Page 1 SECTION 0B GENERAL INFORMATION TABLE OF CONTENTS At Least Annually ..........0B-4 Maintenance And Repair ........0B-2 Maintenance And Lubrication ....... 0B-2 Standard Bolts Specifications ......0B-5 Normal Vehicle Use ..........0B-2 Basic Specification ..........0B-6 Explanation Of Scheduled Dimension ............0B-6 Maintenance Services ........
Page 2 Drain, flush and refill the system with new coolant. Refer to “Recommended Fluids And Lubricants” in this section. Air Cleaner Element Replacement Clean the air cleaner element every. • Gasoline Engine : 15,000 km (10,000 miles) • Diesel Engine : 10,000 km (6,000 miles) YAA0B010 SSANGYONG Y200...
Page 3: Owner Inspections And Services
Avoid overfilling the engine, since this Weather-Strip Lubrication may cause engine damage. 6. Push the indicator all the way back down into the Apply a thin film silicone grease using a clean cloth. engine after taking the reading. SSANGYONG Y200...
Page 4: Each Time The Oil Is Changed
When opening the hood, note the operation of the test the cooling system and the cap in order to help secondary latch. It should keep the hood from opening en-sure proper operation. all the way when the primary latch is released. The hood must close firmly. SSANGYONG Y200...
Page 5: Standard Bolts Specifications
(283 lb-in) (471 lb-in) (682 lb-in) M24 × 2.0 274.4 N•m 460.6 N•m 666.4 N•m 372.4 N•m 617.4 N•m 891.8 N•m (203 lb-in) (341 lb-in) (493 lb-in) (276 lb-in) (457 lb-in) (660 lb-in) *Diameter X pitch in millimeters YAA0B020 SSANGYONG Y200...
Page 6: Basic Specification
0B-6 GENERAL INFORMATION BASIC SPECIFICATION DIMENSION * ( ): Gasoline engine equipped vehicle YAA0B030 SSANGYONG Y200...
Page 7 ← Gear ratio 3.969 ← 2.341 ← 1.457 ← 1.000 ← 0.851 ← Rev. 3.705 ← Model Electronic Automatic ← Type Floor change type transmission ← Gear ratio 2.742 ← 1.508 ← 1.000 ← 0.708 ← Rev. 2.429 SSANGYONG Y200...
Page 8 Vane type conditioner Electrical Battery type/Capacity (V-AH) MF / 12 - 90 MF / 112 - 75 Starter capacity (V-kW) 12 - 2.2 12 - 1.8 Alternator capacity (V-A) 12 - 75 (12 - 90) 12 - 115 SSANGYONG Y200...
Page 9: Recommended Fluids And Lubricants
G23D 10.0~10.5 L G32D 11.0~11.5 L Clean every 10,000 km, Replace every 30,000 km Air Cleaner Diesel Gasoline Clean every 15,000 km, Replace every 60,000 km Fuel filter Diesel Replace every 45,000 km Replace every 60,000 km Gasoline SSANGYONG Y200...
Page 10: Vehicle Identification Number System
1 : 4-Door 2 : 3-Door 4. Line Models G: Rexton (LHD) H : Rexton (RHD) 3. Vehicle Type T : Passengr Cars, A : Truck 2. Maker Identification : P 1. Nation : K *. Symbol according to No. SSANGYONG Y200...
Page 11: Manufacturers Plate
GENERAL INFORMATION 0B-11 MANUFACTURER’S PLATE 1 Type Approval No. 2 Vehicle Identification No. YAA0B050 Manufacturer’s Plate Location Gasoline Engine YAA0B060 Diesel Engine YAA0B070 SSANGYONG Y200...
Page 12: Engine Number
1 : Left - Hand Drive 2 : Right - Hand Drive The engine number is stamped on the cylinder block in front of injection pump. 5 : REXTON 910 :Non-Intercooler Engine 920 :Intercooler Engine 661 : 2299cc 662 : 2874cc YAA0B090 SSANGYONG Y200...
Page 13 The engine number is stamped on the lower rear side of the alternator. 5 : REXTON 99 : 3.2L 97 : 2.3L ENGINE TYPE YAA0B120 Gasolind Engine (2.3L DOHC) YAA0B110 • The engine number is stamped on the upper rear left-hand side of the cylinder block. SSANGYONG Y200...
Page 14: Vehicle Lifting Procedures
Using Floor Jack Front Side Rear Side YAA0B130 YAA0B140 Using Jack YAA0B150 YAA0B160 Forward of Rear Tire Rearward of Front Tire SSANGYONG Y200...
Page 15: Table Of Contents
SECTION 1 ENGINE SECTION 1A ENGINE GENERAL INFORMATION TABLE OF CONTENTS Compression Pressure Test Description and Operation ....... 1A-2 (Diesel Engine) ..........1A-12 Cleanliness and Care ........1A-2 Cylinder Pressure Leakage Test On-Engine Service ..........1A-2 (Gasoline Engine) ........1A-14 Component Locator ..........
Page 16: 1A-2 Engine General Information
Battery cables should be disconnected before any extensive damage when the engine is started. SSANGYONG Y200...
Page 17: Component Locator
16 Engine Mounting Bracket 6 Intake Camshaft 17 Starter 7 Cylinder Head 18 Crankcase 8 Spark Plug Connector 19 Oil Pump Sprocket 9 Valve Tappet 20 Oil Strainer 10 Injector 21 Oil Pan 11 Exhaust Valve 22 Drain Plug SSANGYONG Y200...
Page 18 1A-4 ENGINE GENERAL INFORMATION Side View YAD1A020 23 Camshaft Adjuster 27 Oil Pump Drive Chain 24 Cooling Fan and Viscous Clutch 28 Oil Return Pipe 25 Piston 29 Timing Chain 26 Flywheel of Drive Plate 30 Oil Pump SSANGYONG Y200...
Page 19: M161 Engine
5 Spark Plug Connector 16 Connecting Rod 6 Fuel Distributor 17 Crankshaft 7 Injector 18 Engine Mounting Bracket 8 Exhaust Camshaft 19 Starter 9 Intake Camshaft 20 Crankcase 10 Valve Tappet 21 Oil Pump Sprocket 11 Intake Valve 22 Oil Pan SSANGYONG Y200...
Page 20 29 Oil Pump Drive Chain 24 Oil Filler Cap 30 Oil Strainer 25 Engine Hanger Bracket 31 Oil Pump 26 Cooling Fan and Viscous Clutch 32 Ring Gear and Flywheel of Drive Plate 27 Oil Filter 33 Piston 28 Timing Chain SSANGYONG Y200...
Page 21: Diesel Engine
ENGINE GENERAL INFORMATION 1A-7 DIESEL ENGINE Front View YAD1A050 SSANGYONG Y200...
Page 22 1A-8 ENGINE GENERAL INFORMATION Side View YAD1A060 SSANGYONG Y200...
Page 23: Diagnostic Information And Procedure
The shaft surface is scratched, nicked or damaged. conditoins. • A loose or worn bearing is causing excess seal 4. Visually inspect the suspected component. You wear. should be able to trace the leak path over the white powder surface to the source. SSANGYONG Y200...
Page 24: Compression Pressure Test (Gasoline Engine)
10 : 1 10.4 : 1 ← Normal Engine Temperature 80 °C (176 °F) Normal Compression Pressure Min. 10 bar, Max. 14 bar Min. 11 bar, Max. 15 bar Permissible Pressure Difference Between Individual ← Max. 1.5 bar Cylinders SSANGYONG Y200...
Page 25 Discharge the combustion residues in the 4. Connect the adaptor to compression pressure cylinders before testing the compression tester 001 589 76 21 00 and install it into the spark pressure. plug hole. • Apply the parking brake before cranking the engine. SSANGYONG Y200...
Page 26: Compression Pressure Test (Diesel Engine)
3 Compression Pressure Tester 2 Flexible Connector Standard Service Data Compression Ratio 22 : 1 Normal Engine Temperature 80 °C (176 °F) Normal Compression Pressure 28bar Minimum Compression Pressure Approx.18bar Permissible Pressure Difference Between Individual Max. 3bar Cylinders SSANGYONG Y200...
Page 27 YAD1A100 Notice: If out of standard, do cylinder pressure leakage test. 8. Remove the compression pressure tester 001 589 76 21 00. 9. Install the fuel injection nozzle. SSANGYONG Y200...
Page 28: Cylinder Pressure Leakage Test (Gasoline Engine)
(240 °) Cylinder Number 1, 6 2, 5 3, 4 OT (TDC) UT (BDC 180 °) TDC Mark (M161 Engine) Cylinder Number 1, 4 2, 3 Universal Tool Cylinder Pressure Leakage Tester Bosch, EFAW 210A Sun, CLT 228 SSANGYONG Y200...
Page 29 Notice: Firing Order • M162 Engine: 1 - 5 - 3 - 6 - 2 - 4 • M161 Engine: 1 - 3 - 4 - 2 M161 Engine 11. Compare the leakage pressure with the specifications. YAD1A130 SSANGYONG Y200...
Page 30: Cylinder Pressure Leakage Test (Diesel Engine)
At Valve and Cylinder Head Gasket Max. 10 % At Piston and Piston Ring Max. 20 % Universal Tools Cylinder Pressure Leakage Tester Bosch, EFAW 210 A or Sun CLT 228 Connection Piece Bosch order no. 1 687 010 016 SSANGYONG Y200...
Page 31 • firing order: 1-2-4-5-3 13. Remove the tester. 14. Close the coolant reservoir cap and oil filler cap. 15. Install the air cleaner element and cover. 16. Install the fuel injection nozzle. SSANGYONG Y200...
Page 32: General Diagnosis
Improper ignition timing. Adjust the ignition timing. Ignition System • • Faulty spark plug. Adjust or replace the spark plug. • • Electric leakage or poor Connect the cable correctly or connection of the high tension replace it. cable. SSANGYONG Y200...
Page 33 Others • • Malfunction of the air cleaner Clean or replace the air cleaner system. system. • • Leak of the intake manifold Replace the gasket. gasket. SSANGYONG Y200...
Page 34 • • Lack of engine oil. Refill oil. • • Poor oil pump performance. Replace or repair the pump. • • Other Leakage of oil Repair. • • Damaged cylinder head gas- Replace the gasket. ket. SSANGYONG Y200...
Page 35 Lack of engine oil. Refill oil. • • Blocking oil strainer. Clean the strainer. • • Lowered function of the oil Replace the pump. pump. • • Abrasion or damage of the oil Replace the valve. pump relief valve. SSANGYONG Y200...
Page 36 Grind or replace the crankshaft journal. journal. • • Loosened bearing cap bolt. Tighten to the specified torque. • • Excessive clearance of the Adjust or replace. crankshaft thrust bearing. • • Low oil pressure. Refer to “Page 1A-21” in this section. SSANGYONG Y200...
Page 37: Specifications
Forced by Gear Pump Lubrication Type Combined Full-Flow and Full Flow with ← Oil Filter Type Partial Flow Filter Paper Filter ← Unleaded Gasoline Diesel Fuel MSE : Engine Control Module 3.63D : 6 Cylinder Version 3.53D : 4 Cylinder Version SSANGYONG Y200...
Page 38: Performance Curve
1A-24 ENGINE GENERAL INFORMATION PERFORMANCE CURVE M162 Engine YAD1A160 SSANGYONG Y200...
Page 39 ENGINE GENERAL INFORMATION 1A-25 M161 Engine YAD1A170 SSANGYONG Y200...
Page 40 1A-26 ENGINE GENERAL INFORMATION Diesel Engine YAD1A180 SSANGYONG Y200...
Page 41: Special Tools And Equipment
SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE 001 589 76 21 00 001 589 73 21 00 Compression Pressure Hand Vacuum Pump Tester YAD1A190 YAD1A210 120 589 02 09 00 610 589 65 09 00 Spark Plug Wrench Socket YAD1A220 YAD1A200 SSANGYONG Y200...
Page 42 Specifications ..........1B1-116 Flywheel / Driven Plate ........1B1-57 Timing Device and Valve ........1B1-60 Fastener Tightening Specifications ....1B1-116 Camshaft Adjuster ........... 1B1-60 Special Tools and Equipment ......1B1-118 Camshaft Sprocket Bolt ........1B1-65 Special Tools Table ........1B1-118 SSANGYONG Y200...
Page 43: Repair Instructions
1B1-2 M162 ENGINE MECHANICAL REPAIR INSTRUCTIONS ON-VEHICLE SERVICE ENGINE ASSEMBLY YAD1B010 1 Engine Assembly Tools Required 000 589 10 99 01 Torque Wrench 000 589 40 37 00 Hose Clamp 112 589 00 72 00 Oil Extractor SSANGYONG Y200...
Page 44 (80 - 97 lb-in) KAA1C010 7. Remove the air cleaner cover. Remove the mounting bolts and air cleaner housing and element assembly. YAD1B030 8. Loosen the radiator drain cock and drain the coolant. Notice: Open the coolant reservoir cap. YAD1B040 SSANGYONG Y200...
Page 45 Replace the seal before installation of the drain plug. YAD1B050 10. Remove the cooling fan shroud. Refer to Section 1D, Engine Cooling. YAD1B060 11. Disconnect the each hose from radiator. YAD1B070 12. Remove the upper mounting bolts of radiator and then remove the radiator. YAD1B080 SSANGYONG Y200...
Page 46 YAD1B4M0 16. Remove the fuel feed and return line. Installation Notice 21 - 25 N•m Tightening Torque (15 - 18 lb-ft) Before removing the fuel lines, release the pressure in the fuel system. KAA1F070 SSANGYONG Y200...
Page 47 19. Disconnect the engine main harness ground. YAD1B120 20. Disconnect the engine ground wire. YAD1B130 21. Disconnect following sensors connector. • Coolant temperature sensor. • 2 knock sensors. • Camshaft and crankshaft sensors. YAA1F150 SSANGYONG Y200...
Page 48 YAD1B4N0 25. Remove the automatic transmission oil cooler line. Installation Notice 25 - 35 N•m Tightening Torque (18 - 26 lb-ft) YAD1B150 26. Separate the vacuum hose for brake booster. 27. Separate the other vacuum hoses. YAD1B160 SSANGYONG Y200...
Page 49 32. Install a chain to the bracket of engine, by using a hoist or crane. 33. Remove the engine mounting bracket nuts. Installation Notice Upper : 70 N•m (52 lb-ft) Tightening Torque Lower : 38 N•m (28 lb-ft) YAD1B200 SSANGYONG Y200...
Page 50 M162 ENGINE MECHANICAL 1B1-9 34. Carefully separate the engine assembly from the vehicle. 35. Installation should follow the removal procedure in the reverse order. YAD1B210 SSANGYONG Y200...
Page 51: Poly V-Belt And Tensioning Device
(29.9 - 36.5 lb-ft) 2. Remove the poly v-belt. Notice: Check the belt for damage and tensioning pulley bearing point for wear and replace them if necessary. 3. Install the belt by turning the nut of tensioning YAD1B250 pulley clockwise. SSANGYONG Y200...
Page 52 M162 ENGINE MECHANICAL 1B1-11 Poly V-Belt Arrangement YAD1B340 1 Belt Tensioning Pulley 5 Generator Pulley 6 Idler 2 Crankshaft Belt Pulley 7 Power Steering Pump Pulley 3 A/C Compressor Pulley 8 Cooling Fan and Water Pump Pulley 4 Cooling Fan Pulley SSANGYONG Y200...
Page 53: Poly V-Belt Inspection
1. Rubber lumps in the base of rib. 2. Dirt or grit ingrained. YAD1B380 3. Pointed rib. 4. Belt cord visible in the base of rib. YAD1B390 5. Cord torn out at the side. 6. Outer cords frayed. YAD1B400 SSANGYONG Y200...
Page 54 M162 ENGINE MECHANICAL 1B1-13 7. Rib detached from the base of belt. YAD1B410 8. Splits across the rib. 9. Sections of rib torn out. YAD1B420 10. Splits across several ribs. YAD1B430 11. Splits across the back of the belt. YAD1B440 SSANGYONG Y200...
Page 55: Tensioning Device
Preceding Work : Removal of poly v-belt YAD1B350 3 Water Pump Pulley 1 Belt (L = 2245) 2 Bolt Combi (M8 x 14, 3 pieces) + Washer 4 Nut 5 Belt Tensioning Pulley ......22.5-27.5 N•m (16.6-20.3 lb-ft) SSANGYONG Y200...
Page 56 4. Remove the mounting bolts(M8 x 30, 3 pieces) at the tensioning device, and remove the tensioning device. Installation Notice Tightening Torque 26 - 32 N•m (19 - 24 lb-ft) YAD1B360 5. Installation should follow the removal procedure in the reverse order. SSANGYONG Y200...
Page 57: Crankcase And Cylinder Head
20 Vent Line 8 Oil Pan 9 Air Admission Line A Fresh Air 10 Vent Line B Blowby Gas in Partial Load 11 Restriction Hole (Diameter = 2 mm) 12 Intake Manifold C Blowby Gas in Full Load SSANGYONG Y200...
Page 58 All the blowby gases flow into the intake air duct (13) after passing through the oil separator (15,16) of the cylinder head cover (14) when fully loaded. This dilluted air will be supplied to the combustion chamber through the intake manifold (12). SSANGYONG Y200...
Page 59: Generator
1. Remove the drive belt. 2. Remove the generator. 3. Unscrew the generator carrier bolts and remove the carrier. Installation Notice Tightening Torque 25 N•m (18 lb-ft) 4. Installation should follow the removal procedure in the reverse order. YAD1B240 SSANGYONG Y200...
Page 60: Power Steering Pump And A/C Bracket
4 Bolt (M8 x 105, 4 pieces) ......22.5-27.5 N•m (16.5-20.5 lb-ft) 12 Tensioning Pulley 5 Washer 13 Nut ..... 40.5-49.5 N•m (29.9-36.5 lb-ft) 6 A/C Compressor 7 Bolt (M8 x 40, 3 pieces, M8 x 95, 2 pieces) ......22.5-27.5 N•m (16.5-20.5 lb-ft) SSANGYONG Y200...
Page 61 Installation Notice 22.5 - 27.5 N•m Tightening Torque (16.6 - 20.3 lb-ft) YAD1B260 4. Remove the compressor after disconnecting the wiring connector and refrigerant pipe of A/C compressor. Notice: Discharge all the refrigerant before removing the pipes. YAD1B270 SSANGYONG Y200...
Page 62 YAD1B290 7. Clean the sealing surface. 8. Replace the gasket with new one. 9. Installation should follow the removal procedure in the reverse order. 10. Check the oil leakage by operating the engine after installation. SSANGYONG Y200...
Page 63: Engine Mount
1B1-22 M162 ENGINE MECHANICAL ENGINE MOUNT YAD1B300 SSANGYONG Y200...
Page 64 Tightening Torque 38 N•m (28 lb-ft) 3. Remove the hydraulic engine mounting insulator. Notice: If the insulator is spotted with oil, replace the hydraulic insulator asseambly. 4. Installation should follow the removal procedure in the reverse order. YAD1B320 SSANGYONG Y200...
Page 65: Cylinder Head Cover
........9-11 N•m (80-97 lb-in) 9 Camshaft Seal ........Replace 4 Spacer Sleeve Composition of The Cylinder Head Cover Bolts A. M6 x 50, 4 Pieces - Bolts + Washers B. M6 x 65, 8 Pieces - Bolts + Washers YAD1B460 SSANGYONG Y200...
Page 66 9 - 11 N•m Tightening Torque (80 - 97 lb-in) Replace the gasket with a new one if necessary. 5. Installation should follow the removal procedure in the reverse order. 6. Check for oil leaks by operating the engine. YAD1B500 SSANGYONG Y200...
Page 67 ......22.5-27.5 N•m (16.6-20.3 lb-ft) 8 Bolt (M6 x 16, 3 pieces) ......... 9-11 N•m (80-97 lb-in) Removal & Installation Procedure 1. Remove the camshaft actuator. Installation Notice 9 - 11 N•m Tightening Torque (80 - 97 lb-in) YAD1B520 SSANGYONG Y200...
Page 68 Notice: Install it while the chain tensioner is loose. YAD1B530 4. Remove the gasket (arrow). Notice: Replace the gasket with new one and apply the sealant. 5. Installation should follow the removal procedure in the reverse order. YAD1B540 SSANGYONG Y200...
Page 69: Cylinder Head
55 N•m (141 lb-ft) 5 Cylinder Head 6 Gasket ............ Replace 2nd step 90° 7 Dowel Sleeve 3rd step 90° 2 Washers (14 pieces) 3 Flange Bolts (3 pieces) ......1st step 18-22 N•m (13-16 lb-ft) 2nd step 90°±5° SSANGYONG Y200...
Page 70 Tightening Torque (13 - 16 lb-ft) 2nd step: 90° ± 5° Do not reuse the removed bolts. YAD1B600 5. Separate the chain from the camshaft sprockrt. Notice: Be careful not to drop the chain into the timing case. YAD1B610 SSANGYONG Y200...
Page 71 Replace the bolt if the measured length exceed the max. length. • Apply the oil to the thread surface of bolt. YAD1B640 9. Carefully remove the cylinder head and check the mating surface. 10. Installation should follow the removal procedure in the reverse order. SSANGYONG Y200...
Page 72: Oil Pan
........9-11 N•m (80-97 lb-in) ......22.5-27.5 N•m (16.6-20.3 lb-ft) 3 Drain Plug ..22.5-27.5 N•m (16.6-20.3 lb-ft) 4 Bolt (M6 x 20, 22 pieces) 7 Bolt (M10) ........ 40 N•m (30 lb-ft) 8 Oil Pan ........9-11 N•m (80-97 lb-in) SSANGYONG Y200...
Page 73 YAD1B5C0 6. Check for oil leaks while running the engine. M8 X 40, 4 pieces M6 X 85, 3 pieces M6 X 35, 3 pieces M6 X 22, 6 pieces Others M6 X 20, 28 pieces SSANGYONG Y200...
Page 74: Timing Gear Case Cover
3 Bolt (M8 x 65, 3 pieces) 8 Roll Pin ......22.5-27.5 N•m (16.6-20.3 lb-ft) 4 Bolt (M8 x 40, 1 piece) 9 Bolt (M6 x 22, 6 pieces) ......22.5-27.5 N•m (16.6-20.3 lb-ft) .........9-11 N•m (80-97 lb-in) SSANGYONG Y200...
Page 75 • Be careful not to stain the oil chamber of chain tensioner with the sealant. 5. Installation should follow the removal procedure in the reverse order. 6. Warm up the engine and check for oil leaks. SSANGYONG Y200...
Page 76: Crankshaft Sealing Rear Cover
Preceding Work : Removal of the automatic transmission drive plate YAD1B710 4 Sleeve 1 Bolt (M6 x 20, 6 pieces) .........9-11 N•m (80-97 lb-in) 5 Bolt (M6 x 85, 2 pieces) .........9-11 N•m (80-97 lb-in) 2 Radial Shaft Seal 6 Washer 3 Rear Cover SSANGYONG Y200...
Page 77 601 589 03 43 00. YAD1B760 7. Install the crankshaft sealing rear cover mounting bolts and remove the crankshaft rear seal installer 601 589 03 43 00. Installation Notice 9 - 11 N•m Tightening Torque (80 - 97 lb-in) YAD1B770 SSANGYONG Y200...
Page 78: Crankshaft Assembly
5 Woodruff Key ..2nd step 90°+10° 6 Bolt (M6 x 12, 4 pieces) 2 Vibration Damper Disk ........9-11 N•m (80-97 lb-in) 3 Bolt (M6 x 20, 6 pieces) 7 Cooling Fan Pulley ......7.7-9.5 N•m (68.1-84.1 lb-in) SSANGYONG Y200...
Page 79 5 Crankshaft Front Seal 11 Oil Pan Gasket 6 Timing Gear Case Cover 12 Oil Pan Mounting Bolt (M6 x 22) Service Data Standard Radial Runout 0.6 mm Permissble Deviation of The Vibration Damper Axial Runout 0.6 mm SSANGYONG Y200...
Page 80 2nd step: 90° + 10° YAD1B680 4. Remove the vibration damper assembly using the puller. 5. Installation should follow the removal procedure in the reverse order. Notice: If possible, don’t separate the vibration damper and the pulley. YAD1B250 SSANGYONG Y200...
Page 81: Crankshaft Front Radial Seal
Preceding Work : Removal of belt pulley and vibration damper YAD1B780 1 Center Bolt (M18 x 50) 3 Sleeve (Special Tool) ..1st step 180- 220 N•m (133-162 lb-ft) 4 Crankshaft Front Seal 2nd step 90°+10° 5 Key 2 Center Bolt Washer SSANGYONG Y200...
Page 82 (133 - 162 lb-ft) 2nd step: 90° + 10° 5. Remove the crankshaft front seal installer 601 589 03 14 00, and install the belt pulley and the vibration damper. 6. Check for leaks while operating the engine. SSANGYONG Y200...
Page 83: Crankshaft Rear Radial Seal
1B1-42 M162 ENGINE MECHANICAL CRANKSHAFT REAR RADIAL SEAL Preceding Work : Removal of flywheel or drive plate YAD1B840 1 Special Tool 3 Crankshaft Rear Seal 2 Special Tool SSANGYONG Y200...
Page 84 4. Install the radial seal on the inner parts assembler. 5. Press in the crankshaft rear seal installer 601 589 03 43 00 (1) until the radial seal is stopped. 6. Check for leaks while operating the engine. SSANGYONG Y200...
Page 85: Crankshaft
YAD1B860 1 Crankshaft Bearing Cap Bolt 2 Crankshaft Bearing Cap (M8 x 55, 14 pieces) 3 Crankshaft Lower Main Bearing ..1st step 50- 60 N•m (37-44 lb-ft) 4 Crankshaft Lower Thrust Bearing 2nd step 90°+5° 5 Crankshaft SSANGYONG Y200...
Page 86 Journal Main Bearing #1 - #7 Color Dot Marking The color dot marking are put on the 1 , 2 , 4 , 6 , 8 , 10 , 12 and it indicates the diameter of crankshaft journal by color as below. SSANGYONG Y200...
Page 87 47.94 - 47.96 27.958 - 28.042 1st repair size 57.700 - 57.715 47.75 2.25 or 2nd repair size 57.450 - 57.465 47.50 2.35 or 3rd repair size 57.200 - 57.215 47.25 2.40 4th repair size 56.950 - 56.965 47.00 SSANGYONG Y200...
Page 88 When perfectly installed, the projected part (arrow) locates in the left side (intake manifold side). • Assemble so that the projected part of the cap and crankcase face the same direction. YAD1B920 SSANGYONG Y200...
Page 89 Record the mean value when measured at 3 points (A, B, C). • Measure the inner diameter of bearing and the diameter of journal and if it is out of the standard data, replace the bearing shell. YAD1B960 SSANGYONG Y200...
Page 90 Static condition :0.011 - 0.039 ( NO. 3, 4, 6) Radial Dynamic condition: 0.031 - 0.051 (Consider the expansion 0.015 - 0.022) Axial 0.010 - 0.254 (Connecting Rod Bearing Gap) Item Measuring Position Gap (mm) Connecting Rod Bearing Radial 0.030 - 0.050 SSANGYONG Y200...
Page 91: Connecting Rod
Permissible Deviation of Axial Paralleism of Connecting Rod Bearing Bore to Connecting 0.07 mm Rod Bushing Core Permissible Deviation of Connecting Rod Bearing Bore from Concentricity 0.01 mm Permissible Difference of Each Connecting Rod in Weight 0.4 g SSANGYONG Y200...
Page 92 • Make sure it doesn’t exceed over 4g with other connecting rods when replacing the connecting rods. • Check if the connecting rod and the bearing cap are accurately seated on the groove when replacing the bearing. YAD1B0A0 SSANGYONG Y200...
Page 93: Piston
YAD1B2P0 1 Connecting Rod Bearing Cap 4 Piston 2 Connecting Rod 5 Snap Ring 3 Connecting Rod Bearing Cap Bolt 6 Piston Pin (M9 x 52, 12 pieces) ..1st step 40+5 N•m (30+3.7 lb-ft) 2nd step 90°+10° SSANGYONG Y200...
Page 94 3. Remove the snap ring (5) and pull out the piston pin (6). Notice: Remove the snap ring using a clean cloth as shown in the right picture so that the piston, piston ring, and the snap ring don’t get damaged. YAD1B2Q0 SSANGYONG Y200...
Page 95 1st step: 40 + 5 N•m Tightening Torque (30 + 3.7 lb-ft) 2nd step: 90° + 10° Apply the engine oil to the bearing cap upper and lower bearing shells. 7. Check if the crankshaft rotates without any trouble by rotating it. SSANGYONG Y200...
Page 96: Piston Ring
M162 ENGINE MECHANICAL 1B1-55 PISTON RING Preceding Work : Removal of piston YAD1B2T0 1 Piston Compression Ring 4 Coil Spring and Control Ring 2 Piston Compression Ring 5 Hook Spring 3 Piston Oil Ring SSANGYONG Y200...
Page 97 3. For installation, position the piston ring to be the ‘TOP’ mark on the piston ring upward and arrange the piston ring ends to be 120° apart. 4. Adjust the hook spring joint in the oil ring 180° away from the ring end. YAD1B2V0 SSANGYONG Y200...
Page 98: Flywheel / Driven Plate
Stretch Side Diameter When New 8.5 - 0.2 mm Min. Diameter 8.0 mm Bolt Length 21.8 - 22.2 mm When New Tightening Torque 1st step 45 + 5 N•m (33 + 3.7 lb-ft), 2nd step 90° + 10° SSANGYONG Y200...
Page 99 Tommy-bar to be 90° and tighten YAD1B820 as specified. 2. Remove the flywheel for manual transmission vehicles, or the driven plate (3), and plate (2) for automatic transmission vehicle. 3. Installation should follow the removal procedure in the reverse order. SSANGYONG Y200...
Page 100 2 Cover 9 Bolt 3 Crankshaft Front Seal 10 Front Drive Plate 4 Flywheel Mounting Bolt 11 Rear Drive Plate 5 Crankshaft 12 Rivet 6 Dowel Pin 13 Segment 7 Washer (thickness = 3.5 mm) 14 Ring Gear SSANGYONG Y200...
Page 101: Timing Device And Valve
7 Front Cover 17 Compression Spring 8 Seal 18 Control Piston 9 Camshaft Position Sensor 19 Circlip 10 Bolt (M6 x 16, 2 pieces) 20 Oil Gallery .........9-11 N•m (80-97 lb-in) 21 Pin 11 - 22 Intake Camshaft SSANGYONG Y200...
Page 102 22 Intake Camshaft Leak oil flows off over control and positioning piston 23 Oil Outlet Drilling surface, through the control piston drilling and 2 drillings (23) in the camshaft flange. A Working Chamber (Oil Pressure) Y49 Electromagnetic Actuator (Not Functioning) SSANGYONG Y200...
Page 103 (18) through the control piston (18) and 2 drillings in the camshaft flange (23). Leak oil flows off over the control and adjusting piston surfaces through the control piston drilling and 2 drillings in the camshaft flange (23). SSANGYONG Y200...
Page 104 5. Unscrew the nut (6) and remove the ring and seal cover (11). Installation Notice 60 - 70 N•m Tightening Torque (44 - 52 lb-ft) YAD1B0E0 3 Bolt 13 Camshaft Sprocket 4 Amarture 18 Control Piston 6 Nut (M20 x 1.5) 22 Intake Camshaft 12 Seal Cover SSANGYONG Y200...
Page 105 2nd step: 90° ± 5° The sprocket bolt is designed to be used only once, so always replace with new one. 8. Installation should follow the removal procedure YAD1B0F0 in the reverse order. 9. Adjust the camshaft timing. SSANGYONG Y200...
Page 106: Camshaft Sprocket Bolt
2nd step: 90° ± 5° The sprocket bolts are designed to be used only once, so always replace with new one. YAD1B0H0 E M7 x 13 Collar Bolt Torx-T30 e 6.8 mm 13a Camshaft Sprocket 22a Exhaust Camshaft SSANGYONG Y200...
Page 107: Camshaft
Removal of cylinder head front cover Removal of coolant connection fitting YAD1B0J0 1 Chain Tensioner Assembly 4 Cylinder Head Front Cover ........72-88 N•m (53-65 lb-ft) 5 Intake Camshaft Sprocket 2 Exhaust Camshaft Sprocket 6 Chain 3 Upper Guide Rail 7 Wrench SSANGYONG Y200...
Page 108 (2, 5) and the timing chain (6). YAD1B0L0 6. Unscrew the exhaust camshaft sprocket bolt and remove the sprocket. 7. Separate the chain from the intake camshaft sprocket and put the chain not to be dropped into timing case. YAD1B600 SSANGYONG Y200...
Page 109 (3 o’clock direction at the intake, 9 o’clock direction at the exhaust). Notice: Turn the crankshaft and adjust it to OT so that No. 1 cylinder’s piston would be at TDC. YAD1B0P0 SSANGYONG Y200...
Page 110 7. Install the chain tensioner screw plug (1) and chain tensioner assembly (2) and tighten it as specified. Installation Notice (1) : 40 N•m (30 lb-ft) Tightening Torque (2) : 72 - 88 N•m (53 - 65 lb-ft) YAD1B0S0 SSANGYONG Y200...
Page 111 - Alignments between timing chain and sprocket marks. Notice: • Turn the crankshaft in the direction of engine rotation. • Read just if not aligned. YAD1B670 9. Install the upper guide rail and cylinder head front cover. 10. Install the generator. YAD1B530 SSANGYONG Y200...
Page 112: Camshaft Timing Position
Preceding Work : Removal of cylinder head cover Removal of cylinder head front cover YAD1B0T0 1 Chain Tensioner Assembly 4 Cylinder Head Front Cover 2 Exhaust Camshaft Sprocket 5 Wrench 3 Upper Guide Rail 6 Holding Pin DW 110-120 SSANGYONG Y200...
Page 113 8. Turn the camshaft adjuster of the intake camshaft to the left as much as possible (cam adjuster ‘retarded’ position). 9. Install the chain to the intake camshaft sprocket. Notice: Timing chain must be placed on the guide rail in gear case cover. SSANGYONG Y200...
Page 114 The sprocket bolt is designed to be used only once, so replace with new one. 11. Install the chain tensioner. Installation Notice Screw Plug 40 N•m (30 lb-ft) Tightening Tensioner 72 - 88 N•m Torque Assembly (53 - 65 lb-ft) 12. Check the camshaft timing. SSANGYONG Y200...
Page 115: Valve Spring
7 Thrust Piece 111 589 25 63 00 3 Valve Spring ..Check, Replace if necessary 8 Lever Pusher 111 589 18 61 00 4 Valve Stem Seal 9 Supporting Bar 111 589 01 59 00 5 Lower Retainer SSANGYONG Y200...
Page 116 YAD1B1C0 tangling, and for smooth rotation. 3. Remove the valve tappet (1) using the valve tappet remover DW 110-100. 4. Install the connecting hose DW 110-090 to the spark plug hole. YAD1B1D0 SSANGYONG Y200...
Page 117 Notice: Check the valve stem seal for damage and replace if necessary. 13. Remove the lower retainer (5). Notice: Check the retainer for damages and replace with a new one if necessary. 14. Installation should follow the removal procedure in the reverse order. YAD1B1F0 SSANGYONG Y200...
Page 118 Test (Upper and Lower Valve Tappet and Valve Cotter) • Upper Valve Spring Retainer Size (mm) 12.3 YAD1B1G0 • Lower Valve Spring Retainer Thickness (mm) 0.8 - 1.0 YAD1B1H0 • Valve Cotter Size (mm) 9.2 - 9.8 YAD1B1J0 SSANGYONG Y200...
Page 119: Valve Stem Seal
Notice: Check the valve stem seal for damage and replace if necessary. 2. Coat the valve stem seal with oil and assemble it with the protective sleeve. 3. Insert the valve stem seal by pressing it with the drift 119 589 00 43 00. YAD1B1M0 SSANGYONG Y200...
Page 120: Chain Tensioner
M162 ENGINE MECHANICAL 1B1-79 CHAIN TENSIONER YAD1B1N0 1 Screw Plug ....... 40 N•m (30 lb-ft) 6 Thrust Pin 2 Seal 7 Chain Tensioner Housing 3 Filler Pin ........72-88 N•m (53-65 lb-ft) 4 Compression Spring 8 Seal 5 Snap Ring SSANGYONG Y200...
Page 121 Remove the screw plug only when the seal and compression spring are damaged. YAD1B1Q0 5. Carefully remove the filler pin (3), compression spring (4), snap ring (5), and the thrust pin (6). 6. Remove the chain tensioner housing (7) and the seal (8). YAD1B1R0 SSANGYONG Y200...
Page 122 (3) into chain tensioner housing. YAD1B1S0 4. Lightly apply the grease to the seal (2) and install the screw plug (1). Installation Notice Tightening Torque 40 N•m (30 lb-ft) 5. Check for leaks by operating the engine. YAD1B1T0 SSANGYONG Y200...
