SSANGYONG NEW REXTON 2012 Service Manual

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1) Service Interval
DescriptionDaily
inspectionWeekly
inspectionService interval
Engine oil & oil
filterInspection - 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)
Coolant Inspection - Change every 200,000 km or 5 years
Air cleaner
element- Inspection Diesel EU Change every 20,000 km
(The service interval should
be shortened under severe
conditions)
General Clean every 7,500 km,
change every 15,000 km
(The service interval should
be shortened under severe
conditions)
Gasoline Clean every 15,000 km, replace every
60,000 km (The service interval should
be shortened under severe conditions)
Fuel filter - - EU Change every 40,000 km (Draining
water from fuel filter: whenever replacing
the engine oil)
General Change every 45,000 km (Draining
water from fuel filter: whenever replacing
the engine oil)

2) Specification and Capacity
Engine oilSpecification Quality class: Ssangyong genuine engine oil (Total Quartz INEO
ECS 5W 30, SK ZIC SY 5W 30) or oil Approved by MB Sheet
229.51
Capacity approx. 6.0 litter
Engine
coolantSpecification Ssangyong genuine coolant Anti-Freeze SYC-1025
Capacity approx. 8.5 litter
Severe 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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4. CAUTION WHEN SERVICING THE ENGINE
1) Cleaness
Engine has a lot of precisely machined (grinding, polishing, lapping) surfaces. Thus, there should be great
cautions for cleaness when servicing the engine components. Apply the engine oil on the sliding surfaces
when assemblying the components. Every component should be disassembled and reassembled in
accordance with the correct sequences. Before servicing the engine, the negative cable should be
diconnected from the battery. Otherwise, some electric or electronic components could be damaged.
2) Servicing
(1) Lifting up the vehicle
Always keep the safety precautions.
To prevent the vehicle from rolling down, put the chocks under the tires (when using a 4-post lift).
Make sure to support the correct lifting points (when using a 2-post lift) -
-
-
(2) Exhaust system
Wear the safety glove when removing the exhaust pipe.
Make sure that the exhaust pipe is cooled before removing it. -
-Before service work, be sure to disconnect battery negative (-) terminal to prevent damages by bad
wire and short.
To prevent the foreign material from getting into engine cylinder, cover the inlet of air cleaner if the
air cleaner has been removed -
-

(3) Cautions before service
Prolonged exposure to the engine oil make cause a skin cancer or an irritation.
Used engine cotains the hazardous material that may cause the skin cancer. Do not allow the used
engine to make contact with your skin.
Make sure to wear the protection gloves and goggle when handling the engine oil. If contact happens,
rinse affected areas immediately with plenty of water. Do not wash it with gasoline or solvent. If
irritation persists, consult a doctor.
Improperly disposed engine oil can pollute the environment. Dispose used engine oil in accordance
with local environmental regulations. -
-
-
(5) Tightening the fastener
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. Scalding hot coolant and steam could be blown out under pressure, which could cause serious injury.
Never remove the coolant reservoir cap when the engine and radiator are hot.
(4) Lubrication system
3) Fuel and Oil System
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. -
-Clean the mating surfaces before tightening.
Place the marks with paint to tighten by angle if the angle wrench is not available. -
-

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5. STANDARD BOLTS SPECIFICATIONS
Metric bolt strength is embossed on the head of each bolt. The strength of bolt can be classified as
4T, 7T, 8.8T, 10.9T, 11T and 12.9T in general.
Observe standard tightening torque during bolt tightening works and can adjust torque to be proper
within 15 % if necessary. Try not to over max. allowable tightening torque if not required to do so.
Determine extra proper tightening torque if tightens with washer or packing.
If tightens bolts on the below materials, be sure to determine the proper torque. 1)
2)
3)
4)
Aluminum alloy: Tighten to 80 % of above torque table.
Plastics: Tighten to 20 % of above torque table. -
-

6. TIGHTENING TORQUE
Name SizeNumbers of
fastenerTightening
torque (Nm)Note (total
tightening
torque)
Main bearing cap
10 Not-reusable
Connecting rod cap
8 50 ~80Nm
Crankshaft rear seal
6 -
Oil pump
3 -
Drive plate
8 Not-reusable
Isolation damper center
bolt
1 660~720 Nm
Not-reusable
Oil pan
18 -
2 -
2 -
2 -
2 -
Mounting nut for high
pressure pump
1 -
Mounting bolt for high
pressure pump
3 -
Cylinder head
12 85Nm-
Camshaft cap
16 -
4 -
Exhaust stud bolt 10
-
Exhaust sprocket
1 -
Chain tensioner screw
plug
1 -
Coolant temperature
sensor1
-
Belt auto tensioner
1 -
1 -
Water pump
7 -

