SSANGYONG Rexton Y200 Manuals

Manuals and User Guides for SSANGYONG Rexton Y200. We have 2 SSANGYONG Rexton Y200 manuals available for free PDF download: Manual

SSANGYONG Rexton Y200 Manual (3772 pages)

Brand: SSANGYONG | Category: Automobile | Size: 167 MB

Owner Inspections and Services
3
Each Time the Oil Is Changed
4
Standard Bolts Specifications
5
Basic Specification
6
Recommended Fluids and Lubricants
9
Vehicle Identification Number System
10
Manufacturers Plate
11
Engine Number
12
Vehicle Lifting Procedures
14
Table of Contents
15
1A-2 Engine General Information
16
Description and Operation
16
Cleanliness and Care
16
On-Engine Service
16
Component Locator
17
M162 Engine
17
M161 Engine
19
Diesel Engine
21
Diagnostic Information and Procedure
23
Oil Leak Diagnosis
23
Compression Pressure Test (Gasoline Engine)
24
Compression Pressure Test (Diesel Engine)
26
Cylinder Pressure Leakage Test (Gasoline Engine)
28
Cylinder Pressure Leakage Test (Diesel Engine)
30
General Diagnosis
32
Specifications
37
Engine Specifications
37
Performance Curve
38
Special Tools and Equipment
41
Special Tools Table
41
Repair Instructions
43
On-Vehicle Service
43
Engine Assembly
43
Poly V-Belt and Tensioning Device
51
Poly V-Belt
51
Poly V-Belt Inspection
53
Tensioning Device
55
Crankcase and Cylinder Head
57
Crankcase Ventilation System
57
Generator
59
Power Steering Pump and A/C Bracket
60
Engine Mount
63
Cylinder Head Cover
65
Cylinder Head
69
Oil Pan
72
Timing Gear Case Cover
74
Crankshaft Sealing Rear Cover
76
Crankshaft Assembly
78
Belt Pulley and Vibration Damper
78
Crankshaft Front Radial Seal
81
Crankshaft Rear Radial Seal
83
Crankshaft
85
Connecting Rod
91
Piston
93
Piston Ring
96
Flywheel / Driven Plate
98
Timing Device and Valve
101
Camshaft Adjuster
101
Camshaft Sprocket Bolt
106
Camshaft
107
Camshaft Timing Position
112
Valve Spring
115
Valve Stem Seal
119
Chain Tensioner
120
Timing Chain
124
Tensioning Rail
129
Cylinder Head Guide Rail
130
Crankcase Guide Rail
131
Crankshaft Sprocket
132
Lubrication System
134
Engine Oil Specification
134
Oil Circulation
135
Engine Oil and Oil Filter Element
136
Oil Filter
138
Oil Pump
140
Oil Pressure Relief Valve
141
Oil Non-Return Valve
142
Oil Dipstick Guide Tube
143
Unit Repair
144
Oil Gallery in Crankcase
144
Oil Gallery in Cylinder Head
146
Core Plugs in Crankcase
149
Cylinder Bore
151
Crankcase Mating Surface
153
Cylinder Head Mating Surface
155
Specifications
157
Fastener Tightening Specifications
157
Maintenance and Repair
163
On-Vehicle Service
163
Engine Assembly
163
Crankcase Ventilation System
170
Generator
174
Engine Mount
175
Poly V-Belt
177
Tensioning Device
179
Tensioning Device Shock Absorber
180
Poly V-Belt Inspection
181
Cylinder Head Cover
183
Cylinder Head
187
Timing Gear Case Cover
191
Crankshaft Sealing Rear Cover
194
Belt Pulley and Vibration Damper
196
Crankshaft Front Radial Seal
199
Crankshaft Rear Radial Seal
201
Crankshaft
202
Flywheel / Driven Plate
208
Camshaft Adjuster
211
Camshaft Sprocket Bolt
214
Camshaft
215
Camshaft Timing Position
218
Valve Spring
220
Valve Stem Seal
224
Chain Tensioner
225
Timing Chain
229
Tensioning Rail
234
Cylinder Head Guide Rail
235
Crankcase Guide Rail
237
Crankshaft Sprocket
238
Piston
240
Connecting Rod
243
Piston Ring
245
Oil Pan
247
Engine Oil and Oil Filter Element
249
Oil Pump
252
Oil Pressure Relief Valve
254
Oil Non-Return Valve
255
Oil Dipstick Guide Tube
256
Unit Repair
257
Core Plugs in Crankcase
257
Cylinder Bore
259
Crankcase Mating Surface
261
Cylinder Head Mating Surface
263
Specifications
265
Fastener Tightening Specifications
265
Special Tools and Equipment
267
Special Tools Table
267
Description and Operation
271
Valve Device
271
Component Locator
273
Cylinder Head
273
Cylinder Block
275
Engine Component
277
Repair Instructions
279
On-Vehicle Service
279
Engine Assembly
