0000-00 01-3

1. ENGINE LAYOUT
Front view Rear view

Right view Left view

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2. MAJOR COMPONENTS
▶ Front view

Vacuum pump

Oil filter assembly

Camshaft position sensor

Power steering pump pulley

Water pump pulley

Alternator pulley

Idler pulley No. 2

A/C compressor pulley

Auto tensioner

Idler pulley No. 1

Isolation damper

Oil pressure switch

▶ Rear view

E-EGR valve

Fuel temperature sensor

Fuel HP pump assembly

Coolant temperature sensor

Crankshaft position sensor

IMV valve
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▶ Right view

Front exhaust gas temperature

sensor

Oil dipstick tube &

gauge assembly

E-VGT actuator

E-VGT turbocharger

Coolant screw plug

Oil drain plug

▶ Left view

Thermostat assembly

Variable swirl valve assembly

E-EGR valve

E-EGR solenoid valve

Oil cooler assembly

EGR cooler

Electronic throttle body

01-6

3. ENGINE COMPARTMENT LAYOUT

Brake fluid reservoir

Coolant reservoir

Engine oil filler cap

Fuse & relay

Air cleaner Engine oil dipstick Power steering fluid Washer fluid
gauge reservoir reservoir cap

- Do not work on the engine compartment while the engine, radiator, exhaust manifold, muffler or
catalytic converter is hot. Always turn the engine off and allow it to cool before starting the
maintenance.
- 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.

Operating vehicle with insuffi cient amount of oil can damage the engine. Make sure the engine oil
level is correct and add oil if necessary.
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1) Service Interval
Daily Weekly
Description Service interval
inspection inspection
Engine oil & oil Inspection - EU Change every 20,000 km or 12 months
filter (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 - Inspection Diesel EU Change every 20,000 km (The
element 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 oil Specification 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 Specification Ssangyong genuine coolant Anti-Freeze SYC-1025
coolant
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)
01-8

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)
-

(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.

(4) Lubrication system

- 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

- Clean the mating surfaces before tightening.
- Place the marks with paint to tighten by angle if the angle wrench is not available.

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.

1. 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)
2. 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.
3. 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.
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5. STANDARD BOLTS SPECIFICATIONS

1) 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.
2) 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.
3) Determine extra proper tightening torque if tightens with washer or packing.
4) If tightens bolts on the below materials, be sure to determine the proper torque.
- Aluminum alloy: Tighten to 80 % of above torque table.
- Plastics: Tighten to 20 % of above torque table.
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6. TIGHTENING TORQUE
Tightening Note (total
Name Size Numbers of
torque (Nm) tightening
fastener
torque)
Main bearing cap M12×82 10 55±5Nm, Not-reusable
180˚
Connecting rod cap M9×52 8 40±5Nm, 50 ~80Nm
90˚+10˚
Crankshaft rear seal M6×20 6 10±1Nm -
Oil pump M8×35 3 25±2.5Nm -
Drive plate M10×22 8 45±5Nm, Not-reusable
90˚+10˚
Isolation damper center M18×50 1 200±20Nm, 660 ~ 720Nm
bolt 180˚+20˚ Not-reusable
Oil pan M6×20 18 10±1Nm -
M6×35 2 10±1Nm -
M6×85 2 10±1Nm -
M6×120 2 10±1Nm -
M8×40 2 25±2.5Nm -
Mounting nut for high M14×1.5-8-1 1 65±5Nm -
pressure pump
Mounting bolt for high M8×30 3 25±2.5Nm -
pressure pump
Cylinder head M13×150 12 85Nm -
270°±10°
Camshaft cap M6×30 16 10±1Nm -
M8×60 4 25±2.5Nm -
Exhaust stud bolt 10 15±1.5Nm -
Exhaust sprocket M8x16.5 1 25±2.5Nm -
Chain tensioner screw M8x1.5 1 25±2.5Nm -
plug
Coolant temperature 1 20±2.0Nm -
sensor
Belt auto tensioner M8×30(LOW) 1 25±2.5Nm -
M10×75(Upper) 1 55±5.5Nm -
Water pump M6×25 7 10±1.0Nm -
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Note (total
Numbers of Tightening
Name Size tightening
fastener torque (Nm)
torque)
Hot water inlet pipe M6×12 2 10±1Nm -
Alternator M10×90 1 (LO) 25±2.5Nm -
M10×116 1 (HI) 46±4.6Nm -
Air conditioner M8×85 4 25Nm -
compressor
Air conditioner bracket M6×25 4 10±1Nm -
Intake manifold M8×35 2 25±2.5Nm -
M8×110 6 25±2.5Nm -
Oil filter module M8×40 6 25±2.5Nm -
M8×80 1 25±2.5Nm -
M8×140 2 25±2.5Nm -
Knock sensor M8×28 2 20±5Nm -
Camshaft position M8×14 1 10~14Nm -
sensor
T-MAP pressure M6×20 1 10±1Nm -
sensor
Exhaust manifold M8 10 40±4Nm -
Turbocharger M8 3 25±2.5Nm -
T/C support bolt M8 x 35 1 25±2.5Nm -
(Turbo Side)
M8 x 16 1 25±2.5Nm -
(Block Side)
T/C oil supply pipe M16 1 25±2.5Nm -
(Fitting Screw)
M10 1 17±2.0Nm -
(Hollow Bolt)
T/C oil return pipe M6×16(to block) 2 10±1Nm -
M6×16 2 10±1Nm -
(to turbocharger)
EGR valve M8×30 3 25±2.5Nm -
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Note (total
Numbers of Tightening
Name Size tightening
fastener torque (Nm)
torque)
EGR pipe bolt M6×16 2 10±1Nm -
(to air duct)
EGR pipe bolt M8×25 2 25±2.5Nm -
(to EGR cooler)
Idler pulley/tensioner 1 45±4.5Nm -
pulley
Glow plug M5 4 20±2Nm -
Vacuum pump M6×25 3 10±1Nm -
Timing gear case cover M6×40 7 10±1Nm -
M6×45 1 10±1Nm -
M6×50 3 10±1Nm -
Cylinder head cover M6×35 21 10±1Nm -
Oil dipstick gauge cover M6×16 1 10±1Nm -
Oil filter cap 1 25±2.5Nm -
Fuel rail M8×25 2 25±2.5Nm -
Injector clamp bolt M6×44 2 9±1.0Nm -
130˚±10˚
High pressure pipe M17 1 30±3Nm -
(between high pressure
pump and fuel rail
assembly)
High pressure pipe M17 4 30±3Nm -
(between fuel rail assembly
and injector)
Crankshaft position M5×14 1 8±0.4Nm -
sensor
Main wiring M6×16 5 10±1Nm -
Intake duct M8×25 4 25±2.5Nm -
Power steering pump M8×100 3 25±2.5Nm -
Cylinder head front M6×10 5 10±1Nm -
cover
Ladder frame M8×35 5 30±3Nm -
01-14

