SsangYong Rexton. Manual - part 9

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GENERAL INFORMATION

DI ENG SM - 2004.4

3. Engine Serial Number

The engine serial number is stamped on the lower area of
cylinder block in exhaust manifold side.

4. Manual Transmission Number

The transmission label is affixed on the upper area of clutch
housing.

Y220_0A020

5. Automatic Transmission Number

The transmisson label is affixed on the right area of transmis-
sion housing.

Y220_0A021

6. Transfer Case Number

The transfer case label is affixed on the transfer case housing.

Y220_0A022

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DI ENG SM - 2004.4

Abbreviation of small
group and page

Vehicle model

Describes information on the manual
like modification, application date,
applicable V.I.N

Describes small group name, model
and publication date

Bolded: Notice, Installation Notice,

Note

HOW TO USE AND MAINTAIN WORKSHOP MANUAL

CONSISTS OF WORKSHOP
MANUAL

1. Group: The manual is divided in large group like

engine, transmission, axle and others and this group
is also divided in small group by vehicle state.

2. Small group: Each small group consists of general,

vehicle service, unit repair and special tool usage.

MANUAL DESCRIPTION

• The contents of the manual consist of operational

principle of system, specifications, diagnosis, removal/
installation on vehicle, inspections, disassembly/
assembly of removed assembly, special tool usage.
Not providing simple removal/installation information
but focused on to describe much more functions, roles
and principles of system.

• Every automotive term like part name on the manual

is the same in parts catalog, technical bulletin and
drawings to avoid confusion among them.

 Consists of Small Group

1. Contents: In small group, included subjects and

detailed subjects are described in.

2. General: In the general, summary of the small group

(assembly), function and operational principle,
specifications, structure and components, diagnosis
and circuit diagram are described in.

3. Vehicle service: Service works on the vehicle like

replacement of parts and inspection repairs are
described in the order of repair works with actual
photos and illustrations. Also cautions in service
works, references and inspection methods after
completion of service are described in.

4. Disassembly and assembly of unit assembly:

Detailed service works like disassembly, inspection,
adjustment and assembly on removed component
(assembly) are described in with systematic contents
and photo illustration.

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GUIDELINES FOR SERVICE WORK SAFETY

General

Notice

Notice means precautions on tool/device or part
damages or personal injuries that can occur during
service works.

To maintain and operate the vehicle under optimum state
by performing safe service works, the service works should
be done by following correct methods and procedures.

Accordingly, the purpose of this manual is to prevent dif-
ferences that can be caused by personal working method,
skill, ways and service procedures and to allow prompt/
correct service works.

Note, Notice

While using this manual, there are a lot of Note or Notice
having below meaning.

Note

Note means detailed description of supplementary
information on work procedure or skill.

However, above references and cautions cannot be inclu-
sive measures, so should have habits of taking concerns
and cautions based on common senses.

Cautions on Inspection/Service

Notice

During service works, be sure to observe below general
items for your safety.

• For service works, be sure to disconnect battery

negative (-) terminal if not starting and inspection.

• While inspecting vehicle and replacing various

consumable parts, be sure to take caution not to
damage vehicle and injure people.

• Engine and transmission may be hot enough to

burn you. So inspect related locations when they
cooled down enough.

• If engine is running, keep your clothing, tools, hair

and hands away from moving parts.

• Even when the ignition key is turned off and

positioned to LOCK, electrical fan can be operated
while working on near around electrical fan or
radiator grille if air conditioner or coolant
temperature rises.

• Every oil can cause skin trouble. Immediately wash

out with soap if contacted.

• Painted surface of the body can be damaged if

spilled over with oil or anti-freeze.

• Never go under vehicle if supported only with jack.

• Never near the battery and fuel related system to

flames that can cause fire like cigarette.

• Never disconnect or connect battery terminal or other

electrical equipment if ignition key is turned on.

• While connecting the battery terminals, be cautious

of polarities (+, –) not to be confused.

• There are high voltage and currency on the battery

and vehicle wires. So there can be fire if short-
circuited.

• Do not park while running the engine in an

enclosed area like garage. There can be toxication
with CO, so make sufficient ventilation.

• The electrical fan works electrically. So the fan can

be operated unexpectedly during working causing
injuries if the ignition key is not in LOCK position.
Be sure to check whether ignition key is in LOCK
position before work.

• Be careful not to touch hot components like

catalytic converter, muffler and exhaust pipe when
the engine is running or just stopped. They may
burn you badly.

Y220_0A024

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Guidelines on Engine Service

To prevent personal injuries and vehicle damages that can
be caused by mistakes during engine and unit inspection/
repair and to secure optimum engine performance and
safety after service works, basic cautions and service work
guidelines that can be easily forgotten during engine ser-
vice works are described in.

Cautions before service works

• Before work on engine and each electrical equipment,

be sure to disconnect battery negative (-) terminal.

• Before service works, be sure to prepare the works by

cleaning and aligning work areas.

• Always position the ignition switch to OFF if not

required. If not, there can be electrical equipment
damages or personal injuries due to short-circuit or
ground by mistake.

• There should be no leak from fuel injection system

(HP pump, fuel hose, high pressure pipe) of the D27DT
engine. So they should be protected from foreign
materials.

• While removing the engine, do not position the jack

and others under the oil pan or engine. To secure the
safety, use only safety hook on the engine.

Engine and accessories

Engine has a lot of precise portions so tightening torque
should be correct during disassembly/assembly and re-
moval/installation and service work should be done in clean
ways during disassembly/assembly.

Maintaining working area clean and cautious service ad-
ministration is essential element of service works while
working on the engine and each section of the vehicle. So
the mechanics should well aware of it.

• While removing the engine, related parts (bolts,

gaskets, etc.) should be aligned as a group.

• While disassembling/assembling internal components

of the engine, well aware of disassembly/assembly
section in this manual and clean each component with
engine oil and then coat with oil before installation.

• While removing engine, drain engine oil, coolant and

fuel in fuel system to prevent leakage.

• During service work of removal/installation, be sure to

check each connected portions to engine not to make
interference.

Electrical equipment

Electrical equipment should be handled more carefully.
Currently, the engine is equipped with a lot of electrical
equipments so there can be engine performance drops,
incomplete combustion and other abnormals due to short
and poor contact. Mechanics should well aware of vehicle’s
electrical equipment.

• If have to work on the electrical equipment, be sure to

disconnect battery negative (-) terminal and position
the ignition switch to off if not required.

• When replacing electrical equipment, use the same

genuine part and be sure to check whether ground or
connecting portions are correctly connected during
installation. If ground or connecting portion is loosened,
there can be vehicle fire or personal injury.

Fuel and lubrication system

Painted surface of the body can be damaged or rubber
products (hoes) can be corroded if engine oil and fuel are
spilled over. If spilled over engine, foreign materials in air
can be accumulated on the engine damaging fuel system.

• If work on the fluid system such as fuel and oil, working

area should be well ventilated and mechanic should
not smoke.

• Gasket or seal on the fuel/lubrication system should

be replaced with new and bolts and nuts should be
tightened as specified.

• After removal/installation works, be sure to check

whether there is leak on the connecting section.

If fine dust or foreign material enters into DI engine’s
fuel system, there can be serious damages between
HP pump and injectors. So, be sure to cover removed
fuel system components with cap and protect removed
parts not to be contaminated with dirt. (Refer to clean-
ness in this manual while working on DI engine fuel
system)