Page 123 19 Cylinder Head Gasket 8 Snap Ring 20 Timing Chain 9 Thrust Pin 21 Tensioning Rail Base (Sliding Surface) 10 Ball (Nonreturn Valve) A Oil Supply Hole 11 Compression Spring B Chain Tensioner Oil Storage Hole 12 Thrust Piece SSANGYONG Y200...
Page 124: Timing Chain
M162 ENGINE MECHANICAL 1B1-83 TIMING CHAIN Preceding Work : Removal of cylinder head cover Removal of spark plug YAD1B1V0 1 Pin 5 Link 2 New Timing Chain 6 Center Plate 3 Timing Chain (Used) 7 Outer Plate 4 Wedge SSANGYONG Y200...
Page 125 4. Mount the wedges to both sides of the camshaft sprocket as shown in the figure. YAD1B1X0 5. Cover the chain housing with a clean cloth, and grind off the timing chain pin from the intake camshaft sprocket with the grinder. YAD1B1Y0 SSANGYONG Y200...
Page 126 10. Connect both separators of the new timing chain YAD1B2A0 with the link (5) and the center plate (6). 11. Install the jaw (a) and the thrust piece (b) to the assembly tool as shown in the figures. YAD1B2B0 YAD1B2C0 SSANGYONG Y200...
Page 127 15. Replace the thrust piece (b) as shown in the figure. YAD1B2F0 16. Install the chain assembly 000 589 58 43 00 to the link pin and tighten the spindle (c). Tightening Torque 30 N•m (22 lb-ft) YAD1B2E0 SSANGYONG Y200...
Page 128 Check the condition and it again if necessary. 18. Install the chain tensioner. Installation Notice Screw Plug 40 N•m (30 lb-ft) Tightening Tensioner 72 - 88 N•m Torque Assembly (53 - 65 lb-ft) 19. Check the camshaft timing position. YAD1B2G0 SSANGYONG Y200...
Page 129: Tensioning Rail
Replace the plastic guide (2) if it is damaged. • For installation, exactly align the plastic guide (2) with the tensioning rail (1). 4. Installation should follow the removal procedure in the reverse order. 5. Check the camshaft timing position. SSANGYONG Y200...
Page 130: Cylinder Head Guide Rail
5. Check for damages at the upper sliding rail and replace it if necessary. Install the upper guide rail pin. 6. Install the chain tensioner. Installation Notice Screw Plug 40 N•m (30 lb-ft) Tightening Tensioner 72 - 88 N•m Torque Assembly (53 - 65 lb-ft) SSANGYONG Y200...
Page 131: Crankcase Guide Rail
Replace the plastic guide (2) if damaged. • Connect the plastic guide (2) and the guide rail (1) by aligning them accurately when installing. 4. Installation should follow the removal procedure in the reverse order. 5. Check the camshaft timing position. SSANGYONG Y200...
Page 132: Crankshaft Sprocket
6 Bolt (M8 x 20, 1 piece) / Washer 2 Oil Pump Chain Bushing ........29-35 N•m (21-26 lb-ft) 3 Oil Pump Chain Spring 7 Oil Pump Sprocket 4 Crankshaft Sprocket 8 Oil Pump 5 Key 9 Oil Pump Roller Chain 10 Timing Chain SSANGYONG Y200...
Page 133 615 589 01 33 00. Notice: • Make sure not to lose the crankshaft pulley key (5) when removing. • Install the crankshaft sprocket (4) after warming it up. 6. Installation should follow the removal procedure in the reverse order. YAA1C850 SSANGYONG Y200...
Page 134: Lubrication System
• Quality API SH or above grade • ACEA : A2 or A3 • Approved oil by MB Sheet 229.1 • Viscosity Approved oil by MB Sheet 224.1 • Replacemant Initial at 1000-1500 km, Replace every 15000 km SSANGYONG Y200...
Page 135: Oil Circulation
16 Ball ( φ 15mm) c Oil Return Line (Oil Returns to the Oil Pan when 17 Oil Restriction Inner ( φ 4mm) Replacing the Filter Element) 18 Oil Supply (To Exhaust Camshaft) 19 Oil Supply (To Intake Camshaft) SSANGYONG Y200...
Page 136: Engine Oil And Oil Filter Element
7. Insert new oil filter element into the oil filter housing. 8. Temporarily tighten the oil filter cover. Install the oil filter remover 103 589 02 09 00, and then completely tighten it. Installation Notice Tightening Torque 25 N•m (18 lb-ft) SSANGYONG Y200...
Page 137 9. Fill up engine oil through the engine oil filler opening (3). 10. Check for oil leaks at normal engine temperature after starting the engine. 11. Stop the engine and wait 5 minutes. Check the oil level and fill up as specified if necessary. YAD1B3B0 SSANGYONG Y200...
Page 138: Oil Filter
OIL FILTER Preceding Work : Removal of starter motor Removal of upper intake manifold YAD1B3C0 1 Coolant Line 5 Bolt....22.5-27.5 N•m (16.6-20.3 lb-ft) 2 O-ring ............. Replace 6 Oil Filter 3 Clip 7 Gasket ........... Replace 4 Hose SSANGYONG Y200...
Page 139 Tightening Torque (16.6 - 20.3 lb-ft) Replace the oil filter gasket. 4. Installation should follow the removal procedure in the reverse order. 5. Check engine oil level. 6. Run the engine at idle and check the engine for leaks. SSANGYONG Y200...
Page 140: Oil Pump
3. Remove the oil pump and oil strainer assembly. 4. Replace the strainer in oil pump if necessary. 5. Installation should follow the removal procedure in the reverse order. SSANGYONG Y200...
Page 141: Oil Pressure Relief Valve
Tightening Torque 50 N•m (37 lb-ft) 2. Remove the spring (2), guide pin (3) and the piston (4). 3. Installation should follow the removal procedure in the reverse order. Notice: Don’t use the seal for the screw plug. SSANGYONG Y200...
Page 142: Oil Non-Return Valve
As a result, the chain tensioner can be activated with oil in itself. Replacement Procedure 1. Remove the non-return valve using a pliers. 2. Insert new non-return valve with hand. YAD1B3J0 SSANGYONG Y200...
Page 143: Oil Dipstick Guide Tube
9 - 11 N•m Tightening Torque (80 - 97 lb-in) 3. Install new O-ring to the dipstick guide tube. 4. Installation should follow the removal procedure in the reverse order. 5. Check for leaks by starting the engine. YAD1B3L0 SSANGYONG Y200...
Page 144: Unit Repair
Cleaning Procedure 1. Remove the plug (1) with a screwdriver. 2. Using a round bar (3) and hammer, remove the steel ball (2). 3. Using the compressed air, blow into the oil galleries and clean it off. YAD1B4L0 SSANGYONG Y200...
Page 145 (M16 x 1.5) after applying sealing bond on it. 4. Apply Loctite 270 on new plug and tighten to the hole until the drift 102 589 12 15 00 is stopped after inserting new plug into the drift. SSANGYONG Y200...
Page 146: Oil Gallery In Cylinder Head
1 Screw Plug ....... 15 N•m (11 lb-ft) 2 Seal Cleaning Procedure 1. Remove the screw plug (1) and the seal (2). Installation Notice Tightening Torque 15 N•m (11 lb-ft) Replace the seal with new one. 2. Clean the oil gallery using the compressed air. SSANGYONG Y200...
Page 147 5. Tap in the steel ball (3) from the side to the oil gallery using the punch (13). 6. Pull out the steel ball (3) using the round bar (12). 7. Enlarge the oil gallery to be diameter 9mm, depth 8 mm. YAD1B3U0 SSANGYONG Y200...
Page 148 9. All the oil gallery should be cleaned with the compressed air. 10. Apply the Loctite 270 to new plug and press in using a suitable drift (arrow). YAD1B3V0 11. Tighten the screw plug with the seal (arrow). YAD1B3W0 SSANGYONG Y200...
Page 149: Core Plugs In Crankcase
1B1-108 M162 ENGINE MECHANICAL CORE PLUGS IN CRANKCASE Preceding Work : Draining of the coolant YAD1B3X0 1 Core Plug ..........Replace SSANGYONG Y200...
Page 150 5. Press in new plug using a drift 102 589 00 15 00. Notice: Wait for about 45 minutes before filling the coolant so that the Loctite hardens. 6. Warm up the engine and check the coolant for leaks. YAD1B4C0 SSANGYONG Y200...
Page 151: Cylinder Bore
2nd Repair Size φ 90.406 - φ 90.412 (Standard Size + 0.5) φ 90.412 - φ 90.418 The group code letters are carved on the surface of the piston crown and in the mating surface of the crankcase. SSANGYONG Y200...
Page 152 (1, 2, 3). YAD1B4E0 1,2,3. Measuring Points A. Axial Direction B. Transverse Direction a. Location of the No.1 Piston Ring at TDC b. Location of the Piston BDC c. Location of the Oil Ring at BDC Chamfer Angle YAD1B4F0 SSANGYONG Y200...
Page 153: Crankcase Mating Surface
Crankcase Lower Mating Surface 0.04 mm Permissible Deviation of Parallelism of The Axial Direction 0.1 mm Upper to Lower Mating Surface Transverse Direction 0.05 mm Peak-to-valley Height Crankcase Upper Mating Surface 0.005 - 0.020 mm Crankcase Lower Mating Surface 0.025 mm SSANGYONG Y200...
Page 154 M162 ENGINE MECHANICAL 1B1-113 Chamfering Procedure 1. Chamfer angle : 60° YAD1B4F0 2. Polish the lower chamfered area evenly with a grinder after finishing the chamfering with a suitable tool (e.g., hand milling cutter). YAD1B4H0 SSANGYONG Y200...
Page 155: Cylinder Head Mating Surface
(Between Camshaft Bearing Exhaust 22.21 - 22.75 mm and Valve Stem) Repair Size Intake 23.96 - 24.51 mm 21.96 - 22.51 mm Exhaust Notice: Do not exceed 0.4mm for the milling of the mating surface of crankcase and cylinder head. SSANGYONG Y200...
Page 156 6. Measure the dimension (T) between the camshaft bearing and the valve system (refer to Service data standard). 7. Mill the cylinder head valve seat (refer to Service data standard). Universal Tool Sceledum, Type RTY Surface Grinding Machine Roaro Schio/Italy SSANGYONG Y200...
Page 157: Specifications
22.5 - 27.5 16.6 - 20.3 Oil Filter Bolt 22.5 - 27.5 16.6 - 20.3 Oil Filter Cover Oil Gallery Screw Plug in Cylinder Head Oil Pan Bolt 22.5 - 27.5 16.6 - 20.3 9 - 11 80 -97 SSANGYONG Y200...
Page 158 Under Cover 28 - 47 21 - 35 Upper Engine Mounting Nut Vibration Damper Center Bolt 180 - 220 133 - 162 90° + 10° 90° + 10° Water Pump Pulley Bolt 22.5 - 27.5 16.6 - 20.3 SSANGYONG Y200...
Page 159 111 589 18 61 00 Drift Lever Pusher YAD1B3Y0 YAD1B0X0 102 589 12 15 00 111 589 20 33 00 Drift Sliding Hammer YAD1B3P0 YAD1B580 103 589 02 09 00 111 589 25 63 00 Oil Filter Remover Thrust Piece YAD1B2Y0 YAD1B0Y0 SSANGYONG Y200...
Page 160 YAD1B1L0 YAD1B4K0 601 589 03 14 00 615 589 01 33 00 Crankshaft Front Seal Crankshaft Sprocket Installer Puller YAD1B790 YAD1B2M0 602 589 00 40 00 617 589 00 10 00 Engine Lock Allen Wrench Socket YAD1B720 YAD1B560 SSANGYONG Y200...
Page 161 1B1-120 M162 ENGINE MECHANICAL SPECIAL TOOLS TABLE (Cont’d) DW110-120 DW110-090 Holding Pin Connecting Hose YAD1B0Z0 YAD1B0K0 DW110-100 Valve Tappet Remover YAD1B1A0 SSANGYONG Y200...
Page 162 SECTION 1B2 M161 ENGINE MECHANICAL CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless other-wise noted.
Page 163: Maintenance And Repair
1B2-2 M161 ENGINE MECHANICAL MAINTENANCE AND REPAIR ON-VEHICLE SERVICE ENGINE ASSEMBLY YAD1B4S0 SSANGYONG Y200...
Page 164 YAD1B4T0 5. Remove the air cleaner cover. Remove the mounting bolts and air cleaner housing and element assembly. YAD1B4U0 6. Loosen the radiator drain cock and drain the coolant. Notice: Open the coolant reservoir cap. YAD1B040 SSANGYONG Y200...
Page 165 YAD1B4V0 8. Remove the cooling fan shroud. Refer to Section 1D2, Engine Cooling. YAD1B4W0 9. Disconnect the each hose from radiator. YAD1B4X0 10. Remove the upper mounting bolts of radiator and then remove the radiator. YAD1B080 SSANGYONG Y200...
Page 166 13. Remove the fuel feed and return line. Notice: Before removing the fuel lines, release the pressure in the fuel system. Installation Notice 21 - 25 N•m Tightening Torque (15 - 18 lb-ft) YAD1B4Z0 14. Disconnect the terminals from the generator. YAD1B110 SSANGYONG Y200...
Page 167 • Knock sensor. • Camshaft and crankshaft sensors. YAD1B5A0 19. After removing the ignition coil cover, disconnect the ignition coil connector. 20. Remove the harness cover and disconnect the 4 injection valve connectors. Disconnect the main harness. YAD1B5B0 SSANGYONG Y200...
Page 168 25. Separate the other vacuum hoses. YAD1B160 26. By rotating the crankshaft from the front of engine, remove the 6 torque converter mounting bolts from the engine ring gear plate. Installation Notice Tightening Torque 42 N•m (31 lb-ft) YAD1B5D0 SSANGYONG Y200...
Page 169 30. Remove the engine mount nuts. Installation Notice Tightening Torque 70 N•m (52 lb-ft) YAD1B5G0 31. Carefully separate the engine assembly from the vehicle. 32. Installation should follow the removal procedure in the reverse order. YAD1B5H0 SSANGYONG Y200...
Page 170: Crankcase Ventilation System
5 Vent Line (Full-Load or Over Mid-Load) 16 Crankcase 6 Throttle Valve 17 Chain Housing 7 Restrictor, Diameter 1.1mm (Mid-Load at Idling) A Fresh Air 8 Intake Manifold B Blow-By Gas 9 Vent Line (Mid-Load at Idling) D Vent Connection 10 Air Conditioner Bracket SSANGYONG Y200...
Page 171 (12) through the HFM sensor (1), intake air duct (4), vent line (5), oil separation chamber (3), chain housing (17), and the timing gear case cover (15). The additional supply of the fresh air is needed to prevent from forming the residues of the engine oil. SSANGYONG Y200...
Page 172 5 Vent Line (Full-Load or Over Mid-Load) 16 Crankcase 6 Throttle Valve 17 Chain Housing 7 Restrictor, Diameter 1.1mm A Fresh Air (Mid-Load at Idling) C Blow-By Gas 8 Intake Manifold D Vent Connection 9 Vent Line (Mid-Load at Idling) 10 Air Conditioner Bracket SSANGYONG Y200...
Page 173 Consequently, most of the low-by gases are supplied to the combustion chamber through the timing gear case cover (15), chain housing (17), oil separation chamber (3), vent line (5), throttle valve (6), and intake manifold (8). SSANGYONG Y200...
Page 174: Generator
(1) ; apply 25 Nm of torque when mounting the bolts (2), and (3) ; and then tighten the bolt (1) with 25 Nm of torque. 5. Installation should follow the removal procedure in the reverse order. SSANGYONG Y200...
Page 175: Engine Mount
1B2-14 M161 ENGINE MECHANICAL ENGINE MOUNT YAD1B5M0 SSANGYONG Y200...
Page 176 Tightening Torque 70 N•m (52 lb-ft) YAD1B5G0 2. Unscrew the lower nuts. Installation Notice Tightening Torque 38 N•m (28 lb-ft) 3. Remove the hydraulic engine mounting insulator. 4. Installation should follow the removal procedure in the reverse order. YAD1B5N0 SSANGYONG Y200...
Page 177: Poly V-Belt
12 sided wrench or spanner counterclock-wise. 2. Remove the poly v-belt. Notice: Check the belt for damage and tensioning pulley bearing point for wear and replace them if necessary. 3. Install the belt after prying the tensioning pulley. YAD1A130 SSANGYONG Y200...
Page 178 M161 ENGINE MECHANICAL 1B2-17 Poly V - Belt Arrangement YAD1B5Q0 1 Belt Tensioning Pulley 5 Generator Pulley 2 Crankshaft Belt Pulley 7 Power Steering Pump Pulley 3 A/C Compressor Pulley 8 Water Pump Pulley SSANGYONG Y200...
Page 179: Tensioning Device
2. Insert the pin (111 589 01 15 00) into the hole in tensioning arm. 3. Unscrew the bolts (1, 2) and remove the tensioning device. Installation Notice 22.5 - 27.5 N•m Tightening Torque (16.6 - 20.3 lb-ft) 4. Installation should follow the removal procedure in the reverse order. YAD1B5S0 SSANGYONG Y200...
Page 180: Tensioning Device Shock Absorber
(3). Installation Notice 40.5 - 49.5 N•m Tightening Torque (29.9 - 36.5 lb-ft) 3. Unscrew the bolts (4,6) and remove the shock ab- sorber (7). Installation Notice 22.5 - 27.5 N•m Tightening Torque (16.6 - 20.3 lb-ft) SSANGYONG Y200...
Page 181: Poly V-Belt Inspection
1. Rubber lumps in the base of rib. 2. Dirt or grit ingrained. YAD1B380 3. Pointed rib. 4. Belt cord visible in the base of rib. YAD1B390 5. Cord torn out at the side. 6. Outer cords frayed. YAD1B400 SSANGYONG Y200...
Page 182 M161 ENGINE MECHANICAL 1B2-21 7. Rib detached from the base of belt. YAD1B410 8. Splits across the rib. 9. Sections of rib torn out. YAD1B420 10. Splits across several ribs. YAD1B430 11. Splits across the back of the belt. YAD1B440 SSANGYONG Y200...
Page 183: Cylinder Head Cover
1 Spark Plug Cover 4 Cylinder Head Cover 2 Spark Plug Connector 5 Gasket ............ Replace 3 Bolt (M6 X 45 : 4 pieces, M6 X 60 : 6 pieces) ........9 - 11 N•m (80 - 97 lb-in) SSANGYONG Y200...
Page 184 9 - 11 N•m Tightening Torque (80 - 97 lb-ft) Notice: Replace the gasket with a new one if necessary. 5. Installation should follow the removal procedure in the reverse order. YAD1B5Y0 6. Check for oil leaks by operating the engine. SSANGYONG Y200...
Page 185 3 Bolt (M8 X 35, 2 pieces) 8 O-Ring ............ Replace ...... 22.5 - 27.5 N•m (16.6 - 20.3 lb-ft) 9 Thermostat Housing. 4 Bolt (M6 X 22, 6 pieces) ........9 - 11 N•m (80 - 97 lb-in) SSANGYONG Y200...
Page 186 Apply the sealant at the mating surface of the cylinder head and the front cover. 3. Remove the O-Ring. Notice: Replace the O-ring with new one and apply YAD1B6B0 the sealant. 4. Installation should follow the removal procedure in the reverse order. SSANGYONG Y200...
Page 187: Cylinder Head
5 Cylinder Head 2nd step 90 ° rotation added 6 Gasket ............ Replace 3rd step 90 ° rotation added 7 Dowel Sleeve ..........Note 3 Bolt (M8 X 35, 4 pieces) ......22.5 - 27.5 N•m (16.6 - 0.3 lb-ft) SSANGYONG Y200...
Page 188 5. Remove the exhaust camshaft sprocket. Installation Notice 1st step: 18 - 22 N•m Tightening Torque (13 - 16 lb-ft) 2nd step: 60° ± 5° Notice: The flange bolt is designed to be used only once, so always replace with new one. YAD1B6G0 SSANGYONG Y200...
Page 189 589 01 34 00 (03). Notice: Apply the sealant on guide rail pin when installation. YAD1B6J0 9. Unscrew the bolts (A). Installation Notice 22.5 - 27.5 N•m Tightening Torque (16.6 - 20.3 lb-ft) Bolt (A) : (M8 X 35, 4 pieces) YAD1B6K0 SSANGYONG Y200...
Page 190 15. Check the length of the cylinder head bolt. Installation Notice When New 100 mm Length (L) Max. Length 105 mm Notice: Replace the bolt if the measured length exceed the max. length. 16. Installation should follow the removal procedure in the reverse order. YAD1B6N0 SSANGYONG Y200...
Page 191: Timing Gear Case Cover
1 Bolt (M8 X 60, 3 pieces) 3 Seal ...... 22.5 - 27.5 N•m (16.6 - 20.3 lb-ft) 4 Timing Gear Case Cover 2 Bolt (M8 X 75, 1 piece) 5 O-Ring ...... 22.5 - 27.5 N•m (16.6 - 20.3 lb-ft) 6 Sleeve. SSANGYONG Y200...
Page 192 7. Remove the guide rail pin using the sliding hammer 116 589 20 33 00 (02) and the threaded pin 116 589 01 34 00 (03). Notice: Apply the sealant on guide rail pin when installation. YAD1B6J0 SSANGYONG Y200...
Page 193 Notice: Be careful not to stain the oil chamber of chain tensioner with the sealant. 14. Installation should follow the removal precedure in the reverse order. 15. Warm up the engine and check for oil leaks. SSANGYONG Y200...
Page 194: Crankshaft Sealing Rear Cover
1 Bolt (M6 x 20, 6 pieces) 4 Sleeve ........9 - 11 N•m (80 - 97 lb-in) 5 Bolt (M6 x 85, 2 pieces) 2 Radial Shaft Seal ........9 - 11 N•m (80 - 97 lb-in) 3 Rear Cover 6 Washer SSANGYONG Y200...
Page 195 7. Install the crankshaft sealing rear cover mounting bolts and remove the crankshaft rear seal installer 601 589 03 43 00. Installation Notice 9 - 11 N•m Tightening Torque (80 - 97 lb-ft) 8. Installation should follow the removal procedure in the reverse order. YAD1B6T0 SSANGYONG Y200...
Page 196: Belt Pulley And Vibration Damper
Removal of fan shroud Removal of drive belt YAD1B6U0 1 Vibration Damper Center 2 Vibration Damper Disk ....1st step 200+20 N•m (148 + 15 lb-ft) 5 Vibration Damper Assembly 2nd step 90 ° + 10 ° rotation added 6 Key SSANGYONG Y200...
Page 197 5 Crankshaft Front Seal 11 Oil Pan Gasket 6 Timing Gear Case Cover 12 Oil Pan Mounting Bolt (M6 x 22) Service Data Standard 0.6 mm Permissble Deviation of The Vibration Damper Radial Runout 0.6 mm Axial Ruout SSANGYONG Y200...
Page 198 2nd step: 90° + 10° YAD1B680 4. Remove the vibration damper assembly using the puller. 5. Installation should follow the removal procedure in the reverse order. Notice: If possible, don’t separate the vibration damper and the pulley. YAD1B6W0 SSANGYONG Y200...
Page 199: Crankshaft Front Radial Seal
1 Center Bolt (M18 x 50) 3 Crankshaft Front Seal Installer ..1st step 200 + 20 45 N•m (148 +15 lb-ft) 4 Crankshaft Front Seal 2nd step 90 ° + 10 ° 5 Key 2 Center Bolt Washer SSANGYONG Y200...
Page 200 (148 + 15 lb-ft) 2nd step: 90° ± 10° 5. Remove the crankshaft front seal installer 601 589 03 14 00, and install the belt pulley and the vibration damper. 6. Check for leaks while operating the engine. SSANGYONG Y200...
Page 201: Crankshaft Rear Radial Seal
Notice: Do not use the grease. YAD1B850 4. Install the radial seal on the inner parts assembler. 5. Press in the special tool (1) until the radial seal is stopped. 6. Check for leaks while operating the engine.. SSANGYONG Y200...
Page 202: Crankshaft
1 Bearing Cap Bolt (M8 X 55 - 10 pieces) 4 Lower Main Bearing ........1ststep 55 N•m (41 lb-ft) 5 Upper Thrust Bearing 2nd step 90 °rotation added 6 Lower Thrust Bearing 2 Bearing Cap 8 Crankshaft. 3 Upper Main Bearing SSANGYONG Y200...
Page 203 - j5 Journal Main Bearing #1 - #5 • Color Dot Marking The color dot marking are put on the (1), (2), (4), (6), (8), and it indicates the diameter of crankshaft journal by color as below. SSANGYONG Y200...
Page 204 27.958 - 28.042 1st repair size 57.705 - 57.715 47.700 - 47.715 2nd repair size 57.450 - 57.465 47.450 - 47.465 3rd repair size 57.205 - 57.215 47.200 - 4.215 56.955 - 56.965 4th repair size 46.950 - 46.965 SSANGYONG Y200...
Page 205 When perfectly installed, the projected part (arrow) locates in the left side (intake manifold side). • Assemble so that the projected part of the cap and crankcase face the same direction. YAD1B920 SSANGYONG Y200...
Page 206 Notice: • Record the mean value when measured at 3 points (A,B,C). • Measure the inner diameter of bearing and the diameter of journal and if it is out of the standard data, replace the bearing shell. YAD1B960 SSANGYONG Y200...
Page 207 Static condition : 0.015 - 0.039 Dynamic condition : 0.031 - 0.051 Radial Main Bearing Journal (Consider the expansion 0.011 - 0.016) (NO.1,5,7) Axial 0.010 - 0254 (Connecting Rod Bearing Gap) Item Item Gap (mm) Connection Rod Bearing Radial 0.020 - 0.065 SSANGYONG Y200...
Page 208: Flywheel / Driven Plate
Stretch Side Diameter When New 8.5 - 0.2 mm Min. Diameter 8.0 mm Bolt Length When New 21.8 - 22.2 mm 1st step 45 + 5 N•m (33 + 37 lb-ft), 2nd step 90° + 10° Tightening Torque SSANGYONG Y200...
Page 209 Tommy-bar to be 90 ° and tighten as specified. 2. Remove the flywheel for manual transmission ve- hicles, or the driven plate (3), and plate (2) for Auto transmission vehicle. 3. Installation should follow the removal procedure in the reverse order. SSANGYONG Y200...
Page 210 1 OilPan 8 Washer 2 Cover 9 Bolt 3 Radial Seal 10 Front Drive Plate 4 Bolt 11 Rear Drive Plate 5 Crankshaft 12 Rivet 6 Dowel Pin 13 Segment 7 Washer (Thickness : 3.5 mm) 14 Ring Gear SSANGYONG Y200...
Page 211: Camshaft Adjuster
6 Nut (M20 X 1.5) ..60 - 70 N•m (44 - 52 lb-ft) 15 Circlip 7 Seal Cover 16 Oil Gallery 8 Camshaft Sprocket 17 Straight Pin 9 Adjust Piston 18 Intake Camshaft 10 Conical Spring Y49 Magnetic Actuator (2 - Pin Connector) SSANGYONG Y200...
Page 212 Installation Notice 1st step: 18 - 22 N•m Tightening Torque (13 - 16 lb-ft) 2nd step:60° ± 5° Notice: The flange bolt is designed to be used only once, so always replace with new one. YAD1B6G0 SSANGYONG Y200...
Page 213 2nd step:60° ± 5° Notice: The flange bolt is designed to be used only once, so always replace with new one. 12. Installation should follow the removal procedure in the reverse order. YAD1B7C0 13. Check and adjust the camshaft timing. SSANGYONG Y200...
Page 214: Camshaft Sprocket Bolt
2nd step:60° ± 5° Notice: The sprocket bolts are designed to be used only once, so always replace with new one. E. M7 x 13 Collar Bolt Torx-T30 e. 6.8 mm 13a. Camshaft Sprocket 22a. Exhaust Camshaft YAD1B0H0 SSANGYONG Y200...
Page 215: Camshaft
2nd Step 60 ° ± 5 ° Rotation Added 5 Bearing Cap Bolt (20 pieces) 2 Exhaust Camshaft Sprocket ...... 22.5 - 27.5 N•m (16.6 - 20.3 lb-ft) 3 Timing Chain 6 Camshaft Bearing Cap 4a Intake Camshaft Spocket (E20) 7 Wrench SSANGYONG Y200...
Page 216 5. Take off the timing chain from intake camshaft sprocket, and secure it not to fall down into the timing gear case. YAD1B6G0 6. Using the wrench (7), turn the camshaft until there is no resistence in camshaft bearing area. YAD1B7E0 SSANGYONG Y200...
Page 217 Notice: • Base circle of cam should cantact with the valve tappet. • Install the camshaft bearing caps according to the numbers on the cylinder head cast and bearing cap. 10. Check the camshaft timing position. YAD1B7G0 SSANGYONG Y200...
Page 218: Camshaft Timing Position
1 Holding Pin 111 589 03 15 00 ..... 1ststep 18 - 22 NSm (13 - 16 lb-ft) 2 Intake Camshaft Sprocket 2nd step 60 ° ± 5 ° rotation added 3 Camshaft Bearing Cap 7 StratePin 4 Timing Chain 5 Exhaust Camshaft Sprocket SSANGYONG Y200...
Page 219 The sprocket bolt is designed to be used only once, so replace with new one. 7. Install the chain tensioner. Installation Notice Screw Plug 40 N•m (30 lb-ft) Tightening Torque 72 - 88 N•m Tensioner (53 - 65 lb-ft) Assembly 8. Check the camshaft timing. SSANGYONG Y200...
Page 220: Valve Spring
Lever Pusher 111 589 18 61 00 2 Valve Spring Retainer b Thrust Piece 111 589 25 63 00 3 Valve Spring c Connecting Hose DW 110 - 090 4 Valve Stem Seal d Supporting Bar 111 589 01 59 00 5 Lower Retainer SSANGYONG Y200...
Page 221 YAD1B7J0 3. Remove the valve tappet using the valve tappet remover DW110 - 100. 4. Install the connecting hose DW110 - 090 (c) to the spark plug hole. YAD1B1D0 SSANGYONG Y200...
Page 222 Notice: Check the valve stem seal for damage and replace if necessary. 13. Remove the lower retainer (5). Notice: Check the retainer for damages and replace with a new one if necessary. 14. Installation should follow the removal procedure in the reverse order. YAD1B1F0 SSANGYONG Y200...
Page 223 Test (Upper and Lower Valve Tappet and Valve Cotter) • Upper Valve Spring Retainer Size (mm) 12.3 YAD1B1G0 • Lower Valve Spring Retainer Size (mm) 0.8 - 1.0 YAD1B1H0 • Valve Cotter Size (mm) 9.2 - 9.8 YAD1B1J0 SSANGYONG Y200...
Page 224: Valve Stem Seal
Notice: Check the valve stem seal for damage and replace if necessary. 2. Coat the valve stem seal with oil and assemble it with the protective sleeve. 3. Insert the valve stem seal by pressing it with the drift 119 589 00 43 00. YAD1B1M0 SSANGYONG Y200...
Page 225: Chain Tensioner
If the YAD1B1P0 chain tensioner is tightened again without completely reducing its tension, then the snap ring doesn’t return to the original position and the tension gets exceeded. SSANGYONG Y200...
Page 226 2. Install the chain tensioner housing (7), thrust pin (6), snap ring (5), and the seal (8). Installation Notice 72 - 88 N•m Tightening Torque (53 - 65 lb-ft) 3. Insert the compression spring (4) with the filler pin (3) into chain tensioner housing. YAD1B1S0 SSANGYONG Y200...
Page 227 1B2-66 M161 ENGINE MECHANICAL 4. Lightly apply the grease to the seal (2) and install the screw plug (1). Installation Notice Tightening Torque 40 N•m (30 lb-ft) 5. Check for leaks by operating the engine. YAD1B1T0 SSANGYONG Y200...
Page 228 19 Cylinder Head Gasket 8 Snap Ring 20 Timing Chain 9 Thrust Pin 21 Tensioning Rail Base (Sliding Surface) 10 Ball (Nonreturn Valve) 11 Compression Spring A Oil Supply Hole 12 Thrust Piece B Chain Tensioner Oil Storage Hole SSANGYONG Y200...
Page 229: Timing Chain
1B2-68 M161 ENGINE MECHANICAL TIMING CHAIN Preceding Work: Removal of cylinder head cover Removal of spark plug YAD1B1V0 1 Pin 5 Link 2 New Timing Chain 6 Center Plate 3 Timing Chain (Used) 7 Outer Plate 4 Wedge SSANGYONG Y200...
Page 230 4. Mount the wedges to both sides of the camshaft sprocket as shown in the figure. YAD1B1X0 5. Cover the chain housing with a clean cloth, and grind off the timing chain pin from the intake camshaft sprocket with the grinder. YAD1B1Y0 SSANGYONG Y200...
Page 231 10. Connect both separators of the new timing chain YAD1B2A0 with the link (5) and the center plate (6). 11. Install the jaw (a) and the thrust piece (b) to the assembly tool as shown in the figures. YAD1B2B0 YAD1B2C0 SSANGYONG Y200...
Page 232 15. Replace the thrust piece (b) as shown in the figure. YAD1B2F0 16. Install the chain assembly 000 589 58 43 00 to the link pin and tighten the spindle (c). Installation Notice Tightening Torque 30 N•m (22 lb-ft) YAD1B2E0 SSANGYONG Y200...
Page 233 Check the condition and it again if necessary. 18. Install the chain tensioner. Installation Notice Screw Plug 40 N•m (30 lb-ft) Tightening 72 - 88 N•m Tensioner Torque (53 - 65 lb-ft) Assembly 19. Check the camshaft timing position. YAD1B2G0 SSANGYONG Y200...
Page 234: Tensioning Rail
(2). Notice: • Replace the plastic guide (2) if it is damaged. • For installation, exactly align the plastic guide (2) with the sliding rail (1). 3. Installation should follow the removal procedure in the reverse order. SSANGYONG Y200...
Page 235: Cylinder Head Guide Rail
1B2-74 M161 ENGINE MECHANICAL CYLINDER HEAD GUIDE RAIL Preceding Work: Removal of cylinder head front cover YAD1B7L0 1 Bolt (M6 X 45, 2 pieces) 2 Guide Rail ........9 - 11 N•m (80 - 97 lb-in) SSANGYONG Y200...
Page 236 (53 - 65 lb-ft) 4. Unscrew the bolt (1) and remove the guide rail. Installation Notice 9 - 11 N•m Tightening Torque (80 - 97 lb-ft) 5. Installation should follow the removal procedure in the reverse order. YAD1B7M0 SSANGYONG Y200...
Page 237: Crankcase Guide Rail
(1). Notice: • Replace the plastic guide (2) if damaged. • Connect the plastic guide (2) and the guide rail (1) by aligning them accurately when installing. 3. Installation should follow the removal procedure in the reverse order. SSANGYONG Y200...
Page 238: Crankshaft Sprocket
2 Oil Pump Chain Bushing ........29 - 35 N•m (21 - 26 lb-ft) 3 Oil Pump Chain Spring 7 Oil Pump Sprocket 4 Crankshaft Sprocket 8 Oil Pump 5 Key 9 Oil Pump Roller Chain 10 Timing Chain SSANGYONG Y200...
Page 239 615 589 01 33 00. Notice: • Make sure not to lose the crankshaft pulley key (5) when removing. • Install the crankshaft sprocket (4) after warming it up. YAD1B850 6. Installation should follow the removal procedure in the reverse order. SSANGYONG Y200...
Page 240: Piston
Removal of baffle plate YAD1B2R0 1 Connecting Rod Bearing Cap 4 Piston 2 Connecting Rod 5 Snap Ring 3 Connecting Rod Bolt (M9 x 52, 8 pieces) 6 Piston Pin ........1st step 40 N•m (30 lb-ft) 2nd step 90 ° SSANGYONG Y200...
Page 241 3. Removethe snapring (5)and pulloutthepiston pin (6). Notice: Remove the snap ring using a clean cloth as shown in the right picture so that the piston, piston ring, and the snap ring don’t get damaged. YAD1B2Q0 Installation Procedure YAD1B2R0 SSANGYONG Y200...
Page 242 1st step : 40 N•m (30 lb-ft) Tightening Torque 2nd step : 90 ° Apply the engine oil to the bearing cap upper and lower bearing shells. 7. Check if the crankshaft rotates without any trouble by rotating it. SSANGYONG Y200...
Page 243: Connecting Rod
Permissible Deviation of Axial Paralleism of Connecting Rod 0.045/100 mm Bearing Bore to Connecting Rod Bushing Bore Permissible Deviation of Axial Paralleism of Connecting Rod Bearing Bore from 0.01 mm Concentricity Permissible Difference of Each Connecting Rod in Weight 0.4 g SSANGYONG Y200...
