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SSANGYONG Rexton Y200, Manual

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SSANGYONG Rexton Y200 Manual Download 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.

TABLE OF CONTENTS

Description and Operation ............................... 1B3-2

Valve Device .................................................... 1B3-2

Component Locator .......................................... 1B3-4

Cylinder Head ................................................... 1B3-4

Cylinder Block .................................................. 1B3-6

Engine Component ........................................... 1B3-8

Repair Instructions .......................................... 1B3-10

On-Vehicle Service ........................................... 1B3-10

Engine Assembly .............................................. 1B3-10

Poly V-Belt and Tensioning Device .................... 1B3-19

Poly V-Belt ...................................................... 1B3-19

Tensioning Device .......................................... 1B3-23

Crankcase and Cylinder Head ........................... 1B3-26

Cylinder Head ................................................. 1B3-26

Prechamber .................................................... 1B3-46

Oil Pan ............................................................ 1B3-48

Timing Case Cover ......................................... 1B3-49

Crankshaft Assembly ........................................ 1B3-56

Vibration Damper and Hub ............................. 1B3-56

Flywheel and Crankshaft End Cover ............... 1B3-62

Crankshaft Ball Bearing .................................. 1B3-66

Crankshaft ...................................................... 1B3-67

Crankshaft Sprocket ....................................... 1B3-76

Piston ............................................................. 1B3-81

Flywheel Ring Gear ......................................... 1B3-87

Timing Device and Valve ................................... 1B3-90

Valve Tappets ................................................ 1B3-90

Valve Spring (Cylinder Head Removed) ......... 1B3-92

Valve Spring (Cylinder Head Installed) ........... 1B3-95

Valve Stem Seals ............................................ 1B3-98

Valve Guides ................................................ 1B3-102

Valve Seat Rings .......................................... 1B3-105

Camshaft ...................................................... 1B3-112

Timing Chain ................................................ 1B3-118

Chain Tensioner ............................................ 1B3-122

Lubrication System .......................................... 1B3-124

Oil Filter ........................................................ 1B3-124

Oil Spray Nozzle ........................................... 1B3-126

Oil Pump ....................................................... 1B3-127

Unit Repair ..................................................... 1B3-129

Milling of Prechamber Sealing Surface ......... 1B3-129

TDC(TDC Sensor Bracket) Setting ................ 1B3-133

Machining of Flywheel .................................. 1B3-135

Hydraulic Valve Clearance Compensation

Element Check .......................................... 1B3-136

Valve Springs Check .................................... 1B3-138

Check and Machining of Valves ................... 1B3-139

Machining of Valve Seat ............................... 1B3-144

Camshaft Timing Test ................................... 1B3-149

Cylinder Head Pressure Leakage Test ......... 1B3-151

Facing Cylinder Head Mating Surface .......... 1B3-152

Replacement of Crankcase Core Plug .......... 1B3-154

Facing Crankcase Contacting Surface .......... 1B3-156

Cylinder Bore Measurement ......................... 1B3-157

Specifications ................................................ 1B3-158

Fastener Tightening Specifications ............... 1B3-158

Special Tools and Equipment ...................... 1B3-160

Special Tools Table ...................................... 1B3-160

Summary of Contents for Rexton Y200

Page 1: ...3 At Each Fuel Fill 0B 3 At Least Twice a Month 0B 3 At Least Monthly 0B 3 At Least Twice a Year 0B 3 Each Time The Oil is Changed 0B 4 At Least Annually 0B 4 Standard Bolts Specifications 0B 5 Basic Specification 0B 6 Dimension 0B 6 Specifications 0B 7 Recommended Fluids And Lubricants 0B 9 Vehicle Identification Number System 0B 10 Vehicle Identification Number Vin 0B 10 ManufacturerSPlate 0B 11...

Page 2: ... than those viscosities recommended could result in engine damage Cooling System Service 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 Replace the air cleaner element every Gasoline Engine 60 0...

Page 3: ...above the lower mark Avoid overfilling the engine since this may cause engine damage 6 Push the indicator all the way back down into the engine after taking the reading OWNER INSPECTIONS AND SERVICES If you check the oil level when the oil is cold do not run the engine first The cold oil will not drain back to the pan fast enough to give a true oil level reading Engine Coolant Level and Condition ...

Page 4: ...er tension Adjust or replace the belts as needed Hood Latch Operation When opening the hood note the operation of the secondary latch It should keep the hood from opening all the way when the primary latch is released The hood must close firmly AT LEAST ANNUALLY Lap and Shoulder Belts Condition and Operation Inspect the belt system including the webbing the buckles the latch plates the retractor t...

Page 5: ...in 372 4 N m 276 lb in 1 2 N m 11 lb in 2 6 N m 23 lb in 5 2 N m 47 lb in 9 0 N m 81 lb in 20 6 N m 15 2 lb in 42 1 N m 31 lb in 41 2 N m 30 lb in 75 5 N m 56 lb in 71 5 N m 53 lb in 117 6 N m 87 lb in 186 2 N m 138 lb in 264 6 N m 196 lb in 362 6 N m 268 lb in 490 0 N m 362 lb in 637 0 N m 471 lb in 617 4 N m 457 lb in Diameter X pitch in millimeters Bolt Torque N m Ib in Standard Limit 4T 7T 9T ...

Page 6: ...SSANGYONG Y200 0B 6 GENERAL INFORMATION BASIC SPECIFICATION DIMENSION YAA0B030 Gasoline engine equipped vehicle ...

Page 7: ...ity Turbo charger and cooling type Type Model Type Diesel 4 270 1 870 1 760 AT 2405 MT 2365 AT 1950 MT 1910 5 6 200 Diesel 80 L OM662LA 5 22 1 2 874 cc SOHC 120 ps 4 000 rpm 25 5 kg m 2 400 rpm BTDC 18 1 0 770 50 rpm Water cooled forced circulation 10 5 L 11 L Gear pump forced circulation 8 9 L Turbo charger air cooled Remote control floor change type 3 969 2 341 1 457 1 000 0 851 3 705 Electronic...

Page 8: ...acity V kW Alternator capacity V A Diesel Part time Planetary gear type 1 000 1 2 483 1 Hydraulic A T Torque converter Dry single diaphragm type A T 3 elements 1 stage 2 phases Rack and pinion 36 17 32 40 Ball joint type Build up type Semi floating type Build up type Tandem type Vacuum booster Disc Drum Disc Cable type internal expansion Wishbone Coil spring 5 link Coil spring R134a Vane type MF 1...

Page 9: ...m Changeevery15 000kmor12months But every 7 500 km or 6 months under severe conditions Inspect every 30 000 km or 12 months But change every 60 000 km under severe conditions Initially change at 12 000 km and Inspect every 50 000 km Inspect frequently Change every 40 000 km or 2 years Inspect every 10 000 15 000 km Change every 60 000 km Inspect every 10 000 15 000 km Change every 60 000 km Change...

Page 10: ...er Gasoline E23 9 3199cc In line 6Cylinder Gasoline E32 D 2874cc In line 5Cylinder Diesel 662LA 7 Restraint System 1 3 Point Seat Belts 2 2 Point Seat Belts 6 Trim Level A Standard B Deluxe C Super Deluxe 5 Body Type 0 5 Door 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 YAA0B040 VEHICLE I...

Page 11: ...GENERAL INFORMATION 0B 11 SSANGYONG Y200 YAA0B050 YAA0B060 YAA0B070 MANUFACTURER S PLATE 1 Type Approval No 2 Vehicle Identification No Manufacturer s Plate Location Gasoline Engine Diesel Engine ...

Page 12: ...ne number is stamped on the cylinder block in front of injection pump 662 920 1 0 012345 Serial Number 0 Manual T M 1 Hydr Auto Coupling 2 Automatic T M 910 Non Intercooler Engine 920 Intercooler Engine 661 2299cc 662 2874cc 0 Common 1 Left Hand Drive 2 Right Hand Drive 5 REXTON YAA0B090 ...

Page 13: ...ear side of the alternator 162 990 1 0 012345 Serial Number 0 Manual T M 1 Hydr Auto Coupling 2 Automatic T M 99 3 2L 97 2 3L ENGINE TYPE 0 Common 1 Left Hand Drive 2 Right Hand Drive 5 REXTON YAA0B120 Gasolind Engine 2 3L DOHC YAA0B110 The engine number is stamped on the upper rear left hand side of the cylinder block ...

Page 14: ...rmation Many dealer service facilities and service stations are equipped with automative hoists that bear upon some parts of the frame in order to lift the vehicle If any other hoist method is used take special care to avoid damaging the fuel tank the filter neck the exhaust system or the underbody Using Floor Jack YAA0B130 Front Side YAA0B140 Rear Side YAA0B150 Using Jack YAA0B160 Rearward of Fro...

Page 15: ...1A 7 Diagnostic Information and Procedure 1A 9 Oil Leak Diagnosis 1A 9 Compression Pressure Test Gasoline Engine 1A 10 Compression Pressure Test Diesel Engine 1A 12 Cylinder Pressure Leakage Test Gasoline Engine 1A 14 Cylinder Pressure Leakage Test Diesel Engine 1A 16 General Diagnosis 1A 18 Specifications 1A 23 Engine Specifications 1A 23 Performance Curve 1A 24 Special Tools and Equipment 1A 27 ...

Page 16: ...should be kept in order They should be installed in the same locations and with the same mating surfaces as when they were removed Battery cables should be disconnected before any major work is performed on the engine Failure to disconnect cables may result in damage to wire harness or other electrical parts ON ENGINE SERVICE Caution Disconnect the negative battery cable before removing or install...

Page 17: ...p 4 Cylinder Head Cover 5 Exhaust Camshaft 6 Intake Camshaft 7 Cylinder Head 8 Spark Plug Connector 9 Valve Tappet 10 Injector 11 Exhaust Valve 12 Intake Manifold 13 Connecting Rod 14 Exhaust Manifold 15 Crankshaft 16 Engine Mounting Bracket 17 Starter 18 Crankcase 19 Oil Pump Sprocket 20 Oil Strainer 21 Oil Pan 22 Drain Plug YAD1A010 ...

Page 18: ...0 1A 4 ENGINE GENERAL INFORMATION Side View YAD1A020 23 Camshaft Adjuster 24 Cooling Fan and Viscous Clutch 25 Piston 26 Flywheel of Drive Plate 27 Oil Pump Drive Chain 28 Oil Return Pipe 29 Timing Chain 30 Oil Pump ...

Page 19: ...nition Coil 5 Spark Plug Connector 6 Fuel Distributor 7 Injector 8 Exhaust Camshaft 9 Intake Camshaft 10 Valve Tappet 11 Intake Valve 12 Intake Manifold 13 Cylinder Head 14 Exhaust Manifold 15 Dipstick Guide Tube and Gauge 16 Connecting Rod 17 Crankshaft 18 Engine Mounting Bracket 19 Starter 20 Crankcase 21 Oil Pump Sprocket 22 Oil Pan ...

Page 20: ...Side View YAD1A040 23 Camshaft Adjuster 24 Oil Filler Cap 25 Engine Hanger Bracket 26 Cooling Fan and Viscous Clutch 27 Oil Filter 28 Timing Chain 29 Oil Pump Drive Chain 30 Oil Strainer 31 Oil Pump 32 Ring Gear and Flywheel of Drive Plate 33 Piston ...

Page 21: ...ENGINE GENERAL INFORMATION 1A 7 SSANGYONG Y200 YAD1A050 DIESEL ENGINE Front View ...

Page 22: ...SSANGYONG Y200 1A 8 ENGINE GENERAL INFORMATION Side View YAD1A060 ...

Page 23: ...normal operating conditoins 4 Visually inspect the suspected component You should be able to trace the leak path over the white powder surface to the source Black Light and Dye Method A dye and light kit is available for finding leaks Refer to the manufacturer s directions when using the kit 1 Pour the specified amount of dye into the engine oil fill tube 2 Operate the vehicle normal operating con...

Page 24: ... 2 Diagram Sheet 3 Adaptor 4 Sealing Cone Standard Service Data Application Compression Ratio Normal Engine Temperature Normal Compression Pressure Permissible Pressure Difference Between Individual Cylinders M162 Engine 10 1 80 C 176 F Min 10 bar Max 14 bar Max 1 5 bar YAD1A070 M161 Engine 10 4 1 Min 11 bar Max 15 bar ...

Page 25: ...ptor to compression pressure tester 001 589 76 21 00 and install it into the spark plug hole 5 Crank the engine approx eight revolutions by using the start motor 6 Compare the measurements of compression pressure tester 001 589 76 21 00 with the specifications 7 Measure the compression pressure of the other cylinders in the same way 8 If measured value is not within the specifications perform the ...

Page 26: ... Adaptor 2 Flexible Connector 3 Compression Pressure Tester Standard Service Data Compression Ratio Normal Engine Temperature Normal Compression Pressure Minimum Compression Pressure Permissible Pressure Difference Between Individual Cylinders 22 1 80 C 176 F 28bar Approx 18bar Max 3bar YAD1A080 ...

Page 27: ...2 to the compression pressure tester 001 589 76 21 00 4 Disconnect the vacuum line from the stop unit and connect the hand vacuum pump 001 589 73 21 00 to the stop unit 5 Pump the hand vacuum pump 001 589 73 21 00 and make the fuel injection pump in stop position 6 Using a starter motor crank the engine 8 revolutions 7 Measure the remaining cylinder compression pressure in the same manner and comp...

Page 28: ... Filler Cap 2 Vibration Damper Permissible Pressure Leakage 3 Cylinder Pressure Leakage Tester with Connecting Hose Universal Tool At Whole Engine At Valve and Cylinder Head Gasket At Piston and Piston Ring Max 25 Max 10 Max 20 Cylinder Number By Mark On Vibration Damper At TDC b 240 3 4 a 120 2 5 Cylinder Pressure Leakage Tester Bosch EFAW 210A Sun CLT 228 YAD1A110 OT TDC 1 4 UT BDC 180 2 3 ...

Page 29: ...r 7 Install the connecting hose to spark plug hole 9 Connect the connecting hose to tester and measure the leakage volume after blowing up 5 bar of compressed air Notice Measure the leakage volume in the completely opening condition of throttle valve by pulling the acceleration cable 10 Perform the pressure test according to the firing order Notice Firing Order M162 Engine 1 5 3 6 2 4 M161 Engine ...

Page 30: ...ion Piece 3 Connection Hose Cylinder Pressure LeakageTester Connection Piece Permissible Pressure Leakage Engine at Normal OperatingTemperature of 80 C At Whole Engine At Valve and Cylinder Head Gasket At Piston and Piston Ring Max 25 Max 10 Max 20 Universal Tools Bosch EFAW 210 A or Sun CLT 228 Bosch order no 1 687 010 016 ...

Page 31: ... Calibrate the tester and connect the connection hose 3 10 Pressurize with compressed air and compare the pressure changes with permissible pressure leakage 11 If permissible pressure leakage is out of standard check followings Intake and exhaust lines Sounds in oil filler area Air bubbles in radiator coolant 12 Do pressure leakage test for the remaining cylinders according to the firing order fir...

Page 32: ...ark plug Electric leakage or poor connection of the high tension cable Correction Replace the fuse Clean adjust the plug gap or replace Replace the cable Replace the cable or wires Adjust the ignition timing Replace the ignition coil Feed the fuel Replace the filter Clean the fuel pipe Replace the fuel pump Replace the injector Clean the fuel tank Tighten to the specified torque Compression Replac...

Page 33: ...Correction Clean the pipe Replace the filter Check and repair the system Clean or replace the air cleaner element Replace the gasket Repair or replace the brakes Refer to Page 1A 10 Clean the pipe Replace the filter Replace the regulator Adjust or replace the spark plug Connect the cable correctly or replace it Adjust the ignition timing Replace the ignition coil Clean or replace the air cleaner e...

Page 34: ...lator Adjust or replace the spark plug Connect the cable correctly or replace it Adjust the ignition timing Clean or replace the gasket Connect the hose correctly or replace it Refer to Overheat in this page Replace the spark plug Adjust the ignition timing Connect the cable correctly or replace it Clean or replace the fuel filter and the fuel pipe Replace the gasket Remove the carbon Refill coola...

Page 35: ... strainer Lowered function of the oil pump Abrasion or damage of the oil pump relief valve Correction Refer to Page 1A 10 Repair or replace the fuel tank or the fuel pipe Adjust the ignition timing Replace the plug Connect the cable normally or replace it Repair the thermostat Repair or replace the valve Adjust the pressure of tires Tighten the plug Tighten the bolt Engine Oil Tighten the filter T...

Page 36: ...t Excessive clearance of the crankshaft thrust bearing Low oil pressure Correction Adjust the valve clearance Replace the valve stem or the guide Replace the spring Boring the cylinder or replace the piston the ring or the cylinder Replace the bearing Tighten to the specified torque Replace the bearing Grind or replace the crankshaft journal Tighten to the specified torque Adjust or replace Refer ...

Page 37: ...nition BTDC 8 ATDC 11 ABDC 34 BBDC 31 BTDC 14 Automatic Control 700 50 3 4 8 2 Forced by Gear Pump Full Flow with Paper Filter Unleaded Gasoline SPECIFICATIONS ENGINE SPECIFICATIONS Application Engine Model Displacement CC Cylinder Bore x Stroke mm Fuel Injection Ignition System Compression Ratio Number of Cylinders Camshaft Valve Arrangement Camshaft Drive Type Max Output ps rpm Max Torque kg m r...

Page 38: ...SSANGYONG Y200 1A 24 ENGINE GENERAL INFORMATION PERFORMANCE CURVE M162 Engine YAD1A160 ...

Page 39: ...ENGINE GENERAL INFORMATION 1A 25 SSANGYONG Y200 M161 Engine YAD1A170 ...

Page 40: ...SSANGYONG Y200 1A 26 ENGINE GENERAL INFORMATION Diesel Engine YAD1A180 ...

Page 41: ...SSANGYONG Y200 SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE 001 589 73 21 00 Hand Vacuum Pump 120 589 02 09 00 Spark PlugWrench 001 589 76 21 00 Compression Pressure Tester 610 589 65 09 00 Socket YAD1A190 YAD1A220 YAD1A210 YAD1A200 ...

Page 42: ... Pulley and Vibration Damper 1B1 37 Crankshaft Front Radial Seal 1B1 40 Crankshaft Rear Radial Seal 1B1 42 Crankshaft 1B1 44 Connecting Rod 1B1 50 Piston 1B1 52 Piston Ring 1B1 55 Flywheel Driven Plate 1B1 57 Timing Device and Valve 1B1 60 Camshaft Adjuster 1B1 60 Camshaft Sprocket Bolt 1B1 65 Camshaft 1B1 66 Camshaft Timing Position 1B1 71 Valve Spring 1B1 74 Valve Stem Seal 1B1 78 ChainTensioner...

Page 43: ... 1B1 2 M162 ENGINE MECHANICAL REPAIR INSTRUCTIONS ON VEHICLE SERVICE 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 1 Engine Assembly YAD1B010 ...

Page 44: ...adiator drain cock and drain the coolant Notice Open the coolant reservoir cap 7 Remove the air cleaner cover Remove the mounting bolts and air cleaner housing and element assembly Removal Installation Procedure 1 Disconnect the negative terminal of battery 2 Remove the hood 3 Remove the under cover Installation Notice Tightening Torque 28 47 N m 21 35 lb ft Tightening Torque 9 11 N m 80 97 lb in ...

Page 45: ... upper mounting bolts of radiator and then remove the radiator 11 Disconnect the each hose from radiator 9 Loosen the cylinder block drain plug and then drain the coolant completely Installation Notice Replace the seal before installation of the drain plug Tightening Torque 30 N m 22 lb ft YAD1B050 YAD1B060 YAD1B070 YAD1B080 ...

Page 46: ...e 16 Remove the fuel feed and return line Installation Notice Before removing the fuel lines release the pressure in the fuel system 15 Remove the acceleration control cable and automatic transmission pressure cable 13 Remove the hydraulic pipe of power steering Installation Notice Completely drain the oil Tightening Torque 21 25 N m 15 18 lb ft YAD1B090 YAD1B100 YAD1B4M0 KAA1F070 Tightening Torqu...

Page 47: ...e the starter motor 19 Disconnect the engine main harness ground 21 Disconnect following sensors connector Coolant temperature sensor 2 knock sensors Camshaft and crankshaft sensors 20 Disconnect the engine ground wire 17 Disconnect the terminals from the generator YAD1B110 YAD1B120 YAD1B130 YAA1F150 ...

Page 48: ...Separate the other vacuum hoses 25 Remove the automatic transmission oil cooler line Installation Notice 22 After removing the ignition coil cover disconnect the ignition coil connector 23 Remove the harness cover and disconnect the 6 injection valve connectors Disconnect the main harness YAD1B140 YAD1B4N0 YAD1B150 YAD1B160 Tightening Torque 25 35 N m 18 26 lb ft ...

Page 49: ...transmission from the engine Installation Notice 30 Remove the exhaust manifold and exhaust pipe Installation Notice 32 Install a chain to the bracket of engine by using a hoist or crane 33 Remove the engine mounting bracket nuts Installation Notice Tightening Torque Upper 70 N m 52 lb ft Lower 38 N m 28 lb ft Screw the six bolts mounting the torque converter through the service hole by using a mi...

Page 50: ...M162 ENGINE MECHANICAL 1B1 9 SSANGYONG Y200 34 Carefully separate the engine assembly from the vehicle 35 Installation should follow the removal procedure in the reverse order YAD1B210 ...

Page 51: ...al Installation Procedure 1 Release the belt tension by turning the belt tensioning pulley nut clockwise Installation Notice Tightening Torque 40 5 49 5 N m 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 pulley clockwise YAD1B250 ...

Page 52: ...SANGYONG Y200 Poly V Belt Arrangement 1 Belt Tensioning Pulley 2 Crankshaft Belt Pulley 3 A C Compressor Pulley 4 Cooling Fan Pulley 5 Generator Pulley 6 Idler 7 Power Steering Pump Pulley 8 Cooling Fan and Water Pump Pulley YAD1B340 ...

Page 53: ...d torn out at the side 6 Outer cords frayed 3 Pointed rib 4 Belt cord visible in the base of rib POLY V BELT INSPECTION Make marks on the belt with chalk Rotate the engine and check the belt for damage Notice If one of the following types of damages is found replace the belt YAD1B370 YAD1B380 YAD1B390 YAD1B400 ...

Page 54: ...NICAL 1B1 13 SSANGYONG Y200 8 Splits across the rib 9 Sections of rib torn out 11 Splits across the back of the belt 10 Splits across several ribs 7 Rib detached from the base of belt YAD1B410 YAD1B420 YAD1B430 YAD1B440 ...

Page 55: ...4 M162 ENGINE MECHANICAL TENSIONING DEVICE Preceding Work Removal of poly v belt 1 Belt L 2245 2 Bolt Combi M8 x 14 3 pieces Washer 22 5 27 5 N m 16 6 20 3 lb ft 3 Water Pump Pulley 4 Nut 5 Belt Tensioning Pulley YAD1B350 ...

Page 56: ... Remove the bolts and remove the water pump pulley Installation Notice Tightening Torque 26 32 N m 19 24 lb ft Tightening Torque 40 5 49 5 N m 29 9 36 5 lb ft Tightening Torque 22 5 27 5 N m 16 6 20 3 lb ft 4 Remove the mounting bolts M8 x 30 3 pieces at the tensioning device and remove the tensioning device Installation Notice 5 Installation should follow the removal procedure in the reverse orde...

Page 57: ... Bracket 7 Oil Drain Pipe 8 Oil Pan 9 Air Admission Line 10 Vent Line 11 Restriction Hole Diameter 2 mm 12 Intake Manifold 13 Intake Air Duct Cross Pipe 14 Cylinder Head Cover 15 Oil Separator 16 Oil Separator 17 Air Admission and Vent Connection 18 Air Admission and Vent Connection 19 Throttle Valve 20 Vent Line A Fresh Air B Blowby Gas in Partial Load C Blowby Gas in Full Load YAD1B220 ...

Page 58: ...separated at the air conditioner bracket 6 and then returns into the oil pan through the drain pipe 7 The vacuum pressure generated at the crankcase sucks fresh air from intake air line 13 through the air admission and vent connection 17 18 The fresh air prevents engine oil from being contaminated and the air admission and vent connection 17 18 is designed to control the rapid pressure changes in ...

Page 59: ...5 lb ft 4 Bolt M8 x 70 1 piece 22 5 27 5 N m 16 5 20 5 lb ft 5 Bolt M8 x 75 1 piece 22 5 27 5 N m 16 5 20 5 lb ft Removal Installation Procedure 1 Remove the drive belt 2 Remove the generator 3 Unscrew the generator carrier bolts and remove the carrier Installation Notice TighteningTorque 25 N m 18 lb ft 4 Installation should follow the removal procedure in the reverse order YAD1B230 YAD1B240 ...

Page 60: ...22 5 27 5 N m 16 5 20 5 lb ft 3 Power Steering Pump 4 Bolt M8 x 105 4 pieces 22 5 27 5 N m 16 5 20 5 lb ft 5 Washer 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 8 A C Bracket 9 Gasket Replace 10 Bracket 11 Bolt M8 x 22 2 pieces 22 5 27 5 N m 16 5 20 5 lb ft 12 Tensioning Pulley 13 Nut 40 5 49 5 N m 29 9 36 5 lb ft YAD1B5A0 ...

Page 61: ...e hydraulic pipe of the power steering pump and drain the oil 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 TighteningTorque 40 5 49 5 N m 29 9 36 5 lb ft Pull the tensioning pulley clockwise as shown in the figure TighteningTorque 22 5 27 5 N m 16 6 20 3 lb ft YAD1B250 YAD1B090...

Page 62: ... bracket and the gasket Installation Notice 5 Disconnect the vent hose from the A C bracket Installation Notice 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 TighteningTorque 22 5 27 5 N m 16 6 20 3 lb ft YAD1B280 YAD1B290 Tightening Torque 20 ...

Page 63: ...SSANGYONG Y200 1B1 22 M162 ENGINE MECHANICAL ENGINE MOUNT YAD1B300 ...

Page 64: ...teningTorque 70 N m 52 lb ft TighteningTorque 38 N m 28 lb ft 2 Unscrew the lower engine mounting nut Installation Notice 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 YAD1B310 YAD1B320 ...

Page 65: ...9 11 N m 80 97 lb in 3 Bolt M6 x 50 4 pieces 9 11 N m 80 97 lb in 4 Spacer Sleeve 5 Thrust Piece 6 Cylinder Head Cover 7 Gasket Replace 8 Spart Plug Hole Seal Replace 9 Camshaft Seal Replace Composition of The Cylinder Head Cover Bolts A M6 x 50 4 Pieces Bolts Washers B M6 x 65 8 Pieces Bolts Washers YAD1B450 YAD1B460 ...

Page 66: ...hould follow the removal procedure in the reverse order 6 Check for oil leaks by operating the engine 3 Remove the spark plug connector and ignition cable Removal Installation Procedure 1 Remove the intake air duct Installation Notice TighteningTorque 9 11 N m 80 97 lb in TighteningTorque 9 11 N m 80 97 lb in Unscrew the seven M6 x 60 bolts and remove the spark plug cover YAD1B470 YAD1B480 YAD1B49...

Page 67: ...l of cylinder head cover Removal of coolant connection fitting 1 Camshaft Position Sensor 2 Camshaft Actuator 3 Upper Guide Rail 4 Bolt M6 x 60 3 pieces 22 5 27 5 N m 16 6 20 3 lb ft 5 Bolt M8 x 80 3 pieces 22 5 27 5 N m 16 6 20 3 lb ft 6 Front Cover 7 Rubber Gasket Replace 8 Bolt M6 x 16 3 pieces 9 11 N m 80 97 lb in Tightening Torque 9 11 N m 80 97 lb in YAD1B510 YAD1B520 ...

Page 68: ...w the removal procedure in the reverse order 2 Remove the cylinder head front cover 6 Installation Notice Tightening Torque 22 5 27 5 N m 16 6 20 3 lb ft Apply the sealant at the mating surface of the cylinder head and the front cover 3 Remove the upper guide rail pin and the guide rail 3 Notice Install it while the chain tensioner is loose YAD1B530 YAD1B540 ...

Page 69: ...f cylinder head front cover Removal of upper intake manifold 1 Cylinder Head Bolt 14 pieces 1st step 55 N m 141 lb ft 2nd step 90 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 4 Exhaust Camshaft Sprocket 5 Cylinder Head 6 Gasket Replace 7 Dowel Sleeve YAD1B550 ...

Page 70: ...aded Pin 116 589 20 33 00 Sliding Hammer 617 589 00 10 00 Allen Wrench Socket Removal Installation Procedure 1 Rotate the crankshaft so that the piston of number 1 cylinder is at TDC Notice Rotate the crankshaft in the normal engine direction 2 Put the alignment marks arrows on the timing chain and camshaft sprocket 3 Drain the coolant from the crankcase TighteningTorque 1st step 18 22 N m 13 16 l...

Page 71: ...rocedure in the reverse order 8 Check the length of the cylinder head bolt Installation Notice 6 Remove the guide rail fixing pin from the cylinder head using the threaded pin 116 589 01 34 00 1 and sliding hammer 116 589 20 33 00 2 Tightening Torque 1st step 55 N m 41 lb ft 2nd step 90 3rd step 90 Length L New 160 0 8 mm Max 162 0 7 mm Replace the bolt if the measured length exceed the max length...

Page 72: ...olt M6 x 22 6 pieces 9 11 N m 80 97 lb in 3 Drain Plug 22 5 27 5 N m 16 6 20 3 lb ft 4 Bolt M6 x 20 22 pieces 9 11 N m 80 97 lb in 5 Bolt M6 x 85 3 pieces 9 11 N m 80 97 lb in 6 Bolt M8 x 40 4 pieces 22 5 27 5 N m 16 6 20 3 lb ft 7 Bolt M10 40 N m 30 lb ft 8 Oil Pan YAD1B5B0 ...

Page 73: ...et Notice Arrange the bolts according to each size 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 M8 X 40 4 pieces M6 X 85 3 pieces M6 X 35 3 pieces M6 X 22 6 pieces M6 X 20 28 pieces Others YAD1B5C0 ...

Page 74: ...evice Removal of belt pulley and vibration damper 1 Bolt M8 x 60 3 pieces 22 5 27 5 N m 16 6 20 3 lb ft 2 A C Bracket 3 Bolt M8 x 65 3 pieces 22 5 27 5 N m 16 6 20 3 lb ft 4 Bolt M8 x 40 1 piece 22 5 27 5 N m 16 6 20 3 lb ft 5 Bolt M8 x 60 1 piece 22 5 27 5 N m 16 6 20 3 lb ft 6 Seal 7 Timing Gear Case Cover 8 Roll Pin 9 Bolt M6 x 22 6 pieces 9 11 N m 80 97 lb in YAD1B690 ...

Page 75: ...ocedure 1 Put the alignment marks arrows on the timing chain and camshaft sprocket 2 Unscrew the A C bracket bolts 1 and remove the bracket Installation Notice Tightening Torque 22 5 27 5 N m 16 6 20 3 lb ft Tightening Torque 22 5 27 5 N m 16 6 20 3 lb ft Apply the sealant after cleaning the timing gear case cover surface Be careful not to stain the oil chamber of chain tensioner with the sealant ...

Page 76: ... CRANKSHAFT SEALING REAR COVER Preceding Work Removal of the automatic transmission drive plate 1 Bolt M6 x 20 6 pieces 9 11 N m 80 97 lb in 2 Radial Shaft Seal 3 Rear Cover 4 Sleeve 5 Bolt M6 x 85 2 pieces 9 11 N m 80 97 lb in 6 Washer YAD1B710 ...

Page 77: ...e crankshaft rear seal installer 601 589 03 43 00 Installation Notice 2 Clean the sealing surface of the crankcase and the rear sealing cover 3 Check the radial shaft seal and replace it if necessary 4 Apply the Loctite 573 to the rear cover sealing surface 5 Apply the engine oil to the dust lip of the radial shaft seal Notice Do not use the grease 6 Install the crankshaft rear radial seal and the...

Page 78: ...mper Disk 3 Bolt M6 x 20 6 pieces 7 7 9 5 N m 68 1 84 1 lb in CRANKSHAFT ASSEMBLY BELT PULLEY AND VIBRATION DAMPER Preceding Work Removal of cooling fan and viscous clutch Removal of fan shroud Removal of drive belt 4 Vibration Damper Assembly 5 Woodruff Key 6 Bolt M6 x 12 4 pieces 9 11 N m 80 97 lb in 7 Cooling Fan Pulley YAD1B650 ...

Page 79: ...embly 4 Woodruff Key 5 Crankshaft Front Seal 6 Timing Gear Case Cover 7 Crankshaft Sprocket Camshaft Driven 8 Crankshaft Sprocket Oil Pump Driven 9 Crankshaft 10 Oil Pan 11 Oil Pan Gasket 12 Oil Pan Mounting Bolt M6 x 22 Service Data Standard Permissble Deviation of The Vibration Damper Radial Runout Axial Runout 0 6 mm 0 6 mm YAD1B660 ...

Page 80: ...ve 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 Tools Required 602 589 00 40 00 Engine Lock Removal Installation Procedure 1 Adjust the piston of number 1 cylinder to the TDC YAD1B670 YAD1B680 TighteningTorque 1st step 180 220 N m 133 162lb ft 2nd step 90 ...

Page 81: ...L CRANKSHAFT FRONT RADIAL SEAL Preceding Work Removal of belt pulley and vibration damper 1 Center Bolt M18 x 50 1st step 180 220 N m 133 162 lb ft 2nd step 90 10 2 Center Bolt Washer YAD1B780 3 Sleeve Special Tool 4 Crankshaft Front Seal 5 Key ...

Page 82: ... with engine oil 3 Using the crankshaft front seal installer 601 589 03 14 00 assemble the radial seal 4 Align the sleeve groove and the woodruff key and tighten the center bolt until the center bolt and the damper disk stop in the movement Installation Notice 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 ...

Page 83: ...SSANGYONG Y200 1B1 42 M162 ENGINE MECHANICAL YAD1B840 CRANKSHAFT REAR RADIAL SEAL Preceding Work Removal of flywheel or drive plate 1 Special Tool 2 Special Tool 3 Crankshaft Rear Seal ...

Page 84: ... mounting hole and the crankshaft 2 Install the crankshaft rear seal installer 601 589 03 43 00 2 to the crankshaft 3 Apply the engine oil on the crankshaft rear seal installer 601 589 03 43 00 2 Notice Do not use the grease 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 whil...

Page 85: ... 90 5 CRANKSHAFT Preceding Work Removal of engine assembly Removal of timing gear case cover Removal of cylinder head Removal of crankshaft sealing rear cover Removal of oil pan Removal of oil pump Removal of baffle plate 2 Crankshaft Bearing Cap 3 Crankshaft Lower Main Bearing 4 Crankshaft Lower Thrust Bearing 5 Crankshaft YAD1B860 ...

Page 86: ...in Bearing 1 7 l 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 A Crankcase Side B Bearing Cap Side Oil Pan Side C Axial Fit Bearing Number 5 Bearing Point D Radial Bearing 1 Upper Main Bearing 2 Upper Thrust Bearing 3 Crankshaft 4 Lower Main Bearing 5 Lower Thrust Bearing ...

Page 87: ... Diameter mm 57 960 57 965 57 955 57 960 57 950 57 955 57 945 57 950 57 940 57 945 Punching Mark Bearing Color Selected Blue Yellow Red Marking Letter B Y R W V Bearing Color Selected Blue Yellow Red White Violet YAD1B880 YAD1B890 Service Data Unit mm Crankshaft Bearing Jour nal Diameter Thrust Washer Thickness Crankshaft Journal Width at fit bearing ConnectingRod Bearing Journal Diameter Connecti...

Page 88: ...other and coat with engine oil The oil grooves arrows in the thrust washers must face outward and insert the thrust bearing into the bearing cap There are five kinds of thrust washers by thickness Select the proper washer when repaired 3 Remove the crankshaft 4 Installation should follow the removal procedure in the reverse order 5 After completion of the installation check for the rotating condit...

Page 89: ...earing Notice Measure at 2 points 1 2 Measure A B and C as shown If average value of B and C is less than value A then the average value of B and C is actual average value If average value of B and C is more than value A then the value A is actual average value 4 Measure and record the diameter of the crankshaft bearing journal Notice Record the mean value when measured at 3 points A B C Measure t...

Page 90: ... Bearing Journal NO 3 4 6 Measuring Position Radial Axial Radial Axial Gap mm Static condition 0 015 0 039 Dynamic condition 0 031 0 051 Consider the expansion 0 011 0 016 0 010 0 254 Static condition 0 011 0 039 Dynamic condition 0 031 0 051 Consider the expansion 0 015 0 022 0 010 0 254 Item Connecting Rod Bearing Measuring Position Radial Gap mm 0 030 0 050 ...

Page 91: ...re Width of The Connecting Rod b at Bushing Bore Basic Bore at The Bearing Shell D1 Basic Bore at The Bushing d1 Bushing Inner Diameter d Clearance Between The Piston Pin and The Bushing Peak to valley Height of Connecting Rod Bushing on Inside Permissible Twist of Connecting Rod Bearing Bore to Connecting Rod Bushing Bore Permissible Deviation of Axial Paralleism of Connecting Rod Bearing Bore to...

Page 92: ...or number arrow of the connecting rods and the bearing cap when installing Notice 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 Notice If the length exceeds max length replace it YAD1B980 YAD1B990 YAD1B0A0 Length When New L Max Length L ...

Page 93: ...ngine Removal of cylinder head Removal of oil pan Removal of oil pump Removal of baffle plate 1 Connecting Rod Bearing Cap 2 Connecting Rod 3 Connecting Rod Bearing Cap Bolt M9 x 52 12 pieces 1st step 40 5 N m 30 3 7 lb ft 2nd step 90 10 YAD1B2P0 4 Piston 5 Snap Ring 6 Piston Pin ...

Page 94: ... Remove the connecting rod and the piston upward Notice Make sure that the bearing cap and shell are not changed each other 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 ...

Page 95: ...od bearing journal connecting rod bearing shell and the piston and coat them with engine oil 4 Install the piston ring 5 Install the piston so that the arrow on the piston head faces to the forward of the vehicle 6 After aligning the connecting rod and the bearing cap mark or a number tighten the bolts Installation Notice Apply the engine oil to the bearing cap upper and lower bearing shells 7 Che...

Page 96: ...NGINE MECHANICAL 1B1 55 SSANGYONG Y200 PISTON RING Preceding Work Removal of piston 1 Piston Compression Ring 2 Piston Compression Ring 3 Piston Oil Ring YAD1B2T0 4 Coil Spring and Control Ring 5 Hook Spring ...

Page 97: ...0 mm Groove 2 0 20 0 40 mm Groove 3 0 20 0 45 mm Groove 1 0 015 0 050 mm Groove 2 0 020 0 040 mm Groove 3 0 010 0 045 mm End Gap of The Piston Ring 2 Remove the piston ring with a pliers 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 Y...

Page 98: ...t M10 x 22 8 pieces 1st step 45 5 N m 33 3 7 lb ft 2nd step 90 10 2 Plate 3 Driven Plate A T 4 Dowel Pin 5 Flywheel M T Service Data Standard Stretch Bolt YAD1B810 Nominal Size Stretch Side Diameter Bolt Length Tightening Torque M x 1 5 8 5 0 2 mm 8 0 mm 21 8 22 2 mm When New Min Diameter When New D d L 1st step 45 5 N m 33 3 7 lb ft 2nd step 90 10 ...

Page 99: ...unting bolt is less than 8 0 mm For the stretch bolt tightening keep the socket wrench and Tommy bar to be 90 and tighten 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 TighteningTorque 1st step 40 5 N m 30 3 7 lb ft 2nd step 90 10 YAD1B8...

Page 100: ...NG Y200 Sectional View 1 Oil Pan 2 Cover 3 Crankshaft Front Seal 4 Flywheel Mounting Bolt 5 Crankshaft 6 Dowel Pin 7 Washer thickness 3 5 mm YAD1B830 8 Washer 9 Bolt 10 Front Drive Plate 11 Rear Drive Plate 12 Rivet 13 Segment 14 Ring Gear ...

Page 101: ...3 Bolt 35 N m 26 lb ft 4 Armature 5 Roll Pin 6 Nut M20 x 1 5 60 70 N m 44 52 lb ft 7 Front Cover 8 Seal 9 Camshaft Position Sensor 10 Bolt M6 x 16 2 pieces 9 11 N m 80 97 lb in 11 12 Seal Cover 13 Camshaft Sprocket and Position Indicator b 14 Adjuster Piston 15 Flange Bolt M7 x 13 3 pieces 1st step 18 22 N m 13 16 lb ft 2nd step 90 5 16 Flange Shaft 17 Compression Spring 18 Control Piston 19 Circl...

Page 102: ...49 Electromagnetic Actuator Not Functioning 1 Ignition suitch OFF retarded The compression spring 17 pushes the control piston 18 against the circlip 19 The engine oil pressure in the camshaft is eliminated 2 From 0 to 1000 2000 rpm retarded The torque of the internally helically toothed camshaft sprocket 13 acting in the direction of rotation of the engine pushes the externally helically toothed ...

Page 103: ...n Spring 18 Control Piston Stops Towards The Rear 19 Circlip 22 Intake Camshaft 23 Oil Outlet Drilling A Working Chamber Oil Pressure Y49 Electromagnetic Actuator Not Functioning 4 From 4000 rpm retarded The electromagnetic actuator Y49 is not actuated and allows the control piston to move The compression spring 17 pushes the control piston 18 against the circlip 19 The oil feed to the working cha...

Page 104: ...er to Cylinder Head Front Cover in this section 3 Paint the alignment marks arrows on the intake and exhaust camshaft sprocket and the timing chain 4 Unscrew the bolt 3 from the armature 4 and remove the armature Installation Notice 5 Unscrew the nut 6 and remove the ring and seal cover 11 Installation Notice 3 Bolt 4 Amarture 6 Nut M20 x 1 5 12 Seal Cover 13 Camshaft Sprocket 18 Control Piston 22...

Page 105: ... used only once so always replace with new one 8 Installation should follow the removal procedure in the reverse order 9 Adjust the camshaft timing TighteningTorque 1st step 18 22 N m 13 16 lb ft 2nd step 90 5 6 Unscrew the sprocket bolt from the exhaust camshaft and remove the sprocket Installation Notice The sprocket bolt is designed to be used only once so always replace with new one Tightening...

Page 106: ...igned to be used only once so always replace with new one C M7 x 13 Collar Bolt Torx T30 e 6 8 mm 16 Flange Shaft 18 Control Piston 22 Intake Camshaft E M7 x 13 Collar Bolt Torx T30 e 6 8 mm 13a Camshaft Sprocket 22a Exhaust Camshaft CAMSHAFT SPROCKET BOLT Intake Flange Shaft Bolt Installation Notice TighteningTorque 1st step 18 22 N m 13 16 lb ft 2nd step 90 5 TighteningTorque 1st step 18 22 N m ...

Page 107: ...l of cylinder head cover Removal of cylinder head front cover Removal of coolant connection fitting 1 Chain Tensioner Assembly 72 88 N m 53 65 lb ft 2 Exhaust Camshaft Sprocket 3 Upper Guide Rail 4 Cylinder Head Front Cover 5 Intake Camshaft Sprocket 6 Chain 7 Wrench YAD1B0J0 ...

Page 108: ...move the generator 3 Remove the chain tensioner Refer to Chain Tensioner in this section 4 Remove the cylinder head front cover and the upper guide rail 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 5 Put the alignment marks arrows on the camshaft sprocket 2 5 and the ...

Page 109: ...t BTDC 30 Notice Turn the crankshaft in the direction of engine rotation 3 Turn the camshaft using the wrench so that the intake camshaft adjustment hole lines up with the cylinder head upper side 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 Install the bearing caps according to th...

Page 110: ...aft sprocket and timing chain are aligned with marks Intake camshaft adjuster should be in retarded position 6 Install the chain on the exhaust sprocket and tighten the sprocket bolts Installation Notice 7 Install the chain tensioner screw plug 1 and chain tensioner assembly 2 and tighten it as specified Installation Notice Make sure that the camshaft sprocket and timing chain are aligned with mar...

Page 111: ...over 10 Install the generator 8 Rotate the crankshaft 2 revolutions and check followings TDC of no 1 cylinder OT Alignment between camshaft adjustment hole and cylinder head surface Alignments between timing chain and sprocket marks Notice Turn the crankshaft in the direction of engine rotation Read just if not aligned ...

Page 112: ...SHAFT TIMING POSITION Preceding Work Removal of cylinder head cover Removal of cylinder head front cover 1 Chain Tensioner Assembly 2 Exhaust Camshaft Sprocket 3 Upper Guide Rail 4 Cylinder Head Front Cover 5 Wrench 6 Holding Pin DW 110 120 YAD1B0T0 ...

Page 113: ... chain to the intake camshaft sprocket Notice Timing chain must be placed on the guide rail in gear case cover Tools Required DW 110 120 Holding Pin Inspection 1 Position the No 1 cylinder piston to TDC OT by turning the crankshaft Notice When the OT mark on vibration damper is aligned with timing gear case cover the intake and exhaust cam of cylinder will make the slope to the center and will fac...

Page 114: ...o replace with new one 11 Install the chain tensioner Installation Notice 10 Install the chain to the exhaust camshaft sprocket and install it to the camshaft Installation Notice Tightening Torque 1st step 18 22 N m 13 16 lb ft 2nd step 90 5 Screw Plug Tensioner Assembly Tightening Torque 40 N m 30 lb ft 72 88 N m 53 65 lb ft ...

Page 115: ...l of camshaft Removal of spark plug 1 Valve Cotter 2 Upper Retainer 3 Valve Spring Check Replace if necessary 4 Valve Stem Seal 5 Lower Retainer 6 Connecting Hose DW 110 090 7 Thrust Piece 111 589 25 63 00 8 Lever Pusher 111 589 18 61 00 9 Supporting Bar 111 589 01 59 00 YAD1B0V0 ...

Page 116: ...aring cap and tighten them with the bearing cap bolt Installation Notice 2 Turn the crankshaft to position the each cylinder piston at TDC Notice Remove the valve spring only at TDC Always rotate the crankshaft by holding the chain to prevent from timing chain damage and tangling and for smooth rotation TighteningTorque 22 5 27 5 N m 16 6 20 3 lb ft Mark on The Vibration Damper Cylinder OT 120 240...

Page 117: ...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 7 Install the lever pusher 111 589 18 61 00 8 and the thrust piece 111 589 25 63 00 7 8 Mount the thrust piece 111 589 25 03 00 7 vertically to the valve spring retainer 2 9 Press the valve spring 3 by using the lever pusher 111 589 18 61...

Page 118: ... SSANGYONG Y200 YAD1B1G0 YAD1B1H0 YAD1B1J0 Test Upper and Lower Valve Tappet and Valve Cotter Upper Valve Spring Retainer Lower Valve Spring Retainer Valve Cotter d 12 3 D 8 5 Size mm B 9 2 9 8 H 9 0 Size mm Thickness mm a 0 8 1 0 ...

Page 119: ... spring YAD1B1K0 YAD1B1M0 Tools Required 119 589 00 43 00 Drift Replacement Procedure 1 Remove the valve stem seal 2 using the pliers 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 ...

Page 120: ...NE MECHANICAL 1B1 79 SSANGYONG Y200 1 Screw Plug 40 N m 30 lb ft 2 Seal 3 Filler Pin 4 Compression Spring 5 Snap Ring CHAIN TENSIONER 6 Thrust Pin 7 Chain Tensioner Housing 72 88 N m 53 65 lb ft 8 Seal YAD1B1N0 ...

Page 121: ...er housing 7 and the seal 8 YAD1B1P0 Removal Procedure 1 Position the No 1 cylinder to TDC OT Notice Remove the oil filler cap at adjustment position and check whether the intake camshaft cam s lobe arrow stays in the upper side 2 Cover the generator with a clean cloth 3 Release the tension by unscrewing the screw plug once Notice In case that the tension is reduced by unscrewing the screw plug re...

Page 122: ...at it doesn t protrude at the chain tensioner housing 3 Insert the compression spring 4 with the filler pin 3 into chain tensioner housing 2 Install the chain tensioner housing 7 thrust pin 6 snap ring 5 and the seal 8 Installation Notice Tightening Torque 72 88 N m 53 65 lb ft 4 Lightly apply the grease to the seal 2 and install the screw plug 1 Installation Notice 5 Check for leaks by operating ...

Page 123: ...7 Compression Spring 8 Snap Ring 9 Thrust Pin 10 Ball Nonreturn Valve 11 Compression Spring 12 Thrust Piece 13 Chain Tensioner Housing 14 Seal 15 Timing Gear Case Cover 16 Cylinder Head 17 Bolt Washer 18 Tensioning Rail 19 Cylinder Head Gasket 20 Timing Chain 21 Tensioning Rail Base Sliding Surface A Oil Supply Hole B Chain Tensioner Oil Storage Hole YAD1B1U0 ...

Page 124: ... MECHANICAL 1B1 83 SSANGYONG Y200 TIMING CHAIN Preceding Work Removal of cylinder head cover Removal of spark plug 1 Pin 2 New Timing Chain 3 Timing Chain Used 4 Wedge 5 Link 6 Center Plate 7 Outer Plate YAD1B1V0 ...

Page 125: ...osition the No 1 cylinder to TDC OT 4 Mount the wedges to both sides of the camshaft sprocket as shown in the figure 2 Insert the holding pin DW 110 120 to the intake and exhaust camshaft flange not to rotate camshaft 3 Remove the chain tensioner 5 Cover the chain housing with a clean cloth and grind off the timing chain pin from the intake camshaft sprocket with the grinder ...

Page 126: ...on by pressing the new timing chain against the exhaust camshaft sprocket to prevent it to be tangled Notice Be sure to remove the wedge before cranking the engine 9 Take out the used timing chain out from the chain housing 10 Connect both separators of the new timing chain with the link 5 and the center plate 6 6 Remove the outer plate 7 with the screw driver and remove the link 11 Install the ja...

Page 127: ...tall the chain assembly 000 589 58 43 00 above the link and tighten the spindle c until a block is felt 14 Place the chain assembly 000 589 58 43 00 12 Place the outer plate 7 thickness 1 2 mm inside the thrust piece b 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 ...

Page 128: ...D1B2G0 17 Rivet the link pin Check the condition and it again if necessary 18 Install the chain tensioner Installation Notice 19 Check the camshaft timing position Screw Plug Tensioner Assembly Tightening Torque 40 N m 30 lb ft 72 88 N m 53 65 lb ft ...

Page 129: ...and the timing chain with the paint arrow 2 Remove the exhaust camshaft sprocket 3 Remove the tensioning rail 1 from the tensioning rail pin 3 Notice 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 YAD1B2H0 3 Tension...

Page 130: ...chain at upper guide rail 2 3 Pull out the upper guide rail pin from the guide rail 2 4 Turn the exhaust camshaft to the opposite direction of rotation using the wrench 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 1 Chain Tensioner 2 Upper Guide Rail 3 Upper Guide Rail Pin 4 Wrench Speci...

Page 131: ... sprocket and the timing chain with the paint arrow 2 Remove the exhaust camshaft sprocket 3 Remove the guide rail 1 from the guide rail pin 3 Notice 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 3 Guide R...

Page 132: ... 3 Oil Pump Chain Spring 4 Crankshaft Sprocket 5 Key YAD1B2L0 CRANKSHAFT SPROCKET Preceding Work Removal of oil pan Removal of tensioning rail Removal of crankcase guide rail 6 Bolt M8 x 20 1 piece Washer 29 35 N m 21 26 lb ft 7 Oil Pump Sprocket 8 Oil Pump 9 Oil Pump Roller Chain 10 Timing Chain ...

Page 133: ...ming chain when installing 2 Unscrew the bolt 6 and remove the oil pump sprocket 7 from the oil pump Installation Notice 3 Remove the oil pump roller chain 9 4 Remove the oil pump chain tensioner 1 oil pump chain bushing 2 and the oil pump chain spring 3 Tightening Torque 29 35 N m 21 26 lb ft 5 Remove the crankshaft sprocket 4 using the crankshaft sprocket puller 615 589 01 33 00 Notice Make sure...

Page 134: ...8 lb ft 2 Oil Filter 3 Engine Oil Filler Cap 4 Dipstick Gauge Specifications Application Capacity Quality Viscosity Replacemant Descrition Min 6 7 L Max 8 2 L API SH or above grade ACEA A2 or A3 Approved oil by MB Sheet 229 1 Approved oil by MB Sheet 224 1 Initial at 1000 1500 km Replace every 15000 km YAD1B2W0 ...

Page 135: ...l φ 15mm 17 Oil Restriction Inner φ 4mm 18 Oil Supply To Exhaust Camshaft 19 Oil Supply To Intake Camshaft OIL CIRCULATION 20 Oil Supply To Exhaust Camshaft Bearing 21 Oil Supply To Intake Camshaft Bearing 22 Oil Gallery Oil Supply to Exhaust Valve Tappet 23 Oil Gallery Oil Supply to Intake Valve Tappet 24 Camshaft Closing Cover 25 Ball φ 8 mm 26 Screw Plug 27 Camshaft Adjuster 28 Front Closing Co...

Page 136: ...side of the oil filter remover 103 589 02 09 00 2 Install the wrench to the upper bolt in the oil filter remover 103 589 02 09 00 and remove the oil cover by turning it 3 Remove the oil filter element Notice Work with a cloth under the vehicle when removing the oil filter element to not drain the oil Tightening Torque 25 N m 18 lb ft Replace the seal washer with new one 6 Replace the O ring in the...

Page 137: ...L YAD1B3B0 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 ...

Page 138: ...B1 97 SSANGYONG Y200 OIL FILTER Preceding Work Removal of starter motor Removal of upper intake manifold 1 Coolant Line 2 O ring Replace 3 Clip 4 Hose 5 Bolt 22 5 27 5 N m 16 6 20 3 lb ft 6 Oil Filter 7 Gasket Replace YAD1B3C0 ...

Page 139: ...n the reverse order 5 Check engine oil level 6 Run the engine at idle and check the engine for leaks 3 Remove the oil filter bolt and then remove the oil filter Installation Notice Removal Installation Procedure 1 Drain the coolant from the crankcase 2 Remove the each coolant line and hose Tightening Torque 22 5 27 5 N m 16 6 20 3 lb ft ...

Page 140: ...pump drive sprocket 2 and separate the gear and the oil pump drive chain Installation Notice Tighten the baffle plate and the oil pump with the two bolts in right side first and then tighten the other bolt 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 2 Unscrew the oil pump mou...

Page 141: ... ft 2 Compression Spring Removal Installation Procedure 1 Remove the screw plug 1 Installation Notice 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 3 Guide Pin 4 Piston Tightening Torque 50 N m 37 lb ft YAD1B3G0 ...

Page 142: ...rn valve prevents the oil in the chain tensioner from drying up In other words it stops oil returning in order to prevent the oil in the chain tensioner from getting dry 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 YAD1B3H0 ...

Page 143: ...tick level gauge 1 2 Remove the bolt 4 in the upper intake manifold and remove the oil dipstick guide tube Installation Notice 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 3 O ring 4 Bolt M6 x 12 1 piece 9 11 N m 80 97 lb in Tightening Torque 9 11 N m 80 97 lb in YAD1B3K0 ...

Page 144: ...ingWork Removal of crankshaft Removal of oil spray nozzle 1 Plug 2 Steel Ball 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 3 Round Bar φ 11 x 750 mm YAD1B3M0 ...

Page 145: ... make the thread at the end of main oil gallery 4 3 Throughly clean the oil gallery with compressed air and tighten the screw plug 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 4 Main Oil Gallery 5 Screw Plug Tools Required 102 589 12 15 00 Drift YAD1B3N0 ...

Page 146: ...inder head Removal of camshaft Removal of tappet 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 Replace the seal with new one 2 Clean the oil gallery using the compressed air 3 Steel Ball φ 8mm Tightening Torque 15 N m 11 lb ft YAD1B3Q0 ...

Page 147: ...ery 4 5 6 and 7 using the round bar 12 φ 6 x 700 mm 4 Enlarge the oil gallery at the rear of the cylinder head to be diameter 9mm depth 8mm 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 3 Remove the plug 8 using the screw driver Tightening Torque 15 N m 11 lb f...

Page 148: ...YAD1B3W0 11 Tighten the screw plug with the seal arrow 8 Make a screw hole at the oil gallery using M10 x 1 thread 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 ...

Page 149: ...SSANGYONG Y200 1B1 108 M162 ENGINE MECHANICAL CORE PLUGS IN CRANKCASE Preceding Work Draining of the coolant 1 Core Plug Replace YAD1B3X0 ...

Page 150: ...ifolds 2 Pull back the core plug until the end of one side comes out using the screw driver 3 Pull out the plug carefully using a pliers 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 4 Clean the sealing surface and apply Loctite 241 ...

Page 151: ... 89 918 φ 89 950 φ 89 968 φ 90 000 φ 90 018 Type Standard Size φ 89 9 1st Repair Size Standard Size 0 25 2nd Repair Size Standard Size 0 5 Group Code Letter1 A X B A X B A X B Cylinder Bore Size mm φ 89 900 φ 90 906 φ 89 906 φ 89 912 φ 89 912 φ 89 918 φ 90 150 φ 90 156 φ 89 156 φ 90 162 φ 90 162 φ 90 168 φ 90 400 φ 90 406 φ 90 406 φ 90 412 φ 90 412 φ 90 418 YAD1B4D0 1 The group code letters are ca...

Page 152: ...rse 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 Wear Limit in Longitudinal and Transverse Direction Permissible Deviation of Cylinder Out of round Permissible Deviation of Rectangular Cylinder Height Except Chamfered Area Basic Peak to valley Height After Final Honing and Brushing Chamfer Angle Honing Angle When n...

Page 153: ... Flatness Permissible Deviation of Parallelism of The Upper to Lower Mating Surface Peak to valley Height Crankcase Upper Mating Surface Crankcase Lower Mating Surface Axial Direction Transverse Direction Crankcase Upper Mating Surface Crankcase Lower Mating Surface 282 25 282 35 mm 281 95 mm 0 03 mm 0 04 mm 0 1 mm 0 05 mm 0 005 0 020 mm 0 025 mm YAD1B4G0 ...

Page 154: ...NICAL 1B1 113 SSANGYONG Y200 YAD1B4F0 YAD1B4H0 Chamfering Procedure 1 Chamfer angle 60 2 Polish the lower chamfered area evenly with a grinder after finishing the chamfering with a suitable tool e g hand milling cutter ...

Page 155: ...milling of the mating surface of crankcase and cylinder head Overall Height of Cylinder Head Minimum Height After Machining Flatness Distance T Between Camshaft Bearing and Valve Stem Axial Direction Transverse Direction Standard Size Repair Size 135 9 136 0 mm 135 5 mm 0 08 mm 0 0 mm 24 21 24 75 mm 22 21 22 75 mm 23 96 24 51 mm 21 96 22 51 mm Intake Exhaust Intake Exhaust ...

Page 156: ...nder head 3 Mill the sharp edge of the combustion chamber 4 Re measure the height H of the cylinder head 5 Seal the intake and exhaust valves 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 Surface Grinding Machine Sceledum Type RTY Roaro Schio Italy ...

Page 157: ...lt Crankshaft Bearing Cap Bolt Crankshaft Sealing Rear Cover Mounting Bolt Cylinder Block Drain Plug Cylinder Head Bolt Cylinder Head Cover Bolt Cylinder Head Front Cover Bolt Engine Mounting Bracket Nut Exhaust Camshaft Sprocker Bolt Exhaust Manifold and Pipe Flywheel Mounting Bolt Fuel Feed and Return Hose to Fuel Rail Generator Carrier Bolt Intake Air Duct Nut Intake Flange Shaft Bolt Lower Eng...

Page 158: ...g Gear Case Cover Bolt M8 M6 Torque Converter Mounting Bolt Transmission Mounting Nut Under Cover Upper Engine Mounting Nut Vibration Damper Center Bolt Water Pump Pulley Bolt FASTENER TIGHTENING SPECIFICATIONS Cont d N m 50 29 35 22 5 27 5 29 35 9 11 22 5 27 5 26 32 22 5 27 5 9 11 42 54 68 28 47 70 180 220 90 10 22 5 27 5 Lb Ft 37 21 26 16 6 20 3 21 26 16 6 20 3 19 24 16 6 20 3 31 40 50 21 35 52 ...

Page 159: ... 58 43 00 Chain Assembly 111 589 25 63 00 Thrust Piece 111 589 20 33 00 Sliding Hammer 103 589 02 09 00 Oil Filter Remover YAD1B1W0 YAD1B2Y0 YAD1B0W0 YAD1B0Y0 YAD1B580 102 589 00 15 00 Drift YAD1B3Y0 111 589 18 61 00 Lever Pusher 102 589 12 15 00 Drift YAD1B3P0 111 589 01 59 00 Supporting Bar YAD1B0X0 ...

Page 160: ... 33 00 CrankshaftSprocket Puller 119 589 00 43 00 Drift 601 589 03 14 00 Crankshaft Front Seal Installer 617 589 00 10 00 AllenWrench Socket 601 589 03 43 00 Crankshaft Rear Seal Installer 602 589 00 40 00 Engine Lock YAD1B1L0 YAD1B730 YAD1B790 YAD1B720 YAD1B4K0 YAD1B560 YAD1B2M0 YAD1B570 116 589 01 34 00 Threaded Pin ...

Page 161: ...SSANGYONG Y200 1B1 120 M162 ENGINE MECHANICAL SPECIAL TOOLS TABLE Cont d DW110 100 Valve Tappet Remover YAD1B1A0 YAD1B0K0 DW110 120 Holding Pin DW110 090 Connecting Hose YAD1B0Z0 ...

Page 162: ...ealing Rear Cover 1B2 33 Belt Pulley and Vibration Damper 1B2 35 Crankshaft Front Radial Seal 1B2 38 Crankshaft Rear Radial Seal 1B2 40 Crankshaft 1B2 41 Flywheel Driven Plate 1B2 47 Camshaft Adjuster 1B2 50 Camshaft Sprocket Bolt 1B2 53 Camshaft 1B2 54 Camshaft Timing Position 1B2 57 Valve Spring 1B2 59 Valve Stem Seal 1B2 63 ChainTensioner 1B2 64 Timing Chain 1B2 68 Tensioning Rail 1B2 73 Cylind...

Page 163: ...SSANGYONG Y200 1B2 2 M161 ENGINE MECHANICAL MAINTENANCE AND REPAIR ON VEHICLE SERVICE ENGINE ASSEMBLY YAD1B4S0 ...

Page 164: ... the hood 3 Remove the under cover Installation Notice 4 Disconnect the coupling of HFM sensor and remove the air cleaner cross pipe 5 Remove the air cleaner cover Remove the mounting bolts and air cleaner housing and element assembly 6 Loosen the radiator drain cock and drain the coolant Notice Open the coolant reservoir cap Tightening Torque 28 47 N m 21 35 lb ft ...

Page 165: ... drain the coolant completely Installation Notice 10 Remove the upper mounting bolts of radiator and then remove the radiator 9 Disconnect the each hose from radiator 8 Remove the cooling fan shroud Refer to Section 1D2 Engine Cooling Notice Replace the seal before installation of the drain plug Tightening Torque 5 N m 26 lb ft ...

Page 166: ...n the oil 14 Disconnect the terminals from the generator 13 Remove the fuel feed and return line Notice Before removing the fuel lines release the pressure in the fuel system Installation Notice 12 Discharge the refrigerant from A C system and disconnect the discharge pipe and suction pipe from the compressor Tightening Torque 21 25 N m 15 18 lb ft ...

Page 167: ... engine main harness ground 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 18 Disconnect following sensors connector HFM sensor Coolant temperature sensor Knock sensor Camshaft and crankshaft sensors 17 Disconnect the engine ground wire ...

Page 168: ...f engine remove the 6 torque converter mounting bolts from the engine ring gear plate Installation Notice 24 Separate the vacuum hose for brake booster 25 Separate the other vacuum hoses 22 Remove the automatic transmission oil cooler line retaining bolts from the automatic transmission side and oil pan side 23 Remove the automatic transmission oil cooler line retaining bolts from engine side and ...

Page 169: ... the engine assembly from the vehicle 32 Installation should follow the removal procedure in the reverse order 29 Install a chain to the bracket of engine by using a hoist or crane 30 Remove the engine mount nuts Installation Notice 28 Remove the transmission Refer to Section 5A Au tomatic Transmission Tightening Torque 30 N m 22 lb ft Tightening Torque 70 N m 52 lb ft ...

Page 170: ...d 4 Intake Air Duct Cross Pipe 5 Vent Line Full Load or Over Mid Load 6 Throttle Valve 7 Restrictor Diameter 1 1mm Mid Load at Idling 8 Intake Manifold 9 Vent Line Mid Load at Idling 10 Air Conditioner Bracket 11 Oil Separation Chamber Mid Load at Idling 12 Crank Chamber 13 Oil Return Pipe 14 Oil Pan 15 Timing Gear Case Cover 16 Crankcase 17 Chain Housing A Fresh Air B Blow By Gas D Vent Connectio...

Page 171: ...om the crank chamber 12 through the oil separation chamber 11 air conditioner bracket 10 vent line 9 and restrictor 7 mounted to the cylinder head The circulated engine oil returns to the oil pan through the oil return pipe 13 at the bottom of oil separation chamber 11 The fresh air gets supplied to the crank chamber 12 through the HFM sensor 1 intake air duct 4 vent line 5 oil separation chamber ...

Page 172: ... Air Duct Cross Pipe 5 Vent Line Full Load or Over Mid Load 6 Throttle Valve 7 Restrictor Diameter 1 1mm Mid Load at Idling 8 Intake Manifold 9 Vent Line Mid Load at Idling 10 Air Conditioner Bracket 11 Oil Separation Chamber Mid Load at Idling 12 Crank Chamber 13 Oil Return Pipe 14 Oil Pan 15 Timing Gear Case Cover 16 Crankcase 17 Chain Housing A Fresh Air C Blow By Gas D Vent Connection ...

Page 173: ... opened The air flows very rapidly through the vent line 5 s connection D and the intake air duct when full load at partial load 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 ...

Page 174: ...the drive belt 3 Remove the generator 4 Unscrew the generator carrier bolts and remove the carrier Installation Notice 3 Bolt M8 X 85 1 piece 22 5 27 5 N m 16 6 20 3 lb ft 4 Generator Bracket Notice Apply 3 Nm of torque when mounting the bolt 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 i...

Page 175: ...SSANGYONG Y200 1B2 14 M161 ENGINE MECHANICAL YAD1B5M0 ENGINE MOUNT ...

Page 176: ... the upper engine mount nuts and remove the engine Installation Notice 2 Unscrew the lower nuts Installation Notice Tightening Torque 70 N m 52 lb ft 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 ...

Page 177: ... Removal Installation Procedure 1 Release the belt tension by turning the stud on the cap with 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 3 Belt Tensioner YAD1A130 ...

Page 178: ...NE MECHANICAL 1B2 17 SSANGYONG Y200 YAD1B5Q0 Poly V Belt Arrangement 1 Belt Tensioning Pulley 2 Crankshaft Belt Pulley 3 A C Compressor Pulley 5 Generator Pulley 7 Power Steering Pump Pulley 8 Water Pump Pulley ...

Page 179: ...r 22 5 27 5 N m 16 6 0 3 lb ft Removal Installation Procedure 1 Turn the stud bolt to counterclockwise 2 Insert the pin 111 589 01 15 00 into the hole in tensioningarm 3 Unscrew the bolts 1 2 and remove the tensioning device Installation Notice 3 Tensioning Device 4 Stud bolt 5 Tensioning Arm YAD1B5S0 4 Installation should follow the removal procedure in the reverse order Tightening Torque 22 5 27...

Page 180: ...3 lb ft Removal Installation Procedure 1 Remove the end cover 1 2 Remove the bolt 2 and remove the tensioning pulley 3 Installation Notice 5 Tensioning Device 6 Bolt M8 X 35 Washer 22 5 7 5 N m 16 6 0 3 lb ft 7 Shock Absorber Tightening Torque 22 5 27 5 N m 16 6 20 3 lb ft Tightening Torque 40 5 49 5 N m 29 9 36 5 lb ft 3 Unscrew the bolts 4 6 and remove the shock ab sorber 7 Installation Notice ...

Page 181: ...marks on the belt with chalk Rotate the engine and check the belt for damage Notice If one of the following types of damages is found replace the belt 1 Rubber lumps in the base of rib 2 Dirt or grit ingrained 3 Pointed rib 4 Belt cord visible in the base of rib 5 Cord torn out at the side 6 Outer cords frayed ...

Page 182: ...NICAL 1B2 21 SSANGYONG Y200 YAD1B410 YAD1B420 YAD1B430 YAD1B440 7 Rib detached from the base of belt 11 Splits across the back of the belt 10 Splits across several ribs 8 Splits across the rib 9 Sections of rib torn out ...

Page 183: ...NG Y200 1B2 22 M161 ENGINE MECHANICAL CYLINDER HEAD COVER YAD1B5V0 1 Spark Plug Cover 2 Spark Plug Connector 3 Bolt M6 X 45 4 pieces M6 X 60 6 pieces 9 11 N m 80 97 lb in 4 Cylinder Head Cover 5 Gasket Replace ...

Page 184: ...nd the gasket Installation Notice 2 Remove the spark plug cover Installation Notice Notice Release 3 screws from the spark plug cover and remove the cover for M161 Engine coil Notice 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 Tightening Torque 9 11 N m 80 97 lb ft Tightening To...

Page 185: ...ermostat housing assembly Removal of engine hanger bracket 1 Bolt M6 X 16 3 pieces 9 11 N m 80 97 lb in 2 Camshaft Adjuster 3 Bolt M8 X 35 2 pieces 22 5 27 5 N m 16 6 20 3 lb ft 4 Bolt M6 X 22 6 pieces 9 11 N m 80 97 lb in YAD1B5Z0 5 Front Cover E23 M161 973 6 Front Cover E20 M161 943 7 Sleeve 8 O Ring Replace 9 Thermostat Housing ...

Page 186: ...ve the cylinder head front cover Installation Notice 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 the sealant 4 Installation should follow the removal procedure in the reverse order Tightening Torque 3 Tightening Torque 4 22 5 27 5 N m 16 6 20 3 lb ft 9 11 N m 80 97 lb in Tightening Torque 9 11...

Page 187: ...r Removal of intake manifold Removal of cylinder head lower line intake manifold side 1 Cylinder Head Bolt M12 X 100 10 pieces 1ststep 55 N m 41 lb ft 2nd step 90 rotation added 3rd step 90 rotation added 3 Bolt M8 X 35 4 pieces 22 5 27 5 N m 16 6 0 3 lb ft YAD1B6C0 4 Camshaft Bearing cap 5 Cylinder Head 6 Gasket Replace 7 Dowel Sleeve Note ...

Page 188: ...iston of number 1 cylinder is at ATDC 20 5 Remove the exhaust camshaft sprocket Installation Notice Notice The flange bolt is designed to be used only once so always replace with new one 3 Put the alignment marks arrows on the timing chain and camshaft sprocket 4 Remove the chain tensioner Installation Notice 2 Put the holding pin 111 589 03 15 00 into the cam shaft bearing cap number 1 6 Tighteni...

Page 189: ...0 02 and the threaded pin 116 589 01 34 00 03 Notice Apply the sealant on guide rail pin when installation 9 Unscrew the bolts A Installation Notice Notice The flange bolt is designed to be used only once so always replace with new one 1 Flange Shaft 2 Flange Bolt 3 Compression Spring 4 Adjust Piston 5 Camshaft Sprocket 6 Seal Cover 7 Nut Tightening Torque 1st step 18 22 N m 13 16 lb ft 2nd step 6...

Page 190: ...1 bearing cap of the exhaust cam shaft Installation Notice Tightening Torque 1st step 55 N m 41 lb ft 2nd step 90 3rd step 90 Notice Operate during engine cooling Tightening Torque 22 5 27 5 N m 16 6 20 3 lb ft 12 Carefully remove the cylinder head 13 Check the cylinder head mating surface and clean the crankcase head bolt mounting hole 14 Replace the cylinder head gasket with new one Notice Repla...

Page 191: ... cylinder head front cover Removal of tensioning device Removal of water pump Removal of oil filter element Removal of oil pan Removal of generator bracket 1 Bolt M8 X 60 3 pieces 22 5 27 5 N m 16 6 20 3 lb ft 2 Bolt M8 X 75 1 piece 22 5 27 5 N m 16 6 20 3 lb ft YAD1B6P0 3 Seal 4 Timing Gear Case Cover 5 O Ring 6 Sleeve ...

