MANUAL DE SERVIÇO – SsangYong Rexton 2004

CONTENT:

SsangYong Rexton 2004 – FULL MANUAL SERVICE

SsangYong Rexton 2.9L & 3.2L Diesel Engine Manual

SECTION 1 ENGINE SECTION 1A1(M162 ENGINE) – GENERAL ENGINE INFORMATION
Specifications
– Engine Specifications
Component Locator
– Front View
– Side View
Performance Curve
– E32 Engine
Special Tools
– Special Tools Table
Diagnosis
– Oil Leak Diagnosis
– Engine Cranking at The Front of Crankshaft
– Compression Pressure Test
– Cylinder Pressure Leakage Test
General Information
– Cleanliness and Care
– On-Engine Service

SECTION 1A2(M161 ENGINE) – GENERAL ENGINE INFORMATION
Specifications
– Engine Specifications
Component Locator
– Front View
– Side View
Performance Curve
– E23 Engine
– E20 Engine
Special Tools
– Special Tools Table
Diagnosis
– Oil Leak Diagnosis
– Engine Cranking At The Front of Crankshaft
– Compression Pressure Test
– Cylinder Pressure Leakage Test
General Information
– Cleanliness and Care
– On-Engine Service

SECTION 1A3 (OM600 ENGINE) – GENERAL ENGINE INFORMATION
Specifications
– Engine Specifications
Sectional View
– OM662LA Engine
– OM661LA Engine
Performance Curve
– OM662LA Engine
– OM661LA Engine
Special Tools
– Special Tools Table
Diagnosis
– Oil Leak Diagnosis
– Compression Pressure Test
– Cylinder Pressure Leakage Test
General Information
– Cleanliness and Care
– On-Engine Service

SECTION 1B1 M162 ENGINE MECHANICAL – GENERAL ENGINE INFORMATION

Specifications
– Fastener Tightening Specifications
Special Tools
– Special Tools Table
Maintenance and Repair
– On-Vehicle Service
– Engine Assembly
– Crankcase Ventilation System
– Alternator
– Power Steering Pump and A/C Bracket
– Hydraulic Engine Mounting Insulator
– Poly V-Belt
– Tensioning Device
– Poly V-Belt Inspection
– Cylinder Head Cover
– Cylinder Head Front Cover
– Cylinder Head
– Timing Gear Case Cover
– Crankshaft Sealing Rear Cover
– Belt Pulley and Vibration Damper
– Crankshaft Front Radial Seal
– Crankshaft Rear Radial Seal
– Crankshaft
– Flywheel / Driven Plate
– Camshaft Adjuster
– Camshaft Sprocket Bolt
– Camshaft
– Camshaft Timing Position
– Valve Spring
– Valve Stem Seal
– Chain Tensioner
– Timing Chain
– Tensioning Rail
– Cylinder Head Guide Rail
– Crankcase Guide Rail
– Crankshaft Sprocket
– Piston
– Connecting Rod
– Piston Ring
– Engine Oil Specification
– Oil Pan
– Engine Oil and Oil Filter Element
– Oil Filter
– Oil Pump
– Oil Pressure Relief Valve
– Oil Non-Return Valve
– Oil Dipstick Guide Tube
– Unit Repair
– Oil Gallery in Crankcase
– Oil Gallery in Cylinder Head
– Core Plugs in Crankcase
– Cylinder Bore
– Crankcase Mating Surface
– Cylinder Head Mating Surface