Page 244 • Make sure it doesn’t exceed over 4g with other connecting rods when replacing the connecting rods. • Check if the connecting rod and the bearing cap are accurately seated on the groove when replacing the bearing. YAD1B0A0 SSANGYONG Y200...
Page 245: Piston Ring
1B2-84 M161 ENGINE MECHANICAL PISTON RING Preceding Work: Removal of piston YAD1B2T0 1 Piston Compression Ring (Top Ring) 2 Piston Compression Ring (2nd Ring) 5 Spacer 3 Piston Oil Ring 6 SideRail SSANGYONG Y200...
Page 246 3. For installation, position the piston ring to be the ‘TOP’ mark on the piston ring upward and arrange the piston ring ends to be 120 ° part. 4. Adjust the hook spring joint in the oil ring 180 ° way from the ring end. YAD1B2V0 SSANGYONG Y200...
Page 247: Oil Pan
3. Clean the inside of oil pan and sealing surface, then apply the sealant. 4. Replace the gasket with new one. 5. Install the oil pan with gasket, and tighten each bolt in specified torque. 6. Check for oil leaks while running the engine. SSANGYONG Y200...
Page 248 26 Oil Return Gallery 12 Connecting Rod (Cylinder Head and Crankcase) 13 Piston 27 Oil Return Gallery (Crankcase) 28 End Cover ( φ 20 mm) 14 Oil Spray (Piston Crown Area) 15 Non-Return Valve (Crankcase) 29 Oil Return Pipe SSANGYONG Y200...
Page 249: Engine Oil And Oil Filter Element
1B2-88 M161 ENGINE MECHANICAL ENGINE OIL AND OIL FILTER ELEMENT YAD1B7R0 1 Oil Filter Cover 25 N•m (18 lb-ft) 4 Oil Drain Plug 2 O-Ring Replace 5 Oil Filter Bypass Valve 3 Oil Filter Element SSANGYONG Y200...
Page 250 7. Insert new oil filter element into the oil filter housing. 8. Temporarily tighten the oil filter cover. Install the Oil filter remover 103 589 02 09 00, and then completely tighten it. Installation Notice Tightening Torque 25 N•m (18 lb-ft) SSANGYONG Y200...
Page 251 9. Fill up engine oil through the engine oil filler opening (3). 10. Check for oil leaks at normal engine temperature after starting the engine. 11. Stop the engine and wait 5 minutes. Check the oil level and fill up as specified if neces- sary. SSANGYONG Y200...
Page 252: Oil Pump
11 Bolt (M6 X 12, 6 pieces) Baffle Plate) ........9 - 11 N•m (80 - 97 lb-in) 5 Bolt (M6 X 12, 2 pieces) (E23 Engine Only : Baffle Plate Mounting Bolt) ........9 - 11 N•m (80 - 97 lb-in) SSANGYONG Y200...
Page 253 3. Unscrew the six bolts (11) and remove the baffle plate. Installation Notice Tightening Torque 70 N•m (52 lb-ft) 4. Unscrew the three bolt (1) and remove the oil pump. Installation Notice 22.5 - 27.5 N•m Tightening Torque (16.6 - 20.3 lb-ft) YAD1B7W0 SSANGYONG Y200...
Page 254: Oil Pressure Relief Valve
Tightening Torque 50 N•m (37 lb-ft) 2. Remove the spring (2), guide pin (3) and the piston (4). 3. Installation should follow the removal procedure in the reverse order. Notice: Don’t use the seal for the screw plug. SSANGYONG Y200...
Page 255: Oil Non-Return Valve
As a result, the chain tensioner can be activated with oil in itself. Replacement Procedure 1. Remove the non-return valve using a pliers. 2. Insert new non-return valve with hand. YAD1B7Z0 SSANGYONG Y200...
Page 256: Oil Dipstick Guide Tube
It is very hard to remove the oil dipstick guide tube without special tool. If it is not necessary, do not remove the guide tube. 3. Installation should follow the removal procedure in the reverse order. 4. Check for leaks by starting the engine. SSANGYONG Y200...
Page 257: Unit Repair
1B2-96 M161 ENGINE MECHANICAL UNIT REPAIR CORE PLUGS IN CRANKCASE Preceding Work: Draining of the coolant YAD1B8B0 1 Core Plug ..........Replace SSANGYONG Y200...
Page 258 4. Clean the sealing surface and apply Loctite 241. YAD1B4B0 5. Press in new plug using a drift. Notice: Wait for about 45 minutes before filling the coolant so that the Loctite 241 hardens. 6. Warm up the engine and check the coolant for leaks. YAD1B4C0 SSANGYONG Y200...
Page 259: Cylinder Bore
φ 90.906 - φ 90.912 A, X or B φ 90.912 - φ 90.918 X or B φ 90.950 - φ 90.968 X + 5 X + 5 φ 91.000 - φ 91.018 X + 10 X + 10 SSANGYONG Y200...
Page 260 1, 2, 3 Measuring Points A. Axial Direction B. Transverse Direction a. Location of the No.1 Piston Ring at TDC b. Location of the Piston BDC c. Location of the Oil Ring at BDC YAD1B4E0 Chamfer Angle YAD1B4F0 SSANGYONG Y200...
Page 261: Crankcase Mating Surface
0.04 mm Permissible Deviation of Parallelismof The Axial Direction 0.1 mm Upper to Lower Mating Surface Transverse Direction 0.05 mm Peak-to-valley Height Crankcase Upper Mating Surface 0.012 - 0.009 mm Crankcase Lower Mating Surface 0.025 - 0.020 mm SSANGYONG Y200...
Page 262 M161 ENGINE MECHANICAL 1B2-101 Chamfering Procedure 1. Chamfer angle : 75 ° YAD1B4F0 2. Polish the lower chamfered area evenly with a grinder after finishing the chamfering with a suitable tool (e.g., hand milling cutter). YAD1B4H0 SSANGYONG Y200...
Page 263: Cylinder Head Mating Surface
Exhaust 22.21 - 22.75 mm and Valve Stem) Repair Size Intake 23.96 - 24.51 mm Exhaust 21.96 - 22.51 mm Notice: Do not exceed 0.4 mm for the milling of the mating surface of crankcase and cylinder head. SSANGYONG Y200...
Page 264 6. Measure the dimension (T) between the camshaft bearing and the valve system (refer to Service data standard). 7. Mill the cylinder head valve seat (refer to Service data standard). Universal Tool Sceledum, Type RTY Surface Grinding Machine Roaro Schio / Italy SSANGYONG Y200...
Page 265: Specifications
26 - 32 19 - 24 Water Pump Pulley 22.5 - 27.5 16.6 - 20.3 Upper Intake Manifold Bolt 22.5 - 27.5 16.6 - 20.3 Lower Intake Mainfold Bolt 22.5 - 27.5 16.6 - 20.3 Flange Bolt to Exhaust Mainfold SSANGYONG Y200...
Page 266 Oil Pressure Relief Valve Screw Plug Oil Dipstick Guide Tube Bolt 9 - 11 80 - 97 Oil Gallery Screw Plug Shock Absorber Bolts 22.5 - 27.5 16.6 - 20.3 Crankshaft Bearing Cap Bolts 55/+90° 41/+90° Torque Converter Mounting Bracket Bolts SSANGYONG Y200...
Page 267: Special Tools And Equipment
111 589 25 63 00 Supporting Bar Thrust Piece YAD1B0W0 YAD1B0Y0 111 589 18 61 00 116 589 20 33 00 Lever Pusher Sliding Hammer YAD1B0X0 YAD1B580 116 589 01 34 00 119 589 00 43 00 Threaded Pin Drift YAD1B570 YAD1B1L0 SSANGYONG Y200...
Page 268 Allen Wrench Socket Fan Clutch Holder YAD1B4K0 YAD1B560 615 589 01 33 00 DW110 - 090 Crankshaft Sprocket Connecting Hose Puller YAD1B2M0 YAD1B0Z0 601 589 03 43 00 DW110 - 100 Crankshaft Rear Seal Valve Tappet Remover Installer YAD1B730 YAD1B1A0 SSANGYONG Y200...
Page 269 1B2-108 M161 ENGINE MECHANICAL Special Tools Table (Cont’d) 111 589 03 15 00 Holding Pin YAD1B4R0 SSANGYONG Y200...
Page 270 SECTION 1B3 DIESEL ENGINE MECHANICAL CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
Page 271: Description And Operation
From here, the oil flows through a bore to the relevant adjustment element. The oil to the supply chamber flows via the groove YAD1BA20 provided in the base of the tappet. SSANGYONG Y200...
Page 272 DIESEL ENGINE MECHANICAL 1B3-3 BLANK SSANGYONG Y200...
Page 273: Component Locator
1B3-4 DIESEL ENGINE MECHANICAL COMPONENT LOCATOR CYLINDER HEAD YAD1BA40 SSANGYONG Y200...
Page 274 15 Engine Coolant Temperature Sensor 6 Cylinder Head Cover Gasket 16 Thermo Valve 7 Camshaft Cap Bolt 17 Cylinder Head Gasket 8 Cylinder Head Bolt 18 Valve Assembly 9 Camshaft Bearing Cap 19 Camshaft 10 Pre Chamber Assembly 20 Camshaft Adjust Key SSANGYONG Y200...
Page 275: Cylinder Block
1B3-6 DIESEL ENGINE MECHANICAL CYLINDER BLOCK YAD1BA50 SSANGYONG Y200...
Page 276 7 Screw & Seal Ring 19 Crankshaft Thrust Bearing 8 Crankshaft Bearing Cap 20 Crankshaft Sealing Cover 9 Cylinder Block 21 Bolt 10 Plug 22 Flywheel 11 Crankshaft Journal Bearing 23 Plate 12 Crankshaft Pulley 24 Oil Pump Assembly SSANGYONG Y200...
Page 277: Engine Component
1B3-8 DIESEL ENGINE MECHANICAL ENGINE COMPONENT YAD1BA60 SSANGYONG Y200...
Page 278 DIESEL ENGINE MECHANICAL 1B3-9 1 Fuel Filter Assembly 6 A/C Compressor Assembly 2 Oil Filter Assembly 7 Generator Assembly 3 Injection Pump Assembly 8 Turbo Charger Assembly 4 Power Steering Pump Assembly 9 EGR Valve Assembly 5 Starter Assembly SSANGYONG Y200...
Page 279: Repair Instructions
1B3-10 DIESEL ENGINE MECHANICAL REPAIR INSTRUCTIONS ON-VEHICLE SERVICE ENGINE ASSEMBLY YAD1BA70 1. Engine Assembly SSANGYONG Y200...
Page 280 2. Remove the hood. YAD1BA90 3. Remove the skid plate. Installation Notice 28 - 47 N•m Tightening Torque (21 - 35 lb-ft) YAD1B020 4. Remove the radiator drain cock and drain the coolant. Notice: Open the coolant reservoir tank cap. YAD1BAA0 SSANGYONG Y200...
Page 281 YAD1BAD0 8. Remove the radiator grille mounting screws and radiator grille. 9. Remove the front end upper member mounting blots and front end upper. Installation Notice 30 - 40 N•m Tightening Torque (22 - 30 lb-ft) YAD1BAE0 SSANGYONG Y200...
Page 282 3 - 7 N•m Tightening Torque (27 - 62 lb-in) YAD1BAG0 12. Remove the air cleaner to turbo charger hose(2) with blow by hose(1). YAD1BAH0 13. Disconnect the exhaust gas recirculation (EGR) valve hose and necessary hoses and pipes. YAD1BAJ0 SSANGYONG Y200...
Page 283 Notice: After installation of accelerator cable, check the engine idling and operation condition. YAD1BAL0 16. Disconnect the brake booster hose from vacuum pump. YAD1BAM0 17. Disconnect the fuel feed line with prefilter from the feed pump on injection pump. YAD1BAN0 SSANGYONG Y200...
Page 284 19. Remove the power steering pump lines. Notice: Completely drain the fluid. YAD1BAQ0 20. Remove the fuel lines from the fuel filter and cover the filter with plug. YAD1BAR0 21. Disconnect the coolant hose from the water inlet. YAD1BAS0 SSANGYONG Y200...
Page 285 22. Disconnect the injection timing relay connector from injection pump. YAD1BAT0 23. Disconnect the starter motor wires and necessary connectors. YAD1BAU0 24. Disconnect the preheating time relay cable and glow plug cable. YAD1BAV0 25. Disconnect the ground cable. 26. Disconnect the generator wires. YAD1BAW0 SSANGYONG Y200...
Page 286 Installation Notice 54 - 68 N•m Tightening Torque (40 - 50 lb-ft) YAD1BAZ0 30. Remove the engine mounting bracket bolts. Installation Notice 50 - 75 N•m Tightening Torque (37 - 55 lb-ft) YAD1BB00 SSANGYONG Y200...
Page 287 1B3-18 DIESEL ENGINE MECHANICAL 31. Remove the engine assembly from the vehicle by using a hoistor crane. 32. Installation should follow the removal procedure in the reverse order. YAD1BB10 SSANGYONG Y200...
Page 288: Poly V-Belt And Tensioning Device
DIESEL ENGINE MECHANICAL 1B3-19 POLY V-BELT AND TENSIONING DEVICE POLY V-BELT YAD1BB20 1 Nut ........... 21 N•m (15 lb-ft) 4 Spring 2 Tensioning Lever 5 Tensioning Lever 3 Bolt 6 Poly V-Belt SSANGYONG Y200...
Page 289 (7). YAD1BB50 Length of Belt 7 Tensioning Pulley 8 Crankshaft With Air Conditioner 2,100 mm 9 Generator Length (L) Without Air Conditioner 2,040 mm 10 Water Pump 11 Guide Pulley 12 Power Steering Pump 13 A/C Compressor SSANGYONG Y200...
Page 290 1. Rubber lumps in the base of rips. 2. Dirt or grit ingrained. YAD1B380 3. Pointed rips. 4. Belt cord visible in the base of rips. YAD1B390 5. Cord torn out at the side. 6. Outer cords frayed. YAD1B400 SSANGYONG Y200...
Page 291 1B3-22 DIESEL ENGINE MECHANICAL 7. Belt detached from the base of rip. YAD1B410 8. Splits across the rips. 9. Sections of rip torn out. YAD1B420 10. Splits across several rips. YAD1B430 11. Splits across the back. YAD1B440 SSANGYONG Y200...
Page 292: Tensioning Device
5 Guide Rail Pin 14 Tensioning Lever 6 Bolt 15 Fit Bolt........100 N•m (74 lb-ft) 7 Poly V-Belt 16 Closing Cover 8 Belt Pulley 17 Spring 9 Bolt........... 10 N•m (89 lb-in) 18 Bolt........... 20 N•m (15 lb-ft) SSANGYONG Y200...
Page 293 5. Remove the bolt (1, 18) and take off the damper (2). Installation Notice bolt (1) : 21 N•m (15 lb-ft) Tightening Torque bolt (18): 20 N•m (15 lb-ft) Pay attention to installation position of the damper. YAD1BB80 SSANGYONG Y200...
Page 294 Apply loctite on thread of fit bolt. 10. Remove the tensioning lever (14) and washer (13). 11. Clean thread in the timing case cover and fit bolt. YAD1BBB0 12. Installation should follow the removal procedure in the reverse order. SSANGYONG Y200...
Page 295: Crankcase And Cylinder Head
1B3-26 DIESEL ENGINE MECHANICAL CRANKCASE AND CYLINDER HEAD CYLINDER HEAD YAD1BBC0 SSANGYONG Y200...
Page 296 5 Bolt.......... 10 N•m (89 lb-in) 14 Cylinder Block 6 Threaded Ring ...... 130 N•m (96 lb-ft) 15 Gasket........... Replace 7 Prechamber 16 Cylinder Head 8 Bolt.......... 25 N•m (18 lb-ft) 17 Sliding Rail 9 Camshaft Bearing Cap SSANGYONG Y200...
Page 297 117 mm YAD1BBE0 The twelve-sided socket head bolts are tightened with each stages of torque and torque angle. It is not necessary to retighten the cylinder head bolts at the 1000~1500 km inspection or after 1000~1500 km of repairs. SSANGYONG Y200...
Page 298 4. Remove the bracket oil dipstick tube. YAD1BBG0 5. Remove the tensioning lever nut. 6. Remove the nut on the tensioning lever and insert the rod(φ 18, 180 mm). By pushing the rod to the arrow direction, pull back the bolt. YAD1BB30 SSANGYONG Y200...
Page 299 8. Unscrew the EGR pipe mounting bolts onto the exhaust manifold. 9. Remove the duct bracket from the cylinder head. YAD1BBH0 10. Unscrew the intake duct mounting bolts onto the intake manifold. YAD1BBJ0 11. Separate the connecting rod from the control lever. YAD1BBK0 SSANGYONG Y200...
Page 300 13. Remove the fuel injection line (1) from the fuel injection nozzle (12). YAD1BBM0 14. Remove the fuel injection line from the fuel injection pump. YAD1BBN0 15. Remove the bracket mounting bolts and then remove the fuel injection line (1). YAD1BBP0 SSANGYONG Y200...
Page 301 1B3-32 DIESEL ENGINE MECHANICAL 16. Disconnect the blow by hose from the cylinder head cover. YAD1BBQ0 17. Disconnect the glow plug cables. YAD1BBT0 18. Remove the intake manifold (10) and gasket. YAD1BBR0 19. Remove the cylinder head cover and gasket. YAD1BBS0 SSANGYONG Y200...
Page 302 22. Remove the heater pipe bracket from the oil filter. 23. Pry off the clamp and push the heater feed pipe forward and then pull out the pipe. YAD1BBW0 24. Disconnect the fuel lines from the fuel filter. YAD1BBX0 SSANGYONG Y200...
Page 303 26. Remove the fuel filter. YAD1BBZ0 27. Remove the fuel injection nozzle and nozzle washer. YAD1BC00 28. Rotate the crankshaft and set the no.1 cylinder at TDC. Notice: Do not rotate the crankshaft to the opposite direction of engine revolution. YAD1BC10 SSANGYONG Y200...
Page 304 30. Ensure that the camshaft and the bearing cap marking are aligned. YAD1BC30 31. Remove the starter motor and install the engine lock 602 589 00 40 00 onto the flywheel ring gear. YAD1BC40 32. Remove the exhaust manifold and exhaust pipe. YAD1BC50 SSANGYONG Y200...
Page 305 YAD1BC80 36. Remove the bearing caps and then pull out the camshaft(20) upward. Notice: Be careful not to miss the locking washer. 37. Remove the locking washer. Notice: Check the locking washer and replace if necessary. YAD1BC90 SSANGYONG Y200...
Page 306 41. Remove the socket bolts (13) of the chain box using the T type socket wrench 116 589 03 07 00. YAD1BCC0 42. Remove the cylinder head bolts in numerical sequence. 43. Remove the cylinder head and gasket. YAD1BCD0 SSANGYONG Y200...
Page 307 - Cylinder head bolts arrangement Bore 1 ..........M10 × 80 2 ..........M10 × 102 3 ..........M10 × 115 4 ..........M 8 × 50 5 ..........M 8 × 80 YAD1BCG0 SSANGYONG Y200...
Page 308 6. Install the socket bolts in the chain box using the T type socket wrench 116 589 03 07 00. Installation Notice Tightening Torque 25 N•m (18 lb-ft) YAD1BCK0 7. Connect the vacuum pipe to the thermo valve. 8. Connect the vacuum lines to the vacuum pump. YAD1BCL0 SSANGYONG Y200...
Page 309 589 20 33 00 (36) and threaded pin 116 589 02 34 00 (37). Notice: Apply sealing compound on the each collar of the sliding rail pins. YAD1BCA0 12. Insert the locking washer. 13. Inspect the valve tappet and check that the tappet moves smoothly. YAD1BCM0 SSANGYONG Y200...
Page 310 Tighten the No. 1 bolts (light arrow) first and then tighten the No. 2 bolts (dark arrow) stage by stage. YAD1BCQ0 18. Position the camshaft on marking and install the camshaft sprocket. Notice: Align the alignment marks on the chain and sprocket. YAD1BC30 SSANGYONG Y200...
Page 311 19. Check the TDC position of the crankshaft. YAD1BC10 20. Install the camshaft sprocket bolt. Installation Notice 1st Step 25 N•m (18 lb-ft) Tightening Torque 2nd Step 90° YAD1BC70 Notice: Measure the max. length ‘L’ and replace the bolt if it exceeds 53.6 mm. YAD1BCS0 SSANGYONG Y200...
Page 312 23. Remove the engine lock 602 589 00 40 00. YAD1BC40 24. Insert the nozzle washer into the hole to face round part downward. 25. Install the fuel injection nozzle. Installation Notice Tightening Torque 40 N•m (30 lb-ft) YAD1BCU0 SSANGYONG Y200...
Page 313 29. Install the blow-by hose. YAD1BCV0 30. Connect the wires to the engine coolant temperature sensor and the glow plug sensor. YAD1BBV0 31. Replace the intake manifold gasket. 32. Install the intake manifold. Installation Notice Tightening Torque 25 N•m (18 lb-ft) YAD1BCW0 SSANGYONG Y200...
Page 314 YAD1BCY0 36. Connect the fuel lines to the injection nozzles and to the injection pump. Installation Notice Tightening Torque 18 N•m (13 lb-ft) YAD1BBN0 37. Install the poly V-belt. Notice: Be careful not to contaminate the belt. YAD1BCZ0 SSANGYONG Y200...
Page 315 21 N•m (15 lb-ft) YAD1BB30 39. Install the oil dipstick tube bracket. Installation Notice Tightening Torque 10 N•m (89 lb-in) YAD1BBG0 40. Hold the cooling fan with the counter holder 603 589 00 40 00 and tighten the bolt. YAD1BBF0 SSANGYONG Y200...
Page 316: Prechamber
YAD1BD20 4. Inspect the prechamber. Notice: If the prechamber seats in the cylinder head are leaking or if the prechambers are replaced, the sealing surfaces in the cylinder head must be remachined. YAD1BD30 SSANGYONG Y200...
Page 317 3. Coat the threaded ring with oil and assemble the ring by using the serration wrench 603 589 00 09 Installation Notice Tightening Torque 130 N•m (96 lb-ft) SSANGYONG Y200...
Page 318: Oil Pan
5 Drain Plug ........ 25 N•m (18 lb-ft) 2 Oil Pan 6 Bolt........... 10 N•m (89 lb-in) 3 Bolt........... 10 N•m (89 lb-in) 7 Bolt........... 25 N•m (18 lb-ft) 4 Washer ........... Replace Notice: Replace the washer seal with new one. SSANGYONG Y200...
Page 319: Timing Case Cover
21 Socket Bolt ......23 N•m (17 lb-ft) ......... M8 : 23 N•m (17 lb-ft) 22 Guide Pulley 10 Power Steering Pump 23 Bolt ..........9 N•m (80 lb-in) 11 Bolt 24 Guide Pulley Bracket 12 Belt Pulley 25 Nut ..........23N•m (17 lb-ft) SSANGYONG Y200...
Page 320 8. Disconnect the pipes of power steering pump and remove the belt pulley. Notice: Be careful not to lose the key. 9. Remove the nut and pull out the bolt and then remove the power steering pump. YAD1BD90 SSANGYONG Y200...
Page 321 YAD1BDB0 12. Remove the camshaft. 13. Remove the socket bolts (4) in the chain box using the socket wrench 115 589 03 07 00. YAD1BDC0 14. Remove the injection pump. Refer to Section 1F3 Diesel Engine Control. YAD1BDD0 SSANGYONG Y200...
Page 322 1. Thoroughly clean the sealing surface and apply sealant. YAD1BDG0 2. Install the timing case cover. Installation Notice Tightening Torque 10 N•m (89 lb-in) Bolts arrangement 1. M6 x 60 2. M6 x 70 3. M6 x 40 YAD1BDH0 SSANGYONG Y200...
Page 323 6. Install the generator bracket. Installation Notice Front 25 N•m (18 lb-ft) Tightening Torque Side 25 N•m (18 lb-ft) YAD1BDK0 7. Install the generator. Installation Notice Upper 25 N•m (18 lb-ft) Tightening Torque Lower 45 N•m (33 lb-ft) YAD1BDL0 SSANGYONG Y200...
Page 324 Installation Notice Tightening Torque 23 N•m (17 lb-ft) 13. Install the power steering pump pulley. Installation Notice Tightening Torque 32 N•m (24 lb-ft) YAD1BDP0 14. Install the guide pulley bracket. Installation Notice Tightening Torque 9 N•m (80 lb-in) YAD1BD80 SSANGYONG Y200...
Page 325 17. Install the cooling fan belt pulley and fan clutch. 18. Install the belt tensioning device and then install the belt. 19. Install the cooling fan. 20. Fill the engine oil and check oil leaks by running the engine. YAD1BCV0 SSANGYONG Y200...
Page 326: Crankshaft Assembly
DIESEL ENGINE MECHANICAL 1B3-57 CRANKSHAFT ASSEMBLY VIBRATION DAMPER AND HUB Preceding Work: Removal of the cooling fan Removal of poly V-belt YAD1BDQ0 SSANGYONG Y200...
Page 327 18 Socket Bolt ......23 N•m (17 lb-ft) 7 Washer 19 Washer 8 Straight Pin 20 Bolt ........ 20 N•m (148 lb-ft)+ 90° 9 Hub 21 Hub 10 Oil Pan 22 Straight Pin 11 Radial Seal 23 Crankshaft Velt Pulley 12 Key 24 Vibration Damper SSANGYONG Y200...
Page 328 5. Place alignment marks (arrow) on the vibration damper (5) and crankshaft belt pulley (4). YAD1BDR0 6. Remove the timing sensor bracket. Notice: Remove if necessary. YAD1BDS0 7. Remove the socket bolts (3) and then remove the belt pulley (4) and vibration damper (5). YAD1BDT0 SSANGYONG Y200...
Page 329 8. Remove the washer and bolt. YAD1BDU0 9. Remove the hub by using a puller 103 589 00 33 YAD1BDV0 10. Pull out the radial seal (1) and be careful not to damage the sealing surface of timing case cover. YAD1BDW0 SSANGYONG Y200...
Page 330 200 N•m (148 lb-ft)+ 90° YAD1BDY0 3. Install the vibration damper. Notice: Exactly align and insert onto the straight pin. YAD1BDZ0 4. Install the crankshaft belt pulley. Installation Notice Tightening Torque 23 N•m (17 lb-ft) Align the alignment marks. YAD1BE00 SSANGYONG Y200...
Page 331 2 mm to ensure that is does not run in any groove which the standard radial seal may have left on the crankshaft flange. A Standard Radial Seal B Repair Radial Seal YAD1BE40 SSANGYONG Y200...
Page 332: Flywheel And Crankshaft End Cover
3 Bolt......10 N•m (89 lb-in) Loctite 573 9 12-Sided Stretch Bolt 4 Radial Seal ..........Replace ......Check, 45 N•m (33 lb-ft)+ 90° 5 Dowel Sleeve 10 Drive Plate (Automatic Transmission) 6 Bolt......10 N•m (89 lb-in) Loctite 573 11 Flywheel (Automatic Transmission) SSANGYONG Y200...
Page 333 3. Remove the bolts (3. 6) from end cover, by pulling out the lug (arrow), remove the cover. Notice: Be careful not to damage the oil pan gasket. YAD1BE80 4. Remove the radial seal (4) with care not to damage the sealing surface. YAD1BE90 SSANGYONG Y200...
Page 334 3 mm to ensure that is does not run in any groove which the standard radial seal may have left on the crankshaft flange. A Standard Radial Seal B Repair Radial Seal YAD1BED0 SSANGYONG Y200...
Page 335 45 N•m (33 lb-ft)+ 90° YAD1BEF0 yyyy yyyyy yyyy yyyyy yyyy yyyyy yyyy yyyyy yyyy yyyyy yyyy yyyyy yyyy yyyyy yyyy yyyyy yyyy yyyyy yyyy yyyyy yyyy yyyyy yyyy yyyyy yyyy yyyyy yyyy yyyyy yyyy yyyyy yyyy yyyyy YAD1BEG0 SSANGYONG Y200...
Page 336: Crankshaft Ball Bearing
000 589 33 33 00, pull out the locking ring and ball bearing together. 3. Apply Loctite 241 on the new ball bearing and then insert the ball bearing to be stopped at the spacer ring by using a proper mandrel. YAD1BEJ0 SSANGYONG Y200...
Page 337: Crankshaft
3 Crankshaft Main Bearing Shells (Upper) 7 Thrust Bearings (Lower) 4 Trust Bearings (Upper) 8 Crankshaft Bearing Cap 5 Crankshaft 9 Crankshaft Bearing Cap (Fit Bearing) 6 Crankshaft Main Bearing Shells (Lower) 10 12-sided Stretch Bolts ..55 N•m (41 lb-ft)+ 90° SSANGYONG Y200...
Page 338 B Radial and Axial Bearings (Thrust Bearing) 5 Crankshaft 6 Crankshaft Main Bearing Shells (Lower) 7 Thrust Bearings (Lower) Notice: The gaps between the bearing shell and bore and between the bearing shell and journal are different each other. Refer to service data. SSANGYONG Y200...
Page 339 24.900 - 24.933 mm 2.40 mm 25.000 - 25.033 mm Notice: • Measure crankshaft axial clearance and adjust with proper thrust Bearing. • The same thickness of washer must be installed on both sides of the fit bearing. SSANGYONG Y200...
Page 340 Matching Crankshaft Bearing Shells to Basic Bearing Journal of Crankshaft Marking of bearing journals on crank webs Color code of relevant crankshaft bearing shell Blue or white-blue Blue or white-blue Yellow or white-blue Yellow or white-yellow Red or white-blue Red or white-red SSANGYONG Y200...
Page 341 (7). 4. Remove the lower bearing shell (6) from the bearing cap (9). YAD1BEN0 5. Remove the crankshaft (5). YAD1BEP0 6. Remove the upper thrust bearings (4). 7. Remove the upper bearing shells (3) from crankcase. YAD1BEQ0 SSANGYONG Y200...
Page 342 13. Measure at 3 points (A, B and C) and if the average value of B and C is less than A’s value, the average value of B and C is the mean value and if more than A’s value, A’s value is the mean value. YAD1BET0 SSANGYONG Y200...
Page 343 Notice: The same thickness of thrust washers should be installed on both sides of the thrust bearing. YAD1BEW0 18. Coat the upper thrust bearing (4) with oil and insert into the crankcase so that the oil grooves are facing the crank webs (arrow). YAD1BEX0 SSANGYONG Y200...
Page 344 Notice: If the clearance is out of standard, adjust the axial clearance of crankshaft bearing by replacing the thrust washers. Notice: The same thickness of thrust washers should be installed on both sides of the thrust YAD1BF10 bearing. SSANGYONG Y200...
Page 345 32. Fill oil and run the engine and then check the oil pressure and oil level. Notice: Install the original oil filter element and then change the engine oil and oil filter element after 1,000 - 1,500 km. SSANGYONG Y200...
Page 346: Crankshaft Sprocket
12 Crankshaft Sprocket 3 Camshaft Sprocket 13 Crankshaft 4 Timing Chain 14 Key 5 Bearing Pin 16 Guide Rail 6 Bearing Pin 17 Spring 7 Oil Pump 18 Bushing 8 Oil Pump Sprocket 19 Tensioning Lever 9 Oil Pump Chain SSANGYONG Y200...
Page 347 2. Pull out tensioning lever (19), spring (17) and bushing (18) from the bearing pin (6). YAD1BF60 3. Pull out the guide rail (16). YAD1BF70 4. Remove the bolt(11) and then remove the washer (10), oil pump chain (9) and sprocket (8). YAD1BF80 SSANGYONG Y200...
Page 348 8. Remove the chain tensioner. 9. Remove the bolt (1) and then remove the washer (2) and camshaft sprocket (3). YAD1BC20 10. Remove the crankshaft sprocket (12) by using a puller 102 589 05 33 00 (20). YAD1BFA0 SSANGYONG Y200...
Page 349 Notice: Align the alignment marks (arrow) on the chain and sprocket. YAD1BF90 4. Install the camshaft sprocket (3). Installation Notice Tightening Torque 25 N•m (18 lb-ft)+ 90° Pay attention on the alignment marks and dowel pin (arrow). YAD1BC20 SSANGYONG Y200...
Page 350 7. Install the guide rail (16). Attach the spring (17) to guide rail and to tensioning lever together onto the bearing pins (5, 6). Notice: Ensure that the spring is correctly located in the guide rail (arrow). YAD1BFE0 SSANGYONG Y200...
Page 351: Piston
Notice: There are two kinds of connecting rods (for machining) and they are different in weight approx. 15g. When replacing the connecting rod, measure its weight and ensure that a engine has the same weight of connecting rods. If not, there would be a unbalancing of engine. SSANGYONG Y200...
Page 352 0.735 - 0.965 mm Connecting rod bushing diameter 26.012 - 26.018 mm Connecting Rod Bolt Dimensions Thread M9 x 1 Stretch shaft (C) diameter (new) 7.4 mm Minimum stretch shaft diameter (C) 7.1 mm Length (L) (new) 52 mm SSANGYONG Y200...
Page 353 Notice: Be careful not mix the bearing caps and shells each other. YAD1BFH0 4. Remove the piston (6) and connecting rod (8). YAD1BFJ0 5. Remove the snap ring (4) and pull out the piston pin (5). 6. Separate the piston and connecting rod. YAD1BFK0 SSANGYONG Y200...
Page 354 3. Install the new snap ring (4) into the grooves (arrow). 4. Check the piston rings (1, 2, 3) and replace them if necessary. YAD1BFN0 5. Install and arrange the piston rings to be evenly 120° from each ends gap. YAD1B2V0 SSANGYONG Y200...
Page 355 10. Position the connecting rod bearings caps. Notice: Position so that the retaining lugs are on the same side of the connecting rod bearing (arrow). YAD1BFS0 11. Measure stretch shaft diameter (C) of the connecting rod bolts. Limit ‘C’ 7.1 mm YAD1BFT0 SSANGYONG Y200...
Page 356 15. Position the piston at TDC and measure the distance between the piston crown and the crankcase surface using dial gauge 001 589 00 53 21 and dial gauge holder 363 589 02 21 00. Standard Max. 0.965 mm Notice: Measure at points marked. YAD1BFW0 SSANGYONG Y200...
Page 357: Flywheel Ring Gear
1B3-88 DIESEL ENGINE MECHANICAL FLYWHEEL RING GEAR Preceding Work: Removal of flywheel YAD1BFX0 1 Ring Gear a Centering Collar Diameter 2 Flywheel SSANGYONG Y200...
Page 358 4. Heat up the new ring gear up to 220°C (428°F) by using a heating device. Notice: Use temperature measuring chalk. YAD1BG00 5. Install the new ring gear (1) onto the flywheel (2) by using a drift. YAD1BG10 SSANGYONG Y200...
Page 359 6. Measure axial runout of ring gear (1) on a surface plate using dial gauge 001 589 53 21 00 and dial gauge holder 363 589 02 21 00. Limit Max. 0.4 mm Notice: For correct measurement, put the flywheel on the flat measuring board. YAD1BG20 SSANGYONG Y200...
Page 360: Timing Device And Valve
DIESEL ENGINE MECHANICAL 1B3-91 TIMING DEVICE AND VALVE VALVE TAPPETS Preceding Work: Removal of camshaft YAD1BG30 1 Valve Tappet 4 Seal ............Replace 2 Cylinder Head 5 Screw Plug 3 Oil Gallery SSANGYONG Y200...
Page 361 (3). At this time, check that the outlet bores (arrow) at the seat of the valve tappet are clear. 3. Replace the seal (4) and tighten the plug (5). 4. Insert the new valve tappet. Notice: Coat the valve tappet with oil. YAD1BG50 SSANGYONG Y200...
Page 362: Valve Tappets
Remove of cylinder head YAD1BG60 1 Valve Tappet 5 Cylinder Head 2 Valve Cotters 6 Stud Bolt ........ 12 N•m (106 lb-in) 3 Spring Retainer 7 Nut ......Replace, 25 N•m(18 lb-ft) 4 Valve Spring ..Check, replace if necessary SSANGYONG Y200...
Page 363 3. Pull out the valve tappet (1) with magnetic bar 102 589 03 40 00 (12). Notice: Place the valve tappets upside down (open end upward). YAD1BG90 4. Install the supporting bridge 601 589 02 59 00 (13) on the cylinder head (5). YAD1BGA0 SSANGYONG Y200...
Page 364 6. Remove the spring retainer (3) and spring (4). Notice: Install the valve spring with the color coding (arrow) facing down. 7. Check the valve spring and replace if necessary. 8. Installation should follow the removal procedure in the reverse order. YAD1BGC0 SSANGYONG Y200...
Page 365: Valve Spring (Cylinder Head Installed)
Removal of camshaft YAD1BGD0 1 Valve Tappet 4 Valve Spring ..Check, replace if necessary 2 Valve Cotters 5 Timing Chain 3 Spring Retainer 6 Cylinder Head Notice: Remove the valve springs only when the piston is at TDC. SSANGYONG Y200...
