check oil SSANGYONG NEW REXTON 2012 User Guide

1914-01
2) Inspection of Turbocharger
When problem occurs with the turbocharger, it could cause engine power decline, excessive discharge of
exhaust gas, outbreak of abnormal noise and excessive consumption of oil.
On-board Inspection 1.
Check the bolts and nuts foe looseness or missing
Check the intake and exhaust manifold for looseness or damage
Check the oil supply pipe and drain pipe for damages
Check the housing for crack and deterioration -
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Inspection of turbine 2.
Remove the exhaust pipe at the opening of the turbine and check, with a lamp, the existence of
interference of housing and wheel, oil leakage and contamination (at blade edge) of foreign materials.
Interference: In case where the oil leak sign exists, even the small traces of interferences on the
turbine wheel mean, most of times, that abrasion has occurred on the journal bearing. Must inspect
after overhauling the turbocharger.
Oil Leakage: Followings are the reasons for oil leakage condition -
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Idling for long period of time can cause oil leakage to the turbine side due to low pressure of exhaust
gas and the rotation speed of turbine wheel. Please note this is not a turbocharger problem.
Oil Drain Pipe Defect
In case where oil flow from the turbocharger sensor housing to the crank case is not smooth would
become the reason for leakage as oil builds up within the center housing. Also, oil thickens (sludge) at
high temperature and becomes the indirect reason of wheel hub section. In such case, clogging and
damage of the oil drain pipe and the pressure of blow-by gas within the crank case must be inspected.
Damages due to Foreign Materials
When the foreign materials get into the system, it could induce inner damage as rotating balance of
the turbocharger gets out of alignment. -
-Problems in engine: In case where the oil is smeared on inner wall section of the exhaust gas
opening.
Problems in turbocharger: In case where the oil is smeared on only at the exhaust gas
outlet section. *
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3) Inspection of Turbine
Thoroughly check the followings.
Must absolutely not operate the turbocharger with the compressor outlet and inlet opened as it could
damage the turbocharger or be hazardous during inspection.
Interference: In case where is trace of interference or smallest damage on the compressor wheel
means, most of times, that abrasion has occurred on the journal bearing. Must inspect after the
overhaul.
Oil Leakage: The reason for oil leakage at the compressor section is the air cleaner, clogged by
substances such as dust, causes the compressor inlet negative pressure. -
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Rotating in high speed at no-load for extended period of time can cause oil leakage to the
compressor section as oil pressure within the center housing gets higher than pressure within the
compressor housing.
Overuse of engine break (especially in low gear) in down hill makes significantly low exhaust gas
energy compared to the time where great amount of air is required during idling conditions of the
engine. Therefore, amount of air in the compressor inlet increases but the turbocharge pressure is
not high, which makes negative a.
b.
No problem will occur with the turbocharger if above conditions are found in early stage but oil
leaked over long period of time will solidify at each section causing to breakout secondary defects.
Damages by foreign materials: In case where the compressor wheel is damaged by foreign materials
requires having an overhaul. At this time, it's necessary to check whether the foreign materials have
contaminated intake/exhaust manifold or inside of engine.

1914-01
3. TROUBLESHOOTING
The followings are cautions to take in handling defects of turbocharger, which must be fully aware of.
1) Cautions
After stopping the engine, check whether the bolts on pipe connecting section are loose as well as
the connecting condition of vacuum port and modulator, which is connected to the actuator.
During idling of the engine, check for leakage in the connecting section of pipe (hoses and pipes,
duct connections, after the turbocharger) by applying soap water. The leakage condition in the
engine block and turbine housing opening can be determined by the occurrence of abnormal noise o
f
exhaust.
By running the engine at idle speed, abnormal vibration and noise can be checked. Immediately stop
the engine when abnormal vibration and noise is detected and make thorough inspection whether
the turbocharger shaft wheel has any damages as well as checking the condition of connections
between pipes.
In case where the noise of engine is louder than usual, there is possibility of dampness in the areas
related with air cleaner and engine or engine block and turbocharger. And it could affect the smooth
supply of engine oil and discharge.
Check for damp condition in exhaust gas when there is sign of thermal discoloration or discharge of
carbon in connecting area of the duct.
When the engine rotates or in case where there is change in noise level, check for clogging of air
cleaner or air cleaner duct or if there is any significant amount of dust in the compressor housing.
During the inspection of center housing, inspect inside of the housing by removing the oil drain pipe
to check for sludge generation and its attachment condition at shaft area or turbine side.
Inspect or replace the air cleaner when the compressor wheel is damaged by inflow of foreign
materials.
Inspect both side of the turbocharger wheel after removing inlet and outlet pipe of the turbocharger. 1.
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9.