SECTION 1B2 M161 ENGINE MECHANICAL – GENERAL ENGINE INFORMATION

Specifications
– Fastener Tightening Specifications
Special Tools
Special Tools Table
Maintenance and Repair
– On-Vehicle Service
– Engine Assembly
– Crankcase Ventilation System
– Alternator
– Power Steering Pump and A/C Bracket
– Hydraulic Engine Mounting Insulator
– Poly V-Belt
– Tensioning Device
– Tensioning Device Shock Absorber
– Poly V-Belt Inspection
– Cylinder Head Cover
– Cylinder Head Front Cover
– Cylinder Head
– Timing Gear Case Cover
– Crankshaft Sealing Rear Cover
– Belt Pulley and Vibration Damper
– Crankshaft Front Radial Seal
– Crankshaft Rear Radial Seal
– Crankshaft
– Flywheel/Driven Plate
– Camshaft Adjuster
– Camshaft Sprocket Bolt
– Camshaft
– Camshaft Timing Position
– Valve Spring
– Valve Stem Seal
– Chain Tensioner
– Timing Chain
– Tensioning Rail
– Cylinder Head Guide Rail
– Crankcase Guide Rail
– Crankshaft Sprocket
– Piston
– Connecting Rod
– Piston Ring
– Oil Pan
– Engine Oil and Oil Filter Element
– Oil Pump
– Oil Pressure Relief Valve
– Oil Non-Return Valve
– Oil Dipstick Guide Tube
Unit Repair
– Core Plugs in Crankcase
– Cylinder Bore
– Crankcase Mating Surface
– Cylinder Head Mating Surface

SECTION 1B3 OM600 ENGINE MECHANICAL – TABLE OF CONTENTS
Specifications
– Fastener Tightening Specifications
Special Tools
– Special Tools Table
Maintenance and Repair
– On-Vehicle Service
– Engine Assembly
– Poly V-Belt
– Tensioning Device
– Poly V-Belt Alignment & Inspection
– Prechamber
– Milling of Prechamber Sealing Surface
– TDC (TDC Sensor Bracket) Setting
– Cylinder Head
– Timing Case Cover
– Crankshaft End Cover
– Vibration Damper and Hub
– Crankshaft Front Radial Seal
– Crankshaft Ball Bearing
– Crankshaft
– Flywheel
– Machining of Flywheel
– Flywheel Ring Gear
– Hydraulic Valve Clearance Compensation Element Check
– Valve Tappets
– Valve Spring Check
– Valve Springs (Cylinder Head Removed)
– Valve Springs (Cylinder Head Installed)
– Valve Stem Seals
– Check and Replacement of Valve Guides
– Valve Seat Rings
– Check and Machining of Valves
– Machining of Valve Seat
– Camshaft Timing Test
– Camshaft
– Chain Tensioner
– Timing Chain
– Tensioning Rail
– Cylinder Head Guide Rail
– Timing Case Cover Guide Rail
– Crankshaft Sprocket
– Piston
– Oil Filter
– Oil Pan
– Oil Spray Nozzle
– Oil Pump
Unit Repair
– Cylinder Head Pressure Leakage Test
– Facing Cylinder Head Mating Surface
– Replacement of Crankcase Core Plug
– Facing Crankcase Contacting Surface
– Oil Gallery Steel Ball
– Cylinder Bore Measurement

SECTION 1D1 M162 ENGINE COOLING
Specifications
– General Specifications
– Fastener Tightening Specifications
Special Tools
– Special Tools Table
Diagnosis
– System Leakage Test
Maintenance and Repair
– On-Vehicle Service
– Coolant Drain and Fill Up
– Coolant Connection Fitting
– Water Pump
– Thermostat
– Oil Cooler Pipe Line
– Cooling Fan and Viscous Clutch
– Cooling Fan Shroud
– Radiator

SECTION 1D3 OM600 ENGINE COOLING
Specifications
– General Specifications
– Fastener Tightening Specifications
Diagnosis
– Cooling Circulation
– Thermostat Operation
– Cooling System Leakage Test
Maintenance and Repair
– On-Vehicle Service
– Drain and Filling of Coolant
– Coolant Pump
– Coolant Pump Housing
– Cooling Fan Clutch
– Radiator
– Cooling Sub-System
– Thermostat

SECTION 1E1 M162 ENGINE ELECTRICAL
Specifications
– Alternator Specifications
– Starting Motor Specifications
– Battery Specifications
– Fastener Tightening Specifications
Special Tools
– Special Tools Table
Maintenance and Repair
– On-Vehicle Service
– Alternator
– Starting Motor
– Battery
– Spark Plug
– Ignition Cable
Unit Repair
– Battery

SECTION 1E3 OM600 ENGINE ELECTRICAL
Specifications
– General Specifications
Maintenance and Repair
– On-Vehicle Service
– Glow Plug
– Alternator
– Starter Motor