279
Poly V-Belt and Tensioning Device
288
Poly V-Belt
288
Tensioning Device
292
Crankcase and Cylinder Head
295
Cylinder Head
295
Prechamber
316
Oil Pan
318
Timing Case Cover
319
Crankshaft Assembly
326
Vibration Damper and Hub
326
Flywheel and Crankshaft End Cover
332
Crankshaft Ball Bearing
336
Crankshaft
337
Crankshaft Sprocket
346
Piston
351
Flywheel Ring Gear
357
Timing Device and Valve
360
Valve Tappets
362
Valve Spring (Cylinder Head Removed)
362
Valve Spring (Cylinder Head Installed)
365
Valve Stem Seals
368
Valve Guides
372
Valve Seat Rings
377
Camshaft
382
Timing Chain
388
Chain Tensioner
392
Lubrication System
394
Oil Filter
394
Oil Spray Nozzle
396
Oil Pump
397
Unit Repair
399
Milling of Prechamber Sealing Surface
399
TDC(TDC Sensor Bracket) Setting
402
Machining of Flywheel
404
Hydraulic Valve Clearance Compensation Element Check
405
Valve Springs Check
407
Check and Machining of Valves
408
Machining of Valve Seat
413
Camshaft Timing Test
418
Cylinder Head Pressure Leakage Test
420
Facing Cylinder Head Mating Surface
421
Replacement of Crankcase Core Plug
423
Facing Crankcase Contacting Surface
425
Cylinder Bore Measurement
426
Specifications
427
Fastener Tightening Specifications
427
Special Tools and Equipment
429
Special Tools Table
429
Description and Operation
436
General Description
436
Radiator
436
Coolant Reservoir
436
Water Pump
436
Thermostat
436
Electric Cooling Fan
436
Engine Coolant Temperature Sensor
437
Coolant Temperature Guage
437
Component Locator
438
Gasoline Engine
438
Diesel Engine
439
Diagnostic Information and Procedure
440
Cooling System Diagnosis
440
System Leakage Test
441
Thermostat Test
441
Repair Instructions
442
On-Vehicle Service
442
Coolant Drain and Fill
442
Coolant Connection Fitting (M162 Engine)
445
Water Pump (M162 Engine)
447
Water Pump (M161 Engine)
449
Water Pump (Diesel Engine)
451
Oil Cooler Pipe Line (M162 Engine)
453
Thermostat (M162 Engine)
454
Thermostat and Thermostat Housing Assembly (M161 Engine)
455
Thermostat and Water Pump Housing (Diesel Engine)
457
Cooling Fan and Viscous Clutch (M162 Engine)
459
Cooling Fan and Viscous Clutch (M161 Engine)
461
Cooling Fan and Viscous Clutch (Diesel Engine) . 1D-29
463
Cooling Fan Shroud (Gasoline Engine)
465
Cooling Fan Shroud (Diesel Engine)
467
Radiator (Gasoline Engine)
468
Radiator (Diesel Engine)
470
Specifications
472
General Specifications
472
Fastener Tightening Specifications
473
Special Tools and Equipment
474
Special Tools Table
474
Description and Operation
476
Battery
476
Ratings
476
Charging Time Required
476
Charging a Completely Discharged Battery (off the Vehicle)
477
Jump Starting Procedure
477
Generator
478
Charging System
478
Starter
478
Starting System
478
Diagnostic Information and Procedure
479
Ignition System
479
Preheating System (Diesel Engine)
481
Repair Instructions
483
On-Vehicle Service
483
Generator (Gasoline Engine)
483
Generator (Diesel Engine)
483
Starter
484
Battery
485
Spark Plug and Ignition Coil (Gasoline Engine)
486
Glow Plug (Diesel Engine)
487
Unit Repair
488
Starter
488
Generator (Mando Type)
496
Specifications
502
General Specifications
502
Fastener Tightening Specifications
503
Schematic and Routing Diagrams
504
Starting and Charging System (Diesel Engine)
505
Special Tools and Equipment
507
Special Tools Table
507
Engine and ECM Problem Check Report
510
Diagnostic Information and Procedure
511
Failure Code Diagnosis
511
Clearing Failure Codes
511
Failure Codes Table
511
Ignition System
515
Ignition Coil
517
Crankshaft Position (CKP) Sensor
519
Camshaft Position (CMP) Sensor
523
Camshaft Actuator
527
Knock Sensor (KS)
529
Spark Plug
531
System Voltage
535
Ignition Switch
536
Fuel System
537
Fuel Pump
539
Fuel Injector
543
Purge Control Valve
547
Fuel Rail
549
Fuel Pressure Regulator
551
Induction System
553
Throttle Valve Actuator