Page 366 5. Using the press lever 667 589 00 31 00 (9), press the spring retainer (3) downward and remove the valve cotters (2) with magnetic finger 116 589 06 63 00 (10). Notice: Be careful not to damage guide bore of the valve tappet. YAD1BGG0 SSANGYONG Y200...
Page 367 10. Remove the supporting bar 667 589 02 63 00. 11. Remove the holding wheel 603 589 01 40 00 (7) from the timing chain (5). YAD1BGE0 13. Coat the valve tappet with oil and install it with magnetic bar 102 589 03 40 00. YAD1BG40 SSANGYONG Y200...
Page 368: Valve Stem Seals
Removal of camshaft. YAD1BGJ0 1 Valve Tappet 4 Valve Spring ..Check, replace if necessary 2 Valve Cotters 5 Valve Stem Seal 3 Spring Retainer 6 Valve Notice: Remove the valve stem seals when the pistion is positioned at TDC. SSANGYONG Y200...
Page 369 667 589 00 31 00 Press Lever 667 589 02 63 00 Supporting Bar YAD1BGK0 YAD1BGL0 Intake valve stem seal Exhaust valve stem seal Chamfer Offset All round Inner diameter ‘d’ 7.3mm 8.2 mm Color Brown Green Wire ring Black Yellow SSANGYONG Y200...
Page 370 4. Install the supporting bar 667 589 02 63 00 (8). YAD1BGE0 5. Using press lever 667 589 00 31 00 (9), press the spring retainer (3) downward and remove the valve collets with magnetic finger 116 589 06 63 00 (10). YAD1BGG0 SSANGYONG Y200...
Page 371 9. By pressing the spring seat with press lever 667 589 00 31 00 (9), install the valve cotters (2) with magnetic finger 116 589 06 63 00 (10). Notice: Be careful not to damage guide bore of the valve tappet. YAD1BGG0 SSANGYONG Y200...
Page 372: Valve Guides
Repair size 2 14.440 - 14.451 White 14.400 - 14.411 - 0.051 Repair size 1 14.240 - 14.251 14.200 - 14.211 0.029 Exaust 9.000 - 9.050 37.7 Repair size 2 14.440 - 14.451 White 14.400 - 14.411 - 0.051 SSANGYONG Y200...
Page 373 Guide Sleeve Tool No. Guide Sleeve Side Intake 102 589 00 63 00 115 589 00 53 00 (14.2 mm) Exhaust 102 589 08 63 00 Intake 115 589 01 53 00 (14.4 mm) 601 589 15 63 00 Exhaust SSANGYONG Y200...
Page 374 4. Reaming basic bore in cylinder head (repair size). - Thoroughly remove carbon deposits in cylinder head. Notice: Particularly remove the insides of the valve seat rings. - Remove the elevation (arrow) of intake valve seat rings. YAD1BGV0 SSANGYONG Y200...
Page 375 80°C (176°F) with mounting device 115 589 34 63 YAD1BGY0 6. Cool down the new valve guide (2) into the super cooling box 346 589 00 63 00 with liquid nitrogen. Notice: Do not touch the cooled valve guide by hand. YAD1BGZ0 SSANGYONG Y200...
Page 376 YAD1BH10 9. If necessary, ream the valve guide bore evenly with a reamer (Intake: 000 589 21 53 00, Exhaust: 000 589 10 53 00) (10). Notice: Never turn the reamer against the direction of rotation. YAD1BH20 SSANGYONG Y200...
Page 377: Valve Seat Rings
37.084 - 37.100 mm 33.400 - 33.600 mm 30.400 - 30.600 mm 6.955 - 7.045 mm 6.955 - 7.045 mm Overlap U=D-D2 0.068 - 0.100 mm 0.068 - 0.100 mm 133.4 mm 133.4 mm 142.5 mm 142.5 mm SSANGYONG Y200...
Page 378 Internal Dial Gauge (Range : 25 - 60 mm) Mahr D-7300 Esslingen Order No. 844 External Micrometer (Range : 25 - 60 mm) Mahr D-7300 Esslingen Order No. 40 S Electrically Heated Water Tank Otto Dürr D-7123 Sachsenherm - Ochsenbach SSANGYONG Y200...
Page 379 6. Insert the tensioning head (4) and extracted wedges(arrow) by turning the bolt (5). Notice: Carefully tighten the bolt (5) otherwise the valve seat ring in the cylinder head will be excessively tensioned. 7. Lock the bolt (5) with nut (6). YAD1BH70 SSANGYONG Y200...
Page 380 0.068 - 0.100 mm Example) Measured value D = 37.600 mm Measured value D2 = 37.480 mm Overlap U = 0.120 mm The basic diameter D2 must be machined by 0.020 mm in order to get the required overlap value. YAD1BHB0 SSANGYONG Y200...
Page 381 18. Install the valve guide (3) with a proper drift (Intake: 8 mm, Exhaust: 9 mm) and assembling tool. Notice: The valve guide must be driven in from the cylinder head cover. 19. Machine the valve seats. YAD1BHE0 SSANGYONG Y200...
Page 382: Camshaft
11 Washer 4 Camshaft 12 12-Sided Bolt (M11) 5 Dowel Pin ......... Check, 25 N•m (18 lb-ft)+ 90° 6 Locking Washer 13 Gasket ........... Replace 7 Timing Chain 14 Chain Tensioner ....... 80 N•m (59 lb-ft) 8 Cylinder Head SSANGYONG Y200...
Page 383 In this position, the markings of the camshaft/ camshaft bearing cap (arrow) must be aligned. YAD1BC30 2. Place alignment marks on the camshaft sprocket and timing chain. YAD1BC20 3. Remove the starter motor and install the engine lock 602 589 00 40 00. YAD1BC40 SSANGYONG Y200...
Page 384 In order to avoid damaging the camshaft, it is essential to adhere to the removal order for the camshaft bearing caps. YAD1BC80 7. Remove the camshaft bearing cap. 8. Pull off the camshaft. Notice: Be careful not to miss front locking washer. YAD1BC90 SSANGYONG Y200...
Page 385 5. Tighten the camshaft bearing cap bolts acccording to installation order. Installation Notice Tightening Torque 25 N•m (18 lb-ft)+ 90° Tighten the No. 1 bolts (light arrow) by one revolution in stages first and then tighten the No. 2 bolts (dark arrow). YAD1BCQ0 SSANGYONG Y200...
Page 386 Notice: If max. length ‘L’ of the 12-sided bolt exceeds 53.6mm, replace it. YAD1BCS0 8. Install the chain tensioner. Installation Notice Tightening Torque 80 N•m (59 lb-ft) Replace the seal. Before installation, by pumping in the oil approx. 10 times, fill the oil. YAD1BHJ0 SSANGYONG Y200...
Page 387 1B3-118 DIESEL ENGINE MECHANICAL 9. Remove the engine lock 602 589 00 40 00. YAD1BC40 10. Check the TDC marking of OT on the crankshaft. YAD1BC10 SSANGYONG Y200...
Page 388: Timing Chain
DIESEL ENGINE MECHANICAL 1B3-119 TIMING CHAIN Preceding Work: Removal of glow plug Removal of chain tensioner Removal of cooling fan Removal of cylinder head cover YAD1BHK0 1 Chain Link 3 Camshaft Sprocket 2 Timing Chain 4 Outer Plate SSANGYONG Y200...
Page 389 5. By rotating the crankshaft in the of engine rotation, pull out the old timing chain with installing the new timing chain. 6. Remove the old timing chain and hold the ends of the new timing chain to camshaft sprocket (3) with wire (arrow). YAD1BHP0 SSANGYONG Y200...
Page 390 9. Place the chain assembling device 000 589 58 43 00 (8) onto the chain link and press the outer plate on as far as the stop. YAD1BHS0 10. Switch over the die (9) of the chain assembling device 000 589 58 43 00 (8). YAD1BHT0 SSANGYONG Y200...
Page 391 Notice: In this position, the marking on camshaft / camshaft bearing cap (arrow) must also be aligned. If the markings are not aligned, the timing chain must be re-set and the injection pump timing has to be set. YAD1BC30 SSANGYONG Y200...
Page 392: Chain Tensioner
DIESEL ENGINE MECHANICAL 1B3-123 CHAIN TENSIONER YAD1BHU0 1 Chain Tensioner ....... 80 N•m (59 lb-ft) 2 Seal ............Replace SSANGYONG Y200...
Page 393 4 Aluminum Gasket 12 O-Ring 5 Ball 13 Snap Ring 6 Ball Guide 14 Compression Spring 7 Compression Spring 15 Filler 8 Compression Spring 9 Housing a Feed Bore from Cylinder Head 10 Thrust Pin b To Oil Pan SSANGYONG Y200...
Page 394: Lubrication System
OIL FILTER YAD1BHW0 1 Housing Cap ......25 N•m (18 lb-ft) 5 Bolt........... 25 N•m (18 lb-ft) 2 O-Ring ............ Replace 6 Oil Pressure Switch 3 Oil Filter ....Element replace if necessary 7 Gasket 4 Oil Filter Housing SSANGYONG Y200...
Page 395 2. Remove the oil pressure switch line. 3. Remove the oil filter housing bolts and oil filter housing. Installation Notice Tightening Torque 25 N•m (18 lb-ft) 4. Clean the sealing surface. 5. Installation should follow the removal procedure in the reverse order. YAD1BHY0 SSANGYONG Y200...
Page 396: Oil Spray Nozzle
Removal & Installation Procedure 1. Remove oil pan or crankshaft. 2. Loose the bolt and then remove the nozzle. Installation Notice Tightening Torque 10 N•m (89 lb-in) 3. Installation should follow the removal procedure in the reverse order. YAD1BJ00 SSANGYONG Y200...
Page 397: Oil Pump
8 Bolt ........... 25 N•m (18 lb-ft) Removal & Installation Procedure 1. Removae the bolt from the oil pump drive sprocket and separate the gear and the oil pump drive chain. Installation Notice Tightening Torque 25 N•m (18 lb-ft) YAD1BJ20 SSANGYONG Y200...
Page 398 Installation Notice Tightening Torque 25 N•m (18 lb-ft) YAD1BJ30 3. Unscrew the screw plug and remove the relief valve. Installation Notice Tightening Torque 50 N•m (37 lb-ft) 4. Installation should follow the removal procedure in the reverse order. SSANGYONG Y200...
Page 399: Unit Repair
0.3, 0.6, 1.0 mm If a spacer ring is already fitted, or a marking is made on the cylinder head, the cylinder head must be removed and size ‘C’ measured if further remachining is necessary on a prechamber sealing surface. SSANGYONG Y200...
Page 400 YAD1BJ60 6. Measure the ‘X’ by using a vernier caliper. YAD1BJ70 7. Mount the turning tool onto the counter sink 601 589 00 60 00 and rotate to the right approx. 5 revolutions by applying slight pressure. YAD1BJ80 SSANGYONG Y200...
Page 401 1 3. Install the prechambers. Notice: If the cylinder head is removed, the projection ‘C’ is measured in place of size ‘X’ and the appropriate size of spacer ring selected. Normal Projection (C) 7.6 - 8.1 mm YAD1BJA0 SSANGYONG Y200...
Page 402: Tdc(Tdc Sensor Bracket) Setting
After engine overhauling. If the cylinder head is removed, the measuring pin of the dial gauge can be positioned on the piston crown. This is done by placing the magnetic dial holder on the mating surface of the crankcase. SSANGYONG Y200...
Page 403 8. If the pin does not engage, adjust the setting of the sensor bracket by removing and tightening of the sensor bracket bolts. Installation Notice Tightening Torque 10 N•m (89 lb-in) The timing mark on the damper must be positioned at ATDC 20°. YAD1BJD0 SSANGYONG Y200...
Page 404: Machining Of Flywheel
(B) for the clutch pressure plate should also be machined in accordance with ‘A’ to keep the distance ‘a’. • Do not machine under ‘b’ value. • When machining, fix the flywheel exactly not to exceed the standard runout. SSANGYONG Y200...
Page 405: Hydraulic Valve Clearance Compensation Element Check
1B3-136 DIESEL ENGINE MECHANICAL HYDRAULIC VALVE CLEARANCE COMPENSATION ELEMENT CHECK YAD1BJG0 1 Cylinder Head Cover 4 Valve Tappet 2 Bolt ...........10 N•m (89 lb-in) 5 Cylinder Head 3 Gasket............ Replace SSANGYONG Y200...
Page 406 7. Rotate the engine and check the remaining valve tappets. Notice: • Unnecessary rotation of the engine will damage the valve tappets. • Do not rotate the engine by using the camshaft sprocket bolt or to the opposite direction of the engine rotation. SSANGYONG Y200...
Page 407: Valve Springs Check
Preceding Work : Removal of valve spring YAD1BJJ0 1 Valve Spring 2 Spring Scale Service Data At preloaded Outer diameter Wire diameter Free length Length Tension (new) Limit 33.1 mm 4.20 mm 50.0 mm 27 mm 680 - 740 N 612 N SSANGYONG Y200...
Page 408: Check And Machining Of Valves
Removal of the vale spring Removal of the valve YAD1BJK0 I Valve Length y Half Camshaft Basic Bore Diameter w Camshaft Cam Basic Diameter z Distance (Cylinder Head Cover Parting Surface x Distance (Camshaft Basic Bore - Valve Stem) - Valve Stem) SSANGYONG Y200...
Page 409 I = 105.5 ± 0.2 mm Size (x) 20.2 - 21.2 mm Reuse valve 20.4 - 21.4 mm Use standard size Size (x) valve 21.2 - 21.97 mm 21.4 - 21.97 mm I = 106.4 ± 0.2 mm SSANGYONG Y200...
Page 410 1.7 ± 0.15 mm 3. Machine the valve. Notice: Pay attention to setting angle ‘α’ . YAD1BJP0 4. Measure radial runout between valve stem and valve seat with a dial gauge 001 589 32 21 00. Limit Max. 0.03 mm YAD1BJQ0 SSANGYONG Y200...
Page 411 Notice: If out of standard, replace the valve seat ring. YAD1BJS0 9. Measure camshaft cam basic diameter (w). 38 ± 0.2 mm Diameter ‘w’ or 37.6 ± 0.2 mm YAD1BJT0 10. Measure distance ‘z’ (cylinder head cover parting surface - valve stem). YAD1BJU0 SSANGYONG Y200...
Page 412 Example) Measured value ‘w’ = 38.2 mm Measured value ‘z’= 36.5 mm Value ‘y’ = 15.5 mm ‘x’ = 36.5 - 15.5 = 21.0 mm In this case according to ‘Matching valves’ table, the installed valve may be used. SSANGYONG Y200...
Page 413: Machining Of Valve Seat
Removal and inspection of valve, replace if necessary Inspection of valve guide, replace if necessary YAD1BJV0 1 Valve a Valve Arreare 2 Valve Seat Ring b Valve Seat Width α Valve Seat Angle 3 Cylinder Head β Valve Seat Free Angle 4 Valve Guide SSANGYONG Y200...
Page 414 D-8000 München 70 Type Ventilknecht K2000 Order No. 221 00 100 Valve Seat Turning Tool Hunger D-8000 München 70 Type VDS 1A Order No. 236 03 308 Test Sat for Valves Hunger D-8000 München 70 Order No. 217 93 601 SSANGYONG Y200...
Page 415 1.5 - 2.0 mm width ‘b’ YAD1BJX0 3. If the specification is exceeded, the valve seat width has to be corrected at the lower free angle of ‘β’ =65°. YAD1BJY0 4. Measure radial runout. Max. 0.03 mm Runout YAD1BJZ0 SSANGYONG Y200...
Page 416 0.1 - 0.7 mm YAD1BJS0 6. Measure camshaft cam basic circle diameter (w). 38 ± 0.2 mm Diameter ‘w’ or 37.6 ± 0.2 mm YAD1BJT0 7. Measure distance ‘z’ (cylinder head cover parting surface - valve stem). YAD1BJU0 SSANGYONG Y200...
Page 417 = 15.5 mm ‘x’ = 36.5 - 15.5 = 21.0 mm In the case of a camshaft cam basic circle diameter ‘w’ = 38.2 mm and a distance ‘x’ = 21.0 mm, the installed valve may be used. SSANGYONG Y200...
Page 418: Camshaft Timing Test
3 Gasket............ Replace Timing Intake valve Exhaust valve Condition of camshaft Open Close Open Close ATDC 11.33° ABDC 17° BBDC 28° BTDC 15.25° After approx. 20,000km ATDC 12° ABDC 18° BBDC 27° BTDC 14° At 2mm of valve lifting stroke. SSANGYONG Y200...
Page 419 If a difference of more than 4° exists, the timing chain should be replaced. YAD1BC10 7. Replace the gasket and install the cylinder head cover. Installation Notice Tightening Torque 10 N•m (89 lb-in) SSANGYONG Y200...
Page 420: Cylinder Head Pressure Leakage Test
Immerse with pressure measuring plate into warm water of approx. 60°C (140°F) and pressurize with compressed air of 2 bar. Notice: If air bubbles are seen, replace the cylinder head. Tools Required 115 589 34 63 00 Mounting Device 601 589 00 25 00 Pressure Testing Device SSANGYONG Y200...
Page 421: Facing Cylinder Head Mating Surface
In Transverse Direction Permissible Variation of Parallelism (Longitud. direction) Max. 0.1 mm Peak-to-Valley Height 0.0017 mm Valve Arrears ‘a’ 0.1 - 0.7 mm Intake Valve 0.1 - 0.7 mm Exhaust Valve Prechamber Protrusion ‘c’ 7.6 - 8.1 mm SSANGYONG Y200...
Page 422 0.1 - 0.7 mm Notice: If out of standard, machine the valve seat. YAD1BJS0 3. Install the prechamber and measure protrusion ‘c’ Protrusion ‘c’ 7.6 - 8.1 mm 4. Assemble the engine and check the valve timing. YAD1BK60 SSANGYONG Y200...
Page 423: Replacement Of Crankcase Core Plug
1B3-154 DIESEL ENGINE MECHANICAL REPLACEMENT OF CRANKCASE CORE PLUG Core Plug YAD1BK70 Service Data φ 34 mm Left 3 EA φ 34 mm Right 3 EA φ 17 mm Front 1 EA φ 34 mm Rear 1 EA SSANGYONG Y200...
Page 424 6. Install the new core plug by using a drift. 7. Install the removed parts and fill the coolant. Notice: The adhesive must be allowed to harden for about 45 minutes before filling of coolant. 8. Warm up the engine and check the coolant for leaks. YAD1BK80 SSANGYONG Y200...
Page 425: Facing Crankcase Contacting Surface
Permissible roughness upper contacting surface 0.0006 - 0.0016 mm Permissible variation of parallelism of crankcase upper 0.05 mm surface to lower surface in longitudinal direction Piston protrusion at TDC to crankcase upper surface 0.965 mm Max. 0.735 mm Min. SSANGYONG Y200...
Page 426: Cylinder Bore Measurement
Code letter ‘B’ 89.012 - 89.018 mm Wear limit in direction of travel and in transverse direction Max. 0.20 mm Permissible deviation of cylinder shape When new 0.01 mm Wear limit 0.05 mm Honing angle 50° ± 10° SSANGYONG Y200...
Page 427: Specifications
Guide Pulley Bolt Guide Pulley Bracket Bolt Hub Bolt 200 + 90° 148 + 90° Idle Pulley Bolt Injection Nozzle Injection Pump Mounting Bolt Intake Manifold Nut Oil Dipstick Tube Bracket Bolt Oil Filter Housing Bolt Oil Filter Housing Cap SSANGYONG Y200...
Page 428 21 - 35 Socket Bolt Stud Bolt TDC Sensor Bracket Bolt Tensioning Lever Nut Tensioning Pulley Bolt Timing Case Cover Bolt Transmission Mounting Bolt 54 - 68 40 - 50 Turbo Charger to Exhaust Pipe Bolt Vacuum Pump Mounting Bolt SSANGYONG Y200...
Page 429: Special Tools And Equipment
Counter Support YAD1BLC0 YAD1BKR0 000 589 58 43 00 000 589 10 68 00 Chain Assembling Cylinder Brush Device YAD1BL60 YAD1B1W0 001 589 32 21 00 000 589 21 53 00 Dial Gauge Reamer (for Intake) YAD1BLD0 YAD1BLG0 SSANGYONG Y200...
Page 430 (φ φ φ φ φ 17) Drift YAD1B3Y0 YAD1B1A0 102 589 00 23 00 103 589 00 33 00 Go/No Go Gauge Puller (for Intake) YAD1BLF0 YAD1BKM0 102 589 03 40 00 103 589 02 15 00 Magnetic Bar Drift (for Exhaust) YAD1BKX0 YAD1BL80 SSANGYONG Y200...
Page 431 Drift (for Intake) Magnetic Finger YAD1BL70 YAD1BL10 115 589 34 63 00 116 589 07 15 00 Mounting Device Drift YAD1BKG0 YAD1BKV0 116 589 02 34 00 116 589 20 33 00 Thread Bolt Sliding Hammer YAD1BLH0 YAD1B580 SSANGYONG Y200...
Page 432 Super Cooling Box Counter Sink YAD1BL90 YAD1BKD0 363 589 02 21 00 601 589 01 59 00 Dial Gauge Holder Assembling Board YAD1BKQ0 YAD1BKY0 601 589 02 43 00 366 589 00 21 05 Drift Extension YAD1BKP0 YAD1BL50 SSANGYONG Y200...
Page 433 Measuring Device Sleeve YAD1B790 YAD1BKK0 601 589 03 43 00 602 589 00 40 00 Oil Seal Assembler Engine Lock YAD1BKN0 YAD1B720 601 589 05 15 00 603 589 00 09 00 Drift (for Intake) Serration Wrench YAD1BLA0 YAD1BKB0 SSANGYONG Y200...
Page 434 603 589 01 40 00 667 589 01 21 00 Holding Wheel Fixing Device YAD1BL20 YAD1BKL0 657 589 03 63 00 667 589 02 63 00 Sliding Hammer Supporting Bar YAD1BKC0 YAD1BL30 667 589 00 23 00 Height Gauge YAD1BKE0 SSANGYONG Y200...
Page 435 SECTION 1D ENGINE COOLING CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
Page 436: Description And Operation
This fan is electric and can turn on even when back into the radiator and the engine. This keeps the the engine is not running. radiator filled with the coolant to the desired level at all times and increases the cooling efficiency. SSANGYONG Y200...
Page 437: Engine Coolant Temperature Sensor
ECT sensor. motor relay. • The ECM will turn the cooling fans on at low speed when the coolant temperature reaches 95 °C (203 °F) and at high speed when the coolant temperature reaches 105 °C (221 °F). SSANGYONG Y200...
Page 438: Component Locator
9 Bolt (M6, 4 pieces) 24 Cooling Fan 10 Bolt (M6, 4 pieces) 25 Viscous Clutch 11 Upper Radiator Insulator 26 Bolt (M6, 1 piece) 12 Lower Radiator Insulator 27 Bolt (M6, 3 piece) 13 Plate 14 Clip SSANGYONG Y200...
Page 439: Diesel Engine
27 Plate 11 Reserver Tank 28 Clip 12 Clamp 29 Intercooler 13 3 way Hose 30 Intercooler Outlet Duct 14 Clamp 31 Intercooler Inlet Duct 15 Clamp 32 Clamp 16 - 33 Electric Fan Mounting Bracket 17 Connector SSANGYONG Y200...
Page 440: Diagnostic Information And Procedure
Add sufficient coolant to raise the fluid to the specified Check the coolant level to determine if it is below the mark on the coolant reservoir. LOW mark on the coolant reservoir. SSANGYONG Y200...
Page 441: System Leakage Test
6. The thermostat should begin to open at 82 °C (180 °F) and it should be fully be fully open at 95 °C (203 °F). If it does not open at these temperatures, replace the thermostat. SSANGYONG Y200...
Page 442: Repair Instructions
Collect coolant by using proper container. 4. After complete draining of the coolant, remove the hose connector to drain plug and reinstall the drain plug. YAD1D080 Installation Notice Tightening Torque 30 N•m (22 lb-ft) 5. Tighten the radiator lower drain cock. SSANGYONG Y200...
Page 443 Notice: For the risk of scalding, the cap must not be opened unless the coolant temperature is below 90 °C (194 ° F). YAD1D100 2. Open the drain plug and drain the coolant. Notice: Collect the coolant by using a proper container. YAD1D070 SSANGYONG Y200...
Page 444 Notice: Match the anti-freeze and the water ratio to 50 : 50. YAD1D110 7. Warm up (until thermostat is opened) the engine and recheck the coolant level in the reservoir tank and fill up the coolant if necessary. SSANGYONG Y200...
Page 445: Coolant Connection Fitting (M162 Engine)
Preceding Work : Removal of cooling fan shroud YAD1D120 1 Bolt (M8 X 100, 2 pieces)..22.5 - 27.5 N•m 4 O-ring (16.6 - 20.3 lb-ft) 5 Hose Mounting Clamp 2 Engine Hanger Bracket 6 Hose 3 Coolant Outlet Port SSANGYONG Y200...
Page 446 Tightening Torque (16.6 - 20.3 lb-ft) Replace the O-ring with new one. YAD1D130 4. Installation should follow the removal procedure in the reverse order. 5. Fill up the coolant as specified. 6. Check the leaks in the cooling system. SSANGYONG Y200...
Page 447: Water Pump (M162 Engine)
4 Bolt......9 - 11 N•m (80 - 97 lb-in) 11 Bolt ....22.5 - 27.5 N•m (16.6 - 20.3 lb-ft) 5 Coolant Hose 12 Dowel Sleeve 6 Coolant Hose 13 Seal ............Replace 7 Outlet Coolant Hose SSANGYONG Y200...
Page 448 Installation Notice 22.5 - 27.5 N•m Tightening Torque (16.6 - 20.3 lb-ft) Replace the seal (13). YAD1D160 6. Installation should follow the removal procedure in the reverse order. 7. Fill up coolant. 8. Do coolant system leakage test. SSANGYONG Y200...
Page 449: Water Pump (M161 Engine)
8 Coolant Inlet Hose ........9 - 11 N•m (80 - 97 lb-in) 9 Heater Hose 4 Bolt (M6 X 85, 2 pieces) 10 Coolant Bypass Hose ...... 22.5 - 27.5 N•m (16.6 - 20.3 lb-ft) 11 Gasket SSANGYONG Y200...
Page 450 Notice: Apply the sealant when the sealing surface of water pump housing and coolant mounting area YAD1D190 is clean. 8. Installation should follow the removal procedure in the reverse order. 9. Check for leaks by starting the engine. SSANGYONG Y200...
Page 451: Water Pump (Diesel Engine)
Removal of V-belt YAD1D200 1 Tensioning Lever 4 Water Pump Pulley 2 Gasket ........... Replace 5 Bolt ......9 - 11 N•m (80 - 97 lb-in) 3 Bolt......9 - 11 N•m (80 - 97 lb-in) 6 Water Pump SSANGYONG Y200...
Page 452 3. Pull the tensioning lever (1) to the arrow direction. 4. Remove the water pump (6). Notice: Clean gasket residues on the sealing surface of water pump and replace the gasket. 5. Installation should follow the removal procedure in the reverse order. YAD1D220 SSANGYONG Y200...
Page 453: Oil Cooler Pipe Line (M162 Engine)
Tightening Torque (80 - 97 lb-in) Replace the O-ring with new one. 3. Installation should follow the removal procedure in the reverse order. 4. Fill up the coolant as specified. 5. Check the leaks in the cooling system. SSANGYONG Y200...
Page 454: Thermostat (M162 Engine)
Installation Notice 9 - 11 N•m Tightening Torque (80 - 97 lb-in) Do not separate the thermostat cover and thermostat. 4. Replace the O-ring if necessary. 5. Check the leakage in the cooling system. SSANGYONG Y200...
Page 455: Thermostat And Thermostat Housing Assembly (M161 Engine)
...... 22.5 - 27.5 N•m (16.6 - 20.3 lb-ft) 7 Tensioning Device Shock Absorber c Bolt (M8 X 35, 1 piece) 8 Engine Hanger Bracket ...... 22.5 - 27.5 N•m (16.6 - 20.3 lb-ft) 9 Thermostat Housing Assembly SSANGYONG Y200...
Page 456 (80 - 97 lb-in) Torque 22.5 - 27.5 N•m (16.6 - 20.3 lb-ft) 8. Replace the O-ring with new one. 9. Installation should follow the removal procedure in the reverse order. 10. Check for leaks in cooling system. SSANGYONG Y200...
Page 457: Thermostat And Water Pump Housing (Diesel Engine)
2 Water Pump Housing 7 Coolant Hose 3 Connector 8 Coolant Temperature Guage 4 Bolt......9 - 11 N•m (80 - 97 lb-in) 9 Thermostat Housing Cover 5 Thermostat Notice: The bolt on the arrow should be installed last. SSANGYONG Y200...
Page 458 Tightening Torque (80 - 97 lb-in) Clean gasket residues on the sealing surface of water pump and replace the gasket. 7. Remove he water pump housing (2). 8. Installation should follow the removal procedure in the reverse order. YAD1D300 SSANGYONG Y200...
Page 459: Cooling Fan And Viscous Clutch (M162 Engine)
4 Bolt (M6 X 12, 4 pieces) 2 Viscous Clutch ........9 - 11 N•m (80 - 97 lb-in) 3 Cooling Fan 5 Bolt (M10 X 45, 1 piece) ...... 40.5 - 49.5 N•m (29.8 - 36.5 lb-ft) SSANGYONG Y200...
Page 460 Be sure to make the viscous clutch stand on the ground not to flow silicone oil into another chamber in the viscous clutch. Do not lay down the clutch. 6. Installation should follow the removal procedure YAD1D330 in the reverse order. SSANGYONG Y200...
Page 461: Cooling Fan And Viscous Clutch (M161 Engine)
YAD1D340 1 Bolt (M6 X 14, 3 piece) 3 Viscous Clutch ........9 - 11 N•m (80 - 97 lb-in) 4 Union Nut (Left Threaded Screw) 2 Cooling Fan ...... 40.5 - 49.5 N•m (29.8 - 36.5 lb-ft) SSANGYONG Y200...
Page 462 Installation Notice 9 - 11 N•m Tightening Torque (80 - 97 lb-in) You may change the procedure (2) and (3) if necessary. 4. Installation should follow the removal procedure in the reverse order. SSANGYONG Y200...
Page 463: Cooling Fan And Viscous Clutch (Diesel Engine) . 1D-29
COOLING FAN AND VISCOUS CLUTCH (DIESEL ENGINE) YAD1D380 1 Cooling Fan Pulley 4 Bolt....40.5 - 49.5 N•m (29.8 - 36.5 lb-ft) 2 Viscous Clutch 5 Bolt......9 - 11 N•m (80 - 97 lb-in) 3 Cooling Fan SSANGYONG Y200...
Page 464 2. Remove the socket bolt (5) and then remove the cooling fan (3) and viscous clutch (2). Installation Notice 9 - 11 N•m Tightening Torque (80 - 97 lb-in) Keep the viscous clutch vertically. 3. Installation should follow the removal procedure in the reverse order. YAD1D400 SSANGYONG Y200...
Page 465: Cooling Fan Shroud (Gasoline Engine)
ENGINE COOLING 1D-31 COOLING FAN SHROUD (GASOLINE ENGINE) YAD1D410 2 Bolt........ 3 - 7 N•m (27 - 62 lb-in) 1 Fan Shroud Assembly SSANGYONG Y200...
Page 466 3. Remove the bolts (3) and then remove the cooling fan shroud assembly (4). Installation Notice 3 - 7 N•m YAD1D420 Tightening Torque (27 - 62 lb-in) 4. Installation should follow the removal procedure in the reverse order. SSANGYONG Y200...
Page 467: Cooling Fan Shroud (Diesel Engine)
1. Remove the radiator deaeration hose and tube. 2. Remove the bolt (3) and then remove the cooling fan shroud (2). Installation Notice 3 - 7 N•m Tightening Torque (27 - 62 lb-in) 3. Installation should follow the removal procedure in the reverse order. YAD1D440 SSANGYONG Y200...
Page 468: Radiator (Gasoline Engine)
1D-34 ENGINE COOLING RADIATOR (GASOLINE ENGINE) Preceding Work : Removal of cooling fan shroud YAD1D510 1 Deaeration Hose 5 Lower Radiator Insulator 2 Radiator 6 Plate 3 Inlet Hose 7 Clip 4 Bolt 8 Upper Radiator Insulator SSANGYONG Y200...
Page 469 8. Remove the radiator 9. Check the radiator pin for crack, damage, leakage and bending and replace it if necessary. 10. Installation should follow the removal procedure in the reverse order. 11. Check for leakage in the cooling system. YAD1B080 SSANGYONG Y200...
Page 470: Radiator (Diesel Engine)
1 Radiator Inlet Hose 7 Radiator 2 Radiator Outlet Hose 8 Upper Insulator 3 Radiator Deaeration Tube & Hose 9 Coolant Thermo Switch 4 Clamp 10 Lower Insulator 5 Spring Clamp 11 Lower Radiator Mounting Plate 6 Clip 12 Clip SSANGYONG Y200...
Page 471 8. Remove the radiator. 9. Check the radiator pin for crack, damage, leakage and bending and replace it if necessary. 10. Installation should follow the removal procedure in the reverse order. 11. Check for leakage in the cooling system. YAD1B080 SSANGYONG Y200...
Page 472: Specifications
Resistance (at 20 °C ( 68° F)) Temperature K Ω ← 0.32 - 0.35 Resistance (at 80 ° C ( 176°F)) Sensor ← Anti-Freeze Type ALUTEC-P78 Agent Mixture of Water and Good Quality ← 50 : 50 Ethylene Glycol-Base Anti-Freeze SSANGYONG Y200...
Page 473: Fastener Tightening Specifications
80 - 97 Water Pump Mounting Bolt (M162 Engine) 22.5 - 27.5 16.6 - 20.3 Water Pump Pulley Bolt (Diesel Engine) 9 - 11 80 - 97 Water Pump Pulley Bolt (M161 Engine) 9 - 11 80 - 97 SSANGYONG Y200...
Page 474: Special Tools And Equipment
SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE 111 589 00 40 00 111 589 02 01 00 Holder Open End Wrench YAD1D350 YAD1D360 124 589 15 21 00 603 589 00 40 00 Leakage Tester Fan Clutch Holder YAD1D020 KAA1C2D0 SSANGYONG Y200...
Page 475 SECTION 1E ENGINE ELECTRICAL CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
Page 476: Description And Operation
30 seconds at the specified temperature, while meeting a minimum voltage requirement of 7.2 volts. This rating is a measure of cold cranking capacity. SSANGYONG Y200...
Page 477: Charging A Completely Discharged Battery (Off The Vehicle)
(AH) to restore the battery to a usable state. • If the charge current is still not measurable after using the charging time calculated by the above method, the battery should be replaced. SSANGYONG Y200...
Page 478: Generator
There is no test hole. refer to that component section of the service manual. The starting system circuit consists of the battery, the starter motor, the ignition switch, and all the related electrical wiring. All of these components are connected electrically. SSANGYONG Y200...
Page 479: Diagnostic Information And Procedure
Engine • Adjust the belt tension or Replace the belt. • Faulty wiring harness. • Repair the wiring harness. • Generator Voltage Regulator • Replace Generator Battery Over Charging Faulty • Voltage detecfing wiring faulty • Repair Wiring SSANGYONG Y200...
Page 480 Spark plug malfunction Replace spark plug or adjust Unstable Engine Idling clearance • • Ignition coil faulty Replace ignition coil • • Ignition timing faulty Resetting valve timing • • Enging Acceralation Malfunction Ignition timing faulty Resetting valve timing SSANGYONG Y200...
Page 481: Preheating System (Diesel Engine)
YAD1E030 • Temperature of glow plug The temperature of the glow plug reaches up to 900 °C (1,652 °F) after about 9 seconds and up to 1,050 °C (1,922 °F) after 30 seconds. YAD1E040 SSANGYONG Y200...
Page 482 One or several glow plugs are faulty one minute. Glow indicator comes on constantly. Faulty circuit of glow indicator Faulty control relay Preheating time until glow indicator goes off is too Faulty coolant temperature sensor short/long. Faulty control relay Short/Open circuit in wire. SSANGYONG Y200...
Page 483: Repair Instructions
2. Disconnect the plug connection. 3. Unscrew the bolts and take out the generator. Installation Notice 42 - 50 N•m Tightening Torque (31 - 37 lb-ft) 4. Installation should follow the removal procedure YAD1E090 in the reverse order. SSANGYONG Y200...
Page 484: Starter
(53 - 62 lb-in) 4. Unscrew the mounting bolts (3) of starter. Installation Notice 35 - 48 N•m Tightening Torque (26 - 35 lb-ft) 5. Remove the starter. 6. Installation should follow the removal procedure in the reverse order. YAD1E110 SSANGYONG Y200...