SECTION 1F1 M162 ENGINE CONTROLS
Specifications
– Fastener Tightening Specifications
Special Tools
– Special Tools Table
Schematic and Routing Diagrams
– E32 ECU (HFM)
– E32 ECU (MSE)
Diagnosis
– Self Diagnosis Socket Pin Numbers and Descriptions
– Self Diagnosis Failure Code
– Test Box Connection
– Fuel Injection System Test (MSE3.62)
– Ignition System Test
– Idling Control and Electronic Pedal System Test
– Air Conditioner Control System Test
– Fuel Pressure and Internal Leakage Test
– Fuel Pump Test
– Injector Test
Maintenance and Repair
– On-Vehicle Service
– ECU
– Fuel Pressure Regulator
– Fuel Distributor
– Injector
– Fuel Filter
– Fuel Pump
– Purge Switchover Valve
– Vacuum System
– Crankshaft Position Sensor
– Camshaft Position Sensor
– Hot Film Air Mass (HFM) Sensor
– Oxygen Sensor
– Knock Sensor
– Coolant Temperature Sensor
– Accelerator Pedal Module

SECTION 1F2 M161 ENGINE CONTROLS
Specifications
– Fastener Tightening Specifications
Special Tools
– Special Tools Table
Schematic and Routing Diagrams
– E23 ECU (MSE)
– E23 ECU (HFM)
Diagnosis
– Self Diagnosis Socket Pin Numbers and Descriptions
– Self Diagnosis Failure Code (for E23 ENG)
– Test Box Connection
– Fuel Injection System Test
– Ignition System Test
– Idling Control and Electronic Pedal System Test
– Air Conditioner Control System Test
– Fuel Pressure and Internal Leakage Test
– Fuel Pump Test
– Injector Test
Maintenance and Repair
– On-Vehicle Service
– ECU
– Fuel Pressure Regulator
– Fuel Distributor
– Injector
– Fuel Filter
– Fuel Pump
– Purge Switchover Valve
– Vacuum System
– Crankshaft Position Sensor
– Camshaft Position Sensor
– Hot Film Air Mass (HFM) Sensor
– Oxygen Sensor
– Knock Sensor
– Coolant Temperature Sensor
– Accelerator Pedal Module

SECTION 1F3 OM600 ENGINE CONTROLS
Specifications
– Fastener Tightening Specifications
Maintenance and Repair
– On-Vehicle Service
– Fuel System
– Fuel Injection Pump Coding
– Fuel Tank
– Vacuum Control System Test
– Vacuum Pump(Sectional View)
– Vacuum Pump Test
– Vacuum Pump
– Vacuum Unit Replacement
– Idle Speed Adjustment
– Fuel Pump Test
– Fuel Pump
– Injection Nozzle Test
– Injection Nozzles
– Injection Nozzle Repair
– Removal and Installation of Injection Timing Device
– Injection Timing Device
– Start of Delivery Test (Position Sensor, RIV Method)
– Fuel Injection Pump

SECTION 1G1 M162 ENGINE INTAKE & EXHAUST
Specifications
– Fastener Tightening Specifications
Maintenance and Repair
– On-Vehicle Service
– Air Cleaner
– Intake Air Duct
– Intake Manifold
– Resonance Flap
– Exhaust Manifold

SECTION 1G2 M161 ENGINE INTAKE & EXHAUST
Specifications
– Fastener Tightening Specifications
Maintenance and Repair
– On-Vehicle Service
– Air Cleaner
– Air Intake Shield
– Intake Air Duct
– Intake Manifold
– Exhaust Manifold

SECTION 1G3 OM600 ENGINE INTAKE & EXHAUST
Specifications
– Fastener Tightening Specifications
– Schematic and Routing Diagrams
– EGR Circuit
Maintenance and Repair
– On-Vehicle Service
– Air Cleaner and Inlet Duct & Hose
– Intake and Exhaust Manifold
– Turbocharger
– Charge Air System Diagram
– Intercooler
– Turbocharger Assembly

SSANGYONG REXTON (LHD) ELECTRICAL WIRING DIAGRAM

1. HOW TO USE ELECTRICAL WIRING DIAGRAM
– HOW TO READ ELECTRICAL WIRING DIAGRAM
– CIRCUIT IDENTIFICATION SYMBOL
– FUNCTION OF POWER SUPPLY LINE (NUMBER)
– WIRING HARNESS COLOR IDENTIFICATION
– HOW TO CHECK TERMINAL NUMBER OF CONNECTOR
– PART LOCATION ACCORDING TO PART NUMBER
– ELECTRIC SYMBOLS
– ABBREVIATIONS