553
Hot Film Air Mass (HFM) Sensor
557
Engine Coolant Temperature (ECT) Sensor
561
Accelerator Pedal Module
565
Clutch Switch
568
Cooling Fan
569
A/C Compressor Relay
570
Cruise Control Switch
571
Traction Control System (TCS)
572
Resonance Flap
573
Stop Lamp Switch
574
Engine RPM
575
Exhaust System
576
Catalytic Converter
576
Oxygen Sensor
577
Engine Control Module
583
Serial Data Communication
584
Internal Failure
586
Immobilizer
589
Maintenance and Repair
590
On-Vehicle Service
590
Discharging the Pressure in Fuel System
590
Fuel Pump
590
Fuel Filter
591
Fuel Tank
592
Fuel Pressure Regulator
593
Engine Coolant Temperature Sensor
595
Throttle Body (Integrated with the Actuator)
596
Hot Film Air Mass (HFM) Sensor
597
Knock Sensor
597
Pedal Position Sensor
598
Oxygen Sensor
598
Purge Control Valve
599
Canister
599
Camshaft Position Sensor
599
Crankshaft Position Sensor
600
Engine Control Module
600
1F1-2 M162 Engine Controls
601
Schematic and Routing Diagrams
601
ECM Wiring Diagram
602
Specifications
608
Engine Data Display Table
608
Fastener Tightening Specifications
609
Fuel System Specification
610
Temperature Vs Resistance
610
Special Tools and Equipment
611
Special Tools Table
611
Engine and ECM Problem Check Report
614
Diagnostic Information and Procedure
615
Failure Code Diagnosis
615
Clearing Failure Codes
615
Failure Codes Table
615
Ignition System
619
Ignition Coil
621
Crankshaft Position (CKP) Sensor
623
Camshaft Position (CMP) Sensor
627
Camshaft Actuator
631
Knock Sensor (KS)
633
Spark Plug
635
System Voltage
639
Ignition Switch
640
Fuel System
641
Fuel Pump
643
Fuel Injector
647
Purge Control Valve
651
Fuel Rail
653
Fuel Pressure Regulator
655
Induction System
657
Throttle Valve Actuator
657
Hot Film Air Mass (HFM) Sensor
661
Engine Coolant Temperature (ECT) Sensor
665
Accelerator Pedal Module
669
Cooling Fan
673
A/C Compressor Relay
674
Cruise Control Switch
675
Traction Control System (TCS)
676
Stop Lamp Switch
677
Engine RPM
678
Exhaust System
679
Catalytic Converter
679
Oxygen Sensor
681
Engine Control Module
687
Serial Data Communication
689
Internal Failure
691
Electronic Throttle Controller Safety Malfunction
693
Immobilizer
695
Maintenance and Repair
696
On-Vehicle Service
696
Discharging the Pressure in Fuel System
696
Fuel Pump
696
Fuel Filter
697
Fuel Tank
698
Fuel Pressure Regulator
699
Engine Coolant Temperature Sensor
701
Throttle Body
702
Actuator)
702
Hot Film Air Mass (HFM) Sensor
703
Knock Sensor
703
Pedal Position Sensor
704
Oxygen Sensor
704
Purge Control Valve
705
Canister
705
Camshaft Position Sensor
705
Crankshaft Position Sensor
706
Engine Control Module
706
Schematic and Routing Diagrams
707
ECM Wiring Diagram
708
Description and Operation
719
Fuel System
719
Governor
721
Absolute Metering Manifold Pressure Compensator (ALDA)
727
Pneumatic Idle Speed Increase (PLA)
728
Pneumatic Shut-Off Device (PNAB)
729
Exhaust Gas Recirculation (EGR) Valve
730
Component Locator
732
Fuel Injection Pump
732
Vacuum Pump (Sectional View)
733
Diagnostic Information and Procedure
734
Vacuum Control System Test
734
Vacuum Shut-Off Leak Test
738
Idle Speed Adjustment
740
Fuel Pump Test
742
Injection Nozzle Test
745
Checking and Adjusting Start of Delivery
748
Repair Instructions
758
On-Vehicle Service
758
Vacuum Pump
758
Vacuum Unit Replacement
760
Fuel Pump
761
Injection Nozzles
763
Injection Nozzle Repair
765
Injection Timing Device Assembly
768
Injection Timing Device
773
Fuel Injection Pump
775
Fuel Tank
781
Specifications
783
General Specifications
783
Fastener Tightening Specifications
784
Schematic and Routing Diagrams
785
Special Tools and Equipment
786
Special Tools Table
786
Description and Operation
790
Exhaust System
790
Muffler
790
Catalytic Converter (Gasoline Engine)
790
DOC (Diesel Oxidation Catalyst)
790
Resonance Flap (Gasoline Engine)
793