Page 485: Battery
2. Remove the nut from the battery clamp bolt that fasten the battery holddown bracket. Installation Notice Tightening Torque 15 N•m (11 lb-ft) 3. Remove the battery. YAD1E130 4. Installation should follow the removal procedure in the reverse order. SSANGYONG Y200...
Page 486: Spark Plug And Ignition Coil (Gasoline Engine)
T 1/1 : Cylinder 2 and 5 T 1/2 : Cylinder 3 and 4 T 1/3 : Cylinder 1 and 6 - M161 ENGINE T 1/1 : Cylinder 1 and 4 T 1/2 : Cylinder 2 and 3 YAD1E160 SSANGYONG Y200...
Page 487: Glow Plug (Diesel Engine)
2. Remove the nut (2). Installation Notice Tightening Torque 4 N•m (35 lb-in) YAD1E180 3. Remove the glow plug (4). Installation Notice Tightening Torque 20 N•m (15 lb-ft) 4. Installation should follow the removal procedure in the reverse order. YAD1E190 SSANGYONG Y200...
Page 488: Unit Repair
7 Pinion Gear Assembly 2 Starter Solenoid Assembly 8 Ring Set 3 Starter Housing 9 Field Frame Assembly 4 Shift Lever 10 Brush Holder Assembly 5 Armature Set 11 Contact End Frame Assembly 6 Armature 12 Starter Through – Bolts SSANGYONG Y200...
Page 489 Notice: Complete the testing in a minimum amount of time to prevent overheating and damaging the solenoid. (in 10 seconds) YAD1E230 • Inspect the pinion gear’s moving to the outside (2). • If the pinion gear does not move outside, replace the magnetic switch. YAD1E240 SSANGYONG Y200...
Page 490 YAD1E270 • Check the returning speed of pinion gear (2). If the returning speed is fast, the operation is normal. • Replace the solenoid if the operation is abnormal. YAD1E280 SSANGYONG Y200...
Page 491 Remove the contact end frame bolts (2). • Remove the frame with the spacer (3). YAD1E310 2. Remove the brush holder assembly. • Remove the starter motor terminal M nut (1). • Remove the brush holder assembly (2). YAD1E320 SSANGYONG Y200...
Page 492 • Remove the gasket (6). YAD1E350 Inspection / Measurement (After the Overhaul) 1. Ground test for armature coil. • Inspect the insulation between commutator and armature coil using the voltmeter. • Replace the armature assembly if necessary. YAD1E360 SSANGYONG Y200...
Page 493 (0.445 - 0.453 in) (0.275 - 0.285 in) YAD1E390 Inspection the Commutator Bar 1. Inspect the wear length using the dial indicator after placing the armature coil on the two “V” block. Application Standard (mm) Limit (mm) Wear 0.05 YAD1E400 SSANGYONG Y200...
Page 494 If the pinion gets damaged, inspect the wear and damage of the ring gear. 3. Front and rear bracket bushing Check the wear and damage of the bushing and YAD1E440 replace the front and rear bracket as needed. SSANGYONG Y200...
Page 495 For installing the lever to the starter housing, install it according to its proper direction. (The lever should be installed to the hole of the starter housing at one direction.) 2. Tighten nuts/bolts as specified torque. a. Starter M terminal nut b. Starter pass-through bolt YAD1E450 SSANGYONG Y200...
Page 496: Generator (Mando Type)
5 Generator Collar (Large) 14 Voltage Regulator / Brush Holder Assembly 6 Generator Front Bracket 15 Generator Rear Bracket 7 Front Bearing 16 Battery Positive Terminal Nut 8 Bearing Spot Plate 17 Through Bolt 9 Generator Collar (Small) SSANGYONG Y200...
Page 497 Remove the pulley (4). YAD1E490 4. Remove the front bracket, rotor and collar. • Remove the collar (large) (1). • Remove the rotor from the front bracket (2). • Remove the collar (small) from the rotor shaft (3). YAD1E500 SSANGYONG Y200...
Page 498 • Remove the rectifier / brush holder / regulator connections (1). • Remove the stator and rectifier connections (2). Notice: If the stator connections are welded, melt the lead. Avoid overheating as it can damage the diodes. YAD1E540 SSANGYONG Y200...
Page 499 Test the stator for an open circuit by using the ohmmeter (1). Replace the stator if necessary. YAD1E570 • Test the stator for open or ground circuit by using the ohmmeter (2). Replace the starter if necessary. YAD1E580 SSANGYONG Y200...
Page 500 (1). • Replace the heat sink if necessary (a). YAD1E610 5. Inspect the brush wear. • If the brush wear exceeds the specified valve (a), replace the brush. Application Standard Limit Brushes 18.5 (0.73) 13.5 (0.53) wear YAD1E620 SSANGYONG Y200...
Page 501 6 - 8N•m (53 - 71 Ib-in) (c). YAD1E650 • Tighten the generator pulley nut to 80 - 110 N•m (59 - 81 Ib-ft) (d). • Tighten the through-bolts to 4 - 6 N•m (35 - 53 Ib-in) YAD1E660 SSANGYONG Y200...
Page 502: Specifications
Primary Coil Resistance 0.3 - 0.9 Secondary Coil Resistance KΩ 6 - 8.5 Type WR8DC Spark Plug Clearance 0.8 - 0.9 Resistance KΩ/m High Tension Cable Glow Plug Type Used Voltage 11.5 Circuit Connection Parallel Preheating Time 60 - 90 SSANGYONG Y200...
Page 503: Fastener Tightening Specifications
Glow Plug Nut Ignition Cable Cover Bolt 9 - 11 80 - 97 Ignition Coil Bolt 9 - 11 80 - 97 Spark Plug 25 - 30 15 - 22 Starter Mounting Bolt 35 - 48 26 - 35 SSANGYONG Y200...
Page 504: Schematic And Routing Diagrams
1E-30 ENGINE ELECTRICAL SCHEMATIC AND ROUTING DIAGRAMS YAD1E680 SSANGYONG Y200...
Page 505: Starting And Charging System (Diesel Engine)
STARTING AND CHARGING SYSTEM (DIESEL ENGINE)
Page 506 1E-32 ENGINE ELECTRICAL YAD1E700 SSANGYONG Y200...
Page 507: Special Tools And Equipment
ENGINE ELECTRICAL 1E-33 SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE 120 589 02 09 00 Spark Plug Wrench YAD1E670 SSANGYONG Y200...
Page 508 SECTION 1F1 M162 ENGINE CONTROLS CAUTION: Disconnect the negative battery cabl e beforer emoving or i nstalling any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless other-wise noted.
Page 509 Fuel System Specification ....... 1F1-103 ECM Wiring Diagram Temperature vs Resistance ......1F1-103 (3.2L DOHC - MSE 3.63D) ....... 1F1-94 Special Tools and Equipment ......1F1-104 Specifications ..........1F1-101 Special Tools Table .........1F1-104 Engine Data Display Table ......1F1-101 SSANGYONG Y200...
Page 510: Engine And Ecm Problem Check Report
After warm-up Engine Temperature o Any temp. o Others o Starting o Just after starting (min.) o Idling o Racing o Driving Engine Operation o Constant speed o Acceleration o Deceleration o A/C switch ON/OFF o Other SSANGYONG Y200...
Page 511: Diagnostic Information And Procedure
Engine rpm output circuit short circuit to ground or open 1F1-33 Fuel pump relay short circuit to battery 1F1-33 Fuel pump relay short circuit to ground or open 1F1-41 Purge control valve short circuit to battery 1F1-41 Purge control valve short circuit to ground or open SSANGYONG Y200...
Page 512 Bank 1 system idle adaptation failure (below lean threshold) 1F1-73 Bank 1 system learning control failure (rich, low load) 1F1-73 Bank 1 system learning control failure (lean, low load) 1F1-73 Bank 1 system learning control failure (rich, high load) SSANGYONG Y200...
Page 513 Accelerator pedal position sensor 1 low voltage 1F1-59 Accelerator pedal position sensor 1 high voltage 1F1-59 Accelerator pedal position sensor 2 low voltage 1F1-59 Accelerator pedal position sensor 2 high voltage 1F1-59 Accelerator pedal position sensor 1 not plausible with pedal position sensor 2 SSANGYONG Y200...
Page 514 MSR setpoint fault between CPU 1 and CPU 2 1F1-81 Idle control setpoint fault between CPU 1 and CPU 2 1F1-81 A/D converteroverflow (CPU 2) 1F1-81 ROM f aul t (CPU 2) 1F1-81 RAM f aul t (CPU 2) 1F1-85 Cycle monitor fault (CPU 2) SSANGYONG Y200...
Page 515: Ignition System
The cylinder on the exhaust stroke requires very little of the available energy tofire the spark plug. The remaining energy is available to the spark plug in the cylinder on the compression stroke. YAD1F080 SSANGYONG Y200...
Page 516 M162 ENGINE CONTROLS 1F1-9 BLANK SSANGYONG Y200...
Page 517: Ignition Coil
Each EI system ignition coil provides the high voltage to two spark plugs simultaneously; T1/1: cylinder 2 and 5 T1/2: cylinder 3 and 4 T1/3: cylinder 1 and 6 The EI system ignition coil is not serviceable and must be replaced as an assembly. SSANGYONG Y200...
Page 518 This leaves there remainder of the high voltage to be used to fire the spark plug in the cylinder on its compression stroke. Since the CKP sensor is in a fixed position, timing adjustments are not possible or needed. SSANGYONG Y200...
Page 519: Crankshaft Position (Ckp) Sensor
The output of the sensor is a sinusoidal signal. Each tooth of the pick-up 60 - 2 wheel generates a positive half wave. The Engine Control Module (ECM) uses this sensor signal to generate timed ignition and injection pulses that it sends to the ignition coils and to the fuel injectors. SSANGYONG Y200...
Page 520 2. Measure the resistance between the coupling terminal pin No. 99 and No. 100 using a multimeter. 1,050 ~ 1,400 Ω Specified Value Notice: Measure the insulator resistance of the CKP sensor if out of the specified value. SSANGYONG Y200...
Page 521 2. Measure the resistance between the coupling terminal pin No. 100 and No. 69 using a multimeter. Specified Value >20 kΩ Notice: Measure the check and ground terminal of the CKP sensor if out of the specified value. SSANGYONG Y200...
Page 522 M162 ENGINE CONTROLS 1F1-15 BLANK SSANGYONG Y200...
Page 523: Camshaft Position (Cmp) Sensor
“synchronized pulse” to trigger the injectors in the proper sequence. The ECM uses the CMP signal to indicate the position of the #1 piston during its power stroke. This allows the ECM to calculate true sequential fuel injection mode of operation. SSANGYONG Y200...
Page 524 1. Measure the voltage between the ECM terminal No. 11 and No. 106 while the engine speed is at idle. Specified Value 1.2 ~ 1.7 v Notice: The signal voltage will be changed in the range of 1.2 ~ 1.7 v. SSANGYONG Y200...
Page 525 2. Measure the voltage between the No. 1and No. 3 pin of the CMP sensor connector while the ignition switch is in “ON” position. Specified Value 11 ~ 14 v Notice: If the measured value is not within the specified value, check the cable. SSANGYONG Y200...
Page 526 M162 ENGINE CONTROLS 1F1-19 BLANK SSANGYONG Y200...
Page 527: Camshaft Actuator
Idle speed is improved 0 ~ 1,500 rpm Retard Blow-by gas is decreased Valve overlap is decreased Torque is increased 1,500 ~ 4,300 rpm Advanced Fuel loss is decreased NOx is decreased Above 4,300 rpm Retard Engine overrun is prohibited SSANGYONG Y200...
Page 528 2. Increase the engine rpm up to 2000 rpm 3. Measure the current between the No. 1 and No. 2 pin of the camshaft actuator connector. Specified Value 1 ~1.5 A Notice: If the measured value is not within the specified value, check the cable. SSANGYONG Y200...
Page 529: Knock Sensor (Ks)
The sensors produce an output voltage which increases with the severity of the knock. This signal is sent to the Engine Control Module (ECM) via a shielded cable. The ECM then adjusts the ignition timing to reduce the spark knock. SSANGYONG Y200...
Page 530 No. 114 using a multimeter. Specified Value >10 MΩ Notice: Replace the KS if the measured values is out of the specified values. Check the connector and wire connection between ECM and the KS if the measured values are normal. SSANGYONG Y200...
Page 531: Spark Plug
1F1-24 M162 ENGINE CONTROLS SPARK PLUG YAD1F200 1 Ignition Coil Cable Cover T 1/1 Ignition Coil Cylinder 2 and 5 2 Bolt T 1/2 Ignition Coil Cylinder 3 and 4 3 Spark Plug T 1/3 Ignition Coil Cylinder 1 and 6 SSANGYONG Y200...
Page 532 The ECM monitors the crankshaft and camshaft positions to detect if the engine is misfiring. The ECM looks for a quick drop in crankshaft speed. Misfire multiple cylinder is monitored by engine roughness measuring. The actual roughness value is compared with the actual (emission and catalyst damage) threshold. SSANGYONG Y200...
Page 533 2. Disconnect the spark plug cables Refer to Section 1E1, Engine electrical. 3. Measure the spark plug resistance using a multimeter. Specified Value 1.8 ~ 2.2 kΩ Notice: Replace the spark plug cable if the measured values is out of the specified values. SSANGYONG Y200...
Page 534 M162 ENGINE CONTROLS 1F1-27 BLANK SSANGYONG Y200...
Page 535: System Voltage
2,000 rpm below, or less than (ECM) pin 12, 11, 10, 5 about short 10 volts in 2,000 rpm above. circuit or open with bad contact • Inspection the over voltage protection relay • Inspection the battery • Inspection ECM SSANGYONG Y200...
Page 536: Ignition Switch
IGNITION SWITCH YAD1F230 Failure Description Trouble Area Maintenance Hint Code • Starter signal When not detection of starter Inspection the Engine Control Module recognition failure signal (ECM) pin 2 circuit short or open with bad contact • Inspection ECM SSANGYONG Y200...
Page 537: Fuel System
Also, the fuel is not delivered if there are no reference -36 ° C (-33 ° F) coolant temperature to 14.7 to 1 at pulses received from the CKP sensor. This prevents 94 ° C (201 ° F) coolant temperature. The ECM controls flooding. SSANGYONG Y200...
Page 538 M162 ENGINE CONTROLS 1F1-31 BLANK SSANGYONG Y200...
Page 539: Fuel Pump
12 V Ambient Temperature -30 ~ +70 ° C Minimum Amount of Fuel 114 Liter/Hr (12 V, 3.8 bar, Maximum Amount of Fuel 165 Liter/Hr (12V, 3.8 bar, Supply -30 ~ +70 °C) Supply -30 ~ +70 °C) SSANGYONG Y200...
Page 540 If there are no reference pulses, the ECM will shut off the fuel pump within 2 seconds after the ignition switch is turned ON, engine stopped or engine stalled. Fuel Pump Relay Inspection Measure the voltage between the ECM terminal No. 33 and ground. Ignition Switch : ON 0 V (for1 ~ 2 sec.) Cranking SSANGYONG Y200...
Page 541 2. Using a multimeter, measure the current consumption by connecting the terminal No. 30 and No. 87 of the fuel pump relay connector. Specified Value 5 ~9 A Notice: Replace the fuel pump relay if the measured value is over 9 A. SSANGYONG Y200...
Page 542 M162 ENGINE CONTROLS 1F1-35 BLANK SSANGYONG Y200...
Page 543: Fuel Injector
A fuel injector which is stuck partially open would cause a loss of fuel pressure after the engineis shut down. Also, an extended crank time would be noticed on some engines. Dieseling could also occur because some fuel could be delivered to the engine after the ignition is turned off. SSANGYONG Y200...
Page 544 Inspection the ECM • Inspection the power to injector #3 or No. 3 injector short When malfunction of injector bad contact circuit to battery circuit • Inspection the injector Injector #3 short circuit to power • Inspection the ECM SSANGYONG Y200...
Page 545 Inspection the ECM pin 64 about short No. 6 injector short When malfunction of injector circuit or open with bad contact circuit to ground or circuit open • Inspection the injector Injector #6 short circuit to • ground or open Inspection the ECM SSANGYONG Y200...
Page 546 1. Turn the ignition switch OFF. 2. Install the scan tool. 3. Turn the ignition switch ON. 4. Monitor the “INJECTION TIME” with a scan tool. Cranking 8.0 ms Engine Idle 3 ~5 ms Wide Open Throttle (WOT) 14 ms SSANGYONG Y200...
Page 547: Purge Control Valve
The purge control valve is activated by the ECM for the following conditions: • Coolant temperature of over 80 °C • Engine speed of over 1,000 rpm • 2 minutes after starting • When the fuel cut-off mode is not activated SSANGYONG Y200...
Page 548 4. Remove the line to canister and measure the pressure with the vacuum pressure gauge. > 500 mbar (after approx. 1 min.) Specified Value purge control valve operates at this time Notice: Test while at normal temperature and at idling state by operating the engine. SSANGYONG Y200...
Page 549: Fuel Rail
1F1-42 M162 ENGINE CONTROLS FUEL RAIL YAD1F320 1 Injector Connector 5 Fuel Return Line 2 Injector 6 Bolt 3 Fuel Rail 7 Vacuum Hose 4 Fuel Supply Line 8 O-Ring SSANGYONG Y200...
Page 550 O-ring • Fuel pressure Faulty check valve in YAD1F340 drops rapidly the fuel pump 3. If there is no change in fuel pressure and maintain the following pressure over 30 minutes, it is normal. Fuel pressure (bar) SSANGYONG Y200...
Page 551: Fuel Pressure Regulator
At this moment, the valve (3) sticks to 5 Diaphragm the diaphragm by the fuel pressure, and the fuel return 6 Compression Spring line (2) opens. The fuel over supplied returns to the 8 Fuel Chamber fuel tank through the return line. 9 Spring Chamber SSANGYONG Y200...
Page 552 Thus, the fuel injection volume can only be determined according to the injector’s injecting duration. The pressure difference between the fuel pressure and the intake manifold is approx. 3.2 bars during idling. SSANGYONG Y200...
Page 553: Induction System
When this is done, the throttle valve can be closed further by the servo motor overcoming the force of the • Data transfer through CAN spring capsule (mechanical end stop). If the actuator is deenergized, the throttle valve is resting against the spring capsule. SSANGYONG Y200...
Page 554 When supply voltage of the actuator short circuit to power Inspection the ECM Different mass air flow When shut down of output sensor signal with driver throttle position sensor Both throttle position When defective of both sensor failure potentiometers SSANGYONG Y200...
Page 555 Status (Coolant temperature Idling is over 70 °C) Throttle Actuator DC Motor Resistance 1. Turn the ignition switch to “OFF” position. 2. Measure the resistance between the ECM pin No. 67 and No. 68. <10 Ω Specified Value SSANGYONG Y200...
Page 556 M162 ENGINE CONTROLS 1F1-49 BLANK SSANGYONG Y200...
Page 557: Hot Film Air Mass (Hfm) Sensor
MAF. This concept automatically compensates for variations in air density, as this is one of the factors that determines the amount of warmth that the surrounding air absorbs from the heated element. MAF sensor is located between the air filter and the throttle valve. SSANGYONG Y200...
Page 558 R min.(Ω Ω Ω Ω Ω ) R nom. (Ω Ω Ω Ω Ω ) R max. (Ω Ω Ω Ω Ω ) Temp. (°C) 35140 39260 43760 12660 13850 15120 5119 5499 5829 2290 2420 2551 1096 1166 1238 SSANGYONG Y200...
Page 559 When the air is cold, the resistance is high; therefore the IAT signal voltage will be high. If the intake air is warm, resistance is low; therefore the IAT signal voltage will be low. SSANGYONG Y200...
Page 560 4. Measure the voltage between the ECM pin No. 105 and MAF sensor connecter terminal No. 2. Specified Value 11 ~ 14 V Notice: If the measured value is not within the specified value, the possible cause may be in cable or Over Voltage Protection Relay (OVPR). SSANGYONG Y200...
Page 561: Engine Coolant Temperature (Ect) Sensor
The ECM uses information about coolant temperature to make the necessary calculations for: • Fuel delivery • Ignition control • Knock sensor system • Idle speed • Torque converter clutch application • Canister purge • Cooling fan operation • Others SSANGYONG Y200...
Page 562 Resistance (Ω Ω Ω Ω Ω ) Temperature (°C) Voltage (V) 48,550 4.90 27,000 4.82 15,570 4.70 9,450 4.52 5,890 4.43 3,790 3.96 2,500 3.57 1,692 3.14 1,170 2.70 YAD1F460 2.26 1.86 1.51 1.22 0.98 0.78 0.63 111.6 0.50 0.40 71.2 0.33 SSANGYONG Y200...
Page 563 Engine Coolant Temperature Sensor Inspection 1. Turn the ignition switch to “ON” position. 2. Measure the voltage between the ECM pin No. 78 and No. 79. Temperature (°C) Specified Value (V) 3.57 1.22 0.78 SSANGYONG Y200...
Page 564 6. Measure the resistance between the ECT sensor terminal pin No. 1 and No. 4. Specified Value (Ω Ω Ω Ω Ω ) Temperature (°C) 2,500 Notice: Replace wiring and coolant temperature sensor if out of specified value. SSANGYONG Y200...
Page 565: Accelerator Pedal Module
10° ~ 20° and engine rpm will be controlled by ECM with opening (On/Off) time of injector. The engine rpm will be maintaining 900 rpm (at idle) to 1,800 according to the engine load. SSANGYONG Y200...
Page 566 Accelerator pedal When difference between APP position sensor 1 not 1 sensor and APP 2 sensor plausible with accelerator pedal position sensor 2 Both setpoint When defective of both APP accelerator pedal sensor position sensor defective SSANGYONG Y200...
Page 567 Specified Value (V) Closed Throttle Valve 0.1 ~ 0.4 Fully Depressed Throttle Valve 2.1 ~ 2.5 Notice: If measured value is not within the specified value, check the pedal valve sensor and the supply voltage to APP sensor 2. SSANGYONG Y200...
Page 568: Clutch Switch
Failure Description Trouble Area Maintenance Hint Code • Clutch switch defective When malfunction of clutch Inspection the Engine Control Module switch (ECM) pin 43 about shout circuit or open • Inspection the clutch switch • Inspection the ECM SSANGYONG Y200...
Page 569: Cooling Fan
When the ECM is commanding the control circuit should be high (near battery voltage). If the fault detection circuit senses a voltage other than what is expected, the fault line status will change causing the fault code to set. SSANGYONG Y200...
Page 570: A/C Compressor Relay
When the ECM detects that A/C has been requested, the ECM will activated the A/C clutch relay. When the relay has been activated, voltage should be present at both the A/C clutch relay and A/C switch circuit at ECM. SSANGYONG Y200...
Page 571: Cruise Control Switch
Implausible condition of deceleration signal Circuit Description Cruise control is an automatic speed control system that maintain a desired driving speed without using the accelerator pedal. The vehicle speed must be greater than 40 km/h to engage cruise control. SSANGYONG Y200...
Page 572: Traction Control System (Tcs)
Battery voltage is supplied to the TCS warning lamp with the ignition in ON and START. The warning lamp can be activated only by the Electrical Brake Control Module (EBCM) internally supplying ground to terminal 21. If the TCS input circuit is open or short, this failure code will be set. SSANGYONG Y200...
Page 573: Resonance Flap
Resonance flap is open at full load (over 3,800/rpm). The switch valve will not be adjusted by ECM and resonance flap will be open. The collected air in the air collection housing will not be divided and intake air passage will be shorten. SSANGYONG Y200...
Page 574: Stop Lamp Switch
The stop lamp switch is normally opened. When the ignition switch ON and brake ON, the battery voltage is supplied to the ECM. A scan tool should display ON when brake pedal is depressed and should read OFF with brake pedal released. SSANGYONG Y200...
Page 575: Engine Rpm
• Monitoring the actual rpm in cluster Engine rpm output When short circuit to ground • Inspection the Engine Control Module circuit short circuit to or open (ECM) pin 60 about short circuit or open ground or open SSANGYONG Y200...
Page 576: Exhaust System
CO + O The catalytic converter contains a catalyst, a word → CO coming from the Greek and which designates the HC + O element essential for catalyst which triggers chemical → N reactions without itself being consumed. SSANGYONG Y200...
Page 577: Oxygen Sensor
The atmosphere contains about 21% oxygen. The exhaust from a rich air/fuel ratio contains almost no oxygen. With a large difference between the amounts of oxygen containing the two surface, the sensor generates less voltage. YAD1F580 SSANGYONG Y200...
Page 578 M162 ENGINE CONTROLS 1F1-71 YAD1F590 SSANGYONG Y200...
Page 579 2 A) • Inspection the heating circuit of oxygen Oxygen sensor heater When recognition the heating sensor short circuit to ground voltages than less than set or open values (less than 2v) • Inspection the ECM SSANGYONG Y200...
Page 580 This clean air reference is obtained by way of the oxygen sensor wire(s). Any attempt to repair the wires, connector, or terminal and degrade the oxygen sensor performance. SSANGYONG Y200...
Page 581 2. Measure the oxygen sensor heating current consumption between the ECM terminal No. 9 and No. 5. Specified Value 0.2 ~ 2.0 A Notice: If the measured value is not within the specified value, the possible cause may be in cable, oxygen sensor or ECM SSANGYONG Y200...
Page 582 M162 ENGINE CONTROLS 1F1-75 BLANK SSANGYONG Y200...
Page 583: Engine Control Module
10 Mohm input impedance to get accurate voltage readings. The ECM controls output circuits such as the ignition coils, the fuel injectors, the fuel pump relay, the intake manifold resonance flap, the camshaft actuator, the canister purge valve, etc., by controlling the ground circuit. SSANGYONG Y200...
Page 584: Serial Data Communication
Inspection the TCM unit with CAN failure: TCU (A/T only) missing or implausibility for connection TCU unit or not initialized • Inspection the ECM pin 38, 37 about condition short circuit or open with bad contact • Inspection the ECM SSANGYONG Y200...
Page 585 The message carried on KWP 2000 data streams are also prioritized. If two messages attempt to establish communications on the data line at the same time, only the message with higher priority will must wait. SSANGYONG Y200...
Page 586: Internal Failure
ECM encoding • ECM failure (EPROM) When malfunction of ECM Inspection the ECM internal ECM failure (EEPROM/ Flash - EPPOM checksum failure) ECM failure (coding ID checksum failure) ECM failure (coding checksum failure) ECM failure (programming checksum failure) SSANGYONG Y200...
Page 587 (CPU 2) Cruise control lever dual operation (CPU 2) Cruise control lever safety terminal failure (CPU 2) Unusual pedal position variation (CPU 2) Unusual throttle position variation (CPU 2) Unusual throttle controller monitoring data comparison fault (CPU 2) SSANGYONG Y200...
Page 588 1 and CPU 2 MSR setpoint fault between CPU 1 and CPU 2 Idle control setpoint fault between CPU 1 and CPU 2 A/D converter overflow (CPU 2) ROM fault (CPU 2) RAM fault (CPU 2) Cycle monitor fault (CPU 2) SSANGYONG Y200...
Page 589: Immobilizer
It means immobilizer system disables starting by stopping fuel supply if the code in the transponder does not match the code stored in ECM each other. SSANGYONG Y200...
Page 590: Maintenance And Repair
3. Put aside the floor carpet to remove the fuel pump access cover. 4. Remove the fuel pump access cover. 5. Remove the fuel pump wiring connectors. 6. Disconnect the fuel supply and return pipes. 7. Remove the fuel pump locking cap band. SSANGYONG Y200...
Page 591: Fuel Filter
5. Remove the fuel filter. 6. Install the fuel filter. 7. Perform a leak test of the fuel filter. 8. Installation should follow the removal procedure in the reverse order. SSANGYONG Y200...
Page 592: Fuel Tank
10. Disconnect the fuel filler hose and air vent hose from the fuel tank. 11. Support the fuel tank. 12. Remove the fuel tank retaining nuts. Installation Notice Tightening Torque 38 N•m (28 lb-ft) 13. Carefully lower the fuel tank. YAA1F160 SSANGYONG Y200...
Page 593: Fuel Pressure Regulator
6. Apply the oil to O-ring lightly and then replace it. 7. Perform a leak test of the fuel pressure regulator with the engine off and the ignition on. 8. Installation should follow the removal procedure in the reverse order. KAA1F130 SSANGYONG Y200...
Page 594 10. Remove the six injector connectors. KAA1F070 11. Remove the two left and two right bolts and one center bolt of the fuel rail assembly from the intake manifold. Installation Notice Tightening Torque 25 N•m (18 lb-ft) KAA1F080 SSANGYONG Y200...
Page 595: Engine Coolant Temperature Sensor
YAA1F150 4. Remove the engine coolant temperature sensor from the pump hosing. Installation Notice Tightening Torque 30 N•m (22 lb-ft) 5. Installation should follow the removal procedure in the reverse order. SSANGYONG Y200...
Page 596: Throttle Body (Integrated With The Actuator)
9. Remove the vacuum hose. KAA1F230 10. Remove the throttle body and discard the gasket. Important: Use care in cleaning old gasket material. Sharp tools may damage sealing surfaces. 11. Installation should follow the removal procedure in the reverse order. KAA1F240 SSANGYONG Y200...
Page 597: Hot Film Air Mass (Hfm) Sensor
3. Remove the knock sensor mounting bolt from the knock sensor installed on the cylinder block. Installation Notice Tightening Torque 25 N•m (18 lb-ft) KAA1F180 4. Remove the knock sensor. 5. Installation should follow the removal procedure in the reverse order. SSANGYONG Y200...
Page 598: Pedal Position Sensor
4. Coat the threads of the oxygen sensor with an anti- seize compound, if needed. 5. Installation should follow the removal procedure in the reverse order. SSANGYONG Y200...
Page 599: Purge Control Valve
CAMSHAFT POSITION SENSOR Removal and Installation Procedure 1. Disconnect the negative battery cable. 2. Disconnect the electrical connector from the camshaft position sensor. 3. Remove the camshaft position sensor retaining bolt. Installation Notice Tightening Torque 10 N•m (89 lb-ft) KAA1F170 SSANGYONG Y200...
Page 600: Crankshaft Position Sensor
Control Module (ECM) from the mounting bracket. Installation Notice Tightening Torque 25 N•m (18 lb-ft) KAA1F200 4. Pull out the ECM from the bracket. 5. Disconnect the vehicle side coupling. 6. Installation should follow the removal procedure in the reverse order. SSANGYONG Y200...
Page 601: 1F1-2 M162 Engine Controls
1F1-94 M162 ENGINE CONTROLS SCHEMATIC AND ROUTING DIAGRAMS YAD1F010 SSANGYONG Y200...
Page 602: Ecm Wiring Diagram
ECM WIRING DIAGRAM (3.2L DOHC - 2 OF 7) (MSE 3.63D)
Page 603 ECM WIRING DIAGRAM (3.2L DOHC - 3 OF 7) (MSE 3.63D)
Page 604 ECM WIRING DIAGRAM (3.2L DOHC - 4 OF 7) (MSE 3.63D)
Page 605 ECM WIRING DIAGRAM (3.2L DOHC - 5 OF 7) (MSE 3.63D)
Page 606 ECM WIRING DIAGRAM (3.2L DOHC - 6 OF 7) (MSE 3.63D)
Page 607 ECM WIRING DIAGRAM (3.2L DOHC - 7 OF 7) (MSE 3.63D)
Page 608: Specifications
1=ON/0=OFF Protect Mission 1=ON/0=OFF Purge Control Valve 1=ON/0=OFF Lambda Function 1=ON/0=OFF Catalyst Heating 1=ON/0=OFF Overrun Fuel Cut 1=ON/0=OFF Ful l Fuel Cut 1=ON/0=OFF Brake Switch 1=ON/0=OFF Cruise Control Status 1=ON/0=OFF *Condition : Warmed up, idle, P/N or neutral SSANGYONG Y200...
Page 609: Fastener Tightening Specifications
Fuel Pressure Test Connector Fuel Rail Assembly Bolts Fuel Return And Supply Lines Fuel Tank Retaining Nuts Intake Air Duct Mounting Bolts Knock Sensor Mounting Bolt Oxygen Sensor Pedal Position Censor Mounting Bolts And Nut Throttle Body Bolts SSANGYONG Y200...
Page 610: Fuel System Specification
TEMPERATURE VS RESISTANCE ECT sensor IAT sensor °C °F ohms (Ω) Temperature vs Resistance Values (Approximate) 111.6 1166 1166 1662 1662 2420 2420 3604 3604 5499 5499 8609 8609 13850 13850 22960 22960 39260 39260 SSANGYONG Y200...
Page 611: Special Tools And Equipment
1F1-104 M162 ENGINE CONTROLS SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE 661 589 00 46 00 103 589 00 21 00 Fuel Tank Cap Wrench Fuel Pressure Gauge YAA1F890 KAA1F490 SSANGYONG Y200...
Page 612 SECTION 1F2 M161 ENGINE CONTROLS CAUTION: Disconnect the negative battery cable before removi ng or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
Page 613 1F2-2 M161 ENGINE CONTROLS Specifications ..........1F2-103 Special Tools and Equipment ......1F2-106 Engine Data Display Table ......1F2-103 Special Tools Table .........1F2-106 Fastener Tightening Specifications ....1F2-104 Fuel System Specification ....... 1F2-105 Temperature vs Resistance ......1F2-105 SSANGYONG Y200...
Page 614: Engine And Ecm Problem Check Report
After warm-up Engine Temperature o Any temp. o Others o Starting o Just after starting (min.) o Idling o Racing o Driving Engine Operation o Constant speed o Acceleration o Deceleration o A/C switch ON/OFF o Other SSANGYONG Y200...
Page 615: Diagnostic Information And Procedure
Engine rpm output circuit short circuit to ground or open 1F2-33 Fuel pump relay short circuit to battery 1F2-33 Fuel pump relay short circuit to ground or open 1F2-41 Purge control valve short circuit to battery 1F2-41 Purge control valve short circuit to ground or open SSANGYONG Y200...
Page 616 Bank 1 system learning control failure (lean, low load) 1F1-73 Bank 1 system learning control failure (rich, high load) 1F1-73 Bank 1 system learning control failure (lean, high load) 1F1-47 Throttle position sensor 1 low voltage 1F1-47 Throttle position sensor 1 high voltage SSANGYONG Y200...
Page 617 Accelerator pedal position sensor 2 high voltage 1F1-59 Accelerator pedal position sensor 1 not plausible with pedal position sensor 2 1F1-59 Both setpoint accelerator pedal position sensor defective 1F1-48 Mass air flow sensor and throttle position sensor failure 1F1-82 ECU failure (incompatible CPU) SSANGYONG Y200...
Page 618 MSR setpoint fault between CPU 1 and CPU 2 1F1-83 Idle control setpoint fault between CPU 1 and CPU 2 1F1-83 A/D converteroverflow (CPU 2) 1F1-83 ROM f aul t (CPU 2) 1F1-83 RAM f aul t (CPU 2) 1F1-83 Cycle monitor fault (CPU 2) SSANGYONG Y200...
Page 619: Ignition System
Intake air temperature. cylinder coming up on the compression stroke and in • Crankshaft position. the cylinder coming up on the exhaust stroke. The cylinder on the exhaust stroke requires very little of • Engine speed (rpm). YAA1F910 SSANGYONG Y200...
Page 620 M161 ENGINE CONTROLS 1F2-9 BLANK SSANGYONG Y200...
Page 621: Ignition Coil
Each EI system ignition coil provides the high voltage to two spark plugs simultaneously; T1/1: cylinder 1 and 4 T1/2: cylinder 2 and 3 The EI system ignition coil is not serviceable and must be replaced as an assembly. SSANGYONG Y200...
Page 622 This leaves the remainder of the high voltage to be used to fire the spark plug in the cylinder on its compression stroke. Since the CKP sensor is in a fixed position, timing adjustments are not possible or needed. SSANGYONG Y200...
Page 623: Crankshaft Position (Ckp) Sensor
The output of the sensor is a sinusoidal signal. Each tooth of the pick-up 60-2 wheel generates a positive half wave. The Engine Control Module (ECM) uses this sensor signal to generate timed ignition and injection pulses that it sends to the ignition coils and to the fuel injectors. SSANGYONG Y200...
Page 624 2. Measure the resistance between the coupling terminal pin No. 99 and No. 100 using a multimeter. 1,050 ~ 1,400 Ω Specified Value Notice: Measure the insulator resistance of the CKP sensor if out of the specified value. SSANGYONG Y200...
Page 625 2. Measure the resistance between the coupling terminal pin No. 100 and No. 69 using a multimeter. Specified Value >20 kΩ Notice: Measure the check and ground terminal of the CKP sensor if out of the specified value. SSANGYONG Y200...
Page 626 M161 ENGINE CONTROLS 1F2-15 BLANK SSANGYONG Y200...