Page 192: ...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 4 Put the alignment marks arrows on the timing chain and camshaft sprocket 5 Remove the chain tensioner Installation Notice Notice The flange bolt is designed to be used only once so always replace with new one 6 Remove the intake and exhaust c...

Page 193: ...al shaft seal Notice Installation note replace the seal with new one 12 Clean the timing gear case cover and crankcase sealing surface 13 Replace the O ring with new one and apply the sealant on the sealing surface 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 che...

Page 194: ...SHAFT SEALING REAR COVER Preceding Work Removal of the automatic transmission drive plate or flywheel 1 Bolt M6 x 20 6 pieces 9 11 N m 80 97 lb in 2 Radial Shaft Seal 3 Rear Cover YAD1B6S0 4 Sleeve 5 Bolt M6 x 85 2 pieces 9 11 N m 80 97 lb in 6 Washer ...

Page 195: ... crankshaft rear seal installer 601 589 03 43 00 Installation Notice 6 Install the crankshaft rear radial seal and the crankshaft sealing rear cover using crankshaft rear seal installer 601 589 03 43 00 2 Clean the sealing surface of the crankcase and the rear sealing cover 3 Check the radial shaft seal and replace it if necessary 4 Apply the Loctite 573 to the rear cover sealing surface 5 Apply t...

Page 196: ...TION DAMPER Preceding Work Removal of cooling fan and viscous clutch Removal of fan shroud Removal of drive belt 1 Vibration Damper Center 1st step 200 20 N m 148 15 lb ft 2nd step 90 10 rotation added YAD1B6U0 2 Vibration Damper Disk 5 Vibration Damper Assembly 6 Key ...

Page 197: ... Assembly 4 Key 5 Crankshaft Front Seal 6 Timing Gear Case Cover YAD1B660 7 Crankshaft Sprocket Camshaft Driven 8 Crankshaft Sprocket Oil Pump Driven 9 Crankshaft 10 Oil Pan 11 Oil Pan Gasket 12 Oil Pan Mounting Bolt M6 x 22 Service Data Standard Permissble Deviation of The Vibration Damper Radial Runout Axial Ruout 0 6 mm 0 6 mm ...

Page 198: ...he 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 2 Remove the start motor and install the engine lock 602 589 00 40 00 to the flywheel ring gear 3 Remove the vibration damper center bolt Installation Notice Tightening Torque 1st step 200 20 N m 148 15 lb ft 2nd...

Page 199: ...KSHAFT FRONT RADIAL SEAL Preceding Work Removal of belt pulley and vibration damper 1 Center Bolt M18 x 50 1st step 200 20 45 N m 148 15 lb ft 2nd step 90 10 2 Center Bolt Washer YAD1B6X0 3 Crankshaft Front Seal Installer 4 Crankshaft Front Seal 5 Key ...

Page 200: ...aling lip with engine oil 3 Using the crankshaft front seal installer 601 589 03 14 00 assemble the radial seal 4 Align the sleeve groove and the woodruff key and tighten the center bolt until the center bolt and the damper disk stop in the movement Installation Notice 5 Remove the crankshaft front seal installer 601 589 03 14 00 and install the belt pulley and the vibration damper 6 Check for lea...

Page 201: ...river Notice Use a clean cloth not to damage the radial seal mounting hole and the crankshaft 2 Install the special tool 2 to the crankshaft 3 Apply the engine oil on the special tool 2 Notice Do not use the grease 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 1 Special Tool 2 Speci...

Page 202: ...g gear case cover Removal of crankcase sealing rear cover Removal of oil pan Removal of baffle plate Removal of oil pump 1 Bearing Cap Bolt M8 X 55 10 pieces 1ststep 55 N m 41 lb ft 2nd step 90 rotation added 2 Bearing Cap 3 Upper Main Bearing YAD1B6Y0 4 Lower Main Bearing 5 Upper Thrust Bearing 6 Lower Thrust Bearing 8 Crankshaft ...

Page 203: ... Upper Thrust Bearing 3 Crankshaft 4 Lower Main Bearing 5 Lower Thrust Bearing A Crankcase Side B Bearing Cap Side Oil Pan Side 1 8 Weight Balance Color Marking Point j1 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 ...

Page 204: ...Standard size 1st repair size 2nd repair size 3rd repair size 4th repair size Crankshaft Bearing Jour nal Diameter 57 940 57 965 57 705 57 715 57 450 57 465 57 205 57 215 56 955 56 965 Crankshaft Bearing Diameter 58 Crankshaft Journal Width at fit bearing 24 50 24 533 Connecting Rod Bearing Journal Diameter 47 935 47 965 47 700 47 715 47 450 47 465 47 200 4 215 46 950 46 965 Connecting Rod Bearing...

Page 205: ...e so that the projected part of the cap and crankcase face the same direction Make sure that the upper and lower bearing shells do not change each other Coat the bearing shell with engine oil Install the bearing cap according to the consecutive number Tightening Torque 40 N m 30 lb ft 90 Remove the bearing cap from front pulley side to rear Make sure that the upper and lower bearing shells do not ...

Page 206: ...he inner diameter of bearing and the diameter of journal and if it is out of the standard data replace the bearing shell 3 Measure and record the inner diameter of the crankshaft bearing Notice Measure at 2 points 1 2 Measure A B and C as shown If average value of B and C is less than value A then the average value of B and C is actual average value If average value of B and C is more than value A...

Page 207: ...ain Bearing Gap Connecting Rod Bearing Gap Item Connection Rod Bearing Item Radial Gap mm 0 020 0 065 Item Main Bearing Journal NO 1 5 7 Measuring Position Radial Axial Gap mm Static condition 0 015 0 039 Dynamic condition 0 031 0 051 Consider the expansion 0 011 0 016 0 010 0254 ...

Page 208: ...olt M10 x 22 8 pieces 1st step 45 5 N m 33 3 7 lb ft 2nd step 90 10 2 Plate YAD1B810 3 Driven Plate A T 4 Dowel Pin 5 Flywheel M T Service Data Standard Stretch Bolt Normal Size Stretch Side Diameter Bolt Length Tightening Torque When New Min Diameter When New M x 15 8 5 0 2 mm 8 0 mm 21 8 22 2 mm D d L 1st step 45 5 N m 33 37 lb ft 2nd step 90 10 ...

Page 209: ...mounting bolt is less than 8 0mm For the flywheel mounting bolt tightening keep the socket wrench and 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 Tightening Torque 1st step 45 5 N m 33 3 7 lb ft 2nd step 90 1...

Page 210: ...1B2 49 SSANGYONG Y200 Sectional View 1 OilPan 2 Cover 3 Radial Seal 4 Bolt 5 Crankshaft 6 Dowel Pin 7 Washer Thickness 3 5 mm YAD1B830 8 Washer 9 Bolt 10 Front Drive Plate 11 Rear Drive Plate 12 Rivet 13 Segment 14 Ring Gear ...

Page 211: ... Armature 5 RollPin 6 Nut M20 X 1 5 60 70 N m 44 52 lb ft 7 Seal Cover 8 Camshaft Sprocket 9 Adjust Piston 10 Conical Spring 11 Flange Bolt M7 X 13 3 pieces 1stStep 18 22 N m 13 16 lb ft 2nd Step 60 5 Rotation Added 12 Flange Shaft 13 Compression Spring 14 Control Piston 15 Circlip 16 Oil Gallery 17 Straight Pin 18 Intake Camshaft Y49 Magnetic Actuator 2 Pin Connector ...

Page 212: ...6 Unscrew the exhaust sprocket bolt and remove the exhaust camshaft sprocket Installation Notice 4 Insert the holding pin 111 589 03 15 00 into the no 1 and no 6 bearing cap hole on camshaft to secure intake and exhaust camshaft 5 Remove the chain tensioner 3 Put the alignment marks arrows on the camshaft sprocket and the timing chain Notice The flange bolt is designed to be used only once so alwa...

Page 213: ...Notice 8 Unscrew the nut 6 and remove the seal cover 7 Installation Notice Notice Put the locking slot of nut toward armarture 9 Take off the timing chain from intake camshaft sprocket Tightening Torque 35 N m 26 lb ft Tightening Torque 1st step 18 22 N m 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 12 Installation should follow t...

Page 214: ...replace with new one C M7 x 13 Collar Bolt Torx T30 e 6 8 mm 16 Flange Shaft 18 Control Piston 22 Intake Camshaft Tightening Torque 1st step 18 22 N m 13 16 lb ft 2nd step 60 5 Tightening Torque 1st step 18 22 N m 13 16 lb ft 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 Exh...

Page 215: ...r and cylinder head front cover 1 Bolt M7 X 13 3 pieces 1st Step 18 22 NSm 13 16 lb ft 2nd Step 60 5 Rotation Added 2 Exhaust Camshaft Sprocket 3 Timing Chain 4a Intake Camshaft Spocket E20 YAD1B7D0 4b Camshaft Adjuster and Camshaft Sprocket E23 5 Bearing Cap Bolt 20 pieces 22 5 27 5 N m 16 6 20 3 lb ft 6 Camshaft Bearing Cap 7 Wrench ...

Page 216: ...procket Installation Notice 2 Put the alignment marks arrows on the camshaft sprocket and the timing chain 3 Remove the chain tensioner Installation Notice Notice The sprocket bolt is designed to be used only once so always replace with new one 5 Take off the timing chain from intake camshaft sprocket and secure it not to fall down into the timing gear case Tightening Torque 1st step 18 22 N m 13 ...

Page 217: ...ply the engine oil on the valve tappet and cam shaft bearing 9 Installation should follow the removal procedure in the reverse order 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 Notice Check the numbers on the bearing cap not to be mixed up Tightening Torque 60 70 N m 44 52 lb ft ...

Page 218: ...val of cylinder head cover Removal of cylinder head front cover 1 Holding Pin 111 589 03 15 00 2 Intake Camshaft Sprocket 3 Camshaft Bearing Cap 4 Timing Chain 5 Exhaust Camshaft Sprocket YAD1B7H0 6 Bolt M7 X 13 3 pieces 1ststep 18 22 NSm 13 16 lb ft 2nd step 60 5 rotation added 7 StratePin ...

Page 219: ...ion check if the ATDC 20 mark on vibration damper aligns with the marker on the timing gear case Adjustment Procedure 1 Position the NO 1 cylinder to ATDC 20 2 Remove the chain tensioner 3 Remove the exhaust camshaft sprocket 4 Adjust the timing position with inserting the holding pin 111 589 03 15 00 into the NO 1 and NO 4 camshaft bearing cap hole and flange hole while rotating the camshaft by u...

Page 220: ...ork Removal of camshaft Removal of spark plug 1 Valve Cotter 2 Valve Spring Retainer 3 Valve Spring 4 Valve Stem Seal 5 Lower Retainer YAD1B0V0 a Lever Pusher 111 589 18 61 00 b Thrust Piece 111 589 25 63 00 c Connecting Hose DW 110 090 d Supporting Bar 111 589 01 59 00 ...

Page 221: ...ing cap and tighten them with the bearing cap bolt Installation Notice 2 Turn the crankshaft to position the each cylinder piston at TDC YAD1B7J0 Tightening Torque 22 5 27 5 N m 16 6 20 3 lb ft 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 Notice Remove the valve spring only at TDC Always rotate the crankshaft by...

Page 222: ... 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 7 Install the supporting bar 111 589 01 59 00 d and the lever pusher 111 589 18 61 00 a 8 Mount the thrust piece 111 589 25 63 00 b vertically to the valve spring retainer 2 9 Press the valve spring 3 by using the lev...

Page 223: ... ENGINE MECHANICAL YAD1B1G0 YAD1B1H0 YAD1B1J0 Test Upper and Lower Valve Tappet and Valve Cotter Upper Valve Spring Retainer Valve Cotter Lower Valve Spring Retainer d D Size mm 8 5 12 3 a Size mm 0 8 1 0 B H Size mm 9 0 9 2 9 8 ...

Page 224: ...ed 119 589 00 43 00 Drift Replacement Procedure 1 Remove the valve stem seal 2 using the pliers 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 YAD1B1K0 3 Protective Sleeve YAD1B1M0 ...

Page 225: ...arrow stays in the upper side 2 Cover the generator with a clean cloth 3 Release the tension by unscrewing the screw plug once Notice In case that the tension is reduced by unscrewing the screw plug reinstall after completely removing the chain tensioner If the chain tensioner is tightened again without completely reducing its tension then the snap ring doesn t return to the original position and ...

Page 226: ...ression spring 4 snap ring 5 and the thrust pin 6 2 Install the chain tensioner housing 7 thrust pin 6 snap ring 5 and the seal 8 Installation Notice Installation Procedure 1 Connect the thrust pin 6 and the snap ring 5 to the chain tensioner housing 7 Notice When connecting the thrust pin push in the thrust pin far enough so that it doesn t protrude at the chain tensioner housing 6 Remove the cha...

Page 227: ... Y200 1B2 66 M161 ENGINE MECHANICAL 4 Lightly apply the grease to the seal 2 and install the screw plug 1 Installation Notice 5 Check for leaks by operating the engine Tightening Torque 40 N m 30 lb ft YAD1B1T0 ...

Page 228: ...ller Pin 7 Compression Spring 8 Snap Ring 9 Thrust Pin 10 Ball Nonreturn Valve 11 Compression Spring 12 Thrust Piece 13 Chain Tensioner Housing 14 Seal 15 Timing Gear Case Cover 16 Cylinder Head 17 Bolt Washer 18 Tensioning Rail 19 Cylinder Head Gasket 20 Timing Chain 21 Tensioning Rail Base Sliding Surface A Oil Supply Hole B Chain Tensioner Oil Storage Hole ...

Page 229: ...200 1B2 68 M161 ENGINE MECHANICAL TIMING CHAIN Preceding Work Removal of cylinder head cover Removal of spark plug 1 Pin 2 New Timing Chain 3 Timing Chain Used 4 Wedge YAD1B1V0 5 Link 6 Center Plate 7 Outer Plate ...

Page 230: ...osition the NO 1 cylinder to ATDC 20 5 Cover the chain housing with a clean cloth and grind off the timing chain pin from the intake camshaft sprocket with the grinder 4 Mount the wedges to both sides of the camshaft sprocket as shown in the figure 2 Insert the holding pin 111 589 03 15 00 to the intake and exhaust camshaft flange not to rotate camshaft 3 Remove the chain tensioner ...

Page 231: ... 2 to the used timing chain 3 with the link 5 center plate 6 thickness 1 6 mm and the outer plate 7 8 Rotate the crankshaft in the direction if engine revo lution by pressing the new timing chain against the exhaust camshaft sprocket to prevent it to be tangled Notice Be sure to remove the wedge before cranking the engine 9 Take out the used timing chain out from the chain housing 10 Connect both ...

Page 232: ... 16 Install the chain assembly 000 589 58 43 00 to the link pin and tighten the spindle c Installation Notice 15 Replace the thrust piece b as shown in the figure 13 Install the chain assembly 000 589 58 43 00 above the link and tighten the spindle c until a block is felt 14 Place the chain assembly 000 589 58 43 00 Tightening Torque 30 N m 22 lb ft ...

Page 233: ...D1B2G0 17 Rivet the link pin Check the condition and it again if necessary 18 Install the chain tensioner Installation Notice 19 Check the camshaft timing position Tightening Torque Screw Plug Tensioner Assembly 40 N m 30 lb ft 72 88 N m 53 65 lb ft ...

Page 234: ... Remove the timing gear case cover 3 Notice Be careful not to damage the gasket 2 Remove the sliding rail 1 from the sliding rail pin 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 YAD1B7K0 3 Timing Gear Case Cover ...

Page 235: ...SSANGYONG Y200 1B2 74 M161 ENGINE MECHANICAL YAD1B7L0 CYLINDER HEAD GUIDE RAIL Preceding Work Removal of cylinder head front cover 1 Bolt M6 X 45 2 pieces 9 11 N m 80 97 lb in 2 Guide Rail ...

Page 236: ...2 Install the holding pin 111 589 03 15 00 into the no 1 and no 6 bearing cap hole 3 Remove the chain tensioner Installation Notice 4 Unscrew the bolt 1 and remove the guide rail Installation Notice 5 Installation should follow the removal procedure in the reverse order Tightening Torque 9 11 N m 80 97 lb ft Tightening Torque Screw Plug Tensioner Assembly 40 N m 30 lb ft 72 88 N m 53 65 lb ft ...

Page 237: ...ng gear case cover 3 Notice Be careful not to damage the gasket when removing installing the timing gear case cover 2 Remove the guide rail 2 from the guide rail pin 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 3 Timing Gear Case Co...

Page 238: ... of oil pan Removal of tensioning rail Removal of crank case guide rail 1 Oil Pump Chain Tensioner 2 Oil Pump Chain Bushing 3 Oil Pump Chain Spring 4 Crankshaft Sprocket 5 Key 6 Bolt M8 x 20 1 piece Washer 29 35 N m 21 26 lb ft 7 Oil Pump Sprocket 8 Oil Pump 9 Oil Pump Roller Chain 10 Timing Chain ...

Page 239: ... timing chain when installing 2 Unscrew the bolt 6 and remove the oil pump sprocket 7 from the oil pump Installation Notice 3 Remove the oil pump roller chain 9 4 Remove the oil pump chain tensioner 1 oil pump chain bushing 3 and the oil pump chain spring 2 5 Remove the crankshaft sprocket 4 using crankshaft sprocketpuller 615 589 01 33 00 Notice Make sure not to lose the crankshaft pulley key 5 w...

Page 240: ...emoval of engine Removal of cylinder head Removal of oil pan Removal of oil pump Removal of baffle plate 1 Connecting Rod Bearing Cap 2 Connecting Rod 3 Connecting Rod Bolt M9 x 52 8 pieces 1st step 40 N m 30 lb ft 2nd step 90 YAD1B2R0 4 Piston 5 Snap Ring 6 Piston Pin ...

Page 241: ...Remove the connecting rod and the piston upward Notice Make sure that the bearing cap and shell are not changed each other 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 Installation Procedure ...

Page 242: ...bearing journal connecting rod bearing shell and the piston and coat them with engine oil 4 Install the piston ring 5 Install the piston so that the arrow on the piston head faces to the forward of the vehicle 6 After aligning the connecting rod and the bearing cap mark or a number tighten the bolts Installation Notice Apply the engine oil to the bearing cap upper and lower bearing shells 7 Check ...

Page 243: ...ght of Connecting Rod Bushing on Inside Permissible Wwist of Connecting Rod Bearing Bore to Connecting Rod Bushing Bore Permissible Deviation of Axial Paralleism of Connecting Rod Bearing Bore to Connecting Rod Bushing Bore Permissible Deviation of Axial Paralleism of Connecting Rod Bearing Bore from Concentricity Permissible Difference of Each Connecting Rod in Weight YAD1B970 CONNECTING ROD Prec...

Page 244: ...on or number arrow of the connecting rods and the bearing cap when installing Notice 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 2 Check connecting rod bolts 51 7 52 mm 52 9 mm 1st step 40 N m 30 lb ft 2nd step 90 Notice If the length ...

Page 245: ...NGYONG Y200 1B2 84 M161 ENGINE MECHANICAL PISTON RING Preceding Work Removal of piston 1 Piston Compression Ring Top Ring 2 Piston Compression Ring 2nd Ring 3 Piston Oil Ring YAD1B2T0 4 5 Spacer 6 SideRail ...

Page 246: ...ng 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 2 Remove the piston ring with a pliers End Gap of the Piston Ring Gap Between the Piston and the Piston Ring Groove 1 0 20 0 40 mm Groove 2 0 20 0 40 mm Groove 3 0 20 0 45 mm Groove 1 0 028 0 060 mm Groove 2 0 010 0 045 mm Groove 3...

Page 247: ... 2 Unscrew the bolts and remove the oil pan and gasket Notice Arrange the bolts according to each size 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 YAD1B7P0 5 Bolt 6 OilPan 7 Gasket ...

Page 248: ...ing 11 Crankshaft Bearing 12 Connecting Rod 13 Piston 14 Oil Spray Piston Crown Area 15 Non Return Valve Crankcase 16 Oil Supply To Chain Tensioner 17 Camshaft 18 Cam Bearing 19 Valve 20 Oil Gallery Supply Oil to Intake Tappet 21 Oil Gallery Supply Oil to Exhaust Tappet 22 Ball φ 8 mm 23 Camshaft Plug 24 Seal 25 Screw Plug 26 Oil Return Gallery Cylinder Head and Crankcase 27 Oil Return Gallery Cra...

Page 249: ...SANGYONG Y200 1B2 88 M161 ENGINE MECHANICAL YAD1B7R0 ENGINE OIL AND OIL FILTER ELEMENT 1 Oil Filter Cover 25 N m 18 lb ft 2 O Ring Replace 3 Oil Filter Element 4 Oil Drain Plug 5 Oil Filter Bypass Valve ...

Page 250: ...k with a cloth under the vehicle when removing the oil filter element to not drain the oil 4 Remove the drain plug and drain the engine oil Notice Leave the oil filler cap open to ease the engine oil discharge 5 Tighten the engine oil drain plug after cleaning it Installation Notice Replace the seal washer with new one 6 Replace the O ring in the oil filter cover with new one Notice Apply the engi...

Page 251: ...NICAL 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 ...

Page 252: ...embly 4 Bolt M6 X 20 2 pieces 9 11 N m 80 97 lb in In E23 Engine These Bolts are Combined with Baffle Plate 5 Bolt M6 X 12 2 pieces 9 11 N m 80 97 lb in YAD1B7U0 6 Bolt M8 X 20 1 pieces 29 35 N m 21 26 lb ft 7 Washer 8 Sprocket Oil Pump Drive 9 Chain Oil Pump Drive 10 Plate Baffle 11 Bolt M6 X 12 6 pieces 9 11 N m 80 97 lb in E23 Engine Only Baffle Plate Mounting Bolt ...

Page 253: ...affle plate Installation Notice Insert the steel gasket into the oil pump and bolt 4 mounting surface 2 Unscrew the bolts 4 5 and remove the oil strainer assembly 3 Installation Notice 4 Unscrew the three bolt 1 and remove the oil pump Installation Notice Tightening Torque 70 N m 52 lb ft Tightening Torque 22 5 27 5 N m 16 6 20 3 lb ft Tightening Torque 25 39 N m 21 26 lb ft Tightening Torque Bolt...

Page 254: ...ft 2 Compression Spring YAD1B7X0 Removal Installation Procedure 1 Remove the screw plug 1 Installation Notice 3 Guide Pin 4 Piston 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 Tightening Torque 50 N m 37 lb ft ...

Page 255: ...n return valve using a pliers 2 Insert new non return valve with hand 1 Oil Non return Valve Functions The non return valve prevents the oil in the chain ten sioner from drying up In other words it stops oil returning in order to prevent the oil in the chain tensioner from getting dry As a result the chain tensioner can be activated with oil in itself YAD1B7Z0 ...

Page 256: ... Installation Notice 1 Oil Dipstick Level Gauge 2 Oil Dipstick Guide Tube 3 O Ring 4 Bolt M6 X 16 1 piece 9 11 N m 80 97 lb in 5 Clamp 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 Tightening Torque 9 11 N ...

Page 257: ...SSANGYONG Y200 1B2 96 M161 ENGINE MECHANICAL YAD1B8B0 UNIT REPAIR CORE PLUGS IN CRANKCASE Preceding Work Draining of the coolant 1 Core Plug Replace ...

Page 258: ...ug until the end of one side comes out using the screw driver YAD1B3Z0 YAD1B4A0 YAD1B4B0 YAD1B4C0 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 4 Clean the sealing surface and apply Loctite 241 3 Pull out the plug carefully using a pliers ...

Page 259: ...ed A or X A X or B X or B X 5 X 10 YAD1B8C0 CYLINDER BORE Group Code Letter and Cylinder Bore Size Engine E23 Group Code Letter of Cylinder A X B X 5 X 10 Cylinder Bore Size mm φ 90 906 φ 90 912 φ 90 906 φ 90 912 φ 90 912 φ 90 918 φ 90 950 φ 90 968 φ 91 000 φ 91 018 ...

Page 260: ...9 156 φ 90 162 φ 90 162 φ 90 168 φ 90 400 φ 90 406 φ 90 406 φ 90 412 φ 90 412 φ 90 418 Group Code Letter 1 A X B A X B A X B Group Code Letter Cylinder Standard Size 90 9 1st Repair Size Standard Size 0 25 2nd Repair Size Standard Size 0 5 1 The group code letters are carved on the surface of the piston crown and in the mating surface of the crankcase Service Data Standard Wear Limit in Longitudin...

Page 261: ...Milling Flatness Crankcase Upper Mating Surface Crankcase Lower Mating Surface Permissible Deviation of Parallelismof The Axial Direction Upper to Lower Mating Surface Transverse Direction Peak to valley Height Crankcase Upper Mating Surface Crankcase Lower Mating Surface 289 35 289 45 mm 289 05 mm 0 03 mm 0 04 mm 0 1 mm 0 05 mm 0 012 0 009 mm 0 025 0 020 mm ...

Page 262: ...NICAL 1B2 101 SSANGYONG Y200 YAD1B4F0 YAD1B4H0 Chamfering Procedure 1 Chamfer angle 75 2 Polish the lower chamfered area evenly with a grinder after finishing the chamfering with a suitable tool e g hand milling cutter ...

Page 263: ... milling of the mating surface of crankcase and cylinder head Axial Direction Transverse Direction Standard Size Intake Exhaust Repair Size Intake Exhaust Overall Height of Cylinder Head Minimum Height After Machining 135 9 136 0 mm 135 5 mm 0 08 mm 0 0 mm 24 21 24 75 mm 22 21 22 75 mm 23 96 24 51 mm 21 96 22 51 mm Flatness Distance T Between Camshaft Bearing and Valve Stem ...

Page 264: ...der head 3 Mill the sharp edge of the combustion chamber 4 Re measure the height H of the cylinder head 5 Seal the intake and exhaust valves 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 Roaro Schio Italy Surface Grinding Machine ...

Page 265: ...ke Flange Shaft Bolts Exhaust Camshaft Sprocket Bolts Camshaft Bearing Cap Bolts Chain Tensioner Screw Plug Chain Tension Assembly Oil Pump Sprocket Bolt Tensioning Device Bolts Water Pump Pulley Upper Intake Manifold Bolt Lower Intake Mainfold Bolt Flange Bolt to Exhaust Mainfold SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Lb Ft 15 18 22 52 18 29 9 36 5 16 6 20 3 16 6 20 3 16 6 20 3 41 90 9...

Page 266: ...iner Bracket Bolt Oil Pressure Relief Valve Screw Plug Oil Dipstick Guide Tube Bolt Oil Gallery Screw Plug Shock Absorber Bolts Crankshaft Bearing Cap Bolts Torque Converter Mounting Bracket Bolts FASTENER TIGHTENING SPECIFICATIONS Cont d N m 26 34 25 25 22 5 27 5 29 35 22 5 27 5 9 11 50 9 11 15 22 5 27 5 55 90 42 Lb Ft 19 25 18 18 16 6 20 3 21 26 16 6 20 3 37 11 16 6 20 3 41 90 31 Lb In 80 97 80 ...

Page 267: ... 61 00 Lever Pusher 116 589 01 34 00 Threaded Pin 000 589 58 43 00 Chain Assembly 111 589 01 59 00 Supporting Bar 116 589 20 33 00 Sliding Hammer 119 589 00 43 00 Drift 103 589 02 09 00 Oil Filter Remover 111 589 25 63 00 Thrust Piece YAD1B1W0 YAD1B2Y0 YAD1B0W0 YAD1B0Y0 YAD1B0X0 YAD1B580 YAD1B570 YAD1B1L0 ...

Page 268: ...589 03 43 00 Crankshaft Rear Seal Installer 601 589 03 14 00 Crankshaft Front Seal Installer 603 589 00 40 00 Fan Clutch Holder DW110 090 Connecting Hose DW110 100 Valve Tappet Remover 602 589 00 40 00 Engine Lock 617 589 00 10 00 Allen Wrench Socket YAD1B790 YAD1B720 YAD1B4K0 YAD1B560 YAD1B2M0 YAD1B0Z0 YAD1B730 YAD1B1A0 ...

Page 269: ...SSANGYONG Y200 1B2 108 M161 ENGINE MECHANICAL Special Tools Table Cont d 111 589 03 15 00 Holding Pin YAD1B4R0 ...

Page 270: ...aring 1B3 66 Crankshaft 1B3 67 Crankshaft Sprocket 1B3 76 Piston 1B3 81 Flywheel Ring Gear 1B3 87 Timing Device and Valve 1B3 90 Valve Tappets 1B3 90 Valve Spring Cylinder Head Removed 1B3 92 Valve Spring Cylinder Head Installed 1B3 95 Valve Stem Seals 1B3 98 Valve Guides 1B3 102 Valve Seat Rings 1B3 105 Camshaft 1B3 112 Timing Chain 1B3 118 Chain Tensioner 1B3 122 Lubrication System 1B3 124 Oil F...

Page 271: ...ent by cam tip the element cam go down fully The oil displaced from the working chamber flows via the annular gap clearance between guide sleeve and thrust pin to the supply chamber As soon as the cam lobe rotates upwards from the tappet 2 the load on the guide sleeve 3 is relieved The spring 5 pushes the thrust pin 4 up until the tappet is resting against the cam 1 The vacuum produced in the work...

Page 272: ...SSANGYONG Y200 1B3 6 DIESEL ENGINE MECHANICAL CYLINDER BLOCK YAD1BA50 ...

Page 273: ...t 5 Cylinder Liner 6 Plug 7 Screw Seal Ring 8 Crankshaft Bearing Cap 9 Cylinder Block 10 Plug 11 Crankshaft Journal Bearing 12 Crankshaft Pulley 13 Vibration Damper 14 Hub 15 Crankshaft Sprocket 16 Key 17 Crankshaft 18 Crankshaft Journal Bearing 19 Crankshaft Thrust Bearing 20 Crankshaft Sealing Cover 21 Bolt 22 Flywheel 23 Plate 24 Oil Pump Assembly ...

Page 274: ...SSANGYONG Y200 1B3 4 DIESEL ENGINE MECHANICAL COMPONENT LOCATOR CYLINDER HEAD YAD1BA40 ...

Page 275: ...Bolt 5 Cylinder Head Cover 6 Cylinder Head Cover Gasket 7 Camshaft Cap Bolt 8 Cylinder Head Bolt 9 Camshaft Bearing Cap 10 Pre Chamber Assembly 11 Cylinder Head 12 Plug 13 Plug 14 Connector 15 Engine Coolant Temperature Sensor 16 Thermo Valve 17 Cylinder Head Gasket 18 Valve Assembly 19 Camshaft 20 Camshaft Adjust Key ...

Page 276: ...SSANGYONG Y200 1B3 8 DIESEL ENGINE MECHANICAL ENGINE COMPONENT YAD1BA60 ...

Page 277: ...9 SSANGYONG Y200 1 Fuel Filter Assembly 2 Oil Filter Assembly 3 Injection Pump Assembly 4 Power Steering Pump Assembly 5 Starter Assembly 6 A C Compressor Assembly 7 Generator Assembly 8 Turbo Charger Assembly 9 EGR Valve Assembly ...

Page 278: ...SSANGYONG Y200 1B3 10 DIESEL ENGINE MECHANICAL REPAIR INSTRUCTIONS ON VEHICLE SERVICE ENGINE ASSEMBLY 1 Engine Assembly YAD1BA70 ...

Page 279: ...1B020 YAD1BAA0 Removal Procedure 1 Disconnect the negative battery cable 2 Remove the hood 3 Remove the skid plate Installation Notice 4 Remove the radiator drain cock and drain the coolant Notice Open the coolant reservoir tank cap Tightening Torque 28 47 N m 21 35 lb ft ...

Page 280: ...ghtening Torque 30 N m 22 lb ft 6 Disconnect the lower coolant hose from the radiator 7 Disconnect the upper coolant hose from the radiator 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 After draining replace the seal and reinstall the drain plug Tightening Torque 30 40 N m 22 30 lb ft ...

Page 281: ...cooler intercooler to intake duct 11 Loosen the cooling fan shroud bolts and remove the cooling fan shroud Installation Notice 12 Remove the air cleaner to turbo charger hose 2 with blow by hose 1 13 Disconnect the exhaust gas recirculation EGR valve hose and necessary hoses and pipes Tightening Torque 3 7 N m 27 62 lb in ...

Page 282: ...from the turbo charger Installation Notice Tightening Torque 30 N m 22 lb ft 15 Disconnect the accelerator cable from the control linkage Notice After installation of accelerator cable check the engine idling and operation condition 16 Disconnect the brake booster hose from vacuum pump 17 Disconnect the fuel feed line with prefilter from the feed pump on injection pump ...

Page 283: ...Remove the A C compressor IN OUT pipes Notice Evacuate the refrigerant before removal 19 Remove the power steering pump lines Notice Completely drain the fluid 20 Remove the fuel lines from the fuel filter and cover the filter with plug 21 Disconnect the coolant hose from the water inlet ...

Page 284: ... YAD1BAW0 22 Disconnect the injection timing relay connector from injection pump 23 Disconnect the starter motor wires and necessary connectors 24 Disconnect the preheating time relay cable and glow plug cable 25 Disconnect the ground cable 26 Disconnect the generator wires ...

Page 285: ...l cooler lines Installation Notice Use the new washer before installation of oil cooler lines 29 Remove the transmission mounting bolts and separate the transmission from the engine Installation Notice 30 Remove the engine mounting bracket bolts Installation Notice Tightening Torque 54 68 N m 40 50 lb ft Tightening Torque 50 75 N m 37 55 lb ft Tightening Torque 25 35 N m 18 26 lb ft ...

Page 286: ...SSANGYONG Y200 1B3 18 DIESEL ENGINE MECHANICAL YAD1BB10 31 Remove the engine assembly from the vehicle by using a hoistor crane 32 Installation should follow the removal procedure in the reverse order ...

Page 287: ...DIESEL ENGINE MECHANICAL 1B3 19 SSANGYONG Y200 POLY V BELT AND TENSIONING DEVICE POLY V BELT 1 Nut 21 N m 15 lb ft 2 Tensioning Lever 3 Bolt 4 Spring 5 Tensioning Lever 6 Poly V Belt YAD1BB20 ...

Page 288: ...tension and remove the belt 4 Install the poly V belt beginning at the tensioning pulley 7 7 Tensioning Pulley 8 Crankshaft 9 Generator 10 Water Pump 11 Guide Pulley 12 Power Steering Pump 13 A C Compressor 2 Push the tensioning lever in direction of arrow with a rod φ 12 180 mm and pull out the bolt to the rear Tightening Torque 21 N m 15 lb ft Length of Belt Length L With Air Conditioner Without...

Page 289: ...Mark poly V belt at a clearly visible point with chalk Rotate the engine and check the belt Notice If one of the following types of damage is found replace the belt 1 Rubber lumps in the base of rips 2 Dirt or grit ingrained 3 Pointed rips 4 Belt cord visible in the base of rips 5 Cord torn out at the side 6 Outer cords frayed ...

Page 290: ...0 1B3 22 DIESEL ENGINE MECHANICAL YAD1B410 YAD1B420 YAD1B430 YAD1B440 7 Belt detached from the base of rip 8 Splits across the rips 9 Sections of rip torn out 10 Splits across several rips 11 Splits across the back ...

Page 291: ...5 lb ft 2 Damper 3 Nut 21 N m 15 lb ft 4 Tensioning Lever 5 Guide Rail Pin 6 Bolt 7 Poly V Belt 8 Belt Pulley 9 Bolt 10 N m 89 lb in 10 Tensioning Pulley 11 Socket Bolt 29 N m 21 lb ft 12 Closing Cover 13 Washer 14 Tensioning Lever 15 Fit Bolt 100 N m 74 lb ft 16 Closing Cover 17 Spring 18 Bolt 20 N m 15 lb ft YAD1BLJ0 ...

Page 292: ...nd push out the bolt to the rear 3 Push back the tensioning lever to release the spring tension and remove the belt 4 Remove the bolt 9 and then remove the belt pulley 8 Installation Notice 5 Remove the bolt 1 18 and take off the damper 2 Installation Notice Tightening Torque 21 N m 15 lb ft Pay attention to installation position of the damper Tightening Torque bolt 1 21 N m 15 lb ft bolt 18 20 N ...

Page 293: ...and remove the socket bolt 11 and then remove the tensioning pulley 10 Installation Notice 9 Pry off the closing cover 16 and remove the fit bolt 15 Installation Notice 12 Installation should follow the removal procedure in the reverse order Tightening Torque 29 N m 21 lb ft Apply loctite on thread of fit bolt 10 Remove the tensioning lever 14 and washer 13 11 Clean thread in the timing case cover...

Page 294: ...SSANGYONG Y200 1B3 26 DIESEL ENGINE MECHANICAL CRANKCASE AND CYLINDER HEAD CYLINDER HEAD YAD1BBC0 ...

Page 295: ...proket Relace 4 Camshaft 5 Bolt 10 N m 89 lb in 6 Threaded Ring 130 N m 96 lb ft 7 Prechamber 8 Bolt 25 N m 18 lb ft 9 Camshaft Bearing Cap 10 Cylinder Head Bolt See Table 11 Plug 12 Engine Coolant Temperature 13 Thermo Valve Sensor 14 Cylinder Block 15 Gasket Replace 16 Cylinder Head 17 Sliding Rail ...

Page 296: ...anent tightening They require to be replaced if they exceed the maximum lengthes indicated in the table 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 YAD1BBD0 Length L When New 80 mm 102 mm 115 mm Thread Dia M10 M10 M10 Max Length L...

Page 297: ...nter Holder Removal Procedure 1 Completely drain the coolant from the radiator and cylinder block 2 Remove the cooling fan shroud 3 Hold the fan with counter holder 603 589 00 40 00 and remove the bolt and then remove the cooling fan 4 Remove the bracket oil dipstick tube 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...

Page 298: ... the opposite direction to release the spring tension and remove the poly V belt 8 Unscrew the EGR pipe mounting bolts onto the exhaust manifold 9 Remove the duct bracket from the cylinder head 10 Unscrew the intake duct mounting bolts onto the intake manifold 11 Separate the connecting rod from the control lever ...

Page 299: ...1BBN0 YAD1BBP0 13 Remove the fuel injection line 1 from the fuel injection nozzle 12 14 Remove the fuel injection line from the fuel injection pump 15 Remove the bracket mounting bolts and then remove the fuel injection line 1 12 Pull out the accelerator control linkage ...

Page 300: ...INE MECHANICAL YAD1BBQ0 YAD1BBT0 YAD1BBR0 YAD1BBS0 16 Disconnect the blow by hose from the cylinder head cover 17 Disconnect the glow plug cables 18 Remove the intake manifold 10 and gasket 19 Remove the cylinder head cover and gasket ...

Page 301: ...ct the cables from the glow plug sensor and engine coolant temperature sensor 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 24 Disconnect the fuel lines from the fuel filter 20 Remove the cable channel ...

Page 302: ...1BC10 25 Disconnect the fuel lines from the injection pump 27 Remove the fuel injection nozzle and nozzle washer 26 Remove the fuel filter 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 ...

Page 303: ...50 30 Ensure that the camshaft and the bearing cap marking are aligned 31 Remove the starter motor and install the engine lock 602 589 00 40 00 onto the flywheel ring gear 32 Remove the exhaust manifold and exhaust pipe 29 Place alignment marks on the camshaft gear and timing chain ...

Page 304: ...nd then pull out the sprocket 35 Remove the camshaft bearing cap bolts according to the numerical sequence Notice Remove the No 1 bolts first and then remove the No 2 bolts Do not remove the bolts at a time completely but remove them step by step evenly or camshaft can be seriously damaged 36 Remove the bearing caps and then pull out the camshaft 20 upward Notice Be careful not to miss the locking...

Page 305: ...o valve 42 Remove the cylinder head bolts in numerical sequence 43 Remove the cylinder head and gasket 38 Using the sliding hammer 116 589 20 33 00 36 and the threaded pin 116 589 02 34 00 37 pull out the sliding rail pins 25 26 and remove the sliding rail 24 YAD1BCD0 41 Remove the socket bolts 13 of the chain box using the T type socket wrench 116 589 03 07 00 ...

Page 306: ...e cylinder head holes with the guide pins 3 Measure the length L of cylinder head bolts Notice If the max length is exceeded replace the bolts 4 Coat the head contact surface of bolts and thread with oil and insert them as shown Cylinder head bolts arrangement Bore 1 M10 80 2 M10 102 3 M10 115 4 M 8 50 5 M 8 80 Max Limit L 82 mm 104 mm 117 mm Thread Dia M10 M10 M10 Length L when New 80 mm 102 mm 1...

Page 307: ... Install the socket bolts in the chain box using the T type socket wrench 116 589 03 07 00 Installation Notice 7 Connect the vacuum pipe to the thermo valve 8 Connect the vacuum lines to the vacuum pump Tightening Torque 25 N m 18 lb ft Tightening Torque 1st Step 2nd Step Torque Angle Wait for Torque Angle 10 N m 89 lb in 35 N m 26 lb ft 90 10 minutes 90 ...

Page 308: ...Installation Notice 11 Install the sliding rail 24 and insert the sliding rail pins 25 26 using the sliding hammer 116 589 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 12 Insert the locking washer 13 Inspect the valve tappet and check that the tappet moves smoothly Tightening Torque 13 N m 10 lb ft Be careful not to be c...

Page 309: ...ndard adjust it with the proper thickness of locking washer 16 Install the bearing caps on the camshaft according to the number on the caps 17 Tighten the bearing cap bolts according to the numerical sequence Installation Notice Tightening Torque 25 N m 18 lb ft Tighten the No 1 bolts light arrow first and then tighten the No 2 bolts dark arrow stage by stage 18 Position the camshaft on marking an...

Page 310: ...YAD1BC10 YAD1BC70 YAD1BCS0 19 Check the TDC position of the crankshaft 20 Install the camshaft sprocket bolt Installation Notice Notice Measure the max length L and replace the bolt if it exceeds 53 6 mm Tightening Torque 25 N m 18 lb ft 90 1st Step 2nd Step ...

Page 311: ...lation Notice 23 Remove the engine lock 602 589 00 40 00 24 Insert the nozzle washer into the hole to face round part downward 25 Install the fuel injection nozzle Installation Notice Tightening Torque 80 N m 59 lb ft Tightening Torque 40 N m 30 lb ft 21 Install the exhaust manifold and gasket Installation Notice Tightening Torque 25 N m 18 lb ft ...

Page 312: ...o glow plugs 28 Replace the gasket and install the cylinder head cover Installation Notice 30 Connect the wires to the engine coolant temperature sensor and the glow plug sensor 31 Replace the intake manifold gasket 32 Install the intake manifold Installation Notice 29 Install the blow by hose Tightening Torque 10 N m 89 lb in Tightening Torque 25 N m 18 lb ft ...

Page 313: ... to the injection pump Installation Notice Tightening Torque 18 N m 13 lb ft YAD1BCY0 YAD1BBN0 YAD1BCZ0 37 Install the poly V belt Notice Be careful not to contaminate the belt 33 Replace the O ring of heater feed pipe and install it to the cylinder head Notice For installation clean the hole 34 Install the bracket of heater feed pipe to the oil filter YAD1BCX0 ...

Page 314: ...g lever upper hole and pulling the rod install the bolt and then tighten the nut Installation Notice 39 Install the oil dipstick tube bracket Installation Notice 40 Hold the cooling fan with the counter holder 603 589 00 40 00 and tighten the bolt Tightening Torque 21 N m 15 lb ft Tightening Torque 10 N m 89 lb in ...

Page 315: ...an rag 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 PRECHAMBER Preceding work Removal of glow plug Removal of fuel injection nozzle Tools Required 603 589 00 09 00 Serration Wrench 667 589 03 63 00 Sliding Hammer Removal Procedure 1 Using the serration wrench ...

Page 316: ...he prechamber into the cylinder head at the same time aligning the cam on the collar of the prechambers with the slots in the cylinder head Installation Notice If the spacer rings are fitted to the prechambers the spacer rings should be replaced with rings of the same thickness 3 Coat the threaded ring with oil and assemble the ring by using the serration wrench 603 589 00 09 00 Installation Notic...

Page 317: ... 1B3 49 SSANGYONG Y200 OIL PAN YAD1BD50 1 Gasket Replace 2 Oil Pan 3 Bolt 10 N m 89 lb in 4 Washer Replace 5 Drain Plug 25 N m 18 lb ft 6 Bolt 10 N m 89 lb in 7 Bolt 25 N m 18 lb ft Notice Replace the washer seal with new one ...

Page 318: ... 4 Socket Bolt 25 N m 18 lb ft 5 Fuel Filter 6 Square Nut 7 Oil Pan 8 Socket Bolt 10 N m 89 lb in 9 Bolt M6 10 N m 89 lb in M8 23 N m 17 lb ft 10 Power Steering Pump 11 Bolt 12 Belt Pulley 13 Bolt 32 N m 24 lb ft 14 Timing Case Cover 15 Bolt 23 N m 17 lb ft 16 Generator Bracket 17 Bolt 45 N m 33 lb ft 18 Bolt 25 N m 18 lb ft 19 Bolt 10 N m 89 lb in 20 Closing Cover 21 Socket Bolt 23 N m 17 lb ft 2...

Page 319: ...ey 2 Drain the engine oil completely 3 Remove the crankshaft pulley 4 Loosen the bolt 1 and then remove the cylinder head cover 2 and gasket 5 Remove the vacuum pump 6 Detach the closing cover 20 Remove the bolts 21 and then remove the guide pulley 22 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 bol...

Page 320: ...B0 YAD1BDC0 YAD1BDD0 11 Remove the fuel filter 12 Remove the camshaft 13 Remove the socket bolts 4 in the chain box using the socket wrench 115 589 03 07 00 14 Remove the injection pump Refer to Section 1F3 Diesel Engine Control 10 Remove the generator bracket 16 ...

Page 321: ...ng oil pan bolts 17 Remove the timing case cover 19 bolts and then remove the timing case cover 14 Notice Be careful not to damage the cylinder head gasket or oil pan gasket 2 Install the timing case cover Installation Notice Bolts arrangement 1 M6 x 60 2 M6 x 70 3 M6 x 40 Tightening Torque 10 N m 89 lb in Installation Procedure 1 Thoroughly clean the sealing surface and apply sealant ...

Page 322: ... damper and crankshaft belt pulley Notice Replace front radial seal if necessary 6 Install the generator bracket Installation Notice 7 Install the generator Installation Notice Tightening Torque 25 N m 18 lb ft 45 N m 33 lb ft Upper Lower Tightening Torque 25 N m 18 lb ft Tightening Torque 10 N m 89 lb in 10 N m 89 lb in 25 N m 18 lb ft Socket Bolt M6 Bolt M8 Bolt Tightening Torque 25 N m 18 lb ft...

Page 323: ...Install the vacuum pump Installation Notice 12 Install the power steering pump Installation Notice 13 Install the power steering pump pulley Installation Notice 14 Install the guide pulley bracket Installation Notice Tightening Torque 10 N m 89 lb in Tightening Torque 23 N m 17 lb ft Tightening Torque 25 N m 18 lb ft Tightening Torque 10 N m 89 lb in Tightening Torque 32 N m 24 lb ft Tightening To...

Page 324: ...lace the gasket 3 and install the cylinder head cover 2 Installation Notice 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 Tightening Torque 23 N m 17 lb ft Tightening Torque 10 N m 89 lb in ...

Page 325: ...DIESEL ENGINE MECHANICAL 1B3 57 SSANGYONG Y200 YAD1BDQ0 CRANKSHAFT ASSEMBLY VIBRATION DAMPER AND HUB Preceding Work Removal of the cooling fan Removal of poly V belt ...

Page 326: ...lt Pulley 5 Vibration Damper 6 Bolt 200 N m 148 lb ft 90 7 Washer 8 Straight Pin 9 Hub 10 Oil Pan 11 Radial Seal 12 Key 13 Radial Seal 14 Timing Gear Case Cover 15 Key 16 Crankshaft Sprocket 17 Crankshaft 18 Socket Bolt 23 N m 17 lb ft 19 Washer 20 Bolt 20 N m 148 lb ft 90 21 Hub 22 Straight Pin 23 Crankshaft Velt Pulley 24 Vibration Damper ...

Page 327: ...stall the engine lock 602 589 00 40 00 into the flywheel ring gear 2 Remove the poly V belt 3 Remove the cooling fan Notice Keep the fan in vertical position 4 Remove the cooling fan belt pulley 2 5 Place alignment marks arrow on the vibration damper 5 and crankshaft belt pulley 4 6 Remove the timing sensor bracket Notice Remove if necessary 7 Remove the socket bolts 3 and then remove the belt pul...

Page 328: ...EL ENGINE MECHANICAL YAD1BDU0 YAD1BDV0 YAD1BDW0 8 Remove the washer and bolt 9 Remove the hub by using a puller 103 589 00 33 00 10 Pull out the radial seal 1 and be careful not to damage the sealing surface of timing case cover ...

Page 329: ...the woodruff key and the groove of hub arrow 2 Install the washer and tighten the bolt Installation Notice 3 Install the vibration damper Notice Exactly align and insert onto the straight pin 4 Install the crankshaft belt pulley Installation Notice Align the alignment marks Tightening Torque 200 N m 148 lb ft 90 Tightening Torque 23 N m 17 lb ft ...

Page 330: ...re of the radial seal 11 Coat a little oil on the sealing lip of new radial 1 and contact surface Notice Don t use grease 12 Install the radisl seal 1 by using a sleeve 601 589 03 14 00 4 Notice Align the groove of sleeve and woodruff key arrow Tightening Torque 10 N m 89 lb in YAD1BE30 Notice The sealing lip of the repair radial seal is offset to the inside by 2 mm to ensure that is does not run ...

Page 331: ...clutch YAD1BE50 1 Crankshaft Flange 2 End Clver Clean Loctite 573 3 Bolt 10 N m 89 lb in Loctite 573 4 Radial Seal Replace 5 Dowel Sleeve 6 Bolt 10 N m 89 lb in Loctite 573 7 Straight Pin 8 Flywheel Manual Transmission 9 12 Sided Stretch Bolt Check 45 N m 33 lb ft 90 10 Drive Plate Automatic Transmission 11 Flywheel Automatic Transmission ...

Page 332: ... 602 589 00 40 00 2 Remove the 12 sided stretch bolts Notice Remove the flywheel and drive plate if equipped with automatic transmission 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 4 Remove the radial seal 4 with care not to damage the sealing surface Notice If the length L of bolts exceeds 22 5 mm replace t...

Page 333: ...89 03 43 00 to the crankshaft flange 5 Coat a little oil on the sealing lip of new radial seal and contacting surface Notice Don t use grease 6 Insert the new radial seal 4 on to the oil seal assembler 601 589 03 43 00 7 Notice The sealing lip of the repair radial seal is offset to the inside by 3 mm to ensure that is does not run in any groove which the standard radial seal may have left on the c...

Page 334: ...yy yyyy yyyy yyyy yyyy YAD1BEE0 YAD1BEF0 7 Install the outer oil seal assembler 601 589 03 43 00 on the seal and by tightening the bolts press the radial seal into the end cover as far as the stop Notice The seal must be positioned exactly at right angles in the end cover to ensure that it provide a proper seal 8 Install the flywheel Installation Notice Tightening Torque 45 N m 33 lb ft 90 YAD1BEG...

Page 335: ...l Installation Procedure 1 Remove the manual transmission 2 Using a internal extractor 000 589 25 33 00 and counter support 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 1 Spacer 2 Cover Replace 3 Ball Bearing 4 Bolt 45 N m 33 lb ft 90 YAD1B...

Page 336: ...ver Removal of the piston Removal of the crankshaft sprocket 3 Crankshaft Main Bearing Shells Upper 4 Trust Bearings Upper 5 Crankshaft 6 Crankshaft Main Bearing Shells Lower 7 Thrust Bearings Lower 8 Crankshaft Bearing Cap 9 Crankshaft Bearing Cap Fit Bearing 10 12 sided Stretch Bolts 55 N m 41 lb ft 90 ...

Page 337: ...ing Shells Upper 4 Thrust Bearings Upper 5 Crankshaft 6 Crankshaft Main Bearing Shells Lower 7 Thrust Bearings Lower A Radial Bearings B Radial and Axial Bearings Thrust Bearing Notice The gaps between the bearing shell and bore and between the bearing shell and journal are different each other Refer to service data ...

Page 338: ... width 2 15 mm 2 20 mm 2 25 mm 2 35 mm 2 40 mm Thrust bearing journal width 24 500 24 533 24 600 24 633 24 700 24 733 24 900 24 933 25 000 25 033 Thrust bearing journal diameter 47 950 47 965 47 700 47 715 47 450 47 650 47 200 47 215 46 950 46 965 Thrust bearings thickness Standard size Repair size 1 Repair size 2 Repair size 3 Repair size 4 Crankshaft bearing journal diameter 50 950 57 965 57 500...

Page 339: ...ring bore in lower parting surface 1 punch mark or blue 2 punch marks or yellow 3 punch marks or red Color code of relevant crankshaft bearing shell Blue or white blue Yellow or white yellow Red or white red Marking of bearing journals on crank webs Blue or white blue Yellow or white blue Red or white blue Color code of relevant crankshaft bearing shell Blue or white blue Yellow or white yellow Re...

Page 340: ...e 1 Remove the bearing cab bolt 2 Remove the bearing caps 8 Notice The crankshaft bearing caps are marked with stamped numbers Remove the bearing cap from the vibration damper side 3 Remove the crankshaft bearing caps 9 and lower thrust bearings 7 4 Remove the lower bearing shell 6 from the bearing cap 9 6 Remove the upper thrust bearings 4 7 Remove the upper bearing shells 3 from crankcase 5 Remo...

Page 341: ...ower crankshaft bearing shells 11 Install the bearing caps according to marking and tighten the 12 sided stretch bolts Installation Notice Tightening Torque 55 N m 41 lb ft 90 12 Measure crankshaft bearing diameters E using the dial gauge 001 589 53 21 00 and extension 366 589 00 21 05 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 ...

Page 342: ... crankcase so that the oil grooves are facing the crank webs arrow 16 Remove the crankshaft bearing cap 17 Measure width of thrust bearing journal H and adjust with proper thrust bearings see table Notice The same thickness of thrust washers should be installed on both sides of the thrust bearing Clearance G 0 027 0 051 mm Notice If G is out of standard replace the bearing shells and adjust the ra...

Page 343: ...ing dial gauge 001 589 53 21 00 and dial gauge holder 363 589 02 21 00 Notice If the max length of bolts L exceed 63 8 mm replace them 20 Coat the new crankshaft with engine oil and place it on the crankcase 21 Install the crankshaft bearing caps according to marking and tighten the bolts Installation Notice Tightening Torque 55 N m 41 lb ft 90 Install from No 1 cap Notice If the clearance is out ...

Page 344: ...t rotates smoothly 31 If the bearings are damaged replace the oil presser relief valve clean the oil pump and oil filter housing carefully and replace the hose if necessary Notice After assembling the engine check the camshaft timing adjust the start of fuel injection and check the TDC sensor bracket setting 32 Fill oil and run the engine and then check the oil pressure and oil level Notice Instal...

Page 345: ...se cover YAD1BF40 1 12 Sided Stretch Bolt M11 Check 25 N m 18 lb ft 90 2 Washer 3 Camshaft Sprocket 4 Timing Chain 5 Bearing Pin 6 Bearing Pin 7 Oil Pump 8 Oil Pump Sprocket 9 Oil Pump Chain 10 Washer 11 Bolt 25 N m 18 lb ft 12 Crankshaft Sprocket 13 Crankshaft 14 Key 16 Guide Rail 17 Spring 18 Bushing 19 Tensioning Lever ...

Page 346: ...t the tensioning lever 19 together with the spring 17 and guide rail 16 far enough until the tensioning lever has passed the oil pump chain 9 and is resting against the crankshaft 13 2 Pull out tensioning lever 19 spring 17 and bushing 18 from the bearing pin 6 3 Pull out the guide rail 16 4 Remove the bolt 11 and then remove the washer 10 oil pump chain 9 and sprocket 8 ...

Page 347: ...g chain 4 and crankshaft sprocket 12 6 Remove the woodruff key 15 7 Place alignment marks arrow on the timing chain 4 and camshaft sprocket 3 8 Remove the chain tensioner 9 Remove the bolt 1 and then remove the washer 2 and camshaft sprocket 3 10 Remove the crankshaft sprocket 12 by using a puller 102 589 05 33 00 20 ...

Page 348: ...mp chain and oil pump sprocket for wear and replace if necessary 2 Install the new crankshaft sprocket 12 by using a drift 116 589 07 15 00 21 Notice Align the groove of sprocket and woodruff key arrow exactly 3 Fit the timing chain 4 on the crankshaft sprocket 12 Notice Align the alignment marks arrow on the chain and sprocket 4 Install the camshaft sprocket 3 Installation Notice Tightening Torqu...

Page 349: ...l pump sprocket 8 into the oil pump chain and then install it on the oil pump Installation Notice 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 The curved side of the oil pump sprocket should face the oil pump 6 Insert the woodruff key 15 Tightening...

Page 350: ...eck 8 Connecting Rod 9 Connecting Rod Upper Bearing Shell 10 Connecting Rod Lower Bearing Shell 11 Connecting Rod Bearing Cap 12 Connecting Rod Bolt 35 N m 26 lb ft 90 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 ther...

Page 351: ...cting Rod Bolt Dimensions Piston clearance Piston crown protrusion in TDC position Connecting rod bushing diameter Max 0 12 mm 0 735 0 965 mm 26 012 26 018 mm Thread Stretch shaft C diameter new Minimum stretch shaft diameter C Length L new M9 x 1 7 4 mm 7 1 mm 52 mm ...

Page 352: ... Procedure 1 Remove combustion residues from the cylinder bores 2 Remove the connecting rod bolts 12 and then remove the connecting rod bearing caps 11 5 Remove the snap ring 4 and pull out the piston pin 5 6 Separate the piston and connecting rod 4 Remove the piston 6 and connecting rod 8 3 Remove the connecting rod bearing shells 9 10 Notice Be careful not mix the bearing caps and shells each ot...

Page 353: ...e arrow 15 and the locking slot 16 are facing in direction of the vehicle 5 Install and arrange the piston rings to be evenly 120 from each ends gap 3 Install the new snap ring 4 into the grooves arrow 4 Check the piston rings 1 2 3 and replace them if necessary 2 Coat the piston pin 15 with engine oil and insert it by hand Notice Do not heat up the piston ...

Page 354: ...diameter C of the connecting rod bolts 9 Insert the connecting rod bearing shells 9 10 Notice Be careful of the difference in upper and lower bearing shells and not to be changed 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 8 Insert the piston assembly into the cylinder with a wooden stick 18 Notice...

Page 355: ... 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 14 Measure clearance between the piston crown and cylinder 13 Rotate the crankshaft and check axial clearance between the connecting rod and crankshaft Tightening Torque 35 N m 26 lb ft 90 Notice Measure at points marked Standard Max 0 965 mm Standard Max 0 12 mm ...

Page 356: ...SSANGYONG Y200 1B3 88 DIESEL ENGINE MECHANICAL FLYWHEEL RING GEAR Preceding Work Removal of flywheel 1 Ring Gear 2 Flywheel a Centering Collar Diameter YAD1BFX0 ...

Page 357: ...hole into the ring gear 1 arrow and snap with a chisel 2 Thoroughly clean the collar surfaces of ring gear 5 Install the new ring gear 1 onto the flywheel 2 by using a drift 4 Heat up the new ring gear up to 220 C 428 F by using a heating device Notice Use temperature measuring chalk 3 Measure diameter a of centering collar Diameter a 275 0 5 mm Notice If out of standard replace the flywheel ...

Page 358: ...CHANICAL YAD1BG20 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 Notice For correct measurement put the flywheel on the flat measuring board Limit Max 0 4 mm ...

Page 359: ...DIESEL ENGINE MECHANICAL 1B3 91 SSANGYONG Y200 TIMING DEVICE AND VALVE VALVE TAPPETS Preceding Work Removal of camshaft 1 Valve Tappet 2 Cylinder Head 3 Oil Gallery 4 Seal Replace 5 Screw Plug YAD1BG30 ...

Page 360: ...1 Pull out the valve tappet 1 using magnetic bar 102 589 03 40 00 2 Remove the plug 5 and blow compressed air into the oil gallery 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 ...

Page 361: ...VALVE SPRINGS CYLINDER HEAD REMOVED Proceding Work Remove of cylinder head 1 Valve Tappet 2 Valve Cotters 3 Spring Retainer 4 Valve Spring Check replace if necessary 5 Cylinder Head 6 Stud Bolt 12 N m 106 lb in 7 Nut Replace 25 N m 18 lb ft YAD1BG60 ...

Page 362: ... the washer 7 exhaust manifold 9 and gasket Installation Notice Check the stud bolt 6 for damage and replace if necessary 4 Install the supporting bridge 601 589 02 59 00 13 on the cylinder head 5 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 Replace the gasket and tighten the nuts 8 Tightening Torque 12 N m 106 lb in...

Page 363: ...e valve cotters 2 with magnetic finger 116 589 06 63 00 15 Notice Be careful not to damage guide bore of the valve tappet 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 ...

Page 364: ...INGS CYLINDER HEAD INSTALLED Preceding Work Removal of camshaft 1 Valve Tappet 2 Valve Cotters 3 Spring Retainer 4 Valve Spring Check replace if necessary 5 Timing Chain 6 Cylinder Head Notice Remove the valve springs only when the piston is at TDC YAD1BGD0 ...

Page 365: ...et 1 with magentic bar 102 589 03 40 00 Notice Place the valve tappets upside down open end upward 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 4 Install the supporting bar 667 589 02 63 00 8 2 Install the holding wheel 603 589 01...

Page 366: ... the color coding arrow facing down and insert valve spring Retainer 3 13 Coat the valve tappet with oil and install it with magnetic bar 102 589 03 40 00 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 9 By press the spring retainer 3 with press lever 667 589 00 31 00 9 install the valve cotters with magnetic finger 116 589 06 6...

Page 367: ...ALVE STEM SEALS Preceding Work Removal of camshaft 1 Valve Tappet 2 Valve Cotters 3 Spring Retainer 4 Valve Spring Check replace if necessary 5 Valve Stem Seal 6 Valve YAD1BGJ0 Notice Remove the valve stem seals when the pistion is positioned at TDC ...

Page 368: ...iers 116 589 06 63 00 Magnetic Finger 601 589 02 43 00 Drift 603 589 01 40 00 Holding Wheel 667 589 00 31 00 Press Lever 667 589 02 63 00 Supporting Bar YAD1BGK0 YAD1BGL0 Chamfer Inner diameter d Color Wire ring Exhaust valve stem seal All round 8 2 mm Green Yellow Intake valve stem seal Offset 7 3mm Brown Black ...

Page 369: ...tice Place the valve tappets upside down open end upward 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 2 Install the holding wheel 603 589 01 40 00 7 into the timing chain 11 3 Position the piston of relevant cylinder at TDC 4 Install the supporting bar 667 589 02 63 00 8 ...

Page 370: ...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 8 Insert the cap 12 onto the valve 6 and install the new valve stem seal 5 with drift 601 589 02 43 00 and then remover the cap 7 Remove the valve stem seal with pliers 104 589 00 37 00 5 ...

Page 371: ...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 8 Insert the cap 12 onto the valve 6 and install the new valve stem seal 5 with drift 601 589 02 43 00 and then remover the cap 7 Remove the valve stem seal with pliers 104 589 00 37 00 5 ...

Page 372: ...ing a Basic Bore Diameter Service Data Intake Exaust Repair size 1 Repair size 2 Repair size 1 Repair size 2 14 251 14 440 14 451 14 240 14 251 14 440 14 451 Red White Red White 0 029 0 051 0 029 0 051 14 200 14 211 14 400 14 411 14 200 14 211 14 400 14 411 8 000 8 030 9 000 9 050 39 5 37 7 Item Outer Diameter D Color Code Overlap D a Basic Bore Diameter a Valve Guide Inner Diameter A Length L ...

Page 373: ...auge for Intake 103 589 02 15 00 Drift for Exhaust 103 589 03 15 00 Drift for Intake 115 589 34 63 00 Mounting Device 117 589 03 23 00 GO NO GO Gauge for Exhaust 346 589 00 63 00 Super Cooling Box 601 589 05 15 00 Drift for Intake 601 589 06 15 00 Drift for Exhaust MatchingValve Seat BroachingTools Guide Sleeves Guide Sleeve Side B B A B Valve Seat Intake Exhaust Intake Exhaust Broaching Tool No 1...

Page 374: ...sh 000 589 10 68 00 Replacement Procedure 1 Drive out the valve guide 2 by using a drift Intake 103 589 03 15 00 Exhaust 103 589 02 15 00 5 Notice The valve guide must be driven out upward of the cylinder head 2 Thoroughly clean the basic bore by using a cylinder brush 000 589 10 68 00 3 Check the basic bore in cylinder head for scoring marks and ream to next repair size if necessary 2 Insert the ...

Page 375: ...lastic brush Lubricate the basic bore guide sleeve and broaching tool with petroleum Push broaching tool 6 in broaching direction arrow into the guide sleeve 7 far enough so that the first cut of the broaching tool is positioned in the basic bore when guide sleeve is fitted onto the valve seat ring 3 YAD1BGY0 5 Heat the cylinder head 1 in a wear tank to approx 80 C 176 F with mounting device 115 5...

Page 376: ...the valve guide bore with GO NO GO gauge Intake 102 589 00 23 00 Exhaust 117 589 03 23 00 9 The GO side marked 0 should just still drop If the GO side cannot be inserted the bore of valve guide should be reamed Notice Perform the check only on cooled down cylinder head 7 Drive in new valve guide with drift Intake 601 589 05 15 00 Exhaust 601 589 06 15 00 8 until the wire ring makes contact Notice ...

Page 377: ...urface B Height Cylinder Head Cover Surface Seat of Valve Seat Ring D Valve Seat Ring Outer Diameter D1 Valve Seat Ring Inner Diameter D2 Basic Bore Diameter H Height of Valve Seat Ring Service Data Item D2 D D1 H Overlap U D D2 B A Intake 40 000 40 016 mm 40 084 40 100 mm 33 400 33 600 mm 6 955 7 045 mm 0 068 0 100 mm 133 4 mm 142 5 mm Exhaust 37 000 37 016 mm 37 084 37 100 mm 30 400 30 600 mm 6 ...

Page 378: ...icrometer Range 25 60 mm Electrically Heated Water Tank Hunger D 8000 München 70 Type Ventilknecht K2000 Order No 221 00 100 Hunger D 8000 München 70 Type VDS 1A Order No 236 03 308 Hunger D 8000 München 70 Type RDS 1 Order No 219 00 100 Hunger D 8000 München 70 Type PVM 1 Hunger D 8000 München 70 Order No 250 15 250 Hunger D 8000 München 70 Order No 217 93 601 Hunger D 8000 München 70 Order No 21...

Page 379: ... 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 4 Remove the cylinder head from the clamping device and place it onto wooden blocks 5 Remove the valve guide 3 by using a drift Intake 8 mm Exhaust 9 mm 3 Cut groove into the valve seat ring so that dimension C is approx 2 mm and dimension E ...

Page 380: ... outer diameter D of the new valve seat ring standard size 12 Calculate the overlap value U D D2 Measure machined basic bore and outer diameter D of valve seat ring repair size Measure the overlap U 13 Clamp the cylinder head with clamping device 14 Machining basic bore for valve seat ring repair size Notice Maintain minimum value of B Machine the basic bore Limit Example Measured value D 37 600 m...

Page 381: ...4 63 00 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 17 Drive in new valve seat ring 2 with a proper wooden drift 16 Cool down new valve seat ring 2 into the cooling box 345 589 00 63 00 with liquid nitrogen Notice Do not touch the cooled valve seat ring...

Page 382: ...der head cover 1 Bolt 25 N m 18 lb ft 2 Washer 3 Camshaft Bearing Cap 4 Camshaft 5 Dowel Pin 6 Locking Washer 7 Timing Chain 8 Cylinder Head 9 Oil Pan 10 Camshaft Sprocket 11 Washer 12 12 Sided Bolt M11 Check 25 N m 18 lb ft 90 13 Gasket Replace 14 Chain Tensioner 80 N m 59 lb ft YAD1BHH0 ...

Page 383: ...nkshaft and position the piston of No 1 cylinder at TDC Notice Do not rotate the crankshaft in the opposite direction of engine rotation 3 Remove the starter motor and install the engine lock 602 589 00 40 00 2 Place alignment marks on the camshaft sprocket and timing chain In this position the markings of the camshaft camshaft bearing cap arrow must be aligned ...

Page 384: ...chain tensioner 6 Remove the camshaft bearing cap bolts according to the removal order Notice Remove the camshaft bearing cap bolts of 1 first and then remove the bolts of 2 one revolution in stages until the counter pressure is released In order to avoid damaging the camshaft it is essential to adhere to the removal order for the camshaft bearing caps YAD1BC90 7 Remove the camshaft bearing cap 8 ...

Page 385: ...at tappet moves smoothly 3 Coat the camshaft with oil and install the camshaft onto the cylinder head so that the TDC marking arrow is positioned upward vertically 4 Install the camshaft bearing caps according to markings 1 2 3 etc 5 Tighten the camshaft bearing cap bolts acccording to installation order Installation Notice Tighten the No 1 bolts light arrow by one revolution in stages first and t...

Page 386: ... alignment marks on the timing chain and sprocket 7 Tighten the camshaft sprocket bolt Installation Notice Tightening Torque 25 N m 18 lb ft 90 Notice If max length L of the 12 sided bolt exceeds 53 6mm replace it 8 Install the chain tensioner Installation Notice Replace the seal Before installation by pumping in the oil approx 10 times fill the oil Tightening Torque 80 N m 59 lb ft YAD1BCS0 ...

Page 387: ...SSANGYONG Y200 1B3 118 DIESEL ENGINE MECHANICAL YAD1BC40 YAD1BC10 9 Remove the engine lock 602 589 00 40 00 10 Check the TDC marking of OT on the crankshaft ...

Page 388: ...L 1B3 119 SSANGYONG Y200 TIMING CHAIN Preceding Work Removal of glow plug Removal of chain tensioner Removal of cooling fan Removal of cylinder head cover 1 Chain Link 2 Timing Chain YAD1BHK0 3 Camshaft Sprocket 4 Outer Plate ...

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 3 Loosen the chain tension with approx 4 turns 4 Connect the new timing chain arrow with chain link 1 to the old timing chain 2 2 Remove the outer plate 4 and chain li...

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 10 Switch over the die 9 of the chain assembling device 000 589 58 43 00 8 8 Insert the new outer plate 4 into the chain assembling device 000 589 58 43 00 tool 8 and then the outer plate will be held by a magnet ...

Page 391: ...one 14 Position the no 1 cylinder at TDC 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 12 Check the riveting of chain pins and re rivet if necessary 13 Remove the wire Tightening Torque 35 40 N m 20 30 lb ft ...

Page 392: ...DIESEL ENGINE MECHANICAL 1B3 123 SSANGYONG Y200 CHAIN TENSIONER 1 Chain Tensioner 80 N m 59 lb ft 2 Seal Replace YAD1BHU0 ...

Page 393: ... pin facing up Slowly push down the thrust pin as far as the stop 7 10 times with the aid of a press or a column drill YAD1BHV0 3 Screw Plug 4 Aluminum Gasket 5 Ball 6 Ball Guide 7 Compression Spring 8 Compression Spring 9 Housing 10 Thrust Pin 11 Valve Disc 12 O Ring 13 Snap Ring 14 Compression Spring 15 Filler a Feed Bore from Cylinder Head b To Oil Pan Faulty chain tensioners should be replaced...

Page 394: ... 1B3 125 SSANGYONG Y200 LUBRICATION SYSTEM OIL FILTER YAD1BHW0 1 Housing Cap 25 N m 18 lb ft 2 O Ring Replace 3 Oil Filter Element replace if necessary 4 Oil Filter Housing 5 Bolt 25 N m 18 lb ft 6 Oil Pressure Switch 7 Gasket ...

Page 395: ...Disconnect the oil cooler inlet and outlet hoses 4 Clean the sealing surface 5 Installation should follow the removal procedure in the reverse order 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 ...

Page 396: ...Spray Nozzle 3 Combination Bolt 10 N m 89 lb in a Oil Duct 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 ...