SSANGYONG Rexton Y200 Manual (1627 pages)

Brand: SSANGYONG | Category: Automobile | Size: 69 MB

Section 1 Engine

15
- Table of Contents
  15
- 1A-2 Engine General Information
  
  16
- Description and Operation
  
  16
  - Cleanliness and Care
    16
  - On-Engine Service
    16
- Component Locator
  
  17
  - M162 Engine
    17
  - M161 Engine
    19
  - Diesel Engine
    21
- Diagnostic Information and Procedure
  
  23
- Specifications
  
  37
  - Engine Specifications
    37
  - Performance Curve
    38
- Special Tools and Equipment
  
  41
  - Special Tools Table
    41
Section 1B1 M162 Engine Mechanical

42
- Repair Instructions
  
  43
  - Engine Assembly
    43
  - Poly V-Belt and Tensioning Device
    51
    
    Poly V-Belt
    51
    
    Poly V-Belt Inspection
    53
    
    Tensioning Device
    55
  - Crankcase and Cylinder Head
    57
    
    Crankcase Ventilation System
    57
    
    Generator
    59
    
    Power Steering Pump and A/C Bracket
    60
    
    Engine Mount
    63
    
    Cylinder Head Cover
    65
    
    Cylinder Head
    69
    
    Oil Pan
    72
    
    Timing Gear Case Cover
    74
    
    Crankshaft Sealing Rear Cover
    76
  - Crankshaft Assembly
    78
    
    Belt Pulley and Vibration Damper
    78
    
    Crankshaft Front Radial Seal
    81
    
    Crankshaft Rear Radial Seal
    83
    
    Crankshaft
    85
    
    Connecting Rod
    91
    
    Piston
    93
    
    Piston Ring
    97
    
    Flywheel / Driven Plate
    98
  - Timing Device and Valve
    101
    
    Camshaft Adjuster
    101
    
    Camshaft Sprocket Bolt
    106
    
    Camshaft
    107
    
    Camshaft Timing Position
    112
    
    Valve Spring
    115
    
    Valve Stem Seal
    119
    
    Chain Tensioner
    120
    
    Timing Chain
    124
    
    Tensioning Rail
    129
    
    Cylinder Head Guide Rail
    130
    
    Crankcase Guide Rail
    131
    
    Crankshaft Sprocket
    132
  - Lubrication System
    134
    
    Engine Oil Specification
    134
    
    Oil Circulation
    135
    
    Engine Oil and Oil Filter Element
    136
    
    Oil Filter
    138
    
    Oil Pump
    140
    
    Oil Pressure Relief Valve
    141
    
    Oil Non-Return Valve
    142
    
    Oil Dipstick Guide Tube
    143
- On-Vehicle Service
  
  43
- Unit Repair
  
  144
  - Oil Gallery in Crankcase
    144
  - Oil Gallery in Cylinder Head
    146
  - Core Plugs in Crankcase
    149
  - Cylinder Bore
    151
  - Crankcase Mating Surface
    153
  - Cylinder Head Mating Surface
    155
- Specifications
  