Page 627: Camshaft Position (Cmp) Sensor
“synchronized pulse” to trigger the injectors in the proper sequence. The ECM uses the CMP signal to indicate the position of the #1 piston during its power stroke. This allows the ECM to calculate true sequential fuel injection mode of operation. SSANGYONG Y200...
Page 628 1. Measure the voltage between the ECM terminal No. 11 and No. 106 while the engine speed is at idle. Specified Value 1.2 ~ 1.7 v Notice: The signal voltage will be changed in the range of 1.2 ~ 1.7 v. SSANGYONG Y200...
Page 629 2. Measure the resistance between the No. 1 and No. 3 pin of the CMP sensor connector while the ignition switch is in “ON” position. Specified Value 11 ~ 14 v Notice: If the measured value is not within the specified value, check the cable. SSANGYONG Y200...
Page 630 M161 ENGINE CONTROLS 1F2-19 BLANK SSANGYONG Y200...
Page 631: Camshaft Actuator
0 ~ 1,740 rpm Retard Idle speed is improved Blow-by gas is decreased Valve overlap is decreased 1,740 ~ 3,540 rpm Advanced Torque is increased Fuel loss is decreased NOx is decreased Above 3,540 rpm Retard Engine overrun is prohibited SSANGYONG Y200...
Page 632 2. Increase the engine rpm up to 2000 rpm 3. Measure the current between the No. 1 and No. 2 pin of the camshaft actuator connector. Specified Value 1 ~1.5 A Notice: If the measured value is not within the specified value, check the cable. SSANGYONG Y200...
Page 633: Knock Sensor (Ks)
The sensors produce an output voltage which increases with the severity of the knock. This signal is sent to the Engine Control Module (ECM) via a shielded cable. The ECM then adjusts the ignition timing to reduce the spark knock. SSANGYONG Y200...
Page 634 2. Measure the resistance between the coupling terminal pin No. 118 and No. 117 using a multimeter. Specified Value >10 MΩ Notice: Replace the KS if the measured values is out of the specified values. Check the connector and wire connection between ECM and the KS if the measured values are normal. SSANGYONG Y200...
Page 635: Spark Plug
SPARK PLUG YAA1F990 1 Screw 6 Bolts 2 Adaptor 7 Ignition Coil (T 1/1) 3 Ignition Coil Cable Cover 8 Coupling Plug 4 Spark Plug Connector 9 Spark Plug 5 Ignition Coil Connector 10 Ignition Coil (T 1/2) SSANGYONG Y200...
Page 636 The ECM monitors the crankshaft and camshaft positions to detect if the engine is misfiring. The ECM looks for a quick drop in crankshaft speed. Misfire multiple cylinder is monitored by engine roughness measuring. The actual roughness value is compared with the actual (emission and catalyst damage) threshold. SSANGYONG Y200...
Page 637 2. Disconnect the spark plug cables Refer to Section 1E1, Engine electrical. 3. Measure the spark plug resistance using a multimeter. Specified Value 1.8 ~ 2.2 kΩ Notice: Replace the spark plug cable if the measured values is out of the specified values. SSANGYONG Y200...
Page 638 M161 ENGINE CONTROLS 1F2-27 BLANK SSANGYONG Y200...
Page 639: System Voltage
2,000 rpm below, or less (ECM) pin 12, 11, 10, 5 about short than 10 volts in 2,000 rpm circuit or open with bad contact above. • Inspection the over voltage protection relay • Inspection the battery • Inspection ECM SSANGYONG Y200...
Page 640: Ignition Switch
YAD1F230 Failure Description Trouble Area Maintenance Hint Code • Starter signal recogni- When not detection of Inspection the Engine Control Module tion failure starter signal (ECM) pin 2 circuit short or open with bad contact • Inspection ECM SSANGYONG Y200...
Page 641: Fuel System
This ranges from1.5 to 1 at -36 °C pulses received from the CKP sensor. This prevents (-33 ° F) coolant temperature to 14.7 to 1 at 94 °C (201 flooding. ° F) coolant temperature. The ECM controls the amount SSANGYONG Y200...
Page 642 M161 ENGINE CONTROLS 1F2-31 BLANK SSANGYONG Y200...
Page 643: Fuel Pump
Ambient Temperature -30 ~ +70° C 165 Liter/ Hr Minimum Amount 114 Liter/ Hr Maximum Amount of Fuel of Fuel Supply (12 V, 3.8 bar, -30 ~ +70° C) Supply (12 V, 3.8 bar, -30 ~ +70° C) SSANGYONG Y200...
Page 644 If there are no reference pulses, the ECM will shut off the fuel pump within 2 seconds after the ignitions witch is turned ON, engine stopped or engine stalled. Fuel Pump Relay Inspection Measure the voltage between the ECM terminal No. 33 and ground. Ignition Switch : ON 0 V (for 1 ~ 2 sec.) Cranking SSANGYONG Y200...
Page 645 2. Using a multimeter, measure the current consumption by connecting the terminal No. 30 and No. 87 of the fuel pump relay connector. Specified Value 5 ~ 9 A Notice: Replace the fuel pump relay if the measured value is over 9 A. SSANGYONG Y200...
Page 646 M161 ENGINE CONTROLS 1F2-35 BLANK SSANGYONG Y200...
Page 647: Fuel Injector
A fuel injector which is stuck partially open would cause a loss of fuel pressure after the engine is shut down. Also, an extended crank time would be noticed on some engines. Dieseling could also occur because some fuel could be delivered to the engine after the ignition is turned off. SSANGYONG Y200...
Page 648 Inspection the ECM • No. 3 injector short When malfunction of injector Inspection the power to injector #3 or circuit to battery circuit bad contact • Injector #3 short circuit to Inspection the injector power • Inspection the ECM SSANGYONG Y200...
Page 649 When malfunction of injector Inspection the ECM pin 66 about short circuit to ground or circuit circuit or open with bad contact open • Injector #4 short circuit to Inspection the injector ground or open • Inspection the ECM SSANGYONG Y200...
Page 650 1. Turn the ignition switch OFF. 2. Install the scan tool. 3. Turn the ignition switch ON. 4. Monitor the “INJECTION TIME” with a scan tool. Cranking 8.0 ms Engine Idle 3 ~ 5 ms Wide Open Throttle 14 ms (WOT) SSANGYONG Y200...
Page 651: Purge Control Valve
The purge control valve is activated by the ECM for the following conditions: • Coolant temperature of over 80 °C • Engine speed of over 1,000 rpm • 2 minutes after starting • When the fuel cut-off mode is not activated SSANGYONG Y200...
Page 652 4. Remove the line to canister and measure the pressure with the vacuum pressure gauge. > 500 mbar (after approx. 1 min.) Specified Value purge control valve operates at this time Notice: Test while at normal temperature and at idling state by operating the engine. SSANGYONG Y200...
Page 653: Fuel Rail
2 Fuel Pressure Regulator 10 Bolt 3 Circlip 11 Clamp 4 Vacuum Hose 12 Fuel Return Line 5 O-Ring 13 Hollow Bolt 6 Injector 14 Seal Ring 7 Injector Bracket 15 Seal Ring 8 Fuel Rail 16 Fuel Pressure Test Connector SSANGYONG Y200...
Page 654 O-ring YAA1F0K0 • Fuel pressure Faulty check valve in drops rapidly the fuel pump 3. If there is no change in fuel pressure and maintain the following pressure over 30minutes, it is normal. Fuel pressure (bar) SSANGYONG Y200...
Page 655: Fuel Pressure Regulator
B. Valves Opened the diaphragm by the fuel pressure, and the fuel return 5. Diaphragm line (2) opens. The fuel over supplied returns to the 6. Compression Spring fuel tank through the return line. 8. Fuel Chamber 9. Spring Chamber SSANGYONG Y200...
Page 656 Thus, the fuel injection volume can only be determined according to the injector’s injecting duration. The pressure difference between the fuel pressure and the intake manifold is approx. 3.2 bars during idling. SSANGYONG Y200...
Page 657: Induction System
When this is done, the throttle valve can be closed further by the servo motor overcoming the force of the • Storing faults spring capsule (mechanical end stop). If the actuator • Data transfer through CAN is de-energized, the throttle valve is resting against SSANGYONG Y200...
Page 658 When supply voltage of the actuat or short circuit to power Different mass air flow When shut down of out put sensor signal with driver throttle position sensor Both throttle position When defective of both sensor failure potentiometers SSANGYONG Y200...
Page 659 Idling (Coolant temperature is over 70° C) Throttle Actuator DC Motor Resistance 1. Turn the ignition switch to “OFF” position. 2. Measure the resistance between the ECM pin No. 67 and No. 68. < 10 Ω Specified Value SSANGYONG Y200...
Page 660 M161 ENGINE CONTROLS 1F2-49 BLANK SSANGYONG Y200...
Page 661: Hot Film Air Mass (Hfm) Sensor
MAF. This concept automatically compensates for variations in air density, as this is one of the factors that determines the amount of warmth that the surrounding air absorbs from the heated element. MAF sensor is located between the air filter and the throttle valve. SSANGYONG Y200...
Page 662 R min.(Ω Ω Ω Ω Ω ) R nom. (Ω Ω Ω Ω Ω ) R max. (Ω Ω Ω Ω Ω ) Temp. (°C) 35140 39260 43760 12660 13850 15120 5119 5499 5829 2290 2420 2551 1096 1166 1238 SSANGYONG Y200...
Page 663 When the air is cold, the resistance is high; therefore the IAT signal voltage will be high. If the intake air is warm, resistance is low; therefore the IAT signal voltage will be low. SSANGYONG Y200...
Page 664 4. Measure the voltage between the ECM pin No. 105 and MAF sensor connecter terminal No. 2. Specified Value 11 ~ 14 V Notice: If the measured value is not within the specified value, the possible cause may be in cable or Over Voltage Protection Relay (OVPR). SSANGYONG Y200...
Page 665: Engine Coolant Temperature (Ect) Sensor
The ECM uses information about coolant temperature to make the necessary calculations for: • Fuel delivery • Ignition control • Knock sensor system • Idle speed • Torque converter clutch application • Canister purge • Cooling fan operation • Others SSANGYONG Y200...
Page 666 Resistance (Ω Ω Ω Ω Ω ) Temperature (°C) Voltage (V) 48,550 4.90 27,000 4.82 15,570 4.70 9,450 4.52 5,890 4.43 3,790 3.96 2,500 3.57 1,692 3.14 1,170 2.70 YAD1F460 2.26 1.86 1.51 1.22 0.98 0.78 0.63 111.6 0.50 0.40 71.2 0.33 SSANGYONG Y200...
Page 667 Engine Coolant Temperature Sensor Inspection 1. Turn the ignition switch to “ON” position. 2. Measure the voltage between the ECM pin No. 78 and No. 79. Temperature (°C) Specified Value (V) 3.57 1.22 0.78 SSANGYONG Y200...
Page 668 6. Measure the resistance between the ECT sensor terminal pin No. 1 and No. 4. Specified Value (Ω Ω Ω Ω Ω ) Temperature (°C) 2,500 Notice: Replace wiring and coolant temperature sensor if out of specified value. SSANGYONG Y200...
Page 669: Accelerator Pedal Module
10° ~ 20° and engine rpm will be controlled by ECM will opening (On/Off) time of injector. The engine rpm will be maintaining 900 rpm (at idle) to 1,800 according to the engine load. SSANGYONG Y200...
Page 670 As pushing the accelerator pedal, the output increases so that the output voltages will be about 4.3 ~ 4.8 volts and 2.1 ~ 2.4 volts individually when accelerating fully with the kick down, at Wide Open Throttle (WOT). SSANGYONG Y200...
Page 671 Specified Value (V) Valve Closed Throttle Valve 0.1 ~ 0.4 Fully Depressed Throttle 2.1 ~ 2.5 Valve Notice: If measured value is not within the specified value, check the pedal valve sensor and the supply voltage to APP sensor 2. SSANGYONG Y200...
Page 672 M161 ENGINE CONTROLS 1F2-61 BLANK SSANGYONG Y200...
Page 673: Cooling Fan
When the ECM is commanding the control circuit should be high (near battery voltage). If the fault detection circuit senses a voltage other than what is expected, the fault line status will change causing the fault code to set. SSANGYONG Y200...
Page 674: A/C Compressor Relay
When the ECM detects that A/C has been requested, the ECM will activated the A/C clutch relay. When the relay has been activated, voltage should be present at both the A/C clutch relay and A/C switch circuit at ECM. SSANGYONG Y200...
Page 675: Cruise Control Switch
Implausible condition of deceleration signal Circuit Description Cruise control is an automatic speed control system that maintain adesired driving speed with out using the accelerator pedal. The vehicle speed must be greater than 40 km/h to engage cruise control. SSANGYONG Y200...
Page 676: Traction Control System (Tcs)
Battery voltage is supplied to the TCS warning lamp with the ignition in ON and START. The warning lamp can be activated only by the Electrical Brake Control Module (EBCM) internally supplying ground to terminal 21. If the TCS input circuit is open or short, this failure code will be set. SSANGYONG Y200...
Page 677: Stop Lamp Switch
The stop lamp switch is normally opened. When the ignition switch ON and brake ON, the battery voltage is supplied to the ECM. A scan tool should display ON when brake pedal is depressed and should read OFF with brake pedal released. SSANGYONG Y200...
Page 678: Engine Rpm
Inspection the Engine Control Module battery (ECM) pin 60 about short circuit or open Engine rpm output When short circuit to ground • Inspection the cluster panel board circuit circuit short circuit to or open • Inspection the ECM ground or open SSANGYONG Y200...
Page 679: Exhaust System
→ CO CO + O The catalytic converter contains acatalyst, a word → CO coming from the Greek and which designates the HC + O element essential for catalyst which triggers chemical → N reactions without itself being consumed. SSANGYONG Y200...
Page 680 M161 ENGINE CONTROLS 1F2-69 BLANK SSANGYONG Y200...
Page 681: Oxygen Sensor
The atmosphere contains about 21% oxygen. The exhaust from a rich air/fuel ratio contains almost no oxygen. With a large difference betweenthe amounts of oxygen containing the two surface, the sensor generates less voltage. YAD1F580 SSANGYONG Y200...
Page 682 M161 ENGINE CONTROLS 1F2-71 YAD1F590 SSANGYONG Y200...
Page 683 2 A) • Inspection the heating circuit of oxygen When recognition the heating Oxygen sensor heater sensor short circuit to ground voltages than less than set values (less than 2 v) • or open Inspection the ECM SSANGYONG Y200...
Page 684 Bank 1 system learning When recognition the long control failure term fuel trim exceeds rich (rich, high load) threshold Bank 1 system learning When recognition the long control failure term fuel trim exceeds lean (rich, low load) threshold SSANGYONG Y200...
Page 685 2. Measure the oxygen sensor heating current consumption between the ECM terminal No. 9 and No. 5. Specified Value 0.2 ~ 2.0 V Notice: If the measured value is not within the specified value, the possible cause may be in cable, oxygen sensor or ECM SSANGYONG Y200...
Page 686 M161 ENGINE CONTROLS 1F2-75 BLANK SSANGYONG Y200...
Page 687: Engine Control Module
10 Mohm input impedance to get accurate voltage readings. The ECM controls output circuits such as the ignition coils, the fuel injectors, the fuel pump relay, the camshaft actuator, the canister purge valve, etc., by controlling the ground circuit. SSANGYONG Y200...
Page 688 M161 ENGINE CONTROLS 1F2-77 BLANK SSANGYONG Y200...
Page 689: Serial Data Communication
Inspection the TCM unit with CAN failure: TCU (A/T only) missing or implausibility for connection TCU unit or not initialized • Inspection the ECM pin 38, 37 about condition short circuit or open with bad contact • Inspection the ECM SSANGYONG Y200...
Page 690 The message carried on KWP 2000 data streams are also prioritized. If two messages attempt to establish communications on the data line at the same time, only the message with higher priority will must wait. SSANGYONG Y200...
Page 691: Internal Failure
ECM encoding When malfunction of ECM • ECM failure (EPROM) Inspection the ECM internal ECM failure (EEPROM/ Flash-EPPOM checksum failure) ECM failure (coding ID checksum failure) ECM failure (coding checksum failure) ECM failure (program- ming checksum failure) SSANGYONG Y200...
Page 692 M161 ENGINE CONTROLS 1F2-81 BLANK SSANGYONG Y200...
Page 693: Electronic Throttle Controller Safety Malfunction
(CPU 2) Cruise control lever dual operation (CPU 2) Cruise control lever safety terminal failure (CPU 2) Unusual pedal position variation (CPU 2) Unusual throttle position variation (CPU 2) Unusual throttle controller monitoring data comparison fault (CPU 2) SSANGYONG Y200...
Page 694 CPU 1 and CPU 2 MSR setpoint fault between CPU 1 and CPU 2 Idle control setpoint fault between CPU 1 and CPU 2 A/D converter overflow (CPU 2) ROM fault (CPU 2) RAM fault (CPU 2) Cycle monitor fault (CPU 2) SSANGYONG Y200...
Page 695: Immobilizer
It means immobilizer system disables starting by stopping fuel supply if the code in the transponder does not match the code stored in ECM each other. SSANGYONG Y200...
Page 696: Maintenance And Repair
3. Put aside the floor carpet to remove the fuel pump access cover. 4. Remove the fuel pump access cover. 5. Remove the fuel pump wiring connectors. 6. Disconnect the fuel supply and return pipes. 7. Remove the fuel pump locking cap band. SSANGYONG Y200...
Page 697: Fuel Filter
5. Remove the fuel filter. 6. Install the fuel filter. 7. Perform a leak test of the fuel filter. 8. Installation should follow the removal procedure in the reverse order. SSANGYONG Y200...
Page 698: Fuel Tank
10. Disconnect thefuel filler hoseand air vent hosefrom the fuel tank. 11. Support the fuel tank. 12. Remove the fuel tank retaining nuts. Installation Notice 38 N•m (28 lb-ft) Tightening Torque 13. Carefully lower the fuel tank. YAA1F160 SSANGYONG Y200...
Page 699: Fuel Pressure Regulator
6. Apply the oil to O-ring lightly and then replace it. 7. Perform a leak test of the fuel pressure regulator with the engine off and the ignition on. 8. Installation should follow the removal procedure in the reverse order. YAA1F730 SSANGYONG Y200...
Page 700 10. Remove the six injector connectors. YAA1F750 11. Remove the two left and two right bolts and one center bolt of the fuel rail assembly from the intake manifold. Installation Notice 25 N•m (18 lb-ft) Tightening Torque YAA1F760 SSANGYONG Y200...
Page 701: Engine Coolant Temperature Sensor
YAA1F780 4. Remove the engine coolant temperature sensor from the pump hosing. Installation Notice Tightening Torque 30 N•m (22 lb-ft) 5. Installation should follow the removal procedure in the reverse order. SSANGYONG Y200...
Page 702: Throttle Body
8. Remove the vacuum hose. YAA1F790 9. Remove the throttle body and discard the gasket. Important: Use care in cleaning old gasket material. Sharp tools may damage sealing surfaces. 10. Installation should follow the removal procedure in the reverse order. KAA1D240 SSANGYONG Y200...
Page 703: Hot Film Air Mass (Hfm) Sensor
3. Remove the knock sensor mounting bolt from the knock sensor installed on the cylinder block. Installation Notice 25 N•m (18 lb-ft) Tightening Torque 4. Remove the knock sensor. KAA1F180 5. Installation should follow the removal procedure in the reverse order. SSANGYONG Y200...
Page 704: Pedal Position Sensor
4. Coat the threads of the oxygen sensor with an anti- seize compound, if needed. 5. Installation should follow the removal procedure in the reverse order. SSANGYONG Y200...
Page 705: Purge Control Valve
Removal and Installation Procedure 1. Disconnect the negative battery cable. 2. Disconnect the electrical connector from the cam- shaft position sensor. 3. Remove the camshaft position sensor retaining bolt. Installation Notice 10 N•m (89 lb-in) Tightening Torque YAA1F810 SSANGYONG Y200...
Page 706: Crankshaft Position Sensor
Control Module (ECM) from the mounting bracket. Installation Notice 10 N•m (89 lb-in) Tightening Torque 4. Pull out the ECM from the bracket. KAA1F200 5. Disconnect the vehicle side coupling. 6. Installation should follow the removal procedure in the reverse order. SSANGYONG Y200...
Page 707: Schematic And Routing Diagrams
1F2-96 M161 ENGINE CONTROLS SCHEMATIC AND ROUTING DIAGRAMS YAD1F010 SSANGYONG Y200...
Page 708: Ecm Wiring Diagram
ECM WIRING DIAGRAM (2.3L DOHC - 2 OF 7) (MSE 3.53D)
Page 709 ECM WIRING DIAGRAM (2.3L DOHC - 3 OF 7) (MSE 3. 53D)
Page 710 ECM WIRING DIAGRAM (2.3L DOHC - 4 OF 7) (MSE 3.53D)
Page 711 ECM WIRING DIAGRAM (2.3L DOHC - 5 OF 7) (MSE 3.53D)
Page 712 ECM WIRING DIAGRAM (2.3L DOHC - 6 OF 7) (MSE 3.53D)
Page 713 ECM WIRING DIAGRAM (2.3L DOHC - 7 OF 7) (MSE 3.53D)
Page 714 1=ON/0=OFF Protect Mission 1=ON/0=OFF Purge Control Valve 1=ON/0=OFF Lambda Function 1=ON/0=OFF Catalyst Heating 1=ON/0=OFF Overrun Fuel Cut 1=ON/0=OFF Full Fuel Cut 1=ON/0=OFF Brake Switch 1=ON/0=OFF Cruise Control Status 1=ON/0=OFF * Condition : Warmed up, idle, P/N or neutral SSANGYONG Y200...
Page 715 Fuel Filter Mounting Bracket Bolt Fuel Filter Lines Fuel Pressure Test Connector Fuel Rail Assembly Bolts Fuel Return And Supply Lines Fuel Tank Retaining Nuts Knock Sensor Mounting Bolt Oxygen Sensor Pedal Position Censor Mounting Bolts And Nut Throttle Body Bolts SSANGYONG Y200...
Page 716 TEMPERATURE VS RESISTANCE ECT sensor IAT sensor °C °F ohms (Ω) Temperature vs Resistance Values (Approximate) 111.6 1166 1166 1662 1662 2420 2420 3604 3604 5499 5499 8609 8609 13850 13850 22960 22960 39260 39260 SSANGYONG Y200...
Page 717 1F2-106 M161 ENGINE CONTROLS SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE 661 589 00 46 00 103 589 00 21 00 Fuel Tank Cap Wrench Fuel Pressure Gauge YAA1F890 KAA1F490 SSANGYONG Y200...
Page 718 SECTION 1F3 DIESEL ENGINE CONTROLS Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
Page 719: Description And Operation
FUEL SYSTEM Fuel Injection System YAD1FAA0 1 Fuel Injection Pump 6 Fuel Return Hoses 2 Fuel Feed Pump 7 Injection Line 3 Overflow Valve 8 Fuel Tank 4 Injection Nozzle 9 Fuel Filter 5 Pre-filter 10 Choke Orifice SSANGYONG Y200...
Page 720 M, W - 8 mm, 10 mm YAD1FAB0 P - 10 mm, 11 mm, 12 mm Z - 12 mm O - 15 mm 55 Element Diameter C Modification Letter 320 Assembly Number R Direction of Rotation (clockwise) S167 Special Version SSANGYONG Y200...
Page 721: Governor
Speed-Regulation Range (Working Range of the Maximum Full-Load Speed Governor Spring) Speed at Start of Torque Control g Full-Load Speed Regulation to the High Idle Speed at End of Torque Control Speed h Start of the Auxiliary Idle-Spring Shutoff SSANGYONG Y200...
Page 722 7 Full-Load Stop 19 Full-Load Adjusting Screw 8 Adjusting Screw For Idle Speed 20 Governor Sliding Sleeve 9 Guide Lever 21 Auxiliary-Idle-Spring 10 Idle Stop Switch-Off Device 11 Reverse-Transfer Lever 22 Flyweight 12 Idle-Speed Spring 13 Variable-Fulcrum Lever SSANGYONG Y200...
Page 723 YAD1FAE0 4 Control Rack 11 Reverse-Transfer Lever 6 Control Lever (Outer) 13 Variable-Fuicrum Lever 7 Full-Load Stop 14 Auxiliary-Idle Spring 9 Guide Lever 21 Auxiliary-Idle Spring Switch-Off Cold-start setting (only the components concerned in the governing process shown.) SSANGYONG Y200...
Page 724 15 Adjusting Screw for Auxiliary Idle Spring 9 Guide Lever 18 Spring Retainer (Torque Control) 10 Idle Stop 20 Governor Sliding Sleeve 11 Reverse-Transfer Lever 22 Flyweight Idle-speed setting. (only the components concerned in the governing process are shown) SSANGYONG Y200...
Page 725 YAD1FAG0 4 Control Rack 20 Governor Sliding Sleeve 17 Governor Spring 22 Flyweight 18 Spring Retainer (Torque Control) Full-load setting (only the components concerned in the governing process are shown) SSANGYONG Y200...
Page 726 (2s) the control rod can likewise be pulled into “stop position” on the outside of the governor. The vacuum unit (6) is connected to vacuum from the vacuum pump via the glow starter switch of the vehicle. YAD1FAM0 a Start b Stop SSANGYONG Y200...
Page 727: Absolute Metering Manifold Pressure Compensator (Alda)
YAD1FAJ0 1 Adjusting Screw 4 Aneroid Capsule 2 Aneroid Box 5 Adaptation 3 Connection for the Line to the Engine Manifold 6 Guide Plate SSANGYONG Y200...
Page 728: Pneumatic Idle Speed Increase (Pla)
The PLA ceases to function above a certain temperature. Coolant temperature >0°c The thermovalve is closed. Atmospheric pressure Design and Function reaches the vacuum unit through the choke in the Depending upon temperature, pressure is applied to ventilation filter. The speed increase is cancelled. SSANGYONG Y200...
Page 729: Pneumatic Shut-Off Device (Pnab)
“stop”. This applies vacuum to the shut-off device diaphragm which pulls the control rack to the stop setting. YAD1FAK0 1 Pneumatic Shut-Off Device 4 Spring-Loaded Strap 2 Shut-Off Lever for Manual Operation 5 Control Rack 3 Stop Lever SSANGYONG Y200...
Page 730: Exhaust Gas Recirculation (Egr) Valve
1 Injection Pump 6 Lever 2 Micro Switch 7 Micro Switch 3 Bolt 8 Adjusting Disc “A” Setting Indicator (10 inch) 4 Screw ........5 N•m (44 lb-in) 9 Adjusting Disc “B” Setting Indicator (11 inch) 5 Cam SSANGYONG Y200...
Page 731 7. At this moment, loosen the clamp and insert the adjusting disc “A” to the lever and check again. 8. If the lamp “A” is “on”, the setting is correct, thus, timing of injection pump is OK. If the both lamps are “on”, perform the setting as above procedure. SSANGYONG Y200...
Page 732: Component Locator
4 Idle Speed Adjustment (ALDA) 12 Fly Weight 5 Stop Lever 13 Clamping Piece 6 Adjusting Screw for Idle Speed 14 Plunger Driving Cam 7 Guide Lever 15 Fuel Pump Driving Cam 8 Adjusting Screw for Auxiliary Idle Speed SSANGYONG Y200...
Page 733: Vacuum Pump (Sectional View)
7 O-Ring 28 Piston Ring 8 Pump Housing 30 Seal Ring 9 Pump Cover 31 Oil Return Valve 12 Lever 32 Restrictor 14 Outer Return Spring SB To Brake Booster 15 Inner Spring Retainer SK To Vacuum Lines SSANGYONG Y200...
Page 734: Diagnostic Information And Procedure
4 Chock 10 Chock Filter 5 Rubber Hose 11 Molding Hose 6 Molding Hose Service Data Idle Speed Increase At least 100 rpm at approx. 500 mbr Permissible Pressure Drop of System 400 - 500 mbar approx. 1 min SSANGYONG Y200...
Page 735 667 589 00 21 00 TDC pulse generator Commercial Tools e.g Bosch MOT 001.03 Digital tester Sun DIT 9000 e.g Ahlborm, Therm 2263 - 2 Temperature measuring instrument with test probe Eichenfeldstrabe 1 - 3 WB24 D - 8150 Holzkirichen Tester Connection YAD1FAR0 SSANGYONG Y200...
Page 736 (arrow). Connect the vacuum pump to line to thermovalve and pressurize the line with vacuum. Vacuum is built up? Lines and connections leaking. Faulty thermovalve. YAD1FAU0 Detach line downstream of air admission filter (13). Vacuum drops off? Faulty thermovalve YAD1FAV0 SSANGYONG Y200...
Page 737 (5). Run the engine at idle speed. ± Vacuum drops to ‘0’ at approx. 3°C of the thermovalve. Faulty thermovalve. Defective filter with restriction. YAD1FAS0 Stop the engine. Detach the filter with restriction. Filter with restriction is clear. Defective filter with restriction. YAD1FAW0 SSANGYONG Y200...
Page 738: Vacuum Shut-Off Leak Test
7 Suction Line 4 Control Line 8 Vacuum Tester Service Data Model Permissible loss of vacuum Entire System at 400 + 50 mbar Vacuum 6 mbar / min. Individual Part at 300 + 50 mbar Vacuum 5 mbar / min. SSANGYONG Y200...
Page 739 - Connect the vacuum tester 201 589 13 21 00 to vacuum stop unit (3) and apply vacuum of 300 + 50 mbar. Permissible loss of 5 mbar / min vacuum - If a vacuum drop is more than specified valve, replace the vacuum stop unit. YAD1FB00 SSANGYONG Y200...
Page 740: Idle Speed Adjustment
4. Disconnect the vacuum hose (4) from the PLA unit to check idle speed with tester. 5. Check idle speed with tester. Idle Speed 720 - 820 rpm Notice: To adjust idle speed, loosen the locking nut (6) of PLA unit. YAD1FB20 SSANGYONG Y200...
Page 741 PLA vacuum unit and build up vacuum approx. 500 mbar. If engine rpm increases by approx. 150 rpm. It is normal. YAD1FB40 9. Connect the vacuum line (4). 10. Install the connecting rod. 11. Switch on all ancillaries and check the idle speed. SSANGYONG Y200...
Page 742: Fuel Pump Test
001 589 73 21 00 to the vacuum unit. 4. To avoid the engine starting, build up vacuum (approx. 500 mbar). 5. Operate the starter motor for exactly 30 seconds and measure fuel volume in the beaker. Min. volume 150 cm for 30 seconds YAD1FB70 SSANGYONG Y200...
Page 743 1 Fuel Filter Housing 5 Tester ......At Idle Speed > 0.3 bar 2 Fuel Line ......... At Full Load > 0.5 bar 3 Seal ............Replace 6 Fuel Injection Pump 4 Bolt ........... 13 N•m (10 lb-ft) 7 Fuel Pump SSANGYONG Y200...
Page 744 Notice: If out of standard, replace the fuel feed pump. YAD1FBW0 5. Stop the engine. 6. Remove the tester 617 589 04 21 00. 7. Replace the seal and connect the fuel line (2). Inatallation Notice Tightening Torque 13 N•m (10 lb-ft) YAD1FBA0 SSANGYONG Y200...
Page 745: Injection Nozzle Test
Preceding Work: Removal of fuel injection nozzle YAD1FBB0 1 Fuel Injection Nozzle ...New : 135 - 143 bar 2 Tester ..........Used : min. 120 bar 3 Valve A Closed Spray = good B Stringy Spray = poor SSANGYONG Y200...
Page 746 Operate the hand lever at tester rapidly (approx. 2~3 strokes per second). • Good The spray pattern shows closed and well atomized. YAD1FBD0 • Poor The spray pattern shows split, too wide and stringy. (Repair the fuel injection nozzle) YAD1FBE0 SSANGYONG Y200...
Page 747 Slowly operate the hand lever at the tester until get a pressure of approx. 90 bar. Maintain this pressure for more than 20 seconds and within this period no drop of fuel should build up at the nozzle tip. SSANGYONG Y200...
Page 748: Checking And Adjusting Start Of Delivery
• Governor impulse from the injection pump. then indicated. Both impulses are supplied by pulse generators. YAD1FBF0 1 Fuel Injection Pump 4 TDC Pluse Sender Unit 2 Rl Sensor 5 Battery 3 Digital Testor SSANGYONG Y200...
Page 749 1F3-32 DIESEL ENGINE CONTROLS Position Sensor, RIV Method YAD1FBG0 1 Position Sensor 4 Seal ............Replace 2 Battery 5 Screw Plug ....... 30 N•m (22 lb-ft) 3 Fuel Injection Pump Service Data Start of Delivery (RIV) ATDC 14° - 16° SSANGYONG Y200...
Page 750 ‘A and B’ come on. In this position, check the Rl value on the crankshaft vibration damper. Specification ATDC 14° - 16° Notice: If only lamp ‘A’ lights up, repeat the test and if out of specification, adjust start of delivery. YAD1BC10 SSANGYONG Y200...
Page 751 1F3-34 DIESEL ENGINE CONTROLS Digital Tester, RIV Method (Connection Diagram for Testers Without Adapter) YAD1FBF0 1 Fuel Injection Pump 4 TDC Pulse Generator 2 Rl Sensor 5 Battery 3 Digital Tester SSANGYONG Y200...
Page 752 YAD1FBK0 1 Fuel Injection Pump 4 TDC Pulse Sender Unit 2 Rl Sensor 5 Battery 3 Digital Tester 6 Rl Pulse Generator Service Data Start of Delivery (RIV) ATDC 14° - 16° Idle Speed 720 - 820 rpm SSANGYONG Y200...
Page 753 5. Stop the engine. 6. Remove the Rl sensor, digital tester and TDC pulse YAD1FBM0 generator. 7. Replace the seal and tighten the plug. Installation Notice Tightening Torque 30 N•m (22 lb-ft) 8. Check engine oil level and adjust if necessary. SSANGYONG Y200...
Page 754 Preceding Work: Start of delivery test YAD1FBN0 1 Adjusting Screw 4 Bolt........... 23 N•m (17 lb-ft) 2 Bolt........... 23 N•m (17 lb-ft) 5 Scale ..Rl start of delivery = 14° - 16° ATDC 3 Fuel Injection Pump SSANGYONG Y200...
Page 755 To the right Start of Delievery Retarded To the left Star of Delivery Advanced Notice: If the adjustment range is not adequate, remove the injection pump and reinstall. 5. After adjusting, retighten all the bolt to the specified torque. YAD1FBR0 SSANGYONG Y200...
Page 756 667 589 00 21 00 TDC Pulse Generator Commercial Tools Tools Item Digital Tester With Pulse Generator Bosch, MOT 001.03 Hartmann & Braun, EOMT3 Without Pulse Generator Bosch, ETD 019.00 Sun, DIT 9000 ALV, Diesel - Tester 875 SSANGYONG Y200...
Page 757 3. Run the engine at idle speed. 4. Turn the adjusting screw (2) until the specification (15° ± 1° ATDC) is indicated on the digital tester. To the Right Start of Delivery Retarded To the Left Start Delivery Advanced YAD1FBV0 SSANGYONG Y200...
Page 758: Repair Instructions
DIESEL ENGINE CONTROLS 1F3-41 REPAIR INSTRUCTIONS ON-VEHICLE SERVICE VACUUM PUMP Preceding Work: Removal the poly V-belt YAD1FBX0 1 Bolt........... 10 N•m (89 lb-in) 3 Vacuum Line 2 Vacuum Pump 4 Gasket ........... Replace SSANGYONG Y200...
Page 759 3. Remove the vacuum pump (2). 4. Install the vacuum pump (2). Installation Notice Tightening Torque 10 N•m (89 lb-in) Clean the gasket residues of sealing surface of vacuum pump and replace the gasket (5). 5. Connect the vacuum line. YAD1FC00 SSANGYONG Y200...
Page 760: Vacuum Unit Replacement
DIESEL ENGINE CONTROLS 1F3-43 VACUUM UNIT REPLACEMENT YAD1FC10 4 Vacuum Line 1 Bracket 5 Seal ............Replace 2 Bolt 3 Vacuum Unit SSANGYONG Y200...
Page 761: Fuel Pump
1 Fuel Injection Pump 5 Gasket ........... Replace 2 Pressure Line ......13 N•m (10 lb-ft) 6 Spring Lock Washer 3 Suction Line 7 Hexagon Nuts ......18 N•m (13 lb-ft) 4 Hose Clip ..........Replace 8 Fuel Pump SSANGYONG Y200...
Page 762 13 N•m (10 lb-ft) YAD1FC30 2. Remove the fuel pump mounting bolts. Installation Notice Tightening Torque 17 N•m (10 lb-ft) 3. Remove the fuel pump and gasket. YAD1FC40 4. Installation should follow the removal procedure in the reverse order. YAD1FC50 SSANGYONG Y200...