1543-00
1. SPECIFICATION
The engine oil filter element should be changed at the same time with the engine oil.
Regularly check the engine oil level and add the engine oil if necessary.
Remember to check the engine oil level and shorten the cycle to replace the engine oil under
severe driving conditions. -
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Severe Driving Condition
Frequent stop-and-go traffic, extended idling, short driving distance below 6 km, driving distance
below 16 km when the outside temperature remains below freezing
Driving in a hilly or mountainous terrain, sandy, or dusty area
High load driving such as trailer towing
Taxi, patrol service or delivery service (extended idling and excessive driving with low speed) -
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Unit Specification
Oil pump Lubrication system Gear pump, forced circulation
Type Inscribed gear
Capacity 63 L at 4,000 rpm
Relief pressure
Oil filter Type Full flow/Paper element
Engine oil Specified oil SAE 5W30 (approved by MB SHEET 229.51)
Capacity (L) Min.: 4.5 L
Max.: 6.0 L
Service interval Change every 15,000 km or 12 months (But, shorten
the service interval under severe condition)
Oil injection
nozzleType Piston
Operating pressure 1.5bar
Closing pressure 1.0bar
Oil flow 4 L/min
Permissible pressure 10bar
Unit Specification
Oil pump Lubrication system Gear pump, forced circulation
Type Inscribed gear
Capacity 63 L at 4,000 rpm
Relief pressure
Oil filter Type Full flow/Paper element
Engine oil Specified oil SAE 5W30 (approved by MB SHEET 229.51)
Capacity (L) Min.: 4.5 L
Max.: 6.0 L
Service interval EU Change every 20,000 km or 12 months
(The service interval should be shortened under
severe conditions)
General Change every 15,000 km or 12 months
(The service interval should be shortened under
severe conditions)
Oil pressure
switch

2. MAINTENANCE
1) Level Check
Park the vehicle on a level ground and apply the parking brake. Stop the engine and wait more than 5
minutes.
Pull out the dipstick and wipe it with a clean cloth. Reinsert it all the way.
Pull out it again and check the oil level.
The oil level should be between the maximum (Max) mark and minimum (Min) mark on the oil dipstick.
Oil should be replenished before the level goes below the minimum mark. -
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Operating vehicle with insufficient amount of oil can damage the engine. Make sure the engine oil
level is correct and add oil if necessary.
2) Replenishment
If the level gets to the lower point, open the filler cap on top of the cylinder block and add the genuine oil
without exceeding the level of the upper mark.
Recheck the oil level after 5 minutes.
Regularly check the engine oil level and add Ssangyong genuine engine oil if necessary.
Clean the dipstick with clean cloth so that any foreign materials cannot get into the engine.
The oil should not go above the upper mark on the dipstick.
The engine oil may be consumed more if the engine is new. -
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Engine oil dipstickEngine oil filler