Page 397: ...lt 25 N m 18 lb ft 3 Sprocket 4 Poston 5 Pressure Spring 6 Guide Pin 7 Screw Plug 50 N m 37 lb ft 8 Bolt 25 N m 18 lb ft YAD1BJ20 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 ...

Page 398: ... oil pump mounting bolts and oil pump Installation Notice 3 Unscrew the screw plug and remove the relief valve Installation Notice 4 Installation should follow the removal procedure in the reverse order Tightening Torque 50 N m 37 lb ft Tightening Torque 25 N m 18 lb ft ...

Page 399: ...s essential to adhere to the specified projection C of the prechamber of 7 6 8 1mm This ensures that the required clearance exists between prechamber and piston crown with the piston in TDC For this reason spacer rings should be inserted on remachined sealing surfaces Thickness of spacers 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 ...

Page 400: ...4 Remove the protective sleeve from the counter sink 601 589 00 60 00 and rotate the counter sink 601 589 00 60 00 into the prechamber bore to be machined as far as the stop 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 6 Measure the X by using a vernier caliper 5 Maintain size X from the top edge of mandrel...

Page 401: ...least 0 1 mm and not more than 0 3 mm thicker than the measured on the sealing surface In this example the necessary thickness of spacer ring should be within 0 3 0 5 mm and the thickness of spacer ring to be installed is 0 3 mm 9 Remove the counter sink 601 589 00 60 00 and clean the chips Notice If the sealing surface is not completely flat remachine the sealing surface 10 Remove rag from the pr...

Page 402: ...sensor bracket must be adjusted in case of followings When replacing the TDC sensor bracket When replacing the crankshaft the hub or the vibration damper When replacing or installing the timing case cover 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 s...

Page 403: ...53 21 00 stops TDC position Notice The position of TDC is when the large pointer on the dial gauge is stopped before moving back 5 Remove the reinstall the measuring device and position the dial gauge 001 589 53 21 00 scale at 0 6 Slowly rotate the crankshaft in the direction of engine rotation until the dial gauge 001 589 53 21 00 has moved back counterclockwise by 3 65 mm 7 Insert fixing device ...

Page 404: ...grinding or precision turning If the scores or cracks are severe than permissible specifications replace the flywheel When machining the clutch surface A the mounting surface 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 YAD1BJE0 YAD1BJF0 19 3...

Page 405: ...SSANGYONG Y200 1B3 136 DIESEL ENGINE MECHANICAL HYDRAULIC VALVE CLEARANCE COMPENSATION ELEMENT CHECK 1 Cylinder Head Cover 2 Bolt 10 N m 89 lb in 3 Gasket Replace 4 Valve Tappet 5 Cylinder Head YAD1BJG0 ...

Page 406: ...Stop the engine After 5minutes check the engine oil level and adjust if necessary 3 Remove the cylinder head cover 4 Check the valve tappets at TDC position of each cylinders 5 Using a drift lightly press the valve tappet and measure clearance between the cam and valve tappet Notice If the clearance exceeds 0 4mm replace the valve tappet 6 If a valve tappet moves down too far in comparison to the ...

Page 407: ...ANICAL VALVE SPRINGS CHECK Preceding Work Removal of valve spring 1 Valve Spring 2 Spring Scale Service Data YAD1BJJ0 Limit 612 N Outer diameter 33 1 mm Wire diameter 4 20 mm Free length 50 0 mm At preloaded Length 27 mm Tension new 680 740 N ...

Page 408: ...OF VALVES Preceding Works Removal of cylinder head Removal of the vale spring Removal of the valve I Valve Length w Camshaft Cam Basic Diameter x Distance Camshaft Basic Bore Valve Stem y Half Camshaft Basic Bore Diameter z Distance Cylinder Head Cover Parting Surface Valve Stem ...

Page 409: ... Seat Exhaust Valve 34 90 35 10 mm 1 7 mm 45 9 945 8 960 mm 106 20 106 60 mm 105 30 105 70 mm 0 03 mm Intake Valve 37 90 38 10 mm 1 7 mm 45 7 955 7 970 mm 106 20 106 60 mm 105 30 105 70 0 03 mm Valve to be used Use machined valve if needed new repair valve I 105 5 0 2 mm Reuse valve Use standard size valve I 106 4 0 2 mm Size x Size x Size x Camshaft Cam Basic Dia W 38 0 0 2 mm 19 5 20 3 mm 20 4 2...

Page 410: ...1 Clean the valves and do visual check Notice Valves with wobbled valve disc with worn or scored valve stem should be replaced 2 Measure valve disc height h 3 Machine the valve Notice Pay attention to setting angle α 4 Measure radial runout between valve stem and valve seat with a dial gauge 001 589 32 21 00 Limit Service data Intake Exhaust 1 7 0 15 mm 1 7 0 15 mm Max 0 03 mm YAD1BJQ0 ...

Page 411: ... and insert it into valve guide 7 Insert the valves 1 into the valve guides according to marking 8 Measure amount by which the valve arrears a Notice If out of standard replace the valve seat ring 10 Measure distance z cylinder head cover parting surface valve stem Arrears a 0 1 0 7 mm 38 0 2 mm or 37 6 0 2 mm Diameter w 9 Measure camshaft cam basic diameter w ...

Page 412: ...asic bore valve stem x z y Determine the valve to use according to this measurement See matching valves 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 ...

Page 413: ...ceding Work Removal of prechamber Removal and inspection of valve replace if necessary Inspection of valve guide replace if necessary 1 Valve 2 Valve Seat Ring 3 Cylinder Head 4 Valve Guide a Valve Arreare b Valve Seat Width α Valve Seat Angle β Valve Seat Free Angle YAD1BJV0 ...

Page 414: ...21 97 mm Hunger D 8000 München 70 Type Ventilknecht K2000 Order No 221 00 100 Hunger D 8000 München 70 Type VDS 1A Order No 236 03 308 Hunger D 8000 München 70 Order No 217 93 601 Cylinder Head Clamping Devie Valve Seat Turning Tool Test Sat for Valves Size x Size x Size x Exhaust 0 1 0 7 mm 1 5 2 0 mm 45 65 0 03 mm 106 20 106 60 mm 105 30 105 70 mm Item Valve Arrears a Valve Seat Width b Valve Se...

Page 415: ...replacing the valve When replacing the valve guide When replacing the valve seat or valve seatring 1 Machine the valve seat α 45 4 Measure radial runout 2 Measure valve seat width b Valve seat width b 1 2 1 7 mm 1 5 2 0 mm Intake Exhaust Runout Max 0 03 mm 3 If the specification is exceeded the valve seat width has to be corrected at the lower free angle of β 65 ...

Page 416: ...nsert the valve 1 into the valve guide according to marking and measure amount by which the valve arrears a 7 Measure distance z cylinder head cover parting surface valve stem Arrears a 0 1 0 7 mm 38 0 2 mm or 37 6 0 2 mm Diameter w 6 Measure camshaft cam basic circle diameter w ...

Page 417: ... Diameter z Distance CylinderHead Cover Parting Surface Valve Stem 8 Measure x Camshaft basic bore valve stem x z y 9 Determine the valve to be used See Matching valves 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 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 ...

Page 418: ... Head Cover 2 Bolt 10 N m 89 lb in 3 Gasket Replace 4 Valve Tappet 5 Cylinder Head Condition of camshaft Intake valve Open ATDC 11 33 ATDC 12 Close ABDC 17 ABDC 18 Exhaust valve Open BBDC 28 BBDC 27 CAMSHAFT TIMING TEST Preceding Work Removal of glow plug Close BTDC 15 25 BTDC 14 New After approx 20 000km ...

Page 419: ...ial gauge holder 363 589 02 21 00 and dial gauge 001 589 53 21 00 7 with the extension 366 589 00 21 05 8 to the cylinder head and position the tracer pin 9 onto the valve tappet intake valve of cylinder no 1 with a preload of min 3mm Notice The tracer pin should be positioned exactly vertical 4 Set the dial gauge to 0 5 Rotate the engine further in direction of rotation until the dial gauge has m...

Page 420: ... Connection 4 Gasket Replace 5 Coolant Gallery Sealing 6 Pressure Measuring Plate Completely tight to the cylinder head 7 Cylinder Head 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...

Page 421: ...e Arrears b Prechamber Protrusion Service Data YAD1BK40 Height A Cylinder Head Surface Cylinder Head Cover Surface Minimum Height After Machining Permissible Unevenness of Parting Surface Permissible Variation of Parallelism Longitud direction Peak to Valley Height Valve Arrears a Prechamber Protrusion c In Longitudinal Direction In Transverse Direction Intake Valve Exhaust Valve 142 9 143 1 mm 14...

Page 422: ...t the valve 1 and measure valve arrears a 3 Install the prechamber and measure protrusion c Notice If out of standard machine the valve seat 4 Assemble the engine and check the valve timing Notice If the height is less than 142 5 mm replace the cylinder head Limit 142 5 mm Valve Arrears a 0 1 0 7 mm Protrusion c 7 6 8 1 mm ...

Page 423: ...SSANGYONG Y200 1B3 154 DIESEL ENGINE MECHANICAL REPLACEMENT OF CRANKCASE CORE PLUG Core Plug YAD1BK70 Service Data Left Right Front Rear φ 34 mm 3 EA φ 34 mm 3 EA φ 17 mm 1 EA φ 34 mm 1 EA ...

Page 424: ...injection pump 3 Place the screwdriver to the deepdrawn edge of the core plug and pull forward and then rotate 90 5 Thoroughly clean the sealing surface and apply Loctite 241 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 coo...

Page 425: ...irection Service Data YAD1BK90 Min 299 62 mm 0 06 mm 0 06 mm 0 0006 0 0016 mm 0 05 mm 0 965 mm 0 735 mm Height Y Permissible unevenness of contacting surface Permissible roughness upper contacting surface Permissible variation of parallelism of crankcase upper surface to lower surface in longitudinal direction Piston protrusion at TDC to crankcase upper surface In longitudinal direction B In trans...

Page 426: ... Longitudinal Direction b Transverse Direction c d e Measuring Point Service Data 89 000 89 006 mm 89 006 89 012 mm 89 012 89 018 mm Max 0 20 mm 0 01 mm 0 05 mm 50 10 Code letter A Code letter X Code letter B When new Wear limit Standard size Wear limit in direction of travel and in transverse direction Permissible deviation of cylinder shape Honing angle ...

Page 427: ...ction Nozzle Fuel Pipe to Injection Pump Generator Bracket Bolt Generator Mounting Bolt Guide Pulley Bolt Guide Pulley Bracket Bolt Hub Bolt 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 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS N m 45 90 25 25 90 80 35 90 10 3 7 55 90 23 10 3...

Page 428: ...l Spray Nozzle Bolt Power Steering Dump Pulley Bolt Prechamber Threaded Ring Skid Plate Bolt Socket Bolt Stud Bolt TDC Sensor Bracket Bolt Tensioning Lever Nut Tensioning Pulley Bolt Timing Case Cover Bolt Transmission Mounting Bolt Turbo Charger to Exhaust Pipe Bolt Vacuum Pump Mounting Bolt Lb Ft 18 18 18 18 37 24 96 21 35 18 15 21 40 50 22 Lb In 89 89 89 106 89 89 89 Socket Bolt M6 M8 FASTENER ...

Page 429: ...ing Strap 000 589 10 53 00 Reamer for Exhaust YAD1BLC0 000 589 10 68 00 Cylinder Brush 000 589 21 53 00 Reamer for Intake YAD1BLD0 000 589 25 33 00 Internal Extractor YAD1BKS0 000 589 33 33 00 Counter Support YAD1BKR0 000 589 58 43 00 Chain Assembling Device YAD1B1W0 001 589 32 21 00 Dial Gauge YAD1BLG0 YAD1BL60 YAD1BKW0 ...

Page 430: ...ge YAD1BKJ0 102 589 00 15 00 φ φ φ φ φ 34 Drift YAD1B3Y0 102 589 00 23 00 Go No Go Gauge for Intake YAD1BLF0 102 589 03 40 00 Magnetic Bar YAD1BKX0 102 589 05 33 00 Puller YAD1BKU0 102 589 12 15 00 φ φ φ φ φ 17 Drift YAD1B1A0 103 589 00 33 00 Puller YAD1BKM0 103 589 02 15 00 Drift for Exhaust YAD1BL80 ...

Page 431: ...ers YAD1BL40 105 589 03 15 00 Drift for Intake YAD1BL70 115 589 34 63 00 Mounting Device YAD1BKG0 YAD1BLH0 116 589 02 34 00 Thread Bolt 116 589 03 07 00 T Type Socket Wrench 116 589 06 63 00 Magnetic Finger YAD1BL10 YAD1BKF0 116 589 07 15 00 Drift YAD1BKV0 116 589 20 33 00 Sliding Hammer YAD1B580 ...

Page 432: ...for Exhaust YAD1BLE0 346 589 00 63 00 Super Cooling Box YAD1BL90 363 589 02 21 00 Dial Gauge Holder YAD1BKQ0 366 589 00 21 05 Extension YAD1BKP0 601 589 00 25 00 Pressure Testing Device YAD1BKH0 601 589 00 66 00 Counter Sink YAD1BKD0 601 589 01 59 00 Assembling Board YAD1BKY0 601 589 02 43 00 Drift YAD1BL50 ...

Page 433: ...Bridge YAD1BKZ0 601 589 03 14 00 Sleeve 601 589 03 43 00 Oil Seal Assembler YAD1B790 YAD1BKN0 601 589 05 15 00 Drift for Intake YAD1BLA0 601 589 06 15 00 Drift for Exhaust YAD1BLB0 601 589 07 21 00 Measuring Device YAD1BKK0 602 589 00 40 00 Engine Lock YAD1B720 603 589 00 09 00 Serration Wrench YAD1BKB0 ...

Page 434: ...57 589 03 63 00 Sliding Hammer 667 589 00 23 00 Height Gauge YAD1BKE0 YAD1BKC0 667 589 00 31 00 Press Lever YAD1BL00 603 589 00 40 00 Counter Holder YAD1B4K0 603 589 01 40 00 Holding Wheel YAD1BL20 667 589 01 21 00 Fixing Device YAD1BKL0 667 589 02 63 00 Supporting Bar YAD1BL30 ...

Page 435: ...m 1F1 46 Throttle Valve Actuator 1F1 46 Hot Film Air Mass HFM Sensor 1F1 50 Engine Coolant Temperature ECT Sensor 1F1 54 Accelerator Pedal Module 1F1 58 Clutch Switch 1F1 61 Cooling Fan 1F1 62 A C Compressor Relay 1F1 63 Cruise Control Switch 1F1 64 Traction Control System TCS 1F1 65 Resonance Flap 1F1 66 Stop Lamp Switch 1F1 67 EngineRPM 1F1 68 Exhaust System 1F1 69 Catalytic Converter 1F1 69 Oxy...

Page 436: ...4 ECM Wiring Diagram 3 2L DOHC MSE 3 63D 1F1 94 Specifications 1F1 101 Engine Data Display Table 1F1 101 Fastener Tightening Specifications 1F1 102 Fuel System Specification 1F1 103 Temperature vs Resistance 1F1 103 Special Tools and Equipment 1F1 104 Special Tools Table 1F1 104 ...

Page 437: ...le rpm o High rpm o Low rpm o Idling Unstable o Others o Hesitation o Back fire o Muffler explosion after burning o Surging o Knocking o Poor performance o Other o Soon after starting o After accelerator pedal depressed o After accelerator pedal released o During A C operation o Shifting from N to D or D to N o At full steering o Others Problem Frequency Weather Ambient Temperature Place Engine Te...

Page 438: ...jector short circuit to battery No 3 injector short circuit to ground or open No 4 injector short circuit to battery No 4 injector short circuit to ground or open Oxygen sensor high voltage Bank 1 system short term fuel trim adaptation below lean threshold Oxygen sensor no activity detected Oxygen sensor not lean after overrun fuel shut off Oxygen sensor slow response Oxygen sensor heater failure ...

Page 439: ...re Vehicle speed signal failure Vehicle speed signal failure Cruise control lever failure Cruise control acceleration failure Cruise control deceleration failure Stop lamp switch failure ECU failure RAM ECU failure EPROM Call monitoring Servo motor control output interruption memory failure Servo motor open short Unprogramed ECU with immobilizer Uncoded unprogramed ECU ECU failure EEPROM Flash EPR...

Page 440: ...ure sensor plausibility Engine coolant temperature insufficient for closed loop fuel control System voltage too low Mass air flow sensor plausibility Mass air flow sensor low voltage Mass air flow sensor high voltage Crankshaft position sensor signal failure no engine revolution signal Crankshaft position sensor signal failure rpm max value Camshaft position senosr signal No 1 cylinder recognition...

Page 441: ...t to ground or open ECU failure CPU 2 cruise control message counter failure Over decceleration limit CPU 2 Over acceleration limit 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 monitor data comparison fault CPU 2 Unusual accelerator peda...

Page 442: ...the cylinder that is opposite it 1 6 or 2 5 or 3 4 The spark occurs simultaneously in the cylinder coming upon the compression stroke and in the cylinder coming up on the exhaust stroke 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 IGNITION SYSTEM Th...

Page 443: ...ols the spark advance 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 1 Control Cable Connection 2 Ignition Cable 3 Spark Plug Connector 4 Coupling Plug 5a 5b Secondary Voltage Connection E Iron Core L1 Seconda...

Page 444: ...ap burned electrodes heavy deposit Inspection the ECM 64 65 66 Circuit Description The Electronic Ignition EI system uses a waste spark method of spark distribution The Crankshaft Position CKP sensor sends reference pulses to the ECM The ECM then triggers the EI system ignition coils Once the ECM triggers the EI system ignition coils both of the connected spark plugs fire at the same time One cyli...

Page 445: ...site side of the crankshaft pulley and triggers the pick up wheel teeth which is equipped 60 2 teeth with a gap of 2 teeth at 360 degree spacing This sensor protrudes throughits mount to within 1 1 0 14 mm 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 igniti...

Page 446: ...uble Area Maintenance Hint Crankshaft position sensor signal failure no engine revolution signal Crankshaft position sensor signal failure rpm max value Crankshaft position sensor signal failure gap recognition failure Crankshaft position sensor adaptation failure Even through cam position recognition is normal no crankshaft position signal recognition When more than applicable revolution values o...

Page 447: ...e segment or crankshaft position sensor and air gap if cannot get the output wave as shown in the figure YAD1F130 Crankshaft Position Sensor Insulator Resistance Inspection 1 Disconnect the coupling from ECM while the ignition switch is in OFF position 2 Measure the resistance between the coupling terminal pin No 100 and No 69 using a multimeter Notice Measure the check and ground terminal of the ...

Page 448: ...ule ECM The ECM uses this signal as a 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 1 Camshaft Position Sensor Connector 2 Bolt 3 Camshaft Position Sensor 4 O ring ...

Page 449: ...e speed is at idle Failure Code Description Trouble Area Maintenance Hint Camshaft position sensor signal No 1 cylinder recognition failure Camshaft position sensor signal No 1 cylinder synchronization failure When no cam recognition signal during TN 24 counts more maintain the constant low or high level When synchronization fault of cylinder 1 TDC recognition Inspection the source voltage of CMP ...

Page 450: ...ed is at idle Notice Replace the CAM sensor if cannot get the out put wave as shown in the figure YAD1F160 Camshaft Position Sensor Power Supply Inspection 1 Disconnect the CMP sensor Connector 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 va...

Page 451: ...ressure at the camshaft actuator and on the oil viscosity and oil temperature respectively The camshaft indicator on the camshaft sprocket provides the camshaft rotational speed to the position sensor as an input parameter for the engine ignition control unit Operation Condition of Camshaft Actuator Engine RPM Engine stop 0 1 500 rpm 1 500 4 300 rpm Above 4 300 rpm Camshaft Position Retard Retard ...

Page 452: ...tion Trouble Area Maintenance Hint Camshaft actuator short circuit to battery Camshaft actuator short circuit to ground or open When malfunction of cam phasing control Monitoring the actual operational status through scan tool Inspection the ECM pin 73 about short circuit or open Inspection the power source short circuit or open to cam actuator Inspection the magnet and hardware Inspection the ECM...

Page 453: ...ocking in the engine The two KS are mounted in the engine block near the cylinders 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 ...

Page 454: ...uble Area Maintenance Hint No 1 knock sensor signal failure No 2 knock sensor signal failure When recognition in more than control gain threshold at normal operational condition of other system during over 75 and 3 000 rpm running area cylinder 1 2 3 When recognition in more than control gain threshold at normal operational condition of other system during over 75 and 3 000 rpm running area cylind...

Page 455: ...Y200 1F1 24 M162 ENGINE CONTROLS SPARK PLUG YAD1F200 1 Ignition Coil Cable Cover 2 Bolt 3 Spark Plug T 1 1 Ignition Coil Cylinder 2 and 5 T 1 2 Ignition Coil Cylinder 3 and 4 T 1 3 Ignition Coil Cylinder 1 and 6 ...

Page 456: ... and catalyst damage threshold Failure Code Description Trouble Area Maintenance Hint Random Multiple Misfire When detection misfire of multiple cylinder for source of over the emission threshold or catalyst damage Inspection the ignition system Inspection the injection system Inspection the fuel pressure Inspection the compression pressure Inspection the valve timing or clearance Inspection the a...

Page 457: ... Turn the ignition switch OFF position 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 ...

Page 458: ...em source voltage Less than minimum 8 volts in 2 000 rpm below or less than 10 volts in 2 000 rpm above Monitoring the actual battery voltages through the scan tool Inspection the Engine Control Module ECM pin 12 11 10 5 about short circuit or open with bad contact Inspection the over voltage protection relay Inspection the battery Inspection ECM 08 SYSTEM VOLTAGE ...

Page 459: ...230 Failure Code Description Trouble Area Maintenance Hint Starter signal recognition failure When not detection of starter signal Inspection the Engine Control Module ECM pin 2 circuit short or open with bad contact Inspection ECM 71 IGNITION SWITCH ...

Page 460: ...he ignition is turned ON the ECM turns the fuel pump relay on for 1 second The fuel pump then builds fuel pressure The ECM also checks the Engine Coolant Temperature ECT sensor and the Throttle Position TP sensor and determines the proper air fuel ratio for starting the engine This ranges from1 5 to 1 at 36 C 33 F coolant temperature to 14 7 to 1 at 94 C 201 F coolant temperature The ECM controls ...

Page 461: ...bar 12 V 12 V 114 Liter Hr 12 V 3 8 bar 30 70 C Item Minimum Delivery at 8V Operating Voltage Maximum Allowable Current Ambient Temperature Maximum Amount of Fuel Supply Specified Value 30 Litre Hr 8 V 7 5 A 30 70 C 165 Liter Hr 12V 3 8 bar 30 70 C 1 Flange and Harness Assembly 2 Spring 3 Fuel Pump 4 Float 5 Thermistor 6 Float Arm 7 Thermistor Housing 8 Resistor Card and Wiper Requirements for Fue...

Page 462: ...ction the fuel pump relay Inspection the ECM 34 35 Circuit Description When the ignition switch is turned ON the ECMwill activate the pump relay and run the in tank fuel pump The fuel pump will operate as long as the engine is cranking or running and the ECMis receiving ignition reference pulses If there are no reference pulses the ECM will shut off the fuel pump within 2 seconds after the ignitio...

Page 463: ...e wire 5 Measure the fuel delivery from the fuel pump Specified Value 1 Liter max 35 sec Specified Value 5 9 A Notice Check the fuel filter and fuel line when the fuel delivery is not within specified value Measure the Current Consumption of Fuel Pump 1 Remove the fuel pump relay from fuse and relay box in trunk and turn the ignition switch to ON position 2 Using a multimeter measure the current c...

Page 464: ...ation necessary for both ensuring the maximum homogeneity in the air fuel mixture and holding the condensation along the walls of the intake tract to a minimum Fuel enters the top feed injector from above and flows through its vertical axis The lower end extends into the intake valve Fuel from the tip is directed at the intake valve causing it to become further atomized and vaporized before enteri...

Page 465: ...Injector 2 short circuit to power When malfunction of injector circuit Injector 2 short circuit to ground or open When malfunction of injector circuit Injector 3 short circuit to power Inspection the power to injector 1 or bad contact Inspection the injector Inspection the ECM Inspection the ECM pin 63 about short circuit or open with bad contact Inspection the injector Inspection the ECM Inspecti...

Page 466: ...r 5 short circuit to ground or open When malfunction of injector circuit Injector 6 short circuit to power When malfunction of injector circuit Injector 6 short circuit to ground or open Inspection the ECM pin 66 about short circuit or open with bad contact Inspection the injector Inspection the ECM Inspection the power to injector 4 or bad contact Inspection the injector Inspection the ECM Inspec...

Page 467: ...r for normal spray pattern as shown in the figure Check injector for leaks or later drop Injector Resistance Inspection 1 Turn the ignition switch OFF 2 Remove the fuel injector connectors 3 Measure the fuel injector coil resistance using a multimeter YAD1F280 YAD1F290 Notice Replace the fuel injector if the measured value is out of the specified values Check the connector and wire connection betw...

Page 468: ...this reason the Engine Control Module ECM transacts the engine speed air inflow quantity coolant temperature and intake temperature The purge control valve is activated by the ECM frequency according with the engine rotating speed to adjust the purification rate The purification rate is determined by the continuous valve opening interval The purge control valve is activated by the ECM for the foll...

Page 469: ...d vale Inspection the ECM 40 41 54 YAD1F0J0 Specified Value 0 3 0 5 A 4 Remove the line to canister and measure the pressure with the vacuum pressure gauge Test 1 Maintain the normal temperature and idling state by operating the engine 2 Connect the ECM terminal No 11 and No 34 and check for normal operation through the output waves using oscilloscope Notice Test during purge control valve operati...

Page 470: ...SSANGYONG Y200 1F1 42 M162 ENGINE CONTROLS FUEL RAIL YAD1F320 1 Injector Connector 2 Injector 3 Fuel Rail 4 Fuel Supply Line 5 Fuel Return Line 6 Bolt 7 Vacuum Hose 8 O Ring ...

Page 471: ... pressure gauge 103 589 00 21 00 to the fuel pressure test connector 2 Stop the engine for approximately 30 minutes and then check the fuel pressure changes 5 Replace the pressure regulator diaphragm if out of the specification YAD1F340 Vacuum Hose Connected bar Vacuum Hose Disconnected bar 3 2 3 6 3 7 4 2 Fuel pressure bar 2 5 3 If there is no change in fuel pressure and maintain the following pr...

Page 472: ...ne Operating at full load There is no negative pressure applied to the spring chamber 9 during the full load and it is separated from the fuel chamber 8 by the diaphragm 5 When the fuel pressure goes up the diaphragm forces the compression spring 6 in the direction of compression At this moment the valve 3 sticks to the diaphragm by the fuel pressure and the fuel return line 2 opens The fuel over ...

Page 473: ...3 2 bars during idling Operating at Idle and partial load The spring chamber 9 is connected to the intake manifold with the vacuum hose at the intake pipe connection 7 The negative pressure generated in the intake manifold activates the diaphragm and thus the fuel pressure gets reduced to the rate of the operating extent of the diaphragm by the intake manifold s negative pressure YAD1F380 YAD1F390...

Page 474: ...pending on coolant temperature and engine load When this is done the throttle valve can be closed further by the servo motor overcoming the force of the spring capsule mechanical end stop If the actuator is deenergized the throttle valve is resting against the spring capsule Consequently the throttle valve opening is a constant 10 12 approximately At no load this produces an engine speed of about ...

Page 475: ... position sensor failure TPS 1 short circuit to ground or open TPS 1 short circuit to power TPS 2 short circuit to ground or open TPS 2 short circuit to power When actuator adaption fluctuation or not meet the condition scan tool When return spring defective of actuator with bad contact When supply voltage of the actuator short circuit to power Inspection the ECM When shut down of output driver Wh...

Page 476: ...ions are for instance idle control speed control drive slip control load shock damping and similar functions When the actuator current fails the throttle valve is returned to emergency operating position by a spring The throttle valve position thereby the actuator drive position check back is provided by two potentiometers The motor positions the throttle valve against the return spring force Moto...

Page 477: ...ream and downstream of the heating area show the same temperature without incoming flow With incoming flow upstream part is cooled down but downstream temperature retains its temperature more or less due to the air heated up in the heating area This temperature difference in quantity and direction depends on the direction of the incoming flow ECM modulates the flow of heating current to maintain t...

Page 478: ...e Air Temperature IAT sensor is a part of Hot Film Air Mass HFM sensor and is a thermistor a resistor which changes value based on the temperature of the air entering the engine Low temperature produces a high resistance while high temperature causes a low resistance as the following table The ECM provides 5 volts to the IAT sensor through a resistor in the ECM and measures the change in voltage t...

Page 479: ...eater It is located on a ceramic plate together with the other elements in the bridge circuit The temperature sensitive resistor flow sensor also included in the bridge The separation of heater and flow sensor facilitates design of the control circuitry Saw cuts are employed to ensure thermal decoupling between the heating element and the intake air temperature IAT sensor The complete control circ...

Page 480: ... position 4 Measure the voltage between the ECM pin No 108 and MAF sensor connecter terminal No 3 Notice If the measured value is not within the specified value the possible cause may be in cableor ECM coupling 5 Measure the voltage between the ECM pin No 105 and MAF sensor connecter terminal No 4 Notice If the measured value is not within the specified value the possible cause may be in cableor E...

Page 481: ...tance which the ECM detects as a high signal voltage As the engine warms up the sensor resistance becomes lower and the signal voltage drops At normal engine operating temperature the ECT signal will measure about 1 5 to 2 0 volts The ECM uses information about coolant temperature to make the necessary calculations for Fuel delivery Ignition control Knock sensor system Idle speed Torque converter ...

Page 482: ...0 30 40 50 60 70 80 90 100 110 120 130 140 Resistance Ω Ω Ω Ω Ω 48 550 27 000 15 570 9 450 5 890 3 790 2 500 1 692 1 170 826 594 434 322 243 185 143 111 6 88 71 2 Voltage V 4 90 4 82 4 70 4 52 4 43 3 96 3 57 3 14 2 70 2 26 1 86 1 51 1 22 0 98 0 78 0 63 0 50 0 40 0 33 YAD1F460 ...

Page 483: ...hen minimum temperature for lambda control after warm up Monitoring the actual coolant temperature through scan tool Inspection the ECM pin 78 79 about short circuit or open with bad contact Inspection the ECT sensor Inspection the ECM 00 01 02 06 Circuit Description The ECT sensor uses a thermistor to control the signal voltage to the ECM The ECM supplies a voltage on the signal circuit to the se...

Page 484: ...connect the ECT sensor connector 5 Turn the ignition switch to ON position 6 Measure the resistance between the ECT sensor terminal pin No 1 and No 4 Notice Replace wiring and coolant temperature sensor if out of specified value Temperature C 20 80 100 Specified Value Ω Ω Ω Ω Ω 2 500 322 185 ...

Page 485: ... pedal reaction is not response correctly and also the engine rpm will be reacted to 4 000 rpm slowly If the APP 1 sensor is out of order the APP 2 sensor will be conducted with signal as a default signal but the throttle valve opening is limited 60 and delayed opening speed When the TP sensor or servo motor is defected When the TP 1 2 sensor or servo motor is defected condition the throttle valve...

Page 486: ...t accelerator pedal position sensor defective YAD1F490 Failure Code Description Trouble Area Maintenance Hint When malfunction of APP sensor APP 1 sensor short circuit to ground or open APP 1 sensor short circuit to power APP 2 sensor short circuit to ground or open APP 2 sensor short circuit to power bad contact When difference between APP 1 sensor and APP 2 sensor When defective of both APP sens...

Page 487: ...le operating the accelerator pedal as following conditions Not depress the pedal closed throttle position Fully depress the pedal full throttle with kick down Acceleration Pedal Position Sensor 2 Inspection 1 Turn the ignition switch to ON position 2 Measure the signal voltage between the ECM pin No 48 and No 50 while operating the accelerator pedal as following conditions Not depress the pedal cl...

Page 488: ...itch defective YAD1F500 Failure Code Description Trouble Area Maintenance Hint When malfunction of clutch switch Inspection the Engine Control Module ECM pin 43 about shout circuit or open Inspection the clutch switch Inspection the ECM 62 CLUTCH SWITCH ...

Page 489: ...ith bad contact Inspection the power source Inspection the cooling fan Inspection the ECM 44 COOLING FAN 45 Circuit Description Ignition voltage is supplied directly to the cooling fan relay coil The ECM controls the relay by grounding the control circuit When the ECM is commanding a command ON the voltage of the control circuit should be low near 0 volt When the ECM is commanding the control circ...

Page 490: ...ing the actual operation through scan tool Inspection the Engine Control Module ECM pin 44 about short circuit or open with bad contact Inspection the relay short circuit or open Inspection the ECM 228 A C COMPRESSOR RELAY 229 Circuit Description 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 ...

Page 491: ... Cruise control system Implausible condition of acceleration signal Cruise control system Implausible condition of deceleration signal Monitoring the actual recognition status and vehicle speed signal through scan tool Inspection the Engine Control Module ECM pin 52 53 54 55 57 about short circuit or open with bad contact Inspection the CAN and ABS Inspection the cruise control lever switch Inspec...

Page 492: ... Engine Control Module ECM pin 45 about short circuit or open with bad contact Inspection the TCS lamp of I P cluster Inspection the ECM 150 TRACTION CONTROL SYSTEM TCS 151 Circuit Description 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 termina...

Page 493: ...e ECM 198 RESONANCE FLAP 199 Circuit Description A pneumatically actuated resonance flap is located on the intake manifold and will be opened and closed by load which operates resonance flap according to engine and controlled by ECM and rpm Resonance flap is closed at idle partial load less than 3 800 rpm The switch valve will be adjusted by ECM and resonance flap will be closed By increasing air ...

Page 494: ...le speed signal through scan tool Inspection the Engine Control Module ECM pin 49 about short circuit or open with bad contact Inspection the contact condition of stop lamp switch Inspection the ECM 135 STOP LAMP SWITCH Circuit Description 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 b...

Page 495: ... ground or open YAD1F560 Failure Code Description Trouble Area Maintenance Hint When short circuit to battery When short circuit to ground or open Inspection the cluster panel board circuit Inspection the ECM Monitoring the actual rpm in cluster Inspection the Engine Control Module ECM pin 60 about short circuit or open 32 ENGINE RPM 33 ...

Page 496: ...alytic converter contains a catalyst a word coming from the Greek and which designates the element essential for catalyst which triggers chemical reactions without itself being consumed These catalysts in the 3 way catalytic converter are the rare metals platinum Pt and rhodium Rh The catalytic converter consists essentially of three main elements The exhaust gases flow through the catalytic conve...

Page 497: ...he ECM compares this reference voltage with the voltage generated by oxygen sensor The amount of voltage the oxygen sensor generates is proportionate to the difference between the amount of oxygen in the outside air and the exhaust gases 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 con...

Page 498: ...M162 ENGINE CONTROLS 1F1 71 SSANGYONG Y200 YAD1F590 ...

Page 499: ...ition the output that not active the sensor etc When recognition the output that no lean signal after overrun fuel shut off When slow response of sensor signal When recognition the heating circuit When recognition the heating currents that more or less than set values less than 0 2 A or more than 2 A When recognition the heating voltages than less than set values less than 2v Monitoring the actual...

Page 500: ...cognition the long term fuel trim exceeds rich threshold When recognition the long term fuel trim exceeds lean threshold When recognition the long term fuel trim exceeds rich threshold When recognition the long term fuel trim exceeds lean threshold When recognition the long term fuel trim exceeds rich threshold When recognition the long term fuel trim exceeds lean threshold Inspection the intake a...

Page 501: ...intain the engine speed is at idle while the coolant temperature is over 80 C 2 Measure the oxygen sensor signal voltage between the ECM terminal No 11 and No 9 Specified Value 11 14 V Notice If the measured value is not within the specified value the possible cause may be in cable oxygen sensor or ECM Oxygen Sensor Heating Current Consumption Inspection 1 Turn the ignition switch to ON position 2...

Page 502: ...red in the ECM in the Programmable Read Only Memory PROM The ECM supplies either 5 or 12 volts to power the sensors or switches This is done through resistance in the ECM which are so high in value that a test light will not come ON when connected to the circuit In some cases even an ordinary shop voltmeter will not give and accurate reading because its resistance is too low You must use a digital...

Page 503: ...itialized condition When CAN signal message missing or implausibility for TCU unit or not initialized condition Inspection the ASR unit with CAN connection Inspection the Engine Control Module ECM pin 38 37 about short circuit or open with bad contact Inspection the ECM Inspection the ABS unit with CAN connection Inspection the ECM pin 38 37 about short circuit or open with bad contact Inspection ...

Page 504: ...tact Inspection the ECM Inspection the ABS ABD unit with CAN connection Inspection the ECM pin 38 37 about short circuit or open with bad contact Inspection the ECM Inspection the each control unit with CAN connection Inspection the ECM pin 38 37 about short circuit or open with bad contact Inspection the ECM Inspection the MSR unit with CAN connection Inspection the Engine Control Module ECM pin ...

Page 505: ...hecksum failure Failure Code Description Trouble Area Maintenance Hint When faulty of variant coding of transmission When malfunction of random access memory ECM internal error When malfunction of ECM coding required ECM encoding When malfunction of ECM internal Inspection the coding condition through scan tool Inspection the Engine Control Module ECM Inspection the CAN line Inspection the TCM Ins...

Page 506: ...re CPU 2 fault ECM failure CPU run time failure between CPUs ECM failure CPU 2 cruise control message counter failure Over deceleration limit CPU 2 Over acceleration limit 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 comp...

Page 507: ...sition sensor set point fault between CPU 1 and CPU 2 ECM Position controller set point fault between 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 Failure Code Description Trouble Area Maintenance Hint System internal failure Inspection the Engine...

Page 508: ...nit Inspection the transponder condition broken etc Inspection the ECM Fulfill the immobilizer pairing 25 IMMOBILIZER 141 Circuit Description Immobilizer is a device disabling vehicle ignition unless a specific key is used and designed to help prevent vehicle theft Immobilizer is comprised of two devices a key with encoded transponder and ECM with the same encoding of the transponder When a key is...

Page 509: ...e it is necessary to relieve the fuel system pressure before disconnecting the fuel lines 1 Relieve the fuel system pressure Refer to Discharging the Pressure in Fuel System in this section 2 Disconnect the negative battery cable 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 suppl...

Page 510: ...avoid fuel spillage and the risk of personal injury or fire it is necessary to relieve the fuel system pressure before disconnecting the fuel lines 2 Relieve the fuel system pressure Refer to Discharging the Pressure in Fuel System in this section 3 Disconnect the fuel lines from the fuel filter Installation Notice Tightening Torque 28 N m 21 lb ft 4 Remove the fuel filter mounting bracket bolt In...

Page 511: ...section 2 Disconnect the negative battery cable 3 Drain the fuel tank 4 Put aside the floor carpet to remove the fuel pump access cover 5 Remove the fuel pump access cover YAA1F170 YAA1F160 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 6 Disconnect the return line 7 Disconnect the supply l...

Page 512: ...ce 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 Caution The fuel system is under pressure To avoid fuel spillage and the risk of personal injury or fire it is necessary to relieve the fuel system pressure before disconnecting the fuel lines 3 Relieve the fuel pressure in fuel ...

Page 513: ...e fuel pressure test connector 2 Disconnect the negative battery cable 3 Disconnect the vacuum hose from the fuel pressure regulator 4 Remove the cable guide 5 Disconnect the Hot Film Air Mass HFM sensor connector 6 Remove the intake air duct mounting bolts Installation Notice Tightening Torque 9 N m 80 lb ft 7 Remove the intake air duct clamps 8 Remove the intake air duct 9 Remove the fuel return...

Page 514: ...he fuel rail assembly to prevent damage to the electrical connectors and injector spray tips Prevent dirt and other contaminants from entering open lines and passages Fittings should be capped and holes plugged during service Important If an injector becomes separated from the rail and remains in the cylinder head replace the injector O ring seals and the retaining clip 12 Remove the injectors and...

Page 515: ... sensor connector 3 Disconnect the mass air flow sensor from the air filter housing 4 Remove the intake air duct mounting bolts Installation Notice Tightening Torque 9 N m 80 lb ft 5 Remove the air inlet housing clamps 6 Remove the inlet air housing 10 Remove the throttle body and discard the gasket Important Use care in cleaning old gasket material Sharp tools may damage sealing surfaces 11 Insta...

Page 516: ...ure 1 Disconnect the negative battery cable 2 Disconnect the Hot Film Air Mass HFM sensor electrical connector 3 Remove the HFM sensor retaining screws 4 Turn the HFM sensor coupling in the direction shown in the figure in the left so that it gets separated from the contact surface Notice Make sure the HFM sensor coupling connects completely with the contact surface installation 5 Remove the HFM s...

Page 517: ...erse order PEDAL POSITION SENSOR Removal and installation Procedure 1 Disconnect the negative battery cable 2 Disconnect the pedal position sensor connector 3 Unscrew the bolts and nut Installation Notice Tightening Torque 6 N m 53 lb ft 4 Remove the pedal and sensor assembly 5 Installation should follow the removal procedure in the reverse order OXYGEN SENSOR Removal and Installation Procedure 1 ...

Page 518: ...nstallation Procedure Caution Canister and vacuum hoses contain fuel vapors Do not smoke in the area or permit an open flame 1 Disconnect the fuel tank to canister hose form the canister 2 Disconnect the canister to purge control valve hose form the canister Tightening Torque 6 N m 53 lb ft 4 Remove the canister 5 Installation should follow the removal procedure in the reverse order 3 Remove the c...

Page 519: ...taining bolt Installation Notice Tightening Torque 25 N m 18 lb ft 4 Installation should follow the removal procedure in the reverse order ENGINE CONTROL MODULE Removal and installation Procedure 1 Disconnect the negative battery cable 2 Remove the cowl side trim form passenger side Refer to Section 9G Interior trim 3 Remove the four securing nuts for the Engine Control Module ECM from the mountin...

Page 520: ...SSANGYONG Y200 1F1 94 M162 ENGINE CONTROLS ECM WIRING DIAGRAM 3 2L DOHC 1 OF 7 MSE 3 63D SCHEMATIC AND ROUTING DIAGRAMS YAD1F010 ...

Page 521: ...M162 ENGINE CONTROLS 1F1 95 SSANGYONG Y200 ECM WIRING DIAGRAM 3 2L DOHC 2 OF 7 MSE 3 63D YAD1F020 ...

Page 522: ...SSANGYONG Y200 1F1 96 M162 ENGINE CONTROLS ECM WIRING DIAGRAM 3 2L DOHC 3 OF 7 MSE 3 63D YAD1F030 ...

Page 523: ...M162 ENGINE CONTROLS 1F1 97 SSANGYONG Y200 ECM WIRING DIAGRAM 3 2L DOHC 4 OF 7 MSE 3 63D YAD1F040 ...

Page 524: ...SSANGYONG Y200 1F1 98 M162 ENGINE CONTROLS ECM WIRING DIAGRAM 3 2L DOHC 5 OF 7 MSE 3 63D YAD1F050 ...

Page 525: ...M162 ENGINE CONTROLS 1F1 99 SSANGYONG Y200 ECM WIRING DIAGRAM 3 2L DOHC 6 OF 7 MSE 3 63D YAD1F060 ...

Page 526: ...SSANGYONG Y200 1F1 100 M162 ENGINE CONTROLS ECM WIRING DIAGRAM 3 2L DOHC 7 OF 7 MSE 3 63D YAD1F070 ...

Page 527: ...Control Protect Mission Purge Control Valve Lambda Function Catalyst Heating Overrun Fuel Cut Ful l Fuel Cut Brake Switch Cruise Control Status Unit C C rpm rpm Kg h TA CA Nm ms V Km h Km h V V V V mv 1 ON 0 OFF 1 ON 0 OFF 1 ON 0 OFF 1 ON 0 OFF 1 ON 0 OFF 1 ON 0 OFF 1 ON 0 OFF 1 ON 0 OFF 1 ON 0 OFF 1 ON 0 OFF 1 ON 0 OFF 1 ON 0 OFF 1 ON 0 OFF 1 ON 0 OFF 1 ON 0 OFF Value greater than 95 C after warm...

Page 528: ...l Module ECM Mounting Bracket Nuts 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 Intake Air Duct Mounting Bolts Knock Sensor Mounting Bolt Oxygen Sensor Pedal Position Censor Mounting Bolts And Nut Throttle Body Bolts N m 10 6 30 10 10 6 28 25 25 23 38 9 25 55 6 12 Lb Ft 22 21 18 18 17...

Page 529: ...damage the fuel sys tem Vehicle Fueling from Drums or Storage Containers For safety reasons particularly when using noncom mercial fueling systems fuel containers pumps and hoses must be properly earthed Static electricity build up can occur under certain atmo spheric and fuel flow conditions if unearthed hoses par ticularly plastic are fitted to the fuel dispensing pump It is therefore recommende...

Page 530: ...SSANGYONG Y200 1F1 104 M162 ENGINE CONTROLS SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE 661 589 00 46 00 Fuel Tank Cap Wrench 103 589 00 21 00 Fuel Pressure Gauge YAA1F890 KAA1F490 ...

Page 531: ... Actuator 1F2 46 Hot Film Air Mass HFM Sensor 1F2 50 Engine Coolant Temperature ECT Sensor 1F2 54 Accelerator Pedal Module 1F2 58 Cooling Fan 1F2 62 A C Compressor Relay 1F2 63 Cruise Control Switch 1F2 64 Traction Control System TCS 1F2 65 Stop Lamp Switch 1F2 66 EngineRPM 1F2 67 Exhaust System 1F2 69 Catalytic Converter 1F2 69 Oxygen Sensor 1F2 70 Engine Control Module 1F2 76 Serial Data Communi...

Page 532: ...TROLS Specifications 1F2 103 Engine Data Display Table 1F2 103 Fastener Tightening Specifications 1F2 104 Fuel System Specification 1F2 105 Temperature vs Resistance 1F2 105 Special Tools and Equipment 1F2 106 Special Tools Table 1F2 106 ...

Page 533: ...le rpm o High rpm o Low rpm o Idling Unstable o Others o Hesitation o Back fire o Muffler explosion after burning o Surging o Knocking o Poor performance o Other o Soon after starting o After accelerator pedal depressed o After accelerator pedal released o During A C operation o Shifting from N to D or D to N o At full steering o Others Problem Frequency Weather Ambient Temperature Place Engine Te...

Page 534: ...e Intake air temperature sensor plausibility Engine coolant temperature insufficient for closed loop fuel control System voltage too low Mass air flow sensor plausibility Mass air flow sensor low voltage Mass air flow sensor high voltage Crankshaft position sensor signal failure no engine revolution signal Crankshaft position sensor signal failure rpm max value Camshaft position sensor signal No 1...

Page 535: ...No 4 injector short circuit to ground or open Oxygen sensor high voltage Bank 1 system short term fuel trim adaptation below lean threshold Oxygen sensor no activity detected Oxygen sensor not lean after overrun fuel shut off Oxygen sensor slow response Oxygen sensor heater failure Oxygen sensor heater short circuit to battery Oxygen sensor heater short circuit to ground or open Oxygen sensor low ...

Page 536: ...l deceleration failure Stop lamp switch failure ECU failure RAM ECU failure EPROM Call monitoring Servo motor control output interruption memory failure Servo motor open short Unprogramed ECU with immobilizer Uncoded unprogramed ECU ECU failure EEPROM Flash EPROM checksum failure ECU failure coding ID checksum failure ECU failure coding checksum failure ECU failure programing checksum failure TCS ...

Page 537: ...ontrol lever safety terminal failure CPU 2 Unusual pedal position variation CPU 2 Unusual throttle position variation CPU 2 Unusual throttle controller monitor data comparison fault CPU 2 Unusual accelerator pedal position sensor comparison fault CPU 2 Throttle potentiometer comparision fault CPU 2 Unusual CPU communication CPU 2 Unusual CPU configuration CPU 2 A D converter failure CPU 2 Accelera...

Page 538: ...h the cylinder that is opposite it 2 3 or 1 4 The spark occurs simultaneously in the cylinder coming up on the compression stroke and in the cylinder coming up on the exhaust stroke The cylinder on the exhaust stroke requires very little of IGNITION SYSTEM the available energy to fire the spark plug The remaining energy is available to the spark plug in the cylinder on the compression stroke These...

Page 539: ...which controls the spark advance 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 1 Control Cable Connection 2 Ignition Cable 3 Spark Plug Connector 4 Coupling Plug 5a 5b Secondary Voltage Connection E Iron Core L1 Secondary Ignition...

Page 540: ...ion the ECM 64 65 Circuit Description The Electronic Ignition EI system uses a waste spark method of spark distribution The Crankshaft Position CKP sensor sends reference pulses to the ECM The ECM then triggers the EI system ignition coils Once the ECM triggers the EI system ignition coils both of the connected spark plugs fire at the same time One cylinder is on its compression stroke at the same...

Page 541: ...teeth which is equipped 60 2 teeth with agap of 2 teeth at 360 degree spacing This sensor protrudes through its mount to within 1 1 0 14 mm 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...

Page 542: ...lator resistance of the CKP sensor if out of the specified value Failure Code Description Trouble Area Maintenance Hint Crankshaft position sensor signal failure no engine revolution signal Crankshaft position sensor signal failure rpm max value Crankshaft position sensor signal failure gap recognition failure Crankshaft position sensor adaptation failure Even through cam position recognition is n...

Page 543: ...position sensor and air gap if cannot get the output wave as shown in the figure YAD1F130 Crankshaft Position Sensor Insulator Resistance Inspection 1 Disconnect the coupling from ECM while the ignition switch is in OFF position 2 Measure the resistance between the coupling terminal pin No 100 and No 69 using a multimeter Notice Measure the check and ground terminal of the CKP sensor if out of the...

Page 544: ...ule ECM The ECM uses this signal as a 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 1 Camshaft Position Sensor Connector 2 Bolt 3 Camshaft Position Sensor 4 O Ring ...

Page 545: ...is at idle Notice The signal voltage will be changed in the range of 1 2 1 7 v YAD1F150 Failure Code Description Trouble Area Maintenance Hint Camshaft position sensor signal No 1 cylinder recognition failure Camshaft position sensor signal No 1 cylinder synchronization failure When no cam recognition signal during TN 24 counts more maintain the constant low or high level When synchronization faul...

Page 546: ... is at idle Notice Replace the CAM sensor if cannot get the output wave as shown in the figure YAD1F160 Camshaft Position Sensor Power Supply Inspection 1 Disconnect the CMP sensor Connector 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 v...

Page 547: ...ressure at the camshaft actuator and on the oil viscosity and oil temperature respectively The camshaft indicator on the camshaft sprocket provides the camshaft rotational speed to the position sensor as an input parameter for the engine ignition control unit Operation Condition of Camshaft Actuator Engine RPM Engine stop 0 1 740 rpm 1 740 3 540 rpm Above 3 540 rpm Camshaft Position Retard Retard ...

Page 548: ...tion Trouble Area Maintenance Hint Camshaft actuator short circuit to battery Camshaft actuator short circuit to ground or open When malfunction of cam phasing control Monitoring the actual operational status through scan tool Inspection the ECM pin 73 about short circuit or open Inspection the power source short circuit or open to cam actuator Inspection the magnet and hardware Inspection the ECM...

Page 549: ...ocking in the engine The two KS are mounted in the engine block near the cylinders 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 ...

Page 550: ...s in OFF position 2 Measure the resistance between the coupling terminal pin No 118 and No 117 using a multimeter Failure Code Description Trouble Area Maintenance Hint No 1 knock sensor signal failure When recognition in more than control gain threshold at normal operational condition of other system during over 75 and 3 000 rpm running area cylinder 1 2 3 4 Inspection the ECM pin 118 117 about s...

Page 551: ...24 M161 ENGINE CONTROLS SPARK PLUG YAA1F990 1 Screw 2 Adaptor 3 Ignition Coil Cable Cover 4 Spark Plug Connector 5 Ignition Coil Connector 6 Bolts 7 Ignition Coil T 1 1 8 Coupling Plug 9 Spark Plug 10 Ignition Coil T 1 2 ...

Page 552: ... and catalyst damage threshold Failure Code Description Trouble Area Maintenance Hint Random Multiple Misfire When detection misfire of multiple cylinder for source of over the emission threshold or catalyst damage Inspection the ignition system Inspection the injection system Inspection the fuel pressure Inspection the compression pressure Inspection the valve timing or clearance Inspection the a...

Page 553: ... Turn the ignition switch OFF position 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 ...

Page 554: ...em source voltage Less than minimum 8 volts in 2 000 rpm below or less than 10 volts in 2 000 rpm above Monitoring the actual battery voltages through the scan tool Inspection the Engine Control Module ECM pin 12 11 10 5 about short circuit or open with bad contact Inspection the over voltage protection relay Inspection the battery Inspection ECM 08 SYSTEM VOLTAGE ...

Page 555: ...30 Failure Code Description Trouble Area Maintenance Hint Starter signal recogni tion failure When not detection of starter signal Inspection the Engine Control Module ECM pin 2 circuit short or open with bad contact Inspection ECM 71 IGNITION SWITCH ...

Page 556: ...he ignition is turned ON the ECM turns the fuel pump relay on for 1 second The fuel pump then builds fuel pressure The ECM also checks the Engine Coolant Temperature ECT sensor and the Throttle Position TP sensor and determines the proper air fuel ratio for starting the engine This ranges from1 5 to 1 at 36 C 33 F coolant temperature to 14 7 to 1 at 94 C 201 F coolant temperature The ECM controls ...

Page 557: ... 3 8 bar 8 5 bar 12 V 5 0 bar 12 V 12 V 114 Liter Hr 12 V 3 8 bar 30 70 C Specified Value 30 Litre Hr 8 V 7 5 A 30 70 C 165 Liter Hr 12 V 3 8 bar 30 70 C Item Minimum Delivery at 8V Operating Voltage Maximum Allowable Current Ambient Temperature Maximum Amount of Fuel Supply 1 Flange and Harness Assembly 2 Spring 3 Fuel Pump 4 Float 5 Thermistor 6 Float Arm 7 Thermistor Housing 8 Resistor Card and...

Page 558: ...econds 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 Failure Code Description Trouble Area Maintenance Hint Fuel pump relay short circuit to battery Fuel pump relay short circuit to ground or open When short circuit to power source When short circuit to ground or open Inspection the E...

Page 559: ...e wire 5 Measure the fuel delivery from the fuel pump Measure the Current Consumption of Fuel Pump 1 Remove the fuel pump relay from fuse and relay box in trunk and turn the ignition switch to ON position 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 me...

Page 560: ...ion necessary for both ensuring the maximum homogeneity in the air fuel mixture and holding the condensation along the walls of the intake tract to a minimum Fuel enters the top feed injector from above and flows through its vertical axis The lower end extends into the intake valve Fuel from the tip is directed at the intake valve causing it to become further atomized and vaporized before entering...

Page 561: ...Injector 2 short circuit to power When malfunction of injector circuit Injector 2 short circuit to ground or open When malfunction of injector circuit Injector 3 short circuit to power Inspection the power to injector 1 or bad contact Inspection the injector Inspection the ECM Inspection the ECM pin 63 about short circuit or open with bad contact Inspection the injector Inspection the ECM Inspecti...

Page 562: ...ground or open When malfunction of injector circuit Injector 4 short circuit to power When malfunction of injector circuit Injector 4 short circuit to ground or open Inspection the ECM pin 65 about short circuit or open with bad contact Inspection the injector Inspection the ECM Inspection the power to injector 4 or bad contact Inspection the injector Inspection the ECM Inspection the ECM pin 66 a...

Page 563: ... beaker for taking the fuel 4 Connect the shop made cable to the inject or with a firing order 5 Connect the other end of shop made cable to the positive battery cable and negative battery cable 6 Turn the ignition switch ON 7 Check the inject or for normal spray pattern as shown in the figure Check inject or for leaks or later drop Injector Resistance Inspection 1 Turn the ignition switch OFF 2 R...

Page 564: ...eason the Engine Control Module ECM transacts the engine speed air inflow quantity coolant temperature and intake temperature The purge control valve is activated by the ECM frequency according with the engine rotating speed to adjust the purification rate The purification rate is determined by the continuous valve opening interval The purge control valve is activated by the ECM for the following ...

Page 565: ...th the vacuum pressure gauge YAD1F310 Failure Code Description Trouble Area Maintenance Hint Purge control valve short circuit to battery Purge control valve short circuit to ground or open Purge control circuit malfunction When short circuit to power source When short circuit to ground or open When malfunction of purge control not work Inspection the ECM pin 34 about short circuit or open with ba...

Page 566: ...AIL YAA1F0E0 1 O Ring 2 Fuel Pressure Regulator 3 Circlip 4 Vacuum Hose 5 O Ring 6 Injector 7 Injector Bracket 8 Fuel Rail 9 Combination Bolt 10 Bolt 11 Clamp 12 Fuel Return Line 13 Hollow Bolt 14 Seal Ring 15 Seal Ring 16 Fuel Pressure Test Connector ...

Page 567: ...at idling by operating the engine using the fuel pressure gauge 103 589 00 21 00 YAA1F700 Vacuum Hose Connected bar Vacuum Hose Disconnected bar 3 2 3 6 3 7 4 2 YAA1F0K0 2 Stop the engine for approximately 30 minutes and then check the fuel pressure changes Pressure change Fuel pressure drops slowly Fuel pressure drops rapidly Fuel leakage at the injector Faulty fuel pressure regulator s diaphragm...

Page 568: ...ne Operating at full load There is no negative pressure applied to the spring chamber 9 during the full load and it is separated from the fuel chamber 8 by the diaphragm 5 When the fuel pressure goes up the diaphragm forces the compression spring 6 in the direction of compression At this moment the valve 3 sticks to the diaphragm by the fuel pressure and the fuel return line 2 opens The fuel over ...

Page 569: ...negative pressure generated in the intake manifold activates the diaphragm and thus the fuel pressure gets reduced to the rate of the operating extent of the diaphragm by the intake manifold s negative pressure YAD1F380 1 Fuel Pressure Regulator 2 Intake Manifold 3 Fuel Return to fuel tank 4 Fuel Supply from fuel pump 7 Fuel Pressure approx 3 2 bars 8 Intake Manifold Negative Pressure 0 6 bars YAD...

Page 570: ... coolant temperature and engine load When this is done the throttle valve can be closed further by the servo motor overcoming the force of the spring capsule mechanical end stop If the actuator is de energized the throttle valve is resting against YAA1F540 the spring capsule Consequently the throttle valve opening is a constant 10 12 approximately At no load this produces an engine speed of about ...

Page 571: ...sor Both throttle position sensor failure TPS 1 short circuit to ground or open TPS 1 short circuit to power TPS 2 short circuit to ground or open TPS 2 short circuit to power When actuat or adaption fluctuation or not meet the condition When return spring defective of actuator When supply voltage of the actuat or short circuit to power When shut down of out put driver When defective of both poten...

Page 572: ...e slip control load shock damping and similar functions When the actuator current fails the throttle valve is returned to emergency operating position by a spring The throttle valve position there by the actuator drive position check back is provided by two potentiometers The motor positions the throttle valve against the return spring force Motor and return spring are two separate energy sources ...

Page 573: ...eam and downstream of the heating area show the same temperature without incoming flow With incoming flow upstream part is cooled down but downstream temperature retains its temperature more or less due to the air heated up in the heating area This temperature difference in quantity and direction depends on the direction of the incoming flow ECM modulates the flow of heating current to maintain th...

Page 574: ...ECM uses this information to enrich the mixture thus increasing the fuel injector on time to provide the correct amount of fuel When decelerating the mass flow decreases This mass flow change is sensed by the MAF sensor and read by the ECM which then decreases the fuel injector on time due to the low fuel demand conditions To facilitate the installation of the HFM in the intake passage lubricating...

Page 575: ...rn around the sensor The IAT sensor uses a thermistor to control the signal voltage to the ECM The ECM supplies 5 volt reference and a ground to the sensor 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 Failure Code Description Trouble Area Maintenance Hint Intake air...

Page 576: ... 105 and MAF sensor connecter terminal No 2 Ignition ON Idling Engine Status Specified Value Application 0 9 1 1 V 1 3 1 7 V Coolant temperature is over 70 C Notice If the measured value is not within the specified value the possible cause may be in cable or MAF sensor in itself Perform the 5 volt power supply inspection procedures Mass Air Flow Sensor 5 volt Power Supply Inspection 1 Turn the ign...

Page 577: ...tance which the ECM detects as a high signal voltage As the engine warms up the sensor resistance becomes lower and the signal voltage drops At normal engine operating temperature the ECT signal will measure about 1 5 to 2 0 volts The ECM uses information about coolant temperature to make the necessary calculations for Fuel delivery Ignition control Knock sensor system Idle speed Torque converter ...

Page 578: ...10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 Resistance Ω Ω Ω Ω Ω 48 550 27 000 15 570 9 450 5 890 3 790 2 500 1 692 1 170 826 594 434 322 243 185 143 111 6 88 71 2 Voltage V 4 90 4 82 4 70 4 52 4 43 3 96 3 57 3 14 2 70 2 26 1 86 1 51 1 22 0 98 0 78 0 63 0 50 0 40 0 33 ...

Page 579: ...int Engine coolant temperature sensor low voltage Engine coolant temperature sensor high voltage Engine coolant temperature sensor plausibility Engine coolant temperature insufficient for closed loop fuel control ECT sensor short circuit to ground or open ECT sensor short circuit to power Malfunction in recognition of ECT When drop to about 50 C below after warm up Malfunction in recognition of EC...

Page 580: ...connect the ECT sensor connector 5 Turn the ignition switch to ON position 6 Measure the resistance between the ECT sensor terminal pin No 1 and No 4 Temperature C 20 80 100 Specified Value Ω Ω Ω Ω Ω 2 500 322 185 Notice Replace wiring and coolant temperature sensor if out of specified value ...

Page 581: ...se correctly and also the engine rpm will be reacted to 4 000 rpm slowly If the APP 1 sensor is out of order the APP 2 sensor will be conducted with signal as adefault signal but the throttle valve opening is limited 60 and delayed opening speed WhentheTPsensororservomotorisdefected When the TP 1 2 sensor or servomotor is defected condition the throttle valve will be closed to the spring capsule b...

Page 582: ...ion pedal position sensor signal failure Acceleration pedal position 1 sensor low voltage Acceleration pedal position sensor 1 high voltage Acceleration pedal position sensor 2 low voltage Acceleration pedal position sensor 2 high voltage Accelerator pedal position sensor 1 not plausible with accelerator pedal position sensor 2 Both setpoint accelerator pedal position sensor defective When malfunc...

Page 583: ...ce If measured value is not within the specified value check the pedal valve sensor and the supply voltage to APP 1 sensor Acceleration Pedal Position Sensor 2 Inspection 1 Turn the ignition switch to ON position 2 Measure the signal voltage between the ECM pin No 48 and No 50 while operating the accelerator pedal as following conditions Not depress the pedal closed throttle position Fully depress...

Page 584: ...n with bad contact Inspection the power source Inspection the cooling fan Inspection the ECM 44 45 Circuit Description Ignition voltage is supplied directly to the cooling fan relay coil The ECM controls the relay by grounding the control circuit When the ECM is commanding a command ON the voltage of the control circuit should be low near 0 volt When the ECM is commanding the control circuit shoul...

Page 585: ...essor control Monitoring the actual operation through scan tool Inspection the Engine Control Module ECM pin 44 about short circuit or open with bad contact Inspection the relay short circuit or open Inspection the ECM 228 229 Circuit Description 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 ...

Page 586: ... failure Cruise control acceleration failure Cruise control deceleration failure Cruise control system message counter fault When malfunction of auto cruise system Implausible condition of vehicle speed signal Cruise control lever defective Cruise control system Implausible condition of acceleration signal Cruise control system Implausible condition of deceleration signal Monitoring the actual rec...

Page 587: ...If the TCS input circuit is open or short this failure code will be set Failure Code Description Trouble Area Maintenance Hint TCS input signal short circuit to battery TCS input signal short circuit to ground or open TCS short circuit to power TCS short circuit to ground or open Inspection the Engine Control Module ECM pin 45 about short circuit or open with bad contact Inspection the TCS lamp of...

Page 588: ... status and vehicle speed signal through scan tool Inspection the Engine Control Module ECM pin 49 about short circuit or open with bad contact Inspection the contact condition of stop lamp switch Inspection the ECM 135 Circuit Description 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 b...

Page 589: ...circuit short circuit to battery Engine rpm output circuit short circuit to ground or open When short circuit to battery When short circuit to ground or open Monitoring the actual rpm in cluster Inspection the Engine Control Module ECM pin 60 about short circuit or open Inspection the cluster panel board circuit Inspection the ECM 32 33 ...

Page 590: ...talytic converter contains acatalyst a word coming from the Greek and which designates the element essential for catalyst which triggers chemical reactions without itself being consumed These catalysts in the 3 way catalytic converter are the rare metals platinum Pt and rhodium Rh The catalytic converter consists essentially of three main elements The exhaust gases flow through the catalytic conve...

Page 591: ...e ECM compares this reference voltage with the voltage generated by oxygen sensor The amount of voltage the oxygen sensor generates is proportionate to the difference between the amount of oxygen in the outside air and the exhaust gases 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 conta...

Page 592: ...M161 ENGINE CONTROLS 1F2 71 SSANGYONG Y200 YAD1F590 ...

Page 593: ...output that not active the sensor etc When recognition the output that no lean signal after overrun fuel shut off When slow response of sensor signal When recognition the heating circuit When recognition the heating currents that more or less than set values less than 0 2 A or more than 2 A When recognition the heating voltages than less than set values less than 2 v Monitoring the actual output s...

Page 594: ...trol range of adaptation values through fuel and air mixture formation When recognition the value more than nominal control threshold it means that when big deviation in control range of adaptation values through fuel and air mixture formation When recognition the short term fuel trim that more than nominal threshold When recognition the short term fuel trim that less than nominal threshold When r...

Page 595: ...to harmless water vapor and carbon dioxide The ECM has the ability to monitor this process by using a oxygen sensor The oxygen sensor produces and output signal which indicates the storage capacity of the catalyst This in turn indicates the catalyst s ability to convert exhaust emission effectively If the oxygen sensor pigtail wiring connector or terminal is damaged Do not attempt to repair the wi...

Page 596: ...ibrations are stored in the ECM in the Programmable Read Only Memory PROM The ECM supplies either 5 or 12 volts to power the sensors or switches This is done through resistance in the ECM which are so high in value that a test light will not come ON when connected to the circuit In some cases even an ordinary shop voltmeter will not give and accurate reading because its resistance is too low You m...

Page 597: ...ity for ABS unit or not initialized condition When CAN signal message missing or implausibility for TCU unit or not initialized condition Inspection the ASR unit with CAN connection Inspection the Engine Control Module ECM pin 38 37 about short circuit or open with bad contact Inspection the ECM Inspection the ABS unit with CAN connection Inspection the ECM pin 38 37 about short circuit or open wi...

Page 598: ...h bad contact Inspection the ECM Inspection the each control unit with CAN connection Inspection the ECM pin 38 37 about short circuit or open with bad contact Inspection the ECM Inspection the MSR unit with CAN connection Inspection the Engine Control Module ECM pin 38 37 about short circuit or open with bad contact Inspection the ECM Inspection the ASR unit with CAN connection Inspection the Eng...

Page 599: ...ailure coding checksum failure ECM failure program ming checksum failure When faulty of variant coding of transmission When malfunction of random access memory ECM internal error When malfunction of ECM coding required ECM encoding When malfunction of ECM internal Inspection the coding condition through scan tool InspectiontheEngine ControlModule ECM Inspection the CAN line Inspection the TCM Insp...

Page 600: ...ilure ECM failure CPU 2 configuration failure ECM failure CPU 2 fault ECM failure CPU run time failure between CPUs ECM failure CPU 2 cruise control message counter failure Over deceleration limit CPU 2 Over acceleration limit 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...

Page 601: ...on CPU 2 A D converter failure CPU 2 Accelerator pedal position sensor setpoint fault between CPU 1 and CPU 2 Position controller setpoint fault between CPU 1 and CPU 2 MSR setpoint fault between CPU 1 and CPU 2 Idle control setpoint faultbetween CPU 1 andCPU 2 A D converter overflow CPU 2 ROM fault CPU 2 RAM fault CPU 2 Cycle monitor fault CPU 2 System internal failure Inspection the Engine Contr...

Page 602: ...ans immobilizer system disables starting by stopping fuel supply if the code in the transponder does not match the code stored in ECM each other Failure Code Description Trouble Area Maintenance Hint Communication with transponder missing Unprogramed ECM with immobilizer When missing the transpon der signal When malfunction of immobilizer Required immobilizer encoding no paired condition of immobi...

Page 603: ...dure in the reverse order FUEL PUMP Tools Required 661 589 00 46 00 Fuel Tank Cap Wrench Removal and Installation Procedure Caution The fuel system is under pressure To avoid fuel spillage and the risk of personal injury or fire it is necessary to relieve the fuel system pressure before disconnecting the fuel lines 1 Relieve the fuel system pressure Refer to Discharging the Pressure in Fuel System...

Page 604: ... avoid fuel spillage and the risk of personal injury or fire it is necessary to relieve the fuel system pressure before disconnecting the fuel lines 2 Relieve the fuel system pressure Refer to Dis chargingthe Pressure in Fuel System in this sec tion 3 Disconnect the fuel lines from the fuel filter Installation Notice Tightening Torque 28 N m 21 lb ft 4 Remove the fuel filter mounting bracket bolt ...

Page 605: ...2 Disconnect the negative battery cable 3 Drain the fuel tank 4 Put aside the floor carpet to remove the fuel pump access cover 5 Remove the fuel pump access cover KAA1F370 YAA1F170 YAA1F160 6 Disconnect the return line 7 Disconnect the supply line 8 Disconnect the fuel tank to canister hose from the fuel tank 9 Disconnect the fuel pump wiring connector 10 Disconnect thefuel filler hoseand air ven...

Page 606: ...ressure before disconnecting the fuel lines 3 Relieve the fuel pressure in fuel supply systemby pressing the service valve 4 Disconnect the vacuum hose 5 Disconnect the circlip and remove the fuel pressureregulator 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 remov...

Page 607: ...he fuel return and supply line Notice For removal cover around parts with cloths not to be stained by fuel In case of checking the injector only do not remove the fuel return and supply line Installation Notice 11 Remove the two left and two right bolts and one center bolt of the fuel rail assembly from the intake manifold Installation Notice YAA1F740 4 Remove the cable guide 5 Disconnect the Hot ...

Page 608: ...s 14 Remove the fuel injectors by pulling them down and out 15 Discard the fuel injector O rings 16 Lubricate the new fuel injector O rings with engine oil Install the new O rings on the fuel injectors 17 Perform a leak check of the fuel rail and fuel injectors 18 Installation should follow the removal procedure in the reverse order YAA1F770 YAA1F780 ENGINE COOLANT TEMPERATURE SENSOR Removal and I...

Page 609: ...250 KAA1D240 6 Disconnect the throttle body electrical connector 7 Remove the throttle body bolts Installation Notice 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 KFC1F240 4 Remove the blow by hose 5 Remove the intake air duck Tigh...

Page 610: ...HFM sensor coupling connects completely with the contact surface installation 5 Remove the HFM sensor 6 Installation should follow the removal procedure in the reverse order KAC1F270 KAA1F180 KNOCK SENSOR Removal and installation Procedure 1 Disconnect the negative battery cable 2 Disconnect the knock sensor electrical connector from the intake manifold bracket 3 Remove the knock sensor mounting b...

Page 611: ...Carefully remove the oxygen sensor from the exhaust pipe Installation Notice Tightening Torque 6 N m 53 lb in Tightening Torque 55 N m 41 lb ft 4 Remove the pedal and sensor assembly 5 Installation should follow the removal procedure in the reverse order Important A special anti seize compound is used on the oxygen sensor threads This compound consists of aliquid graphiteand glass beads The graphi...

Page 612: ...olts Installation Notice CAMSHAFT POSITION SENSOR 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 YAD1F660 CANISTER Removal and Installation Procedure Caution Canister and vacuum hoses contain fuel vapors Do not smoke in the ar...

Page 613: ...Control Module ECM from the mounting bracket Installation Notice KAA1F160 CRANKSHAFT POSITION SENSOR Removal and installation Procedure 1 Disconnect the negative battery cable 2 Disconnect the electrical connector at the crankshaft position sensor 3 Remove the crankshaft position sensor retaining bolt Installation Notice Tightening Torque 10 N m 89 lb in 4 Installation should follow the removal pr...