  157
  - Fastener Tightening Specifications
    157
- Special Tools and Equipment
  
  159
  - Special Tools Table
    159
Section 1B2 M161 Engine Mechanical

162
- On-Vehicle Service
  
  163
  - Engine Assembly
    163
  - Crankcase Ventilation System
    170
  - Generator
    174
  - Engine Mount
    175
  - Poly V-Belt
    177
  - Tensioning Device
    179
  - Tensioning Device Shock Absorber
    180
  - Poly V-Belt Inspection
    181
  - Cylinder Head Cover
    183
  - Cylinder Head
    187
  - Timing Gear Case Cover
    191
  - Crankshaft Sealing Rear Cover
    194
  - Belt Pulley and Vibration Damper
    196
  - Crankshaft Front Radial Seal
    199
  - Crankshaft Rear Radial Seal
    201
  - Crankshaft
    202
  - Flywheel / Driven Plate
    208
  - Camshaft Adjuster
    211
  - Camshaft Sprocket Bolt
    214
  - Camshaft
    215
  - Camshaft Timing Position
    218
  - Valve Spring
    220
  - Valve Stem Seal
    224
  - Chain Tensioner
    225
  - Timing Chain
    229
  - Tensioning Rail
    234
  - Cylinder Head Guide Rail
    235
  - Crankcase Guide Rail
    237
  - Crankshaft Sprocket
    238
  - Piston
    240
  - Connecting Rod
    243
  - Piston Ring
    245
  - Oil Pan
    247
  - Engine Oil and Oil Filter Element
    249
  - Oil Pump
    252
  - Oil Pressure Relief Valve
    254
  - Oil Non-Return Valve
    255
  - Oil Dipstick Guide Tube
    256
- Maintenance and Repair
  
  163
- Unit Repair
  
  257
  - Core Plugs in Crankcase
    257
  - Cylinder Bore
    259
  - Crankcase Mating Surface
    261
  - Cylinder Head Mating Surface
    263
- Specifications
  
  265
  - Fastener Tightening Specifications
    265
- Special Tools and Equipment
  
  267
  - Special Tools Table
    267
Section 1B3 Diesel Engine Mechanical

270
- Description and Operation
  
  271
  - Valve Device
    271
- Component Locator
  
  274
  - Cylinder Head
    274
  - Engine Component
    276
  - Engine Assembly
    278
- On-Vehicle Service
  
  278
- Repair Instructions
  
  278
  - Poly V-Belt and Tensioning Device
    287
    
    Poly V-Belt
    287
    
    Tensioning Device
    291
  - Crankcase and Cylinder Head
    294
    
    Cylinder Head
    294
    
    Prechamber
    315
    
    Oil Pan
    317
    
    Timing Case Cover
    318
  - Crankshaft Assembly
    325
    
    Vibration Damper and Hub
    325
    
    Flywheel and Crankshaft End Cover
    331
    
    Crankshaft Ball Bearing
    335
    
    Crankshaft
    336
    
    Crankshaft Sprocket
    345
    
    Piston
    350
    
    Flywheel Ring Gear
    356
  - Timing Device and Valve
    359
    
    Valve Tappets
    361
    
    Valve Spring (Cylinder Head Removed)
    361
    
    Valve Spring (Cylinder Head Installed)
    364
    
    Valve Stem Seals
    367
    
    Valve Guides
    372
    
    Valve Seat Rings
    377
    
    Camshaft
    382
    
    Timing Chain
    382
    
    Chain Tensioner
    392
  - Lubrication System
    394
    
    Oil Filter
    394
    
    Oil Spray Nozzle
    396
    
    Oil Pump
    397
- Unit Repair
  
  399
  - Milling of Prechamber Sealing Surface
    399
  - TDC(TDC Sensor Bracket) Setting
    402
  - Machining of Flywheel
    404
  - Hydraulic Valve Clearance Compensation Element Check
    405
  - Valve Springs Check
    407
  - Check and Machining of Valves
    408
  - Machining of Valve Seat
    413
  - Camshaft Timing Test
    418
  - Cylinder Head Pressure Leakage Test
    420
  - Facing Cylinder Head Mating Surface
    421
  - Replacement of Crankcase Core Plug
    423
  - Facing Crankcase Contacting Surface
    425
  - Cylinder Bore Measurement
    426
- Specifications
  
