: 1,000 km

Inspect at every 20,000 km, replace if necessary

Inspect at every 10,000 km, check or adjust if necessary

Clean at every 15,000 km,

Replace at every 60,000 km

Initial clean: 5,000 km,

If vehicle is operated under dusty or sandy area, frequently clean and inspect the air cleaner system. If necessary, replace the air cleaner element.

Clean at every 10,000 km, replace if necessary,

Replace at every 30,000 km

Replace at every 60,000 km

Replace at every 30,000 km (Drain the water from fuel filter at every 10,000 km)

Replace at every 40,000 km

Inspect at every 30,000 km or 1 year, replace if necessary (replace at every 60,000 km if the vehicle is operated

More frequent maintenance is required if the vehicle is operated under severe condition.

- Driving in unpaved road

- Towing a trailer

under severe conditions)

Inspect at every 10,000 km,

Replace at every 60,000 km

Inspect at every 10,000 km,

Replace at every 60,000 km (but, frequently chexk the leaks)

Replace at every 30,000 km

Replace at every 10,000 km

More frequent maintenance is required if the vehicle is operated under severe condition.

- Driving in sandy, dusty, and unpaved road

- Excessive operation of air conditioner or heater

Replace at every 60,000 km

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GENERAL INFORMATION

DI ENG SM - 2004.4

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