Page 614: ...SSANGYONG Y200 1F2 96 M161 ENGINE CONTROLS ECM WIRING DIAGRAM 2 3L DOHC 1 OF 7 MSE 3 53D SCHEMATIC AND ROUTING DIAGRAMS YAD1F010 ...

Page 615: ...M161 ENGINE CONTROLS 1F2 97 SSANGYONG Y200 ECM WIRING DIAGRAM 2 3L DOHC 2 OF 7 MSE 3 53D YAD1F0A0 ...

Page 616: ...SSANGYONG Y200 1F2 98 M161 ENGINE CONTROLS ECM WIRING DIAGRAM 2 3L DOHC 3 OF 7 MSE 3 53D YAD1F030 ...

Page 617: ...M161 ENGINE CONTROLS 1F2 99 SSANGYONG Y200 ECM WIRING DIAGRAM 2 3L DOHC 4 OF 7 MSE 3 53D YAD1F040 ...

Page 618: ...SSANGYONG Y200 1F2 100 M161 ENGINE CONTROLS ECM WIRING DIAGRAM 2 3L DOHC 5 OF 7 MSE 3 53D YAD1F0B0 ...

Page 619: ...M161 ENGINE CONTROLS 1F2 101 SSANGYONG Y200 ECM WIRING DIAGRAM 2 3L DOHC 6 OF 7 MSE 3 53D YAD1F0C0 ...

Page 620: ...SSANGYONG Y200 1F2 102 M161 ENGINE CONTROLS ECM WIRING DIAGRAM 2 3L DOHC 7 OF 7 MSE 3 53D YAD1F0D0 ...

Page 621: ... Control Protect Mission Purge Control Valve Lambda Function Catalyst Heating Overrun Fuel Cut Full Fuel Cut Brake Switch Cruise Control Status Unit C C rpm rpm Kg h TA CA Nm ms V Km h Km h V V V V mv 1 ON 0 OFF 1 ON 0 OFF 1 ON 0 OFF 1 ON 0 OFF 1 ON 0 OFF 1 ON 0 OFF 1 ON 0 OFF 1 ON 0 OFF 1 ON 0 OFF 1 ON 0 OFF 1 ON 0 OFF 1 ON 0 OFF 1 ON 0 OFF 1 ON 0 OFF 1 ON 0 OFF Value greater than 95 C after warm...

Page 622: ...Bolt Engine Control Module ECM Mounting Bracket Nuts 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 N m 10 6 30 10 10 6 28 25 25 23 38 25 55 6 12 Lb Ft 22 21 18 18 17 28 18 41 Lb In...

Page 623: ... damage the fuel sys tem Vehicle Fueling from Drums or Storage Containers For safety reasons particularly when using noncom mercial fueling systems fuel containers pumps and hoses must be properly earthed Static electricity build up can occur under certain atmo spheric and fuel flow conditions if unearthed hoses particularly plastic are fitted to the fuel dispensing pump It is therefore recommende...

Page 624: ...SSANGYONG Y200 1F2 106 M161 ENGINE CONTROLS SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE 661 589 00 46 00 Fuel Tank Cap Wrench 103 589 00 21 00 Fuel Pressure Gauge YAA1F890 KAA1F490 ...

Page 625: ...13 Component Locator 1F3 15 Fuel Injection Pump 1F3 15 Vacuum Pump Sectional View 1F3 16 Diagnostic Information And Procedure 1F3 17 Vacuum Control System Test 1F3 17 Vacuum Shut Off Leak Test 1F3 21 Idle Speed Adjustment 1F3 23 Fuel Pump Test 1F3 25 Injection Nozzle Test 1F3 28 Checking and Adjusting Start Of Delivery 1F3 31 Repair Instructions 1F3 41 On Vehicle Service 1F3 41 Vacuum Pump 1F3 41 ...

Page 626: ...ROLS DESCRIPTION AND OPERATION FUEL SYSTEM Fuel Injection System 1 Fuel Injection Pump 2 Fuel Feed Pump 3 Overflow Valve 4 Injection Nozzle 5 Pre filter 6 Fuel Return Hoses 7 Injection Line 8 Fuel Tank 9 Fuel Filter 10 Choke Orifice YAD1FAA0 ...

Page 627: ...0 RS 167 P Injection Pump E Self Driven S End Flange Mounting 5 Number of Cylinders 5EA M Pump Size Flange Stroke M 7 mm A 8 mm M W 8 mm 10 mm 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 ...

Page 628: ...imum speed governor It is suitable for use in those on road vehicles passenger cars and commercial vehicles in which YAD1FAC0 S Start Setting With Accelerator Pedal fully Depressed Cold Start S Start Setting With Accelerator Pedal Released Hot Warm Start L Low Idle Speed Setting O High Idle Speed Setting n1u Low Idle Speed n1o High Idle Speed nvo Maximum Full Load Speed n1 Speed at Start of Torque...

Page 629: ...move except in the idle full load torque control and speed regulation breakaway ranges The fuel delivery quantity needed for the required engine torque is selected by the actuator mechanism control lever The guide lever 9 is movably connected at pivot point B with the governor sliding sleeve In addition guide lever and tensioning lever 16 also pivot at point A YAD1FAD0 1 Stop Shutoff Lever 2 Strap...

Page 630: ...l rack in the stop shoutoff direction Starting the engine The engine is to be started according to the vehicle manufacturer s operating instructions Normally it can be started without pressing the accelerator pedal Only with a cold engine at low temperatures is the accelerator pedal to be pushed to the floor so that control lever 6 is shifted up against full load stop 7 a fixed stop on the governo...

Page 631: ...ontrol Rack 5 Linkage Lever Inner 6 Control Lever 8 Adjusting Screw For Idle Speed 9 Guide Lever 10 Idle Stop 11 Reverse Transfer Lever Intermediate speed After passing through the idle stage a governor sliding sleeve 20 and spring retainer 18 for torque control come into contact with each other In the uncontrolled range between idle and maximum speed the position of the flyweights 22 remains cons...

Page 632: ...r the full load quantity is injected until the maximum full 4 Control Rack 17 Governor Spring 18 Spring Retainer Torque Control Full load setting only the components concerned in the governing process are shown 20 Governor Sliding Sleeve 22 Flyweight load speed nvo is reached If engine speed increases beyond full load speed the force exerted by the flyweights 22 suffices to overcome the force of g...

Page 633: ... connected to vacuum from the vacuum pump via the glow starter switch of the vehicle As a result the diaphragm of the vacuum unit is pulled against the compression spring The vacuum unit 6 is connected with a stop lever 2r This lever pivots around the fulcrum D pulling the control rod of the injection pump into the stop position The bypass spring of the fulcrum lever is overcome in this process Vi...

Page 634: ... effects of variants in atmospheric pressure have an especially large influence when considerable differences in attitude are encountered in driving Because the engine s turbocharger further compresses the prevailing atmospheric pressure the absolute pressure in the engine s intake manifold is a combination of the atmospheric pressure and the charge air pressure The absolute metering manifold pres...

Page 635: ...rtain temperature Design and Function Depending upon temperature pressure is applied to the aneroid capsule s diaphragm which in turn shifts a sliding bolt to change the pretension on the idle spring The control rack now moves towards increased fuel quantity via the governor linkage and the control rack Operation Coolant temparature 0 c The thermovalve is open The vacuum of approx 700 mbar reaches...

Page 636: ...UMATIC SHUT OFF DEVICE PNAB To shut off the engine the key in the steering lock is turned to stop This applies vacuum to the shut off device diaphragm which pulls the control rack to the stop setting YAD1FAK0 4 Spring Loaded Strap 5 Control Rack This device can only be installed on vehicle which are equipped with a vacuum pump ...

Page 637: ...lating some amount of the exhaust gas into the combustion chamber to reduce the combustion temperature But the recirculated gas results in reduced charging efficiency of mixture so that the engine performance drops down Because of this fact EGR valve is tuned to operate in the area where oxidized substances are generated much Condition of working the EGR valve 100 seconds after starting the engine...

Page 638: ...nstall the micro switch setting device 017 589 08 21 01 in the injection pump 3 Adjust and fix the lever 6 at 10 1 4 Insert the harness into the micro switch setting device 617 589 08 21 01 5 Install the cam on the injection pump when the both lamps are on 6 Install the screw 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 se...

Page 639: ...l Lever 3 Engine Stop Unit 4 Idle Speed Adjustment ALDA 5 Stop Lever 6 Adjusting Screw for Idle Speed 7 Guide Lever 8 Adjusting Screw for Auxiliary Idle Speed YAD1FAN0 9 Governor Assembly 10 Hinge Lever 11 Spring Retainer Torque Control 12 Fly Weight 13 Clamping Piece 14 Plunger Driving Cam 15 Fuel Pump Driving Cam ...

Page 640: ...sure Valve 6 Safety Valve 7 O Ring 8 Pump Housing 9 Pump Cover 12 Lever 14 Outer Return Spring 15 Inner Spring Retainer 16 Roller Cam 17 Piston Rod 21 Inner Return Spring 23 Upper Spring Retainer 28 Piston Ring 30 Seal Ring 31 Oil Return Valve 32 Restrictor SB To Brake Booster SK To Vacuum Lines YAD1FAP0 ...

Page 641: ...YSTEM TEST YAD1FAQ0 1 Rubber Hose 2 Air Filter 3 Distributor 4 Chock 5 Rubber Hose 6 Molding Hose 7 Distributor 8 Molding Hose 9 Connector 10 Chock Filter 11 Molding Hose Service Data Idle Speed Increase Permissible Pressure Drop of System At least 100 rpm at approx 500 mbr 400 500 mbar approx 1 min ...

Page 642: ...Pump 201 589 13 21 00 Vacuum Tester 667 589 00 21 00 TDC pulse generator Commercial Tools Tester Connection Digital tester Temperature measuring instrument with test probe WB24 YAD1FAR0 e g Bosch MOT 001 03 Sun DIT 9000 e g Ahlborm Therm 2263 2 Eichenfeldstrabe 1 3 D 8150 Holzkirichen ...

Page 643: ... vacuum pump Connect vacuum pump 14 direct to PLA vacuum unit 5 and pressurize with vacuum Vacuum is built up and idle speed increases approx 150 200rpm YES NO Faulty PLA vacuum unit Coolant Temperature 0 3 C Stop the engine and seal the air admission line with plug arrow Connect the vacuum pump to line to thermovalve and pressurize the line with vacuum YES NO Lines and connections leaking Faulty ...

Page 644: ...mp Detach the plug from air admission line Vacuum drops off Connect vacuum pump 14 with Y adapter to PLA vacuum unit 5 Run the engine at idle speed Vacuum drops to 0 at approx 3 C of the thermovalve YES NO Faulty thermovalve Defective filter with restriction Test step 2 Filter with restriction is clear Stop the engine Detach the filter with restriction YES NO Defective filter with restriction OK ...

Page 645: ... Pump 2 Fuel Injection Pump 3 Engine Stop Unit 4 Control Line 5 Check Valve to Brake Booster 6 Engine Shut Off Valve 7 Suction Line 8 Vacuum Tester Service Data Model Permissible loss of vacuum Entire System at 400 50 mbar Vacuum Individual Part at 300 50 mbar Vacuum 6 mbar min 5 mbar min ...

Page 646: ...a vacuum drop is more than sperified value check the engine shut off valve or vacuum unit 4 Engine Shut off valve test Turn the ignition switch to ON position Connect the vacuum tester 201 589 13 21 00 to engine shut off valve 6 and apply vacuum of 300 50 mbar If a vacuum drop is more than specified value replace the engine shut off valve 6 Notice Before replacing the valve for the glow starter sy...

Page 647: ...1 00 11 2 Run the engine and warm up the coolant to 60 80 C 4 Disconnect the vacuum hose 4 from the PLA unit to check idle speed with tester 5 Check idle speed with tester Commercial Tool YAD1FB10 YAD1FDV0 YAD1FB20 3 Disconnect the connecting rod 3 from control lever 2 Notice To adjust idle speed loosen the locking nut 6 of PLA unit Engine OM662LA Engine Idle Speed 720 820 rpm e g Bosch MOT 001 03...

Page 648: ...tighten the locking nut and place the position marking with different color of paint Notice If there are no changes in idle speed with PLA unit adjustment perform the service at a BOSCH Service Center 8 Connect the vacuum pump 001 589 73 21 00 to the PLA vacuum unit and build up vacuum approx 500 mbar If engine rpm increases by approx 150 rpm It is normal 9 Connect the vacuum line 4 10 Install the...

Page 649: ...d seal up it with plug 3 Disconnect the vacuum line from vacuum unit engine stop 5 and connect the vacuum pump 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 2 Insert the plastic hose 5 and put the end into the measuring beaker 6 Min volume 150 cm3 for 30 sec...

Page 650: ... 1F3 26 DIESEL ENGINE CONTROLS YAD1FB80 Fuel Pressure Test 1 Fuel Filter Housing 2 Fuel Line 3 Seal Replace 4 Bolt 13 N m 10 lb ft 5 Tester At Idle Speed 0 3 bar At Full Load 0 5 bar 6 Fuel Injection Pump 7 Fuel Pump ...

Page 651: ...ump and remove the seals 3 and fuel line 2 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 3 Connect the tester 617 589 04 21 00 5 4 Start the engine and read off the fuel pressure on tester 617 589 04 21 00 5 Tightening Torque 13 N m 10 lb ft Notice If out of standard replace the fuel feed pump At Idle Speed At Full Load 0 ...

Page 652: ... 28 DIESEL ENGINE CONTROLS INJECTION NOZZLE TEST Preceding Work Removal of fuel injection nozzle 1 Fuel Injection Nozzle New 135 143 bar Used min 120 bar A Closed Spray good B Stringy Spray poor 2 Tester 3 Valve YAD1FBB0 ...

Page 653: ...onnect the fuel injection nozzle to the fuel injection nozzle tester 000 589 14 27 00 2 Close the valve 3 and pump 5 times strongly 3 Chatter test Slowly operate the hand lever at tester approx 1 stroke per second The nozzle must spray with a gentle chattering Poor The spray pattern shows split too wide and stringy Repair the fuel injection nozzle 4 Spray pattern test Operate the hand lever at tes...

Page 654: ...re opening pressure Notice If out of standard repair the injection nozzle 6 Leak test 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 New Nozzle Used Nozzle Difference Between Nozzles 135 143 bar Min 120 bar Max 5 bar ...

Page 655: ...tors with a minimum speed idle speed A measuring instrument measures the time interval of the two impulses converting the result into an angular value which is then indicated 4 TDC Pluse Sender Unit 5 Battery YAD1FBF0 In order to be able to register the relationship of the injection pump relative to the engine two signals are required TDC impulse from the crankshaft Governor impulse from the injec...

Page 656: ... Y200 1F3 32 DIESEL ENGINE CONTROLS Position Sensor RIV Method YAD1FBG0 Service Data 4 Seal Replace 5 Screw Plug 30 N m 22 lb ft 1 Position Sensor 2 Battery 3 Fuel Injection Pump Start of Delivery RIV ATDC 14 16 ...

Page 657: ...he crankshaft carefully further until both lamps A and B come on In this position check the Rl value on the crankshaft vibration damper 2 Install the position sensor 617 589 08 21 00 1 into the governor housing of the injection pump to be the guide pin of the position sensor facing up 3 Connect the battery terminal of position sensor 617 589 08 21 00 1 to positive terminal of battery Notice If onl...

Page 658: ...ANGYONG Y200 1F3 34 DIESEL ENGINE CONTROLS DigitalTester RIV Method Connection Diagram forTestersWithout Adapter 1 Fuel Injection Pump 2 Rl Sensor 3 Digital Tester 4 TDC Pulse Generator 5 Battery YAD1FBF0 ...

Page 659: ...YONG Y200 Connection Diagram forTesters With Adapter YAD1FBK0 1 Fuel Injection Pump 2 Rl Sensor 3 Digital Tester 4 TDC Pulse Sender Unit 5 Battery 6 Rl Pulse Generator Service Data ATDC 14 16 720 820 rpm Start of Delivery RIV Idle Speed ...

Page 660: ...ect the digital tester and TDC pulse generator 667 589 00 21 00 according to connection diagram 4 Run the engine at idle speed and check the Rl value on the digital tester Notice If out of standard adjust the start of delivery 5 Stop the engine 6 Remove the Rl sensor digital tester and TDC pulse generator 7 Replace the seal and tighten the plug Installation Notice Commercial Tools Item Digital Tes...

Page 661: ...7 SSANGYONG Y200 AfterTesting Position Sensor RIV Method Preceding Work Start of delivery test 1 Adjusting Screw 2 Bolt 23 N m 17 lb ft 3 Fuel Injection Pump 4 Bolt 23 N m 17 lb ft 5 Scale Rl start of delivery 14 16 ATDC YAD1FBN0 ...

Page 662: ...he supporting bracket Installation Notice 3 Remove the bolt 4 at the timing case cover Installation Notice 4 Turn the adjusting screw 1 until both lamps A B on the position sensor 617 589 08 21 00 light up Tightening Torque 23 N m 17 lb ft Tightening Torque 23 N m 17 lb ft Notice If the adjustment range is not adequate remove the injection pump and reinstall 5 After adjusting retighten all the bol...

Page 663: ...delivery advanced 3 Bolt 23 N m 17 lb ft Tools Required 617 589 09 21 00 Rl Adaptor 617 589 10 21 00 RI Sensor 667 589 00 21 00 TDC Pulse Generator Service Data Start of Delivery RIV Ldling Speed Item Digital Tester With Pulse Generator Without Pulse Generator Tools Commercial Tools ATDC 14 16 720 820 rpm Bosch MOT 001 03 Hartmann Braun EOMT3 Bosch ETD 019 00 Sun DIT 9000 ALV Diesel Tester 875 ...

Page 664: ...ion Notice 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 2 remove the bolts 1 at the timing case cover Installation Notice Tightening Torque 23 N m 17 lb ft Tightening Torque 23 N m 17 lb ft To the Right To the Left Start of Delivery Retarded Start Delivery Advanced ...

Page 665: ...L ENGINE CONTROLS 1F3 41 SSANGYONG Y200 REPAIR INSTRUCTIONS ON VEHICLE SERVICE VACUUM PUMP Preceding Work Removal the poly V belt YAD1FBX0 1 Bolt 10 N m 89 lb in 2 Vacuum Pump 3 Vacuum Line 4 Gasket Replace ...

Page 666: ...he bolts 1 evenly Notice If necessary rotate the engine until the pressure on the tappet of the vacuum pump is released 3 Remove the vacuum pump 2 4 Install the vacuum pump 2 Installation Notice Clean the gasket residues of sealing surface of vacuum pump and replace the gasket 5 5 Connect the vacuum line Tightening Torque 10 N m 89 lb in ...

Page 667: ...DIESEL ENGINE CONTROLS 1F3 43 SSANGYONG Y200 VACUUM UNIT REPLACEMENT YAD1FC10 1 Bracket 2 Bolt 3 Vacuum Unit 4 Vacuum Line 5 Seal Replace ...

Page 668: ...F3 44 DIESEL ENGINE CONTROLS YAD1FC20 FUEL PUMP 1 Fuel Injection Pump 2 Pressure Line 13 N m 10 lb ft 3 Suction Line 4 Hose Clip Replace 5 Gasket Replace 6 Spring Lock Washer 7 Hexagon Nuts 18 N m 13 lb ft 8 Fuel Pump ...

Page 669: ...re 1 Disconnect the fuel pressure and suction line Installation Notice 2 Remove the fuel pump mounting bolts Installation Notice 3 Remove the fuel pump and gasket 4 Installation should follow the removal procedure in the reverse order Tightening Torque 17 N m 10 lb ft Tightening Torque 13 N m 10 lb ft ...

Page 670: ...SANGYONG Y200 1F3 46 DIESEL ENGINE CONTROLS YAD1FC60 INJECTION NOZZLES 1 Fuel Injection Nozzle 35 40N m 26 30 lb ft 2 Fuel Return Hose 3 Plug 4 Nozzle Washer Replace 5 Fuel Injection Pipe 18 N m 13 lb ft ...

Page 671: ...g torque Tools Required 001 589 65 09 00 Serration Wrench Removal Installation Procedure 1 Remove the plastic clip from the injection pipe 2 Remove the fuel return hose 5 3 Remove the plug 3 4 Disconnect the injection pipes from the injection nozzles and push them to the side Installation Notice 5 Remove the fuel injection nozzle 4 with serration wrench 001 589 65 09 00 Installation Notice Tighten...

Page 672: ...TROLS INJECTION NOZZLE REPAIR Preceding Work Removal of fuel injection nozzle YAD1FCA0 1 Nozzle Holder 2 Steel Washer 3 Compression Spring 4 Thrust Pin 5 Intermediate Disc 6 Nozzle Needle 7 Nozzle Body 8 Nozzle Tensioning Nut 80 N m 59 lb ft ...

Page 673: ...zzle needle 6 and nozzle body 7 with an abradant 4 Clean the nozzle seat with cleaning cutter 5 Immerse nozzle needle 6 and nozzle body 7 in filtered diesel fuel When the nozzle body is held vertical the weight of the nozzle needle must cause it to slide down toward the nozzle needle seat 6 Assemble the injection nozzle so that the tip of the thrust 4 pin is facing toward the nozzle holder Install...

Page 674: ...he 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 ...

Page 675: ...0 N m 89 lb in 3 Gasket Replace 4 Fuel Injection Pump 5 Seal Replace 6 Screw Plug 30 N m 22 lb ft 7 Oil Pan 8 Locking Pin 9 Injection Timing Device 10 Washer 11 Bolt Left Hand Thread 46 N m 34 lb ft 12 Camshaft Sprocket 13 Washer 14 12 Sided Stretch Bolt Check 25 N m 18 lb ft 90 15 Timing Chain 16 Seal 17 Chain Tensioner 80 N m 59 lb ft YAD1FCF0 ...

Page 676: ...hen remove the cylinder head cover 1 and gasket 3 Installation Notice 3 Loosen the bolt 11 left hand thread Installation Notice 2 Loosen the camshaft sprocket bolt 14 Installation Notice Replace the gasket Rotate the engine 1 revolution by hand and check TDC marking of the crankshaft and camshaft Tightening Torque 10 N m 89 lb in Do not remove the bolt If max length of bolt exceeds 53 6 mm replace...

Page 677: ... 589 05 21 00 18 into the injection pump Notice Before tightening the bolts for the injection timing device and the camshaft sprocket always remove the locking screw 601 589 05 21 00 from the injection pump and reinstall the plug 7 Place alignment marks arrow on the timing chain 12 and camshaft sprocket 15 5 Remove the plug 6 and seal 5 from the fuel injection pump and collect oil in a suitable ve...

Page 678: ... out the 12 sided stretch bolt 14 and washer and remove the camshaft sprocket 12 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 Replace the seal 16 Tightening Torque 80 N m 59 lb ft 10 Pull out the bolt 11 and washer 10 Notice Be careful that the bolt is left hand thread ...

Page 679: ...ush back the timing chain with retaining plate 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 ...

Page 680: ...DIESEL ENGINE CONTROLS INJECTION TIMING DEVICE Preceding Work Removal of injection timing device assembly 1 Cam Sprocket Check 2 Bushing Check 3 Governor Weights 4 Segment Flange and Drive Hub 5 Compression Springs YAD1FCR0 ...

Page 681: ...1FCU0 Removal Installation Procedure 1 Remove the governor weights 3 2 Pull out the compression springs 5 and cam sprocket 1 from the segment flange 4 3 Knock out the bushing 2 with a proper drift 4 Installation should follow the removal procedure in the reverse order ...

Page 682: ... Removal of air cleaner housing Removal of intake manifold 18 Chain Tensioner 80 N m 59 lb ft 19 Seal Replace 20 Bolt Left Hand Thread 46 N m 34 lb ft 21 Washer 22 Bolt 23 N m 17 lb ft 23 Seal Replace 24 Oil Pan 25 Fuel Injection Pump 26 Seal Replace 27 Screw Plug 30 N m 22 lb ft 28 Square Nut YAD1FCV0 ...

Page 683: ...n of engine rotation 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 5 Remove the suction line 16 and pressure line 4 6 Remove the banjo bolt 1 and then remove the seal 2 and fuel line 3 7 Remove the plastic clip 8 on the injection line 2 Remove the connecting rod 9 3 Disconnect the vacuum lines 13 14 4 Remove th...

Page 684: ...89 05 14 00 29 and remove the bolt 20 and pull off the washer 21 Notice Be careful that the bolt 20 is left hand thread 13 Remove the bolt 22 and pull off the square nut 28 14 Pull out the fuel injection pump 25 and seal 23 12 Remove the bolt 12 and pull off the washer 11 11 Remove the chain tensioner 18 and seal 19 ...

Page 685: ... Procedure 1 Remove the screw plug 27 and seal 26 and collect oil in a vessel 4 Ensure that the no 1 cylinder is positioned at ATDC 15 3 Tighten the locking screw 601 589 05 21 00 2 Insert flange 601 589 00 08 00 31 onto the injection pump camshaft and turn until the cam of the governor is visible in the hole ...

Page 686: ... bolt 12 Installation Notice 9 Insert the washer 21 and tighten the bolts 20 and then remove the assembly cage 601 589 05 14 00 29 Installation Notice 7 Remove the locking screw 32 Tightening Torque 23 N m 17 lb ft Tightening Torque 23 N m 17 lb ft Tightening Torque 46 N m 34 lb ft Return Line 5 Fuel Injection Line 15 Fuel feed Line 3 Suction and Pressure Line 4 13 N m 10 lb ft 18 N m 13 lb ft 13 ...

Page 687: ...0 12 Connect the vacuum line 13 14 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 ...

Page 688: ...F3 64 DIESEL ENGINE CONTROLS FUEL TANK YAD1FDB0 1 Fuel Tank Mounting Bracket 2 Fuel Return Line 3 Fuel Supply Line 4 Fuel Filter 6 Fuel Tank 7 Fuel Pump 8 Fuel Tank Rear Pipe 9 Fuel Tank Air Cap 10 Fuel Filler Assembly ...

Page 689: ...ure before disconnecting the fuel lines 1 Disconnect the negative battery cable 2 Disconnect the fuel filler hoses 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 3 Put aside the floor carpet to remove the fuel pump access cover 4 Remove the fuel pump access cover 5 Disconect the fuel return a...

Page 690: ...ve Type Flange Stroke Flange Outside Diameter Rack Movement Max Speed Injected Fuel Quantity Stroke Lubrication Type Individual Injection Type Same Number of Cylinder and Plunger 5 Cylinder End Flange Mounting Inside Chain Connected with Camshaft 7 mm 5 5 mm 21 mm 2 500 rpm 35 mm3 Stroke Sump Lubrication Type Connected with Engine Oil Passage ...

Page 691: ...njection Pipe Fuel Injection Pump Mounting Bolt at the Timing Cast Cover 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 N m 25 90 80 10 13 35 40 18 23 23 13 13 13 46 80 30 10 Lb Ft 18 90 59 10 26 30 13 17 17 10 10...

Page 692: ...SSANGYONG Y200 1F3 68 DIESEL ENGINE CONTROLS SCHEMATIC AND ROUTING DIAGRAMS YAD1FDF0 EGR SYSTEM ...

Page 693: ...m Pump 116 589 20 33 00 Sliding Hammer 000 589 00 68 00 Cleaning Set 000 589 77 03 00 Box Wrench Insert 116 589 02 34 00 Threaded Bolt 201 589 13 21 00 Vacuum Tester 000 589 14 27 00 Fuel Injection Nozzle Tester 001 589 65 09 00 Serration Wrench YAD1FDU0 YAD1FDK0 YAD1FDT0 YAD1BKB0 YAD1A190 YAD1BLH0 YAD1B580 YAD1FDG0 ...

Page 694: ...er 617 589 08 21 00 Position Sensor 601 589 05 14 00 Assembly Cage 610 589 00 08 00 Flange 617 589 08 21 01 Micro Switch Setting Device 617 589 09 21 00 Ri Adapter 601 589 05 21 00 Locking Sensor 617 589 00 21 00 Ri Sensor YAD1FDS0 YAD1FDQ0 YAD1FDP0 YAD1FDN0 YAD1FDJ0 YAD1FDL0 YAD1FDL0 YAD1FDM0 ...

Page 695: ...DIESEL ENGINE CONTROLS 1F3 71 SSANGYONG Y200 SPECIAL TOOLS TABLE Cont d 667 589 00 21 00 TDC Pulse Generator 667 589 04 63 00 Retaining Plate YAD1FDH0 YAD1FDR0 ...

Page 696: ... 2C 5 Cross Sectional View 2C 6 Suspension Assembly 2C 6 Shock Absorber 2C 7 Diagnostic Information and Procedures 2C 8 Repair Instructions 2C 9 On vehicle Service 2C 9 Stabilizer 2C 11 Shock Absorber Assembly 2C 12 Upper Lower Arm Assembly 2C 14 Unit Repair 2C 16 Front Coil Spring 2C 16 Hub and Bearing 2C 18 Special Tool and Equipment 2C 20 Special Tools Table 2C 20 ...

Page 697: ...he both end of the stabilizer bar are connected to the control bar the center of the stabilizer bar is mounted to the body frame Coil Spring The coil spring is made by winding solid steel rod to form the coil shape Its energy absorption rate per weight is higher than that of the leaf spring and it allows to absorb little vibration properly resulted in keeping the ride comfort Therefore it s diffic...

Page 698: ...y mounts the shock absorber with bushings in order to support the load delivered from the spring 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 YAD2C040 ...

Page 699: ...k Absorber Stabilizer Wheel Alignment Toe In Camber Caster SPECIFICATIONS Specification Double Wishbone Coil spring Telescopic Double Tube Type GAS Torsion Bar Type 2 2 mm 0 30 Both side difference must be below 30 2 45 30 Both side difference must be below 30 Application ...

Page 700: ...ION 2C 5 SSANGYONG Y200 COMPONENT LOCATOR FRONT SUSPENSION ASSEMBLY 1 Stabilizer Bar 2 Cam bolt 3 Lower arm 4 Yoke 5 Stabilizer Bar Link 6 Knuckle 7 Upper arm 8 Shock Absorber Assembly Including coil spring YAD2E050 ...

Page 701: ...SSANGYONG Y200 2C 6 FRONT SUSPENSION CROSS SECTIONAL VIEW SUSPENSION ASSEMBLY YAD2C060 ...

Page 702: ...ER 1 Lower Spring Sheet 2 Yoke Bracket 3 Rebound Stopper 4 Cylinder 5 Piston 6 Shock Absorber assembly 7 Spring 8 Yoke 9 Boot 10 Bump Stopper 11 Spring Sheet Rubber 12 Upper Spring Sheet 13 Rubber 14 Rubber 15 Spacer 16 Washer 17 Nut 18 Bolt YAD2C070 ...

Page 703: ... Loosening Mountings Damaged or Worn Wheel Bearing Damaged Shock Absorber Damaged Tire Over Inflated Tire Faulty Shock Absorber Loosened Wheel Nut Bent or Broken Coil Spring Damaged Tire Worn Bushing Deformed Arm Assembly Worn Bushing Bent or Broken Coil Spring Incorrect Front Wheel Alignment Excessive Resistance of Lower Arm Ball Joint Insufficient Tire Pressure Faulty Power Steering Incorrect Fr...

Page 704: ...FRONT SUSPENSION 2C 9 SSANGYONG Y200 REPAIR INSTRUCTIONS ON VEHICLE SERVICE YAD2C080 ...

Page 705: ... 5 Bushing 6 Upper Spring Sheet 7 Rubber 8 Spring Sheet Rubber 9 Boot 10 Boot 11 Spring 12 Shock Absorber 13 Lower Spring Sheet 14 Yoke 15 Nut 16 Bolt 17 Bolt 18 Bolt 19 Bushing 20 Nut 21 Upper Arm 22 Nut 23 Bushing 24 Washer 25 Bolt 26 Lower Arm 27 Bushing 28 Bushing ...

Page 706: ...t stabilizer bar link Remove the front stabilizer bar link 3 Remove the mounting cap bolt from the front stabilizer bar and remove the front stabilizer bar YAD2C120 Installation Procedure 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 Tightening Torque 60 80 N ...

Page 707: ... Remove three upper nuts from the shock absorber assembly 2 Install the bra link between the stabilizer bar and the lower arm and tighten the mounting nut as the specified torque Installation Notice YAD2C130 Tightening Torque 1 110 120 N m 2 110 130 N m YAD2C160 2 Remove the yoke mounting pin nut at the lower arm and the yoke mounting pin Tightening Torque 35 N m 26 lb ft ...

Page 708: ...ion Procedure 1 Install the coil spring shock absorber assembly and the yoke to the body And then install the lower shock absorber into the yoke hole and insert the upper shock absorber to bolt hole by tightening the nut manually Installation Notice YAD2C200 2 Tighten bolts of the shock absorber assembly and yoke Be careful to tightening direction of the bolt as shown See the arrow Installation No...

Page 709: ...rate the upper arm YAD2C210 YAD2C220 YAD2C230 UPPER LOWER ARM ASSEMBLY Removal Procedure Notice Perform the pre work before the removal procedure Remove the shock absorber Remove the steering knuckle by referring the steering section 1 Remove the mounting nut slotted nut and the split pin cotter pin from the upper lower arm ball joint Notice Separate the ball joint from the steering knuckle using ...

Page 710: ...C260 YAD2C270 YAD2C280 Installation Procedure 1 Install the lower arm to the frame bracket and tighten the mounting bolt and nut as the specified torque Notice Tighten the bolt on the direction from rear side to front side of the vehicle Fix the bolt center with the bracket indication Installation Notice 2 Install the upper arm to the frame bracket Installation Notice Tightening Torque 160 170 N m...

Page 711: ...val Procedure 1 Remove the front coil spring assembly 2 Fix the special tool to the coil spring assembly as shown and compress the coil spring Notice Install the special tool to the coil spring tightly not to separate it during work and be careful to spring end portion should look forward to the person during compressing the coil spring YAD2C290 YAD2C300 3 Remove the shock absorber mounting nut an...

Page 712: ...ightening torque of lock nut 334 N m 25 40 N m 18 30 lb ft Notice Be careful to the installation direction for installing the coil spring Note When it s difficult to tighten the nut as specified torque fix the length from upper lock nut to bolt end to 23 24 mm YAD2C330 2 Check the coil spring installation Check the installation direction of the coil spring Verify that the coil spring is installed ...

Page 713: ...One of the upper bracket bolts should coincide with the lower yoke insert projection as shown YAD2C340 HUB AND BEARING Disassembly Assembly Part time 1 Remove the front hub and bearing assembly 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 ...

Page 714: ... Install the outer bearing race using the front outer bearing race installer and handle YAD2C390 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 ...

Page 715: ...00 Front hub adjust nut remover installer DW340 050 Sliding Hammer DW 340 060 Front hub cap remover installer DW 340 021 02 Front inner bearing race installer DW 340 021 03 Front outer bearing race installer 661 589 13 33 00 Ball joint remover DW 340 021 01 Handle YAD2C400 YAD2C440 YAD2C410 YAD2C450 YAD2C420 YAD2C460 YAD2C430 YAD2C470 ...

Page 716: ...nt Locator 2D 4 Rear Suspension Assembly 2D 4 Shock Absorber 2D 5 Diagnostic Information and Procedures 2D 6 Rear Suspension 2D 6 Wheel Bearing End Play 2D 7 Wheel Bearing Free load 2D 7 Repair Instructions 2D 8 On Vehicle Service 2D 8 Rear Suspension Assembly 2D 9 Special Tools and Equipment 2D 16 Special Tools Table 2D 16 ...

Page 717: ...and to minimize the vehicle s slope when both right and left wheels move differently 2 Lateral Rod It allows to control the load at the lateral direction 3 Upper Lower Arm It allows to control the load at the front rear direction side 4 Shock Absorber It allows to absorb the vibration at the vertical direction in order to make ride comfort feel better and reduce the spring fatigue 5 Coil Spring It...

Page 718: ... Height C O D D Constant Suspension Type Spring Type Stabilizer Type Shock Absorber 5 Links Two Upper Arm Two Lower Arm One Lateral Rod Coil Spring Torsion Bar Type YAD2D020 GSL 3 2 DSL A T 13 1 mm Ø 114 mm 405 7 mm 260 0 mm Ø127 1 mm 2 45 5 DSL M T 13 0 mm Ø114 mm 386 8 mm 250 0 mm Ø127 0 mm 2 45 5 Telescopic Double Tube Type 495 mm 308 mm ...

Page 719: ...4 REAR SUSPENSION COMPONENT LOCATOR REAR SUSPANSION ASSEMBLY 1 Coil Spring Seat upper 2 Coil Spring 3 Lateral Rod 4 Shock Absorber 5 Upper arm link 6 Lower Arm link 7 Stabilizer Link 8 Stabilizer 9 Pump Stopper YAD2D030 ...

Page 720: ...REAR SUSPENSION 2D 5 SSANGYONG Y200 SHOCK ABSORBER YAD2D040 ...

Page 721: ...er Bar Faulty Shock Absorber Loosening Mountings Damaged or Worn Wheel Bearing Damaged Shock Absorber Damaged Tire Over Inflated Tire Faulty Shock Absorber Loosened Wheel Nut Bent or Broken Coil Spring Damaged Tire Worn Bushing Deformed Arm Assembly Worn Bushing Bent or Broken Coil Spring Excessive Resistance of Lower Arm Ball Joint Insufficient Tire Pressure Faulty Power Steering Worn or Loosened...

Page 722: ...easuring tool to the hub bolt and measure the free load at the drum starts to rotate 5 Check the free load of the rear wheel bearing within the specified value Rear wheel bearing end play 0 mm 4 If the wheel bearing end play is excessive retighten the castle nut 5 If the wheel bearing end play continues to be excessive replace the wheel bearing Specified free load 1 4 4 3 kg cm 6 Retighten the cas...

Page 723: ... Y200 2D 8 REAR SUSPENSION REPAIR INSTRUCTIONS ON VEHICLE SERVICE YAD2D070 1 Rear Suspension Assembly 2 Rubber 3 Upper Arm 4 Lower Arm 5 Stabilizer Link 6 Stabilizer 7 Coil Spring 8 Shock Absorber 9 Lateral Rod ...

Page 724: ...n YAD2D080 YAD2D090 YAD2D100 2 Remove the mounting nut of the lower link connected the stabilizer bar and separate the stabilizer bar 3 Remove the mounting cap bolt retaining both end of the stabilizer bar and remove the stabilizer bar the mounting cap and the bushing YAD2D110 4 Remove the upper mounting nut of the link with the stabilizer bar removed and remove the link ...

Page 725: ...ounting nut by retaining the frame 8 Remove the upper nut and remove the shock absorber YAD2D120 YAD2D130 YAD2D140 6 Remove the lateral rod mounting nut by retaining the axle and remove the lateral rod assembly 7 Remove the lower nut of the shock absorber YAD2D150 ...

Page 726: ...etaining the frame 12 Remove the lower arm mounting bolt nut retaining the axle and then remove the lower arm YAD2D160 YAD2D170 YAD2D180 YAD2D180 10 Remove the upper bolt and nut retaining the axle and remove the upper arm 11 Remove the lower arm mounting the frame ...

Page 727: ...ring correctly Notice 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 13 Loosen the brake hose and remove the spring by pushing to incline the rear axle YAD2D190 YAD2D200 14 Remove the mounting nut of the shock absorber bottom and the upper arm And ...

Page 728: ...per arm to the frame bracket and the axle And then tighten bolts as specified torque Installation Notice 5 Install the lower arm to the frame bracket and the axle And then tighten bolts as specified torque Installation Notice Tightening Torque frame 1 Tightening Torque axle 2 165 N m 165 N m Tightening Torque frame 1 Tightening Torque axle 2 165 N m 165 N m Tightening Torque frame 1 Tightening Tor...

Page 729: ...he bar with the connecting rod And then tighten the mounting cap bolt and nut as specified torque Installation Notice 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 Tightening Torque Tightening Len...

Page 730: ...REAR SUSPENSION 2D 15 SSANGYONG Y200 YAD2D290 Notice For scrapping the gas shock absorber drill the hole in the A section with the shock absorber full expansion and discharge the gas ...

Page 731: ...SSANGYONG Y200 2D 16 REAR SUSPENSION SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE 661 589 12 33 00 Rear spring compressor Torque Wrench YAD2D300 YAD2D310 ...

Page 732: ... 2E 5 Diagnostic Information and Procedures 2E 6 General Inspection 2E 7 Inspection the Appearance 2E 7 General Inspection 2E 9 Component Locator 2E 12 Tire and Wheel Assembly 2E 12 Repair Instructions 2E 13 ON Vehicle Service 2E 13 GeneralTire 2E 13 SpareTire 2E 14 Maintenance and Replacement 2E 15 Separation 2E 15 Maintenance 2E 16 Installation 2E 17 ...

Page 733: ...anufacturer s recommendations Structure of Tubeless Tube DESCRIPTION AND OPERATION The tire structure is different slightly according to the types of the tire but a various type of the tire has the common structure as following 1 Tread A part that contacts road surfaces directly is fixed on the outsude of carcass and breaker It is a strong rubber coat made of high anti abrasion rubber Its running ...

Page 734: ...850 875 900 925 94 95 96 97 98 99 100 101 102 103 104 105 Symbol Limit Speed km h The Relation Between Inflation Pressure and Tire The Relation Between Load and Tire TIRE S ABNORMAL ACTION Standing Wave During running the rotating tire repeats deformation and restoring movement generated in tread But when the wheel rotating speed reaches high the next deformation applied to tire before restoring l...

Page 735: ...lf return and that the tire rolling effort and the road friction be held to a negligible force in order to allow the customer to direct the vehicle with the least effort and the most comfort A complete wheel alignment check should include measurements of the rear toe and camber Toe in Toe in is the turning in of the tires while toe out is the turning out of the tires from the geometric centerline ...

Page 736: ...FICATIONS 2 2 mm 0 30 Below 30 the difference between right and left 2 45 30 Below 30 the difference between right and left Aluminum Type Steel Type Aluminum Wheel Steel Wheel Radial Tire P225 75R15 P235 70R16 P255 65R16 7JJ x 16 6 5JJ x 16 8 12 kgf m 11 13 kgf m Radial Tire 30 psi 30 psi 30 psi Wheel Nut Tightening Torque ...

Page 737: ...egular tires wear Driving noise Vibration Rapid wear Condition Improper tire inflation pressure Poor wheel balance Improper tire rotation Poor toe in Poor adjusting the pre load of the wheel bearing Poor braking performance Low tire inflation pressure Poor balance of wheels tires Severe vibration due to wheels tires Irregular tires wear Excessive tire inflation pressure High speed driving with low...

Page 738: ...ure Action Rapid wear at shoulders Condition Under inflation or lack of rotation Cause Rapid wear at center Over inflation or rotation Tread damage Low the inflation pressure Adjust camber Uneven wear Incorrect camber Incorrect toe in YAD2E100 YAD2E110 YAD2E120 YAD2E130 YAD2E140 YAD2E150 YAD2E160 YAD2E110 ...

Page 739: ...Feathered edge Condition Incorrect toe in Cause Bold spot Unbalanced wheel Sharply wear at the tread outside Unbalanced wheel Wheel bearing play Ball joint play Faulty shock absorber YAD2E170 YAD2E180 YAD2E190 YAD2E200 YAD2E210 Adjust wheel balance Adjust Check play Check pre load Check Check ...

Page 740: ...reakage and tire rim bruises etc Higher than recommended pressure can cause hard ride tire bruising or damage and rapid tread wear at the center of the tire YAD2E220 YAD2E230 YAD2E240 Tire Wear Measure the depth of the tire tread If the depth of the tread is below the specified value replace the tire Inspection the Inflation of Tires 1 Inflation pressure You can see the mark in the groove this is ...

Page 741: ...tion Steel and Alloy Wheels Free radial runout 1 5 mm 0 06 inch Free lateral runout 1 5 mm 0 06 inch Notice If any measurement exceeds the above specifications replace the applicable tires or wheels YAD2E250 YAD2E260 YAD2E270 Wheel Balance Balance is the easiest procedure to perform and should be done first if the vibration occurs at high speeds or if the tires or the wheels are replaced When proc...

Page 742: ...neven wear of tires and to prolong tire life inspect and rotate the tires every 5 000 km 3 100 miles After rotating the tires adjust the tire inflation pressures and be sure to check wheel nuts tightness Caution at replacement tires 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 affec...

Page 743: ...SSANGYONG Y200 2E 12 TIRES AND WHEELS COMPONENT LOCATOR TIRE AND WHEEL ASSEMBLY 1 Wheel Nut 2 Wheel 3 Balance Weight 4 Tire 5 Wheel Cap 6 Wheel Cap 7 Wheel Cap 8 Wheel Cap YAD2E290 ...

Page 744: ...ICE GENERAL TIRE 1 Remove the wheel cap YAD2E300 YAD2E310 YAD2E320 2 Loosen the wheel nuts and then raise and suitably support the vehicle 3 Remove the wheel nuts 4 Installation should follow the removal procedure in the reverse order REPAIR INSTRUCTIONS ...

Page 745: ... handle and the wheel nut wrench Notice Keep the spare tire available always When reinstall the spare tire install the tire tightly If the spare tire may move after installation reinstall the tire or contact to the approved 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 in...

Page 746: ...angerous working job So only the skillful worker must work this job following the approved procedures YAD2E360 YAD2E370 YAD2E380 2 Tighten the locker in the center of the equipment to assemble the rim to the equipment 3 Remove the balance weight on the rim 4 Separate the tire s bead from the rim flange using the approved lubricant Notice Do not use silicone synthetic detergent and gasoline etc MAI...

Page 747: ...r the rim as welding or soldering Replace the new valve as replaces new tire YAD2E390 YAD2E400 YAD2E410 6 Insert the removal lever between the tire s bead and the rim and separate the rim from the tire Notice Do not use the tool that may cause any damage such as pipe damaged bar 7 Pull out the opposite bead upward using the lever and then separate the bead from the rim ...

Page 748: ...reign material or liquid for the tire inside and then install to push down the tire YAD2E420 YAD2E430 YAD2E440 YAD2E450 2 Install the rim to the equipment with the valve upward 3 Tighten the locker in the center of the equipment to assemble the rim to the equipment 4 Apply the lubricant at the both bead portions and both rim s flange of the tire ...

Page 749: ...0 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 YAD2E460 Specification of the tire pressure 2 1 kg cm2 30 psi ...

Page 750: ... Procedures 3A 5 Component Locator 3A 6 Front Axle Shaft 3A 6 Front Axle Housing 3A 7 Vacuum Line 3A 10 Maintenance and Repair 3A 11 On Vehicle Service 3A 11 Front Axle Shaft 3A 11 Vacuum Line 3A 18 Axle Housing 3A 19 Unit Repair 3A 20 Axle Housing Assembly 3A 20 Differential Joint Assembly 3A 26 Wheel Joint Assembly 3A 28 Special Tools And Equipment 3A 30 Special Tools Table 3A 30 ...

Page 751: ...e Bracket RH The front axle is installed between the left and right wheel It have the function which transfers the power of engine to the wheels Especially it transfers the high power to the front wheels when driving 4 wheel 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...

Page 752: ...FRONT AXLE 3A 3 SSANGYONG Y200 AXLE SHAFT ASSEMBLY YAD3A030 1 Drive Shaft 2 Housing Inboard 3 Boot Outboard 4 Boot Inboard 5 Shaft 6 Boot Band 7 Boot Band 8 Boot Band 9 Boot Band 10 Seal 11 Ball Joint ...

Page 753: ...Housing Type Differential Reduction Ratio Gaso E32 or E23 Oil Type Gear Type Gasoline M T Diesel M T Gasoline M T Diesel M T Capacity Specification SPECIFICATIONS CV Joint Build up Conventional Hypoid Gear 3 73 4 27 4 56 4 89 1 4 L SAE 80W 90 or API Gl 5 ...

Page 754: ...ear of Pinion Shaft Excessive Backlash of Pinion Gear and Side Gear Excessive End Play of Rear Axle Shaft Incorrect Contact of Side Gear and Differential Case Axle Housing Crack Distortion or Poor Installation of Drive pinion Oil Seal Damaged of Torn Drive Pinion Oil Seal Loosened Bearing Collar Worn or Damaged Universal Joint Worn or damaged Axle Shaft Bearing Lack of Oil Insufficient Backlash of...

Page 755: ...A040 1 Front Axle Inner Shaft Mounting Axle Housing 2 Front Axle Drive Shaft 3 Washer 4 Bolt 5 Steering Knuckle 6 Dust Seal 7 Outboard Joint Assembly 8 Boot Clamp 9 Outboard Boot 10 Boot Clamp 11 Shaft 12 Boot Clamp 13 Inboard Boot 14 Boot Clamp 15 Inboard Joint Assembly ...

Page 756: ...T AXLE HOUSING YAD3A330 1 Axle Mounting Bracket 2 Breather Hose 3 Bolt 4 Nut 5 Cross Member 6 Bolt 7 Bushing 8 Spacer 9 Spacer 10 Nut 11 Front Axle Housing 12 Nut 13 Bolt 14 Washer 15 Inner Shaft Left 16 Inner Shaft Right 17 Washer Plain ...

Page 757: ...SSANGYONG Y200 3A 8 FRONT AXLE YAD3A380 ...

Page 758: ...2 Pinion Lock Nut 13 Washer 14 Companion Flange 15 Oil Seal Replace Apply grease to the sealing Rib 16 Bearing 17 Shim 18 Bearing Baffle 19 Shim 20 Bearing 21 Oil Slinger 22 Driver Pinion 23 Oil Filler Plug 24 Bolt 25 Axle Housing Cover Apply Liquid Gasket 26 Ring Gear 27 Bearing 28 Shim 29 Shaft Lock Pin 30 Differential Case 31 Bolt 32 Bolt 33 Washer 34 Bearing Cap 35 Thrust Washer 36 Side Gear 3...

Page 759: ...N m 37 44 lb ft 3 Washer 4 Auto locking Hub Cap 5 Retaining Ring 6 Shim 7 Locking Hub 8 Hose and Tube Assembly 9 T Connector 10 Hose Molded 11 Check Valve 12 Corrugated Tube 13 Auto locking Hub Solenoid Valve 14 Bolt 15 Hose L 2000 Yellow 16 Hose L 3200 Red 17 Hose L 1500 White DSL Hose L 800 Blue GSL ...

Page 760: ... ABS Only part time vehicle Remove the wheel speed sensor from the steering knuckle and pull off the cable 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 MAINTENANCE AND REPAIR ...

Page 761: ... the lock Notice For assembly adjust the clearance between the snap ring 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 Detach the vacuum hose of locking hub from steering knuckle YAD3A090 4 Remove the two knuckle brake caliper assembly mounting blots and pull off the caliper assembly Notice Be careful not to damage t...

Page 762: ...rive shaft tip with the hub tip and cork apply the paint and grease to the corking part Remove the front disc assembly from the axle shaft 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 YAD3A120 Remove the hub brake disc assembly ...

Page 763: ...embly replace the split pin with new one 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 10 Carefully remove the steering knuckle assembly 11 Remove the drive shaft using the special tool YAD3A160 7 Remove two dust shield mounting bolts M6 and pull off the dust shield ...

Page 764: ...bolts applied the lock tight Blue color Installation Notice Tightening Torque 100 130 N m 140 160 N m 140 160 N m Tightening Torque Lower arm Upper arm YAD3A200 Installation Clean all the parts Check O ring snap ring for the wear and damage If damaged replace them with new ones 1 Insert the axle shaft to the axle housing Be sure to insert the axle shaft to the housing Notice When you insert the ax...

Page 765: ...ot exceed Max 0 2mm on condition that you pull the shaft completely in outside direction Fix the hub body using the snap ring Tightening Torque 100 130 N m 0 2 0 3 0 5 1 0 mm 0 2 mm Shim thickness Max clearance Install the hub cover to the body and tighten it as the specified torque Installation Notice 50 60 N m 37 44 lb ft Tightening torque YAD3A230 Install the front disc and tighten the hub nut ...

Page 766: ...3A290 9 Install the wheel speed sensor and connect the vacuum line with ABS only Installation Notice 35 45 N m 26 33 lb ft Tightening torque 6 8 N m 53 71 lb in ABS wheel speed sensor mounting bolt 10 Install the tire and test the braking force YAD3A270 7 Tighten the front disc brake caliper assembly mounting bolts on condition that the front disc is mounted Installation Notice Tightening Torque 8...

Page 767: ...m 6 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 VACUUM LINE Removal Installation 1 Be careful not to change the direction of valve when connecting the check valve 11 with each hose YAD3A310 YAD3A320 Tightening Torque 50 60 N m 37 44 lb ft Normal MAX 0 2 mm ...

Page 768: ...r and axle housing mounting nut 1 Installation Notice 5 Remove the frame and cross member mounting nut 2 and pull off the cross member Installation Notice Tightening torque 95 142 N m Tightening Torque 62 93 N m 45 69 lb ft 6 Support the axle housing on a suitable jack remove the axle housing mounting bracket nuts Installation Notice Tightening Torque 62 93 N m 45 69 lb ft 7 Lowering the jack care...

Page 769: ...D3A410 YAD3A420 Tightening Torque 28 40 N m 21 30 lb ft 2 Remove the axle housing mounting bracket bolt and pull off the bracket and inner shaft assembly 3 Remove the bearing fixing snap ring of inner shaft and pull off the bearing Remove the inner shaft and housing bracket 4 Remove the axle housing cover Notice Clean the gasket dregs of the cover and housing contact surface YAD3A430 ...

Page 770: ...ng cap Pull out the differential carrier assembly Notice Do alignment marks on the bearing dap not to change the caps before removal When pulling out be careful not to damage the axle housing 6 Disassemble the parts of differential carrier assembly 7 Remove the drive pinion lock nut Disassemble the parts of drive pinion ...

Page 771: ... the drive pinion toward ring gear center line Excessive backlash Noise can be occurred Insufficient backlash Tooth can be damaged or broken under heavy load Excessive backlash Drive pinion shaft is apart from the ring gear Noise can be occurred Insufficient backlash Gear contacts on the low flank Gear can be damaged or worn Noise can be occurred Inspection of Ring GearTooth Contact Pattern 1 Norm...

Page 772: ...tial carrier for crack and wear bearing contact surface Check the gear case for crack YAD3A560 YAD3A570 YAD3A590 YAD3A580 2 Assemble the drive pinion assembly to the axle housing and then tighten the pinion lock nut Installation Notice Tightening torque 240 310 N m Tightening Torque 75 90 N m 55 66 lb ft 3 Assemble the differential carrier assembly Align the ring gear to the mark of differential c...

Page 773: ...to change the caps Be sure to keep the original position of the caps Tightening Torque 48 69 N m 35 51 lb ft 6 Measure the backlash of drive pinion and ring gear Specified value 0 13 0 20 mm 7 Install the axle housing cover Tighten the fixing bolts Installation Notice 8 Assemble the parts of the front axle inner shaft and housing mounting bracket Notice Apply the grease to the oil seal rib Tighten...

Page 774: ...YONG Y200 YAD3A640 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 Tightening Torque 80 100 N m 59 74 lb ft ...

Page 775: ... 1 Remove the drive axle 2 Detach the joint boot clamp 1 Detach the boot clamp large After pressing the clamp prominence using the special tool detach the clamp 2 Detach the boot clamp small After unfolding the clamp holding part using the driver hammer detach the clamp 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 ...

Page 776: ...embly 1 Assembly should follow the dismantlement in the reverse order 2 Apply the specified grease to the joint housing Notice If not use the specified grease the joint and boot may be damaged Notice For assembly replace the boot clamp with the new one 3 Check the followings after completing the assembly Check whether the joint move to up down left right forward freely Check whether the grease lea...

Page 777: ...rease in the joint assembly 4 Remove the joint assembly 1 Spread out the circlip 2 Pull out the joint assembly to the wheel side with the circlip spread out 5 Remove the drive axle shaft Assembly 1 Assembly should follow the disassembly procedure in the reverse order 2 Install the joint assembly Put the joint assembly in drive axle shaft to spread out the circlip opening slightly 1 Insert driver i...

Page 778: ...e boot clamp with the new one YAD3A750 YAD3A760 Injection quantity 80 90 g 4 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 Notice Because the wheel joint cannot be repaired in single part if there is defect replace it whit the new assembly ...

Page 779: ...SSANGYONG Y200 3A 30 FRONT AXLE SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE 661 589 13 33 00 Ball Joint Remover Part Time Snap Ring Remover Installer Snap Ring Plier YAD3A770 YAD3A780 YAD3A790 ...

Page 780: ...ration 3C 2 Specifications 3C 2 Diagnostic Information and Procedures 3C 3 Component Locator 3C 4 Cross Sectional View 3C 4 Propeller Shaft Assembly 3C 5 Maintenance and Repair 3C 6 On Vehicle Service 3C 6 Propeller Shaft Assembly 3C 6 Unit Repair 3C 9 Propeller Shaft 3C 9 ...

Page 781: ... Unbalance Quantity at 4 500 RPM SPECIFICATIONS GENERAL DESCRIPTION AND OPERATION The propeller shaft transfers the power through the transmission and transfer case to the front rear axle differential carrier final reduction fear It is manufactured by a thin rounded steel pipe to have the strong resisting force against the torsion and bending Both ends of propeller shaft is connected with the spid...

Page 782: ...eft Right of Universal Joint Snap Ring Loosened Yoke connection bolt Worn or Damaged Universal Joint Bearing Separation of Universal Joint Snap Ring Loosened Yoke connection part Warn sliding Joint Spline pant Insufficient Grease Adjust Replace Adjust Tightening Replace Adjust Replace Tightening Replace Replenish Checks Phenomena Vibration Noise Action ...

Page 783: ...IONAL VIEW YAD3C020 1 Flange Yoke 2 Journal Bearing Cap 3 Cross Shaft Journal 4 Slip Yoke Assembly 5 Grease Nipple 6 Dust Cap 7 Oil Seal 8 Split Washer 9 Slip Tube Shaft 10 Tube 11 Tube Yoke 12 Flange Yoke 13 Center Bearing Rear Propeller Shaft Rear Propeller Shaft ...

Page 784: ...PROPELLER SHAFT 3C 5 SSANGYONG Y200 PROPELLER SHAFT ASSEMBLY YAD3C030 1 Front Axle 2 Bolt 3 Front Propeller Shaft 4 Bolt 5 Transfer Case 6 Bolt 7 Rear Propeller Shaft 8 Bolt 9 Rear Axle ...

Page 785: ...re removing the propeller shaft YAD3C040 YAD3C060 YAD3C050 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 3 Remove the flange yoke bolt nut of transfer case side in rear propeller shaft MAINTENANCE AND REPAIR ...

Page 786: ...he disassembled parts visually 2 Align the assembly mark of each propeller shaft 3 Install the front propeller shaft Installation Notice Tightening Torque 81 89 N m 60 66 lb ft 4 Set up the rear propeller shaft between the transmission and axle housing Tighten the center bearing manually Installation Notice Tightening Torque 80 95 N m 59 70 lb ft YAD3C070 4 Remove the fixing bolt of middle bearing...

Page 787: ...NG Y200 3C 8 PROPELLER SHAFT YAD3C110 5 Align the rear propeller shaft to the assembly mark Tighten the bolts nuts and then the center bearing bolts Installation Notice Tightening Torque 70 80 N m 52 59 lb ft ...

Page 788: ...k and remove the propeller shaft 2 Do alignment mark before separating the spider 3 Remove the snap ring using the snap ring plier 4 Slightly tapping the yoke shoulder using a brass hammer remove the bearing Remove the remaining bearing in the same way YAD3C150 5 If it is not removed clamp the welding part of yoke in the vise ...

Page 789: ...ace them if necessary 2 Spider outer diameter YAD3C160 YAD3C170 YAD3C180 6 Disassemble the universal joint parts As axles move up and down universal joints allow drive angle to change without bending of propeller shaft 7 Remove the center bearing bracket and center bearing using the special tool standard Limit 16 647 mm 16 668 mm standard Limit 0 03 0 098 mm 0 25 mm ...

Page 790: ... of vibration Separation of balance weights Excessive runout of the propeller shaft Using the general bolts Excessive wear of universal joint Sticks in sleeve joint Vibration is caused by front rear universal joint pinion angle change and is generally broke out when the vehicle speed is around 60 100km h Specified Value 3 8 kg cm YAD3C220 Assembly Clean the disassembled parts and replace then if d...

Page 791: ...earing cap to the yoke and insert the spider Install the opposite cap by tapping with a plastic hammer 4 Assembly the center bearing to the rear propeller shaft YAD3C230 2 Apply the grease to the inner of bearing cap of needle roller bearing and assemble the needle roller ...

Page 792: ...3D 3 Component Locator 3D 4 Rear Axle Assembly 3D 4 Cross Sectional View 3D 5 Rear Axle Shaft Assembly 3D 6 Maintenance and Repair 3D 8 On Vehicle Service 3D 8 Axle Shaft Assembly With Disc Brake 3D 8 Axle Shaft Assembly With Drum Brake 3D 11 Rear Axle Housing 3D 13 Unit Repair 3D 18 Axle Assembly 3D 18 Differential Gear Assembly 3D 19 ...

Page 793: ... Differential Reduction Ratio Oil Type Gear Gasoline A T Diesel A T Gasoline A T Diesel A T Capacity Specification Semi floating Build up Conventional Type Hypoid Gear 3 73 4 27 4 56 4 89 1 9L SAE 80W 90 or API GL 5 GENERAL DESCRIPTION AND OPERATION SPECIFICATIONS ...

Page 794: ...ear of Pinion Shaft Excessive Backlash of Pinion Gear and Side Gear Excessive End Play of Rear Axle Shaft Incorrect Contact of Side Gear and Differential Case Axle Housing Crack Distortion or Poor Installation of Drive pinion Oil Seal Damaged of Torn Drive Pinion Oil Seal Loosened Bearing Collar Worn or Damaged Universal Joint Worn or damaged Axle Shaft Bearing Lock of Oil Insufficient Backlash of...

Page 795: ...SANGYONG Y200 3D 4 REAR AXLE COMPONENT LOCATOR REAR AXLE ASSEMBLY YAD3D101 1 Axle Shaft Tube 2 Stabilizer Bar 3 Spring Seat Spring 4 Upper Arm 5 Shock Absorber 6 Lateral Rod 7 Input Shaft 8 Axle Housing ...

Page 796: ...00 CROSS SECTIONAL VIEW YAD3D020 1 Rear Axle Shaft Assembly 2 Bracket Assembly 3 Hub Oil Seal 4 Bolt 5 Axle Shaft Tube 6 Coil Spring Seat Lower 7 Caliper Assembly 8 Input Shaft Flange 9 Rod Mounting Bracket 10 Wheel Speed Sensor ...

Page 797: ...R AXLE SHAFT ASSEMBLY With disc brake YAD3D030 1 Brake Disc 2 Plug 3 Rear Axle Shaft 4 Nut 5 Washer 6 Parking Brake Cable 7 Parking Brake Lining Back Plate Assembly 8 Brake Caliper Assembly 9 Spring Washer 10 Bolt 11 Rear Axle Housing ...

Page 798: ... With drum brake YAD3D150 1 Brake Drum 2 Plug 3 Rear Axle Shaft 4 Wheel Bolt 5 Nut 6 Washer 7 Retainer Plate 8 Oil Seal 9 Bearing 10 Snap Ring 11 Snap Ring 12 Oil Seal 13 Brake Shoe Back Plate Assembly 14 Bolt 15 Rear Axle Housing ...

Page 799: ...g brake 3 Remove the fixing pin of parking brake 4 After detaching the parking brake lever detach the cable 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 MAINTENANCE AND REPAIR ...

Page 800: ...er and then pull out the dust shield cover YAD3D090 YAD3D100 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 11 Remove the rear axle drive shaft YAD3D070 7 Remove the brake disc ...

Page 801: ...t shield Installation Notice 4 Install the brake disc and caliper assembly Installation Notice 5 Install the parking brake cable and tire 50 65 N m 37 48 lb ft Tightening torque 4 8 N m 35 71 lb in Tightening torque Tightening torque 85 105 N m YAD3D110 Installation Clean the detached axle shaft check the damage or wear 1 After checking the spline shaft of rear axle shaft assemble the shaft into t...

Page 802: ...move the tire YAD3D160 YAD3D170 YAD3D180 YAD3D190 3 Remove the brake drum Notice Insert the bolt into the service hole while tightening the both side bolts uniformly remove the brake drum 4 Remove the fixing pin of parking brake 5 After detaching the cover of parking brake disconnect the cable 6 After pulling out the two plastic plug of axle shaft flange remove the fixing nuts of inner bracket ...

Page 803: ... yyyyyyy yyyyyyy yyyyyyy 7 Remove the axle shaft YAD3D200 YAD3D210 YAD3D230 YAD3D220 Tightening Torque 50 65 N m 37 48 lb ft Installation 1 Check the rear axle shaft 2 Insert the rear axle shaft into the axle housing and tighten the fixing nuts of axle shaft flange Installation Notice 3 Connect the brake cable and install the brake drum 4 Install the tire and test the braking force ...

Page 804: ...ixing nut of axle housing bracket YAD3D240 YAD3D250 YAD3D260 YAD3D270 3 Disconnect the brake oil hose oil line pipe 1 Brake pipe nut 2 Brake pipe mounting clip 3 3 way connector 4 Brake pipe assembly 4 Detach the air breather 5 Remove the propeller shaft from rear axle input shaft Notice Do alignment marks before removing ...

Page 805: ... After removing the parking brake lever pull out the cable YAD3D310 8 Remove the lower arm mounting nuts and remove the lower arm from the axle housing 9 Detach the lower mounting of shock absorber from the axle housing 10 Remove the upper arm mounting nuts and remove the upper arm from the axle housing ...

Page 806: ...12 Remove the lateral rod mounting nut and detach the lateral rod from the axle housing 13 Lowering the axle slowly remove the coil spring spring seat 14 Lower the axle housing by using the safety jack Installation 1 Placing the rear axle housing on the assembly position install both coil springs ...

Page 807: ...zer bar and upper lower arm in axle housing Installation Notice 5 Install the propeller shaft of rear axle side and tighten above the fixing bolts nuts Installation Notice 30 45 N m 22 33 lb ft 150 180 N m 150 180 N m Stabilizer bar cap bolt Upper arm nut Lower arm nut 6 Install the brake cable air bleeder hose oil pipe LCRV unit in rear axle assembly with assembled completely Installation Notice ...

Page 808: ...0 YAD3D430 Inspection 1 Check the shaft spline for the wear and damage YAD3D420 Specified value Within 1 0 mm 3 Measure the run out of shaft flange Specified value Within 0 13 mm 4 Install the axle shaft and measure the clearance of shaft direction Specified value Within 0 38 mm ...

Page 809: ...Housing 12 Oil Drain Plug 28 42 N m 13 Shim 14 Bearing 15 Drive Pinion 16 Bearing Cap 17 Bolt 87 124 N m 18 Bearing 19 Shim 20 Ring Gear 21 Shaft Lock Pin 22 Differential Case 23 Ring Gear Mounting Bolt 75 90 N m 24 Thrust Washer 25 Differential Pinion 26 Thrust Washer 27 Side Gear 28 Differential Shaft 29 Housing Cover 30 Bolt 38 46 N m 31 Oil Filler Plug 28 42 N m UNIT REPAIR AXLE ASSEMBLY YAD3D...

Page 810: ...que 28 42 N m 21 31 lb ft 2 Remove the axle housing cover Notice Clean the cover and housing contact surface 3 Remove the bearing cap bolts and remove the bearing cap 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 4 Disassemble the parts of differential carrier asse...

Page 811: ...SSANGYONG Y200 3D 20 REAR AXLE 5 Remove the drive pinion lock nut Disassemble the parts of drive pinion YAD3D490 ...

Page 812: ...d the drive pinion toward ring gear center line Excessive backlash Noise can be occurred Insufficient backlash Tooth can be damaged or broken under heavy load Excessive backlash Drive pinion shaft is apart from the ring gear Noise can be occurred Insufficient backlash Gear contacts on the low flank Gear can be damaged or worn Noise can be occurred Inspection of Ring GearTooth Contact Pattern 1 Nor...

Page 813: ...tial carrier for crack and wear bearing contact surface Check the gear case for crack YAD3D590 YAD3D600 YAD3D620 YAD3D610 2 Assemble the drive pinion assembly to the axle housing and then tighten the pinion lock nut Installation Notice Tightening torque 240 310 N m Tightening Torque 75 90 N m 55 66 lb ft 3 Assemble the differential carrier assembly Align the ring gear to the mark of differential c...

Page 814: ... the cap bolts Installation Notice Notice Be careful not to change the caps Be sure to keep the original position of the caps Tightening Torque 48 69 N m 35 51 lb ft 6 Measure the backlash of drive pinion and ring gear Specified value 0 13 0 20 mm 7 Install the axle housing cover Tighten the fixing bolts Installation Notice Tightening Torque 39 46 N m 29 34 lb ft ...

Page 815: ...es 4A 6 Brake Pedal 4A 7 Stoplamp Switch 4A 8 Brake Booster Functional Check 4A 9 LCRV Load Conscious Reducing Valve 4A 9 Component Locator 4A 11 Hydraulic Line 4A 11 Brake System W CBS 4A 12 Master Cylinder and Booster 4A 13 Repair Instructions 4A 14 On Vehicle Service 4A 14 Vacuum Hose 4A 14 Brake Oil Level Switch 4A 15 Brake Fluid Reservoir 4A 16 Master Cylinder 4A 17 Brake Booster 4A 19 Stopla...

Page 816: ...s Misalignment of the wheels particularly conditions of excessive camber and caster will cause the brakes to pull to one side HYDRAULIC BRAKE SYSTEM BRAKE PEDAL YAD4A010 This system uses the principle of the leverage and PASCAL s When you pushes the brake pedal the pressure by adapting the pedal increases through the power booster and delivers it into the master cylinder to generate hydraulic pres...

Page 817: ...ter pushrod 1 pushes the poppet 2 and valve plunger 3 and the poppet 2 goes closely to the power piston 5 resulting in closing the vacuum valve 9 The power cylinder A and B is isolated and the valve plunger 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 pres...

Page 818: ... Parking Brake Brake Fluid MANDO Brake KDAC Brake Disc Type Solid Disc Disc Type Rear Wheel Internal Expansion Mechanical DOT4 or DOT3 Type Tandem Type W Lever Sensor Type Vacuum Booster Type I D of Caliper Cylinder Ø 60 mm Ø 60 mm Thickness of Brake Pad 10 mm Thickness of Disc Plate 24 mm Shoe Type Leading End Trailing Type Leading End Trailing Type I D of Wheel Cylinder Ø 23 87 mm Ø 23 81 mm I D...

Page 819: ...Incorrectly Mounted Wheel Cylinder Faulty Auto Adjuster Dirty or Lack of Fluid Air in Brake System Faulty Brake Booster Poor Contact of Pad or Lining Oil or Grease on Pad Faulty Auto Adjuster Over Heated Rotor Due to Dragging Pad or Lining Clogging Brake Line Faulty Proportioning Valve Air in Brake System Fluid Leaking Excessive Clearance Between Push Rod and M Cylinder Parking Brake is not Fully ...

Page 820: ...n the bleeder screw after loosening the bleeder screw and draining the fluid Notice Hold the brake pedal until tightening the bleeder screw 6 Repeat the step 5 6 until all the air is removed 7 Check the leaks for the bleeder screw 8 Bleed air in the system at four wheels in order as shown in the figure if pressure building is not enough by depressing the pedal after above air bleeding Notice Alway...

Page 821: ... several times to build pressure and then keep the pedal fully depressed 3 Loosen the screw of primary and secondary pipe at the master cylinder outlets to bleed air 4 Repeat above step No 3 several times until there are no more air bubbles 5 Bleed air in the system at the hydraulic unit outlet pipe and wheel if pressure building is not enough by depressing the pedal only after above air bleeding ...

Page 822: ...edal height is not in the specified value loosen the lock nut and adjust the height Specification C 138 mm Pedal Free Play Notice If the pedal free play is not in the specified value loosen the stop bolt and the lock nut and adjust free play up to max travel Brake Pedal Free Play Push the brake pedal several times to discharge the vacuum of the power booster Measure the pedal movement until the ha...