Page 763: Injection Nozzles
1F3-46 DIESEL ENGINE CONTROLS INJECTION NOZZLES YAD1FC60 1 Fuel Injection Nozzle . 35 - 40N•m (26 - 30 lb-ft) 4 Nozzle Washer ........Replace 2 Fuel Return Hose 5 Fuel Injection Pipe ....18 N•m (13 lb-ft) 3 Plug SSANGYONG Y200...
Page 764 Tightening Torque (26 - 30 lb-ft) YAD1BCU0 6. Replace the washers (6). 7. Installation should follow the removal procedure in the reverse order. Notice: Pay attention to the installation position of new nozzle washer and tightening torque. YAD1BFC90 SSANGYONG Y200...
Page 765: Injection Nozzle Repair
Preceding Work: Removal of fuel injection nozzle YAD1FCA0 1 Nozzle Holder 5 Intermediate Disc 2 Steel Washer 6 Nozzle Needle 3 Compression Spring 7 Nozzle Body 4 Thrust Pin 8 Nozzle Tensioning Nut .... 80 N•m (59 lb-ft) SSANGYONG Y200...
Page 766 6. Assemble the injection nozzle so that the tip of the thrust (4) pin is facing toward the nozzle holder. Installation Notice Tightening Torque 80 N•m (59 lb-ft) Nozzle needle (6) and nozzle body (7) should always be replaced as a pair. YAD1FCE0 SSANGYONG Y200...
Page 767 7. Check the fuel injection nozzle and adjust opening pressure if necessary. Opening pressure adjustment Disassemble the fuel injection nozzle and replace the steel washer (2). Notice: Each 0.05 mm thickness of the washer results in a pressure difference of approx. 3 bar. SSANGYONG Y200...
Page 768: Injection Timing Device Assembly
6 Screw Plug ....... 30 N•m (22 lb-ft) ......Check, 25 N•m (18 lb-ft)+ 90° 7 Oil Pan 15 Timing Chain 8 Locking Pin 16 Seal 9 Injection Timing Device 17 Chain Tensioner ....... 80 N•m (59 lb-ft) SSANGYONG Y200...
Page 769 25 N•m (18 lb-ft)+ 90° Do not remove the bolt. If max. length of bolt exceeds 53.6 mm, replace YAD1FCG0 3. Loosen the bolt (11) (left-hand thread). Installation Notice Tightening Torque 46 N•m (34 lb-ft) Do not remove the bolt. YAD1FCH0 SSANGYONG Y200...
Page 770 601 589 05 21 00 from the injection pump and reinstall the plug. YAD1FCK0 7. Place alignment marks (arrow) on the timing chain (12) and camshaft sprocket (15). YAD1BC20 SSANGYONG Y200...
Page 771 10. Pull out the bolt (11) and washer (10). Notice: Be careful that the bolt is left-hand thread. YAD1FCN0 11. Using special tool (Sliding Hammer 116 589 20 33 00 - 24,Threaded bolt 116 589 02 34 00 - 25), remove the locking pin (8). YAD1FCP0 SSANGYONG Y200...
Page 772 667 589 04 63 00 (26) and remove the injection timing device (9). 13. Installation should follow the removal procedure in the reverse order. 14. After assembling the engine, check start of delivery and adjust if necessary. YAD1FCQ0 SSANGYONG Y200...
Page 773: Injection Timing Device
1F3-56 DIESEL ENGINE CONTROLS INJECTION TIMING DEVICE Preceding Work: Removal of injection timing device assembly YAD1FCR0 1 Cam Sprocket ..........Check 4 Segment Flange and Drive Hub 2 Bushing ............Check 5 Compression Springs 3 Governor Weights SSANGYONG Y200...
Page 774 2. Pull out the compression springs (5) and cam sprocket (1) from the segment flange (4). YAD1FCT0 3. Knock out the bushing (2) with a proper drift. 4. Installation should follow the removal procedure in the reverse order. YAD1FCU0 SSANGYONG Y200...
Page 775: Fuel Injection Pump
25 Fuel Injection Pump 20 Bolt(Left-Hand Thread) .... 46 N•m (34 lb-ft) 26 Seal ............Replace 21 Washer 27 Screw Plug ....... 30 N•m (22 lb-ft) 22 Bolt ........... 23 N•m (17 lb-ft) 28 Square Nut 23 Seal ............Replace SSANGYONG Y200...
Page 776 7. Remove the plastic clip (8) on the injection line. YAD1FCX0 8. Disconnect the injection lines (15) from the injection pump (25). 9. Remove the banjo bolt (6) and then remove the seal (7) and return line (5). YAD1FCY0 SSANGYONG Y200...
Page 777 11. Remove the chain tensioner (18) and seal (19). YAD1FD00 12. Remove the bolt (12) and pull off the washer (11). YAD1FD10 13. Remove the bolt (22) and pull off the square nut (28). 14. Pull out the fuel injection pump (25) and seal (23). YAD1FD20 SSANGYONG Y200...
Page 778 YAD1FD40 3. Tighten the locking screw 601 589 05 21 00. YAD1FD50 4. Ensure that the no.1 cylinder is positioned at ATDC 15°. YAD1BC10 SSANGYONG Y200...
Page 779 13 N•m (10 lb-ft) Fuel Injection Line (15) 18 N•m (13 lb-ft) Fuel feed Line (3) 13 N•m (10 lb-ft) Suction and Pressure Line (4) 13 N•m (10 lb-ft) Replace the seal. 11. Assemble the plastic clip (8). YAD1FD90 SSANGYONG Y200...
Page 780 13. Connect the connecting rod (15). 14. connect the accelerator control damper (16). (Manual transmission vehicle) 15. Install the chain tensioner. 16. Install the vacuum pump. 17. Check the start of delivery. 18. Adjust the idle speed. YAD1FDA0 SSANGYONG Y200...
Page 781: Fuel Tank
FUEL TANK YAD1FDB0 1 Fuel Tank Mounting Bracket 7 Fuel Pump 2 Fuel Return Line 8 Fuel Tank Rear Pipe 3 Fuel Supply Line 9 Fuel Tank Air Cap 4 Fuel Filter 10 Fuel Filler Assembly 6 Fuel Tank SSANGYONG Y200...
Page 782 5. Disconect the fuel return and supply line. 6. Disconnect the fuel pump wiring connector. YAD1FDD0 7. Remove the fuel pump moumting bolts and bracket. 8. Carefully lower the fuel tank. 9. Installation should follow the removal precedure in the reverse order. YAD1FDE0 SSANGYONG Y200...
Page 783: Specifications
Inside Chain Connected with Camshaft Flange Stroke 7 mm Flange Outside Diameter 5.5 mm Rack Movement 21 mm Max. Speed 2,500 rpm Injected Fuel Quantity / Stroke 35 mm / Stroke Lubrication Type Sump Lubrication Type (Connected with Engine Oil Passage) SSANGYONG Y200...
Page 784: Fastener Tightening Specifications
Fuel Injection Pump Supporting Bracket Bolt Fuel Line Bolt (at Fuel Filter) Fuel Pressure Line (at Fuel Pump) Fuel Return Line (at Fuel Injection Pump) Injection Timing Device Bolt Nozzle Tensioning Nut Screw Plug Vacuum Pump Mounting Bolt SSANGYONG Y200...
Page 785: Schematic And Routing Diagrams
1F3-68 DIESEL ENGINE CONTROLS SCHEMATIC AND ROUTING DIAGRAMS YAD1FDF0 SSANGYONG Y200...
Page 786: Special Tools And Equipment
Box Wrench Insert Serration Wrench YAD1FDT0 YAD1BKB0 001 589 73 21 00 116 589 02 34 00 Vacuum Pump Threaded Bolt YAD1A190 YAD1BLH0 116 589 20 33 00 201 589 13 21 00 Sliding Hammer Vacuum Tester YAD1B580 YAD1FDG0 SSANGYONG Y200...
Page 787 Flange Ri Sensor YAD1FDP0 YAD1FDN0 617 589 08 21 01 617 589 04 21 00 Micro Switch Setting Tester Device YAD1FDJ0 YAD1FDL0 617 589 08 21 00 617 589 09 21 00 Position Sensor Ri Adapter YAD1FDL0 YAD1FDM0 SSANGYONG Y200...
Page 788 DIESEL ENGINE CONTROLS 1F3-71 SPECIAL TOOLS TABLE (Cont’d) 667 589 04 63 00 667 589 00 21 00 Retaining Plate TDC Pulse Generator YAD1FDH0 YAD1FDR0 SSANGYONG Y200...
Page 789 SECTION 1G ENGINE INTAKE & EXHAUST TABLE OF CONTENTS Air Cleaner and Intake Air Duct Description and Operation ....... 1G-2 (Gasoline Engine) .......... 1G-6 Exhaust System..........1G-2 Air Cleaner (Diesel Engine) ......1G-9 Muffler ............... 1G-2 Intake Manifold (Gasoline Engine) ....1G-11 Catalytic Converter (Gasoline Engine) .....
Page 790: Description And Operation
(HC) and carbon monoxide (CO) from the exhaust gas. The three-way catalyst has coatings which contain platinum and rhodium, which additionally lower the levels of oxides of nitrogen (NOx). SSANGYONG Y200...
Page 791 Purification of soluble organic fraction (SOF) over 180°C Chemical reaction formula → • SOF(HC)+O → • 2CO+O → • • By catalytic action of two primary catalytic converter, oxidation occurs in order to decrease HC and CO. YAD1G030 SSANGYONG Y200...
Page 792 • EGR valve is installed on the diesel engine of Musso, Korando, Istana and Rexton. And micro switch is installed together to control EGR valve. • The setting method of micro switch is identical with the existing one. SSANGYONG Y200...
Page 793: Resonance Flap (Gasoline Engine)
The switch valve (7) will not be adjusted by ECU and resonance falp (5) will be open. The collected air in the air collection housing (8) will not be divided and intaking air passage will be shorten. YAD1G090 SSANGYONG Y200...
Page 794: Repair Instructions
8 Sleeve 2 Air Cleaner Lower Housing 9 HFM Sensor 3 Element 10 Intake Air Duct 4 Air Duct Inlet 11 Blow-by Hose 5 Insulator 12 Clamp (2 Pieces) 6 Bolt 13 Intake Air Duct Mounting Clamp 7 Clamp SSANGYONG Y200...
Page 795 YAD1G110 2. remove the air cleaner lower housing bolt and air cleaner lower housing and insulators. YAD1G120 3. Disconnect the HFM sensor connector. YAD1G130 4. Remove the intake air duct housing clamp and intake air duct assembly. YAD1G140 SSANGYONG Y200...
Page 796 1G-8 ENGINE INTAKE & EXHAUST 5. Install the intake air duct to intake manifold and intake air duct mounting clamp. 6. Connect the HFM sensor connector. YAD1G150 7. Install the air cleaner housing assembly. YAD1G160 SSANGYONG Y200...
Page 797: Air Cleaner (Diesel Engine)
ENGINE INTAKE & EXHAUST 1G-9 AIR CLEANER (DIESEL ENGINE) YAD1G170 1 Air Cleaner Upper Housing 5 Insulator 2 Air Cleaner Lower Housing 6 Air Cleaner to T/C Hose 3 Element 7 Clamp 4 Air Duct Inlet 8 Bolt SSANGYONG Y200...
Page 798 YAD1G180 2. Remove the air cleaner lower housing bolt, air cleaner lower housing, air duct inlet and insulators. YAD1G120 3. Installation should follow the removal procedure in the reverse order. SSANGYONG Y200...
Page 799: Intake Manifold (Gasoline Engine)
......22.5-27.5 N•m (16.6-20.3 lb-ft) 18 Nipple 7 Gasket............ Replace 19 Seal Ring 8 Blow-by Hose 20 Connector 9 Blow-by Hose 21 Connection House 10 Clamp 22 Clamp 11 Blow-by Nipple 23 Noise Damper Assembly 12 Inlet Air Housing 24 Tapping Screw SSANGYONG Y200...
Page 800 (16). Installation Notice 22.5 - 27.5 N•m Tightening Torque (16.6 - 20.3 lb-ft) YAD1G210 4. Installation should follow the removal procedure in the reverse order. 5. Start the engine and check for leaks at each connection part. SSANGYONG Y200...
Page 801: Intake Manifold (Diesel Engine)
15 Gasket 6 Nut ..... 22.5-27.5 N•m (16.6-20.3 lb-ft) 16 Bolt ..... 22.5-27.5 N•m (16.6-20.3 lb-ft) 7 Gasket 17 Bracket 8 Bolt..... 22.5-27.5 N•m (16.6-20.3 lb-ft) 18 Bolt 9 Intake Manifold 19 Bolt 10 Stud Bolt 20 Nut SSANGYONG Y200...
Page 802 Installation Notice 22.5 - 27.5 N•m Tightening Torque (16.6 - 20.3 lb-ft) YAD1G250 6. Remove the intake manifold mounting bolts and intake monifold. Installation Notice 22.5 - 27.5 N•m Tightening Torque (16.6 - 20.3 lb-ft) YAD1G260 SSANGYONG Y200...
Page 803: Resonance Flap (Gasoline Engine)
Tightening Torque (80 - 97 lb-ft) 3. Check the O-ring (3) and replace it if necessary. 4. Remove the lower resonance flap (5). 5. Replace the gasket (6). 6. Installation should follow the removal procedure in the reverse order. SSANGYONG Y200...
Page 804: Exhaust Line (Gasoline Engine)
4 Gasket............ Replace 12 Bolt......... 15-28 N•m (11-21 lb-ft) 5 Gasket............ Replace 13 Nut ......... 28-47 N•m (21-35 lb-ft) 6 Hanger 14 Nut ........8-18 N•m (6-13 lb-ft) 7 Hanger 15 Screw 8 Heat Protector No. 1 16 Oxygen Sensor SSANGYONG Y200...
Page 805 28 - 47 N•m Tightening Torque (21 - 35 lb-ft) YAD1G300 5. Remove the muffler to tail exhaust pipe nuts. Installation Notice 28 - 47 N•m Tightening Torque (21 - 35 lb-ft) YAD1G310 6. Remove the Mounting hunger and muffler. YAD1G320 SSANGYONG Y200...
Page 806 8. Check the muffler and pipes for holes, damage, open seams, or other deterioration. Which could permit exhaust fumes to seep into the passenger compartment or the trunk. 9. Installation should follow the removal procedure in the reverse order. YAD1G330 SSANGYONG Y200...
Page 807: Exhaust Line (Diesel Engine)
9 Heat Protector No. 3 3 Muffler 10 Nut ......... 15-28 N•m (11-21 lb-ft) 4 Tail Exhaust Pipe 11 Nut ......... 28-47 N•m (21-35 lb-ft) 5 Gasket 12 Nut ........8-18 N•m (6-13 lb-ft) 6 Hanger 13 Screw 7 Hanger SSANGYONG Y200...
Page 808 6. Check the muffler and pipes for holes, damage, open seams, or other deterioration which could permit exhaust fumes to seep into the passenger compartment or the trunk. 7. Installation should follow the removal procedure in the reverse order. YAD1G320 SSANGYONG Y200...
Page 809: Specifications
22.5 - 27.5 16.6 - 20.3 Intake Manifold Mounting Bolt 22.5 - 27.5 16.6 - 20.3 Muffler to Tail Exhaust Pipe Nut 28 - 47 21 - 35 Resonance Flap Mounting Bolt 9 - 11 80 - 97 SSANGYONG Y200...
Page 810 SECTION 2C FRONT SUSPENSION TABLE OF CONTENTS Description and Operation ........2C-2 Repair Instructions ..........2C-9 Front Suspension ..........2C-2 On-vehicle Service ..........2C-9 Specifications ............2C-4 Stabilizer ............2C-11 Component Locator ..........2C-5 Shock Absorber Assembly ........ 2C-12 Front Suspension Assembly ......... 2C-5 Upper/Lower Arm Assembly ......
Page 811: Description And Operation
Therefore, it’s difficult to make a effect on vibration damping because there is not any friction between coils. SSANGYONG Y200...
Page 812 , the shock absorber and the bumper. The upper arm also supports the load delivering to the knuckle. This assembly enables to absorb the various shock and to ensure the driving safety. SSANGYONG Y200...
Page 813: Specifications
Telescopic Double Tube Type(GAS) Shock Absorber Torsion Bar Type Stabilizer 2 ± 2 mm Wheel Alignment Toe-In 0° ± 30´ (Both side difference must be below 30´) Camber 2° 45 ± 30´ (Both side difference must be below 30´) Caster SSANGYONG Y200...
Page 814: Component Locator
FRONT SUSPENSION 2C-5 COMPONENT LOCATOR FRONT SUSPENSION ASSEMBLY YAD2E050 1 Stabilizer Bar 5 Stabilizer Bar Link 2 Cam bolt 6 Knuckle 3 Lower arm 7 Upper arm 4 Yoke 8 Shock Absorber Assembly (Including coil spring) SSANGYONG Y200...
Page 815: Cross-Sectional View
2C-6 FRONT SUSPENSION CROSS-SECTIONAL VIEW SUSPENSION ASSEMBLY YAD2C060 SSANGYONG Y200...
Page 816: Shock Absorber
2 Yoke Bracket 11 Spring Sheet Rubber 3 Rebound Stopper 12 Upper Spring Sheet 4 Cylinder 13 Rubber 5 Piston 14 Rubber 6 Shock-Absorber assembly 15 Spacer 7 Spring 16 Washer 8 Yoke 17 Nut 9 Boot 18 Bolt SSANGYONG Y200...
Page 817: Diagnostic Information And Procedures
Replace Arm Ball Joint Insufficient Tire Pressure Adjust Faulty Power Steering Repair or Replace Incorrect Front Wheel Alignment Repair Steering Instability Worn or Loosened Lower Arm Re-Tighten or Replace Bushing Vehicle Bottoming Worn or Broken Coil Spring Replace SSANGYONG Y200...
Page 818: Repair Instructions
FRONT SUSPENSION 2C-9 REPAIR INSTRUCTIONS ON-VEHICLE SERVICE YAD2C080 SSANGYONG Y200...
Page 819 7 Rubber 21 Upper Arm 8 Spring Sheet Rubber 22 Nut 9 Boot 23 Bushing 10 Boot 24 Washer 11 Spring 25 Bolt 12 Shock Absorber 26 Lower Arm 13 Lower Spring Sheet 27 Bushing 14 Yoke 28 Bushing SSANGYONG Y200...
Page 820: Stabilizer
1. Install the front stabilizer bar to the frame and tighten manually the stabilizer bar mounting cap bolt. It allows the bar link to install to it’s original position. Installation Notice 60 - 80 N•m Tightening Torque (44 - 59 lb-ft) YAD2C120 SSANGYONG Y200...
Page 821: Shock Absorber Assembly
35 N•m (26 lb-ft) YAD2C140 SHOCK ABSORBER ASSEMBLY Removal Procedure 1. Remove three upper nuts from the shock absorber assembly. YAD2C150 2. Remove the yoke mounting pin nut at the lower arm and the yoke mounting pin. YAD2C160 SSANGYONG Y200...
Page 822 (30 - 44 lb-ft) YAD2C190 2. Tighten bolts of the shock absorber assembly and yoke. Be careful to tightening direction of the bolt as shown.(See the arrow). Installation Notice 60 - 70 N•m Tightening Torque (44 - 52 lb-ft) YAD2C200 SSANGYONG Y200...
Page 823: Upper/Lower Arm Assembly
Notice: Separate the ball joint from the steering knuckle using the special tool as shown. YAD2C230 2. Remove mounting bolts and nuts of the upper arm/ frame bracket (both front and rear) and separate the upper arm. YAD2C240 SSANGYONG Y200...
Page 824 3. Install the knuckle assembly to the shaft and insert the ball joint of the upper/lower arm. And then tighten the slotted nut and split pin. Installation Notice Slotted nut Upper side (1) 110 - 120 N•m Tightening Torque Lower side (2) 110 - 130 N•m YAD2C280 SSANGYONG Y200...
Page 825: Unit Repair
YAD2C300 4. Remove the coil spring components in specified disassemble order. Notice: Be careful to cause the spring elasticity to any personal injury when it is separated the special tool from the coil spring. YAD2C310 SSANGYONG Y200...
Page 826 23 ~ 24 mm. 2. Check the coil spring installation. • Check the installation direction of the coil spring. • Verify that the coil spring is installed onto the spring sheet correctly. YAD2C330 SSANGYONG Y200...
Page 827: Hub And Bearing
2. Remove the outer bearing (1) and inner seal. Notice: Always use a new part as replacing inner seal. 3. Remove the inner bearing (2). YAD2C350 4. Remove the inner bearing race. YAD2C360 5. Remove the outer bearing race. YAD2C370 SSANGYONG Y200...
Page 828 Install the outer bearing race using the front outer bearing race installer and handle. YAD2C380 • Install the inner bearing race using the front inner bearing race installer and handle 6. Installation should follow the removal procedure in the reverse order YAD2C390 SSANGYONG Y200...
Page 829: Special Tools Table
DW 340 - 021 - 02 Front hub flange Front inner bearing race remover installer YAD2C420 YAD2C460 661 589 01 07 00 DW 340 - 021 - 03 Front hub adjust nut Front outer bearing race remover/installer installer YAD2C430 YAD2C470 SSANGYONG Y200...
Page 830 SECTION 2D REAR SUSPENSION TABLE OF CONTENTS Wheel Bearing End Play ........2D-7 Description and Operation ........2D-2 Wheel Bearing Free load ........2D-7 Rear Suspension ..........2D-2 Repair Instructions ..........2D-8 Specifications ............2D-3 Component Locator ..........2D-4 On-Vehicle Service ..........2D-8 Rear Suspension Assembly .........
Page 831: Description And Operation
5. Coil Spring: It is installed between the rear axle and body frame. YAD2D010 This unit enables to release any shock or any vibration from tires in order to prevent its force from delivering to the body. SSANGYONG Y200...
Page 832: Specifications
Coil O.D. 13.1 mm Coil I.D(A) Ø 114 mm Ø 114 mm Free-load Height(B) 405.7 mm 386.8 mm Compression Height(C) 260.0 mm 250.0 mm O.D(D) Ø 127.1 mm Ø 127.0 mm 2.45 ± 5% Constant 2.45 ± 5% YAD2D020 SSANGYONG Y200...
Page 833: Component Locator
2D-4 REAR SUSPENSION COMPONENT LOCATOR REAR SUSPANSION ASSEMBLY YAD2D030 1 Coil Spring Seat(upper) 6 Lower Arm (link) 2 Coil Spring 7 Stabilizer Link 3 Lateral Rod 8 Stabilizer 4 Shock Absorber 9 Pump Stopper 5 Upper arm(link) SSANGYONG Y200...
Page 834: Shock Absorber
REAR SUSPENSION 2D-5 SHOCK ABSORBER YAD2D040 SSANGYONG Y200...
Page 835: Diagnostic Information And Procedures
Replace Excessive Resistance of Lower Replace Hard Steering Arm Ball Joint Insufficient Tire Pressure Replace Faulty Power Steering Adjust Worn or Loosened Lower Arm Re-Tighten or Replace Steering Instability Bushing Worn or Broken Coil Spring Replace Vehicle Bottoming SSANGYONG Y200...
Page 836: Wheel Bearing End Play
5. Check the free load of the rear wheel bearing within the specified value. Specified free load 1.4 ~ 4.3 kg.cm 6. Retighten the castle nut as specified torque when the measured value is not within the specified YAD2D060 value. 7. Replace the wheel bearing as needed. SSANGYONG Y200...
Page 837: Repair Instructions
2D-8 REAR SUSPENSION REPAIR INSTRUCTIONS ON-VEHICLE SERVICE YAD2D070 1 Rear Suspension Assembly 6 Stabilizer 2 Rubber 7 Coil Spring 3 Upper Arm 8 Shock Absorber 4 Lower Arm 9 Lateral Rod 5 Stabilizer Link SSANGYONG Y200...
Page 838: Rear Suspension Assembly
3. Remove the mounting cap bolt retaining both end of the stabilizer bar and remove the stabilizer bar, the mounting cap and the bushing. YAD2D100 4. Remove the upper mounting nut of the link with the stabilizer bar removed and remove the link. YAD2D110 SSANGYONG Y200...
Page 839 6. Remove the lateral rod mounting nut by retaining the axle and remove the lateral rod assembly. YAD2D130 7. Remove the lower nut of the shock absorber. YAD2D140 8. Remove the upper nut and remove the shock absorber YAD2D150 SSANGYONG Y200...
Page 840 10. Remove the upper bolt and nut retaining the axle and remove the upper arm. YAD2D170 11. Remove the lower arm mounting the frame. YAD2D180 12. Remove the lower arm mounting bolt & nut retaining the axle and then remove the lower arm. YAD2D180 SSANGYONG Y200...
Page 841 1. Be careful that the diameter of the upper coil spring is longer than that of the lower’s. 2. Verify that the coil spring should be installed onto the spring seat of the axle and body(frame) correctly. YAD2D210 SSANGYONG Y200...
Page 842 And then tighten bolts as specified torque. Installation Notice 165 N•m Tightening Torque(frame(1)) Tightening Torque(axle(2)) 165 N•m YAD2D240 6. Install the lateral rod to both the frame and axle side. Installation Notice Tightening Torque(frame(1)) 165 N•m Tightening Torque(axle(2)) 165 N•m YAD2D250 SSANGYONG Y200...
Page 843 9. The rubbers installation should follow the connecting order of the link rubber(packing). Notice: Always replace a new part when there is any wear or damage in the lever. 10. Check the shock absorber for any damage, oil leakage or abnormal noise. YAD2D280 SSANGYONG Y200...
Page 844 REAR SUSPENSION 2D-15 Notice: For scrapping the gas shock absorber, drill the hole in the “A” section with the shock absorber full expansion and discharge the gas. YAD2D290 SSANGYONG Y200...
Page 845: Special Tools And Equipment
2D-16 REAR SUSPENSION SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE 661 589 12 33 00 Torque Wrench Rear spring compressor YAD2D300 YAD2D310 SSANGYONG Y200...
Page 846 SECTION 2E TIRES AND WHEELS TABLE OF CONTENTS Description and Operation ........2E-2 Component Locator ........... 2E-12 General ............... 2E-2 Tire and Wheel Assembly ........2E-12 Tire’s Abnormal Action ........2E-3 Repair Instructions ..........2E-13 Wheel Alignment ..........2E-4 ON-Vehicle Service ..........2E-13 Specifications ............
Page 847: Description And Operation
1. Tread A part (that contacts) road surfaces directly is fixed YAD2E020 on the outsude of carcass and breaker. It is a strong rubber coat made of high anti-abrasion rubber. Its running performance depends on is surface profile. SSANGYONG Y200...
Page 848: Tire's Abnormal Action
Above 240 portion. The lower the tire pressure the severe the trembling wave appears during the high speed. The Relation Between Inflation Pressure and Tire Hydroplaning YAD2E030 YAD2E060 SSANGYONG Y200...
Page 849: Wheel Alignment
Always correct the toe dimension last. amount of positive caster. Caster is measures in degrees and is not adjustable. SSANGYONG Y200...
Page 850: Specifications
P235/70R16 30 psi P255/65R16 30 psi Wheel Alignment Toe-in 2 ± 2 mm Camber 0° ± 30’ (Below 30' the difference between right and left) Caster 2° 45 ± 30’ (Below 30' the difference between right and left) SSANGYONG Y200...
Page 851: Diagnostic Information And Procedures
Poor balance of wheels, tires Adjust Severe vibration due to wheels, tires Adjust or replacement Irregular tires wear Check and adjust Rapid wear Excessive tire inflation pressure Adjust High speed driving with low tire pressure Adjust Excessive vehicle weight Proper weight SSANGYONG Y200...
Page 852: General Inspection
Under inflation or lack of rotation Adjust inflation shoulders pressure YAD2E100 YAD2E110 Rapid wear at center Over inflation or rotation YAD2E120 YAD2E130 Tread damage Low the inflation pressure YAD2E140 YAD2E150 Uneven wear Incorrect camber Adjust camber Incorrect toe-in YAD2E160 YAD2E110 SSANGYONG Y200...
Page 853 Adjust toe-in YAD2E170 YAD2E180 Bold spot Unbalanced wheel Adjust wheel balance YAD2E190 YAD2E200 Sharply wear at the tread outside Unbalanced wheel Adjust Wheel bearing play Check play Check pre-load Ball joint play Check Faulty shock absorber Check YAD2E210 SSANGYONG Y200...
Page 854: General Inspection
• Higher than recommended pressure can cause hard ride, tire bruising or damage and rapid tread wear at the center of the tire. YAD2E240 SSANGYONG Y200...
Page 855 YAD2E260 nylon-coated, clip-on wheel weights. Balance Weight 10 g 20 g 30 g 40 g 50 g 60 g 0.4 oz 0.7 oz 1.10 oz 1.40 oz 1.80 oz 2.10 oz YAD2E270 SSANGYONG Y200...
Page 856 Caution at replacement tires YAD2E280 • Do not mix different types of tires on the same vehicle such as radial, bias and bias-belted tires except in emergencies, because vehicle handling may be seriously affected and may result in loss of control. SSANGYONG Y200...
Page 857: Component Locator
2E-12 TIRES AND WHEELS COMPONENT LOCATOR TIRE AND WHEEL ASSEMBLY YAD2E290 1 Wheel Nut 5 Wheel Cap 2 Wheel 6 Wheel Cap 3 Balance Weight 7 Wheel Cap 4 Tire 8 Wheel Cap SSANGYONG Y200...
Page 858: Repair Instructions
GENERAL TIRE 1. Remove the wheel cap. YAD2E300 2. Loosen the wheel nuts and then raise and suitably support the vehicle. 3. Remove the wheel nuts. YAD2E310 4. Installation should follow the removal procedure in the reverse order. YAD2E320 SSANGYONG Y200...
Page 859: Spare Tire
YAD2E350 service shop for repair. • For installing the spare tire on the vehicle, follow the installation direction. If you may install the tire in reverse direction, it is not possible to install it correctly. SSANGYONG Y200...
Page 860: Maintenance And Replacement
3. Remove the balance weight on the rim. YAD2E370 4. Separate the tire’s bead from the rim flange using the approved lubricant. Notice: Do not use silicone, synthetic detergent and gasoline, etc. YAD2E380 SSANGYONG Y200...
Page 861: Maintenance
YAD2E410 MAINTENANCE 1. Check any damage the rim and replace as needed. Notice: • Do not repair the rim as welding or soldering. • Replace the new valve as replaces new tire. SSANGYONG Y200...
Page 862: Installation
YAD2E430 4. Apply the lubricant at the both bead portions and both rim’s flange of the tire. YAD2E440 5. Check any foreign material or liquid for the tire inside and then install to push down the tire. YAD2E450 SSANGYONG Y200...
Page 863 2E-18 TIRES AND WHEELS 6. Set the tire pressure to the specifications. Notice: Do not remove the tire from the equipment before setting the tire pressure. Specification of the 2.1 kg•cm (30 psi) tire pressure YAD2E460 SSANGYONG Y200...
Page 864 SECTION 3A FRONT AXLE TABLE OF CONTENTS Front Axle Shaft ..........3A-11 General Description and Operation ....3A-2 Vacuum Line ........... 3A-18 Front Axle Housing Assembly ......3A-2 Axle Housing ..........3A-19 Axle Shaft Assembly ........3A-3 Specifications ........... 3A-4 Unit Repair ............
Page 865: General Description And Operation
The axle shaft connected with CV joint in left/right of axle and differential carrier in center is installed. The length of left/right axle shaft is different and the structure is independent. Both ends part of shaft is fixed with the spline. SSANGYONG Y200...
Page 866: Axle Shaft Assembly
FRONT AXLE 3A-3 AXLE SHAFT ASSEMBLY YAD3A030 1 Drive Shaft 7 Boot Band 2 Housing (Inboard) 8 Boot Band 3 Boot (Outboard) 9 Boot Band 4 Boot (Inboard) 10 Seal 5 Shaft 11 Ball Joint 6 Boot Band SSANGYONG Y200...
Page 867: Specifications
Conventional Gear Type Hypoid Gear Reduction Ratio Gaso. Gasoline + M/T 3.73 (E32 or E23) Diesel + M/T 4.27 Gasoline + M/T 4.56 Diesel + M/T 4.89 Capacity 1.4 L Specification SAE 80W / 90 or API Gl-5 SSANGYONG Y200...
Page 868: Diagnosis Information And Procedures
Damaged of Torn Drive Pinion Oil Seal Replace Loosened Bearing Collar Replace Worn or Damaged Universal Joint Replace Worn or damaged Axle Shaft Bearing Replace Heating Lack of Oil Replenish Insufficient Backlash of Gears Adjust Excessive Preload of Bearing Adjust SSANGYONG Y200...
Page 869: Component Locator
2 Front Axle Drive Shaft 10 Boot Clamp 3 Washer 11 Shaft 4 Bolt 12 Boot Clamp 5 Steering Knuckle 13 Inboard Boot 6 Dust Seal 14 Boot Clamp 7 Outboard Joint Assembly 15 Inboard Joint Assembly 8 Boot Clamp SSANGYONG Y200...
Page 870: Front Axle Housing
2 Breather Hose 11 Front Axle Housing 3 Bolt 12 Nut 4 Nut 13 Bolt 5 Cross Member 14 Washer 6 Bolt 15 Inner Shaft (Left) 7 Bushing 16 Inner Shaft (Right) 8 Spacer 17 Washer Plain 9 Spacer SSANGYONG Y200...
Page 871 3A-8 FRONT AXLE YAD3A380 SSANGYONG Y200...
Page 872 34 Bearing Cap 15 Oil Seal ..............35 Thrust Washer ..Replace, Apply grease to the sealing Rib 36 Side Gear 16 Bearing 37 Differential shaft 17 Shim 38 Differential Pinion 18 Bearing Baffle 39 Thrust Washer 19 Shim SSANGYONG Y200...
Page 873: Vacuum Line
4 Auto-locking Hub Cap 13 Auto-locking Hub Solenoid Valve 5 Retaining Ring 14 Bolt 6 Shim 15 Hose (L:2000/Yellow) 7 Locking Hub 16 Hose (L:3200/Red) 8 Hose and Tube Assembly 17 Hose (L:1500/White) (DSL) 9 T-Connector Hose (L:800/Blue) (GSL) SSANGYONG Y200...
Page 874: Maintenance And Repair
3. Remove the split pin from steering linkage link- knuckle mounting and pull off the slot nut and detach the link from knuckle arm. Notice: Replace the split pin with new one when it is installed again. YAD3A070 SSANGYONG Y200...
Page 875 & hub not to exceed 0.2mm. (Shim thickness : 0.2, 0.3, 0.5, 1.0mm) Notice: For assembly, be careful not to damage O-ring of the locking hub. YAD3A100 • Detach the vacuum hose of locking hub from steering knuckle. YAD3A110 SSANGYONG Y200...
Page 876 YAD3A140 • Remove three wheel bearing bolts (M12) and pull off hub assembly by using the special tool. Notice: For reassembly, replace the wheel bearing bolt with new one which applied the lock tight (blue color). YAD3A150 SSANGYONG Y200...
Page 877 9. Remove the split pin and nut from the steering knuckle arm and lower arm ball joint connection. Notice: For assembly, replace the split pin with new one. YAD3A170 10. Carefully remove the steering knuckle assembly. YAD3A180 11. Remove the drive shaft using the special tool. YAD3A190 SSANGYONG Y200...
Page 878 4. Install the dust shield to the knuckle. YAD3A210 5. With full time transfer case only • Install the hub assembly to the axle shaft and tighten the hexagon bolts applied the lock tight (Blue color). Installation Notice Tightening Torque 100 - 130 N•m YAD3A220 SSANGYONG Y200...
Page 879 0.2, 0.3, 0.5, 1.0 mm Max. clearance 0.2 mm YAD3A250 • Install the hub cover to the body and tighten it as the specified torque. Installation Notice 50 - 60 N•m Tightening torque (37 - 44 lb-ft) YAD3A260 SSANGYONG Y200...
Page 880 9. Install the wheel speed sensor and connect the vacuum line (with ABS only). Installation Notice ABS wheel speed 6 - 8 N•m sensor mounting bolt (53 - 71 lb-in) YAD3A290 10. Install the tire and test the braking force. SSANGYONG Y200...
Page 881: Vacuum Line
MAX. 0.2 mm Notice: Shim thickness 0.1, 0.2, 0.3, 0.5, 1.0 mm 3. Tighten the auto locking hub cap bolt to the specified torque and order. Installation Notice 50 - 60 N•m Tightening Torque YAD3A320 (37 - 44 lb-ft) SSANGYONG Y200...
Page 882: Axle Housing
Installation Notice 62 - 93 N•m Tightening Torque (45 - 69 lb-ft) YAD3A360 7. Lowering the jack carefully, remove the axle housing assembly. 8. Installation should follow the removal procedure in the reverse order. YAD3A370 SSANGYONG Y200...
Page 883: Unit Repair
3. Remove the bearing fixing snap ring of inner shaft and pull off the bearing. Remove the inner shaft and housing bracket YAD3A420 4. Remove the axle housing cover. Notice: Clean the gasket dregs of the cover and housing contact surface. YAD3A430 SSANGYONG Y200...
