oil SSANGYONG NEW REXTON 2012 Manual PDF

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1. D27DT ENGINE STRUCTURE
1) Major Components in Engine and Engine Compartment
The advanced electronically controlled D27DT engine that has high pressure fuel system has
been introduced to this vehicle. It satisfies the strict emission regulation and provides improved
output and maximum torque.
1. Coolant reservoir
2. FFH device
3. Brake fluid reservoir
4. Washer fluid reservoir
5. Common rail6. Fuse box
7. Battery
8. Fuel filter
9. Power steering pump
10. Priming pump11. EGR valve
12. Air cleaner assembly
13. Turbo charger
14. Oil dipstick

2) Engine Structure
1. TVD (Torsional Vibration Damper)
2. Air conditioner compressor
3. Power steering pump pulley
4. Idle pulley
5. Coolant pump pulley
6. Alternator7. Viscos fan clutch
8. Auto tensioner pulley
9. Auto tensioner
10. Poly-grooved belt
11. Cam position sensor
12. Drive plate (MT: DMF)13. Oil filter
14. Vacuum pump
15. Crank position sensor
16. EGR valve
17. Power steering pump
18. EGR to center pipe
Front View
Rear View

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Top View
19. Cylinder head cover
20. Intake manifold
21. Water outlet port
22. Common rail
23. Fuel pressure sensor24. Fuel pipe
25. Injector
26. Fuel return line
27. Oil filler cap
28. Glow plug29. Booster pressure sensor
30. PCV valve and oil separator
31. Oil dipstick
32. EGR-LH (#1) pipe

Left Side View
33. Cylinder head
34. Cylinder block
35. Oil pan
36. Drain plug
37. Turbo charger38. EGR-RH (#3) pipe
39. PCV valve and oil separator
40. Oil dipstick
41. High pressure pump42. Turbo charger booster vacuum
modulator
43. EGR valve vacuum modulator
44. EGR valve
45. Exhaust manifold
Right Side View

2) D27DTP (Power Up) Engine Performance Curve
(1) Output and Torque: vehicle with automatic transmission
Oil Temperature/Pressure and Boost Pressure: vehicle with automatic
transmission (2)

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3) D27DT Engine Performance Curve
(1) Output and Torque
(2) Oil Temperature/Pressure and Boost Pressure

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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.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

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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Engine Compartment Layout
Engine assembly
Engine oil dipstick
Vacuum pump
Oil filter and cooler
Fuel filter and priming pump
Brake booster
Brake oil tank
AQGS unit
Washer fluid filler cap
Engine compartment fuse box
PTC relay box
Battery
Vacuum modulator (for VGT turbo charger) 1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.FFH Assembly (Only for vehicle with FFH)
Power steering oil tank
Engine oil filler cap
Fan shroud
E-EGR Valve
High-capacity PCV oil separator
HFM sensor (6.0)
VGT turbo charger
Air cleaner housing
2Coolant surge tank
ABS/ESP HECU (Including TPMS function:
optional)
Exhaust gas FRT Temp. sensor (T3) 14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.