Page 823: ...does not drop the vacuum system is probably defective and should be checked If no defect is revealed by checking the vacuum system the defect is in the booster itself LCRV LOAD CONSCIOUS REDUCING VALVE LCRV consists of sensing part and hydraulic control part 1 Sensing Part It detects the changes of vehicle height caused by vehicle load It consists of load sensing spring and control lever which cha...

Page 824: ...N m 10 13 lb ft Inspection When it occurs the malfunction in the LCRV the sensor spring valve body assembly rear axle or rear spring may be replaced For these replacement the following inspection should perform Symptom Poor Braking Performance Rear Wheels Lock Early Possible Cause Air in Brake System Poor Adjustment of Sensor Spring Damaged Sensor Spring Fluid Leaking from LCRV Poor Adjustment of ...

Page 825: ...ENT LOCATOR HYDRAULIC LINE YAD4A060 1 Brake Booster 2 Brake Reservoir and Master Cylinder 3 ABS Control Unit 4 Front Disc Brake and Caliper 5 Hydraulic Pressure Control Valve LCRV 6 3 way Connector 7 Rear Drum Disc and Wheel Cylinder Caliper ...

Page 826: ... Cylinder Assembly 8 Brake Oil Tank Assembly 9 Brake Oil Tank Cap 10 Brake Oil Tank 11 Grommet Seal 12 Master Cylinder 13 Brake Stoplamp Switch 14 Pedal Assembly 15 Pedal Bracket Assembly 16 Clutch Pedal Pad 17 Clutch Pedal 18 Brake Pedal Pad 19 Brake Pedal 20 Brake Pedal Spring 21 Rear Brake Hose 22 Clip 23 Front Brake Hose 24 Union Bolt 25 Plain Washer ...

Page 827: ...BRAKE SYSTEM 4A 13 SSANGYONG Y200 MASTER CYLINDER AND BOOSTER KDAC Delphi Korea YAD4A210 MANDO YAD4A220 ...

Page 828: ... YAD4A240 YAD4A250 REPAIR INSTRUCTIONS ON VEHICLE SERVICE VACUUM HOSE Removal Procedure 1 Disconnect the vacuum hose from the brake booster 2 Disconnect the vacuum hose from the vacuum pump 3 Remove the vacuum hose with the vacuum hose bracket ...

Page 829: ...m pump and the power booster Gasoline Engine Tightening Torque Bracket Mounting Bolt Union Bolt to Vacuum Pump 35 45 N m 26 33 lb ft 35 45 N m 26 33 lb ft Bracket Mounting Bolt Union Bolt to Vacuum Pump 35 45 N m 26 33 lb ft 35 45 N m 26 33 lb ft BRAKE OIL LEVEL SWITCH Removal Installation Procedure 1 Disconnect the brake fluid level switch connector 2 Disconnect the switch wiring connector 3 Disc...

Page 830: ... and drain the brake fluid completely 2 Remove the brake reservoir tank using the driver Notice Note that pulling the reservoir tank out excessively result in damage of the tank on removal 3 Remove the grommet from the master cylinder 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 install...

Page 831: ...ng the snap ring plier 2 Loosen the mounting nut of the master cylinder and remove the master cylinder from the power booster MASTER CYLINDER Removal Procedure 1 Disconnect the brake lines from the master cylinder Notice The brake fluid may damage paintwork if spillage onto paintwork wash with cold water immediately Remove the 1st piston and 2nd piston assembly from the master cylinder assembly ...

Page 832: ...ed oil of the assembly Install the 1st piston and 2nd piston assembly from the master cylinder assembly Installation Procedure 1 Install the retainer ring using the snap ring plier 2 Install the master cylinder into the booster Installation Notice Tightening Torque 8 12 N m 71 106 lb in 3 Install the master cylinder completely and then connect the brake pipe Installation Notice Tightening Torque 1...

Page 833: ...der assembly and pull out the cotter pin from the push rod of the brake booster 2 Remove the clevis pin Installation Procedure 1 Installation should follow the removal procedure in the reverse order 2 Bleed the brake system after the installation 4 Remove the brake booster from the vehicle 3 Remove the nuts mounting the booster ...

Page 834: ...y cable 2 Separate the stoplamp switch from the connector 3 Remove the stoplamp switch nut and disconnect the switch 4 Installation should follow the removal procedure in the reverse order Tightening Torque 21 35 N m 15 26 lb ft BRAKE PEDAL Removal Installation Procedure 1 Remove the bolts nuts mounting the brake pedal and disconnect the cotter pin ...

Page 835: ...rake pedal assembly 3 Installation should follow the removal procedure in the reverse order Tightening Torque 16 32 N m 12 24 lb ft BRAKE HOSE PIPE Removal Procedure 1 Remove the brake pipe Remove the pipe from the master cylinder For ABS ABD remove the brake pipe from the control unit ...

Page 836: ...e pipe nut Remove the E ring Disconnect the strut from the brake mounting Remove the union bolt from the caliper and remove the brake hose 3 Remove the rear brake hose Remove the brake pipe nut Remove the E ring 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 For drum type from the cylinder ...

Page 837: ...ear brake at LCRV side Tightening Torque at the caliper Tightening Torque at the wheel cylinder 15 18 N m 11 13 lb ft 15 19 N m 11 13 lb ft Installation Procedure 1 Install the rear brake hose and tighten the union bolts Tightening Torque 15 18 N m 11 13 lb ft 2 Install the front brake hose and tighten the union bolts ...

Page 838: ...he brake pipe retaining the LCRV 3 Remove the LCRV mounting bolt from the LCRV bracket and remove the LCRV YAD4A620 3 Install the brake pipe to the correct position 4 Bleed the brake system after replacement of the pipes hoses 3 way Connector LCRV System ABS ABD Control Unit Port M12 15 19 N m 11 14 lb ft 15 19 N m 11 14 lb ft 15 19 N m 11 14 lb ft 20 24 N m 15 18 lb ft ...

Page 839: ...4A660 Notice Bleed the brake system 4 Installation should follow the removal procedure in the reverse order Valve Body Mounting nut Bracket Mounting Bolt Stud Mounting Nut 14 18 N m 10 13 lb ft 10 13 N m 89 115 lb in 14 18 N m 10 13 lb ft ...

Page 840: ...nformation and Procedures 4B 3 Inspection 4B 4 Pad Thickness 4B 4 Brake Disc Thickness 4B 4 Brake Disc Run Out 4B 5 Caliper Housing I D 4B 5 Component Locator 4B 6 Cross SectionalView 4B 6 Front Caliper Brake 4B 7 Repair Instructions 4B 8 On Vehicle Service 4B 8 Front Brake 4B 8 Brake Pad Replacement 4B 10 Unit Repair 4B 13 Brake Caliper 4B 13 ...

Page 841: ...eased from the piston a restoring elastic force is generated at the seal and pushes the piston rightward and back it in original position As the pads wear away and the clearance between rotor and pads become larger the piston moves larger The seal then could change in shape further but since end of the seal is fixed into the groove in the cylinder the distortion is limited to the same amount as pr...

Page 842: ...tive Caliper Returning Pad Wear Pad Wear Hardening Damage On The Disc Interference Of The Dust Cover Loose Caliper Mounting Bolts Replace Replace and Repair Replace Replace Replace and Repair Replace Replace Replace Replace Replace Replace Repair Tighten Poor Braking Uneven Braking Dragging Brake Excessive Pedal Travel Noise and Vibration When Brake Applied DIAGNOSTIC INFORMATION AND PROCEDURES Co...

Page 843: ...n the guide pin Pad uneven wear and oil contamination Boot s damage and tear Disc plate s scratch and bending INSPECTION PAD THICKNESS 1 Remove the front wheel 2 Measure the thickness and replace as needed BRAKE DISC THICKNESS 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 br...

Page 844: ...ke disc side and measure the run out by rotating the disc 2 If lateral run out exceeds the specification replace the brake disc to prevent the pedal s vibration at braking Run Out Limit 0 03 mm Disc only 0 07 mm On vehicle Application Spec Ø 60 0 mm Ø 61 0 mm Non ABS ABS I D Wear Limit CALIPER HOUSING I D ...

Page 845: ... 4B 6 FRONT BRAKE YAD4B030 COMPONENT LOCATOR CROSS SECTIONAL VIEW 1 Brake Disc 2 Wheel Rim 3 Hub Range 4 Knuckle 5 Dust Shield 6 Vacuum Hose Nipple 7 Caliper 8 Brake Fluid Nipple 9 Caliper Guide Bolt 10 Caliper Bolt ...

Page 846: ...SSANGYONG Y200 YAD4B080 FRONT CALIPER BRAKE 1 Brake Caliper Assembly 2 Guide Rod Set 3 Brake Pad 4 Brake Pad Spring 5 Caliper Mounting Bolt 6 Piston Seal 7 Piston 8 Piston Boot 9 Caliper Guide Rod Bolt 10 Bleeder Screw ...

Page 847: ...KE Removal Procedure 1 Remove the front wheel and remove the brake hose from the brake caliper Notice Be carefully to prevent the brake fluid loss and contamination 2 Remove the cylinder mounting bolt and remove the disc pad and the cylinder 3 Remove the caliper mounting bolt and remove the caliper assembly ...

Page 848: ...disc Full time 4WD 5 Pull out the cotter pin from the front hub assembly and remove the lock nut Full time 4WD 6 Remove the hub assembly mounting bolt and remove the hub assembly Notice For part time 4WD remove the locking hub assembly and hub range before removing the brake disc ...

Page 849: ...REPLACEMENT 1 Remove lower mounting bolt of the brake caliper cylinder 2 Move the caliper cylinder assembly upward and fix it to prevent hose damage 3 Remove the brake pad and replace the new pad 4 Install the caliper cylinder assembly and fasten the lower bolt Full time Part time ...

Page 850: ...lock nut as specified torque full time 4WD YAD4B200 YAD4B210 YAD4B220 Install the front brake disc to the knuckle and install the locking hub hub range Fasten the mounting bolt part time 4WD 2 Install the caliper assembly to the front disc and fasten the caliper mounting bolt Installation Notice Tightening Torque 85 105 N m 63 79 lb ft ...

Page 851: ...2 FRONT BRAKE YAD4B230 3 Connect the brake hose to the caliper cylinder Installation Notice Tightening Torque 7 13 N m 62 115 lb in Notice The washer should be replaced new part 4 Bleed the brake system after replacement ...

Page 852: ...d bolt Separate the cylinder assembly and carrier 3 Disassemble the carrier Remove the pad Remove the spring Remove the guide rod and the boot 4 Remove the cylinder assembly Remove the bleeder plug Remove the bleeder plug cap Remove the piston boot YAD4B270 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 ...

Page 853: ...erse order Notice Clean all the parts in denatured alcohol or brake fluid Dry the parts with unlubricated compressed air and blow out all the passages in the housing and the bleeder valve Apply the brake fluid on the surface of the piston and cylinder 2 Fasten the guide rod bolt as specified torque Installation Notice Tightening Torque 7 13 N m 62 115 lb in Tightening Torque 22 32 N m 16 24 lb ft ...

Page 854: ...nformation and Procedures 4C 4 Inspection 4C 5 Drum Brake Type 4C 5 Disc Brake Type 4C 5 Cross Sectional View 4C 7 Drum Brake KDAC 4C 7 Disc Brake 4C 8 Component Locator 4C 9 Drum Brake 4C 9 Disc Brake 4C 10 Rerair Instructions 4C 11 On Vehicle Service 4C 11 Disc Brake Assembly 4C 11 Drum Brake Assembly 4C 16 Unit Repair 4C 21 Wheel Cylinder 4C 21 Parking Brake Lever 4C 22 ...

Page 855: ... the drum surface continues to keep high the friction coefficient goes down and the fade development occurs When the brake is applied often on the hill any accident may be occur YAD4C010 WHEEL CYLINDER Both wheel cylinder diameters are same in order to balance the friction forces of both shoes The hydraulic pressure from the master cylinder is provided to the wheel cylinder and the piston in the w...

Page 856: ...s moved by this reaction resulted in pushing the pad at the other side to compress to the disc Because the brake disc contacts atmospheric conditions and effect on good radiation the braking variation keeps uniform forces the uneven braking may not be generated on high speed driving YAD4C030 Application Delphi Korea Ø 42 mm 10 mm 10 4 mm Drum I D Shoe Type Lining Width x Length x Thickness Wheel C...

Page 857: ...arance Automatic Control System Lining Wear Hardening Foreign Material Inside Drum Loosen The Brake Plate Bolt Drum Deformation Or Surface Damage Lining Wear Hardening Oil Contamination On The Lining Inoperative Clearance Automatic Control System Replace Replace or Repair Replace Repair Adjust Replace or Repair Replace Repair Replace Replace Replace Repair Replace Clean Tighten Replace Replace Rep...

Page 858: ...e or defor mation 2 Measure the inside diameter Measure two more position Brake Lining 1 Inspect the surface hardening or excessive wear of the lining Inspect the lining for stain with oil 2 Measure the lining thickness Wear Limit 1 mm If the measured value is below the limit value replace the brake lining DISC BRAKE TYPE Pad Thickness 1 Remove the front wheel 2 If the measured value is below the ...

Page 859: ...C100 Brake Disc Thickness 1 Measure the thickness of the rotor at four or more points around the circumference of the disc 2 If the thickness of the brake disc is below the specified value replace the brake disc Disc Thickness Limit 8 5 mm Brake Disc Run Out 1 Set a dial indicator to the brake disc side and measure the run out by rotating the disc On Vehicle Disc only Run Out Limit ...

Page 860: ...e 2 Wheel Cylinder 3 Brake Shoe Lining 4 Brake Shoe 5 Lower Return Spring Lower Shoe Spring 6 Retainer Spring Pin 7 Compression Spring 8 Retainer Spring Plate 9 Adjuster Assembly 10 Adjuster Lever 11 Return Spring Adjuster 13 Upper Return Spring Upper Shoe Spring 14 Bolt 15 Air Bleeder Nipple ...

Page 861: ...SSANGYONG Y200 4C 8 REAR BRAKE YAD4C050 DISC BRAKE 1 Backing Plate 2 Parking Cable 3 Parking Cable Lever 4 Caliper Assembly 5 Disc 6 Wheel 7 Air Bleeder Nipple 9 Shaft Assembly ...

Page 862: ...y 4 Rear Brake Plate 5 Wheel Cylinder 6 Strut Assembly Clearance Automatic Control System 7 Brake Leading Shoe 8 Middle Return Spring 9 Upper Return Spring 10 Brake Shoe Retaining Spring Pin 11 Trailing Shoe 12 Brake Shoe Retaining Spring 13 Brake Shoe Retaining Spring Cap 14 Lower Return Spring 15 Hub Bolt 16 Rear Brake Drum ...

Page 863: ...ONG Y200 4C 10 REAR BRAKE YAD4C110 DISC BRAKE 1 Rear brake disc assembly 2 Brake pad 3 Brake caliper 4 Gasket Replace 5 Bolt 20 N m 15 lb ft 6 Gasket Replace 7 Brake hose 8 Gasket Replace 9 Hose bolt 8 18 N m ...

Page 864: ...nd and fix the vehicle not to move it Release the parking brake Position the transmission in NEUTRAL 2 Remove the brake hose from the rear brake caliper Notice Be carefully to prevent the brake fluid loss and contamination 3 Remove the caliper cylinder mounting bolt and remove the disc pad and the cylinder YAD4C120 YAD4C130 YAD4C140 RERAIR INSTRUCTIONS ...

Page 865: ... cable from the parking brake lever 6 Remove the brake disc 7 Using the rubber hammer hit to separate the parking brake lining lightly and move the lining upward YAD4C160 YAD4C170 YAD4C180 4 Remove the caliper mounting bolt and remove the caliper assembly YAD4C150 ...

Page 866: ...nspect the brake pad thickness Pad Thickness 10 mm Max wear Limit 2 mm Notice If the thickness of both pads is not same replace both pads at the same time 3 Inspect the disc thickness Pad Thickness 10 4 mm Max wear Limit 8 5 mm 4 Inspect the disc plate s scratch and deformation Brake Pad 1 Remove the cylinder mounting bolt lower at the brake caliper 2 Raise and fix the caliper assembly at the prop...

Page 867: ...rake lining between the backing plate and the flange Installation Notice Tightening Torque 4 8 N m 35 71 lb in Notice Apply a certain amount of grease on the parking brake lining surface 2 Install the brake disc and connect the parking brake cable to the lever YAD4C230 YAD4C240 YAD4C250 3 Remove the brake pad and replace the new pad YAD4C220 ...

Page 868: ...allation Notice Tightening Torque 4 8 N m 35 71 lb in 4 Install the brake hose Notice The washer should be replaced new part 5 Tighten the air bleeder screw Installation Notice Tightening Torque 7 13 N m 62 115 lb in 6 Bleed the brake system after replacement YAD4C260 YAD4C270 ...

Page 869: ...le on the flat ground and fix the vehicle not to move it Position the transmission in NEUTRAL 2 Disconnect the brake pipe from the rear brake Notice Be carefully to prevent the brake fluid loss and contamination 3 Insert the bolt M8 to the service hole of the brake drum and remove the brake drum 4 Remove the service hole plug of the axle shaft YAD4C120 YAD4C290 YAD4C300 YAD4C310 ...

Page 870: ...e lower return spring 3 Disconnect the lever spring 4 Disconnect the adjuster lever from the adjuster 6 Rotate the lining shoe hold down washer in the plug hole of the axle shaft flange and disconnect the pin and the spring 7 Disconnect the parking cable from the parking lever YAD4C320 YAD4C330 YAD4C340 YAD4C350 ...

Page 871: ...rake drum and replace as needed I D Ø 254 mm Wear Limit Ø 255 5 mm Notice Measure two more position 2 Inspect the surface between the lining and brake 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 YAD4C360 YAD4C370 YAD4C380 YAD4C...

Page 872: ...htening Torque 8 12 N m 71 106 lb in 2 Install both brake linings between the wheel cylinder and the bottom anchor plate And then install adjuster and each return spring 3 Connect the parking cable 4 The outside diameter of the lining set to Ø 253 08 Ø 253 50 mm by rotating the adjuster screw YAD4C400 YAD4C410 YAD4C420 YAD4C430 ...

Page 873: ... that the brake drum is rotated properly by hand Notice Adjust the adjuster screw as needed 7 Connect the brake pipe to the wheel cylinder Installation Notice Tightening Torque 15 19 N m 11 14 lb ft 8 Bleed the brake system and verify the parking brake operation Install the tire YAD4C440 YAD4C450 ...

Page 874: ...e it 3 Remove the spring assembly 4 Remove the bleeder screw 5 3 Clean all the parts with the denatured alcohol Dry the parts with unlubricated compressed air Bleeder Screw 7 10 N m 62 89 lb in 8 12 N m 71 106 lb in Wheel Cylinder Mounting Bolt Notice Lubricate the new seals the piston the piston cup and the wheel cylinder bore with clean brake fluid before assembly 4 Installation should follow th...

Page 875: ... arrow and Disconnect the the parking brake lever and the adjuster lever 3 Installation should follow the removal procedure in the reverse order YAD4C500 PARKING BRAKE LEVER 1 Disconnect the parking brake lever and the adjuster lever from the lining YAD4C490 ...

Page 876: ...ake 4D 2 Parking Brake Switch and Indicator 4D 2 Braking Inspection 4D 2 Specifications 4D 3 Diagnostic Information and Procedure 4D 4 Component Locator 4D 5 Cross Sectional View 4D 5 Parking Brake Lever and Cable 4D 6 Repair Instructions 4D 7 On Vehicle Service 4D 7 Parking Brake 4D 7 ...

Page 877: ...r is pulled out with the ignition ON the parking brake indicator turns on via lever switch YAD4D010 BRAKING INSPECTION Inspect the parking brake as following 1 Count the number of the notch sounds on pulling out the parking brake at 19kg force Specified Notch 5 4 If the braking force is not operated properly check the parking brake lever and cable and replace them as needed 2 If the notch number i...

Page 878: ...PARKING BRAKE 4D 3 SSANGYONG Y200 Type Operation Mechanical Rear Wheel Drive Internal Expanded Manual Parking Brake SPECIFICATIONS Application Spec ...

Page 879: ...er Contamination On The Lining Brake Cable Sticked Or Damage Excessive Pedal Travel Inoperative Clearance Automatic Control System Replace Replace Or Repair Replace Notch Adjustment Repair Poor Braking DIAGNOSTIC INFORMATION AND PROCEDURE Symptom Possible Cause Action ...

Page 880: ...G Y200 COMPONENT LOCATOR CROSS SECTIONAL VIEW YAD4D020 1 Parking Brake Lever 2 Parking Brake Cable Bracket Rear 3 Parking Brake Cable Bracket Front 4 Parking Brake Cable Bracket Center 5 Cable 6 With Drum Brake 7 With Disc Brake ...

Page 881: ...E LEVER AND CABLE YAD4D050 1 Parking Brake Lever 2 Parking Brake Warning Lamp Switch 3 Bolt 4 Bolt 5 Front Parking Brake Cable 6 Equalizer 7 Nut 8 Bolt 9 Rear Parking Brake Cable 10 Brake Disc Rear Disc Brake Type 11 Brake Drum Rear Drum Brake Type ...

Page 882: ...CTIONS ON VEHICLE SERVICE PARKING BRAKE Removal Procedure 1 Remove the console assembly 2 Disconnect the parking brake warning lamp connector 3 Disconnect the cable from the parking brake lever with parking brake released YAD4D060 YAD4D070 YAD4D080 ...

Page 883: ...6 Disconnect the parking brake cable from the rear brake DiscType Disconnect the cable from the parking brake lever Remove the clip from the brake plate 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 YAD4D090 YAD4D100 YAD4D110 YAD4D120 ...

Page 884: ...cable to the body 3 Install the parking brake lever assembly Installation Notice 4 Insert the parking brake cable to the lever hole and install the cable plate Installation Notice 5 Install the parking brake switch and check the warning lamp and brake operation Tightening Torque 22 N m 16 lb ft Tightening Torque 6 N m 53 lb in YAD4D130 YAD4D140 YAD4D150 YAD4D160 ...

Page 885: ...YONG Y200 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 ...

Page 886: ... Right Rear Wheel Speed Sensor Fault 4E 52 DTC Right Rear Wheel Speed Sensor Continuity Fault 4E 54 DTC 245 Wheel Speed Sensor Frequency Error 4E 56 DTC 930 Acceleration Sensor Fault 4E 60 DTC Acceleration Sensor Continuity Fault 4E 62 DTC 060 065 Left Front Inlet and Outlet Valve Solenoid Fault 4E 64 DTC 070 075 Right Front Inlet and Outlet Valve Solenoid Fault 4E 66 DTC 080 085 Left Rear Inlet a...

Page 887: ...of Circuit Testing Tools You should know how to use a test light and how to bypass components to test circuits using fused jumper wires You should be familiar with a digital multimeter You should be able to measure voltage resistance and current and be familiar with the controls and how to use them correctly Basic Hydraulic System Each solenoid valve consists of one inlet valve and one outlet valv...

Page 888: ...ng Lamp Ignition ON ABS Operation TCS Operation TCS Passive Due to Temperature Model 2 second on for lamp check OFF OFF ON OFF TCS Info Lamp 2 second on for lamp check OFF Blinking FLASHING OFF ON EBD Warning Lamp 2 second on for lamp check EBD operation OFF OFF ON OFF The temperature of the brakes is calculated by a mathematical model and TCS is switched passive if the calculated temperature is g...

Page 889: ...valve and outlet valve according to the following table YAD4E020 Control Algorithm The input signals for the control algorithm are the filtered wheel speed signals from the ABS speed processing With the speed difference of the driven wheels the control deviation is calculated If the control deviation exceeds a certain threshold value the wheel with the greater slip is braked actively The threshold...

Page 890: ...ny variables in algorithm a pressure hold increase and or decrease pulsetrain may be triggered at the rear wheels insuring vehicle stability Vehicle approaches the ideal brake force distribution front to rear Constant brake force distribution during vehicle lifetime EBD function is monitored via ABS safety logic conventional proportioning valves are not monitorable Keep alive function Service Prec...

Page 891: ...SSANGYONG Y200 4E 6 ABS AND TCS Electronic Brake Force Distribution EBD Failure Matrix YAD4E040 ...

Page 892: ...ressure is applied through the brake pedal and fluid comes from the master cylinder into the hydraulic unit The normally open isolation cartridge and normally closed dump cartridge would remain in these positions to allow fluid pressure to the calipers and the wheel cylinders And each wheel begins locking YAD4E050 ...

Page 893: ...SSANGYONG Y200 4E 8 ABS AND TCS Electronic Brake Force Distribution EBD Failure Matrix For Malfunction YAD4E060 ...

Page 894: ... increasing speed The sensor is not repairable nor is the air gap adjustable Front Wheel Speed Sensor Rings The toothed ring mentioned above is pressed onto the wheel side outer constant velocity joint Each ring contains 52 equally spaced teeth Exercise care during service procedures to avoid prying or contacting this ring Excessive contact may cause damage to one or more teeth If the ring is dama...

Page 895: ...D TCS 1 Master Cylinder 2 Hydraulic Modulator 3 Damper 4 Pump 5 Pump Motor HYDRAULIC CIRCUIT ABS 5 3 Pressure Increase YAD4E070 6 Accumulator 7 Inlet Valve for each wheel 8 Outlet Valve for each wheel 9 Front Wheel 10 Rear Wheel ...

Page 896: ...4E 11 SSANGYONG Y200 Pressure Hold 1 Master Cylinder 2 Hydraulic Modulator 3 Damper 4 Pump 5 Pump Motor YAD4E080 6 Accumulator 7 Inlet Valve for each wheel 8 Outlet Valve for each wheel 9 Front Wheel 10 Rear Wheel ...

Page 897: ... 4E 12 ABS AND TCS Pressure Decrease 1 Master Cylinder 2 Hydraulic Modulator 3 Damper 4 Pump 5 Pump Motor YAD4E090 6 Accumulator 7 Inlet Valve for each wheel 8 Outlet Valve for each wheel 9 Front Wheel 10 Rear Wheel ...

Page 898: ...r 2 Hydraulic Modulator 3 Damper 4 Pump 5 Pump Motor 6 Accumulator 7 Inlet Valve for each wheel ABS TCS 5 3 Pressure Increase YAD4E100 8 Outlet Valve for each wheel 9 Wheel 10 Prime Valve 11 Pilot Valve 12 Check Valve 13 ISD Integrated Suction Damper ...

Page 899: ... Cylinder 2 Hydraulic Modulator 3 Damper 4 Pump 5 Pump Motor 6 Accumulator 7 Inlet Valve for each wheel Pressure Hold YAD4E110 8 Outlet Valve for each wheel 9 Wheel 10 Prime Valve 11 Pilot Valve 12 Check Valve 13 ISD Integrated Suction Damper ...

Page 900: ...ecrease 1 Master Cylinder 2 Hydraulic Modulator 3 Damper 4 Pump 5 Pump Motor 6 Accumulator 7 Inlet Valve for each wheel YAD4E120 8 Outlet Valve for each wheel 9 Wheel 10 Prime Valve 11 Pilot Valve 12 Check Valve 13 ISD Integrated Suction Damper ...

Page 901: ...00 4E 16 ABS AND TCS 2 5 4 3 1 COMPONENT LOCATOR ABS ABS TCS 5 3 1 ABS TCS Hydraulic Unit and Control Unit 2 Rear Wheel Speed Sensor 3 ABS Warning Indicator YAD4E130 4 Diagnosis connector 5 Front Wheel Speed Sensor ...

Page 902: ...following steps in order when servicing the ABS TCS system Failure to do so may result in the loss of important diagnostic data and may lead to difficulties and time consuming diagnosis procedures 1 Perform the tests of the table below 2 Perform a road test if directed by the table Test drive the vehicle while using the snapshot feature of the scan tool Perform normal acceleration stopping and tur...

Page 903: ...gnition to LOCK 2 Use a DVM to measure the resistance from the EBCM harness connector terminals 16 and 19 to ground Is the resistance equal to the specified value Repair the open in the circuit that failed Is the repair complete Use a DVM to measure the resistance between terminal 11 of the EBCM harness connector and terminal 8 of the data link connector DLC Is the resistance below the specified v...

Page 904: ...out indicator lamp or a contact problem in a connector Cause A fuse has blown The indicator lamp has burned out There is a corroded or broken connector terminal There is a faulty ground connection There is a broken wire in a wring harness The EBCM is faulty Test Description The number s below refer to step s on the diagnostic table 1 This test checks for any DTCs that may cause the ABS indicator l...

Page 905: ...e from the negative battery terminal 3 Measure the resistance between the negative battery wire which is attached to ground and the shorting bar in the EBCM connector Is the resistance equal to the specified valve Repair the open or high resistance in the circuit from EBCM connector terminal 16 to ground G106 Is the repair complete 1 Remove the I P cluster 2 Remove and check the ABS indicator bulb...

Page 906: ...ignition to LOCK 2 Check fuse F2 in the I P fuse block Is fuse F2 blown Replace fuse F2 Is the repair complete 1 Turn the ignition on 2 Check the voltage at Fuse 2 Is the voltage equal to the specified value Repair the power supply to Fuse 2 Is the repair complete 1 Remove the instrument cluster 2 Check the circuit from fuse F2 to terminal B15 of the I P cluster connector 3 Repair any open or high...

Page 907: ...connector Cause A fuse has blown The indicator lamp has burned out There is a corroded or broken connector terminal There is a faulty ground connection There is a broken wire in a wiring harness The EBCM is faulty Test description The number s below refer to step s on the diagnostic table 1 This test checks for any DTCs that may cause the TCS indicator lamp to be inoperative 2 This test verifies a...

Page 908: ...wire from the negative battery terminal 3 Measure the resistance between the negative battery wire which is attached to ground and the shorting bar in the EBCM connector Is the resistance equal to the specified value Repair the open or high resistance in the circuit from EBCM connector terminal 16 19 to ground G106 Is the repair complete 1 Remove the I P cluster 2 Remove and check the TCS indicato...

Page 909: ...2 Check fuse F2 in the I P fuse block Is fuse F2 blown Replace fuse F2 Is the repair complete 1 Turn the ignition ON 2 Check the voltage at fuse F2 Is the voltage equal to the specifies value Repair the power supply to fuse F2 Is the repair complete 1 Remove the I P cluster 2 Check circuit from fuse F2 to terminal 15 of the I P cluster connector 3 Repair any open or high resistance found in a wiri...

Page 910: ...lem in a connector Cause A fuse has blown The indicator lamp has burned out There is a corroded or broken connector terminal There is a faulty ground connection There is a broken wire in a wiring harness The EBCM is faulty Test Description The number s below refer to step s on the diagnostic table 1 This test checks for any DTCs that may cause the EBD indicator lamp to be inoperative 2 This test v...

Page 911: ...re from the negative battery terminal 3 Measure the resistance between the negative battery wire which is attached to ground and the shorting bar in the EBCM connector Is the resistance equal to the specified value Repair the open or high resistance in the circuit from EBCM connector terminal 16 19 to ground G106 Is the repair complete 1 Remove the I P cluster 2 Remove and check the EBD indicator ...

Page 912: ...fuse F2 in the I P fuse block Is fuse F2 blown Replace fuse F2 Is the repair complete 1 Turn the ignition ON 2 Check the voltage at fuse F2 Is the voltage equal to the specifies value Repair the power supply to fuse F2 Is the repair complete 1 Remove the I P cluster 2 Check circuit from fuse F2 to terminal 15 of the I P cluster connector 3 Repair any open or high resistance found in a wiring harne...

Page 913: ...s a defective ground connection A wire is broken or shorted A fuse is blown The ignition switch is malfunctioning Action Taken When the DTC Sets ABS action is disabled during the period of low voltage and the ABS warning lamp is ON for the remainder of the ignition cycle Test Description The number s below refer to step s on the diagnostic table 1 This step determines whether there is voltage at t...

Page 914: ...2 2 Turn the ignition to ON Does the fuse blow again Check the ABS function Is the repair complete 1 Turn the ignition to OFF 2 Remove fuse F2 3 Disconnect the ABS connector from the EBCM 4 Measure the resistance between ground and terminal 20 Is the resistance equal to the specified value Repair the short to ground in circuit fuse F2 of the I P fuse block and terminal 20 of the ABS harness EBCM c...

Page 915: ...e 1 Turn the ignition to OFF 2 Check the resistance between ground and terminals 16 of the EBCM connector Is the resistance equal to the specified value Examine terminals 15 20 16 of the EBCM connector Is there a defective terminal Repair the defective terminal or replace the connector or wiring harness as required Is the repair complete Replace the ABS unit Is the repair complete Repair the defec...

Page 916: ...he ignition in ON or START The warning lamp should be activated only by the ABS control module internally supplying ground to terminal 20 Diagnosis This procedure checks for a short to ground in the wiring or a defective electronic brake control module EBCM Cause There is a short to ground in the circuit between the cluster terminal D7 and the EBCM terminal 31 The EBCM is faulty ...

Page 917: ...e shorting bar in the connector away from terminal 20 Does the ABS indicator lamp go out Replace the ABS unit Is the repair complete Repair the short to ground in circuit Lg between I P cluster connector B7 and terminal 20 EBCM Is the repair complete ABS Indicator Lamp Illuminated Continuously No DTCs Stored Step 1 Action Yes No Value 2 3 Go to Step 4 Go to Step 5 4 5 System OK System OK Go to Ste...

Page 918: ... operation and the absence of DTCs when the clearing procedure is completed The EBCM will not permit DTC clearing until all DTCs have been displayed Also ETC s cannot be cleared by disconnecting the EBCM disconnecting the battery cables or turning the ignition switch to LOCK Scan Tool Method The scan tool can clear ABS TCS system DTCs using the mess storage cartridge 1 Install the scan tool and th...

Page 919: ...ic table 1 This step begins an examination for a defective wheel speed sensor 6 This step tests the wiring for a short to voltage 8 This step tests the wiring for a short to ground 10 This step tests for an open or a high resistance in the wiring Diagnostic Aids Be sure that the speed sensor wiring is properly routed and retained This will help to prevent false signals due to the pickup of electri...

Page 920: ...plete 1 Disconnect the harness from the EBCM 2 Connect a DVM between ground and one terminal of the wheel speed connector 3 Turn the ignition to ON 4 Repeat the above test for the other terminal of the wheel speed connector Is the voltage for either of these terminals within the specified value Repair the short to voltage in the affected circuit Is the repair complete 1 Turn the ignition to LOCK 2...

Page 921: ...e There is a problem in the wiring There is a problem with a connector Action Taken When the DTC Sets ABS action is disabled and the ABS warning lamp is ON Test Description The number s below refer to step s on the diagnostic table 1 This step begins an examination for a defective wheel speed sensor 4 This step tests the wiring for a short to voltage 6 This step tests the wiring for a short to gro...

Page 922: ...nce to ground from terminal 6 at the harness EBCM connector 3 Measure the resistance to ground from terminal 7 at the harness EBCM connector Is the resistance at either circuit less than the specified value Repair the short to ground in the affected circuit Is the repair complete 1 Measure the resistance between terminal 6 at the harness EBCM connector and the harness wheel speed sensor connector ...

Page 923: ...ic table 1 This step begins an examination for a defective wheel speed sensor 6 This step tests the wiring for a short to voltage 8 This step tests the wiring for a short to ground 10 This step tests for an open or a high resistance in the wiring Diagnostic Aids Be sure that the speed sensor wiring is properly routed and retained This will help to prevent false signals due to the pickup of electri...

Page 924: ...Repair the short to voltage in the affected circuit Is the repair complete 1 Turn the ignition to LOCK 2 Measure the resistance to ground from terminal 4 at the harness EBCM connector 3 Measure the resistance to ground from terminal 5 at the harness EBCM connector Is the resistance at either circuit less than the specified value Repair the short to ground in the affected circuit Is the repair comp...

Page 925: ...ve There is a problem in the wiring There is a problem with a connector Action Taken When the DTC Sets ABS action is disabled and the ABS warning lamp is ON Test Description The number s below refer to step s on the diagnostic table 1 This step begins an examination for a defective wheel speed sensor 4 This step tests the wiring for a short to voltage 6 This step tests the wiring for a short to gr...

Page 926: ... Turn the ignition go LOCK 2 Measure the resistance to ground from terminal 4 at the harness EBCM connector 3 Measure the resistance to ground from terminal 5 at the harness EBCM connector Is the resistance at either circuit less than the specified value 1 Measure the resistance between terminal 4 at the harness EBCM connector and the harness wheel speed sensor connector 2 Measure the resistance b...

Page 927: ...agnostic table 1 This step begins an examination for a defective wheel speed sensor 4 This step tests the wiring for a short to voltage 6 This step tests the wiring for a short to ground 8 This step tests for an open or a high resistance in the wiring Diagnostic Aids Be sure that the speed sensor wiring is properly routed and retained This will help to prevent false signals due to the pickup of el...

Page 928: ...e Repair the short to voltage in the affected circuit Is the repair complete 1 Turn the ignition to LOCK 2 Measure the resistance to ground from terminal 8 at the harness EBCM connector 3 Measure the resistance to ground from terminal 9 at the harness EBCM connector Is the resistance at either circuit less than the speci fied value Repair the short to ground in the affected circuit Is the repair c...

Page 929: ...There is a problem in the wiring There is a problem with a connector Action Taken When the DTC Sets ABS action is disabled and the ABS warning lamp is ON Test Description The number s below refer to step s on the diagnostic table 1 This step begins an examination for a defective wheel speed sensor 4 This step tests the wiring for a short to voltage 6 This step tests the wiring for a short to groun...

Page 930: ... Turn the ignition go LOCK 2 Measure the resistance to ground from terminal 8 at the harness EBCM connector 3 Measure the resistance to ground from terminal 9 at the harness EBCM connector Is the resistance at either circuit less than the specified value 1 Measure the resistance between terminal 8 at the harness EBCM connector and the harness wheel speed sensor connector 2 Measure the resistance b...

Page 931: ...stic table 1 This step begins an examination for a defective wheel speed sensor 6 This step tests the wiring for a short to voltage 8 This step tests the wiring for a short to ground 10 This step tests for an open or a high resistance in the wiring Diagnostic Aids Be sure that the speed sensor wiring is properly routed and retained This will help to prevent false signals due to the pickup of elect...

Page 932: ... value Repair the short to voltage in the affected circuit Is the repair complete 1 Turn the ignition to LOCK 2 Measure the resistance to ground from terminal 1 at the harness EBCM connector 3 Measure the resistance to ground from terminal 2 at the harness EBCM connector Is the resistance at either circuit less than the specified value Repair the short to ground in the affected circuit Is the repa...

Page 933: ...nnected There is a problem in the wiring There is a problem with a connector Action Taken When the DTC Sets ABS action is disabled and the ABS warning lamp is ON Test Description The number s below refer to step s on the diagnostic table 1 This step begins an examination for a defective wheel speed sensor 6 This step tests the wiring for a short to voltage 8 This step tests the wiring for a short ...

Page 934: ...e 1 Turn the ignition go LOCK 2 Measure the resistance to ground from terminal 1 at the harness EBCM connector 3 Measure the resistance to ground from terminal 2 at the harness EBCM connector Is the resistance at either circuit less than the specified value 1 Measure the resistance between terminal 1 at the harness EBCM connector and the harness wheel speed sensor connector 2 Measure the resistanc...

Page 935: ...eth on the toothed wheel Damaged or broken teeth on the toothed wheel Open or short in speed wheel speed sensor wiring Action Taken When the DTC Sets Antilock brake system ABS action is disabled and the ABS warning lamp is ON Test Description The number s below refer to Step s on the diagnostic table 1 This step begins the examination of the front wheel speed sensor sensors 3 This step checks for ...

Page 936: ... incorrect outer CV joint with the proper unit Is the repair complete 1 Disconnect the wheel speed sensor harnesses from the wheel speed sensor connectors 2 Measure the wheel speed sensor resistance at the wheel speed sensor connector terminals Does the resistance fall within the specified values for both wheel speed sensors Replace the faulty wheel speed sensor Is the repair complete 1 Disconnect...

Page 937: ... for both wheel speed sensors Replace the faulty wheel speed sensor Is the repair complete 1 The ABS control module connector should still be disconnected Disconnect it now if it is not 2 Check each wheel speed sensor harness for a short circuit between its wires with a digital ohmmeter attached to the two terminals at the harness side of the wheel speed sensor connector 3 Also check each wheel sp...

Page 938: ...ystem OK System OK Step Repair the discontinuity found in the rear wheel speed sensor harness Is the repair complete Replace the ABS unit Is the repair complete DTC 245 Wheel Speed Sensro Frequency Error Cont d Action Yes No Value 19 20 ...

Page 939: ...iring There is a problem with a connector Wrong installed vertical acceleration sensor Fail Action ABS action is disabled and the ABS warning lamp is ON Test Description The number s below refer to step s on the diagnostic table 2 This step checks for the voltage reference from the EBCM 5 This step checks for the voltage signal from the acceleration sensor Diagnostic Aids Be sure that the accelera...

Page 940: ...e repair complete 1 Place the acceleration sensor horizontally and let the acceleration sensor 2 Turn the ignition switch to ON 3 Use a digital voltmeter DVM to measure the voltage between terminal 28 and 10 of EBCM Is the voltage within the specified value Repair the open in the affected circuit or replace the acceleration sensor if necessary Is the repair complete Replace the ABS unit Is the rep...

Page 941: ...There is a problem with a connector Wrong installed vertical acceleration sensor Action Taken When the DTC Sets ABS action is disabled and the ABS warning lamp is ON Test Description The number s below refer to step s on the diagnostic table 2 This step checks for the voltage reference from the EBCM 5 This step checks for the voltage signal from the acceleration sensor Diagnostic Aids Be sure that...

Page 942: ...pair complete 1 Place the acceleration sensor horizontally and let the acceleration sensor 2 Turn the ignition switch to ON 3 Use a digital voltmeter DVM to measure the voltage between terminal 28 and 10 of EBCM Is the voltage within the specified value Repair the open in the affected circuit or replace the acceleration sensor if necessary Is the repair complete Replace the ABS unit Is the repair ...

Page 943: ...nosis This procedure checks whether the left front inlet and outlet valves are functioning Cause A valve has failed A solenoid coil is open or shorted Action Taken When the DTC Sets ABS is disabled and the ABS warning lamp is turned ON for the remainder of the ignition cycle If the failure is intermittent the EBCM will enable the system at the next ignition cycle and set a history DTC Test Descrip...

Page 944: ... an assistant attempt to rotate the wheel again Can the wheel be rotated now 1 Maintain pressure on the brake pedal 2 When the scan tool indicates Pressure release on have an assistant attempt to rotate the wheel again Can the wheel be rotated 1 Release brake pedal pressure when the scan tool indicates Pressure release off 2 Clear all DTCs 3 Road test the vehicle Does the DTC set again 1 Check the...

Page 945: ... each coil Diagnosis This procedure checks whether the right front inlet and outlet valves are functioning Cause A solenoid coil is open or shorted Action Taken When the DTC Sets ABS is disabled and the ABS warning lamp is turned ON for the remainder of the ignition cycle If the failure is intermittent the EBCM will enable the system at the next ignition cycle and set a history DTC Test Descriptio...

Page 946: ...e have an assistant attempt to rotate the wheel again Can the wheel be rotated now 1 Maintain pressure on the brake pedal 2 When the scan tool indicates Pressure release on have an assistant attempt to rotate the wheel again Can the wheel be rotated 1 Release brake pedal pressure when the scan tool indicates Pressure release off 2 Clear all DTCs 3 Road test the vehicle Does the DTC set again 1 Che...

Page 947: ... This procedure checks whether the left rear inlet and outlet valves are functioning Cause s A valve has failed A solenoid coil is open or shorted Action Taken When the DTC Sets ABS is disabled and the ABS warning lamp is turned ON for the remainder of the ignition cycle If the failure is intermittent the EBCM will enable the system at the next ignition cycle and set a history DTC Test Description...

Page 948: ... attempt to rotate the wheel again Can the wheel be rotated now 1 Maintain pressure on the brake pedal 2 When the scan tool indicates Pressure release on have an assistant attempt to rotate the wheel again Can the wheel be rotated 1 Release brake pedal pressure when the scan tool indicates Pressure release off 2 Clear all DTCs 3 Road test the vehicle Does the DTC set again 1 Check the wiring harne...

Page 949: ... This procedure checks whether the right rear inlet and outlet valves are functioning Cause s A valve has failed A solenoid coil is open or shorted Action Taken When the DTC Sets ABS is disabled and the ABS warning lamp is turned ON for the remainder of the ignition cycle If the failure is intermittent the EBCM will enable the system at the next ignition cycle and set a history DTC Test Descriptio...

Page 950: ...attempt to rotate the wheel again Can the wheel be rotated now 1 Maintain pressure on the brake pedal 2 When the scan tool indicates Pressure release on have an assistant attempt to rotate the wheel again Can the wheel be rotated 1 Release brake pedal pressure when the scan tool indicates Pressure release off 2 Clear all DTCs 3 Road test the vehicle Does the DTC set again 1 Check the wiring harnes...

Page 951: ...tched ground is provided by the electronic brake control module EBCM to each coil Diagnosis This procedure checks whether the left rear TCS valves are functioning Cause s A solenoid coil is open or shorted Action Taken When the DTC Sets Antilock brake system ABS is disabled and the ABS warning lamp is turned ON for the remainder of the ignition cycle If the failure is intermittent the EBCM will en...

Page 952: ... tool indicates that the prime valve was turned OFF attempt to rotate the wheel again Can the wheel be rotated now When the scan tool indicates that the pilot valve and the pump motor were switched OFF attempt to rotate the wheel again Can the wheel be rotated 1 Clear all DTCs 2 Road test the vehicle Does the DTC set again 1 Check the wiring harness and connector terminals for an intermittent prob...

Page 953: ...uring the self test Diagnosis This procedure checks whether there is a poor ground connection for the electronic brake control module EBCM Cause s A connector terminal is corroded The wiring harness is damaged The ground terminal is not conducting properly The valve relay is defective The EBCM is defective Action Taken When the DTC Sets ABS TCS is disabled and the ABS warning lamp is turned ON for...

Page 954: ...rt circuit and repair it if necessary 2 Replace fuse SB2 Is the repair complete 1 Disconnect the valve relay 2 Check the voltage between the valve relay connec tor terminal 15 and ground of EBCM Is the voltage equal to the specified valve Repair the open circuit between the valve relay connector terminal 15 and terminal SB2 of EBCM Is the repair complete Replace the hydraulic modulator Is the repa...

Page 955: ...al in the pump motor connector There is faulty terminal in EBCM connector There is high resistance in the chassis ground The EBCM defective There is a problem in the wiring from the pump motor connector to the motor Action Taken When the DTC Sets ABS is disabled and the ABS warning lamp is ON Test Description The number s below refer to step s on the diagnostic table 2 This step checks for poor co...

Page 956: ...e resistance equal to the specified value Repair the open circuit between the motor relay connector terminal 17 and fuse SB2 of EBCM Is the repair complete 1 Turn the ignition to ON 2 Check the voltage between the motor relay connector terminal 15 and ground of EBCM Is the voltage equal to the specified value 1 Repair the open circuit between the motor relay connector terminal 87 and terminal 14 o...

Page 957: ...agnosis This procedure will check whether there is no output or constant output from the stoplamp switch and will determine the cause as a faulty switch or a problem in the circuitry Cause The ground connection or the positive connection at the EBCM has failed There is an open short to ground of short to positive in the vehicle wiring The stoplamp switch has failed Action Taken When the DTC Sets T...

Page 958: ...itch Is the repair complete 1 Disconnect the electronic brake control module EBCM connector 2 Visually inspect the EBCM and its connector for damaged pins or terminals Are there any damaged pins or terminals Repair the damaged pins or terminals Is the repair complete 1 With the EBCM connector disconnected applied the brake 2 Check the voltage at terminal 14 of the EBCM Is the voltage equal to the ...

Page 959: ...ND TCS Step Repair the open circuit between ground and terminal 14 of the EBCM Is the repair complete Replace the ABS unit Is the repair complete DTC 161 Stoplamp Switch Fault Cont d 17 Action Yes No Value 18 System OK System OK ...

Page 960: ...functioning Action Taken When the DTC Sets ABS action is disabled during the period of low voltage and the ABS warning lamp is ON for the remainder of the ignition cycle If the failure is intermittent the EBCM will enable the system at the next ignition cycle and set a history DTC 800 Test Description The number s below refer to step s on the diagnostic table 1 This step determines whether there i...

Page 961: ...r the terminal Is the repair complete 1 Turn the ignition to OFF 2 Install the scan tool 3 Clear all DTCs 4 Rood test the vehicle Does DTC 800 reset Check fuse F7 in the I P fuse block Is fuse F7 blown 1 Replace fuse F7 2 Turn the ignition to ON Does fuse F7 blow again 1 Turn the ignition to OFF 2 Trace the WHT RED wires in the ABS wiring harness from fuse F7 to terminal 15 of the EBCM connector 3...

Page 962: ...BS harness EBCM connector Is the resistance equal to the specified value Examine terminals 15 16 17 18 and 19 of the EBCM connector Is there a defective terminal Repair the defective terminal or replace the connector or wiring harness as required Is the repair complete Repair the defective ground connection Is the repair complete 1 Install the scan tool 2 Clear all DTCs 3 Road test the vehicle Doe...

Page 963: ...hen the DTC Sets ABS is disabled and the ABS warning lamp is turned ON If the failure is intermittent the control module will enable the system at the next ignition cycle and will store a history DTC 550 Test Description The number s below refer to step s on the diagnostic table 3 This step begins the testing for a poor voltage or ground connection Diagnostic Aids It is very important to perform a...

Page 964: ...nd 18 of the EBCM harness connector Is the voltage equal to the specified value 1 Check the voltage supply and the ground connections to the EBCM 2 Repair any open or high resistance found Is the repair complete Check the EBCM connector for any damaged terminals Are there any problems Repair any connector problem found Is the repair complete Clear all DTCs and road test the vehicle Does DTC 550 se...

Page 965: ...SSANGYONG Y200 4E 88 ABS AND TCS SCHEMATIC AND ROUTING DIAGRAMS YAD4E280 ABS 5 3 CIRCUIT ...

Page 966: ...ABS AND TCS 4E 89 SSANGYONG Y200 YAD4E290 ABD 5 3 CIRCUIT ...

Page 967: ...round Right Front Speed Sensor Left Front Speed Sensor Ground Left Front Speed Sensor Left Rear Speed Sensor Ground Left Rear Speed Sensor Acceleration Sensor Signal Data Link Connector Not Used TOD Stoplamp SW Ignition Ground Wire Color RED WHT RED WHT BLK GRN BRN GRN BLK BLU YEL GRN RED GRN Pin 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Circuit Battery Battery Ground ABS Warning Lamp EBD Warni...

Page 968: ...ecommended Reduced brake performance or durability may result Notice Avoid spilling brake fluid on any the vehicle s painted surfaces wiring cables or electrical connectors Brake fluid will damage paint and electrical connections If any fluid is spilled on the vehicle flush the area with water to lessen the damage Electronic System Service Precautions Take care to avoid electronic brake control mo...

Page 969: ...c unit a simple bleeding procedure is all the system will require 4 Remove the brake pipes from the hydraulic modulator Installation Notice Tightening Torque 14 N m 124 lb in 5 Loosen the mounting nuts on the hydraulic unit 6 Move the brake pipes aside far enough to allow for lifting the ABS 5 3 unit out of the mounting bracket 7 Cap the brake pipes Installation Notice Tightening Torque 6 N m 53 l...

Page 970: ...kle near tie rod end 5 Remove the bolt and the front wheel speed sensor from the steering knuckle Installation Notice Tightening Torque 7 N m 62 lb in 6 Installation should follow the removal procedure in the reverse order REAR WHEEL SPEED SENSOR Removal Installation Procedure 1 Disconnect the negative battery cable 2 Disconnect the rear wheel speed sensor electrical connector 3 Raise and suitably...

Page 971: ...oth wheel installer 661 589 17 33 00 YAD4E400 YAD4E410 UNIT REPAIR ABS FRONT TOOTH WHEEL Tool Requires 661 589 16 33 00 ABS Tooth Wheel Puller Removal Procedure 1 Remove the disc brake rotor Refer to Front Disc Brakes Section 2 Remove the ABS front toothed wheel using the ABS tooth wheel puller 661 589 16 33 00 ...

Page 972: ...SSANGYONG Y200 4E 96 ABS AND TCS SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE 661 589 16 33 00 ABS Tooth Wheel Puller YAD4E420 661 589 17 33 00 ABS Tooth Wheel Installer YAD4E430 ...

Page 973: ...sion Fluid Level Service Procedure 5A 38 Fluid Leak Diagnosis and Repair 5A 39 Electrical Garage Shift Test 5A 40 Road Test Procedure 5A 40 Electronic Adjustments 5A 41 Symptom Diagnosis 5A 42 Drive Faults 5A 42 Faulty Shift Pattern 5A 43 Shift Quality Faults 5A 45 After Teardown Faults 5A 47 Trouble Code Diagnosis Gasoline Vehicle 5A 50 TCM Diagnostic System Overview 5A 50 Clearing Trouble Codes ...

Page 974: ...itch to control all shift feel and shift schedule aspects The TCM drives a single proportional solenoid multi plexed to three regulator valves to control all shift feel aspects The output pressure of this solenoid is con trolled as a function of transmission fluid temperature to maintain consistent shift feel throughout the operating range Shift scheduling is highly flexible and several indepen de...

Page 975: ...located on the instrument panel Auto shift indicator light comes ON when the ignition switch ON and shows the gear shift control lever posi tion POWER mode indicator light comes ON when the POWER mode is selected and when the kickdown switch is depressed WINTER mode indicator light comes ON when the WINTER mode is selected CONTROL SYSTEMS BTRA M74 4WD automatic transmission consists of two control...

Page 976: ...ontinuously monitors every input and output circuit for short or open circuits and operating range When a failure or abnormal operation is detected the TCM records the condition code in the diagnostics memory and implements a Limp Home Mode LHM The actual limp home mode used depends upon the fail ure detected with the object to maintain maximum drive ability without damaging the transmission In ge...

Page 977: ...nverter Both these actions combine to reduce the oil temperature in the transmission Minimum Temperature C Resistance Ohms 20 0 20 100 135 Overheat Mode Threshold 13 638 5 177 2 278 117 75 Maximum 17 287 6 616 2 723 196 85 Throttle Position Sensor Gasoline Engine The throttle position signal is sent from the ECM to the TCM via the CAN Refer to Engine Section for further details Diesel Engine The t...

Page 978: ...driver has pressed the acclerator to the floor and requires a kickdown shift When this switch is used the POWER light comes ON and the POWER shift pattern is used Diagnostic Inputs The diagnostic control input or K line is used to initiate the outputting of diagnostic data from the TCM to a diagnostic test instrument This input may also be used to clear the stored fault history data from the TCM s...

Page 979: ... S4 switches the front band regula tor valve OFF or ON S5 also provides the signal pressure for the converter clutch regulator valve Solenoid 5 S5 is a variable pressure solenoid that ramps the pressure during gear changes This sole noid provides the signal pressure to the clutch and band regulator thereby controlling the shift pres sures S5 also provides the signal pressure for the converter clut...

Page 980: ...0mA S3OFF S3 ON S4OFF S4 ON 3 4 S1 ON 750mA to 600mA S4OFF S4 ON 4 3 S4 ON 750mA to 900mA S1OFF S4OFF 4 2 S3 ON S1OFF 750mA to 950mA S2 ON S3OFF 4 1 S3 ON S2 ON S4 ON 600mA to 1000mA S3OFF S4OFF 3 2 S2 ON S4OFF S4 ON 600mA to 450mA 20 kph 550mA to 400mA 60 kph 800mA to 650mA 100 kph 3 1 S3 ON S1 ON S4 ON S2 ON S3OFF 700mA to 950mA S4OFF 2 1 S4 ON 800mA to 950mA S1 ON S4OFF Conv Clutch ON S7 ON 700...

Page 981: ...nd the plunger The friction elements are then fed oil pressure equal to Line 500 multiplied by the amplification ratio When a shift is initiated the required ON OFF solenoid is switched ON cutting the supply of Line 500 to the plunger At the same time the VPS pressure is reduced to the ramp start value and assumes control of the regulator valve by pushing the plunger away from the valve The VPS th...

Page 982: ...The shift is completed by switching the regulators OFF and at the same time causing the VPS to reach maximum pressure All downshifts are accomplished by switching VPS pres sure to the band and or clutch regulator valve and send ing a ramped current to the VPS The shift is completed by simultaneously switching the regulators OFF switching the shift valves and at the same time causing the VPS to ret...

Page 983: ...AUTOMATIC TRANSMISSION 5A 11 SSANGYONG Y200 HYDRAULIC CONTROL CIRCUIT KAA5A08A ...

Page 984: ... shift valve to disengage the C4 clutch in first gear and engage C4 in second gear When Manual 1 is selected the C4 clutch and rear band B2 are engaged 2 3 Shift Valve The 2 3 shift valve is a two position valve It is used on all 2 3 and 3 2 gearshifts The switching of this valve is achieved by S2 which is located at the end of the valve spool In the 1 2 position second gear oil from the 1 2 shift...

Page 985: ...ure is controlled by S6 which acts as the line pressure control valve When S6 pressure is applied to the end of the Primary Regulator Valve PRV it is opposed by spring force and causes LOW line pressure for light throttle application and cruising Heavy throttle application causes the normally open S6 to open switch Off thus closing line 500 and opening S6 to exhaust Removal of S6 pressure from the...

Page 986: ... servo piston applying B2 If any of the above conditions are not satisfied the TCM switches solenoids S1 and S2 to ON Primary Regulator Valve The Primary Regulator Valve PRV regulates the trans mission line pressure or pump output pressure This valve gives either high or low line pressure depending on whether S6 is switched OFF or ON When S6 is switched ON S6 pressure is applied to the PRV moving ...

Page 987: ...se the converter clutch piston is sealed against the flat friction surface of the converter cover To provide oil flow to the cooler the converter clutch control valve directs converter feed oil from the PRV directly to the cooler circuit B1R Exhaust Valve The B1R exhaust valve is a two position spring loaded valve located in the transmission case directly adjacent to the front servo It permits the...

Page 988: ... by re applying the B1 band and overrunning the 3 4 OWC Reverse gear is engaged by applying the C3 clutch and the B2 band The C4 clutch is applied in the Manual 1 2 and 3 ranges to provide engine braking In addition the C4 clutch is also applied in the Drive range for second and third gears to eliminate objectionable freewheel coasting The B2 band is also applied in the Manual 1 range to accomplis...

Page 989: ...p the converter and eliminating unwanted slippage Whenever lock up occurs improved fuel consumption is achieved Torsional damper springs are provided in the damper and piston assembly to absorb any engine torque fluctuations during lock up Clutch Packs There are four clutch packs All clutch packs are com posed of multiple steel and friction plates C1 CLUTCH When applied this clutch pack allows the...

Page 990: ...ne Way Clutches The transmission uses two OWCs the 1 2 OWC and the 3 4 OWC Note that a third OWC is located in the torque converter also known as a sprag The 1 2 OWC is located between the planetary carrier assembly and the center support This allows the carrier to rotate around the center support in one direction only The one way clutch is engaged only in Drive 1 This 3 4 OWC is located between t...

Page 991: ...rive 3 Lock Up Power Flow Drive 4 Overdrive Power Flow Drive 4 Lock Up The following table details the engaged elements versus the gear selected for all transmission selections C1 X X X X 1 2 OWC X 3 4 OWC X X X X X X X B2 X X X B1 X X X Gear State Park and Neutral Reverse Manual 1 Drive 1 Drive 2 and Manual 2 Drive 3 and Manual 3 Drive 3 Lock Up and Manual 3 Lock Up Drive 4 Overdrive Drive 4 Lock...

Page 992: ...5A 20 AUTOMATIC TRANSMISSION SSANGYONG Y200 PARK AND NEUTRAL KAA5A31A ...

Page 993: ...y state sole noids and valves are activated as follows Solenoids S1 and S2 are switched OFF Line pump pressure is applied to the Primary Regu lator Valve PRV and to the solenoid supply pressure regulator valve The converter oil cooler and lubrication circuits are charged from the primary regulator valve The line 500 circuit is charged by the solenoid supply pressure regulator valve The S5 circuit ...

Page 994: ...5A 22 AUTOMATIC TRANSMISSION SSANGYONG Y200 REVERSE KAA5A33A ...

Page 995: ...he output shaft drives it in an anti clockwise or reverse direction Control To maintain this arrangement in the steady state sole noids and valves are activated as follows Solenoids S1 and S2 are switched OFF Line pressure is directed through the reverse lockout valve to both the inner and outer apply areas of the rear servo piston for B2 band application Line pressure feeds the reverse oil circui...

Page 996: ...5A 24 AUTOMATIC TRANSMISSION SSANGYONG Y200 MANUAL 1 KAA5A35A ...

Page 997: ...e inter nal ring gear and the output shaft in a clockwise or forward direction The C4 clutch provides engine braking through the 3 4 OWC on overrun Control To maintain this arrangement in the steady state sole noids and valves are activated as follows Solenoids S1 and S2 are switched ON The 1 2 2 3 and 3 4 shift valves are held in their first gear positions by line 500 pressure Drive line pressure...

Page 998: ...5A 26 AUTOMATIC TRANSMISSION SSANGYONG Y200 DRIVE 1 KAA5A37A ...

Page 999: ...etary gear carrier from rotating under reaction force and the long pinion rotates on its axis driving the internal ring gear and output shaft in a clockwise or forward direction There is no engine braking on overrun Control To maintain this arrangement in the steady state sole noids and valves are activated as follows Solenoids S1 and S2 are switched ON The 1 2 2 3 and 3 4 shift valves are held in...

Page 1000: ...5A 28 AUTOMATIC TRANSMISSION SSANGYONG Y200 DRIVE 2 AND MANUAL 2 KAA5A39A ...

Page 1001: ...FF S2 is switched ON Drive line pressure oil from the manual valve en gages the C2 clutch When S1 switches OFF S1 oil pressure which is derived from line 500 pressure moves the 3 4 shift valve to the left At the same time S1 oil is directed to the 1 2 shift valve which moves the valve to the second gear position 2nd oil line pressure from the 1 2 shift valve is di rected to the band apply regulato...

Page 1002: ...5A 30 AUTOMATIC TRANSMISSION SSANGYONG Y200 DRIVE 3 AND MANUAL 3 KAA5A41A ...

Page 1003: ...e 1 2 shift valve is di rected to the band apply feed regulator valve and to the 2 3 shift valve The band apply feed regulator valve supplies 2nd oil regulated to line pressure multiplied by the valve ra tio to the Band Apply Feed BAF circuit Band apply feed oil is directed to The outer apply area of the front servo The 1 2 shift valve to provide an exhaust port when the transmission is shifted to...

Page 1004: ...5A 32 AUTOMATIC TRANSMISSION SSANGYONG Y200 DRIVE 3 LOCK UP AND MANUAL 3 LOCK UP KAA5A43A ...

Page 1005: ...eed oil to the converter clutch control valve is switched OFF and allowed to exhaust through the S7 solenoid This allows the valve to move to the clutch engage position Regulated apply feed oil drive oil at the converter clutch regulator valve is directed by the converter clutch control valve to the engage side of the converter clutch Converter clutch release oil is exhausted at the con verter clu...

Page 1006: ...5A 34 AUTOMATIC TRANSMISSION SSANGYONG Y200 DRIVE 4 OVERDRIVE KAA5A45A ...

Page 1007: ...itched OFF the 2 3 shift valve is held in the fourth gear position by line 500 pressure on the large end of the valve The 1 2 shift valve is held in the fourth gear position by S2 oil pressure 2nd oil line pressure from the 1 2 shift valve is di rected to the band apply feed regulator valve and to the 2 3 shift valve The band apply feed regulator valve supplies 2nd oil regulated to line pressure m...

Page 1008: ...5A 36 AUTOMATIC TRANSMISSION SSANGYONG Y200 DRIVE 4 LOCK UP KAA5A47A ...

Page 1009: ...alve is switched OFF and allowed to exhaust through the S7 solenoid This allows the valve to move to the clutch engage position Regulated apply feed oil drived from drive oil at the converter clutch regulator valve is directed by theconverter clutch control valve to the engage side of the converter clutch Converter clutch release oil is exhausted at the con verter clutch control valve Converter fe...

Page 1010: ...ion trouble codes have been set DIAGNOSTIC INFORMATION AND PROCEDURES Refer to the appropriate Diagnostic Trouble Code DTC information and repair the vehicle as directed After repairing the vehicle perform the road test and verify that the code has not set again Perform the Electrical Garage Shift Tests Perform the Road Test Procedure in this section Inspect the oil and check for metal or other co...

Page 1011: ...ler plug Remove the fluid filler plug Clean the filler plug and check that there is no damage to the O ring 4 Lower the vehicle with the filler pump still connected and start the vehicle in P Park with the parking brake and the brake applied With the engine idling move the gear shift control lever through the gear ranges pausing a few seconds in each range and adding the fluid until gear applicati...

Page 1012: ... the parking brake 2 Connect scan tool to Data Link Connector DLC terminal 3 Start engine 4 Turn the scan tool ON 5 Verify that the appropriate signals are present These signals may include ENGINE SPEED VEHICLE SPEED THROTTLE POSITION ACCEL PEDAL POSITION TRANSMISSION GEAR STATE GEAR SHIFT LEVER POSITION TRANSMISSION FLUID TEMPERATURE CLOSED THROTTLE POSITION LEARN OPEN THROTTLE POSITION LEARNT CL...

Page 1013: ...the selector lever to 1st gear and WINTER mode 3 Move the selector lever to 2nd gear and ECONO or POWER mode 4 Move the selector lever to 3rd gear and WINTER mode Throttle Position Calibration Should the throttle position data stored in the TCU be lost or be out of specification as indicated by a diagnostic trouble message it may be re established by the following procedure Check that the hot engi...

Page 1014: ...y Regulator Valve PRV Damaged broken pump gears Dislodged output shaft snap ring Action Check the fluid level Top up as necessary Inspect and clean C1 C2 feed Reinstall renew the z link Remove clean and re install the PRV Inspect and replace as necessary Inspect and replace as necessary Inspect and replace as necessary Check servo adjustment or replace rear band as necessary Check for failure in C...

Page 1015: ... Check for open circuit or wiring fault Inspect S2 Repair or replace as necessary Check for open circuit or wiring fault Inspect and repair as necessary Inspect and adjust as necessary Inspect and repair as necessary Inspect and replace or refit as necessary Inspect O ring Refit or replace as necessary Inspect the 2 3 shift valve Repair or replace as necessary Inspect C1 clutch Repair or replace a...

Page 1016: ...y regulator valve Action Inspect the release valve Repair or replace as necessary Inspect S3 or S2 Repair or replace as necessary Inspect the regulator valve Repair or replace as necessary Inspect the ball Refit or replace as necessary Inspect the sealing rings Refit or replace as necessary Inspect the O rings Refit or replace as necessary Inspect the bleed ball Refit or replace as necessary Inspe...

Page 1017: ...fitted correctly or replace S5 Inspect band apply and clutch apply regulator springs Refit or replace as necessary Inspect the ball Refit or replace as necessary Inspect C4 clutch Replace or repair as necessary Check the alignment Realign as necessary Inspect S5 and replace as necessary Check the clearance and adjust as necessary Inspect C4 Repair or replace as necessary Inspect piston Repair or r...

Page 1018: ...pring Jammed Converter Clutch Control Valve CCCV Faulty solenoid 7 Action Check the resistance Replace the inhibitor switch as necessary Inspect and replace the sensor as necessary Inspect and adjust the band as necessary Inspect and replace the O rings as necessary Inspect repair or replace S5 as necessary Inspect repair or replace S1 or S4 as necessary Inspect repair or replace the BAR as necess...

Page 1019: ...nspect replace the sealing rings and or shaft as necessary Repair C2 Inspect repair or replace the C2 piston as necessary Inspect C4 and repair as necessary Inspect and adjust the C4 pack clearance as necessary Repair C4 Inspect and realign the wave plate as necessary Repair C4 Inspect and realign the sealing rings and or shaft as necessary Repair C4 Inspect and replace the C2 piston as necessary ...

Page 1020: ... or damaged Converter clutch regulator valve in backwards Input shaft O ring missing or damaged C1 bias valve in backwards Action Inspect and replace the O ring as necessary Inspect and refit the valve as necessary Inspect and replace the O ring as necessary Inspect and refit the valve as necessary No lock up at light throttle ...

Page 1021: ...ction 1F Engine Control for details on EOBD system function checks and fault clearing CLEARING TROUBLE CODES TCM DTCs should be cleared after repairs have been completed Some diagnostic tables will tell you to clear the codes before using the chart which will help to find the cause of the problem more quickly Always note the DTCs present before clearing this information may be helpful in the diagn...

Page 1022: ...y DTC on the first driving cycle with a fail EOBD system stores a history DTC on the second consecutive driving cycle with a fail the DTC will be armed after the first fail EOBD system stores a freeze frame on the second consecutive driving cycle with a fail if empty Type D Non Emissions related Does not request illumination of any lamp Stores a history DTC on the first driving cycle with a fail E...

Page 1023: ...L VEHICLE TCM DIAGNOSTIC SYSTEM OVERVIEW Notice To prevent Transmission Control Module TCM damage The ignition key must be OFF when disconnection or reconnection the power to the TCM for example bttery cable TCM pigtail connector TCM fuse jumper cables etc When the TCM detects a system fault a Diagnostic Trouble Code DTC is set in the TCM This code is present while the fault conditions are met and...

Page 1024: ...AUTOMATIC TRANSMISSION 5A 53 SSANGYONG Y200 DIAGNOSTIC TROUBLE CODES Cont d DTC P1745 P1746 P1747 Description Solenoid 5 Circuit Short Solenoid 6 Circuit Short Solenoid 7 Circuit Short ...

Page 1025: ...ay be caused by a poor connec tion rubbed through wire insulation or a wire broken inside the insulation Check for poor connections or a damaged harness Inspect the TCM harness and con nections for improper mating broken locks improperly formed or damaged terminals poor terminal to wire connection and damaged harness TCM Diagnostic System Check YAD5A010 1 Step Action Value s Yes No 2 1 Turn the ig...

Page 1026: ...rt to ground and the DLC ground circuit for an open Is a problem found Repair the open short to ground or short to voltage in the serial data circuit or the DLC ignition feed circuit or the DLC ground circuit Is a repair complete Check the TCM ignition feed circuit for an open or short to ground and the TCM ground circuit for an open Is a problem found Repair the open or short to ground in the TCM...

Page 1027: ...Disconnect the speedometer connector from transfer case 4 Disconnect the inhibitor connector gear position sensor connector and transmission case connector REPAIR INSTRUCTIONS 5 Remove the rear propeller shaft bolts Installation Notice YAD5A080 YAD5A090 YAD5A100 6 Remove the cross member bolts and nuts Installation Notice Tightening Torque 70 80 N m 52 59 lb ft Tightening Torque 70 80 N m 52 59 lb...

Page 1028: ...emove the shift rod Notice Removal and installation performed when the shift procedure should be lever is in D range 11 Remove the oil cooler pipes Installation Notice 9 Disconnect the 10 Pins Plug connector from trans mission YAD5A110 7 Remove the front propeller shaft bolts from transfer case Installation Notice Tightening Torque 44 N m 33 lb ft Tightening Torque 70 80 N m 52 59 lb ft Tightening...

Page 1029: ...otice Screw the six bolts mounting the torque converter through the service hole by using a mirror and rotating the engine 14 Remover the starter Refer to Section 1E Engine Electrical Tightening Torque 42 N m 31 lb ft YAD5A150 15 Remove the extension housing to case bolts and remove the transmission assembly Installation Notice Be careful not to drop the torque converter while removing the transmi...

Page 1030: ...fitted With the front cooler line connected and the rear line run into a suitable container measure the flow over 15 seconds with the vehicle idling in park The flow rate should exceed 1 liter in 15 seconds Be wary of any situation where water enters the transmission This may result in fluid foaming and leaking through the breather Ensure that both earth straps one at the battery terminal and one ...

Page 1031: ...ppropriate subject Refer to Special Tools Table in this chapter for details of all special tools required when performing disassembly procedures Technicians overhauling these transmissions will also require a selection of good quality Torx bit sockets in particular numbers 30 40 and 50 and an 8mm 10mm and 12 mm double hex socket 1 Remove the converter and the converter housing 2 Mount the transmis...