2. POSITION OF CONNECTORS AND GROUNDS
– POSITION OF CONNECTOR, GROUND & SPLICE PACK
– CONNECTOR, GROUND & SPLICE PACK INFORMATION
– COMPONENTS LOCATION
– WIRING HARNESS, CONNECTOR & GROUND LOCATION
– CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION

3. WIRING DIAGRAM FOR POWER SUPPLIES

– POWER WIRING DIAGRAM (DSL)
1) 2002 MODEL
2) 2003 MODEL
– POWER WIRING DIAGRAM (GSL)
1) 2002 MODEL
2) 2003 MODEL
– POWER WIRING DIAGRAM (XDi, 2003 MODELS )
1) ENG ROOM & FUSE BOX
(1) SB1 ~ SB5
(2) SB6 ~ SB11
(3) Ef1 ~ Ef4
(4) Ef5 ~ Ef9
(5) Ef10 ~ Ef14
(6) Ef15 ~ Ef20
(7) Ef21 ~ Ef26
2) FUSE BOX
(1) F1 ~ F5
(2) F6 ~ F15
(3) F16 ~ F21
(4) F22 ~ F28
(5) F29 ~ F31

USAGE AND CAPACITY OF FUSES IN FUSE BLOCK
1. ENGINE ROOM FUSE & REALY BLOCK
2. I.P FUSE & RELAY BOX

ELECTRICAL WIRING DIAGRAMS
1. STARTING & CHARGING
1) ~ 2002 MODEL
(1) DIESEL (M/T, A/T)
(2) GASOLINE (M/T, A/T)
2) 2003 MODEL (W/ XDi) ~
(1) DIESEL (M/T, A/T)
(2) GASOLINE (M/T, A/T)
2. PREHEATING UNIT CIRCUIT
1) ~ 2002 MODEL
2) 2003 MODEL ~
3) XDi
3. EGR (EXHAUST GAS RECIRCULATION) CONTROL CIRCUIT (DSL)
1) ~ 2002 MODEL
(1) GENERAL
(2) EURO
2) HUBER EGR
4. ECU (ELECTRONIC CONTROL UNIT) (E23)
1) ~ 2002 MODEL
(1) OVPR, FUEL PUMP, CANISTER PURGE VALVE, O2 SENSOR, PEDAL MODULE CIRCUIT
(2) SPARK PLUG, SENSOR (CAM SHAFT POSITION, MAP, NTC, CRANK SHAFT POSITION, THROTTLE MOTOR, AIR TEMP, KNOCK), CAM SHIFT ACTUATOR CIRCUIT
(3) DIGITAL CLOCK, ENG TEMP SENSOR, IMMOBILIZER CIRCUIT
2) 2003 MODEL ~
(1) OVPR, FUEL PUMP, CANISTER PURGE VALVE, O2 SENSOR, PEDAL MODULE CIRCUIT
(2) SPARK PLUG, SENSOR (CAM SHAFT POSITION, MAP, NTC, CRANK SHAFT POSITION, THROTTLE MOTOR, AIR TEMP, KNOCK), CAM SHIFT ACTUATOR CIRCUIT
(3) DIGITAL CLOCK, ENG TEMP SENSOR, IMMOBILIZER CIRCUIT
5. ECU (ELECTRONIC CONTROL UNIT) (E28, E32)
1) ~ 2002 MODEL
(1) OVPR, FUEL PUMP, CANISTER PURGE VALVE, PEDAL MODULE CIRCUIT
(2) SPARK PLUG, SENSOR (CAM SHAFT POSITION, NTC, CRANK SHAFT POSITION, THROTTLE MOTOR & SENSOR, KNOCK), CAM SHIFT ACTUATOR, RESONANCE FLAP CIRCUIT
(3) DIGITAL CLOCK, ENG TEMP SENSOR, IMMOBILIZER CIRCUIT
(4) O2 SENSOR
2) 2003 MODEL ~
(1) OVPR, FUEL PUMP, CANISTER PURGE VALVE, PEDAL MODULE CIRCUIT