  427
  - Fastener Tightening Specifications
    427
- Special Tools and Equipment
  
  429
  - Special Tools Table
    429
Section 1F1 M162 Engine Controls

435
- Engine and ECM Problem Check Report
  
  437
- Diagnostic Information and Procedure
  
  440
- Failure Code Diagnosis
  
  440
  - Clearing Failure Codes
    440
  - Failure Codes Table
    440
- Ignition System
  
  442
  - Ignition Coil
    443
  - Crankshaft Position (CKP) Sensor
    445
  - Camshaft Position (CMP) Sensor
    448
  - Camshaft Actuator
    451
  - Knock Sensor (KS)
    453
  - Spark Plug
    455
  - System Voltage
    458
  - Ignition Switch
    459
- Fuel System
  
  460
  - Fuel Pump
    461
  - Fuel Injector
    464
  - Purge Control Valve
    468
  - Fuel Rail
    470
  - Fuel Pressure Regulator
    472
- Induction System
  
  474
  - Throttle Valve Actuator
    474
  - Hot Film Air Mass (HFM) Sensor
    477
  - Engine Coolant Temperature (ECT) Sensor
    481
  - Accelerator Pedal Module
    485
  - Clutch Switch
    488
  - Cooling Fan
    489
  - A/C Compressor Relay
    490
  - Cruise Control Switch
    491
  - Traction Control System (TCS)
    492
  - Resonance Flap
    493
  - Stop Lamp Switch
    494
  - Engine RPM
    495
- Exhaust System
  
  496
  - Catalytic Converter
    496
  - Oxygen Sensor
    497
- Engine Control Module
  
  502
  - Serial Data Communication
    503
  - Internal Failure
    505
  - Electronic Throttle Controller Safety Malfunction . 1F1-80
    506
  - Immobilizer
    508
- Maintenance and Repair
  
  509
- On-Vehicle Service
  
  509
  - Discharging the Pressure in Fuel System
    509
  - Fuel Pump
    509
  - Fuel Filter
    510
  - Fuel Tank
    511
  - Fuel Pressure Regulator
    512
  - Fuel Rail and Injector
    513
  - Engine Coolant Temperature Sensor
    514
  - Throttle Body (Integrated with the Actuator)
    515
  - Hot Film Air Mass (HFM) Sensor
    516
  - Knock Sensor
    516
  - Pedal Position Sensor
    517
  - Oxygen Sensor
    517
  - Purge Control Valve
    518
  - Canister
    518
  - Camshaft Position Sensor
    518
  - Crankshaft Position Sensor
    519
  - Engine Control Module
    519
- Schematic and Routing Diagrams
  
  520
  - ECM Wiring Diagram
    521
- Specifications
  
  527
  - Engine Data Display Table
    527
  - Fastener Tightening Specifications
    528
  - Fuel System Specification
    529
  - Temperature Vs Resistance
    529
- Special Tools and Equipment
  
  530
  - Special Tools Table
    530
Section 1F2 M161 Engine Controls

531
- Engine and ECM Problem Check Report
  
  533
- Diagnostic Information and Procedure
  
  534
- Failure Code Diagnosis
  
  534
  - Clearing Failure Codes
    534
  - Failure Codes Table
    534
- Ignition System
  
  538
  - Ignition Coil
    539
- Crankshaft Position (CKP) Sensor
  
  541
  - Camshaft Position (CMP) Sensor
    544
  - Camshaft Actuator
    547
  - Knock Sensor (KS)
    549
  - Spark Plug
    551
  - System Voltage
    554
  - Ignition Switch
    555
- Fuel System
  
  556
  - Fuel Pump
    557
  - Fuel Injector
    560
  - Purge Control Valve
    564
  - Fuel Rail
    566
  - Fuel Pressure Regulator
    568
- Induction System
  
  570
  - Throttle Valve Actuator
    570
  - Hot Film Air Mass (HFM) Sensor
    573
  - Engine Coolant Temperature (ECT) Sensor
    577
  - Accelerator Pedal Module
    581
  - Cooling Fan
    584
  - A/C Compressor Relay
    585
  - Cruise Control Switch
    586
  - Traction Control System (TCS)
    587
  - Stop Lamp Switch
    588
  - Engine RPM
    589
- Exhaust System
  
  590
  - Catalytic Converter
    590
  - Oxygen Sensor
    591
- Engine Control Module
  