Page 1032: ...sing bolts and adaptor housing 10 Remove the pump to case bolts using a multi hex 8 mm spanner 11 Using the pump puller 0555 336257 remove the pump and pump cover 12 Remove the input shaft forward clutch cylinder and the overdrive shaft as an assembly withdrawing them through the front of the case 13 Remove the C3 clutch cylinder and sun gears 14 Remove the front band struts Remove the front band ...

Page 1033: ...nd of rear band using the plier and lean forward about 15 degrees 20 Remove the output shaft assembly Transmission Case Tools Required 0555 336258 Cross Shaft Pin Remover Installer Detent Lever 0555 336261 Cross Shaft Seal Remover 0555 336265 Cross Shaft Pin Remover Installer Inhibitor Switch 1 Remove the pin from the side of cross shaft inhibitor switch using cross shaft pin remover installer inh...

Page 1034: ...raw the 10 pin connector into the case Remove the wiring loom assembly 9 Detach the No 7 solenoid wire from the front of the case 10 Remove the parking pawl pivot pin and the pawl and spring from the case 11 Remove the shaft and the rear servo lever 12 Remove the rear servo cover and piston assembly 13 Remove the B1R circlip valve and spring 14 Remove both band adjustment shims 15 Inspect the outp...

Page 1035: ...0555 336259 Clutch Spring Compressor 1 Place the assembly in a horizontal position 2 Remove the No 4 needle bearing 2 and adjust ment shims 1 from the input shaft 3 Remove the circlip from the front of the clutch cylin der and remove the input shaft 4 Remove the overdrive shaft and the C1 clutch hub assembly from the clutch cylinder 5 Remove the C1 clutch plates from the cylinder 6 Remove the circ...

Page 1036: ... the circlip keeper and spring Notice Make sure that the spring keeper is not caught in the circlip groove and that all the spring pressure is released before removing the tool 12 Invert the clutch cylinder on the compressor tool and removethe C1 clutch piston return spring in asimilar manner 13 To remove the clutch pistons from the clutch cylinder apply air pressure to the apply ports in the bore...

Page 1037: ...tch cylinder 8 To remove the clutch piston from the clutch cylinder apply air pressure to the port between the iron sealing rings on the bearing journals of the cylinder 9 Remove the reverse sun gear and C3 washer from the cylinder Planet Carrier Assembly and Centre Support 1 Remove the No 9 2 needle bearing and washer 1 from the output shaft and the planet carrier 2 Separate the centre support fr...

Page 1038: ...d 7 with a T30 Torx bit 2 Remove the five washer head bolts from the cover plate using a multi point 8 mm socket 3 Remove the five Torx head screws from the cover plate with T30 Torx bit Note that the long screw holds the pump body to the pump body cover Notice Do not strike the converter support tube to loosen the pump body 4 Separate the pump body from the pump cover 5 Remove the cover plate gas...

Page 1039: ...d retain er plate using a T40 Torx bit 2 Slide the manual valve out of the lower valve body Notice Be aware that the manual valve will fall out of the valve body 3 Take note of the angular relationship of the solenoid terminals to the valve body and remove the solenoids 1 2 3 4 5 6 and valve assemblies Notice Take care that the bracket is not separated from the solenoid 4 Place the valve body asse...

Page 1040: ...will drop out when the valve body is turned over 12 Remove the 1 2 2 3 and 3 4 shift valves 13 Depress the 4 3 sequence valve plug and remove the retaining plate Notice The plug is preloaded by the spring and may unexpectedly fall out of the valve body 14 Remove the plug spring and valve 15 Depress the solenoid 5 valve Remove the retaining in and remove the valve damper guide and spring Notice The...

Page 1041: ...and 50 and an 8 mm 10 mm and 12 mm double hex socket Ensure that the B1R circlip is fitted to the case If this is not fitted the valve will peen its way into and through the separator plate Ensure that the E clip is fitted to the cross shaft Ensure that all aspects of the parking mechanism are working 3 Assemble the B1R valve and spring and secure with the circlip Ensure that the circlip is comple...

Page 1042: ...tween the pin and the lever 6 Secure the pivot pin with the circlip Notice The lever must pivot freely on its pin and the spring must return the park rod lever to its correct location 7 Install the parking pawl pivot pin and spring Notice The pawl must pivot freely on its pin 8 Connect the park rod to the manual valve detent lever Ensure the spring and cam collar is firmly installed on the rod 9 C...

Page 1043: ...ll the inhibitor switch on the case Torque the bolts as per specifications Press the pin into the shaft until the tool bottoms using cross shaft pin installer remover inhibitor switch 0555 336265 Installation Notice 18 Thoroughly check the terminal wiring loom for condition and continuity Tightening Torque 4 6 N m 35 53 lb in 13 Install the detent lever drive pin in the shaft using cross shaft pin...

Page 1044: ...s not worn or damaged Replace if necessary 2 Check for damage to parking pawl teeth on the ring gear Replace if necessary 3 Check that the sealing ring grooves have not been damaged 4 Lubricate the sealing rings with automatic transmission fluid 5 Assemble the sealing rings to the output shaft with the scarf cut uppermost 6 If previously dismantled assemble the ring gear to the output shaft and se...

Page 1045: ... plate and tighten the screws to specification Installation Notice Rear Servo Assembly 1 Check the servo piston O rings and gasket for any damage 2 Lubricate the servo piston O rings with automatic transmission fluid and fit the O rings to the piston grooves 3 Assemble the piston to the cover ensuring that O ring compression is adequate but not excessive 4 Align the spring on the piston spigot the...

Page 1046: ...OWC 1 into the outer race with the lip edge uppermost Lubricate the sprags with auto matic transmission fluid 5 Check that the plugs are fitted to the centre support then assemble the centre support into the OWC ensuring that the support will rotate in an anti clock wise direction only 6 Lubricate the No 9 needle bearing and washer with petroleum jelly and fit them to the rear face of the planet c...

Page 1047: ...ransmission fluid and fit to the cover 2 Lubricatethepiston O rings with automatic trans mission fluid and fit to the piston 3 Assemble the piston push rod spring belleville washer seat and retaining ring 4 Fit the piston push rod assembly into the front servo cover 5 Install the front servo block and spring into the case 6 Install the front servo assembly into the case 7 Compress the servo cover ...

Page 1048: ...nd engage it with the band and anchor strut 6 Position the apply strut in its retaining clip and engage it with the band and the servo piston rod C2 C4 Clutch Assembly Tools Required 0555 336259 Clutch Spring Compressor 0555 336260 Clutch Pack Clearance Kit Notice Check pistons for cracks Do not mix the clutch piston return springs Ensure that the snap rings are fitted correctly 1 Check the feed o...

Page 1049: ...e outside of the cylinder until the outer diameter of the C2 piston enters the inner diameter of the cylinder 11 Assemble the piston return spring to the piston and fit the spring retainer over the spring 12 Using 0555 336259 clutch spring compressor compress the spring sufficiently to enable the installation of the retaining circlip ensuring that the circlip is firmly seated in its groove then re...

Page 1050: ...p ensuring that the circlip is firmly seated in its groove then remove the tool Notice The wire diameter of this spring is 5 26 mm 18 Install the C2 wave washer into the cylinder with the crest of one wave covering one of the bleed orifices inthe C2 piston 19 Measure and record the thickness of the flange of the C2 sleeve 20 Install the C4 clutch plates and wave washer into the C2 actuating sleeve...

Page 1051: ...the outside of the cylinder until the sleeve contacts the C2 wave washer 22 Check the C4 clutch pack clearance using 0555 336260 clutch pack clearance kit Notice With the C2 wave spring compressed and the clutch Pack supporting a 2 kg weight the dimension from the underside of the C2 pressure plate to the selective steel is to be between 1 4 1 8 mm If the clutch is to be gauged from the top of the...

Page 1052: ...elements are soaked in ATF 28 Lubricate and fit the 3 4 OWC and end caps to the C2 hub 32 Apply petroleum jelly to the No 5 needle bearing and fit it to the C4 hub 33 Remove the C2 clutch plates from the clutch cylin der 34 Fit the thrust plate over the cylinder inner hub 35 Engage the C2 C4 clutch hub assembly in the C4 clutch plates 36 Install the C2 clutch plates 37 Install the C3 hub and secur...

Page 1053: ...se sun gear in the C3 cylinder en suring that the O ring compression is adequate but not excessive Notice O rings must not be twisted in the grooves 6 Coat the C3 piston O rings with automatic trans mission fluid and fit the small O ring onto the inner ring and the large O ring onto the outer ring of the C3 piston 7 Check that the bleed orifices of the piston are clean and clear of obstructions 8 ...

Page 1054: ...re facing away from the clutch plates 13 Install the circlip 14 Check the C3 clutch clearance using 0555 336260 clutch pack clearance kit in the following manner weight only a Place the weight on the pressure plate and measure the distance from the end of the cylinder to the top of the pressure plate b Record this figure c Remove the weight d Lift the pressure plate up against the circlip and meas...

Page 1055: ...rd Sun Gear and C3 Clutch Pack Assembly 1 Fit the No 7 needle bearing assembly over the for ward sun gear ensuring that the thrust washer is between the bearing and the sun gear 2 Lubricate the lipped thrust plate with petroleum jelly and fit the thrust plate onto the reverse sun gear 3 Align and fit the C3 clutch assembly over the for ward sun gear 4 Lubricate the No 6 needle bearing with petrole...

Page 1056: ...e the No 6 bearing doesn t drop out of the bearing retainer 1 Check the overdrive shaft grooves for any defect 2 Coat the sealing rings large and small with petro leum jelly and fit them to the overdrive shaft The sealing rings may be held in place with a small amount of petroleum jelly 3 Assemble the clutch plate and disc into the cylinder in the following sequence Steel plate Friction disc Steel...

Page 1057: ...r and secure it with the circlip ensuring that the circlip is completely seated in the groove 12 Coat the sealing rings with petroleum jelly and fit onto the input shaft 4 Check the clutch pack clearance using 0555 336260 clutch pack clearance kit 5 Use selective plates to achieve the correct specifi cation Notice With the clutch pack supporting a 2 kg weight the dimension from the input shaft loc...

Page 1058: ...the bush is firmly staked in the drive gear 2 Install the seal flush with the front face of the pump body 3 Lubricate the pump bush and the drive and driven gears with automatic transmission fluid 4 Install the pump driven gear and the pump drive gear into the pump body 5 Using a straight edge and thickness gauge check that the clearance between pump face and gears is 0 04 0 018 mm 6 Lubricate the...

Page 1059: ...gulator valve spring and plunger to the pump cover ensuring that the regulator valve slides freely then fit the regulator valve plug and O ring 10 Install the retaining pin KAA5A1F0 KAA5A1G0 KAA5A1E0 7 Ensure that the pump cover cavities ports and holes are clean and free of any obstruction 8 Lubricate all loose parts with automatic transmission fluid prior to assembly KAA5A1D0 ...

Page 1060: ...phery of the pump cover 18 Tighten the screws to specification in the order 1 5 Installation Notice 19 Tighten the solenoid 7 screw Installation Notice Tightening Torque 13 16 N m 10 12 lb ft Check that neither the wiring nor the connector protrudes excessively in order that at assembly neither the wiring and the connector contacts or rubs on the input shaft or the C1 C2 clutch cylinder 13 Install...

Page 1061: ...steps to check the end float a Attach a dial indicator to the front of the trans mission case with the stylus resting on the end of the input shaft b Apply a force of approximately 250 N or 25 kg to the input shaft c Zero the dial indicator d Place a small lever behind the forward clutch cylinder and lever the cylinder forward e The measurement recorded on the dial indicator is the transmission en...

Page 1062: ...id 5 damper spring is not broken Locate the detent spring central to the detent lever Wash the upper and lower valve bodies thoroughly with cleansing solvent and blow dry Check the valve body cavities ports and holes for damage or obstructions The orifices in the valve body are for stability and safeguard Do not drill them larger Thoroughly wash all loose components Check that all valves slide fre...

Page 1063: ...1R0 KAA5A870 KAA5A860 6 Install the 1 2 shift valve plug and retaining pin 7 Install the 2 3 shift valve and retaining pin 4 Install the solenoid 5 damper guide and spring piston and retaining pin 5 Install the 4 3 sequence valve spring plug and retaining plate ...

Page 1064: ...ining plate Notice This aluminum valve is easily damaged 11 Install solenoid 6 plunger spring and retaining pin 12 Position the third feed ball large nylon in the valve body and install the solenoid 6 filter 13 Check the separator plate for burrs and damage Repair or replace the separator plate as necessary 14 Check the upper and lower valve body gaskets for damage Replace the gaskets as necessary...

Page 1065: ... 2 3 4 and 6 Ensure the solenoid is firmly secured by the retainer and that the screw is tightened to specification Installation Notice The wiring loom ground wire eyelet terminal is secured beneath the solenoid 1 retainer 16 Install the reverse lockout valve spring plug and retaining plate Ensure that the valve is correctly oriented 17 Position the five nylon ball checks in the upper valve body 1...

Page 1066: ...pecification Check the spring for wear or damage Installation Notice 23 Install the manual shift valve Notice Be aware that the manual valve will fall out of the valve body 24 Align the valve body assembly on the transmission case and install the manual valve lever to manual valve link Fit the long end of the link to the manual valve first Install the securing bolts and tighten to specification in...

Page 1067: ... detailed below Solenoid 1 red Solenoid 2 bIue Solenoid 3 yellow Solenoid 4 orange Solenoid 5 green Solenoid 6 violet Notice All hardware must be correctly installed and torqued to specification Oil Filter and Pan Assembly Notice Replace the filter whenever rebuilding a transmission where a significant amount of mechanical damage has occurred To aid the assembly of the pan gasket use a small amoun...

Page 1068: ...are engaged in the pump gear Ensure that the tangs do not contact the pump seal Output Flange Assembly 2WD Mode 1 Position the transmission detent lever into the park position and lock the output shaft 2 Clear the threads on the output shaft and apply Loctite 243 or equivalent as required to threads 3 Install the flange O ring and torque the nut to specification Installation Notice Tightening Torq...

Page 1069: ... 2 Fit the selected shim s to the shank of the anchor strut as follows a Inspect the shim s for damage wear or corro sion Replace as necessary b The shim s are to be installed between the case abutment face and the anchor strut flange c The shim s are to be fitted by hand and under no circumstances to be hammered or forced d Shim s are to be pressed on by hand until an audible click is heard The c...

Page 1070: ...Fit the selected shim s to the shank of the anchor strut as follows a Inspect the shim s for damage wear or corrosion and replace as necessary The shim s are to be installed between the case abutment face and the anchor strut flange b The shim s are to be fitted by hand and under no circumstances to be hammered or forced c The shim s are to be pressed on by hand until an audible click is heard The...

Page 1071: ...AUTOMATIC TRANSMISSION 5A 203 SSANGYONG Y200 KAA5A2G0 ...

Page 1072: ...ion switches assembly bolts 8 Remove the middle housing with the mode selector switch wiring harness from the gear shift control lever assembly 9 Separate the P position switches assembly with the P position lamp wiring harness from the gear shift control lever assembly Notice Adjust the brake transmission shift interlock ease the operation well 10 Remove the clips supporting the springs and bushe...

Page 1073: ...moval procedure in the reverse order KAA5A5S0 TRANSMISSION CONTROL MODULE Removal and Installation Procedure 1 Disconnect the negative battery cable 2 Push the driver s seat and disconnect the transmission control module connector 4 Installation should follow the removal procedure in the reverse order Tightening Torque 10 N m 89 lb ft 3 Removal the TCM mounting bolts and TCM Installation Notice YA...

Page 1074: ...plication Torque Converter Mean Diameter of Fluid Circuit Description Maximum Torque Multiplication Gear Ratios First Second Third Fourth Reverse Lubricant Type Capacity Dry System Service Refill Gear Train End Float Gear Set Pinion End Float Transmission 0574 000013 0574 000012 0574 000014 Torque Converter 179K 150K 150K Engine Version E23 E32 662LA SYMC P NO 36100 05442 36100 05432 36100 05412 C...

Page 1075: ...2 4 18 9 19 2 24 7 28 4 32 6 45 5 86 9 8 9 8 9 17 3 24 7 29 7 37 8 42 5 47 7 66 7 86 9 2 1 9 2 9 2 9 2 9 3 9 3 10 9 12 1 18 6 34 6 45 4 9 2 9 2 9 2 9 2 10 4 15 1 18 1 20 8 33 0 45 4 UNL3 50 7 50 7 50 7 50 7 50 7 59 4 66 8 71 7 81 6 90 7 73 0 73 0 73 0 73 6 76 2 81 6 86 6 86 6 86 6 90 7 LCK3 79 1 79 1 79 1 90 3 58 1 66 8 74 2 76 7 95 1 95 5 75 4 75 4 79 1 94 0 103 9 110 8 116 3 121 2 136 0 95 5 UNL...

Page 1076: ... 5 46 1 51 2 67 3 87 7 113 3 148 4 163 8 3 2 10 2 10 2 14 6 19 7 21 9 27 8 32 2 39 5 46 8 104 7 10 2 10 2 17 5 24 9 27 8 37 3 51 2 66 5 89 9 104 7 2 1 10 5 10 5 10 5 11 0 11 7 13 9 17 3 21 9 26 50 3 10 5 10 5 11 0 11 6 12 0 15 4 21 4 28 7 42 4 50 3 UNL3 37 4 37 4 37 4 39 5 40 9 46 8 54 1 64 3 93 6 116 4 76 0 76 0 76 0 81 9 84 8 102 4 111 1 111 1 111 1 116 4 LCK3 81 9 81 9 81 9 83 4 62 9 70 2 79 0 ...

Page 1077: ...0 54 4 69 4 100 7 26 7 31 3 32 7 47 6 54 4 61 2 65 3 70 7 83 0 100 7 3 2 9 3 9 3 13 6 21 8 22 0 25 9 28 6 31 3 38 1 63 9 9 3 9 3 16 3 27 2 35 4 40 8 46 3 50 3 54 4 63 9 2 1 9 5 9 5 9 5 9 5 9 5 12 2 13 6 15 0 19 6 31 3 9 5 9 5 10 2 12 8 14 4 15 8 17 4 20 4 23 1 31 3 UNL3 47 6 47 6 47 6 47 6 47 6 47 6 47 6 49 0 57 1 61 2 61 2 61 2 61 2 61 2 61 2 61 2 61 2 61 2 61 2 61 2 LCK3 76 2 76 2 76 2 76 2 50 3...

Page 1078: ... Screw Extension Housing to Case Bolts Front Propeller Shaft Bolts Inhibitor Switch to Case Bolts Oil Cooler Pipes Oil Pan to Case Bolts On Off Solenoid Retainer Screws Output Flange Nuts Pump Cover Plate to Crescent Screw Pump Cover Plate to Pump Cover Screws Pump Cover to Case Bolts Pump to Pump Cover Bolts Rear Propeller Shaft Bolts Rear Servo Cover to Case Bolts TCM Mounting Bolt Torque Conver...

Page 1079: ...AUTOMATIC TRANSMISSION 5A 211 SSANGYONG Y200 TCM WIRING DIAGRAM GASOLINE ENGINE 1 OF 2 SCHEMATIC AND ROUTING DIAGRAMS YAD5A210 ...

Page 1080: ...5A 212 AUTOMATIC TRANSMISSION SSANGYONG Y200 TCM WIRING DIAGRAM GASOLINE ENGINE 2 OF 2 YAD5A220 ...

Page 1081: ...AUTOMATIC TRANSMISSION 5A 213 SSANGYONG Y200 TCM WIRING DIAGRAM DIESEL ENGINE 1 OF 2 YAD5A230 ...

Page 1082: ...5A 214 AUTOMATIC TRANSMISSION SSANGYONG Y200 TCM WIRING DIAGRAM DIESEL ENGINE 2 OF 2 YAD5A240 ...

Page 1083: ...AUTOMATIC TRANSMISSION 5A 215 SSANGYONG Y200 CONNECTOR END VIEW KAA5A5O0 ...

Page 1084: ... SPECIAL TOOLS TABLE 0555 336256 Transmission Bench Cradle 0555 336260 Clutch Pack Clearance Kit 0555 336262 Cross Shaft Seal Installer 0555 336257 Pump Puller 0555 336259 Clutch Spring Compressor 0555 336261 Cross Shaft Seal Remover KAA5A2P0 KAA5A2R0 KAA5A2T0 KAA5A2V0 KAA5A2Q0 KAA5A2S0 KAA5A2U0 KAA5A2W0 ...

Page 1085: ...A5A3C0 KAC5A050 0555 336265 Cross Shaft Pin Remover Installer Inhibitor Switch 0555 336267 Pump Alignment Tool 0555 336269 End Float Measuring Adaptor 0555 336302 Output Shaft Bullet 0555 336045 Solenoid Bench Tester 0555 336266 Adaptor Housing Seal Installer 0555 336268 Pump Seal Installer 0555 336270 End Float Measuring Shaft ...

Page 1086: ...5A 218 AUTOMATIC TRANSMISSION SSANGYONG Y200 0555 332083 Solenoid Thermistor ElectronicTester SPECIAL TOOLS TABLE Cont d KAC5A060 ...

Page 1087: ...ocator 5B 7 Cross SectionalView 5B 7 PowerFlow 5B 8 Seni Remote Kit Disassembly and Assembly 5B 9 Transmission Assembly 5B 10 Transmission Assembly Disassembled View 5B 11 Maintenance and Repair 5B 14 On Vehicle Service 5B 14 Semi Remote Kit 5B 14 Transmission 5B 19 Unit Repair 5B 24 Major Unit 5B 24 Main Shaft 5B 34 Input Shaft 5B 38 Counter Shaft 5B 40 Extension Housing 5B 40 Shift Cover 5B 41 I...

Page 1088: ...NERAL DESCRIPTION AND OPERATION SHIFT LEVER The shift lever is a type of linkage connected directly and lock shifting from 5th to reverse This unit decreases the possibility of any blown wear etc YAD5B010 YAD5B020 YAD5B030 TRANSMISSION ASSEMBLY ...

Page 1089: ...4th 5th Reverse Specification Capacity litre Change Interval Application SPECIFICATIONS T5WC Floor Change 3 969 1 2 341 1 1 457 1 1 000 1 0 851 1 3 710 1 ATF DEXRON II III 3 4 L Check Every 15 000 km Replace Every 50 000 km 33kg Description Notice Add LUBRIZOL 280cc in oil after overhauling ...

Page 1090: ...sem bly Remove extension adapter or case cover Check or replace damaged parts Adjust or replace clutch Add or replace with specified oil Remove extension adapter or case cover Check or replace damaged parts Remove extension adapter or case cover Check synchronizers and gears and replace damaged parts Check or replace backup switch Replace pilot bushing Adjust idle speed to specified speed Adjust o...

Page 1091: ...ed surfaces then check for leaks Clean or replace vent or breather Check oil level Tighten as specified Clean leaking surfaces Reapply sealant Replace oil seal Action Worn or damaged synchronizer Worn or damaged gears Improper or low transmission oil Loose bolts or other attaching parts Improper flywheel housing to engine crankshaft alignment Noisy transmission bearing Noisy gears Leakage from tra...

Page 1092: ...aring Reverse Idler Gear Bushing Counter Shaft Front Bearing Counter Shaft Rear Bearing Counter Shaft Thrust Bearing 5th Speed Drive Gear Bearing Slip Yoke Bushing Slip Yoke Seal Speedometer Drive Driven Gears Speedometer Driven Gear Housing Input Shaft Seal 1 2 Synchronizer Assembly 3 4 Synchronizer Assembly 5th Synchronizer Assembly Applicatio 1 Shift Hop out 2 Shift Gear Crash 3 Shift Block out...

Page 1093: ...ANGYONG Y200 COMPONENT LOCATOR CROSS SECTIONAL VIEW YAD5B040 1 4th Gear 2 3rd 4th Synchronizer 3 3rd Gear 4 2nd Gear 5 1st 2nd Synchronizer 6 Reverse Gear 7 1st Gear 8 5th Gear 9 5th Synchronizer 10 Counter Shaft 11 Reverse Idler ...

Page 1094: ...SSANGYONG Y200 5B 8 MANUAL TRANSMISSION POWER FLOW YAD5B100 YAD5B080 YAD5B060 YAD5B090 YAD5B070 YAD5B050 1st 3rd 5th Reverse 4th 2nd ...

Page 1095: ...ift Socket 5 Control Housing Arm Insulator 6 Control Housing Arm 7 Bushing 8 Shift Rod Link 9 Washer 10 Clip 11 Shift Rod Pin 12 Cover Assembly 13 Shift Tower Cover 14 Bolt 15 Breather Hose Bar 16 Control Shift Spring 17 Offset Control Lever 18 Retainer Ring 19 Pin 20 Shift Rail 21 Grove Pin 22 Pin Clip 23 Joint Assembly 24 Joint Housing 25 Bushing ...

Page 1096: ...mission Assembly 4 Back up Switch 5 Washer 6 Bolt 77 87 N m 7 Oil Drain Plug 25 N m 8 Bolt 81 89 N m 9 Washer 10 Front Propeller Shaft 11 Transfer Case Assembly 12 Speedometer Cable 13 Rear Propeller Shaft 14 Washer 15 Bolt 70 80 N m 16 Cross Member 17 Washer 18 Bolt 21 35 N m 19 Washer 20 Bolt 62 93 N m 21 Breather Hose ...

Page 1097: ...MANUAL TRANSMISSION 5B 11 SSANGYONG Y200 YAD5B460 TRANSMISSION ASSEMBLY DISASSEMBLED VIEW ...

Page 1098: ...51 1 2nd Blocking Ring 52 Outer Corn Race 53 Inner Corn 54 Sleeve Bearing 55 Sleeve 56 Needle Bearing 57 1st Speed Driven Gear 58 Bearing Corn 59 Bearing Cup 60 Thrust Bearing 61 Thrust Race 62 Blocking Ring 63 Spring 64 Insert 65 Synchronizer Sleeve 66 Spring 67 Blocking Ring 68 Synchronizer 69 3rd Speed Gear 70 Needle Bearing 71 Spacer 72 Snap Ring 73 Washer 74 2nd Speed Gear 75 Needle Bearing 7...

Page 1099: ...olt 116 Spacer Seal and O ring 117 Pivot Pin 118 Back up Switch 119 Transmission Case 120 Filler Drain Plug 121 Plug 122 Bolt 123 Input Bearing Retainer 124 Oil Seal 125 Shim 126 Bearing Cap 127 Bearing Corn 128 Input Drive Shaft 129 Roller Bearing ...

Page 1100: ...l Procedure 1 Remove the control housing arm insulator from the semi remote kit YAD5B120 YAD5B140 YAD5B130 2 Remove two snap rings and two screws using the snap ring plier Notice Do not reuse the damaged snap ring 3 Disconnect the shift rod pin using the punch MAINTENANCE AND REPAIR ...

Page 1101: ...socket lining and shift lever from the semi remote kit YAD5B160 YAD5B170 YAD5B180 7 Remove the control housing arm by rotating the clip pin 8 Remove the retainer ring from the U joint assembly using the snap ring plier YAD5B150 4 Remove the shift rod link from the semi remote kit 5 Remove four metal bushing from the shift rod ...

Page 1102: ...13 Inspect and clean all of the disassembled parts and replace as needed YAD5B200 YAD5B210 YAD5B220 Installation Procedure 1 Insert the shift rail to the cover 2 Pull the shift rail to the offset lever using the punch and assemble them YAD5B190 9 Remove the pin from the U joint assembly using the punch 10 Remove the U joint assembly from the cover assembly ...

Page 1103: ...ft socket from the control housing arm YAD5B160 YAD5B170 YAD5B240 5 Insert the clip pin to fix the cover assembly and the control housing arm 6 Insert the metal bushing to the shift rod YAD5B230 3 Insert the rail to U joint assembly and assemble the retainer ring using the snap ring plier ...

Page 1104: ...ANUAL TRANSMISSION 8 Insert the washer and assemble the snap ring YAD5B130 YAD5B260 9 Insert the control housing arm insulator to the semi remote kit YAD5B250 7 Assemble the shift rod the shift rail and U joint using the pin ...

Page 1105: ...ery 2 Lift up the vehicle and fix it safely 3 Remove the drain plug from the transmission housing and drain the oil Reinstall the drain plug 4 Disconnect the back up switch connector 5 Remove the breather hose YAD5B280 YAD5B290 YAD5B300 YAD5B310 6 Remove the speedometer connector and other wiring harnesses and connectors ...

Page 1106: ...des mounting bolts and remove the cross member 9 Remove the transmission mounting bolts Notice For removing the transmission there may be any damage in the clutch housing inside CSC Thus remove the transmission with the clutch housing 10 Move the transmission jack backward careful and disengage the transmission input shaft from the engine Remove the transmission YAD5B320 YAD5B330 YAD5B340 YAD5B020...

Page 1107: ... and release bearing 3 Check the pressure plate spring Notice Inspect each parts and replace the excessively worn parts 4 Check the clutch housing alignment as follows Place the magnetic base on the pressure plate spring Check the housing bore alignment YAD5B350 YAD5B360 YAD5B370 YAD5B380 Place the dial indicator on the bore By rotating the crankshaft one revolution record the dial indicator readi...

Page 1108: ...l Input shaft pilot bearing Notice Replace the excessively worn parts 6 Lubricate the clutch release bearing bore fork pivot head during assembly Installation Procedure 1 Install the transmission to the vehicle At this time seat correctly the input shaft of the transmission on the pilot bearing of the flywheel 2 Tighten the transmission mounting bolts as the specified torque on the vehicle Install...

Page 1109: ...lamp switch 7 Install the speedometer cable YAD5B430 YAD5B440 YAD5B450 YAD5B310 81 89 N m 60 66 lb ft 70 90 N m 52 66 lb ft Tightening Torque Front Rear 8 Charge the approved oil in the transmission housing and tighten the drain plug and the filler plug Installation Notice Oil 25 N m 18 lb ft 25 N m 18 lb ft Tightening Torque Filler Plug Drain Plug Spec Capacity 3 4L 2 0L 4WD 2WD ATF Dexron II ...

Page 1110: ...ition the offset lever in the 3 4 position of neutral Notice Removal of the offset lever in a position other than 3 4 of neutral will be difficult 4 Using a pin punch and a hammer remove the roll pin to remove the shift lever from the offset lever 5 Using a 15 mm wrench remove the 8 bolts from the extension housing 6 Separate the extension housing from the case and shift cover Separate the offset ...

Page 1111: ...using YAD5B510 YAD5B520 YAD5B540 YAD5B530 9 Remove the counter shaft thrust race and bearing 10 Carefully remove the oiling funnel from the end of the counter shaft 11 Using a 10 mm wrench remove the 10 bolts from the shift cover Notice For assembly note the location of the two bolts 12 Lift up the shift cover after sliding it toward the drain plug about 3 cm At this time remove sealer bond ...

Page 1112: ...a T 50 bit remove the 5th R lever pivot bolt Notice Apply sealer bond to this bolt during assembly 15 Using a 22 mm wrench remove the back up lamp switch from the 5 R lever side Notice Apply sealer to the threads 16 Pull out the 5th R lever out of the transmission 17 Using a snap ring pliers remove the 5th synchronizer snap ring from the end of the counter shaft ...

Page 1113: ...9 Remove the slip yoke snap ring from the main shaft 20 Remove the 5th speed drive gear snap ring from the main shaft 21 Make alignment marks on the case and input bearing retainer and remove the 4 input shaft bearing retainer bolts using a 13 mm wrench Remove the input bearing retainer with the bearing outer race and shim Notice Apply sealer on these bolts during assembly ...

Page 1114: ...ear blocking ring Main shaft thrust race and bearing Main shaft pilot bearing rollers 15 rollers Notice Be careful not to dissipate the pilot bearing rollers YAD5B630 YAD5B640 YAD5B660 YAD5B650 24 Remove the main shaft in 2 steps To remove the rear bearing outer race push the main shaft rearward Tilt and lift the main shaft from the case 25 Remove the reverse fork and spring from the case ...

Page 1115: ... and shim from the case Push the counter shaft rearward to remove the rear bearing outer race YAD5B670 YAD5B680 YAD5B700 YAD5B690 27 Using a pin punch and a hammer remove the roll pin fixed on the reverse idler shaft 28 By pushing the reverse idler shaft rearward and out of the case remove the reverse idler gear and O ring 29 Using a puller remove the rear bearing assembly from the counter shaft ...

Page 1116: ...ainer and counter shaft rear bearing outer race Tighten the 4 retainer bolts Installation Notice 3 Place a dial indicator on the case and measure counter shaft end play by moving up and down 4 Select a shim which is the same thickness as the indicator rearing up to 0 004 inch and assemble it 5 When the end play is correctly adjusted remove the counter shaft rear bearing retainer and outer race 6 U...

Page 1117: ...into the rear of the case Install the 4th speed blocking ring onto the front of the main shaft Install the input shaft onto the front of the main shaft Install the input bearing retainer without shim onto the front of the case Using a torque wrench tighten the 4 bolts Installation Notice 9 Install the 5th speed drive gear and blocking ring on the counter shaft 10 Install the 5th synchronizer and r...

Page 1118: ... Check the operation of the 5 R shift mechanism at this time 15 Using a snap ring piers install the slip yoke snap ring onto the end of the main shaft 16 Make sure that the 1 2 and 3 4 synchronizer sleeves and 5 R shift lever are in neutral position 17 Align the holes the case and cover with alignment type bolts Tighten the 10 bolts Installation Notice 18 Apply RTV sealant on the sealing surface o...

Page 1119: ...roll pin 25 Turn the transmission case reversely and place a dial indicator on the extension housing Move the input and main shift up and down and measure end play Select a shim which is the same thickness as the measurement 0 001 inch After shim installation the end play should be 0 26 Remove the input bearing retainer and do the following Install the adjusting shim behind the input bearing outer...

Page 1120: ...cables to the shift lever YAD5B850 YAD5B870 YAD5B860 MAIN SHAFT Disassembly Procedure 1 For correct reassemble place an alignment mark on the 3 4 Synchronizer hub and sleeve 2 Using a hydraulic press and puller plate remove the 3 4 Synchronizer assembly and the 3rd speed gear 3 Remove the 3rd speed gear bearing and spacer 4 Using a snap ring pliers remove the 2nd speed gear snap ring 5 Remove the ...

Page 1121: ...river remove the spiral retaining ring 8 Remove the thrust washer and three piece 2nd speed blocking ring assembly 9 For correct reassembly place an alignment mark on the 1 2 synchronizer hub and sleeve 10 Remove the 1 2 synchronizer sleeve from the hub with following parts The anti rattle ball and spring The three keys One of the 3 springs ...

Page 1122: ...a hydraulic press and puller plate remove the 5th speed driven gear from the main shaft YAD5B920 YAD5B930 YAD5B950 YAD5B940 12 Remove the main shaft rear bearing assembly from the shaft 13 Remove the 1st speed gear and bearing 14 Remove the inner race ...

Page 1123: ...ng installation Notice Before assembly coat all parts with lubricant In case of the paper lined blocking rings soak them in DexronII III before installation 2 Assemble the following parts 1st speed blocking ring Alignment pin and 1st speed gear bearing race 1st speed gear and its bearing 3 Install the rear bearing assembly to the main shaft YAD5B980 4 Using a hydraulic press and installer press th...

Page 1124: ... gear 3rd speed blocking ring YAD5B0A0 YAD5B0B0 YAD5B0D0 YAD5B0C0 6 Using a hydraulic press and installer install the 3 4 synchronizer hub onto the main shaft Notice Align the blocking ring with the synchronizer keys while installing the hub INPUT SHAFT Disassembly Procedure 1 Remove the following parts from the input shaft Main shaft thrust race and bearing Main shaft pilot bearing rollers 15 rol...

Page 1125: ...c press and installer press the input shaft bearing onto the input shaft 2 Apply grease to the thrust bearing inner roller 15 rollers and install the main shaft thrust bearing and its race in the rear of the input shaft YAD5B0G0 3 Using a rubber hammer and installer install the input bearing retainer and input shaft seal after applying grease 4 Install the bearing outer race to the retainer withou...

Page 1126: ...installer press the front bearing assembly onto the counter shaft 2 Install is as follows Install a new O ring on the counter shaft outer race and lubricate it Using a installer lightly tap the race into its bore until the O ring is compressed Install the race to be fully seated on the inside of the case EXTENSION HOUSING Disassembly Procedure 1 Remove the vent from the extension housing 2 Remove ...

Page 1127: ...e removal note the correct position of the interlock plate and selector arm and remove the shift shaft 3 Check and clean all removed parts and replace if necessary YAD5B0P0 Assembly Procedure 1 If the shaft cup plug was removed apply plug outer surface with sealer and install it into the cover 2 Install the fork pads and selector plates onto the 1 2 and 3 4 shift forks 3 Assemble the sift cover pa...

Page 1128: ... and its selector plate YAD5B0R0 YAD5B0S0 YAD5B0U0 YAD5B0T0 Push the shift shaft through the 1 2 shift fork Place the selector arm and interlock plate in the cover Note the position of the interlock plate and selector arm Push the shift shaft through the 3 4 shift fork ...

Page 1129: ...gh the 3 4 shift fork YAD5B0X0 YAD5B0V0 Install the roll pin that fixes the selector arm to the shift shaft 4 Check the shift cover parts for proper assembly as follows Insert a pin punch 3 16 into the offset lever hole of the shift shaft Place the shift cover to the flat ground and rotate the shift shaft so that the punch is vertical ...

Page 1130: ...SSANGYONG Y200 5B 44 MANUAL TRANSMISSION Selector arm should be aligned with the 3 4 shift fork selector plate YAD5B0Z0 YAD5B1A0 5 Lubricate and install the O ring on the rear of the shift cover ...

Page 1131: ...ift Cover Input bearing retainer Counter shaft rear bearing retainer 2 Check the parts which support bearings and shafts for excessive wear and replace them if necessary YAD5B1D0 YAD5B1B0 3 Check the bearing surfaces of the following parts Input shaft Main shaft and its gears Counter shaft and 5th drive gear 4 Check the reverse idler shaft and its gears Notice Replace excessive wear parts and do n...

Page 1132: ...s on the following parts Selector arm Interlock plate Selector plates for the 1 2 and 3 4 shift forks 5 R shift lever and the rollers on the reverse fork and the 5th shift rail fork 7 Check worn mating surfaces on the following parts 1 2 shift fork pads and synchronizer sleeve 3 4 shift fork pads and synchronizer sleeve 5th shift rail fork pads and synchronizer sleeve Reverse fork and reverse idle...

Page 1133: ...bearing Main shaft pilot bearing rollers Main shaft thrust Bearing and its surfaces Speed gear roller bearing on the main shaft Main shaft rear bearing Counter shaft front and rear bearings YAD5B1L0 YAD5B1J0 9 Check the gear tooth surfaces of all gear sets 10 Check the reverse gear set surfaces Check the surfaces of gear teeth for excessive wear pitting scoring and spalling and replace if necessar...

Page 1134: ...en the hub and sleeve of each synchronizer Excessively tight or loose hub to sleeve fit Wear of the cone clutch surfaces of brass blocking rings and gears 13 Measure the clearance between the blocking ring and the speed gear New 1 2 blocking ring 0 87 1 4mm New 3 4 blocking ring 0 88 1 5mm Notice Excessive wear of the blocking ring or the speed gear cone surface will cause shift block out gear cla...

Page 1135: ...L TRANSMISSION 5B 49 SSANGYONG Y200 14 Check for gear clash on the synchronizer sleeve teeth or the clutch teeth on the speed gear 15 Check the synchronizer sleeve and gear clutch tooth for hop out YAD5B1S0 ...

Page 1136: ...C 5 Component Locator 5C 6 Cross Sectional View 5C 6 Clutch Hydraulic Lines 5C 7 Clutch Disc Assembly 5C 8 Clutch Pedal Assembly 5C 9 Maintenance and Repair 5C 10 On Vehicle Service 5C 10 Clutch Disc 5C 10 Master Cylinder 5C 12 Clutch Pedal 5C 13 Clutch Pedal Box 5C 14 Inspecton Procedure 5C 15 Clutch Disc 5C 15 Clutch Pedal 5C 16 Special Tools and Equipment 5C 17 Special Tools Table 5C 17 ...

Page 1137: ...nput shaft through these same splines The driving and driven members are held in contact by spring pressure This pressure is exerted by a diaphragm spring in the pressure plate assembly Operating members The clutch release system consists of the clutch pedal the clutch release shaft the clutch cable the release arm and the release bearing When pressure is applied to the clutch pedal the clutch rel...

Page 1138: ...ove the air bolt cap of the release cylinder Connect a vinyl tube to the bolt 2 Insert the other end of the tube in a vacant container 3 Slowly depress the clutch pedal several times 4 With clutch pedal fully depressed open the air bolt and release air rind fluid in the fluid line 5 Repeat this procedure until there are no more air bubbles in the fluid flows YAD5C030 YAD5C040 ...

Page 1139: ...tch Cover Assembly Setting Weight Clutch Master Cylinder Clutch Fluid Type Max Pedal Stroke Pedal Free Play Type Facing O D I D Thickness Facing and Quantity Thickness of Disc Stroke Inner Diameter SPECIFICATIONS Hydraulic Suspended 5 10 mm Single Dry Diaphragm 240 155 mm 22 cm2 1 610 kg 28 4 mm Ø15 87 mm DOT3 or DOT4 ...

Page 1140: ...Faulty Pressure Plate Bent Clutch Diaphragm Spring Hard or Bent Flywheel Engine Mounts Loose or Burnt Lever Poor Lubrication on Clutch Cable Poor Lubrication on Pedal Shaft Poor Lubrication on Clutch Pedal Insufficient Clutch Pedal Free play Excessive Wear of Facing Worn or Damaged Release Bearing Poor Lubrication Contact Surface of Bearing Faulty Installation of Clutch Assembly or Bearing Damaged...

Page 1141: ...TCH COMPONENT LOCATOR CROSS SECTIONAL VIEW YAD5C050 1 Clutch Disc 2 Clutch Cover 3 Clutch Housing 4 Concentric Slave Cylinder 5 Adapter 6 Bolt 7 Bolt 8 Hose 9 Spring Lock Washer 10 Transmission Input Spline 11 Bolt 12 Gasket ...

Page 1142: ...CLUTCH 5C 7 SSANGYONG Y200 CLUTCH HYDRAULIC LINES YAD5C020 1 Clutch Pedal 2 Clutch Master Cylinder 3 Clutch Hydraulic Line 4 Clutch Oil Chamber 5 Clutch Hydraulic Hose ...

Page 1143: ...CLUTCH CLUTCH DISC ASSEMBLY YAD5C060 1 Clutch Disc 2 Clutch Cover 3 Concentric Slave Cylinder 4 Clutch Housing 5 Bolt and Washer 35 N m 26 lb ft 6 Bolt and Washer 47 N m 35 lb ft 7 Bolt and Washer 47 N m 35 lb ft 8 Adapter ...

Page 1144: ... 7 Nut 8 18 N m 8 Fulcrum Pin 9 Turn Over Spring Apply Grease 10 Bushing Replace Apply Grease 11 Full Stroke Stopper Contact Pad 12 Interlock Switch Stopper Pad 13 Clutch Pedal 14 Pedal Pad 15 Pedal Mounting Bracket 16 Stopper Bolt 16 22 N m 12 16 lb ft Notice Assembly should follow the disassembly procedure in the reverse order Grease specification Long term grease T Mn DBL6611 00 ...

Page 1145: ...ice Notice When the clutch housing and the transmission is removed it may be possible any damage in the concentric slave cylinder 3 Unscrew the clutch housing bolts and remove the clutch housing release fork and release bearing Insert the centering pin into the clutch spline Loosen the clutch cover bolts 1 2 turn in crisscross sequence until the spring tension is released Notice Do not remove the ...

Page 1146: ...de 7 Remove the concentric slave cylinder mounting bolt and remove the concentric slave cylinder from the input shaft 8 Remove the spacer from the input shaft YAD5C100 4 Unscrew the bolts and remove the clutch cover pressure plate and clutch disc Notice Be careful not to drop the pressure plate and clutch disc Installation Notice Tightening Torque 21 27 N m 15 20 lb ft ...

Page 1147: ...tch tube Installation Notice Notice Be careful not the fluid contact a painted surface Tightening Torque 15 18 N m 11 13 lb ft 4 Remove the master cylinder mounting nuts and pull off the master cylinder Installation Notice 5 Check the clutch pedal operation 6 Bleed the clutch system 7 Installation should follow the removal procedure in the reverse order Tightening Torque 15 18 N m 11 13 lb ft YAD5...

Page 1148: ...ylinder push rod and separate the push rod and the clutch pedal 3 Remove the pedal mounting and nut from the clutch pedal bracket and remove the pedal from the bracket YAD5C190 YAD5C200 YAD5C210 YAD5C220 4 Installation should follow the removal procedure in the reverse order Perform the following procedure for installation Apply the grease to the clutch pedal clevis pin and pedal bushing ...

Page 1149: ...he height according to the A free play of the push rod CLUTCH PEDAL BOX Removal Installation Procedure 1 Remove the clutch master cylinder 2 Remove the upper bolt from the clutch pedal box and remove the clutch pedal assembly 3 Installation should follow the removal procedure in the reverse order Notice Charge the clutch oil as specified and then bleed the system YAD5C230 YAD5C240 YAD5C250 YAD5C26...

Page 1150: ...ivet for looseness and replace the clutch cover if loosened 2 Clutch Disc Check the facing for rivet looseness excessive runout sticks oil and grease Measure the rivet head depth If out limit replace the disc 3 Clutch Disc Plane Rate Measure the clutch disc plane rate and replace the disc as needed YAD5C270 YAD5C280 YAD5C290 Unevenness Limit 0 8 mm Wear Limit 0 3 mm Limit Value 0 7 mm INSPECTION P...

Page 1151: ...olt until the height is correct 3 Pedal Free Play E Notice To adjust the pedal free play loosen the lock nut F of the master cylinder and turn the push rod until the free play is correct 4 Check the fulcrum pin and the bushing for wear the pedal for bending and the spring for damage YAD5C310 Max Stroke 158 mm 148 mm GSL DSL Height From the Floor Carpet 182 5 mm Free Play 5 10 N m YAD5C300 4 Concen...

Page 1152: ...CLUTCH 5C 17 SSANGYONG Y200 SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE 602 589 00 40 00 Engine Lock 661 589 00 15 00 Centering Pin YAD5C320 YAD5C330 ...

Page 1153: ...Infromation and Procedures 5D1 10 General Diagnosis 5D1 10 Self Diagnosis Test 5D1 11 Diagnostic Diagram 5D1 15 Component Locator 5D1 16 Cross Sectional View 5D1 16 Transfer Case Assembly 5D1 17 Disassembly and Assembly 5D1 18 Maintenance and Repair 5D1 20 On Vehicle Service 5D1 20 Maintenance of Transfer Case Lubricant 5D1 20 4H and 4L Indicator 5D1 21 TCCU Inspection 5D1 21 Transfer Case Assembl...

Page 1154: ...riving force requiring condition such as towing rough road When a vehicle is driven in turning at low speed on the paved road a vibration and a noise may be occurred by tight corner braking 2WD 4WD transfer is possible below 70 km without operating the clutch Manual Transmission Transfer starts after the vehicle stops and the clutch is applied Automatic Transmission Transfer starts after the vehic...

Page 1155: ... yy yy yy y y yy yy y y yy y yyy yy yy yy y yy yy y yyy y y y y y yy yy y yy y y yyy yyyyyyy yyyyyyy yy yy y y y y y y yy y yyy yy yy yy yy yy y yyy yyy y y y y y y yy yy yy yy y y y yy yy yy y y yyy yyy yyy yyy yyyyy y y y y y y y yy yyyy yyyy yyyy yyyy yyyy yy yy yy yy y y y y y y y y y yy y y SYSTEM STRUCTURE YAD5D010 ...

Page 1156: ... 4 PART TIME T C Power Flow TCCU Switch Transfer 2H 4H 4L Rear Propeller Shaft Rear Wheel Front Axle Transfer Locking Hub Solenoid Locking Hub Operation Vacuum System Operation Front Propeller Shaft Front Wheel Rear Axle ...

Page 1157: ...y y y y yy yy yy yyyy yyyyyyyyyy yyyyyyyyyy yyyyyyyyyy yy yy y y y y y y yyy y yy yy yy yy y y yyyy yyyy y y y y y yy yy y y yy yy y yy yy yyy yyy yyy y y yy yy yyy yyy yyy yyy yy yy yyyyyy y y yy yy yy yy yy yy yyyyyy yyyyyy yyyyyy yyyyyy yyyyyy yy yy yy yy y y y y y yy yy y y yy yy yy yy y y y y 2H MODE REAR WHEEL DRIVE YAD5D020 Power Flow Rear Axle Rear Wheel Transmission Output Shaft T C Input...

Page 1158: ...yyyy yyyyyyyyyy yyyyyyyyyy yyyyyyyyyy yy yy y y y y y y yyy y yy yy yy yy y y yyyy yyyy y y y y y yy yy y y yy yy y yy yy yyy yyy yyy y y yy yy yyy yyy yyy yyy yy yy yyyyyy y y yy yy yy yy yy yy yyyyyy yyyyyy yyyyyy yyyyyy yyyyyy yy yy yy yy y y y y y yy yy y y yy yy yy yy y y y y 4H MODE 4WD DRIVE HIGH SPEED YAD5D030 Power Flow Hub Chain Motor Output Shaft Front Propeller Shaft Transmission Input...

Page 1159: ...yy yyyyyyyyyy yyyyyyyyyy yyyyyyyyyy yy yy y y y y y y yyy y yy yy yy yy y y yyyy yyyy y y y y y yy yy y y yy yy y yy yy yyy yyy yyy y y yy yy yyy yyy yyy yyy yy yy yyyyyy y y yy yy yy yy yy yy yyyyyy yyyyyy yyyyyy yyyyyy yyyyyy yy yy yy yy y y y y y yy yy y y yy yy yy yy y y y y 4L MODE 4WD DRIVE LOW SPEED YAD5D040 Power Flow Chain Motor Output Shaft Front Propeller Shaft Transmission Input Shaft ...

Page 1160: ...icle to shift from two wheel drive to four wheel drive and back shift according to drivers switch operation during driving For the shifting between 4WD HIGH and 4WD LOW stop the vehicle 3 Shifting between 4H and 4L Shifting is possible when the vehicle is almost stopped below approx 2 km h so it would be better stop the vehicle In case of manual transmission equipped vehicle apply clutch pedal In ...

Page 1161: ...l Type Gear Ratio Oil Manufacturer Weight High Low Specification Capacity Lubrication SPECIFICATIONS Part Time 4408 E E S O F Type 1 1 2 48 1 ATF S 3 S 4 or DEXRON II III 1 2 L Check Every 15 000 km Replace Every 50 000 km Borg Warner 30 kg ...

Page 1162: ... and check replace if neces sary Overhaul and check for wear and damage Replace if necessary Check sliding parts replace if neces sary Drain and replace with specified oil Retighten as specified Disassemble bearings and parts and check for wear or damage Replace if necessary Check for wear and damage including speedometer gear replace if neces sary Disassemble and check for wear and damage replace...

Page 1163: ...tor switch Motor position sensor YAD5D110 3 Transfer case system is malfunctioning when 4H 4L indicator lights are remain on after 0 6 second when turning the ignition switch ON 4H 4L indicator lights are continuously come on during driving 4 If only 1 part is malfunctioning 4WD CHECK indicator light will display defective code 3 times continuously 5 If more then 2 part is malfunctioning the first...

Page 1164: ...n the ignition switch to ON 4 Read the flashing 4WD CHECK indicator light and identify the malfunctioning part See Diagnosis Table How to Clear the Fault Code 1 Position the ignition switch to OFF 2 Using a service connector connect the No 2 pin GND and No 13 pin TCCU of the diagnosis socket in the engine room 3 Position the ignition switch to ON over 5 seconds 4 Do defective code reading and make...

Page 1165: ...ond and turn off for 3 seconds and then display a defective code 3 times continuously 4WD CHECK Light ON OFF 4WD CHECK Light ON OFF 4WD CHECK Light ON OFF 4WD CHECK Light ON OFF 4WD CHECK Light ON OFF TCCU Shift Motor Synchronizer Clutch Speed Sensor Locking Hub Solenoid Defective Code No 1 2 3 4 5 Malfunctioning Part YAD5D140 YAD5D150 YAD5D160 YAD5D170 YAD5D180 ...

Page 1166: ...SSANGYONG Y200 5D1 14 PART TIME T C 4WD CHECK Light ON OFF 4WD CHECK Light ON OFF Selector Switch Motor Position Sensor Defective Code No 6 7 Malfunctioning Part YAD5D190 YAD5D200 ...

Page 1167: ...PART TIME T C 5D1 15 SSANGYONG Y200 DIAGNOSTIC DIAGRAM YAD5D210 ...

Page 1168: ... yy yy yy yy yy yy yyy y y y y y yy yy yy yyy yyy y y yy yy yy yy yy y yy yy yy yy yy yyyy yyyyyyyyyy yyyyyyyyyy yy yy yy yy y y yy yy yy yy yy yyy yyy y y y yy yy yy yyy yyy y y yy yy yy yy yy yy yy y yy yy yy yy yy y y yyy yyy yyy yyy yyyyyyy y y yy yy yy yy yy yy yyyyy yyyyy yyyyy yyyyy yyyyy yyyyy yy yy yy yy y y y yy yy y y yy yy yy yy y y COMTONENT LOCATOR CROSS SECTIONAL VIEW YAD5D250 ...

Page 1169: ...EMBLY YAD5D260 1 Rear Companion Flange 2 Case Cover 3 Front Companion Flange 4 Breather Plug 5 Transfer Case 6 Input Shaft 7 Mounting Bolt 8 Transmission Extension Housing 9 Bolt 10 Washer 11 Front Propeller Shaft 12 Bolt 13 Washer 14 Rear Propeller Shaft ...

Page 1170: ...SSANGYONG Y200 5D1 18 PART TIME T C DISASSEMBLY AND ASSEMBLY YAD5D370 ...

Page 1171: ...g 34 Magnet 35 Clutch Housing 36 Snap Ring 37 Snap Ring 38 Lock up Hub 39 Sleeve Return Spring 40 Lock up Collar 41 Rail Shaft 42 Lock up Fork 43 Snap ring 44 Spacer 45 Driven Sprocket 46 Driving Sprocket 47 Drive Chain 48 Nut 49 Gasket 53 Spring Pin 54 Hose Clamp 55 Hose Coupling 56 Oil Strainer 58 Reduction Hub 59 Shift Fork Assembly 60 Shift Fork Facing 61 Roller and Retainer 66 Nut 67 Plane Wa...

Page 1172: ...TENANCE AND REPAIR Tightening Torque 20 30 N m 15 22 lb ft 2 Oil Change Clean the oil level plug and surrounding area Place a suitable container under the transfer case Remove the oil and tighten the drain plug Fill the oil through the oil level plug until oil begins to drip out Tighten the oil level plug 3 Cautions for oil level check and plugs tightening Do not use an impact wrench to remove or ...

Page 1173: ...ied Clutch pedal released 4L indicator light ON 4L indicator light OFF Motor OFF Motor ON Motor OFF Motor ON Auto locking hub ON Auto locking hub OFF TCCU INSPECTION 4 75 5 35 0 0 50 1 00 11 00 4 75 5 35 0 0 50 0 50 11 00 1 00 11 00 1 00 11 00 1 00 11 00 11 00 1 00 Pin No Voltage V Operation Condition Notice DC 12V for the TCCU operation should be maintained In case of J1 8 and J1 15 indicator lig...

Page 1174: ...e Front Rear YAD5D270 YAD5D280 TRANSFER CASE ASSEMBLY 1 Disconnect the negative terminal from the battery 2 Lift up the vehicle and fix it safely 3 Remove the damper mounting bolt 4 Remove the drain plug and drain the oil Reinstall the drain plug Installation Notice Tightening Torque 19 30 N m 14 22 lb ft YAD5D290 5 Remove the breather hose 6 Disconnect the speedometer cable connector and other ca...

Page 1175: ...ter mounting nuts and end sides mounting bolts of the cross member and then remove the cross member Installation Notice 9 Remove the transfer case by removing the bolts attaching the transfer case to the transmission Installation Notice Notice Apply long term grease to the inner spline of the transfer case input shaft 10 Installation should follow the removal procedure in the reverse order ...

Page 1176: ...D340 YAD5D350 YAD5D360 2 Remove the TCCU connector 3 Remove the TCCU mounting bolt and remove the TCCU TCCU installation position Under the driver s seat 4 Installation should follow the removal procedure in the reverse order Notice Be careful not to give any impact to the TCCU body Installation Notice Tightening Torque 10 N m 89 lb ft ...

Page 1177: ...ge 1 Holding the companion flange remove the nut and washer and then remove the companion flange 2 Remove the oil seal 3 Remove the companion flange from the case cover Case Cover Assembly 1 Remove the cover mounting bolts 9 and the case mounting bolts 5 Notice Identification tag has information required for ordering replacement parts so be careful not to lose it 2 Using a driver pry and disconnec...

Page 1178: ... connector 4 Remove the clutch coil assembly mounting nut YAD5D440 YAD5D450 5 Remove the snap ring and pull out the ball bearing from the cover to remove the speed gear 6 Remove the clutch coil assembly and the oil seal from the cover 7 Remove the speed sensor and the O ring from the case cover ...

Page 1179: ...490 2 Remove the clutch housing assembly from the output shaft Clutch Housing Component 1 Retaining Ring 2 Shift collar Hub 3 Clutch Housing Remove the shift cam from the shaft Fix the shaft at the vise with the cam removed and remove the torsion bar using a driver 3 Remove the 2WD 4WD lock up assembly the lock up fork and rail shaft from the output shaft ...

Page 1180: ...Lock up Hub 39 Return Spring 40 Lock up Collar 4 Remove the snap ring from the front output driven sprocket and separate the snap ring and the spacer 5 Remove the driving sprocket the driven sprocket and the driving chain from the front rear output shaft 6 Remove the oil pump assembly and the magnetic from the output shaft ...

Page 1181: ...ing from the output shaft Separate the front pump and remove the output shaft YAD5D560 Reduction Shift Parts 1 Remove the reduction hub and reduction shift fork assembly from the case 2 Remove the 2 shill fork facings from the shift fork assembly 3 To remove the roller cam and pin cut elf the plastic retainer when disassembling the fork assembly Front Output Assembly 1 Holding the companion flange...

Page 1182: ...ap ring pull out the bearing and thrust washer from the input shaft assembly and separate the input shaft assembly from the carrier gear assembly 6 Remove the needle bearing and sleeve bearing from the input shaft assembly 7 Remove the retaining ring thrust plate rind sun gear from the planet carrier assembly Notice Do not disassemble the planet carrier assembly Transfer Case Assembly Front 1 Remo...

Page 1183: ...arts Notice Always replace the hose coupling O ring and oil seal with new parts 2 Inspection Terms Burr Local rise of material forming protruding sharp edge Chip An area from which a small fragment has been broken off or cut Crack Surface break of line nature indicating partial or complete separation of material Excessive wear Heavy or obvious wear beyond expectations considering conditions of ope...

Page 1184: ...ontact and non contact surfaces Uneven wear Condition of localized unevenly distributed wear Includes hollows shiny spots uneven polish and other visual indications 3 Specific Inspection Referring to normal gear tooth face specifically inspect the uneven wear and chips of gear tooth Replace or repair if necessary YAD5D590 ...

Page 1185: ...ONG Y200 Normal Wear End Face Wear Traveling Face Wear Upper Face Wear Lower Face Wear Normal Description Abnormal YAD5D600 YAD5D610 YAD5D630 YAD5D620 YAD5D640 YAD5D650 YAD5D660 4 Inspection of contact patterns YAD5D670 YAD5D680 ...

Page 1186: ...ve face Corner chip at coast face Chip within contact pattern Chip completely through tooth Side edge chip at drive face Patterns Description Action YAD5D690 YAD5D700 YAD5D710 YAD5D720 5 Chip pattern of the gear face YAD5D730 Repair Repair Repair Replace Replace Replace YAD5D740 ...

Page 1187: ... was removed align the outer diameter of the new replaced ring gear with transfer case and assemble it 2 Insert the pin 3 Insert the ball bearing to the case and install the retaining ring 4 Install the new oil seal by pressing into the case 5 Make sure that all parts are correctly and firmly installed into the case Electric Shift Cam Parts 1 Insert the spacer into torsion spring 2 Insert the end ...

Page 1188: ...the end of the first spring to fix on the drive tang 4 Push the end of the second spring to right and fix it on the drive tang 5 Push the torsion spring and spacer together back them completely 6 Slide the electric shift cam onto the shift shaft 7 Install the electric shift cam assembly into the transfer case after installation of the shift fork ...

Page 1189: ...y 6 Install the planet carrier assembly onto the input shaft and install the thrust washer Press the bearing over input shaft 7 After pressing the bearing install the retaining ring 8 Press the pin into the front adapter 9 Slowly press the oil seal into the front adapter 10 Install the front adapter assembly Notice After installation make sure that snap ring is correctly installed into the groove ...

Page 1190: ...hift Parts 1 Install the new pin roller and retainer into the reduction shift fork 2 Press the pin roller and retainer into the reduction spilt fork bore completely Notice Make sure that the cam roller turns freely 3 Install the 2 fork facing on the reduction shift fork assembly 4 Install the reduction shift fork onto the previously installed reduction hub in the transfer case 5 Install the output...

Page 1191: ...mp 6 Position the pump rear cover to be the TOP REAR mark up and located at the top of transfer case when installed in vehicle Position the pump retainer on the cover so that tab on the retainer is in notch in the transfer case Apply Loctite to the bolts and tighten the bolts with turning the output shaft by hand to make the pump pins move freely Installation Notice Tightening Torque 4 8 5 N m 35 ...

Page 1192: ... hub to the output shaft spline 5 Install the previously assembled electric shift cam and assemble the clutch housing as follows Rotate the shift cam assembly to right so that the end of the torsion spring contacts with reduction shift fork side Holding the rail shaft lift up the fork assembly slightly Adjust electric shift cam assembly so that the roller on reduction shift fork assembly is in gro...

Page 1193: ...oil assembly Install the clutch coil assembly inside the cover and tighten 3 nuts Installation Notice Install the bearing and motor bearing into the cover YAD5D910 Cover Assembly 1 Install the return spring over rail shaft in the transfer case 2 Insert the magnet into the transfer case slot 3 Apply 1 6mm bead of Loctite RTV 598 to the transfer case mounting surface Notice For installation of cover...

Page 1194: ... 48 N m 21 35 lb ft YAD5D920 YAD5D930 YAD5D940 External Electric Shift 1 Align the motor with shift shaft and position the motor assembly onto the cover 2 Install the motor to the shift shaft and contact cover and rotate the motor clockwise direction to check correct engagement 3 Insert the 0 ring on the speed sensor assembly to the cover 4 Install the bracket to the motor assembly and tighten 3 b...

Page 1195: ...on Flange 1 Install the 2 plugs to the cover 2 Install the companion flange oil seal and washer 3 Holding the companion flange tighten the nut Installation Notice Notice Apply Loctite 262 to nut before installation Tightening Torque 346 380 N m ...

Page 1196: ...ator Blink Steadily 5D2 33 Diagnostic Trouble Code DTC 1714 5D2 34 Diagnostic Trouble Code DTC 1715 5D2 36 Diagnostic Trouble Code DTC 1716 5D2 38 Diagnostic Trouble Code DTC 1721 5D2 40 Diagnostic Trouble Code DTC 1722 5D2 42 Diagnostic Trouble Code DTC 1731 5D2 44 Diagnostic Trouble Code DTC 1732 5D2 46 Diagnostic Trouble Code DTC 1733 5D2 48 Diagnostic Trouble Code DTC 1734 5D2 50 Diagnostic Tr...

Page 1197: ...joins with output shaft and drives at low position The TOD system has 2 selectable mode 4H and 4L 4H is the normal operating mode when drive of which gear ratio is 1 1 and 4L mode distributes power to front and rear wheels 50 50 of which gear ratio is 2 48 1 TOD SYSTEM FUNCTION 4H Mode The TOD system transfer case controls the clutch mechanism to comply with rotation in front and rear propeller sh...

Page 1198: ...driving force requiring condition such as towing rough road Same function as part time transfer case 4L A vehicle should stop for transfer Manual Transmission Transfer starts after the vehicle stops and the clutch is applied Automatic Transmission Transfer starts after the vehicle stops and the shift lever is shifted N position Operation Condition Mode Position Notice After the vehicle stops and t...

Page 1199: ...y ÀÀ ÀÀ y y Q Q Q Q Q QQ Q Q Q y y y QQ QQ QQQ QQQ y yyy QQ Q Q ÀÀ y À y À ÀÀ ÀÀ y yy Q QQQ QQQ À À yyy Q Q Q Q Q y Q yyy yyy yyy y ÀÀÀ ÀÀÀ yy yy yy Q Q yy yy Q QQ QQ QQ QQ QQQQ ÀÀ Q Q ÀÀ ÀÀ ÀÀ ÀÀ ÀÀÀ À yy À À yyy yyy ÀÀÀ ÀÀÀ ÀÀÀ y y Q Q Q Q Q Q Q Q Q ÀÀÀ yy yy À À ÀÀÀ ÀÀÀ ÀÀÀ y y yyy yyy SYSTEM STRUCTURE YAD5D010 ...

Page 1200: ... yy y y ÀÀ ÀÀ yyy yyy ÀÀÀ ÀÀÀ ÀÀÀ ÀÀÀ y Q Q Q Q Q Q Q Q Q y y yy yy QQ QQQQ QQQQ QQQQ y yyyy yyyy QQ QQ QQ ÀÀÀ ÀÀÀ yy À À y y ÀÀ ÀÀ ÀÀÀ ÀÀÀ ÀÀÀ y yyy yyy QQ QQQQ QQQQ À À yyyy yyyy QQ Q Q Q yy yy QQ yyyy yyyy yyyy yyyy yyyy y ÀÀÀÀ ÀÀÀÀ ÀÀÀÀ yyy yyy yy yy QQ QQ yy yy Q Q Q Q Q QQQQQ ÀÀ Q Q Q 4H MODE 4WD DRIVE HIGH SPEED YAD5D020 ...

Page 1201: ... Shaft Rear Propeller Shaft Rear Speed Sensor TOD Control Unit Magnetic Clutch MAX DUTY Multi Plate Clutch Front Propeller Shaft Throttle Open Rate TPS Value Driving Sprocket Force Distribution Unit BALL RAMP Transmission Input Shaft Front Speed Sensor Chain ...

Page 1202: ...À yy y y ÀÀ ÀÀ yyy yyy ÀÀÀ ÀÀÀ ÀÀÀ ÀÀÀ y Q Q Q Q Q Q Q Q Q y y yy yy QQ QQQQ QQQQ QQQQ y yyyy yyyy QQ QQ QQ ÀÀÀ ÀÀÀ yy À À y y ÀÀ ÀÀ ÀÀÀ ÀÀÀ ÀÀÀ y yyy yyy QQ QQQQ QQQQ À À yyyy yyyy QQ Q Q Q yy yy QQ yyyy yyyy yyyy yyyy yyyy y ÀÀÀÀ ÀÀÀÀ ÀÀÀÀ yyy yyy yy yy QQ QQ yy yy Q Q Q Q Q QQQQQ ÀÀ Q Q Q 4L MODE 4WD DRIVE LOW SPEED YAD5D030 ...

Page 1203: ... Propeller Shaft Rear Speed Sensor TOD Control Unit Magnetic Clutch MAX DUTY Multi Plate Clutch Front Propeller Shaft Front Speed Sensor Throttle Open Rate TPS Value Driving Sprocket Force Distribution Unit BALL RAMP Transmission Input Shaft Planetary Gear 2 483 Chain ...

Page 1204: ... kg 4H and 4L 1 1 2 48 1 ATF S 3 S 4 or Dexron II III 1 4 L Inspect Every 15 000km Replace Every 50 000km 550 lb ft 76kg cm 9 16 V 6 16 V 2 mA 1 A 7 A 20 A High Low Specification Capacity Interval TOD TOD Control Unit Model Length Weight w oil Shift Mode Gear Ratio Oil Max Torque Voltage Current Below Max Operation Voltage Max Operation Current SPECIFICATIONS Check Action ...

Page 1205: ...ransfer Case Mounting Bolt Rear Output Shaft Flange Mounting Nut Rear Propeller Shaft Rear Output Shaft Flange Mounting Bolt Shift Motor Adjusting Nut Shift Motor Bracket Bolt Shift Motor Mounting Bolt Speed Sensor Retaining Bolt Transfer Case Control Unit TCCU Retaining Bolts Transfer Case Transmission Adapter Housing Mounting Bolt N m 10 25 25 31 85 35 167 85 5 10 10 5 10 48 Kgf m 1 0 2 5 2 5 3 ...

Page 1206: ...QQ QQ QQ QQ QQ QQ QQ QQ yy y y QQ QQ QQ QQQQ QQQQ QQQQ QQQQ QQQQ yy yy yy yy yy yy Q Q QQ QQ ÀÀ ÀÀ ÀÀ y ÀÀ yy yy ÀÀÀ ÀÀÀÀ ÀÀÀÀ ÀÀÀÀ ÀÀÀÀ yy yyy yyy yyy yyy Q Q Q QQQ QQQ QQQ QQQ QQQ ÀÀ ÀÀ yy yy yy yy yy QQ QQ Q QQ yy yy Q Q yyyyyyy yyyyyyy yyyyyyy yyyyyyy yyyyyyy yy yy ÀÀÀ ÀÀÀ ÀÀÀ ÀÀÀ yyy yyy yyy yy yy QQ Q yy yy QQQ QQ QQ QQ Q Q Q Q Q Q Q À À À QQ QQ QQ QQ COMPONENT LOCATOR TRANSFER CASE CROSS SE...

Page 1207: ...reather Plug 30 Shift Rail 31 Intermediate Shaft 32 Thrust Washer 33 Pump 34 Clamp Hose 35 Upper Sprocket 36 Thrust Washer 37 Chain 38 Cover 39 Bearing 40 Oil Seal 41 Dowel Pin 42 Bearing Sleeve 43 Seal 44 Snap Ring 45 Center Bearing Support 46 Ball Bearing 47 Dowel Pin 48 Viscous Coupling 49 Pinion Gear 50 Thrust Washer 51 Pinion Shaft 52 Thrust Washer 53 Thrust Washer 54 Bushing 55 Output Shaft ...

Page 1208: ...ANSFER CASE TOD 5D2 13 SSANGYONG Y200 TRANSFER CASE ASSEMBLY YAD5D050 1 Input Shaft 2 Air Control Cap 3 Front Companion Flange 4 Rear Companion Flange 5 Drain Plug 6 Filler Plug 7 Shift Cam Driving Motor ...

Page 1209: ...cted and returns the 4WD high speed mode 4H switch Slef return Type 4L switch Push Lock Type YAD5D060 TOD SYSTEM SELECT MODE 4H is the mode when drive normally of which gear ratio is 1 1 and 4L mode distributes power to front and rear wheels 50 50 of which gear ratio is 2 48 1 COMPONENT FUNCTION Shift Motor It locates backside transfer case which drives rotary helical cam When mode select switch c...

Page 1210: ...nsor Voltage Supply Rear Speed Sensor Voltage Supply Rear Speed Rear Speed Return Pin H I J K L M N Pin A B C D E F G Function Motor HI LO clockwise Motor HI LO counter clockwise Position Return Position 1 Position 2 Position 3 Position 4 Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Function Motor HI LO Motor LO HI EMC Battery Ignition Position Return Diagnosis Display HI LO Switch Position 2 Front Spe...

Page 1211: ...red according to the operating condition TPS is an abbreviation of Throttle Position Sensor For MSE engine the potentiometer in the throttle actuator acts as TPS PWM is an abbreviation of Pulse Width Modulation and is a type of output value control by adjusting pulse width Duty Cycle is the time the EMC is on divided by the period in which it is being modu lated A minimum amount of duty cycle appl...

Page 1212: ...t of 4 Gray code switches which provide feedback to the TOD indicating the position of the Shift Motor A switch on vehicles equipped with a manual transmission which indicates that the clutch pedal is depressed A switch on vehicles equipped with an automatic transmission which indicates that the transmission is in neutral The vehicle speed above which Transfer Case shifts are disallowed Vehicle sp...

Page 1213: ...D2 18 TRANSFER CASE TOD CONTROL UNIT Input Output diagram TOD control unit and main wiring harness is linked by 30 pin connector Each pin joins with switch and actuator whose details refer to the below diagram YAD5D130 ...