(2) SPARK PLUG, SENSOR (CAM SHAFT POSITION, NTC, CRANK SHAFT POSITION, THROTTLE MOTOR & SENSOR, KNOCK), CAM SHIFT ACTUATOR, RESONANCE FLAP CIRCUIT
(3) DIGITAL CLOCK, ENG TEMP SENSOR, IMMOBILIZER CIRCUIT
(4) O2 SENSOR
6. ECU(XDi)
1) ENG MAIN RLY, PEDAL MODULE, HFM SENSOR, VALVE (TURBO CHANGER BOOSTER, EGR VACUUM MODULE, INLETMETERING VALVE)
2) FUEL FILTER WARNING LAMP, IMMOBILIZER, SENSOR (FUEL PRESSURE, CAM SHAFT, BOOSTER PRESSURE, CRANK SHAFT, KNOCK, WATER PUMP, FUEL TEMP)
3) INJECTOR, CAN LINE
7. DIAGNOSIS CIRCUIT
1) ~ 2002 MODEL
2) 2003 MODEL ~
3) XDi
8. TCU (TRANSMISSION CONTROL UNIT) (4-SPEED)
1) ~ 2002 MODEL
(1) DSL
(2) GSL
2) 2003 MODEL ~
(1) DSL
(2) GSL
3) 2004 MODEL (DSL)
9. TCU (5-SPEED)
1) START MOTOR, A/T LEVER, CAN LINE
2) SOLENOID OIL TEMP SENSOR, SPEED SENSOR
10. TCCU (TRANSFERCASE CONTROL UNIT)
1) ~ 2002 MODEL
2) 2003 MODEL
3) 2004 MODEL ~
4) XDi
11. TOD(TORQUE ON DEMAND)
1) ~ 2002 MODEL
2) 2003 MODEL ~
3) XDi
12. BRAKE SYSTEM
1) ABS & ABS/ABD 5.3 II
2) ABS(TEVES)
3) ABS/ESP(TEVES)
(1) WHEEL SPEED SENSOR, STOP LAMP SW, DIAGNOSIS, WARNING LAMP
(2) BRAKE PRESSURE SENSOR, SWAS, SENSOR CLUSTER, ESP OFF SW
13. A/T SHIFT LOCK CIRCUIT
14. AIR BAG & SIDE AIR-BAG CIRCUIT
15. CLUSTER
1) ~ 2002 MODEL
(1) POWER SUPPLY, GROUND, LAMP (FUEL LOW WARNING, 4H, 4L) CIRCUIT
(2) WARNING LAMP, DEFOGGER CIRCUIT
2) 2003 MODEL ~
(1) POWER SUPPLY, GROUND, LAMP (FUEL LOW WARNING, 4H, 4L) CIRCUIT
(2) WARNING LAMP, DEFOGGER CIRCUIT
3) XDi
(1) GAUGE(SPEED, RPM, FUEL, TEMP), WARNING (FUEL, DR OPEN, FUEL FILTER ABS/ESP)
(2) WARNING(BAT CHANGE OIL, BRAKE, EGR CHECK, AIR BAG, SSPS, SEAT BELT), TURN SIGNAL DEFOGGER
16. MULTI METER CIRCUIT
17. RAIN SENSING WIPER CIRCUIT
1) ~ 2002 MODEL
2) XDi, 2003 MODEL ~
18. POWER SEAT CIRCUIT
19. FRT SEAT WARMER(W/O MEMORY)
20. POWER O/SIDE MIRROR, DEFOGGER SEAT WARMER CIRCUIT (W/ MEMORY)
21. POWER O/SIDE MIRROR, DEFOGGER CIRCUIT (W/O MEMORY)
1) ~ 2002 MODEL
2) XDi
22. CENTRAL DOOR LOCKING SYSTEM
23. SEAT BELT, TENSION REDUCER CIRCUIT (2002 MODEL ONLY)
24. PASSENGER POWER SEAT CIRCUIT
25. AUTO LIGHT CONTROL CIRCUIT
1) ~ 2002 MODEL
2) XDi