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Hot water inlet pipe2 -
1 -
1 -
4 25~2.5Nm -
4 -
2 -
6 -
6 -
1 -
2 -
2 -
1 10~14Nm -
1 -
M8 10
-
M8 3
-
1
-
M8 1
-
T/C oil supply pipe M6(to block) 1
-
M6
(to turbocharger)1
-
T/C oil return pipe
2 -
(to turbocharger)2
-
EGR valve
3 -
EGR pipe bolt (to exhaust
manifold)
2 -
EGR pipe bolt (to EGR
cooler)
2 -
Name SizeNumbers of
fastenerTightening
torque (Nm)Note (total
tightening
torque)
Hot water inlet pipe
2 -
Alternator
1 -
1 -
Air conditioner
compressor
4 25~2.5Nm -
Air conditioner bracket
4 -
Intake manifold
2 -
6 -
Oil filter module
6 -
1 -
2 -
Knock sensor
2 -
Camshaft position sensor
1 10~14Nm -
T-MAP pressure sensor
1 -
Exhaust manifold M8 10
-
Turbocharger M8 3
-
T/C support bolt M8 1
-

Name SizeNumbers of
fastenerTightening
torque (Nm)Note (total
tightening
torque)
Idler pulley/tensioner
pulley1
-
Glow plug M5 4
-
Vacuum pump
3 -
Timing gear case cover
7 -
1 -
3 -
Cylinder head cover
21 -
Oil dipstick gauge cover
1 -
Oil filter cap 1
-
Fuel rail
2 -
Injector clamp bolt
2 -
High pressure pipe
(between high pressure
pump and fuel rail
assembly)M17 1
-
High pressure pipe
(between fuel rail
assembly and injector)M17 4
-
Crankshaft position
sensor
1 -
Main wiring
5 -
Intake duct
3 -
Power steering pump
3 -
Cylinder head front cover
5 -

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7. CODING AND INITIALIZATION
1) Engine Variant Coding
Unit Selection Description Remarks
PTC auxilary heater NO For PTC auxilary heater
equipped vehicle, select
"YES".-
YES YES
Glow plug Relay (K-line) Select "AQGS". -
AQGS (CAN) AQGS (CAN)
Transmission 6-speed M/T Select the appropriate system. Select
5-speed A/T (DC 5 AT) Select
6-speed A/T (DSI 6 AT) Select
Pressure sensor for
A/C refrigerantNO Select the appropriate system. -
Type Pressure sensor
for A/C
refrigerant
Immobilizer NO Select "YES" if the vehicle has
immobilizer.-
YES YES
Vehicle speed input
typeCAN Select "CAN" if the vehicle has
ABS or ESPCAN
WIRE -
Fan 2 relays Select "PWM". -
PWM fan PWM fan
Auto cruise NO Select "YES" if the vehicle has
cruise contro.-
YES YES
G-sensor NO 2WD ABS & Non-ABS: NO
4WD ABS & ESP: YESSelect
YES Select

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1. SPECIFICATION
Unit Description Specification Remark
Cylinder head Height 131.9 to 132.1 mm -
Flatness below 0.1 mm -
Valve protrusion Intake valve 0.6 to 1.0 mm -
Exhaust valve 0.6 to 1.0 mm -
Flatness on manifold
sideIntake manifold 0.08 mm -
Exhaust manifold 0.08 mm -
Connecting rod End play 0.5 to 0.31 mm -
Camshaft Axial end play Intake 0.1 to 0.35 mm -
Exhaust 0.1 to 0.35 mm -
Camshaft position
sensorDistance between Camshaft position sensor
and sprocket0.20 to 1.80 mm -
Valve Clearance between
valve and pistonIntake 0.6 to 1.0mm -
Exhaust 0.6 to 1.0mm -
Valve recess Intake 0.6 to 1.0mm -
Exhaust 0.6 to 1.0mm -
Cylinder block Piston protrusion 0.475 to 0.745mm -
Piston ring TOP ring end gap 0.20 to 0.35 mm -
2nd ring end gap 0.35 to 0.50 mm -
3rd ring end gap 0.2 to 0.40 mm -
Offset 0.3 mm -
Head gasket Piston protrusion 0.475~0.540 1.2t -
0.541 to 0.649 1.3t -
0.650 to 0.745 1.4t -