  596
  - Serial Data Communication
    597
  - Internal Failure
    599
  - Electronic Throttle Controller Safety Malfunction
    600
  - Immobilizer
    602
- On-Vehicle Service
  
  603
  - Discharging the Pressure in Fuel System
    603
  - Fuel Pump
    603
  - Fuel Filter
    604
  - Fuel Tank
    605
  - Fuel Pressure Regulator
    606
  - Fuel Rail and Injector
    607
  - Engine Coolant Temperature Sensor
    608
  - Throttle Body
    609
  - Actuator)
    609
  - Hot Film Air Mass (HFM) Sensor
    610
  - Knock Sensor
    610
  - Pedal Position Sensor
    611
  - Oxygen Sensor
    611
  - Purge Control Valve
    612
  - Canister
    612
  - Camshaft Position Sensor
    612
  - Crankshaft Position Sensor
    613
  - Engine Control Module
    613
- Maintenance and Repair
  
  603
- Schematic and Routing Diagrams
  
  614
  - ECM Wiring Diagram
    615
  - Engine Data Display Table
    621
- Specifications
  
  621
  - Fastener Tightening Specifications
    622
  - Fuel System Specification
    623
  - Temperature Vs Resistance
    623
Section 1F3 Diesel Engine Controls

625
- Description and Operation
  
  626
  - Fuel System
    626
  - Governor
    628
  - Absolute Metering Manifold Pressure Compensator (ALDA)
    634
  - Pneumatic Idle Speed Increase (PLA)
    635
  - Pneumatic Shut-Off Device (PNAB)
    636
  - Exhaust Gas Recirculation (EGR) Valve
    637
- Component Locator
  
  639
  - Fuel Injection Pump
    639
  - Vacuum Pump (Sectional View)
    640
- Diagnostic Information and Procedure
  
  641
  - Vacuum Control System Test
    641
  - Vacuum Shut-Off Leak Test
    645
  - Idle Speed Adjustment
    647
  - Fuel Pump Test
    649
  - Injection Nozzle Test
    652
  - Checking and Adjusting Start of Delivery
    655
- On-Vehicle Service
  
  665
  - Vacuum Pump
    665
  - Vacuum Unit Replacement
    667
  - Fuel Pump
    668
  - Injection Nozzles
    670
  - Injection Nozzle Repair
    672
  - Injection Timing Device Assembly
    675
  - Injection Timing Device
    680
  - 25 Fuel Injection Pump
    682
  - Fuel Tank
    688
- Repair Instructions
  
  665
- Specifications
  
  690
  - General Specifications
    690
  - Fastener Tightening Specifications
    691
- Schematic and Routing Diagrams
  
  692
- Special Tools and Equipment
  
  693
  - Special Tools Table
    693
Section 2C Front Suspension

696
- Description and Operation
  
  697
  - 2C-2 Front Suspension
    697
  - Specifications
    699
- Component Locator
  
  700
  - Front Suspension Assembly
    700
- Cross-Sectional View
  
  701
  - Suspension Assembly
    701
  - Shock Absorber
    702
  - Diagnostic Information and Procedures
    703
- Repair Instructions
  
  704
- On-Vehicle Service
  
  704
  - Stabilizer
    706
  - Shock Absorber Assembly
    707
  - Upper/Lower Arm Assembly
    709
- Unit Repair
  
  711
  - Front Coil Spring
    711
  - Hub and Bearing
    713
  - Special Tools Table
    715
Sectiond Rear Suspension

716
- Description and Operation
  
  717
  - 2D-2 Rear Suspension
    717
  - Specifications
    718
- Component Locator
  
  719
  - Shock Absorber
    720
- Diagnostic Information and Procedures
  
  721
  - 2D-6 Rear Suspension
    721
  - Wheel Bearing End Play
    722
  - Wheel Bearing Free Load
    722
- On-Vehicle Service
  
  723
- Repair Instructions
  
  723
  - Rear Suspension Assembly
    724
- Special Tools and Equipment
  
  731
  - Special Tools Table
    731
Section 2E Tires and Wheels

732
- Description and Operation
  
  733
  - General
    733
  - Tire's Abnormal Action
    734
  - Wheel Alignment
    735
  - Specifications
    736
- Diagnostic Information and Procedures
  