2. INSPECTION
1) Alternator Output Test
Item How to check DTC set value / Action
Output
current
B terminal
current
Rotor
coil
resistance
L terminal
voltage
Disconnect the cable connected to the B
terminal on the alternator. Connect one end
of the ammeter to the B terminal and the
other end to the cable connected to the B
terminal.
Measure the maximum output value.
(Maintain the engine speed between 2,500
and 3,000 rpm.)
(Turn the headlamp and all the electrical
switches on.) 1.
2.Pass: If the measured current is 45
A or higher.
Fail: If the measured current is less
than 45 A.
Check the current of the B terminal. -
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Move the gear selector lever to the neutral
position.
Maintain the engine speed at 2,500 rpm
with the vehicle unloaded.
(Turn all the electrical switches off.) 1.
2.Open circuit: If the measured
current is 5 A or higher. -
Disconnect the negative cable from the
battery.
Remove the B terminal and turn off the
ignition switch.
Measure the resistance between the L and
F terminals with an ohmmeter. 1.
2.
3.Pass: If the measured resistance is
Faulty rotor coil or slip ring: If the
measured resistance is less than
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Connect the B terminal wiring.
Measure the voltage with the engine running. 1.
2.Specification: 12.5 V to 14.5 V
Faulty IC regulator or field coil: If
the measured voltage is 14.5 V or
higher. -
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Disconnect the negative battery cable.
Connect the negative cable again after connecting the ammeter. -
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2. CAUTIONS
Standard pattern of soot accumulation
(1) Abnormal Soot Accumulation (2) Normal Soot Combustion
Cautions to protect the catalyst filter
Use the designated fuel only.
Observe the recommended service intervals of engine oil.
Check the engine oil level frequently and add if necessary.
Do not idle the vehicle unnecessarily.
Do not turn off the engine while the vehicle is running.
Do not shift the gear selector lever to neutral when going downhill.
Do not use improper engine oil or fuel additives.
Do not drive for a long time when the warning lamp is illuminated.
Make sure no flammable material, such as dry grass or tissue paper, contacts with the catalyst filter
while the vehicle is parked.
For the vehicles used in urban traffic, driving on the expressways for more than 1 hour at least once
per week is needed so that the PM inside CDPF isn't collected to one side only. -
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2) Cautions on Service Procedures
Before lifting up the vehicle with a lift, correctly support the lifting points.
When using a jack, park the vehicle on a level ground and place the wheel chocks under the
tires. Position the jack under the frame and lift up the vehicle and then support with chassis
stand before service work.
Make sure to disconnect the negative (-) cable from the battery to prevent any damage to
electric systems.
If you have to work on vehicle, cover the seats and floor with protection covers to avoid any
damage and contamination.
Brake fluid and anti-freeze can damage the painted surface of body. So carefully handle them
during service work.
To improve the efficiency of service work, use only recommended and specified tools.
Use only Ssangyong genuine spare parts.
Never reuse the cotter pin, gasket, O-ring, oil seal, lock washer and self-locking nut. Replace
them with new ones. If reused, normal functions cannot be maintained.
Store the disassembled parts as a set based on disassembly order and unit.
Pay particular attention not to miss or mix the fasteners.
If necessary, especially for inspection, clean the removed parts completely.
Apply the oil or grease on the running and sliding surfaces before installation. Use the specified
sealant and gasket to prevent leakage if necessary.
Tighten the fasteners with the specified tightening torque.
As a final stage of service work, check if the serviced system is working properly and the
problem has been eliminated clearly. 1.
2.
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6.
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14.

0000-00
3) Guidelines on Engine Service
To prevent personal injuries and vehicle damages that can be caused by mistakes during engine
and unit inspection/repair and to secure optimum engine performance and safety after service
works, basic cautions and service work guidelines that can be easily forgotten during engine
service works are described in.
Cautions before service works
For safe and correct works, you must observe the working procedures and instructions in this
manual. And, use the designated tools as follow:
Engine stand / Heavy duty engine jack
To prevent the engine from starting abruptly, do not allow anybody to get in the vehicle while
servicing in engine compartment.
Before work on engine and electrical equipment, be sure to disconnect battery negative (-)
terminal.
Before service works, be sure to prepare the works by cleaning and aligning work areas.
Do not allow the foreign material get into the fuel injection system.
When removing the engine, use only the safety hook on engine and engine hanger. Do not
support the bottom of oil pan with a jack. -
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Completely drain the engine oil, coolant and fuel from engine before removal.
Before disassembling/assembling the engine components, carefully read the working
procedures in this manual.
Make sure to keep the specified tightening torques during installation.
Clean and properly lubricate the parts before reassembly.
Carefully check that there is not any interference while servicing. -
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Do not allow the fluid and engine oil to make contact with the body paintwork and hoses.
If work on the fluid system such as fuel and oil, working area should be well ventilated and
smoking should be prohibited.
Gasket or seal on the fuel/lubrication system should be replaced with new ones and bolts and
nuts should be tightened as specified.
After removal/installation works, be sure to check whether there is leak on the connecting
section. -
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If fine dust or foreign material enters into DI engine's fuel system, there can be serious
damages between HP pump and injectors. So, be sure to cover removed fuel system
components with cap and protect removed parts not to be contaminated with dirt. (Refer to
cleanness in this manual while working on DI engine fuel system)
When working on the fuel line between priming pump and injector (including return line),
always plug the openings with caps to prevent foreign materials or dust from entering to the
openings and connections.
The HP fuel supply pipe (HP pump to fuel rail) and HP fuel pipe (Fuel rail to injector) should
be replaced with new ones when removed. 1.
2.
3.
Electric devices should be handled more carefully.
Currently, the engine has a lot of electric devices. There could be poor engine performance,
incomplete combustion and other abnormal symptoms due to short circuit or poor contact.
Before work on engine and electrical equipment, be sure to disconnect battery negative (-)
terminal.
When replacing the electric device, use only genuine part and check the conditions of
connections and grounds. Loosened connection or ground makes cause a fire and personal
injury. -
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