26. STICS
1) ~ 2002 MODEL
(1) POWER SUPPLY, GND, CHIME BELL, BUZZER, WARNING LAMP (PARKING BRAKE, SEAT BELT) CIRCUIT
(2) FRT WIPER, DR SWITCH, LAMP (ROOM, MAP) CIRCUIT
(3) DR LOCK, DEFOGGER, POWER WINDOW CIRCUIT
2) 2003 MODEL
(1) POWER SUPPLY, GND, CHIME BELL, BUZZER, WARNING LAMP (PARKING BRAKE, SEAT BELT) CIRCUIT
(2) FRT WIPER, DR SWITCH, LAMP (ROOM, MAP) CIRCUIT
(3) DR LOCK, DEFOGGER, POWER WINDOW CIRCUIT
3) XDi
(1) POWER SUPPLY, GND, CHIME BELL, BUZZER, WARNING LAMP (PARKING BRAKE, SEAT BELT) CIRCUIT
(2) FRT WIPER, DR SWITCH, LAMP (ROOM, MAP) CIRCUIT
(3) DR LOCK, DEFOGGER, POWER WINDOW CIRCUIT

27. POWER WINDOW CIRCUIT
28. REAR GLASS WIPER & WASHER CIRCUIT
1) REAR GLASS WIPER & WASHER (W/O FLIP UP GLASS)
2) REAR GLASS DPS WIPER & WASHER (W/ FLIP UP GLASS)
3) REAR GLASS DPS WIPER & WASHER (W/ FLIP UP GLASS) (XDi)

29. HORN CIRCUIT
30. CIGAR LIGHTER CIRCUIT
31. REKES CIRCUIT (~ 2003 MODEL)
32. SUN ROOF CIRCUIT
34. HEAD LAMP CIRCUIT
34. HEAD LAMP LEVELING DEVICE CIRCUIT
35. DRL (DAY TIME RUNNING LIGHT) UNIT (EU)
36. TAIL LAMP CIRCUIT
1) ~ 2002 MODEL
2) 2003 MODEL
3) XDi

37. TURN SIGNAL & HAZARD LAMP CIRCUIT
1) ~ 2002 MODEL
2) 2003 MODEL
3) XDi

38. FOG LAMP CIRCUIT
1) ~ 2002 MODEL
2) XDi
39. STOP & BACK UP LAMP CIRCUIT
40. INTERIOR LAMP CIRCUIT
41. AUTO DIMMING ROOM MIRROR CIRCUIT
42. AUDIO, DIGITAL CIOCK CIRCUIT
43. AUDIO(MULTI VISION)
1) HEAD UNIT, 2CH EXT AMP, REMOCON, NAVI UNIT, GPS
2) HEAD UNIT, TUNER UNIT, VCD CHANGER

44. AIR-CON (MANUAL, DSL)
1) ~ 2002 MODEL
(1) ACTUATOR (MODE, AIR MIX), BLOWER UNIT CIRCUIT
(2) INTAKE MOTOR, BLOWER MOTOR CIRCUIT
2) 2004 MODEL ~
(1) ACTUATOR (MODE, AIR MIX), BLOWER UNIT CIRCUIT
(2) INTAKE MOTOR, BLOWER MOTOR CIRCUIT
3) XDi
(1) ACTUATOR (MODE, AIR MIX), BLOWER UNIT CIRCUIT
(2) INTAKE MOTOR, BLOWER MOTOR CIRCUIT

45. FATC (FULL AUTO TEMPERATURE CONTROL) CIRCUIT
1) DIESEL
(1) AIR MIX ACTUCTOR, SENSOR (SUN, AMBIENT, INCAR, WATER TEMP) CIRCUIT
(2) ACTURATOR (MODE, INTAKE) CIRCUIT
2) GASOLINE & XDi
(1) AIR MIX ACTUCTOR, SENSOR (SUN, AMBIENT, INCAR, WATER TEMP) CIRCUIT
(2) ACTURATOR (MODE, INTAKE) CIRCUIT

46. IMMOBILIZER (DSL)
47. PARKING AID CIRCUIT
48. TRAILER CONNECTOR CIRCUIT
49. P.T.C HEATER(POSITIVE TEMPERATURE COEFFICIENT)
50. F.F.H (FUEL FIRED HEATER)
51. S.S.P.S.