Page 1214: ...attery HI to LO or motor brake join with ground Motor output port HI to LO join with battery LO to HI or motor brake join with ground TOD Output When the transfer case is in 4L mode illumi nates 4L indicator Position encoder ground Illuminates 4L indicator 4WD check lamp turns ON Upon defect Ground circuit Ground for speed sensor TPS Pin No 17 18 4 19 5 27 10 28 30 9 24 12 16 11 29 25 26 22 23 20 ...

Page 1215: ...der The Position Encoder is used by the TOD to determine the position of the Shift Motor Each motor position is identified by a position code below Notice All other position codes are invalid Position Input Open Circuit 4 5V 1 Position Input shorted to Speed Position Return 0 5V 0 Position Code 1 2 3 4 1110 1010 0010 0000 1110 Motor Position Left Stop Left of High High Right of High Zone 1 Positio...

Page 1216: ... 4L stop blinking 4L bulb Same as above Blink 4L bulb After the shift conditions are met attempt a shift to 4L After successfully shifting into 4L stop blinking 4L bulb Same as above Same as above Same as above Same as above Same as above Same as above No action required 4L bulb on No action required 4L bulb on Motor Position Left Stop Left of High High Right of High Zone 1 Neutral Zone 2 Low Righ...

Page 1217: ...k until the criteria are met again or the 4H 4L Switch is returned to the original position Range change When the shift criteria are met the motor is rotated in the appropriate direction as determined by the selector switch until one of the following occurs 1 The motor reaches its destination 2 The motor is on for 5 seconds without reaching its destination The shift has failed and the TOD will res...

Page 1218: ...the following sources On vehicles equipped with CAN the TOD receives the TPS signal from the CAN bus 2 When Slip Detection The TOD continuously monitors the front and rear propeller shaft speeds to detect wheel slip 3 Wheel Slip Control When wheel slip is detected the TOD controls the EMC duty cycle as necessary until the wheel slip is reduced below the allowable limit The EMC Duty Cycle will then...

Page 1219: ...e TOD will cancel the command and not respond to any subsequent shift commands 6 If a shift command is in progress when an invalid position code is confirmed it will be halted and the TOD will turn the motor toward the high position Afterwards the TOD will not respond to any shift commands 7 If the shift motor position encoder assembly failure other than a motor failure which occurs when the motor...

Page 1220: ... tested for open circuit or short circuit to ground If a fault is detected continuously for 0 8 second the 4WD CHECK lamp is turned on and all TODTM activity is halted If the EMC recovers continuously for 0 8 second the TOD will function normally The 4WD CHECK lamp is turned off but the fault code will remain in memory CODING ON TOD Connection of Coding Tool Construct SCANNER into diagnosis connec...

Page 1221: ...llowing Self Diagnosis Result is Normal 6 When system confirmation screen displays press ENTER key 7 If there is any fault in the system it displays as shown Eliminate the Memorized Fault Code When diagnose by SCANNER it is required that you make adequate service on defects against all fault codes And then you should delete the memorized fault codes in TOD control unit using SCANNER as follows 1 C...

Page 1222: ...TRANSFER CASE TOD 5D2 27 SSANGYONG Y200 SCHEMATIC WIRING DIAGRAM YAD5D190 ...

Page 1223: ...3 Turn the ignition ON Does the scan tool communicate with TOD Check whether the scan tool communicates with other control units Does the scan tool communicate with other control units Repair the diagnostic line between the TOD terminal A12 and DLC connector 13 Is the repair complete Change the scan tool Does the scan tool communicate with other control units 1 Replace the TOD 2 Connect the data d...

Page 1224: ...732 1733 1734 1735 1736 1741 1742 1743 1750 1751 1752 1753 1754 Description EEPROM Checksum Fault TPS Loss of Signal TPS Out of Range EMC Open Short to Battery EMC Short to ground Front Speed Sensor Voltage Low Front Speed Sensor Voltage High Rear Speed Sensor Voltage Low Rear Speed Sensor Voltage High Speed Sensor Reference Voltage Low Speed Sensor Reference Voltage High Motor Open Shorted to Bat...

Page 1225: ...d request the DTC Does the scan tool display any DTC 1 Turn the ignition switch to OFF 2 Disconnect the 18 pin connector from transfer case control unit TOD 3 Turn the ignition switch to ON and check the 4WD CHECK bulb operation Does the 4WD CHECK indicator come on steadily Repair any short to ground circuit between terminal A2 of TOD connector and terminal 31 of cluster Is the repair complete 1 T...

Page 1226: ...ep checks for the normal bulb operation Value Step 1 2 3 4 5 6 7 Action Check the position of 4H 4L switch Does the 4H 4L switch set on 4L 1 Turn the ignition switch to ON 2 Set the shift lever to N neutral 3 Turn the 4H 4L switch to 4H Does the 4WD LOW indicator go off 1 Turn the ignition switch to ON 2 Set the shift lever to N neutral 3 Turn the 4H 4L switch to 4L Does the 4WD LOW indicator go o...

Page 1227: ...OK System OK Go to Step 6 System OK System OK No Go to Step 5 Go to Step 4 Go to Step 7 Go to Step 7 Go to Step 7 Go to Step 7 Value Step 1 2 3 4 5 6 7 Action Check the bulb operation when the ignition switch turns to ON Does the only 4WD LOW indicator come on and goes after 0 6 seconds 1 Turn the ignition switch to OFF 2 Disconnect 18 pin connector from the transfer case control unit TOD 3 Using ...

Page 1228: ...ng from low to high range or high to low range If the indicator blinks steadily it warns the shifting command and real position of the shift motor or position encoder are not matched 4WD LOW INDICATOR BLINK STEADILY Yes Go to Step 2 System OK System OK No Go to Step 3 Go to Step 3 Value Step 1 2 3 Action 1 Stop the vehicle 2 Turn the 4H 4L switch to original position Does the 4WD LOW indicator sto...

Page 1229: ...diagnostic table 2 This step checks the battery supply voltage 4 This step checks the ground condition 6 This step checks the connection status Yes Go to Step 2 Go to Step 4 Go to Step 4 Go to Step 6 Go to Step 6 No Go To TOD Control Unit Diagnostic System Check Go to Step 3 Go to Step 5 Step 1 2 3 4 5 Action Was the TOD Diagnostic System Check performed 1 Turn the ignition switch OFF 2 Disconnect...

Page 1230: ... Connect the scan tool to data link connector DLC and follow the directions given in the scan tool manual 5 Turn the ignition switch to ON 6 Delete and request DTC with scan tool Is DTC 1714 still present 1 Replace the TOD 2 Turn the ignition switch to OFF 3 Connect the scan tool to data link connector DLC and follow the directions given in the scan tool manual 4 Turn the ignition switch to ON 5 D...

Page 1231: ...his step checks the connection status Yes Go to Step 2 Go to TOD Diagnostic System Check Refer to Section Engine Go to Step 5 System OK No Go to TOD Diagnostic System Check Go to Step 3 Go to Step 4 Value 0 Ω Step 1 2 3 4 Action Was the TOD Diagnostic System Check performed 1 Turn the ignition switch to OFF 2 Connect the scan tool to data link connector DLC and follow the directions given in the s...

Page 1232: ... 5D2 37 SSANGYONG Y200 Yes System OK System OK No Go to Step 6 Value Step 5 6 Action 1 Replace the TOD 2 Connect all connectors 3 Request DTC with scan tool Is the repair complete Replace the ECU Is the repair complete ...

Page 1233: ... checks the connection status Yes Go to Step 2 Go to TOD Diagnostic System Check Go to specific engine DTC diagnosis Go to Step 4 System OK No Go to TOD Diagnostic System Check Go to Step 2 Go to Step 5 Value 0 Ω Step 1 2 3 4 Action Was the TOD Diagnostic System Check performed 1 Turn the ignition switch to OFF 2 Connect the scan tool to data link connector DLC and follow the directions given in t...

Page 1234: ... 5D2 39 SSANGYONG Y200 Yes System OK System OK No Go to Step 6 Value Step 5 6 Action 1 Replace the TOD 2 Connect all connectors 3 Request DTC with scan tool Is the repair complete Replace the ECU Is the repair complete ...

Page 1235: ...ks the ground condition 7 This step checks the continuity of the wire and short to battery condition Step 1 2 3 Yes Go to Step 2 Go to Step 3 Go to Step 5 No Go to TOD Diagnostic System Check System OK Go to Step 4 Value 11 14 V Action Was the TOD Diagnostic System Check performed 1 Turn the ignition switch to OFF 2 Disconnect two connectors of the transfer case control unit TOD and white 7 pin co...

Page 1236: ...es the resistance of the all circuits measure within the value specified Repair or replace any open or damaged circuit Is the repair complete 1 Disconnect the 7 pin connector under the body 2 Measure the voltage between terminal 4 and ground Is the resistance within the value specified Repair open or short to battery circuit Is the repair complete Measure the resistance between the clutch coil ter...

Page 1237: ...y condition Yes Go to Step 2 Go to Step 3 Go to Step 5 Go to Step 5 Step 1 2 3 4 No Go to TOD Diagnostic System Check System OK Go to Step 4 Value 11 14 V Action Was the TOD Diagnostic System Check performed 1 Turn the ignition switch to OFF 2 Disconnect two connectors of the transfer case control unit TOD and white 7 pin connector for propeller shaft speed sensor and clutch coil located under the...

Page 1238: ...Repair or replace any open or damaged circuit Is the repair complete 1 Disconnect the 7 pin connector under the body 2 Measure the voltage between terminal 4 and ground Is the resistance within the value specified Repair open or short to battery circuit Is the repair complete Measure the resistance between the clutch coil terminal H and ground Is the measurement within the value specified 1 Replac...

Page 1239: ...l be completed DIAGNOSTIC TROUBLE CODE DTC 1731 Diagnostic Aids Check for short to ground or open circuit Check for front propeller speed sensor Test Description The number s below refer to step s on the diagnostic table 3 This step checks the continuity 5 This step checks the speed sensor Value 0 Ω Step 1 2 3 Yes Go to Step 2 Go to DTC 1735 Speed Sensor Reference Voltage Low Go to Step 5 No Go to...

Page 1240: ...5 Request the DTC with scan tool Is the DTC still current Measure the resistance between terminals of the male white 7 pin connector Is the measurement within specified range Terminal 6 and terminal 3 Terminal 6 and terminal 2 Terminal 3 and terminal 2 Replace front propeller shaft speed sensor Is the repair complete 1 Replace the TOD 2 Turn the ignition switch to OFF 3 Connect the scan tool to da...

Page 1241: ...pin connector for propeller shaft speed sensor and clutch coil located under the body 3 Measure the voltage between terminals B6 and ground Is measured value below the specified value Value 0 Ω Front Speed Sensor Voltage High Circuit Description The transfer case control unit TOD supplies 5 volts reference voltage to the front speed sensor and receives speed signals generated by Hall effect speed ...

Page 1242: ...quest the DTC with scan tool Is the DTC still current Measure the resistance between terminals of the male white 7 pin connector Is the measurement within specified range Terminal B and terminal C Terminal B and terminal D Terminal C and terminal D Replace front propeller shaft speed sensor Is the repair complete 1 Replace the TOD 2 Turn the ignition switch to OFF 3 Connect the scan tool to data l...

Page 1243: ... will be completed Diagnostic Aids Check for short to ground or open circuit Check for front propeller speed sensor Test Description The number s below refer to step s on the diagnostic table 3 This step checks the continuity 5 This step checks the speed sensor Step 1 2 3 Yes Go to Step 2 Go to DTC 1735 Speed Sensor Reference Voltage Low Go to Step 5 No Go to TOD Diagnostic System Check Go to Step...

Page 1244: ...5 Request the DTC with scan tool Is the DTC still current Measure the resistance between terminals of the male white 7 pin connector Is the measurement within specified range Terminal 7 and terminal 5 Terminal 7 and terminal 1 Terminal 5 and terminal 1 Replace rear propeller shaft speed sensor Is the repair complete 1 Replace the TOD 2 Turn the ignition switch to OFF 3 Connect the scan tool to dat...

Page 1245: ... until the Ignition is cycled If a shift is in progress it will be completed Diagnostic Aids Check for short to ground or open circuit Check for front propeller speed sensor Test Description The number s below refer to step s on the diagnostic table 3 This step checks the continuity 5 This step checks the speed sensor Step 1 2 3 Yes Go to Step 2 Go to DTC 1736 Speed Sensor Reference Voltage High G...

Page 1246: ...5 Request the DTC with scan tool Is the DTC still current Measure the resistance between terminals of the male white 7 pin connector Is the measurement within specified range Terminal 7 and terminal 5 Terminal 7 and terminal 1 Terminal 5 and terminal 1 Replace rear propeller shaft speed sensor Is the repair complete 1 Replace the TOD 2 Turn the ignition switch to OFF 3 Connect the scan tool to dat...

Page 1247: ...agnostic System Check performed 1 Disconnect white 7 pin connector for propeller shaft speed sensor and clutch coil located under the body 2 Turn the ignition switch to ON 3 Measure the voltage between following terminals of male white 7 pin connector Terminal D E and terminal B G Is measured value within the specified range Measure the resistance between terminal A8 and terminals B8 of transfer c...

Page 1248: ...minal 2 Terminal 3 and terminal 2 Terminal 7 and terminal 5 Terminal 7 and terminal 1 Terminal 5 and terminal 1 Is the measurement within specified range Replace front or rear propeller shaft speed sensor Is the repair complete 1 Replace the TOD 2 Turn the ignition switch to OFF 3 Connect the scan tool to data link connector DLC and follow the directions given in the scan tool manual 4 Turn the ig...

Page 1249: ...tion 5 This step checks the continuity of ground line 7 This step checks the speed sensors Yes Go to Step 2 Go to Step 7 Go to Step 5 Go to Step 5 No Go to TOD Diagnostic System Check Go to Step 3 Go to Step 4 System OK Value 4 5 5 5 V 4 5 5 5 V Step 1 2 3 4 Action Was the TOD Diagnostic System Check performed 1 Disconnect white 7 pin connector for propeller shaft speed sensor and clutch coil loca...

Page 1250: ... of TOD connector and ground Is the resistance below the specified value Repair any short to circuit Is the repair complete Measure the resistance between terminals of the male white 7 pin connector Terminal 6 and terminal 3 Terminal 6 and terminal 2 Terminal 3 and terminal 2 Terminal 7 and terminal 5 Terminal 7 and terminal 1 Terminal 5 and terminal 1 Is the measurement within specified range Rep...

Page 1251: ...tor Yes Go to Step 2 Go to Step 3 Go to Step 7 No Go to TOD Diagnostic System Check System OK Go to Step 4 Value 11 14 V 11 14 V Step 1 2 3 Action Was the TOD Diagnostic System Check performed 1 Turn the ignition switch to OFF 2 Disconnect two connectors of the transfer case control unit TOD and 7 pin connector under the body 3 Inspect the terminals for damage or improper connection 4 Repair any d...

Page 1252: ...ange 1 Disconnect 12 pin connector from transfer case control unit TOD and black 7 pin connector 2 Measure the resistance between following terminals A2 TOD and 6 7 pin connector A7 TOD and 6 7 pin connector A1 TOD and 7 7 pin connector A6 TOD and 7 7 pin connector Is the resistance equal to specified value 3 Measure the voltage between following terminals A2 A7 TOD and ground A1 A6 TOD and ground...

Page 1253: ...to Step 3 Go to Step 7 Step 1 2 3 No Go to TOD Diagnostic System Check System OK Go to Step 4 Value 11 14 V 11 14 V Action Was the TOD Diagnostic System Check performed 1 Turn the ignition switch to OFF 2 Disconnect two connectors of the transfer case control unit TOD and black 7 pin connector under the body 3 Inspect the terminals for damage or improper connection 4 Repair any damaged pins or ter...

Page 1254: ... 4H switch from 4L to 4H Is the voltage within specified range 1 Disconnect 12 pin connector from transfer case control unit TOD and 7 pin connector 2 Measure the resistance between following terminals A2 A7 TOD and 6 7 pin connector A1 A6 TOD and 7 7 pin connector A1 A6 TOD and ground A2 A7 TOD and ground Is the resistance equal to specified value Repair any short to ground or short between circu...

Page 1255: ...TOD Diagnostic System Check performed 1 Turn the ignition switch to OFF 2 Connect a scan tool to the data link connector DLC and follow the directions given in the scan tool manual 3 Turn the ignition switch to ON 4 Request DTC with scan tool Is the DTC 1741 or 1742 also shown 1 Turn the ignition switch to OFF 2 Disconnect two connectors of the transfer case control unit TOD and black 7 pin connec...

Page 1256: ...Go to Step 5 Go to Step 5 System OK Action Was the TOD Diagnostic System Check performed 1 Turn the ignition switch to OFF 2 Connect a scan tool to the data link connector DLC and follow the directions given in the scan tool manual 3 Turn the ignition switch to ON 4 Request DTC with scan tool Is the DTC 1751 1752 1753 or 1754 also shown 1 Disconnect 18 pin connector from the transfer case control ...

Page 1257: ...GYONG Y200 5D2 62 TRANSFER CASE TOD Step 6 7 Yes System OK System OK No Go to Step 7 Value Action Replace the shift motor with position encoder Is the repair complete Replace the TOD Is the repair complete ...

Page 1258: ...ect 18 pin connector from the transfer case control unit TOD 3 Measure the resistance between terminal A15 of TOD connector and ground Is the resistance equal to specified value Repair short to ground circuit Is the repair complete 1 Turn the ignition switch to OFF 2 Disconnect two connectors of the transfer case control unit TOD and 7 pin connector under the body 3 Inspect the terminals for damag...

Page 1259: ...eck performed 1 Turn the ignition switch to OFF 2 Connect a scan tool to the data link connector DLC and follow the directions given in the scan tool manual 3 Turn the ignition switch to ON 4 Request DTC with scan tool Is the DTC 1752 only current trouble code 1 Turn the ignition switch to OFF 2 Disconnect 18 pin connector from the transfer case control unit TOD 3 Measure the resistance between te...

Page 1260: ...n the ignition switch to OFF 2 Connect a scan tool to the data link connector DLC and follow the directions given in the scan tool manual 3 Turn the ignition switch to ON 4 Request DTC with scan tool Is the DTC 1753 only current trouble code 1 Turn the ignition switch to OFF 2 Disconnect 18 pin connector from the transfer case control unit TOD 3 Measure the resistance between terminal A28 of TOD c...

Page 1261: ...n the ignition switch to OFF 2 Connect a scan tool to the data link connector DLC and follow the directions given in the scan tool manual 3 Turn the ignition switch to ON 4 Request DTC with scan tool Is the DTC 1754 only current trouble code 1 Turn the ignition switch to OFF 2 Disconnect 18 pin connector from the transfer case control unit TOD 3 Measure the resistance between terminal A30 of TOD c...

Page 1262: ...0 MAINTENANCE AND REPAIR ON VEHICLE SERVICE TRANSFER CASE TOD COMPONENT LOCATOR 1 Transmission A T 2 TOD Transfer Case 3 Extension Housing 4 Bolt 35 60 N m 5 Front Propeller Shaft 6 Bolt M14 4 81 89 N m 7 Rear Propeller Shaft 8 Bolt M14 4 81 89 N m ...

Page 1263: ... and drain transfer case and manual transmission oil If planar damper is installed unscrew 4 bolts and remove the planar damper Notice Oil drain should be along with whole transfer case disassembly and assembly 5 Disconnect transmission extension wiring connector back side transfer case Notice When disconnect connector make sure on direction of locking tab towards inside 6 Disconnect shift motor c...

Page 1264: ...Notice 12 Unscrew 4 units of M12 bolts from case flange then disconnect rear propeller shaft from transfer case Installation Notice 11 Unscrew 4 units of M12 bolts from case flange then disconnect front propeller shaft from transfer case Installation Notice Tightening Torque 81 89 N m 60 66 lb ft Tightening Torque 81 89 N m 60 66 lb ft Notice Make sure the connecting surface is clean Applying long...

Page 1265: ...e When replace TOD control unit it is required to make a coding correspondent with vehicle specification Installation Notice 3 Unscrew 2 bolts Tightening Torque 10 N m 89 lb in SHIFT MOTOR Removal Installation Procedure 1 Disconnect cable from battery 2 Disconnect shift motor magnetic clutch coil connector black pin7 upper backside 3 Unscrew 3 shift motor mounting bolts M10 4 Unscrew a bracket mou...

Page 1266: ... installation make sure that motor position match with mode of 4H 4L switch Notice When accord position of motor with 4H 4L switch and transfer case match position of the disconnected motor and new one YAD5D320 SPEED SENSOR IN FRONT AND REAR PROPELLER SHAFT Replacement Procedure 1 Disconnect cable from battery 2 Detach shift motor assembly 3 Disconnect front and rear speed sensor connector white 3...

Page 1267: ...y pulling sticking long nose plier into L pin in connector 11 On the same way disconnect pin and wire M and N from connector Notice Do not touch the wires related with EMC 12 Prepare new speed sensor 13 Connect 3 pins with wires of speed sensor to coincide with each connection position 14 Using long nose plier connect tightly by pulling pins 15 Apply rubber cap into connector using long nose plier...

Page 1268: ... speed sensor connector then locking sleeve Notice Front propeller shaft should be premised by removal of shift motor After disconnecting shift motor procedure of replacement on sensor assembly of accords with one of rear speed sensor Tightening Torque 3 6 N m 27 53 lb in ...

Page 1269: ...SSANGYONG Y200 5D2 74 TRANSFER CASE TOD UNIT REPAIR TRANSFER CASE DISASSEMBLED VIEW YAD5D360 ...

Page 1270: ...32 Nut 33 Washer 34 Bolt M10 X 105 X 30 35 Tag Identification 36 Thrust Bearing 37 Clutch Coil Assembly 38 Fork Reduction Shift 39 Shift Rail 40 Shaft Shift 41 Spacer 42 Torsion Spring 43 Electric Shift Cam 44 Transfer Case Shift Motor 45 Bolt 46 J clip 47 Connector Retainer 48 Bolt 49 Support Stud 50 Lower Speed Sensor Front 51 Plug 52 Identification Decal 53 Cover 54 Tone Wheel Lower 55 Chain Dr...

Page 1271: ...onnector and speed sensor connector from upper bracket of transfer case Notice When disconnect connector pull forwards grasping connector housing 4 Remove outer tube on speed sensor connector 5 Remove wire supporting cape back side of speed sensor connector 7 Remove shift motor Notice When remove shift motor pay attention to the location of triangular slot and shaft in transfer case inside motor 6...

Page 1272: ...se from the rear case 12 Remove all traces of gasket sealant from the mating surfaces of the front case and rear case 13 If the speedometer drive gear is to be replaced first remove the flange seal by prying and pulling the curved up lip of the flange seal Notice Be careful not to damage the bearing bearing cage or case Remove and discard the flange seal 14 Remove the speedometer drive gear and up...

Page 1273: ...f required to remove the pump from the output shaft rotate the pump to align 29 Pull out the shift rail 30 Remove the helical cam from the front case 31 If required remove the helical cam torsion spring and sleeve from the shaft 24 Remove the chain driven sprocket and drive sprocket as an assembly 25 Remove thrust washer from output shaft 21 Remove the balls and apply cam and wave washer from the ...

Page 1274: ... 34 With the input shaft against a bench push the case down and slide the main drive gear bearing retainer off the bearing 35 Lift the input shaft and front planet from the case 36 If required remove the oil seal from the case by prying and pulling on the curved up lip of the oil seal Notice Be careful not to damage the bearing bearing cage or case 40 Place the input shaft in a vise and remove the...

Page 1275: ...ate and using Pinion Bearing Cone Replacer as a spacer Insert Input Shaft Bearing Remover into the input shaft so it is resting on top of the bearing cage Tighten the actuator pin until it stops then press the bearing and bushing out together YAD5D500 YAD5D510 Assembly Procedure 1 Before assembly lubricate all parts with Automatic Transmission Fluid or equivalent 2 If removed drive the bearing int...

Page 1276: ...needle bearing into the end of the input shaft until it seats in the input shaft 12 Install the front planet to the sun gear and input shaft 13 Install the internal snap ring to the planetary carrier 7 The recessed face of the sun gear and the snap ring groove on the bearing outer race should be toward the rear of the transfer case 8 The stepped face of the thrust washer should face toward the bea...

Page 1277: ...r mating surfaces Install a bead of gasket sealant on the surface of the front case 19 Install the output shaft and oil pump in the input shaft Make sure that the internal splines of the ouput shaft engage the internal splines of the high low shift collar Make sure that the oil pump retainer arm and oil filter leg are in the groove and slot of the front case 18 Inspect the outside surfaces and bor...

Page 1278: ...ring insulator washer and armature Three offset slots must align with housing to be installed Notice Three slots on the thrust washer must be aligned with the three tabs on the clutch pack housing 24 Install tone wheel onto the front output shaft Make sure the spline on the tone wheel engages the spline on the front output shaft 25 Install clutch pack assembly onto the rear output shaft Make sure ...

Page 1279: ...t kink or trap the wire while seating the clutch coil to the case 36 Install the washers and nuts and tighten Installation Notice 33 If removed install the rear output bearing in the rear case bore Drive the bearing into the rear case bore with Output Shaft Bearing Replacer and Driver Handle Make sure that the bearing is not cocked in the bore 34 Install the internal snap ring that retains the bea...

Page 1280: ...are pointing toward the top side of the transfer case and just touching the high low shift fork Notice Do not bend the helical cam during installation to the front case because of possible damage to the pin at the tang end of the motor shaft 43 Install the shift rail through the high low shift fork and make sure that the reverse gear shift rail is seated in the front case bore 40 Push the torsion ...

Page 1281: ... followed prior to installing the rear case onto the front case half Align the output shaft with the rear case output shaft bore Align the helical cam with the rear case motor bore If difficulty is encountered with seating the rear case tap the rear output shaft with a sharp blow using a rubber mallet in a direction away from the triangular shaft while pushing down on the rear case 45 Install uppe...

Page 1282: ...igned with the triangular slot in the transfer case shift motor Notice If triangular shaft will not rotate rotate the rear output shaft 51 Tighten manually the two nuts that attach the slotted support bracket to the end of the motor house 52 Apply Black Non Acid Cure Silicone Rubber or equivalent to motor housing base and install on transfer case 53 Install the transfer case shift motor and three ...

Page 1283: ... to the 7 pin connector black 57 Install the connector retainer at the connector end 58 Connect the front and rear speed sensors wiring to the 7 pin connector white 59 Install the rear case flange on the output shaft 60 Install the rubber seal output shaft yoke washer and nut Tighten the nut Installation Notice 61 Install the drain plug and tighten Tightening Torque 19 30 N m 14 22 lb ft 62 Fill t...

Page 1284: ... TOD 5D2 89 SSANGYONG Y200 SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE Snap Ring Plier Bearing Installer YAD5D780 YAD5D800 Input Shaft Support Bearing Removal Installer YAD5D790 YAD5D810 Seal Installer YAD5D820 ...

Page 1285: ...r Steering Assembly 6A 6 General Inspection 6A 7 Oil Pump Pressure 6A 7 Power Steering Gear Preload Adjustment 6A 8 Oil Change 6A 8 Oil Quantity Check and Air Bleeding 6A 9 Maintenance and Repair 6A 12 On Vehicle Service 6A 12 Power Steering Pipe Hose 6A 12 Power Steering Box Assembly 6A 13 Steering Gear Pump 6A 14 Assembly Installation 6A 14 Unit Repair 6A 17 Steering Gear Box 6A 17 Special Tools...

Page 1286: ...e MAX Pressure Outlet Size Upper Lower Turning Radius Type Capacity Steering Wheel Steering Gear Box Oil pump Tilt column Angle Oil GENERAL DESCRIPTION AND OPERATION SPECIFICATIONS 4 Spoke Type 390 mm Rack and pinion 36 17 32 40 Vane 82 92 kgf cm 10 5L min 124mm 4 4 5 7 m ATF DEXRON II 1 L Inner Outer ...

Page 1287: ...oint Worn or Damaged Front Wheel Bearing Damaged Wheel or Tire Faulty Suspension System Loosened Steering Gearbox Mounting Bolt Faulty Steering Gear Steering Column Linterference Loosened Steering Linkage Damaged or Loosened Oil Pump Drive Belt Loosened Oil Pump Bracket Loosened Oil Pump Mounting Bolt Air in System Faulty Oil Pump Lubricate Replace Replace gear assembly Adjust Replace Repair or re...

Page 1288: ...SSANGYONG Y200 6A 4 POWER STEERING A 1 COMPONENT LOCATOR POWER STEERING SYSTEM LOCATOR YAD6A020 A Mounting Position 1 Steering Component ...

Page 1289: ...5 SSANGYONG Y200 1 2 3 4 10 5 6 7 8 9 STEERING GEAR BOX CROSS SECTION YAD6A030 1 Tie Rod End 2 Tie Rod 3 Bellows 4 Rack Housing 5 Feed Tube 6 Mounting Bracket 7 Tie Rod End 8 Tie Rod End 9 Cylinder Tube 10 Valve Assembly ...

Page 1290: ...ING ASSEMBLY YAD6A150 1 Power Steering Pump Reservoir Assembly 2 Power Steering Pump Cap Assembly 3 Clip 4 Return Line 5 Pressure Line 6 Power Steering Gear 7 Power Steering Pipe Mounting Bracket Clip 8 Hexagon Bolt 9 Fan Screw M5 10 Welded Nut 11 Pipe Clamp 12 Hexagon Bolt 13 Nut 14 Bolt ...

Page 1291: ...nsmission in neutral position 4 Pull the lever of parking brake 5 Open the installed pressure check gauge valve completely 6 Start the engine and keep it to the idling 7 Turn the steering wheel several times until the oil temperature is up to the normal operating temperature 8 Close the pressure check gauge valve completely and then measure the oil pressure Notice Do not keep the valve closed for ...

Page 1292: ... plug Tighten the adjustment plug by 45 55 kg cm Tighten the adjustment plug by 67 5 to C C W direction 6 Tighten the adjustment plug lock nut YAD6A070 OIL CHANGE 1 Lift the vehicle slightly using the lifter 2 Separate the oil supply hose from the power steering pump 3 Discharge the oil in the oil tank 4 Connect the oil supply hose with the power steering pump 5 Separate the oil return line from t...

Page 1293: ...y turning the steering wheel left to right check the oil level change Notice Do bleeding with engine cranking If bleed with idling there con be a air contact with oil If oil is not changes more than 5mm do bleeding again If oil level rises suddenly when stopped engine do bleeding again YAD6A080 OIL QUANTITY CHECK AND AIR BLEEDING Oil Quantity Check 1 Place the vehicle on flat road and start the en...

Page 1294: ...0 Power steering wheel Freeplay Check 1 Start the engine and place the wheels in straight ahead position 2 Slightly move the steering wheel to the left right and measure the steering wheel free play when the front wheel is start to move Notice If exceeds standard the steering column shaft and steering linkage clearance Replace or repair if necessary Standard Max 30 mm YAD6A130 Steering Angle Check...

Page 1295: ...icle on the paved flat ground with front wheels In a straight ahead position 2 Start the engine and run it at 1 000 rpm 3 Using a scale measure the steering effort in both directions Notice The difference in steering effort of left right should be within 0 6 kg Standard Max 3 0 kg ...

Page 1296: ...installing the pipe and hose prepare the oil container in order that the oil may not drop down YAD6A160 YAD6A170 2 Remove the supply return pipe installed in power steering gear box 3 Remove the oil pipe bracket bolt installed in front bumper and pull off the oil pipe Notice First remove the pipe from the pipe clamp installed in front panel and then pull off the pipe YAD6A180 MAINTENANCE AND REPAI...

Page 1297: ...ie rod end and pull off the tie rod using the special tool YAD6A190 YAD6A200 YAD6A220 YAD6A210 2 Remove the joint blot of steering lower shaft and separate the lower shaft from the gear box 3 Remove the center bolt in gear box and left mounting bolt Remove the supply return pipe connection bolt 4 Remove the clamping bolt and pull off the steering gear box assembly ...

Page 1298: ...23 N m 17 lb ft 23 N m 17 lb ft Nut Bolt Upper Lower 2 Install the power steering gear box in frame Tighten the mounting bolts slightly and then install the gear box clamp in left Tighten the bolt nut as specified torque Notice Because the length of bolt is same install them after checking Installation Notice 70 90 N m 52 66 lb ft 70 90 N m 52 66 lb in 95 mm Bolt Nut Upper 95 mm Bolt Nut Lower YAD...

Page 1299: ...70 3 Completely tighten the mounting bolt nut which is tightened slightly Notice First tighten the center bolt nut and then tighten bolt nut as specified torque Installation Notice 70 90 N m 52 66 lb ft 70 90 N m 52 66 lb in Center Bolt Nut Left Bolt Nut Tightening Torque 25 30 N m 18 22 lb ft 5 Install the tie rod end in steering knuckle Tighten the sloted nut and then insert the new split pin In...

Page 1300: ...sert the spring clamp 3 as like the picture Notice After inserting the hose into the reservoir tank completely install in order that the spring clamp is placed in the center of nipple 10 After installing completely do bleeding 7 Install the supply return pipe in gear box housing Installation Notice YAD6A310 12 18 N m 9 13 lb ft 12 18 N m 9 13 lb ft Supply Pipe 2 Return Pipe 1 ...

Page 1301: ...ock nut 1 and separate the plug 2 and spring 3 YAD6A350 5 Remove the dust cover 1 and pull off the retainer ring 2 a YAD6A340 UNIT REPAIR STEERING GEAR BOX Disassembly 1 Disassembly the tie rod end boot a 2 Remove the cylinder tube 2 in gear box 3 Remove the valve tube 1 in gear box ...

Page 1302: ...ar housing and rack gear if the damage happened replace them with assembly YAD6A390 7 Tapping the pinion lower part carefully using the plane draft and hammer remove the steering pinion 5 from the pinion bearing Notice Tap the draft using the hammer as lik the picture 6 Remove the pinion dust cover lower 3 and remove the pinion lock nut 4 Notice When removing the steering pinion lock nut be sure t...

Page 1303: ...teering pinion gear for the damage Check the pinion gear 1 for the wear or damage Check the looseness and normal operating of bearing 2 4 Check the steering gear housing for the crack deformation and wear 1 2 4 3 YAD6A420 Rack Gear Shaft Checks 1 Check the rack gear damage Set up the v block 1 on the plane table Put the rack gear 2 4 on the V block Measure the straightness of rack gear using the d...

Page 1304: ...l for the wear or leakage Check the needle bearing for the wear Check the steering pinion bearing for the wear 11 After checking if out of specified value or damaged replace them with the new one YAD6A470 7 Check the tie rod end and the rotation part of ball joint for the damage 5 Check the tie rod end and ball joint for the damage Check the tie rod end ball joint for the normal operating Check th...

Page 1305: ...nion bearing is inserted into the pinion lock nut by force be careful not to be eccentric 4 Install the rack bearing Install the adjustment spring Tighten the adjustment plug as specified torque Tighten the adjustment plug lock nut Adjust the steering gear preload 1 YAD6A500 Assembly 1 Install the steering pinion assembly gear Install the retaining ring Install the needle bearing Tapping the pinio...

Page 1306: ...oot Notice Apply the grease to the tie rod end ball joint and boot YAD6A540 1 2 5 Install the fluid pressure line in power steering gear and tighten them as specified torque 1 Tighten the fitting to the piston side 2 Tighten the fitting to the cylinder side YAD6A530 ...

Page 1307: ...POWER STEERING 6A 23 SSANGYONG Y200 SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE Tie Rod End Remover YAD6A550 ...

Page 1308: ... 6E 3 Diagnostic Information and Procedures 6E 4 Component Locator 6E 5 Steering Column Assembly 6E 5 Steering Assembly Cross Section 6E 6 Steering Column Wheel 6E 7 Maintenance and Repair 6E 8 On Vehicle Service 6E 8 Steering Column 6E 8 Steering Wheel Shaft 6E 11 Unit Repair 6E 15 Steering Gear Box 6E 15 Special Tools And Equipment 6E 16 Special Tools Table 6E 16 ...

Page 1309: ...If pulling the ignition switch in LOCK position and draw out the key as the lock cylinder installed in column operates you cannot steer the vehicle STEERING WHEEL YAD6E020 YAD6E010 YAD6E030 GENERAL DESCRIPTION AND OPERATION 4 Spoke Type 390 mm The vibration absorbing damper is mounted in steering wheel in order that the vibration may be minimized COLUMN SHAFT ASSEMBLY LOWER SHAFT 4 Spoke Type 390 ...

Page 1310: ...t Steering Gear Box and Pressure Hose Connection Nut Steering Gear Box and Return Line Connection Nut Power Pump Bracket and Timing Gear Case Cover Mounting Bolt Power Pump and Pressure Hose Connection Nut Return Line and Cilp Connection Bolt 20 25 N m 15 18 lb ft 20 25 N m 15 18 lb ft 40 60 N m 30 44 lb ft 7 11 N m 62 97 lb in 25 30 N m 18 22 lb ft 70 90 N m 52 66 lb ft 25 30 N m 18 22 lb ft 35 4...

Page 1311: ...Poor Interm shaft Pinch Bolt Worn or Damaged Steering Shaft Bearing Inner Defect of Lock Cylinder Inner Defect of Ignition Switch Retightening Replace steering column Retightening Replace steering column Replace steering column Replace ignition switch Checks Phenomena Noise When operating the steering wheel Excessive Steering Force Poor Operating of Ignition Switch Action ...

Page 1312: ...STEERING COLUMN 6E 5 SSANGYONG Y200 1 2 3 4 COMPONENT LOCATOR STEERING COLUMN ASSEMBLY YAD6E040 1 Steering Wheel 2 Column Shaft Assembly 3 Lower Shaft Assembly 4 Steering Gear Assembly ...

Page 1313: ...SSANGYONG Y200 6E 6 STEERING COLUMN YAD6E050 Side Rear STEERING ASSEMBLY CROSS SECTION ...

Page 1314: ...STEERING COLUMN 6E 7 SSANGYONG Y200 1 3 2 6 7 5 4 STEERING COLUMN WHEEL YAD6E060 1 Steering Column shaft 2 Lower Shaft 3 Bolt 4 Nut 5 Bolt 6 Washer 7 Bolt ...

Page 1315: ...odule assembly in the wheel At this time remove the airbag module connector simultaneously YAD6E080 YAD6E090 YAD6E070 3 Untighten the wheel fixing nuts and remove the steering wheel using the special tool Notice When you remove the wheel be sure to do alignment mark in column shaft and wheel Remove the remote control switch connector airbag connector horn connector 4 Remove the fuel filler door re...

Page 1316: ...umn fixing bolts from the steering column shaft and then remove the upper lower column cover 8 Disconnect the connector connected with the combination switch and the fuel cut vacuum hose Notice Be sure to check the fuel cut hose because the identification color is marked YAD6E100 5 Remove the instrument panel side cover and untighten the fixing bolts of inner fuse box ...

Page 1317: ... airbag module is separated YAD6E150 YAD6E160 YAD6E170 11 Mark the assembly marking on the column shaft and lower shaft and then untighten the upper fixing bolt of column shaft 12 Untighten the housing floor fixing bolts of steering column shaft YAD6E140 9 Remove the contact coil from the steering column shaft ...

Page 1318: ...he blots as specified torque Notice Install the lower shaft to tighten the bolt in non spline part of upper spline part Install to align the assembly marking Installation Notice 2 Install the steering column shaft in the lower shaft to align the assembly marking and then tighten the bolt Notice Install the lower shaft to tighten the bolt in non spline part of upper spline part Install to align the...

Page 1319: ...otice When you adjust the neutral position of contact coil rotate the contact coil to C W direction until it stops and then again rotate it by 2 9 0 2 to C C W direction Align the mark Which is marked in contact coil 3 Tighten the floor bolt of steering column as specified torque Installation Notice 4 Tighten the upper bolt of steering column shaft as specified torque Installation Notice Tightenin...

Page 1320: ...ed to the inside of molding and then installed 11 Install the steering wheel in order that it is aligned to the assembly marting of column shaft Notice Apply the grease to the shaft spline part in order that the wheel is installed easily YAD6E260 8 Connect the fuel cut vacuum hose with the connector Notice The identification color is marked in fuel cut vacuum hose Color Green Blue Classification F...

Page 1321: ...teering wheel first install each connector and then install the horn pad Notice When installing the pad insert the safety pin to the wheel hold and align the shaf end part with the pad groove 13 Tighten the left right screw of steering wheel and connect the negative terminal of battery ...

Page 1322: ...ing column steering column shaft is not gotten the impact If being gotten the impact in case of the frontal collision the plastic sleeve may be broken YAD6E300 YAD6E310 YAD6E330 YAD6E320 2 Remove the steering column shaft from the steering column Remove the retainer ring Push the steering column shaft strongly downward Assembly 1 Assemble in reverse order of disassembly ...

Page 1323: ...SSANGYONG Y200 6E 16 STEERING COLUMN SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE SteeringWheel Remover YAD6E340 ...

Page 1324: ...s 7A 7 Insufficient Heating Or Defrosting 7A 7 Blower Electrical 7A 9 Improper Air Delivery Or No Mode Shift 7A 10 Too Much Heat 7A 11 Heater Controls 7A 12 Blower Noise 7A 13 Component Locator 7A 14 Airflow Through Vents With Rear Heating Duct 7A 14 Repair Instructions 7A 15 On Vehicle Service 7A 15 Air Duct Assembly 7A 15 Rear Cooler Duct 7A 16 Heater and Blower Module Assembly 7A 17 Heater Suct...

Page 1325: ...r and designed for heating and defrosting in the passenger room Heater system is consist of heater hose heater module blower motor and adjustment system The control switch assembly adjustment system equipped with the instrument panel can control the temperature the amount and the direction of the outlet Also this system can use the suction air as separation between ambient air and intake air on th...

Page 1326: ...e Heating Capacity Cooling Capacity Expansion Valve Input Power Type Cooling Capacity Expansion Valve Input Power Engine Type SPECIFICATIONS Heater Evaporator and Blower 2 pieces Min 4600 kcal h 5 5 m3 Min Min 4700 kcal h 7 5 m3 Min Block Type Max 250 W Evaporator and Blower only Cooler Min 2700 kcal h 5 m3 Min ANGLE Type Max 180 W GSL GSL 7 425 9 075 kcal h 1 52 mm 194 6 x180 x 35 mm 8 250 Min 4 ...

Page 1327: ...Vent Bi level Foot Foot Def or Def Intake Door Motor Installation Location It s located at the upper and right side of blower housing Function It operates ambient intake door motor by the control command of automatic temperature control to set up the inlet mode of ambient intake door Air Mix Door Motor Installation Location It s located at the lower side of heater housing Function It controls the ...

Page 1328: ...NTERVENT 1 SIDEVENT 2 FOOT 3 DEFROSTER 4 SIDEDEF 5 VENT 6 FOOT 7 Front A A B MODE Rear INTAKE Door AIR MIX Door VENT B B C C C BI LEVEL B B D D B FOOT B C C D D FOOT DEF B B C DEF REC A Recirculation Switch FRE B Tempera ture Control Lever A B C YAD7A030 ...

Page 1329: ...SSANGYONG Y200 7A 6 HEATING AND VENTILATION SYSTEM SCHEMATIC ROUTING DIAGRAM YAD7A040 BLOWER MOTOR DIAGRAM ...

Page 1330: ...case and Vents 2 Repair and replace any leaks or obstructions Are the repairs complete Set all the selection switches to Defrost Is there a heavy airflow from any step Check the vent outlets and repair as needed Is the repair complete Check for change in the airflow at various blower speeds and then repair as needed Is the repair complete Check for obstructions in the system at the blower inlet an...

Page 1331: ...d outlet hose warm Check the system for any obstruction between blower heater case and airflow delivery outlet and then repair or replace as required Is the repair complete 1 Repair the temperature door travel cables and linkage as required 2 Verify the accuracy of the temperature control at full hot and full cold and then repair as required Is the repair complete Check thermostat and then repair ...

Page 1332: ...ister block From the blower resister block to the blower speed switch Is there any short in the above positions Repair any short Is the repair complete 1 Disconnect the power connector from the blower motor 2 Use the test lamp to locate a possible short between the terminal 1 of the blower switch connectors and the terminals 6 3 5 4 of the blower switch connectors sequentially Does the test lamp l...

Page 1333: ...er and air delivery case Go to Blower Electrical System OK Set the blower switch to 4th Rotate the temperature control from full cold to full hot Listen to an airflow change Repair or replace any obstruction between the blower and the system outlets Check and repair the door adjustments the cables the linkage and the control Action Check IMPROPER AIR DELIVERY OR NO MODE SHIFT Check connection and ...

Page 1334: ...ull hot full cold position and then adjust as needed Check for a change in the airflow at different blower speed Check the change System OK Go to Blower Electrical Turn the ignition OFF Turn the temperature control knob to full hot then rapidly to full cold Check the system case for leaks and check the floor outlet attachment Adjust the vent door to vent mode Check the door travel the cables the c...

Page 1335: ...le to the door Repair the instrument panel interference with the cable Remove the cable from the control Check the control for binding Replace the control switch Replace the cable Remove the cable from the control Operate the control switch System OK System OK Replace the control switch Check a binding door for the shaft alignment a bent shaft a bent door or warped case and then repair as needed R...

Page 1336: ...any noise in the floor mode Remove any obstruction or foreign material of the duct Check the floor defroster door seals Repair or replace as needed Check any noise in the vent mode Remove any obstruction or foreign material of the duct Check the vent door seals Repair or replace as needed Check the temperature door seals Check the system for obstructions foreign materials between the fan and the t...

Page 1337: ...Assembly 2 Heater Assembly 3 Side Defroster Duct LH 4 Main Defroster Nozzle 5 Side Defroster Duct RH 6 Side Defroster Joint 7 Console Front Ventilation Duct 8 A C Controller 9 Console Middle Ventilation Duct 10 Console FOOT Duct 11 Console Rear Ventilation Duct 12 Rear cooler Duct 13 Rear cooler Assembly 14 Rear cooler Controller YAD7A050 ...

Page 1338: ...y 2 Remove the defroster nozzle retaining screws and the defroster nozzle assembly REPAIR INSTRUCTIONS 3 Remove the ventilation duct 4 Remove the air distributor at console side Remove the center console Remove the parking brake lever assembly Remove the middle duct retaining bolt 5 Remove the middle duct and the lower duct YAD7A060 YAD7A070 YAD7A080 ...

Page 1339: ...ventilation duct to the instrument panel Install the duct at console side with air duct REAR COOLER DUCT Removal Installation Procedure 1 Remove the rear quarter inner panel 2 Remove the tapping screw and hex screw at the duct 3 Remove the duct 4 Installation should follow the removal procedure in the reverse order YAD7A090 YAD7A100 YAD7A110 YAD7A120 ...

Page 1340: ...move the blower module Notice A C pipe should be removed previously 3 Remove the heater module retaining bolts and heater module assembly Notice Note that it is possible to remove the heater module only when you remove the heater hose previously 4 Installation should follow the removal procedure in the reverse order Tighten the heater module with the retaining bolts Retaining Bolt 5 N m 44 lb in Y...

Page 1341: ...push back the suction heater hose clamp near the fire wall 3 Twist the hose slowly from the left side to the right side to loosen the connection between the hose and the tube 4 Remove the hose end from the tube 5 Remove the clip and push back the heater suction hose at engine block side 6 Remove the heater suction hose and discharge hose on the vehicle 7 Installation should follow the removal proc...

Page 1342: ...ormation and Procedures 7B 10 General Diagnosis 7B 10 Diagnosis Using The Manifold Gauge 7B 11 Maintenance and Repair 7B 13 Refrigerant Charging 7B 13 Compressor Oil Replacement 7B 17 Replacement of Refrigerant Connection 7B 18 Repair Instructions 7B 19 On Vehicle Service 7B 19 Air Filter Auto A C 7B 19 Receiver Dryer 7B 20 Condenser 7B 21 Compressor 7B 23 A C High Low Pressure Line 7B 23 A C Modu...

Page 1343: ...pe Size Capacity Desiccant Pressure Switch Type Refrigerant Capacity Component DESCRIPTION AND OPERATION SPECIFICATIONS MFC 6 PASS 620 w x 479 h x 20 t 250 cc XH 9 35 g DSL Dual Pressure GSL Triple Pressure R 134a Single 850 50 g Dual 1200 50 g Specifications V 5 Variable Displacement 9 8 151 cc rev Ø130 5 265 ml V 7 9 8 179 cc rev 7 Application ...

Page 1344: ...strictions or kinks inthe condenser core the hoses and the pipes 3 Check the operation of the blower fan 4 Check all the air ducts for leaks or restrictions Low airflow rate may indicate a restricted evaporator core 5 Check for slippage of the compressor clutch 6 Check the drive belt tension Handling O Ring 1 Even though O rings may look identical it is extremely important that only recommended se...

Page 1345: ...opening the connection This will prevent the entry of dirt foreign material and moisture 3 Keep all tools clean and dry including the manifold gauge set and all replacement parts 4 Use a clean and dry transfer device and container to add PAG refrigerant oil This will ensure that the oil remains as moisture free as possible 5 When opening an A C system have everything needed to perform all operatio...

Page 1346: ...ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ÀÀÀÀÀÀÀ ...

Page 1347: ...SSANGYONG Y200 7B 6 GENERAL HVAC SYSTEM Airflow Typical A C System Typical YAD7B020 YAD7B030 ...

Page 1348: ...TEM COMPONENT 1 Condenser 2 Receiver Drier 3 Compressor 4 A C Heater Blower Module 5 Defrost Nozzle Duct 6 Front A C Controller 7 Rear Duct 8 Rear Cooler Assembly 9 Rear Cooler Duct 10 Suction Rear Pipe Line 11 Liquid Rear Pipe Line 12 Rear Cooler Controller YAD7B040 ...

Page 1349: ...7B 8 GENERAL HVAC SYSTEM 1 High Pressure Pipe 2 Low Pressure Pipe 3 Heater Hose 4 High Pressure Hose And Pipe 5 High Pressure Hose 6 Receiver Drier 7 Condenser 8 Liquid Hose 9 Compressor YAD7B330 A C SYSTEM PIPE LINE ...

Page 1350: ...GENERAL HVAC SYSTEM 7B 9 SSANGYONG Y200 COMPRESSOR LOCATION Gasoline Engine Diesel Engine YAD7B050 YAD7B060 ...

Page 1351: ...sor Check the pressure Check the expansion valve Replace Replace Replace Replace Replace Replace Replace Adding refrigerant Replace Adjusting belt Replace Replace Replace Replace Replace Replace Evacuating and charging refrigerant Replace Adding refrigerant Replace Cleaning surface Replace Recharging refrigerant Adjusting belt Replace Evacuating and charging refrigerant Replace Check Symptom Magne...

Page 1352: ...and low pressure are abnormally low 2 Air at cooler outlet is not cold 1 High and low pressure are abnormally high 1 High and low pressure are abnormally high 2 Connection at the low pressure is not cold There is a gas leak in the cooling system Insufficient cooling and faulty condenser cooling by excessive refrigerant Belt is slipped There is an air in the cooling system Check the oil leak repair...

Page 1353: ...ormal inter mittently The dust and moisture etc are frozen at the expansion valve A gas leak in the heat reducer The mixed moisture is frozen at the expansion valve The faulty expansion valve the improper installation of the heat reducer Fail to control the flow rate Repair the receiver drier Replace the expansion valve for the faulty heat reducer Repair the receiver drier and perform the bleeding...

Page 1354: ...is allowed to escape too fast compressor oil will be drawn out of the system 4 Check whether the shop towel gets wet in oil and if wet close the hand valve 5 After the high pressure gauge reading drops below 3 5 kg cm2 slowly open the low pressure valve 6 When both high and low pressure gauges reading drops to 0 kg cm2 discharging is completed Evacuating Refrigeration System Notice The unit tank m...

Page 1355: ...on in use Check for Refrigerant Leaks 1 Connect the center hose of the gauge to the refrigerant tank 2 Open the high pressure valve of the gauge to charge with refrigerant gas 3 Charge until the low pressure gauge reads 1 0 kg cm2 and close the valve 4 Using a gas leak detector check the system for leaks 5 If any leak is found replace O ring or repair the faulty connection How to Use the Tap Valve...

Page 1356: ...e the specified amount to the charging valve and close the low pressure valve Notice If the charging speed is low it s more efficient to place the refrigerant tank in the warm water 40 C But the temperature should keep below 52 C at any situation Be careful not to contact the heating device or material Charging for Liquid Notice Do not operate when charging the system through the high side rpessur...

Page 1357: ...ck the temperature of air inlet within 25 35 C 8 Calculate the relative humidity from the psychrometic graph comparing the wet dry temperature at the air inlet 9 Measure the wet dry temperature at the cold air outlet and calculate the temperature difference of the dry bulb between the inlet and the outlet 10 Check the cross point of the relative humidity and check the temperature difference betwee...

Page 1358: ...any other material If the oil leaves outside for long time it s possible to mix it with the moistures and so keep the oil sealed with a container Circulating Oil For checking or adjusting the oil level set the control unit to full cold and max blower speed with keeping the engine run at idle for 20 30 minutes in order to circulate the oil through the compressor Replacement Oil 1 Perform the oil ci...

Page 1359: ...ter inserting the pipe to the union tighten the nut by hand as much as possible and tighten the nut with the specified torque 3 Measure the amount of the discharged oil If the the amount of the discharged oil is below 70 cc it means the oil leak Check the connections of the system and repair or replace as needed 4 Check the oil contamination and add the oil or adjust the oil level Notice For conta...

Page 1360: ... Procedure 1 Remove the glove box 2 Remove the lower bracket of crash pad 3 Remove the air filter 4 For replacing the air filter verify that the flowing direction mark of the air filter face toward the evaporator core Notice Installation should follow the removal procedure in the reverse order YAD7B300 YAD7B310 YAD7B320 ...

Page 1361: ...er the refrigerant from the system 2 Remove the head lamp assembly 3 Disconnect refrigerant pressure sensor connector 4 Remove the receiver drier Remove two flange nuts Remove the O ring Remove the bracket bolt retaining the receiver drier and then remove the receiver drier YAD7B340 YAD7B350 YAD7B360 YAD7B370 ...

Page 1362: ... system Notice Before installing check the O ring and apply the compressor oil CONDENSER Removal Installation Procedure 1 Discharge and recover the refrigerant from the system 2 Remove the radiator grill and front bumper 3 Remove the inlet pipe Remove the O ring at the same time 4 Remove the outlet pipe at the bottom side with O ring YAD7B380 YAD7B390 YAD7B400 YAD7B410 ...

Page 1363: ...fan connector and then remove the condenser fan from the condenser 8 Remove the bolts and nuts retaining condenser and then remove the condenser from the vehicle 9 Installation should follow the removal procedure in the reverse order Notice The used O ring must be replaced by the new part YAD7B420 YAD7B430 YAD7B440 YAD7B450 ...

Page 1364: ... 4 Lift the vehicle and support safely 5 Remove the skid plate 6 Remove the compressor Disconnect the connector of the compressor Remove three front bracket bolts retaining compressor Notice Discard the used sealing washer 7 Installation should follow the removal procedure in the reverse order Tighten the bolts with the specified torque Evacuate and recharge the A C system A C HIGH LOW PRESSURE LI...

Page 1365: ... from the system 3 Disconnect the inlet and outlet hose of the heater 4 Disconnect the high low pressure pipe from the evaporator core 5 Remove five bolts securing the A C module two bolts at evaporator two bolts at heater core a bolt at I P 6 Remove the instrument panel 7 Remove the fiber panel 8 Remove the A C module assembly Installation Procedure 1 Installation should follow the removal proced...

Page 1366: ...or holding fixture to the compressor and hold the compressor holding fixture using a bench vise Use the clutch hub holding tool to keep the clutch drive plate and the hub assembly from turning to remove the shaft nut Remove the snap ring using the ring plier Remove the clutch drive using the special tool Remove the clutch shaft key and spring YAD7B510 YAD7B520 YAD7B530 ...

Page 1367: ...l connector at the clutch housing Remove the clutch coil using the special tool 5 Assembly should follow the disassembly procedure in the reverse order 3 Remove the compressor pulley Remove the snap ring using the ring plier Remove the compressor pulley using the special tool YAD7B540 YAD7B550 YAD7B560 ...

Page 1368: ...GENERAL HVAC SYSTEM 7B 27 SSANGYONG Y200 SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE DW100 010 Spring Clamp Remover Installer YAD7B570 ...

Page 1369: ...CONTENTS Description and Operation 7C 2 System Components Functional 7C 2 Specifications 7C 4 Diagnostic Information and Procedures 7C 5 Insufficient Cooling Diagnosis 7C 5 Abnormal Refrigerant Pressure 7C 7 Repair Instructions 7C 8 On Vehicle Service 7C 8 Control Switch Assembly 7C 8 ...

Page 1370: ...based on bench overhaul with the compressor removed from the vehicle except as noted They have been prepared in the order of accessibility of the components When a compressor is removed from the vehicle for servicing the amount of oil remaining the compressor should be drained measured and recorded This should then be discarded and new polyalkaline glycol PAG refrigerant oil added to the compresso...

Page 1371: ...e heat in the air passing through the evaporator core is transferred to the cooler surface or the core which cools the air As the process of heat transfer from the air the evaporator core surface is taking place any moisture humidity in the air condenses on the outside surface of the evaporator core and is drained off as water Pressure Relief Valve The compressor is equipped with a pressure relies...

Page 1372: ...Capacity A C ON OFF A C ON OFF High Pressure Low Pressure Component SPECIFICATIONS 6 000 7 500 rpm R 134a Synthetic PAG Oil 260 cc Aluminum 260 cc 11 400 Kcal h 263 0 x 228 6 x 88 9 mm 6 500 Kcal h 305 425 psi 39 30 psi 32 Kgf cm2 4 Kgf cm2 Description Single Dual Gasoline Single Dual Gasoline Single Dual V 5 Compressor V 7 Compressor 10PAIRC 9 8 151 cc rev 179 cc rev 170 5 cc rev 850 50 g 1200 50...

Page 1373: ... open or short in the wiring Repair the faulty wiring as needed Is the repair complete Replace the compressor clutch coil Is the replacement complete Check for a knocking noise from the A C compressor Cycle the A C compressor ON and OFF in order to verify the source of the noise Do you hear a loud knocking noise 1 Recover the A C system refrigerant 2 Replace the A C compressor 3 Evacuate and recha...

Page 1374: ...otor switch to 4th 5 Set the temperature control switch to full cold 6 Turn the A C switch ON and OFF every 20 seconds for 3 minutes 7 Measure the compressor high and low pressure Are both pressures within the specified value Add the specified amount of the refrigerant to the A C system Is the amount within the specified value 1 Turn the ignition to LOCK 2 Set the A C switch to OFF position Can yo...

Page 1375: ...specified value 3 Repair any leaks as needed Is the repair complete 1 Check the freezing clogging of the expansion valve 2 Check the clogging of the receiver drier 3 Check the amount of the refrigerant Is the low side refrigerant pressure low abnormally 1 Clean the expansion valve and replace it as needed 2 Replace the receiver drier as needed Is the repair complete 1 Check the expansion valve and...

Page 1376: ...AIR INSTRUCTIONS ON VEHICLE SERVICE CONTROL SWITCH ASSEMBLY 1 Remove the center instrument panel 2 Remove four screws securing the A C control switch assembly 3 Remove the A C control switch assembly from the instrument panel YAD7C010 YAD7C020 YAD7C030 ...

Page 1377: ...MANUAL CONTROL HVAC SYSTEM 7C 9 SSANGYONG Y200 4 Installation should follow the removal procedure in the reverse order Notice Insert connector to the switch and then assembly the YAD7C040 ...

Page 1378: ...er Motor Does Not Run At All 7D 19 No Cool Air From Blower 7D 21 Mode Controls Does Not Work 7D 22 Mode Controls Does Not Work 7D 22 Abnormal Refrigerant Pressure 7D 23 Compressor Magnetic Clutch Does not Engage 7D 24 Inside Air Temperature Sensor Error 7D 24 Ambient Air Temperature Sensor Error 7D 24 Coolant Temperature sensor Error 7D 25 Air Mix Door Error 7D 25 SunSensorError 7D 27 PowerTransis...

Page 1379: ...details for the following System Components Functional The V5 A C System V5 Compressor Operation V5 Compressor General Description DESCRIPTION AND OPERATION Vacuum Fluorescent Display panel provides system operating information for the driver With the system in OFF mode the outside temperature is displayed continuously The driver may display the current temperature setting by selecting any mode ex...

Page 1380: ...AUTOMATIC CONTROL HVAC SYSTEM 7D 3 SSANGYONG Y200 FATC CONTROL YAD7D010 ...

Page 1381: ...SSANGYONG Y200 7D 4 AUTOMATIC CONTROL HVAC SYSTEM FATC INPUT OUTPUT ROUTING DIAGRAM YAD7D020 ...

Page 1382: ...oller to its normal function DTC 0 1 2 3 4 5 6 7 Description Normal No Error Inside Air Temperature Sensor Error Ambient Air Temperature Sensor Error Coolant Temperature Sensor Error Air Mix Door Error Sun Sensor Error Power Transistor Error Action Taken When the Faulty Occurred When any faulty is occurred in the automatic temperature control system it s sign is informed to the driver by flashing ...

Page 1383: ...sor detects above 20 C and also the blower step increases gradually according to going up the coolant temperature When the coolant temperature goes up above 40 C the heating operation stops Vent Rate Control By Cooling Operation When the air inside the resonance duct is hot in summer after the system keeps the low vent rate 1st operating for 5 seconds and discharges the hot air to the windshield s...

Page 1384: ...ng Therefore the ambient temperature sensor indicates the ambient temperature accurately on the condition of above 40 km h running Delivery Condition For the initial installation the initial current draw the initial mode follows Vent inlet Control Manual Control When you push the I A control switch you can control the I A door manually and the I A door changes between the recirculation air and the...

Page 1385: ...oster mode Operation Condition When the passenger operates the wiper on AUTO mode the system controls the wiper on the A C AUTO mode after sending the wiper signal and controlling the delay for 1 minutes FATC Controller Illumination Control When the tail lamp is ON ATC Controller illumination lamp turns on SYSTEM COMPONENTS CONTROL Controller Assembly The operation of the A C system is controlled ...

Page 1386: ...hen it s normal Coolant Temperature Sensor Coolant temperature sensor is a thermistor that decreases its resistance when temperature up and increases when temperature down It detects coolant temperature to operate the blower speed at low when the coolant temperature is less than 50 C 122 F If the coolant temperature sensor is open or short 100 C 212 F will be substitute Inspection When the coolant...

Page 1387: ...nspection When the vent inlet mode displayed in the AUTO temperature control is different from the actual mode check the followings 1 Turn the ignition ON 2 Measure the voltage between positive terminal and negative terminal of the Mtr Act AI connector Specified value 12 V 3 Measure the voltage between P1 P2 P3 and terminal If it changes from 0V before the mode selection to 12 V after the mode sel...

Page 1388: ...ng the terminal to the Mtr Act mode and each terminal P1 P5 to terminal sequentially using 12 V power Air Mix Door Motor The air mix door motor is located on left side of heater module The air mix door motor controls the exhaust air temperature by the signal of the FATC Inspection When the air mix door motor error displays check the followings 1 Turn the ignition ON 2 Measure the voltage within P1...

Page 1389: ...sistor basic current Inspection When the power transistor error displays check the followings 1 Turn the ignition ON 2 Measure the voltage between blower connectors by changing the step from 1st to 6th 3 The voltage value by each step is the followings specified value 0 5 4 If the value is outside the specified value check the open or short circuit 5 When there is no problem in the wiring harness ...

Page 1390: ...ent Max RPM Material Capacity Type Capacity Type Capacity Max Capacity A C ON A C OFF A C ON A C OFF Max Capacity Fin Pitch Size Capacity Component SPECIFICATIONS Description Variable Displacement V 5 Compressor 9 8 151 cc rev 6 000 6 500 rpm AL R DRIER 210 cc R 134a 750 20 g Synthetic PAG Oil 220 cc 11 400 Kcal h 305 psi 425 psi 39 psi 30 psi 7 475 9 075 Kcal h 1 52 mm 200 5 x 168 2 x 25 0 mm 8 2...

Page 1391: ...g procedures A C Performance Test Insufficient Cooling Quick Check Procedure Insufficient Cooling Diagnosis Leaking Testing the Refrigerant System Low and High Side Pressure Relationship Chart Pressure Temperature Relationship of R 134a Testing the refrigerant system Pressure Test Chart R 134a System If the FATC detects some errors it will blink the temperature display screen for 5 seconds when th...

Page 1392: ... open or short in the compressor wiring Is there any open or short in the wiring Repair the faulty wiring as needed Is the repair complete Replace the compressor clutch coil Is the replacement complete Check for a knocking noise from the A C compressor Cycle the A C compressor ON and OFF in order to verify the source of the noise Do you hear a loud knocking noise 1 Recover the A C system refrigera...

Page 1393: ... motor switch to 4th 5 Set the temperature control switch to full cold 6 Turn the A C switch ON and OFF every 20 seconds for 3 minutes 7 Measure the compressor high and low pressure Are both pressures within the specified value Add the specified amount of the refrigerant to the A C system Is the amount within the specified value 1 Turn the ignition to LOCK 2 Set the A C switch to OFF position Can ...

Page 1394: ...Repair the faulty circuit between the ground G203 and terminal A1 of the ATC wiring connector Is the repair complete Action 1 Remove the controller with connecting ATC wiring connector 2 Turn the ignition switch to ON 3 Measure the voltage between terminal A4 and A3 of the controller Is the voltage within the specified value Repair the wiring harness between splice S206 and terminal A3 of the cont...

Page 1395: ...es in good condition Replace the coolant hoses Is the repair complete Check the coolant reservoir cap Is the coolant tank cap in hood condition Replace the coolant reservoir cap Is the repair complete 1 Turn the A C switch to ON 2 Set the temperature control to full hot HI 3 Set the blower motor speed to full high 4 Remove the coolant reservoir cap all segments illuminated on the display 5 Start t...

Page 1396: ...e the fuse Is the repair complete 1 Turn the ignition switch to ON 2 Measure the voltage between ground and terminal 87 of blower relay Is the voltage within the specified value 1 Measure the voltage between ground and terminal 86 of blower relay Is the voltage within the specified value 1 Check the circuit between terminal 86 of the blower relay and fuse SB7 in the I P fuse block 2 Repair any pro...

Page 1397: ...asure the resistance of the blower motor Does the measured resistance indicate 0 5 Ω Replace the blower motor Is the repair complete Measure the open or short of the circuit between terminal 1 of the blower connector and terminal 30 of the blower high relay and terminal 6 of the power transistor Is there any open or short circuit Repair the problem in the circuit Is the repair complete Measure the...

Page 1398: ...the air mix door actuator functioning properly Perform the checks found in Insufficient Cooling Diagnosis Is the system operating normally now Place the controller in the AUTO mode Is smoke taken into the intake port of the inside air sensor Replace the intake hose Is the repair complete Check the each sensor and sensor wiring using the Diagnostic Table Is there a problem indicated in the sensor t...

Page 1399: ... complete Action Measure the voltage between terminal 4 of the intake control door motor and ground Is the voltage within the specified value Repair the connector and the circuit for any wiring or terminal problems Is the repair complete 1 Measure the voltages at the specified terminals of the specified motor connectors 2 Change the mode settings and observe the voltage changes Is the voltage with...

Page 1400: ... C system according to the specified value 3 Repair any leaks as needed Is the repair complete 1 Check the freezing clogging of the expansion valve 2 Check the clogging of the receiver drier 3 Check the amount of the refrigerant Is the low side refrigerant pressure low abnormally 1 Clean the expansion valve and replace it as needed 2 Replace the receiver drier as needed Is the repair complete 1 Ch...

Page 1401: ...cate 2 2 kΩ at 25 C Replace the inside air sensor Is the repair complete Replace the controller Is the repair complete Action 1 Remove the ambient air temperature sensor 2 Measure the resistance between the ambient air temperature sensor connector terminals Does the measured resistance indicate 2 2 kΩ at 25 C Replace the ambient air temperature sensor Is the repair complete 1 Remove the controller...

Page 1402: ...sistance between terminals 2 and 3 on the air mix door motor Does the measured resistance indicate approximately 3 kΩ Replace the air mix door motor Is the repair complete Use an ohmmeter to measure the resistance between terminals 6 and 3 6 and 2 on the air mix door motor Does the measured resistance indicate approximately 3 kΩ Replace the air mix door motor Is the repair complete Check the conne...

Page 1403: ...terminal A9 at the control ler Specified voltage 12 V 5 Change the temperature setting on the controller to LO and measure the voltage 0 V Is the voltage within the specified value Recheck all wiring circuits between the controller and the air mix door motor with changing the temperature setting Does the air mix door operate normally Replace the air mix door motor Is the repair complete Recheck al...

Page 1404: ...or Is the repair complete Replace the FATC controller Is the repair complete Action 1 Disconnect the Sun sensor connector 2 Place the sun sensor under the sun light and measure the current between the connector terminals 3 Place the sun sensor under the shadow place and measure the current between the connector terminals Is the measured current lower at the shadow place replace the sun sensor Is t...

Page 1405: ...and ground Does the measured voltage indicate 0V Replace the FATC controller Is the repair complete 1 Check the wiring harness associated with blower high relay and terminals 2 Repair any defects found 3 Install the component Is DTC retrieved as a current DTC Replace blower high relay Is the repair complete MAX HIGH RELAY ERROR Action Step 1 2 3 4 Yes System OK Go to Step 4 System OK Go to Step 3 ...

Page 1406: ... REPAIR INSTRUCTIONS ON VEHICLE SERVICE CONTROL SWITCH ASSEMBLY 1 Remove the center instrument panel 2 Remove the four screws securing the control switch assembly 3 Remove the control switch assembly from the instrument panel YAD7D160 YAD7D170 YAD7D180 ...

Page 1407: ... switch and then assemble the control switch completely BLOWER MOTOR 1 Remove the glove box and put the floor mat aside 2 Disconnect the connectors connecting the blower motor 3 Remove four bolts securing the blower motor and remove the motor assembly 4 Installation should follow the removal procedure in the reverse order YAD7D190 YAD7D200 YAD7D210 YAD7D220 ...

Page 1408: ...g the power transistor 3 Remove the power transistor assembly AIR MIX DOOR ACTUATOR 1 Disconnect the negative battery cable 2 Remove the glove box 3 Disconnect the connectors of the air mix door actuator 4 Remove three screws securing the mode control door actuator and heater air distributor case 5 Remove the mode control actuator slowly and then remove the air mix door actuator 6 Installation sho...

Page 1409: ...ol door actuator 6 Installation should follow the removal procedure in the reverse order SUN SENSOR 1 Remove the sun sensor from the instrument panel 2 Disconnect the sensor connector and remove the sun sensor 3 Installation should follow the removal procedure in the reverse order Notice For disconnecting the connector from the sun sensor be careful that the wiring must not come into the instrumen...

Page 1410: ...t panel 4 Installation should follow the removal procedure in the reverse order AMBIENT AIR TEMPERATURE SENSOR 1 Remove the left headlamp assembly 2 Disconnect the ambient air temperature sensor at the clip hole of the headlamp support outer panel and then disconnect the connector YAD7D300 YAD7D310 YAD7D320 YAD7D330 ...

Page 1411: ...ENSOR 1 Disconnect the coolant temperature sensor at the side of the heater core at left bottom of the glove box 2 Installation should follow the removal procedure in the reverse order 3 Installation should follow the removal procedure in the reverse order YAD7D340 YAD7D350 ...

Page 1412: ...ill help prevent personal injury and damage to the vehicle The ignition must be in B unless otherwise noted TABLE OF CONTENTS Specifications 8A 2 Fastener Tightening Specifications 8A 2 Diagnosis 8A 3 Seat Belt Warning Lamp is Inoperative 8A 3 Component Locator 8A 4 Seat Belt Assembly 8A 4 Maintenance and Repair 8A 5 On Vehicle Service 8A 5 Front Seat Belt 8A 5 Front Seat Belt Buckle 8A 6 2nd Row ...

Page 1413: ... 22 33 22 33 22 33 22 33 22 33 22 33 22 33 Front Seat Belt 2nd Row Seat Belt 3rd Row Seat Belt Adjuster Mounting Bolt Retractor Mounting Bolt Upper Bolt Lower Bolt Belt Buckle Bolt Retractor Mounting Bolt Upper Bolt Upper Bolt Lower Bolt Retractor Bolt SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Lb In Application ...