  737
- General Inspection
  
  738
  - Inspection the Appearance
    738
  - General Inspection
    740
- Component Locator
  
  743
  - Tire and Wheel Assembly
    743
  - ON-Vehicle Service
    744
    
    General Tire
    744
    
    Spare Tire
    745
- Repair Instructions
  
  744
- Maintenance and Replacement
  
  746
  - Separation
    746
  - Maintenance
    747
  - Installation
    748
Section 3A Front Axle

750
- General Description and Operation
  
  751
  - Front Axle Housing Assembly
    751
  - Axle Shaft Assembly
    752
  - Specifications
    753
- Diagnosis Information and Procedures
  
  754
- Component Locator
  
  755
  - Front Axle Shaft
    755
  - Front Axle Housing
    756
  - Vacuum Line
    759
- Maintenance and Repair
  
  760
  - On-Vehicle Service
    760
    
    Front Axle Shaft
    760
    
    Vacuum Line
    767
    
    Axle Housing
    768
- Unit Repair
  
  769
  - Axle Housing Assembly
    769
  - Differential Joint Assembly
    775
  - Wheel Joint Assembly
    777
- Special Tools and Equipment
  
  779
  - Special Tools Table
    779
Section 3C Propeller Shaft

780
- General Description and Operation
  
  781
  - Specifications
    781
- Diagnostic Information and Procedures
  
  782
- Component Locator
  
  783
  - Cross Sectional View
    783
  - Propeller Shaft Assembly
    784
- Maintenance and Repair
  
  785
  - On-Vehicle Service
    785
    
    Propeller Shaft Assembly
    785
- Unit Repair
  
  788
  - Propeller Shaft
    788
Sectiond Rear Axle

792
- General Description and Operation
  
  793
  - Specifications
    793
- Diagnostic Information and Procedures
  
  794
- Component Locator
  
  795
  - Rear Axle Assembly
    795
  - Cross Sectional View
    796
  - Rear Axle Shaft Assembly
    797
- Maintenance and Repair
  
  799
  - On-Vehicle Service
    799
    
    Axle Shaft Assembly (with Disc Brake)
    799
    
    Axle Shaft Assembly (with Drum Brake)
    802
    
    Rear Axle Housing
    804
- Unit Repair
  
  809
  - Axle Assembly
    809
  - Differential Gear Assembly
    810

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SSANGYONG Rexton Y200 Manuals

SSANGYONG Rexton Y200 Manual (3772 pages)

Table of Contents

SSANGYONG Rexton Y200 Manual (1627 pages)

Table of Contents

Section 1 Engine

1A-2 Engine General Information

Description and Operation

Component Locator

Diagnostic Information and Procedure

Specifications

Special Tools and Equipment

Section 1B1 M162 Engine Mechanical

Repair Instructions

On-Vehicle Service

Unit Repair

Specifications

Special Tools and Equipment

Section 1B2 M161 Engine Mechanical

On-Vehicle Service

Maintenance and Repair

Unit Repair

Specifications

Special Tools and Equipment

Section 1B3 Diesel Engine Mechanical

Description and Operation

Component Locator

On-Vehicle Service

Repair Instructions

Unit Repair

Specifications

Special Tools and Equipment

Section 1F1 M162 Engine Controls

Engine and ECM Problem Check Report

Diagnostic Information and Procedure

Failure Code Diagnosis

Ignition System

Fuel System

Induction System

Exhaust System

Engine Control Module

Maintenance and Repair

On-Vehicle Service

Schematic and Routing Diagrams

Specifications

Special Tools and Equipment

Section 1F2 M161 Engine Controls

Engine and ECM Problem Check Report

Diagnostic Information and Procedure

Failure Code Diagnosis

Ignition System

Crankshaft Position (CKP) Sensor

Fuel System

Induction System

Exhaust System

Engine Control Module

On-Vehicle Service

Maintenance and Repair

Schematic and Routing Diagrams

Specifications

Section 1F3 Diesel Engine Controls

Description and Operation

Component Locator

Diagnostic Information and Procedure

On-Vehicle Service

Repair Instructions

Specifications

Schematic and Routing Diagrams

Special Tools and Equipment

Section 2C Front Suspension

Description and Operation

Component Locator

Cross-Sectional View

Repair Instructions

On-Vehicle Service

Unit Repair

Sectiond Rear Suspension

Description and Operation

Component Locator

Diagnostic Information and Procedures