7. CODING AND INITIALIZATION

1) Engine Variant Coding
Unit Selection Description Remarks
Additional heater YES For PTC auxiary heater equipped YES
vehicle, select "YES"
NO -
Gear box 5 MT "DSI 6 AT" is selected -
automatically.
6 MT Select
5 AT(DC 5 AT) -
6 AT(DSI 6 AT) Select
7 AT(DC 7 AT) -
Immobilizer NO Select "YES" if the vehicle has -
immobilizer.
YES YES
Fan PWM control Select "PWM" PWM fan
Relay -
Engine level control NO
YES
SKM key NO NO
YES -
Glow plug AQGS (CAN) Select "AQGS" AQGS (CAN)
Relay (K-line) -
A/C Refrigerant pressure Select the appropriate system. Pressure sensor
sensor for A/C refrigerant

NO -
Vehicle speed sensor CAN Select "CAN" if the vehicle has CAN
ABS or ESP
WIRE -
Cruise control YES Select "YES" if the vehicle has YES
cruise control.
NO -
G-sensor YES 2WD ABS & Non-ABS: NO Select
4WD ABS & ESP: YES
NO Select
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2) Chassis Variant Coding

Unit Selection Description
Domestic/Export Domestic Select the region.
GEN. Export
EUROPE
EPB application YES Select "NO".
NO
Shift lever type MT AT: Select "DURA lever (CAN)".
MT: Select "MT".
DC lever (CAN)
DURA lever (CAN)
DSIH (NO-CAN)
Electric power steering NO NO
(EPS)
YES
Transper case P/T Select "2WD" or "P/T".
4WD
2WD
TOD
AWD
Sedan/Limousine Sedan (RV) Select "Sedan (RV)".
Limousine
Vehicle code (Engine) Undefined Select "D20DTR".
D32DT
D27DT
D27DTP
D20DTR
EAS NO Select "NO".
ECS
EAS2 corner
EAS4 corner
Telematics NO Select "NO".
YES
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Unit Selection Description

Brake system ESP Select "ABS" or "ESP".
ABS
TCS
NO
SSPS NO Select "YES".
YES
TPMS NO Select "NO".
YES
T/M type MT Select "M/T" or "DSIH 6 AT".
DC AT
DSIH 6 AT
Vehicle code Rodius / Stavic Select "Rodius".
Rexton
Korando C
Actyon sports
Kyron
ECU coding status ECU not coded Select "ECU coded".
ECU coded
Signal not valid
Not defind