service SSANGYONG NEW REXTON 2012 Service Manual

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4. MAINTENANCE
1) Scheduled Maintenance Services (EU) - Diesel Engine (D20DTR)

2) Scheduled Maintenance Services (GEN) - Diesel Engine
(D20DTR)

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3) Scheduled Maintenance Services (GEN) - Diesel Engine
(D27DT/D27DTP)

4) Scheduled Maintenance Services (Gasoline Engine)

Injector washer puller
2. SPECIAL SERVICE TOOLS
1) Using the Special Service Tools on Engine
Injector pullerGlow plug socket
HP remover/installerHigh pressure pipe
remover/installerCylinder head bolt wrench
Sealing caps
(fuel line)

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
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.
(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) -
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(2) Exhaust system
Wear the safety glove when removing the exhaust pipe.
Make sure that the exhaust pipe is cooled before removing it. -
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(3) Cautions before service
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.

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1. OVERVIEW FOR CDPF (EURO IV)
The CDPF (Catalyst & Diesel Particulate Filter) was installed to the Rexton II D27DTP engine previously.
However, it is now installed to the all 2009 DI engine models, except the Actyon Sports. The DI engine
type sinstalled to Rexton are D27DTP, D27DT and D20DT, and their CDPF, related sensor and
operation logic are the same.This section describes the CDPF system (based on Euro IV) which is
installed to the Rexton II D27DTPengine (older model).
1) General Description
2) Compatibility of CDPF System by Vehicle Model
Rexton II: Same CDPF system for D27DTP and D27DT engines (including its components)
Kyron & Actyon: Same CDPF system for D27DT and D20DT engines (including its components)
The CDPF assemblies installed to the Euro IV D27DTP Rexton II and 2009 Rexton II are
different in their mounting layout, but their front/rear exhaust temperature sensors and
differential pressure sensors are same. -
3) System Met with EURO IV Regulations
The Ssangyong vehicles installed with the D27DT engine manufactured from July 2007 to December
2007 comply with the EURO IV regulations. Modified components from the old engine model are as
follow:
- E-EGR valve
- EGR cooler
- Engine ECU (Ver. 3.2)
- HFM senso
- C3I injector
- Electronic throttle valve (body)
- Other engine mounting components
For details about the modified components and system related to the EURO IV regulations, refer to the
2008 Rodius engine service manual.

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1. SPECIFICATIONS
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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Engine Oil Quality classSsangyong genuine engine oil (Approved by MB
Sheet 229.1 or 229.3 or 229.31 for DSL/GSL ENG
without CDPF)
(Approved by MB Sheet 229.31 for DSL ENG with
CDPF)
Viscosity: MB sheet No. 224.1
Capacity
Service
intervalEUInitial check: 5,000 km, and replenish if necessary,
change every 20,000 km or 12 months (But,
shorten the service interval under severe condition)
GeneralInitial change: 5,000 km, change every 15,000 km
or 12 months (But, shorten the service interval
under severe conditions)
Engine oil filterSame interval with the engine oil
Oil filter relief valve opening pressure

2. SPECIAL SERVICE TOOL
Name Description
Glow plug remover
Tool for removing the glow plug from cylinder head

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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)