Page 884 When pulling out, be careful not to damage the axle housing. YAD3A440 6. Disassemble the parts of differential carrier assembly. YAD3A450 7. Remove the drive pinion lock nut. Disassemble the parts of drive pinion. YAD3A460 SSANGYONG Y200...
Page 885 (Decrease pinion shim) • Gear contacts on the • low flank Move the ring gear toward the drive pinion • Gear can be damaged (toward ring gear or worn center line) • Noise can be occurred YAD3A540 YAD3A550 SSANGYONG Y200...
Page 886 Installation Notice 75 - 90 N•m Tightening Torque (55 - 66 lb-ft) YAD3A580 4. Measure the backlash of side gear and pinion gear. Specified value 0 - 0.5 mm YAD3A590 SSANGYONG Y200...
Page 887 Installation Notice 39 - 46 N•m Tightening Torque (29 - 34 lb-ft) YAD3A620 8. Assemble the parts of the front axle inner shaft and housing mounting bracket. Notice: Apply the grease to the oil seal rib. YAD3A630 SSANGYONG Y200...
Page 888 FRONT AXLE 3A-25 9. Align the axle shaft and differential carrier spline and insert the axle shaft. Assemble the axle housing mowiting bracket to the axle housing. Installation Notice 80 - 100 N•m Tightening Torque (59 - 74 lb-ft) YAD3A640 SSANGYONG Y200...
Page 889: Differential Joint Assembly
2 Joint housing YAD3A660 4. Get rid of the grease in the joing assembly. 5. Remove the triport joint. 1 Pull out the circlip. 2 Pull out the triport joint. YAD3A670 6. Remove the drive axle shaft boot. YAD3A680 SSANGYONG Y200...
Page 890 YAD3A700 3. Check the followings after completing the assembly. • Check whether the joint move to up/down, left/ right, forward freely. • Check whether the grease leak in the clamp part after checking the operation. SSANGYONG Y200...
Page 891: Wheel Joint Assembly
Put the joint assembly in drive axle shaft to spread out the circlip opening slightly. 1 Inser t (-) driver into the circlip opening to spread out the circlip. 2 Put the joint assembly in circlip home with the circlip spread out. YAD3A740 SSANGYONG Y200...
Page 892 • Check whether the grease leak in the clamp part after checking the operation. Notice: Because the wheel joint cannot be repaired in single par t, if there is defect, replace it whit the new assembly. YAD3A760 SSANGYONG Y200...
Page 893: Special Tools And Equipment
3A-30 FRONT AXLE SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE 661 589 13 33 00 Snap Ring Plier Ball Joint Remover YAD3A770 YAD3A780 Part Time Snap Ring Remover / Installer YAD3A790 SSANGYONG Y200...
Page 894 SECTION 3C PROPELLER SHAFT TABLE OF CONTENTS General Description and Operation ..... 3C-2 Maintenance and Repair ........3C-6 Specifications ............3C-2 On-Vehicle Service ..........3C-6 Propeller Shaft Assembly ........3C-6 Diagnostic Information and Procedures ....3C-3 Unit Repair ............3C-9 Component Locator ..........
Page 895: General Description And Operation
591.1 × Ø59.5 × Ø63.5 Diesel + M/T•A/T + 4408 T/C Rear Shaft Dimension (LXI.DXO.D) (585.2+569.5) × Ø59.5 × Ø63.5 Gasoline + M/T•A/T + 4421 T/C (566.1+569.5) × Ø59.5 × Ø63.5 Unbalance Quantity (at 4,500 RPM) within 30 g·cm SSANGYONG Y200...
Page 896: Diagnostic Information And Procedures
Poor Symmetry (Left/Right) of Universal Joint Snap Ring Adjust Loosened Yoke connection bolt Tightening Noise Worn or Damaged Universal Joint Bearing Replace Separation of Universal Joint Snap Ring Adjust/Replace Loosened Yoke connection part Tightening Warn sliding Joint Spline pant Replace Insufficient Grease Replenish SSANGYONG Y200...
Page 897: Component Locator
8 Split Washer 2 Journal Bearing Cap 9 Slip Tube Shaft 3 Cross Shaft Journal 10 Tube 4 Slip Yoke Assembly 11 Tube Yoke 5 Grease Nipple 12 Flange Yoke 6 Dust Cap 13 Center Bearing 7 Oil Seal SSANGYONG Y200...
Page 898: Propeller Shaft Assembly
PROPELLER SHAFT 3C-5 PROPELLER SHAFT ASSEMBLY YAD3C030 1 Front Axle 6 Bolt 2 Bolt 7 Rear Propeller Shaft 3 Front Propeller Shaft 8 Bolt 4 Bolt 9 Rear Axle 5 Transfer Case SSANGYONG Y200...
Page 899: Maintenance And Repair
2. Remove the flange yoke fixing bolt/nut that connects the front propeller shaft axle side with transfer case. Pull out the front propeller shaft assembly. YAD3C050 3. Remove the flange yoke bolt/nut of transfer case side in rear propeller shaft. YAD3C060 SSANGYONG Y200...
Page 900 Tightening Torque (60 - 66 lb-ft) YAD3C090 4. Set up the rear propeller shaft between the transmission and axle housing. Tighten the center bearing manually. Installation Notice 80 - 95 N•m Tightening Torque (59 - 70 lb-ft) YAD3C100 SSANGYONG Y200...
Page 901 3C-8 PROPELLER SHAFT 5. Align the rear propeller shaft to the assembly mark. Tighten the bolts/nuts and then the center bearing bolts. Installation Notice 70 - 80 N•m Tightening Torque (52 - 59 lb-ft) YAD3C110 SSANGYONG Y200...
Page 902: Unit Repair
4. Slightly tapping the yoke shoulder using a brass hammer, remove the bearing. Remove the remaining bearing in the same way. YAD3C140 5. If it is not removed, clamp the welding part of yoke in the vise. YAD3C150 SSANGYONG Y200...
Page 903 Check the disassembled parts for wear and crack. Replace them if necessary. 2. Spider outer diameter standard 16.647 mm Limit 16.668 mm YAD3C180 3. Clearance between the spider and bearing standard 0.03 ~ 0.098 mm Limit 0.25 mm YAD3C190 SSANGYONG Y200...
Page 904 YAD3C210 out when the vehicle speed is around 60 ~ 100km/h. Assembly Clean the disassembled parts and replace then if damaged. 1. Align the alignment marks of the yoke and assemble the spider, bearing and snap ring. YAD3C220 SSANGYONG Y200...
Page 905 YAD3C230 3. Install the bearing cap to the yoke and insert the spider. Install the opposite cap by tapping with a plastic hammer. YAD3C240 4. Assembly the center bearing to the rear propeller shaft. YAD3C250 SSANGYONG Y200...
Page 906 SECTION 3D REAR AXLE TABLE OF CONTENTS General Description and Operation ....3D-2 Maintenance and Repair ........3D-8 Specifications ........... 3D-2 On-Vehicle Service ..........3D-8 Axle Shaft Assembly (With Disc Brake) ..3D-8 Diagnostic Information and Procedures ..3D-3 Axle Shaft Assembly (With Drum Brake) ..3D-11 Component Locator .........
Page 907: General Description And Operation
Axle Housing Type Build up Differential Type Conventional Type Gear Hypoid Gear Reduction Ratio Gasoline + A/T 3.73 Diesel + A/T 4.27 Gasoline + A/T 4.56 Diesel + A/T 4.89 Capacity 1.9L Specification SAE 80W/90 or API GL-5 SSANGYONG Y200...
Page 908: Diagnostic Information And Procedures
Damaged of Torn Drive Pinion Oil Seal Replace Loosened Bearing Collar Replace Worn or Damaged Universal Joint Replace Worn or damaged Axle Shaft Bearing Replace Heating Lock of Oil Replenish Insufficient Backlash of Gears Adjust Excessive Preload of Bearing Adjust SSANGYONG Y200...
Page 909: Component Locator
3D-4 REAR AXLE COMPONENT LOCATOR REAR AXLE ASSEMBLY YAD3D101 1 Axle Shaft/Tube 5 Shock Absorber 2 Stabilizer Bar 6 Lateral Rod 3 Spring Seat & Spring 7 Input Shaft 4 Upper Arm 8 Axle Housing SSANGYONG Y200...
Page 910: Cross Sectional View
YAD3D020 1 Rear Axle Shaft Assembly 6 Coil Spring Seat (Lower) 2 Bracket Assembly 7 Caliper Assembly 3 Hub Oil Seal 8 Input Shaft/Flange 4 Bolt 9 Rod Mounting Bracket 5 Axle Shaft Tube 10 Wheel Speed Sensor SSANGYONG Y200...
Page 911: Rear Axle Shaft Assembly
1 Brake Disc 7 Parking Brake Lining & Back Plate Assembly 2 Plug 8 Brake Caliper Assembly 3 Rear Axle Shaft 9 Spring Washer 4 Nut 10 Bolt 5 Washer 11 Rear Axle Housing 6 Parking Brake Cable SSANGYONG Y200...
Page 912 10 Snap Ring 3 Rear Axle Shaft 11 Snap Ring 4 Wheel Bolt 12 Oil Seal 5 Nut 13 Brake Shoe & Back Plate Assembly 6 Washer 14 Bolt 7 Retainer Plate 15 Rear Axle Housing 8 Oil Seal SSANGYONG Y200...
Page 913: Maintenance And Repair
5. Remove the two fixing bolt of brake caliper. Notice: Be careful not to damage the brake oil hose. 6. Remove the brake caliper assembly. Notice: If replacing the brake pad only, remove the upper fixing bolt of caliper pad and lower it. YAD3D060 SSANGYONG Y200...
Page 914 YAD3D080 9. Remove the two plastic plug in the axle shaft flange. 10. Remove the four fixing bolts & washers of axle housing flange from the retainer plate. YAD3D090 11. Remove the rear axle drive shaft. YAD3D100 SSANGYONG Y200...
Page 915 Installation Notice 4 - 8 N•m Tightening torque (35 - 71 lb-in) YAD3D130 4. Install the brake disc and caliper assembly. Installation Notice Tightening torque 85 - 105 N•m 5. Install the parking brake cable and tire. YAD3D140 SSANGYONG Y200...
Page 916: Axle Shaft Assembly (With Drum Brake)
5. After detaching the cover of parking brake, disconnect the cable. YAD3D170 YAD3D180 6. After pulling out the two plastic plug of axle shaft flange, remove the fixing nuts of inner bracket. yyyyyyy yyyyyyy yyyyyyy yyyyyyy yyyyyyy yyyyyyy yyyyyyy yyyyyyy yyyyyyy yyyyyyy yyyyyyy YAD3D190 SSANGYONG Y200...
Page 917 50 - 65 N•m Tightening Torque yyyyyyy (37 - 48 lb-ft) yyyyyyy yyyyyyy yyyyyyy yyyyyyy YAD3D210 3. Connect the brake cable and install the brake drum. YAD3D220 4. Install the tire and test the braking force. YAD3D230 SSANGYONG Y200...
Page 918: Rear Axle Housing
1 Brake pipe nut. 2 Brake pipe mounting clip 3 3-way connector 4 Brake pipe assembly YAD3D250 4. Detach the air breather. YAD3D260 5. Remove the propeller shaft from rear axle input shaft. Notice: Do alignment marks before removing. YAD3D270 SSANGYONG Y200...
Page 919 YAD3D290 9. Detach the lower mounting of shock absorber from the axle housing. YAD3D300 10. Remove the upper arm mounting nuts and remove the upper arm from the axle housing. YAD3D310 SSANGYONG Y200...
Page 920 13. Lowering the axle slowly, remove the coil spring & spring seat. 14. Lower the axle housing by using the safety jack. YAD3D340 Installation 1. Placing the rear axle housing on the assembly position, install both coil springs. YAD3D350 SSANGYONG Y200...
Page 921 (9 - 17 lb-ft) 6 - 8 N•m Air Breather Hose Bolt (53 - 71 lb-in) 15 - 19 N•m Brake Oil Pipe (M10) (11 - 14 lb-ft) YAD3D390 7. Bleeding the air in brake, install the tire. SSANGYONG Y200...
Page 922 2. Measure the run-out of shaft. Specified value Within 1.0 mm YAD3D410 3. Measure the run-out of shaft flange. Specified value Within 0.13 mm YAD3D420 4. Install the axle shaft and measure the clearance of shaft direction. Specified value Within 0.38 mm YAD3D430 SSANGYONG Y200...
Page 923: Unit Repair
12 Oil Drain Plug ........28 - 42 N•m 28 Differential Shaft 13 Shim 29 Housing Cover 14 Bearing 30 Bolt ........... 38 - 46 N•m 15 Drive Pinion 31 Oil Filler Plug ........28 - 42 N•m 16 Bearing Cap SSANGYONG Y200...
Page 924: Differential Gear Assembly
Pull out the differential carrier assembly. Notice: Do alignment marks on the bearing cap not to change the caps before removal. When pulling out, be careful to damage the axle housing. YAD3D470 4. Disassemble the parts of differential carrier assembly. YAD3D480 SSANGYONG Y200...
Page 925 3D-20 REAR AXLE 5. Remove the drive pinion lock nut. Disassemble the parts of drive pinion YAD3D490 SSANGYONG Y200...
Page 926 (Decrease pinion shim) • Gear contacts on the • Move the ring gear low flank toward the drive pinion • Gear can be damaged (toward ring gear or worn center line) • Noise can be occurred YAD3D570 YAD3D580 SSANGYONG Y200...
Page 927 Installation Notice 75 - 90 N•m Tightening Torque (55 - 66 lb-ft) YAD3D610 4. Measure the backlash of side gear and pinion gear. Specified value 0 - 0.5 mm YAD3D620 SSANGYONG Y200...
Page 928 6. Measure the backlash of drive pinion and ring gear. Specified value 0.13 - 0.20 mm YAD3D640 7. Install the axle housing cover. Tighten the fixing bolts. Installation Notice 39 - 46 N•m Tightening Torque (29 - 34 lb-ft) YAD3D650 SSANGYONG Y200...
Page 929 SECTION 4A BRAKE SYSTEM TABLE OF CONTENTS Description and Operation ........4A-2 Component Locator ........... 4A-11 Braking System Testing ........4A-2 Hydraulic Line ............ 4A-11 Hydraulic Brake System ........4A-2 Brake System (W/CBS) ........4A-12 Brake Pedal ............4A-2 Master Cylinder and Booster ......4A-13 Master Cylinder ...........
Page 930: Description And Operation
Hydraulic pressure generated by the master cylinder delivers to the caliper through the brake pipe or hose. This hydraulic pressure allows the caliper pad to push the disc plate. Thus it generates the braking forces. SSANGYONG Y200...
Page 931: Brake Booster
(3) is separated from the poppet (2). And then the air valve (6) opens in order to flow air into (B) through the filter and thus, the power piston (5) enables to push the master cylinder pushrod (7) for pressure distribution. SSANGYONG Y200...
Page 932: Specifications
Ø 42.9 mm Ø 42 mm Cylinder Thickness of 10 mm 10 mm Brake Pad Thickness of 10.4 mm 10.4 mm Disc Plate Parking Brake Type Rear Wheel Internal Expansion Type Mechanical Brake Fluid Spec. DOT4 or DOT3 SSANGYONG Y200...
Page 933: Diagnostic Information And Procedures
Insufficient Clearance Between Push Rod and Master Adjust Cylinder Poor Parking Brake Worn Brake Lining Replace Dirty Brake Lining Surface by Grease or Oil Replace Binding Parking Brake Cable Replace Faulty Auto Adjuster Repair Excessive Lever Stroke Adjust Lever Travel or Check the Cable SSANGYONG Y200...
Page 934: Maintenance And Repair
YAD4A080 • Care must be taken to prevent the brake fluid contacting any painted surface to prevent damage to the paint finish. • Check any leak for the applicable portion after bleeding. SSANGYONG Y200...
Page 935: Brake Pedal
5. If the pedal height is not in the specified value, YAD4A110 loosen the lock nut of the brake booster push rod and adjust the push rod length. SSANGYONG Y200...
Page 936: Stoplamp Switch
Check the faulty and repair, YAD4A130 adjust as needed. STOPLAMP SWITCH The multi-meter connects the stoplamp switch connector and push the plunger. When the stoplamp switch does not connected with pushing the plunger, the stoplamp switch is normal. YAD4A140 SSANGYONG Y200...
Page 937: Brake Booster Functional Check
It consists of load sensing spring and control lever which change according to vehicle load. YAD4A170 2. Hydraulic Control Part It consists of valve stem devices which controls hydraulic pressure according to load detected by sensing part. YAD4A180 SSANGYONG Y200...
Page 938 Fluid leaking from LCRV results from poor valve open/close or sealing wear caused by the foreign materials in the LCRV. • When you change or repair the LCRV, it may affect the braking performance. Thus, ensure to use the approved part. SSANGYONG Y200...
Page 939: Component Locator
HYDRAULIC LINE YAD4A060 1 Brake Booster 5 Hydraulic Pressure Control Valve (LCRV) 2 Brake Reservoir and Master Cylinder 6 3-way Connector 3 ABS Control Unit 7 Rear Drum (Disc) and Wheel Cylinder (Caliper) 4 Front Disc Brake and Caliper SSANGYONG Y200...
Page 940: Brake System (W/Cbs)
8 Brake Oil Tank Assembly 21 Rear Brake Hose 9 Brake Oil Tank Cap 22 Clip 10 Brake Oil Tank 23 Front Brake Hose 11 Grommet Seal 24 Union Bolt 12 Master Cylinder 25 Plain Washer 13 Brake Stoplamp Switch SSANGYONG Y200...
Page 941: Master Cylinder And Booster
BRAKE SYSTEM 4A-13 MASTER CYLINDER AND BOOSTER KDAC (Delphi Korea) YAD4A210 MANDO YAD4A220 SSANGYONG Y200...
Page 942: Repair Instructions
REPAIR INSTRUCTIONS ON-VEHICLE SERVICE VACUUM HOSE Removal Procedure 1. Disconnect the vacuum hose from the brake booster. YAD4A230 2. Disconnect the vacuum hose from the vacuum pump. YAD4A240 3. Remove the vacuum hose with the vacuum hose bracket. YAD4A250 SSANGYONG Y200...
Page 943: Brake Oil Level Switch
(26 - 33 lb-ft) YAD4A270 BRAKE OIL LEVEL SWITCH Removal & Installation Procedure 1. Disconnect the brake fluid level switch connector. YAD4A280 2. Disconnect the switch wiring connector. 3. Disconnect the switch from the brake oil tank. YAD4A290 SSANGYONG Y200...
Page 944: Brake Fluid Reservoir
3. Remove the grommet from the master cylinder. YAD4A320 4. Installation should follow the removal procedure in the reverse order. Notice: • Lubricate the new brake fluid reservoir seals with clean brake fluid. • After the installation, bleed the brake system. YAD4A330 SSANGYONG Y200...
Page 945: Master Cylinder
• Retain the master cylinder in the vice and remove the retainer ring from the master cylinder using the snap ring plier. YAD4A360 • Remove the 1st piston and 2nd piston assembly from the master cylinder assembly. YAD4A370 SSANGYONG Y200...
Page 946 Installation Notice 8 - 12 N•m Tightening Torque (71 - 106 lb-in) YAD4A400 3. Install the master cylinder completely and then connect the brake pipe. Installation Notice 15 - 18 N•m Tightening Torque (11 - 13 lb-ft) YAD4A410 SSANGYONG Y200...
Page 947: Brake Booster
3. Remove the nuts mounting the booster. YAD4A430 4. Remove the brake booster from the vehicle. YAD4A440 Installation Procedure 1. Installation should follow the removal procedure in the reverse order. 2. Bleed the brake system after the installation. YAD4A450 SSANGYONG Y200...
Page 948: Stoplamp Switch
4. Installation should follow the removal procedure in the reverse order. 21 - 35 N•m Tightening Torque (15 - 26 lb-ft) YAD4A480 BRAKE PEDAL Removal & Installation Procedure 1. Remove the bolts/nuts mounting the brake pedal and disconnect the cotter pin. YAD4A490 SSANGYONG Y200...
Page 949: Brake Hose & Pipe
Tightening Torque (12 - 24 lb-ft) YAD4A510 BRAKE HOSE & PIPE Removal Procedure 1. Remove the brake pipe. • Remove the pipe from the master cylinder. YAD4A520 • For ABS/ABD, remove the brake pipe from the control unit. YAD4A530 SSANGYONG Y200...
Page 950 Disconnect the strut from the brake mounting. • Remove the union bolt from the caliper and remove the brake hose. - For disc type : from the caliper YAD4A560 - For drum type : from the cylinder YAD4A570 SSANGYONG Y200...
Page 951 Tightening Torque 15 - 19 N•m at the wheel cylinder (11 - 13 lb-ft) YAD4A590 YAD4A600 2. Install the front brake hose and tighten the union bolts. 15 - 18 N•m Tightening Torque (11 - 13 lb-ft) YAD4A610 SSANGYONG Y200...
Page 952: Lcrv (Load Conscious Reducing Valve)
REDUCING VALVE) 1. Remove the nut mounting the stud from the LCRV connecting rod. YAD4A630 2. Remove the brake pipe retaining the LCRV. YAD4A640 3. Remove the LCRV mounting bolt from the LCRV bracket and remove the LCRV. YAD4A650 SSANGYONG Y200...
Page 953 Valve Body 14 - 18 N•m Mounting nut (10 - 13 lb-ft) Bracket Mounting 10 - 13 N•m Bolt (89 - 115 lb-in) Stud Mounting 14 - 18 N•m (10 - 13 lb-ft) Notice: Bleed the brake system. YAD4A660 SSANGYONG Y200...
Page 954 SECTION 4B FRONT BRAKE TABLE OF CONTENTS Description and Operation ........4B-2 Component Locator ..........4B-6 Caliper ..............4B-2 Cross-Sectional View ........... 4B-6 Clearance Calibration ........... 4B-2 Front Caliper Brake ..........4B-7 Specifications ............4B-2 Repair Instructions ..........4B-8 Diagnostic Information and Procedures ....4B-3 On-Vehicle Service ..........
Page 955: Description And Operation
The piston seal, which extent considerable pressure against the piston, moves with cylinder. YAD4B020 SPECIFICATIONS MANDO Delphi Korea ← Application Ventilated Disc Type ← Caliper Cylinder I.D. Ø 60 mm ← Pad Thickness 10 mm ← Disc Thickness 24 mm SSANGYONG Y200...
Page 956: Diagnostic Information And Procedures
Dragging Brake Inoperative Caliper Returning Replace Excessive Pedal Travel Pad Wear Replace Noise and Vibration When Pad Wear, Hardening Replace Brake Applied Damage On The Disc Replace Interference Of The Dust Cover Repair Loose Caliper Mounting Bolts Tighten SSANGYONG Y200...
Page 957: Inspection
1. Measure the thickness of the rotor at four or more points around the circumference of the rotor. 2 If the thickness of the rotor is below the specified value, replace the brake rotor. Thickness Max wear Limit 24 mm 22 mm YAD4B050 SSANGYONG Y200...
Page 958: Brake Disc Run Out
2. If lateral run out exceeds the specification, replace the brake disc to prevent the pedal’s vibration at braking. 0.03 mm (Disc only) Run Out Limit 0.07 mm (On vehicle) YAD4B060 CALIPER HOUSING I.D Application Spec. Ø 60.0 mm Non-ABS/ABS Wear Limit Ø 61.0 mm YAD4B070 SSANGYONG Y200...
Page 959: Component Locator
4B-6 FRONT BRAKE COMPONENT LOCATOR CROSS-SECTIONAL VIEW YAD4B030 1 Brake Disc 6 Vacuum Hose Nipple 2 Wheel (Rim) 7 Caliper 3 Hub Range 8 Brake Fluid Nipple 4 Knuckle 9 Caliper Guide Bolt 5 Dust Shield 10 Caliper Bolt SSANGYONG Y200...
Page 960: Front Caliper Brake
FRONT CALIPER BRAKE YAD4B080 1 Brake Caliper Assembly 6 Piston Seal 2 Guide Rod Set 7 Piston 3 Brake Pad 8 Piston Boot 4 Brake Pad Spring 9 Caliper Guide Rod Bolt 5 Caliper Mounting Bolt 10 Bleeder Screw SSANGYONG Y200...
Page 961: Repair Instructions
Notice: Be carefully to prevent the brake fluid loss and contamination. YAD4B090 2. Remove the cylinder mounting bolt and remove the disc pad and the cylinder. YAD4B100 3. Remove the caliper mounting bolt and remove the caliper assembly. YAD4B110 SSANGYONG Y200...
Page 962 (Full-time 4WD) YAD4B120 6. Remove the hub assembly mounting bolt and remove the hub assembly. YAD4B130 Notice: For part-time 4WD, remove the locking hub assembly and hub range before removing the brake disc. YAD4B140 SSANGYONG Y200...
Page 963: Brake Pad Replacement
2. Move the caliper cylinder assembly upward and fix it to prevent hose damage. YAD4B160 3. Remove the brake pad and replace the new pad. 4. Install the caliper cylinder assembly and fasten the lower bolt. Full-time YAD4B170 Part-time YAD4B180 SSANGYONG Y200...
Page 964 & hub range. Fasten the mounting bolt (part-time 4WD). YAD4B200 2. Install the caliper assembly to the front disc and fasten the caliper mounting bolt. Installation Notice 85 - 105 N•m Tightening Torque (63 - 79 lb-ft) YAD4B210 YAD4B220 SSANGYONG Y200...
Page 965 4B-12 FRONT BRAKE 3. Connect the brake hose to the caliper cylinder. Installation Notice 7 - 13 N•m Tightening Torque (62 - 115 lb-in) Notice: The washer should be replaced new part. 4. Bleed the brake system after replacement. YAD4B230 SSANGYONG Y200...
Page 966: Unit Repair
Remove the bleeder plug cap. • Remove the piston boot. YAD4B260 • Using the compressed air, blow out the piston from housing. Notice: Do not face in the direction of removing. • Remove the piston. • Remove the piston seal. YAD4B270 SSANGYONG Y200...
Page 967 2. Fasten the guide rod bolt as specified torque. Installation Notice YAD4B280 22 - 32 N•m Tightening Torque (16 - 24 lb-ft) 3. Fasten the bleeder screw as specified torque. Installation Notice 7 - 13 N•m Tightening Torque (62 - 115 lb-in) YAD4B290 SSANGYONG Y200...
Page 968 SECTION 4C REAR BRAKE TABLE OF CONTENTS Description and Operation ........4C-2 Component Locator ..........4C-9 Drum Brake ............4C-2 Drum Brake ............4C-9 Wheel Cylinder ............ 4C-2 Disc Brake ............4C-10 Brake Lining ............4C-2 Rerair Instructions ..........4C-11 Disc Brake ............
Page 969: Description And Operation
Generally the drum brake must be adjusted regularly and thus the clearance automatic control system enables to adjust the clearance between the brake lining and the drum resulting from brake lining wear. SSANGYONG Y200...
Page 970: Disc Brake
Lining Width x Length x Thickness 55 x 243 x 4.7 mm Wheel Cylinder I.D. Ø 23.81 mm Caliper Cylinder I.D. Ø 42.9 mm Ø 42 mm Brake Pad Thickness 10 mm 10 mm Disc Thickness 10.4 mm 10.4 mm SSANGYONG Y200...
Page 971: Diagnostic Information And Procedures
Brake Applied Foreign Material Inside Drum Clean Loosen The Brake Plate Bolt Tighten Drum Deformation Or Surface Damage Replace Inoperative Parking Brake Lining Wear, Hardening Replace Oil Contamination On The Lining Replace Inoperative Clearance Automatic Control System Repair SSANGYONG Y200...
Page 972: Inspection
Pad Thickness 1. Remove the front wheel. yyyy 2. If the measured value is below the limit value, yyyy replace the pad. yyyyy yyyy yyyyy yyyy Wear Limit 2 mm yyyyy yyyy yyyyy yyyy yyyyy yyyyy yyyyy YAD4C080 SSANGYONG Y200...
Page 973 On-Vehicle Max. 0.07 mm Run Out Limit Disc only Max. 0.03 mm 2. If lateral run out exceeds the specification, replace the brake disc to prevent the pedal’s vibration at braking. YAD4C100 SSANGYONG Y200...
Page 974: Cross Sectional View
3 Brake Shoe Lining 10 Adjuster Lever 4 Brake Shoe 11 Return Spring (Adjuster) 5 Lower Return Spring (Lower Shoe Spring) 13 Upper Return Spring (Upper Shoe Spring) 6 Retainer Spring Pin 14 Bolt 7 Compression Spring 15 Air Bleeder Nipple SSANGYONG Y200...
Page 975: Disc Brake
4C-8 REAR BRAKE DISC BRAKE YAD4C050 1 Backing Plate 5 Disc 2 Parking Cable 6 Wheel 3 Parking Cable Lever 7 Air Bleeder Nipple 4 Caliper Assembly 9 Shaft Assembly SSANGYONG Y200...
Page 976: Component Locator
12 Brake Shoe Retaining Spring 5 Wheel Cylinder 13 Brake Shoe Retaining Spring Cap 6 Strut Assembly (Clearance Automatic Control 14 Lower Return Spring System) 15 Hub Bolt 7 Brake Leading Shoe 16 Rear Brake Drum 8 Middle Return Spring SSANGYONG Y200...
Page 977: Disc Brake
1 Rear brake disc assembly 6 Gasket............ Replace 2 Brake pad 7 Brake hose 3 Brake caliper 8 Gasket............ Replace 4 Gasket............ Replace 9 Hose bolt ........... 8 - 18 N•m 5 Bolt ........... 20 N•m (15 lb-ft) SSANGYONG Y200...
Page 978: Rerair Instructions
2. Remove the brake hose from the rear brake caliper. Notice: Be carefully to prevent the brake fluid loss and contamination. YAD4C130 3. Remove the caliper cylinder mounting bolt and remove the disc pad and the cylinder. YAD4C140 SSANGYONG Y200...
Page 979 YAD4C150 5. Disconnect the parking brake cable from the parking brake lever. YAD4C160 6. Remove the brake disc. YAD4C170 7. Using the rubber hammer, hit to separate the parking brake lining lightly and move the lining upward. YAD4C180 SSANGYONG Y200...
Page 980 4. Inspect the disc plate’s scratch and deformation. YAD4C200 Brake Pad 1. Remove the cylinder mounting bolt (lower) at the brake caliper. 2. Raise and fix the caliper assembly at the proper position not to cause any damage in the hoses or others. YAD4C210 SSANGYONG Y200...
Page 981 4 - 8 N•m Tightening Torque (35 - 71 lb-in) Notice: Apply a certain amount of grease on the parking brake lining surface. YAD4C240 2. Install the brake disc and connect the parking brake cable to the lever. YAD4C250 SSANGYONG Y200...
Page 982 4. Install the brake hose. Notice: The washer should be replaced new part. 5. Tighten the air bleeder screw. Installation Notice 7 - 13 N•m Tightening Torque (62 - 115 lb-in) 6. Bleed the brake system after replacement. YAD4C270 SSANGYONG Y200...
Page 983: Drum Brake Assembly
3. Insert the bolt (M8) to the service hole of the brake drum and remove the brake drum. YAD4C300 4. Remove the service hole plug of the axle shaft. yyyyyyy yyyyyyy yyyyyyy yyyyyyy yyyyyyy yyyyyyy yyyyyyy yyyyyyy yyyyyyy yyyyyyy yyyyyyy YAD4C310 SSANGYONG Y200...
Page 984 (4) Disconnect the adjuster lever from the adjuster. YAD4C320 YAD4C330 6. Rotate the lining shoe hold down-washer in the plug hole of the axle shaft flange and disconnect the pin and the spring. YAD4C340 7. Disconnect the parking cable from the parking lever. YAD4C350 SSANGYONG Y200...
Page 985 Mark the brake drum inside using chalk and scrub the shoe & lining assembly. If there is excessive contact problem, replace the shoe & lining assembly or the brake drum. Notice: Clean any chalk mark after inspection complete. YAD4C390 SSANGYONG Y200...
Page 986 And then install adjuster and each return spring. YAD4C410 3. Connect the parking cable. YAD4C420 4. The outside diameter of the lining set to Ø 253.08 - Ø 253.50 mm by rotating the adjuster screw. YAD4C430 SSANGYONG Y200...
Page 987 Notice: Adjust the adjuster screw as needed. YAD4C440 7. Connect the brake pipe to the wheel cylinder. Installation Notice 15 - 19 N•m Tightening Torque (11 - 14 lb-ft) 8. Bleed the brake system and verify the parking brake operation. Install the tire. YAD4C450 SSANGYONG Y200...
Page 988: Unit Repair
(62 - 89 lb-in) Wheel Cylinder 8 - 12 N•m Mounting Bolt (71 - 106 lb-in) Notice: Lubricate the new seals, the piston, the piston cup and the wheel cylinder bore with clean brake fluid before assembly. YAD4C480 SSANGYONG Y200...
Page 989: Parking Brake Lever
1. Disconnect the parking brake lever and the adjuster lever from the lining. YAD4C490 2. Pull out the lever pin (arrow) and Disconnect the the parking brake lever and the adjuster lever. 3. Installation should follow the removal procedure in the reverse order. YAD4C500 SSANGYONG Y200...
Page 990 SECTION 4D PARKING BRAKE TABLE OF CONTENTS Description and Operation ........4D-2 Component Locator ..........4D-5 Parking Brake ............4D-2 Cross Sectional View ........... 4D-5 Parking Brake Switch and Indicator ...... 4D-2 Parking Brake Lever and Cable ......4D-6 Braking Inspection ..........4D-2 Repair Instructions ..........
Page 991: Description And Operation
3. Check the parking brake force after adjusting the specified value. YAD4D030 4. If the braking force is not operated properly, check the parking brake lever and cable and replace them as needed. YAD4D040 SSANGYONG Y200...
Page 992: Specifications
PARKING BRAKE 4D-3 SPECIFICATIONS Application Spec. Parking Brake Type Mechanical Rear-Wheel Drive Internal Expanded Operation Manual SSANGYONG Y200...
Page 993: Diagnostic Information And Procedure
DIAGNOSTIC INFORMATION AND PROCEDURE Symptom Possible Cause Action Poor Braking Lining Wear, Hardening Replace Oil Or Water Contamination On The Lining Replace Or Repair Brake Cable Sticked Or Damage Replace Excessive Pedal Travel Notch Adjustment Inoperative Clearance Automatic Control System Repair SSANGYONG Y200...
Page 994: Component Locator
COMPONENT LOCATOR CROSS SECTIONAL VIEW YAD4D020 1 Parking Brake Lever 5 Cable 2 Parking Brake Cable Bracket (Rear) 6 With Drum Brake 3 Parking Brake Cable Bracket (Front) 7 With Disc Brake 4 Parking Brake Cable Bracket (Center) SSANGYONG Y200...
Page 995: Parking Brake Lever And Cable
2 Parking Brake Warning Lamp Switch 8 Bolt 3 Bolt 9 Rear Parking Brake Cable 4 Bolt 10 Brake Disc (Rear Disc Brake Type) 5 Front Parking Brake Cable 11 Brake Drum (Rear Drum Brake Type) 6 Equalizer SSANGYONG Y200...
Page 996: Repair Instructions
PARKING BRAKE 4D-7 REPAIR INSTRUCTIONS ON-VEHICLE SERVICE PARKING BRAKE Removal Procedure 1. Remove the console assembly. YAD4D060 2. Disconnect the parking brake warning lamp connector. YAD4D070 3. Disconnect the cable from the parking brake lever with parking brake released. YAD4D080 SSANGYONG Y200...
Page 997 Remove the clip from the brake plate. YAD4D110 Drum Type • Remove the clip from the brake plate. • Move the parking brake lever as shown using driver etc. and then disconnect the cable. 7. Disconnect the cable bracket and the cable. YAD4D120 SSANGYONG Y200...
Page 998 4. Insert the parking brake cable to the lever hole and install the cable plate. Installation Notice 6 N•m Tightening Torque (53 lb-in) YAD4D150 5. Install the parking brake switch and check the warning lamp and brake operation. YAD4D160 SSANGYONG Y200...
Page 999 4D-10 PARKING BRAKE 6. If there is any operation problem in the parking brake, adjust the cable tension at the equalizer position. 7. Install the console assembly and perform the braking test. YAD4D170 SSANGYONG Y200...
Page 1000 SECTION 4E ABS SYSTEM AND TRACTION CONTROL SYSTEM TABLE OF CONTENTS DTC 245-Wheel Speed Sensor Frequency Description and Operation ........4E-2 Error ............... 4E-56 ABS (Anti-Lock Brake System) ......4E-2 DTC 930-Acceleration Sensor Fault ..... 4E-60 TCS (Traction Control System) Description .... 4E-3 DTC-Acceleration Sensor Continuity Fault ...

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