Page 1414: ...NING LAMP IS INOPERATIVE Condition Seat belt warning lamp is inoperative Probable Cause Seat belt warning lamp wiring harness is open circuit or a short circuit The continuity between the two terminals at the switch side of the connector is fail The continuity between the terminal for the BLK wire and ground is fail The warning lamp bulb in the instrument cluster is blown ...

Page 1415: ...SSANGYONG Y200 8A 4 SEAT BELTS COMPONENT LOCATOR SEAT BELT ASSEMBLY 1 Upper anchor plate 2 Seat Belt 3 Retractor 4 Buckle 5 Retractor 6 Rear Seat Belt 7 Seat Belt YAD8A010 ...

Page 1416: ...e bolt cap of the seat belt and remove the lower bolt YAD8A020 YAD8A030 YAD8A040 3 Pry off the upper bolt cap using the special tool and remove the upper bolt 4 Pry off the lower B pillar trim 5 Disconnect the connector in the front seat belt retractor and remove the mounting bolt 6 Separate the front seat belt and the retractor assembly MAINTENANCE AND REPAIR ...

Page 1417: ...e buckle assembly Installation Procedure 1 Tighten the adjuster and the seat belt retractor bolt as specified torque Installation Notice YAD8A060 Adjuster Mounting Bolt 1 30 40 N m 22 30 lb ft 30 45 N m 22 33 lb ft Retractor Mounting Bolt 2 Upper Bolt 1 30 45 N m 22 33 lb ft 30 45 N m 22 33 lb ft Lower Bolt 2 YAD8A050 7 Remove the upper B pillar trim and remove the bracket mounting bolt of the hei...

Page 1418: ...D8A110 YAD8A120 2 Remove the lower quarter trim 3 Remove the upper quarter trim 4 Remove the seat belt upper bolt 5 Remove the retractor bolt and screw Remove the seat belt assembly YAD8A090 2 Installation should follow the removal procedure in the reverse order Tighten the mounting bolt as specified torque Installation Notice Tightening Torque 30 45 N m 22 33 lb ft ...

Page 1419: ... row seat down and perform the work with the upper quarter trim removed 2 Remove the retractor bolt and screw of the 3rd row seat and then remove the seat belt assembly YAD8A130 6 Installation should follow the removal procedure in the reverse order Tighten the seat belt retractor bolt and the upper bolt as specified torque Installation Notice Retractor Mounting Bolt 1 30 45 N m 22 33 lb ft 30 45 ...

Page 1420: ...llation should follow the removal procedure in the reverse order Tighten each bolt as specified torque Installation Notice YAD8A170 Upper Bolt 1 30 45 N m 22 33 lb ft 30 45 N m 22 33 lb ft Lower Bolt 2 30 45 N m 22 33 lb ft Retractor Bolt 3 ...

Page 1421: ... Locator 8B 9 Driver Airbag Assembly 8B 9 Passenger Airbag Assembly 8B 10 Diagnostic Information and Procedures 8B 11 General Diagnosis 8B 11 Diagnosis 8B 12 Diagnostic Trouble Codes 8B 13 Maintenance and Repair 8B 16 On Vehicle Service 8B 16 Airbag Module Driver 8B 16 Contact Coil 8B 17 Airbag Module Passenger 8B 18 Belt Pretensioner 8B 19 Sensing and Diagnostic Module SDM 8B 19 Special Tool and ...

Page 1422: ...ersonnel at franchised SsangYong dealers and authorized SsangYong service dealerships may service the airbag system Never attempt to disassemble repair or reuse the following component Airbag modules Clock spring Sensing and diagnostic module Wiring harness When repairing SIR component follow the service notice Inspect any SIR part before it is installed Use only new parts Do not install used SIR ...

Page 1423: ...the vehicle Before deploying the airbags remove all loose objects from the airbag s expansion area Deploy the airbags with the vehicle doors closed and the side windows open Deploy the airbags only in an evacuated area Service personnel who must be present during the deployment should be at least 10 meters 33 feet in front of the vehicle Do not connect the voltage source until after having complet...

Page 1424: ...fter having completed all other preparations for the deployment of the airbags Allow a deployed airbag module or pretensioner to cool for at least 30 minutes before handling If the deployment fails disconnect the voltage source and wait 5 minutes before approaching the vehicle 1 Position the airbag module face up on flat ground outdoors at least 10 meters 33 feet from any obstacle or people 2 Plac...

Page 1425: ...center pad of the steering wheel The passenger airbag module is installed in the instrument panel at passenger side The driver and passenger side airbag is inside each seat Notice Do not disassemble the airbag module because unintentional deployment of the airbags resulting from any damage or interference of the module can cause injury SDM Sensing and Diagnostic Module 1 The airbag system consists...

Page 1426: ...itions with the front wheels ahead Align the pointed marks AirbagWarning Lamp The instrument cluster contains an airbag warning indicator bulb to verify the operation of the AIRBAG indicator and sensing and diagnostic module SDM YAD8B080 Fault contents System OK System fault Internal SDM fault Power supply circuit open and fuse open Warning lamp circuit open SDM fault Warning lamp status Flash at ...

Page 1427: ... is made by injection molding Door Assembly It is a part of the airbag steering and is made by vacuum bubble PSM injection Cushion Cushion is made mainly of nylon 66 material It is made by assembling various panel pieces and sometimes some surfaces of these panel pieces handled by coating The coating material is used as silicon rubber generally Inflator The inflator generates gas to fill the cushi...

Page 1428: ...B Pillar Trim and Structure 6 Airbag Wiring Harness Component 1 Side Airbag Module LH RH 2 Side Airbag Sensor LH RH 3 SDM Common use the SDM for frontal airbag Side Airbag Module SAB Chest Head and Gas Airbag Installed on door or seatback Side Airbag Module SAB Chest Head and Gas Airbag Installed on door or seatback SDM Side Airbag Sensor Side Impact Detection Deployment Decision Self Diagnosis In...

Page 1429: ...ROSS SECTIONAL VIEW DRIVER AIRBAG ASSEMBLY 1 Cover 2 Carrier 3 Retainer cover assembly 4 Retainer cushion assembly 5 Cushion assembly 6 Inflator assembly 7 Membrane switch assembly 8 Reaction plate 9 Steering wheel 10 Remote control switch YAD8B090 ...

Page 1430: ...SSANGYONG Y200 8B 10 RESTRAINTS PASSENGER AIRBAG ASSEMBLY 1 Cover assembly 2 Housing assembly 3 Upper Door Retainer YAD8B100 4 Lower Door Retainer 5 Cushion assembly 6 Inflator assembly ...

Page 1431: ...an five types of faults Perform the diagnosis using the scan tool Warning lamp stays ON Connection fault between the SDM wiring harness connector and the SDM connector or the airbag wiring harness fault No the indicator turn ON Power supply malfunction indicator circuit open bulb fault SDM internal defect Diagnosis by Using Scan Tool Check the fault code by connecting the diagnostic ALDL connector...

Page 1432: ...nnect wiring connector Check any wiring short between fuse and wiring connector Repair wiring Disconnect SDM wiring connector Check wiring short between connector terminal and SDM connector terminal Replace airbag wiring Check any open between ALDL connector No 4 No 5 terminal and ground Repair wiring Ignition ON Measure voltage at the cigar lighter socket Check any open or short between ALDL conn...

Page 1433: ...eck the connection of the passenger airbag connector Check the wiring condition of the passenger airbag Check the bending of the airbag terminal Check the connection of the driver pretensioner connector Check the wiring condition of the driver pretensioner Check the bending of the airbag terminal Check the connection of the driver pretensioner connector Check the wiring condition of the driver pre...

Page 1434: ...tion of the passenger side airbag connector Check the wiring condition of the passenger side airbag Check the bending of the airbag terminal Check the connection of the passenger side airbag connector Check the wiring condition of the passenger side airbag Check the bending of the airbag terminal Check the connection of the passenger side airbag connector Check the wiring condition of the passenge...

Page 1435: ...r output voltage Check the battery voltage Check the bending of the airbag terminal Check generator output voltage Check the battery voltage Check the bending of the airbag terminal Replace the SDM Replace the SDM Code 51h 52h 53h 54h 55h 56h 57h 17h 18h 1Eh 1Fh Fault Contents Passenger side airbag circuit short to ground Communication malfunction of the driver side airbag Internal fault of the dr...

Page 1436: ... steering wheel at the straight driving direction 3 Remove the screw of the airbag module YAD8B110 YAD8B120 YAD8B130 4 Disconnect the airbag module connector the horn connector and then remove the airbag module 5 Verify to tighten all of the module and each connector Installation should follow the removal procedure in the reverse order MAINTENANCE AND REPAIR ...

Page 1437: ... coil mounting screw Remove the contact coil assembly CONTACT COIL Removal and Installation Procedure 1 Remove the steering wheel the lower panel at the driver side YAD8B140 YAD8B170 4 Tighten the contact coil mounting screw as the specified torque Installation should follow the removal procedure in the reverse order Installation Notice Tightening Torque 3 N m 27 lb in ...

Page 1438: ...bags from deploying during a crash Both of these outcomes can result in injury Notice Turn the label of the clock spring clockwise to lock and turn the label of the clock spring counterclockwise approximately 2 9 0 2 turns to the neutral positions with the front wheels ahead And also Align the pointed marks YAD8B180 YAD8B190 AIRBAG MODULE PASSENGER Removal and Installation Procedure 1 Disconnect t...

Page 1439: ...sembly 4 Remove the SDM mounting bolt and remove the SDM assembly 5 Installation should follow the removal procedure in the reverse order YAD8B210 YAD8B220 YAD8B230 5 Tighten the pretensioner mounting bolt as the specified torque Installation should follow the removal procedure in the reverse order SENSING AND DIAGNOSTIC MODULE SDM Removal and Installation Procedure 1 Disconnect the negative batte...

Page 1440: ...SSANGYONG Y200 8B 20 RESTRAINTS SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE Scan Tool Wheel Wrench YAD8B250 YAD8B260 ...

Page 1441: ...ENERAL BODY TABLE OF CONTENTS Specification 9A 2 Dignosis and ActionTaken 9A 3 Diagnosis for Leaking Water 9A 3 Check and Repair 9A 4 Check 9A 4 Repair 9A 7 Special Tool and Equipment 9A 9 Special Tools Table 9A 9 ...

Page 1442: ...d Keep Injecting Water 30 of Lower Direction and 45 of Backwards Approximately at the corner Line of Rear Door Keep Injecting Water 30 of Lower Direction and 45 of Forwards Approximately at Distance of 60mm to the Corner of Rear Door Type Structure Type of Regulator Lock System Structure Type of Regulator Lock System Type Wind Shield Front Door Glass Rear Door Glass Rear Fix Glass Glass of Tail Ga...

Page 1443: ...r hose 2 First of all test dubious section of leaking water by injecting water or air until technician detect section of leaking water point of checking is moving from the low of vehicle to the upper of vehicle Check the Water Hose 1 In order to detect section of leaking water another technician is moving into the internal of vehicle 2 Use water hose not having a nozzle 3 First of all test dubious...

Page 1444: ...rew driver Driving test should be observed as followings 1 Select straight and even road which is available to East West South and North 2 Select road not preventing test which has no noise or traffic obstacle 3 Drive the vehicle when wind noise is occurred Keep in mind within specified vehicle speed 4 If following condition happen each one is defined as external wind noise wind noise is occurred ...

Page 1445: ...nd prevention of noise YAD9A070 Bolt and Nut Notice Contacting surface to the non characteristic of each metal cause each metal to corrode so for prevention of early corrosion use specified bolt and nut Alloy of aluminium is using currently most vehicle Contacting between steel and aluminium cause to corrode if those are not hardening Special bolt and nut are using for prevention of corrosion in t...

Page 1446: ...trim to detect position of leaking water it is necessary for technician to remove trim and garnish moulding 2 During injecting water on the leaking section to detect quantity of leaking water carefully push the glass external area 3 Mark accurate position of leaking water 4 Wash section of leaking water and dry up air hose YAD9A090 YAD9A100 5 Remove ununiform section of cohesive material on the di...

Page 1447: ...oving parts treat soundproof Uniform surface of friction can prevent harding state 7 Wait approximately 5 minutes until drying up prima 8 Spread cohisive material on the distance of 75 100 mm to leaking section 9 After spreading cohisive material using the flat stick and similar equipment keep body and cohisive material uniform in order not to leak water 10 To make sure to finish repairing leaking...

Page 1448: ...lant 09861 31400 Glass Holder 09793 21000 Adjusting Wrench of Door Wrench 09853 31000 Remover of Headlning Clip 09861 31300 Sealant Gun 09861 31000 Remover of Wind Shield Molding 09800 21000 Ornament Remover 09861 31100 Cutting Tool of Sealant YAD9A120 YAD9A130 YAD9A140 YAD9A150 YAD9A160 YAD9A170 YAD9A180 YAD9A190 ...

Page 1449: ...de Trim and Roof Assembly 9B 3 Seat 9B 4 Console 9B 5 Removal and Installation 9B 6 Instrument 9B 6 Console Box 9B 9 Groove Box 9B 10 Trim and Roof 9B 10 Handler 9B 15 Sunvisor 9B 15 RoomMiror 9B 15 Seat 9B 16 Removal and Installation 9B 18 FrontSeat 9B 18 TwoRowSeat 9B 19 Seat of Three Row 9B 20 ...

Page 1450: ... INSTRUMENTS ASSEMBLY YAD9B010 1 Fuse Box Cover 2 Side Facia Panel 3 Instrument Panel 4 Instrument Lower Main Panel 5 Cluster Facia Panel 6 Center Facia Lower Panel 7 Groove Box 8 Side Facia Panel 9 Duct 10 Instrument Assembly 11 Center Facia Upper Panel ...

Page 1451: ...oor Scuff Rear 3 A Pillar 4 B Upper Pillar 5 B Lower Pillar 6 Side Cowl 7 Side Cowl 8 Out Side Step Front 9 Out Side Step Rear 10 Upper Quarter 11 Rear Aircon Facia 12 Lower Quarter 13 Jack Cover 14 Lower Quarter Cover 15 Lower Quarter 16 Rear Transverse Trim 17 Baggage Room Cover 18 Roof Panel ...

Page 1452: ...SSANGYONG Y200 9B 4 BODY INTERIOR SEAT YAD9B030 1 Front Seat Right Side 2 Rear Seat Right Side 3 3 Row Seat 4 Rear Seat Left Side 5 Front Seat Left Side ...

Page 1453: ...BODY INTERIOR 9B 5 SSANGYONG Y200 CONSOLE YAD9B040 ...

Page 1454: ...ation 1 Remove negative terminal from battery 2 Remove seat of passenger to remove easily panel of instrument REMOVAL AND INSTALLATION 4 Remove lower panel of driver seat in the instrument panel 3 Remove cover 1 of fuse box switch panel 2 of side mirror release lever 3 of fuel tank cover ...

Page 1455: ...right side 2 Removing screw of side of foot board side of door in the side cowl and then come to removal of side cowl 7 Removing center facia panel remove Audio 1 Aircon controller Assembly 2 6 Separating connector and vacuum hose from steering column assembly remove steering column shaft assembly 3 After driver put clearance between pillar and panel remove side cowl ...

Page 1456: ...sole box 10 After releasing fixing bolt and nut in the instrument panel remove panel assembly 9 Remove connector of main harness linking to center and right side left in the instrument panel 1 Connector linking to left side 2 Connector linking to right side 3 Connector linking to center ...

Page 1457: ...ing the reverse of removal insert each connectors tightly COSOLE BOX Removal Installation 1 Separate front console cover and console tray 3 Separate fixing bolts from console tray internal in the console box of rear side 2 After removing front console cover separate fixing bolts 2 ...

Page 1458: ...move hook of left right side in the groove box from instrument Notice If excessive force is put on hook hook may be broken 2 While the groove box is opened completely release fixing bolt of bracket and then remove groove box assembly TRIM AND ROOF Removal Installation Notice Installation proceed reverse order of removal A pillar 1 Remove trim of A pillar Pull key of A pillar trim out of key home ...

Page 1459: ...l trim 1 Separate fixing screw of door side and fixing screw of foot board of side cowl trim in the driver seat 2 Remove trim of side cowl right left Upper lower quarter 1 Remove rear window cover seat belt cover of upper quarter trim 2 Release fixing bolt of rear seat belt lower ...

Page 1460: ...rate lower quarter trim in order to make easy repair cover of lower quarter trim right left is separated in advance Door scuff trim 1 Using special tool separate door scuff trim of front and rear Notice First of all remove door scuff trim of front and rear in advance while door scuff trim of front and rear is installed finally ...

Page 1461: ...ose box 2 Separate multi purpose box from luggage compartment Rear transverse trim of tail gate 1 After opening the tail gate release fixing screw of rear transverse trim 2 Separate rear transverse B pillar trim 1 Release fixing bolt upper and lower of seat belt 2 After pulling trim of upper B pillar trim by the hand pick up key of trim from panel and then separate trim ...

Page 1462: ...ght and left 2 Separate upper trim right and left 3 Separate four handle 4 Separate room lamp sun roof door opening weather strip 5 After pulling clip bolt out of headlining separate headlining YAD9B350 3 Separate trim of lower B pillar trim with the same method to separate upper trim ...

Page 1463: ...D9B390 YAD9B400 HANDLE 1 After downing handle release screw 2 Separate handle ROOM MIRROR 1 Pulling room mirror separate it 2 After separating fixing bracket separate connector of mirror lamp 3 Separate sun visor SUNVISOR 1 Separate fixing hook of sun visor ...

Page 1464: ...installed technician should tight the torque as following Tightening Torque 35 55 N m 44 52 lb ft YAD9B410 YAD9B420 SEAT Removal Installation Front seat 1 Remove plastic cap 3ea of seat rail 2 Separate fixing bolt 4ea M10 of seat rail right and left 3 After separating connector of floor wiring remove front seat Position of connectors 1 Driver seat 2 each SAB 3 each 2 Passenger seat 1each SAB 2 eac...

Page 1465: ... as following Tightening Torque 60 70 N m 44 52 lb ft Three row seat 1 Pull seat cushion of three row seat forward 2 Separate fixing bolt of three row in the seat right and left 3 After separating fixing bolt of mounting in the rear seat right and left remove seat While the seat is installed technician should tight fixing bolt as following Torque fo front fixing bolt Torque fo front fixing bolt 35...

Page 1466: ...at is installed technician should tight the fixing bolt as following Torque fo front fixing bolt Torque fo front fixing bolt 41 2 49 N m 41 2 49 N m 2 Separate seat cushion from the seat rail at this time if seat warmer is equipped separate connector 3 After separating connector of adjusting switch remove external cover of seat 4 Remove fixing bolt of seat rail M10 x P1 25 2each ...

Page 1467: ...fter releasing fixing bolt of bracket in the two row seat of two person separate seat cushion 1 Remove nob of recliner 2 Remove cover of recliner External cover of seat screw one 3 Separate fixing bolt of seat and remove cable M10 x P 1 25 2 each 2 Position of fixing bolt differs in the left and right each other in the seat of one person see picture after checking the position remove seat cushion ...

Page 1468: ...SSANGYONG Y200 9B 20 BODY INTERIOR YAD9B560 YAD9B570 YAD9B580 3 Install reverse order of removal ...

Page 1469: ...After releasing bolt of seat socket at the bracket of the seat right and left remove seat Replacing Seat Motor In The Guide Rail Of Seat 1 Separate seat cushion 2 After releasing A of part of seat motor separate wire 3 After releasing fixing nut of seat motor separate motor assembly ...

Page 1470: ...ide Mirror 9C 22 Door Assembly 9C 23 Door Hinge 9C 24 Door Check Link 9C 24 Door Lock Assembly 9C 25 Door Handle 9C 26 Door Trim 9C 27 Door Opening Weathr Strip 9C 28 Fork Striker 9C 29 Tail Gate Crank 9C 31 TailGate 9C 32 Tail Gate Flip Up System 9C 33 Tail Gate Air Spoiler 9C 34 Check and Adjust Tail Gate 9C 35 Front Door Window 9C 37 Front Door Glass Run And Regulator 9C 38 RearWindow 9C 39 Rea...

Page 1471: ...SSANGYONG Y200 9C 2 BODY EXTERIOR PARTS COMPONENTS FRONT BUMPER 1 Front Bumper Facia Assembly 2 Energy Absorber 3 Front Nudge Bar Assembly 4 Bumper YAD9C010 ...

Page 1472: ...inge 2 Key 3 Tail Gate Release Handle 4 Garnish 5 Glass Handle 6 Guide Bumper 7 Body Side Guide Bumper 8 Tail Gate Latch 9 Door Safety Rod Box Crank 10 Safety Nob 11 Glass Open Latch 12 Key Rod 13 Over Slam Bumper 14 Ball Stud 15 Lifter 16 Ball Stud YAD9C020 ...

Page 1473: ...SSANGYONG Y200 9C 4 BODY EXTERIOR FLIP UP SYSTEM YAD9C030 ...

Page 1474: ...ter 2 Ball Stud Bracket 3 Bolt Pad 4 Spoiler 5 Glass Open Hinge 6 Glass Handle 7 Glass Weather Strip 8 Glass Release Handle 9 Over Slam Bumper 10 Latch 11 Striker 12 Panel 13 Glass Standard 4 0 T Flip Up 5 0 T 14 Bracket Cover Of Ball Stud 15 Bolt ...

Page 1475: ...SSANGYONG Y200 9C 6 BODY EXTERIOR 1 Bolt 2 Shock Absorber 3 Hood Hinge 4 Hood 5 Hood Striker YAD9C040 HOOD ...

Page 1476: ...ODY EXTERIOR 9C 7 SSANGYONG Y200 SUN ROOF AND ROOF RACK 1 Sun Roof Glass 2 Glass Moulding 3 Head Lining Assembly 4 Roof Channel 5 Sun Roof Glass Panel 6 Roof Carrier 7 Nut 8 Motor And Relay Box YAD9C050 ...

Page 1477: ...SSANGYONG Y200 9C 8 BODY EXTERIOR MOULDING 1 Nut M5 2 Wheel Arch Front Moulding 3 Front Door Garnish 4 Rear Door Garnish 5 Wheel Arch Rear Moulding 6 Moulding 7 Side Step YAD9C060 ...

Page 1478: ...le fixing bracket of shock absorber is removed back up hood to prevent closing of hood or use another supporting bar to prevent closing of hood 3 Remove hose of wiper washer 4 After releasing fixing bolt of hood hinge remove hood assembly 2 Remove shock absorber Method to remove shock absorber refer to replacement shock absorber of hood 5 After releasing fixing bolt of hood hinge remove hood hinge...

Page 1479: ...panel 2 Push cable removed through groove of body into direction of engine room 3 After releasing fixing bolt of hood latch remove latch and cable 4 Remove cable of hood latch 7 Install the reverse order of removal 1 After installing hood hinge into body and hood tighten fixing bolt with the torque of specification Tightening Torque 29 39 N m 21 29 lb ft ...

Page 1480: ... bolt of hood hinge 2 After adjusting hood hinge to forward and backward left and right check whether right position of hood is installed or not Adjusting Hood Latch 1 Install hood latch on the right position if hood latch is not installed on the right position while hood is installed hood may distort and be unbalanced 3 After adjusting over slam bumper adjust height of front end of hood ...

Page 1481: ...enter of latch Replacement Shock Absorber of Hood 1 After inserting driver on the upper of bending equipped both end of shock absorber get the bending out of shock absorber and then remove shock absorber 2 Insert shock absorber until is sounded like a kind of equipped sound COWL GRILL Removal and Installation 1 Remove wiper arm and fixing nut of wiper in the right and left M8 2 Remove weather stri...

Page 1482: ...f right is removed and then cowl of left is removed 5 Install reverse order of removal 3 Separate fixing clip of cowl 4 EA Wiper Fixing Nut 14 17 N m 44 52 lb ft RADIATOR GRILL Removal and Installation 1 Remove fixing screw 2 ea of radiator grill and rivet 3 ea 2 Remove radiator grill and fixing rubber of grill ...

Page 1483: ...lation 1 After releasing screw of radiator grill and screw rivet remove grill assembly 2 After releasing fixing bolt remove connector of headlamp and remove headlamp first after removing cap of wheel house cover remove fixing nut of headlamp 3 After releasing fixing bolt 4 ea of bumper guide remove bumper guide from bumper After releasing fixing bolt of bumper guide support remove bumper guide sup...

Page 1484: ...nut 2 ea of internal section of bumper facia 5 Remove bumper cover 1 Separate rivet 6 ea of the upper of bumper facia Remove screw 2 ea and nut 2 ea of fender 2 Separate screw of the lower of bumper facia 2 ea 3 Separate screw of bumper facia in the wheel house Side section 4 ea Rivet of lower section 1 ea ...

Page 1485: ...of center of bumper facia remove bumper facia Left 1 ea Right 1 ea 6 Remove energy absorber 7 After releasing fixing bolt of bumper in the frame remove bumper 8 Install reverse order of removal 76 114 N m 2 8 5 2 N m 16 8 31 2 N m Fixing Bolt of Bumper Bolt of Bumper cover Bolt of Bumper Guide ...

Page 1486: ...parate screw of the upper of the bumper left 1 ea right 1 ea 4 Separate rivet of the upper of bumper facia 5 ea 5 Separate fixing screw of bumper facia in the rear wheel house left 4 ea right 4 ea 6 Install reverse order of removal BACK BEAM 1 After releasing fixing bolt of rear bumper remove back beam assembly 2 Install reverse order of removal Tightening Torque 41 6 62 4 N m 44 52 lb ft ...

Page 1487: ...fore the fender is removed adjust and check the gap and clearance between front door side sill and front bumper 2 Remove front bumper facia 1 ea head lamp 2 ea head lamp guide bracket side repeater 3 Separate wheel guard mud guard and spring nut 4 Using driver special service tool remove fender garnish Notice Be careful about damage paint of body not to make blemishes ...

Page 1488: ...a of the section of bumper facia 8 Separate fixing bolt 1ea of rear section of hood hinge and separate fixing bolt 3ea of the upper section of fender and then remove fender 9 Install reverse order of removal Notice 1 Paint internal section of fender and installed section of fender 2 After installing fender tighten temporarily bolt 2 ea the upper section of hood in the back and front adjust the gap...

Page 1489: ...m 44 52 lb ft 3 After spread water proof materials on the section of tightening tighten the bolt with the torque of specification FUEL FILLER OPENING SYSTEM 1 After opening the door of fuel filler separate fixing bolt of door 3 Remove the cable of fuel filler in the vehicle 2 Separate release handle of fuel filler in the lower main panel of driver seat ...

Page 1490: ...ssembly 3 Install reverse order of removal Roof Carrier Nut 7 10 N m 44 52 lb ft Notice Maximum load of roof carrier is approximately 45 kg all the load should equivalently distribute on the roof carrier SIDE STEP Removal and Installation 1 After releasing bolt and nut of side step remove side step assembly 2 Install reverse order of removal Bolt and Nut of Side Step 16 8 31 2 N m 44 52 lb ft 4 In...

Page 1491: ...sing special service tool remove door moulding of front and rear Notice While door moulding and moulding of wheel housing is removed pay attention on the damage of painting section in order not to make scratch of moulding 3 Install reverse order of removal Notice While moulding is installed install moulding tightly not to make the gap OUTSIDE MIRROR Removal and Installation 1 Remove trim cover of ...

Page 1492: ...l reverse order of removal DOOR ASSEMBLY Removal and Installation 1 remove the negative terminal of battery 2 After removing the trim of cowl side separate connector of door 1 3 Disassemble the bolt of check link 2ea in the body 4 Disassemble the fixing bolt 3ea of hinge in the body 5 Remove the door assembly 2 Remove inner cover of outside mirror or cover of speaker assembly ...

Page 1493: ... door remove hinge of door 1 Release the bolt 2ea of in the body side 2 Release the bolt 2ea of door 3 Remove the hinge 2 Install the reverse order of removal Bolt of Door Hinge 16 29 N m 44 52 lb ft DOOR CHECK LINK Removal and Installation 1 Remove vinyl seal of door trim 2 Remove door check link 1 Release bolt 3 ea 2 Remove door check link 3 Install reverse order of installation Door Check Link ...

Page 1494: ...onnector 3 After removing internal cable of handle remove door lock assembly DOOR LOCK ASSEMBLY Removal and Installation 1 Remove the negative terminal of battery 2 Remove vinyl seal and internal trim of door 3 In case door lock of central locking system separate connector of door actuator and then remove actuator 4 After releasing fixing bolt of door lock separate glass panel Door Lock Bolt 7 9 N...

Page 1495: ...ng door trim separate internal handle cable of door trim 5 Install reverse order of installation 4 Remove external handle of door Fixing Nut of Handle 4 5 N m 44 52 lb ft 2 Remove door lock assembly Notice After removing rod of key lock separate fixing nut of front external door handle 3 Release external fixing nut of door ...

Page 1496: ...ve connector of door lamp and cable of internal door handle 5 Remove seal of door trim Notice Pay attention about damage of seal DOOR TRIM Removal and Installation 1 Remove the negative terminal of battery 2 Separate power window switch assembly 3 After inserting special tool or driver remove door trim ...

Page 1497: ...ector and then remove speaker 7 After releasing nut of regulator and window motor remove regulator and window assembly 8 Install reverse order of removal Notice Spread sealant on the seal of door trim and then install the right position DOOR OPENING WEATHER STRIP Removal and Installation 1 Remove door checker in the body ...

Page 1498: ... Install the striker of door lock 1 Install temporarily striker of door lock 2 After opening and closing the door tighten screw in the proper position Screw of Door Lock 20 28 N m 44 52 lb ft 2 Remove the upper section from the rail 3 After removing the clip remove the lower section Notice As clip and door opening weather strip is removed due to damage of those part install the new one ...

Page 1499: ...n fixing bolt of striker 6 Proceed to repair adjusting up and down forward and backward Adjusting Striker of Door Lock Notice Striker of door lock consists of striker and plate of floating cage in the pillar body plate of floating cage can easily adjust by controlling striker up and down left and right As fork snap of door lock is linking the striker the door comes to position of closing Adjusting...

Page 1500: ...tallation of new weather strip wind noise difficulty of opening and closing door in case adjusting up and down left and right proceed to repair the following 1 Door keep on the one line between door lock fork and striker 2 Release fixing bolt of door striker 3 Plate of plotting gauge moves little bit to end of striker screw plate of plotting gauge is put to adjust the position which is wanted Noti...

Page 1501: ...th gas lifter remove gas lifter right left 8 After separating fixing bolt 3 ea of crank of tail gate remove crank Notice If rekes is installed key road is removed 9 Install reverse order of removal TAIL GATE Removal and Installation 1 After separating grommet of tail gate and wiring connector 2 section remove hose of nozzle washer ...

Page 1502: ... damage of body of technician and explosion make hole diameter 3 mm into gas lifter for removal gas TAIL GATE FLIP UP SYSTEM Removal and Installation 1 Remove the upper garnish 2 Separate wiring 2 ea in the connector of heating line of rear glass and wiring 1 ea of stop lamp section of left spoiler 3 After releasing nut 4 ea of body of tail gate hinge remove tail gate from the body proceed to remo...

Page 1503: ...ing bolt 2 ea of hinge right left of glass remove glass from tail gate 5 Install reverse order of removal TAIL GATE AIR SPOILER Removal and Installation 1 Separate fixing bolt 2 ea of hinge in the left right 2 Remove air spoiler of tail gate 3 Install reverse order of removal YAD9C0F0 ...

Page 1504: ...sition of closing Notice As latch of tail gate and glass latch is installed bolt of ground should be used Adjust Striker Forward and Backward Left and Right Adjusting of striker of tail gate to forward and backward left and right is required in case of damage of frame due to collision wind noise difficulty of opening and closing If striker is adjusted to forward and backward left and right proceed...

Page 1505: ...or repeatedly 4 Technician can see and keep fork of door lock alignment with striker fork of door lock is linking perpendicular to center of striker is linking center of body pillar 5 As striker is required for adjusting to up and down proceed to repair following the descriptions 1 Release fixing bolt of striker 2 If striker move to upward put addition spacer 2 mm 3 Tighten fixing bolt of striker ...

Page 1506: ... Remove seal and door trim 2 After adjusting glass left and right fit gap with quarter glass Torque of Tightening 9 10 N m 44 52 lb ft Check the Deflection As tail gate is pushed from the external not to occur the deflection adjust overlap Standard 18 mm Adjust Gap of Fitting mm Section Gap C 5 A 11 B 5 D 5 7 E 4 2 ...

Page 1507: ...f section of body painting may happen so glass should not interfere body 3 Install reverse order of removal Fixing Bolt of Glass 3 N m 26 lb ft Notice If water of soap spread on contacting section between glass run and glass so that can be installed easily FRONT DOOR GLASS RUN AND REGULATOR Removal and Installation 1 Remove door trim seal and window glass 2 Remove door glass run from door 3 After ...

Page 1508: ...r window 2 Remove front garnish of rear door 4 Remove door regulator assembly Notice After separating door glass run and regulator remove and install them 5 As door glass run is installed water of soap spead on section of glass run so door glass run can be installed easily 6 Install reverse order of removal Fixing Nut of Regulator 8 N m 26 lb ft ...

Page 1509: ...ss should not interfere body 5 Install reverse order of removal Fixing Nut of Glass 3 N m 26 lb ft Notice As door glass run is installed water of soap spead on section of glass run so door glass run can be installed easily REAR GLASS RUN REGULATOR CHANNEL 1 Remove door trim seal and glass 2 Remove glass run Pull door glass run internally and then extract glass run Notice As door glass run is insta...

Page 1510: ...lass channel 1 Remove internal 1 panel of rear door 3 Remove door regulator assembly 1 Separate connector of window motor 2 After separating fixing nut 7 ea of window regulator remove regulator assembly 3 Remove regulator assembly Installation Fixing Nut of Regulator 8 N m 26 lb ft ...

Page 1511: ...ve glass channel 3 As glass channel is installed in order for glass channel not to change up and down should be installed right position tighten fixing bolt WIND SHIELD GLASS Removal 1 Remove cowl grill 2 Remove room back mirror 3 Remove moulding a of wind shield glass 4 Using special tool cut sealant of wind shield glass ...

Page 1512: ... prevent damage of painting approximately 1mm of sealant should not be removed from body Installation 1 Clean up section to spread primer of wind shield glass by washing 1 Section of washing keep distance 15 mm from the end of glass 2 After using gauze 20 times gauze is thrown away 3 Gauze is a solvent isopropyl alcohol gauze keep wet completely 4 Keep an eye on the washed section of glass not to ...

Page 1513: ... any thing polluted After washed body flange spread primer on the glass section of wet state If oil is stuck on the body flange primer does not spread on the body flange After spreading is available time for use from 3 hours to 8 hours As the body is polluted by primer as soon as possible mixing with ethil alcohol and ethil asetate as a volume 50 50 and with this wet cloth is wiping solvent Term o...

Page 1514: ... shield glass and then check leaking of water If leaking of water happen after keep wind shield glass dry fill sealant on the section of leaking if leaking of water goes on wind shield glass is removed the above descriptive work proceed to repair once again FRONT QUARTER GLASS Removal 1 After releasing fixing nut of quarter glass remove cover of glass moulding 2 After removing quarter glass using ...

Page 1515: ...lation 1 Wash up body frame section of glass installed 2 As keeping distance like the left picture spread primer on the section of frame of installed glass 3 Spread primer on the moulding of quarter glass of new quarter glass YAD9C1Z0 YAD9C2A0 ...

Page 1516: ...B0 YAD9C2C0 4 As keep distance like left picture spread sealant on the glass 5 After Install glass of front quarter on the body frame tighten nut on the bolt of mounting 6 After installing front quarter glass proceed to check leaking of water ...

Page 1517: ...TER GLASS Removal 1 After using special tool remove sealant around glass 2 Remove rear quarter glass 3 After spread on the new rear quarter glass install glass moulding Installation 1 Wash up the section of body frame 2 As keep distance like the left picture spread primer ...

Page 1518: ... quarter glass 5 After installing rear quarter glass on the body frame tighten nut on the bolt of mounting 6 After installing rear quarter glass proceed to check leaking of water TAIL GATE GLASS Removal 1 Separate negative cable of battery 2 Separate connector of heat line of back door glass ...

Page 1519: ...letely Keep an eye on the washing section of glass not to be touched by any thing polluted After washing glass spread primer on the glass section of wet state Wash up on the section of spreading primer without being touched by any thing polluted 2 After washing up outer panel of tail gate and then spread primer Keep primer in the refrigerator Mix up primer Opening vessel use them within 2 hours Op...

Page 1520: ...lass keep distance 15 mm from the end of glass After using gauze 20 times gauze is thrown away Gauze is a solvent isopropyl alcohol gauze keep wet completely Keep an eye on the washing section of glass not to be touched by any thing polluted After washing glass spread primer on the glass section of wet state Wash up on the section of spreading primer without being touched by any thing polluted 4 I...

Page 1521: ...is passed this sealant is throwing away available date of sealant is 90 day for use After using gauze 20 times gauze is thrown away Spread uniformly primer on the surface of glass 6 Spread sealant on the glass Spread sealant point 200 mm of lower section of right like right picture If shape of spreading thickness is not uniform leaking of water may occur 7 After spreading sealant using compressor ...

Page 1522: ...ter If leaking of water occur keeping door glass of tail gate dry fill sealant in the section of leaking Leaking of water goes on remove door glass of tail gate and then proceed to repair above procedure Connect connector of heating line to the door glass of tail gate Connect negative cable of battery SUN ROOF Removal and Installation 1 Remove headlining room lamp and sun visor 2 Separate hose cli...

Page 1523: ...of 5 After releasing mounting bolt of sun remove sun roof assembly 6 Install reverse order of removal Bracket Bolt of Sun Roof Fixing Bolt of Sun Roof 25 35 N m 25 35 N m MOTOR AND RELAY BOX Removal and Installation 1 Close sun roof 2 Remove head lining room lamp and sun visor 3 Cut tie wrap of relay box ...

Page 1524: ...lose NORMAL CLOSE POSITION After connecting between relay box and motor connect the power and then touch on switch and then the motor stop 3 Install the motor 4 Tighten the fixing bolt of motor 5 Separate power connector in the relay box 6 After releasing fixing bolt of relay box separate relay box from front beam pushing hook of relay box of front beam by hand remove it Tightening Torque 3 N m 26...

Page 1525: ...l 1 Turn on the switch tilt glass 2 Remove side inner cover 3 Separate fixing bolt 6 ea glass 4 Extract panel of glass Installstion 1 Install glass panel on internal panel of cover check the tightening position in the vehicle Notice Install for marking glass indicator to put rear direction ...

Page 1526: ...djust the height of glass and body 5 After hight of front glass put the same of height of body and glass seal and 1 mm height to the rear is higher than height of body and then tighten the bolt Tightening Torque 5 N m 26 lb ft 6 Using switch of sunroof check operation 7 Turn on the switch up the glass 8 Insert side cover left right Notice Check the state of installation between side inner cover an...

Page 1527: ...sh hook of support drain channel by hand remove drain channel 3 Close panel of sun shade using driver extract slide block of sun shade panel from the guide rail 4 ea 4 Remove panel of sun shade Installation 1 Put sun shade on the guide rail 2 Using driver pushing slide block of sun shade panel and then insert guide rail ...

Page 1528: ... Y200 YAD9C3U0 3 After inserting drain channel into roof and then insert drain channel into support drain channel and push front hook Tightening Torque 12 N m 26 lb ft 4 Check operation of sun shade panel 5 Install the glass panel ...

Page 1529: ...strument Panel Assembly 9D 13 Check And Repair 9D 17 Removal And Installation Of Instrument Panel 9D 20 Switch Of Multi Function 9D 22 Component Of Lighting 9D 27 Location Of Lamp 9D 31 Horn And Audio System 9D 39 Wiper And Washer 9D 44 PowerWindow 9D 61 Switch And Electrical System 9D 70 Function Of Operation And The Characteristic 9D 76 Self Diagnosis 9D 84 Chart Of Diagnosis 9D 85 Repair Of The...

Page 1530: ...g switch or all the switch of lamp off if switches are not turned off parts of semi conductor may be impaired Notice Memory values of electrical parts may be erased so those value should be kept another place 2 If harness is interfered by other sharp section wrap them and then for protecting of harness 3 While parts is instslled on the vehicle keep in mind in order not to tear or impair to the wir...

Page 1531: ...apacity parts may be impaired or fired 7 If connector is connecting loose this cause to repair make sure connecting of connector 6 Electrical parts are impaired by heat so if work of repair should be done excessive temperature of 8 C remove electrical parts before done this 5 Sensors and relays should not be influenced by impact and should not be dropped on the floor ...

Page 1532: ...if connector is kind of sealing type probe is set through hole of cap in the wiring rubber At this time keep in mind not to damage isolation of wiring insert probe until contact connector of terminal completely Notice Tester of circuit is not used on the air bag system while this system is checked scanner should be used 10 While connector is linked insert this until sounds like tack tack 9 While c...

Page 1533: ...ween parts of terminal and other metal parts 6 Check applying an electrical current complete between fixing bolt and body on the section of ground 7 Check lay out of wiring proper 8 After fixing wiring completely wiring should not be contacting by section of sharpness section of high temp For example exhaust manifold exhaust pipe 9 Keep the clearance between wiring and fan pully fan belt other par...

Page 1534: ...ning lamp ABS warning lamp Pre heating lamp Air bag warning lamp Hazard lamp 4WD check lamp 4WD high lamp 4WD low lamp Winter lamp Power lamp EBD lamp Engine check warning lamp TCS lamp Rear defogger lamp 14 V 1 4 W 2 2 V 20 mA 2 2 V 20 mA 2 2 V 20 mA 14 V 3 W 2 2 V 20mA 2 2 V 20 mA 2 2 V 20 mA 14 V 1 4 W 2 2 V 20 mA 14 V 1 4 W 2 2 V 20 mA 2 2 V 20 mA 14 V 1 4 W 2 2 V 20 mA 14 V 1 4 W 2 2 V 20 mA ...

Page 1535: ...ion Spec Rear combi lamp Licensee lamp Room lamp Door lamp Glove box lamp Tail Stop Tail lamp Stop lamp Turn signal lamp Brake lamp Front Center Rear 27 W X 2 8 W X 2 27 W X 2 27 W X 2 27 W X 2 5 W X 2 8 W X 2 10 W X 1 10 W X 1 5 W X 4 10 W Lamp ...

Page 1536: ...Cut of fuse Failure of bulb Defective warning switch of brake fluid Defective parking brake switch Defective wiring or defective grounding Cut of fuse Failure of bulb Defective door switch Defective wiring or defective grounding Cut of fuse Failure of bulb Defective buckle switch Defective wiring or defective grounding Check short of fuse replace fuse Check tacometer If necessary repair wiring Che...

Page 1537: ...alfunction of switch of turn signal Malfunction of wiring or grounding Cut of fuse Malfunction of flasher unit Malfunction of hazard lamp switch Malfunction of wiring or grounding Standard of bulb is out of specification Cut of bulb malfunction of connecting Malfunction of flasher unit Cut of fuse Malfunction of switch of back up lamp Malfunction of wiring or grounding Cut of fusible link Malfunct...

Page 1538: ...f OVM every thing is unloaded and vehicle is parked on the even place If beam adjusting is not installed focus of head lamp can be arranged by using screen Using Beam Adjusting Equipment 1 Beam adjusting equipment should be arranged with vehicle 2 Switch on control lever of up and down left and right by the screw arrange focus of head lamp Arrange Focus of Head Lamp by Screen Unit mm 1 After scree...

Page 1539: ...ontal line of center of head lamp and center of screen 3 Keep engine R P M of 2000 and then switch head lamp on at this time focus of head lamp should indicate position of A 4 If focus of head lamp get out of specification after switching control lever of up and down left and right arrange focus of head lamp ...

Page 1540: ...SSANGYONG Y200 9D 12 BODY ELECTRICAL YAD9D190 ...

Page 1541: ...BODY ELECTRICAL 9D 13 SSANGYONG Y200 REPAIR OF EACH SYSTEM INSTRUMENT PANEL ASSEMBLY YAD9D200 ...

Page 1542: ...ine 14 Power Lamp Automatic Transmission 15 Lamp of Engine Check for Gasoline 16 Warning Lamp of Seat Belt 17 Warning Lamp of Charge 18 Warning Lamp of Oil Pressure 19 Lamp of Pre Heating 20 Lamp of Selector Lever Automatic Transmisson 21 Button of Reset 22 Warning Lamp of Air Bag 23 Warning Lamp of ABS 24 Warning Lamp of EBD 25 Lamp of TCS 26 Warning Lamp of Door Opening 27 Lamp of Outside And La...

Page 1543: ...ing ILL EBD 1GN B Ground2 ACC B Checking of 4 WD Checking of 4 WD Low speed of 4 WD ILL High speed of 4 WD Turn signal lamp Left High beam Lamp of position Lamp of position Turn signal lamp Right Brake Automatic transmission D range Automatic transmission 3 range Automatic transmission 2 range Automatic transmission 1 range Automatic transmission R range Automatic transmission N range Automatic tr...

Page 1544: ...t Number of Pin B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 B17 B18 B19 B20 Description Unit of tacometer Speed sensor Chime bell Signal out of speed ABS Air bag Engine check TCS Fuel sender Temp sender Gnd ground1 IGN A Emegency Rear defogger Pre heat YAD9D230 ...

Page 1545: ...0 5 5 0 5 Gasoline vehicle rpm CHECK AND REPAIR Speed Meter 1 Using tester of speed meter check error of allowance of speed meter and operation of tacometer Tacometer 1 Connect tacometer of testing start engine 2 Comparing value indicated between tester and tacometer error is big enough replace tacometer 3 While tacometer is inspected tap tacometer and then remove magnetic power Diesel vehicle rpm...

Page 1546: ...osition of float E 1 2 F Specified resistence approximately 285 Ω approximately 101 5 Ω approximately 40 Ω Fuel sender 1 Connect testing bulb 12 V 3 4 W of fuel gauge terminal deepen thermister in the water 2 See if thermister is deepened in the water light is off and see if thermister get out of water light is on Notice If malfunction may happen replace fuel sender assembly After this testing hav...

Page 1547: ... resistence Ω C 50 254 C 50 77 C 50 42 2 C 50 27 8 Switch of Oil Pressure 1 After stopping engine check applying of electric current between terminal and ground 2 After driving engine check applying of electric current between terminal and ground 3 Separate connector from terminal of ground and warning switch to wiring harness 4 After ignition switch turn to on and then check if the light is on if...

Page 1548: ... of parking brake is located under lever of parking brake if switch of parking brake is adjusted after releasing parking brake switch of parking brake is installed 1 While switch is turned on lever is pulling check applying of electric current between terminal and switch 2 While switch is turned off lever is released check applying of electric current between terminal and switch applying of electr...

Page 1549: ...arate connector 3ea and then remove instrument panel 6 Install reverse order of removal after installing check operation of instrument panel 5 After separating the glass of instrument and then release fixing screw 5ea and separate instrument panel and housing 4 Separate all the bulb from the instrument removed like the left picture ...

Page 1550: ... BODY ELECTRICAL SWITCH OF MULTI FUNCTION YAD9D400 1 Multi Function Switch Assembly 2 Turn Signal Switch Assembly 3 Turn Signal Switch Assembly 4 Screw 5 Switch of Light 6 Switch of Auto Light 7 Connector 8 Switch of Wiper ...

Page 1551: ... of head lamp upper beam Switch passing of head lamp Front washer switch Wiper and washer ground Auto wiper Wiper parking Ground of light switch Auto light switch Switch of head lamp Switch of tail lamp Ground of dimmer and passing switch Low speed of wiper High speed of wiper Ground of intermittent wiper Intermittent wiper Horn relay Name of connector TL TB TR HU HS 2 W EW AUTO P ES A HS 1 TS EB ...

Page 1552: ...rent below terminal at each position of multi function switch if each terminals are not applied of electric current replace multi function switch YAD9D420 YAD9D450 YAD9D430 YAD9D440 YAD9D470 YAD9D460 Light switch Dimmer and passing Auto light switch Turn signal lamp Wiper switch Washer ...

Page 1553: ... While module of air bag and coil of contact are separated do not force them to push excessively Before coil of contact is not installed after keep front tire forward in align keep in line between mark of contact coil and mark of neutral and then install contact coil If mark of contact coil does not keep in line properly steering wheel does not revolve flat cable can be damaged air bag does not op...

Page 1554: ...ove steering wheel Notice Separate all the connector 8 Remove switch of multi function 9 Install reverse order of removal 6 Separate vacuum hose of fuel cut and connector which is linked to switch of multi function 7 After separating coil connector of air bag contact remove contact coil 5 Separate cover equipped in the steering column shaft YAD9D520 ...

Page 1555: ...ignal lamp is turned off Fog lamp Switch of fog lamp is located on the instrument panel of left gauge panel of audio system after position lamp and head lamp are turned on in the result of this turn switch of fog lamp on so fog lamp is on if switch of fog lamp is turned on fog lamp is on indicated lamp also is turned on in the instrument panel instead of head lamp fog lamp should not be used in ca...

Page 1556: ...t if mode is set on AUTO head lamp and tail lamp is automatically turned on and off during the vehicle is driven on the time of day through tunnel area foggy area rainy day or snowy day due to the low of illumination around atmosphere this system is operating Specification Name of part Description Sensor unit of auto light Voltage of load Load Temp available Room temp for keeping Position of attac...

Page 1557: ... switch function 1 After turning ignition on operate multi function switch OFF TAIL LAMP HEAD LAMP AUTO switch 2 Turn tail lamp head lamp on and off 3 Turn switch of AUTO ON While sensor is sensing illumination of light which is set on the diode of photo As quantity of illumination of light is equivalent to voltage which is set on the internal CPU tail lamp and head lamp is turned on and off autom...

Page 1558: ...peration YAD9D550 Check After turn to position of AUTO put black cloth on the section of sensor check if head lamp tail lamp are turned on or not Operation condition should be under on and off range with tail lamp head lamp T1 3 1 0 sec T2 500 100 msec YAD9D560 ...

Page 1559: ...AD9D570 1 Head Lamp Low 2 Head Lamp High Beam Position Lamp 3 Position Lamp 4 Turn Signal Lamp 5 Fog Lamp 6 High Mounted Stop Lamp Plate 7 Tail and Stop Lamp 8 Tail Lamp 9 Stop Lamp 10 Turn Signal Lamp 11 Back up Lamp 12 Rear Back Mirror 13 Lamp of License ...

Page 1560: ...SSANGYONG Y200 9D 32 BODY ELECTRICAL YAD9D580 1 Lamp of Glove 2 Room Ramp 3 Lamp of Center Room 4 Door Lamp 5 Turn Signal Lamp of Side 6 Lamp of Cosmetic Mirror ...

Page 1561: ... L R 1 1 L R 1 1 L R 2 2 L R 1 1 L R 1 1 4 EA L R 1 1 L R 1 1 L R 1 1 L R 1 1 55 W 55 W 5 W 27 8 W 28 W 5 W 27 8 W 8 W 27 W 27 W Rear combi lamp Back mirror Lamp of license plate Room Side combi Back up lamp Rear Lamp of license plate Glove box Front room lamp Lamp of center room Door lamp Cosmetic mirror lamp Turn signal lamp L R 1 1 L R 1 1 2 1 2 2 4 L R 1 1 L R 1 1 27 W 5 W 10 W 8 W 10 W 5 W 5 ...

Page 1562: ... Head Lamp 1 Remove negative terminal of battery 2 Remove the grill of radiator 3 Remove mounting bolt 3ea of head lamp 6 Install the reverse order of removal 5 Separate cover of bulb connector and bulb orderly from head lamp separated 4 After separating connector of head lamp remove the head lamp ...

Page 1563: ...ve the negative terminal from battery 2 Separate fixing screw 2ea of rear combi lamp Turn signal lamp fog lamp 1 Remove the negative terminal of battery and head lamp 2 After releasing fixing bolt of lamp of front turn signal lamp and fog lamp remove connector 3 Remove lamp assembly from the bumper 4 Install the reverse order of removal Fix the left of lamp on the hook of bumper and then tighten t...

Page 1564: ...e lamp Lamp of glove box 1 Open up cover of glove box 2 After pushing lamp as indicated mark remove lamp of glove box 3 After separating connector of lamp remove lamp 4 Install the reverse order of removal 2 After separating fixing screw 2 ea of lamp spoiler of tail gate and then remove connector 3 Remove lamp assembly 4 Install the reverse order of removal High mounted lamp 1 Remove spoiler from ...

Page 1565: ... and then separate connector of lamp Room lamp Front lamp 1 After removing lense of lamp remove bulb Lamp of license plate 1 Remove lamp of license plate 2 Separate bulb from lamp 3 After insert bulb into lamp and then insert in the hole of mounting of tail gate 3 After releasing fixing screw of lamp remove lamp 4 Install the reverse order of removal ...

Page 1566: ...g 3 After separating connector of lamp housing remove lamp housing 4 Install the reverse order of removal 2 After releasing housing fixing screw of lamp separate the housing 3 After removing connector from the lamp housing remove lamp housing 4 Install the reverse order of removal Center rear lamp 1 After removing lense of lamp remove bulb ...

Page 1567: ...er of cd is applied option specification which is installed on the room of trunk Front and rear speaker Eight of speaker is installed in the vehicle two of speaker is installed on the front door rear door and tail gate and an speaker is installed each side mirror left right Glass antenna Glass antenna is different from existing antenna is not appeared external shape of antenna this one is installe...

Page 1568: ... connector of speaker remove speaker 3 Install the reverse order of removal Speaker 1 Remove front door speaker and rear 1 Remove door trim and seal 2 After separating connector of speaker and then release fixing screw of speaker 3 Remove speaker 4 Install the reverse order of removal 3 Adjust After operating the horn and then adjust tone of horn proper adjust screw of controlling Notice After adj...

Page 1569: ...mote 1 Remove air bag module of steering wheel or horn pad on the driver seat 2 After releasing connector and fixing screw and then remove remote control 3 Install the reverse order of removal 3 Remove audio Release fixing screw of audio Separate cable of antenna and connector Remove audio 4 Install the reverse order of removal Accessory of audio system Audio 1 Separate the negative terminal of ba...

Page 1570: ...ng cover of power antenna 3 Install the reverse order of removal Module of glass antenna 1 Remove the upper quarter panel 2 Remove module of glass antenna Separate connector of glass antenna Separate jack of antenna Release bolt 2ea Separate connector of rear heating line Remove module of glass antenna 3 After separating motor connector of power antenna and then release fixing nut of motor 4 Remov...

Page 1571: ...ry and AUDIO 2 Separate cable of CD changer from the AUDIO 5 After releasing bracket fixing bolt of changer of CD remove changer of CD 6 After Installing the reverse order of removal check unusual noise or state of operation 3 Remove rear lower quarter panel in the driver seat 4 Remove cable from the changer of CD ...

Page 1572: ...cs But wiper system of rexton is sensing quantity of rain by the unit of sensing rain which is installed on the upper center of windshield this unit is controlling operation of wiper low and high speed according to quantity of rain Diagram Of System Multifunction switch Control wiper mode and ON OFF Quantity of rain Unit of sensing rain Unit of sensing is sensing quantity of rain according to quan...

Page 1573: ...ng by the LED and the diode of photo 2 As infrared ray is emitting from LED diode of photo which is reflected by drop of rain is sensing the quantity of rain 3 Unit of sensing rain is correcting itself so regardless of transmitting of windshield this unit is constantly sensing rain 4 This unit is sensing the area between the LED and diode of photo Principle of Rain Sensor YAD9D940 Wave which is tr...

Page 1574: ...ution Main function of rain sensor is controlling wiper speed and delaying of time to between the driving time due to sensing and the accumulation of rain algorithm of rain sensor is deciding mode of motion automatic intermittent automatic low speed and automatic high speed If the stage is set without the operation of driver wiper is continuously operating 3 Transfer between the modes Algorithm of...

Page 1575: ...tage into 3 step stage 5 If wiper is operating once this means self diagnosis of FAULT OF B Replace new rain sensor Wiper blade Check the state of wear of wiper blade due to excessive wear of wiper blade if is not cleaned up over section of sensor quantity of rain is not sensed accurately Coupler Check if blister is shaped on the external section of coupler which is stuck on the wind shield If the...

Page 1576: ...e motor within approximately 1 second relay 2 of CONT is on turning motor counter clockwise apply the current between P ground of CAM switch and C ground and then relay 2 of CONT is OFF motor can stop Operation for washer mode Turn washer switch on above 0 5 second after operation of wiper mode is operating twice after operation of parking mode is operating and then motor is stopped but if washer ...

Page 1577: ...er on and then 1of relay is operated so wiper motor is controlled 2 While wiper motor is operating after contact signal of W is feeding so 2 of relay is operated cause wiper motor to reverse direction angle of revolution of wiper motor 260 3 As above the description under the control of wiper motor if wiper switch is off turn power of wiper motor until position of P is feeding and then back to the...

Page 1578: ...oting Flow Chart Mode Of Wiper Operation Ground of W is ON 1 of relay is OFF 2 of relay is ON Motor is turning to counter clockwise Ground of W is ON Turn wiper switch ON 1 of relay is ON 2 of relay is OFF Motor is turning to clockwise ON YES ON YES ...

Page 1579: ...otor is operating to the clock wise wiper switch is off or switch of intermittent is off Ground of W is ON YES 1 of relay is OFF 2 of relay is ON motor stop NO NO YES 1 of relay is OFF 2 of relay is OFF motor stop wate for 1 minute 1 of relay is OFF 2 of relay is ON motor is turning to counter clock wise Ground of P is ON Motor is operating to the counterclock wise wiper switch is off or switch of...

Page 1580: ...y is OFF 2 of relay is ON Turn washer switch on Is it passing time o 5 second YES Ground of W is ON NO YES 1 of relay is ON 2 of relay is OFF motor is turning to clockwise YES Ground of W is ON YES Parking is operating under the clockwise motor stop 1 of relay is off 2 of relay is off motor stop NO NO NO Operation Of Washer Mode ...

Page 1581: ... OFF 2 of relay is OFF motor stop YES 1 of relay is ON 2 of relay is OFF motor is turning clockwise Ground of P is ON 1 of relay is OFF 2 of relay is OFF motor stop NO NO Limit switch is ON Wiper switch is ON or Intermittent is ON 1 of relay is OFF 2 of relay is OFF motor stop Operation of Limit Switch YES ...

Page 1582: ...eration of wiper mode is operating twice and then back to parking position 3 Power of wiper motor is operating with the same mode of wiper operation Operation of limit switch ON OFF mode 1 As turn ignition switch on if wiper motor turn limit on without delay back to parking position and then stop motor 2 Being state of turning on stop control power of wiper motor Namely opening up rear glass for w...

Page 1583: ...15 V DC 8 V 500 V 1 MΩ 1 1 Km 14 A 40 c 80 C DC 12 V DC 9 16 V 30 C 80 C 40 C 90 C 1 MΩ 500 V 0 5 V 14 0 0 5 A 10 A Motor Control Torque Current Description Range of atmosphere temp allowed Rated voltage Range of allowed voltage Range of allowed temperature Range of conserved temperature Insulated resistence Voltage dropping Test voltage Load allowed current Restraint test YAD9D0C0 YAD9D0D0 Circui...

Page 1584: ...SSANGYONG Y200 9D 56 BODY ELECTRICAL Components 1 Wiper Blade 2 Wiper Motor And Link 3 Washer Tank Assembly YAD9D0F0 4 Wiper Blade 5 Wiper Motor ...

Page 1585: ... front hood remove wiper arm 4 Install the reverse order of removal 3 From linkage separated releasing fixing bolt of wiper motor separate linkage and motor 2 After cowl left is removed remove wiper linkage assembly At this time separate connector of wiper motor Fixing bolt of motor Nut of linkage Nut of blade 7 11 N m 4 6 N m 19 28 N m ...

Page 1586: ...nd blade of wiper 5 Install the reverse order of removal Wiper motor assembly 2 Remove trim of tail gate 3 After connector of wiper motor is separated release fixing nut 4 Remove wiper motor assembly from the tail gate Torque of Tightening 19 28 N m 44 52 lb ft Rear wiper blade Bolt of motor Bolt of motor bracket 7 11 N m 7 9 N m ...

Page 1587: ...into positive terminal of battery and 2 terminal into 3 negative terminal 3 Aftter motor of washer is operated check the fluid of washer is operated Check motor of rear wiper 1 Remove connector from the motor of rear wiper 2 Connect positive terminal into 4 terminal and negative terminal into 3 terminal 3 Check motor is operating normally if motor has a problem replace motor Check operation of aut...

Page 1588: ...While installing wiper arm check position of front wiper arm and rear wipe arm and reinstall to positioned original position Front wiper arm Distance from the end of cowl grill to the blade 45 mm Rear wiper arm Distance from the lower section of rear glass to the blade 30 mm ...

Page 1589: ...G Y200 POWER WINDOW Components YAD9D0T0 1 Power Window Switch Of Passenger Seat 2 Power Window Switch Of Rr Seat LH 3 Power Window Switch Of Rr Seat RH 4 Power Window Switch Of Driver Seat 5 Window Regulator 6 Window Motor 7 Window ...

Page 1590: ...ndow in the door handle separate grip of fixing hook 3 Remove trim of door and seal 4 After window glass is removed remove regulator assembly 5 Remove motor of window from the regulator which is separated 6 Install the reverse order of removal 2 After connector of window switch is separated remove window switch assembly ...

Page 1591: ...ONG Y200 YAD9D0Z0 YAD9D0Y0 Check and Repair Main switch of power window 2 Lockong system of window YAD9D0X0 1 After main switch of power window is removed in the driver seat check that applying an electric current of each terminal ...

Page 1592: ...NG Y200 9D 64 BODY ELECTRICAL YAD9D1C0 Serve switch of passenger set and rear seat 1 After switch is removed check that applying an electric current of each terminal Rear seat YAD9D1A0 YAD9D1B0 Passenger seat ...

Page 1593: ...ss Notice It is prevention for the defogger not to have a impact so after taping foil of tin at the end of tester foil of tin is moving along with line of grid for checking the circuit open or not 2 If defogger is damaged by a fire between center and positive terminal value of voltage is indicated 12 V 1 At the state of idling after switch of defogger is turned on check the below description 1 Aft...

Page 1594: ...ch is broken 1 Paint of applying electric current 2 Thinner of paint 3 Masking tape 4 Alcohol 2 After turn switch of defogger off check the below description Using voltmeter measure resistence of each defogger in the center of grid line resistence between the same terminal and defogger orderly Broken section of defogger is 2 times rather than other the section of defogger section which is impacted...

Page 1595: ...tape out of the section broken to finish up better after drying up completely approximately after one day remove the edge painting unnecessary with knife Notice After repairing clean up glass with the soft towel grid line with the towel wet YAD9D1M0 YAD9D1N0 YAD9D1P0 3 After checking grid line scraping approximately 6 mm to both section from disconnection of a line with wooden spoon clean up these...

Page 1596: ... with soft wiper Repair of defogger of tail gate Copper line of glass defogger have reinstallation available with soldering soldering consists of 30 silver solder and rosin solvent 1 Disconnect negative cable of battery 2 Scrape the around section of repair with wooden spoon 3 After spreading on the copper line clean up on the section which is repaired with brush 9 Check if grid line is repaired o...

Page 1597: ...SANGYONG Y200 YAD9D1U0 4 Put soldering on the the end of soldering gun 5 If copper line is repaired with soldering for copper line not to overheat this work should be repaired under limit of temperature which can melt solder ...

Page 1598: ...ng Lamp 5 Sensing Unit of Auto Lighting 6 Air Bag of Passenger 7 Unit of EGR Unit of OVPR 8 ECM 9 SDM 10 Nevigation System YAD9D1V0 11 Switch of Seat Warmer 12 Unit of Seat Position and Seat Warmer 13 TCM 14 Switch of Position Memory 15 TOD TCCU 16 Internal Sensor of Temp 17 Connector of Self Dignosis 18 Stics Rekes 19 Fold Switch of Side Mirror 20 Sensor of Sun ...

Page 1599: ... Operation Type SEAT Regardless of ignition switch Outside mirror Description Operating voltage Rang of operating temp Specification DC 11 15 V 30 C 80 C 20 7 mm sec 10 6 5 mm sec 7 2 mm sec 228 3 mm 23 0 48 30 3 mm 7 A 8 A DC 12 V 1A 35 c 45 c 0 3 0 7 kgf 8 8 8 8 67 Slide Tilt Height Slide Recline Lift Slide Tilt and lift Rated load Range of operating temp Foceofswitchoperation Angle of up and do...

Page 1600: ...ver passenger Up and down Left and right Part of function YAD9D1X0 Function of Memory Return Item Operation condition The state of operation Another condition is set under function of memory is returning Description 1 Position of selector lever is P and N on condition that ignition switch is ON 2 Automatic vehicle P N or parking brake is ON 3 Manual transmission parking brake is ON 4 Memory return...

Page 1601: ...BODY ELECTRICAL 9D 73 SSANGYONG Y200 The characteristic of operation Function of outside mirror folding unfolding Function of seat warmer YAD9D1Y0 YAD9D1Z0 YAD9D2A0 ...

Page 1602: ...eater Control Unit 1 Slide Adjusting Motor 2 Height Adjusting Motor 3 Tilt Adjusting Motor 4 Recline Adjusting Motor Power seat Connector and connected circuit NO A1 A2 A3 A4 B1 B2 B3 B4 B5 B6 B7 B11 Size color BW BLACK WB Y GB RG BY GY BR GB Connected circuit Battery Ground Slide Slide Tilt Tilt Recline Height Height Recline YAD9D2C0 ...

Page 1603: ...YONG Y200 YAD9D2E0 YAD9D2F0 Seat warmer switch Connected circuit Stics Summary Stics which is electron control unit has the function of sixteen if stics is unnormal at the sensor or load unit of stics has self diagnosis YAD9D2D0 ...

Page 1604: ...e intermittent time Intermittent time is set at 0 km h 2 6 0 5 sec 18 sec 2 sec 2 After IGN 2 switch is ON turn auto switch on or after turn auto switch is ON turn IGN2 on immediately velocity linking mode is operating 2 While the intermittent wiper is operating washer switch is turned on more than 0 6 seconds and then washer linked wiper is operating if washer switch is turned between 0 2 and 0 6...

Page 1605: ...ng on which is less than 0 2 seconds 3 Capacity of time resolving is more than 32 stem per 1 seconds Function of defogger timer 1 At state of engine which is operated if switch of defogger is operated defogger is operated 12 minutes 2 Under defogger is operating if switch of defogger is reoperated operating is stopped 3 After operation of defogger is finished within 10 minutes again switch of defo...

Page 1606: ...at seat belt is taken off chime bell is always operating Warning lamp of parking breake 1 Parking brake is pulling under vehicle s stopping warning lamp is turned ON under this situation vehicle is running and then speed of vehicle goes up to 3 5 km h or after speed of vehicle goes up more than 5 km h if parking brake is pulled lamp of warning should be turned off After switch of ignition is turne...

Page 1607: ...f lock switch of driver seat or passenger seat is locked unlock relay is operating for 5 seconds at this time if all the door of driver seat and passenger seat are closed or switch of tail lamp is OFF relay of unlock is OFF immediately YAD9D2R0 YAD9D2S0 The waring of opening door 1 At state of warning lamp to the door which is opened if door is opened up the state of half closing if velocity of ve...

Page 1608: ...the same situation will be happen YAD9D2V0 YAD9D2T0 The warning of not being pulling key out of key hole 1 If the switch of ignition is turned on and then open up the door chime bell is operating if nob of door lock is locking nob is up from the original position door should get back to the state of unlock 2 This function should not be operated under the state of IGN 1 switch of BEING TURNED ON If...

Page 1609: ...0 seconds door should be locked automatically YAD9D2X0 The alarming of robbery Function of alarming robbery is made a alarming unrecognized method by intruder which cause buzzer to make a alarming sound and notice to surrounding people has operating mode as below 1 set on the situation of vigilance Setting on the situation of vigilance is available on condition that door is locked by the transmitt...

Page 1610: ... be operating immediately If only one thing among alarm conditions is satisfied immediately the operation should begin to start siren is operating continuously for 27 seconds after siren condition of alarming is again satisfied once again siren is operating continuously for 27 seconds Under the state of vigilance if only tail gate is opened by key the state of vigilance should be set on the regula...

Page 1611: ...of door 1 Under turning ignition switch on while vehicle is running more than 15km h if vehicle has a collision with other vehicle automatically all the door should be unlocked After switch of IGN1 is turned on and then passing time 1 5 seconds velocity of vehicle should be sensed 2 Auto unlock of door with is operating with average of vehicle velocity which is setting for 8 seconds While velocity...

Page 1612: ...hould get back to original position 4 While switch of diagnosis is ON data which is diagnosed should output only once 5 If switch is operated by operation of other switch among them first input data will be output buzzer is ON and output is OFF for one seconds and remaining input data is proceeding output 6 Output of buzzer is as following T1 0 3 0 1 seconds T2 0 3 0 1 seconds T 0 6 0 2 seconds No...

Page 1613: ...ndow buzzer Three times Buzzer frequency once Buzzer frequency once Parking of wiper motor 3 times Switch of washer once Relay of wiper twice Wiper motor parking 3times Wiper auto switch once Relay of wiper twice Buzzer frequency once Buzzer frequency once Buzzer frequency once Buzzer frequency once Conditions NO Normal Confirm 0f beginning to dignose Check battery Tail gate rear door lock switch ...

Page 1614: ...anel on the panel of IP Switch of Center IP 1 After panel of center IP is removed each switch can be separated 2 After center panel is removed disconnect connector 3 Separate each switch from removed panel 4 Install the reverse order of removal Notice While each switch is checked refer to the following circuit and then check whether apply an electric current or not Switch of front fog lamp REPAIR ...

Page 1615: ... left picture separate switch cover of seat memory 3 After disconnecting the connector remove the switch 4 Install the reverse order of removal Siren 1 After opening up the hood disconnect the negative terminal of battery 2 Disconnect the connector indicating arrow of siren 3 After fixing bolt is released remove the siren 4 Install the reverse order of removal Diagram of Switch Circuit ...

Page 1616: ...SION TABLE OF CONTENTS Body S Measuring Dimension 9E 2 Under Body Frame 9E 2 Frame 9E 3 Side Structure Complete 9E 4 EngineRoom 9E 6 Windshield And Rear Glass 9E 7 TailGate 9E 8 Chart Of Gap 9E 9 Under Coating 9E 11 Body Mounting 9E 12 ...

Page 1617: ...SSANGYONG Y200 9E 2 BODY S MEASURING DIMENSION BODY S MEASURING DEMENSION UNDER BODY FRAME YAD9E010 ...

Page 1618: ...BODY S MEASURING DIMENSION 9E 3 SSANGYONG Y200 FRAME YAD9E020 ...

Page 1619: ...SSANGYONG Y200 9E 4 BODY S MEASURING DIMENSION YAD9E030 SIDE STRUCTURE COMPLETE ...

Page 1620: ...BODY S MEASURING DIMENSION 9E 5 SSANGYONG Y200 YAD9E040 ...

Page 1621: ...SSANGYONG Y200 9E 6 BODY S MEASURING DIMENSION ENGINE ROOM YAD9E050 ...

Page 1622: ...BODY S MEASURING DIMENSION 9E 7 SSANGYONG Y200 WIND SHIELD AND REAR GLASS YAD9E060 ...

Page 1623: ...SSANGYONG Y200 9E 8 BODY S MEASURING DIMENSION TAIL GATE YAD9E070 ...

Page 1624: ...YONG Y200 CHART OF GAP YAD9E080 Chart of measuring demension Position A B C D E Control of Measuring Demension 2 2 40 3 0 0 5 4 4 5 4 2 Variable Position F G H I J Control of Measuring Demension 2 5 5 0 0 5 3 5 4 9 0 5 5 7 1 0 5 1 0 5 2 0 ...

Page 1625: ...IMENSION YAD9E090 Chart of measuring demension Position A B C D E F G Control of Measuring Demension 4 4 0 4 5 4 2 Variable 2 2 4 5 4 5 6 5 1 Position H I J K L M N Control of Measuring Demension 4 5 2 2 5 0 5 3 5 1 0 5 1 0 5 1 0 1 0 1 0 1 0 ...

Page 1626: ...BODY S MEASURING DIMENSION 9E 11 SSANGYONG Y200 UNDER COATING YAD9E100 ...

Page 1627: ...SSANGYONG Y200 9E 12 BODY S MEASURING DIMENSION YAD9E110 BODY MOUNTING Mounting Point ...

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